SM152

BBA12C1-01

SERVICE MANUAL
AE50/AM50 Electric Forklift Truck
AE50 FB15U/18U-12, FB15FU/18FU-12 S/N 837898~
FB20AU-12, FB20AFU-12
AM50 FB15MU/18MU-12, FB15MFU/18MFU-12 S/N 826828~
FB20MU-12, FB20MFU-12

AE50
AM50

WARNING
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.

ISSUED: FEBRUARY 2010

The information and specifications contained herein were accurate at the time of publica-
tion, but may change without notice as required for product improvements. Neither
Komatsu Forklift USA, LLC, nor its parent company nor any of its subsidiaries will be held
responsible for damages due to misuse or inappropriate use of its products.

© Copyright 2010, Komatsu Forklift USA, LLC. All rights reserved. No part of this docu-
ment may be photocopied or reproduced in any way without prior written consent of
Komatsu Forklift USA, LLC.
 CONTENTS
Page No.
1. SPECIFICATIONS AND GENERAL INFORMATION
OUTSIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
PERIODIC REPLACEMENT OF CONSUMABLE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
STANDARD TIGHTENING TORQUE FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
HOW TO USE LOCTITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
BASIC PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
START-UP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
TRAVELING THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
LOAD HANDLING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
PRECAUTIONS FOR INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
HOISTING AND TRANSPORTING THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
STRUCTURE AND STABILITY OF THE LIFT TRUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

2. TESTING AND ADJUSTING

SERVICE DATA (4-WHEEL LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
SERVICE DATA (3-WHEEL LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
RELEASING THE PRESSURE IN THE HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
LIFT INTERRUPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
METER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
OPERATION OF METER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
ADJUSTMENT OF WET TYPE BRAKE AND PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
WET TYPE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
MAST (1.5 - 1.75 TON LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
MAST (2.0 TON LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
FINGER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
NATURALLY DESCENDING AMOUNT OF HYDRAULIC OIL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
LIST OF LUBRICANT AND GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

3. REMOVAL AND INSTALLATION

UNIT LOCATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
UNIT MASS (4-WHEEL LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
UNIT MASS (3-WHEEL LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
DRAWING OF DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

1
 LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
HYDRAULIC PUMP AND PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

4. DISASSEMBLY AND ASSEMBLY

DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
TRANSFER (BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
TRANSFER (HUB BEARING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
TRANSFER (TRANSFER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
BRAKE WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
STEERING GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
ORBITROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
POWER STEERING CYLINDER (4-WHEEL LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
STEERING AXLE (3-WHEEL LIFT TRUCK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
REAR AXLE (4-WHEEL LIFT TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

5. MAINTENANCE STANDARD
DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
WHEEL CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
STEERING AXLE (3-WHEEL LIFT TRUCK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
MAST, FINGER BAR, FORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

6. STRUCTURE AND FUNCTION

BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

2
7. TROUBLESHOOTING
DIAGNOSIS TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CONFIGURATION PARTS, SENSOR, UNIT LOCATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
LOCATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
LOCATION OF CPU BOARD CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
OVERVIEW OF TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
PREPARATION FOR VOLTAGE CHECK AND CURRENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
INPUT / OUTPUT SIGNAL OF CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
TROUBLE CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
DIAGNOSTIC PROCEDURE BY TROUBLE CODE (ALA CODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIAGNOSIS PROCEDURE BY TROUBLE CODE (ERR CODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
DIAGNOSTIC PROCEDURE BY METER DISPLAY TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
TROUBLE WITHOUT ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-111
PROPORTIONAL SOLENOID VALVE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-119
ADJUSTMENT PROCEDURE OF TILT AUTOMATIC HORIZONTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124
METER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
HARNESS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137

8. YEARLY INSPECTION CRITERIA

9. CONVERSION TABLES

APPENDIX
3BA-97-99710 (INPUT GEAR/BEARING PRESS-FITTING JIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
3BA-97-99720 (MULTIPLE DISC ALIGNMENT JIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
3BA-97-99730 (MULTIPLE HOLDER CLEARANCE ALIGNING JIG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
3BA-97-99740 (3-WHEEL REAR AXLE PRESS-FITTING JIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
3BA-97-99760 (3-WHEEL REAR AXLE SENSOR ALIGNMENT JIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
SERVICE TOOL CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
ELECTRIC WIRING DIAGRAM - TYPE A (LIFT TRUCK WITH 3 PORTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
ELECTRIC WIRING DIAGRAM - TYPE B (LIFT TRUCK WITH 4 PORTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

3
1. Specifications and
General Information

OUTSIDE VIEW ................................................................................................. 1-2

SPECIFICATIONS ............................................................................................. 1-4

PERIODIC REPLACEMENT OF CONSUMABLE PARTS................................. 1-8

STANDARD TIGHTENING TORQUE FOR BOLTS .......................................... 1-9

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS .............................. 1-10

HOW TO USE LOCTITE.................................................................................. 1-11

1-1
1. SPECIFICATIONS AND GENERAL INFORMATION

OUTSIDE VIEW
4-WHEEL LIFT LIFT TRUCK
b10
b1

h4
h3
h1
h2 b3
x
1
2
y

Wa

h6
b11

1-2
 1. SPECIFICATIONS AND GENERAL INFORMATION

3-WHEEL LIFT TRUCK

b10
b1

h4
h3
h1
h2 b3
x
1
2
y

Wa

h6
b11

1-3
 SPECIFICATIONS

1. SPECIFICATIONS AND GENERAL INFORMATION

4-WHEEL LIFT TRUCK
Model Manufacturer’s Designation Unit FB15U-12 FB18U-12 FB20AU-12
Power Type Electric, Diesel, Gasoline, LPG, Cable Electric Electric Electric
Characteristics

Operation Type Sitting Sitting Sitting

Rated Capacity Q Rated Capacity kg [lb] 1350 [2976] 1570 [3461] 1800 [3968]
Load Center c Rated Load Center mm [in] 600 [23.6] 600 [23.6] 600 [23.6]
Load Distance x Front Axle Center to Fork Face mm [in] 405 [15.9] 405 [15.9] 425 [16.7]
Wheelbase y mm [in] 1410 [55.5] 1410 [55.5] 1470 [57.9]
Service Weight Including Max. Capacity Battery kg [lb] 3130 [6900] 3370 [7430] 3800 [8378]
Front kg [lb] 3840 [8466] 4210 [9281] 4800 [10582]
Weight

Loaded
Rear kg [lb] 640 [1411] 740 [1631] 790 [1742]
Axle Loading
Front kg [lb] 1590 [3505] 1600 [3527] 1830 [4034]
Unloaded
Rear kg [lb] 1540 [3395] 1780 [3924] 1970 [4343]
Tire Type Cushion, Elastic Cushion, Pneumatic, Polyurethane Elastic Cushion Elastic Cushion Elastic Cushion
Front 18x7-8 18x7-8 200/50-10
Tire Size
Rear 16x6-8 16x6-8 16x6-8
Tires

Number of Wheel Front/Rear (x=driven) 2*/2 2*/2 2*/2

1-4

Tread, Front b10 mm [in] 940 [37.0] 940 [37.0] 950 [37.4]
Tread, Rear b11 mm [in] 865 [34.1] 865 [34.1] 865 [34.1]
Tilting Angle a/b Forward/Backward degree 6/10 6/10 6/10
Mast Height, Lowered h1 2-stage Mast mm [in] 2145 [84.4] 2145 [84.4] 2260 [89.0]
Std. Free Lift h2 2-stage Std. Mast, from Ground mm [in] 140 [5.5] 140 [5.5] 150 [5.9]
Std. Lift Height h3 2-stage Std. Mast, from Ground mm [in] 3300 [130.0] 3300 [130.0] 3300 [130.0]
Mast Height, Extended h4 2-stage Std. Mast mm [in] 4255 [167.5] 4255 [167.5] 4270 [168.1]
Height, Overhead Guard h6 mm [in] 2070 [81.5] 2070 [81.5] 2070 [81.5]
Length, with Std. Forks l1 mm [in] 3130 [123.2] 3165 [124.6] 3250 [128.0]
Dimensions

Length, to Fork Face l2 mm [in] 2060 [81.1] 2095 [82.5] 2180 [85.8]
Width, at Tire b1 Single mm [in] 1110 [43.7] 1110 [43.7] 1160 [45.7]
Forks s/e/l Thickness / Width / Length mm [in] 35x100x1070 [1.4x3.9x42.1] 35x100x1070 [1.4x3.9x42.1] 36x122x1070 [1.4x4.8x42.1]
Fork Carriage Class ISO 2328, Type A/B/no Class 2, Type A Class 2, Type A Class 2, Type A
Width, Fork Carriage b3 mm [in] 970 [38.2] 970 [38.2] 970 [38.2]
m1 Under Mast mm [in] 95 [3.7] 95 [3.7] 95 [3.7]
Ground Clearance
m2 at Center of Wheelbase mm [in] 125 [4.9] 125 [4.9] 125 [4.9]
Ast with L1000 x W1200 pallet mm [in] 3155 [124.2] 3190 [125.6] 3275 [128.9]
Right Angle Stacking Aisle
Ast with L1200 x W800 pallet mm [in] 3355 [132.1] 3390 [133.5] 3475 [136.8]
Turning Radius Wa mm [in] 1750 [68.9] 1785 [70.3] 1850 [72.8]
 Model Manufacturer’s Designation Unit FB15U-12 FB18U-12 FB20AU-12
Travel Speed (FWD) Loaded / Unloaded km/h [mph] 15.0/17.0 [10/11] 15.0/17.0 [10/11] 14.0/16.0 [9/10]
Lifting Speed Loaded / Unloaded mm/s [fpm] 340/600 [67/118] 320/600 [63/118] 280/500 [55/98]
Performance

Lowering Speed Loaded / Unloaded mm/s [fpm] 450/550 [89/108] 450/550 [89/108] 370/440 [73/87]
Max. Drawbar Pull Loaded, 3 min. rating N [lbf] 9560 [2150] 9560 [2150] 9045 [2033]
Max. Gradeability Loaded, 3 min. rating/1.5/h % 19 16 14
Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS FHPS
Drive Motor (AC) 60 min. rating kW 4.5x2 4.5x2 4.5x2
Pomp Motor (AC) 5 min. rating kW 9.0 9.0 9.0
Drive

Battery Voltage V 48 48 48
Battery Capacity, Max. Ah/6hr 600 600 600
Battery Weight Max. Capacity Battery kg [lb] 950 [2094.4] 950 [2094.4] 950 [2094.4]
Drive Motor Control Transistor Transistor Transistor
Others

Relief Pressure Attachment 2 176 [17.6, 180, 2560] 176 [17.6, 180, 2560] 176 [17.6, 180, 2560]
bar [MPa, kg/cm , PSI]
Reservoir Capacity Ltr [U.S. gal] 23 [6.1] 23 [6.1] 23 [6.1]
1-5

1. SPECIFICATIONS AND GENERAL INFORMATION

 3-WHEEL LIFT TRUCK

1. SPECIFICATIONS AND GENERAL INFORMATION

Model Manufacturer’s Designation Unit FB15MU-12 FB18MU-12 FB20MU-12
Power Type Electric, Diesel, Gasoline, LPG, Cable Electric Electric Electric
Characteristics

Operation Type Sitting Sitting Sitting

Rated Capacity Q Rated Capacity kg [lb] 1350 [2976] 1570 [3461] 1800 [3968]
Load Center c Rated Load Center mm [in] 600 [23.6] 600 [23.6] 600 [23.6]
Load Distance x Front Axle Center to Fork Face mm [in] 405 [15.9] 405 [15.9] 425 [16.7]
Wheelbase y mm [in] 1340 [52.8] 1390 [54.7] 1485 [58.5]
Service Weight Including Max. Capacity Battery kg [lb] 3180 [7011] 3470 [7650] 3900 [8598]
Front kg [lb] 3850 [8488] 4250 [9367] 4860 [10714]
Weight

Loaded
Rear kg [lb] 680 [1499] 790 [1742] 840 [1852]
Axle Loading
Front kg [lb] 1550 [3417] 1620 [3572] 1900 [4189]
Unloaded
Rear kg [lb] 1630 [3594] 1850 [4079] 2000 [4409]
Tire Type Cushion, Elastic Cushion, Pneumatic, Polyurethane Elastic Cushion Elastic Cushion Elastic Cushion
Front 18x7-8 18x7-8 200/50-10
Tire Size
Rear 15x4 1/2-8 15x4 1/2-8 15x4 1/2-8
Tires

Number of Wheel Front/Rear (x=driven) 2*/2 2*/2 2*/2

Tread, Front b10 mm [in] 940 [37.0] 940 [37.0] 950 [37.4]
1-6

Tread, Rear b11 mm [in] 170 [6.7] 170 [6.7] 170 [6.7]
Tilting Angle a/b Forward/Backward degree 6/10 6/10 6/10
Mast Height, Lowered h1 2-stage Mast mm [in] 1995 [78.5] 1995 [78.5] 2110 [83.1]
Std. Free Lift h2 2-stage Std. Mast, from Ground mm [in] 140 [5.5] 140 [5.5] 150 [5.9]
Std. Lift Height h3 2-stage Std. Mast, from Ground mm [in] 3300 [130.0] 3300 [130.0] 3300 [130.0]
Mast Height, Extended h4 2-stage Std. Mast mm [in] 4255 [167.5] 4255 [167.5] 4270 [168.1]
Height, Overhead Guard h6 mm [in] 2070 [81.5] 2070 [81.5] 2070 [81.5]
Length, with Std. Forks l1 mm [in] 3005 [118.3] 3070 [120.9] 3185 [125.4]
Dimensions

Length, to Fork Face l2 mm [in] 1935 [76.2] 2000 [78.7] 2115 [83.3]
Width, at Tire b1 Single mm [in] 1110 [43.7] 1110 [43.7] 1160 [45.7]
Forks s/e/l Thickness / Width / Length mm [in] 35x100x1070 [1.4x3.9x42.1] 35x100x1070 [1.4x3.9x42.1] 36x122x1070 [1.4x4.8x42.1]
Fork Carriage Class ISO 2328, Type A/B/no Class 2, Type A Class 2, Type A Class 2, Type A
Width, Fork Carriage b3 mm [in] 970 [38.2] 970 [38.2] 970 [38.2]
m1 Under Mast mm [in] 95 [3.7] 95 [3.7] 95 [3.7]
Ground Clearance
m2 at Center of Wheelbase mm [in] 125 [4.9] 125 [4.9] 125 [4.9]
Ast with L1000 x W1200 pallet mm [in] 2935 [115.6] 2995 [117.9] 3115 [122.6]
Right Angle Stacking Aisle
Ast with L1200 x W800 pallet mm [in] 3135 [123.4] 3195 [125.8] 3315 [130.5]
Turning Radius Wa mm [in] 1530 [60.2] 1590 [62.6] 1690 [66.5]
 Model Manufacturer’s Designation Unit FB15MU-12 FB18MU-12 FB20MU-12
Travel Speed (FWD) Loaded / Unloaded km/h [mph] 15.0/17.0 [10/11] 15.0/17.0 [10/11] 14.0/16.0 [9/10]
Lifting Speed Loaded / Unloaded mm/s [fpm] 340/600 [67/118] 320/600 [63/118] 280/500 [55/98]
Lowering Speed Loaded / Unloaded mm/s [fpm] 450/550 [89/108] 450/550 [89/108] 370/440 [73/87]
Performance

Max. Drawbar Pull Loaded, 3 min. rating N [lbf] 9560 [2150] 9560 [2150] 9045 [2033]
Max. Gradeability Loaded, 3 min. rating/1.5/h % 19 16 14
Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS FHPS
Drive Motor (AC) 60 min. rating kW 4.5x2 4.5x2 4.5x2
Pomp Motor (AC) 5 min. rating kW 9.0 9.0 9.0
Drive

Battery Voltage V 48 48 48
Battery Capacity, Max. Ah/6hr 600 600 600
Battery Weight Max. Capacity Battery kg [lb] 950 [2094.4] 950 [2094.4] 950 [2094.4]
Drive Motor Control Transistor Transistor Transistor
Others

Relief Pressure Attachment bar [MPa, kg/cm2, PSI] 176 [17.6, 180, 2560] 176 [17.6, 180, 2560] 176 [17.6, 180, 2560]
Reservoir Capacity Ltr [U.S. gal] 23 [6.1] 23 [6.1] 23 [6.1]
1-7

1. SPECIFICATIONS AND GENERAL INFORMATION

1. SPECIFICATIONS AND GENERAL INFORMATION

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

To operate the lift truck truck safely, replace periodically the parts, which are especially related to safety and
fire, on the important replacement parts list below.
Since the materials change as time goes, these parts are subject to wear and degradation. But, it is hard to
judge the degree of deterioration in the periodic maintenance. Therefore, after a certain period of use, even if
no defect is observed, these parts should be replaced with new ones to maintain the lift truck in safe condition.
However, if any abnormality is found on these parts before periodic maintenance, repair or replace them.
When replacing the hose, if the degradation of hose clamp such as deformation and crack is found, replace
the hose clamp at the same time.
The periodic replacement is not covered by the warranty.

Important Replacement Parts List

No. Part name Years

1 Master cylinder and wheel cylinder caps, dust seals 1
2 Brake hose or tube 1-2
3 Brake reserve tank, tube 2-4
4 Power steering hose 2
5 Rubber parts of power steering 2
6 Lift chain 2-4
7 Hose of load handling 1-2

1-8
 1. SPECIFICATIONS AND GENERAL INFORMATION

STANDARD TIGHTENING TORQUE FOR BOLTS

TIGHTENING TORQUE when using torque wrench or spanner shall be in accordance with Table. This torque
shall be used when TIGHTENING TORQUE of especially narrow range is required.

1. Using impact wrenches or spanners 2. Using torque wrenches

Unit: kgm (Nm) [ft. lb]

Unit: kgm (Nm) [ft. lb]

S43C, SMn34CH SMn40CH, S43C, SMn34CH SMn40CH,

Width across flats mm Width across flats mm
(in) SCM3H (in) SCM3H
Thread or superior ones Thread or superior ones
dia. dia.
mm (in) Conven- mm (in) Conven-
ISO ISO
tional threads Range Torget tional threads Range Torget
threads threads
0.9 - 1.5 1.2 1.2 - 1.5 1.35
6 10 10 6 10 10
(0.24) (0.39) (0.39) (8.8 - 15) (12) (0.39) (12 - 15) (13.2)
(0.24) (0.39) [8.7 - 11] [9.8]
[6.5 - 11] [8.7]
1.5 - 3.5 2.5 2.8 - 3.5 3.2
8 14 13 8 14 13
(0.31) (0.55) (0.51) (15 - 34) (25) (0.51) (27 - 34) (31)
(0.31) (0.55) [20 - 25] [23]
[11 - 25] [18]
3.5 - 7.5 5.5 6 - 7.5 6.7
10 17 17 10 17 17
(0.39) (0.67) (0.67) (34 - 74) (54) (0.67) (59 - 74) (66)
(0.39) (0.67) [43 - 54] [48]
[25 - 54] [40]
5.5 - 12.5 9.0 10 - 12.5 11.5
12 19 19 12 19 19
(0.47) (0.75) (0.75) (54 - 123) (88) (0.75) (0.75) (98 - 123) (113)
(0.47) [72 - 90] [83]
[40 - 90] [65]
8.5 - 20.0 14.0 21 16 - 20.0 18
14 21 22 14 22
(0.55) (0.83) (0.87) (83 - 196) (137) (0.83) (0.87) (157 - 196) (177)
(0.55) [116 - 145] [130]
[61 - 145] [101]
15.0 - 31.5 23.5 16 25 - 31.5 28.5
16 23 24 23 24
(0.63) (0.91) (147 - 309) (230) (0.63) (0.91) (0.94) (245 - 309) (279)
(0.94) [181 - 228]
[108 - 228] [170] [206]
20.5 - 43.5 32.0 18 26 35 - 43.5 39
18 26 27 27
(0.71) (1.02) (201 - 427) (314) (0.71) (1.02) (1.06) (343 - 427) (382)
(1.06) [253 - 315]
[148 - 315] [231] [282]
32.5 - 62.0 47.0 20 50 - 62.0 56
20 29 30 29 30
(0.79) (1.14) (319 - 608) (461) (0.79) (1.14) (1.18) (490 - 608) (549)
(1.18) [362 - 448]
[235 - 448] [340] [405]
48.0 - 84.5 66.5 22 67.5 - 84.5 76
22 32 32 32 32
(0.87) (1.26) (471 - 829) (652) (0.87) (1.26) (1.26) (662 - 829) (745)
(1.26) [488 - 611]
[347 - 611] [481] [550]
60.0 - 105 82.5 24 84 - 105 94.5
24 35 36 35 36
(0.94) (1.38) (588 - 1030) (809) (0.94) (1.38) (1.42) (824 - 1030) (927)
(1.42) [608 - 759]
[434 - 759] [597] [684]
90.0 - 150 120 120 - 150 135
27 41 41 27 41 41
(883 - 1471) (1177) (1.06) (1177 - 1471) (1324)
(1.06) (1.61) (1.61) (1.61) (1.61)
[651 - 1085] [668] [868 - 1085] [976]
115 - 195 155 155 - 195 175
30 46 46 30 46 46
(1128 - 1912) (1520) (1.18) (1520 - 1912) (1716)
(1.18) (1.81) (1.81) (1.81) (1.81)
[832 - 1410] [1121] [1121 - 1410] [1266]
150 - 250 200 200 - 250 225
33 50 50 33 50 50
(1471 - 2452) (1961) (1.30) (1961 - 2452) (2206)
(1.30) (1.97) (1.97) (1.97) (1.97)
[1085 - 1808] [1447] [1447 - 1808] [1627]
190 - 310 250 250 - 310 280
36 54 55 36 54 55
(1863 - 3040) (2452) (1.42) (2452 - 3040) (2746)
(1.42) (2.13) (2.17) (2.13) (2.17)
[1374 - 2242] [1808] [1808 - 2242] [2025]
230 - 370 300 295 - 370 335
39 58 60 39 58 60
(2256 - 3628) (2942) (2893 - 3628) (3285)
(1.54) (2.28) (2.36) (1.54) (2.28) (2.36)
[1664 - 2676] [2170] [2134 - 2676] [2423]

a This table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be
used, or which requir to tighten to otherwise specified torque.

Conventional screw threads ISO screw threads

1-9
1. SPECIFICATIONS AND GENERAL INFORMATION

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

Elbows, nipples and unions

22 30 36
Width across flats B mm (inch)
(0.866) (1.181) (1.417)
19 22 30
Width D mm (inch)
(0.748) (0.866) (1.181)
29.4 - 39.2 {3 - 4} 78.5 - 103 {8 - 10.5} 117.7 - 161.8 {12 - 16.5}
Tightening torque Nm {kgm} [ft.Ib]
[21.7 - 28.9] [57.9 - 75.9] [86.8 - 119.3]
Port size(inch) 3/4-16UNF 13/16-12UNF 15/16-12UNF
68.6 - 73.6 {7 - 7.5} 117.7 - 161.8 {12 - 16.5} 107.9 - 147{11 - 15}
Tightening torque Nm {kgm} [ft.Ib]
[50.6 - 54.2] [86.8 - 119.3] [79.5 - 108.4]

High-pressure rubber hoses, pipes and sleeve nuts

Width across flats B 19 24 27 32 36

(mm) (inch) (0.748) (0.945) (1.063) (1.260) (1.417)
Bore A 14 18 22 24 30
mm (inch) (0.551) (0.709) (0.866) (0.945) (1.181)
147 - 206 {15 -
19.6 - 29.4 {2 - 23.5 - 68.6 {3 - 58.8 - 98.1 {6 - 107.9 - 166.7
Tightening torque 21}
3} 7} 10} {11 - 17}
Nm {kgm} [ft.Ib] [108.52 -
[14.5 - 21.7] [21.7 - 50.6] [43.7 - 72.3] [79.6 - 122.9]
151.8]

1-10
 1. SPECIFICATIONS AND GENERAL INFORMATION

HOW TO USE LOCTITE

4. Assembly
After applying LOCTITE, tighten the screw or fit the
Male side shaft to the hole as usual. (When using LOCTITE for
structures or LOCTITE of instant glue type, press
Degreasing Air drying the mating parts lightly (about 49 kPa {0.5 kgf/cm2}).
Female
side Removal of parts
When screws and shafts are secured with LOC-
TITE, they usually can be removed with common
Leaving Applying
Assembly tools such as spanners, wrenches, and pulley pull-
LOCTITE ers. If LOCTITE is so strong that a part may be bro-
ken when it is removed, heat it (to 200 - 250°C) with
1. Degreasing and cleaning a soldering iron, gas torch, etc., and you can
remove it easily. It is generally difficult to dissolve
1) Clean the parts in trichloroethylene, acetone,
LOCTITE in chemical solutions.
ether, alkaline solution, etc. which are highly
volatile.
When assembling again
2) Degrease the parts as perfectly as possible. 1) If a LOCTITE film on threads is broken, it is left
3) Since gasoline, light oil, kerosene, etc. are not as white powder on the threads. In this case,
highly volatile, they are not recommended. If it you can apply LOCTITE again to the threads
is obliged to use them, dry them completely. without removing the white powder.
4) If the mating parts are made of thermosetting 2) If shafts or flanges secured with LOCTITE are
resin, treat them with LOQUICK PRIMER after disconnected, LOCTITE remaining on them
degreasing them. may need to be removed to maintain dimen-
2. Air drying sional accuracy. You can remove the remaining
LOCTITE easily, however, with a wire brush,
1) Wait until the cleaning fluid dries out. etc.
2) If the parts are treated with LOQUICK 3) If plates secured with LOCTITE need to be
PRIMER, do not wipe them but dry them in air assembled again after they are separated, be
for 5 - 10 minutes. (If LOCTITE is used before sure to remove all the hardened LOCTITE and
LOQUICK PRIMER dries out, its effect is low- roughen the mating surfaces with sandpaper.
ered.)
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads or
the shaft and hole to be fitted by amount to fill the
clearance between them by one of the following
methods.
• Applying directly from LOCTITE container nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.

1-11
SAFETY

SAFETY

PRECAUTIONS WHEN PERFORMING SERVICE WORK

Always pay attention to “Safety” before starting any work — this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag mark
inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.

DESCRIPTION OF SYMBOLS
The symbols described below are used in this manual for convenience and better understanding.

Symbol Item Description

Safety Special safety precautions are needed to perform the work.

Note Special technical precautions are needed to perform the work

Tightening Fastening parts that require specified tightening force when assembling.
torque

Weight Weight of parts or systems

Coat Places to be coated with adhesives, etc. when assembling

1-12
 FIRE PREVENTION

FIRE PREVENTION
BATTERY FIRE PREVENTION

PREVENTION OF FIRE CAUSED BY

HYDROGEN GAS EMITTED FROM BATTERY
• Batteries generate flammable hydrogen gas.
• Never smoke or allow any flame near the battery.
• Sparks may ignite the gas. Do not place tools, parts or
other metal objects on the battery.
• Charge batteries always in a well-ventilated place with
the battery hood open.
• If flammables are deposited or attached to around the
motor or batteries, they may cause fire. Remove the
deposits and attached material from the above locations.

CAUTIONS WHEN HANDLING BATTERY

• Handling error of batteries may cause explosions, fires and other critical injuries. Handle batteries after
fully understanding their hazards and how to handle them.
• Leave the battery hood open while charging: batteries generate flammable hydrogen gas that may collect
and explode in contact with fire.
• Do not smoke or allow any flame near the battery: sparks may ignite and explode the gas.
• Do not place tools, parts or other metal objects on the battery.
• To clean the top surface of battery, wipe with wet cloth before recharging. DO NOT use dry cloth for
wiping and dusting the battery, DO NOT cover battery with vinyl sheeting: these generate static
electricity that may cause explosion.
• Depending on the weather, environmental, clothing material and other conditions, human bodies may
transmit static electricity. Before touching lift truck during or after charging, discharge the static electricity
deposit in human bodies by grounding.
• Charge batteries always in a well-ventilated place with the battery hood open.
• Flammable substances or water deposited on or adhered to the motor or battery may cause a fire.
Remove deposits and attached substances.
• When repairing the electrical system, disconnect the battery plug to stop power supply.
DO NOT start repairing electrical system by merely depressing emergency power cut-off button.

1-13
FIRE PREVENTION

ACTION FOR ABNORMALITIES

DO NOT drain battery electrolyte, disassemble or repair batteries or battery plugs: doing so may
cause explosion and/or electric shock. If the following are detected, call KOMATSU FORKLIFT
dealer for service:
• Battery plug and charging plug mating become loosened or play occurs (plug becomes abnormally
heated).
• Battery electrolyte temperature is high.
• Battery electrolyte decreases sharply.
• Battery emits odor.
• Battery electrolyte becomes turbid.
• Looseness and play of the battery terminals
• Leakage from or corrosion on the top surface of the battery
• Corrosion in periphery of battery
• Damage to battery cap (vent plug)
• Charging requires too long a time.

FIRE PREVENTION DURING CHARGING

CAUTIONS BEFORE CHARGING

• Carry on charging in a well-ventilated place sheltered
from rainfall. Do not recharge batteries near fire or
hazardous substances, in place of high humidity or place
splashed by water, which may cause fire.
• Before starting charging, first set the starting switch to
[Q] (OFF) position.
• Open the battery hood fully and lock the gas spring
stopper (bright red) to prevent hydrogen gas from
accumulating.
• Do not allow electrolyte to drop below minimum level:
battery may become overheated and cause fire.
• Wipe the top surface of battery before recharging to
prevent static electricity build-up during cleaning.
• Inspection of plugs and cables (items to be inspected monthly):
- Check the charging plug, battery plug and cables for damage.
- Check the engaged portion of the plug on the lift truck and charging plug for any looseness or play.
If any abnormalities are detected, do not use the lift truck until the affected part has been repaired.
- In particular, ensure that the battery plug is locked and securely engaged to the plug on the lift truck
without any looseness or play.
• When connecting or disconnecting a plug, be sure to relieve the lock by holding the plug body. Pulling
cable may cause short circuit of the cable and plug, leading to fires.
• Do not remove or modify the lock of the battery plug.
• Please use the charging plug attached to the lift truck as this plug has been specified by the
manufacturer.
Do not use plugs from other manufacturers or that are different shapes.

1-14
 FIRE PREVENTION

CHARGING OPERATION CAUTIONS

• When charging the battery, do it in a well-ventilated
location with battery hood (1) open.
• Connection of charging cord:
- Connect charging plug (4) attached to the charging
cord securely into battery plug (5). Please use the
charging plug attached to the lift truck as this plug
has been specified by the manufacturer.
- Do not use plugs from other manufacturers or that
are different shapes.

CAUTIONS WHEN CHARGING

• During or immediately after the battery is charged, surrounding area may be filled with flammable
hydrogen gas. Never smoke or use fire near the battery.
• Sparks and/or static electricity may ignite the gas. Do not handle tools and other metal carelessly in the
surrounding area of the lift truck. Ground and release static electricity charged to human bodies before
touching the lift truck or charger.
• When stopping battery charging that is already underway:
- Press the "STOP" button on the battery charger before disconnecting the charging plug. Discon-
necting the plug without pressing the "STOP" button may generate sparks, potentially leading to
burns or fire.
- Release the lock before disconnecting the plug. The plug may be damaged if you try to forcibly dis-
connect it without releasing the lock.
• Charge battery when the ambient temperature reads 0°C - 40°C (32°F - 104°F).
• Battery and charger form a set to enable optimal charging. To avoid fire, do not charge batteries outside
the rated capacity of charger or different types of batteries.

1-15
FIRE PREVENTION

INSPECTION AND MAINTENANCE

• The following are to be inspected monthly. They must all be checked.
- Engagement status and damage to the charging plug and the battery plug
- Engagement status and damage to the battery plug and the plug on the lift truck
• Do not place the charging plug directly on the ground, or store it in a location where it may be exposed to
dripping water or be otherwise damaged.
• Transformer tap adjustment for charger shall be carried out by your KOMATSU FORKLIFT dealer. To
avoid the risk of fire due to overheated charger, do not modify the charger by yourself.
• Work on the power supply equipment should be made under the instructions of chief electric engineer or
by an electric contractor designated by a power company.
• Connect the grounding wire to the electrical outlet on the plant side to prevent electrical shock accident.
• Do not use supply voltage and receptacles other than those specified.
• Use earth leakage breaker for the breaker.
• For the variation of supply voltage, see the Operation and Maintenance Manual attached to the charger.
• Do not disassemble or modify the charger.
• Charger is designed and manufactured according to the life of lift truck. To prevent accident, dispose the
charger on conventional lift truck simultaneously with the disposal of the lift truck. Do not use it
continually.

PREVENTION OF FIRE CAUSED BY OIL AND GREASE

Oil and greases are flammable, so keep them away from open flame. Strictly follow the instructions below.
Failure to comply with these safety policies may result in serious injury or death.
• Do not smoke or allow any flame near oil, clothes soaked in them.
• Tighten caps securely.
• Do not spill oil and greases on the overheated surface or electrical system components.
• Store oil and greases in a well-ventilated dark cold place.
• Store oil and grease in a designated place. Keep unauthorized people off the storage.
• Wipe off the spilled oil and greases.
• Put clothes soaked in oil and other flammable objects in a secure container and store them in a safe
place.
• Be cautious and take measures for fires that may be ignited with a spark or flame when handling equip-
ment and devices for inspection and/or maintenance.

PREVENTION OF FIRE CAUSED BY LEAKED OIL

Leaked oil may catch fire. If an oil leakage is detected in the following locations, contact your KOMATSU
FORKLIFT dealer.
• Hydraulic oil tank
• Hydraulic piping
• Pump motor
• Control valve

1-16
 FIRE PREVENTION

PREVENTION OF FIRE CAUSED BY DEPOSITED OR ADHERED FLAMMABLE

SUBSTANCES
Flammable substances or water that is deposited on or that has adhered to the motor or battery may cause a
fire. Remove the deposits and attached substances.

PREVENTION OF FIRE CAUSED BY FAULTY ELECTRICAL WIRING

Short-circuiting of the electrical wiring may cause a fire.
• Clean all the electrical wiring connections, and fix them firmly.
• Check daily for looseness, wear and damage of the wiring. Re-tighten the loose connector and wiring
clamp. Damaged wiring must be repaired or replaced by your dealer.

PREVENTION OF FIRE CAUSED BY FAULTY PIPING

Make sure that the clamp, guard and cushion of the hose and tube are fixed securely. A loose hose or tube
may be damaged by vibration during operation or by rubbing against other parts, and cause the high pressure
fluid to spurt out and cause a fire or bodily injury.

CLEANING
After the operation, use an air blower or similar device to
clean off any dirt or dust that has entered into the battery
hood or that has been deposited on the traveling motor.
In particular, any dirt or dust that has accumulated in the fol-
lowing locations must be removed. Clean other locations as
necessary.
• Periphery of the battery
• Periphery of the left and right traveling motors

IF A FIRE BREAKS OUT

• If a fire breaks out, press emergency power cut-off button (red), cut off the electric circuit and stop the lift
truck.
• Do not jump off the lift truck in a rush. Support yourself securely with handrails and steps to evacuate.

1-17
BASIC PRECAUTIONS

BASIC PRECAUTIONS

FOLLOW RULES
• Only trained and qualified persons are allowed to operate
this lift truck.
• Fully understand and follow this operation and mainte-
nance manual.
• Do not operate the lift truck when you are ill, taking medi-
cine that causes drowsiness, under the influence of alco-
hol, or mentally unstable.
• Plan safety work beforehand.
Before operation, make up an operating plan that fits the
workplace conditions, type and capacity of the lift truck,
and the load conditions.
In confined areas or when loading/unloading large items,
position a signal person and carry out operations in
accordance with their instructions.
• During operation, safety must be your primary responsi-
bility ensuring the safety of those you are working around,
the lift truck, yourself, and other property in the work area.

NEVER OPERATE A BROKEN-DOWN LIFT

TRUCK
• If any abnormality is detected during the start-up inspec-
Never
use

tion or during the operation (noise, vibration, odor, malad-

justed gauge, smoke, oil leak, or erroneous indication of
warning device or monitor), report the administrator
immediately and take adequate corrective actions. Danger

• Do not operate the lift truck until the abnormality is cor-

rected.
• Remove the key from the faulty lift truck and put up signs
in the operator’s compartment to prevent its use.
• If the lift truck has a failure and must be parked without lowering the forks, put markers on the tips of the
forks and take steps to prevent pedestrians or other vehicles from hitting the forks.
• Select a parking place where people or vehicles do not pass. Take measures to prevent anyone to go
under the forks. (Space under lifted forks is dangerous zone.)

1-18
 BASIC PRECAUTIONS

WEAR ADEQUATE CLOTHES AND SAFETY

EQUIPMENT FOR OPERATION
• Avoid loose clothing and accessories; there is danger that
they may catch on control levers and projections.
• Long, loose hair can be caught in a rotating part: it must
be tied back.
• Always wear a safety helmet and safety shoes. Wear
other safety equipment appropriate for the working condi-
tions or as required by your administrator.
• Check that the safety equipment works properly before
use.

FIRE EXTINGUISHER AND FIRST AID KIT

In preparation for a fire or bodily injury, check the locations of
fire extinguisher and first aid kit, and be familiar with the
usage.

CAUTIONS FOR SAFETY-RELATED EQUIPMENT

• Confirm that all protective guards, covers, and mirrors are properly mounted. Repair them immediately
when broken.
• Be sure that you fully understand how to use safety-related equipment.
• Never remove the safety-related equipment. Keep them fully functional at any time.
• Do not operate this lift truck if the overhead guard or load backrest has been or appears to have been
damaged or loosened until repairs have been made by your authorized KOMATSU FORKLIFT dealer.

PRACTICE SUFFICIENTLY BEFORE OPERATION

• Take sufficient time for practice until you become familiar with the operation of each component before
starting the actual operation.
• Even after you become familiar with it, operate with caution and avoid harsh operation; it can cause bodily
injury or damage.
• Each lift truck is more or less peculiar in the performance of brake, accelerator, and load handling device
even though it is the same model type. When you changeover lift trucks, understand the peculiarity of
each lift truck before starting operation. Be especially careful with brake, since its performance varies by
individual lift truck.

1-19
BASIC PRECAUTIONS

JUMPING ON AND OFF THE LIFT TRUCK IS

STRICTLY PROHIBITED
• Never jump on or off the lift truck. It is extremely danger-
ous.
• Even if the lift truck accidentally starts to move without
operator onboard, never attempt to jump on the lift truck
to stop.
• Always mount and dismount the lift truck from the left
side.
• While mounting and dismounting the lift truck, always
support yourself securely with your hands and feet at
more than 3 locations: put your left foot on the step, grab the assist grip (handrail) with your left hand, and
grab the backrest or hip support of the seat with your right hand.
• Do not hold on the control levers or steering wheel when mounting or dismounting the lift truck.

KEEP THE OPERATOR’S COMPARTMENT

AND PLATFORM CLEAN AND TIDY
Always keep the operator’s compartment and platform (assist
grip, step, floor) clean and tidy. Oil, attached mud or dust, or
spare parts or tools left lying around in the operator’s com-
partment may cause the operator’s hand or foot to slip or
clothes to get caught, leading to a fall or a mistake in opera-
tion.

PRECAUTIONS WHEN WASHING LIFT TRUCK

Water entering into the electrical parts (controllers, sensors,
connectors) may cause a dangerous malfunction. DO NOT
wash the electrical parts of the lift truck or use a high-
pressure washer (steam cleaner) on them.

1-20
 BASIC PRECAUTIONS

TO AVOID BURN INJURY

HIGH TEMPERATURE PARTS AND OIL

To prevent burns caused by high temperature parts such as
motor, controller, charger, or by the spurt of oil, carry out
inspection and maintenance work after these parts cool down
and can be touched safely with bare hands.

DO NOT MODIFY THE LIFT TRUCK

• Contact your KOMATSU FORKLIFT dealer in advance for any modification (installation, removal and
modification) of the lift truck, attachment or option. It may cause safety hazard and may violate the law.
• KOMATSU FORKLIFT will not be responsible for any bodily injury, damage or failure which results from
the modification made without prior consent of your KOMATSU FORKLIFT dealer in writing.

DO NOT REMOVE THE OVERHEAD GUARD

AND LOAD BACKREST
• Do not remove the overhead guard or load backrest,
which are installed to protect the operator from falling
objects.
• Do not operate this lift truck unless it is equipped with the
overhead guard and load backrest shipped with the lift
truck from the factory by the manufacturer.
• The overhead guard is built in compliance with the safety
standards. However, it is not designed to withstand every
possible impact. Always be careful to prevent damage or
injury from falling objects.

1-21
BASIC PRECAUTIONS

SECURE SAFETY AT THE WORKING AREA

• Working on a rough surface can result in bodily injuries
such as backache. Always keep the passages and work
areas flat and smooth without bumps.
• Wipe up all spiledl oil and grease from the ground to pre-
vent tip over or collision due to slipping.
• When working on platforms, docks, quays, or other
places where there is danger of falling, set up blocks to
prevent the lift truck from going over the edge.
• Put warning signs up in dangerous places to warn the
operator not to approach.
• Mark the traffic areas clearly, and establish a clear traffic
rule such as temporary stop line, speed limit, no-entry
area for other vehicles and pedestrians.
• Provide adequate lighting for safety operations.

ASBESTOS CAUTION
• Non-Genuine Parts (unspecified parts of KOMATSU FORKLIFT) such as clutch disc, brake lining, gasket
and packing may contain asbestos. Use Genuine Parts.
• All the parts used in this lift truck are asbestos-free.

1-22
 START-UP INSPECTION

START-UP INSPECTION

ALWAYS CONDUCT A START-UP INSPECTION IN THE BEGINNING OF THE DAY

FOR YOUR SAFETY OPERATION OF THE LIFT TRUCK
• Do not operate the lift trucks before completing start-up inspection.
• Report abnormality, if any, immediately to the administrator. Never operate the lift truck in question until
the repair is completed.

CAUTIONS FOR OPERATING STARTING

SWITCH, STARTING THE LIFT TRUCK AND
OPERATING WORK EQUIPMENT
• When operating the starting switch, always seat yourself
properly on the operator’s seat, apply the parking brake
lever and turn the starting switch ON.
• Before starting the lift truck or operating the work
equipment (mast, fork), check the safety in the
surrounding areas and sit in the operator’s seat.
• Before moving the lift truck or operating the work
equipment, sound the horn to warn people nearby.

CAUTIONS WHEN CHECKING SAFETY FUNCTION

Before checking safety function, retain wide safety space around the lift truck in case it makes a sudden,
unexpected movement. Check that the area is free of people and obstacles. (Apply travel interlock, lift
interlock, neutral safety and parking brake.)

CAUTION IN COLD WEATHER

• Immediately upon starting operation for the day in cold weather, travel and lifting speed may be slow or
steering effort may be heavier or steering movement may change suddenly, leading to accident. Operate
the lift truck carefully until oil and lift truck components warm up properly.

1-23
TRAVELING THE LIFT TRUCK

TRAVELING THE LIFT TRUCK

PREPARATION BEFORE TRAVELING THE LIFT TRUCK

USE THE SEAT BELT

• Always fit the seat belt properly before operation.
• Not using the seat belt properly may result in serious
bodily injuries if the lift truck tips over.
• Make sure the seat belt is free from damage and flaw.

TAKE A RIGHT POSTURE ON THE SEAT

If you operate the lift truck when you are not seated properly
or off the seat, an accident may happen unexpectedly. To
forestall such a possible accident, this lift truck is provided
with TRAVEL INTERLOCK and LIFT INTERLOCK that
make traveling and lift truck operation disabled if you are not
seated properly.

TAKE A RIGHT POSTURE WHILE OPERATING

• Do not stick the hand or foot outside the lift truck body.
• Always keep your body under the overhead guard.

1-24
 TRAVELING THE LIFT TRUCK

BEFORE TRAVELING THE LIFT TRUCK,

CHECK THE SAFETY OF SURROUNDING
AREA
• Raise the forks approx. 15 - 20 cm (6 - 8 in) from the
ground and tilt the mast back.
• Before starting to travel the lift truck, check that the
surrounding area is clear of obstructions such as
pedestrians, other trucks and loads. 15 - 20 cm
(6 - 8 in)
• Sound the horn areas as may be needed.

WHILE TRAVELING THE LIFT TRUCK

BE ALWAYS CONSCIOUS OF SAFETY WHILE

TRAVELING
• Avoid sudden starting, braking, or making sharp turns.
• Keep a clear view of the path of travel.
• When passing oncoming vehicles, reduce speed and
keep a safe distance from the other vehicle.
• In places where there are speed limits, observe the
speed limit and maintain a safe distance from other
vehicles.
• When traveling, always pay careful attention to the area
around your lift truck, particularly in the direction of travel
or when turning.
• Do not attempt to pass another lift truck or vehicle on a narrow path or on a spot of limited view like a
crossing.
When passing through a crossing or turning a corner, or when traveling into a narrow path, stop the lift
truck once to check the safety. Sound the horn to warn people around if necessary.
Even if you sound the horn, not everyone in the surrounding area will necessarily hear it. Always pay
careful attention to the movements of people in the surrounding area.
• Do not allow people to enter the working area.
• When traveling on a slope or through a crowded spot, always give way to a loaded lift truck.

DO NOT ALLOW ANY PASSENGER

• Never allow any other person to ride with you on the lift
truck for whatever reasons.
• Do not use anyone for a counterbalance-weight.

1-25
TRAVELING THE LIFT TRUCK

NEVER TURN OFF THE STARTING SWITCH WHILE TRAVELING

If the starting switch is turned to [Q] (OFF) while traveling, the power steering effort may become heavier,
which is a dangerous condition.

OPERATING BRAKE PEDAL

Allow plenty of time for brake operation, depending on the situation, as the road surface and weight of the
load affect the stopping distance. Longer distance is required to stop on a downhill, wet or slippery surfaces,
and with heavy load.

DO NOT KEEP YOUR FOOT ON THE BRAKE

PEDAL WHILE TRAVELING
If you travel the lift truck with your foot on the brake pedal,
brakes may not work satisfactorily or wear out earlier. If this
situation continues, overheat protection function may work
to deteriorate the accelerating performance. Keep your foot
off the brake pedal during normal traveling.

WHEN BACKING UP THE LIFT TRUCK,

CHECK REVERSE DIRECTION VISUALLY
• When backing up the lift truck, always look back and
make a direct visual check on the rear of the lift truck.
The rear view mirror is simply an auxiliary aid for
checking the rear. When reversing, do not depend on the
rear view mirror alone for checking safety.
• Even if you sound the backup buzzer (option), the
people behind the lift truck do not necessarily hear it.
Always visually check directly with your eyes that there
is no one behind the lift truck while traveling.
• When carrying a high load, use a signal person or travel backward. If the view to the front is obstructed by
the load, operate the lift truck in reverse while minding safety in the area the lift truck is heading to, or
have a signal person to guide the travel.

1-26
 TRAVELING THE LIFT TRUCK

DO NOT TRAVEL THE LIFT TRUCK WHEN

THE FORKS ARE RAISED HIGH
If loaded or unloaded, raising the forks also raises the
center of gravity of the lift truck increasing a risk of tipping
over. Do not travel the lift truck with up-raised forks. (During
a travel, keep the forks approx. 15 - 20 cm (6 - 8 in) above
the ground with the mast tilted backward.)

NEVER JUMP OFF THE LIFT TRUCK WHEN THE LIFT TRUCK SEEMS TIPPING
OVER
1. Always use your seat belt during operations for your safety if lift truck should tip over.
2. Do not jump off the lift truck if the lift truck seems tipping over. Or you may be crushed by the lift truck
resulting a serious bodily injury.
3. Lean yourself in the opposite direction to the direction the lift truck is tipping.
4. Grip the steering wheel tightly.
5. Brace yourself with both feet to support your body.
Practice the following series of actions from time to time to master how to act in emergency situations.

WHEN MAKING A TURN, BE CAREFUL OF

THE SWINGING TAIL
• The lift truck has rear steering wheels. Be careful as it
behaves differently than passenger cars.
• When turning while traveling forward, the
counterbalance-weight will swing far out. Keep an ample
clearance from walls to ensure safety.

1-27
TRAVELING THE LIFT TRUCK

PAY CAREFUL ATTENTION TO THE LIFT

TRUCK MAXIMUM HEIGHT AND WIDTH
• Ensure that there is ample height and width for the lift
truck to pass.
• Keep clearance from doors, ceiling, wiring and pipes.
• Be careful with the height of the mast and load backrest
when the forks go up.

DO NOT TRAVEL ON ROUGH OR SLIPPERY ROAD

• Do not try to travel on bumpy or soft ground. It can lead to a serious accident when you lose steering
control or the tires stIck in the mud.
• Avoid traveling on the slippery road covered with water and oil. You will lose brake or steering control.

OBSERVE THE WEIGHT LIMIT

Do not allow overweight on the floors and roads where weight limit is specified.

DO NOT TRAVEL DIRECTLY OVER

OBSTACLES ON THE ROAD
Avoid clutter, curbs, rails, ditches, or other obstacles, and do
not travel directly over them. Also, the impact applied when
traveling over obstacles can result in bodily injuries such as
backache.

TRAVELING ON A ROAD SHOULDER IS

STRICTLY PROHIBITED
• There is danger that soft road shoulders may collapse.
Do not approach them.
• Always maintain a safe distance from the edge of road
shoulders and platforms to prevent the lift truck from
falling off.

1-28
 TRAVELING THE LIFT TRUCK

CAUTION WHEN TRAVELING ON SLOPES

• Do not turn on or traverse slopes, and be careful about
the approach/departure angle as the lift truck may tip
over.
• Before traveling uphill, stop the lift truck and adjust the
fork clearance from the ground. Keep the bottom of the
forks or pallet off the ground to prevent the tips of the
forks from sticking into the ground when traveling.
• For safe travel on slopes
When loaded Travel forward uphill and in reverse
downhill.
When unloaded Travel in reverse uphill and forward
downhill. When loaded

• On a down slope, depress the brake pedal and travel

slow.
• Lifting the hip up during uphill travel activates travel
interlock to cut off drive power, which may cause the lift
truck to stop and slide down the slope even if the
accelerator pedal is pressed, leading to possible
collision or tipping over. Take a right posture while When unloaded
operating.

EXERCISE CARE WHEN TRAVELING INTO A

RAILWAY WAGON OR CONTAINER
• Check that brake and block are applied to wagons,
trailers, and containers to keep them stationary.
• Tell the carrier drivers not to move their vehicles until the
load handling operation is completed.
• Ramps used for approaching the wagon and/or trailers
must withstand the repeated travel of loaded lift trucks.
• Engage the ramps securely to wagons and trainers.
• Do not travel at the edge of the platforms or loading
docks as there is danger of the lift truck falling down.

1-29
TRAVELING THE LIFT TRUCK

STOPPING AND PARKING

FOLLOW THE STEPS FOR STOPPING AND

PARKING
1. Stop the lift truck on firm level ground. Free
2. Apply the parking brake lever to prevent the lift truck
from moving.
Lock
3. Set the forward/reverse switch to N (Neutral).
4. Tilt the mast forward and lower the forks to the floor.
5. Turn the starting switch key to the [Q] (OFF) position.
6. Pull out the starting key and leave the lift truck.

PARK THE LIFT TRUCK IN A SAFE PLACE

• Park the lift truck on firm level ground.
• Do not stop or park near any emergency exit or safety equipment.
Stop or park the lift truck in a place where it will not obstruct pedestrians or other vehicles.
• Do not park the lift truck on a slope. If parking on a slope is unavailable, apply blocks to the tires.

TOWING

BE CAREFUL WHEN USING THE DRAWBAR

PIN
• The drawbar pin is provided for use by the wrecking
truck when the tires are stuck in a ditch or mud.
• Do not use the drawbar pin for towing or hoisting.
• The drawbar pin can be used for an anchor point of this
lift truck when being transported by a truck.

DO NOT TOW A DISABLED LIFT TRUCK

If there is any problem with the brakes or steering system of your lift truck, do not tow it with another lift truck.
There is a danger that the disabled lift truck may move accidentally.

1-30
 LOAD HANDLING OPERATION

LOAD HANDLING OPERATION

SIT ON THE SEAT CORRECTLY FOR LOAD HANDLING OPERATION

To avoid accidents, Load Handling Interlock activates to disable the load handling operation when you are
not seated properly or off the seat.

DO NOT ALLOW ANYONE IN THE WORKING AREA EXCEPT THE SIGNAL PERSON
• To avoid accidents, keep unauthorized people and other vehicle off the working area except a signal
person during the load handling operation.
• Use a signal person when it is necessary to ensure visibility or for other safety reasons.
• When working with a signal person, always follow their instructions.

DO NOT GO UNDER LIFTED FORKS

Lifted forks may accidentally fall down to cause serious
injuries to persons below. Keep everyone away from under
lifted forks.

WORKING ON THE FORKS IS STRICTLY

PROHIBITED
• Do not directly place a load manually on the forks.
• Do not directly remove a load manually from the forks.
• Do not step on the forks to handle a load. The load may
slip down the forks.
• Do not hold the load on the forks by hands. Sudden lift
truck movement may cause the load to fall on the person
below.

1-31
LOAD HANDLING OPERATION

BE CAREFUL NOT TO GET CAUGHT IN THE

MAST STRUCTURE
• Never put your hands, feet, or other body parts into the
mast structure or you may get caught in moving parts
and be seriously injured.
• Do not stand between mast and operator’s compartment
as you may be crushed and be seriously injured or killed.
• Always operate the mast and forks from the operator’s
compartment.

DO NOT CLIMB ON THE MAST OR LOAD

BACKREST
If you climb on the mast or load backrest, there is a danger
of being caught in the moving parts or fall off.

USE A PALLET OR SKID OF AMPLE STRENGTH

• Always use pallets and skids of robust construction. Do not use broken or damaged pallets or skids.
• Before traveling, always check that the load is positioned securely and safely on the pallet.

1-32
 LOAD HANDLING OPERATION

HANDLE A LONG OR WIDE LOAD WITH

EXTRA CARE
• Be extremely careful when carrying long or wide loads.
Lift the load slowly and avoid hitting anything in the
surrounding area.
• When switching direction, keep the load as low as
possible and maintain the balance.

BE CAREFUL WITH THE MAST HEIGHT

• As the forks go up, the mast height increases. Be
mindful of this fact during the operation.
• Take care not to hit with the mast electric wirings, piping,
sprinklers, beams in the ceiling. If a hit occurs, there is
danger that the load on the forks drops off or the lift truck
tips over.

OVERLOADING IS STRICTLY PROHIBITED

Overloading may cause the rear wheels to come off the
ground and the lift truck to lose balance and tip over. DO
NOT load the lift truck over the maximum capacity
shown in the load table. For details, see “ACTUAL
CAPACITY” on page 1-46 and “SERIAL NUMBER AND
LOAD TABLE” on page 1-47.

1-33
LOAD HANDLING OPERATION

DO NOT TILT THE MAST FORWARD WITH A

LOAD ON THE FORKS
• Do not tilt the mast forward with the load raised.
• Do not raise the load with the mast tilted forward or the
load may fall or the lift truck may tip over.
• Do not travel with the mast tilted forward.

DO NOT HANDLE A LOAD IN AN INSECURE

MANNER
• Make sure that the center of gravity of the load is in line
with the center of the lift truck. Do not carry loads off-
center.
• Secure the load in position to prevent collapsing or
falling.
Do not handle unstable loads.
• Place the load so that it makes contact with the load
backrest.

DO NOT LOAD AND UNLOAD ON SLOPES

Loading or unloading on the slopes may cause the lift truck
to lose its balance and tip over.

DO NOT LOWER THE LOADED FORKS HASTILY

Do not operate the forks roughly or make a sudden stop. Sudden lowering may cause the collapsing or
falling of the load, and the lift truck may go off balance and tip over.

1-34
 LOAD HANDLING OPERATION

DO NOT HANDLE A LOAD EXCEEDING THE

LOAD BACKREST HEIGHT
If the load is higher than the load backrest, there is danger
that it may fall back on the operator. DO NOT handle a
load exceeding the load backrest height.

DO NOT PRY SOMETHING WITH THE TIPS OF

THE FORK
Or the hooked object may suddenly come off the tip and be
damaged. The reaction may result in an unexpected motion
of the lift truck or load that may become a safety risk.

DO NOT USE THE FORKS TO PUSH OR PULL

A LOAD
There is the risk that the load will be damaged or fall.

1-35
LOAD HANDLING OPERATION

DO NOT USE THE LIFT TRUCK FOR ANY

OTHER PURPOSE
• Do not use the lift truck for any other purpose than load
handling with forks or attachments.
• Do not open or close the doors of railroad cars or
warehouses with the forks.
• Do not push or pull any other vehicle.
• Do not lift loads suspended from the fork with ropes. The
rope may slip, come off, break, or even cause cracks on
the forks. Also the lift truck may lose its balance and tip
over as the load swings.

1-36
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

ALWAY PERFORM THE START-UP

INSPECTION
• This Operation and Maintenance Manual provides only
simple inspection and maintenance information that
operators can perform relatively easily. For inspection
and maintenance that requires trained, skilled and
qualified personnel, contact your KOMATSU FORKLIFT
dealer.
• Do not operate lift trucks before completing start-up
inspection.
• Report abnormality, if any, immediately to the
administrator. Do not operate faulty lift truck until the repair is completed.
• Incorrect inspection, maintenance and repair services may cause critical accident or shorten machine
service life. For your safety operation, contact your KOMATSU FORKLIFT dealer for inspection,
maintenance and repair services.

PUT UP A WARNING SIGN DURING

INSPECTION AND MAINTENANCE
• Put up a warning sign on the steering wheel or load
handling lever during inspection and maintenance work.
Put up the sign around the lift truck, if necessary.
• Do not let any person other than the inspector or
maintenance staff start lift truck or touch the load
handling lever during inspection and maintenance or
serious injuries may result. When jointly making
inspection or maintenance with other personnel, name
the leader and follow their instructions.

KEEP THE WORKING AREA CLEAN AND TIDY

• Keep the working area clean and tidy.
• Get obstacles out of the way.
• Wipe off any grease or oil.
• Perform the work on level surface with ample space.
• If the work is carried out inside a building, keep it well-ventilated.

1-37
PRECAUTIONS FOR INSPECTION AND MAINTENANCE

CAUTIONS BEFORE INSPECTION AND

MAINTENANCE
• Arrange for a fire extinguisher. Know the location and
how to use it.
• Prepare the lift truck for inspection and/or maintenance
as follows:
- Lower the forks to the floor.
- Apply the parking lever. (Parking brake activated)
- Set the operating lever and forward/reverse switch
to N (Neutral) position.
- Turn the starting switch to [Q] (OFF) to cut off
power.
• Do not allow anyone with loose clothing or long loose
hair near the mast while in operation.
• Wear adequate working clothes and protective items
(safety helmet, safety shoes, goggles and gloves).
• Block the front and rear tires.

KEEP UNAUTHORIZED PEOPLE OFF

No unauthorized person is allowed near the lift truck under maintenance service.

USE OF RIGHT TOOLS AND EQUIPMENT

Use a suitable tool correctly. Do not use broken or deformed
tools, or wrong tools designed for another purpose, or a
serious accident may result.

CAUTIONS WHEN WORKING UNDER WORK

EQUIPMENT
Before working under the raised forks, block the forks and
mast to prevent falling or a serious accident.

1-38
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

AVOID GETTING CAUGHT UP BY THE MAST

OR FALLING OFF
• Do not put your hands, feet, or other body parts into the
mast structure or you may be caught by the mast parts.
• Do not stand between mast and operator’s compartment
as you may be crushed and be seriously injured or killed.
• Always operate the mast and forks from the operator’s
compartment.
• Do not climb on the mast load backrest or on top of the
dashboard. You may slip and fall or get caught in the
moving parts. Use a stepladder for inspection and
maintenance at elevated level.

BE CAREFUL OF HIGH PRESSURE OIL

Remember that the hydraulic system is constantly under
pressure. Check that the hydraulic system is not
pressurized before inspecting or replacing piping or hose, or
a serious accident may result. Follow the instructions below:
• When checking hydraulic piping or hose for leakage,
don’t touch it directly by hand. The pipe or hose may be
pressurized.
• If your skin and/or eye are injured by high-pressure oil,
wash it with fresh water and immediately see a
physician.

1-39
PRECAUTIONS FOR INSPECTION AND MAINTENANCE

BEWARE OF ROTATING COOLING FAN

Keep hand off the rotating fan.

CAUTION FOR USING COMPRESSED AIR FOR CLEANING

• The dust particles may cause a serious bodily injury if compressed air is used for cleaning.
• Always wear protective gears such as goggles, dust mask, and gloves.

CAUTION WHEN REPLACING THE SEAT

Seat is equipped with important safety functions:
• Seat belt and support to operator’s body
• Travel and lift interlock function switches
• Storage case for instruction manual
Always use Genuine Seat for replacement.

REMOVING THE BATTERY PLUG

• When repairing the electrical system, disconnect the battery plug to stop power supply.
• Do not start repairing electrical system by merely depressing emergency power cut-off button.

1-40
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

CAUTION WHEN HANDLING BATTERY

Handling error of batteries may cause explosions, fires and
other critic al injuries. Handle batteries after fully
understanding how to handle them and their hazards.

• Batteries generate flammable hydrogen gas and may

explode in contact with fire. Always keep the battery
hood open while charging batteries.
• Do not smoke or allow any flame near the battery.
• Sparks may ignite the gas. Do not place tools, parts or
other metal objects on the battery.
• To clean the battery surface, use a wet piece of cloth. Dry cloth may generate static electricity and cause
explosion.
• Depending on the weather, environmental, clothing
material and other conditions, human bodies may
transfer static electricity. Before touching lift truck being
charged or after charging, discharge the static electricity
in human bodies by grounding.
• Batteries for battery-driven lift trucks store high energy in
high-tension. Beware of the risk of electric shock and
burns. Be careful to keep human bodies from touching
energized portions during maintenance, inspection and/
or installation or removal.
• Battery electrolyte contains sulfuric acid, and can quickly
burn the skin and eat holes in clothing. Always wear
protective glasses, rubber gloves and rubber sole shoes for maintenance inspection.
• If battery electrolyte gets into your eyes, flush them
immediately with fresh tap water for 10 to 15 minutes
continually and consult a doctor.
• If you spill battery electrolyte on yourself, immediately
take off clothes and flush the contact portion of the skin
with a large quantity of tap water and consult a doctor.
• If one swallows battery electrolyte by mistake, drink a
large amount of water or milk mixed with raw egg whites
or salad oil and consult a doctor at once.
• If battery electrolyte is spilt or leaked in the surrounding
area, floor surfaces and cargoes will be damaged.
Neutralize the area with a neutralizing agent such as
baking soda, calcium hydroxide or sodium carbonate, and wash it down with large amount of water.
• Do not drain battery electrolyte or disassemble or repair
batteries; it is dangerous.
• If the following abnormalities are detected, please call
your KOMATSU FORKLIFT dealer for service:
- If battery plug and charging plug mating become
loosened or play is generated (plug becomes
abnormally heated).
- If battery electrolyte temperature is high or electro-
lyte level drops sharply.
- If charging requires too long time (charging does
not complete even though the battery was not used
until late in the preceding day).

1-41
PRECAUTIONS FOR INSPECTION AND MAINTENANCE

CAUTION ON HOW TO INSTALL BATTERIES

Disconnected batteries from tipped or fallen lift truck may
cause critical physical injuries. Securely set and install the
battery anchoring devices as follows:
• Rotate the battery lock sideways to prevent batteries
from shifting laterally.
• Fix the side cover securely with two bolts.
• Side cover is designed to stop the battery lock from
turning.
• When the battery hood is closed, check that the lock
lever of battery hood is securely locked.

CAUTION WHEN HANDLING TIRES

The lift truck tires are very highly pressurized with the air. Do
not mishandle, or the tires may burst, be damaged or the
rim may break into pieces causing a serious injury. For your
safety, follow the instructions shown below.
• Do not disassemble/assemble tire, tube or rim, nor
inflate removed tires with the air.
• For safety, when filling a tire with air or replacing it, place
your body in front of the tread face of the tire (see the
figure at right). Do not work from the side of the tire.
• When removing the tire with divided rim from the lift
truck, always loosen the hub nuts (1) after depressurizing the tire.
Do not loosen the rim bolt (irregular shape) (2) of the divided rim.
• Always use the specified tire of KOMATSU FORKLIFT
and observe the specified tire inflation pressure.
• When filling up the tires, make sure no one is around
and use a clip-on air chuck that can be fixed to the air
valve. Fill up the tire while checking with an air gauge to
avoid over inflation.
• The rim will not " fit " the tire if either the tire or rim is
defective, or if it is not properly assembled. To fit, the rim
must contact with the tire evenly around the
circumference. Contact your KOMATSU FORKLIFT
dealer as needed.

1-42
 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

CAUTION IN WASTE DISPOSAL

Take full cautions for waste disposal to prevent environment
pollution.
• Always drain waste fluid such as oil and battery
electrolyte into containers like cans and tanks. (Do not
drain the battery electrolyte into metallic containers.
Always use plastic containers.) Do not pour on the
ground or into rivers, drains, seas or lakes.
• Comply strictly with applicable laws and regulations
when disposing of harmful objects such as oil, solvent,
filters, batteries and refrigerant (CFCs).

CAUTION AFTER INSPECTION AND REPAIR

• Wipe off the spilt oil and grease immediately. If the lift truck is dirty, it becomes difficult or impossible to
find cracks or other problems.
• Test the lift truck upon completion of the repair to check if there is no abnormality.

PERIODIC INSPECTION OF SAFETY CRITICAL PARTS

• To ensure the safety and long service life of the lift truck, be sure to perform lubrication, inspection and
maintenance regularly. Especially the safety critical parts, must be replaced regularly.
• Quality of these parts may change over time or deteriorate, wear or fatigue as they are repeatedly used,
causing serious bodily injuries and damages. Furthermore, the remaining service life of such parts is
usually hard to determine for operators or during visual inspection.
• Replace the safety critical parts with a new one periodically even if no anomaly is found.
• Replace the safety critical parts immediately when any abnormality is found, even if the replacement
interval is not up yet.
• This Operation and Maintenance Manual does not describe the details on how to inspect or replace the
safety critical parts. Inspection and replacement of the safety critical parts, and refilling of greases must
be done by your KOMATSU FORKLIFT dealer.

1-43
HOISTING AND TRANSPORTING THE LIFT TRUCK

HOISTING AND TRANSPORTING THE LIFT TRUCK

CAUTION WHEN HOISTING THE LIFT TRUCK AE50

• Never lift up by the overhead guard.
• Before lifting-up, check that the mast is tightened with
torque as specified.
• To hoist the lift truck, hook on the holes on the top of the
outer mast for the front. For the rear:
- AE50: use the counterbalance-weight and rear axle
- AM50: use the drawbar pin.
• Do not go under the lifted truck.
• Use undamaged sling and wire having sufficient
strength. AM50

PRECAUTIONS FOR LOADING AND

UNLOADING THE LIFT TRUCK
Loading and unloading a lift truck to and from a trailer
always involve a hazard of the lift truck tipping over or falling
off by handling error. Follow the instructions below: Ramp
• Stop the trailer on level, flat road. Always apply parking
brake. Apply blocks to the tires.
• Use ramps or dock plate of appropriate length, width and
strength. Secure it tightly to prevent it from being
dislocated or disengaged. Blocks
• Take a right posture on the seat while operating.
• If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like
standing up or leaning forward or sideways, Travel Interlock activates to cut off the transmission of the
power. Then the lift truck may slither down even if the accelerator pedal is stepped on or an uphill.
Operate the lift truck assisted by a signal person if necessary so that you don’t have to stand up or lean
forward or sideways to watch.
• When using the ramps, set them in gentle gradient, align the center of both the trailer and the lift truck and
lock securely to prevent misalignment.
• Do not change the course of the lift truck while on the ramps. If course change is needed, move off the
ramps once and make another uphill travel on them in right direction.

1-44
 STRUCTURE AND STABILITY OF THE LIFT TRUCK

STRUCTURE AND STABILITY OF THE LIFT TRUCK

To prevent the lift truck from tipping, and to operate the lift truck safely, it is important to understand the struc-
ture and stability of the lift truck.

LONGITUDINAL STABILITY
The front wheels of the lift truck act as a fulcrum, and the load
weight and the weight on the rear wheels are kept in balance
Load
to prevent the lift truck from falling forward.
When an overbalanced load weight is applied, the rear
wheels will be raised off the ground. It is very dangerous and
poses a high risk of serious accident like tipping over.

Load weight Fulcrum Weight on the rear

wheels

CENTER OF GRAVITY OF A LOAD

• The shapes of loads carried by lift trucks vary from boxes to planks and long objects.
• To judge the stability of the lift truck, it is important to determine the position of the center of gravity for
loads of various shapes.

Center of gravity Center of gravity

1-45
STRUCTURE AND STABILITY OF THE LIFT TRUCK

COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED

LIFT TRUCK
COMBINED CENTER OF GRAVITY
The center of gravity of the loaded lift truck shifts to a com- Combined center
bined center of gravity of both the lift truck and the load. When of gravity at high Center of
lifting height gravity of
the load is raised, its center of gravity will rise, hence the com- load
bined center of gravity will also rise. Combined
center of
gravity at low
lifting height
Center of
gravity of
lift truck

COMBINED CENTER OF GRAVITY AND STABILITY

The higher the position of the center of gravity, the worse the longitudinal and lateral stabilities become. In
addition, swaying or shock encountered during traveling or load handling will have a larger impact on the sta-
bility of the lift truck.
Stability of the lift truck also changes depending on the following factors.
• Size, weight, shape of load (position of center of gravity)
• Lifting height
• Tilting angle of mast
• Inflation pressure of tires
• Acceleration, deceleration and turning speed when traveling and load handling
• Road condition and gradient
• Type of attachments
Do not travel with the forks (load) raised. Do not make sharp turns or apply sudden brakes. Do not raise or tilt
the forks abruptly. There are dangerous and poses a high risk of serious accident like tipping over.

ACTUAL CAPACITY
• The horizontal distance from the position of the center of
gravity of a load on the forks to the upright load backrest
of the fork is called a load center. Actual capacity means
the maximum weight of a load that can be loaded at a
certain load center.
• The load table is given in the name plate accessible from
the operator’s seat. The table shows the relationship
between the actual capacity and load center.
• When the load center shifts toward the fork tips, the load
Load center: Small Load center: Large
weight (mass) has to be decreased in the actual opera- Load: Large Load: Small
tion to maintain the balance.

1-46
 STRUCTURE AND STABILITY OF THE LIFT TRUCK

SERIAL NUMBER AND LOAD TABLE

EXPLANATION OF LOAD TABLE
• In the load table of the serial number plate, actual capac-
ity (2) is shown in relation to load center (1).
• Actual capacity and maximum load are determined
according to each model on the condition of the specifica-
tions shown in area (3).
• Before loading, make sure that the load center and the
load are well within the range of capacity.
• When the load is in a complex shape, pull the load so that
the heaviest portion of the load comes to closer to the
load backrest and the lateral center comes to the two
forks center.
• Should a load be loaded beyond the range of capacity, it would pose a big danger to the lift truck as the
rear wheels (for steering) may lift off the ground, letting the operator lose control of steering, or the lift
truck may tip over. Always keep the load within the range of capacity.
• Work within the specification ranges given in the serial number plate attached to the lift truck. Replace the
broken or unreadable serial number plate. Call your KOMATSU FORKLIFT dealer for a new serial number
plate.

EXAMPLE OF LOAD CENTER AND ACTUAL CAPACITY

• Areas (1) and (2) in the example provide the following information:
When the load center is 600 mm (24 in) - - - - -Capacity : 1,800 kg (3,970 lb)
• Area (3) shows the main specifications of the model.
Max. lifting height 3 m (118 in)
Attachment Not equipped
Mast tilting angle (forward/backward) 6/10 degrees
Front wheel size, inflation pressure 200/50 - 10, no inflation (*1)
Rear wheel size, inflation pressure 16 x 6 - 8, no inflation
*1: Elastic cushion tire in this example, does not require air inflation.
• The following symbols indicate the types of attachment if any.

Symbol Symbol
Attachment Attachment
Type Capacity Type Capacity
Side shifter F S • • • • Pusher P A • • • •
Fork positioner F M • • • • Clamp C • • • • •
Load stabilizer F T • • • • Roll clamp R S • • • •
Hinged fork H F • • • • Rotating fork R F • • • •
Push pull P P • • • • Ram L • • • • •

LOAD CAPACITY WHEN EQUIPPED WITH ATTACHMENT AND / OR HIGH MAST

• Please note that the lift truck equipped with attachments and/or high mast has a smaller maximum capac-
ity and actual capacity than the standard lift truck.
• Follow the load limit as indicated in the load table of the serial number plate.

1-47
STRUCTURE AND STABILITY OF THE LIFT TRUCK

OTHER INFORMATION ON THE SERIAL

NUMBER PLATE
The area (4) shows other basic information of the lift truck.
• Model
• Serial number
• Year of manufacture
• Truck weight
• Truck weight without battery
• Battery weight max/min
• Battery capacity
[ - ] means that no information is required.
Logo and the company name are shown on the top of the serial number plate.

1-48
2. Testing and
Adjusting

SERVICE DATA (4-WHEEL LIFT TRUCK)........................................................ 2-3

SERVICE DATA (3-WHEEL LIFT TRUCK)........................................................ 2-3

RELEASING THE PRESSURE IN THE HYDRAULIC PIPING.......................... 2-4

LIFT INTERRUPT .............................................................................................. 2-4

METER PANEL.................................................................................................. 2-5

OPERATION OF METER PANEL...................................................................... 2-6

BATTERY........................................................................................................... 2-9

FUSE................................................................................................................ 2-10

TRANSFER CASE ........................................................................................... 2-12

ADJUSTMENT OF WET TYPE BRAKE AND PARKING BRAKE ................... 2-13

WET TYPE BRAKE.......................................................................................... 2-15

HYDRAULIC OIL TANK ................................................................................... 2-16

MAST (1.5 - 1.75 TON LIFT TRUCK) .............................................................. 2-17

MAST (2.0 TON LIFT TRUCK) ........................................................................ 2-18

FINGER BAR ................................................................................................... 2-19

NATURALLY DESCENDING AMOUNT OF HYDRAULIC OIL CYLINDER..... 2-21

AIR BLEEDING ................................................................................................ 2-22

LIST OF LUBRICANT AND GREASE.............................................................. 2-23

2-1
 2. TESTING AND ADJUSTING

SERVICE DATA (4-WHEEL LIFT TRUCK)

FB15U-12
Item Unit FB15FU-12
Front wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Tightening torque of hub nut
Rear wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Tightening torque of rim set nut Rear wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Play of steering wheel mm [in] 30 - 60 [1.2 - 2.2]
Play of brake pedal mm [in] 0 - 4 [0 - 0.2]
Parking lever operating force N {kgf} [lbf] 98 - 147 {10 - 15} [22 - 33]
Relief valve set pressure MPa {kgf/cm2 } [PSI] 17.6 {180} [2560]
Stretch of lift chain (Length of 17 links) mm [in] Less than 275.5 [10.8]
Thickness of fork (at the root portion) mm [in] More than 30 [1.18]

Item Unit FB18U-12 FB20AU-12

FB18FU-12 FB20AFU-12
Front wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Tightening torque of hub nut
Rear wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Tightening torque of rim set nut Rear wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Play of steering wheel mm [in] 30 - 60 [1.2 - 2.2]
Play of brake pedal mm [in] 0 - 4 [0 - 0.2]
Parking lever operating force N {kgf} [lbf] 98 - 147 {10 - 15} [22 - 33]
Relief valve set pressure MPa {kgf/cm2} [PSI] 17.6 {180} [2560]
Less than 275.5
Stretch of lift chain (Length of 17 links) mm [in] Less than 330 [13.0]
[10.8]
Thickness of fork (at the root portion) mm [in] More than 33 [1.30] More than 32.5 [1.28]

SERVICE DATA (3-WHEEL LIFT TRUCK)

FB15MU-12 FB18M-12 FB20M-12
Item Unit
FB15MFU-12 FB18MFU-12 FB20MFU-12
Front wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Tightening torque of hub nut
Rear wheel Nm {kgm} [ft. lb] 157 - 245 {16 - 25} [116 - 181]
Play of steering wheel mm [in] 30 - 60 [1.2 - 2.2]
Play of brake pedal mm [in] 0 - 4 [0 - 0.2]
Parking lever operating force N {kgf} [lbf] 98 - 147 {10 - 15} [22 - 33]
Relief valve set pressure MPa {kgf/cm2} [PSI] 17.6 {180} [2560]
More than
Stretch of lift chain (Length of 17 links) mm [in] Less than 275.5 [10.8] 330 [13.0]
More than More than More than
Thickness of fork (at the root portion) mm [in] 30 [1.18] 33 [1.30] 32.5 [1.28]

2-3
2. TESTING AND ADJUSTING

RELEASING THE PRESSURE IN THE HYDRAULIC PIPING

Before performing the work of hydraulic piping, release the pressure in the piping.
Method: Turn OFF the key switch and leave the lift truck for about 30 minutes.

WHEN THE LIFT CANNOT BE LOWERED

If the lift cannot be lowered, tighten the hydraulic oil pressure 1
release valve (1) at the control valve so that the lift can be
released.

LIFT INTERRUPT
The lift interrupt is the function to warn an operator to stop
the cargo operation and charge the battery when the battery
discharges 80% of capacity (Two displays marked with "A" at
the lower side of battery capacity meter blink alternately and
the warning buzzer beeps.) so that the deterioration of bat-
tery caused by over-discharge can be prevented.
Although the cargo operation cannot be continued, the lift A
truck can travel. Therefore, drive to the charging location and
charge the battery.
To release this function, operate from the PC.

2-4
 2. TESTING AND ADJUSTING

METER PANEL
OPERATION CHECK OF METER PANEL
WARNING LIGHT
1. Disconnect the battery plug from the plug in the side of
the lift truck.

2. When re-connecting the battery plug, if all of the indica-

tors of meter panel light for one second, the warning light
and display are normal.
a In this method, a problem (For example, abnormality of
sensor or wiring) other than the meter display cannot be
checked.

2-5
2. TESTING AND ADJUSTING

OPERATION OF METER PANEL

By operating switches (1), (2), (3), and (4) on the meter
panel, perform the settings and adjustments of speed limit /
traveling power /lift speed, select the display of date-time /
hour meter and adjust it.
• To operate the switch on the panel, touch it lightly by fin-
ger. If the following operations are performed during set-
ting, the setting cannot be renewed. In this case, start
settings from the beginning.
• When the key switch is set to "Q" (OFF) or driving
operation is performed
• When the switch is not operated for 30 seconds

SELECTION OF DATE-TIME / HOUR METER

To toggle the display between [date-time] and [hour meter],
press the select switch (shift switch) (1).
• The hour meter can display up to 99999.9 hours by 0.1
hour (6 minutes) increments.
• Selection during operation is not possible.
• Time is displayed in 24 hour format.
• Working hours of traveling and cargo operation can be
managed as an option.

SETTING OF DATE-TIME
1. Keep pressing the mode / set select switch (4) for more
than 2 seconds. (To enter the vehicle speed limit mode)
2. Press the mode / set select switch (4) once more to
enter the date-time adjusting mode.
The calendar year (lowermost two digits) - month date -
time is displayed and the calendar year blinks.
3. To change the calendar year, press the power select
switch (up-switch) (3) or vehicle speed limit select switch
(down-switch) (2).

4. After setting, press the date-time / hour meter select

switch (shift switch) (1). Then, the display of month
blinks and the month can be changed. By pressing the
switch (2) or (3), change the month in the same manner
as done in the calendar year change.
5. According to the procedure, press the switches (1), (2)
and (3), and set the displays in orders of calendar year
o month o date o hour o minute.

2-6
 2. TESTING AND ADJUSTING

ON / OFF SETTING OF VEHICLE SPEED LIMIT

FUNCTION
Every time when pressing the vehicle speed limit select
switch (down-switch) (2), the vehicle speed limit function is
switched to the enable (ON) or disable (OFF).
When setting to the enable (ON) by pressing the switch, the
vehicle speed limit indicator (5) (turtle icon) is displayed and
the value of vehicle speed limit at this moment blinks for two
seconds at the same time.
a The initial set value of vehicle speed limit is 9 mph.

SETTING OF VEHICLE SPEED LIMIT VALUE

1. Keep pressing the mode / set select switch (4) for more
than 2 seconds. (The vehicle speed limit mode is dis-
played and the vehicle speed limit value blinks.)
2. To change the value of vehicle speed limit, press the
power select switch (up-switch) (3) or vehicle speed limit
select switch (down-switch) (2).
The speed can be set within the range of 2 - 10 mph by
increment of 1 mph.
3. After determining the value of vehicle speed limit, press
the mode / set select switch (4) at last.
After blinking, the value of vehicle speed limit is set.

TRAVEL / CARGO HANDLING POWER

SETTING
The vehicle traveling and performance of cargo operation
can be set to three steps of L, M and H.
1. Every time when pressing the power select switch (up-
switch) (3), the power mode selected changes in the fol-
lowing orders.
(Blinking State)
L o M o H o Go off o L…

2. When the mode / set select switch (4) is pressed in

either state of L, M or H, setting is completed and blink-
ing stops. L M H Go off
Power Mode Description
Even at low speed, the cargo operation
L Low Power - traveling is possible and the energy
can be saved.
The cargo operation - traveling suitable
M Middle Power for normal work can be performed.
The vehicle can travel strongly at high
speed and the high performance of car-
H High Power go operation can be achieved. The bat-
tery consumption increases.
Characteristics desired by a user can
Go-off User Mode be set with the service tool.

2-7
2. TESTING AND ADJUSTING

LIFT SPEED ADJUSTMENT

This function adjusts the lift speed to meet the requirements
such as swiftness and prudence for cargo operation. The lift
speed can be set arbitrarily to 1 to 100%. 100% is the maxi-
mum speed.
1. Press the power select switch (UP switch) (3) and then
press the mode/select switch (4) after the display of
travel power indicator goes off. (The user mode is set.)
2. Keep pressing the mode / set select switch (4) for 2 sec-
onds. (The mode becomes the vehicle speed limit
mode.)
3. Press the shift switch (1) several times.
(The display changes to the lift speed setting mode.)
The display below appears on the date-time display area
and the numeral part blinks.
a Example of display: LIFT-SPd-95
4. By pressing the up-switch (3) or down-switch (2), change
the numerals to the desired value (%).
5. After changing the value to the desired lift speed, press
the mode / set select switch (4) to set it.
6. In addition, press the mode/select switch (4) twice so
that the menu returns to the normal one.
(The menu returns to the date-time setting mode at the
first switch-pressing and then to the normal one at the
second switch-pressing.)
• In considering the lift speed and working hour, the appro-
priate adjustment range is 60 to 95%.
If set low, the lift operation may fail. If set too low or too
high, the capable working hour will decrease.
• Corresponding to the state of the lift truck with load or
without load, the lift speed of battery powered fork lift
varies.
However, the speed undulation arising from the load
fluctuation cannot be eliminated by the adjustment func-
tion of lift speed.
• The set lift speed is enabled only when selecting the
state that the power mode display area on the meter
panel goes off (In the state of user mode).
When switching the power mode to L, M or H, the lift
speed of L, M or H is the initially set lift speed.
• When selecting the state that the power mode display
area on the meter panel goes off (In the state of user
mode), the set lift speed is enabled. But, the travel power
is set to the M mode same as the factory setting.
To adjust the lift speed only while keeping the H or L
travel power mode, set the set value of H or L travel
power mode to the user mode with the service tool.

2-8
 2. TESTING AND ADJUSTING

BATTERY
CHECK OF BATTERY SOLUTION
Check the battery electrolyte level. If battery electrolyte is below the standard level, refill distilled water or puri-
fied water.
a For information about inspecting and refilling of battery electrolyte, see “Operation & Maintenance Man-
ual” attached to the battery.

CHECK OF SPECIFIC GRAVITY OF BATTERY

ELECTROLYTE
As the specific gravity of battery electrolyte changes, along
with the temperature, read the specific gravity and electrolyte
temperature and convert it to the value equivalent at 20°C
[68°F], using the conversion table.

CHECK OF BATTERY STRUCTURE

Confirm bracket (1) and stay (2) are installed on the battery.
(The fire prevention/retaining plug system)
1. Bracket (3BA-55-71260)
2. Stay (3BA-08-73130)
a Bracket (1) and stay (2) are sent with the lift truck.

2-9
2. TESTING AND ADJUSTING

FUSE
CONTROLLER BLOCK
To reduce the risk of fire, replace only with
same type and capacity of fuse.

1. Turn OFF the key switch, open the battery hood and dis-
connect the battery plug.
2. Remove the upper cover of counterweight and then
cover of controller inside.
3. Open the fuse holder, remove the fuse from inside, and
inspect whether or not the fuse has blown using a tester.
4. If a fuse is blown, replace it with spare fuse of same
capacity.

a Use a Little 326 (model code) slow-blow fuse which

complies with the UL standard

2-10
 2. TESTING AND ADJUSTING

FUSE LIST

Fuse Wire
Capacity Target device
No.* color**
1 2A R/R EMG. switch Contactor
2 10A GB/O B+
3 15A GB/R B+
4 2A RW/O R Traction controller
RW/O L Traction controller
5 2A
Pump controller
• R Traction controller
• L Traction controller
• Pump controller
6 2A RW/O Key switch • Meter panel
• Direction switch
• CV Controller
• Optional relay 48V (option)
Cooling fan
R/O
7 2A Meter panel
Meter panel
8 2A WG/R Horn switch Horn
9 2A Combination switch Head lamp relay
10 2A Y/R Head lamp relay R Head lamp
11 2A R/R Head lamp relay L Head lamp
• Clearance lamp (option)
12 2A WG/R Combination switch • Tail lamp (option)
WG/R Brake lamp switch Stop lamp (option)
13 2A • F winker lamp (option)
Flasher unit Combination switch • R winker lamp (option)
• Brake lamp (option)
WG/R Backward relay 12V • Back chime 48V (option)
14 2A
Forward relay 12V (op- Forward chime 48V (option)
tion)
WG/R Optional relay 48V (op- Beacon lamp switch Beacon lamp (option)
15 2A tion) Working lamp switch Working lamp (option)
20 2A YR/W Lift up solenoid
21 2A GR/Y Lift down solenoid
22 2A GW/O Tilt backward solenoid
23 2A GB/Gray Tilt forward solenoid
24 2A WL/W Att1 A-valve
25 2A W/Y Att1 B-valve
26 2A Att2 A-valve (option)
27 2A Att2 B-valve (option)
* The fuse number is located near the fuse holder.
** Wire color key:
GB green + black stripe O orange WG white + green stripe
GR green + red stripe R red WL white + lavender stripe
Gray gray RW red + white stripe Y yellow
GW green + white stripe W white YR yellow + red stripe

2-11
2. TESTING AND ADJUSTING

TRANSFER CASE
OIL LEVEL CHECK
1
1. Remove the oil level plug (2) and check the oil level.
2. If the oil is filled at the lower line of hole of oil level plug, it
is correct.
3. If the oil is insufficient, remove the oil filler port plug (1)
and re-fill the powertrain oil.

OIL REPLACEMENT
1. Remove the oil filler port plug (1) and the drain plug (3), 1
and then drain the oil.
2. After draining, tighten the drain plug (3) and re-fill the
specific amount of powertrain oil from the oil filler port.
Replacement oil level:
Both transfer cases at right and left sides: 0.5 liters
3. After re-filling, check the oil level with the oil level plug
(2) and keep the oil level appropriate.
(Refer to [Oil Level Check] mentioned above.) 3

2-12
 2. TESTING AND ADJUSTING

ADJUSTMENT OF WET TYPE BRAKE AND PARKING BRAKE

ADJUSTMENT
In case of following symptoms, adjust the brake.
• In case of deep margin when stepping on the brake pedal: (However, check the wear amount of wet type disc. If the
disc has no margin, replace a set of wet disc.)
• In case of inappropriate operating power of parking brake: (Heavy or light)
• In case of disassembling the drive axle:

Adjustment of wet type disc cut margin and adjustment

of parking brake lever Free
1. Place the stoppers at the front and rear wheels.
2. Release the parking brake lever (1). Lock
3. Adjust by turning the adjustment bolt (3) from the win-
dow (2) at the lower side so that the lever operating force
meets the specification below. 3
1
296 - 343 N
Lever Operating Force {30 - 35 kgf}
[66 - 77 lb] 2

4. Pull up the parking brake.

0 mm [0 in] A
5. Adjust by turning the adjustment bolt (4) so that the
4
clearance (A) between the adjusting bolt and lever (5) is
2.0 - 2.2 mm [0.08 - 0.09 in]. 5

6. Release the parking brake lever.

7. Turn the adjustment volt (3) so that the clearance (A)
between the adjusting bolt and lever (5) is 0 mm [0 in].
(As the adjustment bolt has detent, the adjustment can
be performed by every 1/2 turns.)
8. Confirm that the lever operating force is within the range
below. When the parking When the parking
brake is released brake is applied
98 - 147 N
Lever Operating Force: {10 - 15 kgf}
[22 - 33 lb]

a If the above clearance (A) of right axle is different from

that of left axle, adjust the imbalance at the right and left
axles with yoke (6) of brake lever block. 6

2-13
2. TESTING AND ADJUSTING

CONFIRMATION OF BRAKE PEDAL STROKE

1. Release the parking brake.
2. When stepping on the brake pedal (Leg power: about 20
kgf [44.1 lb]), if the pedal stroke (H2) is more than 80 mm S1
[3.15 in], go back to the steps of wet type disc cut margin
and parking lever adjustment. Then, adjust the parking S2
lever operating force a little heavier.
H1
Reference
Check Point Dimension Value H2
(mm) [in]
0-4
Play S1 [0 - 0.16]
105
Pedal Height H1 [4.1]
Pedal Height 60
H2
when stepped on [2.4]
10
Switch ON Position S2 [0.40]

a When the parking lever operating force is too heavily

adjusted, even if the parking lever is released, the clear-
ance does not become 0 mm and braking will be
dragged. Be careful not to adjust heavily the parking
lever operating force.

3. Adjust the height of adjustment bolt so that the clearance

(A) between the tip of adjustment bolt (1) installed to the 0 mm [0 in] A
wheel cylinder and the brake lever (2) meets the specific 1
value. 2

Check Item Dimension A

When the parking brake is applied 2.0 - 2.2 mm
(The lever is pulled up.) [0.08 - 0.09 in]
When the parking brake is released 0 mm
(The lever is released.) [0 in]

4. Confirm the brake pedal stroke again and adjust so that

When the parking When the parking
the stroke meets the specific value. brake is released brake is applied
a Before measuring the pedal height, remove the floor
mat.

2-14
 2. TESTING AND ADJUSTING

WET TYPE BRAKE

1. Place the wheel stoppers at the front and rear wheels.
2. Pull up the parking brake so that the piston (3) contacts 1
closely to the disc (A).
3. Using the caliper (2), measure the depth to the piston (3)
from the check opening (1) for measuring the disc wear.
a If the measured value is more than 13.5 mm [0.53 in],
replace the disc and a set of plate. (Initial value: 12.5
mm [0.49 in])

2-15
2. TESTING AND ADJUSTING

HYDRAULIC OIL TANK

OIL LEVEL CHECK
1. Open the check cover (1) on the floor and pull out the oil
level gauge (2).
2. Wipe out the hydraulic oil from the oil level gauge with 3 2
clean cloth and insert it in the oil tank.
3. Pull out the oil level gauge (2) and check that the
hydraulic oil on the oil level gauge is in range L.
4. If the hydraulic oil is insufficient, re-fill Genuine hydraulic L
oil from the oil filler port (3). 1

a Be sure to use Genuine hydraulic oil for hydraulic oil.

REPLACEMENT OF HYDRAULIC OIL,

REPLACEMENT OF LINE FILTER, CLEANING
OF STRAINER
1. Remove the drain plug (1) to drain the oil. After draining,
2
install the drain plug (1) and tighten it securely.
2. Remove the cover (2) and take out the strainer (3) and
line filter (4).
3. Oil-wash the strainer (3), blow air to the strainer from the
inner side to dry it and install the completely dried 4
strainer.
4. Replace the line filter (4) with a new one.
5. Install the cover (2). 3
6. Re-fill the specific amount of hydraulic oil from the oil
filler port and confirm the oil level with the oil level
gauge.
1
7. Operate the cylinder (lift, tilt and attachment) to the
stroke end five to six times to bleed of air.
Amount of oil needed for replacement
(A total amount of oil reserved in the hydraulic system when
lifting up the standard mast to 3 m [118 in].)

FB15U/15FU-12 24 l
FB15MU/15MFU-12
FB18U/18FU-12 24 l
FB18MU/18MFU-12
FB20AU/20AFU-12 24 l
FB20MU/20MFU-12

2-16
 2. TESTING AND ADJUSTING

MAST (1.5 - 1.75 TON LIFT TRUCK)

ROLLER CHOICE AND SHIM ADJUSTMENT
Outer Main Roller

1. Choice of Roller Size

Choose the roller size (NS, NM) so that the clearances a Outer main roller
"a" at the left and right sides become equal.

2. Shim Adjustment
Insert the shims (1) with identical thickness at the right 2
and left sides so that b = 0 - 0.3 mm [0 - 0.012 in] is
achieved. Insert the shim (2) so that c = 0.1 - 0.4 mm
[0.004 - 0.016 in] is achieved all along the inner rail when
pushing the roller to the rail.
(The target is 0.1 mm [0.004 in].)

1
Outer main roller

Inner Main Roller

1. Choice of Roller Size d
Inner main roller
Choose the roller size (NS, NM, ML, NLL) so that d = 0.2
- 0.7 mm [0.008 - 0.028 in] is achieved.
e

2. Shim Adjustment
While pushing the roller to the rail, insert the shim (3)
with identical thickness at the right and left sides so that
e = 0 - 0.3 mm [0 - 0.012 in] is achieved.
Inner main
roller

2-17
2. TESTING AND ADJUSTING

MAST (2.0 TON LIFT TRUCK)

ROLLER CHOICE AND SHIM ADJUSTMENT
Outer Main Roller

1. Choice of Roller Size

Choose the roller size (NS, NM) so that the clearances a Outer main roller
"a" at the left and right sides are equal.

2. Shim Adjustment
Insert the shims (1) with identical thickness at the right 2
and left sides so that b = 0 - 0.3 mm [0 - 0.012 in] is
achieved.
Insert the shim (2) so that c = 0.1 - 0.4 mm [0.004 - 0.016
in] is achieved all along the rail when pushing the roller
to the rail.
(The target is 0.1 mm [0.004 in].)

1
Outer main roller

Inner Main Roller

1. Choice of Roller Size
Inner main roller
d
Choose the roller size (S, M, L) so that d = 0.2 - 0.7 mm
[0.008 - 0.028 in] is achieved.
e

2. Shim Adjustment
Adjust by inserting the shim (3) so that e = 0 - 0.5 mm [0
- 0.020 in] (when lifted up to the maximum) is achieved.

Inner main
roller

2-18
 2. TESTING AND ADJUSTING

FINGER BAR
a While pushing the backrest at the portion A to the board
side, tighten the bolt.

1. Cut View BB (In case of 3 rollers)

1) Choose the roller so that a1 = 0.3 - 1.1 mm [0.012 - 0.043
in] is achieved.
2) Insert the shims with identical thickness at the right and
left sides so that b1 = 0.4 - 0.7 mm [0.016 - 0.028 in] is
achieved at the top end of finger bar.

2. Cut View CC
1) Choose the roller so that a2 = 0.3 - 1.1 mm [0.012 - 0.043
in] is achieved.
2) Insert the shims with identical thickness at the right and
left sides so that b2 = 0.1 - 0.4 mm [0.004 - 0.016 in] is
achieved at the top end of finger bar.

2-19
2. TESTING AND ADJUSTING

3. Cut View DD
1) Choose the roller so that a3 = 0.3 - 1.1 mm [0.012 - 0.043
in] is achieved.
2) Insert the shims with identical thickness at the right and
left sides so that b3 = 0 - 0.2 mm [0 - 0.008 in] is achieved
at the top end of finger bar.

4. Amount B of protrusion
(When lifted down to the lowest position) 1
1) Lift down the fork to the ground level and measure the
dimension B that is the distance from the lower end of
roller (3) of inner rail (1) to the finger bar (2).
Amount B of roller protrusion (mm) [in]

0.9 - 1.8 t 27 [1.06 in] B

2.0 t 18 [0.71 in]
2 3

2-20
 2. TESTING AND ADJUSTING

NATURALLY DESCENDING AMOUNT OF HYDRAULIC OIL CYLINDER

MEASUREMENT OF NATURALLY FORWARD
TILTING AMOUNT
Precautions on measurement
1. When measuring, keep a person out of the area beneath the cargo.
2. Do not climb up, stepping on the mast stay and dashboard. Do not measure the naturally descending
amount in this state. If done so, hand and foot may be trapped.
When measuring, use the sturdy and stable step.
3. Before measuring, check the dirtiness of hydraulic oil, entry of foreign oil and oil level.
4. Ensure to measure on the horizontal and flat ground and in front of the rear body strong enough to sup-
port the lift truck when fallen.

MEASURING PROCEDURE
1. Park the lift truck at a distance of 500 mm [19.6 in] in
front of the rear body.
2. By repeating the operation of lift and tilt, raise the tem- 1
perature of hydraulic oil to 50°C [122°F].
3. Load the cargo of rated weight and fix to the finger bar
with wire.
4. Lift up the cargo at the height H of about 1,500mm [59.0
in] and erect the mast (1) vertical.
H

[Naturally descending amount]

5. After 3 minutes passes, align the linear scale with the A
piston rod of lift cylinder (2) and mark with the marking
A.
6. Measure the descending amount of hydraulic oil cylinder
in 15 minutes.

Naturally descending amount of within 30 mm [1.18 in]/

hydraulic oil cylinder 15 min
2

[Naturally slanting amount]

3
7. After 3 minutes passes, align the linear scale with the
piston rod of tilt cylinder (3) and mark with the marking
B.
8. Measure the slanting amount for 15 minutes.

within 23 mm [0.91 in]/

Naturally slanting amount 15 min B

2-21
2. TESTING AND ADJUSTING

AIR BLEEDING
BRAKE PIPING
1) Drive Axle 2
1
2) Brake nipple
3) Vinyl hose
4) Brake fluid container
1. Remove the cap of brake nipple (2). Then, install one
end of vinyl hose (3) there, and put the other end in the
container (4) containing brake fluid. 3

2. Step down the brake pedal, loosen the air bleeder plug
(2) by about 3/4 turns and exhaust of the brake fluid.
B (MAX)
3. Tighten the air bleeder plug (2) and release the brake.
4. Repeat steps 2 and 3 until bubbles do not come out from
the hose (3).
5
5. After bleeding of air completely, tighten the plug (2) and
install the cap. A (MIN)
6. After completing the air bleeding, remove the cap of
brake reserve tank and check the fluid level. Replenish
the fluid lost by air bleeding and confirm that the fluid
level is within the range of A (MIN) - B (MAX).

LIFT CYLINDER
1. Turn ON the key switch.
2. Lift up and down the fork.
a Stop the fork at 100 mm [3.94 in] before the highest
position and at 100 mm [3.94 in] before the lowest
position respectively.
3. Repeat the operation in step 2 four to five times.
4. Lift up the fork to the highest position and lift it down to
the lowest position respectively.
5. Repeat the operation in step 4 four to five times.

2-22
 2. TESTING AND ADJUSTING

LIST OF LUBRICANT AND GREASE

TABLE OF LUBRICANT AND GREASE INSPECTION AND MAINTENANCE INTERVALS

Chain
Fork stopper
Mast mount
Tilt cylinder pin

Transfer case
(Powertrain oil) Brake fluid reserve tank

Hydraulic oil tank

Knuckle

King pin

Tie-rod

Chain

Fork stopper
Mast mount
Tilt cylinder pin

Transfer case
(Powertrain oil) Brake fluid reserve tank

Hydraulic oil tank

Check everyday
Every two weeks (100 hours)
Every one month (200 hours)
Every three months (400 hours)
Every six months (1,200 hours)

Symbol Type of Oil E Check and add fluid if necessary

EO
HO
Engine Oil
Hydraulic Oil
Q Total oil change or greasing and applica-
tion

BF Brake Fluid w All change

G Lithium Grease T Figure inside the box shows the number of

places to apply oil or grease
TO Powertrain Oil

2-23
2. TESTING AND ADJUSTING

LIST OF SPECIFIC FUEL/LUBRICANT/GREASE

Location used Type of Oil Total amount of oil

1 [0.3 U.S. gal]

Transfer Case Powertrain Oil TO-10W (SAE J300 10W) (0.5 x two locations)
Shell: Rimula D-10W

ZFHO70 (HO15)
Hydraulic Oil Tank Hydraulic Oil 24 [6.3 U.S. gal]
ZFHO90 (HO32SR) (STD FV 3 m
[118 in] mast)

Brake System Brake Fluid BF3/BF1 (DOT 3) 0.4 [0.1 U.S. gal]

GLT2-LI
Each Greasing Lithium Grease
Location
G2-LI

Each Greasing
Engine oil FEO 10-CD
Location

Be sure to use the Komatsu Utility genuine oil and grease.

If the wrong brake fluid is used, the serious brake trouble may occur in the brake system.
Be sure to use the specific brake fluid (non-mineral oil brake fluid for automobile).

2-24
3. Removal and
Installation

UNIT LOCATION DIAGRAM.............................................................................. 3-3

UNIT MASS (4-WHEEL LIFT TRUCK) .............................................................. 3-4

UNIT MASS (3-WHEEL LIFT TRUCK) .............................................................. 3-5

DRAWING OF DISASSEMBLY/ASSEMBLY ..................................................... 3-6

MAST ............................................................................................................... 3-10

LIFT CYLINDER............................................................................................... 3-13

DRIVE AXLE .................................................................................................... 3-16

STEERING AXLE............................................................................................. 3-21

REAR AXLE ..................................................................................................... 3-23

BATTERY......................................................................................................... 3-25

HYDRAULIC PUMP AND PUMP MOTOR....................................................... 3-27

3-1
 3. REMOVAL AND INSTALLATION

UNIT LOCATION DIAGRAM

4-wheel vehicle 3-wheel vehicle

8 5 6 7 14

1
2

13

12

11

10

14

3 4 C3Z15501

1. Control Valve 7. Rear Axle

2. Drive Motor 8. Drive Axle
3. Hydraulic Oil Pump 9. Steering Gear Box
4. Pump Motor 10. Tilt Cylinder
5. Tank 11. Brake Master Cylinder
6. Main Controller 12. Lift Cylinder

3-3
3. REMOVAL AND INSTALLATION

UNIT MASS (4-WHEEL LIFT TRUCK)

Unit: kg [lb]

Model FB15U-12 FB18U-12 FB20U-12

Remark
Unit FB15FU-12 FB18FU-12 FB20AFU-12

Drive Axle (Total) 165 [363.8] 165 [363.8] 165 [363.8]

Drive Motor 40 [88.2] 40 [88.2] 40 [88.2]

Transfer 125 [275.6] 125 [275.6] 125 [275.6]

Pump Motor 40 [88.2] 40 [88.2] 40 [88.2]

Rear Axle 90 [198.4] 90 [198.4] 90 [198.4]

Front Wheel 20 [44.1] 20 [44.1] 40 [88.2]

Rear Wheel 15 [33.1] 15 [33.1] 25 [55.1]

Head Guard 85 [187.4] 85 [187.4] 85 [187.4]

Counterweight 790 [1741.6] 990 [2182.6] 1270 [2799.8]

Mast (3 m, inner / outer masts only) 300 [661.4] 300 [661.4] 365 [804.7]

Lift Cylinder (For 3 m mast) 26 [57.3] 26 [57.3] 25 [55.1]

Tilt Cylinder 17 [37.5] 17 [37.5] 17 [37.5]

Finger Bar 75 [165.3] 75 [165.3] 85 [187.4]

Fork 75 [165.3] 75 [165.3] 85 [187.4]

Backrest 20 [44.1] 20 [44.1] 20 [44.1]

Hydraulic Pump 5 [11.0] 5 [11.0] 5 [11.0]

Tank and Grease 30 [66.1] 30 [66.1] 30 [66.1]

Control Valve + Lever 20 [44.1] 20 [44.1] 20 [44.1]

Steering Gear Box 20 [44.1] 20 [44.1] 20 [44.1] Column included

a The values show the standard specification.

Battery

Capacity Max. Mass

Model Voltage
(Ah) (kg)

FB15U-12, FB15FU-12, FB18U-12, FB18FU-12 600 935 [2061.3]

48 V
FB20U-12, FB20AFU-12 600 935 [2061.3]

a Confirm the battery capacity by reading the manufac-

turer plate on the front of battery case.

3-4
 3. REMOVAL AND INSTALLATION

UNIT MASS (3-WHEEL LIFT TRUCK)

Unit: kg [lb]

Model FB15MU-12 FB18MU-12 FB20MU-12 Remark

Unit FB15MFU-12 FB18MFU-12 FB20MFU-12

Drive Axle (Total) 165 [363.8] 165 [363.8] 165 [363.8]

Drive Motor 40 [88.2] 40 [88.2] 40 [88.2]

Transfer 125 [275.6] 125 [275.6] 125 [275.6]

Pump Motor 40 [88.2] 40 [88.2] 40 [88.2]

Rear Axle 45 [99.2] 45 [99.2] 45 [99.2]

Front Wheel 20 [44.1] 20 [44.1] 40 [88.2]

Rear Wheel 12 [26.5] 16 [35.3] 16 [35.3]

Head Guard 85 [187.4] 85 [187.4] 85 [187.4]

Counterweight 890 [1962.1] 1150 [2535.3] 1450 [3196.7]

Mast (3 m, inner and outer masts
300 [661.4] 300 [661.4] 365 [804.7]
only)

Lift Cylinder (For 3 m mast) 26 [57.3] 26 [57.3] 25 [55.1]

Tilt Cylinder 17 [37.5] 17 [37.5] 17 [37.5]

Finger Bar 75 [165.3] 75 [165.3] 85 [187.4]

Fork 75 [165.3] 75 [165.3] 85 [187.4]

Backrest 20 [44.1] 20 [44.1] 20 [44.1]

Hydraulic Pump 5 [11.0] 5 [11.0] 5 [11.0]

Tank and Grease 30 [66.1] 30 [66.1] 30 [66.1]

Control Valve + Lever 20 [44.1] 20 [44.1] 20 [44.1]

Steering Gear Box 20 [44.1] 20 [44.1] 20 [44.1] Column included

a The values show the standard specification.

Battery

Capacity Max. Mass

Model Voltage
(Ah) (kg)
FB15MU-12, FB15MFU-12
600 935 [2061.3]
FB18MU-12, FB18MFU-12 48 V

FB20MU-12, FB20MFU-12 600 935 [2061.3]

a Confirm the battery capacity by reading the manufacturer plate on the front of battery case.

3-5
3. REMOVAL AND INSTALLATION

DRAWING OF DISASSEMBLY/ASSEMBLY
4-WHEEL LIFT TRUCK

3-6
 3. REMOVAL AND INSTALLATION

C3Z15502

3-7
3. REMOVAL AND INSTALLATION

3-WHEEL LIFT TRUCK

3-8
 3. REMOVAL AND INSTALLATION

C3Z15503

3-9
3. REMOVAL AND INSTALLATION

MAST
Before starting the work, turn OFF the key switch and leave the lift truck for about 30 minutes to
release the pressure in the piping.

REMOVAL
1. Place the wheel stoppers at the front and rear wheels.
2. Remove the fork (1).

When removing the fork, be careful of the

following.
Do not insert your hand or foot in the side to
which the fork is pushed.
Do not hold the lifting part of fork by hand.
Push the fork from the opposite side to the
moving direction. (Do not pull to move it.)
1

3. Remove the hydraulic piping hose (2).

4. Lift up the finger bar (3) with the crane and remove the
support fixing bolt (4) at the lower side.

3-10
 3. REMOVAL AND INSTALLATION

5. Lower down the finger bar (3) to the ground.

a To prepare for lifting up the mast with the crane,
tighten firmly the lower stay of outer mast and the fin-
ger bar with wire so that the finger bar does not
move.

6. Remove the bolt (5) and pull out the tilt cylinder pin (6).
7. Remove the support fixing bolt (7) at the upper side. 6

5
7

8. Lift up the mast with the crane.

3-11
3. REMOVAL AND INSTALLATION

Place horizontally the mast assembly on the

square lumber with the finger bar facing up. A
Place the mast assembly with caution for the
hook of crane not to come off the mast.
When carrying horizontally the mast assem-
bly removed, fix the lower stay of outer mast
and finger bar with the wire (A).

INSTALLATION
Install in reverse steps and pay attention to the following
points.

1. Tightening torque of support fixing bolt (1)

343 - 427 Nm
{35 - 43.5 kgm}
[253.2 - 314.6 ft. lb]

2. Hammering the tilt cylinder pin

Fix the mast with the crane. Aligning the holes by operat-
ing the tilt lever, hammer the tilt cylinder pin (2).
a As the cylinder head is covered with the spherical
bushing, the bushing is subject to falling when ham-
mered. Therefore, do not hammer forcibly the pin.

3-12
 3. REMOVAL AND INSTALLATION

LIFT CYLINDER
REMOVAL
The removal of lift cylinder at one side is explained as an
example.

1. Erect the mast (1) vertically and place the wheel stop-
pers at the front and rear wheels.
2. Lift up the finger bar with the crane by 300 mm [11.8 in]. 1

3. Remove the cotter pin (3) and pull out the pin (4). Then,
separate the chain and remove the chain from the chain
roller.

4. By operating the lift lever, lift up the mast.

a When performing the traveling and cargo operation,
be seated correctly on the operator’s seat.
Unless an operator is correctly seated on the opera-
tor’s seat or is out of the seat, the traveling and cargo
operation cannot be performed.

3-13
3. REMOVAL AND INSTALLATION

5. Draw out the finger bar forward.

6. Place the concrete block under the inner mast

3
7. Remove the stopper bolt (3).
8. Lift down the cylinder rod by operating the lift lever.
9. Turn OFF the key switch and leave for one minute as is.
Then, remove the piping.
a After removing the piping, cap with the blank cap to
prevent the drain of hydraulic oil and dust entry.

10. Remove the cylinder clamp (4).

a The cylinder clamp differs in model.
4
11. Using the sling belt, lift up the cylinder with the crane by
300 mm [11.8 in] and pull out the cylinder downward.

3-14
 3. REMOVAL AND INSTALLATION

INSTALLATION
Install in reverse steps and pay attention to the following
points. 1
1. Inner Mast
4 5
2. Cylinder Rod
3. Outer Mast 2

4. Shim (right side)

5. Shim (left side)

Synchronization Adjustment of Mast

1. Lift up the mast to the maximum high lifting height.
2. Check the plays at the right and left sides of mast.
3. Adjust by inserting shims so that the right and left cylin-
ders are synchronized when lifted up to the maximum 5
high lifting height.

Insert the shim (5) in the cylinder at the left

Swings left.
side.
4
Insert the shim (4) in the cylinder at the right
Swings right.
side.

3-15
3. REMOVAL AND INSTALLATION

DRIVE AXLE
REMOVAL
1. Place the wheel stoppers at the front and rear wheels.
2. Remove the battery (1).
a Refer to “Battery” on page 3-25 to perform correctly
and safely. 2

3. Remove the mast (2).

a Refer to “Mast” on page 3-10 to perform correctly and
safely.
1

4. Place the concrete blocks under the frame at the right

and left sides or jack up placing the jacks under the
frame at the right and left sides so that the front wheels
float by 100 mm [3.9 in] from the ground.

5. Remove the wheel stoppers from the front wheels. Then,

remove the front tire and stabilizer (3).

3-16
 3. REMOVAL AND INSTALLATION

6. Remove the cover (4) and parking brake cable (5).

6 5
7. Remove the bracket (6).
5

8. Remove the brake piping in the wheel cylinder block (7,

8).

7 8

9. Remove the wiring from the left drive motor.

• DUL (9) 14 13
• DWL (10) 9
• DVL (11)
10. Remove the wiring from the right drive motor.
12
• DUR (12)
• DWR (13)
• DVR (14) 11
10

11. Remove the connector from each sensor of left drive

19 15
motor.
• Speed Sensor A (Connector Color: dark gray) (15)
• Speed Sensor B (Connector Color: brown) (16)
• Temperature Sensor (Connector Color: light gray) (17)
12. Remove the connector from each sensor of right drive
motor.
• Speed Sensor A (Connector Color: white) (18)
• Speed Sensor B (Connector Color: blue) (19) 17
• Temperature Sensor (Connector Color: black) (20)
20 18 16

3-17
3. REMOVAL AND INSTALLATION

13. Remove the temperature sensor (21).

21

14. Place the pallet under the drive axle and set the wooden
block in between the drive motor and pallet.

15. Remove the left front axle fixing bolts (22). (4 locations)

22

16. Remove the right front axle fixing bolts (23). (4 locations)

23

3-18
 3. REMOVAL AND INSTALLATION

17. Draw out slowly the pallet, on which the drive axle is
placed, in front of the lift truck.
Then, remove the drive axle.

Be careful not to bend or damage the brake

piping.

INSTALLATION
1
Install in reverse steps and pay attention to the following
points.
1. Tightening torque of drive motor mounting bolt
98 - 123 Nm
(Both of right and left) {10 - 12.5 kgm}
[72.3 - 90.4 ft. lb] 1

Tightening torque of drive axle fixing bolt (1)

343 - 427 Nm
(Both of right and left) {35 - 43.5 kgm}
[253.1 - 314.6 ft. lb]

2. Adjustment of stabilizer projection amount

Tighten evenly the outer nuts at the right and left sides,
measuring with the scale so that the amounts of stabi-
lizer projections at the right and left sides become equal.

63 - 147 Nm
(Both of right and left) {6.4 - 15.0 kgm}
[46.3 - 108.5 ft. lb]
A

3. Tightening torque of drive motor wire fixing bolt

DUL DWR
9 - 11 Nm
{0.9 - 1.1 kgm}
[6.5 - 8.0 ft. lb]

DVL
DVR

DWL DUR

3-19
3. REMOVAL AND INSTALLATION

4. Wiring 6 2
Tie the wires with the tying lap not to touch the sharp
edge of lift truck or to be caught.
Connect the connector to each sensor of left drive motor.
• Speed Sensor A (Connector Color: dark gray) (2)
• Speed Sensor B (Connector Color: brown) (3)
• Temperature Sensor (Connector Color: light gray) (4)
Connect the connector to each sensor of right drive
motor.
• Speed Sensor A (Connector Color: white) (5)
7 5 3 4
• Speed Sensor B (Connector Color: blue) (6)
• Temperature Sensor (Connector Color: black) (7)

5. Tightening torque of brake pipe nipple (8, 9)

10 - 13 Nm
(nipple) {1.0 - 1.3 kgm}
[7.2 - 9.4 ft. lb]

8 9

3-20
 3. REMOVAL AND INSTALLATION

STEERING AXLE
REMOVAL
1. Remove the battery.
a See “Battery” on page 3-25. 1

2. Hook the hoisting accessory such as the sling belt to the

hole (1) for hoisting at the top of outer mast and towing
pin (2), and lift up the lift truck with the crane.

Do not hang the lift truck at the location

other than the location specified.
Before lifting the lift truck, make sure the 2
state of mast installation.

3. Set the wooden blocks (3) under the right and left
frames.
4. Remove the tires from the rear wheels.

5. Remove the power steering piping (4).

4

6. Lift up a little the lift truck with the crane.

7. Set the special jig (5) to the position shown in the figure.
8. Lift down quietly the crane.
5

3-21
3. REMOVAL AND INSTALLATION

9. Remove three fixing bolts (6).

10. Lift up the lift truck with crane to the height where the jig
and steering axle can be removed.
11. Draw out the jig and steering axle backward at the same
time.

INSTALLATION
Install in reverse steps and pay attention to the following
points.

Tightening torque of fixing bolt (6) 6

175 - 215 Nm
{18 - 22 kgm}
[130.2 - 159.1 ft. lb]

3-22
 3. REMOVAL AND INSTALLATION

REAR AXLE
REMOVAL
1. Lift up the lower side of counterweight rear with the
crane and place the wooden blocks (1) under the right
and left frames.
2. Place the fork (2) (Something movable up and down)
under rear axle.

1
2

3. Remove the power steering piping (3).

3

4. Remove four plate fixing bolts (4).

5. Remove two plates (5).

3-23
3. REMOVAL AND INSTALLATION

6. Lift down the fork and extract the fork from lift truck.
Then, draw out the rear axle in the horizontal direction.

INSTALLATION
Install in reverse steps and pay attention to the following
points.

Tightening torque of plate fixing bolt (4)

175 - 215 Nm
{18 - 22 kgm} 4
[130.2 - 159.1 ft. lb]

3-24
 3. REMOVAL AND INSTALLATION

BATTERY
REMOVAL
1. Open the battery hood and lock the stopper (1) of gas
spring.

C3Z15504

2. Plug out the battery plug (2).

C3Z15505

3. Remove the side cover (3) at the right side of lift truck. 3

C3Z15506

4. To draw out the battery, unlock by turning the battery

lock (4) upward.
4

C3Z15507

3-25
3. REMOVAL AND INSTALLATION

5. Using the fork pocket (5) under the battery, lift the battery
with other fork lift and draw the battery slowly out.

5
C3Z15508

INSTALLATION
Install in reverse steps.

If the battery is lifted up too high, the battery

may hit the battery hood and gas spring,
resulting in damage.
Be careful not to lift up the battery too high.

Table of Battery Mass (Maximum)

Mass
Model Capacity (Ah) Voltage
(kg) [lb]

FB15U-12, FB15FU-12
600 935 [2061.3]
FB18U-12, FB18FU-12 48 V
FB20U-12, FB20AFU-12 600 935 [2061.3]

Mass
Model Capacity (Ah) Voltage
(kg) [lb]
FB15MU-12, FB15MFU-12
600 935 [2061.3]
FB18MU-12, FB18MFU-12 48 V

FB20MU-12, FB20MFU-12 600 935 [2061.3]

a Confirm the battery capacity by reading the manufac-

turer plate on the front of battery case.

3-26
 3. REMOVAL AND INSTALLATION

HYDRAULIC PUMP AND PUMP MOTOR

11
9 3
13 2

4
1

7 14

12

10

5 6

REMOVAL
1. Remove the floor plate.
2. Remove the wirings of (2), (3) and (4) of pump motor (1),
temperature sensor (5) and speed sensor (6).
3. Remove the hydraulic piping and then the fixing bolt (8).
4. Remove the hydraulic pump (7) from the pump motor
(1).
5. Remove the fixing bolts (9) and (10) and nut (11). Then,
remove the plate (13) and pump motor.
6. When removing the plate (14), remove the nut (12).
INSTALLATION
Install in reverse steps and pay attention to the following
points.
Tightening torque of fixing bolt (8)

34 - 74 Nm
{3.5 - 7.5 kgm}
[25.3 - 54.2 ft. lb]

3-27
NOTES
4. Disassembly and
Assembly

DRIVE AXLE ...................................................................................................... 4-2

TRANSFER (BRAKE) ........................................................................................ 4-5

TRANSFER (HUB BEARING).......................................................................... 4-11

TRANSFER (TRANSFER) ............................................................................... 4-14

BRAKE WHEEL CYLINDER ............................................................................ 4-17

BRAKE MASTER CYLINDER.......................................................................... 4-21

STEERING GEAR BOX ................................................................................... 4-25

ORBITROL....................................................................................................... 4-27

POWER STEERING CYLINDER (4-WHEEL LIFT TRUCK)............................ 4-29

STEERING AXLE (3-WHEEL LIFT TRUCK) ................................................... 4-31

REAR AXLE (4-WHEEL LIFT TRUCK)............................................................ 4-38

LIFT CYLINDER............................................................................................... 4-43

TILT CYLINDER............................................................................................... 4-52

HYDRAULIC PUMP ......................................................................................... 4-60

CONTROL VALVE ........................................................................................... 4-65

DRIVE MOTOR................................................................................................ 4-67

PUMP MOTOR ................................................................................................ 4-68

4-1
4. DISASSEMBLY AND ASSEMBLY

DRIVE AXLE
DISASSEMBLY
G2-LI *1. When assembling, scrub and clean.
*2. Adjust so that the start-up torque of hub alone is
3.92 - 5.88 Nm {0.4 - 0.6 kgm} [2.9 - 4.3 ft. lb].
*3. Apply the powertrain oil (TO-10W) to the inner
face.

59 - 74 Nm
{6 - 7.5 kgm}
[43.4 - 54.2 ft. lb]

27 - 34 Nm
{2.8 - 3.5 kgm}
[20.3 - 25.3 ft. lb]

G2-LI

G2-LI (Lip portion)

G2-LI
27 - 34 Nm
{2.8 - 3.5 kgm}
[20.3 - 25.3 ft. lb]

63 - 147 Nm
{6.4 - 15.0 kgm}
[46.3 - 108.5 ft. lb]

4-2
 4. DISASSEMBLY AND ASSEMBLY

CHECK

2 ton vehicle

1 ton vehicle

E, F

J
C, D
H
I
A, B

4-3
4. DISASSEMBLY AND ASSEMBLY

JUDGING STANDARD
Unit: mm [in]

Criteria
Mark Part Check Item Standard Limit Remedy
Dimension allowed
19.96 - 19.98 19.9
A Diameter of piston shaft
[0.786 - 0.787] [0.783]
Inner diameter of piston shaft sliding part of 20 - 20.033 20.1
B
cover [0.787 - 0.789] [0.791]
35 - 35.039 35.1
C Inner diameter of piston sliding part
[1.378 - 1.379] [1.382]
Brake Outer diameter of sliding part of cover and 34.950 - 34.975 34.9
D
(In drive axle) piston [1.376 - 1.377] [1.374]
2.32 - 2.47 2.1
E Thickness of wet type disc Replacing parts
[0.091 - 0.097] [0.083]
1.7 - 1.8
F Thickness of plate * –
[0.067 - 0.071]
29.5 - 30.5 28
G Free length of spring
[1.16 - 1.20] [1.10]
0.95 - 1.05 0.85
H Thrust washer a
[0.037 - 0.041] [0.033]
2.23 - 2.37 2.13
I Thrust washer b
[0.088 - 0.093] [0.084]
Drive Axle
Replace with a
new one at dis-
J O-ring, seals – –
assembly/as-
sembly.

4-4
 4. DISASSEMBLY AND ASSEMBLY

TRANSFER (BRAKE)
ASSEMBLY
1. Insert four discs and four plates.
a Be careful of orders so that the disc should be posi-
tioned in the depth.
2. Set the springs.

Discs Plates

3. Tighten temporarily the piston with three bolts.

4-5
4. DISASSEMBLY AND ASSEMBLY

4. Set the special jig (3BA-97-99730).

5. Tighten fully the bolts with the flat blade screwdriver and
turn them back by 1/2 turns.

6. Remove the special jig and confirm that the gap A is 6 ±

0.3 mm (at three locations).

4-6
 4. DISASSEMBLY AND ASSEMBLY

7. Apply LOCTITE (#271) to the screwed portions and

tighten the nuts with specific torque. LOCTITE
8.8 - 10.8 Nm
{0.9 - 1.1 kgm}
[6.5 - 8.0 ft. lb]

8. Fix the housing case and place the brake on it.

9. Fix the brake to the housing case with six bolts with the
specific tightening torque. 59 - 74 Nm
{6 - 7.5 kgm}
[43.4 - 54.2 ft. lb]

4-7
4. DISASSEMBLY AND ASSEMBLY

10. Turn upside down the housing case and insert the shaft.

11. Fix the wheel cylinder with three bolts with tightening the
specific torque. 59 - 74 Nm
{6 - 7.5 kgm}
[43.4 - 54.2 ft. lb]

12. Tighten the nut to the measurement opening for wear

check of brake disc.

13. Loosen the parking brake lever adjustment bolt.

Adjustment Bolt

4-8
 4. DISASSEMBLY AND ASSEMBLY

14. Align the direction of spline teeth.

• In case of using the special tool:
1) Insert the special tool (3BA-97-99720) in the spline
of disc and align the direction of spline teeth.

2) After setting the adjustment bolt of wheel cylinder

high to apply the brake, remove the special jig.
As the brake is applied, the direction of spline Adjustment Bolt
remains unchanged.

• In case of not using the special tool:

1) Align the direction of spline teeth of disc with the flat
blade screwdriver.

2) Insert the gear slowly and engage the teeth of spline

to each other.

4-9
4. DISASSEMBLY AND ASSEMBLY

3) Set the adjustment bolt of wheel cylinder high to

apply the brake.
As the brake is applied, the direction of spline Adjustment Bolt
remains unchanged.

4) Pull out the gear once.

15. Proceed to the assembly of transfer (see “Transfer

(Transfer)” on page 4-14).
16. After installing the transfer to the lift truck, perform the
following adjustment.
• Bleeding the brake pipe of air; see “Air Bleeding” on
page 2-22
• Adjustment of wet type brake; see “Adjustment of Wet
Type Brake and Parking Brake” on page 2-13.

4-10
 4. DISASSEMBLY AND ASSEMBLY

TRANSFER (HUB BEARING)

ASSEMBLY
1. Drive the outer race. (Inner side)

2. Drive the outer race. (Outer side)

3. Insert the inner races. (Both of inner and outer sides)

4. Insert the oil seal and then apply grease to the entire
inner circumference of lip portion. G2-LI

4-11
4. DISASSEMBLY AND ASSEMBLY

5. Apply the grease to the spline block of carrier and

assemble the hub.

G2-LI

6. Tighten the hub nut so that the startup torque meets the 3.92 - 5.88 Nm
specific value. {0.4 - 0.6 kgm}
The reading on the spring scale when measured at [2.9 - 4.3 ft. lb]
the hub bolt: 56 - 84 N {5.7 - 8.5 kgf} [12.6 - 18.7 lb]

8 7 6 5 4

7. Caulk the hub nut.

8. Drive the cap.

4-12
 4. DISASSEMBLY AND ASSEMBLY

9. Tighten the breather.

10. Rotate the hub by hand and confirm that the hub
smoothly rotates.

4-13
4. DISASSEMBLY AND ASSEMBLY

TRANSFER (TRANSFER)
ASSEMBLY
1. Tighten the gear with sixteen bolts with the specific tight- 27 - 34 Nm
ening torque. {2.8 - 3.5 kgm}
[20.3 - 25.3 ft. lb]

2. Clip the planetary gears with the snap rings.

3. Set two knock pins to the housing.

4. Insert the gear.

4-14
 4. DISASSEMBLY AND ASSEMBLY

5. Apply the liquid gasket (THREEBOND #1207B) to the

housing face mating with the case.
Liquid gasket

6. While aligning the knock positions, combine the housing

and case.
a Set the adjustment bolt of wheel cylinder high to
apply the brake and confirm that the directions of
splines of discs are correctly oriented.

7. Fix the case to the housing with ten bolts with the spe- 27 - 34 Nm
cific tightening torque. {2.8 - 3.5 kgm}
[20.3 - 25.3 ft. lb]

8. Loosen the lock nut and set low the height of adjustment
bolt to release the brake.
Adjustment Bolt
a Perform the final height adjustment of adjustment nut
in the item of parking lever adjustment.

Lock Nut

4-15
4. DISASSEMBLY AND ASSEMBLY

9. Apply the powertrain oil (TO-10W) to the bearing and

contact side of case.
10. Insert the motor shaft pinion gear assembly.
a Press-fit the inner wheel/outer wheel of outer bearing
simultaneously.
06300-06908

Apply oil.

3BA-21-71140 06300-06005
Apply oil.

11. Using the special jig (3NA-97-99710), drive the pinion

gear assembly.

12. Clip the gear with the snap ring.

13. Rotate the hub by hand and confirm that the hub
smoothly rotates.
a If you have forgotten to turn back the adjustment bolt,
due to braking, the hub does not rotate.
a Unless the directions of splines of discs are correctly
oriented, the hub does not rotate after assembled.

4-16
 4. DISASSEMBLY AND ASSEMBLY

BRAKE WHEEL CYLINDER

11
9

5
4
6
10
12
7
8
1

1. Cylinder 5. Spring 9. Cup

2. Boot 6. Holder A 10. Cup
3. Piston 7. Holder B 11. Backup Ring
4. Snap Ring 8. Dust Seal 12. Backup Ring

Judging Standard
Unit: mm [in]

No. Check Item Standard Value Limit allowed Remedy

• Inner diameter of cylinder:
40.0 - 40.062 [1.575 - 1.577]
Clearance between cylinder and • Outer diameter of piston: 0.2 [0.0079] at
1
piston 39.911 - 39.950 [1.571 - 1.573] the maximum
• Clearance:
0.05 - 0.151 [0.002 - 0.006]
• Inner diameter of holder A/B:
12.0 - 12.043 [0.472 - 0.474]
Clearance between holder and • Outer diameter of rod: 0.15 [0.006] at Replace individual
2 part or cylinder as-
piston rod part 11.957 - 11.984 [0.471 - 0.472] the maximum
sembly.
• Clearance:
0.016 - 0.086 [0.001 - 0.006]
Interference of cup
3 About 1.7 - 1.8 [0.067 - 0.071] 0.75 [0.030]
(large diameter)
Interference of cup
4 About 1.0 - 1.2 [0.039 - 0.047] 0.40 [0.016]
(small diameter)
25.8 [1.016] ± 3 %
5 Free length of spring 22.5 [0.886]
(25.03 - 26.57 [0.985 - 1.046])

4-17
4. DISASSEMBLY AND ASSEMBLY

DISASSEMBLY

Do not use any oil other than alcohol or braking fluid for scrubbing the parts. Especially,
never use mineral oil (kerosene, gasoline). (If the rubber product is contaminated by the
mineral oil, the rubber swells and becomes useless.)
When scrubbing the rubber product by alcohol, do not dip it in the alcohol more than 30
seconds.
After scrubbing, place the parts on the clean place to avoid dust.
Be careful of entry of foreign matter. Be careful not to damage the cylinder, piston and
cup.
Arrange the disassembled parts in order.

1. Remove the boot (2) and cylinder from the piston.

2

2. Pull out the piston (3) from the cylinder (1).

(Be careful not to drop the spring.) 9

3. Remove the snap ring (4) and holder/cup in the order of

figures.
4. If necessary, remove the cup (9) from the piston.
(Do not re-use the cup once removed.)
4

4-18
 4. DISASSEMBLY AND ASSEMBLY

CHECK
Backup Ring
Base portion (white)
Lip portion

Lip portion

Base portion

Backup Ring Cup (large diameter)

(white) Cup (small diameter) Dust Seal

Part Name Check Item Remedy

Scar on bore, wear, dam- Remove a tiny scar with paper.
Cylinder
age, corrosion If scars affect the cup, replace the cylinder assembly.
Scars, damage, bending,
wear and corrosion on slid- Remove a tiny scar with the oil grinding stone.
ing part (large diameter If scars affect the cylinder bore and cup, replace the piston with a new one.
side, small diameter side)
Piston
Clearance between cylin- If the clearance exceeds the limit, replace the cylinder assembly or piston as-
der and piston sembly. Limit of clearance: 0.2 mm [0.008 in]
Gap between piston and If the clearance exceeds the limit, replace the holder A/B or piston assembly.
holders A / B Limit of clearance: 0.15 mm [0.006 in]
Scar on lip If any tiny scar is found, replace the cup.
Gall on base portion If the gall is serious, replace the cup.
Cup If abnormal fatigue, wear or swelling is found, replace the cylinder assembly or
Wear / swelling
(large di- the cup with a new one.
ameter) The interference (outer diameter of cup - inner diameter of cylinder) is less than
0.75 mm [0.03 in], replace cylinder assembly or the cup with a new one.
Interference
Reference: The interference of new cup is about 1.7 to 1.8 mm [0.067 to
0.074 in].
Scar, wear, falling If the spring has serious scars or wear, replace it.
Spring If the free length is less than 22.5 mm [0.89 in], replace it.
Free length Reference: The free length of new spring is about 25 to 26.6 mm [0.98 to
1.05 in].
Holder A
Scar on bore, wear Remove a tiny scar with paper. If it has serious scars, wear or crack, replace it.
Holder B
Scar on lip If any tiny scar is found, replace the cup.
Gall of base portion If the gall is serious, replace the cup.
Cup If abnormal fatigue, wear or swelling is found, replace the cylinder assembly or
Wear / swelling
(small di- the cup with a new one.
ameter) The interference (outer diameter of rod - inner diameter of cup) is less than 0.40
mm [0.016 in], replace cylinder assembly or the cup with a new one.
Interference
Reference: The interference of new cup is about 1.0 to 1.2 mm [0.039 to
0.047 in].
Scar on lip If any tiny scar is found, replace it.
If abnormal fatigue, wear or swelling is found, replace the dust seal with a new
Wear / swelling
one.
Dust Seal
The interference (outer diameter of rod - inner diameter of cup) is less than 0.10
Interference mm [0.004 in] or none, replace dust seal with a new one.
Reference: The interference of new cup is about 0.5 mm [0.02 in].
Boot Appearance If any bending or crack is found, replace it.
Boot Interference of cylinder /
If the interference is a little or none, replace it.
piston

4-19
4. DISASSEMBLY AND ASSEMBLY

ASSEMBLY
1. Apply evenly the rubber grease or brake fluid to the inner
part of cylinder (1).
2. Assemble in order of dust seal (8), holder B (7), backup
ring (12), cup (10) and holder A (6). At last, clip the snap
ring (4). 4
a When assembling, be careful of the direction and 6
order of the dust seal, holder and cup. 10
12
7
8

3. When the cup is removed from the piston, assemble the

backup ring (11) and cup (9) to the piston in order. 11
9
Place the spring (5) on the piston with the cup, and build
them in the cylinder.
a Confirm that the rod at the tip of piston passes
through the dust seal and comes out of the cylinder.

3
5

4. After confirming, insert the boot (2) into the boot groove
and then assemble the boot into the boot groove of the
2
cylinder side while pushing in the piston geatly.
1

4-20
 4. DISASSEMBLY AND ASSEMBLY

BRAKE MASTER CYLINDER

CONFIGURATION PARTS

No. Part Name Qty No. Part Name Qty

1 Cylinder 1 10 Breather Valve 1
2 Piston Assembly 1 11 Breather Cap 1
3 Snap Ring 1 12 Valve Spring 1
4 Boot 1 13 Sheet 1
5 Push Rod 1 14 Valve Rubber 1
6 Nut 1 15 Gasket 1
7 Yoke 1 16 Bolt 1
8 Bushing 1 17 Valve Assembly 1
9 Filler Union 1

11

9 10
8
2 1

4 12

13
5
17
6 14
7
15

16

Unit: mm [in]

No. Check Item Standard Value Limit Remedy Code

Clearance between cylinder and 0.020 - 0.105 0.15 Replace. 1.2

1 piston [0.001 - 0.004] [0.006] (Cylinder Assembly) [0.047]
Primary side: about 1.0
[0.039] 0.4 Replace. 2
2 Interference of cup
Secondary side: about 1.2 [0.016] (Cylinder Assembly) [0.079]
[0.047]
70 2
3 Free length of spring 78.8 [3.1] Replace.
[2.76] [0.079]
a The code at the right side shows the location of configuration parts.

4-21
4. DISASSEMBLY AND ASSEMBLY

DISASSEMBLY

Do not use any cleaning agent other than alcohol or hydraulic oil for scrubbing parts.
Be careful of entry of foreign matter. Be careful not to damage the cylinder, piston and
cup.
When disassembling, understand the structure of cylinder and arrange parts in order of
disassembly.
Do not disassembly the piston assembly.
Do not push strongly the outer wall of cylinder with the vise.

1. Remove the yoke and boot.

2. Remove the bolt (16).
3. Remove the snap ring (3) with the flat blade screwdriver 2
and take out the piston assembly. 16
3
a If it is hard to pull out the snap ring, press the push
rod (2) a little so that the snap ring can be easily
pulled out.

4-22
 4. DISASSEMBLY AND ASSEMBLY

CHECK / ADJUSTMENT
Part Name Check Item Remedy
Scar on the inner face, eccentric Remove a tiny scar with paper.
Cylinder
wear, corrosion If the scar affects the cup, replace the cylinder assembly.
Remove a tiny scar with the oil grinding stone.
Scar on the sliding portion, eccen-
If the scar affects the inner surafce of cylinder and cup, replace
tric wear, corrosion
Piston the cylinder assembly.
Clearance between cylinder and If the clearance exceeds the limit, replace it.
piston Limit of dimension: 0.15 mm [0.006 in]
Scar on the lip If a tiny scar is found, replace the piston assembly.
Eaten base portion If any hazardous eating is found, replace the piston assembly.
If the abnormal fatigue or wear/swelling is found, replace the
Wear, swelling
piston assembly.
Cup
If the clearance is less than the limit, replace the piston assem-
bly. Limit of dimension: 0.4 mm [0.016 in]
Interference a The cup is the periodic replacement part.
It is safer to replace the cup at every disassembly.
Deformation, scar and wear of If any abnormal deformation, scar or wear is found, replace the
Piston Assembly
valve rod, valve cut, spring piston assembly.
1. Base Block
2. Lip Block
3. Base Block
4. Lip Block

Part Name Check Item Remedy

Scar, wear, falling The scars are heavy, replace the spring.
Spring If it is less than the limit, replace the spring.
Free length
Dimension of limit: 70 mm [2.76 in]
Push Rod Bending, deformation If the bending or deformation is found, replace it.
Crack, damage If the crack or damage is found, replace it.
Boot
Cylinder, interference with rod If the interference is a little or none, replace it.
Crack If any tiny crack is found, replace it.
Filler Union Discoloration If discolored heavily, replace it.
Scar If any scar is found, replace it.
Bushing Crack, degradation If cracks or degradation is found, replace it.

4-23
4. DISASSEMBLY AND ASSEMBLY

MAINTENANCE STANDARD
Unit: mm [in]

No. Check Item Standard Value Limit Remedy

Clearance between cyl- 0.020 - 0.105 0.15 Replace.
1
inder and piston [0.001 - 0.004] [0.006] (Cylinder assembly)
Primary side: about 1.0 [0.039] 0.4 Replace.
2 Interference of cup
Secondary side: about 1.2 [0.047] [0.016] (Cylinder assembly)
78.8 70
3 Free length of spring Replace.
[3.10] [2.76]

4-24
 4. DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

DISASSEMBLY / ASSEMBLY

29 - 39 Nm
{3 - 4 kgm}
[21.7 - 29.0 ft. lb]

*1

34 - 44 Nm
{3.5 - 4.5 kgm}
[25.3 - 32.5 ft. lb]

*1 Orient the pin marked with the black marking in the direction of front of lift truck.

4-25
4. DISASSEMBLY AND ASSEMBLY

INITIAL SETTING WORK (KNOB CORRECTION TEACHING WORK)

State of steering
Procedure Work Item wheel neutral Confirmation Item Remarks
switch connector
Turn the steering wheel to After completing the air-bleed- When turning OFF the key, the
Disconnected
1 the extreme end five times ing, confirm that the steering steering operation does not be-
(Open)
to bleed the circuit of air. has no play. come light.
Set the tires in the straight- Disconnected
2 Straight-forward state
forward state. (Open)
In the state that the tires are
straight-forwarded, install Disconnected Confirm the positions of steer-
3
the steering wheel in the (Open) ing wheel and tires.
original position.
Connect the steering neu- Connect and
When displaying [ALA5000],
4 tral switch connector once disconnect it.
the meter beeps.
and then disconnect it. (Close o Open)
After the meter shows the
[ALA5000], turn fully clock-
wise the steering wheel and
fully counterclockwise. During teaching
Operate fully the steering
Then, return the steering Disconnected (The controller is memorizing
5 wheel in the right and left direc-
wheel in the neutral posi- (Open) the steering turns and angle of
tions.
tion. steered tire.)
a Turn the steering
wheel slowly.
During teaching or after stop-
ping the steering, if either of
displays below appears, the
Disconnected Confirm that the meter display work failed. Perform again
6 Stop steering.
(Open) returns to the normal menu. starting step No.2.
• [ALA3005]
• [ALA3205]
• [ALA5005]
Disconnected Operate and confirm that the
7 Finished
(Open) knob position is corrected.

Error Display related to Initial Setting

Content Error Display

The initial setting work failed.
ALA5000
a In case of incorrect setting work
The initial setting work failed. ALA3005
(During teaching) ALA3205
a In case of quick steering operation ALA5005

Abnormal steering sensor 5055

Abnormal tire sensor 3054
No error display
Normal steering operation
(The normal display is
(The initial setting is completed)
correct.)

4-26
 4. DISASSEMBLY AND ASSEMBLY

ORBITROL

44 36 42 37 44 31 41 32 39 38
30 34

43 33

40
35

27
20 45
23 2
17
13 5*
16
12
4
22

15
21
14 24 18 19 28 29 11 8 9 10 7 26 6 25 3 1

*: 4 wheel lift truck only

1. Screw 16. Rotor 31. Spool

2. Retainer Screw Assembly 17. Hexagon Socket Head 32. Tube Assembly
3. Roll End Cap Stopper Screw (tip of stick)
33. Nut
18. Race Bearing
4. Gerotor 34. Coil with connector
5. Spacer 19. Thrust Needle
35. O-ring
6. Spacer Plate 20. O-ring
36. O-ring
21. Oil Seal (Y Packing)
7. Drive 37. Hexagon Socket Head Bolt
8. Housing 22. Dust Seal
38. Spring
9. Sleeve 23. Retaining Ring
39. Core
24. Seal Ground Bushing
10. Spool 40. Plug with hexagon hole
11. Pin 25. O-ring
41. O-ring
12. Centering Spring 26. O-ring
42. Check Valve Assembly
27. Ball
13. Flat Spring 43. Relief Valve Cartridge
14. Handle Angle Sensor 28. Name Plate
44. O-ring
15. Cross-Recessed Flat Head 29. Rivet
45. Check Valve Assembly
Screw 30. Valve Block

4-27
4. DISASSEMBLY AND ASSEMBLY

OIL PRESSURE MEASURING PORT OF P PORT

Oil pressure
measuring port of P port

4-28
 4. DISASSEMBLY AND ASSEMBLY

POWER STEERING CYLINDER (4-WHEEL LIFT TRUCK)

PARTS CONFIGURED

No. Part Name Qty No. Part Name Qty

1 Cylinder Tube 1 6 Rod Packing 2
2-1 Piston Rod 1 7 Backup Ring 2
2-2 Piston 1 8 O-ring 2
3 Rod Guide 2 9 Piston Packing 2
4 Tie Rod 2 10 Wound Bushing 2
5 Dust Seal 2 11 Small-type Flange Nut 4

2-1
3
1
3

7
11
6
8 10
9
2-2
4
8
5 7 6 11 10

6
7
5

8
10

4-29
4. DISASSEMBLY AND ASSEMBLY

DISASSEMBLY
1. Clamp the outer diameter and fix the cylinder tube (1).

Clamp cylinder tube

1 outer diameter

2. Loosen four nuts (11) and remove the tie-rod (4).

11

3. Draw out the tie-rod guides (3) from both left and right 3
side slowly.
a When drawing out, be careful not to damage the
packing.

4. Pull out the piston rod (2) straightly.

2

ASSEMBLY
Assemble in reverse steps. Some precautions:
• When assembling, apply the grease or hydraulic oil to the O-ring, dust seal and lip side of packing.
• Before applying the bond, clean the screwed portions (4), (11).
• Warm the packing of piston in hot water (below 80°C [176°F]) and install it.

4-30
 4. DISASSEMBLY AND ASSEMBLY

STEERING AXLE (3-WHEEL LIFT TRUCK)

DISASSEMBLY

*4

G2-LI

2.9 - 4.9 Nm
{0.3 - 0.5 kgm}
[2.2 - 3.6 ft. lb]

39 - 49 Nm
G2-LI {4 - 5 kgm}
(Upper side of [29.0 - 36.2 ft. lb]
bushing, lip
portion)
*2
*5

*6
G2-LI

G2-LI(Cup portion)
*5

137 - 157 Nm
*1 {14 - 16 kgm}
*1 The gap and rattle should not exist. [101.3 - 115.7 ft. lb]
*2 Orient the seal in the correct direction. *3
When assembling the seal, ring and
packing, apply the hydraulic oil to them. 157 - 245 Nm
*3 Place the chamfered side inward. {16 - 25 kgm}
[115.7 - 180.8 ft. lb]
*4 To engage the pinion with the rack, align
the position of roll pin of pinion with
marking on the rack.
*5 Apply the LOCTITE #271 to the screwed
portion at the housing side.
*6 Apply the hydraulic oil.

4-31
4. DISASSEMBLY AND ASSEMBLY

CHECK

A B

Judging Standard
Unit: mm [in]

Criteria
Mark Check Item Remedy
Standard Dimension Limit allowed
A Diameter of cylinder rod 48 [1.89] 47.8 [1.88]

B Inner diameter of cylinder housing 48 [1.89] 48.2 [1.90]

Replace
C Press-fitted portion of bearing 37 [1.46] 36.8 [1.45]

D Press-fitted portion of axle Rotation, looseness, rattle

4-32
 4. DISASSEMBLY AND ASSEMBLY

ASSEMBLY
1. Assemble the seal (1) (black), seal (3) (blue) and ring (2)
to the piston.
Rack Piston
a Be careful of the orientation of seals.

1 2 3

2. Using the special jig (6), insert the shaft (5) in the axle
(4) with the press machine.

5
6

3. Drive the outer race in the housing.

4. Apply the grease to the screwed portion of rack (7) and

entire outer circumference, and assemble it in the hous- G2-LI
ing.
Marking

G2-LI
7

4-33
4. DISASSEMBLY AND ASSEMBLY

5. Apply the grease to the gear portion and bearing portion

in the housing.
6. While aligning the position of roll pin of pinion with the
marking on the rack, insert the housing in the axle.

7. Apply the grease (G2-LI) to the outer circumference of

bearing (8) and insert it in the housing.

8. Refer to “Shim Adjustment Procedure” on page 4-37 and

LOCTITE #271
determine the thickness and quantity of shim.
9. Assemble the shim (9) and plate (10) and fix them with
the bolt (11) with the specific tightening torque.
11
176 - 216 Nm
{18 - 22 kgm} 10
[130.2 - 159.1 ft. lb]

10. Apply LOCTITE #271 to screwed portions of four stud

bolt (12).
LOCTITE #271

12

4-34
 4. DISASSEMBLY AND ASSEMBLY

11. Insert the cylinder (13).

13

12. Confirm the direction of piston (14) and insert it in the

cylinder.
13. Assemble the cap (15) and tighten the nut (16) with the 14
specific tightening torque.

Rack Piston 15 16

14. Install the cover (17) and tighten the bolt (18).
18

17

15. Install the plate (19).

• In case of knock pin:
Align the plate with the knock pin (A) and install the 19 20
plate with the bolt (20).
A

4-35
4. DISASSEMBLY AND ASSEMBLY

• In case of no knock pin:

Install the alignment jig (3BA-97-99760) (A) to the
cover (17). 19 20
After performing the alignment of plate (19), install
17
the plate with the bolts (20).
A

16. Apply the grease to the bushing (21). While aligning the
direction of cut portion, assemble the bushing in the 21
housing.

17. While orienting the cut portion of pin of sensor (22),

assemble the sensor (22) in the housing and tighten the 23
bolts (23) with the specific torque. 22

18. Apply the grease to the tip of shaft (25) and insert the
hub (24) in the shaft.
19. Install the washer (26) with the chamfered side facing
inward and tighten the nut (27) with the specific torque.
137 - 157 Nm
{14 - 16 kgm} 24
[101.3 - 115.7 ft. lb] 25
26
27

26

4-36
 4. DISASSEMBLY AND ASSEMBLY

SHIM ADJUSTMENT PROCEDURE

1. Tighten tentatively the plate (10) with the center bolt (11)
without shim.
11
15 Nm
{1.53 kgm}
[11.1 ft. lb] 10

2. Pull out the center bolt (11) and remove the plate (10).
9
3. Measure dimension : Measure the height from the end
face of pinion shaft to the end face of bearing inner race
by the unit of 5/100.
4. Calculate the clearance S: S =  – 4.8 (mm)
5. According to the table below, determine the thickness
and quantity of shim. Then, install the shims.

Clearance S Thickness and quantity of shim

(mm) t = 0.2 (mm) t = 0.3 (mm) t = 1.0 (mm)
1.04 - 1.13 1
1.14 - 1.23 1 3
1.24 - 1.33 1 1
1.34 - 1.43 1 1
1.44 - 1.53 2 1
1.54 - 1.63 1 1 1
1.64 - 1.73 2 1
1.74 - 1.83 2 1 1
1.84 - 1.93 1 2 1
1.94 - 2.03 3 1
2.04 - 2.13 2
2.14 - 2.23 1 3 1
2.24 - 2.33 1 2
2.34 - 2.43 1 2
2.44 - 2.53 2 2

4-37
4. DISASSEMBLY AND ASSEMBLY

REAR AXLE (4-WHEEL LIFT TRUCK)

DISASSEMBLY / ASSEMBLY

G2-LI (*4)

*5

G2-LI (*1)
a
B

G2-LI (*2)

*4
*5 2.94 - 4.90 Nm
Start-up Torque (*3) {0.3 - 0.5 kgm}
[2.2 - 3.6 ft. lb]

*1 Lip portion
*2 Fill the grease in the 1/2 to 2/3 of capacity of bearing space.
*3 Adjust by the nut C.
*4 Upper side of bushing
*5 After driving the plug in, caulk it at three locations of circumference.

4-38
 4. DISASSEMBLY AND ASSEMBLY

*1

*2

Frame

98 - 147 Nm *1
{10 - 15 kgm}
*2
[72.3 - 108.5 ft. lb]

a
175 - 215 Nm
{18 - 22 kgm}
[130.2 - 159.1 ft. lb]

157 - 245 Nm
175 - 215 Nm {16 - 25 kgm}
{18 - 22 kgm} [115.7 - 180.8 ft. lb]
[130.2 - 159.1 ft. lb]

235 - 285 Nm
{23.5 - 29.5 kgm} *1. When installing the ball sockets at two locations,
[170.0 - 213.4 ft. lb] clean the installing portion and hole for installation.
*2. After adjusting the start-up torque of hub, insert the
cotter pin in the location where the nut matches
with the hole of shaft, and bend it securely.

4-39
4. DISASSEMBLY AND ASSEMBLY

CHECK / INSPECTION
Unit: mm [in]

Criteria
Mark Check Item Remedy
Standard Dimension Limit allowed
A Diameter of king pin 28 [1.10] 27 [1.06] Replace
B Rattle at top and bottom of knuckle – 0.2 [0.01] Shim adjustment
• Crack
– Rear axle, hub, knuckle, bearing • Damage, peeling Replace
• Burnt-out, rotational defect, foreign noise
a The mark corresponds to the alphabet in the disassembly/assembly drawings.

1. Hub Bearing
Fill the grease (G2-LI) in the 1/2 - 2/3 of hub bearing A
space (A).
a For cold storage specification, use the severe cold
use lithium grease (GLT2-LI-1).

2. Adjustment of Hub Rotational Start-up Torque

1) Tighten the hub (1) until rotating the hub by one
hand becomes tough. Then, loosen the lock nut (2)
by 1/4 turns. 8 7 6 5 4

2) Hook the spring scale to the hub bolt and adjust the
lock nut (2) to give the pre-pressure to the roller
bearing so that the rotational start-up torque (4.3 -
7.2 kgf by reading the spring scale) meets the spe-
cific value. 1 3
2
2.94 - 4.90 Nm
Start-up Torque {0.3 - 0.5 kgm}
[2.2 - 3.6 ft. lb]
42 - 70 N
Reading on the
{4.3 - 7.2 kgf}
spring scale
[9.5 - 15.9 lb]

3) After adjusting the start-up torque, be sure to bend

the cotter pin.

4-40
 4. DISASSEMBLY AND ASSEMBLY

3. Align the end face of needle bearing (A) with the end
face of boss.
A
4. Make 6 mm [0.24 in] the distance from the end face nee-
dle bearing (B) to the end face of boss.

0 mm
[0 in]

6 mm
[0.24 in]
B

5. Adjust so that the rattle (C) is less than 0.2 mm [0.008

in].
6. Install the stopper bolt (D).

7. Drive the plug (E) and caulk it at three locations on the

circumference.

8. Install the hub bearing so that the flat portion of hole for
inserting the shaft of potentiometer faces outside of lift
truck. F

4-41
4. DISASSEMBLY AND ASSEMBLY

REAR AXLE ASSEMBLY DRAWING

98 - 147 Nm
{10 - 15 kgm}
[72.3 - 108.5 ft. lb]

Start-up 2.94 - 4.90 Nm

G2-LI (*2)
Torque {0.3 - 0.5 kgm}
(*3) [2.2 - 3.6 ft. lb]

*1

G2-LI (*4)
*1
157 - 245 Nm
{16 - 25 kgm}
[115.7 - 180.8 ft. lb]

Tread 865 mm [34.1 in]

*1. Be sure to bend the cotter pin.

*2. Fill the grease in 1/2 to 2/3 of capacity of bearing space.
*3. Adjust by the nut A.
*4. Lip face

4-42
 4. DISASSEMBLY AND ASSEMBLY

LIFT CYLINDER

1. Cylinder 9. Bushing
2. Piston Rod Assembly 10. Cushion Bearing
3. Cylinder Head 11. Snap Ring
4. Bushing 12. O-ring
5. Wiper Ring 13. Spacer
6. O-ring 14. O-ring
7. U-ring 15. Wear Ring
8. Backup Ring

4-43
4. DISASSEMBLY AND ASSEMBLY

DISASSEMBLY
Preparation Maintenance Standard
Before disassembling, prepare as fol- According to the list below, replace the sliding parts and seal
lows. parts.
1. Preparation of work bench
The 1/4 th circumference is worn in
Prepare the sturdy work bench Bushing
copper color.
which has the space enough to
When disassembled, replace it with
place parts and is stable so that no Seal block
a new one.
part will be dropped during work.
When the bending of more than 0.5
2. Preparation of tools and materi- Piston rod
mm [0.020 in] / 1m [39.4 in]) occurs
als
Prepare the tools and materials a The bushing at the cylinder head side is press-fitted. For
shown in the item. replacement of bushing, use the [cylinder head kit].
(Cylinder head kit: Replacement kit of cylinder head with
General Caution Items on Work bushing press-fitted)

1. Before disassembling, scrub the Check after assembled

cylinder to remove soil and dust on
the cylinder face. When fully stroked without load more
No load operation
than 5 times, the cylinder moves
check
2. As every part is finely manufac- smoothly and no abnormality exists.
tured, handle them with caution. Confirm the contraction/stretch and
Avoid the collision of parts and do Dimension check stroke specified by the design draw-
not drop them. ing.
When the test pressure specified by
3. If parts are hit or tried to open forci- the design drawing is applied to each
bly on the work, they may lead to stroke end for more than 3 minutes,
Pressure resis-
blurs and damage. And eventually the looseness, deformation and exter-
tance check
nal leakage do not occur.
they will result in the failure of Warning:
assembling, oil leakage or perfor- When checked, fix the lift cylinder.
mance drop. Therefore, perform the Confirm the oil leakage in the rod
External leakage
work with caution. check
block. (Refer to “Judging the oil leak-
age in the rod block” below.)
4. If disassembled parts are left or the Internal leakage
disassembling is stopped and left Oil leakage: Less than 3 ml/10 min
check
as is, parts will be rusted.
Therefore, whenever you are forced
to interrupt the work, keep parts
rust-free and dust-free. Judging the oil leakage in the rod block
After shuttled 20 times at the oil temperature of 20 - 40 °C [68
- 104°F], judge by the state of oil ring formed on the rod.
If the oil ring collapses as shown in the state A, it is abnormal.
Refer to “Lift Cylinder” on page 5-10 (maintenance standard)
and treat.

4-44
 4. DISASSEMBLY AND ASSEMBLY

Tools Required
1. General Tool
No. Tool Name Quantity

1 Flat blade screwdriver 1

2 Allen wrench set 1 system

3 Vice 1

4 Torque wrench 1 system

5 Hammer (Plastic hammer) 1

6 Adjustable wrench 1

7 knife 1 pair

8 Hook spanner 1

2. Special Jig
Jig Name Sketch Drawing

Wiper ring press-fit tool

Piston seal press tool

4-45
4. DISASSEMBLY AND ASSEMBLY

Disassembly Procedure

1. Drain the oil.

2. Loosen the cylinder head (3).
Loosen the cylinder head (3) with the hooked spanner
and remove the cylinder head (3) from the cylinder tube
assembly (1).
The remaining oil may drop. So place the oil pan under
the opening of cylinder tube assembly.
3. Pull out the cylinder head (3).

Pull out the cylinder head (3) straightly and

prudently.
When pulling out the cylinder head (3),
depending on the shape of tip of piston rod
assembly (2), it may scratch other parts by
touching immediately after pulled out of the
rod. Therefore, pull out the cylinder head (3)
with caution not to damage other parts.

4. Pull out the piston rod assembly (2).

Pull out the piston rod assembly (2) while keeping it hori-
zontally. And place the piston rod assembly (2) on the
wooden sleeper.

When pulling the piston rod assembly (2), it

may be damaged by touching the screw at
the opening of cylinder tube assembly (1) or
dropping.
The lift cylinder with a long contraction/
stretch is subject to damage.

5. Pull out the spacer (13).

Pull out the spacer (13) from the piston rod (2). However,
as the spacer with the wear ring (15) is non-assembled
part, do not remove the spacer. But, the wear ring (15)
can be easily removed.

4-46
 4. DISASSEMBLY AND ASSEMBLY

6. Disassembly of Piston Block

Remove the U-ring (8), backup ring (9), bushing (10) and
cushion bearing (11).
a Do not disassemble the piston rod and piston.
1) Draw out the U-ring (8) and backup ring (9) with
knife or screwdriver.
2) Remove the bushing (10) with the screwdriver while
widening the joint.
a Do not re-use the seal removed.
3) Remove the snap ring (12), and draw out the cush-
ion bearing (11). Draw the snap ring (12) out of the
groove with the tool of sharp tip.

7. Disassembly of seal in cylinder head (3) block

Remove the U-ring (5), wiper ring (6) and O-ring (7).
1) Remove the U-ring (5) with the knife or screwdriver.
2) As the wiper ring is press-fitted, stick the screw-
driver in the rubber from the bushing side and pull
out by hitting.
3) In the same manner, remove the O-ring (7) and U-
ring (5) with the knife or screwdriver.
a Do not re-use the removed seal.

8. Scrubbing and store

1) After scrubbing the removed parts with kerosene,
apply the hydraulic oil to them and store them, being
covered.
2) If the disassembled parts are left as are, due to rust
and dust, they may not function well after assem-
bled.

4-47
4. DISASSEMBLY AND ASSEMBLY

ASSEMBLY

The debris of paint coming off each part may enter in the cylinder when assembled, caus-
ing the oil leakage. Therefore, be careful of entry of paint in the cylinder.

1. Assembly of cylinder head (3)

Prepare the disassembled cylinder head or [cylinder
head kit]. Before assembling, scrub both of them well.
1) Assembly of U-ring (5)
Push the U-ring (5) in the U-ring groove of cylinder
head (3). Install the U-ring with the knife not to dam-
age.
To make it easier to install the U-ring (5), warm the
U-ring up to 70°C (be careful of burn).
After installation, confirm that any permanent defor-
mations such as wrinkles are not left on it.

2) Installation of wiper ring (6)

Using the jig (dolly block), assemble.
Push it in with the press machine.

3) Assembly of O-ring (7)

When assembling O-ring (7), be careful not to make
scratch or cut.
After installing the O-ring, check that the O-ring is
not twisted.

4-48
 4. DISASSEMBLY AND ASSEMBLY

2. Assembly of piston block

Before assembling, scrub the piston well and keep it out
of dust.
1) Assembly of U-ring (8)
While expanding the U-ring (8), install it in the U-ring
groove of piston. At this moment, be careful of its
direction. Apply the hydraulic oil to the U-ring so that
it can be easily installed.
If the insertion jig shown in the figure at the left side
is available, it can be safely installed.

2) Assembly of backup ring (9)

Install the backup ring (9) to the back of U-ring (8).
If installed to the wrong place, the backup ring does
not function properly. Furthermore, the backup ring
damages the U-ring (8) and the cylinder may not
function.

3) Assembly of bushing (10)

Install the bushing (10) in the bushing groove of pis-
ton while widening the joint of bushing (10).

4-49
4. DISASSEMBLY AND ASSEMBLY

4) Installation of cushion bearing (11)

Insert the cushion bearing (11) in the piston. It can
be inserted in either direction. After insertion, install
the snap ring (12) in the snap ring groove of piston
and fix it with cushion bearing (11).

3. Installation of Cylinder Tube Assembly (1), Piston Rod Assembly (2) and Cylinder Head (3)
1) Fixing of Cylinder Tube Assembly (1)
Fix the cylinder tube assembly (1) horizontally.
2) Insertion of Spacer (13)
(Installation of wear ring (18))
Insert the spacer (13) in the piston rod assembly (2). Install the O-ring (14) in the O-ring groove on
the outer circumference of rod. Insert the spacer from the piston rod insertion part. When inserting,
push it in at the O-ring portion. If it is hard to push in, apply the hydraulic oil to the O-ring so that it can
be easily inserted. Do not insert the spacer until it touches the piston.
In case of non-disassembled spacer with wear ring (15), install the wear ring in the wear ring groove
of spacer.
3) Insertion of piston rod assembly (2)
Insert the piston rod assembly (2) in the cylinder tube assembly (1).
Insert the piston rod assembly in the cylinder tube assembly in the depth.

When inserting the piston rod assembly (2), be careful not to damage the piston seal by
the piston block touching to the screwed portion at the mouth cylinder tube assembly (1).
While keeping the piston rod assembly (2) horizontally, insert it prudently.

4-50
 4. DISASSEMBLY AND ASSEMBLY

4) Installation of cylinder head (3)

Insert the cylinder head (3) in the piston rod assem-
bly (2) from the tip and assemble it while pushing it
in.
Insert the cylinder head (3) in the screwed portion of
cylinder tube assembly (1), and tighten with the
hooked spanner with specific torque.

Test Run
After installing the cylinder to the lift truck, operate the switch-
over valve slowly and perform the full stroke eight times so
that the cylinder is fully filled with oil.
Never operate quickly from the beginning. If done so, the
hydraulic oil causes the aeration.

4-51
4. DISASSEMBLY AND ASSEMBLY

TILT CYLINDER
DISASSEMBLY DRAWING

23

15 16
14
15
13

10
11

20 9
21 2
17 8
6 7
4 5

18 12

22
19

1. Cylinder 7. Packing Head 13. Piston 19. Bolt

2. Piston Rod 8. Snap Ring 14. O-ring 20. Spring Washer
3. Cylinder Head 9. Wiper Ring 15. Backup Ring 21. Nut
4. Bushing 10. O-ring 16. Piston Nut 22. Fitting
5. Backup Ring 11. Backup Ring 17. Rod Head 23. Bushing
6. U-ring 12. O-ring 18. Bushing

4-52
 4. DISASSEMBLY AND ASSEMBLY

235 - 372 Nm 206 Nm

{24 - 38 kgm} {21 kgm}
[173.6 - 274.9 ft. lb] [151.9 ft. lb]
A B

E D C
F

Judging Standard
Unit: mm [in]

Criteria
Mark Check Item Remedy
Standard Dimension Limit allowed
0.04 - 0.167 0.3
A Clearance between piston rod and bushing
[0.002 - 0.007] [0.012] Replace the
0.05 - 0.23 0.5 bushing
B Clearance between rod head bushing and pin
[0.002 - 0.009] [0.020]
C Outer diameter of cylinder 73 [2.87]
D Inner diameter of cylinder 60 [2.36]
–
E Diameter of piston rod 25 [0.98]
F Stroke 122 [4.8]

a High Lifting Height: 3 m [118 in]

4-53
4. DISASSEMBLY AND ASSEMBLY

DISASSEMBLY

Before disassembling, remove the stain on

the face of cylinder and clean it.
Apply the hydraulic oil to the disassembled
and cleaned parts, wrap them with clean
papers or clothes and store them.
Arrange parts to identify the relationship of
parts before disassembled.

1. Drain the oil from the cylinder.

2. By using the bottom pin hole of cylinder tube (1), fix the
cylinder tube (1) to the vice vertically or horizontally.
3. Hook the wrench to the cut portion of cylinder head (3)
and loosen the cylinder head (3) by 1 to 2 turns.

4. In the state that the piston rod (2) is fully pulled, remove
the cylinder head (3) and pull out the piston rod (2).
a Confirm that the port of piping is open.
a Place the oil pan at the port of contraction side (cylin-
der side).
2

When fixing the cylinder vertically and per-

forming the disassembly/assembly: 3
To avoid dropping of cylinder, do not
unscrew all of the screws fixing the cylinder
head.
When fixing the cylinder horizontally and
performing the disassembly/assembly:
When pulling out the piston rod, the rod may
drop and be damaged. To avoid dropping of
piston rod, place the wooden sleeper under
the piston rod and pull out it horizontally. 2 3

5. Draw out the cylinder head and piston together and

place them on the wooden sleeper.

4-54
 4. DISASSEMBLY AND ASSEMBLY

6. Mark the index marking on the rod head (17) portion to

confirm the amount of screwing.

Index Marking

7. Wind the tape around the screwed portion A of rod (2) to

prevent the dust seal and U-ring in the cylinder head
from being damaged.

8. Remove the cylinder head.

a As the nut at the piston block is caulked and is a non-
disassembly part, remove the cylinder head from the
rod head side.

9. Remove the O-ring (14)and backup ring (15).

15
14
15

4-55
4. DISASSEMBLY AND ASSEMBLY

10. Remove the snap ring (8) and packing head (7), and
take out the U-ring (6). 12 11 10

11. Remove the wiper ring (9).

12. Remove the bushing (4). 9

4 5 6 7 8

4-56
 4. DISASSEMBLY AND ASSEMBLY

ASSEMBLY

When assembling, debris of paint, which comes off each part, may enter in the cylinder. If
entered, it results in the oil leakage. Therefore, avoid the paint entry in the cylinder.

1. Assembly of cylinder head

Apply the hydraulic oil to the inner side of cylinder head
and press-fit the bushing (4).
After press-fitted, confirm that no stepping exists on the
face of bushing.
4

2. Assembly of U-ring block

1) Assemble the backup ring (5), U-ring (6) and pack-
ing head (7) in order. Then, fix them with the snap
ring (8).
a Push in the U-ring and backup ring until their back
sides touch so as not to make scratches.
a As the U-ring has the direction, be careful of its orien-
tation.
4 5 6 7 8

2) Using the jig, assemble the wiper ring (9).

4-57
4. DISASSEMBLY AND ASSEMBLY

3) Assemble the backup ring (14) and O-ring (13).

15
14
15

3. Assembly of piston block seal

1) Install the O-ring in the installation groove with cau-
tion not to twist the O-ring.
2) Install the backup ring in the installation groove with
the knife.
a To make it easier to install the O-ring, warm it up to
80°C [176°F].
a When the backup spring is installed, it is stretched.
Therefore, after installed, correct it with the correction
jig.

Confirm that the correction jig and the tip of

knife are flawless, clean and smooth.

4. Installation of cylinder head

1) Wind the tape around the screwed portion of piston
rod.

2) Insert the cylinder head with caution to prevent the

wiper ring of cylinder head and lip portion of U-ring
from being scratched by the screwed portion of pis-
ton rod.
a Fix the tube with the vice horizontally or vertically.

4-58
 4. DISASSEMBLY AND ASSEMBLY

3) Insert the piston rod in the tube.

When the piston block and cylinder block

are inserted in the tube, insert them with
caution for seals not to be damaged by the
inner screw portion of tube.
Screw portion

4) Tighten the cylinder head with the specific torque.

233 - 374 Nm
{24 - 38 kgm}
[173.6 - 274.9 ft. lb]

5) After installing the cylinder to the lift truck, operate

slowly the cylinder up to the full stroke eight times
so that the oil is fully filled in the cylinder.

Do not operate suddenly.

If the air bleeder is installed, to bleed air, add
the pressure so that the air bleeding side
becomes the pressure side (oil returning
side).
Lubricate the pins at both sides.

4-59
4. DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP
DISASSEMBLY DRAWING

13

4
6
7
8

1
11 5
12

14

10

2
9
8
7

1. Front Cover 8. Gasket

2. Rear Cover 9. Bushing
3. Body 10. Washer
4. Drive Gear 11. Oil Seal
5. Driven Gear 12. Snap Ring
6. Side Plate 13. Key
7. 3-shaped Gasket 14. Hexagon Socket Head Bolt

4-60
 4. DISASSEMBLY AND ASSEMBLY

DISASSEMBLY

Before disassembly, scrub the face of pump and drive shaft and clean them.
Place the disassembled parts on a clean paper or cloth. Be careful not to make scars or
dent by hitting.
Arrange the parts to identify the relationship before disassembled.
Especially, the side plate, 3-shaped gasket and gasket at the front and rear are re-used by
reversing the direction. Therefore, be careful of direction and position.

1. Mark the index marking on the joint at drive side of front

cover (1), body (3) and rear cover (2). Index Marking
3 2
2. Fix the installation part of front cover with the vice, facing 1
the rear cover up.
a When fixing with the vice, to protect the part, use soft
materials such as wooden chip, aluminum and cop-
per for sandwiching.

3. Remove four hexagon socket head bolts, rear cover (2)

and body (3) in order.
4. Remove the side plate (6), 3-shaped gasket (7) and gas-
ket (8).
3

2
8
7
6

5. As the engaging position of the drive gear (4) and driven

gear (5) is already determined, mark the index marking Rotational direction
of gear drive
on the shaft end as shown in the figure.
Marking

Discharge side Suction side

Rotational direction
of gear drive
(In case of counterclockwise rotation)

4-61
4. DISASSEMBLY AND ASSEMBLY

6. Remove the snap ring (12).

Pliers

12

7. Remove the drive gear (4) and driven gear (5) from the
front cover.
4
8. Remove the side plate (6), 3-shaped gasket (7) and gas-
ket (8).

6 5
7
8

9. Remove the oil seal (11) from the front cover.

a Be careful not to make scars on the oil seal. 11

4-62
 4. DISASSEMBLY AND ASSEMBLY

JUDGMENT OF PARTS
Referring to “CHAPTER 5. Maintenance Standard”, judge whether the part is good or not.

ASSEMBLY

Use new parts for seal and gasket.

Scrub each part, blow air on them to dry, then install them.

1. Fix the front cover with the vice, facing the body installa-
tion side up. 7 6
a Apply the soft material such as wooden chip, alumi- 8
num or copper to the vice to protect the front cover.
2. Apply the grease to the gasket (8) and 3-shaped gasket
(7) and install them in the groove without twist and biting.
a Install the 3-shaped gasket with the flat face sitting on Groove 7
Bottom
the groove bottom.

3. Install the side plate (6), facing the LBC face (yellow
face) to the gear side so that the long outlet hole Short outlet hole Long outlet hole
becomes the intake side.

Discharge side Suction side

(Viewed from LBC side)

4. Align the engaging positions and install the drive gear (4)
and driven gear (5). G2-LI

G2-LI

4-63
4. DISASSEMBLY AND ASSEMBLY

5. Fix the cover with four hexagon socket head bolts with
the specific tightening torque. Dust lip
Fill the grease
88 - 93 Nm Main lip
{8.9 - 9.5 kgm}
[64.4 - 68.7 ft. lb]

6. Turn the assembled pump so that the oil seal side faces
upward, and fix the front cover with the vice.
7. Apply the grease (G2-LI) between the main lip and dust
lip of oil seal.

8. Using the oil seal guide and oil seal snap, drive the oil
seal (11) until it touches the bottom of hole.
Oil Seal Snap

Oil Seal Guide

11

9. Fix with the snap ring (12).

10. Rotate the shaft end of drive gear with the tool. If it
rotates lightly by hand, foreign matter and seal are not
Pliers
bitten.
If it rotates heavily, the abnormality such as biting exists
in the assembly.
Therefore, perform the disassembly / assembly again. 12

11. After finishing the assembly, confirm that the assembly

procedure and rotational direction are correct, and install
it to the lift truck.
When installing, pay attention to the following points.
1) The faucet boss block used as a reference for align-
ment should be flawless.
2) Scars and dust should not exist on the flat installa-
tion face of front cover (1).
(Especially, be careful of over-tightening with the
vice.)
3) Scars and dust should not exist on the flange face of
piping.
a If the gouge or scar is found, remove it with the fine
oil grinding stone.

When assembling, the body, gear and bush-

ing should be placed in the same position
and direction as before disassembled.

4-64
 4. DISASSEMBLY AND ASSEMBLY

CONTROL VALVE
Proportional Solenoid Valve Specification

DISASSEMBLY / ASSEMBLY

C
PG 1

T
2
P 5

3 4
A
B

*1

*1. indicates "with port relief valve".

1. Lift Spool 4. Attachment Spool

2. Tilt Spool 5. Attachment Spool
3. Attachment Spool

TORQUE LIST
A: AG port 69 - 88 Nm {7 - 9 kgm} [50.6 - 65.1 ft. lb]

B: A1 port 128 - 158 Nm {13 - 16 kgm} [94.0 - 115.7 ft. lb]

C: CF port 43 - 53 Nm {4.4 - 5.4 kgm} [31.8 - 39.1 ft. lb]

D: A2, B2 port 74 - 90 Nm {7.5 - 9 kgm} [54.2 - 65.1 ft. lb]

E: A3, B3 port 74 - 90 Nm {7.5 - 9 kgm} [54.2 - 65.1 ft. lb]

P: P port 128 - 158 Nm {13 - 16 kgm} [94.0 - 115.7 ft. lb]

PG: PG port 34 - 38 Nm {3.5 - 3.9 kgm} [25.3 - 28.2 ft. lb]

T: T port 170 - 210 Nm {17 - 21 kgm} [123.0 - 151.9 ft. lb]

4-65
4. DISASSEMBLY AND ASSEMBLY

PRECAUTIONS

Scrub each part well and blow air to remove completely the cleaning agent and dust.
Then, apply the hydraulic oil to them, and assemble them.
Do not use a waste to remove the cleaning agent and dust.
Use kerosene or trichlene for cleaning agent. As they are flammable, be careful of fire.
Replace the dust seal, U-packing and O-ring with new ones. Apply the grease to them and
install with caution not to make scratches.

SCRUBBING ASSEMBLY
Using clean mineral oil, scrub all the disassembled 1. When assembling, pay attention to the items
parts. After drying them by blowing the com- below for handling the O-ring.
pressed air, place them on a clean paper or cloth 1) If the O-ring has any defect in manufac-
for inspection. turing or scars caused by poor handling,
do not use it.
INSPECTION
2) Apply the grease or hydraulic oil to the
Inspect that blurs, scratches, scars and other flaws ring and its ornamental portion to lubricate
do not exist on all faces of each part. enough.
1. Confirm that scratches and scars caused by 3) Do not stretch the O-ring to be deformed.
hitting do not exist on the outer circumference 4) When assembling the O-ring, do not twist
of spool. or roll it.
If a scar is tiny, remove it with oilstone or cloth
containing lapping agent. a The twisted O-ring does not recover after
installed and will cause the oil leakage.
2. Confirm that all of sliding parts move lightly
and no foreign matter is present in all of the 2. When handling the spool, pay attention to the
grooves and on the paths. items below.
3. If the spring is broken, deformed or worn out, 1) As over-tightening screws cause the mal-
replace it with a new one. function of spool, be sure to tighten the
screws with specific torque.
4. Confirm that the seal groove of housing is
smooth and no dust, dent or rust is present. 2) The combination of each spool, spring
and spool end should be the same as
5. If a dent or scar is found on the check sheet of before disassembled.
valve housing, remove it by lapping. Be careful
not to leave the lapping agent in the valve. 3. When assembling each section assembly and
valve assembly, pay attention to the items
6. If the relief valve does not work well, disas- below.
semble the relief valve and inspect it.
1) The O-ring on the valve face to be com-
7. Replace the O-ring and backup ring with new bined should be seated in the O-ring
ones. groove.
8. After removing the cap or plug, confirm that no 2) Before assembling, scrubbing oil and
debris of paint is left around the holes on the hydraulic oil should not be left on the loca-
body and plug sitting. tion mentioned below.
a If the debris of paint enters in the valve, bit- (1) Mating face of each section, outer
ing or blinding occurs, resulting in malfunc- face of O-ring groove
tion and oil leakage. (2) On the capping side, outer face of O-
ring groove
9. Confirm that no dust is present on the filter of
solenoid valve. If found, remove it by scrub- a If assembled with oil left on the above loca-
bing. tions, when operated, oil left there is misun-
derstood as an oil leakage.

4-66
 4. DISASSEMBLY AND ASSEMBLY

DRIVE MOTOR
NAME OF EACH BLOCK

1. Frame 6. Temperature Sensor

2. Stator 7. Speed Sensor
3. Rotor 8. Bracket (Opposite the connection side)
4. Bracket (Connection side) 9. Tube
5. Shaft 10. NOMEX Paper

4-67
4. DISASSEMBLY AND ASSEMBLY

PUMP MOTOR
NAME OF EACH BLOCK

1. Frame 6. Temperature Sensor

2. Stator 7. Speed Sensor
3. Rotor 8. Bracket (Opposite the connection side)
4. Bracket (Connection side) 9. Tube
5. Shaft 10. NOMEX Paper

4-68
5. Maintenance
Standard

DRIVE AXLE ...................................................................................................... 5-3

WHEEL CYLINDER BLOCK .............................................................................. 5-4

BRAKE MASTER CYLINDER............................................................................ 5-6

STEERING AXLE (3-WHEEL LIFT TRUCK) ..................................................... 5-8

REAR AXLE ....................................................................................................... 5-9

LIFT CYLINDER............................................................................................... 5-10

TILT CYLINDER............................................................................................... 5-13

CONTROL VALVE ........................................................................................... 5-14

HYDRAULIC PUMP ......................................................................................... 5-16

MAST, FINGER BAR, FORK ........................................................................... 5-20

DRIVE MOTOR................................................................................................ 5-21

PUMP MOTOR ................................................................................................ 5-23

 5. MAINTENANCE STANDARD

DRIVE AXLE

2 ton vehicle

1 ton vehicle

E, F R

J
C, D

H
I

A, B

5-3
5. MAINTENANCE STANDARD

WHEEL CYLINDER BLOCK

K M P N O

5-4
 5. MAINTENANCE STANDARD

Judging Standard
Unit: mm [in]

Criteria
Mark Part Check Item Standard Limit Remedy
Dimension allowed
19.96 - 19.98 19.9
A Piston shaft diameter
[0.786 - 0.787] [0.783]
Inner diameter of piston shaft sliding por- 20 - 20.033 20.1
B
tion of cover [0.787 - 0.789] [0.791]
35 - 35.039 35.1
C Inner diameter of piston sliding portion
[1.378 - 1.379] [1.382]
Brake
Cover & outer diameter of piston sliding 34.950 - 34.975 34.9
D (In the drive ax-
portion [1.376 - 1.377] [1.374]
le)
2.32 - 2.47 2.1
E Thickness of wet type disc Replace the part
[0.091 - 0.097] [0.083]
1.7 - 1.8
F Thickness of plate * –
[0.067 - 0.071]
29.5 - 30.5 28
G Free length of spring
[1.16 - 1.20] [1.10]
0.95 - 1.05 0.85
H Thrust washer (a)
[0.037 - 0.041] [0.033]
2.23 - 2.37 2.13
I Thrust washer (b)
[0.088 - 0.093] [0.084]
Drive Axle
Replace with a
new one at dis-
J O-ring, seal – –
assembly / as-
sembly.
0.050 - 0.151 0.20
K Clearance between cylinder and piston
[0.002 - 0.006] [0.008]
0.016 - 0.086 0.15
L Clearance of holder and piston rod
[0.001 - 0.003] [0.006]
1.7 - 1.8 0.75
M Interference of cup (large diameter)
[0.067 - 0.071] [0.030]
Wheel Cylinder
1.0 - 1.2 0.40
N Interference of cup (small diameter)
[0.039 - 0.047] [0.016]
Replace the part
0.5 - 0.6 0.10
O Interference of dust seal
[0.020 - 0.024] [0.004]
25.0 - 26.6 22.5
P Free length of spring
[0.98 - 1.05] [0.89]
12.060 - 12.168 12.3
Q Inner diameter of bushing
[0.475 - 0.479] [0.484]
Brake Lever
8 - 8.036 7.9
R Pin diameter
[0.315 - 0.316] [0.311]
*: When the wet type disc is worn out, replace the entire system at the same time.

5-5
5. MAINTENANCE STANDARD

BRAKE MASTER CYLINDER

11

9 10
8
2 1

4 12

13
5
17
6 14
7
15

16

Unit: mm [in]

No. Check Item Standard Limit Remedy Code

Clearance between 0.15 Replace 1.2
1 0.020 - 0.105 [0.0008 - 0.0041]
cylinder and piston [0.006] (Cylinder assembly) [0.047]
Primary side: about 1.0 [0.039] 0.4 Replace 2
2 Interference of cup
Secondary side: about 1.2 [0.047] [0.016] (Cylinder assembly) [0.079]
70 2
3 Free length of spring 78.8 [3.10] Replace
[2.76] [0.079]

a In the table above, the code in the rightmost column denotes [Configuration Part].

Part Name Check Item Remedy

Scar, Wear, falling If a serious scar is found, replace it.
Spring If less than the limit, replace it.
Free length
Dimension of limit: 70 mm [2.76 in]
Push-rod Bending, deformation If any bending or deformation is found, replace it.
Crack, damage, split If any of crack, damage or split is found, replace it.
Boot
Interference with cylinder and rod If no interference or a little interference exists, replace it.
Crack If a tiny crack is found, replace it.
Filler union Discoloration If discolored seriously, replace it.
Scar If any scar is found, replace it.
Bushing Crack, degradation If any of crack, split or degradation is found, replace it.

5-6
 5. MAINTENANCE STANDARD

CHECK / ADJUSTMENT
Part Name Check Item Remedy
Scar, eccentric wear or corrosion Remove a tiny scar with the sandpaper.
Cylinder
on the inner face If scars affect the cup, replace the cylinder assembly.
Remove a tiny scar with the oil grinding stone.
Scar, eccentric wear or corrosion
If scars affect the inner side of cylinder and cup, replace the pis-
on the sliding part
Piston ton assembly.
Clearance between cylinder and If exceeds the limit, replace.
piston Dimension of limit: 0.15 mm [0.006 in]
Scar on lip If a tiny scar is found, replace the piston assembly.
Eating of base portion If a hazardous eating is found, replace the piston assembly.
If abnormal fatigue, wear or swelling is found, replace the piston
Wear, swelling
assembly.
Cup
If less than the limit, replace piston assembly.
Dimension of limit: 0.4 mm [0.016 in]
Interference
a The cup is the periodical replacement part. It is safer to
replace the cup at every disassembly.
Deformation, scar and wear on
If abnormal deformation, scar or wear is found, replace the pis-
Piston Assembly valve rod, valve cup, spring and
ton assembly.
thimble

1. Base Block
2. Lip Block
3. Base Block
4. Lip Block

5-7
5. MAINTENANCE STANDARD

STEERING AXLE (3-WHEEL LIFT TRUCK)

A B

Judging Standard
Unit: mm [in]

Criteria
Mark Check Item Remedy
Standard Dimension Limit allowed
A Diameter of cylinder rod 48 [1.89] 47.8 [1.88]
B Inner diameter of cylinder housing 48 [1.89] 48.2 [1.90]
Replace
C Press-fitted bearing of shaft 37 [1.46] 36.8 [1.45]
D Press-fitted shaft of axle Rotation, looseness, play

5-8
 5. MAINTENANCE STANDARD

REAR AXLE

D, E

Judging Standard
Unit: mm [in]

Criteria
Mark Check Item Remedy
Standard Dimension Limit allowed
A Diameter of king pin 28 [1.10] 27.8 [1.09] Replace
Shim ad-
B Rattle of knuckle at the top and bottom – 0.2 [0.008]
justment
C Thickness of tie-rod (cylinder side) 2 [0.079] –
D Diameter of tie-rod hole 18 [0.71] 17.8 [0.70]
E Outer diameter of cylinder pin 18 [0.71] 17.8 [0.70]
Replace
– Mounting rubber of center pin Crack, fatigue
Crack, damage, peeling, burn, rotation defect, for-
– Rear axle, hub, knuckle, bearing
eign noise

5-9
5. MAINTENANCE STANDARD

LIFT CYLINDER

Judging Standard
Unit: mm [in]

Criteria
Mark Check Item Standard Remedy
Limit allowed
Dimension
0.06 - 0.235 0.4
1.0 - 1.75 ton
Clearance between piston rod [0.002 - 0.009] [0.016]
A Replace the bushing
and bushing 0.04 - 0.023 0.35
2.0 ton
[0.002 - 0.001] [0.014]
0.05 - 0.30 0.5
1.0 - 1.75 ton
Clearance between piston [0.002 - 0.012] [0.020] Replace the piston
B
ring and cylinder 0.05 - 0.035 0.5 ring
2.0 ton
[0.002 - 0.001] [0.020]

5-10
 5. MAINTENANCE STANDARD

DIAGNOSIS
Item Symptom Part Related Trouble Item Countermeasure / Remedy
1. Remove scars and make the sliding surface
smooth with the oil grinding stone (less than 0.4a).
When the rod surface is made smooth, if the oil
Scars detected by nail-
leakage continues, the seal may be damaged by
scratching and rust ex-
the scar. So, disassemble and check it.
ist on the sliding sur-
2. If scars cannot be repaired with the oil grinding
Piston rod face.
stone and rust exists, replace the piston rod, U-ring,
seal of wiper ring (seal) and bearing material of pis-
ton rod.
1. Plate it again or replace the piston rod.
Peeled plating 2. At this moment, check the seal and pivot material of
piston rod. If any damage is found, replace it.
Oil leakage from
sliding part of pis- Biting of foreign matter 1. Remove foreign matters.
ton rod in the inner / outer 2. If the packing is damaged, replace it.
diameter block
Damage in the inner/
Replace.
outer diameter block

Rod packing The packing material

(U-ring) loses the elasticity and Replace.
becomes corruptive. The lifespan of packing expires. Or the local part may
The lip portion is entire- be exposed to high temperature. So, check it.
ly damaged.
1
1. Replace.
The projection of heel
2. The packing is suspected to be affected by the ab-
part of packing is large.
normally high temperature. Check the piston seal.
The lip bites foreign
Remove foreign matters.
matters.
Wiper ring The lip is damaged.
Other abnormal dam- Replace.
age exists.
Due to too much wear,
the clearance exists
Replace.
between piston rod and
The oil leaks from Bearing ma- bearing.
sliding part of pis- terial
ton rod. Large scars exist on 1. Replace.
the sliding surface. 2. Check the piston rod at the same time.
If the cylinder head with 1. Remove scars and rust with the oil grinding stone.
scars and rust on the 2. If not repairable, replace the cylinder head.
seal installing part is di-
Cylinder
rectly used as the slid-
head
ing part of piston head,
refer to [Bearing mate-
rial] above.

5-11
5. MAINTENANCE STANDARD

Item Symptom Part Related Trouble Item Countermeasure / Remedy

1. Remove foreign matters.
The inner / outer 2. If the O-ring is damaged, replace it.
diameters bite foreign 3. Check the inside of tube. : If any scar or rust is
O-ring matters. found, make the surface smooth with the oil grind-
The O-ring is dam- ing stone.
aged. 4. Check the O-ring groove of cylinder head. : Confirm
the above items and replace the O-ring.
The oil leaks from
2 the mating part of 1. Disassemble the cylinder head and check the O-
cylinder head. Cylinder ring. If any damage, replace it.
Loosened
head 2. After check, tighten with the specific torque. Refer
to the torque specified in the assembly diagram.
Replace with a new one.
Cylinder The oil leakage from the mating part may result from
Abnormal swelling
tube the abnormal high pressure. Check the swelling of
tube, deformation and circuit pressure.
The bending is large
and exceeds the spe-
Piston rod Replace with a new one.
cific bent distortion.
Cylinder The seal and sliding part material may be damaged.
(Bent distortion: Refer
tube Check them and replace if damaged.
to the item in [Mainte-
nance Standard].
Poor operation.
Cylinder Replace with a new one.
The movement is Dent
tube Check the seal and sliding part material per above.
not smooth.
Abnormal wear of 1. Replace with a new one.
Piston rod
sliding part, foreign Check the seal and sliding part material per above.
Cylinder
matters bitten by 2. Remove foreign matters.
tube
damaged piston block Check the seal and sliding part material per above.
Sliding part
and cylinder head
material
sliding part.
The oil leaks in- Damages such as Replace with a new one.
Piston seal
side. scars and wear exist. Check the inside of cylinder tube.
When the piston
rod operates, it 1. Remove scars and rust by honing or oil grinding
3 expands or stone and make the surface smooth. If not repair-
shrinks before- able, replace the cylinder tube with a new one.
hand and the Cylinder The inner face is 2. Remove the piston seal with a new one.
specific speed tube scarred and rusted.
output cannot be
achieved during
operation.
Bleed the air.
1. Cylinder without bleeder
Shuttle the cylinder several times at the constant
pressure and low speed.
2. Cylinder with bleeder
Loosen the bleeder carefully so that the inner pres-
The operation is The air remains in the
Air sure does not become high.
unstable. cylinder.
Bleed the air well enough.
(Reference)
When the cylinder is suddenly stopped, the cylinder
may expand or shrink. This symptom arises from the
compressibility of hydraulic oil. This symptom is sub-
ject to occurrence to the long stroke cylinder.

Depending on the variation of temperature and pressure, the hydraulic oil expands or
shrinks.
Because of this, as the cylinder expands or shrinks, the symptom is incorrectly judged as
the inside oil leakage.
Check the inside oil leakage under the constant pressure.

5-12
 5. MAINTENANCE STANDARD

TILT CYLINDER
*1
235 - 372 Nm 206 Nm
{24 - 38 kgm} {21 kgm}
[173.6 - 274.9 ft. lb] [151.9 ft. lb]

A B

E D C
F

*1: As it is caulked, do not disassemble it.

Judging Standard
Unit: mm [in]

Criteria
Mark Check Item Remedy
Standard Dimension Limit allowed
0.04 - 0.167 0.3
A Clearance between piston rod and bushing
[0.002 - 0.007] [0.012] Replace the
0.05 - 0.23 0.5 bushing
B Clearance between rod head bushing and pin
[0.002 - 0.009] [0.020]
C Outer diameter of cylinder 73 [2.87]
D Inner diameter of cylinder 60 [2.36]
–
E Diameter of piston rod 25 [0.98]
F Stroke 122 [4.80]
a High lifting height: 3 m [118 in]

5-13
5. MAINTENANCE STANDARD

CONTROL VALVE
Proportional Solenoid Valve Specification

A C

G
C

H
I
C

D F
B

*1

*1. denotes "with the port relief valve".

Judging Standard
Unit: mm [in]

Criteria
Mark Check Item Standard Treatment
Limit allowed
Dimension
A Spool Return Spring 36.3 [1.429] 35.5 [1.398]
B Spool Return Spring (Lift descending) 36.4 [1.433] 35.6 [1.402]
C Load Check Valve Spring 21.0 [0.83] 19.0 [0.75]
D Lift Lock Main Plunger Spring 20.4 [0.80] 19.4 [0.76]
Free length of
E Tilt Lock Main Plunger Spring 21.7 [0.85] 19.7 [0.78]
spring Replace
F Sequence Spring 26.5 [1.04] 24.8 [0.98]
G Flow Regulator Spring (large) 55.2 [2.17] 53.8 [2.12]
H Tilt Lock Pilot Spring 12.9 [0.51] 11.9 [0.47]
I Priority Spring 35.9 [1.41] 35.1 [1.38]
– Spool and Housing No blur and no scar

5-14
 5. MAINTENANCE STANDARD

CHECK
Check scratches, scores and other defects on the entire face of each part.
1. Confirm that scratches and gouges do not exist on the outer circumference of spool.
If a scar is tiny, remove it with a cloth to which the oil stone or lapping agent is applied.
2. The sliding parts should move lightly. And the grooves and paths should be free from foreign matters.
3. If the spring is broken, deformed or worn, replace it.
4. Confirm that the surface of seal groove is sleek and free from dust, dent or rust.
5. If the dent or scar exists on the surface of check sheet of valve housing, remove it by lapping. Be careful
not to leave the lapping agent in the valve.
6. If the relief valve does not function well, check the relief valve.
7. Replace all of the O-rings and back-up rings with new ones.
8. After removing the caps or plugs, confirm that debris of paint is not left around the holes on the body and
sittings of plugs. If debris of paint enters in the valve, it causes biting or blinding, causing the malfunction
and oil leakage.
9. Confirm that no dust exists on the filter of solenoid valve. If any dust captured by the filter exists, scrub the
filter.

5-15
5. MAINTENANCE STANDARD

HYDRAULIC PUMP

13

4
6
7
8

1
11 5
12

14

10

2
9
8
7
6

1. Front Cover 8. Gasket

2. Rear Cover 9. Bushing
3. Body 10. Washer
4. Drive Gear 11. Oil Seal
5. Driven Gear 12. Snap Ring
6. Side Plate 13. Key
7. 3-shaped Gasket 14. Hexagon Socket Head Bolt

5-16
 5. MAINTENANCE STANDARD

DIAGNOSIS
Symptom Cause Remedy
The oil is not The oil level in the tank is low. Re-fill the hydraulic oil to the specific oil level.
discharged
from the gear The pipe at the suction side or the strainer is Clean immediately. If the oil is dirty, replace it with
pump. clogged. new oil or percolate the oil.

The gasket and bushing are excessively worn. Replace with a new one.
Using the pressure gauge, build the pressure to the
The relief valve is poorly adjusted.
specific pressure.
The pressure in
the gear pump • Correct the looseness of pipe at the suction side.
does not build
• Re-fill the oil in the tank.
up.
It is sucking air. • Check the oil seal in the pump.
• Do not operate the lift truck until the bubbles in the
tank disappears.
The hose at the suction side is crushed or the
Remove dust.
strainer is clogged, causing the cavitation.
The coupler at the intake side is loosened and
Tighten each coupler again.
sucking air.
The pump
makes strange Due to high viscosity of oil, the cavitation is • Replace the oil with an appropriate viscosity.
noise. caused. • Operate at the appropriate oil temperature.
The pump and the shaft from engine are not
Re-align.
aligned.
The hydraulic oil bubbles. Examine the cause of bubble and improve.

The oil leaks The oil seal (11) of pump is defective. Replace with a new one.
from the pump. Dust is stuck to the seal. Check the pump again.

5-17
5. MAINTENANCE STANDARD

CHECK / REPAIR

Confirm the extent of dirtiness and discoloration of disassembled parts and scrub them in
the kerosene. But never dip the rubber parts in the kerosene.

Check each part at the points below. If any abnormality is found, repair or replace.

1. Body (3)
To enhance the volume efficiency, the gear pump is
designed to rotate while the teeth tip of gear is contact-
ing the inner wall of gear hole. Accordingly, a vestige A
of contact made by the teeth tip can be observed on the
area near the suction port of pump once operated.
The vestige B of contact should be normally less than 1/
2 of inner circumference of gear. The depth "a" of con-
tact vestige B should be normally 0.05 mm [0.002 in].
If the dimension "a" is greater than 0.15 mm [0.006 in] (a
X 0.15 mm [0.006 in]), replace the pump assembly with a
new one.

2. Drive Gear (4), Driven Gear (5)

If the hydraulic oil is clean, the shaft and side face of
gear touch smoothly. If the shaft and side face are
coarse to such an extent that the surface is scratched by
nail or teeth surfaces are eccentric-worn, replace with
new ones.
If the diameter of shaft b is smaller than 18.935 mm
[0.7455 in] (b < 18.935 mm [0.7455 in]), replace with a
new gear set.

3. Bushing
If the inner diameter sliding surface of bushing is not
coarse and the half of surface at suction side is shining,
it is ideal. If the contact D of the side is strong at the suc-
tion side (near black color) and very weak at the high
pressure side, it is normal.
In cases below, replace.
1) The contact is entirely on the inner diameter sliding
surface of bushing and the surface is coarse to such
an extent that it is scratched by nail.
2) The side of bushing has many scratches in the cir-
cumference direction and the surface is coarse to
such an extent that it is scratched by nail.
3) The vestige of biting foreign matter is on the inner
diameter sliding surface and side of bushing.
The dimension of limit of bushing used is as follows.
If the dimensions "c" and "d" become as shown below, replace both of bushing assembly and gear sup-
plied as a kit.
Inner diameter of bushing:19.123 mm [0.7529 in] < c
Length of bushing: 26.411 mm [1.0398 in] > d

5-18
 5. MAINTENANCE STANDARD

4. Gasket, Oil Seal, Snap Ring

When disassembled, be sure to replace with new ones.

5. Side Plate
If the contact (D) of sliding surface (copper alloy side) of
D
side plate is strong at the suction side (A) and is very
weak at the high pressure side, it is normal.
• If many scratches detected by nail-scratching in the A
circumference direction are found, replace it.
• If the thickness of side plate is greater than 1.95 mm
[0.077 in] (≤ 1.95 mm [0.077 in]), replace it.

The gasket, oil seal and snap ring should be

replaced with new ones when disassembled.

5-19
5. MAINTENANCE STANDARD

MAST, FINGER BAR, FORK

1.5 - 1.75 ton lift truck Unit: mm [in]

Criteria
Check Item Standard Remedy
Limit allowed
Dimension
Right & left 0.1 - 0.3 [0.004 - 0.012] Within 2.0 [0.079] Shim adjustment
Roller clearance between outer
mast and inner mast Replace with over-size
Rear & front 0.5 - 1.0 [0.020 - 0.039] Within 2.0 [0.079]
roller
Right & left 0.5 - 2.0 [0.020 - 0.079] Within 2.5 [0.098] Shim adjustment
Roller clearance between inner
mast and finger bar Replace with over-size
Rear & front 0.5 - 1.0 [0.020 - 0.039] Within 2.0 [0.079]
roller
Bush oil groove at mast support block Oil groove exists. Is oil groove present? Replace bushing
Thickness of fork A (At root por- 1.5 ton 35 [1.38] More than 30 [1.18]
Replace
tion) 1.75 ton 35 [1.38] More than 33 [1.30]

2.0 ton lift truck Unit: mm [in]

Criteria
Check Item Standard Remedy
Limit allowed
Dimension
Right & left 0.5 - 1.0 [0.020 - 0.039] Within 2.5 [0.098] Shim adjustment
Roller clearance between outer
mast and inner mast Replace with over-
Rear & front 0.2 - 0.7 [0.008 - 0.028] Within 2.0 [0.079]
size roller
Right & left 0.5 - 1.0 [0.020 - 0.039] Within 2.5 [0.098] Shim adjustment
Roller clearance between inner
mast and finger bar Replace with over-
Rear & front 0.2 - 0.7 [0.008 - 0.028] Within 2.0 [0.079]
size roller
Bush oil groove at mast support block Oil groove exists. Is oil groove present? Replace bushing
Thickness of fork A (At root portion) 36 [1.42] More than 32.5 [1.28] Replace

5-20
 5. MAINTENANCE STANDARD

DRIVE MOTOR
NAME OF EACH BLOCK

1. Frame 6. Temperature Sensor

2. Stator 7. Speed Sensor
3. Rotor 8. Bracket (Opposite the connection side)
4. Bracket (Connection side) 9. Tube
5. Shaft 10. NOMEX Paper

5-21
5. MAINTENANCE STANDARD

MAINTENANCE
1. Routine Maintenance at operation
Check Item Check Location Criteria Remedy
No change comparing with normal operation. If dust is heavily accumulated,
Environment

Dust Motor frame

Normal temperature rise. Visual check. stop and clean it.

Foreign matters, No change comparing with normal operation.

Motor frame Recover to the normal state.
spray, liquid Visual check.

No vibration different from normal one or no If values exceed the level al-
Motor frame
Vibration increase of amplitude. lowed, stop and eliminate the
Bearing, cover
Visual check. Hearing check. cause.
No sound different from normal or no increase
Motor frame If the operation is affected,
Foreign Noise of noise level. Compare with new one by using
Bearing, cover stop and eliminate cause.
a hearing stick. Hearing check.

2. Routine Maintenance at stop

Check Item Check Location Criteria Remedy
Tightening por- Looseness, sticking of dust and rust should
Tightening screws Tighten. Clean. Paint.
tion not exist. Visual check. Hitting sound check.
Connection should be correct.
Tighten.
Connection block Connected parts should not be loose.
Check the insulation.
Terminal They should be insulated. Visual check.
Connection block of ter- No damage on sheath (cladding).
Repair at the special factory.
minal and harness Visual check.
Iron core Dust sticking. Visual check. Clean.
Stator and rotor Clean.
assembly Coil and insulation of con- Insulating resistance is more than 1 MΩ.
Dry by heating.
nected part (Measure at 500 V mega.)
Vanish work.
Speed sensor Confirmation of gap No sticking of foreign matters Remove foreign matters.
Reference value:
Temperature
Measure the resistance. At 20°C [68°F]: 11.7 - 14.3 kΩ
sensor
At 25°C [77°F]: 9.7 - 11.8 kΩ
No dust, discolor, peeling and rust. Rust prevention.
Paint Damage
Visual check. Re-paint.
Clean.
No dirt, sticking of dust and rust.
Cleaning Dirt, dust accumulation Rust prevention.
Visual check.
Re-paint.

5-22
 5. MAINTENANCE STANDARD

PUMP MOTOR
NAME OF EACH BLOCK

1. Frame 6. Temperature Sensor

2. Stator 7. Speed Sensor
3. Rotor 8. Bracket (Opposite the connection side)
4. Bracket (Connection side) 9. Tube
5. Shaft 10. NOMEX Paper

5-23
5. MAINTENANCE STANDARD

MAINTENANCE
1. Routine Maintenance at operation
Check Item Check Location Criteria Remedy
If dust is heavily accu-
No change comparing with normal operation. Normal
Environment

Dust Motor frame mulated, stop and clean

temperature rise. Visual check.
it.
Foreign mat-
No change comparing with normal operation. Recover to the normal
ters, spray, Motor frame
Visual check. state.
liquid
If values exceed the
Motor frame No vibration different from normal one or no increase
Vibration level allowed, stop and
Bearing, cover of amplitude. Visual check. Hearing check.
eliminate the cause.
No sound different from normal one or no increase of If the operation is affect-
Motor frame
Foreign Noise noise level. Compare with new one by using a hearing ed, stop and eliminate
Bearing, cover
stick. Hearing check. cause.

2. Routine Maintenance at stop

Check Item Check Location Criteria Remedy
Tightening Looseness, sticking of dust and rust should not exist.
Tightening portion Tighten. Clean. Paint.
screws Visual check. Hitting sound check.
Connection should be correct.
Connection Tighten. Check the insu-
Connected parts should not be loose.
block lation.
They should be insulated. Visual check.
Terminal
Connection
No damage on sheath (cladding). Repair at the special
block of terminal
Visual check. factory.
and harness
Iron core Dust sticking. Visual check. Clean.
Stator and rotor as- Coil and insula- Clean.
sembly Insulating resistance is more than 1 MΩ.
tion of connected Dry by heating.
(Measure at 500 V mega.)
part Vanish work.
Confirmation of Remove foreign mat-
Speed sensor No sticking of foreign matters
gap ters.
Reference value:
Measure the re-
Temperature sensor At 20°C [68°F]: 11.7 - 14.3 kΩ
sistance.
At 25°C [77°F]: 9.7 - 11.8 kΩ
No dust, discolor, peeling and rust. Rust prevention.
Paint Damage
Visual check. Re-paint.
Clean.
Dirt, dust accu- No dirt, sticking of dust and rust.
Cleaning Rust prevention.
mulation Visual check.
Re-paint.

5-24
6. Structure and
Function

BRAKE ............................................................................................................... 6-3

HYDRAULIC CIRCUIT DIAGRAM ..................................................................... 6-6

CONTROL VALVE ............................................................................................. 6-7

6-1
 6. STRUCTURE AND FUNCTION

BRAKE
PIPING

Fill in the brake fluid FB1.

Amount of oil 0.4L

9.8 - 12.7 Nm
{1.0 - 1.3 kgm}
[7.2 - 9.4 ft. lb]
7.8 - 9.8 Nm
{0.8 - 1.0 kgm}
[5.8 - 7.2 ft. lb]

PARKING LEVER

When released

When locked

6-3
6. STRUCTURE AND FUNCTION

OVERVIEW OF FUNCTION
This brake equipment converts the fluid pressure generated by the operation of master cylinder in to a push-
ing force for braking. Besides, the function, which generates the pushing force mechanically by operating the
parking lever, is built in the brake equipment.

Operation of Fluid Pressure

When the brake is open

Wet Type Multi-disc Brake

Brake Pedal
Disc

Brake Piston

Master Cylinder Case

Brake Pipe

Wheel Cylinder

Cylinder Piston

When the brake is applied

Leg-power

1. When stepping on the brake pedal, the brake fluid is

transferred from the master cylinder to the power cylin-
der.
2. The fluid pressure is generated in the brake fluid that is
transferred from the master cylinder. Then, the cylinder
piston, that receives the fluid pressure, pushes the brake
piston.
3. The brake piston pushed by the cylinder piston pushes
the multi-disc, causing the friction of multi-disc simulta-
neously.
Eventually the braking effort is generated.

6-4
 6. STRUCTURE AND FUNCTION

Operation of Parking Brake

When the hand brake is open

Wet Type Multi-disc Brake

Cable
Disc

Hand Brake
Brake Piston
Lever

Brake Pedal Case

Master Cylinder Cylinder Piston

Brake Pipe
Wheel Cylinder

When the hand brake is applied

Cable

Hand Brake

1. When applying the parking brake, the cylinder piston

relayed by the lever pushes the brake piston.
2. The brake piston pushed by the cylinder piston pushes
the multi-disc, causing the friction simultaneously.
Eventually, the braking effort is generated.

6-5
6. STRUCTURE AND FUNCTION

HYDRAULIC CIRCUIT DIAGRAM

for 3W
D50XL104.4 CONTROL VALVE

R L SV
0.5 MPa

A3
B3
for 4W
D65Xd40XL136 TILT CYLINDER
LC
L R sal, a3 sal, b3
A2
TLM
TLP
B2
ORBITROL D60Xd25XL121
L R (STEERING VALVE)
60cc/rev for 4W LC
40cc/rev for 3W AG PRESSURE
sal, a2 sal, b2
SENSOR
A1
LLM
LLP LIFT
CYLINDER

LC
sal, a1 sal, b1

12.3 Mpa (1.0 t ~ 1.8 t)

CF DOWN D45Xd35XL1500
SAFETY (2.0 t)
LS T P VALVE D50Xd40XL1505
LS

PV
17.7 MPa RV
MR 1.4 MPa
T P PG

RETURN PIPING
M 18.0 cc/rev FV4.0 ~ /VT6.5 ~

6-6
 6. STRUCTURE AND FUNCTION

CONTROL VALVE
OVERVIEW
This valve is the bank type multiple control valves developed for forklift, and is the control valve that controls
the operational direction and speed of each actuator by feeding the electricity.

1. Display of Model
KMC10L–3001A
Remodeling symbol
Rotation No.
Number of spools (Example: 3)
Proportional solenoid multi-control valve for lift trucks

2. Specification
Maximum Operating Pressure 24.5 MPa {250 kgf/cm2} [3550 PSI]
Maximum Flow 70 l/min
Allowable Backing Pressure 0.98 MPa {10 kgf/cm2} [142 PSI]
General
Operating Hydraulic Oil Mineral Hydraulic oil, equivalent to ISOVG32
Specification
Degree of Allowable Contamination of Hydraulic Oil Less than NAS10
Range of Operating Temperature -20 to + 90°C [-4°F to 194°F]
Range of Operating Viscosity 5 to 500 mm2/s (cSt)
Rating Current 0.7 A
Electrical Spec-
Recommended Dither 100 Hz, 180 to 200 mApp
ification
Coil Resistance 17.5 ± 0.5Ω (At 20°C [68°F])

3. Hydraulic Circuit (KMC10L-3065)

LIFT TILT ATT1

A1 AG B2 A2 B3 A3

LLP TLP
RV sol. b1 sol. b2 sol. b3
PG

LC LC LC SV
PV
P
LLM TLM
MR

sol. a1 sol. a2 sol. a3

LS CF

6-7
6. STRUCTURE AND FUNCTION

4. Configuration and Function

Mark Name Function
(1) Main relief valve Controls the maximum operating pressure in the circuit.
(2) Main control Valve Holds the direction to each actuator port, flow control and neutrality.
(3) Load check valve Prevents the back flow from the load port.
(4) Lift lock valve Prevents the leakage when holding the lift in neutral.
(5) Tilt lock valve Prevents the leakage when holding the tilt in neutral.
Proportional Solenoid Generates the secondary pilot pressure proportional to the electric input and con-
(6)
pressure reducing valve trols the amount of stroke of main control valve spool.
Keeps the primary pressure of proportional solenoid pressure reducing valve (6)
(7) Pressure reducing valve
the constant pressure (1.8 MPa).
Secures the primary pressure of pressure reducing valve (7) in the unloading
(8) Sequence valve
state.
(9) Priority valve Gives the CF port of high priority of supplying oil.
(10) Port relief valve Regulates the maximum operating pressure of installed port.

5. Explanation of Operation
The oil discharged from the oil pump is divided at the end section (1) into the bypass path and the parallel
path. The bypass path is connected to the tank via the sequence valve of end section (2). The parallel path
passes each valve section and is blocked by the end section (2).

In neutral
The pilot pressure (pressure in the spring chamber) in neutral is the tank pressure at both (a) side and (b)
side. The main spool is hold in the neutral position by returning spring force. As the bleed-off control block is
open and the meter-in control and meter-out control blocks are closed, all of the oil discharged from pump is
returned to the tank after passing the bypass path. At this moment, unload pressure (2.2 MPa) is secured by
the sequence valve.

Bypass Path

P port
Sequence Valve

End Section (1) Parallel Path End Section (2)

6-8
 6. STRUCTURE AND FUNCTION

When the lift ascends

When current flows in the a1 solenoid, the pilot pressure proportional to the current is generated by the pro-
portional pressure reducing valve. Due to this pilot pressure, the main spool starts to stroke to the B side
against the returning spring force.
When the main spool is stroked, the bypass path is blocked and the pressure in the parallel path increases.
Eventually when the parallel port and the A1 port are linked together by the meter-in control block, the oil from
the parallel path pushes the main plunger and the oil is discharged from A1 port. At this moment, the amount
of oil flow is controlled in proportional to the input current by the bleed-off control block and meter-in control
block. If the pump pressure (the pressure in the parallel path) is lower than the load pressure, the back flow is
prevented by the load check valve.

When the lift descends

When current flows in the b1 solenoid, the pilot pressure proportional to the current is generated by the pro-
portional pressure reducing valve and the lift lock valve pilot spool starts to stroke. Then, the notch of lock
valve pilot spool opens and the lock valve main plunger is pushed up.
At he same time when the lock valve pilot spool starts to stroke, the main spool also starts to stroke to the A
side.
When the main spool is stroked and the A1 port and path to the tank are linked by the meter-out control block,
the oil flows. At this moment, the amount of flow is controlled in proportional to the input current by the meter-
out control block. The link to the meter-out control block is designed to be done after the lock valve main
plunger opens. The maximum flow amount flowed in the tank from the A1 port is kept constant by the flow reg-
ulation valve built in the main spool.
The flow regulation valve consists of the compensator spool and spring. The oil discharged from the A1 port
flows in the main spool once and then in the tank after passing the meter-out control block. However, when
the flow passing the throttle exceeds a certain amount of oil, the compensator spool regulates the flow by
throttling the flow control block.

Flow Control Valve Bypass Path Lift Lock Valve Pilot

Lift Lock Valve
Main Plunger

a1 Solenoid b1 Solenoid
Meter-out Bleed-off
Control Block Load Check Parallel Path Meter-in Control Block
Control Block Valve
1st Link (Lift Section)
Flow

Compensator Spool Spring

Flow Control Block Throttle Block
Detail of Flow Control Valve

6-9
6. STRUCTURE AND FUNCTION

When backward-tilting
When current flows in the a2 solenoid, the pilot pressure proportional to the current is generated by the pro-
portional pressure reducing valve and the main spool starts to stroke to the B side against the returning spring
force.
When the main spool is stroked, the bypass path is blocked, the pressure in the parallel path increases. And
the parallel port and A2 port are linked by the meter-in control block, and the B2 port and tank path are linked
by the meter-out control block. Due to these, the oil from the parallel port pushes up the lock valve main
plunger and is discharged from the A2 port.
The oil returned from the cylinder passes from the B2 port to the meter-out control block, and is discharged to
the tank path. At this moment, the amount of flow is controlled in proportion to the input current by the bleed-
off control block, meter-in control block and meter-out control block. If the pump pressure (the pressure in the
parallel path) is lower than the load pressure, the back flow is prevented by the load check valve.

When forward-tilting
When current flows in the b2 solenoid, the pilot pressure proportional to the current is generated by the pro-
portional pressure reducing valve and tilt lock valve pilot spool starts to stroke. Then, the notch of lock valve
pilot spool opens and the lock valve main plunger is pushed up.
At he same time when the lock valve pilot spool starts to stroke, the main spool also starts to stroke to the A
side.
At the same time when the lock valve pilot spool starts to stroke, the main spool also starts to stroke to the A1
port. When the main spool is stroked, the bypass path is blocked and the pressure in the parallel path
increases.
The parallel port and B2 port are linked by the meter-in control block, and the A2 port and tank path are linked
by the meter-out control block. Due to these, the oil from the parallel port pushes up the lock valve main
plunger and is discharged from the B2 port.
The oil returned from the cylinder passes from the A2 port to the meter-out control block, and is discharged to
the tank path. At this moment, the amount of flow is controlled in proportion to the input current by the bleed-
off control block, meter-in control block and meter-out control block.
The links of the meter-in control block and meter-out control block are designed to be done after the lock valve
main plunger opens.

Bypass Path

Tilt Lock
Tilt Lock Valve Valve Pilot
Main Plunger

a2 Solenoid b2 Solenoid
Meter-out Control Block (b) Bleed-off Load Check Valve Parallel Path Meter-out Control Block (a)
Control Block
Meter-in Control Block (a) Meter-in Control Block (b)

2nd Link (Tilt Section)

6-10
 6. STRUCTURE AND FUNCTION

When the attachment operates

When current flows in the a side solenoid, the pilot pressure proportional to the current is generated by the
proportional pressure reducing valve. Due to this pilot pressure, the main spool starts to stroke to the B side
against the returning spring force.
When the main spool is stroked, the bypass path is blocked and the pressure in the parallel path increases.
The parallel port and load port at the A side are linked by the meter-in control block, and the load port at the B
side and tank path are linked by the meter-out control block. Due to these, the oil from the parallel port is dis-
charged from the load port at the A side.
The oil returned from the cylinder passes from the load port at the B side to the meter-out control block, and is
discharged to the tank path. At this moment, the amount of flow is controlled in proportion to the input current
by the bleed-off control block, meter-in control block and meter-out control block.

Bypass Path

a-side Solenoid b-side Solenoid

Meter-out Control Bleed-off Control Load Check Parallel Path Meter-out Control Block (a)
Block (b) Block Valve
Meter-in Control Block (a) Meter-in Control Block (b)
3rd to 5th (Attach Section)

6-11
6. STRUCTURE AND FUNCTION

Operation of Lift Lock Valve

When in neutral
When in neutral, the pressure at (1) and (2) becomes identical (holding pressure) by the oil flowing
through the throttle hole of lock valve plunger, the lock valve plunger is pushed to the sheet by the load
pressure PL worked on D12.

(1) PL

Throttle Hole

(2)

When descending
Due to the 2nd pressure increase of proportional pressure reducing valve, the lock valve pilot spool
strokes, and (2) and tank path (3) are linked. Therefore, the load pressure PL, which is worked by the dif-
ferential-area of D12 and D11, pushes up the lock valve plunger. At this moment, through the throttle
hole of lock valve plunger, the oil flows in (3) at the constant flow.

PL (3)

Throttle Hole

(2)

When ascending
When the pump pressure increases and PP (= P13) exceeds the load pressure PL, the lock valve plunger
opens.

PL

P13

6-12
 6. STRUCTURE AND FUNCTION

In case of emergency
In emergency, tighten the screw at the part (4) so that the lock valve pilot spool can be stroked. At this
moment, as the main spool is not stroked, the oil through the throttle hole flows at the constant flow.

PL (4)

Throttle Hole

Operation of Tilt Lock Valve

When in neutral
When in neutral, the pressure at (1) and (2) becomes identical (holding pressure) by the oil flowing
through the throttle hole of lock valve plunger, the lock valve plunger is pushed to the sheet by the load
pressure PT1 worked on D22.

(2) (1) PT1

When forward-tilting
Due to the 2nd pressure increase of proportional pressure reducing valve, the lock valve pilot spool
strokes, and (2) and tank path (3) are linked, being blocked by the (1). Therefore, the load pressure PL,
which is worked by the differential-area of D22 and D21, pushes up the lock valve plunger.

(2) (1) PT1 (3)

6-13
6. STRUCTURE AND FUNCTION

When backward-tilting
When the pump pressure increases and PP (= P23) exceeds the load pressure PT1, the lock valve plunger
opens.

PT1

P23

6-14
 6. STRUCTURE AND FUNCTION

Operations of pressure reducing valve, priority valve and sequence valve

Operation of pressure reducing valve block
The chamber (1) is the pressure reducing valve primary pressure (pump pressure). The chamber (2) is
the pressure reducing valve secondary pressure. The chamber (3) is the drain pressure.
The pressure reducing valve secondary pressure passes through the path (4) and is guided to the cham-
ber (5). The pressure reducing spool reduces the primary pressure (pump pressure) so that the pressure
of chamber (5), which is acting to the cross-sectional area of spool, balances with the spring force of
pressure reducing valve spring. Namely, the pressure reducing valve of chamber (2) acts to keep con-
stant the pressure (1.8 MPa) determined by the spring force.
Operation of Priority Valve Block
The chamber (6), chamber (7) and chamber (8) are linked to the P port, CF port and LS port respectively.
They operate as follows and give the priority to supplying the oil to the steering circuit.
The CF port pressure of chamber (7) passes through the path (10) and is guided to the chamber (11).
The priority valve acts to supply the oil flow (P port o CF port flow) of steering circuit so that the CF port
pressure of chamber (11) balances with the LS port pressure of chamber (8) and priority valve spring
force (It differs in stroke. 02 - 0.6 MPa equivalent).
When the steering circuit pressure (CF port pressure) is lower than the cargo system circuit pressure
(bypass path pressure), the priority spool throttles the path from chamber (6) to chamber (9) so that the
CF port pressure is reduced to the level required.

(5) (10) (11) (7)

(1)

(6)

(4)

(9)
(2)

(3)
(8)

End Section (1)

6-15
6. STRUCTURE AND FUNCTION

Operation of Sequence Valve Block

The chamber (12) and chamber (13) are linked to the bypass path and tank path respectively. When the
main control valve is unload or operating to lower the lift, they work as follows and keep the primary pres-
sure of pressure reducing valve.
The pressure of chamber (12) is guided to the chamber (15) by the path (14). The pressure reducing
valve secondary pressure is guided to the spring chamber (16) of sequence valve. Therefore, when the
oil flows P port o bypass path o chamber (12) o chamber (13) (T port), even if the main control valve is
in the unload state, the pressure of chamber (12) always becomes as follows.
Pressure Reducing Valve Secondary Pressure (1.8 MPa [261 PSI])
+ Sequence Valve Spring Force (Equivalent to 0.4 MPa [58.2 PSI])
= 2.2 MPa [318 PSI]

(14)
(17)

(15)

(16)

(12)

(13)

End Section (2)

6-16
 6. STRUCTURE AND FUNCTION

Operation of proportional solenoid pressure reducing valve

The chamber (1), chamber (2) and chamber (3) are the pressure reducing valve primary pressure (P1:
1.5 MPa [217 PSI]), the pressure reducing valve secondary pressure (P2) and the drain pressure respec-
tively.
When no current is running in the proportional solenoid, the pressure reducing valve spool contacts the
end face of proportional solenoid by the spring force fs.
In this state, the chamber (1) and chamber (2) are shut off by the land 1 of pressure reducing valve, and
the chamber (2) is the drain pressure as the chamber (2) and chamber (3) are linked.
When the suction force becomes greater than the spring force fs (Fi > fS) by flowing current in the propor-
tional solenoid, the pressure reducing valve spool strokes, the chamber (1) and chamber (2) are linked by
the notch (1), and the paths of chamber (2) and chamber (3) are throttled by the land 2 and notch 2. Thus,
the pressure of chamber (2) (secondary pressure) increases.
At this moment, as the diameter D1 of land 1 is greater than the diameter D2 of land 2, the oil pressure
force FH, which is against the solenoid suction force Fi, acts to the pressure reducing valve spool.
According to the stroke of pressure reducing valve spool, FH increases. And when FH + fS = Fi is
achieved, the spool stops and becomes balanced. In this way, the secondary pressure P2 becomes the
pressure proportional to the solenoid suction force Fi.

Chamber (1) Proportional Solenoid

Chamber (2)
Spring fS
Notch 1

Chamber (3) P1
P2
FH
Notch 2 Pressure Reducing Suction Force Fi
Spool

6-17
NOTES
7. Troubleshooting

DIAGNOSIS TOOL ............................................................................................ 7-3

CONFIGURATION PARTS, SENSOR, UNIT LOCATION DRAWING............... 7-4

LOCATION DRAWING ...................................................................................... 7-5

LOCATION OF CPU BOARD CONNECTOR .................................................... 7-7

OVERVIEW OF TROUBLE CODES .................................................................. 7-8

PREPARATION FOR VOLTAGE CHECK AND CURRENT CHECK ................ 7-9

INPUT / OUTPUT SIGNAL OF CONTROLLER............................................... 7-11

TROUBLE CODE LIST .................................................................................... 7-19

DIAGNOSTIC PROCEDURE BY TROUBLE CODE (ALA CODE) .................. 7-23

DIAGNOSIS PROCEDURE BY TROUBLE CODE (ERR CODE).................... 7-27

DIAGNOSTIC PROCEDURE BY METER DISPLAY TROUBLE CODE.......... 7-85

TROUBLE WITHOUT ERROR CODES......................................................... 7-111

PROPORTIONAL SOLENOID VALVE CONTROLLER................................. 7-119

ADJUSTMENT PROCEDURE OF TILT AUTOMATIC HORIZONTAL .......... 7-124

METER PANEL.............................................................................................. 7-125

7-1
 7. TROUBLESHOOTING

DIAGNOSIS TOOL
a Prepare the tools needed for abnormal diagnosis.

Service Tool • When reading out the trouble

code, connect it to the data link (3)
(1) Service Tool Software connector.
3BA-97-71260 • Parameter Setting Personal Computer
Windows2000, XP
(2) CAN Communication Con- • IO Monitor Display (Prepared by distributor)
verter (1.5 m [59.1 in]) • Error History
3BA-97-71220 • Error Content and its Remedy
(3) Body Connection Cable
(2 m [78.7 in])
3BA-97-71230 (1)
CD (2)

Analog Tester Check the breaking of wire and mea-

sure the resistance of equipment.
Judge whether the measured item is
good or not.

Wire Lead When measuring the resistance of

wire, insert the wire lead in the con-
nector.

Connector Jumper Unit Used when measuring the voltage at

3BA-97-99750 the terminal of control unit.

7-3
7. TROUBLESHOOTING

CONFIGURATION PARTS, SENSOR, UNIT LOCATION DRAWING

1. Meter Panel 5. Cargo Handling Controller

2. Proportional Solenoid Valve Controller 6. Connector for service tool
3. Travel (L) Controller 7. Tilt Horizontal Offset Switch
4. Travel (R) Controller 8. Fuse Holder

7-4
 7. TROUBLESHOOTING

LOCATION DRAWING

Tilt Horizontal Switch

Lift Lever Sensor
Tilt Lever Sensor
ATT1 Sensor
Tilt Potentiometer ATT2 Sensor

Lift Pressure Sensor

Steering Wheel Angle Potentiometer

Seat Switch

FR Switch

Accelerator Switch

Pump Motor Temperature Sensor

Pump Motor Speed Sensor B3Z16214

7-5
7. TROUBLESHOOTING

7-6
 7. TROUBLESHOOTING

LOCATION OF CPU BOARD CONNECTOR

The CPU board controls the controller and drives the gate. Check visually for harmful
scars or damages, serious discoloration or corrosion on the connector block.

Pay attention to the items below when checking.

• To prevent damage to the printed circuit board from static electricity, do not touch the board components.
• Hold the edge of the printed circuit board when handling.
• When carrying or storing the printed circuit board, be sure to pack it in the electrostatic prevention bag.

1. Location of connectors on the CPU board

• CN1: Harness connector at the vehicle side CNG1 CNG2 DSW2 DSW1 CNF
• CN2: Harness connector at the vehicle side
• CN3: Harness connector at the vehicle side CN3
• CNG1: Power module gate connector
(Connect with the FET module) CN2
• CNG2: Power module gate connector
(Connect with the FET module) CN1
• CNF: Connector for software download
(Normally not used)

2. DSW Setting
ON KSD04
The DSW1 is the switch for selecting the travel R, travel L All of bits are
and cargo handling. (The DSW2 is not used.) set to OFF.
1 2 3 4
a The switch-over of travel R and travel L can be set.
The switch-over of cargo handling and travel (R, L) can- DSW1

not be set. Setting of travel R inverter unit

ON KSD04

Bit No.1 only is

set to ON.
1 2 3 4

DSW1
Setting of travel L inverter unit

ON KSD04

Bit No.2 only is

set to ON.
1 2 3 4

DSW1
Setting of cargo handling inverter unit

3. Pin number of connector

CNG1: 6P connector CNG1 CNG2
CNG2: 11P connector

Viewed from engagement side of connector

7-7
7. TROUBLESHOOTING

OVERVIEW OF TROUBLE CODES

TROUBLE DETECTION
When an abnormality occurs on the vehicle, the trouble is
indicated by the lighting of either of two lamps:
• travel system error indicator (tire icon)
• operation error indicator (spanner icon)
For the first 10 seconds of display, the indicators blink and
the alarm beeps.

DISPLAY OF TROUBLE CODE

Meter Panel
Two types of trouble code are provided. One is the alarm
(ALA) code and the other is the error (ERR) code.
• When an abnormality in normal operation is detected,
the alarm (ALA) code is displayed.
• When traveling or operation cannot be conducted, the
error (ERR) code is displayed.

To view trouble codes using the PC service tool

1. Turn OFF the key switch.
2. Remove the rear cover.
3. Remove the charger transformer protection cover.
4. Connect the service tool to the service tool connector.
5. Turn ON the key switch.
6. Confirm the trouble code on the service tool.
a When the service tool is connected but the communica-
tion with the control unit cannot be established, the CAN
communication line might be shorted, so check it first.

7-8
 7. TROUBLESHOOTING

PREPARATION FOR VOLTAGE CHECK AND CURRENT CHECK

When checking the voltage and current, be sure to pre-
pare as follows.
1. Park the lift truck on the flat ground and pull the parking
brake.
2. Put the wheel stoppers to the rear wheels to lock them.
3. Place the wooden blocks under the right and left frames
and float the front wheels.
1
4. Lift down the fork to the ground and tilt the mast forward.
5. Turn OFF the key switch.
6. Open the cover (1) at the rear.

BATTERY VOLTAGE CHECK

Before starting the diagnosis, use this check to verify that the lift truck is in the normal state.

Unless specified, disconnect the battery before performing the diagnosis.

While performing the diagnosis, pay attention to safety in case the lift truck moves.

1. Check the electrolyte solution level and specific gravity.

Confirm that the value is correct.

2. Disconnect the battery plug.

Set the tester to the voltage measuring range.
Set the black lead (-) of tester to the negative polarity
plug of battery and the red lead (+) of tester to the posi-
tive polarity plug of battery.
Measure the voltage.
3. Judge whether the battery is good or not.
Measured Voltage Judging
Battery Voltage: Higher than 48V Good
Battery Voltage: Lower than 48V Not good (recharge)

7-9
7. TROUBLESHOOTING

CHECK OF ELECTRICAL PARTS OF CONTROLLER

Looseness of fitting parts and defective contact of con-
nectors 19.6 - 34 Nm
{2 - 3.5 kgm}
If a bolt or a nut of a power terminal fitting part of a controller [14.5 - 25.3 ft. lb]
is loosened, it may heat and cause a burn. Accordingly, if any
fitting part is loosened or heated, polish it carefully with sand-
paper and retighten it.
If there is defective contact in a connector, the related parts
do not operate normally. Accordingly, remove dirt and rust
from the connector to prevent defective contact, and then
connect and disconnect the connector 2 or 3 times. At this
time, check the lead wires for disconnection and terminals for
deformation.

Check of the controller-mounted lift truck

It is very dangerous to touch the electrical parts by hand
while the lift truck is electric-powered.
When removing a new part or touching the part, be sure to
disconnect the battery connector and leave it for more than
10 minutes before starting the work.
An electric charge of 3 to 5V may be left in the capacitor. In
this case, if P3 and N1 are shorted or P12 and N1 are
shorted with a screwdriver, due to a sudden discharge, it may
spark.
Although a sudden discharge will not cause electrification or
burn, use the discharge resistor (100Ω - 1,000Ω) for dis-
charging.
When measuring in the electric-powered state, float the drive
wheels and fix them firmly not to rotate when the motor sud-
denly starts to rotate. In this state, apply the brake, measure
the maximum current, and perform the switch-back operation
and hydraulic operation.

FUSE CHECK
With a tester, confirm that the fusible links and fuses are not
blown out.

7-10
 7. TROUBLESHOOTING

INPUT / OUTPUT SIGNAL OF CONTROLLER

1. TRAVEL (R) CONTROLLER

CN3-D1 CN2-D1 CN1-D1

13 14 15 16 17 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9

(Viewed from wire insertion side)

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 Backward-run switch (DSR) 0V
2 Forward-run (DSF) 0V
3 Main Contact Coil (-) Contact ON: 9 - 12V
4 Main Contact Coil (+) 12V
5 F-LED 11.8V at FSW ON
6 KEY SW VB
7 VB Battery Voltage
8 Quick Charging Resistor (+) VB × 0.85
9 Quick Charging Resistor (-) VB × 0.85
10 —
11 —
12 GND for Right Travel Speed Sensor Shield 0V
13 Right Travel Speed Sensor A (S) 1.3 - 3.3V
14 Right Travel Speed Sensor A (+) 13.5V
15 SW - GND 0V
16 Accelerator SW Step on: 0V, Release: 4.6V
CN1-D1 17 Brake SW Step on: 0V, Release: 4.6V
18 Parking SW Release: 0V, Pull up: 4.6V
19 Seat SW - a Seated: 0V, Not seated: 4.6V
20 Right Travel Motor Temperature Sensor (-) 0V
Power supply for Travel Accelerate VR (+) Accelerator
21 5V
Potentiometer
22 —
23 —
24 —
25 GND for Accelerator Shield 0V
26 GND for Right Travel Motor Speed Sensor Shield 0V
27 Right Travel Motor Speed Sensor B (S) 1.3 - 3.3V
28 Right Travel Motor Speed Sensor B (+) 13.5V
29 Right Travel Motor Temperature Sensor (+) At 25°C [77°F]: About 3.48V *1
30 Accelerator GND 0V
Lower than 0.94V
31 Accelerator Potentiometer Signal (Changed from 0.94 to 3.5V
in the accelerator stepping angle.)

7-11
7. TROUBLESHOOTING

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 FAN Power Supply (48V) VB
2 —
3 FAN Power Supply (lower side) When FAN stopped: VB
4 —
5 —
6 —
7 —
8 —
9 —
10 Model Select 2 SW Closed: 0V, Open: 4.6V
11 Model Select 1 SW Closed: 0V, Open: 4.6V
12 Travel Speed Limit 2 SW Limited: 0V, Not limited: 4.6V
CN2-D1
13 —
14 —
15 —
16 —
17 SW - GND 0V
18 Seat SW - b Seated: 4.6V, Not seated: 0V
19 Model Select 3 SW Closed: 0V, Open: 4.6V
20 High Lifting SW Limited: 4.6V, Not limited: 0V
21 GND for Tire Angle POT Shield 0V
22 GND for Tire Angle POT 0.45V
23 Tire Angle POT Signal Tire in center: 2,5V *2
24 Power Supply for Tire Angle POT 4.5V
1 CAN_L2 (MR) 2.4 - 2.6V
2 CAN_L2 2.4V
3 CAN_L1 2.4V
4 —
5 —
6 —
7 CAN COM 0V
8 CAN_H2 2.6V
CN3-D1 9 CAN_H1 2.6V
10 —
11 —
12 —
13 GND for CAN Shield 0V
14 GND for CAN Shield 0V
15 CAN COM 0V
16 —
17 —
*1: Depending on the temperature, the voltage varies in the range of 0.2 - 4.8V.
*2: Depending on the tire position, the voltage varies in the range of 0.2 - 4.5V.

7-12
 7. TROUBLESHOOTING

2. TRAVEL (L) CONTROLLER

CN3-D2 CN1-D2

13 14 15 16 17 22 23 24 25 26 27 28 29 30 31
7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9

(Viewed from wire insertion side)

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 —
2 —
3 —
4 —
5 R - LED 0V
6 KEY SW VB
7 VB Battery Voltage
8 —
9 —
10 —
11 —
12 GND for Left Travel Motor Speed Sensor Shield 0V
13 Left Travel Motor Speed Sensor A (S) 1.3 - 3.3V
14 Left Travel Motor Speed Sensor A (+) 13.6V
15 —
CN1-D2 16 —
17 —
18 —
19 —
20 Left Travel Motor Temperature Sensor (-) 0V
21 —
22 —
23 —
24 —
25 —
26 GND for Left Travel Motor Speed Sensor 0V
27 Left Travel Motor Speed Sensor B (S) 1.3 - 3.3V
28 Left Travel Motor Speed Sensor B (+) 13.6V
29 Left Travel Motor Temperature Sensor (+) At 25°C [77°F]: About 3.48V *
30 —
31 —

7-13
7. TROUBLESHOOTING

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 CAN_L2(MR) 2.4 - 2.6V
2 CAN_L2 2.4V
3 CAN_L1 2.4V
4 —
5 —
6 —
7 CAN COM 0V
8 CAN_H2 2.6V
CN3-D2 9 CAN_H1 2.6V
10 —
11 —
12 —
13 GND for CAN Shield 0V
14 GND for CAN Shield 0V
15 CAN COM 0V
16 —
17 —
* Depending on the temperature, the voltage varies in the range of 0.2 - 4.8V.

7-14
 7. TROUBLESHOOTING

3. CARGO HANDLING CONTROLLER

CN3-P CN2-P CN1-P

13 14 15 16 17 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9

(Viewed from wire insertion side)

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 —
2 —
3 Knob Correction Valve (-) 12V
4 Knob Correction Valve (+) 12V
5 Backward-run Buzzer 0V
6 KEY SW VB
7 VB Battery Voltage
8 —
9 —
10 —
11 —
12 —
13 —
14 —
15 SW GND 0V
16 ATT 1 SW Push the lever: 0V, Return: 4.6V
CN1-P 17 Tilt SW Push the lever: 0V, Return: 4.6V
18 Lift 2 SW Push the lever: 0V, Return: 4.6V
19 Lift 1 SW Push the lever: 0V, Return: 4.6V
20 Pump Motor Temperature Sensor (-) 0V
21 —
22 —
23 —
24 —
25 GND for Hydraulic Analog Directive Shield 0V

26 GND for Pump Motor Speed Sensor Shield 0V

27 Pump Motor Speed Sensor A (S) 1.3 - 3.3V
28 Pump Motor Speed Sensor A (+) 13.5V
29 Pump Motor Temperature Sensor (+) At 25°C: About 3.48V *
30 Hydraulic Analog Directive (COM) 0V
31 Hydraulic Analog Directive (S) Lower than 1.9V

7-15
7. TROUBLESHOOTING

* Depending on the temperature, the voltage varies in the range of 0.2 - 4.8V.

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 —
2 —
3 —
4 —
5 —
6 —
7 —
8 —
9 —
10 H Meter Start SW Closed: 0V, Open: 4.6V
11 ATT 3 SW Pull the lever: 0V, Return: 4.6V
12 ATT 2 SW Pull the lever: 0V, Return: 4.6V
CN2-P
13 For Steering Wheel Angle Sensor Shield 0V
14 GND for Steering Wheel Angle Sensor 0V
15 Steering Wheel Angle Sensor (S) 0.5 - 4.5V
16 —
17 SW GND 0V
18 Steering Wheel Neutral SW Closed: 0V, Open: 4.6V
19 Capacitor Presence/Absence SW Closed: 0V, Open: 4.6V
20 —
21 —
22 —
23 —
24 —
1 CAN_L2 (MR) 2.4 - 2.6V
2 CAN_L2 2.4V
3 CAN_L1 2.4V
4 —
5 Power Supply for Steering Wheel Angle Sensor 11.2V
6 —
7 CAN_COM 0V
8 CAN_H2 2.6V
CN3-P 9 CAN_H1 2.6V
10 —
11 —
12 —
13 GND for CAN Shield 0V
14 GND for CAN Shield 0V
15 CAN_COM 0V
16 —
17 —

7-16
 7. TROUBLESHOOTING

4. PROPORTIONAL SOLENOID VALVE CONTROLLER

(Viewed from wire insertion side)

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 Lift Sensor
2 Lift Lever
3 Tilt Lever
4 ATT1 Lever
5 ATT2 Lever
6 ATT3 Lever
7 SENS +5V +5V
8 A GND
9 Reserve
10 Tilt Angle
11 A GND
12 Pump Motor COM
13 A GND
CN1S
14 Tilt Offset
15 Tilt Shisei
16 Select 1
17 Select 2
18 —
19 GND
20 +48V +48V (From Key Switch)
21 CANBUS H1
22 CANBUS L1
23 CANBUS TMR
24 CANBUS H2
25 CANBUS L2
26 GND

7-17
7. TROUBLESHOOTING

Input/Output
Connector Terminal
Signal Name (Switch ON, Vehicle stopped, Refer-
No. No.
ence Voltage)
1 ATT1 Sol COM
2 Tilt Backward Sol
3 Tilt Sol COM
4 Lift Down Sol
5 ATT3 A Sol
6 ATT3 Sol COM
7 ATT2 B Sol
8 ATT1 B Sol
9 Tilt Forward Sol
10 Lift Up Sol
11 Lift Sol COM
12 ATT3 B Sol
13 ATT2 A Sol
CN2S
14 ATT1 A Sol
15 —
16 ATT3 Switch
17 ATT2 Switch
18 —
19 ATT2 Sol COM
20 Power Supply (+) VB 2 +
21 —
22 ATT1 Switch
23 Lift Switch
24 Tilt Switch
25 Power GND (P-GND)
26 Power GND (P-GND)

7-18
 7. TROUBLESHOOTING

TROUBLE CODE LIST

ALARM (ALA) CODE
If not recovered,
Code No. Content of Detection Remedy
go to page
The key switch is turned on when the lift Return the lift lever to neutral position, turn
ALA-5206 7-23
lever is in other than neutral position. off the key switch then turn it on again.
The key witch is turned on when the tilt le- Return the tilt lever to neutral position, turn
ALA-5207 7-23
ver is in other than neutral position. off the key switch then turn it on again.
The key switch is turned on when the ATT Return the ATT 1 lever to neutral position,
ALA-5208 7-24
1 lever is in other than neutral position. turn off the key switch then turn it on again.
The key switch is turned on when the ATT Return the ATT 2 lever to neutral position,
ALA-5209 7-24
2 lever is in other than neutral position. turn off the key switch then turn it on again.
The tilt automatic horizontal stops before Return the tilt lever to neutral position and
ALA-5229* 7-25
or after the completion position. turn off the tilt horizontal button.
The tilt automatic horizontal is operated incorrectly.
• The tilt lever is operated in reverse di- • Operate the tilt lever in the horizontal di-
rection. rection.

ALA-5255* • Set the tilt lever in other than horizontal 7-26

• The tilt horizontal is operated when the
position and operate the automatic hori-
tilt lever is in the horizontal position.
zontal.

• The automatic horizontal is operated • Unload the cargo and operate the auto-
with the cargo loaded. matic horizontal without load.

* Lift truck equipped with the tilt automatic horizontal function.

ERROR (ERR) CODE

Code No. Content of Abnormality Go to Page
ERR-3082 The communication between travel (R) controller and travel (L) controller is abnormal. 7-30
The communication between travel (R) controller and cargo handling controller is ab-
ERR-3084 7-30
normal.
ERR-3281 The communication between travel (R) controller and travel (L) controller is abnormal. 7-29
The communication between cargo handling controller and travel (L) controller is ab-
ERR-3284 7-30
normal.
The communication between travel (R) controller and cargo handling controller is ab-
ERR-5081 7-30
normal.
The communication between travel (L) controller and cargo handling controller is ab-
ERR-5082 7-30
normal.
The communication between proportional solenoid valve controller and cargo han-
ERR-5085 7-31
dling controller is abnormal.
ERR-5211 The lift lever signal is abnormal. 7-32
ERR-5212 The tilt lever signal is abnormal. 7-33
ERR-5213 The ATT 1 lever signal is abnormal. 7-34
ERR-5214 The ATT 2 lever signal is abnormal. 7-35
ERR-5215 The ATT 3 lever signal is abnormal. 7-36
ERR-5216 The lift pressure sensor signal is abnormal. 7-37
ERR-5217 The tilt angle sensor signal is abnormal. 7-38
ERR-5218 The lift proportional solenoid valve operation is abnormal. 7-39
ERR-5219 The tilt proportional solenoid valve operation is abnormal. 7-42

7-19
7. TROUBLESHOOTING

Code No. Content of Abnormality Go to Page

ERR-5220 The ATT 1 proportional solenoid valve operation is abnormal. 7-45
ERR-5221 The ATT 2 proportional solenoid valve operation is abnormal. 7-48
ERR-5292 The power supply in the proportional solenoid valve controller is abnormal. 7-51
ERR-5293 The proportional solenoid valve controller is abnormal. 7-52
ERR-5294 The work machine switch signal is abnormal. 7-53
ERR-5295 The proportional solenoid valve controller is abnormal. 7-54
ERR-5296 The relay in the proportional solenoid valve controller is abnormal. 7-55
ERR14-8110 7-56
ERR18-8110 7-58
ERR30-8110 Deleted: Not applicable. 7-60
ERR34-8110 7-62
ERR40-8110 7-64
ERR14-8120 The CAN transmission/reception process of travel (R) controller is abnormal. 7-66
ERR18-8120 The CAN transmission/reception process of travel (L) controller is abnormal. 7-67
ERR30-8120 The CAN transmission/reception process of cargo handling controller is abnormal. 7-68
The CAN transmission/reception process of proportional solenoid valve controller is
ERR34-8120 7-69
abnormal.
ERR40-8120 The CAN transmission/reception process of meter panel is abnormal. 7-70
ERR14-8130 The CAN communication between travel (R) controller and meter panel is abnormal. 7-71
ERR18-8130 The CAN communication between travel (L) controller and meter panel is abnormal. 7-72
The CAN communication between cargo handling controller and meter panel is abnor-
ERR30-8130 7-73
mal.
The CAN communication between proportional solenoid valve controller and meter
ERR34-8130 7-74
panel is abnormal.
ERR14-8140 The CAN transmission of travel (R) controller is abnormal. 7-75
ERR18-8140 The CAN transmission of travel (L) controller is abnormal. 7-76
ERR30-8140 The CAN transmission of cargo handling controller is abnormal. 7-77
ERR34-8140 The CAN transmission of proportional solenoid valve controller is abnormal. 7-78
ERR40-8140 The CAN transmission of meter panel is abnormal. 7-79
ERR40-8314 The CAN communication between travel (R) controller and meter panel is abnormal. 7-80
ERR40-8318 The CAN communication between travel (L) controller and meter panel is abnormal. 7-81
The CAN communication between cargo handling controller and meter panel is abnor-
ERR40-8330 7-82
mal.
The CAN communication between proportional solenoid valve controller and meter
ERR40-8334 7-83
panel is abnormal.
ERR40-8510 The CAN communication of meter panel, after turning on the key, is abnormal. 7-84

7-20
 7. TROUBLESHOOTING

METER DISPLAY TROUBLE CODE (TRAVEL CONTROLLER)

Code No. Content of Abnormality Go to Page
ERR-3001 (Travel R) Breaking of main contactor, Blown-out fuse 7-85
ERR-3002 (Travel R) Short of main contactor 7-85
ERR-3004 (Travel R)
Low voltage detection (Drop of battery voltage) 7-86
ERR-3204 (Travel L)
ALA-3005 (Travel R)
Warning of incorrect teaching operation 7-86
ALA-3205 (Travel L)
ERR-3010 (Travel R)
Travel controller (The upper and lower FETs are shorted) 7-87
ERR-3210 (Travel L)
ERR-3011 (Travel R)
Travel controller (The upper side is shorted) 7-88
ERR-3211 (Travel L)
ERR-3012 (Travel R)
Travel controller (The lower side is shorted) 7-88
ERR-3212 (Travel L)
ERR-3013 (Travel R)
Travel controller (Breaking of U phase wire) 7-88
ERR-3213 (Travel L)
ERR-3014 (Travel R)
Travel controller (Breaking of V phase wire) 7-88
ERR-3214 (Travel L)
ERR-3015 (Travel R)
Travel controller (Breaking of W phase wire) 7-88
ERR-3215 (Travel L)
ERR-3016 (Travel R) Quick Charging Defect (Charging defect of capacitor between P and N) 7-89
ALA-3021 (Travel R)
Travel controller (Temperature rise) 7-89
ALA-3221 (Travel L)
ERR-3021 (Travel R)
Travel controller (Abnormal temperature) 7-90
ERR-3221 (Travel L)
ALA-3031 (Travel R)
Travel motor (Temperature rise) 7-90
ALA-3231 (Travel L)
ERR-3031 (Travel R)
Travel motor (Abnormal temperature) 7-91
ERR-3231 (Travel L)
ERR-3030 (Travel R)
Short between phases of travel motor (Load is shorted.) 7-92
ERR-3230 (Travel L)
ERR-3050 (Travel R)
Defective temperature sensor of travel controller 7-92
ERR-3250 (Travel L)
ERR-3051 (Travel R)
Defective temperature sensor of travel motor 7-93
ERR-3251 (Travel L)
ERR-3052 (Travel R)
Defective output of travel current sensor (U phase, W phase) 7-94
ERR-3252 (Travel L)
ERR-3053 (Travel R)
Defective accelerator, Abnormal accelerator switch 7-94
ERR-3253 (Travel L)
ERR-3054 (Travel R) The tire angle potentiometer is defective. (Abnormal detection angle) 7-95
ERR-3056 (Travel R)
Travel motor speed sensor (A phase output is abnormal.) 7-96
ERR-3256 (Travel L)
ERR-3057 (Travel R)
Travel motor speed sensor (B phase output is abnormal.) 7-97
ERR-3257 (Travel L)
ERR-3061 (Travel R) FR direction switch defective 7-98
ERR-3062 (Travel R) The logic of seat switch _a and seat switch _b is defective. 7-98
ERR-3082 (Travel R)
ERR-3084 (Travel R)
The CAN communication is abnormal. (Breaking of communication line) 7-30
ERR-3281 (Travel L)
ERR-3284 (Travel L)

7-21
7. TROUBLESHOOTING

METER DISPLAY TROUBLE CODE (CARGO HANDLING CONTROLLER)

Code No. Content of Abnormality Go to Page
ERR-5004 Low voltage detection (Drop of battery voltage) 7-99
ALA-5005 Warning of incorrect teaching operation 7-100
ERR-5010 Cargo handling controller (Upper and lower FETs are shorted) 7-101
ERR-5011 Cargo handling controller (Upper side is shorted) 7-102
ERR-5012 Cargo handling controller (Lower side is shorted) 7-102
ERR-5013 Cargo handling controller (Breaking of U phase wire) 7-102
ERR-5014 Cargo handling controller (Breaking of V phase wire) 7-102
ERR-5015 Cargo handling controller (Breaking of W phase wire) 7-102
ALA-5021 Cargo handling controller (Temperature rise) 7-103
ERR-5021 Cargo handling controller (Abnormal temperature) 7-103
ERR-5030 Shorted phases of pump motor (Load shorted) 7-105
ALA-5031 Pump Motor (Temperature rise) 7-105
ERR-5031 Pump Motor (Abnormal temperature) 7-105
ERR-5040 The external controller signal input range is abnormal 7-107
ERR-5050 The temperature sensor of cargo handling controller is defective 7-107
ERR-5051 The temperature sensor of pump motor is defective 7-108
ERR-5052 The output of cargo handling current sensor (U phase, W phase) is defective 7-108
ERR-5055 The steering wheel angle sensor is defective (Detection angle is abnormal) 7-109
ERR-5057 The pump motor speed sensor is defective 7-109
ERR-5081 The CAN communication is abnormal (Breaking of communication line) 7-30

7-22
 7. TROUBLESHOOTING

DIAGNOSTIC PROCEDURE BY TROUBLE CODE (ALA CODE)

Meter Display Code: ALA-5206 Meter Display Code: ALA-5207

Content of Detection Content of Detection

The key switch is turned ON when the lift lever is in The key switch is turned ON when the tilt lever is in
the position other than neutral. the position other than neutral.

Symptom of vehicle Symptom of vehicle

• The lift only is inoperable. • The tilt only is inoperable.
• When turning ON the key, the error appears immedi- • When turning ON the key, the error appears immedi-
ately. ately.

Cause of trouble Cause of trouble

• The lift lever sensor is improperly adjusted. • The tilt lever sensor is improperly adjusted.
• The lift lever sensor is defective. • The tilt lever sensor is defective.
• The harness of lift lever sensor circuit is defective. • The harness of tilt lever sensor circuit is defective.
• Fuse 20 or 21 is defective. • Fuse 22 or 23 is defective.

Repair Procedure Repair Procedure

1. Confirm that the lift lever sensor signal is input. 1. Confirm that the lift lever sensor signal is input.
Measure the voltage between terminals 3 and 2 of Measure the voltage between terminals 4 and 2 of
connector CS1S. connector CS1S.
Normal Value: 2.39 - 2.61V Normal Value: 2.39 - 2.61V
2. If the voltage is normal in step 1, replace the pro- 2. If the voltage is normal in step 1, replace the pro-
portional solenoid valve controller board. portional solenoid valve controller board.
4. If the voltage is abnormal in step 1, check the har- 3. If the voltage is abnormal in step 1, check the har-
ness between lever sensor and proportional sole- ness between lever sensor and proportional sole-
noid valve controller and repair it, or check fuse 20 noid valve controller and repair it, or check fuse 22
or 21 and change the fuse (2A). or 23 and change the fuse (2A).
5. If the voltage is abnormal in step 1 and the har- 4. If the voltage is abnormal in step 1 and the har-
ness is normal in step 3, repair the lever sensor. ness is normal in step 3, repair the lever sensor.

Remark Remark
When 5292 and 5294 are simultaneously displayed, When 5292 and 5294 are simultaneously displayed,
check these codes first. check these codes first.
For remedy, refer to the item of each trouble code. For remedy, refer to the item of each trouble code.
Condition of abnormal detection: Condition of abnormal detection:
Lever sensor neutral output voltage Lever sensor neutral output voltage
Other than 2.14 - 2.82V. Other than 2.14 - 2.82V.

Quick Check Quick Check

Improper adjustment: Only display error "5206". Improper adjustment: Only display error "5207".
Short circuit or disconnect wire: Short circuit or disconnect wire:
Two errors "5206, 5211". Two errors "5207, 5212".
Poor power supply (5V): Poor power supply (5V):
More than 4 errors "5206, 5211, 5292, 5294". More than 4 errors "5207, 5212, 5292, 5294".
You need to know the error code or codes if more than You need to know the error code or codes if more than
one is displayed. one is displayed.

7-23
7. TROUBLESHOOTING

Meter Display Code: ALA-5208 Meter Display Code: ALA-5209

Content of Detection Content of Detection

The key switch is turned ON when the ATT 1 lever is The key switch is turned ON when the ATT 2 lever is
in the position other than neutral. in the position other than neutral.

Symptom of vehicle Symptom of vehicle

• The ATT 1 only is inoperable. • The ATT 2 only is inoperable.
• When turning ON the key, the error appears immedi- • When turning ON the key, the error appears immedi-
ately. ately.

Cause of trouble Cause of trouble

• The ATT 1 lever sensor is improperly adjusted. • The ATT 2 lever sensor is improperly adjusted.
• The ATT 1 lever sensor is defective. • The ATT 2 lever sensor is defective.
• The harness of ATT 1 lever sensor circuit is defective. • The harness of ATT 2 lever sensor circuit is defective.
• Fuse 24 or 25 is defective. • Fuse 26 or 27 is defective.

Repair Procedure Repair Procedure

1. Confirm that the ATT 1 lever sensor signal is input. 1. Confirm that the ATT 2 lever sensor signal is input.
Measure the voltage between terminals 5 and 2 of Measure the voltage between terminals 6 and 2 of
connector CS1S. connector CS1S.
Normal Value: 2.39 - 2.61V Normal Value: 2.39 - 2.61V
2. If the voltage is normal in step 1, replace the pro- 2. If the voltage is normal in step 1, replace the pro-
portional solenoid valve controller board. portional solenoid valve controller board.
3. If the voltage is abnormal in step 1, check the har- 3. If the voltage is abnormal in step 1, check the har-
ness between lever sensor and proportional sole- ness between lever sensor and proportional sole-
noid valve controller and repair it, or check fuse 24 noid valve controller and repair it, or check fuse 26
or 25 and change the fuse (2A). or 27 and change the fuse (2A).
4. If the voltage is abnormal in step 1 and the har- 4. If the voltage is abnormal in step 1 and the har-
ness is normal in step 3, repair the lever sensor. ness is normal in step 3, repair the lever sensor.

Remark Remark
When 5292 and 5294 are simultaneously displayed, When 5292 and 5294 are simultaneously displayed,
check these codes first. check these codes first.
For remedy, refer to the item of each trouble code. For remedy, refer to the item of each trouble code.
Condition of abnormal detection: Condition of abnormal detection:
Lever sensor neutral output voltage Lever sensor neutral output voltage
Other than 2.14 - 2.82V. Other than 2.14 - 2.82V.

Quick Check Quick Check

Improper adjustment: Only display error "5208". Improper adjustment: Only display error "5209".
Short circuit or disconnect wire: Short circuit or disconnect wire:
Two errors "5208, 5213". Two errors "5209, 5214".
Poor power supply (5V): Poor power supply (5V):
More than 4 errors "5208, 5213, 5292, 5294". More than 4 errors "5209, 5214, 5292, 5294".
You need to know which error code or codes displayed. You need to know which error code or codes displayed.

7-24
 7. TROUBLESHOOTING

Meter Display Code: ALA-5229

Content of Detection
The tilt horizontal stops before or after the completion
position.

Symptom of vehicle
• The tilt horizontal stops before or after the completion
position. (Manual operation is possible.)

Cause of trouble
• Mechanical trouble.

Repair Procedure
It is not abnormal. But if the symptom appears fre-
quently, check and repair the mechanical cause that
hinders the movement.

Remark
Condition of abnormal detection:
It is shifted from the horizontal position.

Quick Check
1. Always wrong same position stop:
Wrong adjustment of potentiometer.
2. Always stop position move:
Stick tilt lock valve or tilt spool at hydraulic control
valve.
Note: Not an electrical failure.

7-25
7. TROUBLESHOOTING

Meter Display Code: ALA-5255 Meter Display Code: ALA-5255

(Manual operation is possible.) (Manual operation is impossible.)

Content of Detection Content of Detection

Case 1: Wrong operation The tilt automatic horizontal is incorrectly operated.
When in tilt back position, push the tilt switch 1) The tilt lever is reversely operated.
and pull tilt lever. 2) The automatic horizontal operation is performed
When fork is already horizontal, push tilt when the tilt lever is in the horizontal position.
switch and pull or push tilt lever.
3) The automatic horizontal operation is performed
When fork is in forward position, push tilt with the cargo loaded.
switch and push tilt lever.
Symptom of vehicle
Case 2: When cargo is loaded, push the tilt switch
and try to fork horizontal position. This option • The tilt automatic horizontal operation cannot be per-
only works with empty load condition. formed.
If load is empty and truck still displays the
error code, the hydraulic pressure sensor or Cause of trouble
its wire may be damaged.
• The tilt horizontal button is shorted.
Case 3: Shorted tilt switch.
When the tilt switch is shorted, the tilt horizon- • The tilt horizontal harness is shorted.
tal function is actuated. In this case, carry out
CASE 1 operation. Repair Procedure
Error is always displayed. 1) Operate the tilt horizontal button and confirm that
the automatic horizontal display lights (or blinks) /
ACTION TO BE TAKEN goes off.
Connect PC and start analyzer software; then If normal, replace the proportional solenoid valve
observe the tilt switch function and hydraulic pres- controller board.
sure value at monitor screen. 2) If the automatic horizontal display is abnormal in
step 1, remove the tilt horizontal button connector
Symptom of vehicle and check the resistance of button. If abnormal, re-
place the button.
• The tilt automatic horizontal operation cannot be per-
formed. Normal Resistance Value:
Between terminals 1 and 2
Cause of trouble • Button ON: 0Ω
• The lever is operated in the reverse direction. • Button OFF: cΩ
• The automatic horizontal operation is performed when 3) If the resistance value is normal in step 2, check and
placed in the horizontal position. repair the short of tilt horizontal harness.
• The automatic horizontal operation is performed with
loaded forks. Remark
None
Repair Procedure
Operate correctly.

Remark
If 5207, 5216, 5217 and 5219 are simultaneously dis-
played, check these codes first.
For remedy, refer to the item of each trouble code.
Condition of abnormal detection:
When the lever is reversely operated:
• Automatic operation is performed when placed
in the horizontal position.
• Automatic operation is performed with loaded
forks.

7-26
 7. TROUBLESHOOTING

DIAGNOSIS PROCEDURE BY TROUBLE CODE (ERR CODE)

ERR-3082: Abnormal communication between travel (R) controller and travel (L)
controller (Pair to the travel (L) controller)

Content of Trouble Symptom of vehicle

Cannot communicate with the travel controller. • When turning ON the key switch, all functions stop.
• When started normally, traveling stops.

Repair Procedure
1. Check visually that the connectors and terminals
of travel (R) controller and travel (L) controller are CN3-D1 CN3-D2
not disconnected or not loosened.
Judging: No disconnection of connectors and no 17 16 15 14 13 17 16 15 14 13
looseness of terminal. 12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the

engagement
side of connector

OK: Go to step 3.
NG: Repair or replace the harness.
3. Connect the service tool and confirm that it can
communicate with the travel (R) controller on the
error history menu.
OK: Replace the travel (L) controller.
OK: Go to step 2.
NG: Replace the travel (R) controller.
NG: After cleaning the connector with the contact
refreshing agent, re-connect the connector.
How to reset
2. Disconnect the harness from the controller and
measure the resistance of harness between travel Turn OFF the key switch.
(R) controller and travel (L) controller.
Judging: Remark
• Between CN3-D1 terminal 8 (green/white) and None
CN3-D2 terminal 9 (green/white): 0Ω
• Between CN3-D1 terminal 2 (blue/white) and
CN3-D2 terminal 3 (blue/white): 0Ω

Quick Check
If error codes 3082, 5082 are detected, travel (L) con-
troller is defective.
Note: If CAN connector (CN3-D2) is loose, error code
is not shown.

7-27
7. TROUBLESHOOTING

ERR-3084: Abnormal communication between travel (R) controller and cargo handling
controller (Pair to the cargo handling controller)

Content of Trouble Symptom of vehicle

Cannot communicate with the cargo handling con- • When turning ON the key switch, all functions stop.
troller. • When started normally, cargo-handling stops.

Repair Procedure 3. Connect the service tool and confirm that it can
communicate with the travel (R) controller on the
1. Check visually that the connectors and terminals error history menu.
of travel (R) controller and cargo handling control-
ler are not disconnected or not loosened. OK: Go to step 4.
Judging: No disconnection of connector and no NG: Replace the travel (R) controller.
looseness of terminal. 4. Connect the service tool and confirm that it can
communicate with the cargo handling controller on
the error history menu.
OK: Poor contact of connector pin (repair or replace
the harness.)
NG: Replace the cargo handling controller.

How to reset
Turn OFF the key switch.

Quick Check
If cargo handling connector is proper, cargo controller
is defective.
OK: Go to step 2.
NG: After cleaning the connector with the contact
refreshing agent, re-connect the connector.
2. Disconnect the harness from the controller and
measure the resistance of harness between travel
(R) controller and cargo handling controller.
Judging:
• Between CN3-D1 terminal 9 (green) and CN3-
P terminal 8 (green): 0Ω
• Between CN3-D1 terminal 3 (blue) and CN3-P
terminal 2 (blue): 0Ω

CN3-D1 CN3-P

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the

engagement
side of connector

OK: Go to step 3.
NG: Repair or replace the harness.

7-28
 7. TROUBLESHOOTING

ERR-3281: Abnormal communication between travel (L) controller and travel (R)
controller (Pair to the travel (R) controller)

Content of Trouble Symptom of vehicle

Cannot communicate with the travel (R) controller. • When turning ON the key switch, all functions stop.
• When started normally, traveling stops.

Repair Procedure
1. Check visually that the connectors and terminals
of travel (R) controller and travel (L) controller are CN3-D1 CN3-D2
not disconnected or not loosened.
Judging: No disconnection of connector and no 17 16 15 14 13 17 16 15 14 13
looseness of terminal. 12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the

engagement
side of connector

OK: Go to step 3.
NG: Repair or replace the harness.
3. Connect the service tool and confirm that it can
communicate with the travel (L) controller on the
error history menu.
OK: Replace the travel (R) controller.
OK: Go to step 2.
NG: Replace the travel (L) controller.
NG: After cleaning the connector with the contact
refreshing agent, re-connect the connector.
How to reset
2. Disconnect the harness from the controller and
measure the resistance of harness between travel Turn OFF the key switch.
(R) controller and travel (L) controller.
Judging: Quick Check
• Between CN3-D1 terminal 8 (green/white) and • If error codes 3281 and 5081 are detected, travel con-
CN3-D2 terminal 9 (green/white): 0Ω troller (R) was damaged.
• Between CN3-D1 terminal 2 (blue/white) and • If error codes 3281 and 5082 are detected, travel con-
CN3-D2 terminal 3 (blue/white): 0Ω troller (R) was loose.

7-29
7. TROUBLESHOOTING

ERR-3284: Abnormal communication between travel (L) controller and cargo handling
controller (Pair to the cargo handling controller)

Content of Trouble Symptom of vehicle

Cannot communicate with the cargo handling con- • When turning ON the key switch, all functions stop.
troller. • When started normally, cargo-handling stops.
Repair Procedure
According to the error code ERR-3084 or ERR-3281 displayed simultaneously, check and examine.

ERR-5081: Abnormal communication between cargo handling controller and travel (R)
controller (Pair to the travel (R) controller)

Content of Trouble Symptom of vehicle

Cannot communicate with the travel (R) controller. • When turning ON the key switch, all functions stop.
• When started normally, traveling stops.
Repair Procedure
According to the error code ERR-3084, check and examine.

ERR-5082: Abnormal communication between cargo handling controller and travel (L)
controller (Pair to the travel (L) controller)

Content of Trouble Symptom of vehicle

Cannot communicate with the travel (R) controller. • When turning ON the key switch, all functions stop.
• When started normally, traveling stops.
Repair Procedure
According to the error codes ERR-3084, ERR-3284, ERR-3082 and ERR-3281, check and examine.

Quick Check
If connector of cargo handling controller is proper, cargo handling controller is defective.

7-30
 7. TROUBLESHOOTING

ERR-5085: Abnormal communication between cargo handling controller and proportional

solenoid valve controller (Pair to the proportional solenoid valve controller)

Content of Trouble Symptom of vehicle

Cannot communicate with the cargo handling con- Functions normally.
troller.

Repair Procedure 2. Disconnect the harness from the harness control-

ler and measure the resistance of harness
1. Check visually that the connectors and terminals between proportional solenoid valve controller
of cargo handling controller and proportional sole- and cargo handling controller.
noid valve controller are not disconnected or not
loosened. Judging:
Judging: No disconnection of connector and no • Between CN2S terminal 24 (green/white) and
looseness of terminal. CN3-P terminal 9 (green/white): 0Ω
• Between CN2S terminal 25 (blue/white) and
CN3-P terminal 3 (blue/white): 0Ω

CN2S CN3-P
17 16 15 14 13
7 6 5 4 3 2 1
12 11 10 9 8 7
13 12 11 10 9 8
6 5 4 3 2 1
19 18 17 16 15 14
26 25 24 23 22 21 20

Viewed from the

engagement
side of connector

OK: Go to step 2. B3Z16222

NG: After cleaning the connector with the contact
OK: Go to step 3.
refreshing agent, re-connect the connector.
NG: Repair or replace the harness.
3. Replace the proportional solenoid valve controller
Quick Check and turn ON the key switch.
If connector of proportional controller is proper, propor- Judging: The trouble does not occur.
tional controller is defective.
OK: The repair is finished.
NG: Replace the cargo handling controller.

How to reset
Turn OFF the key switch.

7-31
7. TROUBLESHOOTING

ERR-5211: Abnormal Lift Lever Signal

For troubleshooting, see “Meter Display Code: ALA-5206” on page 7-23.

Content of Trouble Symptom of vehicle

• The lift only is inoperable. • The lift lever is improperly adjusted.
• When operating the lift lever, the trouble code ap- • The lift lever sensor is defective.
pears. • The harness of lift lever sensor circuit is defective.

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and lever sen-
of proportional solenoid valve controller and lever sor.
sensor are not disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 8 (black/yellow) and
terminal of lever sensor 8 (black/yellow): 0 Ω
(GND)
• Between CN2S terminal 2 (red/green) and ter-
minal of lever sensor 2 (red/green): 0Ω (S)
• Between CN2S terminal 7 (green/white) and
terminal of lever sensor 1 (green/white): 0Ω
(Power)

CN2S
Lever
7 6 5 4 3 2 1 Sensor
OK: Go to step 2. 13 12 11 10 9 8
19 18 17 16 15 14 1 2 3 4
NG: After cleaning the connector with the contact 26 25 24 23 22 21 20 5 6 7 8
refreshing agent, re-connect the connector.
Viewed from the engagement side of connector
2. Measure the voltage of signal to the proportional
solenoid valve controller when operating the lift
lever. B3Z16223
Judging: OK: Go to step 4.
• When fully forward-tilted: NG: Repair or replace the harness.
Terminals 3 - 2: 3.9 - 4.3V
4. Replace the lever sensor and turn ON the key
• When fully backward-tilted: switch.
Terminals 3 - 2: 0.7 - 1.1V
Judging: The trouble does not occur.
OK: Replace the proportional solenoid valve control-
OK: The repair is finished.
ler.
NG: Go to step 3.
How to reset
Turn OFF the key switch.

Remark
When 5206 - 5210, 5292 and 5294 are simultane-
ously displayed, check these codes first.
For remedy, refer to the item of each trouble code.
Condition of abnormal detection:
Lever sensor output voltage: Other than 0.45 - 4.5V

7-32
 7. TROUBLESHOOTING

ERR-5212: Abnormal Tilt Lever Signal

For troubleshooting, see “Meter Display Code: ALA-5207” on page 7-23.

Content of Trouble Symptom of vehicle

• The tilt only is inoperable. • The tilt lever is improperly adjusted.
• When operating the tilt lever, the trouble code ap- • The tilt lever sensor is defective.
pears. • The harness of tilt lever sensor circuit is defective.

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and lever sen-
of proportional solenoid valve controller and lever sor.
sensor are not disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 8 (black/yellow) and
terminal of lever sensor 8 (black/yellow): 0Ω
(GND)
• Between CN2S terminal 3 (red/white) and ter-
minal of lever sensor 4 (red/white): 0Ω (S)
• Between CN2S terminal 7 (green/white) and
terminal of lever sensor 1 (green/white): 0Ω
(5V)

CN2S
Lever
7 6 5 4 3 2 1 Sensor
OK: Go to step 2. 13 12 11 10 9 8
19 18 17 16 15 14 1 2 3 4
NG: After cleaning the connector with the contact 26 25 24 23 22 21 20 5 6 7 8
refreshing agent, re-connect the connector.
2. Measure the voltage of signal to the proportional Viewed from the engagement side of connector
solenoid valve controller when operating the tilt
lever. B3Z16224
Judging: OK: Go to step 4.
• When fully forward-tilted: NG: Repair or replace the harness.
Terminals 3 - 8: 3.9 - 4.3V
4. Replace the lever sensor and turn ON the key
• When fully backward-tilted: switch.
Terminals 3 - 8: 0.7 - 1.1V
Judging: The trouble does not occur.
OK: Replace the proportional solenoid valve control-
OK: The repair is finished.
ler.
NG: Go to step 3.
How to reset
Turn OFF the key switch.

Remark
When 5206 - 5210, 5292 and 5294 are simultane-
ously displayed, check these codes first.
For remedy, refer to the item of each trouble code.
Condition of abnormal detection:
Lever sensor output voltage: Other than 0.45 - 4.5V

7-33
7. TROUBLESHOOTING

ERR-5213: Abnormal ATT 1 Lever Signal

For troubleshooting, see “Meter Display Code: ALA-5208” on page 7-24.

Content of Trouble Symptom of vehicle

• The ATT 1 only is inoperable. • The ATT 1 lever is improperly adjusted.
• When operating the ATT 1 lever, the trouble code ap- • The ATT 1 lever sensor is defective.
pears. • The harness of ATT 1 lever sensor circuit is defective.

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and lever sen-
of proportional solenoid valve controller and lever sor.
sensor are not disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 8 (black/yellow) and
terminal of lever sensor 8 (black/yellow): 0Ω
(GND)
• Between CN2S terminal 4 (red/blue) and termi-
nal of lever sensor 3 (red/blue): 0Ω (S)
• Between CN2S terminal 7 (green/white) and
terminal of lever sensor 1 (green/white): 0Ω
(5V)

CN2S
Lever
7 6 5 4 3 2 1 Sensor
OK: Go to step 2. 13 12 11 10 9 8
19 18 17 16 15 14 1 2 3 4
NG: After cleaning the connector with the contact 26 25 24 23 22 21 20 5 6 7 8
refreshing agent, re-connect the connector.
2. Measure the voltage of signal to the proportional Viewed from the engagement side of connector
solenoid valve controller when operating the ATT
1 lever. B3Z16225
Judging: OK: Go to step 4.
• When fully forward-tilted: NG: Repair or replace the harness.
Terminals 4 - 8: 3.9 - 4.3V
4. Replace the lever sensor and turn ON the key
• When fully backward-tilted: switch.
Terminals 4 - 8: 0.7 - 1.1V
Judging: The trouble does not occur.
OK: Replace the proportional solenoid valve control-
OK: The repair is finished.
ler.
NG: Go to step 3.
How to reset
Turn OFF the key switch.

Remark
When 5206 - 5210, 5292 and 5294 are simultane-
ously displayed, check these codes first.
For remedy, refer to the item of each trouble code.
Condition of abnormal detection:
Lever sensor output voltage: Other than 0.45 - 4.5V

7-34
 7. TROUBLESHOOTING

ERR-5214: Abnormal ATT 2 Lever Signal

For troubleshooting, see “Meter Display Code: ALA-5209” on page 7-24.

Content of Trouble Symptom of vehicle

• The ATT 2 only is inoperable. • The ATT 2 lever is improperly adjusted.
• When operating the ATT 2 lever, the trouble code ap- • The ATT 2 lever sensor is defective.
pears. • The harness of ATT 2 lever sensor circuit is defective.

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and lever sen-
of proportional solenoid valve controller and lever sor.
sensor are not disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 8 (black/yellow) and
terminal of lever sensor 8 (black/yellow): 0Ω
(GND)
• Between CN2S terminal 5 (blue/white) and ter-
minal of lever sensor 5 (blue/white): 0Ω (S)
• Between CN2S terminal 7 (green/white) and
terminal of lever sensor 1 (green/white): 0Ω
(5V)

CN2S
Lever
7 6 5 4 3 2 1 Sensor
OK: Go to step 2. 13 12 11 10 9 8
19 18 17 16 15 14 1 2 3 4
NG: After cleaning the connector with the contact 26 25 24 23 22 21 20 5 6 7 8
refreshing agent, re-connect the connector.
2. Measure the voltage of signal to the proportional Viewed from the engagement side of connector
solenoid valve controller when operating the ATT
2 lever. B3Z16226
Judging: OK: Go to step 4.
• When fully forward-tilted: NG: Repair or replace the harness.
Terminals 5 - 8: 3.9 - 4.3V
4. Replace the lever sensor and turn ON the key
• When fully backward-tilted: switch.
Terminals 5 - 8: 0.7 - 1.1V
Judging: The trouble does not occur.
OK: Replace the proportional solenoid valve control-
OK: The repair is finished.
ler.
NG: Go to step 3.
How to reset
Turn OFF the key switch.

Remark
When 5206 - 5210, 5292 and 5294 are simultane-
ously displayed, check these codes first.
For remedy, refer to the item of each trouble code.
Condition of abnormal detection:
Lever sensor output voltage: Other than 0.45 - 4.5V

7-35
7. TROUBLESHOOTING

ERR-5215: Abnormal ATT 3 Lever Signal

Content of Trouble Symptom of vehicle

• The ATT 3 only is inoperable. • The ATT 3 lever is improperly adjusted.
• When operating the ATT 3 lever, the trouble code ap- • The ATT 3 lever sensor is defective.
pears. • The harness of ATT 3 lever sensor circuit is defective.

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and lever sen-
of proportional solenoid valve controller and lever sor.
sensor are not disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 8 (black/yellow) and
terminal of lever sensor 8 (black/yellow): 0Ω
(GND)
• Between CN2S terminal 6 (blue/yellow) and
terminal of lever sensor 6 (blue/yellow): 0Ω (S)
• Between CN2S terminal 7 (green/white) and
terminal of lever sensor 1 (green/white): 0Ω
(5V)

CN2S
Lever
7 6 5 4 3 2 1 Sensor
OK: Go to step 2. 13 12 11 10 9 8
19 18 17 16 15 14 1 2 3 4
NG: After cleaning the connector with the contact 26 25 24 23 22 21 20 5 6 7 8
refreshing agent, re-connect the connector.
2. Measure the voltage of signal to the proportional Viewed from the engagement side of connector
solenoid valve controller when operating the ATT
3 lever. B3Z16227
Judging: OK: Go to step 4.
• When fully forward-tilted: NG: Repair or replace the harness.
Terminals 6 - 8: 3.9 - 4.3V
4. Replace the lever sensor and turn ON the key
• When fully backward-tilted: switch.
Terminals 6 - 8: 0.7 - 1.1V
Judging: The trouble does not occur.
OK: Replace the proportional solenoid valve control-
OK: The repair is finished.
ler.
NG: Go to step 3.
How to reset
Turn OFF the key switch.

Remark
When 5206 - 5210, 5292 and 5294 are simultane-
ously displayed, check these codes first.
For remedy, refer to the item of each trouble code.
Condition of abnormal detection:
Lever sensor output voltage: Other than 0.45 - 4.5V

7-36
 7. TROUBLESHOOTING

ERR-5216: Abnormal Lift Pressure Sensor Signal

Content of Trouble Symptom of vehicle

• All operations are possible. But the response is sup- • The output of lift pressure sensor is abnormal.
pressed and anti-hunting control does not function • The harness of sensor circuit is defective.
when lifting down.
• The tilt automatic horizontal work is inoperable.
(Only vehicle equipped with the tilt automatic horizon-
tal function)
• When turning ON the key switch, the trouble code ap-
pears.

Repair Procedure 4. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and the lift pres-
of proportional solenoid valve controller and lift sure sensor.
pressure sensor are not disconnected or not loos-
ened. Judging:
Judging: No disconnection of connector and no • Between CN2S terminal 13 (black/white) and
looseness of terminal. terminal of lift pressure sensor 3 (black/white):
0Ω
• Between CN2S terminal 1 (blue) and
terminal of lift pressure sensor 2 (blue): 0Ω
• Between CN2S terminal 7 (green/white) and
terminal of lift pressure sensor 1 (green/white):
0Ω

Lift Pressure
CN2S Sensor
7 6 5 4 3 2 1 3 2 1

OK: Go to step 2. 13 12 11 10 9 8
19 18 17 16 15 14
NG: After cleaning the connector with the contact 26 25 24 23 22 21 20
refreshing agent, re-connect the connector.
2. Measure the operating voltage of lift pressure sen- Viewed from the engagement side of connector
sor.
B3Z16228
Judging: Terminals 1 - 13: 0.33 - 4.3V
OK: Replace the proportional solenoid valve control- OK: Go to step 5.
ler. NG: Repair or replace the harness.
NG: Go to step 4. 5. Replace the lift pressure sensor and turn ON the
key switch.
3. Remove the battery plug.
Judging: The trouble does not occur.
Quick Check OK: The repair is finished.

Check by PC.
How to reset
Connect wire PC to truck.
Start analyzer software. Turn OFF the key switch.
See the voltage of hydraulic pressure at I/O monitor
screen. Remark
• 0V: Disconnected wire. Condition of abnormal detection:
• More than 5V: Short circuit of wire. Lever sensor output voltage: Other than 0.32 - 4.72V
• Other than 0V or 5V: Poor pressure sensor.

7-37
7. TROUBLESHOOTING

ERR-5217: Abnormal Tilt Angle Sensor Signal

Content of Trouble Symptom of vehicle

• The tilt automatic horizontal work is inoperable. • The output of tilt angle sensor is abnormal.
(Only the vehicle equipped with the tilt automatic hori- • The harness of tilt angle sensor circuit is defective.
zontal function)
• When turning ON the key switch, the trouble code ap-
pears.

Repair Procedure 4. Remove the battery plug.

1. Check visually that the installation of tilt angle sen- 5. Disconnect the harness from the controller and
sor is not disconnected or not loosened. measure the resistance of harness between pro-
portional solenoid valve controller and the tilt
angle sensor.
Judging:
• Between CN2S terminal 7 (green/white) and
terminal of tilt horizontal 3 (green/white): 0Ω
• Between CN2S terminal 10 (yellow) and
terminal of tilt horizontal 2 (yellow): 0Ω
• Between CN2S terminal 13 (black/white) and
terminal of tilt horizontal 1 (black/white): 0Ω
2. Check visually that the connectors and terminals
of proportional solenoid valve controller and tilt
angle sensor are not disconnected and not loos-
ened. CN2S
Judging: No disconnection of connector and no Tilt
looseness of terminal. Horizontal
7 6 5 4 3 2 1 3 2 1
13 12 11 10 9 8
19 18 17 16 15 14
26 25 24 23 22 21 20

Viewed from the engagement side of connector

B3Z16229
OK: Go to step 6.
NG: Repair or replace the harness.
OK: Go to step 3. 6. Measure the resistance at terminals of tilt angle
NG: After cleaning the connector with the contact sensor.
refreshing agent, re-connect the connector. Judging:
3. Measure the operating voltage to the tilt angle • Between terminals 1 and 3: 2kΩ
sensor. • Between terminals 2 and 3: 0 - 2kΩ
Judging: Between terminals 10 - 13: 0.4 - 4.6V (For- OK: The repair is finished.
ward tilt end - backward tilt end) NG: Replace the tilt angle sensor.
OK: Replace the proportional solenoid valve control-
ler. How to reset
NG: Go to step 4. Set the tilt operation lever in the neutral position.

Quick Check Remark

Check by PC. Condition of abnormal detection:
Connect wire PC to truck. Tilt angle sensor output voltage: Other than 0.3 -
Start analyzer software. 4.7V
See the voltage of tilt angle sensor at I/O monitor
screen.
• 0V: Disconnected wire.
• More than 5V: Short circuit of wire.
• Other than 0V or 5V: Tilt angle sensor defective.

7-38
 7. TROUBLESHOOTING

ERR-5218: Abnormal Lift Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• The lift only is inoperable. • Breaking of lift proportional solenoid valve coil
• When operating the lever, the error appears. • Leakage, poor contact and breaking of harness be-
(The pump motor rotates momentarily.) tween lift proportional solenoid valve and lift propor-
tional solenoid valve controller
• Open of proportional solenoid valve drive circuit in the
proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance at terminals of lift propor- portional solenoid valve controller and the propor-
tional solenoid valve (both of ascent and descent). tional solenoid valve (descent).
Judging: Between terminals 1 and 4: 17 - 18Ω Judging:
OK: Go to step 2. • Between CN3S terminal 11 (green/black) and
NG: Replace the lift proportional solenoid valve. terminal of proportional solenoid valve descent
1 No.4 (green/black): 0Ω
2. Disconnect the harness from the controller and
measure the resistance of harness between pro- • Between CN3S terminal 4 (yellow) and
portional solenoid valve controller and the propor- terminal of proportional solenoid valve descent
tional solenoid valve (ascent). 1 No.1 (green/red): 0Ω
If resistance is infinity, check fuse 21.
Judging:
• Between CN3S terminal 11 (green/black) and
terminal of proportional solenoid valve ascent 1
No.4 (green/black): 0Ω CN3S Proportional
• Between CN3S terminal 10 (yellow/red) solenoid valve
descent 1
and terminal of proportional solenoid valve
ascent 1 No.1 (yellow/red): 0Ω
If resistance is infinity, check fuse 20. 7 6 5 4 3 2 1
13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4
26 25 24 23 22 21 20

CN3S Proportional
solenoid valve
ascent 1 Viewed from the engagement side of connector
B3Z16231
7 6 5 4 3 2 1 OK: Replace the proportional solenoid valve control-
13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4 ler.
26 25 24 23 22 21 20 NG: Repair or replace the harness.

Viewed from the engagement side of connector How to reset

B3Z16230 Turn OFF the key switch.
OK: Go to step 3.
NG: Repair or replace the harness.

Quick Check
Troubleshoot by PC.
Note: Only lift operation is defective.
Connect PC and truck by cable.
Start analyzer software.
Slowly pull the lift lever and watch the current of lift
solenoid valve in the I/O monitor.
Current of lift solenoid valve is:
• Always 0 mA (No current)
Disconnect wire of solenoid valve.
• Always more than 1000 mA
Short circuit or burned out solenoid.

7-39
7. TROUBLESHOOTING

ERR-5218: Abnormal Lift Proportional Solenoid Valve Operation

Case 2: Battery power not reach to solenoid valve.
Content of Trouble Symptom of vehicle
• All operations are inoperable. • Open EMG relay in the proportional solenoid valve
• When operating the lever, the error appears. controller
(The pump motor rotates momentarily.) • Wire breaking or leakage of the proportional solenoid
valve power supply harness between battery and pro-
portional solenoid valve controller, CH interlock (main)
relay, fuse and EMG/switch
• Drop of battery voltage during lever operation *1
(It is not the trouble of proportional solenoid valve con-
troller.) [rarely required]
• The proportional solenoid valve power circuit is shut
down by operating EMG/switch during lever operation
*2 [rarely required] (It is not the trouble of proportional
solenoid valve controller.)

Repair Procedure How to reset

1. Install the connector jumper unit (3BA-97-99750) Turn OFF the key switch.
to the proportional solenoid valve controller.
(If customer have same other trucks, exhange the Remark
proportional controller.)
When 5206 - 5210, 5211 - 5215, 5292 and 5294 are
2. Measure the voltage of power supply to the pro- simultaneously displayed, check these codes first.
portional solenoid valve controller. For remedy, refer to the item of each trouble code.
Judging: Between terminals 20 and 26: *1 Example: Shorted transistor of main controller.
Battery voltage 30 - 54V [rarely required]
OK: Replace the proportional solenoid valve control- *2 Example: Momentary or imperfect pressing of
ler. EMG switch. [rarely required]
NG: Go to step 2.
3. Check the wire-breaking or leakage of the propor-
tional solenoid valve power supply harness
between battery and proportional solenoid valve
controller, CH interlock (main) relay, fuse, and
EMG/switch.
Judging: If abnormal, repair or replace.

Quick Check
Check the 15 A fuse at fuse holder.
(Power will supply through 15 A fuse)
If 15 A fuse is good, check voltage at 15 A fuse.
Fuse wire connection is OK, print card of controller.

7-40
 7. TROUBLESHOOTING

ERR-5218: Abnormal Lift Proportional Solenoid Valve Operation

Case 3: Solenoid valve power supply is short circuit.
Content of Trouble Symptom of vehicle
• All operations are inoperable. • Shorted proportional solenoid valve coil
• When operating the lever, the error appears. • Shorted drive circuit of proportional solenoid valve in
(The pump motor rotates momentarily.) the proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance at terminals of lift propor- portional solenoid valve controller and the lift pro-
tional solenoid valve (both of ascent and descent). portional solenoid valve (descent).
Judging:Between terminals 1 and 4: 17 - 18Ω Judging:
OK: Go to step 2. • CN3S terminal 11 (green/black) -
NG: Replace the lift proportional solenoid valve. terminal of proportional solenoid valve descent
1 No.4 (green/black): 0Ω
2. Disconnect the harness from the controller and
measure the resistance of harness between pro- • CN3S terminal 4 (yellow) -
portional solenoid valve controller and the propor- terminal of proportional solenoid valve descent
tional solenoid valve (ascent). 1 No.1 (green/red): 0Ω
If resistance is infinity, check fuse 21.
Judging:
• Between CN3S terminal 11 (green/black) and
terminal of proportional solenoid valve ascent 1
No.4 (green/black): 0Ω CN3S Proportional
• Between CN3S terminal 10 (yellow/red) solenoid valve
descent 1
and terminal of proportional solenoid valve
ascent 1 No.1 (yellow/red): 0Ω
If resistance is infinity, check fuse 20. 7 6 5 4 3 2 1
13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4
26 25 24 23 22 21 20

CN3S Proportional
solenoid valve
ascent 1 Viewed from the engagement side of connector
B3Z16231
7 6 5 4 3 2 1
OK: Replace the proportional solenoid valve control-
13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4 ler.
26 25 24 23 22 21 20 NG: Repair or replace the harness.

Viewed from the engagement side of connector How to reset

B3Z16230 Turn OFF the key switch.

OK: Go to step 3.
NG: Repair or replace the harness.

7-41
7. TROUBLESHOOTING

ERR-5219: Abnormal Tilt Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• The tilt only is inoperable. • Breaking of tilt proportional solenoid valve coil
• When operating the lever, the error appears. • Poor contact, leakage or breaking of the harness be-
(The pump motor rotates momentarily.) tween tilt proportional solenoid valve and proportional
solenoid valve controller
• Open drive circuit of proportional solenoid valve in the
proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance of terminals of tilt propor- portional solenoid valve controller and the propor-
tional solenoid valve (both of backward-tilt and for- tional solenoid valve descent 1 (forward tilt).
ward-tilt).
Judging:
Judging: Between terminals 2 and 5: 17 - 18Ω
• Between CN3S terminal 3 (green)
OK: Go to step 2. and terminal of proportional solenoid valve
NG: Replace the tilt proportional solenoid valve. descent 1 No.5 (green): 0Ω
2. Disconnect the harness from the controller and • Between CN3S terminal 9 (red/white) and ter-
measure the resistance of harness between pro- minal of proportional solenoid valve descent 1
portional solenoid valve controller and the propor- No.2 (green/black): 0Ω
tional solenoid valve ascent 1 (backward tilt). If resistance is infinity, check fuse 23.
Judging:
• Between CN3S terminal 3 (green)
and terminal of proportional solenoid valve Proportional
ascent 1 No.5 (green): 0Ω solenoid valve
CN3S descent 1
• Between CN3S terminal 2 (orange) and termi-
nal of proportional solenoid valve ascent 1 No.2
(green/white): 0Ω 7 6 5 4 3 2 1
If resistance is infinity, check fuse 22. 13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4
26 25 24 23 22 21 20

Proportional
solenoid valve Viewed from the engagement side of connector
CN3S ascent 1 B3Z16233
OK: Replace the proportional solenoid valve control-
7 6 5 4 3 2 1
3 2 1
ler.
13 12 11 10 9 8
19 18 17 16 15 14 6 5 4 NG: Repair or replace the harness.
26 25 24 23 22 21 20

How to reset
Viewed from the engagement side of connector Turn OFF the key switch.
B3Z16232
OK: Go to step 3.
NG: Repair or replace the harness.

Quick Check
Troubleshoot by PC.
Note: Only tilt operation is defective.
Connect PC and truck by cable.
Start analyzer software.
Slowly pull the tilt lever and watch the current of tilt
solenoid valve in the I/O monitor.
Current of tilt solenoid valve is:
• Always 0 mA (No current)
Disconnect wire of solenoid valve.
• Always more than 1000 mA
Short circuit or burned out solenoid.

7-42
 7. TROUBLESHOOTING

ERR-5219: Abnormal Tilt Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• All operations are inoperable. • Open EMG relay in the proportional solenoid valve
• When operating the lever, the error appears. controller
(The pump motor rotates momentarily.) • Leakage or wire-breaking of the proportional solenoid
valve power supply harness between battery and pro-
portional solenoid valve controller, CH interlock (main)
relay, fuse and EMG/switch
• Drop of battery voltage during lever operation *1
(It is not the trouble of proportional solenoid valve con-
troller.) [rarely required]
• The proportional solenoid valve power circuit is shut
down by operating EMG/switch during lever operation
*2 [rarely required] (It is not the trouble of proportional
solenoid valve controller.)

Repair Procedure How to reset

1. Install the connector jumper unit (3BA-97-99750) Turn OFF the key switch.
to the proportional solenoid valve controller.
2. Measure the voltage of power supply to the pro- Remark
portional solenoid valve controller. When 5206 - 5210, 5211 - 5215, 5292 and 5294 are
Judging: Between terminals 20 and 26: simultaneously displayed, check these codes first.
Battery voltage 30 - 54V For remedy, refer to the item of each trouble code.
OK: Replace the proportional solenoid valve control- *1 Example: Shorted transistor of main controller.
ler. [rarely required]
NG: Go to step 2. *2 Example: Momentary or imperfect pressing of
EMG switch. [rarely required]
3. Check the wire-breaking or leakage of the propor-
tional solenoid valve power supply harness
between battery and proportional solenoid valve
controller, CH interlock (main) relay, fuse, and
EMG/switch.
Judging: If abnormal, repair or replace.

Quick Check
Check the 10 A fuse at fuse holder.
(Power will supply through 10 A fuse)
If 10 A fuse is good, check voltage at 10 A fuse.
Voltage is proper, replace print card of proportional
valve controller.

7-43
7. TROUBLESHOOTING

ERR-5219: Abnormal Tilt Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• All operations are inoperable. • Shorted proportional solenoid valve coil
• When operating the lever, the error appears. • Shorted drive circuit of proportional solenoid valve in
(The pump motor rotates momentarily.) the proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance at terminals of tilt propor- portional solenoid valve controller and the propor-
tional solenoid valve (both of backward tilt and for- tional solenoid valve descent 1 (forward tilt).
ward tilt).
Judging:
Judging: Between terminals 2 and 5: 17 - 18Ω
• Between CN3S terminal 3 (green) and terminal
OK: Go to step 2. of proportional solenoid valve descent 1 No.5
NG: Replace the tilt proportional solenoid valve. (green): 0Ω
2. Disconnect the harness from the controller and • Between CN3S terminal 9 (red/white) and ter-
measure the resistance of harness between pro- minal of proportional solenoid valve descent 1
portional solenoid valve controller and the propor- No.2 (green/black): 0Ω
tional solenoid valve ascent 1 (backward tilt). If resistance is infinity, check fuse 23.
Judging:
• Between CN3S terminal 3 (green) and
terminal of proportional solenoid valve ascent 1 Proportional
No.5 (green): 0Ω solenoid valve
• Between CN3S terminal 2 (orange) and CN3S descent 1
terminal of proportional solenoid valve ascent 1
No.2 (green/white): 0Ω 7 6 5 4 3 2 1
If resistance is infinity, check fuse 22. 13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4
26 25 24 23 22 21 20

Proportional
solenoid valve Viewed from the engagement side of connector
CN3S ascent 1 B3Z16233
OK: Replace the proportional solenoid valve control-
7 6 5 4 3 2 1
3 2 1
ler.
13 12 11 10 9 8
19 18 17 16 15 14 6 5 4 NG: Repair or replace the harness.
26 25 24 23 22 21 20

How to reset
Viewed from the engagement side of connector Turn OFF the key switch.
B3Z16232
OK: Go to step 3.
NG: Repair or replace the harness.

7-44
 7. TROUBLESHOOTING

ERR-5220: Abnormal ATT1 Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• The ATT1 only is inoperable. • Breaking of ATT1 proportional solenoid valve coil
• When operating the lever, the error appears. • Leakage, poor contact or breaking of the harness be-
(The pump motor rotates momentarily.) tween the ATT1 proportional solenoid valve and the
proportional solenoid valve controller
• Open drive circuit of proportional solenoid valve in the
proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance at terminals of ATT1 pro- portional solenoid valve controller and the propor-
portional solenoid valve (both of ascent and tional solenoid valve descent 1 (descent).
descent).
Judging:
Judging: Between terminals 3 - 6: 17 - 18Ω
• Between CN3S terminal 1 (violet) and
OK: Go to step 2. terminal of proportional solenoid valve descent
NG: Replace the ATT1 proportional solenoid valve. 1 No.6 (violet): 0Ω
2. Disconnect the harness from the controller and • Between CN3S terminal 8 (yellow) and
measure the resistance of harness between pro- terminal of proportional solenoid valve descent
portional solenoid valve controller and the propor- 1 No.3 (white): 0Ω
tional solenoid valve ascent 1 (ascent). If resistance is infinity, check fuse 25.
Judging:
• Between CN3S terminal 1 (violet) and
terminal of proportional solenoid valve ascent 1 Proportional
No.6 (violet): 0Ω solenoid valve
CN3S descent 1
• Between CN3S terminal 14 (yellow/red) and
terminal of proportional solenoid valve ascent 1
No.3 (white/blue): 0Ω 7 6 5 4 3 2 1
If resistance is infinity, check fuse 24. 13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4
26 25 24 23 22 21 20

Proportional
solenoid valve Viewed from the engagement side of connector
CN3S ascent 1 B3Z16235
OK: Replace the proportional solenoid valve control-
7 6 5 4 3 2 1
3 2 1
ler.
13 12 11 10 9 8
19 18 17 16 15 14 6 5 4 NG: Repair or replace the harness.
26 25 24 23 22 21 20

How to reset
Viewed from the engagement side of connector Turn OFF the key switch.
B3Z16234
OK: Go to step 3.
NG: Repair or replace the harness.

Quick Check
Troubleshoot by PC.
Note: Only ATT1 operation is defective.
Connect PC and truck by cable.
Start analyzer software.
Slowly pull the ATT1 lever and watch the current of
ATT1 solenoid valve in the I/O monitor.
Current of ATT1 solenoid valve is:
• Always 0 mA (No current)
Disconnect wire of solenoid valve.
• Always more than 1000 mA
Short circuit or burned out solenoid.

7-45
7. TROUBLESHOOTING

ERR-5220: Abnormal ATT1 Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• All operations are inoperable. • Open EMG relay in the proportional solenoid valve
• When operating the lever, the error appears. controller
(The pump motor rotates momentarily.) • Leakage or breaking of the proportional solenoid valve
power supply harness between battery and propor-
tional solenoid valve controller, CH interlock (main) re-
lay, fuse and EMG/switch
• Drop of battery voltage during lever operation *1
(It is not the trouble of proportional solenoid valve con-
troller.) [rarely required]
• The proportional solenoid valve power circuit only is
shut down by operating EMG/switch during lever oper-
ation *2 [rarely required]
(It is not the trouble of proportional solenoid valve con-
troller.)

Repair Procedure How to reset

1. Install the connector jumper unit (3BA-97-99750) Turn OFF the key switch.
to the proportional solenoid valve controller.
2. Measure the voltage of power supply to the pro- Remark
portional solenoid valve controller. When 5206 - 5210, 5211 - 5215, 5292 and 5294 are
Judging: Between terminals 20 and 26: simultaneously displayed, check these codes first.
Battery voltage 30 - 54V For remedy, refer to the item of each trouble code.
OK: Replace the proportional solenoid valve control- *1 Example: Shorted transistor of main controller.
ler. [rarely required]
NG: Go to step 3. *2 Example: Momentary or imperfect pressing of
EMG switch. [rarely required]
3. Check the leakage or wire-breaking of the propor-
tional solenoid valve power supply harness
between battery and proportional solenoid valve
controller, CH interlock (main) relay, fuse, and
EMG/switch
Judging: If abnormal, repair or replace.

Quick Check
Check the 10 A fuse at fuse holder.
(Power will supply through 10 A fuse)
If 10 A fuse is good, check voltage at 10 A fuse.
Fuse wire connection is OK, replace print card.

7-46
 7. TROUBLESHOOTING

ERR-5220: Abnormal ATT1 Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• All operations are inoperable. • Shorted proportional solenoid valve coil
• When operating the lever, the error appears. • Shorted drive circuit of proportional solenoid valve in
(The pump motor rotates momentarily.) the proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance at terminals of ATT1 pro- portional solenoid valve controller and the propor-
portional solenoid valve tional solenoid valve descent 1 (descent).
(both of ascent and descent).
Judging:
Judging: Between terminals 3 and 6: 17 - 18Ω
• Between CN3S terminal 1 (violet) and
OK: Go to step 2. terminal of proportional solenoid valve descent
NG: Replace the ATT1 proportional solenoid valve. 1 No.6 (violet): 0Ω
2. Disconnect the harness from the controller and • Between CN3S terminal 8 (yellow) and
measure the resistance of harness between pro- terminal of proportional solenoid valve descent
portional solenoid valve controller and the propor- 1 No.3 (white): 0Ω
tional solenoid valve ascent 1 (ascent). If resistance is infinity, check fuse 25.
Judging:
• Between CN3S terminal 1 (violet) and terminal
of proportional solenoid valve ascent 1 No. 6 Proportional
(violet): 0Ω solenoid valve
CN3S descent 1
• Between CN3S terminal 14 (yellow/red) and
terminal of proportional solenoid valve ascent 1
No. 3 (white/blue): 0Ω 7 6 5 4 3 2 1
If resistance is infinity, check fuse 24. 13 12 11 10 9 8 3 2 1
19 18 17 16 15 14 6 5 4
26 25 24 23 22 21 20

Proportional
solenoid valve Viewed from the engagement side of connector
CN3S ascent 1 B3Z16235
OK: Replace the proportional solenoid valve control-
7 6 5 4 3 2 1
3 2 1
ler.
13 12 11 10 9 8
19 18 17 16 15 14 6 5 4 NG: Repair or replace the harness.
26 25 24 23 22 21 20

How to reset
Viewed from the engagement side of connector Turn OFF the key switch.
B3Z16234
OK: Go to step 3.
NG: Repair or replace the harness.

7-47
7. TROUBLESHOOTING

ERR-5221: Abnormal ATT2 Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• The ATT2 only is inoperable. • Breaking of ATT 2 proportional solenoid valve coil
• When operating the lever, the error appears. • Wire-breaking, leakage or poor contact of harness be-
(The pump motor rotates momentarily.) tween ATT2 proportional solenoid valve and propor-
tional solenoid valve controller
• Open drive circuit of proportional solenoid valve in the
proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance of terminals of ATT2 pro- portional solenoid valve controller and the propor-
portional solenoid valve tional solenoid valve descent 2 (descent).
(both of ascent and descent).
Judging:
Judging: Between terminals 1 and 3: 17 - 18Ω
• Between CN3S terminal 19 (green/red) and ter-
OK: Go to step 2. minal of proportional solenoid valve descent 2
NG: Replace the ATT2 proportional solenoid valve. No.3 (green/red): 0Ω
2. Disconnect the harness from the controller and • Between CN3S terminal 7 (red/white) and ter-
measure the resistance of harness between pro- minal of proportional solenoid valve descent 2
portional solenoid valve controller and the propor- No.1 (green/white): 0Ω
tional solenoid valve ascent 2 (ascent). If resistance is infinity, check fuse 27.
Judging:
• Between CN3S terminal 19 (green/red) and ter-
minal of proportional solenoid valve ascent 2
No.3 (green/red): 0Ω
• Between CN3S terminal 13 (orange) and termi- CN3S Proportional
nal of proportional solenoid valve ascent 2 No.1 solenoid valve
(gray/black): 0Ω 7 6 5 4 3 2 1 descent 2
If resistance is infinity, check fuse 26. 13 12 11 10 9 8
19 18 17 16 15 14 2 1
26 25 24 23 22 21 20 4 3

Viewed from the engagement side of connector

B3Z16237
CN3S Proportional
solenoid valve OK: Replace the proportional solenoid valve control-
ascent 2
7 6 5 4 3 2 1
ler.
13 12 11 10 9 8
19 18 17 16 15 14 2 1 NG: Repair or replace the harness.
26 25 24 23 22 21 20 4 3

How to reset
Viewed from the engagement side of connector Turn OFF the key switch.
B3Z16236
OK: Go to step 3.
NG: Repair or replace the harness.

Quick Check
Troubleshoot by PC.
Note: Only ATT2 operation is defective.
Connect PC and truck by cable.
Start analyzer software.
Slowly pull the ATT2 lever and watch the current of
ATT2 solenoid valve in the I/O monitor.
Current of ATT2 solenoid valve is:
• Always 0 mA (No current)
Disconnect wire of solenoid valve.
• Always more than 1000 mA
Short circuit or burned out solenoid.

7-48
 7. TROUBLESHOOTING

ERR-5221: Abnormal ATT2 Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• All operations are inoperable. • Open EMG relay in the proportional solenoid valve
• When operating the lever, the error appears. controller
(The pump motor rotates momentarily.) • Wire leakage or breaking of the proportional solenoid
valve power supply harness between battery and pro-
portional solenoid valve controller, CH interlock (main)
relay, fuse and EMG/switch
• Drop of battery voltage during lever operation *1
(It is not the trouble of proportional solenoid valve con-
troller.) [rarely required]
• The proportional solenoid valve power circuit only is
shut down by operating EMG/switch during lever oper-
ation. *2 [rarely required]
(It is not the trouble of proportional solenoid valve con-
troller.)

Repair Procedure How to reset

1. Install the connector jumper unit (3BA-97-99750) Turn OFF the key switch.
to the proportional solenoid valve controller.
2. Measure the voltage of power supply to the pro- Remark
portional solenoid valve controller. When 5206 - 5210, 5211 - 5215, 5292 and 5294 are
Judging: Between terminals 20 and 26: simultaneously displayed, check these codes first.
Battery voltage 30 - 54V For remedy, refer to the item of each trouble code.
OK: Replace the proportional solenoid valve control- *1 Example: Shorted transistor of main controller.
ler. [rarely required]
NG: Go to step 2. *2 Example: Momentary or imperfect pressing of
EMG switch. [rarely required]
3. Check the leakage or wire-breaking of the propor-
tional solenoid valve power supply harness
between battery and proportional solenoid valve
controller, CH interlock (main) relay, fuse, and
EMG/switch.
Judging: If abnormal, repair or replace.

Quick Check
Check the 15 A fuse at fuse holder.
(Power will supply through 15 A fuse)
If 15 A fuse is good, check voltage at 15 A fuse.
Fuse wire connection is OK, replace print card.

7-49
7. TROUBLESHOOTING

ERR-5221: Abnormal ATT2 Proportional Solenoid Valve Operation

Content of Trouble Symptom of vehicle

• All operations are inoperable. • Shorted proportional solenoid valve coil
• When operating the lever, the error appears. • Shorted drive circuit of proportional solenoid valve in
(The pump motor rotates momentarily.) the proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness from the controller and

measure the resistance of harness between pro-
1. Measure the resistance at terminals of ATT2 pro- portional solenoid valve controller and the propor-
portional solenoid valve (both of ascent and tional solenoid valve descent 2 (descent).
descent).
Judging:
Judging: Between terminals 1 - 3: 17 - 18Ω
• Between CN3S terminal 19 (green/red) and ter-
OK: Go to step 2. minal of proportional solenoid valve descent 2
NG: Replace the ATT2 proportional solenoid valve. No.3 (green/red): 0Ω
2. Disconnect the harness from the controller and • Between CN3S terminal 7 (red/white) and ter-
measure the resistance of harness between pro- minal of proportional solenoid valve descent 2
portional solenoid valve controller and the propor- No.1 (green/white): 0Ω
tional solenoid valve ascent 2 (ascent). If resistance is infinity, check fuse 27.
Judging:
• Between CN3S terminal 19 (green/red) and
erminal of proportional solenoid valve ascent 2
No.3 (green/red): 0Ω
• Between CN3S terminal 13 (orange) and termi-
CN3S Proportional
nal of proportional solenoid valve ascent 2 No.1 solenoid valve
(gray/black): 0Ω 7 6 5 4 3 2 1 descent 2
If resistance is infinity, check fuse 26. 13 12 11 10 9 8
19 18 17 16 15 14 2 1
26 25 24 23 22 21 20 4 3

Viewed from the engagement side of connector

CN3S Proportional B3Z16237

solenoid valve
7 6 5 4 3 2 1 ascent 2 OK: Replace the proportional solenoid valve control-
13 12 11 10 9 8 ler.
19 18 17 16 15 14 2 1
NG: Repair or replace the harness.
26 25 24 23 22 21 20 4 3

How to reset
Viewed from the engagement side of connector
Turn OFF the key switch.
B3Z16236
OK: Go to step 3.
NG: Repair or replace the harness.

7-50
 7. TROUBLESHOOTING

ERR-5292: Abnormal Power Supply in Proportional Solenoid Valve Controller

(This error is less or more than 5V of controller)
Content of Trouble
• All operations are inoperable.
• When turning ON the key switch, the trouble code appears.

Repair Procedure 2. Disconnect the harnesses from the controller.

Measure the resistance of harnesses between
1. Check visually that the connectors and the termi- proportional solenoid valve controller and lift lever
nals of connector of proportional solenoid valve sensor, lift pressure sensor and tilt horizontal sen-
controller are not disconnected or not loosened. sor respectively.
Judging: No disconnection of connector and no Judging:
looseness of terminal.
• Between CN2S terminal 7 (green/white) and
lever sensor terminal 1 (green/white): 0Ω
• Between CN2S terminal 7 (green/white) and lift
pressure terminal 1 (green/white): 0Ω
• Between CN2S terminal 7 (green/white) and tilt
horizontal terminal 3 (green/white): 0Ω

1 2 3 4
Lever
CN2S 5 6 7 8 Sensor

7 6 5 4 3 2 1 Lift
13 12 11 10 9 8 pressure
OK: Go to step 2. 19 18 17 16 15 14 3 2 1 Sensor
26 25 24 23 22 21 20
NG: Clean the connector with the contact restorer Tilt
and re-connect the connector. Horizontal
Proportional 3 2 1
Sensor
solenoid valve descent 2
Quick Check B3Z16238
OK: Replace the proportional solenoid valve control-
In case of 2-spool valve (Lift & Tilt) ler.
If this error code will be displayed, error code 5206, NG: Repair or replace the harness.
5207, 5211, 5212 (2-spool valve) will be displayed.

In case of 3-spool valve (Lift, Tilt, ATT1)

If this error code will be displayed, error code 5206,
5207, 5208, 5211, 5212, 5213 will be displayed.

Solution
Only replace new print card of proportional valve
controller.
Note: Forklift truck shows only 5 error codes, PC
shows 10 error codes. So 4-spool, 5-spool valve
may not show all error codes.

7-51
7. TROUBLESHOOTING

ERR-5293: Abnormal Proportional Solenoid Valve Controller

(Watch frequency and wave shape of electricity in the controller)
Content of Trouble
• All operations are inoperable.
• When turning ON the key switch, the trouble code appears.

Repair Procedure
1. Check visually that the connectors and terminals
of proportional solenoid valve controller are not
disconnected or not loosened.
Judging: No disconnection of connector and no
looseness of terminal.

OK: Replace the proportional solenoid valve control-

ler.
NG: Clean the connector with the contact restorer
and re-connect the connector.

Quick Check
If this error will displayed, just replace print card.

7-52
 7. TROUBLESHOOTING

ERR-5294: Abnormal Work Machine Signal

Content of Trouble
• All operations are inoperable.
• When turning ON the key switch, the trouble code appears.

Repair Procedure 4. Measure the resistance of harness between pro-

portional solenoid valve controller and cargo han-
1. Check visually that the connectors and terminals dling controller.
of connector of proportional solenoid valve con-
troller are not disconnected or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3S terminal 22 (blue/white)
looseness of terminal. and CN1-P terminal 16 (blue/white): 0Ω
• Between CN3S terminal 23 (blue/orange) and
CN1-P terminal 18 & 19 (blue/orange): 0Ω
• Between CN3S terminal 24 (blue/yellow) and
CN1-P terminal 17 (blue/yellow): 0Ω
• Between CN3S terminal 17 (blue) and
CN2-P terminal 12 (blue): 0Ω
• Between CN3S terminal 16 (blue/red) and
CN1-P terminal 11 (blue/red): 0Ω

CN3S
CN1-P
31 30 29 28 27 26 25 24 23 22
OK: Go to step 2. 21 20 19 18 17 16 15 14 13 12 11 10
7 6 5 4 3 2 1
9 8 7 6 5 4 3 2 1
NG: Clean the connector with the contact restorer 13 12 11 10 9 8
and re-connect the connector. 19 18 17 16 15 14 CN2-P
26 25 24 23 22 21 20
24 23 22 21 20 19 18 17
2. Install the SST connector jumper unit (3BA-97- 16 15 14 13 12 11 10 9 8
99750) to the proportional solenoid valve control- 7 6 5 4 3 2 1
ler.
Viewd from the engagement side of connector
3. Measure the operating voltage of power supply to B3Z16239
the proportional solenoid valve controller.
OK: Go to step 5.
Judging:
NG: Repair or replace the harness.
• Between CS2S terminal 14 and
CS2S terminal 19: Higher than 4V 5. Measure the operating voltage of power supply to
the cargo handling controller.
• Between CS2S terminal 15 and
CS2S terminal 19: Higher than 4V Judging:
• Between CS2S terminal 10 and • Between CN1-P terminal 16 and
CS2S terminal 19: Higher than 4V CN1-P terminal 15: Higher than 4 - 5V
• Between CS2S terminal 22 and • Between CN1-P terminal 17 and
CS2S terminal 19: Higher than 4V CN1-P terminal 15: Higher than 4 - 5V
• Between CS2S terminal 24 and • Between CN1-P terminal 19 and
CS2S terminal 19: Higher than 4V CN1-P terminal 15: Higher than 4 - 5V
OK: Replace the proportional solenoid valve control- • Between CN2-P terminal 11 and
ler. CN1-P terminal 15: Higher than 4 - 5V
NG: Go to step 4. • Between CN2-P terminal 12 and
CN1-P terminal 15: Higher than 4 - 5V
OK: Replace the proportional solenoid valve control-
ler.
NG: Replace the cargo handling controller.
Quick Check
Connect PC to forklift truck and start software.
Watch Lift, Tilt, ATT1, ATT2, ATT3 signal (0 or 1).
If data is correct, hydraulic controller is defective.
If no, proportional valve controller is defective.

7-53
7. TROUBLESHOOTING

ERR-5295: Abnormal Proportional Solenoid Valve Controller

(CPU error)
Content of Trouble
• All operations are inoperable.
• When turning ON the key switch, the trouble code appears.
• The EMG relay in the proportional solenoid valve controller repeats ON/OFF periodically.

Repair Procedure
1. Check visually that the connectors and terminals
of proportional solenoid valve controller are not
disconnected or not loosened.
Judging: No disconnection of connector and no
looseness of terminal.

OK: Replace the proportional solenoid valve control-

ler.
NG: Clean the connector with the contact restorer
and re-connect the connector.

Quick Check
Just replace new print card.

7-54
 7. TROUBLESHOOTING

ERR-5296: Abnormal Relay in Proportional Solenoid Valve Controller

(Watch emergency relay on the print card of proportional controller.)
Content of Trouble
• When turning ON the key switch, the trouble code appears.

Repair Procedure
1. Check visually that the connectors and terminals
of proportional solenoid valve controller are not
disconnected or not loosened.
Judging: No disconnection of connector and no
looseness of terminal.

OK: Replace the proportional solenoid valve control-

ler.
NG: Clean the connector with the contact restorer
and re-connect the connector.

Quick Check
Just replace the print card of proportional valve control-
ler.

7-55
7. TROUBLESHOOTING

ERR14-8110: Abnormal CAN Communication Process of Travel (R) Controller

Not available. Too long data received.
Content of Trouble
• Poor contact or short circuit of CAN communication harness

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line at the meter
1. Check visually that the connectors and terminals panel side.
of travel (R) controller are not disconnected or not
loosened. Judging: Between meter panel terminal 11 (green)
and meter panel terminal 9 (blue): 20kΩ -
Judging: No disconnection of connector and no 100kΩ
looseness of terminal.

Meter Panel

1 2 3 4 5 6
7 8 9 10 11 12

Viewed from the engagement side of connector

OK: Go to step 4.
OK: Go to step 2.
NG: Repair or replace the equipment.
NG: Clean the connector with the contact restorer
and re-connect the connector. 4. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (R)
2. In the state that connectors of all equipments are controller side.
connected, measure the resistance at the termi-
nals of service tool. Judging: Between CN3-D1 terminal 9 (green) and
CN3-D1 terminal 3 (blue): 20kΩ - 100kΩ
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

CN3-D1

Service Tool 13 14 15 16 17
7 8 9 10 11 12
2 1
1 2 3 4 5 6
4 3

Viewed from the engagement side of connector

Viewed from the engagement side of connector OK: Go to step 5.

NG: Repair or replace the equipment.
OK: Perform step 3 and later. Perform the short cir-
cuit test of CAN communication line of harness.
NG: Repair or replace the harness.

7-56
 7. TROUBLESHOOTING

5. Disconnect the harness and measure the resis- 7. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (L) tance of CAN communication line at the propor-
controller side. tional solenoid valve controller side.
Judging: Between CN3-D2 terminal 9 (green/white) Judging: Between CN2S terminal 24 (green/white)
and CN3-D2 terminal 3 (blue/white): 20kΩ - and CN2S terminal 25 (blue/white): 20kΩ -
100kΩ 100kΩ

CN2S
CN3-D2
7 6 5 4 3 2 1
13 12 11 10 9 8
13 14 15 16 17 19 18 17 16 15 14
7 8 9 10 11 12 26 25 24 23 22 21 20

1 2 3 4 5 6

Viewed from the engagement side of connector

Viewed from the engagement side of connector
B3Z16240
OK: Go to step 6. OK: Replace the travel (R) controller.
NG: Repair or replace the equipment. NG: Repair or replace the equipment.
6. Disconnect the harness and measure the resis-
tance of CAN communication line at the cargo
handling controller side.
Judging: Between CN3-P terminal 9 (green/white)
and CN3-P terminal 3 (blue/white): 20kΩ -
100kΩ

CN3-P

13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6

Viewed from the engagement side of connector

OK: Go to step 7.
NG: Repair or replace the equipment.

7-57
7. TROUBLESHOOTING

ERR18-8110: Abnormal CAN Communication Process of Travel (L) Controller

Not available. Too long data received.
Content of Trouble
Poor contact or short circuit of CAN communication harness

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line at the meter
1. Check visually that the connectors and terminals panel side.
of travel (L) controller are not disconnected or not
loosened. Judging: Between meter panel terminal 11 (green)
and meter panel terminal 9 (blue): 20 kW -
Judging: No disconnection of connector and no 100kΩ
looseness of terminal.

Meter Panel

1 2 3 4 5 6
7 8 9 10 11 12

Viewed from the engagement side of connector

OK: Go to step 4.
OK: Go to step 2.
NG: Repair or replace the equipment.
NG: Clean the connector with the contact restorer
and re-connect the connector. 4. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (R)
2. In the state that connectors of all equipments are controller side.
connected, measure the resistance at the termi-
nals of service tool. Judging: Between CN3-D1 terminal 9 (green) and
CN3-D1 terminal 3 (blue): 20kΩ - 100kΩ
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

CN3-D1
Service Tool
13 14 15 16 17
2 1 7 8 9 10 11 12
4 3 1 2 3 4 5 6

Viewed from the engagement side of connector

Viewed from the engagement side of connector
OK: Go to step 5.
OK: Perform step 3 and later. Perform the short cir- NG: Repair or replace the equipment.
cuit test of CAN communication line of harness.
NG: Repair or replace the harness.

7-58
 7. TROUBLESHOOTING

5. Disconnect the harness and measure the resis- 7. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (L) tance of CAN communication line at the propor-
controller side. tional solenoid valve controller side.
Judging: Between CN3-D2 terminal 9 (green/white) Judging: Between CN2S terminal 24 (green/white)
and CN3-D2 terminal 3 (blue/white): 20kΩ - and CN2S terminal 25 (blue/white): 20kΩ -
100kΩ 100kΩ

CN2S
CN3-D2
7 6 5 4 3 2 1
13 12 11 10 9 8
13 14 15 16 17 19 18 17 16 15 14
7 8 9 10 11 12 26 25 24 23 22 21 20

1 2 3 4 5 6

Viewed from the engagement side of connector

Viewed from the engagement side of connector
B3Z16240
OK: Go to step 6. OK: Replace the travel (R) controller.
NG: Repair or replace the equipment. NG: Repair or replace the equipment.
6. Disconnect the harness and measure the resis-
tance of CAN communication line at the cargo
handling controller side.
Judging: Between CN3-P terminal 9 (green/white)
and CN3-P terminal 3 (blue/white): 20kΩ -
100kΩ

CN3-P

13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6

Viewed from the engagement side of connector

OK: Go to step 7.
NG: Repair or replace the equipment.

7-59
7. TROUBLESHOOTING

ERR30-8110: Abnormal CAN Communication Process of Cargo Handling Controller

Not available. Too long data received.
Content of Trouble
Poor contact or short circuit of CAN communication harness

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line at the meter
1. Check visually that the connectors and terminals panel side.
of cargo handling controller are not disconnected
or not loosened. Judging: Between meter panel terminal 11 (green)
and meter panel terminal 9 (blue): 20kΩ -
Judging: No disconnection of connector and no 100kΩ
looseness of terminal.

Meter Panel

1 2 3 4 5 6
7 8 9 10 11 12

Viewed from the engagement side of connector

OK: Go to step 4.
OK: Go to step 2.
NG: Repair or replace the equipment.
NG: Clean the connector with the contact restorer
and re-connect the connector. 4. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (R)
2. In the state that connectors of all equipments are controller side.
connected, measure the resistance at the termi-
nals of service tool. Judging: Between CN3-D1 terminal 9 (green) and
CN3-D1 terminal 3 (blue): 20kΩ - 100kΩ
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

CN3-D1

Service Tool 13 14 15 16 17
7 8 9 10 11 12
2 1
1 2 3 4 5 6
4 3

Viewed from the engagement side of connector

Viewed from the engagement side of connector OK: Go to step 5.

NG: Repair or replace the equipment.
OK: Perform step 3 and later. Perform the short cir-
cuit test of CAN communication line of harness.
NG: Repair or replace the harness.

7-60
 7. TROUBLESHOOTING

5. Disconnect the harness and measure the resis- 7. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (L) tance of CAN communication line at the propor-
controller side. tional solenoid valve controller side.
Judging: Between CN3-D2 terminal 9 (green/white) Judging: Between CN2S terminal 24 (green/white)
and CN3-D2 terminal 3 (blue/white): 20kΩ - and CN2S terminal 25 (blue/white): 20kΩ -
100kΩ 100kΩ

CN2S
CN3-D2
7 6 5 4 3 2 1
13 12 11 10 9 8
13 14 15 16 17 19 18 17 16 15 14
7 8 9 10 11 12 26 25 24 23 22 21 20

1 2 3 4 5 6

Viewed from the engagement side of connector

Viewed from the engagement side of connector
B3Z16240
OK: Go to step 6. OK: Replace the travel (R) controller.
NG: Repair or replace the equipment. NG: Repair or replace the equipment.
6. Disconnect the harness and measure the resis-
tance of CAN communication line at the cargo
handling controller side.
Judging: Between CN3-P terminal 9 (green/white)
and CN3-P terminal 3 (blue/white): 20kΩ -
100kΩ

CN3-P

13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6

Viewed from the engagement side of connector

OK: Go to step 7.
NG: Repair or replace the equipment.

7-61
7. TROUBLESHOOTING

ERR34-8110: Abnormal CAN Communication Process of Proportional Solenoid Valve Controller

Not available. Too long data received.
Content of Trouble
Poor contact or short circuit of CAN communication harness

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line at the meter
1. Check visually that the connectors and terminals panel side.
of proportional solenoid valve controller are not
disconnected or not loosened. Judging: Between meter panel terminal 11 (green)
and meter panel terminal 9 (blue): 20kΩ -
Judging: No disconnection of connector and no 100kΩ
looseness of terminal.

Meter Panel

1 2 3 4 5 6
7 8 9 10 11 12

Viewed from the engagement side of connector

OK: Go to step 4.
OK: Go to step 2.
NG: Repair or replace the equipment.
NG: Clean the connector with the contact restorer
and re-connect the connector. 4. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (R)
2. In the state that connectors of all equipments are controller side.
connected, measure the resistance at the termi-
nals of service tool. Judging: Between CN3-D1 terminal 9 (green) and
CN3-D1 terminal 3 (blue): 20kΩ - 100kΩ
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

CN3-D1

Service Tool 13 14 15 16 17
7 8 9 10 11 12
2 1
1 2 3 4 5 6
4 3

Viewed from the engagement side of connector

Viewed from the engagement side of connector OK: Go to step 5.

NG: Repair or replace the equipment.
OK: Perform step 3 and later. Perform the short cir-
cuit test of CAN communication line of harness.
NG: Repair or replace the harness.

7-62
 7. TROUBLESHOOTING

5. Disconnect the harness and measure the resis- 7. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (L) tance of CAN communication line at the propor-
controller side. tional solenoid valve controller side.
Judging: Between CN3-D2 terminal 9 (green/white) Judging: Between CN2S terminal 24 (green/white)
and CN3-D2 terminal 3 (blue/white): 20kΩ - and CN2S terminal 25 (blue/white): 20kΩ -
100kΩ 100kΩ

CN2S
CN3-D2
7 6 5 4 3 2 1
13 12 11 10 9 8
13 14 15 16 17 19 18 17 16 15 14
7 8 9 10 11 12 26 25 24 23 22 21 20

1 2 3 4 5 6

Viewed from the engagement side of connector

Viewed from the engagement side of connector
B3Z16240
OK: Go to step 6. OK: Replace the travel (R) controller.
NG: Repair or replace the equipment. NG: Repair or replace the equipment.
6. Disconnect the harness and measure the resis-
tance of CAN communication line at the cargo
handling controller side.
Judging: Between CN3-P terminal 9 (green/white)
and CN3-P terminal 3 (blue/white): 20kΩ -
100kΩ

CN3-P

13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6

Viewed from the engagement side of connector

OK: Go to step 7.
NG: Repair or replace the equipment.

7-63
7. TROUBLESHOOTING

ERR40-8110: Abnormal CAN Communication Process of Meter Panel

Not available. Too long data received.
Content of Trouble
Poor contact or short circuit of CAN communication harness

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line at the meter
1. Check visually that the connectors and terminals panel side.
of meter panel are not disconnected or not loos-
ened. Judging: Between meter panel terminal 11 (green)
and meter panel terminal 9 (blue): 20kΩ -
Judging: No disconnection of connector and no 100kΩ
looseness of terminal.

Meter Panel

1 2 3 4 5 6
7 8 9 10 11 12

Viewed from the engagement side of connector

OK: Go to step 4.
OK: Go to step 2.
NG: Repair or replace the equipment.
NG: Clean the connector with the contact restorer
and re-connect the connector. 4. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (R)
2. In the state that connectors of all equipments are controller side.
connected, measure the resistance at the termi-
nals of service tool. Judging: Between CN3-D1 terminal 9 (green) and
CN3-D1 terminal 3 (blue): 20kΩ - 100kΩ
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

CN3-D1
Service Tool
13 14 15 16 17
2 1 7 8 9 10 11 12
4 3 1 2 3 4 5 6

Viewed from the engagement side of connector

Viewed from the engagement side of connector
OK: Go to step 5.
OK: Perform step 3 and later. Perform the short cir- NG: Repair or replace the equipment.
cuit test of CAN communication line of harness.
NG: Repair or replace the harness.

7-64
 7. TROUBLESHOOTING

5. Disconnect the harness and measure the resis- 7. Disconnect the harness and measure the resis-
tance of CAN communication line at the travel (L) tance of CAN communication line at the propor-
controller side. tional solenoid valve controller side.
Judging: Between CN3-D2 terminal 9 (green/white) Judging: Between CN2S terminal 24 (green/white)
and CN3-D2 terminal 3 (blue/white): 20kΩ - and CN2S terminal 25 (blue/white): 20kΩ -
100kΩ 100kΩ

CN2S
CN3-D2
7 6 5 4 3 2 1
13 12 11 10 9 8
13 14 15 16 17 19 18 17 16 15 14
7 8 9 10 11 12 26 25 24 23 22 21 20

1 2 3 4 5 6

Viewed from the engagement side of connector

Viewed from the engagement side of connector
B3Z16240
OK: Go to step 6. OK: Replace the travel (R) controller.
NG: Repair or replace the equipment. NG: Repair or replace the equipment.
6. Disconnect the harness and measure the resis-
tance of CAN communication line at the cargo
handling controller side.
Judging: Between CN3-P terminal 9 (green/white)
and CN3-P terminal 3 (blue/white): 20kΩ -
100kΩ

CN3-P

13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6

Viewed from the engagement side of connector

OK: Go to step 7.
NG: Repair or replace the equipment.

7-65
7. TROUBLESHOOTING

ERR14-8120: Abnormal CAN Transmission/Reception Process of Travel (R) Controller

Intermittent connection at connector of (R) controller.
Content of Trouble
• Poor contact or short circuit of harness connector of travel (R) controller
• Abnormal travel (R) controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (R) controller and travel (L) controller.
of travel (R) controller are not disconnected or not
loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D1 terminal 8 (green/white) and
looseness of terminal. CN3-D2 terminal 9 (green/white): 0Ω
• Between CN3-D1 terminal 2 (blue/white) and
CN3-D2 terminal 3 (blue/white): 0Ω

CN3-D1 CN3-D2

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the

engagement
side of connector
OK: Go to step 2.
NG: Clean the connector with the contact restorer
OK: Replace the travel (R) controller.
and re-connect the connector.
NG: Repair or replace the harness.
2. In the state that connectors of all equipments are
connected, measure the resistance at the termi-
nals of service tool.
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

Service Tool

2 1
4 3

Viewed from the engagement side of connector

OK: Go to step 3.
NG: Repair or replace the harness.

7-66
 7. TROUBLESHOOTING

ERR18-8120: Abnormal CAN Transmission/Reception Process of Travel (L) Controller

Intermittent connection at connector of (L) controller.
Content of Trouble
• Poor contact or short circuit of harness connector of travel (L) controller
• Abnormal travel (L) controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (L) controller and meter panel.
of travel (L) controller are not disconnected or not
loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D2 terminal 8 (green) and meter
looseness of terminal. panel terminal 11 (green): 0Ω
• Between CN3-D2 terminal 2 (blue) and meter
panel terminal 9 (blue): 0Ω

CN3-D2 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
OK: Go to step 4.
and re-connect the connector.
NG: Repair or replace the harness.
2. In the state that connectors of all equipments are
connected, measure the resistance at the termi- 4. Disconnect the harness and measure the resis-
nals of service tool. tance of CAN communication line between travel
Judging: Between service tool terminal 2 (green) and (R) controller and travel (L) controller.
service tool terminal 3 (blue): 40 - 70Ω Judging:
• Between CN3-D1 terminal 8 (green/white) and
CN3-D2 terminal 9 (green/white): 0Ω
• Between CN3-D1 terminal 2 (blue/white) and
CN3-D2 terminal 3 (blue/white): 0Ω
Service Tool

2 1
4
CN3-D1 CN3-D2
3

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 3. Viewed from the

engagement
NG: Repair or replace the harness. side of connector

OK: Replace the travel (L) controller.

NG: Repair or replace the harness.

7-67
7. TROUBLESHOOTING

ERR30-8120: Abnormal CAN Transmission/Reception Process of Cargo Handling Controller

Intermittent connection at connector of cargo handling controller.
Content of Trouble
• Poor contact or short circuit of harness connector of cargo handling controller
• Abnormal cargo handling controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between cargo
1. Check visually that the connectors and terminals handling controller and travel (R) controller.
of cargo handling controller are not disconnected
or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-P terminal 8 (green) and CN3-
looseness of terminal. D1 terminal 9 (green): 0Ω
• Between CN3-P terminal 2 (blue) and CN3-D1
terminal 2 (blue): 0Ω

CN3-D1 CN3-P

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the

engagement
side of connector
OK: Go to step 2.
NG: Clean the connector with the contact restorer
OK: Go to step 4.
and re-connect the connector.
NG: Repair or replace the harness.
2. In the state that connectors of all equipments are
connected, measure the resistance at the termi- 4. Disconnect the harness and measure the resis-
nals of service tool. tance of CAN communication line between cargo
Judging: Between service tool terminal 2 (green) and handling controller and proportional solenoid
service tool terminal 3 (blue): 40 - 70Ω valve controller.
Judging:
• Between CN3-P terminal 9 (green/white) and
CN2S terminal 24 (green/white): 0Ω
• Between CN3-P terminal 3 (blue/white) and
Service Tool CN2S terminal 25 (blue/white): 0Ω
2 1
4 3
CN3-P CN2S

7 6 5 4 3 2 1
17 16 15 14 13 13 12 11 10 9 8
12 11 10 9 8 7 19 18 17 16 15 14
6 5 4 3 2 1 26 25 24 23 22 21 20
Viewed from the engagement side of connector

OK: Go to step 3.
NG: Repair or replace the harness.
Viewed from the engagement side of connector
B3Z16241
OK: Replace the cargo handling controller.
NG: Repair or replace the harness.

7-68
 7. TROUBLESHOOTING

ERR34-8120: Abnormal CAN Transmission/Reception Process of Proportional Solenoid

Valve Controller
Intermittent connection at connector of proportional valve controller.
Content of Trouble
• Poor contact or short circuit of harness connector of proportional solenoid valve controller
• Abnormal proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and cargo
of proportional solenoid valve controller are not handling controller.
disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 24 (green/white) and
CN3-P terminal 9 (green/white): 0Ω
• Between CN2S terminal 25 (blue/white) and
CN3-P terminal 3 (blue/white): 0Ω

CN2S CN3-P

7 6 5 4 3 2 1
13 12 11 10 9 8 17 16 15 14 13
19 18 17 16 15 14 12 11 10 9 8 7
26 25 24 23 22 21 20 6 5 4 3 2 1

OK: Go to step 2. Viewed from the engagement side of connector

NG: Clean the connector with the contact restorer B3Z16242
and re-connect the connector.
OK: Replace the proportional solenoid valve.
2. In the state that connectors of all equipments are
connected, measure the resistance at the termi- NG: Repair or replace the harness.
nals of service tool.
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

Service Tool

2 1
4 3

Viewed from the engagement side of connector

OK: Go to step 3.
NG: Repair or replace the harness.

7-69
7. TROUBLESHOOTING

ERR40-8120: Abnormal CAN Transmission/Reception Process of Meter Panel

Intermittent connection at connector of meter panel.
Content of Trouble Symptom of vehicle
• The meter panel cannot communicate with other • Abnormal meter panel display.
equipment. (The content of display cannot be renewed.)
The vehicle operates normally.

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between meter
1. Check visually that the connectors and terminals panel and travel (L) controller.
of meter panel are not disconnected or not loos-
ened. Judging:
Judging: No disconnection of connector and no • Between meter panel terminal 11 (green) and
looseness of terminal. CN3-D2 terminal 8 (green): 0Ω
• Between meter panel terminal 9 (blue) and
CN3-D2 terminal 2 (blue): 0Ω

CN3-D2
Meter Panel
17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
OK: Replace the proportional solenoid valve.
and re-connect the connector.
NG: Repair or replace the harness.
2. In the state that connectors of all equipments are
connected, measure the resistance at the termi-
nals of service tool.
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

Service Tool

2 1
4 3

Viewed from the engagement side of connector

OK: Go to step 3.
NG: Repair or replace the harness.

7-70
 7. TROUBLESHOOTING

ERR14-8130: Abnormal CAN Communication between Travel (R) Controller and Meter Panel

Content of Trouble
• Poor contact or short circuit of harness connector between travel (R) controller and meter panel
• Abnormal travel (R) controller

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (R) controller and meter panel.
of travel (R) controller and meter panel are not dis-
connected or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D1 terminal 8 (green) and meter
looseness of terminal. panel terminal 11 (green): 0Ω
• Between CN3-D1 terminal 2 (blue) and meter
panel terminal 9 (blue): 0Ω

CN3-D1 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
OK: Replace the travel (R) controller.
and re-connect the connector.
NG: Repair or replace the harness.

7-71
7. TROUBLESHOOTING

ERR18-8130: Abnormal CAN Communication between Travel (L) Controller and Meter Panel

Content of Trouble
• Poor contact or short circuit of harness connector between travel (L) controller and meter panel
• Abnormal travel (L) controller

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (L) controller and meter panel.
of travel (L) controller and meter panel are not dis-
connected or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D2 terminal 8 (green) and meter
looseness of terminal. panel terminal 11 (green): 0Ω
• Between CN3-D2 terminal 2 (blue) and meter
panel terminal 9 (blue): 0Ω

CN3-D2 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
OK: Replace the travel (L) controller.
and re-connect the connector.
NG: Repair or replace the harness.

7-72
 7. TROUBLESHOOTING

ERR30-8130: Abnormal CAN Communication between Cargo Handling Controller and Meter
Panel

Content of Trouble
• Poor contact or short circuit of harness connector between cargo handling controller and meter panel
• Abnormal cargo handling controller

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between cargo
1. Check visually that the connectors and terminals handling controller and meter panel.
of cargo handling controller and meter panel are
not disconnected or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-P terminal 8 (green) and meter
looseness of terminal. panel terminal 11 (green): 0Ω
• Between CN3-P terminal 2 (blue) and meter
panel terminal 9 (blue): 0Ω

CN3-P Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Replace the cargo handling controller.
NG: Repair or replace the harness.

7-73
7. TROUBLESHOOTING

ERR34-8130: Abnormal CAN Communication between Proportional Solenoid Valve

Controller and Meter Panel

Content of Trouble
• Poor contact or short circuit of harness connector between proportional solenoid valve controller and meter panel
• Abnormal proportional solenoid valve

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and meter
of proportional solenoid valve controller and meter panel.
panel are not disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 24 (green/white) and
meter panel terminal 11 (green): 0Ω
• Between CN2S terminal 25 (blue/white) and
meter panel terminal 9 (blue): 0Ω

CN2S Meter Panel

7 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 12 11 10 9 8 7
19 18 17 16 15 14
26 25 24 23 22 21 20

OK: Go to step 2. Viewed from the engagement side of connector

NG: Clean the connector with the contact restorer B3Z16243
and re-connect the connector.
OK: Replace the proportional solenoid valve control-
ler.
NG: Repair or replace the harness.

7-74
 7. TROUBLESHOOTING

ERR14-8140: Abnormal CAN Transmission of Travel (R) Controller

Content of Trouble
• Poor contact or short circuit of harness connector of travel (R) controller
• Abnormal travel (R) controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (L) controller and travel (R) controller.
of travel (R) controller are not disconnected or not
loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D1 terminal 8 (green/white) and
looseness of terminal. CN3-D2 terminal 9 (green/white): 0Ω
• Between CN3-D1 terminal 2 (blue/white) and
CN3-D2 terminal 3 (blue/white): 0Ω

CN3-D1 CN3-D2

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the

engagement
side of connector
OK: Go to step 2.
NG: Clean the connector with the contact restorer OK: Go to step 4.
and re-connect the connector.
NG: Repair or replace the harness.
2. In the state that connectors of all equipments are
connected, measure the resistance at the termi- 4. Disconnect the harness and measure the resis-
nals of service tool. tance of CAN communication line between travel
(R) controller and cargo handling controller.
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω Judging:
• Between CN3-D1 terminal 9 (green) and CN3-
P terminal 8 (green): 0Ω
• Between CN3-D1 terminal 3 (blue) and CN3-P
terminal 2 (blue): 0Ω
Service Tool

2 1
4 3
CN3-D1 CN3-P

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the engagement side of connector

Viewed from the
OK: Go to step 3. engagement
side of connector
NG: Repair or replace the harness.

OK: Replace the travel (R) controller.

NG: Repair or replace the harness.

7-75
7. TROUBLESHOOTING

ERR18-8140: Abnormal CAN Transmission of Travel (L) Controller

Content of Trouble
• Poor contact or short circuit of harness connector of travel (L) controller
• Abnormal travel (L) controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (L) controller and meter panel.
of travel (L) controller are not disconnected or not
loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D2 terminal 8 (green) and
looseness of terminal. meter panel terminal 11 (green): 0Ω
• Between CN3-D2 terminal 2 (blue) and
meter panel terminal 9 (blue): 0Ω

CN3-D2 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Go to step 4.
2. In the state that connectors of all equipments are NG: Repair or replace the harness.
connected, measure the resistance at the termi- 4. Disconnect the harness and measure the resis-
nals of service tool. tance of CAN communication line between travel
Judging: Between service tool terminal 2 (green) and (L) controller and travel (R) controller.
service tool terminal 3 (blue): 40 - 70Ω Judging:
• Between CN3-D2 terminal 9 (green/white) and
CN3-D1 terminal 8 (green/white): 0Ω
• Between CN3-D2 terminal 3 (blue/white) and
Service Tool CN3-D1 terminal 2 (blue/white): 0Ω

2 1
4 3 CN3-D1 CN3-D2

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Viewed from the engagement side of connector

OK: Go to step 3. Viewed from the

NG: Repair or replace the harness. engagement
side of connector

OK: Replace the travel (L) controller.

NG: Repair or replace the harness.

7-76
 7. TROUBLESHOOTING

ERR30-8140: Abnormal CAN Transmission of Cargo Handling Controller

Content of Trouble
• Poor contact or short circuit of harness connector of cargo handling controller
• Abnormal cargo handling controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between cargo
1. Check visually that the connectors and terminals handling controller and travel (R) controller.
of cargo handling controller are not disconnected
or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-P terminal 8 (green) and
looseness of terminal. CN3-D1 terminal 9 (green): 0Ω
• Between CN3-P terminal 2 (blue) and
CN3-D1 terminal 3 (blue): 0Ω

CN3-D1 CN3-P

17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

Viewed from the

engagement
side of connector
OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Go to step 4.
2. In the state that connectors of all equipments are NG: Repair or replace the harness.
connected, measure the resistance at the termi- 4. Disconnect the harness and measure the resis-
nals of service tool. tance of CAN communication line between cargo
Judging: Between service tool terminal 2 (green) and handling controller and proportional solenoid
service tool terminal 3 (blue): 40 - 70Ω valve controller.
Judging:
• Between CN3-P terminal 9 (green/white) and
CN2S terminal 24 (green/white): 0Ω
Service Tool • Between CN3-P terminal 3 (blue/white) and
CN2S terminal 25 (blue/white): 0Ω
2 1
4 3
CN3-P CN2S

7 6 5 4 3 2 1
17 16 15 14 13 13 12 11 10 9 8
12 11 10 9 8 7 19 18 17 16 15 14
6 5 4 3 2 1 26 25 24 23 22 21 20
Viewed from the engagement side of connector

OK: Go to step 3.
NG: Repair or replace the harness.
Viewed from the engagement side of connector
B3Z16241
OK: Replace the cargo handling controller.
NG: Repair or replace the harness.

7-77
7. TROUBLESHOOTING

ERR34-8140: Abnormal CAN Transmission of Proportional Solenoid Valve Controller

Content of Trouble
• Poor contact or short circuit of harness connector of proportional solenoid valve controller
• Abnormal proportional solenoid valve controller

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and cargo
of proportional solenoid valve controller are not handling controller.
disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 24 (green/white) and
CN3-P terminal 9 (green/white): 0Ω
• Between CN2S terminal 25 (blue/white) and
CN3-P terminal 3 (blue/white): 0Ω

CN2S CN3-P

7 6 5 4 3 2 1
13 12 11 10 9 8 17 16 15 14 13
19 18 17 16 15 14 12 11 10 9 8 7
26 25 24 23 22 21 20 6 5 4 3 2 1

OK: Go to step 2. Viewed from the engagement side of connector

NG: Clean the connector with the contact restorer B3Z16242
and re-connect the connector.
OK: Replace the proportional solenoid valve control-
2. In the state that connectors of all equipments are ler.
connected, measure the resistance at the termi-
nals of service tool. NG: Repair or replace the harness.
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

Service Tool

2 1
4 3

Viewed from the engagement side of connector

OK: Go to step 3.
NG: Repair or replace the harness.

7-78
 7. TROUBLESHOOTING

ERR40-8140: Abnormal CAN Transmission of Meter Panel

Content of Trouble
• Poor contact or short circuit of harness connector of meter panel
• Abnormal meter panel

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between cargo
1. Check visually that the connectors and terminals handling controller and meter panel.
of meter panel are not disconnected or not loos-
ened. Judging:
Judging: No disconnection of connector and no • Between meter panel terminal 11 (green) and
looseness of terminal. CN3-D2 terminal 8 (green): 0Ω
• Between meter panel 9 (blue) and
CN3-D2 terminal 2 (blue): 0Ω

CN3-D2 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Replace the meter panel.
2. In the state that connectors of all equipments are NG: Repair or replace the harness.
connected, measure the resistance at the termi-
nals of service tool.
Judging: Between service tool terminal 2 (green) and
service tool terminal 3 (blue): 40 - 70Ω

Service Tool

2 1
4 3

Viewed from the engagement side of connector

OK: Go to step 3.
NG: Repair or replace the harness.

7-79
7. TROUBLESHOOTING

ERR40-8314: Abnormal CAN Communication between Travel (R) Controller and Meter Panel

Content of Trouble
• Poor contact or short circuit of harness connector of travel (R) controller and meter panel
• Abnormal travel (R) controller

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (R) controller and meter panel.
of travel (R) controller and meter panel are not dis-
connected or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D1 terminal 8 (green) and meter
looseness of terminal. panel terminal 11 (green): 0Ω
• Between CN3-D1 2 (blue) and
meter panel terminal 9 (blue): 0Ω

CN3-D1 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Replace the travel (R) controller.
NG: Repair or replace the harness.

7-80
 7. TROUBLESHOOTING

ERR40-8318: Abnormal CAN Communication between Travel (L) Controller and Meter Panel

Content of Trouble
• Poor contact or short circuit of harness connector of travel (L) controller and meter panel
• Abnormal travel (L) controller

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between travel
1. Check visually that the connectors and terminals (L) controller and meter panel.
of travel (L) controller and meter panel are not dis-
connected or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-D2 terminal 8 (green) and meter
looseness of terminal. panel terminal 11 (green): 0Ω
• Between CN3-D2 2 (blue) and
meter panel terminal 9 (blue): 0Ω

CN3-D2 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Replace the travel (L) controller.
NG: Repair or replace the harness.

7-81
7. TROUBLESHOOTING

ERR40-8330: Abnormal CAN Communication between Cargo Handling Controller and Meter
Panel

Content of Trouble
• Poor contact or short circuit of harness connector between cargo handling controller and meter panel
• Abnormal cargo handling controller

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between cargo
1. Check visually that the connectors and terminals handling controller and meter panel.
of cargo handling controller and meter panel are
not disconnected or not loosened. Judging:
Judging: No disconnection of connector and no • Between CN3-P terminal 8 (green) and meter
looseness of terminal. panel terminal 11 (green): 0Ω
• Between CN3-P 2 (blue) and
meter panel terminal 9 (blue): 0Ω

CN3-P Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Replace the cargo handling controller.
NG: Repair or replace the harness.

7-82
 7. TROUBLESHOOTING

ERR40-8334: Abnormal CAN Communication between Proportional Solenoid Valve

Controller and Meter Panel

Content of Trouble
• Poor contact or short circuit of harness connector between proportional solenoid valve controller and meter panel
• Abnormal proportional solenoid valve controller

Repair Procedure 2. Disconnect the harness and measure the resis-

tance of CAN communication line between pro-
1. Check visually that the connectors and terminals portional solenoid valve controller and meter
of proportional solenoid valve controller and meter panel.
panel are not disconnected or not loosened.
Judging:
Judging: No disconnection of connector and no
looseness of terminal. • Between CN2S terminal 24 (green/white) and
meter panel terminal 11 (green): 0Ω
• Between CN2S terminal 25 (blue/white) and
meter panel terminal 9 (blue): 0Ω

CN2S Meter Panel

7 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 12 11 10 9 8 7
19 18 17 16 15 14
26 25 24 23 22 21 20

OK: Go to step 2. Viewed from the engagement side of connector

NG: Clean the connector with the contact restorer B3Z16243
and re-connect the connector.
OK: Replace the proportional solenoid valve control-
ler.
NG: Repair or replace the harness.

7-83
7. TROUBLESHOOTING

ERR40-8510: Abnormal CAN Communication of Meter Panel After Turning ON the Key
Switch

Content of Trouble
• Abnormal communication after turning ON the key switch
• Poor contact or short circuit of harness connector of meter panel
• Abnormal meter panel

Repair Procedure 3. Disconnect the harness and measure the resis-

tance of CAN communication line between meter
1. Check visually that the connectors and terminals panel and travel (L) controller.
of meter panel are not disconnected or not loos-
ened. Judging:
Judging: No disconnection of connector and no • Between meter panel terminal 11 (green) and
looseness of terminal. CN3-D2 terminal 8 (green): 0Ω
• Between meter panel terminal 9 (blue) and
CN3-D2 terminal 2 (blue): 0Ω

CN3-D2 Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Go to step 2.
NG: Clean the connector with the contact restorer
and re-connect the connector. OK: Go to step 4.
2. In the state that connectors of all equipments are NG: Repair or replace the harness.
connected, measure the resistance at the termi- 4. Disconnect the harness and measure the resis-
nals of service tool. tance of CAN communication line at the meter
Judging: Between service tool terminal 2 (green) and panel side.
service tool terminal 3 (blue): 40 - 70Ω Judging: Between meter panel terminal 11 (green)
and meter panel terminal 9 (blue): 20 -
100kΩ

Service Tool

2 1 Meter Panel
4 3
1 2 3 4 5 6
7 8 9 10 11 12

Viewed from the engagement side of connector

OK: Go to step 3. Viewed from the engagement side of connector

NG: Repair or replace the harness.

OK: Replace the meter panel.
NG: Repair or replace the harness.

7-84
 7. TROUBLESHOOTING

DIAGNOSTIC PROCEDURE BY METER DISPLAY TROUBLE CODE

ERR-3001 (Travel R) ERR-3002 (Travel R)

Content of Trouble Content of Trouble
Breaking of main contactor Shorted main contactor
Blown-out fuse
Symptom of vehicle
Symptom of vehicle Inoperable travel/cargo handling/HPS
Inoperable travel/cargo handling/ HPS (The main contactor does not open.)
Retry of contactor turning-on process
Troubled set after retry of 5 times Repair Procedure
(The retry is continued after set.)
1. Check the connection of battery cable. (Check the
leaking of (+) potential to secondary voltage side
Repair Procedure
of contactor.)
1. Check the main contactor (foreign matters in the 2. Check the main contactor (foreign matters in the
contactor, mechanical interference). Repair or contactor, mechanical interference).
replace it. Repair or replace it.
2. Check and replace the fuse. 3. Disconnect the harness and check the harness
3. Disconnect the harness and check the harness between travel (R) controller and contactor coil.
between travel (R) controller and contactor coil. Repair or replace it.
Repair or replace it. Judging:
Judging: • Between CN1-D1 terminal 3 (black/white) and
• Between CN1-D1 terminal 3 (black/white) and contactor coil terminal 2: 0Ω
contactor coil terminal 2: 0Ω • Between CN1-D1 terminal 4 (black/white) and
• Between CN1-D1 terminal 4 (black/white) and contactor coil terminal 1: 0Ω
contactor coil terminal 1: 0Ω

Main Contactor
Main Contactor
CN1-D1
CN1-D1
22 23 24 25 26 27 28 29 30 31
22 23 24 25 26 27 28 29 30 31 10 11 12 13 14 15 16 17 18 19 20 21 1 2
10 11 12 13 14 15 16 17 18 19 20 21 1 2 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9

Viewed from the engagement side of connector

Viewed from the engagement side of connector
4. If normal in the above check, replace the travel
4. If normal in the above check, replace the travel (R) controller.
(R) controller.
How to reset
How to reset Turn OFF the key switch.
Turn OFF the key switch.
Remark
Remark None
In case of broken contactor, if succeeded in the try,
the error is reset.

7-85
7. TROUBLESHOOTING

ERR-3004 (Travel R) / ERR-3204 (Travel L) ALA-3005 (Travel R) / ALA-3205 (Travel L)

Content of Trouble Content of Trouble
The low voltage is detected. (Drop of battery voltage) Warning of incorrect teaching operation
• Incorrect steering direction of steering wheel
Symptom of vehicle • Incorrect steering amount of steering wheel
Inoperable travel/cargo handling/ HPS
(The main contactor is open.) Symptom of vehicle
Operable
Repair Procedure (Occurrence of defect of knob shift correction)
1. Measure the battery voltage. If necessary, re-
charge the battery. Repair Procedure
2. Check visually that the connectors and terminals 1. Perform the teaching operation in the normal pro-
of travel (R) controller and travel (L) controller are cedure.
not disconnected or not loosened.
2. Change the road condition and perform the teach-
3. Check the harness between 7 of connector CN- ing operation in the normal procedure again.
D1 of travel (R) controller and battery.
Check the harness between 7 of connector CN- 3. Measure the resistance of harness between the
D2 of travel (L) controller and battery. travel (R) controller and tire angle sensor.
Repair or replace it. Judging:
• Between CD2-D1 terminal 24 (red/blue) and
How to reset tire angle sensor terminal 3 (red/blue): 0Ω
Turn OFF the key switch. • Between CD2-D1 terminal 23 (yellow) and tire
angle sensor terminal 2 (yellow): 0Ω
Remark • Between CD2-D1 terminal 22 (black/yellow)
and tire angle sensor terminal 1 (black/yellow):
VB = lower than 28.2V / 800 rms: 48V specification 0Ω
(VB = lower than 21.2V /800 rms: 36V specification)
Lower than 15V / 30 ms detection

CN2-D1 Tire Angle Sensor

24 23 22 21 20 19 18 17 3 2 1
16 15 14 13 12 11 10 9 8
7 6 5 4 3 2 1

Viewed from engagement side of connector

4. Check and replace the tire angle sensor.

5. If normal in the above check, replace the travel
(R) controller.

How to reset
Turn OFF the key switch.

Remark
When warning, it functions in the initial setting value.
(Not memorized in the EEPROM)
The error appears in teaching when the rear tire is
locked or in teaching on the rough road where the
road friction is large.

7-86
 7. TROUBLESHOOTING

ERR-3010 (Travel R) / ERR-3210 (Travel L)

Content of Trouble 6. Measure the resistance between 8 and 9 of con-
nector CN1-D1 at the harness side of travel (R)
Travel controller
controller.
(The upper and lower FETs are shorted.)

Symptom of vehicle
Inoperable travel/cargo handling/HPS.
(The main contactor does not close.)
CN1-D1
Repair Procedure
1. Disconnect the battery connector and leave the 31 30 29 28 27 26 25 24 23 22
vehicle for 10 minutes. 21 20 19 18 17 16 15 14 13 12 11 10
2. Check visually that the copper bar connecting the 9 8 7 6 5 4 3 2 1
travel (R) controller, travel (L) controller and cargo
handling controller and their mounting bolts (P Viewed from engagement side of connector
and N terminals) are not shorted by foreign mat-
ters.
• 0Ω or cΩ:
3. Check visually that the U, V and W terminals are Repair or replace the quick charging resistor con-
not shorted by foreign matters. nection cable and resistor.
4. Remove the copper bars connecting the control- • About 39Ω:
lers and measure shorting between P and N termi- Replace the travel (R) controller.
nals of controller with the tester. 7. If normal in the above check, replace the travel
• Shorted: Replace the shorted controller. (R) controller or travel (L) controller.
• Not shorted: Check the next item.
5. Measure the resistance between the EMG switch How to reset
harness and the travel (R), travel (L) and cargo Turn OFF the key switch.
handling harnesses respectively.
Judging: Remark
• Between EMG switch harness terminal 2 (red/ As the travel (R), travel (L) and cargo handling are
white) and CN1-D1 terminal 7 (red/white): 0Ω connected via fuses, the trouble code 5010 (shorted
• Between EMG switch harness terminal 2 (red/ cargo controller) appears. If the controller is shorted,
white) and CN1-D2 terminal 7 (red/white): 0Ω the trouble code 3016 (quick charge error) appears
• Between EMG switch harness terminal 2 (red/ as the capacitor between P and N cannot be
white) and CN1-P terminal 7 (red/white): 0Ω charged.

Quick Check
CN1-D1 Error codes 3010, 3210, 5010 are detected at same
31 30 29 28 27 26 25 24 23 22 time.
4 3
2 1
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
Measure the resistance (+) and (minus) terminal of
travel controller (L), travel controller (R), and cargo
Body EMG CN1-D2 handling controller.
31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10
(If one of controller is defective, resistance becomes
9 8 7 6 5 4 3 2 1 0 kΩ)
CN1-P
31 30 29 28 27 26 25 24 23 22

Viewed from engagement 21 20 19 18 17 16 15 14 13 12 11 10

9 8 7 6 5 4 3 2 1
side of connector

OK: Check the next item.

NG: Repair or replace the harness.

7-87
7. TROUBLESHOOTING

ERR-3011 (Travel R) / ERR-3211 (Travel L) ERR-3013 (Travel R) / ERR-3213 (Travel L)

ERR-3012 (Travel R) / ERR-3212 (Travel L) ERR-3014 (Travel R) / ERR-3214 (Travel L)
ERR-3015 (Travel R) / ERR-3215 (Travel L)
Content of Trouble Content of Trouble
Travel Controller (The upper side is shorted.) Travel controller (Breaking of U phase wire) (3013,
(3011, 3211) 3213)
Travel Controller (The lower side is shorted.) Travel controller (Breaking of V phase wire) (3014,
(3012, 3212) 3214)
Travel controller (Breaking of W phase wire) (3015,
3215)
Symptom of vehicle
Unable to travel Symptom of vehicle
Unable to travel
Repair Procedure
1. Disconnect the battery connector and leave the Repair Procedure
vehicle for 10 minutes.
1. Disconnect the battery connector and leave the
2. Disconnect the motor cable from the U, V and W vehicle for 10 minutes.
terminals and measure with the tester between
the motor cable and P terminal and between 2. Check the loosened cable tightening at the motor
motor cable and N terminal. If leaked, remove or terminal and the breaking of cable.
repair. 3. Remove the cable from the motor terminal and
3. Confirm that no foreign matters exist on the P and check the breaking of wire between phases.
N terminals and around the U, V and W terminals. Between U and V phases, Between V and W
(Check visually foreign matters on the CPU phases, Between W and U phases
board.) (The resistance between phases of motor is nor-
mally several tens mΩ.)
4. Confirm that the motor cables are correctly con-
nected to the U, V and W terminals of motor. • Breaking of wire: Replace the motor.
(The cables should be connected to the right and • Normal: Return the cables to the original termi-
left terminals without error.) nals. Be careful not to misconnect the cables at
the right and left terminal.
5. Check the travel (R) controller, travel (L) controller
and cargo handling controller. If abnormal, replace 4. Prepare for removing the travel (R) controller and
it. (Replace the CPU board at the same time.) travel (L) controller.
6. If normal in the above check, replace the travel 5. Swap the travel (R) controller and travel (L) con-
(R) controller or travel (L) controller. troller. At this moment, ensure to set the select
switch in the travel controller.
How to reset 6. To apply the power, return the wiring of travel (R)
Turn OFF the key switch. controller, travel (L) controller, cargo handling con-
troller and proportional solenoid valve controller
again.
Remark
7. After connecting the battery connector, be seated
Check the cable between motor and vehicle. on the seat and turn ON the key switch.
Check the leakage of rain-water.
Check foreign matters on the CPU. 8. Confirm that the error code issuing controller is
displayed on the same position (right or left).
• Displayed on the same position:
Loosened motor and motor wiring
• Displayed on the different position:
Replace the error issuing controller.

How to reset
Turn OFF the key switch.

Remark
None

7-88
 7. TROUBLESHOOTING

ERR-3016 (Travel R) ALA-3021 (Travel R) / ALA-3221 (Travel L)

Content of Trouble Content of Trouble
Defect of quick charging Travel Controller (Temperature Rise)
(Defect of charging the capacitor between P and N)
Symptom of vehicle
Symptom of vehicle Unable to travel
Inoperable travel/cargo handling/HPS. The warning is detected over 108°C [226°F].
(The main contactor does not close.) The warning is released below 105°C [221°F].
The current cut-off works over 105°C [221°F].
Repair Procedure
Repair Procedure
1. Check the repair method of trouble codes 3010
and 3210. 1. When heavily loaded or operated continuously,
2. Check the repair method of trouble code 5010. stop the vehicle to cool down the controller.

3. If normal in the above checks, replace the travel 2. When normally traveling, if the alarm occurs in a
(R) controller. short period of time, check ERR-3021 and ERR-
3022.
How to reset
How to reset
Turn OFF the key switch.
Can be recovered below 105°C [221°F].
Remark
Remark
The trouble codes of 3010, 3210 and 5010 also
appear. Resistance / voltage of temperature sensor in the
(About 15 seconds later, they are displayed as the normal condition:
capacitor between P and N cannot be charged.) 25°C [77°F]: 100kΩ / 3.2V (± 10%)
50°C [122°F]: 36kΩ / 2.0V (± 10%)
75°C [167°F]: 15kΩ / 1.0V (± 10%)
100°C [212°F]: 6.5kΩ / 0.5V (± 10%)
Check the insufficient cooling caused by malfunction-
ing fan.

7-89
7. TROUBLESHOOTING

ERR-3021 (Travel R) / ERR-3221 (Travel L) ALA-3031 (Travel R) / ALA-3231 (Travel L)

Content of Trouble Content of Trouble
Travel Controller (Abnormal Temperature) Travel Controller (Temperature Rise)

Symptom of vehicle Symptom of vehicle

Unable to travel Unable to travel
The error is detected over 130°C [266°F]. The warning is detected over 163°C [325°F].
The error is released below 130°C [266°F]. The warning is released below 160°C [320°F].
The current cut-off works over 160°C [320°F].
Repair Procedure
Repair Procedure
1. Stop the vehicle and cool down the controller.
2. Check the mounting of travel controller. (Loose- 1. When heavily loaded or operated continuously,
ness) stop the vehicle to cool down the travel motor.
3. Check the harnesses between the power module 2. When normally traveling, if the alarm occurs in a
temperature sensor and the terminals 10 and 11 short period of time, check ERR-3021 and
of connector CN2G on the CPU board respec- ERR-3022.
tively. Repair or replace.
How to reset
4. Disconnect the harness and measure the resis-
tance / voltage of temperature sensor. If abnormal, Can be recovered below 160°C [320°F].
replace the power module.
5. Check the fan. Repair or replace it. Remark
6. If normal in the above checks, replace the travel Resistance / voltage of travel motor temperature sen-
(R) controller or travel (L) controller as the error sor in normal condition
arises from the controller. 25°C [77°F]: 10.7kΩ / 3.5V (± 10%)
50°C [122°F]: 4.4kΩ / 2.4V (± 10%)
How to reset 100°C [167°F]: 1.0kΩ / 0.9V (± 10%)
150°C [212°F]: 0.3kΩ / 0.3V (± 10%)
Lower the temperature below 130°C [266°F] and turn
OFF the key switch.

Remark
Resistance / voltage of temperature sensor in the
normal condition
25°C [77°F]: 100kΩ / 3.2V (± 10%)
50°C [122°F]: 36kΩ / 2.0V (± 10%)
75°C [167°F]: 15kΩ / 1.0V (± 10%)
100°C [212°F]: 6.5kΩ / 0.5V (± 10%)
Check the insufficient cooling caused by malfunction-
ing fan.

7-90
 7. TROUBLESHOOTING

ERR-3031 (Travel R) / ERR-3231 (Travel L)

Content of Trouble 3. Measure the resistance/voltage of right or left
travel motor temperature sensor. Replace it.
Travel Motor (Abnormal Temperature)
4. (Check at the terminals 20 and 29 of connector
Symptom of vehicle CN1-D1 and check at the terminals 20 and 29 of
CN1-D2 of controller.)
Unable to travel
The error is detected over 175°C [347°F]. 5. If normal in the above check, replace the travel
The error is released below 175°C [347°F]. (R) controller or travel (L) controller.

Repair Procedure How to reset

Lower the temperature below 170°C [338°F] and turn
1. Stop the vehicle and cool down the travel motor.
OFF the key switch.
2. Measure the resistance of harness between travel
(R) controller and (right or left) travel motor tem- Remark
perature sensor and the resistance of harness
between travel (L) controller and (right or left) Resistance / voltage of travel motor temperature sen-
travel motor temperature sensor. sor in normal condition
Judging: 25°C [77°F]: 10.7kΩ / 3.5V (± 10%)
50°C [122°F]: 4.4kΩ / 2.4V (± 10%)
• Between CN-D1 terminal 20 (yellow/green) and
100°C [167°F]: 1.0kΩ / 0.9V (± 10%)
right travel motor temperature sensor terminal
150°C [212°F]: 0.3kΩ / 0.3V (± 10%)
1 (yellow/green): 0Ω
• Between CN-D1 terminal 29 (yellow/black) and
right travel motor temperature sensor terminal
2 (yellow/black): 0Ω
• Between CN-D2 terminal 20 (green/red) and
left travel motor temperature sensor terminal 1
(green/red): 0Ω
• Between CN-D2 terminal 29 (green/red) and
left travel motor temperature sensor terminal 2
(green/red): 0Ω

Right or left
CN1-D1 CN1-D2 travel motor
speed sensor

31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.

7-91
7. TROUBLESHOOTING

ERR-3030 (Travel R) / ERR-3230 (Travel L) ERR-3050 (Travel R) / ERR-3250 (Travel L)

Content of Trouble Content of Trouble
Short circuit between phases of travel motor. Defective travel controller temperature sensor.
(The load is shorted.)
Symptom of vehicle
Symptom of vehicle The vehicle can travel normally.
Unable to travel • Operative in the normal temperature
• Fan drive
Repair Procedure
1. Disconnect the battery connector and leave the Repair Procedure
vehicle for 10 minutes.
As the error arises from the controller, replace the
2. Check visually that foreign matters do not exist travel (R) controller or travel (L) controller.
around the U, V and W terminals of travel control-
ler. How to reset
3. Perform the short circuit test of motor cables. When recovered to the normal condition, the error
(broken cladding, entry of foreign matters). codes are reset.
4. Swap the right and left cables and turn ON the key
switch. Then, check the error code. Remark
• The short display is swapped: When the abnormality is detected, the voltage of
Repair or replace the motor or cable. temperature sensor is lower than 0.2V or higher than
• The short display remains unchanged: 4.95V.
Repair or replace the defective controller.

How to reset
Turn ON the key switch.

Remark
As a resistor of several ten mΩ is connected
between phases of motor, it cannot be checked with
the tester.

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 7. TROUBLESHOOTING

ERR-3051 (Travel R) / ERR-3251 (Travel L)

Content of Trouble 3. Measure the resistance / voltage of travel motor
temperature sensor. Replace it.
Defective travel motor temperature sensor
4. If normal in the above check, replace the travel
Symptom of vehicle (R) controller or travel (L) controller.

• The vehicle can travel normally.

How to reset
• Operative in the normal temperature
When recovered to the normal condition, the error
code is reset.
Repair Procedure
1. Confirm that the temperature sensor connector of Remark
right or left travel motor is firmly connected.
When the abnormality is detected, the voltage of
2. Measure the resistance of harness between travel travel motor temperature sensor is lower than 0.2V
(R) controller and (right or left) travel motor tem- or higher than 4.95V.
perature sensor and the resistance of harness
between travel (L) controller and (right or left)
travel motor temperature sensor
Judging:
• Between CN-D1 terminal 20 (yellow/green) and
right travel motor temperature sensor
terminal 1 (yellow/green): 0Ω
• Between CN-D1 terminal 29 (yellow/black) and
right travel motor temperature sensor
terminal 2 (yellow/black): 0Ω
• Between CN-D2 terminal 20 (green/red) and
right travel motor temperature sensor terminal
1 (green/red): 0Ω
• Between CN-D2 terminal 29 (green/red) and
right travel motor temperature sensor terminal
2 (green/red): 0Ω

Right or left
CN1-D1 CN1-D2 travel motor
speed sensor

31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.

7-93
7. TROUBLESHOOTING

ERR-3052 (Travel R) / ERR-3252 (Travel L) ERR-3053 (Travel R)

Content of Trouble Content of Trouble
The output of travel current sensor (U phase, W Defective travel accelerator.
phase) is defective. Abnormal accelerator switch.

Symptom of vehicle Symptom of vehicle

Unable to travel Unable to travel

Repair Procedure Repair Procedure

1. Confirm that foreign matters do not exist around 1. Confirm that the connectors and terminals of
the current sensor on the CPU. accelerator are not disconnected or not loosened.
2. If normal in the above check, replace the travel 2. Check the resistance of harness between travel
(R) controller or travel (L) controller. (R) controller and accelerator.
Judging:
How to reset
• Between CN-D1 terminal 16 (red) and
Turn ON the key switch. accelerator terminal 6 (red): 0Ω
• Between CN-D1 terminal 21 (black) and
Remark accelerator terminal 1 (black): 0Ω
Check visually the current sensor. If it is abnormal, • Between CN-D1 terminal 30 (green) and
replace the travel controller. accelerator terminal 3 (green): 0Ω
• Between CN-D1 terminal 31 (yellow) and
accelerator terminal 2 (yellow): 0Ω

CN1-D1 Accelerator

31 30 29 28 27 26 25 24 23 22 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 6 5 4
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Replace the travel (R) controller.

NG: Repair or replace the harness.

How to reset
Turn OFF the key switch.

Remark
The voltage of accelerator in the normal condition
• When stepping on the accelerator: 0V
• When releasing the accelerator: about 4.6V

7-94
 7. TROUBLESHOOTING

ERR-3054 (Travel R)
Content of Trouble
Defective tire angle sensor
(The detection angle is abnormal.)

Symptom of vehicle
Unable to travel (It works as a tire center.)

Repair Procedure
1. Confirm that the connectors and terminals of tire
angle sensor are not disconnected or not loos-
ened.
2. Check the resistance of harness between travel
(R) controller and tire angle sensor.
Judging:
• Between CN2-D1 terminal 22 (black/yellow)
and tire angle sensor terminal 1 (black/yellow):
0Ω
• Between CN2-D1 terminal 23 (yellow) and
tire angle sensor terminal 2 (yellow): 0Ω
• Between CN2-D1 terminal 24 (red/blue) and
tire angle sensor terminal 3 (red/blue): 0Ω

CN2-D1 Tire Angle Sensor

24 23 22 21 20 19 18 17 3 2 1
16 15 14 13 12 11 10 9 8
7 6 5 4 3 2 1

Viewed from engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.
3. Check and replace the tire angle sensor.
4. If normal in the above check, replace the travel
(R) controller.

How to reset
When returned to the normal condition, the error
code is reset.

Remark
When abnormal, the swing control and knob shift cor-
rection do not work.

7-95
7. TROUBLESHOOTING

ERR-3056 (Travel R) / ERR-3256 (Travel L)

Content of Trouble 3. Check the right (or left) travel motor speed sensor
phase A. Repair or replace it.
Travel motor speed sensor
(The A phase output is abnormal.) 4. Check the gear of travel motor (poor mesh of gear
with sensor, entry of magnetic substance). Repair
Symptom of vehicle or replace the motor.

Unable to travel 5. If normal in the above check, replace the travel

(R) controller or travel (L) controller.
Repair Procedure
How to reset
1. Confirm that the connectors and terminals of right
When returned to the normal state, the error code is
(or left) travel motor speed sensor A phase are not
reset.
disconnected or not loosened.
2. Measure the resistance of harness between the Remark
travel (R) controller and right (or left) travel motor
speed sensor A phase and the resistance of har- Voltage at terminal in the normal state
ness between the travel (L) controller and right (or Terminal 14: When the key switch is turned ON, it is
left) travel motor speed sensor A phase. about 13.5V.
Judging: Terminal 13: When the key switch is turned ON
• Between CN1-D1 terminal 13 (white) and (stop), it is 1.3 - 3.3V.
right travel motor speed sensor A terminal 1 Terminal 13: When the key switch is turned ON
(white): 0Ω (operating), it is about 2.3V.
• Between CN1-D1 terminal 14 (black) and (Average voltage when the motor is rotating.)
right travel motor speed sensor A terminal 2
(black): 0Ω
• Between CN1-D2 terminal 13 (white) and
left travel motor speed sensor A terminal 1
(white): 0Ω
• Between CN1-D2 terminal 14 (black) and
left travel motor speed sensor A terminal 2
(black): 0Ω

Right or left
CN1-D1 CN1-D2 travel motor
speed sensor A

31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.

7-96
 7. TROUBLESHOOTING

ERR-3057 (Travel R) / ERR-3257 (Travel L)

Content of Trouble 3. Check the right (or left) travel motor speed sensor
phase B. Repair or replace it.
Travel motor speed sensor
(The B phase output is abnormal.) 4. Check the gear of travel motor (poor mesh of gear
with sensor, entry of magnetic substance). Repair
Symptom of vehicle or replace the motor.

Unable to travel 5. If normal in the above check, replace the travel

(R) controller or travel (L) controller.
Repair Procedure
How to reset
1. Confirm that the connectors and terminals of right
When returned to the normal state, the error code is
(or left) travel motor speed sensor B phase are not
reset.
disconnected or not loosened.
2. Measure the resistance of harness between the Remark
travel (R) controller and right (or left) travel motor
speed sensor A phase and the resistance of har- Voltage at terminal in the normal state
ness between the travel (L) controller and right (or Terminal 28: When the key switch is turned ON, it is
left) travel motor speed sensor A phase. about 13.5V.
Judging: Terminal 27: When the key switch is turned ON
• Between CN1-D1 terminal 27 (white) and (stop), it is 1.3 - 3.3V.
right travel motor speed sensor B terminal 1 Terminal 27: When the key switch is turned ON
(white): 0Ω (operating), it is about 2.3V.
• Between CN1-D1 terminal 28 (black) and (Average voltage when the motor is rotating.)
right travel motor speed sensor B terminal 2
(black): 0Ω
• Between CN1-D2 terminal 27 (white) and
left travel motor speed sensor B terminal 1
(white): 0Ω
• Between CN1-D2 terminal 28 (black) and
left travel motor speed sensor B terminal 2
(black): 0Ω

Right or left
CN1-D1 CN1-D2 travel motor
speed sensor A

31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.

7-97
7. TROUBLESHOOTING

ERR-3061 (Travel R) ERR-3062 (Travel R)

Content of Trouble Content of Trouble
Defective FR direction switch Defective logic of seat switch _a and seat switch _b

Symptom of vehicle Symptom of vehicle

Unable to travel Inoperable travel/cargo handling/HPS

Repair Procedure Repair Procedure

1. Measure the resistance of harness between travel 1. Measure the resistance of harness between travel
(R) controller and FR direction switch. (R) controller and seat switch.
Judging: Between CN1-D1 terminal 2 (blue) and FR Judging:
direction switch 2 (blue): 0Ω • Between CN1-D1 terminal 19 (blue/red) and
seat switch terminal 2 (blue/red): 0Ω
• Between CN2-D1 terminal 18 (red/black) and
seat switch terminal 3 (red/black): 0Ω
CN1-D1 Direction Switch

CN1-D1 Seat Switch

31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 3 2 1
31 30 29 28 27 26 25 24 23 22
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 1 2 3
9 8 7 6 5 4 3 2 1

Viewed from the engagement of connector

24 23 22 21 20 19 18 17
CN2-D1
OK: Check the next item. 16 15 14 13 12 11 10 9 8
NG: Repair or replace the harness. 7 6 5 4 3 2 1 Viewed from the engagement
side of connector
2. Check the FR direction switch. Repair or replace
it. OK: Check the next item.
3. If normal in the above check, replace the travel NG: Repair or replace the harness.
(R) controller. 2. Check the seat switch. Repair or replace it.
3. If normal in the above check, replace the travel
How to reset (R) controller.
When returned to the normal state, the error code is
reset. How to reset
When returned to the normal state, the error code is
Remark reset.
When DSF SW and DSR SW are turned on simulta-
neously, it is detected. Remark
When turning ON the seat switch _a and seat switch
_b, it is detected.
When turning OFF the seat switch _a and seat
switch _b, it is detected.

7-98
 7. TROUBLESHOOTING

ERR-3082 (Travel R) / ERR-3084 (Travel R) ERR-5004 (Cargo Handling)

ERR-3281 (Travel L) / ERR-3284 (Travel L)
Content of Trouble
Content of Trouble The low voltage is detected.
Abnormal CAN communication (Breaking of commu- (Drop of battery voltage)
nication line between travel (R) and travel (L))
Symptom of vehicle
Symptom of vehicle Inoperable travel/cargo handling/ HPS
• Inoperable travel/cargo handling/HPS (The main contactor is open.)
(In case of occurrence when the key switch is turned
OFF) Repair Procedure
• Unable to travel 1. Measure the battery voltage.
(In case of occurrence when the key switch is turned If necessary, re-charge the battery.
ON)
2. Check visually that the connectors and terminals
of cargo handling controller are not disconnected
Repair Procedure or not loosened.
1. Confirm that the connectors CN3-D1 and CN4-D2 3. Check the harness between battery and terminal
and terminals of travel (R) controller and travel (L) 7 of connector CN1-P of cargo handling controller.
controller are not disconnected and not loosened.
2. Check the CN3-D1 and CN3-D2 harnesses How to reset
between each inverter. Repair or replace it. Turn OFF the key switch.
3. Check and correct the DIP switch settings of each
controller. Remark
4. If normal in the above check, replace the travel VB = lower than 28.2V / 800 rms: 48V specification
(R) controller or travel (L) controller. (VB = lower than 21.2V /800 rms: 36V specification)
Lower than 15V / 30 ms detection
How to reset
Turn OFF the key switch.

Remark
None

7-99
7. TROUBLESHOOTING

ALA-5005 (Cargo Handling)

Content of Trouble How to reset
Warning of incorrect teaching operation Turn OFF the key switch.
(Incorrect steering speed of steering wheel or incor-
rect steering wheel knob position) Remark
When warning, it functions in the initial setting value.
Symptom of vehicle (Not memorized in the EEPROM)
Operable The error appears in teaching when the rear tire is
locked or in teaching on the rough road where the
Repair Procedure road friction is large.
1. Perform the teaching operation in the normal pro-
cedure.
2. Change the road condition and perform the teach-
ing operation in the normal procedure again.
3. Measure the resistance of harness between the
cargo handling controller and steering wheel
angle sensor.
Judging:
• Between CN2-P terminal 14 (blue/yellow) and
steering wheel angle terminal 6 (blue/yellow):
0Ω
• Between CN2-P terminal 15 (green/red) and
steering wheel angle sensor terminal 5 (green/
red): 0Ω
• Between CN3-P terminal 5 (red) and steering
wheel angle sensor terminal 1 (red): 0Ω

Steering Wheel
CN2-P Angle Sensor

24 23 22 21 20 19 18 17 4 3 2 1
16 15 14 13 12 11 10 9 8 8 7 6 5
7 6 5 4 3 2 1

17 16 15 14 13 CN3-P
12 11 10 9 8 7
6 5 4 3 2 1 Viewed from engagement
side of connector

OK: Check the next item.

NG: Repair or replace the harness.
4. Check the steering wheel angle sensor and
replace it.
5. If normal in the above check, replace the cargo
handling controller.

7-100
 7. TROUBLESHOOTING

ERR-5010 (Cargo Handling)

Content of Trouble 6. Measure the resistance between 8 and 9 of con-
nector CN1-D1 at the harness side of travel (R)
Cargo handling controller
controller.
(The upper and lower FETs are shorted.)

Symptom of vehicle
Inoperable travel/cargo handling/HPS
(The main contactor does not close.)
CN1-D1
Repair Procedure
1. Disconnect the battery connector and leave the 31 30 29 28 27 26 25 24 23 22
vehicle for 10 minutes. 21 20 19 18 17 16 15 14 13 12 11 10
2. Check visually that the copper bar connecting the 9 8 7 6 5 4 3 2 1
travel (R) controller, travel (L) controller and cargo
handling controller and their mounting bolts (P Viewed from engagement side of connector
and N terminals) are not shorted by foreign mat-
ters.
• 0Ω or cΩ:
3. Check visually that the U, V and W terminals are Repair or replace the quick charging resistor
not shorted by foreign matters. connection cable and resistor.
4. Remove the copper bars connecting the control- • About 39Ω:
lers and measure shorting between P and N termi- Replace the travel (R) controller.
nals of controller with the tester. 7. If normal in the above check, replace the travel
• Shorted: Replace the shorted controller. (R) controller or travel (L) controller.
• Not shorted: Check the next item.
5. Perform the conduction test of harness connecting How to reset
between EMG switch harness and travel (R), Turn OFF the key switch.
travel (L) and cargo handling harnesses respec-
tively. Remark
Judging:
As the travel (R), travel (L) and cargo handling are
• Between contactor harness F terminal (orange) connected via fuses, the trouble codes 3010 and
and CN1-D1 terminal 7 (red/white): 0Ω 3210 (shorted travel controller) appear. If the control-
• Between contactor harness F terminal (orange) ler is shorted, the trouble code 3016 (quick charge
and CN1-D2 terminal 7 (red/white): 0Ω error) appears as the capacitor between P and N
• Between contactor harness F terminal (orange) cannot be charged.
and CN1-P terminal 7 (red/white): 0Ω
Quick Check
Error codes 3010, 3210, 5010 are detected at same
time.
Measure the resistance (+) and (minus) terminal of
travel controller (L), travel controller (R), and cargo
handling controller.
H F (If one of controller is defective, resistance becomes
31 30 29 28 27 26 25 24 23 22 G E 0kΩ)
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1

CN1-D1 CN1-D2 CN1-P

Viewed from the engagement side of connector

B3Z16244

OK: Check the next item.

NG: Repair or replace the harness.

7-101
7. TROUBLESHOOTING

ERR-5011 (Cargo Handling) ERR-5013 (Cargo Handling)

ERR-5012 (Cargo Handling) ERR-5014 (Cargo Handling)
ERR-5015 (Cargo Handling)
Content of Trouble
Cargo Handling Controller (The upper side is Content of Trouble
shorted.) Cargo handling controller (Breaking of U phase wire)
Cargo Handling Controller (The lower side is Cargo handling controller (Breaking of V phase wire)
shorted.) Cargo handling controller (Breaking of W phase wire)

Symptom of vehicle Symptom of vehicle

Unable to handle the cargo Unable to handle the cargo

Repair Procedure Repair Procedure

1. Disconnect the battery connector and leave the 1. Disconnect the battery connector and leave the
vehicle for 10 minutes. vehicle for 10 minutes.
2. Disconnect the motor cables from the U, V and W 2. Check the loosened cable tightening at the motor
terminals and measure with the tester between terminal and the breaking of cable.
the motor cable and P terminal and between
motor cable and N terminal. If leaked, remove or 3. Remove the cables from the motor terminal and
repair it. check the breaking of wire between phases.
Between U and V phases
3. Confirm that no foreign matters exist on the P and Between V and W phases
N terminals and around U, V and W terminals. Between W and U phases
(Check visually foreign matters on the CPU (The resistance between phases of motor is nor-
board.) mally several tens mΩ.)
4. Confirm that the motor cables are correctly con- • Breaking of wire: Replace the motor.
nected to the U, V and W terminals of motor.
(The cables should be connected to the right and • Normal: Replace the cargo handling controller.
left terminals without error.)
How to reset
5. Check the travel (R) controller, travel (L) controller
and cargo handling controller. If abnormal, replace Turn OFF the key switch.
it. (Replace the CPU board at the same time.)
6. If normal in the above check, replace the cargo Remark
handling controller. None

How to reset
Turn OFF the key switch.

Remark
Check between motor cable and vehicle cable.
Check for leakage of rainwater.
Check for foreign matter on the CPU.

7-102
 7. TROUBLESHOOTING

ALA-5021 (Cargo Handling)

Content of Trouble
Cargo Handling Controller (Temperature Rise)

Symptom of vehicle
Unable to handle the cargo
The warning is detected over 108°C [226°F].
The warning is released below 105°C [221°F].
The current cut-off works over 105°C [221°F].

Repair Procedure
1. When heavily loaded or operated continuously,
stop the vehicle to cool down the controller.
2. When normally traveling, if the alarm occurs in a
short period of time, check ERR-5021.

How to reset
When recovered below 105°C [221°F].

Remark
Resistance / voltage of temperature sensor in the
normal condition
25°C [77°F]: 100kΩ / 3.2V (± 10%)
50°C [122°F]: 36kΩ / 2.0V (± 10%)
75°C [167°F]: 15kΩ / 1.0V (± 10%)
100°C [212°F]: 6.5kΩ / 0.5V (± 10%)
Check the insufficient cooling caused by malfunction-
ing fan.

7-103
7. TROUBLESHOOTING

ERR-5021 (Cargo Handling)

Content of Trouble How to reset
Cargo Handling Controller (Abnormal Temperature) Lower the temperature below 130°C [266°F] and turn
OFF the key switch.
Symptom of vehicle
Unable to handle the cargo Remark
The error is detected over 130°C [266°F]. Resistance / voltage of temperature sensor in the
The error is released below 130°C [266°F]. normal condition
25°C [77°F]: 100kΩ / 3.2V (± 10%)
Repair Procedure 50°C [122°F]: 36kΩ / 2.0V (± 10%)
75°C [167°F]: 15kΩ / 1.0V (± 10%)
1. Stop the vehicle and cool down the controller.
100°C [212°F]: 6.5kΩ / 0.5V (± 10%)
2. Check the mounting of cargo handling controller. Check the insufficient cooling caused by malfunction-
(Looseness) ing fan.
3. Check the harness between the power module
temperature sensor and the terminals 10 and 11
of connector CN2G on the CPU board. Repair or
replace.
4. Disconnect the harness and measure the resis-
tance / voltage of temperature sensor. If abnormal,
replace the power module.
5. Measure the resistance of harness between the
connector CN2-D1 of travel (R) controller and the
fan connection.
Judging: Between CN2-D1 terminal 3 (black) and fan
connection harness terminal 2 (black): 0Ω

CN2-D1 Cooling
Fan

24 23 22 21 20 19 18 17 2 1
16 15 14 13 12 11 10 9 8
7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.
6. Check the fan. Repair or replace it.
7. If normal in the above check, replace the cargo
handling controller.

7-104
 7. TROUBLESHOOTING

ALA-5031 (Cargo Handling) ERR-5030 (Cargo Handling)

Content of Trouble Content of Trouble
Pump Motor (Temperature Rise) Short circuit between phases of pump motor
(The load is shorted.)
Symptom of vehicle
Unable to handle the cargo Symptom of vehicle
The warning is detected over 163°C [325°F]. Unable to handle the cargo
The warning is released below 160°C [320°F].
The current cut-off works over 160°C [320°F]. Repair Procedure
1. Disconnect the battery connector and leave the
Repair Procedure
vehicle for 10 minutes.
1. When heavily loaded or used continuously, stop 2. Check visually that foreign matters do not exist
the vehicle to cool down the pump motor. around the U, V and W terminals of cargo han-
2. When normally traveling, if the alarm occurs in a dling controller.
short period of time, check ERR-5031. 3. Check short circuiting between motor cables (bro-
ken cladding, entry of foreign matters).
How to reset
4. Remove the cargo handling motor cable from the
Can be recovered below 160°C. cargo handling controller. Insulate the ends of
cargo handling cable with the insulation tape to
Remark prevent the interference with other controller, “+”
polarity and “-” polarity.
Resistance / voltage of travel motor temperature sen-
sor in normal condition 5. To apply the power, return the wiring of propor-
tional solenoid valve controller.
25°C [77°F]: 10.7kΩ / 3.5V (± 10%)
50°C [122°F]: 4.4kΩ / 2.4V (± 10%) 6. After connecting the battery connector, be seated
100°C [212°F]: 1.0kΩ / 0.9V (± 10%) on the seat and turn ON the key switch.
150°C [267°F]: 0.3kΩ / 0.3V (± 10%) Confirm that the error code 5030 goes off.
• It goes off: Replace the cargo handling motor.
• It does not go off: Replace the cargo handling
controller.

How to reset
Turn ON the key switch.

Remark
As a resistor of several ten mΩ is connected
between phases of motor, it cannot be checked with
the tester.

7-105
7. TROUBLESHOOTING

ERR-5031 (Cargo Handling)

Content of Trouble How to reset
Pump Motor (Abnormal Temperature) Lower the temperature below 175°C [347°F] and turn
OFF the key switch.
Symptom of vehicle
Unable to handle the cargo Remark
The error is detected over 175°C [347°F]. Resistance / voltage of travel motor temperature sen-
The error is released below 175°C [347°F]. sor in normal condition
25°C [77°F]: 10.7kΩ / 3.5V (± 10%)
Repair Procedure 50°C [122°F]: 4.4kΩ / 2.4V (± 10%)
100°C [212°F]: 1.0kΩ / 0.9V (± 10%)
1. Stop the vehicle and cool down the pump motor.
150°C [267°F]: 0.3kΩ / 0.3V (± 10%)
2. Measure the resistance of harness between the
cargo handling controller and the pump motor
temperature sensor.
Judging:
• Between CN1-P terminal 20 (yellow/green) and
pump motor temperature sensor terminal 1
(yellow/green): 0Ω
• Between CN1-P terminal 29 (yellow/black) and
pump motor temperature sensor terminal 2
(yellow/black): 0Ω

Pump motor
CN1-P temperature sensor

31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 1 2
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.
3. Measure the resistance / voltage of pump motor
temperature sensor.
(Check at the terminals 20 and 29 of CN1-P con-
nector of controller.)
4. If normal in the above check, replace the cargo
handling controller.

7-106
 7. TROUBLESHOOTING

ERR-5040 (Cargo Handling) ERR-5050 (Cargo Handling)

Content of Trouble Content of Trouble
Abnormal input range of proportional solenoid valve Defective cargo handling controller temperature sen-
controller sor

Symptom of vehicle Symptom of vehicle

Driven by the cargo handling 100% directive The normal cargo handling is possible.
• Operated in the normal temperature
Repair Procedure • Fan drive
1. Confirm that proportional solenoid valve controller
connector is firmly connected. Repair Procedure
2. Measure the resistance of harness between 1. Confirm the insertion of module temperature sen-
cargo handling controller and proportional sole- sor connector and connector CN2G in the CPU
noid valve controller. board.
Judging: 2. Check the harness between the temperature sen-
• Between CN1-P terminal 30 (yellow) and CN2S sor and terminal 10 and 11 of connector CN2G on
terminal 11 (yellow): 0Ω the CPU board. Repair or replace it.
• Between CN1-P terminal 31 (green) and CN2S 3. Remove the harness and confirm the resistance /
terminal 12 (green): 0Ω voltage of temperature sensor. If abnormal,
replace the power module.
4. If normal, replace the cargo handling controller.

How to reset
When returned to the normal state, the error code is
CN1-P CN2S reset.
31 30 29 28 27 26 25 24 23 22
7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
13 12 11 10 9 8 Remark
9 8 7 6 5 4 3 2 1
19 18 17 16 15 14
When the abnormality is detected, the temperature
26 25 24 23 22 21 20
sensor voltage is lower than 0.2V or higher than
4.95V.
Viewed from the engagement side of connector
B3Z16245

OK: Check the next item.

NG: Repair or replace the harness.
3. Check the proportional solenoid valve controller.
Repair or replace it.
4. If normal in the above check, replace the cargo
handling controller.

How to reset
Turn OFF the key switch.

7-107
7. TROUBLESHOOTING

ERR-5051 (Cargo Handling) ERR-5052 (Cargo Handling)

Content of Trouble Content of Trouble
Abnormal pump motor temperature sensor Abnormal output of cargo handling current sensor
(U phase, W phase)
Symptom of vehicle
The cargo handling is normally operative. Symptom of vehicle
• Operated in the normal temperature. Unable to handle the cargo

Repair Procedure Repair Procedure

1. Confirm that the pump motor temperature sensor 1. Check foreign matters around the current sensor
connector is firmly connected. on the CPU board.
2. Check the conduction of harness between the ter- 2. If normal in the above check, replace the cargo
minals 20 and 29 of CN1-P of cargo handling con- handling controller.
troller and the pump motor temperature sensor.
Judging: How to reset
• Between CN1-P terminal 20 (yellow/green) and Turn OFF the key switch.
pump motor temperature sensor terminal 1
(yellow/green): 0Ω Remark
• Between CN1-P terminal 29 (yellow/black) and Check visually the current sensor. If abnormal,
pump motor temperature sensor terminal 2 replace the cargo handling controller.
(yellow/black): 0Ω

Pump motor
CN1-P temperature sensor

31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 1 2
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Check the next item.

NG: Repair or replace the harness.
3. Check the resistance / temperature of pump motor
temperature sensor and replace.
4. If normal in the above check, replace the cargo
handling controller.

How to reset
When returned to the normal state, the error code is
reset.

Remark
When the abnormality is detected, the temperature
sensor voltage is lower than 0.2V or higher than
4.95V.

7-108
 7. TROUBLESHOOTING

ERR-5055 (Cargo Handling) ERR-5057 (Cargo Handling)

Content of Trouble Content of Trouble
Defective steering wheel angle sensor Defective pump motor speed sensor
(The detection angle is abnormal.)
Symptom of vehicle
Symptom of vehicle Unable to handle the cargo
Operable
• HPS: The FR link system works. Repair Procedure
1. Confirm that the connectors and terminals of
Repair Procedure pump motor speed sensor are not disconnected
1. Confirm that the connectors and terminals of and not loosened.
steering wheel angle sensor are not disconnected 2. Measure the resistance of harness between the
and not loosened. cargo handling controller and the pump motor
2. Measure the resistance of harness between the speed sensor.
cargo handling controller and the steering wheel Judging:
angle sensor. • Between CN1-P terminal 27 (white) and
Judging: pump motor speed sensor terminal 1 (white)
• Between CN3-P terminal 5 (red) and steering • Between CN1-P terminal 28 (black) and
wheel angle sensor terminal 1 (red) pump motor speed sensor terminal 2 (black)
• Between CN2-P terminal 15 (green/red) and
steering wheel angle sensor terminal 5 (green/ Pump Motor
red) CN1-P Speed Sensor
• Between CN2-P terminal 14 (blue/yellow) and
steering wheel angle sensor terminal 6 (blue/
yellow) 31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
Steering Wheel 9 8 7 6 5 4 3 2 1
CN2-P Angle Sensor

Viewed from the engagement side of connector

24 23 22 21 20 19 18 17 4 3 2 1
16 15 14 13 12 11 10 9 8 8 7 6 5
OK: Check the next item.
7 6 5 4 3 2 1 NG: Repair or replace the harness.
3. Check the pump motor speed sensor. Repair or
replace it.
17 16 15 14 13 CN3-P 4. Check the gear of pump motor (poor mesh of gear
12 11 10 9 8 7
Viewed from the engagement
with the sensor, entry of magnetic substance).
6 5 4 3 2 1
side of connector Repair or replace the motor.
5. If normal in the above check, replace the cargo
OK: Check the next item. handling controller.
NG: Repair or replace the harness.
3. Check the steering wheel angle sensor. How to reset
Repair or replace it. When returned to the normal state, the error code is
4. If normal in the above check, replace the cargo reset.
handling controller.
Remark
How to reset Voltage at terminal in the normal state
When returned to the normal state, the error code is Terminal 28:
reset. When the key switch is turned ON, it is about 13.5V.
Terminal 27:
Remark When the key switch is turned ON (stop), it is 1.3 -
When abnormal: The knob shift cannot be corrected. 3.3V.
HPS control: The on-demand system is changed to Terminal 27:
the FR link system. When the key switch is turned ON (operating), it is
about 2.3V.
(Average voltage when the motor is rotating.)

7-109
7. TROUBLESHOOTING

ERR-5062 (Cargo Handling) ERR-5081

Content of Trouble Content of Trouble
Defective logic of seat switch _a and seat switch _b Abnormal CAN communication
(Breaking of communication line between travel (R)
Symptom of vehicle and cargo handling)
Inoperable travel/cargo handling/HPS
Symptom of vehicle
Repair Procedure Inoperable travel/cargo handling/HPS
(The main contact does not close.)
1. Measure the resistance of harness between travel
(R) controller and seat switch.
Repair Procedure
Judging:
1. Confirm that the connectors and terminals of
• Between CN1-D1 terminal 19 (blue/red) and travel (R) controller and the connectors CN3-D1
seat switch terminal 2 (blue/red): 0Ω and CN3-P of cargo handling controller are not
• Between CN2-D1 terminal 18 (red/black) and disconnected and not loosened.
seat switch terminal 3 (red/black): 0Ω
2. Check and correct the DIP switch setting of each
controller.
CN1-D1 3. Check CN3-D1 and CN3-P harnesses between
Seat Switch inverters. Repair or replace it.
4. If normal in the above check, replace the travel
31 30 29 28 27 26 25 24 23 22 (R) controller or cargo handling controller.
21 20 19 18 17 16 15 14 13 12 11 10 1 2 3
9 8 7 6 5 4 3 2 1
How to reset
Turn OFF the key switch.

24 23 22 21 20 19 18 17
CN2-D1 Remark
16 15 14 13 12 11 10 9 8
7 6 5 4 3 2 1 Viewed from the engagement None
side of connector

OK: Check the next item.

NG: Repair or replace the harness.
2. Check the seat switch. Repair or replace it.
3. If normal in the above check, replace the travel
(R) controller.

How to reset
When returned to the normal state, the error code is
reset.

Remark
Detected when the seat switch _a and seat switch _b
are turned ON simultaneously.
Detected when the seat switch _a and seat switch _b
are turned OFF simultaneously.

7-110
 7. TROUBLESHOOTING

TROUBLE WITHOUT ERROR CODES

Even when the direction switch or accelerator is operated, the vehicle does not travel
normally.
Content of Trouble
Right or Left
The speed sensor connectors A and B are reversely CN1-D1 CN1-D2 Travel Motor
connected. Speed Sensor A
31 30 29 28 27 26 25 24 23 22
1 2
Repair Procedure 21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
1. Check the connection of connectors A and B of
right and left motors. Re-connect them correctly. Right or Left
CN1-D1 CN1-D2
2. Measure the resistance of harness between con- Travel Motor
Speed Sensor B
nectors CN-D1 and CN-D2 of travel motor speed
sensor A phase and the resistance of harness 31 30 29 28 27 26 25 24 23 22 1 2
between connectors CN-D1 and CN-D2 of travel 21 20 19 18 17 16 15 14 13 12 11 10
motor speed sensor B phase respectively. 9 8 7 6 5 4 3 2 1 Viewed from the engagement
Judging: side of connector

• Between CN1-D1 terminal 13 (white) and OK: Confirm the connection of connector.
right travel motor speed sensor A terminal 1 NG: Repair or replace the harness.
(white): 0Ω
• Between CN1-D1 terminal 14 (black) and How to reset
right travel motor speed sensor A terminal 2
(black): 0Ω Normal recovery
• Between CN1-D2 terminal 13 (white) and
left travel motor speed sensor A terminal 1 Remark
(white): 0Ω When replacing the motor, confirm the connection to
• Between CN1-D2 terminal 14 (black) and prevent misconnection.
left travel motor speed sensor A terminal 2
(black): 0Ω
• Between CN1-D1 terminal 27 (white) and
right travel motor speed sensor B terminal 1
(white): 0Ω
• Between CN1-D1 terminal 28 (black) and
right travel motor speed sensor B terminal 2
(black): 0Ω
• Between CN1-D2 terminal 27 (white) and
left travel motor speed sensor B terminal 1
(white): 0Ω
• Between CN1-D2 terminal 28 (black) and
left travel motor speed sensor B terminal 2
(black): 0Ω

7-111
7. TROUBLESHOOTING

Even when the direction switch or accelerator is operated, the vehicle does not travel
normally. (Continued)
Content of Trouble Content of Trouble
The tire angle sensor and its signal circuit are abnor- The accelerator unit and its signal circuit are abnor-
mal. (Between travel R unit and tire angle sensor) mal.
(Between travel R unit and accelerator)
Repair Procedure
Repair Procedure
1. Confirm that the tire angle sensor voltage (at ter-
minal 23 of connector CN2-D1) is around 2.5V 1. Confirm that the accelerator VR voltage input to
when the tires are located in the position of the controller normally increases when the accel-
straight forward of vehicle. erator is opened gradually and the accelerator
Confirm that the voltage increases when turning switch is input. If abnormal, repair or replace the
the steering wheel right and the voltage accelerator unit.
decreases when turning the steering wheel left. 2. Measure the resistance of harness between con-
If abnormal, repair or replace it. nector CN1-D1 and accelerator unit.
2. Measure the resistance of harness between con- Judging:
nector CN2-D1 and tire angle sensor.
• Between CN1-D1 terminal 16 (red) and
Judging: accelerator unit terminal 6 (red): 0Ω
• Between CN2-D1 terminal 22 (black/yellow) • Between CN1-D1 terminal 21 (black) and
and tire angle sensor terminal 1 (black/yellow): accelerator unit terminal 1 (black): 0Ω
0Ω
• Between CN1-D1 terminal 30 (green) and
• Between CN2-D1 terminal 23 (yellow) and tire accelerator unit terminal 3 (green): 0Ω
angle sensor terminal 2 (yellow): 0Ω
• Between CN1-D1 terminal 31 (yellow) and
• Between CN2-D1 terminal 24 (red/blue) and accelerator unit terminal 2 (yellow): 0Ω
tire angle sensor terminal 3 (red/blue): 0Ω

CN1-D1 Accelerator
CN2-D1 Tire Angle Sensor

31 30 29 28 27 26 25 24 23 22 3 2 1
24 23 22 21 20 19 18 17 3 2 1 21 20 19 18 17 16 15 14 13 12 11 10 6 5 4
16 15 14 13 12 11 10 9 8 9 8 7 6 5 4 3 2 1
7 6 5 4 3 2 1

Viewed from the engagement side of connector

Viewed from the engagement side of connector

OK: Replace the accelerator unit.

OK: Replace the tire angle sensor.
NG: Repair or replace the harness.
NG: Repair or replace the harness.
How to reset
How to reset
Normal recovery
Normal recovery
Remark
Remark
No leakage from the signal line.
No leakage from the signal line. An error is detected when the accelerator VR wire is
An error is detected when the wire is broken. broken.

7-112
 7. TROUBLESHOOTING

Even when the direction switch or accelerator is operated, the vehicle does not travel
normally. (Continued)
Content of Trouble Content of Trouble
The direction switch and its signal circuit are abnor- Wrong connection of travel R and travel L motor wir-
mal. ing

Repair Procedure Repair Procedure

1. Measure the resistance of harness between con- 1. Confirm that the travel R inverter unit is connected
nector CN1-D1 of travel R inverter unit and direc- to the right travel motor wire and the travel L
tion switch. inverter unit is connected to the left travel motor
Judging: wire respectively. If wrong, correct it.
• Between CN1-D1 terminal 1 (white/black) and
direction switch terminal 3 (white/black): 0Ω How to reset
• Between CN1-D1 terminal 2 (blue) and Normal recovery
direction switch terminal 2 (blue): 0Ω
Remark
When replacing the motor, confirm the connection to
prevent misconnection.
Direction Switch

CN1-D1

31 30 29 28 27 26 25 24 23 22 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1

Viewed from the engagement side of connector

OK: Replace the direction switch.

NG: Repair or replace the harness.

How to reset
Normal recovery

Remark
No leakage from the signal line.

7-113
7. TROUBLESHOOTING

Stop of Vehicle during traveling

Content of Trouble Content of Trouble
The hyper voltage is detected. • The detection of inching operation is abnormal. (The
simultaneous operation of accelerator and brake can
Repair Procedure be continued.)
• The occurrence by mis-operation is not the trouble.
1. Confirm that the battery connector is not poorly
connected.
Repair Procedure
2. Check the harness between VB and terminal 7 of
connector CN1 on the CPU board. Repair or 1. Confirm that the brake switch does not turn on
replace it. when the brake pedal is not stepped on. Repair it.
2. Confirm that the accelerator switch does not turn
How to reset on when the accelerator pedal is not stepped on.
Normal recovery Repair it.
3. Check the harness between brake switch and ter-
Remark minal 17 (brake switch input) of connector CN1 on
the CPU board. Repair or replace it.
Protection when the battery connector is poorly con-
tacted or disconnected during regeneration. 4. Check the harness between accelerator unit and
terminal 16 (accelerator switch input) of connector
CN1 on the CPU board. Repair or replace it.
5. Repair or replace the accelerator unit and brake
switch.

How to reset
Normal recovery

Remark
None

Steering is heavy. The steering wheel cannot be turned.

Content of Trouble How to reset
The steering wheel angle sensor and its signal circuit Normal recovery
are abnormal.
(Between cargo handling unit and steering wheel Remark
angle sensor)
No leakage from the signal line.
Repair Procedure
1. Check the terminal 14 and 15 of connector CN2
on the CPU board.
Check the harness between steering wheel angle
sensor and terminal 5 of connector CN3 on the
CPU board. Repair or replace it.
2. Confirm that the voltage changes when the steer-
ing wheel is operated and no noise voltage is
applied.
3. Check the steering wheel angle sensor. Repair or
replace it.

7-114
 7. TROUBLESHOOTING

Even when the cargo handling switch, steering wheel or direction switch is not operated,
the pump motor rotates.

(As driving the pump motor is controlled for one second immediately after turning ON the key switch, it is not the trou-
ble.)
Content of Trouble Content of Trouble
The proportional solenoid valve controller and its sig- The steering wheel angle sensor and its signal circuit
nal circuit are abnormal. are abnormal.
(Between the cargo handling unit and the propor- (Between cargo handling unit and steering wheel
tional solenoid valve controller) angle sensor)

Repair Procedure Repair Procedure

1. Check harness between the proportional solenoid 1. Check the terminal 14 and 15 of connector CN2
valve controller and the terminal 30 and 31 of con- on the CPU board.
nector CN1 on the CPU board. Then, repair or Check the harness between steering wheel angle
replace it. sensor and terminal 5 of connector CN3 on the
2. Confirm the voltage at the terminal 30 and 31 of CPU board. Then, repair or replace it.
connector CN1 on the CPU board when not oper- 2. If normal in the above check, confirm the steering
ated. wheel angle sensor and replace it.
If abnormal, check the proportional solenoid valve
controller unit. Then, repair or replace it. How to reset
Normal recovery
How to reset
None Remark
No leakage from the signal line.
Remark
An error is detected when the wire is broken.
When not operated, the voltage should not be higher
than 1.9V.
No leakage from the signal line.
An error is detected when the wire is broken.

7-115
7. TROUBLESHOOTING

The pump motor does not rotate.

Content of Trouble Content of Trouble
• The work switch circuit in the proportional solenoid • The harness of pump motor DUTY signal is shorted.
valve controller is defective. • The directive IC in the proportional solenoid valve con-
• The detection circuit in the main controller is defective. troller is defective.
• The work equipment switch signal harness is defec-
tive. Repair Procedure
1. Check the short of harness between proportional
Repair Procedure solenoid valve controller and cargo handling con-
Check when operating the lift lever to the full troller.
ascent. Judging: Between CN2S terminal 12 (green) and
(In the state that the pump motor is rotating) CN1-P terminal 31 (green)

1. Measure the voltage between pin 16 of CN1S

(white) and pins 10, 11, 12, 21 and 22 of CN2S
(gray) of proportional solenoid valve controller CN2S CN1-P
respectively.
If higher than 4V, replace the proportional solenoid
valve controller board.
2. If lower than 4V in step 1, measure the voltage at 7 6 5 4 3 2 1
31 30 29 28 27 26 25 24 23 22

pins 16, 17 and 19 of connector CN1-P of main 13 12 11 10 9 8

21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
controller and the voltage between pin 15 of CN1- 19 18 17 16 15 14
P (white) and pins 10 and 11 of connector CN2-P 26 25 24 23 22 21 20
of main controller.
If higher than 4V in step 1, check the wire-break- Viewed from the engagement side of connector
ing.
B3Z16246
3. If lower than 4V in step 2, check the short of wire,
OK: Replace the proportional solenoid valve control-
4. If normal in step 3, replace the main controller
ler.
board.
NG: Repair or replace the harness.
How to reset
None
How to reset
None
Remark
None
Remark
None

7-116
 7. TROUBLESHOOTING

The pump motor rotates fully when The Tilt Automatic Horizontal (OPTION)
operating the lever of work machine. cannot be operated. (Open)
Content of Trouble Content of Trouble
• The harness of pump motor DUTY signal is broken. • Tilt horizontal button is open.
• The directive IC in the proportional solenoid valve con- • Tilt horizontal harness is open.
troller is defective.
Repair Procedure
Repair Procedure
1. Operate the tilt horizontal button and check that
1. Check harness between the proportional solenoid the tilt horizontal display lights (or blinks) and goes
valve controller and cargo handling controller. off.
Judging: If normal, replace the proportional solenoid valve
controller board.
• Between CN2S terminal 11 (yellow) and CN1-P
terminal 30 (yellow): 0Ω 2. If abnormal in step 1, remove the tilt horizontal
button connector and measure the resistance of
• Between CN2S terminal 12 (green) and CN1-P
button.
terminal 31 (green): 0Ω
Abnormal: Replace the button.
Normal resistance: between pin 1 and 2
• Button ON: 0Ω
CN2S CN1-P
• Button OFF: cΩ
3. If normal in step 2, check the breaking of tilt hori-
zontal harness and repair it.
31 30 29 28 27 26 25 24 23 22
7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 How to reset
13 12 11 10 9 8
19 18 17 16 15 14
9 8 7 6 5 4 3 2 1 None
26 25 24 23 22 21 20

Remark
Viewed from the engagement side of connector None
B3Z16247
OK: Replace the proportional solenoid valve control-
ler.
NG: Repair or replace the harness.

How to reset
None

Remark
None

No response when operating the specified work equipment control lever

(The coil of proportional solenoid valve is not energized.)
Content of Trouble How to reset
No output of work equipment control lever None

Repair Procedure Remark

Check the work equipment control lever sensor of Idling is suspected while the output of work equip-
specified work equipment lever controller portion and ment lever sensor remains 2.5V.
replace it.

7-117
7. TROUBLESHOOTING

When the abnormality of communication When the abnormality of communication

occurs immediately after turning on the occurs during operation
key (Error Code 40-8510 non-display) (Error Code 40-83XX non-display)
How to discriminate the abnormality of com- How to discriminate the abnormality of com-
munication munication
1. The error codes 40-8120 and 40-8140 are dis- 1. The error codes 40-8120 and 40-8140 are dis-
played for 2 seconds and go off. played for 2 seconds and go off.
2. The forklift truck does not move at all. 2. Only the steering wheel (PS) of forklift truck can
3. The liquid crystal display on the meter panel be operated.
becomes as shown below. 3. The liquid crystal display on the meter panel
becomes as shown below.

E F
LNH E F
LNH

km/h
mph

Two segments at the The traveling speed

BDI E side blink. is not displayed. The indications of traveling speed and
F/R are frozen. (They remain unchanged.)
B3Z16262

Remedy
The CAN communication line is incompletely short- Remedy
circuited. The CAN communication line is incompletely short-
According to the diagnosis of error code 40-8510, circuited.
remedy it. According to the diagnosis of error code 40-83XX,
remedy it.

7-118
 7. TROUBLESHOOTING

PROPORTIONAL SOLENOID VALVE CONTROLLER

CHECK BEFORE ABNORMAL DIAGNOSIS

Unless specified, disconnect the battery before performing the abnormal diagnosis.
During diagnosis, pay attention to safety in case the vehicle (travel, cargo handling)
moves.
Before abnormal diagnosis, check the power supply voltage.

1. Disconnect the battery plug.

2. Remove the upper cover of weight. Protection Cover Upper Cover

3. Remove the protection cover inside.

4. Set the tester to the voltage measuring range. Set the leads of
tester to the measuring locations.
5. Connect the battery plug again and turn ON the key switch.
6. Confirm that the voltage is within the range below.
Judging: CN2S
• Between CN2S terminal 20 and 26: VB
7 6 5 4 3 2 1
• Between CN2S terminal 7 and 13: 4.9 - 5.1V 13 12 11 10 9 8
• Between CN2S terminal 20 and 8: VB 19 18 17 16 15 14
26 25 24 23 22 21 20

Viewed from the engagement side of connector

B3Z16248

7-119
7. TROUBLESHOOTING

1. Check of Lever and Lever Sensor of Work Equipment

Voltage Check Check of harness resistance

1. Disconnect the battery plug. 1. Remove the cover under the lever of work equip-
2. Remove the upper cover of weight. ment and disconnect the middle connector of
lever sensor of work equipment.
3. Remove the protection cover inside.
2. Disconnect the connector CN2S (white) from the
4. Set the tester to the voltage measuring range. proportional solenoid valve controller.
5. Set the black lead (-) of tester to the terminal 13 of 3. Set the tester to the resistor measuring range and
connector CN2S of proportional solenoid valve set the leads of tester to the measuring locations.
controller. Measure the resistance and confirm that the value
6. Set the red lead (+) of tester to the measuring is within the range below.
locations shown below, re-connect the battery
plug, and turn ON the key switch.
7. Confirm that the voltage is within the range of nor- CN2S Potentiometer
mal voltage shown below.

7 6 5 4 3 2 1 1 2 3 4
13 12 11 10 9 8 5 6 7 8
19 18 17 16 15 14
26 25 24 23 22 21 20

CN2S
Viewed from the engagement side of connector
7 6 5 4 3 2 1
13 12 11 10 9 8
B3Z16250
19 18 17 16 15 14
26 25 24 23 22 21 20
Judging:
• Between CN2S terminal 7 and
Viewed from the engagement side of connector potentiometer terminal 1: 0Ω
B3Z16249 • Between CN2S terminal 2 and
potentiometer terminal 2: 0Ω
Measuring Location:
• Between CN2S terminal 4 and
• Lift Lever Sensor: potentiometer terminal 3: 0Ω
Between terminal 2 and 13
• Between CN2S terminal 3 and
• Tilt Lever Sensor: potentiometer terminal 4: 0Ω
Between terminal 3 and 13
• Between CN2S terminal 5 and
• ATT1 Lever Sensor: potentiometer terminal 5: 0Ω
Between terminal 4 and 13
• Between CN2S terminal 6 and
• ATT2 Lever Sensor: potentiometer terminal 6: 0Ω
Between terminal 5 and 13
• Between CN2S terminal 8 and
Judging: potentiometer terminal 8: 0Ω
• Lever in the neutral position: 2.61 - 2.39V
• Lever in the forward tilt end position: 4.3 - 3.9V
• Lever in the backward tilt end position: 4.3 -
3.9V When checking the connector block, if the
tester lead is strongly pushed to the engage-
ment side, the poor contact may occur after
assembled. Therefore, check as follows.
The Hall element type sensor is employed. •In case of the water-proof connector,
Therefore, unlike the conventional variable remove the retainer from the engagement
resistor type, the resistance of sensor can- side and touch lightly the side of terminal
not be measured. So measure the voltage with the tester lead.
above.
•In case of non water-proof connector, check
from the harness side.

7-120
 7. TROUBLESHOOTING

2. Lift Pressure Sensor Check

Voltage Check Harness Resistance Check

1. Set the tester to the voltage measuring range. 1. Disconnect the connector from the pressure sen-
2. Set the black lead (-) of tester to the terminal 13 of sor in the operation valve block.
connector CN2S of proportional solenoid valve 2. Disconnect the connector CN2S (white) of propor-
controller. tional solenoid valve controller.
3. Lift down the lift to the ground and measure the 3. Set the tester to the resistance measuring range
voltage. and the leads of tester to the measuring locations.
4. Lift up the lift and operate the fork to reach the Measure the voltage and confirm the resistance is
upper stroke end. While operating the fork, mea- within the range of values shown below.
sure the voltage.
5. Confirm that the voltage is within the range of nor-
mal voltages below.

Lift Pressure
CN2S
Sensor
7 6 5 4 3 2 1 3 2 1
13 12 11 10 9 8
19 18 17 16 15 14
26 25 24 23 22 21 20
CN2S

7 6 5 4 3 2 1 Viewed from the engagement side of connector

13 12 11 10 9 8
B3Z16252
19 18 17 16 15 14
26 25 24 23 22 21 20
Judging:
Viewed from the engagement side of connector • Between CN2S terminal 7 and
B3Z16251 lift pressure sensor terminal 1: 0Ω
Measuring Location: Terminal 1 - 13 • Between CN2S terminal 1 and
lift pressure sensor terminal 2: 0Ω
Judging:
• Between CN2S terminal 13 and
• When the fork is grounded:
lift pressure sensor terminal 3: 0Ω
0.33 - 0.63V
When checking the connector block, if the tester
• When the fork is at the ascent stroke end: lead is strongly pushed to the engagement side,
3.89 - 4.30V the poor contact may occur after assembled.
Therefore, check as follows.

When checking, select the place spacious

enough to operate the work equipment. Pay In case of the water-proof connector, remove
attention during operation. the retainer from the engagement side and
touch lightly the side of terminal with the
tester lead.
In case of non water-proof connector, check
from the harness side.

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7. TROUBLESHOOTING

3. Proportional Solenoid Valve Coil Check (Hydraulic Control Valve)

a In the proportional solenoid valve block, 6P and 4P connectors are provided at the upper and lower sides.

6P Connector 4P Connector CN3S Harness Resistance Check

7 6 5 4 3 2 1
1. Disconnect the connector of proportional solenoid
13 12 11 10 9 8
valve.
3 2 1 2 1 19 18 17 16 15 14 2. Disconnect the connector CN3S of proportional
6 5 4 4 3 26 25 24 23 22 21 20
solenoid valve controller.
Viewed from the engagement side of connector 3. Set the tester to the resistance measuring range.
B3Z16253 According to the table below, set the leads of tes-
ter to the measuring locations and measure the
Coil Resistance Check resistance.
1. Disconnect the connector of proportional solenoid 4. Confirm that the measured values are within the
valve. range of normal values.
2. Set the tester to the resistance measuring range. Judging: (The CN3S side is negative polarity.) [0Ω]
According to the table below, set the leads of tes- • Lift ascent
ter to the measuring locations and measure the Between lower side connector (6P) terminal 1
resistance. and CN3S terminal 10
3. Confirm that the measured values are within the Between lower side connector (6P) terminal 4
range of normal values. and CN3S terminal 11
Judging: • Backward tilt
Between lower side connector (6P) terminal 2
• Lift ascent and CN3S terminal 2
Between (+) lower side connector (6P) terminal Between lower side connector (6P) terminal 5
1 and (-) lower side connector (6P) terminal 4: and CN3S terminal 3
17 - 18Ω • ATT1_Asol
• Backward tilt Between lower side connector (6P) terminal 3
Between (+) lower side connector (6P) terminal and CN3S terminal 14
2 and (-) lower side connector (6P) terminal 5: Between lower side connector (6P) terminal 6
17 - 18Ω and CN3S terminal 1
• ATT1_Asol • ATT2_Asol
Between (+) lower side connector (6P) terminal Between lower side connector (4P) terminal 1
3 and (-) lower side connector (6P) terminal 6: and CN3S terminal 13
17 - 18Ω Between lower side connector (4P) terminal 3
• ATT2_Asol and CN3S terminal 19
Between (+) lower side connector (4P) terminal • ATT3_Asol
1 and (-) lower side connector (4P) terminal 3: Between lower side connector (4P) terminal 2
17 - 18Ω and CN3S terminal 5
• ATT3_Asol Between lower side connector (4P) terminal 4
Between (+) lower side connector (4P) terminal and CN3S terminal 6
2 and (-) lower side connector (4P) terminal 4: • Lift descent
17 - 18Ω Between upper side connector (6P) terminal 1
• Lift descent and CN3S terminal 4
Between (+) upper side connector (6P) terminal 1 Between upper side connector (6P) terminal 4
and (-) upper side connector (6P) terminal 4: 17 - and CN3S terminal 11
18Ω • Forward tilt
• Forward tilt Between upper side connector (6P) terminal 2
Between (+) upper side connector (6P) terminal 2 and CN3S terminal 9
and (-) upper side connector (6P) terminal 5: 17 - Between upper side connector (6P) terminal 5
18Ω and CN3S terminal 3
• ATT1_Bsol • ATT1_Bsol
Between (+) upper side connector (6P) terminal 3 Between upper side connector (6P) terminal 3
and (-) upper side connector (6P) terminal 6: 17 - and CN3S terminal 8
18Ω Between upper side connector (6P) terminal 6
• ATT2_Bsol and CN3S terminal 1
Between (+) upper side connector (4P) terminal 1 • ATT2_Bsol
and (-) upper side connector (4P) terminal 3: 17 - Between upper side connector (4P) terminal 1
18Ω and CN3S terminal 7
• ATT3_Bsol Between upper side connector (4P) terminal 3
Between (+) upper side connector (4P) terminal 2 and CN3S terminal 19
and (-) upper side connector (4P) terminal 4: 17 - • ATT3_Bsol
18Ω Between upper side connector (4P) terminal 2
and CN3S terminal 12
Between upper side connector (4P) terminal 4
and CN3S terminal 6

7-122
 7. TROUBLESHOOTING

4. Proportional Solenoid Valve Controller

Check signal voltage of harness between work equip-

ment and operating lever switch
1. Disconnect the connector of proportional solenoid Judging:
valve. • Lift switch
2. Set the tester to the voltage measuring range. Between CN3S terminal 23 and terminal 7:
According to the table below, set the leads of tes- higher than 4V
ter to the measuring locations and measure the • Tilt switch
voltage. Between CN3S terminal 24 and terminal 7:
3. Confirm that the measured voltages are within the higher than 4V
range of normal voltages. • ATT1 switch
Between CN3S terminal 22 and terminal 7:
higher than 4V
• ATT2 switch
Between CN3S terminal 17 and terminal 7:
higher than 4V
• ATT3 switch
Between CN3S terminal 16 and terminal 7:
7 6 5 4 3 2 1 higher than 4V
13 12 11 10 9 8
CN3S 19 18 17 16 15 14
26 25 24 23 22 21 20

Viewed from the engagement side of connector

B3Z16254

7-123
7. TROUBLESHOOTING

ADJUSTMENT PROCEDURE OF TILT AUTOMATIC HORIZONTAL

(OPTION)
Remove the cover at the upper side of weight and adjust using the 1P connector (tilt horizontal offset
switch) installed near the fuse holder (10 A, 5 A).

1. Confirm that the tilt horizontal offset switch connector is con-

nected.
2. Operate the tilt to set the mast to the required angle.
3. Turn the key switch ON o OFF o ON.
4. After turning ON the key switch, unplug the tilt offset switch
within 30 seconds.
5. Then, plug in the tilt offset switch within 10 seconds.
6. Operate the tilt automatic horizontal and confirm that it stops at
the set position.

7-124
 7. TROUBLESHOOTING

METER PANEL
DIAGNOSIS BY SYMPTOM
No. Symptom Page
1 When turning ON the key switch, the meter panel does not work at all. ..................................................................................................... 7-126
2 When the battery is connected, the entire meter panel keeps lighting. ....................................................................................................... 7-126
3 When the battery is connected, all lamps light, but some segments and some warning lamps do not light. .............................................. 7-126
4 After turning ON the key switch, the LCD backlight does not light. ............................................................................................................. 7-127
5 The buzzer does not beep during meter operation...................................................................................................................................... 7-127
6 Some segments on the LCD do not work during meter operation............................................................................................................... 7-127
7 The LCD display is not renewed.................................................................................................................................................................. 7-127
8 When turning OFF the key switch, the display of meter panel does not go off............................................................................................ 7-127
9 All of LCD and warning lamps light and go off repeatedly. .......................................................................................................................... 7-127
10 The neutral safety warning lamp does not light or go off. ............................................................................................................................ 7-128
11 The parking warning light does not light or does not go off. ........................................................................................................................ 7-128
12 The warning lamp of battery electrolyte lights. ............................................................................................................................................ 7-128
13 The warning lamp of travel system trouble lights (blinks). ........................................................................................................................... 7-128
14 The warning lamp of travel system trouble does not light (blinks). .............................................................................................................. 7-129
15 The warning lamp of cargo handling system trouble lights (blinks). ............................................................................................................ 7-129
16 The warning lamp of cargo handling system trouble does not light (blink). ................................................................................................. 7-129
17 The warning lamp of trouble lights (blinks). ................................................................................................................................................. 7-129
18 The warning lamp of trouble does not light (blinks). .................................................................................................................................... 7-129
19 The display of battery remaining goes off or is obviously different from the actual remaining. ................................................................... 7-130
20 The display of power is obviously different from the actual power. ............................................................................................................. 7-130
21 The display of forward-run/backward-run goes off or is different from the actual state of traveling. ........................................................... 7-130
22 The display of travel speed goes off or is different from the actual travel speed......................................................................................... 7-130
23 The display of travel speed limit (turtle icon) is different from the actual state. ........................................................................................... 7-131
24 The display of tilt horizontal is different from the actual state of vehicle...................................................................................................... 7-131
25 The display cannot be switched to the clock or time cannot be set............................................................................................................. 7-131
26 When turning ON the key switch, the display of clock is obviously incorrect............................................................................................... 7-131
27 The display cannot be switched to the key ON time.................................................................................................................................... 7-131
28 The display of key ON time is obviously incorrect or shows [Tol-----.-]........................................................................................................ 7-132
29 The display cannot be switched to [Travel R] time. ..................................................................................................................................... 7-132
30 The display of [Travel R] time is not accumulated or remains [0.0h]. .......................................................................................................... 7-132
31 The display cannot be switched to the cargo handling time. ....................................................................................................................... 7-132
32 The display of cargo handling time is not accumulated or remains [0.0h]. .................................................................................................. 7-132
33 The display cannot be switched to the load meter....................................................................................................................................... 7-132
34 When displaying the load meter, the value obviously different from the actual state of vehicle is displayed. ............................................. 7-133
35 The load meter cannot be adjusted to zero. ................................................................................................................................................ 7-133
36 The history of trouble cannot be displayed. ................................................................................................................................................. 7-133
37 Even when the button is pressed, the display cannot be switched to the code of trouble history and hour time at the occurrence. .......... 7-133
38 Even when the button is pressed, the travel speed limit setting (user adjustment mode) cannot be displayed. ......................................... 7-133
39 Even when the UP and DOWN buttons are pressed, the travel speed limit setting cannot be incremented or decremented. ................... 7-133
40 Even when the MODE button is pressed after changing the value, the travel speed limit setting cannot be reflected. .............................. 7-134
41 Even when the button is pressed, the lift speed setting (user adjustment mode) cannot be displayed....................................................... 7-134
42 Even when the UP and DOWN buttons are pressed, the lift speed limit setting cannot be incremented or decremented.......................... 7-134
43 Even when the MODE button is pressed after changing the value, the lift speed limit setting cannot be reflected. ................................... 7-134
44 Even when the LMH button (UP button) is pressed, the lift power setting (user adjustment mode) cannot be switched............................ 7-134
45 Even when the MODE button is pressed after changing the value, the power setting (user adjustment mode) cannot be reflected. ........ 7-135
46 Even when the turtle icon button (DOWN button) is pressed, the ON/OFF of travel speed limit cannot be changed. ................................ 7-135
47 The meter panel communication error is displayed. ([Err---????] is displayed on the LCD.) ...................................................................... 7-135
48 The controller communication error is displayed. ([Err??---????] is displayed on the LCD.) ...................................................................... 7-135

7-125
7. TROUBLESHOOTING

CONNECTOR PIN ASSIGNMENT

NO. Name NO. Name
1 6
1 Key switch 7 TMR
2 Presence/Absence of sensor 8 CANL (2)
3 Load meter display switch 9 CANL (1)
4 Battery electrolyte level sensor 10 CANH (2)
7 12 5 GND 11 CANH (1)
AMP 174973-2 6 SW GND 12 BATT

When the CAN termination resistor in the meter panel is used, pin 7 is connected to pin 10
by the harness at the vehicle side. If the abnormality of CAN communication is suspected
on the vehicle in which the termination resistor in the meter panel is used, before check-
ing the items below, confirm that the connection mentioned above is implemented on the
harness at the vehicle side.

1. When turning ON the key switch, the meter panel does not work at all.
(The LCD is not displayed. The LCD backlight and warning lamps do not light at all.)
Cause Remedy

Is the voltage applied to pin YES YES

(1) and pin (5) and to pin (12)
and pin (5) of connector?
Defective meter panel Replace

NO NO

Breaking of harness
Is the battery voltage YES Poor contact of connector Check
normal?
Defective key switch

NO
Check
Abnormal battery
Re-charge

2. When the battery is connected, the entire meter panel keeps lighting.
Cause Remedy

Defective meter panel Replace

3. When the battery is connected, all lamps light, but some segments and some warning lamps do not light.
Cause Remedy

Defective meter panel Replace

7-126
 7. TROUBLESHOOTING

4. After turning ON the key switch, the LCD backlight does not light.
(The LCD display and warning lamps work normally.)
Cause Remedy

Defective meter panel Replace

5. The buzzer does not beep during meter operation.

Cause Remedy

Defective meter panel Replace

6. Some segments on the LCD do not work during meter operation.

Cause Remedy

Defective meter panel Replace

7. The LCD display is not renewed.

Cause Remedy

Is the communication data YES Do all controllers output YES Defective meter panel Replace
inputted to pins (11) [(10)] normally the communication
and (9) [(8)] of connector? data?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

8. When turning OFF the key switch, the display of meter panel does not go off.
Cause Remedy

NO Defective meter panel Replace

The harness or
YES
connector is shorted Check
Abnormal key switch

9. All of LCD and warning lamps light and go off repeatedly.

The meter panel does not function normally.
Cause Remedy

Is the voltage between pins (12) and (5) NO Defective meter panel Replace
of connector lower than 26 V?

YES Over-discharge of battery

(Voltage drop of power sup- Re-charge
ply)

7-127
7. TROUBLESHOOTING

10. The neutral safety warning lamp does not light or go off.
Cause Remedy

Is the communication data YES Does the controller normally output YES Defective meter panel Replace
inputted to pins (11) [(10)] the communication data according
and (9) [(8)] of connector? to the state of vehicle?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

11. The parking warning light does not light or does not go off.
Cause Remedy

Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according
Defective meter panel Replace
and (9) [(8)] of connector? to the state of vehicle?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

12. The warning lamp of battery electrolyte lights.

(Without the electrolyte level sensor)
Cause Remedy

Is the pin (2) of connector YES Defective meter panel Replace

opened by the harness at the
vehicle side?

NO The harness or
Check
connector is shorted

13. The warning lamp of travel system trouble lights (blinks).

Cause Remedy

Is the trouble code* of travel NO Defective meter panel Replace

system displayed on the
LCD?
Other controller
YES detects the trouble Check
(meter panel is normal)
* [ALA---3???] or [Err---3???] is displayed.

7-128
 7. TROUBLESHOOTING

14. The warning lamp of travel system trouble does not light (blinks).
Cause Remedy

Is the trouble code* of travel NO Normal —

system displayed on the
LCD?

YES Defective meter panel Replace

* [ALA---3???] or [Err---3???] is displayed.

15. The warning lamp of cargo handling system trouble lights (blinks).
Cause Remedy

Is the trouble code* of cargo NO Defective meter panel Replace

handling system displayed on
the LCD?
Other controller
YES detects the trouble. Check
(The meter panel is nor-
* [ALA---5???] or [Err---5???] is displayed.

16. The warning lamp of cargo handling system trouble does not light (blink).
Cause Remedy

Is the trouble code* of travel NO Normal —

system displayed on the
LCD?

YES Defective meter panel Replace

* [ALA---5???] or [Err---5???] is displayed.

17. The warning lamp of trouble lights (blinks).

Cause Remedy

Is the trouble code* of NO Defective meter panel Replace

displayed on the LCD?

Other controller
YES detects the trouble. Check
(meter panel is normal)
* [Err??-????] is displayed.

18. The warning lamp of trouble does not light (blinks).

Cause Remedy

Is the trouble code* of NO Normal —

displayed on the LCD?

YES Defective meter panel Replace

* [Err??---????] is displayed.

7-129
7. TROUBLESHOOTING

19. The display of battery remaining goes off or is obviously different from the actual remaining.
Cause Remedy

Is the communication data YES Does the controller normally output YES
Defective meter panel Replace
inputted to pins (11) [(10)] the communication data according
and (9) [(8)] of connector? to the state of battery?

NO NO Abnormal controller Check

Breaking of harness Check

Poor contact of connector

20. The display of power is obviously different from the actual power.
Cause Remedy

Is the communication data YES Does the controller normally YES

inputted to pins (11) [(10)] output the communication data
Defective meter panel Replace
and (9) [(8)] of connector? according to the state of power?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

21. The display of forward-run/backward-run goes off or is different from the actual state of traveling.
Cause Remedy

Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according
Defective meter panel Replace
and (9) [(8)] of connector? to the actual traveling?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

22. The display of travel speed goes off or is different from the actual travel speed.
Cause Remedy

Is the communication data YES Does the controller normally output YES Defective meter panel Replace
inputted to pins (11) [(10)] the communication data according
and (9) [(8)] of connector? to the actual travel speed?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

7-130
 7. TROUBLESHOOTING

23. The display of travel speed limit (turtle icon) is different from the actual state.
Cause Remedy

Is the communication data YES Does the controller normally output YES Defective meter panel Replace
inputted to pins (11) [(10)] the communication data according
and (9) [(8)] of connector? to the actual set speed limit?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

24. The display of tilt horizontal is different from the actual state of vehicle.
Cause Remedy

Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according
Defective meter panel Replace
and (9) [(8)] of connector? to the actual state of vehicle?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

25. The display cannot be switched to the clock or time cannot be set.
Cause Remedy

Defective meter panel Replace

26. When turning ON the key switch, the display of clock is obviously incorrect.
Cause Remedy

Is the battery without NO Defective meter panel Replace

connection* left more than 15
days?
Discharge of battery for
YES backing up the Reset time
clock in the meter panel
* In the state that the voltage between connector pins 12 and 5 is lower than 26V.

27. The display cannot be switched to the key ON time.

Cause Remedy

Defective meter panel Replace

7-131
7. TROUBLESHOOTING

28. The display of key ON time is obviously incorrect or shows [Tol-----.-].

Cause Remedy

Defective meter panel Replace

29. The display cannot be switched to [Travel R] time.

Cause Remedy

Defective meter panel Replace

30. The display of [Travel R] time is not accumulated or remains [0.0h].

Cause Remedy

Is the communication data YES Does the controller normally YES Defective meter panel Replace
inputted to pins (11) [(10)] accumulate the [travel 1] time and
and (9) [(8)] of connector? output the communication data?

NO NO Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

31. The display cannot be switched to the cargo handling time.

Cause Remedy

Defective meter panel Replace

32. The display of cargo handling time is not accumulated or remains [0.0h].
Cause Remedy
Is the communication data Does the controller normally
inputted to pins (11) [(10)] YES accumulate the cargo handling time YES Defective meter panel Replace
and (9) [(8)] of connector? and output the communication data?
NO NO
Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

33. The display cannot be switched to the load meter.

Cause Remedy

Is the load meter display SW YES Defective meter panel Replace

signal inputted to pins (3) and
(6) of connector?.

NO Breaking of harness
Check
Poor contact of connector

7-132
 7. TROUBLESHOOTING

34. When displaying the load meter, the value obviously different from the actual state of vehicle is dis-
played.
Cause Remedy
Is the communication data Does the controller normally
inputted to pins (11) [(10)] YES output the communication data YES Defective meter panel Replace
and (9) [(8)] of connector? related to the load meter?
NO NO
Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

35. The load meter cannot be adjusted to zero.

Cause Remedy

Defective meter panel Replace

36. The history of trouble cannot be displayed.

Cause Remedy

Defective meter panel Replace

37. Even when the button is pressed, the display cannot be switched to the code of trouble history and hour
time at the occurrence.
Cause Remedy

Defective meter panel Replace

38. Even when the button is pressed, the travel speed limit setting (user adjustment mode) cannot be dis-
played.
Cause Remedy

Defective meter panel Replace

39. Even when the UP and DOWN buttons are pressed, the travel speed limit setting cannot be incremented
or decremented.
Cause Remedy

Defective meter panel Replace

7-133
7. TROUBLESHOOTING

40. Even when the MODE button is pressed after changing the value, the travel speed limit setting cannot
be reflected.
Cause Remedy
Is the communication data Does the controller normally output
inputted to pins (11) [(10)] YES the communication data related to YES Defective meter panel Replace
and (9) [(8)] of connector? the travel speed limit setting?
NO NO
Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

41. Even when the button is pressed, the lift speed setting (user adjustment mode) cannot be displayed.
Cause Remedy

Defective meter panel Replace

42. Even when the UP and DOWN buttons are pressed, the lift speed limit setting cannot be incremented or
decremented.
Cause Remedy

Defective meter panel Replace

43. Even when the MODE button is pressed after changing the value, the lift speed limit setting cannot be
reflected.
Cause Remedy
Is the communication data Does the controller normally output
inputted to pins (11) [(10)] YES the communication data related to YES Defective meter panel Replace
and (9) [(8)] of connector? the lift speed limit setting?
NO NO
Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

44. Even when the LMH button (UP button) is pressed, the lift power setting (user adjustment mode) cannot
be switched.
Cause Remedy

Defective meter panel Replace

7-134
 7. TROUBLESHOOTING

45. Even when the MODE button is pressed after changing the value, the power setting (user adjustment
mode) cannot be reflected.
Cause Remedy
Is the communication data Does the controller normally output
inputted to pins (11) [(10)] YES the communication data related to YES Defective meter panel Replace
and (9) [(8)] of connector? the power speed limit setting?
NO NO
Abnormal controller Check

Breaking of harness
Check
Poor contact of connector

46. Even when the turtle icon button (DOWN button) is pressed, the ON/OFF of travel speed limit cannot be
changed.
Cause Remedy
Is the communication data Does the controller normally output Defective meter panel
inputted to pins (11) [(10)] YES the communication data related to YES Replace
and (9) [(8)] of connector? the travel speed limit setting?
NO NO
Abnormal controller
Check

Breaking of harness
Check
Poor contact of connector

47. The meter panel communication error is displayed. ([Err---????] is displayed on the LCD.)
Cause Remedy

Is the communication data YES Defective meter panel Replace

inputted to pins (11) [(10)]
and (9) [(8)] of connector?

NO Does the controller normally YES Breaking of harness

Check
output the communication Poor contact of connector
data?

NO Abnormal controller Check

48. The controller communication error is displayed. ([Err??---????] is displayed on the LCD.)
Cause Remedy

The controller communica-

Replace
tion error is detected

7-135
NOTES
HARNESS LIST
Main harness

7-137
8. Yearly Inspection
Criteria

MOTOR.............................................................................................................. 8-3
CONTROL EQUIPMENT ................................................................................... 8-3

BATTERY........................................................................................................... 8-7

POWER TRANSFER EQUIPMENT ................................................................... 8-8

TRAVELING EQUIPMENT ................................................................................ 8-8

STEERING EQUIPMENT................................................................................... 8-9

BRAKING EQUIPMENT....................................................................................8-11

CARGO HANDLING EQUIPMENT .................................................................. 8-14

HYDRAULIC EQUIPMENT .............................................................................. 8-16

BODY, SAFETY EQUIPMENT......................................................................... 8-18

TOTAL TEST.................................................................................................... 8-18

8-1
 8. YEARLY INSPECTION CRITERIA

a The Nos. of the inspection items correspond to those in the specific self-inspection record table.

Check Item Check Content

1. Foreign noise at
No foreign noise
rotation
Motor

2. Looseness of
Looseness of bolt
coupler block

5-9. Contact 1) Contact

(Magnet Switch) • Check visually the coarseness. If worn, replace.
• Check visually the hazardous scars, damage and discolor.

2) Measure the resistance of coil.

1. Remove the coil wiring connector.
2. Set the meter to resistance range and measure the resistance between termi-
nals of coil.

Resistance Judge

About 20Ω Good

c Cut-off
0 Short

3) Installation state of main circuit wires, Looseness

Control Equipment

Tighten so that the installation state is good and the connection is not loose.

5-9. Potentiometer 1) Set Voltage

(Proportional
Solenoid Valve Measurement Location
Set Voltage Value
Specification) Classification Cargo handling controller (Reference Value)
Pin No. of CN1-P, CN2-P

Lift CN1-P, 19, 18

When forward Tilt CN1-P, 17
tilting the lever 3.9 - 4.3V
(Push) CN2-P, 11, 12
ATT
CN1-P, 16
Lift CN1-P, 19, 18

Tilt CN1-P, 17
Lever in neutral 2.4 - 2.6V
CN2-P, 11, 12
ATT
CN1-P, 16

Lift CN1-P, 19, 18

When backward Tilt CN1-P, 17
tilting the lever 0.7 - 1.1V
(Pull) CN2-P, 11, 12
ATT
CN1-P, 16

8-3
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

5-9. Potentiometer 2) Replacement of multiple Link Sensor (potentiometer)

(Proportional 1. Remove the screw (1) fixing the plate of
Solenoid Valve potentiometer.
Specification) 2. Remove the screw (2) fixing the potenti-
ometer.
3. Remove the potentiometer (3).
4. Align the pin of lever with the center of arm 2
3 2 3
and fix the plate of potentiometer to the
frame.
5. Fix the potentiometer temporarily with the 1
screw.
1
3) Sensor Adjustment
1. Loosen the screw compressing the spring
of damper so that the spring length is loos-
ened by 2 mm [0.08 in] from end face of
damper (Do not disassemble.)
2. Loosen two screws fixing the potentiometer.
(In this state, the spring washer is lightly pressed)
3. When the lever is in the neutral position, adjust the potentiometer so that the
output voltage is 2.45 - 2.55V. (When returned from forward and backward, the
voltage should be returned to the voltage mentioned above.)
Control Equipment

4) Replacement of multiple lever damper

1. Remove the adjustment screw (1).
2. Remove the fixing screw (2).
3. Remove the damper.
4. Clean the cylinder portion of lever.
5. Apply the specific grease to the contacting
face of damper to the cylinder.
6. Install the damper to the cylinder of lever with
8 mm
faced. Insert the looseness prevention hexa- [0.32 in] 1
gon nut in the hexagon hole at the sensor side
and fix with fixing screw.
7. Insert the adjustment screw in the hexagon
hole and fix it temporarily. 2
8. Adjust so that the clearance between the 5 mm
lever and lever plate is 5 mm [0.20 in]. [0.20 in]
3
5) Damper Adjustment
1. Adjust the screw compressing the spring of damper so that the length of spring
from the end face of damper is about 8 mm [0.32 in]. Fine-adjust to meet the
specifications in steps 2 to 5.
2. The maximum operating force should be less than 8.8 N {0.9 kgf} [2.0 lb].
(Output voltage 4V•1V respectively)
3. When returning the lift lever from the maximum operating position to the neutral,
the reaction of lever should be less than 3 N {0.3 kgf} [0.7 lb].
4. After falling down the lever, the lever should securely return to the neutral posi-
tion.
5. After adjusted, the output voltage of operation should return to the range of 2.4V
- 2.6V after operated.

8-4
 8. YEARLY INSPECTION CRITERIA

Check Item Check Content

9. FR switch 1) Operating State

Confirm that the FR switch securely operates from neutral position to F and R.
F/R switch side: male

2) Conduction Test
Confirm by conduction check that the wirings inside are not broken.
Measuring Method Judge 3 2 1
Set the FR lever to F, and measure
resistance between pins 1 and 2. 0Ω: Normal
Set the FR lever to R, and measure c: Disconnected
resistance between pins 1 and 3.

3) Damage, looseness of installed block

Confirm that no damage exists and the installed blocks are properly tightened.

11. Cut-off current 1) Measurement of cut-off current

1. Park the lift truck on flat ground. Put the wheel stopper to the rear wheels to lock
them.
2. Place the wooden block under the both right and left frames to float the lift truck
from the ground. (Only when measuring the cut-off current at traveling)
3. Lower down the fork on the ground, tilt the mast forward and apply the parking
Control Equipment

brake.
4. Disconnect the wiring from the brake switch. (Only when measuring the cut-off
current at traveling)
5. Set the ammeter (clamp tester) to the cable to be measured and measure the
cut-off current under the condition listed on the table below.

Cable to be
Motor Measuring Condition Clamp Setting Cut-off Current
measured

Set the power mode to the H DUR,

mode, shift the FR lever to the F DVR, 337 - 372 A
DWR DC 1,000 A
position and step on the brake peak range (peak)
Travel pedal fully. and
Measure the current 2 seconds (AC 1,000 A (238 - 263 A
DUL, peak range)
after stepping on the accelerator DVL, (rms))
pedal fully. DWL

Set the power mode to the H DC 1,000 A 363 - 402 A

mode and turn the tilt lever fully PU, peak range (peak)
Cargo
forward to tilt the mast forward. PV,
Handling (AC 1,000 A (257 - 284 A
Measure the current in the PW
above condition. peak range) (rms))

Set the power mode to the H

mode, direct the rear wheel tire DC 1,000 A 184 - 205 A
straight-forward and turn the PU, peak range (peak)
PS steering wheel fully right or left PV,
direction. PW (AC 1,000 A (130 - 145 A
Measure the current in the peak range) (rms))
above condition.

• After finishing the check, re-connect the wiring to the brake switch.
(Only when measuring the cut-off current at traveling)

8-5
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

13. Fuse

To reduce the risk of fire, replace only with same type and capac-
ity of fuse.

1. Turn OFF the key switch,

open the battery hood and
disconnect the battery plug.
2. Remove the upper cover of
counterweight and then
cover of controller inside.
3. Open the fuse holder,
remove the fuse from
inside, and inspect whether
or not the fuse has blown
using a tester.
Control Equipment

4. If a fuse is blown, replace it

with spare fuse of same
capacity.
 Use a Little 326 (model
code) slow-blow fuse which
complies with the UL stan-
dard. Refer to “CHAPTER
2. Testing and Adjusting”.

14. Wiring Examine the items below by visual check and touching by finger.
(Including the
charger cord) 1) Damage to the wire harness, loose clamp
2) Loose terminal connection block, state of taping
3) Contact of battery connector, loose bolts
4) Damage to the wire harness sheath (cladding)

8-6
 8. YEARLY INSPECTION CRITERIA

Check Item Check Content

18. Electrolyte 1) Check electrolyte solution

solution Check the battery electrolyte level. If battery electrolyte is below the standard
level, refill distilled water or purified water.
 For information about inspecting and refilling of battery electrolyte, see “Opera-
tion & Maintenance Manual” attached to the battery.

Caution on handling the battery

(1) Emergency medical care when poring the electrolyte solution on your body.
Eyes, skin and clothes are contaminated with the electrolyte solution, wash
with a large amount of water.
Especially, for eye, take the diagnosis of medical doctor immediately.
(2) Fire inhibited
Do not make short-circuit or spark. Do not approach fire such as tobacco.
(3) Prevention of electrification
In the maintenance and check, wear rubber gloves to avoid the electrifica-
tion.
(4) Ventilation
Whether the lift truck is working or not, ventilate the work area fully.

2) Check specific gravity of elec-

trolyte solution
(1) Rubber ball
(2) Feed tube
(3) Outer cylinder
Battery

(4) Electrolyte solution

(5) Specific gravity meter
1. Charge the battery fully. After com-
pleting the charging, set the electro-
lyte level properly.
2. Measure the specific gravity and
temperature of electrolyte solution
with the specific gravity meter and
thermometer.
 See “Operation & Maintenance Man-
ual” attached to the battery.
Keep the measured data.

19. Cell (Battery jar) 1) Voltage

Charge the battery fully. After completing the charging, measure the voltage
with the DC voltmeter. The voltage should be more than the value set (2.0V/
cell) and voltages of all cells should be almost equal.

2) Damage
20. Terminal 1) Looseness
2) Dirt
3) Damage
4) Corrosion/ Electric erosion
20. Battery case 1) Damage
2) Dirt

8-7
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

21-24. Transfer 1) Oil Leakage

Check visually.

2) Oil Level Check, Oil Replace-

ment
1
Oil Level Check
1. Remove the oil level plug (2) and
Power Transfer Equipment

check.
2. If the oil is filled to the line below
the hole of level plug, it is normal.
3. If the oil is not sufficient, remove 3
the plug (1) of oil filler port and refill 2
the oil.

Oil Replacement
1. Remove the plug (1) of oil filler port and then drain plug (3) to drain the oil.
2. After draining the oil, tighten the drain plug (3) and re-fill the specific amount of
gear oil from the oil filler port.
Amount of oil to be replaced: both cases at the right and left sides 0.5 liter.
3. After re-filling, check the oil level with the oil level plug and keep the oil level
appropriate. (Refer to “Oil Level Check” above.)

3) Loose Bolts
Check that the bolts are not loosened and tightened properly.

25. Front axle 1) Deformation, Crack, Damage

Check visually. If necessary, check in the crack search method.

2) Loose mounting bolt

The bolts should be tightened with the 1
specific torque.
Traveling equipment

26. Rear axle 1) Support Mounting Bolt (4-wheel / 3-wheel lift truck)

175 - 215 Nm {18 - 22 kgm} [130.2 - 159.1 ft. lb]

8-8
 8. YEARLY INSPECTION CRITERIA

Check Item Check Content

27-28. Tire 1) Crack and damage of tire

Check visually the crack, defect of tread and side wall. If serious, replace the
tire.

2) Depth of groove
In case of pneumatic (air inflated) tire,
measure the depth of groove C at the
location B of tread width 1/4 and confirm
that the dimension C is more than 1.6
mm [0.06 in].

3) Abnormal wear of tire

Check visually the abnormal wear,
eccentric wear and stepped wear.

4) Biting of foreign matter, sticking

Check visually the biting of metal fragment, stone, foreign matter and sticking.

28. Hub bolt, nut rim 1) Looseness

set volt, nut
Traveling equipment

Tighten with the hub nut wrench and check. If loosened, tighten with the torque
listed on the table below.

Item Unit 1.5 - 2.0 ton

Nm 157 - 245
Hub nut tightening Front
{kgm } {16 - 25}
torque Rear
[fb. lb] [116 - 181]
Nm 157 - 245
Rim set nut {kgm } {16 - 25}
Rear
tightening torque
[fb. lb] [116 - 181]

2) Damage
Check visually that no damage exists.

28. Rim 1) Damage, deformation and crack

Check visually by crack search method.

28. Wheel bearing Jack up the lift truck and check the items below.

1) Rattle
Hold the upper and lower sides of tire by hand and check whether the rattle
exists or not.

2) Foreign noise
Rotate the tire by hand and check by hearing the foreign noise during rotation by
inertia and heaviness at this moment.

30. Steering wheel 1) Play

30 - 60 mm
Play L
Steering equipment

[1.18 - 2.36 in]

2) Rattle
Move the steering in the shaft direction
and diameter direction and check
whether the rattle exists or not.

3) Steering Condition
Travel and steer. And check that any abnormality exists.

8-9
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

33. Knuckle 1) Rattle of king pin (4-wheel lift truck only)

Jack up the rear wheels. Hold the upper and lower sides of tire by hand and
check whether the rattle exists or not.

2) Damage and crack of knuckle

Check visually or by the crack search method.

34. Radius of right 1) Measurement of minimum turning radius

and left turn 1. Ask your assistant to drive the lift truck to make the minimum turning radius.
2. Fix the stick with chalk to the outermost part of weight and draw the circle on the
ground.
3. Measure the circle drawn on the ground.
4. Perform the right turn (swing) and left turn.

4-wheel lift truck 3-wheel lift truck

Within 1750 mm Within 1530 mm

FB15U-12 FB15MU-12
[68.9 in] ±5 % [60.2 in] ±5 %

Within 1785 mm Within 1590 mm

FB18U-12 FB18MU-12
Steering equipment

[70.3 in] ±5 % [62.6 in] ±5 %

Within 1850 mm Within 1690 mm

FB20AU-12 FB20MU-12
[72.8 in] ±5 % [66.5 in] ±5 %

35. Steering wheel 1) Drop

2) Contact of wheel to other parts
36. Steering valve 1) Oil leakage
2) Loose mounting bolt, drop
36-37.Power steering 1) Oil leakage from power steer-
equipment ing cylinder and hose
2) Damage/degradation of hose
3) Looseness/drop of mount-
ing bolt
4) Conflict with the lift truck

8-10
 8. YEARLY INSPECTION CRITERIA

Check Item Check Content

39-40.Brake Pedal 1) Pedal Height (Before measurement, remove the floor mat.)
Reference
Check Location Dimension Value S1
(mm) [in]

0-4 S2
Play S1
[0 - 0.2]
H1
105
Pedal Height H1 H2
[4.13]

Pedal Height when 60

Braking equipment

H2
stepping on [2.36]

Position of switch 10
S2
ON [0.39]

2) Braking effect
Travel on the dry flat paved road at the maximum speed. Then, stop suddenly
and measure the items below.
1. Pulled steering
2. Pull of brake
3. Foreign noise
4. Brake stopping distance

When not loaded Within 4.5 m [1.77 in] (When traveling at the maximum speed)
When loaded Within 2.0 m [78 in] (When traveling at 10 km/h [6 mph])

8-11
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

41. Parking brake 1) Parking Lever

1. Lever Operation Force: 98 20 - 147 N {10 -15 kgf} [22 - 23 lb]
2. Braking force
Check that the parking brake can hold the lift truck on the following slopes.

With no load Slope of 20% (11.2°) or steeper

With load Slope of 15% (8.5°) or steeper

3. Adjustment for when the braking force is abnormal

1) Release the parking brake lever.
2) Turn the adjustment bolt (1) from the window at the lower side so that the
lever operating force becomes 296 - 343 N {30 - 35 kgf} [66 - 67 ib].
3) In the state that the parking brake is pulled up, turn the adjustment bolt (4)
so that the clearance between adjustment bolt (4) and lever (5) is 2.0 - 2.2
mm [0.08 - 0.09 in].
4) Release the parking brake lever.
5) Adjust by turning the adjustment bolt (4) so that the clearance (A) between
adjustment bolt and lever (5) is 0 mm [0 in].
(As the adjustment bolt has the detent, it can be adjusted by a half turns (1/
2)).
Braking equipment

6) Confirm that lever operating force is within the range of 98 - 147 N {10 -15
kgf} [22 - 23 lb].
7) If the clearance (A) mentioned above differs in the right and left axles,
adjust the balance of right and left axles with the yoke (6) in the brake lever
block.

Free 0 mm [0 in] A
4
Lock 5

When the parking When the parking

brake is released brake is applied

42. Rod, link, cable 1) Damage, looseness, rattle

2) Damage of cotter pin

8-12
 8. YEARLY INSPECTION CRITERIA

Check Item Check Content

43. Brake piping Check the following items on pipe, hose and joint.

1) Damage
2) Oil leakage
3) Risk of contacting
4) Degradation of hose
5) Loose mounting bolt
44-46.Traveling brake 1) Oil Leakage 1
Check visually.

2) Brake Fluid A (MAX.)

Remove the cap (1) and confirm that the level of
brake fluid is within the optimum range (between B (MIN.)
A and B). 2
(1) Cap
(2) Brake reserve tank

3) Operation of master cylinder and wheel

cylinder.
Step on the brake pedal and check the items below.
1. The heaviness of brake pedal when stepped on.
2. The variation of heaviness of brake pedal.
Braking equipment

3. The variation of pedal position when keeping stepping on the brake pedal.
4. Return of brake pedal when released.

4) Check visually the oil leakage and damage of master cylinder and
wheel cylinder.
5) Wear and damage of cylinder, piston and cup.
If any abnormality is found in steps 3) and 4), disassemble and examine.

Judging Standard
Unit: mm [in]
Criteria
Check Item Standard Limit
Dimension allowed

0.050 - 0.151 0.20

Clearance between cylinder and piston
[0.002 - 0.006] [0.008]

0.016 - 0.086 0.15

Clearance of holder and piston rod
[0.001 - 0.003] [0.006]

1.7 - 1.8 0.75

Interference of cup (large diameter)
[0.067 - 0.071] [0.030]

1.0 - 1.2 0.40

Interference of cup (small diameter)
[0.039 - 0.047] [0.016]

0.5 - 0.6 0.10

Interference of dust seal
[0.020 - 0.024] [0.004]

25.0 - 26.6 22.5

Free length of spring
[0.98 - 1.05] [0.89]

8-13
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

48-49.Brake Disk 1) Wear of disc 1

1. Put the wheel stoppers to the front
and rear wheels to lock them.
2. Pull the parking lever so that the pis-
ton (3) closely contacts the disc (A).
3. Measure the depth to the piston (3)
with the caliper (2) from the opening
for measuring the wear of disc.
3
Braking equipment

 If the measured value is more than

13.5 mm [0.53 in], replace the disc A
and a set of plate.

53-54. Fork 1) Damage and wear of fork and fork pin

2) Deformation of fork
Align the fork in the center of lift truck
and measure the height difference C and
open distance B. Check that the mea-
sured values meet the specification.

Height
Within 15 mm [0.59 in]
Difference C
Cargo handling equipment

Open Distance Within 35 mm [1.38 in]

3) Wear of fork
Measure the thickness A at the root of fork and check it to meet the specifica-
tion.

1.5t More than 30 mm [1.18 in]

1.75t More than 33 mm [1.30 in]

2.0t More than 32.5 mm [1.28 in]

4) Crack of fork
Especially, as the force will be concentrated on the location below, check in the
crack search method.
• Part at the foot of fork
• Hook of fork

8-14
 8. YEARLY INSPECTION CRITERIA

Check Item Check Content

55-57.Mast, finger bar 1) Crack

Check visually or in the crack search method. (Especially welded portion)
• Each stay
• Chain wheel shaft
• Tilt cylinder bracket
• Each welded portion of finger bar
• Roller shaft

2) Rattle of roller bearing

Erect vertically the mast and lift up the fork by 100 mm [3.94 in] from the ground.
Then, check the clearance between inner mast and finger bar and the clear-
ances between inner mast and outer mast at the front and rear and the right and
left respectively. With this, judge the rattle of roller and rail.

Item 1.5 - 1.75 ton 2.0 ton

Clearance at Within 2.0 mm Within 2.0 mm

front and rear [0.079 in] [0.079 in]
Clearance between outer
mast and inner mast Within 2.0 mm Within 2.5 mm
Clearance at
right and left [0.079 in] [0.098 in]

Clearance at Within 2.0 mm Within 2.0 mm

Cargo handling equipment

front and rear [0.079 in] [0.079 in]

Clearance between finger
bar and inner mast Within 2.0 mm Within 2.5 mm
Clearance at
right and left [0.079 in] [0.098 in]

3) Clearance between the spherical bushing and pin in the mast sup-
port block

Within
Clearance 0.016 mm Spherical Bushing
[0.0006 in]
Bolt

Support Pin

Support

4) Spherical bushing in the mast support block

Confirm that the oil groove exists on the spherical bushing.

5) Crack and damage of roller and roller pin

1. Check visually whether the abnormality exists or not in the roller rolling block on
the inner face of mast.
2. Insert the metal stick of 200 mm [7.87 in] in length in between the outer mast
and inner mast, and check the crack and damage of roller and roller pin by gall-
ing.
 If the welded portion of roller pin is suspected, disassemble the mast and check
in the crack search method.

8-15
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

58-59. Chain 1) Tension

Erect vertically the mast and lift up the fork by 100 mm [3.9 in] from the ground.
Then, confirm that the tension is proper by pushing the lift chain in the middle by
finger.
Adjustment: Adjust with the chain stopper.

2) Stretch
Measure the length L of 17 links and confirm that it meets the specification.
Length L of 17 links

Within 275.5 mm
1.5 - 1.75 ton
[10.8 in]
Cargo handling equipment

Within 330 mm
2.0 ton
[13.0 in]

3) Deformation, damage, state of fueling, rust

Check visually.

4) Deformation and damage of bearing

Check visually.

58-59.Chain wheel 1) Deformation, damage

Check visually.

2) Rattle of bearing
Rotate the chain wheel by hand and check the rattle of bearing.

60-61.Attachments 1) Looseness, deformation, crack, damage, wear

Operate the attachment and check visually.

2) State of installation
Operate the attachment and check visually.

62. Hydraulic oil 1) Oil Amount

tank (1) Oil gauge 1
(2) Floor plate 2
(3) Oil Filler Port L
In the state that the fork is lowered,
peel off the floor carpet and open rear
side of floor plate (2). Then, check
Hydraulic equipment

with the hydraulic oil level gauge (1)

that the oil is filled to the level of opti-
mum range L. If not, re-fill the hydrau- 3
lic oil from the oil filler port.

2) Replacement of hydraulic oil, cleaning of strainer, replacement of

line filter.
Refer to “CHAPTER 2. Testing and Adjusting”.

65. Oil Pump 1) Oil leakage

2) Abnormal vibration
3) Foreign noise
4) Abnormal wear of spline
5) Looseness of mounting bolt

8-16
 8. YEARLY INSPECTION CRITERIA

Check Item Check Content

67-71. Cylinder 1) Looseness, deformation, cracks, damage

Check the looseness, deformation, crack and damage of piston rod, screwed
portion of rod and rod end.
Important check location
1. Bending, scar and rust of piston rod (Check visually or by finger-touching.)
2. Crack of screwed portion of piston rod (Check visually or by color.)
3. Looseness of lift cylinder mounting bolt

Lift cylinder mounting bolt 59 - 74 Nm {6 - 7.5 kgm} [43 - 54 lb]

2) Naturally descending amount, naturally tilting amount

Naturally descending Fork block Within 60 mm [2.36 in] / 15 minutes

amount Cylinder block Within 30 mm [1.18 in] / 15 minutes
Naturally tilting amount Cylinder block Within 23 mm [0.91 in] / 15 minutes

 For measuring procedure, refer to “CHAPTER 2. Testing and Adjusting”.

Adjustment: Replace control valve and cylinder packing

3) Oil Leakage, Damage

Check visually.
Hydraulic equipment

4) Clearance between bushing of tilt cylinder rod at head side and

mounting pin.

1.5 - 1.75 ton Less than 0.5 mm [0.020 in]

Clearance
2.0 ton Less than 0.6 mm [0.024 in]

72-74.Control valve 1) Oil Leakage

Check visually.

2) Operation of relief valve

After reaching the maximum high lifting height, check by listening to the operat-
ing noise of relief valve.

3) Relief Pressure
1
1. Install the oil pressure (maximum oil
pressure 24.5 MPa {250 kgf/cm2}
[3555 PSI] to the relief pressure mea-
suring port (1) (plug of sensor mount-
ing block).
2. Lift up the fork to the maximum high
lifting height and measure the oil pres-
sure when relieving the oil. Check the
measured oil pressure to meet the
specific pressure.

17.1 - 18.1 MPa

Specific
pressure {174 - 185 kgf/cm2 }
[2474 - 2631 PSI]

 When the port valve is installed, perform in the state that the lever for attach-
ment is forward-tilted.

8-17
8. YEARLY INSPECTION CRITERIA

Check Item Check Content

75. Frame, Body 1) Crack, deformation

2) Mounting bolt, loose nut, drop
76. Cab 1) Crack, deformation
2) Corrosion, rainwater leakage
3) Close/open, lock, rattle and damage of door
77. Seat 1) Operation
2) Loose mounting bolt
78. Lifting 1) Crack, damage, deformation
equipment,
2) Loose mounting bolt
Body, Safety Equipment

anti-slipping

79. Display 1) Damage

2) State of installation
80. Head Guard 1) Looseness of installation block
2) Deformation, crack and damage
81. Backrest 1) Looseness of installation block
2) Deformation, crack and damage
82. Lighting 1) Operation of light
system,
meters, alarm 2) State of installation, damage, water penetration
3) Operation of meters
83. Mirror, reflector 1) Dirt, damage
2) Mirrored image
84. Greasing 1) Greased state
2) Operation of automatic greasing equipment
85. Function of each 1) Confirm by traveling and work test.
Total test

equipment

8-18
9. Conversion Tables

Millimeters to Inches .......................................................................................... 9-3

Inches to Millimeters .......................................................................................... 9-3

Cubic meters to Cubic yards .............................................................................. 9-4

Cubic yards to Cubic meters .............................................................................. 9-4

Liter to U.S. Gallon............................................................................................. 9-5

U.S. Gallon to Liter............................................................................................. 9-5

Liter to U.K. Gallon............................................................................................. 9-6

U.K. Gallon to Liter............................................................................................. 9-6

Kilogram to Pound.............................................................................................. 9-7

Pound to Kilogram.............................................................................................. 9-7

kg/cm2 to Ib/in2................................................................................................... 9-8

kgm to ft. Ib ........................................................................................................ 9-9

Temperature..................................................................................................... 9-10

9-1
 9. CONVERSION TABLES

Millimeters to Inches 1 mm=0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.881 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 2.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Inches to Millimeters

0.1 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09

0 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286

0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826

0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366

0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906

0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446

0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986

0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526

0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066

0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606

0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146

9-3
9. CONVERSION TABLES

Cubic meters to Cubic yards 1 m3= 1.308 cu.yd

0 1 2 3 4 5 6 7 8 9

1.31 2.62 3.92 5.23 6.54 7.85 9.16 10.46 11.77

10 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85

20 26.16 27.47 28.78 30.08 31.39 32.70 34.01 35.32 36.62 27.93

30 39.24 40.55 41.86 43.16 44.47 45.78 47.09 48.40 49.70 51.01

40 52.32 53.63 54.94 56.24 57.55 58.86 60.17 61.48 62.78 64.09

50 65.40 66.71 68.02 69.32 70.63 71.94 73.24 74.56 75.86 77.17

60 78.48 79.79 81.10 82.40 83.71 85.02 86.33 87.64 88.94 90.25

70 91.56 92.87 94.18 95.48 96.79 98.10 99.41 100.72 102.02 103.33

80 104.64 105.95 107.26 108.56 109.87 111.18 112.49 113.80 115.10 116.41

90 117.72 119.03 120.34 121.64 122.95 124.26 125.57 126.88 128.18 129.49

Cubic yards to Cubic meters

0 1 2 3 4 5 6 7 8 9

0.76 1.53 2.29 3.06 3.82 4.59 5.35 6.12 6.88

10 7.65 8.41 9.18 9.94 10.70 11.47 12.23 13.00 13.76 14.53

20 15.29 16.06 16.82 17.59 18.35 19.12 19.88 20.64 21.41 22.17

30 22.94 23.70 24.47 25.23 26.00 26.76 27.53 28.29 29.05 29.82

40 30.58 31.35 32.11 32.88 33.64 34.41 35.17 35.94 36.70 37.47

50 38.23 38.99 39.76 40.52 41.29 42.05 42.82 43.58 44.35 45.11

60 45.88 46.64 47.41 48.17 48.93 49.70 50.46 51.23 51.99 52.76

70 53.52 54.29 55.05 55.82 56.58 57.35 58.11 58.57 59.64 60.40

80 61.17 61.93 62.70 63.46 64.23 64.99 65.76 66.52 67.28 68.05

90 68.81 69.58 70.34 71.11 71.87 72.64 73.40 74.17 74.93 75.70

9-4
 9. CONVERSION TABLES

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586

60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228

70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870

80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511

90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

U.S. Gallon to Liter 1 U.S. Gal = 3.7854l

0 1 2 3 4 5 6 7 8 9

3.79 7.57 11.36 15.14 18.93 22.71 26.50 30.28 34.07

10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92

20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78

30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63

40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49

50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34

60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 353.62 257.41 261.19

70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05

80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90

90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76

9-5
9. CONVERSION TABLES

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0.200 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978

60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577

90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

U.K. Gallon to Liter 1 U.K. Gal = 4.5461l

0 1 2 3 4 5 6 7 8 9

4.55 90.09 13.64 18.18 22.73 27.28 31.82 36.37 40.92

10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38

20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84

30 136.38 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30

40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76

50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22

60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68

70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14

80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60

90 409.15 413.69 418.24 422.79 427.33 431.88 436.42 440.97 445.52 450.06

9-6
 9. CONVERSION TABLES

Kilogram to Pound 1 kg = 2.2046 Ib

0 1 2 3 4 5 6 7 8 9

2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Pound to Kilogram 1 Ib = 0.4536 kg

0 1 2 3 4 5 6 7 8 9

0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082

10 4.536 4.990 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618

20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154

30 13.608 14.061 14.515 14.969 15.422 15.876 16.329 16.783 17.237 17.690

40 18.144 18.597 19.051 19.505 19.958 20.412 20.865 21.319 21.772 22.226

50 22.680 23.133 23.587 24.040 24.494 24.948 25.401 25.855 26.308 26.762

60 27.216 27.669 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298

70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843

80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370

90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906

9-7
9. CONVERSION TABLES

kg/cm2 to Ib/in2 1 kg/cm2 = 14.2233 Ib/in2

0 1 2 3 4 5 6 7 8 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2

20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5

30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2

60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1644 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 2863 1877 1892 1906 1920 1934 1946 1963 1977

140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 223 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2360 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

9-8
 9. CONVERSION TABLES

kgm to ft. Ib 1 kgm = 7.233 ft. Ib

0 1 2 3 4 5 6 7 8 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1

40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8

60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1

70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7

90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4

110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7

120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1

130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4

140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0

160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1220.7 1207.9 1215.1 1222.4

170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7

180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0

190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

9-9
9. CONVERSION TABLES

Temperature
Fahrenheit-Centigrade
A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice
versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired it convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahr-
enheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C °F °C °F °C °F °C °F

-40.4 -40 -40.9 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.6 17 62.6 11.1 52 125.6 30.6 84 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.8 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 112.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

9-10
Appendix

3BA-97-99710 (INPUT GEAR/BEARING PRESS-FITTING JIG) ......................A-3

3BA-97-99720 (MULTIPLE DISC ALIGNMENT JIG).........................................A-4

3BA-97-99730 (MULTIPLE HOLDER CLEARANCE ALIGNING JIG) ...............A-5

3BA-97-99740 (3-WHEEL REAR AXLE PRESS-FITTING JIG) ........................A-6

3BA-97-99760 (3-WHEEL REAR AXLE SENSOR ALIGNMENT JIG)...............A-7

SERVICE TOOL CONFIGURATION..................................................................A-8

ELECTRIC WIRING DIAGRAM - TYPE A (LIFT TRUCK WITH 3 PORTS).......A-9

ELECTRIC WIRING DIAGRAM - TYPE B (LIFT TRUCK WITH 4 PORTS).....A-10

A-1
 APPENDIX

3BA-97-99710 (INPUT GEAR/BEARING PRESS-FITTING JIG)

A-3
APPENDIX

3BA-97-99720 (MULTIPLE DISC ALIGNMENT JIG)

A-4
 APPENDIX

3BA-97-99730 (MULTIPLE HOLDER CLEARANCE ALIGNING JIG)

A-5
APPENDIX

3BA-97-99740 (3-WHEEL REAR AXLE PRESS-FITTING JIG)

A-6
 APPENDIX

3BA-97-99760 (3-WHEEL REAR AXLE SENSOR ALIGNMENT JIG)

A-7
APPENDIX

SERVICE TOOL CONFIGURATION

A-8
ELECTRIC WIRING DIAGRAM - TYPE A (LIFT TRUCK WITH 3 PORTS)

A-9
ELECTRIC WIRING DIAGRAM - TYPE B (LIFT TRUCK WITH 4 PORTS)

A-10
KOMATSU FORKLIFT USA, LLC