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SHOP MANUAL FB10EX/14EX/ 15EX/18EX-7 FB15GT/18GT-7 FB20EX/25EX-5 FB20GT/25GT-5 FBSOEX-5 MACHINE MODEL SERIAL NO. BEX/18EX-7 60001 and w 39001 and up FOREWORD Froper operation, maintenance, iroubleshoating and repal’s afe TeseiS ert to preserve the perior Freee. oPvahicles over @ lang periad of time and to ensure that fault ane breakdowns do not oscur. Fee pject of this Shop Manuai is to provide the information NECeSsetY ‘aspeciaily in connection with je obermance of inspections and repairs mainly in the maintenance 2820 ihe Pe orapoze, it includes sections on “General end Specifications” “Removal and Installation”, Sisassemaly and Assembly”, "Electrical Sysiem” and the “Inspection and Maintenance”. Fee sey for the periormence of maintenance an the machines 's sis0 Include: Marte aye should be made to the Operation and Maintenance Mande! fer fursher details. ae eter rmuld zlso be made to this manual in connecsion with correct opersiion of the machine. The content of the items mentioned above is as follows. General and Spe Enea ao Myer indicates ihe name of each part of the machine, and the installation posi operating devices and instruments. n oF the Removel and Installation rey chapter explains the weight of component parts 2s well a5 the order OF removal of the mast, lift v- tinder and power train etc., and the point of reinstallation of them. Disassembly and Assembly SaeeeMapler axplains the point of disassembly, inspection/repair (or individual component psrts, Electrical System Seer fon is provided In zhis chaprer of the siectrcel pers used insiae she ™ when 2 breakdown occur scribed. chine, Troublesnooting Inspection and Maintenane: This chagter expigins servicing, be referred to Suri Jervice deta, adjustment procedure, and dimensions Reference should be made to the “General Shop Manuel” for saie operstng Ete working methods wich sen as the basis for the performence of repair and inspection werks on machines 00-1 00. Ot. 10. 20. 30. 40, 50. SECTION INDEX FOREWORD GENERAL AND SPECIFICATIONS REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM INSPECTION AND MAINTENANCE CONVERSION TABLE 00-3 01. GENERAL AND SPECIFICATIONS Precautions for maintenance .........-..+ Periodic replacement of consumable parts Standard tightening torque for bolts Standard tightening torque for pipe joints Spesifications Tleslal o1-1 GENERAL AND SPECIFICATIONS PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Careless performing of the easy work may cause injuries. Take care to always perform work safely, at feast observing the following, ® Oil is a dangerous substence. Never handle oil, grease or olly clothes in places where there is any fire or flame, ‘As preparation in case of fire, always know the location and directions for use of fire extingui- shers and other fire-fighting equipment. © Wear welliting helmet, safety shoes and working clothes. When drilling, grinding or hammering, always wear protective goggles. Always do up safety clothes properly so that they do not catch on protruding parts of ma chines. Do not wear olly clothes. When checking, always release battery plug. * Flames should never be used instead of lamps. Never use @ naked flame 10 check lesks or the level of cil ar electrolyte. © Exhaust gas is dangerous. Provide adequate ventilation when working in a closed space. Ad Be panicularly careful when removing the radiator cap and the hydraulic oll tank filer cap. if this is done immedictely ater using ‘the machine, there is a danger thet boiling oil may spurt out © The procedure for releasing the hydraulic pressure is as follows: lower the fork to the ground, and stop the engine (motor): move the control levers to each position two or three times. 01-2 GENERAL AND SPECIFICATIONS: © When working on top of the machine, be care- ful not to lose your balance and fall © Hang a caution sign in the operator's compart ment (for example "Do not start” or “Mainten- ance in progress"). This will prevent anyone from starting or moving the machine by mis- take. Itis extremely dangerous to try to check the fen belt tension while the engine is running. When inspecting the fen belt or other mav- ‘ing parts, or near such parts, always stop the engine first Before checking or servicing accumulator or piping, depress brake pedal repeatedly to release pressure. © Park the machine on firm, flat ground. Lawer the fork to the ground and stop the engine. Return each lever to "NEUTRAL" end apply the brake lock. PRECAUTIONS FOR MAINTENANCE Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. it is very dangerous if someone slips while on the machine. When working with others, choose @ group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work. Unless you have special instruc contrary, maintenance should always be cer- ried out with the engine stopped. If mainten- ance is carried out with the engine running, there must be two men present: one sitting in the operator's seat and the other one perfor- ming the maintenance. In such a case, never touch any moving part. Always remember that the hydraulic oil circuit Is under pressure. When feeding or draining the oil or carrying out inspection and meinten- ance, release the pressure first. GENERAL AND SPECIFICATIONS PRECAUTIONS FOR MAINTENANCE © Thoroughly clean the machine. In particular, be careful to clean the filer caps, grease fit- tings and the ares around the dipsticks. Be ‘careful not to let any dirt or dust into the sys- tem. # Always use Komatsu Forklift genuine parts for replacement: «Always use the grades of grease and oil rec- ommended by Komatsu Forklift. Choose the viscosity specified for the ambient tempera- ture. Always use pure oil or grease, and be sure to use ciean containers. © When checking or changing the oil, do it in place free of dust, and prevent any dirt from getting into the oil ‘= Before draining the oil, warm it up to 2 tem- perature of 30 to 40°C. ‘© After replacing oil, filter element or str bleed the air from the circuit. * When the strainer is locsted in the oil filler, the strainer must not be removed while adding oil * When adding oll, use the dipstick to check that the oil is at the correct level. © When changing the oll or filter, check the drained ail and fiter for any signs of excessive metal particles or other foreign materials. © When removing parts containing O-ring, ges- kets or seals, clean the mounting surface and replace with new sealing parts. «After injecting grease, always wipe off the old ‘grease that was forced out = Do net handle electrical equioment while wear- ing wet gloves, or in wet places, as this can cause electric shock. * uring maintenance do not allow any unauth- rized person ta stand near the machine. * Be sure you fully understand the contents of the operation. It is important to prepare necessary tools and parts and to keep the opereting ares clesn. ‘© When checking an open geer case there is @ Fisk of dropping things in. Before removing the covers to inspect such cases, empty everything from your pockets. Be particularly careful to remove wrenches and nuts. * Way to use dipstick Push the dipstick fully into the guide, and then pull our. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the Komarsu Forklit distributor to carry it out. GENERAL AND SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS. PERIODIC REPLACEMENT OF CONSUMABLE PARTS For operation safety, never fail to perform pt ‘odic maintenance or make periodic replace- ment of the consumable parts listed in the fol- lowing. ‘These parts may deteriorate in time and are sus- ceptible to wear. It is difficult to estimate the de- gree of weer at time of periodic maintensnce; therefore, aven if no apparent wear is found, al- ways replace with new parts within the prescribed period of replacement (or earlier if trouble is found) Note that periodic replacement has nothing to do with guarantee service. No. Part name Period of replacement 1 | Cups and seals for master and wheel cylinders Every 1 yeer Hoses or tubes for brakes Every 1 or 2 years 3 | Hoses and tubes for brake reservoir tank 4 | Hoses for power steering Every 2 t0 4 years Every 2 years 5 | Rubber parts for power steering Every 2 years 6 | Hydraulic hoses 7 | Liftchains 01-5 Every 1 or 2 years Every 2 to 4 years GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR BOLTS STANDARD TIGHTENING TORQUE FOR BOLTS TIGHTENING TORQUE when using torque wrench or spanner shail be in accordance with Table. This tor- que shall be used when TIGHTENING TORQUE of especially narrow range is required, 1. In the case of using impact wrenches 2. In the case of using torque wrenches or spanners. rat gi Ne Ue: gen IN) ff 1b) ote 7 sicc, Sucr 7 we | site Sassen wanacasts | SURES, wan scon tee | SESSMES, ‘Thread ine ‘or superior ones ae ‘or superior ones a mmminh | Conve 180 ‘50 tenal, | senor sence zoe | ae |) eas |e = |e | om Piesie | as soko |e | oS) | Bemis | fa os | aay | eam | faa | dae Bene 3 | ot | oe | Gece 1s} os ois | esa | aim | mse of | oan fends ee ee iow | ow wis | ee | aan | Beata aan | ean Boa 2 | | ag | Sees 2 cin | as | ots | emis on ‘a— a { ie | om | om | dsowo fon | 2 yoss) | (as, tan | (3-18 oss) | we | (0.87 ao I 16. 23 28 150-315 16 a | ou wa | @sy | ay | her 3 ag | een | in Hos = 2 | 3 | ox | oa | ieee «| oe | op oh | ey | obo | armen em | ot | oe fis =a 2 |» |e ee 2 | (1) inter | Gis — 603) io | Bsr aa | 2 az | 89-38 2 a | cis | my | Tes eis | onde | eae | hae i Seren | om | eames | ona gg | cata, | eae —1a30) | ‘ees — 1030) | I ae ar aa oy | ain irate (eee — oe | 7 oe So iso sta | | fia =a i tana Bone an | t= 2 rset zea | toes Heo fi = tac | {Sse Bons ois se 39 ig tea ! 11374 — 2242}, {1808 — 22621: bose) | p> ao Be _ ie | aaa | 236 ]1226— seam! 2042) (2863 — 3822) i i fest ~ dere) 1 i Sa tert % This table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are 10 be used, or which require to tighten to otherwise specified toraue. GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS Elbows, nipples and unions Width across flats 8 (ram) 2 30 36 Width D (em) 9 2 20 Tiahening torque (kom) 3 8105 12-165 Port size (inch) 3/4-16UNF 18/16-12UNF 18/16-42UNF Tightening torque (kom) 7-18 32-165 na15 Union Bow High-pressure rubber hoses, pipes and sleeve nuts ‘Width across flats B (mm) 8 Ey 7 2 6 Bore A (earn) a 8 2 2a Tightening torque (kar) 3 - wa | a2 01-7 GENERAL AND SPECIFICATIONS SPECIFICATIONS: SPECIFICATIONS FBIOEX/14EX-7 (i FBtaex LOAD CAPACITY CHART FenEx LOAD CENTER jin) FB14EX CAPACITY tha APACATY ty 5 5 z z z 3 LOAD CENTER {mm LOAD CENTER (mm cities shown ate for tucks equioned with 2-sage view mast uo through £000 mm {387 n) maximum fork news, 870 ev (382 ia) eariege 770 me (20.3 in) forks for #FBTOEN are 920 mrs 196.2 im) forks for FBTAEX, (Contact your Gisvioutar or desier for capacity information with cther equipment 01-8 GENERAL AND SPECIFICATIONS SPECIFICATIONS FBIOEX/14EX.7 ry Tiers aaa i Fae r eer Sesaciy = Stren (20 aca Toa az0q) sea cc) ai soba (20] teas Coie ao wrorz 00) t Heo aE Fane Toe L Taare Tes pe So Preemie t Freurate ‘Geertor pe ‘iver Sasa, Sing Ses | Whe P= eas) ——| Number tou eem i 77a 7 | We For nae =m Sea te _| Fre nA Tas T or [eal | Themear swan Li in (Eg TOoTrO 4 xBSRIES [WOE Oro (ce TOES "ig Ra [75 rena aoa ze ari [Cienega Gvorias oo se a ey a (Co ergo tce fs aia | Srrrine orem ‘sn THT ing aoe sae Sart (erg ar eneroer aT So Tag ao ae as ST COC ae) S| TT va | Batam Pusioadiengih ‘arn | 2135 (88.1 I 2140 (ge) tweaks Comer] mor iarieea7aat = ‘Ting ‘Toaced /Uricaded mers (ered | 73207 500 153.95) T "3107 500 (67) Towers Sed ewes oT 2505 OST a aE x] aaa raise aed = aT 1 er Sees Wag eng Bay (50TH atlases oa ee ia eon gist] SRT so waco Ta | SOT eo s10 | { (uss —— [roar Spier aero vassh7 aon — [rao eso (20073 Sam Fa 1 EeaEISRT) aa c Ea7AT) cer i aT wasn 082) Ter {Sa ear oc 7a (35.8 EST Gem | esi ‘aa S05) a | Gone Fan aa 19137 =a [Lene Trae fa t san eae ype i Fane Sa Te i Tease Tage wt a ster S10 eaiaiy Ta hat 3 ee ive 0 day win ce ae nT ne Wao a Pape Sa aap “art over Sing i107 a] ire waar Cost ipa oom 1 7 (Ci Pressure Spar —— (iss casior Tessa aan ap ary cu oaraeg concen Th atom yn ee ai ce eng eon ‘Speoleatore se met io imprvarani and ranges winout rete * alves uncer ypc! peng condi. GENERAL AND SPECIFICATIONS FBISEX/18EX.7 ‘SPECIFICATIONS LOsD CAPACITY CHART FBISEX ‘LOAD CENTER fin) FBrgex i z 3 5 LOAD CENTER trim) Capacities shown are for trices aauioned with 2-tage view mast uo through 4000 mm in.) maximum fork height, £70 rm (38-2) carriage, and 820 rn [26.2 in) forks Contact yaur aistitulor or desler for eauaeityinvormstion with other equisment, 01-10 Sea 2GRBEE cAPACITY LOA CENTER (ou GENERAL AND SPECIFICATIONS SPECIFICATIONS 9 FBISEX/18EX-7 Tea Tanta agree n i 1 Teaeaesy ssn ao )asGm TSR 720 0.081, tee (27 toed Cai Pl 350.008, Srver Sang, SES Homer ( H ‘ie Metr Corel r Tyee ator Cone Tees Cisne Wess 7 ee saat « ne | ree i “rm in) | 445 (571 = SS rans age seat | SSR a OTT Sages ——— fa Pee ee fat Se ee casa : a ee eanaoe Ser as Stans ae San Ta ies nan eee San meets isin aes =a ar Tagg [ir oa Se a a TT Flats arate Plus teaaitengin em je 60 4 1 188 Sar mf amy | asa _—— aaa FEET cpm tee Heise] iret aareaerea iG ig eee a TS aay aes Uae Sa Toa aT Hehe a aa a = =f oe Co — SS ae Ser saree St > : Hasse heer eras ee een vase ta t ERE jaa esr T “5008-6 PALIT 3 “Wheettase ty Tae tiny | 1250 682) igs ans — era St ama Sy : eae Set SE a ———— ma] Centar ol rare, ‘rem (el | 410 4.31, a Serves Hydrate 3te eae a Tier se hee Berta : ier a sey (avesar a i Hieeesesara = i: HigeesrSeaey ame sat Tats i (oes ay at Geviee ens at evctoon aang Sr t Pavranes may vay su 9 ceraing coins, The paarmance shown Woresnis ait ales ce pic peeing covions. te srolnin na pubicanan te rounerd. Taree, ore canveion Seweeh rae ard reel may Be sign arent or thse shown, ‘Schoatans ae suberto oovererisondcnanges wiht rte. GENERAL AND SPECIFICATIONS 7 SPECIFICATIONS FBISGT/18GT-7 {i Fetect LOAD CAPACITY CHART FBIscT LOAD CENTER tin FaxecT CAPACITY thon cAPACITY CAPACITY tht TE Sw Te LOAD CENTER Irom) LOAD CENTER ime) Capacities shown are for trucks eauloped with 2-tage view mast up through 000 mm (957 ing maximum fork height, 370 om (88-2 in) cariage, ang 820 mt [362 ini fore, ‘Centact your distributor or dealer fer capecty iMfermstion wih cthar 2cuiamen o1-12 GENERAL AND SPECIFICATIONS. SPECIFICATIONS: FBISGT/18GT-7 Se ao ae a0 (ees aes Seeger i t Feral ae : Feeaie (aera SE oa (ister aaa ‘ 272 Saar =e oa ae Pr Sa SI Sar Tener s Wananga ro OPTS ES) TOT ais Trem asc seper ain (isp nenes¢ Gase————ri eT Se epic es | __— aTT SEBT Srnncene ater oa Tass fr Hagh aR eT aa Taarar esa a ee aa ST Tang Aaa a aoe Stamatis 35ers est Roane a ata | 210 627 | 207.9 Ta eee Tears pnd pede _[inatssa|—— wah ot waneeera i Sina TE Be ST ee STS Toa —T Tar sa ana aaa ona = ae 7 es Seer Wag wate Se et a ETD = Se ear Sel aetna an arso aang tes ea SE ca ae hiatsso eerie aera (Fear 1 poe see ier i Gerace eo =a Toi0 tres ce =a saw ne EH if ene =a eas : ase at ane : (eee 1 ae é ee i i ear ane ee tana co zi Hroeser saa | (ine Ssriosienst ——— ss era | } Hagens oman mer! Sees Tew at Sistas fein art [BeweSegiter es ra Hina cbe t Capone con 7 (Lame soe BT HESS muses ferrmane nay vary eu cowaing contr, Te gree son een rm serio Stesheanenratenubont oievoverans ane an 7 aes uncar pel coeine ears. 01-13 GENERAL AND SPECIFICATIONS SPECIFICATIONS FB20EX/25EX-5 LOAD CAPACITY CHART Fezcex LOAD CENTER (in FB2sEx capacity, caracy caraciy LOAD CENTER (mvt (57 in maximums fork hai {Cantact your altributer ar tnreugh 4000 men 2 in forks. z 5 GENERAL AND SPECIFICATIONS: FB20EX/25EX-5 a Tamers seg Fane Fa iad {sty ase 20 toss Cone ——SSL | os a) Beso ice [Cat son cs Cer ier 9 0) ros 001 1 n Fecal Sota Fama a Prsasie Sovate Tee Tbe Sanaa, SE T ‘Siang 7 ta | Wax Fane =a Sean Ta Fee ana Ea wa Fas Rr peinens Wace eager ee Ga a ATE) eS TEES | Te ae THE Pore Sapenart araie | S70 [iT wea rare cane con 0 e277 vent [Ee Tarsni aes eran ent ae. i Sema Somme [ewe =ailt Tes cea Se Re aaa Eta aesi7es) } Tae ig Mae neni ania SD. Sang Rech |W busi ania} 686 FBT T Bear (eae Saree TR Frew cone Pan San a0 TIS ie) Banat [Ps ise rae eae zo a4) 2418 25.) vo SS Se er Saeed felna [integer taps} 107 80(83 931 | rao va@ 8) roy Tented Unsaaeg"os sah | 279790165708) —_|—_—_ 28048060765) Tone Tossee/Unessed (6) 7 (TH) Ta oar cc ‘races 1 Caaeee anasto Seb me “Tynce Wage neleig Stir SBE Toa wae 0 Ga pene (ease [SH eat sper erarres vaste sao. [Cosiesse ——T teeta aie sp Be 380 FEST 7 Len r Party hakaal Fraser 1 Tae 7 asa a) Toes TT =a 06 6531 Teas ‘Cer Timea a ‘seer Baa a86 078 a ema cummma 7 PB | bores at eh nana 7 re | Genito a ate Hevea el Sees 1 erie fo i Tecnaned aa Tipps i Fewer Sera vege z 3 suet ‘Srb oxetay Taserame | zy T a ge Sat STS Sen eg = ca a Tc (ete Her Tear oo zz Sie [apse prance tp ai [CBeve tor cones [Cpgravie noir ret ‘erermance may vary cv wo comaing concns. ‘Mest suas town tea uteason are ounce, Ther, dete Efofeoness re sunjoc © smprverarts ane changes wine ree paternarce shown 7 receris rsming valves urate pis oar cones er semen sea td roa ay 28 Sy eae or Hose =how 01-15 GENERAL AND SPECIFICATIONS SPECIFICATIONS FBZ0GT/25GT-5 (1 Feescr cao LOAD CAPACITY CHART Fezost LOAD CENTER fin razscr Lond CENTER in E Bg 5 CCapstities shown are for tucks eovioped with 2stage view mast uo through 2000 mm (057 in) maxienum fare heign, 370 com (38.2 in) carriage, ane 870 mmm 6.2 in forks Contact your distributor or dealer for capacity inarmation with ether equipment. O11 GENERAL AND SPECIFICATIONS SPECIFICATIONS FB20GT/256T-5 am aaa Sa anes ners a2 coecay ey anes goiceceve gS] taeda so i teen 2 Las Ce Sees ness reer ramp : 1 Uipteetee 5a aie 3 (Ce cesar Fine i song, ST isa Sas) be eT i a 7 Ce wera sar aan u Oe es ee Fan RS wer nogs aren eee |e eR ies aE Ta Farar aac sage a8 (i Regie oven oT seri Hoe a ‘gr fess et ‘Sinensons i oo TEST [apes maa arene ‘Setar war a1 {Cn rig as eer er 789 58 Tang naan ——— wa ele =n =a wT Taare me =a ae) i (ea) eee a = poorer Tago { E | c Teed eT ae iste snr] saris 3/ag0 aa 01878 Tages Oapasee soe om] 70790 65708) | 9879049788) ‘ane onset eee Dew Ta oes ‘wi 1612300) Sana (eae = = i we Sas Wag neg Saree EE smi ae esa Saas Tt er Stayt aieramo seo ey_| wore naai07 TTT 9 Lise Se oor ia staan) | —Toeo ze ea 8 ' ! aESsGEFALY tae ese + PETA § Ge maa =m 755 S35), 2 az hese 1 a ces —— sr ol ara 0 2th Gooaee pa [ tomo ‘asia 91 q (Ce contest ai aa Ts HET vee (sess t Ta 6 Pag H Necross Sea Lies i Famer Sea Chae i Tae base a se (socsneir eo ra (abe Gast EST Sear as : a é Spas as Ver wT a 1 tecretitoe Ra Sewg Wei Pew SS = a i ‘Tryarr con [SSeclawece se najec improvement anseranges miu eee a gamnng onan. The erm own 01-17 ‘eoeens nana values ieee aie pang sortons. on paral ay be gy etaron Po hese shear, GENERAL AND SPECIFICATIONS FBSOEX-5 LOAD CAPACITY CHART LOAD CENTER (in) 202422880 200 5800 3400 15000 H 800 4200 CAPACITY (kg) CAPACITY (ib) 309 600 700 G00 200 1000 1100 1200 LOAD CENTER mm) jes shown are for tucks equioped with 2-stage view mast up through &600 mm 3G 920 mm (36.2 In Forks. ‘wits other equipmant. Capes (157 ing manirura fork neigh, 979 ram (32-2 Il eariage 01-18 SPECIFICATIONS GENERAL AND SPECIFICATIONS ‘SPECIFICATIONS FBROEXS Tose Tics Seon FREE T casecn | ssc st soon ePcond CORE ou 16800, | casey [itesomm tess cat 272016091 H aes | Sa ame eae (Bivens. Sg ‘ng Corer four ze CET a in| a Fe eas 31 | Fee ea ca Ee | Thekeenry SH Tagore 9 sD se rg ae a1 | Rowe Bea ar =r [Di Regge Overans ced Ta ae 51ST cveat (Ce aang a os S971 Le Satins Wh oo Tena ac ni ra ae oo i531 et Frag was ene =r) we (85) 77 Tua Raaas Wa onto eta i001 4 less Daanee | Fen eon ae ‘mnie TECasT | ae Pius oad erg ance) | ‘450(106.9) zy Fagae| eeS_T TaBTeOT STE Espen ‘oval eee Unease] | oriomre itz Tad ea Uses en | seo7 soa 67 5 Tavera tence neated na ECoETIEGY Fert 1 Wer T2380) easy aera st ia ee Saves wens 1 mcg sary ee arr 9 (5) capeae (Lisases ‘eta eT 5790 300) 9 Z sense sa eras 075.21 Fa i PALIT Tre see Ta es PAT qe Ceri iT ae 50 (635) 2 cap iesd ‘ai ies Tot, mnt 575958 = Br | Lots fi "35 531 GL ae] See cewmnce Tascam ame in 135 53) eae Sete I erie 8 a Fania Tes Soni ree 1 Fave Seer Te H Tass ve uw a ner Sra cass Tere co ra Targa Saray (ST Srererame = tz Tg So Bate wih Ts (2557 cat re rr ag a =] Panb NOS! Seana ate ae | Secne Mors Fone: Sang Wet. Pine a Ge ‘evar Coal i Tae i yar Watt Con i Tanase LET yyuuae [its ree =a eee [apy Prom rss casser Tus] aan Fedeenance ay vary eu coating cancion Te prarmancs sewn Feed wan ns pleasant ranges. Thoreae, ect ceneon teen MANE a [ecleaton are paactto meroverans ana harges wnat ne 01-19 ret ema vetes vader recs csarang cocitons cera may 0 gh aera om nase sear 10. REMOVAL AND INSTALLATION LOCATIONS OF UNITS... HOW TO INSTALL UNITS WEIGHT TABLE ose ccsscneoe REMOVAL AND INSTALLATION + Drive motor) Pump motor. : Power steering pump moor Steering gear box EPS actuator .... Power steering vaive Steering axle . Power steering cylinder Charger (Mounted type} REMOVAL AND INSTALLATION LOCATIONS OF UNITS FB10EX/14EX/15EX/18EX-7 . Steering axle Mast Lift eylinder Tilt cylinder Drive axle Transier Drive motor Pump motor Hydraulic pump, EPS actuator Steering gear box Control valve Master cylinder Controller Charger (Controller section} Charger {Transformer section} LOCATIONS OF UNITS REMOVAL AND INSTALLATION FB20EX/25EX/30EX-5 Mast Lift eylinder oylinder ive axle & Transfer Drive motor Pump motor Hydraulic pump EPS actuator ‘Steering gear box |. Steering axle Control vaive Master cylinder Controller Charger (Controller section} Charger (Transformer section} LOCATIONS OF UNITS REMOVAL AND INSTALLATION LOCATIONS OF UNITS FB15GT/18GT-7 FB20GT/25GT-5 Opvompens Mast Lift cylinder Tilt eylinder Drive axle & Transfer Drive motor Pump motor Hydraulic pump Power steering pump motor Power steering pump Power steering valve Steering axle Power steering cylinder Control valve Master cylinder Controller Charger (Controller section} Charger (Transformer section) REMOVAL AND INSTALLATION HOW TO INSTALL UNITS HOW TO INSTALL UNITS Name of unit Method oi stallation “fhe mast is made to embrace the drive axle by appiving a cap from act underside. he lift cylinders are mounted on the outer mast by a clamp and on the Lift cylinder inner mast by a Bolt. Tilt eylinder “The tit cylinders ere mounted by pins on bath the head and bottom sides. Drive axle “The drive axle is mounted on the freme by 2 ceps and 4 bolts. FB10EX-18EX cata “The transfer Is mounted on the drive exle by 9 bolts and on the frame via drive motor. Dive axle & | FB15GT-25GT manstar EBISGT-25G7 | the drive axe & transfer is mounted on the frame by 4 bolts. The drive motor is mounted on the transfer by S.bolts end on the frame FBIEX-18EX | vig mounting bracket. Drive motor Hydra EPS actuator pump. FBISGT-25GT_ FB20EX-30EX FBI0EX-30EX FB1eGT-25GT_ FBIOEX-30EX ‘The drive motor is mounted on the transfer by 5 bolts. The pump motor is mounted on the frame by 4 bolts via mounting bracket. “The pump motor is mounted on the frame ecross 4 mounting cushions, The hydraulic pump is mounted on the pump motor by 2 bolts. The EPS actuator is mounted on the frame by 4 bolts and connected to the linkage with ball socket. Power steering pump motor The power steering motor is mounted on the frame by 2 bolts end 3 mounting cushions via bracket. Power steering | caisqT-26GT pump “The power steering pump is mounted on the power steering motor by 4 bolts. Power steering “The powar steering cylinder is mounted on the steering axle by 4 bolts end evince eee Se ce ne siete | ryce406x |e teen arbor mounedon re ame ret ty 2 st au Te Hara veer Done mud on te ame across pet by nts valve FBISGT-256T | Vie bracket, ae se ncarng iW nTed on Te Fane by # bas Ba or Boe 0 (1-1.75t) via supports. ‘Control valve “The control valve is mounted on the frame across 2 plate by 3 bolts. ‘Master cylinder “The mester cylinder is mounted on the bracket of frame by 2 bolts. Controller FBTOEX-30EX he controller is mounted en the counter-weight by 2 brackets and & bolts. | FeiseT-256T, Charger (Controller section) Charger (Transformer section) The controller is mounted on the frame by 4 bolts. The charger [Controller section) is mounted on the dashboerd by ¢ bolts, The charger (wrensformer section} is mounted on the frame by 4 bolts. 10-5 REMOVAL AND INSTALLATION WEIGHT TABLE WEIGHT TABLE FB10EX/14EX/15EX/18EX-7 FBISGT/18GT-7 Unitsketto) 70 — 1.75 ton trucks tems Remarks |rav0ex Fei aex (Fe sex/eraexaisGTFaTaGT SS0AH 00AH Toa | 4BV/SHR Battery (STO) 610 m0 1220 (1348) (1585) (2680) Conirat valve air) Steering gear box 70122) = Power steering valve = 70122) Drive 7oUTs4) Motor Pump 42(83) 20188) Transfer 5189) Dive axle transter Drive axle 931205) "Te5(a0e) Front 76135) 23150) wheel Rear 72127) Steering axle assy 515) Exel rear wheel é 5 320 | 480 | 590 | 765 | 490 | 560 Coumterweight (705) | (7060) | (1300) | (1690) | (950) | (1235) Gverhead guard 701154) Power steering cylinder = 7533) 255(565) am (787 3400750) am 1877) 370(815) 45m (1777) 00/860) Sm (1877) Titteylinder 20144) ‘am (7787) Fork carriage 75165) aoIT76) Backrest t 7583) x 38 a] 3] 41 | Forklengin fone (75) | (85) | eo) | 188) | (90) 820mm (36") Hydraulic 307) Pump 75 7 Tis) | PS: Power Stserna Titevlinder arta) Power steering pump motor = 7351 EPS motor 3217) = EPS; Eleciie Power BPS actuator 7563) 7 Steering 10-6 9 2 REMOVAL AND INSTALLATION WEIGHT TABLE FB20EX/25EX/30EX-5 FB20GT/25GT-5 Unit:kg tb) 1 20 — 300 ton trucks tems Remarks |FB20EX/FB2SEX[FBz0GTFB25GT| FBSOEX ‘@50AH }S65AH| 800A @50AH | FR20EX/25EX/20GT/25CT: Battery (STD) 820 | ‘915 1450 1200 48V/SHR_ isto) | (2020) | 3200) 2650) | FB30EX; 72v/SHA Control valve ata) Steering gear box 10(22), = 10(22) Power steering valve aul 0{22) ane Drive e587) 7201265) Motor Pump 52(115) 65(145) “Drive axle & Transfer 254(560) {_ 2691693) Front EE Wheel 77) Rear 17/38) Steering axle assy a2(t80) sei) | ~_2(780) 650 975 350 no 1126 aim 1425 | (2150) | (772) | (1565) | (2480) Overhead guard 7770) B7T82} Power steering cylinder eo 15(33) = 430(950) 445(980) 3m (118") 540(1790) 575(1270) 4m (157") Mast (outer & inner oni) 580(1280) 625(1380) 4.5m (177") 675 (1380) eas(ISiGy | Bm (187) Lift cylinder (25(55) 32(70) ‘3m (118") Fork carriage 95(210) 115(255) Back rest 18(40) 28(65) a [a |] | « o Fork length a go) | (100) | 190) | 00) 320mm (26°) = Teia7O) | Fa7omm 82") [Hydraulic 37) Pump [Ps = 26) | = | PS: Power Steering Tilt cylinder 12(27), Power steering pump moter; — 11781 S EPS motor a | (11) __| EPS: Elecwic Power EPS actuator wea | 15135), Te 10-7 REMOVAL AND INSTALLATION MAST REMOVAL 1. Place blocks to the front and rear wheels. 2. Remove the forks. 3. Raise the fork carriage with a crane to remove hydraulic piping. 4. Place a block under the fork carriage. 5. Actuate the operating lever of the machine sev- eral times to bleed the remaining pressure in the piping and then disconnect. * Put a blank cap immediately after discon- necting the piping to prevent hydraulic oll from fiowing out and dirt from coming in. 6. Lift the fork carriage slightly with @ crane to remove the block. 7. Lower the fork carriage. 8. Hook the mast on the crane. 8. Remove the mast cap. 10. Remove the tit pin. 11. Remove the mast. By Se the mast assembly horizontally on Square bars with the finger bar on top. % Installation shall be performed in the reverse order to removal. 10-8 MAST REMOVAL AND INSTALLATION LIFT CYLINDER LIFT CYLINDER REMOVAL 10-178 20-30 a Stopper bolt Place the mast vertically. 2. Remove the stopper bolt. a7 t= sim — 3. Hoist the mest with a erane. l fl 4, Insert a block‘under the Inner mast iin a : inder lL cptoder 5, Remove the cylinder clamp. babe 6. Actuate the operating lever several times 10 bleed the remaining pressure in the piping. “Then disconnect piping. 4 Put a lank cap immediately after ciscon- necting the piping to prevent hydraulic oil hae Stone bt . {rom flowing out and dirt coming in 7. Hoistthe cylinder with the aid ofa sting beltend remove. a INSTALLATION Installation shall be performed in the reverse order to remaval, paying attention to the following. Synchronizing of the mast a 2 3. Angled to lett __| Insert shims into left cylinder Angled to right _| Insert shims into right cylinder Raise the mast to the maximum lifting height. Check for the play on both sides. Adjustwith shims so thatthe rightand left cylin- ders are synchronized with each other at the highest position. 10-9 REMOVAL AND INSTALLATION POWER TRAIN POWER TRAIN (Drive axle + Transfer + Drive motor) REMOVAL 1. Place blocks to the front and reer wheels. 2. Remove the bettery. 3. Remove the mast. (See P.30-8) 4. Disconnect the wirings (A, B, E and F] from the drive motor. Note: FB10EX-18EX: Disconnect wirings(A,B,Eand F} from the controller. 5. Disconnect the wiring connector for the speed sensor. 6. Remove the brake pipings. 10-10 FBNOEX-18EX controller REMOVAL AND INSTALLATION OF UNIT POWER TRAIN 7. Remove the parking brake cable with the lever attached. & Insert blocks under the frame to lift up approx ‘JOcm the front wheel. 9. Place a carriage to hold three units (Drive axle, Transfer and Drive motor} of equipment. 10. Remove the mounting bolts from the drive mmotar bracket. (F810EX-18EX only] i Soe Frame 10-11 REMOVAL AND INSTALLATION POWER TRAIN 11. Removal of the power train FB1OEX-18EX; 1) Remove the mounting caps of the drive axle. 2) Draw out slowly the power train (Drive axle + Transfer + Drive motor! and frant wheels on the carriage, 10-12 REMOVAL AND INSTALLATION 7 POWER TRAIN FB15GT-25GT,FB20EX-30EX; 1) Remove the mounting bolts of the drive axle. 2) Draw out slowly the power train (Drive axle + Transfer + Drive motor) and front wheels on the cérriage. 10-13 REMOVAL AND INSTALLATION INSTALLATION {FB10EX-18EX) Installation shall be performed in the raverse order to removal, paying attention to the fellowing. 1. Tightening torque of the cap mounting bolts (1) for the drive axle: 10 —125 kam 98 — 123 Nm 72 — 90 fb 2. Tightening torque of the mounting bolts (A) for the drive motor: 10 125 kom 98 — 123 Nm 72 — 80 ft.lb 3. Tightening of the mounting nuts for the drive ‘motor mount bracket. Tighten the nut (C) until the rubber mount (B) is bent by 2—3 mm, 4, Tightening torque of the wirings (A, B, E and F} connecting nuts to the controller: 68 — 85 kgem 6.7—8.3Nm 49— 62 ftlb 5. Bundle wires using 2 tiewrep or similar so that they will not touch or catch on sharo edges of the vehicle body. 6. Tightening torque of the nigples for the brake piping 11.3 kgem 10 —13 Nm 794 fb POWER TRAIN ‘9 REMOVAL AND INSTALLATION INSTALLATION (FB1SGT-25GT, FB20EX-30EX) Installation shall be performed in the reverse order to removal, paying attention to the following. ightening torque of the mounting bolts (1) for the drive axle; FBISGT/18GT | 84 —105 kgm FB20GT/25GT | #24 — 1030 Nm FB20EX/25EX | 608 — 760 ftlb 155 — 195 kam FB30EX 1520 — 1912 Nm nai 2. Tightening torque of the wirings (A, B, E and F) connecting nuts to the drive motor; 68 — 85 kgom 67—83Nm 49-62 itIb 3. Bundle wires using 2 tiewrap or similar so that they will not touch or catch on sharp edges of the vehicle body. 4, Tightening torque of the nipples for the brake piping: 11.3 kgem 30—33.Nm 79.4 fel 10-15 POWER TRAIN PUMP MOTOR REMOVAL (FB10EX-30EX) 2. Disconnect the wirings (PA and’ PB) fram the a) 5 : a] lp & a “e 3 oF 9 oc al .. Remove the pipings (1 and2) from the hydraulic pump. 4. Remove the three mounting bolts (4) of the pump motor bracket (3). 5. Draw out slowly the hidraulic pump, pump motor and motor mount bracket from the frame. 6. Remove the two mounting bolts (5) when remo- ving the hydraulic pump, 7. Remove the four mounting bolts (6) when removing the motor mount bracket (3). INSTALLATION (FB10EX-30EX} Installation shall be performed in the reverse order t0 removal, paying attention to the following. 1. Tightening torque of the wirings (PA and PB) connecting nuts to the controller; 68 — 85 kgem 6.7—8.3Nm 49-62 tlb PB PA seen pump 10-16 REMOVAL AND INSTALLATION REMOVAL (FB15GT-25GT] a jeconnect the battery connector. 2. Remove the rear legs from the overhead guard. 3. Remove the counterweight from the frame. 4. Disconnect the wirings (PA and PB) from the controller. 5. Remove the pipings (2 snd 3} from the hydraulic pump. 6. Remove the four mounting nuts (4) for the cushion, and draw up the pump motor with the hycraulic pump from the frame. 7. Remove the two mounting bolts (5} when remo ving the hydraulic purnp. INSTALLATION (FB1SGT-25GT} Installation shall be performed in the reverse order 30 removal, paying attention to the following. 4. Tightening torque of the wirings (PA and PB) connecting nuts to the controller: 68 — 85 kgcm 6.7 —8.3 Nm 49 — 62 ftlb 2. Tightening torque for the counterweight mount: ing bolt (1} to the frame: 50 kgm 490 Nm 362 fib 10-17 PUMP MOTOR REMOVAL AND INSTALLATION POWER STEERING PUMP MOTOR REMOVAL (FB15GT-25GT only) 1. Disconnect the battery connectar. 2. Remove the rear legs from the overhead guard. 3. Remove the counterweight from the frame. 4, Disconnectthe wirings (PS and G) for the power steering pump motor from the controller. 5. Remove the pipings (2 and 3) from the power steering pump. & Remove the three mounting boits (4) for the motor mount bracket, and draw up the power steering pump motor with the power steering pump. il 7. Remove the mount bracket and power steering pump from the power steering pump mator. INSTALLATION (FB15GT-25GT only) Instellstion shail be performed in the reverse order ta removal, paying attention to the following. 1, Tightening torque of the witings (PS and Gj con- necting outs to the controller 68 — 85 kgem 6.7 —8.3 Nm 43 —62 ttlb 2, Tightening torque for the counterweight mounting bolt (1) to the frame: 50 kgm 490 Nm 362 fib 10-18 POWER STEERING PUMP MOTOR Power steering puma motor REMOVAL AND INSTALLATION STEERING GEAR BOX e STEERING GEAR BOX REMOVAL (FB10EX-30EX only) 1. Remove the floor plate from the frame, 2. Disconnect the wiring connector (1) for the tor- que sensor. Remove the ball socket (2) of the dru pitman arm. 4. Remove the stopper bolt (3) of the universal 2 joint spline portion, 5. Remove the four mounting bolts (4) for the steering gear box, and draw out the spline por- tion. After draw up the steering gear ox. 10-19 REMOVAL AND INSTALLATION EPS ACTUATOR EPS ACTUATOR REMOVAL (FB10EX-30EX only} 1, Remove the battery. 2. Remove the ball joint (1) of the actuator assem- bly from the bell crank, and draw aut the steer~ ing axle (see P.10-22) 3. Remove the ball socket (2) of the drug link from ‘the actuator assembly. 4, Disconnect the wiring connector (3} for the EPS motor. 5. Remove the mounting bolts (4) of the actuator assembly from the frame. . Draw out the actuator assembly on the steering axle side. INSTALLATION (FB10EX-30EX oniy) Installation shall be performed in the reverse order to removal, paying attention to the following, 1. Tightening torque for the actuator assembiy mounting bolts (4) to the frame; 5— 7 kam 49 — 69 Nm 36 — 51 ft.lb 2. Make sure to bend the new cotter pin (5), Bee , = ‘etal « a Frame A 4 REMOVAL AND INSTALLATION POWER STEERING VALVE ® , POWER STEERING VALVE REMOVAL (FB15GT-25GT only) 1. Remove the floor plate from the frame. Fram power steering ‘ump motor Power steering cylinder 2. Disconnect the wiring connector (1) for the pressure sensor, 3. Remove the piping (R, L. T snd P) from the power sigering valve, 4, Remove the stopper bolt (2) of the universal joint spline portion, 5. Remove the four mounting bolts (3) for the power steering valve, and draw out the spline portion. Alter draw up the power steering valve. 10-21 REMOVAL AND INSTALLATION REMOVAL (FB10EX-30£X) 1. Lift the truck frame by 2 crane in the rear and place wooden blacks under the both sides of the frame. 2. Remave the rear legs from the overhead guard, 3. Remove the counterweight from the frame. 4. Remove the rear tires from the steering axle, 5. Remove the bail joint of the actuator assembly from bell crank. 6. Place a carriage to hold the steering axle. 7. Remove the support mounting bolts for the steering axle. FBI0EX-18EX: The two mounting bolts (1) on the rear side, FB20EX-30EX: The each two mounting bolts (2 and 3) on the both sides of the front and rear. 8. Drew out the steering exle from the frame. FB10EX-18EX; Slide the stearing axle back- ward (toward the weight), Separate the axle shaft from the front support and lower the steering axle to remove it from the vehicle body. FB20EX-30EX; Lower the steering axle io remove it from the vehicle body. STEERING AXLE 10-22 For FBTOEX-18EX Detail “Pr For FB20EX-306x REMOVAL AND INSTALLATION REMOVAL (FB15GT-25GT) 41, Lift the truck frame by a crane in the rear and place wooden blocks under the both sides of the frame. 2. Remove the reer legs from the overhead guard. 3. Remove the counterweight from the frame. 4, Remove the rear tires from the steering axle. 5. Remove the piping (hoses) from the power steering cylinder. 6. Place a carriage to hold the steering axle. 7. Remove the support mounting bolts for the steering axle. FBISGT/18GT; The twomounting bolts (1) on the rear side, FB20GT/25GT; The each two mounting bolts (2 and 3} on the both sides of the front and reer. 8. Draw out the stesring axle from the irame. FBISGT/18GT; Slide the steering axle back- ward (toward the weight), separate the axle shaft from the front support and lower the steering axle to remove it le body. FBZ0GT/25GT; Lower the steering axle to remove it from the vehicle body. STEERING AXLE — OSes i 2 i gq Detail“0" For FRISGT/18GT 10-23 For FB20GT/25GT REMOVAL AND INSTALLATION INSTALLATION Installation shall be performed in the reverse order 10 remaval, paying attention to the following. 1. Tightening torque for the steering axle mount- ing bolts to the frame. FRIOEX-18EX, FBISGT/18GT; 25 — 31.5 kam 245 — 309 Nm 181 — 228 ft.lb : 2S (Bolt) FB20EX-30EX, FB20GT/25GT; 25 — 31.5 kgm 2== (Bolt 2) 245 — 303 Nm 181 — 228 ftlb 2. Tightening must be adjusted by the shim to make the opening less than 0.3 mm (0.012 in}. 3. The bushing must be tightened so that the holes are in the upward position. 4. Tightening torque of the counterweight mount: ing bolt 50 kom Bolt 4) == __[ Malvedenam aiauipyide > Coat the mounting bolt with molybdenum disulshide then tighten the bolt. 10-24 STEERING AXLE Hotes are in the ‘upward positien, REMOVAL AND INSTALLATION + POWER STEERING CYLINDER POWER STEERING CYLINDER REMOVAL (FB15GT-25GT only) FRISGT/NEGT 4. Draw outthe steering axle from the frame. (See P.10-23}. 2. Remove the joint bolt (1) of the piston rod and link. * 3, Remove the four mounting bolts (2) for power steering cylinder from steering axle. INSTALLATION (FB1SGT-25GT} Installation shall be performed in the reverse order 10 removal, paying attention to the following. feet 4. Tightening torque of the power steering cylin der mounting bolt. 25 — 31.5 kom Faz (Bott 2) 245 — 309 Nm te — 228 ftlb ce Meee hae ightening torque of the joint bolt of the piston rod and link. 8B kgm S== (ot) 29—49 Nm 22 — 36 ft.lb 3, Make sure to bend the new cotter pin (3). 10-25 REMOVAL AND INSTALLATION CHARGER REMOVAL (Mounted type) 1. Controller section 1) Screw the four mounting bolts for side panel, and remove the side panel from the dashboard, 2) Remove the four mounting bolts (1) for the charging controller. 3) Disconnect the wirings on the charging con- ‘roller side, (3 connector, 2° connector and two termi- nis) 1. Transformer section 1) Remove the battery. 2) Disconnect the two wirings on the transfor- mer side. 3) Remove the side cover on the rightside, and disconnect the wirings for the supply volt age tap. 4) Remove the four mounting bolts (2) for the transformer. 10-26 CHARGER 20. DISASSEMBLY AND ASSEMBLY POWER TRAIN Outline eect 20-2 ‘Transfer 1. Convertional power train <2 3 2. Transvere power train to 2B Differential : 20-18 Drive axle 2 eceeeeeeceeseeeeces 206 27 BRAKE SYSTEM ‘Master cylinder 37 Wheel brake hatielahak 40 Parking brake lever =... 20- 47 Brake pedal .......0.0 20- 48 STEERING SYSTEM (EPS type) EPS (Electric Power Steering) ........ 20° 51 Steering gear box ... ciesesess 206 53 Steering linkage : 20- 72 Actuator : Lie 20-73 EPS motor .... oe 1 20 80 Troubleshooting for EPS... ss... 20+ 83 STEERING SYSTEM {€-FHPS type) E-FHPS (Energy saving Full Hydraulic Power Steering) - Power steering valve E-FHPS motor . Steering axie = 20+ 85 2 20-86 2 20401 20-103 Power steering cylinds 20-118 ACCELERATOR “Accelerator and accelerator pedal .... 20-120 HYDRAULIC SYSTEM Hydraulic cireuit disgram 20-422 Power steering pump 20-124 Hydraulic pump 20-126 Control valve... LL. 20929 Control valve micro-switeh ..........- 20-131 Dili, 20-136 Tilteylinder -.. : 20-136 Mast Mest edetatahaeateaial Fork carriage ce wiiee, 20-142 20-1 DISASSEMBLY AND ASSEMBLY POWER TRAIN-OUTLINE POWER TRAIN OUTLINE The power train system is an integrated structure of the power train from the drive motor to the drive axle, iene oherating hours have been extended and the operation noise while traveling has been reduced by the low-noise “high-ecdendum helical gear” which has been successfully proved with Komatsu AM cares vo Wall as the highly efficient system that can transmit the energy most effectually from the drive moter ie the drive axle, POWER TRAIN DIAGRAM Convertional power train Transvere power train FB10EX/14EX/15EX/18EX-7 FB1SGT/18GT-7 FB20GT/25GT-5 FB20EX/25EX/0EX-5 - Drive motor Trensier Drive axie Wheel brake Brake drum Front whee! 20-2 DISASSEMBLY AND ASSEMBLY TRANSFER TRANSFER 1. CONVERTIONAL POWER TRAIN (FB10EX/14EX/15EX/18EX-7) STRUCTURE Input seer High-adsencum Input gear (Gearing-supported) —heleal gear ined ef “Tapered voter bearing (Adjusiment required) Hotieal gear “epered roller bearing {No adjussment caquired) New structure Old structure 1) Efficiency improved that was formerly fitted directly to the motor shaft is now supported by bearings. The ity of gear support prevents the deflection of the shaft and the variation in gearing. It also reduces loss in power. 2) Noise reduced ‘The advanced designing and manufacturing technologies together with the high-addendum helical gear that has been favourably accepted with Komatsu AR and BR series have improved the gear ratio and reduced the operation ncise while traveling, 3) Serviceability improved ‘The adoption of the non-adjustment tapered roller bearing for the pinion shaft has improved the eff ciency in assembling as well as serviceability. 20-3 DISASSEMBLY AND ASSEMBLY : TRANSFER DISASSEMBLY AND ASSEMBLY FB1QEX/14EX/15EX/18EX 7 | lene 4271 vend Woe) 1. Case 8. Pinion shaft 2. Cap 7, Bevel gear 3. Bearing 8. Gear 4, Plate 9. Bearing 5. Shim 10. Lock nut DISASSEMBLY AND ASSEMBLY ‘TRANSFER @ 7 . CALCULATING METHOD OF THE SHIM THICK- NESS OF THE PINION SHAFT ASSEMBLY 1. Difference in size “a” Read the stamp “a” on the end of the pinion shaft. Sesooramter ae QT 2. Difference in size “b” Read the stamp “b” on the case. 3. Difference in size "c” 1) Set the bearing on the special tool as shown in the drawing. Special too! 3€A-97-99200 2) Tighten the set bolt 9 kgm oe | a8Nm 65 Ftlb 3) Measure the difference in height “Ca” bet- ween the height of the master (h) and that of the bearing with e diel gauge. 4) Use the following formula to calculate D. D=h—Ca ‘The figure shown on the circumference of the mast (4 places}. % “h” shows the actual value and differs in each toot. 5) Use the following formula to calculate C. [ c= (47.95 —D) x 100 47.95: Standard size of the bearing 20-5 Set bolt 9 kgm) ‘Specie! too! DISASSEMBLY AND ASSEMBLY TRANSFER 4. Calculating the shim thickness Substiute the difference in size “a, b, €* determined 2 above In the folowing for mula, and calculate the shim thickness § i | Rounded to || | TOO | one decimal | | CHECK AND INSPECTION FB10EX/14EX/15EX/18EX om ty cherie no check ten famed Standard size | Repair timit To daage tran wew or aleve get TomaS =| Exch gear ;attrn shoud be found onthe tooth surface, Replace Tclienh serves pion gaa wd bel a * | gen 7 [oat Sain | = Aut = | each bearing | "No batkesh or scratches should be foune. Replace \ | I + ff ! 1 20-6 DISASSEMBLY AND ASSEMBLY TRANSFER TIGHTENING TORQUE OF PINION SHAFT LOCK NUT 32 — 45 kam Some | 4 — 4a Nm 231 — 325 ftlb SUMMARY OF NUT CAULKING After igntering nut, ‘caulk with ene, (Two postions), Sen ar INSTALL SPEED SENSOR FBIOEX-18€X Make sure to connect the harness Connector marked “A ith vertical speed sensor. isting the speed sansor slightly and 7 ‘ering that i night contact wit Section B-B (gear, Tait back 1/4 turn. «+ fp tne positon after twisting back 1/4 turn, sacurely lock it in lace with ¢ rt. 20-7 DISASSEMBLY AND ASSEMBLY TRANSFER 2, TRANSVERE POWER TRAIN (FB1SGT/18GT-7, FB20GT/25GT-5, FB20EX/25EX/30EX-5) STRUCTURE Li, ‘Tepered cater bearing Ball basing New structure Old structure 1) Efficiency improved (1) The differential is decelerated by the helical gear in place of the hypoid gear to improve the trans- mitting efficiency. (2} The change from the hypoid gear to the helical gear enabled the tapered roller bearing thet sup- ported the differential case and the pinion shatt, t0 be altered to the ball bearing or the roller bear- ing. As a result, the change can not only reduce loss in power but improve transmitting efficiency. Eliminated adjustment of the shims for the tapered roller bearing and the hynoid gear has improved serviceability. 2) Noise reduced “High-addendum helical gear" has been adopted to reduce the operation noise while traveling. 3) Servi Adjustment of the shims for tapered roller bearing and hypoid gear is no longer required, ability improved 20-8 DISASSEMBLY AND ASSEMBLY TRANSFER DISASSEMBLY AND ASSEMBLY FBISGT/18GT-7 ‘TRANSFER DISASSEMBLY AND ASSEMBLY FB20EX/25EX/20GT/25GT-5 20-10 TRANSFER DISASSEMBLY AND ASSEMBLY FBS0EX-5 20-11 DISASSEMBLY AND ASSEMBLY DISASSEMBLY FBISGT-25GT, FB20EX-30EX 7. Remove the drain piug (6) and drain the gear oil. 2. Remove the drive motor. (Remove the five mounting bolts (28).) 3. Remove the two torque shafts (26). 4 Turn the transfer ass'y 90° and fix it on the workbench, 5. Remove the cage (18). 6. Remove the plate (13). 20-12 ‘TRANSFER DISASSEMBLY AND ASSEMBLY TRANSFER D 7. Remove the case mounting bolts (30, 31 and 32), and lift the case (3) with 2 crane or simi jar means and hold it in the raised position. Crane switch 8. Lift the case (@) gradually. At this time, ifthe bearing (12) of the shatt (10) does not come out af the case, remove it by hitting the shaft {10) with 2 mallet or similar means. (The inner 3 ear ihe bearing wil come out together i y with the shaft) 9. Lift the case (3) about 55 — 60 mm and turn (Glide) it about 20° as shown in the figure to prevent the gear of the shaft ass'y (10) from fouching the case (3). Then, lift the case (3) further, and remove it. case 3 40. Remove the differential ass'y (16 — 23) and we each gear from the case (1). Differential as'y 20-13 DISASSEMBLY AND ASSEMBLY ‘TRANSFER CHECK AND INSPECTION FB1SGT/18GT-7 FB20GT/25GT-5 FB20EX/25EX/30EX-5 % ene . tees ese * Gat faite Sao eesae — | ech bearing (No backlash or scratches should'be found Replece A | Press-fitted part berween shat and g¢ | No clearance should be found 20-14 DISASSEMBLY AND ASSEMBLY ‘TRANSFER: ASSEMBLY 1. Mount the bearing (18) on each gear and dif- ferential ass'y. However, mount only the inner race of the bearing on the small gear side of the shaft ass'y (10). Note 1: The bearing (BA) for the FBISGT/ 18GT is a ball bearing and those for the F820GT/25GT and FB20EX-20EX are roller bearings. Mount the roller earings in such 3 way that the col- lar ef the inner race is positioned on the gear side. 20-15 DISASSEMBLY AND ASSEMBLY Note 2: The mounting direction of the bear- ing (11) onto the lerge gear side of the shaft ass'y (10) is predeter- mined. The bearing is fixed with a snap ring only on the FB1SGT/18GT. Note 3: The number of bearings (12} to be fixed on the small gear side of the shaft ass'y (10) is one for the FRISGT/18GT and two for the FBZ0GT/25GT and FB20EX-30EX. 2. Fix the case (1) on the workbench, 20-16 ‘TRANSFER Fevscrniacr SS Lom \ Z a LLL, FezoctiascT FB2OEX-30EX H G LEE: FeisaT;ecT VE oe a FazocT/2scT B206x-306x DISASSEMBLY AND ASSEMBLY . Mount each gear and differential ass‘y in se- quence on the case starting from the input shat. If any of the bearings cannot be put in the case, tap in with a copper hammer or similar. 20-17 TRANSFER DISASSEMBLY AND ASSEMBLY 4. Lift the case (3) with a crane or similar means and hold it above the case. Then, lower it gradually. The case holding positon must be turned (slid) about 20° beforehand as shown in the figure. At this time, lower the case carefully so that gears and differential ass’y do not fall down. 5. While ensuring that the gedr (24) enters the notched pert of the case (3}, give a turn so ‘that both cases are aligned when the ciear- ance from the case (1) becomes about 55 mm, then lower the case (3) to adjust it to the bolt'hole. 6. Set the case mounting bolts (30, 31 and 32) temporarily. 7. Drive the outer race of the bearing (12) for the shaft ass'y (10) into the case (2) and ‘mount the driving plate (13) and cover (16). snap ring (9) for the bear- ing (8A) end also mount the cap (28), 9. Tighten the case mounting bolts (30, 31 and 32). 10. Mount the drive motor, (Tighten the five fixing bolts (28},) 20-18 case 3 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL DIFFERENTIAL STRUCTURE FB10EX/14EX/15EX/18EX-7 FBISGT/18GT-7 FB20EX/25EX-5 FB30EX-5 FB20GT/25GT-5 ‘ : CO] CO] 20-19 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, DISASSEMBLY AND ASSEMBLY FBI0EX/14EX/15EX/18EX Fa | teste 277 f 3 Gisken 243 — 427 Nm 255315 fel Apoly grosee (G2-U) wo the oxary fo sicing portions, i Fun out of bevel gear | Within 01 mm (0.008 in) Bacitech | 0.18 — 0.73 mm (0.0059 — 0.0081 In) — 73 —33 gm i8—32Nm 18 fb Toctie e277 {Serow then) Seta ee 2 Staring torave [200— 350 keer (To be adjusted bby he nut A) 20—44Nm ua ukB 20-20 @ DISASSEMBLY AND ASSEMBLY CHECK AND INSPECTION FB10EX/14EX/15EX/18EX ram fo) criteria No. Ccheet item Remedy Standard size eps iit ‘a. | Differential pinion gear and citferential 7 Scratches on esse apace side gear the toot surtace | RSE ise — 21.900 270 B | Ouice ciamesr of spider ae FED 22.000 — 22.200, 22200 | inside diameter of cttarentil pinion gear oy a Tse — 186 730 | Trckness of bushing arto Ae Replace 1st — 156 330 aad o.c6as — o.06sa) (0.0512) 7540 — 7542 7255 — | inside diameter of brake drum pane eae ay = | asker, Oring and seats = a Bis spencer 20-21 DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY FBISGT/18GT 20-22 Apply grease (G2-Li 0 the rotary 2nd ting portions, DIFFERENTIAL DISASSEMBLY AND ASSEMBLY CHECK AND INSPECTION FBISGT/18GT DIFFERENTIAL (Gastar O-ring and seats Chere 7 lela Fenny ‘a. | Diferentil inion aear and difterental 7 Seratches on ‘sptce epee aie a8 = | ecm aemenr alsae Zeaas | as aa aa 2a 7 |macconenciccoisonngu| agp [Bae ; Tate a . | ees orig eat | a tegece pa = = [ete dren tee nen ate EE er laacomay 20-23 DISASSEMBLY AND ASSEMBLY 7 DIFFERENTIAL DISASSEMBLY AND ASSEMBLY FB20EX/25EX/30EX FB20GT/25GT 20-24 DISASSEMBLY AND ASSEMBLY ‘ DIFFERENTIAL CHECK AND INSPECTION FB20EX/25EX/30EX FB20GT/25GT in ( Hy. Te a | | * rh Us| | E — 7 E | | on cr v0. covet tem pena Sanaa se Peni 7 | cesar gee eran 7 coches woe SON See as aE @ | oasis canner ee oa a ; 700 =00 00 © | we guowerctanecvia pronase | __teaees Sam a vot 208 75 9 | mies tuning onan ne 152 — 1.30, mn E | Thctiness of busting (0.0588 1) (0.0572) ARSE | — perme] amet [opevmer| —otwectisy | ca - | exegen sng 588 sz | ex sae ta waa Gasket, Oving and seats 20-25 ‘tytn canes DISASSEMBLY AND ASSEMBLY DRIVE AXLE DRIVE AXLE STRUCTURE Improvement to conform to low-profile tires (except 1.0 and 1.35 ton trucks} FB10EX/14EX/15EX/18EX-7 . ‘Teansior Hypoldgesr _— Seoarily poitones ait Y f iy 4 yr Fixed diffefensial case: | (Enclosed in frame) } FBISGT/18GT-7 FB20EX/25EX/30EX-5 FB20GT/25GT-§ Fixed citterentat Hatiesl gear —. {WBotes co tare) fl ‘itferantil eas of i vided strucure \ of Graneier and diferenval ase integrated) ‘SPECIFICATIONS Faw” | Fame” | FesGy | Pemex” | Fezciy em une | Me [Pig | iker_| "esex | “aser_| Fee Tee - | Fixed, ingle axl, ful flossing Reduction gear = Hypoid gear Halical gear Inside diameter sf arake drum | mom ‘9284 (10 in) zee (tin) —— [a310(22in1 Tread 346 % (Corer ote sh =| = | mn no 08 (Overal widtn mm | 1080, | as 165 1238 Git eapeciny 7 TIncludes vansfer cose) 50 7 a o 20-27 DISASSEMBLY AND ASSEMBLY DRIVE AXLE STRUCTURE FB1OEX/14EX/15EX/18EX [ape Rar \ Sones Fal ne 200 300 of \ ene Geum eres) \ (owe lations LH end mK tase pete mae ebemter y if dee teaod be case pi bond #1215) Tighning treve 30 7 eam rat FPVAN | - = i (16 tocations LH and RAY ‘rnb dee DISASSEMBLY AND ASSEMBLY DRIVE AXLE DISASSEMBLY AND ASSEMBLY FB10EX/14EX/15EX/18EX il wi reas (G2 SE Sa see =@ om] BER ‘apsaky on te nbs Poa ane 18— 25 kgm (gm | ase a oanng surace Sout be Hac fet ioe orae ih oe oe Ae A sree / ol see Hub star. 17 be adusied ing torque "by the nut A Ze ZS | oct grt CHECK AND INSPECTION nmin cite Check item fered Sonavasee | ___onam a aimee a 7 Taide dar Fra [eee] = = io Secretar os Insc the deformation sack ne dmage — | | seus hn = ea inside surk 20-29 DISASSEMBLY AND ASSEMBLY DRIVE AXLE STRUCTURE FBISGT/18GT 0 Se 308 ata ot 0 agen Tai ees arene 025) {he es. fo ested 20-30 > 8 DRIVE AXLE DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY FBISGT/18GT “The basing sutace shoud be CHECK AND INSPECTION ae Crate chest fenety Geaweme | Resor ; mea | = Tas dare tbat esa, ar wa ey : . as ro Lalas ke sna Secs naa wan oso ae inside surface 20-31 DISASSEMBLY AND ASSEMBLY DRIVE AXLE STRUCTURE FB20EX/25EX FB20GT/25GT —: . ae Sslasnn co wium grease) + Belore assembly, pass fhe iter races Being fo te sat Uitata the Searing aca te diction rownin the Oa) > aS stunts grate aa oy Su Gi bon #101 thea ee LEE ys igs” me ren Mak sre tach bessing fe sre aa Inle sid 1 Stace eincoatt “eas ] rime =| STB 20-32 DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY Baa FB20EX/25EX oom |pse— teh FE20GT/25GT Ze imran Sa] ue Bararauel Se ens / Rt oer ere DRIVE AXLE CHECK AND INSPECTION et es fare | da rene Hub play 0 i 0 faa oe inside surface 20-38 DISASSEMBLY AND ASSEMBLY DRIVE AXLE STRUCTURE FB30EX 20-34 DISASSEMBLY AND ASSEMBLY DRIVE AXLE DISASSEMBLY AND ASSEMBLY FBSOEX CHECK AND INSPECTION mm ion cites eek tam hemes Standard sire wpa ay inde damerer of brake drum oz aa, faslace vib olay 0 | ° mae Drive ee Inspect the deformation, crack ane damage ‘ue outing eolace scuba Tape he uve wear of and sea Gre inside surface 20-35 DISASSEMBLY AND ASSEMBLY ; BRAKE SYSTEM GENERAL Reservoir MASTER CYLINDER When bleeding the air, first bleed the air from Inside the master cylinder using the bieeder valve, then bleed the air at the brake end Cylinder bore 9 19.05 mm (0.75 in} Effective stroke 28 mm (1.10 in) Cylinder 11. Boot Piston ass'y 12. Push rod Stopper pin 13. Yoke Gasket 14, Nut O-ring 45. Coupling Valve seat 16. Bend ass'y Check valve 17. Bleeder valve Soring 18. Bleeder cap Stop plate Stop wire Brake pedal MASTER CYLINDER From regerveir Bleeder valve Toleiehend sop brake yy gs eo To right hand side brake wQ on & ran 7 DISASSEMBLY AND ASSEMBLY DISASSEMBLY 1. Remove the boot (1) from the cylinder groove 2. Remove the stopper pin (2). 3. Push the push rod (3) slightly and remove the stop wire (a) by a screw-driver. 4. Pull our the piston ass'y (5), the spring (6), the check valve (7) and the valve seat (8) from the cylinder. % Be careful thet the cylinder, the piston ass'y end the cap will not be damaged. % The piston ass'y should not be disassembled. CHECK AND INSPECTION MASTER CYLINDER an > mm Gin) Remedy Stuncard sie Aepaie mit Simsiade 202) — 008 oe Fasiscerent of Clearance between cvindar sna piston 9.0008 — 9.0081 10.006) cilinger as Guar da, of cua — inner cia. ctevinden | —_ caged — 0.02 sera) Bison ess'y 7 78 & Soring free iengtn a im eolacement 20-38 7a ee” DISASSEMBLY AND ASSEMBLY MASTER CYLINDER ASSEMBLY os Coat the interior of the cylinder and the exte- rior of the piston thoroughly with brake fiuid. ‘Assemble the vaive seat (1) and the check vaive (2) into the cylinder. Assemble the piston ass'y (3) and the spring (4) with the cylinder. Match the piston graove with the stopper pin hole of the cyiinder. Fix the stopper pin (5) cum the O-ring and the gasket, pushing the piston ass’y (3) to the cy- finder. 0.25 — 0.35 kgm 25 —3.4Nm 18-25 ftlb G3 Stopper pin (5) Pass the stop plate (6) through the push rod (7) and pushing the piston assy (3) lightly, es- semble them into the cylinder with the stop wire (6). Fix the boot (8) Fix the yoke (10) to the push rod (7) and tighten the nut (11). The nut (11) must be tightened only after proper adjustment has been completed with the master cylinder installed on the ruck. 0.8 —1.2 kam 73 —11.8Nm 5.8 — 87 fb = Nut itt) LLL TES VALE Lh a cone mst —_/ Seas > Cleaning the parts: Parts must be cleaned in alcohol or brake fluid, but never in mineral oil Never leave any rubber parts in sicohot longer than 30 seconds. 20-39 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE WHEEL BRAKE FB10EX/14EX/15EX/18EX/15GT/18GT-7 STRUCTURE AND SPECIFICATIONS Section AA, Section 5.8 tem Unie. Specification Front wheel inarnal Tee = expanding, hydraulic Strcwre - uo serve at om | 9250 101m Resin mola | thon-asbestos tne liner pet ‘ning warn mm 28,5 (1.21 int Thickness | mm 45 (0.18 in) Tener diam wrest el fen (918.05 (073 in} 20-40 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE DISASSEMBLY AND ASSEMBLY Details of parts A CHECK AND INSPECTION mm fin cra cheek tm a % ry Pistia Tih ae r a 7 Deteoreton of eum sorng Pee natn) | z as | Aestcanent Ticmeaatnoomdsori etoumaning | lly Rotating dicsction cf adjuster wnan brake shoe is sem 8 Section aA ——ra fox ‘Speciation Front wheat irra Tyee) a expanding, hyarae Suueure = Duo serve ‘nner dams a 2.279014 in) T Rea meld Meera | = | wwonasbestor fed ner pe) tunig | wctn mm 55 217m ‘ thiewness | rom 211020) Inner diameter of Manis shee! cvinger am (922.22 (0.87 in} ® DISASSEMBLY AND ASSEMBLY WHEEL BRAKE DISASSEMBLY AND ASSEMBLY eo — 30 Kgem Bam {190 — 270 kger y17—265.Nm 3a 1354 7e— 20. PL 181 188m Te— 145 fib so fo? 3 CHECK AND INSPECTION seni Check tem Remesy Standard se Repaie timit Sa rT 75) Thickness of ring a | a Te 70 72 etoraon of eu sing ree nas) | 35) | sa csiraton of eum song ee leresn) | — 7 = 7 se) I 1625 Realecement 7 32 t 38 “Thickness of hooked portion of return 0.128 H (oa orig 7 25 | 20 2 (0.021 \ 0072) Sosa 32 Clesrance between piston are evinder pata aaah as “& inspect that there are any scratches on the sliding face of the wheel cylinder and any damage or dete~ rioration to the cup. + Replace the return spring if itis damaged or cracked. 20-43 DISASSEMBLY AND ASSEMBLY FB30EX-5 STRUCTURE AND SPECIFICATIONS WHEEL BRAKE Section AA rem Unit Specification Front whee, inemal Te = Scenig arte Sica = Oe ave fener ame of om 9310122) maw | — | esi ald Wonaaneve oo i worsen ices | mm ain mm 978.58 0.128 nl 20-44 = = Section 5-8 = Section c-¢ DISASSEMBLY AND ASSEMBLY WHEEL BRAKE DISASSEMBLY AND ASSEMBLY owen yas aaa ne A OF eaten goat Beet 7 2 2, o® o o®* e Detail A eo (CHECK AND INSPECTION mm (in) crera neck tem heresy Standard size | Repair limit 7 Thicke af ing eae l ‘oar 7 1 735 powvoratan of eum sara Fee erat ie | sy ete 73 20 Thickness of honed prion of etn arna ety | ‘cay a 32 Cierancs between sivton ore ringer ra, | ‘cody 4 Check thet there are no scratches on the sliding face of the whesl cylinder. 4 Check also that there is no damage or loss of elasticity of the cup. 4 Replace the return spring if it is damaged or cracked. 20-45 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE ADJUSTMENT AND TEST 1. Adjustment of wheel brake Jack up the vehicle and extend the adjuster- screw to stick the shoe and lining fast to the brake drum. Return the screw by 25 — 30 eth. %* When returning the screw, raise the adjus- ter-lever as shown in the drawing (right) to keep the lever free from unreasonable load. Bending the lever by accident may result in malfunction. 2. Test after adjustment Pull the cable by finger to the direction shown by the arrow in the drawing (right) and the lever engages with the next tooth. Release the cable and the lever returns to the original position atter skipping one tooth. When the lever fails to function as described above, inspect the lever above the adjuster- screw. Right position of lever ‘The adjusier-wheel at ¢ distance of 5 — 7 mm from the center of the adjuster-seraw. Any it correct position of the lever may resuit malfuntion of tooth engagement. Countermeasure for malfunction 1) Make sure that the cable guide is properly fitted to the specified hole on the second- ary shoe. 2) Make sure that the adjusterspring is properly pleced on the primary shoe. Replace the cable with a new one, if necessary, 4) Replace the adjuster-lever with new one. 5) Replace the adjuster ass'y, if necessary. 3) 20-46 Acjvstsaring 20% DISASSEMBLY AND ASSEMBLY PARKING BRAKE LEVER Main points for assembling parking brake cable 1. After attaching the inner cable A: to the park: ing lever, fasten the outer cable Br to the po- sition marked by a star. 2, Install inner eable As and cuter cable Bz the same way as in 1. above. 3, When assembling, make the overall curvature of the cable smail to make it easier to attach. Main points for adjusting the parking brake force 1, Release the parking brake. 2. Remove the rubber cap. 3. Pull the parking brake fever forward just enough to take up the slack 4. Hold pin © with your hand to keep it from dropping down. 5. Ff the lever is released, the adjust bolt D will pop up, s0 use 8 screwdriver to tighten it so that the operating force of the lever is 20 kgm. 6. Fit the double width of adjust bolt D to stop- per E and let go. 7. Install the rubber cap. Adjust the clearance of the brake fining and drum ft points V and W in the drawing to 0.25 — 0.5 mm at the widest point of the shoe. Note: With a drum radius of 127.0 mm, start with the shoe butting up against the drum and return the adjusting screw 22 coma to pro- duce a gap on one side of approximately 0.35 mm, 12 feetons L# and Rt) = | Ge i ogy ee aR wo loesbans A and APD PARKING BRAKE LEVER ‘win we earking arake on lever ould forwercl, heck to see atthe aarking SW i on — a = S wy Detail P sed ng BRAKE PEDAL ASSEMBLING DRAWING Siarcara vericle Higreaetormance veri 20-49 “ae DISASSEMBLY AND ASSEMBLY STEERING SYSTEM EPS STEERING SYSTEM (EPS type) EPS (Electric Power Steering) APPLICABLE MODELS: FB10EX/14EX/15EX/18EX-7, FB20EX/25EX/30EX-5 1, Operating principle of EPS When the steering wheel is turned by the ‘operator, the steering torque of the wheel is applied to the pitman arm and activates the torque sensor that is an integral part of the steering gear box. The controller outputs the voltage (sensor voltage) in line with the steer ing torque and roteting direction of the wheel. The output voltage is converted to electric current through the controller, rotat- ing the EPS motor of the ectustor and turning the rear wheels. 4) The torque sensor is an integral part of the steering gear box which is connected 10 the actuator through the pitman arm and the linkage. 2) When the steering wheel is tured, the input shaft (warm shaft) in the steering gear box slides axially in response to the Steering force. The torque sensor converts the sliding amount to an electric signal which is output to the controller. 3) The signal fram the torque sensor is con- verted to electric current through the con- troller, rotating the EPS motor and actuat- ing the actuator to the same direction 35 the steering direction. 4) The actuator tums the reer through the beil crank. wheels ‘Common parts: [All the parts of the EPS system are common for 1.0 to 3,0-ton models except the control ler, EPS motor and drag fink. rivertydraulie contrater ~ \ UJ Steere west SSS fo me rae A tert ZX, Fear wheel gear box Achumor Fergus’ ieman Linkage S motor EPS system constitution diagram STEERING SYSTEM DISASSEMBLY AND ASSEMBLY EPS : : = 2. Mechanism for adequate steering effort RB 1) The steering gear box contains the input frou aat shaft (warm shaft, the coil springs, the an slide tube and the side plate, The input copureat shaft is suspended thraugh the side plate by four coil springs. 2) By turning the steering wheel, the input shaft turns, 3) The loaded output shat (sector ‘shaft) slides the input sheft axially down (1.8 mm}. The sliding input shaft compresses the coil Springs through side plate and their reac- tion adds an adequate steering effort to the steering wheel. 1) When the steering wheel is tumed (e.g. counterclockwise) with the output shaft loaded, the input shaft slides down axially (as indicated by an errow in the right illus tration) by 1.6 mm in the maximum. 2) As the input shaft slides down, the slide tube moves down simultaneously. 3) An arm with 2 pin at the fulcrum point is fitted to the middle of the slide tube. When the slide tube moves, the arm ro tates with the pin as the fulcrum. 4) ‘The sensor is installed at the end of the arm. The resistance value of the sensor's potentiometer varies with the arm's rota tion, resulting in a change in the electric signal to the controller. | -isector snsm) Slide woe Coil sering Thrust nescio beating Lock aut Steering gear box 3. Mechanism for electric signal from torque sensor CCounterciackwise II Torque sensor 20-52 DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX STEERING GEAR BOX COMPONENT PARTS are z 5. Ball = eas 2 nee m \ eee 10. Se 2-H a & toe = P02 NS 13. Front cover 4a. Potentiometer 15. Cover DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX DISASSEMBLY 1. Fix the pitman arm in & vice and ioosen the nut. 2 Remove any dust and stains. However, do Net perform washing with washing oil, ga. soline, thinner, etc. {To avoid damaging che potentiometer) 3. Fix the main steering section in the vice 4, Remove the pitman arm by using 2 pitman erm puller with the slit mark on the end face Of the sector shaft facing downward, At this time, position = block to prevent the Pitman arm from summing, Cautions: * Avoid removing the pitman arm with hammer. ‘* Avoid performing any aeration at the end of the steering operation angle. (The above aims at preventing damage to internal parts.) 5. Disassembling the sensor 1) Remove the potentiomere remove the potentiometer. cover and Caution: Never remove the potentiometer unless absolutely necessary. DISASSEMBLY AND ASSEMBLY 2) Loosen the frant cover tightening bolt and remove the ront cover, 3) Install a set plate jig (see page 20-70) in place of the ‘ront cover and tighten the bolt ‘Tightening torque ‘Approx. 4.5 kam. 44.Nm 33 ftlb 4) Raise the caulking portion of the lock nut with 2 screwdriver and loosen the lock screw. STEERING GEAR BOX DISASSEMBLY AND ASSEMBLY 5) Fix the serration portion of the warm shaft and loosen the lock nut, d Perform this operation at the position where the slit mark of the sector shaft faces downwards. Caution: Perform the operation with clean hands 10 avoid intrusion of dirt. 5 After removing the 4 parts of lock nut. spacer (031 mm, t = 1.0 mm), thrust needle bearing and spacer (a40 mm, t = 4.9 mm), remave the set plate. 20-56 STEERING GEAR BOX DISASSEMBLY AND ASSEMBLY 7) Withdraw the antire sensor housing. (At this time, be careful not to drop the spring.] 8) Remove the following 3 parts. Spacer (040 mm, t = 4.0 mm) Thrust needle bearing Spacer (931 mm, t = 4.0 mm) 9) Remove the O-ring of the matching sur- face for the sensor housing. 6, Steering disassembly 1) Loosen the 3 bolts and withdraw the side cover. At this time, the sector shaft can eiso be removed. Cautior ‘The slit position of the sector sheft should face downwards. 2) Remove the side cover packing. 3) Remove the dust cover snd foosen che 3 bolts. Then, remove the 7237 Cover. 4) Witndraw the worm shai. is completes disassemaiy. STEERING GEAR BOX DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX ASSEMBLY 1. Steering assembly 1) Fix the gear box in the vice as shown in the figure at right and mount it with the tooth surface of the ball screw assembly ut uoward, Caution: t * Before starting the operation, apply grease to the oil seal lip and bearing «Perform the operation with clean hands in a tidy location. ‘+ Weering gloves is strictly prohibited. 2 After mounting the steering, confirm no peeling of the cil seal fin on the screw side. 3) Mount the rear cover and tighten the 2 bolts. Tightening torque: 1.7 —2.8 kgm 16.7 — 27.5 Nm 12.3 — 20.3 itl 1 Aealy a markeo ubishi Diamond Grease CLS No. 1 or No.0 (6 the portions ‘ciel (ol seal DISASSEMBLY AND ASSEMBLY a, pes fotos subassen 1) Shim adjustment Mou aes a sean a the sector shaft. Then, adjust shims so 2) apy seme th Tone a si Recommended grease: Mitsubishi Dia: mond Grease CLS No. 1 or No. 0. te — 3 i 3. Side cover mounting 1) Apply grease to the side cover gearing ‘and mount the sector shaft. Screw in be- forehand. 2) Next, screw in the hexagonal nut (Apply liquid packing to the screw for seal- ing.) Recommended packing materisl: Seal End No. 22 made by Seal End Co., Ltd. Mounting the sector shaft 4) Mount the sector shaft so that the center of the ball nut gear is aligned with the center of the hole. STEERING GEAR BOX DISASSEMBLY AND ASSEMBLY 2} Mount the sector shaft by aligning che center of the sector shaft gear with the Center of the hole. ‘At this time, do not omit to install the side cover packing. 5. Mounting the side cover ‘Mount the side cover and tighten the 3 bolts, Tightening torque: ————_—_ 1.72.8 kgm 16.7 —275 Nm 12.3 — 203 tb 6. Sensor assembly % Perform this operation with clean hands to avoid dirt intrusion. Set the O-ring into the O-ting groove. At this time, apply grease to the O-ring. 20-60 STEERING GEAR BOX DISASSEMBLY AND ASSEMBLY ‘STEERING GEAR BOX 7. Mounting of track ring Mounting Procedure 1) Spacer (031 mm, ¢ = 4.0 mm) 2) Thrust needle bearing 3) Spacer (40 mm, t = 40 mm) Before mounting, apaly grease to the above 3 pars. Grease name: Multemp SL No. 2 made by Kyado Oils and Fats Co., Ltd. 8. Mounting of sensor housing 1) Apply greese to the inside of the slide ring ‘and mount the sensor housing. Grease name: Multemp SL-F No. 2 made ‘by Kyodo Oils and Fats Co., Ltd. 2) Install the set plate jig [see pages 20-70) ‘ang tighten it with the mounting bolt. Tightening torque a ‘Approx. 4.5 kgm 4aNm 33 #t1b 20-81 DISASSEMBLY AND ASSEMBLY : STEERING GEAR BOX 9. Mounting of track ring Mounting Procedure MV Spacer (od. mm, ¢ = 4.0 mm) 2) Thrust needle bearing 3) Spacer (031 mm, t = "1.0 mm) Apply grease to the above 3 pans beiore ‘mounting, Grease name: Multemp SL-F No. 2 made by Kyodo Oils and Fats ©o., Ltd, 4) Screw in the lock nut slightly by hand, 5 Set the lock nut so that when the pitman atm is tuned clockwise, the sector shaft is fixed, {lt must not reech the end of the operation angle.) 6) Next, twist the warm shaft counterclock- wise. (At this time, the warm shaft slides abour 1.6mm.) While Swisting the warm shaft, slightly hand-tighten the lock nut to prevent back lash in the axial direction, 10. Caulking operation On completion of the temporary mounting, ( release the warm shaft. Then, caulk the thie SU Portion of the lack nut using a caulking punch {(se8 pages 20-70) at the milled portion at ihe end face of the warm shaft. (2 positions) No cracks should be found in the thin portion, No Div shoula be fours, \ Ax AS 20-62 8 DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX 11, Backlash check 4} While twisting the warm shaft counter clockwise, chack shat no backiash exists in the circumferential direction of the lock nut, (if any backlash is found, perform caulking once agzin.) 2) Remove the set piste jig and mount the front cover. At this time, do not amit to mount the ‘O-ring. into the O-ring groave of the matching surface of the front caver. Tightening toraus: 2.5 — 5.4 kgm 34.5 — 3.0 Nm 25.3 — 38.0 itib Adjusting Operations 1. Centering the operation angle ‘Turn the warm shaft and set it at the half-way position of the LOCK TO LOCK turning angie. ‘At this time, LOCK TO LOCK should be 4.8 turns or more. If the LOCK TO LOCK is smaller than 48 turns, there may be 2 positional difference in engagement between the bell nut gear and the sector shaft gear. Accordingly, perform mounting procedura for the sector shaft again. 20-63 DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX 2. Backlash measurement Mount the pitman arm and set the dial gauge at the specified position away from the conne Of the sector shat. Then, measure the beck lsh By pushing and pulling with a force af =2 komt Assembly Standard Meesuring position r = 135 mm. . X mm ( Backlash x = 0.3 mm or loss 3. Backlash adjustment Force in the adjustment screw and tighten the ut to obtain the specified backlash valve. Tightening torque: oor 2.0~3.0 kgm 19.6 — 29.4 Nm 145 ~ 21.7 fb Caution: Se sure to make backlash adjustment with the steering operation angle in neutray * On completion of adjustment operation, inject grease, Recommended grease: Mitsubishi Diamond Grease CLS No. 1 of No. 9 Injection vaiume: 180 = 20 g STEERING GEAR BOX DISASSEMBLY AND ASSEMBLY Operation check 4. Perform reverse movement by pushing and pulling the pitman arm. ‘At this time, check the operating condition. {No roughness should be found.) 2. Rotate the warm shaft and measure the oper- ing torque. The operating torque of the warm shaft should be 5 kgem or less. Sensor characteristic measurement 1. Fix the pitmen arm in @ vice as shown in the fixing it near the end of the steering operation angle. 2. Apply grease to the roller at the end of the potentiometer. g Grease name: Multemp SL-F No. 2 made by iKyode Oils and Fas Co, Lid 3, Mount the potentiometer. Do not omit to install the O-ring. 20-65 DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX 4. Tighten the potentiometer fixing screw 5. Sensor voltage measurement T 1) Measuring circuit i > Tester CG i cI eS asst a ESO es | pean ieee (ES) 2) Centering of potentiometer ‘Measure the sensor voltage when twisting and releasing the warm shaft as shown in the figure at right. (Twist clockwise and release) (Twist counterclockwise and release) Main voltage mesurement Adjust the voltage by turning the poten Slometer so thet it is 2.5 V = 0.1 when re- leasing che warm shaft, then tighten the screw to the specified torque. DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX 6. Mounting of cover 3) Mount the potentiometer cover and fix it with the bolts. (attach clip 10 right-hand bolt as shown in figure at right.) 2) Clamp the potentiometer harness with the clip. : (Clamp the harness with proper allow: ance} 3) Align the slit mark of the pitman arm with chat of the sector shaft. Fix the pitman arm ina vies and tighten the nut. Tightening torque: 18 — 22 kgm 177 — 216 Nm 130 — 159 ftlb ‘st mark ‘On completion of tightening, mount the dust cover onto the serrated portion. This completes the assembly operation. 20-67 DISASSEMBLY AND ASSEMBLY ‘ STEERING GEAR BOX If the voltage is not within the standard when the main voltage is measured, the lock nut may be improperty fixed. In such case, remove the potentiometer and try Performing the operation again, starting irom temporary setting of the lock nut. 4) Next, measure the voltage when twisting to the left and right ends, and check that it becomes as fallows. Standard: Twisting to right end: 0.9 —1.4V Twisting toleftend: 36—47V 5 Sub voltage measurement Check if the sub-sensor vottege is within the following range when releasing from Clockwise twist and releasing from = counterciackwise twist a Stendard: 2520.4 V Measure the voltage when twisting to the left and right ends, end check that it comes within + 0.3 V as compared with the standard main voltage. 6) 20-68 DISASSEMBLY AND ASSEMBLY ‘STEERING GEAR BOX 7. Torque voltage measurement Measure the reletionship between the input torque and the sensor voltage with an XY re corder, and check that it is within the stn- dard shown in the belaw figure. , Torque-sensor voltage characteris (Only the main charecter ic diagram ies are measured.) “The ceturn should be incids ‘The reture should be inside et sige) this Ine. “The leading point of the sensor voltage should be within the hatched po DISASSEMBLY AND ASSEMBLY 8. Special tools Shape of sat piate jig ‘ Set plate mounting side Soo108 STEERING GEAR BOX Unies am 0) 20-70 DISASSEMBLY AND ASSEMBLY ' STEERING GEAR BOX EPS TORQUE SENSOR AND STEERING: GEAR BOX ASSEMBLY DRAWING oss section AR 20-71 DISASSEMBLY AND ASSEMBLY STEERING LINKAGE STEERING LINKAGE ASSEMBLY DRAWING DISASSEMBLY AND ASSEMBLY ACTUATOR STRUCTURE 4. Gear box 2. Plate 3. Lock mut 4. Ball screw assembly Cross section of actuator |. Universal joint assembly 9. Bresther plug 6. Idler gear 10. Packing 7. Pinion gear V1. EPS motor 8, Joint 42, Packing ACTUATOR 13. Boot 14. Wire clamp 45. Connector 46. Bell joint assembly Actuator subassembly (for service parts) Special parts for actuator subassembly Dust cover Cover Hexagon head bolts \ J When you use this subassembly, remave these three parts frst, then inscall she motor, and assemble the connector and the ball join it with the boot. < A hexagon head bolt cannot be used for securing the motor because I'S (nr tended for securing & cover and its screw part is very shor. 20- DISASSEMBLY AND ASSEMBLY ACTUATOR COMPONENT PARTS 1. Motor ass'y 8. Clamp 2. Actuator sub ass'y 7. Clamp 3 Packing 8. Connector 4. Bolt 8. Nut 5. Boor 10. Bail joint ass’y DISASSEMBLY AND ASSEMBLY MOTOR REPLACEMENT 14. Fix the actuator in a vice. Fix it in the horizontal direction as shown in the figure, If it is fixed vertically, the ball screw assy will be rotated by dead weight when the boot is femoved, and the ball tube may be broken by excessive elongation. 2. Remove the 3 bolts and remove the motor. If the motor is jammed, tap it with 2 plastic mallet or similar to remove it. 3. Remove the old packing on the motor mount- ing surface and clean it with @ waste cloth. Note: When removing the motor, take care not to lose the motor joint. 4, Mounting the motor ‘Apply grease to the tooth surface inside the motor joint and mount the motor using new packing. Bolt tightening torque: 1.9 —3.1 kom 18.6 — 30.0Nm 13.7 — 22.4 fb g ACTUATOR DISASSEMBLY AND ASSEMBLY ACTUATOR BALL JOINT REPLACEMENT 1. Fix the actuator in a vice, Fix the connector by vice es shown in the figure. Fe ey See Clamp this portion in the vice 2. Loosen the hexagonal nut and remove the ball joint from the connector. wD (Because @ screw locking agent is applied to the screw portion, a large force will be re- \ quired to loosen it.) 3. Mounting of new bail joint Apply a screw locking agent to the screw por- tion (connector and hexagonal nut) and install ky 2 new ball joint, ensuring that the mounting [ position and phase are as shown in the figure. Then tighten the hexagonal nut, Nut tightening torque: 18 — 22 kgm Screw locking agent: Loctite 2271 = aut ae SS SS SS oi ‘tthe boot Bremer plug position | ee ACTUATOR DISASSEMBLY AND ASSEMBLY : = BOOT REPLACEMENT 4. Fix the actuator in 2 vice. Fix the connector by vice as shown in the figure. fe eed Sa P {clamp this portion 2. Remove the wire clamp of the boot. Move the boot and loosen the hexagonal nut. (Because screw locking agent is applied to the screw portion, a large force is necessary to loosen it) 3. Fit the spanner, provided on the warm sheft, to fiet faces of the connector and turn the connector to loosen it for removal as shown in the figure. Note: Be sure to fix the ball screw shaft side to perform this operation. Otherwise, when the warm shaft is excessively stretched, the ball tube of the ball screw assy may be broken. 4, Remove the old boot and mount a new one. [At this time, it should be mounted so that th: farger bellows side is positioned on the side of the actuator proper. ‘Also, a wire clamp should be mounted et the same time. DISASSEMBLY AND ASSEMBLY ACTUATOR 5. Set the actuator in the vice again and install the connector as shown in the figure. Apply @ screw locking agent to the s tion (connector and hexagonal nut} Screw locking agent: Loctite 2271 Ww por Flotete the warm shaft fully counterclockwise until it hits the stopper, then perform posi- tioning. = 6. On completion of positioning, reset the actua- tor and tighten the hexagonal nut. Tightening torque: 18 — 22 kam 177 — 216 Nm 130 — 159 #15 7. Set the main actuator, connector and bell icint in the order indicated in the figure and clamp them with wire. (Two positions) ind the wire 2 turns, then wist it 4 or § times. The wire itself should not turn. Ensure the wire does not cross on the opposite side of the twists. After correcting any twisting of the boot, perform clamping, Fold the wire ina Gireetion in which it does not interfere with the boot and chassis, 20-78 ACTUATOR DISASSEMBLY AND ASSEMBLY ASSEMBLY DRAWING - DISASSEMBLY AND ASSEMBLY 1 EPS MOTOR, EPS MOTOR 1. Structure The entirs moxor is a lightweight totelly-en- closed (with drain in lower part) magnet motor emplaying a bipolar ferrite magnet. However, its structure is such that it can with- stand overload, and consists of the following : component parts shown in Fig. 1. (see P. 20-82) 2. Specifications hem nit Tener | __‘Fezoexasex Fe20ex ater = ste Instr Co. Lid Rated votage v 6 | 3 72 Rated ouput w 300 | 550 on fate me «| ® = Excitation meron - | Magnet I ‘Magner Instat ase - | case { uss Weight 22 | { 27 done a occa mm 835 «1715 96% 190 86 + 120 Note: The brushes of the motor (72 V) for tne FBSOEX are ofclferent material from those forthe WB V, 3. Cautions on handling 1) Avoid giving any excessive force or shock to the yoke of the motor. (it may damage the magnet) 2) Avoid giving any excessive load to the leads oft 3) Inspection and maintenance of brushes Check the brushes and commutator after unclamping and removing the brush band. 20-80 ‘er DISASSEMBLY AND ASSEMBLY EPS MOTOR 4. Inspection and maintenance of brushes Check the brushes and commutetor after un- clamping and removing the brush bend. 4) The brushes can slide slightly up and Gown on the brush holder and are held against the commutator surface by the brush springs. Note that if the brushes cannot slide ‘smoothly or the brush pressure is too low, this will lead to commutator failure. Brushes in a perfect operating status will not wear easily. When brushes wear down fo the reference line for brush replace: ment shown in the below figure after reins operation, replace ther. sont 4 2) Aiter lengthy operation, the commutator surface will become black or produce & burn mark, gradually causing bigger sparks and eventually resuiting in 2 com- mutator feilure. ‘Recordingly, polish the commutator sur- face cleanly with #400 sandpaper or sand cloth, then wipe it with dry cloth. Ifthe degree of wear is minimal, wipe off any brush dust powder with 2 dry cloth dnd avoid the unnecessary use of sande paper. 5, Brush replacement 4) Remove the band. (Cover assy} 2) Remove the Mé tightening screw. 2) Raise the brush springs and take out the brushes from the brush box. Then, replace with new ones. On completion of replace ment, insvall it by reversing the above procedure. Note: Brushes are made of 3 specific material. Engure the designated one is used. 20-81 DISASSEMBLY AND ASSEMBLY EPS MOTOR 1 Motor assembly structural drawing 1. Armature ass'y 2 Bearing 3 Stmoture @ Bearing 5 Shim 8 Rear bracket ass'y 7 Brash 2: Gress recessed hexagonal Head! bot kt 9. Grush hater ay 10. Brush sone 11, eer brackes 12, Hexsgonel hese bot kt 18. Front oocker say's 1a. Oise 18. Front bracket 18. Yous eary 17. Cover ass'y 6. Maintenance standard Inspection item teoneg | Remedy commana tL Verner caiers 305 | 5 Replecerent ois e commu dariar | _2¥/asuRe |e Note: Replace srusnes and commutator when their apening Correction ia requires Correction is imeroper. 20-82 Ve time reaches 5,000 hours. az swtndard, DISASSEMBLY AND ASSEMBLY ‘TROUBLESHOOTING FOR EPS TROUBLESHOOTING FOR EPS Partto be chaceed | Mechanieat section Proaiem Remarks Check the connection beeen He ‘The EPS wheel is stuck Datentiometer and marr. The EPS wheel turns only Irene dvecton “The most likely cause is Gamage to the IGBT. “The EPS wheel ie heavy : heck she sensors veltage frst and if no defest is run found, check to fing sry mechanicsl dyes. "The EPS wheel exces 7 ‘Check the sensors voltage first and if no defects . sively vibrates found, eneck the printed circuit card, "The resistance value of the poventiometer is fetes epee 2 ‘The sider in the torque sensor does nat move smoothly. Tnermient noise: A gear is gouged or burr, Persistent nolee: The accuracy of tbe gears is low. | Lt Turning the EPS wheel produces 3 big noise ‘A big impact noiae produced at sroke enc Wioise Notes on maintenance lf the slider o piston in the torque sensor does not move smoothly, the EPS wheel vibrates or sticks. When the EPS wheel does not operate properly, first check the parts other than the torque sensor. The torque sensor must be very carefully adjusted or repaired with @ measuring instrument and special grease. 20-83 STEERING SYSTEM DISASSEMBLY AND ASSEMBLY E-FHPS STEERING SYSTEM (E-FHPS type) E-FHPS (Energy saving-Full Hydraulic Power Steering) APPLICABLE MODELS: FB15GT/18GT-7 FB20GT/25GT-5 E-FHPS system constitution diegram rivetiydraulle convoter E-FHPS controller aareny _From ank EFHPS cump FHS eyfinder Pawar soaring valve ( Tone E-FHPS applies an electronic control system to reduce energy consumption and noise. Hydraulic system and electrical system diagram E-FHPS cylinder cantroler DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE POWER STEERING VALVE COMPONENT PARTS 18 1. Dust seal ring 10. Cardan shaft 22-4. Plug 2. Housing 11. Spring Seal washer 3. Ball 12. Oving Setting scraw 4. Thread bushing 13. Distributor piate Spring 3. O-ring 14. Gear assembly . Piston 6. Ring 33. O-ring Vaive seat 7-1. Outer bearing race 16. End cover 24. Bal 7-2. Needle be: 17. Washer 2. Pin 7-3. Inner bearing race 18. Bolt 28. Spoci 8. Aing 39. Bolt 27. Sleeve 8. Cross pin 20. Name plate 21. Screw 20-86 DISASSEMBLY AND ASSEMBLY DISASSEMBLY 4. Place the steering valve in the holding tool. ‘Screw out the screws in the end cover (16). [Goff plus one of the boits (18 and 18)] 2. Remove the end cover (16) sideways. 3, Lift the gear assembly (14) off the steering valve. Take out the two O-rings (18) 4. Remove cardan shaft (10). 20-87 POWER STEERING VALVE DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE 5. Remove distributar plate (12). 8. Screw out the thread bushing (4} over the check valve, 7. Remove O-ring (12) 8. Shake out two balls (24) and two pins (25) of the check valve. Bm 20-88 DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE 9. Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and needle bearing will be pushed out of the housing together. 10. Take ring (8), bearing races and nt ing trom sleeve and spocl. The outer (thin) bearing race can sometimes “stick” in the housing, therefore, check that it has come out 11. Press out the crass pin (9). Use the rolled pin from the end cover. 12. A small mark has been made with @ pumice stone on both spool (26) and sleeve (27) close ‘to one of the slots for the neutral position springs (see drawing). Ifthe mark is not visible, remember to leave mark of your own on sieve end spool before the neutral position springs are dismantied. 20-89 DISASSEMBLY AND ASSEMBLY * POWER STEERING VALVE 13. Cerefully press the spool (26) our of the sleeve (27) 44. Press the neutral position springs (11) out of their slots in the spoal (26) 15. Remove dust seal ring (1) and O-ring (S\/ring @. 20-90 | DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF THE PRESSURE RELIEF VALVE (CARTRIDGE) 16. Sctew out the plug (22-1) using an @ mm hex- agon socket spanner. Remove seal washer (22-2). 17. Unscrew the setting screw (22-3) using an 8 mm hexagon socket spanner. 18, Shake out spring (22-4) and piston (22-8). The valve seat (23) is bonded into the housing (2) and cannot be removed. 49. The pressure relief vaive is now disassem- bled. Cleanin: Ciean all parts carefully in Shellsol K oF the Tike, Inspection and replacement: Roplace all seals and washers. Check all parts, carefully and make any replacements necess- ary. Lubrication: Before assembly, lubricate all parts with hy- draulic oi 20-91 POWER STEERING VALVE DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE REASSEMBLY 20. Place the two flat neutral position springs in the slot of spool (26). Place the curved springs between the flet ones and press them into place. 21. Line up the springs (11) set. 22. Guide the spool! (26) into the sieeve (27). ‘Make sure that spool and sleeve are placed correctly in relation to each other. 23, Press the springs together and push the neu: tal position springs into place in the sleeve (27). DISASSEMBLY AND ASSEMBLY : POWER STEERING VALVE 24, Line up the springs (11) and center them, 25. Guide the ring (8) down over the sleeve (27). Note: The cing (€) should be able to rotate . free of the springs (11). 26. Fit the cross pin (9) into the spool/sieeve as- sembly. 27. Fit bearing races (7-1 and 7-3) end needle bearing (7-2) as shown on below drawing. ‘The inside chamfer on the inner bearing race (7-3) must face the inner spool. Outer bearing race (7-1) Needle bearing (7-2) Inner bearing race (7-3) Spoot (26) Sleeve (27) @6@8O 20-93 DISASSEMBLY AND ASSEMBLY INSTALLATION INSTRUCTIONS FOR O-RING/RING 28. Turn the steering unit until the bore is ha zontal. Guide the outer part of the assembly tool into the bore for the spool/sieeve assem- bly. 28. Grease O-ring (5) and ring (6) with hydraulic oil and piace them on the assembly tool, 2, OF 30. Hold the outer part of the assembly tool in the bottom of the steering valve housing and guide the inner part of the tool right to the bottom, 31. Press and turn the O-ring (5)/ring (6) into po- sition in the housing (2) POWER STEERING VALVE a — DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE 32, Drew the inner and outer parts of the assem- bly tool out of the steering valve bore, leaving the guide from the inner part (O-ring end ring) in the bore. 33. With 3 fight turning movement 9 spool/sleeve assembly into the bore. Note: Fit the spool set holding the cross pin horizontal. 134, The spool set will push out the assembly tool guide. The O-ring (5) and ring (6) ere now in position. 35. Turn the steering vaive until the bore is verti- cal again, Put the check valve ball (3) into the hole indicated by the arrow. DISASSEMBLY AND ASSEMBLY 36. Screw the thread bushing (4) lightly into the check valve bore. The top of the bushing ™ust lie just below the surface of the hous- ing. 37. Place a ball (24) in the two holes indicated by the arrows, and place @ in (25) in the same iwo holes. 38. Grease the O-ring (12) with hydraulic oif and place them on the housing (2). 39. Place the distributor plate (13) so that the channel holes match the holes in the housing a 20-96 POWER STEERING VALVE DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE 40. Guide the cardan shaft (10) down into the bore so that the slot is parallel with the con- nection flange. 41. Place the cardan shaft (10) as shown - so that It is held in position by the mounting fork. 42. Grease the two O-rings with hydraulic oil and place them in the two grooves in the gear rim. Fit the gear assembly (14) on the cardan shaft. 43, Important: Fit the gearwheel (rotor) and car- dan shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown. Turn the gesr rim so that the seven through holes match the holes in the housing, 20-97 DISASSEMBLY AND ASSEMBLY 44, Place the end cover (16} in position, 48. Fit the bolt (18) with washer (17) and place it / in the hole shown, 46. Fit the six bolts (19) with washers (17) and in- sert them. Cross-tighten ail the bolts (78) and 19) with 3 torque of 3.0 + 0.6 daNm. 47. Place the dust seal ring (1) in the housing (2). 48, Fit the dust sezl ring (1) in the housing (2) using special tool SJ 150-3000-22 (see page 20-100) and a plastic hammer. 20-98 POWER STEERING VALVE DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE ASSEMBLY OF THE PRESSURE RELIEF VALVE 49. Fit the piston (22-5). 50. Fit the spring (22-4). 51. Screw in the setting screw (22-3) with an 8 mm hexagon socket spanner. Make the pressure setting with oil pressure gauge. 21.9 spring for 70 — 105 bar 52. Screw plug (22-1) with seal washer (22-2) into the housing using an 8 mm hexagon socket spanner. Tightening torque: 5 = 1 daNm 20-99 DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE ‘SPECIAL TOOLS Holding tool Code No.: SJ 150-9000-2 Assembly tool for O-ring and ring Code No.: SJ 150-8000-11 Assembly tool for cardan shaft Code No.: SJ 150-8000-3 Assembly toal for dust seal Code No.; SJ 150-8000-22 Note: Code No. is Part No. by Danfoss 20-100 DISASSEMBLY AND ASSEMBLY LE-FHPS MOTOR: E-FHPS MOTOR 1, COMPONENT PARTS Power steering motor ass'y Cover Starter ass'y Nut Cover Screw Bearing Reteining ring Armature ass'y . Bearing: . Brush spring . Brush Screw |. Cover ass'y NoMa wEo 2. SPECIFICATIONS 7 Fevsei ear em rie FEROGTI25GT Manufscurer mo ELECTRIC MOTORS Rated vote v “3 Fated ouput w 350 Tioe rating rin ‘waigne ks " Dimensions mom 124% 255.4 (iameter % length). 20-101 DISASSEMBLY AND ASSEMBLY E-FHPS MOTOR 3. DISASSEMBLY i. Remove through bolts. 2. Remove pulley end cover. 3, Pull the ermature out of the assembly in ‘one swift motion. It is important that the pulling motion on the armature ‘be con- tinuous. Do not pull part way out and re- lease. If this is Gone, the magnets will pull the armature back into the stetor and cause severe damage. 4. Remove commutator end cover. NOTE: Do not place the stator ring in any mechanical holding device during the disassembly or assembly operation. Permanent distortion or other damage will resut. 4, TROUBLESHOOTING Once the motor hes been disassembled, go through the following check list steps 10 determine where the problem lies. ‘A. Bearings — Should spin smoothly and easily and have ample lubrication and be free of corrosion. 8. Armature — Check for grounds and shorted tums. Refinish commutator sur face if pitted or excessively worn, C. Brushes — Check brushes for wear and to ensure that they are free in the brush hol- ders. Note: Observe how brushes are assem- bled in brush holders and position of brush lead. New brushes must be installed in the same manner. Brushes should be removed as fol- lows: 3. Remove brush spring clip ftom its mounting on brush assembly. 6, Lift brush assembly from brush holder ©. Disconnect brush assembly lead. 4d. New brush assembly to be installed by reversing above procedure. D. inspect wire harness and all connections for signs of damage due to overheating. &. Stator — Check magnats to sae if they are securely mounted, 5. CHECK AND INSPECTION epi Brush height Vemiar saivere 722 2 20-102 DISASSEMBLY AND ASSEMBLY ‘STEERING AXLE STEERING AXLE FB10EX/14EX/15EX/18EX-7 STRUCTURE AND SPECIFICATIONS Se rater a 4 \ Seam | Oe see Sy a ee aaa ee SS SSS = Sebeaeiehact €z a =| eon) er pring he it ras i coeneee cel Sea ee coccinea | tone Tosin | mm o camber | esas te Caster | degree 0 Wemrceeae [sass rosso ile [ere] BA Teme [= soln 20-103 DISASSEMBLY AND ASSEMBLY STEERING AXLE DISASSEMBLY AND ASSEMBLY E ceusning) eA men @ > ror aN Bal rank pint Disushings CAUTION: Al four ball socket (3#) assemblies and their con- necting portions must be cleaned and any grease must be removed. 20-104 DISASSEMBLY AND ASSEMBLY STEERING AXLE CHECK AND INSPECTION \r? Eoin! ( 7 coo riot [omnes Fe ee = oa jiameter of bellerank pin | oes | Play of steering axle {Te front/rear) = | CS a 20-105 DISASSEMBLY AND ASSEMBLY STEERING AXLE PRECAUTIONS WHEN ASSEMBLING 1. Hub bearing Fill grease (G2-Li) 1/2 — 2/3 in the space of the hub bearing, 2. Adjustment of hub starting preload 1) Tighten the lock aut until no further hub rotation by a single hand is possible. 2) Loosen the lock nut be @ quarter rotation, 3) Hook @ spring balance to one of the hub bolts and acjust the nut to obtain a start. ing force of 2 — 2.6 kg and to give proper preload to the taper roller bearing, esi) 3. Adjustment of toe-in 1) Fix the bell crank with the pin and connect the tie rod with the knuckle. 2| Align the axle center hole (022 mm) with the hole (022 mm) in the bell crank and in- sert the pin into the aligned holes, Adjust toe-in with the steering axle in the straight forward position, 3) Loose the tie-rod lock nut and turn the tie- | 5 rod until toe-in will be 0 to - i lL i 4) Tighten the lock nut 1 25 — 1 kgm 245 — 304 Nm Toesin = La ~ Lr = 0:0 =2 mm [181 — 226 itt 20-106 DISASSEMBLY AND ASSEMBLY STEERING AXLE FB15GT/18GT-7 STRUCTURE AND SPECIFICATIONS Eatin Jf Reeae wa {aeearonet Fara @) CL -/ ——aagrecipmascin Ataragioning me mc aie sure = tah : = : 20-107 DISASSEMBLY AND ASSEMBLY STEERING AXLE DISASSEMBLY AND ASSEMBLY 20-108 DISASSEMBLY AND ASSEMBLY STEERING AXLE CHECK AND INSPECTION cl E (Bushing) som crea Son Check tem famedy sarcneee | _Rsran z ae | Bienes of ng pin eae | ay Reales 8 | vertcat py of knuckle - | a eae S| ise daar oF PS ander 8 7 ea boskeg (ono esi a 1 D | ise deme of knee pin buthing ah | ey st i = apace & | Insioe diameter of center pin bushing Incas | ay = | ay of neering (To hondrew = | a onal 20-109 DISASSEMBLY AND ASSEMBLY : STEERING AXLE PRECAUTIONS WHEN ASSEMBLING 4. Hub bearing Fill grease (G2-LI) 1/2 — 2/3 in the space of the hub bearing, 2, Adjustment of hub starting preload 1) Tighten the lock nut until no further hub rotation by a single hand is passible, 2) Loosen the lock nut by a quarter rotation, 3) Hook a spring balance to one of the hub bolts and adjust the nut to abtain @ start: ing force of 2 — 2.6 kg and to give proper preload to the taper roller bearing. 3. Adjustment of toe-in For toe-in adjustment, set the distance La — Le shown in the attached assembly drawing to a value of 0 to +2 mm with the eccentric bolt. Place of eccentric bolt: See page 20-108, Toe In La Le = 019-2 mm 20-110 DISASSEMBLY AND ASSEMBLY FBZ0EX/25EX/30EX-5 STRUCTURE AND SPECIFICATIONS Type Structure af knvekle Center pin suppor single shaft Elon type Camber 15 castor egree ° ing pin angie er 50 ogres ors? om 595 (358m 20-117 STEERING AXLE DISASSEMBLY AND ASSEMBLY STEERING AXLE DISASSEMBLY AND ASSEMBLY CAUTION: All jour ball socket (2) assemblies and their con- necting portions must be cleaned end any grease must be removed, 20-112 DISASSEMBLY AND ASSEMBLY STEERING AXLE CHECK AND INSPECTION E ieushinal — = i 7 ‘| aay 7 i : | hz yy u B aa \ | i Section 22 smn citaa Sian heck item emesy Suncordsie | = aa © | emer ta in Reg EE eee Pesce a2 ase | versel ply of ect 7 cal Aaa © | oennert pean a wm © | tise ameter of Sean sin busing ny | a eolace | tnsige ciamerer of cena pin bushing ss | — | steering ante, uo, ruck besrng | Sef abmarmal noite, defect rotation 7 Tajuee = | Pay of serine axe (To tones - | agi 20-113 DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN ASSEMBLING 1. Fill 1/2 — 2/8 of the space in the hub bearing with lithium grease. 2. Adjustment of hub bearing preload 1) Tighten the lock nut until it becomes diffi cult to rotate the hub by a hand, 2) Tum back the locknut by @ querter turn, 3) Hook the spring balance to a hub bolt and carefully adjust tightness of the nut until a starting force of: 0.9 to 4.7 kg (2 — 10 Ib) is obtained, so that a proper preload is given to the taper roller besring. 3. Adjustment of toe-in 1) Fix the bellerank with its pin and connect the tie-rod to the knuckle, 2) Align the axle center hole (028 mm) with the hole (028 mm) in the bellcrank and in- sert the pin into the aligned holes. Place the steering axle in the straight traval posi- tion and adjust toe-in, 3) Loosen the tie-rod locknut. Turn in the tle: od until toe-in becomes 0 to +2 mm. 4) Tighten the locknut securely, | 25 — 35 kam [245 — 343 Nm [131 — 253 fib 20-114 STEERING AXLE @ [u] Lr Totin © La = te = 0 t0 +2 mm DISASSEMBLY AND ASSEMBLY ‘STEERING AXLE FB20GT/25GT-5 STRUCTURE AND SPECIFICATIONS Type = | center pie support single share Structure of knuckle lier vp Torin mm ° cember degree 1s ca dearee 0 ing pin angle degree ° ‘ax steering angio of - wna insige/utsids) | 329 78158 ‘Tread mm 935 363 in 20-115 DISASSEMBLY AND ASSEMBLY | ‘STEERING AXLE DISASSEMBLY AND ASSEMBLY PS evinder Bo Sn Ajusting nut DISASSEMBLY AND ASSEMBLY STEERING AXLE Oo CHECK AND INSPECTION | \ | { N D é E (Gushinat A 8 1 mn) itera sign check tem Remesy ‘Stancerd siza | Repair mit = as | otameter of king pin | fa | (ae Teoiece 8 | vertical play of kructie | - | (one) fhe ] | inside Gemeier of FS cvindar rod e "ea bushing (0830) (0585) faoice | Inside clameter of center in bushing cn | a = | Steering axle, nub, knuckle, bering 1 BARERE Wee sl woke, defective rotation — | Play of steering (To frontier} - | a ental 20-117 DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN ASSEMBLING 1. Hub bearing Fill grease {G2-L) 1/2 — 2/3 in the soace of the hub bearing. 2. Adjustment of hub starting preload 1) Tighten the lock nut until no further hub rotation by @ single hand is possible. 2) Loosen the lock nut by a quarter rotation. 3) Hook a spring balance to one of the hub bolts and adjust the nut te obtain a start- ing force of 2 — 2.6 kg anc to give proper preload to the taper roller bearing 3. Adjustment of toe-in For toe-in adjustment, set the distance Ly — Li shown in the attached assembly drawing to a velue of 0 ta +2 mm with the eccentric bolt. Place of eccentric bolt: See page 20-116. 20-118 STEERING AXLE DISASSEMBLY AND ASSEMBLY i POWER STEERING CYLINDER POWER STEERING CYLINDER FBISGT/18GT-7, FB20GT/25GT-5 NO Re mm ba) tern Fetscact FanocT/2scT Diameter of evinaer SSN 730 inner > Ours (280x287) —_ we 2 Diameter of piston cod a ry 7s Stroke 6.23) 28 Cylinder head 8. Piston packing Cylinder tube 9, Piston packing expander Piston rod and piston 10. Rod wiper Tie rod 1. Rod seat -rod nut 12, Bushing Seal 13, Dust seal Back-up seal 14. Piston seal ring 20-119 DISASSEMBLY AND ASSEMBLY ACCELERATOR AND ACCELERATOR PEDAL ACCELERARATOR ACCELERATOR AND ACCELERATOR PEDAL Circuit diagrem scceier 1. NEW TYPE [Potentiomerer section Idle switen section 1) Compact and light accelerator gives si pler linkage mechanism, greatly improving the reliability. 2) Weter-aroaf accelerator protects the me- chanism trom water and humicity. 2. Cautions 1) Adjustment of the accelerator pedal The accelerator pedal is adjusted deli- cately at shipping time to allow the ma chine to provide its running performance on a high level. Do not alter arbitrarily the height of the pedal stopper bolt and the tilt Of the accelerator; if you do, the machine may become disabled, Note: Refer to the section “How to Adjust the Accelerator Pedal” if you need 10 adjust the accelerator pedal to replace the parts. 2) Removal and installation of the acceler- ator wire harness {When removing the floor plate) ‘The wire harness is connected to the ac. _/S3 (paslen Pull the connector out pressing the connector lock css Before you rove he Nose plate, remove the harness conneeror oo Eno thet you should not eut the wire hemess, Wt =ES Ramave the accelerator wire harness con- Ce hector se chounin he gue ooteriaen | CSS voce (When installing the floor plate) Be sure to connect the accelerator wire harness connector when you install the floor plate, 20-120 DISASSEMBLY AND ASSEMBLY ACCELERATOR AND ACCELERATOR PEDAL 3. ADJUSTING THE ACCELERATOR PEDAL 1 v 2 3) 4) ‘Supply the following grease to each sec- tion’ ed = an | ‘Spectiaton for ‘hia ara Settee” [ose] Pash Teste nares [cou eur After fastening shaft (a) to plate (b) with 2 ut, apply Loctite #241. Main points for setting accelerator pedel (1) With the eccelerator lever fitted in the tabs of plate (b), then adjust the vol ume of accelerator and fastened to | bracket {d) with screw (el, (2) The accelerator pedal stopper bolt (f) is set by accelerator volume resistance 2. [Adjustment of accelerator resistance value (1)} ‘ (Set with the accelerator pedal free, not depressed} Rotate accelerator (c} with respect to bracket (d) and stop the accelera- tor with the resistance between ac- colerator Via and E: in the range of 0.69 to 0.92 KQ and the idle SW be- tween IDL and Ez off. [Adjustment of accelerator resistance vaiue (2)] {Set with accelerator pedal depressed) With the accelerator pedal de- pressed, set the pedal stopper boit 0 that the resistance value be- tween accelerator Via and Ez the range fram 3.41 to 3.64 KQ. Whan ie scaarsor [0 ‘i Foot pressure (at the pedal location marked with 2 star) ‘en cessing a eal VS When deproesing the pec fly 2088 Section A-A 20-121 DISASSEMBLY AND ASSEMBLY 7 HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM FB10EX/14EX/15EX/18EX-7 FB20EX/25EX/30EX-5 a Helle — Eee * aH ARC i 1 Sowa control valve | 180 ka/em* 2 Le | Hydeeuic sank ‘Sbamer Fikar (105 uh (20) 20-122 DISASSEMBLY AND ASSEMBLY HYDRAULIC CIRCUIT DIAGRAM FBISGT/18GT-7 FB20GT/25GT-5 Tic cylinder 2-Spoe! contral valve 2 a | Eitevlinder | ' ies Suraier (05 ot Powsr stesting Power ssering eylinder (ype of both zie ods) 20-123 DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP POWER STEERING PUMP STRUCTURE __seureme | stoveatoovon DISASSEMBLY 1. Remave nyian ball (3), 2. Remove bolt. 3. Ten cover (b) and remove dowel pin (1). 4. Remove cover, Do ner tur thi bake when removing or installing asim ‘34Nm 25 hb 2. Nylon bail b. Cover . Pinion shaft d. Internal gear Kot f. Bush g. Flange h. Ol seal i. Dowel sin i. Mounting bolt to pump motor k. O-ring 20-124 DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP CHECK AND INSPECTION Check method: visual check/ealiper Ts Check tem | ‘ena fnit, jaan Gussie ciameter of pinion shaft | 1290508) Inada lamer of joural hole I 115 518 ne ‘usie oiamerr of intemal gear en) Inside diameter of housing | 71 951.616) ASSEMBLY Assemble in opposite order to saaserty Pay attention to the folowing points Wash all parts in flushing ei, and remove dirt and dust from the side of the cove flange and inside of the housing and othur parts. When assem dirt or dust get i © When assembiing the internal gear, insort it the housing so that the "0" mark at the rot of the teeth is on the cover side. © Tighten the mounting bolts of the cover to th most 70% of the specified _tightom ing torque (3.5 kgm) and check that the shalt rotates easily by hand. © After checking, tighten fully. 1, be careful not to let ny * Knock in the dowel pin so that the tip of pin is level with the end face of the cover 20-125 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP. HYDRAULIC PUMP STRUCTURE Pump modet kzPa-t9088 1. Bolt 41. Snap ring 2. Packing ring (RH) 12. Oil seal 3. Cover 13. Fienge 4, Bushing seal 14, Packing ring [R.H) 5. Bushing 15. Bushing seal & Body 16. Bushing 7. Driven gear 17. Drive gear 8. Bushing 18. Bushing 9. Body seal 19. Body seal 10. Packing ring (LM) 20. Packing ring (LH) DISASSEMBLY A 1. Grip the pump lightly in 2 vies and remove the mounting bolts (1) of the cover (3). 2, Remove the cover (3) and flange (13) then remove the oil seals (12). 3, Remove the bushing (5, 8, 16, 18] and the gear (7, 17) from the body (6). > If itis difficult to remove the bushing, push the gear in. 20-126 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP CHECK AND INSPECTION 1 Checking body for signs of contact with ge For the gear pump to work efficiently, it is necessary for the tip of the teeth to be slightly in contact with the body when the gear rotates. % If the dimension A in the figure on the right is @39.180 mm (1.543 in} or if the contact covers more than half the inside surface, replace the assembly. Checking the bushing for contact with the gear ideally, the sliding face of the inside diameter should be smooth, with about half the suction side showing shining traces of contact. The contact an the side face should be slightly stronger on the intake side with only slight contact on the delivery side. % If there Is contact on the whole of the slid- ing surface of the inside diameter, and there are scratches deep enough for @ finger nail to catch in, or if there are many scratches around the circumference of the side face and the scratches are deep enough for a finger nail to catch in, re- place the bushing and the gear tagether. + Measure the distances in the figure on the right, Replace if the measurements are to the following. Inside diameter: Min, 619.123 mm (0.753 in) 126.411 mm {1.040 in) Overall length: Ma Checking sliding surface of gear in contact with bushing o If there are scratches on the shaft or the side face of the gear deep enough for a finger neil to catch in, or if there is abnor mal uneven wear on the face of the teeth, replace the gear. + Measure the diemeter of the shaft shown in the diagram on the right. Replace if it is bolow: Diemeter: Max. 018.935 mm {0.745 in) eat side Gear sie LS cl Lnera “nee dtameser 20-127 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY 1. Clean all parts end coat the seals with arease. Insart the two bushings on the cover side in- side the body at the same time. % When doing this, be careful there is no mistake in the combination. Do not let the : bushings slip out of place when inserting. 2. Turn over the body and insert the drive gear and driven gear. Insert the bushings on the fiange side at the same time as in step 1 % Install the bushing seal, body seal, and packing ring, Be careful not to let the center part of the packing ring overlap. | 3. Wind tape on the drive gear shaft, then fit the flange. Turn over the body and install the cover. Tighten the bolts. 4.7 — 4.3 kgm 46 — 43 Nm 34 — 35 ftlb 20-128 DISASSEMBLY AND ASSEMBLY CONTROL VALVE CONTROL VALVE ssombling te spel DISASSEMBLY AND ASSEMBLY ‘rt lock sp00! re z=] ae pa jae ecco =» [Tt yl —— wT. Sue antion to the direction c=| Bm OY * Same 8S eee Soca [ma ae ot = #5 rit spoat ——— : ae pen ee | BE Sune Titioek soo! ne ele ro = Wo. + Wesh all parts thoroughly. Remove detergent and dust completely with compressed air, and coat with hydraulic oil for assembling. Do nat use rags to remove detergent and dust. + Use light oil or sichlene 35 detergent, Keen the detergent away from fire. Replace dust seals, U-packings, and O-rings, Install new ones coated with grease, taking care not to scratch them. 20-12! =p o ep [a8 ate ave ay Bhs . : 180 kg/em? (177 bar) [2560 psi] 9 DISASSEMBLY AND ASSEMBLY CONTROL VALVE CHECK AND INSPECTION w crest tem fe Stance seem Roser or At | Ror sing a, tea i i | pS ate 33m) [as | cnece vatve spring [ #. 8 | Scoot ane rousing Scratches, burs % if the spring is deteriorated or bent, replace it. PRECAUTION WHEN ASSEMBLING ‘* Be extremely careful not to let any dirt or % Tift spool 1) 8e careful to install the poppet facing in the correct direction. amt Titec sacol ‘S22 Tiltlock plug: 1.2 — 1.4 kam \ (12 —14 Nm) i f al assemble inside the housing > Be careful to assemble the spoo! fecing in the correct direction. 3) Coat the return spring with lithium grease No. 2 and install the cap. Install the seal plate at the head end, ==. Mounting bolt: Head end 0.3 kgm (3 Nm) [2 ftib] Bottom end: 1.0 kgm {70 Nm) 17 ft. Ib) 4) To connect the blocks with each other, ‘ighten the 3 bolts (010, 1 bolt; 8, 2 bolts) == 010 mm (0.4 in): 4.7 kgm (46 Nm) [34 ft.lb} € Assembling the tit spool Fay anemion tome cteeton of the tt fee spo 98 mm (0.3 in} 1.94 kam (19 Nm) [14 Ft1bj CONTROL VALVE MICRO-SWITCH ‘The micro-switch serves to tum on and off the hy- draulic system in conformity with the movement of levers. i Tripte-valve lever Tittever= utever— uniever (Only fer siplewsive ee Wing diegram Ttlever Triole-valve lever ! f ‘Same forall evers: 2.5 XGF or less 2. Apply KES 07-531 Ihium grease to eech tikage 3, Microswitch instalation sejustment unt fetmer UR? v e-a 750 F from Dac 770, § (1-18 ow to connec: the merase Make sure Ya face 77 teat e008 Rot ge : ‘mroswiteh and tha deshoars, ve uka Tiki. Cam Sx View W View Be carafut ofthe civeesion “tho pn is Inserted Connect the lirkage to operating vaive, With all of the levers in neutal, check the fastening Tocation to mate sure thatthe following stroke | {not including link g::p) twens the micraswitch on. Diet, it, atachment: Framleverin neutral positon, shoul wen : fon berween 15 and & uma: \ From ever ia neutral postion, should turn fon berwaen 25 and 50 n this case, how (200,727 the lover aed ohe fe 2 ‘sill na tum on, \_Only for standard mace! {EPS specifeation) install he plug IF th] ob For two valves 20-131 DISASSEMBLY AND ASSEMBLY LIFT CYLINDER LIFT CYLINDER (1.0 t — 1.75 t) STRUCTURE A safety valve is screwed into the bottom of the lift cylinder on the outside. The same cylinder is used for both left and right sides. Diamevors of evinaer Bam Sm 1. Piston rod 6. Cylinder heed inner * Outer IT in 200) 2 Oring 7. Wiper ring Diameter of piston rod 38mm 3. Holder & Seal ring 11.38 in) 4, Bushing 8. Usring alate tara | Ze 5. Cylinder 10. Wear ring * Acollar is added for the mast higher than 3.8 om '™m. Tilting angle must be adjusted to 6/6” for bie the mast higher than § m. CHECK AND INSPECTION ‘Cheek item Cearance betwaen sistan rea 1} ang Qusning ih | Resecenan @ Loman oftusnng francs between pion easing 1B) na Oe exlingsr (8, e002 agizim | 0.02 ny 20-134 . DISASSEMBLY AND ASSEMBLY LIFT CYLINDER LIFT CYLINDER (2.0 t — 3.0 t) STRUCTURE [A safety valve is screwed into the bottom of the iit evlinder on the outside. The same cylinder is {sed for both left and right sides. Tam J ont | zrnase Tt. Piston rod 7. Dust seal wee [ow] ces | 2 ovina 2 Seal Tiina law | SO Bae 3. Holder 8. U-packing ib o01 insrxzzsiny | fat 28 in) Bushing 10. Stopper er ry [ 5 5. Cylinder 11. Retainer s0.0) 11.57 iol 77 inh 6. Cylinder head 42, U-packing: = 2 weiattieacn) | 453 | thoy cay © Accollar is added for the mast higher then 3.8 = m Lit Sc Fi A 4 a ke lt as ay S la oH { op | op.etred |e. en eeahe | | | O+ing. CHECK AND INSPECTION fade noone) ein Lae | Saas 20-135 DISASSEMBLY AND ASSEMBLY TILT CYLINDER é TILT CYLINDER (1.0 t — 1.75 t) * Tilting angle can be adjusted Sy the spacer fixed outside the cylinder. Diameter oeyinder Bans Team Times ast Ganson iston rag 25mm Lerewrcipmoned [ite od head 8. Piston rod eno 323 mm 2. Shim (6°/6") 9. Piston Stroke IL {48 ior 3. Spacer (6°/6") 10. O-ring = Stim Orem (e764 1. Backup ring pee) Oaindarherd =z, Lact a Traetcbatalelec em 8. Unpacking inew type) 13. Sushing (29 int 7. Cylinder 14, Back-up ring is—Hsigm igi — B0Nm 134 = 1700 DISASSEMBLING AND ASSEMBLING * Before disassembling, mark to verify the tightened depth of the rod, * Use the following special tools to remove the cylinder head, Wrench (SEA-6#-13982) Spe Bar (26A-84-12970) > Protect the threaded portion of the rod by 4 tape to the effect neither the oil seal nor the U-packing will be damaged. CHECK AND INSPECTION | Criteris | Check tem - Remedy | Standard size ium) | Rena i Tzorance oenveen pan rou 1H ano aaa T busning 13) (0.002 — 9.087 i 2012 in warily Glarance beeen rad hand Bushing nd #008 — 073 08 of Bushing on | toc02 aoa im 82m # In order to measure the clearance, place 3 dial gauge at the rod heed pin and fix the bushing firmly. ‘The clearance can be obtained by the movernent when the bushing has been pushed, 20-136 {DISASSEMBLY AND ASSEMBLY TILT CYLINDER TILT CYLINDER (2.0 t — 3.0 t) FaeOeK EEE FB20GT/256T Liaienid Diener a eine Tanta ther Owen grein 325%) | “aie ciamesar of Zam piston rod 1.18 10) 1. Rod head 8, Piston rod eno 126 mm 138. mm 2, Shim (6/6) 9. Piston tasin | Bele = . eel 3. Spacer (67/6") 10. O-ring | oe ton wean 4, Oring (6/6) 11. Back-up ring ‘ == int 5. Cylinder head 12. Lock nut want [ae | Sam &. Urpacking (new type) 13. Bushing == ict 7. Cylinder 14, Back-up ring 2 i dae 4 When disessembling, wind tape round the threaded part of the rod and be careful not to damage the oll seal and U-packing inside ey- linder head. CHECK AND INSPECTION check item Smaecitoms _| Ready Repair ric (mm) Clearance berwaan oison rod (6) and ey T aS bushing (13) (0.002 — 0.007 ini ‘0.072 int Peeled! ‘Clearance between fod head bushing ane 3 of busning ia i (0.024 in | jnorder to measure the clearance, place e dial gauge at the rad head pin and fs Pe bushing firmly. ee easy be obiained by the movement when zhe bushing has been pushed. 20-137 DISASSEMBLY AND ASSEMBLY £ MasT MAST MAST (For 1.0 t — 1.75 t) FBIOEX/14EX/15EX/18EX FB1SGT/18GT DISASSEMBLY AND ASSEMBLY MAST ADJUSTMENT OUTER MAIN ROLLER 1, Selection of roller size Select such rollers (NS, NM, L and NLL) as no difference can be made at the “V" bet. ween the left end right masts. 2, Shim adjustment Use the shims A of the same thickness with @ clearance of 0 — 0.3 mm at “f" at the maxk mum lifting height. Put the shims B to make the clearance “b’ 0.1 — 0.4 mm all along the inner rail, when the roller is pushed to the rail INNER MAIN ROLLER 1. Selection of roller size Select such rollers (NS, NM, Land NLL) as to make the clearance “a” to be 0.2 — 0.7 mm. 2) Shim adjustment At the maximum lifting height, insert the shims C, when the coller is pushed to the rail, to make the clearance “c” to identically 0 — 0.3 mm in the left and right rails. Outer main ‘alee role [os i x Oe ” 20-139 DISASSEMBLY AND ASSEMBLY MAST MAST (For 2.0 t — 3.0 t) INNER MAST FB20EX/25EX FB20GT/25GT FB30EX FB20EX(GT)/25EX(GT) FB30EX OUTER MAST FB20EX/25EX FB20GT/25GT 20-140 DISASSEMBLY AND ASSEMBLY MAST © ADJUSTMENT OUTER MAIN ROLLER “pew 1. Selection of roller size 7 Select rollers (S, M, L, Q size) so that there is no difference in the fet and right dimension v" at the strip. 2. Adjusting shims ‘Adjust with shim A so thet clearance “b” is within 0.1 to 0.4 mm (0.004 to 0.016 in). Adjust with shim B so that clesrance “” within 0 to 0.5 mm (0 to 0.02 in} at max. li height position. INNER MAIN ROLLER 1. Selection of roller size Select rollers (S, M, L, O size) so that clear- ance “a” is within 0.2 to 0.7 mm (0.008 to 2. Adjusting shims ‘Adjust with shim so that clearance “c” is wthin 0 to 0.5 mm (0 to 0.2 in} at mex. lifting height position. cory 20-141 DISASSEMBLY AND ASSEMBLY FORK CARRIAGE (For 1.0 — 1.75 t) 1. Section A-A (3-roller type; FB18EX/18GT only) 1) Select such rollers as to make the clear- ance “e,” to be 0.3—1.1 mm, 2) Use the shims of the same thickness 10 make the clearance “f," to be 0.1 — 0.3 mm in the left and right at the top of the fork carraige. 2. Section B-B 1) Select such rollers as to make the clear- ance “e,” to be 0.3 — 1.1 mm. 2) Use the shims of the sama thickness to make the clearance “f" to be 0.4 — 0.7 mm (Soller) or 0 — 0.2 mam (2-roller) in the left and right at the top of the fork car- riage. 3. Section C-C 1) Select such rollers as to make the clear- ance “e,” to be 0.3 — 1.1 mm, 2) Use the shims of the same thickness to make the clearance of "f," 0 be 0 — 0. mm in the laft and right at the top of the fork carriage. FORK CARRIAGE Grouna Undersice rile ot fork carrags| Fork ese Protrusion “D” {at the lower position) revoexnaex | @ TeERIGEX 1.08 im FBISGT/IAGT 20-142 DISASSEMBLY AND ASSEMBLY FORK CARRIAGE CHECK AND INSPECTION craeiem ay a re aot Tamas | Raa cure een ne aah at oon | oe corn Saree iam 2a] Rann ose —_(| ecole — a Ce or oa | ee Seiad etic” oe a | (oot 0s aca’ | Sarina Jeoth of oil groove in mast support | yroove nate No oil groove Replacement of Gaon ciolgroeinnen arortating | Olioreerete | : fee : = iin bial 138i) 19.22 in) FRNGEX | Min. 36 Thess of at a ee Taser 7 tey288 = 3 rues naw 20-143 DISASSEMBLY AND ASSEMBLY FORK CARRIAGE (For 2.0 t — 3.0 t) 1. Section B-B 1) Select a roller to machine “a” with 0.2 — 0.7 mm (0.008 to 0.028 in). 2) Insert the shims of the same thickness and adjust both sides to get 0 Sf (0.004 in), (with the fork carr end) 2. Section C-c 1) Select a roller to match "b* with 0.2 — 0.7 ‘mm {0.008 to 0.028 in) 2) Insert the shims of the same thickness and adjust both sides to get 0 Sf 0.1 mm (0.004 in). (with the fark carriage on top end} 3. Section D-D ee * Select a roller to match “e" with 02 — 0.7 mim (0.008 to 0.028in). 4. Section EE FORK CARRIAGE “Push the back rest te the beer and tighten the boit Underside rote of fork carriage Fore ‘+ Adjust with a shim to gata sas (0.008 in), (with fork carriage on top end) et poten a @ 10.35 in DISASSEMBLY AND ASSEMBLY FORK CARRIAGE CHECK AND INSPECTION Criteria Check item : Remesy Standard se (mt |. Repair tii (rm) als 10 7 Within 25 ‘Ajusment wit Clerance baoween immer | St (2.02 — 0. int iin shims mastand outer mest [oT 2-07 | Within 20 Replacermene with fone (000.078 in) | (0.98) over sia rls ale E10 j Within 25 ‘djesenent with Clearance besween inner |_"° (oa —a08in | Quin stim smascand forecarnege | 02— 07, | Within 20 Replacement with Fo froniear (aca a.078 inn | 10.08) versie alrish ‘Depth ef oil groove in mast support bushing Oi groove nated — | Noll areove Replacement of 7 = Win 328 renovmet omy | ti : erelHn © Min 385 Replacomant Thickness of root of fors | Fa256X/256T Roa | vine apiece 0 Min coos gin | 20-145 MOTORS (Drive motor & Pump motor) 30. ELECTRICAL SYSTEM Specifications 30 3 Structure, Disassembly and Assembly. 30-4 Cheek and Inspection of Drive motor ... 30- 28 Check and Inspection of Pump motor .. 30- 29 Note; EPS motor -...ii.n- See 20- 60 E-FHPS motor See 20-101 CONTROLLERS 1, Outline - 30- 30 2. Features . 1. 30- 30 3. Types and Equipment 30- 30 4. Specifications .. 30- 31 5. External View i 30+ 32 8. Chopper Circuit 30-37 7. Location of Controllers 20-38 8. Electrical Components 30- 41 8, Principle of Drive motor Speed change ....-. . . 30-46 40. Control Funetions =... Peoeeeee BO 48 11, Setting the Control Functions ...-...-- 30+ 60 12, Checking of Electrical Components ... 30- 51 15. Inspection Tools and Tightening Torque... . 30-59 14. Table of Check point and Voltage... 30-608 ‘TROUBLESHOOTING (For Controllers) 1. Troubleshooting by Use of Diagnosis Indicator (Read of Failure Code) ...... 30- 61 2. Troubleshooting for IMS (Intelligent Monitoring System) Display panel ... 30-117 Power Cable Wiring Diagram ......ee..+ 30-420 Controller Schematic Diagram ~ 30-123 Electrical Schematic Diagram 30-433, CHARGER 1. Qutside appearances 30137 2. Circuit Diagram ce 30-138 3. Troubleshooting Flowchart 20-141 30-1 ELECTRICAL SYSTEM MoTORS. Ay MOTORS SPECIFICATIONS 1. DRIVE MOTOR : Forme | FBISGT |FB208X/256X| peagey tem unit | FRISEX | rere jFBz0GT/2scr| FBTBEX Manufecturer | _— [Nikko Denki Kogyo Co. Lid.| __Meidensha Ltd, Ratedvotage | V 8 8 @ R Rated ouiput__|_kw 68 68 7 37 Ratedtime | min 0 0 Ey @ Excling method | — | Series Series Series Series Type ofinsuiation | — | TypeF | TyeeF | ‘TypeF | Tyrer 7 Weight [ko EJ 8 a 720 Dimensions (dia. x length)| mm | 242x342 | 242x312 | 268x330 | 319 x 387 a 2. PUMP MOTOR BS10% | reisct | Fez0ex | Faz0cT | paaey item unit | F3'EX | peiect | Fe2sex | FB2sGr FBISEX Manufacturer —_|Nikko Denki Kogyo Ce., Ltd.| MEIBETSTS | Nikko Denki Kogyo Co., Lid, Rated voltage v 8 48 48 6 7 Rated output kw aa 38 10 70 126 Rated time in 3 5 = 3 5 Exciting method =| Series Series Series Series Series Type ofinsulation | — | TweeF | Tweer | TveeF | TypeF Type F Weight kg a5 3 518 518 645 Dimensions (dia. ¥ engin)| mm | 205%325 | 20x s28 | 218x300 | Exsa | 219% 386 30-3 MoToRS ELECTRICAL SYSTEM DRIVE MOTOR (FB10EX-18EX) STRUCTURE ELECTRICAL SYSTEM MOTORS PUMP MOTOR (FB10EX-25EX) STRUCTURE Armature shaft 28s'y \ Field coil ass'y ‘This illustration shows she FBTOEX-14EX model. 30-5 ELECTRICAL SYSTEM Motors Note; Although the explanatory illustrations are of the drive motor. the same procedures can also be applied to the pump motor. DISASSEMBLY 1. Remove the brush band. 2. Remove the mounting screws of the brush lead wire. 3. Remove the brush from the brush holder, 4. Remove the mounting bolts of the front bracket, and remove the front bracket. 30-6 ELECTRICAL SYSTEM MOTORS: 5, Remove slowly the armature shaft assembly. 6. Remove the lead wire holder. 7. Remove the mounting bolts af the rear bracket. 8. Remove the rear bracket irom the yoke. 30- a ELECTRICAL SYSTEM MoTORS 9. Disconnect the lead wire from the field coil assembly, 10. Remove the mounting bolts of the pole core. 11. Remove the pole cores and the field coil as- sembly from the yoke. 12. Disconnect the lead wire from the brush holder. 30-8 ELECTRICAL SYSTEM MOTORS 13, Remove the mounting bolts of the holder ring 14. Remove the holder ring from the rear bracket. Parts evaluation: Determine if each partis eccept- able by referring to the applic: able clause in the maintenance standard. 30-9 ELECTRICAL SYSTEM Motors ASSEMBLY Assembly shall be performed in the reverse orderto ssembly paying ettention to the following points: 1. Mounting field coil and pole core After mounting the field coil to the yoke by ‘means ofthe pole core, try ta move the coil back and forth, leftend rightand up and down to con- firm that the mounting is not loose, 2, Mounting the holder ring ‘Set the holder ring (4) on the rear bracket (1) so that the holder ring set-screw hole (2) comes to the center of the slotted hole (3) before tighten- ing the set-screw. 3. Operation of brushes After placing the brushes into the brush holder and setting the brush springs, confirm that the brushes move inside the brush holder smoothly 30-10 ELECTRICAL SYSTEM MOTORS DRIVE MOTOR (FB15GT/18GT) STRUCTURE Save tnt ps n.,. pa al Cr oF ae Armature shaft ass'y 30-11 ELECTRICAL SYSTEM MoTORS DISASSEMBLY 1. Remove the brush band. 2. Remove the mounting screws of the brush lead wire. 3. Remove the brush from the brush holder. 30-12 ELECTRICAL SYSTEM MOTORS o 4. Remove the snap ring of the fan, 5. Remove the fan with the two bolts (thread diameter; 6 mm). “N 30-13 ELECTRICAL SYSTEM moToRS. 6. Remove the mounting bolts ofthe frontbracket. and remove the front bracket. 7. Remove slowly the armature shaft assembly. 8. Remove the mounting bolts of the rear bracket, 9. Remove the rear bracket from the yoke. 30-14 ELECTRICAL SYSTEM 10. Remove the auts for the terminal from yoke. 11. Remave the mounting bolts of the pole core. 12. Remove the pole cores and the field coil asser- bly from the yoke. MOTORS \ KO 30-15 ELECTRICAL SYSTEM MoTORS 13, Disconnect the lead wire fram the brush holder. 14, Remove the nuts for the terminal ftom ‘rear bracket, 45. Remove the mounting bolts of the halder ring. 16. Remove the holder ring from the rear bracket, Parts evaluation: Determine if each partis accept- able by referring to the applic- able clause in the maintenance standard, 30-16 ELECTRICAL SYSTEM MOTORS ASSEMBLY ‘Assembly shall be performed in the reverse order to disessembly paying attention to the following points: 4. Mounting field coil and pote core After mounting the field coil to the yoke by ‘means of the pole core, try to move the coill back and forth, leftend rightand up and down to con- firm that the mounting is not loose. 2. Mounting the holder ring Set the holder ring (4) on the rear bracket (1) 50 ‘thot the holder ring set-screw hole (2) comes to the center of the slotted hole (3) before tighten ing the set-screw. 3. Operation of brushes After placing the brushes into the brush holder and setting the brush springs, confirm that the brushes move inside the brush holder smoothly and without impediment. 30-17 | ELECTRICAL SYSTEM MOTORS PUMP MOTOR (FB15GT-25GT, FB30EX) ‘STRUCTURE Brosh band oN Keo Sy ke~ ce Rear bracker—_| 8 { 8 604 Os Psy aN ft Bj — Helder ing i F* af Jo Brush sting GD) S ( Fiald coll ass'y Pole core Yoke Armature shaft ass'y ‘This ilustration snows zhe #31SGT/18GT model, 30-18 ELECTRICAL SYSTEM DISASSEMBLY 1, Remove the brush band. 2. Remove the mounting screws of the brush iead + wire. 3. Remove the brush from the brush holder. 30-19 MOTORS ELECTRICAL SYSTEM Motors 4. Remove the mounting bolts of the front bracket, and remove the front bracket. 5. Remove slowly the armature shaft assemaly. 6. Remove the mounting bolts of the rear bracket. 7. Remove the rear bracket from the yoke. 30-20 ELECTRICAL SYSTEM 8, Remove the nuts for the terminal from yoke. 9, Remove the mounting boits of the pole core. ( 40, Remove the pole coresand the field coll assern- by from the yoke. 41. Disconnectthe lead wire from the brush holder. 30-21 MOTORS ELECTRICAL SYSTEM MoToRS i 12, Remove the auts for the terminal from rear bracket. 13. Remove the mounting bolts of the holder ring. 14. Remove the holder ring from the rear bracket, Parts evaluation: Determine if each partis accept- able by referring to the applic- able clause in the maintenance standard, ELECTRICAL SYSTEM MOTORS ASSEMBLY ‘Assembly shall be performed in the reverse order to disassembly paying attention to the following points: 4. Mounting field coil and pole core After mounting the field coil to the yoke by ‘means ofthe pole core, try to mave the coilback and forth, leftand rightand up and down to con- firm that the mounting is not loose. +2, Mounting the holder ring Set the holder ring (4) on the rear bracket(1) 50 ‘that the holder ring set-screw hole (2) comes to ‘the center of the slotted hole (3) before tighten- ing the set-serew. 3, Operation of brushes After placing the brushes into the brush holder ‘and setting the brush springs, confirm that the brushes moveinside the brush holder smoothly ‘and without impediment, 30-23 ELECTRICAL SYSTEM motors DRIVE MOTOR (FB20EX(GT)/25EX(GT)/30EX) Armature shaft 30-24 ELECTRICAL SYSTEM MoTORS DISASSEMBLY 4. Removal of fan Remove the snap ring and take out the fan by pulling out the Mé bolt. At this time, pay atten- tion not to lose the key inserted into the shaft section. 2. Remove the brush cover and lift the brushes from the commutator surface, (So that the commutator is not demaged.} 3. Remove the front bracket fixing bolt and i Femove the front bracket. 30-25 ELECTRICAL SYSTEM L morors é 4, Pull out the armature shaft ass'y smoothly. (When doing this, be very careful nottodamage the commutator surface. 5. Logsen the brush holderterminal bolttodiscon- ect the field coil wires from the brush holder and remave the wiring. 6. Remove the rear bracket fixing bolt. 7. Remove the rear bracket from the yoke. The sbove step concludes the disassembly to enable internal inspection. Any further disas- sembly may be made when necessary but it is suggested not to attempt to separate the field coil and core since they are tightly fixed with resin Parts evaluation: Determine if each partis accept- able by referring to the applic able clause in the maintenance € standard, 30-26 ELECTRICAL SYSTEM : MoToRS ASSEMBLY ‘Assembly shall be performed in the reverse order to disassembly peying attention to the following points: 1. When assembling, confirm that the relative po- sition and direction of the brush holder and brushes is the same as before disassembly. '* Relative position means: that the brush formerly placed inthe brush holder A should be put back in brush holder A. * Directivity means: that ifthe a-side of the brush was directed to the riser side, the same side should be set in the seme direction at reassembly. (Do not reverse the directions of the a and b sides from those be- fore disassembly.) fiser / Srush 7 6 Commutator 2. When reassembly is completed, try to turn the armature by hand to confirm correct reassem- bly. (Atthis time, itis suggested that the brushes be separated from the commutator to facilitate checking.) 30-27 ELECTRICAL SYSTEM MoToRS CHECK AND INSPECTION OF DRIVE MOTOR FB10EX/14EX/15EX/18EX, FB1SGT/18GT Measurement boidieke re <_< Standard dee (nm) Toleronae imictmms | OMe Outer ci. of commutator | Canes 70 707 Replace Undeeut depth caliber 06s Tarnow Fepair Deacon of armature sak [Dial gouge = Tess than 02 ‘armature insulation Meggor (068000) — [8 Me or more Field eo nevation eager (005000) 7 CSwDormoe | heplace i Insulation of holder ring Megger {DCSOOV) - 0.5 MQ or more Pushing force of bush saring | Spring blence a 7 Brosh height Calipers = 2 FB20EX/25EX, Faz0GT/25GT eee “Sat” Saadowia [Tamme] Outer Gi, of common eaters 18 Te eslece Datecton of armature shat | Dal anuse = iets hen? ‘Armature inaction ‘Meyer C5000) = TOMO oF mora cl nauiion ‘Meoger (BCS00¥) = TOMermae | Revlace Teslaton ofhoiter ing | Mega C5000) = 19 Mi or more Pushing force of brush saving | Sorina balance 1 388 Ke Brush height Calipers B 3 FBSOEX jeasurement Cries Outer dia, of eommuraior [Cainer 70 17 Rapiace | Uneraut depth Caliers 73 as er more Reneir “2 Detecion of amare shake [Dial age] = [es than 02 Armature naulon ‘egger 0630041 = [hon oro Fle ci naulation Mager (0C500v) 7 TOM@ormore | Replace Insulation of older ne | Megger 0¢3001 7 2OMG armors Pasting force of push sang | Spring balance Tai 28 6 Brush heighe atners = = the commutator using # 400 sandoaper. Repair ~2: Undercut mica and polish the surface of the commurator usng # 600 sendgaper. 30-28 ELECTRICAL SYSTEM MOTORS CHECK AND INSPECTION OF PUMP MOTOR 1 FB10EX/14EX/15EX/18EX. FBISGT/186T Inspection terns Measurement one Romady Siandard sae (rim) | Taterance it (mrt Guier dia afcommutator | Calipers 2 7 Reviace Undereut depth Calpers ams 2 or more Feptirt Defiecion of amature shah [Dial gauge = iess than 02 ematare inslaion | Maguer (065000) = DE MB or mare ald coi insulation eager (005000) = GsM@ ormore | ‘Replace inaulaion ofholder tna | Meage”(BC5000) 7 05 MO or more Pushing free of brash spring _| Spring balance Take a Brush height Calne 3 Z #B20EX/25EX, FB20GT/2SGT. FBOEX insaection items Measurement or Remedy Sranderd wee trend _[ Tolerance li Durer Gia afeommursior | Calne ve a7 Replace Underevt dept Catoers a8 Od or more Feraie“ Deflecion of amnature sak | Dial gauge = Tees than 02 ‘armature insulation eager (065000) = TEMG or mere Fed eal insulation eager (OCS00V) 7 GEMDormore | Replace insulation of hater ing | Meager (DCS00Vi 7 05 MO oF more Pushing force of brush spring | Sering Balance Se 709 Brush neigh Caters a Zz Repair *1: Undercut mica and polish the surface of the commutator using # 400 sandpaper. ELECTRICAL SYSTEM CONTROLLERS CONTROLLERS 1. OUTLINE The control device controls the speed of the drive, pump and EPS ar E-FHPS) motors, and consistsofthe fol- lowing units: 1) Controlter This consists of the chopper control section and the contactor section (FR con- tactor, regenerative braking contactor, drive system bypass contactor and EPS. {or E-FHPS) system contactor), and controls the speed of the drive, pump and i EPS (or E-FHPS) motors. 2) FR lever + This FR lever contains two switches for selection of the forward or reverse, 3) Accelerator + This controls the travel speed by changing the ratio of current supplied to the rive motor chopper in accordance with the voltage that varies depending on depress angle of the accelerator pedal. 4) Others s+. PCS (Power Control Switch} volume, torque sensor, etc. 4 2. FEATURES (Some of the following items do nat apply to some models.) 1) Microcomputer controller A microcomputer controls the speed of the drive, pump and EPS motors. 5) Regenerative braking (Plugging and brak- ing) Regenerative brakingis used to increase the Operating time. The regenerative braking 2) Low-noise design force can be adjusted for the type of the A power transistor is used for the drive and work hydraulic choppers to minimize a noise from this control device, 6) Accelerator ‘The accelerator uses potentiometer and soit 3) Increased reliati has high responsibilty ‘The chopper driving method is simplified to increase reliability. 7) Detection of current Since the magnetic detection of current is 4) Self-diagnosties function used, the measuring points are not affected This control device is equipped with the self- Giagnosties function as standard, so that @ feulty location can easily be isolated, TYPES AND EQUIPMENT The following table shows the five types of controllers, bya voltage and no electricity is lost by heet. 8) Speed contral function This control device provides other travel speed control functions. 0: Standard equipment 7 Tyoe af convoiier |Drive/Hycraulic|Seltciagaostics| EPS [EFAS [Regenerative | Gauary Model af it truck ‘Part Na) contrat function | system | system | braking FRIOEX/14EX/186X/18EX7 | $1/3BA-47-41112) | Chopper a of- ° FSTSGT/TaGT7 ‘S1L(98A.47-48111) | Chopper o = [eo o BV FRQUEK/25EX5 '$2(988-47-31112) | Chopper 3 = ° a6v Fe20GT/256T-5 S2L(388-47-35111) | Chopper 3 -[e 2 aa FESOEX-S s31388-47-21212) | Chopper ° e[- °. jav The drive control is equiped with the BP{Bypass} contactor. 30-30 ELECTRICAL SYSTEM CONTROLLERS 4. SPECIFICATIONS Tyne of controller = st sib s2 sa. 83 tem input valioge| ev mv Drive sysiam 330A or more [230A or more (400A or more| [Maximum current imit [Rydraulle system ZIOA or more 300A or more [220A or morel Power steoring sytem AOA or moreliBA or moref!6A or more)!BA or more] 40A or more [Curing off ime at short of the chopper [Drive system 150mis or less eicuie Rated vottase a8 V [Suction voltage 20V or more FR contactor Release voltage ary [Maximum cut off current 70008 e008 Rated voage eV (Suetion votage 0 Wor mare Fe contactor Release vatage TeV (Veximom cut off eurcent 7008 e008 Roxed votage “BV Suction voltage 20 V or mare 1° contactor Release voltage 3a 18V ‘Maximum eut off current 70008, 7E00a ated voltage wav EPS contactor Suction voltage 20V er more E-FHPS contactor rgigase voltage —i5V Maximum eut aff current 308 ELECTRICAL SYSTEM 7 CONTROLLERS 5. EXTERNAL VIEW 1) S1 type (for FB10EX/14EX/15EX/18EX-7) 1. Drive system transistor 2. Drive system diode 3. Drive system forward contactor 4. Drive system reverse contactor 5. Drive system bypass contactor . Drive system current sensor . Drive system fuse &. Drive system temperature sensor 8. Regenerative braking transistor 10. Regenerative braking diode 11. Regenerative braking contactor 12, Regenerative braking resistance 30-32 Hydraulic system transistor |. Hydraulic system diode Hydraulic system current sensor Hydraulic system fuse EPS system transistor (IGBT) EPS system contactor EPS system current detector EPS system fuse Hydraulic/EPS system temperature sensor Condenser 1 for surge absorption Condanser 2 for surge absorption ELECTRICAL SYSTEM t CONTROLLERS 2) StL type (for FB1SGT/18GT-7) 1. Drive system transistor Drive system diode 3. Drive system forward contactor Drive system reverse contactor Drive system bypass contactor Drive systam current sensor _ Drive system fuse . Drive system temperature sensor Regenerative braking transistor Regenerative braking diode Regenerative braking contactor Regenerative braking resistance 13. Hydraulic system transistor 34, Hydraulic system diode 45. Hydraulic system current sensor 16. Hydraulic system fuse 17. E-FHPS system transistor 18. E-FHPS system contactor 19, E-FHPS system current detector 20. E-FHPS system diode 21. E-FHPS system fuse 22. Hydraulic/E - FHPS system temperature sensor 23. Condenser 1 for surge absorption 24. Condenser 2 for surge absorption 30-33 ELECTRICAL SYSTEM 10. 1" 12, 3) 82 type [for FB20EX/25EX-5) Drive system transistor Drive system diode Drive system forward contactor Drive system reverse contactor . Drive system bypass contactor Drive system current sensor Drive system fuse . Drive system temperature sensor |. Regenerative braking transistor Regeneretive braking diode Regenerative braking contactor Regenerative braking resistance CONTROLLERS ¥ 13 14, 16. 17, 18. 18, 20. 2 22 23 30-34 Hydraulic system transistor Hydraulic system diode Hydraulic system current sensor Hydraulic system fuse EPS system transistor (IGBT) EPS system contactor EPS system current detector EPS system fuse Hydreulic/EPS system temperature sensor Condenser 1 for surge absorption Condenser 2 for surge absorption ELECTRICAL SYSTEM CONTROLLERS 4) S2L type (for FB20GT/25GT-5) Drive system transistor . Drive system diode Drive system forward contactor Drive systam reverse contactor . Drive system bypass contactor Drive system current sensor Drive system fuse . Drive system temperature sensor Regenerative braking transistor Regenerative braking diode |. Regenerative braking contactor Regenerative braking resistence 13, Hydraulic system transistor 14. Hydraulic system diode 15. Hydreulic system current sensor 16. Hydraulic system fuse 17. E-FHPS system transistor 18. E-FHPS system contactor 19, E-FHPS system current detector resistance 20. E-FHPS system diode 21. E-FHPS system fuse 22. Hydraulic/E - FHPS system temperature sensor 23. Condenser | for surge absorption 24. Condenser 2 for surge absorption ELECTRICAL SYSTEM. 5) S3 type (for FB30EX-5) 1. Drive system transistor 2. Drive system diode 3. Drive system forward contactor 4. Drive system reverse contactor 5. Drive system bypass contactor 6, Drive system current sensor 7. Drive system fuse 8. Drive system temperature sensor 8. Regenerative braking transistor 10. Regenerative braking diode 11, Regenerative braking contactor 12, Regenerative braking resistance 13, 14, 15 16. 7. 18, 12, 20, 21 22, ‘CONTROLLERS 13 Hydraulic system transistor Hydraulic system diode Hydraulic system current sensor Hydraulic system fuse EPS system transistor (IGBT) EPS eystem contactor EPS system current detector EPS system fuse Hydraulic/EPS system temperature sensor Condenser 1 for surge absorption Condenser 2 for surge absorption 30-37 6) S1, S2 and $3 Type (for EX type) 6. CHOPPER CIRCUIT Drive system fuse Power steering (EPS or E-FHPS) system fuse Hydraulic pump system fuse Drive system transistor + Hydraulic eystem transistor Regenerative braking transistor E-FHPS system transistor Drive system flywheel diode + Drive system plugging diode + EPS system transistor (IGB7) + EPS system transistor (ISBT) Regenerative braking diode Hydraulic system flywheel diode + E-FHPS system flywheel diode Forward contactor S. Reverse contactor + Bypass contactor Regenerative braking contactor + Power steering (EPS or E-FHPS) system contactor Regenerative braking resistance © Power steering motor current detector (Shant type) Condenser for surge absorption Drive motor current sensor Hydraulic pump motor current sensor Sattary 4av ‘SIL {FB15GT/18GT-7) eo is lL. RE | a roa def Pie] Lf Alo Bs ace boson Hydraulic control section S2 [FB20EX/25EX-5} Drive control section Re 1 ney | “7 Aigh Hycrautie control section E-FHPS eontrol section Drive control section S21 (FB20GT/25GT-5) 7 2, 7 ved Bek Hysroulle control section EPS control sftion 83 (FB30EX-5} Drive control section Hydraulic control section EPS control scstion Drive control section Drive control seesion Hydraulic control section E-FHPS control section. 30-38 ne st rarsar/iecr-7 Ber = oe C i val Ise =f ree] Of Bites 7 Let i! et} Der hay | | Panne i cpm | : wal She : eel a 5 Ge we TEES t t 3 om 7 | ° “t eal Aa = omSotsaier Waa cael ecdon BAW mal ncimn” bow oor ha € 30-38 CONTROLLERS ELECTRICAL SYSTEM 7. LOCATION OF CONTROLLERS FB10EX/14EX/15EX/18EX-7 Contralae FBISGT/18GT-7 30-39 CONTROLLERS ELECTRICAL SYSTEM FB20EX/25EX-5 30-40 ELECTRICAL SYSTEM ' CONTROLLERS 8, ELECTRICAL COMPONENTS 1) Diode ‘The diodes are devices which allow a cur- rent to flow in one direction only, and they ere modularized. Drive system diodes module {4BV and 72V) This module contains two drive system diodes (for plugging ang flywheel). Hydraulic system diode module (48V and 72V) This module contains hydraulic system diode {far flywheel Regenerative braking diode module (48Vand 72V) This madule contains a regenerative brak- ing diode (far converting the energy to the battery, {Hydraulic system/regenerative braking diode module} 2 CPU card (printed circuit card) “The heartof the microcomputer consists of several special components such as the * CPU of contains the "* ROM and iC. 1) Drive/nydraulic/EPS system chopper control circuits (2) Drive/hydraulic system soft start cie- cults (3) Drive/hydraulic/EPS system current limit circuits (a) Drive/hydraulic/EPS system runaway prevention circuits (6) Drive/hydraulic/EPS system contactor ON circuits {6) Regenerative braking circuit (7) Self-diegnostic circuit * CPU; Control Processing Unit ** ROM; Read Only Memory 30-41 ELECTRICAL SYSTEM 3) Power transistor ‘The power transistor is fitted to the fin cooling plate| by installing screws through the holes on the metal seat, The metal seat the collectar, and the terminals E and B are respectively the emitter and the base Sending a current to the hase turns ON the transistor, © 801 jee Current sensor ‘The current sensor measures the quantity of magnetism proportional toa motar cur- rent, and accordingly supplies a propor- tional output voltage. it then applies this output voltage te the current limit circuit in ‘the CPU card to reduce the ratio of current supplied tothe chopper te limitthe current, 4 5) Fuse ‘The fuse protects the contral device from an over-current. When an excessive cur- rentis suddenly supplied, the fuse accumu- lates most of the heat in the fuse-element ind immediately starts melting, It can eas- ly be seen when the fuse has melted since the color of the circular display atthe center of the cylindrical case changes from white to black. The type of the fuse is BF, which contains a fuse-element and arc-extinguishing ma- terial that quickly extinguishes arcs during melting to prevent damage to the control device. 6) Thermister ‘The thermister is used for the temperature sensor of transistor, and supervises an ex- cessive temperature rise to prevent dam- age toit. Ifthe temperature exceeds a spe- cified value, the temperature-sensor o- ‘wers the current limit (mator current) to prevent overheating of the power transis: tor, 30-42 CONTROLLERS ELECTRICAL SYSTEM 7) Regenerative system transi The regenerative system transistor is fitted to the base plate in the controller by instell- ing serews through the holes on the metal seat. The metal seat is insulated from the internal circuit. The terminals C, E and B are respectively the collector, the emitter and the base. Sendinga currenttothe base turns ON the transistor. a @ + et ob 21/02 The EPS system transistor is fitted to the base plate in the controller by installing screws through the holes on the metal seat ‘The metal seat is insulated from the inter- nal circuit, The EPS system transistor con sists of two transistars, as shown in the above figure. The terminals C1, £1 and BY are respectively the collector, the emitter and the gate of the upper transistor. The terminals C2, £2 and B2 are respectively the collector. the emitter and the gate of the lower transistor, Sending a current to the gate turns ON the transistor. CONTROLLERS Top view 30-43 ELECTRICAL SYSTEM i CONTROLLERS H « 9} FR contactor Thismagnetic switch consists ofthe forward contactor (FC) andthe reverse contactor (RC), and changes the direction of travel between forward and reverse. Each contactor hasa pair of contacts, which opoee or closes when voltage is applied to the exciting coil of FC or RC. Forward and reverse switching (A) Neutral (both FC and RC are inactive) (B) Forward (FCis active) _(C) Reverse (RC is active) ' 1 Fo RC FC RC FC Re When the FC closes as shown in Figure (B}, 2 ‘This way, changing the direction ofthe current flow- current flows along the exerting coll fom let to ing along the exciting coil can invertor return the ro- right to normally rotate the drive maton When tation dizection of the drive motor to switch the the RC closes as shown in Figure (C), # currect rection of travel between forward and reverse. flows along the exciting coll from right 0 left to reverse the drive motor. feverse the drive moto a Operation sequence of contactor and power transistor D Neutral @ ContactorON @ TransistorON © Transistor OFF 3 Contactor OFF (reverse) e e : e Q 7 £ 2 (mn) & é FI Re FC, IRC FC, Re Femi FC, YRC € ° 3! $ ; t y The FAicontactoranéthepowertransistoroper- __ when amotorcurrentisentered orbroken, the aper- ate in the order illustrated sbove ations shown above are not performed correctiy. Since the contactor does not emer or break a The coilis connected with diodes in parallel on the motor current, the contacts do not damage. If CPU card) to suppress surge voltage occurring amarcoccursatthe contacts ofthe FR contactor = when an exciting current is broken. - 30-44 {ELECTRICAL SYSTEM CONTROLLERS 10) m 12) Regenerative braking contactor (RB con- actor) The AB contactor is used for regenerative braking, Turning ON the key switch closes the AB contactor. It opens at plugging and forms the regenerative braking circuit. EPS, E-FHPS system contactor The EPS (or E-FHPS) system contactor is used for the EPS lor E-FHPS) system chop- per. Turning ON the key switch closes the EPS system contactor. When the EPS system chopper circuit becomes inoperative, the EPS system contactor opens to disconnect the EPS motor circuit, and consequently the steering wheel changes to manual mode. Bypass contactor (BP contactor] This magnetic switch short-circuits the drive system transistor. This contactor closes when the tuck travels at high speed or goes up a slope with the accelerator in full admission. 30-45 ELECTRICAL SYSTEM CONTROLLERS! 9. PRINCIPLE OF DRIVE MOTOR SPEED CHANGE ‘The drive motor is of the OC series, This type of motor provides high starting and climbing power like an ox, and high speed like @ horse. So itis used not only forthe Shinkansen (Bullet) trains and electric locomotives, but also for bat- tery lift trucks. The speed control system is Gf the DC chopper type. The work “chopper” means a intermitting device. The DC chopper turns on and off linter= mits} the DC voltage by means'afa semiconduc- ‘or switch to continuously vary the voltage ap- plied to the motor. This allows a smooth, effi- cient speed control because there are no parts, like a resistor which consume’ power. In Figure (A) an the right, the motor, switeh and battery are connected in seties.’ When the switch is quickly turned on and off, the motor cannot follow this operation ‘because of the inertia of rotation, and it smoothly rotates. The ‘meen voltage applied to thé motor is rap- resented by the following equation, where “t” is. the time thatthe switch is ONand "Tis the dura- tion of the cycle: ‘Vy (Mean voltage of mator) = Vy (Battery voltage) x t/T ‘The expression t/T is the ratio of the time the switch is ON, and is called the ratio of current. Figure (B) shows the condition of voltage when the motor is running at low speed. Figure (C} shows the concition of voltage when the motor is running at high speed. For the switch shown in Figure (A), @ power ansistor oF @ semiconductor switch (SCR) is used because the contacts of a mechanical switch are immediately damaged. 30-46 Vig (Mean voltage) Time (8) Low-speed rotation TY (C) High-speed rotation ELECTRICAL SYSTEM L CONTROLLERS 4) Toturn ON the FSW, turn ON the key ewitch, and shifted the FR controller lever forward. This activates the forward contactor FC and connects the exciting coil ofthe motor to the Grmature. Depress the accelerator pedal hhas the CPU card senda signal activating the power transistor TR, so thata currents sup pliad to the motor. 7 2) To tum OFF the power transistor TA, turn revs Sey switch Ger the base current. The current in the . Sroror continues to flow through the fly- i a | Genanen A ( oe Fave Repeating the above twostens operatesthe chopeer Depressing fully the acceleratorpedel increases the ae peaf current or the chopper beyond 96%, so that the travel speed increases. ‘This also applies to the hydraulic system chopper. 30-47 ELECTRICAL SYSTEM CONTROLLERS 10. CONTROL FUNCTIONS 1) Change of travel direction and speed control are iteetion of FA lever end depress angle of the accelerator pedal changes the direction of travel and the speed in stepless. 2) Limiting of current The maximum level ofthe current supplied to the motors controlled so thet the value stored on the CPU Card is exceeded, to prevent damage to the motor and transistor, 3) Overheat prevention The jomperature sensor for the transistor supervises a rie in temperature.’ When the temperature ex- Gee SC the temperature sensor lowers the ratio of current andlimits the aureus re prevent damage due to overheating, 4) Regenerative braking he egenerative braking has improved the braking force, extending the life of motor ‘brushes, and also extending the operating time per charge. ime regenerative braking converts the braking energy toelectricity and charge the battery in the follow- ing sequence of motions. When the FA leveris shifted while traveling, the CPU can monitor the lever shift byway of the switch wir- GS,And the CPU can monitor the truck traveling in the situation by way of the eee speed sensors, The SFid can then monitor the reasnerative braking through bath signals fom the Famers and the speed sensors. AS the C°U monitors the regenerative braking, the AB contactor is tumed OFF and the RE transistor ig The netcs stantaneously (approx. 80 ms}, sending electric current to the motor nel cern magnetize ong Nelgccl Then, electricity is generetedin he armature coll and part ofelectity ‘supplied tothe field coil to continue the generation, {heeneray thus generated is transmitted to the battery through the RB diode to ‘charge the battery. When, On eagel sBeed lowers to araund 2km/h, the CPU stops the regenerative brekingtowenteene contactor ON, starting the plugging operstion, FR switch on. ox 1 I Forward wove! —~ye——fegenerave trsting—_— 1a Motor current rave The braking force of the regenerative brake can be adjusted by the volume on the CPU card. 30-48 ELECTRICAL SYSTEM : CONTROLLERS 5) Travel speed control function Using a volume in the CPU card can control the maximum ratio of current so that the maximurn travel speed is not reached when the accelerator is in full admission. This function is useful to use safely the truck in a small space. A circuit for canceling the setting of the maximurn ratio of current is also provided to allow the truck to travel at a higher soeed afterit moves to 2 large place. 6) Lift speed limit function Using the volume LIFT inthe CPU card o- lift PCS on operating panel can controlthe maximum ratio of Cur Tent when raising the fork so that the maximum lifting speed is not reached when the liftlever is setto the maximum speed position. Adjust the maximum ratio of current according to the conditions of cargoes, such as whether they are easy fall down. Using the volume TILT or ATT (Attachment) in the CPU card can control the maximum ratio of current. 7) Runaway prevention circuit This curcult opens the FR contactér when the power transistor shor-circuits. 8) Low voltage protection circuit “This circuit opens the FR contactor when the supply voltage drops below a limit (when over discharge oc- curs) to prozact the controller. Note: This circuit does not protect the battery. To detect anover discharge from the battery, see the bat- tery meter. 9) Hydraulic motor chopper Start contral: This chopper prevents an excess current from generating when the hydraulic motor starts. ‘Speed control: This chopper controls the rotation apaed of the hydraulic motor in accordance with the type of operation (such as lifting and tilting) and the angle of the operating lever. Note: The hydraulic motor chopper helps extend the life of the hydraulic motor brush and save energy. 30-49 ELECTRICAL SYSTEM CONTROLLERS 11. SETTING THE CONTROL FUNCTIONS Volumes | Deton swish seal Claes tm No [Name 1 | SPEED | operation panei | Cons hE maximum Havel aver speed neraaues OFT [UR swieh Sets the Ing speed The iting speed inreases ATT [Attachment switch | Sete the snachment =pse0 | The anachment speed increases «| me - Gono the regenerative Baling | Ths braking force increases 5 TILT Tilt switch Sets the tilting speed The tilting speed increases Volumes location 30-50 ELECTRICAL SYSTEM 12, CHECKING OF ELECTRICAL COMPONENTS 1) Preparation before voltage check and current check (1) Insert blocks under the frame to lift up approx. 10 cm (3.9 in) the front wheels. (2) The tilting forward and lower the mast (3) Remove the mounting bolt for the rear checking cover. Note: Before performing a voltage check and currant check, be sure to make the above preparations. Lower the forks. (1) Disconnect the battery plug. (2} Measure the voltage between the bat tery plug (+) and plug (—} byusing a tes- ter. Set the tester to the more than D.C 100 valk range (150 — 300 V). Connect the tester's plus probe to the battery plug (+) and connect the minus (-} probe to the plug (— Voltage Judgement Battery voltage (48V or 72V)| Good Tower than battery voltage | Re-charging 30-51 CONTROLLERS ELECTRICAL SYSTEM 3} Checking the drive fuse (7) Make preparation before voltage check and current check, (2) Ser the tester to the more then D.C 100 volt range {150 ~ 300 V), Connect the tester’s minus (—] probe to the control- ler minus (—} terminal (3) Then connect the tester’s plus (+) probe to the upper side terminal on the drive fuse and measure the valtage, Voltage table : Messing seee Volz udgemens orer ica ev Sood tereinat w Repoce the hae Lower ice terminal a = 8V: etter Voltage 4) Checking the hydraulic fuse (1) Make preparation before voltage check and current check. (2) Set the tester to the more than D.C 100 volt range (150-300 V}. Connect tes- ter’s minus (—) probe to the controller minus (~) terminal, (3) Then connect the tester’s plus (+) probe to the upper side terminal on the hydraulic tuse and measure the voltage. Voltage table Measuring atace Vvotage “Tudgemnent Upper sice ev Good termina w Raplace the fe a. Good BV; Bonery Vous 30-52 CONTROLLERS: ELECTRICAL SYSTEM 5) Checking the power steering fuse (1) Make preparation before voltage check and current check. (2) Set the tester to the more than D.C 100 volt range (180 ~ 300 V). Connect the tester's minus (~) probe to the controller minus (-} terminal. (3) Then connectthe tester's plus (+) probe to the lower side terminal on the power steering fuse and measure the voltage. Voltage table Measuring lace Votoos | Judgement Terminal | Wire color 7 Loversige | Whi | BV | Good Black (ov _ | Replace he fuse Unser side | whine | @V | Good BV: Banery Volage 6} Preparation before continuity check (1) Lower the forks. (2) Disconnect the battery connector. (3) Remove the mounting bolt for the rear checking cover. (4) Disconnect the wiring connector for CPU card. (8) Remove the CPU card mounting plate with the CPU card from the controller. 30-53 CONTROLLERS ELECTRICAL SYSTEM CONTROLLERS 7) Checking the drive power transistor (1) Make preparation before = continuity check. (2) Remove the buss-bar for drive power transistor. (3) Remove the all wires for drive power transistor. Note: Record the connection to each ‘terminal so that rewiring cen be performed correctly. (4) Set the tester to the resistance range { and measure the resistance value (2) between the each position by below table. (8) Judge the good or No-good by measured resistance value, Posiion _[Prabe (1 [Probe (+)] Standard valve 8 © | Apprex. e000 Approx 50.9 ‘Approx 80 2, S2t ane 83 type ‘Approx a0 2 ‘Approx 1100 0 x|>|m| ol mele > ( 8) Checking the Diode Drive system flywheel diode (2) Hydraulic system flywheel diode (8) Drive system plugging diode (@} Regenerative braking diode (S) (1) Make preparation before = continuity check, (2} Set the tester to the resistance range and measure the resistance value (Q) between the each position by below ‘able. (3) Judge the good or No-good by meesured resistance value, Postion [Probe )|Proce i] Senaara vaae [a «| Aspren. 7005 Leal = ELECTRICAL SYSTEM 9} Checking the hydraulic power transistor (1) Make preperation before a continuity check. (2)Remove the buss-bar for hydraulic power transistor. (3) Remove the all wires for hydraulic power transistor. Note: Record the connection to each terminal so that rewiring can be performed correctly. (a) Set the tester to the resistance range and measure the resistance value (9) between the each position by below table. (8) Judge the good or No-good by measured resistance value, Position [rane (~i[Probe (=| Standerd value 2 © _| Approx. 8009 B-c e 3 = 2 | Aporox. 30.0 e = a | Approx. 900 cme = | Approx. 00 2 A ‘Anprox. 1100. ack « a = 10) Checking the regener sistor (All controller types) and the E-FHPS transistor (SiL, S21 types} (1 Make preperation before @ continuity check. (2) Remove the all wires for RB transistor and E-FHPS transistor. Note: Record the connection to each terminal so that rewiring can be performed correctly. (9) Set the taster to the resistance range and measure the resistance value (2) between the each position by below table. (4) Judge the good an No-good by measured resistance value. Posen [Prabe [Probe imi] Standere value = | Aaprox. 500 2 c 5 = [ Aoprox. 306 2 [ aesrox 3002 [se eee [| Aprox. 300.0 30-55 CONTROLLERS ELECTRICAL SYSTEM 11) Checking the EPS power transistor (Controller $1, $2 and $3 type only) (1) Make preparation before a continuity check. (2) Remove the all wires for EPS power transistor. Note: Record the connection to each terminal so that rewiring can be performed correctly. 1 (8) Set the tester to the resistance range and measure the resistance valve (Q) between the each position by below table. 4[4) Judge the good or No-good by measured resistance value Position [Probe -||Probe (H] Stancard value et ct = are a a = a = = 7 a = a & = cae & 1 _| Approx. 650 9 a | @ = ao 2 22 = 22 5 = Bn a | = @ 2 = ee 22 c2_| Aparex. 650.0 2 |__| Approx 1308 12) Checking the EPS motor current limit (controller S1, S2 and $3 type only) (1) Set the ampere meter on the wire for EPS motor, (2) Measure the current when the steering wheel is turned until stroke end clock- wise (to right) or counterclockwise (to a left), (S)Judge the good or No-good by measured current value. Current] Judgement More than 204 Good NGIEPS power transistor or coment resistance for current defector) Lower than 0A CONTROLLERS 30-56