Service Manual ET3000 CAT

Service Manual
Chassis, Mast & Options

ET3000 ETB12-00011-up
ET3500 ETB14-00011-up
ET4000 ETB14-50001-up
99719-88110
FOREWORD
This service manual is a guide for servicing Cat ® lift trucks . For your convenience the
instructions are grouped by systems as a ready reference.
The long productive life of your lift trucks depend on regular and proper servicing. Servicing
consistent with what you will learn by reading this service manual. Read the respective
sections of this manual carefully and familiarize yourself with all of the components before
attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks with
serial numbers in effect at the time of printing. Cat lift trucks reserves the right to change
specifications or design without notice and without incurring obligation.
Safety Related Signs
The following safety related signs are used in this service

manual to emphasize important and critical instructions:
Indicates a potentially hazardous

! WARNING situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous

! CAUTION
situation which, if not avoided, may
result in death or serious injury or
damage to the machine.
Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine
Pub. No. 99719-88110

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

Disassembling sequence
209603
Sequence
1 Cover , Bolt, Washer (part name)
2 Snap ring ................ (part name)
Suggestion for disassembling

1. Output shaft, Removing
Remove output shaft using a special tool.
209604
Service Data
0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.
Item SI unit Customary unit

1N 0.1020 kgf
Force
(1 lbf) (0.4536 kgf)
1 kPa 0.0102 kgf/cm2
Pressure
(1 psi) (0.0703 kgf/cm2)
1 N·m 0.1020 kgf·m
Torque
(1 lbf·ft) (0.1383 kgf·m)
GROUP INDEX
GROUP INDEX Items
GENERAL INFORMATION Serial number locations, Dimensions, Technical data 1
VEHICLE ELECTRICAL
COMPONENTS
Console box, Key switch, Lamp specification chart 2
Controller system, Controller features, Setup option, Diagnosis,
CONTROLLER Removal and installation, Basic check 3
TROUBLESHOOTING FOR Faulty central vehicle monitor system, Faulty diagnosis indication, or
CONTROL CIRCUITS Other abnormalities 4
POWER TRAIN Procedure and suggestions for removal and installation 5

Motor installation positions, Specifications, Structures, Tightening of high-
MOTORS power cable terminals, Procedures and suggestions for removal and 6
installation, Procedures and suggestions for disassembly and reassembly
TRANSFER UNITS Procedures and suggestions for disassembly and reassembly 7
REAR AXLE Rear axle, Rear wheels 8
BRAKE SYSTEM Caliper, Brake pedal, Master cylinder 9
STEERING SYSTEM Steering control valve 10

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
HYDRAULIC SYSTEM Down safety valve 11
MASTS AND FORKS Simplex mast, Duplex mast, Triplex mast 12

Inspection standards, Periodic replacement of parts, Lubrication
SERVICE DATA standards, Main component weight, Tightening torque for standard bolts 13
and nuts, Special tools
OPTIONS Working lamp kit, Tire kit, Foot direction control 14

GENERAL INFORMATION
1
Vehicle Exterior ....................................................................................... 1–1
Models ....................................................................................................... 1–1
Serial Number Locations ...................................................................... 1–2
Chassis and Mast Model Identification ............................................ 1–3
Dimensions .............................................................................................. 1–4
Technical Data ......................................................................................... 1–5
GENERAL INFORMATION
Vehicle Exterior
211334
Models
This manual applies to ET3000, ET3500 and ET4000.
Truck Model Serial Number

ET3000 ETB12-00011-up
ET3500 ETB14-00011-up
ET4000 ETB14-50001-up
1-1
GENERAL INFORMATION
Serial Number Locations

Mast number Chassis number Nameplate
211335
1-2
GENERAL INFORMATION
Chassis and Mast Model Identification
[Chassis]
E T 3000
Maximum capacity
3000: 1600 kg (3500 lb)
3500: 1800 kg (4000 lb)
4000: 2000 kg (4400 lb)
Three wheel models
Battery type
[Mast]
2 G 15 A 30
Maximum lifting height

[“30” stands for 3000 mm (118 in.)]
Order of the minor change

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

15: 1 ton class
20: 2 ton class
Kind of mast
G: simplex mast
H: duplex mast
J: triplex mast
Major change
(“1” for the original, “2” for the first change, and so
on up to “9”)
1-3
GENERAL INFORMATION
Dimensions
B E F
211336
1-4
GENERAL INFORMATION
Technical Data
Truck Models ET3000 ET3500 ET4000
Class 1.6 ton 1.8 ton 2.0 ton
Load Capacity/Load Center N (kgf)/mm 15690 (1600)/500 17650 (1800)/500 19610 (2000)/500
[lbf/in.] [3000/24] [3500/24] [4000/24]
Truck size Length to Fork Face A mm (in.) 1893 (74.5) 1996 (78.6) 2037 (80.2)
Width B mm (in.) 1070 (42.1) 1070 (42.1) 1070 (42.1)
Height of Overhead
C 2040 (80.3) 2040 (80.3) 2040 (80.3)
Guard mm (in.)
Wheelbase D mm (in.) 1305 (51.4) 1410 (55.5) 1410 (55.5)
Service Weight (including battery) kg (lb) 3090 (6812) 3290 (7253) 3520 (7760)
mm 894/170 894/170 894/170
Tread Front/Rear E/F
(in.) (35.2/6.7) (35.2/6.7) (35.2/6.7)
Tires Number Front/Rear 2/2 2/2 2/2
Tires Size Front 18 × 7 × 12 1/8 18 × 7 × 12 1/8 18 × 7 × 12 1/8
Rear 15 × 5 × 11 1/4 15 × 5 × 11 1/4 15 × 5 × 11 1/4
Turning Radius mm (in.) 1517 (59.7) 1620 (63.8) 1645 (64.8)
Travel Speeds 48 V 17/17 (10.6/10.6) 17/17 (10.6/10.6) 17/17 (10.6/10.6)
km/h (mph)
Unloaded/Loaded 36 V 17/15.1 (10.6/9.4) 17/14.4 (10.6/8.9) 17/13.7 (10.6/8.5)
Maximum gradeability
48 V 35/27 35/25 35/23
Unloaded/Loaded %
36 V 30/13 28/12 26/11
at 1.6 km/h (1 mph)
Lift Speed 48 V 0.60/0.50 (23.6/19.7) 0.60/0.44 (23.6/17.3) 0.60/0.40 (23.6/15.7)
m (in.)/sec
Unloaded/Loaded 36 V 0.56/0.40 (22.0/15.7) 0.56/0.35 (22.0/13.8) 0.56/0.34 (22.0/13.4)
Lowering Speed 48 V 0.50/0.52 (19.7/20.5) 0.50/0.52 (19.7/20.5) 0.50/0.52 (19.7/20.5)
m (in.)/sec
Unloaded/Loaded 36 V 0.56/0.40 (22.0/15.7) 0.56/0.35 (22.0/13.8) 0.56/0.34 (22.0/13.4)
Battery Voltage V 36 48 36 48 36 48
Battery Rated Capacity (6 hrs.) MAX Ah 675 600 825 720 825 720
Battery Compartment mm 521 × 1006 × 650 624 × 1006 × 650 624 × 1006 × 650
Length × Width × Height (in.) (20.5 × 39.6 × 25.6) (24.6 × 39.6 × 25.6) (24.6 × 39.6 × 25.6)
Tilt Angle (forwards-backwards) 6°-7° 6°-7° 6°-7°
Traction Motor, 60 min short duty kW 2 × 5.0 2 × 5.0 2 × 5.0
Hydraulic Motor kW 14 14 14
Traction Motor Control Method MOSFET MOSFET MOSFET
Hydraulic Motor Control Method MOSFET MOSFET MOSFET
1-5
VEHICLE ELECTRICAL COMPONENTS
Console Box ............................................................................................ 2 – 1

Functions of Central Vehicle Monitor System ............................................ 2 – 1 2
Electrical Components in Console Box ..................................................... 2 – 5
Disassembly and Reassembly .................................................................. 2 – 6
Direction Lever ........................................................................................ 2– 7
Accelerator Control ............................................................................... 2– 8
Key Switch ............................................................................................... 2– 9
Lighting Switch ....................................................................................... 2– 9
Fuses ......................................................................................................... 2 – 10
Lamp Specification Chart .................................................................... 2 – 10
Troubleshooting of Lighting and Horn Systems ............................ 2 – 11
Console Box 1
1 Central vehicle monitoring system 6

(CVMS)
2 Mode selector button 2
3 Steering tilt lever
4 Key switch 5
5 Lighting switch (option)
3
6 Mode check button
4
NOTE
103043
For setting the clock and selection of KPH or MPH,
refer to “Selection of KPH or MPH” and “Setting the
clock”.
Functions of Central Vehicle Monitor System (CVMS)
9 8
10
1 2 3 4 5 6 7
Operations 211131
No. Monitor name When OFF When ON or flashing Remarks

1 Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached.
Seat belt warning Seat belt is fastened. Seat belt is not
light fastened when
2 operator sits on seat
(seat switch is turned
on).
2-1
No. Monitor name When OFF When ON or flashing Remarks

Controller/motor Controller, drive motors and Overheating Overheating causes a
overheat indicator pump motor in normal significant output loss. When
3 temperature component temperature returns
to normal levels, output power
returns.
Remaining Normal battery condition Flashing indicates
battery charge battery needs to be
warning light recharged soon.
4 ON indicates battery
needs to be recharged
and lifting function
inoperable.
5 Brake fluid level indicator Normal fluid level Low fluid level
6 Parking brake warning Parking brake disengaged Parking brake
light engaged
7 Malfunction lamp Normal Vehicle malfunction
Speedometer
8 KPH, MPH
Error indicator
Battery discharge When no bars show, vehicle is drivable but lifting Indicates remaining battery
9
indicator function is inoperable. power.
Hour meter 1 2 3 4 5
Advances every 0.1 hour
10
(Number advances every 6 minutes.)
Hour indication
2-2
Selection of KPH or MPH

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position. Button 1 Button 2
4. Push and hold button 1 for one to two seconds.

NOTICE: Display will show KPH and a 24-hour clock
until it is changed. When MPH is selected, the
clock will change to a 12-hour clock.
Setting the clock 103043

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 until the minutes’ display
flashes.
5. Release button 1.
6. Adjust the minutes with button 2.
7. Push button 1 and release when the hours’ display
flashes.
8. Adjust the hour with button 2.
9. Push button 1 to lock in the time.
2-3
Error code display
Indication Condition
E Indicator flickers if seat switch is turned off during driving operation. Then,
indicator turns on when seat switch is turned on again. Indicator turns off when
direction lever and accelerator pedal are returned.
E 0 ON Right drive motor overheated
E 1 ON Left drive motor overheated
E 2 ON Pump motor overheated
E 5 ON Right traction inverter overheated
E 6 ON Left traction inverter overheated
E 7 ON Pump inverter overheated
H 1 ON Faulty setting of lift lever
H 2 ON Faulty setting of tilt lever
H 3 ON Faulty setting of attachment 1 lever
(L) Indicator flickers if seat switch is turned off during lifting operation.
Then, H1 to H5 turn on when seat switch is turned on again. Indicator turns off
when lifting operation is suspended.
2-4
Electrical Components in Console Box
Horn cable
Monitor cable
2
Direction lever switch cable

1
211132
1 Key switch
2 Lighting switch (option)
2-5
Disassembly and Reassembly

Disassembly
2
6
4
211133
Sequence
1 Console box (front panel) 5 Console box (rear panel)
2 Central vehicle monitor panel 6 Key switch
3 Direction lever 7 Light switch
4 Steering tilt lever
Disassembly procedure
(1) Remove the front panel and monitor panel from the
console box.
(2) Disconnect the harness connectors from the horn and T-nut
direction lever.
(3) Remove the screw from the steering tilt lever, and Steering tilt
remove the lever from the rear panel of the console lever
box. Screw
(4) Remove the rear panel.
211134
Reassembly
Follow the disassembly procedure in reverse.
2-6
Direction Lever
Structure
211135
1 Lever 3 Connector
2 Harness 4 Screw
2-7
Accelerator Control
Accelerator pedal
Initial position
Stopper bolt
1.5 to 2.5
Lock nut
Switching position
of idle switch
Floor plate
30 to 32 mm
(1.18 to 1.26 in.)
Accelerator lever
Accelerator
Adjusting screw
Position meter
211136
Adjustment procedure
(1) Disconnect the battery plug.
(2) Set the stopper bolt to 30 to 32 mm (1.18 to 1.26 in.)
from the floor to the upper face of bolt.
(3) Adjust the mounting angle of the position meter using
the adjusting screw so the switch inside the position
meter turns on when the accelerator lever is moved 1.5°
to 2.5° from the initial position. 206805B
Make sure the inside switch turns ON by checking the

continuity between the two terminals (indicated by
arrows) by using an ohmmeter.
2-8
Key Switch
Terminal B M
Connection Main fuse
Logic card
destination Battery
● (OFF) ●
I (ON) ● ●
206806
Lighting Switch (option)
Terminal 2 5 3 6
Connection Battery Battery Head Working
destination lamps lamp 2
6 3 5 2 3
OFF ● ●
5
ON (1) ● ● ● 21 6
ON (2) ● ● ● ●
Head
Lamp Fuse
Working
Lamp
211137
2-9
Fuses
Capacity (A) Location Main connecting device
500 Drive motor
Contactor assembly
500 Pump motor
15 Key switch, Lighting switch
Fuse holder
10 Power relay
NOTE
Refer to Parts Manual for proper replacement fuses.
Lamp Specification Chart
Item Bulb
Quantity Bulb color Remarks
Lamp 36 V/48 V External diagram
Head lamps (option) 2 Clear 45 W
Working lamp (option) 1 Clear 45 W
205833
2-10
Troubleshooting of Lighting and Horn Systems
Complaint Possible cause Remedy

Will not light a) Dead or weak battery Recharge or replace.
b) Fuses blown Check and replace.
c) Open or short in circuit Repair or replace.
d) Poor grounding Clean ground spot and
re-make connection.
Lamps-general
e) Bulbs burnt out Replace.

Will light dimly a) Dead or weak battery Check and recharge.
b) Burned contact points in switches Repair or replace.
c) Loose terminals Retighten.
d) Dirty lenses Clean.
e) Water drops inside lenses Dry and replace packings.
f) Bulbs’ service life expired Replace.
lamps
Head
Will not light a) Lighting switch defective Replace.

b) Bulbs burnt out Replace.
Other lamps
Working lamp will a) Working lamp switch defective Correct if improperly

not light installed: replace if
internally defective.
b) Bulbs burnt Replace.
Will not give blast a) Fuse blown out Check and replace.
of sound b) Open or short in circuit Repair or replace.
c) Horn switch defective Replace.
Horn
d) Horn defective Replace.

e) Horn button defective Repair or replace.
Will give an offensive a) Horn switch defective Replace.

blast of sound b) Horn defective Replace.
2-11
CONTROLLER
Controller System .................................................................................. 3 – 1

System Layout .......................................................................................... 3 – 1
Controller Area Network (CAN) ................................................................. 3 – 2
Outline of Controller .................................................................................. 3 – 3 3
Controller Features ................................................................................ 3 – 7
Traction Features ...................................................................................... 3 – 7
Lifting Features ......................................................................................... 3 – 9
Outline Features ....................................................................................... 3 – 10
Setup Option ........................................................................................... 3 – 13
Outline ...................................................................................................... 3 – 13
Operation Procedure ................................................................................ 3 – 13
Details of Setup Options ........................................................................... 3 – 15
Diagnostics .............................................................................................. 3 – 32
Outline ...................................................................................................... 3 – 32
Operation Procedure ................................................................................ 3 – 32
Self-Diagnostics ........................................................................................ 3 – 35
Power Steering Diagnostics ....................................................................... 3 – 36
Self-Diagnostics (Power steering system).................................................. 3 – 37
Run Time Diagnostics ............................................................................... 3 – 38
Removal and Installation ...................................................................... 3 – 40
Inverter Discharging Procedure ................................................................ 3 – 40
Replacing Inverter ..................................................................................... 3 – 41
Replacing DSP (Digital Signal Processor) Card ........................................ 3 – 43
Replacing Logic Unit ................................................................................. 3 – 45
Replacing Logic Card ............................................................................... 3 – 46
Replacing Power Supply Card .................................................................. 3 – 47
Basic Check ............................................................................................. 3 – 48
Testing Tools ............................................................................................. 3 – 48
Measurement of Card Voltage .................................................................. 3 – 49
Checking Contactor Coil ........................................................................... 3 – 52
Checking Contactor Tips ........................................................................... 3 – 52
Checking Inverter ...................................................................................... 3 – 53
Regeneration Check ................................................................................. 3 – 54
AC Motor System Basics ..................................................................... 3 – 55
CONTROLLER
Controller System
The inverters are connected to each motor.
System Layout The logic unit is connected to the other devices.
Four independent controllers are linked together by the
Controller Area Network (CAN) to communicate with
each other to control the truck.
The logic unit is the heart of the control system for the
lift trucks.
System layout
Contactors
Switches Logic Unit
Display Logic card

Contactor control signal
Traveling control,
Lifting control,
Key Lift lock solenoid control signal
switch Safety function,
etc.
Power
B2
R
N
F
FC control lever
Direction lever
Motor control Input
command FC lever input unit
Accelerator Sensing
data
FC solenoid
CAN bus command
FC solenoid Lift cylinder,

Right Left Output control signal Tilt cylinder
traction inverter Pump inverter
traction inverter unit
DSP card DSP card DSP card
FC hydraulic
control valve
Sensors Sensors Sensors
assembly
U U U Lift lock
M solenoid valve
V M V V M
W W W
Left traction motor Pump motor Hydraulic

Right traction motor pump
Contactor Battery
Electric power
213090
3-1
CONTROLLER
Controller Area Network (CAN)

Each controller is linked with the truck harness to form a
network as follows.
The terminal resistors are built into the right traction
inverter and the pump inverter.
If the terminal resistors are not properly connected, the
communication failure may occur between the logic unit
and the inverters.
For details, see the “Traction Inverter R.H. Fault (63)”,
“Traction Inverter L.H. Fault (64)” and “Pump Inverter
Fault (65)” in “Troubleshooting for Control Circuits.”
Right Left Logic Pump

traction traction unit inverter
inverter inverter
CAN H
CAN L
211337
The data are expressed as electric potential difference

between high- and low-level signals as follows.
The signals are transferred to each controller through
the serial communication protocol.
Kind of VCAN-L
potential
bit Logic Vdiff Vdiff
dominant 0 VCAN-H
recessive 1 recessive dominant recessive

time
211176
Main specifications
Communication protocol CANbus 2.0B passive Non-Return to Zero method

Broadcast communication protocol
Communication line Dual 2-wire type serial communication
Communication speed 500 kbps
Data length 0 to 8 bytes
3-2
CONTROLLER
Outline of Controller
1. Logic unit
This controller includes the power card and logic card.
It controls all the jobs for the truck based on the
operator’s input.
The controller sends a motor control command to the
right and left traction inverters through the input of the
direction lever or the accelerator pedal. It also monitors
malfunctions of the traction system.
The lever input triggers to send the motor control
commands to the pump inverter. It also monitors
malfunctions in the hydraulic control system.
The truck speed and residual battery power are
monitored and shown on the display unit.
The logic unit sets its model information and optional
default data into internal memory. The information is
secured even if the power supply for the logic unit is
turned off. This information is set at the factory.
The following table shows the model information. The
system will not work properly if the actual controller
system is different from the model information.
Model information
Item Description SUO No.

Truck type Model set #40
Battery voltage 36 V, 48 V #41
Battery type Battery type #42
Hydraulic control selection MC type #43
Mast type Mast type #44
Valve section Number of valves #45
Battery voltage adjust Battery voltage adjustment #46
Foot direction Optional equipment #47
The current information is available to confirm and

modify.
Refer to Setup Option on page 3-13 for details and
setting procedure.
The model information and various features are set by
the Setup Option (SUO).
The power supply card changes the battery voltage and
supplies power to the logic card and the DSP card.
3-3
CONTROLLER
Logic unit
Model
Serial No. XXXXXX
211177
Logic card
CN1
Harness B side CN3 Harness B side CN2 Harness B side CN1

211178
Power supply card
2 1
16A70-00500 Ver4.3
CN1
16 15
X X X X X X
MITSUBISHI HEAVY INDUSTRIES,LTD 2005.Mar.Ver4.3
Power supply card side CN1 Harness B side CN4

211179
The Service Tool connector exists on harness B CN21.

3-4
CONTROLLER
2. Inverter When a malfunction occurs, it stops the motors and

informs to the logic unit.
The inverter is a motor drive controller that consists of
Digital Signal Processor (DSP) card, Insulated Metal The DSP card has the DSP chips that enables high-
Substrate (IMS) module and their drive boards. speed calculation and controls the AC induction
motors.
It drives the AC induction motors according to the
motor control command from the logic unit. It also The IMS module has multiple MOS-FET modules
monitors malfunctions of motors and its own condition. which convert battery DC current into AC current for
the traction and pump motors. See also the “AC Motor
System Basics” section on page 3-55.
Traction inverter (right and left)
DSP card
Serial No.
Model
XXXXXX
211180
Traction inverter
DSP card
(right and left)
XXXXXX
CN2
Harness B side, Traction Right CN7

Inverter card side CN2 Harness B side, Traction Left CN6
211181
3-5
CONTROLLER
Pump inverter
DSP card
Serial No.
Model
XXXXXX
211182
Pump inverter
DSP card
XXXXXX
CN2
Inverter card side CN2 Harness B side, Pump CN5

211183
3-6
CONTROLLER
Controller Features
The following describes the features of controller.
Traction Features
1. Modification of traction characteristics
Acceleration power, maximum output power and There are two types of auto regeneration and selectable.
battery consumption can be set. The following two Accelerator regeneration type: The regeneration starts
parameters can be set. when the accelerator
Acceleration rate: Sets acceleration power. pedal is released during
Traveling power: Selection of the maximum output traction.
power changes the amount of Brake regeneration type: Releasing the accelerator
battery consumption. It also pedal during traction
influences the acceleration power causes dry run. The
during loading operation. regeneration starts when
Regeneration power and type of regeneration can be the brake pedal is
set. There are two types of regeneration and each has pressed.
availability of setting for regeneration power. The lever regeneration starts when the travel direction
Auto regeneration: Normal deceleration that occurs and the direction lever are in opposite directions. The
between the traveling and the amount is determined by the pressure on the accelerator
direction lever when they are in the pedal.
same direction.
Lever regeneration: The deceleration that occurs
between the travel and the direction
lever when they are in the opposite
directions.
Setting feature for traction characteristics

Description SUO No.
Acceleration rate Acceleration of traction #8
Powering Traveling power Max. power, amount of battery #9
consumption
Regen function Selection of auto regeneration #21
Regen adjustment for auto regen Rate of regeneration at normal #23
Regeneration slowdown
Regen adjustment for lever regen Rate of regeneration when operating to #22
the opposite direction
Refer to page 3-13 for details and setting procedure of controlled roll-back function prevents hazardous
the “Setup Option.” descending of the truck.
The application preset feature (#1) has the preset The descending speed changes with the steepness of
setting pattern registered. grade, the weight of load and value setting of the SUO
#23.
2. Controlled roll-back NOTICE: When the regeneration is selected by SUO

#21, the controlled roll-back does not work.
When the accelerator pedal is released on a grade, the
3-7
CONTROLLER
3. Boost
When truck traveling is blocked by a step, the boost Fully depress the accelerator pedal for 2 seconds. The
function prevents stalling of the truck. Usually the boost function increases the motor maximum torque for
motor maximum torque is set by SUO #9, but this 5 seconds. If the pressure to the accelerator pedal is
function allows the truck to bypass a step regardless of reduced or the direction lever is moved, the boost
the value setting of the motor maximum torque. function will be cancelled immediately.
Torque [%]
* Torque required to
climb over a step
* #9
100 HIGH POWER; Full acceleration
85 STANDARD; Full acceleration

70 ECONOMY; Full acceleration
0 Time [sec]
2 7
211324
NOTICE: When the motor overheats, the boost will not work.
If the stall time setting is small, the motor protection function will be applied during prolonged slow
speed traveling.
4. Limitation of maximum travel speed

The speed limitation is classified into two major types Conditional type: The limitation that is triggered from a
and available to set each maximum speed. specific switch input occurrence.
Normal type: The limitation that functions at all Selectable quadruple input signals.
times and is used to keep the speed Available to set a speed limit for each
within the limits. signal.
Feature of maximum speed limit
Description SUO No. Harness Pin No.

Normal Top travel speed limit Always effective #7 –
Auxiliary travel speed limit 1 Effective when aux. input 1 close/open #11, 12 CN2-30
Conditional
Auxiliary maximum travel speed Effective when aux. switch close/open #30, 31 CN2-31
3-8
CONTROLLER
5. Miscellaneous features for traction
Miscellaneous features for traction

Item Description SUO No. Harness Pin No.
Auxiliary power reduction 1 Effective when aux. input 1 close/open #11, 13 CN2-30
Auxiliary output power limit Effective when aux. switch close/open #30, 32 CN2-31
Speed alarm 1 Alarm 1 signal output if speed exceeds set value. #26 CN1-61
Speed alarm 2 Alarm 2 signal output if speed exceeds set value. #34 CN1-62
Tire size adjustment Correction value to compensate for a diameter change #27 –
resulting from tire wear
Stall timer Stops traction motor to protect if truck does not move within #20 –
set time.
Lifting Features
1. Setting and limitation of lift work speed
Each lift work speed can be set. The lift work speed can
be limited or stopped when specific switch input
occurs.
Triple input signals are selectable and available to set
limit value to each signal.
Feature of lifting work speed setting
Description SUO No. Harness Pin No.

Start lift speed Start lift speed setting #2 –
Top lift speed Top lift speed setting #3 –
Lowering lift speed Lowering lift speed setting #35 –
Normal Tilt speed Tilt speed setting #4 –
Auxiliary 1 speed Attachment 1 #5 –
Auxiliary input for lift 1 Stops lift when aux. input 1 close/open #11 CN2-30
Conditional Auxiliary input for lift 2 Stops lift when aux. input 2 close/open #14 CN2-40
Auxiliary input for lift 3 Stops lift when aux. input 3 close/open #17 CN2-41
Refer to page 3-13 for details and setting procedure of

the “Setup Option.”
The application preset feature (#1) has the preset
setting pattern registered.
3-9
CONTROLLER
Outline Features
two additional modes: the mode related to truck failure
1. Diagnostics/Run/Setup (DRS) modes
and the mode for setting the truck parameter as shown
In addition to the normal operation mode for controlling in the table below.
the traveling and lifting operations, the controller has
DRS modes
Mode Description
Self diagnostics Performs failure diagnostics of each equipment.
Diagnostics Displays and deletes fault data that were detected and
Run time diagnostics stored in normal operation mode.
Run – Normal operation mode
Default data set Sets default data of Group 1 & Group 2.
Group 1 data set Sets basic function (#1 to #10).
Setup
Group 2 data set Sets detailed function (#11 to #35).
Group 3 data set Sets model information (#40 to #47)
Refer to page 3-13 for details and setting procedure of
the “Setup Option.” Also, refer to page 3-32 for details
and setting procedure of the “Diagnostics.”
R
DRS switch
DRS switch is installed under floor

plate at right side of truck. 211186
2. PDS (Presence Detection System) features

This controller is part of the “Presence Detection which provides “certain product intelligence” to the
System” (PDS) of the truck. This system features an operator. The table shows processes for traction and
enhanced, integral computer based feed back system lifting. Refer to the Status Transfer Chart for details.
PDS features
Protect condition Result Release method

Seat Sit → Leave Slowdown Sit
Traction control and Direction lever: N
Direction lever F or R Stop Accelerator pedal: Release
Sit
Hydraulic control Seat Sit → Leave Stop
Control valve SW: All open
3-10
CONTROLLER
Status transfer chart
Traction Control PDS Seat SW

Seat Sw flag: ON Seat SW off time Delay time
2 sec or 3 sec
Normal operation
Seat SW flag: OFF Seat Sw flag :
Seat SW: ON OFF
Direction lever: N (Chosen foot direction: no effect)
Seat SW flag: OFF

Motor: Regen brake Travel speed 0.5km/h
Display: Blinking "E"
Motor: Zero torque

Seat SW flag: OFF Seat SW flag: ON Display: Blinking "E"
Line Contactor OFF
Motor: Regen brake Seat SW flag: OFF Seat SW flag: ON

Display: "E"
Motor: Zero torque

Display: "E"
Direction lever: N
Travel speed 0.5km/h Line Contactor OFF
Accelerator pedal: OFF
Direction lever: N
Accelerator pedal: OFF
Hydraulic Control PDS Seat SW

Seat Sw flag: ON Seat SW off time Delay time
2 sec or 3 sec
Seat Sw flag :
Seat SW: ON OFF
Normal operation
Seat SW flag: OFF
Lift lock valve: LOCK

Unload valve: UNLOAD
Display: Blinking "L"
Seat SW flag: ON
Seat SW flag: OFF
Lift lock valve: LOCK

Unload valve: UNLOAD
Display: "H1 to H5"
Control valve SW: All off

(LIFT lever doesn't have SW to detect DOWN.) 211338
3-11
CONTROLLER
3. BDI display features

This feature shows with 11 levels (BDI 0 to BDI 10) of
remaining battery capacity of the current battery
voltage.
Set #41 or #42 depends on installed battery type and

voltage.
For further details, see OMM.
4. Warning buzzer features

• Parking brake warning
The buzzer sounds when the key switch is turned off
or the operator leaves the operator’s seat with the
parking brake not applied.
• Seat belt warning
The buzzer sounds when the seat belt is not fastened
with the operator on the operator’s seat.
5. Miscellaneous features
The table shows miscellaneous features.
Miscellaneous features
Item Description SUO No.

Service indicator Shows or warns maintenance time. #10
Speed, error code, hour-meter, BDI, etc. are shown depending on DRS
mode.
Display unit Diag. mode: Refer to Operation on page 3-32. –
Run mode: Normal operation mode.
Setup mode:Refer to Operation on page 3-13.
3-12
CONTROLLER
Setup Option off.

The model information and various features are set
Outline before factory shipment.
The logic unit is equipped with a memory module that The setup options are categorized from Group 1 to
retains recorded data even if the main power is turned Group 3 according to the feature levels.
Setup group
Group Description
Group 1 Basic function (#1 to #10)
Group 2 Detailed function (#11 to #35)
Group 3 Model information (#40 to #47)
The Group 1 and 2 are available to set the default value each setup mode.
in a one-step operation and can be customized in Summary list in each group is shown on page 3-28 to 3-
accordance with applications. Since the Group 3 is for 31.
model information, it is required to be set to the same
value as actual control system. It will not work properly
if the model information is different. Operation Procedure
When setting the setup option data for the first time Turning on the key switch allows you to enter one of
after the assembly is completed or the logic card is the modes in each setup group and shows as the figure.
replaced, be sure to set Group 3 data first, then the You can not transfer to another mode unless the source
default data of Group 1 and 2, with the “service tool” in power is turned off.
Entry to setup mode
DRS Direction Accel. Lift Tilt Attachment 1

Function Description Seat
switch lever pedal lever lever lever
Default data Sets default data of Not
S R ON OFF OFF OFF
set Group 1 & Group 2. seated
Checks and sets basic Not
Group 1 data S N OFF OFF OFF OFF
function (#1 to #10). seated
Checks and sets detailed Not Pull Pull
Group 2 data S N OFF OFF
function (#11 to #35). seated back back
Checks and sets model Not Pull
Group 3 data S N OFF OFF OFF
information (#40 to #47). seated back
First SUO # of each group

“01” for group 1
Current set value for SUO #11*

donE flashes for default data set. 209558 *The current value is displayed. For the meaning of
each number or symbol displayed, refer to the
First SUO # of Group 2 setup options “Range” column of the relevant Setup Options
(example) table and Notes below the table.
3-13
CONTROLLER
Selecting SUO # and changing set value

How to change set value
The set value change procedure consists of selecting the When changing setting of SUO #20 (stall timer) from
desired SUO # using the DRS switch, changing the set default 5 seconds to 3 seconds:
value by moving the direction lever, and registering the new
value. Step 1. Since SUO #20 belongs to Group 2 setup
options, the first SUO # “11” of the group
appears on the screen when using the operation
• Cycle the DRS switch S → R → S. The set value procedure on page 3-13.
displayed on the screen is registered. The SUO # on the
screen then advances to the next SUO #. Changing the
set value is now possible for the SUO #.
The first half of the DRS switch operation (S→R) is for Step 2. Move the DRS switch as follows to change the
overwriting the previous value with the value on the current setting for the SUO #20.
screen (registering). When the value is registered, a set
S
R (1) Move the DRS switch S →R.
of three dotted lines appears on the screen as shown in The display changes as shown
Pull
the illustration on the right. The second half of the below. The set value (0) for
operation (R→S) is for advancing the SUO #. the SUO #11 is overwritten
simultaneously.
• Every time the DRS switch is cycled S→R→S, the SUO
# increments. When advancing the SUO # without
changing the set value, simply repeat by cycling the
switch as many times as necessary. When the last SUO
# is reached, “donE” appears in the set value display
area. R (2) Move the DRS switch R →S.
S
Pull The display shows the current
• Use the direction lever to change the set value. The
setting for the next SUO #12.
value increases when the lever is cycled N →F→N; it
decreases when the lever is cycled N→R→N. In either
case, by increasing or decreasing direction, the value
returns to the first or last value in the available value
range.
(3) Cycle the DRS switch S→R→S 8 times to cause the
SUO #20 to appear on the screen.
Default value 5 for SUO #20
Step 3. Change the set value from 5 to 3 by moving the

direction lever N→R twice.
Value increases.
Direction
lever F
N
R
Value decreases.
Step 4. Register the new value by cycling the DRS
switch S → R → S. The current value is
overwritten with the new value. The screen
shows the next SUO #21. 213091
3-14
CONTROLLER
Details of Setup Options

1. Setup Options (Group-1)
#1 Application Pre-Sets (Truck Operation Mode)

Truck mode can be selected from A to E, each with
preset values for maximum vehicle speed, acceleration
rate, power, automatic regeneration power, start lift
speed, top lift speed and tilt speed.
These 7 settings are automatically set by changing the
value of this setting.
Preset values for each setting are as follows (#40 EE
type : C only) .
• 48V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium High
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 6 10 3 6 6 3
Tilt Speed 5 7 5 7 7 4
Max Vehicle Speed 15 17 12 17 15 7
Default value
Acceleration Rate 3 5 2 3 5 8
Traveling Power 2 3 1 3 2 9
Automatic
5 9 3 7 9 23
Regeneration
You can modify these 7 settings afterwards

individually. When settings are changed, the indication
(A to E) flashes to indicate that the settings are
modified.
3-15
CONTROLLER
• 36V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Medium
Characteristic
Acceleration Medium Medium Medium Medium Medium
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium High
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 6 10 3 6 6 3
Tilt Speed 5 7 5 7 7 4
Max Vehicle Speed 15 17 12 17 13 7
Default value
Acceleration Rate 3 3 2 3 3 8
Traveling Power 2 3 1 3 2 9
Automatic
5 9 3 7 9 23
Regeneration
#2 Start Lift Speed

This setting affects pump speed when you start lifting
operation.
MC spec: speed when lift switch 1 is turned on
Lift speed in the rise direction will become faster if the
setting value is increased.
The setting range is 1 to 10 (#40 EE type : 1 to 8).
3-16
CONTROLLER
#3 Top Lift Speed

Pump motor
This setting affects pump speed and FC solenoid output [%]
current when you pull the lift lever. If you set a smaller
SUO #3
value than #2, then the #2 setting will be ignored.
100
FC spec: speed when the lift lever is pulled 10
9
MC spec: speed when lift switch 2 is turned on 8
Lifting speed will become faster if the value setting is SUO #2
increased.
0
SW1 SW2 Lever operation
Close Close
209553
Pump motor output characteristics

(Lift-up operation)
#4 Tilt Speed
Pump motor
This setting affects pump speed and FC solenoid output [%]
current when you operate the tilt lever or tilt switch.
SUO #5, #6, #33
Tilt speed will be faster if the value setting is increased.
100 10
Tilt speed has priority over lifting speed, when the two
levers are operated simultaneously.
2
1
0 SW Close Lever operation

209554
Pump motor output characteristics

(Tilt and attachment 1, 2 and
3 operations)
3-17
CONTROLLER
#5 Auxiliary 1 Speed
This setting affects pump speed and FC solenoid
current when you operate the attachment 1 lever or
attachment 1 switch.
Attachment 1 speed will become faster if the value
setting is increased. The setting range is 1 to 10.
This setting affects pump speed and FC solenoid
current when you operate the attachment 2 lever or
attachment 2 switch.
Characteristic is almost the same as auxiliary 1.
Attachment 2 speed will become faster if the value
setting is increased. The setting range is 1 to 10.
#7 Top Travel Speed Limit

This setting affects maximum truck speed without load.
Truck speed with load will be less than this setting.
This setting affects top speed, and does not affect
gradability or acceleration.
The setting range is 5 to 17 [km/h] (#40 EE type : 5 to
13)
#8 Acceleration Rate
This setting affects response time to calculate torque
order from accelerator pedal position.
Acceleration of trucks becomes faster if the value
setting is increased. The setting range is 1 to 5 (#40 EE
type : 1 to 3)
3-18
CONTROLLER
#9 Traveling Power
This setting affects torque order which is calculated The figure is a torque characteristic at the time of
from accelerator pedal position. Powering.
The values are selected from three types : ECONOMY,
STANDARD and HIGH POWER (#40 EE type :
ECONOMY only).
Torque
[%] HIGH POWER(3)
100 STANDARD(2)
85
ECONOMY(1)
70
Brake limit*1 (48V: 40%, 36V: 52%)
Thermal, BDI [0] or Service indicator*2
(48V: 32%, 36V: 42%)
Speed
0 5 13 15 17
(km/h)
211190
*1
Brake limit : Torque value resulting from reduction in *2
Thermal, BDI [0] or Service indicator :
current when the service brake or Curve of limited torque under a condition of
parking brake is applied. overheating or battery voltage low or
maintenance time over.
#10 Service Indicator
This setting sets the maintenance time. The time set You can reduce the truck power when the LED flashes
here is added to the truck’s hour meter and that value is by setting the service indicator selection. You can also
stored in memory as the “maintenance time.” set the demo-mode, which shows the Service Indicator
When the truck’s hour meter reaches maintenance time, function in a short period of time.
the service reminder LED turns on. The setting value is as follows.
It will flash 20 hours before the time.
– 6 min (test) 100 150 In increments 950 1000

Maintenance time [hour]
of 50
Invalid 0
Set data on display Only warning 0.1 100 150 ····· 950 1000
Torque limit =0.1 =100 =150 ····· =950 =1000
The present hour meter time will be registered if the

DRS switch is operated after the display of #10.
3-19
CONTROLLER
#11 Auxiliary Input for Lift and Drive Speed 1

(Harness pin No. CN2-30)
This setting defines the function of “Auxiliary 1”
switch. This value has an effect on #12 and #13 when 2,
3, 5 or 6 is selected.
The setting value is as follows.
Value Lift Travel

0 – –
1 Stop lift *1 (switch closed) –
2 – Speed limit (switch closed)
3 – Power reduction (switch closed)
4 Stop lift (switch opened) –
5 – Speed limit (switch opened)
6 – Power reduction (switch closed)
*1
Lever is returned to neutral. Lift moves with
operating lever again.
#12 Auxiliary Travel Speed Limit 1 (Harness pin No. #16 Auxiliary Power Reduction 2 (Harness pin No.
CN2-30) CN2-40)
This setting defines maximum speed when the This setting defines traction power reduction when the
“Auxiliary 1” switch is closed or opened. “Auxiliary 2” switch is closed or opened.
The setting range is 5 to 17 [km/h]. Effective when the The setting range is 0 to 100 [%]. Effective when the
data of #11 is 2 or 5. data of #14 is 3 or 6.
#13 Auxiliary Power Reduction 1 (Harness pin No.

CN2-30)
This setting defines traction power reduction when the
“Auxiliary 1” switch is closed or opened.
The setting range is 0 to 100 [%]. Effective when the
data of #11 is 3 or 6.

The setting value is the same as that of #11.
#15 Auxiliary Travel Speed Limit 2 (Harness pin No.

CN2-40)
This setting defines maximum speed when the
The setting range is 5 to 17 [km/h]. Effective when the
3-20
CONTROLLER

The setting value is the same as that of #11.
#18 Auxiliary Travel Speed Limit 3 (Harness pin No.

CN2-41)
This setting defines maximum speed when the
The setting range is 5 to 17 [km/h]. Effective when the
#19 Auxiliary Power Reduction 3 (Harness pin No.

CN2-41)
This setting defines traction power reduction when the
The setting range is 0 to 100 [%]. Effective when the
#20 Stall Timer

This setting shuts down the truck when the traction
motor torque is high and it continues for preset time.
This function is used to detect pulse sensor faults and to
prevent the controller from overheating.
The setting range is 2 to 10 [second].
#21 Regen Function

This setting defines which regeneration function is
activated.
One is “Brake regen.” “Brake regen” will be applied
while “the brake pedal is pressed” and “the accelerator
pedal is released.”
The other is “Accelerator regen.” “Accelerator regen”
will be applied while “the accelerator pedal is
released.”
In any case, deceleration torque is constant and defined
by #23.
These two regeneration functions are collectively
termed “Auto regen.”
3-21
CONTROLLER
#22 Regen Adjustment for Lever Regen

This setting defines the “Lever regen” characteristic.
When the direction lever is shifted into the position
opposite to the truck’s traveling direction, the “Lever
regen” function is activated. The “Lever regen”
characteristic is shown in this diagram. The setting
range is 1 to 10.
(%)
100 10
Amount of lever Value of #22

regeneration
60 1
100
Level of throttle pedal [%]
213092
Amount of deceleration relative to setting “1” is about

60% of maximum (Setting “10”).
“Lever regen” function is available regardless of the
#21 setting.
Amount of deceleration when the accelerator pedal is
released is determined by #23.
3-22
CONTROLLER
#23 Regen Adjustment for Auto Regen Amount of auto regeneration

[%]
This setting defines amount of deceleration when 100 Accelerator regen
“Auto regen” is activated. Amount of deceleration
relative to setting “1” is about 40% of maximum
(Setting “10”). The setting range is 1 to 10 (#40 EE
type : 1 to 7).
0
1 2 3 4 5 6 7 8 9 10
Value of #23 211400
Brake regen Truck

speed [m/s] Accelerator regen
#23
10 9 1
Truck
0 Time [s]
speed [km/h]
211192 213093
#26 Speed Alarm 1 (Harness Pin No. CN1-61)

This setting defines speed of turning on “Speed alarm
1” light.
The setting range is 5 to 17 [km/h].
#27 Tire Size Adjustment

This setting is used to adjust the truck speed indicator.
1 digit equals 1 mm (0.04 in.) of wear in the diameter.
Default setting is 20.
When the tire diameter becomes 8 mm (0.31 in.)
smaller than original, set 12 into this setting.
The range setting is 0 to 40. This allows fitting a bigger
diameter wheel.
3-23
CONTROLLER
#30 Auxiliary Input for Travel Speed (Harness Pin

No. CN2-31)
This setting defines the function of “Speed Limit”
switch.
According to the combination of #30, #31 and #32, you
can reduce travel speed or traction power (torque).
Value Traction power Travel speed

0 – –
1 – Speed limit (switch closed)
2 Power reduction (switch closed) –
3 – Speed limit (switch opened)
4 Power reduction (switch opened) –
#31 Auxiliary Maximum Travel Speed Setting

(Harness Pin No. CN2-31)
This setting defines the maximum travel speed when the
speed limit function is activated by #30. The range
setting is 5 to 17 [km/h].
#32 Auxiliary Output Power Limit (Harness Pin No.

CN2-31)
This setting defines the maximum traction power
(torque) when speed limit function is activated by #30.
This value means a proportion of output torque to
normal condition.
The setting range is 0 to 100 [%].

This setting affects pump speed when you operate the
attachment 3 lever.
MC spec: Speed when attachment 3 switch is turned on
Characteristic is almost the same as tilt.
Attachment 3 speed will become faster if the setting
value is increased. The range setting is 1 to 10.
#34 Speed Alarm 2 (Harness Pin No. CN1-62)

This setting defines speed of turning on “Speed alarm
2” light. The setting range is 5 to 17 [km/h].
3-24
CONTROLLER
#40 Truck Type

This setting defines the type of truck.
The setting value is as follows.
Display value Model

II II II II II No setting
P16:3 ET3000
P16:3.E ET3000EE
P18:3 ET3500
P18:3.E ET3500EE
P20:3 ET4000
P20:3.E ET4000EE
P16 EP16N
P18 EP18N
P20:C EP20CN
! CAUTION
If the truck type setting is incorrect, the truck may
show unexpected movement.
#41 Battery Voltage

This setting defines the voltage of battery carried in the truck.
The setting value is 36 or 48 [v].
No setting shows “II II II II II.”
3-25
CONTROLLER
#42 Battery Type

This setting defines the type of battery carried in the
truck.
The setting value is 0, 1 or 2.
0: Normal 1: Tubular 2: Reserve
This value selects Battery Discharge Indicator (BDI)
table. The table is as follows.
Normal BDI Tubular BDI
BDI# 36V 48V BDI# 36V 48V

0 – 34.4 – 45.9 0 – 35.2 – 46.9
1 34.5 – 34.8 46.0 – 46.4 1 35.3 – 35.5 47.0 – 47.3
2 34.9 – 35.2 46.5 – 46.9 2 35.6 – 35.8 47.4 – 47.7
3 35.3 – 35.6 47.0 – 47.4 3 35.9 – 36.1 47.8 – 48.1
4 35.7 – 36.0 47.5 – 47.9 4 36.2 – 36.4 48.2 – 48.5
5 36.1 – 36.4 48.0 – 48.4 5 36.5 – 36.7 48.6 – 48.9
6 36.5 – 36.7 48.5 – 48.9 6 36.8 – 37.0 49.0 – 49.2
7 36.8 – 37.0 49.0 – 49.8 7 37.1 – 37.2 49.3 – 49.5
8 37.1 – 37.3 49.4 – 49.7 8 37.3 – 37.4 49.6 – 49.8
9 37.4 – 37.6 49.8 – 50.1 9 37.5 – 37.6 49.9 – 50.1
10 37.7 – 50.2 – 10 37.7 – 50.2 –
Reserve BDI
BDI# 36V 48V

0 – –
1 – –
2 – –
3 – –
4 – –
5 – –
6 – –
7 – –
8 – –
9 – –
10 – –
3-26
CONTROLLER
#43 Hydraulic Control Selection #46 Battery Voltage Adjust

This setting defines the type of hydraulic control. This setting corrects the gap of the battery voltage
1: MC system which the controller recognizes, and actual battery
voltage. The display shows battery voltage which the
#44 Mast Type controller recognizes.
This setting defines the type of the mast. Measure actual battery voltage using a tester (or a
2-FF: 2-stage full-free 3-FF: 3-stage full-free multi-meter) and operate the direction lever to adjust
the value.
2-SP: 2-stage panorama
Refer to the “Measurement of battery voltage” below.
#45 Valve Section
This setting defines the number of valve sections.
1: 3ways (lift, tilt, attachment 1)
2: 4ways (lift, tilt, attachment 1, 2)
3: 5ways (lift, tilt, attachment 1 to 3)
Direction lever Accelerator pedal Value change [V]

N→F – +0.1
N→R – –0.1
F Release → depress +10
R Release → depress –10
Line contactor
Pump contactor
Contactor
- +
Battery
49.6V
V
- + Set 49.6 on display.
Tester or Multi-meter
Right traction
inverter
211327
Measurement of battery voltage

#47 Foot Direction
This setting defines the foot direction option.
1: Standard direction lever
2: Foot Directional Control (FoDiCo)
3-27
CONTROLLER
Setup Options (Group 1)
Option Default
Title of Option Description Range
# Value
The value setting of the following 7 items
are registered beforehand.
Application Pre-Sets Top travel speed, Acceleration rate,
#1 A, b, C, d, E A
(Truck Operation Mode) Traveling power, Regen adjustment, Start
(1)
lift speed, Top lift speed, Tilt speed.
Refer to the explanation for details.
Beginning lift speed
Start lift speed cannot exceed top lift
#2 Start Lift Speed 1 to 10 1
speed.
(1: SLOW → 10: FAST)
Lift speed when operating the lever at
#3 Top Lift Speed 1 to 10 6
maximum
#4 Tilt Speed Speed setting for tilt 1 to 10 5
#5 Auxiliary 1 Speed Speed setting for attachment 1 1 to 10 3
#6 Auxiliary 2 Speed Speed setting for attachment 2 1 to 10 1
#7 Top Travel Speed Limit Maximum travel speed 5 to 17 [km/h] 15
Choice of acceleration rate
#8 Acceleration Rate 1 to 5 3
(1: SLOW → 5: FAST)
Choice of power characteristic
#9 Traveling Power (1: ECONOMY, 2: STANDARD, 3: HIGH 1, 2, 3 2
POWER)
This function notifies service personnel 0, 0.1,
that maintenance time is approaching or 100, 150, ...950, 1000,
has passed. =0.1 (6 min.),
It means the lapsed time when setting up. =100, =150, ..=950, =1000
#10 Service Indicator Approached: !LED flashes (20 hour) (In increments of 50 [hour]) 0
Passed :!LED turn on
and power reduction (selected) “=”: power reduction
(2) 0: no action
NOTICE: (1) Before changing, when parameter data are different from the values of the selected mode, the truck
mode indicator (A to E) flashes.
When the truck mode is changed, all parameter data is replaced by the set values of the selected
mode.
(2) The data from the truck hour meter at set time is saved apart from the selected value. If the key switch
is turned off without setting the DRS switch to R, the data at set time is maintained.
When the DRS switch is set to R, the data at set time is replaced by the current truck hour meter data.
3-28
CONTROLLER
Option Default Harness

# Value Pin No.
When the auxiliary input 1 signal is on, 0: Disable
travel speed or lift speed is limited to 1: Disable lift (switch closed)
set value. 2: Speed limit (switch closed)
Auxiliary Input for The amount of maximum speed is 3: Power reduction
#11 Lift and Drive defined at #12. (switch closed) 0 CN2-30
Speed 1 The amount of power reduction is 4: Disable lift (switch opened)
defined at #13. 5: Speed limit (switch opened)
6: Power reduction
(switch opened)
Auxiliary Travel
#12 Travel speed limit for #11 5 to 17 [km/h] 12 CN2-30
Speed Limit 1
Auxiliary Power
#13 Traction power reduction ratio for #11 0 to 100 [%] 70 CN2-30
Reduction 1
When the auxiliary input 2 signal is on,
travel speed or lift speed is limited to
Auxiliary Input for set value.
#14 Lift and Drive The amount of maximum speed is Same as #11 0 CN2-40
Speed 2 defined at #15.
The amount of power reduction is
defined at #16.
Auxiliary Travel
Speed Limit 2
Auxiliary Power
#16 Traction power reduction ratio for #14 0 to 100 [%] 70 CN2-40
Reduction 2
When the auxiliary input 3 signal is on,
travel speed or lift speed is limited to
Auxiliary Input for set value.
#17 Lift and Drive The amount of maximum speed is Same as #11 0 CN2-41
Speed 3 defined at #18.
The amount of power reduction is
defined at #19.
Auxiliary Travel
Speed Limit 3
Auxiliary Power
#19 Power reduction ratio for #17 0 to 100 [%] 70 CN2-41
Reduction 3
This option allows to shut down truck
#20 Stall Timer when the traction motor torque is too 2 to 10 [sec] 5 –
high.
3-29
CONTROLLER
Option Default Harness

# Value Pin No.
1: Brake regen
This option enables one of two Regen (accel must be off)
#21 Regen Function 2 –
Modes. 2: Accelerator regen
(also called “auto regen”)
Regen Adjustment
#22 10 steps for regen power on lever regen 1 to 10 7 –
for Lever Regen
Regen Adjustment 10 steps for regen power on
#23 1 to 10 5 –
for Auto Regen brake/accelerator regen
CN1-61,
#26 Speed Alarm 1 Sets speed for turning on alarm 1 light. 5 to 17 [km/h] 12
max.1A
Tire Size Adjusts the amount of tire wear. It

#27 0 to 40 20 –
Adjustment changes truck’s speed recognition.
0: Disabled
When the auxiliary input signal is on, 1: Travel speed limit
travel speed or traction power is limited (switch closed)
at value of set. 2: Power reduction
Auxiliary Input for
#30 The amount of maximum speed is (switch closed) 0 CN2-31
Travel Speed
defined at #31. 3: Travel speed limit
The amount of power reduction is (switch opened)
defined at #32. 4: Power reduction
(switch opened)
Auxiliary
This option detemines the maximum
#31 Maximum Travel 5 to 17 [km/h] 12 CN2-31
travel speed limit of #30.
Speed Setting
Auxiliary Output This option detemines the output

#32 0 to 100 [%] 70 CN2-31
Power Limit traction power limit in % of #30.
#33 Auxiliary 3 Speed Speed setting for attachment 3 1 to 10 3 –
CN1-62,
#34 Speed Alarm 2 Sets speed for turning on alarm 2 light. 5 to 17 [km/h] 12
max.1A
3-30
CONTROLLER
Option Default
# Value
This option is used to set the size and type
P16:3 (ET3000) to
#40 Truck Type of the truck. –
P20:C (EP20CN) 9 pattern
This option is used to set the voltage of
#41 Battery Voltage 36, 48 [V] –
the battery.
This option is used to set the type of the
0: Normal BDI
battery.
#42 Battery Type 1: Tubular BDI –
The electric discharge characteristic of a
2: Reserve BDI
battery changes with battery type.
Hydraulic Control This option is used to set the type of the
#43 1: MC specification –
Selection hydraulic control.
2FF: 2-stage full-free
This option is used to set the type of the
#44 Mast Type 3FF: 3-stage full-free –
mast.
2SP: 2-stage panorama
1: 3ways
(lift, tilt, attachment 1)
This option is used to set the number of 2: 4ways
#45 Valve Section –
valve sections. (lift, tilt, attachment 1,2)
3: 5ways
(lift, tilt, attachment 1-3)
This setting corrects the gap of the battery
voltage which the controller recognizes,
and actual battery voltage.
Measure actual battery voltage and
operate the direction lever in order to
#46 Battery Voltage Adjust 5.0 to 120.0 [V] –
adjust the value which is shown on the
display to actual battery voltage.
N→F: +0.1 F, Accel off→on: +10
N→R:–0.1 R, Accel off→on: –10
Refer to the explanation for operation. (4)
1: Standard direction lever
This option is used to enable the function
#47 Foot Direction 2: Foot Directional Control –
for foot direction option.
(FoDiCo)
NOTICE: (1) The data of a group 3 has no default value, but it needs to set data by the actual truck type. If the
value and the truck model aren’t in agreement, the truck does not operate normally.
(2) When you set up for the first time, set up a group 3 first, and then set default data of group 1 and 2.
(3) If SUO data is not set, “| |” is displayed.
(4) This value was adjusted at the time of LOGIC CARD inspection. Adjust the value, when the value
shown on the display is different from actual battery voltage.
3-31
CONTROLLER
Diagnostics
Outline
The controller monitors status of various input/output
equipment to allow diagnostics of truck’s malfunction.
There are two types of diagnostics: Run Time
Diagnostics, diagnostics during normal operation, and
Self Diagnostics, performing equipment check during
maintenance.
Diagnostics
Mode Description
Self diagnostics Checks function of electrical systems.
Diagnostics
Run time diagnostics Diagnostics during normal operation.
The logic unit is equipped with a memory module that

retains recorded data even if the main power is turned
off. The errors occurring during truck use are
compared with the Run Time Diagnostics and recorded
so as to be able to show.
Self diagnostics that exclusively checks the power
steering system is also available.
Operation Procedure
Turning on the key switch allows to enter each
diagnostics mode. You can not transfer to another
mode unless the source power is turned off.
Entry to diagnostics mode
DRS
Function Seat Lift lever Tilt lever Note
switch
When run time diagnostics can
Self diagnostics D – – –
not be performed
Run time diagnostics D Not seated ON ON
3-32
CONTROLLER
Perform diagnostics using the following procedure.
1. Preparatory operations
(1) Place the parking brake lever in the locked position.
(2) Turn OFF the key switch.
(4) Discharge all inverters. See page 3-40.
(5) Place the direction lever in the N position.
(6) Set the DRS switch to the D (diagnostics) position.
R
(7) Remove the line fuse and pump fuse (500 A).
S D
(8) Connect the battery plug.
Pull
2. Diagnostics procedure
Perform the procedure using the Self-Diagnostics table
in accordance with the following guide.
(1) Start diagnostics with the Step 0 in the table. Turn 211195
ON the key switch according to the instruction in
the “Do this” box on the Step 0 line. If the item
passes the check without any problem, the next step
number “01” appears on the display. If the item Diagnostics result indication
involves any problem and fails in the check,“dd” is
shown on the display. The display also shows “dd”
when diagnostics is started without removing the
fuse. In this case, diagnostics is prohibited from
going even to the first step.
(2) When the Step 0 has passed the check, diagnostics
may advance to the Step 1 item (seat switch). 209561
Cycle the seat switch OFF→ON→OFF according
to the instruction in the “Do this” box on the Step
1 line. If the item passes the check, the next step
number “02” appears on the display. Do likewise
for the succeeding items, following the instructions
in the “Do this” column boxes. If the step fails in
the check, diagnostics does not advance
automatically. In this case, diagnostics can be
forcibly advanced to the next step by cycling the
DRS switch D→R→D.
3-33
CONTROLLER
(3) When all the steps have been checked through, turn
OFF the key switch and place the DRS switch in the R R
position. Do not forget to reinstall the 500 A line fuse S D
and pump fuse.
Pull
• Turn OFF the key switch to exit from the diagnostics
mode.
• Repair all faults found immediately after diagnostics.
Diagnostics procedure requires moving the DRS switch to 211196
the D or R position. Follow the instructions in the
diagnostics procedure guide above as well as those in the
applicable boxes in the “Do this” column.
3. Fault Data Record of Run Time Diagnostics

When the fault is detected by the Run Time Diagnostics,
Battery discharge indicator
the fault data will be stored in the memory of the logic at the time of fault
card. The fault data includes the error code, the battery
discharge indicator at the time of fault and the vehicle
hourmeter reading at the time of fault. The stored data is
maintained even if the key switch is turned off.
E F
The maximum number of faults that can be stored in the
memory is 32. When faults exceeding 32 occur, the oldest
data will be erased to accommodate new data.
The data on the latest fault will appear on the display unit.
After all the fault data are reviewed or when there are no Vehicle hourmeter reading Error code
data items stored for the fault, “donE” will appear. at the time of fault
211412
Perform the following procedures to review the stored fault
data.
• To review the data of the next older fault
Move the DRS switch from the D position to the R
position and then back to the D position.
• To review the data of the latest fault again E F
With “donE” appeared on the display after all the fault
data are reviewed, move the DRS switch from the D
position to the R position and then back to the D
position.
• To delete all the stored fault data After all the fault data are reviewed or when
With “donE” appeared on the display after all the fault there are no data items stored for the fault,
"donE" will appear.
data are reviewed, move the DRS switch from the D When all the stored data have been deleted,
position to the R position and then to the S position. "donE" flashes.
When all the stored data have been deleted, “donE” 211413
flashes. Never turn off the key switch until “donE”
flashes.
NOTICE: If the key switch is turned off before data
deletion is completed, erroneous data will be
displayed when reviewing the fault data. In this
case, be sure to delete all the stored fault data
by using the proper procedure again.
3-34
CONTROLLER
Self-Diagnostics
Step Checking Do this Controller check this Result Display Motion
Line contactor
Power line Pass 01
Close line contactor and closes and opens.
0 voltage Turn on key switch.
check power line voltage. Line contactor closes
(Fuse check) Fail dd
and doesn’t open.
Release & press & release Input Pass 02
1 Seat switch
seat SW. OFF → ON → OFF Fail 01
Direction Cycle direction lever. Input changes as Pass 03
2
switch N→R→N→F→N N→R→N→F→N Fail 02
Release & apply & release Input Pass 04
3 Parking brake
parking brake. OFF → ON → OFF Fail 03
Depress and release Input Pass 05
4 Service brake
service brake. OFF → ON → OFF Fail 04
Number 0 to 15 flashes as
Depress accelerator and Pass
accelerator is pressed.
5 Accelerator release.
Fail -
DIAG → RUN - 06
Number r7-r1, 0, L1-L7 flashes
Present steering wheel SW Pass
as steering is rotated.
6 Steering sensor information is shown.
Fail -
RUN → DIAG → RUN - 07
Check battery voltage: Pass 08
7 Battery voltage Automatic
(34V-51V) Fail 07
Input Pass 09
8 Lift switch Pull and release lift lever.
OFF → ON → OFF Fail 08
Input Pass 10
9 Tilt switch Pull and release tilt lever.
OFF → ON → OFF Fail 09
Auxiliary 1 Pull and release Aux. 1 Input Pass 11
10
switch lever. OFF → ON → OFF Fail 10
11
12
Pull any lever and see Pass Flashing pump speed value
Hydraulic
13 display. Fail Other than above
speed check
RUN → DIAG → RUN - 14
Pass 14 Contactor closes
RUN → DIAG See line contactor close.
Fail 14 No operation
14 Line contactor
Pass 15 Contactor opens
DIAG → RUN See line contactor open.
Fail 15 No operation
See pump contactor Pass 15 Contactor closes
RUN → DIAG
Pump close. Fail 15 No operation
15
contactor See pump contactor Pass 98 Contactor opens
DIAG → RUN
open. Fail 98 No operation
Controller
See software version No.
98 software RUN → DIAG → RUN - donE
in hourmeter.
version
3-35
CONTROLLER
Power Steering Diagnostics

Perform power steering diagnostics using the following
procedure.
1. Preparatory operations
(1) Place the parking brake lever in the locked position.
(2) Turn OFF the key switch.
(4) Discharge all inverters. See page 3-40.
(5) Place the direction lever in the N position.
(6) Set the DRS switch to the D (diagnostics) position.
R
(7) Remove the pump fuse (500 A).
S D
(8) Connect the battery plug.
Pull
2. Diagnostics procedure
Perform the procedure using the Self-Diagnostics
(Power steering system) table in accordance with the
following guide.
211195
(1) Start diagnostics with the Step 0 in the table. Turn
ON the key switch according to the instruction in
the “Do this” box on the Step 0 line. If the item
passes the check without any problem, the next step
Diagnostics result indication
number “20” appears on the display. If the item
involves any problem and fails in the check, “dd” is
shown on the display. The display also shows “dd”
when diagnostics is started without removing the
fuse. In this case, diagnostics is prohibited from
going even to the first step.
(2) When the Step 0 has passed the check, diagnostics 213094
may advance to the Step 20 item (steering sensor).
Check the steering sensor according to the
instruction in the “Do this” box on the Step 20 line.
(3) When all the steps have been checked through, turn
OFF the key switch and place the DRS switch in R
the R position. Do not forget to reinstall the pump S D
fuse.
Pull
• Turn OFF the key switch to exit from the
diagnostics mode.
• Repair all faults found immediately after
diagnostics.
Diagnostics procedure requires moving the DRS 211196
switch to the D or R position. Follow the instructions
in the diagnostics procedure guide above as well as
those in the applicable boxes in the “Do this”
column.
3-36
CONTROLLER
Self-Diagnostics (Power steering system)
Step Checking Do this Controller check this Result Display Motion

Line contactor
Power line Close line contactor and Pass 20
closes and opens.
0 voltage Turn on key switch.
check power line voltage. Line contactor closes
(Fuse check) Fail dd
and doesn’t open.
Number r7-rl, 0, L1-L7
Present steering wheel SW Pass
flashes as steering is rotated.
20 Steering sensor information is shown.
Fail -
RUN → DIAG → RUN -
3-37
CONTROLLER
Run Time Diagnostics

Display
Steering operation
LED
Service Indicator
To return
Parking Brake
Battery Low
Fault How to detect Result
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Cool
Traction Motor R.H., Overheating Thermistor (145°C, -25°C) * E0 Power reduction
Cool
Traction Motor L.H., Overheating Thermistor (145°C, -25°C) * E1 Power reduction
Cool
Pump Motor, Overheating Thermistor (135°C, -25°C) * E2 Power reduction
Thermistor Cool
Traction Inverter R.H., Overheating (IMS 100°C, -25°C, Capacitor 110°C, -25°C) * E5 Power reduction
Thermistor Cool
Traction Inverter L.H., Overheating (IMS 100°C, -25°C, Capacitor 110°C, -25°C) * E6 Power reduction
Thermistor Cool
Pump Inverter, Overheating (IMS 100°C, -25°C, Capacitor 110°C, -25°C) * E7 Power reduction
Turn key off
Brake Oil, Low Level Level sensor (Contact) *
Traction Motor Current Sensor R.H. Line contactor off(*) Turn key off
Fault Out of normal range * 14 Pump contactor hold
Line contactor off Turn key off
Traction Motor R.H., Over-current More than 492 Amps (1.6 ms), 557 Amps (1 ms) * 15 Pump contactor hold
Traction Motor R.H., Stall Timer Measure time (set by SUO #20) while stalling * 16 Pump contactor hold
Traction Motor Current Sensor L.H. Line contactor off(*) Turn key off
Fault Out of normal range * 24 Pump contactor hold
Traction Motor L.H., Over-current More than 492 Amps (1.6 ms), 557 Amps (1 ms) * 25 Pump contactor hold
Traction Motor L.H., Stall Timer Measure time (set by SUO #20) while stalling * 26 Pump contactor hold
Line contactor off(*) Turn key off
Pump Motor Current Sensor Fault Out of normal range * 34 Pump contactor off(*)
More than 985 Amps (1.6 ms), Line contactor off Turn key off
Pump Motor Over-current 1115 Amps (1.0 ms) * 35 Pump contactor off
Line Contactor Fault Check voltage of power circuit * 40 Pump contactor off(*)
Pump Contactor Fault Check voltage of power circuit * 42 Pump contactor off(*)
Traction Motor R.H. Open Traction R.H. Motor Open * 45 Pump contactor hold
Traction Motor L.H. Open Traction L.H. Motor Open * 46 Pump contactor hold
Pump Motor Open Pump Motor Open * 47 Pump contactor off
Sensor output is 0 or intermittent Line contactor off(*) Turn key off
Steering Sensor Fault (More than 10V) * 50 Pump contactor hold
Accel SW ON: Below 0.3V
Accelerator Sensor Fault Accel SW OFF: More than 1.41V/Below 0.2V, * 51 Pump contactor hold
More than 4.8V
Traction Motor R.H. Pulse Line contactor off Turn key off
Input Fault Out of normal range (5800 rpm) * 52 Pump contactor hold
Traction Motor L.H. Pulse Line contactor off Turn key off
Input Fault Out of normal range (5800 rpm) * 53 Pump contactor hold
Pump Motor Pulse Input Fault Out of normal range (4000 rpm) Line contactor off Turn key off
With no rotation input during output * 57 Pump contactor off
Display Communication Fault When serial communication is not going on * 60 Indicate if it possible Turn key off
Logic Card Initialize Failure Line contactor off Turn key off
SUO Gr. #3 and default setting are not set * 61 Pump contactor off
Logics Fault Parity check of SUO data Line contactor off Turn key off
Sum check of ROM and RAM * 62 Pump contactor off
When CAN communication is not going on
Traction Inverter R.H. Fault Line contactor off Turn key off
Sum check of ROM & RAM
Initial mode SW setting Fault
* 63 Pump contactor off
When CAN communication is not going on

Traction Inverter L.H. Fault Line contactor off Turn key off
Sum check of ROM & RAM
* 64 Pump contactor off
3-38
CONTROLLER
Display
Steering operation
LED
Service Indicator
To return
Parking Brake
Battery Low
Fault How to detect Result
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Pump Inverter Fault When CAN communication is not going on Line contactor off Turn key off
65
Sum check of ROM & RAM * Pump contactor off
Contactor Coil Fault 72 Line contactor off Turn key off
Contactor coil current sensor * Pump contactor off
Hydraulic Lock Solenoid Fault Check current of unload valve 74 Turn key off
Check current of lift lock valve * Disable all lever op.
Battery Voltage Too Low 78 Line contactor off Turn key off
Voltage class is not correct * Pump contactor off
Battery Voltage Too High 79 Line contactor off Turn key off
Voltage class is not correct * Pump contactor off
FNR Neutral
Direction Lever or Accelerator, Lever/accel is not neutral at power-on and seat Line contactor off Accel Open
switch closed E Disable traction Seat SW
Faulty Setting Seat switch is turned on after lever/accel is Slow down and Line Close
operated contactor off
FNR Neutral
Switch is off at power-on Line contactor off Accel Open
Seat Switch, Faulty Setting For
Traction (E) Disable traction Seat SW
Seat switch is off during operation Slow down and Line Close
contactor off
Lever
Switch is off at power-on Line contactor off Off/Neutral
Seat Switch, Faulty Setting For
Hydraulic (L) Pump contactor off Seat SW
Seat switch is off Disable all lever op. Close
Line contactor off Lever

Lever is not neutral at power-on and seat switch Pump contactor off Off/Neutral
Lift Lever, Faulty Setting on H1 Disable pump and Seat SW
steering op. Close
Seat switch is turned on after lever is pulled Disable all lever op.
Tilt Lever, Faulty Setting on H2 Disable pump and Seat SW
steering op. Close
Attachment 1 Lever, Faulty Setting on H3 Disable pump and Seat SW
steering op. Close
steering op. Close
steering op. Close
Battery Consumption Too Much Too much consumption with small capacity (Lo) Line contactor off(*) Turn key off
battery * Pump contactor off(*) Charge
Battery Consumption Much battery
Much consumption with small capacity battery (*) Power reduction
NOTICE: (1) E0-E7 don’t appear on the display, but are stored in the history folder.
(2) E, (E), (L), H1-H5, and Lo appear on the display, but not stored in the history folder. (E) means
flashing.
(3) “Line contactor off(*)” means that the contactor will open immediately when a fault is detected.
“Line contactor off” means that the contactor will open when a current gets to 0.
(4) Contactor “hold” means “no change.” When the error occurs while the contactor is turned on, it
keeps on.
3-39
CONTROLLER
Removal and Installation
Inverter Discharging Procedure

Discharge the inverters by using the following procedure.
1. Turn off the key switch.
2. Disconnect the battery plug.
3. Lift up the seat.
! CAUTION
Be careful not to be pinched yourself between the
head guard and seat.
211197
4. Place a 150 Ω/25 W resistor between P and N

terminals in the right traction inverter to discharge the
inverter.
5. After touching the resistor to the P and N terminals for
approx. five seconds, measure the voltage between the
terminals with a multimeter and confirm a reading of 5
V or less.
6. Perform the same procedure for the left traction
inverter and pump inverter in order to discharge all
inverters.
Check whether the resistance between + and - of the battery

plug on the truck side is 1 kΩ or more when connecting the 211198
battery plug for the first time after maintenance.
(Discharge all inverters completely before measuring.
Longer measurement time reduces resistance value.)
3-40
CONTROLLER
Replacing Inverter
Removal
1. Raise the front wheels.
2. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Be sure to discharge all inverters.
3. Disconnect all five power cables from P, N, U, V and

W terminals. For the pump inverter, leave P terminal
connected, and disconnect F terminal.
4. Disconnect the connector.
! CAUTION
When disconnecting the connector, hold the
connector housing and plug, and unlock the
connector.
Holding the case may cause damage to the inside
card, while holding the cable may cause wire 211199
breakage.
5. Remove M10 bolts (four places) fixing the inverter,

then remove the inverter.
Installation
1. Wipe off the dirt and thermal paste from the inverter
mounting surface once, and also remove dirt from the
mounting surface and the aluminum base plate of the
inverter.
2. Apply thermal paste approx. 1 mm (0.04 in.) thick to
the area where the aluminum base plate of the inverter
comes into contact with the truck body.
! CAUTION
Apply thin and even thermal paste since it works
to release generated heat from the inverter to the
truck body.
3. Fix the inverter with M10 bolts.

4. Connect the power cables to P, N, U, V and W
terminals. For the pump inverter, include F terminal.
3-41
CONTROLLER
! CAUTION
Use the correct power cables and terminate
marked cable ends to the correct terminals
marked on the motor.
Cables terminated at the wrong terminals on the
motor may cause the motor to rotate in the
opposite direction when activated.
Tightening torque
16 ± 1.0 N·m
U, V and W terminals [1.63 ± 0.10 kgf·m]
[11.80 ± 0.74 lbf·ft]
M8 nut
10 ± 1.0 N·m
P, N and F terminals (1.02 ± 0.10 kgf·m)
[7.38 ± 0.74 lbf·ft]
5. Connect the main harness connector to the inverter.
! CAUTION
Forcibly pressing the connector may cause
damage to the DSP card. Hold the connector
housing and press the connector, if required.
3-42
CONTROLLER
Replacing DSP (Digital Signal Processor)

Card
Removal
1. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Be sure to discharge inverters before working on
the electrical system.
2. Disconnect the connector.
! CAUTION
connector.
card, while holding the cable may cause wire
breakage.
3. Push and lift up at the four corners of the card cover to

remove the cover.
211200
4. Unlock the connector that is connected to the flat cable.

Hold the both ends of the white part of the connector
and pull it straight up.
5. Pull the flat cable connector to disconnect it.
If it cannot be disconnected smoothly, raise the lock
again to unlock.
6. Pinch the plastic spacers at the four corners of the DSP
card with pliers to unlock and remove the card.
! CAUTION
211201
Be careful not to damage mounted parts with the
pliers since the card has a number of fragile
parts.
3-43
CONTROLLER
Installation
1. Align the four mounting holes of the new DSP card
with the plastic spacer positions and press it into place.
! CAUTION
Press at the card edges.
Make sure that the spacer lock works completely
and the card is secure.
2. Confirm that the flat cable connector is unlocked by

raising the connector lock.
3. Insert the flat cable into the connector. Press down the
connector lock.
! CAUTION
Do not forcibly bend the flat cable. Insert its
conductive surface in the direction shown in the
illustration.
Confirm that the cable is inserted squarely into
the connector.
4. Install the cover while pushing the flat cable toward the
211202
card side slightly.
! CAUTION
Do not force the flat cable into the inverter cover.
Do not forcibly bend the flat cable. Make sure
that the cable will not be pinched underneath the
cover. Confirm that the cover is completely
locked.
5. Connect the main harness connector to the inverter.
! CAUTION
211357
Forcibly pressing the connector may cause
damage to the DSP card. Hold the connector
housing and press the connector, if required (for
the card with vertical type connector).
3-44
CONTROLLER
Replacing Logic Unit

Removal
1. Turn off the key switch.
2. Disconnect the battery plug.
3. Remove the right side step.
211203
Logic unit
211204
4. Disconnect the connector (CN1, 2 and 3 complex) from

the logic card and the connector (CN4) from the power
supply card.
! CAUTION
connector.
card, while holding the cable may cause wire
breakage.
5. Remove M10 bolts (two places) and remove the logic

unit.
Installation
Follow the removal sequence in reverse. 211205
3-45
CONTROLLER
Replacing Logic Card

Cover
Removal
1. Perform step 1 to 5 in Replacing Logic Unit.
2. Remove M3 flat head screws (two places) from the
bottom of the logic unit to remove the cover.
3. Remove M3 screws (four places) fixing the logic card
plate to the logic unit case to remove the logic card and
logic card plate as an assembly.
Logic unit
case
211206
Logic card
Heat sink
Installation
Follow the removal sequence in reverse.
Logic card
plate 211207
! CAUTION
When installing the logic card onto the logic card Logic card
plate, carefully tighten the logic card and heat
sink mounting screws to the specified torque to
avoid excessive stresses. Mount the heat sink
first.
Logic card
Tightening torque plate
0.98 ± 0.20 N·m

M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft] Logic card assembly 211328
3-46
CONTROLLER
Replacing Power Supply Card

Removal
1. Perform step 1 to 5 in Replacing Logic Unit. Cover
2. Remove M3 screws (two places) from the bottom of the

logic unit to remove the cover.
3. Remove M3 screws (four places) from the logic unit
case to remove the logic card and logic card plate as an
assembly.
Logic unit
case
211208
Power supply
card
Heat
sink
Installation
! CAUTION
When installing the power supply card onto the
Power supply card assembly 211209
logic unit case, carefully tighten the power supply
card and heat sink mounting screws to the
specified torque to avoid excessive stresses.
Mount the heat sink first.
Tightening torque
0.98 ± 0.20 N·m
M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft]
3-47
CONTROLLER
Basic Check
Always follow basic troubleshooting steps.

• Talk to the operator.
• Confirm the operator’s description of the problem with
an operational check.
• Visually inspect cables, connectors, contactor tips, etc.
• Perform basic battery cables to frame resistance test. (at
least 20 k ohm)
• Check battery condition.
Always check each option and write down the reading.
Testing Tools
(a) Multimeter
(b) Clamp meter (b)
(c) IC clip
(a)
NOTE
(c)
The illustrations show digital multimeters. In these
multimeters, the positive (+) terminal is applied with
positive charge, and the negative (–) terminal with
negative charge. It should be noted that the terminals
must be connected inversely when using an analog
meter. 208282
! WARNING
Disconnect the battery plug before inspecting or
adjusting the controller.
3-48
CONTROLLER
Measurement of Card Voltage
! WARNING
To prevent accidental movement of the truck,
place wood blocks under the truck to lift the front
wheels off the ground. Do not close to the front
wheels.
1. Tilt the mast fully backward. Place blocks under the

mast, and tilt the mast forward.
2. Turn the key switch off.
3. Disconnect the battery plug. Remove the cover.
4. Reconnect the battery plug.
5. Turn the key switch on. Connect the negative terminal
of the multimeter to the V GND terminal of the card.
6. Set the multimeter to the 100 VDC range.
7. Connect the positive terminal of the multimeter to each
pin of connectors detailed on the following pages.
NOTE
Be careful not to short-circuit pins. For the normal
voltage value, refer to the card voltage chart on the
following pages.
3-49
CONTROLLER
Logic card voltage chart

CN1
No. Name Stand-by voltage Active voltage Note
1 GND-L 0V 0V
2 +15V-L 13.0V to 16.0V 13.0V to 16.0V
3 GND-L 0V 0V
4 +5V-L 5V 5V
5 CANH 0 to 5V 0 to 5V Do not measure the voltage between CAN and Logic GND
6 CANL 0 to 5V 0 to 5V terminal.
7 BOOT 11.5V 0V
8 FWE 11.5V 0V
9 GND 0V 0V
10 -
11 -
12 -
13 -
14 DISPLAY1-TxD 0 to 12V 0 to 12V
15 -
16 DISPLAY1-RxD 0 to 12V 0 to 12V
17 GSE-TxD - -
18 GSE-RxD - -
19 POS VOLTAGE Vbatt Vbatt Battery connector attached : Vbatt
20 ACCEL ANGLE 0V 0 to 4.7V
21 -
22 -
23 GND 0V 0V
24 +5V 5V 5V
25 GND 0V 0V
26 +5V 5V 5V
27 -
28 -
29 -
30 LIFT LIMIT SW1 11.5V 0V
31 SPEED LIMIT SW 11.5V 0V
32 SEAT BELT SW 11.5V 0V
33 SEAT SW 11.5V 0V
34 PARK BRAKE SW 11.5V 0V
35 SERVICE BRAKE SW 11.5V 0V
36 REVERSE SW 11.5V 0V
37 FORWARD SW 11.5V 0V
38 BRAKE FLUID SW 11.5V 0V
39 STEERING PRESSURE SW 11.5V 0V
42 ACCEL IDLE SW 11.5V 0V
43 GND 0V 0V
44 PDS BUZZER 0V 0 to Vbatt
45 DIAG SW 11.5V 0V
46 SET SW 11.5V 0V
47 ATTACH3 SW 11.5V 0V
50 TILT SW 11.5V 0V
51 LIFT2 SW 11.5V 0V
52 LIFT1 SW 11.5V 0V
53 STEERING-1 11.5V 0V
57 LIFT LOCK + 0V 0 to Vbatt
58 LIFT LOCK - 0V 0V
59 LINE CONTACTOR CON 0V 0 to Vbatt
60 HYDRAULIC CONTACTOR CON 0V 0 to Vbatt
61 ALARM1 0V 0 to Vbatt
62 ALARM2 0V 0 to Vbatt
63 CON VE Vbatt Vbatt
64 UNLOAD SOL 0V 0 to Vbatt
Vbatt: Battery voltage
3-50
CONTROLLER
Power supply card voltage chart

CN1
No. Name Voltage Note
1 +12V 12V Fan
2 GND 0V Fan
3 +15V-L 13.0V to 16.0V DSP
4 +5V 8V DSP
5 +15V-G 12V DSP
6 GND 0V DSP
7 +VE-L Vbatt
8 +VE-L Vbatt
9 +15V-L 13.0V to 16.0V Logic
10 +5V 5V Logic
11 GND 0V Logic
12 GND 0V Logic
13 V POW Vbatt Input
14 V POW Vbatt Input
15 V GND 0V Input
16 V GND 0V Input
DSP card voltage chart

CN2
No. Name Stand-by voltage Active voltage Note
1 MOTOR THERMAL + 0 to 5V 0 to 5V
2 MOTOR THERMAL - 0 to 5V 0 to 5V
3 CANH 0 to 5V 0 to 5V Do not measure the voltage between
4 CANL 0 to 5V 0 to 5V CAN and Logic GND terminal.
5 ROTARY SENSOR +15V 12V 12V
6 ROTARY SENSOR A+ 0 to 5V 0 to 5V
7 ROTARY SENSOR B+ 0 to 5V 0 to 5V
8 MODE1 11.5V 0V
9 MODE2 11.5V 0V
10 BOOT 11.5V 0V
11 GND 0V 0V
12 TxD(GSE) - -
13 RxD(GSE) - -
14 CANR+ - -
15 CANR- - -
16 +15V-G 12V 12V
17 +15V-L 13.0V to 16.0V 13.0V to 16.0V
18 +5V 8V 8V
19 GND 0V 0V
20 GND 0V 0V
3-51
CONTROLLER
Checking Contactor Coil
! CAUTION
Disconnect the battery plug and discharge the
inverters before working on electrical system.
1. Disconnect coil lead wire.

2. Set the multimeter to the 200 ohm range.
3. Measure coil resistance.
The resistance must be between 44 ohm at -30°C
(-22°F) and 65 ohm at 80°C (176°F).
• If the measured value deviates from the above range,
replace the contactor assembly.
4. With the lead wire of contactor coil connected, set the
multimeter to the 200 VDC range.
5. Connect the negative (–) terminal of the multimeter to
the negative-side coil terminal (small terminal) and the
positive (+) terminal of the multimeter to the positive-
side coil terminal (large terminal).
6. Connect the battery, and operate the control device that
activates the contactor.
7. The multimeter should indicate about 24V after the
contactor operates. When the contactor is found to be
normal for the coil resistance test, but measured
voltage is not 24V, replace the logic card.
Checking Contactor Tips

1. Visually inspect the contactor tips for melting,
adhesion, heat seizure and pitting corrosion.
2. To check for interference, press the tips and release
them.
3. Visually inspect the contactor assembly. Make sure
there is no foreign material that could interfere with
contactor movement.
4. Measure the gap at the contactor tips using a feeler 208284
gauge.
[It must be 3 ± 0.5 mm (0.12 ± 0.02 in.)]
• If you find any trouble, replace or repair the
contactor.
3-52
CONTROLLER
Checking Inverter
! CAUTION
Disconnect the battery plug and discharge the
inverters before working on electrical system.
1. Disconnect all five power cables from P, N, U, V and

W terminals. For the pump inverter, leave P terminal
connected, and disconnect F terminal.
2. Check the resistance between the terminal as shown in
the following table.
Positive probe Negative probe Resistance (ohm)

U
N V
W - +
8k to 11k
U
V P Multimeter
W 211212
NOTICE: Short- or open-circuits of the inverter MOSFET

can be confirmed with this check. Other
internal faults cannot be determined with this
check.
3-53
CONTROLLER
Regeneration Check
The AC motor uses a common circuit for current flow in
both loading and regeneration. The following procedure
will confirm the regeneration operation.
1. Place the clamp ammeter onto the cable connected to Clamp ammeter
the inverter’s P terminal (use DC current range). This setting direction
is positive direction as current flows from the battery to
the inverter.
2. Run the truck forward. With the direction lever shifted
in F position, release the accelerator pedal. Then
perform a full-reverse operation.
3. The clamp ammeter should show a negative value. This
value becomes the regeneration current.
Energy is generated when a motor is rotated by an external

force. The regeneration power is produced when this
energy is larger than the one that is consumed by the
controller and motor. This means that the regeneration 211213
current is not measured if the speed or load changes
gradually.
3-54
CONTROLLER
AC Motor System Basics
1. Feature of AC motor
The AC motor model trucks covered by this manual use The frequency and voltage can be controlled in a
AC motors (three-phase induction motors) as the variety of methods including the “vector control
traction motor and pump motor. AC motors have the method” employed in the AC motor model trucks. This
following advantages over DC motors: method provides highly responsive control according to
(1) AC motors are simple in construction. Since they ever changing truck-operating conditions through high-
do not have friction parts like brushes and speed calculation on huge amount of data. The vector
commutators, daily maintenance is significantly control calculation is performed by the inverter. (Fig. 2)
reduced.
(2) AC motors are compatible with high-speed
operation. U
(3) An AC motor of a certain size produces higher
power than a DC motor of the same size. Inverter V IM
2. Speed control of induction motors W
Speed control of DC motors depends on regulation of
the field and armature current amounts, while that of
AC motors basically depends on adjustment of the V V
frequency of the alternating current power supply. The U V W
speed of an AC motor is determined by the frequency of
the power supply AC current and the load on the motor. t t
In addition, the voltage and current to the motor must
be controlled properly so that the motor operates in its Low-speed operation High-speed operation
(low frequency)
optimum characteristic range. (Fig. 1) 209542
Fig. 1
Logic unit Inverter
Gate
driving MOS-FET modules
pulse
Torque
Calculation for order
Accelerator Vector control
required output
F
calculation IM
N
R
Truck
speed
Current
Brake Speed
211214
Fig. 2
3-55
CONTROLLER
3. Inverter Switch
The truck battery delivers DC current, so the current must
be converted into AC current to drive an AC motor. The VB VL Load
device that converts direct current into alternating current is
generally called an “inverter.” The processes involved in
T1 T2 T1 T2 T1
creating AC current from DC current are described below. VL = × VB
T1 + T2
ON OFF ON
(1) Changing DC voltage cyclically
Average voltage VL
If the switch in a circuit like a one shown in Fig. 3 is
turned on for time T1 and then turned off for time T2
and this on-off operation is repeated many times, the Small duty ratio Large duty ratio
ON ON ON
average of the voltage applied to the load is determined
by the ratio between T1 and T2. Varying the ratio,
therefore, results in varying voltage. The ratio between
OFF OFF
T1 and T2 is called “duty ratio.” By changing the duty 209544
ratio cyclically, it is possible to obtain cyclically
Fig. 3
changing DC voltage shown in Fig. 3.
(2) Converting DC power into AC power
Driving a three-phase AC motor using battery delivered
power requires creating three phase outputs (U, V, W)
of an identical waveform that differ in phase by 120°
using a circuit with six switches S1 to S6 that are S1 S3 S5
arranged as shown in Fig. 4. The outputs thus created U
V
forms a three-phase alternating current. Fig. 5 shows W
on-off condition of each switch (arm) and output S2 S4 S6
voltage variation.
Functioning as switches in the inverter of the AC motor
trucks are MOS-FET transistors. The MOS-FET
209545
transistors can switch at very high speeds, thus creating
smooth waveforms of alternating current. Fig. 4
S1 ON
Switching for U phase

S3 ON
S2 ON
Switching for V phase
S5 ON S4 ON
Switching for W phase
S6 ON
209546
V lt b t t t i
Fig. 5
3-56
TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information ............................................................................... 4– 1

E0 Traction Motor R.H., Overheating ............................................. 4– 3
E1 Traction Motor L.H., Overheating ............................................. 4– 6
E2 Pump Motor, Overheating ........................................................... 4– 9
E5 Traction Inverter R.H., Overheating ......................................... 4 – 12
E6 Traction Inverter L.H., Overheating .......................................... 4 – 15 4
E7 Pump Inverter, Overheating ....................................................... 4 – 18
Brake Oil, Low Level .................................................................... 4 – 21
14 Traction Motor Current Sensor R.H. Fault .............................. 4 – 23
15 Traction Motor R.H., Over-current ............................................ 4 – 25
16 Traction Motor R.H., Stall Timer ................................................ 4 – 28
24 Traction Motor Current Sensor L.H. Fault .............................. 4 – 30
25 Traction Motor L.H., Over-current ............................................ 4 – 32
26 Traction Motor L.H., Stall Timer ................................................ 4 – 35
34 Pump Motor Current Sensor Fault ........................................... 4 – 37
35 Pump Motor Over-current ........................................................... 4 – 39
40 Line Contactor Fault .................................................................... 4 – 42
42 Pump Contactor Fault ................................................................. 4 – 44
45 Traction Motor R.H. Open ........................................................... 4 – 46
46 Traction Motor L.H. Open ........................................................... 4 – 49
47 Pump Motor Open ........................................................................ 4 – 52
50 Steering Sensor Fault .................................................................. 4 – 55
51 Accelerator Sensor Fault ............................................................ 4 – 58
52 Traction Motor R.H. Pulse Input Fault ..................................... 4 – 61
53 Traction Motor L.H. Pulse Input Fault ..................................... 4 – 64
57 Pump Motor Pulse Input Fault .................................................. 4 – 67
60 Display Communication Fault ................................................... 4 – 70
61 Logic Card Initialize Failure ........................................................ 4 – 72
62 Logics Fault .................................................................................... 4 – 73
63 Traction Inverter R.H. Fault ........................................................ 4 – 74
64 Traction Inverter L.H. Fault ......................................................... 4 – 77
65 Pump Inverter Fault ...................................................................... 4 – 79
72 Contactor Coil Fault ..................................................................... 4 – 82
74 Hydraulic Lock Solenoid Fault .................................................. 4 – 84
78 Battery Voltage Too Low ............................................................. 4 – 86
79 Battery Voltage Too High ............................................................ 4 – 88
E Direction Lever or Accelerator, Faulty Setting ...................... 4 – 90
(E) Seat Switch, Faulty Setting For Traction ................................ 4 – 92
(L) Seat Switch, Faulty Setting For Hydraulic ............................. 4 – 94
H1 Lift Lever, Faulty Setting ............................................................. 4 – 96
H2 Tilt Lever, Faulty Setting ............................................................. 4 – 98
H3 Attachment 1 Lever, Faulty Setting .......................................... 4 – 100
((Lo)) Battery Consumption Too Much ............................................... 4 – 106
(Lo) Battery Consumption Much ....................................................... 4 – 108
Locations of Major Components and Connectors ........................ 4 – 110
Electrical Schematic (AC motor, MC models) ................................ 4 – 113
Electrical Diagram (AC motor, MC models) .................................... 4 – 115
General Information
Before replacing devices

Do not replace devices casually even if replacement is required as a result of troubleshooting. Be sure to check the
following items before replacing devices (logic unit, logic card, power supply card, inverters and inverter DSP cards).
• Loose battery connectors
• Abnormal wire harness connections
• Loose connectors
• Broken, bent or loose connector pins
• Dirty connectors
If connectors are dirty, remove the connector and clean connectors.
See "How to clean harness connectors and system components" on page 4-2.
• Ensure that the main harness is not short-circuited to the truck body by using the following procedures.
Disconnect battery plug and discharge the inverters before

working on electrical system.
Disconnect connector CN4 of logic unit. Check continuity between

CN4-15(21) and truck body (logic unit installation bolts, etc.).
No continuity Continuity
Normal Repair or replace harness.
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a
new one. Be sure to check the above items and replace carefully.
Connection of the service tool Error code display

1. Turn off the truck power.
2. Remove floor plates.
3. Find the connector to the service tool near the logic unit.
Logic unit
4. Remove the cover and connect the PC as shown.
5. Turn on the truck power.
6. Start the service tool software.
211331
4-1
How to clean harness connectors and system

components
1. Open-circuits are often caused by dirty harness
connectors and components. Dust together with greasy
matter forms grime which, in time, penetrates electrical
connections, resulting in loose metal-to-metal contact
or, in the worst case, electrical separation of surfaces in
contact. For this reason, it is essential that the
connectors and components be cleaned at each periodic
inspection and at when servicing the truck. Instead of a
commonly used solvent, use electronic parts cleaner (in
the manner illustrated on the right).
Electronic parts cleaner

211223
Electronic parts Three Bond 29D or
cleaner Pow-R-Wash CZ*
NOTE
The cleaner liquid is volatile (evaporates by itself).
All that is required is to thoroughly wash off the grime
with the spray.
No need to wipe off the sprayed liquid.
2. After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray contact
surface activator onto contact surfaces. Install and
remove the connector several times to wet the surfaces
thoroughly with the activator liquid. After coupling up Electronic parts
the connector, check to be sure that it is in locked state. cleaner
Contact surface Three Bond 2501S (aerosol)

activator or Nyogel 760G*
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some resins
(plastic materials).
*: Products contained in Terminal Maintenance Kit

Contact surface
(SE000003) activator
205047
4-2
Problem: Traction Motor R.H., Overheating (E0)

(1) Situation
Controller/motor overheat indicator ON. Poor pulling power and acceleration.
Normal pump motor and power steering operations. Service tool "Alarm status" and "E0" displayed.
(2) Possible cause

Overheating of right traction motor, faulty right traction motor or thermal sensor, faulty or open harness wiring,
faulty right traction inverter DSP card, abnormal power supply of logic unit, brake or parking brake drag,
abnormality in front axle, faulty display unit.
(3) How the error code is triggered

Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F).
It becomes normal when motor temperature is less than 70 °C (158 °F).
(4) Checks
Let truck cool for 15 minutes.
Overheat indicator ON Overheat indicator OFF
(5) Traction motor becomes normal.
If problem reoccurs
(6) Disconnect battery plug. Disengage brake
and parking brake, and check their drag.
No drag Drag
(7) Adjust brake.
(8) Lift front wheels, and disengage parking brake.

Turn key switch to OFF, rotate front wheels.
Confirm there is no difference in rotation load
between right and left wheels.
No difference Difference
(9) Check if truck is operated on steep

upgrade or to pull large cargo load.
Normal
(10) Perform inverter discharging work. See page 3-40.
(11) Replace right traction (12) Replace right traction

motor. motor or front axle.
See page 6-4. See page 6-4 or 5-1.
With service tool
(13) Confirm temperature of right traction motor with

Without service tool input/output monitor.
70 °C(158 °F) or more Less than 70 °C(158 °F)
(14) Disconnect battery plug. Wait until right traction motor (15) Disconnect battery plug.
temperature becomes close to room temperature.
4-3
(16) Perform inverter discharging work. See page 3-40. (17) Replace display unit. See page 2-6.
(18) Disconnect connector CN14 of right traction motor

speed and thermal sensor. Measure resistance
between CN14(124) and (125) at motor side.
6kΩ at 40°C (104°F) to
19kΩ at 10°C (50°F) Out of range
Thermal
(19) Disconnect connector CN7 of right traction inverter. (20) Replace right traction motor. See page 6-4.
Check continuity between CN7-1 and CN14(125).
Continuity No continuity
Power supply
(21) Check continuity between CN4-3 and CN7-17(252).
Check continuity between CN4-6 and CN7-20(255).
CAN
(22) Disconnect connector CN3 of logic unit.
Check continuity between CN3-5(211) and CN7-3(224).
(23) Connect connector CN4, then turn on power again. (24) Repair or replace harness.
(25) Measure voltage between CN7-17(252) and

CN7-20(255). Confirm value is 14V±2V.
Normal Abnormal
(26) Disconnect battery plug.
(27)Replace power supply card of logic unit. See page 3-47.

With service tool
Without service tool
(28) Ensure all connectors are connected. Check Run
Time Diagnostics data. See page 3-38.
The latest data is "E0". Not "E0"
(29) Disconnect battery (30)Disconnect battery plug.

plug, then perform Replace display unit.
inverter discharging
work. See page 3-40.
(31)Replace DSP card of right traction inverter. See page 3-43.
4-4
Logic
CN3 CN7 Traction inverter (right)
BG 0 to 5V V
CAN 5 WP 211 0 to 5V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
5 WG 254 12V WG 16 P Fuse
RP 252 14V RP
Power 3 RL 253 8V RL
17
N Battery (-)
4 18 DSP IMS
B 255 GND B 20 card card
6 U IUR
5V * 1 Y 1
Power card GND G V IVR
2 Flat
CN4 12V Y
5 cable W IWR
0 to 5V Y 6
0 to 5V B
7
GND O 19
CN14 Traction motor (right)

O 127 Speed
B sensor W TWR
Y
146
M U TUR
145 TVR
Y V
126
G Thermal
124 sensor
Y 125 283Ω to 163kΩ
1: With connector disconnected
*
211224
4-5
Problem: Traction Motor L.H., Overheating (E1)

(1) Situation
(2) Possible cause

Overheating of left traction motor, faulty left traction motor or thermal sensor, faulty or open harness wiring, faulty
left traction inverter DSP card, abnormal power supply of logic unit, brake or parking brake drag,
abnormality in front axle, faulty display unit.

(4) Checks
(5) Traction motor becomes normal.
If problem reoccurs
(6) Disconnect battery plug. Disengage brake
and parking brake, and check their drag.
No drag Drag
(7) Adjust brake.
(8) Lift front wheels, and disengage parking brake.

Turn key switch to OFF, rotate front wheels.
Confirm there is no difference in rotation load
between right and left wheels.
No difference Difference
(9) Check if truck is operated on steep
upgrade or to pull large cargo load.
Normal
(11) Replace left traction (12) Replace left traction

motor. motor or front axle.
See page 6-4. See page 6-4 or 5-1.
With service tool
(13) Confirm temperature of left traction motor with

(14) Disconnect battery plug. Wait until left traction motor (15) Disconnect battery plug.
4-6
(18) Disconnect connector CN15 of left traction motor

between CN15(129) and (130) at motor side.
6kΩ at 40°C (104°F) to
Thermal
(19) Disconnect connector CN6 of left traction inverter. (20) Replace left traction motor. See page 6-4.
Power supply
(21) Check continuity between CN4-3(252) and CN6-17(260).
CAN
(22)Disconnect connector CN3 of logic unit.

Normal Abnormal
(27) Replace power supply card of logic unit. See page 3-47.
With service tool

(29) Disconnect battery (30) Disconnect battery plug.

(31) Replace DSP card of left traction inverter. See page 3-43.
4-7
Logic
CN3 CN6 Traction inverter (left)
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
5 WG 254 12V 259 RY
16 P Fuse
RP 14V 260 RGr 17
Power 3 RL 252 8V 261 R 18 N Battery (-)
4 253 DSP IMS
B 255 GND 262 B card
6 20 card U IUL
5V * 1 Y 1
Power card GND G V IVL
2
CN4 12V V 5 Flat
cable W IWL
0 to 5V L
6
0 to 5V G
7
GND O
19
CN15 Traction motor (left)

O 132 Speed
G sensor W TWL
L
148
M U TUL
147 TVL
V
V 131 Thermal
G 129 sensor
Y 130 283Ω to 163kΩ
*1: With connector disconnected
211225
4-8
Problem: Pump Motor, Overheating (E2)

(1) Situation
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor
and power steering operations. Service tool "Alarm status" and "E2" displayed.
(2) Possible cause

Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty pump
motor inverter DSP card, abnormal power supply of logic unit, abnormal oil pressure of gear pump or
hydraulic lines, faulty display unit.

(4) Checks
(5) Pump motor becomes normal.
If problem reoccurs
(6) Check if truck is operated to lift large cargo load.
Normal
(8) Check oil pressure of gear pump and hydraulic lines.

Normal Abnormal
(9) Replace pump motor. (10)Repair or replace gear

See page 6-5. pump or piping.
With service tool See page 11-10.
(11) Confirm temperature of pump motor with

(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
(16) Disconnect connector CN20 of pump motor

between CN20(134) and (135).
6kΩ at 40°C (104°F) to
Thermal
(17) Disconnect connector CN5 of pump motor inverter. (18) Replace pump motor. See page 6-5.
4-9
Power supply
CAN

Normal Abnormal
(24)Disconnect battery plug.
With service tool
(26)Ensure all connectors are connected. Check Run
(27) Disconnect battery (28) Disconnect battery

plug, then perform plug. Replace display
inverter discharging unit.
(29) Replace DSP card of pump motor inverter. See page 3-43.
4-10
Logic
CN3 CN5 Pump inverter
BG 0 to 5V V
234
L
3 Inside Inside Pump contactor
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265 RG 16 P
RP 14V 266 RY
Power 3 RL 252 8V 267 RW
17
N Battery (-)
4 253 18 DSP IMS
B 255 GND 268 B 20 card card
6 U IU
5V* 1 RB 1
Power card GND W V IV
2 Flat
CN4 12V L
5 cable W IW
0 to 5V R 6
0 to 5V Y
7
GND V 19
CN20 Pump motor

V 138 Speed
Y sensor W PW
R
137
M U PU
136 PV
L V
133 Thermal
W 134 sensor
RB 135 160Ω to 163kΩ
1: With connector disconnected
*
211226
4-11
Problem: Traction Inverter R.H., Overheating (E5)

(1) Situation
(2) Possible cause

Overheating of right traction inverter, faulty right traction inverter thermal sensor, open harness wiring, faulty
right traction inverter PC board, abnormal power supply of logic unit, faulty radiation of right traction
inverter, faulty display unit.

Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F).
Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to 230 °F).
It becomes normal when temperature is less than 70 °C (158 °F).
(4) Checks
(5) Right traction inverter becomes normal.
If problem reoccurs
(6) Check if truck is operated on steep upgrade or to pull
large cargo load.
Normal
Check thermal paste applied on inverter mounting
surface. Thermal paste film should be thin and even.
Normal Abnormal
(8) Replace right traction (9) Clean mounting surface,

inverter. See page 3-41. apply thermal paste,
With service tool then reinstall inverter.
See page 3-41.
(10)Confirm temperature of controller and head capacitor

Without service tool with input/output monitor.
(11) Disconnect battery plug. Wait until inverter (12) Disconnect battery plug.
(14) Replace display unit. See page 2-6.

Thermal
(15) Remove right traction inverter DSP card cover, then
check harness looseness or wire breakage. See page 3-43.
Normal Abnormal
Power supply
(16) Disconnect connector CN7 of right traction inverter. (17) Secure harness if loose.
Check continuity between CN4-3 and CN7-17(252). Replace inverter if wire breaks. See page 3-41.
4-12
CAN
(19)Connect connector CN4, then turn on power again. (20) Repair or replace harness.

Normal Abnormal
With service tool
(25) Disconnect battery (26)

plug, then perform Disconnect battery plug.
inverter discharging Replace display unit.
(27) Replace DSP card of right traction inverter. See page 3-43.
If fault remains
(28) Disconnect battery plug, then perform inverter
discharging work. See page 3-40.
(29)Replace right traction inverter. (DSP card is normal.)

See page 3-41.
4-13
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
RP 252 14V RP
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card Controller V IVR
2 Flat thermistor
CN4
5 cable W IWR
6
7 Capacitor
thermistor
19

DSP flat 127 Speed
cable sensor W TWR
Inverter
146
M U TUR
145 TVR
case V
126
Thermal
DSP card 124 sensor
125
211227
4-14
Problem: Traction Inverter L.H., Overheating (E6)

(1) Situation
(2) Possible cause

Overheating of left traction inverter, faulty left traction inverter thermal sensor, open harness wiring, faulty
left traction inverter PC board, abnormal power supply of logic unit, faulty radiation of left traction
inverter, faulty display unit.

(4) Checks
(5) Left traction inverter becomes normal.
If problem reoccurs
(6) Check if truck is operated on steep upgrade or to pull
large cargo load.
Normal
Normal Abnormal
(8) Replace left traction (9) Clean mounting surface,

inverter. See page 3-41. apply thermal paste,
then reinstall inverter.
With service tool See page 3-41.
(10) Confirm temperature of controller and head

Without service tool capacitor with input/output monitor.
(11) Disconnect battery plug. Wait until inverter (12)Disconnect battery plug.
(13) Perform inverter discharging work. See page 3-40. (14)Replace display unit. See page 2-6.
Thermal
(15)Remove left traction inverter DSP card cover, then
check harness looseness or wire breakage. See page 3-43.
Normal Abnormal
Power supply
(16)Disconnect connector CN6 of left traction inverter. (17) Secure harness if loose.
Check continuity between CN4-3(252) and CN6-17(260). Replace inverter if wire breaks. See page 3-41.
4-15
CAN

Normal Abnormal
With service tool
(25) Disconnect battery (26) Disconnect battery plug.

(27)Replace DSP card of left traction inverter. See page 3-43.
If fault remains
(28)Disconnect battery plug, then perform inverter
(29)Replace left traction inverter. (DSP card is normal.)

See page 3-41.
4-16
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
5 WG 254 12V 259 RY
16 P Fuse
RP 14V 260 RGr 17
Power 3 252
RL 253 8V 261 R 18 N Battery (-)
4 DSP IMS
6 20 card U IUL
1
Power card Controller V IVL
2 thermistor
CN4 Flat
5 cable W IWL
6
Capacitor
7 thermistor
19

DSP flat 132 Speed
cable sensor W TWL
Inverter
148
M U TUL
147 TVL
case V
131
Thermal
DSP card 129 sensor
130
211228
4-17
Problem: Pump Inverter, Overheating (E7)

(1) Situation
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor
and power steering operations. Service tool "Alarm status" and "E7" displayed.
(2) Possible cause

Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty pump inverter
PC board, abnormal power supply of logic unit, faulty radiation of pump inverter, faulty display unit.

(4) Checks
(5) Pump inverter becomes normal.
If problem reoccurs
(6) Check if truck is operated to lift large cargo load.
Normal
Normal Abnormal
(8) Replace pump inverter. (9)Clean mounting surface,

See page 3-41. apply thermal paste, then
With service tool reinstall inverter.
See page 3-41.
(10) Confirm temperature of controller and head
capacitor with input/output monitor.
(11) Disconnect battery plug. Wait until inverter (12) Disconnect battery plug.
Thermal
(15) Remove pump inverter DSP card cover, then check
harness looseness or wire breakage. See page 3-43.
Normal Abnormal
Power supply
(16) Disconnect connector CN5 of pump inverter. (17) Secure harness if loose.
4-18
CAN
(19) Connect connector CN4, then turn on power again. (20)Repair or replace harness.

Normal Abnormal
With service tool

(25) Disconnect battery (26)Disconnect battery plug.

(27)Replace DSP card of pump inverter. See page 3-43.
If fault remains

(29)Replace pump inverter. (DSP card is normal.)

See page 3-41.
4-19
Logic
BG 0 to 5V V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
RP 14V RY
Power 3 RL 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card Controller V IV
2 Flat thermistor
CN4
5 cable W IW
6
Capacitor
7 thermistor
19
CN20 Pump motor

DSP flat 138 Speed
cable sensor W PW
Inverter
137
M U PU
136 PV
case V
133 Thermal
DSP card 134 sensor
135
211229
4-20
Problem: Brake Oil, Low Level

(1) Situation
Lower brake oil indicator ON. Normal truck operation.
(2) Possible cause

Insufficient brake oil, faulty brake oil level sensor, shorted wiring, faulty logic unit, faulty display unit.

Sensor signal is open or short.
(4) Checks
Check oil level in brake oil reservoir tank.
Normal Abnormal
(5) Add brake oil. See page 9-10.
With service tool
Without service tool (6) Confirm brake oil level switch with input/output
monitor.
ON OFF
(7) Disconnect battery plug, then perform inverter (8) Disconnect battery plug. Replace display unit.
discharging work. See page 3-40. See page 2-6.
(9) Disconnect connectors CN2 and CN3 of logic unit and

CN11 of sensor. Check continuity between CN11(139)
and CN11(140) at harness side.
(10) Check continuity of brake oil level sensor connector

coupled to CN11. (11) Repair or replace harness.
(12) Replace brake oil level sensor.

With service tool
Without
service tool
(13) Replace display unit. See page 2-6.
If fault remains
(15) Reinstall display unit and replace logic card of logic

unit. See page 3-46.
4-21
Logic Logic
CN2 CN3
38 23
0V/12V GND
O L
139 140
CN11
O L
Brake fluid
sensor
211230
4-22
Problem: Traction Motor Current Sensor R.H. Fault (14)

(1) Situation
Display: "14". All truck operations inhibited. This fault occurs only when turning on power. Line contactor OPEN
and pump contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction
inverter, faulty right traction inverter, faulty main harness, faulty logic unit.

When turning on power, current sensor voltage is out of range of -120 A to 120 A.
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 3-40.
(5) Disconnect connector CN7 of right traction inverter

and remove DSP cover. Check DSP flat cable for
looseness or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4 and CN7-18(253). (7) Secure DSP flat cable if loose.
Continuity Abnormal and No continuity
CAN
Continuity Abnormal and No continuity
(9) Connect connector CN4 to logic unit, then turn on (10)Repair or replace harness.
power again.

Normal Abnormal
(12) Disconnect battery plug, then perform inverter discharging work. See page 3-40.
(13)Replace DSP card of right traction inverter. See page 3-43. (14) Replace power supply card of logic unit. See page 3-47.
If fault remains
(15) Perform inverter discharging work, then replace

right traction inverter. (DSP card is normal.)
See page 3-41.
4-23
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14 U current sensor
O
15
RP 252 14V RP
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4
5 cable W IWR
6
V current sensor
7
19

DSP flat 127 Speed
cable sensor W TWR
Inverter
146
M U TUR
145 TVR
case V
126
Thermal
DSP card 124 sensor
125
211231
4-24
Problem: Traction Motor R.H., Over-current (15)

(1) Situation Display: "15". Traction motor operation inhibited. Pump motor and power steering operations inhibited
if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor
CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction
inverter, faulty right traction inverter, faulty right traction motor, faulty contact or wire breakage of right
traction motor speed sensor harness, faulty main harness, faulty logic unit.

Motor current is more than 1000 A (Moment). Motor current is more than 788 A (Fixed time 1).
Motor current is more than 696 A (Fixed time 2).
(4) Checks
(5) Check right traction motor and terminal for burning

and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections

(U, V, W phases) for right traction inverter and motor. (7) Replace right traction motor. See page 6-4.
Normal Abnormal

(9) Secure cable if loose or connect cable correctly.
Normal Abnormal
(10) Confirm connection of right traction motor speed (11) Secure DSP flat cable if loose.
sensor connector CN14. Replace inverter if wire breaks. See page 3-41.
Normal Abnormal
Sensor
(12) Disconnect connectors CN7 and CN14. (13) Connect connector securely.
8V power
supply
CAN
power again.
4-25

Normal Abnormal
If fault remains
(22)Perform inverter discharging work, then replace right

traction inverter. (DSP card is normal.) See page 3-41.
If fault remains
(23)Perform inverter discharging work, then reinstall right
traction inverter and replace right traction motor.
4-26
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
RP 252 14V RP
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4 12V Y
5 cable W IWR
0 to 5V Y
6
0 to 5V B
7
GND O 19

DSP flat O 127 Speed
cable B sensor W TWR
Inverter Y
146
M U TUR
145
case Y V TVR
126
Thermal
DSP card 124 sensor
125
211232
4-27
Problem: Traction Motor R.H., Stall Timer (16)

(1) Situation
Display:"16". Traction motor operation inhibited. Pump motor and power steering operations inhibited
(2) Possible cause

Stall current flowed more than set time (#20) in right traction motor, faulty right traction inverter current sensor,
shorted harness wiring, faulty right traction inverter DSP card, faulty logic unit.

Stall timer set time (set by Setup Option #20) is measured while stalling.
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
No error, problem reoccurs Error code 14
(5) Confirm stall timer set time of Setup Option #20.

(6) See troubleshooting for code "14". See page 4-23.
Maximum value set Larger value can be set
(7) Check to see if truck is operated with heavy cargo (8) Change set time. See page 3-21.
load or on steps when motor stalls.
Note: The more stall occurs, the more overheating
Normal steeps Heavy load
occurs. Operate truck under normal condition.

(10) Operate under normal condition.

and remove DSP cover, then check DSP flat cable for
looseness or wire breakage. See page 3-43.
Normal Abnormal
Power supply
(12) Check continuity between CN4-5 and CN7-16(254). (13) Secure harness if loose. Replace right traction
Check continuity between CN4-6 and CN7-20(255). inverter if wire breaks. See page 3-41.
CAN
Continuity Abnormal and no continuity
(15)Connect connector CN4 to logic unit, then turn on (16)Repair or replace harness.
power again.

Normal Abnormal
(19) Replace DSP card of right traction inverter. See page 3-43. (20)Replace power supply card of logic unit. See page 3-47.
4-28
Logic
BG V
CAN 5 WP 211 224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14 U current sensor
O
15
RP 252 14V RP
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4
5 cable W IWR
6
V current sensor
7
19
127 Speed
sensor W TWR
146
M U TUR
145 TVR
V
126
Thermal
124 sensor
125
211233
4-29
Problem: Traction Motor Current Sensor L.H. Fault (24)

(1) Situation
Display: "24". All truck operations inhibited. This fault occurs only when turning on power.
Line contactor OPEN and pump contactor OPEN.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction
inverter, faulty left traction inverter, faulty main harness, faulty logic unit.

(4) Checks
(5)Disconnect connector CN6 of left traction inverter and

remove DSP cover. Check DSP flat cable for looseness
or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4(253) and CN6-18(261). (7) Secure DSP flat cable if loose.
CAN
(9) Connect connector CN4 to logic unit, then turn on

(10) Repair or replace harness.
power again.
(11)Measure voltage between CN6-18(261) and

Normal Abnormal
(12)Disconnect battery plug, then perform inverter discharging work. See page 3-40.
(13) Replace DSP card of left traction inverter. See page 3-43. (14) Replace power supply card of logic unit. See page 3-47.
If fault remains
(15) Perform inverter discharging work, then replace left

4-30
Logic
BG 0 to 5V V 3
CAN 5 WP 211
0 to 5V
224
L 4 Inside Inside
6 212 229 of of
cover case
14 U current sensor
15
5 WG 254 12V 259 RY
16 P Fuse
RP 14V 260 RGr 17
4 253 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 Flat
5 cable W IWL
6
V current sensor
7
19

DSP flat 132 Speed
cable sensor W TWL
Inverter
148
M U TUL
147 TVL
case V
131 Thermal
DSP card 129 sensor
130
211234
4-31
Problem: Traction Motor L.H., Over-current (25)

(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction inverter,
faulty left traction inverter, faulty left traction motor, faulty contact or wire breakage of left traction motor speed
sensor harness, faulty main harness, faulty logic unit.

(4) Checks
(5) Check left traction motor and terminal for burning

and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections

(U, V, W phases) for left traction inverter and motor. (7) Replace left traction motor. See page 6-4.
Normal Abnormal
(8) Disconnect connector CN6 of left traction inverter and (9) Secure cable if loose or connect cable correctly.
or wire breakage.
Normal Abnormal
(10) Confirm connection of left traction motor speed (11) Secure DSP flat cable if loose.
sensor connector CN15. Replace inverter if wire breaks. See page 3-41.
Normal Abnormal
Sensor
(12) Disconnect connectors CN6 and CN15. (13) Connect connector securely.
8V power
supply
(14)Check continuity between CN4-4(253) and CN6-18(261).
CAN
power again.
4-32
(18)Measure voltage between CN6-18(261) and

Normal Abnormal
If fault remains

If fault remains
(23) Perform inverter discharging work, then reinstall left
traction inverter and replace left traction motor.
4-33
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14 U current sensor
15
5 WG 254 12V 259 RY
16 P Fuse
RP 14V 260RGr 17
4 253 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 12V V 5 Flat
cable W IWL
0 to 5V L
6
0 to 5V G V current sensor
7
GND O 19

DSP flat O 132 Speed
cable G sensor W TWL
Inverter L
148
M U TUL
147 TVL
case V
V 131 Thermal
DSP card 129 sensor
130
211235
4-34
Problem: Traction Motor L.H., Stall Timer (26)

(1) Situation
Display:"26". Traction motor operation inhibited. Pump motor and power steering operations inhibited
(2) Possible cause
Stall current flowed more than set time (#20) in left traction motor, faulty left traction inverter current sensor,
shorted harness wiring, faulty left traction inverter DSP card, faulty logic unit.

Stall timer set time (set by Setup Option #20) is measured while stalling.
(4) Checks
No error, problem reoccurs Error code 24
(5) Confirm stall timer set time of Setup Option #20.

Maximum value set Larger value can be set
(7) Check to see if truck is operated with heavy cargo (8) Change set time. See page 3-21.
load or on steps when motor stalls. Note: The more stall occurs, the more overheating
Normal steps Heavy load occurs. Operate truck under normal condition.
(9) Disconnect battery plug, then perform inverter (10) Operate under normal condition.
(11) Disconnect connector CN6 of left traction inverter and

remove DSP cover, then check DSP flat cable for
looseness or wire breakage. See page 3-43.
Normal Abnormal
Power supply
(12) Check continuity between CN4-5(254) and CN6-16(259). (13) Secure harness if loose. Replace left traction
Check continuity between CN4-6(255) and CN6-20(262). inverter if wire breaks. See page 3-41.
CAN
Continuity Abnormal and no continuity
power again.

Normal Abnormal
(19) Replace DSP card of left traction inverter. See page 3-43. (20)Replace power supply card of logic unit. See page 3-47.
4-35
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14 U current sensor
15
WG 254 12V 259 RY
5 16 P Fuse
RP 14V 260 RGr 17
4 253 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 Flat
5 cable W IWL
6
V current sensor
7
19
132 Speed
sensor W TWL
148
M U TUL
147 TVL
V
131 Thermal
129 sensor
130
211236
4-36
Problem: Pump Motor Current Sensor Fault (34)

(1) Situation
Display: "34". All truck operations inhibited. This fault occurs only when turning on power.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump
inverter, faulty pump inverter, faulty main harness, faulty logic unit.

(4) Checks
(5) Disconnect connector CN5 of pump inverter and

or wire breakage.
Normal Abnormal
8V power
supply
Check continuity between CN4-6(255) and CN5-20(268). Replace pump inverter if wire breaks. See page 3-41.
CAN
(9) Connect connector CN4 to logic unit, then turn on (10) Repair or replace harness.
power again.

Normal Abnormal
(13) Replace DSP card of pump inverter. See page 3-43. (14) Replace power supply card of logic unit. See page 3-47.
If fault remains
pump inverter. (DSP card is normal.) See page 3-41.
4-37
Logic
BG 0 to 5V V U current sensor
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
RP 14V RY
Power 3 RL 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4
5 cable W IW
6
V current sensor
7
19
CN20 Pump motor

DSP flat Speed
cable 138
sensor W PW
Inverter
137
M U PU
case 136 PV
V
133 Thermal
DSP card 134 sensor
135
211237
4-38
Problem: Pump Motor Over-current (35)
(1) Situation
Display: "35". All truck operations inhibited.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter,
faulty pump inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness,
faulty main harness, faulty logic unit.

(4) Checks
(5) Check pump motor and terminal for burning and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections (U,

V, W phases) for pump inverter and motor. (7) Replace pump motor. See page 6-5.
Normal Abnormal

(9) Secure cable if loose or connect cable correctly.
or wire breakage.
Normal Abnormal
(10) Confirm connection of pump motor speed sensor (11) Secure DSP flat cable if loose.
connector CN20. Replace pump inverter if wire breaks. See page 3-41.
Normal Abnormal
Sensor
(12) Disconnect connectors CN5 and CN20.
(13) Connect connector securely.
8V power
supply
(14)Check continuity between CN4-4(253) and CN5-18(267).
CAN

power again.
4-39

Normal Abnormal
(20) Replace DSP card of pump inverter. See page 3-43. (21)Replace power supply card of logic unit. See page 3-47.
If fault remains
If fault remains
(23) Perform inverter discharging work, then reinstall
pump inverter and replace pump motor.
4-40
Logic
0 to 5V U current sensor
BG V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
RP 14V RY
Power 3 RL 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4 12V L
5 cable W IW
0 to 5V R 6
0 to 5V Y V current sensor
7
GND V 19
CN20 Pump motor

DSP flat V 138 Speed
cable Y sensor W PW
Inverter R
137
M U PU
136
case L V PV
133 Thermal
DSP card 134 sensor
135
211238
4-41
Problem: Line Contactor Fault (40)

(1) Situation
(2) Possible cause

Faulty line contactor, faulty main harness, faulty logic unit, faulty right traction inverter, faulty left traction
inverter.

Inverter voltage data is checked when contactor is closed (400 mS).
(4) Checks
Error code 40 Error code 63 or 64
(5) Block wheels, then confirm line contactor (6) See troubleshooting for code "63" or "64". See page
operation in self-diagnostics mode [14]. See page 3-35. 4-74 or 4-77.
Not operated Operated
With service tool
(7) Check DC voltage of right and left traction (8) Disconnect battery plug, then perform
inverters with monitor. These values should be inverter discharging work. See page 3-40.
same as battery voltage.
Right inverter value Left inverter value
abnormal abnormal
(11) Replace right traction inverter.
See page 3-41.
(9) Disconnect battery (10) Disconnect battery
plug, then perform plug, then perform If fault remains
inverter discharging inverter discharging
work. See page 3-40. work. See page 3-40. (14) Disconnect battery plug, then perform
inverter discharging work. See page 3-40.
(12)Replace right traction (13) Replace left traction
inverter. See page 3-41. inverter. See page 3-41.
(15)Replace left traction inverter. See page 3-41.
(17) Check to see if line contactor tip moves smoothly.

Check line contactor tip for melting.
Normal Abnormal
(18) Measure resistance of contactor coil.

[44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)]
Within range Out of range
(19) Disconnect connectors CN1 and CN4 of logic unit.

Check continuity between CN4-13(4) and contactor (20) Replace line contactor.
coil plus(+)(249). Check continuity between CN1-59
and contactor coil minus(-)(247).
(21) Perform inverter discharging work, then replace logic

card of logic unit. See page 3-46.
4-42
Logic
CN7
CN3
BG 0 to 5V V Traction inverter
5 211 224 3
CAN 0 to 5V L (right)
6 WP 212 229 4 P
CN6
V
224 3 Traction inverter
L (left) P
229 4
Logic
CN1
voltage
-
Output 59 G 247
Line
Power card
contactor
R +
CN4 13 4 249
27V to battery
voltage
Fuse
211239
4-43
Problem: Pump Contactor Fault (42)

(1) Situation
(2) Possible cause

Faulty pump contactor, faulty main harness, faulty logic unit, faulty pump inverter.

Inverter voltage data is checked when contactor is closed (400 mS).
(4) Checks
Error code 42 Error code 65
(5) Block wheels, then confirm pump contactor

operation in self-diagnostics mode [15]. See page 3-35.
Not operated Operated
(8) Check to see if pump contactor tip moves smoothly. (9) Replace pump inverter. See page 3-41.
Check pump contactor tip for melting.
Normal Abnormal
(10) Measure resistance of contactor coil.

[44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)]
Within range Out of range

(12)Replace pump contactor.
Check continuity between CN4-13(4) and contactor
coil plus(+)(250). Check continuity between CN1-60
and contactor coil minus(-)(248).

logic card of logic unit. See page 3-46.
4-44
Logic
CN3 CN5
BG 0 to 5V V
5 211 234 3
CAN WP 0 to 5V L Pump inverter
6 212 239 4 P
Fuse
F
Logic
CN1 27V to battery
voltage
-
Output 60 B 248
B
Pump
Power card 27V to battery contactor
voltage
R R +
CN4 13 4 250
211332
4-45
Problem: Traction Motor R.H. Open (45)

(1) Situation
Display: "45". Traction motor operation inhibited. Pump motor and power steering operations inhibited
(2) Possible cause

Faulty contact or wire breakage of right traction motor cable, faulty right traction motor, faulty contact or wire
breakage of right traction inverter connector, faulty contact of DSP flat cable in right traction inverter, wire
breakage of main harness, faulty power supply card of logic unit, faulty DSP card of right traction inverter,
faulty right traction inverter, when restarting after motor shorted.

Motor voltage is abnormal when power is turned on.
Current does not flow when torque instruction is requested.
(4) Checks
(5) Check right traction inverter and motor for cable

looseness and improper contact.
Normal Abnormal
(6) Disconnect right traction motor cables from inverter.

(7) Secure cable if loose.
Measure resistance of motor cables
(U, V and W phases).
Less than 1Ω 1Ω or more
(8) Check connector CN7 of right traction inverter for (9) Measure resistance between terminals of both cable
looseness. ends (between U and U, V and V, and W and W).
Normal Abnormal Less than 1Ω 1Ω or more
(10) Disconnect connector CN7 of right

traction inverter and remove DSP
cover. Check DSP flat cable for
Normal Abnormal (12) Replace right traction motor. (13) Replace motor cables.
Gate power
supply
(14) Check continuity between CN4-5 and CN7-16(254). (15) Secure DSP flat cable if loose.
CAN
power again.
4-46

Normal Abnormal
If fault remains
(23)Perform inverter discharging work, then replace right

4-47
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
RP 252 14V RP
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4
5 cable W IWR
6
7
19

DSP flat
127 Speed
cable sensor W TWR
Inverter 146
M U TUR
case 145 TVR
V
126
DSP card Thermal
124 sensor
125
211241
4-48
Problem: Traction Motor L.H. Open (46)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of left traction motor cable, faulty left traction motor, faulty contact or wire
breakage of left traction inverter connector, faulty contact of DSP flat cable in left traction inverter, wire breakage
of main harness, faulty power supply card of logic unit, faulty DSP card of left traction inverter, faulty left
traction inverter, when restarting after motor shorted.

Current does not flow when torque instruction is requested.
(4) Checks
(5) Check left traction inverter and motor for cable

looseness and improper contact.
Normal Abnormal
(6) Disconnect left traction motor cables from inverter.

(8) Check connector CN6 of left traction inverter for (9) Measure resistance between terminals of both cable
(10) Disconnect connector CN6 of left

traction inverter and remove DSP
Normal Abnormal
(12) Replace left traction motor. (13) Replace motor cables.
Gate power
supply
CAN
power again.
4-49

Normal Abnormal
If fault remains

4-50
Logic
BG 0 to 5V V 3
CAN 5 WP 211
0 to 5V
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
5 WG 254 12V 259 RY
16 P Fuse
RP 14V 260 RGr 17
Power 3 252
RL 253 8V 261 R 18 N Battery (-)
4 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 Flat
5 cable W IWL
6
7
19

DSP flat
132 Speed
cable sensor W TWL
Inverter 148
M U TUL
case 147
V TVL
131 Thermal
DSP card 129 sensor
130
211242
4-51
Problem: Pump Motor Open (47)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of
pump inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness,
faulty power supply card of logic unit, faulty DSP card of pump inverter, faulty pump inverter, when restarting
after motor shorted.

Current does not flow when rotational speed instruction is requested.
(4) Checks
(5) Check pump inverter and motor for cable looseness

and improper contact.
Normal Abnormal
(6) Disconnect pump motor cables from inverter.

(8) Check connector CN5 of pump inverter for (9) Measure resistance between terminals of both cable
(10) Disconnect connector CN5 of

pump inverter and remove DSP
Normal Abnormal (12) Replace pump motor. (13) Replace motor cables.
Gate power
supply
CAN
power again.
4-52

Normal Abnormal
If fault remains

4-53
Logic
BG 0 to 5V V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
RP 14V RY
Power 3 RL 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4
5 cable W IW
6
7
19
CN20 Pump motor

DSP flat 138 Speed
cable sensor W PW
Inverter
137
M U PU
136 PV
case V
133 Thermal
DSP card 134 sensor
135
211243
4-54
Problem: Steering Sensor Fault (50)

(1) Situation
(2) Possible cause
Faulty steering sensor, faulty main harness, faulty logic unit.

All signal is zero. (longer 200 mS)
(4) Checks
Power supply
(5) Disconnect connectors CN4 of logic unit and CN28 of steering sensor.
Check continuity between CN4-13(4) and CN28(112).
Signal cable

Without With service tool
service tool
(8) Replace steering sensor. (9) Connect connectors CN1 and CN4.
Short-circuit CN28(114) and CN28(113).
Turn on power and check "Steer angle sw."
If fault remains of service tool input/output monitor.
(10)Disconnect battery plug. Reinstall steering sensor and 0001 [bin] Abnormal
replace logic card of logic unit. See page 3-46.
(11) Turn off power. Open CN28(114) and
CN28(113). Short-circuit CN28(115) and
CN28(113). Turn on power and check
"Steer angle sw." of service tool input/
output monitor.
0010 [bin] Abnormal
(12) Turn off power. Open CN28(115) and CN28(113).

Turn on power and check "Steer angle sw." of
service tool input/output monitor.
0100 [bin] Abnormal
(13) Turn off power. Open CN28(116) and CN28(113).

Turn on power and check "Steer angle sw." of
service tool input/output monitor.
1000 [bin] Abnormal
4-55
(14) (15) Disconnect battery plug.

Disconnect battery plug. Replace logic card of
Replace steering sensor. logic unit. See page 3-46.
4-56
Power card
CN28
CN4
R Battery voltage 112 113
13 4
BW 21 114 117
15
GND 115 116
Logic CN28
CN1 112
R
sig 1 53 G 114
G
sig 2 54 W 115
W
Y Y
sig 3 55 116
L L
sig 4 56 117
113 B Steering
sensor
Angle sig 4 sig 3 sig 2 sig 1

Left 0 1 0 0 "0": 12 V
0 1 0 1 "1": 0 V
0 1 1 1
0 1 0
Sensor type is
1
0
open collector.
0 1 0
0 0 1 1
0 0 0 1
Center 1 0 0 0
1 0 0 1
1 0 1 1
1 0 1 0
1 1 1 0
1 1 1 1
1 1 0 1
Right 1 1 0 0
211244
4-57
Problem: Accelerator Sensor Fault (51)

(1) Situation
(2) Possible cause

Improper accelerator pedal linkage, faulty accelerator sensor, faulty main harness, faulty logic unit.

Accelerator sensor voltage is out of range of 0.2 V to 4.8 V.
Sensor voltage is 1.41 V or more when accelerator switch is opened.
Sensor voltage is 0.3 V or less when accelerator switch is closed.
(4) Checks
Raise front wheels until they clear floor.
Without service tool With service tool
(6) Check accelerator sensor voltage with input/output

(5) Disconnect battery plug. monitor and confirm value is in range of 0.2V to 4.8V.
Check relation between sensor voltage and accelerator
switch operation.
0.3V or less: OFF
(7) Check link length of accelerator pedal. 1.41V or more: ON
Abnormal signal Interrupted
Normal Abnormal
(9) Disconnect battery plug. (10) Adjust accelerator

(8) Adjust accelerator pedal
pedal linkage.
linkage.

Disconnect connector CN16 of accelerator sensor.
(13) Check continuity between CN3-20 and CN16(142).

(Sensor voltage)

(Switch)


With service tool
Without
service tool
4-58
Without With service tool

service tool
(17) Replace accelerator pedal. (18)Connect connector CN2 and CN3. Turn on power and
check voltage between CN16(141) and CN16(140).
If fault remains 5V Not 5 V

(20) Turn off power. Short-circuit CN16(141)
and CN16(142). Turn on power and check
accelerator voltage with service tool.
(21) Reinstall accelerator pedal, then replace logic card 5V Not 5 V
of logic unit. See page 3-46.
(22) Turn off power. Open CN16(141) and
CN16(142). Short-circuit CN16(142) and
CN16(143). Turn on power and check
accelerator voltage with service tool.
0V Not 0 V
(23) Replace accelerator (24) Disconnect battery

pedal. plug.
(25) Replace logic card of

logic unit.
See page 3-46.
4-59
CN16
Logic
CN2 143 144 142 141
L 12V/0V
SW 42 144
Accelerator
CN16
L
RW 5V RW
24 141
G 0.30 to 1.40V G
ACCEL ANGLE 20 142
L 140 GND B
23 143
Logic
CN3
211245
4-60
Problem: Traction Motor R.H. Pulse Input Fault (52)

(1) Situation
(2) Possible cause

Faulty contact of right traction inverter connector, faulty connection of right traction motor connector and cable,
faulty 12V input voltage of right traction inverter, faulty contact or wire breakage of right traction motor speed
sensor harness, faulty DSP card of right traction inverter, faulty right traction motor speed sensor.

Motor rotation speed is more than 5800 rpm.
(4) Checks
(5) Check to see if right traction motor cables (U, V and W-

phases) are connected to right traction inverter properly.
Normal Abnormal
(6) Check to see if connector CN7 of right traction

(7) Connect cables properly.
inverter is fastened securely.
Normal Abnormal
(8) Check to see if connector CN14 of right traction

(9) Fasten connector securely.
motor speed sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN
power again.
4-61

Normal Abnormal
(18) Replace DSP card of right traction inverter. See page 3-43. (19) Replace power supply card of logic unit. See page 3-47.
If fault remains

right traction motor. (DSP card is normal.)
See page 6-4.
4-62
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
RP 252 14V RP
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4 12V Y
5 cable W IWR
0 to 5V Y
6
0 to 5V B
7
GND O 19

O 127 Speed
B sensor W TWR
Y
146
M U TUR
145 TVR
Y V
126
Thermal
124 sensor
125
211246
4-63
Problem: Traction Motor L.H. Pulse Input Fault (53)

(2) Possible cause

Faulty contact of left traction inverter connector, faulty connection of left traction motor connector and cable,
faulty 12V input voltage of left traction inverter, faulty contact or wire breakage of left traction motor speed
sensor harness, faulty DSP card of left traction inverter, faulty left traction motor speed sensor.

(4) Checks
(5) Check to see if left traction motor cables (U, V and W-

phases) are connected to left traction inverter properly.
Normal Abnormal
(6) Check to see if connector CN6 of left traction inverter

is fastened securely.
Normal Abnormal
(8) Check to see if connector CN15 of left traction motor

speed sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN

power again.
4-64

Normal Abnormal
If fault remains

traction motor. (DSP card is normal.) See page 6-4.
4-65
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
5 WG 254 12V 259 RY
16 P Fuse
RP 14V 260 RGr 17
4 253 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 12V V 5 Flat
cable W IWL
0 to 5V L
6
0 to 5V G
7
GND O 19

O 132 Speed
G sensor W TWL
L
148
M U TUL
147 TVL
V
V 131 Thermal
129 sensor
130
211247
4-66
Problem: Pump Motor Pulse Input Fault (57)

(1) Situation
(2) Possible cause

Faulty contact of pump inverter connector, faulty connection of pump motor connector and cable,
faulty 12V input voltage of pump inverter, faulty contact or wire breakage of pump motor speed sensor harness,
faulty DSP card of pump inverter, faulty pump motor speed sensor.

Motor rotation speed is zero while current flows to motor.
Motor rotates in reverse.
(4) Checks
(5) Check to see if pump motor cables (U, V and W-phases)

are connected to pump inverter properly.
Normal Abnormal
(6) Check to see if connector CN5 of pump inverter is

fastened securely.
Normal Abnormal
(8) Check to see if connector CN20 of pump motor

speed sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN
power again.
4-67

Normal Abnormal
If fault remains

pump motor. (DSP card is normal.) See page 6-5.
4-68
Logic
BG 0 to 5V V
CAN 5 WP 211
0 to 5V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
RP 14V RY
Power 3 RL 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4 12V L
5 cable W IW
0 to 5V R 6
0 to 5V Y
7
GND V 19
CN20 Pump motor

V 138 Speed
Y sensor W PW
R
137
M U PU
136 PV
L V
133 Thermal
134 sensor
135
211250
4-69
Problem: Display Communication Fault (60)

(1) Situation
Display: "60".
Normal truck operation All truck operations inhibited
(2) Possible cause (2) Possible cause

Faulty main harness, faulty display unit, Faulty logic unit
faulty logic unit.
(3) How the error code is triggered (3) How the error code is triggered
Communication is impossible. Communication is impossible.
Hour meter data of display unit is abnormal.
(4) Checks (4) Checks

Disconnect battery plug, then perform inverter Disconnect battery plug, then perform inverter
discharging work. See page 3-40. discharging work. See page 3-40.
(5) Disconnect connector CN3 of controller. Disconnect (5) Replace logic card of logic unit. See page 3-46.
connector CN8 of display unit.
(6) Check to see if these are shorted to other signal cables. (7) Repair or replace harness.
Not shorted Shorted
(8) Replace display unit. (9) Repair or replace harness.
If fault remains

(11) Replace logic card of logic unit. See page 3-46.
4-70
CN9 Key switch

R
Power card 4
G
CN4 13
Battery +
R CN18
13 4 G
2 10 A
G
Fuse holder
CN8
Logic CN8
CN3 152 149
Battery voltage
151 R
151150
WB 149 0 to 12V G
TXD 14
Display
L 0 to 12V L
RXD 16 150
GND 23 L 140
GND
152 B
211251
4-71
Problem: Logic Card Initialize Failure (61)

(1) Situation
(2) Possible cause

Setup Option Group 3 data not set, Setup Option Group 1 and 2 default data not set, faulty Setup Option data,
faulty logic unit.

Setup Option data is in abnormal setting range.
Other model is set at #40 while steering sensor is installed.
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 3-13.
(5) Set Setup Option Group 3 data. See page 3-25 to 3-27.
(6) Set Setup Option default data. See page 3-13.
(7) Turn on power in "RUN" mode. See page 3-13.
If fault remains
(8) With service tool, set Setup Option Group 3 data.
(9) With service tool, set Setup Option default data.
If fault remains
(13) With service tool, set Setup Option default data.
4-72
Problem: Logics Fault (62)

(1) Situation
(2) Possible cause

Faulty EEPROM data, faulty logic unit.

ROM/RAM SUM value of logic card is different from check data.
EEPROM SUM value of logic card is different from check data.
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 3-13.
(5) Set Setup Option Group 3 data.
(6) Set Setup Option default data.
(7) Turn on power in "RUN" mode. See page 3-13.

Error code "61"
If fault remains "62"
(8) Disconnect battery plug, then perform inverter (9) See troubleshooting for code "61". See page 4-72.

Set Setup Option default data.
4-73
Problem: Traction Inverter R.H. Fault (63)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction inverter,
faulty right traction inverter, faulty main harness, faulty logic unit.

Right traction inverter is connected as pump inverter (CN7-9 is connected to GND).
ROM/RAM SUM value of right traction inverter is different from check data.
Communication with right traction inverter is impossible.
(4) Checks

Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4 and CN7-18(253). (7) Refasten flat cable or replace inverter. See page 3-41.
CAN
(9) Measure resistance of CAN with connectors CN3 and

CN7 disconnected.
Resistance between CN3-5 (211) and CN3-6 (212)
120Ω±5% Other than 120Ω±5%
(10) Perform CAN check of

Pump Inverter Fault (65).
4-74
(11) Measure resistance of CAN for right traction inverter DSP card.
Resistance between CN2-3 and CN2-4 of DSP card side connectors
(12) Replace DSP card of right

traction inverter.
(13) Connect connector CN7 of right traction inverter.

Measure resistance of CAN with connector CN3 disconnected.
Resistance between CN3-5(211) and CN3-6(212)
Mode
(15) Check CN7-8 and CN7-9 that pin is not inserted in.
Normal Abnormal
(16) Connect connector CN4 to logic unit, then turn on power (17) Repair or replace harness.
again.

Normal Abnormal
(20) Replace DSP card of right traction inverter. (21) Replace power supply card of logic unit.
See page 3-43. See page 3-47.
4-75
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
RP 252 14V RP
17
N Battery (-)
4 18 DSP IMS
6 U
mode 1 8
Power card V
mode 2 9 Flat
CN4
cable W
DSP flat
cable
Inverter
case
DSP card
211252
4-76
Problem: Traction Inverter L.H. Fault (64)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction inverter,
faulty left traction inverter, faulty main harness, faulty logic unit.

Left traction inverter is connected as pump inverter (CN6-9 is connected to GND).
ROM/RAM SUM value of left traction inverter is different from check data.
Communication with left traction inverter is impossible.
(4) Checks
(5) Disconnect connector CN6 of left traction inverter and

or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4(253) and CN6-18(261). (7) Refasten flat cable or replace inverter. See page 3-41.
CAN
Mode
(10) Check CN6-9 that pin is not inserted in.

Normal Abnormal
power again.

Normal Abnormal
(15) Replace DSP card of left traction inverter. (16) Replace power supply card of logic unit.
4-77
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
5 WG 254 12V 259 RY
16 P Fuse
RP 14V 260 RGr 17
4 253 DSP IMS
6 20 card U
B
mode 1 8
Power card 262 V
mode 2 9 Flat
CN4
cable W
GND
DSP flat
cable
Inverter
case
DSP card
211253
4-78
Problem: Pump Inverter Fault (65)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter,
faulty pump inverter, faulty main harness, faulty logic unit.

Pump inverter is connected as traction inverter (CN5-9 is opened).
ROM/RAM SUM value of pump inverter is different from check data.
Communication with pump inverter is impossible.
(4) Checks

or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4(253) and CN5-18(267). (7) Refasten flat cable or replace inverter. See page 3-41.
CAN
(9) Measure resistance of CAN with connectors CN5 and CN3 disconnected.
(10) Perform CAN check of Traction

Inverter R.H. Fault (63).
(11) Measure resistance of CAN for pump inverter DSP card.

Resistance between CN2-3 and CN2-4 of DSP card side connectors
(12) Replace DSP card of pump

inverter.
4-79
(13) Connect connector CN5 of pump inverter.

Measure resistance of CAN with connector CN3 disconnected.
Mode
(16) Check CN5-8 that pin is not inserted in.

Normal Abnormal
power again.

Normal Abnormal
(21) Replace DSP card of pump inverter. (22) Replace power supply card of logic unit.
4-80
Logic
BG 0 to 5V V
CAN 5 WP 211
0 to 5V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG
16 P
RP 14V RY
Power 3 RL 252 8V
266 17
RW N Battery (-)
4 253 267 18 DSP IMS
B 255 GND 268 B20 card card
6 U
mode 1 8
Power card mode 2 B V
9 Flat
CN4 263
cable W
GND
DSP flat
cable
Inverter
case
DSP card
211254
4-81
Problem: Contactor Coil Fault (72)

(1) Situation
Display: "72". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN.
(2) Possible cause

Faulty line contactor, faulty pump contactor, faulty main harness, faulty logic unit.

With short circuit detection signal of logic card.
(4) Checks
(5) Find faulty contactor (line contactor or pump

contactor) with input/output monitor.
(7) Check line contactor or pump contactor. (Check faulty contactor if found with service tool.)
Line contactor Pump contactor
(8) Remove coil side terminals of (14) Remove coil side terminals of
line contactor. Disconnect connector pump contactor. Disconnect
CN1 of logic unit. connector CN1 of logic unit.
(9) Check short circuit between coil (15) Check short circuit between
terminal plus(+)(249) and minus(-) coil terminal plus(+)(250) and
(247) of harness. minus(-)(248) of harness.
Not shorted Shorted Shorted Not shorted
(10) Measure coil resistance. (16) Measure coil resistance.

[44Ω at -30 °C (-22 °F) to (11) Repair or replace main harness. [44Ω at -30 °C (-22 °F) to
66Ω at 80 °C (176 °F)] 66Ω at 80 °C (176 °F)]
Abnormal Normal Normal Abnormal
(12) Replace line contactor. (13) Replace logic card of logic unit. (17) Replace pump contactor.
See page 3-46.
4-82
Power card
27V to
R battery voltage
+
CN4 13 4 249
27V to
battery voltage
247 -
Logic
Line contactor
CN1
+
G 250
59
B
60 27V to
battery voltage
248 -
Pump contactor
211257
4-83
Problem: Hydraulic Lock Solenoid Fault (74)

(1) Situation
Display: "74". Pump motor operation inhibited. Normal traction motor operation and power steering operation.
(2) Possible cause

Faulty unload valve, faulty lift lock valve, faulty main harness, faulty logic unit.

With short circuit detection signal of logic card.
(4) Checks
(5) Find faulty valve (unload valve or lift lock valve) with
input/output monitor.
(7) Disconnect connector CN4 of logic unit. (Check faulty valve if found with service tool.)
Unload valve Lift lock valve
(8) Disconnect connector CN1 of logic (14) Disconnect connector CN1 of logic
unit. Disconnect connector CN27 unit. Disconnect connector CN24
of unload valve. of lift lock valve.
(9) Check short circuit between CN27 (15) Check short circuit between
(317) and CN27(318). CN24(308) and CN24(309).
Not shorted Shorted Shorted Not shorted
(10) Check short circuit between (16) Check short circuit between lift
(11) Repair or replace main harness. lock valve side connectors.
unload valve side connectors.
Measure coil resistance. Measure coil resistance.
[7.5Ω at -30 °C (-22 °F) to [7.5Ω at -30 °C (-22 °F) to
12.8Ω at 80 °C (176 °F)] 12.8Ω at 80 °C (176 °F)]
Shorted Not shorted Normal Abnormal
(12) Replace unload valve. (13)Replace logic card of logic unit. (17) Replace lift lock valve.
See page 3-46.
4-84
Power card
CN4 CN27
R G
13 4 318
Unload
Logic B valve
317
CN1 CN27
B
64
317 318
Logic
Harness B CN24
CN1
309
Y
57 Y Lift
lock
58 B B
308 valve
CN24
308 309
Harness B
211258
4-85
Problem: Battery Voltage Too Low (78)

(1) Situation
(2) Possible cause

Faulty or discharged battery, low voltage battery, improper battery voltage setting (Setup Option #41), improper
battery voltage adjustment setting (Setup Option #46), faulty main harness, faulty logic unit.

Corrected battery voltage is too low.
Battery voltage is corrected with #46 value.
36 V battery: less than 30 V 48 V battery: less than 42 V
(4) Checks
Disconnect battery plug.
Measure battery voltage with multimeter.
36 V battery: 34 V to 42 V, 48 V battery: 45 V to 60 V Abnormal
(5) Turn on power in Setup Option Group 3 setting.

See page 3-13. (6) Charge battery or replace with proper battery.
(7) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 3-25 to 3-27.
(8) Turn off power and turn on power again.
If fault remains

(10) Check continuity between CN3-19(269) and contactor

POS(3).
(11) Perform inverter discharging work, then replace logic (12) Repair or replace main harness.
4-86
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
4-87
Problem: Battery Voltage Too High (79)

(1) Situation
(2) Possible cause

Faulty or highly charged battery, high voltage battery, improper battery voltage setting (Setup Option #41),
improper battery voltage adjustment setting (Setup Option #46), faulty logic unit.

Corrected battery voltage is too high.
36 V battery: more than 42 V 48 V battery: more than 60 V
(4) Checks
Measure battery voltage with multimeter
36 V battery: 34 V to 42 V, 48 V battery: 45 V to 60 V Abnormal
(5) Turn on power in Setup Option Group 3 setting.

See page 3-13. (6) Replace with proper battery.
(7) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 3-25 to 3-27.
(8) Turn off power and turn on power again.
If fault remains


POS(3).
(11) Perform inverter discharging work, then replace logic (12) Repair or replace main harness.
4-88
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
4-89
Problem: Direction Lever or Accelerator, Faulty Setting (E)

(1) Situation
Display: "E". Traction motor operation inhibited. Normal pump motor and power steering operations.
Line contactor OPEN.
(2) Possible cause

Key switch turned on while direction lever was left either in forward or reverse position, key switch turned on
while accelerator pedal was depressed, seat switch turned off during running, faulty direction lever switch,
faulty accelerator sensor, faulty main harness, faulty logic unit.

Detects following signal when turning on power.
Direction lever: F or R Accelerator sensor voltage: More than 0.3 V
(4) Checks
Move direction lever to neutral, and release accelerator pedal.
If fault remains
(5) Turn off power. Move direction lever to neutral, release

accelerator pedal, then turn on power again.

With service tool
(6) Check direction lever and accelerator sensor operations (7) Turn on power in diagnostics mode. Inspect direction
with input/output monitor. lever and accelerator sensor. See page 3-32.
(8) Turn off power. (Check faulty unit if found with service tool.)
Direction lever Accelerator sensor
(9) Disconnect connector CN10 of direction lever.

Turn on power. (10) Refer to error code "51". See page 4-58.
Normal (E)
(11) Replace direction lever. (12) Disconnect connectors CN2 and CN3 of logic unit.
(13) Check short circuit between CN4-15(21) and

CN2-36(104), CN4-15(21) and CN2-37(103).
Not shorted Shorted
(15) Repair or replace

main harness.
4-90
Logic
CN2 CN10
0/12V OL
Forward 37 OL 103 F
Br Direction
Reverse 36 Br 104
0/12V
R lever
GND
102
G
B2
Accel idle 42 L 144
switch CN10
1
104 103
Power card 102
CN4
Main harness
GND 15 BW 21
0/12V
Accelerator
Logic CN16
CN3 L
+ 5V 24 RW 141 5V RW
G 142 0 to 5V G
ACCEL ANGLE 20
L 140 GND B
GND 23 143
CN16
143 144 142 141
Main harness
213095
4-91
Problem: Seat Switch, Faulty Setting For Traction ((E))

(1) Situation
Display: "E" flashes. Traction motor operation inhibited. Normal pump and power steering operations.
Line contactor OPEN.
(2) Possible cause

Operator not on seat, seat switch turned off during running, improper seat suspension adjustment,
faulty seat switch, faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during running.
(4) Checks
If this fault occurred If this fault occurred when
during running turning on power
(5) Stop truck, then move direction lever to neutral.

Sit properly in operator's seat and release accelerator pedal.
If fault remains Normal
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position
(10) Disconnect connector CN25, then short-circuit

between terminals (110) and (111). Turn on
power again.

(12) Replace seat switch.

Check continuity between CN25(110) and CN3-25(108).
Check continuity between CN25(111) and CN2-33.
(14) Replace logic card of logic unit. See page 3-46. (15) Repair or replace main harness.
4-92
Logic
CN2
0/12V G
32
0/12V YW
33
Seat belt switch CN25
G 310 Logic
YW 111 CN3
G 110 GND W
108 25 GND
Seat switch CN25
111 110 310
Main harness
211261
4-93
Problem: Seat Switch, Faulty Setting For Hydraulic ((L))

(1) Situation
Display: "L" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault
occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN
if truck stops.
(2) Possible cause

Operator not on seat, seat switch turned off during pump motor operation, improper seat suspension adjustment,
faulty seat switch, faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during pump operation.
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
(5) Sit on seat, then stop pump motor operation.

Fail-safe function
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position
(10) Disconnect connector CN25, then short-circuit

between terminals (110) and (111). Turn on
power again.
(11) Disconnect battery plug, then perform inverter (12) Replace seat switch.

Check continuity between CN25(110) and CN3-25(108).
Check continuity between CN25(111) and CN2-33.
4-94
Logic
CN2
0/12V G
32
0/12V YW
33
Seat belt switch CN25
G 310 Logic
YW 111 CN3
G 110 GND W
108 25 GND
Seat switch CN25
111 110 310
Main harness
211261
4-95
Problem: Lift Lever, Faulty Setting (H1)

(1) Situation
Display: "H1" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault
if truck stops.
(2) Possible cause

Key switch turned on while operating lift lever, faulty lift switches 1 and 2, faulty main harness, faulty logic unit.
(3) How the error code is triggered.

Detects lift microswitch 1 or 2 when turning on power.
(4) Checks

Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again
without lift operation.
Error code
If fault remains "L" flashes
(7) Turn off power. (8) Refer to error code "(L)".
(9) Disconnect connector CN22 of microswitch. Sit on seat,

then turn on power again.
(10) Disconnect battery plug, then perform inverter (11) Replace lift switch 1 or 2.

Check short circuit between CN22(303) and CN22(302).
Continuity, Not shorted No continuity, Shorted
(13) Disconnect battery plug. (14) Repair or replace main harness.
4-96
Logic
CN22 CN1
Lift 1
0/12V
304 W 51
GND
302
Lift 2 Logic
CN3
W
108 25
302 304 CN22
305 303 Logic
306 307 CN1
0/12V Y
Main harness 303 52
213147
4-97
Problem: Tilt Lever, Faulty Setting (H2)

(1) Situation
if truck stops.
(2) Possible cause

Key switch turned on while operating tilt lever, faulty tilt switch, faulty main harness, faulty logic unit.

Detects tilt microswitch when turning on power.
(4) Checks

Fail-safe function
without tilt operation.
Error code
(9) Disconnect connector CN22 of microswitch. Sit on seat,

then turn on power again.
(10) Disconnect battery plug, then perform inverter (11) Replace tilt switch.

4-98
Logic
CN22 CN1
Tilt 0/12V L
305 50
302
GND Logic
CN3
W
108 25
302 304 CN22
305 303
306 307
Main harness
213148
4-99
Problem: Attachment 1 Lever, Faulty Setting (H3)

(1) Situation
if truck stops.
(2) Possible cause

Key switch turned on while operating attachment 1 lever, faulty attachment 1 switch, faulty main harness, faulty logic
unit.

Detects attachment 1 microswitch when turning on power.
(4) Checks If this fault occurred during If this fault occurred when

Fail-safe function
without attachment 1 operation.
Error code
(9) Disconnect connector CN22 of microswitch.

Sit on seat, then turn on power again.
(10) Disconnect battery plug, then perform inverter (11) Replace attachment 1 switch.

Check short circuit between CN22(306) and
CN22(302).
4-100
CN22 Logic
CN3
GND W
302 108 25
Aux 1
Logic
CN1
0/12V G
306 49
302 304 CN22
305 303
306 307
Main harness
213149
4-101

(1) Situation
if truck stops.
(2) Possible cause

Key switch turned on while operating attachment 2 lever, faulty attachment 2 switch, faulty main harness, faulty logic
unit.

Detects attachment 2 microswitch when turning on power.
(4) Checks

Fail-safe function
without attachment 2 operation.
Error code
(9) Disconnect connector CN22 of microswitch.

Sit on seat, then turn on power again.
(10) Disconnect battery plug, then perform inverter (11) Replace attachment 2 switch.

Check short circuit between CN22(307) and
CN22(302).
4-102
CN22 Logic
CN3
GND W
302 108 25
Aux 2
Logic
CN1
0/12V R
307 48
302 304 CN22
305 303
306 307
Main harness
213150
4-103

(1) Situation
if truck stops.
(2) Possible cause

Faulty logic unit.

Detects attachment 3 signal when turning on power.
(4) Checks

Fail-safe function
If fault remains
(7) Check to see if dust is accumulated on terminal CN1-47.
Normal Abnormal
(8) Clean terminal.

If fault remains
4-104
Logic
CN1
47 Attachment 3
switch
Logic
CN3
25 GND
211266
4-105
Problem: Battery Consumption Too Much ((Lo))

(1) Situation
Display: "Lo" flashes. Battery low indicator ON. All truck operations inhibited.
(2) Possible cause

Extremely consumed battery, faulty main harness, faulty logic unit.

Corrected battery voltage is less than 22 V.
(4) Checks
(5) Check battery voltage.

22V or more Less than 22V
(6) Set #46 of Setup Option Group 3. See page 3-27. (7) Charge battery or replace with new battery.
If fault remains

POS(3).
4-106
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
4-107
Problem: Battery Consumption Much (Lo)

(1) Situation
Battery low indicator flashes. Traction motor operation restricted to "ECONOMY" mode. Normal pump motor
and power steering operations.
(2) Possible cause

Consumed battery, improper battery voltage adjustment setting (Setup Option #46), faulty main harness,
faulty logic unit.

Corrected battery voltage is less than 25 V.
(4) Checks
(5) Check battery voltage.

25V or more Less than 25V
(6) Set #46 of Setup Option Group 3. See page 3-27. (7) Charge battery or replace with new battery.
If fault remains

POS(3).
4-108
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
4-109
Locations of Major Components and Connectors
NOTE
1. The figures described below contain the major components and connectors based on the actual model.
2. The component names are basically quoted from the Electrical Schematic and some of the names may be
different from the text and the Electrical Diagram.
Logics, micro switches and connectors
Seat assy
Micro switch CN22
Logics GSE CN21 Logics power CN4
Seat harness
Control valve
Logics
DRS switch CN17
211343
4-110
Head lamp (R)
Head lamp (L)
Display
FNR lever assy
CN10
CN8
Horn
PDS relay
PDS buzzer
CN15
CN14
211290
Accelerator, foot brake switch, park brake switch, brake fluid sensor and connectors
Horn SW
Park brake SW
CN11
Accelerator CN16
Brake fluid sensor
Foot brake SW
211291
4-111
Motors, inverters, contactor panel assembly and battery cable
Traction motor R Traction inverter (L)
Traction inverter (R)
Battery cable
Pump inverter
Contactor panel assy
Traction motor L
Pump motor 211288
Wheel angle sensor, backup buzzer, working lamp and connectors
Working lamp
Backup buzzer
Inverter pump CN5
Inverter trac (L) CN6
Inverter trac (R) CN7
Wheel angle sensor
CN28
CN20
211292
4-112
MITSUBISHI CATERPILLAR FORKLIFT
AMERICA INC.
SCHEMATIC(S) INSERTION
Schematic(s) name/number
Replace this page with page 1 of 2

99719-88110s.pdf
4-113
MITSUBISHI CATERPILLAR FORKLIFT
AMERICA INC.
SCHEMATIC(S) INSERTION
Schematic(s) name/number
Replace this page with page 2 of 2

99719-88110s.pdf
4-115
POWER TRAIN
Procedures and Suggestions for Removal and Installation ....... 5–1

Removal .................................................................................................... 5–1
Installation ................................................................................................. 5–7
Service Data ............................................................................................ 5–9
5
POWER TRAIN
Procedures and Suggestions for Removal and Installation

Removal
1. Remove the masts.
(Refer to MASTS AND FORKS section.)
2. Removing batteries
(2) Open the battery cover, and lock it in the open
position.
(3) Remove the side covers (L.H., R.H.) and front
covers (L.H., R.H.).
213016
(4) Attach suspending ropes or adequate lifting device

to the batteries.
Unit: kg (lb)
Truck Model ET3500,
ET3000
Item ET4000
Battery weight 1090 1225
(maximum) (2403) (2700)
(5) Remove the battery retaining plate and pin, and

then remove the batteries. 206918
5-1
POWER TRAIN
3. Removing front wheels

(1) Pull the parking brake lever and block the rear
wheels.
(2) Loosen the wheel nuts by two turns. Then, raise
the front end of the truck using a hoist or the
hydraulic system.
(a) Hoisting
Using a sling and eye-bolts at both ends of the
cross member at the top of the outer mast, lift the
front end of the truck with a hoist.
(b) Using hydraulic system
Tilt the mast fully backward and place wood
blocks under the mast. Tilt the mast forward to
raise the front end.
! CAUTION
After raising the front end, place wood blocks
under the frame to prevent the truck from falling.
210757
(3) Remove the wheel nuts.

(4) Remove the wheel.
Truck Model
1 ton class 2 ton class Cushion tire
Item
Tire size of front 18 × 7 × 12 1/8 18 × 7 × 12 1/8
wheels
211344
4. Removing steps and floor plates

(1) Steps (L.H., R.H.) (3)
(2) Step plates (L.H., R.H.) Floor plate B
(3) Floor plate
(1) (1)
(2)
Remove floor plate B. Floor plate A
Disconnect the accelerator connector mounted on the
back side of the floor plate, then remove floor plate A. (2)
211153
5-2
POWER TRAIN
5. Removing steering hoses

Disconnect the steering hoses and pipes at the
connectors.
206922
6. Removing delivery pipe and drive motor harness

(1) Remove the drive motor harness at the connector.
Disconnect the harnesses of the thermal and speed
sensors located on the right and left sides.
(2) The harnesses are secured to the delivery pipe
with clamps. Loosen the clamps, and remove the
delivery pipe.
Delivery
pipe
211345
5-3
POWER TRAIN
7. Removing brake components
(i)
(ii)
(iii)
(v)
(iv)
(vi)
206824
(1) Loosen the parking brake lever, and remove

parking brake cable assemblies (i) (L.H.) and (ii)
(R.H.).
Disconnect the parking brake cables at the
calipers, and keep the cables together on the frame
near the center brake.
(2) Position a drip pan, and disconnect brake fluid
tube (iii) at the master cylinder.
(3) Disconnect brake pipes (iv, v) (L.H., R.H.) at the
master cylinder. Disconnect the branch brake
hoses (L.H., R.H.) from the brake pipes.
(4) Remove brake pedal assembly (vi).
5-4
POWER TRAIN
8. Removing return hoses

Remove return hose (1) from the control valve, and
(1)
return hose (2) from the lift cylinder.
(2)
206925
9. Remove drive motors cables (L.H., R.H.).

10. Removing tension rods and brackets (3) (3)
Loosen right and left nuts (1) by approximately 6 mm
(0.24 in.). Left (2) (2) Right
transfer (4) transfer
Remove bolts (2), and take out bracket (3) and tension
bolt (4) together from each side of the vehicle.
(1)
206926
5-5
POWER TRAIN
11. Removing transfer assemblies, drive motors and

calipers
Left Right
transfer transfer
(iii)
Gravity
center
(ii) (ii)
(i)
(i)
Frame
Frame
(iv) Gravity (iii) (iv)
center
206927
Remove the transfer assemblies with the drive motors

and calipers mounted.
First, dismount the left transfer, lower it, then pull it
out from the front of the vehicle. Then, dismount the Cow hitch
right transfer, lower it, then pull it out from the front.
(1) When suspending the assembly, position the wire
rope at the gravity center.
The suspending wire rope must be cow hitched.
When using a textile sling, make two loops to 206928
prevent slipping.
(2) Remove bolt (i) from the lower part of the step Total weight of transfer, 115 kg
and remove bolt (ii) from the frame, then remove drive motor and caliper (253.5 lb)
the assembly.
(3) Remove bolt (iii), and dismount the caliper
assembly.
(4) Remove bolt (iv) and dismount the drive motor.
(See illustration No. 206927.)
5-6
POWER TRAIN
Installation
Follow the removal sequence in reverse. For installation,
follow the instructions below.
! CAUTION
When mounting the transfer assembly on the
frame, do not insert a finger into the bolt hole to
check hole alignment.
1. Be sure to tighten bolts to the specified torque.
Front of vehicle
3 4 4 3
5 5
2
1 1
206785
A: Standard value
Drive motor mounting bolt 1 A 108 ± 10 (11 ± 1) [79.56 ± 7.23]
Transfer assembly mounting bolt 2 A 508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]
Tightening torque
Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]
N·m (kgf·m) [lbf·ft]
Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]
Hub nut 5 A 157 (16) [115.8]
2. Bleed the brake oil line.

(Refer to BRAKE SYSTEM section.)
5-7
POWER TRAIN
3. After installing the parking brake cable, be sure to

adjust.
(Refer to BRAKE SYSTEM section.)
4. Pour oil into the transfer cases:
Left transfer
Remove oil level plug (1).
Remove oil inlet plug (2).
(2)
Pour appropriate oil in the oil inlet. Make sure the oil
level reaches the level plug location.
Unit: liter (U.S. gal)
(1)
Left transfer Right transfer
1.09 1.86
Oil quantity
(0.29) (0.49) Front
of
vehicle
Right transfer
(2)
(1)
206786
5. Bleeding hydraulic oil line and inspecting oil level

Operate the tilt cylinders in the forward and backward
directions to bleed the tilt cylinders. Operate the lift
cylinders in the vertical directions to fill the cylinders
with oil.
Lower the lift cylinders to the lowest position, and
check the oil level gauge. If the oil level is low, add oil
to the specified level.
6. Checking steering oil line
Operate the steering wheel to make sure that it operates
smoothly.
5-8
POWER TRAIN
Service Data
A : Standard value
Truck Models 1 ton class 2 ton class

Item
Drive motor mounting bolt 1 A 108 ± 10 (11 ± 1) [79.56 ± 7.23]
Tightening torque Transfer assembly mounting bolt 2 A 508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]
N·m Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]
(kgf·m)
[lbf·ft] Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]
Hub nut 5 A 157 (16) [115.8]
3 4 4 3
Power Train
5 5
2
1 1
206785
5-9
MOTORS
Motor Installation Positions ................................................................ 6– 1

Specifications .......................................................................................... 6– 1
Structures ................................................................................................. 6– 2
Tightening of High-power Cable Terminals ..................................... 6– 3
Procedures and Suggestions for Removal and Installation ....... 6– 4
Procedures and Suggestions for Disassembly and
Reassembly .......................................................................................... 6– 6
Troubleshooting ...................................................................................... 6– 8
Service Data ............................................................................................ 6– 9
6
MOTORS
Motor Installation Positions
Brake discs
Pump motor
Traction motor
Output shaft
211164
Specifications
Item Traction Motor Pump Motor
Type Induction, three-phase AC Induction, three-phase AC
Voltage (V) 48 36 48 36
Output (kW) 6.3 kW [6.3 kW 14 kW [14 kW

(S2 60 min.) (S2 60 min.)] (S3 15%) (S3 15%)]
Weight kg (lb) 50 (110) 46 (101)
6-1
MOTORS
Structures
Traction Motor
Thermal and speed

sensor connector
U, V, W terminals
211165
Pump Motor
U, V, W terminals
Thermal and speed

sensor connector
211166
The AC motor model lift trucks covered by this manual For the feature and speed control of AC motors, see
use three-phase induction AC motors as the traction “AC Motor System Basics” in CONTROLLER section.
motors and pump motor.
6-2
MOTORS
Tightening of High-power Cable Terminals
! CAUTION
If the high-power cable terminals of the battery-
operated vehicle are not tightened properly, the
increased contact resistance causes excessive Right traction motor
heat generation, and could cause a fire in the (3 terminals)
worst case. To prevent accidents and equipment
problems, be sure to regularly check the
tightening torque of the high-power cable Left traction motor
(3 terminals)
terminals. Do not pull the cables to check
connections or during adjustment. If the cable
terminal sections are moved, re-tighten the
connections.
Pump motor
Number of (3 terminals)
Name of Motor Tightening Torque
Terminals
15 N·m
Traction motor 3 (1.5 kgf·m)
[11 lbf·ft]
15 N·m
Pump motor 3 (1.5 kgf·m)
[11 lbf·ft]
211167
6-3
MOTORS
Traction Motors
Removal
(2) Using a crane, remove the head guard and batteries.
(3) Remove the floor plate and battery cover.
(4) Disconnect the harness and cables connected to the
motor.
(5) Remove the brake caliper.
(6) Remove the bolts that secure the front axle on the
vehicle frame. With the traction motor still mounted on
the vehicle, remove the front axle from the vehicle
frame.
(7) Using a crane, lift the traction motor to suspend it.
NOTE
Position the hook above the gravitational center of the
traction motor.
Installation
Follow the removal sequence in reverse. 206902
6-4
MOTORS
Pump Motor
Removal
(2) Remove the controller cover and the battery partition
plate.
(3) Disconnect the harness, cables and pipes connected to
the motor.
(4) Remove the pump motor.
Installation
6-5
MOTORS
Procedures and Suggestions for Disassembly and Reassembly
Disassembly
Traction motor
10
12 11
1 2
5
8
6 7
3 4
211168
Sequence
1 Drive end cover 6 Seal 11 Terminal
2 Commutator end plate 7 Sensor bearing 12 Terminal base
3 Rotor 8 Wavy washer
4 Stator 9 O-ring
5 Ball bearing 10 Sensor connector
6-6
MOTORS
Pump motor
2 4 3 11 10
8
5 7
6
211169
Sequence
1 Commutator end plate 5 Ball bearing 9 O-ring
2 Drive end cover 6 Seal 10 Sensor connector
3 Rotor 7 Sensor bearing 11 Terminal
4 Stator 8 Wavy washer
Suggestion for Disassembly and Reassembly

Ball bearings at both ends are of maintenance free. If it is
necessary to remove the bearings when repairing the motor,
the bearings and seals must be replaced.
If a bearing which is to be replaced has only one sealing
lip, it should be greased with quality bearing grease when
installing it.
Replace the bearings and seals after approximately 10,000
operating hours.
6-7
MOTORS
Troubleshooting
Low supply voltage Charge battery and improve power
supply condition.
Blown fuse Replace.
Motor does not Excess load Reduce load.
start. Faulty wire connection Repair, or re-tighten wire connections.
Broken wire in control device Repair or replace.
Broken wire in field coil Repair or replace.
Broken wire in armature coil Repair or replace.
Motor starts but Low supply voltage Charge battery and improve power
does not run at supply condition.
rated speed. Faulty connection of armature circuit Repair connections.
Motor produces Defective bearings Replace bearings.

abnormal
vibrations Loose mounting bolts Retighten bolts and nuts.
and noise. Contact between armature and field coil Repair or replace.
Incorrect installation Correct installation condition.

Severe external vibration Remove the cause of vibration, or take
Bearing appropriate vibration-insulating
overheats. measures.
Defective bearings Replace.
Oil degradation or shortage in bearings Replace.
6-8
MOTORS
Service Data
A: Standard value
Unit: mm (in.)
Truck Models
1 ton class 2 ton class
Item
Traction motor and pump motor
Stator coil insulation resistance A 1 MV min.
U–V A 0
Traction motor
Terminal conductivity
V–W A 0
(V)
Pump motor
W–U A 0
N·m 15 N·m
Cable terminal tightening torque (kgf·m) (1.5 kgf·m)
[lbf·ft] [11 lbf·ft]
6-9
TRANSFER UNITS
Specifications .......................................................................................... 7 – 1
Structure and Functions ....................................................................... 7 – 2
Reassembly ............................................................................................. 7 – 4
Disassembly ............................................................................................. 7 – 4
Inspection after Disassembly .................................................................... 7 – 5
Reassembly .............................................................................................. 7 – 6
Service Data ............................................................................................ 7 – 8
7
TRANSFER UNITS
Specifications
Truck Model
Item 1 ton class 2 ton class
Gear type Constant-mesh type, 3 stages (helical gears)

Transfer
58 x 83 x 45 =20.151
Reducing gear ratio
24 16 28
7-1
TRANSFER UNITS
Structure and Functions (Part 1)
Front of vehicle
7
7
A 8 8 A
6 6
1 3
4
5
2
206785
1 Transfer (left) 6 Wheel hub

2 Drive motor (left) 7 Front tire
3 Transfer (right) 8 Bracket
4 Drive motor (right) 9 Tension rod
5 Frame Section A: Mast support mounting section
Since two drive motors are installed in a limited space, Sections A support masts.
the drive motors are offset in position.
Tension rod 9 connects brackets 8, and includes a
turnbuckle to serve as a thrust rod for the left and right
transfer units.
7-2
TRANSFER UNITS
Structure and Functions (Part 2)
17
7 Left side
9 10 14 5
6
16
17
11
Front of vehicle
6 12 13
Right side
4
16
15
3 1
15
2 (View from left side)
Bolts marked with × : Bolts for mounting transfer units to frame 211346
1 Drive motor 8 Main case 15 Ball bearing

2 Input gear 9 Nut 16 Oil level plug
3 Second gear 10 Plate 17 Air breather
4 Third gear 11 Spacer
5 Output shaft 12 Retainer
6 Wheel hub 13 Taper roller bearing
7 Cover 14 Oil seal
The left and right transfer units are identical, and are Helical gears are used for reduced operating noise.
mounted on the frame with bolts marked with an × in The output shaft is provided with two taper roller
the diagram. bearings to withstand heavy loads.
The left and right transfer units are installed to the drive
motors. The motor shafts are jointed to the involute
Transfer reducing
splines of the input gears. 20.151
gear ratio
Driving force is transmitted via the input gear, second
gear, third gear, then to the output shaft that rotates the
wheel hub.
7-3
TRANSFER UNITS

Preparation
1. Remove the power train consisting of the transfer, 2. Drain oil from the transfer.
drive motor and caliper. (Refer to Removal and 3. Remove the drive motor and caliper.
Installation of Power Train.)
Disassembly
8
12
9 19
7
6
5
4
3 10
11
18
16
17 14
15 13
18
2 16 14
1
211047
Sequence
1 Bolt 10 Output shaft, O-ring
Remove parts 2 to 12 as sub-assembly. 11 Taper roller bearing
2 Cover 12 Oil seal
3 Cap 13 Input gear
4 Nut 14 Ball bearing
5 Plate 15 Second gear
6 Spacer, O-ring 16 Ball bearing
7 Wheel hub, Hub bolt 17 Third gear
8 Taper roller bearing 18 Ball bearing
9 Retainer 19 Main case, Dowel pin
7-4
TRANSFER UNITS
Suggestions for Disassembly
1. Removing nut 4
Nut 4 is secured to output shaft 10 by punching.
Use a chisel to scrape punched section carefully. Do not
scratch output shaft 10.
Nut 4 is not reusable.
206789
2. Cover 2
Outer laces of taper bearings 8 and 11 that are press-fit into
cover 2 do not have to be disassembled if inspection finds
no abnormality.
Remove oil seal 12, and use a new seal.
Inspection after Disassembly

1. Inspect the gear teeth and splines for wear and damage.
2. Inspect the bearings for wear, damage, rotating
resistance and noise.
3. Inspect main case 19 and cover 2 for cracking and
damage.
4. Inspect the oil seal contact surface of retainer 9 for
scratches and damage.
7-5
TRANSFER UNITS
Reassembly
1 12
6 4 5
11
10
9 14
7 3 2
14
13
15
16
16
18
17
18
19
211048
Sequence
Assemble parts 1 to 4 prior to final assembly. 8 Spacer, O-ring
1 Cover 9 Plate
2 Taper roller bearing (outer) 10 Nut
3 Taper roller bearing (outer) 11 Cap
4 Oil seal 12 Main case
5 Output shaft, Inner lace of taper roller bearing 13 Third gear
2, O-rings 14 Ball bearing
Assemble parts 6 and 7, and inner lace of taper roller 15 Second gear
bearing 3 prior to final assembly. 16 Ball bearing
6 Wheel hub, Hub bolt 17 Input gear
7 Retainer 18 Ball bearing
Install sub-assemblies 5 and 6 in cover 1. 19 Bolt
7-6
TRANSFER UNITS
Suggestions for Reassembly

1. Inspect the mounting surfaces of cover 1 and main case
Unit: mm
12 for dents and burrs, and clean the surfaces.
2. To install oil seal 4, use a jig. Tap the jig to fit the oil 3- φ16.5
seal evenly. 2- φ18
Apply a thin coat of liquid gasket (Three Bond #1104) 80
109
on the oil seal mounting surface of cover 1.
50
68
54
3. Tighten nut 10, and check the preload of taper roller
.2
bearings 2 and 3. 10
When tightening the nut, insert vinyl tubes on three
symmetrical locations relative to the hub bolt and use a
hub holding tool. 207207
Hub holding tool: To be fabricated at service location
NOTE
Cut a vinyl tube with an inside diameter of 14 mm

(0.55 in.) into pieces of 25 mm (1 in.) in length, and
use these vinyl tube pieces to protect the screw sections
when using the spring scale for measurement.
Preload
Tangential force 59 to 88 N
206791
on hub bolt (6 to 9 kgf)
[13.3 to 19.8 lbf]
4. After checking preload, stake one side of nut 10 with a

dull punch to secure the nut in place.
Make sure the groove is flattened completely and the
Unit: mm (in.)
flattened area measures more than 4 mm (0.16 in.) in
diameter.
5. When installing cover 1 sub-assembly on main case

12, apply a thin coat of liquid gasket (Three Bond
#1104) on the mounting surfaces.
φ4
Tighten bolt 19 to the specified torque. (0.16)
108 ± 10 N·m
Bolt tightening torque (11.0 ± 1.0 kgf·m)
206792
[79.7 ± 7.4 lbf·ft]
7-7
TRANSFER UNITS
Service Data A: Standard value

Unit: mm (in.)
Truck Model
Item
Input gear and second gear 1 A 0.11 to 0.24 (0.0043 to 0.0094)
Gear backlash Second gear and third gear 2 A 0.11 to 0.24 (0.0043 to 0.0094)
Third gear and output shaft 3 A 0.12 to 0.30 (0.0047 to 0.0118)
Preload of output shaft and taper roller bearing 4
Tangential force on hub bolt A 59 to 88 (6 to 9) [13.3 to 19.8]
N (kgf) [lbf]
Tightening torque of cover mounting bolt 5
N·m (kgf·m) [lbf·ft] A 108 ± 10 (11.0 ± 1.0) [79.7 ± 7.4]
Transfer
211049
7-8
REAR AXLE

Rear Wheels ............................................................................................. 8 – 2
Procedures and Suggestions for Removal and Installation ........ 8 – 3
Rear Wheels ............................................................................................. 8 – 3
Rear Axle .................................................................................................. 8 – 4
Reassembly ............................................................................................. 8 – 7
Steering Axle ............................................................................................ 8 – 7
Rear Axle Assembly .................................................................................. 8 – 10
Inspection and Adjustment ................................................................. 8 – 14
Making sure of Minimum Turning Radius .................................................. 8 – 14
Service Data ............................................................................................ 8 – 15
8
REAR AXLE
Structure and Functions
2
3
4
19
18
11 8
10 12
13
14
15
16
17
16 206811
1 Housing 8 Oil seal 15 Taper roller bearing

2 Pinion gear 9 Steering axle 16 Nut
3 Rack gear 10 Wheel hub 17 Lock washer
4 Piston 11 Hub bolt 18 Hydraulic oil inlet (left
5 Cap 12 Hub nut wheel)
6 Taper roller bearing 13 Oil seal 19 Hydraulic oil inlet (right
7 Taper roller bearing 14 Taper roller bearing wheel)
The rear axle is coupled with the pinion gear and rack The steering axle connected to the pinion gear is linked
gear. The rack gear is mounted with pistons on both to two symmetrically arranged rear wheels. The
ends, and converts the reciprocal motion generated by steering axle and the taper roller bearing of the pinion
oil pressure to the rotational movement of the pinion gear support the rear wheel load.
gear. The pinion gear serves as a steering device.
8-1
REAR AXLE
Rear Wheels
Cushion Tire
φ292.1 mm (11.5 in.)
φ381 mm (15 in.)

127 mm (5 in.)
1
3
2
211347
1 Steering axle 3 Wheel nut

2 Rear wheel 4 Rim
Tire size 15 × 5 × 11 1/4
8-2
REAR AXLE
Rear Wheels
Removal
1 Wheel nut
2 Rear wheel
Sequence
1. Pull the hand brake lever, and place wheel stoppers at
the front wheels.
1
2. Turn the key switch ON, and turn the steering wheel all 2
the way to either the right or the left.
3. Locate the hub nut on the one side of the vehicle where 206813
it is visible from the rear. Loosen the hub nut by
turning it two or three rotations.
4. Turn the steering wheel to the opposite direction, and
loosen the hub nut on the opposite side by turning it
two or three rotations.
5. Turn the key switch OFF, and lift the back of the
vehicle until the rear tires are off the ground.
a. Place a jack at the rear center (under the draw bar
pin) of the counterweight, and lift.
b. Attach a wire rope to the draw bar pin and lift with
a crane.
6. After the back of the vehicle is lifted, place jack stands
under the frame on both sides at the rear as a safety
measure.
7. Turn the key switch ON, turn the steering wheel, and
remove the right and left tires.
8. Turn the key switch OFF.
211050
Installation
NOTE
Tighten the wheel nuts evenly to the specified torque.
Wheel nut 157 N·m

101212
tightening torque (16 kgf·m)
[116 lbf·ft]
8-3
REAR AXLE
Rear Axle
Removal (Part 1)
11
2
12
10
4
1 7
5
213037
Sequence
1 Battery cover, Gas spring, Seat 7 Hose (hydraulic suction)
2 Controller cover 8 Pipe (hydraulic delivery)
3 Battery 9 Motor, Hydraulic pump
4 Battery shield 10 Hose (hydraulic return)
5 Controller 11 Hose (rear axle return)
6 Suction pipe 12 Hydraulic tank
Preparation
1. Remove the rear wheels.
(Refer to Rear Wheel Removal procedure.)
2. Disconnect the battery plug located on the right side of
the foot area of the operator’s seat to cut off power.
8-4
REAR AXLE
Suggestions for Removal

The rear axle is mounted to the counterweight. To remove
the rear axle, it is necessary to remove all the surrounding
components such as the motor, hydraulic pump, hydraulic
tank and controller.
Removing battery cover

Before removal, open the battery cover and disconnect the
seat switch terminal. Remove the gas spring from the
frame, and remove the hinge bolts located on the
counterweight. The seat does not have to be removed.
Removing controller
Remove all cables connected to the controller. During
removal, record cable connecting locations so that they can
be reconnected to the original positions. Disconnect all
harness connectors, and bind them to keep them out of the
way during rear axle removal.
Removing motor and hydraulic pump

Disconnect the cables and harness connectors of the motor.
Arrange an oil pan to receive drained oil, and remove hoses
6, 7 and pipe 8. Do not remove the pipe on the suction side.
Removing hydraulic tank

Disconnect hoses 10, 11, then remove the hydraulic tank.
Since the tank contains oil, keep the tank balanced during
removal.
8-5
REAR AXLE
Removal (Part 2)
14
15
13
16
206816
Sequence
13 Connector 15 Steering hose
14 Overflow hose 16 Rear axle assembly and Steering axle
assembly

A steering sensor is mounted on the top of the rear axle. Be
careful not to damage the sensor when lifting the assembly.
Installation
Suggestions for Installation
Tighten the rear axle assembly mounting bolts to the
specified torque.
Bolt tightening torque 436 N·m (44.5 kgf·m) [322 lbf·ft]
8-6
REAR AXLE
Steering Axle
Disassembly
6
5
4
3
2
1 206817
Sequence
1 Cap 6 Wheel hub, Hub bolt
2 Nut 7 Oil seal
3 Lock washer 8 Taper roller bearing
4 Nut 9 Steering axle
5 Taper roller bearing

1. Removing wheel hubs
Use a puller to remove the wheel hubs from the steering
axle.
8-7
REAR AXLE
Reassembly
3 2 5 6 7
211051
Sequence
1 Steering axle 6 Nut
2 Taper roller bearing 7 Lock washer
3 Oil seal 8 Nut
4 Wheel hub 9 Cap
5 Taper roller bearing

1. Assembling wheel hubs
(1) Insert the inner races of the taper roller bearings using
the bearing installer A (special tool).
A
Special tool needed
Bearing installer A 91268 - 01500
206820
8-8
REAR AXLE
(2) Filling insides of rear axle hubs with grease

Insert grease into the rear axle hubs. See the diagram
for proper grease filling condition. Add grease to the
roller holding devices. Fill grease to approximately
80% of the cavity. Do not add grease to the full level.
Adding grease to the maximum level causes excessive
heat generation and quickly deteriorates the grease.
When coating oil seal lips with grease, be careful not to
apply too much grease, as an excessive amount of
grease can cause leaks.
Refilling with grease 206821
2. Preload adjustment and lock nut

First, adjust the inside nut, next tighten the outside nut
(lock nut) to the specified torque, and then, check the
preload. To measure the preload, attach a spring
balance to one of the hub bolts, then read the force to
start the rotation of hub.
Use the following allowable ranges when readjusting
used bearings.
Outside nut
0.5 to 5 N·m Inside nut
206821
Preload of hub bearing (0.051 to 0.51 kgf·m)
[0.37 to 3.7 lbf·ft]
6.5 to 65 N
Tangential force on hub bolt (0.66 to 6.6 kgf)
[1.46 to 14.6 lbf]
157 N·m
Lock nut tightening torque (16 kgf·m)
[116 lbf·ft]
8-9
REAR AXLE
Rear Axle Assembly

Disassembly
14 2
17
Section A
4
10 11
12 9
7
A 1 3
15
16
6
13 4
207204
Sequence
1 Bolt 10 Bolt, washer
2 Plate 11 Piston assembly
3 Shim 12 Rack gear
4 Pinion gear 13 Oil seal
5 Taper roller bearing (inner) 14 Oil seal
6 Taper roller bearing (inner) 15 Taper roller bearing (outer)
7 Bolt, washer 16 Taper roller bearing (outer)
8 Cap 17 Housing
9 Seal, O-ring
8-10
REAR AXLE
Suggestions for Disassembly Press

1. Removal of the pinion gear
17
Remove bolt 1, plate 2 and shim 3. Position housing
17 on a base, and use a press to remove pinion gear 4.
2. Inspect taper roller bearing (inner) 6 which is press-fit

in pinion gear 4 and taper roller bearings 15, 16 which 4 207205
are press-fit in housing 17. If the roller bearings are in
good condition, they do not have to be removed.

1. Housing
Inspect the sliding surface of piston assembly 11 for
damage.
If there are small scratches on the surface, use
sandpaper to remove the scratches.
2. Pinion gear and rack gear

Inspect the tooth surfaces for damage. Inspect the
steering axle mounting screw at the lower pinion gear
section for damage. Inspect the contact section of the
oil seal at the lower pinion gear section for damage.
3. Taper roller bearing

Inspect the rolling contact surface of the bearing.
4. Inspect the contact section of the oil seal of plate 2 for

damage.
5. Oil seal, O-ring and other parts

Replace oil seals 4, 5, other seals, O-ring 9, and piston
seal of piston assembly 11 with new parts.
8-11
REAR AXLE
Reassembly
4 16
Section A
12
8 7
6 9
11
10
A 17 15 B
14
13
5 12 207204
Sequence
1 Housing 10 Cap
2 Taper roller bearing (outer) 11 Bolt, washer
3 Taper roller bearing (outer) 12 Pinion gear
4 Oil seal 13 Taper roller bearing (inner)
5 Oil seal 14 Taper roller bearing (inner)
6 Rack gear 15 Shim
7 Piston assembly 16 Plate
8 Bolt, washer 17 Bolt
9 Seal, O-ring B: Overflow port
For reassembly, follow the disassembly sequence in

reverse.
1. When inserting oil seals 4, 5 into housing 1, use a
backing plate and strike the oil seals uniformly to set
the seals evenly into position.
8-12
REAR AXLE
2. Before installing piston assembly 7, apply sealant

1E2200J on the periphery of the piston and the sliding
surface of housing 1.
3. When installing taper roller bearings (inner) 13, 14,

coat them with hydraulic oil.
4. Coat the lips of oil seals 4, 5 with hydraulic oil and

install the seals.
5 To adjust the bearing end play after the installation of

taper roller bearings 13, 14, measure clearance 14 Clearance
between pinion gear 12 and taper roller bearing 14.
Subtract a value of 0.01 to 0.035 mm (0.0004 to 0.0014
in.) from the measured value, and insert a shim having
the thickness of the calculated value, then tighten plate
16.
12
Clearance – 0.01 to 0.035 mm = Shim thickness
(0.0004 to 0.0014 in.) 207206
6. Tighten bolt 17 to the specified torque.
45 ± 7 N·m
Bolt tightening torque (4.6 ± 0.7 kgf·m)
[33.2 ± 5.2 lbf·ft]
7. After reassembly, pour hydraulic oil into overflow port

B until the oil surface reaches the overflow port. Cover
the overflow port with tape.
8-13
REAR AXLE
Inspection and Adjustment
Making sure of Minimum Turning Radius

(1) While operating the vehicle at low speed, turn the
steering wheel all the way to the right, then to the left,
and check the diameter of the tire tracks in both turning
operations.
(2) Calculate minimum turning radius R by dividing the
turning diameter by two then adding the distance
R
between the center of the outside rear wheel and the
outside edge of the counterweight.
Unit : mm (in.)
206822
Item
Minimum turning radius
Truck Model
ET3000 1517 (59.7)
ET3500 1620 (63.8)
ET4000 1645 (64.8)
8-14
REAR AXLE
Truck Model
Item
Preload of hub bearing 1
N·m (kgf·m) [lbf·ft] A 0.5 to 5.0 (0.051 to 0.51) [0.37 to 3.7]
Tangential force on hub bolt

N (kgf) [lbf] A 6.5 to 65 (0.66 to 6.6) [1.46 to 14.6]
Rear axle Lock nut 2 A 157 (16) [116]

Tightening
torque Rear axle tightening bolt 3 A 436 (44.5) [322]
N·m Steering axle tightening bolt 4 A 224 (22.9) [166]
(kgf·m)
Wheel nut 5 A 157 (16) [116]
[lbf·ft]
Plat bolt 6 A 45 ± 7 (4.6 ± 0.7) [33.2 ± 5.2]
211052
8-15
BRAKE SYSTEM
Specifications .......................................................................................... 9 – 1
Caliper Assembly ...................................................................................... 9 – 3
Brake Pedal Assembly .............................................................................. 9 – 4
Master Cylinder ........................................................................................ 9 – 5
Parking Brake Lever .................................................................................. 9 – 6
Reassembly ............................................................................................. 9 – 7
Master Cylinder ........................................................................................ 9 – 7
Pad Clearance Adjustment ....................................................................... 9 – 9
Brake Pedal Adjustment ............................................................................ 9 – 9
Brake Switch Installation ........................................................................... 9 – 10
Brake Fluid Line Bleeding ......................................................................... 9 – 10
Parking Brake Adjustment ......................................................................... 9 – 10 9
Troubleshooting ....................................................................................... 9 – 11
Service Data ............................................................................................ 9 – 12
BRAKE SYSTEM
Specifications
Truck Model
Item
Type Hydraulic (mechanical) motor disc brake system
Brake disc effective
162 (6.378)
diameter mm (in.)
Disc outside diameter
200 (7.874)
mm (in.)
Disc thickness
10 (0.39)
mm (in.)
Disc effective thickness
9 (0.35)
mm (in.)
Brake Main brake and Pad area
28.8 × 2 (4.46 × 2)
system parking brake cm2 (in2.)
Pad thickness
5 (0.2)
mm (in.)
Pad effective thickness
4 (0.16)
mm (in.)
The minimum clearance of
0.4 (0.016)
disc and pads mm (in.)
Pad material NS 179
Wheel cylinder inside
19.05 (0.75)
diameter mm (in.)
Wheel cylinder area
2.85 (0.44)
cm2 (in2.)
9-1
BRAKE SYSTEM
8 1
4
206824
1 Caliper assembly 5 Reservoir tank

2 Brake disc 6 Parking lever assembly
3 Traction motor 7 Equalizer bracket
4 Brake pedal assembly 8 Lever D
The brake pads clamp the brake disc, mounted on the The brake pedal assembly is mounted on the left side of
traction motor, to provide stopping force. the frame.
The caliper assemblies are installed on the rib section The cable linked to the parking lever pulls lever D of
of the drive motor. the caliper to provide stopping force.
9-2
BRAKE SYSTEM
Caliper Assembly
8 7 15 1
3
B 17
9
10
4 2 11
8 5 14 13
1
7 16
8
10
6
11
13 12
A 4
206825
1 Body assembly 8 Pin 15 Spring

2 Lever A 9 Spring 16 Bleeder screw
3 Lever B 10 Pad assembly 17 Brake disc
4 Pin, Split pin 11 Bolt, Washer A: Brake fluid inlet
5 Lever C 12 Adjustment bolt B: Parking brake cable
6 Lever D 13 Adjustment bolt
mounting hole
7 Pin, Split pin 14 Lock nut, Washer
The brake pads clamp the brake disc, mounted on the link sides, causing the pad assembly to clamp the brake
traction motor, to provide stopping force. disc. When the parking brake cable connected to
The caliper assemblies are installed on the traction section B pulls the lever in the direction of the arrow,
motor. Pressurized brake fluid entering from section A the pad assembly operates mechanically. Adjustment
pushes the piston into the cylinder of the body bolts 12, 13 and spring 15 maintain proper clearances
assembly. The piston then presses pin 7, which then between the brake disc and pads. The caliper assembly
pushes levers C and D to an open position. Levers A installed on the opposite side of the vehicle is
and B move with pin 4 as the fulcrum and open their symmetrically constructed.
9-3
BRAKE SYSTEM
Brake Pedal Assembly
Brake fluid 6
5
3 7
1
4
211053
1 Pedal bracket 5 Master cylinder

2 Brake pedal 6 Adjustment bolt
3 Brake link 7 Brake switch
4 Return spring
The brake pedal assembly is mounted on the left side of Brake fluid is supplied to the master cylinder from the
the frame. reservoir tank located under the left side of the
The adjustment bolt is used to set the brake pedal dashboard.
height.
The installation length of the brake switch is pre-
adjusted. When the pedal is pressed, the switch
activates and controls the operating speed of the
traction motor.
9-4
BRAKE SYSTEM
Master Cylinder
12
13
1 7
8
2 4 3
10 11 9
14
15
16 5 6 17 18
211054
1 Cylinder body 10 Clevis

2 Safety ring 11 Nut
3 Piston 12 Filler
4 Secondary cup 13 Gasket
5 Primary cup 14 Clevis pin
6 Spring pad 15 Snap pin
7 Spring 16 Valve
8 Dust cover 17 Valve body
9 Push rod 18 Valve seal
The inside diameter of the cylinder is 19.05 mm (3/4

in.), and the maximum stroke is 30 mm (1.2 in.).
9-5
BRAKE SYSTEM
Parking Brake Lever
Maximum stroke: 50°
8
3
2
211055
1 Lever body 5 Stopper

2 Gear 6 Spring
3 Notch 7 Hook
4 Grip 8 Pin
The parking brake lever is mounted on the left side of The maximum lever stroke is 50 degrees. There are a
the dashboard. total of 14 gear teeth. Adjust the parking brake so that
When the grip is pulled, the parking brake cable moves the brake activates and applies force when the third or
fourth tooth of gear 2 engages with the notch.
the pad assembly of the caliper to clamp the brake disc
and apply stopping force.
Notch 3 engages with gear 2 to retain the lever in
Grip operating effort 343 N (35 kgf) [77 lbf]
position. To release the parking brake, pull the grip and
press stopper 5. This disengages the gear from the
notch, and the lever returns to the original position.
9-6
BRAKE SYSTEM
Master Cylinder
Disassembly
8
6
5 7
4
3
2
213017
Sequence
1 Clevis, Nut, Push rod 5 Cup spacer, Primary cup, Spring seat
2 Boot 6 Return spring
3 Stopper ring 7 Cylinder body
4 Secondary cup, Piston 8 Filler, Clamp
NOTE
Parts marked with (❋) are included in the repair kit.
9-7
BRAKE SYSTEM
1. Cylinder body
(1) Check the inner surface of the cylinder for rust,
corrosion and scuffing.
(2) Check the inlet port and relief port for clogging.
And check the joint bolts and boot for damage.
A : Standard value
2. Piston
B : Service or repair limit
Check the piston for damage, and replace if damaged.
If the clearance between the piston and cylinder 0.020 to 0.105 mm
A
Clearance between (0.0008 to 0.0041 in.)
exceeds the limit, replace both cylinder and piston.
cylinder and piston 0.2 mm
3. Return spring B
(0.0078 in.)
Replace the return spring once a year.
4. Primary cup, Secondary cup and Spring seat

Inspect rubber parts for damage and swelling. Replace
the primary cup, secondary cup and spring seat once a
year.
Reassembly
Follow the disassembly sequence in reverse. Also
follow the instructions below.
(1) Clean metal parts with a volatile cleaning solution,
and thoroughly dry using compressed air.
(2) Apply a thin coat of brake rubber grease (Metal
Rubber #20) or brake fluid on the inner surface of
the cylinder and the piston cup.
9-8
BRAKE SYSTEM
Pad Clearance Adjustment

Pad B
Loosen the lock nut and turn adjustment bolt A to adjust
pad A clearance. Pad B moves as adjustment bolt A is
turned.
Therefore, use adjustment bolt B to adjust pad B clearance.
One rotation of adjustment bolt A moves pads A and B Clearance
approximately 1 mm (0.04 in.) to the right or left according
Lock nut Pad A
to the direction of the bolt rotation. One rotation of
Adjustment bolt 206825A
adjustment bolt B moves pad B approximately 1 mm (0.04
in.) to the right or left according to the direction of the bolt
rotation.
Adjust the clearance to a range of 0.4 to 1.1 mm (0.0157 to Adjustment bolt A
0.0433 in.) at the tip on each side.
After adjustment, tighten the lock nut.
2.94 to 5.88 N·m

Lock nut tightening torque (30 to 60 kgf·cm)
[2.17 to 4.34 lbf·ft]
Adjustment bolt B
206825B
Brake Pedal Adjustment

(1) Use the stopper bolt to adjust pedal height A (distance
C
between frame and the top of pedal pad). D
(2) Set push rod length B to the specified dimension, and
install the push rod into the master cylinder. The
A’ A
clearance between the push rod and piston should be Stopper bolt
0.5 to 1.5 mm (0.02 to 0.06 in.). The pedal play C
should be 3 to 9 mm (0.12 to 0.35 in.).
(3) After adjustment, check to make sure that pedal stroke
D (brake activating point) is as specified.
Unit : mm (in.)
Truck Model
Item
B 206830
Pedal height A 192.6
from floor plate (7.58)
Pedal height A’ 198.6
from frame (7.82)
Push rod length B 118.6 (4.67)
Free play C 3 to 9 (0.12 to 0.35)
Pedal stroke D 21 to 32
(brake activating point) (0.8 to 1.3)
9-9
BRAKE SYSTEM
Brake Switch Installation

(ON/OFF point)
(1) Use the adjustment bolt to adjust the brake pedal Brake switch
0.7 to 1.3 mm
height, then tighten the lock nut. (0.027 to 0.05 in.)
(2) By rotating the push rod of the brake master cylinder,
adjust the clearance between the push rod and piston to
a range of 0.5 to 1.5 mm (0.019 to 0.059 in.).
When properly adjusted, the pedal should travel a
distance of 3 to 9 mm (0.12 to 0.35 in.) when pressed.
Lock nut
(3) Install the brake switch, and adjust so that the switch
205753
activates when the brake pedal is pressed 7 to 13 mm
(0.27 to 0.51 in.). Then, tighten the lock nut.
The brake switch should turn ON and OFF with pedal
movement of 0.7 to 1.3 mm (0.027 to 0.051 in.).
Brake Fluid Line Bleeding
When any part of the brake fluid system is disassembled for
repair or when brake pedal movement is spongy, bleed the
brake fluid line as follows:
(1) Attach a clear vinyl tube to the bleeder screw of the
right caliper assembly, which is located furthest from
the master cylinder.
(2) Check the brake fluid level in the reserve tank. Add if
the level is low.
(3) Pump the brake pedal several times, and then keep the
pedal pressed. While holding the pedal pressed, loosen
the bleeder screw. While brake fluid is flowing into the
vinyl tube, tighten the bleeder screw.
(4) Repeat the above procedure until no air bubbles are in
the brake fluid.
Repeat the same procedure to bleed the left caliper
assembly.
After air bleeding is completed, add brake fluid in the
tank to the specified level.
Parking Brake Adjustment
When the pad clearances are adjusted to approximately 1.1
mm (0.043 in.), the notch should engage with the third or
fourth tooth of the gear when the parking brake lever is
pulled.
If the pads are worn, tighten the adjustment bolts of the
calipers to adjust the clearances. To adjust the cable length,
use the cable adjustment bolt.
206833
9-10
BRAKE SYSTEM
Troubleshooting *
Oil leak from master cylinder Inspect cylinder. If no abnormality
primary cup is found, replace piston cup.
Oil leak from caliper cylinder If piston cup is deformed, replace
cup cup and brake fluid (use genuine
Inadequate braking force brake fluid).
Oil leak from oil pipe joint Re-tighten, or replace pipe
and joint.
Worn lining Replace.
Oil adhesion on lining Clean with brake component
cleaner and repair or replace.
Air in hydraulic system Bleed master cylinder and

caliper cylinder.
Faulty master cylinder or Replace piston cup.
piston cup
Excessive pedal stroke
Low oil level in master cylinder Add brake fluid.
Foot Excessive clearance of master Adjust.
brake cylinder push rod
Brake fluid leak Refer to above section marked
with *.
Oil or grease adhesion on Clean with brake component cleaner

Imbalance in braking lining or disc and repair. If oil and grease cannot be
power removed from lining, replace lining.
Brake disc wobbling or loose Replace disc. If problem is caused
mounting by loose mounting, re-adjust and
re-tighten.
Lining surface too smooth Replace brake pad.

Worn lining
Brake squealing
Loose caliper tightening bolt Re-tighten.
Dirty disc Clean with brake component cleaner.
Inadequate clearance Adjust to standard clearance

Parking brake stroke too
between disc and lining value.
short
Parking brake cable too short Adjust cable length using
adjustment bolt.
Abnormal noise from Inadequate clearance between Adjust to standard clearance

Parking hand brake during brake pad and disc value.
brake driving Warped brake disc Repair brake disc according to
repair standard, or replace.
Parking brake cable too long Adjust cable length using

adjustment bolt.
Parking brake not
producing stopping force Brake lining worn beyond Replace brake pad.
limit
Excessive clearance between Adjust clearance between
brake pad and disc brake pad and disc.
9-11
BRAKE SYSTEM
Unit: mm (in.)
Truck Model
Item
Pedal height 1
A 192.6 (7.58)
(between upper pedal edge and floor)
Pedal stroke 2 (brake activating point) A 21 to 32 (0.8 to 1.3)
Free play 3 A 3 to 9 (0.12 to 0.35)
Push rod length 4
A 118.6 (4.67)
(standard assembly dimension)
Clearance between piston and push rod 5 A 0.5 to 1.5 (0.019 to 0.059)
Brake switch activating pedal stroke 6 A 7 to 13 (0.27 to 0.51)
Brake switch activating dimension 7 A 0.7 to 1.3 (0.027 to 0.05)
Brake 2
6
pedal 3
5
4
206831
9-12
BRAKE SYSTEM
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
Item
+0.052 +0.00205
Cylinder body inside diameter 1 A 19.05 0 (0.7500 0 )
-0.020 -0.00079
Piston outside diameter 2 A 19.05 -0.053 (0.7500 -0.00209 )
A 0.020 to 0.105 (0.00079 to 0.00413 )
Clearance between cylinder and piston
B 0.2 (0.08)
0 0
A 20 -0.3 (0.79 -0.012)
Primary cup lip-side outside diameter 3
B (Replace once a year.)
A 20.2 ± 0.2 (0.795 ± 0.008 )
Secondary cup lip-side outside diameter 4
Master B (Replace once a year.)
cylinder A 46.8 (1.843 )
Return spring free-movement length 5
B (Replace once a year.)
4 2
1 3 5
208380A
9-13
BRAKE SYSTEM
Unit: mm (in.)
Truck Model
Item
Tightening Pad assembly tightening
A 17.65 to 26.48 (180 to 270) [13.02 to 19.53]
torque bolt 1
N·m
(kgf·cm) Adjustment bolt lock nut 2 A 2.94 to 5.88 (30 to 60) [2.17 to 4.34]
[lbf·ft] Bleeder screw 3 A 6.86 to 11.77 (70 to 120) [5.06 to 8.68]
A 5 (0.2)
Pad lining thickness 4
B 1 (0.039)
Lever D pin hole stroke with 1.1 mm
(0.043 in.) of clearance between brake A 5 (0.197)
disc and pad 5
Lever D pin hole stroke with 4 mm
A 20 (0.787)
(0.157 in.) of pad thickness wear 6
Brake disc thickness 7 A 10 (0.394)
Caliper
2 1
206832
9-14
STEERING SYSTEM
Specifications ..........................................................................................10 – 1
Structure and Functions .......................................................................10 – 2
General .....................................................................................................10 – 2
Steering Control Valve ..............................................................................10 – 3
Procedures and Suggestions for Removal and Installation .......10 – 4
Steering Column Assembly .......................................................................10 – 4
Steering Control Valve ..........................................................................10 – 6
Disassembly .............................................................................................10 – 6
Inspection .................................................................................................10 – 8
Reassembly ..............................................................................................10 – 9
Hydraulic Circuit Diagram .................................................................... 10 – 14
Troubleshooting ...................................................................................... 10 – 15
Service Data ............................................................................................ 10 – 16
10
STEERING SYSTEM
Specifications
Truck Models
Items
Type All hydraulic power steering
Diameter of steering wheel mm (in.) 328 (12.9)
Manufacturer Ognibene
Steering control valve
Flow rate liter (cu. in.) /min 7.6 (464)
10-1
STEERING SYSTEM
General
3 6
7 T2
T T1
L 8
P
R P
4
CF EF
Priority valve
LS
2 1
SL SR
Oil flow Right turn: R SL SR L

Tank 1 Pump 2 CF P T T2 T1 Tank 1
Left turn: L SR SL R
211349
1 Hydraulic tank 5 Steering cylinder

2 Hydraulic pump 6 Hydraulic control valve
3 Steering wheel 7 Pressure switch
4 Steering gear 8 Return line
The steering system of this vehicle is hydraulically the steering wheel and forces the oil into the steering
operated and controlled. cylinder through port R or L. This pushes the piston in
The oil drawn by hydraulic pump 2 from hydraulic tank steering cylinder 5 and forces the oil on the other side,
1 is forced to steering gear 4 through port CF in the towards port L or R of the steering gear. The oil then
priority valve. When steering wheel 3 is not turned, the goes out of the steering gear through port T and enters
oil from port CF is blocked by the directional control port T2 of hydraulic control valve 6. From port T1 of
valve in steering gear 4. the hydraulic control valve, the oil flows into hydraulic
tank 1.
When the operator turns the steering wheel, the oil
flows through the control valve (that is now opened) to When the operator stops rotating the steering wheel, the
a small hydraulic pump in the steering gear. The pump flow of oil through the steering gear is interrupted.
rotor in the small hydraulic pump rotates together with
10-2
STEERING SYSTEM
Steering Control Valve
13
T L R P
5 6 7 8 1 9 10 2 11 3 12 4
208230
1 Long housing 8 Drive shaft P: Pump port

2 Spacer plate 9 Control sleeve T: Tank port
3 “Gerotor” set 10 Control spool L: Cylinder port (left)
4 End cap 11 Spacer R: Cylinder port (right)
5 Thrust needle 12 Spacer
6 Centering spring 13 Check valve
7 Pin
10-3
STEERING SYSTEM
Steering Column Assembly

Removal
1
3
8
5
4
B
2
9
B
8
10 6
A
9 A
211085
Sequence
1 Steering wheel, Cap, Nut, Washer 7 Hose, Pipe, Hose clamp, Connector, O-ring
2 Console box (front panel) 8 Tilt steering lock lever, Spacer, Shaft, Bolt,
3 Central vehicle monitor panel Split pin
4 Direction lever 9 Pin, Washer, Split pin
5 Console box (rear panel) 10 Steering column assembly
6 Floor plate
10-4
STEERING SYSTEM
Suggestion for Removal
Steering wheel removal

Use the Wheel puller (special tool).
Special tool needed
Wheel puller 91268 - 10600
205770
Inspection
(1) Steering wheel free play
Check the free play with the key switch in the ON
position.
(2) Steering effort
(a) Apply the parking brake with the key switch in the
ON position, operate the lift lever to raise and
lower the lift bracket until the hydraulic oil
temperature increases to 30 to 60°C (86 to 140°F).
(b) Attach a spring scale to the rim (or a spoke) of the
steering wheel. Pull the scale in a tangential
direction and read the scale just as the wheel
begins to turn. 206836A
1.6 N·m
Steering effort (0.16 kgf·m)
[1.18 lbf·ft]
16 N
Spring balance
(1.6 kgf)
reading
[3.6 lbf]
10-5
STEERING SYSTEM
Steering Control Valve
Disassembly
11
6
12
10
208232
Sequence
1 End cap, Bolts, O-ring and Spacers 7 Control sleeve
2 “Gerotor” set, O-ring 8 Control spool
3 Drive shaft, Spacer plate and O-ring 9 Pin
4 Retaining ring 10 Centering springs
5 Seal gland bushing, O-ring, Oil seal and 11 Check valve, Check ball retainer, Ball, O-ring,
Dust seal Check seat and Screw
6 Thrust needle, Race bearing 12 Long housing
10-6
STEERING SYSTEM

(1) Retaining ring removal
Remove the ring from the housing by prying the end
of the ring out of the groove. Do not damage the
machined surface.
208233
(2) Seal gland bushing removal

Position the control spool and control sleeve assembly
so that the pin is even with the center of the assembly.
Remove the bushing.
208234
(3) Control spool and sleeve removal

Remove the control spool and sleeve assembly from
the housing by pulling it toward the end of the housing
opposite to the flange. Remove the pin from the
assembly.
NOTE
To prevent damage to the housing, slowly pull out the
assembly while twisting.
208235
(4) Control spool and sleeve disassembly
NOTE
Before removing the spool from the sleeve, put a mark
across the spool and sleeve so that the spool can be
installed in the same position.
Pull the control spool from the sleeve enough to permit

removal of the centering springs. Remove the centering
springs. Remove the spool from the sleeve by pulling it 200668
toward the rear end of the sleeve while turning slowly.
10-7
STEERING SYSTEM
Inspection
Spool movement in housing and sleeve
(a) Check for sliding movement in the sub-assembly
condition.
(b) If any defective movement is found, check sliding
surfaces.
If any defect such as abnormal wear, scratch, burr or
rust is found, replace the entire unit with a new one.
10-8
STEERING SYSTEM
Reassembly
9 7 10
12
4 5 3 6 1 11
208236
Sequence
1 Long housing 7 Thrust needle, Race bearings
2 Check valve, Check ball retainer, Ball, O-ring, 8 Seal gland bushing, Oil seal, Dust seal and
Check seat and Set screw O-ring
3 Control sleeve 9 Retaining ring
4 Control spool 10 Drive shaft, Spacer plate and O-ring
5 Centering springs 11 “Gerotor” set, O-ring
6 Pin 12 End cap, O-ring, Spacer and Bolts
Start by :
(a) Replace worn or defective parts.
(b) Wash all metal parts and blow dry.
(c) Replace O-rings and seals.
(d) Apply grease to O-rings and other sealing parts.
10-9
STEERING SYSTEM

(1) Check valve assembling
Put the retainer in position on the housing. Put the seat
in position in the housing with the hole at the bottom.
Apply Loctite 271 to the threads of the set screw and
tighten the screw to the specified torque.
11.3 N·m
Tightening torque for set
(1.2 kgf·m)
screw
[8.3 lbf·ft] 208237
(2) Control spool and sleeve assembling

Check the direction in which the spring groove of the
sleeve is aligned with that of the spool and then, slide
the spool into the sleeve while twisting the spool.
If there are any alignment marks made at the time of
disassembly or alignment marks installed by the
manufacturer, use the marks to align the assemblies.
NOTE
200670
Check that the control spool rotates smoothly in the
control sleeve.
(3) Centering spring installation

Align the spring grooves of the spool-and-sleeve and
stand the spool-and-sleeve on a flat bench. Use the
spring inserting tool to install springs. Place each set
of three springs back to back and pinch six springs in
the tool with notches on both sides facing downward.
See the illustration on the right.
200671
As shown in the illustration, push one end of the
springs with fingers and push the springs into the
spool-and-sleeve groove. In case there is no inserting
tool, assemble the springs by inserting them one by one
and right and left alternately.
Spring inserting tool 97157 - 00100
10-10
STEERING SYSTEM
(4) Control spool and sleeve assembly installation to

housing
Insert the pin into the hole of the control spool-and-
sleeve assembly and align both ends of the pin with the
outside diameter of the sleeve. Insert the spool-and-
sleeve assembly into the housing from the rear (in the
direction as shown in the illustration).
Insert the spool-and-sleeve assembly while slowly
twisting it with the pin kept at a horizontal position. 208238
Insert the spool-and-sleeve assembly until its rear edge
face becomes flush with the edge face of the housing.
Do not insert any further.
(5) Seal installation
• Install the dust seal on the seal gland bushing to
place the flat side facing the bushing.
• Install the quad ring seal in the bushing by
smoothing it into place with your finger.
207184
(6) Reassembling the seal gland bushing

• Install the bushing assembly over the spool end with
a twisting motion. Tap it into place with a soft head
mallet. Make sure the bushing is flush against the
bearing race.
208239
• Install the retaining ring in the housing and pry it

with a screwdriver around the entire circumference
to ensure a good sitting.
207195
10-11
STEERING SYSTEM
(7) Reassembling the wear plate

• Clamp the housing in a vise, equipped with soft jaws
or softened with rag. Clamp lightly over the flats of
the flange. Do not overtighten the vise jaws.
NOTE
Check that the spool and sleeve are flush with or
slightly below the surface of the housing.
208240
• Install the O-ring in the housing. Place the spacer

plate on the housing and align the bolt holes with the
tapped holes in the housing.
208241
(8) Reassembling the drive shaft

Turn the control spool-and-sleeve assembly to make Port surface
the port surface of the housing parallel with the pin. Drive
Insert the drive shaft to engage the pin in the yoke of
the drive shaft. To ensure positioning in the following
work process, draw a line such as line B in the Pin parallel with
illustration right below on the end face of the drive port surface
shaft spline with a felt-tip pen. Pin

208242
10-12
STEERING SYSTEM
(9) Reassembling the Gerotor set

• Install O-ring in the Gerotor set. Gerotor set star valley A
• Face the O-ring side of the Gerotor set toward the
spacer plate side. Fit the Gerotor set into the drive B
shaft by aligning the root (line A) of the Gerotor set
with line B of the drive shaft.
Drive(marked) C
Check that lines A, B, C, and D are in parallel with
each other. D
Align bolt holes of the Gerotor set with the drive

shaft and star kept engaged.
This procedure is important in determining the valve
timing of this unit.
Pin Port surface

208243
(10) Reassembling the end cap

• Install the drive spacer in the Gerotor set. Install the End cap
O-ring in the end cap. Install the end cap in the
Gerotor set and align the holes. Cap screw
O-ring
Drive spacer
208244
• Apply oil to bolt threads and tighten bolts evenly in

the sequence as shown in the illustration on the right.
The tightening torque is shown in the table below.
12 N·m
Initial torque for (1.2 kgf·m)
screws [8.9 lbf·ft]
22 N·m
Finishing torque for (2.2 kgf·m)
screws [16.2 lbf·ft] 200677
After installing the end cap, install the steering shaft to the
spool and make sure the spool rotates smoothly.
10-13
Displacement: L R
Hydraulic control valve 63 cm3 (3.8 cu. in.)/rev
(AC motor, MC models )
STEERING SYSTEM
T1
B4
A4
B3 EL Steering cylinder
Hydraulic Circuit Diagram
A3
Pressure
switch
B2
P T LS
A2
10-14
A1 CF EF
LS
P Priority valve
Gear pump
Displacement:
24.5 cm3 (1.49 cu. in.)/rev
M
G1 P 18.1 MPa T2 Pump motor
36/48V Dual voltage
11.56 kW Operation
at 48V
Return Suction
filter strainer
15 mm 100 mesh
213018
STEERING SYSTEM
Troubleshooting
Clogged metering section Disassemble and clean.

Control valve
Faulty spool operation Disassemble and clean.
malfunction
Faulty bearing Disassemble and
replace.
Heavy steering
Rear axle cylinder
wheel operation Faulty piston seal Replace.
malfunction
Others Flattened pipe, mixing of Clean or replace oil line.

foreign particles
Control valve Sticking of spool or sleeve Replace.

malfunction Damaged centering spring Replace.
Instability in
steering wheel
operation Flattened pipe, mixing of Clean or replace oil line.
Others foreign particles
Faulty piston seal in rear Replace.
axle cylinder
10-15
STEERING SYSTEM
Service Data
A: Standard value
Unit: mm (in.)
Truck Models
Items
Steering effort (at steering wheel rim)

(Standard value measured with key switch ON, A 1.6 (0.16) [1.18]
steering wheel turning speed of 1 revolution/sec, and
stationary swing operation)
Steering
wheel Inside wheel A 83°
Turning angle deg
Outside wheel A 56°
Steering wheel nut A 53.9 to 58.8 (5.5 to 6.0) [39.8 to 43.4]

Tightening torque
Steering bracket bolts A 29.4 (3) [21.7]
Displacement cc (cu. in.)/rev. A 63 (3.84)
Rated flow rate liter (cu. in.)/min. A 7.6 (464)
Maximum operating pressure

A 6.5 (66.3) [943]
MPa (kgf/cm2) [psi]
End cap bolts 1 A 22 (2.2) [16.2]

Tightening torque
Check valve set screw 2 A 11.3 (1.2) [8.3]
Steering
control
2 1
valve
208246
10-16
HYDRAULIC SYSTEM
Specifications ...........................................................................................11 – 1
Structure and Functions ........................................................................11 – 2
Hydraulic Line ............................................................................................11 – 2
Control Valve .............................................................................................11 – 3
Lift and Tilt Cylinders .................................................................................11 – 8
Flow Regulator Valve .................................................................................11 – 9
Down Safety Valve .....................................................................................11 – 9
Gear Pump ................................................................................................. 11 – 10
Procedures and Suggestions for Removal and Installation ........................ 11 – 10
Control Valve ............................................................................................. 11 – 11
Lift Cylinders ............................................................................................. 11 – 12
Dual-stage Panoramic Mast (Simplex Mast) ............................................ 11 – 12
Triple-stage Full Free Panoramic Mast (Triplex Mast)............................... 11 – 15
Procedures and Suggestions for Disassembly and Reassembly................ 11 – 18
Simplex Mast, Triplex Mast Second Cylinders.......................................... 11 – 18
Duplex Mast, Triplex Mast First Cylinder .................................................. 11 – 20
Duplex Mast Second Cylinders ................................................................ 11 – 22
11
Tilt Cylinders ............................................................................................. 11 – 24
Flow Regulator Valve .............................................................................. 11 – 28
Suction Strainer and Return Filter ....................................................... 11 – 29
Inspection and Adjustment ................................................................... 11 – 30
Hydraulic Tank ........................................................................................... 11 – 30
Control Valve ............................................................................................. 11 – 31
Lift Cylinders and Tilt Cylinders ................................................................. 11 – 33
Test ............................................................................................................ 11 – 34
Hydraulic Circuit Diagram ..................................................................... 11 – 35
Hydraulic Circuits..................................................................................... 11 – 36
Troubleshooting ........................................................................................ 11 – 40
Service Data .............................................................................................. 11 – 42
HYDRAULIC SYSTEM
Specifications
Truck Model
Item
Type Gear pump
Model type TMG1A23A3H8-L511
Gear pump Rated discharge volume 24.5 (1.49)
cc/rev. (cu. in./rev.)
Drive system Direct connection with pump motor
Type KVMF-70 (equipped with microswitches)
Control valve Main relief pressure
18142 (185) [2631]
kpa (kgf/cm2) [psi]
Type Variable type
Flow regulator
Control flowrate
Hydraulic system
valve 48 (12.7)
liter/min (U.S. gal./min)
Simplex mast lift Inside diameter mm (in.) 45 (1.77)

cylinder Stroke mm (in.) 1645 (64.76)
Duplex and Triplex Inside diameter mm (in.) 70 (2.75)
mast first lift
cylinder Stroke mm (in.) 850 (33.46)
Duplex mast second Inside diameter mm (in.) 45 (1.77)
lift cylinder Stroke mm (in.) 1595 (62.80)
Triplex mast Inside diameter mm (in.) 45 (1.77)
second lift cylinder Stroke mm (in.) 1525 (60.00)
Inside diameter mm (in.) 63 (2.48)
Tilt cylinder
Stroke mm (in.) 82 (3.23)
Operating oil volume N level: 14.7 (3.88)
liter (U.S. gal) H level: 16.8 (4.44)
11-1
HYDRAULIC SYSTEM
Hydraulic Line
View from operator's seat
8
6
6
5
7
7
R
211284
1 Hydraulic tank 6 Lift cylinder

2 Gear pump 7 Tilt cylinder
3 Control valve R: From rear axle
4 Flow regulator valve 8 First lift cylinder (three-stage and two-stage
5 Down safety valve full-free panorama mast system)
When the lift lever or tilt lever is operated, the The oil flows from the oil pump to the hydraulic system
microswitches located in the spool of the control valve in the same way as in engine-powered models.
send signals to the logic card in the main controller.
Based on received signals, the logic card drives the
pump motor and operates the oil pump.
11-2
HYDRAULIC SYSTEM
Control Valve
Description
13 14 15 15
9
8
10
6
12
11
12
11
4
5
1 2 3 3
211278
1 Lift valve assembly 9 Unload solenoid valve

2 Tilt valve assembly 10 Lift lock solenoid valve
3 Attachment valve assembly 11 Tie-bolt
4 End cover 12 Nut
5 Pump port 13 Lift switches 1, 2 (Microswitch)
6 From steering control valve 14 Tilt switch (Microswitch)
7 To tank 15 Attachment switch (Microswitch)
8 Main relief valve
The control valve structure is shown above. The parts The microswitches located on top of the control valve
are joined together by three tie-bolts. turn ON and OFF according to the spool movement,
Since a lapping process is used for the coupling of the and send lift and tilt signals to the logic card.
body and spool, the body and spool combination cannot The lift valve is equipped with two microswitches for
be changed. two-step lift speed selection.
The lift valve assembly contains the main relief valve,
lift lock solenoid valve and unload solenoid valve. The
tilt valve spool contains the tilt lock valve.
11-3
HYDRAULIC SYSTEM
Lift valve assembly
C C
B B
A A
15
1
14
16
13
12
11
10
10
2
8
7 9 6 3
5 4
21
22 Section A - A
23 24 20 26
17
25
18
20 19
17 18
Section B- B Section C- C
211279
11-4
HYDRAULIC SYSTEM
1 Body 10 Bolts 19 Poppet

2 Spool 11 Poppet 20 Springs
3 Plates 12 Spring 21 Plug
4 O-rings 13 Plug 22 O-ring
5 Wipers 14 O-ring 23 Unload solenoid valve
6 Cap 15 Lift lock solenoid valve 24 Poppet
7 Seats 16 Shut-off valve 25 Plug
8 Screw 17 Plugs 26 O-ring
9 Spring 18 O-rings
Tilt valve assembly
12 11 13
10
14 1
15
9 16 2
8
7
13 3 5 4
211280
1 Body 7 Seats 13 Bolts

2 Spool 8 Screw 14 Tilt lock valve
3 Plate 9 Spring 15 Spring
4 O-rings 10 Poppet 16 O-ring
5 Wipers 11 Spring
6 Cap 12 O-ring
11-5
HYDRAULIC SYSTEM
Attachment valve assembly
12 13
11 10
9 2
8
13 3 5 4
211281
1 Body 6 Cap 11 Spring

2 Spool 7 Seats 12 O-ring
3 Plate 8 Screw 13 Bolts
4 O-rings 9 Spring
5 Wipers 10 Poppet
11-6
HYDRAULIC SYSTEM
Main relief valve
13 10 11 12 14
3 4 9 5 6 8 1 2 7
203490
1 Cap 6 Pilot poppet 11 Backup ring

2 Plug 7 Lock nut 12 O-ring
3 Sleeve 8 Pilot spring 13 O-ring
4 Main poppet 9 Spring 14 O-ring
5 Pilot seat 10 O-ring
11-7
HYDRAULIC SYSTEM
Lift and Tilt Cylinders

Lift cylinder (Simplex mast)
(Triplex mast second cylinder)
207073
(Duplex and triplex mast first cylinder)
207604
(Duplex mast second cylinder)
000825C
Tilt cylinder
213020
The left and right lift cylinders are a single-acting type. The left and right tilt cylinders are a double-acting type.
Air and oil remaining inside air chamber 1 of the rod The piston rod carries a screw-on socket. This socket is
and inside rod chamber 2 between the tubes open check to be repositioned by turning, as necessary, when the
valve 3 when compressed, thus the air and oil flow out cylinder is connected to the outer mast. The right and
of the cylinder. left cylinders are hydraulically connected to each other.
Only the second cylinders of the Duplex Mast are The tilt angle can be increased or decreased by means
provided with bleeding valves. of spacer and shim of each cylinder.
11-8
HYDRAULIC SYSTEM
Flow Regulator Valve

From control valve To control valve
To lift cylinder From lift cylinder

203558
The flow regulator valve is located between each lift lowering speed regardless of load when the loaded forks
cylinder and control valve. It limits the flow of oil are lowered.
forced out of the cylinder to keep a constant safe
Down Safety Valve
Normal
Burst
When hose burst

204971
The down safety valve is located at the bottom of regulator valve is broken, or if the flow of return oil
second lift cylinder. This safety valve regulates the from the lift cylinder becomes excessive due to a
flow of oil to prevent the fork from moving down too maladjusted regulator valve or a fault of another
quickly in the following situations: component.
If the piping between the lift cylinder and flow
11-9
HYDRAULIC SYSTEM
Gear pump
Procedures and Suggestions for Removal

and Installation
1. Gear pump
The gear pump is mounted on the counterweight.
The rear axle is also connected to the counterweight,
and the rear axle must be removed after other
components are dismounted. For the removal of the
motor and gear pump, refer to the procedures for rear
axle removal and installation.
After the parts are removed from the counterweight,
disconnect the suction pipe from the gear pump, then
remove the gear pump from the motor.
NOTE
Do not remove the rear wheel during preparation
work.
11-10
HYDRAULIC SYSTEM
Control Valve

and Installation
Control lever
Removal rod
(1) Remove the floor plate. 1
(2) Remove the clevis pin from the control lever rod, and
disconnect the rod from the control valve spool.
(3) Disconnect the microswitches at connector 1.
211282
(4) Remove the pipes.

2 Tilt pipe
3 Hose
(from steering control valve)
2
4 Delivery hose
(from hydraulic pump) 3
5 Tilt pipe
6 Lift pipe
7 Return hose
4
5 7
6 211283
(5) Remove the bolts and nuts that mount the control valve
to the dashboard, and remove the control valve.
Installation
Follow the removal procedure in reverse. During
installation, conduct the following inspection.
206881
Check the hydraulic oil level. If the oil level is low, add oil
to the specified level.
11-11
HYDRAULIC SYSTEM
Lift Cylinders

Dual-stage Panoramic Mast (Simplex Mast)
7 6
4
3
1 2
4
213021
Sequence
1 Nuts 5 Set bolt, Shims 7 Lift cylinder, Bracket
2 Fork, Lift bracket 6 Cylinder clamp,
3 Hose guard Cushion, Collar, Shims
4 High-pressure hose
1. Lift bracket removal

(1) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts
from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away from the lift bracket and fork assembly.
204873A
11-12
HYDRAULIC SYSTEM
2. Removing hose guard

With the masts at the maximum lift position, remove the
hose guard from the front side.
Lowering masts
Operate the lift lever gradually to lower the masts.
3. Disconnecting high-pressure hoses

Right-hand cylinder Left-hand cylinder
Disconnect the high-pressure hoses at the joints indicated
by arrows. Use a drip pan to catch oil flowing out of the
hoses.
213022
4. Removing set bolts

(1) Remove the set bolt at the top of each lift cylinder. Lift
the inner mast to separate the cylinder rod ends. To lift
the inner mast, hitch a sling around the mast with
protective rag.
NOTE
The rod end of either lift cylinder is shim adjusted to
eliminate the difference in stroke between the
cylinders. Before removing the set bolts, make a
record of the amount of shims and cylinders to which
the shims are fitted.
204934
(2) Tie wood blocks under the inner mast, and detach the
sling. Use blocks strong enough to support the mast.
Make sure the right and left wood blocks are the same
in height.
202983
11-13
HYDRAULIC SYSTEM
5. Removing lift cylinders

Hitch a sling to the lift cylinder from the rear side of the
mast, and remove the cylinder. Hitch the sling before
removing the cylinder clamp.
204935
Installation
To install, follow the removal sequence in reverse, and
follow the instructions below:
1. Extend and retract the lift cylinders several times under
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
2. Check the oil level in the hydraulic tank with an oil
level gauge. (Refer to Hydraulic Tank section,
Inspection and Adjustment.)
3. Check to make sure that the lift height is correct.
4. After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the
two cylinders. (Refer to Group 12 MAST AND
FORK.)
11-14
HYDRAULIC SYSTEM
The following describes the procedures for removing and installing the mast assembly. Note that the triple-stage full
free panoramic mast (Triplex Mast) is used as an example.
Triple-stage Full Free Panoramic Mast (Triplex Mast)
207612
Sequence
1 Nuts 3 First lift cylinder
2 Lift bracket assembly 4 Chain wheel support assembly
5 Second lift cylinder
1. Removing lift bracket assembly 2

(1) Lower lift bracket assembly 2, and place wood blocks
under the assembly. Tilt the mast forward, lower the
inner mast to the bottom, then remove nuts 1 from the
anchor bolts of the first lift chains. 1
207613
11-15
HYDRAULIC SYSTEM
(2) Position the mast upright. Raise the inner mast until
main rollers 6 of lift bracket assembly 2 become free.
Then, slowly move the vehicle in reverse to separate
from lift bracket 2.
6
2
207762
2. Removing first lift cylinder 3

(1) Hitch a sling to the first lift cylinder 3, and suspend the
cylinder with a hoist. Wind the sling securely around
the lift cylinder to prevent slipping.
(2) Remove the lift cylinder connecting and mounting
bolts, and gently dismount first lift cylinder 3.
207616
3. Removing second lift cylinders 5

(1) Disconnect hoses from second lift cylinders 5.
(2) Remove stopper bolts at the upper sections of second
lift cylinders 5, and lift the inner mast (dual-stage full
free panoramic mast) or middle mast (triple-stage full
free panoramic mast) approximately 550 mm (21.67
in.) using slings.
207617
11-16
HYDRAULIC SYSTEM
(3) Place wood blocks under the inner mast (dual-stage full
free panoramic mast) or middle mast (triple-stage full
free panoramic mast).
Make sure the right and left wood blocks are the same
in height.
202983
(4) Hitch a sling to second lift cylinder 5 behind the mast,

remove cylinder clamp retaining bolts, and gently
remove second lift cylinder 5.
Hitch the sling securely to the cylinder. The cylinder
cannot be lifted straight up since the mast cross-member
is located above the cylinder. Tilt the cylinder and
move it away from the cross-member to remove. Be
careful not to place the hands caught between the
cylinder and mast.
207618
Installation
To reinstall, follow the removal sequence in reverse, and
follow the instructions below:
(1) Install chain wheel support assembly 4 parallel to a line
connecting the centers of chain anchor bolt holes on
first lift cylinder 3 to prevent chains from twisting.
(2) Adjust the chain tensions.
Good Bad
(See the section on Inspection and Adjustment.)
(3) Extend and retract the lift cylinders several times under 207638
no load condition to bleed air out of the cylinder circuits
and to make sure that the cylinders move smoothly.
(4) After proper operation is confirmed, check the oil level.
11-17
HYDRAULIC SYSTEM

Simplex Mast, Triplex Mast Second Cylinders
Disassembly
❋: Parts contained in seal kit
207064
Sequence
1 Retainer 6 Check valve, O-ring
2 Wiper, Rod seal, Backup rings, O-ring 7 Wiper ring, Piston seal, Backup ring
3 Spacer 8 Cylinder rod
Remove parts 4 through 8 as assembly. 9 Cylinder tube
4 Circlip, Sleeve
5 Washer
11-18
HYDRAULIC SYSTEM
Reassembly
1 2 3 4 5 6 7
13 15 14 16 17 18 12 11 8 9 10
207073
Sequence
1 Piston rod, Piston 7 Circlip Install parts 14 through 18 to
Install parts 2 through 10 to 8 Backup ring part 13.
part 1. 9 Piston seal 14 Rod seal
2 Check valve 10 Wiper ring 15 Wiper
3 O-ring 11 Spacer 16 Backup ring
4 Washer 12 Cylinder tube 17 O-ring
5 Circlip 13 Retainer 18 Backup ring
6 Sleeve

1. Use all parts in the seal kit to replace removed parts.
2. After installing seal kit parts, apply hydraulic oil before
assembling the cylinder tube and piston rod.
3. Fill the space between the cylinder tube and piston rod
with the specified amount of hydraulic oil before
installing the retainer.
57 cc
Amount of hydraulic oil
(3.48 cu. in.)
4. Tighten the retainer to the specified torque.
170 to 240 N·m

Retainer tightening torque (17.3 to 24.5 kgf·m)
[125.4 to 177.0 lbf·ft]
11-19
HYDRAULIC SYSTEM
Duplex Mast, Triplex Mast First Cylinder
Disassembly
207642
Sequence
1 Retainer 4 Circlip, Washer, O-ring, Check valve
2 O-ring, Backup ring, Rod seal, Wiper 5 Piston rod, Piston
Remove parts 3 through 5 as sub-assembly from 6 Cylinder tube
part 6.
3 Wear ring, Nylon ring, Piston seal
11-20
HYDRAULIC SYSTEM
Reassembly
13 12 14 15 1 6 7 8 9
11 10 2 3 4 5
207604
Sequence
1 Piston rod, Piston 6 Nylon ring Install parts 12 through 15 to
Install parts 2 through 9 to 7 Piston seal part 11.
part 1. 8 Nylon ring 12 Rod seal
2 Check valve 9 Wear ring 13 Wiper
3 O-ring 10 Cylinder tube 14 Backup ring
4 Washer 11 Retainer 15 O-ring
5 Circlip

1. Use all parts in the seal kit to replace removed 4. Tighten the retainer to the specified torque.
parts.
353 to 380 N·m
2. After installing seal kit parts, apply hydraulic oil Retainer tightening
(36 to 39 kgf·m)
before assembling the cylinder tube and piston rod. torque
[260 to 280 lbf·ft]
3. Fill the space between the cylinder tube and piston
rod with the specified amount of hydraulic oil
before installing the retainer.
20 to 25 cc
Amount of hydraulic oil
(1.2 to 1.5 cu. in.)
11-21
HYDRAULIC SYSTEM
Duplex Mast Second Cylinders
Disassembly
10
6
5❋
9
3❋
1
2❋
11
211091
Sequence
1 Retainer 6 Spacer
Remove parts 3 through 10 as sub-assembly from 7 Snap ring
part 11. 8 Sleeve
2 Wiper ring, Rod seal, O-ring, Backup ring 9 Piston rod
3 Backup ring, Piston seal, Wear ring 10 Bleed screw, Seal washer
4 Piston 11 Cylinder tube
5 Pull-in wire
NOTE
Spacer is installed in the cylinder with lifting height of
3.7 m (146 in.) or more.
11-22
HYDRAULIC SYSTEM
Reassembly
8 6 3 2
❋ 7 5 ❋ 10 4 ❋ ❋ 1
9
11
000825C
Sequence
1 Retainer 6 Pull-in wire
2 Wiper ring, Rod seal 7 Piston
3 Backup ring, O-ring 8 Backup ring, Piston seal, Wear ring
4 Piston rod 9 Sleeve, Snap ring
Install parts 1, 2, 3, 5, 6, 7 to Part 4 10 Cylinder tube
5 Spacer 11 Seal washer, Bleed screw

1. Use all parts in the seal kit to replace removed 4. Tighten the set screws (2 locations) to the specified
parts. torque.
2. Apply hydraulic oil to the sliding sections on the Unit: N·m (kgf·m) [lbf·ft]
cylinder tube inner surface and piston rod outer
4.5 to 5.0
surface before installation.
Set screw tightening torque (0.46 to 0.51)
3. Tighten the piston and holder to the specified [3.3 to 3.7]
torque.
Unit: N·m (kgf·m) [lbf·ft]
170 to 240
Holder tightening torque (17.3 to 24.5)
[125.3 to 177.0]
11-23
HYDRAULIC SYSTEM
Tilt Cylinders
1
4
and Installation
Removal
Sequence
1 Rubber hose
2 Tilt socket pin, Bolt, Washer
3 Tilt cylinder pin, Bolt, Washer
4 Tilt cylinder
2 3
206883
Start by:
(1) Lower the forks to the bottom, and tilt the mast fully
forward.
(2) Hitch lifting slings to the top crossmember of the outer
mast by using eye-bolts. Support the weight of the mast
with the hoist.
205740
11-24
HYDRAULIC SYSTEM

4
213038
Sequence
1 Cylinder socket, Grease nipple, Spherical 3 Piston rod, Piston seal, Piston
bearing, Nut, Seal, Bolt 4 Tube, Socket end, O-ring, Set screw, Bushing
2 Guide, Set screw, O-ring, Wiper ring, Rod seal
NOTE
Do not remove the tilt socket bearing and cylinder tube
bushing unless they are defective.
11-25
HYDRAULIC SYSTEM
Removing bushing
Wrap the cylinder with a rag, and clamp it in a vise. Using
a wrench, remove the guide bushing from the cylinder.
Inspection after disassembly
1. Cylinder tube
(1) Check the bore wall for wear, grooving, scratches and
rusting. 200351
(2) Check the welds for cracks.
2. Piston rod
Check for surface flaws such as grooving, scratches, rusting
and wear. The rod must be replaced if its threads show a
sign of stripping or any other damage.
3. Packings and rings

Replace all parts contained in the seal kit, once the cylinder
is disturbed.
11-26
HYDRAULIC SYSTEM
Reassembly
17 14 1 8 4 9 2 12 13
7 6 5 3 11 10
213025
Sequence
1 Piston rod 10 Set screw
2 Piston 11 O-ring
3 Piston seal 12 Socket end
4 Set screw 13 Bushing
5 O-ring 14 Cylinder socket
6 Rod seal 15 Spherical bearing
7 Wiper ring 16 Seal
8 Guide 17 Grease nipple
9 Tube

1. Use all parts in the seal kit to replace removed
parts.
2. After installing seal kit parts, apply hydraulic oil
before assembling the tube and piston rod.
3. Tighten the guide to the specified torque.
200 ± 25 N·m
Piston, guide and socket end (20.4 ± 2.5 kgf·m)
[148 ± 18 lbf·ft]
11-27
HYDRAULIC SYSTEM
Flow Regulator Valve

Disassembly
203559
Sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims
Inspection after disassembly

1. Check spring for fatigue.
2. Check seat and sliding faces of the valve and piston.
3. Check the sliding surfaces of the piston and valve body
for damage.
NOTE
Replace the flow regulator valve as an assembly if any
defect is found.
11-28
HYDRAULIC SYSTEM
Suction Strainer and Return Filter

and Installation
Removal
The hydraulic tank is mounted on the counterweight. 1
Before dismounting the hydraulic tank, remove other parts
2
such as the motor, gear pump and controller. For the
4
removal sequence, refer to Removal (Part 1) section in
REAR AXLE. 5
Sequence 3
7
1 Hose (rear axle return), Clamp
2 Hose (suction), Clamp 6
3 Hose (return), Clamp
4 Cap, Oil level gauge
5 Coupling
6 Return pipe, Return filter, O-ring
8
7 Suction pipe, Suction strainer, Packing, Plate
8 Hydraulic tank
213026
Inspection
Clean the parts. Replace parts that are clogged or damaged.
Installation
Follow the removal procedure in reverse. Observe the
following instructions during installation.
(1) When replacing the strainer or filter, observe the
specified tightening torque during installation to the
pipe.
Tightening torque 49 ± 9.8 N·m

for strainer and filter (5 ± 1 kgf·m)
(installation to pipes) [36 ± 7.2 lbf·ft]
(2) Replace the packings and O-ring with new parts.

213027
11-29
HYDRAULIC SYSTEM
Hydraulic Tank
Oil
Oil level, contamination, clouding (mixing of air or oil)
Tank capacities and mast types

Unit: liter (U.S. gal)
Truck Model
Mast
Two-stage panorama masts Lift

2.0 to 6.0 m N level: 14.7 (3.88)
(Simplex mast) H level: 16.8 (4.44)
(79 to 236 in.)
Two-stage full-free masts Lift

2.8 to 4.0 m N level: 14.7 (3.88)
(Duplex mast) H level: 16.8 (4.44)
(110 to 157 in.)
Three-stage full-free masts Lift

3.7 to 7.0 m N level: 14.7 (3.88)
(Triplex mast) H level: 16.8 (4.44)
(146 to 276 in.)
NOTE
In all models, and in any combinations of mast and
attachment, the oil level in the tank should not exceed
the H level when the masts are lowered.
Suction strainer
Damage, clogging
Return filter
Damage, clogging
11-30
HYDRAULIC SYSTEM
Control Valve
(1) External oil leaks
(a) Oil leaks from O-rings between housings
(b) Oil leaks from scraper O-ring
(c) Oil leaks from bolt sections
(2) Oil leaks

Since it is difficult to measure the amount of oil leaks from
3° to 4°
the dismounted control valve, inspect oil leaks with the
control valve connected to the cylinder by following the
steps (a) through (c) below:
The internal leakage to be checked includes leakages
occurring at the lift spool, tilt spool, tilt lock valve and
check valves at the oil temperature of approximately 50°C
(122°F). Approx. 1 m
(3.3 ft)
(a) Place rated load on the forks and lift it to a height of
approximately 1 m (3.3 ft). Tilt the masts 207764
approximately 3 or 4 degrees forward from the upright
position, then turn the key switch off.
(b) Remove the oil return hose, and collect oil from the
port.
Standard volume of oil 20 cc

drained in 15 minutes (1.22 cu. in.) max.
(c) When the gravitational-pull lowering distance and

forward tilt distance are large, check the amount of oil
leakage from each cylinder even if the amount of oil
drained in 15 minutes is less than 20 cc (1.22 cu.in.).
(Measured amount of oil leakage is a standard value; it
does not denote the allowable limit.)
211285
(3) Adjustment of main relief valve

(a) Mount an oil pressure gauge with a measuring range of
24.5 MPa (250 kgf/cm ) [3556 psi] on the delivery pipe
2
by using Special Tool Kit (64309-17701).
211286
11-31
HYDRAULIC SYSTEM
(b) Operate the tilt lever, and tilt the masts backward to the
maximum position. When the tilt cylinder reaches the
limit in its backward tilt movement, check the oil
pressure gauge. If the gauge indicates 18142 kPa (185
kgf/cm2) [2631 psi], it is normal.
(c) If the relief pressure is not normal, loosen the lock nut
of the relief valve, and while observing the gauge
indication, adjust the pressure using the adjusting
screw.
(d) While pressing the adjusting screw, tighten the lock nut
securely.
(e) After tightening the lock nut, check the set pressure of
the relief valve again.
+490
18142 0 kPa
Main relief valve
(185 +50 kgf/cm )
2
setting pressure
[2631 +71
0 psi]
11-32
HYDRAULIC SYSTEM
Lift Cylinders and Tilt Cylinders
(1) Adjustment of mast tilt angle

(a) Adjust the air pressure of the tires, and place the
vehicle on level ground.
(b) Tilt the masts backward to the maximum position.
(c) Measure the backward tilt angles of both right and left
tilt cylinders.
(d) To adjust, loosen the socket tightening bolt, turn the tilt
cylinder rod, and adjust the cylinder stroke until the
right and left tilt cylinders are tilted at the same angle. 206890
NOTE
The forward tilt angle of the masts is automatically set
when the backward tilt angle is adjusted.
Forward tilt – Backward tilt

6° – 7°
(STD)
(2) Adjustment of right and left lift cylinder strokes

(a) Gently raise the inner masts, and observe the right and
left piston rod stopping conditions when they reach the
maximum lift position.
(b) If the upper parts of the inner masts shake at the
moment of stopping, make adjustment with shims.
Improper adjustment causes the inner mast to slant
slightly when the mast is stopped, and also causes the
lift cylinder with a longer cylinder stroke to shake 204698
when the lift cylinder is stopped.
Adjustment method
(1) Raise the inner masts, and place wood blocks under the
inner masts. Lower the masts until the inner masts
contact the wood blocks.
202983
11-33
HYDRAULIC SYSTEM
(2) Loosen the stopper bolt located at the upper part of the
lift cylinder that stopped first. Lower the piston rod,
and insert a shim at the upper piston rod end.
NOTE
When lowering the piston rod, operate the lift lever to
lower the masts and release oil from the cylinder.
(3) Raise the piston rod, then tighten the lift cylinder
stopper bolt. Remove the wood blocks from under the 200365
inner masts.
(4) Lower the inner masts gently, and check to see if the
piston rods move smoothly until the inner masts reach
the lowest position.
Test
(1) Gravitational-pull lowering test
(a) Set the masts upright with rated load, raise the masts
approximately 1 to 1.5 m (3.3 to 4.9 ft), then turn the
key switch off.
(b) Draw a reference line on a mast, and measure the
descent (retraction of lift cylinder) for 15 minutes.
Unit: mm/15 min (in./15 min)
206891
Gravitational-pull lowering
50 (1.97) max.
distance (with load)
(2) Gravitational-pull forward tilt test

(a) Set the masts upright with rated load, raise the forks
approximately 500 mm (19.7 in.), then turn the key
switch off.
(b) Measure the amount of the tilt cylinder extension after
15 minutes.
Unit: mm/15 min (in./15 min)
Truck Models
Item 206892
Gravitational-pull
forward tilt distance 22 (0.87) 22 (0.87)
(with load)
Inspection of Piping
(1) Check the piping for oil leaks.
(2) Check the rubber hoses for damage, twisting and
sagging.
11-34
Displacement: L R
Hydraulic control valve 63 cm3 (3.8 cu. in.)/rev
(AC motor, MC models )
T1
B4
A4
B3 EL Steering cylinder
A3
Hydraulic Circuit Diagram
Pressure
switch
B2
P T LS
Std. tilt A2
cylinder
Flow A1 CF EF
11-35
regurator
LS
P Priority valve
Gear pump
Displacement:
24.5 cm3 (1.49 cu. in.)/rev
M
G1 P 18.1 MPa T2 Pump motor
36/48V Dual voltage
11.56 kW Operation
at 48V
Return Suction
filter strainer
Lift cylinder 15 mm 100 mesh
with down safety valve
213035
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Hydraulic Circuits
Lift Up
211350
11-36
HYDRAULIC SYSTEM
Lift Down
211351
11-37
HYDRAULIC SYSTEM
Tilt Forward
211352
11-38
HYDRAULIC SYSTEM
Tilt Backward
211353
11-39
HYDRAULIC SYSTEM
Troubleshooting
Improper oil viscosity

Excessive workload caused by severe work condition
Local heating caused by large resistance due
Hydraulic tank heats to clogged line
Hydraulic tank
extremely Improper adjustment of relief valve
Low set pressure due to spring fatigue or damage
Worn gear pump
Flattened discharge line or clogged line
Insufficient pump suction

Pump produces loud
abnormal noise
Cavitation
Oil pump
Damage in pump case, Applied pressure exceeded rating.
drive gear or pump
port flange Deformation or damage caused by external force
Oil leaks from oil seal

Oil leaks from sliding surface of drive shaft
Oil leaks from pump
Loose pump tightening bolt
Deteriorated seal inside pump
11-40
HYDRAULIC SYSTEM
Insufficient oil in hydraulic tank

Masts do not rise or Relief valve malfunction
tilt in either forward (1) Sticking of main valve
or backward direction (2) Broken valve spring
Oil pump malfunction
Relief valve malfunction
(1) Low relief set pressure
Rated cargo load (2) Faulty plunger or poppet seat
cannot be lifted (3) Spring fatigue
(4) Damaged valve case O-ring
Oil pump malfunction
Worn or damaged piston seal
Insufficient oil (due to natural oil consumption)
Oil leaks from oil line or due to damaged seal
Cylinders operate Oil viscosity higher than specified
very slowly No oil suction by gear pump
Oil leaks from hydraulic circuit
Abnormal oil temperature rise
Slow pump rotation
Rising speed is very Insufficient spool stroke due to loose operation
slow lever
Clogged tank strainer
Insufficient gear pump discharge volume
Lift cylinder
lowering speed is Sticking of flow regulator valve piston
very slow Clogged flow regulator valve, bent hydraulic
hose, or large resistance in hydraulic circuit due to
Lift and tilt cylinders sectional clogging
Cylinders shake Bent piston rod

during operation Air mixed in hydraulic piping
Insufficient operating oil in tank
Leaks inside control valve spool
Scratches on sliding surface of cylinder tube
Large gravitational- that are deep enough to be detected by finger
pull lowering nails
distance in lift Large scratches on sliding surface of cylinder
cylinders tube
Damage or deformation of piston seal
Oil leaks from hydraulic piping
Large gravitational- Leaks inside control valve spool

pull forward tilt Lodging of foreign particles on packing
distance in tilt Damaged piston seal
cylinder Scratches on piston seal
Abnormal shape deformation or leaks from
hydraulic piping
Lift cylinders or
tilt cylinder drop or Large sectional scratches or rusting on inner
tilt forward naturally surface of cylinder
at certain position Deformed cylinder
Lodging of foreign particles on seal
Oil leaks from bushing Scratches on oil seal or periphery of dust seal
Damaged O-ring
Abnormal shape deformation
11-41
HYDRAULIC SYSTEM
Service Data
A : Standard value
Unit: mm (in.)
Truck Model
Item
ET3000: 500 (19.7) ET4000

48 V A
Simplex mast ET3500: 440 (17.3) 400 (15.7)
Lift speed (rated load)
mm/sec (in./sec) ET3000: 400 (15.7) ET4000

36 V A
ET3500: 350 (13.8) 340 (13.4)
Simplex mast
Simplex mast
48 V
Lowering speed (rated load)
A 520 (20.5)
mm/sec (in./sec)
36 V
Forward tilt angle A 6°

Backward tilt angle A 7°
Lift cylinder rod drift (rated load)

Oil temperature 45 °C (113 °F) A 50 (1.97), max
mm (in.)/15 min.
Tilt cylinder rod drift (forward) (rated load)

mm (in.)/15 min.
Main relief valve setting +490 +5 +71
A 18142 +0 (185 +0) [2631+0 ]
kPa (kgf/cm2) [psi]
Power steering relief valve setting
A 6500 (66.3) [943]
kPa (kgf/cm2) [psi]
Capacity A 24.5 (1.49)

cc (cu. in.)/rev
Hydraulic pump
33.3
Mounting bolts
A (3.39)
[24.6]
11-42
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
Item
Duplex mast
— —
Lift speed (rated load/no load) A
mm/sec (in./sec)
Duplex mast
Duplex mast
Lowering speed (rated load) A — —

mm/sec (in./sec)

No. 1
Oil temperature 45 °C (113 °F) A —
mm (in.)/15 min.
No. 2
mm (in.)/15 min.
Triplex mast
— —
Lift speed (rated load/no load) A
mm/sec (in./sec)
Triplex mast
Triplex mast
Lowering speed (rated load) A — —

mm/sec (in./sec)

No. 1
Oil temperature 45 °C (113 °F) A —
mm (in.)/15 min.
No. 2
mm (in.)/15 min.
11-43
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
Item
[Piston] 45
A
Inside diameter of cylinder tube 1 (1.77)
Lift cylinders (Simplex mast) (Triplex mast second)
Diameter of piston rod 2 A 35 (1.38)

170 to 240
Tightening torque for retainer 3
A (17.3 to 24.5)
[125.4 to 177.0]
Amount of hydraulic oil 4 cc (cu. in.) A 57 (3.48)
2 1
3 4
207073
Flow regulator Return
filter
Tightening torque
A 45 (4.59) [33.2]
Flow rate (no load)
A 48 (12.7)
liter (U.S. gal)/min
valve
Tightening torque of elbow and connector

(for mounting on flow regulator valve) A 63.7 (6.5) [47]
11-44
HYDRAULIC SYSTEM
A : Standard value
Unit: mm (in.)
Truck Model
Item
[Piston] 70
A
Diameter of piston rod 2 A 50.8 (2.0)
353 to 380
Lift cylinders (Duplex mast, triplex mast first cylinder)
Tightening torque for retainer 3

A (36 to 39)
[260 to 280]
Amount of hydraulic oil 4 20 to 25
A
cc (cu. in.) (1.2 to 1.5)
1
2
3 4
207604
11-45
HYDRAULIC SYSTEM
A: Standard value
Unit: mm (in.)
Truck Model
Item
[Piston] 45
A
A 32
Diameter of piston rod 2
(1.26)
170 to 240
Tightening torque for holder 3
A (17.3 to 24.5)
[125.3 to 177.0]
Lift cylinders (Duplex mast second cylinders)
Holder thread diameter 3 A M52 × 2

4.5 to 5.0
Air bleed screw tightening torque 4
A (0.46 to 0.51)
[3.3 to 3.7]
1 2
4
000825C
11-46
HYDRAULIC SYSTEM
Truck Model
Item
63
Inside diameter of tube 1 A
(2.48)
25
Diameter of piston rod 2 A
(0.98)
0
(2.48) 35–0.012
Inside diameter of spherical bearing (fitted) 3 A 0
(1.38 –0.0005)
32 +0.085
0
Inside diameter of bushing (fitted) 4 A
(1.26 +0.003
0 )
[Guide]
A M73 × 1.5
Thread diameter 5
[Guide]
Tightening torque 5 A 200 ± 25 (20.4 ± 2.5) [148 ± 18]
[Cylinder socket]
A M24 × 1.5
Tilt cylinders
Thread diameter 6
Tightening torque Socket end 7
N·m (kgf·m) [lbf·ft] A 200 ± 25 (20.4 ± 2.5) [148 ± 18]
Piston 8
6 5 8 7
3
4
1 2
213028
11-47
MAST AND FORKS
Mast Systems ..........................................................................................12 – 1

Mast Type Code Stamping Position ..........................................................12 – 1
Explanation of Mast Type Code ................................................................12 – 1
Mast Types ...............................................................................................12 – 1
Description ...............................................................................................12 – 2
Dual-stage Panoramic Mast (Simplex Mast) .............................................12 – 2
Dual-stage Full Free Panoramic Mast (Duplex Mast) ................................12 – 3
Triple-stage Full Free Panoramic Mast (Triplex Mast) ................................12 – 4
Operation of Dual-stage Full Free Panoramic Mast ...................................12 – 5
Operation of Triple-stage Full Free Panoramic Mast .................................12 – 5
Removal and Installation ......................................................................12 – 6
Mast and Lift Bracket Assembly .................................................................12 – 6
Dual-stage Panoramic Mast (Simplex Mast) ...........................................12 – 6
Triple-stage Full Free Panoramic Mast (Triplex Mast) ..............................12 – 9
Disassembly and Reassembly ............................................................ 12 – 12
Dual-stage Panoramic Mast (Simplex Mast) ............................................. 12 – 12
Dual-stage Full Free Panoramic Mast (Duplex Mast) ................................ 12 – 16
Triple-stage Full Free Panoramic Mast (Triplex Mast) ................................ 12 – 20
Forks ........................................................................................................ 12 – 24
12
Chain Tension Adjustment ........................................................................ 12 – 25
Clearance Adjustment on Lift Bracket ....................................................... 12 – 28
Mast Clearance Adjustment ...................................................................... 12 – 30
Main Roller Shim Replacement.................................................................. 12 – 32
Mast Strip Adjustment ............................................................................... 12 – 36
Tilt Angle Adjustment ................................................................................ 12 – 36
Lift Cylinder Stroke Adjustment ................................................................. 12 – 37
Troubleshooting ...................................................................................... 12 – 38
Service Data ............................................................................................ 12 – 39
MAST AND FORKS
Mast Systems
This manual applies to the following vehicle models (names).
Mast Types Dual-stage Dual-stage Full Free Triple-stage Full Free

Model Panoramic Mast System Panoramic Mast System Panoramic Mast System
1 ton class 2G15A 2H15A 2J15A
2 ton class 1G20A 1H20A 1J20A
NOTE : Maximum fork lift height [30 : 3000 mm (118 in.)]
Mast Type Code Stamping Position Mast Types
Code Mast Type
Dual-stage panoramic masts

G
Simplex mast
Dual-stage full free panoramic masts

H
Duplex mast
Triple-stage full free panoramic masts

J
Triplex mast
211100
Explanation of Mast Type Code

Example: 2 G 15 A 30
Maximum fork lift height [30 : 3000 mm (118 in.)]

Revision code (A ➞ B ➞ C ··· Z)
Representative model (not allowable load)
Mast type
Major revision record (1 to 9)
12-1
MAST AND FORKS
Description
207082
Unit: mm (in.)
Diam. of 1 ton class 2 ton class
Main Roller
S 99 (3.90)
207760
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02)
1 Inner mast A: Main roller

2 Outer mast B: Main roller
3 Lift chain C: Main roller
4 Lift bracket D: Side roller
5 Mast-support bearing cap E: Main roller
F: Main roller
G: Mast strip
The panoramic mast features two lift cylinders placed Mast strips are fitted to the top end of outer mast.
behind the mast columns, right and left, to provide These strips are for backing up the inner mast when the
maximum visibility. mast is tilted backward.
12-2
MAST AND FORKS
Dual-stage Full Free Panoramic Mast (Duplex Mast)
207608
1 Lift chain 5 Outer mast 8 Lift bracket main roller

2 First lift cylinder 6 Lift bracket 9 Mast upper main roller
3 Second lift cylinder 7 Chain wheel 10 Mast lower main roller
4 Inner mast
The duplex mast provides a free lift amount until the When the first lift cylinder rod extends fully, the second
top of lift bracket reaches the mast height. lift cylinders raise the assembly consisting of the lift
The mast assembly consists of the inner mast, outer bracket, first lift cylinder and inner mast.
mast, lift bracket, first lift cylinder and second lift The shoulder sections of the mast main rollers contact
cylinders. the mast rails. The rollers are installed perpendicular to
The first lift cylinder raises the lift bracket, while the the sliding surfaces.
second cylinders operate the inner mast and lift bracket. The main rollers used in the 1 ton and 2 ton classes are
For lifting operation, oil is first sent to the first lift the same as those in dual-stage panoramic mast
cylinder which raises the forks until the cylinder rod (simplex mast).
reaches its stroke end.
12-3
MAST AND FORKS
207609 207610
1 First lift chain 5 Inner mast 9 Second chain wheel

2 First lift cylinder 6 Middle mast 10 Lift bracket main roller
3 Second lift chain 7 Outer mast 11 Mast upper main roller
4 Second lift cylinder 8 Lift bracket 12 Mast lower main roller
The triplex mast provides a free lift amount until the top For lifting operation, oil is first sent to the first lift
of lift bracket reaches the mast height. cylinder which raises the forks until the cylinder rod
The mast assembly consists of the inner mast, middle reaches its stroke end.
mast, outer mast, lift bracket, first lift cylinder and When the first lift cylinder rod extends fully, the second
second lift cylinders. lift cylinders raise the assembly consisting of the lift
The first lift cylinder raises the lift bracket, while the bracket, first lift cylinder, inner mast and middle mast.
second cylinder operates the three-stage telescopic The shoulder sections of the mast main rollers contact
mechanism and lift bracket. Two pairs of lift chains are the mast rails. The rollers are installed perpendicular to
installed. The cylinders and lift chains are designed for the sliding surfaces.
smooth and effective operation. The main rollers used in the 1 ton and 2 ton classes are
the same as those in dual-stage panoramic mast
(simplex mast).
12-4
MAST AND FORKS
Operation of Dual-stage Full Free Panoramic Mast
203598
Operation of Triple-stage Full Free Panoramic Mast
203600
12-5
MAST AND FORKS
Removal and Installation
Mast and Lift Bracket Assembly

5 4
1
7 6
213030
Sequence
1 Nuts 5 High-pressure hose for lift cylinders
2 Forks, Lift bracket 6 Mast support cap
3 Tilt socket pins 7 Mast support bushing
4 Tilt cylinders
1. Lift bracket removal

(1) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts
from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away from the lift bracket and fork assembly.
207084
12-6
MAST AND FORKS
2. Removing lift cylinder high pressure hoses

Lower the mast to the bottom position, disconnect the
hoses at the flow regulator valve.
3. Removing tilt cylinders

(1) Hitch a sling to the mast. Using two eye-bolts and a
sling as shown, support the mast with a hoist.
! CAUTION
Be sure to use a hoist with enough capacity to
support the mast assembly.
204845
(2) Remove the tilt socket pins, and separate the masts
from the tilt cylinders.
(3) Turn the key switch to ON and pull back the tilt lever to
contract the tilt cylinder rods.
(4) Turn the key switch to OFF and disconnect the high-
pressure hose from tilt cylinders.
207086
4. Removing mast support bearing caps

(1) Mark the bearing caps to ensure the correct
reassembling before removing them.
(2) Remove the cap bolts and lift off the mast assembly.
Lay it down flat on a level floor.
NOTE
Lay the mast assembly on the floor, so that you have
enough space to disassemble the parts.
207087
12-7
MAST AND FORKS
Installation
follow the steps below:
Inner Inner cap
1. Procedure for mounting mast support bushings 7 and
bushing
caps 6.
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings 7 and caps 6, making sure
that the sides with larger chamfered area face toward
the center of the vehicle. Bushing 7
(3) Be sure to tighten the mast support bolts securely. Refer
Cap 6
to chart on page 13-11. Chamfered faces 211101
2. Adjust the chain tensions.

(Refer to the Inspection and adjustment section.)
Tighten the nuts to the specified torque.
Tightening torque
Tightening Torque
55.8 to 56.8 N·m

Upper nut ➁ (5.7 to 5.8 kgf·m)
[41.2 to 41.9 lbf·ft]
102709
98 to 103 N·m
Double nut (lower) ➀ (10 to 10.5 kgf·m)
[72.3 to 76.0 lbf·ft]
3. Air bleeding of lift cylinders

Due to internal drain type cylinder, the lift cylinders do
not require air bleeding.
4. After proper operation is confirmed, check the oil level.
12-8
MAST AND FORKS
Mast and Lift Bracket Assembly

The following describes the procedures for removing and reinstalling the mast assemblies of dual-stage full free
panoramic mast (Duplex Mast) and triple-stage full free panoramic mast (Triplex Mast). Note that the triple-stage
full free panoramic mast (Triplex Mast) is used as an example.
2 6 5 4
213031
Sequence
1 Nuts 5 Mast support cap
2 Fork, Lift bracket assembly 6 Mast support bushing
3 Tilt socket pin
4 High-pressure hose for lift cylinders

1. Removing lift bracket assembly 2
(1) Lower lift bracket assembly 2, and place wood
blocks under the assembly. Tilt the mast forward,
lower the inner mast to the bottom, then remove
nuts 1 from the anchor bolts of the first lift chains.
207613
12-9
MAST AND FORKS
(2) Position the mast upright. Raise the inner mast until
main rollers 7 of the lift bracket become free. Then,
slowly move the vehicle in reverse to separate from lift
bracket 2.
7
2
207762
2. Separating mast and tilt cylinders

(1) Lower the inner mast. Hitch a sling to the upper cross-
member of the outer mast. For sling attachment, install
eye-bolts in the holes on the right and left sides. Use a
crane and lift.
! CAUTION
Be sure to use a hoist with enough capacity to
support the mast assembly. 207614
(2) Place wood blocks under the tilt cylinder mounting

sections, and remove pins.
(3) Turn the key to ON, and pull back the tilt lever to
contract the tilt cylinder rods.
(4) Disconnect high-pressure hose from tilt cylinders.
207086
3. Removing mast support caps 5

(1) Mark caps 5 to ensure the caps are reinstalled in
original positions during reassembly.
(2) Remove cap mounting bolts. Dismount the mast
assembly from vehicle in the suspended condition.
With the lift bracket side facing up, place the mast
assembly horizontally on wooden blocks on the level
ground. 5
207615
12-10
MAST AND FORKS
Installation
1. Procedure for installing mast support bushings 6 and
Inner Inner cap
caps 5.
bushing
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings 6 and caps 5, making sure
that the sides with larger chamfered area face toward
the center of the vehicle.
Bushing 6
2. Adjust the chain tensions.
Cap 5
(Refer to the Inspection and adjustment section.) Chamfered faces 211101
(1) Be sure to tighten the mast support bolts securely. Refer
to chart on page 13-11.
Tighten the nuts to the specified torque.
Tightening torque
Tightening Torque
55.8 to 56.8 N·m

[41.2 to 41.9 lbf·ft]
98 to 103 N·m
[72.3 to 76.0 lbf·ft]
3. Bleeding lift cylinders.

102709
In the dual-stage full free panoramic mast, only the
second lift cylinders are provided with air bleeding
valves.
The other lift cylinder does not require air bleeding
since it is an internal drain type cylinder.
4. After proper operation is confirmed, check the oil level.
12-11
MAST AND FORKS

Disassembly
12 10
15
3
11 10
13
9
2 16 8
17
8
6
6
6 14
1
4
5
213032
Sequence
1 Nuts 10 Cylinder clamps, Seats, Shims, Cushion,
2 Forks, Lift bracket Collar, Bolts
3 Backrest 11 Bolt, Shims
4 Main roller, Shims 12 Mast strip, Shims
5 Main roller, Shims 13 Main roller, Shims
6 Side roller, Brackets, Shims 14 Main roller, Shims
7 Hose guard 15 Inner mast
8 Lift hose (high pressure), 16 Lift cylinders
Rubber hose, T-joint, Down safety valve 17 Outer mast
9 Snap ring, Chain wheel

1. Removing mast strips and main rollers
Remove bolts 10, 11 to free lift cylinder 16.
Displace the tops of the two lift cylinders from
inner mast 15. Slide inner mast 15 toward the
bottom of outer mast 17, and remove main rollers
13, 14 and mast strips 12.
12-12
MAST AND FORKS
2. Inner mast removal

After removing the main rollers, hitch a sling to the
inner mast crossmember and slide the inner mast to the
upper side of the outer mast to clear the outer mast
roller shafts. Hitch a sling to the inner mast again and
remove it from the outer mast.
207089

1. Mast
(1) Check each roller for wear, binding or other defects.
(2) Check each roller on rolling surface for pitting or other
defects.
(3) Check the mast member and the welded joints of cross-
members, shafts and supports for cracks.
(4) Check the mast support bushings for wear or other
defects.
207090
2. Lift bracket
(1) Check the main rollers and side rollers for smooth
rotation. Inspect each roller for wear and cracks.
(2) Check the welded portions of the bracket for cracks.
(3) Check the finger bar for bend or distortion.
A: Standard value
5 mm (0.2 in.),
Distortion of finger bar A
maximum 207091
12-13
MAST AND FORKS
3. Lift chains, chain wheels and chain wheel supports

(1) Measure the length of each chain to make sure that two
chains are equal in length. Also check the chains for
wear, sign of breakage, link binding and twist.
(2) Check each chain anchor bolt for cracks or defects on
thread.
(3) Check each chain wheel support and chain wheel for
crack or wear. Check that the wheels rotate smoothly.

Unit: mm (in.)
Truck Model
Item
Length of lift chain A 318 (12.52) 381 (15.00)
(per 20 links) B 327 (12.87) 392 (15.43)
4. Mast strips
Check the mast strips for damage, wear or distortion.
Reassembly
To reassemble, follow the reverse of disassembly procedure,
and follow the steps below:
1. Longitudinal clearance adjustment between mast
and lift bracket
Rollers for mast and lift bracket are available in three
sizes (diameters) for selective use. Select the size that
will provide a longitudinal clearance of 1 mm (0.04
in.) or less.
Roller sizes
Unit: mm (in.)
Main Roller 207096
S 99 (3.90)
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02)
12-14
MAST AND FORKS
2. Cylinder clamps
Install each lift cylinder in place (in vertical position)
by fitting to the support, and see if there is any
space between the outer mast and cylinder. Reduce the
space, if any, to zero by shimming.
207093
3. Mast supports
Inner Inner cap
(1) Apply grease to the inside surfaces and grooves of the bushing
caps.
(2) Install mast support bushings and caps orienting the
chamfered faces inward.
Place wood blocks under mast to facilitate greasing
work.
Bushing
Cap
Chamfered faces 211101
4. Precautions for installing chain anchor kit

Be careful not to confuse the center plate with the link
plate.
207094
1 Link plate (stamped mark on surface)

2 Center plate (no stamped mark)
3 Link
4 Split pin
12-15
MAST AND FORKS
Dual-stage Full Free Panoramic Mast (Duplex Mast)

Disassembly
10
16
15
14
13
1
9
11
6 14
5 8
6 12
8
1
4
12
2 9 1
2 3
18
17
7
213033
Sequence
1 High-pressure hose for first cylinder, 10 Bolt, Washer, Shims
Clamp 11 Mast strip, Shims
2 Bolt, Washer, Shims 12 Main roller, Shims
3 First lift cylinder 13 Inner mast
4 Chain guard 14 Second lift cylinder
5 Chain wheel support, Pin 15 Cylinder bracket
6 Chain wheel, Snap ring 16 O-ring, Plug
7 Cylinder guard, Bolt, Washer 17 Mast cap, Bolt, Washer
8 High-pressure hose 18 Outer mast, Grease nipple
9 Cushion, Collar, Shims, Bolt, Washer, Clamp
NOTE
For lift bracket disassembly procedure, refer to the
dual-stage panoramic mast (simplex mast), as the
procedure is the same.
12-16
MAST AND FORKS
Preparation
horizontally on wood blocks. Use a wood block as a wedge
to prevent the inner mast from sliding.

(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on first lift cylinder 3, and gently remove
the cylinder.
Use two slings. Wind or tie slings securely to prevent
from slipping.
207619
2. Removing main rollers 12 and mast strips 11

(1) Remove clamp bolts from the second lift cylinders.
(2) Remove bolts from the upper rod sections of the second
lift cylinders, and place the cylinders on the outer mast.
(3) Check the number of shims and the shim thickness at
the rod end sections.
(4) Lower the inner mast, then remove main rollers 12,
mast strips and shims 11.
207620
3. Removing inner mast 13

18
Using slings, lift and remove inner mast 13, steering it
to pass over the roller shaft sections of outer mast 18.
13 207621

Follow the inspection procedure described in the dual-stage
panoramic mast (simplex mast).
12-17
MAST AND FORKS
Reassembly
1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims 12.
207622
(2) When replacing lift bracket main rollers, make sure

clearance A between each roller and mast surface is 1
mm (0.04 in.) or less.
207623
(3) To install main rollers on shafts, use a driving tool. Be

careful not to strike the outer roller surface with the
driving tool.
Place the roller with its larger chamfered side facing
outside.
202263
2. Installing second lift cylinders

When installing second lift cylinders 14, make sure the
cylinders are parallel to the mast to prevent torsional
stress on the lift cylinders when the mast is positioned
9
at the bottom. Adjust the installation positions of lift
14
cylinder brackets 15 with shims 9.
207632 15
12-18
MAST AND FORKS
3. Installing first lift cylinder

The first lift cylinder must be installed parallel to the
mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 2, adjust the backward inclination so that
clearance at section B is 0 to + 0.5 mm (0 to + 0.02 in.)
larger than clearance at section A.
201752
4. Precaution for installation of chain anchor kit

plate.
200383

3 Link
4 Split pin
12-19
MAST AND FORKS

Disassembly
15
17
9 16
1
15
1
23
26
10
28
22
24
25
12 19
21
7
6
7 8
27
14
30 20
5 19
3 13
29
2 4
11 18
213034
Sequence
1 Hose for first lift cylinder, Clamp, Bolt, Washer 17 Snap ring, Hose pulley, Shaft, Snap ring,
2 Bolt, Washer Chain wheel
3 Shims 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose, clamp, Bolt, Washer
5 Chain guard 20 Joint
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, Shims, Bracket
8 Nut (chain for second lift cylinder) 23 Bolt, Washer, Shims
9 Mast strip, Shims 24 Second lift cylinder
10 Main roller, Shims 25 Mast strip, Shims
11 Main roller, Shims 26 Main roller, Shims
12 Inner mast 27 Main roller, Shims
13 Nuts 28 Middle mast
14 Lift chain (for second lift cylinder) 29 Cap, Bolt, Washer
15 Chain guard, Bolt, Washer 30 Outer mast, Grease nipple
16 Snap ring, Chain wheel
12-20
MAST AND FORKS
NOTE
For lift bracket disassembly procedure, refer to the
dual-stage panoramic mast (simplex mast), as the
procedure is the same.
Preparation
horizontally on wood blocks. Use a wood block as a wedge
to prevent the inner and middle masts from sliding.

(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on lift cylinder 4, and gently remove the
cylinder.
Use two slings. Wind or tie slings securely to prevent
from slipping.
207624
2. Removing inner mast and main rollers

Lower inner mast 12 so that the main rollers can be
removed. Remove main rollers 10, 11 and mast strips
9.
207625
3. Removing inner mast

Using slings, lift and remove the inner mast 12,
steering it to pass over the roller shaft sections of the
middle mast.
207626
12-21
MAST AND FORKS
4. Removing main rollers 26, 27 from middle mast 28

and outer mast 30
Remove the bolts that are holding second lift cylinders
24. Place the cylinder rod ends on the outer mast.
Lower middle mast 28 so that main rollers 26, 27 can
be removed. Then, remove the main rollers.
207627

Follow the inspection procedure described in the dual-stage
panoramic mast (simplex mast).
Reassembly
1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims.
207630
(2) When replacing lift bracket main rollers, make sure

clearance A between each roller and mast surface is 1
mm (0.04 in.) or less.
207629
12-22
MAST AND FORKS
(3) To install main rollers on shafts, use a driving tool. Be

careful not to strike the outer roller surface with the
driving tool.
Place the roller with its larger chamfered side facing
outside.
202263
2. Installing second lift cylinders 24

When installing second lift cylinders 24, make sure the
cylinders are parallel to the mast to prevent torsional
stress on the lift cylinders when the mast is positioned
at the bottom. Adjust the installation positions of lift
cylinder brackets with shims 22.
207631
3. Installing first lift cylinders

The first lift cylinder must be installed parallel to the
mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 3, adjust the backward inclination so that
clearance at section B is 0 to + 0.5 mm (0 to + 0.02 in.)
larger than clearance at section A.
201752
4. Precautions for installation of chain anchor kit

plate.
3 Link
4 Split pin
200383
12-23
MAST AND FORKS
Forks (all mast models)
Fork calipers perform two tasks at once.

OUTSIDE INSIDE They measure the thickness of the fork arm
JAWS JAWS shank (Fig. 1) and then automatically
100% 90% indicate what a 10% wear factor would be when
the calipers are applied to the blade cross section (Fig. 2).
NEW FORK ARM

SHANK CROSS
50 mm (2 in.) SECTION = 100%
Figure 1
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
Not for use on full tapered forks. 210995
Forks are often mistreated and forgotten. As drum or on the boom hook makes the safety
insubstantial as they seem, neglecting forks could make difference.
them dangerous. • Forks are often used to open rail car doors and break
Forks carry larger loads than almost any lifting device loads out or away from other loads. They are also
but there are no mandatory requirements for used to pick up capacity loads not seated against the
maintenance or inspection. fork shank and to pick up off-balanced loads far from
You can find thousands of extra parts for lift trucks in the side of the truck. The fork tips are sometimes
some fleet repair shops, but you’ll seldom see spare inserted under other fork trucks to lift them during
forks. Even when all the trucks on the fleet are the maintenance operations.
same, fleet maintenance managers rarely order spare • Lift trucks may collide with building columns and
forks. Forks last a long time if treated properly, but walls, and though the forks show no discernible
they can deceive by looking as good from most viewing bend, they may be damaged beyond safety.
angles when they are worn as when they are new. • Any time excessive heat is applied to any part of a
It’s true that most forks are customized to the truck by fork–during repair, for instance–hidden damage may
model and capacity: they are big and heavy and thought occur.
of as indestructible. But forks can be abused or ruined The fork itself is a concern but so are the hooks that
in the course of daily work. secure them to the lift carriage.
Here are some examples of ways that forks can be damaged:
DESIGNED TO TAKE A BEATING
• Forks can be overloaded either by picking up a load
too far out on the forks, or simply by picking up Forks for counterbalanced and straddle lift trucks are
loads heavier than the truck rating. not just bent bars of steel. The manufacturing process
is careful and precise with many checks and inspections
• Maintenance shops may bend forks back into shape,
critical to their safety. Some factors essential to fork
weld on them, or drill holes through them. Lift truck
manufacture include the steel, the bend and thickness of
users can add attachments to the truck that stress the
the heel, the welding of the hooks that hold them on the
forks. Drum clamps and portable booms can be
carriage, and the heat treatment of the finished product.
supported on the forks–but what is contained in the
12-24
MAST AND FORKS
Chain Tension Adjustment

Two-stage panoramic mast (Simplex Mast)
NOTE
Follow the same chain tightening procedure for all
masts except for the Simplex Mast chains on the lift
bracket side.
! WARNING
Personal injury can be caused by sudden
movement of the mast and lift bracket. Use blocks
to fix the mast and lift bracket from any movement
while the adjustments are made. Keep hands and
feet clear of any parts that can move.
1. Have the truck on the level floor, with the mast vertical,
and the fork lowered to the bottom.
Check that the lift cylinders are fully retracted.
2. Loosen the double nut (lower) ➀ and upper nut ➁.
3. Set the anchor bolts with double nut (upper) ➂.
4. Raise the forks slightly and push the chains inward
midway between the chain wheel and anchor alternately
to check the tension. When adjusting the chains by 102709
means of the double nut (upper) ➂ , tilt the mast
forward to slacken the chains to facilitate adjustment.
5. Turn double nut (upper) ➂ to adjust the chain tension.
Then, hold the anchor bolt in place with a wrench and
tighten upper nut ➁ to the specified torque.
6. Hold double nut (upper) ➂ in place with a wrench, and
tighten double nut (lower) ➀ to the specified torque.
Tightening Torque
Unit: N·m (kgf·m) [lbf·ft]
55.8 to 56.8 N·m

102708
[41.2 to 41.9 lbf·ft]
98 to 103 N·m
[72.3 to 76.0 lbf·ft]
7. With the lift cylinder rods fully contracted, make sure

the amount of protrusion of each lift bracket main roller
is 40% of the roller diameter or less.
8. Make sure that the chain tension is correct with the
mast in vertical (0°) position. 207634
12-25
MAST AND FORKS
Dual-stage full free panoramic mast

(Duplex Mast)
1. On the level ground, position the mast at a right angle

to the ground surface, lower the forks to the ground,
and make sure the lift cylinder rods are contracted fully.
2. Secure the anchor bolts on the lift bracket side by
tightening the upper nuts and double nuts.
207633
3. Adjust the chain tensions by turning the double nuts

(upper) on the lift cylinder side. With the mast standing
perpendicular to the ground, lift the forks slightly, then
press the chains alternately at a midpoint between the
chain wheel and the secured end of the chain to make
sure the tension is the same in both chains.
NOTE
Tilting the mast slightly forward causes the chains to 102708
sag, thus making it easier to adjust the chain tensions
with the double nuts (upper).
4. Tighten the upper nuts and double nuts on the cylinder

side to the specified torque.
6. Conduct final adjustment with the mast positioned
perpendicular to the ground.
207634
12-26
MAST AND FORKS
Triple-stage full free panoramic mast

(Triplex Mast)
Adjust each of the first and second chains (total of four).
1. On the level ground, position the mast perpendicular to

the ground surface, lower the forks to the ground, and
make sure the lift cylinder rods are fully contracted.
2. Secure the anchor bolts on the lift bracket (first chains)
side and the lower inner mast section (second chains)
by tightening the upper nuts and double nuts.
NOTE
When installing the second chains (between the inner
mast and the outer mast) in the triple-stage full free
panoramic mast, adjust the chain tensions to be 207635
slightly tighter. If the chains are loose, damage can
occur to the hose pulley.
3. Adjust the chain tensions by turning the double nuts

(upper) on the lift cylinder side. With the mast standing
perpendicular to the ground, lift the forks slightly, then
press the chains alternately at a midpoint between the
chain wheel and the secured end of the chain to make
sure the tension is the same in both chains.
NOTE
Tilting the mast slightly forward causes the chains to
sag, thus making it easier to adjust the chain tensions 102708
with the double nuts (upper).
4. Tighten the upper nuts and double nuts on the cylinder

side to the specified torque.
6. Conduct final adjustment with the mast positioned
perpendicular to the ground.
207636
12-27
MAST AND FORKS
Clearance Adjustment on Lift Bracket
NOTE
The adjustment procedure for the lift bracket is the same
for the Simplex Mast, Duplex Mast and Triplex Mast.
1. Longitudinal clearance adjustment on lift bracket

main rollers
(1) Raise the forks slightly from the floor.
(2) Insert a bar between the upper part of lift bracket and
the inner mast, and push the inner mast to one side.
Using feeler gauges, measure the clearance F between
the main roller and inner mast on the opposite side.
Clearance F 1.0 mm (0.04 in.) or less

207095
(3) If the clearance F is out of specification, use oversize
rollers.
Roller sizes Unit: mm (in.)
Main Roller
S 99 (3.90)
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02) 207096
(4) Lift bracket main rollers (upper and center rollers)

The upper rollers should be the same in size or 1-rank
larger than the center rollers.
2. Lateral clearance adjustment on lift bracket main
rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its contact
point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and push the
203818
lift bracket to one side with a bar. Set the indicator to
zero.
(4) Insert a bar between the inner mast and lift bracket on
the indicator side, and push the lift bracket to the
opposite side.
(5) Read the indicator.
0.1 to 0.5 mm
Clearance G1 (0.004 to 0.020 in.)
(6) Adjust clearance G1 between the center main roller and
weld plate ➁ at the maximum lift position by
increasing or decreasing the thickness of the shim.
202276
Do not install any shim at upper main roller ➀.
12-28
MAST AND FORKS
For the lift bracket upper main roller or center main

roller, to extend 0.5 mm (0.02 in.), insert a 0.5 mm
(0.02 in.) shim (a) on its inside and remove the 0.5 mm
(0.02 in.) shim (b) from the lower stopper, then tighten
the bolts.
207156
(7) Lower the lift bracket slightly from the top, then adjust
clearance G2 between the side roller and mast by
increasing or decreasing the thickness of the shims.
0.1 to 0.5 mm
Clearance G2
(0.004 to 0.020 in.)
202277
Adjust the side roller clearance by adding shims

between the roller bracket and lift bracket.
207098
(8) With the lift bracket at the top, adjust clearance G3

with shims.
0.1 to 0.5 mm
Clearance G3
(0.004 to 0.020 in.)
207158
12-29
MAST AND FORKS
Mast Clearance Adjustment
NOTE
Adjust mast clearances at the locations indicated
below.
1. Simplex Mast and Duplex Mast: Main rollers
between the outer mast and inner mast
2. Triplex Mast: Main rollers between the outer mast
and middle mast, and main rollers between the
middle mast and inner mast.
207157
1. Longitudinal clearance adjustment on mast main
rollers
(1) Tilt the mast fully backward.
(2) Using feeler gauges, measure the clearance H between
the inner mast lower roller and outer mast.
Clearance H 1.0 mm (0.04 in.) or less
(3) If the clearance H is out of the specification, use

oversize rollers.
Roller sizes 207099

Unit: mm (in.)
Main Roller
S 99 (3.90)
M 100 (3.94)
L 101 (3.98)
LL 102 (4.02)
2. Lateral clearance adjustment on inner mast main

rollers
(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the inner mast.
inner mast against the outer mast. Set the indicator to
zero.
204886
12-30
MAST AND FORKS
(4) Insert a bar between the outer and inner masts on the
indicator side, and push the inner mast to the opposite
side.
0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)
207101
(6) If the clearance J is out of specification, adjust by

shims.
NOTE
Refer to Main Roller Shim Replacement.
207102
3. Lateral clearance adjustment on outer mast main

rollers
(2) Set a dial indicator on the outer mast with its contact
point rested on the inner mast.
outer mast against the inner mast with a bar. Set the
indicator to zero.
(4) Insert a bar between the outer and inner mast, and push 204889
the inner mast to the opposite side.
0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.)
207103
12-31
MAST AND FORKS
(6) If the clearance K is out of specification, adjust it by

shims.
NOTE
207104
Main Roller Shim Replacement
Procedure for replacing main roller shims

(Simplex Mast)
1. Remove the lift bracket from the mast.
NOTE
Refer to Removal and Installation section, “1. Lift
bracket removal.”
2. Lower the inner mast below the outer mast as follows:

(1) Raise the front end of the truck, and support that end
with block.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
the crossmember of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner 202961
and outer masts. Remove the mast strips and shims in
advance as they drop easily under this condition.
12-32
MAST AND FORKS

[Dual-stage full free panoramic mast (Duplex Mast)]
NOTE
Refer to “Removing lift bracket” section in the
HYDRAULIC SYSTEM.
2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a hoist. Wind the sling securely to prevent
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.
207616
3. Position the inner mast lower than the outer mast by

following the steps below:
with block.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to 202961
the crossmember of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
12-33
MAST AND FORKS

[Triple-stage full free panoramic mast (Triplex Mast)]
NOTE
Refer to “Removing lift bracket” section in the
HYDRAULIC SYSTEM.
2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a hoist. Wind the sling securely to prevent
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.
207616
3. Position the inner mast lower than the middle mast by

with block.
(2) Hitch slings to the upper cross-member of the inner
mast, and suspend with a hoist.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
and place them in front of the inner mast. 207639
(5) Lower the inner mast until main rollers can be removed.
(6) Place wood blocks under the inner mast for support.
NOTE
In this condition, second lift cylinders cannot be
dismounted.
12-34
MAST AND FORKS
4. Position the middle mast lower than the outer mast by

(1) Lift the inner mast to the height of the middle mast,
then place wood blocks for support.
(2) Hitch slings to both middle mast and inner mast, and
suspend with a hoist.
(3) Remove set bolts from the upper sections of the middle
mast lift cylinders, then lift the middle mast and inner
mast.
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the lower outer
mast section. Tilt the cylinders by moving the top
sections towards the center of the vehicle, then secure
the cylinders to the cross-member of the outer mast
with a rope.
(5) Lower the middle mast and inner mast until main rollers
can be removed.
(6) Place wood blocks under the middle mast and inner
mast for support.
207640
12-35
MAST AND FORKS
Mast Strip Adjustment

1. Check the clearance L with the clearance between the
outer mast rollers and inner mast set to zero (0) in
0.1 to 0.5 mm
Clearance L
(0.004 to 0.020 in.)
200391
2. If the clearance L is out of specification, adjust it by

shims.
NOTE
3. After adjusting all clearances, move the mast and lift

bracket slowly to make sure that they move smoothly 200392
through their full stroke.
Tilt Angle Adjustment

1. Adjust the tire pressure correctly and park the truck on
the level floor.
2. Tilt the mast fully backward and turn the key switch to
off.
3. Measure the backward tilt angle of the mast at both
sides.
4. To adjust the tilt angle, loosen the bolt of tilt cylinder
socket, and adjust the rod length by turning the rod. Bolt
Adjust cylinders so that there is no difference in tilt
angle between the cylinders, left and right. 207105
NOTE
It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.
Forward – backward tilt

6° – 7° (standard)
angle
12-36
MAST AND FORKS
5. After adjusting the tilt angle, tighten the socket bolts to

the specified torque.
127 to 152 N·m

Tightening torque for tilt
(13 to 15.5 kgf·m)
cylinder socket bolt
[94 to 112 lbf·ft]
Lift Cylinder Stroke Adjustment

1. Gently raise the inner masts, and observe the right and
left piston rod stopping conditions when they reach the
2. If the upper parts of the inner masts shake at the

moment of stopping, make adjustment with shims.
Improper adjustment causes the inner mast to slant
slightly when the mast is stopped, and also causes the
lift cylinder with a longer cylinder stroke to shake when 204698
the lift cylinder is stopped.
3. Adjusting method
(1) Raise the inner masts, and place wood blocks under the
inner masts. Lower the masts until the inner masts
contact the wood blocks.
(2) Loosen the stopper bolt located at the upper part of the
lift cylinder that stopped first. Lower the piston rod,
and insert a shim at the upper piston rod end.
NOTE
When lowering the piston rod, operate the lift lever to 202983
lower the masts and release oil from the cylinder.
(3) Raise the piston rod, then tighten the lift cylinder
stopper bolt. Remove the wood blocks from under the
inner masts.
(4) Lower the inner masts gently, and check to see if the
piston rods move smoothly until the inner masts reach
the lowest position.
Bleeding lift cylinders

When air and oil remaining inside the air chamber of the
rod and inside the rod chamber between the tubes are
compressed, they open the check valve and flow out of the
cylinder. Therefore, there is no need to bleed the lift
cylinders.
200365
12-37
MAST AND FORKS
Troubleshooting
Lift bracket, inner masts and Faulty rotation of rollers Apply grease or replace rollers.
middle masts do not rise or Improper mast strip clearance Adjust with shims.
lower smoothly. Improper main roller or side roller Adjust front-to-back and
clearance right-to-left clearances.
Uneven chain tension between right and Adjust chain tension.

left chains
Excessive side roller clearance Adjust by adding shims.
Lift bracket or inner masts are
lopsided. Uneven adjustment of shims between Adjust by removing shims.
right and left lift cylinders
(at maximum lift position)
Lift bracket retaining stopper in contact Adjust chain tension.
Faulty rotation of rollers Apply grease or replace rollers.

Masts generate abnormal noise
Defective hose pulley bearing Replace.
(for triple-stage full free panoramic
mast system only)
Lift cylinders descent due to Damaged gaskets in lift cylinders Replace.

leaks. Internal leak of control valve Replace.
Entire masts shake Worn mast support bushings and caps Re-tighten, or replace bushings
and caps.
Masts are deformed in shape. Uneven cargo load or overload Replace assembly.
Bent finger bars Repair or replace.

Uneven fork end heights Bent forks Replace.
Mast deformation due to uneven cargo Repair or replace.
load
Low oil temperature Increase oil temperature by

raising and lowering lift
Second lift cylinders move when bracket.
first lift cylinder operates. No clearance for lift bracket roller Readjust rollers.
(triple-stage full free panoramic surfaces
mast system)
Clogged pipes Inspect and clean hydraulic line.
Improper air bleeding Bleed hydraulic system.
Spongy operation of
fall-prevention function when Improper air bleeding Bleed hydraulic system.
lifting operation is stopped.
12-38
MAST AND FORKS
Service Data
Simplex Mast, Duplex Mast, Triplex Mast

Unit: mm (in.)
Item
Difference in height between fork tips A 5 (0.20)
Chains A 318 (12.52) 381 (15.00)
Length of lift chains (per 20 links)
B 327 (12.87) 392 (15.43)
S A 99 (3.90)
M A 100 (3.94)
Diameter of main roller
Rollers L A 101 (3.98)
LL A 102 (4.02)
Diameter of side roller A 42 ± 0.1 (1.65 ± 0.004)
Width of outer mast B A 610 (24)
Simple mast,
Duplex mast Width of inner mast B2 A 516 (20.3)
Width of lift bracket C A 408 (16.1)
Dimensions
(Reference) Width of outer mast B A 610 (24)
Width of middle mast B1 A 516 (20.3)
Triplex mast
Width of inner mast B2 A 426 (16.8)
Width of lift bracket C A 318 (12.5)
Clearance between main roller circumference
A 1.0 (0.04) or less
and mast thrust surface H
Masts Clearance between main roller side surface
and mast thrust surface G A 0.1 to 0.5 (0.004 to 0.020)
Clearance between inside mast and mast strip G2 A 0.1 to 0.5 (0.004 to 0.020)
Clearance between upper and lower roller A 1.0 (0.04) or less
Clearances circumference and inner mast thrust surface F
Clearance between middle roller side
surface and inner mast thrust plate G A 0.1 to 0.5 (0.004 to 0.020)
Lift brackets
Clearance between lower roller side
surface and inner mast thrust surface G A 0.1 to 0.5 (0.004 to 0.020)
Clearance between side roller circumference

and inner mast surface G1 A 0.1 to 0.5 (0.004 to 0.020)
Tightening torque Upper nut ➁ A 55.8 to 56.8 (5.7 to 5.8) [41.2 to 41.9]
N·m (kgf·m) [lbf·ft] Double nut (lower) ➀ A 98 to 103 (10 to 10.5) [72.3 to 76.0]
Finger bar bend A 5.0 (0.2) or less
12-39
MAST AND FORKS

Item
G
G2
F
G
G
G1
G
F
G1 G
H G
B2
G G
G G
B2 B1
C
Lift bracket
B B
Simplex mast, Triplex mast
Duplex mast
Mast width is slightly wide at the lower portion than at the upper portion.
Measure the clearance at the mast upper position. 208742
102709
12-40
SERVICE DATA
Inspection Standards ............................................................................13 – 1

Periodic Replacement of Parts ..........................................................13 – 7
Critical Safety Parts ..................................................................................13 – 7
Lubricating Standards ..........................................................................13 – 8
Lubrication Chart ......................................................................................13 – 8
Lubricant Quantities ..................................................................................13 – 9
Recommended Lubricant ..........................................................................13 – 9
Main Component Weights ................................................................... 13 – 10
Tightening Torque for Standard Bolts and Nuts ............................ 13 – 11
Special Tool Table .................................................................................. 13 – 13
13
SERVICE DATA
Inspection Standards
Inspect and conduct maintenance according to the specified hourmeter indication or the number of calendar days,
whichever comes first.
: Inspect or clean
: Replace or adjust
Periodic Inspection
Pre-operation Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
Inspection/Maintenance Location and Item
1000 Hours
2000 Hours
Service Standard
500 Hours
Electrical system
Abnormal noise during rotation
Commutator contamination,
streaks and wear irregularities
Motors Looseness of connections
Grease replacement in motors,
shafts and couplings
Insulation resistance
Electrolyte levels Inspection: Every week or 50 hours
Specific gravity of electrolyte after Inspection: Every week or 50 hours
charging Specific gravity: 1.28
Voltage of each cell 48 V, 36 V
Batteries Terminal corrosion, damage,

contamination and looseness
Case damage and contamination,
and fluid leaks
Insulation resistance
Charge level
Contactors Contact looseness, damage and

wear
13-1
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
1000 Hours
2000 Hours
Service Standard
500 Hours
Control valve microswitch
operating condition
Damage and mounting looseness
Foot brake switch operating
Micro condition
switches
Damage, mounting looseness
Hand brake switch operating
condition
Damage and mounting looseness
Controller operating condition
(1) Seat switch
(2) Forward/reverse selector switch
(3) Control valve switch
(4) Brake switch
Main (5) Accelerator switch

controller (6) Line contactors
(7) Forward
(8) Reverse
(9) Regeneration bypass
Internal contamination and damage
Over-current limit value
Fuse mounting looseness
Fuses
Fuse capacity
Wire harness damage and
clamp looseness
Wiring Terminal connection looseness and

taping condition
Battery connector contacts and
bolt looseness
Power transmitting system
Transfer oil level and L.H.: 1.09 liter (0.29 U.S. gal)
contamination R.H.: 1.86 liter (0.49 U.S. gal)
Transfers
Oil leaks
Bolt looseness
13-2
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
1000 Hours
2000 Hours
Service Standard
500 Hours
Drive system
Tire cracking and damage
Tire tread depth
Tires Abnormal tire wear
Metal pieces, rocks, other foreign
materials on tires
Hub bolts Damage and looseness
Rims and
wheel discs Damage
Wheel bearing rattle
Wheel
bearings Abnormal noise in wheel bearings
Grease replacement
Steering system
Play, looseness, rattling and
Steering Play: 15 to 30 mm (0.6 to 1.2 in.)
operating condition
wheel
Gear box mounting looseness
Deformation, cracking and damage
Rear axle Oil leaks
Bolt looseness
Braking system
Free play 3 to 9 mm (0.12 to 0.35 in.)
Distance between depressed brake
pedal and floor board
Air trapped in fluid
Brakes
Braking performance
Uneven braking performance
between right and left
Reservoir tank level and oil leaks 99 cc (6.04 cu. in.)
Parking Lock condition
brake Braking performance 3rd or 4th notch engagement
Rods and Operating condition
cables Looseness of links and clamps
13-3
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
1000 Hours
2000 Hours
Service Standard
500 Hours
Damage, leaks and contact with
Hoses and other parts
pipes
Looseness of links and clamps
Clearance between brake disc and
0.4 to 1.1 mm (0.016 to 0.043 in.)
pad
Brake disc mounting looseness
Brake discs Brake pad wear Service limit : 1 mm (0.039 in.)

and pads Brake pad operating condition
Rusting of pins
Return spring fatigue and damage
Brake disc wear and damage Service limit : 9 mm (0.354 in.)
Lift system
Fork and stopper pin damage
Forks Forks—wear and distortion
Cracking and wear in fork base

and tooth weld
Cracking in cross-member welds
of outer and inner masts
Cracking in welds of tilt cylinders
and masts
Cracking in welds of outer masts
and cylinder support
Masts and Cracking in lift bracket welds
lift bracket Roller bearing rattle
Wear and damage of mast support

metal
Cracking and damage in rollers,
roller pins and welds
Mast operating condition and
mounting looseness
13-4
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
1000 Hours
2000 Hours
Service Standard
500 Hours
Allowed lift chain stretch:
Length of lift chains (20 links) 1 ton class: 327 mm (12.87 in.)
2 ton class: 392 mm (15.43 in.)
Chain deformation, damage,
lubrication and rusting
Chains and
chain wheels Chain bushing coupling, bolt
deformation and damage
Chain wheel deformation and
damage
Chain wheel bearing rattle
Attachments Attachment abnormality and

mounting conditions
Hydraulic system
Looseness, deformation and
damage of rods, rod bolts and
rod ends
Cylinder operating condition
Drift lowering distance:
Cylinders Drift lowering and forward 50 mm (1.97 in.)/15 min
tilting distances Drift forward tilting distance:
22 mm (0.87 in.)/15 min
Cylinder oil leaks and damage
Wear and damage of piston and
cylinder shaft bearings
Oil pump Oil leaks, abnormal noise, wear in

drive unit, and mounting looseness
N level: 14.7 liter (3.88 U.S. gal)
Hydraulic Oil level and contamination
H level: 16.8 liter (4.44 U.S. gal)
tank
Filter clogging
Operation Linkage looseness
levers Lever functions
Oil leaks
Control Safety valves

valves 18142 + 0490 kPa
Release pressure measurement (185 + 05 kgf/cm2)
[2631 + 071 psi]
13-5
SERVICE DATA
Periodic Inspection
Interval
Every 12 Months or
Every 3 Months or
Every 6 Months or
Remarks
1000 Hours
2000 Hours
Service Standard
500 Hours
Safety devices and others
Mounting looseness
Head guard
and backrest Deformation, cracking and damage
Turn signal operation and
mounting condition
Alarm device operation and
mounting condition
Lamp operation and mounting
condition
Safety Backup warning device operation

devices and mounting condition
Rear-view mirror dirtiness and
damage
Rear-view mirror image and
condition
Proper function of seat belt and
hip restraint
Instruments Instrument operations

Seat Looseness and damage
Vehicle Damage and cracking in frame and

body cross-members
Inspection of chassis lubricating
Oil and conditions after cleaning
grease Confirmation of oil replacement
replacement intervals
13-6
SERVICE DATA
Periodic Replacement of Parts
Replace the following critical safety-related parts and elements according to the specified intervals.
Replacement Interval
Parts for Periodic Replacement Method After 1
Every Every Every Every
Month of
Month 6 Months Year 2 Years
Initial Use
1 * Rubber parts in brake master cylinder Replace
2 * Rubber parts in brake caliper cylinders Replace
3 * High-pressure hoses for lift and tilt Replace
systems
4 * Lift chains Replace
Hydraulic tank return oil filter Replace
NOTICE: “ * ” mark indicates critical safety parts.
Critical Safety Parts
3
1
206929
13-7
SERVICE DATA
Lubricating Standards
Lubrication Chart
Lift chain HO
MPG Tilt socket

Roller surface
MPG
Mast strip
MPG Mast support

Lift bracket MPG
side roller
Brake BF
fluid
Transfer HO HO
Hydraulic HO
oil
Every 3 months or 500 hours
: Inspection, replenishment MPG: Multipurpose grease

: Replacement BF: Brake fluid
❋: Parts located on both sides of vehicle HO: Hydraulic oil 211155
13-8
SERVICE DATA
Lubricant Quantities
Truck Models
Items
L.H.: 1.09 (0.29)

Transfer oil capacity liter (U.S. gal)
R.H.: 1.86 (0.49)
N level: 14.7 (3.88)

Hydraulic system oil capacity liter (U.S. gal)
H level: 16.8 (4.44)
Brake fluid capacity cc (cu. in.) 99 (6.04)
Recommended Lubricant
• Greases
Specifications NLGI No. 1 NLGI No. 2

Viscosity
Manufacturer Consistency 310 - 340 Consistency 265 - 295
Mobil Mobilux EP 1 Mobilux EP 2
Shell Retinax HD NLGI 1 Retinax HD NLGI 2
Exxon Ronex Extra Duty 1 Ronex Extra Duty 2
Castrol Castrol EPL 1 Castrol EPL 2
• Brake fluids
Specifications
Viscosity
Manufacturer SAEJ1703
Mobil Mobil Universal Brake Fluid
Shell Shell Advance Brake Fluid
Exxon Brake Fluid DOT-3
Castrol Castrol GT LMA Brake Fluid
• Hydraulic, transfer and rear axle oils
Specifications API service classification CD

Viscosity
Manufacturer SAE5W SAE10W
Mobil Mobil 1 5W-30 Mobil 1 10W-30
Shell Shell Rotella T Synthetic 5W-40 Shell Rotella T 10W
Exxon XD-3 10W-30
Castrol Castrol Syntec 5W-20 Castrol Syntec 10W-30

NOTICE: Brands of oil are subject to change without notice. When you buy oil, check specification.
13-9
SERVICE DATA
Main Component Weights

Unit: kg (lb)
Truck Models
ET3000 ET3500 ET4000
Item
740 805 955

Counterweight
(1631) (1775) (2105)
Power train
72.4 72.4 72.4

Transfer
(159.6) (159.6) (159.6)
50 50 50
Traction motor
(110) (110) (110)
70 70 70
Head guard
(154.3) (154.3) (154.3)
33 33 33
Rear axle
(72.8) (72.8) (72.8)
Mast [3.3 m (130 in.), Simplex]
Outer mast 164.84 (363.4) 164.84 (363.4) 164.84 (363.4)
Inner mast 136.73 (301.4) 136.73 (301.4) 136.73 (301.4)
Lift bracket (including backrest) 93.34 (205.8) 93.34 (205.8) 108.22 (238.6)
Forks (set of two) 63.6 (140.2) 63.6 (140.2) 80 (176.4)
Lift cylinders, etc. 78.47 (173) 78.47 (173) 78.47 (173)
Mast [3.3 m (130 in.), Duplex] 566 (1248) 566 (1248) 577 (1272)
Mast [4.8 m (189 in.), Triplex] 691 (1523) 691 (1523) 702 (1548)
13-10
SERVICE DATA
Tightening Torque for Standard Bolts and Nuts
With Spring Washer 101656
Nominal Size Pitch
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 191.2 19.5 141.8
16 0.63 1.5 0.06 154.9 15.8 114.3 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.6 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 305.2 537.4 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
Metric Without Spring Washer 101656
fine
thread Nominal Size Pitch
6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 39.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1215.0 123.9 896.2 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3
Remarks : 1. The tolerance on these torques is ±10%.

2. These torques are for “dry” condition.
13-11
SERVICE DATA
With Spring Washer 101656
Nominal Size Pitch
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.1 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 715.9 73.0 528.0
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 1.65 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
Metric Without Spring Washer 101656
coarse
thread Nominal Size Pitch
10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4
Remarks : 1. The tolerance on these torques is ±10%.

2. These torques are for “dry” condition.
13-12
SERVICE DATA
Special Tool Table
Reference Truck Models 1 ton 2 ton

Part No. Name
No. Application class class
1 64309-17701 Gauge kit Measurement of hydraulic pressure
2 91268-01500 Installer Installation of rear axle inner bearing and inner race
3 91268-01400 Installer Installation of rear axle outer bearing and inner race
Steering wheel
4 91268-10600 Removal of steering wheel
puller
5 91268-03200 Puller Removal of steering column and needle roller bearing
6 91268-01600 Installer Installation of tilt cylinder tube bushing
7 09305-00680 Hook wrench Removal and installation of tilt cylinder guide bushing
09305-00520 Hook wrench Removal and installation of lift cylinder guide bushing
Removal and installation of first lift cylinder guide

09305-00750 Hook wrench
bushing
8 97157-00100 Spring installer Installation of centering spring in steering gear
13-13
SERVICE DATA
Gauge kit Puller
➀ 203544 ➄ 203552
Installer Unit: mm (in.) Installer Unit: mm (in.)
➁ 200447 ➅ 200448
Installer Unit: mm (in.) Hook wrench
➂ 200446 ➆ 203556
Steering wheel puller Unit: mm (in.) Spring installer
➃ 203551 ➇ 206997
13-14
OPTIONS
Working Lamp Kit ...................................................................................14 – 1

Tire Kit (nonmarking cushion) .............................................................14 – 2
Foot Direction Control Kit ....................................................................14 – 3
14
OPTIONS
Working Lamp Kit
Strobe bracket
Work lamp Amber strobe lamp

Work lamp
Grommet
Work lamp bracket
Harness D Harness C
211354
14-1
OPTIONS
Tire Kit (nonmarking cushion)
Tire (18x7x12 1/8)
Rim (18x7x12 1/8)
Detail B
Bolt (washer assembled)
Static strap
Center plate
Nonmarking
cushion tire Nut Spring
washer
211355
14-2
OPTIONS
Foot Direction Control Kit
Screw
Screw
Screw Washer Lock

Washer
Clip
Harness Pedal
Plug
Foot direction control

harness
Screw, Washer, Nut
Foot direction control
pedal assembly
Pad
Spring
Floor plate
Accelerator Bolt
assembly Floor plate
Bolt stopper height: Bolt (washer assembled)

42 mm (1.65 in.)
Clip
Front
211356
14-3
Cat Lift Trucks Service Manual ET3000, ET3500, ET4000 Lift Trucks 99719-88110
Mitsubishi Caterpillar Forklift America Inc.
2121 W. Sam Houston Parkway N.
Houston, TX 77043-2305
Copyright © 2008 by MCFA. All Rights Reserved.

99719-88110 CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. Printed in the U.S.A.

Service Manual ET3000 CAT

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Service Manual

Chassis, Mast & Options

Safety Related Signs

The following safety related signs are used in this service

Indicates a potentially hazardous

Indicates a potentially hazardous

Indicates a condition that can cause

Pub. No. 99719-88110

Disassembly diagram (example)

Procedures are described in the text.

Suggestion for disassembling

Item SI unit Customary unit

GROUP INDEX Items

GENERAL INFORMATION Serial number locations, Dimensions, Technical data 1

POWER TRAIN Procedure and suggestions for removal and installation 5

TRANSFER UNITS Procedures and suggestions for disassembly and reassembly 7

REAR AXLE Rear axle, Rear wheels 8

BRAKE SYSTEM Caliper, Brake pedal, Master cylinder 9

STEERING SYSTEM Steering control valve 10

MASTS AND FORKS Simplex mast, Duplex mast, Triplex mast 12

OPTIONS Working lamp kit, Tire kit, Foot direction control 14

This manual applies to ET3000, ET3500 and ET4000.

Truck Model Serial Number

Serial Number Locations

Chassis and Mast Model Identification

Three wheel models

Maximum lifting height

Order of the minor change

Applicable truck model designation

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

1 Central vehicle monitoring system 6

Functions of Central Vehicle Monitor System (CVMS)

No. Monitor name When OFF When ON or flashing Remarks

No. Monitor name When OFF When ON or flashing Remarks

Selection of KPH or MPH

4. Push and hold button 1 for one to two seconds.

Setting the clock 103043

Error code display

E 0 ON Right drive motor overheated

E 1 ON Left drive motor overheated

E 2 ON Pump motor overheated

E 5 ON Right traction inverter overheated

E 6 ON Left traction inverter overheated

E 7 ON Pump inverter overheated

H 1 ON Faulty setting of lift lever

H 2 ON Faulty setting of tilt lever

H 3 ON Faulty setting of attachment 1 lever

H 4 ON Faulty setting of attachment 2 lever

H 5 ON Faulty setting of attachment 3 lever

Electrical Components in Console Box

Direction lever switch cable

Disassembly and Reassembly

Make sure the inside switch turns ON by checking the

Lighting Switch (option)

Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart

Head lamps (option) 2 Clear 45 W

Working lamp (option) 1 Clear 45 W

Troubleshooting of Lighting and Horn Systems

Complaint Possible cause Remedy

e) Bulbs burnt out Replace.

Will not light a) Lighting switch defective Replace.

Working lamp will a) Working lamp switch defective Correct if improperly

d) Horn defective Replace.