Service Manual

Chassis, Mast & Options

EP20K ETB8B-00011-up
EP25K ETB8B-50001-up
EP30K ETB9B-00011-up
EP35K ETB9B-50001-up

For use with EP20K-EP35K

Controller Service Manual. 99759-6D100
 FOREWORD

This service manual is a guide for servicing Cat® lift trucks of 2.0 ton, 2.5 ton, 3.0 ton
and 3.5 ton models. The instructions are grouped by systems to conveniently provide a
ready reference.
A long productive life of your lift truck depends to a great extent on correct servicing —
servicing consistent with what you will learn from this service manual. Read the
respective sections of this manual carefully and familiarize yourself with all the
components you will work on before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are of the
trucks with the serial numbers in effect at the time it was approved for printing. Cat lift
truck 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 specific potential hazard

! WARNING
that could result in serious bodily
injury or death.

Indicates a specific potential hazard

! CAUTION
that may result in bodily injury, or
damage to, or destruction of, the
machine.

Indicates a condition that can cause

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

Pub. No. 99759-6D100

 ! WARNING
SAFETY
! WARNING
The proper and safe lubrication and
maintenance for this lift truck, recommended
by Cat lift truck, are outlined in the OPERATION
& MAINTENANCE MANUAL for these trucks.
Improper performance of lubrication or
maintenance procedures is dangerous and
could result in injury or death. Read and
understand the OPERATION & MAINTENANCE
MANUAL before performing any lubrication or
maintenance.
The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. A knowledge of the system and/or components
is important before the removal or disassembly of any
component.
Because of the size of some of the truck components,
the serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting procedures
when removing any components.
Following is a list of basic precautions that should
always be observed.
1. Read and understand all warning plates and decals
on the truck before operating, lubricating or
repairing the product.
2. Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any part
of the truck or its attachments with a hammer or
sledge. Use welders gloves, hood/goggles, apron
and other protective clothing appropriate to the
welding job being performed. Do not wear loose-
fitting or torn clothing. Remove all rings from
fingers when working on machinery.
3. Do not work on any truck that is supported only by
lift jacks or a hoist. Always use blocks or jack
stands to support the truck before performing any
disassembly.
! WARNING
Do not operate this truck unless you have read
and understand the instructions in the
OPERATION & MAINTENANCE MANUAL.
Improper truck operation is dangerous and
could result in injury or death.
4. Lower the forks or other implements to the ground
before performing any work on the truck. If this
cannot be done, make sure the forks or other
implements are blocked correctly to prevent them
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any mud
or debris from steps, walkways or work platforms
before using. Always face truck when using steps,
ladders and walkways. When it is not possible to
use the designed access system, provide ladders,
scaffolds, or work platforms to perform safe repair
operations.
6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting operation.
7. To avoid burns, be alert for hot parts on trucks
which have just been stopped and hot fluids in
lines, tubes and compartments.
8. Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located at
opposite ends of the cover or device and pry cover
loose to relieve any spring or other pressure, before
removing the last two bolts or nuts completely.
9. Be careful when removing filler caps, breathers and
plugs on the truck. Hold a rag over the cap or plug
to prevent being sprayed or splashed by liquids
under pressure. The danger is even greater if the
truck has just been stopped because fluids can be
hot.
10. Always use tools that are in good condition and be
sure you understand how to use them before
performing any service work.
11. Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements are
necessary.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not
roll while working on or under truck.
13. Disconnect battery and discharge any capacitors
(electric trucks) before starting to work on truck.
Hang “Do not Operate” tag in the Operator’s
Compartment.
14. Repairs, which require welding, should be
performed only with the benefit of the appropriate
reference information and by personnel adequately
trained and knowledgeable in welding procedures.
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.
19. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot
exhaust components in event of a line, tube or seal
failure, must be installed correctly.
20. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting any
device from a system that utilizes pressure.
21. Do not operate a truck if any rotating part is
damaged or contacts any other part during
operation. Any high speed rotating component that
has been damaged or altered should be checked for
balance before reusing.
22. When handling the parts containing asbestos, be
careful not to inhale the asbestos. Doing so is
hazardous to your health.
If the shop dust may contain asbestos, follow the
precautions described below.
a. Do not use compressed air for cleaning.
b. Do not brush or apply grinder on asbestos
containing materials.
c. To clean asbestos containing materials, wipe
with moistened cloth or use a vacuum cleaner
with particle filter.
d. If you have to handle the parts containing
asbestos for a long time, be sure to do it in a
well-ventilated area.
e. If the asbestos in the air cannot be removed,
wear a mask.
f. Be sure to observe the working rules and
regulations.
g. When disposing of materials with asbestos, be
sure to observe the environmental protection
regulations of your area.
h. Avoid working in the atmosphere where
asbestos particles may be suspended.
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

Serial Number Locations, Chassis and Mast Model Identification, Dimensions,

GENERAL INFORMATION
Technical Data 1

VEHICLE ELECTRICAL Electrical Component Locations, Console Box, Key Switch,

COMPONENTS Lamp Specification Chart, Electrical System of FC 2

POWER TRAIN General Structure, Removal and Installation 3

TRANSFER AND Structure and Functions, Procedures and Suggestions for Disassembly and
DIFFERENTIAL Reassembly, Service Data 4

Structure and Functions, Disassembly and Reassembly of Front Axle Assembly,

FRONT AXLE
Service Data 5

Rear Axle, Rear Wheels, Removal and Installation, Disassembly and Reassembly,
REAR AXLE
Adjustment, Troubleshooting, Service Data 6
Specifications, Structure and Functions, Procedures and Suggestions for
BRAKE SYSTEM Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, 7
Service Data
Specifications, Structure and Functions, Procedures and Suggestions for Removal
STEERING SYSTEM and Installation, Steering Gear, Hydraulic Circuit, Troubleshooting, 8
Service Data

Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve,
HYDRAULIC SYSTEM
Down Safety Valve 9

MAST AND FORK Simplex Mast, Duplex Mast, Triplex Mast 10

Inspection Standards, Periodic Replacement of Parts, Lubrication Standards,
SERVICE DATA Main Component Weights, Tightening Torque for Standard Bolts and Nuts, 11
Special Tools

Rearview Mirror Kit, Backup Buzzer Kit, Working Lamp Kit, Tire Kit,
OPTIONS
Foot Direction Control Kit 12
 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

Joystick box
(FC models)

Control lever
(MC models)

103142

Models

This manual applies to EP20K, EP25K, EP30K and EP35K.

Class Truck Model Serial Number

2 ton EP20K ETB8B-00011-up
2.5 ton EP25K ETB8B-50001-up
3 ton EP30K ETB9B-00011-up
3.5 ton EP35K ETB9B-50001-up

1-1
GENERAL INFORMATION

Serial Number Locations

Mast number Chassis number Nameplate

208204

1-2
 GENERAL INFORMATION

Chassis and Mast Model Identification

[Chassis]
EP 20 K

Generation designator

Maximum capacity
20: 2000 kg (4400 lb)
25: 2500 kg (5500 lb)
30: 3000 kg (6600 lb)
35: 3500 kg (7700 lb)

Battery type

[Mast]
4 R 35 C 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

35: 3.5 ton class

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

1-3
GENERAL INFORMATION

Dimensions

B E F

211638

1-4
 GENERAL INFORMATION

Technical Data

Truck model EP20K EP25K

Class 2.0 ton 2.5 ton

Load capacity/load center N (kgf)/mm 19600 (2000)/500 24500 (2500)/500

[lbf/in.] [4400/20] [5500/20]

Truck size Length to fork face A mm (in.) 2249 (88.5) 2274 (89.5)

Width B
1190 (46.9) 1190 (46.9)
mm (in.)

Height of overhead guard C

2200 (86.6) 2200 (86.6)
mm (in.)

Wheelbase D mm (in.) 1520 (59.8) 1520 (59.8)

Truck weight (w/o battery) kg (lb) 2790 (6151) 2983 (6576)

Tread Front/rear E/F mm (in.) 990/898 (39.0/35.4) 990/898 (39.0/35.4)

Tires size Front 23 × 9 − 10 23 × 9 − 10

Rear 18 × 7 − 8 18 × 7 − 8

Turning radius mm (in.) 1950 (76.8) 1970 (77.6)

Travel speeds Unloaded/loaded km/h (mph) 16.4/16.0 (10.2/9.9) 16.4/16.0 (10.2/9.9)

Lift speeds Unloaded/loaded m (in.)/sec 0.60/0.40 (23.6/15.7) 0.60/0.38 (23.6/14.96)

Lowering speeds Unloaded/loaded m (in.)/sec 0.50/0.50 (19.7/19.7) 0.50/0.50 (19.7/19.7)

Battery voltage V 80 80

Battery rated capacity (5 hrs.) MAX Ah 600 600

mm 1025 × 708 × 769 1025 × 708 × 769

Battery compartment size
(in.) (40.4 × 27.9 × 30.3) (40.4 × 27.9 × 30.3)

Battery weight kg (lb) 1385 (3053) 1385 (3053)

Tilt angle (forwards – backwards) 6° − 8° 6° − 8°

Drive motor capacity (60 min. short duty) kW 12.0 12.0

Pump motor output @ 15% duty factor kW 15 15

Steering pump motor output W 550 550

Drive motor control method IGBT chopper IGBT chopper

Pump motor control method IGBT chopper IGBT chopper

1-5
GENERAL INFORMATION

Truck model EP30K EP35K

Class 3.0 ton 3.5 ton

Load capacity/load center

29400 (3000)/500 [6600/20] 34300 (3500)/500 [7700/20]
N (kgf)/mm [lbf/in.]

Truck size Length to fork face A mm (in.) 2522 (99.3) 2577 (101.5)

Width B
1230 (48.4) 1230 (48.4)
mm (in.)

Height of overhead guard C

2250 (88.6) 2259 (88.9)
mm (in.)

Wheelbase D mm (in.) 1690 (66.5) 1690 (66.5)

Truck weight (w/o battery) kg (lb)3231 (7123) 3665 (8080)

Tread Front/rear E/F mm (in.) 990/898 (39.0/35.4) 990/898 (39.0/35.4)

Tires size Front 28 × 9 − 15 250 − 15

Rear 18 × 7 − 8 18 × 7 − 8

Turning radius mm (in.) 2180 (85.8) 2230 (87.8)

Travel speeds Unloaded/loaded km/h (mph) 16.4/16.0 (10.2/9.9) 16.4/16.0 (10.2/9.9)

Lift speeds Unloaded/loaded m (in.)/sec 0.54/0.34 (21.3/13.4) 0.45/0.28 (17.7/11.0)

Lowering speeds Unloaded/loaded m (in.)/sec 0.50/0.50 (19.7/19.7) 0.50/0.50 (19.7/19.7)

Battery voltage V 80 80

Battery rated capacity (5 hrs.) MAX Ah 750 750

mm 1025 × 852 × 769 1025 × 852 × 769

Battery compartment size
(in.) (40.4 × 33.5 × 30.3) (40.4 × 33.5 × 30.3)

Battery weight kg (lb) 1872 (4127) 1872 (4127)

Tilt angle (forwards – backwards) 6° − 8° 6° − 8°

Drive motor capacity (60 min. short duty) kW 12 12

Pump motor output @ 15% duty factor kW 15 15

Drive motor control method IGBT chopper IGBT chopper

Pump motor control method IGBT chopper IGBT chopper

1-6
 VEHICLE ELECTRICAL COMPONENTS

Electrical Component Locations ........................................................ 2 – 1

Console Box ............................................................................................ 2 – 4 2
Functions of Central Vehicle Monitor System (CVMS) ............................... 2 – 4
Electrical Components in Console Box ..................................................... 2 – 7
Disassembly and Reassembly .................................................................. 2 – 8
Direction Lever ........................................................................................ 2– 9
Accelerator Control ............................................................................... 2 – 10
Key Switch ............................................................................................... 2 – 11
Lighting Switch ....................................................................................... 2 – 11
Fuses ......................................................................................................... 2 – 12
Lamp Specification Chart .................................................................... 2 – 12
Troubleshooting of Lighting and Horn Systems ............................ 2 – 13
Electrical System of FC (Finger-tip Control System) .................... 2 – 14
Nomenclature ........................................................................................... 2 – 14
Precautions to be taken when handling FC system .................................. 2 – 15
Description ................................................................................................ 2 – 15
Operating Principles ................................................................................. 2 – 16
How to Set Controller (Setup Option Setting) ............................................ 2 – 18
Troubleshooting ........................................................................................ 2 – 19
 VEHICLE ELECTRICAL COMPONENTS

Electrical Component Locations

5
5

2
1

3
4

View "A"

7
8

211639

1 Central vehicle monitoring system (CVMS) 6 Horn

2 Direction lever 7 Brake fluid level sensor
3 Lighting switch 8 Accelerator sensor
4 Key switch 9 Speed sensor
5 Head lamp

2-1
VEHICLE ELECTRICAL COMPONENTS

10

12

11

13
211640

10 Joystick box (FC only) 12 Hydraulic controller

11 Traction controller 13 Contactor

2-2
 VEHICLE ELECTRICAL COMPONENTS

18

17

14
15

16

211641

14 Fuse holder 17 Pump motor

15 FC hydraulic control valve 18 Steering motor
16 Drive motor (2 ton class and 2.5 ton class only)

2-3
VEHICLE ELECTRICAL COMPONENTS
Console Box

1 Central vehicle monitoring system

(CVMS)
2 Mode selector button
3 Steering tilt lever
4 Key switch
5 Lighting switch
6 Mode check button

NOTE
For setting the clock and selection of KPH or MPH,
103148
refer to “Selection of KPH or MPH” and “Setting the
clock”.

Functions of Central Vehicle Monitor System (CVMS)

208077
Operations

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.

2 Worn motor brush Drive motor and pump motor Worn brushes After brushes are replaced,
indicator brushes in operable condition indicator turns OFF.

Controller/motor Controller, drive motors and Overheat Overheat causes significant

overheat indicator pump motor in normal output loss. When component
3
temperature temperature lowers to normal
level, output power returns.

Remaining Normal battery condition Flashing indicates

battery charge battery needs to be
warning indicator 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
2-4
 VEHICLE ELECTRICAL COMPONENTS

No. Monitor name When OFF When ON or flashing Remarks

6 Parking brake indicator Parking brake disengaged Parking brake engaged

Fault detection Normal Vehicle malfunction Error codes appear on the

7
indicator error code display.

Vehicle speed and Displays the vehicle speed during normal operation The vehicle speed display can
error code display and displays an error code in the event of a be switched between KPH and
8 malfunction. MPH. Follow the steps in
“Selection of KPH or MPH”
below.

Battery discharge The battery charge status is indicated by the ten element indicator. When fully
indicator (BDI) charged, all elements are lit through to the right side. As the battery discharges, the
indicator elements decrease toward the left side. When only one element is on, the
9 remaining battery charge warning indicator 4 in the LED section will flash. When
the indicator completely goes off, the remaining battery charge indicator 4 will be
continuously lit and the vehicle enters power reduction mode.

Hourmeter, It normally displays the time. The time of clock can be

time display When the key switch is set to the I (ON) position, adjusted. Follow the steps in
10
the drive motor, pump motor, and vehicle service “Setting the clock” below.
hours are indicated sequentially.

Selection of KPH or MPH

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL. Button 2
3. Turn the key switch to the I (ON) position.
Button 1
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 211642

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.

2-5
VEHICLE ELECTRICAL COMPONENTS

Error code display

Indication Condition

E If the key switch is turned I (ON) while the direction lever is either in the forward
or reverse position and/or if the accelerator pedal is depressed.

(E) Faulty setting of seat switch

E 0 ON Drive motor overheated

E 2 ON Pump motor overheated

E 3 ON Traction module overheated

E 4 ON Worn drive motor brush

E 6 ON Worn pump motor brush

E 7 ON Hydraulic module overheated

H 1 ON Faulty setting of lift lever

H 2 ON Faulty setting of tilt lever

H 3 ON Faulty setting of attachment lever 1

H 4 ON Faulty setting of attachment lever 2

L O ON Battery consumption too much

(E) indicates flashing E.

2-6
 VEHICLE ELECTRICAL COMPONENTS

Electrical Components in Console Box

Monitor harness

Direction lever
harness

211643

1 Key switch 2 Lighting switch

2-7
VEHICLE ELECTRICAL COMPONENTS

Disassembly and Reassembly

Disassembly

1
5

211644

Sequence
1 Console box (front panel) 4 Steering tilt lock lever
2 Central vehicle monitor panel 5 Console box (rear panel)
3 Direction lever

Disassembly procedure
(1) Remove the front panel and monitor panel from the
console box.
(2) Disconnect the harness connectors from the horn and
direction lever.
(3) Remove the screw from the steering tilt lock lever, and
remove the lever from the rear panel of the console
box.
(4) Remove the rear panel.

Reassembly
Steering tilt
Follow the disassembly procedure in reverse. lock lever 211645

2-8
 VEHICLE ELECTRICAL COMPONENTS

Direction Lever

Structure

211646

1 Lever 3 Connector
2 Harness 4 Screw, Spring washer

2-9
VEHICLE ELECTRICAL COMPONENTS

Accelerator Control

Accelerator pedal

Accelerator pedal rod

Stopper bolt
Initial position
Lock nut
1.5 to 2.5°
For reference:
H H: 38 to 40 mm
(1.50 to 1.57 in.)
Switching position
of idle switch
Lever E2

IDL
Adjusting screw
Position meter

209531

Adjustment Procedures
1. Disconnect the battery plug.
2. Install the position meter by loosely mounting the
adjusting screws.
3. Connect the accelerator pedal rod to the lever.
4. Check that there is no continuity between the E2 and
IDL terminals.
5. Move the lever 1.5 to 2.5° from the initial position.
6. Check that there is continuity between the E2 and IDL
terminals (the idle switch in the position meter is ON),
then finally tighten the adjusting screws of the position
meter.
7. Make sure the stopper bolt height H is approximately
38 to 40 mm (1.50 to 1.57 in.). Depress the accelerator
pedal until it comes in contact with the stopper bolt.
Adjust the height H of the stopper bolt until letter “15”
flashes on the I/O diagnosis display.

2-10
 VEHICLE ELECTRICAL COMPONENTS

Key Switch

Terminal B M1, M2

Connection Main fuse Logic card

destination Battery

(OFF)

I (ON)

206806A

Lighting Switch

Terminal 2, 5 3 6
Push OFF
Connection Battery Head Working 2 1
BAT
destination lamps lamps 1st (cir. 1) 3 Cir. 1
5 4
2nd (cir. 1 & 2) Cir. 2
1st position 6
(Circuit 1)

2nd position
(Circuit 1 & 2) 209515

2-11
VEHICLE ELECTRICAL COMPONENTS

Fuses

Capacity (A) Location Main connecting device

325 Traction motor

325 Contactor assembly Pump motor

50 Steering pump motor

15 Horn switch, Lighting switch

Fuse holder
10 Key switch, Contactor

NOTE

Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart

Item Bulb
Quantity Bulb color Remarks
Lamp 80 V External diagram

Head lamps 2 Clear 55 W

Working lamp 1 Clear 55 W

205833

2-12
 VEHICLE ELECTRICAL COMPONENTS

Troubleshooting of Lighting and Horn Systems

Complaint Possible cause Remedy

Lamps- Will not light 1. Dead or weak battery Recharge or replace.

general 2. Fuses blown out Check and replace.
3. Open or short in circuit Repair or replace.
4. Bulbs burnt out Replace.

Will light dimly 1. Dead or weak battery Check and recharge.

2. Burned contact points in switches Repair or replace.
3. Loose terminals Retighten.
4. Dirty lenses Clean.
5. Water drops inside lenses Dry and replace packings.
6. Bulbs service life expired Replace.

Head Will not light 1. Lighting switch defective Replace.

lamps 2. Bulbs burnt out Replace.

Other Backup lamps will 1. Backup lamp switch defective Correct if improperly installed:
lamps not light replace if internally defective.
2. Bulbs burnt out Replace.

Horn Will not sound 1. Fuse blown Check and replace.

2. Open or short in circuit Repair or replace.
3. Horn switch defective Replace.
4. Horn defective Replace.
5. Horn button defective Repair or replace.

Will give an 1. Horn switch defective Replace.

offensive sound 2. Horn defective Replace.

2-13
VEHICLE ELECTRICAL COMPONENTS

Electrical System of FC (Finger-tip Control System)

Nomenclature

103144

1 FC hydraulic control valve 4 Controller

2 Flow regulator valve 5 Emergency switch
3 Seat switch 6 FC control levers (finger-tip control system)

2-14
 VEHICLE ELECTRICAL COMPONENTS

Precautions to be taken when handling FC

system
The FC system is controlled by a microcomputer in the
controller. As the microcomputer is a delicate electronic
component, take the following precautions when handling
and inspecting the FC system.
(1) When removing the controller cover, take proper
precautions to keep out all moisture such as rain and
splashing water.
(2) After using the controller setting function, check to
make sure control system is within truck specifications.
208084A

NOTE
Improper setting of the system will result in the
inability to lower the forks in an incremental manner.

(3) Before performing repairs which require welding, be

sure to disconnect the battery plug and the controller
from the system at its connectors.
(4) When handling the controller by hand, never touch its
electrical terminals, or the static charge from your body
will rupture some of the electronic elements in the
internal controller circuits.

Description
The FC system, unlike the conventional mechanical
control, is electronically actuated to reduce the effort
required of the operator in moving the control levers for
lift, tilt and attachment functions.

101466A
• This system provides the following safety functions:

(a) The lift, tilt and attachment functions are not
performed even if the control levers are moved
when the emergency switch is in ON (pushed)
position.
(b) The lift, tilt and attachment functions are not
performed even if the control levers are moved
when the seat switch is not ON (the operator is
not seated).
(c) The system indicator light in the LED
section alerts the operator to problems
occurring in the electrical system and, at the
same time, stops function. (If any problem
occurs in the lift system, for example, the
system becomes inoperative.)

2-15
VEHICLE ELECTRICAL COMPONENTS

Operating Principles
(1) The system is activated by turning OFF (pulled, not
pushed) the emergency switch when the key switch and
the seat switch are ON (when the operator is seated).
(2) As the control levers (joysticks) are moved to operate
the equipment (mast and forks), the amount of lever
movement will be translated into an electrical signal;
this signal goes into the controller where it is converted
to an output signal. At this point the controller issues
an ON signal to increase the pump motor speed,
thereby hydraulic pressure will be introduced into the
control valve. The system is now ready to actuate the
equipment. The output signal is applied to the
proportioning solenoid, selected by the direction of the
joystick movement. Inside the control valve of the
solenoid, the spool valve is forced to slide, altering the
internal oil passage that directs the oil to the
corresponding cylinders. The spool keeps on sliding
until it comes to the position where the pressure of its
pilot chamber becomes equal to the force of its
centering spring. In the meantime, the cylinder extends
or retracts against its load. As the joystick is moved
back to its neutral position, the signal to the
proportioning solenoid decreases in order to lower the
pilot chamber pressure and allow the centering spring
to push the spool to its neutral position, whereby the
line to the cylinder shuts off. The pressure in the line is
now trapped, holding the cylinder in place. At the
same time, the motor speeds lowers and the part of the
system actuating the equipment goes into a no-load
state.
(3) Supply power to the controller is initiated from the
Power Relay through a 10-Amp fuse. Pressing the
emergency switch shuts down the output to solenoids.

2-16
VEHICLE ELECTRICAL COMPONENTS
How to Set Controller (Setup Option Setting)
Set the controller on any of the following occasions:
Occasions:
• After the mast has been changed, or an optional
equipment added.
• After the controller assembly has been replaced.
How to set:
See the “Setup Option Setting” section in the “Controller
Service Manual GROUP 1 CONTROLLER”.
General Precautions:
(1) Use low air pressure to clean electrical equipment
(controller, motor, battery, cable, etc.). If using
steam, do not blow it directly on the equipment.
(2) When the counterweight back door is removed,
make proper measures to keep out rain.
(3) After using DRS (Diagnosis Run Set) switch,
recheck the switch setting.
(4) The controller containing the microcomputer
should never come into contact with water. When
the cover is removed, take proper precautions to
keep out all moisture such as rain and splashing
water.
(5) In case of some welding work on the frame or body,
disconnect the battery from the power supply line.
And disconnect the controller from the system by
undoing all connectors. If the welding job has to be
performed near the controller position, remove the
controller from the truck.
(6) Your body could pick up a large static charge.
Keep this in mind when you handle the controller
by hand: never touch its electrical terminals, or the
static charge from your body will rupture some of
the electronic elements in the controller's internal
circuit.
2-18
Failures resulting from incorrect setting
(1) Incorrect setting for truck size (2.5 ton, 3 ton) or
incorrect model setting
(a) An incorrect setting will result in abnormal
lowering speed and inching feel. If a setting
for a 2.5 ton model is made on a 3 ton model,
for example, the lowering speed will be
abnormally low. If a setting for a 3 ton model
is made on a 2.5 ton model, the lowering
speed will be abnormally high.
(2) Incorrect setting for number of control valve spools
(a) If the setting made for the number of spools is
greater than the actual (FAULT lamp lights
and error code is displayed), the equipment
does not operate.
(Regarded as open-circuit in control valve
solenoid or joystick.)
(b) If the setting made for the number of spools is
less than the actual, only the devices equal to
the number of set spools will be actuated.
(3) Incorrect setting for mast
(a) A setting for a dual-stage full free mast or
triple-stage full free mast on a truck with dual-
stage panoramic mast will not affect the
lowering speed.
(b) If the setting is made for dual-stage panoramic
mast on a truck with dual-stage full free or
triple-stage full free mast, the lowering speed
of the 1st lift cylinder will be abnormally low.
This setting will not affect the lowering speed
of the 2nd lift cylinders.
 VEHICLE ELECTRICAL COMPONENTS

Troubleshooting

1. Preparatory steps
(1) The system receives supply power when the battery
connector is connected, the key switch is turned to the
ON position, and the emergency switch is turned OFF
(pulled, not pushed). The finger-tip control becomes
operable after the seat switch closes (when operator is
seated).
(2) Before deciding to replace a blown fuse, make sure the
harness connectors in the power line are all in good
condition.
(3) The use of the test-use connector (special tool) is
recommended for checking the connector-to-connector
lines for continuity and for reading the voltage across
two terminals and the ohmic resistance of a line.
205038
(4) When coupling or uncoupling a connector, make sure
that the key switch is turned OFF and the battery
connector is disconnected. Never try to forcibly insert
or pull off the connector, or its pins will be damaged.
When coupling a connector, be sure that the inserted
half snaps into its self-locking position.
(5) Before starting troubleshooting work, check to be sure
that the conditions indicated in the following table are
met on the machine side.

2-19
VEHICLE ELECTRICAL COMPONENTS

Inspection of machine side components

Shown in the following table are the machine side basic
components that must be inspected first when a problem
occurs in the FC system and the conditions and points for
performing their checking.

Conditions in
Check item What to check Remedy
the machine

Hydraulic line Hoses, pipes and connectors for damage Repair leaking or
and sign of leak. damaged parts.

Key switch OFF Hydraulic devices Check control valve and hydraulic cylinders Repair damaged or
Emergency switch for damage and oil leaks. leaking parts, if any.
ON
Electrical connectors Check connectors for tightness, burns and Repair.
and wires breakage; check wires for insulator
stripping and signs of rubbing.

System check lamp Check to be sure the lamp goes ON and Replace lamp bulb if
OFF properly; if not, check the bulb. blown.

Hydraulic devices With your hands off the control levers, Refer to the sections
see if the solenoid valves and hydraulic dealing with control
pump are making any abnormal sounds. valve and hydraulic
pump, respectively.
Key switch ON
Operate the control levers to see if any (Proper function of
Emergency switch
abnormal sounds, indicative of flow solenoid valves is
OFF
throttling, comes from control solenoid essential to
valve or from any other solenoid valve. troubleshooting.)

Work attachments Check each work attachment for the See “4. Troubleshooting
following: guide for solenoid
(a) Does it work properly? control valves” on page
(b) Does it “inch” properly? 2-24.
(c) Does mast go down with proper speed?

2-20
 VEHICLE ELECTRICAL COMPONENTS

2. How to move the mast in an emergency

If the truck fails during operation, and you have to drive it
(if the engine is OK) or tow it to some distant place like the
repair shop, follow the instruction below.

! CAUTION
Before doing these steps, be sure that there is no
one standing under the mast.

(1) Mast lowering

(a) Loosen lock nut 1 on the lift section of the control
208076A
valve.
(b) Using an Allen wrench, slowly loosen screw 2.
This causes the mast to go down by gravity:
tighten screw 2 and the mast will stop.
(c) Tighten lock nut 1.

! CAUTION
Leaving nut 1 loose is dangerous: the mast might
suddenly start descending by gravity.

2-21
VEHICLE ELECTRICAL COMPONENTS

(2) How to cope with a failed (open-circuit) seat switch.

Your troubleshooting investigation might reveal that the
seat switch is an open-circuit or otherwise faulted and
will not function.
In such a case, you can create a temporary circuit
through the seat switch wiring. The method is
explained in this illustration. The seat switch is a
safety part. Be sure to replace it with a new one as
soon as possible.

Two connectors are in the seat

switch line at the indicated
location; Open these connectors,
and couple up the male and
female connector halves to form
a circuit bypassing the seat
switch.

205012B

! CAUTION
Illustrated above is a band-aid method
permissible only in an emergency situation. Be
sure to restore the seat switch line to the normal
hookup after replacing the failed switch.

2-22
 VEHICLE ELECTRICAL COMPONENTS

3. How to clean harness connectors and system

components
(1) Open-circuit troubles are often due to 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
electrical separation of contact surfaces. For this
reason, it is essential that the connectors and
components be cleaned at each periodic inspection and
at the time of servicing the truck. Instead of a
commonly used solvent, use the electronic parts cleaner 205046A
(in the manner illustrated on the right).

Electronic parts
Three Bond 29D or Pow-R-Wash CZ*
cleaner

NOTE
The cleaner liquid is volatile. All you have to do is
just give a strong spray to wash off grime. 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 the
contact surface activator onto contact surfaces. Now,
install and remove the connector several times to wet
the surfaces thoroughly with the activator liquid. After
coupling up the connector, check to be sure that it is
correctly locked.

Contact surface Three Bond 2501S (aerosol)

activator or Nyogel 760G*

NOTE
Do not spray too much: bear in mind that this spray
liquid reacts with some resins (plastic materials).

* : Products contained in Terminal Maintenance Kit

(SE000003).
205047

2-23
VEHICLE ELECTRICAL COMPONENTS
4. Troubleshooting guide for solenoid control valves
Trouble symptom
The pump discharge pressure
will not build up
Sticky spool
Possible cause
1. Sticky plunger in proportioning
solenoid of reducing valve, or
sticky shuttle in reducing valve
2. Open in lead wire or in solenoid
coil
3. Input current to solenoid too small
4. Unload valve stuck open
5. Spool stuck in flow-divider valve
Sticky plunger in proportioning
solenoid of reducing valve, or sticky
shuttle in reducing valve.
2-24
Remedy
Disassemble and clean by washing.
If the plunger is sticky, replace the
solenoid.
Repair or replace.
Check to make sure that solenoid is
drawing specified maximum input
current.
• Check unload solenoid for action.
• Check unload valve for action.
Disassemble and clean by washing.
Disassemble and clean by washing.
If plunger is sticky, replace solenoid.
 POWER TRAIN

General Structure ................................................................................... 3–1

Common Removal and Installation Procedures ............................ 3–2
Front Wheel Removal and Installation ....................................................... 3–2
Battery Removal and Installation ............................................................... 3–4 3
Power Train Assembly Removal ......................................................... 3–5
Power Train Assembly Installation .................................................... 3–8

General Structure
Power flow
Location of Power Train Component
1 Drive motor
2 Transfer gear
3 Differential gear assembly
4 Right axle shaft
5 Right wheel hub
The power train mainly consists of the following three
units.
1) Drive motor
2) Transfer and differential assembly
3) Front axle assembly
These units are connected to each other internally
through splines and gears to transmit driving power and
externally through cases joined together with bolts to
form a power train assembly.
The power train assembly is secured to the vehicle
frame with bolts at the front axle supports.
The output of the drive motor 1 is first transmitted to
the input gear shaft of the transfer gear 2. The transfer
gear 2 is a 3-stage reduction gear. At each reduction
stage, the motor output is decreased in the gear speed
and increased in the turning torque in inverse
proportion before transmitted to the output gear (bolted
to the differential gear) of the final reduction stage.
The gears used are noise-free helical gears for quiet
vehicle operation.
To allow the vehicle to make a curve smoothly, outside
wheels must turn faster than inside wheels. The
3-1
POWER TRAIN
208364
6 Right wheel brake
7 Left axle shaft
8 Left wheel hub
9 Left wheel brake
differential gear system is a device that makes it
possible; it detects the difference in turning resistance
between inside and outside wheels being turned and
automatically differentiates the number of revolutions
between them accordingly.
The power transmitted to the output gear is then sent to
the differential gear assembly 3. When the vehicle is
turning, the right axle shaft 4 and left axle shaft 7
rotate at different speeds. The power distributed to the
right axle shaft 4 is transmitted to the right front wheel
by way of the right wheel hub 5.
The power distributed to the left axle shaft 7 is
transmitted to the left front wheel via the left wheel hub
8. When the vehicle is running in a straight direction,
its left and right wheels are equal in turning resistance
and therefore no speed difference occurs between them.
Each of the left and right wheel hubs 5, 8 is provided
with a wheel brake drum. In the brake drum is housed
the internal expansion duo-servo type wheel brake 6, 9.
For further information about the structures of
individual components and system operation, refer to
the relevant sections.
POWER TRAIN

Common Removal and Installation

Procedures

Front Wheel Removal and Installation

Removal
1. Park the truck on level floor with the parking brake
applied, the direction lever in neutral, the forks
101206A
lowered, and the key switch in the OFF position.
2. Prepare tools, jacks, and wheel blocks.
To Raise Front Wheel
3. Block the rear wheels.
4. Loosen the wheel nuts about two turns.

NOTE

Loosen, but do not remove, the wheel nuts.

5. Raise the front end of the truck. Use one of the

100828A
appropriate methods illustrated at right.
Position the jack under the frame and raise the front
wheel.
! WARNING
To prevent possible injury, do not replace the front
wheel when the truck is loaded.
Alternative Method
Dismount the truck before raising the front wheel.
To prevent possible personal injury, raise the truck
only until the front wheel just clears the ground.
Do not put any portion of your body under the
truck. Securely support the truck on blocks after
raising it.

6. Remove the wheel nuts (loosened in Step 4.).

NOTE 100913
Be careful not to damage the bolt threads when
Tilt the mast all the way back, place blocks under
removing the wheel.
the mast, and tilt the mast forward.

7. Remove the wheel.

Inspection of Tires for Wear

Replace the tire if the depth of its tread groove is less than
5 mm (0.2 in.).

100680

3-2
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