99759-65100

Service Manual

EP10KRT, EP12KRT, EP15KRT

Chassis, Mast & Options

EP10KRT ETB10-00011
EP12KRT ETB10-20001
EP15KRT ETB10-50001
 FOREWORD

This service manual is a guide to servicing of Caterpillar® Lift Trucks of 1.0 ton, 1.25
ton and 1.5 ton models. The instructions are grouped by systems to serve the
convenience of your ready reference.
Long productive life of your lift trucks depends to a great extent on correct servicing —
the servicing consistent with what you will learn from this service manual. We hope you
read the respective sections of this manual carefully and know all the components you
will work on before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual were of the
trucks of serial numbers in effect at the time it was approved for printing. Caterpillar
reserves the right to change specifications or design without notice and without incurring
obligation.

Safety Related Signs

The following safety related signs are used in this service

manual to emphasize important and critical instructions:

WARNING Indicates a specific potential hazard

resulting in serious bodily injury or
death.

CAUTION Indicates a specific potential hazard

resulting in bodily injury, or damage
to, or destruction of, the machine.

Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.

Pub. No. 99759-65100

 HOW TO READ THIS MANUAL
Disassembly diagram (example)

Each disassembly diagram is followed by

Disassembly sequence and Suggestion for
disassembly.

Disassembly sequence

1 Cover, Bolt, Washer (part name)

2 Output shaft (part name)

Suggestion for disassembly

(1) Output shaft removal

Unit: mm
Clearance A 0.020 to 0.105
between
cylinder and
piston B 0.15

A: Standard value
B: Repair or service limit
 WARNING

SAFETY

WARNING WARNING
The proper and safe lubrication and Do not operate this truck unless you have
maintenance for this lift truck, recommended read and understand the instructions in the
by Caterpillar, are outlined in the OPERATION & MAINTENANCE MANUAL.
OPERATION & MAINTENANCE MANUAL for Improper truck operation is dangerous and
these trucks. could result in injury or death.
Improper performance of lubrication or
maintenance procedures is dangerous and 4. Lower the forks or other implements to the ground
could result in injury or death. Read and before performing any work on the truck. If this
understand the OPERATION & cannot be done, make sure the forks or other
MAINTENANCE MANUAL before performing implements are blocked correctly to prevent them
any lubrication or maintenance. from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
The serviceman or mechanic may be unfamiliar with mounting or dismounting a truck. Clean any mud
many of the systems on this truck. This makes it or debris from steps, walkways or work platforms
important to use caution when performing service before using. Always face truck when using steps,
work. A knowledge of the system and/or components ladders and walkways. When it is not possible to
is important before the removal or disassembly of any use the designed access system, provide ladders,
component. scaffolds, or work platforms to perform safe repair
operations.
Because of the size of some of the truck components,
the serviceman or mechanic should check the weights 6. To avoid back injury, use a hoist when lifting
noted in this Manual. Use proper lifting procedures components which weigh 23 kg (50 lb.) or more.
when removing any components. Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity. Be
Following is a list of basic precautions that should
sure hooks are positioned correctly. Lifting eyes
always be observed.
are not to be side loaded during a lifting
1. Read and understand all warning plates and decals operation.
on the truck before operating, lubricating or
7. To avoid burns, be alert for hot parts on trucks
repairing the product.
which have just been stopped and hot fluids in
2. Always wear protective glasses and protective lines, tubes and compartments.
shoes when working around trucks. In particular,
8. Be careful when removing cover plates.
wear protective glasses when pounding on any
Gradually back off the last two bolts or nuts
part of the truck or its attachments with a hammer
located at opposite ends of the cover or device and
or sledge. Use welders gloves, hood/goggles,
pry cover loose to relieve any spring or other
apron and other protective clothing appropriate to
pressure, before removing the last two bolts or
the welding job being performed. Do not wear
nuts completely.
loose-fitting or torn clothing. Remove all rings
from fingers when working on machinery. 9. Be careful when removing filler caps, breathers
and plugs on the truck. Hold a rag over the cap or
3. Do not work on any truck that is supported only
plug to prevent being sprayed or splashed by
by lift jacks or a hoist. Always use blocks or jack
liquids under pressure. The danger is even greater
stands to support the truck before performing any
if the truck has just been stopped because fluids
disassembly.
can be hot.
10. Always use tools that are in good condition and 18. Loose or damaged fuel, lubricant and hydraulic
be sure you understand how to use them before lines, tubes and hoses can cause fires. Do not
performing any service work. bend or strike high pressure lines or install ones
11. Reinstall all fasteners with same part number. which have been bent or damaged. Inspect lines,
Do not use a lesser quality fastener if tubes and hoses carefully. Do not check for
replacements are necessary. Do not mix metric leaks with your hands. Pin hole (very small)
fasteners with standard nuts and bolts. leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can
12. If possible, make all repairs with the truck
penetrate the skin and cause personal injury. Use
parked on a level, hard surface. Block truck so it
cardboard or paper to locate pin hole leaks.
does not roll while working on or under truck.
19. Tighten connections to the correct torque. Make
13. Disconnect battery and discharge any capacitors
sure that all heat shields, clamps and guards are
(electric trucks) before starting to work on truck.
installed correctly to avoid excessive heat,
Hang “Do not Operate” tag in the Operator’s
vibration or rubbing against other parts during
Compartment.
operation. Shields that protect against oil spray
14. Repairs, which require welding, should be onto hot exhaust components in event of a line,
performed only with the benefit of the tube or seal failure, must be installed correctly.
appropriate reference information and by
20. Relieve all pressure in air, oil or water systems
personnel adequately trained and knowledgeable
before any lines, fittings or related items are
in welding procedures. Determine type of metal
disconnected or removed. Always make sure all
being welded and select correct welding
raised components are blocked correctly and be
procedure and electrodes, rods or wire to provide
alert for possible pressure when disconnecting
a weld metal strength equivalent at least to that
any device from a system that utilizes pressure.
of parent metal.
21. Do not operate a truck if any rotating part is
15. Do not damage wiring during removal
damaged or contacts any other part during
operations. Reinstall the wiring so it is not
operation. Any high speed rotating component
damaged nor will it be damaged in operation by
that has been damaged or altered should be
contacting sharp corners, or by rubbing against
checked for balance before reusing.
some object or hot surface. Do not connect
wiring to a line containing fluid.
16. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
 GROUP INDEX

GROUP INDEX Items involved

GENERAL INFORMATION Serial Number Locations, Dimensions, Technical Data 1

VEHICLE ELECTRICAL
Console Box, Key Switch, Lamp Specification Chart 2
COMPONENTS

Outline, Controller Components, Logic Card Components, Controller Models,

MAIN CONTROLLER Operation Outline, Drive System, Hydraulic System, Fail-safe System, 3
Malfunction Detection, Malfunction Data Record, Setting, Self-diagnosis, etc.

TROUBLESHOOTING Faulty Central Vehicle Monitor System, Faulty Diagnosis Indication, or

FOR CONTROL CIRCUITS Other Abnormalities 4
Motor Installation Positions, Specifications, Structures, Tightening of
MOTORS High-power Cable Terminals, Inspection of Brushes for Wear and Brush 5
Replacement, Procedures and Key Points for Removal and Installation, etc.

Structure and Functions, Disassembly and Reassembly of Front Axle

FRONT AXLE 6
Assembly, Service Data

Rear Axle, Rear Wheels, Removal and Installation, Disassembly and

REAR AXLE 7
Reassembly, Adjustment, Troubleshooting, Service Data

Specifications, Structure and Functions, Procedures and Key Points for

BRAKE SYSTEM Disassembly and Reassembly, Inspection and Adjustment, 8
Troubleshooting, Service Data
Specifications, Structure and Functions, Procedures and Key Points for
STEERING SYSTEM Removal and Installation, Steering Control Valve, Hydraulic Circuit, 9
Troubleshooting, Service Data

Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator
HYDRAULIC SYSTEM 10
Valve, Down Safety Valve

MASTS AND FORKS Simplex Mast, Duplex Mast, Triplex Mast 11

Inspection Standards, Periodic Replacement of Parts, Lubrication
SERVICE DATA Standards, Main Component Weights, Tightening Torque for Standard 12
Bolts and Nuts, Special Tools

OPTIONS Amber Strobe Kit, Back Buzzer Kit, Working Lamp Kit, Tire Kit 13
 GENERAL INFORMATION

1
Vehicle Exterior ....................................................................................... 1–1
Models ....................................................................................................... 1–1
Serial Number Locations ...................................................................... 1–2
Chassis and Mast Model Identification ............................................ 1–3
Dimensions .............................................................................................. 1–4
Technical Data ......................................................................................... 1–5
 GENERAL INFORMATION

Vehicle Exterior

103378

Models

This manual applies to EP10KRT, EP12KRT and EP15KRT.

Truck Model Serial Number

EP10KRT ETB10-00011-up
EP12KRT ETB10-20001-up
EP15KRT ETB10-50001-up

1-1
GENERAL INFORMATION

Serial Number Locations

Mast number Chassis number Nameplate

209010

1-2
 GENERAL INFORMATION

Chassis and Mast Model Identification

[Chassis]
EP 10 KRT

Generation designator and truck type

Rated capacity
10: 1000 kg
12: 1250 kg
15: 1500 kg
Battery type
EP: Electric Pneumatic
EC: Electric Cushion

[Mast]
2 G 15 A 33

Maximum lifting height

“33” stands for 3300 mm

Order of the minor change

(“A” for the original, “B” for the first change, “C” for
the second change, and so on)

Applicable truck model designation

15: 1.0 ton class

Kind of mast
G: simplex mast
H: duplex mast
J: triplex mast
Major change
(“2” for the original, “3” for the first change, and so
on up to “9”)

1-3
GENERAL INFORMATION

Dimensions

209011

1-4
 GENERAL INFORMATION

Technical Data
With 2G15A33 Mast Installed
Truck model EP10KRT EP12KRT EP15KRT
Mast tilt, forward/backward A (deg) 5/7 5/7 5/7
Height with mast lowered B (mm) 2110 2110 2110
Standard free lift C (mm) 120 120 120
Standard lift height D (mm) 3300 3300 3300
Overall height with mast raised (without backrest)
3895 3895 3895
E (mm)
Overall length F (mm) 2500 2500 2575
Length to fork face (includes fork thickness) G (mm) 1700 1700 1775
Overall width H (mm) 997 997 997
Forks dimensions (thickness × width × length) I (mm) 35 × 80 × 800 35 × 80 × 800 35 × 80 × 800
Turning circle radias J (mm) 1370 1370 1445
Fork carriage width K (mm) 920 920 920
Ground clearance under mast, with load L (mm) 80 80 80
Ground clearance center of wheelbase, with load
100 100 100
M (mm)
Travel speed, with/without load km/h 11.5/13.5 11.2/13 11/12.5
Lifting speed, with/without load m/s 0.29/0.48 0.27/0.48 0.26/0.48
Lowering speed, with/without load m/s 0.52/0.50 0.52/0.50 0.52/0.50
Rated drawbar pull, with/without load
1569/1667 1520/1669 1470/1670
(60 min. short duty) N
Maximum drawbar pull, with/without load
4217/4315 4168/4315 4119/4314
(5 min. short duty) N
Gradeability, with/without load % 5.5/8.0 4.5/7.5 3.5/6.5
Maximum gradeability, with/without load % 13/20 11/18 10/16
Battery to DIN 43531/35/36A/B/C/No. DIN43535A
Battery voltage/capacity at 5-hour discharge V/Ah 24/600, 720 24/600, 720 24/720, 840
Battery weight kg 445, 540 445, 540 540, 620
Truck weight, without load/including battery kg
2333 2568 2778
(Maximum battery)
Drive motor capacity (60 min. short duty) kW 4.8 4.8 4.8
Pump motor output @15 % duty factor kW 8.8 8.8 8.8
Drive motor control method Mosfet-chopper
Pump motor control method Chopper

1-5
 VEHICLE ELECTRICAL COMPONENTS

Console Box ............................................................................................ 2 – 1

Functions of Vehicle Monitor System ........................................................ 2 – 1
2
Electrical Components .............................................................................. 2 – 3
Disassembly and Reassembly .................................................................. 2 – 4
Forward/Reverse Lever ........................................................................ 2– 5
Accelerator Control ............................................................................... 2– 6
Key Switch ............................................................................................... 2– 7
Lighting Switch ....................................................................................... 2– 7
Fuses ......................................................................................................... 2– 8
Lamp Specification Chart .................................................................... 2– 8
Electrical Schematic (Type: Chopper) .............................................. 2 – 11
Electrical Diagram (Type: Chopper) .................................................... 2 – 13
 VEHICLE ELECTRICAL COMPONENTS

Console Box

1 Central Vehicle Monitoring System (CVMS)

2 Steering tilt knob
3 Key switch
4 Lighting switch

103380

Functions of Central Vehicle Monitor System (CVMS)

209140C
Operations

No. Monitor name When OFF When ON or flashing Remarks

1 Service indicator No service is required Wrench-symbol warning lamp

comes on when error has occurred
Worn motor brush Drive motor and pump motor Worn brushes After brushes are replaced,
2
lamp brushes in operable condition lamp turns OFF.

Controller/motor Controller, drive motors and Overheat Error code is indicated on

3 overheat pump motor in normal display 8 when overheating
temperature condition has occurred.

80% battery Normal battery condition Red LED comes on.

discharged Drive 1:
4
warning Lifting function operates in
indicator restricted mode.

Brake fluid level Normal fluid level Low fluid level

5
lamp

2-1
VEHICLE ELECTRICAL COMPONENTS

No. Monitor name When OFF When ON or flashing Remarks

6 Parking lamp Parking brake disengaged Parking brake engaged

7 Malfunction lamp Normal Vehicle malfunction

Error indicator Error code is displayed as follows when an error is present.

8
A L × × ×

Any of four green LEDs

Battery discharge
9 comes on when corresponding
indicator (BDI)
battery is discharged.

Hourmeter
time display
10

Error indicator

Indication Condition

A L 0 0 6 ON Data communication error

A L 0 1 7 ON Pump motor overheated

A L 0 2 8 ON Pump motor armature diode error

A L 0 3 2 ON Drive motor armature diode error

A L 0 3 2 ON Regeneration diode error

A L 0 3 5 ON Pump motor overcurrent

A L 0 5 7 ON Drive motor field overcurrent

A L 0 6 2 ON Traction controller overheated

A L 0 6 4 ON Hydraulic controller overheated

A L 0 6 5 ON Drive motor overheated

A L 0 6 9 ON Drive motor armature overcurrent

A L 0 7 2 ON Drive motor stall timer

A L 0 7 9 ON Key switch turned [ON] with forward/reverse lever in [F] or [R] position

A L 0 7 9 ON Faulty setting of tilt lever

A L 0 7 9 ON Faulty setting of attachment lever 1

A L 0 7 9 ON Faulty setting of attachment lever 2

2-2
 VEHICLE ELECTRICAL COMPONENTS

Electrical Components

209141

1 Key switch 5 Contactor

2 Display 6 Fuse holder
3 Horn 7 Plate
4 Controller 8 Rivet

2-3
VEHICLE ELECTRICAL COMPONENTS

Disassembly and Reassembly

Disassembly

209142

Sequence
1 Console box (front panel) 3 Console box (rear panel)
2 Forward/reverse lever 4 Steering column assembly

Disassembly procedure
(1) Remove the rear panel and front panel from the
steering column assembly.
(2) Disconnect the harness connectors of the
forward/reverse lever.
(3) Disconnect the harness connectors of the horn.
(4) Remove the steering tilt knob from the rear panel of the
console box.
(5) Remove the steering column assembly.
209143

Reassembly
Follow the disassembly procedure in reverse.

2-4
 VEHICLE ELECTRICAL COMPONENTS

Forward/reverse Lever

Structure

209144

1 Knob 4 Connector
2 Lever 5 Screw, Spring washer
3 Harness

2-5
VEHICLE ELECTRICAL COMPONENTS

Accelerator Control

206805A

Adjustment procedure
(1) Disconnect the battery plug.
(2) Fix the stopper bolt to 32 to 34 mm from the floor to
the upper face of bolt.
(3) Adjust the mounting angle of the position meter using
the adjusting screws so the switch inside the position
meter turns on when the accelerator pedal is depressed
1.5 to 2.6 mm.
Make sure the inside switch is ON by checking 208081
continuity between terminals 143 and 144 on
connector CN7 using a tester.
(4) Perform the accelerator self-diagnostics according to
the table on page 3-10. The display should read OFF
and Speed 0 without the accelerator depressed. The
display should change to ON before the speed changes
from 0 to 1. If not, then readjust accelerator switch.
(5) Make sure when the accelerator is fully depressed the
display reads Speed 15. If not, readjust the stopper bolt.

2-6
 VEHICLE ELECTRICAL COMPONENTS

Key Switch

Terminal B M1, M2

Connection Main fuse Logic card

destination battery

(OFF)

I (ON)

206806A

Lighting Switch

Terminal B W H

Connection Battery Working Head

destination lamp lamps

1st position

2nd position
103042

209145

2-7
VEHICLE ELECTRICAL COMPONENTS

Fuses

Capacity (A) Location Main connecting device

500 Battery
Contactor assembly Refer to “Group 3 Main Controller”.
325 Loading hydraulic motor

15 Electric parts

Fuse holder

10 Controller

103402

NOTE

Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart

Item Bulb
Quantity Bulb color Remarks
Lamp 24 V External diagram

Head lamps 2 Clear 70 W Option

Working lamp 1 Clear 70 W Option

205833

2-8
Electrical Schematic (Type : Chopper)
SWITCH
CABLE J
PARKING BRAKE PANEL INDICATOR MOTOR CABLE H CABLE C CABLE D
INDICATOR ASSY BWI D I S P L AY LIGHTING SW HORN SW
(OP) 13 2
CN 9
20 3 CABLE G CABLE B CONTACTOR ASSY
COMBISEM2 CONTROLLER
204 205 2 0 6 LINE
CABLE A
FUSE HOLDER MAIN
201 202 2 0 3 LIGHTING POS FUSE
CONTACTOR
CN 4 SWITCH (+BATT)
2 5 3 6 FIELD
BRIDGE

Br

Br
O

O
6 5 P 3 4 2

CN 4 206 205 201 203 204 202 2 F1

CN 19 242 140 128 138 241 21 3 POS NEG
F2

15A
10A
5 POS NEG

B
G
P

R
Y
6 e E
2 3 20 13 CN 9 F N R LEVER
CONNECTING TABLE BRAKE TRACTION
F N MOSFET MOTOR
12 TERMINAL CORD R
B1 WL 124 (+) (-)
IGNITION SWITCH B2 GW SH M B
VMN

16G
14Y
14R
16G
W
11

V
Y
G
L
CONNECTING TABLE F G BATTERY
N DRIVE 125 A 24V
3 13 OFF ON GR
CN 14 R B MOSFET
20 5 9 BAT
9 HARNESS E 2 20 IGN
104 103
126 127
102
20 5 (OP) ACC
140 138 CN 6
CN 14 PUMP
103
O SH FUSE CABLE E
103 F +SH

R
W
242 128 241 Br
104 104 R
Y

16W
14Y
14Y
102 102 B2 F N R LEVER ASSY
N PUMP MOTOR
1.3 k ohm FREEWHEEL
1/2W POWER
W
R
DIODE 134 A1 CABLE F
G
P

B
Y
M D2
135
136 158
HARNESS B STD PUMP -SH
203 202 206 RVQ MOSFET
+ CAPACITOR
BANK
201 204 205 RVR RVP
NEG
CN 7 (-BATT)
ACCELERATOR
143 144 142 141

251 253

L
R
B
WORK LIGHT 24V (OP) 1 4 3 1 4 2 1 4 1 1 4 4 CN 7 1 252 254
SEAT ASSY

14B

R
B

B
16W
16B

HARNESS D
(OP) CN 5 HARNESS , A
Y
4 111
W
13 110
B
101
CN 5 210
6 16G 16G BAT
13 SWITCH , IGNITION

W
R

O
W

W
Y

W
16R 4 16R IGN
5
ACC
231
CN 8
W
118
123
R ATT 2 (OP) MICRO SWITCH 232
G
122
121
L ATT 1 (OP)
V
120
TILT
212 B 212 R
SENSOR , STROKE B
14R
16R

211 120
O

Br

L
R

V
G
R

B
R
G
R
L
211 W 110
HORN FILTER (IN HARNESS B) 3 104 141 123 121 211 Y 111
103 143 CN 8

v
211 122 121 118
COMBISEM2 CONTROLLER
250V 1 micro W 12 4 144 142 118 122 120 212 212 123 120 148 RVP CONNECTOR
10 ohm 1/4 W 14B
1 CN A
14 W RVP CN A
Y 125 24V (FROM KEY)
1 4
15 W
124 2 24V COM 241 1 3
16R 4 241 104
B 4 3 BACKWARD SW 104
O 103
HORN W
Br
4 FORWARD SW 103
103 111 144
104 5 SEAT SW 111
8 V 107 6 ACCEL ENABLE SW 144
G 363 3 6 3 231 232
16B

7 PARKING BRAKE SW 363

14R 3 8 LINE CTR +24V 231
R 107 141
345 9 LINE CTR GND 232
16Y 9 10 SERVICE BRAKE SW 107
Y
14B
241 11 AUX 1 SW 13 143 142 3 5 5 15
HARNESS D L
1 12 +5V 141
16W
16B

144
(OP) 13 GND 143
14 ACCELERATOR 142
8 B 355 15 BACKUP BUZZER 355
V
7 120
L
121
G 122 CN B
R
123
W 108 CN B
1 TILT SW 121
WORK LIGHT 24V (OP) B
143 2 ATT 1 SW 122 1 3
G 121 122 123
142 3 ATT 2 SW 123
R 141 4 LIFT SW
5 AUX 2 SW
211
R 211 6 +5V 211
7 LIFT 120 120 212 125
B 212 8 GND 212
9 TRACTION MOTOR TH. SW 125 10 135 12
16Y
9 10 PUMP MOTOR TH. SW 135
11
16B
10 12
G 16 CN C
R 135
W 134 CN C
W 3
201 1 PCLRXD 201 1 2
B 202 2 GND 202
R 201 202 203
203 3 +12V 203
Y
204 4 NCLTXD 204
G
205 5 PCLTXD 205
204 205 206
P 206 4 5 6
6 NCLRXD 206
W

W
O

V
G

B
B
B
R

107 9 16 18
373 139 ( 2 ) The drawings of connectors are harness B and their
16Y
16B
10 1 7 1 9

B
G
L
HARNESS C
109 372 108
9 10 19 18 16 17 (OP) views are from connecting side.
CN 13
345 355 317 17
Notis ( 1 ) Cable sizes are 20 AWG. Unless otherwise specified.
372139 CN10
17
16 BACKUP BUZZER (OP)
CAT
STROBE (OP)
18
19 Scematic.No. User for Truck Model Serial Number
CN 18
PARK BRAKE FOOT 10 WORK LIGHT 24V (OP) EP10KRT ETB10-00011-up
BRAKE SW FLUID BRAKE SW 9
SENSOR
ES059-65100 99759-65100 EP12KRT ETB10-20001-up
140 139 CN10
POWER RELAY (OP)
EP15KRT ETB10-50001-up

345 17 CN 18
355 317
Pub.No.99759-65100
2-11
Electrical Daiagram ( Type : Chopper )
CONNECT

CONTROLLER NO CONNECT

PILOT LAMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6
PARK BRAK BRAKE FLUID
INDICATOR INDICATOR MOTOR BWI

241
104
103

144
363
231
232
107

141
143
142
355

121
122
123

120
212
125
135

201
202
203
204
205
206
2 11
111
P CN 19

4
263 128 241 CN A CN B CN C
242 138 140
FUSE
ACCEL
CONTROL
13 2 CN 9

FOOT BRAKE
20 3
OUTLET SCHEMATIC & WIRING LEGEND

231
232
DISCONNECTION
SWITCH 108
SWITCH FORMAL ABBREVIATION
ACCELERATOR CONTROL ACCEL CONTROL
CHARGER ACCELERATOR CONTROL SWITCH ACCEL CONTROL SW
LINE
107 CONTACTOR ATTACH 1 SWITCH ATT 1 SW
MAIN CONTROLLER ATT 2 SW
ATTACH 2 SWITCH
FUSE BATTERY BACK UP BUZZER (-)
ACCEL CONN BATTERY (-)
CONTROL CN 7
143 144 142 141 BATTERY CONNECTOR BATTERY CONN
r v BRAKE FLUID INDICATOR (-)
BRAKE FLUID SWITCH (-)
POS -
LIFT DI + CHARGER (-)

ZAPI

AGN S
BATTERY CONNECTOR CN

O
TIC
F1 COMMON
1 2 0 2 11 2 11 1 2 2 1 2 1 11 8 CN 8 COM
210 212 123 120 CONNECTION CONNECT
CONTROLLER (-)
DIODE ASSY DIODE AS
NEG DISCONNECTION SWITCH (-)
F2 DISPLAY (-)
T I LT BATTERY
SW FRONT CONN FORWARD / NEUTRAL F N R LEVER
FLOODLIGHT VMN / REVERSE LEVER
COM 11 8 RIGHT FRONT FLOODLIGHT LEFT (-)
NO 121 FRONT FLOODLIGHT RIGHT (-)
NC FUSE (-)
5
ATT 1 F1 (-)
POS F2 (-)
SW
HORN (-)
COM 153 (-)
6
POS HORN BUTTON
NO 122 + SH HORN FILTER (-)
NC HORN NEG KEY SWITCH (-)
ATT 2 FILTER LIFT (-)
SW NEG LIGHTING SWITCH (-)
HORN 14 (-)
COM 154 LINE CONTACTOR
NO 123 MAIN FUSE (-)
5 6 - SH
NC MOTOR BRUSH WEAR INDICATOR MOTOR BWI
15
NORMALLY CLOSE NC
NEGATIVE NEG
NO CONNECTION NO CONNECT
DISPLAY NORMALLY OPEN NO
OUTLET (-)
CN 4 PARK BRAKE SWITCH (-)
PARK BRAKE INDICATOR (-)
+-
204 205 206 PUMP PILOT LAMP (-)
FUSE POSITIVE POS
201 202 203 (-)
POWER RELAY
PUMP FUSE (-)
PUMP MOTOR (-)
REAR FLOODLIGHT (-)
REAR OPTIONS (-)
SEAT SWITCH (-)
4 CN 5 STROBE (-)
11 TILT SWITCH TILT SW
13 (-)
TRACTION MOTOR
VMN (-)
+SH (-)
12 POWER RELAY - SH (-)
HORN CN 18
TRACTION F A A1 D2
BUTTON 345 17 MOTOR
PUMP
101 355 317 MOTOR
9
5 E B
21 13
20
4
LIGHTING CN 14 REAR
SWITCH KEY DIODE AS DIODE AS
SWITCH OPTIONS
251
252

124
125
126
127

253
254

134
135
136
156
9
20 5 9 16 18
126 128 127 10 17 19 136 148 158

CN 13
SEAT SWITCH
BRAKE FLUID BACK UP
SWITCH BUZZER STROBE
FNR 16 17 9 10 REAR
LEVER FLOODLIGHT
139 18 19

140
11 0
104 103 CN 10
102 CN 6
111
CAT
7 Daiagram No. User for Truck Model Serial Number
FRONT
FLOODLIGHT EP10KRT ET10-00011-up
LEFT PARK BRAKE
8 ED059-65100 99799-65100 EP12KRT ET10-20001-up
8 SWITCH
108 EP15KRT ET10-50001-up

7
109
Pub.No.99759-65100
2-13
 MAIN CONTROLLER
Parámetros de programación

Variation....................................................................................... 3– 1
Outline of Controller .................................................................... 3– 2
Outline of Contactor Module....................................................... 3– 3
Operation Outline ........................................................................ 3– 4
Drive System ............................................................................... 3– 4
3
Neutral Position ........................................................................................ 3 – 4
Powering ................................................................................................... 3 – 4
Regenaration ............................................................................................ 3 – 6
Hydraulic System ........................................................................ 3 – 6
Fail Safe System.......................................................................... 3 – 7
Output Power Control at Low Battery Voltage ........................................... 3 – 7
Overheat ................................................................................................... 3 – 7
Maximum Vehicle Speed Control .............................................................. 3 – 7
Output Power Control During Braking ....................................................... 3 – 7
Chat Timer ................................................................................................ 3 – 7
Seat Switch Timer ..................................................................................... 3 – 7
Stall Timer ................................................................................................. 3 – 8
Malfunction Detection (Run Time Diagnostics) .......................... 3 – 8
Malfunction Data Record (History Folder) .................................. 3 – 8
Data Storage ............................................................................................ 3 – 8
Review of Stored Data .............................................................................. 3 – 8
Setting ......................................................................................... 3– 8
Self-diagnostics .......................................................................... 3– 8
Safety Functions ......................................................................... 3– 9
Display ........................................................................................ 3 – 13
Combination Display ................................................................................. 3 – 13
Action Lights ............................................................................................. 3 – 13
Removal and Installation............................................................. 3 – 14
Removal and Installation of Controller ...................................................... 3 – 14
Removal and Installation of Logic Card .................................................... 3 – 16
Basic Check ................................................................................ 3 – 17
Testing Tools ............................................................................................. 3 – 17
Measurement of Logic Card Voltage ......................................................... 3 – 17
Check Contactor Coil ................................................................................ 3 – 19
Check Contactor Tip ................................................................................. 3 – 19
System Construction ................................................................................. 3 – 20
Controller Interface Pin Assign .................................................................. 3 – 21
 MAIN CONTROLLER

Variation

(1) There is one controller model, as shown in the table

below.

Voltage Controller Configuration

DC24 V Chopper –

(2) There is one controller and one contactor module.

Item Remarks

Traction 24 V 500 A max.

Controller
Hydraulic 24 V 550 A max.

Contactor Line contactor, fuse (drive and

pump) and switches

(3) The maximum vehicle speed varies depending on load

weight, as shown in the table below.
Unit: km/h

Truck model EP10KRT EP12KRT EP15KRT

Travel speeds
11.5 11.2 11.0
with load

3-1
MAIN CONTROLLER

Outline of Controller

The controller is the heart of the truck operating system.

The logic card contains judgement-making functions, and is
equipped with a battery discharge indicator and a
malfunction diagnostic function.
The controller is used to operate the drive motor and
hydraulic motor.

209026

1 Controller 5 Washer
2 Logics assembly 6 Spring washer
3 Cover 7 Connector
4 Screw

3-2
 MAIN CONTROLLER

Outline of Contactor Module

The contactor module has function of main switch and

circuit protector. One contactor is operated by the
controller.

209027

1 Bracket 5 Pump fuse (325 A)

2 Contactor 6 Main fuse (500 A)
3 Bar 7 Screw, Washer
4 Insulator/Studd

3-3
MAIN CONTROLLER

Operation Outline Drive System

(1) Power ON, default condition Neutral position

Turning on the key switch supplies power to the If the truck runs and the forward/reverse lever is in the
controller. When power is ON, the controller neutral position, then the regeneration function is
checks all switch and sensor input conditions and activated.
the combination display indicates the vehicle’s If the truck is powered by turning the key switch to ON
condition. Under the next conditon, it turns line and the forward/reverse lever is in the neutral position,
contactor ON and provides battery power to the then controller checks to see if the traction motor is
main circuit, the pump motor starts rotation (idle turning or not. It will hold the truck to speed ‘0’ as an
revolution is 500 to 600 rpm). “anti roll back” feature.
Seat switch: ON
Forward/reverse lever: Neutral Powering
Hydraulic lever: OFF
(1) Outline
Accelerator: Neutral
The accelerator is a combination sensor of digital
Static Return OFF
signal (accelerator idle SW) and analog signal
Under the line contactor on condition, the (accelerator input). Digital signal has the relation
hourmeter indicates cumulative hours. to analog signal.
(2) Normal mode (RUN mode) • Analog signal range is from 0 to 5 V.
When the forward/reverse lever is operated and the • Digital signal change voltage (open ↔ close) is
accelerator pedal is pressed, the vehicle moves typical 0.94 V ± 0.47 V.
forward or backward. During deceleration, the In vehicle mounting condition, accelerator signal
motors conduct various regenerative operations range is from the voltage that accelerator idle SW
according to the settings. become CLOSE (typical 0.94 V ± 0.47 V) to about
When the vehicle is running, the pump motor is 4 V.
always rotating for steering pump motor (700 to Its signal range data can be adjustable by using
800 rpm). console. The controller uses this signal as
Operating a hydraulic lever activates the pump continuous input data.
motor and provides hydraulic power. Accelerator signal is a torque demand data.
The controller monitors operating conditions. In actual, motor torque is determined by accelerator
When an abnormality occurs, the display unit signal and vehicle speed.
indicates an error code and activates the line
Power selection can be selected by using console.
contactor fail-safe function. The error code is
The current rise rate can be adjustable by using
stored in the controller memory and combination
console.
display indicates the error code.
(2) Truck mode
The truck mode can be selected from A and B by
using console, each with preset values for drive
speed, acceleration, lift speed, tilt speed, and regen
brake. Details are shown on the next page.

3-4
 MAIN CONTROLLER

Truck Mode 1.0 ton, 1.25 ton class 1.5 ton class
Item Mode A – Normal duties Mode B – High performance
Mode A – Battery Alert Mode B – Exchange Value

Drive speed (without load) 0 to 10.0 km/h 0 to 12.5 km/h

Acceleration Comfortable Fast

Lift speed (without load) 0 to 0.42 m/s 0 to 0.48 m/s

Tilt speed Fixed Fixed

Regen brake Moderate braking Hard braking

3-5
MAIN CONTROLLER

Regeneration (5) Overspeed Protection

When the vehicle runs a downward grade with the
(1) Lever regeneration key switch ON and runs over maximum speed, then
When the forward/reverse lever is shifted into the regeneration is activated.
position opposite to the vehicle’s traveling
direction, the regeneration function is activated.
The amount of regeneration is determined by the
truck speed and accelerator position. Hydraulic System
The regenerative characteristic can be selected by
When the hydraulic lever is operated, the pump motor
using console. The degree of acceleration serves as
rotates. The motor is driven by specified chopping rate.
the parameter. The deeper the accelerator pedal is
pressed, the more the amount of regeneration (1) Lift speed
becomes.
When the lift lever operated, the lift analog signal
The regeneration function is activated until the changes continuously.
vehicle stops.
Lift potentiometer is the stroke sensor.
The maximum current of regeneration must be
In vehicle mounting conditon, lift signal range is
under the powering current.
from 1 V to about 4 V.
(2) Neutral regeneration Its signal range data can be adjustable by using
When the forward/reverse lever is shifted into the console.
neutral position, the regeneration function is The controller uses this signal as continueous input
activated. data.
The regenerative characteristic can be selected by
(2) Tilt speed
using console.
One specified duty is set by a controller. This duty
The regeneration function is activated until the
cannot be adjustable by using console. It is
vehicle stops.
activated by a micro switch.
The maximum current of regeneration must be
under the powering current. (3) Attachment 1 speed, attachment 2 speed
One specified duty is set by a terminal for each
(3) Accel regeneration (auto regeneration)
attachment by a micro switch. Those duty can be
When the forward/reverse lever is in the position adjustable by using console.
same to the vehicle’s traveling direction and accel
is released, then the regeneration function is (4) Priority
activated. When two or more levers are operated at the same
The regeneration character is determined by auto time, the following priority order is effective.
regenerative characteristics and can be selected by Tilt lever (high priority), Att. 1 lever, Att. 2 lever,
using console. The maximum current of lift lever (low priority).
regeneration must be under the powering current.
The regeneration function is activated until the
vehicle stops.

(4) Anti roll-back

When the vehicle runs with the key switch ON in
spite of accelerator position is neutral, then
regeneration is activated to keep the vehicle speed
at “0”.

3-6
 MAIN CONTROLLER

Fail Safe System manage to travel with full load. The output duty of
lift and attachment 1, 2 is cut by 50 %.
Output Power Control at Low Battery
Voltage Maximum Vehicle Speed Control
(1) Battery discharge characteristic Limits the maximum vehicle speed.
Available for the different discharge characteristic
battery. It can be adjustable by using console.
Output Power Control During Braking
(2) Output power control
The maximum current is controlled during the use of
When the battery voltage is lower than the set data, the service brake and parking brake.
then output power is limited.
(1) Service brake
[Output power controls]
Maximum field current: 20A
Traction: In powering, limits the output power.
Maximum armature current: 125A
The figure is under the condition of full load and
(2) Parking brake
the vehicle can run.
Maximum field current: 20A
Pump: The operation of lift and attachment 1, 2 are
going to cut it’s output duty ratio by 50 %. Maximum armature current: 125A

When operated at the same time: Prohibeted the

pump motor can operate only when the truck stops Chat Timer
and direction lever is neutral. Battery voltage from
When the following conditions occur for a set time, the
15 to 18 volt at that time, output controls are as
pump motor stops.
follows.
(1) Accelerator: 0
[Output power control]
(2) Forward/reverse lever: Neutral
Traction: In powering, limits the output power.
(3) Lift, tilt and attach levers: OFF
Under the condition of full load, the vehicle can
run. (4) Steering: Not operated
Pump: Don’t output control. Operating any of the above, expect (4), activates the
pump motor. Chat timer can be selected by using of
Line contactor is OFF when battery voltage is
console (5 to 40 sec).
below 15 V. To reset switch, turn key off and on again.

Overheat Seat Switch Timer

When the operator leaves the seat for a set time, the line
(1) Traction motor overheat contactor turns OFF. When the key switch is turned on
In powering, the controller restricts the traction without the operator sitting the seat, the line contactor
motor operation to the extent that the trucks can turns OFF.
manage to travel with full load. If acceleration is 0, forward/reverse lever in neutral and
(2) Pump motor overheat hydraulic levers are all OFF, turning on the seat switch
activates the line contactor.
The output duty of lift and attachment 1, 2 is cut by
50 %. Seat switch timer can be set by using of console (3 to
15 sec).
(3) Controller overheat
In powering, the controller restricts the traction
motor operation to the extent that the trucks can

3-7
MAIN CONTROLLER

Stall Timer Setting

Stall timer will be pre-set at 10 sec to protect the Use serial communication, and operate console tool.
motors from overheating.
Truck mode
This setting should not be adjustable by using console.
The truck mode can be selected between Mode A and
Mode B by using of console.

Setup parameter
Malfunciton Detection (Run Time
In addition to standard setup parameters, those setup
Diagnostics)
parameters can be selected by using console tool.
Every parameters can be setup in 10 steps.
If a malfunction is detected, the red LED flashes and
error code is indicated on the combination display. The (1) Drive speed
corresponding fail-safe function is activated at the same (2) Acceleration
time.
(3) Regen braking (auto-regen, direction regen, neutral
Regarding details, refer to the malfunction detection regen)
tables and add to standard malfuncton. See page 2-2
(4) Lift speed
for error code descriptions.
(5) Att speed 1
(6) Att speed 2
(7) Seat switch timer (5 to 40 sec)
Malfunction Data Record (History
folder) (8) Chat timer (3 to 15 sec)

Data Storage
Errors are automatically stored in the memory. A Self-diagnostics
maximum of 5 sets of data can be stored.
Check the input and output status. Use serial
communication, and operate console.
Review of Stored Data

(1) To review data

Use serial communication, and operate console.
(2) To delete data
Use serial communication, and operate console.

3-8
 MAIN CONTROLLER

Safety Functions

The controller must meet the safety conditions below:

(1) When the CPU has a problem, the vehicle will stop.
(2) When the accelerator has a problem, the vehicle
will stop.
(3) It has a function that protects motor short circuits
and contactor short circuits.
(4) If forward and reverse signals turn on at the same
time, the vehicle will stop.
(5) If something unusual happened, it can indicate the
status via the display.
(6) When a different voltage battery has been
connected, the controller indicates the status.
(7) When the lift potentiometer signal has a problem,
the lift will stop.

3-9
 MDI Meaning MDI Meaning
Alarm no. Alarm no.
00 NONE 51 RIGHT I=0 EVER
01 CHOPPER RUNNING 52 PUMP I=0 EVER
02 NO COMMUNICATION 53 STBY I HIGH
03 UNKNOWN CHOPPER 54 LEFT STBY I HIGH
04 CONSOLE EEPROM 55 RGT STBY I HIGH
05 SERIAL ERROR #2 56 PUMP STBY I HIGH
06 SERIAL ERROR #1 57 HIGH FIELD CUR.
07 CHOPPER NOT CONF 58 NO FIELD CURRENT
08 WATCHDOG 59 HIGH BRAKING CURRENT
09 FIELD FF FAILURE 60 CAPACITOR CHARGE
10 EEPROM DATA KO 61 HIGH TEMPERATURE
11 EEPROM PAR. KO 62 TH. PROTECTION
12 EEPROM CONF. KO 63 THERMIC LEVEL #2
13 EEPROM KO 64 PUMP TEMPERATURE
14 EEPROM OFFLINE 65 MOTOR TEMPERAT.
15 VFIELD NOT OK 66 BATTERY LOW
16 SYSTEM CHECK KO 67 BATTERY LEVEL #2
17 PUMP MOTOR TEMP. 68 BATTERY LEVEL #1
18 BRAKE DRIVE KO 69 CURRENT SENS. KO
19 LOGIC FAILURE #1 70 POWER FAILURE #4
20 FORW VMN LOW 71 POWER FAILURE #3
21 FORW VMN HIGH 72 POWER FAILURE #2
22 BACK VMN LOW 73 POWER FAILURE #1
23 BACK VMN HIGH 74 DRIVER SHORTED
24 LEFT VMN LOW 75 CONTACTOR DRIVER
25 LEFT VMN HIGH 76 COIL SHORTED
26 RIGHT VMN LOW 77 COIL INTERRUPTED
27 RIGHT VMN HIGH 78 VACC NOT OK
28 PUMP VMN LOW 79 INCORRECT START
29 PUMP VMN HIGH 80 FORW + BACKW
30 VMN LOW 81 BAD STEER 0-SET
31 VMN HIGH 82 ENCODER ERROR
32 VMN NOT OK 83 BAD ENCODER SIGN
33 NO FULL COND. 84 STEER SENSOR KO
34 RGT NO FULL COND 85 STEER HAZARD
35 LFT NO FULL COND 86 PEDAL WIRE KO
36 PU NO FULL COND 87 PEDAL FAILURE
37 CONTACTOR CLOSED 88 TRACTION BRUSHES
38 CONTACTOR OPEN 89 PUMP BRUSHES
39 BRAKE CON CLOSED 90 DRIVER 1 KO
40 BRAKE CONT OPEN 91 DRIVER 2 KO
41 DIR CONT CLOSED 92 DRIVER 1 SIC KO
42 DIR CONT OPEN 93 DRIVER 2 SIC KO
43 RIGHT CON CLOSED 94 INPUT ERROR #6
44 RIGHT CONT OPEN 95 INPUT ERROR #5
45 LEFT CONT CLOSED 96 INVERTION
46 LEFT CONT OPEN 97 POSITION HANDLE
47 MAIN CONT CLOSED 98 INPUT ERROR #2
48 MAIN CONT OPEN 99 INPUT ERROR #1
49 I=0 EVER bzw.
50 LEFT I=0 EVER CHECK UP erreicht
MAIN CONTROLLER

Malfunction Detection

Display
LED

Malfunction Detection Method/Condition Error Fail-safe Process Reset

Flashing Code
Code Method

Thermal
Battery
Brake

Brush
Error
Traction motor overheat Signal input 7 * AL065 Output power control Cooling
Pump motor overheat Signal input 7 * AL017 Output power control Cooling
Controller overheat Signal input 7 * AL062 Output power control Cooling
Traction motor brush wear — *
Pump motor brush wear — *
Brake fluid low — *

Traction motor transistor wire Check the main circuit voltage level 3 * AL060 Line contactor OFF
breakage
Traction motor transistor shorting Check the main circuit voltage level 3 * AL032 Line contactor OFF Power reset
Traction motor stall timer Time duration elapsed 5 * AL072 Line contactor OFF Power reset
Traction motor transistor drive error Error detection signal from drive card 5 * AL060 Line contactor OFF Power reset
Traction motor current sensor error Check the current sensor output value 5 * AL053 Line contactor OFF Power reset
Traction motor armature over current 500 A 5 * AL069 Line contactor OFF Power reset
Traction motor field over current 50 A 5 * AL057 Line contactor OFF Power reset
Traction motor field error Compare the current instruction 5 * AL058 Line contactor OFF Power reset
value and actual current value
Traction motor field drive error Error detection signal from H 3 * AL015 Line contactor OFF Power reset
bridge card

Pump motor transistor wire breakage Check the main circuit voltage level 3 * AL028 Line contactor OFF
Pump motor transistor shorting Check the main circuit voltage level 3 * AL028 Line contactor OFF Power reset
Pump motor transistor drive error Error detection signal from drive card 3 * AL028 Line contactor OFF Power reset
Pump motor current sensor error Check the current sensor output value 5 * AL056 Line contactor OFF Power reset
Pump motor over current 500 A 5 * Al035 Line contactor OFF Power reset

Line contactor error Check the main circuit voltage level 6 * AL037 Line contactor OFF Power reset
Regeneration diode error Check the main circuit voltage level 3 * AL032 Line contactor OFF Power reset
Traction motor armature diode error Check the main circuit voltage level 3 * AL032 Line contactor OFF Power reset
Pump motor armature diode error Check the main circuit voltage level 3 * AL028 Line contactor OFF Power reset
Traction motor armature breakage Check the main circuit voltage level 3 * AL032 Line contactor OFF Power reset
Pump motor armature breakage Check the main circuit voltage level 3 * AL028 Line contactor OFF Power reset
Accelerator error Input range exceeded 4 * AL078 Line contactor OFF Power reset

3-10
 MAIN CONTROLLER

Display
LED

Malfunction Detection Method/Condition Error Fail-safe Process Reset

Flashing Code
Code Method

Thermal
Battery
Brake

Brush
Error
Forward/Reverse lever or When lever is not in neutral or 2 AL080 Line contactor OFF Power reset
acceleration setting error acceleration is not 0 at power ON
Seat switch setting error When signal is not input at power ON 2 AL079 Line contactor OFF Switch ON
Tilt lever setting error When signal is not input at power ON AL079 Line contactor OFF Switch ON
Attach 1 lever setting error When signal is not input at power ON AL079 Line contactor OFF Switch ON
Attach 2 lever setting error When signal is not input at power ON AL079 Line contactor OFF Switch ON
Lift potentiometer error Input range exceeded 4 * Line contactor OFF Power reset

Data communication error The display indicates an error code — * AL006 Display Power reset
when there is no data communication
EEPROM error 1 * AL013 Line contactor OFF Power reset
Controller error ROM and RAM check at power ON * Line contactor OFF Power reset
Battery voltage low The battery voltage is lower than xxV 32 * AL055 Line contactor OFF Power reset
at power ON
Battery voltage high The battery voltage is higher than 32 * AL059 Line contactor OFF Power reset
xx V at power ON
Battery voltage low When the truck is working, the 32 * AL068 Output power control Voltage
battery voltage from 15V to 18V recovered
Battery voltage low When the truck is working, the 32 * AL067 Line contactor OFF Power reset
battery voltage lower than 15 V

3-11
MAIN CONTROLLER

Main Circuit

209028

3-12
 MAIN CONTROLLER

Display

Combination Display
Combination display communicates with controller and
has the functions as below.
Its power is supplied from the controller.
(1) BDI (Battery discharge indicator) function
Showing battery status with 5LEDs representing
battery charge status.
(2) Hourmeter function
Hourmeter indicates cumulative line contactor ON
hours. When the hourmeter is working, hourglass
symbol flashes.
(3) Error code display function
The display shows an error code and flashes red
LED when an abnornality occurs.
(4) Truck mode display function
The display shows the turtle symbol when truck
mode A is selected.

Action Lights
(1) Parking brake
The indicator illuminates while the parking brake is
being applied.
(2) Brake fluid indicator
The indicator indicates when the brake fluid level
becomes low.
(3) Brush wear indicator: Traction motor, pump motor
The indicator indicates when the traction motor or
pump motor brush becomes weared.

3-13
MAIN CONTROLLER

Removal and Installation

Removal and Installation of Controller

WARNING
Disconnect the battery plug before approaching
the controller.

(1) Removal of rear cover

(a) Turn the key switch off.
(b) Disconnect the battery plug.
(c) Remove the rear cover of the counterweight.

(2) Removal of controller

CAUTION
Be sure to regularly check the tightened torque
of the high-tension battery cable terminals. If
the cables are loosely connected, excessive
contact resistance results, and it can cause
over heating and lead to a fire in the worst case.
When checking or adjusting the cable routing,
avoid pulling the cables. If cables move even
slightly at the terminals loose connections will 209029
result. While working with the cables, be sure
to tighten the terminal connections.

NOTE
Discharge the internal head capacitors by putting a
25w/150Ω (Cat #0358280) resistor for about 30
seconds over B+ and B— terminal.

Remove the power cables (for battery and motors).

Tightening torque for 11.8 ± 2.0 N·m

stud terminal (M6) (1.2 ± 0.2 kgf·m)

(a) Note that a flat washer and a disc spring are

installed on each connector terminal. (See the
illustration at right.)

209030

3-14
 MAIN CONTROLLER

Disconnect connectors CNA, CNB and CNC

NOTE
Hold the connectors to unplug. Do not pull the
harnesses to disconnect the connectors.

209031

Remove the controller mounting screws (M8: 4 places for

controller), and remove the controller.

209032

(3) Installation of controller

Follow the removal procedure in reverse.

NOTE
There is a heat conducting compound between
counterweight and controller. It is important to cooling
the controller.
Spread the compound flatly then mount controller on
it. Apply only a thin coat.

209033

3-15
MAIN CONTROLLER

Removal and Installation of Logic Card

(1) Removal of controller cover

Remove the cover mounting screws (M4: 3 places),
and remove the controller cover.

209034

(2) Removal of logic card

(a) Disconnect J1, J2 and J3.
(b) Remove the logic card bracket mounting screws
(M4: 2 places), and remove the logic card with
bracket.
(c) Remove the logic card mounting screws (M3: 5
places), and the heat-sink mounting screws (M4: 2
places behind the bracket), and remove the logic
card.

(3) Installation
Follow the procedure in reverse.

209035

3-16
 MAIN CONTROLLER

Basic Check

Always following basic troubleshooting steps.

• Talk to the operator.
• Confirm his description of the problem with an
operational check.
• Visually inspect cables, connectors, contactor tips, etc.
• Perform basic battery cables to frame resistance test. (at
least 20 k ohm)
• Check battery condition.
Always check each option and write down the reading.

Testing Tools
(a) Circuit tester
(b) Clamp meter (b)
(c) IC tip
(d) MCF Console 97M22-04900 (a)

(c)
NOTE
The illustrations show digital circuit testers. In these
testers, the positive (+) terminal is applied with positive
charge, and the negative (-) terminal with negative
charge. It should be noted that the terminals must be 208282
connected inversely when using an tester.

WARNING
Disconnect the battery plug before inspecting
or adjusting the controller.

Measurement of Logic Card Voltage

WARNING
To prevent accidental movement of the vehicle,
place wood blocks under the vehicle to lift the
rear wheel off the ground. Do not stand close
to the rear wheel. 209036

3-17
MAIN CONTROLLER

(a) Place wood blocks under the vehicle to lift the rear
wheel off the ground.
(b) Turn the key switch off.
(c) Disconnect the battery plug.
(d) Remove the rear cover from counterweight.
(e) Reconnect the battery plug.
(f) Turn the key switch on. Connect the negative terminal
of the circuit tester to the NEG terminal of the
controller.
(g) Set the circuit tester to the 50- or 100- VDC range.
(h) Connect the positive terminal of the circuit tester to
each pin of connectors CNA, CNB and CNC.

NOTE
Be careful not to short circuit pins. For the normal
voltage value, refer to the logic card voltage chart on
the following pages.

3-18
 MAIN CONTROLLER

Check Contactor Coil

CAUTION
Disconnect the battery plug before close the
controller.

Disconnect the lead wire of coil. Set the circuit tester to

200 ohm range. Measure coil resistance. Minimum 15 ohm,
maximum 32 0hm.
• If the measured value deviates from the above range,
replace the contactor assembly.
With the lead wire of contactor coil connected, set the
circuit tester to 200 VDC range.
Connect the negative (-) terminal of the circuit tester to the
negative-side coil terminal (small fasten terminal) and the
positive (+) terminal of the circuit tester to the positive-side
coil terminal (large fasten terminal).
Connect the battery, and operate the control device that
activates the contactor.
The circuit tester should indicate a value between 23.4 and
52 V after the contactor the contactor operates. When the
contactor is found normal in the coil resistance test and if
the measured voltage is not within this range, replace the
logic card.

Check Contactor Tip

Turn key switch off. Disconnect battery plug. Check
voltage of contactor terminal.
Check the tip condition and the movement.
Check the gap.
• If the contactor shows any fault, replace or correct the
contactor.

209037

3-19
MAIN CONTROLLER

System Construction

209038

3-20
 MAIN CONTROLLER

Controller Interface Pin Assign

CNA
1 24 V (from key) 4
2 24 V Com 241
3 Backward switch 104
4 Forward switch 103
5 Seat switch 111
6 Accel enable switch 144
7 Parking brake switch 363
8 LINE CTR +24 V 231
9 LINE CTR GND 232
10 Foot brake switch 107
11 AUX 1 switch
12 Accelerator +5 V 141
13 Accelerator GND 143
14 Accelerator 142
15 Backup buzzer,1 amp max. 355

CNB
1 Tilt switch 121
2 Att 1 switch 122
3 Att 2 switch 123
4 Lift start switch
5 AUX 2 switch
6 Lift sensor +5 V 211
7 Lift sensor neutral 120
8 Lift sensor negative 212
9 Traction motor 125
thermal switch
10 Pump motor thermal 135
switch
11
12

CNC
1 PCLRXD 201
2 GND 202
3 +12 V 203
4 NCLTXD 204
5 PCLTXD 205
6 NCLRXD 206

209039

3-21
TROUBLESHOOTING FOR CONTROL CIRCUITS

Display Failure .........................................................................................

Drive Motor, Overheating ..................................................................... AL065
Pump Motor, Overheating .................................................................... AL017
Traction Controller, Overheating ........................................................ AL062
Drive Motor or Pump Motor Worn Brushes .................................... Ind.ON
Brake Oil, Low Level .............................................................................. Ind.ON
Pump Controller, Overheating ............................................................ AL064
Drive Transistor, Breaking .................................................................AL060/AL032 4
Drive Transistor, Short Circuit ..........................................................AL060/AL032
Drive Transistor, Drive Fault .............................................................AL060/AL032
Drive Current Sensor, Fault ..............................................................AL053/AL049
Drive Motor, Armature Over-current .................................................. AL069
Drive Stall Timer ..................................................................................... AL072
Drive Motor, Field Fault ........................................................................ AL058
Drive Motor, Field Drive Fault ............................................................. AL015
Drive Motor, Field Over-current .......................................................... AL057
Pump Transistor, Breaking ................................................................... AL028
Pump Transistor, Short Circuit ............................................................ AL028
Pump Transistor, Drive Fault ............................................................... AL028
Pump Motor, Current Sensor Fault .................................................AL056/AL052
Pump Motor, Over-current ................................................................... AL035
Line Contactor, Fault ...............................................................AL07/AL037/AL075/AL076
Drive Motor, Open Circuit .................................................................AL032/AL049
Pump Motor, Open Circuit ................................................................AL028/AL052
Accelerator Sensor, Fault ............................................................AL078/AL086/AL87
Forward / Reverse Lever, Tilt Lever, Att 1 Lever, Att 2 Lever,
Faulty Setting ........................................................................................ AL079
Lift Lever, Faulty Setting ...................................................................AL082/AL073
Tilt Lever, Faulty Setting ....................................................................... AL079
Attach 1 Lever, Faulty Setting ............................................................. AL079
Attach 2 Lever, Faulty Setting ............................................................. AL079
Display Communication, Fault ........................................................... AL06
EEPROM, Abnormality .......................................................................... AL013
Controller, Fault ...................................................................................... AL06
 Battery Voltage, Too Low ..................................................................... AL055
Baterry Voltage, Too High .................................................................... AL059
Battery Consumption ............................................................................ AL066
Battery Consumption, Too Much ....................................................... AL067
Buzzer Mos Drive Broken .................................................................... AL018
System Check Ko ................................................................................... AL016
Parking Brake Active ............................................................................. AL071

NOTE
For your reference, most pages are provided with
schematics of pertinent electrical circuits.
Before conducting troubleshooting, read the procedures
carefully and also refer to the Electrical Schematics in
the “Group 2 Vehicle Electrical Components” .

TROUBLESHOOTING EN CASTELLANO
TROUBLESHOOTING FOR CONTROL CIRCUITS

Display Failure ......................................................................................... 4– 1

Drive Motor, Overheating ..................................................................... 4– 2
Pump Motor, Overheating .................................................................... 4– 3
Traction Controller, Overheating ........................................................ 4– 4
Drive Motor or Pump Motor Worn Brushes .................................... 4– 5
Brake Oil, Low Level .............................................................................. 4– 6
Pump Controller, Overheating ............................................................ 4– 7
Drive Transistor, Breaking .................................................................... 4– 8 4
Drive Transistor, Short Circuit ............................................................. 4– 9
Drive Transistor, Drive Fault ................................................................ 4 – 10
Drive Current Sensor, Fault ................................................................. 4 – 11
Drive Motor, Armature Over-current .................................................. 4 – 12
Drive Stall Timer ..................................................................................... 4 – 13
Drive Motor, Field Fault ........................................................................ 4 – 14
Drive Motor, Field Drive Fault ............................................................. 4 – 15
Drive Motor, Field Over-current .......................................................... 4 – 16
Pump Transistor, Breaking ................................................................... 4 – 17
Pump Transistor, Short Circuit ............................................................ 4 – 18
Pump Transistor, Drive Fault ............................................................... 4 – 19
Pump Motor, Current Sensor Fault .................................................... 4 – 20
Pump Motor, Over-current ................................................................... 4 – 21
Line Contactor, Fault ............................................................................. 4 – 22
Drive Motor, Open Circuit .................................................................... 4 – 23
Pump Motor, Open Circuit ................................................................... 4 – 24
Accelerator Sensor, Fault ..................................................................... 4 – 25
Forward / Reverse Lever, Tilt Lever, Att 1 Lever, Att 2 Lever,
Faulty Setting ........................................................................................ 4 – 26
Lift Lever, Faulty Setting ...................................................................... 4 – 27
Tilt Lever, Faulty Setting ....................................................................... 4 – 28
Attach 1 Lever, Faulty Setting ............................................................. 4 – 29
Attach 2 Lever, Faulty Setting ............................................................. 4 – 30
Display Communication, Fault ........................................................... 4 – 31
EEPROM, Abnormality .......................................................................... 4 – 32
Controller, Fault ...................................................................................... 4 – 33
 Battery Voltage, Too Low ..................................................................... 4 – 34
Baterry Voltage, Too High .................................................................... 4 – 35
Battery Consumption ............................................................................ 4 – 36
Battery Consumption, Too Much ....................................................... 4 – 37
Buzzer Mos Drive Broken .................................................................... 4 – 38
System Check Ko ................................................................................... 4 – 39
Parking Brake Active ............................................................................. 4 – 40

NOTE
For your reference, most pages are provided with
schematics of pertinent electrical circuits.
Before conducting troubleshooting, read the procedures
carefully and also refer to the Electrical Schematics in
the “Group 2 Vehicle Electrical Components” .
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Display Failure

Symptom:
(1) Display does not work.

Possible Cause:
(2) Faulty wiring, display unit defect.

Checks:
(3) Disconnect battery plug. Check continuity between wire 203-R (red) of display connector CN4 and controller
connector CNC.
(4) Between 202-B (black) of display connector CN4 and CNC.
• No continuity
Correct or replace wiring.
• Continuity
Replace display.

209046

4-1
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Motor, Overheating

Symptom:
(1) Motor is overheated; “AL065” appears on display.
Poor traction power and acceleration. Normal pump motor and power steering operation.
Possible Cause:
(2) Overheating of drive motor, drive motor thermal switch defect, open wiring, logic card defect, display unit
defect.
Checks:
(3) Allow truck to cool 15 minutes.
• “AL065” goes OFF
Drive motor was overheated. Resume normal operation. If condition repeats, check the following.
Operating cycle for excessive ramp climbing, towing, or pushing.
Brake drag, parking brake adjustment.
Brake switch operation.
• “AL065” still ON
(4) Connect Zapi console to controller, then check whether “Motor temperat.” appears on display.
• No “Motor temperat.”
Replace display unit.
• “Motor temperat.”
(5) Disconnect battery plug. Wait until drive motor temperature becomes close to room temperature. Disconnect
drive motor thermal switch connector. Check continuity of thermal switch. Should have continuity below
130 °C.
• No continuity
Replace drive motor.
• Continuity
(6) Check continuity between wire 124-W (white) of thermal switch harness connector and NEG9.
• No continuity
Correct or replace wiring.
• Continuity
(7) Remove controller connector CNB. Check continuity motor sensor 125-Y (yellow) and CNB-9, and shorting of
these terminals with NEG.
• No continuity
Correct or replace wiring. Drive motor thermal switch: Normally ON
• Continuity
Replace logic card or controller.

209047

4-2
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor, Overheating

Symptom:
(1) Pump motor is overheated; “AL017” appears on display.
Lifting speed slower than normal. Normal drive motor and power steering operation.
Possible Cause:
(2) Overheating of pump motor, pump motor thermal switch defect, open wiring, logic card defect, display unit
defect.
Checks:
(3) Allow truck to cool 15 minutes.
• “AL017” goes OFF
Pump motor was overheated. Resume normal operation. If condition repeats, check the following.
Operating cycle.
Power supply to pump motor.
Large cargo load.
• “AL017” still ON
(4) Connect Zapi console to controller, then check whether “Pump motor temp.” appears on display.
• No “Pump motor temp.”
Replace display unit.
• “Pump motor temp.”
(5) Disconnect battery plug. Wait until pump motor temperature becomes close to room temperature. Disconnect
pump motor thermal switch connector. Check continuity of thermal switch. Should have continuity below
130 °C.
• No continuity
Replace pump motor.
• Continuity
(6) Check continuity between wire 134-W (white) of thermal switch harness and NEG.
• No continuity
Correct or replace wiring.
• Continuity
(7) Remove controller connector CNB. Check continuity motor sensor 135-R (red) and CNB-10, and shorting of
these terminals with NEG.
• No continuity Pump motor temperature sensor: Normally ON

Correct or replace wiring.

• Continuity
Replace logic card or controller.

209048
4-3
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Controller, Overheating

Symptom:
(1) Controller is overheated; “AL062” appears on display.
Poor traction power and acceleration. Normal pump motor and power steering operation.
Possible Cause:
(2) Overheating of traction controller panel, traction controller thermistor defect, open wiring, logic card defect,
display unit defect.
Checks:
(3) Allow truck to cool 15 minutes.
• “AL062” OFF
Traction controller was overheated. Resume normal operation. If condition repeats, check the following.
Operating cycle for excessive ramp climbing, towing, or pushing.
Brake drag, parking brake adjustment.
Brake switch operation
• “AL062” still ON
(4) Connect Zapi console to controller, then check whether “Th. protection” appears on display.
• No “Th. protection”
Replace display unit.
• “Th. protection”
(5) Disconnect battery plug. Wait until traction controller panel temperature becomes close to room temperature.
Open the controller cover. Connect Zapi console to controller again, then check whether “Th. protection”
appears on display.
• No “Th. protection”
Everything is normal.
• “Th. protection” appears.
Replace logic card.

4-4
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Motor or Pump Motor Worn Brushes

Symptom:
(1) Worn brush indicator ON.

Possible Cause:
(2) Worn drive motor or pump motor brush, short circuit, display unit defect.

Checks:
(3) Disconnect battery plug. Disconnect drive motor brush wear detector connector.
Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
• Indicator OFF
Inspect brushes and replace, if necessary.
• Indicator ON
(4) Disconnect battery plug. Check continuity between wire 126-W (white) of drive motor sensor connector and
NEG. (For protect diode, current can through only from CNB-7 to sensor’s connector.) Check continuity
between wire 127-O (orange) of drive motor sensor connector and NEG.
• No continuity or shorted
Correct or replace wiring.
• Continuity

209049

4-5
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Brake Oil, Low Level

Symptom:
(1) Low brake oil indicator ON.
Normal vehicle operation.

Possible Cause:
(2) Insufficient brake oil, open wiring, display unit defect.

Checks:
(3) Check oil level in bare oil reservoir tank
• Oil level lower than LOW mark
Add brake oil.
• Oil level higher than LOW mark
(4) Disconnect battery plug. Disconnect level sensor connector CN10, and check continuity.
• Continuity
Replace level sensor.
• No continuity
(5) With connector CN10 and CN19 disconnected, check continuity between harness connector CN10 socket wire
140-L (blue) and CN19 and between 139-O (orange) and controller.
• No continuity
Correct or replace wiring.
• Continuity
Replace traction logic card.
Brake oil level sensor: Normally OFF
(Low oil level: ON)

209050
4-6
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Controller, Overheating

Symptom:
(1) “AL064” appears on display.
Lifting speed slower than normal. Normal drive motor and power steering operation.
Possible cause:
(2) Overheating of hydraulic controller panel, hydraulic controller thermistor defect, open wiring, logic card defect,
display unit defect.
Checks:
(3) Allow truck to cool 15 minutes.
• “AL064” goes OFF
Hydraulic controller was overheated. Resume normal operation, If condition repeats, check the following.
Operating cycle.
Power supply to pump motor.
Large cargo load
• “AL064” still ON
(4) Check stored fault code, Verify pump temperature is present.
• No pump temperature
Replace display unit.
• Pump temperature
(5) Check continuity between wire J3-2 (black) of thermistor harness connector and NEG.
• No continuity
Correct or replace wiring.
• Continuity
(6) Remove hydraulic controller harness connector J1. Check continuity between thermistor J3-1 (brown) and J1-13.
• No continuity
Correct or replace wiring.
• Continuity
Replace logic card.

208291
4-7
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Transistor, Breaking

Symptom:
(1) Display = “AL060” or “AL032”.
Inhibit drive and hydraulic operation. Line contactor OFF.

Possible Cause:
(2) Wire break in transistor, traction CS current sensor failure, logic card defect.

Checks:
(3) Disconnect battery plug.
Inspect armature wiring for wire breakage and shorting.
• Broken or shorted
Correct or replace faulty components.
• No broken and no shorted
(4) Replace logic card.
• Unacceptable
Replace controller.

4-8
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Transistor, Short Circuit

Symptom:
(1) Display = “AL060” or “AL032”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Short circuit in traction transistor, drive card failure, traction CS current sensor failure, logic card fault.

Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.

4-9
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Transistor, Drive Fault

Symptom:
(1) Display = “AL060” or “AL032”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Wire break in traction transistor, drive card failure, traction CS current sensor failure, faulty wiring, logic card
fault.

Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.

4-10
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Current Sensor, Fault

Symptom:
(1) Display = “AL053” or “AL049”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Wire break in traction transistor, faulty wire connection, drive card defect, traction CS current sensor failure,
logic card defect.

Checks:
(3) Disconnect battery plug.
Check state of wiring.
• Unacceptable
Repair wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.

4-11
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Motor, Armature Over-current

Symptom:
(1) Display = “AL069”.
Inhibit drive and hydraulic operation. Normal power steering operation.

Possible cause:
(2) Short circuit in transistor, faulty wire connection, drive card defect, traction current sensor failure, logic card
defect.

Checks:
(3) Disconnect battery plug.
Inspect armature wiring for breakage and shorting.
• Broken or shorting
Correct or replace faulty components.
• No broken and No shorting
(4) Replace logic card.
• Unacceptable
Replace controller.

4-12
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Stall Timer

Symptom:
(1) Display = “AL072”.
Inhibit drive and hydraulic operation. Normal power steering operation.

Possible Cause:
(2) Stall current flowed more than set time in drive motor. Faulty current sensor, faulty logic card.

Checks:
(3) Check to see if vehicle is operated on steep upgrade or to pull large cargo load when motor stalls.
• Operated under heavy load
Do not operate vehicle for more than set time under a condition that causes the motor to stall.
• Operated under normal condition
(4) Disconnet battery plug.
Replace logic card.
• Unacceptable
Replace controller.

4-13
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Motor, Field Fault

Symptom:
(1) Display = “AL058”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Drive motor field circuit defect, faulty drive card, faulty logic card.

Checks:
(3) Disconnect battery plug.
Inspect field wiring for wire breakage and shorting.
• Broken or shorted wire
Correct or replace faulty components.
• No broken and no shorted wire
(4) Replace logic card.
• Unacceptable
Replace controller.

4-14
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Motor, Field Drive Fault

Symptom:
(1) Display = “AL015”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Drive card failure, faulty wiring, logic card fault.

Checks:
(3) Disconnect battery plug.
Inspect field wiring for open or short circuit.
• Open or short circuit
Repair or replace faulty components.
• No open or short circuit
Replace logic card.
• Unacceptable
Replace controller.

4-15
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Motor, Field Over-current

Symptom:
(1) Display = “AL057”.
Inhibit drive and hydraulic operation. Normal power steering operation.

Possible Cause:
(2) Traction current sensor failure, faulty wiring, fault in logic card.

Checks:
(3) Disconnect battery plug.
Inspect field wiring for wire breakage and short.
• Broken or shorting
Correct or replace faulty components.
• No broken and no shorted wire
(4) Replace logic card.
• Unacceptable
Replace controller.

4-16
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Transistor, Breaking

Symptom:
(1) Display = “AL028”.
Inhibit vehicle operation.

Possible Cause:
(2) Wire break in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.

Checks:
(3) Disconnect battery plug.
Inspect pump wiring for wire breakage and shorting.
• Broken or shorted
Correct or replace faulty components.
• No broken and no shoreted
(4) Replace logic card.
• Unacceptable
Replace controller.

4-17
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Transistor, Short Circuit

Symptom:
(1) Display = “AL028”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Short circuit in pump transistor, drive card defect, pump current sensor failure, logic card defects.

Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.

4-18
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Transistor, Drive Fault

Symptom:
(1) Display = “AL028”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Wire break in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.

Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.

4-19
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor, Current Sensor Fault

Symptom:
(1) Display = “AL056” or “AL052”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Wire break in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.

Checks:
(3) Disconnect battery plug.
Check state of wiring.
• Unacceptable
Repair wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.

4-20
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor, Over-current

Symptom:
(1) Display = “AL035”.
Inhibit vehicle operation.

Possible Cause:
(2) Short circuit in pump transistor, faulty wire connection, drive card defect, pump current sensor failure, logic card
defect.

Checks:
(3) Disconnect battery plug.
Inspect pump wiring for breakage and shorting.
• Broken or shorting
Correct or replace faulty components.
• No broken and no shorting
(4) Replace logic card.
• Unacceptable
Replace controller.

4-21
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Line Contactor, Fault

Symptom:
(1) Display = “AL037”, “AL07”, “AL075”, “AL076”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Faulty line contactor, faulty wire connection, logic card defect.

Checks:
(3) Disconnect battery plug. Check line contactor tip for wire breakage and shorting (melting). Check line contactor
tip move freely.
• Broken or shorted wire
Replace contactor.
• No Broken or shoreted wire
(4) Check resistance of contactor coil.
• Minimum 15 ohm, maximum 32 ohm
Replace contactor coil.
• 15 to 32 ohm
(5) Check continuity between CNA-8 and line contactor coil red. Disconnect controller connector CNA.
• No continuity
Replace or correct contactor wiring.
• Continuity
(6) Check continuity between CNA-9 and line contactor coil black.
• No continuity
Correct or replace contactor wiring.
• Continuity
Replace traction logic card.
• Unacceptable
Replace controller.

209051

4-22
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Drive Motor, Open Circuit

Symptom:
(1) Display = “AL032” or “AL049”.
Inhibit drive and hydraulic operation.

Possible Cause:
(2) Open circuit in drive motor, traction current sensor failure, traction logic card fault.

Checks:
(3) Disconnect battery plug.
Disconnect controller terminals (A, B). Measure resistance between A and B.
• Open
Replace motor or motor wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.

209052

4-23
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor, Open Circuit

Symptom:
(1) Display = “AL028” or “AL052”.
Inhibit vehicle operation.

Possible Cause:
(2) Open circuit in pump motor, pump current sensor failure, logic card fault.

Checks:
(3) Disconnect battery plug.
Disconnect controller terminals (A1, D2). Measure resistance between A1 and D2.
• Open
Replace motor or motor wiring.
• Acceptable
(4) Replace logic card.
• Unacceptable
Replace controller.

209053

4-24
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Accelerator Sensor, Fault

Symptom:
(1) Display = “AL078”, “AL086”, “AL087”.
Inhibit drive and hydraulic operation.

Possible Cause:
(2) Accelerator sensor defect, faulty wiring, logic card fault.

Checks:
(3) Disconnect battery plug. Check continuity between accelerator socket and traction logic card.
CN7-141R ↔ CNA-12
CN7-142G ↔ CNA-14
CN7-143B ↔ CNA-13
CN7-144L ↔ CNA-6
• No continuity
Correct or replace wiring.
• Continuity
(4) Reconnect battery plug and connectors. Check voltage of CNA-14 without pressing accelerator pedal and while
pressing accelerator pedal fully. And check continuity between acccelerator 143 and 144 without pressing
accelerator pedal and while pressing accelerator pedal fully.

Without pressing 0.2 to 1.72 V Conitnuity

Pressing 3.74 to 4.8 V No continuity

• Acceptable
Replace Drive logic card.
• Unacceptable
(5) Check accelerator return adjustment and interference.
• Properly adjusted
Replace accelerator.
• Conduction
Adjust accelerator linkage.

209054
4-25
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Forward / Reverse Lever, Tilt Lever, Att 1 Lever, Att 2 lever, Faulty
Setting

Symptom:
(1) Display = “AL079”.
Inhibit vehicle operataion. Line contactor OFF.

Possible Cause:
(2) Key switch turned on while forward / reverse lever was left either in forward or reverse position. Key switch
turned on while tilt lever, Att 1 lever or Att 2 lever was in ON position or accelerator pedal was depressed.
Faulty forward / reverse lever switch, tilt lever switch, Att 1 lever switch and Att 2 lever switch; logic card
defect.

Checks:
(3) Move forward / reverse, tilt, Att 1 and / or Att 2 levers to neutral. Select direction of movement again and depress
accelerator pedal.
• Normal vehicle operation
Correct starting procedure requires all of forward / reverse, tilt, Att 1 and Att 2 levers be in neutral position
and accelerator pedal be released when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty component.

209055

209056

4-26
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Lift Lever, Faulty Setting

Symptom:
(1) Display = “AL082” or “AL083”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Key switch turned on while lift lever was in ON position. Faulty lift lever potentiometer. Faulty logic card.

Checks:
(3) Set lift lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that lift lever be in neutral position when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.

209057

4-27
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Tilt Lever, Faulty Setting

Symptom:
(1) Display = “AL079”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Key switch turned on while tilt lever was in ON position. Faulty tilt lever switch. Faulty logic card

Checks:
(3) Set tilt lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that tilt lever be in neutral positon when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.

209058

4-28
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Attach 1 Lever, Faulty Setting

Symptom:
(1) Display = “AL079”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Key switch turned on while Attach 1 lever was in ON position. Faulty Attach 1 lever switch, faulty logic card.

Checks:
(3) Set Attach 1 lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that Attach 1 lever be in OFF position when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.

209059

4-29
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Attach 2 Lever, Faulty Setting

Symptom:
(1) Display = “AL079”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Key switch turned on while Attach 2 lever was in ON position. Faulty Attach 2 lever switch, faulty logic card.

Checks:
(3) Set Attach 2 lever to OFF, then ON again.
• Normal hydraulic system operation
Proper starting procedure requires that Attach 2 lever be in OFF position when key switch is turned on.
• No change
(4) Use self-diagnostic function to locate faulty circuit or component.
• Faulty component located
Correct or replace faulty components.
• Faulty component not located
Replace logic card.

209060

4-30
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Display Communication, Fault

Symptom:
(1) Display = “AL006”.
Normal vehicle operation. Inhibit vehicle operaton line contactor OFF.

Possible Cause:
(2) Faulty display, faulty wiring, faulty logic card.

Checks:
(3) Disconnect battery plug. Check continuity between display CN4 and logic card CNC.
• No continuity
Correct or replace wiring.
• Continuity
(4) Inspect display.
• Unacceptable
Replace display.
• Acceptable
Replace logic card.

209046

4-31
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: EEPROM, Abnormality

Symptom:
(1) Display = “AL013”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Faulty EEPROM on logic card.

Checks:
(3) Conduct initial adjustment of controller.
• Normal vehicle operation
Vehicle operates normally.
• No change
Replace logic card.

4-32
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Controller, Fault

Symptom:
(1) Display = “AL006”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Faulty logic card.

Checks:
(3) Replace logic card.

4-33
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Voltage, Too Low

Symptom:
(1) Display = “AL055”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Discharge battery, faulty battery, misuse of lower voltage battery, faulty logic card, faulty BD1 adjustment.

Checks:
(3) Measure the voltage.
For 24V truck > 15
• Unacceptable
Replace battery.
• Acceptable
(4) Conduct Set-up option.
• Normal vehicle operation
Vehicle operates normally.
• No change
Replace logic card.

208229

4-34
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Voltage, Too High

Symptom:
(1) Display = “AL059”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Overcharge battery, faulty battery, misuse of higher voltage battery, faulty logic card, faulty BDI adjustment.

Checks:
(3) Measure the voltage.
For 24 V truck < 36
• Unacceptable
Replace battery.
• Acceptable
(4) Conduct Set-up option.
• Normal vehicle operation
Vehicle operates normally.
• No change
Replace logic card.

208229

4-35
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Consumption

Symptom:
(1) Battery low indicator “AL066”.
Poor traction power and acceleration. Lifting speed slower than normal.

Possible Cause:
(2) Much consumption with small capacity or poor battery.

Checks:
(3) Check battery voltage in case of both operating and non operating.
• Battery voltage lower than 23.6 V
Check the following:
Battery capacity
Power supply to pump motor
Large cargo load
• Battery voltage higher than 23.6 V
Replace logic card.

4-36
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Consumption, Too Much

Symptom:
(1) Display = “AL067”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Too much consumption with small capacity or poor battery.

Checks:
(3) Check battery voltage in case of both operating and non operating.
• Battery voltage lower than 15 V
Check the following:
Battery capacity
Power supply to pump motor
Large cargo load
• Battery voltage higher than 15 V
Replace logic card.

4-37
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Buzzer Mos Drive Broken

Symptom:
(1) Display = “AL018”.
Normal vehicle operation

Possible Cause:
(2) Faulty wiring, power relay and / or logic card.

Checks:
(3) Disconnect battery plug, disconnect CNA from CN18, then check continuity between CNA’s terminals 8 and 15.
• Continuity present
Replace harness.
• No continuity
Check power relay coil resistance.
If resistance is 0 ohm, replace relay.
If resistance is 320 ohm, replace logic card.

209062

4-38
 TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: System Check Ko

Symptom:
(1) Display = “AL016”.
Inhibit vehicle operation. Line contactor OFF.

Possible Cause:
(2) Faulty logic card.

Checks:
(3) Disconnect battery plug.
Replace logic card.
• Unacceptable
Replace controller.

4-39
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Parking Brake Active

Symptom:
(1) Display = “AL071”.
Poor traction power and acceleration. Normal pump motor and power steering operation.

Possible Cause:
(2) Faulty parking brake switch, unreleased parking brake, faulty foot brake switch, faulty wiring, faulty logic card.

Checks:
(3) Disconnect battery plug. Set parking brake. Check whether CNA’s terminals 7 and 10 are grounded.
• If grounded, there is no problem.
• If not grounded, release the parking brake and check again whether CNA’s terminals 7 and 10 are grounded.
• If grounded, check parking brake switch wiring; replace switch if necessary.
• If not grounded, replace foot brake switch.
• If above actions do not solve problem, replace logic card.

209063

4-40
 Troubleshooting EPKRT

PROBLEMA: fallo del Display

Síntoma:

(1) El display no funciona.

Causa posible:

(2) Fallo del cableado, unidad de display defectuoso.

Comprobaciones:

(3) Desconecte el conector de batería. Compruebe la continuidad entre los cables 203-R (rojo) del
conector del display CN4 y el conector CNC del controlador.

(4) Entre el 202-B (negro) del conector CN4 del display y el CNC.

• No hay continuidad
Repare o cambie el cable
• Hay continuidad
Cambie el display

1
 Troubleshooting EPKRT

PROBLEMA: desgaste de escobillas del motor de tracción ó del motor de bomba

Síntoma:

(1) Indicador de desgaste de escobillas en ON.

Causa posible:

(2) Desgaste de escobillas del motor de tracción o del motor de bomba, cortocircuito, unidad de
display defectuosa.

Comprobaciones:

(3) Desconecte la batería. Desconecte el conector que detecta el desgaste de escobillas del motor de
tracción.
Vuelva a conectar la batería y cierre el interruptor de llave. Compruebe si el indicador se ha
apagado.
• El indicador se ha apagado (OFF).
Revise las escobillas y cámbielas si es necesario.
• El indicador sigue encendido (ON).

(4) Desconecte la batería. Compruebe la continuidad entre los cables 126-W (blanco) del conector del
sensor del motor de tracción y NEG (para proteger se coloca un diodo para que la corriente sólo
puede circular del conector CNB-7 al conector del sensor). Compruebe la continuidad entre el
cable 127-O (naranja) del conector del sensor del motor de tracción y NEG.
• No hay continuidad o hay cortocircuito.
Repare o cambie el cable.
• Hay continuidad.

2
 Troubleshooting EPKRT

PROBLEMA: bajo nivel del líquido de frenos

Síntoma:

(1) Indicador de nivel bajo de líquido de frenos en ON.

Funcionamiento normal de la unidad.

Causa posible:

(2) Falta de líquido de frenos, cables al descubierto, unidad de display defectuosa.

Comprobaciones:

(3) Comprobar el nivel de líquido.

• El nivel es inferior a la marca de bajo nivel
Añadir líquido
• El nivel es superior a la marca de bajo nivel

(4) Desconecte la batería. Desconecte el conector CN10 del sensor de nivel y comprobar la
continuidad.
• Hay continuidad.
Cambie el sensor de nivel.
• No hay continuidad.

(5) Con el conector CN10 y CN19 desconectados, comprobar la continuidad del cable 140-L (azul)
del conector CN10 y CN19 y entre 139-O (naranja) y el controlador.
• No hay continuidad
Repare o cambie el cable.
• Continuidad
Cambie la tarjeta lógica de tracción.

3
 Troubleshooting EPKRT

PROBLEMA: fallo en la comunicación del display

Síntoma:

(1) Display = “AL06”

Funcionamiento normal de la unidad. Inhibidas las funciones del vehículo. Contactor de línea en
OFF.

Causa posible:

(2) Fallo del display, fallo en el cableado, fallo de la tarjeta lógica.

Comprobaciones:

(3) Desconecte la batería. Compruebe la continuidad entre los conectores CN4 del display y CNC de
la tarjeta lógica.
• No hay continuidad
Reparar o cambiar el cableado.
• Hay continuidad

(4) Revisar el display.

• Estado no aceptable.
Cambiar el display.
• Estado aceptable.
Cambiar la tarjeta lógica.

4
 Troubleshooting EPKRT

PROBLEMA: fallo del controlador

Síntoma:
(1) Display = “AL06”
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Fallo de la tarjeta lógica.

Comprobaciones:
(3) Cambiar la tarjeta lógica.

5
 Troubleshooting EPKRT

PROBLEMA: fallo de la EEPROM

Síntoma:

(1) Display = “AL013”.

Inhibidas las operaciones de la unidad. Contactor de línea en OFF.

Posible causa:

(2) Fallo de la EEPROM de la tarjeta lógica.

Comprobaciones:

(3) Realizar el ajuste por defecto del controlador.

• Funcionamiento normal de la unidad
La unidad funciona correctamente
• No hay cambios
Cambiar la tarjeta lógica

6
 Troubleshooting EPKRT

PROBLEMA: fallo en el control del circuito de campo del motor de tracción

Síntoma:

(1) Display = “AL015”.

Quedan inhibidas la funciones de la unidad. El contactor de línea está en OFF.

Causa posible:

(2) Defecto en la tarjeta de mando, fallo de cableado, tarjeta lógica defectuosa.

Comprobaciones:

(3) Desconecte la batería.

Inspeccione el cableado de campo:
• Hay cables rotos o cortocircuitados
Cambie o repare los componentes defectuosos.
• No hay cables rotos ni cortocircuitados
Cambie la tarjeta lógica.
• Estado no aceptable
Cambie el controlador

7
 Troubleshooting EPKRT

PROBLEMA: sistema de chequeo kO.

Síntoma:
(1) Display = “AL016”
Inhibidas las funciones de la unidad. Contactor de línea OFF.

Posible causa:
(2) Fallo de la tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería.
Cambie la tarjeta lógica.
• Estado no aceptable
Cambie el controlador.

8
 Troubleshooting EPKRT

PROBLEMA: sobrecalentamiento del motor de bomba

Síntoma:
(1) El motor de bomba está sobrecalentado. Aparece la alarma “AL017” en el display.
Velocidad de elevación más baja de lo normal. El funcionamiento del motor de tracción y sistema
de dirección son normales.

Causa posible:
(2) Sobrecalentamiento del motor de bomba, interruptor térmico del motor de bomba defectuoso,
cables desprotegidos, tarjeta lógica defectuosa, unidad de display defectuosa.

Comprobaciones:
(3) Deje enfriar la unidad 15 minutos.
• “AL017” desaparece.
El motor de bomba estaba sobrecalentado. Vuelven las condiciones normales de
funcionamiento. Si las condiciones vuelven a repetirse comprobar lo siguiente:
- Comprobar el ciclo de trabajo
- Alimentación al motor de bomba
- Exceso de carga de trabajo
• “AL017” permanece en el display

(4) Conectar la consola Zapi al controlador y comprobar si aparece en el display “Pump motor temp.”
• No aparece “Pump motor temp.”
Cambie la unidad de display
• Aparece “Pump motor temp.”

(5) Desconecte la batería. Espere hasta que la temperatura del motor de bomba se acerque a la
temperatura ambiente. Desconecte el conector del interruptor de temperatura del motor de
bomba. Compruebe la continuidad del mismo. Debe dar continuidad por debajo de 130ºC.
• No hay continuidad
Cambie el motor de bomba
• Hay continuidad

(6) Compruebe la continuidad entre el cable 134-W (blanco) del mazo de cables del interruptor
térmico y NEG.
• No hay continuidad
Repare o cambie el cable
• Hay continuidad

(7) Desconecte el conector CNB del controlador. Compruebe la continuidad del sensor del motor 135-
R (rojo) y CNB-10, y el corto a neg.
• No hay continuidad.
Repare o cambie el cable.
• Hay continuidad.
Cambie la tarjeta lógica o el controlador.

9
 Troubleshooting EPKRT

PROBLEMA: rotura del MOSFET de tracción

Síntoma:

(1) Display = “AL018”.

Operación normal de la unidad.

Posibles causas:

(2) Fallo en el cableado, relé de potencia y/ó tarjeta lógica.

Comprobaciones:

(3) Desconecte la batería, desconecte CNA de CN18, compruebe la continuidad de los terminales 8 y
15 de CNA.
• Hay continuidad
Cambie el mazo de cables.
• No hay continuidad
Compruebe la resistencia de la bobina del relé.
Si la resistencia es de 0 ohmios, cambie el relé.
Si la resistencia es de 320 ohmios, cambie la tarjeta lógica.

10
 Troubleshooting EPKRT

PROBLEMA: rotura del transistor de bomba

Síntoma:
(1) Display = “AL028”.
Quedan inhibidas la funciones de la unidad.

Causa posible:
(2) Rotura de cables en el transistor de bomba, fallo en las conexiones del cableado, tarjeta de mando
defectuosa, fallo del sensor de corriente, tarjeta lógica defectuosa.

Comprobaciones:
(3) Desconecte la batería.
Inspeccione el cableado por si hay cables rotos o cortocircuitados.
• Rotos o cortocircuitados.
Repare o cambie los componentes defectuosos.
• No hay cables rotos ni cortocircuitados.

(4) Cambie la tarjeta lógica.

• Estado no aceptable
Cambie el controlador.

11
 Troubleshooting EPKRT

PROBLEMA: transistor de bomba cortocircuitado

Síntoma:
(1) Display = “AL028”.
Quedan inhibidas la funciones de la unidad. El contactor de línea está en OFF.

Causa posible:
(2) Cortocircuito en el transistor de bomba, fallo de la tarjeta de mando, fallo del sensor de corriente
de la bomba, tarjeta lógica defectuosa.

Comprobaciones:
(3) Desconecte la batería.
Cambie la tarjeta lógica.
• Estado no aceptable
Cambie el controlador

12
 Troubleshooting EPKRT

PROBLEMA: fallo en la conducción del transistor de bomba

Síntoma:
(1) Display = “AL028”
Inhibe las operaciones de la unidad. Contactor de línea en OFF.

Causa posible:
(2) Rotura de cables en el transistor de bomba, fallo en las conexiones del cableado, fallo de la
tarjeta lógica de mando, fallo del sensor de corriente para la bomba, fallo de la tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería.
Cambie la tarjeta lógica.
• Estado no aceptable
Cambie el controlador

13
 Troubleshooting EPKRT

PROBLEMA: circuito abierto en el motor de bomba

Síntoma:
(1) Display = “AL028” o “AL052”.
Quedan inhibidas la funciones de la unidad.

Causa posible:
(2) Circuito abierto del motor de bomba, fallo del sensor de corriente para la bomba, fallo de la tarjeta
lógica.

Comprobaciones:
(3) Desconecte la batería.
Desconecte los terminales (A1, D2) del controlador. Mida la resistencia entre A1 y D2.
• Abierto.
Cambie el motor o el cableado del motor.
• Aceptable.

(4) Cambie la tarjeta lógica

• Estado no aceptable
Cambie el controlador

14
 Troubleshooting EPKRT

PROBLEMA: circuito abierto en el motor de tracción

Síntoma:
(1) Display = “AL032” o “AL049”.
Quedan inhibidas la funciones de tracción e hidráulico.

Causa posible:
(2) Circuito abierto del motor de tracción, fallo del sensor de corriente para la tracción, fallo de la
tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería.
Desconecte los terminales (A, B) del controlador. Mida la resistencia entre A y B.
• Abierto.
Cambie el motor o el cableado del motor.
• Aceptable.

(4) Cambie la tarjeta lógica

• Estado no aceptable
Cambie el controlador

15
 Troubleshooting EPKRT

PROBLEMA: sobrecorriente en el motor de bomba

Síntoma:
(1) Display = “AL035”
Inhibidas las operaciones de la unidad.

Causa posible:
(2) Cortocircuito en el transistor de la bomba, fallo en la conexión del cableado, defecto de la tarjeta
lógica de mando, fallo del sensor de corriente para la bomba, tarjeta lógica defectuosa.

Comprobaciones:
(3) Batería desconectada
Inspeccione el cableado del circuito de bomba por si hay cable rotos o en corto.
• Cables rotos o en corto
Repare o cambie los componentes defectuosos.
• No hay cables ni rotos ni defectuosos

(4) Cambie la tarjeta lógica

• Estado no aceptable
Cambie el controlador

16
 Troubleshooting EPKRT

PROBLEMA: fallo del contactor de línea

Síntoma:
(1) Display = “AL037”, “AL07”, “AL075”, “AL076”.
Inhibidas las operaciones de la unidad. Contactor de línea en OFF.

Causa posible:
(2) Fallo del contactor de línea, fallo en la conexión del cableado, tarjeta lógica defectuosa.

Comprobaciones:
(3) Desconecte la batería. Compruebe los contactores por si hay cables rotos o fusionados.
Comprobar que además el movimiento sea libre.
• Cables rotos o en corto
Cambie el contactor.
• No hay cables ni rotos ni defectuosos

(4) Compruebe la resistencia de la bobina del contactor.

• Mín. 15 ohmios, máx. 32 ohm.
Cambie la bobina del contactor.
• Entre 15 y 32 ohmios.

(5) Compruebe la continuidad entre CNA-8 y la bobina roja del contactor de línea. Desconecte el
conector CNA del controlador.
• No hay continuidad.
Repare o cambie el cableado del contactor.
• Hay continuidad.

(6) Compruebe la continuidad entre CNA-9 y la bobina negra del contactor de línea.
• No hay continuidad
Repare o cambie el cableado del contactor
• Hay continuidad
Cambie la tarjeta lógica de la tracción.
• Estado no aceptable
Cambie el controlador.

17
 Troubleshooting EPKRT

PROBLEMA: fallo del sensor de corriente de tracción

Síntoma:
(1) Display = “AL053” ó “AL049”
Inhibe las operaciones de la unidad. Contactor de línea en OFF.

Causa posible:
(2) Rotura de cables en el transistor de tracción, fallo en las conexiones del cableado, fallo de la
tarjeta lógica de mando, fallo del sensor de corriente CS de la tracción, fallo de la tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería.
Comprobar el estado del cableado.
• Estado no aceptable.
Repare el cableado.
• Estado aceptable

(4) Cambie la tarjeta lógica

• Estado no aceptable
Cambie el controlador

18
 Troubleshooting EPKRT

PROBLEMA: voltaje de batería muy bajo

Síntoma:
(1) Display = ”AL055”
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Batería descargada, fallo de la batería, abuso de batería por debajo del voltaje mín., fallo de la
tarjeta lógica, fallo del ajuste del BDI.

Comprobaciones:
(3) Mida el voltaje.
Para unidades de 24V > 15
• No aceptable
Cambie la batería
• Aceptable

(4) Realice las operaciones de ajuste.

• Funcionamiento normal de la unidad
La unidad funciona normalmente
• No hay cambios
Cambie la tarjeta lógica.

19
 Troubleshooting EPKRT

PROBLEMA: fallo del sensor de corriente para la bomba

Síntoma:
(1) Display = “AL056” ó “AL052”
Inhibe las operaciones de la unidad. Contactor de línea en OFF.

Causa posible:
(2) Rotura de cables en el transistor de bomba, fallo en las conexiones del cableado, fallo de la
tarjeta lógica de mando, fallo del sensor de corriente de la bomba, fallo de la tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería.
Comprobar el estado del cableado.
• Estado no aceptable.
Repare el cableado.
• Estado aceptable

(4) Cambie la tarjeta lógica

• Estado no aceptable
Cambie el controlador

20
 Troubleshooting EPKRT

PROBLEMA: sobrecorriente de campo del motor de tracción

Síntoma:
(1) Display = “AL057”.
Quedan inhibidas las funciones de tracción e hidráulico. La dirección funciona normalmente.

Causa posible:
(2) Fallo del sensor de corriente de tracción, fallo de cableado, fallo de la tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería.
Inspeccione el cableado de campo:
• Hay cables rotos o cortocircuitados
Cambie o repare los componentes defectuosos.
• No hay cables rotos ni cortocircuitados

(4) Cambie la tarjeta lógica.

• Estado no aceptable
Cambie el controlador

21
 Troubleshooting EPKRT

PROBLEMA: fallo del campo del motor de tracción

Síntoma:
(1) Display = “AL058”.
Quedan inhibidas la funciones de la unidad. El contactor de línea está en OFF.

Causa posible:
(2) Defecto en el circuito de campo del motor de tracción, tarjeta de mando defectuosa, tarjeta lógica
defectuosa.

Comprobaciones:
(3) Desconecte la batería.
Inspeccione el cableado de campo:
• Hay cables rotos o cortocircuitados
Cambie o repare los componentes defectuosos.
• No hay cables rotos ni cortocircuitados

(4) Cambie la tarjeta lógica.

• Estado no aceptable
Cambie el controlador

22
 Troubleshooting EPKRT

PROBLEMA: voltaje de batería demasiado alto

Síntoma:
(1) Display = “AL059”.
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Batería sobrecargada, fallo de la batería, sobrevoltaje en batería, fallo de la tarjeta lógica, fallo del
ajuste del BDI.

Comprobaciones:
(3) Mida el voltaje.
Para unidades de 24V < 36
• No aceptable
Cambie la batería
• Aceptable

(4) Realice las operaciones de ajuste.

• Funcionamiento normal de la unidad
La unidad funciona normalmente
• No hay cambios
Cambie la tarjeta lógica.

23
 Troubleshooting EPKRT

PROBLEMA: rotura del transistor de tracción

Síntoma:
(1) Display = “AL060” o “AL032”.
Quedan inhibidas la funciones de tracción e hidráulicas. El contactor de línea está en OFF.

Causa posible:
(2) Rotura de cables en el transistor, fallo del sensor de corriente CS de la tracción, tarjeta lógica
defectuosa.

Comprobaciones:
(3) Desconecte la batería.
Inspeccione el cableado del inducido por si hay cables rotos o cortocircuitados.
• Rotos o cortocircuitados.
Repare o cambie los componentes en mal estado.
• No hay cables rotos ni cortocircuitados.

(4) Cambie la tarjeta lógica.

• Estado no aceptable
Cambie el controlador.

24
 Troubleshooting EPKRT

PROBLEMA: transistor de tracción cortocircuitado

Síntoma:
(1) Display = “AL060” o “AL032”.
Quedan inhibidas las funciones de la unidad. El contactor de línea está en OFF.

Causa posible:
(2) Cortocircuito en el transistor de tracción, fallo de la tarjeta de mando, fallo del sensor de corriente
CS de tracción, tarjeta lógica defectuosa.

Comprobaciones:
(3) Desconecte la batería.
Cambie la tarjeta lógica.
• Estado no aceptable
Cambie el controlador

25
 Troubleshooting EPKRT

PROBLEMA: fallo del control del transistor

Síntoma:
(1) Display = “AL060” ó “AL032”
Inhibe las operaciones de la unidad. Contactor de línea en OFF.

Causa posible:
(2) Rotura de cables del transistor de tracción, fallo de la tarjeta de mando de tracción, fallo del
sensor de corriente CS de la tracción, fallo en el cableado, fallo de la tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería.
Cambie la tarjeta lógica.
• Estado no aceptable
Cambie el controlador

26
 Troubleshooting EPKRT

PROBLEMA: sobrecalentamiento del motor de tracción

Síntoma:
(1) El motor está sobrecalentado. Aparece la alarma “AL065” en el display.
Bajo poder de tracción y aceleración. Las operaciones del motor del hidráulico y sistema de
dirección son normales.

Causa posible:
(2) Sobrecalentamiento del motor de tracción, interruptor térmico del motor de tracción defectuoso,
cables desprotegidos, tarjeta lógica defectuosa, unidad de display defectuosa.

Comprobaciones:
(3) Deje enfriar la unidad 15 minutos.
• “AL065” desaparece.
El motor de tracción estaba sobrecalentado. Vuelven las condiciones normales de
funcionamiento. Si las condiciones vuelven a repetirse comprobar lo siguiente:
- comprobar el ciclo de trabajo (rampas, remolques, empujes)
- frenos, ajuste del freno de servicio
- funcionamiento del micro del freno
• “AL065” permanece en el display

(4) Conectar la consola Zapi al controlador y comprobar si aparece en el display “Motor temperat.”
• No aparece “Motor temperat.”
Cambie la unidad de display
• Aparece “Motor temperat.”

(5) Desconecte la batería. Espere hasta que la temperatura del motor se acerque a la temperatura
ambiente. Desconecte el conector del interruptor de temperatura del motor de tracción.
Compruebe la continuidad del mismo. Debe dar continuidad por debajo de 130ºC.
• No hay continuidad
Cambie el motor de tracción
• Hay continuidad

(6) Compruebe la continuidad entre el cable 124-W (blanco) del mazo de cables del interruptor
térmico y el NEG9.
• No hay continuidad
Repare o cambie el cable
• Hay continuidad

(7) Desconecte el conector CNB del controlador. Compruebe la continuidad del sensor del motor
125-Y (amarillo) y CNB-9, y el corto de estos terminales con neg.
• No hay continuidad.
Repare o cambie el cable.
• Hay continuidad.
Cambie la tarjeta lógica o el controlador.

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 Troubleshooting EPKRT

PROBLEMA: sobrecalentamiento del controlador de tracción

Síntoma:
(1) El controlador está caliente. Aparece la alarma “AL062” en el display.
Bajo poder de traslación y aceleración. Funcionamiento normal del motor de bomba y sistema de
dirección.

Causa posible:
(2) Sobrecalentamiento del panel de control de tracción, interruptor térmico del panel del hidráulico
defectuoso, cables desprotegidos, tarjeta lógica defectuosa, unidad de display defectuosa.

Comprobaciones:
(3) Deje enfriar la unidad 15 minutos.
• “AL062” desaparece.
El controlador para la tracción estaba sobrecalentado. Vuelven las condiciones normales de
funcionamiento. Si las condiciones vuelven a repetirse comprobar lo siguiente:
Comprobar el ciclo de trabajo
Ajuste del freno de estacionamiento.
Funcionamiento del micro del freno.
• “AL062” permanece en el display

(4) Conectar la consola Zapi al controlador, compruebe entonces si “ Th. protection” aparece en el
display.
• No aparece “Th. protection” .
Cambie la unidad de display
• Aparece “Th. protection”

(5) Desconecte la batería. Espere hasta que la temperatura del panel de control de tracción alcanze
una temperatura similar a la temperatura ambiente. Quite la tapa del controlador. Conecte de
nuevo el controlador Zapi, y compruebe si “Th. protection” aparece en el display.
• No aparece “Th. protection”.
Todo es normal.
• Aparece “Th. protection”
Cambie la tarjeta lógica

28
 Troubleshooting EPKRT

PROBLEMA: sobrecalentamiento del controlador del hidráulico

Síntoma:
(1) Aparece la alarma “AL064” en el display.
La velocidad de elevación es más baja de lo normal. El funcionamiento del motor de tracción y
sistema de dirección son normales.

Causa posible:
(2) Sobrecalentamiento del panel de control del hidráulico, interruptor térmico del panel del hidráulico
defectuoso, cables desprotegidos, tarjeta lógica defectuosa, unidad de display defectuosa.

Comprobaciones:
(3) Deje enfriar la unidad 15 minutos.
• “AL064” desaparece.
El controlador para el hidráulico estaba sobrecalentado. Vuelven las condiciones normales de
funcionamiento. Si las condiciones vuelven a repetirse comprobar lo siguiente:
Comprobar el ciclo de trabajo
Alimentación al motor de bomba
Exceso de carga de trabajo
• “AL064” permanece en el display

(4) Comprobar las averías almacenadas. Verifique que la temperatura del motor esté presente.
• No aparece la temperatura del motor de bomba
Cambie la unidad de display
• Aparece la temperatura del motor de bomba

(5) Compruebe la continuidad entre el cable J3-2 (negro) del mazo de cables del interruptor térmico y
NEG.
• No hay continuidad
Repare o cambie el cable
• Hay continuidad

(6) Desconecte el conector J1 del controlador hidráulico. Compruebe la continuidad entre el termistor
J3-1 (marrón) y J1-13.
• No hay continuidad
Repare o cambie el cable
• Hay continuidad
Cambie la tarjeta lógica

29
 Troubleshooting EPKRT

PROBLEMA: consumo de batería

Síntoma:
(1) Indicador de batería baja “AL066”.
Bajo poder de tracción y aceleración. La velocidad de elevación es más baja de lo normal.

Posibles causas:
(2) Excesivo consumo con poca capacidad o batería baja.

Comprobaciones:
(3) Compruebe el voltaje de batería cuando la unidad está trabajando ó cuando está en reposo.
• Voltaje de batería inferior a 23.6V
Compruebe lo siguiente:
Capacidad de batería
Alimentación al motor de bomba
Exceso de carga de trabajo.
• Voltaje de batería mayor que 23.6V
Cambie la tarjeta lógica.

30
 Troubleshooting EPKRT

PROBLEMA: excesivo consumo de batería

Síntoma:
(1) Display = “AL067”.
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Excesivo consumo con poca capacidad o batería baja.

Comprobaciones:
(3) Compruebe el voltaje de batería cuando la unidad está trabajando ó cuando está en reposo.
• Voltaje de batería inferior a 15V
Compruebe lo siguiente:
Capacidad de batería
Alimentación al motor de bomba
Capacidad de carga
• Voltaje de batería mayor que 15V.
Cambie la tarjeta lógica

31
 Troubleshooting EPKRT

PROBLEMA: sobrecorriente en el inducido del motor de tracción

Síntoma:
(1) Display = “AL069”
Inhibidas las operaciones de tracción e hidráulico. Funcionamiento normal de las operaciones de
dirección.

Causa posible:
(2) Cortocircuito en el transistor, fallo en la conexión del cableado, defecto de la tarjeta lógica de
mando, fallo del sensor de corriente para la tracción, tarjeta lógica defectuosa.

Comprobaciones:
(3) Batería desconectada
Inspeccione el cableado del inducido por si hay cable rotos o en corto.
• Cables rotos o en corto
Repare o cambie los componentes defectuosos.
• No hay cables ni rotos ni defectuosos

(4) Cambie la tarjeta lógica

• Estado no aceptable
Cambie el controlador.

32
 Troubleshooting EPKRT

PROBLEMA: freno de estacionamiento activado

Síntoma:
(1) Display = “AL071”
Poder de traslación y aceleración bajos. Funcionamiento normal del motor de bomba y de la
dirección.

Posibles causas:
(2) Fallo del micro del freno de estacionamiento, freno de estacionamiento parcialmente activado,
fallo del micro del freno de servicio, fallo del cableado, fallo de la tarjeta lógica.

(3) Desconecte la batería. Aplique el freno de estacionamiento. Compruebe que los terminales 7 y 10
están derivados a masa.
• Si están a masa, no hay problema.
• Si no están a masa, suelte el freno de estacionamiento y compruebe de nuevo si los
terminales 7 y 10 están derivados a masa.
• Si están a masa, compruebe el cableado del micro del freno; cambie el micro si es necesario.
• Si no está a masa, cambie el micro del freno de servicio.
• Si las acciones anteriores no resuelven el problema, cambie la tarjeta lógica.

33
 Troubleshooting EPKRT

PROBLEMA: temporizador de calado

Síntoma:
(1) Display = “AL072”.
Quedan inhibidas la funciones de tracción e hidráulico. La dirección funciona correctamente.

Causa posible:
(2) La corriente de calado fluyó más tiempo del tiempo programado por el motor de tracción. Fallo del
sensor de corriente, fallo de la tarjeta lógica.

Comprobaciones:
(3) Compruebe si la unidad estaba trabajando en rampas de fuerte pendiente o empujando cargas
pesadas cuando el motor se caló.
• Operando bajo condiciones extremas.
No opere la unidad en condiciones extremas por más tiempo del que esté programado el
tiempo de calado.
• Operando bajo condiciones normales.

(4) Desconecte la batería.

Cambie la tarjeta lógica
• Estado no aceptable
Cambie el controlador.

34
 Troubleshooting EPKRT

PROBLEMA: fallo del sensor del acelerador

Síntoma:
(1) Display = “AL078”, “AL086”, “AL087”.
Inhibidas las funciones de tracción e hidráulico.

Posible causa:
(2) Fallo del sensor del acelerador, fallo del cableado, fallo de la tarjeta lógica.

Comprobaciones:
(3) Desconecte la batería. Compruebe la continuidad entre el conector del acelerador y la tarjeta
lógica de tracción.
CN7 – 141R ↔ CNA - 12
CN7 – 142G ↔ CNA - 14
CN7 - 143B ↔ CNA - 13
CN7 – 144L ↔ CNA - 6
• No hay continuidad
Repare o cambie el cableado.
• Hay continuidad

(4) Conecte nuevamente la batería y los conectores. Compruebe el voltaje de CN-14 sin pisar el pedal
del acelerador y mientras se va pisando sobre el mismo hasta su recorrido final. Compruebe la
continuidad entre los cables 143 y 144 del acelerador sin pisar y pisándolo hasta el final.

Sin pisar 0.2 a 1.72V Hay continuidad

pisando 3.74 a 4.8V No hay continuidad

• Resultados aceptables
Cambie la lógica de tracción
• Resultados no aceptables

(5) Compruebe el ajuste del retorno del acelerador e interferencias.

• Ajustado correctamente
Cambie el acelerador
• Sigue activado
Ajuste el varillaje del acelerador.

35
 Troubleshooting EPKRT

PROBLEMA: palanca de marcha adelante/atrás, palanca de inclinación, palanca de att 1,

palanca de att 2, fallo de programación

Síntoma:
(1) Display = “AL079”.
Quedan inhibidas la funciones de la unidad. El contactor de línea está en OFF.

Causa posible:
(2) La llave de contacto se giró a ON cuando la palanca de dirección estaba en posición marcha
adelante/marcha atrás. La llave de contacto se giró a ON cuando la palanca de inclinación, att 1 ó
att 2, estaban fuera de neutro o el pedal del acelerador pisado. Fallo del micro de marcha
adelante/marcha atrás, del de inclinación, fallo del micro del att1 y att2, tarjeta lógica defectuosa.

Comprobaciones:
(3) Ponga en neutro: la palanca marcha adelante/marcha atrás, la de inclinación, la del att1 y / ó el
att2. Seleccione nuevamente una dirección y pise el pedal del acelerador.
• Funcionamiento normal de la unidad.
El arranque correcto de la unidad requiere que se encuentre en neutro la palanca de sentido
de marcha, así como todas las palancas del hidráulico cuando se gire la llave a la posición de
ON.
• La unidad sigue sin funcionar.

(4) Usar la función de test para localizar fallos en el circuito o componentes.

• Encontrado componente defectuoso
Cambie o repare el componente averiado.

36
 Troubleshooting EPKRT

PROBLEMA: fallo del ajuste de la palanca de inclinación.

Síntoma:
(1) Display = “AL079”
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Llave de contacto girada a ON cuando la palanca de inclinación estaba fuera de neutro. Fallo del
micro de inclinación. Fallo de la tarjeta lógica.

Comprobaciones:
(3) Ponga la palanca de inclinación en neutro y vuelva a desplazarla
• La función hidráulica vuelve a funcionar normalmente.
El arranque correcto requiere que la unidad tenga la palanca de inclinación en neutro cuando
esta sea arrancada.
• No se han producido cambios.

(4) Usar la función de test para localizar fallos en el circuito o componentes.

• Encontrado componente defectuoso.
Cambie o repare el componente averiado.
• No se ha encontrado ningún componente defectuoso
Cambie la tarjeta lógica.

37
 Troubleshooting EPKRT

PROBLEMA: fallo del ajuste de la palanca del att 1

Síntoma:
(1) Display = “AL079”
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Llave de contacto girada a ON cuando la palanca del att 1 estaba fuera de neutro. Fallo del micro
de la palanca del att 1. Fallo de la tarjeta lógica.

Comprobaciones:
(3) Ponga la palanca en neutro y vuelva a desplazarla
• La función hidráulica vuelve a funcionar normalmente.
El arranque correcto requiere que la unidad tenga la palanca del att 1 en neutro cuando esta
sea arrancada.
• No se han producido cambios.

(4) Usar la función de test para localizar fallos en el circuito o componentes.

• Encontrado componente defectuoso.
Cambie o repare el componente averiado.
• No se ha encontrado ningún componente defectuoso
Cambie la tarjeta lógica.

38
 Troubleshooting EPKRT

PROBLEMA : fallo del ajuste de la palanca del att 2

Síntoma:
(1) Display = “AL079”
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Llave de contacto girada a ON cuando la palanca del att 2 estaba fuera de neutro. Fallo del micro
del att 2. Fallo de la tarjeta lógica.

Comprobaciones:
(3) Ponga la palanca en neutro y vuelva a desplazarla
• La función hidráulica vuelve a funcionar normalmente.
El arranque correcto requiere que la unidad tenga la palanca del att 2 en neutro cuando esta
sea arrancada.
• No se han producido cambios.

(4) Usar la función de test para localizar fallos en el circuito o componentes.

• Encontrado componente defectuoso.
Cambie o repare el componente averiado.
• No se ha encontrado ningún componente defectuoso
Cambie la tarjeta lógica.

39
 Troubleshooting EPKRT

PROBLEMA: fallo del ajuste de la palanca de elevación

Síntoma:
(1) Display = “AL082” o “AL083”.
Inhibidas las funciones de la unidad. Contactor de línea en OFF.

Posibles causas:
(2) Llave de contacto girada a ON cuando la palanca de elevación estaba fuera de neutro. Fallo del
potenciómetro de elevación. Fallo de la tarjeta lógica.

Comprobaciones:
(3) Ponga la palanca en neutro y vuelva a desplazarla
• La función hidráulica vuelve a funcionar normalmente.
El arranque correcto requiere que la unidad tenga la palanca de elevación en neutro cuando
esta sea arrancada.
• No se han producido cambios.

(4) Usar la función de autodiagnosis para localizar fallos en el circuito o componentes.

• Encontrado componente defectuoso
Cambie o repare el componente averiado.
• No se ha encontrado ningún componente defectuoso
Cambie la tarjeta lógica.

40
 MOTORS

Motor Installation Positions ................................................................ 5 – 1

Specifications .......................................................................................... 5 – 1
Structure and Function ......................................................................... 5 – 2
Drive Motor ............................................................................................... 5 – 2
Pump Motor .............................................................................................. 5 – 4
Removal and Installation ...................................................................... 5 – 6
Drive Motor ............................................................................................... 5 – 6
Pump Motor .............................................................................................. 5 – 6
Inspection of Brushes for Wear and Brush Replacement .......... 5 – 7 5
Disassembly and Reassembly ............................................................ 5 – 8
Disassembly ............................................................................................. 5 – 8
Inspection ................................................................................................. 5 – 10
Interpreting Commutator Surface Conditions ................................ 5 – 12
Troubleshooting ...................................................................................... 5 – 14
 MOTORS

Motor Installation Positions

Pump motor

Drive motor

Rear axle

209186

Specifications

Item Drive Motor Pump Motor

DC separately excited, with external DC series – wound with external electric

Type
electric cooling fan cooling fan

Voltage 24 V 24 V

Output 4.8 kW (1 hour rating) 8.8 kW (15 % duty cycle)

Number of brushes 4 4

5-1
MOTORS

Structure and Function

Drive Motor
A

B
9

F
Fan
BW1 Fan
BW1

4
6

E 7
Themal switch

Commutator

8 Field coil
3
5

F2
F F1
E
1

2 M B VMN

A Batt +
Output shaft splines
(to be coupled with internal
splines of rear axle input gear)

Thermo Fan Brush

switch wear
sensor
(BW1) 209187

Main components
1 Armature assembly 6 Brush plate assembly
2 Frame and field assembly 7 Brush kit
3 Drive end head 8 Brush spring kit
4 Commutator end head 9 Fan (DC motor drive)
5 Bearing (commutator end)

5-2
 MOTORS

The drive motor is a separately excited DC motor with to the armature windings via the terminal A in
an electric fan. This vertically installed electric motor proportion to the amount of accelerator pedal stroke.
provides the drive wheels of the truck with driving Change in the current causes change in the motor speed
power. and torque.
The armature assembly 1 is the motor ’s rotating In addition to change in foot pressure on the accelerator
component. It consists of a shaft, windings and pedal, the motor output is also changed by operation of
commutator. The commutator end of the output shaft is the fail-safe system.
supported by a sealed ball bearing 5 and the other end This motor has a so-called “regenerative function” with
is splined to the input gear of the rear axle, being which it operates as a generator when the truck is
supported by the gear. braked and creates electricity that will be sent back to
The field coils are attached to the inner surface of the the battery.
motor frame 2. When the preset condition is reached, the operation of
Insulation of both the field coils and armature windings the motor is switched into the regeneration mode. In
meets the “Class H” requirements. this mode, current is made to flow through the field
On the commutator end of the motor, there are the windings, which develops voltage in the armature
brush plate assembly 6, brushes 7, brush springs 8 and windings.
terminals A, B and BW1, which are all fitted in the
commutator end head 4.
There are four brushes, each being held in the brush
holder and pressed against the commutator by the brush
spring 8 with a force even between the four brushes.
The fan 9 driven by an independent 24V DC motor
provides cooling to the motor’s windings. The fan
rotates continuously as long as the key switch is in the
ON position.
The motor incorporates the brush wear sensor and
thermal switch.
The brush wear sensor causes the indicator light circuit
to close when a brush has worn down close to the limit,
thus warning the operator of the fact by illuminated
light.
The thermal switch has a function of causing the load
on the motor to be reduced if the windings overheat.
When the thermal switch operates, the current to the
armature windings is reduced.
The motor rotates in either forward or reverse direction
according to the position of the F.N.R. lever selected by
the operator. When the lever is moved from a truck
movement position to the other, the polarities (+/-) of
the field winding terminals E and F interchange, which
causes the rotating direction of the motor to change.
The motor also can change the rotating speed according
to the amount of stroke through which the accelerator
pedal is depressed by the operator. This is achieved by
a circuit which changes the duty of the current supplied

5-3
MOTORS

Pump Motor

D2 −SH

M A1 +SH

Thermo Fan Brush

switch wear
Indicator

D2
A1

1 6
2
5

13

12

10
8 11

7
209188

Main components
1 Drive end bracket 8 Set of brushes with springs
2 Bearing 9 Thermal protector
3 Armature 10 Bearing
4 Gasket 11 Commutator end bracket
5 Connection plate 12 Fan
6 Stator 13 Cover
7 Brush holder

5-4
 MOTORS

The pump motor is a series-wound coil type DC motor

fitted with an electric fan. This electric motor drives
the hydraulic pump which supplies the hydraulic
system with pressure oil.
The motor’s terminals A1 and D2 are connected to the
positive (+) and negative (-) terminals of the DC power
supply circuit, so that the motor rotates invariably
clockwise as viewed from the output shaft end of the
motor.
The armature 3 –the motor’s rotating component–
consists of the shaft, windings and commutator. The
armature is supported at both ends by the sealed ball
bearings 2 and 10.
The field windings are attached to the inside surface of
the motor frame (stator) 6.
Insulation of both field coils and armature windings
meets the “Class H” requirements.
On the commutator end of the motor, there are the
brush holders 7, brushes and brush springs 8, thermal
protectors 9, bearing 10 and connection plate 5, which
are all fitted in the commutator end bracket 11.
There are four brushes, each being held in the brush
holder and pressed against the commutator by the brush
spring with a force even between the four brushes.
The fan driven by an independent 24V DC motor
provides cooling to the motor’s windings. The fan
continuously rotates as long as the key switch is in the
ON position.
The motor incorporates the brush wear sensor and
thermal switch.
The brush wear sensor causes the indicator light circuit
to close when a brush has worn down close to the limit,
thus warning the operator of the fact by illuminated
light. On the dashboard LED light indicated as:

The thermal switch has a function of causing the load

on the motor to be reduced if the motor overheats.
When the thermal switch operates, the current to the
motor is reduced.
The speed and torque of the motor are changed
according to change in the duty of the hydraulic system
and also by operation of the fail-safe system.
Refer to the “Main Controller” chapter of this manual
for further details.
5-5
MOTORS

Removal and Installtion

Drive Motor
Removal
Drive motor
(1) Park the truck on a flat surface in the service area. Drive motor
mounting bolt Lifting eye
(2) Turn off (press) the battery switch, then disconnect the (M12, 1.75 pitch
battery cable by detaching the plug from the jack on thread)
the side of the battery box.
(3) Remove the battery cover.
(4) Remove the rear cover.
(5) Discharge the head capacitors by using resistor part B
number 0358280. F
(6) Disconnect all the cables and harnesses that are Fan
connected to the motor terminals and sensors. Put
marks as necessary to facilitate reconnection.
E
(7) Screw an eyebolt (M12, 1.75 pitch) into the motor shaft
and attach it to a hoist using a sling.
Ground
(8) Remove the six motor mounting bolts (hex socket
bolts), then hoist away the motor from the truck. A
Thermo sensor

Installation Brush wear sensor

Follow the removal sequence in reverse while respecting 209189

the following instructions.
(1) Apply molybdenum grease to the splines on the shaft.
(2) When installing the motor on the truck, use guide bolts
while making sure each section of the motor faces in
the correct direction. Lifting eye
(M10, 1.25 pitch thread)
(3) Tighten the motor mounting bolts to a torque
Hydraulic pump
equivalent to that specified for 7T bolts.
(4) Use Locktite 271 to secure the 6 bolts.
(5) Install the terminal of each cable such that it does not
interfere with another. Pump motor
(6) Each cable terminal should be properly covered with a
boot.
Pump Motor
Mounting bolts
Removal
(1) Remove the hydraulic pump complete with the bracket
from the truck following the instructions on page 10- *
14. * *
(2) Separate the hydraulic pump from the pump motor.
NOTE: Remove the nuts marked * if the bracket is to
be hoisted up.
Motor bracket
*
Installation
(1) Apply molybdenum grease to the internal splines in the
shaft before assembling the hydraulic pump. 209095
(2) Respect the same instructions about installation of
cables and harnesses described in the “Drive Motor”
section above.
5-6
 MOTORS

Inspection of Brushes for Wear and Brush Replacement

(Drive Motor and Pump Motor)
Normally, the inspection of the motor brushes becomes Brush holder
necessary when the brush wear indicator is lit or the Sufficient wear margin
Spring remains even when sink
brushes are suspected to be worn out. depth is 5 to 8 mm.
The brush still has sufficient wear margin even when it has
worn to an extent that its top sinks below the outer edges of
the brush holder by 5 to 8 mm.
Projecting Brush
Start by:
Commutator
(1) Park the truck on a flat surface in the service area. surface
(2) Turn off (press) the battery switch, then pull out the New brush Worn brush 209190
cable plug.
(3) Get access to the motor brushes as follows: Determining degree of wear
(a) Drive motor
(b) Discharge the internal capacitors by using resistor
part number 0358280. Battery
switch
Remove the rear cover. Disconnect any of the Cable plug
cables connected to the motor as necessary.
(c) Pump motor
Remove the motor complete with the hydraulic
pump. Follow the hydraulic pump removal
procedure shown in the “Hydraulic System”
chapter of this manual.

Brush Removal and Inspection

Battery box 103399
1. Remove the brush cover.
2. Remove the brush wire attaching bolt (A).
3. While pulling the curled section of the spring by a Brush spring Pull up
hooked wire, remove the brush from each holder.
Hooked wire
NOTE
Do not try to raise the brush spring using a screwdriver Brush wire
or pliers. Doing so could dislodge or deform the
Brush
spring.

4. Visually check the removed brush for degree of wear.

Determine whether the brush should be replaced or not Brush wire
based on the length remaining below the wear limit attaching bolt (A)
notch on the brush and taking into account the expected
operation time before the next overhaul. Brush holder 209192
5. Remove carbon powder resulting from wear from the
brush holder, the area around the brush and the
connector by using compressed air. Brush wire
6. Check the contact surfaces on both the brushes and
commutator for roughness. If necessary, rectify the
surfaces selecting the method appropriate for the
degree of roughness. Refer to the “Interpreting
Commutator Surface Conditions” section on pages 5-
12 and 5-13. Brush

Brush Installation
Follow the removal sequence in reverse, taking care not to Wear limit notch 209193
soil the brushes with oil or grease.
5-7
MOTORS

Disassembly and Reassembly

Disassembly
Drive Motor

3
10

4
7

209194

Sequence
1 Fan mounting kit (with fan) ❋6 Ball bearing – commutator end
❋2 Brush kit ❋7 Brush spring kit
3 Circlip 8 Armature assembly
Remove parts 4 and 6 as a unit. 9 Frame and field assembly
4 Commutator end head assembly 10 Drive end head
5 Circlip

NOTE
1. Putting mating marks across components
before disassembly will help to prevent errors
during reassembly.
2. Replace the ❋ marked parts with new ones once
the motor was disassembled.
5-8
 MOTORS

Pump Motor

12

13
4
5
8

9
3 7

11

10
209195

Sequence
1 Cover Remove parts 7 and 11 as a unit.
2 Fan 7 Commutator end bracket
❋3 Brush
8 Connection plate
❋9 Bearing
Remove parts 4 to 6 as a unit. 10 Brush holder
4 Drive end bracket 11 Thermal protector
❋5 Bearing 12 Armature
❋6 Gasket 13 Stator (frame assembly and field)

NOTE
1. Putting mating marks across components
before disassembly will help to prevent errors
during reassembly.
2. Replace the ❋ marked parts with new ones once
the motor was disassembled.

5-9
MOTORS

Inspection

1. Inspection and Tests Performed before

Disassembly and after Reassembly (as Required)
(1) Using a 500 V megger or similar instrument, measure
insulation resistance between each terminal and the
motor unit.

Resistance limit 3 M ohm min.

If the measured values are less than the limit value,

there may be an internal short-circuit. Check wires for
short-circuiting during disassembly.
209196

(2) Using an ordinary circuit tester or digital multimeter,

measure continuity between terminals.

Measuring Standard
terminals values

E–F 0 ohm
Drive motor
A–B 0 ohm

Pump motor D2 – A1 0 ohm

209197

If the measured values deviate from the standard

values, there may be a broken wire. Check wires for
breakage during disassembly.
(3) Inspect the brushes for wear referring to the section
entitled “Inspection of Brushes for Wear and Brush
Replacement” on page 5-7.
(4) Measure the brush spring tension. To measure the
tension, hook a spring scale to the curled end of the
brush spring.

9.8 to 19.6 N
Brush spring tension
(1 to 2 kgf)

It is essential that the tension of all the springs are

equal to each other.
209198
If the measured tension deviates from the standard
value, replace the spring.

5-10
 MOTORS

2. Inspection after Disassembly

(1) Using compressed air and clean cloth, remove dust and
oil/grease from the commutator.
(2) Compare the condition of commutator surface against
the photographs on pages 5-12 and 5-13. If the
commutator surface is found to be in any of the
“unsatisfactory” conditions, take appropriate measures
to improve the condition. When rectifying the surface
of the commutator, use the method described below as
206010
a guide.
(a) If repairable with sand paper:
Smooth the surface with sand paper (#600) and
clean with compressed air.
(b) If the surface is scratched:
Grind the surface to remove scratches using the
dedicated machine. As a general rule, the grinding
allowance is approximately 1.5 mm on one side.
After grinding, measure the undercut. Make the
undercut deep enough, if necessary, by removing
as much of mica as necessary.
(3) Check the brushes for wear not only with respect to the
degree of wear but also to roughness of contact
surfaces.
(4) Inspect the oil seal as follows (applicable only to the
pump motor):
Visually check the lip of the oil seal for wear and
damage.
* It is recommended that the oil seal be replaced if the
208360A
pump motor is used for long hours and disassembled
at a time when its disassembly is generally required.
(5) Inspect the sealed ball bearing as follows:
Rotate the bearing by hand to check for noise, rough
rotation and leakage of grease (defective sealing).
* It is recommended that the bearing be replaced if the
motor is used for long hours and disassembled at a
time when its disassembly is generally required.

Reassembly
Reassemble the drive motor and pump motor by following
the removal sequence in reverse.

NOTE
In the case of the pump motor, install the oil seal in
correct direction. Otherwise, oil could enter the motor.

5-11
MOTORS

Interpreting Commutator Surface

Conditions

GOOD CONDITION UNSATISFACTORY CONDITION

LIGHT FILM UNEVEN FILM
Uniform coloring indicates This condition characterized by
satisfactory operation of the truck patchy colors of varying densities
and brushes. Film color is largely and shape can occur due to
an effect of thickness. Therefore, unclean operating conditions or
provided the film is uniform, it is incorrect physical condition of
perfectly acceptable. commutator.

SATISFACTORY CONDITION UNSATISFACTORY CONDITION

LIGHT AND DARK PATTERN FILM WITH DARK AREAS

This is not a good condition but This condition with dark areas
not detrimental to satisfactory either isolated or regular can occur
operation of the truck. This when the commutator is out of
condition can appear in alternating round. This can be caused by
bars as shown or every 3rd or 4th vibration or mechanical
bar, etc. This is related to the deficiencies in equipment
winding design of the armature. operation, bearings, couplings, etc.

UNSATISFACTORY CONDITION UNSATISFACTORY CONDITION

STREAKY FILM WITH NO EXAMPLE OF POOR

COMMUTATOR WEAR COMMUTATOR MACHINING
This condition can occur due to This condition occurs if the
under-loaded operation of the commutator is machined
truck or use of brushes of an improperly with its bars low on
incorrect grade. Atmosphere and entry and leaving edges. This
environmental conditions can gives rise to the brushes riding on
contribute. the middle of the bars, creating a
pattern like the one the photograph
shows. This condition indicates
the need for better maintenance.

5-12
 MOTORS

UNSATISFACTORY CONDITION UNSATISFACTORY CONDITION

EXAMPLE OF POOR BRUSH CONTACT MARK
COMMUTATOR MACHINING Storage of machines, for lengthy
This condition occurs if the periods, with brushes in position
commutator is machined can cause this condition.
improperly with its bars low in the This can also result from operation
middle. This gives rise to the of machine in prolonged stall
brushes riding on entry and leaving conditions.
bar edges, creating a pattern like
the one the photograph shows.
This condition indicates the need
for better maintenance.

UNSATISFACTORY CONDITION UNSATISFACTORY CONDITION

STREAKY FILM WITH BAR EDGE BURNING CAUSE
COMMUTATOR WEAR HIGH MICA
This is a further development of If high mica appears in every slot
the third example, previous page. as shown in this photograph or on
Brush grade, truck applications one bar only, a high or low bar is
and working environment can all the cause.
be suspect. Earlier corrective
action should have been taken.

UNSATISFACTORY CONDITION UNSATISFACTORY CONDITION

DOUBLE POLE PITCH SMALL BRIGHT SPOTS
Darkening of commutator in This condition occurs when the
sequences two pole pitches apart is truck is over-loaded or brush
due to armature fault, defective pressure is too low. Under such a
coil, riser bars or equalizer condition, sparking taking place
connections. under brush gives rise to spots
being of a random distribution. If
not corrected, the commutator will
be scored significantly.

5-13
MOTORS

Troubleshooting
Problems with rotation of the motor are attributable not only to a fault in the motor itself but also to a fault in the
controller that supply the motor with electric power. Therefore, you should perform motor troubleshooting also
referring to the Troubleshooting section in the “Group 3 Main Controller” in addition to this page.
Low supply voltage Charge battery and improve power
supply condition.
Blown fuse Replace.
Excess load Reduce load.
Motor does not Faulty wire connection Repair, or re-tighten wire connections.
start.
Broken wire in control device Repair or replace.
Faulty brush connection Clean and repair.
Broken wire in field coil Repair or replace.
Broken wire in armature coil Repair or replace.

Motor starts but Low supply voltage Charge battery and improve power
does not run at supply condition.
rated speed. Faulty connection of armature circuit Repair connections.

Motor produces Defective bearings Replace bearings.

abnormal Loose mounting bolts Retighten bolts and nuts.
vibrations Contact between armature and field coil Repair or replace.
and noise. Abnormal whistling sound Clean and repair brush.
Incorrect installation Correct installation condition.
Severe external vibration Remove the cause of vibration, or take
appropriate vibration-insulating
Bearing overheat measures.
Defective bearings Replace.
Oil degradation or shortage in bearings Replace.
Faulty brush contact surfaces Correct brush surfaces to ensure full
contact on commutator.
Faulty brush contact Clean commutator surface.
Brush Replace brush and spring.
malfunction
Faulty brush sliding Clean brush holder and ensure free
movement of brushes.
Incorrect brush dimension or material Replace.
Spartks generated at brushes (faulty commutation)

Dirtiness or damage Grind with sand paper or stone, and

Commutator wipe with clean cloth.
malfunction High mica Undercut mica.
High bar (commutator surface Grind with grinding stone or correct
irregularity) with lathe.
Short-circuit of commutator Remove conductive foreign materials
Armature from commutator and commutator
malfunction segments.
Broken wire or short-circuit in Repair or replace.
armature coil

Field coil Broken wire or short-circuit in field coil Repair or replace.

malfunction Broken wire or short-circuit in external Correct by referring to wiring diagram.
circuit on field side

Excessive Excessive load Reduce load.

armature current Short-circuit in external circuit on Correct short-circuit.
armature side
Insufficient ventilation due to dust Clean
Excessive load Reduce load.
Coil overheat
Short-circuit or broken wire Correct by referring to wiring diagram.
Insulation degradation due to moisture Dry.
5-14
 FRONT AXLE

Structure ................................................................................................... 6– 1
Disassembly of Front Axle Assembly ............................................... 6– 2
Inspection after Disassembly ............................................................. 6– 3
Reassembly of Front Axle Assembly ................................................ 6– 4

6
 FRONT AXLE

Structure

7 8 9

Grease 10

Brake assembly Detail of oil seal fitting area

11

Mast bearing

13

12

2 5

3 4
209111

1 Front axle 7 Oil seal

2 Front axle mounting bolt (four each side) 8 Snap ring
3 Brake backplate mounting bolt 9 Taper roller bearing
4 Hub bolt 10 Taper roller bearing
5 Wheel nut 11 Nut (inner and outer)
6 Hub 12 Lock washer
13 Cap

6-1
FRONT AXLE

Disassembly of Front Axle Assembly

209112

Sequence 14 Oil seal

1 Wheel nut Remove parts 8 to 14 as sub-
2 Solid tire assembly assembly.
3 Cap 8 Hub and drum
4 Outer nut 9 Bearing cup
5 Lock washer 10 Bearing cup
6 Inner nut 11 Hub bolt and nut
7 Bearing cone 12 Snap ring
13 Bearing cone

6-2
 FRONT AXLE

If the front axle shaft needs to be removed completely, Inspection after Disassembly
proceed in the following sequence.
1. Taper roller bearing
a) Remove the mast.
b) Disconnect the brake pipe at the front axle. Examine the rollers and bearing races for grooving,
abrasive wear, pitting, bruising, or corrosion. If any of
c) Remove the axle shaft mounting bolts and nuts 15.
the defects is found, replace the whole bearing with a
Then, remove the axle shaft 16.
new one.
Start by:
2. Oil seal 14
Lift the front of the truck and support it with wood
blocks placed under the frame. Make sure the truck is Check the oil seal 14 for damage or wear. Replace it
supported in a stable manner. with a new one if necessary.
3. Brake drum
Suggestion for Disassembly If uneven wear or damage is found on the inner surface
of the brake drum, grind and repair.
1. Removing nuts 4 and 6
Loosen the nuts 4 and 6 using the following special A: Standard value B: Repair or service limit
tool. Unit: mm
+ 0.13
Special tool needed A 203.2 0
Inner diameter of
Socket wrench brake drum
91268 - 00701 B 204.2
(width across flats = 46 mm)

2. Removing bearing cups 9 and 10

If no abnormalities are found on each bearing cup and
its cone, the bearing cup does not need to be removed.
Use a bearing cup puller to remove the bearing cups.

NOTE
The bearing cup and cone must be replaced in a
pair. If one of them is faulty, replace the whole
bearing with a new one.

6-3
FRONT AXLE

Reassembly of Front Axle Assembly

8 7 5

8 7 5

6
6

4
9

3 Detail of oil seal fitting area

11

Mast bearing
15

14
1

13

12

2 17

Stake 10 Grease 16
209111A

Sequence
1 Axle (if previously removed) 11 Bearing cone
2 Bolt, lockwasher and nut (if previously removed) 12 Nut (inner)
3 Brake assembly (if previously removed) 13 Lock washer
Assemble parts 4 to 10 prior to final assembly. 14 Nut (outer)
4 Hub and drum 15 Cap
5 Bearing cup 16 Solid tire assembly
6 Bearing cone 17 Wheel nut
7 Snap ring
8 Oil seal
9 Bearing cup
10 Wheel bolt and nut

6-4
 FRONT AXLE

Suggestion for Reassembly

1. If the front axle has been removed, refit it onto the
523.3 N·m
truck frame using the bolts, lock washers and nuts 2. Nut tightening torque
(53.4 kgf·m)
Tighten the nuts 2 to the torque shown on the right.
2. Reassembly of hub and drum sub-assembly
(1) Press-fit the bearing cups 5 and 9 in the hub 4
using the bearing and seal driver. 7 5 6 9 4
(2) Pack the bearing cone 6 with Shell Alvania R3 or
equivalent grease; force grease inside the bearing 8
cage using your palm.
(3) Install the bearing cone 6 as shown. Then install
the snap ring 7 into the hub 4.
(4) Install the oil seal 8 in the illustrated directon into
the hub 4 using the bearing and seal driver.
Stake
(5) Fill Shell Alvania R3 or equivalent grease into the crisscross
portion shown with in the illustration. Apply
the grease also to the oil seal lip. Take care that
grease does not enter inside the brake drum.
(6) If the wheel bolts 10 have been removed,
10 Fill grease
reassemble with new bolts and nuts. Tighten each
nut to the standard torque and then stake it at
209113
equally spaced four points.
3. Installation of wheel hub and drum sub-assembly
Align the center of the axle shaft with the center of the
hub and drum sub-assembly. While keeping the sub-
assembly horizontal, slide it onto the axle shaft.
4. Pack the bearing cone 11 with Shell Alvania R3 or
equivalent grease; force grease inside the bearing cage
using your palm. Force the bearing cone 11 onto the
axle shaft.

6-5
FRONT AXLE

5. Preload adjustment and lock nut tightening

4 9 11 12
Proceed as follows:
(1) Tighten the inner nut 12 until the hub 4 can no
longer be turned by hand. Then loosen it by 60 to 14
80°.
(2) Rotate the hub several times to settle the bearing.
(3) Tighten the inner nut securely, and measure the 15
torque required to start the rotation of the hub. If
the measured value is not within the specified 13
limit, perform the preload adjustment again.
To measure preload, attach a spring scale to a
wheel bolt, then read the tangential force Wheel bolt
17 209114
generated when the hub starts rotating.
(4) After adjusting the preload, tighten a new lock
washer and an outer nut 14 to the specified torque.
290 to 490 N·cm
(5) Bend the lock washer 13 to both sides (inward and Preload of hub bearing
(30 to 50 kgf·cm)
outward).
Tangential force on 40 to 68 N
6. Fill the cap 15 with grease, and install the cap.
hub bolt (4.1 to 7.0 kgf)
7. Install the solid tire assembly 16. Tighten the wheel
nuts 17 to the following torque. Outer nut tightening 157 N·m
torque (16 kgf·m)
157 N·m
Wheel nut tightening torque
(16 kgf·m)

205436

6-6
 REAR AXLE

Structure and Function ......................................................................... 7 – 1

General ..................................................................................................... 7 – 2
Simple Service and Maintenance ...................................................... 7 – 3
1. Removal and Installation of Drive Wheels ............................................ 7 – 3
2. Removal and Installation of Steering Chain ......................................... 7 – 3
3. Rear Axle Oil Change .......................................................................... 7 – 5
4. Lubrication of Pivot Bearing ................................................................. 7 – 6
Removal and Installation ....................................................................... 7 – 7
Disassembly and Reassembly ............................................................. 7 – 8
General Data ............................................................................................ 7 – 9
Disassembly ............................................................................................. 7 – 18
Reassembly .............................................................................................. 7 – 26
Post-Reassembly Tests ............................................................................ 7 – 42 7
Troubleshooting ...................................................................................... 7 – 44
Service Data ............................................................................................. 7 – 44
 REAR AXLE

Structure and Function

2
4 5 9
10
7 Counterweight
Motor flange
8
15 13

12

11

14 Lubricated with grease

Chain tensioner

16

17

Lubricated with oil

18
Lubricated with grease 209199

Main component
1 Drive motor The parts 7 to 18 are components 12 Sprocket
2 Hydraulic motor of the rear axle assembly. 13 Breather valve
3 Solid tire assembly 7 Centering ring 14 Input pinion
4 Rear axle mounting bolts 8 Housing top section 15 Helical gear
5 Drive motor mounting bolts (pivot bearing) 16 Bevel gear set
6 Rear axle assembly 9 Lock plate 17 Wheel shaft
10 Final stop 18 Drain plug
11 Chain

7-1
REAR AXLE

General 3 Lubrication
Rear axle assembly components are lubricated as
1. Configuration follows:
(1) The centering ring 7 is fitted in a bore formed in (1) Pivot bearing
the bottom of the counterweight which is located at
Lubricated with grease (through two grease
the rear of the truck. The centering ring keeps the
fittings)
drive motor 1 and rear axle assembly 6 centered on
each other. (2) Gear box
(2) The rear axle assembly is suspended from the Lubricated with gear oil (filler and drain plugs are
counterweight using the six socket head bolts 4 provided)
which secures the assembly to the bottom surface (3) Wheel shaft bearing
of the counterweight with the centering ring 7 in
Lubricated with grease (service-free type)
between.
Final stop
(3) The drive motor 1 seats itself on the centering ring Lock plate
7 by way of the frame flange which is secured to
the centering ring using the six socket head bolts 5. 90°
Hydraulic
The output shaft of the drive motor is splined to the motor
input pinion 14.

2. Flow of Drive Motor Torque and Steering

Operation
(1) Drive motor torque flow
The output of the drive motor is transmitted to the
solid tire assembly (wheel) 3 through the following
path: input pinion 14 ➝ helical gear 15 ➝ bevel
gear set 16. As the power is transmitted from a
component to the next, the speed is reduced step by 90°
step while the torque being increased conversely
before the power reaches the tires and generates Final stop
traction forces. Front of truck 209200
(2) Steering operation
The sprocket 12 of the steering hydraulic motor 2
is linked with the pivot bearing 8 via the chain 11. Filler plug
When the hydraulic motor 2 turns, the rotating (gear oil)
force is transmitted through the chain 11 to the
element that plays the role of an inner race in the
pivot bearing 8. Because this element forms an
integral part of the rear axle housing, the tire
assembly 3 turns when the element is forced to
turn. This creates a steering action. Drain plug

The turning angle of the housing in each direction

is prevented from exceeding 90° by means of the Grease fitting
final stop 10 on the housing and the lock plate 9 on 209201
the centering ring (stationary component), which
come in contact with each other when the
maximum turning angle is reached.

7-2
 REAR AXLE

Simple Service and Maintenance

1. Removal and Installation of Drive Wheels

Use only genuine solid tire assemblies as drive wheels.

Removal
(1) Turn the rear axle to a position in which drive wheel
removal and installation operations can be carried out
most easily. Block the front wheels.
(2) Loosen the five wheel nuts.
(3) Lift up the truck slightly with a hoist, block up the
truck, then remove the wheel nuts and wheel (solid tire
assembly).

Installation
(1) Visually inspect the mating surfaces of the wheel shaft
and rim to make sure they are clean and free from 209202
damage.
(2) Fit the drive wheel on the wheel shaft. Install the five
wheel nuts and tighten them evenly to the final torque
indicated below. Wheel nut 157 N·m
5
tightening torque (16.0 kgf·m)

3 2

1 4

NOTE
Retighten the wheel nuts at first 25 service hours after
change of the drive wheel.

2. Removal and Installation of Steering Chain

Start by:
(a) Turn the rear axle to a position in which the steering
chain can be removed and installed most easily.
(b) Disconnect the cable connector, then remove the
battery box.
(c) Remove the battery bulkhead.
(d) If the rear axle is to be removed, remove the drive 103395A

motor according to the relevant instructions in the

“Group 5 Motors”.

NOTE
The rear axle can be moved even after the battery has
been removed if the hydraulic hose is disconnected
from the hydraulic motor.

7-3
REAR AXLE

Removal of Chain
(1) Loosen the lock nut 3, then loosen the chain tension
bolt 2 to slightly slacken the chain. Joint link B
(2) Remove the lock plates (a) and (b) from the joint links Link (d) Joint link A
A and B at both ends of the chain.
Link (c)
(3) Pull the links (c) and (d) of the joint links A and B.
Now the chain is ready for removal.
The parts removed from the joint links A and B are
small in size, be careful not to lose them.
Lock plate (a)
Installation
(1) Follow the removal sequence in reverse while Lock plate (b)
connecting both ends of the chain via the tensioner 1
using the joint links A and B. Chain
DIN 8187-10B-1
(2) Apply grease to the chain and hydraulic motor Pitch: 15.88 mm
sprocket. Chain link: 67 units

(3) Adjust the tension of the chain using the procedure

described below.
Joint link A
(4) Reinstall all the components removed during the “Start Pitch: 15.88 mm × 2
by” procedure to restore their original conditions. Spring pin
Chain Tension Adjustment 2
Bolts
(1) Loosen the lock nut 3. 1
(2) Turn in or out the tension bolt 2 as necessary to adjust
Dowel pin
the tension of the chain properly. 3
(3) The tension of the chain is correct if the tightening
torque of the tension bolt 2 conforms to the torque 4
shown below.
Joint link B
Pitch: 15.88 mm
Tension bolt 6 N·m
tightening torque (8 kgf·m)

209203
(4) Turn the rear axle several times and check again the
tightening torque of the tension bolt. 1 Chain tensioner
2 Tension bolt
After the correct torque is confirmed, tighten the lock
3 Lock nut
nut 3 to complete the adjustment.
4 Adjusting element

7-4
 REAR AXLE

3. Rear Axle Oil Change

Rear Axle Oil Specifications and Service
(1) Park the truck on a level surface. Intervals
(2) Clean the area around the oil filler plug 1 and drain (1) Specifications
plug 3. API specifications: GL4 or GL5
(3) Place an oil catch container with a capacity of at least 5 Viscosity class: SAE 80W to 90
liters below the rear axle. (2) Required oil quantity: Approx. 4.2 liters
(3) Oil level check and oil change intervals
NOTE
Oil level check: Every 1200 service hours or
Never drain oil into the soil or the sewerage system. once a year, whichever
Pay attention to kind and quality of the debris. comes first
Oil change: Perform twice at the
following timing; no further
(4) Remove the filler plug 1 and seal ring 2.
change is required.
CAUTION First change; 150 hours after start of
operation of new or
After long time operation the rear axle will be changed gear
hot. Use heat resistant gloves. Second change; 500 hours after start of
operation of new or
(5) Remove the drain plug (magnet plug) 3 and seal ring 4 changed gear
to allow oil to be drained completely into the container Use an oil of the same brand as far as
(this takes about five minutes). possible.

(6) Clean the magnet of the drain plug 3. Fit a new seal
ring 4 on the drain plug 3 and install the plug by
tightening it to the following torque.

Tightening torque of 22 N·m

filler and drain plugs (2.2 kgf·m)

(7) Fill the rear axle with a gear oil (that satisfies the
requirements shown at the upper right of this page) by
pouring the oil through the hole of the filler plug 1.
The oil level should be at the bottom of the filler plug
hole.
(8) Fit a new seal ring 2 on the filler plug 1 and install the 209204
plug by tightening it to the torque shown above.

NOTE
Remove any spilled oil residue with a suitable oil-
cleaning agent.

(9) Re-examine oil level after several hours of operation,

top up if necessary.

209205

7-5
REAR AXLE

4. Lubrication of Pivot Bearing

Lubricant Specifications and Service
(1) The pivot bearing has two grease nipples 1. Intervals
(2) Wipe clean the nipples and use a grease gun to fill the (1) Specifications
bearing with grease through the two nipples.
Shell Alvania R3 or equivalent
(3) Rotate the rear axle several times in the direction of the
(2) Greasing intervals
allow to distribute the grease throughout the bearing,
then supply grease again. Repeat this cycle several Operation under normal conditions:
times. Every 1200 service hours or once a year,
whichever comes first
(4) Wipe grease off the nipples and other areas.
Operation under extremely dusty or damp
(e.g. cold rooms) conditions: Twice a month
NOTE
(3) Quantity of grease required to fill a dry
Do not over fill with grease. This will be collected on bearing: 55 grams
top of the steer/rear axle, when becoming hot, the
grease will start to leak onto the tire and floor.

209206

7-6
 REAR AXLE

Removal and Installation

Removal – Rear Axle Assembly

NOTE
Put mating marks as necessary before disassembling to
facilitate reassembly. Use holes in top section
to attach ropes.

(1) Park the truck over a pit in a service area.

Lift the truck with jacks or a hoist so that the rear
wheel is off the ground. As a safety measure, place
wood blocks under the right and left rear parts of the
frame, then lower the truck.
(2) Remove the battery box.
(3) Remove the drive motor. (Refer to the “Group 5
Weight: about 54 kg
Motors”.) (when dry)
(4) Disconnect the steering motor end of the hydraulic
hose.
(5) Remove the chain. (Refer to page 7-4.)
(6) Remove the drive wheel. (Refer to page 7-3.) 209207

(7) Drain oil out of the rear axle.

(8) Support the weight of the rear axle assembly using a
hand chain hoist and wire ropes attached to the top
section of the assembly as shown.
(9) Remove the six socket head bolts.
Counterweight
(10) While supporting the rear axle assembly by hand at
the bottom, lower the assembly very carefully. The Mounting bolts × 6
assembly weighs about 54 kg. Centering ring

Installation – Rear Axle Assembly

Follow the removal sequence in reverse while taking care
of the following:
(1) Be careful with the direction in which each part of the
rear axle assembly should face. See the drawing on
Rear axle
page 7-2.
assembly
(2) Lift up the rear axle assembly in a manner appropriate
for fitting the centering ring into the bore in the
counterweight without any undue force.
(3) Apply Loctite No. 271 to the threads of the mounting
bolts.
209199A

7-7
REAR AXLE

Disassembly and Reassembly of Rear Axle Assembly

(Model: ZF-Lift Truck Transmission GK25LD)

209223

7-8
 REAR AXLE

General Data

(1) Tightening torques

This tightening torque table is applicable only to the bolts used with a rear axle produced by ZF. For the standard
tightening torques of the fasteners used with the components other than the rear axle, refer to “Group 12 Service
Data”.

Tightening torques for screws in N·m according to ZF-Standard 148

If not especially indicated, tightening torques can be taken from the following chart:

Metric ISO standard thread DIN 13, Metric ISO-fine thread DIN 13,
sheet 13 sheet 13
Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M8 × 1 24 36 43
M5 5.5 8.1 9.5 M9 × 1 36 53 62
M6 9.5 14 16.5 M10 × 1 52 76 89
M7 15 23 28 M10 × 1.25 49 72 84
M8 23 34 40 M12 × 1.25 87 125 150
M10 46 68 79 M12 × 1.5 83 120 145
M12 79 115 135 M14 × 1.5 135 200 235
M14 125 185 215 M16 × 1.5 205 300 360
M16 195 280 330 M18 × 1.5 310 440 520
M18 280 390 460 M18 × 2 290 420 490
M20 390 560 650 M20 × 1.5 430 620 720
M22 530 750 880 M22 × 1.5 580 820 960
M24 670 960 1100 M24 × 1.5 760 1100 1250
M27 1000 1400 1650 M24 × 2 730 1050 1200
M30 1350 1900 2250 M27 × 1.5 1100 1600 1850
M33 1850 2600 3000 M27 × 2 1050 1500 1800
M36 2350 3300 3900 M30 × 1.5 1550 2200 2550
M39 3000 4300 5100 M30 × 2 1500 2100 2500
M33 × 1.5 2050 2900 3400
M33 × 2 2000 2800 3300
M36 × 1.5 2700 3800 4450
M36 × 3 2500 3500 4100
M39 × 1.5 3450 4900 5700
M39 × 3 3200 4600 5300

Friction coefficient: µ total 0.12 for screws and nuts without aftertreatment as well as for
phosphatized nuts.
Tighten by hand!

7-9
REAR AXLE

(2) Rear axle assembly schematic

1 Rear axle housing

2 Wheel shaft
not illustrated gear set, consisting of input pinion, helical gear, bevel pinion shaft and crown gear
3 Housing top section (with integrated input pinion)
4 Housing cover
5 Centering ring
6 Lock plate
7 Final stop (2x)
8 Oil filler-and oil inspection plug
9 Oil drain plug

3 5
7

6
7 6

1 4

9
209224

7-10
 REAR AXLE

(3) Consumables

For cleaning
Appropriate cold or quick cleaning agent as for instance LOCTITE

CAUTION
Keep away cleaning agent from your skin, do not drink it or inhale its vapours!
Wear safety gloves and goggles! In case of skin contact rinse immediately with a lot of water!
If by mistake the cleaning agent was swallowed, call medical aid immediately!
Observe regulations for prevention of accidents!

For reassembly

LOCTITE No. 243 Bolt fastening up to and exceeding size M10

LOCTITE No. 270 Shaft- and hub connection
LOCTITE No. 574 Sealing compound for housing top section with housing
Sealing compound for housing top section with housing to glue the shaft seal
into the housing

Grease “Shell Alvania R3” for lubrication of the pivoting bearing

Marking ink: for contact pattern check
Rear axle oil: acc. to API GL-4 or GL-5

NOTE
Use the same oil quality for refilling or oil change as for the first filling.

7-11
REAR AXLE

(4) Standard tools

Open jaw spanner 10 mm

13 mm
30 mm

Allen wrench 6 mm
10 mm

Torque spanner
adjustable from 9.5 to 300 N·m

Hexagonal socket spanner 10 mm 6 mm

13 mm 10 mm
24 mm
30 mm

Plastic hammer 1000 g

Steel hammer 250 g
stable screwdrivers or levers

Two-armed or three-armed puller

Grease gun
with adapter for hydraulic-type lubricating
nipple acc. to DIN 71412-M8x1

209225
7-12
 REAR AXLE

(5) Measuring tools

Dial gauge with magnetic stand

Micrometer depth gauge

measuring depth up to 70 mm

Micrometer
Measuring range up to 25 mm

Measuring device
For determination of installation dimension for bevel
pinion shaft

209226

7-13
REAR AXLE

(6) Special tools

Illustrations are not binding for the design!

“A” Assembly plate Ident No. 618709

Part No. 97M68-00100

If no assembly fixture is available.

“B” Bush Ident No. 618712

To press off bearing inner ring from Part No. 97M68-00200
bevel pinion shaft

“C” Bush Ident No. 618715

To press bearing inner ring onto bevel Part No. 97M68-00300
pinion shaft

“D” Measuring bush Ident No.618718

For determination of installation Part No. 97M68-00400
dimension for bevel pinion shaft

“F” Clamping fixture Ident No. 618727

To clamp bevel pinion shaft into the Part No. 97M68-00500
housing

209227

7-14
 REAR AXLE

Illustrations are not binding for the design!

“G” Bush
To press bearing inner ring onto bevel Ident No. 618842
pinion shaft Part No. 97M68-00600

“H” Sleeve
To press bearing inner ring Ident No. 618845
onto wheel shaft and onto crown gear Part No. 97M68-00700

“M” Puller
To pull off bearing inner rings from the Ident No. Basic tool 454421
wheel shaft and the crown gear Part No. 97M68-00800

Clamping pliers Ident No. 487665 Bearing 32011

Part No. 97M68-00900

“N” Pressure piece

To pull off bearing inner ring from the Ident No. 487744
crown gear Part No. 97M68-01100

209228

7-15
REAR AXLE

Illustrations are not binding for the design!

“S” Assembly drift

Install protective shield Ident No. 651057
Part No. 97M68-01200

“T” Assembly drift

Install radial shaft seal Ident No. 651059
Part No. 97M68-01300

“U” Assembly drift

To install breather filter Ident No. 489564
Part No. 97M68-01400

“V” Assembly drift

To install grooved ball bearings into Ident No. 215835.0
the housing seat Part No. 97M68-01500

209229

7-16
 REAR AXLE

(7) General instructions for the correct disassembly and reassembly

Cleanliness is essential for a correct work.
Rear axle assembly removed from the truck have to be cleaned prior to opening.
Special care and cleanliness are essential for a correct disassembly and reassembly of the unit as well as for the
installation of each spare part. A fault during installation can result in an early wear and chips as well as foreign
particles in the unit could cause fatal damage in the axle. It is essential to replace all parts which were damaged or
became unusable during disassembly of the axle, such as shaft seals, Viton-rings, rectangular rings, copper rings and
O-rings, ball bearings, roller bearings and barrel-shaped bearings, cotter pins, lock plates, worn seal rings.
Burrs and other damages caused during removal on machined surfaces have to be eliminated.
The cavities of the rear axle, especially edges and corners, must be carefully rinsed with flushing oil, if required, with
an appropriate cold cleaning agent.
Prior to reassembly all parts must be cleaned and inspected for wear and other defects.
It would be a false economy to reinstall parts which are not in a perfect condition.
Apply a sealing compound onto housing- and cover faces, which must be tight towards the outside (see 1-(3), page 7-
11).

For heating of bearings etc. use heating plates, heating elements or heating furnaces.
Never heat directly with an opem flame!
If there is no other possibility you may also heat an oil-filled container with the open flame and place the bearing into
it, thus avoiding damage to the bearings.

If not otherwise indicated heat ball bearings, gears, flanges etc. to approx. 90-100°C.

Parts which have been installed in a warm condition must be subsequently driven in after cooling down to ensure a
perfect contact.
Lubricate both parts before shafts, bearings etc. are pressed into position.

For reassembly all of the indicated setting values, test data and tightening torques must be observed.
Rear axle units will be filled with oil after repair work.
Procedure and admissible oil qualities are indicated in the “Rear Axle Oil Change” section on page 7-5.

If the rear axle assembly is found to be significantly different from the description in this manual during disassembly
or reassembly, the model to which the assembly belongs may have undergone later modifications.
If this is the case, please contact our Service Engineering Department for the disassembly, reassembly and adjustment
instructions appropriate for the particular assembly.

7-17
REAR AXLE

Disassembly
Introduction
Prior to disassemlby clean transmission carefully.
A great help is a bright, spacious working place, free of dirt and chips.
The necessary working steps are described ane illustrated in the correct sequence.
Parts only available as assembly groups will not be stripped any further.
For dis- and reassembly we recommend to use a fixture as shown in below figure.

209230

Disassembly Procedure

1. Drain off rear axle oil

Place a suitable oil catch container under the oil drain plug
1 and unscrew it with a 6 mm Allen wrench.
Drain rear axle oil completely into the oil catch container.

NOTE
Do not drain rear axle oil into the sewage system or
into the soil!
Observe oil drain time!
Container should be suitable for 5 liters!

209231

7-18
 REAR AXLE

2. Remove housing top section

Loosen and remove the socket head bolts 1 on the bottom
side of the rear axle housing as well as inside the housing
top section.

5xM8x35
2xM8x50
8xM10x45

209232

This rear axle version has the housing top

section additionally fastened to the axle
housing by means of two socket head bolts 2,
hexagon nuts 3 and washers 4.

209233

For motor fixing the centering ring 2 is bolted onto the

2
pivoting bearing 1.
Two final stops 3 on the chain tread and the lock plate 4
connected with the centering ring are required for the
steering lock.

3
NOTE
Only in case of damage the lock plate and the two
final stops have to be removed and replaced. 1 4

209234

7-19
REAR AXLE

Tap with a plastic hammer or a copper mandrel from the

bottom against the top secton 1, so that it loosens from the
axle housing.
Cautiously lift off and remove the housing top section.
1
NOTE
Housing top section can only be replaced completely.
Centering ring can be reused.

NOTE
209235
Remove cylinder pins, breather valve and grease
nipples only in case of damage. Check housing top
section according to chapter “Reassembly”, step 15.1
and keep it properly.

2.1 Remove input from the housing top section and 2

disassemble it
With two assembly levers press cover assembly 2
cautiously against the bearing outer ring (with radial shaft
seal, grooved ball bearing, O-ring and input pinion) out of
the bearing bore.
209236
CAUTION
Do not damage the input pinion toothing!
Damages might cause louder running noises!

Helical gear
NOTE
Prior to removing the grooved ball bearing 3 , the 3
helical gear has to be taken off first, as indicated in
page 7-31 step 7.1.

209237

Pull grooved ball bearing 3 with a bearing extractor out of

the bore hole in the housing top section and remove it.

209238
7-20
 REAR AXLE

With two assembly levers press input pinion 4 cautiously

out of the cover and remove it.

CAUTION
Do not damage the input pinion toothing!
Damages might cause louder running noises! 4

209239

Remove radial shaft seal 5 from the cover, only when it is

absolutely necessary.
➯ radial shaft seal will be destroyed at removal!
➯ use new radial shaft seal for reassembly!

With bush press radial shaft seal and grooved ball bearing 6
out of the cover 7 and remove them. Remove O-ring 8
from the slot in the cover. 7

209240

NOTE
6
Use O-ring only once.
5
For reassembly an new O-ring is to be used!

8
209241

Unsnap and remove circlip 8 with a screw driver from the

housing top section.

209242

7-21
REAR AXLE

3. Remove housing cover

Remove hexagon bolts 1 in the housing cover.
Loosen and remove housing cover 2 from the housing by
tapping with a plastic hammer against th outer edge.

209243

4. Remove wheel shaft and crown gear

Place rear axle into the fixture and fasten it with screws.
Screw two wheel nuts onto the wheel bolts and hold the
wheel shaft with a lever.
Screw off the hexagon bolts with a hexagonal spanner
WAF=24 mm and remove it with the washer from the
wheel shaft.

209244

Drive wheel shaft 1 with a copper mandrel and a hammer

out of the housing and remove it.

CAUTION
Take care that the wheel shaft is not damaged
during removal.

NOTE
During disassembly of the wheel shaft the sealing ring
2 on the wheel shaft and the radial shaft seal in the
housing can be damaged and should always be
replaced!
209245
Then carefully remove the crown gear 3 from the housing.

7-22
 REAR AXLE

5. Remove bearing inner rings from wheel shaft and

crown gear
If the taper roller bearings are to be reused, we recommend
to use puller “M”.
5.1 Remove bearing inner ring from wheel shaft
Place clamping pliers of the puller onto the rollers of the
bearing inner ring.
By means of union nut tightly connect clamping pliers with
the rollers.
Bolt spindle to the wheel shaft face and remove the bearing
inner ring cautiously and evenly at all sides.
Take off the sealing ring 1 from the wheel shaft.

NOTE 209246
Avoid damage at the wheel bolt threads at counter-
supporting!
Protect wheel bolt theread against damage with
suitable fixtures.

5.2 Remove bearing inner ring from crown gear

Proceed as described under step 5.1 for removal of the
bearing inner ring from crown gear.
Crown gear should be clamped on the work bench and
pressure piece “N” be inserted into the crown gear bore hole
to support the spindle.
For replacement of the taper roller bearings, the following
steps are required:
• Open bearing cage 1 by cutting and remove the rollers 2
• Cautiously remove the bearing inner ring with a puller
(e.g. three-armed puller) over the bearing collar (➯).
209247
• Remove sealing ring 3 from wheel shaft.

6. Press wheel bolts out of the wheel shaft

Wheel bolts 1 can only be pressed out of removed wheel
shaft.

NOTE
Make these two steps only in case of emergency!
Do not damage wheel bolt threads at pressing-out!

• Place wheel shaft 2 into a suitable bush and press out

wheel bolts with a press.
• With a copper mandrel and a hammer drive wheel bolts
out of the wheel shaft.
Be especially careful at this step, since at replacement or
installation of the new wheel bolt with the old wheel
shaft, the position of both parts to each other must 209248
exactly be obtained again.
7-23
REAR AXLE

7. Remove bevel pinion shaft

7.1 Remove helical gear

Bevel pinion shaft can only be removed, when crown gear
was taken off before.
Unscrew hexagon nut 1.

NOTE
Use hexagon nut only once!

Pull off and remove helical gear 2 from bevel pinion shaft
3 with a puller (three-armed puller).
209249

7.2 Drive out bevel pinion shaft

Drive out bevel pinion shaft with a plastic hammer from the
bearing seat.
Take off and remove the taper roller bearing inner ring 2
from the bearing bore hole.

CAUTION
Take care that the bevel pinion shaft is not
damaged during removal!

209250

7.3 Press off taper roller bearing inner ring from the
bevel pinion shaft
With bush “B” press off the bearing inner ring 1 from the
bevel pinion shaft 2.

209251

7-24
 REAR AXLE

8. Remove taper roller bearing outer rings and radial

shaft seal
Cautiously drive the bearing outer rings1, 2, 3 and 4 for
supporting of the wheel- and bevel pinion shaft with a
copper mandrel and a hammer out of the housing.
Take care that shim rings 5, 6, 7 and 8 are not damaged
during removal of the bearing outer rings.

NOTE
Put bearing outer ring to the respective bearing inner
ring.
Do not reuse deformed or damaged shim rings!

209252
With a copper mandrel or robust screw driver and a
hammer drive out and remove radial shaft seal 9 from the
housing.

CAUTION
During disassembly of the wheel shaft the radial
shaft seal can be damaged and must always be
replaced!

9. Remove thread protective shield (Gamma ring)

Witha a robust screw driver and a plastic hammer
cautiously drive out and remove the thread protective
shield from the adhesive point on the housing neck.

NOTE
Use the thread protective shield only once.
For reassembly a new thread protective shield must be
used!

209253

7-25
REAR AXLE

Reassembly
Introduciton
Clean all parts with a suitable cleaning agent and remove residues of LOCTITE.

CAUTION
Keep away cleaning agent from your skin, do not drink it or inhale its vapours! Wear safety gloves
and goggles! In case of skin contact rinse immediately with a lot of water! If by mistake the
cleaning agent was swallowed, call medical aid immediately!
Observe regulation for prevention of accidents!

Check all parts for wear, damages and cracks, if required replace them.
In case of damaged running teeth, the gear set parts have to be replaced as a set.
Always replace damaged taper roller bearings (inner- and outer ring).
Do not reuse deformed shim rings and worn thrust washers.
Touch up seal faces or smoothen them with a fine file.

For reassembly the following new parts should be used:

• Hexagon nut for bevel pinion shaft and helical gear fastening
• Hexagon bolt and washer for crown gear fastening
• Radial shaft seal on the wheel shaft
• Spring washers and lock washers
• Deformed or damaged shim rings
• Sealing rings on oil drain- and oil filler plug

7-26
 REAR AXLE

1. Determination of instllation dimension for bevel pinion shaft

The bevel gear set, consisting of bevel gear shaft and bevel gear, is provided with certain installation dimensions.
The installation dimension of the bevel pinon shaft is 100.00 mm.
The correct adjustment of the bevel pinion shaft is required for an exact setting of the contact pattern and the
torsional backlash of the gearing.
Shim ring thickness and the correct adjsutment of the bevel pinion shaft respectively can be determined according to
the following method:
• Place measuring bush “D” into the housing- bearing bore and measure dimension F.
• Determine housing dimension E by the following equation.
E = L - F + d/2
which means:
L = Length of the measuring bush “D” (dimension marked on it 77.50 mm)
F = Difference dimension from bearing seat diameter to front face measuring bush “D”
d/2 = Measure housing borehole
By means of the equation:
X=E-B-T
it is possible to calculate the thickness of the shim rings 1.
which means:
B = Installation dimension of bevel pinion shaft is 100.00 mm
(Factory setting of the installation dimension with a tolerance of ± 0 is marked on the bevel pinion
shaft!)
T = Bearing width of the bearing 2

209254

7-27
REAR AXLE

2. Preassemble housing

2.1 Bearing for bevel pinion shaft

Shim ring thickness determined in step 1. has to be
obtained by combining shim rings of variable thicknesses.
Place shim rings 1 into the bearing seat.
Install bearing outer ring 2 into bearing seat in the housing.

NOTE
A tolerance of ± 0.05 from the determined dimension
is permissible.

209255

2.2 Bearing for wheel shaft

Place shim ring pack (1 and 3, removed at disassembly) for
presetting into both bearing seats.
With a copper mandrel and a hammer install the bearing
outer rings 2 and 4 of the wheel shaft bearings into the
bearing bores until contact on both side of the housing.

NOTE
Do not reuse distorted shim rings.

CAUTION
209256
Radial shaft seal between taper roller bearings
and the thread protective shield are only
allowed to be pressed in when the bearing is
adjusted.

7-28
 REAR AXLE

3. Preassemble wheel shaft

3.1 Press in wheel bolts

Wheel bolts 1 can only be pressed in when the wheel shaft
is removed.

NOTE
Make these steps only in case of emergency! For
pressing-in take care that the flattened side on the bolt
collar shows to the center of the wheel shaft.

• Place wheel shaft 2 into a suitable bush and press in

wheel bolts with a press.
Be especially careful at this step, since at pressing in of 209257
the new wheel bolt with the old wheel shaft, the position
of both parts to each other must exactly be obtained
again.

3.2 Install sealing ring and bearing inner ring onto the
wheel shaft
Push sealing ring 1 on the wheel shaft 2.
With sleeve “H” press bearing inner ring 3 onto the wheel
shft until contact.

NOTE
Only when the bearing is adjusted, the sealing and the
taper roller bearing can be filled with grease SHELL
Alvania R3.

209258

4. Press bearing inner ring onto the crown gear

With sleeve “H” press bearing inner ring 1 onto the crown
gear 2 until contact.

209259
7-29
REAR AXLE

5. Preassemble bevel pinion shaft

With bush “C” cautiously install bearing inner ring 1 until
contact.
If no press is available, the bearing can be installed in
accordance with the follwoing NOTE.

NOTE
Heat bearing inner ring up to max. 90°C and install it
until contact.
Install subsequently until contact after cooling down!

206260

6. Install bevel pinion shaft into the housing

Wet cage space between rollers of the bearing inner ring
with gear oil.
Insert preassembled bevel pinion shaft from the bottom into
the housing and with clamping fixture “F” apply a slight
preload to the bearing outer ring in the housing.

209261

7-30
 REAR AXLE

7. Measure bearing play of bevel pinion shaft and

adjust bearing preload

7.1 Measure bearing play

With the following method the thickness of the shim ring(s)
1 to be added is determined.
Dim. C = Distance from collar of bevel pinion shaft to
contact bearing outer ring.
Dim. S = Distance from plane face of bearing outer ring to
plane face of bearing inner ring.

209264

Calculate shim ring thickness 1 by means of equation

Z=C+S
209262
Add shim ring corresponding with thickness Z.
Example: C = 0.7 measured on housing and shaft
S = 0.08 measured on bearing
Z = 0.7 + 0.08 = 0.78 mm
As per experience +0.02 mm will be added to dimension Z,
so that a bearing preload from 0.02 to 0.07 mm is set.
Z = 0.78 + 0.02 = 0.8 mm

NOTE
A bearing preload of 0.07 mm shall be achieved!

Shim ring thickness (thickness Z) determined in step 7. has

to be obtained by combining shim rings of variable
thicknesses.
Place shim ring(s) 1 into the bearing seat.
Install bearing outer ring 2 by means of a copper mandrel
and a hammer into bearing seat of the housing until contact
with the shim ring.
Then install with bush “G” the bearing inner ring 3 for the
bevel pinion shaft onto the bevel pinion shaft until contact.

209263

7-31
REAR AXLE

NOTE
Prior to helical gear installation, the grooved ball
bearing must be installed into the housing seat first.

Drive grooved ball bearing 1 with assembly drift “V” into

the bearing bore of the housing until contact.
1

209265

Carefully push the helical gear 1 onto the spline profile of

the bevel pinion shaft and mount it until contact.
Hold helical gear with a suitable strap wrench, unscrew and
tighten the hexagon nut.
Do not damage helical gearing at counter-supporting.
Tightening torque of the hexagon nut: 150 N·m
(15.3 kgf·m)

NOTE
Use a new hexagon nut.
Stake hexagon nut after contact pattern check!

209266

Press bevel pinion shaft down by hand and rotate it several

times, so that the taper rollers in the bearing rings are
aligned.
Position dial gauge as shown and put the dial gauge
indicator to “Zero”.
Mark position of the dial gauge on the helical gear with a
colour pencil.
With both hands press bevel pinion shaft upwards and read
the bearing play on the dial gauge.
(as shown in drawing)
For checking no bearing play is allowed to be
measurable!
209267

NOTE
This step has to be made with utmost caution and several times, in order to check the adjusted bearing preload.
A direct checking of the now adjsuted bearing preload is not possible.
However, the bevel pinion shaft must be rotatable by hand.

7-32
 REAR AXLE

7.2 Adjust bearing preload

Beairng preload: 0.02 to 0.07 mm
Remove helical gear and bevel pinion shaft.
Add necessary shim rings to obtain the required bearing
preload and install the bevel pinion shaft as indicated in
step 7.1.
Apply a thin layer of LOCTITE NO. 270 onto inner
toothing of the helical gear (hub spline).
Install helical gear as in step 7.1.

NOTE
Remove excess LOCTITE with a cloth.

209268
8. Mount wheel shaft and crown gear into the
housing

NOTE
Radial shaft seal between the taper roller bearings has
to been installed into the housing, only when bearing
preload of the wheel shaft was determined.

Insert crown gear 1 into the housing. Cautiously install the

wheel shaft 2 into the crown gear toothing. Bolt together
the crown gear and the wheel shaft with hexagon bolt 3 and
washer 4.
Tightening torque of hexagon bolt: 245 N·m
(25.0 kgf·m)
NOTE 209269
Use hexagon bolt and washer only once!

9. Measure and adjust torsional backlash on the

crown gear
For measurement of the torsional backlash on the crown
gear, the bevel pinion shaft has to be blocked against
torsion, e.g. with a wooden wedge.
Position dial gauge with magnetic stand right-angled to a
tooth flank and measure the torsional backlash rotating the
wheel shaft.
Torsional backlash: 0.03 - 0.11 mm

NOTE
A mean value is to be achieved.

Torsional backlash is corrected by adding or removing of

209270
the shim ring(s).
7-33
REAR AXLE

Apply marking ink onto 3-4 tooth flanks of the crown gear
and have it to get in mesh with the bevel pinion shaft Marking ink
several times. Contact pattern
Check contact pattern as described under step 10.

209271

10. Contact pattern check

For a contact pattern check it is necessary to apply marking ink onto 3-4 tooth flanks of the crown gear.
Have the ink-marked tooth flanks get into mesh with bevel pinion several times. A better recognition of the contact
pattern is possible, when the bevel pinion is braked slightly.
The contact patterns obtained have to be compared with the specified contact pattern as regards size and position.
The specified contact patterns are indicated in below diagram.
Insignificant deviations of the ideal shape are possible and permissible. These deviations are firstly due to the
varying contact pressures during contact pattern checking.
If there are considerable deviations it has to be checked if the installation dimensions were correctly kept.
As a rule wrong installation dimensions are the cause for wrong contact patterns.
Only when at a repeated checking of the installation dimensions no correct contact patterns are obtainable, the
position of the contact pattern should be corrected according to the diagram as shown below.
Installation specifications

Correct contact pattern

Correct contact pattern adjustment by changing of

Tooth contact on crown gear false contact patterns
the installation dimension in direction of the arrow
Contact on tip

Contact on root

Setting specifications:
On principle all gear sets have to be mounted in accordance with the installation dimension (A).
Only in case of incorrect contact patterns the instllation dimension (A) has to be changed.
The extent of a change depends on the position of the contact patterns.
7-34
 REAR AXLE

11. Measure bearing play on wheel shaft and adjust

bearing preload
Press wheel shaft down by hand and rotate it several times,
so that the taper rollers in the bearing rings are aligned.
Position dial gauge as shown in the right and put the dial
gauge indicator to “Zero”.
Mark position of the dial gauge on the wheel shaft with a
colour pencil.
With two levers (robust assembly levers) press wheel shaft
upwards and read the bearing play on th dial gauge.

209273
NOTE
By using shim rings a minimum bearing play of
approx. 0.02 mm shall be achieved. Only then the
final preload is to be adjusted.

Remove wheel shaft, with a copper mandrel and a hammer

drive taper bearing outer ring out of the housing. (also see 1 2
step 8 in the “Disassembly” section.)
Determine shim ring thickness 1 and install with shim
ring into bearing seat of housing until contact.
Required bearing preload: 0.05 to 0.10 mm

NOTE
It is not possible to check the bearing preload adjusted
now. At a check no bearing play is allowed to be
measurable. However the wheel shaft must be
rotatable by hand.

209274

NOTE
After setting of the bearing preload check the torsional backlash once more.
If the bearing friction torque (see step 13.1) or the torsional backlash are beyond the requested values a new adjustment
is required. The final value has to be obtained by adding or removing of shim rings (see the drawing above).

CAUTION

If for correction of the torsional backlash shim rings 2 are removed or added at bearing point “2”,
those have to be added or removed from the shim ring pack 1 at bearing point “1”.

After correct adjustment of the bearing preload and the torsional backlash the wheel shaft has to be removed once
again in order to install the thread protective shield and the radial shaft seal.
Please observe steps 12 and 13.
7-35
REAR AXLE

12. Install thread protective shield (Gamma ring)

Spray seat for thread protective shield with LOCTITE Fast
Cleaner. Have fast cleaner work and thoroughly remove
the dissolved dirt with a clean cloth.
Spray surface again and have it dried.

CAUTION
Hazardous when breathed or swallowed!
Avoid contact with eyes or skin! Do not spray
near open flame and glowing parts!

Apply LOCTITE No. 270 onto seat for the thread

protective shield on the housing and press on the thread
protective shield 1 by means of assemlby drift “S” until 209275
contact.

13. Install radial shaft seal into the housing

Remove wheel shaft and crown gear (also see step 4 in the
“Disassembly” section.). Drive out taper roller bearing
outer ring from the housing.
Provide outer diameter of radial shaft seal 1 with a thin
layer of LOCTITE No. 574 and install by means of
assembly drift “T” into the housing.
Observe installation dimension A: GK25LD 3.0 +0.5 mm

Apply a thin layer of LOCTITE No. 270 onto surface of

inner toothing (hub spline) of the crown gear 1.

NOTE
Apply LOCTITE only to the inner toothing of the 209276

crown gear.

Fill sealing ring and taper roller bearings on the wheel shaft
2 with SHELL Alvania R3 grease. Cautiously install wheel
shaft 2 into the crown gear toothing.

NOTE
Remove excess LOCTITE with a clean cloth.

Bolt together the crown gear and the wheel shaft with
hexagon bolt 3 and washer 4.
Bolt two wheel nuts onto the wheel bolts and lock wheel
shaft with a lever.
209277
Tightening torque: 245 N·m (25.0 kgf·m)
7-36
 REAR AXLE

13.1 Check bearing friction torque

1
Rotate wheel shaft several times in order to have aligned
the taper rollers in the bearing rings.
No bearing play must be measurable during the check!
However, the wheel shaft must be rotatable by hand.
The bearing preload described in step 11 is correctly
adjusted when a bearing friction torque of 9 to 12 N·m
(0.91 to 1.22 kgf·m) is reached.
Use an electronic torque spanner 1 to check the bearing
friction torque.
209278
NOTE
If the bearing friction torque is beyond the requested
values, a new adjustment is required.

14. Install housing cover

Apply a thin layer of LOCTITE sealing compound No. 574
onto plane face of the housing.
Apply one drop each of LOCTITE 243 onto threads of the
hexagon bolts 2.
CAUTION
If tapped holes are drilled through the housing,
the hexagon bolts must be sealed completely
with LOCTITE.

Fasten housing cover 1 with hexagon bolts 2 onto the

housing.
Tighten torque: 9.5 N·m (0.96 kgf·m)
209279

15. Check pivoting bearing (housing top section)

The housing top section has to be replaced, if;
• the staked cover disc on the pivoting bearing has
loosened
• the pivoting bearing is difficult to rotate or sticking
• the cage segments or balls are damaged
• the maximum bearing play is exceeded.

NOTE
The housing top section can only replaced completely!

Checking of housing top section:

Clamp the housing top section onto the assemlby table.
Screw three eye bolts into the outer ring of the pivoting 209280
bearing. Have the pivoting bearing rotated several times.

7-37
REAR AXLE

Position three dial gauges onto the pivoting bearing and put the dial gauge indiccator to “Zero”.
Mark position of the dial gauge on the pivoting bearing with a colour pencil.
Pull with approx. 50 kg at the pivoting bearing with a medium pillar swivel crane and a spring scale.
Have the pivoting bearing rotated several times and put it back to the marking. See the figure at the bottom of the
preceding page.
Max. bearing play of pivoting bearing: 0.03 mm

15.1 Install breather valve

Drive breather valve 1 with a press-in mandrel “U”
carefully into the housing top section.

NOTE
Take care for mounting that the cap of the breather
valve can still move freely.

15.2 Install hydraulic-type lubricating nipple

Screw in hydraulic-type lubricating nipple 2 with an open-
jaw spanner into the housing top section until contact.
Tightening torque: 10 N·m (1.0 kgf·m)
209281

16. Install input into the housing top section

Cautiously install the input pinion 1 through the helical
gearing.
1
NOTE
Do not damage toothing of input pinion and helical
gear! Damage might cause louder running noises!

With a copper mandrel cautiously install the input pinion 1

into the bearing bore or onto the bearing seat until contact.
209282

Install the grooved ball bearing 2 with a suitable bush onto

the bearing seat of the input pinion until contact.

Bush
2
1

209283

7-38
 REAR AXLE

Preassemble cover 3 as follows:

• Install radial shaft seal 4 with an assembly drift “V” with V
the correct side until contact.

NOTE 4
Do not damage sealing lip of the shaft seat.
Apply a thin layer of grease onto the sealing lip! 3

209284

Cautiously put cover 3 (with radial shaft seal

3
preassembled) onto the pinion shaft and install it.
With a plastic hammer mount cover until contact.

209285

Insert O-ring 5 into slot of the cover.

5
NOTE
Use new O-ring for installation!
Slightly wet O-ring with gear oil.

209286

Insert and snap in circlip 6 into bore hole of the housing

top section.

209287

7-39
REAR AXLE

16.1 Install housing top section

Provide sealing surface of the housing with a thin layer of
4
LOCTITE 574.

NOTE
Plane face of the housing and the housing top section
have to be cleaned carefully before with LOCTITE
Fast Cleaner and must be free of grease!

209288

Place housing top section onto the rear axle housing, so that
the cylindrical pins in the rear axle housing are positioned
in the fitting bores of the top section.
Screw in the socket head bolts 1 at the bottom side of the
rear axle housing as well as inside the housing top section
and tighten them uniformly.
In addition, install the two socket head bolts 2, hexagon
nuts 3 and washers 4

209232A

16.2 Check axial play of the input in housing top

section
209233A
Have wheel shaft rotated several times.
For measurement of the axial play of the input, a dial gauge
with a magnetic stand is to be positioned right-angled onto
Dial gauge
the plane face of the input pinion and the dial indicator
must be put to “Zero”.
Mark position of the dial gauge on the plane face with a
colour pencil. 4
With both hands press input pinion upwards and
downwards.
Read the axial bearing play on the dial gauge.
Axial play of grooved ball bearing: 0.1 to 0.4 mm
when checking a bearing play has to be
209289
measurable.
7-40
 REAR AXLE

Place centering ring 2 for motor fixing onto the pivoting

bearing 1 and bolt it with the pivoting bearing. 2 3

Observe min. screw-in depth of the six fixing bolts!

Steering lock is installed as follows:
• screw two final stops 4 onto the chain tread
• place lock plate 5 into the groove in the centering ring 4
and connect it with the pivoting bearing by means of
screws.
1 5
• Tightening torques of the screws according to ZF-
standard 209290

17. Relubrication of pivoting bearing

Under normal operating conditions the pivoting bearing has
to be relubricated once a year.
After cleaning with a steam jet device or similar, the
pivoting bearing has to be relubricated.
For the operation in a heavily dust-loaded or humid
environment (e.g. cold store application) the pivoting
bearing has to be relubricated twice a month at least.
We recommend a grease of the quality SHELL Alvania R3
or grease of an equal composition and an equal 209291
specification.

Procedure:
(a) The pivoting bearing has two grease nipples 1.
(b) Through the two grease nipples press in the grease with
a grease gun into the pivoting bearing.
Rear axle has to be turned slowly.

NOTE
Required grease volume for dry pivoting bearing
approx. 55 g.

(c) Rotate rear axle several times, so that the grease

distributes completely.
(d) Remove the grease pressed out of the pivoting bearing
with a cloth.

7-41
REAR AXLE

Post-Reassembly Tests
After reassembly the rear axle should be subject to a functional test. For this purpose the rear axle must be filled with
oil, an electric motor and a drive wheel have to be installed.
Start drive motor and have it run at different speeds and directions of rotation for some minutes.
The drive wheel should be slightly decelerated. A visual inspection has to be made and attention to be paid to
irregular running noises.

Fault Possible cause Remedy

1. Oil leakage on wheel shaft – Radial shaft seal wrongly – Remove wheel shaft and install a
installed or damaged new radial shaft seal

– Race on wheel shaft damaged – Remove wheel shaft. Check wheel

shaft race for reusability;
if possible, rework

2. Oil leakage on housing – Housing cover not sealed – Seal housing cover with LOCTITE
cover No. 574

– Housing cover or housing plane – Touch up plane faces with oil rubber
face uneven

– Bolts not tightened to the – Tighten bolts to the specified

specified tightening torque tightening torque

3. Oil leakage on oil filler- or – Dirt between sealing ring and – Cleaning required
oil drain plug housing

– Old sealing ring was used – Use new sealing ring

– Bolts not tightened to the – Tighten bolts to the specified

specified tightening torque tightening torque

4. Oil leakage between – Seal faces not sealed or uneven – Apply LOCTITE 574 onto seal
housing and top section faces

– Touch up seal faces with oil rubber.

– Burrs on cylinder pin – Use new cylinder pin

– Bolts not tightened to the – Tighten bolts to the specified

specified tightening torque tightening torque

5. Oil leakage on top section – Too much oil in rear axle – Check oil level
within helical gear
stage/input – O-ring on cover defective – Install new O-ring

– Breather valve defective – Replace breather valve

7-42
 REAR AXLE

Fault Possible cause Remedy

6. Beating noise at helical – Teeth on input pinion and/or – Check tooth flanks for damage and
gear stage helical gear damaged by false touch up damaged spots with oil
installation rubber

7. Ringing noise – Helical gear stage running – Check oil level. Refill oil
without oil

8. Grinding noise – Bearing preload or backlash not – Checking and new adjustment
correctly adjusted

9. Bearing damage on input – No axial play – Install new bearing and adjust axial
pinion play

10. Pivoting bearing is difficult – Cover disc loosened and dirt – Replace pivoting bearing
to rotate or backlash entered into the bearing
recognizable
– Cage segments are damaged – Replace pivoting bearing

– Plastic deformation of balls or – Replace pivoting bearing

ball race

– Bearing not relubricated – Relubricate pivoting bearing

– Grease not distributed – Rotate pivoting bearing several

times by hand

7-43
REAR AXLE

Troubleshooting

Refer to the “Post-Reassembly Tests” section (page 7-42).

Service Data

Manufacturer and model of the rear axle assembly: Model GK25LD produced by ZF GOTHA GMBH
Manufacturer and model of the hydraulic motor: Model BR130 produced by SAMHYDRAULIC
Standard of the chain: DIN 8187-10B-1
Number of chain links excluding joint links at both ends: 67

Important setting data for the rear axle assembly

Bearing preload bevel pinion shaft: 0.02 to 0.07 mm
Bearing preload wheel shaft: 0.05 to 0.10 mm
Axial play input pinion: 0.1 to 0.4 mm
Torsional backlash, bevel drive: 0.03 to 0.11 mm
Max. bearing play pivoting bearing 0.03 mm

Tightening torques of the rear axle assembly

Hexagon nut for helical gear fastening: 150 N·m (15.3 kgf·m) locked by peening
Hexagon bolt on wheel shaft: 245 N·m (25 kgf·m)
Oil drain- and oil filler plug: 22 N·m (2.2 kgf·m)
Wheel nuts: 157 N·m (16.0 kgf·m)

If tightening torques are not separately indicated ref. is made to ZF-standard 148.

7-44
 BRAKE SYSTEM

Structure and Functions ....................................................................... 8 – 1

General ..................................................................................................... 8 – 1
Wheel Brake Assembly ............................................................................. 8 – 2
Brake Pedal Assembly .............................................................................. 8 – 5
Brake Master Cylinder .............................................................................. 8 – 6
Reservoir Tank .......................................................................................... 8 – 7
Wheel Cylinder ......................................................................................... 8 – 7
Disassembly and Reassembly ............................................................ 8 – 8
Wheel Brake ............................................................................................. 8 – 8
Master Cylinder and Fluid Reservoir ......................................................... 8 – 14
Wheel Cylinder ......................................................................................... 8 – 16
Inspection and Adjustment ................................................................. 8 – 18
Automatic Adjustment ............................................................................... 8 – 18
Manual Adjustment ................................................................................... 8 – 18
1. Brake Pedal Adjustment ................................................................... 8 – 19 8
2. Brake Switch Installation .................................................................. 8 – 19
3. Brake Fluid Line Bleeding ................................................................ 8 – 20
4. Parking Brake Cable Adjustment ...................................................... 8 – 20
5. Parking Brake Limit Switch Adjustment ............................................ 8 – 21
Troubleshooting ...................................................................................... 8 – 22
Service Data ............................................................................................ 8 – 24
 BRAKE SYSTEM

Structure and Functions

General

ply
Ap
2 Depress to apply service brakes.

se
elea 8
R

3
11

10

5
4
6

7
7

Wheel brake assembly (L.H.)

209155

Main components
1 Wheel brake assembly 7 Brake shoe and lining assembly
2 Brake pedal 8 Parking brake lever
3 Reservoir tank 9 Parking brake cable
4 Master cylinder 10 Parking brake switch
5 Brake pipe 11 Service brake switch
6 Wheel cylinder
Service brakes are provided in the front wheel hubs, braking action, stopping the rotation of the drum and, in
one each for the right and left wheels. They are of a turn, of the wheel.
drum and internal expanding shoe type. When the operator pulls the parking brake lever 8
When the operator depresses the brake pedal 2, the backward, the parking brake cable 9 connected to the
master cylinder 4 forces brake fluid into each wheel lever pulls the parking lever inside each wheel brake
cylinder 6. The pressure developing in the wheel assembly. The lever then pushes the brake shoes 7
cylinder expands the brake shoes 7 against the inside against the drum. The same brakes serving as the
surface of the revolving drum. The friction thus service brakes now function as parking brakes.
generated between the shoes and drum produces
8-1
BRAKE SYSTEM

Wheel Brake Assembly

Main components
1 Wheel cylinder
2 Shoe and lining assembly
(primary)
3 Shoe and lining assembly
(secondary)
4 Connecting rod
5 Return spring (anchor-to-shoe)
6 Return spring (anchor-to-shoe)
7 Spring (shoe-to-shoe)
8 Parking cable assembly
9 Parking lever
10 Strut
11 Anchor pin
12 Fitting cable
13 Adjusting screw
14 Automatic adjuster lever
15 Shoe hold-down spring

209156

The wheel brakes are duo-servo drum brakes. Brakes • a mechanism that allows the brake to function as a
of this type are suitable for trucks, which move parking brake;
backward as frequently as they move forward, because • a mechanism that automatically adjusts the shoe-to-
they can generate the same level of braking force in drum clearance.
both directions.
The operation of these mechanisms is described on the
Each wheel brake incorporates: following pages.
• a mechanism that allows the brake to function as a
service brake;

8-2
 BRAKE SYSTEM

1. Service Brake Mechanism

When the brake pedal is depressed during forward Drum rotation
(during forward movement)
movement of the truck, wheel cylinder 1 pushes primary
shoe 2 and secondary shoe 3 outward symmetrically. Anchor pin
When the lining of the primary shoe touches the drum, the 6
shoe is dragged by the drum in the direction of drum 5
2 3
rotation. The primary shoe thus moves adjusting screw 13
in the direction of the arrow such that the adjuster end of
the adjusting screw pushes the secondary shoe with 1
significant force. Now pressed firmly against the anchor
pin at the top, secondary shoe 3 cannot move further in the
direction of rotation. As a result, it is pushed against the
drum more strongly than the primary shoe. Adjuster end
Brake drum
The directions of component movements are opposite when
13
the brake pedal is depressed during reverse movement of
the truck. 208681

When the brake pedal is released, shoes 2 and 3 are moved

toward the center of the wheel by the forces of return
springs 5 and 6.

2. Parking Brake Mechanism

Release button

Strut
Pivot A Parking brake lever
Anti-rattle spring

Pivot B Secondary shoe

Switch

Rod assembly

Parking brake
cable assembly

Primary shoe Parking lever

209157

When the parking brake lever is pulled, the parking position. The ratchet engages automatically when the
brake cable is pulled accordingly. The other end of the lever is pulled but does not disengage unless the release
cable is connected to the parking lever in the wheel button at the top of the lever is pressed. The amount of
brake. When pulled by the cable, the parking lever the stroke and force required to move the lever to the
turns about pivot A, pushing the strut rightward. The brake application point can be adjusted by extending or
strut pushes the secondary shoe against the drum. The contracting the rod assembly.
parking lever next turns about pivot B, pushing the The parking brake lever assembly is fitted with a switch
primary shoe against the drum. The wheel brake thus that closes when the parking brake is applied, causing
acts as a parking brake. illumination of the parking indicator in the monitoring
The parking brake lever assembly also incorporates a system.
ratchet mechanism which holds the lever in a pulled

8-3
BRAKE SYSTEM

3. Automatic Adjusting Mechanism

Shoe end moves

away from Primary shoe
anchor pin. Secondary
Anchor pin shoe
Drum rotation
(during reverse movement)

Brake released Brake applied Brake released

Fitting cable

ll
Pu Pivot

Adjusting nut Adjusting screw Sprocket (24 teeth) Adjusting lever

spring

Adjusting lever
s ion
ten
Ex Adjusting sprocket

Sprocket rotation in direction of arrow causes

extension by this dimension

209158

The automatic adjusting mechanism maintains the The adjusting mechanism does not operate while the
correct lining-to-drum clearance of approximately 0.1 lining-to-drum clearance is within the proper range.
to 0.25 mm. It can operate only when the brakes are The adjusting screw in the brake on an RH wheel has a
applied during reverse movement of the truck. When right-handed thread, and the adjusting screw in the
the lining has worn approximately 0.03 mm, the brake on an LH wheel has a left-handed thread.
adjusting sprocket turns by one tooth to recover a
proper lining-to-drum clearance.
When the operator depresses the brake pedal with the
lining-to-drum clearance excessively large, the top end
of the secondary shoe moves away from the anchor pin.
At this time, the fitting cable that runs from the anchor
pin to the adjusting lever via the sheave on the
secondary shoe is pulled upward, causing the adjusting
lever to swing about its pivot. The edge of the
adjusting lever thus turns the sprocket. The resulting
increase in the adjuster’s dimension causes the lining-
to-drum clearance to decrease.

8-4
 BRAKE SYSTEM

Brake Pedal Assembly

6
2 7

9
4

5 8

209159

1 Pedal bracket 6 Adjusting bolt (pedal height)

2 Brake pedal 7 Brake switch
3 Brake link 8 Push rod
4 Return spring 9 Reservoir tank
5 Master cylinder

The brake pedal assembly is mounted on the left-hand Adjusting bolt 6 is used to set the brake pedal height.
side of the frame. Brake switch 7 is adjusted to its proper length at the
When brake pedal 2 is depressed, brake link 3 turns in time of installation. When the brake pedal is depressed,
the direction of the curved arrow, moving push rod 8 of the switch issues a signal to the drive motor controller.
master cylinder 5 in the direction of the arrow shown In response, the drive motor controller reduces the drive
next to the push rod. This movement of the push rod motor’s output.
forces the piston into the master cylinder and causes the
master cylinder to deliver pressurized fluid to the wheel
brake cylinders in the wheel brakes.
Return spring 4 serves to return brake pedal 2 to its
non-depressed position.

8-5
BRAKE SYSTEM

Brake Master Cylinder

1 Push rod
2 Cylinder
From reservoir
Inlet port To wheel 3 Piston
cylinder 4 Primary cup, Cup spacer
2 3 5 Secondary cup
1
6 Spring seat
7 Return spring

5 4 6 7

Condition with brake pedal released. 207077A

The inside diameter of the cylinder is 19.05 mm (3/4 in.). The maximum stroke of
the piston is 28 mm.

Master Cylinder Operation

1. Brake pedal not depressed 3. Moment when brake pedal is released

Clearance exists. Return port is open. Inlet port Return port

Small holes

Piston moves quickly.

Primary cup
208381 208383

Fluid from reservoir enters to fill cavity formed in front

of primary cup.

2. Brake pedal depressed 4. Short time after release of brake pedal

Return port is closed.

208382 Pressurized brake fluid 208384

8-6
 BRAKE SYSTEM

Reservoir Tank
The brake fluid reservoir tank is located just above the
Connector
master cylinder, forming an integral part of the master
cylinder. It incorporates a brake fluid level sensor, which
consists of a reed switch (this is built into the bottom of the
reservoir tank) and a float (this follows changes in fluid
level). The float contains a permanent magnet.
Cap
When the fluid level drop below the minimum level marked Reservoir
on the tank, the switch closes, causing the brake fluid level
indicator to illuminate. While the fluid level is sufficiently Float
Fluid level:
high, the switch remains open and the indicator remains Max
off.
Min

Switch Permanent
magnet
To master cylinder

208379A

Wheel Cylinder
A wheel cylinder is located in each wheel brake assembly.
When the brake pedal is depressed, pressurized brake fluid
Body
from the master cylinder enters the wheel cylinder body
through the inlet port. The fluid acts on the left and right- Piston Connecting link
hand pistons, causing them to expand the primary and
secondary shoes via the corresponding connecting links.
When the brake pedal is released, the pistons are moved
back to their original positions by the brake shoe return
spring in the wheel brake assembly.
Spring
Each wheel cylinder has a bleeder screw, which is used to
Bleeder screw
remove any air that enters the brake system when the
system is serviced. The bleeder screw is loosened to
remove the air.
Inlet port

208385

8-7
BRAKE SYSTEM

Disassembly and Reassembly

Wheel Brake
Disassembly

The LH brake is shown; the RH brake

is symmetrically opposit to it.
209160

Sequence
1 Return spring (secondary) Remove parts 11 and 12 as a unit.
2 Return spring (primary) 11 Primary shoe and lining assembly
3 Fitting cable, Cable guide 12 Retainer, Wave washer, Parking lever
4 Adjusting lever, Adjusting lever spring 13 Bolt washer assembly, Wheel cylinder
5 Spring 14 Cover
6 Adjusting screw 15 Snap ring, Parking brake cable
7 Hold-down spring, Cup, Pin, Washer 16 Brake mounting bolt, Spring washer
8 Strut, Anti-rattle spring 17 Backing plate assembly
9 Shoe guide plate
10 Secondary shoe and lining assembly

Start by:
(1) Remove the front wheel. (3) Disconnect the brake pipe from the wheel brake
(2) Remove the wheel hub and brake drum. assembly.
See “Disassembly of front axle assembly” (page 6- (4) If necessary, free the end of the parking brake cable
2) in “Group 6 Front Axle”. closer to the parking brake lever.

8-8
 BRAKE SYSTEM

Suggestions for Disassembly

1. Removing return springs

Use the Spring Remover to remove the return springs.
Special tool needed

Spring remover 64309 - 15411

200271

2. Shoe hold-down spring removal

Use the Spring Retainer to remove the shoe hold-down
springs.
Special tool needed

Spring retainer 64309 - 15412

208340

3. Adjusting screw
Measure and note the adjusting screw length L for
reference during later reassembly.

L
208387

Inspection after Disassembly

1. Backing plate
Check the backing plate for cracks.

2. Shoes and linings

(1) Check each shoe and lining for cracks.
(2) Replace the shoe and lining assembly if it is fouled
with grease matter, burnt or glazed.
(3) Check the thickness of the lining. Replace the shoe
and lining assembly if it is worn to or in excess of the
service limit.
A: Standard value B: Repair or service limit
203005
Unit: mm
A 4.68
Thickness of linings
B 1.0

8-9
BRAKE SYSTEM

3. Brake drum
Check the inside (friction) surface of the drum for
abnormal wear, grooving and other defects. Minor
grooving can be removed by grinding, provided that the
inside diameter does not exceed the service limit.
A: Standard value B: Repair or service limit
Unit: mm
A 203.2 + 00.006
Inside diameter of
brake drum
B 204.2

4. Adjusting screws
Check the sprocket for wear. Turn the screw by hand to see
if its rotating parts turn smoothly.

5. Parking brake cable

Replace the cable if it shows stretch, rust or damage.

6. Others
(1) Check the return springs for cracks or fatigue.
(2) Check the adjusting springs for cracks or fatigue.
(3) Check the fitting cable for stretching.

8-10
 BRAKE SYSTEM

Reassembly

209156A

Sequence
1 Backing plate assembly 9 Washer (back of backing plate), Pin,
2 Parking brake cable, Snap ring Hold-down spring, Cup
3 Wheel cylinder 10 Shoe guide plate
Assemble parts 4 to 6 prior to final assembly. 11 Fitting cable
12 Return spring (primary)
4 Parking lever
13 Return spring (secondary)
5 Shoe and lining assembly (primary)
14 Adjusting lever, Adjusting lever spring
6 Wave washer, Retainer
15 Spring
7 Shoe and lining assembly (secondary)
16 Adjuster
8 Strut, Anti-rattle spring

8-11
BRAKE SYSTEM

Suggestions for Reassembly

1. Wheel cylinder installation

Apply liquid gasket to the mounting surface of the wheel
cylinder before positioning the cylinder in place. Secure
the wheel cylinder by tightening the bolts to the specified
torque:

2. Backing plate installation

Apply thread lock to thread. Tighten the bolts to the
specified torque.
200275
Tightning torque of backing 132.3 N·m
plate bolt (13.5 kgf·m)

Tightning torque of wheel 8 to 12 N·m

cylinder bolt (80 to 120 kgf·cm)

3. Greasing
Apply thin coat, of the specified brake grease to the
following parts:
(1) Shoe ledges (6 places)
The ledges are those portions of the backing plate in
contact with the shoe.
(2) Anchor pin surface in contact with the shoe ends

4. Shoe and lining installation

Check to be sure that each connecting link of the wheel
cylinder is snugly fitted to its shoe web.

5. Return spring installation

Use the spring installer to install the return springs to the
backing plate pins.
Install the primary shoe return spring first, then the
secondary shoe return spring.
Special tool needed

Spring installer 65309 - 15413

200276

8-12
 BRAKE SYSTEM

6. Automatic adjusting device installation

(1) Clean the adjusting screw and associated parts and
apply a thin cost of grease to the screw threads and
screw socket. Check that the screw turns smoothly
when rotated by hand.
If the screw is hard to turn, replace it with a new one.
(2) Adjusting screws in LH wheel brakes are different
from those in RH wheel brakes. Each type can be
identified by its thread direction (left-handed or right- 200277
handed) or by the shape of its sprocket teeth. Thread
directions are shown below.

Adjusting screw in LH
Left-hand thread
wheel brake

Adjusting screw in RH
Right-hand thread
wheel brake

(3) Adjust the length of the adjusting screw. If a new shoe

and lining assembly has been installed, adjust the
adjusting screw to a length as that as appropriate.
Otherwise, it is probably sufficient to keep the
adjusting screw at the length that was noted at the time
of disassembly.
(4) Install the automatic adjusting device, then perform
inspection and adjustment in accordance with the
“Automatic Adjustment” subsection in the “Inspection
and Adjustment” section (on page 8-18).

NOTE
After reassembly, bleed air out of the brake fluid lines.
(Refer to “Inspection and Adjustment” on page 8-20.)

8-13
BRAKE SYSTEM

Master Cylinder and Fluid Reservoir

Disassembly

209161

Sequence
1 Clevis, Lock nut, Push rod 6 Return spring
2 Boot 7 Cylinder body
3 Stopper ring 8 Clamp
4 Secondary cup, Piston 9 Fluid reservoir
5 Spring seat, Primary cup, Cup spacer 10 Harness

NOTE
Replacement parts marked with an asterisk (❋) are
included in the repair kit.

8-14
 BRAKE SYSTEM

Inspection after Disassembly

1. Reservoir Tank Level Sensor

(1) Reduce the amount of brake fluid in the reservoir tank
until the fluid level is below the MIN line. The brake
fluid level sensor is normal if the brake fluid level
indicator illuminates.
(2) If the indicator does not illuminate with the fluid level
below the MIN line, perform a continuity test on the
reservoir switch. Continuity will exist if the switch is
normal.
202813
(3) If the reservoir switch is normal but the fluid level
indicator does not illuminate, there may be a fault in
the wiring between the switch and the LED circuitry.
Check the wiring and connectors for open circuits and
poor contact.

2. Cylinder body
(1) Check the bore of the cylinder for rusting, erosion and
scoring.
(2) Check the inlet port and discharge port for cleanliness.
Also, check the threads of screw connection of each
joint for damage. Make sure that the boot is free from
any defects.
A: Standard value B: Repair or service limit
3. Piston
Unit: mm
Replace the piston if it is damaged. Check the piston
clearance in the cylinder body. Replace the cylinder A 0.020 to 0.105
Clearance between
assembly if the clearance is in excess of the service limit. piston and cylinder
B 0.2
4. Return spring
Replace the return spring every year.

5. Primary cup, secondary cup

Check these rubber parts for swelling, tearing and
deterioration due to aging. Replace them every year.

Reassembly
Perform the followign steps, then follow the disassembly
procedure in reverse.
(1) Wash all metal parts clean with a volatile cleaning
solvent, and dry them with pressurized air.
(2) Apply a thin coat of brake fluid to the piston cups and
the bore of the cylinder.

8-15
BRAKE SYSTEM

Wheel Cylinder
Disassembly

200278 200279

Sequence
1 Connecting link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup

NOTE
Replacement parts marked with an asterisk (❋) are
included in the repair kit.

8-16
 BRAKE SYSTEM

Inspection after Disassembly

1. Cylinder bodies
(1) Check the bore for rusting, erosion and scoring.
(2) Check the threads of bleeder screw and oil pipe for
damage.

2. Pistons
(1) Check the sliding surface for rusting and scratching.
(2) Check the piston clearance in the cylinder body.
Replace the cylinder body and piston if the clearance is
in excess of the service limit.
A: Standard value B: Repair or service limit
Unit: mm
A 0.020 to 0.105
Clearance between
piston and cylinder 200280
B 0.15

3. Piston cups
Check for swelling or other defects. Replace the cups at the
time of overhaul and every year.

4. Boots
Replace the boots if they are hardened, damaged or
otherwise deteriorated.

Reassembly
Follow the disassembly procedure in reverse while
observing the following instructions:
(1) Coat the piston cups and the cylinder bore with brake
fluid.
(2) Be careful not to damage the lips of the cups.

8-17
BRAKE SYSTEM

Inspection and Adjustment

Automatic Adjustment
1. With all wheel brake components installed correctly,
the drum-to-shoe clearance should be within the correct
range of 0.10 to 0.25 mm as seen at right angles to the
side of the brake. Push the cable by thumb to pull the
adjusting lever. Observe the lever turns the adjusting
screw by one tooth, and remove the push to observe the
adjusting screw returns to the original position. 200281A
2. If the lever fails or is sluggish to turn the adjusting
screw in the above test, the likely cause is that the lever
is not properly positioned relative to the sprocket
wheel. Be sure that the lever is so positioned that its
actuating tip touches the sprocket wheel at a level
about 4.5 mm under the center line of the screw, as
shown.
3. Where the automatic adjusting device is suspected of
malfunctioning during normal use of the truck, the
following possible causes must be considered:
(1) Check that springs A and B are correctly installed. 200282A
(2) Any of these parts is in bad condition and requires Adjusting sprocket wheel and lever positions
replacement:
a) fitting cable, b) adjusting lever, and c) adjusting
screw.
4. Use the following methods to determine whether the
drum-to-shoe clearance is correct.
(1) Fit the wheel hub in position, then turn it by hand. If
the drum-to-shoe clearance is correct, you will feel
only slight resistance. If you feel significant resistance,
the clearance is too small.
(2) Air-bleed the brake fluid lines, then depress the brake
pedal. If the pedal stroke is unusually long, the drum-
to-shoe clearance is too large.
If the drum-to-shoe clearance is incorrect, make the
necessary adjustment in accordance with the “Manual
Adjustment” subsection.

Manual Adjustment
The drum-to-shoe clearance can be adjusted by rotating the
adjusting screw with a screwdriver put to the sprocket
wheel. The hole thorough which the screwdriver tip can be
inserted is provided in the backing plate.

200283

8-18
 BRAKE SYSTEM

1. Brake Pedal Adjustment

1 5 Unit: mm
Brake pedal pad
Show in ( ) are reference
dimensions.

1 ± 0.3 mm
2

* (198)

ON/OFF position
*288 ± 3

Play of push rod

(102.2)
1 ± 0.5
(87.6)
3 4

209162

Sequence
1 Stopper bolt 4 Lock nut
2 Lock nut 5 Brake switch
3 Push rod 6 Lock nut

(1) Adjust the brake pedal pad position to the * marked

dimensions using the stopper bolt 1.
(2) Check difference in height of the brake and accelerator m
m
3

pedals. The brake pedal should be higher than the

±
10

accelerator pedal by 10 ± 3 mm. Accelerator pedal

If necessary, adjust the height of the brake pedal using

stopper bolt 1. After adjustment, prevent the stopper Brake pedal pad
bolt from turning using lock nut 2.
(3) Turn push rod 3 to adjust the clearance of its end from
the piston to 1.0 ± 0.5 mm.
Retain the clevis in the adjusted position using lock nut
4. If correctly adjusted, the amount of movement of
depressed pedal as measured at the top of the pedal pad
should be 3 to 10 mm.

209163

2. Brake Switch Installation

After the adjustment of brake pedal, adjust the brake switch
5 so that it activates when the brake pedal is pressed 6 to
13 mm. Then, tighten the lock nut 6.
The brake switch should turn ON and OFF with link lever
movement of 0.7 to 1.3 mm.

8-19
BRAKE SYSTEM

3. Brake Fluid Line Bleeding

When part of the brake fluid system is disassembled for a
repair or when brake pedal movement is spongy, it is
necessary to bleed the brake fluid line by following the
procedure below.
(1) Fit a vinyl tube over the end of the bleeder screw on
the right brake assembly. Place the other end of the
tube into a jar filled with brake fluid.
(2) Check the brake fluid level in the reservoir tank. Add
fluid, if the level is low.
(3) Pump the brake pedal several times, then keep the
pedal pressed. While holding the pedal pressed, loosen
the bleeder screw. While brake fluid is flowing inside
the vinyl tube, tighten the bleeder screw.
(4) Repeat the above procedure until there are no air 200285
bubbles in the brake fluid.
Repeat the same procedure to bleed the left brake
assembly.
After air bleeding is completed, add brake fluid in the
reservoir tank to the specified level.

4. Parking Brake Cable Adjustment

Parking brake lever
(1) With the parking brake lever released, attach the rod (apply) Pawl
assembly complete with the parking brake cable to the
Parking brake lever
lever. (release)
(2) Perform adjustment to make dimensions B of the right Ratchet
and left parking brake cables equal to each other.
Leave an allowance of 5 mm for adjustment as shown Rod assembly
in the drawing. After adjustment, tighten the lock nuts
(a) of each parking cable.
(3) Measure the force required to pull the parking brake
lever until the pawl engages with the third notch of the
ratchet. The result should conform to the following A Lock nut (b)
specification:
Bracket
Parking brake lever 245 to 294 N Parking brake cable
operating effort (25 to 30 kgf)

47 ± 4 mm
If the measurement is not up to specification, perform B
necessary adjustment by turning the rod assembly.
After adjustment, tighten the lock nuts (b) of the rod
assembly. Allowance for
adjustment: 5 mm
Lock nut (a)
209164

8-20
 BRAKE SYSTEM

5. Parking Brake Limit Switch Adjustment

Adjust the position of the bolt head by changing the
number of washers under it as shown in the drawing so that Adjusting washer
the contact lever of the limit switch comes in contact with Contact lever
the bolt head (i.e., the limit switch turns on) when the
parking brake lever is pushed forward.

Limit switch

209165

8-21
BRAKE SYSTEM

Troubleshooting
*
Brake fluid leaks over primary cup in master Inspect cylinder. If no abnormaliry
cylinder, or brake fluid leaks over cups in is found, replace piston cup.
wheel cylinders Replace the cup and fluid if the cup
Inadequate braking is distored.
force Brake fluid leaking from pipe connection Retighten, or replace pipe and joint.
Shoe linings excessively worn Replace.
Linings fouled with oil or grease Clean or replace.

Air trapped in brake fluid line Bleed air at wheel cylinder.

Piston cup defective in master cylinder Replace.
Not enough fluid in reservoir Add brake fluid.
Excessive pedal Push rod to piston clearance too large in Adjust.
stroke master cylinder
Brake fluid leakage Refer to above section marked
with *.
Automatic adjusting device out of order Remove wheel hub to expose brake
mechanism, then check operation of
automatic adjusting device.
Replace any defective part(s).
Wheel brake

Lining or durm fauled with oil or grease in Clean or replace.

less effective brake
Imbalance in braking
Wobbly or loose-mounted drum in less Replace durm.
power
effective brake Readjust and retighten.
Automatic adjusting device in left or right Remove wheel hub to expose brake
brake malfunctioning mechanism, then check operation of
automatic adjusting device.
Replace any defective part(s).

Linings glazed Sand.

Linings worn Replace shoe and lining assembly.
Brake squealing Backing-plate securing bolts loose Retighten.
Wheel hub bearings loose Readjust preload and retighten.
Brake durm fouled Clean.

Shoe’s anchor end hitting anchor wih Replace backing plate or wheel
** excessive force due to excessive wear of cylinder, whichever appropriate.
shoe ledge or wheel cylinder No special action is required
Brake chattering or
provided sound is not loud.
clattering
Shoes leges worn Replace backing plate.
Piston worn in wheel cylinder Replace.

**: A chattering or clattering sound occurs the first time the brakes are applied after a change of direction from
forward to reverse or vice versa. This sound is an inherent characteristic of the brake design and does not
usually indicate a fault. However, the sound becomes noticeably louder when the play in brake components
becomes excessive due to wear. When this happens, either or both of the backing plate and wheel cylinder
must be replaced.
8-22
 BRAKE SYSTEM

Linings worn to the service limit Replace shoe and lining assembly.
Parking brake

Shoe-to-drum clearance too large Readjust. Check operation of

Weak stopping force automatic adjusting device.
of parking brake
Lever lacks operating force Adjust.
Excessive distance between cable lock nuts Adjust by changing positions of
and cable bracket lock nuts.

8-23
BRAKE SYSTEM

Service Data
A: Standard value B: Repair or service limit
Unit: mm

Truck Model EP10KRT EP12KRT EP15KRT

Item
Height of pedal 1 A 288 ± 3
Free play of pedal 2 A 3 to 10
Play of push rod 3 A 1 ± 0.5
2

Brake
pedal

209162A
+ 0.052
Inside diameter of cylinder body 1 A 19.05 0 (3/4 inch)
− 0.020
Diameter of piston 2 A 19.05 − 0.053

A 0.020 to 0.105
Clearance between cylinder and piston
B 0.2
0
Diameter of primary cup (lip side) 3 A 20 − 0.3

Diameter of secondary cup (lip side) 4 A 20.2 ± 0.2

Master Free length of return spring 5 A 46.8

cylinder
4 2 5

1 3 207077

8-24
 BRAKE SYSTEM

A: Standard value B: Repair or service limit

Unit: mm

Truck Model EP10KRT EP12KRT EP15KRT

Item
Inside diameter of cylinder body 1 A 19.05 (3/4 inch)
A 0.040 to 0.125
Clearance between cylinder and piston 2
B 0.15 (0.0059)

Tightening torque Wheel cylinder bolts 3 A 7.85 to 11.77 (0.8 to 1.2)

N·m (kgf·m) Bleeder screw 4 A 5.88 to 8.83 (0.6 to 0.9)

Wheel
cylinder

200426A 209156B

A 203.2
Inside diameter of brake drum 1
B 204.2
Wheel A 4.88
brake Thickness of lining 2
B 1.0 (min)
Clearance between drum and lining 3 A 0.1 to 0.25
(one side)
Lever operating effort F N (kgf) A 245 to 294 (25 to 30)

Parking
brake

103388A

8-25
 STEERING SYSTEM

Structure and Functions ....................................................................... 9 – 1

General ..................................................................................................... 9 – 1
Steering Hydraulic System ........................................................................ 9 – 2
Steering Valve ........................................................................................... 9 – 5
Hydraulic Motor ........................................................................................ 9 – 6
Steering Column Assembly ....................................................................... 9 – 7
Removal and Installation ...................................................................... 9 – 8
Steering Column Assembly ....................................................................... 9 – 8
Disassembly and Assembly ................................................................ 9 – 11
Steering Valve ........................................................................................... 9 – 11
Hydraulic Motor ........................................................................................ 9 – 16
Troubleshooting ...................................................................................... 9 – 17
Service Data ............................................................................................ 9 – 18

9
 STEERING SYSTEM

Structure and Functions

General
1 Main components
Right turn
1 Steering wheel
Left turn
2 Steering column shaft
2 3 Steering valve
9
6 4 Hydraulic control valve assembly
3 5 Priority valve (component of
T hydraulic control valve)
6 Hydraulic motor for steering
P 7 Hydraulic pump
LS
13 L 8 Hydraulic tank
12
R 9 Rear axle assembly
10 Chain for steering
10
11 High-pressure oil hose connecting
priority valve to steering valve
14
12 Load sensing pressure hose
13 Low-pressure return oil hose
connecting steering valve to tank
5 14 High-pressure oil hoses connecting
4 steering valve to hydraulic motor
11 15 High-pressure oil hose connecting
hydraulic pump to hydraulic valve
15

209166

Entire steering system of this truck is controlled Oil to the steering valve 3 is supplied from the
hydraulically. The core component of this system is the hydraulic pump 7 by way of the priority valve 5 that is
steering valve 3 which is linked to the steering wheel 1 included in the control valve assembly 4. The priority
through the steering column shaft 2. valve preferentially directs to the steering system the
When the operator turns the steering wheel 1, the rotary hydraulic pump output oil which is also used for
valve and hand metering pump in the steering valve 3 controlling operation of the mast.
allows pressure oil to flow to the hydraulic motor 6 For detailed description of operation of the individual
through either of the hoses 14 according to the hydraulic system components, refer to the section
direction in which the steering wheel is turned and at a relevant to each of them.
rate corresponding to the angle through which the The “Group 10 Hydraulic System” of this manual also
steering wheel is turned. The hydraulic motor 6 is then provides general description of the hydraulic system
rotated by the pressure oil. Rotation of the hydraulic (see “General” in the “Structure and Functions”
motor is transmitted to the rear axle assembly 9 via the section).
chain 10. This turns the whole rear axle body and
changes the moving direction of the truck.
9-1
STEERING SYSTEM

Steering Hydraulic System

12
13

R L
Metering pump
1 Rotary
valve
8

Hydraulic tank

10 T

Inlet valve section 15 P LS

e 5
c z a b 11
PF P EF
d 14

LS

a Passage (P to PF)
(2) b Passage (P to EF)
f c Orifice (PF to LS)
d Orifice
e Orifice
f Passage (Z to PF)
g 7 g Drain passage
Main pressure relief valve
4 3 (6) z Chamber
209167

1 Hydralic pump 10 Pump delivery line

2 Priority valve 11 Feed line (PF to P )
3 Spool 12 Feed line (to motor ) or return line (from motor)
4 Spring 13 Return line (from motor) or feed line (to motor)
5 Check valve 14 Load sensing pressure line
6 Steering relief valve 15 Return line (to tank)
7 Poppet Port P: From pump
8 Steering valve Port PF: To steering system
9 Hydraulic motor Port EF: To mast control valve
Port LS: Load sensing pressure

9-2
 STEERING SYSTEM

The pressure oil from the hydraulic pump 1 enters the P When the steering wheel is turned and pressure oil is
port in the inlet section of the hydraulic control valve flowing to the steering valve, the PF port pressure is
assembly. The oil is then distributed among the higher than the LS port pressure.
following three routes by way of the priority valve 2. The differential pressure then pushes right the spool 3
The first is the route through which the oil for operating until it balances with the spring force; the spool stays
the steering system is supplied. The oil flows through there.
this route only while the steering wheel is being turned. When the steering wheel is turned quickly, i.e., the
The flow of oil is controlled such that a quantity of oil variable throttle formed in the steering valve is
adequate to meet the requirement of the steering system narrowed only a little, the pressure difference between
is always supplied from the PF port to the system. the PF port and LS port pressures is small. The spool 3
The second is the route through which oil flows when then moves left, opening the passage a wide and
the steering system is not in operation. Letting oil flow allowing flow of pressure oil in large amount from the
through this route makes it possible for the spool 3 and PF port to the steering valve 8. The spool stays at a
the rotor valve in the steering valve 8 to be always position determined by the amount of the differential
ready for operating smoothly whenever operation of the pressure.
steering system is commanded through steering wheel When the steering wheel is turned slowly, the variable
input. Oil flows through this route as follows: P ➝ c throttle in the steering valve is narrowed to an extent
➝ d ➝ LS port ➝ line 14 ➝ steering valve 8 ➝ that the differential pressure between the PF port and
T port ➝ line 15 ➝ Tank. Oil is flowing through this LS port pressures is significant.
route at a low rate.
This large differential pressure forces the spool 3 right,
The third route is an “excess oil flow” route through which narrows the passage a and allows pressure oil
which the P port oil remaining after flowing through to flow at a restricted rate determined by the balance of
the abovementioned two routes flows. The oil flows the forces acting on both ends of the spool to the
through passage EF to the mast control hydraulic steering valve.
system.
Check valve 5 affects the manner in which the spool 3
During operation of the truck, the flow rate and moves. When the spool 3 moves right, the check valve
pressure of the P port oil, the PF port oil pressure and 5 blocks the passage f , causing pressure oil to flow
the steering resistance always change. The steering only through the orifice e into the chamber z .
system must always be able to supply its hydraulic
When the spool 3 moves left, on the other hand, the oil
motor with oil in an amount proportional to a turning
can flow out of the chamber z through both orifice
angle of the steering wheel regardless of such changes.
e and passage f without restriction by the check
The system achieves this as described below.
valve 5. This enables the spool 3 to move left much
The priority valve 2, which is also called the “flow quicker than when it moves right.
divider valve”, uses the difference in pressure between
The function of the check valve 5 helps to supply oil
the upstream and downstream of an orifice of the oil
responsively to demands by the system and prevent
that flows passing through the rotary valve (a kind of
hunting of the spool 3; this assures smooth operation of
variable throttle) in the steering valve 8 to control the
the steering system.
flow of the PF port output oil that is directed to the
steering valve. (In the following description, the oil
pressures before and after the orifice are called the “PF
port pressure” and “LS port pressure”, respectively.)
The spool 3 in the priority valve operates as follows:
The PF port oil enters the chamber z through the
orifice e of the check valve 5, pushing right the spool
3. The spool is also pushed left by the LS port oil and
the spring 4. The drawing on page 9-2 shows the
position of the spool 3 in this condition.
9-3
STEERING SYSTEM

Steering Relief Valve

The steering relief valve 6 has a function of protecting the
steering system from excessive pressures. When the
steering system is brought to its stroke end state or imposed
on by an excessive load and the oil pressure exceeds the
preset relief pressure as a result, the P port oil flows
through the passage a , orifice c and the hollow in the
spool 3, pushes open the poppet valve 7 of the relief valve
overcoming the force of the spring, and drains into the
hydraulic tank through the passage g . This is done in
such a manner that any much oil does not leak into the LS
port circuit through the orifice d .

9-4
 STEERING SYSTEM

Steering Valve

a, b, c: Metering pump inlets

d, e, f: Metering pump outlets

208407

1 Spool 8 Drive shaft A: Control section

2 Sleeve 9 Centering spring B: Metering section
3 Outlet port (port T) 10 Pin
4 Load sensing port 11 Left turn port (port L)
5 Inlet port (port P) 12 Right turn port (port R)
6 Rotor 13 Housing
7 Rotor ring

The steering valve consists of two sections: control When the operator turns the steering wheel clockwise,
section A and metering section B. the passage in the steering valve opens, allowing
Control section A includes spool 1, sleeve 2, and pressure oil to flow through inlet port 5 into areas a, b,
housing 13, constituting a rotary type directional and c.
control valve. Spool 1 is spline-coupled to the steering As rotor 6 turns together with the steering wheel, the oil
shaft. When spool 1 is turned, sleeve 2 rotates, opening in areas d, e, and f is forced into the hydraulic motor
the following passages to form a hydraulic circuit: through right turn port 12. When the steering wheel is
(1) A passage that allows oil to flow from inlet port 5 turned counterclockwise, oil flows in the direction
to metering section B reverse to the above, entering the hydraulic motor
through left turn port 11.
(2) A passage that allows oil to flow from metering
section B to port L or R Since the pressure oil from port 5 applies rotating force
to rotor 6, necessary operator’s effort on the steering
(3) A passage that allows the return oil from the wheel is reduced.
hydraulic motor to port T
When the operator stops turning the steering wheel,
Metering section B is a trochoid-gear type, small centering spring 9 returns spool 1 to the original
hydraulic pump consisting of rotor ring 7 and rotor 6. position. In this position, spool 1 and sleeve 2 block the
Spool 1 and rotor 6 are connected to each other with oil flow from the hydraulic pump into the steering valve
drive shaft 8. The rotor, therefore, turns in the same and also close the passages between ports.
direction and at the same speed as the steering wheel.
When the operator does not turn the steering wheel,
spool 1 and sleeve 2 block almost completely the oil
passage in the steering valve.

9-5
STEERING SYSTEM

Hydraulic Motor

Oil passage “b”

Oil passage “a”
4, 5 1 6
9

Geroller set

Direction of rotation of shaft as

viewed from top of hydraulic motor
209168

Main components
1 Geroller set (part of hydraulic motor) 6 Geroller ring
2 Output shaft (also serves as rotary valve) 7 Star gear (with six teeth)
3 Drive shaft 8 Rollers (seven pieces)
4 Pressure oil inlet/outlet 9 Relief valve
5 Pressure oil inlet/outlet 10 Housing

The hydraulic motor has a Geroller set which is the The star gear 7 is forced to rotate by the pressure oil in
motor’s core component generating rotational drive the direction in which the volume of each chamber is
force using pressure of oil. expanded.
The Geroller set consists of the ring 6, rollers 8 and The rotation of the star gear 7 is transmitted to the output
star gear 7. shaft 2 which thus turns together with the star gear 7.
Pressure oil from the steering valve flows into either Outlet oil from the Geroller set 1 returns to the steering
the port 4 or 5 of the hydraulic motor. The oil then valve through the three oil passages “b”, through the
flows through the three oil passages “a” formed in the three oil passages “a” and then through the return port 5
surface of the output shaft, through the three oil or 4.
passages “b” formed in the pump housing and then into Pressure oil inlet ports and corresponding directions of
the three chambers formed between the rollers 8 and rotation of the hydraulic motor are shown in the
teeth of star gear 7 in the Geroller set. drawing above.
9-6
 STEERING SYSTEM

Steering Column Assembly

Boss 2
(internally threaded)
9 11
8
Spacer 3

Da
sh 10
bo
ard

12

209169

1 Steering wheel 6 Horn button 11 Steering valve mounting

2 Column bushing 7 Horn switch bolts
3 Ball bearing 8 Horn cord 12 Tilt pivot pin
4 Steering shaft 9 Knob bolts
5 Column bracket 10 Steering valve

The steering shaft 4 is mounted in the column bracket 5 The column bracket 5 is attached to the dashboard by
via the ball bearing 3 and column bushing 2 such that it means of its pins 12 and also its internally threaded
is rotatable. boss complete with the spacer in such a way that it can
The steering wheel 1 is installed on the top end of the turn abound the pins 12. By loosening the knob bolt 9,
steering shaft 4 using a nut. the operator, therefore, can tilt the whole steering
column assembly.
The steering valve 10 is attached to the column bracket
5 using the bolts 11. When the horn button 6 is pressed, the horn switch 7
closes the horn circuit, causing the horn to sound.
As the steering shaft 4 is splined to the steering wheel
at the top end and to the steering valve at the bottom
end, the steering valve shaft can rotate completely
together with the steering wheel 1.

9-7
STEERING SYSTEM

Removal and Installation

Steering Column Assembly

Removal

8
4
5 9 7

2
6

16

3
13 14

12

15

10

11

209170

Sequence
1 Horn button, Nut, Spring washer 9 F·N·R lever assembly
2 Steering wheel 10 Steering hydraulic lines
3 Tapping screw 11 LS pressure line
4 Tapping screw 12 Split pin, Plain washer
5 Front cover 13 Knob bolt, Spacer
6 Machine screw 14 Bolt
7 Rear cover 15 Steering valve assembly
8 Machine screw, Washer 16 Column assembly

9-8
 STEERING SYSTEM

Start by:
WARNING
(a) Disconnect the horn wiring from the terminals.
Hydraulic pressure can cause personal
(b) Disconnect the turn signal switch wiring connector.
injury. Before any steering system hydraulic
(c) Remove floor plate. lines or components are disconnected,
make sure all hydraulic pressure is released
in the steering system. Turn the steering
wheel to the left and right, then straight.

Inspection
Perform the following inspection both before disassembly
and after reassembly.
(1) Steering wheel free play
Check the free play with the key switch in the ON
position.
(2) Steering effort
(a) Set the parking brake with the key switch in the
ON position, operate the lift lever to raise and
lower the lift bracket until the hydraulic oil
209171
temperature increases to 40 to 60°C.
(b) Hook a spring scale to the rim of the steering
wheel. Pull the scale in the tangential direction
and look at the reading on the scale just when the
wheel begins to turn to find the free play.

1.6 N·m
Steering effort
(0.16 kgf·m)

Tangential force 12.3 N

(reading on spring scale) (1.25kgf)

Suggestion for Removal

1. Steering wheel removal
Remove the steering wheel with a soft head hammer. Do
not strike hard with the hammer.

NOTE
Do not hit the end of steering shaft when the steering
wheel is removed.

2. Put marks on hydraulic hoses and wiring connectors to

facilitate reinstallation. 208748

9-9
STEERING SYSTEM

Installation

209169A

Sequence
Follow the removal sequence in reverse.

Suggestion for Installation

A Steering wheel nut
Tighten to the torque shown to the right.
B Splines on the shaft 58.5 N·m
Nut tightening torque
(6.0 kgf·m)
Apply molybdenum grease to the splines before
installation.
C Bushing surfaces that come in contact with the horn
contact
Apply molybdenum grease to the top and side surfaces
of the bushing before installing the steering wheel.
D Tapered portion of the steering shaft
Avoid applying grease to this portion.
E Tilt pivot pins
Before installation, apply molybdenum grease to the
surfaces of the pins that rubs against the frame.
9-10
 STEERING SYSTEM

Disassembly and Assembly

Steering Valve
Disassembly

209172

Sequence
1 End cap, Bolts, O-ring and spacer 6 Centering spring
2 “Gerotor” set, O-ring 7 Control spool
3 Drive shaft, Spacer plate and O-ring 8 Thrust needle bearing
4 Control sleeve 9 O-ring
5 Pin 10 Dust seal

9-11
STEERING SYSTEM

Suggestions for Disassembly

(1) Control spool and sleeve removal
Remove the control spool and sleeve assembly from
the housing by pulling it toward the end of the housing
opposite to the flange. Remove the pin from the
assembly.

NOTE
When removing the assembly, slowly turn it in the
housing in both directions while pulling out to prevent
damage to the housing. 208235

(2) Control spool and sleeve disassembly

Pull the control spool from the sleeve enough to permit
removal of the centering springs. Remove the
centering springs. Remove the spool from the sleeve
by pulling it toward the rear end of the sleeve while
turning slowly.

NOTE
Before removing the spool from the sleeve, put a mark
across the spool and sleeve so that the spool can be 200668
installed in the same position.

Inspection
Spool movement in housing and sleeve
(a) Check the spool in sub-assembly condition for free
movement.
(b) If the spool is sticky or otherwise erratic in its
movement, disassemble the steering control valve, and
check its sliding surfaces for abnormal condition. If
the sliding surfaces are found in bad condition, replace
the whole control valve assembly.

9-12
 STEERING SYSTEM

Reassembly
Follow the disassembly sequence in reverse.

Start by:
(1) Replace worn or defective parts.
(2) Wash all metal parts and blow dry.
(3) Replace O-rings and seals.
(4) Apply grease to O-rings and other sealing parts.

Suggestions for Reassembly

(1) Control spool and sleeve assembling
Put the spool in the sleeve with the spring groove in
alignment with the spring groove in the sleeve. Make
sure the marks put during disassembly are in
alignment.

NOTE

Make sure the spool rotates freely in the sleeve.

200670

(2) Centering spring installation

Hold two sets of three springs back to back. Using
Spring Inserting Tool, put these sets of the springs in
the groove with the bevel ends at the bottom.
Special tool needed

Spring inserting tool 97157 - 00100

200671

(3) Control spool and sleeve assembly installation to

housing
Put the pin in the holes in the spool and sleeve. Put the
control spool and sleeve assembly in the housing from
the rear side while rotating it in both directions with the
pin kept level with center of the spool.

NOTE
Make sure the rear end of the spool and sleeve 208238
assembly is even with the rear end of the housing.

9-13
STEERING SYSTEM

(4) Reassembling the wear plate

• Clamp the housing in a vise, equipped with soft jaws
or softened with rag. Clamp lightly over the edges
of the mounting area. Do not overtighten the vise
jaws.

NOTE
Check that the spool and sleeve are flush with or
slightly below the surface of the housing.
208240

• Install the O-ring in the housing. Place the wear

plate on the housing and align the bolt holes with the
tapped holes in the housing.

208241

(5) Reassembling the driver

• Make a mark across the splined end of the drive to
indicate the direction of the slot at the opposite end
of the drive.
• Rotate the spool and sleeve assembly until the pin is
parallel with the port surface. Install the drive and
make sure that it engages the pin. The mark should
be parallel to the port surface.

208242

9-14
 STEERING SYSTEM

(6) Reassembling the gerotor set

• Install O-ring in the gerotor set.
• With the O-ring side of the gerotor set towards the
wear plate, align the star valleys A with the mark on
the drive B. Noting the parallelism of reference
lines A, B, C, and D, align the bolt holes without
disengaging the gerotor set from the drive.

208243

(7) Reassembling the end cap

• Install the drive spacer in the gerotor set. Install the
O-ring in the end cap. Install the end cap in the
gerotor set and align the holes

208244

• Tighten all screws snug, then tighten them

progressively to the specified torque in the sequence
as shown.

17 N·m
Initial torque for screws
(1.7 kgf·m)

31.2 N·m
Finishing torque for screws
(3.2 kgf·m)
200677

After installing the end cap, install the steering wheel to the
spool and make sure the spool rotates smoothly.

9-15
STEERING SYSTEM

Hydraulic Motor
Disassembly

Check valve
Flange
Housing

5
6

209173

Sequence
1 End cap 6 Flange, Dust seal, Anti-extrusion ring, Oil seal
2 Spacer, O-ring, Geroller set, O-ring as a unit
3 Drive 7 O-ring
4 Spacer plate, O-ring 8 Check valve, O-ring (two set)
5 Output shaft, Needle bearing, Fifth wheel for 9 Housing
needle bearing

Reassembly
Follow the disassembly sequence in reverse.

9-16
 STEERING SYSTEM

Troubleshooting

Clogged metering section Disassemble and clean.

Steering valve malfunction Faulty spool operation Disassemble and clean.
Faulty bearing Disassemble and replace.
Heavy steering wheel operation

Sticky spool due to foreign Disassemble, wash and

particles reassemble.
Priority valve malfunction Clogged orifice Disassemble, wash and
reassemble.
Too low set pressure of Set pressure correctly.
relief valve

Others Flattened pipe, mixing of Clean or replace oil line.

foreign particles

Sticking of spool or sleeve Replace.

Steering valve malfunction
Damaged centering spring Replace.
Instability in steering wheel operation

Hydraulic motor malfunction Sticky internal components Replace.

Malfunction of rear axle and

Inspect.
related components

Sticky spool due to foreign Disassemble, wash and

Priority valve malfunction particles reassemble.
Clogged orifice Disassemble, wash and
reassemble.
Flattened pipe, mixing of Clean or replace oil line.
Others foreign particles
Air trapped in system Perform air bleeding.

9-17
STEERING SYSTEM

Service Data
A: Standard value
Unit: mm

Truck Models
EP10KRT EP12KRT EP15KRT
Item

Steering system relief valve set pressure MPa (kgf/cm2) A 8.8 (90)

Steering effort
Tangential force (measured on steering wheel A 12.3 (1.25)
Steering rim) with motor running N (kgf)
wheel
Steering wheel nut tightening torque
A 58.5 (6.0)
N·m (kgf·m)

Steering Manufacture A OGNIBENE

valve
Displacement cm3/rev. A 70

Hydraulic Manufacture A SAMHYDRAULIK

motor
Displacement cm3/rev. A 130

9-18
 HYDRAULIC SYSTEM

Structure and Functions .......................................................................10 – 1

General .....................................................................................................10 – 1
Schematic of Hydraulic System ................................................................10 – 2
Hydraulic Pump ........................................................................................10 – 3
Hydraulic Tank ..........................................................................................10 – 4
Hydraulic Control Valve and Control Levers...............................................10 – 5
Inlet Valve Section .................................................................................10 – 7
Tilt Valve Section ...................................................................................10 – 8
Lift Valve Section ...................................................................................10 – 9
Main Relief Valve ................................................................................... 10 – 10
Flow Regulator Valve ................................................................................ 10 – 11
Down Safety Valve .................................................................................... 10 – 11
Lift Cylinders ............................................................................................. 10 – 12
Tilt Cylinders ............................................................................................. 10 – 13
Removal and Installation ...................................................................... 10 – 14
Hydraulic Pump ........................................................................................ 10 – 14
Hydraulic Control Valve Assembly ............................................................ 10 – 16
Lift Cylinders (Simplex Mast) .................................................................... 10 – 18
Lift Cylinders (Duplex and Triplex Mast) ................................................... 10 – 21 10
Tilt Cylinders ............................................................................................. 10 – 24
Disassembly and Reassembly ............................................................ 10 – 25
Hydraulic Pump ........................................................................................ 10 – 25
Hydraulic Control Valve Assembly ............................................................ 10 – 27
General Rules for Disassembly, Inspection and Reassembly of
Valve Sections .................................................................................... 10 – 28
Inlet Valve Section ................................................................................. 10 – 29
Tilt Valve Section ................................................................................... 10 – 30
Lift Valve Section ................................................................................... 10 – 31
 Lift Cylinders ............................................................................................. 10 – 32
Tilt Cylinders ............................................................................................. 10 – 38
Flow Regulator Valve ................................................................................ 10 – 41
Down Safety Valve .................................................................................... 10 – 42
Inspection and Adjustment ................................................................. 10 – 43
Hydraulic Tank (Hydraulic Oil).................................................................... 10 – 43
Hydraulic Pump ........................................................................................ 10 – 43
Control Valve ............................................................................................ 10 – 44
Adjustment of Main Relief Valve ............................................................... 10 – 45
Adjustment of Steering System Relief Valve ............................................. 10 – 46
Adjustment of Flow Regulator Valve ......................................................... 10 – 46
Lift Cylinder and Tilt Cylinders .................................................................. 10 – 47
Adjustment of Mast Tilt Angle ................................................................ 10 – 47
Adjustment of Right and Left Lift Cylinder Strokes ................................ 10 – 47
Lift Cylinder Drift Test ............................................................................ 10 – 48
Tilt Cylinder Drift Test ............................................................................ 10 – 48
Adjustment of Tilt Lever Switch and Lift Stroke Sensor ............................. 10 – 49
Troubleshooting ...................................................................................... 10 – 50
Service Data ............................................................................................ 10 – 54
 HYDRAULIC SYSTEM

Structure and Functions

General

12 15
14
9
19
18

22 6
21

5
4

3 20

11 17
16

1
10

2 23
13
209086

1 Hydraulic tank 9 Tilt cylinder (R.H.) 17 Oil level gauge

2 Suction pipe 10 Tilt cylinder (L.H.) 18 Oil feed line of steering valve
3 Hydraulic pump 11 Flow regulator valve 19 Oil sensing pressure line
4 Pump delivery hose 12 Lift cylinder (R.H.) 20 Return line
5 Control valve inlet section 13 Lift cylinder (L.H.) 21 Return line
6 Control valve tilt section 14 Steering valve 22 Return line
7 Control valve lift section 15 Hydraulic motor 23 Return filter
8 Control valve end section 16 Breather

The hydraulic system of this truck includes the mast (1) Lift control valve section
control circuit and the full-hydraulic steering system (2) Tilt control valve section
circuit.
The tilt control valve section controls extension and
The oil drawn by the hydraulic pump 3 from the retraction of the tilt cylinders 9 and 10 to cause the
hydraulic tank 1 flows into the control valve inlet mast to lean forward or backward.
section 5 through the pump delivery hose 4.
The lift control valve section controls the operation of
The flow priority valve in the control valve inlet the lift cylinders 12 and 13 to raise or lower the mast.
section 5 preferentially distributes the oil to the
steering valve 14 through the oil feed line 18. The The return oils from the steering valve and mast control
priority valve distributes the remainder of the oil to the system go to the hydraulic tank through the return lines
mast control circuit. In the standard configuration, the 20, 21 and 22.
following two valve sections are used for the mast
control purposes:
10-1
 Flow regulator valve Hydraulic motor
Flow rate: 55 liter/min displacement:
130 cm3/rev.
HYDRAULIC SYSTEM

Steering valve
displacement: R L
70 cm 3/rev.
T Hydraulic control valve

(L.H.) (R.H.)
Schematic of Hydraulic System

A2
Lift cylinder with
down safety valve T

B1
P LS

A1

10-2
Pump motor
24 V DC
output 8.8 kW

Return Hydraulic pump

Tilt cylinder P LS PF filter 15 µm (gear pump)
Displacement:
20.0 cm3/rev.

Main relief valve

Set pressure: Steering system relief valve
+0.5 +5 2
13.7 0 MPa (140 0 kgf/cm ) +0.5 2
Set pressure: 8.8 0 MPa (90 kgf/cm )

209087
 HYDRAULIC SYSTEM

Hydraulic Pump

200333

209088

Main Parts
1 Pump body 4 Bushing (R.H.) 6 Mounting flange
2 Drive gear 5 Bushing (L.H.) 7 Cover
3 Driven gear

The hydraulic pump is a gear pump, driven by a pump In order to prevent the internal oil leakage, this
motor. hydraulic pump is designed to direct a portion of pump
The drive gear 2 is splined to the armature shaft of the delivery oil to the back of the bushings 4 and 5. The
pump motor. oil pushes the bushings against the ends of the gears 2
and 3, thus minimizing the clearances between the
With a high-pressure gear pump, oil tends to leak from
gears and bushings (see the drawing above). This
the high-pressure side to the low-pressure side through
design can ensure high pumping efficiency for an
clearances at the ends of each pump gear (internal oil
extended period of time by making up for the
leakage). This leakage reduces pumping efficiency (or
clearances as the bushings and gears wear.
pump's volumetric efficiency).

10-3
HYDRAULIC SYSTEM

Hydraulic Tank
1 Hydraulic tank
2 Tank mounting bolts
3 Suction pipe
4 Oil level gauge
5 Return pipe
6 Breather
7 Return filter

209089

The hydraulic tank is made of plastic. It is mounted on the

front portion of the truck frame (approximately at the
center) using the tank mounting bolts 2.
In addition to the suction pipe 3 and return pipe 5, the
hydraulic tank is fitted with the oil level gauge 4 and
breather 6. The return pipe 5 is fitted with the return filter
7 (15 µm) to keep the hydraulic oil clean.
The return filter 7 has a built-in relief valve. The hydraulic
oil normally flows through the filter before it returns to the
hydraulic tank. If the filter is clogged, the relief valve
opens, allowing the oil to bypass the filter and return
directly to the tank. It is therefore important to periodically
replace the return filter.
The oil level in the hydraulic tank changes as the mast is
raised and lowered, causing air to flow out of and into the
tank through the breather. The breather is fitted with a filter
to prevent dust from entering the tank.
10-4
 HYDRAULIC SYSTEM

Hydraulic Control Valve and Control Levers

N
Tilt-backward
N
Tilt-forward Lift-up

Lift-down
13 12

Swing 8
11

Spring pin
9

10 9

12

3
6
4
B1
2

PF
T

5
1
7
A2
A1
209090

1 Control valve assembly 8 Tilt lever P: From pump

(consisting of parts 2 to 6) 9 Tilt rod PF: To steering system
2 Inlet valve section 10 Switch A1: From/to tilt cylinder
3 Tilt valve section 11 Lift lever B1: From/to tilt cylinder
4 Lift valve section 12 Lift rod A2: From/to lift cylinder
5 End cover 13 Stroke sensor T: To hydraulic tank
6 Main relief valve
7 Steering relief valve

10-5
HYDRAULIC SYSTEM

General The rate of oil flow to the cylinder depends on how far
the control lever is moved from the neutral position.
The drawing on page 10-5 shows the truck’s hydraulic
The longer the distance from the neutral position, the
control valve, valve control levers and related electrical
larger the valve opening and, therefore, the greater the
switch.
flow rate.
The control valve assembly 1 consists of the following
The volume of the oil flowing into the cylinder is equal
five sections:
to that of the oil going out of the cylinder.
(1) Inlet valve section 2
The tilt rod 9 is linked to the switch 10. This switch
(2) Tilt valve section 3 senses the initial movement of the rod, i.e., the
(3) Lift valve section 4 movement of the spool, and signals this to the electrical
(4) End cover 5 controller, which in turn increases the speed of the
pump motor.
(5) Main relief valve 6
Each valve section will be described briefly in the 3. Lift Valve Section
following paragraphs. For more details about their The lift valve section 4 is a directional control valve.
operation in the system, refer to the relevant sections in This valve switches the direction of oil flow to the mast
this manual. lift cylinder to cause the mast to move either upward or
downward. It also controls the rate of oil flow to the
1. Inlet Valve Section
cylinder.
The inlet valve section 2 incorporates the priority valve
The direction of oil flow depends on whether the
and steering system relief valve. Also contained in this
control lever 11 is pushed forward or pulled backward.
section is the main relief valve.
If the control lever is in the “lift-up” position, pressure
Pump output oil enters the inlet section through port P
oil flows into the lift cylinder through the A2 port. If
and flows to the priority valve. The priority valve
the control lever is in the “lift-down” position, the oil in
preferentially allows oil to be directed to the steering
the cylinder goes out through the same port.
system through the PF port in as much an amount as
the system requires. The rate at which oil flows into and out of the cylinder
depends on how far the control lever 11 is moved from
The excess oil is directed to the tilt and lift sections as
the neutral position. The longer the distance from the
the mast operation control oil.
neutral position, the larger the valve opening and,
2. Tilt Valve Section therefore, the greater the rate at which oil flows through
the A2 port.
The tilt valve section 3 is a directional control valve.
This valve switches the direction of oil flow to the mast The lift rod 12 is linked to the stroke sensor 13. This
tilt cylinder to cause the mast to tilt either forward or sensor senses the distance over which the spool has
backward. It also controls the rate of oil flow to the moved and signals it to the electrical controller, which
cylinder. in turn adjusts the pump motor speed accordingly.
The direction of oil flow depends on whether the 4. End Cover
control lever 8 is pushed forward or pulled backward,
The end cover terminates the control valve assembly
as shown in the drawing.
and has the T port.
If the control lever is in the “tilt-backward” position,
pressure oil flows into the tilt cylinder through the A1 5. Main Relief Valve
port and the oil in the cylinder goes out through the B1 The main relief valve is a safety valve which protects
port. all the hydraulic systems except the steering system
If the control lever is in the “tilt-forward” position, the from an excessively high pressure.
flow of oil is reverse to the above.

10-6
 HYDRAULIC SYSTEM

Inlet Valve Section

a
PF P b
c EF
2 3

5
LS

4 209091

1 Priority valve assembly P: From pump

2 Valve spool PF: To steering system
3 Spring EF: Center bypass port of passage to tilt and lift
4 Steering system relief valve sections
5 Main relief valve LS: Load sensing pressure
a: Passage (P to PF)
b: Passage (P to EF)
c: Passage
z: Chamber

Hydraulic pump output oil flows through the P port used by the steering system flows out of the valve
into the inlet valve section. through the EF passage.
Passage (a) is always open, allowing pressure oil from The rate at which oil flows through the PF port to the
the P port to flow through the PF port toward the steering system is controlled by the movement of the
steering valve. valve spool 2. Passages (a) and (b) are correlated such
After passing through the PF port, pressure oil flows that when one opens the other closes.
through passage (c) into chamber (z), pushing the valve As the steering system demands higher rates of oil
spool 2 to the right against the combined force of LS flow, the valve spool 2 moves toward the left. This
pressure and the spring 3 (see the drawing above). opens passage (a) wider, achieving a higher rate of oil
As a result, passage (b) is open, opening the P port to flow to the PF port and onwards. As the steering
passage EF. This allows oil to flow from the EF port system demands lower rates of oil flow, the spool 2
to the tilt and lift sections for the use in control of the moves toward the right. This opens passage (b) wider,
mast. achieving a higher rate of oil flow to the EF passage
and onward.
The priority valve 1 ensures that the steering system is
always supplied with pressure oil through the PF port The movement of the valve spool (2) is controlled by
in an amount enough for its operation irrespective of the relationship between the PF port pressure and LS
variation in the oil flow rate and pressure at the P port port pressure. This is described in detail in the “Group
and also in the steering resistance. The excess oil not 9 Steering Valve” of this manual.

10-7
HYDRAULIC SYSTEM

Tilt Valve Section

Passage A
High pressure port
3
4
5 Center bypass port
A1 B1

Tilt-backward
N
Tilt-forward

T 1 209092

1 Spool 4 Tilt lock valve A1: To tilt cylinder rod end

2 Return spring 5 Tilt lock valve spring B1: To tilt cylinder head end
3 Load check valve T: Drain port

The drawing above shows the state of the tilt valve with Tilt-backward position:
the spool 1 in the neutral position. The spool 1 is moved to the right, closing the center
Neutral position: bypass port. Since this blocks the flow of oil from the
high pressure port, the oil of increased pressure pushes
The center bypass port is open. This allows the pump- open the load check valve 3 and makes its way into
delivered oil to flow to the hydraulic tank through the passage A. As the spool 1 has moved to the right
center bypass port and port T in the end cover. The oil opening passage A to port A1, the oil flows to port A1
does not flow to ports A1 and B1 as the passages to the and its pressure acts in the direction in which the tilt
ports are blocked by spool 1. cylinder rod is retracted in the cylinder.
Tilt-forward position: As ports B1 and T are now open to each other, the oil
The spool 1 is pushed to the left, closing the center in the head end of the tilt cylinder returns to the tank.
bypass port. This causes the pressure in the high In combination with the oil flow mentioned above, this
pressure port to rise. The increased pressure pushes enables the tilt cylinder rod to be retracted in the
open the load check valve 3 allowing pressure oil to cylinder or the mast to be tilted rearward.
flow into passage A. The pressure oil in passage A then The tilt lock valve 4 is a safety valve, provided to
flows into port B1 and acts on the tilt cylinder rod to prevent the mast from tilting forward when the pump
extend it forward, that is, to tilt the mast forward. motor is not running. With the motor stopped, pump
The pressure oil in passage A also flows to the tilt lock pressure does not act on the tilt lock valve, so the valve
valve 4 and pushes the valve to the left against the blocks the oil in port A1. Since the oil cannot move
force of the spring 5. This opens port A1 to port T, anywhere, the tilt cylinder rod is kept unextended. The
allowing the oil in the rod end of the tilt cylinder to oil in port A1 remains blocked even if the valve is
return to the tank. In combination with the oil flow moved to “the tilt forward” side while the motor is
mentioned above, this enables the tilt cylinder rod to stationary. This means that the mast does not tilt
extend forward. forward.

10-8
 HYDRAULIC SYSTEM

Lift Valve Section

Passage A
3

High pressure port

A2 B2

2 1

Lift-up
N
Lift-down
T Center bypass port
209093

1 Spool A2: To/from lift cylinder

2 Return spring B2: Blind (plugged)
3 Load check valve T: Drain port (to hydraulic tank)

The drawing above shows the lift valve with the spool Lift-down position:
1 in the neutral position. The spool moves to the left (in the drawing), opening
Neutral position: port A2 to port T. The oil in the lift cylinder is then
The center bypass port is open. This allows the pump- pushed out by the load acting on the cylinder piston and
delivered oil to flow to the hydraulic tank through the flows through ports A2 and T and back to the tank, at a
center bypass port and port T in the end cover. The oil rate controlled by the flow regulator valve and the
does not flow to ports A2 and B2 as the passages to the amount of movement (distance from the neutral
ports are blocked by spool 1. position) of the spool 1.

Lift-up position:
When the lift lever is pulled towards the operator, the
spool 1 moves up (moves to the right in the drawing),
opening passage A to port A2 while at the same time
closing the center bypass port. This causes the pressure
in the high pressure port to rise. The increased pressure
pushes open the load check valve 3. As passage A
opens to the high pressure port as a result, pressure oil
eventually flows into port A2.

10-9
HYDRAULIC SYSTEM

Main Relief Valve

203490

1 Cap 8 Pilot spring HP: High-pressure oil

2 Plug 9 Spring LP: Low-pressure oil
3 Sleeve 10 O-ring A: Pilot pressure relief port
4 Main poppet 11 Backup ring B: Main pressure relief port
5 Pilot seat 12 O-ring C: Spring chamber
6 Pilot poppet 13 O-ring
7 Adjusting screw 14 O-ring

Pump pressure (HP) to the tilt and lift cylinders is always

acting on the pilot poppet 6.
If the pump pressure exceeds the set pressure of the main
relief valve, the poppet 6 moves to the right against the
force of the spring 8. This allows the oil in the spring
chamber C to escape through the A port into the low-
pressure (LP) side of the system.
As a result, the pressure in the chamber C drops, which
enables the pump pressure oil to push the main poppet 4 to
the right. The high-pressure oil then flows through the B
port into the LP side of the system.
To adjust the set pressure of the main relief valve, turn the
adjusting screw 7 in or out to change the preload on the
spring 8.

10-10
 HYDRAULIC SYSTEM

Flow Regulator Valve

203558

The flow regulator valve is located between each lift lowered to keep a constant safe lowering speed
cylinder and control valve. It limits the flow of oil regardless of load.
forced out of the cylinder when the loaded forks are

Down Safety Valve

204971

The down safety valve is located at the bottom side of

left-hand lift cylinder. This valve provides a means of
preventing the load from lowering, unsafely, rapidly,
when the hose bursts.

10-11
HYDRAULIC SYSTEM

Lift Cylinders

Lift cylinder
Type 1: Simplex mast and triplex mast second cylinder

Top end Bottom end

207765

Type 2: Duplex and triplex mast first cylinder

2

Top end Bottom end

1 3 Inlet
000825B

Type 3: Duplex mast second cylinder

Top end Bottom end

To first cylinder Inlet

000825C

The lift cylinders (first cylinder and second cylinder) The type 3 cylinder is used as the duplex mast’s second
are of the single-acting type. The type 1 cylinder shown cylinder. Oil flowing in from the bottom end first flows
in the drawing above is used as the simplex mast’s lift through a passage in the rod toward the first cylinder
cylinder and as the triplex mast’s second cylinder. (see part 2 above). When the first cylinder’s rod has
When oil flows in from the bottom end, the rod is been extended fully, the second cylinder’s piston moves
extended. Oil in the space between the rod and cylinder upward.
tube returns to the tank. When the rod moves Part 4 is a down-stroke cushioning mechanism. This
downward, air from the tank is drawn into this space. mechanism prevents the piston from bottoming hard
The type 2 cylinder is used as the duplex and triplex against the head just as the rod completely retracts.
masts’ respective first cylinders. When oil flows in from This is achieved by narrowing the oil flowing gap
the bottom end, the rod is extended. Air and oil (mostly between the piston and head further as the piston moves
air) are contained in a chamber 1 inside the rod and in downward.
the space 2 between the rod and cylinder tube. As the
piston moves upward, the oil in the chamber 1 and
space 2 opens the check valve 3 and flows out of the
inlet port. When the piston moves downward, the space
2 becomes empty.
10-12
 HYDRAULIC SYSTEM

Tilt Cylinders

To tilt valve To tilt valve

A1 port B1 port
4 8 1 3 8 6
5 2

Adjustable
7

209094

1 Cylinder assembly 5 Tilt socket

2 Piston and rod assembly 6 Bushing
3 Spacer 7 Spherical bearing
4 Guide 8 Set screw
A: Spanner fitting portion

The tilt cylinders are of a double-acting type.

Each cylinder has the tilt socket 5 screwed onto the piston
rod 2. This allows adjusting the length of a piston rod if
necessary to make same the tilt angles on the right and left
sides of the mast when the cylinders are connected to the
mast.
To turn the rod 2 for adjustment, use a spanner fitted on
portion A.

10-13
HYDRAULIC SYSTEM

Removal and Installation

Hydraulic Pump
Removal

3
5

Lifting eye
(M10, 1.25 pitch thread)

2
1

Motor bracket

209095

Sequence
1 Bolts 3 Bolts
2 Bolts 4 Hydraulic pump
5 Pump motor

10-14
 HYDRAULIC SYSTEM

Start by:
NOTE
Disconnect all hydraulic pipes
1. Before disconnecting any hydraulic pipe or hose, and hoses from their connectors
Control valve
take all necessary measures to prevent risk of on the control valve.
injury by falling attachments and high-pressure oil
jetting out of the system. For details, refer to the
“Start by” part of the hydraulic valve removal
section in this manual.
2. When disconnecting hydraulic pipes and hoses,
cap or plug their disconnected ends and the
openings from which they are disconnected to
prevent dust and other foreign matter from
Pump suction hose
entering the hydraulic system.

(1) Park the truck over the pit and lower the forks. Relieve
oil pressure from the hydraulic system.
(2) Remove the floor mat and plate.
(3) Disconnect the brake pipe from the master cylinder. Pump delivery
hose
(4) Remove the brake pedal assembly complete with the
master cylinder. Refer to the “Group 8 Brake System”
209096
of this manual.
(5) Disconnect the hydraulic lines from the control valve
(see the drawing on the right).
(6) Disconnect the pump suction and delivery hoses (see
the drawing on the right).

Suggestions for Removal

1. To facilitate reassembly, put mating marks on the oil
pipes and electric harness connectors before they are
disconnected.
• Disconnect the battery convertor.
• Discharge the head capacitors using resistor part
number 0358280.
2. Disconnect the motor wiring harness from the
connector on the motor.
3. Support the weight of the motor 5 using lifting eye
bolts and a hoist.
4. Remove the bolts 1 and 2. Lower the motor complete
with the motor bracket and hydraulic pump.
5. Remove the bolts 3 to separate the hydraulic pump 4
from the motor 5.
NOTE: It is recommended that the motor as well as the
pump be inspected when the pump is separated
from the motor.

Installation
Follow the removal procedure in reverse.
10-15
HYDRAULIC SYSTEM

Hydraulic Control Valve Assembly

Removal

Tilt control lever Lift control lever

11

Bracket

10

9
2
12
3

5 6
7 209097

Sequence
1 Return hose 7 LS pressure hose
2 Hose (to steering system) 8 Snap pin, Washer
3 Tilt pipe 9 Pin
4 Pump delivery hose 10 Bolt, Nut (x 2)
5 Tilt pipe 11 Bolt (screw type, x 1)
6 Lift pipe 12 Hydraulic control valve assembly

10-16
 HYDRAULIC SYSTEM

Start by:
(1) Before disconnecting the pipes from the control valve,
bring the mast to the vertical position and place the fork
to the lowest position in order to release the residual
pressure in the pipes.
(2) Support the weight of the mast with a crane.
(3) If an attachment is connected, take necessary measures
to prevent it from moving.
(4) Remove the floor plate.
(5) Remove the battery box.

Suggestions for Removal

1. Disconnect all the hydraulic pipes and hoses from the
control valve.
2. Remove the snap pin and washer 8, then pull out the
pin 9. Separate the control rods from the valve spools.
3. While holding the control valve assembly by hand,
remove the two bolts 10 and bolt 11. Remove the
control valve assembly 12.

Installation
Follow the removal procedure in reverse.

NOTE
Avoid applying undue force to electrical devices such
as the stroke sensor and microswitch when they are
removed and installed. Using excessively large forces
can damage these devices.

10-17
HYDRAULIC SYSTEM

Lift Cylinders (Simplex Mast)

Removal

209098

Sequence
1 Nuts 4 Hose guard 7 Cylinder clamp,
2 Lift bracket assembly 5 High-pressure hose Cushion, Collar, Shims
3 Low-pressure (return) hose 6 Set bolt, Shims 8 Lift cylinder, Bracket

Suggestions for Removal

1. Removing lift bracket assembly 2

(1) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts 1
from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away from the lift bracket and fork assembly.

204873A

10-18
 HYDRAULIC SYSTEM

2. Removing low-pressure (return) hoses for lift

cylinder 3
Disconnect the return hose from the right and left lift
cylinders at the connectors.

Removing hose guard

With the masts at the maximum lift position, remove the
hose guard from the front side.

Lowering masts
Operate the lift lever gradually to lower the masts.

3. Disconnecting high-pressure hoses 5

Disconnect the high-pressure hoses at the joints indicated Low-pressure
by arrows. Use a drip pan to catch oil flowing out of the hose
hoses.

High-pressure hose

209099

4. Removing set bolts 6

(1) Remove the set bolt at the top of each lift cylinder. Lift
the inner mast to separate the cylinder rod ends. To lift
the inner mast, hitch a sling around the mast with
protective rag.
NOTE
The rod end of either lift cylinder is shim adjusted to
eliminate the difference in stroke between the
cylinders. Before removing the set bolts, make a
record of the amount of shims and cylinders to which
the shims are fitted. 204934

(2) Tie wood blocks under the inner mast and detach the
sling. Use blocks strong enough to support the mast.
Make sure the right and left wood blocks are the same
in height.

202983

10-19
HYDRAULIC SYSTEM

5. Removing lift cylinders 8

Hitch a sling to the lift cylinder from the rear side of the
mast, and remove the cylinder. Hitch the sling before
removing the cylinder clamp.

204935

Installation
To install, follow the reverse of removal sequence, and do
the following steps:
1. Extend and retract the lift cylinders several times under
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
2. Check the oil level in the hydraulic tank with an oil
level gauge.
3. Check to make sure that the lift height is correct.
4. After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the two
cylinders. (Refer to “Group 11 Mast and Fork”.)

10-20
 HYDRAULIC SYSTEM

Lift Cylinders (Duplex and Triplex Mast)

Removal
The procedures that follow apply to the lift cylinders of the Triplex Mast models. However, you can follow them to
remove the cylinders of the Duplex Mast models as well.

207612

Sequence
1 Nuts 4 Chain wheel support assembly
2 Lift bracket assembly 5 Second lift cylinder
3 First lift cylinder

Suggestions for Removal

1. Removing lift bracket assembly 2

(1) Lower lift bracket assembly 2, and place wood blocks
under the assembly. Tilt the mast forward, lower the
inner mast to the bottom, then remove nuts 1 from the
anchor bolts of the first lift chains.

207613

10-21
HYDRAULIC SYSTEM

(2) Position the mast upright. Raise the inner mast until
main rollers 6 of lift bracket assembly 2 become free.
Then, slowly move the vehicle in reverse to separate
from lift bracket 2.

207762

2. Removing first lift cylinder 3

(1) Hitch a sling to first lift cylinder 3, and suspend the
cylinder with a hoist. Wind the sling securely to
prevent slipping.
(2) Remove the lift cylinder connecting and mounting
bolts, and gently dismount first lift cylinder 3.

207616

3. Removing second lift cylinders 5

(1) Disconnect hoses from second lift cylinders 5.
(2) Remove stopper bolts at the upper sections of second
lift cylinders 5, and lift the inner mast (duplex mast) or
middle mast (triplex mast) approximately 550 mm
using slings.

207617

10-22
 HYDRAULIC SYSTEM

(3) Place wood blocks under the inner mast (duplex mast)
or middle mast (triplex mast).
Make sure the right and left wood blocks are the same
in height.

202983

(4) Hitch a sling to second lift cylinder 5 behind the mast,

remove cylinder clamp retaining bolts, and gently
remove second lift cylinder 5.
Hitch the sling securely to the cylinder. The cylinder
cannot be lifted straight up since the mast cross-
member is located above the cylinder. Tilt the cylinder
and move it away from the cross-member to remove.
Be careful not have the hands caught between the
cylinder and mast.

207618

Installation
To reinstall, follow the removal sequence in reverse, and
service as follows.
(1) Install chain wheel support assembly 4 parallel to a line
connecting the centers of chain anchor bolt holes on
first lift cylinder 3 to prevent chains from twisting.
(2) Adjust the chain tensions.
(Refer to “Inspection and Adjustment” in “Group 11
Mast and Fork”.)
207638
(3) Extend and retract the lift cylinders several times under
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
(4) After proper operation is confirmed, check the oil level.

10-23
HYDRAULIC SYSTEM

Tilt Cylinders
Removal

209100

Sequence
1 Tilt cylinder pin 3 Tilt cylinder pin
2 Hoses (two for each cylinder) 4 Tilt cylinder

Start by:
(1) Lower the forks to the bottom, and tilt the mast
fully forward.
(2) Attach a sling to the round holes, right and left, in
the top crossmember of outer mast, and support the
weight of the mast with a hoist.

Suggestions for Removal

1. Retracting piston rod

Remove tilt cylinder pin 1, start the pump motor and
205740
retract the piston rod fully, then stop the pump motor.
2. Disconnecting hoses Installation
Disconnect hoses 2 from the cylinder at the connectors. Follow the removal procedure in reverse.
Use a drip pan to catch oil flowing out of the cylinder.
Attach caps to the connectors of the cylinder to protect (1) Install the tilt cylinder pin 3 by tightening the bolt
the threads of the connectors and to prevent oil from to the following torque.
flowing out of the cylinder when the cylinder is
removed. 33.3 N·m
Tightening torque
(3.4 kgf·m)
3. Removing tilt cylinders
Remove the tilt cylinder pin 3, then remove the tilt (2) Make sure that the tilt angles on the right and left
cylinders 4. of the mast are not different. If necessary, perform
adjustment by turning the piston rod.
10-24
 HYDRAULIC SYSTEM

Disasembly and Reassembly

Hydraulic Pump
Disassembly and Reassembly

209101

Sequence
1 Cover, Bolt 5 Drive gear
2 Mounting flange, Snap ring, Oil seal 6 Driven gear
3 Body seal, Bushing seal 7 Backing ring, Bushing
4 Backing ring, Bushing 8 Body

NOTE NOTE
The primary cause of faults that necessitate 1. It is recommended that parts marked with ❋ in
disassembly of the hydraulic pump is the drawing above be replaced whenever the
contamination of oil. If this is the case, you should hydraulic pump is disassembled. These parts
not only repair the hydraulic pump but also flush are available as a seal kit.
the hydraulic system and fill the system with new 2. The parts marked with in the drawing above
oil. Another cause of faults in the hydraulic pump should be replaced as an assembly. They are
is an excessive pressure in the system due to a available as a repair kit.
faulty relief valve.

10-25
HYDRAULIC SYSTEM

Suggestions for Disassembly

Do not use a hammer or similar tool in an attempt to loosen
or force out cover 1 and mounting flange 2. Use a soft head
mallet.
Do not remove the oil seal in mounting flange 2 if it does
not show any abnormality.

Inspection and Repair

1. Drive and driven gears

(1) Check the gear teeth for wear, chipping or other defects.
(2) Check the end faces of the gears for wear or damage.
(3) Check the journals and splines of the shafts for wear or
damage.
NOTE: Roughness or discoloring of gear surfaces is a sign
indicating that there may be defects in the bushings
and pump body. If this is the case, check the
bushings and pump body as well. 200344

2. Covers, body and bushings

Check these parts for wear or damage. There may be wear
(contact marks) found on the inner surfaces of the pump
body on the suction side where the gears come into contact
with them. Such wear is normal unless it is excessive.

Suggestions for Resassembly

(1) Before starting reassembly, visually inspect all parts to
be sure they are perfectly clean, and apply hydraulic oil 205876
to the sliding surfaces or the gear pump.
(2) Reassemble using new seals marked with ❋ in the
drawing on Page 10-25.
(3) Apply a thin coat of grease to the seals and seal lips.
(4) Take care that the four bushings are correctly paired.
(5) Insert the bushings into the pump body making sure
that the flats of the two bushings face each other
squarely. Do not insert them at an angle or forcefully.
(6) Install the mounting flange taking care not to damage
the seal lips with the splines on the drive gear.
(7) Tighten the bolts evenly.
(8) The fit of the pump gears in the reassembled pump may
be satisfactory if the pump shaft rotates smoothly and
lightly when turned by hand with pipe wrench.

10-26
 HYDRAULIC SYSTEM

Hydraulic Control Valve Assembly

Disassembly and Reassembly
Control valve assembly (2-valve type)
5
Main Component
1 Inlet valve section
2 TIlt valve section
1 3 Lift valve section
4 End cover
5 Main relief valve
6 Steering relief valve

Tightening torque:
19 N·m (2.0 kgf·m)

2 4
3
Tightening torque:
46 N·m (4.7 kgf·m)
209102

Suggestions for Disassembly and Reassembly

(1) Do not disassemble main relief valve 1 or steering
system relief valve 2 unless it is impossible to adjust
the setting of the valve.
(2) Tighten the tie bolts (securing the valve housings) as
evenly as possible to prevent distorsion of the housings.
Remember, a failure to follow this precaution will result
in sluggish movement of the spools.

10-27
HYDRAULIC SYSTEM

General Rules for Disassembly, Inspection and

Reassembly of Valve Sections
Suggestions for Disassembly
(1) The control valve assembly is made up of precision
parts. Handle it carefully.
(2) The valve body and spool are matched parts. If one of
them is faulty, replace both as an assembly.

Inspection and Repair

(1) Check the valve housings for cracks and sliding
surfaces for wear. Also, inspect the load check valve
seat for wear.
(2) Check the spools for damage, seizure or distortion.
Also, check for operating effort.

Neutral
71 (7.2)
N (kgf)
Operating effort of
spool
Full stroke
88 (9.0)
N (kgf)

Reassembly
To reassemble, follow the reverse of disassembly sequence,
and do the following steps:
(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Apply hydraulic oil to the spools when inserting them
into the valve body.
(3) Position the poppet (tilt lock valve) correctly.
(4) Apply grease to the O-rings when fitting them between
the valve housings to prevent them from twisting.
(5) Do not use any type of sealant.

10-28
 HYDRAULIC SYSTEM

Inlet Valve Section

Disassembly and Reassembly

6 1 2 3 6 4
❋ ❋
17 5 ❋18

Orifice

15, 16
12

13

14

11
❋
9 8 7 10
209103

1 Inlet valve housing 7 Housing 13 Set screw

2 Spool 8 Poppet 14 Lock nut
3 Spring 9 Spring 15 Plug
4 Plug 10 O-ring 16 O-ring
5 Plug 11 Plate 17 Check valve
6 O-ring 12 Socket head bolt 18 O-ring

NOTE NOTE
It is recommended that parts marked with ❋ in the Parts marked with in the drawing above are
drawing above be replaced with new parts available only as an assembly. They are not
whenever the inlet valve section is disassembled. supplied individually.
These parts are available as a repair kit.

Suggestions for Disassembly and Reassembly

(1) Do not attempt to disassemble the steering system relief
valve (consisting of parts 7 to 14) unless it is
appearently faulty. Turning the set screw 13 will
change the set pressure.
(2) Refer to page 10-28 for the general rules to be respected
during disassembly and reassembly of the inlet valve
section.
(3) Install the check valve 17 with their ends pointing in
the correct directions as shown in the drawing above.

10-29
HYDRAULIC SYSTEM

Tilt Valve Section

Disassembly and Reassembly

❋ 10 Tightening torque:
2 3 1
2.9 N·m (0.3 kgf·m)
17
15 16

7
9 ❋ 14
8

11
4
❋ ❋ ❋ ❋
11 12 13 13 12 209092A

Disassembly sequence
1 O-ring 7 O-ring 13 O-ring
2 Spring (load check) 8 Spring seat 14 Spool
3 Poppet (load check) 9 Spring 15 Spring
4 Socket head bolt 10 Screw 16 Tilt lock valve
5 Cap 11 Seal plate 17 Body
6 Cap screw 12 Wiper

NOTE
It is recommended that parts marked with ❋ in the
drawing above be replaced with new parts whenever
the tilt valve section is disassembled. These parts are
available as a repair kit.

Suggestions for Disassembly and Reassembly

(1) Refer to page 10-28 for the general rules to be respected
during disassembly and reassembly of the tilt valve
section.
(2) Install the tilt lock valve 16 with its ends pointing in
the correct directions as shown in the drawing above.

10-30
 HYDRAULIC SYSTEM

Lift Valve Section

Disassembly and Reassembly

❋
2 3 1 9
14
15

13
7

10
4
❋ ❋ ❋ ❋
10 11 12 12 11 209093A

Disassembly sequence
1 O-ring 7 Spring seat 13 Spool
2 Spring (load check) 8 Spring 14 Plug
3 Poppet (load check) 9 Screw 15 O-ring
4 Socket head bolt 10 Seal plate 16 Body
5 Cap 11 Wiper
6 Cap screw 12 O-ring

NOTE
It is recommended that parts marked with ❋ in the
drawing above be replaced with new parts whenever
the lift valve section is disassembled. These parts are
available as a repair kit.

Suggestions for Disassembly and Reassembly

(1) Refer to page 10-28 for the general rules to be respected
during disassembly and reassembly of the lift valve
section.

10-31
HYDRAULIC SYSTEM

Lift Cylinders
Simplex Mast Cylinder/Triplex Mast Second Cylinder

Disassembly

207769

Sequence
1 Bearing 4 Piston rod, Piston seal, Piston guide ring
2 Wiper ring, O-ring, Rod guide rings, Seal 5 Cylinder tube
3 Spacer

NOTE
Replacement parts marked with an asterisk (❋) are
included in the seal kit.

Suggestion for Disassembly

Removing piston rod

When withdrawing the piston rod from the shell, take care
not to damage the rings.

10-32
 HYDRAULIC SYSTEM

Reassembly

207765

Sequence
1 Piston rod Install 7 through 10 to 6, and screw into 5.
2 Piston guide ring 7 Seal
3 Piston seal 8 Rod guide rings
4 Spacer 9 O-ring
5 Cylinder tube 10 Wiper ring
6 Bearing

NOTE
Replacement parts marked with an asterisk (❋) are
included in the seal kit.

Suggestions for Reassembly

1. Use all parts in the seal kit to replace removed parts.
2. After installing seal kit parts, apply hydraulic oil before
installing to the cylinder tube or piston rod.
3. Tighten the bearing to the specified torque.

200 to 230 N·m

Bearing tightening torque
(20.4 to 23.5 kgf·m)

10-33
HYDRAULIC SYSTEM

Duplex Mast First Lift Cylinder and Triplex Mast First Lift Cylinder

Disassembly

207767A

Sequence
1 Cylinder head assembly 5 Snap ring, Washer, Check valve
2 O-rings, Wiper ring, Backup ring, Seal 6 Piston rod, Piston
Remove parts 3 through 6 as sub-assembly from part 9. 7 Washer
8 Screw
3 Piston guide ring
9 Cylinder tube
4 Piston seal

NOTE NOTE
Replacement parts marked with an asterisk (❋) are Screw 8 and washer 7 must not be removed during
included in the seal kit. a regular overhaul. The screw is for plugging the
oil hole through which oil is poured before storage.

10-34
 HYDRAULIC SYSTEM

Reassembly

11 10 9 13 8 12 1 7 5 6
❋ ❋ ❋ ❋ ❋ ❋ ❋

❋
14 2 3 4

000825B

Sequence
1 Piston rod, Piston 8 Cylinder head assembly
Install parts 2 through 6 to part 1. Install parts 9 through 13 to part 8.
2 Check valve 9 Seal
3 Washer 10 Backup ring
4 Snap ring 11 Wiper ring
5 Piston seal 12 Backup ring, O–ring
6 Piston guide ring 13 O–ring
7 Cylinder tube 14 Washer, Screw

NOTE
Replacement parts marked with an asterisk (❋) are
included in the seal kit.

Suggestions for Reassembly

1. Use all parts in the seal kit to replace removed parts.
2. After installing seal kit parts, apply hydraulic oil before
installing to the cylinder tube or piston rod.
3. Fill the space between the cylinder tube and piston rod
with the specified amount of hydraulic oil before
installing the cylinder head.

Amount of hydraulic oil 70 to 85 cc

4. Tighten the cylinder head to the specified torque.

Cylinder head tightening 300 to 350 N·m

torque (30.6 to 35.7 kgf·m)

10-35
HYDRAULIC SYSTEM

Duplex Mast Second Cylinders

Disassembly

207641A

Sequence
1 Retainer 6 Spacer
Remove parts 3 through 10 as sub-assembly from part 7 Snap ring
11. 8 Sleeve
9 Piston rod
2 Wiper ring, Rod seal, O-ring, Backup ring
10 Bleed screw, Seal washer
3 Backup ring, Piston seal, Wear ring
11 Cylinder tube
4 Piston
5 Pull-in wire

NOTE
Replacement parts marked with an asterisk (❋) are
included in the seal kit.

10-36
 HYDRAULIC SYSTEM

Reassembly

8 7 5 6 10 4 3 2 1
❋ ❋ ❋ ❋

9 11

000825C

Sequence
1 Retainer 6 Pull-in wire
2 Wiper ring, Rod seal 7 Piston
3 Backup ring, O–ring 8 Backup ring, Piston seal, Wear ring
4 Piston rod 9 Sleeve, Snap ring
Install parts 1, 2, 3, 5, 6, 7 to Part 4. 10 Cylinder tube
11 Seal washer, Bleed screw
5 Spacer

NOTE
Replacement parts marked with an asterisk (❋) are
included in the seal kit.

Suggestions for Reassembly

1. Use all parts in the seal kit to replace removed 6. Tighten the bleed screws 11 to the specified torque.
parts. Unit: N·m (kgf·m)
2. Apply hydraulic oil to the bore surface of tube and
4.5 to 5.0
also to the wiper ring, rod seal, and wear ring. Bleed screw tightening torque
(0.46 to 0.51)
3. When holding the tube in a vise, take care not to
distort the tube.
4. Fill the cavity between the shell and rod with 25 to
30 cm3 of hydralic oil before installing the retainer.
5. Tighten the retainer 1 to the specified torque.
Unit: N·m (kgf·m)

170 to 240
Retainer tightening torque
(17.3 to 24.5)

10-37
HYDRAULIC SYSTEM

Tilt Cylinders
Disassembly

209104

Sequence
1 Tilt socket, Spherical bearing, Grease nipple 4 Piston rod assembly
2 Guide bushing, Dust seal, Packing, O-ring, 5 Cylinder tube, Bushing, Set screw
Piston seal, Set screw
3 Spacer

NOTE
(1) The parts marked with an asterisk (❋) are repair
kit parts.
(2) Do not remove the tilt socket bearing and cylinder
tube bushing unless they are defective.

10-38
 HYDRAULIC SYSTEM

Suggestions for Disassembly

Removing bushing
Wrap the cylinder with a rag, and clamp it in a vise. Using
a wrench, remove the guide bushing from the cylinder.

Inspection after disassembly

1. Cylinder tube
(1) Check the bore wall for wear, grooving, scratch marks
and rusting.
(2) Check the welds for cracks.

2. Piston rod
(1) Check for deflection as shown.
(2) Check for surface flaws such as grooving, scratch
marks, rusting and wear. The rod must be replaced if
its threads show a sign of stripping or any other
damage.

3. Packings and rings

Replace all parts contained in the seal kit, once disturbed.
200319

10-39
HYDRAULIC SYSTEM

Reassembly

12 11 8 7 6 10 5 3 2
❋ ❋ ❋ 11
4

14 13 ❋ Loctite 243 Loctite 638

9
209094A

Sequence
1 Piston rod assembly 8 Dust seal
2 Piston seal 9 O-ring
3 Spacer 10 Set screw
4 Bushing 11 Tilt socket
5 Cylinder tube 12 Spherical bushing
6 Guide bushing 13 Bolt, Washer, Nut
7 Packing 14 Grease nipple

NOTE
The parts marked with an asterisk (❋) are repair kit
parts.

Suggestions for Disassembly

1. Use all parts in the seal kit to replace removed 6. Mount the tilt cylinder to the vehhicle body and
parts. check the front-and -back tilting angle of the mast,
2. After installing seal kit parts, apply hydraulic oil then tighten the bolt and nut on the tilt socket 11 to
before installing to the cylinder tube or piston rod. the specified torque.

3. Apply Loctite 243 to the threads of the cylinder

Tightening torque of bolt 127 to 152 N·m
tube before screwing in the guide bushing.
and nut on the tilt socket (13 to 15 kgf·m)
4. When reinstalling the piston rod assembly 1 and
cylinder tube 5, apply Loctite 638 to their threads.
5. Tighten the guide bushing 6 to the specified torque.

Guide bushing tightening 200 ± 25 N·m

torque (20.4 ± 2.5 kgf·m)

10-40
 HYDRAULIC SYSTEM

Flow Regulator Valve

Disassembly

Sequence
1 Lock nut
2 Plug, O-ring
3 Spring, Shims
4 Piston, Pin, Washer, Spring, Valve
5 Valve body

203559

Start by:
Measure and note the dimension labeled A in the drawing
ready for use during reassembly.

Inspection after disassembly

1. Check spring fatigue.
2. Check seat and sliding faces of valve and piston.
3. Check the sliding surfaces of the piston and valve body
for damage.
208623

NOTE
Replace the flow regulator valve an assembly if any
part is defective.

Reassembly
(1) Follow the disassembly procedure in reverse, making
sure that dimension A is the same as it was before
disassembly.
(2) When repair work is complete, measure the fork
lowering speed. If it is out of specification, adjust it by
turning plug 2. For the on-machine adjustment
method, see page 10-46.

10-41
HYDRAULIC SYSTEM

Down Safety Valve

Disassembly

Sequence
1 Spring pin
2 Valve
3 Spring
4 Connector
5 O-ring

208624

Suggestions for Disassembly

Push out spring pin 1. All parts except O-ring 5 can then
be removed.

Inspection after disassembly

Inspect all parts. If any part is abnormal, replace the
assembly with a new one.

Reassembly
Follow the disassembly procedure in reverse.

10-42
 HYDRAULIC SYSTEM

Inspection and Adjustment

Hydraulic Tank (Hydraulic Oil) Hydraulic Pump

An SAE 10W hydraulic oil should be used as the It is normal and essential to subject the hydraulic pump
standard oil for the hydraulic system of the truck. to a full performance test when it has been
After oil replacement, fully extend and retract the tilt reassembled. The method for use when a full
and lift cylinders several times, then check the oil level performance test cannot be performed is as follows:
using the level gauge. (1) Connect between the pump’s delivery side and the
The oil level should be at or below the H mark on the hydraulic control valve a pressure gauge of about
level gauge when the mast is completely lowered. 25,000 kPa (250 kgf/cm2).

Oil should also be checked regularly for contamination. (2) Place the control valve in its neutral position, then
If oil is found contaminated, locate the cause and run the pump at low speed for approximately 10
source of contamination. If necessary, flush the entire minutes. Check for abnormal pump noise.
hydraulic system. (3) Adjust the main relief valve’s set pressure to
approximately 1,000 kPa (10 kgf/cm2), then move
the tilt control lever in the tilt back direction such
that the main relief valve opens. Keep the pump
operating for approximately five minutes with the
main relief valve in this condition. Check for
abnormalities in the pump’s surface temperature
and operating sound.
(4) Increase the main relief valve’s set pressure to
18,100 kPa (185 kgf/cm2) in steps of 2,000 kPa (20
kgf/cm2), running the pump for approximately five
minutes at each pressure level.
(5) Monitor changes in the pump’s surface
temperature, operating sound, and oil temperature
while performing step (4). If you hear any
abnormal noise, take either of the following steps
as you deem appropriate.
(a) Place the pump in a no-load condition to lower
its temperature, then continue with test
operation.
(b) Disassemble the pump and inspect its internal
parts.
(6) Check whether the fork movement is normal.

10-43
HYDRAULIC SYSTEM

Control Valve

(1) External oil leaks

(a) Oil leaks from O-rings between housings
(b) Oil leaks from wiper and O-ring located between valve
housing and spool
(c) Oil leaks from bolt sections

(2) Oil leaks

Since it is difficult to measure the amount of oil leaks from
the dismounted control valve, inspect oil leaks with the
control valve connected to the cylinder by following steps
(a) through (c).
Measured amounts of oil leakage refer to the total amount
of oil leakage from the lift spool, tilt spool, tilt lock valve
and load check valves.
[Oil temperature for oil leak measurement: Approx. 50°C]
(a) Place rated cargo load on the forks and lift to a height
of approximately 1 m. Tilt the masts approximately 3 207764
or 4 degrees forward from the upright position, then
turn the key switch off.
(b) Remove the oil return hose, and collect the drained oil.

Standard volume of oil

60 cc
drained in 15 minutes

(c) When the gravitational-pull lowering distance and

forward tilt distance are large, check the amount of oil
leakage from each cylinder even if the amount of oil
drained in 15 minutes is less than 60 cc. (Measured
amount of oil leakage is a standard value; it does not
denote the allowable limit.)

209105

10-44
 HYDRAULIC SYSTEM

Adjustment of Main Relief Valve

(1) Make an adjustment setup by connecting a pressure
gauge at some point in the oil line between the
hydraulic pump and the hydraulic control valve’s inlet
section. The pressure gauge must be capable of
measuring a relief valve set pressure of 13.7 MPa (140
kgf/cm2). Also, the connector and adapters (whether
purchased or made) must be sufficiently strong. To tilt cylinder
rod end
Alternatively, the set pressure of the relief valve can be
measured by installing a pressure gauge on the line
connecting the A1 port in the tilt valve section of the
control valve and the tilt cylinders.
The drawing on the right shows a pressure gauge
installed on the line connecting the tilt cylinder rod
Pressure measuring
ends and the control valve A1 port. connector
(2) Place the key switch in the ON position to start the (91268 - 06200)
209106
pump. Allow the oil temperature to increase to
approximately 50°C.
(3) Move the tilt control lever in the tilt back direction to
tilt the mast fully backward. The pump speed will
increase during this operation, and the pressure will Adjusting screw
increase accordingly. When the mast reaches the
Main pressure
position in which it is fully tilted backward, the main relief valve Lock nut
relief valve will open to allow oil to escape to the tank,
thereby protecting the hydraulic system. Thus, the
pressure will increase no further and the needle of the
pressure gauge will settle in one position. The gauge
indication at this time is the relief valve’s set pressure.
The specified set pressure is shown below.
Unit: MPa (kgf/cm2)

+0.5 +5
Main relief valve set pressure 13.7 0 (140 0 )

(4) If the set pressure is out of specification, loosen the

lock nut and adjust the set pressure by turning the screw
while observing the pressure gauge indication.
(5) When the set pressure is correct, hold the adjusting
screw in position and tighten the lock nut.
209102A
(6) Check again that the set pressure is correct.

NOTE
Do not keep the relief valve open continuously for
longer than necessary. Doing so could overload the
motor and battery.

10-45
HYDRAULIC SYSTEM

Adjustment of Steering System Relief

Valve Main pressure
relief valve
The steering system relief valve is incorporated in the inlet
valve section of the control valve.
Although the relief pressure of the valve can be measured
LS pressure
with the control valve mounted on the truck, the adjustment measurement port
of the relief pressure can only be performed after the
control valve is removed from the truck.
Measure and adjust the relief pressure setting as follows:
(1) Remove the 1/8G socket head plug from the LS
pressure measurement port on the side of the inlet valve
section. Connect a pressure gauge to the port. Steering system
relief valve 209107
(2) Use a pressure gauge capable of measuring a pressure
of 8.8 MPa (90 kgf/cm2), i.e., the set pressure of the
steering system relief valve.
(3) Run the pump and allow the oil temperature to increase
to approximately 50°C.
Turn the steering wheel to either full-lock position to
relief oil pressure in the steering system. When the
relief valve opens, the pressure will stop increasing and
the needle of the pressure gauge will settle in one 1
position. The gauge indication at this time is the relief
valve’s set pressure. The specified set pressure is
shown below.
Unit: MPa (kgf/cm2)
3 2 209108
Steering system relief valve +0.5 +5
8.8 0 (90 0 )
set pressure
1 Steering system relief valve
2 Adjusting screw
3 Lock nut
(4) Adjust the set pressure by loosening the lock nut 3 and
turning the adjusting screw 2 in or out. Turning in the
screw increases the set pressure; turning out the screw
decreases the set pressure. Tighten the lock nut after
adjustment.
Flow regulator valve

Adjustment of Flow Regulator Valve

Measure the lowering speed of the fork without a load. If
the lowering speed is out of specification, loosen the lock
Lock nut
nut and adjust the lowering speed by altering the extent to
which the plug is screwed in. Turn the plug clockwise to
increase the lowering speed and counterclockwise to reduce
it. When the adjustment is complete, tighten the lock nut.
The specified lowering speed is 0.5 m per second. Plug
209109

10-46
 HYDRAULIC SYSTEM

Lift Cylinders and Tilt Cylinders

(1) Adjustment of mast tilt angle

(a) Park the truck on a level ground.
(b) Tilt the mast backward to the maximum position.
(c) Measure the backward tilt angles of both right and left
tilt cylinders.
(d) To adjust, loosen the socket tightening bolt, turn the tilt
cylinder rod and adjust the cylinder stroke until the
right and left tilt cylinders are tilted at the same angle.
103420

NOTE
The forward tilt angle of the masts is automatically set
when the backward tilt angle is adjusted.

Forward tilt – Backward tilt

5° – 7°
(STD)

(2) Adjustment of right and left lift cylinder strokes

(a) Slowly raise the inner mast, and observe how the
piston rods, left and right, stop at the moment the inner
mast reaches its maximum height.
(b) If the top of the inner mast jolts at that moment, make a
shim adjustment. Abnormal condition can be detected
by a little time lag in stopping between the piston rods,
left and right, and shaking of the rod with a longer
cylinder stroke. 204698

Adjustment method
(1) Raise the inner mast, and place wood blocks under the
inner mast. Lower the mast until the inner mast contact
the wood blocks. Use blocks strong enough to support
the mast.

202983

10-47
HYDRAULIC SYSTEM

(2) Loosen the stopper bolt located at the upper part of the
lift cylinder that stopped first. Lower the piston rod,
and insert a shim at the upper piston rod end.
NOTE
When lowering the piston rod, operate the lift lever to
lower the mast and release oil from the cylinder.

(3) Raise the piston rod, then tighten the lift cylinder
stopper bolt. Remove the wood blocks from under the 200365
inner mast.
(4) Lower the inner mast gently, and check to see if the
piston rods move smoothly until the inner mast reach
the lowest position.

Test

(1) Lift cylinder drift test

(a) Set the mast upright with rated cargo load, raise the
mast approximately 1 to 1.5 m, then turn the key
switch off.
(b) Draw a reference line on a mast, and measure the
distance of fork lowering after 15 minutes.
Unit: mm/15 min

Lift cylinder drift

50 max.
(with load) 208334A

(2) Tilt cylinder drift test

(a) Set the mast upright with rated cargo load, raise the
forks approximately 500 mm, then turn the key switch
off.
(b) Measure the amount of the tilt cylinder extension after
15 minutes.
Unit: mm/15 min

Tilt cylinder drift

22 max.
(with load)
103420M

Inspection of Piping
(1) Check the piping for oil leaks.
(2) Check the rubber hoses for damage, twisting and
sagging.

10-48
 HYDRAULIC SYSTEM

Adjustment of Tilt Lever Switch and Lift Stroke Sensor

Turn right or left

Tilt control lever
to adjust stroke
4 sensor position.

Lever Lift control lever

Very small clearance

5

Lock nuts
Roller

Guide
Move up or down to
adjust tilt lever switch
position.

Hydraulic control
valve

209110

1 Tilt rod 4 Stroke sensor

2 Switch 5 Spring pin
3 Lift rod

Adjustment of Tilt Lever Switch Adjustment of Lift Lever Stroke Sensor

With the tilt control valve spool in the neutral position, With the lift control valve spool in the neutral position,
the position of the tilt lever switch is correctly adjusted the position of the lift lever sensor is correctly adjusted
if the roller of the switch 2 extends completely to the if there is a very small clearance between the lever of
right and seat in the recess of the guide, as shown in the the stroke sensor 4 and the spring pin 5, as shown in the
drawing above. If the roller is not seated in the recess, drawing above. If necessary, adjust the sensor position
move the switch 2 up or down to bring the roller into by turning the sensor to the right or left.
the recess. Tighten the lock nut after adjustment.

10-49
HYDRAULIC SYSTEM

Troubleshooting

Not enough oil in hydraulic tank Add oil.

Oil viscosity improper Change oil.
Overload Check working conditions and,
if over-loaded, urge the operator
Hydraulic tank to stay within the load limit.
heats excessively Local overheating of oil line due Repair or replace.
to a large restriction to flow
Relief valve adjustment improper Readjust pressure setting.
Hydraulic pump worn Replace.
Hydraulic Outlet pipe or tube flattened, or Repair or replace.
tank restriction to flow

Shortage of oil due to a natural Add oil.

loss
Cylinders move
too slow Oil leakage due to damaged oil Repair or replace.
line seals
Oil viscosity too higher Change oil.

Hydraulic pump defective Check pump and piping; repair

or replace.
Oil leakage from oil line Check oil for level and condition;
Cylinders move add or change oil.
too slow
Abnormal oil temperature rise Check control valve spools for
misalignment; repair or replace.
Hydraulic
pump Hydraulic pump internally leaking Replace pump.

Poor pumping Check oil level; add oil if

Noisy necessary.
Cavitation 1) Check suction pipe for any
flat portion or loose connection;
retighten or replace.
2) Check shaft oil seal for air-
tightness; replace pump.
3) Check pump body for any
outside interference; repair.

10-50
 HYDRAULIC SYSTEM

Pump case, drive Pressure too high Replace pump. (Check to see if
gear or pump port relief valve setting is correct.)
flange damaged Distortion or damage due to Replace pump.
external strain or stress
1) Check to see if return line
is restricted.
2) Check to see if pipe
Hydraulic connection have been
pump externally strained or stressed.

Oil leakage past oil seal Replace seal.

Oil leakage past sliding surfaces Replace whole pump assembly.
Oil leakage from of drive shaft
pump
Pump securing bolts loose Retighten.
Excessive internal leakage Replace internal parts.

Relief valve setting too low Readjust.

Main poppet valve in relief valve Wash poppet valve and check
stuck open to see if it moves smoothly;
or replace whole relief valve
Slow or no motion assembly.
of lift and tilt
cylinders O-ring on relief valve body Replace O-ring.
damaged
Control lever installed loose, Readjust.
resulting in not enough spool stroke
Faulty tilt switch or lift stroke sensor Replace or adjust.
Control
valve Load drops or
mast tilts forward Control valve internally leaking Replace a leaky block
with control lever assembly.
in neutral
Oil leakage from spool ring and Replace O-ring; check spool
spool O-ring for flaws and if any, repair or
Oil leakage replace a leaky block assembly.
Loose plugs Retighten.
O-ring damaged Replace.

10-51
HYDRAULIC SYSTEM

Not enough oil in hydraulic tank Add oil.

Relief valve out of order,
because of:
Will not lift nor
tilt • Seized main valve Replace.
• Broken valve spring Replace.
Gear pump defective Replace.

Relief valve out of order,

because of:
• Too low a relief valve setting Readjust.
• Defective plunger or poppet seat Replace.
Will not lift rated
load • Fatigued spring Replace.
• Damaged O-ring in valve case Replace O-ring.
Hydraulic pump defective Replace.
Piston seals worn or damaged Replace.

Lift and tilt

Pump speed too low Check motor control system.
cylinders Lifting speed is Repair or replace if necessary.
too low
Pump not delivering enough oil Repair or replace.

Sleeve seized in flow regulator Repair.

valve
Lowering speed is
Dirt in flow regulator valve Clean, repair system and
too low
replace defective hose.
Abnormal resistance to flow due Replace hose.
to flattened hose or local clogging

Piston rod distorted Repair or replace.

Cylinder vibrates Air in oil circuit Bleed air by operating cylinder
when actuated through full stroke.
Not enough oil in hydraulic tank Add oil.

Control valve spool internally Replace.

leaking
Sliding (inside) surface of cylinder Repair or replace cylinder
tube slightly grooved assembly.
Load will not hold
Sliding (inside) surface of cylinder Replace.
tube badly grooved
Piston seals broken or distorted Replace seal kit.
Oil leakage from piping Repair or replace.

10-52
 HYDRAULIC SYSTEM

Control valve spool internally Replace.

leaking
Mast tilts forward Foreign particles lodged between Replace packing.
(drift) packing and mating surface
Piston seals damaged Replace.
Cylinder distorted Repair or replace.

Lift and tilt

Lift cylinders drop Sliding surface of cylinder tube Repair or replace.
cylinders
or tilt cylinders tilt badly grooved or rusted at one
forward (drift) at a point
certain point of
stroke Cylinder tube distorted Replace.

Foreign particles lodged between Replace.

sealing members such as oil seals
and dust seals
Bushing leaks Oil seals and dust seals defective Replace.
O-rings damaged Replace.
Cylinder distorted Repair or replace.

10-53
HYDRAULIC SYSTEM

Service Data
A: Standard value
Unit: mm
Truck Model
EP10KRT EP12KRT EP15KRT
Item
Lift speed (rated load) (simplex mast)
A 290 270 260
mm/sec
Lift speed (no load)
A 480 480 480
mm/sec
Lowering speed (rated load) (simplex mast)
A 500 500 500
mm/sec
Forward tilt angle (standard model with simplex mast) A 5°
Backward tilt angle (standard model with simplex mast) A 7°
Lift cylinder drift (retraction of piston rod)
A 50, maximum
(rated load for 15 minutes) [Oil temperature: 45°C]
Tilt cylinder drift (extension of piston rod)
A 22, maximum
(rated load for 15 minutes) [Oil temperature: 45°C]
+ 0.5 +5
Main relief valve setting MPa (kgf/cm ) A 2
13.7 0 (140 0 )
Hydraulic pump (gear pump) displacement cm /rev A
3
20.0/rev

Spool operating Neutral N (kgf) A 71 (7.2)

effort Full stroke N (kgf) A 88 (9.0)
Control
valve M8 N·m (kgf·m) A 19 (2.0)
Tightening torque
for tie bolts M10 N·m (kgf·m) A 46 (4.7)
Steering system relief valve setting + 0.5 +5
A 8.8 0 (90 0 )
MPa (kgf/cm ) 2

Flow rate (no load)

Flow regulator valve A 55
liter/min

10-54
 HYDRAULIC SYSTEM

A: Standard value
Unit: mm

Truck Model
EP10KRT EP12KRT EP15KRT
Item

[Piston]
A 45
Inside diameter of cylinder tube 1

Diameter of piston rod 2 A 35

Bearing thread diameter 3 A M48 − 1.5

Lift cylinders (Simplex mast) (Triplex mast second)

Outside diameter of bearing 4 A 55

Tightening torque for bearing 4

A 200 to 230 (20 to 23)
N·m (kgf·m)

207765

10-55
HYDRAULIC SYSTEM

A: Standard value
Unit: mm

Truck Model
EP10KRT EP12KRT EP15KRT
Item

[Piston]
A 70
Inside diameter of cylinder tube 1

Diameter of piston rod 2 A 55

Outside diameter of cyliner head 3 A 85

Lift cylinders (Duplex and triplex mast first cylinder)

Tightening torque for cylinder head 3

A 300 to 350 (30.6 to 35.7)
N·m (kgf·m)

Tightening torque for plug 4

A 3.92 (0.4)
N·m (kgf·m)

2 3 1

000825B

10-56
 HYDRAULIC SYSTEM

A: Standard value
Unit: mm

Truck Model
EP10KRT EP12KRT EP15KRT
Item

[Piston]
A 45
Inside diameter of cylinder tube 1

Diameter of piston rod 2 A 32

Outside diameter of retainer 3 A 60

Lift cylinders (Duplex mast second cylinders)

Tightening torque for retainer 3

A 170 to 240 (17.3 to 24.5)
N·m (kgf·m)

Bleed screw tightening torque 4

A 4.5 to 5.0 (0.46 to 0.51)
N·m (kgf·m)

4 1 2

000825C

10-57
HYDRAULIC SYSTEM

A: Standard value
Unit: mm

Truck Model
EP10KRT EP12KRT EP15KRT
Item

Inside diameter of cylinder tube 1 A 63

Diameter of piston rod 2 A 25

Inside diameter of tilt socket bushing 3 A 35

Inside diameter of cylinder tube head bushing 4 A 32

Outside diameter of bushing 5 A 84

Guide bushing 6 A 200 ± 25 (20.4 ± 2.5)

Tightening torque
N·m (kgf·m)
Tilt socket bolt 7 A 127 to 152 (13 to 15)

3
4

7 5 1 2

209094B

10-58
 MAST AND FORKS

Mast Systems .......................................................................................... 11 – 1

Structure ................................................................................................... 11 – 2
Simplex Mast (2G15A) .............................................................................. 11 – 2
Duplex Mast (2H15A) ............................................................................... 11 – 3
Triplex Mast (2J15A) ................................................................................. 11 – 4
Operation of Duplex Mast ......................................................................... 11 – 5
Operation of Triplex Mast .......................................................................... 11 – 5
Removal and Installation ...................................................................... 11 – 6
Mast and Lift Bracket Assembly ................................................................ 11 – 6
Simplex Mast ......................................................................................... 11 – 6
Duplex Mast and Triplex Mast ............................................................... 11 – 9
Disassembly and Reassembly ............................................................ 11 – 12
Disassembly ............................................................................................. 11 – 12
Simplex Mast ......................................................................................... 11 – 12
Duplex Mast .......................................................................................... 11 – 14
Triplex Mast ........................................................................................... 11 – 16
Inspection after Disassembly (All Mast Models) ........................................ 11 – 19
1. Mast .................................................................................................. 11 – 19
2. Lift bracket ........................................................................................ 11 – 19
3. Lift chains, chain wheels and chain wheel supports .......................... 11 – 19
4. Mast strips ......................................................................................... 11 – 19
11
Reassembly .............................................................................................. 11 – 20
1. Installing lift bracket rollers (all mast models) .................................... 11 – 20
2. Installing mast rollers (all mast models) ............................................ 11 – 22
3. Measuring and adjusting clearance G2 between mast strip
and inside mast (all mast models) ..................................................... 11 – 23
4. Installing first lift cylinder (duplex mast and triplex mast models) ...... 11 – 23
5. Installing second lift cylinders (all mast models) ................................ 11 – 23
6. Installing chain on lift bracket ............................................................ 11 – 24
7. Installing hydraulic lines .................................................................... 11 – 25
Inspection and Adjustment ................................................................. 11 – 27
Forks ........................................................................................................ 11 – 27
Chain Tension Inspection and Adjstment .................................................. 11 – 28
Simplex Mast ......................................................................................... 11 – 28
Duplex Mast and Triplex Mast ............................................................... 11 – 29
Chain, Chain Wheel Support and Chain Wheel ......................................... 11 – 29
Checking Clearance between Lift Bracket Roller and Inner Mast ............. 11 – 30
Checking Clearance for Mast Roller ......................................................... 11 – 32
Removing Mast Rollers ............................................................................. 11 – 34
Simplex Mast ......................................................................................... 11 – 34
Duplex Mast .......................................................................................... 11 – 35
Triplex Mast ........................................................................................... 11 – 36
Mast Strip Clearance, Inspection and Adjustment ..................................... 11 – 38
Tilt Angle Adjustment ................................................................................ 11 – 38
Lift Cylinder Stroke Inspection and Adjustment ......................................... 11 – 39
Troubleshooting ...................................................................................... 11 – 40
Service Data ............................................................................................ 11 – 41
 MAST AND FORK

Mast Systems

This manual applies to the following vehicle models (names).

Mast Types
Simplex Mast Duplex Mast Triplex Mast
Model

EP10KRT

EP12KRT 2G15A 2H15A 2J15A

EP15KRT

NOTE : Maximum fork lift height (33 : 3300 mm)

Mast Type Code Stamping Position Mast Types

Code Mast Type

G Simplex mast

H Duplex mast

J Triplex mast

209115

Explanation of Mast Type Code

Example: 2 G 15 A 33

Maximum fork lift height (33 : 3300 mm)

Revision code (A ➞ B ➞ C ··· Z)
Representative model (not allowable load)
Mast type
Major revision record (2 to 9)

11-1
MAST AND FORK

Structure

Simplex Mast (2G15A)

Lift bracket
Inner mast Outer mast Inner mast

Side roller

Detail of A Detail of D

Inner mast Inner mast

Detail F
Detail E Outer mast
Lift bracket
Lift bracket

Detail of B Detail of E and F

Inner mast
Lift bracket Outer mast
Mast strip
207760

Unit: mm

S M L LL Shims

Main roller O.D. 99 100 101 102 Detail of C Detail of G

209116

1 Inner mast A: Main roller E: Main roller

2 Outer mast B: Main roller F: Main roller
3 Lift chain C: Main roller G: Mast strip
4 Lift bracket D: Side roller
5 Mast-support bearing cap

The simplex mast features two lift cylinders placed Mast strips are fitted to the top end of outer mast.
behind the mast columns, right and left, to provide These strips are for backing up the inner mast when the
maximum visibility. mast is tilted backward.

11-2
 MAST AND FORK

Duplex Mast (2H15A)

207608

1 Lift chain 5 Outer mast 8 Lift bracket main roller

2 First lift cylinder 6 Lift bracket 9 Mast upper main roller
3 Second lift cylinder 7 Chain wheel 10 Mast lower main roller
4 Inner mast

The duplex mast provides a free lift amount until the When the first lift cylinder rod extends fully, the second
top of lift bracket reaches the mast height. lift cylinders raise the assembly consisting of the lift
The mast assembly consists of the inner mast, outer bracket, first lift cylinder and inner mast.
mast, lift bracket, first lift cylinder and second lift The shoulder sections of the mast main rollers contact
cylinders. the mast rails. The rollers are installed perpendicular to
The first lift cylinder raises the lift bracket, while the the sliding surfaces.
second cylinders operate the inner mast and lift bracket. The main rollers used in the duplex mast models are the
For lifting operation, oil is first sent to the first lift same as those used in the simplex mast models.
cylinder which raises the forks until the cylinder rod
reaches its stroke end.

11-3
MAST AND FORK

Triplex Mast (2J15A)

207609 207610

1 First lift chain 5 Inner mast 9 Second chain wheel

2 First lift cylinder 6 Middle mast 10 Lift bracket main roller
3 Second lift chain 7 Outer mast 11 Mast upper main roller
4 Second lift cylinder 8 Lift bracket 12 Mast lower main roller

The triplex mast provides a free lift amount until the For lifting operation, oil is first sent to the first lift
top of lift bracket reaches the mast height. cylinder which raises the forks until the cylinder rod
The mast assembly consists of the inner mast, middle reaches its stroke end.
mast, outer mast, lift bracket, first lift cylinder and When the first lift cylinder rod extends fully, the second
second lift cylinders. lift cylinders raise the assembly consisting of the lift
The first lift cylinder raises the lift bracket, while the bracket, first lift cylinder, inner mast and middle mast.
second cylinder operates the three-stage telescopic The shoulder sections of the mast main rollers contact
mechanism and lift bracket. Two pairs of lift chains are the mast rails. The rollers are installed perpendicular to
installed. The cylinders and lift chains are designed for the sliding surfaces.
smooth and effective operation. The main rollers used in the triplex mast models are the
same as those used in the simplex mast models.

11-4
 MAST AND FORK

Operation of Duplex Mast

203598

Operation of Triplex Mast

203600

11-5
MAST AND FORK

Removal and Installation

Mast and Lift Bracket Assembly

Simplex Mast
Removal

209117

Sequence
1 Nuts 5 Low-pressure hose
2 Forks, Lift bracket assembly 6 High-pressure hose for lift cylinders
3 Tilt socket pins 7 Mast support bearing cap
4 Tilt cylinders 8 Mast support bushing

Suggestions
1. Removing lift bracket assembly 2
(1) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts
from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away, from the lift bracket and fork assembly.

207084

11-6
 MAST AND FORK

2. Separating mast and tilt cylinders 4

(1) Hitch a sling to the mast. Using two eye-bolts and a
sling as shown and support the mast with a hoist.

CAUTION
Be sure to use a hoist having a capacity enough
to support the mast assembly.

205740

(2) Place wood blocks under the tilt cylinder mounting

section and remove the tilt socket pins, and separate the
mast from the tilt cylinders.
(3) Turn the key to ON and pull back the tilt lever to retract
the tilt cylinder rods.

3. Disconnecting low-pressure hose for lift cylinder

Disconnect the hoses at the hydraulic tank.

4. Disconnecting high-pressure hoses for lift cylinder

Place the mast in the bottom position, disconnect the
hoses at the flow regulator valve. 209185

5. Removing mast support bearing caps 7

(1) Mark the bearing caps to ensure the correct
reassembling before removing them.
(2) Remove the cap bolts and lift off the mast assembly.
Lay it down flat on a level floor.

NOTE
Lay the mast assembly on a floor large enough to
disassemble the parts.
207087

11-7
MAST AND FORK

Installation
To install, follow the removal sequence in reverse, and
service as follows.
1. Procedure for mounting mast support bushings and
caps.
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings and caps, making sure
that the sides with larger chamfered area face toward
the center of the vehicle.
(3) Be sure to tighten the support tightening bolts securely.
203712

2. Adjust the chain tensions.

(Refer to the Inspection and Adjustment section.)
Tighten the nuts to the specified torque.

Tightening Torque

57 N·m
Upper nut ➁
(5.8 kgf·m)

98 N·m
Double nut (lower) ➀
(10.0 kgf·m)

102709
3. Air bleeding of lift cylinders
Turn the key to ON. Raise and lower the lift bracket
over full stroke several times to bleed the cylinder.

4. After proper operation is confirmed, check the oil level.

11-8
 MAST AND FORK

Mast and Lift Bracket Assembly

The following describes the procedures for removing and reinstalling the mast assemblies of Duplex Mast and
Triplex Mast. Note that the Triplex Mast is used as an example.

Duplex Mast and Triplex Mast

Removal

209118

Sequence
1 Nuts 5 Low-pressure hose
2 Fork, Lift bracket assembly 6 High-pressure hose for lift cylinders
3 Tilt socket pin 7 Mast support cap
4 Tilt cylinder 8 Mast support bushing

Suggestions
1. Removing lift bracket assembly 2
(1) Lower lift bracket assembly 2, and place wood
blocks under the assembly. Tilt the mast forward,
lower the inner mast to the bottom, then remove
nuts 1 from the anchor bolts of the first lift chains.

207613

11-9
MAST AND FORK

(2) Position the mast upright. Raise the inner mast until
main rollers 9 of the lift bracket become free. Then,
slowly move the vehicle in reverse to separate from lift
bracket 2.

207762A

2. Separating mast and tilt cylinders 4

(1) Lower the inner mast. Hitch a sling to the upper cross-
member of the outer mast. For sling attachment, install
eye-bolts in the holes on the right and left sides. Use a
hoist and lift.

CAUTION
Be sure to use a hoist having a capacity enough
to support the mast assembly.
207614

(2) Place wood blocks under the tilt cylinder mounting

sections, and remove pins.
(3) Turn the key to ON, and pull back the tilt lever to
retract the tilt cylinder rods.

3. Disconnecting low-pressure hose for lift cylinder

Disconnect the hoses at the hydraulic tank.

4. Disconnecting high-pressure hoses for lift cylinder

Place the mast in the fully lowered position, then
disconnect the hoses at the flow regulator valve.
209185

5. Removing mast support caps 7

(1) Mark caps 7 to ensure the caps are reinstalled in
original positions during reassembly.
(2) Remove cap mounting bolts. Dismount the mast
assembly from vehicle in the suspended condition.
With the lift bracket side facing up, place the mast
assembly horizontally on wooden blocks on the level
ground.
207615A

11-10
 MAST AND FORK

Installation
To install, follow the removal sequence in reverse, and
service as follows.
1. Procedure for installing mast support bushings and
caps.
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings and caps making sure that
the sides with larger chamfered area face toward the
center of the vehicle.
(3) Be sure to tighten the support tightening bolts securely.
203712

2. Adjust the chain tensions.

(Refer to the Inspection and Adjustment section.)
Tighten the nuts to the specified torque.

Tightening Torque

57 N·m
Upper nut ➁
(5.8 kgf·m)

98 N·m
Double nut (lower) ➀
(10.0 kgf·m)

102709
3. Bleeding lift cylinders.
Whenever the oil supply line is disconnected from the
lift cylinders and reconnected, raise and lower the lift
bracket a few times to bleed all air out of the piping
and the areas below pistons in the cylinders.
In the duplex mast, only the second lift cylinders are
provided with air bleeding screws.
The first lift cylinder does not require air bleeding
since it is an internal drain type cylinder.

4. After proper operation is confirmed, check the oil level.

11-11
MAST AND FORK

Disassembly and Reassembly

Simplex Mast
Disassembly

209119

Sequence
1 Nuts 10 Snap ring, Chain wheel
2 Forks, Lift bracket 11 Cylinder clamps, Seats, Shims, Cushion,
3 Backrest Collar, Bolts
4 Main roller, Shims 12 Bolt, Shims
5 Main roller, Shims 13 Mast strip, Shims
6 Side roller, Brackets, Shims 14 Main roller, Shims
7 Hose guard 15 Main roller, Shims
8 Lift hose (high pressure), 16 Inner mast
Rubber hose, T-joint, Down safety valve 17 Lift cylinders
9 Low-pressure hose 18 Outer mast

11-12
 MAST AND FORK

Start by:
Before disassembling the mast and fork assembly, measure
and record all clearances between each lift bracket and
roller and between each mast and roller. Recorded
measurements will be helpful when replacing rollers or
selecting shims to adjust clearances. Refer to pages 11-30
through 11-33.

Suggestions
1. Removing mast strips and main rollers
Remove bolts 11, 12 to free lift cylinder 17. Displace the
tops of the two lift cylinders from inner mast 16. Slide
inner mast 16 toward the bottom of outer mast 18, and
remove main rollers 14, 15 and mast strips 13.

2. Inner mast removal

After removing the main rollers, hitch a sling to the inner
mast crossmember and slide the inner mast to the upper side
of the outer mast to clear the outer mast roller shafts. Hitch
a sling to the inner mast again and remove it from the outer
mast.

207089

11-13
MAST AND FORK

Duplex Mast
Disassembly

209120

Sequence
1 High-pressure hose for first cylinder, Clamp 11 Mast strip, Shims
2 Bolt, Washer, Shims 12 Main roller, Shims
3 First lift cylinder 13 Stopper cushion, Cushion plate, Shims, Bolt,
4 Chain guard Washer
5 Chain wheel support, Pin 14 Inner mast
6 Chain wheel, Snap ring 15 Second lift cylinder
7 Hose guard, Bolt, Washer 16 Cylinder bracket
8 High-pressure hose 17 O-ring, Plug
9 Cushion, Collar, Shims, Bolt, Washer, Clamp 18 Mast cap, Bolt, Washer
10 Bolt, Washer, Shims 19 Outer mast, Grease nipple

NOTE
The lift bracket disassembly procedure is the same as
for the simplex mast.

11-14
 MAST AND FORK

Start by:
With the lift bracket side facing up, place the mast
horizontally on wood blocks. Place a wood block as a
wedge to prevent the inner and middle masts from sliding.
Before disassembling the mast and fork assembly, measure
and record all clearances between each lift bracket and
roller and between each mast and roller. Recorded
measurements will be helpful when replacing rollers or
selecting shims to adjust clearances. Refer to pages 11-30
through 11-33.
207619

Suggestions
1. Removing first lift cylinder 3
(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on first lift cylinder 3, and gently remove
the cylinder.
Use two slings. Wind or tie slings securely to prevent
slipping.

2. Removing main rollers 12 and mast strips 11

(1) Remove clamp bolts from the second lift cylinders.
(2) Remove bolts from the upper rod sections of the second
lift cylinders, and place the cylinders on the outer mast.
(3) Check the number of shims and the shim thickness at
the rod end sections.
(4) Move the inner mast down, then remove main rollers
12, mast strips and shims 11.

207620

3. Removing inner mast 14

Using slings, lift and remove inner mast 14, steering it
clear of the roller shaft sections of outer mast 19.

207621

11-15
MAST AND FORK

Triplex Mast
Disassembly

19

20

19

209121

Sequence
1 Hose for first lift cylinder, Clamp, Bolt, Washer 17 Snap ring, Hose pulley, Shaft, Snap ring,
2 Bolt, Washer Chain wheel
3 Shims 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose, clamp, Bolt, Washer
5 Chain guard 20 Connector
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, Shims, Bracket
8 Nut (chain for second lift cylinder) 23 Bolt, Washer, Shims
9 Mast strip, Shims 24 Second lift cylinder
10 Main roller, Shims 25 Mast strip, Shims
11 Main roller, Shims 26 Main roller, Shims
12 Inner mast 27 Main roller, Shims
13 Nuts 28 Middle mast
14 Lift chain (for second lift cylinder) 29 Cap, Bolt, Washer
15 Chain guard, Bolt, Washer 30 Outer mast, Grease nipple
16 Snap ring, Chain wheel

11-16
 MAST AND FORK

NOTE
The lift bracket disassembly procedure is the same as
for the duplex mast.

Start by:
With the lift bracket side facing up, place the mast
horizontally on wood blocks. Place a wood block as a
wedge to prevent the inner and middle masts from sliding.
Before disassembling the mast and fork assembly, measure
and record all clearances between each lift bracket and
roller and between each mast and roller. Recorded
measurements will be helpful when replacing rollers or
selecting shims to adjust clearances. Refer to pages 11-30
through 11-33.

Suggestions
1. Removing first lift cylinder 4
(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on lift cylinder 4, and gently remove the
cylinder.
Use two slings. Wind or tie slings securely to prevent
207624
slipping.

2. Removing inner mast and main rollers

Lower inner mast 12 until the main rollers can be
removed. Remove main rollers 10, 11 and mast strips
9.

207625

3. Removing inner mast

Using slings, lift and remove the inner mast 12,
steering it clear of the roller shaft sections of the
middle mast.

207626

11-17
MAST AND FORK

4. Removing main rollers 26, 27 from middle mast 28

and outer mast 30
Remove the bolts that are holding second lift cylinders
24. Place the cylinder rod ends on the outer mast.
Lower middle mast 28 until main rollers 26, 27 can be
removed. Then, remove the main rollers.

207627

11-18
 MAST AND FORKS

Inspection after Disassembly (All Mast Models)

1. Mast
(1) Check each roller for wear, binding or other defects.
(2) Check each roller on rolling surface for pitting or other
defects.
(3) Check the mast member and the welded joints of cross-
members, shafts and supports for cracks.
(4) Check the mast support bushings for wear or other
defects. 207090

2. Lift bracket
(1) Check the main rollers and side rollers for smooth
rotation. Inspect each roller for wear an cracks.
(2) Check the welded portions of the bracket for cracks.
(3) Check the finger bar for bend or distortion.

A: Standard value
Unit: mm
Distortion of finger bar A 5, maximum 207091

3. Lift chains, chain wheels and chain wheel supports

(1) Measure the length of each chain to make sure that two
chains are equal in length. Also check the chains for
wear, indication of breakage, link binding and twist.
(2) Check each chain anchor bolt for cracks or defects on
thread.
(3) Check each chain wheel support and chain wheel for
crack or wear. Check that the wheels rotate smoothly.

A: Standard value B: Repair or service limit

Unit: mm

A 317.5
Length of lift chain
(per 20 links)
B 326.5

4. Mast strips
Check the mast strips for damage, wear or distortion.

11-19
MAST AND FORKS

Reassembly
Follow the disassembly sequence in reverse. Be careful with the following key point.
Suggestions for Reassembly
1. Installing lift bracket rollers (all mast models)

F 2 F 3
1 2 1 1

No shim Shim (a)

Thrust
plate
6
G

1 mm thick shim Shim (b)

5 Upper roller Middle roller
6
G 4
F 6
1 Shim (d)
3
Shim (c)
1 G1

4
Lower roller Side roller
209122

Sequence
1 Lift bracket F: Clearance between roller circumference and
2 Lift bracket upper roller inner mast thrust surface (back-to-front play)
3 Lift bracket middle roller G: Clearance between roller side surface and
4 Lift bracket lower roller inner mast thrust surface (right-to-left play)
5 Side roller G1: Clearance between side roller circumference
6 Inner mast and inner mast side roller thrust surface

The lift bracket has three main roller bearings at one • Clearance G is used for determining the correct
side and a side roller at both sides as shown. amount of shims at the bearing seat.
Clearances F and G must be maintained between these Shims (a), (b) and (c) are used in the rollers for
rollers and thrust surface of the inner mast. clearance adjustment.
• Clearance F is used for determining the proper size
of the rollers. Clearance G 0.1 to 0.5 mm

Clearance F 1.0 mm or less • Clearance G1 is used for determining the correct

amount of shims (shim (d)) under the seat of roller
bracket.

Clearance G1 0.1 to 0.5 mm

11-20
 MAST AND FORKS

(1) Selecting main rollers of the appropriate diameter Roller size

• As for upper roller 2, middle roller 3 and lower roller 4, Unit: mm
take measurements of clearance F. Based on the value, S 99
select rollers of the appropriate size from the table.
M 100
• Rollers should rotate smoothly when installed. Diameter of main roller
L 101
LL 102

(2) Measuring and adjusting right-to-left clearance G at lift

bracket middle and lower rollers Lift bracket middle roller
Inner mast
Note: It is not necessary to adjust the lift bracket upper Lift bracket
roller with shims.
• Measurement Roller
stopper
Move lift bracket to the top of the inner mast and press Shim (a)
the bracket to either the leftmost or rightmost position.
Take measurements of clearance G between the side Shim (b)
surface of roller and inner mast.
• Adjusting middle roller
G
If clearance G is excessive, a proper amount of shims 0.1 to 0.5 mm
should be added at location (a) and the same amount of
shims should be added at location (b), theoretically.
However, shims for location (a) are available in two 209123
sizes: 0.5 mm and 1.0 mm. Shims for location (b) are
available in only one size: 1.0 mm.
When a 0.5 mm thick shim is added at location (a), it is
not necessary to add the shim at location (b) [the 0.5 mm Lift bracket lower roller
Inner mast
difference can be ignored]. Lift bracket
G
Note: At the time of shipment from the factory, a 1 mm 0.1 to 0.5 mm
thick shim is installed at location (a) and a 2 mm
thick shim is installed at location (b). Shim (c)
• Adjusting lower roller
If clearance G is too large, an appropriate amount of
shims should be added at location (c).
Note: At the time of shipment from the factory, a 1 mm
thick shim is installed at location (c).
209138

(3) Installation
To install main rollers on shafts, use a driving tool. Be
careful not to accidentally strike the outer roller surface
with the driving tool.
The side of the roller with larger chamfered area must
face toward the outside.
Make sure the rollers rotate smoothly when installed.

202263

11-21
MAST AND FORKS

(4) Measuring and adjusting clearance G1 between side

Lift bracket
roller and inner mast Inner mast
• Measurement Shim (d)
Move side roller to the upper end of the inner mast and
press the lift bracket to either the leftmost or rightmost Roller Side roller
position. Take measurement of clearance G1 between mounting bolt
the roller circumference and inner mast.
• Adjustment
If measurement of clearance G1 is excessive, add a G1
proper amount of shims (d) under the seat of the roller Lift bracket
bracket.
Note: At the time of shipment from the factory, a 1mm 209124
thick shim is installed at location (d).

2. Installing mast rollers (all mast models)

Triplex mast
Mast rollers are identical in shape and size with lift bracket Middle mast
lower rollers. Outer mast
Therefore:
G G
• Clearance F should be 1.0 mm or less. F

• Clearance G should be 0.1 to 0.5 mm. Inner mast

For mast rollers, both clearances F and G should meet
specifications. Shim (e) Shim (f)

(1) Select appropriate roller size. Refer to “Selecting main

rollers of the appropriate diameter” on page 11-21.
(2) Adjust to proper clearance. Refer to “Measuring and Middle mast Outer mast roller
adjusting right-to-left clearance G at lift bracket middle upper roller
209139
and lower rollers” on page 11-21.
Outer mast roller and middle mast upper roller
(3) The installation procedure and precautions are same as
those for the lift bracket main rollers.
Note: At the time of shipment from the factory, shim of Triplex mast
the following thickness are installed at the Middle mast Outer mast
indicated locations. Inner mast
Lift bracket G G G
F
Location Shim thickness
Shim (g) Shim (i)
(e) 1 mm Shim
(h)
(f) 2 mm

(g) 1 mm

(h) 2 mm

(i) 2 mm
209125

Lift bracket, middle mast lower roller and

inner mast roller

11-22
 MAST AND FORKS

3. Measuring and adjusting clearance G2 between

Triplex mast
mast strip and inside mast (all mast models) Middle mast
Shim (j)
• Measurement
G2
Make a clearance between the mast strip and inside mast. G2
Insert a thickness gage to measure the clearance G2.
Inner mast Mast strip
Clearance G2 0.1 to 0.5 mm

• Adjustment
If clearance G2 is excessive, add a proper amount of Outer mast
shims under the mast strip (shim (j)). Usually, a 1.0 mm
thick shim is already used. 209139A

4. Installing first lift cylinder (duplex mast and triplex

mast models)
Adjust with shims so that the first lift cylinder becomes
First lift cylinder
vertical when it is installed and placed at the lowered
Shim
position.
• Usually, a 2.0 mm thick shim is already used.
• The thickness of each shims is 1.0 mm.
Mounting bolt
• Forward inclination is undesirable. It should be rather
inclined rearward.
Tighten the mounting bolt after completing necessary
209126
adjustment using shims.

5. Installing second lift cylinders (all mast models)

(1) Install cylinder bracket on lift cylinder.
(2) Install lift cylinder between outer mast and inner mast. Inner mast

(3) Attach the upper part of the cylinder rod to the Shim A
appropriate position on the inner mast. If shim A was
removed during disassembly, install shim A. Usually,
shim A is not used. Cylinder bracket
(4) With the cylinder rod fully retracted and in a
perpendicular position, take measurement of clearance
H. 209127

Clearance H 1.6 mm or less

If the clearance H is excessive, add shim B to adjust.

Usually, shim B is not used.
1.6 mm thick shims are available as service parts.
If the clearance is larger than 3.2 mm, use a 3.2 mm
thick seat rather than using two pieces of 1.6 mm thick
shim.
(5) After reassembly, perform an operation test to check if
207003A
the stroke of the left and right cylinders is the same. For
check procedure, refer to page 11-39.
11-23
MAST AND FORKS

6. Installing chain on lift bracket

1 Simplex mast 2 Duplex and triplex mast

Link plate
(with stamped mark)
B
Sprit pin

Chain anchor kit

Center plate
(without mark) A
Joint

To chain anchor
209128

(1) Simplex mast only (Drawing 1 )

Be careful not to install the center plate in the position
for link plate.
(2) Other models (Drawing 2 )
Tighten nuts to torques specified in the table.
Tightening torque
(3) Install chain on the lift bracket first. Then place the Unit: N·m (kgf·m)
chain around the chain wheel and install on the cylinder
Mast Duplex, Triplex Triplex
side. Adjust the tension of the chain with the anchor Model (lift bracket (inner mast
bolt nuts at the cylinder side. side) side)
Item
For adjustment procedure, refer to page 11-28.
Nut A 98 (10) 98 (10)
(4) If either of the anchor bolts at both ends of the chain
assembly is damaged, anchor kits are available as Nut B 57 (5.8) –
service parts.

11-24
 MAST AND FORKS

7. Installing hydraulic lines

General precautions • Tighten to the specified torque whenever shown.
• Use care not to let abrasive dust or dirt to enter the • Fittings C and E (fittings with straight threads
hydraulic system. and O-ring seals) shown in the drawing has each
• Apply a thin coat of oil to O-rings before backup washer and locknut. Use the procedure
installation. shown below to install it properly.

(1) Hydraulic lines in simplex mast models (2) Hydraulic lines in duplex mast models

Hydraulic tank E
Elbow

Flow regulator
A
valve
A

C D A
B Cylinder

Down A
B
safety valve
C Second cylinder
C B
B
Tightening torques Down
safety valve C
Part to be tightened Tightening torque
Nut A 58.8 ± 5.9 N·m (6 ± 0.6 kgf·m) D
E
Nut B 49 ± 4.9 N·m (5 ± 0.5 kgf·m) Down
safety valve
Nut C 39.2 N·m (4.0 kgf·m)
First cylinder
Nut D 58.8 ± 5.9 N·m (6 ± 0.6 kgf·m)
Nut E 58.8 N·m (6.0 kgf·m)
209129

Installation of a fitting with straight threads and

O-ring seal
1. Turn lock nut 3 to move it as close to fitting body 2 as
possible. Place washer 4 and O-ring seal 5 against the
lock nut.
2. Screw the fitting into the mating component until
washer 4 comes in contact with the surface of the
component and O-ring seal 5 seats correctly. Elbow body assembly
3. Turn the fitting in the tightening direction as necessary 1 End of fitting body 4 Backup washer
to bring it to a position appropriate for conneciton. (connects to tube) 5 O-ring seal
2 Fitting body 6 End of fitting that
4. Tighten lock nut 3 to the specified torque. 3 Locknut goes into other part.
11-25
MAST AND FORKS

(3) Hydraulic lines in triplex mast models

st
r ma
Oute

Hydraulic tank

Down safety valve

Second cylinder First cylinder

Flow regulator
valve
A A

C
B

Second cylinder
Tightening torques

Part to be tightened Tightening torque

B
Nut A 58.8 ± 5.9 N·m (6 ± 0.6 kgf·m) C

Nut B 49 ± 4.9 N·m (5 ± 0.5 kgf·m)

Nut C 39.2 N·m (4.0 kgf·m)
Nut D 58.8 ± 5.9 N·m (6 ± 0.6 kgf·m) Down safety valve
Plug E 58.8 N·m (6.0 kgf·m)
209130

NOTE

When installing fittings C and E , follow the

procedure under “Installation of a fitting with straight
threads and O-ring seal” on page 11-25.

11-26
 MAST AND FORKS

Inspection and Adjustment

The inspection and adjustment procedures described in the

following pages can be carried out without performing
major service work. These can be used for checking
abnormalities or testing operation after disassembly and
reassembly.

Forks
1. Carefully inspect the forks for cracks. Special attention
should be given to the heel section A, all weld areas and
mounting brackets B.
Forks with cracks should be removed from service. B
Magnetic particle inspection is generally preferred due A
to its sensitivity and the ease of interpreting the results.

101628

2. Check the difference in height of one fork tip to the

other when mounted on the fork carrier. A difference in
fork tip height can result in uneven support of the load
and cause problems when loaded.
The maximum allowable difference in fork tip
elevation C is 5 mm for pallet forks.
Replace one or both forks when the difference in fork
tip height exceeds the maximum allowable difference. 101629

3. Check the fork blade thickness D. The fork should be

removed from service if the thickness is reduced to less
than the allowable thickness.
Fork blade length may also be reduced by wear,
especially on tapered forks and platens. Remove the
forks from service when the blade length is no longer
adequate for the load size.
A: Standard value B: Repair or service limit 101630
Unit: mm
Truck Models
EP10KRT EP12KRT EP15KRT
Item

A 35
Fork
thickness
B 33

11-27
MAST AND FORKS

Chain Tension Inspection and Adjustment

Simplex Mast

WARNING
Turn the key to the OFF position before making
the inspection or adjustment of lift chains, anchor
bolts and nuts. Place blocks below the forks
when they are lifted.

1. Inspection of chain tension

(1) Place the mast vertical on a level ground, then lower the
forks to the ground. Check that the lift cylinders are
fully retracted. 102709

(2) Raise the forks approx. 100 mm from the ground.

(3) Turn the key to the OFF position. Tightening torque
(4) Place blocks approx. 90 mm high below the forks. Unit: N·m (kgf·m)

(5) Push the chains at the middle point between the chain Upper nut ➁ 57 (5.8)
wheel and chains fixed end on the lift bracket. Check
the right and left chains for even tightness. Double nut lower ➀ 98 (10.0)

2. Adjustment of right and left chain balance

(1) Remove the blocks below the forks.
Turn the key to ON position.
(2) Lower the forks to the ground and tilt forward until the
tips come in contact with the ground.
The chains are now slack to facilitate the adjustment.
(3) Turn the key to the OFF position.
(4) Loosen double nut (lower) ➀, then upper nut ➁.
(5) Turn double nut (upper) ➂ to adjust the chain tension.
102708
(6) Turn the key to the ON position, and place the mast
vertical again.
(7) Repeat (2) through (5) of procedure 1, to check the
chain tension.

3. Tightening of nuts after adjustment

(1) Hold the anchor bolt at two flats with a wrench so as
not to twist the chain, then tighten the upper nut ➁ to
the specified torque.
(2) Hold the double nut (upper) ➂ with a wrench and
tighten double nut (lower) ➀ to the specified torque.
4. When the lift cylinders are fully extended or retracted,
check the protrusion of each lift bracket main roller to 209131
be 40 % of the roller diameter or less.

11-28
 MAST AND FORKS

Duplex Mast and Triplex Mast

Duplex mast Triplex mast

207633 207635

The inspection and adjustment procedures are completely

the same as those for simplex mast models. Follow the
procedures in the previous page to perform inspection or
adjustment as necessary.

Chain, Chain Wheel Support and Chain

Wheel
(1) Check the right and left chains for uneven length, wear,
adhesion or torsion.
Lift the forks high enough to put their full weight on
the carriage and chains.
Check to be sure the lift chains have equal tension.
(2) Check the chain anchor bolt for cracks or damaged
thread.
(3) Check the chain wheel support and the chain wheel for
cracks, wear or adhesion. 201768

(4) Replace chain or chain anchor bolt. If new parts are

installed, refer to “Installing chain on lift bracket” on A: Standard value B: Repair or service limit
page 11-24. A 317.5
Chain extension
NOTE mm/20 links
B 326.5
To lubricate lift chains, molybdenum disulfide oil
(spray type) is recommended since it is easy to use and
provides long lubrication.
Super chain guard oil: 9101M-00150

11-29
MAST AND FORKS

Checking Clearance between Lift Bracket

Roller and Inner Mast
NOTE
Lift bracket middle roller
• The check procedure for the lift bracket is the same Inner mast
for the Simplex mast, Duplex mast and Triplex F a
Lift bracket
mast.

For the lift bracket to move smoothly, it is essential that the

following three clearances are within the specified ranges.
(1) Clearance F between main roller circumference and
mast thrust surface a
b
Clearance F 1.0 mm or less
G
Thrust plate
(2) Clearance G between roller side surface and mast thrust
209123A
surface b
Clearance G 0.1 to 0.5 mm Typical example of relation between main roller
and inner mast
(3) Clearance G1 between side roller circumference and *: Only the middle roller requires clearance to the
mast side roller thrust surface thrust plate.
Clearance G1 0.1 to 0.5 mm
Lift bracket
Necessity of clearance check for lift bracket rollers Inner mast

Clearance
Clearance F Clearance G
Roller Roller Side roller
mounting bolt
**
Upper roller required not required

Middle roller required required

G1
Lift bracket
Lower roller required required

**: Not necessary to adjust.

209124A

1. Back-to-front clearance check on lift bracket main Relation between side roller and inner mast
rollers
(1) Raise the forks a little from the ground.
(2) Insert a bar between the upper part of lift bracket and
the inner mast, and push the inner mast to one side.
Using feeler gauges, measure the clearance F between
the main roller and inner mast on the opposite side.
(3) If clearance F is out of specification, use oversize
rollers. Remove lift bracket from mast and replace
rollers with proper sized rollers. For roller replacement
procedure, refer to “Installing lift bracket rollers” on
pages 11-20 and 11-21. 207095

11-30
 MAST AND FORKS

2. Right-to-left clearance check on lift bracket main

rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its contact
point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and push the
lift bracket to one side with a bar. Set the indicator to
zero.
(4) Insert a bar between the inner mast and lift bracket on
203818
the indicator side, and push the lift bracket to the
opposite side.
(5) Read the indicator.
This reading is the clearance G between middle roller
and thrust plate ➁.
(6) If clearance G is out of specification, it is necessary to
add shims to the seat of the roller to adjust to correct
clearance. Remove lift bracket from mast and adjust
the thickness of the shims for the rollers. For
adjustment and installation procedures, refer to
“Installing lift bracket rollers” on page 11-21. 207821

➀ Upper roller ➁ Thrust plate

(7) Lower the lift bracket sligtly from the top, then check
clearance G1 between the side roller.
If clearance G1 is out of specification, it is necessary to
add shims to the seat of the roller bracket to adjust to
correct clearance. Remove lift bracket from mast and
adjust the shim thickness. For adjustment and
installation procedures, refer to “Installing lift bracket
rollers” on page 11-22.

206687A

(8) With the lift bracket at the top, check clearance G.

If clearance G is out of specification, it is necessary to
add shims to the seat of the roller to adjust to correct
clearance. Remove lift bracket from mast and adjust
the shim thickness for the rollers. For adjustment and
installation procedures, refer to “Installing lift bracket
rollers” on page 11-21.

207822

11-31
MAST AND FORKS

Checking Clearance for Mast Roller

NOTE
• Adjust mast clearances at the locations indicated
below.
1. Simplex mast and Duplex mast: Main rollers
between the outer mast and inner mast
2. Triplex mast: Main rollers between the outer
mast and middle mast, and main rollers between
the middle mast and inner mast.
• For the structure, refer to “Installing mast rollers”
on page 11-22.

Regardless of the mast model, the inner mast slides up and

Triplex
down guided by the outer mast. Mast rollers are provided
for smooth movement and clearances at two locations must Middle mast Outer mast
be within specified ranges. Inner mast
Lift bracket G G G
(1) Clearance F between main roller circumference and b
mast thrust surface a
Unit: mm
Clearance F 1.0 or less

F
(2) Clearance G between roller side surface and mast
a
channel surface b
Unit: mm
Clearance G 0.1 to 0.5

209125A

Check clearances between the mast rollers and mast Lift bracket, midle mast lower roller and inner mast
channels as follows: roller

1. Back-to-front clearance inspection on mast main

rollers
(1) Tilt the mast fully backward. F

(2) Using feeler gauges, measure the clearance F between

the inner mast lower roller and outer mast.
(3) If the clearance F is out of the specification, use
oversize rollers.
For mast roller replacement and installation procedures,
refer to “Installing mast rollers” on page 11-22. For
207099
mast roller removal procedure, refer to “Removing mast
rollers” on page 11-34.

11-32
 MAST AND FORKS

2. Right-to-left clearance inspection on inner mast

main rollers
(1) Raise the mast to the rop.
(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the inner mast.
(3) Go over to the opposite side of the mast, and push the
inner mast against the outer mast. Set the indicator to
zero.
(4) Insert a bar between the outer and inner masts on the
204886
indicator side, and push the inner mast to the opposite
side.
(5) Read the indicator.
This reading is the clearance G between inner mast
roller and outer mast.
(6) If the clearance G is out of specification, it is necessary
to add shims to the seat of the roller to adjust to correct
clearance. For adjustment and installation procedures,
refer to “Installing mast rollers” on page 11-22. For
mast roller removal procedure, refer to “Removing mast
rollers” on page 11-34.

3. Right-to-left clearance check on outer mast main

rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the outer mast with its contact
point rested on the inner mast.
(3) Go over to the opposite side of the mast, and push the
outer mast against the inner mast with a bar. Set the
indicator to zero.
(4) Insert a bar between the outer and inner mast, and push
204889
the inner mast to the opposite side.
(5) Read the indicator.
This reading is the clearance G between outer mast
roller and inner mast.
(6) If the clearance G is out of specification, adjust it by
shims.
It is necessary to add or remove shims at the seat of the
roller to adjust to correct clearance. For adjustment and
installation procedures, refer to “Installing mast rollers”
on page 11-22. For mast roller removal procedure,
refer to “Removing mast rollers” on page 11-34.

11-33
MAST AND FORKS

Removing mast rollers (simplex mast)

1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 11-6.

2. Position the inner mast lower than the outer mast by

following operations.
(1) Raise the front end of the truck, and support that end
with block or the like.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull out the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
the cross-member of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in 202961
advance because they are apt to come off under this
condition.

11-34
 MAST AND FORKS

Removing mast rollers (duplex mast)

1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 11-6.

2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a crane. Wind the sling securely to prevent from
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.

NOTE
The rest of the procedure is the same as the procedure
for simplex mast models.

209132

3. Position the inner mast lower than the outer mast by

following operations.
(1) Raise the front end of the truck, and support that end
with block or the like.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull out the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
202961
the cross-member of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition.

11-35
MAST AND FORKS

Removing mast rollers (triplex mast)

1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 11-6.

2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a hoist. Wind the sling securely to prevent from
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.

207616

3. Position the inner mast lower than the middle mast by

following operations.
(1) Raise the front end of the truck, and support that end
with block or the like.
(2) Hitch slings to the upper cross-member of the inner
mast, and suspend with a hoist.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
207639
and place them in front of the inner mast.
(5) Lower the inner mast until main rollers can be removed.
(6) Place wood blocks under the inner mast for support.
(7) Now the main rollers can be removed from the inner
and middle masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition.

NOTE
In this condition, second lift cylinders cannot be
dismounted.

11-36
 MAST AND FORKS

4. Position the middle mast lower than the outer mast by

following operations.
(1) Lift the inner mast to the height of the middle mast,
then place wood blocks for support.
(2) Hitch slings to both middle mast and inner mast, and
suspend with a hoist.
(3) Remove set bolts from the upper sections of the middle
mast lift cylinders, then lift the middle mast and inner
mast.
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the lower outer
mast section. Tilt the cylinders by moving the top
sections towards the center of the vehicle, then secure
the cylinders to the cross-member of the outer mast
with a rope.
(5) Lower the middle mast and inner mast until main
rollers can be removed.
(6) Place wood blocks under the middle mast and inner
mast for support.
(7) Now the main rollers can be removed from the middle
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition.

207640

11-37
MAST AND FORKS

Mast Strip Clearance, Inspection and

Adjustment
1. Check the clearance G2 with the clearance between the
outer mast rollers and inner mast set to zero (0) in
maximum lift position.
Unit: mm
Clearance G2 0.1 to 0.5

2. If clearance G2 is out of specification, remove upper

mast roller (refer to “Removing mast rollers”). Remove
mast strip and adjust the clearance. For adjustment 200391

procedure, refer to “Measuring and adjusting clearance

G2 between mast strip and inner mast” on page 11-23.
3. After adjusting the all clearance, move the mast and lift
bracket slowly to make sure that they move smoothly
through their full stroke.

Tilt Angle Adjustment

1. Park the truck on a level ground.
2. Tilt the mast fully backward and stop the pump motor.
3. Measure the backward tilt angle of the mast at both
sides.
4. To adjust the tilt angle, loosen the bolt of tilt cylinder
socket, and adjust the rod length by turning the rod.
Adjust cylinder so that there is no difference in stroke
tilt angle between the cylinders, right and left.
103420
NOTE
It is not necessary to adjust the forward tilt angle if the Standard tilt angles
backward tilt angle is properly adjusted.
Forward Backward
Mast Models

5. After adjusting the tilt angle, tighten the socket bolts to Lifting height:
5° 7°
the specified torque. up to 5.0 m
Simplex
mast
Lifting height:
Tightening torque for tilt 127 to 152 N·m 5° 5°
higher than 5.5 m
cylinder socket bolt (13 to 15 kgf·m)
Duplex mast 5° 5°

Lifting height:
5° 5°
up to 5490 mm
Triplex
mast
Lifting height:
5° 3°
higher than 5990 mm

11-38
 MAST AND FORKS

Lift Cylinder Stroke Inspection and

Adjustment
1. Slowly raise the inner mast, and observe how the piston
rods, left and right, stop at the moment the inner mast
reaches its maximum height.
2. If the top of the inner mast jolts at that moment, make a
shim adjustment. Abnormal condition can be detected
by a little time lag in stopping between the piston rods,
left and right, and shaking of the rod with a longer
cylinder stroke.

204698

3. Adjusting method
(1) Raise the inner mast, place blocks under the right and
left sides of the inner mast, and lower the mast until its
rests on the blocks.

202983

(2) Remove the set bolt at the top of lift cylinder which
showed earlier stroke end, retract the piston rod, and Shim
insert shims at the top of piston rod end. Inner mast
(3) Extend the piston rod, and tighten the cylinder set bolt.
Remove the blocks from under the inner mast.
(4) Slowly lower the inner mast to the bottom to ensure the
piston rods move smoothly and that the left and right Cylinder bracket
lift cylinders come to the end of stroke simultaneously.

209127A

11-39
MAST AND FORKS

Troubleshooting

Faulty rotation of side roller Supply grease or replace.

Lift bracket, inner mast and Faulty rotation of main rollers Replace rollers.
middle mast do not rise or
lower smoothly. Improper mast strip clearance Adjust with shims.
Improper main roller or side roller Adjust front-to-back and
clearance right-to-left clearances.

Uneven chain tension between right and Adjust chain tension.

Lift bracket or inner mast is out left chains
of square. Excessive side roller clearance Adjust by adding shims.
Uneven adjustment of shims between Adjust by removing shims.
right and left lift cylinders
(at maximum lift position)

Faulty rotation of side roller Supply grease or replace rollers.

Abnormal noise is generated by
Faulty rotation of main rollers Supply grease or replace rollers.
mast.
Defective hose pulley bearing Replace.
(Triplex mast system only)

Damaged gaskets in lift cylinders Replace.

Lift cylinder drift is too large.
Internal leak of control valve Replace.

Entire mast shake Worn mast support bushings and caps Retighten, or replace bushings
and caps.

Mast is deformed in shape. Uneven cargo load or overload Replace assembly.

Bent finger bars Repair or replace.

Uneven fork end heights Bent forks Replace.
Mast deformation due to uneven cargo Repair or replace.
load

Low oil temperature Increase oil temperature by

raising and lowering lift
Second lift cylinders move when bracket.
first lift cylinder operates No clearance for lift bracket roller Readjust rollers.
(only in Duplex and Triplex surfaces
masts).
Clogged pipes Inspect and clean hydraulic line.
Improper air bleeding Bleed hydraulic system.

Lift bracket is spongy when it

Air is present under each lift cylinder Bleed hydraulic system.
stops in lifting operation.
piston due to poor air bleeding.

11-40
 MAST AND FORKS

A: Standard value B: Repair or service limit

Service Data
Unit: mm
Truck Model
EP10KRT EP12KRT EP15KRT
Item
Gap of fork end heights A 5
A 35
Fork thickness
B 33
Forks and A 317.5
chains Chain extension (mm/20 links)
B 326.5
Tightening torque of lock nut (double nut) for
chain anchor bolts (both ends) A 98 (10)
N·m (kgf·m)
LL A 102

Main roller external diameter L A 101

Rollers (for lift bracket and mast) M A 100
S A 99
Side roller external diameter A 42.0
Width of outer mast B A 610
Simplex mast and
Width of inner mast B2 A 518
duplex mast
Width of lift bracket C A 408
Dimensions
(for Width of outer mast B A 610
reference)
Width of middle mast B1 A 518
Triplex mast
Width of inner mast B2 A 426
Width of lift bracket C A 318
Clearance between main roller
A 1.0 or less
circumference and mast thrust surface F
Clearance between main roller side
Mast A 0.1 to 0.5
surface and mast thrust surface G
Clearance between inside mast and mast
A 0.1 to 0.5
strip G2
Clearance between upper, middle and
Clearance lower roller circumference and inner A 1.0 or less
mast thrust surface F
Clearance between middle roller side
Lift A 0.1 to 0.5
surface and inner mast thrust plate G
bracket
Clearance between lower roller side
A 0.1 to 0.5
surface and inner mast thrust surface G
Clearance between side roller
A 0.1 to 0.5
circumference and inner mast surface G1
Finger bar bend A 5 or less

11-41
MAST AND FORKS

Truck Model
EP10KRT EP12KRT EP15KRT
Item

208742

11-42
 SERVICE DATA

Inspection Standards ............................................................................12 – 1

Planned Replacement of Parts ...........................................................12 – 3
Recommended Lubricants and Brake Fluid ...................................12 – 4
Tightening Torque for Standard Bolts and Nuts ............................12 – 5
Special Tool Table ..................................................................................12 – 7

12
 SERVICE DATA

Inspection Standards

Daily inspection and maintenance can be broadly divided into the following two categories:
(1) Daily pre-start inspection
This inspection is performed by the operator before start of day’s operation. The relevant Operation & Maintenance
Manual describes the procedure of this inspection in detail.
(2) Planned maintenance
This preventive maintenance of the truck includes checking of various components, change of hydraulic oil and
lubricant and other all kinds of service that are vital to maintain the performance of the truck at a level equivalent to
that having been available when it was new for the longest possible period. The planned maintenance should be
carried out regularly according to the schedule determined based on service hour intervals or calender day intervals.

1. Pre-start inspection

Maintenance problems found the day before

Oil or battery electrolyte leaks
Tires
Wheel nuts
Walk around Lights
inspection Backrest extension
Forks
Tilt cylinder socket bolts
Overhead guard
Brake fluid level
Battery electrolyte level
With seat tipped/
remove floor plate Fastener of battery cover
Hydraulic oil level
Seat adjustment and seat belt
Brake pedal
In seat check Parking brake lever
Horn
Lights
Vehicle monitoring system
Turn key to
I (ON) position Battery discharge indicator
Steering wheel
Lift chains
Operating check Mast
Driving check (drive motor, steering, service brakes)

12-1
SERVICE DATA

2. Planned maintenance

: Lubricate
: Check or clean
: Change or adjust
Periodic Maintenance
Interval

Every 100 hours or

Every 200 hours or

Every 50 hours or

Every 1200 hours

Every 2400 hours

Inspection/Maintenance Location and Item Remarks

or 2 years
2 months

or 1 year
2 weeks
weekly
Check – Worn brushes and Indicator comes on when brush has
Motor commutator worn down to limit.
Check – Looseness of connector
Battery Check – Specific gravity of battery
Contactors Check – Contact looseness, damage
and wear
Check – Gear box oil level Gear oil: GL-4 or GL-5
Should be changed 150 hours and 500
hours after start of use of new truck or
Change – Gear box oil
Rear axle after it has been overhauled.
No change is required thereafter.
Lubricate – Steering pivot bearing
Multi purpose type grease
Lubricate – Steering chain
Hydraulic Change – Oil filter
oil Change – Hydraulic oil Hydraulic oil (13.1 liter)
Brake fluid Change – Brake fluid Brake fluid (130 cc)
Mast supports Lubricate
Mast strips Lubricate
Roller Multi purpose type grease
surfaces Lubricate
Lift bracket
side rollers Lubricate
Lift chains Lubricate Engine oil
Tilt sockets Lubricate
Front axle
Lubricate Multi purpose type grease
supports
Tilt cylinders Lubricate

12-2
 SERVICE DATA

Planned Replacement of Parts

The following parts should be periodically
Ref.
changed as noted below. Parts to be changed Interval
No.
These parts are made of materials which
will deteriorate with time. Further, it is Rubber parts of brake 2400 service hours or 2 years,
1
master cylinder whichever comes first
difficult to determine visually whether or
not they are still in good condition. Rubber parts of wheel 2400 service hours or 2 years,
2
Changing at proper intervals will reduce cylinders whichever comes first
the chance of injury to the operator and High-pressure hoses of 2400 to 4800 service hours or 2 to 4
3
damage to the truck. hydraulic system years, whichever comes first
NOTICE: Periodic change of these parts 4800 service hours or 4 years,
4 Power steering hoses
is not covered by Warranty. whichever comes first
4800 service hours or 4 years,
5 Lift chains
whichever comes first

103419A

12-3
SERVICE DATA

Recommended Lubricants and Brake Fluid

Recommendation for ambient temperature, °C (°F)

Lubricants/brake fluid Specification -30 -20 -10 0 10 20 30

(-22) (-4) (14) (32) (50) (68) (86)

Rear axle gear box oil API GL-4 or GL-5 Gear oil SAE 80W SAE 80 to 90

Hydraulic oil Hydraulic oil SAE 5W SAE 10W

Brake fluid F.M.V.S.S. No. 116 – DOT 3 or DOT 4 (SAE J1703)

Wheel bearings NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 to 295
Grease
Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 to 340

NOTICE: Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other
and deteriorate when mixed. It is best to stick with the same brand at successive service intervals.

Refill Capacities (standard models)

Rear axle gear box 4.2 liter

Normal level: 13.1 liter

Hydraulic tank
High level: 14.1 liter

Brake fluid reservoir 130 cm3

12-4
 SERVICE DATA

Tightening Torque for Standard Bolts and Nuts

The bolts for the rear axle gear box should be tightened in accordance with the Standard Torque table for ZF products
given in the “Group 7 Rear Axle” of this manual.
With Spring Washer 101656

Nominal Size Pitch

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 192.2 19.5 141.8
16 0.63 1.5 0.06 154.9 15.8 114.3 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.6 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 305.2 537.4 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
Metric Without Spring Washer 101656
fine
thread Nominal Size Pitch

6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 29.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1216.0 123.9 894.2 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3
Remarks : 1. The tolerance on these torques is ±10%.
2. These torques are for “dry” condition.
12-5
SERVICE DATA

With Spring Washer 101656

Nominal Size Pitch

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.14 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 715.9 73.0 528.0
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 1.65 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
Metric Without Spring Washer 101656
coarse
thread Nominal Size Pitch

10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4

Remarks : 1. The tolerance on these torques is ±10%.

2. These torques are for “dry” condition.

12-6
 SERVICE DATA

Special Tool Table

Truck Models EP10 EP12 EP15

No. Part No. Name
Application KRT KRT KRT
1 91268-00701 Socket wrench Removal and installation of front wheel hub nut
(46 mm)
2 64309 - 15411 Spring remover Removal of wheel brake return spring
3 64309 - 15412 Hold down spring Removal and installation of brake shoe
retainer
4 65309 - 15413 Return spring Installation of wheel brake return spring
installaer
5 Hook wrench (Disassembly and reassembly of lift cylinder)
05312 - 20580 φ 60 mm Duplex: second
05312 - 20520 φ 55 mm Simplex and triplex: second
6 97157 - 00100 Spring installer Installation of steering gear centering spring
Special tool (Disassembly and reassembly of rear axle
GK 25LD.)
A 97M68 - 00100 Assembly plate
B 97M68 - 00200 Bush
C 97M68 - 00300 Bush
D 97M68 - 00400 Measuring bush
F 97M68 - 00500 Clamping fixture
G 97M68 - 00600 Bush
H 97M68 - 00700 Sleeve See “Group 7 Rear Axle” for shape, application
M 97M68 - 00800 Puller and other information.

M’ 97M68 - 00900 Clamping pliers

N 97M68 - 01100 Pressure piece
S 97M68 - 01200 Assembly drift
T 97M68 - 01300 Assembly drift
U 97M68 - 01400 Assembly drift
V 97M68 - 01500 Assembly drift

12-7
SERVICE DATA

Unit: mm

➀ 200440 ➃ 203550

Hook wrench

➁ 203548 ➄ 203556A

Spring installer

➂ 203549 ➅ 206997

12-8
 OPTIONS

Amber Strobe Kit ....................................................................................13 – 1

Back Buzzer Kit ......................................................................................13 – 2
Working Lamp Kit ...................................................................................13 – 3
Connector Kit ..........................................................................................13 – 4
Battery Box Kit ........................................................................................13 – 5
Road Light Kit .........................................................................................13 – 6
Suspension Seat Kit ..............................................................................13 – 7
Tire Kit .......................................................................................................13 – 8
Foot Direction Kit ................................................................................... 13 – 12
Lever Kit .................................................................................................... 13 – 13
Piping Att Kit ........................................................................................... 13 – 14

13
 OPTIONS

Amber Strobe Kit

209209

13-1
OPTIONS

Back Buzzer Kit

209210

13-2
 OPTIONS

Working Lamp Kit

209211

13-3
OPTIONS

Connector Kit

209212

13-4
 OPTIONS

Battery Box Kit

209213

13-5
OPTIONS

Road Light Kit

209214

13-6
 OPTIONS

Suspension Seat Kit

209215

13-7
OPTIONS

Tire Kit

Non Marking Tire

Unit: mm
209216

13-8
 OPTIONS

Tire Kit

Wide Axle Solid Tire

Unit: mm
209217

13-9
OPTIONS

Tire Kit

Wide Axle Non Marking Tire

Unit: mm
209218

13-10
 OPTIONS

Tire Kit

Non Marking Tire Rear

Unit: mm
209219

13-11
OPTIONS

Foot Direction Kit

209220

13-12
 OPTIONS

Lever Kit

209221

13-13
OPTIONS

Piping Att Kit

209222

13-14
 TECHNICAL PUBLICATIONS FEEDBACK

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Operation & Maintenance Manual Option Bulletin

Part List/Manual Special Instruction

Service Manual Service Data Manual

Electronic Manual Other: ___________________________

Publication # ________________________ Engine model # ________________________

Truck model # _______________________ Issue date # ___________________________
Truck serial # _______________________ Page # _______________________________

(Please print)

Explanation of discrepancy or omission:

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

Please fax or mail completed form to:

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2011 W. Sam Houston Parkway N. P. O. Box 30171
Houston, Texas 77043-2421 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-861-9277
Service Manual EP10KRT, EP12KRT, EP15KRT Chassis & Mast Pub. No. 99759-65100
 Mitsubishi Caterpillar Forklift Europe B.V.
Hefbrugweg 77 1332 AM
Almere, The Netherlands

Copyright © 2002 by MCFA. All Rights Reserved. Printed in

99759-65100 CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. the Netherlands