1N1 / A1N1

3-4 wheel

SERVICE MANUAL (DRAFT)

TCM

T
AF
R
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21-12-2012
 INTRODUCTION
This service manual has been prepared to provide necessary information concerning the maintenance and repair
procedures for the TCM Forklift (A)1N1 series.

Any changes effected in the series after publication of this service manual will be announced in a technical bulletin. It is,
therefore, recommended that each relevant technical bulletin be inserted in front of each section and be used together with
the service manual as a reference.
If a new model requires different service method or has undergone a major change, revised sections will be issued to replace
the applicable sections. Each revised section will include the description of how to service the parts for the former
specifications. The publication of a revised section will be announced in the technical bulletin.
This service manual consists of Sixteen sections as shown in the following table, which gives the updated symbols. When a
revised service manual is issued, this ‘‘INTRODUCTION” sheet should be replaced with a revised one.

Section Symbol
GENERAL INFORMATION (GI)
MAINTENANCE (MA)

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CONTROL SYSTEM (CS)

BATTERY & CHARGER (BC)

ELECTRICAL SYSTEM
AF (EL)
MOTOR MECHANISM (MM)

DRIVE UNIT (DU)

FRONT TIRE & REAR TIRE (TR)

BRAKE SYSTEM (BR)

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REAR AXLE (RA)

STEERING SYSTEM (ST)

(HD)
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HYDRAULIC SYSTEM

LOADING MECHANISM (LM)

BODY & FRAME (BF)

OPTION (OP)

December 2012

0-0
 FOREWORD
This manual contains maintenance and repair procedures.

In order to assure your safety and the efficient functioning of the lift truck, this manual should be
read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely
understood before starting any repair task.

All information in this manual is based on the latest product information at the time of publication.
The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the technician and the efficient
functioning of the lift truck.
The service methods in this Service Manual are described in such a manner that the service may be
performed safety and accurately.
Service varies with the procedures used, the skills of the technician and the tools and parts available.

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Accordingly, anyone using service procedures, tools or parts which are not specifically recommended
by TCM must first completely satisfy himself that neither his safety nor the lift truck’s safety will be
jeopardized by the service method selected.
AF
No modifications or alterations to a powered industrial truck, which may affect, for example,
capacity, stability or safety requirements of the truck shall be made without the prior written
approval of TCM, its authorized representative, or a successor thereof. Contact an authorized TCM
dealer before making any modification or alteration to your industrial truck that may affect, for
example braking, steering, visibility and the addition of removable attachments. After getting
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approval of TCM, its authorized representative, or a successor thereof, capacity plate, decals tags
and operation and maintenance handbooks shall also be changed to the appropriate one.
Only in the event that TCM is no longer in business and there is no successor in the interest to the
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business, the user may arrange for a modification or alteration to a powered industrial truck,
provided, however, that the user shall:

A. Arrange for the modification or alteration to be designed, tested and implemented by an

engineer(s) expert in industrial trucks and their safety;
B. Maintain a permanent record of the design, test(s) and implementation of the modification or
alteration;
C. Approve and make appropriate changes to the capacity plate(s), decals, tags and Instruction
Handbook;
D. Affix a permanent and readily visible label to the truck stating the manner in which the truck
has been modified or altered together with the date of the modification or alteration, and the
name and address of the organization that accomplished the tasks.

© 2010 TCM Printed in The Netherlands

 GENERAL INFORMATION

SECTION GI
CONTENTS

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HOW TO USE THIS MANUAL ............................ GI-2 GENERAL PRECAUTIONS ................................ GI-7
Outline of This Manual ................................... GI-2 JACKING, TOWING AND LIFTING .................. GI-11
Technical Term Definitions ............................. GI-3 Jacking ......................................................... GI-11
AF
Manual Illustrations ........................................ GI-5 Towing (Freeing a stuck forklift) ................... GI-14
IDENTIFICATION INFORMATION ..................... GI-6 Lifting ............................................................ GI-14
Vehicle Model Classification Number ............. GI-6 TIGHTENING TORQUE OF STANDARD
MODEL comparison for chassis serial BOLTS .............................................................. GI-15
number ........................................................... GI-6
Vehicle Identification Number ......................... GI-7
Identification Plate .......................................... GI-7
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 HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

Outline of This Manual

Section symbol Section title Topics

How to use this manual, identification information, general precautions, jacking, lifting, towing
GI General information
and tightening torque of standard bolts.
MA Maintenance Inspection, adjustment, part replacement and lubricant replenishment
Precautions, controller unit inspection and adjustment, meter panel, LCD mode description,
CS Control system switches and sensors inspection, trouble diagnostic procedures, trouble diagnoses for
controller.
Battery and battery
BC Precautions, battery and battery charger.
charger
Precautions, electrical component parts, location of electrical units, harness layout, fuses,
EL Electrical system
lighting system, switches, miscellaneous electrical parts and location of optional parts.
Service data and specifications, trouble diagnoses and corrections, precautions and
MM Motor mechanism
preparation, traction motor, hydraulic pump motor and motor inspection.
Service data and specifications, trouble diagnoses and corrections, precautions and
DU Drive unit
preparation, construction, removal, disassembly, inspection, assembly and installation.
Service data and specifications, trouble diagnoses and corrections, precautions and
TR Front tire and rear tire
preparation, tire and road wheel.
Service data and specifications, trouble diagnoses and corrections, precautions and

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BR Brake system preparation, construction, service brake (wet type), brake pedal, master cylinder, brake piping
and parking brake.
Service data and specifications, trouble diagnoses and corrections, precautions and
RA Rear axle
preparation, construction, component parts, removal, inspection, installation and adjustment.
AF
Service data and specifications, trouble diagnoses and corrections, precautions and
ST Steering system preparation, steering wheel, steering column assembly, power steering valve, power cylinder,
rear axle and steering piping.
Service data and specifications, trouble diagnoses and corrections, precautions and
HD Hydraulic system preparation, hydraulic piping system, hydraulic pump (gear pump), control valve, control lever,
tilt cylinder, lift (mast) cylinder and oil tank.
Service data, trouble diagnoses and corrections, precautions and preparation, construction,
LM Loading mechanism
fork, lift chain, carriage assembly and mast assembly.
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BF Forklift body and frame Service data, precautions, construction, removal, installation, body parts and accessories.

This Manual contains the essential information required to perform

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effective forklift maintenance procedures. All forklift units are

included. Informational configuration in the CS (control system)
section differs from that of other sections. The CS section introduces
how to utilize information in the section.

GI-2
HOW TO USE THIS MANUAL

Outline of This Manual (Cont’d)

MAIN TEXT ENTRIES
Main text entries describe unit removal, unit disassembly, inspection,
unit reassembly, unit installation and adjustment procedures. Step-
by-step descriptions are provided for all of these procedures.
Together with the step-by-step descriptions, other important
information is provided. This information includes service points and
tips, basic units and values, required specified tightening torques
and required special service tools. Information pertaining to
common tools generally found in all maintenance facilities is
generally omitted. This information is included in the exploded part
views and other drawings as required.

OTHER ENTRIES
The following information is included at the beginning of all sections
as a supplement to the main text.

Service data and specifications

Adjustment values, part selection information and specified

T
tightening torque values are shown for all procedures described in
the main text.

Trouble diagnoses and corrections

AF Individual symptoms, probable causes and remedial measures
indicated by these symptoms are described.

Precautions and preparation

• Precautionary and reference information related to the entire
section is provided.
• Special service tools are required for some maintenance
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procedures. Special service tool name, tool number and tool
application information as well as illustrations depicting tool
shapes are included.
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Technical Term Definitions

SPECIFIC TERMS
WARNING:
Warns you of instructions that must be followed to prevent
severe personal injury and/or fatal accident.
CAUTION:
Warns you of instructions that must be followed to prevent
personal injury and/or damage to some parts of the vehicle.
NOTE:
Provides helpful information to perform a smooth and effective
service procedure.
Standard value or specifications:
The allowable range for a given measured value during inspection
and adjustment.
Limit value:
The maximum or minimum acceptable measured value during
inspection and adjustment.

GI-3
HOW TO USE THIS MANUAL

Technical Term Definitions (Cont’d)

MEASURING UNITS AND VALUES
Specified torque, pressure, force and other values used in this
Manual are primarily expressed as the SI unit (International System
of Unit). The values following the SI unit and enclosed in
parentheses ( ) are expressed in the metric system and in the
foot/pound system.
Example:
Tightening torque:
9 - 12 N•m (0.9 - 1.2 kg-m, 6.5 - 8.7 ft-lb)

SI unit Metric system Foot/pound system

Main unit conversions

Conversion
Foot/pound
SI unit Metric system factor to SI
system
unit

Torque and kg-m – 9.807

N•m
moment – ft-lb 1.356
kg – 9.807

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Force N
– lb 4.448
2 – 98.07
kg/cm
kPa
– psi 6.895
AF Pressure
kg/cm 2 – 0.0981
MPa
– psi 0.0069

NOTE:
Converting the unit in metric system or foot/pound system to SI unit
is shown below.
Unit in metric system or foot/pound system x conversion factor = SI
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unit
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GI-4
 HOW TO USE THIS MANUAL

Manual Illustrations
EXPLODED VIEWS
These contain part names, tightening torques, lubrication points and other information necessary to perform
removal, disassembly, repair, reassembly and installation procedures. (See example below.)

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AF
BRT0005
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Symbols used in exploded views

Symbol Meaning Symbol Meaning

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Specified tightening torque is required for part

installation. When a torque range is given, use the Always replace after every disassembly.
average figure as the standard.
Should be lubricated with specified grease. Select parts of proper thickness.
Should be lubricated with oil. Adjustment is required.
Sealing point

GI-5
 IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION

Vehicle Model Classification Number

FTB 15-E1S

Wheelbase
S: Short wheelbase (only for 1.5t 3W)
L: Long wheelbase (only for 1.8t 3W)

Production
E: Europe
1: 1st generation

Loading capacity
13: 1.25 ton (2,756lb)

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15: 1.5 ton (3,308lb)
16: 1.6 ton (3,528)
18: 1.8 ton (3,969lb) or 1.75 ton (3,860lb)
20 : 2.0 ton (4,410lb)
AF
Truck type
FB: 4-wheel counter balance
FTB: 3-wheel counter balance
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MODEL comparison for chassis serial

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number

AS1N1 A1N1 AG1N1 JAG1N1

FTB13-E1
FTB15-E1S FTB15-E1 FTB16-E1 FB16-E1
FTB18-E1 FTB18-E1L FB18-E1
FTB20-E1 FB20-E1

GI-6
 GENERAL PRECAUTIONS

Vehicle Identification Number

The vehicle identification number is stamped on the front of the
frame.

VEHICLE IDENTIFICATION NUMBER

ARRANGEMENT
(A)G1N1 - XXXXXX
J(A)G1N1 - XXXXXX

GIM0094

Identification Plate
The identification plate shows the vehicle type, vehicle model
classification number, vehicle identification number (chassis
number), permissible load at load center, mast type, maximum mast
elevation, battery voltage, available vehicle attachments and vehicle
weight.

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AF
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GENERAL PRECAUTIONS
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GI-7
GENERAL PRECAUTIONS

• The vehicle may be hoisted and/or suspended only under the

direct supervision of a person who has completed the required
educational courses in forklift hoisting and suspension
techniques.
• The forklift service area must be well ventilated and free of
flammable objects and materials.
• If servicing the forklift in an area that has previously been closed
off or poorly ventilated, open all windows and doors and
thoroughly ventilate the area before starting the service
procedure.
• Be extremely careful whenever handling flammable materials and
other dangerous objects.
• Do not smoke during service operations.
• Exercise care when working around high-temperature, rotating or
sliding area of the forklift. Avoid burns and other serious injuries.
• When removing a heavy unit or component from the forklift, be
careful not to lose you balance and drop it.
• Before beginning disassembly and inspection, remove all rings,
your watch and other metallic objects from your body to prevent
an accidental short circuit.
• Carefully analyze all symptoms during troubleshooting. This will

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allow you to make repairs safely and efficiently. After completing a
troubleshooting and repair procedure, carefully check to make
sure that all existing problems have been rectified.
• Before beginning part removal and disassembly, carefully note the
AF manner in which the unit or part is installed to the forklift and the
way in which the part or unit is assembled. This will ensure
smooth reassembly and installation.
• Make alignment marks on parts to be disassembled as required
for easier and proper reassembly. Marks should be made in areas
of the parts that will not affect function.
• When removing wires, note the color codes and remember the
wiring configuration before removal.
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• Use the proper tools for the disassembly and inspection
procedures. Use the designated special service tools if required.
• Tools used for disassembly and inspection must be clean and
completely free of foreign material. Place disassembled parts in a
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clean area after disassembly.

• Turn the key switch to the OFF position and disconnect the battery
plugs before beginning the disassembly and inspection
procedure.
• Do not mix up disassembled parts. Place them carefully to the
side in their order of removal.
• Under no circumstances should electrical components
(controllers, motors, battery charging units and wiring) be steam-
cleaned.
• Clean internal areas of the controllers, motors with an air blower
(never with steam). Following cleaning, check the insulation
resistance.
• When disconnecting pressurized pipes or hoses, release the
pressure from the line before removing.
• When removing the battery or the counterweight chock the
wheels. Never remove the battery or the counterweight when the
forklift is raised on jacks.
• Carefully clean all disassembled parts before inspection and
reassembly.
• Use only the specified nuts and bolts to install parts. Tighten the
nuts and bolts to the specified torque as required.

GI-8
GENERAL PRECAUTIONS

• Carefully check all removed oil seals, gaskets, packing materials,

O-rings, lock washers, cotter pins and self-locking nuts against
the instructions on each section to see whether or not they can be
reused. If they cannot be reused, they must be replaced with new
ones. If replacement parts are required, refer to the Parts Catalog.
Be sure that the replacement parts have the correct part number.
Use only genuine parts.
• When replacing taper roller bearings or needle bearings, always
replace their inner races and outer races as a set.
• Use only the specified lubricants and sealants.
• Be careful not to splash the brake fluid on the body or other
painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, immediately wipe it and wash the area
with water.
• Never reuse drained brake fluid.
• Following repair of any system containing oil or brake fluid,
carefully check the system for fluid leakage.
• Do not carelessly dispose of discarded oil from oil changes and
part cleaning operations. Dispose of the oil following established
procedures.

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PRECAUTIONS FOR ELECTRICAL SYSTEM
INSPECTION
WARNING:
AF • Always raise drive tires OFF floor before working on
electrical system.
• Turn the key switch to the OFF position and disconnect the battery
plugs when disconnecting or connecting the print board
connectors. Disconnecting and/or connecting the main print board
or meter print board connectors with the key switch ON and the
battery plugs in place can damage the print board. Exercise care.
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• Avoid twisting and turning the print board connectors when
connecting and/or disconnecting them. This can result in poor
connector connections.
• When disconnecting connectors, do not pull on the wire attached
to the connector. Always hold the connector body.
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• When using a circuit tester, be very careful not to use the wrong
range (A, V or Ω) and/or polarity.
• Static electricity can damage the main and meter print boards. Be
sure to eliminate static electrical charges when handling the print
boards.
• Following completion of the inspection procedure, once again
check that all of the leads are connected to their original
terminals.
CAUTION:
• Before changing any components (i.e. lamps, fuses, meter
panel) or disconnecting any wiring. Always turn OFF key
switch and disconnect battery. This will reduce the
possibility of damage to controller system.

GI-9
GENERAL PRECAUTIONS

WARNING:
• When working with any battery always wear personal
protective equipment (PPE), as in rubber gloves, rubber
apron and protective face shield.

PRECAUTIONS FOR HANDLING BATTERY

• Do not permit open flames in close proximity to the battery when
handling it.
• It is possible to burn yourself when working with a battery. Be
careful not to allow your body and clothing to come in direct
contact with the battery fluid.
• If large amounts of battery fluid have been spilled or leaked over
an area, immediately neutralize the spill with some neutralizing
agent (sodium bicarbonate, calcium hydroxide, carbon soda, etc.).
Rinse the area with a large volume of water.
• Highly-explosive hydrogen gas leaks from the battery. If this gas is
ignited by sparking from a short circuit in the battery terminal
area, an explosion and serious damage can result. Avoid this
danger by not placing tools and other metallic objects on top of
the battery where they might short the battery terminals.
• Hydrogen gas escaping from the battery can also be ignited by

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static electricity in the area. Again, an explosion can result. Never
wipe or dust the battery upper surface and terminal areas with a
completely dry cloth as this will generate static electricity. Never
AF cover the battery with a vinyl sheet or similar object to protect it.
This can also generate static electricity. Clean the battery with a
damp cloth.
CAUTION:
• Fluid leakage from a loosely closed battery electrolyte filler
cap can cause many problems. Always be sure that the filler
cap is tightly closed.
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• Never entrust battery maintenance procedures to personnel
who are not familiar with the techniques and safety
precautions required for battery maintenance.
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SPECIAL SERVICE TOOLS

Special Service Tools play a very important role in the maintenance
of the vehicle. These are essential to safe, accurate and speedy
servicing.
The working times listed in the column under FLAT RATE TIME in
FLAT RATE SCHEDULE are computed based on the use of Special
Service Tools.
The identification code of maintenance tools is made up of 2
alphabetical letters and 8-digital figures.
The heading two letters roughly classify tools or equipment as:
ST00000000
KV00000000

GI-10
JACKING, TOWING AND LIFTING
JACKING, TOWING AND LIFTING

CAUTION:
• Never get under the forklift or the fork while jacking or lifting
the forklift.
• Always perform jacking or lifting operation on a flat and solid
surface.
• Operate the key switch and individual operational levers only
when sitting in the operator's seat. Never touch these
controls when you are standing near the forklift.
• Be sure to apply the parking brake whenever jacking or
lifting the forklift.
• Do not chock the forklift with multiple wooden blocks
stacked one on top of the other. Only use one wooden block
in place.
• Be sure to use wooden blocks of sufficient strength to
support the weight of forklift.
• Never use cracked or broken wooden blocks. These may
cause unstable support, putting you in danger.
• Never place wooden blocks of different heights side by side
under the vehicle or the mast.

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Jacking
CAUTION:
• Using the mast to raise the front wheels for an extended time
AF period will eventually bend the mast. Place wooden blocks
tightly under the front of the frame on both sides of the
forklift to take the stress off the mast.
• Wooden block area and height should be such that the
wooden blocks can just be inserted between the mast and
the ground surface when the mast is tilted back. Front-to-
back wooden block length should be 50 - 100 mm (1.97 - 3.94
in) larger than the mast rail front-to-back length. Side-to-side
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wooden block width should be 20 - 40 mm (0.79 - 1.57 in)
greater than the outer mast outside width.
• When jacking up the forklift, raise it until the wheels are
slightly clear of the ground. Stop jacking. Do not attempt to
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raise the forklift above this level.

JACKING FRONT OF FORKLIFT

1. Place the forklift on a level and solid surface.
2. Raise the forks approximately 100 mm (3.94 in).

GI-11
JACKING, TOWING AND LIFTING

Jacking (Cont’d)
3. Place a wedge block behind the rear wheel to avoid slipping.

GIM0095

4. Place the jack under the one side of the frame, as shown in the
illustration.
5. Slowly raise the front of the forklift until the front wheel is slightly
clear of the floor or ground. Do not go higher.
CAUTION:
Do not allow the jack to slip when jacking up the forklift.

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GIM0106
AF 6. Apply a wooden block under the front end of the frame.
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GIM0107
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7. Similarly perform steps 4 and 5 on the other side.

JACKING REAR OF FORKLIFT (3 - WHEEL)

1. Place the forklift on a level and solid surface.
2. Raise the fork approximately 100 mm (3.94 in).
3. Apply the parking brake and place wedge blocks on the front
wheels to avoid slipping.
4. Attach a lifting wire or nylon sling to the hook of the
counterweight. Slowly raise the rear of forklift until rear wheels
are slightly clear of the floor or ground. Do not go higher.

GIM0100

GI-12
JACKING, TOWING AND LIFTING

Jacking (Cont’d) (3 - wheel)

5. Place wooden blocks under the counterweight, as shown in the
illustration. Lower the vehicle, and then support it with wooden
blocks.

GIM0101

Jacking (Cont’d) (4 - wheel)

6. Tilt the mast forward until the front wheels lift up.
7. Place a square timber under the left and right frame.
8. Block the rear wheels.

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AF
MOM8503

REAR
1. Raise the forks about 100 mm (3.94 in) from the ground, and tilt
them slightly back.
2. Block the front wheels.
3. Place a garage jack under the counterweight center, and then
jack it up.
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4. Jack up until the tires are slightly raised from the ground, place
a square timber under the left and right frame, and then slowly
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MOM2106 lower the jack.

GI-13
JACKING, TOWING AND LIFTING

Towing (Freeing a stuck forklift)

If the forklift becomes stuck and cannot move under its own power, it
may be recovered by a truck or similar vehicle. Attach the towing
cable to the hook provided on the counterweight.
CAUTION:
• Do not use the hook for towing operation.
• Be sure that the towing cable is in perfect condition and that
it has sufficient strength to pull the vehicle.
• Whenever towing this unit always ensure key is in OFF
GIM0102 position and battery is disconnected (unplugged) to reduce
damage to electrical system.

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MOM8505
AF
Lifting
CAUTION:
• Do not use wooden blocks whose height exceeds 300 mm
(11.81 in).
• Never hoist the vehicle unless it is absolutely necessary.
• Be sure that the hoist, nylon sling and lifting wire are in
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perfect condition. The hoist and wire must have sufficient
strength to lift and support the forklift.
• Attach the lifting wire only to the specified points. Never
attach the wire to any other part of the forklift.
GIM0103
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LIFTING FRONT OF VEHICLE

1. Attach lifting wire to outer mast crossbeam. Use hoist to raise
the front of vehicle.
2. Place wooden blocks under frame on both sides.
3. Slowly lower vehicle onto wooden blocks. Double-check to
make sure that wooden blocks are positioned correctly.
4. Make sure that vehicle is settled firmly on wooden blocks by
trying to shake the vehicle. It should be perfectly steady.
5. Chock rear wheels to hold vehicle stationary.

GI-14
 TIGHTENING TORQUE OF STANDARD BOLTS

Lifting (Cont’d)
LIFTING REAR OF VEHICLE
1. Secure lifting wire to the hole of the battery plate. Slowly raise
forklift using hoist.
2. Place wooden block under counterweight.
3. Slowly lower forklift onto wooden block. Double-check to make
sure that wooden block is positioned correctly.
4. Make sure that forklift is settled firmly on wooden block by trying
to shake the forklift. It should be perfectly steady.
5. Chock front wheels to hold vehicle stationary.

GIM0104

LIFTING ENTIRE FORKLIFT

Secure lifting wire to outer mast crossbeam and to the hole of the
battery plate. Slowly raise vehicle.
CAUTION:
Be sure that lifting wire does not come into contact with
overhead guard.

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TIGHTENING TORQUE OF STANDARD BOLTS

GIM0105
AF
Specified tightening torque
Nominal diameter Pitch
Grade
(mm) (mm)
(N•m) (kg-m) (ft-lb)

M6 1.00 3-4 0.3 - 0.4 2.2 - 2.9

1.25 8 - 11 0.8 - 1.1 5.8 - 8.0
M8
1.00 8 - 11 0.8 - 1.1 5.8 - 8.0
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1.50 16 - 22 1.6 - 2.2 12 - 16
4T M10
1.25 16 - 22 1.6 - 2.2 12 - 16
1.75 26 - 36 2.7 - 3.7 20 - 27
M12
1.25 30 - 40 3.1 - 4.1 22 - 30
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M14 1.50 46 - 62 4.7 - 6.3 34 - 46

M6 1.00 6-7 0.6 - 0.7 4.3 - 5.1
1.25 14 - 18 1.4 - 1.8 10 - 13
M8
1.00 14 - 18 1.4 - 1.8 10 - 13
1.50 25 - 35 2.6 - 3.6 19 - 26
M10
1.25 26 - 36 2.7 - 3.7 20 - 27
1.75 45 - 61 4.6 - 6.2 33 - 45
7T M12
1.25 50 - 68 5.1 - 6.9 37 - 50
M14 1.50 76 - 103 7.7 - 10.5 56 - 76
M16 1.50 118 - 157 12.0 - 16.0 87 - 116
M18 1.50 177 - 235 18.0 - 24.0 130 - 174
M20 1.50 245 - 324 25.0 - 33.0 181 - 239
M22 1.50 324 - 441 33.0 - 45.0 239 - 325

GI-15
 TIGHTENING TORQUE OF STANDARD BOLTS

Specified tightening torque

Nominal diameter Pitch
Grade
(mm) (mm)
(N•m) (kg-m) (ft-lb)

M6 1.00 8 - 11 0.8 - 1.1 5.8 - 8.0

1.25 19 - 25 1.9 - 2.5 14 - 18
M8
1.00 20 - 27 2.0 - 2.8 14 - 20
1.50 36 - 50 3.7 - 5.1 27 - 37
M10
1.25 39 - 51 4.0 - 5.2 29 - 38
1.75 65 - 88 6.6 - 9.0 48 - 65
9T M12
1.25 72 - 97 7.3 - 9.9 53 - 72
M14 1.50 108 - 147 11.0 - 15.0 80 - 108
M16 1.50 167 - 226 17.0 - 23.0 123 - 166
M18 1.50 255 - 343 26.0 - 35.0 188 - 253
M20 1.50 343 - 461 35.0 - 47.0 253 - 340
M22 1.50 471 - 632 48.0 - 64.4 347 - 466

CAUTION:
• Special parts are excluded.
• This standard is applicable to bolts having the following marks embossed on the bolt head.

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Grade........... Mark
4T ................ 4 or no mark
7T ................ 7
9T ................ 9
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GI-16
 MAINTENANCE

SECTION MA
CONTENTS

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LUBRICATION CHART .................................... MA-2 DRIVE UNIT (REDUCTION GEAR) ................. MA-13
Lubrication Chart ........................................... MA-2 Drive Unit (Reduction Gear) ........................ MA-13
MAINTENANCE SCHEDULE ........................... MA-4 TIRES AND ROAD WHEELS .......................... MA-14
AF
Maintenance Schedule .................................. MA-4 Tires and Road Wheels ............................... MA-14
BATTERY .......................................................... MA-6 BRAKE SYSTEM ............................................. MA-16
Battery ........................................................... MA-6 Brake System .............................................. MA-16
CONTROL SYSTEM ....................................... MA-10 STEERING SYSTEM ....................................... MA-21
Control System ............................................ MA-10 Steering System .......................................... MA-21
MOTORS ......................................................... MA-11 HYDRAULIC SYSTEM .................................... MA-22
Motors ......................................................... MA-11 Hydraulic System ........................................ MA-22
ELECTRICAL COMPONENTS ....................... MA-12 LOADING MECHANISM .................................. MA-27
R
Electrical Components ................................ MA-12 Loading Mechanism .................................... MA-27
D
 LUBRICATION CHART
LUBRICATION CHART

Lubrication Chart
(1) LUBRICATION SCHEDULE CHART

T
AF
BSM0688EU

SUITABLE OIL
R
ITEM BELOW ABOVE
15°C (60°F) 15°C (60°F)
GASOLINE ENGINE OIL SAE NO. 20 SAE NO. 30
GEAR OIL SAE NO. 80 SAE NO. 140
D

W.B. GREASE N.L.G.I. NO. 2

CHASSIS GREASE N.L.G.I. NO. 1
1N1: DOT4
BRAKE FLUID A1N1: PSF (Power Steering
Fluid)
BRAKE DISK FLUID SAE 80W/API GL-4
Standard
ISO VG32 or equivalent
forklift
HYD. OIL
Cold storage SAE NO. 10W
forklift (ISO VG15)
REPLACE ELEMENT

MAM8510E

MA-2
 LUBRICATION CHART
(2) GREASE/OIL AND CAPACITY 1N1

Capacity
System/component Oil and grease
1N1 JG1N1

Reduction gear SAE 80W/API GL4 0.4 (7/8 US pt, 3/4 Imp pt)/one side
(Drive unit)
Brake disk SAE 80W/API GL4 0.18 (3/8 US pt, 3/8 Imp pt)/one side
Brake DOT 4 -
Hydraulic oil tank Hydraulic oil I.S.O. VG32 17.9 (4-3/4 US gal, 4 Imp gal) 20.9
Greasing point The greasing points and grease type in use are listed in the above lubrication schedule chart.

GREASE/OIL AND CAPACITY A1N1

System/component Oil and grease Capacity

Reduction gear SAE 80W/API GL4 0.35 (0.74 US pt, 0.62 Imp pt)/one side
(Drive unit)
Brake disk SAE 80W/API GL4 0.16 (0.34 US pt, 0.28 Imp pt)/one side
Brake fluid type PSF (Power Steering Fluid) or DEXRON
0.15 (0.32 US pt, 0.26 Imp pt)

T
equivalent
Hydraulic oil tank Hydraulic oil I.S.O. VG32 A1N1 17.9 (4.73 US gal, 3.94 Imp gal)
JAG1N1 20.9 (5.52 US gal, 4.60 Imp gal)
Greasing point
AF
The greasing points and grease type in use are listed in the above lubrication schedule chart.
R
D

MA-3
 MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE

Maintenance Schedule
The first maintenance should be at 1 month or 200 hours (which
ever comes first) after the truck is first put into use. See the (1)
marked interval. Periodic maintenance should be performed at least
every 6 months following the interval schedule:
 Schedule A (Months):For trucks operating less then 600 hours
(effective), maintenance should be
performed according the maintenance
intervals in Months (A).
 Schedule B (Hours): For trucks operating more then 600 hours
(effective), maintenance should be
performed according the maintenance
intervals in hours (B).
NOTE:
Under dusty, dirty or heavy operations, more frequent maintenance
is necessary. All items listed above must be maintained in order to
meet and keep control systems operating at design level. Failure to
maintain the systems could compromise the warranty.

I = Inspect. (Correct or replace if necessary.) D = Drain R = Replace

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A = Adjust C = Clean T = Retighten L = Lubricate/Grease

Interval
(1) How to
Inspection items
AF
A (months)
B (hours) 200
1
(1) 600
6
1200 1800
12
2400 3000
18
3600 4200
24
4800
…
…
check

Motor (Dust) C C C C C … Clean

Motor

Commutator surface (Q02 models only) I I I I I I I I I … Visual

Brushes (wear / spring tension)
I I I I I … Visual
(Q02 models only)
Drive system

Resistance between Forklift body and + / - Meassure

I I I I I I I I I … tension
terminal of battery / controller
Contactor operation I I I I I I I I I … Visual
Controller

R
Contactor tips I I I I I I I I I … Visual
Resistance contactor coil I I … Measure
Low voltage detection I I I … Test
Wiring, bolts and nuts I I I I I I I I I … Visual
Controller surface C C C C C C C C C … Clean
D

Battery: Mounting, Level & Specific

I I I I I I I I I … Visual / Test
gravity
Harness & Connectors I I I I I I I I I … Visual
Electric system

Fuses I I I I I I I I I … Visual
Relays I I I I I I I I I … Visual
Switches I I I I I I I I I … Test
Lights (all) I I I I I I I I I … Test
Horn / buzzer I I I I I I I I I … Test
Gauge and Indicators I I I I I I I I I … Test
Wipers I I I I I I I I I … Visual / Test
Oil level I I I I I I I I I … Visual
Differential /
drive unit

Crack, damage and leakage I I I I I I I I I … Visual

Differential / drive unit oil R R … Replace

Cracks, distortion, etc. I I I I I I I I I … Visual

Front axle
Chassis & Body maintenance

Mounting bolts I I I I I I I I I … Visual

Oil leakage I I I I I I I I I … Visual
Wheel play I I I I I I I I I … Test
Wheel bearing grease R R … Replace
Fore-aft play I I I I I I I I I … Meassure
Silent blocks I I I I I I I I I … Visual
Rear axle

Wheel play I I I I I I I I I … Test

Tie-rod L L L L L L L L L … Grease
Wheel bearing grease R R … Replace
Kingpin L L L L L L L L L … Grease

MA-4
 MAINTENANCE SCHEDULE
Interval
How to
Inspection items A (months) 1(1) 6 12 18 24 …
check
B (hours) 200(1) 600 1200 1800 2400 3000 3600 4200 4800 …
Visual /
Wheel nuts T T T T T T T T T …
Torque
Wheels

Rim, side rings and wheel disc damage I I I I I I I I I … Visual

Tire: pressure, wear, damage and foreign
I I I I I I I I I … Visual
materials
Function of steering system I I I I I I I I I … Test
Steering system

Mounting of column, orbitrol, cylinder &

I I I I I I I I I … Visual
tubes & hoses
Leakage (Valve, Cylinder & Orbitrol) I I I I I I I I I … Visual
Tubes and Hoses (leakage, mounting,
I I I I I I I I I … Visual
cracks, damaging)
Steering wheel (movement & play) I I I I I I I I I … Test
Function of brake system I I I I I I I I I … Test
Brake fluid (Level & Condition) I I I I I I I I I … Visual
Leakage I I I I I I I I I … Visual
Brake fluid R R … Replace
Brake disc fluid (1N1 models only) R R … Replace
Brake system

Brake pedal adjustment I I I I I I I I I … Check

Pedal rubbers I I I I I I I I I … Visual
Brake lining wearing I I … Visual
Brake drum / lining cleaning

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C C … Clean
(Not for 1N1 models)
Brake tubes & hoses ( mounting, cracks, I I I I I I I I I … Visual
damaging)
Test /
Hand brake function / effort I I I I I I I I I …
AF Meassure
Chassis & Body maintenance

Function of hydraulic system I I I I I I I I I … Test

Hydraulic leakage I I I I I I I I I … Visual
Hydraulic oil level I I I I I I I I I … Visual
Hydraulic oil replacement R R … Replace
Hydraulic system

Micron oil filter R R … Replace

Suction filter C C … Clean
Control valve (Mounting) I I I I I I I I I … Visual
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Movement & Connection of levers I I I I I I I I I … Test
Hydraulic hoses (Cracks, damage, I I I I I I I I I … Visual
Fittings)
Lift & Tilt cylinder mounting I I I I I I I I I … Visual
Tilt cylinder pin L L L L L L L L L … Grease
D

Function of mast I I I I I I I I I … Test

Mast system (Damage / cracks/ wear) I I I I I I I I I … Visual
Clearance of each stage I I I I I I I I I … Meassure
Mast Rail L L L L L L L L L … Grease
Mast / carraige rollers I I I I I I I I I … Visual / Test
Back up metals L L L L L L L L L … Grease
Thrust metals L L L L L L L L L … Grease
Mast

Lift chains wear / tension I I I I I I I I I … Meassure

Attachments mounting I I I I I I I I I … Visual
Attachments L L L L L L L L L … Grease
Lift chains L L L L L L L L L … Lubricate
Hose pulley's I I I I I I I I I … Visual / Test
Mast support L L L L L L L L L … Grease
Forks (Wearing / Damage / Cracks) I I I I I I I I I … Visual
Seat belt (function / damage) I I I I I I I I I … Test / Visual
Load capacity plate
General

I I I I I I I I I … Visual
(readable / correct)
Warning labels (readable) I I I I I I I I I … Visual
Overhead guard (damage / cracks) I I I I I I I I I … Visual
General All bolt and nuts I I I I I I I I I … Visual

MA-5
 BATTERY
BATTERY

Battery
(1) INSPECTION OF ELECTROLYTE LEVEL
CAUTION:
Fill distilled water when battery electrolyte level drops.

1. Open the cap and check the electrolyte level. If electrolyte level
is in between - in left figure, it is OK.
CAUTION:
Be careful because battery specifications may vary with each
maker.
BCM0014
2. If inspection finds a cell in which electrolyte level is too low,
check if there is any leakage and fill with distilled water. Continue
filling up with cap opened until electrolyte level rises to
position. However, be careful, for it may vary with each maker.
NOTE:
• Probable causes of leakage are as follows:
• Damage to cap
• Excessive filling with distilled water

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• High electrolyte temperature during charging, leading to
electrolyte overflow
CAUTION:
AF • Use care not to fill distilled water excessively. It may cause
short or leakage.
• Electrolyte lid is pushed into battery cell and needs to be
secured to prevent leakage.
• If there are any cracks in electrolyte lid, replace with new one.
• Be careful because battery specifications may vary with each
maker.
R
• Before changing any components (i.e. lamps, fuses, meter
panels) or disconnecting any wiring. Always turn OFF key
switch and disconnect battery. This will reduce the
possibility of damage to the controller system.
D

(2) INSPECTION OF ELECTROLYTE TEMPERATURE

Measure electrolyte temperature of each battery cell with a
thermometer.
NOTE:
When battery electrolyte temperature rises, electrolyte and capacity
of the battery expand. However, specific gravity decreases because
there is no change in weight. Contrary when electrolyte temperature
drops, specific gravity increases. Thus, when measuring specific
gravity, evaluate result by converting electrolyte temperature at 20°C
BCT0017
(68°F). (Refer to “INSPECTION OF SPECIFIC GRAVITY”)

MA-6
 BATTERY

Battery (Cont’d)
(3) INSPECTION OF SPECIFIC GRAVITY
NOTE:
Specific gravity is very useful for determining battery life and
condition.
1. To measure specific gravity of each battery cell by gravimeter.
CAUTION:
Measure with gravimeter placed in battery cell. Use extra care
to prevent scattering of battery electrolyte outside when pulling
it out of the cell.
BCT0018

2. Keep scale of gravimeter at eye level and read upper end

portion of battery electrolyte swollen due to surface tension.
CAUTION:
• If there is variance in specific gravity among cells, perform
equation charging and measure specific gravity again. (For
method of equation charging, refer to CS section). If result
shows big variance in specific gravity among cells, battery
has reached the end of its life. (Battery life depends on years

T
of use, conditions of use and maintenance; equation
charging may be necessary several times depending on
BCT0019
cases).
AF • If specific gravity is below 1.250 after charging, battery has
reached the end of its life.
• Carefully determine the battery life based on the above
observation, together with advice by battery maker
personnel.
3. When battery electrolyte temperature is other than 20°C (68°F),
convert specific gravity into temperature.
Sz0 = St + 0.0007 x t – 0.014
R
Sz0 : Specific gravity of battery electrolyte at standard
temperature [20°C] (68°F)
St : Specific gravity of battery electrolyte measured at
t°C
D

t : Temperature of battery electrolyte during measuring

When specific gravity converted into temperature is below 1.145,
immediately perform charging.
NOTE:
Specific gravity at the time of charging end: 1.280 [electrolyte
temperature 20°C (68°F)]

(4) INSPECTION OF BATTERY VOLTAGE

Inspection of battery voltage can be performed in an interactive
diagnosis mode without using tester. Refer to CS section.

(5) INSPECTION OF CELL VOLTAGE

Measure the voltage of each cell.
BCT0020 NOTE:
This is useful for determining battery life and condition.

MA-7
 BATTERY

Battery (Cont’d)
(6) INSPECTION OF EXTERNAL LEAKAGE (⊕ LEAK)
Locate leaking cell following the flow chart below.
NOTE:
• Put tester to paint erased portion (paint is erased by file) when
putting the tester to iron box.
• White zinc sulphate crystals are most often stuck to terminal of
electrolyte leaking cell.

V Measure voltages by putting tester to terminal of

100 battery connector and tester to iron box.

No
Remove battery Voltage is OK (no leak)
from vehicle body generated.
and wash it with
water. Yes

T
First time
BCT0006
Second time
AF V Measure voltages in sequence by putting tester to
100 terminal of battery connector and tester to terminal
of each cell.

Find cell close to measured value of .

R
Select another cell.
BCT0007
D

V Measure voltages by putting tester to iron box and

100 tester to terminals of found cell and adjacent cells (in
serial direction).

Cell whose voltage value is close No Electrolyte non-

to 0V. leaking cell

Yes

Electrolyte leaking cell

BCT0008

NOTE:
For inspection of leak, measure in reverse polarity of all and
for leak inspection.

MA-8
 BATTERY

Battery (Cont’d)
(7) INSPECTION OF BODY RESISTANCE
Check resistance between truck body and negative/positive
terminals of battery connector track side.
Normal: Ω
If resistance value is “no infinity”, check lead wires, controller and
motor windings for grounding. Correct or replace faulty parts as
necessary.

MOM1994a

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AF
R
D

MA-9
 CONTROL SYSTEM
CONTROL SYSTEM

Control System
(1) INSPECTION OF MAIN CONTACTOR
Contactor points
Make sure each contactor arm moves smoothly when pushed, and
that it quickly returns to its original position when released. If it is
questionable, disassemble and check the condition of the contactor.
If the contactor point is damaged or worn, beyond wear limit (1N1),
replace the contactor base and contactor frame as a unit.

Wear limit of movable and stationary contact points:

1N1: 0.7 mm (0.028 in)
CST0014
A1N1: not available
Contactor coil
Using a circuit tester, check continuity in coil circuit.

Normal Abnormal (open circuit)

Continuity

NOTE:
The circuit tester range selector must be set to “x1 Ω”.

T
(2) CLEANING CONTROLLER
MAM0156
AF Clean controller surface. Clean dust with dry compressed air.

(3) INSPECTION OF LOW VOLTAGE DETECTING

CIRCUIT
Check operation of low voltage detecting circuit.
1. Raise drive wheels with a jack, placing chocks at rear wheels to
prevent truck from moving.
R
2. Turn all electrical switches and key switch to OFF. (ex. Lighting
switch).
3. Disconnect battery plug.
4. Remove main fuse.
D

5. Connect power supply (described below) to battery plug (on the

chassis harness side).
Voltage 18 - 50 (V) ... Variable
Ampere About 2 (A)
6. Turn key switch on.
7. Gradually decrease power supply voltage until remaining
battery capacity meter moves from 2nd-step to 1st-step position
on scale. Check that battery warning mark lamp is flashing.
8. After battery warning mark lamp begins to flash, the buzzer
should sound indicating the preset time has elapsed.
9. Further decrease power supply voltage. After the remaining
battery capacity meter has moved from 1st-step to 0-step
position on the scale, check that battery warning mark is lit.

(4) INSPECTION OF WIRING, BOLT AND NUT

Check wirings, bolts and nuts.
1. Check harness covering of system components for damage or
burns. Replace if necessary.
2. Check terminals and nuts of controller, contactors and motor for
looseness. Retighten nuts and bolts as required.

MA-10
 MOTORS
MOTORS

Motors
(1) CLEANING OF MOTOR
When motor is operated under severe dust conditions, occasionally
clean motor interior using dry compressed air in order to maintain
original insulation resistance.

(2) INSPECTION OF ROTOR (MOTOR)

Turn the rotor to check the rotor shaft for being de-centered and
check the bearing for looseness.

T
AF
R
D

MA-11
 ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS

Electrical Components
(1) INSPECTION/REPLACEMENT OF FUSE
Check for blown fuse by referring to the right side of the figure.
Replace blown fuse with a new one.
CAUTION:
• When replacing fuse, always use one of specified capacity,
indicated on the fuse capacity label.
• If fuse blows again after replacing, electrical trouble is
considered. Immediately inspect and eliminate cause of the
trouble.
• Before changing any components (i.e. lamps, fuses, meter
panels) or disconnecting any wiring. Always turn OFF key
MAM0157
switch and disconnect battery. This will reduce the
possibility of damage to the controller system.

Power supply No. Fuse capacity (A) Applicable parts

Battery 1 5 Meter
2 10 Option (Battery power supply)
Headlamp, tail lamp, stop lamp,

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3 10
horn, back operation lamp (option)
4 10 (1N1) 20 Power supply for key switch
(A1N1)
AF
ELM0262
Key switch 5 10 Controller
6 5 Option
7 5 Meter
8 10 Reverse lamp, back buzzer

(2) REPLACEMENT OF BULBS

R
Specifications
CAUTION:
When installing a new bulb, always use the one with the
D

specified capacity.

Wattage (W)
Number of
Lamps
48V 36V parts

Headlamp 25 25 2
Front turn signal lamp 25 25 2
Stop/tail 25/10 25/10 2/2
Rear combination
Turn 25 25 2
lamp
Reverse 10 8 2
Back operation lamp (option) 25 25 1

MA-12
DRIVE UNIT (REDUCTION GEAR)
DRIVE UNIT (REDUCTION GEAR)

Drive Unit (Reduction Gear)

(1) INSPECTION OF GEAR OIL LEVEL
CAUTION:
• Place the vehicle on level ground. Ensure that the unit is
cooled down.
• Only use the authorized genuine gear oil.

1. Remove the oil level plug and check the gear oil level. Add if
necessary using the filler plug.
2. Apply liquid packing to the threads of the oil level plug. Then
install and tighten the plug to the specified torque.
Tightening torque [N•m (kg-m, ft-lb)]:
20 - 29 (2.1 - 2.9, 15 - 21)

MAM0158

(2) REPLACEMENT OF GEAR OIL

T
1. Remove the drain plug and discharge the oil.
2. Apply liquid packing to the threads of the drain plug. Then install
and tighten the plug to the specified torque.
Tightening torque [N•m (kg-m, ft-lb)]:
AF 20 - 29 (2.1 - 2.9, 15 - 21)

MAM0159
R

3. Add new gear oil from the filler port after removing the filler plug.
CAUTION:
D

Only use the authorized genuine gear oil.

4. Apply liquid packing to the threads of the filler plug. Then install
and tighten the plug to the specified torque.
Tightening torque [N•m (kg-m, ft-lb)]:
20 - 29 (2.1 - 2.9, 15 - 21)
CAUTION:
MAM0160 After refilling, always check the oil level.

MA-13
 TIRES AND ROAD WHEELS
TIRES AND ROAD WHEELS

Tires and Road Wheels

(1) GENERAL SPECIFICATIONS
Except North America
···standard ···option
Model
(A)S1N1L13Q (A)S1N1L15Q (A)1N1L15Q (A)1N1L18Q (A)G1N1L16Q (A)G1N1L18Q (A)G1N1L20Q J(A)G1N1L16Q J(A)G1N1L18Q J(A)G1N1L20Q
Tire
Tire size
18x7-8 18x7-8 18x7-8 200/50-10 18x7-8 200/50-10 200/50-10
(Pneumatic solid)
Rim size
4.33R-8 4.33R-8 4.33R-8 6.50F-10 4.33R-8 6.50F-10 6.50F-10
(Pneumatic solid)
Tire size (Cushion) 18x7x12-1/8 18x7x12-1/8 18x7x12-1/8 — — —
Single
Front

Tire size
18x7-8 18x7-8 18x7-8 200/50-10 18x7-8 200/50-10 200/50-10
(Pneumatic solid)
Pneumatic
solid
Type

Clean (White)

Cushion — — —

Tire size
15x4.5-8 15x4.5-8 140/55-9 140/55-9 16x6-8 16x6-8 16x6-8
(Pneumatic solid)
Rim size

T
3.00D-8 3.00D-8 4.00E-9 4.00E-9 4.33R-8 4.33R-8 4.33R-8
(Pneumatic solid)
Rear

Tire size (Cushion) 15x5x11-1/4 15x5x11-1/4 — — — —

-

Pneumatic
solid
AF
Type

Clean (White)

Cushion — — — — — —

North America only

···standard ···option

Model (A)1N1 (A)G1N1

R
Tire
15 18 20
Tire size (Pneumatic solid) 18×7-8 200/50-10
Rim size (Pneumatic solid) 4.33R-8 6.50F-10
D

Tire size (Cushion) 18×7×12-1/8 18×7×12-1/8

Single
Front

Tread (Pneumatic solid) in (mm) 35.9 (913) 36.6 (930)

Tread (Cushion) in (mm) 36.6 (930) 36.6 (930)
Pneumatic solid
Type

Cushion
Tire size (Pneumatic solid) 15×4.5-8 140/55-9 140/55-9
Rim size (Pneumatic solid) 3.00D-8 4.00E-9 4.00E-9
Tire size (Cushion) 15×5×11-1/4 15×5×11-1/4
Rear

Tread in (mm) 6.9 (176) 6.9 (176)

Pneumatic solid
Type

Cushion

MA-14
 TIRES AND ROAD WHEELS

Tire and Road Wheels (Cont’d)

(2) INSPECTION OF WHEEL NUTS
Inspect the wheel nuts for looseness. Tighten them if necessary to
the specified torque.
Front and rear wheel nuts:
1N1: 157 - 196 N•m (16 - 20 kg-m, 116 - 145 ft-lb)
A1N1: 167 - 226 N•m (17 - 23 kg-m, 123 - 166 ft-lb)
CAUTION:
Always tighten wheel nuts in a criss-cross fashion.

TRM0003 (3) INSPECTION OF TIRE WEAR

Inspect all tires for tread groove depth. Visually check for
appearance of tread wear indicator (slip-sign mark) on the tire.

(4) INSPECTION OF UNEVEN TIRE WEAR

Inspect all tires for abnormal or uneven wear. Abnormal or uneven
wear often results from one of the causes indicated in the table
below. Check and locate the cause of the abnormal or uneven wear.
If necessary, replace the tire with a new one.

T
Condition Probable cause Corrective action

Wear at both tire • Abrupt turns under

AF shoulders heavy loads
• Overloading • Reduce carrying load
volume.

MAT0006

Wear in center of tire • Slips during braking

R
tread
D

MAT0007

Uneven tire tread wear • Uneven braking • Adjust brakes.

applications

MAT0008

MA-15
 BRAKE SYSTEM
BRAKE SYSTEM

Brake System
(1) INSPECTION OF BRAKE FLUID LEVEL
Check brake fluid level in brake reservoir tank. If it is between MAX
(upper limit) and MIN (lower limit) marks on the reservoir tank, fluid
level is correct. If it is lower than MIN (lower limit) mark, refill
specified brake fluid up to MAX (upper limit) mark.
CAUTION:
• Type of brake fluid: DOT4 (1N1), Power Steering Fluid, PSF
(A1N1).
• Do not overfill brake fluid.
BRM0087
• Be careful not to allow foreign matter to enter reservoir tank.
• Be careful not to splash brake fluid on painted areas; it may
cause paint damage.
• If brake fluid decreases abnormally, check for leaks in brake
line. Eliminate the cause of problem.
• Only use the authorized genuine brake fluid. Do not mix
different types of brake fluids.

(2) REPLACEMENT OF BRAKE FLUID

T
CAUTION:
• Type of brake fluid: DOT4 (1N1), Power Steering Fluid, PSF
(A1N1).
AF • Only use the authorized genuine brake fluid. Do not mix
different types of brake fluids.
• Do not replace the brake fluid for both brake lines at once.
Make sure to work on a single line at a time.
• The brake fluid is highly hygroscopic. When handling the
brake fluid, exercise extreme caution.
• Do not reuse the extracted brake fluid.
R
1. Block the front wheels and release the parking brake.
2. Raise the carriage to facilitate the work.
CAUTION:
After raising the carriage, support it securely so that it will not
D

fall.

3. Remove the bleeder cap. Connect a clear vinyl tube to the

bleeder valve and insert the other end of the tube in an
appropriate container.
CAUTION:
Before connecting the vinyl tube, always clean the bleeder
valve port.

4. Loosen the bleeder valve.

BRM0098

MA-16
 BRAKE SYSTEM

Brake System (Cont’d)

5. While adding new brake fluid to the reservoir tank of the brake,
depress the brake pedal until the new brake fluid starts coming
out from the bleeder valve.
6. Tighten the bleeder valve and fill the reservoir tank with the
specified amount of brake fluid. Perform “(3) Bleeding of Brake
System” described below.

MAT0223L

(3) BLEEDING OF BRAKE SYSTEM

If a portion of the brake fluid line system has been disassembled and
repaired, or if the pedal feels spongy when pressed, bleed the air
from the system.
1. Insert a transparent vinyl tube into the bleeder screw of the drive
unit that is far to the right from the brake chamber. Insert the
other side of the tube into a container filled with brake fluid.

T
2. Check the level of the brake fluid in the reservoir tank. Add fluid
if the fluid level is low.
3. Loosen air bleeder and depress the brake pedal. Repeat the
above procedure until air bubbles no longer appear. Tighten air
AF bleeder.
4. Following the same procedure, bleed the air from the left side.
Finally, add the prescribed amount of brake fluid to the reservoir
tank.
CAUTION:
• While working, ensure that the reservoir tank is constantly
filled with brake fluid.
R
• Use the designated brand of brake fluid. Do not mix with
other products.
• Do not allow any foreign materials to get into the brake fluid.
D

5. Depress the brake pedal several times to verify the pedal feel is
getting heavy.
6. Repeat the operations from step 3 until the brake fluid stream in
the vinyl tube contains no air bubbles.
7. Tighten the bleeder valve securely. Perform the same
operations for the other side.
8. After bleeding the air, check the reservoir tank fluid level and
add an appropriate amount of brake fluid if necessary.

MA-17
 BRAKE SYSTEM

Brake System (Cont’d)

(4) INSPECTION OF BRAKE DISK OIL LEVEL

CAUTION:
• Type of brake oil: SAE 80W/API GL4
• Place the vehicle on level ground. Ensure that the unit is
cooled down.
• Only use the authorized genuine brake oil.

1. Remove the oil level plug and check the brake oil level. Add new
brake oil from the filler port after removing the filler plug if
necessary.
BRM0071bEU
2. Apply liquid packing to the threads of the plugs. Then install and
tighten the plugs to the specified torque.
Tightening torque [N•m (kg-m, ft-lb)]: 15 (1.5, 11)

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AF
BRM0069EU
R
D

MA-18
 BRAKE SYSTEM

Brake System (Cont’d)

(5) INSPECTION/ADJUSTMENT OF BRAKE PEDAL
1. Measure pedal height (distance between floor panel and pedal
pad surface). If necessary, adjust using pedal stopper. Then,
securely tighten lock nut.
Standard:
122 mm (4.80 in)
: 12 - 15 N•m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)

BRM0079

2. Check brake pedal free play at push rod. If brake pedal free play
is outside specifications, adjust using push rod adjusting nut.
Then tighten adjusting nut and check pedal play at pedal pad.
Free play:
At push rod
0 - 0.5 mm (0 - 0.020 in)
At pedal pad

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0 - 2.3 mm (0 - 0.091 in)
: 16 - 22 N•m (1.7 - 2.2 kg-m, 12 - 16 ft-lb)
AF
BRM0080

CAUTION:
Always properly adjust play. If play is much less than standard,
push rod is continuously applied with load. This results in
blocking master cylinder return port, causing brake dragging.
Also, excessive play may cause push rod to come out of place.
R
3. With brake pedal free play adjusted properly, measure pedal
depressed height. If it is excessively outside the standard,
check brake system other than brake pedal assembly.
D

Standard:
80 mm (3.15 in)
4. Depress and release brake pedal several times to see if it
travels smoothly over its entire stroke without binding, twisting
or interfering with adjacent parts.
5. Depress and release brake pedal several times. Make sure that
brake switch comes on when the pedal is depressed 8.0 to 12.0
BRM0081 mm (0.315 to 0.472 in) and goes off when it is released.

MA-19
 BRAKE SYSTEM

Brake System (Cont’d)

(6) INSPECTION/ADJUSTMENT OF PARKING
BRAKE OPERATION EFFORT
1. Measure the operation force required to move the lever to the
lock position by applying force to point P shown in the figure.
Standard [N (kg, lb)]: 176 - 225 (18 - 23, 39 - 50)

MAM0162

2. If the measured operation force is not within the specified range,

perform the following adjustment.
• Unlock lever.
• Adjust adjusting bolt using a screwdriver so that the operation
force required to move the lever to the lock position is within the

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AF standard.

BRM0099
R
D

MA-20
 STEERING SYSTEM
STEERING SYSTEM

Steering System
(1) INSPECTION OF STEERING WHEEL FOR PLAY
Check that the steering wheel play is within the standard on the
circumference with key switch turned off.
Play: 20 - 30 mm (0.79 - 1.18 in )

MAM0164

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AF
R
D

MA-21
 HYDRAULIC SYSTEM
HYDRAULIC SYSTEM

Hydraulic System
(1) INSPECTION OF HYDRAULIC FLUID LEVEL
CAUTION:
• To ensure precise measurement, place the vehicle on level
ground, set the mast upright and lower the carriage to the
lowest limit.
• Only use the authorized genuine hydraulic fluid. Do not mix
different types of fluids.

1. Remove the level gauge for hydraulic fluid and clean the level
gauge with a shop cloth.
BSM617EU
2. Insert the level gauge into the port and pull out the gauge.
3. On the level gauge, check that the fluid level is within the
optimum range shown in the figure. Add the specified fluid if
necessary.
CAUTION:
• Do not overfill the tank.
• Do not allow any foreign materials to get into the tank.
• If the fluid consumption is too large, there is a possibility of

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fluid leakage. Inspect the system piping to identify the causal
points.

MAM0163EU
AF (2) REPLACEMENT OF HYDRAULIC FLUID
Contaminated or deteriorated hydraulic fluid may lead to
malfunctions of the hydraulic pump and control valves. To prevent
such symptoms, replace the hydraulic fluid at regular intervals.
CAUTION:
Only use the authorized genuine hydraulic fluid. Do not mix
different types of fluids.
R

1. Turn key switch to ON and raise the fork slightly by operating the
MOM8507
lift (mast) cylinder. (The fork should not touch the ground when
the tilt cylinder is fully tilted forward.)
D

2. Operate the tilt cylinder forward to the full stroke.

3. Return the control lever to the neutral position and turn key
switch to OFF. Loosen the connectors in front of the left and
right tilt cylinders and disconnect the hoses.
4. With key switch ON, set the control lever in the backward
position and tilt the mast fully backward using a crane, in order
to return the oil from the tilt cylinder to the oil tank.
5. Return the control lever to the neutral position.
6. Turn key switch to ON and raise the lift (mast) cylinder to the full
stroke.
7. Return the control lever to the neutral position and turn key
switch to OFF.
8. Move the control lever to the lift (mast) cylinder lowering position
to lower the lift (mast) cylinder gradually. By doing so, return the
fluid from the lift (mast) cylinder to the oil tank.
9. Drain the oil from the oil tank and extract the fluid.
10. Remove dust collected in the oil tank and clean inside the oil
tank.

MA-22
 HYDRAULIC SYSTEM

Hydraulic System (Cont’d)

CAUTION:
• When cleaning the tank, be careful not to leave any lint or
dust inside. These residues may cause filter plugging or
hydraulic component malfunctions.
• Make sure to replace the micron filter as well. Clean the
suction filter and fluid cap.

11. Attach the hoses and fill the oil tank with new hydraulic fluid
referring to the table below.
Model (A)1N1 J(A)G1N1

(US gal, Imp gal) 17.9 (4-3/4, 4) 20.9 (5-3/4, 5)

CAUTION:
The oil level should be between the upper limit and the lower
limit on the level gauge when the hydraulic fluid has permeated
through the hydraulic system and piping.

(3) REPLACEMENT OF MICRON FILTER

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CAUTION:
• Cover the surrounding areas with shop cloths to catch any
fluid overflow.
AF • Do not allow foreign materials to get into the piping.
• Wipe away any spilt fluid.
• Securely seal the taper thread of HYD pipe with seal tape.

1. Remove the return hose (low pressure hose).

2. Remove micron filter bracket assembly from the tank.
R
D

1 = Oiltank
2 = Micron filter assy
MAM0165 MAM0165

MA-23
 HYDRAULIC SYSTEM

Hydraulic System (Cont’d)

3. Remove micron filter from the micron filter bracket assembly.
4. Install a new micron filter to the micron filter bracket assembly.

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MAM0166
AF
(4) CLEANING OF SUCTION FILTER
1. Extract the hydraulic fluid referring to “(2) Replacement of
Hydraulic Fluid”.
2. Remove the hoses from the oil tank.
3. Remove the oil tank from frame.
4. Remove the suction filter from the oil tank.
R
CAUTION:
Do not allow foreign materials such as dust and dirt to get into
the hydraulic fluid tank.
5. Clean the filter with kerosene. If damaged, replace the filter.
D

6. Install the suction filter to the oil tank.

Tightening torque [N•m (kg-m, ft-lb)]:
5 - 6 (0.52 - 0.66, 45 - 53)
CAUTION:
Be sure to align packing and suction filter with their mounting
holes before installation.

(5) INSPECTION OF HYDRAULIC PRESSURE

1. Verify that the fluid level in the hydraulic fluid tank is appropriate
and remove the plug from the high-pressure pipe of hydraulic
pump.

MA-24
 HYDRAULIC SYSTEM

Hydraulic System (Cont’d)

2. Attach the adapter to the port and connect a pressure gauge to
the adapter.
3. Turn key switch to ON and operate control lever for hydraulic
system and turn steering wheel fully right or left for power
steering system and check the pressure referring to Table
below.

Standard pressure
MPa (bar, kg/cm2, psi)

Main relief pressure 16.7 (167.0, 170.34, 2,421)

HDM0165
Tilt relief pressure 9.3 (93.0, 94.86, 1,348)
3rd, 4th relief pressure 11.8 (118.0, 120.36, 1,711)
Power steering relief pressure 6.9 (69.0, 70.38, 1,000.5)

4. If out of specification, adjust the pressure.

(6) ADJUSTMENT OF HYDRAULIC PRESSURE

• Turn key switch to OFF, and then disconnect the battery

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connection.
• Disconnect seat switch harness connection, and then connect the
seat switch harnesses on body harness side.
• Relief valve on control valve upper side
AF
1. Remove control valve switch (for mechanical).
2. Loosen lock nut of relief valve assembly.
3. Connect battery cable, and then turn key switch to ON.
4. Push control valve switch to ON (for mechanical). Operate
control lever (for joystick).
5. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard, turn clockwise.
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• If greater than the standard, turn counterclockwise.
CAUTION:
• One rotation of the adjusting screw corresponds to a
pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80 kg/
D

HDM0144
cm2, 995 - 1,138 psi), so do not turn carelessly.
• Carefully adjust pressure, observing the pressure gauge
reading.
6. After completing adjustment, hold adjusting screw in place and
tighten lock nut.
7. Implement the pressure test again to check whether the set
pressure is correct.
• Relief valve on control valve lower side
1. Remove battery from the vehicle.
2. Connect battery cable to the vehicle using an extension cable.
3. Turn key switch to ON and operate control lever.
4. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard: Turn clockwise.
• If greater than the standard, turn counterclockwise.
CAUTION:
• One rotation of the adjusting screw corresponds to a
pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80
kg/cm2, 995 - 1,138 psi), so do not turn carelessly.
• Carefully adjust pressure, observing the pressure gauge
reading.

MA-25
HYDRAULIC SYSTEM

Hydraulic System (Cont’d)

5. After completing adjustment, hold adjusting screw in place and
tighten lock nut.
6. Implement the pressure test again to check whether the set
pressure is correct.

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AF
R
D

MA-26
 LOADING MECHANISM
LOADING MECHANISM

Loading Mechanism
(1) INSPECTION OF FORK
• Visually inspect the fork and replace it if cracked or damaged. (To
identify minute cracks, use the dye penetrant method.)
• If the fork is worn by 3 mm or more compared to a new one,
replace it. (The grounding face at the fork base is prone to wear.)

LMM0227

(2) INSPECTION/ADJUSTMENT OF CARRIAGE

HEIGHT
1. Set the mast upright and fully lower the carriage.
CAUTION:
Before inspecting and adjusting the carriage height, remove the
fork or park the vehicle in a place where the fork will not be
grounded.

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2. Measure the distance from the ground level to the carriage
bottom end to see if it fulfills the following criterion.
AF Standard: 76 mm (2.99 in)
3. If not as specified, loosen the lock nut and adjust with the lift
chain adjusting nut.
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MAT0159J
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MA-27
 LOADING MECHANISM

Loading Mechanism (Cont’d)

(3) INSPECTION/ADJUSTMENT OF LIFT CHAIN
TENSION
CAUTION:
Before this maintenance work, always ensure that the carriage
height is appropriate.

1. Set the mast upright and raise the fork by 20 to 30 mm from the
ground level.
2. For the 2W mast, pull the lift chain at the middle point and check
the deflection. For the 2F, 3F and 3V masts, press the lift chain
at the middle point and check the deflection.
Standard: 25 - 30 mm (0.98 - 1.18 in)
3. If the deflection is outside the specified range, loosen the lock
nut and adjust the chain tension with the lift chain adjusting nut.
CAUTION:
• Ensure that equivalent tension is applied to the left side and
right side of the lift chain.
• After adjustment, always check the carriage operation for

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AF smoothness.

LMT0152L
R
(4) INSPECTION OF CARRIAGE ROLLER
• If the carriage roller does not operate smoothly or has undergone
deformation, stepped wear or damage, replace it.
• Check the clearance between the carriage roller rolling face and
D

the inner mast. If the clearance is outside the specified range,

replace the carriage roller with a new one with an appropriate
size.
Standard clearance mm (in):
0.1 - 0.6 (0.004 - 0.024)
Available roller sizes mm (in):
97.0, 97.5 and 98.0 (3.819, 3.839 and 3.858)
Center mast roller diameter (2W/2F/3F mast) mm (in):
97.0 (3.819)
MAT0172J

MA-28
 LOADING MECHANISM

Loading Mechanism (Cont’d)

(5) INSPECTION OF MAST ROLLER
• If the mast roller does not operate smoothly or has undergone
deformation, stepped wear or damage, replace it.
• Check the clearance between the mast roller rolling face and the
mast rail. If the clearance is outside the specified range, replace
the mast roller with a new one with an appropriate size.
Standard clearance mm (in):
0.1 - 0.6 (0.004 - 0.024)
Roller diameter type mm (in):
2W inner mast:
Mast height: 3,500 or more (137.80 or more):
105.0, 105.5, 106.0 (4.13, 4.15, 4.17)
Mast height: 2,700 - 3,300 (106.30 - 129.92):
LMT0027 105.0 (4.13)
2F mast inner mast:
Mast height: 3,500 or more
105.0, 105.5, 106.0 (4.13, 4.15, 4.17)
Mast height: 2,700 - 3,300 (106.30 - 129.92),
105 (4.13)

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3F/3V middle mast lower side:
105.0, 105.5, 106.0 (4.13, 4.15, 4.17)
3F/3V inner mast side:
97.0, 97.5, 98.0 (3.82, 3.84, 3.86)
AF
(6) ADJUSTMENT OF MAST ROLLER CLEARANCE
1. Preliminarily set the roller pitches (dimension L) of the inner and
outer masts referring to the table below.
CAUTION:
For the 3F and 3V mast, set the roller pitches in two steps: first
R
for the inner and middle masts, then for the middle and outer
masts. Setting the roller pitches of the three masts at once will
deteriorate the stability.

2W mast
D

Unit: mm (in)

Lifting height Dimension “L”

2,700 (106.30), 3,000 (118.11), 3,300 (129.92) 283 (11.14)

3,500 (137.80) 318 (12.52)
3,700 (145.67) 343 (13.50)
4,000 (157.48), 4,500 (177.17), 5,000 (196.85) 383 (15.08)

2F mast
Unit: mm (in)
LMT0029
Lifting height Dimension “L”

2,700 (106.30), 3,000 (118.11), 3,300 (129.92) 284 (11.18)

3,500 (137.80) 354 (13.94)
3,700 (145.67) 404 (15.91)
4,000 (157.48) 484 (19.06)

MA-29
 LOADING MECHANISM

Loading Mechanism (Cont’d)

3F and 3V mast

LMT0035

3F mast
Unit: mm (in)

Lifting height Dimension “L”

3,850 (151.57), 4,300 (169.29), 4,750 (187.01), 5,150 369 (14.53)
(202.76)

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5,500 (216.54) 384 (15.12)
6,000 (236.22) 419 (16.50)
6,500 (255.91) 504 (19.84)
AF 7,000 (275.59) 604 (23.78)

3V mast
Unit: mm (in)

Lifting height Dimension “L”

3,600 (141.73), 4,050 (159.45), 4,500 (177.17), 4,900 369 (14.53)

(192.91)
R
5,250 (206.69) 384 (15.12)
5,750 (226.38) 419 (16.50)
6,330 (249.21) 504 (19.84)
6,880 (270.87) 604 (23.78)
D

2. Slide the mast to the leftmost or rightmost end. Check the

clearance between the mast and the opposite mast roller. If the
clearance is outside the specified range, adjust it with the
clearance adjusting shims for the roller.
Standard: 0.1 - 0.6 mm (0.004 - 0.024 in)
Shim type: 0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in)

LMT0030

MA-30
 LOADING MECHANISM

Loading Mechanism (Cont’d)

CAUTION:
Create an equivalent clearance at both the right and left sides
wherever possible.

LMT0031

3. Visually inspect the mast liner. Replace it if worn excessively or

damaged.
4. Check the clearance between the mast liner and the inner mast.
If not as specified, adjust the clearance using the shims.
Standard: 0.1 - 0.6 mm (0.004 - 0.024 in)
Shim type: 0.5 and 1.0 mm (0.020 and 0.039 in)

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AF
LMT0161L

(7) INSPECTION OF MAST OPERATION

• Raise, lower, and tilt forward/backward the mast. The mast should
generate no drag feel or unusual noises.
• Check that the mast support maintains an appropriate free play
and the mast support cap bolt has no looseness.

(8) INSPECTION OF MAST CYLINDER

R
• Operate the cylinder and check that no dragging and unusual
noises are present.
• Check that no oil leaks are present.
D

• The piston rod should be free from scratches.

• The cylinder tube should be free from dents and damages.

(9) INSPECTION OF TILT CYLINDER

Check the following points:
• No dragging or unusual noises are present during operation.
• No oil leaks are present.
• The piston rod should be free from scratches.
• The tilt cylinder rod and lock nut are not loose.

LMT0124J

MA-31
 LOADING MECHANISM

Loading Mechanism (Cont’d)

(10) GREASING POINT
Tilt cylinder pivot pin
• Supply grease from the grease nipple.

BET0236L

Lift chain
• Apply gasoline engine oil to the entire surface of the chain.

T
AF
MAT0163J

Mast support
• Supply grease from the grease nipple.
R
D

LMM0223

Mast roller and mast liner

• Apply grease to the roller sliding faces and mast liner.

MAT0164J

MA-32
 LOADING MECHANISM

Loading Mechanism (Cont’d)

• Apply grease to the rolling face of the roller and the rail of the
thrust metal contact face.

LMM0231

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LMM0212
AF
R
D

MA-33
LOADING MECHANISM

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AF
R
D

MA-34
 CONTROL SYSTEM

1N1 SECTION CS
CONTENTS
TECHNICAL DESCRIPTION ............................. CS-2 How To Follow Flow Chart .......................... CS-79
System .......................................................... CS-2 Symbol Identification ................................... CS-80
PRECAUTIONS ............................................... CS-10 Voltage and Resistance Measurement
LOCATION OF UNITS (LAYOUT) ................... CS-11 Procedures .................................................. CS-81

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Standard Equipment (3 - wheel) .................. CS-11 TROUBLE DIAGNOSIS FOR CONTROLLER
Standard Equipment (4 - wheel) .................. CS-12 SYSTEM ........................................................... CS-82
Optional Equipment ..................................... CS-13 TROUBLE DIAGNOSIS FOR DRIVING
AF
METER PANEL ................................................ CS-14 SYSTEM ........................................................... CS-90
Meters, Indicators and Lamps ..................... CS-14 TROUBLE DIAGNOSIS FOR LOADING
Setting Adjustment Items (Normal Mode) ... CS-14 SYSTEM OF MECHANICAL TYPE ................. CS-97
Meter Panel Explanation ............................. CS-15 TROUBLE DIAGNOSIS FOR LOADING
LCD MONITOR ................................................ CS-23 SYSTEM OF JOYSTICK TYPE ..................... CS-102
Adjustment Mode ........................................ CS-23 TROUBLE DAIGNOSIS FOR POWER
Diagnostic Mode .......................................... CS-31 STEERING SYSTEM ..................................... CS-108
Table of Error Code ..................................... CS-42 TROUBLE DIAGNOSIS FOR TURN SIGNAL
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CONTROLLER ................................................. CS-43 LAMP SYSTEM ............................................. CS-109
Construction ................................................ CS-43 REFERENCE DATA OF CONTROL
Connector (Terminal layout) ........................ CS-45 SYSTEM ......................................................... CS-110
Controller Element Inspection ..................... CS-49 Main Print Board ........................................ CS-110
D

Removal and Installation (3 - wheel) ........... CS-56 Drive FET Board

Removal and Installation (4 - wheel) ........... CS-57 (for RH traction motor control) ................... CS-114
UNIT INSPECTION AND ADJUSTMENT ........ CS-58 Drive FET Board
Control System ............................................ CS-58 (for LH traction motor control) ................... CS-114
Joystick Control System (Option) ................ CS-70 Pump FET Board ....................................... CS-114
Knob Position Control System Traction Condenser Board ........................ CS-115
(Option 3 - wheel only) ................................ CS-77 Loading Condenser Board ........................ CS-115
TROUBLE DIAGNOSTIC PROCEDURES ...... CS-78 Joystick Controller ..................................... CS-116
Precautions ................................................. CS-78

CAUTION:
Where towing this truck always ensure key is in OFF position and battery is disconnected (unplugged) to
reduce possible damage to electrical system.
Bulletin issued:
Service Bulletins Issue date
SB-TX-CS0501-2 Prevention to damage controller 05-01-2006
SB-TX-CS0502 Changing ground circuit MP 29-11-2005
SB-TX-CS0601 Power mode indication scrolling on meter panel 05-05-2006
SB-TX-CS0602 Error code 558 occur with FN1+FN3 05-05-2006
SB-TX-CS0702 Incorrect measurement with damaged controller insulation 01-10-2007

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AF
R
D

CS-1
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION

System
COMPARISON OF PREVIOUS TYPE AND NEW TYPE

T
AF
CSM0086
R
CORRELATION DIAGRAM OF SYSTEM
Drive system
D

CSM0087

CS-2
 TECHNICAL DESCRIPTION

System (Cont’d)
AC motor control

T
AF
CSM0088

DRIVE SYSTEM FUNCTION

R

Item Function Outline

Drive control Drive control type Induction motor AC inverter vector control
D

Drive control 2 motor turning control

Regeneration control Switchback, brake, accelerator off regeneration
Performance adjustment Power level (3 steps+ accurate adjustment 5 steps)/Acceleration Level (8 steps),
Regeneration level (8 steps each)
Anti-roll (8 steps)
Anti-roll control Anti-roll braking force control on slope
Various limitation Speed, high lift height, power cut (brake, parking brake)
Pump control Drive control Induction motor AC inverter vector control
Drive control Speed control by loading operation
Regeneration control Loading regeneration when loading operation stopped
Performance adjust. Power level (3 steps + accurate adjust 5 steps) Acceleration Level (8 steps)
Various limitation High lift height, high driving speed, cutout when reverse drive, pump cut
Mast lowering control Mast lowering lock when key switch is off
Magnetic proportional control Magnetic proportional loading control for optional unit (Joystick control system)
PS control Drive control type Electronic controlled hydraulic power steering
Drive control method Common pump motor control for loading
Control function Starting with steering operation detected/steering speed sensing control
Knob position control Compensate steering angle and tire angle offset by magnetic valve control

CS-3
 TECHNICAL DESCRIPTION

System (Cont’d)
Item Function Outline

System control Inhibitor control Accelerator, FR SW, Loading, Seat

Meter communication Trace truck mode changeover by meter indication
Meter display of various truck conditions, diagnoses and adjustments
Log in function Setting of each truck by pass word input
Diagnosis function Diagnosis function in normal mode/self checking/dialog checking
Adjustment function Drive, pump, power steering system adjustment and memory
Accessory control Automatic power off/Parking brake warning
Cooling fan drive/External accessory source relay/Flasher
Truck model variation Automatic model variation change by harness
Electromagnetic Mag. proportional valve Magnetic proportional valve control corresponding to control valve opening
control (Joystick
Loading corresp. control Pump motor revolution control corresponding to control valve opening
control system)
Communication function CAN communication between main control
Others Adjustment and diagnosis function
Temperature Motor temp. control Controlling temperature of motor. When the motor temperature exceeds a temperature of
control 130 degrees C (266 degrees F), controller will slow down the motor(s) until motor cools
Controller temp. control Controlling temperature of controller. When the controller temperature exceeds a

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temperature of 130 degrees C (266 degrees F), controller will slow down the motor(s) until
controller cools
AF
R
D

CS-4
 TECHNICAL DESCRIPTION

System (Cont’d)
FEATURE OF DRIVE SYSTEM
Maintenance free AC Traction/Pump Motors
Pump motor is used for PS

Accessories concentrated control

Various model changing function (Same controller for various models)
Lift lowering, PS valve control
Flasher control
Cooling fan control (Including external fan)
Electric source relay (Auto power off, valve electric source)

High technology for superior function and high reliability by adoption of sensors with high performance
AC motor digital control adopting 32bit RISC CPU
Adoption of HEV (Hybrid Electric Vehicle) high responsible items such as resolver
CAN (Controller Area Network) communication between units

Magnetic proportional control (Joystick control system)

No special modification is necessary on controller, Add on installation
Accurate loading control by coordinating with main controller

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COMPARISON OF FORKLIFT MOTOR CONTROL
AF
R
D

CSM0089

CS-5
TECHNICAL DESCRIPTION

System (Cont’d)

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AF
CSM0090
R
D

CSM0091

CS-6
TECHNICAL DESCRIPTION

System (Cont’d)
PRINCIPLE OF AC MOTOR

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AF
R
D

CSM0092

CS-7
TECHNICAL DESCRIPTION

System (Cont’d)
KNOB POSITION CONTROL SYSTEM
(OPTION 3 - WHEEL ONLY)
Knob position control
This ensures that the steering knob position constantly reflects the
correct tire angle.
NOTE:
The neutral level for the tire angle sensor must be adjusted
individually for each vehicle. (To absorb any variants in sensor
mounting and vehicle differences.)

Input Output

Steering wheel angle sensor

angle 1 signal
Steering wheel angle sensor
Steering wheel Power steering correction
angle 2 signal
solenoid
Steering wheel angle sensor
neutral signal
Tire angle sensor

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AF
R
D

CS-8
 TECHNICAL DESCRIPTION

System (Cont’d)
Knob position control system (option 3 - wheel only)

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AF
R
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CSM0093

CS-9
 PRECAUTIONS
PRECAUTIONS

CAUTION:
• Before removing or inserting main/meter print board
connectors, turn the key switch to the OFF position and
remove the battery plug. Failure to do so may cause a
malfunction in the print board.
• Make sure the controller/meter connector cord is free from
twisting when the connector is removed or inserted. A
twisted cord may cause poor connector contact. When
removing the connector, always hold the connector body and
do not pull on the cord.
• When removing wiring harnesses and/or bus bars, note their
relative locations so they can be reinstalled in their original
positions during reassembly.
• When installing a controller element which is used with
insulating film, be sure to place insulating film on the
contacting surface of the element and mating part. If a
controller element is not used with insulating film, apply
silicone-based grease to the contacting surface of the
element and mating part during installation.
• Before checking controller elements during on-vehicle
inspection, remove the wiring harnesses and bus bars.

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Inadvertent current flow may damage the element or other
parts being checked.
• Before using flow charts as a guide to troubleshoot units and
AF parts, become familiar with the instructions outlined under
“TROUBLE DIAGNOSTIC PROCEDURES”.
NOTE:
Controller and unit conditions are determined by checking/
measuring the resistance values (continuity) of, or voltage values
produced across, various parts affected. However, this section deals
with only resistance measurement procedures.
R
D

CS-10
LOCATION OF UNITS (LAYOUT)
LOCATION OF UNITS (LAYOUT)

Standard Equipment (3 - wheel)

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AF
R
D

CSM0094

CS-11
LOCATION OF UNITS (LAYOUT)

Standard Equipment (4 - wheel)

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AF
R
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CSM0094EU

CS-12
LOCATION OF UNITS (LAYOUT)

Optional Equipment

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AF
R
D

CSM0095EU

CS-13
 METER PANEL
METER PANEL

Meters, Indicators and Lamps

T
AF
CSM0096EU

Setting Adjustment Items (Normal Mode)

R
Adjustment item Shift to adjust mode Adjustment Details Function lock on
Push FN1 LCD contrast is brightened.
LCD contrast – Unlocked (OFF)
Push FN2 LCD contrast is dimmed.
Traction and loading P H M E
– Push FN3 Locked (ON)
D

power mode
Hour meter select – Push FN4 Locked (ON)
Push FN3 Hour Minute Day
Push FN4 Hour Minute Day
Clock setting Push FN1 + FN2 Unlocked (OFF)
Push FN1 The digit is increased, or the day is advanced.
Push FN2 The digit is decreased, or the day is set back.
Push FN3 Hour Minute Day
Push FN4 Hour Minute Day
Alarm setting Push FN2 + FN4 Unlocked (OFF)
Push FN1 The digit is increased, or the day is advanced.
Push FN2 The digit is decreased, or the day is set back.
Push FN3 D-ACC P-LEVEL
Push FN4 D-ACC P-LEVEL
Acceleration level Push FN1 + FN4 Locked (ON)
Push FN1 Increase
Push FN2 Decrease
Push FN2 + FN5
+
Push FN5
+
Push FN2
Function lock/
+ – The above functions are locked (ON)/unlocked (OFF).
unlock code
Push FN3
+
Push FN5
+
Push FN5

CS-14
 METER PANEL

Meter Panel Explanation

DESCRIPTION
The meter panel consists of two sections: LCD (Liquid Crystal
Display) monitor and function keys.
1. Function keys
Function keys control the LCD contrast, display changes and
other adjustments. Function key operation is described in the
individual part descriptions and in the items related to
adjustment.
2. LCD
When the key switch is in the ON position, backlighting makes
the displays clearly visible to the forklift operator. It displays
normal operation (battery capacity meter, hour meter, clock,
steering wheel angle gauge, speedometer, etc.), malfunction
and adjustment data.

LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
To darken the contrast, push function switch FN2. To lighten the
contrast, press function switch FN1.

T
HOUR METER (4 MODES)
CSM0097
This hour meter has 4 modes (functions).
AF 1. Key “ON” time : Equal to the total operating hours when the
key switch is in the ON position.
2. Operating time : Equal to the traveling or loading time (the
time for whichever operation in progress is displayed).
3. Traveling time : Equal to the total time that the traction motor
is operational.
4. Loading time : Equal to the total time that the forks are
R
operational (tilting and lifting).
The hour meter operates when the key switch is in the ON position,
and it indicates the total operating period in hours (key “ON” time).

STEERING WHEEL ANGLE GAUGE/SPEEDOMETER

D

When the vehicle speed is 3 km/h or less, the speedometer

indicates the angle of rear wheel tires, instead of the speed.

NOTE:
Only for 3 - wheel trucks

CSM0098

CS-15
 METER PANEL

Meter Panel Explanation (Cont’d)

When vehicle speed is 4 km/h or more, the speedometer shows
forklift speed in either kilometers per hour (km/h) or miles per hour
(mph). The maximum vehicle speed and speed alarm can both be
set.

NOTE:
Speedometer factory settings at time of shipping:
Maximum speed: 20 km/h (12 MPH)
Setting speed range: 1 - 20 km/h (3 - 12 MPH)
Forklift speed alarm 1 - 2 setting: 25 km/h (16 MPH)
Forklift speed alarm 1 setting range (WSL1):
5 - 25 km/h (3 - 16 MPH)
Forklift speed alarm 2 setting range (WSL2):
WSL1 - 25 km/h (WSL1 - 16 MPH)

T
CSM0099
AF POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function switch FN3 is pressed, the power
mode is switched.

Mode M: Manual mode:

The power levels for traveling and loading can be individually set
R
according to customer requests.
Factory defaults:
Traveling power level: Level 1
CSM0100 Loading power level: Level 1
D

Adjustable range for traveling and loading power levels: Levels 1 - 5

Mode E: Economy mode:

For work requiring operation time to be saved or customers using
the machine for a long time (Traveling and loading power levels:
Level 1)

Mode P: Power mode:

Factory setting (Traveling and loading power levels: Level 3)

Mode H: High-power mode:

For work or customers requiring higher power (Traveling and loading
power levels: Level 5)

CS-16
 METER PANEL

Meter Panel Explanation (Cont’d)

CLOCK/ALARM/ACCELERATION ADJUSTMENT
Clock/alarm
When the key switch is in the ON position, both the day and time are
displayed.

Push function switches FN1 and FN2 simultaneously. The time set
mode will appear.

AM and PM hour adjustment: The hour display will advance by 1

hour each time function switch FN1 or FN2 is pushed.
CSM0101

Minute adjustment: The minute display will advance by 1 minute

each time function switch FN1 or FN2 is pushed.

Day-of-the-week adjustment: The day-of-the-week display will

advance by one day each time function switch FN1 or FN2 is
pushed.

After setting the clock to the correct time, push function switch FN5.

T
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
AF • Push FN1 to increase the numerical value or advance one day of
the week.
• Push FN2 to decrease the numerical value or reverse one day of
the week.
• If an alarm is set, “ ” appears next to the time display. When
the preset time is reached, the buzzer sounds to notify the
operator. Press FN5 to stop the buzzer. The day of the week can
be set to every day (ALL: every day).
R

Traction acceleration adjustment

This control adjusts acceleration during forklift starting and
D

subsequent operation.

Simultaneously press function switches FN1 and FN4. The clock will
move to the traction acceleration control mode.

The acceleration level can be adjusted in a series of 8 steps.

For faster acceleration (Quick): Push function switch FN1.

CSM0102

Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.

For slower acceleration (Slow): Push function switch FN2.

Each time the key is pushed, the acceleration level (speed) will
decrease by 1 step.

After setting the acceleration level, push function switch FN5. The
acceleration level will appear, and clock will return to its original letter
mode.

CS-17
 METER PANEL

Meter Panel Explanation (Cont’d)

NOTE:
Acceleration factory setting at time of shipping:
D-ACC NOM SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After acceleration level adjustment, operate the forklift slowly
and carefully until you become accustomed to the new
acceleration level. Be especially careful when the acceleration
level has been increased. Higher acceleration levels can cause
loads to shift, to fall off or to be unstable during starts.

Pump acceleration adjustment

Simultaneously push function switches FN1 and FN4. Next, push
function switch FN3. The clock will move to the pump acceleration
control mode.

The acceleration level can be adjusted in a series of 8 steps.

T
For faster acceleration (Quick): Push function switch FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
CSM0103
AF For slower acceleration (Slow): Push function switch FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.

After setting the acceleration level, push function switch FN5. The
pump acceleration level will appear, and the clock will return to its
original letter mode.
R
NOTE:
Pump acceleration factory setting at time of shipping:
P-LEVEL SET: Level 6
(Permissible setting range: Level 1 - 8)
D

WARNING:
After pump acceleration level adjustment, operate the forklift
mast control slowly and carefully (up, down and tilt) until you
become accustomed to the new pump acceleration level. Be
especially careful when the acceleration level has been
increased. Higher pump acceleration levels can cause loads to
shift, to fall off or to be unstable during starts.

CS-18
 METER PANEL

Meter Panel Explanation (Cont’d)

PARKING BRAKE WARNING MARK
This mark is displayed whenever the parking brake lever is in the
locked position. The mark disappears whenever the parking brake
lever is released.

SEAT BELT WARNING MARK

This lamp indicates that the seat belt is not fastened securely. It will
lights up if the seat belt is not fastened when the ignition switch is
turned to the ON position, and it will turn off when the seat belt is
fastened.

MALFUNCTION AND WARNING INDICATIONS

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AF
R
D

CSM0104

If any malfunction occurs when the key switch is in the ON position,

the LCD will show a wrench mark “ ” or a battery mark “ ”.
Simultaneously, the LCD will display letters explain the details of the
malfunction.
NOTE:
During forklift operation, periodically check the battery capacity.
Make every effort to recharge the battery before the battery warning
mark “ ” and wrench mark “ ” appear.

Wrench mark
The controller and the sensors act together to regulate the forklift’s
electrical system. The wrench mark will appear whenever one of the
malfunctions listed below occurs. Simultaneously, the LCD will show
an indication explaining the details of the malfunction.

CS-19
 METER PANEL

Meter Panel Explanation (Cont’d)

• Control system malfunction (Traction, Cargo-handling, Power
steering)
• Overheating controller or motor
• Low brake fluid level

BATTERY WARNING MARK

Pump cut warning
Pump cut warning is displayed when the battery capacity meter’s
remaining capacity indication changes from 2/6 to 1/6.

CSM0105

When function switch FN5 is pressed, the display will switch.

T
AF
CSM0106

After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
R
D

CSM0105

When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle may be operated during the pump cut warning.
However, move the vehicle to a safe location, and promptly charge
the battery.

CSM0106

CS-20
 METER PANEL

Meter Panel Explanation (Cont’d)

Low voltage lock warning
If the vehicle is subjected to continuous operation after the pump cut
warning was activated, the low voltage lock warning will be
activated. Then, the display will appear as shown below, and the
warning buzzer will be activated.

CSM0105

When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle cannot be operated during the low voltage lock warning.
NOTE:
The interval between the first appearance of the battery warning
mark and warning buzzer operation is set at the time of shipping.

T
Factory setting: 10 minutes
Permissible setting range: 1 - 20 minutes
AF
CSM0106
R
D

CS-21
 METER PANEL

Meter Panel Explanation (Cont’d)

MALFUNCTION INDICATIONS
Affected system or area Indication Malfunction description
Control system (Traction, D-FET SHORT A malfunction has occurred in
Cargo-handling, Power the forklift traction system.
steering): Units, Sensors, Further operation of the forklift is
Motors, Switches, FETss not possible.

P-FET OPEN A malfunction has occurred in

the forklift cargo-handling
system. Further lifting (lifting
and tilting) operation is not
possible. The forks cannot be
raised or tilted.

TIRE ANGLE SENSOR LOW A malfunction has occurred in

the forklift power steering
system. Forklift steering control
is possible.

D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor is WARNING
overheating. Immediately stop
Ignoring the warning indication and
forklift operation. Park the forklift in
continuing to operate the forklift
a safe area where there is no
can result in serious motor and
pedestrian or vehicular traffic.

T
controller damage.
Allow the controller and/or the
motor to cool.

P/MO TEMP SENSOR HIGH TEMP

AF
Essential fluid BRAKE FLUID LEVEL DOWN The brake fluid level has fallen
below the specified level.

Battery Battery over voltage The controller has detected a high Turn the key switch OFF and ON
battery voltage again. If no error displayed, you can
operate the forklift without a
problem. If problem reoccur, contact
R
your dealer.
D

CS-22
 LCD MONITOR
LCD MONITOR

Adjustment Mode

T
AF
R
D

CSM0107

CS-23
 LCD MONITOR

Adjustment Mode (Cont’d)

NOTE:
This mode is only available for qualified technicians to perform
various adjustments on setting values other than traction/loading
acceleration adjustments in the normal mode.
CAUTION:
• Adjustment values can be advanced or retarded by pushing
FN3 or FN4, respectively.
• Following adjustment value settings, do not turn the key
switch to the OFF position before pressing FN5 to return to
the adjustment item display. Doing so will erase adjustment
value settings.

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AF
R
D

CS-24
 LCD MONITOR

Adjustment Mode (Cont’d)

T
AF
R
D

CSM0109

CS-25
 LCD MONITOR

Adjustment Mode (Cont’d)

T
AF
R
D

CSM0110EU

CS-26
 LCD MONITOR

Adjustment Mode (Cont’d)

T
AF
R
D

CSM0190

CS-27
 LCD MONITOR

Adjustment Mode (Cont’d)

T
AF
R
D

CSM0191EU

CS-28
 LCD MONITOR

Adjustment Mode (Cont’d)

T
AF
R
D

CSM0192

CS-29
 LCD MONITOR

Adjustment Mode (Cont’d)

T
AF
R
D

CSM0193

CS-30
 LCD MONITOR

Diagnostic Mode

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AF
R
D

CSM0108

CS-31
 LCD MONITOR

Diagnostic Mode (Cont’d)

There are two types of diagnostic method. One type is self-diagnosis
and the other is interactive diagnosis. Self-diagnosis allows for
controller diagnosis of a system, while the interactive diagnosis is
used for diagnosing switches and sensors. When malfunctions occur
in systems or components, check and eliminate probable causes of
the malfunction using either self-diagnostic or interactive diagnostic
techniques. After the malfunctioning area has been repaired,
confirm the malfunction has been eliminated by using the
appropriate diagnostic method.
NOTE:
When checking each component, operate each component if
necessary.

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AF
R
D

CS-32
 LCD MONITOR

Diagnostic Mode (Cont’d)

T
AF
R
D

CSM0111

CS-33
 LCD MONITOR

Diagnostic Mode (Cont’d)

T
AF
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D

CSM0112

CS-34
 LCD MONITOR

Diagnostic Mode (Cont’d)

T
AF
R
D

CSM0194

CS-35
 LCD MONITOR

Diagnostic Mode (Cont’d)

T
AF
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D

CSM0195

CS-36
 LCD MONITOR

Diagnostic Mode (Cont’d)

T
AF
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D

CSM0196

CS-37
 LCD MONITOR

Diagnostic Mode (Cont’d)

T
AF
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D

CSM0197

CS-38
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
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D

CSM0198

CS-39
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CSM0199

CS-40
 LCD MONITOR

Diagnostic Mode (Cont’d)

CAUTION:
If an interactive diagnostic result indicates that a unit is
abnormal, also check the condition of the associated harness
and connector.
NOTE:
• The number of malfunctions which have occurred in each system
is recorded in the “FAIL LOG” row on the display, without regard to
the nature of the malfunctions experienced.
• For unit inspection procedures, refer to “UNIT INSPECTION AND
ADJUSTMENT” on page 56.

RESULT OF SELF-CHECK
If the error is not detected:

T
AF
CSM0113

If the error is detected:

NOTE:
The 3-digit number in the figure indicates the error code of the
component for which the error is detected. For the error code, refer
to “Table of Error Code” on page 41.
R
CAUTION:
If a self-diagnostic result indicates that an element or
component is abnormal, also check the condition of the
associated harness and bus bar.
D

CSM0114
NOTE:
For element inspection procedures, refer to “Controller Element
Inspection” on page 48.

CS-41
 LCD MONITOR

Table of Error Code

Error Detect mode Reference Error Detect mode Reference
Failure part Fail mode Remarks Failure part Fail mode Remarks
code Work Self page code Work Self page

CONTROLLER ACTUATOR
Main contactor Short 400 - Lift down valve Short 500
CS-52 - CS-69 -
Open 401 - Open 501
Main fuse Open 403 CS-53 - PS correction valve Short 502 Knob
Battery voltage Low voltage 404 - Open 503 position
CS-77
control
Over 405 - - -
(Option)
voltage
Tilt Horizontal valve Short 504
CONT capacitor Abnormal 406 - - - Not equipped
Open 505
Drive FET Short 408
Lift valve Pull Short 506
Open 409 Joystick
CS-49 - Open 507
Drive FET left Short 410 control
Push Short 508 (Option)
Open 411
Open 509
Pump FET Short 412
CS-50 - Tilt valve Pull Short 510
Open 413 Joystick
Open 511
Drive current U Low output 414 control
sensor Push Short 512 (Option)
High output 415
Open 513
V Low output 416
3rd valve Pull Short 514
High output 417 Joystick
CS-51 - Open 515
Drive current U Low output 418 control
sensor left Push Short 516

T
High output 419 (Option)
Open 517 CS-72-73
V Low output 420
4th valve Pull Short 518
High output 421 Joystick
Open 519
D/Mo TEMP Abnormal 422 control
sensor Push Short 520 (Option)
D/Mo TEMP
Overheat
Abnormal
423
424
AF -
CS-54 - Open 521
sensor left 5th valve Pull Short 522
Overheat 425 - Joystick
Open 523
D/CONT TEMP Abnormal 426 control
sensor - - Push Short 524 (Option)
Overheat 427 -
Open 525
D/CONT TEMP Abnormal 428
sensor left - - C1 solenoid valve Short 526 Joystick
Overheat 429 - control
Open 527
Pump current U Low output 430 (Option)
sensor High output 431 SENSOR
R
CS-51 -
V Low output 432 F/R Switch Same ON 450 - CS-58, -
72
High output 433
Accel sensor Low output 452
P/Mo TEMP Abnormal 434 CS-64 -
sensor CS-54 - High output 453
Overheat 435 -
Tire angle sensor Low output 454 CS-61
P/CONT TEMP Abnormal 436
D

(3 WH)
- - High output 455 CS-62
-
sensor Overheat 437 - (4 WH)
D/Mo REV Abnormal 438 - Tilt angle sensor Low output 456
sensor Not equipped
High output 457
D/Mo REV Abnormal 440 - Lift sensor Low output 458
CS-54 -
sensor left
High output 459
P/Mo REV Abnormal 442 -
sensor Tilt sensor Low output 460
CONT Abnormal 444 - - - High output 461 Joystick
CS-72,
communication control
3rd sensor Low output 462 73
(Option)
CONT type Abnormal 446 - - High output 463
select
4th sensor Low output 464
Meter
High output 465
Meter Abnormal 558 - - -
communication LIFT ACCEL Low output 466 Not equipped
Tilt H switch Short 468
Not equipped
Open 469
Steer Angle sensor Abnormal 470 - CS-60 -
Weight sensor Low output 472
Not equipped
High output 473

CS-42
 CONTROLLER
CONTROLLER

Construction

T
AF
R
CSM0117

No. QTY. Part name No. QTY. Part name

D

1 1 Main print board 9 3 Thermistor

2 3 Power source print board 10 6 Current sensor
3 1 Capacitor board 11 6 Fan motor
4 1 Drive FET board, Traction RH 12 1 Controller harness
5 1 Drive FET board, Traction LH 13 1 Bus bar kit
6 3 Pump FET module 14 1 Screw kit
7 1 Insulator 15 1 Fan assembly
8 13 Stud bolt 16 3 Film capacitor

CS-43
 CONTROLLER

Construction (Cont’d)

T
AF
R
D

CSM0118

No. QTY. Part name No. QTY. Part name

1 1 Main print board 9 3 Thermistor

2 3 Power source print board 10 6 Current sensor
3 1 Capacitor board 11 6 Fan motor
4 1 Drive FET board, Traction RH 12 1 Controller harness
5 1 Drive FET board, Traction LH 13 1 Bus bar kit
6 3 Pump FET module 14 1 Screw kit
7 1 Insulator 15 1 Fan assembly
8 13 Stud bolt 16 3 Film capacitor

CS-44
 CONTROLLER

Connector (Terminal layout)

CONTROLLER

CSM0119

Controller assy
Input/
PIN NO. Contents Notes
Output
Input D20 KEY SW 2 (RESTART) For restart of timer auto off (Battery voltage)
D5 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
D6 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)

T
Output D1 A.P.O. RELAY DRIVE A.P.O. Relay ON/OFF drive, Coile load; 0.1A
Input D19 FORWARD SWITCH F Switch ON then forward
D25 REVERSE SWITCH R Switch ON then backward
D10
AF
ACCEL SENSOR POWER Sensor power (+5.0V)
D12 ACCEL SENSOR SIGNAL A Steps in the pedal then output voltage increase
D14 ACCEL SENSOR SIGNAL B Steps in the pedal then output voltage increase B = A/2
D8 ACCEL SENSOR GND Sensor GND
P7 TIRE ANGLE SEN. POWER Sensor power +5.0V ±0.2V
P14 TIRE ANGLE SEN. SIGNAL Steering right turn then output voltage increase
P11 TIRE ANGLE SEN. GND Sensor GND
R
P12 STEER ANGLE SEN. POWER Sensor power +12.8V ±0.2V 0.2A
P19 STEER ANGLE SEN. SIGNAL A 45 Pulse per revolution
P21 STEER ANGLE SEN. SIGNAL B 45 Pulse per revolution, Phase late from SIG.A (90 deg)
P22 STEER ANGLE SEN. SIGNAL N For neutral detects, 1 Pulse per revolution
D

P8 STEER ANGLE SEN. GND Sensor GND

D31 RIGHT TURN SWITCH R SW ON (Low level) then flasher ON/OFF
D35 LEFT TURN SWITCH L SW ON (Low level) then flasher ON/OFF
Output D7 FLASHER POWER Power for flasher Lamp
D2 R FLASHER OUT Flasher drive output Right
Input D22 PARKING BRAKE SWITCH Operates a parking brake then SW ON
D23 BRAKE SWITCH Steps in the brake pedal then SW ON
P28 LIFT UP SWITCH Operates a lift up then SW ON
P29 TILT SWITCH Operates a tilt lever then SW ON
P24 3RD SWITCH Operates a 3rd lever then SW ON
P25 4TH SWITCH Operates a 4th up lever then SW ON
P26 5TH SWITCH Operates a 5th up lever then SW ON
D24 HIGH MAST SWITCH Detects SW ON (1 Shot) then Hi-Mast mode
D26 SEAT SWITCH Site on the seat then SW ON
D15 MODE SELECT 1 For 36V only
D16 MODE SELECT 2 For G1N1 48V only
D18 MODE SELECT 3 For JG1N1 only
D28 SWITCH GND Switch GND
D29 SWITCH GND Switch GND
Input/ D33 M TO C COMMUNICATION DATA Meter to Controller communication data
Output D34 C TO M COMMUNICATION DATA Controller to Meter communication data

CS-45
 CONTROLLER

Connector (Terminal layout) (Cont’d)

Input/
PIN NO. Contents Notes
Output
Output P59 GND GND for Valve Chopper assy connect
P60 GND GND for Valve Chopper assy connect
P58 POWER Power for Valve Chopper assy connect
P61 POWER Power for Valve Chopper assy connect
Input/ P57 C TO O COMMUNICATION DATA Controller to option unit communication data
Output P56 O TO C COMMUNICATION DATA Option unit to controller communication data
Output P4 PS C SOLENOID (PWM Drive) Drive of the solenoid for PS neutral correction (1.1A at 24V)
P1 LIFT DOWN SOL. (PWM Drive) Drive of the solenoid for lift down (0.5A at 24V)
P17 OPT. COOLING FAN Drive of the cooling fan for the controller (0.1A at 48V)
P5 EMERGENCY RELAY 1 Power cut relay 1 for solenoid (0.1A at 48V)
P3 SOL. POWER RETURN Power return for solenoid
Input P54 PM TEMP SENSOR - Sensor GND
P52 PM TEMP SENSOR + Temperature sensor+ for pump motor
D60 LDM TEMP SENSOR - Sensor GND
D58 LDM TEMP SENSOR + Temperature sensor+ for Left drive motor
D54 RDM TEMP SENSOR - Sensor GND
D52 RDM TEMP SENSOR + Temperature sensor+ for Right drive motor

T
P51 PM REV. SEN.SIGNAL SHIELD Revolution sensor signal shield for pump motor
P47 PM REV. SEN. SIGNAL B GND Revolution sensor B GND for pump motor
P45 PM REV. SEN. SIGNAL B Revolution sensor signal B for pump motor
P46
AF
PM REV. SEN. SIGNAL A GND Revolution sensor A GND for pump motor
P44 PM REV. SEN. SIGNAL A Revolution sensor signal A for pump motor
P49 PM REV. SENSOR GND Sensor GND
P48 PM REV. SENSOR POWER + Sensor power+
P50 PM REV. SEN. POWER SHIELD Revolution sensor power shield for pump motor
D61 LDM REV. SEN. SIGNAL SHIELD Revolution sensor signal shield for Left drive motor
D57 LDM REV. SEN. SIGNAL B GND Revolution sensor B GND for Left drive motor
R
D55 LDM REV. SEN. SIGNAL B Revolution sensor signal B for Left drive motor
D56 LDM REV. SEN. SIGNAL A GND Revolution sensor A GND for Left drive motor
D53 LDM REV. SEN. SIGNAL A Revolution sensor signal A for Left drive motor
D49 LDM REV. SENSOR GND Sensor GND
D

D48 LDM REV. SENSOR POWER + Sensor power +

D59 LDM REV. SEN. POWER SHIELD Revolution sensor power shield for Left drive motor
D51 RDM REV. SEN. SIGNAL SHIELD Revolution sensor signal shield for Right drive motor
D47 RDM REV. SEN. SIGNAL B GND Revolution sensor B GND for Right drive motor
D45 RDM REV. SEN. SIGNAL B Revolution sensor signal B for Right drive motor
D46 RDM REV. SEN. SIGNAL A GND Revolution sensor A GND for Right drive motor
D44 RDM REV. SEN. SIGNAL A Revolution sensor signal A for Right drive motor
D43 RDM REV. SENSOR GND Sensor GND
D42 RDM REV. SENSOR POWER + Sensor power +
D50 RDM REV. SEN. POWER SHIELD Revolution sensor power shield for Right drive motor
Output D3 MAIN CONTACTOR DRIVE + Main contactor drive +
D4 MAIN CONTACTOR DRIVE - Main contactor drive -
D17 L FLASHER OUT Flasher drive output Left
Input D21 BATT OFF DETECT Battery off detect

CS-46
 CONTROLLER

Connector (Terminal layout) (Cont’d)

METER
System wiring

T
AF
R

CSM0120
D

Input/Output Pin No. Contents Notes

External of meter
Input 1 Battery voltage Meter Wake up, Battery voltage and capacity detect
2 Battery power + Meter power to battery +
3 Blank terminal -
4 Brake fluid level SW Low fluid level then SW: ON
5 Seat belt SW Belt set then SW: ON
6 Parking BK Key Input Key Input for Parking BK Warning Buzzer
7 Blank terminal -
8 Blank terminal -
9 Parking brake SW Brake OFF then SW: ON
10 Blank terminal -
11 Power GND Meter GND
12 Blank terminal -

CS-47
 CONTROLLER

Connector (Terminal layout) (Cont’d)

Input/Output Pin No. Contents Notes

Output 13 OPT relay 2 Output: Coil load 0.1A (Open Collector)

14 OPT relay 1 Output: Coil load 0.1A (Open Collector)
15 Warning buzzer drive relay Key OFF and PBK OFF then drive of relay
16 Blank terminal -
17 Blank terminal -
18 Blank terminal -
Input/Output 19 C to M Communication data Communication data of meter receive
20 M to C Communication data Communication data of meter transmit
Internal of meter
Input M01 Blank terminal -
M02 Blank terminal -
M03 Function SW 1 -
M04 Function SW 2 -
M05 Function SW 3 -
M06 Function SW 4 -

T
M07 Function SW 5 -
M08 SW GND -
M09 Ambient TEMP. sensor 1 For LCD contrast level
M10 Ambient TEMP. sensor 2
AF
R
D

CS-48
 CONTROLLER

Controller Element Inspection

CAUTION:
• To check each controller element, use circuit tester and
measure resistance between disconnected terminals to
determine if circuit continuity exists ( Ω).
To check the current sensor, measure voltage only.
• When checking controller elements, also check the
associated harnesses and bus bars.
• The following tables list resistance values measured across
respective terminals and should be used as reference
information. Keep in mind the resistance values vary with the
type of circuit tester (such as analog or digital) used for
measurements.
NOTE:
Measure resistance between terminals after terminals are
disconnected from bus bars, as listed in the following tables.

DRIVE FET BOARD

Specifications

T
Item Specification

Construction 9 FET elements construction

AF Durable voltage 100V

Service data

Item Normal (Reference value) NG

Tester+ Tester- Resistance Resistance

(Analog tester) (Digital tester)
R
D1 S1D2 0Ω >20MΩ
S1D2 D1 <2MΩ
D1 G1 4MΩ
G1 D1
D

G1 S1D2 4MΩ
Module Failed Mosfet
S1D2 G1 4MΩ
S1D2 S2 0Ω >20MΩ
S2 S1D2 <2MΩ
S1D2 G2 4MΩ
CSM0121
G2 S1D2
G2 S2 4MΩ
S2 G2 4MΩ

Note: - When testing the mosfets, keep in mind the location of

the small connectors G1/G2.
- The small connectors will be the referential point to
determine which bank is the D1(U) / S2(W) phase etc.
Note: - Above service data is for checking 1 phase.
- Repeat the test for the other 2 pahses.
- Do the same test for both Right FET and Left FET.

CS-49
 CONTROLLER

Controller Element Inspection (Cont’d)

PUMP FET MODULE
Specifications

Item Specification

Type PDM5001
Durable voltage 100V

Service data

Item Normal (Reference value) NG

Tester+ Tester- Resistance Resistance

(Analog tester) (Digital tester)
D1 S1D2 0Ω
S1D2 D1 <5MΩ
D1 G1 3MΩ
G1 D1
G1 S1D2 3MΩ

T
Module Failed Mosfet
S1D2 G1 3MΩ
S1D2 S2 0Ω
S2 S1D2 <5MΩ
AF
CSM0122
S1D2 G2 3MΩ
G2 S1D2
G2 S2 3MΩ
S2 G2 3MΩ
R
D

CS-50
 CONTROLLER

Controller Element Inspection (Cont’d)

CURRENT SENSOR
Specifications

Item Specification

Type HC-TSA800V2YP12AR
Actual current ±800A
Output voltage +0.56 ~ +2.56V ~ +4.56V

Service data

Item Normal NG

Output V Approx. 2.5V between 3-4 Failed sensor

Source V Approx. 12.0V between 1-4 Failed CPU board

T
AF
CSM0123

FAN ASSEMBLY
Specifications

Item Specification

Type 2410ML-05W-B40-BQ1
R
6 pieces/controller
Numbers of fan
One piece/external fan
Rated voltage 24V
D

CSM0124 Service data

Item Normal NG

Operation check with

Operation Failed cooling fan
Constant voltage

CS-51
 CONTROLLER

Controller Element Inspection (Cont’d)

CONTACTOR ASSEMBLY
Specifications

Item Specification

Rated current 300A

Cutout current 2500A
Mechanical life 100 M cycle

Service data

CSM0125 Item Normal NG

Coil resistance 30 ~ 70Ω

Movable/fixed 0.7 mm (0.28 Abnormal contact
Contact wear limit
in) Max

T
AF
R
D

CSM0126

CS-52
 CONTROLLER

Controller Element Inspection (Cont’d)

Fuse
Specifications

Capacity
500A

CSM0127

Inspection
Using a circuit tester, check continuity of each fuse.

Normal indication Abnormal (open-circuit) indication

Continuity

T
NOTE:
The circuit tester range selector must be set to “x1 Ω”.
AF
CST0019
R
D

CS-53
 CONTROLLER

Controller Element Inspection (Cont’d)

MOTOR (TRACTION, LOADING)

T
CSM0128
AF
Temperature sensor
Specifications

Item Specification

R 100°C (212°F) = Approx. 3.3 kΩ

Resistance
R 25°C (77°F) = Approx. 50 kΩ
R
Service data

Item Normal NG
D

CSM0129 Sensor resistance

Resistance Failed temp. Sensor
25°C (77°F) = Approx. 50 kΩ

Revolution sensor
Specifications

Item Specification

Temperature range -55 to +155°C (-67 to 311°F)

Anti vibration 20G
Anti impact force 100G
Type Magnetic induce

Service data
CSM0130

Item Normal NG

Revolution sensor Self check by revolution Failed revolution sensor

sensor IC detection

CS-54
 CONTROLLER

Controller Element Inspection (Cont’d)

CAUTION:
When installing the revolution sensor to the motor, harness
connection A should be forward (motor rear side) (Refer to MM
section).

MMM0020

T
AF
R
D

CS-55
 CONTROLLER

Removal and Installation (3 - wheel)

T
AF
R
D

CSM0131EU

CS-56
 CONTROLLER

Removal and Installation (4 - wheel)

T
AF
R
D

CSM0132EUb

CS-57
UNIT INSPECTION AND ADJUSTMENT
UNIT INSPECTION AND ADJUSTMENT

Control System
CAUTION:
• Before measuring resistance values, be sure to turn the key
switch to the OFF position, and disconnect the battery plug.
• When checking a unit, also check the condition of the
associated harness and connector.
• All units can be checked using interactive diagnostic
procedures. (Refer to “LCD MONITOR” on page 30.)
NOTE:
• The relative condition of a unit is evaluated by making required
voltage or resistance value measurements.
• This section deals with only resistance measurement procedures
for unit inspection.

FORWARD REVERSE SWITCH

T
AF
R
D

ELM0272

CS-58
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

Inspection
Check continuity at each lever position between the following
terminals.

Lever position Terminal with continuity

Forward -
Neutral -
Reverse -

T
CSM0133
AF
R
D

CS-59
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

STEERING WHEEL ANGLE SENSOR
Specifications

Rated voltage (V) 12

Rated load current (mA) 10 - 50
Output voltage (V) Low Less than 0.5
High 2.5 - 3.5
Pulse (1, 2) (pulse/rotation) 45
Neutral position signal (pulse/rotation) 1

Service data

Measuring points (terminals) Standard value (V)

- 12

T
AF
CSM0134
R
D

CSM0135

CS-60
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

TIRE ANGLE SENSOR (3 - WHEEL)
Specifications

Total resistance (kΩ) 1 - 1.4 (Reference value)

Service data

Measuring
points Standard value Remarks
(terminals)

- 0Ω 1 kΩ The resistance value decreases as the

shaft is rotated.
- 1 kΩ The resistance value remains unchanged
regardless of the shaft rotation.

T
AF
CSM0136

Adjustment
1. Call up tire angle sensor diagnostic screen from interactive
diagnostic display.
2. Loosen tire angle sensor securing screws.
3. While observing the tire angle sensor output on the display to
check if it is within the specified range, rotate the tire angle
R
sensor.
4. Tighten tire angle sensor securing screws.
: 1.2 - 1.8 N•m (0.13 - 0.18 kgf-m, 11 - 15 in-lb)
D

CSM0137

CS-61
UNIT INSPECTION AND ADJUSTMENT

TIRE ANGLE SENSOR (4 - WHEEL)

Specifications

Total resistance (kΩ) 1.6 - 2.4 (Reference value)

Service data

Measuring
points Standard value Remarks
(terminals)

- 0Ω 2 kΩ The resistance value decreases as the

shaft is rotated.
- 2 kΩ The resistance value remains unchanged
regardless of the shaft rotation.

T
CSM0207
AF
R
D

CS-62
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

Adjustment Tire angle Sensor

T
AF
CSM0239

Tire angle sensor fixes the kingpin plate to the kingpin as shown in
R
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the tire angle sensor by
engaging the shaft of the tire angle sensor. Therefore, it is necessary
to assemble the tire angle sensor correctly to make the steering
D

control system function correctly. Notes concerning assembly are as

follows.
1. When the kingpin plate is installed in the kingpin, it is necessary
to insert the plate vertically in the direction shown in the above
figure.
2. When the sensor shaft is engaged in the kingpin plate, it is
necessary to set the plane part of the sensor shaft to the spring and
the other side of the kingpin plate (left side in the above figure).
3. Securely insert plate into side groove of kingpin hole.
CAUTION:
When the tire angle sensor is removed, installed, and replaced,
the neutral level adjustment must be performed for the new
sensor.

CSM0240

CS-63
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

ACCELERATOR SENSOR

T
AF
CSM0138

Specification
R
Total resistance (kΩ) 2.5 - 5.0 (Reference value)

Service data
D

Measuring
Standard value
points Remarks
(V)
(terminals)

Vcp1 - Ep1 (GND) 5.02 - 5.22 Always

Aps1 - Ep1 (GND) 0.668 - 0.868 When the accelerator pedal is released.
CSM0139
4.454 - 4.654 When the accelerator pedal is fully
depressed.

Adjustment
If the accelerator sensor output is not within the specified range,
adjust it as follows.
1. Call up accelerator sensor diagnostic screen from interactive
diagnostic display.
2. Loosen accelerator sensor securing screws.
3. While observing the accelerator sensor output on the display to
check if it is within the specified range, rotate the accelerator
sensor.
4. Tighten accelerator sensor securing screws.
CSM0140 : 1.5 - 1.8 N•m (0.16 - 0.18 kgf-m, 14 - 15 in-lb)

CS-64
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

T
AF
CSM0141

Linkage stroke adjustment

Fully-closed position adjustment
R
1. Depress the accelerator pedal until the accelerator linkage is
fully opened.
2. Rotate the stopper bolt counterclockwise by 180 degrees, and
then tighten the nut.
D

CAUTION:
• The accelerator linkage operation should move smoothly
with no binding. When releasing the pedal, immediately
return it to the fully-closed position.
• The return spring should be securely installed as shown in
the figure.
• Move the accelerator pedal, and then check that the
accelerator pedal roller moves smoothly in the groove.

CS-65
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

BRAKE SWITCH
Inspection
Check continuity between brake switch terminals when the brake
pedal is depressed 8 to 12 mm (0.13 to 0.47 in). Continuity must
exist.
<Reference data>

Brake switch ON/OFF switching point Pedal height: 115.5 mm (4.547 in)
(from floor upper surface)

CSM0142

Adjustment

T
AF
R
D

CSM0202

1. Adjust the height of brake pedal point P to 122 mm (4.803 in)

from the floor upper surface by the stopper bolt, and then
tighten the lock nut.
: 12 - 15 N•m (1.2 - 1.5 kgf-m, 9 - 11 ft-lb)
2. When depressing the pedal within 8 - 12 mm (0.31 - 0.47 in)
(pedal height: 115.5 mm (4.547 in)), adjust the brake switch so
that the brake switch is “ON”, and then tighten the lock nut.
: 12 - 15 N•m (1.2 - 1.5 kgf-m, 9 - 11 ft-lb)
3. Make sure that the brake switch is “OFF” when the pedal is
released.

CS-66
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

CONTROL VALVE SWITCHES (LIFT, TILT, 3RD, 4TH
SWITCHES FOR MECHANICAL CONTROL VALVE)
Inspection
When the control lever is operated, continuity must exist between
terminals affected.
NOTE:
• Circuit continuity must be checked after removing the affected
switch connector.
• Check for audible sounds which indicate control valve switches
are operating.
• If switches do not operate, adjust the switch position, then recheck
the switches operation. Refer to “Adjustment” on page 64.

T
AF
CSM0143
R
D

CS-67
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

Adjustment
Using adjusting nuts and , adjust the dog-to-switch clearance
to specifications indicated in the figure below.
CAUTION:
The control valve must be set in Neutral and switches must be
freed during clearance adjustments.

T
AF
R

CST0038

Centering adjustment
D

Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.

CST0039

CS-68
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

LIFT SOLENOID (MECHANICAL CONTROL VALVE)
Specifications

Rated voltage (V) 24

Coil resistance (Ω) 36 at 20°C (68°F)
(Reference value)
44 at 90°C (194°F)

Inspection
Measure resistance between lift solenoid terminals.

<Reference value>
CSM0144

36Ω 20°C (68°F)

44Ω 90°C (194°F)

T
AF
R
D

CS-69
 UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option)

CAUTION:
If erroneous cargo handling operation is noted regardless of
the joystick lever position, press the emergency stop button on
the console box, suspend cargo handling operations. (To
release the emergency stop button, turn it in the direction
indicated by the arrow.)

CSM0145

JOYSTICK CONTROLLER

T
AFCSM0146

Chopper assy for hydraulic control valve

Input/Output PIN NO. Contents Notes
Input O25 POWER Power for Joystick controller
O26 POWER Power for Joystick controller
O27 GND GND for Joystick controller
O30 GND GND for Joystick controller
O32 KEY SW 2 (RESTART) For restart of timer auto off (Battery voltage)
R
O31 KEY SW 1 (IGN) Key SW input, Controller power (Battery voltage)
O34 JS SENSOR POWER Sensor Power + 5.0V
O36 LIFT SIGNAL 1 Operates a lift up then output voltage increase
O37 LIFT SIGNAL 2 Operates a lift up then output voltage decrease
O35 JS SENSOR GND Sensor GND
D

O38 TILT SIGNAL 1 Pull a tilt lever then output voltage increase
O39 TILT SIGNAL 2 Pull a tilt lever then output voltage decrease
O40 3RD SIGNAL 1 Pull a 3rd lever then output voltage increase
O41 3RD SIGNAL 2 Pull a 3rd lever then output voltage decrease
O42 4TH SIGNAL 1 Pull a 4th lever then output voltage increase
O43 4TH SIGNAL 2 Pull a 4th lever then output voltage decrease
O44 1 STICK DETECT SW Switch OFF then 1 stick lever control
O45 MULTI FUNCTION DETECT SW Switch ON then detect a Multi Function lever
O46 MULTI FUNCTION 1 TO 4 SW Switch of 1 to 4 SOL. Ports select for Multi Function
O47 SWITCH GND Switch GND
Output O7 CHOPPER GND Power GND for solenoid
O8 CHOPPER GND Power GND for solenoid
O23 5TH SOLENOID B (PWM Drive) 5th solenoid push side (0.5A at 24V)
O22 5TH SOLENOID A (PWM Drive) 5th solenoid pull side (0.5A at 24V)
O20 4TH SOLENOID B (PWM Drive) 4th solenoid push side (0.5A at 24V)
O19 4TH SOLENOID A (PWM Drive) 4th solenoid pull side (0.5A at 24V)
O17 3RD SOLENOID B (PWM Drive) 3rd solenoid push side (0.5A at 24V)
O16 3RD SOLENOID A (PWM Drive) 3rd solenoid pull side (0.5A at 24V)
O15 TILT SOLENOID B (PWM Drive) Tilt solenoid push side (0.5A at 24V)
O14 TILT SOLENOID A (PWM Drive) Tilt solenoid pull side (0.5A at 24V)
O13 LIFT SOLENOID B (PWM Drive) Lift solenoid push side (0.5A at 24V)
O12 LIFT SOLENOID A (PWM Drive) Lift solenoid pull side (0.5A at 24V)
O24 C1 SOLENOID (PWM Drive) C1 solenoid valve (0.5A at 24V)
O4 EMERGENCY RELAY 2 Power cut relay 2 for solenoid (0.1A at 48V)
O10 SOL. POWER RETURN Power return for solenoid
O11 SOL. POWER RETURN Power return for solenoid
Input/Output O29 O to C COMMUNICATION DATA Joystick controller to controller communication data
O28 C to O COMMUNICATION DATA Controller to joystick controller communication data

CS-70
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

JOYSTICK CONTROL VALVE

T
AF
CSM0200

Specifications
R
Electromagnetic Rated voltage (V) 24
proportioning solenoid Coil resistance (Ω)
30 at 20°C (68°F)
valve (Reference value)
D

Rated voltage (V) 24

C1 Solenoid valve Coil resistance (Ω) 36 at 20°C (68°F)
(Reference value) 44 at 90°C (194°F)

Inspection
Check resistance between terminals using circuit tester (Ω range).

Resistance (Ω)
Terminals Remarks
(Reference value)

A (+)-A (-)
30 20°C (68°F)
B (+)-B (-)
36 20°C (68°F)
C1 (+)-C1 (-)
44 90°C (194°F)

CS-71
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

FORWARD-REVERSE SWITCH
Inspection
Check continuity between terminals using circuit tester (Ω range).

Normal condition (Ω range)

Terminals
Neutral F position R position

No continuity No continuity
- Continuity
( ) ( )
No continuity No continuity
- Continuity
( ) ( )
CSM0147

CONTROL VALVE LEVER

1-lever type

T
AF
R
D

CSM0148

CS-72
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

Specification

Lever operation angle ±22.5°

Electrical angle (potention) ±18°
Rated voltage (V) DC 5±0.5
Output voltage (V) 0.5 - 4.5 (±0.05)

2-lever type and 3rd, 4th type

T
AF
R
D

CSM0149

Specification

Lever operation angle ± 20° - 22°

Electrical angle (potention) ±18°
Rated voltage (V) DC 5 ± 0.5
Output voltage (V) 0.5 - 4.5 (±0.05)

Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).

CS-73
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

EMERGENCY STOP BUTTON

T
AF
CSM0150

Inspection
R
Check continuity between terminals using circuit tester (Ω range).

Terminals Normal condition Pushing the button

- Continuity No continuity
D

- Continuity No continuity

CS-74
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

REMOVAL AND INSTALLATION

T
AF
R
D

CSM0151

CS-75
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

T
AF
R
D

CSM0152

CS-76
UNIT INSPECTION AND ADJUSTMENT

Knob Position Control System

(Option 3 - wheel only)
PS KNOB POSITION SOLENOID VALVE
Specifications

Rated voltage (V) 24

Coil resistance (Ω) 21.8±5%
(Reference value) at 20°C (68°F)

Inspection
Check resistance between terminals using circuit tester.

21.8±5% 20°C (68°F)

CSM0153

For steering wheel angle sensor and tire angle sensor inspections,
refer to “UNIT INSPECTION AND ADJUSTMENT” on page 58 and
59.

T
AF
R
D

CS-77
TROUBLE DIAGNOSTIC PROCEDURES
TROUBLE DIAGNOSTIC PROCEDURES

Precautions
CAUTION:
• Before performing self-diagnosis, check condition of blade
fuses, fusible links, etc.
• After repairing trouble areas, operate the vehicle to confirm
that malfunctions have been eliminated.
• When checking the traction system, raise the front wheels off
the ground using a jack. Refer to GI section for details.
• When malfunction occurs, do not attempt to inspect
connectors, harnesses, etc. but perform self-diagnosis and/
or interactive diagnosis. This can avoid unnecessary repair
or replacement.
• Basic trouble diagnostic procedures must be performed as
follows:

Malfunction occurrence

Confirm trouble message and

malfunctioning symptom.

T
Perform self-diagnosis.

YES
AF Does self-diagnosis pinpoint
malfunctioning part?
Check malfunctioning
part and the circuit. Refer
NO to “SELF-DIAGNOSIS”.

Perform interactive diagnosis.

Does interactive diagnosis pinpoint YES Check malfunctioning

malfunctioning part? part and the circuit. Refer
R
NO to topic “Unit inspection”.

Use troubleshooting flow charts, wiring

diagrams and circuit diagrams as a
guide to locate and eliminate trouble
D

causes.

NOTE:
Test probes of a circuit tester are too large to be inserted into
connectors during voltage measurements on the print board side. It
is advisable to have the tips of the test probes fastened with thin
conductive wire to be used as an extension lead. In this way,
connector terminals are prevented from sustaining damage. (Such
an extension lead will be referred to as a temporary tool in
troubleshooting flow charts.)

CST0062

CS-78
 TROUBLE DIAGNOSTIC PROCEDURES

How To Follow Flow Chart

Trouble diagnostic procedures for controllers (including charging
system) are indicated in flow charts. Inspection and confirmation
procedures are shown in illustrations, making the respective flow
charts more comprehensive. Circuit diagrams are also included
where necessary, along with applicable flow charts.
NOTE:
The entire system wiring diagram and circuit diagram are included at
the end of this manual. Refer to these diagrams as necessary during
diagnostic procedures.

MALFUNCTIONING SYMPTOMS
Typical trouble symptom entries are treated as titles.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Probable trouble areas or parts are indicated in relation to
malfunctions that may occur.

T
WORK FLOW
Confirmation of malfunction
AF
Inspection and/or confirmation Inspection and confirmation procedures
procedures must be explained
as required in the illustration.
Specifications, judgment and/or (Use a temporary tool.)
evaluation
*Tester range
R
Remedial procedures

* Examples of tester range selection

D

V
100 : Voltage measurement in 100-volt range (DC)
V
500
: Voltage measurement in 500-volt range (AC)
R
X1
: Resistance measurement in 1Ω range

CAUTION:
Always use the digital tester to measure the resistance of the
sensor (potentiometer). If the analog tester is used, the sensor
(potentiometer) may be damaged by the internal battery of the
analog tester.

A
: Current measurement in 50-ampere range (AC)
50

About temporary tool:

A temporary tool refers to a circuit tester whose test probe ends are
temporarily wrapped with thin conductive wires. The tip ends of
respective wires are attached to connector terminals on the print
board side during required voltage measurements. Refer to
“Precautions” on page 74.

CS-79
TROUBLE DIAGNOSTIC PROCEDURES

Symbol Identification
HARNESS CONNECTOR SYMBOLS
Male and female connectors
• Connector guides for male terminals are shown in black.
• Connector guides for female terminals are shown in white.

CST0063

Connector direction
• Connector symbols shown from the terminal side (in direction A)
are enclosed by a single line.
• Connector symbols shown from the harness side (in direction B)
are enclosed by a double line.

T
AF
R
CST0064

Controller or other single unit connectors

Controller connector symbols are indicated so that connectors are
D

being shown from the terminal side; enclosed by a single line with
connector guides shown in black.

CST0065

KEY TO SYMBOLS
Symbol Explanation Symbol Explanation
Check after disconnecting Turn key switch to the OFF
harness connector. position.

Check after connecting Turn key switch to the ON

harness connector. position.

Check after disconnecting Turn battery switch to the

battery plug. OFF position.

Check after connecting Turn battery switch to the ON

battery plug. position.

CS-80
TROUBLE DIAGNOSTIC PROCEDURES

Voltage and Resistance Measurement

Procedures
VOLTAGE MEASUREMENT
• Connector terminals on the print board side are too closely
arranged so it is difficult for test probes of a conventional circuit
tester to gain access to them. For this reason, it is advisable to
wrap thin conductive wires around the ends of the test probes and
use the wires as test probe extensions (which are referred to as
the temporary tools in troubleshooting flow charts).
• To facilitate voltage measurements for parts or terminals
(adjacent to controllers), it is best to use an alligator clip with the
black (ground) test probe of a circuit tester and fasten it to the
battery ground terminal during measurements.

T
CST0066

RESISTANCE MEASUREMENT
AF • Before measuring resistance, turn the key switch to the OFF
position, remove the battery plug, then remove the connector and
the part whose resistance is to be measured.
• A broken wiring circuit must be measured between connector
terminals affected using a circuit tester.
R
D

CST0067

CS-81
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

CAUTION:
• To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully
understand under what conditions the symptoms occur.
• For checking each controller element, use circuit tester and
measure resistance between terminals to determine whether
circuit continuity exists or not ( Ω).
For checking the current sensor, only measure voltage.
• When checking controller elements, also check the
associated harnesses and bus bars.
• If the cause of the malfunction may be in the mechanical
systems, always check the mechanical systems that are not
included in the flowchart.

T
AF
R
D

CS-82
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

SYMPTOM:
The meter does not display. The forklift also does not operate
(in any operation of traction/loading/power steering).

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Battery, Battery switch, Main fuse, Auxiliary fuse, Fusible link, key
switch, Main contactor, Main print board, Harness, cable and
Insulation resistance

T
CSM0153
AF
R

CSM0154
D

CSM0155

CS-83
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

T
CSM0156
AF
R
D

CSM0157

CSM0158

CS-84
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

CSM0159

T
AF
CSM0160
R
D

CSM0161

CS-85
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

SYMPTOM:
The meter does not display. The forklift operates (in any
operation of traction/loading/power steering).

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Auxiliary fuse, A.P.O. relay, Harness and Meter print board

CSM0162

T
AF
R
CSM0163
D

CSM0164

CS-86
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

SYMPTOM:
The meter displays. The forklift does not operate (in any
operation of traction/loading/power steering).

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Battery, Battery switch, Main fuse, Auxiliary fuse, Insulation
resistance Main contactor, Main print board, Harness, cable and
Seat switch
NOTE:
For these items, the fuse 1 and the main contactor can be checked
at the self-diagnosis.

T
CSM0153
AF
R

CSM0155
D

CSM0156

CS-87
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

CSM0157

T
AF
CSM0158
R
D

CSM0159

CS-88
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM

CSM0160

T
AF
CSM0165
R
D

CS-89
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM

SYMPTOM:
Cannot move forward and backward.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Capacitor board, FET board, D/CONT. TEMP. sensor, Drive current
sensor, FR-SW, Accel. sensor, D/Mo. REV. sensor, Brake switch,
Parking BK switch, Traction motor, Main print board, Cable and
Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0166
R
D

CSM0167

CS-90
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM

CSM0168

SYMPTOM:
Cannot drive forward or backward.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS

T
FR-SW, Main print board and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
AF parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.
R
D

CSM0169

CSM0167

CS-91
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM

SYMPTOM:
The traction speed is slow. The acceleration is slow. Or, there
is no power.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
D/Mo. TEMP. sensor, D/CONT. TEMP. sensor, Cooling fan, Main
print board and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0170
R
D

CSM0171

CS-92
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM

CSM0172

T
AF
CSM0173
R
D

CSM0174

CS-93
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM

CSM0167

T
AF
CSM0175
R
D

CS-94
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM

SYMPTOM:
Straight-line instability

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
D/Mo. TEMP. sensor, D/CONT. TEMP. sensor, Tire angle sensor, PS
correction valve, Main print board and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0176
R
D

CSM0167

CS-95
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM

SYMPTOM:
Regenerative braking malfunction

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Brake switch, Main print board and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0177
R
D

CSM0167

CS-96
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE

SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Capacitor board, Pump FET board, P/CONT. TEMP. sensor, Pump
current sensor, P/Mo. REV. sensor, HYD-control valve switch, Pump
motor, Main print board, Cable and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0178
R
D

CSM0167

CS-97
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE

CSM0179

SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.

PROBABLE TROUBLE AREAS CAUSING

T
MALFUNCTIONS
HYD-control valve switch, Main print board and Harness
CAUTION:
AF The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.
R
D

CSM0167

CS-98
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE

SYMPTOM:
The mast does not lower (but can be raised).

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
EMG relay, Lift down valve, Main print board and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0180
R
D

CSM0181

CSM0167

CS-99
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE

SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
P/Mo. TEMP. sensor, P/CONT. TEMP. sensor, Cooling fan, Main
print board and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0170
R
D

CSM0171

CSM0182

CS-100
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE

CSM0183

T
AF
CSM0167
R
D

CSM0175

CS-101
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE

SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Emergency stop button, Main print board, Fusible link, Relay for
joystick controller, Capacitor board, Pump FET board, P/CONT.
TEMP. sensor, Pump current sensor, P/Mo. REV. sensor, HYD-
control valve switch, CI solenoid valve, HYD-control valve solenoid,
Pump motor, Joystick controller, Cable and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0184
R
D

CSM0185

CS-102
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE

CSM0186

T
AF
R

CSM0201
D

CSM0180

CS-103
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE

CSM0187

T
AF
R
D

CSM0167

CSM0179

CS-104
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE

SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
HYD-control valve solenoid, HYD-control valve switch, Joystick
controller and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0188
R
D

CSM0167

CS-105
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE

SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
P/Mo. TEMP. sensor, P/CONT. TEMP. sensor, HYD-control valve
switch, Cooling fan, Joystick controller and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
CSM0170
R
D

CSM0171

CSM0182

CS-106
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE

CSM0183

T
AF
R
CSM0167
D

CSM0175

CS-107
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM

SYMPTOM:
Power steering malfunction (include the knob position
malfunction of OPT mechanism)

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
PS correction valve, Tire angle sensor, Steering angle sensor, Main
print board and Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.

T
AF
R
D

CSM0189

CSM0167

CS-108
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM

SYMPTOM:
Turn signal lamp malfunction

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Main print board, Bulb, Lighting switch and Harness

T
AF
R
D

CS-109
 REFERENCE DATA OF CONTROL SYSTEM
REFERENCE DATA OF CONTROL SYSTEM

Main Print Board

Terminal
No. Possible error mode/
Items Characteristic/Specification Related trouble diagnosis
(Print board Related symptom
side)

D20 KEY SW2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
D5 KEY SW1 (IGN) VB level (key switch 1 ON) • The controller does not –
operate
D21 BATT OFF DETECT VB level (battery switch ON) • The controller does not –
operate
D81 Capacitor voltage VB level (main relay ON) • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
• Low voltage protection • Battery low voltage: 404
D1 A.P.O. RELAY DRIVE Operation (key ON) • The meter does not operate • Controller communication
malfunction: 444
D19 FORWARD SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved forward
D25 REVERSE SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved backward

T
D10 ACCEL SENSOR POWER 5.0±0.2V • The traction is not possible • Accelerator pedal position
D12 ACCEL SENSOR SIGNAL A 0.2 - 4.7V (normal) • Poor acceleration/maximum sensor output large: 453
speed • Accelerator pedal position
D14 ACCEL SENSOR SIGNAL B 0.2 - 4.7V (normal) sensor output small: 452
D8 ACCEL SENSOR GND
AF GND connection
P7 TIRE ANGLE SEN. POWER 5.0±0.2V • Straight-line instability • Tire angle sensor output
• Poor turning ability large: 455
P14 TIRE ANGLE SEN. SIGNAL 0.3 - 4.8V (normal)
• Knob position malfunction • Tire angle sensor output
P11 TIRE ANGLE SEN. GND GND connection small: 454
P12 STEER ANGLE SEN. POWER 12.8±1V • Knob position malfunction • Steering angle sensor
• The steering is not possible malfunction: 470
P19 STEER ANGLE SEN. SIGNAL A 0 - 3.5V rectangular pulse
• Steering force malfunction
R
P21 STEER ANGLE SEN. SIGNAL B 0 - 3.5V rectangular pulse
P22 STEER ANGLE SEN. SIGNAL N 0 - 3.5V rectangular pulse
P8 STEER ANGLE SEN. GND GND connection
D31 RIGHT TURN SWITCH GND level (switch ON) • Turn signal does not blink –
D

• Turn signal continues

D35 LEFT TURN SWITCH GND level (switch ON)
blinking
D7 FLASHER POWER VB input • Turn signal does not turn on –
D2 RIGHT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D17 LEFT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D22 PARKING BRAKE SWITCH GND level (switch ON) • The traction is not possible –
D23 BRAKE SWITCH GND level (switch ON) • The traction is not possible –
• Brake regenerative
malfunction
P28 LIFT UP SWITCH GND level (switch ON) • The lift does not rise –
• The loading motor does not
rotate
P29 TILT SWITCH GND level (switch ON) • No tilt operation –
• The loading motor does not
rotate
P24 3RD SWITCH GND level (switch ON) • No 3rd operation –
• The loading motor does not
rotate
P25 4TH SWITCH GND level (switch ON) • No 4th operation –
• The loading motor does not
rotate

CS-110
 REFERENCE DATA OF CONTROL SYSTEM

Main Print Board (Cont’d)

Terminal
No. Possible error mode/
Items Characteristic/Specification Related trouble diagnosis
(Print board Related symptom
side)

P26 5TH SWITCH GND level (switch ON) • No 5th operation –

• The loading motor does not
rotate
D24 HIGH MAST SWITCH At a lift up level • No limited operation at a lift –
• 1 shot type: GND level up level
Open
• N.C type: Open
• N.O type: GND level
D26 SEAT SWITCH GND level (switch ON) • No traction/loading/PS –
operation
• Seat switch warning
D15 MODE SELECT 1 (GND connection or Open • The designated –
according to the mode setting) performance is not shown
D16 MODE SELECT 2
because the model type
D18 MODE SELECT 3 setting is incorrect
D28 SWITCH GND GND • No GND level at each switch –
ON

T
D29 SWITCH GND GND • The switch signal detection –
is not possible
D33 METER TO CONTROLLER Rectangular wave (meter • The meter communication is • Controller communication
COMMUNICATION DATA
AF
output) not possible malfunction: 444
D34 CONTROLLER TO METER Rectangular wave (controller • The meter communication is • Controller communication
COMMUNICATION DATA output) not possible malfunction: 558
• CAN communication
between main print board
and joystick controller
cannot be performed
P59 GND GND – –
R
P69 GND GND – –
P58 POWER Joystick controller power • Joystick controller –
supply: 8.5±1V malfunction
P61 POWER
P57 COMMUNICATION TO P57-GND • Joystick controller • Controller communication
D

JOYSTICK CONTROLLER 0 - 5V rectangular wave (CAN malfunction malfunction: 558

communication between main
print board and Joystick
controller)
P56 COMMUNICATION TO P56-GND
JOYSTICK CONTROLLER 0 - 5V rectangular wave (CAN
communication between main
print board and Joystick
controller)
P4 PS C SOLENOID (PWM Drive) PS correction solenoid (PWM) • Knob position malfunction • PS correction solenoid
• PS correction solenoid open: 503
malfunction • PS correction solenoid
short: 502
P1 LIFT DOWN SOL. (PWM Drive) Lift down solenoid (PWM) • The lift cannot be lowered • Lift down solenoid valve
open: 501
• Lift down solenoid valve
short: 500
P17 OPT. COOLING FAN Optional cooling fan operation • Optional cooling fan –
(GND level at driving) malfunction
P5 EMERGENCY RELAY 1 Operation at starting the • PS correction solenoid • PS correction solenoid
controller (GND level at malfunction open: 503
driving) • Lift down valve malfunction • Lift down solenoid valve
• Knob position malfunction open: 501
• The lift cannot be lowered

CS-111
 REFERENCE DATA OF CONTROL SYSTEM

Main Print Board (Cont’d)

Terminal
No. Possible error mode/
Items Characteristic/Specification Related trouble diagnosis
(Print board Related symptom
side)

P3 SOL. POWER RETURN (Solenoid chopper return line) • Unstable valve control at –
open
P54 PM TEMP SENSOR - Voltage between P52 and P54: • Loading speed decrease • PM temperature rise: 435
Approx. 3.8V (25°C) • PM temperature sensor
P52 PM TEMP SENSOR +
malfunction: 434
D60 LH TM TEMP SENSOR - Voltage between D58 and • Left traction speed decrease • Left TM temperature sensor
D58 LH TM TEMP SENSOR + D60: Approx. 3.8V (25°C) rise: 425
• Left TM temperature sensor
malfunction: 424
D54 RH TM TEMP SENSOR - Voltage between D52 and • Right traction speed • Right TM temperature
D54: Approx. 3.8V (25°C) decrease sensor rise: 423
D52 RH TM TEMP SENSOR +
• Right TM temperature
sensor malfunction: 422
P51 PM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • PM motor revolution sensor
operate malfunction: 442
P47 PM REV. SEN. SIGNAL B GND GND
P45 PM REV. SEN. SIGNAL B (The measurement is not

T
possible)
P46 PM REV. SEN. SIGNAL A GND GND
P44 PM REV. SEN. SIGNAL A (The measurement is not
possible)
P49 PM REV. SENSOR GND
AF (The measurement is not
possible)
P48 PM REV. SENSOR POWER + (The measurement is not
possible)
P50 PM REV. SEN. POWER SHIELD GND connection
D61 LH TM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • LH TM motor revolution
D57 LH TM REV. SEN. SIGNAL B GND GND operate sensor malfunction: 440
R
D55 LH TM REV. SEN. SIGNAL B (The measurement is not
possible)
D56 LH TM REV. SEN. SIGNAL A GND GND
D53 LH TM REV. SEN. SIGNAL A (The measurement is not
D

possible)
D49 LH TM REV. SENSOR GND (The measurement is not
possible)
D48 LH TM REV. SENSOR POWER + (The measurement is not
possible)
D59 LH TM REV. SEN. POWER SHIELD GND connection
D51 RH TM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • RH TM motor revolution
operate sensor malfunction: 438
D47 RH TM REV. SEN. SIGNAL B GND GND
D45 RH TM REV. SEN. SIGNAL B (The measurement is not
possible)
D46 RH TM REV. SEN. SIGNAL A GND GND
D44 RH TM REV. SEN. SIGNAL A (The measurement is not
possible)
D43 RH TM REV. SENSOR GND (The measurement is not
possible)
D42 RH TM REV. SENSOR POWER + (The measurement is not
possible)
D50 RH TM REV. SEN. POWER GND connection
SHIELD

CS-112
 REFERENCE DATA OF CONTROL SYSTEM

Main Print Board (Cont’d)

Terminal
No. Possible error mode/
Items Characteristic/Specification Related trouble diagnosis
(Print board Related symptom
side)

D3 MAIN CONTACTOR DRIVE + VB level • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
D4 MAIN CONTACTOR DRIVE - PWM drive (VB-GND)
• The main contactor is not
input
D68 Traction current sensor power 12.5±1V • The controller does not • Traction right U-phase
supply operate current sensor output large:
D70
415
D71 • Traction right U-phase
D72 current sensor output small:
414
D73 Right U-phase traction current At no motor driving: 2.5±0.1V
• Traction right V-phase
sensor signal current sensor output large:
D75 Right W-phase traction current 417
sensor signal • Traction right V-phase
current sensor output small:
D78 Left U-phase traction current
416
sensor signal
• Traction left U-phase current
D79 Left W-phase traction current sensor output large: 419

T
sensor signal • Traction left U-phase current
D62 Traction current sensor power GND sensor output small: 418
supply GND • Traction left V-phase current
D69
sensor output large: 421
D74
AF • Traction left V-phase current
sensor output small: 420
D80
P70 Loading current sensor power 12.5±0.1V • The controller does not • Loading U-phase current
supply operate sensor output large: 431
P71
• Loading U-phase current
P72 sensor output small: 430
P73 Loading U-phase traction cur- At no motor driving: 2.5±0.1V • Loading V-phase current
rent sensor signal sensor output large: 433
• Loading V-phase current
R
P75 Loading V-phase traction current
sensor output small: 432
sensor signal
P74 Loading current sensor power GND
supply GND
P78
D

D64 Cooling fan power supply At fan driving: 24.0±3V • Internal cooling fan • Right Drive Cont.
D65 malfunction temperature sensor
malfunction: 426
• Loading Pump Cont.
temperature sensor
malfunction: 436
D102 Traction right controller tempera- Voltage between D102 and • The controller does not • Right Drive Cont.
ture + D103: Approx. 3.8V (25°C) operate temperature sensor rise:
Traction right controller tempera- • Left traction speed decrease 427
D103
ture - • Right Drive Cont.
temperature sensor
malfunction: 426
D85 Traction left controller tempera- Voltage between D85 and • The controller does not • Left Drive Cont. temperature
ture + D86: Approx. 3.8V (25°C) operate sensor rise: 429
• Right traction speed • Left Drive Cont. temperature
D86 Traction left controller tempera-
ture - decrease sensor malfunction: 428

P85 Loading controller temperature + Voltage between P85 and P86: • The controller does not • Pump Cont. temperature
Approx. 3.8V (25°C) operate rise: 437
P86 Loading controller temperature -
• Loading speed decrease • Pump Cont. temperature
sensor malfunction: 436

CS-113
 REFERENCE DATA OF CONTROL SYSTEM

Drive FET Board (for RH traction motor

control)
Terminal
Possible error mode/Related
No. (Print Items Characteristic/Specification Related trouble diagnosis
symptom
board side)

D99 INV-RESET Inverter block signal: Inverter • Right traction malfunction • Traction right FET short:
stops at 5V or more 408
• Traction right FET open:
D100 FAIL Inverter malfunction diagnosis
409
at GND level
D101 GND-C GND
D104 KEY1 VB level
D105 12V 12.5±1V
D106 INV DIA At normal inverter: Range of
1/4VB - 3/4VB

Drive FET Board (for LH traction motor

control)
Terminal

T
Possible error mode/Related
No. (Print Items Characteristic/Specification Related trouble diagnosis
symptom
board side)

D82 INV-RESET Inverter block signal: Inverter • Left traction malfunction • Traction left FET short: 412
stops at 5V or more • Traction left FET open: 411
AF
D83 FAIL Inverter malfunction diagnosis
at GND level
D84 GND-C GND
D107 KEY1 VB level
D108 12V 12.5±1V
D109 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
R

Pump FET Board

D

Terminal
Possible error mode/Related
No. (Print Items Characteristic/Specification Related trouble diagnosis
symptom
board side)

P99 INV-RESET Inverter block signal: Inverter • Loading malfunction • Loading FET short: 412
stops at 5V or more • Loading FET open: 413
P100 FAIL Inverter malfunction diagno-
sis at GND level
P101 GND-C GND
P104 KEY1 VB level
P105 12V 12.5±1V
P106 INV DIA At normal inverter: Range of
1/4VB - 3/4VB

CS-114
 REFERENCE DATA OF CONTROL SYSTEM

Traction Condenser Board

Terminal
Possible error mode/Related
No. (Print Items Characteristic/Specification Related trouble diagnosis
symptom
board side)

E1 Batt+ • VB level (E1-E2) (contactor • The controller does not • CONT condenser
input) operate malfunction: 406
E2 Batt-
• Main contactor short: 400
E13 Batt+ • VB level (E13-E14) • Main contactor open: 401
(contactor input) • Main fuse open: 403
E14 Batt-

Loading Condenser Board

Terminal
Possible error mode/Related
No. (Print Items Characteristic/Specification Related trouble diagnosis
symptom
board side)

E16 Batt+ • VB level (E16-E15) • The controller does not • CONT condenser
E15 Batt- (contactor input) operate malfunction: 406
• Main contactor short: 400
• Main contactor open: 401
• Main fuse open: 403
F1A Controller cooling fan 1 power Voltage between F1* and F2* • Controller internal cooling • Right Drive Cont.

T
supply At fan driving: 24.0±3V fan malfunction temperature sensor
malfunction: 426
F1B Controller cooling fan 2 power
• Loading Pump Cont.
supply
temperature sensor
F1C Controller cooling fan 3 power
supply
AF malfunction: 436

F1D Controller cooling fan 4 power

supply
F1E Controller cooling fan 5 power
supply
F1F Controller cooling fan 6 power
supply
R
F2A Controller cooling fan 1 GND
F2B Controller cooling fan 2 GND
F2C Controller cooling fan 3 GND
F2D Controller cooling fan 4 GND
D

F2E Controller cooling fan 5 GND

F2F Controller cooling fan 6 GND

CS-115
 MEMO

Joystick Controller
Terminal
No. Possible error mode/Related
Items Characteristic/Specification Related trouble diagnosis
(Controller symptom
side)
O25 POWER Joystick controller input power • Joystick controller –
supply: 8.5±1V malfunction
O26 POWER Joystick controller input power
supply: 8.5±1V
O27 GND Joystick controller power • Joystick controller –
supply GND malfunction
O30 GND Joystick controller power
supply GND
O32 KEY SW 2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
O31 KEY SW 1 (IGN) VB level (key switch 1 ON) • Joystick controller –
malfunction
O34 JS SENEOR POWER Proportional solenoid control • Proportional solenoid –
lever power supply: 5.0±0.2V control malfunction
• Proportional solenoid valve
malfunction

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• The loading motor does not
rotate
• The loading motor speed is
slow
O36 LIFT SIGNAL 1
AF
At lever operation • No lift operation • Lift sensor output large: 459
Between D34 voltage x 90% • The loading motor does not • Lift sensor output small:
and D34 voltage x 10% rotate 458
O37 LIFT SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O35 JS SENSOR GND Proportional solenoid control • Proportional solenoid –
lever power supply GND control malfunction
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• Proportional solenoid valve
malfunction
• The loading motor does not
rotate
O38 TILT SIGNAL 1 At lever operation • No tilt operation • Tilt sensor output large: 461
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Between D34 voltage x 90% • The loading motor does not • Tilt sensor output small:
and D34 voltage x 10% rotate 460
O39 TILT SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O40 3RD SIGNAL 1 At lever operation • No 3rd operation • 3rd sensor output large:
Between D34 voltage x 90% • The loading motor does not 461
and D34 voltage x 10% rotate • 3rd sensor output small:
O41 3RD SIGNAL 2 At lever operation • The loading motor speed is 462
Between D34 voltage x 90% slow
and D34 voltage x 10%
O42 4TH SIGNAL 1 At lever operation • No 4th operation • 4th sensor output large: 465
Between D34 voltage x 90% • The loading motor does not • 4th sensor output small:
and D34 voltage x 10% rotate 464
O43 4TH SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O44 1 STICK DETECT SW GND level (switch ON) • Unstable joystick control –
(FC-B)
O45 MULTI FUNCTION DETECT GND level (switch ON) • Unstable joystick control –
SW (JS-A)
O46 MULTI FUNCTION 1 TO 4 SW GND level (switch ON) • Multifunction lever –
4th/5th malfunction

CS-116
 REFERENCE DATA OF CONTROL SYSTEM

Joystick Controller (Cont’d)

Terminal
No. Possible error mode/Related
Items Characteristic/Specification Related trouble diagnosis
(Controller symptom
side)

O47 SWITCH GND Joystick controller switch – –

circuit GND
O7 CHOPPER GND Proportional solenoid GND • Proportional solenoid valve • Each proportional solenoid
malfunction valve open
O8 CHOPPER GND Proportional solenoid GND
O23 5TH SOLENOID B (PWM Drive) Proportional solenoid PWM • 5th valve malfunction • 5th valve push open: 525
drive • 5th loading malfunction • 5th valve push short: 524
O22 5TH SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O20 4TH SOLENOID B (PWM Drive) Proportional solenoid PWM • 4th valve malfunction • 4th valve push open: 521
drive • 4th loading malfunction • 4th valve push short: 520
O19 4TH SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O17 3RD SOLENOID B (PWM Drive) Proportional solenoid PWM • 3rd valve malfunction • 3rd valve push open: 517
drive • 3rd loading malfunction • 3rd valve push short: 516
O16 3RD SOLENOID A (PWM Drive) Proportional solenoid PWM

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drive
O15 TILT SOLENOID B (PWM Drive) Proportional solenoid PWM • Tilt valve malfunction • Tilt valve push open: 513
drive • Tilt loading malfunction • Tilt valve push short: 512
O14 TILT SOLENOID A (PWM Drive) Proportional solenoid PWM
AF
drive
O13 LIFT SOLENOID B (PWM Drive) Proportional solenoid PWM • Lift valve malfunction • Lift valve push open: 509
drive • Lift loading malfunction • Lift valve push short: 508
O12 LIFT SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O24 C1 SOLENOID (PWM Drive) Proportional solenoid PWM • Loading malfunction • C1 solenoid open: 527
output • C1 solenoid short: 526
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O4 EMERGENCY RELAY 2 EMG 2 relay drive (GND level • Proportional solenoid valve • Each proportional solenoid
at driving) malfunction valve open
O10 SOL. POWER RETURN (Solenoid PWM return line) • Unstable valve control at –
O11 SOL. POWER RETURN open
D

O28 COMMUNICATION TO CONT. D28-GND • Joystick controller • Controller communication

0 - 5V rectangular wave (CAN malfunction malfunction: 558
communication between main
print board and Joystick
controller)
O29 COMMUNICATION TO CONT. D29-GND
0 - 5V rectangular wave (CAN
communication between main
print board and Joystick
controller)

CS-117
 CONTROL SYSTEM

A1N1 SECTION CS
CONTENTS
TECHNICAL DESCRIPTION ............................. CS-1 Connector (Terminal layout) ........................ CS-51
System .......................................................... CS-1 Controller Element Inspection ..................... CS-55
PRECAUTIONS ............................................... CS-10 Removal and Installation ............................. CS-58
LOCATION OF UNITS (LAYOUT) ................... CS-11 UNIT INSPECTION AND ADJUSTMENT ........ CS-59

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Standard Equipment (3 - wheel) .................. CS-11 Control System ............................................ CS-59
Standard Equipment (4 - wheel) .................. CS-12 Joystick Control System (Option) ................ CS-71
Optional Equipment ..................................... CS-13 Knob Position Control System
AF
METER PANEL ................................................ CS-14 (Option) ....................................................... CS-78
Meters, Indicators and Lamps ..................... CS-14 Tilt Leveling Device (Option) ....................... CS-79
Setting Adjustment Items (Normal Mode) ... CS-14 TROUBLE DIAGNOSTIC PROCEDURES ...... CS-83
Meter Panel Explanation ............................. CS-16 Precautions ................................................. CS-83
LCD MONITOR ................................................ CS-26 How To Follow Flow Chart .......................... CS-84
Adjustment Mode ........................................ CS-26 Symbol Identification ................................... CS-85
Manager Mode ............................................ CS-34 Voltage and Resistance Measurement
Diagnostic Mode .......................................... CS-38 Procedures .................................................. CS-86
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Table of Error Code (1) ............................... CS-49 Table of Error Code (2) ............................... CS-87
CONTROLLER ................................................. CS-50
Construction ................................................ CS-50
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CAUTION:
Where towing this truck always ensure key is in OFF position and battery is disconnected (unplugged) to
reduce possible damage to electrical system.
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION

System
VEHICLE CONTROL SYSTEM COMPONENTS

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AF
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CORRELATION DIAGRAM OF SYSTEM
Drive system
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CS-1
 TECHNICAL DESCRIPTION

System (Cont’d)
AC motor control

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AF
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DRIVE SYSTEM FUNCTION

D

Item Function Outline Input Output

• The vehicle speed is controlled by open percent of • Accelerator sensor
Speed control accelerator pedal. • F/R SW
• Max speed is limited by settings.
• The vehicle acceleration is controlled by open percent and • Accelerator sensor
Acceleration operating speed of accelerator pedal.
control • The acceleration level of Normal and after switch back
regenerative is different.
• Max speed and acceleration are limited when the vehicle is • Tire angle sensor
turning.
Dual motor
• Turning of vehicle is judged by steer tire angle.
control
Driving • In case of turning, the revolution of Right and Left drive
motors are different. • Traction motors
control
• The vehicle regenerative torque is controlled with 4 • Accelerator sensor
regenerative modes by accelerator pedal, brake pedal, • Brake SW
vehicle speed and shift lever. 4 regenerative modes are • Revolution sensor
switch back, accelerator off (and half off), brake and anti-roll • F/R SW
4-mode off.
regenerative • The Switch back regenerative torque is controlled by open
control percent of accelerator pedal. The Switch back regenerative
is not controlled with less than setting rotation at changing
shift lever. The Switch back regenerative control must finish
with less than setting rotation during regenerative mode.
• The anti-roll off speed is kept constant.

CS-2
 TECHNICAL DESCRIPTION

System (Cont’d)
Item Function Outline Input Output
• The controller must prevent rapid torque change in case of • Accelerator sensor
follows; • Brake SW
• Changing accelerator pedal from ON to OFF or F/R SW • Revolution sensor
Cushion from F (or R) to neutral. • F/R SW
(Ramp) control • Starting each regenerative control, the controller must
prevent rapid torque change.
• Finishing accelerator off/brake regenerative control
because of going down the vehicle's speed.
• The controller must limit max motor output in case of • Brake SW
follows; • PKB SW
• According to the quantity of open percent of accelerator
pedal.
Power down
• During brake SW ON.
control
• During PKB SW ON.
Driving
• If max motor output limitation by brake or PKB SW is
control • Traction motors
keeping for a setting time, the controller must stop motor
(Cont’d)
output.
• Max acceleration is changed by power mode and drive • Meter panel
accelerator level.
• NT characteristic for running is changed by power mode.
• The acceleration after switch back regenerative is changed

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by SB regenerative level.
Driving • The switch back regenerative torque is changed by power
performance mode and SB regenerative level.
change control • The brake regenerative torque is changed by BK
AF
regenerative level.
• The accelerator off regenerative torque is changed by AOL
regenerative level.
• The anti-roll off speed is changed by ARL regenerative
level.
• The pump motor revolution speed is controlled by load SW. • Load SW
• The revolution speed is depended on each load SW. • Traction revolution
Speed and
• In case of multi load SW input, the rotation speed is sensor
acceleration
controlled by decided priority.
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control
• Max revolution speed is limited by the vehicle speed.
• The pump motor revolution speed is controlled by load SW.
Loading • In case of stopping load operation, revolution of motor is • Load SW
regenerative decreased by regenerative. • Pump motor
control
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• In case of receiving pump cut signal from meter, the • Meter panel
Power down
controller stop Loading control.
control
• This case is caused by near empty of battery.
Loading Loading • Max acceleration is changed by load accelerator level. • Meter panel
control
performance • NT characteristic for running is changed by power mode.
change control
• The motor revolution is controlled by open percent of each • Finger tip sensor
joystick. • Oil pressure sensor
• Servo solenoid is controlled with by open percent of each
joystick and load weight.
Servo solenoid
• C1 solenoid is controlled in case of loading operation.
valve control • Pump motor
• In case of one stick, the controller limits one operation that
(Joystick • C1 servo solenoid
is tilt forward and lift down simultaneously.
control)
• Due to prevent the lift hunting, shock at start/stop and lift
down rapidly and some other feeling problem. The
controller takes in ramp and delay control about servo
solenoid.

CS-3
 TECHNICAL DESCRIPTION

System (Cont’d)
Item Function Outline Input Output
• During operating the steer with no load operation, the • Steer sensor
Speed control controller controls the motor revolution by steer speed and • Thermo sensor
ambient temperature of the vehicle. (meter)
• Due to prevent the kick back and scratch of steer, the • Traction revolution
Power controller takes in ramp and delay control. sensor
Ramp and
steering • PKB SW • Pump motor
delay control
control • Load SW
• F/R SW
Starting • Starting motor control is 4 modes. That is “Steering”, “F/R • Steer sensor
control of SW”, “Accelerator pedal”, “Steering and Accelerator pedal” • F/R SW
motor and “Steering continue”. • Accelerator sensor
• The controller controls PS C solenoid to agree with steering • Steering sensor
Steering knob
and tire angle. • Tire angle sensor • PS C correct
position
• The relationship between steering and tire angle are solenoid
correct control
calculated by formula.
Lift down • In case of sitting of operator, lift down solenoid is driven • Seat SW
solenoid with PWM. • Tilt down solenoid
control (MC) • This function is only MC.
• In case of pushing the tilt horizontal SW with no load, if the • Tilt angle sensor
tilt angle is horizontal, the controller drives tilt horizontal • Oil pressure sensor

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Tilt auto solenoid. • Tilt horizontal SW
• Tilt horizontal
horizontal • In case of pushing the tilt horizontal SW with load, the
solenoid
control controller drives tilt horizontal solenoid without tilt angle.
• Aux output
(Optional) • The controller judged by oil pressure whether load or no
load.
AF
• During tilt angle is horizontal, AUX OUTPUT is driven.
• In case of operating turn SW, the controller switches each • Turn SW
Flasher control • Flasher out
flasher out ON and OFF by the direction of turn SW.
• In case of password entry, the meter informs power mode • Meter panel
and level to the controller. So, the controller controls with
Password
informed power mode and level.
entry (Log in)
• This function is related to “Driving performance change
control” and “Loading performance change control”.
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• The controller checks the vehicle spec. by MODE SELECT • Mode select SW -
Vehicle SW at every key ON. And if the vehicle spec. is changed • Meter panel
control before, NT characteristic is changed and all settings that
Vehicle status
are record to EEPROM are reset.
change
D

• If the battery voltage setting is changed at Adjustment

mode, NT characteristic is also changed and the control
function that is related to voltage is also changed.
Real time • The controller calculates consumption energy by • Battery current
energy multiplying battery voltage and current and inform it to sensor
consumption meter panel. • Battery voltage
meter
• The controller calculates load by oil pressure sensor and • Oil pressure sensor • Meter panel
Load meter inform it to meter panel. And it calculates three load that is,
• current load • load for indicator • load for warning
• In case of PKB OFF during not sitting, the controller informs • PKB SW
PKB alarm
this to meter panel.
• The controller judges the sitting or not sitting by seat SW. • Key SW
• At the time of key OFF to ON, • Accelerator sensor
if the operator doesn’t sit the seat, then traction and load • F/R SW
operation is stopped. • Load SW
Inhibiter if the operator operates shift lever or accelerator pedal, then • Steer sensor
• All output
control traction operation is stopped. • Brake SW
if the operator operates load lever, then load operation
(except steering) is stopped.
• At the time of key ON to START during auto power mode,
inhibiter control is same as key OFF to ON.

CS-4
 TECHNICAL DESCRIPTION

System (Cont’d)
Item Function Outline Input Output
• If the setting time passes with no operation, the vehicle is • Accelerator sensor
controlled with minimum current consumption mode. At • F/R SW
that case, the controller controls APO relay to OFF. Other • Load SW
Auto power case, APO relay is controlled with ON. • Steer sensor
OFF • Traction revolution
sensor
• Load revolution
sensor
• In case of low battery voltage that is setting, the controller • Battery voltage
controls the vehicle to be stopped except power steering
Vehicle and lift down.
control • In regenerative mode, if the battery cut off, should not be • All output
(Cont’d) damaged by overvoltage.
• If the power circuit is open at very short time by vibration,
the power switching devices must be controlled not to
Voltage
detect any error after closing the power circuit.
protection
• To prevent over discharge of battery, the motor output is
control
limited by battery voltage level. If this function does not
work, the vehicle detects low battery voltage and stopped
before power down control by pump cut signal. We have to
obey the sequence that the vehicle detects pump cut signal
and limits the loading control first, then if the operator still

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use the vehicle, the vehicle detects low battery voltage and
stops the vehicle almost.
• If the controller detects the main circuit failure, the controller
Main circuit
protection
AF
controls specified fail safe control. The main circuit
includes FET, condenser and contactor.
Input (Sensor, • If controller detects the input failure, the controller controls
digital input) specified fail safe control.
Output (Relay, • If the controller detects the output failure, the controller
solenoid) controls specified fail safe control.
Fail safe
Overheat • If the controller detects overheat, the controller limits the - -
control
protection output of motor. The controller must not stop the control.
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Current fail • If the current is out of specified range, the controller
safe controls specified fail safe control.
Voltage fail • If the voltage is out of specified range, the controller
safe controls specified fail safe control.
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• Others fail safe includes such as “sum check error”, “vehicle

Others
status error” and “communication error”.
• Transmission method: RS-232C start-stop synchronous
communication
• Rate: 2400bps±2% (2403.85)
• Data length: 8bit
• Parity check: odd number
• Stop bit: 1bit
• Data structure: “start bit” + “data 8bit” + “odd number parity
bit” + 1 stop bit” (11 bit)
Communi-
• Signal voltage level: logic level 1 input = -3 to -25V
cation with Protocol - -
output = -5 to -15V
meter
0 input = +3 to +25V
output = +5 to +15V
• Data format (packet format): “LF” + “address” + “data n” +
“data n+1” + ….. + “SUM”
• Detection of communication error: if the period of packet is
longer than 1 sec, the controller detects communication
error. The controller controls with previous data that is not
detected error.

CS-5
 TECHNICAL DESCRIPTION

System (Cont’d)
Item Function Outline Input Output
• First of all, the controller and meter communicate of initial
communication for realizing the vehicle spec. and control
mode.
Initial • Data meter ← controller: “vehicle spec” such as vehicle
type, area, battery voltage and weight
• Data controller ← meter: “control mode
• Transmission period: 40ms
• This is communicated during normal mode.
• The controller and meter communicate the present vehicle
status and error.
• Data controller ← meter: “vehicle stop sig”, “pump cut sig”,
Normal
“log in sig”, “ambient temperature”, “power mode”, “accel
level (traction and pump)” and “setting for password entry”
• Data meter ← controller: “vehicle status” and “error sig”
Communi- • Transmission period: 200ms
cation with
• This is communicated during adjustment mode. - -
meter
• The controller and meter communicate the present vehicle
(Cont’d)
settings.
Adjustment
• Data meter ← controller: “function ON/OFF”, “sensor
setting” and “vehicle performance setting”
• Transmission period: 200ms

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• This is communicated during factory mode.
• The controller and meter communicate the present vehicle
settings.
Factory
• Data meter ← controller: “function ON/OFF”, “sensor
AF
setting” and “vehicle performance setting”
• • Transmission period: 200ms
• This is communicated during diagnosis mode.
• The controller and meter communicate the present vehicle
Diagnosis
settings and status.
• Transmission period: 200ms
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D

CS-6
TECHNICAL DESCRIPTION

System (Cont’d)
PRINCIPLE OF AC MOTOR

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AF
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CSM001

CS-7
TECHNICAL DESCRIPTION

System (Cont’d)
KNOB POSITION CONTROL SYSTEM
(OPTION)
Knob position control
This ensures that the steering knob position constantly reflects the
correct tire angle.
NOTE:
The neutral level for the tire angle sensor must be adjusted
individually for each vehicle. (To absorb any variants in sensor
mounting and vehicle differences.)

Input Output

Steering wheel angle sensor

angle 1 signal
Steering wheel angle sensor
Steering wheel Power steering correction
angle 2 signal
solenoid
Steering wheel angle sensor
neutral signal
Tire angle sensor

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AF
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D

CS-8
TECHNICAL DESCRIPTION

System (Cont’d)
Knob position control system (option)

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AF
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CSM002

CS-9
 PRECAUTIONS
PRECAUTIONS

CAUTION:
• Before removing or inserting main/meter print board
connectors, turn the key switch to the OFF position and
remove the battery plug. Failure to do so may cause a
malfunction in the print board.
• Make sure the controller/meter connector cord is free from
twisting when the connector is removed or inserted. A
twisted cord may cause poor connector contact. When
removing the connector, always hold the connector body and
do not pull on the cord.
• When removing wiring harnesses and/or bus bars, note their
relative locations so they can be reinstalled in their original
positions during reassembly.
• When installing a controller element which is used with
insulating film, be sure to place insulating film on the
contacting surface of the element and mating part. If a
controller element is not used with insulating film, apply
silicone-based grease to the contacting surface of the
element and mating part during installation.
• Before checking controller elements during on-vehicle
inspection, remove the wiring harnesses and bus bars.

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Inadvertent current flow may damage the element or other
parts being checked.
• Before using flow charts as a guide to troubleshoot units and
AF parts, become familiar with the instructions outlined under
“TROUBLE DIAGNOSTIC PROCEDURES”.
NOTE:
Controller and unit conditions are determined by checking/
measuring the resistance values (continuity) of, or voltage values
produced across, various parts affected. However, this section deals
with only resistance measurement procedures.
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CS-10
LOCATION OF UNITS (LAYOUT)
LOCATION OF UNITS (LAYOUT)

Standard Equipment (3 - wheel)

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AF
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212014EU

CS-11
LOCATION OF UNITS (LAYOUT)

Standard Equipment (4 - wheel)

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AF
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2012013EU

CS-12
LOCATION OF UNITS (LAYOUT)

Optional Equipment

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AF
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BSM0663EU

CS-13
 METER PANEL
METER PANEL

Meters, Indicators and Lamps

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AF
Setting Adjustment Items (Normal Mode)
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Shift to adjust
Adjustment item Adjustment Details Function lock
mode
Push FN1 The items displayed become darkened, and the display becomes darker.
LCD contrast — Lock OFF
Push FN2 The items displayed become faded, and the display becomes brighter.
D

Traction and loading power mode — Push FN3 Lock ON

Hour meter select/Real time

— Push FN4 Lock ON
energy consumption indicator

Push FN3 Hour → Minute → Day

Push FN4 Hour ← Minute ← Day
Push FN1 +
Clock setting Push FN1 The digit is increased, or the day is advanced. Lock OFF
FN2
Push FN2 The digit is decreased, or the day is set back.
Push FN5 Setting complete.
Push FN3 Hour → Minute → Day
Push FN4 Hour ← Minute ← Day
Push FN2 +
Alarm setting Push FN1 The digit is increased, or the day is advanced. Lock OFF
FN4
Push FN2 The digit is decreased, or the day is set back.
Push FN5 Setting complete.
Push FN3 D-ACC → P-LEVEL
Push FN4 D-ACC ← P-LEVEL
Push FN1 +
Acceleration level Push FN1 Increase Lock ON
FN4
Push FN2 Decrease
Push FN5 Setting complete.
Default setting (tilt horizontal level Push FN1 +
Push FN5 Setting complete. Lock ON
and simple load indicator) FN5

CS-14
 METER PANEL

Setting Adjustment Items (Normal Mode)

(Cont'd)
Shift to adjust
Adjustment item Adjustment Details Function lock
mode
Push FN1 The digit is increased.
Alarm weight setting (simple Push FN4 +
Push FN2 The digit is decreased. Lock ON
load indicator option only) FN5
Push FN5 Setting complete.
Push and hold
Help menu — The operating method of the function switch is displayed. —
FN5
Push FN2 +
FN5
+
Push FN5
+
Push FN2 The function LCD contrast, clock setting and alarm setting
Function lock/unlock — —
+ cannot be locked in the lock ON position.
Push FN3
+
Push FN5
+
Push FN5

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AF
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D

CS-15
 METER PANEL

Meter Panel Explanation

DESCRIPTION
The meter panel consists of two sections: LCD (Liquid Crystal
Display) monitor and function keys.
1. Function keys
Function keys control the LCD contrast, display changes and
other adjustments. Function key operation is described in the
individual part descriptions and in the items related to
adjustment.
2. LCD
When the key switch is in the ON position, backlighting makes
the displays clearly visible to the forklift operator. It displays
normal operation (battery capacity meter, hour meter, clock,
steering wheel angle gauge, speedometer, etc.), malfunction
and adjustment data.

LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
To darken the contrast, push function switch FN2. To lighten the
contrast, press function switch FN1.

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HOUR METER (4 MODES)/REAL TIME ENERGY
CONSUMPTION INDICATOR
AF This hour meter has 4 modes (functions).
1. Key “ON” time : Equal to the total operating hours when the
key switch is in the ON position.
2. Operating time : Equal to the traveling or loading time (the
time for whichever operation in progress is displayed).
3. Traveling time : Equal to the total time that the traction motor
is operational.
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4. Loading time : Equal to the total time that the forks are
operational (tilting and lifting).
5. Real time energy consumption indicator : Electric power
consumed by each operation is displayed (When - (minus) kW
D

is displayed, the regeneration mark is displayed, too).

The hour meter operates when the key switch is in the ON position,
and it indicates the total operating period in hours (key “ON” time).

STEERING WHEEL ANGLE GAUGE/SPEEDOMETER

NOTE:
When the vehicle speed is 3 km/h or less, the speedometer
indicates the angle of rear wheel tires, instead of the speed.

CSM0098

CS-16
 METER PANEL

Meter Panel Explanation (Cont’d)

SIMPLE LOAD INDICATOR (OPTION)
Cargo weight is displayed.
Display condition:
The vehicle speed is 3 km/h (2 MPH) or less.
For 5 seconds after cargo lifting has been stopped.
Display range: 100 kg (220 lb) to maximum load
Minimum display unit: 20 kg (44 lb)
CAUTION:
In vehicles equipped with a 2F or 3F mast, the cargo weight is
displayed by converting the pressure from the full-free cylinder.
Therefore, if a load is applied which exceeds the full-free range,
it may not be possible to display the cargo weight.

DEFAULT SETTING
Perform the initial value setting after operating the vehicle into the
following position.
Mast: vertical
Lift: 30 cm (11.8 in) up (no load or tare weight (palette, etc)

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condition)
NOTE:
If the vehicle is equipped with the tilt horizontal function (option),
AF simple load indicator (option), the mast angle and the load indicator
are set to the zero position after performing the initial value setting.
1. When FN1 and FN5 are pressed at the same time, the clock
display switches to the initial value setting screen.
2. When FN5 is pressed, the initial values are set and the screen
returns to the clock display.
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D

OVER SETTING WEIGHT

When this function is used, if the cargo weight on the lift exceeds the
value that has been set as the alarm weight, a buzzer and an
indicator will alert the operator.

CS-17
 METER PANEL

Meter Panel Explanation (Cont’d)

ALARM WEIGHT SETTING
1. When FN4 and FN5 are pressed at the same time, the clock
display switches to the alarm weight setting screen.
2. Push FN1 to increase the weight (in increments of 20 kg (40
lb)).
3. Push FN2 to decrease the weight (in increments of 20 kg (40
lb)).
Push and hold for 5 seconds to increase/decrease in
increments of 200 kg (400 lb).
4. When FN5 is pressed, the alarm weight is set and the screen
returns to the clock display.

REGENERATION MARK
When the real time energy consumption indicator is displayed and
then when - (minus) kW is displayed, the regeneration mark is
displayed, too.

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AF
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D

CS-18
 METER PANEL

Meter Panel Explanation (Cont’d)

When vehicle speed is 4 km/h or more, the speedometer shows
forklift speed in either kilometers per hour (km/h) or miles per hour
(mph). The maximum vehicle speed and speed alarm can both be
set.

NOTE:
Speedometer factory settings at time of shipping:
Maximum speed: 20 km/h (12 MPH)
Setting speed range: 1 - 20 km/h (3 - 12 MPH)
Forklift speed alarm 1 - 2 setting: 25 km/h (16 MPH)
Forklift speed alarm 1 setting range (WSL1):
5 - 25 km/h (3 - 16 MPH)
Forklift speed alarm 2 setting range (WSL2):
WSL1 - 25 km/h (WSL1 - 16 MPH)

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CSM0099
AF POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function switch FN3 is pressed, the power
mode is switched.

Mode M: Manual mode:

The power levels for traveling and loading can be individually set
R
according to customer requests.
Factory defaults:
Traveling power level: Level 1
CSM0100 Loading power level: Level 1
D

Adjustable range for traveling and loading power levels: Levels 1 - 5

Mode E: Economy mode:

For work requiring operation time to be saved or customers using
the machine for a long time (Traveling and loading power levels:
Level 1)

Mode P: Power mode:

Factory setting (Traveling and loading power levels: Level 3)

Mode H: High-power mode:

For work or customers requiring higher power (Traveling and loading
power levels: Level 5)

CS-19
 METER PANEL

Meter Panel Explanation (Cont’d)

CLOCK/ALARM/ACCELERATION ADJUSTMENT
Clock/alarm
When the key switch is in the ON position, both the day and time are
displayed.

Push function switches FN1 and FN2 simultaneously. The time set
mode will appear.

AM and PM hour adjustment: The hour display will advance by 1

hour each time function switch FN1 or FN2 is pushed.
CSM0101

Minute adjustment: The minute display will advance by 1 minute

each time function switch FN1 or FN2 is pushed.

Day-of-the-week adjustment: The day-of-the-week display will

advance by one day each time function switch FN1 or FN2 is
pushed.

After setting the clock to the correct time, push function switch FN5.

T
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
AF • Push FN1 to increase the numerical value or advance one day of
the week.
• Push FN2 to decrease the numerical value or reverse one day of
the week.
• If an alarm is set, “ ” appears next to the time display. When
the preset time is reached, the buzzer sounds to notify the
operator. Press FN5 to stop the buzzer. The day of the week can
be set to every day (ALL: every day).
R

Traction acceleration adjustment

This control adjusts acceleration during forklift starting and
D

subsequent operation.

Simultaneously press function switches FN1 and FN4. The clock will
move to the traction acceleration control mode.

The acceleration level can be adjusted in a series of 8 steps.

For faster acceleration (Quick): Push function switch FN1.

Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.

For slower acceleration (Slow): Push function switch FN2.

Each time the key is pushed, the acceleration level (speed) will
decrease by 1 step.

After setting the acceleration level, push function switch FN5. The
acceleration level will appear, and clock will return to its original letter
mode.

CS-20
 METER PANEL

Meter Panel Explanation (Cont’d)

NOTE:
Acceleration factory setting at time of shipping:
D-ACC NOM SET: Level 5
(Permissible setting range: Level 1 - 8)
WARNING:
After acceleration level adjustment, operate the forklift slowly
and carefully until you become accustomed to the new
acceleration level. Be especially careful when the acceleration
level has been increased. Higher acceleration levels can cause
loads to shift, to fall off or to be unstable during starts.

Pump acceleration adjustment

Simultaneously push function switches FN1 and FN4. Next, push
function switch FN3. The clock will move to the pump acceleration
control mode.

The acceleration level can be adjusted in a series of 8 steps.

T
For faster acceleration (Quick): Push function switch FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
AF For slower acceleration (Slow): Push function switch FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.

After setting the acceleration level, push function switch FN5. The
pump acceleration level will appear, and the clock will return to its
original letter mode.
R
NOTE:
Pump acceleration factory setting at time of shipping:
P-LEVEL SET: Level 4
P-LEVEL SET: Level 6 (36V battery model for North America)
D

(Permissible setting range: Level 1 - 8)

WARNING:
After pump acceleration level adjustment, operate the forklift
mast control slowly and carefully (up, down and tilt) until you
become accustomed to the new pump acceleration level. Be
especially careful when the acceleration level has been
increased. Higher pump acceleration levels can cause loads to
shift, to fall off or to be unstable during starts.

CS-21
 METER PANEL

Meter Panel Explanation (Cont’d)

PARKING BRAKE WARNING MARK
This mark is displayed whenever the parking brake lever is in the
locked position. The mark disappears whenever the parking brake
lever is released.

SEAT BELT WARNING MARK

This lamp indicates that the seat belt is not fastened securely. It will
lights up if the seat belt is not fastened when the ignition switch is
turned to the ON position, and it will turn off when the seat belt is
fastened.

MALFUNCTION AND WARNING INDICATIONS

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AF
R
D

CSM0102

If any malfunction occurs when the key switch is in the ON position,

the LCD will show a wrench mark “ ” or a battery mark “ ”.
Simultaneously, the LCD will display letters explain the details of the
malfunction.
NOTE:
During forklift operation, periodically check the battery capacity.
Make every effort to recharge the battery before the battery warning
mark “ ” and wrench mark “ ” appear.

Wrench mark
The controller and the sensors act together to regulate the forklift’s
electrical system. The wrench mark will appear whenever one of the
malfunctions listed below occurs. Simultaneously, the LCD will show
an indication explaining the details of the malfunction.

CS-22
 METER PANEL

Meter Panel Explanation (Cont’d)

• Control system malfunction (Traction, Cargo-handling, Power
steering)
• Overheating controller or motor
• Low brake fluid level

BATTERY WARNING MARK

Pump cut warning
Pump cut warning is displayed when the battery capacity meter’s
remaining capacity indication changes from 2/6 to 1/6.

CSM0103

When function switch FN5 is pressed, the display will switch.

T
AF
CSM0104

After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
R
D

CSM0105

When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle may be operated during the pump cut warning.
However, move the vehicle to a safe location, and promptly charge
the battery.

CSM0106

CS-23
 METER PANEL

Meter Panel Explanation (Cont’d)

Low voltage lock warning
If the vehicle is subjected to continuous operation after the pump cut
warning was activated, the low voltage lock warning will be
activated. Then, the display will appear as shown below, and the
warning buzzer will be activated.

CSM0105

When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle cannot be operated during the low voltage lock warning.
NOTE:
The interval between the first appearance of the battery warning
mark and warning buzzer operation is set at the time of shipping.

T
Factory setting: 10 minutes
Permissible setting range: 1 - 20 minutes
AF
CSM0106
R
D

CS-24
 METER PANEL

Meter Panel Explanation (Cont’d)

MALFUNCTION INDICATIONS
Affected system or area Indication Malfunction description
Control system (Traction, D-FET SHORT A malfunction has occurred in
Cargo-handling, Power the forklift traction system.
steering): Units, Sensors, Further operation of the forklift is
Motors, Switches, FETss not possible.

P-FET OPEN A malfunction has occurred in

the forklift cargo-handling
system. Further lifting (lifting
and tilting) operation is not
possible. The forks cannot be
raised or tilted.

TIRE ANGLE SENSOR LOW A malfunction has occurred in

the forklift power steering
system. Forklift steering control
is possible.

D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor is WARNING
overheating. Immediately stop
Ignoring the warning indication and
forklift operation. Park the forklift in
continuing to operate the forklift
a safe area where there is no
can result in serious motor and
pedestrian or vehicular traffic.

T
controller damage.
Allow the controller and/or the
motor to cool.

P/MO TEMP SENSOR HIGH TEMP

AF
Essential fluid BRAKE FLUID LEVEL DOWN The brake fluid level has fallen
below the specified level.

Battery Battery over voltage The controller has detected a high Turn the key switch OFF and ON
battery voltage again. If no error displayed, you can
operate the forklift without a
problem. If problem reoccur, contact
R
your NISSAN FORKLIFT dealer.
D

CS-25
 LCD MONITOR
LCD MONITOR

Adjustment Mode

T
AF
R
D

CS-26
 LCD MONITOR

Adjustment Mode (Cont’d)

NOTE:
This mode is only available for qualified technicians to perform
various adjustments on setting values other than traction/loading
acceleration adjustments in the normal mode.
CAUTION:
• Adjustment values can be advanced or retarded by pushing
FN3 or FN4, respectively.
• Following adjustment value settings, do not turn the key
switch to the OFF position before pressing FN5 to return to
the adjustment item display. Doing so will erase adjustment
value settings.

T
AF
R
D

CS-27
 LCD MONITOR

Adjustment Mode (Cont’d)

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AF
R
D

CS-28
 LCD MONITOR

Adjustment Mode (Cont’d)

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AF
R
D

CS-29
 LCD MONITOR

Adjustment Mode (Cont’d)

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AF
R
D

CS-30
 LCD MONITOR

Adjustment Mode (Cont’d)

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AF
R
D

CS-31
 LCD MONITOR

Adjustment Mode (Cont’d)

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AF
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CS-32
 LCD MONITOR

Adjustment Mode (Cont’d)

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AF
R
D

CS-33
 LCD MONITOR

Manager Mode

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AF
R
D

CS-34
 LCD MONITOR

Manager Mode (Cont’d)

CAUTION:
• Adjustment values can be advanced or retarded by pushing
FN3 or FN4, respectively.
• Following adjustment value settings, do not turn the key
switch to the OFF position before pressing FN5 to return to
the adjustment item display. Doing so will erase adjustment
value settings.

T
AF
R
D

CS-35
 LCD MONITOR

Manager Mode (Cont’d)

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AF
R
D

CS-36
 LCD MONITOR

Manager Mode (Cont’d)

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AF
R
D

CS-37
 LCD MONITOR

Diagnostic Mode

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AF
R
D

CS-38
 LCD MONITOR

Diagnostic Mode (Cont’d)

There are two types of diagnostic method. One type is self-diagnosis
and the other is interactive diagnosis. Self-diagnosis allows for
controller diagnosis of a system, while the interactive diagnosis is
used for diagnosing switches and sensors. When malfunctions occur
in systems or components, check and eliminate probable causes of
the malfunction using either self-diagnostic or interactive diagnostic
techniques. After the malfunctioning area has been repaired,
confirm the malfunction has been eliminated by using the
appropriate diagnostic method.
NOTE:
When checking each component, operate each component if
necessary.

T
AF
R
D

CS-39
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CS-40
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CS-41
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CS-42
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CS-43
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CS-44
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
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CS-45
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CSM0198

CS-46
 LCD MONITOR

Diagnostic Mode (Cont’d)

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AF
R
D

CSM0199

CS-47
 LCD MONITOR

Diagnostic Mode (Cont’d)

CAUTION:
If an interactive diagnostic result indicates that a unit is
abnormal, also check the condition of the associated harness
and connector.
NOTE:
• The number of malfunctions which have occurred in each system
is recorded in the “FAIL LOG” row on the display, without regard to
the nature of the malfunctions experienced.
• For unit inspection procedures, refer to “UNIT INSPECTION AND
ADJUSTMENT” on page 56.

RESULT OF SELF-CHECK
If the error is not detected:

T
AF
CSM0113

If the error is detected:

NOTE:
The 3-digit number in the figure indicates the error code of the
component for which the error is detected. For the error code, refer
to “Table of Error Code” on page 41.
R
CAUTION:
If a self-diagnostic result indicates that an element or
component is abnormal, also check the condition of the
associated harness and bus bar.
D

CSM0114
NOTE:
For element inspection procedures, refer to “Controller Element
Inspection” on page 48.

CS-48
 LCD MONITOR

Table of Error Code (1)

Error Detect mode Error Detect mode
Failure part Fail mode Remarks Failure part Fail mode Remarks
code Work Self code Work Self
CONTROLLER ACTUATOR
Main contactor Short 400 Lift down valve Short 500
-
Open 401 -
Open 501
Battery voltage Low voltage 404
PS correction valve Short 502 Knob position
Over 405 -
voltage Open 503 control (Option)
CONT capacitor Abnormal 406 - Tilt Horizontal valve Short 504 Tilt horizon device
Drive FET right Short 408 Open 505 (Option)
Open 409 Lift valve Pull Short 506
-
Drive FET left Short 410 Open 507
Open 411 Joystick control
Push Short 508
Pump FET Short 412
- Open 509
Open 413
Tilt valve Pull Short 510
Drive current U Low output 414
sensor right High output 415 Open 511
Joystick control
V Low output 416 Push Short 512
High output 417 Open 513
-
Drive current U Low output 418 3rd valve Pull Short 514
sensor left High output 419 Open 515
V Low output 420 Joystick control
Push Short 516
High output 421 Open 517

T
Drive load short short 415 & -
4th valve Pull Short 518
(Right and Left) 417
D/Mo TEMP Abnormal 422 Open 519
Joystick control
sensor right Overheat 423 Push Short 520
- Open 521
D/Mo TEMP Abnormal 424
sensor left Overheat 425
AF C1 solenoid valve Short 526
Joystick control
D/CONT TEMP Abnormal 426 Open 527
sensor right -
Overheat 427 SENSOR
D/CONT TEMP Abnormal 428 F/R Switch Same ON 450 -
sensor left -
Overheat 429 Accel sensor Low output 452
Pump current U Low output 430 -
High output 453
sensor High output 431
- Tire angle sensor Low output 454
V Low output 432 -
High output 455
High output 433
Tilt angle sensor Low output 456
R
Pump load short short 431 & - Tilt horizon device
433 High output 457 (Option)
P/Mo TEMP Abnormal 434 Lift sensor Low output 458
sensor -
Overheat 435 High output 459
P/CONT TEMP Abnormal 436
- Tilt sensor Low output 460
sensor Overheat 437
D

High output 461 Joystick control

D/Mo REV Abnormal 438 -
sensor right 3rd sensor Low output 462 (Option)
D/Mo REV Abnormal 440 - High output 463
-
sensor left 4th sensor Low output 464
P/Mo REV Abnormal 442 -
High output 465
sensor
CONT type Abnormal 446 - Tilt H switch Short 468
Option
select Open 469
Drive Abnormal 446 & - Steer angle sensor Abnormal 470 -
EEPROM&SUM 610
Weight sensor Low output 472
or Software error Option
Pump Abnormal 446 & - High output 473
EEPROM&SUM 602 Battery current Low output 476 -
or Software error sensor High output 477
VCM&JOYSTICK Abnormal 446 & -
EEPROM&SUM 604 COMMUNICATION
or Software error Cont <- Meter Abnormal 444
Drive Hardware Abnormal 406 & - Communication
error 610 Drive PC receive 602
Pump Hardware Abnormal 406 & - Communication V&F receive 604 -
error 602
Abnormal - - -
VCM&JOYSTICK Abnormal 406 & -
Hardware error 604 Pump DC receive 610
FAN Drive circuit Abnormal 426 & - Communication V&F receive 614 -
436 Abnormal - - -
VCM&JOYSTICK DC receive 620
Communication PC receive 622 -
Abnormal - - -

CS-49
 CONTROLLER
CONTROLLER

Construction

T
AF
R
D

No. QTY. Part name No. QTY. Part name

1 1 VCM controller 6 - Fan cable connector
2 1 Pump controller 7 4 Power cable
3 1 Traction controller (LH) 8 5 Screw (M8)
4 1 Traction controller (RH) 9 10 Screw (M6)
5 3 Fan assy

CS-50
 CONTROLLER

Connector (Terminal layout)

CONTROLLER ASSEMBLY
VCM Controller

CN A (35 pins) CN B (23 pins)

35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
23 22 21 20 19 18 17 16 15 14 13 15 14 13 12 11 10 9 UNIT SIDE
12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

UPSIDE
L/W R Y/BR B G/R Y L P W Y OR B B L P GY L/W W/R L W
718 717 716 978 715 801 802 803 804 127 129 992 993 315 669 762 761 906 680 681
L P W W Y/L B/W PU G Y P B/Y
781 771 704 743 670 665 664 705 742 671 660
G BR/Y R BR/W Y/L G G/B
691 690 688 687 685 684 682
HARNESS SIDE
L L/B BR G R W L G B B GY B/R OR L BR/W GY B/Y L R
786 711 710 126 253 254 410 450 960 940 979 934 124 733 723 724 722 811 810 : MC only
: Joystick Contorl only
BSM0665

Input/ Terminal No.

Connector Signal name Descriptions
Output (Unit side)

CN A Input 1 -BATT (MC) Power supply (-)

T
2 KEY IGN Key switch signal
3 KEY START Key start switch signal
4 VOUT Current sensor signal
5 GND Current sensor power supply (-)
6 GND
AF Current sensor power supply (-)
9 STEER ANGLE SEN GND Steer angle sensor power supply (-)
10 STEER ANGLE SEN SIGNAL A Steer angle sensor signal A
11 STEER ANGLE SEN SIGNAL B Steer angle sensor signal B
12 STEER ANGLE SEN SIGNAL N Steer angle sensor signal N
17 ACCEL SEN SIGNAL A Accelerator sensor signal A
18 ACCEL SEN SIGNAL B Accelerator sensor signal B
19 TIRE ANGLE SEN SIGNAL Tire angle sensor signal
R
20 OIL PRESSURE SEN SIGNAL Oil pressure sensor signal
21 TILT ANGLE SEN SIGNAL Tilt angle sensor signal
24 ACCEL SEN GND Accelerator sensor power supply (-)
25 TIRE ANGLE SEN GND Tire angle sensor power supply (-)
D

26 OIL PRESSURE SEN GND Oil pressure sensor power supply (-)
27 TILT ANGLE SEN GND Tilt angle sensor power supply (-)
30 L FLASHER OUT L flasher (-)
31 R FLASHER OUT R flasher (-)
32 A.P.O. RELAY DRIVE ON/OFF Auto power off relay
Output 7 +15V Current sensor power supply (+)
8 STEER ANGLE SEN POWER (+12V) Steer angle sensor power supply (+)
13 ACCEL SEN POWER (+5V) Accelerator sensor power supply (+)
14 TIRE ANGLE SEN POWER (+5V) Tire angle sensor power supply (+)
15 OIL PRESSURE SEN POWER (+5V) Oil pressure sensor power supply (+)
16 TILT ANGLE SEN POWER (+5V) Tilt angle sensor power supply (+)
28 FLASHER POWER IN Flasher power supply (+) IN
29 FLASHER POWER OUT Flasher power supply (+) OUT
Input/ 22 CAN L Low level CAN BUS voltage I/O
Output 23 CAN H High level CAN BUS voltage I/O
33 RS232 TX RS232 transmission (meter)
34 RS232 RX RS232 reception (meter)
35 CAN T CAN termination: connect to No.23 (CAN H) to
insert a 120Ω termination resistance. (MC)

CS-51
 CONTROLLER

Connector (Terminal layout) (Cont’d)

Input/ Terminal No.
Connector Signal name Descriptions
Output (Unit side)
CN B Input 1 LIFT SIGNAL 1 Joystick sensor lift signal 1 (Joystick Control)
3 JS SENSOR GND Joystick sensors power supply (-) (Joystick Control)
4 FORWARD SW Forward switch signal
5 REVERSE SW Reverse switch signal
6 BRAKE SW Brake switch signal
7 PARKING BK SW Parking brake switch signal
8 -BATT (MC) Power supply (-)
9 LIFT SIGNAL 2 Joystick sensor lift signal 2 (Joystick Control)
10 TILT SIGNAL 1 Joystick sensor tilt signal 1 (Joystick Control)
11 TILT SIGNAL 2 Joystick sensor tilt signal 2 (Joystick Control)
12 3RD SIGNAL 1 Joystick sensor 3rd signal 1 (Joystick Control)
13 3RD SIGNAL 2 Joystick sensor 3rd signal 2 (Joystick Control)
14 4TH SIGNAL 1 Joystick sensor 4th signal 1 (Joystick Control)
15 4TH SIGNAL 1 Joystick sensor 4th signal 2 (Joystick Control)
17 COOLING FAN NEG ON/OFF Cooling fan (-)
18 LIFT DOWN SOLENOID NEG (PWM) Lift down solenoid (-) (MC)

T
19 TILT HOR SOLENOID NEG (PWM) Tilt horizontal solenoid (-) (MC)
21 PS C SOLENOID NEG (PWM) PS C solenoid (-)
23 SOL POWER IN Lift down solenoid, tilt horizontal solenoid, aux output

Output 2
AF
JS SENSOR POWER (+5V)
solenoid and PS C solenoid power supply (+) IN
Joystick sensors power supply (+) (Joystick Control)
16 FAN POWER (+24V) Cooling fan power supply (+)
22 SOL POWER RETURN Lift down solenoid, tilt horizontal solenoid, aux output
solenoid and PS C solenoid power supply (+) OUT

Pump Controller
R
D

Input/ Terminal No.

Signal name Descriptions
Output (Unit side)
Input 1 KEY IGN Key switch signal
2 12V Traction inverter (RH) and traction inverter (LH) digital input
7 ENC A Pump motor encoder signal A
14 ENC B Pump motor encoder signal B
15 GND Encoder power supply (-)
22 PTHERM Pump motor thermal sensor (+)
23 NTHERM Pump motor thermal sensor (-)
Output 8 12V Encoder power supply (+)
Input/ 12 CAN T CAN termination: connect to No.21 (CAN H) to insert a 120Ω
Output termination resistance.
20 CAN L Low level CAN BUS voltage I/O
21 CAN H High level CAN BUS voltage I/O

CS-52
 CONTROLLER

Connector (Terminal layout) (Cont’d)

Traction Controller (RH)

Input/ Terminal No.

Signal name Descriptions
Output (Unit side)
Input 1 SEAT SW Seat switch signal
5 GND Encoder power supply (-)
10 KEY IGN Key switch signal
13 ENC B Traction motor (RH) encoder signal B

T
14 ENC A Traction motor (RH) encoder signal A
17 MODE SELECT 1 Mode select 1 switch signal
19 LEFT TURN SW Left turn switch signal
20 RIGHT TURN SW Right turn switch signal
22 THMOT
AF Traction motor (RH) thermal sensor
35 MODE SELECT 3 Mode select 3 switch signal
12 NMCC Main contactor coil driver
Output 25 12V Encoder power supply (+)
Input/ 27 CAN L Low level CAN BUS voltage I/O
Output 28 CAN H High level CAN BUS voltage I/O
R
Traction Controller (LH)
D

Input/ Terminal No.

Signal name Descriptions
Output (Unit side)
Input 1 TILT HORIZONTAL SW Tilt horizontal switch signal
5 GND Encoder power supply (-)
6 A.O.R. SELECT Accelerator OFF regen select switch signal
7 3RD SW 3rd switch signal (MC)
10 KEY IGN Key switch signal
13 ENC B Traction motor (LH) encoder signal B
14 ENC A Traction motor (LH) encoder signal A
16 4TH SW 4th switch signal (MC)
19 TILT SW Tilt switch signal (MC)

CS-53
 CONTROLLER

Connector (Terminal layout) (Cont’d)

Input/ Terminal No.
Signal name Descriptions
Output (Unit side)

Input 20 LIFT UP SW Lift up switch signal (MC)

22 THMOT Traction motor (LH) thermal sensor
Output 25 12V Encoder power supply (+)
Input/ 27 CAN L Low level CAN BUS voltage I/O
Output
28 CAN H High level CAN BUS voltage I/O
Input 32 STICK DETECT SW Single lever joystick

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AF
R
D

CS-54
 CONTROLLER

Controller Element Inspection

CAUTION:
• For checking each controller element, use circuit tester and
measure resistance between terminals to determine whether
circuit continuity exists or not ( Ω).
• For checking the current sensor, only measure voltage.
• When checking controller elements, also check the
associated harnesses and cables.
• The following tables list resistance values measured across
respective terminals and should be used as reference
information. Keep in mind the resistance values vary with
the type of circuit tester (such as analog or digital) used for
measurements.
NOTE:
Measure resistance between terminals listed in the following tables
to check each element.

PUMP AND TRACTION CONTROLLERS

Specifications

T
Item Description
Pump controller ACE2 36-48/400
Traction controller RH ACE0 PW 36-48/280 (MASTER)
LH ACP0 PW 36-48/280 (SLAVE)
AF
(1) Pump controller (2) Traction controller (LH)
(3) Traction controller (RH) (4) VCM controller

Service data
Measurement
terminals Normal value (Ω)
Controller Judge of abnormal
Tester Tester (Reference value)
R
(+) (-)
Pump VB U 26k
U VB 26k
VB V 25k
V VB 25k
D

VB W 26k
W VB 26k
(-) U 26k
U (-) 26k
(-) V 25k
V (-) 25k
(-) W 26k
W (-) 26k
±10%
Traction +B U 19k
(RH and LH) U +B 19k
+B V 21.5k
V +B 21.5k
+B W 21.5k
W +B 21.5k
-B U 19k
U -B 19k
-B V 21.5k
V -B 21.5k
-B W 21.5k
W -B 21.5k

NOTE:
• Measurement with digital tester and circuit tester range selector
must be set to "Auto range".
• Measured values may differ depending on the model of the digital
testers, the above values are for reference.

CS-55
 CONTROLLER

Controller Element Inspection (Cont’d)

FAN ASSEMBLY
Specifications
Item Specification
Type 614NGHH
Number of fan 3 pieces/controller
Rated voltage (voltage range) 24 V (18 to 26 V)

Service Data
Item Normal NG
Operation Operation check with constant voltage Failed cooling fan

CONTACTOR ASSEMBLY
Specifications
Item Specification
Type SU280
Rated voltage 36/48 V

T
Contacting voltage (1 h after conducting coil) Less than 22 V
Open voltage Less than 9 V
Rated time 1 hour (48 V chopper)
Cut off capacity 1500A
AF Mechanical life Over 3 million cycle
(1) Contactor coil
(2) Battery current sensor
(3) FS1 fuse

Service Data
Item Normal NG
R
Coil resistance 44 Ω / at 20°C (68°F) Abnormal contact
D

BATTERY CURRENT SENSOR (ON CONTACTOR

ASSEMBLY)
Specifications
Item Specification
Type L05Z800S05
Actual current ± 800 A
Signal voltage 1.0 - 4.0 V

Service Data
Item Normal NG
Output V Approx. 2.5 V between 3-4 Failed sensor
Source V Approx. 5.0 V between 1-2 Failed VCM

NOTE:
The circuit tester range selector must be set to "X1DCV".

CS-56
 CONTROLLER

Controller Element Inspection (Cont’d)

FS1 FUSE (ON CONTACTOR ASSEMBLY)
Specifications
Item Specification
Type CNL500
Capacity 500 A

Inspection
• Visually check the fuse is not broken. If necessary replace it with
a new one.
• Using a circuit tester, check continuity of the fuse.

Normal indication Abnormal (open-circuit) indication

Continuity

NOTE:
The circuit tester range selector must be set to “x1 Ω”.

T
MOTORS (TRACTION AND PUMP)
(1) Temperature sensor connector
(2) Revolution sensor connector
AF Temperature sensor
Specifications
Item Specification
Resistance R 100°C (212°F) 1000 Ω
R 25°C (77°F) 603 Ω
R
Service Data
Item Normal NG
Sensor
603 Ω [at 25°C (77°F)] Failed temp. sensor
D

resistance

Revolution sensor
Specifications
Item Specification
Input voltage 5 - 24 DCV
Temperature range -40 ~ 140°C (-40 ~ 284°F)
Anti vibration 4G
Type Magnetic pickup

Service Data
Item Normal NG
Revolution
Self check by revolution sensor IC
sensor Failed revolution sensor
detection
checking

CS-57
 CONTROLLER

Removal and Installation

NOTE:
To disconnect/connect the battery and motor cables, refer to "Battery
Cables and Motor Cables" in the EL section.

T
AF
R
D

(1) Controller assembly (2) Air guide plate (3) Contactor assembly (4) Controller cable (VB)
(5) Battery plug cable (+) (6) Body harness (+) (7) Contactor bracket (8) Clip
(9) Joystick controller assembly

CS-58
UNIT INSPECTION AND ADJUSTMENT
UNIT INSPECTION AND ADJUSTMENT

Control System
CAUTION:
• Before measuring resistance values, be sure to turn the key
switch to the OFF position, and disconnect the battery plug.
• When checking a unit, also check the condition of the
associated harness and connector.
• All units can be checked using interactive diagnostic
procedures. (Refer to “LCD MONITOR” on page 30.)
NOTE:
• The relative condition of a unit is evaluated by making required
voltage or resistance value measurements.
• This section deals with only resistance measurement procedures
for unit inspection.

FORWARD REVERSE SWITCH

T
AF
R
D

ELM0272

CS-59
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

Inspection
Check continuity at each lever position between the following
terminals.

Lever position Terminal with continuity

Forward -
Neutral -
Reverse -

T
CSM0116
AF
R
D

CS-60
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

STEERING WHEEL ANGLE SENSOR
Specifications

Rated voltage (V) 12

Rated load current (mA) 10 - 50
Output voltage (V) Low Less than 0.5
High 2.5 - 3.5
Pulse (1, 2) (pulse/rotation) 45
Neutral position signal (pulse/rotation) 1

Service data

Measuring points (terminals) Standard value (V)

- 12

T
AF
CSM0117
R
D

CSM0118

CS-61
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

TIRE ANGLE SENSOR (3 - WHEEL)
Specifications

Total resistance (kΩ) 1 - 1.4 (Reference value)

Service data

Measuring
points Standard value Remarks
(terminals)

- 0Ω 1 kΩ The resistance value decreases as the

shaft is rotated.
- 1 kΩ The resistance value remains unchanged
regardless of the shaft rotation.

T
AF
CSM0119

Adjustment
1. Call up tire angle sensor diagnostic screen from interactive
diagnostic display.
2. Loosen tire angle sensor securing screws.
3. While observing the tire angle sensor output on the display to
check if it is within the specified range, rotate the tire angle
R
sensor.
4. Tighten tire angle sensor securing screws.
: 1.2 - 1.8 N•m (0.13 - 0.18 kgf-m, 11 - 15 in-lb)
D

CSM0120

CS-62
UNIT INSPECTION AND ADJUSTMENT

TIRE ANGLE SENSOR (4 - WHEEL)

Specifications

Total resistance (kΩ) 1.6 - 2.4 (Reference value)

Service data

Measuring
points Standard value Remarks
(terminals)

- 0Ω 2 kΩ The resistance value decreases as the

shaft is rotated.
- 2 kΩ The resistance value remains unchanged
regardless of the shaft rotation.

T
CSM0207
AF
R
D

CS-63
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

Adjustment Tire angle Sensor

T
AF
CSM0239

Tire angle sensor fixes the kingpin plate to the kingpin as shown in
R
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the tire angle sensor by
engaging the shaft of the tire angle sensor. Therefore, it is necessary
to assemble the tire angle sensor correctly to make the steering
D

control system function correctly. Notes concerning assembly are as

follows.
1. When the kingpin plate is installed in the kingpin, it is necessary
to insert the plate vertically in the direction shown in the above
figure.
2. When the sensor shaft is engaged in the kingpin plate, it is
necessary to set the plane part of the sensor shaft to the spring and
the other side of the kingpin plate (left side in the above figure).
3. Securely insert plate into side groove of kingpin hole.
CAUTION:
When the tire angle sensor is removed, installed, and replaced,
the neutral level adjustment must be performed for the new
sensor.

CSM0240

CS-64
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

ACCELERATOR SENSOR

T
AF
CSM0121

Specification
R
Total resistance (kΩ) 2.5 - 5.0 (Reference value)

Service data
D

Measuring
Standard value
points Remarks
(V)
(terminals)

Vcp1 - Ep1 (GND) 5.02 - 5.22 Always

Aps1 - Ep1 (GND) 0.668 - 0.868 When the accelerator pedal is released.
CSM0122
4.454 - 4.654 When the accelerator pedal is fully
depressed.

Adjustment
If the accelerator sensor output is not within the specified range,
adjust it as follows.
1. Call up accelerator sensor diagnostic screen from interactive
diagnostic display.
2. Loosen accelerator sensor securing screws.
3. While observing the accelerator sensor output on the display to
check if it is within the specified range, rotate the accelerator
sensor.
4. Tighten accelerator sensor securing screws.
CSM0123 : 1.5 - 1.8 N•m (0.16 - 0.18 kgf-m, 14 - 15 in-lb)

CS-65
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

T
AF
CSM0124

Linkage stroke adjustment

Fully-closed position adjustment
R
1. Depress the accelerator pedal until the accelerator linkage is
fully opened.
2. Rotate the stopper bolt counterclockwise by 180 degrees, and
then tighten the nut.
D

CAUTION:
• The accelerator linkage operation should move smoothly
with no binding. When releasing the pedal, immediately
return it to the fully-closed position.
• The return spring should be securely installed as shown in
the figure.
• Move the accelerator pedal, and then check that the
accelerator pedal roller moves smoothly in the groove.

CS-66
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

BRAKE SWITCH
Inspection
Check continuity between brake switch terminals when the brake
pedal is depressed 8 to 12 mm (0.13 to 0.47 in). Continuity must
exist.
<Reference data>

Brake switch ON/OFF switching point Pedal height: 115.5 mm (4.547 in)
(from floor upper surface)

CSM0125

Adjustment

T
AF
R
D

CSM0202

1. Adjust the height of brake pedal point P to 122 mm (4.803 in)

from the floor upper surface by the stopper bolt, and then
tighten the lock nut.
: 12 - 15 N•m (1.2 - 1.5 kgf-m, 9 - 11 ft-lb)
2. When depressing the pedal within 8 - 12 mm (0.31 - 0.47 in)
(pedal height: 115.5 mm (4.547 in)), adjust the brake switch so
that the brake switch is “ON”, and then tighten the lock nut.
: 12 - 15 N•m (1.2 - 1.5 kgf-m, 9 - 11 ft-lb)
3. Make sure that the brake switch is “OFF” when the pedal is
released.

CS-67
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

CONTROL VALVE SWITCHES (LIFT, TILT, 3RD, 4TH
SWITCHES FOR MECHANICAL CONTROL VALVE)
Inspection
When the control lever is operated, continuity must exist between
terminals affected.
NOTE:
• Circuit continuity must be checked after removing the affected
switch connector.
• Check for audible sounds which indicate control valve switches
are operating.
• If switches do not operate, adjust the switch position, then recheck
the switches operation. Refer to “Adjustment” on page 64.

T
AF
CSM0126
R
D

CS-68
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

Adjustment
Using adjusting nuts and , adjust the dog-to-switch clearance
to specifications indicated in the figure below.
CAUTION:
The control valve must be set in Neutral and switches must be
freed during clearance adjustments.

T
AF
R

Centering adjustment
D

Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.

CST0039

CS-69
UNIT INSPECTION AND ADJUSTMENT

Control System (Cont’d)

LIFT SOLENOID (MECHANICAL CONTROL VALVE)
Specifications

Rated voltage (V) 24

Coil resistance (Ω) 36 at 20°C (68°F)
(Reference value)
44 at 90°C (194°F)

Inspection
Measure resistance between lift solenoid terminals.

<Reference value>
CSM0127

36Ω 20°C (68°F)

44Ω 90°C (194°F)

T
AF
R
D

CS-70
 UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option)

CAUTION:
If erroneous cargo handling operation is noted regardless of
the joystick lever position, press the emergency stop button on
the console] box, suspend cargo handling operations. (To
release the emergency stop button, turn it in the direction
indicated by the arrow.)

CSM0144

JOYSTICK CONTROLLER

T
AF
Input/ Terminal No.
Connector Signal name Descriptions
Output (Unit side)

CN B Input 1 KEY IGN Key switch signal

2 PAUX Valves power supply (+)
R
3 -BATT (FTC) Power supply (-)
Input/ 4 CAN L Low level CAN BUS voltage I/O
Output 9 CAN T CAN termination: connect to No.14 (CAN H-OUT)
to insert a 120Ω termination resistance.
D

13 CAN H High level CAN BUS voltage I/O

14 CAN H-OUT High level CAN BUS voltage I/O
CN C Input 1 LIFT SOLENOID A Lift solenoid A (-)
3 LIFT SOLENOID B Lift solenoid B (-)
4 3RD SOLENOID A 3rd solenoid A (-)
6 3RD SOLENOID B 3rd solenoid B (-)
7 TILT SOLENOID A Lilt solenoid A (-)
12 4TH SOLENOID A 4th solenoid A (-)
14 4TH SOLENOID B 4th solenoid B (-)
15 TILT SOLENOID B Lilt solenoid B (-)
19 C1 SOLENOID C1 solenoid (-)
23 -BATT (FTC) Power supply (-)
Output 2 PEV Lift solenoid A and Lift solenoid B (+)
5 PEV 3rd solenoid A and 3rd solenoid B (+)
8 PEV Tilt solenoid A and Tilt solenoid B (+)
13 PEV 4th solenoid A and 4th solenoid B (+)
20 PEV C1 solenoid (+)

CS-71
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

JOYSTICK CONTROL VALVE

T
AF
CSM0200

Specifications
R
Electromagnetic Rated voltage (V) 24
proportioning solenoid Coil resistance (Ω)
30 at 20°C (68°F)
valve (Reference value)
D

Rated voltage (V) 24

C1 Solenoid valve Coil resistance (Ω) 36 at 20°C (68°F)
(Reference value) 44 at 90°C (194°F)

Inspection
Check resistance between terminals using circuit tester (Ω range).

Resistance (Ω)
Terminals Remarks
(Reference value)

A (+)-A (-)
30 20°C (68°F)
B (+)-B (-)
36 20°C (68°F)
C1 (+)-C1 (-)
44 90°C (194°F)

CS-72
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

FORWARD-REVERSE SWITCH
Inspection
Check continuity between terminals using circuit tester (Ω range).

Normal condition (Ω range)

Terminals
Neutral F position R position

No continuity No continuity
- Continuity
( ) ( )
No continuity No continuity
- Continuity
( ) ( )
CSM0145

CONTROL VALVE LEVER

1-lever type

T
AF
R
D

CSM0146

CS-73
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

Specification

Lever operation angle ±22.5°

Electrical angle (potention) ±18°
Rated voltage (V) DC 5±0.5
Output voltage (V) 0.5 - 4.5 (±0.05)

2-lever type and 3rd, 4th type

T
AF
R
D

CSM0147

Specification

Lever operation angle ± 20° - 22°

Electrical angle (potention) ±18°
Rated voltage (V) DC 5 ± 0.5
Output voltage (V) 0.5 - 4.5 (±0.05)

Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).

CS-74
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

EMERGENCY STOP BUTTON

T
AF
CSM0148

Inspection
R
Check continuity between terminals using circuit tester (Ω range).

Terminals Normal condition Pushing the button

- Continuity No continuity
D

- Continuity No continuity

CS-75
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

REMOVAL AND INSTALLATION

T
AF
R
D

CSM0149

CS-76
UNIT INSPECTION AND ADJUSTMENT

Joystick Control System (Option) (Cont’d)

T
AF
R
D

CSM0150

CS-77
UNIT INSPECTION AND ADJUSTMENT

Knob Position Control System

(Option)
PS KNOB POSITION SOLENOID VALVE
Specifications

Rated voltage (V) 24

Coil resistance (Ω) 21.8±5%
(Reference value) at 20°C (68°F)

Inspection
Check resistance between terminals using circuit tester.

21.8±5% 20°C (68°F)

CSM0151

For steering wheel angle sensor and tire angle sensor inspections,
refer to “UNIT INSPECTION AND ADJUSTMENT” on page CS-59
and further.

T
AF
R
D

CS-78
UNIT INSPECTION AND ADJUSTMENT

Tilt Leveling Device (Option)

INSPECTION
Tilt horizontal switch
Check continuity.
When press button: Continuity should not exist.
When do not press button: Continuity should exist.

CSM0245

Oil pressure sensor

Key switch is turned on and check out put voltage while connecting
harness.
Output voltage (V): 0.25 - 4.75
Battery voltage (V): 5 ± 0.5 (Power supply - GND)

T
AF
R
CSM0299

Tilt angle sensor

Key switch is turned on and check out put voltage while connecting
D

harness.
Output voltage (V): 0.5 - 4.5 (2 - 3)
Battery voltage (V): 5 ± 0.5 (1 - 3)

CSM0242

CS-79
UNIT INSPECTION AND ADJUSTMENT

Tilt Leveling Device (Option) (Cont’d)

Tilt horizontal solenoid valve
Check resistance.

Item Resistance
Normal (Ω) 30 - 77
Malfunction (Ω) 0 or

T
CSM0243
AF
R
D

CS-80
UNIT INSPECTION AND ADJUSTMENT

Tilt Leveling Device (Option) (Cont’d)

Tilt angle sensor

2012012

SETTING

T
1. Park the vehicle on a flat, level road.
2. Set rear tire to the straight-ahead position. (Knob can take any
position.)
AF 3. Set the mast to vertical.
4. Raise the fork approximately 300 mm (11.8 in) from the ground.
5. After calling up “ADJUSTMENT MENU” → “1-2. SENSOR” →
“16 SENSOR INITIAL SET”, push function key FN3 and turn
“OFF” to “ON”.
NOTE:
Procedure is same as “Knob Position Control and Neutral Setting”
R
as above.

SETTING OF TILT HORIZONTAL (SIMPLE SETTING)

Push function keys FN1 + FN5 to turn the normal display to the tilt
D

horizontal setting display. Push function key FN5 to set the tilt
leveling condition.

CS-81
UNIT INSPECTION AND ADJUSTMENT

Tilt Leveling Device (Option) (Cont’d)

CONFIRMATION OF OPERATION
Check the movement of following table at tilt forward (with tilt switch:
ON) from tilt back.

T
AF
CSM0244
R
D

CS-82
TROUBLE DIAGNOSTIC PROCEDURES
TROUBLE DIAGNOSTIC PROCEDURES

Precautions
CAUTION:
• Before performing self-diagnosis, check condition of blade
fuses, fusible links, etc.
• After repairing trouble areas, operate the vehicle to confirm
that malfunctions have been eliminated.
• When checking the traction system, raise the front wheels off
the ground using a jack. Refer to GI section for details.
• When malfunction occurs, do not attempt to inspect
connectors, harnesses, etc. but perform self-diagnosis and/
or interactive diagnosis. This can avoid unnecessary repair
or replacement.
• Basic trouble diagnostic procedures must be performed as
follows:

Malfunction occurrence

Confirm trouble message and

malfunctioning symptom.

T
Perform self-diagnosis.

YES
AF Does self-diagnosis pinpoint
malfunctioning part?
Check malfunctioning
part and the circuit. Refer
NO to “SELF-DIAGNOSIS”.

Perform interactive diagnosis.

Does interactive diagnosis pinpoint YES Check malfunctioning

malfunctioning part? part and the circuit. Refer
R
NO to topic “Unit inspection”.

Use troubleshooting flow charts, wiring

diagrams and circuit diagrams as a
guide to locate and eliminate trouble
D

causes.

NOTE:
Test probes of a circuit tester are too large to be inserted into
connectors during voltage measurements on the print board side. It
is advisable to have the tips of the test probes fastened with thin
conductive wire to be used as an extension lead. In this way,
connector terminals are prevented from sustaining damage. (Such
an extension lead will be referred to as a temporary tool in
troubleshooting flow charts.)

CST0062

CS-83
 TROUBLE DIAGNOSTIC PROCEDURES

How To Follow Flow Chart

Trouble diagnostic procedures for controllers (including charging
system) are indicated in flow charts. Inspection and confirmation
procedures are shown in illustrations, making the respective flow
charts more comprehensive. Circuit diagrams are also included
where necessary, along with applicable flow charts.
NOTE:
The entire system wiring diagram and circuit diagram are included at
the end of this manual. Refer to these diagrams as necessary during
diagnostic procedures.

MALFUNCTIONING SYMPTOMS
Typical trouble symptom entries are treated as titles.

PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Probable trouble areas or parts are indicated in relation to
malfunctions that may occur.

T
WORK FLOW
Confirmation of malfunction
AF
Inspection and/or confirmation Inspection and confirmation procedures
procedures must be explained
as required in the illustration.
Specifications, judgment and/or (Use a temporary tool.)
evaluation
*Tester range
R
Remedial procedures

* Examples of tester range selection

D

V
100 : Voltage measurement in 100-volt range (DC)
V
500
: Voltage measurement in 500-volt range (AC)
R
X1
: Resistance measurement in 1Ω range

CAUTION:
Always use the digital tester to measure the resistance of the
sensor (potentiometer). If the analog tester is used, the sensor
(potentiometer) may be damaged by the internal battery of the
analog tester.

A
: Current measurement in 50-ampere range (AC)
50

About temporary tool:

A temporary tool refers to a circuit tester whose test probe ends are
temporarily wrapped with thin conductive wires. The tip ends of
respective wires are attached to connector terminals on the print
board side during required voltage measurements. Refer to
“Precautions” on page 74.

CS-84
TROUBLE DIAGNOSTIC PROCEDURES

Symbol Identification
HARNESS CONNECTOR SYMBOLS
Male and female connectors
• Connector guides for male terminals are shown in black.
• Connector guides for female terminals are shown in white.

CST0063

Connector direction
• Connector symbols shown from the terminal side (in direction A)
are enclosed by a single line.
• Connector symbols shown from the harness side (in direction B)
are enclosed by a double line.

T
AF
R
CST0064

Controller or other single unit connectors

Controller connector symbols are indicated so that connectors are
D

being shown from the terminal side; enclosed by a single line with
connector guides shown in black.

CST0065

KEY TO SYMBOLS
Symbol Explanation Symbol Explanation
Check after disconnecting Turn key switch to the OFF
harness connector. position.

Check after connecting Turn key switch to the ON

harness connector. position.

Check after disconnecting Turn battery switch to the

battery plug. OFF position.

Check after connecting Turn battery switch to the ON

battery plug. position.

CS-85
TROUBLE DIAGNOSTIC PROCEDURES

Voltage and Resistance Measurement

Procedures
VOLTAGE MEASUREMENT
• Connector terminals on the print board side are too closely
arranged so it is difficult for test probes of a conventional circuit
tester to gain access to them. For this reason, it is advisable to
wrap thin conductive wires around the ends of the test probes and
use the wires as test probe extensions (which are referred to as
the temporary tools in troubleshooting flow charts).
• To facilitate voltage measurements for parts or terminals
(adjacent to controllers), it is best to use an alligator clip with the
black (ground) test probe of a circuit tester and fasten it to the
battery ground terminal during measurements.

T
CST0066

RESISTANCE MEASUREMENT
AF • Before measuring resistance, turn the key switch to the OFF
position, remove the battery plug, then remove the connector and
the part whose resistance is to be measured.
• A broken wiring circuit must be measured between connector
terminals affected using a circuit tester.
R
D

CST0067

CS-86
 TROUBLE DIAGNOSTIC PROCEDURES

Table of Error Code (2)

Parts Error Code Details
Fail mode: Short (includes driver short)
400 Fail operation: Stop control
Hot to reset: Recover Battery voltage
Main Contactor
Fail mode: Open (Includes driver open)
401 Fail operation: Stop control
How to reset: Recover Battery voltage
Fail mode:
• Low voltage 28 ± 2Volt for 700 mS
404
Fail Operation: Stop control except PS and lift down solenoid control.
How to reset: Key OFF
Battery voltage Fail mode:
• High voltage (65V)
• In case of Set and actual battery voltage are different when Key ON.
405
Fail Operation: Stop control except PS and lift down solenoid control.
How to reset: Key OFF
Fail mode: Abnormal

T
Cont Capacitor 406 Fail operation: Stop control
How to reset: Key OFF
Fail mode: Short
AF 408 Fail operation: Stop driving
CONTROLLER

Drive FET How to reset: Key OFF

(right) Fail mode: Open
409
Fail operation: Stop driving
How to reset: Key OFF
Fail mode: Short
R
410 Fail operation: Stop driving
Drive FET How to reset: Key OFF
(left) Fail mode: Open
411 Fail operation: Stop driving
D

How to reset: Key OFF

Fail mode: Short
412 Fail operation: Stop loading and steering except lift down control
How to reset: Key OFF
Pump FET
Fail mode: Open
413 Fail operation: Stop loading and steering except lift down control
How to reset: Key OFF
Fail mode: Low output
414 Fail operation: Stop driving

Drive current sensor How to reset: Key OFF

(Right, U) Fail mode: High output
415 Fail operation: Stop driving
How to reset: Key OFF

CS-87
 TROUBLE DIAGNOSTIC PROCEDURES

Parts Error Code Details

Fail mode: Low output
416 Fail operation: Stop driving
Drive current sensor How to reset: Key OFF
(Right, V) Fail mode: High output
417 Fail operation: Stop driving
How to reset: Key OFF
Fail mode: Low output
418 Fail operation: Stop driving
Drive current sensor How to reset: Key OFF
(Left, U) Fail mode: High output
419 Fail operation: Stop driving
How to reset: Key OFF
Fail mode: Low output
420 Fail operation: Stop driving
Drive current sensor How to reset: Key OFF
(Left, V) Fail mode: High output
421 Fail operation: Stop driving
How to reset: Key OFF
415 Fail mode: Short
Drive load short
and Fail operation: Low output
(Right and Left)
417 How to reset: Key OFF

T
Fail mode: Abnormal
D/Mo 422 Fail operation: Motor max output is limited with 65%.
TEMP How to reset: The temperature is returned to normal range.
sensor Fail mode: Over rise
(Right)
AF 423 Fail operation: Motor max output is limited
CONTROLLER

How to reset: The temperature is returned to normal range.

Fail mode: Abnormal
D/Mo 424 Fail operation: Motor max output is limited with 65%.
TEMP How to reset: The temperature is returned to normal range.
sensor Fail mode: Over rise
(Left) 425 Fail operation: Motor max output is limited.
How to reset: The temperature is returned to normal range.
R
Fail mode: Abnormal
D/Cont 426 Fail operation: Motor max output is limited with 50%.
TEMP How to reset: The temperature is returned to normal range.
sensor Fail mode: Over rise
D

(Right) 427 Fail operation: Motor max output is limited.

How to reset: The temperature is returned to normal range.
Fail mode: Abnormal
D/Cont 428 Fail operation: Motor max output is limited with 50%.
TEMP How to reset: The temperature is returned to normal range.
sensor Fail mode: Over rise
(Left) 429 Fail operation: Motor max output is limited.
How to reset: The temperature is returned to normal range.
Fail mode: Low output
430 Fail operation: Stop loading and steering except lift down control
How to reset: Key OFF
Pump current sensor (U)
Fail mode: High output
431 Fail operation: Stop loading and steering except lift down control
How to reset: Key OFF
Fail mode: Low output
432 Fail operation: Stop loading and steering except lift down control
How to reset: Key OFF
Pump current sensor (V)
Fail mode: High output
433 Fail operation: Stop loading and steering except lift down control
How to reset: Key OFF

CS-88
 TROUBLE DIAGNOSTIC PROCEDURES

Parts Error Code Details

431 Fail mode: Short
Pump load short and Fail operation: Stop loading and steering except lift down control
433 How to reset: Key OFF
Fail mode: Abnormal
434 Fail operation: Motor max output is limited with 65%.
How to reset: The temperature is returned to normal range.
P/Mo TEMP sensor
Fail mode: Over rise
435 Fail operation: Motor max output is limited
How to reset: The temperature is returned to normal range.
Fail mode: Abnormal
436 Fail operation: Motor max output is limited with 50%.
How to reset: The temperature is returned to normal range
P/Cont TEMP sensor
Fail mode: Over rise
437 Fail operation: Motor max output is limited.
How to reset: The temperature is returned to normal range
Fail mode: Abnormal
Fail operation:
• One side pulse is not detected.
D/Mo REV sensor
438 • Speed changed suddenly.
(Right)
• Both sides pulse is not detected over 15 seconds when the motor
starts up.

T
How to reset: Stop driving
Fail mode: Same as 438
D/Mo REV sensor
440 Fail operation: Stop driving
(Left)
How to reset: Key OFF
AF Fail mode: Same as 438
P/Mo REV sensor 442 Fail operation: Stop loading and steering except lift down control
CONTROLLER

How to reset: Key OFF

Fail mode: Abnormal (Detect non-definition mode select SW settings.)
CONT type select 446 Fail operation: Controller controls with North America 36v spec.
How to reset: Key OFF
446 Fail mode: Abnormal
Drive EEPROM, SUM, Software
and Fail operation: Stop control
R
error
610 How to reset: Key OFF
446 Fail mode: Abnormal
Pump EEPROM, SUM, Software
and Fail operation: Stop control
error
602 How to reset: Key OFF
D

446 Fail mode: Abnormal

VCM and FTC, EEPROM, SUM,
and Fail operation: Stop control
Software error
604 How to reset: Key OFF
406 Fail mode: Abnormal
Drive and hardware error and Fail operation: Stop control
610 How to reset: Key OFF
406 Fail mode: Abnormal
Pump hardware error and Fail operation: Stop control
602 How to reset: Key OFF
406 Fail mode: Abnormal
VCM and FTC Hardware error and Fail operation: Stop control
604 How to reset: Key OFF
426 Fail mode: Abnormal
FAN Drive circuit and Fail operation: Motor max output is limited with 50%.
436 How to reset: The state is returned to normal.
Fail mode: Abnormal
Fail operation:
• Controller controls limited.
Cont <- Meter Communication 444
• The communication data remain at the closest to the pointer where
data were normally received.
How to reset: Communication is returned to normal.

CS-89
 TROUBLE DIAGNOSTIC PROCEDURES

Parts Error Code Details

Fail mode: Abnormal
Drive <- Pump Communication 602 Fail operation: Stop the truck
How to reset: Same as 444
Fail mode: Abnormal
Drive <- FTC, VCM
604 Fail operation: Same as 602
Communication
How to reset: Same as 444
Fail mode: Abnormal
CONTROLLER

Pump <-Drive Communication 610 Fail operation: Same as 602

How to reset: Same as 444
Fail mode: Abnormal
Pump <-FTC, VCM <-Drive
614 Fail operation: Same as 602
Communication
How to reset: Same as 444
Fail mode: Abnormal
FTC, VCM <-Drive
620 Fail operation: Same as 602
Communication
How to reset: Same as 444
Fail mode: Abnormal
FTC, VCM <-Pump
622 Fail operation: Same as 602
Communication

T
How to reset: Same as 444
Fail mode: F and R is ON simultaneously
Fail operation: Brake Regenerative power is created.
F/R SW 450
AF After stopping the truck, drive control is prohibited.
How to reset: Simultaneous ON is not applied.
Fail mode: Low output (Sig. A or Sig. B x 2 Less than 0,2 Volt
452 Fail operation: Same as 450
How to reset: Output is return to normal range.
Accel sensor Fail mode: High output 4.8 Volt
Or signal A - 2 x Signal B > 0.4 Volt
R
453
Fail operation: Same as 450
How to reset: Output is return to normal range.
Fail mode: Low output
• 3 wheel signal 0.05 volt for 15 secs
D

• 4 wheel signal 0.2 volt for 15 secs.

Fail operation:
SENSOR

454
• Stop the steering knob position correct control
• Turn angle
• Max turn speed and max turn accel are limited.
Tire angle sensor
How to reset: Output is return to normal range.
Fail mode:
• 3 wheel signal 4.95 volt for 15 secs
• 4 wheel signal 4.8 volt for 15 secs.
455
Fail operation: Same as 454
How to reset: Output is return to normal range.
Fail mode: Low output (Sig. is less than 0,2 Volt over 100ms)
Fail operation:
456 • Tilt auto horizontal control
stops tilt operation in case of tilt horizontal SW is applicable.
Tilt angle sensor How to reset: Key OFF
Fail mode: High output (Sig. is over 4.8 Volt over 100ms)
457 Fail operation: Same as 456
How to reset: Key OFF

CS-90
 TROUBLE DIAGNOSTIC PROCEDURES

Parts Error Code Details

Fail mode: Low output (Sig. 1 or Sig.2 is less than 0.2 Volt over 100ms)
458 Fail operation: Stop solenoid of FTC
How to reset: Key OFF
Joystick sensor
(Lift) Fail mode: High output (Sig. 1 or Sig.2 is over than 0.8 Volt over 100ms)
(“Sig. 1 - Sig. 2” is out of “0V± 0.4 Volt over 100ms)
459
Fail operation: Same as 458
How to reset: Key OFF
Fail mode: Same as 458
460 Fail operation: Same as 458

Joystick sensor How to reset: Key OFF

(Tilt) Fail mode: Same as 459
461 Fail operation: Same as 459
How to reset: Key OFF
Fail mode: Same as 458
462 Fail operation: Same as 458

Joystick sensor How to reset: Key OFF

(3rd) Fail mode: Same as 459

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463 Fail operation: Same as 459
Fail mode: Same as 458
SENSOR

Fail mode: Same as 458

AF 464 Fail operation: Same as 458

Joystick sensor How to reset: Key OFF

(4th) Fail mode: Same as 459
465 Fail operation: Same as 459
Fail mode: Same as 458
Fail mode: In case of Tilt H switch type is N.O.
• Tilt horizontal operation is applicable at the moment of Key ON.
R
In case of ATH is ON
468
Fail operation: Stops tilt operation in case of tilt SW is applicable.

Tilt horizontal SW How to reset: Key OFF

Fail mode: In case of Tilt H switch type is N.C.
D

• Tilt horizontal operation is applicable at the moment of Key ON.

469
Fail operation: Same as 458
How to reset: Key OFF
Fail mode:
• Steer sensor doesn’t count pulse even if tire angle changes over 45°
within 1 sec.
• The direction of steer is reverse between steer sensor and tire angle
sensor.
Steer angle sensor 470
Fail operation:
• Stop the steering knob position correct control
• Steer Speed is set to 0rps
How to reset: Key OFF

CS-91
 TROUBLE DIAGNOSTIC PROCEDURES

Parts Error Code Details

Fail mode: Low output (Sig. is less than 0.2 Volt over 100ms)
472 Fail operation: Current load is “3000kg”
How to reset: The voltage is returned to normal range.
Oil press sensor
Fail mode: High out (Sig. is over 4.8 Volt over 100ms)
473 Fail operation: Same as 472
SENSOR

How to reset: The voltage is returned to normal range.

Fail mode: Low output
476 Fail operation: Battery wattage is 0kW temporary
How to reset: The current is returned to normal range.
Battery current sensor
Fail mode: High output
477 Fail operation: Battery wattage is 0kW temporary
How to reset: The current is returned to normal range.
Fail mode: Short (current is over 0.3A at Duty=0. It continues over
50ms.)
500
Fail operation: Drive OFF of lower FET.
How to reset: Key OFF
Lift down solenoid
Fail mode: Open (current is onder 0.15A at abjective current is over

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0.3A It continues over 50ms.)
501
Fail operation: Drive OFF of upper and lower FET
How to reset: Key OFF
Fail mode: Short (same as 500)
AF Fail operation: Same as 500
502
How to reset: In case of the current returned to normal-range when next
PS correction solenoid operation is required.
Fail mode: Open (same as 501)
503 Fail operation: Same as 501
How to reset: Key OFF
R
Fail mode: Short (same as 500)
ACTUATOR

504 Fail operation: Same as 500

Tilt horizontal solenoid How to reset: Same as 502

Fail mode: Open (same as 501)
D

505 Fail operation: Same as 501

How to reset: Key OFF
Fail mode: Short (same as 500)
506 Fail operation: Same as 501

FTC proportional solenoid pull lift How to reset: Same as 502

up Fail mode: Short (same as 501)
Fail operation: Same as 501
507
How to reset: Driver shorted: function request, coil open: return to
neutral
Fail mode: Short (same as 500)
508 Fail operation: Same as 501

FTC proportional solenoid push How to reset: Same as 502

lift down Fail mode: Short (same as 501)
509 Fail operation: Same as 501
How to reset: Same as 507

CS-92
 TROUBLE DIAGNOSTIC PROCEDURES

Parts Error Code Details

Fail mode: Short
510 Fail operation: Same as 500

FTC proportional solenoid How to reset: Same as 501

pull tilt back Fail mode: Open
511 Fail operation: Same as 501
How to reset: Same as 507
Fail mode: Short
512 Fail operation: Same as 500

FTC proportional solenoid How to reset: Same as 501

push tilt forward Fail mode: Open
513 Fail operation: Same as 501
How to reset: Same as 507
Fail mode: Short
514 Fail operation: Same as 500
FTC proportional solenoid
How to reset: Same as 501
pull
Fail mode: Open
3rd B
515 Fail operation: Same as 501

T
How to reset: Same as 507
Fail mode: Short
516 Fail operation: Same as 500
ACTUATOR

FTC proportional solenoid

pull
AF How to reset: Same as 501
Fail mode: Open
3rd A
517 Fail operation: Same as 501
How to reset: Same as 507
Fail mode: Short
518 Fail operation: Same as 500
FTC proportional solenoid
R
How to reset: Same as 501
pull
Fail mode: Open
4th B
519 Fail operation: Same as 501
How to reset: Same as 507
D

Fail mode: Short

520 Fail operation: Same as 500
FTC proportional solenoid
How to reset: Same as 501
pull
Fail mode: Open
4th A
521 Fail operation: Same as 501
How to reset: Same as 507
Fail mode: Short
526 Fail operation: Same as 500
FTC How to reset: Same as 501
C1
Solenoid Fail mode: Open
527 Fail operation: Same as 501
How to reset: Same as 507

CS-93
 BATTERY AND CHARGER

SECTION BC
CONTENTS

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PRECAUTIONS AND PREPARATION ............. BC-2 CHARGER ....................................................... BC-11
Precautions ................................................... BC-2 How to Charge the Battery
BATTERY ........................................................... BC-3 (Off-Forklift Type) ........................................ BC-11
AF
Specifications ................................................ BC-3 BATTERY MOUNTING .................................... BC-12
Trouble Diagnoses and Corrections .............. BC-4
Removal ........................................................ BC-5
Installation ..................................................... BC-6
Inspection ...................................................... BC-6
R

NOTE:
This section describes the general precautions and maintenance information for the handling and charging of the
battery.
D

For the actual handling and charging of the battery, please confirm with the instruction manual of battery and charger
used.
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
WARNING:
• Do not smoke or place any fire near the battery being
serviced or handled.
• Be careful not to spill electrolyte on your body or clothes as
this may cause injury or chemical burns.
• If electrolyte flows out or leaks from the battery case,
immediately dilute with a neutralizing detergent (such as
sodium bicarbonate, calcium hydroxide, etc.) and then rinse
with a large amount of running water.
• Never place any metal objects (such as tools, etc.) on or
across battery terminals. This may ignite and explode
hydrogen gas emitted from the battery or cause damage to
the battery and personal injury.
• Static electricity may explode the battery. Do not attempt to
wipe or clean the upper surface or terminals of the battery
with a dry cloth or do not place a vinyl cover over the battery.
Always wipe clean the battery case with a wet cloth.
CAUTION:
• Electrolyte leakage may corrode the battery itself. Always

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tighten battery vent caps firmly.
• Do not allow any one who is unfamiliar with battery handling
instructions to inspect the battery.
AF
R
D

BC-2
 BATTERY
BATTERY

Specifications
EXCEPT NORTH AMERICA

(A)S1N1 (A)1N1 (A)G1N1 / J(A)G1N1

L13Q L15Q L15Q L18Q L16Q L18Q L20Q

Width mm 995 995 995

Dimension of battery
Length mm 425 530 640
compartment
Height mm 655 655 655
Width W mm 985 985 985

Recommended Length L mm 417 522 632

battery case Height H mm 651 651 651
size
Hook
P mm 230 300 350
hole pitch
Min. 520 630 675 675 900 1000
Effective battery weight kg
Max. 765 765 900 745 1150 1150
Anderson SBE 320 Anderson SBE 320
Battery connector type CE area Anderson SBE 320 (BLUE)
(BLUE) (BLUE)
Truck voltage V 48 48 48

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Number of cell PCS 24 24 24
Capacity AH/5h 375 430 460 625 750
Optional
battery Cells kg 475 575 625 810 980

Weight
Battery
AFkg 75 85 120
case
Total kg 550 650 710 930 1100

NORTH AMERICA ONLY

(A)G1N1 /
R
(A)1N1
J(A)G1N1

L15V L18V L20V

Width inch (mm) 39.17 (995)

D

Dimension of battery compartment Length inch (mm) 20.86 (530) 25.19 (640)
Height inch (mm) 25.78 (655)
Battery connector type Anderson SB 350 (GRAY)
Width W inch (mm) 38.78 (985)

Recommended Length L inch (mm) 20.55 (522) 24.88 (632)

battery case size Height H inch (mm) 25.63 (651)
Hook hole pitch P inch (mm) 11.8 (300) 13.78 (350)
Min. 1545 (700) 2315 (1050)
Weight lbs (kg)
Max. 2425 (1100)/1875 (850) 2535 (1150)
Effective battery Voltage V 36/48 36/48

Capacity Min. 680/510 750/600

AH/6h
(36V/48V) Max. 800/600 1000/700

BC-3
 BATTERY

Trouble Diagnoses and Corrections

CAUTION:
• The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the user's
complaints and check the actual vehicle to fully understand under what conditions the symptoms occur.
• Request battery maker to replace cells.

Trouble Condition Probable cause Corrective action

Short-circuited 1. Extremely low cell voltage and • Short-circuited on bottom or side part • Replace faulty cell by single charged
specific gravity during charging, due to dropping of active materials cell.
discharging and electrostatic charging • Short-circuited due to broken or holed
2. Low gassing during charging separator (Warping of plates due to
3. Excessive rise of electrolyte repetition of overdischarging will
temperature during charging accelerate such fault.)
4. Quick dropping of specific gravity • Short-circuited due to incursion of
after charging broken pieces during fabrication of
battery
Sulfation 1. Voltage and electrolyte temperature • Repetition of overcharging and • If the condition is in early stage,
are higher during charging discharging remove the probable cause and carry
2. Accelerated gassing during charging • Exposed plates in air for a long time on equation charging.
and specific gravity not rising to due to lack of electrolyte • Replace faulty cell by single charged
normal value • Careless storage without additional cell if damage cannot be remedied.
3. Quick dropping voltage during charging

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discharging (Low battery capacity) • Use of battery at excessively high
4. Whitened plates in extreme cases specific gravity
• Excessive self-discharging due to
incursion of impurities
AF
Excessive self- 1. Quick dropping of specific gravity • Use of impure water other than • Take daily care of battery.
discharging after charging distilled water • Replace faulty cell by single charged
2. Considerably reduced charging • Incursion of impurities cell.
capacity • Too high specific gravity
• Electrolyte temperature high
• Insufficient cleaning of container,
leakage of blocked fluid
Exchange of 1. Exchanged polarity of some cells in a • Due to quick discharge without • Replace cell.
polarity battery during discharging or high noticing the extremely low capacity of
R
electrolyte temperature of some cells some cells
2. Caused by emission of gas due to • Lack of necessary preparative means • Take daily care of battery.
dissolving of electrolyte such as equation charge
Other factors 1. Electrolyte color changed to brown • Due to old battery corroded active • Check for voltage and specific gravity.
dropped from fatigued positive plates If OK, use the battery for the time
D

and mixed into electrolyte being.

2. Smell of chlorine during charging • Sea water mixed into electrolyte • Replace electrolyte and charge
battery until chlorine smell
disappears.
3. Electrolyte excessively reduced • Cracked battery cells • Replace cells.
• Excessively high electrolyte • Find causes and follow proper
temperature during charging procedure to repair.
• Excessive sulfation • Take proper measure for sulfation.
4. Excessively high electrolyte • Lack of electrolyte • Refer to each corrective action.
temperature • Shorted cells
• Reversed polarity
5. Heat from connector portion • Poor contact of connector with • Solder (Inquire with battery maker).
binding posts

Battery has reached its life if the following phenomena appear. (Also take into account the battery age and operating
conditions.):
• Electrolyte decreases fast and supplying frequency increases.
• Electrolyte temperature becomes 50°C (122°F) or more.
• Timer of charger cannot be turned OFF (or sometimes cannot be turned OFF).
• There is greater variance in voltage and specific gravity among cells.
• Electrolyte color changed to brown (emergence of PbO2 sediment in electrolyte).
• Electrolyte color changed to gray (high electrolyte temperature causes Pb sediment and dropping).
• Specific gravity does not reach 1.250 or more even after charging or equation charging is complete.

BC-4
 BATTERY

Removal
CAUTION:
• Always use chain block and hoist which can stand battery
weight when mounting and removing battery.
• Stabilize vehicle body by pulling parking brake lever and
fixing stoppers to front and rear wheels before operation.
• Always employ a person who has completed a slinging or a
hoisting skill course to perform battery hoisting and lowering
work.
• Use care not to damage harness of battery cable, etc.,
battery support and overhead guard when mounting and
removing battery.

1. Disconnect battery connector.

CAUTION:
• Do not pull cable when holding battery connector.
• Disconnect battery connector after turning OFF key switch.
2. Unlock the top panel latch and then open it.

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3. Remove the side panels from the left and right sides of the
battery.
AF
BCM0012

4. Align the battery raising tool with the hook and the notch in the
protection roof.
5. Lift the battery box vertically out of its lodging.
WARNING:
R
Use extra care with hanger. Never let it make contact with
terminal of battery when placing it. If contact is made, sparks,
leading to burns and explosions occur.
D

6. Carefully remove to one side and place it on the ground.

BCM0013

BC-5
 BATTERY

Installation
Battery mounting follows procedure in reverse order of removal.
CAUTION:
• Confirm mounting direction of battery case.
• Mount battery by putting battery case to rear plate and
sliding it so as not to damage bracket of battery connector
and electrolyte level warning harness.
• Connect battery connector.
• Sandwiching of harness causes short and burns of harness,
leading to unexpected malfunctions.

Inspection
WARNING:
• Never use fire in a spot for inspecting battery.
• Never let battery electrolyte containing dilute sulfuric acid
stick to eyes, skins, clothes or the like. It may cause loss of
eye sight and burns and holes on clothes. If stuck, wash it
with a lot of water. If it enters eyes or you drink it by mistake,
wash or drink a lot of water and consult with a doctor as

T
soon as possible.

MEASURING CELL VOLTAGE

AF NOTE:
This is useful for determining battery life and condition.
Measure voltage of each cell.
R
D

BC-6
 BATTERY

Inspection (Cont’d)
ELECTROLYTE LEVEL
CAUTION:
Fill distilled water when battery electrolyte level drops.

1. Open the cap and check the electrolyte level. If electrolyte level
is in between - in left figure, it is OK.
CAUTION:
Be careful because battery specifications may vary with each
maker.
BCM0014
2. If inspection finds a cell in which electrolyte level is too low,
check if there is any leakage and fill with distilled water. Continue
filling up with cap opened until electrolyte level rises to
position. However, be careful, for it may vary with each maker.
NOTE:
• Probable causes of leakage are as follows:
• Damage to cap
• Excessive filling with distilled water

T
• High electrolyte temperature during charging, leading to
electrolyte overflow
CAUTION:
AF • Use care not to fill distilled water excessively. It may cause
short or leakage.
• Electrolyte lid is pushed into battery cell and needs to be
secured to prevent leakage.
• If there are any cracks in electrolyte lid, replace with new one.
• Be careful because battery specifications may vary with each
maker.
R
ELECTROLYTE TEMPERATURE
Measure electrolyte temperature of each battery cell with a
thermometer.
D

NOTE:
When battery electrolyte temperature rises, electrolyte and capacity
of the battery expand. However, specific gravity decreases because
there is no change in weight. Contrary when electrolyte temperature
drops, specific gravity increases. Thus, when measuring specific
gravity, evaluate result by converting electrolyte temperature at 20°C
BCT0017
(68°F). (Refer to “SPECIFIC GRAVITY” section.)

BC-7
 BATTERY

Inspection (Cont’d)
SPECIFIC GRAVITY
NOTE:
Specific gravity is very useful for determining battery life and
condition.
1. To measure specific gravity of each battery cell by gravimeter.
CAUTION:
Measure with gravimeter placed in battery cell. Use extra care
to prevent scattering of battery electrolyte outside when pulling
it out of the cell.
BCT0018

2. Keep scale of gravimeter at eye level and read upper end

portion of battery electrolyte swollen due to surface tension.
CAUTION:
• If there is variance in specific gravity among cells, perform
equation charging and measure specific gravity again. (For
method of equation charging, refer to CS section). If result
shows big variance in specific gravity among cells, battery
has reached the end of its life. (Battery life depends on years

T
of use, conditions of use and maintenance; equation
charging may be necessary several times depending on
BCT0019
cases).
AF • If specific gravity is below 1.250 after charging, battery has
reached the end of its life.
• Carefully determine the battery life based on the above
observation, together with advice by battery maker
personnel.
3. When battery electrolyte temperature is other than 20°C (68°F),
convert specific gravity into temperature.
Sz0 = St + 0.0007 x t – 0.014
R
Sz0 : Specific gravity of battery electrolyte at standard
temperature [20°C] (68°F)
St : Specific gravity of battery electrolyte measured at
t°C
D

t : Temperature of battery electrolyte during measuring

When specific gravity converted into temperature is below 1.145,
immediately perform charging.
NOTE:
Specific gravity at the time of charging end: 1.280 [electrolyte
temperature 20°C (68°F)]

BCT0020

BC-8
 BATTERY

Inspection (Cont’d)
BATTERY MAINTENANCE
Cleaning
If dust is accumulated on upper surface of battery, the dust can
absorb water and cause leakage between terminals. Periodically
clean the upper surface of the battery with a wet cloth and dry it
when inspecting electrolyte level.
WARNING:
• Never clean the upper surface of the battery with a dry cloth,
dust it or put a vinyl cover on it. It may generate static
electricity and cause battery explosion.
• Never put fingers or driver into battery connection. Never
touch connection terminal of the battery. It may cause
electric shock and short.
CAUTION:
Always clean the battery before charging.

Supplying distilled water

T
CAUTION:
• Fill distilled water up to prescribed level on daily basis.
Further, it is recommended that distilled water always be
available.
AF • Never mix tap water. It may shorten life because it contains
impurities such as chlorine, Fe (iron) and the like.
NOTE:
Distilled water is made by using ion exchange resin. Ingredients are
as follows:

ITEM IMPURITY LIMIT ITEM IMPURITY LIMIT

R
Transparent and
Appearance Fe (iron) below 0.0005%
colorless
NO2 (nitric acid) below 0.0005% Cu (copper) below 0.0005%
D

NH3 (ammonia) below 0.0005% Mn (manganese) below 0.0005%

KMnO4
Cl (chlorine) below 0.0005% (potassium below 0.0003%
permanganate)

STORING BATTERY
• Be sure battery is fully charged before placing it in storage.
CAUTION:
Before charging, add distilled water so that electrolyte is a little
higher than the prescribed level.
• When not in use, battery should be stored in cool and dark place
(well ventilated and temperature and humidity are low). Check
specific gravity from time to time and, when it is below 1.200,
charge the battery. Perform equation charging once every two
months. Battery determines a life of forklift, and thus be sure to
record every maintenance work.

BC-9
 BATTERY

Inspection (Cont’d)
EXTERNAL LEAKAGE OF BATTERY ELECTROLYTE
(⊕ LEAK)
Locate leaking cell following the flow chart below.
NOTE:
• Put tester to paint erased portion (paint is erased by file) when
putting the tester to iron box.
• White zinc sulphate crystals are most often stuck to terminal of
electrolyte leaking cell.

V Measure voltages by putting tester to terminal of

100 battery connector and tester to iron box.

No
Remove battery Voltage is OK (no leak)
from vehicle body generated.

T
and wash it with
water. Yes

First time
AF
BCT0006
Second time

V Measure voltages in sequence by putting tester to

100 terminal of battery connector and tester to terminal
of each cell.

Find cell close to measured value of .

R

Select another cell.

D

BCT0007

V Measure voltages by putting tester to iron box and

100 tester to terminals of found cell and adjacent cells (in
serial direction).

Cell whose voltage value is close No Electrolyte non-

to 0V. leaking cell

Yes

Electrolyte leaking cell

BCT0008

NOTE:
For inspection of leak, measure in reverse polarity of all and
for leak inspection.

BC-10
 CHARGER
CHARGER

How to Charge the Battery (Off-Forklift Type)

WARNING:
Charge the battery according to the instruction manual
supplied with the battery charger being used.
CAUTION:
• Do not connect the battery charger output plug to the body
harness connection. The battery will not charge through this
connection.
• Do not disconnect the input plug while charging is taking
place.
• Keep the parking brake lever engaged during the battery
charging process on the forklift.
• Before charging the battery, add distilled water up to the
upper limit level. Do not overfill.
• Periodically clean the caps, removing any foreign matter
from gas vents. The caps need not be removed during the
charging operation.
• When charging is complete, ascertain with a gravimeter that
the specific gravity is 1.28 at a temperature 20°C (68°F).
• Charge the battery with battery cover open and in well

T
ventilated areas. During battery charging, there is a high risk
of hydrogen gas explosion. To reduce the risk always charge
in well ventilated area’s and continue ventilation for at least
AF 30 minutes after completion of charging.

BCM0015
R
D

BC-11
BATTERY MOUNTING
BATTERY MOUNTING

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AF
R
BCM0016
D

BC-12
 ELECTRICAL SYSTEM

1N1 SECTION EL
CONTENTS

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PRECAUTIONS ................................................. EL-2 SWITCHES ....................................................... EL-19
Precautions .................................................... EL-2 Key Switch ................................................... EL-19
LOCATION OF ELECTRICAL UNITS ............... EL-3 Battery Switch .............................................. EL-19
AF
Electrical Component Parts (3 - wheel) .......... EL-3 Combination Switch ..................................... EL-20
Electrical Component Parts (4 - wheel) .......... EL-3 Back Operation Lamp Switch (Option) ......... EL-21
HARNESS LAYOUT .......................................... EL-5 Seat Switch .................................................. EL-21
Outline ............................................................ EL-5 Seat Belt Switch ........................................... EL-22
Body Harness for Mechanical Parking Brake Switch ................................... EL-22
Control System ............................................... EL-6 MISCELLANEOUS ELECTRICAL PARTS ...... EL-22
Body Harness for Joystick Control System .... EL-9 Horn Switch .................................................. EL-23
Tail Harness ................................................. EL-12 Horn Relay ................................................... EL-23
R
Guard Harness ............................................. EL-12 Tail Lamp, Auto Power Off, Battery Switch,
Hydraulic Control Valve Switch Harness Joystick Control System Relay ..................... EL-24
for Mechanical Control System .................... EL-13 Horn ............................................................. EL-24
Sub-harness for Joystick Control Warning Buzzer ............................................ EL-25
D

System (Option) ........................................... EL-13 Back Buzzer ................................................. EL-25

FUSES ............................................................. EL-14 BATTERY CABLES AND MOTOR CABLES ... EL-25
Fuse and Fuse Box ...................................... EL-14 Battery Cables and Moter Cables ................ EL-25
Fusible Link .................................................. EL-15 LOCATION OF OPTIONAL PARTS ................. EL-28
LIGHTING SYSTEM ........................................ EL-16 Earth Band ................................................... EL-28
Lamps ........................................................... EL-16
Headlamp ..................................................... EL-17
Back operation lamp (Option) ....................... EL-17
Patrol lamp (Option) ..................................... EL-18

Bulletin issued:
Service Bulletins Issue date
SB-TX-EL-0701-02 RPM sensor error with new motor 12-112007
 PRECAUTIONS
PRECAUTIONS

Precautions
CAUTION:
• When performing removal and installation procedures, be
sure to turn key switch to OFF and disconnect battery plug.
• When replacing a fuse or a bulb for accessories, alway use
one of specified capacity.

T
AF
R
D

EL-2
LOCATION OF ELECTRICAL UNITS
LOCATION OF ELECTRICAL UNITS

Electrical Component Parts (3 - wheel)

T
AF
ELM0250EU

Electrical Component Parts (4 - wheel)

R
D

ELM0801EU

EL-3
LOCATION OF ELECTRICAL UNITS

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AF
ELM0251EU
R
D

EL-4
 HARNESS LAYOUT
HARNESS LAYOUT

Outline

T
AF
R
D

ELM0252EU

EL-5
 HARNESS LAYOUT

Body Harness for Mechanical Control

System

T
AF
R
D

ELM0253
*: For EUROPE only
**: Except for NORTH AMERICA

EL-6
 HARNESS LAYOUT

Body Harness for Mechanical Control System

(Cont’d)

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AF
R
D

ELM0254
***: For NORTH AMERICA only

EL-7
 HARNESS LAYOUT

Body Harness for Mechanical Control System

(Cont’d)
B1 : To guard harness RH G1 B40 : To revolution sensor LH (Traction motor)

B2 : To guard harness RH G2 B41 : To horn (Except for NORTH AMERICA)

B3 : To guard harness RH G3 B42 : To horn (Except for NORTH AMERICA)

B4 : To guard harness RH G4 B43 : To temperature sensor LH (Traction motor)

B5 : To diode (brake) B44 : To lift solenoid valve

B6 : To fuse block B45 : To hydraulic control valve switch harness H1

B7 : To diode (reverse) B46 : To accel sensor

B8 : To diode (tail) B47 : To brake switch

B9 : To combination meter B48 : To temperature sensor (Pump motor)

B10 : To brake fluid level switch B49 : To revolution sensor (Pump motor)

B11 : To brake fluid level switch B50 : To revolution sensor (Shield earth)

B12 : To lighting and turn signal lamp switch B51 : To revolution sensor (Shield earth)

B13 : To key switch B52 : To tire angle sensor

T
B14 : To cabin harness (Option) B53 : To PS correction solenoid (Except for NORTH AMERICA)

B15 : To horn switch B54 : To back buzzer

B16 : To steering angle sensor B55 : To contactor assy

B17 : To parking brake buzzer

AF B56 : To (+) terminal

B18 : To forward-reverse switch B57 : To rear combination lamp RH

B19 : To guard harness LH G5 B58 : To rear combination lamp RH

B20 : To guard harness LH G6 B59 : To rear combination lamp RH

B21 : To guard harness LH G7 B60 : To pump controller

B22 : To guard harness LH G8 B61 : To pump controller

R
B23 : To parking brake switch B62 : To traction controller

B24 : To back operation lamp switch (Option) B63 : To traction controller

B25 : To relay (tail) B64 : To fusible link

D

B26 : To relay (tail) B65 : To fusible link

B27 : To relay (EMG) B66 : To seat belt switch

B28 : To relay (EMG) B67 : To seat switch

B29 : To relay (APO) B68 : To seat switch

B30 : To relay (APO) B69 : To battery switch

B31 : To relay (horn) B70 : To battery switch

B32 : To electrical horn (For NORTH AMERICA) B71 : To patrol lamp (Option)(Except for NORTH AMERICA)

B33 : To electrical horn (For NORTH AMERICA) B72 : To patrol lamp (Option)(Except for NORTH AMERICA)

B34 : To temperature sensor RH (Traction motor) B73 : To rear combination lamp LH

B35 : To revolution sensor RH (Shield earth) B74 : To rear combination lamp LH

B36 : To revolution sensor RH (Shield earth) B75 : To rear combination lamp LH

B37 : To revolution sensor RH (Traction motor) B76 : To tail harness T2

B38 : To revolution sensor LH (Shield earth) B77 : To tail harness T1
B39 : To revolution sensor LH (Shield earth)

EL-8
 HARNESS LAYOUT

Body Harness for Joystick Control System

T
AF
R
D

ELM0255

*: For EUROPE only

**: Except for NORTH AMERICA

EL-9
 HARNESS LAYOUT

Body Harness for Joystick Control System

(Cont’d)

T
AF
R
D

ELM0256
***: For NORTH AMERICA only

EL-10
 HARNESS LAYOUT

Body Harness for Joystick Control System

(Cont’d)
B1 : To guard harness RH G1 B43 : To temperature sensor LH (Traction motor)
B2 : To guard harness RH G2 B46 : To accel sensor
B3 : To guard harness RH G3 B47 : To brake switch
B4 : To guard harness RH G4 B48 : To temperature sensor (Pump motor)
B5 : To diode (brake) B49 : To revolution sensor (Pump motor)
B6 : To fuse block B50 : To revolution sensor (Shield earth)
B7 : To diode (reverse) B51 : To revolution sensor (Shield earth)
B8 : To diode (tail) B52 : To tire angle sensor
B9 : To combination meter B53 : To PS correction solenoid (Except for NORTH AMERICA)
B10 : To brake fluid level switch B54 : To back buzzer
B11 : To brake fluid level switch B55 : To contactor assy
B12 : To lighting and turn signal lamp switch B56 : To (+) terminal
B13 : To ignition switch B57 : To rear combination lamp RH
B14 : To cabin harness (Option) B58 : To rear combination lamp RH
B15 : To horn switch B59 : To rear combination lamp RH

T
B16 : To steering angle sensor B60 : To pump controller
B17 : To parking brake buzzer B61 : To pump controller
B18 : To forward-reverse switch B62 : To traction controller
B19 : To guard harness LH G5
AF B63 : To traction controller
B20 : To guard harness LH G6 B64 : To fusible link
B21 : To guard harness LH G7 B65 : To fusible link
B22 : To guard harness LH G8 B66 : To seat belt switch
B23 : To parking brake switch B67 : To seat switch
B24 : To back operation lamp switch (Option) B68 : To seat switch
R
B25 : To relay (tail) B69 : To battery switch
B26 : To relay (tail) B70 : To battery switch
B27 : To relay (EMG) B71 : To patrol lamp (Option)(Except for NORTH AMERICA)
D

B28 : To relay (EMG) B72 : To patrol lamp (Option)(Except for NORTH AMERICA)
B29 : To relay (APO) B73 : To rear combination lamp LH
B30 : To relay (APO) B74 : To rear combination lamp LH
B31 : To relay (horn) B75 : To rear combination lamp LH
B32 : To electrical horn (For NORTH AMERICA) B76 : To tail harness T2
B33 : To electrical horn (For NORTH AMERICA) B77 : To tail harness T1
B34 : To temperature sensor RH (Traction motor) B78 : To relay (Joystick controller)
B35 : To revolution sensor RH (Shield earth) B79 : To relay (Joystick controller)
B36 : To revolution sensor RH (Shield earth) B80 : To C1 solenoid
B37 : To revolution sensor RH (Traction motor) B81 : To hydraulic control valve A (Pull)
B38 : To revolution sensor LH (Shield earth) B82 : To hydraulic control valve B (Push)
B39 : To revolution sensor LH (Shield earth) B83 : To sub harness S2
B40 : To revolution sensor LH (Traction motor) B84 : To sub harness S1
B41 : To horn (Except for NORTH AMERICA) B85 : To Joystick controller
B42 : To horn (Except for NORTH AMERICA) B86 : To Joystick controller

EL-11
HARNESS LAYOUT

Tail Harness

T
ELM0257

Guard Harness
AF
R
D

ELM0258

EL-12
 HARNESS LAYOUT

Hydraulic Control Valve Switch Harness for

Mechanical Control System

T
ELM0259
AF
Sub-harness for Joystick Control System
(Option)
R
D

ELM0260

EL-13
 FUSES
FUSES

Fuse and Fuse Box

REMOVAL
CAUTION:
• For removal or installing fuse box cover, be careful not to
damage cover.
• Always use a fuse of specified capacity.

1. Remove instrument panel lower cover fixing screw, then remove

instrument panel lower cover.
2. Remove fuse box cover by pushing and turning the hook on
cover.
CAUTION:
Be careful not to damage cover.

T
AF
ELM0261

3. Take out fuse extractor equipped with inside of cover and

R
remove fuse with fuse extractor.
CAUTION:
Draw out fuse toward you.
D

INSTALLATION
1. Always use a fuse of specified capacity.
2. Return fuse extractor to original position and install fuse in
reverse order of removal.
NOTE:
• When removing fuse box, remove fuse box cover. Insert a small
screwdriver into hook to unlock, then remove fuse box from
bracket.
• When installing fuse box, insert part to be fitted into bracket and
securely lock with hook.

EL-14
 FUSES

Fuse and Fuse Box (Cont’d)

INSPECTION
Check for blown fuse by referring to the right side of the figure.
Replace blown fuse with a new one.
CAUTION:
• When replacing fuse, always use one of specified capacity,
indicated on the fuse capacity label.
• If fuse blows again after replacing, electrical trouble is
considered. Immediately inspect and eliminate cause of the
trouble.
Power supply No. Fuse capacity (A) Applicable parts

ELT0008 Battery 1 5 Meter

2 10 Option (Battery power supply)

Headlamp, tail lamp, stop lamp,

3 10
horn, back operation lamp (option)

4 10 Power supply for key switch

Key switch 5 10 Controller

T
6 5 Option

7 5 Meter
AF
ELM0262
8 10 Reverse lamp, back buzzer

Fusible Link
R

INSPECTION
Check for blown fusible link using circuit tester.
D

CAUTION:
If fusible link is blown, replace with a new one of specified
capacity. Also, check related electrical parts to determine the
cause of problem, and repair if necessary.

Identification color Size (mm2) Application

Brown 0.3 Controller, meter

Green 0.5 Lamps, cabin
ELT0011

Identification color Size (mm2) Application

Brown 0.3 Joystick control circuit

ELM0263

EL-15
LIGHTING SYSTEM
LIGHTING SYSTEM

Lamps
REMOVAL AND INSTALLATION.

T
AF
R
D

ELM0265

EL-16
 LIGHTING SYSTEM

Lamps (Cont’d)
SPECIFICATIONS

Wattage (W) Number of

Lamps
parts
48V 36V

Headlamp 25 25 2
Front turn signal lamp 25 25 2
Stop/tail 25/10 25/10 2/2
Rear combination
Turn 25 25 2
lamp
Reverse 10 8 2
Back operation lamp (option) 25 25 1

CAUTION:
In checking, make sure that resistance between connector
terminal and case/screw is 100 kΩ or more using circuit tester.

T
AF Headlamp
CAUTION:
Install lens with water-drain hole facing down.

ADJUSTMENT
Adjust headlamp aim so that axis of light is 6 degrees below
R
horizontal line.
CAUTION:
• Place vehicle and tester on the same horizontal plane.
• Keep all tires inflated to correct pressure.
D

ELM0266

Back operation lamp (Option)

CAUTION:
• Install lens with water-drain hole facing down.
• Adjust back operation lamp aim so that axis of light is 5 to 10
degrees toward center line of vehicle.

EL-17
LIGHTING SYSTEM

Patrol lamp (Option)

REMOVAL AND INSTALLATION

T
ELM0267
AF
R
D

EL-18
 SWITCHES
SWITCHES

Key Switch
REMOVAL
1. Disconnect harness connector.
2. Remove ring nut and remove key switch from rear cover.

INSTALLATION
Install key switch in reverse order of removal.

ELM0268

INSPECTION
Check continuity between terminals using circuit tester (Ω range).

Switch position
Terminal Remarks
OFF ON RE-START

1 To fuse
2 From fuse
3

T
4 Re-start
ELM0269
AF
Battery Switch
CAUTION:
Remove battery switch after turning off key switch,
disconnecting battery plug and making battery switch off
(pushed state).
R
INSPECTION
Check continuity between terminals using circuit tester (Ω range).
D

Switch condition
Terminal
ELM0270 Pulled Pushed
For battery cables Continuity

For normal closed circuit Continuity

For normal open circuit Continuity

ELM0271

EL-19
 SWITCHES

Combination Switch

ELM0272

DESCRIPTION
• The turn signals and forward-reverse switches were integrated

T
into a single unit. Also, a lighting switch structure was adopted.
• An auto return function was adopted for the turn signal lever.
• Turn signal switch is installed left side for joystick control system
(option) vehicle.
AF
NOTE:
Please refer to control system (CS) section for forward-reverse
switch (lever) and steering angle sensor.
ELM0273

Lighting switch
R
Switch position Lamps
1st step Tail lamp
• Tail lamp
2nd step
• Headlamp
D

ELM0274

INSPECTION
Check continuity between terminals using circuit tester (Ω range).

Turn signal switch

Lever position
Terminal
Left Neutral Right

T-1
T-2
T-3
ELM0275

EL-20
 SWITCHES

Combination Switch (Cont’d)

Lighting switch
Knob position
Terminal
OFF 1st step 2nd step

L-1
L-2
L-3

Back Operation Lamp Switch (Option)

INSPECTION
Check resistance between terminals using circuit tester (Ω range).
Terminal 1 2 3 4

Switch OFF
Switch ON

T
BET0141L
AF
R

ELM0277
D

Seat Switch
INSPECTION
Check continuity.
When sitting on the seat: Continuity should exist.
When not sitting on the seat: Continuity should not exist.

VCT0023L

EL-21
 SWITCHES

Seat Belt Switch

INSPECTION
Check continuity.
When insert buckle: Continuity should exist.
When disconnect buckle: Continuity should not exist.

VCT0031L

Parking Brake Switch

INSPECTION
Check continuity between terminals using circuit tester (Ω range).

Parking brake lever

Terminal
Applied Released

T
1
VCT0037L
2
3
AF
R
D

EL-22
MISCELLANEOUS ELECTRICAL PARTS
MISCELLANEOUS ELECTRICAL PARTS

Horn Switch
INSPECTION
• Check horn sound by pushing horn switch while turning steering
wheel from lock to lock.
• Remove steering wheel (Refer to ST section) and visually check
horn brush for wear or damage.

Horn Relay
SPECIFICATIONS

Rated voltage (V) 48

Rated load (A) 2
Operating voltage (V) 28 - 56

ELM0276

INSPECTION

T
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals and
using circuit tester (Ω range) while applying or releasing battery
AF voltage to/from coil side terminals and .

ELM0278
R
D

EL-23
MISCELLANEOUS ELECTRICAL PARTS

Tail Lamp, Auto Power Off, Battery Switch,

Joystick Control System Relay
SPECIFICATIONS

Rated voltage (V) 48

Rated load (A) 4
Minimum operating voltage (V) 25

ELM0279

INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals using circuit
tester (Ω range) while applying or releasing battery voltage to/
from coil side terminals.

T
Terminal

Coil - Continuity
Contacting point - Continuity
AF
ELM0280

Horn
SPECIFICATIONS

Horn
R
Except for NORTH For NORTH
AMERICA AMERICA
Rated voltage (V) 48 24 - 48
Operating voltage (V) 36 - 58 19.6 - 55
D

Sound pressure level (At 2 m) dB (A) 97 - 115 103 - 111

Frequency Hz 337 - 363 880 - 1,320

ELM0281

EL-24
MISCELLANEOUS ELECTRICAL PARTS

Warning Buzzer
SPECIFICATIONS

Warning buzzer

Rated voltage (V) 48/36

Operating voltage (V) 28 - 52
Sound pressure level (At 1 m)dB (A) 70 - 80
Frequency Hz 2,100 - 3,500

ELM0282
INSPECTION
A warning buzzer sounds when the driver stands up from the seat
without applying the parking brake.

Seat Parking brake

lgnition Warning
switch buzzer
Seated Unseated Applied Released

– – ×
– – ×
ON

T
– – ×
– –
– ×
AF – –
OFF
– – ×
– –
• 3-second delay is implemented for detection of unseated status.

Back Buzzer
SPECIFICATIONS
R

Back buzzer

Rated voltage (V) 48/36

D

Operating voltage (V) 28 - 56

Sound pressure level (At 1 m)dB (A) 88.5 - 101
FrequencyHz 2,300 - 3,300

ELM0283

EL-25
BATTERY CABLES AND MOTOR CABLES
BATTERY CABLES AND MOTOR CABLES

Battery Cables and Moter Cables

REMOVAL AND INSTALLATION
CAUTION:
When removing the battery cable, always put the marks on the
battery cable. The marks indicate the original position (of the
cable installed) so as to prevent installation in the incorrect
position.
Especially when the positive cable (VB) and the negative cable
[-] were installed oppositely, the controller may be damaged. Be
careful not to install them incorrectly.

T
AF
R
D

ELM0287

EL-26
BATTERY CABLES AND MOTOR CABLES

Battery Cables and Moter Cables (Cont’d)

T
AF
R
D

ELM0289

EL-27
LOCATION OF OPTIONAL PARTS
LOCATION OF OPTIONAL PARTS

Earth Band
DESCRIPTION
For normal tires (black tires), the carbon is contained as a material.
Therefore, if the vehicle is charged with electricity, it will be
discharged from the tires.
For non-marking tires (colored tires), the carbon is not contained as
a material. Therefore, if the vehicle is charged with electricity, it
cannot be discharged.
The circuit board, element, or parts may be damaged by this
electrification.
To prevent this damage, install the earth band to the vehicle and
discharge the static electricity from the vehicle.

REMOVAL AND INSTALLATION

CAUTION:
Always install the earth band with the non-marking tires on the
ground.

T
AF
R
D

ELM0284

WIRING DIAGRAM
WIRING DIAGRAM
CIRCUIT DIAGRAM

EL-28
 ELECTRICAL SYSTEM

A1N1 SECTION EL
CONTENTS

T
PRECAUTIONS ................................................. EL-2 MISCELLANEOUS ELECTRICAL PARTS ...... EL-15
Precautions .................................................... EL-2 Horn Switch .................................................. EL-15
LOCATION OF ELECTRICAL UNITS ............... EL-3 Horn Relay ................................................... EL-15
AF
Electrical Component Parts (3 - wheel) .......... EL-3 Tail Lamp, Auto Power Off, Battery Switch,
Electrical Component Parts (4 - wheel) .......... EL-3 Joystick Control System Relay ..................... EL-16
HARNESS LAYOUT .......................................... EL-5 Horn ............................................................. EL-16
Outline ............................................................ EL-5 Warning Buzzer ............................................ EL-17
FUSES ............................................................... EL-6 Back Buzzer ................................................. EL-17
Fuse and Fuse Box ........................................ EL-6 BATTERY CABLES AND MOTOR CABLES ... EL-18
Fusible Link .................................................... EL-7 Battery Cables and Motor Cables ................ EL-18
LIGHTING SYSTEM .......................................... EL-8 LOCATION OF OPTIONAL PARTS ................. EL-21
R
Lamps ............................................................. EL-8 Earth Band ................................................... EL-21
Headlamp ....................................................... EL-9 DC/DC converter (Option) ............................ EL-22
Back operation lamp (Option) ......................... EL-9 WIRING DIAGRAM ........................................... EL-23
Patrol lamp (Option) ..................................... EL-10 Power Supply for Controller ......................... EL-23
D

SWITCHES ...................................................... EL-11

Key Switch .................................................... EL-11
Battery Switch .............................................. EL-11
Combination Switch ...................................... EL-12
Back Operation Lamp Switch (Option) ......... EL-13
Seat Switch .................................................. EL-13
Seat Belt Switch ........................................... EL-14
Parking Brake Switch ................................... EL-14
 PRECAUTIONS
PRECAUTIONS

Precautions
CAUTION:
• When performing removal and installation procedures, be
sure to turn key switch to OFF and disconnect battery plug.
• When replacing a fuse or a bulb for accessories, alway use
one of specified capacity.

T
AF
R
D

EL-2
LOCATION OF ELECTRICAL UNITS
LOCATION OF ELECTRICAL UNITS

Electrical Component Parts (3 - wheel)

T
AF
ELM0250EU

Electrical Component Parts (4 - wheel)

R
D

ELM0801EU

EL-3
LOCATION OF ELECTRICAL UNITS

T
AF
ELM0251EU
R
D

EL-4
 HARNESS LAYOUT
HARNESS LAYOUT

Outline

T
AF
R
D

ELM0252EU

EL-5
 FUSES
FUSES

Fuse and Fuse Box

REMOVAL
CAUTION:
• For removal or installing fuse box cover, be careful not to
damage cover.
• Always use a fuse of specified capacity.

1. Remove instrument panel lower cover fixing screw, then remove

instrument panel lower cover.
2. Remove fuse box cover by pushing and turning the hook on
cover.
CAUTION:
Be careful not to damage cover.

T
AF
ELM0261

3. Take out fuse extractor equipped with inside of cover and

R
remove fuse with fuse extractor.
CAUTION:
Draw out fuse toward you.
D

INSTALLATION
1. Always use a fuse of specified capacity.
2. Return fuse extractor to original position and install fuse in
reverse order of removal.
NOTE:
• When removing fuse box, remove fuse box cover. Insert a small
screwdriver into hook to unlock, then remove fuse box from
bracket.
• When installing fuse box, insert part to be fitted into bracket and
securely lock with hook.

EL-6
 FUSES

Fuse and Fuse Box (Cont’d)

INSPECTION
Check for blown fuse by referring to the right side of the figure.
Replace blown fuse with a new one.
CAUTION:
• When replacing fuse, always use one of specified capacity,
indicated on the fuse capacity label.
• If fuse blows again after replacing, electrical trouble is
considered. Immediately inspect and eliminate cause of the
trouble.
Power supply No. Fuse capacity (A) Applicable parts

ELT0008 Battery 1 5 Meter

2 10 Option (Battery power supply)

Head lamp, tail lamp, stop lamp,

3 10
horn, back operation lamp (option)

4 20 Power supply for key switch

Key switch 5 10 Controller

T
6 5 Option

7 5 Meter
AF
ELM0262
8 10 Reverse lamp, back buzzer

Fusible Link
R

INSPECTION
Check for blown fusible link using circuit tester.
D

CAUTION:
If fusible link is blown, replace with a new one of specified
capacity. Also, check related electrical parts to determine the
cause of problem, and repair if necessary.

Identification color Size (mm2) Application

Brown 0.3 Controller, meter

Green 0.5 Lamps, cabin
ELT0011

Identification color Size (mm2) Application

Brown 0.3 Joystick control circuit

ELM0263

EL-7
LIGHTING SYSTEM
LIGHTING SYSTEM

Lamps
REMOVAL AND INSTALLATION.

T
AF
R
D

BSM0619

EL-8
 LIGHTING SYSTEM

Lamps (Cont’d)
SPECIFICATIONS

Wattage (W) Number of

Lamps
parts
48V 36V

Headlamp 25 25 2
Front turn signal lamp 25 25 2
Stop/tail 25/10 25/10 2/2
Rear combination
Turn 25 25 2
lamp
Reverse 10 8 2
Back operation lamp (option) 25 25 1

CAUTION:
In checking, make sure that resistance between connector
terminal and case/screw is 100 kΩ or more using circuit tester.

T
AF Headlamp
CAUTION:
Install lens with water-drain hole facing down.

ADJUSTMENT
Adjust headlamp aim so that axis of light is 6 degrees below
R
horizontal line.
CAUTION:
• Place vehicle and tester on the same horizontal plane.
• Keep all tires inflated to correct pressure.
D

ELM0266

Back operation lamp (Option)

CAUTION:
• Install lens with water-drain hole facing down.
• Adjust back operation lamp aim so that axis of light is 5 to 10
degrees toward center line of vehicle.

EL-9
LIGHTING SYSTEM

Patrol lamp (Option)

REMOVAL AND INSTALLATION

T
ELM0267
AF
R
D

EL-10
 SWITCHES
SWITCHES

Key Switch
REMOVAL
1. Disconnect harness connector.
2. Remove ring nut and remove key switch from rear cover.

INSTALLATION
Install key switch in reverse order of removal.

ELM0268

INSPECTION
Check continuity between terminals using circuit tester (Ω range).

Switch position
Terminal Remarks
OFF ON RE-START

1 To fuse
2 From fuse
3

T
4 Re-start
ELM0269
AF
Battery Switch
CAUTION:
Remove battery switch after turning off key switch,
disconnecting battery plug and making battery switch off
(pushed state).
R
INSPECTION
Check continuity between terminals using circuit tester (Ω range).
D

Switch condition
Terminal
ELM0270 Pulled Pushed
For battery cables Continuity

For normal closed circuit Continuity

For normal open circuit Continuity

ELM0271

EL-11
 SWITCHES

Combination Switch

ELM0272

DESCRIPTION
• The turn signals and forward-reverse switches were integrated

T
into a single unit. Also, a lighting switch structure was adopted.
• An auto return function was adopted for the turn signal lever.
• Turn signal switch is installed left side for joystick control system
(option) vehicle.
AF
NOTE:
Please refer to control system (CS) section for forward-reverse
switch (lever) and steering angle sensor.
ELM0273

Lighting switch
R
Switch position Lamps
1st step Tail lamp
• Tail lamp
2nd step
• Headlamp
D

ELM0274

INSPECTION
Check continuity between terminals using circuit tester (Ω range).

Turn signal switch

Lever position
Terminal
Left Neutral Right

T-1
T-2
T-3
ELM0275

EL-12
 SWITCHES

Combination Switch (Cont’d)

Lighting switch
Knob position
Terminal
OFF 1st step 2nd step

L-1
L-2
L-3

Back Operation Lamp Switch (Option)

INSPECTION
Check resistance between terminals using circuit tester (Ω range).
Terminal 1 2 3 4

Switch OFF
Switch ON

T
BET0141L
AF
R

ELM0277
D

Seat Switch
INSPECTION
Check continuity.
When sitting on the seat: Continuity should exist.
When not sitting on the seat: Continuity should not exist.

VCT0023L

EL-13
 SWITCHES

Seat Belt Switch

INSPECTION
Check continuity.
When insert buckle: Continuity should exist.
When disconnect buckle: Continuity should not exist.

VCT0031L

Parking Brake Switch

INSPECTION
Check continuity between terminals using circuit tester (Ω range).

Parking brake lever

Terminal
Applied Released

T
1
VCT0037L
2
3
AF
R
D

EL-14
MISCELLANEOUS ELECTRICAL PARTS
MISCELLANEOUS ELECTRICAL PARTS

Horn Switch
INSPECTION
• Check horn sound by pushing horn switch while turning steering
wheel from lock to lock.
• Remove steering wheel (Refer to ST section) and visually check
horn brush for wear or damage.

Horn Relay
SPECIFICATIONS

Rated voltage (V) 48

Rated load (A) 2
Operating voltage (V) 28 - 56

ELM0276

INSPECTION

T
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals and
using circuit tester (Ω range) while applying or releasing battery
AF voltage to/from coil side terminals and .

ELM0278
R
D

EL-15
MISCELLANEOUS ELECTRICAL PARTS

Tail Lamp, Auto Power Off, Battery Switch,

Joystick Control System Relay
SPECIFICATIONS

Rated voltage (V) 48

Rated load (A) 4
Minimum operating voltage (V) 25

ELM0279

INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals using circuit
tester (Ω range) while applying or releasing battery voltage to/
from coil side terminals.

T
Terminal

Coil - Continuity
Contacting point - Continuity
AF
ELM0280

Horn
SPECIFICATIONS

Horn
R
Except for NORTH For NORTH
AMERICA AMERICA
Rated voltage (V) 48 24 - 48
Operating voltage (V) 36 - 58 19.6 - 55
D

Sound pressure level (At 2 m) dB (A) 97 - 115 103 - 111

Frequency Hz 337 - 363 880 - 1,320

ELM0281

EL-16
MISCELLANEOUS ELECTRICAL PARTS

Warning Buzzer
SPECIFICATIONS

Warning buzzer

Rated voltage (V) 48/36

Operating voltage (V) 28 - 52
Sound pressure level (At 1 m)dB (A) 70 - 80
Frequency Hz 2,100 - 3,500

ELM0282
INSPECTION
A warning buzzer sounds when the driver stands up from the seat
without applying the parking brake.

Seat Parking brake

lgnition Warning
switch buzzer
Seated Unseated Applied Released

– – ×
– – ×
ON

T
– – ×
– –
– ×
AF – –
OFF
– – ×
– –
• 3-second delay is implemented for detection of unseated status.

Back Buzzer
SPECIFICATIONS
R

Back buzzer

Rated voltage (V) 48/36

D

Operating voltage (V) 28 - 56

Sound pressure level (At 1 m)dB (A) 88.5 - 101
FrequencyHz 2,300 - 3,300

ELM0283

EL-17
BATTERY CABLES AND MOTOR CABLES
BATTERY CABLES AND MOTOR CABLES

Battery Cables and Motor Cables

REMOVAL AND INSTALLATION
CAUTION:
When removing the battery cable, always put the marks on the
battery cable. The marks indicate the original position (of the
cable installed) so as to prevent installation in the incorrect
position.
Especially when the positive cable (VB) and the negative cable
[-] were installed oppositely, the controller may be damaged. Be
careful not to install them incorrectly.

T
AF
R
D

EL-18
BATTERY CABLES AND MOTOR CABLES

Battery Cables and Motor Cables (Cont’d)

A1N1 Model

T
AF
R
D

EL-19
BATTERY CABLES AND MOTOR CABLES

JAG1N1 Model (only EUROPE)

T
AF
R
D

EL-20
LOCATION OF OPTIONAL PARTS
LOCATION OF OPTIONAL PARTS

Earth Band
DESCRIPTION
For normal tires (black tires), the carbon is contained as a material.
Therefore, if the vehicle is charged with electricity, it will be
discharged from the tires.
For non-marking tires (colored tires), the carbon is not contained as
a material. Therefore, if the vehicle is charged with electricity, it
cannot be discharged.
The circuit board, element, or parts may be damaged by this
electrification.
To prevent this damage, install the earth band to the vehicle and
discharge the static electricity from the vehicle.

REMOVAL AND INSTALLATION

CAUTION:
Always install the earth band with the non-marking tires on the
ground.

T
AF
R
D

BSM0623

EL-21
 LOCATION OF OPTIONAL PARTS

DC/DC converter (Option)

DESCRIPTION
Set as option for:
• Wipers and interior lamp in case of cabin option (CABS, CABT)
• 12V option in RH FR pillar (CABY)
• For 3 and 4 wheel models
• Input voltage: 48V
• Output voltage: 12V
• Rated output: 240W

LOCATION

DC/DC converter
Connector

T
3 wheel 20121008EU
AF
Connector

DC/DC converter
R
4 wheel
20121009EU
D

Connection type
20121010EU

12V CONNECTION
CIRCUIT DIAGRAM

Connector

20121011EU

EL-22
 WIRING DIAGRAM
WIRING DIAGRAM

Power Supply for Controller

FUSE BOX
BAT
METER
W 100 5A 740 Y
OPT
10A 520 SB
LIGHT
10A 401 R
To Rear Comb Lamp LH
KEY SW
20A 110 P
To Cabin Harness
IGN
CONT
GY 120 10A 125 GY
OPT
5A 516 W
METER
5A 727 L
LIGHT
10A 451 G

1
2
3
IGN SW
110 120 120 110
127 127
OFF ON RE START 4
127 127 Y 5

T
120 120 GY 6
110 110 P

7
AF
727 727 8

728 728

AUTO POWER 125 126 126 125

OFF RELAY
728 L
727 L
R
125 GY
126 G

20 711
D

19 710

6 905
9

2 740
1 11 990 728
COMB. METER

IGN 728 L
PKB INPUT 905 L
BAT 740 Y
RS232C(C_to_M) 710 BR 10
RS232C(M_to_C) 711 L/B 11
GND 990 B 12

13

Power Supply
Signal
CAN
Earth
BSM0624

EL-23
 WIRING DIAGRAM

Power Supply for Controller (Cont’d)

CONTACTOR UNIT
BATTERY SW
CURRENT VB To Rear Comb
FS1 SEN
Lamp LH CONTROLLER

To Rear Comb
W 100 802 804 803 801 280 281 Lamp RH CN A CN A
801 802 803 804 280 281 W 254 786 35
100 R 253 781 23

G/B
711 34

GY
802 804 803 801 280 281 To Turn

W
P
Y
L
L 410 771 22
Lamp LH 710 33
W 804 126 32
P 803 253 31
BATTERY L 802 254 801 7 30
Y 801 410 802 6 29
G 450

VCM CONTROLLER
450 803 5 28
Y 127
804 4
G 126
127 3
BR 710
129 2
L/B 711 992 1
B 992
OR 129 CN B CN B
L 781
124 993 8 23
1
L
P
786
771
* 315 7
669 6
2
3
*MC Model Only OR 124 662 5
To Brake SW P 669
To PKB SW L 315
To F/R SW GY 662 811 17
4 B 993 810 16
5 R 810

T
6 811 811 L 811
810 810

7 810 R 853 281 12 35

811 L
122 10

TRACTION CONTROLLER
AF FAN

L 783
411 20
412 19
P 773
G/B 281 851 17
8 GY 122 783 28
G/Y 411 773 27

(RIGHT )
L/R 412
B 106
OR 851 106 1
Y 853

+B
R
To Light & Turn SW
-B

To Seat SW
D

121 10
TRACTION CONTROLLER

L 782
P 772
9 GY 121
782 28
772 27
(LEFT)

+B

10 -B
11
12

FUSIBLE LINK VB
900 900
W/R 900 -B
0.5A

13 GY 123
PUMP CONTROLLER

P 771
L 787
L 781 781 21
R 105 771 20
787 12
CONTROLLER GND
B 990
105 2
123 1

BSM0625

EL-24
 WIRING DIAGRAM

Lighting System
IGN SW
HEADLAMP TURN LAMP
CABIN HARN RH RH
110 120 120 110 FUSE BOX
127 127
OFF ON RE START BAT
METER
127 127 Y W 100 5A 740 Y
120 120 GY OPT

GND
BAT
10A 520 SB

IGN
110 110 P
LIGHT
10A 401 R 516 520 981
225 223 KEY SW 520 516
DIODE 20A 110 P
981

SB
W

B
IGN 200 213 409 251
225 R CONT
GY 120 10A 125 GY
223 W
OPT

G
R
R
Y
222 224 224 222 5A 516 W
METER
5A 727 L
901 901 LIGHT 409 213
10A 451 G 251 200
200 213 409 251
TAIL LAMP RELAY 221 221 GUARD
251 200 HARNESS RH
222 409 213

G
R

R
W

Y
224 R
901 B 1
221 OR 2
3
4
5
431 431
430 430 6
HORN RELAY 432 432
7
430 R 8
432 Y/L 9
431 W

T
HORN 10

431 W
947 B

727 727

728 728
AF 11
12
AUTO POWER 125 126 126 125
OFF RELAY
728 L
727 L
125 GY
126 G

COMB. SW 13
14
HORN SW 970 432 432 970
15
R
432 Y/L 16
970 B

662 662
F/R SW
661 910 910 661 17
FWD
D

661 L/Y 18
REV
662 GY 19
910 B 20
21
22
411 413 413 411
23
900 412 412 900
24
213 222 222 213
25
LIGHT&TURN SW
OFF TAIL HEAD R L
900 900 W/R
222 222 W 212 410
W
R
Y
L

213 213 Y 201 252 GUARD

413 413 R HARNESS LH
201 212 410 252
411 411 G/Y 201 252
412 412 L/R 212 410

BACK OPERATION
LAMP SW
OR
B/R

L/B

OR
BR

381
W
B
G
G

R
Y
P
Y
B

Y
L
L

241 G 315 935 382

380
242 R
480 710 711 990 740 311 905 728 382 380 380 381 382 315 935 201 212 410 252
243 G
973 B 380
315 935 382
381
243 241 241 243
SEAT BELT SW

PKB INPUT
IGN
PKB SW
RS232C(C_to_M)
RS232C(M_to_C)
GND
BAT
BRAKE FLUID SW

BUZZER DRIVE

242 973 973 242

390 905 480 311 740 728

711 710 380 990
Power Supply
Signal 20 19 15 11 HEADLAMP TURN LAMP
WARNING PKB SW LH LH
Earth 9 6 5 4 2 1
COMB. METER BUZZER
BSM0626

EL-25
 WIRING DIAGRAM

Lighting System (Cont’d)

CONTACTOR UNIT REAR COMB.
BATTERY SW 441 441
CURRENT VB To Pump Controller (PUMP VB ) LAMP RH
220 220
FS1 SEN
OR 220
P 441
STOP/TAIL
452 452
400 400
W 100 464 464
R 400
100
BATTERY GY 464
G 452 REVERSE

900 900 FUSIBLE LINK 253 253

404 404
W/R 900
R 253
0.5A TURN
982 982 G 404
B 982 To Pump Controller
(PUMP -B )
0.3A

L 410 28 FLASHER POWER IN

R 253 31 R FLASHER OUT
1 G 450 29 FLASHER POWER OUT
2 W 254 30 L FLASHER OUT
3 Y 127
4 B 992 To VCM Controller (CN A)
5 BR 710
6 L/B 711
7 G 126
8
9
L/Y 661
CONTROLLER GND L 315

T
10 B 990 P 669 To VCM Controller (CN B)
GY 662
B 993

R 105 To Pump Controller

11
AF B
G/Y
106
411 To Traction Controller (RIGHT )
12 L/R 412

SUB HARNESS (OPT)

950 505 505 950 950 505

R 505 R 505
B 950 B 950
13
14
15 505 950
R
16
982 521
DC/DC CONVERTER
B 950 OUTPUT (-)
R 505 OUTPUT (+12V)
B 982 INPUT (-)
17 L 521 INPUT (+IGN48V)
D

18 361 361
19 BACK BUZZER
360 250
20
21 GY 361
22 G 360
23
24 PATO LAMP
25
G 250
B 989

241 240 240 241 BACK OPERATION LAMP

R 240
G 241

254 254 REAR COMB.

LAMP LH
480 405 405
B/R

GY
PU

BR

442 465
P
B

R
B
P
B

W 254
986 936 669 443 454 TURN
L 405
311 911 986 480 936 669 105 106 443 442 454 465
986 936 669 451 451
401 401
465 465
480
G 451
REVERSE
GY 465
R 401
BRAKE SW DIODE DIODE 442 442
221 221
STOP/TAIL
P 442
BRAKE FLUID SEAT BELT OR 221
SW SW SEAT SW
BSM0627

EL-26
 WIRING DIAGRAM

Traction System
CONTACTOR UNIT
BATTERY SW
CURRENT VB
FS1 SEN
1

W 100 802 804 803 801 801 802 803 804 280 281 280 281 2
3

G/B
GY
100 802 804 803 801 280 281 4

W
P
Y
L
5
BATTERY 6
7
8
9
10
11
12
13
14

15

FUSE BOX 16
BAT 17
METER 18
W 100 5A 740 Y
19
OPT
10A 520 SB 20
To Cabin Harness
IGN SW LIGHT
10A 401 R
110 120 120 110 KEY SW
20A 110 P

T
127 127
OFF ON RE START
127 127 Y IGN
CONT
120 120 GY GY 120 10A 125 GY 21
110 110 P OPT
5A 516 W
METER 22
727
AF 5A
10A
LIGHT
451
L

G
To Rear Comb Lamp LH
23

727 727

728 728
AUTO POWER 125 126 126 125
OFF RELAY
728 L
727 L
125 GY
126 G
R
COMB. SW

662 662
D

661 910 910 661

F/R SW
24
FWD
661 L/Y
REV
662 GY
910 B
25

To Rear Comb 26
Lamp LH
B/W
B/R

B/R
B/Y

B/Y
L/B

OR

OR
BR

PU
GY

382
PU

BR

905 740 728 442 465 667 664 660

Y

B
L
L

P
B
L

711 710 990 315 935 382

936 669 443 454 932 665 934
728 905 740 710 711 990 382 382 315 935 936 669 443 442 454 465 660 664 934 665 667 932
936 669 932 665 934
20 19 11 315 935 382
9 6 2 1 667 664 660
RS232C(C_to_M)
RS232C(M_to_C)
BAT

GND
IGN
PKB INPUT

PKB SW

Power Supply
Signal DIODE DIODE
CAN BRAKE SW
Earth PKB SW ACCEL SEN
COMB. METER
BSM0628

EL-27
 WIRING DIAGRAM

Traction System (Cont’d)

1
CONTROLLER
2 Y 127
3 G 126 CN A CN A
4 BR 710 786 35
5 L/B 711 781 23
711 34
6 W 804 771 22
710 33
7 P 803 126 32
8 L 802
9 Y 801
801 7
10 B/Y 660 665 18
802 6
11 PU 664 664 17

VCM CONTROLLER
803 5
12 B/R 934
804 4
13 B/W 665
127 3
14 OR 129
129 2
B 992 660 13
934 992 1 24
L 781

15
*MC Model Only L
P
786
771
* CN B CN B
124 993 8 23
16 OR 124 315 7
17 L/Y 661 669 6
18 L 315 662 5
19 P 669 661 4
20 GY 662
To Light & Turn SW B 993
900 900 FUSIBLE LINK

T
W/R 900
0.5A
982 982
21 B 982 281 12
To DC/DC Converter 0.3A
843 22
122 10

TRACTION CONTROLLER
22 G/B 281
23
AF GY
R
122
843
B 829
W 827
826 783 829 5 28
L
825 773 27
R

(RIGHT )
L 783 826 14
P 825 25
W

773
R

R
B

827 13
843 842 829 827 826 825 B 106 106 1
842 843 829 827 826 825
843 842 829 827 826 825 W
+B
V
R
-B
W U
V
TEMP SEN REVO SEN U

TRACTION MOTOR RH 845 22

121 10
TRACTION CONTROLLER
D

24 GY 121
R 845
B 833
650 6
W 832
782 833 5 28
L 831
772 27
R 830
(LEFT)

25 L 782 831 14
P 772 830 25
832 13
990 B R 650

CONTROLLER W +B
GND
V
-B
U
26

VB
W

W
R

R
B

845 844 833 832 831 830

-B
844 845 833 832 831 830
845 844 833 832 831 830 GY 123
PUMP CONTROLLER
R
B

P 771
L 787
W 106 105 781 21
L 781
771 20
R 105 787 12
V
TEMP SEN REVO SEN U ACCEL OFF REGEN SELECT
650 105 2
R
651 123 1
TRACTION MOTOR LH BR
EU&NORTH AMERICA:CONNECTED
JPN&GOM:UNCONNECTED

SEAT SW BSM0629

EL-28
 WIRING DIAGRAM

Pump and Power Steering System

CONTACTOR UNIT 1
BATTERY SW
CURRENT VB 2
FS1 SEN 3
4
5
W 100 802 804 803 801 801 802 803 804 280 281 280 281 6
7
8

G/B
BATTERY

GY
802 804 803 801 280 281

W
P
Y
L
100 9
10
11
12
13
14
15
16
17
18
19
FUSE BOX To Rear Comb 20
BAT Lamp LH 21
METER 22
W 100 5A 740 Y
OPT
10A 520 SB To Cabin
IGN SW LIGHT Harness
10A 401 R
110 120 120 110 KEY SW
127 127 20A 110 P
OFF ON RE START
127 127 Y IGN
CONT
120 120 GY GY 120 10A 125 GY
110 110 P OPT
5A 516 W

T
METER
718 718 5A 727 L 23
978 715 715 978 LIGHT 24
10A 451 G
STEERING 716 717 717 716 25
ANGLE SEN 26
12V 715 G/R 27
GND
SIG A
978
716
B
Y/BR
AF
SIG B 717 R
SIG N 718 L/W

727 727

728 728
28
AUTO POWER 125 126 126 125 29
OFF RELAY
728 L
727 L
R
125 GY
126 G

COMB. METER
30
IGN 728 L 31
D

PKB INPUT 905 L 32

BAT 740 Y 33
RS232C(C_to_M) 710 BR
RS232C(M_to_C) 711 L/B
GND 990 B

20 711
19 710

34
6 905
35
705 704 724
GY
W

R
B
G

L
B

INST SUB 960 746 744 734

2 740 HARNESS
1 11 990 728 960 704 705 724 734 744 746

960 746 744 734

705 704 724
BR/W
B/Y
GY

L
W

733 723
W

L
R
B
G

B
L
B

705 704 960 722 732

940 743 742
960 704 705 724 734 744 746 742 743 940 732 722 733 723
940 743 742
705 704 960 722 732 733 723

Power Supply
Signal
TILT ANGLE LIFT PRESSURE
CAN SEN SEN LIFT DOWN PS KNOB
SOL VALVE SOL VALVE
Earth TILT HORI S/V TILT HORI SW (PS.C)
BSM0630

EL-29
 WIRING DIAGRAM

Pump and Power Steering System (Cont’d)

1 G/R 715
2 B 978
3 Y/BR 716 CONTROLLER
4 R 717
5 L/W 718
6 G 126 CN A CN A
7 BR 710 786 718 12 35
8 L/B 711 781 23
711 717 11 34
9 B 992 771 22
710 716 10 33
10 W 804 704 21
126 978 9 32
11 P 803 743 20
715 8
12 L 802 670 19
801 7

VCM CONTROLLER
13 Y 801 802 6
14 OR 129
450 803 5 28
15 B 960 705 16
960 804 4 27
16 W 704 742 15
940 127 3 26
17 G 705 671 14
979 129 2 25
18 Y 127
19 992 1
Y 742
20 W 743 CN B CN B
21 B 940
22 G 450 124 993 8 23
L 781 732 22
723 21
*MC Model Only L
P
786
771
*
671 P P 671 724 19
670 Y/L Y/L 670 722 18
979 GY GY 979

CONTROLLER
671 671 671 671 GND
TIRE ANGLE TIRE ANGLE
979 979 SEN (4W) 670 670 SEN (3W) 990 B

T
670 670 979 979
23 OR 124
24 GY 724
25 L 732

TRACTION CONTROLLER
26 B/Y 722
27 BR/W 723 853 281 12 35
AF FUSIBLE LINK
B 993
122 10
900 900
To Light & Turn SW W/R 900
0.5A

(RIGHT )
982 982
To DC/DC Converter B 982 851 17
0.3A
28 G/B 281
29 GY 122 +B
B 106 106 1
775 977
OR 851 -B
785
Y 853
R
MAINTE CONN
977 B
CAN H 785 L

TRACTION CONTROLLER
CAN L 775 P

30
31
D

32 121 10
33 676 20
SEAT SW
677 19
678 7
(LEFT)

106 B
105 R 679 16
GY 121
W 676 +B
BR 677
Y/R 678 746 1
-B
34 LG 679
35 B 746

PUMP MOTOR
VB
TEMP SEN 841 841 -B
Y/R
BR

LG
W

840 840
679 678
PUMP CONTROLLER

677 676 675 840 W P 771

841 R L 787 840 820 8 23
823 15
676 677 678 679 675 L 781 841 821 7 22
823 823 822 14
GY 123 781 21
677 676 675 822 822 105 771 20
R 787 12
679 678 821 821 840
W
REVO SEN 820 820 841
R
823 B B 823 105 2
822 W W 822 123 1
821 L L 821 U V W
820 R R 820
LIFT TILT 3RD 4TH COM
U
V
CONTOROL VALVE SW W
BSM0631

EL-30
 WIRING DIAGRAM

Joystick Control System

CONTACTOR UNIT
BATTERY BATTERY SW
CURRENT VB
FS1 SEN
To Pump Controller (PUMP VB )

280 281
W 100 802 804 803 801 801 802 803 804 280 281 1
To Pump Controller
(PUMP -B ) 280 281 2

G/B
GY
802 804 803 801 3

W
100

P
Y
L
4
5
6
FUSE BOX 7
BAT 8
METER 9
W 100 5A 740 Y
OPT
10A 520 SB To Cabin 10
IGN SW LIGHT Harness 11
10A 401 R To Rear Comb
110 120 120 110 KEY SW Lamp LH
20A 12
127 127 110 P
OFF ON RE START 13
127 127 Y IGN 14
CONT 15
120 120 GY GY 120 10A 125 GY
110 110 P 16
OPT
5A 516 W 17
727 727 METER 18
5A 727 L 19
728 728 LIGHT 20
10A 451 G
21
AUTO POWER 125 126 126 125 22
OFF RELAY 23
728 L 24
727 L

T
125 GY
126 G
COMB. METER
IGN 728 L
PKB INPUT 905 L
BAT
RS232C(C_to_M)
740
710
Y
BR
AF
RS232C(M_to_C) 711 L/B
GND 990 B To Controller GND
To Fusible Link
20 711
19 710
25
26
6 905 27
28
29
30
R
2 740 To Horn Relay
1 11 990 728
D

680
749 971 763 906
691 688 685 682
W/R

BR/W
L/W

745 750 761 604

G/B

BR/Y
B/Y

Y/L

Y/L
OR
GY
GY
GY

G
R

R
Y

747 433 762 615 690 687 684 681

SUB HARNESS
750 749 762 761 763 745 747 604 615 971 433 681 682 680 906 684 685 687 688 690 691
747 433 762 615 690 687 684 681
W/R

BR/W
L/W

G/B

BR/Y
B/Y

Y/L
Y/L
OR
GY
GY
GY

G
R
R

R
Y

745 750 761 604 691 688 685 682

749 971 763 906
680
OR
GY
GY

Y/L
R

W/R

BR/W
L/W

G/R
G/B

Y/G
Y/R
B/Y

BR/Y

683 685 686 688 689 691

Y/L

680 682
GY

G
R
R
Y

B
L

761 763 762 604 615 906 681 902 684 903 687 904 690
762 761 763 604 615 681 682 680 906 684 685 683 902 687 688 686 903 690 691 689 904
JOYSTICK
OPT 761 763 762 604 615 906 681 902 684 903 687 904 690
680 682 683 685 686 688 689 691
Power Supply 762 761 763
Signal R
N
CAN
F
Earth TILT HORIZONTAL HORN SW LIFT SEN TILT SEN 3RD SEN 4TH SEN
SW EMERGENCY SW
F/R SW JOYSTICK BSM0632

EL-31
 WIRING DIAGRAM

Joystick Control System (Cont’d)

CONTROLLER

CN A CN A
To Controller GND B 992
1 Y 127 781 23
711 34
2 OR 129 771 22
710 33
3 G 126 126 32
4 BR 710
5 L/B 711 801 7
6 W 804 802 6
7 P 803 803 5
8 L 802 804 4

VCM CONTROLLER
9 Y 801 3
127
L 781
129 2
10 P 771 1
992
11
CN B CN B
12 OR 124
13 W 681 124 23
691 15
14 G/B 682 690 14
15 L 680 688 13
16 W/R 906 762 5
687 12
17 G 684 761 4
685 11
18 Y/L 685 906 3
684 10
19 BR/W 687 680 2
682 9
20 R 688 681 1
21 BR/Y 690
22 G 691
23 GY 762
24 L/W 761
PUMP MOTOR

T
TEMP SEN 841 841
840 840

PUMP CONTROLLER
840 820 8 23
W 823 15
840 P 771 841 821 7 22
822 14
841 R L 787 781 21
L 781 771 20
12
AF 823
822
823
822
GY
R
123
105
787

821 821 840

W 105 2
820 820 841
REVO SEN R 123 1
823 B B 823
822 W W 822 U V W
821 L L 821
25 820 R R 820
26
U
27
28 V
29
W
30
R
GY 749
SEAT SW To Traction Controller (LEFT )
OR 747

105 R
106 B G/B 281
To Traction Controller (RIGHT )
B 106
D

To Controller GND

JOYSTICK CONTROL VALVE C1 SOL

L 614 L
630 631 631 630 G/Y 612 G/Y
LIFT SOL A 632 633 633 632
612 612
634 635 635 634 614 614
636 637 637 636
TILT SOL A L 631 L
R 630 R JOYSTICK CONTROLLER
L 633 L
3RD SOL A W 632 W CN B CN B
L 635 L
P 634 P P 774
W 637 W L 784 784 774 4 13
4TH SOL A Y 636 Y GY 603
Y 604 603 2
604 1
B 946
622 623 623 622 L 614
LIFT SOL B 624 625 625 624 G/Y 612
625 627 627 625 L 631
628 629 629 628 CN C CN C
OR 622
TILT SOL B W 623 W R 630 946 633 8 23
624 15
OR 622 OR L 633 632 7
628 14
W 625 W W 632 626 6
637 13
G 624 G P 634 614 635 5 20
3RD SOL B 636 12
W 627 W L 635 612 634 4 19
BR 626 BR Y 636 622 3
W 629 W W 637 631 2
4TH SOL B PU 628 PU G 624 630 1
BR 626
PU 628 BSM0633

EL-32
 MOTOR MECHANISM

SECTION MM
CONTENTS

T
SERVICE DATA AND SPECIFICATIONS ........ MM-2 PUMP MOTOR ................................................ MM-11
General Specifications ................................. MM-2 Removal ..................................................... MM-11
Tightening Torque ........................................ MM-2 Installation 1N1 .......................................... MM-12
AF
General Specifications ................................. MM-3 Installation A1N1 ........................................ MM-12
Tightening Torque ........................................ MM-3 MOTOR DISASSEMBLY AND ASSEMBLY .. MM-13
TROUBLE DIAGNOSES AND Disassembly 1N1 ....................................... MM-13
CORRECTIONS ................................................ MM-4 Assembly .................................................... MM-14
PRECAUTIONS AND PREPARATION ............ MM-6 Inspection ................................................... MM-15
Precautions .................................................. MM-6 Disassembly A1N1 ..................................... MM-16
Special Service Tool ..................................... MM-6 Assembly .................................................... MM-17
TRACTION MOTOR .......................................... MM-7 Inspection ................................................... MM-17
R
Removal ....................................................... MM-7
Removal ....................................................... MM-8
Installation 1N1 ............................................. MM-9
Installation A1N1 ........................................ MM-10
D
 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications
TRACTION MOTOR PUMP MOTOR
Applied model 1N1 series 1N1 series
Applied model
Type Open-self AC motor S1N1 & 1N1 G1N1 & JG1N1 36V model
Model MTA450-1 Type Open-self AC power
Rated voltage V 36 48
Model MPA480-01 MPA4110-01
Rated output kW/h 4.0 5.0
Rated voltage V 48 48 36
Weight kg (lb) 35 (77) Rated output kW/h 8.0 11.0 8.0
Maker HITACHI
Weight kg (lb) 39.5 (87.1) 47 (104)
Maker HITACHI

Tightening Torque
TRACTION MOTOR PUMP MOTOR
MTA450-1 MPA480-01/MPA4110-01
Unit Unit
N•m kg-m ft-lb N•m kg-m ft-lb

Motor assembly Motor assembly

T
Front bracket to rear bracket fixing 11 - 14 1.2 - 1.4 9 - 10 Front bracket to rear bracket fixing 19 - 23 2.0 - 2.3 14 - 16
through bolt through bolt
Terminal fixing bolt 5.1 - 6.6 0.52 - 3.8 - 4.8 Terminal fixing bolt 5.1 - 6.6 0.52 - 3.8 - 4.8
AF 0.67 0.67
Motor installation Motor installation
Motor-to-drive unit fixing bolt Short 39 - 52 4.0 - 5.3 29 - 38 Mounting bracket fixing bolt Frame 39 - 52 4.0 - 5.3 29 - 38
bolt side
Long 39 - 50 4.0 - 5.0 29 - 36 Motor 39 - 50 4.0 - 5.0 29 - 36
bolt side
Drive unit fixing bolt M14 150 - 16 - 19 111 -
bolt 190 140
R
M8 19 - 25 2.0 - 2.5 14 - 18
bolt
D

MM-2
 SERVICE DATA AND SPECIFICATIONS

General Specifications
TRACTION MOTOR PUMP MOTOR
Applied model A1N1 series A1N1 series

Type Open-self AC motor Applied model

AS1N1 &
AG1N1 36V model
Model TSA200-100-209 A1N1

Rated voltage V 36 48 Type Open-self AC power

Rated output kW/h 5.2 7.1 TSA200-140-
Model TSA200-160-208
207
Weight kg (lb) 35 (77)
Maker SCHABMULLER (Germany) Rated voltage V 48 48 36
Rated output
14.5 14.6 10.7
kW/S3-20%
Weight kg (lb) 48 (106) 52 (115)
Maker SCHABMULLER (Germany)

Tightening Torque
TRACTION MOTOR PUMP MOTOR
TSA200-100-209 TSA200-140-207/
Unit TSA200-160-208

T
N•m kg-m ft-lb Unit
N•m kg-m ft-lb
Motor assembly
Front bracket to rear bracket fixing 11 1.12 8.1 Motor assembly
through bolt
AF Front bracket to rear bracket fixing
through bolt
15 1.53 11.1
Terminal fixing nut 13 - 17 1.4 - 1.7 10 - 12
Terminal fixing nut 13 - 17 1.4 - 1.7 10 - 12
Motor installation
Motor installation
Motor-to-drive unit fixing bolt Short 38 - 52 3.9 - 5.3 29 - 38
bolt Mounting bracket fixing bolt Frame 38 - 52 3.9 - 5.3 29 - 38
side
Long 38 - 52 3.9 - 5.3 29 - 38
bolt Motor 39 - 50 4.0 - 5.0 29 - 36
side
R
Drive unit fixing bolt M14 150 - 16 - 19 111 -
bolt 190 140
M8 19 - 25 2.0 - 2.5 14 - 18
bolt
D

MM-3
 TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS

CAUTION:
• The following tables list only typical examples. To perform an accurate diagnosis, carefully listen to the
user's complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.
• The same symptoms as the following may occasionally be caused by the control system. Perform the
trouble diagnosis for not only mechanical cause but also control system cause. For the trouble diagnosis
of control system, refer to the CS section.

Condition Probable cause Corrective action

• Check by measuring the voltage of

• Single-phase drive controller output terminal or motor
cable terminal.
Speed suddenly drops
• Check battery charge condition, and
• Voltage drops
charge.
• Overload • Stop overload drive.
• Check battery charge condition, and
• Voltage drops
charge.
Motor overheats
• Overload • Stop overload drive.
• Air flow orifice plugged with dust • Check and clean.
At motor unit, axis cannot • Disassemble and replace with new

T
• Burnout bearing
Motor with be rotated manually. ones.
load (on the Motor stops • Malfunction of resistance balance or
vehicle) • Disassemble and check. Repair or
Nasty smell from motor insulation on each phase (with cable
replace as necessary.
terminal disconnected)
AF • Open circuit or short circuit in motor • Disassemble and check. Repair or
cable replace as necessary.
Motor stops
• Check controller. (Refer to CS
• Controller malfunction
section.)
• Check by measuring the voltage of
• Single-phase drive controller output terminal or motor
Noise/vibration while driving cable terminal.
R
• Looseness of each assembly part • Check and retighten.
Bearing overheats, noise from bearing • Disassemble and replace with new
• Bearing malfunction
(check by proper tools) ones.
• Connect the cable terminals while
D

The rev direction is opposite • Misconnection adjusting to each phase (replace 2

out of 3).

If it is no-load • Gap between stator iron core and • Disassemble and check. Repair or
Whining noise
condition, rotor iron core is unbalanced replace as necessary.
motor turns • Disassemble and check. Repair or
Yoke overheats • Partially short circuit in stator coil
replace as necessary.
• Disassemble and replace with new
Bearing noise • Bearing malfunction
ones.

MM-4
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

• Check controller. (Refer to CS

• Malfunction of battery, controller, and section.)
wiring Check battery charge condition, and
charge.
No rotation sound • Open circuit in wiring • Check and repair, or replace.
• Disassemble and check. Replace as
• Open circuit in stator coil
necessary.
• Loose terminal connection • Tighten completely.
Even if it is • Check by measuring the voltage of
no-load • Single-phase drive controller output terminal or motor
condition, cable terminal.
motor does
not turn When turning by hand, motor turns in • Open circuit in single-phase of wiring
• Check and repair.
any direction between motor and controller
• Open circuit in single-phase of stator • Disassemble and check. Replace as
coil necessary.
• Loose terminal connection • Tighten completely.
• Disassemble and replace with new
• Damaged bearing(s)
Whining noise is heard, but motor does ones.
not turn • Prying of rotation axis by looseness of • Disassemble and check. Properly
bolts assemble and retighten bolts.

T
AF
R
D

MM-5
 PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
CAUTION:
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• When removing or installing motor assembly, be sure to turn
the key switch OFF and disconnect battery plug to cut power
supply in advance. This prevents motors from unexpectedly
rotating, avoiding danger.
• Always assemble parts in a clean work place to prevent
foreign matter from entering assembly.
• Before disassembling, be sure to clean off the parts.
• Do not use water or cleaning oil to clean any part. Use
compressed air or wipe with dry rag.
• Carefully handle removed motor so as not to drop or impact
the motor.

NOTE:
Be sure to use the special service tool when lifting and supporting
traction motor.

T
Special Service Tool
Tool number
Tool name
AF
Description

KV991B0400 Lifting and supporting traction motor

Eyebolt
R
MMT0001 M8×1.25
D

MM-6
 TRACTION MOTOR
TRACTION MOTOR

COMPONENT PARTS
1N1 series

T
AF
MMM0013

Removal
R
1. Remove battery from vehicle. Refer to BC section.
2. Remove floor mat and floor panel. Refer to BF section.
3. Remove pedal bracket. Refer to BR section.
4. Disconnect cables connected to traction motor.
D

5. Remove traction motor and drive unit as a unit. Refer to DU

section. Then remove traction motor from drive unit.

MMM0014

MM-7
 TRACTION MOTOR

COMPONENT PARTS
A1N1 series

T
AF
Removal
R
1. Remove battery from vehicle. Refer to BC section.
2. Remove floor mat and floor panel. Refer to BF section.
3. Remove pedal bracket. Refer to BR section.
4. Disconnect cables connected to traction motor.
D

5. Remove traction motor and drive unit as a unit. Refer to DU

section. Then remove traction motor from drive unit.

MM-8
 TRACTION MOTOR

Installation 1N1
To install, reverse the order of removal. Observe the following:
For inspection of revolution sensor and temperature sensor, refer to
CS section.
Traction motor-to-drive unit securing bolt:
Long bolt
: 39 - 50 (4.0 - 5.0, 29 - 36)
Short bolt
: 38 - 52 (3.9 - 5.3, 28 - 38)

CAUTION:
When installing motor to drive unit, be careful not to damage oil
seal of front bracket at shaft spline and drive unit.

T
AF
R

MMM0017
D

MM-9
TRACTION MOTOR

Installation A1N1
To install, reverse the order of removal. Observe the following:
For inspection of revolution sensor and temperature sensor, refer to
CS section.
Traction motor-to-drive unit securing bolt:
Long bolt
: 38 - 52 (3.9 - 5.3, 29 - 38)
Short bolt
: 38 - 52 (3.9 - 5.3, 28 - 38)

CAUTION:
When installing motor to drive unit, be careful not to damage oil
seal of front bracket at shaft spline and drive unit.

T
AF
R

MMM0017
D

MM-10
 PUMP MOTOR
PUMP MOTOR

COMPONENT PARTS
(A)1N1 series

T
AF
MMM0021

CAUTION:
• Always relieve oil pressure remaining in hydraulic lines.
R
• When cutting off pipes, be careful to avoid splashing
hydraulic fluid to other parts by covering with waste cloths
around the cutting areas.
• When connecting pipes, be careful that foreign material does
D

not enter into pipes.

• Clamp suction hose so that the hydraulic fluid does not leak.

Removal
1. Remove floor mat and floor board. Refer to BF section.
2. Remove brake pedal bracket. Refer to BR section
3. Remove piping from hydraulic pump.
4. Disconnect motor cables.
5. Lift up the motor with hydraulic pump.
6. Remove bracket hydraulic pump from motor.

MM-11
 PUMP MOTOR

Installation 1N1
To install, reverse the order of removal. Observe the following:
Pump motor mounting bracket fixing bolt:
Frame side
: 39 - 52 N•m (4.0 - 5.3 kg-m, 29 - 38 ft-lb)
Pump motor side
: 39 - 50 N•m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Oil pump fixing bolt:
: 24.5 - 31.3 N•m (2.5 - 3.1 kg-m, 18 - 23 ft-lb)

CAUTION:
When installing the oil pump to the pump motor, apply the
molybdenum disulfide grease to the oil pump shaft spline.

Connector tightening torque (discharge side)

: 79 - 88 N•m (8.1 - 8.9 kg-m, 59 - 64 ft-lb)
Connector tightening torque (suction side)
: 92 - 108 N•m (9.4 - 11.0 kg-m, 68 - 79 ft-lb)

T
Installation A1N1
To install, reverse the order of removal. Observe the following:
Pump motor mounting bracket fixing bolt:
AF Frame side
: 39 - 52 N•m (3.9 - 5.3 kg-m, 29 - 38 ft-lb)
Pump motor side
: 39 - 50 N•m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Oil pump fixing bolt:
: 25 - 31 N•m (2.6 - 3.1 kg-m, 19 - 23 ft-lb)
R
CAUTION:
When installing the oil pump to the pump motor, apply the
molybdenum disulfide grease to the oil pump shaft spline.
D

Connector tightening torque (discharge side)

: 79 - 88 N•m (8.1 - 8.9 kg-m, 59 - 64 ft-lb)
Connector tightening torque (suction side)
: 92 - 108 N•m (9.4 - 11.0 kg-m, 68 - 79 ft-lb)

MM-12
 MOTOR DISASSEMBLY AND ASSEMBLY
MOTOR DISASSEMBLY AND ASSEMBLY

Disassembly 1N1
COMPONENT PARTS
1N1 series

T
AF
R
D

MMM0015

MM-13
MOTOR DISASSEMBLY AND ASSEMBLY

Disassembly (Cont’d)
1. Remove sensor cover.
2. Remove revolution sensor.

MMM0016

3. Remove motor cable terminal.

4. Put the matching marks between end bracket and stator and
between stator and front bracket, and then remove through
bolts.
5. Remove end bracket.
6. Remove rotor assembly.
CAUTION:

T
Be careful not to damage oil seal of front bracket at shaft
spline.

7. Remove stator assembly from front bracket.

AF 8. Pull out bearing from rotor assembly shaft using bearing puller if
necessary.

Assembly
To assemble, reverse the order of disassembly. Observe the
following:
R
Terminal fixing screw:
: 5.1 - 6.6 N•m (0.52 - 0.67 kg-m, 3.8 - 4.8 ft-lb)
Front bracket to rear bracket fixing through bolt:
Traction motor
: 11 - 14 N•m (1.2 - 1.4 kg-m, 9 - 10 tf-lb)
D

Pump motor
: 19 - 23 N•m (2.0 - 2.3 kg-m, 14 - 16 ft-lb)

• When installing the bearing to rotor assembly, drive the pipe in

using a piece of metal. The pressure should be applied to the
inner race side of the bearing.

CAUTION:
When heating the bearing with a heater, be careful not to
increase the bearing temperature to above 60 to 80°C.

MMM0018

MM-14
MOTOR DISASSEMBLY AND ASSEMBLY

Assembly (Cont’d)
Install the oil seal in the front bracket of traction motor.
Ensure that the oil seal is pressed against the endstop.
The flat face of the oil seal should be faced towards the inside.

MMM0019a

• When assembling rotor assembly, always assemble the wave

washer facing it toward the front bracket contact surface of
bearing. Before installing to the front bracket, apply a thin film of
MP grease to wave washer in order to prevent it from dropping.
• For the parts that utilized matching marks during disassembly,
align matching marks and assemble them.

T
MMM0019
AF • A: For revolution sensor, the installation direction is decided: the
lead wire side of revolution sensor is faced to motor rear side.
R

MMM0020
D

Inspection
For inspection of revolution sensor and temperature sensor, refer to
CS section.

MM-15
 MOTOR DISASSEMBLY AND ASSEMBLY

Disassembly A1N1
COMPONENT PARTS

T
AF
R
D

(1) Screw (2) Cover (3) Spur wheel (4) Screw

(5) Revolution sensor (6) Tolerance ring (7) Nut (8) Schnorr disk
(9) Nut (10) Disk (11) Terminal board (12) Terminal bolt
(13) Temperature sensor (14) Through bolt (15) Drive end shield (16) Non-drive end shield
(17) Rotor (18) Wave washer (19) Bearing (20) O-ring
(21) Cir-clip (22) Bearing (23) O-ring (24) Cir-clip
(25) Wave washer (26) Stator

MM-16
MOTOR DISASSEMBLY AND ASSEMBLY

Disassembly (Cont’d)
9. Remove the cover.
10. Remove the revolution sensor and spur wheel.
(1) Revolution sensor
(2) Spur wheel
(3) Tolerance ring

11. Remove terminal board for motor cables.

12. Put the matching marks between drive end shield and stator
and between stator and non-drive end shield, and then remove
the through bolts.
13. Remove the drive end shield.
14. Remove rotor assembly.
CAUTION:

T
Be careful not to damage oil seal of front bracket at shaft
spline.

15. Remove the non-drive end shield from stator.

AF 16. Remove the cir-clip and disassemble the rotor assembly, if
necessary.

Assembly
Assemble in the reverse order of disassembly. Observe the
following:
R
Terminal fixing screw:
: 13 - 17 N•m (1.4 - 1.7 kgf-m, 10 - 12 ft-lb)
Front bracket to rear bracket fixing through bolt:
Traction motor
: 11 N•m (1.12 kgf-m, 8.1 ft-lb)
D

Pump motor
: 15 N•m (1.53 kgf-m, 11.1 ft-lb)

• Should it be necessary to remove the bearings in case of repair,

they should be replaced. In any case the sealing parts have to be
replaced.
• If a bearing which is to be replaced has only one sealing lip, this
should be greased with quality bearing grease.
• After approximately 10,000 operating hours the bearings have to
be replaced.

Inspection
For inspection of revolution sensor and temperature sensor, refer to
CS section.

MM-17
MOTOR DISASSEMBLY AND ASSEMBLY

T
AF
R
D

MM-18
 DRIVE UNIT

SECTION DU
CONTENTS

T
SERVICE DATA AND SPECIFICATIONS ......... DU-2 DRIVE UNIT ....................................................... DU-5
General Specifications 1N1 ........................... DU-2 Reduction Gear Assembly ............................. DU-5
Tightening Torque 1N1 .................................. DU-2 Removal ........................................................ DU-6
AF
General Specifications (J)A(G)1N1 ............... DU-2 Installation ..................................................... DU-7
Tightening Torque (J)A(G)1N1 ...................... DU-2 Component Parts .......................................... DU-8
TROUBLE DIAGNOSES AND Disassembly ................................................ DU-10
CORRECTIONS ................................................. DU-3 Assembly ..................................................... DU-12
Trouble Diagnoses ........................................ DU-3 Inspection .................................................... DU-15
PRECAUTIONS AND PREPARATION ............. DU-4
Precautions ................................................... DU-4
Special Service Tool ...................................... DU-4
R
D
 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications 1N1

1N1 series

Type Half floating

Reduction gear type Planetary gear
Gear ratio 24.1
Gear oil type SAE 80W / API GL4
Oil capacity (US qt, lmp qt)/one side 0.4 (3/8, 3/8)
Unit weight without traction motor
38 (84)
kg ( b)/one side

Tightening Torque 1N1

Unit N•m kg-m ft-lb

Drive unit fixing bolt 150 - 190 16 - 19 111 - 140

Spacer fixing bolt 19 - 25 2.0 - 2.5 14 - 18
Drain plug 20 - 29 2-3 14 - 22

T
Filler plug 20 - 29 2-3 14 - 22

General Specifications (J)A(G)1N1

AF
A1N1 and JAG1N1
series

Type Half floating

Reduction gear type Planetary gear
Gear ratio 24.1
R
Gear oil type SAE 80W / API GL4
Oil capacity (US pt, lmp pt)/one side 0.35 (0.74, 0.62)
Unit weight without traction motor
38 (84)
kg (lb)/one side
D

Tightening Torque (J)A(G)1N1

Unit N•m kg-m ft-lb

Wheel nut 167 - 226 17 - 23 123 - 166

Drive unit fixing bolt 150 - 190 16 - 19 111 - 140
Spacer fixing bolt 19 - 25 2.0 - 2.5 15 - 18
Drain plug 20 - 29 2.1 - 2.9 15 - 21
Filler plug 20 - 29 2.1 - 2.9 15 - 21

DU-2
 TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS

Trouble Diagnoses
REDUCTION GEAR

Condition Possible cause Corrective action

Oil leakage Distinguish between oil staining and oil leakage, and locate the point of leak, then take proper
corrective action.
• Worn, faulty, or improperly installed oil seal. Repair or replace.
• Loose gear carrier mounting bolts. Retighten, or replace gasket.
• Faulty gasket. Replace gasket.
• Loose filler plug or drain plug. Retighten.
• Worn, faulty, or improperly installed axle hub oil Repair or replace.
seal.
Seizure Replace any seized or damaged parts. Check related parts for condition. Repair or replace them if
necessary.
• Bearing seizure. Replace.
• Insufficient oil, or use of improper oil. Add or replace as specified.
Unusual noise • Pitted or worn gear tooth surface, or broken Replace.
tooth.
• Loose pinion nut, or any other bolts or nuts. Retighten.
• Insufficient oil, or use of improper oil. Add or change oil as specified.
• Abnormally worn or broken gear. Replace.

T
AF
R
D

DU-3
 PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
CAUTION:
• When raising or lowering the vehicle using a jack, refer to GI
section for safe operation.
• Be careful not to drop heavy components or parts. Always
use a lifting device.
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• Always clean working area to prevent foreign matter from
getting into parts being assembled or serviced.
• Use a paper rag rather than a cloth when wiping clean parts.
Use of a cloth rag may leave lint or other foreign matter on
parts being wiped.

Special Service Tool

Tool number
Description
Tool name

99513GA10A Removing or installing bearing nut

T
Tool bearing nut
AF
DUM0001
R
D

DU-4
 DRIVE UNIT
DRIVE UNIT

Reduction Gear Assembly

T
AF
R
D

DUM0002

DU-5
 DRIVE UNIT

Removal
• Remove the carriage.
• Turn the ignition switch OFF, and then disconnect the battery
connector.
• Jack up the vehicle and support it using a piece of wood.
• Remove the following parts.
• Mast (if necessary) (Refer to the LM section)
• Side panel (LH) (Refer to the BF section)
• Floor mat, floorboard (Refer to the BF section)
• Brake pedal (Refer to the BR section)
• PS piping (PS valve side)(Refer to the HD section)
• Mast piping (Refer to the HD section)
• Horn (Refer to the EL section)
• Brake cable, brake piping (drive unit side)
(Refer to the BR section)
• Traction motor cables (Refer to the EL section)
• Tire (Refer to the TR section)
• Drain the gear oil from the drive unit.
• Remove the spacer (between the drive unit and the frame).
• Remove the drive unit with a traction motor as unit. (Disconnect
the connections of the revolution sensor and the temperature

T
sensor.)
• Remove the motor.
DUM0003
AF
R
D

DUM0004

DU-6
 DRIVE UNIT

Installation
Install in the reverse order of removal.
Tightening Torque:

Unit N•m kg-m ft-lb

Drive unit fixing bolt 150 - 190 16 - 19 111 - 140

Spacer fixing bolt 19 - 25 2.0 - 2.5 14 - 18
Drain plug 20 - 29 2-3 14 - 22
Filler plug 20 - 29 2-3 14 - 22

CAUTION:
• Always bleed air from the brake piping.
• When installing the motor to drive unit, be careful not to
damage the oil seal of front bracket at shaft spline and drive
unit.

T
AF
R
D

MMM0017

DU-7
 DRIVE UNIT

Component Parts

T
AF
R
D

DUM0006

DU-8
 DRIVE UNIT

Component Parts (Cont’d)

No Designation Q.ty No Designation Q.ty

1 Drive axle hub 1 20 Bearing nut 1

2 Hub bolt 5 21 Retaining ring 6
3 Bearing 1 22 Pinion gear 3
4 Dust seal 1 23 Bearing 3
5 Dust cover 1 24 Retaining ring 3
6 Taper roller bearing 2 25 Snap ring 1
7 Gear carrier 1 26 Second reduction gear 1
8 Air breather 1 27 Rectangular key 1
9 Filler plug 3 28 Snap ring 1
10 Filler plug 1 29 Bearing 1
11 Locking pin 2 30 Snap ring 1
12 Needle bearing 1 31 Reduction gear 1
13 Spacer 1 32 Rectangular key 1
14 Spacer 1 33 Gear cover 1
15 Circular spring 1 34 Bolt 8

T
16 Ring gear washer 1 35 Bearing 1
17 Bolt 10 36 Input shaft 1
18 Ring gear 1 37 O-ring 1
19 Pinion gear
AF
1 38 Sun gear 1
R
D

DU-9
 DRIVE UNIT

Disassembly
CAUTION:
For disassembly of wet type brake, refer to the BR section.

GEAR COVER REMOVAL (33)

Unscrew the 8 bolts (34) on the cover (33). Two of the holes where
the screws are located have a M10 thread: Screw in two bolts (M10
× 1.25, = 30mm), until the gear cover (33) is extracted.

T
AF
DUM0007

DISASSEMBLY OF THE INPUT SHAFT (36)

It is possible to remove the input shaft (36) without disassembling it.
Using a rubber hammer take out the input shaft beating it from the
internal side of the cover.
R
To remove the reduction gear (31) first release the snap ring (30),
then, using an extractor, pull out the reduction gear (31).
D

DUM0026

DISASSEMBLY OF THE SUN GEAR (38)

NOTE:
Prior to this operation you have to drain the brake chamber oil and to
remove the brake disk unit. Refer to the BR section.

Remove the snap ring (25). To remove the second reduction gear
(26) use an extractor.

DUM0009

DU-10
 DRIVE UNIT

Disassembly (Cont’d)
DISASSEMBLY OF THE RING GEAR (18) AND OF
THE DRIVE AXLE HUB (1)

1. In order to pull out the pinion gears (22) and their bearings (23),
remove the retaining ring (24) and use a special extractor.

T
DUM00010
AF 2. To unscrew the bearing nut (20) a special service tool
(99513GA10A) is required; this tool is described on page DU-4.
To remove the drive axle hub (1) place a pipe [diameter = 32 mm
(1.26 in) and diameter = 40mm (1.57 in)] on the centre of the
M30 thread of the hub, and carefully press it out. At this point slip
off the pinion gear (19).
R

DUM00011
D

3. Unscrew the 10 bolts (17) and pull out the ring gear (18).

DUM00012

DU-11
 DRIVE UNIT

Assembly
After the worn-out parts have been replaced, to assemble the unit
again follow the disassembling process steps in reverse order.

ASSEMBLY OF THE SUN GEAR (38)

1. Key the bearing (29) in its own slot on the gear cover (33),
locking it with the snap ring (28).

DUM00013

2. Place the sun gear (38) on a chock on the press surface. Insert
the gear cover (33) on the pinion, then using a pipe [diameter =
35 mm (1.38 in) and diameter = 41 mm (1.61 in)] placed on the
bearing (29) inner ring, press down the cover.

T
DUM00014

3. Place the rectangular key (27) into its own slot and insert the
second reduction gear (26) on the sun gear (38).
AF Insert the snap ring (25).
R
DUM0027

ASSEMBLING THE RING GEAR (18) AND THE DRIVE

AXLE HUB (1)
D

1. Insert the cup (outer ring) of the taper roller bearings (6) in their
front and rear housings on the gear carrier (7); insert the cone
(inner ring) of bearing (6) onto the hub (1) -possibly heating it up
to 100°C (212°F)-. Insert the dust seal (4) into its housing in the
hub.
Insert the bearing (3) in its own slot in the hub (1).

DUM00016

2. Introduce the dust cover (5) in its own housing on the gear
carrier (7) the wheel side.
Introduce the pre-assembled hub into the casing, insert the
spacer (13) into the shaft and then place the cone of the bearing
(6), pressure-keying it in.
CAUTION:
In order to respect the max end play [0.04 mm (0.0016 in)] it is
possible to ask for a kit with calibrated pieces including 2
bearings (6), spacer (13) and all the required spacers.

DUM00017

DU-12
 DRIVE UNIT

Assembly (Cont’d)
3. Insert the ring-gear washer (16) into the ring gear (18) and fix it
introducing the spring (15) in its housing.

DUM00018

4. Place the disk in the gear carrier (7) and tighten the 10 bolts
(17) with a 80 Nm torque wrench setting.
Torque:
80 N•m (8.2 kg-m, 59 ft-lb)

T
DUM00019
AF 5. Heat the pinion gear (19) up to 80 - 100°C (176°F - 212°F), then
place it onto the hub spline (1) and press it down until the group
is pack-closed; tighten the bearing nut (20) with an adapted key
set at 300 Nm torque wrench, then lay the outer edge low.
Torque:
300 N•m (31 kg-m, 221 ft-lb)
R

DUM00020

6. Insert the pinion gears pre-mounted with their bearings

D

(22+23+21+21) into the 3 axes of the pinion carrier (19), then

lock them with the retaining rings (24), one for each pinion gear.

DUM00021

DU-13
 DRIVE UNIT

Assembly (Cont’d)
ASSEMBLING THE INPUT SHAFT (36)
1. Key the bearing (35) onto the input shaft (36), then place the
rectangular key (32) into its own slot on the shaft, insert the
reduction gear (31), and finally lock all with the snap ring (30).

DUM0026

2. Insert it into the housing in the cover (33).

T
DUM00023
AF ASSEMBLY OF THE COVER (33)
Lay a coat of sealant on the gear carrier contact surface (7) and key
the gear cover (33) onto the casing centring it on the 2 pins (11) and,
using a rubber hammer.
Insert the 8 bolts (34) into their own seats and tighten them at 40
Nm torque wrench setting.
Torque:
40 N•m (4.1 kg-m, 30 ft-lb)
R
D

DUM00024

DU-14
 DRIVE UNIT

Inspection

The drive unit is supplied without oil. For oil filling operations, follow
these specifications:

Use refill plug for filling, oil level check plug for checking the oil level
and drain plug for draining (see the figure).

MAM0158

T
AF
R
D

DU-15
 MEMO

T
AF
R
D

DU-16
 FRONT TIRE AND REAR TIRE

SECTION TR
CONTENTS

T
SERVICE DATA AND SPECIFICATIONS ......... TR-2 TROUBLE DIAGNOSES AND CORRECTIONS TR-5
General Specifications 1N1 ........................... TR-2 TIRE AND ROAD WHEEL ................................. TR-6
Tightening Torque ......................................... TR-2 Tire and Road Wheel Assembly .................... TR-6
SERVICE DATA AND SPECIFICATIONS .........
AF TR-3 Replacing Tires ............................................. TR-9
General Specifications (J)A(G)1N1 ............... TR-3 Inspection ...................................................... TR-9
Tightening Torque ......................................... TR-3
PRECAUTIONS AND PREPARATION ............. TR-4
Precautions ................................................... TR-4
R
D
 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications 1N1

EXCEPT NORTH AMERICA
···standard ···option
Model
S1N1L13Q S1N1L15Q 1N1L15Q 1N1L18Q G1N1L16Q G1N1L18Q G1N1L20Q JG1N1L16Q JG1N1L18Q JG1N1L20Q
Tire
Tire size
18x7-8 18x7-8 18x7-8 200/50-10 18x7-8 200/50-10 200/50-10
(Pneumatic solid)
Rim size
4.33R-8 4.33R-8 4.33R-8 6.50F-10 4.33R-8 6.50F-10 6.50F-10
(Pneumatic solid)
Tire size (Cushion) 18x7x12-1/8 18x7x12-1/8 18x7x12-1/8 — — —
Single
Front

Tire size
18x7-8 18x7-8 18x7-8 200/50-10 18x7-8 200/50-10 200/50-10
(Pneumatic solid)
Pneumatic
solid
Type

Clean (White)

Cushion — — —

Tire size
15x4.5-8 15x4.5-8 140/55-9 140/55-9 16x6-8 16x6-8 16x6-8
(Pneumatic solid)
Rim size
3.00D-8 3.00D-8 4.00E-9 4.00E-9 4.33R-8 4.33R-8 4.33R-8
(Pneumatic solid)
Rear

T
Tire size (Cushion) 15x5x11-1/4 15x5x11-1/4 — — — —
-

Pneumatic
solid
Type

Clean (White)

Cushion
AF — — — — — —

NORTH AMERICA ONLY

···standarad ···option
1N1 G1N1 / JG1N1
Model
Tire 15 18 20
R
Tire size (Pneumatic solid) 18×7-8 200/50-10
Rim size (Pneumatic solid) 4.33R-8 6.50F-10
Tire size (Cushion) 18×7×12-1/8 18×7×12-1/8
D
Single
Front

Tread (Pneumatic solid) in (mm) 35.9 (913) 36.6 (930)

Tread (Cushion) in (mm) 36.6 (930) 36.6 (930)
Pneumatic solid
Type

Cushion
Tire size (Pneumatic solid) 15×4.5-8 140/55-9 140/55-9
Rim size (Pneumatic solid) 3.00D-8 4.00E-9 4.00E-9
Tire size (Cushion) 15×5×11-1/4 15×5×11-1/4
Rear

Tread in (mm) 6.9 (176) 6.9 (176)

Pneumatic solid
Type

Cushion

Tightening Torque

Model 1N1 series

Wheel nut Front 157 to 196 (16 to 20, 116 to 145)
N•m (kgf-m, ft-lb)
Rear 157 to 196 (16 to 20, 116 to 145)

TR-2
 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications (J)A(G)1N1

EXCEPT NORTH AMERICA
···standarad ···option
Model AS1N1L13Q AS1N1L15Q A1N1L15Q A1N1L18Q AG1N1L16Q AG1N1L18Q AG1N1L20Q AJG1N1L16Q AJG1N1L18Q AJG1N1L20Q
Tire
Tire size
18×7-8 18×7-8 18×7-8 200/50-10 18×7-8 200/50-10 200/50-10
(Pneumatic solid)
Rim size
4.33R-8 4.33R-8 4.33R-8 6.50F-10 4.33R-8 6.50F-10 6.50F-10
(Pneumatic solid)
Tire size (Cushion) 18×7×12-1/8 18×7×12-1/8 18×7×12-1/8 – – –
Single
Front

Pneumatic
solid
Type

Clean (White)

Cushion – – –

Tire size
15×4.5-8 140/55-9 15×4.5-8 140/55-9 140/55-9 16×6-8 16×6-8 16×6-8
(Pneumatic solid)
Rim size
3.00D-8 4.00E-9 3.00D-8 4.00E-9 4.00E-9 4.33R-8 4.33R-8 4.33R-8
(Pneumatic solid)
Rear

Tire size (Cushion) 15×5×11-1/4 15×5×11-1/4 – – – –

-

T
Pneumatic
solid
Type

Clean (White)

Cushion – – – – – –
AF
NORTH AMERICA ONLY
···standarad ···option
A1N1 AG1N1
Model
Tire
15 18 20
R
Tire size (Pneumatic solid) 18×7-8 200/50-10
Rim size (Pneumatic solid) 4.33R-8 6.50F-10
Tire size (Cushion) 18×7×12-1/8 18×7×12-1/8
Single
Front

Tread (Pneumatic solid) in (mm) 35.9 (913) 36.6 (930)

D

Tread (Cushion) in (mm) 36.6 (930) 36.6 (930)

Pneumatic solid
Type

Cushion
Tire size (Pneumatic solid) 15×4.5-8 140/55-9 140/55-9
Rim size (Pneumatic solid) 3.00D-8 4.00E-9 4.00E-9
Tire size (Cushion) 15×5×11-1/4 15×5×11-1/4
Rear

Tread in (mm) 6.9 (176) 6.9 (176)

Pneumatic solid
Type

Cushion

Tightening Torque

Model A1N1 series

Wheel nut Front 167 - 226 (17 - 23, 123 - 166)

N•m (kgf-m, ft-lb) Rear 167 - 226 (17 - 23, 123 - 166)

TR-3
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
CAUTION:
• When raising or lowering the vehicle using a jack, refer to GI
section for safe operation and follow all safety precautions.
• Be careful not to drop heavy components or parts. Always
use a lifting device.

T
AF
R
D

TR-4
 TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS

CAUTION:
The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the
user's complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.

Condition Probable cause Corrective action

Unstable driving and vehicle vibration • Loose wheel nuts • Tighten.

• Deformed road wheels • Replace.
• Different type tire or wheel on right or left • Replace.
• Differently worn right and left tires • Check and replace.

T
AF
R
D

TR-5
TIRE AND ROAD WHEEL
TIRE AND ROAD WHEEL

Tire and Road Wheel Assembly

FRONT TIRE 1N1

T
AF TRM0001

REAR TIRE 1N1 (3 - WHEEL)

R
D

TRM0002

TR-6
TIRE AND ROAD WHEEL

REAR TIRE 1N1 (4 - WHEEL)

T
TRM0002EU

FRONT TIRE A1N1

AF
R
D

TR-7
TIRE AND ROAD WHEEL

REAR TIRE A1N1 (3 - WHEEL)

T
REAR TIRE A1N1 (4 - WHEEL)
AF
R
D

TR-8
 TIRE AND ROAD WHEEL

Replacing Tires
1. Before removing a tire, loosen wheel nuts slightly. Then raise
vehicle using a jack. For jacking information, refer to GI section.
2. Remove wheel nuts, then remove tire.
3. To install tire, reverse the order of removal. Always observe the
torque specifications and instructions outlined above.

Inspection
CHECKING WHEEL NUTS
Before each day's operation, check wheel nuts for looseness.
Check wheel nuts for torque specification at specified regular
intervals.
Front and rear wheel nuts:
157 - 196 N•m (16 - 20 kg-m, 116 - 145 ft-lb) for 1N1
167 - 226 N•m (17 - 23 kg-m, 123 - 166 ft-lb) for A1N1
CAUTION:
Always tighten wheel nuts in a criss-cross fashion.
TRM0003
CHECKING TIRE WEAR

T
Check all tires for tread groove depth. Visually check for appearance
of tread wear indicator (slip-sign mark) on the tire.
AF CHECKING UNEVEN TIRE WEAR
Check all tires for abnormal or uneven wear. Abnormal or uneven
wear often results from one of the causes indicated in the table
below. Check and locate the cause of the abnormal or uneven wear.
If necessary, replace the tire with a new one.

Condition Probable cause Corrective action

R
Wear at both tire • Abrupt turns under
shoulders heavy loads
• Overloading • Reduce carrying load
volume.
D

MAT0006

Wear in center of tire • Slips during braking

tread

MAT0007

Uneven tire tread wear • Uneven braking • Adjust brakes.

applications

MAT0008

TR-9
TIRE AND ROAD WHEEL

T
AF
R
D

TR-10
 BRAKE SYSTEM

SECTION BR
CONTENTS

T
SERVICE DATA AND SPECIFICATIONS ......... BR-2 MASTER CYLINDER ....................................... BR-15
General Specifications .................................. BR-2 Removal ...................................................... BR-16
Tightening Torque ......................................... BR-2 Installation ................................................... BR-16
TROUBLE DIAGNOSIS AND
AF Disassembly ................................................ BR-16
CORRECTIONS ................................................. BR-3 Assembly ..................................................... BR-16
Service Brake ................................................ BR-3 Inspection .................................................... BR-17
Parking Brake ................................................ BR-4 RESERVOIR TANK ......................................... BR-18
PRECAUTIONS AND PREPARATION ............. BR-5 Brake Fluid Level ......................................... BR-19
Precautions ................................................... BR-5 BRAKE PIPING ............................................... BR-20
CONSTRUCTION ............................................... BR-6 Brake Piping ................................................ BR-20
Brake System ................................................ BR-6 Brake Line Air Bleeding ............................... BR-21
R
SERVICE BRAKE .............................................. BR-7 PARKING BRAKE ........................................... BR-22
Removal ........................................................ BR-7 Removal ...................................................... BR-22
Installation ..................................................... BR-7 Installation ................................................... BR-23
Disassembly .................................................. BR-9 Disassembly and Assembly ........................ BR-24
D

Assembly ..................................................... BR-10 Inspection .................................................... BR-24

Inspection .................................................... BR-10
BRAKE PEDAL ................................................ BR-11
Removal ...................................................... BR-11
Installation ................................................... BR-12
Disassembly and Assembly ........................ BR-13
Inspection .................................................... BR-13
Adjustment .................................................. BR-14

Revised December 2012

 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications
Item (A)1N1 series

Service Type Hydraulic, wet disk in drive

brake unit
Brake disk oil type SAE 80W / API GL4
Brake disk oil capacity
(US fl oz, lmp fl oz)/ 0.16 (3/8 US pt, 3/8 lmp pt)
one side
Stroke of the brake piston
Less than 3 (0.12)
mm (in)
Master Type Single conventional
cylinder Inner diameter mm (in) 19.05 (0.7500)
Stroke mm (in) 33 (1.30)
Allowable clearance
between cylinder and Less than 0.15 (0.0059)
piston mm (in)
Reservoir Tank capacity
60 - 102 (2.0 - 3.4, 2.1 - 3.6)
tank m (US fl oz, lmp fl oz)
Brake fluid type 1N1 DOT4 / A1N1 PSF

T
(Power Steering Fluid)
Brake Pedal height mm (in) 122 (4.80)
pedal
Pedal free play mm (in) 0 - 2.3 (0 - 0.091)
Brake switch operated
AF
115.5 (4.547)
height mm (in)
Depressed height
80 (3.15)
mm (in)
Parking Type Dead point lock type
brake pulling force N (kg, lb) 175 - 225 (18 - 23, 39 - 50)
R
Tightening Torque
Unit N•m kg-m ft-lb
D

Service Brake cartridge cover 15 1.5 11

brake fixing bolt
Air bleeder 2-3 0.2 - 0.3 1.5 - 2.2
Master Master cylinder fixing 9 -11 1.0 - 1.1 7-8
cylinder bolt
Push rod lock nut 16 - 22 1.7 - 2.2 12 - 16
Brake Brake pedal bracket 36 - 50 3.7 - 5.0 27 - 36
pedal fixing bolt
Pedal stopper lock nut 12 - 15 1.3 - 1.5 9 -11
Brake switch 12 - 15 1.3 - 1.5 9 -11
Accel unit attaching 9 -12 1.0 - 1.2 7-8
bolt
Reservoir Reservoir tank fixing 4-5 0.4 - 0.5 3.0 - 3.6
tank bolt
Brake Brake tube flare nut 15 -18 1.6 - 1.8 11 - 13
tube

BR-2
TROUBLE DIAGNOSIS AND CORRECTIONS
TROUBLE DIAGNOSIS AND CORRECTIONS

Service Brake

T
AF
R
D

BRM0066

BR-3
TROUBLE DIAGNOSIS AND CORRECTIONS

Parking Brake

T
BRM0067
AF
R
D

BR-4
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
CAUTION:
• When servicing, be sure to chock rear wheels and lift up front
of vehicle using a jack. Refer to GI section.
• Never get under the vehicle while it is supported only by
wooden blocks.
• When disassembling or replacing the brake system, always
perform operational check after servicing.
• To avoid splashing the brake fluid on painted surfaces such
as the body, always protect them with a rag during operation.
• When brake tube is disconnected, brake fluid may leak.
Attach a cap to the flare nut.
• Never reuse brake fluid.
• Use only genuine brake fluid or equivalent. Never mix
different types of brake fluid.
• When disconnecting or replacing brake piping, be sure to
perform leak check after servicing.
• Do not discard used brake fluid or cleaning oil without
permission. Dispose of them in accordance with the legal
procedure.

T
AF
R
D

BR-5
CONSTRUCTION
CONSTRUCTION

Brake System

T
AF
R
D

BR-6
 SERVICE BRAKE

SERVICE BRAKE

T
AF
BRM0069

Removal
For removing the drive unit, refer to DU section.
R
CAUTION:
Drain the fluid from the brake piping. Refer to “BRAKE PIPING”.
D

NOTE:
Disconnect the brake cables. Refer to “PARKING BRAKE”.

Installation
For installing the drive unit, refer to DU section.
CAUTION:
Refill the brake fluid and bleed the air from the brake piping.

NOTE:
For connection and installation of the brake cable, refer to “PARKING
BRAKE” section.

BR-7
 SERVICE BRAKE

T
AF
R
D

BRM0070

Gear cover Push disk Plug (4 pcs)

Pin (2 pcs) Flexible disk Lock pin (2 pcs)
Spring (2 pcs) Seal Washer
Snap ring (2 pcs) Brake piston Connector for brake tube
Pin (4 pcs) Piston seal Bleeder cap
Reaction disk Piston seal (2 pcs) Bleeder screw
Disk plate (7 pcs) Brake housing Pin (2 pcs)
Spring (24 pcs) Bolt (2 pcs) Pin
Wear brake disk (6 pcs) Bolt (12 pcs) Lever for parking cable

BR-8
 SERVICE BRAKE

Disassembly
1. On the gear cover of the brake cartridge four hexagon socket
headcup plugs are symmetrically placed. These plugs may
be used for any possible topping-up/checking of the brake disk
oil level. The level is indicated by the top plug.

BRM0071

2. Remove the plugs and drain the oil off, at least in part;
unscrew the 14 bolts and .

T
BRM0072
AF 3. Two of the holes where the screws are located have a M8
thread: screw in two bolts (M8 × 1.25, = 25 mm (0.98 in)), until
the brake housing is extracted.
R

BRM0097

4. The brake disk unit is made of 7 disk plates and 6 wear

D

brake disks , ordered in an alternate way (the first one and

the last one must be smooth). Between every couple of disk
plates four springs are inserted, one spacer on each locking
pin .
Remove first the 2 snap rings from the pins , then the
disk pusher device + and all 13 brake disks. Pull the
springs out from the pins . Remove the aluminum
reaction disk .

BRM0073

BR-9
 SERVICE BRAKE

Assembly
Wash down the cartridge thoroughly, then to assemble the parts
again following the next steps:
1. Insert the reaction disk .
2. Insert disk plate, wear brake disk , 4 springs one spacer
on each locking pin.
3. Repeat step 2 for 5 times.
4. Place the last disk plate and the 2 springs in the pins .
5. Insert the disk pusher device + onto the pins , then
pressing down all of them, place the 2 snap rings into the
seat on the pins .
BRM0073

Place the spacer-seal on the gear cover contact surface.

Insert the brake cartridge cover, centre on its 2 pins and, using a
rubber hammer, fine-tune the cartridge position until it is completely
inserted.
Now, insert the 14 bolts in their own holes and set them with the
following torque wrenches.
Brake housing attaching bolt:
6. , : 15 N•m (1.53 kg-m, 11 ft-lb)

T
BRM0074
AF
Oil level 1N1
CAUTION:
Always refill the brake disk oil after assembly.

Refill the brake disk unit with brake disk oil using the refill plug, fill
with the advised quantity (for oil level A1N1 see page BR-7).
R

BRM0071aEU
D

Inspection
Inspection of brake piston stroke.
It is necessary to check every 2,400 working hours or 1 year that the
stroke of the brake piston is not over 3 mm, otherwise it is necessary
to replace the brake disk.

BRM0071

BR-10
 BRAKE PEDAL
BRAKE PEDAL

T
AF
BRM0076

Removal
1. Disconnect battery connector.
2. Remove floor mat and floor panel. Refer to BF section.
R
3. Remove master cylinder fixing nuts.
4. Disconnect harness connectors for brake switch and
accelerator unit.
5. Remove snap pin and clevis pin or the push rod of master
D

cylinder.
6. Remove pedal bracket fixing bolts, then remove pedal bracket
assembly (with brake pedal and accelerator unit).

CAUTION:
Suspend master cylinder from instrument panel, etc. using
string so as not to allow the master cylinder to swing.

BRM0077

BR-11
 BRAKE PEDAL

Installation
1. To install, reverse the order of removal.
Pedal bracket fixing bolt:
36 - 50 N•m (3.7 - 5.0 kg-m, 27 - 36 ft-lb)
Master cylinder fixing bolts:
9 - 11 N•m (1.0 - 1.1 kg-m, 7 - 8 ft-lb)
Brake switch lock nut:
12 - 15 N•m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
2. After installation, adjust brake pedal. Refer to “Adjustment”.

CAUTION:
Install clevis pin connecting brake pedal and push rod in
correct direction. Be sure to install snap pin.

T
BRM0077
AF
R
D

BR-12
 BRAKE PEDAL

Disassembly and Assembly

T
AF
BRM0078

NOTE:
• Assembly is to be smoothly separated without foreign parts, and
there is to be no parts missing, incorrect assembly, etc.
R
• Chassis grease (NCS-1 or equivalent) shall be applied properly to
sliding area of shaft hole. It is to be free from non-standard
conditions such as unusual noise when the pedal is actuated to
the full stroke.
D

• Chassis grease (NCS-1 or equivalent) must be applied on return

spring during assembly.

Inspection
Check for deformation or damage of each part, looseness of pedal
movable area, and malfunction of pedal return. Replace if
necessary.

BRAKE SWITCH
Refer to CS section for inspection.

BR-13
 BRAKE PEDAL

Adjustment
1. Adjust pedal height (distance between floor panel and pedal
pad surface) to the standard by adjusting pedal stopper. Then,
securely tighten lock nut.
Standard:
122 mm (4.80 in)
: 12 - 15 N•m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)

BRM0079

2. Adjust play at push rod to the standard by adjusting push rod.

Then tighten adjusting nut and check pedal play at pedal pad.
Free play:
At push rod
0 - 0.5 mm (0 - 0.020 in)
At pedal pad
0 - 2.3 mm (0 - 0.091 in)
: 16 - 22 N•m (1.7 - 2.2 kg-m, 12 - 16 ft-lb)

T
BRM0080
AF CAUTION:
Always properly adjust play. If play is much less than standard,
push rod is continuously applied with load. This results in
blocking master cylinder return port, causing brake dragging.
Also, excessive play may cause push rod to come out of place.
R
3. Check pedal depressed height. If it is excessively outside the
standard, check brake system other than brake pedal assembly.
Standard:
80 mm (3.15 in)
D

4. Depress and release brake pedal several times to see if it

travels smoothly over its entire stroke without binding, twisting
or interfering with adjacent parts.
5. Depress and release brake pedal several times. Make sure that
brake switch comes on when the pedal is depressed 8.0 to 12.0
mm (0.315 to 0.472 in) and goes off when it is released.
BRM0081

BR-14
 MASTER CYLINDER
MASTER CYLINDER

T
BRM0082
AF
R
D

BRM0083

BR-15
 MASTER CYLINDER

Removal
CAUTION:
Drain brake fluid in brake line before removing master cylinder.
Refer to BRAKE PIPING for draining brake fluid.
1. Remove floor mat and floor panel. Refer to BF section.
2. Loosen left and right flare nuts and disconnect brake piping.
3. Remove master cylinder fixing bolt snap pin, clevis pin and
remove master cylinder from pedal bracket assembly.
NOTE:
Always remove master cylinder together with push rod.

Installation
CAUTION:
• After installation, bleed the air from brake piping.
• Install clevis pin connecting brake pedal and push rod in
correct direction. Be sure to install snap pin.
To install, reverse the order of removal. Observe the following:
Master cylinder attaching bolt:

T
: 9 - 11 N•m (1.0 - 1.1 kg-m, 7 - 8 ft-lb)
• Tighten brake piping flare nut with special service tool.
: 15 - 18 N•m (1.6 - 1.8 kg-m, 11 - 13 ft-lb)
• After installation, refill brake fluid and bleed air. Refer to
AF “BRAKE PIPING” and MA section.

BRM0077

Disassembly
1. Remove nipple and gasket.
2. Remove dust cover.
3. Remove stopper ring and piston stopper. Then remove push
R
rod, piston assembly, return spring and spring retainer.
4. Remove primary and secondary piston cups and spacer from
piston assembly.
D

CAUTION:
Disassemble parts in a clean place. Place disassembled parts
in order for easier reassembly.

Assembly
CAUTION:
• Clean all parts in clean brake fluid.
• Apply brake fluid to sliding surfaces before assembly.
• Be careful not to damage cylinder or piston during assembly.
• Replace piston cup with a new one. Do not reuse.
• Be sure to use the same manufacturer's item for replacement
of cylinder main body and inner parts.
• When installing a new piston cup, make sure the
manufacturer’s name and size is on the back of the lip.

BR-16
 MASTER CYLINDER

Assembly (Cont’d)
1. Install secondary piston cup with the lip (recess) facing return
spring side.
2. Insert spring retainer in cylinder body. Install spacer, primary
piston cup, spring seat and return spring to piston assembly,
then insert the assembly into cylinder body.
CAUTION:
• Install primary piston cup with the lip (recess) facing return
spring side.
• Install spring seat with its flange surface (recess) attached to
primary piston cup.
BRM0084
3. Install push rod, piston stopper and stopper ring.
CAUTION:
Make sure that stopper ring is properly engaged with the
groove.

4. Install dust cover.

5. Install gasket and nipple.

T
Inspection
CAUTION:
AF • Check each part after cleaning in brake fluid. Do not use any
cleaning solvent other than brake fluid.
• Be sure to use the same manufacturer's item for
replacement.

PISTON
• Measure clearance between cylinder inner diameter and piston
R
outer diameter. If it exceeds the limit, replace piston.
Limit:
0.15 mm (0.0059 in)
Cylinder inner diameter (for reference):
D

19.05 mm (3/4 in)

• Check sliding surface of piston for scratches or uneven wear. If
necessary, replace piston.

PISTON CUP
Always replace when disassembling.

RETURN SPRING
• Check for weakening or deformities. Replace if necessary.

DUST COVER AND PUSH ROD

Check for deformities or damage. Replace if necessary.

BR-17
 RESERVOIR TANK
RESERVOIR TANK

T
AF
BRM0085

CAUTION:
• Make sure that there is no fluid leakage from the piping.
R
• Make sure that there is no deformation, damage, and fluid
leakage of reservoir tank.
• Insert the hose and install the clamp as shown in the figure,
and then tighten them securely.
D

BRM0086

BR-18
 RESERVOIR TANK

Brake Fluid Level

Check brake fluid level in brake reservoir tank. If it is between MAX
(upper limit) and MIN (lower limit) marks on the reservoir tank, fluid
level is correct. If it is lower than MIN (lower limit) mark, refill
specified brake fluid up to MAX (upper limit) mark.
CAUTION:
• Do not overfill brake fluid.
• Be careful not to allow foreign matter to enter reservoir tank.
• Be careful not to splash brake fluid on painted areas; it may
BRM0087 cause paint damage.
• If brake fluid decreases abnormally, check for leaks in brake
line. Eliminate the cause of problem.
• Only use the authorized genuine brake fluid. Do not mix
different types of brake fluids.

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AF
R
D

BR-19
 BRAKE PIPING
BRAKE PIPING

Brake Piping

T
AF
BRM0088

CAUTION:
Lift the carriage and support it with a wire or nylon sling to
R
facilitate work.

Drain brake fluid as follows:

• Chock front and rear wheels and release parking brake.
• Remove bleeder cap. Connect a transparent vinyl tube to bleeder.
D

• Put the end of the vinyl tube into a container and loosen the
bleeder.
• Depress brake pedal lightly until brake fluid in the reservoir tank
and master cylinder is emptied and fluid does not come out of air
bleeder.
CAUTION:
• Drain brake fluid from one side to the other.
• Do not reuse drained brake fluid because it may be
deteriorated or foreign material may have entered into it.
• Before disconnecting brake piping, always drain the brake
BRM0098
fluid.

BR-20
 BRAKE PIPING

Brake Line Air Bleeding

If a portion of the brake fluid line system has been disassembled and
repaired, or if the pedal feels spongy when pressed, bleed the air
from the system.
1. Insert a transparent vinyl tube into the bleeder screw that is far
to the right. Insert the other end of the tube into a container filled
with brake fluid.
2. Check the level of the brake fluid in the reservoir tank. Add fluid
if the tank is low.
3. Loosen the bleeder screw.
Repeat until the air bubble is not produced. Tighten air bleeder,
when air bubble occurrence stops.
4. Following the same procedure, bleed the air on the left side.
Finally, add the prescribed amount of brake fluid to the reservoir
BRM0098 tank.
CAUTION:
• Make sure that the level of brake fluid in the reservoir tank
remains sufficient during the procedure.
• Use the designated brand of brake fluid. Do not mix with
other products.

T
AF
R
D

BR-21
 PARKING BRAKE
PARKING BRAKE

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AF
BRM0090
R

Removal
CAUTION:
D

• Securely block the rear wheels, and then jack up the front
wheels.
• Lift up the carriage, and then perform the safe operation.
1. Chock rear wheels and jack up front of vehicle. Refer to GI
section.
2. Disconnect parking brake switch harness.
3. Remove the three parking brake lever assembly attaching bolts
and remove the assembly from vehicle.
4. Loosen cable lock nut at the parking brake lever assembly side.

5. Pull out left and right parking brake cables from parking cable
lever.
6. Remove lock plates and cable clamp.
7. Pull out the end of parking brake cable from parking brake lever.

BRM0091

BR-22
 PARKING BRAKE

Installation
To install, reverse the order of removal. Observe the following:
• Insert parking brake cable into bracket and fix it with lock plate.
CAUTION:
Do not reuse removed lock plate.

BRM0092

• Clamp the left side of parking brake cable facing it toward vehicle
front.

T
BRM0093

• Adjust operational force to lock parking brake lever as follows:

AF 1. Adjust the adjusting nut so that the thread length L of equalizer
mounting portion is 6.5 mm (0.256 in), and then tighten lock nut.
R

BRM0095

2. When locking the parking brake lever, adjust by the adjusting

D

bolt so that the required brake power is maintained when the

grip load is 175 - 225N (17.9 - 23.0 kg, 39.3 - 50.6 lb).
3. Make sure that the equalizer is not tilted when the lever is in the
lock position (dimension difference between S1 and S2 is 2 mm
or less). If it is tilted, adjust dimension L so that the dimension
difference between S1 and S2 is 2 mm or less, and then perform
the above adjustment again.
4. Return parking brake lever completely. Make sure that there is
no drag on the brake.
BRM0099

BR-23
PARKING BRAKE

Disassembly and Assembly

NOTE:
Disassemble parking brake lever as required.

Inspection
PARKING BRAKE LEVER ASSEMBLY
Check assembly parts for deformities or damage. Replace any
damaged part if necessary.

PARKING BRAKE CABLE

• Check for elongation. If necessary, adjust by referring to
“Installation”. If it is excessively elongated, replace with a new
one.
• Check for breaking or bending. Replace if necessary.
• Check connecting areas for deformities or damage. Replace if
necessary.

PARKING BRAKE SWITCH

T
AF Refer to EL section for inspection of parking brake switch.
R
D

BR-24
 REAR AXLE

SECTION RA
CONTENTS

T
SPECIFICATION ................................................ RA-2 STEERING AXLE HUB (4 - WHEEL) .............. RA-13
TROUBLE DIAGNOSES AND Removal ...................................................... RA-13
CORRECTIONS ................................................. RA-3 Inspection .................................................... RA-13
AF
SERVICE DATA AND SPECIFICATIONS ......... RA-4 Installation ................................................... RA-13
Steering Axle Upper Surface (4 - wheel) ....... RA-4 Adjustment .................................................. RA-14
Steering Axle Front Surface (4 - wheel) ........ RA-5 KINGPIN (4 - WHEEL) ..................................... RA-15
Steering Axle Front Surface (3 - wheel) ........ RA-6 Details ......................................................... RA-15
CONSTRUCTION (4 - WHEEL) ......................... RA-7 Removal ...................................................... RA-16
Details of Rear Axle (4 - wheel) ..................... RA-7 Inspection .................................................... RA-16
PRECAUTIONS ................................................. RA-8 Installation ................................................... RA-17
AXLE CENTER (4 - WHEEL) ............................. RA-9 Construction of Tire Angle Sensor .............. RA-18
R
Removal ........................................................ RA-9 AXLE CENTRE (3 - WHEEL) .......................... RA-19
Installation ..................................................... RA-9 Details of Rear axle (3 - wheel) ................... RA-19
COMPONENT PARTS (4 - WHEEL) ............... RA-12 AXLE CENTRE (3 - WHEEL) .......................... RA-20
Disassembly and Assembly ........................ RA-12 Removal ...................................................... RA-20
D

Installation ................................................... RA-20

Assembly ..................................................... RA-22
SPECIFICATION
SPECIFICATION

(A)1N1 / except
Model Only J(A)G1N1
J(A)G1N1
Item series
Series

Suspension type Center support, swing type

Camber (°) 0 X

Caster (°) 0 0
Wheel alignment
Toe-angle (°) 0 0

Kingpin inclination (°) 0 0

Swing angle (°) 2.25 X

Inner wheel (°) 82.45

Maximum steering
185
angle
Outer wheel (°) 57.34

T
AF
R
D

RA-2
 TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS

CAUTION:
The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.

Condition Probable cause Corrective action

Heavy steering wheel Improperly sliding kingpin. Check thrust bearing and needle bearing and replace
operation faulty parts. Apply grease to kingpin.
Insufficient lubrication. Apply grease.
Malfunctioning steering system. Refer to ST section.
Unstable driving and vehicle Loose wheel nuts. Tighten.
vibration Different type tire or wheel on right and left. Replace.
Differently worn right and left tires. Check and replace.
Improperly adjusted spindle stopper. Adjust.
Excessive wheel bearing backlash. Adjust bearing preload. Replace worn wheel
bearings as a set.
Loose kingpin. Check kingpin-related parts (especially bearings).
If necessary, replace.
Adjust by replacing adjusting shims.

T
Loose axle mounting. Check rubber mount. If necessary, replace.
Adjust by replacing adjusting shims.
Improperly inclined vehicle on a slope. Adjust axle swing angle.
Others
AF
Dragging wheels. Check wheel bearing for rust formation. Adjust wheel
bearing preload.
Loose nuts and bolts. Tighten.
R
D

RA-3
 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

Steering Axle Upper Surface (4 - wheel)

T
AF
RAM0026

Model
J(A)G1N1 series
R
Item

Swing angle (degree) (°) 2.25

Toe-angle (°) 0
D

Caster (°) 0

Camber (°) 0

(1) Tie-rod bar connecting pin mounting bolt tightening torque N•m (kg-m, ft-lb) 7.2 - 10.8 (0.8 - 1.1, 6 - 7)

(2) Kingpin lock nut tightening torque N•m (kg-m, ft-lb) 31 - 42 (3.2 - 4.2, 23 - 30)

137 - 186
(3) PS cylinder mounting bolt tightening torque N•m (kg-m, ft-lb)
(14.0 - 18.9, 102 - 137)

39 - 43
(4) PS piping tightening torque N•m (kg-m, ft-lb)
(4.0 - 4.3, 29 - 31)

(5) Top and bottom clearance of axle center pin mm (in) There is no clearance.

Front: Less than 0.6 (0.02)

(6) Front and rear clearance of axle center pin mm (in)
Rear: Less than 0.6 (0.02)

(7) Axle mounting cap mounting bolt tightening torque N•m (kg-m, ft-lb) 50 - 70 (5.1 - 7.1, 37 - 51)

(8) Inner wheel 82.45

Maximum steering angle (°)
(9) Outer wheel 57.34

RA-4
 SERVICE DATA AND SPECIFICATIONS

Steering Axle Front Surface (4 - wheel)

T
RAM0801EU

Item
AF Model
J(A)G1N1

(1) Spindle top and bottom clearance mm (in) 0.2 (0.008) or less

(2) Rotation starting force of wheel bearing 10 - 29

N (kg, lb)
(Reading of hub bolt spring balance) (1.1 - 2.9, 3 - 6)

(3) Lock screw tightening torque N•m (kg-m, ft-lb) 4.4 - 6.6 (0.5 - 0.6, 4 - 5)
R
167 - 226
(4) Wheel nut tightening torque N•m (kg-m, ft-lb)
(17.1 - 23.0, 124 - 166)

(5) Tire angle sensor harness clip mounting bolt

N•m (kg-m, ft-lb)
tightening torque 7.2 - 10.8
D

(0.8 - 1.1,
(6) Tire angle sensor cover mounting bolt tightening 6 - 7)
N•m (kg-m, ft-lb)
torque

24 - 32
(7) Stopper mounting bolt tightening torque N•m (kg-m, ft-lb)
(2.5 - 3.2, 18 - 23)

8.6 - 10.6
(8) Stopper and axle center clearance mm (in)
(0.34 - 0.42)

RA-5
 SERVICE DATA AND SPECIFICATIONS

Steering Axle Front Surface (3 - wheel)

T
AF
R

RAM0802EU
D

Model
(A)1N1 (Except J(A)G1N1)
Item

(1) Steering axle assy mounting bolts 240 - 320 (25 - 32; 177 - 236)

(2) Preload of wheel bearing lock nut 2 - 6 (0.2 - 0.6; 18 - 53)

(3) Steering axle bracket bolts 280 (29; 207)

(4) Wheel nut tightening torque 157 - 196 (16 - 20, 116 - 145) 1N1 / 167 - 226 (17 - 23, 123 - 166) A1N1

(5) Tire angle sensor mounting bolt 1.2 - 1.8 (0.13 - 0.18; 0.9 - 1.3)

RA-6
CONSTRUCTION (4 - WHEEL)
CONSTRUCTION (4 - WHEEL)

Details of Rear Axle (4 - wheel)

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RAM0028EU
AF
R
D

RAM0029EU

RA-7
 PRECAUTIONS
PRECAUTIONS

CAUTION:
• When raising or lowering the vehicle using a jack, refer to GI
section for safe operation and follow all safety precautions.
• Be careful not to drop heavy components or parts. Always
use a lifting device.
NOTE:
• Axle center assembly can be removed or installed after removing
tires. This RA section deals primarily with the disassembly and
reassembly of the axle center assembly.
• For information concerning wheels and tires, refer to MA section.

T
AF
R
D

RA-8
 AXLE CENTER (4 - WHEEL)
AXLE CENTER (4 - WHEEL)

Removal
NOTE:
When remove tire of for cushion model, refer to “STEERING AXLE
HUB”, “Removal”.
1. Loosen wheel nuts until possible to turn by hand. Raise rear
end of vehicle using a jack. Refer to GI section.
2. Remove tires together with rims.

CAUTION:
• When removing wheel nuts (large), do not confuse them with
rim bolts (small). Rim bolts are fixed by welding.
• Before removing pneumatic tires, bleed a slight amount of air
from tires.
3. Support axle center assembly with a jack.

CAUTION:
Properly place jack to prevent axle center assembly from tilting
or slipping during removal.
4. Disconnect tire angle sensor harness connector, then remove
harness mounting bolts.

T
AF
RAM0030

5. Remove PS piping.
R
CAUTION:
• Since oil tends to spill when pipes are disconnected, cover
the surrounding area with rag.
• Stuff stoppers into disconnected pipes to prevent oil spills.
D

• Never allow foreign matter to enter PS cylinder or pipes.

6. Remove mounting cap bolts, then remove axle center assembly.

CAUTION:
After removing axle center, place it on a worktable.
RAM0050
7. Remove rubber mount together with adjusting shim(s).
Installation
Note the following, and install in the reverse order of removal.

CAUTION:
Be sure to prevent axle center from tilting or slipping off of jack
during installation.

RA-9
 AXLE CENTER (4 - WHEEL)

1. Axle center pin top and bottom clearance adjustment.

• Put shim downward to adjust when there is top and bottom
clearance between axle center pin and bushing.
Shim thickness:
1.2 mm (0.05 in)
1.6 mm (0.06 in)

RAM0032

2. Axle center pin front and rear clearance adjustment.

• Adjust shim so that front and rear clearance between axle center
pin and rear frame becomes less than 0.6 mm (0.02 in).
Shim thickness:
0.6 mm (0.02 in)
1.0 mm (0.04 in)
2.3 mm (0.09 in)

T
RAM0033

3. Axle mounting cap installation.

• Axle mounting cap bolt
AF : 50 - 70 N•m (5.1 - 7.1 kg-m, 37 - 51 ft-lb)
4. Tire installation (Pneumatic model).
• Tighten wheel nuts to a lesser value than specification, making
sure it is enough to keep component installation stable when the
vehicle is lowered to the ground.
• Carefully lower vehicle to ground. Tighten wheel nuts to specified
torque.
R
: 167 - 226 N•m (17.1 - 23.0 kg-m, 124 - 166 ft-lb)

CAUTION:
Tighten wheel nuts to the specifled torque evenly.
• Inflate pneumatic tires to specified air pressure (if so equipped).
D

RAM0034 NOTE:
Tire installation for cushion model is refer to “Wheel bearing
adjustment”.
Installation (Cont’d)
5. Axle swing angle adjustment.
• Locate vehicle on a solid and level surface.
• Turn key switch to ON position. Turn steering wheel fully in either
direction so stopper is visible.
• Select and install stopper with proper thickness between stopper
plate and axle center so that stopper plate upper surface-to-swing
stopper clearance “H” is within standard.

Unit: mm (in)

Standard clearance “H”

J(A)G1N1 series 8.6 - 10.6 (0.34 - 0.42)

RAM0035

RA-10
 AXLE CENTER (4 - WHEEL)
Unit: mm (in)

3.2 (0.13)
4.0 (0.16)
5.0 (0.20)
6.0 (0.24)
Available adjusting stoppers
7.0 (0.28)
8.0 (0.31)
9.0 (0.35)
16.0

• After adjusting axle swing angle, tighten stopper plate securing

bolts to specified torque.
: 24 - 32 N•m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
•

RAM0036

T
AF
R
D

RA-11
COMPONENT PARTS (4 - WHEEL)
COMPONENT PARTS (4 - WHEEL)

Disassembly and Assembly

T
AF
R
D

RAM0039

RA-12
STEERING AXLE HUB (4 - WHEEL)
STEERING AXLE HUB (4 - WHEEL)

Removal
• Jack up and securely support body with safety stands.
(Refer to GI section.)
• Remove tires, and then remove hub caps.
• Loosen lock screw, and then remove lock washer, wheel bearing
nut and outer bearing.
• Pull out steering axle hub.

CAUTION:
• Do not drop outer bearing.
• Pull out inner bearing.
• Do not damage grease seal.
• Drive out inner race remaining hub by using hub groove.
RAM0040

Inspection
Clean each disassembled part and check.

WHEEL BEARING

T
Check for damage, seizure, peeling, improper rotation and noise.
Replace if necessary.
AF HUB, SPINDLE
Check for cracks (by dye test). Replace if necessary.

GREASE SEAL
Check for damage and wear. Make sure that oil seal is removed from
spindle. Replace if necessary.
R
Installation
Note the following, and install in the reverse order of removal.
• Apply wheel bearing grease (NWB-2) to each roller, race surface
D

and grease seal lip of wheel bearing.

• Adjust wheel bearing. (Refer to “Wheel Bearing Adjustment”.)
• Do not apply grease to inside inner race (where it is engaged to
spindle).

RA-13
STEERING AXLE HUB (4 - WHEEL)

Adjustment
WHEEL BEARING
NOTE:
For the cushion model, the tires are installed instead of the steering
axle hub.
1. Rotate steering axle hub with one hand, and then tighten wheel
bearing nut until it is hard to rotate.
2. Return wheel bearing nut approximately 60°.
3. Rotate steering axle hub several turns under this condition to fit
bearing.
4. Rotate steering axle hub with one hand again, tighten wheel
bearing nut until it is hard to rotate, and then return it
approximately 60°.
5. Align lock washer protrusion with spindle groove and lock
washer hole with thread hole of wheel bearing nut, and then
RAM0041
tighten lock screws.
Lock screw:
: 4.4 - 6.6 N•m (0.45 - 0.67 kg-m, 3.3 - 4.8 ft-lb)
CAUTION:

T
Position lock screw so that both holes are close if the holes are
not aligned. And then, rotate wheel bearing nut so as to align
with the nearest hole.
6. Turn and return steering axle hub several times, and then make
AF sure that rotation starting force is within the standard.
Rotation starting force
(Reading of hub bolt spring balance) N•m (kg-m, ft-lb):
10 - 29 (1.1 - 2.9, 3 - 6) (1B1)

RAM0042
CAUTION:
Readjust if it is outside the standard.
7. Check steering axle hub axial direction for looseness.
R
Axial direction gap: 0.08 mm (0.003 in) or less

CAUTION:
Readjust if looseness is still detected.
D

RA-14
 KINGPIN (4 - WHEEL)
KINGPIN (4 - WHEEL)

Details

T
AF
RAM0043EU
R
D

RA-15
 KINGPIN (4 - WHEEL)

Removal
1. Disassemble spindle and tie-rod bar.
2. Loosen lock nut, and then remove lock screw.
3. Remove grease nipple, dust cover, and tire angle sensor from
kingpin upper, and then drive out kingpin downward while
positioning a piece of metal on the kingpin.

CAUTION:
• Hold kingpin so as not to drop.
• Install the plate for tire angle sensor positioning to kingpin
RH. Do not deform the plate when installing.

RAM0044

T
AF
RAM0045

4. Remove spindle together with thrust bearing and shim.

5. Pull out grease seal and needle bearing if necessary.

Inspection
Clean each disassembled part and check.
R

NEEDLE BEARING, THRUST BEARING

• Check for damage, seizure, peeling, improper rotation, noise,
D

corrosion and deformation. Replace if necessary.

• Check seal and O-ring of needle bearing and thrust bearing for
damage and excessive wear. Replace if necessary.

SPINDLE
Check for cracks (by dye test). Replace if necessary.

GREASE SEAL
Check for cracks (by dye test). Replace if necessary. Also replace if
grease seal is removed from steering axle.

RA-16
 KINGPIN (4 - WHEEL)

Installation
Note the following, and install in the reverse order of removal.

CAUTION:
• Assemble tire angle sensor correctly so as to correctly
operate knob position correction system function.
• See the following procedure for assembly.

• Assemble kingpin from lower side facing up. (Shim may be

damaged if assembling in incorrect direction.)
• Assemble bearing to spindle upper and shim to spindle lower.
• Install thrust bearing with cover side facing up, and then adjust
axial direction looseness with shim so that it is within the
standard.
Standard:
0.20 mm (0.008 in) or less
• Adjusting shim
Thickness:
0.20 mm (0.008 in)
0.60 mm (0.02 in)

T
RAM0046

• Assemble upper needle bearing with seal side facing up and

lower needle bearing with seal side facing down.
AF • Assemble kingpin grease seal with the dent facing outward.
R

RAM0047
D

• Apply wheel bearing grease (NWB-2) to lower part of thrust

bearing (A) and gap between boss and spindle (B) until the
grease begins to ooze.

RAM0046

RA-17
 KINGPIN (4 - WHEEL)

Construction of Tire Angle Sensor

T
RAM0048

Tire angle sensor fixes the kingpin plate to the kingpin as shown in
AF the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the angle sensor by engaging
the shaft of the angle sensor. Therefore, it is necessary to assemble
the angle sensor correctly to make steering control system function
correctly. Notes concerning assembly are as follows.
• When the kingpin plate is installed in the kingpin, it is necessary to
insert the plate vertically in the direction shown in the above
R
figure.
• When the sensor shaft is engaged in the kingpin plate, it is necessary
to set the plane part of the sensor shaft to the spring and the other
side of the kingpin plate (left side in the above figure).
D

• Securely insert plate into side groove of king pin hole.

CAUTION:
When the tire angle sensor is removed, installed and replaced,
the neutral level adjustment must be performed for the new
sensor.
Refer to CS section for neutral level adjustment.

RAM0049

RA-18
AXLE CENTRE (3 - WHEEL)
AXLE CENTRE (3 - WHEEL)

Details of Rear axle (3 - wheel)

T
AF
R

RA0079EU
D

RA-19
 AXLE CENTRE (3 - WHEEL)
AXLE CENTRE (3 - WHEEL)

CAUTION:
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines is completely bled off.
• To prevent foreign material from entering, always maintain a
clean workplace.
• When disconnecting pipes, cover the surrounding area with
waste cloths and ensure that oil does not contaminate other
parts.
• Never allow foreign material to enter pipes when connecting.
• Put disassembled parts on clean paper or waste cloths and
use care so as not to contaminate, scratch or dent them.
• Turn the key switch to OFF and disconnect the battery cables
before removal.

Removal
1. Jack up and support the bottom of the frame around the
steering axle assy.. (Refer to the GI section.)
2. Remove the battery. (Refer to the BC section.)
3. Remove the counterweight. (Refer to the BF section.)
4. Remove the controller assembly. (Refer to the CS section.)

T
5. Remove the rear tire. (Refer to the TR section.)
6. Disconnect the tire angle sensor harness connector.
7. Disconnect the PS piping connection.
8. Remove the steering axle mounting bolt.
AF 9. Remove the steering axle assy. from the vehicle.
NOTE:
The rear tire interferes with the frame if it is removed together with
the steering axle assy.. Therefore, the steering axle assy. cannot be
removed.

10. Disconnect the PS hose from the PS cylinder and drain the oil.
R
D

STM0078

Installation
Install in the reverse order of removal.
Steering axle mounting bolt
Tightening torque
[N•m (kg-m)]: 240 - 320 (25 - 32), 177 - 236 ft-lb

RA-20
AXLE CENTRE (3 - WHEEL)

STEERING AXLE BRACKET

DISASSEMBLY

T
STM0086
AF 1. Remove the cap.
2. Pull off the cotter pin, and then remove the nut.

CAUTION:
Always replace the cotter pin with new one.

3. Remove the spacer, and then remove the outer bearing.

R
4. Remove the hub.
5. Remove the inner bearing from the shaft.
6. Remove the seal from the hub if necessary.

CAUTION:
D

Always replace the seals with new ones.

RA-21
 AXLE CENTRE (3 - WHEEL)

Disassembly (Cont’d)
ASSEMBLY
Assemble in the reverse order of disassembly.

CAUTION:
• Always replace the cotter pin and the seal (if removed) with
new ones.
• Be careful of the direction of the seal when assembling the
seals to the hub.
• Apply the bearing grease to 4 positions shown in the figure.

PRELOAD ADJUSTMENT
1. Tighten the lock nut once.
2. Loosen the lock nut.
3. Tighten the lock nut again.
Preload torque [N•m (kg-m)]: 2 - 6 (0.2 - 0.6), 18 - 53 in-lb
4. Assemble the cotter pin and lock the lock nut within the above
torque.

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STM0087

Assembly
1. Assemble the steering axle mounting assembly and the
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steering axle bracket.

Tightening torque [N•m (kg-m)]: 280 (29), 207 ft-lb
2. Install the tire angle sensor.
3. Apply the chassis grease to the steering axle mounting
assembly.

STM0088

RA-22
 MEMO

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RA-23
AXLE CENTRE (3 - WHEEL)

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RA-24
 STEERING SYSTEM

SECTION ST
CONTENTS

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SERVICE DATA AND SPECIFICATIONS ......... ST-2 Construction ................................................. ST-14
General Specifications .................................. ST-2 Specification ................................................. ST-14
Tightening Torque ......................................... ST-2 Removal ....................................................... ST-15
AF
PRECAUTIONS AND PREPARATION ............. ST-3 Installation .................................................... ST-15
Special Service Tool ...................................... ST-3 Troubleshooting ........................................... ST-16
STEERING COLUMN ASSEMBLY ................... ST-4 Disassembly ................................................. ST-18
Installation ..................................................... ST-5 Assembly ...................................................... ST-20
Inspection After Installation ........................... ST-5 Periodical Inspection and Maintenance ........ ST-24
PS VALVE .......................................................... ST-6 PS CYLINDER. (3 - WHEEL) ............................ ST-26
Parts Construction ......................................... ST-6 Construction ................................................. ST-26
Disassembly .................................................. ST-7 Removal ....................................................... ST-29
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Inspection ...................................................... ST-8 Installation .................................................... ST-29
Assembly ....................................................... ST-9 PS PIPING ........................................................ ST-33
Trouble Diagnosis and Corrections ............. ST-12
PS CYLINDER (4 - WHEEL) ............................ ST-14
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 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications
(A)1N1 J(A)G1N1

Type Full hydraulic power steering system

Steering wheel Outer diameter mm (in) 320 (12.60)
Number of turns (Lock to lock) 5.9 4,2
Maximum steering angle (Lock to lock) (Degree) 185
PS valve Type Load sensing of dynamic single type

Discharge cm3/rev. 51 6,9

PS flow rate l/min 7.2 8,3

Power steering relief pressure MPa (kg/cm 2) (psi) 6.9 (70.38) (1,000.5) 8

Tightening Torque
Unit N•m kg-m ft-lb
Steering wheel nut 18 – 22 1.9 – 2.2 14 – 16
Steering column cover bolt 1.5 – 2.0 0.16 – 0.20 1.1 – 1.4

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Steering column shaft upper joint pinch bolt 16 – 22 1.7 – 2.2 12 – 16
Steering column bracket bolt 27 – 36 2.8 – 3.6 20 – 26
Tilt lock lever securing bolt 8 – 11 0.9 – 1.1 6–8
PS valve bolt
AF 30 – 40 3.1 – 4.0 23 – 29
Steering axle mounting bolt 240 – 320 25 – 32 177 – 236
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ST-2
 PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Special Service Tool

Tool number
Description
Tool name
PS cylinder remover Removing PS cylinder
99514GA10A

STM0075

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ST-3
STEERING COLUMN ASSEMBLY
STEERING COLUMN ASSEMBLY

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STM0067

CAUTION:
• Turn the key switch to OFF and disconnect the battery cables
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before removing and installing the steering column.

• For removal, do not tap the steering wheel mounting nut with
a hammer. It causes the damage of the combination switch.
• Neutral knob position must be redetected after removing and
installing or replacing the steering wheel angle sensor of the
steering axle.
• Apply grease to the specified position shown on the
illustration above.

ST-4
STEERING COLUMN ASSEMBLY

Installation

COMBINATION SWITCH AUTO RETURN FUNCTION

Combination switch auto return function is operated by the steering
wheel operation.
In addition, a full hydraulic steering system is adopted, which
features a function that corrects the knob position by detecting the
steering wheel rotation and road wheel steering angle (knob position
control system as an option). It is necessary to retain steering wheel
and steering wheel angle sensor. The following paragraphs explain
that procedure.
1. Position the P section of the combination switch as shown and
apply grease (NAV-1) to the Q section (bottom of steering wheel
boss).
2. With the vehicle front wheels set in the straight-ahead position
(the wheels should be directly straightforward), locate the
steering wheel in the position as shown and align its projections
to the switch holes by turning left and right several times.
To check if the projections are correctly aligned to the switch
holes, verify that the combination switch’s auto return function
operates normally.

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STM0068
3. If the auto return function does not operate correctly, repeat
steps above.
4. After ensuring that the projections and holes are aligned
AF correctly, tighten the steering wheel nut.
Tightening torque [N•m (kg-m)]: 18 - 22 (1.8 - 3.3)
5. Install the horn pad on the steering wheel.

TILT LOCK OPERATION

1. Insert a bolt and washers into the steering column bracket as
shown.
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2. Tighten adjustment nut.
Tightening torque [N•m (kg-m)]: 11 - 15 (1.2 - 1.5)
3. Adjust position of the adjusting lever by serration and insert it as
shown. Then, tighten the adjusting lever.
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Tightening torque [N•m (kg-m)]: 8 - 11 (0.9 - 1.1)

4. Make sure that the steering column slides smoothly over entire
tilt angle by releasing the adjusting lever.
STM0069 5. Make sure that the steering column locks securely when the
adjusting lever sets to its locking position.

Inspection After Installation

INSPECTION OF STEERING WHEEL FOR PLAY

Make sure that the steering wheel play is within the standard on the
circumference with key switch turned off.
Play: 20 - 30 mm (0.79 - 1.18 in )

STM0076

ST-5
 PS VALVE
PS VALVE

Parts Construction

COMPONENT PARTS LOCATION

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STM0070

ST-6
 PS VALVE

Disassembly
Be careful the following when repairing PS valve.
• Work in a clean place.
• Clean unit around the port before disconnecting piping.
• Remove dust or dirt on the joint of circumference of unit using
wire brush.
• Be careful so as not to dent and damage because parts drop and
contact.
CAUTION:
Take care not to be injured by any sharp, machined edges in the
sleeve, spool and housing.

1. Hold the main body with a vise with end cap side facing up.
Make sure to hold it at the mounting flange of the housing by
applying moderate pressure. Do not apply excessive pressure.
Use copper plates between the component and the vise as
necessary.
2. Remove the six screws and one retainer screw assembly.
3. Remove the end cap.
4. Remove the O-ring from the end cap.

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5. Remove the plug and O-ring from the gerotor.
6. Take out the spacer from the inner spline of the gerotor.
STT0100L
NOTE:
AF Depending on the gerotor’s displacement, some units have no
spacers and others have two spacers, etc.

7. Remove the gerotor. Do not allow the star to drop from the
gerotor.
8. Remove the O-ring from the gerotor.
9. Remove the drive.
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10. Remove the spacer plate.
11. Remove the O-ring from the housing.
12. Remove the adapter screw from the housing.
13. Remove the housing from the vise and remove the ball by
turning the housing upside down.
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CAUTION:
Do not drop or lose the ball.

14. Place the housing on a clean fabric with the flange side facing
up so that the finished faces are not damaged. Lift the end of
the retaining ring with a screwdriver and remove it from the
housing.
CAUTION:
Always wear safety goggles. The retaining ring may pop out of
the housing.

15. Place the housing on a clean fabric so that the axial direction of
the main body is held in a horizontal direction. After setting the
STT0101L
pin to a level position by turning the spool and sleeve assembly,
slightly push out the spool and sleeve assembly to remove the
seal gland bushing from the housing.
NOTE:
The spool and sleeve assembly mentioned above includes the
sleeve, spool, pin, centering spring and flat spring.

ST-7
 PS VALVE

Disassembly (Cont'd)
16. Remove the oil seal from the seal gland bushing.
17. Remove the dust seal from the seal gland bushing.
18. Remove the two race bearings, thrust needle and oil seal.
19. Press the inner spline of the spool with thumb and pull off the
spool and sleeve assembly from the opposite side to the
housing flange. At that time, ensure that the sleeve outer wall is
not caught in the housing inner wall.
CAUTION:
Depending on the spool/sleeve combinations, even a 180° shift
in position may render the unit inoperative. To prevent such a
symptom, put alignment marks at the positions shown in figure
on the spool and sleeve assembly during this step.

STT0102L
20. Pull out the pin from the spool and sleeve assembly.
CAUTION:
Always wear safety goggles. The centering spring may pop out
of the spool.

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21. Slightly push forward the spool in the sleeve and carefully
remove the centering spring from the spool with fingers.
22. Pull out the sleeve from the spool. To do so, gently turn the
sleeve while pulling it.
AF
Inspection
Inspect the fitting faces of all parts. Any parts with scratches or burrs
must be replaced. These may cause oil leakage.
Clean all metal parts with clean solvent and dry them by blowing air.
Do not use cloth or paper. Lint or particles from these materials may
enter the main body, resulting in contamination of the hydraulic
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system and subsequent symptoms.
Do not use files or sandpaper on the parts.
CAUTION:
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Take care not to be injured by any sharp, machined edges in the

sleeve, spool and housing.

ST-8
 PS VALVE

Assembly
CAUTION:
• Assemble a new O-ring and seal when assembling.
• Apply a small amount of clean grease to O-rings before
assembly.
• Do not confuse O-rings and because they are sizes very
near.

1. Slowly insert the spool in the sleeve while turning the spool.
After that, hold the spool spline and try to turn it. The spool
should turn smoothly in the sleeve.
WARNING:
Make sure to align the two parts correctly by referring to the
alignment marks that have been placed during disassembly.
Misalignment may cause malfunctions, resulting in serious
accidents.

2. Position the spool and sleeve correctly by aligning the two

opposite spring grooves. Insert the spring inserting tool in the
spring grooves. Arrange the centering springs as shown in the

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figure and fit them to the inserting tool so that the end cutouts
face downward.
CAUTION:
AF Ensure that the centering springs are arranged and positioned
correctly. Incorrect positions or arrangement may lead to
malfunctions.

STM0077

3. Slightly lift the spool from the sleeve. While pressing and
holding the opposite end of the centering spring, push them into
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the grooves of the spool and sleeve. At that time, make sure to
slide the inserting tool at the same speed as pushing the
springs. After inserting the springs, align the spring ends to the
sleeve periphery.
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CAUTION:
Always wear safety goggles. The centering spring may pop up
from the spool.

STT0104L
4. Insert the pin in the sleeve hole and align both ends of the pin
with the sleeve periphery.
5. Place the housing on a clean fabric so that the axial direction of
the main body is held in a horizontal direction. Insert the spool
and sleeve assembly from the opposite end to the housing
flange.
Verify that the spool and sleeve assembly can turn smoothly in
the housing in this status.

ST-9
 PS VALVE

Assembly (Cont'd)
CAUTION:
• When inserting the spool and sleeve assembly, ensure that
they are not slanted and caught by the housing inner wall.
During the insertion process, turn the assembly left and right
to a small stroke while keeping the pin in a horizontal
position.
• After insertion, the spool and sleeve assembly must be flush
with the housing end face. Do not insert the assembly
further. Any excessive insertion may cause the pin to drop in
the inner portion of the housing.

6. Place the housing on a clean flat surface and install the O-ring.
7. Install the two race bearings and thrust needle bearing. Make
sure to insert the thrust needle bearing between the race
bearings.
(In the order of race bearing, thrust needle bearing, and then
race bearing)
8. Install the dust seal into the seal gland bushing. Ensure that the
flat face of the dust seal comes to the seal gland bushing side.

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9. Attach the oil seal to the seal gland bushing.
CAUTION:
Ensure that the oil seal is not twisted and deformed.
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10. Insert the seal gland bushing in the spool while turning the
bushing. Lightly tap on the bushing with a plastic hammer to
insert it to the specified position.
11. Install the retaining ring into the housing.
CAUTION:
• Expand the retaining ring with a flat-bladed screwdriver so
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that the entire periphery of the ring fits into the housing
groove.
• Always wear safety goggles. The retaining ring may pop out
of the housing.
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ASSEMBLY OF GEROTOR SIDE

1. Hold the main body with a vise with end cap side facing up.
Make sure to hold it at the mounting flange of the housing by
applying moderate pressure. Do not apply excessive pressure.
Use copper plates between the component and the vise as
necessary.
2. Put the ball into the bolt hole shown in the figure.
NOTE:
This bolt hole is for attaching the retainer screw assembly.

3. Install the adapter screw into the hole in which the ball has been
put.

STT0105L

4. Attach the O-ring onto the housing.

5. Place the spacer plate and align the bolt holes.

ST-10
 PS VALVE

Assembly (Cont'd)
NOTE:
The bolt hole differs from the oil hole in pitch and diameter.

6. Turn the spool and sleeve assembly so that the pin and the
housing port are parallel. Insert the drive and engage the drive
yoke and the pin.
For accurate positioning, draw a line on the drive end face
parallel to the pin using a marker pen.
7. Attach the O-ring to the gerotor.
CAUTION:
There are two O-rings. Ensure that the correct one is selected.

8. Position the O-ring side of the gerotor toward the spacer plate
and assemble it while aligning the concaves of the gerotor star
gear to the line marked. At that time, ensure that the pin, drive
and star concaves are all aligned parallel as shown in the figure.
Turn the gerotor ring to align the bolt holes while keeping the
drive and the gerotor star engaged with each other.

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WARNING:
Make sure to restore the correct positional relation. Incorrect
combinations will cause a malfunction, which may lead to
serious accidents.
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CAUTION:
STT0106L
• Be sure to perform above steps 6 to 8 because they are
important procedure for mating valve timing.
• The bolt hole differs from the oil hole in pitch and diameter.

9. Install the spacer into the spline of the gerotor star.

10. Fit the plug to the gerotor star.
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Attach the O-ring to the plug and fit the plug into the star
groove of the gerotor.
11. Attach the O-ring to the end cap. Place the end cap on the
gerotor and align the bolt holes.
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12. Apply oil to the threads of the six screws and a retainer screw,
and install them into the end cap. Ensure that the retainer screw
fits in to the correct positions instructed in the sectional
structure view. Tighten the seven screws to approximately 14.7
N•m (1.5 kg-m) as the initial tightening. Then tighten them to the
specified torque in the order shown in the figure.
Tightening torque [N•m (kg-m)]: 20.6 (2.1)
13. Install the handle to the spool and verify that the spool can
rotate.

STT0108L

ST-11
 PS VALVE

Trouble Diagnosis and Corrections

Condition Possible cause Corrective action

High-effort steering 1. Hydraulic system

• High backpressure • Lower backpressure to under allowable level.
• Set steering relief valve pressure too low • Reset pressure.
2. PS valve
• No centering to column • Repair. (If the steering effort is reduced when
the PS valve retaining bolts are loosened, the
cause is incorrect centering.)
• Seizure due to foreign objects between spool • Replace.
and sleeve or sleeve and housing
• Excessive tightening torque of end cap screw • Evenly tighten to correct torque.
• Missing ball in emergency steering check valve • Install ball.
3. Direct valve or other attached control valves
• Excessive tightening torque of port connector • Tighten to the specified torque.
• Excessive tightening torque of retaining bolts • Tighten to the specified torque.
• Foreign object in relief valve • Disassemble, clean, reassemble, adjust set
pressure or replace valve assembly.
• Foreign object between housing and spool • Replace valve assembly.
• Malfunction (inappropriate operation) • Replace valve assembly.
• Clogged orifice • Disassemble, clean, reassemble.
• Incorrect assembly of control spring • Replace with optimum spring.

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4. Pump
• Not operating • Activate.
• Worn, malfunctioning • Replace.
• Reverse rotation • Repair.
AF
5. Vehicle
• Excessive wear of mechanical parts • Lubricate or replace bearing joint.
Steering wheel will not return to neu- 1. Hydraulic system
tral position after it is released, or • High backpressure • Lower pressure to under allowable level.
steering wheel turns spontaneously
2. PS valve
(except load reaction type).
• Seizure due to foreign objects between spool • Replace.
and sleeve
• No centering to column • Repair.
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• Damaged centering spring • Replace spring.
Cylinder does not follow steering 1. Hydraulic system
wheel at all or only unsatisfactorily, • Air inclusion • Bleed the air.
wheel slip is too large.
2. PS valve
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• Worn internal parts • Replace, clean, reassemble, and adjust set

pressure.
• Insufficient tightening torque of end cap screw • Evenly tighten to correct torque.
• Missing drive or spacer • Assemble correctly.
3. Direct valve or other attached control valves
• Foreign objects in overload relief valve and anti- • Disassemble, clean, reasemble, and adjust set
cavitation check valve pressure or replace valve assembly.
• Damaged O-ring • Replace.
4. Pump
• Insufficient volume efficiency • Replace.
5. Cylinder
• Damaged piston seal • Replace.
Steering wheel is pulled back or wheel 1. Hydraulic system
kick symptom occurs. • Incorrect piping to 4 ports • Repair.
2. PS valve
• Incorrect valve timing assembly • Assemble correctly.
Vibration 1. Hydraulic system
• Air inclusion • Bleed the air.
2. Vehicle
• Worn mechanical joints • Replace worn parts.

ST-12
 PS VALVE

Trouble Diagnosis and Corrections (Cont’d)

Unusual noise (including unusual 1. Hydraulic system
release noise) • Noise by interference of hydraulic piping • Eliminate interference.
2. Direct valve or other attached control valves
• Foreign objects in steering relief valve or • Disassemble, clean, reassemble, and adjust set
overload relief valve or excessive wear pressure or replace valve assembly.
Oil leakage 1. PS valve [Worn or damaged axle (spool) oil
seal]
• Contaminated fluid • Replace fluid and filter element.
• High backpressure • Lower pressure to under allowable level.
• Rust on spool sealing face • Replace assembly.
• Damage in disassembly/assembly [Damaged • Replace.
O-ring for fitting face (gerotor)]
• Bite during disassembly/assembly • Replace.
• Damaged O-ring groove • Replace relevant parts.
• Insufficient tightening torque of end cap screw • Tighten to correct torque.
2. Direcat valve or other attached control valves
• Loose direct retaining bolts to PS valve • Tighten to correct torque.
• Damaged O-ring • Replace.
• Damaged sealing face and groove • Replace relevant parts or assembly.

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ST-13
 PS CYLINDER (4 - WHEEL)
PS CYLINDER (4 - WHEEL)

Construction

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STM0091

1. Cylinder tube
AF
7. Backup ring 13. Spherical bushing
2. Piston rod 8. Wiper ring 14. Snap ring
3. Cylinder head 9. O-ring 15. Tie rod
4. Bushing 10. O-ring 16. Nut
5. Snap ring 11. Slip seal 17. Washer
6. U-ring 12. O-ring
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Specification
Vehicle model

Items J(A)G1N1
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Cylinder outer diameter mm (in) 75 (2.95)

Cylinder inner diameter mm (in) 65 (2.56)

Piston rod diameter mm (in) 45 (1.77)

Stroke mm (in) 167 (6.57)

ST-14
 PS CYLINDER (4 - WHEEL)

Removal
1. Jack up the vehicle and support it securely with a rigid rack.
2. Disconnect the hydraulic tube from the PS cylinder.

STM0099EU

3. Remove the tie-rod clevis pin connecting the piston rod and tie
rod bar.

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AF
STT0112L

4. Remove the bolt from the steer axle joint.

5. Turn the kingpin and pull it aside from the steer axle.

Installation
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Note the following, and install in the reverse order of removal.
• Clean the inner wall of the spherical bushing mounting hole to
prevent risk of seizure due to foreign objects.
• Apply grease to the sliding faces and dust cover lips.
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PS cylinder mounting bolt

: 137 - 186 N•m (14 - 18 kg-m, 101 - 137 ft-lb)
Tie-rod clevis pin mounting bolt:
: 7.2 - 10.8 N•m (0.74 - 1.10 kg-m, 6 - 7 ft-lb)
Flare nut:
: 39 - 59 N•m (4.0 - 6.0 kg-m, 29 - 43 ft-lb)
PS cylinder connector
: 39 - 43 N•m (4.0 - 4.4 kg-m, 29 - 32 ft-lb)

ST-15
 PS CYLINDER (4 - WHEEL)

Troubleshooting
Condition Possible causes Corrective action

Oil leakage from piston Piston 1. Eliminate the scratches and smoothen the sliding face
rod sliding face rod (1.5s or less) using oilstone. If the oil still leaks, the sealing
*: Refer to “Inspection • Rust or scratches on parts such as U-ring may be damaged by the scratches.
After Assembly” for sliding face, which can be Overhaul the piston.
judgement. felt by fingernails. 2. If the scratches and rust zone is too wide to repair with
oilstone, replace the piston rod, U-ring, seals such as the
wiper ring, and piston rod bearings.

1. Re-plate or replace the piston rod.

• Detached plating 2. At the same time, inspect the seals and piston rod
bearings, and replace them if necessary.

Rod • Foreign object in inner/ 1. Remove the foreign objects.

packing outer faces 2. Replace any damaged packing.
(U-ring)
• Scratches on inner/outer 1. Replace.
faces

1. The symptom may be caused by adiabatic compression of

residual air in the cylinder.
• Lip and groove partially
2. After replacing the packing, always perform initial
carbonized (burnt)
operations at low pressure and low speed to bleed the air
from the cylinder sufficiently.

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1. Replace.
2. The packing may have reached its end of life or the fluid
• Packing deteriorated in
may have been deteriorated or overheated.
elasticity and shredded in
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pieces
• Replace the fluid.
• Check the fluid temperature. [The desirable temperature
• Lip faces widely lost
is 80°C (176°F) or less.]
• Check for any partially heated portion.

1. Replace.
2. The packing may be subject to excessive high pressure.
• Excessive projection of
• Check the operation pressure.
packing heel
• If equipped with a buffer ring, the buffer ring may be the
cause. Check the buffer ring.
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Backup ring 1. As a rule, also replace the rod packing.
(If equipped with a buffer ring, the buffer ring should be
replaced at the same time.)
• Largely deformed
2. The cause may be excessive high pressure. In this case,
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follow the above instructions for the excessive projection of

packing heel.

Wiper ring • Foreign objects in lip 1. Remove the foreign objects.

• Damaged lip Other 1. Replace.

damages

Bearing • Too much wear resulting in 1. Replace.

materials excessive gap with piston
rod (Refer to “Disassembly”,
“Maintenance criteria”.)
• Large scratches on sliding 1. Replace.
face 2. At the same time, inspect the piston rod.

Oil leakage from piston Cylinder • Cylinder head used in 1. Remove the scratches and rust with oilstone.
rod sliding face head piston rod contains rust or 2. If not repairable, replace the cylinder head.
*: Refer to “Inspection scratches on seal fitting
After Assembly” for face. Refer to “Bearing
judgement. materials” above.

ST-16
 PS CYLINDER (4 - WHEEL)

Troubleshooting (Cont’d)
Condition Possible causes Corrective action

Oil leakage from cylinder O-ring 1. Remove the foreign objects.

head fitting face 2. Replace the damaged O-ring.
• Foreign objects in inner/
3. Inspect the tube inner face: If any scratches or rust are
outer faces
present, smoothen the surface with oilstone.
• Damaged O-ring
4. Inspect the O-ring groove of the cylinder head: Same as
above. After checking the above points, replace the O-ring.

Cylinder 1. Disassemble the cylinder head and inspect the O-ring. If

head damaged, replace it.
2. After inspection, tighten to the specified torque.
• Looseness
Refer to “Assembly”.
3. When tightening, securely hold the component so that it
does not rotate.
Tie rod and • Looseness, stretch, 1. Replace all tie rods and nuts. Tighten them to the specified
nut damage torque.

Cylinder 1. Replace with a new one.

tube 2. Oil leakage from fitting faces may be caused by
• Excessive swelling excessive high pressure (including cushion pressure).
Check tube for swelling and deformation and inspect the
circuit pressure.

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Inappropriate functioning Piston rod • Excessive bending 1. Replace with a new one.
No smooth operation or cylinder deformation over specified Also inspect the seals and sliding parts, which may be
tube limit damaged. Replace them if necessary.
(Bending deformation:
AF Refer to “Disassembly”,
“Maintenance criteria”.)

Cylinder 1. Replace with a new one. As in the above, also inspect the
• Dent
tube seals and sliding parts.

Piston rod • Excessive wear and 1. Replace with a new one. As in the above, also inspect the
Cylinder damage of sliding faces, seals and sliding parts.
tube Sliding foreign objects in piston 2. Remove the foreign objects. As in the above, also inspect
part and cylinder head sliding the seals and sliding parts.
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materials faces

Internal oil leakage Piston seal 1. Replace with a new one. Also inspect the inside of the
• Scratches or wear
Piston rod moves cylinder tube.
spontaneously during
operation or specified Cylinder 1. Remove scratches and rust by honing or with oilstone to
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speed output is not tube smoothen the surfaces. If the damaged area is too large to
• Scratches or rust inside
available. repair, replace the cylinder tube.
2. Replace the piston seal.

Valves 1. Check the valve leakage amount and service as

• Leakage from valves
necessary.

Spongy operation feel Air 1. Bleed the air.

• Cylinder without air bleeder
Make several strokes at low pressure and low speed to
bleed air.
• Cylinder with air bleeder
• Residual air in cylinder Unload the cylinder so that the internal temperature builds
up excessively. Loosen the air bleeder and extract air.
(Reference)
The cylinder may stroke slightly when it is stopped abruptly.
This is caused by the compressibility of the fluid. In particular,
the phenomenon is likely to occur with long cylinders.

Too much impact at a Pin bushing 1. Measure the dimensions of the pin and pin bushing.
changeover point Pin • Too large gap between Replace the parts if the dimensions exceed the allowable
between expansion and mounting and pin bushing limits.
retraction.

Noise during cylinder Lubrication • Insufficient lubrication 1. Lubricate.

operation
Pin bushing 1. Replace with a new one and lubricate.
• Bite in fitting face
Pin

ST-17
PS CYLINDER (4 - WHEEL)

Troubleshooting (Cont’d)
CAUTION:
• The hydraulic fluid expands or shrinks due to changes in the
ambient temperature and pressure. The resultant cylinder
stroke may be recognized incorrectly as internal oil leakage.
• When checking for any internal oil leakage, ensure that the
temperature and pressure do not change during the check.

Disassembly
PREPARATION
Before starting disassembly work, make the following preparations.
• Work bench
Prepare a wide and robust workbench so that the components on
the bench are supported stably and securely.

GENERAL PRECAUTIONS
• Before disassembling the cylinder, remove soil and dust from the
cylinder outside wall.
• All components are precision-made. Always handle the

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components with great care. Do not allow the components to hit
other parts or drop on the floor.
• When working, do not use excessive force. Tapping strongly or
AF prying forcibly may create burrs or damage the components,
rendering the component unusable and causing oil leakage and
performance deterioration. Always work with patience.
• Do not interrupt disassembly or assembly work in the interim
wherever possible. Moisture and dust may enter the exposed
components and rust may develop later. If it is inevitable to
interrupt the work, take appropriate measures for rustproofing and
dustproofing.
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MAINTENANCE CRITERIA
The sliding parts and sealing parts must be replaced according to
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the following criteria.

• Bushing
When one-fourth of the periphery is worn out and turned copper
brown
• Seals
Whenever the cylinder is disassembled
• Spherical bearing
If a significant bite is observed
• Piston rod
If a bend of 0.5 mm (0.020 in)/1 m (3 ft) or more is observed

ST-18
 PS CYLINDER (4 - WHEEL)

Disassembly (Cont’d)
DISASSEMBLY
1. Extract fluid.
2. Place the cylinder on a horizontal surface.
3. Set the piston rod in the neutral position.
4. Loosen the nut and remove the tie rod.
5. Remove the cylinder heads.
CAUTION:
There are two cylinder heads. Before removing each cylinder
head, prepare an appropriate container to collect oil drained
from the joint between cylinder head and cylinder tube.

6. Pull out the piston rod.

CAUTION:
When removing the piston rod, make sure to hold the rod in a
horizontal position and pull it with great care. The piston rod
may drop abruptly as soon as it comes off from the cylinder,
resulting in component damage.
7. Remove the piston seal.

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• To remove the slip seal, place a flat-bladed screwdriver as shown
in the figure, and then hit the end of the screwdriver with a
hammer to cut the seal.
• To remove the O-ring, use a spatula.
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CAUTION:
Do not reuse sealing parts.

STT0113L
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8. Disassemble the U-ring and wiper ring.
• To remove the U-ring and backup ring, use a screwdriver or an
equivalent tool.
• The wiper ring is press-fit. To remove it, apply the tip of a
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screwdriver to the rubber portion and tap on the screwdriver to

take out the ring.
CAUTION:
Do not reuse sealing parts.

STT0114L

9. Disassemble the bushing.

• Insert a screwdriver in the open end of the snap ring, and pry out
the ring.
• To remove the bushing, use the jig and a press to push it out.

STT0115L

ST-19
 PS CYLINDER (4 - WHEEL)

Disassembly (Cont’d)
10. Remove the pin bushing.
• Remove the snap ring.
Insert the tip of a screwdriver in the open end of the snap ring,
and pry out the ring from the groove.
If the ring is the C-snap type, use pliers to remove it.
• To remove the pin bushing, push it out by using a press as shown
in the figure.

11. Cleaning and storage.

• Clean the removed parts with kerosene and apply a thin coat of
STM0100 fluid. When storing the parts, cover them with sheets of
appropriate materials.
• Do not leave the parts exposed to the ambient air. Otherwise the
parts may exhibit only deteriorated performance when
reassembled due to rust and dust adhesion.

Assembly
CAUTION:
The paint of the components may flake off and enter inside the

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cylinder, resulting in oil leakage. When assembling, exercise
extreme caution not to allow any paint to come off.
AF INSTALL THE PIN BUSHING (SPHERICAL BEARING)
1. Press-fit the bushing into the piston rod and tube using the
installation jig. (Apply a thin coat of fluid beforehand.)
2. Attach the snap ring (or C-snap) to hold the pin bushing in
place.
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D

STM0101

ASSEMBLY OF CYLINDER HEAD

1. Press-fit the bushing using the press-fit jig.
(Before assembling, apply a thin coat of fluid to the inner face of
the cylinder head. After press-fitting, ensure that no height
difference is present.)

ST-20
 PS CYLINDER (4 - WHEEL)

Assembly (Cont’d)
2. Install the wiper ring using an impact block.

STT0118L

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AF
STT0119L

3. Assembly of U-ring.
• Attach the backup ring and U-ring in order into the U-ring groove.
• Ensure that the U-ring is correctly positioned and free from
damage.
• Reverse installation will lead to oil leakage.
• After attaching the rings, verify that no permanent deformation,
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such as wrinkles, is created.
4. Install the snap ring to retain the bushing.
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STT0120L

5. Install the O-ring.

CAUTION:
Ensure that the size of the O-ring and the installation position
are correct.

STT0121L

ST-21
 PS CYLINDER (4 - WHEEL)

Assembly (Cont’d)
ASSEMBLY OF PISTON SEALS
1. Attach the O-ring into the groove.
• Ensure that the O-ring is not twisted.
2. Push the slip seal onto the piston while stretching the seal. The
slip seal insertion jig will help to attach it safely. Heating the slip
seal to approximately 80°C (176°F) also facilitates the assembly
work.

STT0122L

3. If the slip seal is still stretched when fitted onto the piston,
straighten it with the straightening jig.
• The stretched slip seal will prevent subsequent assembly work.

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AF
STM0092

ASSEMBLY OF PISTON ROD, CYLINDER HEAD AND

CYLINDER TUBE
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1. Hold the tube in a horizontal position.
2. Insert the piston rod into the tube.
CAUTION:
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Ensure that the slip seal is not damaged.

3. Insert the piston rod into the cylinder head. When inserting the
rod, ensure that the lips of the wiper ring and U-ring are not
damaged by the height gap of the piston rod. The insertion jig
will help to assemble safely.
4. Insert the cylinder head into the cylinder tube.
CAUTION:
Ensure that the antirust O-ring is not caught and damaged by
the tube end face.

STT0124L

ST-22
PS CYLINDER (4 - WHEEL)

Assembly (Cont’d)
INSTALLATION AND TIGHTENING OF TIE ROD
1. Install the tie rod and nut and hold the two cylinder heads in
place.
CAUTION:
Ensure that the cylinder heads are positioned correctly.

2. Tighten the nut to the specified torque using a torque wrench.

: 45 N•m (4.5 kg-m, 33 ft-lb)

TEST OPERATION
1. Turn the key switch to ON position while lifting up rear wheels.
2. Turn the handle left/right rapidly or slowly, and then repeat
several times. However, do not turn the handle to full stroke at
first, increase the stroke gradually.
Do not move the cylinder rapidly from the beginning.
Doing so will cause aeration.
3. Repeat above operations to fill the cylinder with oil.
4. Lubricate both end bushings.

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ST-23
 PS CYLINDER (4 - WHEEL)

Periodical Inspection and Maintenance

To ensure a longer life and satisfactory performance of the PS
cylinder, regularly perform inspections and maintenance based on
the “Self-inspection list”. If any symptom is found, diagnose and
repair it without delay based on “Troubleshooting”.
CAUTION:
When performing periodical inspections/maintenance, avoid
any potential risk by adopting appropriate protective measures
to the workplace and controlling one’s behavior in a reasonable
manner.
Inspection list
Inspection/
maintenance Inspection and maintenance contents Daily Monthly Annual Remarks
point

Appearance Cleanness of cylinder (particularly rod sliding face)

Oil leakage from piping connections and mounting parts

Paint detachment, exfoliation, rust

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Operation Smooth motion, unusual noises or conditions

Response

Oil leakage from sliding face

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Internal leakage

Correct operation pressure

Correct set pressure of overload relief valve

Hydraulic fluid Contamination or deterioration of fluid

Periodical replacement of fluid

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Periodical inspection of filter

Mount to main Greasing to bushing

body
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Unusual noise or seizing of bushing

Loose or worn bushing

Bushing seal functionality

Loose or missing screws

Additional tightening to mounting bolts

Piston rod Worn sliding face If the piston rod sliding

face is to be exposed
Scratches or dent on sliding face for a long period of
time, apply antirust oil
Plating detachment from sliding face to the piston rod.
Bend of sliding face

Cracks or damages of welds

Cylinder tube Loose nuts and bolts

(including piping)
Additional tightening of nuts and bolts

Cracks or damages of welds

Large depression or dent on tube

ST-24
 PS CYLINDER (4 - WHEEL)

Periodical Inspection and Maintenance (Cont’d)

QUANTITATIVE JUDGEMENT FOR OIL LEAKAGE

FROM ROD
• Judge from the oil rings that are created after 20 strokes at a fluid
temperature of 20°C (68°F) to 40°C (104°F).
• The deformed oil ring A below suggests possible oil leakage. Take
appropriate measures referring to “Troubleshooting”.

STM0093

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ST-25
PS CYLINDER. (3 - WHEEL)
PS CYLINDER. (3 - WHEEL)

Construction

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STM0801EU

ST-26
PS CYLINDER. (3 - WHEEL)

Construction (Cont’d)

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STM0080

ST-27
PS CYLINDER. (3 - WHEEL)

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STM0071

•
CAUTION:
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines is completely bled off.

ST-28
 PS CYLINDER. (3 - WHEEL)

• To prevent foreign material from entering, always maintain a

clean workplace.
• When disconnecting pipes, cover the surrounding area with
waste cloths and ensure that oil does not contaminate other
parts.
• Never allow foreign material to enter pipes when connecting.
• Put disassembled parts on clean paper or waste cloths and
use care so as not to contaminate, scratch or dent them.
• Turn the key switch to OFF and disconnect the battery cables
before removal.

Removal
1. Jack up and support the bottom of the frame around the
steering axle assy.. (Refer to the GI section.)
2. Remove the battery. (Refer to the BC section.)
3. Remove the counterweight. (Refer to the BF section.)
4. Remove the controller assembly. (Refer to the CS section.)
5. Remove the rear tire. (Refer to the TR section.)
6. Disconnect the tire angle sensor harness connector.
7. Disconnect the PS piping connection.
8. Remove the steering axle mounting bolt.

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9. Remove the steering axle assy. from the vehicle.
NOTE:
The rear tire interferes with the frame if it is removed together with
AF the steering axle assy.. Therefore, the steering axle assy. cannot be
removed.

10. Disconnect the PS hose from the PS cylinder and drain the oil.
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STM0078

Installation
Install in the reverse order of removal.
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Steering axle mounting bolt

Tightening torque
[N•m (kg-m)]: 240 - 320 (25 - 32), 177 - 236 ft-lb
Disassembly
1. Remove the tire angle sensor together with the bracket.
2. Remove the bolt, and then separate the steering axle mounting
assembly and the steering axle bracket.

ST-29
 PS CYLINDER. (3 - WHEEL)

STEERING AXLE MOUNTING ASSY.

DISASSEMBLY
1. Unlock the lock washer, and then remove the lock nut.
2. Remove the washer, the dust cover, and the roller bearing.
3. Separate the steering axle mounting and the steering mounting
plate.
4. Remove the roller bearing from the shaft of the steering
mounting plate.
5. Remove the seals and the rings from the steering axle mounting
if necessary.
CAUTION:
Always replace the seals with new ones.

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STM0081
AF
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ST-30
 PS CYLINDER. (3 - WHEEL)

Disassembly (Cont’d)
ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
• Be careful of the direction of the seal when assembling the
seals.
• Always use the Loctite 620 when assembling the upper seal
and the lower ring to the steering axle mounting.
• Assemble the steering axle mounting to the steering
mounting plate so that the center tooth of the rack is
positioned between two teeth of the steering mounting plate
shaft.

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STM0082

• Apply the bearing grease to 3 positions shown in the figure.

PRELOAD ADJUSTMENT
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1. Tighten the lock nut once.

2. Loosen the lock nut.
3. Tighten the lock nut again.
Preload torque (with rack and without PS cylinder)
[N•m (kg-m)]: 15 - 25 (1.6 - 2.5), 11 - 18 ft-lb
4. Securely lock the lock nut using the lock washer within the
above torque.
STM0083

ST-31
 PS CYLINDER. (3 - WHEEL)

Disassembly (Cont’d)

PS CYLINDER
DISSASEMBLY

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AF
STM0084

1. Remove the PS cylinder tube using a SST (99514GA10A).

2. Remove the piston.
3. Remove the O-ring.
4. Remove the bushing and the seal from the piston.
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ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
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• Always use new O-ring, seal, and bushing.

• Turn the end gap of the bushing by 180 degrees, and then
assemble the bushing to the piston.
• Face the flat surface of the piston to the rack side, and then
assemble the piston.

STM0085

ST-32
 PS PIPING
PS PIPING

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STM0071EU

ST-33
 PS PIPING

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STM0802EU
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ST-34
 PS PIPING

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STM0072

CAUTION:
• When installing the connector, make sure that electrical line
is free from foreign materials, and no deformation or crush
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occurs.
• When fixing hoses, make sure that the direction and position
of hoses should be correct to protect them from twist and
tension.
• Before bleeding the air, turn the key switch to ON and turn
the steering wheel fully from left to right (lock to lock) 15
times.
• Make sure that steering system is free from oil leakage and
other defects when keeping the steering wheel at relief
pressure position (left and right) over 3 seconds.
• Install hose clamps as shown in the figure.

Refer to CS section for inspection of the knob position control valve.

STM0089

ST-35
 MEMO

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ST-36
 HYDRAULIC SYSTEM

SECTION HD
CONTENTS

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SERVICE DATA AND SPECIFICATIONS ......... HD-2 TILT CYLINDER .............................................. HD-40
General Specifications .................................. HD-2 Construction ................................................ HD-40
Inspection and Adjustment ........................ HD-2 Removal ...................................................... HD-40
AF
Adjusting Shim .............................................. HD-3 Disassembly ................................................ HD-41
Tightening Torque ......................................... HD-3 Inspection .................................................... HD-42
TROUBLE DIAGNOSES AND Assembly ..................................................... HD-42
CORRECTIONS ................................................. HD-4 Installation ................................................... HD-43
PRECAUTIONS AND PREPARATION ............. HD-8 LIFT CYLINDER .............................................. HD-44
Precautions ................................................... HD-8 Construction ................................................ HD-44
Special Service Tool ...................................... HD-9 Removal ...................................................... HD-48
HYDRAULIC SYSTEM ..................................... HD-10 Installation (2W, 2F, 3F, 3V) ........................ HD-52
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Hydraulic Circuit Diagram ............................ HD-10 Disassembly ................................................ HD-53
Disassembly and Assembly ........................ HD-12 Inspection .................................................... HD-53
Inspection .................................................... HD-25 Assembly ..................................................... HD-54
OIL PUMP (GEAR PUMP) ............................... HD-26 Adjustment .................................................. HD-54
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Removal ...................................................... HD-26 FULL-FREE CYLINDER .................................. HD-55

Installation ................................................... HD-26 Construction ................................................ HD-55
Disassembly ................................................ HD-27 Removal ...................................................... HD-58
Inspection .................................................... HD-28 Disassembly ................................................ HD-58
Assembly ..................................................... HD-29 Inspection .................................................... HD-59
Test Procedures .......................................... HD-30 Assembly ..................................................... HD-59
HYDRAULIC CONTROL LEVER ..................... HD-32 Installation ................................................... HD-60
Mechanical Control System ......................... HD-32 Adjustment .................................................. HD-60
CONTROL VALVE ........................................... HD-33 OIL TANK (3-WHEEL) ..................................... HD-61
Removal ...................................................... HD-33 Disassembly ................................................ HD-61
Installation ................................................... HD-34 OIL TANK (4-WHEEL) ..................................... HD-62
Disassembly ................................................ HD-34 Disassembly ................................................ HD-62
Inspection .................................................... HD-37
Assembly ..................................................... HD-37
Hydraulic Test ............................................. HD-37
 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications
Oil pump (Gear pump) Tilt cylinder
(A)1N1 series Applied model (A)1N1 series
Applied model Regular Large Stroke mm (in) 81 (3.19)
capacity capacity Cylinder I.D.mm (in) 65 (2.56)
KFS 2320 KFS 2324 Cylinder O.D.mm (in) 80 (3.15)
Pump type Piston rod diametermm (in) 30 (1.18)
CSNS CSNS
Drive type Direct coupled to motor Tilt angle 2W, 2F 4°/ 6°
(Forward-
Gear system Single, Zero-backlash type
backward) 3F, 3V 5°/ 5°
Normal discharge 20.2 24.0
m (US fl oz, lmp fl oz)/rev. (0.68, 0.71) (0.81, 0.84)
Lift (mast) cylinder
Maximum pressure
20.6 (205.9, 210, 2,986)
MPa (bar, kg/cm2, psi) Mast name 2W 2F 3F and 3V
Cylinder I.D. mm (in) 45 (1.77) 45 (1.77) 45 (1.77)
Control valve Cylinder O.D mm (in) 52 (2.05) 52 (2.05) 52 (2.05)
Piston rod diameter
(A)1N1 series 35 (1.38) 32 (1.26) 35 (1.38)
mm (in)
Applied model Mechanical
Joystick type
type Full-free cylinder

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KVSF- KVSB-
Valve type Mast name 2F and 3F 3V
65VPFLS 65PSL
Main relief set pressure Cylinder I.D. mm (in) 70 (2.76) 50 (1.97)
16.7 (167.0, 170.34, 2,421) Cylinder O.D mm (in) 84 (3.31) 60 (2.36)
MPa (bar, kg/cm2, psi)
Piston rod diameter
Tilt relief set pressure
AF
9.3 (93.0, 94.86, 1,348) mm (in)
50 (1.97) 40 (1.57)
MPa (bar, kg/cm2, psi)
The 3rd and 4th relief set pressure
11.8 (118.0, 120.36, 1,711) Suction filter
MPa (bar, kg/cm2, psi)
Power steering relief set pressure Applied model (A)1N1 series
6.9 (69.0, 70.38, 1,000)
MPa (bar, kg/cm2, psi) Filter type Wire gauze
Relief valve type Cartridge Diameter mm (in) 100 (3.94)
Plunger type Cylinder, spring return Filtration accuracy (mesh) 150
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Rated flow rate Filter area cm2 (sq in) 620 (96.1)
65 (17-1/8, 14-1/4)
(US gal, lmp gal)/min.
Micron filter
Applied model (A)1N1 series
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Filter type Filter paper (cartridge) type

Filtration sizeμm 20

Inspection and Adjustment

Hydraulic oil type and capacity Control valve
Unit: mm (in)
(A)1N1 series
Applied model (except J(A)G1N1 Item Usable limit Remarks
J(A)G1N1)
Clearance between
Hydraulic oil Standard I.S.O. VG32 0.02 (0.0008) All models
plunger and valve
type Cold storage SAE No. 10W (I.S.O. VG15)
Oil capacity (US gal, lmp gal) 17.9 (4-3/4, 4) 20,5 (5-3/4, 5) Tilt cylinder
Unit: mm (in)
Oil pump (Gear pump)
Item Usable limit Remarks
Unit: mm (in)
Clearance between
Item Pump type Usable limit Remarks cylinder head
0.2 (0.008) —
KFS 2320 20.961 Regular bushing and piston
rod
CSNS (0.8252) capacity
Gear shaft O.D. Clearance between
KFS 2324 20.961
Large capacity cylinder tube and 0.2 (0.008) —
CSNS (0.8252)
piston

HD-2
 SERVICE DATA AND SPECIFICATIONS

Inspection and Adjustment (Cont’d)

Lift cylinder
Unit: mm (in)

Item Usable limit Remarks

Clearance between
cylinder head
0.2 (0.008) —
bushings and piston
rod
Clearance between
cylinder tube and 0.7 (0.028) —
piston ring

Adjusting Shim
Unit: mm (in)

Item Usable limit Remarks

Shim for aligning full-
Select proper number
free cylinder parallel 1.0 (0.039)
of shims.
to inner mast

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Shim for adjusting
Select proper number
height of upper end 1.0 (0.039)
of shims.
of lift cylinder
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Tightening Torque
Part name N•m (kg-m, ft-lb)

Oil pump-to-pump motor securing bolts 25 - 31 (2.5 - 3.2, 18 - 23)

Oil pump Intake connector 92 - 108 (9.3 - 11.0, 68 - 80)
Discharge connector 79 - 88 (8.0 - 9.0, 58 - 65)
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M10 47 (4.8, 35)
Control valve assembly Assembly tie rod nut
M8 19 (1.9, 14)
Control valve Main relief valve assembly 49 (5.0, 36)
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Tilt relief valve assembly 49 (5.0, 36)

Control valve assembly attaching bolt 20 - 22 (2.0 - 2.2, 14 - 16)
Striker attaching bolt 13 - 15 (1.3 - 1.6, 10 - 11)
Control lever
Lever bracket attaching nut 26 - 33 (2.6 - 3.3, 19 - 24)
Rod head lock nut 108 - 147 (11 - 15, 80 - 108)
Tilt cylinder
Cylinder head 350 - 400 (36 - 40, 259 - 295)

Cylinder head 2W, 3F and 3V 197 - 245 (20 - 25, 145 - 180)
(Lift Cylinder) 2F 197 - 225 (20 - 23, 145 - 166)
Cylinder mounting bolt 44 - 54 (4.4 - 5.6, 32 - 40)
U-bolt lock nut 26 - 32 (2.6 - 3.3, 19 - 24)
Lift cylinder Adjusting bolt lock nut 74 - 94 (7.5 - 9.6, 54 - 69)

Cylinder head 2F and 3F 300 - 370 (31 - 37, 202 - 272)

(Full-free cylinder) 3V 246 - 274 (25 - 28, 181 - 202)
2F and 3F 128 - 156 (13 - 16, 95 - 115)
Full-free cylinder mounting bolt
3V 44 - 54 (4.4 - 5.6, 32 - 40)
Oil tank mounting bolt 21 - 26 (2.1 - 2.7, 16 - 19)
Suction filter mounting bolt 5 - 6 (0.52 - 0.66, 3.8 - 4.7)
Oil tank
Micron filter unit mounting bolt 21 - 26 (2.1 - 2.7, 16 - 19)
Connector 79 - 88 (8 - 9, 59 - 64)

HD-3
 TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS

CAUTION:
The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.
For malfunctions closely related to pump motor, refer to MM section for diagnosis.
For malfunctions closely related to control system, refer to CS section for diagnosis.

OIL PUMP (GEAR PUMP)

Condition Probable cause Corrective action

No oil supplied from oil pump • Low oil level in tank • Fill up oil to specified level.
• Clogged suction pipe or filter • Clean. If oil is dirty, replace with new.
Low oil pump pressure • Worn gear shaft bushing or faulty packing • Replace with new one.
ring
• Improperly adjusted relief valve • Readjust to specified pressure using
pressure gauge.
• Air in the system • Retighten suction side piping.
• If oil level in tank is too low, add oil to
specified level.

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• Do not operate pump until air bubbles in
tank are removed.
Abnormal noise caused by oil pump • Cavitation due to crushed suction hose or • Remove foreign matter and repair crushed
clogged filter hose.
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• Air sucked from lose suction side joint • Retighten each joint.
• Excessive viscosity of oil • Replace with new oil having proper
viscosity.
• Air bubbles in hydraulic oil • Discharge air, remove foreign matter and
replace oil.
Oil leakage from oil pump • Faulty oil seal or body seal • Replace seal with new one.
• Worn sliding surfaces of gears (Increased • Replace oil pump with new one.
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inner leakage)
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HD-4
 TROUBLE DIAGNOSES AND CORRECTIONS

CONTROL VALVE

Condition Probable cause Corrective action

Fluctuation of steering side oil pressure • Malfunctioning plunger • Clean foreign matter in hydraulic oil, or
change oil.
• Pump discharging oil is less than specified • Check pump performance and if necessary
amount. replace the damaged parts.
• Relief valve pressure set too low • Check and correct relief valve set pressure.
[Standard: 6.9 MPa (68.6 bar, 70 kg/cm2,
995 psi)] (Refer to ST section.)
• Broken spring • Replace.
• Foreign matter caught in fixed orifice of • Disassemble and clean foreign matter.
plunger
Poor steering response until specified oil • Clogged plunger damper orifice • Disassemble and check.
pressure is attained.
• Malfunctioning plunger • Clean foreign matter from hydraulic oil, or
change oil.
Oil leaking • Damaged or scratched O-ring • Replace faulty O-ring.
Pump pressure does not rise. • Lift lock valve does not operate. • Disassemble and clean the valve. In case of
solenoid operation failure, replace the
solenoid.

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• Shuttle of proportional solenoid pressure- • Disassemble and clean the valve. However,
reducing valve or plunger of proportional when the plunger of the proportional
solenoid is stuck. solenoid is stuck, replace the valve because
it cannot be disassembled.
AF• Lead wire or solenoid coil is broken. • Repair or replace the wire or coil.
• Input current of solenoid is small. • Check if the specified maximum current is
applied.
• Lift lock valve is open. • Check the operation of the lift lock solenoid.
• Check the operation of the lift lock valve.
• Spool of flow priority valve is stuck. • Disassemble and clean the valve.
Plunger sticks • Foreign matter between sliding surfaces of • Clean valve housing and plunger.
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valve housing and plunger
• Deteriorated oil • Change oil with new.
• Damaged return spring • Replace.
• Distorted valve housing mounted • Loosen mounting bolts and check.
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• Bent plunger • Replace valve housing and plunger as an

assembly.
• Shuttle of proportional solenoid pressure- • Disassemble and clean the valve. However,
reducing valve or plunger of proportional when the plunger of the proportional
solenoid is stuck. solenoid is stuck, replace the valve because
it cannot be disassembled.
Oil leakage from oil seal • Paint dust or dirt caught in oil seal • Remove seal and clean.
• Distorted seal plate • Clean seal plate and retighten bolts.
• Worn or damaged seal • Replace.
• Damaged plunger • Replace.
Lowered or tilted forward cylinder without • Worn valve housing and plunger • Replace valve housing and plunger as an
control lever operation assembly.
• Oil leaking from cylinder • Check cylinder and replace faulty parts.
Load drops when changing control lever from • Foreign matter caught in load check valve • Disassemble check valve and clean.
NEUTRAL to RAISE position.
• Damaged poppet or check valve seat • Replace or repair by lapping.
Mast tilts forward when control lever is moved • Worn or damaged tilt lock plunger • Replace plunger and tilt valve housing as
forward and backward while key switch is OFF. an assembly.
• Broken tilt lock plunger spring • Replace.
• Oil leakage from O-ring in tilt cylinder piston • Replace.

HD-5
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Cylinder speed is too slow or cylinder does not • Worn relief valve or damaged seat • Replace relief valve assembly.
operate.
• Foreign matter caught in relief valve • Clean or replace relief valve.
• Faulty oil pump • Refer to “OIL PUMP”.
Mast is unstable or does not operate when • Stuck or damaged tilt lock plunger • Replace plunger and tilt valve housing as
control lever is moved to forward while key an assembly.
switch is ON.
• Foreign matter caught between valve and • Disassemble and clean.
plunger, making valve inoperative

RELIEF VALVE

Condition Probable cause Corrective action

Pressure does not rise at all. • Main poppet or pilot poppet is stuck and • Check for foreign objects in the engaged
kept open. area of the poppet.
• Foreign object is caught in poppet seat. • The poppet should slide freely.
• Clean all the parts thoroughly.
Relief pressure is unstable. • Poppet seat is damaged. • Replace the damaged part.
• Clean all the parts thoroughly.
• Poppet is stuck.
• Remove the flaw on the surface.
Relief pressure is abnormal. • Wear caused by foreign object • Replace the damaged part.

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• Perform readjustment.
• Lock nut or adjusting screw is loosened.
Oil leakage • Damage to seat • Replace the damaged part or the worn part.
• Wear of O-ring • Each part should move smoothly.
AF
• Each part is stuck due to foreign objects. • Check for scratch, scoring, and foreign
objects.
Pressure rise is delayed. • Air is trapped in relief valve. • Bleed air.

TILT CYLINDER

Condition Probable cause Corrective action

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Oil leakage (Sliding surfaces between cylinder and piston
rod)
• Foreign matter in U-ring • Remove and clean or replace.
• Damaged U-ring • Replace.
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• Foreign matter in lip of wiper ring • Remove and clean or replace.

• Damaged lip of wiper ring • Replace.
• Damaged sliding surface of piston rod • If damage is minor, repair using oilstone. If
serious, replace piston rod assembly.
• Flaked hard chromium plate of piston rod • Replace.
(Connected portion of cylinder head and tube)
• Damaged O-ring • Replace.
(Welded portion of cylinder tube)
• Damage or cracks • Replace.
(Others)
• Loose connector • Tighten to specified torque.
• Degraded or damaged hose or tube • Replace.
Cylinder tilts forward without control lever • Damaged sliding surface of cylinder tube • If damage is minor, repair using oilstone. If
operation. serious, replace cylinder tube.
• Damaged sliding surface of piston • Replace piston rod assembly.
• Damaged O-ring • Replace.
• Damaged backup ring • Replace.
• Faulty control valve • Refer to “CONTROL VALVE”.

HD-6
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Mast swings to and fro when brakes are • Air in cylinder • Operate cylinder for about five minutes (10 -
applied while driving. 20 strokes).
• Oil leak from piston seal • Replace seal or cylinder.

LIFT/FULL-FREE CYLINDER

Condition Probable cause Corrective action

Oil leakage (Sliding surfaces between cylinder head and

piston rod)
• Foreign matter in U-ring • Remove and clean or replace.
• Damaged U-ring • Replace.
• Foreign matter in lip of wiper ring • Remove and clean or replace.
• Damaged lip of wiper ring • Replace wiper ring.
• Damaged sliding surface of piston rod • If damage is minor, repair using oilstone. If
serious, replace piston rod assembly.
• Flaked hard chromium plate of piston rod • Replace.
Cylinder is lowered without control lever • Foreign matter in U-ring on piston side • Remove and clean or replace.
operation or power is insufficient.
• Damaged lip of U-ring on piston side • Replace U-ring.

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• Damaged sliding surface of cylinder tube • Replace cylinder tube.
• Damaged sliding surface of piston ring • Replace piston ring.
• Faulty down safety valve • Replace down safety valve assembly.
Abnormally low lowering speed of cylinder
AF
• Degraded or broken plunger return spring • Replace flow regulator valve assembly.
of flow regulator valve
• Foreign matter in moving part of flow • Replace flow regulator valve assembly.
regulator valve
• Faulty down safety valve • Replace down safety valve assembly
R
D

HD-7
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
WITH MECHANICAL SYSTEM
• For lift piping, fully tilt the masts forward, operate the control lever
several times forward, and turn key switch OFF. Operate the
control lever several times backward, and release the residual
pressure from piping.
• For lift piping, place the fork at the lowest position, and operate
the lift lever several times downward.

WITH JOYSTICK SYSTEM

• For tilt piping, first place the fork horizontal (tipped slightly
forward) and turn the key switch off. Next, loosen the piping and
let set while the remaining pressure escapes.
• For lift piping, place the fork at the lowest position, turn the key
switch off, loosen the shut-off valve and let the remaining pressure
escape.
• For attachment piping (3rd and 4th)
• Union connector
Place the attachment in neutral, turn the key switch off, loosen

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the piping, and let set while the remaining pressure escapes.
• Coupling
Installing and removing the cup may be difficult if the remaining
pressure inside the piping is high. If this is the case, turn the
AF key switch ON and while idling tip the lever (3rd and 4th)
backwards or forwards, and one of the cups will come off. Then
tip the lever in the other direction and remove the other cup.
CAUTION:
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines is completely bled off.
• To prevent foreign matter from entering, always maintain a
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clean workplace.
• When disconnecting pipes, cover the surrounding area with
rag and ensure oil does not contaminate other parts.
• Never allow foreign matter to enter pipes when connecting.
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• Put disassembled parts on clean paper or rag and use care

not to contaminate, scratch or dent them.
• Always assign lifting operations to qualified operators
trained in slinging or hoisting procedures.
• When handling heavy parts, two people should perform the
work.
NOTE:
• For the removal, installation and service of pump motor, refer to
MM section.
• For the removal of instrument inner cover, floor mat and floor
panel, refer to BF section.
• For removal and installation of mast, refer to LM section.

HD-8
 PRECAUTIONS AND PREPARATION

Special Service Tool

Tool number
Description
Tool name

Pressure gauge Measuring oil pressure

KV991009S1

HDT0001

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AF
R
D

HD-9
 HYDRAULIC SYSTEM
HYDRAULIC SYSTEM

Hydraulic Circuit Diagram

MECHANICAL CONTROL VALVE

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AF
R
D

Hydraulic oil pump PS relief valve Lift cylinder

Hydraulic pump motor Lift valve Down safety valve
Suction filter Shut-off valve Flow regulator valve
Hydraulic oil tank Tilt lock valve Steering wheel
Micron filter Tilt valve PS valve
Relief valve for 4th valve 3rd valve PS cylinder
Relief valve for 3rd valve 4th valve Knob position correction solenoid valve (OPT)
Tilt relief valve To attachment Tilt levelling solenoid valve (OPT)
Lift lock valve Control valve
Main relief valve Tilt cylinder

HD-10
 HYDRAULIC SYSTEM

Hydraulic Circuit Diagram (Cont’d)

JOYSTICK CONTROL VALVE

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AF
R
D

HDM01

Hydraulic oil pump Main relief valve Down safety valve

Hydraulic pump motor Lift valve Flow regulator valve
Suction filter Tilt valve Steering wheel
Hydraulic oil tank 3rd valve PS valve
Micron filter To attachment PS cylinder
Relief valve for 4th valve 4th valve Knob position correction solenoid valve (OPT)
Relief valve for 3rd valve Control valve Tilt levelling solenoid valve (OPT)
Shut-off valve Tilt cylinder
PS relief valve Lift cylinder

HD-11
HYDRAULIC SYSTEM

Disassembly and Assembly

CAUTION:
• Wrap seal tape securely around tapered threads. Never allow
pieces of seal tape to enter hydraulic pipes.
• O-rings are used in the connectors to connect each hydraulic
unit. Before assembling, attach a guide to threads of
connector and insert O-ring along with it so as not to damage
O-ring.
• Tighten connector by hand and after determining connector
position, tighten lock nut to the specified torque (refer to
Figure).
• Discharge hydraulic oil before removing suction hose.
• During assembling of hydraulic system, be careful not to
allow foreign material such as dust in hydraulic line.
• When fixing hoses, adjust their rotation direction and
position so that the hoses are not twisted and pulled.
• Check relief pressure for oil leakage and other malfunctions.
• Insert the suction hoses and return hoses until the groove
end of pipe or connector.

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AF
R
D

HD-12
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

HYDRAULIC PIPING
Tank - oil pump - control valve

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AF
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HDM02EU

HD-13
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

Control valve - tilt cylinder

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AF
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HDM03

HD-14
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

Control valve - PS valve

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AF
R
D

HDM04

HD-15
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

Control valve - flow regulator valve (mast)

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AF
R
D

HDM05

HD-16
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

MAST PIPING
2W mast

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AF
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D

HDM06

HD-17
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

2F mast

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AF
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HDM07

HD-18
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

3F mast

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AF
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D

HDM08

HD-19
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

3V mast

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AF
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HDM09

HD-20
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

ATTACHMENT PIPING
Control valve - mast

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AF
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HDM010

HD-21
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

2W mast

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AF
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D

HDM011

HD-22
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

2F mast

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AF
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HDM012

HD-23
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

3F mast

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AF
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HDM013

HD-24
 HYDRAULIC SYSTEM

Disassembly and Assembly (Cont’d)

3V mast

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AF
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HDM014

Inspection
HOSES
• Leaking, degraded or damaged hoses should be replaced.
• Leaking or damaged connectors should be replaced.

TUBES AND PIPES

• Leaking, bent, broken or scratched hoses should be replaced.
• Leaking or damaged connectors should be replaced.

HD-25
 OIL PUMP (Gear pump)
OIL PUMP (GEAR PUMP)

Removal

T
HDM015

CAUTION:
AF • Clean the area surrounding the pump and remove dust.
• Because oil tends to spill, cover the area surrounding the
pipes with rag. (Especially opening for pump motor fan)
• Never allow foreign matter to enter pump or pipes.

1. Remove battery from the vehicle.

2. Remove floor mat and floor board.
3. Disconnect PS hose from control valve.
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4. Disconnect LS hose (indicated by arrow in the figure on the left)
(for joystick control valve).
5. Disconnect high-pressure hose from pump.
6. Disconnect suction hose from pump.
D

7. Remove pump bolts, and then remove pump.

Installation
CAUTION:
Apply molybdenum disulfide grease to the pump shaft.
HDM0164
Install in the reverse order of removal.

HD-26
 OIL PUMP (Gear pump)

Disassembly

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HDM016

CAUTION:
AF • Before disassembling, thoroughly clean dirt from outside of
pump body.
• Before disassembling, prepare new parts such as packings
and oil seals that are not reusable.
• When loosening bolt (1), be careful not to drop the pump
from the vise, and loosen the bolt slowly.

Disassemble in numerical order as shown in the figure.

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NOTE:
• Before disassembly, put matching marks on between rear cover
(2) and pump body (8) and between pump body (8) and mounting
bracket (14).
D

• Straightly remove rear cover (2) in axial direction.

• Side plate (5) can be easily removed by lifting up the drive gear
(6) and the driven gear (7).

HDM0130

• Insert a slotted screwdriver into the back of oil seal, and then pry
the oil seal upward.

HDM0131

HD-27
 OIL PUMP (Gear pump)

Inspection
Clean all disassembled parts in cleaning oil and check for cracks
and damage.

BODY
Suction Check the sliding mark of the gear teeth tip on the inner surface (at
chamber
Discharge the suction side).
side Suction Limit “a”:
side
Sliding mark
More than half-circumference
Depth of sliding mark
More than 0.20 mm (0.0079 in)
Gear hole
Sliding
mark
HDM0063

GEAR
Check the shaft and gear teeth face. In case of the following, replace
with a new one.
• The side face is rough to the extent that fingernails get caught.
• The teeth face is abnormally worn.

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• The shaft diameter is less than the limit value.
Limit “d”: 20.961 mm (0.8252 in) dia.
AF
HDM0064

SIDE PLATE
Check the side plate. In case of the following, replace with new ones.
• Severe roughness has been caused by many flaws which can be
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felt by fingernails.
• The thickness of the side plate is less than the limit value.
Thickness of pressure plate:
Limit 2.927 mm (0.1152 in)
D

HDM0132

MOUNTING BRACKET AND COVER

Check the bearing for wear. In case of the following, replace with a
new one.
• Teflon coating is worn, and the brown-colored base metal is
exposed for 150° or more in the direction of the circumference
inside the bearing.

HDM0133

HD-28
 OIL PUMP (Gear pump)

Assembly
1. Wash each part.
2. Secure the cast surface of mounting bracket in a vise with the
mounting surface facing downward.
3. Securely insert seal plate and backup into the groove of
mounting bracket so as not to protrude from outer surface. Be
careful about the insertion direction of backup.
4. Install dowel pin to mounting bracket, and then install pump
body to mounting bracket while aligning it with dowel position.
At this time, dowel pin is the positioning pin. If it is hard to insert
dowel, tap and insert it using a plastic hammer.

HDM0134

5. Insert side plate into the bottom of pump body with the copper
alloy side facing up. Be careful about the intake side/exhaust
side of side plate.
When the side plate cannot be moved because it tilted, hold the
drive shaft end of drive gear and slightly push the higher side of

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side plate to insert it easily.
6. Insert the drive gear and driven gear while aligning the
matching marks with it put on shaft end surface. Be careful
about the drive gear and driven gear.
AF After inserting gear, apply clean hydraulic fluid of 2 to 3 m
HDM0135 (0.07 to 0.10 US fl oz, 0.07 to 0.11 Imp fl oz) to the tooth groove.
7. Insert side plate into the pump body with the copper alloy side
facing down. Be careful about the intake side/exhaust side.
8. Securely insert seal plate and backup into the groove of cover
so that they do not protrude from outer surface.
9. Install dowel pin to pump body, and then install cover while
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aligning it with dowel position.
Be careful to prevent the seal plate and backup from dropping
or protruding. If the cover protrudes approximately 2 to 3 mm
(0.08 to 0.12 in) between the pump body and cover after
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installing, the cover might not be installed correctly in step 8.

Check again.
10. Insert and temporarily tighten flanged bolt to the tightening
torque of 2.0 to 4.9 N•m (0.2 to 0.5 kgf-m, 2 to 3 ft-lb). The
thread should be in the wet condition.

HD-29
 OIL PUMP (Gear pump)

Assembly (Cont’d)
11. After temporarily tightening, remove the pump from the vise.
Place the pump body horizontally with intake side facing up on
the stand under the mounting bracket and the cover. Tap the
pump body using a plastic hammer to adjust to the proper
position. This procedure should always be performed because it
is necessary to keep the performance after assembly,
12. Secure the pump on a vise again, and then tighten the bolt to
the specified torque.
Flange bolt
: 88 - 98 N•m (9 - 10 kgf-m, 65 - 72 ft-lb)
CAUTION:
Always tighten bolts to the specified torque.
If the tightening torque is outside the specified torque, it may
cause damage to the bolt and the hydraulic fluid spouting from
pump matching surface, which may cause accident.

13. Remove the pump from the vise, and then rotate the shaft end
of drive gear using a tool. If it rotates lightly, there are no foreign
materials and no seal getting caught. (If any seal gets caught,

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the shaft cannot rotate manually. Perform disassembly and
assembly again.)
HDM0136
AF 14. Install oil seal to mounting bracket. Apply a thin film of clean
lithium grease to lip of oil seal.
When pressing in the oil seal, be careful not to damage the lip
and do not press in the oil seal obliquely. Wrap the front drive
gear shaft end with seal tape to prevent the lip from being
damaged. Always wipe off the tape.
15. Insert the snap ring for stopping the missing oil seal. Always use
a new snap ring.
R

HDM0137

Test Procedures
D

NOTE:
Perform the test under the following conditions.
• Heat the hydraulic oil to approximately 50°C
• Set to P mode in POWER MODE (refer to the CS section)
• Set to 8 in PUMP ACCELERATION LEVEL (refer to the CS
section)
• Set to 100% in PUMP POWER LIMIT (refer to the CS section)
• Set to 100% in LIFT SPEED (refer to the CS section)

HD-30
 OIL PUMP (Gear pump)

Test Procedures (Cont’d)

After installing oil pump, follow test procedures as follows:
1. Check that oil level in tank is OK and install pressure gauge to
control valve.
CAUTION:
For installing pressure gauge and adjusting oil pressure, refer
to “Hydraulic Test and Adjustment” in “CONTROL VALVE”.

2. With pump running, turn adjusting screw on relief valve to

gradually raise pressure from 0 to 16.7 MPa (0 to 167.0 bar, 0 to
170.34 kg/cm2, 0 to 2,421 psi). Place hand on pump body to
HDM0165
check for temperature rise.
If temperature of pump body is excessively higher than that of
hydraulic oil, disassemble oil pump to make sure it is assembled
correctly.
3. Reset relief valve to specified pressure.

Relief valve set pressure

MPa (bar, kg/cm2, psi)

Main relief set pressure 16.7 (167.0, 170.34, 2,421)

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Tilt relief set pressure 9.3 (93.0, 94.86, 1,348)

3rd, 4th relief set pressure 11.8 (118.0, 120.36, 1,711)

AF Power steering relief set pressure 6.9 (69.0, 70.38, 1,000)

4. Perform pump delivery test.

Measure fork lifting speed without load. If the speed is within
standard value, pump delivery is correct.

Lifting speed Lowering speed

R
Model without load (2W mast) without load (2W mast)
mm/s (in/s) mm/s (in/s)

L13Q
(A)S1N1 500 (19.69) 550 (21.65)
L15Q
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L15Q
(A)1N1 500 (19.69) 550 (21.65)
L18Q
L16Q
600 (23.62)
(A)G1N1 L18Q 550 (21.65)
L20Q 580 (22.83)
L15V
(A)1N1
L18V 515 (20.28) 550 (21.65)
(36V)
L20V
L15V
(A)1N1 600 (23.62)
L18V 550 (21.65)
(48V)
L20V 580 (22.83)

5. Move fork up and down with and without load, and check that it
operates correctly.

HD-31
HYDRAULIC CONTROL LEVER
HYDRAULIC CONTROL LEVER

Mechanical Control System

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AF
HDM0138

ADJUSTMENT
R
Adjust the opened/closed area of control lever cover with the
following procedure.
1. Secure the striker on the center of long hole.
2. Connect the catcher and striker of control lever cover, and then
adjust the striker position so that there is no looseness on
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control lever cover.

HDM0139

HD-32
 CONTROL VALVE
CONTROL VALVE

Removal
CAUTION:
• Before discharging remaining pressure, lower lift fully and tilt
completely forward. Next, turn control lever toward backward
tilt side.
• When disconnecting pipes, turn key switch to OFF and
discharge remaining pressure in pipes.
• Never allow foreign matter to enter pipes or control valve.
• Because oil tends to spill, cover the area surrounding the
pipes with a shop cloth. (Especially opening for pump motor
fan)

1. Remove floor mat, floor panel.

2. Remove battery from the vehicle.
3. Remove control lever (for mechanical). Remove clevis pin to
disconnect connection between control lever and control valve.
4. Disconnect harness connector inserted into control valve.
5. Remove high-pressure pipe, low-pressure hose, tilt pipe and lift
pipe. (Remove all pipes from control valve.)
For Joystick, disconnect pilot return hose from the pipe joint

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AF under battery compartment.

HDM0166

6. Remove control valve attaching bolts to remove control valve

assembly with bracket from frame (indicated by arrows in the
figure on the left).
R
CAUTION:
• Before removing the control valve attaching bolts, support
the control valve using a wooden block to prevent it from
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dropping.
• Be careful not to drop control valve because it is heavy and
slippery due to oil.

HDM0140

7. Remove bracket from control valve (indicated by arrows in the

figure on the left).

HDM0141

HD-33
 CONTROL VALVE

Installation
To install, reverse the order of removal. Pay attention to the following
points.
• Never allow foreign matter to enter pipes or control valve.
• After connecting pipes, apply relief pressure to check for any oil
leaks.
• After connecting lever and control valve, adjust the clearance
between control valve switch and dog and implement centering by
referring to CS section.

Disassembly
MECHANICAL CONTROL VALVE

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AF
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HDM0142

JOYSTICK CONTROL VALVE

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HDM0143

HD-34
 CONTROL VALVE

Disassembly (Cont’d)
Inlet spool

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AF
HDM0167

Lift spool
R
D

HDM0168

HD-35
 CONTROL VALVE

Disassembly (Cont’d)
Tilt spool

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HDM0169
AF
3rd and 4th spool
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D

HDM0170

HD-36
 CONTROL VALVE

Disassembly (Cont’d)
1. Remove bracket containing control valve switch from control
valve assembly. (for mechanical)
2. Remove relief valves from control valve assembly.
CAUTION:
• Do not disassemble relief valve assemblies because they are
replaced as an assembly.
• Do not loosen lock nut. If lock nut is loosed, be sure to adjust
set pressure after assembling.
3. Remove the tie rod, and disassemble the control valve to each
section.
Be careful not to lose poppets and poppet springs that are
between each section.

Inspection
• Clean the disassembled parts with detergent oil, and bleed air to
remove foreign objects thoroughly.
• Replace the parts with deformation, cracks, or other damage.
• Replace the O-ring and wiper ring with new ones.

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Assembly
• Assemble in the reverse order of disassembly.
AF • Check for smooth operation.

Hydraulic Test
CAUTION:
• When performing hydraulic test, wear protective eyeglasses.
High pressure oil leaks can cause loss of vision or other eye
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damage.
• Perform the test in an appropriate place to allow lifting of the
mast.
NOTE:
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Perform the test under the following conditions.

• Heat the hydraulic oil to approximately 50°C
• Set to P mode in POWER MODE (refer to the CS section)
• Set to 8 in PUMP ACCELERATION LEVEL (refer to the CS
section)
• Set to 100% in PUMP POWER LIMIT (refer to the CS section)
• Set to 100% in LIFT SPEED (refer to the CS section)

HD-37
 CONTROL VALVE

Hydraulic Test (Cont’d)

PRESSURE TEST
1. Turn key switch to OFF.
2. Remove floor panel.
3. Remove plug of high pressure pipe connector at hydraulic
pump.
4. Attach adapter to plug hole, then install pressure gauge.
5. Turn key switch to ON and operate control lever and read the
pressure referring to Table below.

Standard pressure
HDM0165 MPa (bar, kg/cm2, psi)
Main relief pressure 16.7 (167.0, 170.34, 2,421)
Tilt relief pressure 9.3 (93.0, 94.86, 1,348)
3rd, 4th relief pressure 11.8 (118.0, 120.36, 1,711)
Power steering relief pressure 6.9 (69.0, 70.38, 1,000.5)

6. If out of specification, adjust the pressure.

T
PRESSURE ADJUSTMENT
• Turn key switch to OFF, and then disconnect the battery
connection.
AF • Disconnect seat switch harness connection, and then connect the
seat switch harnesses on body harness side.
• Relief valve on control valve upper side
1. Remove control valve switch (for mechanical).
2. Loosen lock nut of relief valve assembly.
3. Connect battery cable, and then turn key switch to ON.
4. Push control valve switch to ON (for mechanical). Operate
control lever (for joystick).
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5. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard, turn clockwise.
• If greater than the standard, turn counterclockwise.
CAUTION:
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• One rotation of the adjusting screw corresponds to a

pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80 kg/
HDM0144
cm2, 995 - 1,138 psi), so do not turn carelessly.
• Carefully adjust pressure, observing the pressure gauge
reading.
6. After completing adjustment, hold adjusting screw in place and
tighten lock nut.
7. Implement the pressure test again to check whether the set
pressure is correct.
• Relief valve on control valve lower side
1. Remove battery from the vehicle.
2. Connect battery cable to the vehicle using an extension cable.
3. Turn key switch to ON and operate control lever.
4. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard: Turn clockwise.
• If greater than the standard, turn counterclockwise.

HD-38
 CONTROL VALVE

Hydraulic Test (Cont’d)

CAUTION:
• One rotation of the adjusting screw corresponds to a
pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80
kg/cm2, 995 - 1,138 psi), so do not turn carelessly.
• Carefully adjust pressure, observing the pressure gauge
reading.
5. After completing adjustment, hold adjusting screw in place and
tighten lock nut.
6. Implement the pressure test again to check whether the set
pressure is correct.

SHUT-OFF VALVE
• When the forks and masts cannot be lowered with/without load.
• First of all, check the following:

For mechanical valve

Check that lift lock valve (solenoid) operates normally. Refer to the
CS section.

For joystick valve

• Check that C1 solenoid and solenoid for lift operate normally.

T
Refer to the CS section.
• Operate the control valve lever toward the mast lowered side, and
then make sure that the pump motor operates (turns). If not,
repair the vehicle by referring to the CS section.
AF
If the above steps are OK, the forks and masts can be lowered with
the following procedure.
1. Turn key switch to OFF, disconnect the battery connection, and
then remove battery from the vehicle.
2. Remove the floor mat and floor board.
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HDM0171

3. Disconnect the PS piping (LS and PF).

4. Loosen lock nut of shut-off valve on the lower side of control
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valve.
5. Loosen the screw counterclockwise until it stops.
6. Operate the control lever downward slowly.

Return
1. Screw in the screw until it stops.
2. Loosen lock nut.
3. Install the floor board and floor mat, and then install the battery.
CAUTION:
Always return to the lift lock function after repair.

HDM0172

HD-39
 TILT CYLINDER
TILT CYLINDER

Construction

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AF
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HDM0145

Piston rod head Wiper ring Bush

D

Cylinder head U-ring Grease nipple

O-ring Lock nut Bolt
Cylinder tube assembly Bush Washer
Backup ring Rod assembly O-ring
O-ring O-ring Piston

Removal
CAUTION:
• When removing tilt cylinder, lift mast with wire or nylon string
and support cylinder with a block of wood so that it does not
fall.
• During work, be sure to keep your hands and feet out of
danger.

HD-40
 TILT CYLINDER

Removal (Cont’d)
1. Lower fork fully.
2. Remove pivot pin attaching bolt from the joint of outer mast and
pull out pivot pin.
3. Turn key switch to ON and set tilt cylinder to the maximum
backward tilt, then tilt forward to extend cylinder by about 10 mm
(0.39 in). Turn key switch to OFF and disconnect battery plug.
4. Disconnect two pipes connected to tilt cylinder at pipe
connectors.
CAUTION:
• Since oil tends to spill when pipes are disconnected, cover
the surrounding area with rag.
• Stuff stoppers into disconnected pipes to prevent oil spills.

5. Remove pivot pin attaching bolt from joint of body frame and
pull out pivot pin to remove tilt cylinder.
NOTE:
To separate left tilt cylinder on body side, first remove tilt cylinder
cover, then go to next step.

T
AF
R
D

HDM0146

Disassembly
1. Hold cylinder in a vise with piping port down and put a plate
under port. Apply compressed air alternately to two ports and
activate piston rod to discharge oil from cylinder.

2. Loosen head lock nut, then remove rod head from piston rod
assembly.
3. Loosen cylinder head, then remove cylinder head from cylinder
tube assembly.
CAUTION:
Use care not to damage O-ring.

4. Remove piston rod assembly from cylinder tube assembly.

CAUTION:
HDT0023 Use care not to damage O-ring.

HD-41
 TILT CYLINDER

Disassembly (Cont’d)
5. Remove O-ring from piston rod assembly.
CAUTION:
Do not disassemble piston rod assembly.

6. Remove O-ring and backup ring from cylinder head.

CAUTION:
Replace removed O-ring and backup ring with new ones. Do not
reuse.

7. Remove U-ring and wiper ring using a screwdriver.

CAUTION:
Replace removed U-ring and wiper ring with new ones. Do not
reuse.
HDM0012

Inspection
CYLINDER HEAD

T
• Measure inside diameter of cylinder head and outside diameter of
piston rod and calculate the clearance. If the clearance is greater
than usable limit, replace cylinder head.
AF Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Usable limit: 0.2 mm (0.008 in)

CYLINDER TUBE
• Measure inside diameter of cylinder tube and outside diameter of
piston and calculate the clearance. If the clearance is greater than
usable limit, replace cylinder tube.
R
Standard: 0.03 - 0.15 mm (0.0012 - 0.0059 in)
Usable limit: 0.2 mm (0.008 in)
• Check whether the interior is damaged. If damage is minor, repair
using oilstone. If serious, replace cylinder tube.
D

• If welded part is damaged, replace cylinder tube.

PISTON ROD
• Check whether sliding surface is damaged. If damage is minor,
repair using oilstone. If serious, replace piston rod.
• If hard chromium plate flakes, replate piston rod or replace.
• If rod is bent, replace.

O-RING, U-RING, WIPER RING AND BACKUP RING

Do not reuse. Always replace with new ones.

Assembly
To assemble, reverse the order of disassembly. Pay attention to the
following points.
• Lubricate each part with clean hydraulic oil.
• Never allow foreign matter to enter parts.
• Use new O-ring, U-rings, backup ring and wiper ring.
• Use care not to twist or damage O-ring.

HD-42
 TILT CYLINDER

Assembly (Cont’d)
• Use care not to damage O-ring and wiper ring with threads of
piston rod.
Rod head lock nut:
: 108 - 147 N•m (11 - 15 kg-m, 80 - 108 ft-lb)
Cylinder head:
: 350 - 400 N•m (36 - 40 kg-m, 259 - 295 ft-lb)
NOTE:
To prevent O-ring and wiper ring from being damaged, wrap vinyl
tape around threads of piston rod, then attach cylinder head
assembly.

Installation
To install, reverse the order of removal. Pay attention to the following
points.
Pivot pin attaching bolt:
: (M10 4T) 26 - 32 N•m (2.6 - 3.3 kg-m, 18 - 24 ft-lb)
(M10 7T) 43.1-54.9 N•m (4.4 - 5.6 kg-m, 32-40 ft-lb)
• After installing, operate cylinder for about five minutes (10 - 20

T
AF strokes).
R
D

HD-43
 LIFT CYLINDER
LIFT CYLINDER

Construction
2W MAST

T
AF
HDM0147
R
Dust seal Fixing ring Piston
U-ring Wear ring Piston ring
O-ring Ball Pull-in wire
Cylinder head Pull-in wire Washer
D

Cylinder tube assembly Check valve

Piston rod Spring

HD-44
 LIFT CYLINDER

Construction (Cont’d)
2F MAST, RIGHT HAND

T
AF
HDM0148
R
Wiper ring Piston rod Backup ring
U-ring Fixing ring Cushion part
O-ring Wear ring O-ring
D

Cylinder head Pull-in wire Bleed screw

Cylinder tube assembly Piston Seal washer

HD-45
 LIFT CYLINDER

Construction (Cont’d)
2F MAST, LEFT HAND

T
AF
R
D

HDM0149

Wiper ring Piston rod Backup ring

U-ring Fixing ring Cushion part
O-ring Wear ring O-ring
Cylinder head Pull-in wire Bleed screw
Cylinder tube assembly Piston Seal washer

HD-46
 LIFT CYLINDER

Construction (Cont’d)
3F AND 3V MAST

T
AF
R
D

HDM0150

Dust seal Fixing ring Piston

U-ring Wear ring Piston ring
O-ring Ball O-ring
Cylinder head Pull-in wire Washer
Cylinder tube assembly Check valve Cushion part
Piston rod Spring O-ring

HD-47
 LIFT CYLINDER

Removal
CAUTION:
Be sure to keep hands and feet out of danger.

PREPARATION
1. Remove from mast carriage assembly with fork.
2. Jack up the front of vehicle to keep about 120 mm (4.72 in) of
clearance from lower end of outer mast to floor (refer to GI
section).
3. After setting mast vertical and lower lift cylinder at the lower
end, turn key switch OFF and disconnect the battery cable.
CAUTION:
Be sure to lower lift cylinder fully to discharge remaining
pressure in pipes.

2W LIFT CYLINDER
1. Remove lift hose from lift cylinder.
CAUTION:

T
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
2. Disconnect the hose between the lift cylinders.
AF
LMM0232

3. Remove lock nut on the upper plane of lift cylinder to separate

lift cylinder from inner mast.
4. Lift up inner mast with lifting wire/nylon sling.
R
D

HDM0152

HD-48
 LIFT CYLINDER

Removal (Cont’d)
5. Remove lift cylinder attaching bolt and U-bolt, then remove lift
cylinder from the front.
CAUTION:
• Because lift cylinder is very heavy, two people should
perform this task.
• When removing U-bolt, support lift cylinder to prevent it from
falling.

HDM0153

2F LIFT CYLINDER
1. Remove lift hose from lift cylinder.
2. Disconnect the hose between the lift cylinders.
3. Disconnect the piping between the lift cylinder and full-free
cylinder.
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.

T
HDM0089

4. Remove the fixing bolt on the upper plane of lift cylinder to

AF separate lift cylinder from inner mast.
5. Lift up inner mast with lifting wire/nylon sling.
R
D

HDM0175

6. Remove lift cylinder attaching bolt and U-bolt, then remove lift
cylinder from the front.
CAUTION:
• Because lift cylinder is very heavy, two people should
perform this task.
• When removing U-bolt, support lift cylinder to prevent it from
falling.

HDM0154

HD-49
 LIFT CYLINDER

Removal (Cont’d)
3F LIFT CYLINDER
1. Lift up the inner mast until the inner mast lower beam comes to
the position of the upper section of the outer mast tilt beam.
CAUTION:
Because the chain and lift hose become saggy, make sure that
they are not caught while lifting up the inner mast.

2. Remove the chain anchor on the inner mast side, and remove
the mast chain from the inner mast.
3. Remove the hydraulic piping on the lower section of the full-free
cylinder.
4. Remove the hose pulley support on the upper section of the
Inner mast middle mast, and remove the chain wheel.
5. Place a square timber of approximately 100 mm (3.94 in) height
under the inner mast, and lower the inner mast.

T
Chain anchor CAUTION:
Make sure that the chain and the lift hose is not caught while
HDM0091
lowering the inner mast.
AF 6. Fix the lifting tool to the upper beams of both the inner mast and
middle mast.
7. Remove the mounting bolt on the mast cylinder upper surface.
8. Lift up the inner mast and middle mast together, and remove the
upper section of the mast cylinder.
9. Disconnect the lift cylinder hose from the mast cylinder, remove
the lift hose clamp mounting bolt, and remove the cylinder from
R
the mast.
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
D

10. Remove the bolt at the bottom end of the mast cylinder (lower
face of the outer mast support).

HDM0155
11. Remove the U-bolt, and remove the mast cylinder toward the
front of the vehicle.
CAUTION:
• When removing U-bolt, support lift cylinder to prevent it from
falling.
• Because lift cylinder is heavy, two people should perform
this task.

HD-50
 LIFT CYLINDER

Removal (Cont’d)
3V LIFT CYLINDER
1. Remove the mast assembly from the forklift.
WARNING:
After removing the mast assembly, the middle and inner rails
will easily slide. Use ropes to firmly fasten the outer, middle and
inner rail top beams together.

2. Disconnect the high pressure hose at the lower end of the lift
cylinder.

T
HDM0156

3. Remove the lift chain at the chain adjusting bolt.

Adjusting bolt
AF
Lock nut
R
Lift cylinder
LMM0055

4. Remove the securing bolt from the upper end of the lift cylinder.
D

WARNING:
After removing the mast assembly, the middle and inner rails
Securing will easily slide. Use ropes to firmly fasten the outer, middle and
bolt
inner rail top beams together.

Lift
cylinder
LMM0070

5. Slide the middle rail together with the inner rail 250 mm (9.84 in)
in the upper direction.
CAUTION:
Record the thickness and location of the adjusting shim used
to adjust the lift cylinder height in advance. The adjustment
shim is installed to the upper end of the lift cylinder.
WARNING:
The middle and inner rails easily slide. Use ropes to firmly
fasten the outer, middle and inner rail top beams together.

HD-51
 LIFT CYLINDER

Removal (Cont’d)
6. Remove the bolt from the lower end of the lift cylinder.

HDM0157

7. Remove the lift cylinder securing U-bolt.

8. Remove the lift cylinder.
Lift cylinder

U-bolt

T
Lock nut

LMM0073
AF
Installation (2W, 2F, 3F, 3V)
Installation is in the reverse order of removal. Pay attention to the
following points.
• Tighten bolt at the lower end of cylinder.
: 44 - 54 N•m (4.3 - 5.6 kg-m, 32 - 40 ft-lb)
R

• Fit the U-bolt into the cylinder, tighten the adjusting nut by hand,
Stopper and fix with the lock nuts.
Adjusting nut U-bolt : 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
D

Lock nut • Fit the stopper into the hole at the end of the adjusting bolt.
• Tighten the adjusting bolt, and check that the stopper contacts
Adjusting bolt with the cylinder. Then, further tighten for 1/2 to 1 turn and tighten
the lock nut.
: 74 - 94 N•m (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
Lock nut • When tightening the lock nut, make sure that the adjusting
Cylinder nut does not turn.
HDM0094

• For 2W mast, tighten the stud bolts on the set nuts to the bottom
of the threads. Apply thread lock to the threads of the stud bolt on
the cylinder side. And then tighten and fasten the stud bolt on the
top of the lift cylinder. So that the set nut does not become loose,
secure the stud bolt with a cotter pin.

HDM0158

HD-52
 LIFT CYLINDER

Installation (2W, 2F, 3F, 3V) (Cont’d)

• Securely wrap seal tape around tapered threads of pipes. Never
allow pieces of seal tape to enter hydraulic pipes.
• O-rings are used in the connectors to couple each hydraulic unit.
Before assembling, attach a guide to connector threads and insert
O-ring along with it so as not to damage O-ring.
• Tighten connector by hand and after determining connector
position, tighten lock nut to the specified torque.

Disassembly
1. Loosen cylinder head and remove from cylinder tube.
2. Disassemble cylinder head.
• Tap out wiper ring/dust seal using a screwdriver.
CAUTION:
Replace removed wiper ring/dust seal with new one. (Never
reuse a wiper ring/dust seal after tapping it out because outside
diameter is reduced.)

• Remove U-ring using a screwdriver.

T
CAUTION:
Replace removed U-ring with new one.
AF 3. Remove piston rod assembly from cylinder tube.
CAUTION:
Do not disassemble piston rod assembly.

Inspection
CYLINDER HEAD
R
Measure inside diameter of cylinder head and outside diameter of
piston rod and calculate the clearance. If the clearance is greater
than usable limit, replace cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
D

Usable limit: 0.2 mm (0.008 in)

PISTON ROD
• Check for bent. If excessive, replace with new one.
• Check whether sliding surface is damaged. If damage is minor,
repair using oilstone. If serious, replace piston rod.
• If hard chromium plating flakes, re-plate or replace piston rod.

CYLINDER TUBE
If the interior is damaged, replace cylinder tube.

DUST SEAL (WIPER RING), U-RING, O-RING, WEAR

RING AND PISTON RING (BACKUP RING)
Do not reuse. Always replace with new ones.

HD-53
 LIFT CYLINDER

Assembly
To assemble, reverse the order of disassembly. Pay attention to the
following points.
• Before assembling, lubricate each part with new hydraulic oil.
• Clean packings in petroleum-base hydraulic oil.
• During assembly, never allow foreign matter such as dust to enter
parts.
Cylinder head:
2W, 3F, 3V mast : 197 - 245 N•m (20 - 25 kg-m, 145 -
180 ft-lb)
2F mast : 197 - 225 N•m (20 - 23 kg-m, 145 - 166 ft-lb)

Adjustment
BLEEDING AIR
1. Add hydraulic oil up to the upper limit of level gauge.
2. Raise and lower mast slowly.
3. Lower mast fully and check the hydraulic oil capacity in tank. If
hydraulic oil level is reduced, fill up to the upper limit of level
gauge.
4. Repeat steps 2 and 3 until the hydraulic oil capacity is not

T
reduced.
5. Check that cylinder moves smoothly up and down.
AF ADJUSTING OF CYLINDER HEIGHT
NOTE:
To prevent mast from being twisted and deformed, adjust the
cylinder height. Be sure to adjust, especially when replacing only
one cylinder.
1. Check that forklift is placed horizontally.
2. Remove lock nuts/fixing bolts at the upper ends of right and left
R
lift (mast) cylinders.
3. Fully and slowly raise mast without load, then check whether
right and left cylinders reach upper ends simultaneously.
4. If one cylinder is delayed, adjust delayed cylinder by inserting
D

shims.
Thickness of shim: 1.00 mm (0.039 in) (only one type)
5. Repeat the adjustment above until there is no difference
between the right and left cylinders.

HDM0158

6. For 2W mast, tighten the lock nut until it reaches the incomplete
thread of the stud bolt. At this time, the difference between the
upper beam and the lock nut is 1 mm (0.0394 in) or more.

HDM0173

HD-54
 FULL-FREE CYLINDER
FULL-FREE CYLINDER

Construction
2F AND 3F MAST

T
AF
HDM0160
R
Cylinder tube assembly Washer Spring
Piston rod Fuse piston Cylinder head
Piston Spring guide O-ring
D

Pull-in wire Wear ring Backup ring

Ball U-ring U-ring
Check valve Circlip Wiper ring
Spring

HD-55
 FULL-FREE CYLINDER

Construction (Cont’d)
3V MAST, RIGHT HAND

T
AF
HDM0161
R
Wiper ring Cylinder tube assembly U-ring
U-ring Piston rod Wear ring
Backup ring Ball Washer
D

O-ring Check valve Circlip

Cylinder head Spring

HD-56
 FULL-FREE CYLINDER

Construction (Cont’d)
3V MAST, LEFT HAND

T
AF
HDM162
R
Wiper ring Piston rod Washer
U-ring Ball Circlip
Backup ring Check valve Spring guide
D

O-ring Spring Spring

Cylinder head U-ring Hose burst valve
Cylinder tube assembly Wear ring

HD-57
FULL-FREE CYLINDER

Removal
CAUTION:
Be sure to keep hands and feet out of danger.

PREPARATION
1. Remove from mast carriage assembly with fork.
2. Jack up the front of vehicle to keep about 120 mm (4.72 in) of
clearance from lower end of outer mast to floor (refer to GI
section).
3. After setting mast vertical and lower full-free cylinder at the
lower end, turn key switch OFF and disconnect the battery
cable.
CAUTION:
Be sure to lower full-free cylinder fully to discharge remaining
pressure in pipes.

PROCEDURES
1. Disconnect the hydraulic piping from the full-free cylinder.

T
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
2. Lift up the full-free cylinder using a nylon sling or a lifting wire.
AF 3. Remove the full-free cylinder mounting bolt. Lift up the full-free
cylinder, and remove it.

Disassembly
1. Loosen the cylinder head, and remove the cylinder head from
the cylinder tube.
R
2. Disassemble the cylinder head.
• Push the wiper ring out by hitting with a screwdriver.
CAUTION:
Replace a removed wiper ring with a new one. (Because the
D

outer diameter of the removed wiper ring has been reduced, it

cannot be reused.)
• Remove the U-ring by prying with a screwdriver.
CAUTION:
Replace removed U-rings with new ones.
3. Remove the piston rod assembly from the cylinder tube.
CAUTION:
Do not disassemble the piston rod assembly.

HD-58
 FULL-FREE CYLINDER

Inspection
CYLINDER HEAD
Measure the cylinder head inner diameter and piston rod outer
diameter, and calculate the clearance. When the clearance exceeds
the limit value, replace the cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Limit: 0.2 mm (0.008 in)

PISTON ROD
• Check the piston rod for bending. When excessive bend is found,
replace the piston rod.
• Check the sliding face for damage. In case of minor damage,
repair with oil stone. In case of severe damage, replace the piston
rod.
• When the hard chromium plating is peeled off, plate again, or
replace the piston rod.

CYLINDER TUBE
When the inner face is damaged, replace the cylinder tube.

T
WIPER RING, U-RING, BACKUP RING, O-RING AND
WEAR RING
AF Do not reuse. Alwayas replace with new ones.

Assembly
Assemble in the reverse order of disassembly. Pay attention to the
following:
• Before assembling, moisten the parts with Nissan Hydraulic Oil.
• Clean the packing with a petroleum hydraulic fluid.
R
• Prevent foreign objects from entering into the inside during
assembly.
• Tighten the cylinder head to the specified torque.
Cylinder head:
D

2F, 3F mast : 300 - 370 N•m (31 - 37 kg-m, 202 - 272 ft-
lb)
3V mast : 246 - 274 N•m (25 - 28 kg-m, 181 - 202 ft-lb)

HD-59
 FULL-FREE CYLINDER

Installation
Inner mast
Install in the reverse order of removal. Pay attention to the following:
Shim • 2F, 3F MAST:
Adjust with the shim so that the inner mast becomes parallel to
the full-free cylinder.
Shim thickness: 1.0 mm (0.039 in)
Then tighten the mounting bolt.
: 128 - 156 N•m (13 - 16 kg-m, 95 - 115 ft-lb)

Full-free cylinder
HDM0098

• 3V MAST:
Mounting bracket of full free cylinder to be inserted into the notch
of inner mast 2nd-beam. After surface A of 2nd-beam touches
surface B of mounting bracket, bolt is to be tightened. (3V mast)
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)

T
HDM0163

• Seal the taper threads of the piping with seal tape securely.
AF Prevent chips of the seal tape or other foreign object from entering
into the hydraulic piping.
• O-rings are used at the connectors which connect the hydraulic
units. When assembling, insert the connector with a guide on the
threads so that the O-ring is not damaged.
• Screw in the connector by hand. When the connector is
positioned, tighten the lock nut to the specified torque. (For the
tightening torque, refer to “Mast Piping”.)
R

Adjustment
BLEEDING AIR
D

1. Add hydraulic fluid to the upper limit of the level gauge.

2. Lift the mast slowly, then lower it slowly.
3. Lower the mast fully, and check the hydraulic fluid amount in the
tank. When the hydraulic fluid amount is low, add to the upper
limit of the level gauge.
4. Perform the operations mentioned in steps 2 and 3 above
repeatedly until the hydraulic fluid amount does not decrease.
5. Move the cylinder up and down, and check for smooth
operation.

HD-60
 OIL TANK (3-wheel)
OIL TANK (3-wheel)

Disassembly

T
AF
R
D

HDM0174

HD-61
OIL TANK (4-wheel)
OIL TANK (4-wheel)

Disassembly

T
AF
R
D

HDM0801EU

HD-62
 LOADING MECHANISM

SECTION LM
SERVICE DATA AND SPECIFICATIONS ......... LM-2 CARRIAGE ASSEMBLY ................................ LM-10
TROUBLE DIAGNOSES AND Removal ...................................................... LM-10
CORRECTIONS ................................................. LM-4 Inspection .................................................... LM-11
PRECAUTIONS AND PREPARATION ............. LM-5 Adjustment .................................................. LM-11

T
Precautions ................................................... LM-5 Installation ................................................... LM-13
FORK ................................................................. LM-6 MAST ............................................................... LM-14
Removal ........................................................ LM-6 Mast Assembly ............................................ LM-14
AF
Inspection ...................................................... LM-6 Removal ...................................................... LM-18
Installation ..................................................... LM-6 Disassembly ................................................ LM-19
LIFT CHAINS ..................................................... LM-7 Inspection .................................................... LM-22
Removal ........................................................ LM-7 Assembly ..................................................... LM-22
Installation ..................................................... LM-7 Installation ................................................... LM-29
Adjustment .................................................... LM-7 Adjustment .................................................. LM-30
Inspection ...................................................... LM-8 Mast bushing ............................................... LM-31
R
D
 SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

Inspection and Adjustment

ADJUSTMENT SPECIFICATIONS

Applied model (A)1N1 series (A)1N1

Applied model
series
0.1 - 0.6
Outer mast-to-inner mast clearance mm (in)
(0.004 - 0.024) 3,850 (151.57),
4,300 (169.29),
0.1 - 0.6 369 (14.53)
Mast-to-liner clearance mm (in) 4,750 (187.01),
(0.004 - 0.024)
5.150 (202.76)
Mast-to-mast roller rolling surface clearance 0.1 - 0.6 3F 5,500 (216.54) 384 (15.12)
mm (in) (0.004 - 0.024)
6,000 (236.22) 419 (16.50)
Inner mast-to-carriage roller side face 0.1 - 0.6
clearance mm (in) (0.004 - 0.024) 6,500 (255.91) 504 (19.84)
Lift roller lapping allowance 7,000 (275.59) 604 (23.78)
Inner mast-to-carriage roller rolling face 0.1 - 0.6 pitch (Dimension “L”)
clearance mm (in) (0.004 - 0.024) mm (in) 3,600 (141.73),
4,050 (159.45),
Mast forward/backward 2W, 2F 4/6 369 (14.53)
4,500 (177.17),
tilting angle (°) 3F, 3V 5/5 4,900 (192.91)
Carriage lower edge-to-ground distance 3V 5,250 (206.69) 384 (15.12)
76 (2.99)
mm (in) 5,750 (226.38) 419 (16.50)
Lower end of outer mast-to lower end of 6,330 (249.21) 504 (19.84)
0 (0)

T
inner mast (3F, 3V MAST) mm (in)
6,880 (270.87) 604 (23.78)
Chain tension mm (in) 25 - 30 (0.98 - 1.18)
Mast bushing inner 50.25-50.31 (1.978-1.981)
2,700 Diameter
outer 59.85-60.23 (2.356-2.371)
(106.30),
3,000
AF 283 (11.14)
mm (in) wear limit Thickness 3.38 (0.133)
(118.11),
3,300
(129.92) ADJUSTING SHIM/ROLLER
3,500
318 (12.52)
(137.80) Applied model (A)1N1 series
2W
3,700 0.5, 1.0, 2.0
343 (13.50) Carriage roller adjustment shim mm (in)
(145.67) (0.020, 0.039, 0.079)
R
4,000 Carriage side roller and thrust metal 0.5, 1.0, 2.0
(157.48), adjustment shims mm (in) (0.020, 0.039, 0.079)
4,500 0.5, 1.0
Lift roller lapping 383 (15.08) Liner adjustment shim mm (in)
(177.17), (0.020, 0.039)
allowance pitch 5,000
D

(Dimension “L”) mm (in) 2,700 -

(196.85)
3,300
2,700 105 (4.13)
(106.30 -
(106.30), 2W, 129.92)
3,000 2F
284 (11.18) Inner mast roller 3,500 or
(118.11),
mm (in) more 105, 105.5, 106
3,300
(137.80 or (4.13, 4.15, 4.17)
(129.92)
more)
2F 3,500
354 (13.94) 97, 97.5, 98
(137.80) 3F, 3V
(3.82, 3.84, 3.86)
3,700 Upper 97.0 (3.819)
404 (15.91) Middle mast roller 3F,
(145.67)
mm (in) 3V 105, 105.5, 106
4,000 Lower
484 (19.06) (4.13, 4.15, 4.17)
(157.48)
Outer mast roller mm (in) 97 (3.819)
97, 97.5, 98
Upper and lower
Carriage roller mm (in) (3.819, 3.839, 3.858)
Center 97 (3.819)
0.5, 1.0, 2.0
Mast roller adjustment shim mm (in) (0.0197, 0.0394,
0.0787)
Lift cylinder adjustment shim mm (in) 1.0 (0.039)
Full-free cylinder adjustment shim
1.0 (0.039)
(2F, 3F mast) mm (in)

LM-2
 SERVICE DATA AND SPECIFICATIONS

Tightening Torque

Unit N•m (kg-m, ft-lb)

Backrest 177 - 225

Backrest securing bolt
installation (18 - 23, 131 - 165)
Lift chain 92 - 124
Lock nut
installation (9.4 - 13.0, 69 - 93)
Carriage Side roller securing 21 - 26
reassembly bolt (2.1 - 2.7, 16 - 19)
Lift cylinder upper side 78 - 98
bolt (7.9 - 10.0, 58 - 72)
Lift cylinder lower side 44 - 54
bolt (4.4 - 5.6, 32 - 40)
2F, 128 - 156
Full-free 3F (13 - 16, 95 - 115)
cylinder set bolt 44 - 54
3V
(4.4 - 5.6, 32 - 40)
Mast reassembly
26 - 32
U-bolt lock nut
(2.6 - 3.3, 19 - 23)
U-bolt adjusting bolt 74 - 94
lock nut (7.5 - 9.6, 55 - 69)

T
Chain guide securing 21 - 26
bolt (2W MAST) (2.1 - 2.7, 16 - 19)
Lift chain anchor bolt 92 - 124
lock nut
AF
(9.4 - 13.0, 69 - 93)
Mast support cap 89 - 118
securing bolt (9.1 - 12.0, 66 - 87)
26 - 32
Mast installation Pivot pin lock bolt
(2.6 - 3.3, 19 - 23)
Tilt cylinder rod lock 108 - 147
nut (11 - 15, 80 - 108)
R
D

LM-3
 TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS

CAUTION:
The following table lists only typical examples. To perform an
accurate diagnosis carefully listen to the user's complaints and
check the actual vehicle to fully understand under what
conditions the symptoms occur.

Condition Probable cause Corrective action

Forks do not raise or lower smoothly. • Improperly adjusted carriage bracket assembly • Adjust clearances between parts (such as inner
mast, side roller, thrust metal, carriage roller).
Replace faulty parts with new ones.
• Improperly adjusted inner mast-to-outer mast • Adjust using shim(s) or liner.
clearance or roller-to-mast clearance
• Insufficient lubrication • Apply grease to contacting/sliding surfaces of
parts.
• Caught foreign matter in functional parts • Remove foreign matter.
• Deformed inner mast • Adjust.
• Bent carriage bracket assembly • Adjust or replace.
Forks rising unstable • Improperly adjusted lift chain(s) • Adjust lift chain tension.
Lift rollers fail to rotate. • Solidified grease on rollers or sliding surfaces • Clean lift rollers and grease.
or accumulated dirt/dust
• Lift roller(s) are improperly installed. • Check and adjust lift rollers.
• Roller(s) are broken or damaged. • Replace faulty rollers.

T
Mast assembly emits noise. • Insufficient lubrication • Apply grease.
• Improperly adjusted lift rollers, side rollers and/ • Adjust.
or liners
• Worn chain wheels, lift rollers and/or liners • Replace worn parts.
AF
• Damaged lift rollers and/or mast rollers • Replace damaged rollers.
R
D

LM-4
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
• Most of the loading mechanism parts such as forks, mast,
carriages, etc. are heavy. The hoisting and movement of
those objects are inherently dangerous. Therefore, be
extremely careful and always employ an assistant when you
remove them.
• When removing/installing cylinder, always perform the
procedure with two persons because of heavy weight,
paying attention not to catch hands by components.
• Be extremely careful to protect your hands, feet, etc., when
performing maintenance work on or moving heavy objects.
• Always assign lifting operations to qualified operators
trained in slinging or hoisting procedures.
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines must be completely bled off.

WITH MECHANICAL SYSTEM

• For lift piping, fully tilt the masts forward, operate the control lever
several times forward, and turn key switch OFF. Operate the
control lever several times backward, and release the residual

T
pressure from piping.
• For lift piping, place the fork at the lowest position, and operate
the lift lever several times downward.
AF
WITH JOYSTICK SYSTEM
• For tilt piping, first place the fork horizontal (tipped slightly
forward) and turn the key switch off. Next, loosen the piping and
let set while the remaining pressure escapes.
• For lift piping, place the fork at the lowest position, turn the key
switch off, loosen the shut-off valve and let the remaining pressure
R
escape.
• For attachment piping (3rd and 4th)
• Union connector
Place the attachment in neutral, turn the key switch off,
loosen the piping, and let set while the remaining pressure
D

escapes.
• Coupling
Installing and removing the cup may be difficult if the
remaining pressure inside the piping is high. If this is the
case, turn the key switch ON and tip the lever (3rd and 4th)
backwards or forwards, and one of the cups will come off.
Then tip the lever in the other direction and remove the other
cup.

NOTE:
• The fork assembly must be removed as required to make
maintenance work easier to perform.
• Disassembly of the carriage bracket assembly requires the
removal of the forks. Following the removal of forks, remove the
carriage bracket assembly from the mast assembly.
• If the carriage bracket assembly needs not be disassembled upon
removal, remove it with the forks installed to it. This will prevent
the carriage assembly from toppling over.
• When the mast assembly and carriage bracket assembly are to
be removed as a unit, remove the fork assembly beforehand.

LM-5
 FORK
FORK

Removal
CAUTION:
For removal of the fork assembly and carriage assembly as a
unit, refer to “CARRIAGE ASSEMBLY”.
1. Raise the forks approximately 100 to 200 mm (3.94 to 7.87 in)
above the ground.
2. Turn the lock levers 90° at the upper ends of the forks, then
move the forks to the notched portion located in the center of
the carriage assembly.
LMM0204

3. While lifting the tips of the forks, disengage the jaws from the
carriage (finger bar). Lift the upper portions of the forks up and
away from the carriage assembly. Always remove one fork at a
time.

T
LMM0134

Inspection
AF • Check the forks for wear (as shown in the figure). If wear exceeds
specifications, replace the forks with new ones.
Standard wear limit:
More than 3 mm (0.12 in)
• Visually check the forks for cracks, deformation or separation of
welds. If necessary, replace with new fork assembly.
• Check the forks using a dye penetration method. If they are
cracked, replace with new ones.
R

LMM0227
Installation
To install the forks, reverse the order of removal.
D

CAUTION:
After installing both forks, check to ensure that the lock levers
are properly locked.

LM-6
 LIFT CHAINS
LIFT CHAINS

Removal
1. Support the carriage assembly by placing a wooden block
under it or using a crane.
2. Retract the lift cylinders to loosen the lift chains, then remove
the chain anchor bolts from the carriage.
3. Disengage the lift chains at the lift chain joint links and
adjustment bolts on the mast side. Refer to the illustration of
mast assembly.
4. Removal the lift chains from the chain wheel.

LMT0077J

Installation
To install the lift chains, reverse the removal procedures.

CAUTION:
• Before installing the chain anchor bolts, ensure that the lift
chain is not twisted.
• Discard old cotter pins; replace with new ones.

T
Lock nut:
: 92 - 124 N•m (9.4 - 13.0 kg-m, 69 - 93 ft-lb)

Adjustment
AF
CAUTION:
• Before adjusting lift chain tension, park the vehicle on flat
and solid ground.
• On pneumatic tire models, inflate the tires to the specified
pressure.
• As for the 3F and 3V mast, adjust the mast chain and lift
R
chain.
1. Set the mast assembly in the vertical position and lower the
carriage assembly all the way down.
2. Turning the adjustment nut in or out, adjust the carriage
D

assembly until its lower end above the ground is within

specifications.
Standard clearance:
76 mm (2.99 in)

LMT0079J

3. For the 3F and 3V mast, after the adjustment of the lift chain
mentioned above, raise the carriage gradually to adjust the
adjustment nut of the mast chain so that the difference between
the inner mast lower end and the outer mast lower end
conforms to the standard value.
Standard: 0 mm (0 in)

LMT0078J

LM-7
 LIFT CHAINS

Adjustment (Cont’d)
4. With the fork assembly attached to the carriage, adjust the lift
chain adjustment nut so the midpoint of the lift chain can be
pulled (2W mast) or pressed (2F/3F/3V mast) 25 to 30 mm
(0.98 to 1.18 in). The left and right lift chains must be equally
adjusted.

CAUTION:
Check to ensure that the left and right chains are tensioned
equally.
Lock nut:
: 92 - 124 N•m (9.4 - 13 kg-m, 69 - 93 ft-lb)
5. After making the mast and lift chain tension adjustments, move
the carriage assembly up and down to ensure it moves
smoothly.
NOTE:
Every 200 hours of operation or once a month, whichever occurs
first, apply a coat of Nissan Motor Oil to the lift chains requiring
lubrication.

T
LMM0228
AF
R
D

LMM0209

Inspection
• Visually inspect the lift chains for cracks, breaks or damage. If
necessary, replace the left and right lift chains as a unit.
• To check the lift chain for elongation, raise the forks approximately
20 to 30 mm (0.79 to 1.18 in) above the ground.

LM-8
 LIFT CHAINS

Inspection (Cont’d)
NOTE:
• Balance the tension between left and right chains.
• Cracks or breakages often occur at the ends of the lift chains. If
necessary, replace both chains as a unit.
• Elongation often occurs in portions of the lift chain which
experiences contact with the chain wheel.

HOW TO INSPECT THE LIFT CHAIN (REFERENCE)

1. Tilt the mast to vertical position.
2. Lift the fork to above 5 cm from the ground.
3. Confirm the chain type.
The type of the chain is stamped on the side of the chain.
However, special care is needed for the following chain as the
number stamped on the chain is different from the chain type
number.

Stamp on the chain Chain type

LMM0229
BL5 BL534

T
BL6 BL634
BL8 BL834
BL10 BL1034
AF BL12 BL1234

How to count number of links. 4. Apply the chain gauge and measure the chain length counting
the appropriate number of links for the chain type.

Replace the fork chain when the length exceeds the limit.
R
BL834 (14 links), RS40 (28 links), RS80 (14 links):
Standard length:
355.6 mm (14.000 in)
limit length:
364.4 mm (14.346 in)
D

LMM0230 BL534 (22 links), BL1034 (11 links), RS50 (22 links),
RS100 (11 links):
Standard length:
349.2 mm (13.748 in)
limit length:
358.0 mm (14.094 in)
BL634 (18 links), BL1234 (9 links), RS60 (18 links),
RS120 (9 links):
Standard length:
342.9 mm (13.500 in)
limit length:
351.4 mm (13.835 in)

LM-9
 CARRIAGE ASSEMBLY
CARRIAGE ASSEMBLY

LMM0210

T
Removal
AF NOTE:
Removal of the carriage assembly and fork assembly as a unit
prevents the carriage assembly from toppling to the ground.
1. Set the mast assembly in the vertical position, then lower the
forks to the ground.
NOTE:
When removing the carriage assembly without forks, attach a lifting
R
wire/nylon sling, then support the carriage assembly using a hoist or
crane.
2. Disengage the lift chains at the adjusting bolt and lift chain joint
links on the mast side, then drape the lift chains over the
D

backrest.
3. Slowly raise the inner mast, then remove the carriage assembly
from the mast assembly.
CAUTION:
Be careful to prevent the mast from catching the removed
lifting chain.

LMT0083J

4. Back up the vehicle, then remove the carriage assembly from

the mast assembly.
CAUTION:
Be sure to lower the inner mast to the ground after backing the
vehicle up.

LMT0084J

LM-10
 CARRIAGE ASSEMBLY

Inspection
LIFT ROLLERS, SIDE ROLLERS AND SHIMS
Check for unsmooth rotation, deformation, stepped wear or damage.
Replace faulty parts with new ones if necessary.

CARRIAGE ASSEMBLY
• Visually check for cracks, deformation or separation at welds. If
necessary, replace with new ones.
• Check the carriage assembly using a dye penetration method. If it
is cracked, replace with a new one.

Adjustment
1. Select suitable rollers so that the clearance between the rolling
contact surface of the inner mast rail and the carriage roller are
within specifications.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available roller sizes:
97.0, 97.5 and 98.0 mm (3.819, 3.839 and 3.858 in)

T
Center mast roller diameter (2W/2F/3F mast):
97.0 mm (3.819 in)
LMT0085J
AF 2. Measure the inner wall width (A) of the inner mast at three
points (two at upper and lower ends of the inner mast and one
in the center of the inner mast at the cross beam location).
R

LMT0086J
D

LM-11
CARRIAGE ASSEMBLY

Adjustment (Cont’d)

T
LMM0211

3. Measure the pitch of the left and right carriage side rollers,
AF carriage rollers and thrust metals (at points “B”, “B'” and “B"”).
NOTE:
• The upper and middle carriage rollers for 2W/2F/3F mast are
used only for lift rollers. The lower carriage roller is guided and
rolls to the right and left within the rail race.
• Independent side rollers are located on the upper portion of the
carriage assembly.
R
4. Calculate carriage clearances by subtracting the maximum
pitch values of the carriage side rollers, carriage rollers and
thrust metals (B) from the measured minimum inner wall width
of the inner mast (A).
D

5. Whenever possible, use the same number of adjustment shims

to equalize left and right clearances.
Standard carriage clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available adjustment shims:
For use with carriage side rollers and thrust metals
0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in)
For use with carriage rollers
0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in)
CAUTION:
Be extremely careful when adjusting carriage clearances.
Improper adjustment may cause the carriage bracket to deviate
either to the left or right, or tilting of the finger. These
conditions will result in unequal heights for the left and right
forks.

LM-12
 CARRIAGE ASSEMBLY

Adjustment (Cont’d)
6. After carriage clearance adjustment, check to ensure that the
carriage assembly moves smoothly without binding.
CAUTION:
Apply a coat of grease to the roller rolling contact surfaces and
thrust metal contacting surfaces (indicated by arrows in the
figure).

LMM0231

T
AF
LMM0212

Installation
To install the carriage assembly, reverse the order of removal.
Observe the following:
CAUTION:
Discard old cotter pins; replace with new ones.
R
D

LM-13
 MAST
MAST

Mast Assembly
2W MAST

T
AF
R
D

LMM0213

LM-14
 MAST

Mast Assembly (Cont’d)

2F MAST

T
AF
R
D

LMM0214

LM-15
 MAST

Mast Assembly (Cont’d)

3F MAST

T
AF
R
D

LMM0215

LM-16
 MAST

Mast Assembly (Cont’d)

3V MAST

T
AF
R
D

LMM0216

LM-17
 MAST

Removal
CAUTION:
When removing the mast assembly, ensure the forks are
removed beforehand. This is a precaution to ensure the safest
possible maintenance procedure.
NOTE:
• If the carriage assembly need not be disassembled, remove the
carriage assembly together with the forks prior to removing the
mast assembly. Refer to “CARRIAGE ASSEMBLY” for
instructions.
1. Remove the hoses (lift hose, attachment hoses, etc.), then plug
their openings to prevent foreign matter from getting into the
hydraulic lines.
CAUTION:
The oil pressure remaining in hydraulic lines must be
completely bled off.
NOTE:
When removing the lift hose together with the carriage assembly,

T
relieve oil pressure in the hydraulic lines beforehand. Attach a lifting
LMM0232 wire or nylon sling to the carriage, then suspend it in the air with a
hoist to facilitate access to the mast assembly.
2. Attach a lifting wire or nylon sling to the upper beam of the mast
AF assembly, then support the mast assembly using a hoist.
CAUTION:
Be sure to support mast assembly, failure to do so may cause
serious injury or costly damage to the mast or other equipment.
R

LMT0094J

3. Remove the mast support cap bolts; remove the mast support
D

cap from the mast support, located at the frame by the inner
sides of the front tires.

LMM0233

LM-18
 MAST

Removal (Cont’d)
4. Remove the pivot pin lock bolts, then remove the pivot pins
securing the tilt cylinder to the mast assembly.
5. Turn the key switch to the ON position, retract the tilt cylinder all
the way (tilting the mast assembly backward).
CAUTION:
Be sure to retract the tilt cylinder all the way, failure to do so
may interfere with the tilt bracket when installing the mast
assembly.

LMM0234

6. Using a hoist, lift the mast assembly up and away from the
vehicle, then lower it horizontally onto blocks.
CAUTION:
• Be careful not to damage brake pipes, etc. while lifting or
moving the mast assembly away from the vehicle.
• When removing the mast assembly and carriage assembly
from the vehicle as a unit, securely fasten the tilt beam and

T
carriage assembly (finger bar) with a rope or wire. This
prevents carriage assembly movement when mast assembly
is transferred to the ground.
LMT0097J
• Always ensure the mast assembly rests on a flat and solid
AF surface after it has been removed.
• When positioning the mast assembly on the block, be careful
not to damage the mast support.
7. When the mast assembly and carriage assembly are removed
as a unit, remove the carriage assembly from the mast
assembly as follows:
• Attach a lifting wire or nylon sling to the carriage assembly and lift
R
using a hoist.
• Disengage the lift chains at the lift joint link and adjustment bolt on
the mast side, then place the disengaged lift chains on the
carriage.
• Slide the carriage down and extract it from the lower side of the
D

inner mast.
CAUTION:
Do not allow the mast assembly to snag or catch the lift chain
when removing the carriage assembly from the inner mast.

Disassembly
2W MAST
1. Remove the hydraulic lines from the lift cylinders.
2. Remove the fixing nuts from the upper ends of the lift cylinders.

LMM0217

LM-19
 MAST

Disassembly (Cont’d)
3. Draw out the inner masts from the upper end of the outer mast,
then remove the bolts from the lower ends of the lift cylinders
and the U-bolts. Remove the lift cylinders.

LMM0218 4. Remove the chain wheels, if necessary.

5. Slide the inner mast down. Remove the four mast rollers from
the lower end of the inner mast and upper end of the outer
mast.
CAUTION:
• Be careful not to catch your hands by sliding mast.
• Be careful not to catch your hands when roller is being
removed from mast.

T
LMT0100J
AF 6. Remove the liners from the outer mast.
R

LMM0235

7. Attach a lifting wire or nylon sling. Using a hoist, lift the lifting
D

wire or nylon sling until the inner mast is lifted free of the outer
mast.
CAUTION:
Be sure to remove the mast rollers in advance, otherwise, inner
mast cannot be removed from the outer mast with the mast
rollers installed in position.

LMT0102J

LM-20
 MAST

Disassembly (Cont’d)
2F/3F/3V MAST
1. Remove the piping connected to the head block (with the chain
wheel) and full-free cylinder.
• Remove the chain wheel from the head block if necessary.

LMM0219

2. Remove the full-free cylinder.

3. Remove the mast chain and chain wheel. (3F/3V mast)
4. Remove the piping connected to the mast cylinder.
5. Remove the mast cylinder mounting bolt (upper and lower) and
the U-bolt, and remove the mast cylinder.

T
AF
LMM0220

6. Slide the inner mast and middle mast (3F/3V mast) downward,
and remove the mast roller.
CAUTION:
• Do not remove the rollers of the 3F/3V mast at one time.
R
Remove the rollers of the inner mast first, then those of the
middle mast in this order.
• Be careful not to pinch your hand when the mast slides.
• Be careful not to pinch your hand when the roller is removed
D

from the mast.

LMT0100J

7. Remove the liner from the outer mast and middle mast (3F/3V
mast).
8. Pass nylon slings or wires in the mast of the inner mast first,
then the middle mast (3F/3V mast) in this order. While lifting
them by a hoist, etc., pull them upward over the outer mast.
CAUTION:
Because the inner mast and the middle mast (3F/3V mast)
cannot be pulled out if the mast roller has not been removed,
special care should be taken.

LMT0104J

LM-21
 MAST

Inspection
LIFT ROLLERS
Check for unsmooth rotation, deformation, stepped wear or damage.
If necessary, replace with new ones.

LINERS
Check for wear or damage. If necessary, replace with new ones.

CHAIN WHEELS
Check for cracks or damage. If necessary, replace with new ones.

PIPING
Check for cracks, breakage or damage. If necessary, replace with a
new one.

MAST ASSEMBLY
Check for cracks, damage or breakage at welds. If necessary,
replace with new one as an assembly.

T
Assembly
AF CAUTION:
Assemble the mast assembly while adjusting various parts.

2W MAST
1. Attach a lifting wire or nylon sling to the inner mast. Using a
hoist, lift the inner mast and guide it into position for
reinstallation to the outer mast.
R
2. Slide the inner mast down, then install the liner and mast rollers.
CAUTION:
Be sure to install mast rollers in the correct places, since the
inner and outer mast rollers are different in diameter.
D

Outer mast roller diameter:

97.0 mm (3.819 in)
3. Select suitable mast rollers so the clearances between the
rolling contact surfaces of the inner mast roller and outer mast
rail are within specifications.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available roller sizes:
Mast height: 3,500 or more mm (137.80 or more in):
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
Mast height: 2,700 - 3,300 mm (106.30 - 129.92 in):
105.0 mm (4.13 in)
LMT0105J • Apply a coat of grease to the rolling contact surface of the mast
rail.
CAUTION:
After adjustment, ensure that the mast assembly moves
smooth.

LM-22
 MAST

Assembly (Cont’d)
4. According to the following procedures, adjust the liners.
• Using a thickness gauge, measure the inner mast-to-liner
clearance on each side.
• If the clearance is outside specifications, use the same number
and thickness of shims on each side to adjust the clearance.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available shims:
0.5 and 1.0 mm (0.020 and 0.039 in)
CAUTION:
LMT0106J
When installing the liners after making shim adjustments, apply
a coat of bearing grease to the sliding surfaces of the liners and
mast assembly.
NOTE:
The liners are push-in type for easy positioning in the mast
assembly.
<Adjustments with the mast assembly installed to the vehicle>
• For removal procedure of carriage assembly, refer to “CARRIAGE
ASSEMBLY”. For removal procedure of lift cylinder, refer to HD

T
section.
• Lower the inner masts approximately 120 mm (4.72 in), then
adjust the shim of liner in the same manner as previously
AF described.
5. To adjust the mast rollers using adjustment shims, proceed as
follows:
• Adjust the roller pitch (Dimension “L”) for the inner and outer mast
rollers according to the forklift model series, as shown in the table
below.
Unit: mm (in)
R
Lifting height Dimension “L”

2,700 (106.30), 3,000 (118.11), 3,300 (129.92) 283 (11.14)

3,500 (137.80) 318 (12.52)
D

LMT0107J
3,700 (145.67) 343 (13.50)
4,000 (157.48), 4,500 (177.17), 5,000 (196.85) 383 (15.08)

• Move the inner mast all the way to either side of the inner wall of
the outer mast.
• Using a thickness gauge, measure the clearance between the
mast and mast roller on the opposite side.
CAUTION:
The mast-to-mast roller clearance must be measured at four
points (upper, lower, left and right).
• Lower the inner mast, then measure the mast-to-mast roller
clearance at or near the center cross beam of the outer mast.
• Using the same number and type of outer mast roller adjustment
shims, equally adjust the outer mast roller-to-inner mast
clearance on the left and right sides of the mast assembly until the
LMT0108J
clearance is within specifications.

LM-23
 MAST

Assembly (Cont’d)
• Using the minimum clearance value of the measurements
obtained from the upper and middle (at cross beam) portions,
select suitable inner mast roller adjustment shims. The left and
right inner mast roller clearances must be adjusted equally as
much as possible.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available adjustment shims:
0.50, 1.00 and 2.00 mm (0.020, 0.039 and 0.079 in)

LMT0109J

6. If previously removed, install the chain wheels on the inner

masts.
7. Secure the lower ends of the lift cylinders using mounting bolts.
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
8. Tighten the stud bolts on the set nuts to the bottom of the
threads. Apply thread lock to the threads of the stud bolt on the
cylinder side. And then tighten and fasten the stud bolt on the

T
top of the lift cylinder. So that the set nut does not become
loose, secure the stud bolt with a cotter pin.
: 78 - 98 N•m (7.9 - 10.0 kg-m, 58 - 72 ft-lb)
AF
HDM0158

9. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix
with the lock nuts.
: 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
R
10. Fit the stopper into the hole at the end of the adjusting bolt.
11. Tighten the adjusting bolt, and check that the stopper contacts
with the cylinder. Then, further tighten for 1/2 to 1 turn and
tighten the lock nut.
D

: 74 - 94 N•m (7.5 - 9.6 kg-m, 55 - 69 ft-lb)

• When tightening the lock nut, make sure that the adjusting
nut does not turn.
LMM0218

12. Install pipes and tubes to their original positions.

13. For the mast assembly and carriage which were removed as a
unit, adjust the carriage lift rollers. After adjusting carriage lift
rollers, attach a lifting wire or nylon sling to the carriage, then
install it to the inner mast using a hoist. For lift roller
adjustments, refer to “CARRIAGE ASSEMBLY”.
14. Place the lift chains on the chain wheels, engage the lift chains
at the chain joint links and adjustment bolts, then install to the
inner mast.
CAUTION:
LMM0226
Discard the old cotter pins; replace with new ones.

LM-24
 MAST

Assembly (Cont’d)
2F/3F/3V MAST
CAUTION:
When adjusting the 3F/3V masts, do not adjust them at one
time. Adjust the middle mast first, then the inner mast in this
order.
1. Pass nylon slings or wires in the mast of the middle mast (3F/3V
mast) first, then the inner mast in this order. While lifting them by
a hoist, insert them from over the outer mast.
2. Slide the inner mast and the middle mast (3F/3V mast) toward
the bottom of the outer mast, and install the liner, outer mast
roller, and middle mast upper roller.
CAUTION:
The roller diameters of the mast rollers differ on the inner mast
side, middle mast upper and lower sides (3F/3V mast), and
outer mast side. When installing the mast rollers, be sure to
install them in the proper positions.
Middle mast upper side roller diameter (3F/3V mast):
97.0 mm (3.819 in)
Outer mast roller diameter:

T
97.0 mm (3.819 in)
• As for the adjustment of other mast rollers, refer to step 4. on the
next page.
AF
LMT0112J

3. Adjust the liner using the following procedure.

• Measure the clearance between the mast roller and the liner on
the inside of the inner mast and middle mast (3F/3V mast) using a
thickness gauge.
• When the measured value is out of the standard values, perform
the shim adjustment to the right and left evenly.
R
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0 mm (0.020, 0.039 in)
D

LMM0236
CAUTION:
When installing the liner after the shim adjustment, apply
bearing grease to the mast sliding surface.
NOTE:
Because the backup metal is designed to be inserted in the mast, it
can be installed and removed easily.

LM-25
 MAST

Assembly (Cont’d)
<Adjustment of the mast installed to the vehicle>
2F mast
• Hang the mast using wire, etc., and remove the carriage
assembly and lift cylinder. (As for the removal of the carriage
assembly, refer to “CARRIAGE ASSEMBLY”. As for the removal of
the lift cylinder, refer to HD section.)
• Lower the inner mast by approximately 120 mm (4.72 in), and
perform the shim adjustment mentioned above, and then replace
the liner.

3F/3V mast
• Hang the mast using a wire, etc., and remove the carriage
assembly. (Refer to “CARRIAGE ASSEMBLY”.)
• Remove the mast chain.
• Remove the mast cylinder. (Refer to HD section.)
• Lower the inner mast by approximately 120 mm (4.72 in), replace
the liner of the middle mast side, and then perform the shim
adjustment.
• Lower the inner mast and middle mast simultaneously for
approximately 120 mm (4.72 in), replace the liner of the outer

T
mast side, then perform the shim adjustment.
4. Install the inner mast roller, mast roller of the middle mast lower
side, and perform the shim adjustment using the following
AF procedure.
• Set the roller pitches (Dimension “L”) of the inner mast, middle
mast (3F/3V mast), and outer mast to the dimensions indicated in
the table according to the mast lifting height.

Unit: mm (in)

Lifting height Dimension “L1, L2”

R
2F 2,700 (106.30), 3,000 (118.11), 3,300 (129.92) 284 (11.18)
3,500 (137.80) 354 (13.94)
3,700 (145.67) 404 (15.91)
4,000 (157.48) 484 (19.06)
D

3F 3,850 (151.57), 4,300 (169.29), 4,750 (187.01), 369 (14.53)

5,150 (202.76)
5,500 (216.54) 384 (15.12)
6,000 (236.22) 419 (16.50)
6,500 (255.91) 504 (19.84)
7,000 (275.59) 604 (23.78)
3V 3,600 (141.73), 4,050 (159.45), 4,500 (177.17), 369 (14.53)
4,900 (192.91)
5,250 (206.69) 384 (15.12)
5,750 (226.38) 419 (16.50)
6,330 (249.21) 504 (19.84)
6,880 (270.87) 604 (23.78)

LM-26
 MAST

Assembly (Cont’d)

LMM0222

CAUTION:
• For the 3F/3V mast, setting the roller pitches of the inner
mast, middle mast, and outer mast at one time may cause
instability. Adjust in two steps, first for the inner and middle
masts, then for the middle and outer masts.
• Fix the mast with a rope or a wire to prevent it from sliding.
• Select the mast rollers so that the clearances between the mast
roller of the inner mast side and the outer mast (middle mast for

T
3F/3V mast), and between the mast roller of the middle mast
lower side and the rail and roller sliding surface of the outer mast
(for 3F/3V mast only) conform to the standard values.
AF Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
2F mast roller types (Inner mast):
Mast height: 3,500 or more mm
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
LMT0105J Mast height: 2,700 - 3,300 mm,
105 mm (4.13 in)
3F/3V mast roller types (Middle mast lower side):
R
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
3F/3V mast roller types (Inner mast):
97.0, 97.5, 98.0 mm (3.82, 3.84, 3.86 in)
• Place the inner mast or the middle mast (for 3F/3V mast only) to
D

the end of the side, and measure the clearance between the mast
and the mast roller of the reverse side using a thickness gauge.
CAUTION:
Perform measurement for the mast rollers at four points: upper,
lower, right, and left sides (eight points for 3F/3V mast).
• Adjust the shim of the mast roller to the right and left as equally as
possible, so that the closest clearance between the mast roller of
the outer mast side and inner mast (middle mast for 3F/3V mast),
and that between the mast roller of the middle mast upper side
LMT0108J
and the inner mast (for 3F/3V mast only) conform to the standard
values.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0, 2.0 mm (0.020, 0.039, 0.079 in)

LM-27
 MAST

Assembly (Cont’d)
• Adjust the shim of the mast roller to the right and left as evenly as
possible, so that the closest clearance between the mast roller of
the inner mast side and outer mast (middle mast for 3F/3V mast),
and that between the mast roller of the middle mast lower side
and the outer mast (for 3F/3V mast only) conform to the standard
valves.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0, 2.0 mm (0.020, 0.039, 0.079 in)
LMT0109J

• Apply grease to the roller sliding surface of the mast (indicated by

arrows in the figure).
CAUTION:
After adjustment, check for smooth operation of the mast.

T
LMM0231
AF
R

LMM0212
D

5. Set the mast cylinder to the hole of the lower beam on the outer
mast, and set the piston rod to the cylinder setting bracket on
the inner mast. Tighten the mounting bolts at the upper and
lower ends of the cylinder.
Cylinder upper end:
: 78 - 98 N•m (7.9 - 10.0 kg-m, 58 - 72 ft-lb)
Cylinder lower end:
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
6. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix
with the lock nuts.
: 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
7. Fit the stopper into the hole at the end of the adjusting bolt.

LMM0218

LM-28
 MAST

Assembly (Cont’d)
8. Tighten the adjusting bolt, and check that the stopper contacts
with the cylinder. Then, further tighten for 1/2 to 1 turn and
tighten the lock nut.
: 74 - 94 N•m (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
• When tightening the lock nut, make sure that the adjusting
nut does not turn.
9. Install the piping to the mast cylinder.
10. Install the chain wheel and mast chain (3F/3V mast).

LMM0226

11. Install the full-free cylinder. At this time, perform the shim
adjustment so that the inner mast and full-free cylinder become
parallel (2F/3F mast).
Shim: 1.0 mm (0.039 in)
: 128 - 156 N•m (13 - 16 kg-m, 94 - 115 ft-lb)

T
LMT0119J
AF Mounting bracket of full free cylinder to be inserted into the
notch of inner mast 2nd-beam. After surface A of 2nd-beam
touches surface B of mounting bracket, bolt is to be tightened.
(3V mast)
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
R

HDM0163
D

12. Install the piping of the head block (with the chain wheel) and
full-free cylinder.
13. When the mast assembly is removed with the carriage
mounted, adjust the lift roller of the carriage, lift the carriage
assembly by a nylon sling or wire, then install to the inner mast.
(As for the adjustment of the lift roller, refer to “CARRIAGE
ASSEMBLY”.)
14. Pass the lift chain in the chain wheel, connect the adjusting bolt
to the chain joint linking section, and then install it to the full-free
cylinder.
CAUTION:
Replace the cotter pin with a new one.

Installation
1. Attach a lifting wire or nylon sling to the mast assembly, then lift
the mast assembly using a hoist.
CAUTION:
• Before lifting the mast assembly (if equipped with the
carriage assembly), lower the carriage assembly all the way
down. Securely fasten the carriage finger bar to the tilt beam.
• Make sure the lift chains are placed on the chain wheels.
• Make sure the lift chains are not twisted.

LM-29
 MAST

Installation (Cont’d)
2. Apply a coat of multi-purpose grease to the mast mounting
shafts. Then install the bushings.
3. Apply a coat of multi-purpose grease to the outer walls of the
bushings. Place the mast mounting shaft onto the mast support
at the frame, then install the mast support caps.
: 89 - 118 N•m (9.1 - 12.0 kg-m, 66 - 87 ft-lb)
4. Turn the key switch to the ON position. Extend the tilt cylinder
using the tilt lever until the pivot pin holes in the tilt cylinders and
mast are aligned. Insert the pivot pins into the holes, then
secure with the bolts.
LMM0237 : 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
CAUTION:
Be careful not to catch your hands by the tilt cylinder and mast
assembly when the tilt lever is operated.
5. Install the lift hoses to their connections.
CAUTION:
Ensure that the lift hoses shall not be twisted during
installation.

T
6. Apply a coat of multi-purpose grease to the mast supports and
tilt cylinder pivot pins.
7. Lift and tilt the mast assembly several times. Check that no oil
leaks occur at or around the hydraulic lines, and that the mast
AF assembly operates smoothly without binding.
8. Check the lift chains for proper tension. If necessary, adjust the
chain tension. For chain tension adjustments, refer to “LIFT
CHAINS”.

LMM0223
R
Adjustment
ADJUSTING OF CYLINDER HEIGHT
D

NOTE:
To prevent mast from being twisted and deformed, adjust the
cylinder height. Be sure to adjust when reassembling the mast
assembly, especially when replacing only one cylinder.
1. Check that forklift is placed horizontally.
2. Remove upper mounting nuts/bolts of right and left cylinder.
3. Slowly raise mast without load, and then check that right and
left cylinders reach to their stroke end simultaneously.
4. If one cylinder is delayed, adjust delayed cylinder by inserting
shims.
Thickness of shim: 1.0 mm (0.039 in)
5. Repeat the adjustment above until there is no difference
between the right and left cylinders.
6. Ensure that the top of the cylinders are set firmly to the bracket
HDM0158 on the inner (middle) mast, and secure by tightening the
mounting bolts.
Apply Thread Lock to the threads of cylinder mounting bolts.
(2W mast only)
: 78 - 98 N•m (7.9 - 10.0 kg-m, 58 - 72 ft-lb)

LM-30
 MAST

Adjustment (Cont’d)
MAST TILT ANGLE ADJUSTMENT
1. Park the vehicle on flat and solid ground.
2. Tilt the mast assembly all the way forward, then check the left
and right sides of the mast assembly to ensure that the forward
tilt angle is within specifications.

Mast tilting angle

Forward/Backward

2W, 2F 4°/6°
3F, 3V 5°/5°
LMM0225

3. Loosen the lock nuts and turn the tilt cylinder rods using a
wrench until their stroke lengths are within specifications.
CAUTION:
• Adjust the piston rod stroke lengths so the lengths of the
piston rod thread portions do not exceed.
• Adjust the piston stroke lengths so that the tilt angle of the

T
left and right masts are identical.
• Tilt the mast assembly forward and backward. If the left and
right masts are improperly adjusted, make fine adjustments
AF
LMT0123J
of the tilt cylinder stroke lengths as required.

•NOTE:
The backward tilt angle of the mast is automatically set by adjusting
the forward tilt angle.
4. After adjusting the forward-backward tilt angle of the mast
assembly, tighten the lock nuts on the tilt cylinders.
R
: 108 - 147 N•m (11 - 15 kg-m, 80 - 108 ft-lb)
5. Paint alignment marks on mating areas between the tilt cylinder
rod and rod head, and the rod head and lock nut.
6. Operate the mast assembly several times to ensure that it
D

moves smoothly without binding.

LMT0124J

Mast bushing
MAST BUSHING GREASING
• Jack the mast slightly to make sure the grease will go all
around the mast pin.
• Add grease until the new grease comes out all around the
mast pin.
• Clean the exceeding grease.

CHECKING WEAR
LMM0223
To check the wear of the mast bushing, measure the thickness of the
bushing in different places. If the wear limit is reached at one of the
places, replace the bushing.
Wear limit is: 3.38mm (0.133in)

LM-31
 MEMO

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AF
R
D

LM-32
 BODY & FRAME

SECTION BF
CONTENTS

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SERVICE DATA AND SPECIFICATIONS ......... BF-2 Floor Board and Mat ....................................... BF-6
General Specifications .................................. BF-2 Overhead Guard and Rearview Mirror ........... BF-7
Tightening Torque ......................................... BF-3 Seat and Top Panel ....................................... BF-8
PRECAUTIONS AND PREPARATION .............
AF BF-4 Panels and Counterweight ........................... BF-10
Precautions ................................................... BF-4
BODY AND FRAME ........................................... BF-5
Instrument Covers ......................................... BF-5
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D
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

General Specifications

COUNTERWEIGHT

Applied model
Identifica Weight kg
(A)S1N1 (A)1N1 (A)G1N1
tion mark (lb)
13 15 15 18 16 18 20

820 (1808)
H – – – – –

MH
659 (1453) – – – – – –
(A1N1)
M 630 (1389) – – – –

L 520 (1147) – – – – –

T
AF
BFM0031

Applied model
Identifi-
Weight kg
cation J(A)G1N1
(lb)
mark
16 18 20
R
L 520 (1147) – –

M 600 (1323) – –

H 730 (1609) – –
D

BFM0801EU

BF-2
 SERVICE DATA AND SPECIFICATIONS

Tightening Torque
Unit N•m kg-m ft-lb
Instrument covers bolt 1.5 – 2.0 0.16 – 0.20 1.1 – 1.4
Floor board, FR bolt 5.0 – 6.0 0.51 – 0.61 3.7 – 4.4
Instrument frame bolt 93 – 108 9.5 – 11 69 – 79
Rear pillar bolt 137 – 196 14 – 20 101 – 144
Overhead guard bolt 78 – 98 7.9 – 10 58 – 72
Rearview mirror 13 – 15 1.3 – 1.6 10 – 11
Top panel hinge bolt (Pillar side) 56 – 64 5.7 – 6.6 42 – 47
Top panel hinge bolt (Top panel side) 9.3 – 10 0.95 – 1.1 6.9 – 7.3
Gas stay bolt 9.3 – 10 0.95 – 1.1 6.9 – 7.3
Side panel bracket bolt 16 – 17 1.6 – 1.8 11.8 – 12.5
Counterweight bolt 490 – 620 50 – 63 362 – 457

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AF
R
D

BF-3
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION

Precautions
CAUTION:
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• Use a hoist and lifting wire/nylon sling which is capable of
sufficiently withstanding the weight of objects being
handled.
• When disassembling or servicing units or parts of a vehicle,
park it on a solid and level ground and chock the wheels.
Failure to do so may cause the vehicle to move unexpectedly.
Also, be sure to disconnect battery plug in advance.
• Always assign lifting operations to qualified operators
trained in slinging or hoisting procedures.
• Turn the key switch to OFF and disconnect the battery cables
before removing the components.

NOTE:
• For battery removal and installation procedures, refer to BC
section.
• For pedal bracket removal and installation procedures, refer to BR

T
section.
• For steering system and rear axle removal and installation
procedures, refer to ST section.
AF • For reduction gear removal and installation procedures, refer to
DU section.
• For front and rear tires removal and installation procedures, refer
to TR section.
• For removal and installation of traction motor and oil pump motor,
refer to MM section.
• For mast assembly removal and installation procedures, refer to
LM section.
R
• For hydraulic system removal and installation procedures, refer to
HD section.
• For electrical system removal and installation procedures, refer to
EL section.
D

BF-4
 BODY AND FRAME
BODY AND FRAME

Instrument Covers

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AF
R
D

BFM0032

BF-5
BODY AND FRAME

Floor Board and Mat

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AF
R
D

BFM0033

BF-6
 BODY AND FRAME

Overhead Guard and Rearview Mirror

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AF
R
D

BFM0034

CAUTION:
Be sure to attach the lifting wire / nylon sling so as not to allow
it to slide off the overhead guard.

BF-7
 BODY AND FRAME

Seat and Top Panel

T
AF
R
BFM0035

CAUTION:
D

• Be careful not to drop the operator’s seat during removal.

• Have someone assist in removal of the battery hood.
• When opening or closing the battery hood, be careful not to
catch your hands or fingers between the battery hood and
the case.

TOP PANEL OPENING / CLOSING PROCEDURE

NOTE:
On forklifts equipped with a restraint seat, be sure to keep the
steering wheel tilted forward before opening the top panel.

1. Release the lock lever on the console box and tilt the console
box forward (if equipped with the mechanical control type).
2. Unlock the top panel latch.

BFM0036

BF-8
 BODY AND FRAME

Seat and Top Panel (Cont'd)

3. Open the top panel.

CAUTION:
Since the top panel is heavy, exercise caution in handling it.

4. While pressing down the gas stay lock button, close the top
panel.

CAUTION:
BFM0037 Since the top panel is heavy, exercise caution in handling it.

5. Lock the top panel latch.

WARNING:
• Close the top panel slowly, keeping a firm hold on the handle.
Never place your hand under the top panel. This is very
dangerous.
• Make sure that the top panel latch is securely locked.

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AF
BFM0038
R
D

BF-9
BODY AND FRAME

Panels and Counterweight

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AF
R
D

BFM0039

BF-10
 BODY AND FRAME

Panels and Counterweight (Cont'd)

CAUTION:
• When installing the counterweight, slowly lower it with a
hoist until the suport of counterweight is properly positioned
onto its mount in the frame. Then tighten bolts.
: 490 - 620 N•m (50 - 63 kg-m, 362 - 457 ft-lb)
• After installing the counterweight, properly connect
harnesses and cables to and around the controller.

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AF
R
D

BF-11
 MEMO

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AF
R
D

BF-12
 OPTION

SECTION OP
CONTENTS

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OPTION .............................................................. OP-2 Cabin Option
Cabin Option Location of Electrical Component Parts ........ OP-5
Assembly of Front Window and Door ............ OP-2 Cabin Option
Cabin Option
AF Outline ........................................................... OP-6
Assembly of Rear Window ............................ OP-3 Cabin Option
Cabin Option Cabin Harness Layout ................................... OP-7
Location of Electrical Component Parts
(3 - wheel) ..................................................... OP-4
Location of Electrical Component Parts
(4 - wheel) ..................................................... OP-4
R
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 OPTION
OPTION

Cabin Option
Assembly of Front Window and Door
Bracket frame upper
Grommet

Front window

Panoramic mirror
Self-tapping screws

1.3-1.4
(0.13-0.14, 0.94-1.01)

Room light
Bulb

T
9.3-10
(0.95-1.1, 6.9-7.3)

9.3-10
AF (0.95-1.1, 6.9-7.3)

78-98
(7.9-10, 58-72) Bracket frame lower
9.3-10
Bracket gas stay (0.95-1.1, 6.9-7.3)
R
Ball stud gas
stay
9.3-10
(0.95-1.1, 6,9-7.3)
D

Gas stay

Striker

Protrusion rod
Handle rod
9.3-10
Shim (0.95-1.1, 6.9-7.3)

9.3-10
(0.95-1.1, 6.9-7.3)

Door assembly

OP-2
 OPTION

Cabin Option
Assembly of Rear Window

9.3-10
(0.95-1.1, 6.9-7.3)

Patrol lamp

19-21
(2.0-2.1, 14-15) Insulator upper, RH

Grommet

Bracket operation lamp

Seal door assembly

back, upper

T
Back operation lamp
AF
9.3-10
Insulator upper, LH (0.95-1.1, 6.9-7.3)
R
Door assembly-
back, outer

Fixation lower part with

D

controller cover

Insulator lower, RH

Insulator lower, LH
Sheetmetal back, lower

OPM0002

OP-3
 OPTION

Cabin Option
Location of Electrical Component Parts (3 - wheel)

Patrol lamp
Wiper motor rear(STD: Except for
NORTH AMERICA)
(OPT: For NORTH AMERICA)

Controller

T
PS correction solenoid valve

Tire angle sensor

AF Fusible link

DC - DC converter (OPT)
Back buzzer Contactor ASSY
OPM0003

Location of Electrical Component Parts (4 - wheel)

R
D

OPM0801EU

OP-4
 OPTION

Cabin Option
Location of Electrical Component Parts

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AF
OPM0004EU
R
D

OP-5
 OPTION

Cabin Option
Outline

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AF
R
D

ELM0252EU

OP-6
 OPTION

Cabin Option
Cabin Harness Layout

: To FR wiper (E)
: To FR wiper (+)
: To connector for extra options
: To body harness connector B14
: To cabin relay
: To cabin relay
: To diode (cabin)
: To D/C D/C converter (output)
: To D/C D/C converter (input)
: To RR wiper (E)
: To R/R wiper (+)

Front

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AF
OPM0005
R
D

OP-7
 MEMO

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AF
R
D

OP-8