Be30 (FB-11) [PDF]

Zitiervorschau

ELECTRIC LIFT TRUCK

FB10EX/14EX/15EX/18EX-11 FB15EXG /18EXG-11 SERIAL No. 807001 and up

FB20EX/25EX-11 FB20EXG /25EXG-11 SERIAL No. 814001 and up

FB30-11 SERIAL No. 814001 and up

SECTION INDEX 10. GENERAL AND SPECIFICATIONS

20. TESTING AND ADJUSTING

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

70. TROUBLESHOOTING

80. CRITERIA FOR YEARLY INSPECTION

BE30 Series

00-3

FOREWORD For a machine and its components to maintain their performance for a long time, it is necessary to carry out appropriate operation, preventive maintenance, troubleshooting, and service to prevent failures or problems before they occur. Of these operations, this shop manual gives information mainly on operations carried out at a repair shop. These include an outline needed for service and maintenance operations, together with details of the structure and function, inspection and maintenance, installation and removal, disassembly and assembly, maintenance standards, troubleshooting, and periodic inspection and adjustment of components for the machine. The units given for tightening torques in this manual use the SI units as the standard, so a conversion table is given at the end of the section. This shop manual has been prepared with the target of making materials that will help you to gain proper knowledge of the product, its structure and function, and proper methods for maintenance, to use proper judgement and remedies when there is a failure or problem with the machine, and to improve the quality of maintenance. Always be sure that you fully understand the contents of this manual together with the Operation and Maintenance Manual, and make full use of it when handling the machine.

In this manual, for simplification, the weight categories of the machine may be used instead of the model name. Weight category 1

BE30 Series

Model name

ton truck

FB10EX

1.35 ton truck

FB14EX

1.5 ton truck

FB15EX / 15EXG

1.75 ton truck

FB18EX / 18EXG

2

ton truck

FB20EX / 20EXG

2.5 ton truck

FB25EX / 25EXG

3

FB30

ton truck

00-5

PRECAUTIONS WHEN PERFORMING THE SERVICE WORK Always pay attention to "Safety" before starting any work – this is important. Never attempt any work where danger to yourself or to other persons. Whenever work requiring safety precautions are described in this manual, a flag mark inserted, always make double sure that safety measures are taken. Other unmarked work, should always be performed after studying and using your common sense to prevent accidents.

DESCRIPTION OF THE SYMBOLS The symbols described below are used in this manual for convenience and better understanding Symbol

a

Item Safety

Special safety precautions are needed to perform the work.

Note

Special technical precautions are needed to perform the work.

Tightening torque

Fastening parts that require specified tightening force when assembling.

Weight

Coat

00-6

Description

Weight of parts or systems.

Places to be coated with adhesives, etc. When assembling.

BE30 Series

10. GENERAL AND SPECIFICATIONS Outside view and specifications . . . . . . . . . . . . 10- 2 Periodic replacement of consumable parts . . . 10- 5 Safety items for maintenance. . . . . . . . . . . . . . 10- 6 Standard tightening torque for bolts . . . . . . . . . 10-12 Standard tightening torque for pipe joints . . . . 10-13 How to use loctite. . . . . . . . . . . . . . . . . . . . . . . 10-14 Conversion table . . . . . . . . . . . . . . . . . . . . . . . 10-15

BE30 Series

10-1

OUTSIDE VIEW AND SPECIFICATIONS

GENERAL AND SPECIFICATIONS

OUTSIDE VIEW AND SPECIFICATIONS FB10EX-11 – FB18EX-11 Item

Unit

FB10EX-11

FB14EX-11

FB15EX-11

FB18EX-11

kg

1000

1350

1500

1750

• Performance Rated capacity Load center Std. mast lift height

A

mm

500

500

500

500

mm

3000

3000

3000

3000

Lifting speed (loaded)

mm/s

360

350

340

340

Travel speed (unloaded)

km/h

17

17

17

17

% (degree)

22.0 (12.5)

20.0 (11.5)

19.0 (11.0)

17.0 (9.5)

2930

2965

Max. gradeability (loaded) • Dimensions, weight Overall length (with std. forks)

B

mm

2775

2930

Overall width (at tire, single)

C

mm

1070

1070

1115

1115

mm

1970

1970

1970

1970

D

mm

2095

2095

2095

2095

E

mm

135

140

140

140

Fork length

F

mm

770

920

920

920

Wheelbase

G

mm

1250

1250

1250

1250

kg

2510

2715

2905

3080

Overall height

Mast lowered Overhead guard

Free lift (overall mast height)

Service weight (with standard battery) • Motor output Drive

kw/h

AC 7.3

AC 7.3

AC 7.3

AC 7.3

Pump

kw/5min

DC 9.0

DC 9.0

DC 9.0

DC 9.0

kw/h

DC 0.4

DC 0.4

DC 0.4

DC 0.4

Front tires

–

6.00-9-10PR

6.00-9-10PR

21x8-9-14PR

21x8-9-14PR

Rear tires

–

5.00-8-8PR

5.00-8-8PR

5.00-8-8PR

5.00-8-10PR

PS • Tire size

10-2

BE30 Series

GENERAL AND SPECIFICATIONS

Item

OUTSIDE VIEW AND SPECIFICATIONS

Unit

FB15EXG-11

FB18EXG-11

• Performance Rated capacity Load center Std. mast lift height

A

kg

1500

1750

mm

500

500

mm

3000

3000

Lifting speed (loaded)

mm/s

340

340

Travel speed (unloaded)

km/h

17

17

% (degree)

19.0 (11.0)

17.0 (9.5)

Max. gradeability (loaded) • Dimensions, weight Overall length (with std. forks)

B

mm

3150

3150

Overall width (at tire, single)

C

mm

1115

1115

mm

1970

1970

D

mm

2095

2095

Free lift (overall mast height)

E

mm

140

140

Fork length

F

mm

920

920

Wheelbase

G

mm

1470

1470

kg

3105

3305

Drive

kw/h

AC 7.3

AC 7.3

Pump

kw/5min

DC 9.0

DC 9.0

kw/h

DC 0.4

DC 0.4

Front tires

–

21x8-9-14PR

21x8-9-14PR

Rear tires

–

5.00-8-8PR

5.00-8-10PR

Overall height

Mast lowered Overhead guard

Service weight (with standard battery) • Motor output

PS • Tire size

BE30 Series

10-3

OUTSIDE VIEW AND SPECIFICATIONS

GENERAL AND SPECIFICATIONS

FB20EX-11 – FB30-11 Item

Unit

FB20EX-11

kg

2000

FB25EX-11 FB20EXG-11 FB25EXG-11

FB30-11

• Performance Rated capacity Load center Std. mast lift height

A

2500

2000

2500

3000

mm

500

500

500

500

500

mm

3000

3000

3000

3000

3000

Lifting speed (loaded)

mm/s

290

260

290

260

260

Travel speed (unloaded)

km/h

16.5

16.0

16.5

16.0

14.0

% (degree)

19.0 (11.0)

16.0 (9.0)

19.0 (11.0)

16.0 (9.0)

16.0 (9.0)

mm

3175

3365

3325

3480

3590

Max. gradeability (loaded) • Dimensions, weight Overall length (with std. forks)

B

Overall width (at tire, single)

C

Overall height

mm

1165

1165

1165

1165

1235

mm

1995

1995

1995

1995

2015

D

mm

2095

2095

2220

2220

2215

E

mm

150

155

150

155

155

Mast lowered Overhead guard

Free lift (overall mast height) Fork length

F

mm

920

1070

920

1070

1070

Wheelbase

G

mm

1400

1400

1550

1550

1600

kg

3530

3960

4100

4230

5090

Service weight (with standard battery) • Motor output Drive

kw/h

AC 10.3

AC 10.3

AC 10.3

AC 10.3

AC 9.7

Pump

kw/5min

DC 10.0

DC 10.0

DC 10.0

DC 10.0

DC 12.6

kw/h

DC 0.6

DC 0.6

DC 0.6

DC 0.6

DC 0.6

Front tires

–

23x9-1016PR

23x9-1016PR

23x9-1016PR

23x9-1016PR

28x9-1514PR

Rear tires

–

PS • Tire size

10-4

18x7-8-14PR 18x7-8-14PR 18x7-8-14PR 18x7-8-14PR

21x8-910PR

BE30 Series

GENERAL AND SPECIFICATIONS

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

PERIODIC REPLACEMENT OF CONSUMABLE PARTS To operate the vehicle safely, replace periodically the parts, which are especially related to safety and fire, on the important replacement parts list below. Since the materials change as time goes, these parts are subject to wear and degradation. But, it is hard to judge the degree of deterioration in the periodic maintenance. Therefore, after a certain period of use, even if no defect is observed, these parts should be replaced with new ones to maintain the vehicle in the safe condition. However, if any abnormality is found on these parts before periodic maintenance, repair or replace them. When replacing the hose, if the degradation of hose clamp such as deformation and crack is found, replace the hose clamp at the same time. The periodic replacement is not covered by the warranty. Important Replacement Parts List No.

Part name

Years

1

Master cylinder and wheel cylinder caps, dust seals

1

2

Brake hose or tube

1–2

3

Brake reserve tank, tube

2–4

4

Power sttering hose

2

5

Rubber parts of power steering

2

6

Lift chain

2–4

7

Hose of laod handling

1–2

BE30 Series

10-5

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE FOR SAFETY OPERATION USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE • Only persons authorized by the owner or operator of the equipment and having proper certification (local or national) may carry out inspection, maintenance and repairs of the lift truck. If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.

MAINTENANCE LOCATION • When carrying out inspection and maintenance, use a level, dry, dust-free area. • If the work is carried out inside a building, make sure that there is ample ventilation.

PRECAUTIONS FOR INSPECTION AND MAINTENANCE • To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know how to use it. • Before carrying out inspection, lower the forks to the ground and stop the machine. • Do not run the engine unless it is necessary. • Place the directional lever, speed lever, and work equipment control levers in neutral.

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE • Wipe off any oil or grease. Immediately wipe up any oil that has leaked. If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the lift truck before starting inspection. • Do not smoke or allow any flame to exist under any circumstances. Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire. • Wear suitable clothes for the job. • Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the job. • When working on top of the lift truck, be careful not to fall. • Do not put your feet under the forks. • When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught. • When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and mast from dropping. • When carrying out job with another worker, decide who is the leader and carry out the job in accordance with instructions from that person. • After repairing, make sure that the trouble has been corrected by performing a trial run. • During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been fully corrected or that defective parts have not been removed.

10-6

BE30 Series

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS • Avoid loose clothing, jewelry, and loose long hear. They can catch control or in moving parts and cause serious injury or death. • Always wear a hard hat and safety boots. • Depending on the working conditions, wear other safety equipment in addition to the hard hat and safety boots.

USE SUITABLE TOOLS • Always use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools or tools designed for another purpose.

REPLACE SAFETY CRITICAL PARTS PERIODICALLY • Even if no abnormality is found, always replace safety critical parts periodically. As time passes, these parts deteriorate and may cause fire of failure in the work equipment system. • However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately.

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL • Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the filter when the oil is hot. Hot oil may spurt out and cause burns. • When carrying out inspection and maintenance, wait for the oil temperature to go down, and carry out the operation in the order given in this manual. • Do not forget that the work equipment circuits are always under pressure. Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure. • If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits your skin or eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of plywood to check for oil leakage. • Release the internal pressure before checking the accumulator piping. • If you are hit by a jet of high pressure oil, consult a doctor immediately.

BE30 Series

10-7

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS

BE CAREFUL NOT TO GET CAUGHT OR FALL • Never put your hands or feet into the mast structure. There is danger that you will get caught in moving parts and be seriously injured. • Do not use the mast as a ladder. If you slip, there is danger that you will fall.

CHECKING AND INFLATING TIRES • If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immediately. The inflation pressure may have gone down because of damage to the rim. If the rim is damaged or cracked and the tires are inflated, there is danger that the rim will break when the tire is under high pressure, and this may cause personal injury or death. • For safety, when checking tire pressure, place your body in front of the tread face of the tire. Do not check from the side face of the tire. • Suitable qualifications are needed for tire inflation work. Always have the work carried out by properly qualified personnel. • The tire inflation pressure on a forklift truck is several times higher than the pressure on an automobile. When the tires are being inflated, there is danger that dirt or dust may be thrown up by the compressed air and enter your eyes, so always wear safety glasses.

HANDLING OF TIRE Leave disassembly and assembly of each tire to a specialist. Since the tire inflation pressure is very high, you must handle the tire carefully. • Before removing the tire, release the inflation pressure completely. To remove the tire from the chassis, loosen hub nuts (2). • Never touch rim nuts (1), since they are dangerous. • After replacing the tire, perform a test run, then check the mounting nuts for looseness. If the tightening torque of the nuts is insufficient, retighten the nuts to the specified torque. • See the section of tightening torque: [20. TESTING AND ADJUSTING, Service data].

10-8

BE30 Series

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

JACKING UP LIFT TRUCK (when checking or replacing tires) • Do not go under the forklift truck when it is jacked up. • Check the following before jacking up the lift truck. 1) Check that there is no one on the lift truck. 2) Check that there is no load on the forks. • When jacking up, stop when the tires come off the ground surface. Put blocks under both sides of the frame to prevent the lift truck from coming down. • Put blocks under any tires contacting the ground to prevent the lift truck from moving.

LIFTING LIFT TRUCK (when checking tires) • Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting methods. • Fit wire ropes to the specified lifting points. • When lifting the lift truck, check that the wire ropes have ample strength and are not damaged. • Block the tires contacting the ground to prevent the lift truck from moving. • Insert blocks to prevent the truck from coming down. • Do not go under the lift truck during the lifting operation. • If the specified lifting point is the counterweight, check that the counterweight mounting bolts are tightened to the specified torque before carrying out the lifting operation. check also that there is no damage to the lifting portion on the counterweight.

SLINGING VEHICLE (for loading it on trailer, etc.) • Never sling the vehicle by the head guard. If the vehicle needs to be slung often, a special sling device is necessary. In this case, consult your distributor. • The vehicle shall be slung by a person who has completed a course of slinging work. • Install wires to the specified sling parts. • Use wires which is free of defect and has sufficient strength to sling the vehicle.

BE30 Series

10-9

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS

CAUTION WHEN HANDLING BATTERY Handling error of batteries may cause explosions, fires and other critical injuries. Handle batteries after fully understanding how to handle and their hazards. • Batteries generate flammable hydrogen gas and may explode in contact with fire. Always keep the battery hood open while charging batteries. • Do not smoke or allow any flame near the battery. • Sparks may ignite the gas. Do not place tools, parts or other metal objects on the battery. • To clean the battery surface, use wet piece of cloth. Dry cloth may generate static and cause explosion. • Depending on the weather, environmental, clothing material and other conditions, human bodies may deposit and spark statistics. Therefore, before touching lift truck being charged or after charging, discharge statistic deposit in the human bodies by grounding. • Batteries for battery-driven lift trucks store large energy in high-tension. Beware of the risk of electric shock and burns. Be careful to keep human bodies from touching energized portion during maintenance, inspection and/or installation or removal. • Battery electrolyte contains sulfuric acid, and can quickly burn the skin and eat holes in clothing. Always wear protective glasses, rubber gloves and rubber sole shoes for maintenance inspection. • If battery electrolyte gets into your eyes, flush them immediately with fresh tap water for 10 to 15 minutes continually and consult a doctor. • If you spill battery electrolyte on yourself, immediately take off clothes and flush the contact portion of the skin with a large quantity of tap water and consult a doctor. • If one swallows battery electrolyte by mistake, drink a large amount of water or milk mixed with white of raw eggs or salad oil and consult a doctor at once. • If battery electrolyte is spilt or leaked in the surrounding area, neutralize the area with neutralizing agents (baking soda, calcium hydroxide or sodium carbonate, etc.) and wash it down with large amount of water. Or floor surfaces and cargoes will be damaged. • Do not drain battery electrolyte or disassemble or repair batteries, which is dangerous. • If the following abnormalities are detected, please call your Komatsu Forklift distributor/dealer for service: If battery plug and charging plug mating become loosened or play is generated (Plug becomes abnormally heated). If battery electrolyte temperature is high or electrolyte level drops sharply. If charging requires too long time (Charging is not completed although the battery was not used till late hours on the preceding day).

10-10

BE30 Series

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

DO NOT PUT METAL OBJECTS ON TOP OF BATTERY • Never place any metal objects on top of the battery. There is danger that they will cause a short circuit and start a fire. PRECAUTIONS WHEN CHARGING When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. To prevent the danger of gas explosion, always do as follows. • Carry out the charging operation in a well-ventilated place. • Do not smoke or allow any flame. • Start the charging operation when the temperature of the battery electrolyte is below 35°C (95°F). (If the temperature goes above 50°C (122°F) during the charging operation, wait for it to go down below 35°C (95°F) before starting charging operation again.) • When using a battery charger to charge the battery, take the battery caps off.

HANDLING BRAKE FLUID It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped. Always do the following. • Check the level of the brake fluid periodically. • Always use the specified brake fluid. • Check that the breather of the brake fluid reserve tank is not clogged. • Be careful not to let dirt or dust get into the brake fluid reserve tank.

WASTE MATERIALS • Obey appropriate laws and regulations when disposing of harmful objects such as oil, filters, and batteries.

BE30 Series

10-11

STANDARD TIGHTENING TORQUE FOR BOLTS

GENERAL AND SPECIFICATIONS

STANDARD TIGHTENING TORQUE FOR BOLTS TIGHTENING TORQUE when using torque wrench or spanner shall be in accordance with Table. This torque shall be used when TIGHTENING TORQUE of especially narrow range is required. 1.

In the case of using impact wrenches or spanners

2.

In the case of using torque wrenches

Unit: kgm (Nm) [ft. lb]

Thread dia. mm (in)

Width across flats mm (in) Conventional threads

ISO threads

6 (0.24)

10 (0.39)

10 (0.39)

8 (0.31)

14 (0.55)

13 (0.51)

10 (0.39)

17 (0.67)

17 (0.67)

12 (0.47)

19 (0.75)

19 (0.75)

14 (0.55)

21 (0.83)

22 (0.87)

16 (0.63)

23 (0.91)

24 (0.94)

18 (0.71)

26 (1.02)

27 (1.06)

20 (0.79)

29 (1.14)

30 (1.18)

22 (0.87)

32 (1.26)

32 (1.26)

24 (0.94)

35 (1.38)

36 (1.42)

27 (1.06)

41 (1.61)

41 (1.61)

30 (1.18)

46 (1.81)

46 (1.81)

33 (1.30)

50 (1.97)

50 (1.97)

36 (1.42)

54 (2.13)

55 (2.17)

39 (1.54)

58 (2.28)

60 (2.36)

S43C, SMn34CH SMn40CH, SCM3H or superior ones

Unit: kgm (Nm) [ft. lb]

Thread dia. mm (in)

Width across flats mm (in)

S43C, SMn34CH SMn40CH, SCM3H or superior ones

Conventional threads

ISO threads

Range

Torget

6 (0.24)

10 (0.39)

10 (0.39)

8 (0.31)

14 (0.55)

13 (0.51)

10 (0.39)

17 (0.67)

17 (0.67)

12 (0.47)

19 (0.75)

19 (0.75)

14 (0.55)

21 (0.83)

22 (0.87)

1.2 – 1.5 (12 – 15) [8.7 – 11] 2.8 – 3.5 (27 – 34) [20 – 25] 6 – 7.5 (59 – 74) [43 – 54] 10 – 12.5 (98 – 123) [72 – 90] 16 – 20.0 (157 – 196) [116 – 145]

1.35 (13.2) [9.8] 3.2 (31) [23] 6.7 (66) [48] 11.5 (113) [83] 18 (177) [130]

23.5 (230) [170] 32.0 (314) [231] 47.0 (461) [340] 66.5 (652) [481] 82.5 (809) [597]

16 (0.63)

23 (0.91)

24 (0.94)

18 (0.71)

26 (1.02)

27 (1.06)

20 (0.79)

29 (1.14)

30 (1.18)

22 (0.87)

32 (1.26)

32 (1.26)

24 (0.94)

35 (1.38)

36 (1.42)

25 – 31.5 (245 – 309) [181 – 228] 35 – 43.5 (343 – 427) [253 – 315] 50 – 62.0 (490 – 608) [362 – 448] 67.5 – 84.5 (662 – 829) [488 – 611] 84 – 105 (824 – 1030) [608 – 759]

28.5 (279) [206] 39 (382) [282] 56 (549) [405] 76 (745) [550] 94.5 (927) [684]

120 (1177) [668] 155 (1520) [1121] 200 (1961) [1447] 250 (2452) [1808] 300 (2942) [2170]

27 (1.06)

41 (1.61)

41 (1.61)

30 (1.18)

46 (1.81)

46 (1.81)

33 (1.30)

50 (1.97)

50 (1.97)

36 (1.42)

54 (2.13)

55 (2.17)

39 (1.54)

58 (2.28)

60 (2.36)

120 – 150 (1177 – 1471) [868 – 1085] 155 – 195 (1520 – 1912) [1121 – 1410] 200 – 250 (1961 – 2452) [1447 – 1808] 250 – 310 (2452 – 3040) [1808 – 2242] 295 – 370 (2893 – 3628) [2134 – 2676]

135 (1324) [976] 175 (1716) [1266] 225 (2206) [1627] 280 (2746) [2025] 335 (3285) [2423]

Range

Torget

0.9 – 1.5 (8.8 – 15) [6.5 – 11] 1.5 – 3.5 (15 – 34) [11 – 25] 3.5 – 7.5 (34 – 74) [25 – 54] 5.5 – 12.5 (54 – 123) [40 – 90] 8.5 – 20.0 (83 – 196) [61 – 145]

1.2 (12) [8.7] 2.5 (25) [18] 5.5 (54) [40] 9.0 (88) [65] 14.0 (137) [101]

15.0 – 31.5 (147 – 309) [108 – 228] 20.5 – 43.5 (201 – 427) [148 – 315] 32.5 – 62.0 (319 – 608) [235 – 448] 48.0 – 84.5 (471 – 829) [347 – 611] 60.0 – 105 (588 – 1030) [434 – 759] 90.0 – 150 (883 – 1471) [651 – 1085] 115 – 195 (1128 – 1912) [832 – 1410] 150 – 250 (1471 – 2452) [1085 – 1808] 190 – 310 (1863 – 3040) [1374 – 2242] 230 – 370 (2256 – 3628) [1664 – 2676]

a This table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which requir to tighten to otherwise specified torque.

Conventional screw threads

10-12

ISO screw threads BE30 Series

GENERAL AND SPECIFICATIONS

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS Elbows, nipples and unions Width across flats B mm (inch)

22 (0.866)

30 (1.181)

36 (1.417)

Width D mm

19 (0.748)

22 (0.866)

30 (1.181)

29.4 – 39.2 {3 – 4} [21.7 – 28.9]

78.5 – 103 {8 – 10.5} [57.9 – 75.9]

117.7 – 161.8 {12 – 16.5} [86.8 – 119.3]

3/4-16UNF

7/8-14UNF

–

68.6 – 73.6 {7 – 7.5} [50.6 – 54.2]

78.5 – 83.3 {8 – 8.5} [57.9 – 61.5]

–

(inch) Tightening torque Nm {kgm} [ft.Ib] Port size (inch) Tightening torque Nm {kgm} [ft.Ib]

High-pressure rubber hoses, pipes and sleeve nuts Width across flats B (mm) (inch)

19 (0.748)

24 (0.945)

27 (1.063)

32 (1.260)

36 (1.417)

Bore A mm

14 (0.551)

18 (0.709)

22 (0.866)

24 (0.945)

30 (1.181)

(inch)

Tightening torque Nm {kgm} 19.6 – 29.4 {2 – 3} 23.5 – 68.6 {3 – 7} 58.8 – 98.1 {6 – 10} 107.9 – 166.7 {11 – 17} 147– 206 {15–21} [21.7 – 50.6] [43.7 – 72.3] [79.6 – 122.9] [108.52 – 151.8] [ft.Ib] [14.5 – 21.7]

BE30 Series

10-13

HOW TO USE LOCTITE

GENERAL AND SPECIFICATIONS

HOW TO USE LOCTITE 1. PROCEDURE FOR USING LOCTITE Male side Degreasing

Air drying

Female side Leaving

1.

Assembly

Applying LOCTITE

Degreasing and cleaning (a) Clean the parts in trichloroethylene, acetone, ether, alkaline solution, etc. which are highly volatile. (b) Degrease the parts as perfectly as possible. (c) Since gasoline, light oil, kerosene, etc. are not highly volatile, they are not recommended. If it is obliged to use them, dry them completely. (d) If the mating parts are made of thermosetting resin, treat them with LOQUICK PRIMER after degreasing them.

2.

Air drying (a) Wait until the cleaning fluid dries out. (b) If the parts are treated with LOQUICK PRIMER, do not wipe them but dry them in air for 5 – 10 minutes. (If LOCTITE is used before LOQUICK PRIMER dries out, its effect is lowered.)

3.

Applying LOCTITE Apply LOCTITE to either or both of the threads or the shaft and hole to be fitted by amount to fill the clearance between them by one of the following methods. • Applying directly from LOCTITE container nozzle • Dipping (For threads. Use receiving pan.) • Tumbling • Brushing (For shaft and hole. Use receiving pan.) • Sponge • Automatic applier Do not mix metallic foreign matter in LOCTITE or return LOCTITE used in a pan to the container.

10-14

4.

Assembly After applying LOCTITE, tighten the screw or fit the shaft to the hole as usual. (When using LOCTITE for structures or LOCTITE of instant glue type, press the mating parts lightly (about 49 kPa {0.5 kgf/cm2}).

2. REMOVAL OF PARTS When screws and shafts are secured with LOCTITE, they usually can be removed with common tools such as spanners, wrenches, pulley pullers, etc. If LOCTITE is so strong that a part may be broken when it is removed, heat it (to 200 – 250°C) with a soldering iron, gas torch, etc., and you can remove it easily. It is generally difficult to dissolve LOCTITE in chemical solutions.

3. WHEN ASSEMBLING AGAIN (a) If a LOCTITE film on threads is broken, it is left as white powder on the threads. In this case, you can apply LOCTITE again to the threads without removing the white powder. (b) If shafts or flanges secured with LOCTITE are disconnected, LOCTITE remaining on them may need to be removed to maintain dimensional accuracy. You can remove the remaining LOCTITE easily, however, with a wire brush, etc. (c) If plates secured with LOCTITE need to be assembled again after they are separated, be sure to remove all the hardened LOCTITE and roughen the mating surfaces with sandpaper.

BE30 Series

MILLIMETERS TO INCHES INCHES TO MILLIMETERS

GENERAL AND SPECIFICATIONS

CONVERSION TABLE MILLIMETERS TO INCHES 1 mm = 0.03937 in 0 0

1

2

3

4

5

6

7

8

9

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.229

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.254

0.508

0.762

1.016

1.270

1.524

1.778

2.032

2.286

INCHES TO MILLIMETERS 0 0 0.1

2.540

2.794

3.048

3.302

3.556

3.810

4.064

4.318

4.572

4.826

0.2

5.080

5.334

5.588

5.842

6.096

6.350

6.604

6.858

7.112

7.366

0.3

7.620

7.874

8.128

8.382

8.636

8.890

9.144

9.398

9.652

9.906

0.4

10.160

10.141

10.668

10.922

11.176

11.430

11.684

11.938

12.192

12.446

0.5

12.700

12.954

13.208

13.462

13.716

13.970

14.224

14.478

14.732

14.986

0.6

15.240

15.494

15.748

16.002

16.256

16.510

16.764

17.018

17.272

17.526

0.7

17.780

18.034

18.288

18.542

18.796

19.050

19.304

19.558

19.812

20.066

0.8

20.320

20.574

20.828

21.082

21.336

21.590

21.844

22.098

22.352

22.606

0.9

22.860

23.114

23.368

23.622

23.876

24.130

24.384

24.638

24.892

25.146

BE30 Series

10-15

LITER TO U.S. GALLON U.S. GALLON TO LITER

GENERAL AND SPECIFICATIONS

LITER TO U.S. GALLON 1 l = 0.2642 U.S. Gal 0

1

2

3

4

5

6

7

8

9

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

U.S. GALLON TO LITER 1 U.S. Gal = 3.7854 l 0

1

2

3

4

5

6

7

8

9

3.79

7.57

11.36

15.14

18.93

22.71

26.50

30.28

34.07

10

37.85

41.64

45.43

49.21

53.00

56.78

60.57

64.35

68.14

71.92

20

75.71

79.49

83.28

87.06

90.85

94.64

98.42

102.21

105.99

109.78

30

113.56

117.35

121.13

124.92

128.70

132.49

136.27

140.06

143.85

147.63

40

151.42

155.20

158.99

162.77

166.56

170.34

174.13

177.91

181.70

185.49

50

189.27

193.06

196.84

200.63

204.41

208.20

211.98

215.77

219.55

223.34

60

227.12

230.91

234.70

238.48

242.27

246.05

249.84

253.62

257.41

261.19

70

264.98

268.76

272.55

276.33

280.12

283.91

287.69

291.48

295.26

299.05

80

302.83

306.62

310.40

314.19

317.97

321.76

325.55

329.33

333.12

336.90

90

340.69

344.47

348.26

352.04

355.83

359.61

363.40

367.18

370.97

374.76

10-16

BE30 Series

LITTER TO U.K. GALLON U.K. GALLON TO LITER

GENERAL AND SPECIFICATIONS

LITTER TO U.K. GALLON 1 l = 0.21997 U.K. Gal 0

1

2

3

4

5

6

7

8

9

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

U.K. GALLON TO LITER 1 U.K. Gal = 4.5461 l 0

1

2

3

4

5

6

7

8

9

4.55

9.09

13.64

18.18

22.73

27.28

31.82

36.37

40.92

10

45.64

50.01

54.55

59.10

63.65

68.19

72.74

77.28

81.83

86.38

20

90.92

95.47

100.01

104.56

109.11

113.65

118.20

112.74

127.29

131.84

30

136.28

140.93

145.47

150.02

154.57

159.11

163.66

168.21

172.75

177.30

40

181.84

186.39

190.94

195.48

200.03

204.57

209.12

213.67

218.21

222.76

50

227.30

231.85

236.40

240.94

245.49

250.03

254.18

259.13

263.67

268.22

60

272.77

277.31

281.86

286.40

290.95

295.50

300.04

304.59

309.13

313.68

70

318.23

322.77

327.32

331.86

336.41

340.96

345.50

350.05

354.60

359.14

80

363.69

368.23

372.78

377.33

381.87

386.42

390.96

395.51

400.06

404.60

90

409.15

413.69

418.24

422.79

427.33

341.88

436.42

440.97

445.52

450.06

BE30 Series

10-17

KILOGRAM TO POUND POUND TO KILOGRAM

GENERAL AND SPECIFICATIONS

KILOGRAM TO POUND 1 kg = 2.2046 Ib 0

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

POUND TO KILOGRAM 1 Ib = 0.4536 kg 0

1

2

3

4

5

6

7

8

9

0.454

0.907

1.361

1.814

2.268

2.722

3.175

3.629

4.082

10

4.536

4.990

5.443

5.897

6.350

6.804

7.257

7.711

8.165

8.618

20

9.072

9.525

9.979

10.433

10.886

11.340

11.793

12.247

12.701

13.154

30

13.608

14.061

14.515

14.969

15.422

15.876

16.329

16.783

17.237

17.690

40

18.144

18.597

19.051

19.505

19.958

20.412

20.865

21.319

21.772

22.226

50

22.680

23.133

23.587

24.040

24.494

24.948

25.401

25.855

26.308

26.762

60

27.216

27.699

28.123

28.576

29.030

29.484

29.937

30.391

30.844

31.298

70

31.752

32.205

32.659

33.112

33.566

34.019

34.473

34.927

35.380

35.843

80

36.287

36.741

37.195

37.648

38.102

38.555

39.001

39.463

39.916

40.370

90

40.823

41.277

41.731

42.184

42.638

43.091

43.545

43.999

44.452

44.906

10-18

BE30 Series

GENERAL AND SPECIFICATIONS

KG/CM² TO LB/IN²

KG/CM² TO LB/IN² 1 kg/cm² = 14.2233 lb/in² 0

1

2

3

4

5

6

7

8

9

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

996.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1123

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

BE30 Series

10-19

KGM TO FT. LB

GENERAL AND SPECIFICATIONS

KGM TO FT. LB 1 kgm = 7.233 ft.lb 0

1

2

3

4

5

6

7

8

9

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

396.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.6

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

10-20

BE30 Series

GENERAL AND SPECIFICATIONS

TEMPERATURE

TEMPERATURE Fahrenheit-Centigrade Conversion. –A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C

°F

°C

°F

°C

°F

°C

°F

-40.4 -37.2 -34.4 -31.7 -28.9

-40 -35 -30 -25 -20

-40.0 -31.0 -22.0 -13.0 -4.0

-11.7 -11.1 -10.6 -10.0 -9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

-28.3 -27.8 -27.2 -26.7 -26.1

-19 -18 -17 -16 -15

-2.2 -0.4 1.4 3.2 5.0

-8.9 -8.3 -7.8 -7.2 -6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

-25.6 -25.0 -24.4 -23.9 -23.3

-14 -13 -12 -11 -10

6.8 8.6 10.4 12.2 14.0

-6.1 -5.6 -5.0 -4.4 -3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.3 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

-22.8 -22.2 -21.7 -21.1 -20.6

-9 -8 -7 -6 -5

15.8 17.6 19.4 21.2 23.0

-3.3 -2.8 -2.2 -1.7 -1.1

26 27 28 29 30

78.2 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

-20.0 -19.4 -18.9 -18.3 -17.8

-4 -3 -2 -1 0

24.8 26.6 28.4 30.2 32.0

-0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

-17.2 -16.7 -16.1 -15.6 -15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

265.0 275.0 284.0 293.0 302.0

-14.4 -13.9 -13.3 -12.8 -12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

BE30 Series

10-21

20. TESTING AND ADJUSTING Service data (1.0 - 1.75 ton models) . . . . . . . . 20- 2 Service data (2.0 - 3.0 ton models) . . . . . . . . . 20- 4 How to operate lift interrupt function . . . . . . . . 20- 6 How to reset electrolyte level indicator function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 6 How to start hour meter . . . . . . . . . . . . . . . . . . 20- 7 Operation of meter panel . . . . . . . . . . . . . . . . . 20- 7 Adjusting lowering speed of fork . . . . . . . . . . . 20-14 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18 Stationary charger . . . . . . . . . . . . . . . . . . . . . . 20-19 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 Wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 Adjusting parking brake lever . . . . . . . . . . . . . . 20-22 Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . 20-23 Rear axle (Steering axle) . . . . . . . . . . . . . . . . . 20-24 Mast (1.0 - 1.75 ton models) . . . . . . . . . . . . . . 20-26 Mast (2.0 - 3.0 ton models) . . . . . . . . . . . . . . . 20-27 Fork carriage (1.0 - 1.75 ton models) . . . . . . . . 20-28 Fork carriage (2.0 - 3.0 ton models). . . . . . . . . 20-30 Measuring hydraulic drift of hydraulic cylinder and hydraulic drift of leaning forward . . . . . . . 20-32 Bleeding air . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33

BE30 Series

20-1

SERVICE DATA

TESTING AND ADJUSTING

SERVICE DATA (1.0 – 1.75 TON MODELS) Component

Brush height

Motor

Press force of brush spring

Specific gravity

Battery

Insulation of each part

Controller

FB18EX FB18EXG

Min. 22

Min. 22

Min. 22

mm

Min. 13

Min. 13

Min. 13

Pump motor

N {kgf}

Min. 7.35 {0.75}

Min. 7.35 {0.75}

Min. 7.35 {0.75}

Power steering motor

N {kgf}

4.9 –11.76 {0.5–1.2}

4.9 –11.76 {0.5–1.2}

4.9 –11.76 {0.5–1.2}

mm

Min. 87

Min. 87

Min. 87

mm

Min. 29.5

Min. 29.5

Min. 29.5

Pump motor

mm

Min. 0.2

Min. 0.2

Min. 0.2

Power steering motor

mm

Min. 0.2

Min. 0.2

Min. 0.2

Drive motor

Mz

Min. 3

Min. 3

Min. 3

Pump motor

Mz

Min. 0.5

Min. 0.5

Min. 0.5

Unit

FB10EX / FB14EX

Pump motor

mm

Power steering motor

Pump motor Outside diameter of commutator Power steering motor Undercut depth

When discharged to 0 – 20%

—

1.28 – 1.256 (at 20 °C)

When discharged to 20 – 40%

—

1.256 – 1.23 (at 20 °C)

When discharged to 40 – 60%

—

1.23 – 1.194 (at 20 °C)

When discharged to 60 – 80%

—

1.194 – 1.176 (at 20 °C)

When discharged to 80 – 100%

—

1.176 – 1.15 (at 20 °C)

Input voltage

V

Wear limit of contacts of contactors

—

Extreme unevenness must not be detected when checked visually.

For travel

A

48LF-225A

For hydraulic equipment

A

48LF-225A

For power steering

A

48LF-40A

For charging circuit

A

48LF-225A

Control circuit of chassis

A

10

Accessory circuit

A

15

Travel

A

527 – 586

Hydraulic equipment

A

Min. 300

Power steering

A

45 ± 5

Capacity of fuse

Cut-off current (Lock current)

20-2

FB15EX FB15EXG

Inspection item

48

48

48

BE30 Series

TESTING AND ADJUSTING

Component

Inspection item

Power train and travel device

Refill capacity of transfer case Depth of tire groove

Steering and braking devices

FB10EX / FB14EX

l

7

mm

FB15EX FB15EXG

FB18EX FB18EXG

7

7

Min. 1.6 (At place of 1/4 of tread width)

kPa {kgf/cm2}

610 {6.25}

610 {6.25}

610 {6.25}

Rear wheel

kPa {kgf/cm2}

780 {8}

780 {8}

780 {8}

Front wheel

Nm {kgm}

196 – 245 {20 – 25}

196 – 245 {20 – 25}

196 – 245 {20 – 25}

Rear wheel

Nm {kgm}

98 – 147 {10 – 15}

98 – 147 {10 – 15}

98 – 147 {10 – 15}

Front wheel

Nm {kgm}

Rear wheel

Nm {kgm}

59 – 74 {6 – 7.5}

59 – 74 {6 – 7.5}

59 – 74 {6 – 7.5}

mm

30 – 60

30 – 60

30 – 60

Clearance of support thrust

mm

Max. 0.5

Max. 0.5

Max. 0.5

Min. turning radius

mm

1,775

FB15EX: 1,775 FB15EXG: 2,005

FB18EX: 1,805 FB18EXG: 2,005

Play

mm

2–6

2–6

2–6

Height when pressed

mm

Min. 80

Min. 80

Min. 80

Refill quantity of brake fluid

l

0.4

0.4

0.4

Operating effort of parking brake lever

N {kgf}

Min. 147 {15}

Min. 147 {15}

Min. 147 {15}

Tightening torque of back plate mounting bolt

Nm {kgm}

157 – 196 {16 – 20}

157 – 196 {16 – 20}

157 – 196 {16 – 20}

Thickness of lining

mm

Min. 2.0

Min. 2.0

Min. 2.0

Thickness of base

mm

Difference in height

mm

Max. 15

Max. 15

Max. 15

Increase of width at tips

mm

Max. 35

Max. 35

Max. 35

Length of 17 links

mm

Max. 275.5

Max. 275.5

Max. 275.5

Tightening torque of hub nut

Tightening torque of rim fitting nut

Play of steering wheel

98 – 123 {10 – 12.5} 98 – 123 {10 – 12.5} 98 – 123 {10 – 12.5}

Brake pedal

Brake

Fork Cargo handling device

Unit

Front wheel

Tire inflation pressure

Rear axle

SERVICE DATA

Chain

Cylinder

Hydraulic system

1.0-ton models: Min. 26 1.5-ton models: Min. 30

1.35-ton models: Min. 30 1.75-ton models: Min. 33

Hydraulic drift

mm/15 min

At fork: Max. 60 At cylinder: Max. 30

Hydraulic drift of leaning forward

mm/15 min

Relief pressure

MPa {kgf/cm2}

17.6 {180}

17.6 {180}

17.6 {180}

Refill capacity of hydraulic tank

l

25 ( 1.29)

26 ( 1.30)

26 ( 1.30)

Max. 23

1: A value in ( ) is total quantity of oil required when 3-m mast is installed.

BE30 Series

20-3

SERVICE DATA

TESTING AND ADJUSTING

SERVICE DATA (2.0 – 3.0 TON MODELS) Component

Brush height

Motor

Press force of brush spring

Specific gravity

Battery

Insulation of each part

Controller

FB20EX FB25EX

FB20EXG FB25EXG

FB30

Pump motor

mm

Min. 22

Min. 22

Min. 22

Power steering motor

mm

Min. 13

Min. 13

Min. 13

Pump motor

N {kgf}

Min. 5.59 {0.57}

Min. 5.59 {0.57}

Min. 5.59 {0.57}

Power steering motor

N {kgf}

4.9 –11.76 {0.5–1.2}

4.9 –11.76 {0.5–1.2}

4.9 –11.76 {0.5–1.2}

mm

Min. 97

Min. 97

Min. 97

mm

Min. 29.5

Min. 29.5

Min. 29.5

Pump motor

mm

Min. 0.2

Min. 0.2

Min. 0.2

Power steering motor

mm

Min. 0.2

Min. 0.2

Min. 0.2

Drive motor

Mz

Min. 3

Min. 3

Min. 3

Pump motor

Mz

Min. 0.5

Min. 0.5

Min. 0.5

Pump motor Outside diameter of commutator Power steering motor Undercut depth

When discharged to 0 – 20%

—

1.28 – 1.256 (at 20 °C)

When discharged to 20 – 40%

—

1.256 – 1.23 (at 20 °C)

When discharged to 40 – 60%

—

1.23 – 1.194 (at 20 °C)

When discharged to 60 – 80%

—

1.194 – 1.176 (at 20 °C)

When discharged to 80 – 100%

—

1.176 – 1.15 (at 20 °C)

Input voltage

V

Wear limit of contacts of contactors

—

Capacity of fuse

Cut-off current (Lock current)

20-4

Unit

Inspection item

48

48

72

Extreme unevenness must not be detected when checked visually.

For travel

A

48LF-325

48LF-325

96LF-275A

For hydraulic equipment

A

48LF-225

48LF-225

96LF-200A

For power steering

A

48LF-40

48LF-40

96LF-40A

Control circuit of chassis

A

10

10

10

Accessory circuit

A

15

15

15

Travel

A

674 – 746

674 – 746

450 – 520

Hydraulic equipment

A

Min. 340

Min. 340

220

Power steering

A

50 ± 25

50 ± 25

42 – 52

BE30 Series

TESTING AND ADJUSTING

Component

Inspection item

Power train and travel device

Refill capacity of transfer case Depth of tire groove

Steering and braking devices

FB20EX FB25EX

FB20EXG FB25EXG

FB30

l

8

8

8

mm

Min. 1.6 (At place of 1/4 of tread width)

kPa {kgf/cm2}

880 {9.0}

880 {9.0}

780 {8.0}

Rear wheel

kPa {kgf/cm2}

880 {9.0}

880 {9.0}

610 {6.25}

Front wheel

Nm {kgm}

196 – 245 {20 – 25}

196 – 245 {20 – 25}

294 – 490 {30 – 50}

Rear wheel

Nm {kgm}

196 – 245 {20 – 25}

196 – 245 {20 – 25}

196 – 245 {20 – 25}

Front wheel

Nm {kgm}

—

—

—

Rear wheel

Nm {kgm}

157 – 196 {16 – 20}

157 – 196 {16 – 20}

—

mm

30 – 60

30 – 60

30 – 60

Clearance of support thrust

mm

Max. 0.5

Max. 0.5

Max. 0.5

Min. turning radius

mm

FB20EX: 2,000 FB25EX: 2,015

FB20EXG: 2,070 FB25EXG: 2,130

2.215

Play

mm

2–6

2–6

2–6

Height when pressed

mm

Min. 60

Min. 60

Min. 60

Refill quantity of brake fluid

l

0.4

0.4

0.4

Operating effort of parking brake lever

N {kgf}

Min. 196 {20}

Min. 196 {20}

Min. 196 {20}

Tightening torque of back plate mounting bolt

Nm {kgm}

157 – 196 {16 – 20}

157 – 196 {16 – 20}

157 – 196 {16 – 20}

Thickness of lining

mm

Min. 2.0

Min. 2.0

Min. 2.0

Thickness of base

mm

Difference in height

mm

Max. 15

Max. 15

Max. 15

Increase of width at tips

mm

Max. 35

Max. 35

Max. 35

Length of 17 links

mm

Max. 330

Max. 330

Max. 550

Tightening torque of hub nut

Tightening torque of rim fitting nut

Play of steering wheel

Brake pedal

Brake

Fork Cargo handling device

Unit

Front wheel

Tire inflation pressure

Rear axle

SERVICE DATA

Chain

Cylinder

Hydraulic system

2.0-ton models: Min. 33 2.5-ton models: Min. 36.5

Min. 44

Hydraulic drift

mm/15 min

At fork: Max. 60 At cylinder: Max. 30

Hydraulic drift of leaning forward

mm/15 min

Max. 23

Max. 26

Max. 26

Relief pressure

MPa {kgf/cm2}

17.66 {180}

17.66 {180}

17.66 {180}

Refill capacity of hydraulic tank

l

25 ( 1. 31)

26 ( 1. 31)

25 ( 1. 30)

1: A value in ( ) is total quantity of oil required when 3-m mast is installed.

BE30 Series

20-5

HOW TO OPERATE LIFT INTERRUPT FUNCTION, HOW TO RESET ELECTROLYTE LEVEL INDICATOR FUNCTION

TESTING AND ADJUSTING

HOW TO OPERATE LIFT INTERRUPT FUNCTION 1. WHAT IS LIFT INTERRUPT FUNCTION The lift interrupt function means a function of stopping the cargo handling work and warning the operator to charge the battery when the battery is discharged by 80% (at this time, 2 lower display units A flashes alternately and the warning buzzer sounds) so that the battery will not be deteriorated by overdischarge. If this function operates, the lift truck cannot handle cargo but can travel. Accordingly, the operator should return to the charging place and charge the battery.

2. HOW TO RESET LIFT INTERRUPT FUNCTION If the wires shown at right figure Br – YR are connected, the lift interrupt function does not operate. Those wires are connected when the lift truck is shipped.

3. HOW TO OPERATE LIFT INTERRUPT FUNCTION If the wires shown at right figure Br – YR are disconnected, the lift interrupt function operates. If those wires are connected again, the lift interrupt function does not operate.

HOW TO RESET ELECTROLYTE LEVEL INDICATOR FUNCTION To reset the electrolyte level indicator function, disconnect yellow-blue wire B above the battery and connect it to yellow-red wire A. When the electrolyte level sensor is not necessary for some reason, connect those wires.

20-6

BE30 Series

TESTING AND ADJUSTING

HOW TO START HOUR METER, OPERATION OF METER PANEL

HOW TO START HOUR METER

This illustration shows Japanese spec.

The hour meter is so set that it will not operate when the lift truck is shipped. When delivering the lift truck to a customer, remove its left side cover and connect the wires to start the hour meter. (Wire color: RB– BY) 1. Multi-controller 2. Charging mode switch connector (Only in Japanese spec.) 3. Hour meter start connector 4. System controller

OPERATION OF METER PANEL

Standard display (Hour meter display)

(Check of various set values, adjustment values, and switches) 1.

OPERATOR (USER) ADJUSTMENT MODE 1) Turn the key switch ON. Set the forward-reverse lever, work equipment control lever, and accelerator in neutral. 2) Press mode button P3 to set the meter panel in the operator adjustment mode. • If the mode button is pressed, the meter panel changes from the standard display (hour meter display) to the operator adjustment mode display. Then, each time the mode button is pressed, the settable/adjustable items (settable values: data) are indicated by flashing in order.

Operator adjustment mode display

3) Press set value button P1, and the flashing set value changes. When the set value is decided, press mode button P3 to enter it (and move to the next setting mode). 4) Repeat 2) and 3) above to set/adjust the 9 items (See the operator adjustment mode table in the next page). a Use item button P2 to set the year (the number of units and tens), month, date, day of week, hour, minute, etc. for setting the current time and time for starting charging which will have multiple set values. a If the meter panel is returned to the hour meter display by a method other than pressing mode button P3, the set values are not changed. a In each example of display, if the italic item of part A flashes thickly, that item is settable.

BE30 Series

20-7

OPERATION OF METER PANEL

TESTING AND ADJUSTING

5) Returning to hour meter display (standard display) (1) Turn the key switch OFF, then turn it ON again. (2) Operate or press one of the following. • Forward-reverse lever • Work equipment control lever • Accelerator pedal (3) Press the mode buttons in order until the adjustment mode is finished once. (4) Leave the meter panel without adjusting any item. (Reference: Operation (User) adjustment mode table) Settable/Adjustable item 1. Standard display (Hour meter display)

Set/Adjusted data ––

2. Travel power setting (ES control)

Travel power (1 – 8)

3. Lift 1st speed setting

Lift 1st speed (1 – 8)

4. Lift 2nd speed setting

Lift 2nd speed (1 – 8)

5. Tilting speed setting

Tilting speed (1 – 8)

6. Travel speed limit setting

Travel speed limit (5 – 15 km/h, 10 steps)

7. Over-travel speed setting

Overspeed (Set/Not set)

8. Accelerator neutral regeneration setting

Accelerator neutral regeneration (Set/Not set)

9. Current time setting

Current time (Year, month, date, day of week, time)

Note) Limit the overspeed to 15 km/h. (See the section 60 “STRUCTURE AND FUNCTIONS”.)

20-8

BE30 Series

TESTING AND ADJUSTING

2.

SERVICE (DISTRIBUTOR) MODE • In this mode, various set values and adjustment values (11 items in total), except the operator (user) adjustment items, can be changed. a Condition for moving to service adjustment mode Set the forward-reverse lever, accelerator, and work equipment control lever, in neutral. 1) With all of buttons P1, P2, and P3 pressed (Pressing them simultaneously), turn the key switch ON, and the screen is set in the service adjustment mode. 2) Press mode button P3 to display a set/adjustment item to be changed. a The settable/adjustable item (data) is indicated by flashing. 3) Press set value button P1 to select a data (value or letter) to be changed. a If there are multiple settable data (Date, time, characteristic, etc.), select one with item button P2. 4) After selecting a new data (the value or letter selected finally is the selected value), press mode button P3 to enter it (go to the next item). 5) Repeat 2., 3., and 4. above to set/adjust the 11 items (See the service adjustment mode table in the next page). a After each item is set, it is lighted up for 2 seconds, then the next item is selected automatically. a If the meter panel is returned to the hour meter display by a method other than pressing mode button P3, the set values are not changed. a In each example of display, if the italic item of part A flashes thickly, that item is settable.

OPERATION OF METER PANEL

Standard display (Hour meter display)

Service adjustment mode display

In service adjustment mode, • Set the speed of the hydraulic/third valve. ATT speed 1 (1 – 8) Set value 8 •

Change the accelerator characteristic. Accelerator characteristic Characteristic A Characteristic A is reversed. a Select characteristic B with button P2. Accelerator characteristic Characteristic B

Characteristic B is reversed. After finishing setting, return to the standard mode.

BE30 Series

20-9

OPERATION OF METER PANEL

TESTING AND ADJUSTING

6) Returning to standard display (hour meter display) (Conditions) (1) Operate the forward-reverse lever. (2) Operate work equipment control lever. (3) Turn the key switch OFF, then turn it ON again. (4) Finish setting the all set/adjustment items. (Service adjustment mode table) Settable/Adjustable item

Set data in ( )

1. Standard display (Hour meter display)

1.

2. Attachment speed 1 setting (3rd valve)

2. Attachment speed 1 (1 – 8)

3. Attachment speed 2 setting (4th valve)

3. Attachment speed 2 (1 – 8)

4. Attachment speed 3 setting (5th valve)

4. Attachment speed 3 (1 – 8)

5. FR regeneration current setting

5. Set value of FR regeneration current (0 – 100)

6. Brake regeneration current setting

6. Set value of brake regeneration current (0 – 100)

7. Neutral regeneration current setting

7. Set value of neutral regeneration current (0 – 100)

8. Slope regeneration current setting

8. Set value of slope regeneration current (0 – 100)

9. Soft start characteristic setting

9. Soft start characteristic setting (Characteristic A, B, C)

10. Accelerator characteristic setting

10. Accelerator characteristic setting (Characteristic A, B, C)

11. Trip meter display

11. Trip meter display (ON/OFF)

20-10

—

BE30 Series

TESTING AND ADJUSTING

OPERATION OF METER PANEL

(Contents of display in service adjustment mode) Item Service adjustment mode

Contents of display Item

Display (24 characters , 2 lines)

ATT speed 1 (1 – 8) Attachment speed setting Set value 8 ATT speed 2 (1 – 8) Attachment speed setting Set value 8 ATT speed 3 (1 – 8) Attachment speed setting Set value 8 FR regeneration current (0 – 100) FR regeneration current setting Set value 100 Brake regeneration current set- Brake regeneration (0 – 100) ting Set value 100 Neutral regeneration current set- Neutral regeneration (0 – 100) ting Set value 100 Slope regeneration current set- Slope regeneration (0 – 100) ting Set value 100 Soft start characteristic Characteristics A Characteristic A Soft start Soft start characteristic characteris- Characteristics B Characteristic B tic setting Soft start characteristic Characteristics C Characteristic C Accelerator characteristic Characteristics A Characteristic A Accelerator Accelerator characteristic characteris- Characteristics B Characteristic B tic setting Accelerator characteristic Characteristics C Characteristic C Trip meter OFF Trip meter Display OFF display setTrip meter ting ON Display ON

3.

Display code D01 D02 D03 D04 D05 D06 D07

D08

D09

D10

CHECK IN SWITCH MONITOR MODE Display and check the operating conditions of switches and sensors on the display •

Condition for setting meter panel in switch monitor mode Pull the parking brake lever and set the forward-reverse lever, work equipment control lever, and accelerator in neutral.

1) Remove the floor plate. (Keep the key switch in the OFF position.) 2) Disconnect switch monitor connector (1). a Under the floor plate, there is a relay wiring harness and there are lead wires (Color: P → BY) connected by a 1-P white connector out of that harness as shown in the figure at right. Disconnect (Open) those lead wires. a Do not disconnect the wires (Color: YL → BY) connected by the one-pin connector (2).

BE30 Series

20-11

OPERATION OF METER PANEL

3) Turn the key switch ON (to set the meter panel in the switch monitor mode). If the key switch is turned ON after the switch monitor connector is disconnected, the meter panel is set in the switch monitor mode and the name and current state of each switch (sensor) are displayed on the display in the meter panel.

TESTING AND ADJUSTING

Display of switch monitor mode

4) Turn the displayed switch (sensor) ON (Operate it), and its state is displayed by ON OFF on the display. a See the example of the forward switch of the forward-reverse lever which is displayed first in the switch monitor mode and shown in the figure at right.

Control button

5) Press mode button P3 to display the next switch (sensor). 6) Repeat 4) and 5) above to check the other sensors. 7) Returning to standard display (hour meter display) (1) Turn the key switch OFF. (2) Connect the switch monitor connector (Wire color: P ← BY). (3) Install the floor plate. (4) Turn the key switch ON.

Operation of hydraulic tilt lever

Standard display (Display of hour meter)

20-12

BE30 Series

TESTING AND ADJUSTING

OPERATION OF METER PANEL

LIST OF SWITCHES (SENSORS) AND HOW TO CHECK THEM No.

Switch (Sensor) name

1

Directional F switch

2

Directional R switch

3

Accelerator switch

4

Brake switch

5

Lift 1 switch

6

Lift 2 switch

7

Tilt switch

8

Attachment 1 switch

9

Attachment 2 switch

10

Attachment 3 switch

11

Parking brake switch

12

Lift interrupt switch

13

Seat switch

14

Spare

15

16

How to check Shift forward-reverse lever from N to F. If indication changes from OFF to ON, this switch is normal. Shift forward-reverse lever from N to R. If indication changes from OFF to ON, this switch is normal. Press accelerator pedal. If indication changes from OFF to ON, this switch is normal. Press brake pedal by 28 mm. If indication changes from OFF to ON, this switch is normal. Pull lift lever. If indication changes from OFF to ON, this switch is normal. Pull lift lever. If indication changes from OFF to ON, this switch is normal. Pull tilt lever. If indication changes from OFF to ON, this switch is normal. Pull 3-spool valve lever. If indication changes from OFF to ON, this switch is normal. Pull 4-spool valve lever. If indication changes from OFF to ON, this switch is normal. Pull 5-spool valve lever. If indication changes from OFF to ON, this switch is normal. Pull parking brake lever. If indication changes from OFF to ON, this switch is normal. If this switch is normal, it is turned ON while lift interrupt function is not working and turned OFF while lift interrupt function is working.

Remarks — — — —

Adjustable with potentiometer.

— —

Sit in seat. If indication changes from OFF to ON, this switch is normal.

Is seat switch is not installed, circuit for it is turned ON.

—————

—

Travel speed limit 2 switch

ON (above 15 km/h) OFF (below 15 km/h) (Low-speed model, domestic market only)

—

Lifting height switch

This switch is turned ON while automatic lifting function is turned OFF, and turned OFF while automatic lifting function is turned ON

If automatic lifting function is not installed, circuit for it is turned ON.

17

Accelerator output

18

Torque sensor output

BE30 Series

When accelerator pedal is released: If accelerator switch No. 3 is turned OFF while indication is above 7%, this output is normal. When accelerator pedal is pressed: If indication is above 64 – 68%, this output is normal. If indication is 45 – 55% when in neutral, 15 – 25% when at right end, and 75 – 85% when at left end, this output is normal.

If indication is below 64%, maximum speed is not obtained. —

20-13

ADJUSTING LOWERING SPEED OF FORK

TESTING AND ADJUSTING

ADJUSTING LOWERING SPEED OF FORK (PROPORTIONAL SOLENOID VALVE) The lowering speed of the fork cannot be adjusted with the meter panel. Accordingly, if a user wants to lower the lowering speed, apply the following method. 1. Work equipment control lever 2. Potentiometer 3. Bolt 4. Locknut 1.

Apply the parking brake securely.

2.

Remove the cover of work equipment control lever (1) so that the lever device control will be seen.

3.

Loosen locknut (4) of bolt (3).

4.

Tighten bolt (3) very gradually to adjust the lowering speed to a proper level.

5.

Tighten locknut (4) securely.

6.

Install the cover of work equipment control lever (1).

Note) Do not loosen bolt (3), exceeding the standard position. (If it is loosened so much, abnormality will be detected.) a Check the set height of the bolt before adjustment. a See the section 60 of the WORK EQUIPMENT CONTROL LEVER.

20-14

BE30 Series

TESTING AND ADJUSTING

BATTERY

BATTERY 1. CHECKING ELECTROLYTE LEVEL 1) CHECKING WITH ELECTROLYTE LEVEL INDICATOR WARNING FOR ADDING DISTILLED WATER The electrolyte level indicator (battery mark) lights up. a If the above indicator lights up, add distilled water immediately (See the method of adding distilled water shown below). a If the battery is used with insufficient electrolyte, its lifespan is shortened extremely. Accordingly, be sure to add distilled water. a If a battery other than the standard or optional one is used, the electrolyte level indicator cannot be used.

2) CHECK WITH ELECTROLYTE LEVEL GAUGE 1. Stopper 2. Cap 3. Float (Red) Before the float (red) indicates the lowest electrolyte level, add distilled water (See the method of adding distilled water to the battery shown below). When the float (3) of stopper (1) touches the cap (2) (When clearance a shown in the figure at right is 0), the electrolyte level is at the lowest level. a Caps of different battery manufacturers have different shapes.

2. METHOD OF ADDING DISTILLED WATER TO BATTERY A. While distilled water is added B. After distilled water is added 1. Open the battery cap and add refined (distilled) water. 2. Stop adding water immediately when the white line of the float is seen. a If you continue adding water after the white line is seen, the water will spill. Accordingly, never do so.

BE30 Series

20-15

FUSE

TESTING AND ADJUSTING

FUSE 1. UNDER FLOOR PLATE 1.

Turn the key switch OFF and disconnect the battery plug.

2.

Remove the floor plate.

3.

Open the fuse holder cap and replace the fuse. Symbol

Circuit where fuse is used

Capacity

SF1

Control circuit on chassis

10A

SF2

Accessory circuit

15A

2. STATIONARY CHARGER 1.

Disconnect the power cable of the charger from the outlet.

2.

Loosen the nut and replace the fuse.

3.

Tighten the nut securely. Symbol Voltage

Battery capacity 330AH 400AH 485AH 545AH

48V F5

Capacity BFS80A BFS100A

565AH 600AH 700AH

BFS150A

935AH 1,080AH 72V

20-16

450AH 545AH

BF150A

BE30 Series

TESTING AND ADJUSTING

FUSE

3. CONTROLLER 1.

If any fuse is broken, a failure code is displayed on the monitor at the operator's seat. Replace the fuse according to the displayed failure code. a When replacing F1 or F2, remove the printed circuit card mounting bracket. Failure code E20

2.

Corresponding fuse F1 (Fuse for travel circuit)

E33 E52

F2 (Fuse for hydraulic circuit) F3 (Fuse for EPS circuit)

—

F4 (Fuse for charging circuit)

Turn the key switch OFF and disconnect the battery plug.

3. Circuit Symbol where fuse is used

Capacity 1 – 1.75-ton models 48LF-275A

F1

Travel circuit

2 – 2.5-ton models 48LF-325A 3-ton model

96LF-275A

1 – 1.75-ton models 48LF-225A F2

Hydraulic circuit

2 – 2.5-ton models 48LF-225A 3-ton model

96LF-200A

1 – 1.75-ton models 48LF-40A F3

EPS circuit 2 – 2.5-ton models 48LF-40A 3-ton model

96LF-40A

1 – 1.75-ton models 48LF-225A F4

Charging circuit

2 – 2.5-ton models 48LF-225A 3-ton model

4.

Loosen the nut and replace the fuse.

5.

Tighten the nut securely.

BE30 Series

96LF-200A

20-17

TRANSFER CASE

TESTING AND ADJUSTING

TRANSFER CASE 1. CHECKING OIL LEVEL 1. Remove oil level plug (2) and check the oil level. 2. If the oil level is near the lower line of the level plug hole, it is normal. 3. If the oil is insufficient, remove oil filler plug (1) and add gear oil.

2. REPLACING OIL 1. Remove the oil filler plug (1), and then remove drain plug (3) to drain the oil. 2. Tighten drain plug (3) and add gear oil by the specified quantity through the oil filler. Refill capacity

3.

FB10EX/14EX/15EX/18EX FB15EXG/18EXG

7l

FB20EX/25EX FB20EXG/25EXG

8l

FB30

8l

Check the oil level with the oil level plug (2) and adjust it if necessary. (See the 1. CHECKING OIL LEVEL shown above.)

20-18

BE30 Series

TESTING AND ADJUSTING

STATIONARY CHARGER

STATIONARY CHARGER 1. 2.

Charging transformer Electromagnetic switch

a The positional relationship between the charging transformer and electromagnetic switch is different from the above illustration.

1. ADJUSTING SOURCE VOLTAGE TAPS 1.

Measure the source voltage to be used for charging.

a The source voltage fluctuates between daytime and nighttime and between summer and winter. Measure the source voltage when it is highest. 2.

3.

Connect the selected wires to wires D coming from electromagnetic switch (2). If the charger is used for long hours with improper source voltage taps, it may burn. Accordingly, be sure to adjust the source voltage taps periodically.

Select 1 wire each corresponding to the measured source voltage from A, B, and C, according to the following table. Source voltage (V)

Indication of wire

190 – 199

195

200 – 209

205

210 – 219

215

220 – 229

225

BE30 Series

20-19

BRAKE PEDAL

TESTING AND ADJUSTING

BRAKE PEDAL

20-20

BE30 Series

TESTING AND ADJUSTING

WHEEL BRAKE

WHEEL BRAKE 1. ADJUSTING WHEEL BRAKE Jack up the chassis and fit the brake shoe to the brake drum with adjustment screw (2). And then return adjustment screw (2) by 25 – 30 teeth. a When returning adjustment screw (2), raise lever (3) so that an excessive force will not be applied to lever (3). If lever (3) is bent forcibly, it may not operate normally. Take care.

2. OPERATION TEST OF AUTOMATIC ADJUSTER Pull cable (1) in the direction of the arrow with the fingers under the normally adjusted condition, and the lever (3) is engaged with the next tooth of the wheel. Then, return cable (1), and it moves the wheel forward by 1 tooth and the lever is returned. When the cable (1) is pulled, if the lever (3) does not operate normally, check the position of lever (3) above the adjustment screw. Normal position of lever Lever (3) must touch the adjustment wheel when its distance a from the center of the screw is 5 – 7 mm. If distance a is out of this range, the lever is not engaged with the wheel teeth normally and the wheel does not rotate normally when the lever operates. Actions to take when wheel brake does not work 1) Check that the cable guide fits to the specified hole of the secondary shoe. 2) Check that the adjustment spring (4) is hooked correctly on the specified hole of the primary shoe. 3) Replace the cable. 4) Replace the lever. 5) Replace the adjuster assembly.

BE30 Series

20-21

ADJUSTING PARKING BRAKE LEVER

TESTING AND ADJUSTING

ADJUSTING PARKING BRAKE LEVER When adjusting the parking brake lever, put chocks under the front and rear wheels. 1.

Press push button (1) to set parking brake lever (2) in RELEASE position A from position B.

2.

Pull the parking brake lever toward you by the play of the cable.

3.

Release the lever, and adjustment bolt (3) floats. Tighten adjustment bolt (3) with a screwdriver, etc. so that the operating effort of the lever is set into the specified range.

4.

Match the width across flats of adjustment bolt (4) to stopper (5). Operating effort of lever

5.

FB10EX – 18EX

Min. 147 Nm {15 kgm}

FB15EXG/18EXG

Min. 196 Nm {20 kgm}

FB20, 25, 30

Min. 196 Nm {20 kgm}

Procedure for adjusting parking brake switch Loosen the mounting screw of the parking brake switch. Adjust the position of the parking brake switch (6) so that it will be turned OFF (the switch lever will be pressed) when the parking brake lever is set in RELEASE position A. After finishing adjustment, tighten the screw securely.

20-22

BE30 Series

TESTING AND ADJUSTING

HYDRAULIC TANK

HYDRAULIC TANK 1. CHECKING OIL LEVEL 1.

Open inspection cover (1) of the floor and pull out oil level gauge (2).

2.

Wipe oil off the oil level gauge with clean cloth, then insert the oil level gauge in the tank.

3.

Pull out the oil level gauge again and check that the oiled part is in proper range L.

4.

If the hydraulic oil is insufficient, add Komatsu genuine oil through oil filler (3). a Be sure to add Komatsu genuine oil.

2. REPLACING HYDRAULIC OIL AND LINE FILTER AND CLEANING STRAINER 1. 2.

Remove the drain plug to drain the oil. After draining, tighten the drain plug securely. Remove the cover and take out the strainer and line filter.

3.

Clean the strainer in cleaning oil. Then, blow air from its inside to dry and install it.

4.

Replace the line filter.

5.

Install the cover.

6.

Add hydraulic oil by the specified quantity through the oil filler and check the oil level with the oil level gauge.

7.

Move the cylinders (lift, tilt, and attachment) to the stroke ends 5 - 6 times to bleed air.

Refill capacity FB10EX /14EX /15EX /18EX

20l

FB15EXG

20l

FB18EXG

20l

FB20EX /25EX

22l

FB20EXG /25EXG

22l

FB30

30l

BE30 Series

20-23

REAR AXLE

TESTING AND ADJUSTING

REAR AXLE (STEERING AXLE) a Raise the rear part of the lift truck and place a wood block under the rear part of the truck frame to set the rear wheels free and stabilize the truck body. 1.

Tighten adjustment bolt (1) to eliminate clearance A between the rear axle and bearing support (to eliminate the play in the front and rear of the rear axle).

2.

Check that you can swing the rear axle lightly with your hands.

3.

Tighten locknut (2) to lock adjustment bolt (1).

4.

Check again that the rear axle does not have play but swings lightly.

20-24

BE30 Series

MAST

TESTING AND ADJUSTING

MAST (1.0 – 1.75 TON MODELS) 1. SELECTING ROLLERS AND ADJUSTING SHIMS OUTER MAIN ROLLE 1. Selecting roller size Select a roller size (NS, NM, L, or NLL) so that clearance a will be the same on both sides. 2.

Adjusting shims Insert shims (1) of the same thickness on both sides so that b will be 0 – 0.3 mm at the maximum lifting height. Insert shims (2) so that c will be 0.1 – 0.4 mm all over the inner rail when the rollers are pressed against the rails (Target: 0.1 mm).

INNER MAIN ROLLER 1. Selecting roller size Select a roller size (NS, NM, L, or NLL) so that d will be 0.2 – 0.7 mm. 2.

Adjusting shims Insert shims (3) of the same thickness on both sides so that e will be 0 – 0.3 mm at the maximum lifting height when the rollers are pressed against the rails.

20-26

BE30 Series

TESTING AND ADJUSTING

MAST

MAST (2.0 – 3.0 TON MODELS) 1. SELECTING ROLLERS AND ADJUSTING SHIMS OUTER MAIN ROLLER 1. Selecting roller size Select a roller size (S, M, L, or O) so that clearance b will be the same on both sides. 2.

Adjusting shims Adjust shims (2) so that a will be 0.1 – 0.4 mm. Adjust shims (1) so that c will be 0 – 0.5 mm (at the maximum lifting height).

INNER MAIN ROLLER 1. Selecting roller size Select a roller size (S, M, or L,) so that d will be 0.2 – 0.7 mm. 2.

Adjusting shims Adjust shims (3) so that e will be 0 – 0.5 mm with shims (3) (at the maximum lifting height).

BE30 Series

20-27

FORK CARRIAGE

TESTING AND ADJUSTING

FORK CARRIAGE (1.0 – 1.75 TON MODELS) a Press the backrest of part A against the board and tighten the bolts.

1.

Section AA (3-roller type) 1) Select the rollers so that a1 will be 0.3 – 1.1 mm. 2) Insert shims of the same thickness on both sides so that b1 will be 0.4 – 0.7 mm (when the fork carriage is at the top end).

20-28

BE30 Series

TESTING AND ADJUSTING

FORK CARRIAGE

2.

Section BB 1) Select the rollers so that a2 will be 0.3 – 1.1 mm. 2) Insert shims of the same thickness on both sides so that b2 will be 0.1 – 0.3 mm (3-roller type) or 0 – 0.2 mm (2-roller type) (when the fork carriage is at the top end).

3.

Section CC 1) Select the rollers so that a3 will be 0.3 – 1.1 mm. 2) Insert shims of the same thickness on both sides so that b3 will be 0 – 0.2 mm (when the fork carriage is at the top end).

4.

Projection B (When fork is lowered to ground) 1) Lower fork (2) to the ground and measure dimension B between bottom roller (4) of inner rail (1) and fork carriage (3). Projection of roller B

BE30 Series

(mm)

FB10

0

FB14

0

FB15

0

FB18

0

20-29

FORK CARRIAGE

TESTING AND ADJUSTING

FORK CARRIAGE (2.0 – 3.0 TON MODELS) a Press the backrest of part A against the board and tighten the bolts.

1.

Section BB • Select the rollers so that a1 will be 0.2 – 0.7 mm. Standard shim thickness: 2 mm • Insert shims of the same thickness on both sides so that b1 will be 0 – 0.1 mm (when the fork carriage is at the top end).

20-30

BE30 Series

TESTING AND ADJUSTING

FORK CARRIAGE

2.

Section CC • Select the rollers so that a2 will be 0.2 – 0.7 mm. Standard shim thickness: 2 mm • Insert shims of the same thickness on both sides so that b2 will be 0 – 0.1 mm (when the fork carriage is at the top end).

3.

Section DD • Select the rollers so that c will be 0.2 – 0.7 mm.

4.

Section EE • Insert shims of the same thickness on both sides so that d will be 0 – 0.2 mm (when the fork carriage is at the top end). Standard shim thickness: 2 mm

5.

Projection B (When fork is lowered to ground) • Lower fork (2) to the ground and measure dimension B between bottom roller (4) of inner rail (1) and fork carriage (3). Projection of roller B

(mm)

2 – 2.5 ton models

19

3.0 ton model

20

BE30 Series

20-31

MEASURING HYDRAULIC DRIFT OF HYDRAULIC CYLINDER AND HYDRAULIC DRIFT OF LEANING FORWARD

TESTING AND ADJUSTING

MEASURING HYDRAULIC DRIFT OF HYDRAULIC CYLINDER AND HYDRAULIC DRIFT OF LEANING FORWARD Precautions for measurement 1.

When measuring, take care that any person will never be under the cargo.

2.

Do not climb the mast stay or dashboard to measure hydraulic drift. If you do so, your hands or feet may be caught in the mast. Be sure to use a sufficiently strong and stable step.

3.

Before measuring, check that the hydraulic oil is not dirty and not a mixture of oils of different types and its level is proper.

4.

Be sure to measure the hydraulic drift on a level ground in front of a rack which can hold the lift truck when the latter tips forward.

1. MEASURING METHOD 1.

Stop the lift truck 500 mm before a rack.

2.

Repeat lifting and tilting operations to raise the hydraulic oil temperature to 50°C.

3.

Put a cargo of the rated load on the lift truck and secure it to the fin cover with wires.

4.

Lift up the cargo until H is about 1,500 mm and set mast (1) vertically.

[Hydraulic drift] 5.

After 3 minutes, set ruler to the piston rod of lift cylinder (2) and make mark A.

6.

Measure the hydraulic drift after 15 minutes. Hydraulic drift

Max. 30 mm/15 min

[Hydraulic drift of leaning forward] 5.

After 3 minutes, set ruler to the piston rod of tilt cylinder (3) and make mark B.

6.

Measure the hydraulic drift after 15 minutes. Hydraulic drift of leaning forward

20-32

Max. 23 mm/15 min

BE30 Series

TESTING AND ADJUSTING

BLEEDING AIR

BLEEDING AIR 1. BRAKE PIPING 1. 2. 3. 4. 5. 6.

Brake drum cover Air bleed plug Vinyl hose Brake oil container Brake drum Lining

1.

Remove the cap of air bleed plug (2) and install one end of a vinyl hose (3) and put the other end in a brake oil container (4).

2.

Press the brake pedal to fit lining (6) to brake drum (5), and then loosen air bleed plug (2) about 3/4 turns to discharge the brake oil.

3.

Tighten air bleed plug (2), and then release the brake pedal.

4.

Repeat 2. and 3. until no bubbles come out of hose (3).

5.

After bleeding all air, tighten plug (2) and install the cap.

6.

Remove cap (7) and inside cover of brake reservoir tank (8) and check the brake oil level. Add new brake oil by the quantity discharged for bleeding air and check that the brake oil level is in proper range L (25 – 45 mm).

2. LIFT CYLINDER 1.

Turn the key switch ON.

2.

Lift up and down the fork. a Stop the fork about 100 mm before the maximum lifting height and minimum height.

3.

Repeat operation of 2. 4 – 5 times.

4.

Lift up and down the fork to the maximum lifting height and minimum height.

5.

Repeat operation of 4. 4 – 5 times.

BE30 Series

20-33

30. REMOVAL AND INSTALLATION Arrangement of units . . . . . . . . . . . . . . . . . . . . 30- 2 Weight of each unit (1.0 - 1.75 ton models) . . . 30- 3 Weight of each unit (2.0 - 3.0 ton models) . . . . 30- 4 General disassembly and assembly drawing. . 30- 5 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 7 Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 9 Power train (Front axle + Transfer + Drive motor). . . . . . . . 30-11 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 EPS actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Steering gear box. . . . . . . . . . . . . . . . . . . . . . . 30-20 Hydraulic pump + Pump motor. . . . . . . . . . . . . 30-21

BE30 Series

30-1

ARRANGEMENT OF UNITS

REMOVAL AND INSTALLATION

ARRANGEMENT OF UNITS

1. 2. 3. 4. 5. 6. 7.

Hydraulic control valve Drive motor Hydraulic pump Pump motor Tank Main controller Rear axle

30-2

8. 9. 10. 11. 12. 13. 14.

EPS actuator Front axle Steering gear box Tilt cylinder Brake master cylinder Lift cylinder Mast

BE30 Series

REMOVAL AND INSTALLATION

WEIGHT OF EACH UNIT

WEIGHT OF EACH UNIT (1.0 – 1.75 TON MODELS) Model

Unit: kg

FB10EX

FB14EX

FB15EX

FB18EX

FB15EXG

FB18EXG

Remarks

246

246

246

246

246

246

—

Drive motor

60

60

60

60

60

60

—

Front axle

Unit name Power train (Total)

186

186

186

186

186

186

—

Pump motor

40

40

40

40

40

40

—

Rear axle

78

78

78

78

78

78

—

Front wheel

26

26

45

45

45

45

Per piece

Rear wheel

19

19

19

19

19

19

Per piece

Head guard

76

76

76

76

84

84

—

Counterweight

285

480

580

750

285

480

—

Mast (3 m, only inner and outer masts)

238

238

238

238

238

238

—

Lift cylinder (For 3-m mast)

20

20

20

20

20

20

Per piece

Tilt cylinder

17

17

17

17

17

17

Per piece

—

Fork carriage

69

69

69

70

69

70

Fork

32

34

34

34

34

34

Backrest

17

17

17

17

17

17

—

Hydraulic pump

3

3

3

3

3

3

—

Tank, oil, and grease

48

48

48

48

52

52

—

Control valve + lever

20

20

20

20

20

20

—

Steering gear box

13

13

13

13

13

13

—

EPS actuator

17

17

17

17

17

17

—

Per piece

a All of the above values are for the standard specification.

Battery Model FB10EX/14EX FB10EX/14EX FB15EX/18EX FB15EXG/18EXG a

Capacity (Ah)

Weight (kg)

330

625

400

700

485

770

545

845

700

1,115

Voltage (V)

48

Check the battery capacity by the manufacturer plate stuck to the front side of the battery case.

BE30 Series

30-3

WEIGHT OF EACH UNIT

REMOVAL AND INSTALLATION

WEIGHT OF EACH UNIT (2.0 – 3.0 TON MODELS) Model

Unit: kg

FB20EX

FB25EX

FB20EXG

FB25EXG

FB30

Remarks

329

329

329

329

489

—

Drive motor

75

75

75

75

115

—

Front axle

Unit name Power train (Total)

254

254

254

269

374

—

Pump motor

49

49

49

49

53

—

Rear axle

78

78

78

78

130

—

Front wheel

72

72

72

105

72

Per piece

Rear wheel

34

34

34

46

34

Per piece

Head guard

84

84

95

93

95

—

Counterweight

650

950

550

680

995

—

Mast (3 m, only inner and outer masts)

344

344

344

344

401

—

Lift cylinder (For 3-m mast)

25

25

25

25

32

Per piece

Tilt cylinder

25

25

25

25

25

Per piece

Fork carriage

80

80

80

80

108

—

Fork

43

51

43

51

62

Per piece

Backrest

20

20

20

20

20

—

Hydraulic pump

6

6

6

6

3

—

Tank, oil, and grease

48

48

52

48

52

—

Control valve + lever

20

20

20

20

20

—

Steering gear box

13

13

13

13

13

—

EPS actuator

17

17

17

17

17

—

a All of the above values are for the standard specification.

Battery Model FB20EX

FB20EX/25EX

FB20EXG/25EXG

FB30 a

Capacity (Ah)

Weight (kg)

450

820

565

925

600

945

700

1,035

935

1,375

1,080

1,605

450

1,500

545

1,500

Voltage (V)

48

72

Check the battery capacity by the manufacturer plate stuck to the front side of the battery case.

30-4

BE30 Series

REMOVAL AND INSTALLATION

GENERAL DISASSEMBLY AND ASSEMBLY DRAWING

GENERAL DISASSEMBLY AND ASSEMBLY DRAWING

BE30 Series

30-5

GENERAL DISASSEMBLY AND ASSEMBLY DRAWING

30-6

REMOVAL AND INSTALLATION

BE30 Series

REMOVAL AND INSTALLATION

MAST

MAST 1. REMOVAL 1. Put blocks under the front and rear wheels. 2. Lower fork (1). 3. Raise fork carriage (2) with a crane so that the hydraulic piping can be removed. 4. Put a block under the fork carriage.

5. Turn the key switch OFF and leave about 1 minute, and then disconnect hose (3) from the part marked with an arrow. a After disconnecting the hose, plug the adapters immediately to prevent the hydraulic oil from flowing out and dust from entering the system.

6. Raise the fork carriage a little with the crane and remove the block from under the fork carriage. 7. Lower the fork carriage. 8. Install the crane hook to mast (4). 9. Remove the mast cap. 10. Remove tilt cylinder pin (5). 11. Lift off the mast with the crane. Place the mast assembly horizontally on wood blocks with the fork carriage up. When placing the mast assembly, take care extremely that the crane hook will not come off the mast.

BE30 Series

30-7

MAST

REMOVAL AND INSTALLATION

2. INSTALLATION Carry out installation in the reverse order to removal and observe the following points. 1.

2.

Tightening mast cap mounting bolts 1.0 – 1.75 ton models

157 – 196 Nm {16 – 20 kgm}

2.0 – 3.0 ton models

245 – 309 Nm {25 – 31.5 kgm}

Driving in tilt cylinder pin Secure the mast with the crane and align the holes by operating the tilt lever, and then drive in the tilt cylinder pin (5). a A spherical bushing is used at the cylinder head and it leans easily when the pin is driven in. Accordingly, do not drive in the pin forcibly.

30-8

BE30 Series

REMOVAL AND INSTALLATION

LIFT CYLINDER

LIFT CYLINDER 1. REMOVAL How to remove the cylinder on either side is explained below as an example. 1. Set mast (1) vertically and put chocks under the front and rear wheels. 2. Raise fork carriage (2) about 300 mm with a crane.

3. Remove cotter pin (3), pull out pin (4), disconnect the chain, and remove the chain from the roller. 4. Raise the mast by operating the lift lever. 5. Pull out the fork carriage forward. 6. Put chocks under the inner mast.

7. Remove stopper bolt (3). a The stopper bolts of different models are installed to different positions. Stopper bolt (3a): 1.0 – 1.75 ton models Stopper bolt (3b): 2.0 – 3.0 ton models 8. Lower the cylinder rod by operating the lift lever. 9. Turn the key switch OFF and leave about 1 minute, and then disconnect the piping. a After disconnecting the piping, plug the adapters to prevent the hydraulic oil from flowing out and dust from entering the system. 10. Disconnect cylinder clamp (4). a The different cylinder clamps are used of different models. ( 1 shows the cylinder clamp for 2.0 – 3.0 ton models.) 11. Using sling belts, raise the cylinder about 300 mm with the crane and pull it out downward.

BE30 Series

30-9

LIFT CYLINDER

REMOVAL AND INSTALLATION

2. INSTALLATION Carry out installation in the reverse order to removal and observe the following points. 1. Inner mast 2. Outer mast 3. Cylinder rod 4. Shim (Right side) 5. Shim (Left side) 1.

1.0 – 1.75 ton models

Adjusting vertical of mast 1) Raise the mast to the maximum lifting height. 2) Check the play on both sides of the mast. 3) Adjust the mast with a shim so that it will be vertical when it is raised to the maximum lifting height.

30-10

If mast leans to left

Insert shim (5) in left cylinder.

If mast leans to right

Insert shim (4) in right cylinder.

2.0 – 3.0 ton models

BE30 Series

REMOVAL AND INSTALLATION

POWER TRAIN

POWER TRAIN (FRONT AXLE + TRANSFER + DRIVE MOTOR) 1. REMOVAL 1.

Put chocks under the front and rear wheels.

2.

Remove battery (1). a Referring to the section of the battery in this chapter, remove the battery correctly and safely.

3.

Remove mast (2). a Referring to the section of the MAST in this chapter, remove the mast correctly and safely.

4.

Disconnect drive motor cables U, V, and W.

5.

Disconnect the brake pipes from the damping cylinders (A and B in the figure at right) and wheel cylinders (C and D in the figure at right).

6.

Remove parking brake lever (3) together with the cable.

BE30 Series

30-11

POWER TRAIN

7.

REMOVAL AND INSTALLATION

Set chocks both sides of the frame so that the front wheels will be floated about 100 mm above the ground, or using jack E, jack up the frame. Remove the chocks from under the front wheels.

8. Set garage jack F under the power train (front axle + transfer + drive motor) to support the power train.

9. Remove the front axle mounting bolts (4) on the right side (4 pieces). a The right side of the axle is secured with the bolts and nuts through support (5).

10. Remove the front axle mounting bolts (6) on the left side (4 pieces). a The left side of the axle is secured directly to the case with the bolts and nuts.

30-12

BE30 Series

REMOVAL AND INSTALLATION

POWER TRAIN

11. Slowly pull the garage jack forward out of the chassis to take out the power train assembly (7) (front axle + transfer + drive motor).

BE30 Series

30-13

POWER TRAIN

REMOVAL AND INSTALLATION

2. INSTALLATION Carry out installation in the reverse order to removal and observe the following points. 1.

Tightening front axle mounting bolts (Both sides)

2.

343 – 427 Nm {35 – 43.5 kgm}

Tightening drive motor cable mounting bolts 10 – 12 Nm {102 – 122 kgcm}

3.

Connecting cables Bind the cables with tie-wraps so that they will not touch a sharp edge of the lift truck body or will not be caught in parts.

4.

Tightening brake pipe nipples Nipple (A, B, C, D)

30-14

10 – 13 Nm {102 – 133 kgcm}

BE30 Series

REMOVAL AND INSTALLATION

REAR AXLE

REAR AXLE 1. REMOVAL 1.

Sling the rear part of the frame with a crane and put wood chocks under both sides of it.

2.

Slinging counterweight (1) a little, remove its mounting bolts to remove it.

3.

Remove both rear wheels.

4.

Remove ball joint (3) from bell crank (2).

5.

Support the rear axle with garage jack A.

6.

Remove 2 rear axle support bolts (4).

7.

Pull out the rear axle in reverse. Pull the garage jack in reverse until the center pin of the rear axle comes off the support. After the center pin comes off the support, lower the garage jack and pull the rear axle in reverse out of the chassis.

BE30 Series

30-15

REAR AXLE

REMOVAL AND INSTALLATION

2. INSTALLATION Carry out installation in the reverse order to removal and observe the following points. 1.

Adjusting rear axle 1) Tighten adjustment bolt (1) until clearance a between rear axle (3) and bearing support (4) will be 0 (until play is eliminated). 2) Check that you can swing rear axle (3) with your hand. 3) Tighten locknut (2) to lock adjustment bolt (1). 4) Finally, check that rear axle (3) has no play and you can swing it. Tightening rear axle support bolt (5)

2.

1.0 – 1.75 ton models

245 – 309 Nm {25 – 31.5 kgm}

2.0 – 3.0 ton models

490 – 608 Nm {50 – 62 kgm}

Installation direction of rear axle support bushing Install the rear axle support bushing (6) with the hole up.

30-16

BE30 Series

REMOVAL AND INSTALLATION

BATTERY

BATTERY 1. REMOVAL 1.

Disconnect battery plug (1).

2.

Tilt the steering wheel forward. Set steering wheel lock lever (2) in FREE position A, tilt the steering wheel forward, and return lock lever (2) to LOCK position B.

3.

Open battery side covers (3) on both sides.

4.

Remove battery hood catch (4).

BE30 Series

30-17

BATTERY

REMOVAL AND INSTALLATION

5.

Open the battery hood and check that it is fixed with stopper (5) and will not close.

6.

Pass a crane wire through cut C of the head guard.

7.

Install the hooks of the wire to holes D (4 places) of the battery case and lift off battery (6) slowly.

2. INSTALLATION Carry out installation in the reverse order to removal. • Be sure to install crane wires to the 4 holes. • The battery shall be lifted by a person who has finished the slinging work course and who is qualified for using the crane. Battery weight table Model FB10EX/14EX FB10EX/14EX FB15EX/18EX FB15EXG/18EXG

Capacity (Ah)

Weight (kg)

330

625

400

700

485

770

545

845

700

1,115

Voltage (V)

Model FB20EX

48

FB20EX/25EX

FB20EXG/25EXG

FB30

30-18

Capacity (Ah)

Weight (kg)

450

820

565

925

600

945

700

1,035

935

1,375

1,080

1,605

450

1,500

545

1,500

Voltage (V)

48

72

BE30 Series

REMOVAL AND INSTALLATION

EPS ACTUATOR

EPS ACTUATOR 1. REMOVAL 1.

Put chocks under the front wheels.

2.

Disconnect battery plug and lift the battery off the chassis with a crane. (See REMOVAL OF BATTERY in this chapter.)

3.

Remove the rear axle. (See REMOVAL OF REAR AXLE in this chapter.)

4.

Remove ball joint (3) of drag link (2).

5.

Disconnect EPS wiring connector (9).

6.

Remove actuator mounting bolts (8).

7.

Pull actuator (6) in reverse out of the chassis.

2. INSTALLATION Carry out installation in the reverse order to removal and observe the following points. 1.

Tightening actuator mounting bolts Bolt (8)

2.

49 – 69 Nm {5 – 7 kgm}

Replacing and bending cotter pin Cotter pin (5)

BE30 Series

Use a new cotter pin and bend it securely after tightening the nut.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Pitman arm Drag link Ball joint Bell crank Cotter pin EPS actuator Frame Actuator mounting bolt EPS wiring connector

30-19

STEERING GEAR BOX

REMOVAL AND INSTALLATION

STEERING GEAR BOX

1. 2. 3. 4. 5. 6. 7.

Floor plate Bell crank Drag link EPS actuator Frame Ball joint Connector

8. 9. 10. 11. 12. 13.

Pitman arm Dashboard Mounting bolt Steering gear box Stopper bolt Universal joint

A. To controller

1. REMOVAL 1.

Remove floor plate (1).

2.

Disconnect wiring connector (7) for the EPS torque sensor.

3.

Remove ball joint (6) of the drag link from the pitman arm.

4.

Remove stopper bolt (12) of the universal joint spline.

5.

Remove gear box mounting bolts (10) and spline and pull out gear box (11) upward.

30-20

2. INSTALLATION Carry out installation in the reverse order to removal.

BE30 Series

REMOVAL AND INSTALLATION

HYDRAULIC PUMP + PUMP MOTOR

HYDRAULIC PUMP + PUMP MOTOR 1. REMOVAL 1.

Remove right side cover.

2

Disconnect pump motor (8) wires A1 and D2 .

3.

Disconnect wires (1) and (4) from hydraulic pump (3).

4.

Remove 3 bolts (6) of pump motor mounting bracket (5).

5.

Pull the hydraulic pump, pump motor, and pump motor mounting bracket as a unit from floor frame (9).

6.

Remove pump mounting bolts (2) (only when removing the pump).

7.

Remove the motor mounting bracket (7) (only when it needs to be removed).

2. INSTALLATION Carry out installation in the reverse order to removal and observe the following points. 1.

Tightening mounting nuts of wires (A1) and (D2) Mounting nuts of wires A1 and D2

BE30 Series

7.3 – 9.3 Nm {74 – 95 kgcm}

30-21

40. DISASSEMBLY AND ASSEMBLY Transfer (1.0 - 1.75 ton models). . . . . . . . . . . . 40- 2 Transfer (2.0 - 2.5 ton models). . . . . . . . . . . . . 40- 3 Transfer (3.0 ton model). . . . . . . . . . . . . . . . . . 40- 4 Differential (1.0 - 1.75 ton models). . . . . . . . . . 40-10 Differential (2.0 - 3.0 ton models) . . . . . . . . . . . 40-11 Front axle (1.0 - 1.75 ton models) . . . . . . . . . . 40-12 Front axle (2.0 - 2.5 ton models) . . . . . . . . . . . 40-13 Front axle (3.0 ton model) . . . . . . . . . . . . . . . . 40-14 Brake master cylinder . . . . . . . . . . . . . . . . . . . 40-15 Damping cylinder . . . . . . . . . . . . . . . . . . . . . . . 40-17 Wheel brake (1.0 - 1.75 ton models) . . . . . . . . 40-18 Wheel brake (2.0 - 2.5 ton models) . . . . . . . . . 40-19 Wheel brake (3.0 ton model) . . . . . . . . . . . . . . 40-20 Steering gear box. . . . . . . . . . . . . . . . . . . . . . . 40-21 EPS actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38 Rear axle (1.0 - 1.75 ton models). . . . . . . . . . . 40-45 Rear axle (2.0 - 3.0 ton models). . . . . . . . . . . . 40-49 Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52 Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . 40-56 Control valve (Proportional solenoid valve spec.) . . . . . . . . . 40-60 Control valve (Manual valve spec.) . . . . . . . . . 40-62 Drive motor (1.0 - 2.5 ton models) . . . . . . . . . . 40-71 Drive motor (3.0 ton model) . . . . . . . . . . . . . . . 40-72 Pump motor (1.0 - 1.75 ton models) . . . . . . . . 40-74 Pump motor (2.0 - 3.0 ton models) . . . . . . . . . 40-75

BE30 Series

40-1

TRANSFER

DISASSEMBLY AND ASSEMBLY

TRANSFER (1.0 - 1.75 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY

Criteria Symbol

Inspection item

Criteria

—

Press-fitted parts of shaft and gear

No clearance.

—

Each gear

Tooth surface must be free from damage, excessive wear, and bad contact.

—

Bearing

Must be free from play and flaw.

40-2

Remedy

Replace

BE30 Series

DISASSEMBLY AND ASSEMBLY

TRANSFER

TRANSFER (2.0 - 2.5 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY

Criteria Symbol

Inspection item

Criteria

—

Press-fitted parts of shaft and gear

No clearance.

—

Each gear

Tooth surface must be free from damage, excessive wear, and bad contact.

—

Bearing

Must be free from play and flaw.

BE30 Series

Remedy

Replace

40-3

TRANSFER

DISASSEMBLY AND ASSEMBLY

TRANSFER (3.0 TON MODEL) 1. DISASSEMBLY AND ASSEMBLY

Criteria Symbol

Inspection item

Criteria

—

Press-fitted parts of shaft and gear

No clearance.

—

Each gear

Tooth surface must be free from damage, excessive wear, and bad contact.

—

Bearing

Must be free from play and flaw.

40-4

Remedy

Replace

BE30 Series

DISASSEMBLY AND ASSEMBLY

TRANSFER

2. DISASSEMBLY 1.

Remove oil filler plug (1) and drain plug (2) to drain the oil.

2.

Remove front wheels (3), torque shafts (4), hubs (5), and wheel brakes (6) on both sides.

3.

Remove drive motor mounting bolts (7) and drive motor (8).

4.

Set the transfer assembly securely and vertically as shown in the figure at right so that it will fall down.

BE30 Series

40-5

TRANSFER

5.

Remove cage (9) and plate (10).

6.

Remove case mounting bolts, and then sling and hold right-hand case (14) with a crane.

7.

Gradually lift up right-hand case (14) about 30 mm.

DISASSEMBLY AND ASSEMBLY

a If bearing (16) of shaft (15) is not separated from right-hand case (14), hit shaft (15) with a bar. (The inner race of the bearing is removed together with the shaft.)

8.

Slinging right-hand case (14) about 30 mm, turn (slide) it about 20 degrees from left-hand case (17) and lift it off. a If right-hand case (14) is lifted up straight, its part P will interfere with the ring gear (26) of the differential. Accordingly, turn (slide) it in direction A about 20 degrees from left-hand case (17) as shown in the figure, and then lift it up.

9.

Remove differential assembly (18), output shaft (15), intermediate gear (19), and input gear (20) from left-hand case (17).

40-6

BE30 Series

DISASSEMBLY AND ASSEMBLY

TRANSFER

3. ASSEMBLY 1.

Install bearing (21) to input gear (20).

2.

Install bearing (22) to intermediate gear (19).

(1.0 – 1.75 ton models)

(2.0 – 3.0 ton models)

(1.0 – 1.75 ton models)

(2.0 – 3.0 ton models)

(1.0 – 1.75 ton models)

(2.0 – 3.0 ton models)

a Install the roller bearings of the 2.0 – 3.0 ton models so that their inner race flanges B will be on the gear (19) side. (See the figure at right.)

3.

Install the bearing to output shaft (15). a Install only the inner race of bearing (16) on the small gear side. (See the figure at right.) a Install bearing (23) on the large gear side in the correct direction, referring to the figure at right. a Only bearing (23) on the large gear side of the 1.0 – 1.75 ton models is secured with snap ring (24).

4.

Install bearing (25) to differential assembly (18).

BE30 Series

40-7

TRANSFER

5.

Set left-hand case (17) securely and vertically as shown in the figure at right and install gasket (26).

6.

Install the following parts to left-hand case (17) in order. 1. Input gear (20) 2. Intermediate gear (19) 3. Output shaft (15) 4. Differential assembly (18)

DISASSEMBLY AND ASSEMBLY

a If a bearing cannot be fitted to the case, hit it lightly with a copper hammer.

7.

Drive dowel pin (27) into left-hand case (17).

8.

Sling right-hand case (14) with the crane and hold it above left-hand case (17), and then lower it gradually, turning it about 20 degrees as explained below. a If right-hand case (14) is lowered straight, its part P will interfere with ring gear (26) of the differential. Accordingly, turn (slide) it in direction A about 20 degrees from left-hand case (17) as shown in the figure at right, and then lower it.

40-8

BE30 Series

DISASSEMBLY AND ASSEMBLY

TRANSFER

9. After the differential case is set in right-hand case (14) and the distance between the right-hand case (14) and left-hand case (17) becomes 30 mm, return right-hand case (14) to the original position and lower it further. 10. Align the bolt holes of right-hand case (14) and left-hand case (17) and set the guide bolts as shown in the figure at right.

11. Hit right-hand case (14) with a hammer so that each gear and each bearing will be set correctly. 12. Tighten case mounting bolts.

13. 1.5 – 1.75 ton models: Drive in the outer race of roller bearing (16), install the inner race collar, and install plate (10) with bolts (28). 2.0 – 3.0 ton models: Drive in the outer race of roller bearing (16), install the inner race collar, drive in roller bearing (16A), and install plate (10) with bolts (28). Plate (10)

LOCTITE #271 (Bolt hole)

Bolt (28)

14.7 – 34.3 Nm {1.5 – 3.5 kgm}

14. Install cage (9) with bolts (29). 15. Install snap ring (30) and drive in cover (31).

BE30 Series

40-9

DIFFERENTIAL

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL (1.0 – 1.75 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY a Apply Grease (G2-LI) to rotary parts and sliding parts. 1. Hole side of threaded part.

Criteria Symbol

Unit: mm

Inspection item

A

Differential pinion gear and differential side gear

B

Outside diameter of spider

C

Criteria Standard size —

Repair limit

When tooth surface is Replace gear damaged. set

21.959 – 21.980

21.75

Inside diameter of differential pinion gear

22.0 – 22.2

22.3

D

Thickness of bushing

1.54 – 1.66

1.3

E

Thickness of bushing

1.54 – 1.66

1.3

—

Inside diameter of brake drum

254.0 – 254.2

256

—

Gasket, O-ring, seals

—

—

40-10

Remedy

Replace

Replace when reassembling

BE30 Series

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL

DIFFERENTIAL (2.0 – 3.0 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY a Apply Grease (G2-LI) to rotary parts and sliding parts. 1. Hole side of threaded part.

Criteria Symbol

Unit: mm

Inspection item

A

Differential pinion gear and differential side gear

B

Outside diameter of spider

C

Criteria Standard size —

Repair limit

When tooth surface is Replace gear damaged. set

24.959 – 24.980

24.75

Inside diameter of differential pinion gear

25.0 – 25.1

25.2

D

Thickness of bushing

1.94 – 2.06

1.7

E

Thickness of bushing

1.52 – 1.68

1.3

—

Inside diameter of brake drum

279.4 – 279.6

281.4

—

Gasket, O-ring, seals

—

—

BE30 Series

Remedy

Replace

Replace when reassembling

40-11

FRONT AXLE

DISASSEMBLY AND ASSEMBLY

FRONT AXLE (1.0 - 1.75 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY

1. Fill space with grease up to 1/2 – 2/3 of its volume. 2. Lip portion 3. Adjust with nut A. 4. Threaded portion

Criteria Symbol

Unit: mm

Inspection item

Criteria Standard size

Repair limit

254 – 254.2

256

0

0

—

Inside diameter of brake drum

—

Play of hub

—

Front axle

Distortion, crack, damage

—

Shaft pipe

Distortion, crack, damage

—

Brake drum

Uneven wear and flaw of inside wall of brake drum

40-12

Remedy Replace Replace bearing

Replace

BE30 Series

DISASSEMBLY AND ASSEMBLY

FRONT AXLE

FRONT AXLE (2.0 - 2.5 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY 1. Lip portion

2. Seat must be fitted to hub. 3. Threaded portion

4. Fill space with grease up to 1/ 2 – 2/3 of its volume. 5. Adjust with nut A.

Criteria Symbol

Unit: mm

Inspection item

Criteria Standard size

Repair limit

279.4 – 279.6

281.4

0

0

—

Inside diameter of brake drum

—

Play of hub

—

Front axle

Distortion, crack, damage

—

Shaft pipe

Distortion, crack, damage

—

Brake drum

Uneven wear and flaw of inside wall of brake drum

BE30 Series

Remedy Replace Replace bearing

Replace

40-13

FRONT AXLE

DISASSEMBLY AND ASSEMBLY

FRONT AXLE (3.0 TON MODEL) 1. DISASSEMBLY AND ASSEMBLY

1. Fill space with grease up to 1/2 – 2/3 of its volume. 2. Lip portion 3. Adjust with nut A. 4. Threaded portion

Criteria Symbol

Unit: mm

Inspection item

Criteria Standard size

Repair limit

310.0 – 310.2.6

312

0

0

—

Inside diameter of brake drum

—

Play of hub

—

Front axle

Distortion, crack, damage

—

Shaft pipe

Distortion, crack, damage

—

Brake drum

Uneven wear and flaw of inside wall of brake drum

40-14

Remedy Replace Replace bearing

Replace

BE30 Series

DISASSEMBLY AND ASSEMBLY

BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER 1. DISASSEMBLY AND ASSEMBLY 1.

Insert a screwdriver in the fitting groove of bellows (2) of the cylinder to remove the bellows.

2.

Pull out push rod (1).

3.

Remove snap ring (3) and take out piston assembly (4). At this time, push in the piston a little, and you can remove the snap ring. a Take care not to damage the cylinder piston and cup. a Do not disassemble piston assembly (4).

4.

Loosen and remove clamp (5). Grip the cylinder body lightly in a vise and remove filler union (6) with pliers.

Criteria Symbol

Unit: mm

Inspection item

A

Clearance between cylinder and piston

B

Interference of cup (Outside diameter of cup - Inside diameter of cylinder)

C

Spring

BE30 Series

Criteria Standard size

Repair limit

0.020 – 0.104

0.15

P-cup: Approx. 0.8 S-cup: Approx. 1.3

0.3

Must be free from flaw, wear, and lean

Remedy Replace cylinder assembly Replace piston assembly

40-15

BRAKE MASTER CYLINDER

DISASSEMBLY AND ASSEMBLY

2. ASSEMBLY Carry out installation in the reverse order to removal. 1.

Apply rubber grease of brake oil evenly and sufficiently to the inside surface of the cylinder and outside surface of the piston.

2.

Applying a guide or a cushion to filler union (6), hit it lightly with a plastic hammer to fit the filler union, and then tighten clamp (5).

CAUTION • Use only alcohol or brake oil to clean the parts. In particular, never use mineral oil (kerosene, gasoline, etc.) (If mineral oil sticks to a rubber part, the latter swells and cannot be used.) • After cleaning the parts, keep them in a clean place so that dust will not stick to them. • Take care that impurities will not enter and damage the cylinder, piston, cup, etc.

40-16

BE30 Series

DISASSEMBLY AND ASSEMBLY

DAMPING CYLINDER

DAMPING CYLINDER 1. DISASSEMBLY

2. ASSEMBLY Carry out installation in the reverse order to removal.

1.

Remove end plug (3) and take out spring (2).

2.

Supply compressed air through the pipe joint to take out piston assembly (1).

•

Apply rubber grease to the piston end and spring.

1. Apply rubber grease.

Criteria Symbol

Unit: mm

Inspection item

A

Clearance between cylinder and piston

B

Interference of cup (Outside diameter of cup - Inside diameter of cylinder)

C

Spring

BE30 Series

Criteria Standard size

Repair limit

0.020 – 0.104

0.15

Approx. 1.0

0.4

Must be free from flaw, wear, and lean

Remedy Replace cylinder assembly Replace piston assembly

40-17

WHEEL BRAKE

DISASSEMBLY AND ASSEMBLY

WHEEL BRAKE (1.0 – 1.75 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY

Criteria Symbol A

B

C

Unit: mm

Inspection item Lining

Return spring

Wheel cylinder

Thickness of Lining

Repair limit

Free length

B1 B2

97 97

2.0 105 105

Thickness of hook

B1 B2

2.6 2.6

2.0 2.0

4.5

Appearance

Must be free from flaw and cracking.

Sliding surface

Must be free from flaw.

Inside diameter Clearance between of cylinder: wheel cylinder and piston 22.22

D

Piston

Clearance between piston and cylinder

E

Cup

Damage and fatigue

40-18

Criteria Standard size

0 – 0.05

0 – 0.05

Remedy

Replace

0.2 0.2

Must be free from damage and fatigue

BE30 Series

DISASSEMBLY AND ASSEMBLY

WHEEL BRAKE

WHEEL BRAKE (2.0 – 2.5 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY

Criteria Symbol A

Unit: mm

Inspection item Lining

Lining Free length

B

C

Return spring

Wheel cylinder

Thickness of hook

5.1 B1

110

B2 B1

106 3.2

108 2.6

B2

2.6

2.0

Must be free from flaw and crack

Sliding surface

Must be free from flaw

Clearance between cylinder and piston

Inside diameter of cylinder: 25.40

Piston

Clearance between piston and cylinder

E

Cup

Damage and fatigue

Repair limi 2.0 112

Appearance

D

BE30 Series

Criteria Standard size

0 – 0.05

0 – 0.05

Remedy

Replace 0.2 0.2

Must be free from damage and fatigue

40-19

WHEEL BRAKE

DISASSEMBLY AND ASSEMBLY

WHEEL BRAKE (3.0 TON MODEL) 1. DISASSEMBLY AND ASSEMBLY

Criteria Symbol A

Unit: mm

Inspection item Lining

Lining Free length

B

C

Return spring

Wheel cylinder

Thickness of hook

5.67 B1

124

B2 B1

124 2.9

136 2.0

B2

2.9

2.0

Must be free from flaw and crack

Sliding surface

Must be free from flaw

Clearance between cylinder and piston

Inside diameter of cylinder: 28.58

Piston

Clearance between piston and cylinder

E

Cup

Damage and fatigue

Repair limi 2.0 136

Appearance

D

40-20

Criteria Standard size

0 – 0.05

0 – 0.05

Remedy

Replace 0.2 0.2

Must be free from damage and fatigue

BE30 Series

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

STEERING GEAR BOX 1. NAME OF EACH PART

1. 2. 3. 4. 5. 6. 7. 8.

Gear box Sector shaft Pitman arm Ball nut Ball Ball tube Worm shaft Rear cover

BE30 Series

9. 10. 11. 12. 13. 14. 15.

Dust cover Side cover Spring Sensor housing Front cover Potentiometer (Torque sensor) Potentiometer cover

40-21

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

2. DISASSEMBLY 1.

Remove dust and stain. a Do not use fuel oil, gasoline, paint thinner, etc. for cleaning, since they can break the potentiometer.

2.

Grip pitman arm (1) in a vise and loosen the locknut.

3.

Grip the gear box in the vise with slit mark A at the sector shaft end down. a If the slit mark A is set down, its position is the center of the steering angle.

4.

Put block B to lock the pitman arm (1) and remove the pitman arm with pitman arm puller C. a Do not hit the pitman arm with a hammer to remove it. a If you work at the end of the steering angle, the internal parts may be broken. Accordingly, be sure to set the slit mark A down (work at the center of the steering angle).

40-22

BE30 Series

DISASSEMBLY AND ASSEMBLY

5.

STEERING GEAR BOX

Remove potentiometer cover (2) and potentiometer. a Remove the potentiometer only when it needs to be removed.

6.

Remove the front cover mounting bolts and front cover (3).

7.

Install set plate jig D (see page 40-37 SPECIAL TOOLS) instead of the front cover with bolts D1. Bolt D1

BE30 Series

Approx. 44.1 Nm {4.5 kgm}

40-23

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

8. Raise bent part E of the locknut with a screwdriver.

9. Fix serrated part F of the worm shaft and remove locknut (4). a Keep the slit mark at the sector shaft end down during the above work. a Work with clean hands so that dirt will not stick to the parts.

10. Remove the following parts, and then remove set plat jig D installed in step 7. 1) Bearing ring ( 31 mm, t = 1.0mm) 2) Thrust needle roller bearing 3) Bearing ring ( 40 mm, t = 4.0mm)

40-24

BE30 Series

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

11. Taking care not to drop the spring, remove the sensor housing, and then remove the following parts. 1) 2) 3) 4)

Bearing ring ( 40 mm, t = 4.0mm) Thrust needle roller bearing Bearing ring ( 31 mm, t = 4.0mm) O-ring at mounting face of sensor housing

12. Remove the side cover mounting bolts and side cover (5). At this time, the sector shaft comes off, too. Remove the side cover packing. a The slit mark at the sector shaft end must be set down.

13. Remove the dust cover, rear cover mounting bolts, and recover. 14. Pull out worm shaft (6) without removing the ball nut.

BE30 Series

40-25

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

3. ASSEMBLY 1.

Grip the gear box in the vise and install worm shaft (6) and ball nut with the tooth surface of the ball nut up.

a Before starting the work, apply grease to parts G shown in the figure at right. Part G

MITSUBISHI DIAMOND GREASE CLS No. 1, No. 0

a Work in a clean place with the clean hands. Never put on gloves.

2.

Check that the lip of oil seal (1) is not rolled up.

3.

Install rear cover (2) with the rear cover mounting bolts. Rear cover mounting bolt

40-26

16.7 – 27.4 Nm {1.7 – 2.8 kgm}

BE30 Series

DISASSEMBLY AND ASSEMBLY

4.

STEERING GEAR BOX

Sub-assemble the sector shaft. [Adjusting shim] Install shim (4) to adjustment screw (3) and set it in the T-groove of the sector shaft. Select the thickness of the shim so that the clearance in the axial direction will be 0.05 mm or less. Install the shim with more chamfered side H on the thread side.

[Installing adjustment screw] Apply grease (MITSUBISHI DIAMOND GREASE CLS No. 1, No. 0) to the T-groove and shim, and then install adjustment screw (3) to sector shaft (5).

5.

Install side cover (8) to sector shaft (5). 1) Apply grease to the bearing of side cover (8) and install it to sector shaft (5), and then tighten adjustment screw (3) to the end. 2) Apply gasket sealant to the threads of adjustment screw (3) and tighten locknut (7). Gasket sealant

6.

SEALEND No. 22 manufactured by SEALEND

Set ball nut (9) so that its gear will be aligned with the sector shaft mounting hole.

BE30 Series

40-27

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

7.

Install the side cover packing, and then install sector shaft assembly (10) so that its gear will be aligned with the ball nut gear.

8.

Install side cover (11) and tighten the side cover mounting bolts. Side cover mounting bolt

9.

16.7 – 27.4 Nm {1.7 – 2.8 kgm}

Apply grease to O-ring (12) and set it to the Oring groove.

10. Install the bearing rings and thrust needle roller bearing in the following order. 1) 2) 3) a

Bearing ring (13) ( 31 mm, t = 4.0 mm) Thrust needle roller bearing (14) Bearing ring (15) ( 40 mm, t = 4.0 mm) When installing these parts, apply grease to them. Grease

40-28

MULTEMP SC-W manufatured by KYODO-YUSHI

BE30 Series

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

11. Apply grease to the inside wall of slide ring (16) and install sensor housing (17). MULTEMP SC-W manufactured Grease by KYODO-YUSHI

12. Install set plate jig D (See page 40-34 SPECIAL TOOLS) with the mounting bolts. Mounting bolt of set plate jig

Approx. 44.1 Nm {4.5 kgm}

13. Install the bearing rings and thrust needle roller bearing in the following order. 1) 2) 3) a

Bearing ring ( 40 mm, t = 4.0 mm) Thrust needle roller bearing Bearing ring ( 31 mm, t = 4.0 mm) When installing these parts, apply grease (MULTEMP SC-W manufactured by KYODO-YUSHI) to them.

BE30 Series

40-29

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

14. Tighten locknut (18) according to the following procedure. 1) Set pitman arm (1) as shown in the figure at right and secure sector shaft (5). 2) Turn the connecting part of the universal joint of the worm shaft. (At this time, the worm shaft slides about 1.6 mm.) 3) With the worm shaft turned, tighten locknut (18) with the fingers so that axial play will not be made.

15. Release the worm shaft and bend the locknut with bending punch J (See page 40-37 SPECIAL TOOLS). (2 places)

a After bending the locknut, check that part K does not have play or a crack.

16. Turn the connecting part of the universal joint of the worm shaft to the left. Check that locknut (18) does not have circumferential play under this condition. a If the locknut has any play, bend it again. 17. Remove the pitman arm set to secure the sector shaft. 18. Remove set plate jig D.

40-30

BE30 Series

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

19. Fit the O-ring in the O-ring groove of the mounting face of front cover (3), and then install the front cover with the mounting bolts. Front cover mounting bolt 34.3 – 52.9 Nm {3.5 – 5.4 kgm}

20. Determine the center of the operating angle according to the following procedure. 1) Rotate the worm shaft from the left stroke end to the right stroke end, and then set it to the center of its rotation angle. a The worm shaft must be rotated at least 4.8 turns to cover from the left stroke end to the right stroke end. If it is not rotated so many turns, the ball nut gear is not engaged properly with the sector shaft gear. In this case, repeat the installation work of the sector shaft.

21. Measure the backlash. Set pitman arm (1) and dial gauge L as shown in the figure at right, and then push and pull the pitman arm in direction S with a force of 19.6 N {2 kgf} and measure the backlash. Backlash: If below 0.3 mm, normal. If above 0.3 mm, adjust.

BE30 Series

40-31

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

22. Adjust the backlash. Loosen the locknut and turn the adjustment screw to reduce the backlash below 0.3 mm, and then tighten the locknut. Backlash Locknut

Max. 0.3 mm 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

a Be sure to adjust the backlash at the center of the steering angle. 23. Supply grease (MITSUBISHI DIAMOND GREASE CLS No. 1, No. 0) by 180 ± 2 g.

24. Check the operation. 1) Push and pull pitman arm (1) to check its operation. If it is not hitched, it is normal. 2) Measure the turning torque of the worm shaft. Turning torque of worm shaft

Max. 0.49 Nm {5 kgcm}

25. Grip pitman arm (1) in vise M as shown in the figure at right. a Do not grip the pitman arm near an end of the steering angle.

40-32

BE30 Series

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

26. Apply grease to the roller at end of potentiometer (torque sensor) (19) and fit the O-ring, and then install the potentiometer. Grease

MULTEMP SC-W manufactured by KYODO-YUSHI

a Install potentiometer (19) so that the roller at part N will be in the arm.

27. Tighten the potentiometer mounting screw lightly (temporarily).

28. Set stabilized power supply (5 V) P and digital multimeter Q as shown in the circuit diagram to measure the voltage of the potentiometer (torque sensor).

BE30 Series

40-33

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

29. Measure and adjust the output voltage of the potentiometer (torque sensor) when the steering wheel is in neutral. 1) Turn worm shaft (20) to the right and release it. Measure the voltage at this time (voltage in neutral). 2) Turn worm shaft (20) to the left and release it. Measure the voltage at this time (voltage in neutral). Voltage in neutral

Main side

2.5 ± 0.1 V

Sub side

2.5 ± 0.4 V When main side is used When sub side is used

3) If the voltage in neutral is out of the above range, adjust it with potentiometer (19). After adjusting, tighten the mounting screw to the specified torque. Potentiometer mounting screw

40-34

2.94 – 3.92 Nm {30 – 40 kgcm}

BE30 Series

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

a If the voltage is out of the specified range, the mounting screw may be installed defectively. In this case, remove the potentiometer and repeat the work from temporary installation of the mounting screw.

31. Turn the steering wheel to the left and measure the output voltage. Turn the worm shaft to the left and measure the output voltage. Voltage when steered to left

30. Turn the steering wheel to the right and measure the output voltage. Turn the worm shaft to the right end and measure the output voltage. Voltage when steered to right

Main side

0.9 – 1.4 V

Sub side

0.6 – 1.7 V

Main side

3.6 – 4.1 V

Sub side

3.3 – 4.4 V

32. Measure the relationship between the input torque and sensor output voltage with an XY recorder and check that the result is as follows.

Characteristic curves of torque sensor voltage (Main side)

BE30 Series

40-35

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

33. Install potentiometer cover (21) and secure it with the bolts. Install clip (22) to the right bolt as shown in the figure at right.

34. Clamp potentiometer wiring harness (23) with clip (22). a When clamping the wiring harness, slacken it properly.

35. Match the slit marks A of the pitman arm and sector shaft to each other as shown in the figure.

Grip pitman arm (1) in the vise and tighten the locknut. Locknut of pitman arm

17.7 – 21.5 Nm {18 – 22 kgm}

36. Install the dust cover to the serrated part.

40-36

BE30 Series

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

4. SPECIAL TOOLS Set plate jig D 1. Fitting side of set plate

Bending punch J

BE30 Series

40-37

EPS ACTUATOR

DISASSEMBLY AND ASSEMBLY

EPS ACTUATOR 1. NAME OF EACH PART

1. 2. 3. 4. 5. 6.

EPS motor Actuator sub-assembly Packing Motor mounting bolt Bellows Wire clamp

40-38

7. 8. 9. 10. 11. 12.

Wire clamp Connector Locknut Ball joint Ball screw shaft Breather plug

BE30 Series

DISASSEMBLY AND ASSEMBLY

EPS ACTUATOR

2. REPLACING EPS MOTOR 1.

Grip actuator (1) in a vise horizontally as shown in the figure at right. a If the actuator is set vertically, the ball screw assembly rotates automatically when the bellows is removed. If the ball screw extends too much at this time, it may break the ball tube.

2.

Remove 3 motor mounting bolts (2) and EPS motor. a If the motor cannot be separated, hit it lightly with a plastic hammer.

3.

Remove the used packing from the mounting face of the motor and wipe the mounting face with clean cloths. a When removing the motor, take care not to lose motor joint (3).

4.

Apply grease to the inside tooth surfaces of the motor joint and fit new packing, and then install the motor. Motor mounting bolt

BE30 Series

18.7 – 230.3 Nm {1.9 – 3.1 kgm}

40-39

EPS ACTUATOR

DISASSEMBLY AND ASSEMBLY

3. REPLACING BALL JOINT 1.

Grip connector (3) in the vise to secure actuator (1).

2.

Loosen locknut (4) on the ball joint side and remove ball joint (5) from the connector. a Since the threads are coated with LOCTITE, the locknut and connector cannot be loosened easily. Take care.

3.

Apply LOCTITE #271 to connector (3) and threads of locknut (4). Set new joint (5) as shown in the right figure and tighten the locknut. a After finishing work, check that bellows (2) is not twisted.

40-40

Locknut

LOCTITE #271

Locknut

177 – 215 Nm {18 – 22 kgm}

BE30 Series

DISASSEMBLY AND ASSEMBLY

EPS ACTUATOR

a Set breather plug A at 20 degrees from the center of the bolt of the ball joint (5).

BE30 Series

40-41

EPS ACTUATOR

DISASSEMBLY AND ASSEMBLY

4. REPLACING BELLOWS 1.

Grip connector (1) in the vise to secure the actuator.

2.

Remove the wire clamp of bellows (2), and then move bellows (2) and loosen locknut (3). a Since the threads are coated with LOCTITE, the locknut cannot be loosened easily. Take care.

3.

Secure ball screw shaft (4) and apply a spanner to the spanner hook of connector (1), and the turn connector (1) slowly to remove it. a Be sure to secure ball screw shaft (4) side for the above work. If the other side is secured and the ball screw shaft extends, the ball tube of the ball screw may be broken.

4.

Remove the used bellows and install new bellows (2). a Install the bellows with the larger diameter side a on actuator (5) side. Install the wire clamp too, at this time.

40-42

BE30 Series

DISASSEMBLY AND ASSEMBLY

5.

EPS ACTUATOR

Grip actuator (5) in the vise again as shown in the figure and install connector (1). a When installing the connector, apply LOCTITE #271 to it and threads of the locknut. Locknut

LOCTITE #271

6.

Turn ball screw shaft (4) to the left to press part A against the bottom, and then adjust dimension C into the following range. Standard dimension C: 473.5 + 30 mm

7.

After positioning the ball screw shaft, grip connector (1) again as shown in the figure and tighten locknut (3). Locknut

8.

177 – 215 Nm {18 – 22 kgm}

Set the actuator, connector, and ball joint as shown in the figure and clamp the bellows with the wires (2 places). a Set breather plug B at 20 degrees from the center of the bolt of ball joint (6).

BE30 Series

40-43

EPS ACTUATOR

DISASSEMBLY AND ASSEMBLY

a Wind the wire by 2 turns and twist it 4 – 5 times. Bellows must not be dragged. The first and second turns of the wire must not cross each other on the opposite side of the twisted part. Correct twist of the bellows before clamping. Bend the wire so that it will not interfere with the bellows and chassis.

40-44

BE30 Series

DISASSEMBLY AND ASSEMBLY

REAR AXLE

REAR AXLE (1.0 – 1.75 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY

BE30 Series

1. When installing the ball sockets (4 places), clean and degrease their mounting faces and the holes of the mating parts. 2. Lip portion 3. Fill bearing space with grease up to 1/2 – 2/3 of volume of space. 4. Adjust with nut E

40-45

REAR AXLE

DISASSEMBLY AND ASSEMBLY

2. TESTING AND INSPECTION Unit: mm

Symbol

Criteria

Inspection item

Standard size

Repair limit

Remedy

A

Diameter of king pin

28

27.8

Replace

B

Vertical play of knuckle

—

0.2

Adjust shim

C

Diameter of bell crank pin

28

27.8

D

Diameter of center pin

50

49.5

—

Rear axle, hub, knuckle, bearing

Replace

• Crack • Damage, flaking • Seizure, defective rotation, abnormal noise

The symbols correspond to the alphabet letters in the figure on the previous page.

3. PRECAUTIONS FOR ASSEMBLY 1.

Hub bearing Fill hub bearing space A with grease (G2-LI) up to 1/2 – 2/3 of volume of space.

2.

Adjusting turning torque of hub 1) Tighten locknut (2) until it becomes difficult to turn hub (1) with one hand. 2) Loosen locknut (2) by 1/4 turn. 3) Hook a spring balance to the hub bolt and adjust the turning torque to 19.6 – 25.5 N {2 – 2.6 kgf} with locknut (2) to give preload to taper roller bearing (3).

40-46

BE30 Series

DISASSEMBLY AND ASSEMBLY

3.

REAR AXLE

Adjusting toe-in 1) Secure the bell crank with the bell crank pin and connect the tie rod and knuckle. 2) Align the hole ( 22) at the center of the axle with the hole ( 22) of the bell crank and insert the pin to set the wheels in the straight travel position, and then adjust the toe-in. 3) Loosen the locknut of the tie rod and turn the tie rod to adjust the toe-in to 0. Toe-in: L1 – L2 = 0 – --1 4) Tighten the locknut of the tie rod. Locknutt

BE30 Series

245 – 304 Nm {25 – 31 kgm}

40-47

REAR AXLE

DISASSEMBLY AND ASSEMBLY

4. ASSEMBLY DRAWING FOR REAR AXLE 1. Be sure to bend cotter pin. 2. Fill bearing space with grease up to 1/2 – 2/3 of volume of space. 3. Adjust with nut A 4. Press fit bolt with jig. 5. Lip surface

40-48

BE30 Series

DISASSEMBLY AND ASSEMBLY

REAR AXLE

REAR AXLE (2.0 – 3.0 TON MODELS) 1. DISASSEMBLY AND ASSEMBLY

BE30 Series

1. When installing the ball sockets (4 places), clean and degrease their mounting faces and the holes of the mating parts. 2. Fill bearing space with grease up to 1/2 – 2/3 of volume of space. 3. Adjust with nut E 4. Press fit bolt with jig.

40-49

REAR AXLE

DISASSEMBLY AND ASSEMBLY

2. TESTING AND INSPECTION Unit: mm

Symbol

Criteria

Inspection item

Standard size

Repair limit

Remedy

A

Diameter of king pin

28

27.8

Replace

B

Vertical play of knuckle

—

0.2

Adjust shim

C

Diameter of bell crank pin

28

27.8

D

Diameter of center pin

50

49.5

—

Rear axle, hub, knuckle, bearing

Replace

• Crack • Damage, flaking • Seizure, defective rotation, abnormal noise

The symbols correspond to the alphabet letters in the figure on the previous page.

3. PRECAUTIONS FOR ASSEMBLY 1.

Hub bearing Fill hub bearing space A with grease (G2-LI) up to 1/2 – 2/3 of volume of space.

2.

Adjusting turning torque of hub 1) Tighten locknut (2) until it becomes difficult to turn hub (1) with one hand. 2) Loosen locknut (2) by 1/4 turn. 3) Hook a spring balance to the hub bolt and adjust the turning torque to 19.6 – 25.5 N {2 – 2.6 kgf} with locknut (2) to give preload to taper roller bearing (3).

40-50

BE30 Series

DISASSEMBLY AND ASSEMBLY

3.

REAR AXLE

Adjusting toe-in 1) Secure the bell crank with the bell crank pin and connect the tie rod and knuckle. 2) Align the hole ( 22) at the center of the axle with the hole ( 22) of the bell crank and insert the pin to set the wheels in the straight travel position, and then adjust the toe-in. 3) Loosen the locknut of the tie rod and turn the tie rod to adjust the toe-in to 0. Toe-in: L1 – L2 = 0 – --1 4) Tighten the locknut of the tie rod. Locknutt

4.

245 – 343 Nm {25 – 35 kgm}

Adjusting stopper bolts 1) Adjust stopper bolts (1) and (4) so that steering angles A (inside) and B (outside) of the tires will be as follows. A

57°

B

80°

2) Adjustment dimensions of stopper bolts. Stopper (1), (4)

C: 14 mm

Stopper (2), (3)

D: 8 mm

BE30 Series

40-51

LIFT CYLINDER

DISASSEMBLY AND ASSEMBLY

LIFT CYLINDER 1. DISASSEMBLY AND ASSEMBLY

1. 2. 3. 4. 5.

Cylinder Piston rod Cylinder head Bushing U-ring

40-52

6. 7. 8. 9. 10.

1. 2.0 – 3.0 ton models

Wiper seal O-ring U-ring Backup ring Bushing

11. 12. 13. 14.

Bearing Snap ring Spacer O-ring

BE30 Series

DISASSEMBLY AND ASSEMBLY

LIFT CYLINDER

Criteria

Unit: mm

Symbol A

B

C

Criteria Standard size

Inspection item

Repair limit

Clearance between piston rod and bushing

1.0 – 1.75 ton models

0.06 – 0.235

0.4

2.0 – 3.0 ton models

0.04 – 0.023

0.35

Clearance between piston ring and cylinder

1.0 – 1.75 ton models

0.05 – 0.30

0.5

2.0 – 3.0 ton models

0.05 – 0.035

0.5

Outside diameter of cylinder

1.0 – 1.75 ton models

2.0 – 2.5 ton models 57

63

D

Inside diameter of cylinder

45

50

55

E

Diameter of piston rod

35

40

45

F

Stroke

1,505

Replace bushing Replace piston ring

3.0 ton model

52

1,505

Remedy

—

—

1,505

Lifting height: 3 m

BE30 Series

40-53

TILT CYLINDER

DISASSEMBLY AND ASSEMBLY

TILT CYLINDER (6°/12°) 1. DISASSEMBLY DRAWING

1. 2. 3. 4. 5. 6.

Cylinder Piston rod Cylinder head Bushing U-ring Ring

40-54

7. 8. 9. 10. 11. 12.

Snap ring Wiper ring O-ring Backup ring O-ring Piston

13. 14. 15. 16. 17. 18.

O-ring Backup ring Piston nut Rod head Bushing Bolt

19. 20. 21. 22.

Spring washer Nut Fitting Bushing

BE30 Series

DISASSEMBLY AND ASSEMBLY

TILT CYLINDER

Criteria

Unit: mm

Symbol

Criteria Standard size

Inspection item

Repair limit

A

Clearance between piston rod and bushing

0.04 – 0.167

0.3

B

Clearance between rod head bushing and pin

0.05 – 0.23

0.5

C

Outside diameter of cylinder

1.0 – 1.75 ton models

2.0 – 2.5 ton models

Remedy Replace bushing

3.0 ton model

73

84

84

D

Inside diameter of cylinder

60

70

70

E

Diameter of piston rod

25

30

30

F

Stroke

139

141

157

—

—

Lifting height: 3 m

2. DISASSEMBLY 1)

2)

3)

Grip the bottom parallel part of cylinder tube (1) in a vise and make a mark at rod head (16) to check the tightening depth, and then remove the rod head. Apply a wrench to the cut of cylinder head (3) and turn it to pull the cylinder head out of the cylinder tube. At this time, wind a tape onto threaded part A of the rod to protect the dust seal and Upacking in the cylinder head. Pull out piston rod (2), remove piston nut (15), and disassemble piston (12). Line up the removed parts in order.

3. ASSEMBLY Carry out installation roughly in the reverse order to removal. BE30 Series

40-55

HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP 1. DISASSEMBLY AND ASSEMBLY

1. 2. 3. 4. 5.

40-56

Flange Body Cover Drive gear Driven gear

6. 7. 8. 9. 10.

Bushing R assembly Bushing L assembly Bushing seal Body seal Packing ring R

11. 12. 13. 14.

Packing ring L Oil seal Snap ring Hexagon socket head bolt

BE30 Series

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

2. DISASSEMBLY 1) 2) 3)

When disassembling the pump, clean its surface and drive shaft thoroughly. Place the removed parts on a clean sheet of paper or cloth and take care not to stain, scratch, or bruise them. (Arrange the removed parts so that you can see their locations before disassembly.) Grip mounting flange (1) of the pump in a vise with its surface down. Apply pads made of wood, aluminum, copper, etc. to the vise to protect the flange. Remove hexagon socket head bolts (14).

Caution • Loosen the bolts gradually, taking care that the pump will not fall from the vise. • Use a proper wrench which is not worn yet. 4) Remove cover (3). 5) Remove seals (8), (9) and (10). 6) Remove the pump from the vise and place it on a stand with the front pump side up, holding the parts in the body with your hands. 7) Pull out flange (1) straight in the axial direction and remove seals (8), (9) and (11). 8) Pull up the spline of drive gear (4) a little and pull bushings (6) and (7) and gears (4) and (5) on the flange side out of body (2). 9) Turn over body (2) and take out bushings (6) and (7) on the cover side. 10) Remove snap ring (13) from flange (1), and then remove oil seal (12). Remove oil seal (12) in the direction of the arrow with flat-head screwdriver A. 11) The pump is disassembled by the above work. Arrange the removed parts so that you can see their locations.

3. JUDGING PARTS Referring to section 50 MAINTENANCE STANDARD, judge the condition of the parts.

BE30 Series

40-57

HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

4. ASSEMBLY 1) Clean each part. 2) Set body (2) on a flat stand with the cover side up. 3) Insert 2 bushings (6) and (7) on the cover side in body (2) simultaneously. Insert the bushings so that their flat parts will not deviate. If they lean and become hard to insert, do not hit them but remove and insert again carefully. 4) Turn over body (2) and set it with the cover side down. At this time, take care that the bushings inserted in step 3) will not fall. 5) Install gears (4) and (5). Install drive gear (4) and driven gear (5) as they are engaged. 6) Insert 2 bushings (6) and (7) on the flange side in body (2) by the method explained in step 3). 7) Install bushing seal (8), body seal (9), and packing rings (10) and (11). 8) Install flange (1). Since the holes of the flange are aligned with the shafts when assembled in the factory, take care not to damage the flange. 9) Grip the body with flange (1) side down in the vise and install seals (8), (9) and (10) by the method explained in 7). 10) Install cover (3) and tighten bolts (14). Bolt

46.1 – 48.6 Nm {4.7 – 5.0 kgm}

Bushing (6), (7) are carefully attached in suction side A, discharge side B, and combination. Caution • Be sure to tighten the bolts to the specified torque. • If they are not tightened sufficiently or tightened too strongly, they may be broken and hydraulic oil may spouts out through the mounting faces of the pump, and that can cause an accident. 11) Remove the pump from the vise. Install oil seal (12) and snap ring (13) to flange (1). At this time, apply clean lithium grease thinly to the lip of oil seal (12). For the installation direction of oil seal (12), see the figure at right. When press fitting the oil seal, take care not to damage its lip and not to lean it. The lip can be protected by winding a seal tape onto the end of the front drive gear shaft. After fitting the oil seal, be sure to remove the seal tape, however.

40-58

BE30 Series

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

12) Turn the drive gear shaft end with a tool. If you can turn it lightly with the hand, no impurities and seals are caught in the pump. If the shaft is extremely hard to turn, something may be caught in the pump. In this case, disassemble and assemble the pump again. 13) The pump is assembled by the above work. Check again that it is assembled correctly and its rotating direction is correct before installing it to the chassis. When installing it, observe the following points. 1) Check that the spigot joint socket used as the base part for centering is free from flaws. 2) Check that the mounting face of flange (1) is free from flaw and dirt. (Take care particularly if the flange was clamped strongly with the vise.) 3) Check that the piping flanges are free from flaw and dirt. If there is any bruise or flaw, remove it with a fine oilstone. Caution • Install the body, gears, and bushings in the positions and directions before disassembly.

BE30 Series

40-59

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE (Proportional solenoid valve spec.) 1. DISASSEMBLY AND ASSEMBLY

1. 2. 3. 4. 5.

1. Port relief valve

Lift spool Tilt spool Attachment spool Attachment spool Attachment spool

40-60

BE30 Series

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

2. PRECAUTIONS Clean each part carefully and blow compressed air against it to remove all cleaning liquid and dirt. Apply hydraulic oil to it before installing. Do not use cloths to remove cleaning liquid and dirt. Use diesel fuel or trichloroethylene to clean the parts. Take extreme care of fire. Replace all of the dust seals, U-packings, and O-rings with new ones. When installing the new ones, apply grease them and take care not to damage them.

BE30 Series

40-61

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE (Manual valve spec.) 1. DISASSEMBLY AND ASSEMBLY

1. 2. 3. 4.

1. Port relief valve

Lift spool Tilt spool Attachment spool Attachment spool

40-62

BE30 Series

DISASSEMBLY AND ASSEMBLY

BE30 Series

CONTROL VALVE

40-63

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

Attach tags, etc. to the disconnected parts so that you can see their mounting positions when installing. Take care not to damage the sealing surfaces of the mating faces of each section. As a rule, replace spools by the assembly, since their clearances are controlled strictly.

2. DISASSEMBLY PROCEDURE 1.

Remove port relief valve (3) and main relief valve (4).

2.

Loosen nut (1) and pull out stud bolt (2) to separate each block.

3.

Disassembly of lift valve

4.

Disassembly of lift spool assembly 1) Loosen socket head bolt (5) and remove cap (6), and then pull the sub-assembly of spool (7) out of valve housing (8). At this time, remove seal plate (9) on the cap side, O-ring (10), and wiper (11) without separating them from the spool. 2) Loosen screw (25) on the opposite side and remove the seal plate, O-ring, and wiper similarly.

At this time, take care that the cap screw, etc. will not be sent flying by the spring. [Precautions for pulling out spool] • Pull out each spool straight so that it will not be bruised or scratched. • If it has a bruise, scratch, etc., it may damage the body hole when pulled out and may not enter the body hole when inserted. Even if it enters the body hole, it can cause a malfunction. • Attach tags, etc. to all the spools so that you can install them to the correct positions when assembling. • If a spool is installed to a wrong position, the actuator will malfunction, and that will be very dangerous.

3) Loosen the socket head bolt and solenoid valve (12), and then remove the case, wave washer, solenoid, and ring in order. Remove the valve assembly by loosening its hexagonal part. 4) Remove plug (13), poppet (14), and spring (15). 5) Remove plugs (16) and (17) on the side and top of the housing. 6) Remove plug (18) from the bottom, and then remove poppet (19) and spring (20). 7) Loosen and remove shut-off valve (21). 8) Grip spool (7) in a vise, padding it with hard wood boards not to damage its outside. Loosen cap screw (22) and remove spring seats (23) and spring (24), and then remove O-ring (10) and wiper (11).

40-64

BE30 Series

DISASSEMBLY AND ASSEMBLY

5.

Disassembly of tilt spool assembly 1) Remove O-ring (26), poppet (27), and spring (28) from the mating face of the valve. 2) Loosen socket head bolt (30) and remove cap (29), and then pull the sub-assembly of spool (31) out of valve housing (32). At this time, remove seal plate (33) on the cap side, O-ring (34), and wiper (35) without separating them from the spool.

CONTROL VALVE

4) Grip spool (31) in a vise, padding it with hard wood boards not to damage its outside. Loosen cap screw (37) and remove spring seat (38) and spring (39), and then remove O-ring (34) and wiper (35). At this time, take care that the cap screw, etc. will not be sent flying by the spring. 5) Remove spring (40) from inside of spool (31). Pull valve (41) out of spool (31) by using the M3 screw at the end face.

3) Loosen screw (36) on the opposite side and remove the seal plate, O-ring, and wiper similarly.

BE30 Series

40-65

CONTROL VALVE

6.

Disassembly of attachment spool assembly 1) Remove O-ring (42), poppet (43), and spring (44) from the mating face of the valve. 2) Loosen socket head bolt (46) and remove cap (45), and then pull the sub-assembly of spool (47) out of valve housing (48). At this time, remove seal plate (49) on the cap side, O-ring (50), and wiper (51) without separating them from the spool.

DISASSEMBLY AND ASSEMBLY

4) Grip spool (47) in a vise, padding it with hard wood boards not to damage its outside. Loosen cap screw (53) and remove spring seat (54) and spring (55), and then remove O-ring (50) and wiper (51). At this time, take care that the cap screw, etc. will not be sent flying by the spring. Attach tags, etc. to the disconnected parts by section so that you can see their mounting positions when installing.

3) Loosen screw (52) on the opposite side and remove the seal plate, O-ring, and wiper similarly.

40-66

BE30 Series

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

3. CLEANING

5. ASSEMBLY

Clean the all removed parts thoroughly in pure mineral oil, and then place them on clean sheets of paper or cloth to dry them with compressed air and check them.

(1) When assembling, take the following care in handling the O-rings.

4. CHECK Check the all surfaces of each part for a burr, scratch, notch, and other defects. 1)

2)

Check the periphery of the spool for a scratch, bruise, etc. If there is a slight flaw, remove it with an oilstone or a cloth coated with lapping compound. Check that all the sliding parts move smoothly and all the grooves and passages are free from foreign matter.

3)

If a spring is broken, deformed, or worn, replace it.

4)

Check that the seal groove of the valve housing is smooth and free from dirt, dent, rust, etc.

5)

If there is a dent or a flaw on the check seat surface of the valve housing, remove it by lapping. Take care that lapping compound will not be left in the valve.

6)

If the relief valve does not operate normally, disassemble and check it.

7)

Replace the all O-rings and backup rings.

8)

After removing a cap or a plug, check that any paint flake is not left around the body hole or plug seat. If a paint flake enters the valve, it will be caught in the internal parts and will cause a malfunction or oil leakage.

9)

Check that the solenoid valve filter is free from dirt. If any dirt is caught in the filter, remove it.

BE30 Series

1) Do not use an O-ring which has a forming defect or a flaw made by improper handling. 2) Apply grease or hydraulic oil to each O-ring and the part to install it for sufficient lubrication. 3) Do not expand an O-ring so much that it will be deformed plastically. 4) When installing an O-ring, do not roll it. Once it is twisted, it does not untwist easily by itself after it is installed, and that can cause oil leakage. (2) Take the following care in handling the spools. 1) Tightening the screw of a spool too strongly can cause a malfunction. Be sure to tighten it to the specified torque. 2) Combine each spool, spring, and spring end as they were before disassembly. (3) Take the following care in assembling each section assembly and valve assembly. 1) Check that the O-ring of the mating face of the valve does not project from the O-ring groove. 2) Check that cleaning oil, hydraulic oil, etc. does not stick to the following parts before assembly. • The surface out of the O-ring groove on the mating face of each section. • The surface out of the O-ring groove on the mounting face of each cap. If the valve is assembled with any oil sticking to the above parts, that oil may be mistaken for leaking oil during operation.

40-67

CONTROL VALVE

1.

Assembly of valve housing 1) Install the following poppets, springs, and Orings to the mating face of each section. Tilt: Poppet (27), spring (28), O-ring (26) Attachment: Poppet (43), spring (44), O-ring (42) 2) Drive tie rods (2a) and (2b) into the lift section until they stop and install the valve housings of each section in order. Then, tighten tie rods (2a) and (2b) with nuts (1a) and (1b) to the specified torque.

DISASSEMBLY AND ASSEMBLY

3.

Assembly of each spool (Lift spool is used as example below) 1) Set O-ring (10), wiper (11), and seal plate (9) in spool (7) in order, and then place spring (24) between spring seats (23) and install them to the spool with cap screw (22). When assembling the above parts, grip spool (7) in a vise, padding it with hard wood boards not to damage its outside. Apply grease to the periphery of spring (24). Take care that wiper (11) must be installed in the correct direction.

For a 2-spool valve, install the tilt housing to the lift housing with bolts (2a) and (2b). 2.

Assembly of lift spool section assembly 1) Fit the O-ring to each plug. 2) Insert poppet (19) and spring (20) in the bottom and tighten plug (18). 3) Tighten plugs (16) and (17) on the side and port surface. 4) Install shut-off valve (21) with the set screw loosened. Tighten the set screw and secure it with the locknut.

2) For only the tilt section, put valve (41) and spring (40) in spool cap screw (37) and fit the O-ring to cap screw (37) before assembling.

5) Insert poppet (15) and spring (14) and tighten plug (13). 6) Solenoid valve (12) • Install valve assembly (12a) to the housing. • Install ring (12b), solenoid (12c), wave washer (12d), and case (12e) in order to the valve assembly (12a) and set the lead wires in positions, and then tighten socket head bolt (12f).

40-68

BE30 Series

DISASSEMBLY AND ASSEMBLY

4.

CONTROL VALVE

Completion of assembly and check (Lift spool is used as example below) 1) Install the spool sub-assembly to the same position in the same direction in valve housing (8) as before disassembly and secure cap (6) with socket head bolt (5). 2) Install port relief valve (3) and main relief valve (4).

[Precautions for inserting spool] • Insert the spool slowly straight in the hole. • After inserting the spool, slide it with the hand to check that it has no abnormality. • When inserting the spool, if you feel stiffness or roughness, the spool may malfunction. [Precautions for assembly] • After completing assembly, check that the all removed parts are installed and tightened again. • If any part is not tightened, it may be loosened and oil may leak.

BE30 Series

40-69

DISASSEMBLY AND ASSEMBLY

DRIVE MOTOR

DRIVE MOTOR 1. NAME OF EACH PART (1.0 – 2.5 TON MODELS)

1. 2. 3. 4.

BE30 Series

Sensor cover Sensor gear Speed sensor Rotor

5. 6. 7. 8.

Frame Stator Temperature sensor Terminal

40-71

DRIVE MOTOR

DISASSEMBLY AND ASSEMBLY

2. NAME OF EACH PART (3.0 TON MODEL)

46 ～ 55 Nm {4.7 ～ 5.6 kgm}

46 ～ 55 Nm {4.7 ～ 5.6 kgm}

6 Nm {0.6 kgm}

125Nm {12.7 kgm}

10 ～ 12 Nm {1.0 ～ 1.2 kgm}

3 Nm {0.3 kgm}

1. 2. 3. 4. 5. 6. 7. 8. 9.

40-72

Sensor cover Sensor gear Speed sensor Rotor Frame Stator Temperature sensor Terminal Shaft

10. 11. 12. 13. 14. 15. 16. 17. 18.

Rear bracket Bolt Oil seal Nut Front blacket Bolt Stud bolt Screw Bolt

BE30 Series

DISASSEMBLY AND ASSEMBLY

DRIVE MOTOR

3. DISASSEMBLY 1. 2. 3. •

4.

5. 6. 7. 8. 9.

Cutout Remove the sensor cover (1) with a flat-head screwdriver or the like. Flat-head screwdriver Apply a flat-head screwdriver to the sensor gear (2) through the bracket (10) cutout, and secure the shaft not to rotate. Remove the nut (13). Locking adhesive is applied to the thread. If the nut is too tight, apply heat using a drier or the like before loosening. Forcibly applying torque can damage the thread. Remove the rear-side bolts (15) (M12 x 40, 4 bolts). • Locking adhesive is applied to the thread. If the bolt is too tight, apply heat using a drier or the like before loosening. Forcibly applying torque can damage the bolt. Remove the rear bracket (10) together with the sensor gear (2), by lightly tapping with a wooden hammer or the like. Pull out the shaft (9) together with the rotor (4). Be careful not to bend or scratch the fins or balance shaft of the rotor (4). Be careful not to damage the oil seal (12). Remove the front-side bolts (11) (M12 x 40, 4 bolts). • Locking adhesive is applied to the thread. If the bolt is too tight, apply heat using a drier or the like before loosening. Remove the front bracket (14). • If it is difficult to remove, lightly tap with a wooden hammer or the like. Pull out the lock screw (17), and remove the stud bolt (16).

4. ASSEMBLY Assemble in the reverse order of disassembly procedure. Note the followings: • When assembling the sensor gear (2), press it in to the stepped section by lightly tapping with a cylindrical shape jig. • When installing the stud bolt (16), do not tighten the lock bolt (17) with excessive torque so as not to crack the resin.

BE30 Series

40-73

PUMP MOTOR

DISASSEMBLY AND ASSEMBLY

PUMP MOTOR 1. NAME OF EACH PART (1.0 - 1.75 TON MODELS)

1. 2. 3. 4. 5. 6.

40-74

Front bracket Rear bracket Holder ring Brush Brush spring Armature

7. 8. 9. 10. 11.

Field coil Pole core Yoke Fan Brush band

BE30 Series

DISASSEMBLY AND ASSEMBLY

PUMP MOTOR

2. NAME OF EACH PART (2.0 - 3.0 TON MODELS)

7 3 5

9

2 8 4

6 1

10

1. 2. 3. 4. 5. 6.

BE30 Series

Front bracket Rear bracket Holder ring Brush Brush spring Armature

7. 8. 9. 10.

Field coil Pole core Yoke Fan

40-75

PUMP MOTOR

DISASSEMBLY AND ASSEMBLY

3. DISASSEMBLY 1.

Remove the screws of the lead wires (pigtails) of brushes (4).

2.

Remove brushes (4) from the brush holder.

3.

Remove the front bracket mounting bolts and front bracket (11).

4.

Remove armature shaft assembly (6) slowly.

40-76

BE30 Series

DISASSEMBLY AND ASSEMBLY

5.

Remove the rear bracket mounting bolts and remove rear bracket (2) from yoke (9).

6.

Remove terminal bolt and nut of yoke (9).

7.

Remove the mounting bolts of pole cores (8).

8.

Remove pole cores (8) and field coils (7) from yoke (9).

BE30 Series

PUMP MOTOR

40-77

PUMP MOTOR

9.

DISASSEMBLY AND ASSEMBLY

Remove the mounting bolts of holder ring (3)

10. Remove holder ring (3) from rear bracket (2).

4. JUDGING PARTS Referring to section 50 MAINTENANCE STANDARD, judge the condition of the parts.

40-78

BE30 Series

DISASSEMBLY AND ASSEMBLY

PUMP MOTOR

5. ASSEMBLY Carry out installation in the reverse order to removal and observe the following points. 1.

Installation of field coils and pole cores After installing field coils (7) with the pole cores to the yoke, move the field coil in all directions to make sure that it is securely fixed.

2.

Operating condition of brushes Put the brushes in the brush holder and set the brush springs, and make sure that the brushes move smoothly in the holder.

3)

Tightening torque of the bolt (A) Holder ring mounting bolt M6 × 1: 5.1 – 6.6 Nm (52 – 67 kgcm) (B) Terminal mounting bolt M6 × 1: 3.0 – 3.9 Nm (31 – 40 kgcm) (C) Pole core mounting bolt M8 × 1.25: 9.5 – 12.3 Nm (97 – 125 kgcm) (D) Bracket mounting bolt M6 × 1: 5.1 – 6.6 Nm (52 – 67 kgcm)

BE30 Series

40-79

PUMP MOTOR

DISASSEMBLY AND ASSEMBLY

INSPECTION AFTER ASSEMBLY 1)

Rotation Raise the brush (A) by pulling the brush lead wire while the brush spring (B) is raised, then release the brush spring to the state shown in the drawing on the left. Then, turn the armature shaft by hand while the brush is not in contact with commutator (C) and make sure it turns smoothly.

2)

Insulation resistance Connect the earth (-) side of the megohmeter (DC500V) to the pole core mounting bolt (A) and the line (+) side to the terminal (A1), then make sure that the resistance is 0.5 MΩ and above.

3)

No-load operation With 12 V power supplied, perform no-load operation to check the points shown below. (1) That the motor rotates smoothly. (2) That no sparking is generated from the contact faces of the brushes and commutator.

40-80

BE30 Series

50. MAINTENANCE STANDARD Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 2 Differential (1.0 - 1.75 ton models). . . . . . . . . . 50- 3 Differential (2.0 - 3.0 ton models) . . . . . . . . . . . 50- 4 Front axle (1.0 - 1.75 ton models) . . . . . . . . . . 50- 5 Front axle (2.0 - 2.5 ton models) . . . . . . . . . . . 50- 6 Front axle (3.0 ton model) . . . . . . . . . . . . . . . . 50- 7 Brake master cylinder . . . . . . . . . . . . . . . . . . . 50- 8 Damping cylinder . . . . . . . . . . . . . . . . . . . . . . . 50- 9 Wheel brake (1.0 - 1.75 ton models) . . . . . . . . 50-10 Wheel brake (2.0 - 2.5 ton models) . . . . . . . . . 50-11 Wheel brake (3.0 ton model) . . . . . . . . . . . . . . 50-12 Rear axle (1.0 - 1.75 ton models). . . . . . . . . . . 50-14 Rear axle (2.0 - 3.0 ton models). . . . . . . . . . . . 50-16 Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18 Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18 Control valve (Proportional solenoid valve spec.) . . . . . . . . . 50-19 Control valve (Manual valve spec.) . . . . . . . . . 50-20 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . 50-22 Mast, fork carriage, and fork (1.0 - 1.75 ton models) . . . . . . . . . . . . . . . . . . . 50-25 Mast, fork carriage, and fork (2.0 - 3.0 ton models) . . . . . . . . . . . . . . . . . . . . 50-26 Drive motor (1.0 - 2.5 ton models) . . . . . . . . . . 50-27 Drive motor (3.0 ton model) . . . . . . . . . . . . . . . 50-28 Pump motor (1.0 - 1.75 ton models) . . . . . . . . 50-30 Pump motor (2.0 - 3.0 ton models) . . . . . . . . . 50-32 Power steering motor . . . . . . . . . . . . . . . . . . . . 50-34

BE30 Series

50-1

TRANSFER

MAINTENANCE STANDARD

TRANSFER

Symbol

Inspection item

Criteria

A

Fitted parts of shaft and gear

No clearance

—

Each gear

Tooth surface must be free from damage, excessive wear, and bat contact

—

Each bearing

Must be free from play and flaw

50-2

Remedy

Replace

BE30 Series

MAINTENANCE STANDARD

DIFFERENTIAL

DIFFERENTIAL (1.0 – 1.75 TON MODELS)

Unit: mm

Inspection item

Symbol A

Differential pinion gear and differential side gear

B

Outside diameter of spider

C

Criteria Standard size —

Repair limit When tooth surface has damage

21.959 – 21.980

21.75

Inside diameter of differential pinion gear

22.0 – 22.2

22.3

D

Thickness of bushing

1.54 – 1.66

1.3

E

Thickness of bushing

1.54 – 1.66

1.3

—

Inside diameter of brake drum

254.0 – 254.2

256

—

Gasket, O-ring, seals

—

—

BE30 Series

Remedy Replace by set

Replace

Replace when disassembling and assembling

50-3

DIFFERENTIAL

MAINTENANCE STANDARD

DIFFERENTIAL (2.0 – 3.0 TON MODELS)

Unit: mm

Symbol

Inspection item

A

Differential pinion gear and differential side gear

B

Outside diameter of spider

C

Criteria Standard size —

Repair limit When tooth surface has damage

24.959 – 24.980

24.75

Inside diameter of differential pinion gear

25.0 – 25.1

25.2

D

Thickness of bushing

1.94 – 2.06

1.7

E

Thickness of bushing

1.52 – 1.68

1.3

—

Inside diameter of brake drum

279.4 – 279.6

281.4

—

Gasket, O-ring, seals

—

—

50-4

Remedy Replace by set

Replace

Replace when disassembling and assembling

BE30 Series

MAINTENANCE STANDARD

FRONT AXLE

FRONT AXLE (1.0 – 1.75 TON MODELS) 1. Direct the bearing as shown in the drawing.

Unit: mm

Symbol

Inspection item

Criteria Standard size

Repair limit

254 – 254.2

256

0

0

A

Inside diameter of brake drum

B

Play of hub

C

Front axle

Distortion, cracking, damage

D

Shaft pipe

Distortion, cracking, damage

E

Brake drum

Uneven wear and flaw of inside wall of brake drum

BE30 Series

Remedy Replace Replace bearing

Replace

50-5

FRONT AXLE

MAINTENANCE STANDARD

FRONT AXLE (2.0 – 2.5 TON MODELS) 1. Direct the bearing as shown in the drawing.

Unit: mm

Symbol

Inspection item

Criteria Standard size

Repair limit

279.4 – 279.6

281.4

0

0

A

Inside diameter of brake drum

B

Play of hub

C

Front axle

Distortion, cracking, damage

D

Shaft pipe

Distortion, cracking, damage

E

Brake drum

Uneven wear and flaw of inside wall of brake drum

50-6

Remedy Replace Replace bearing

Replace

BE30 Series

MAINTENANCE STANDARD

FRONT AXLE

FRONT AXLE (3.0 TON MODEL) 1. Direct the bearing as shown in the drawing.

Unit: mm

Symbol

Inspection item

Criteria Standard size

Repair limit

310.0 – 312

312

0

0

A

Inside diameter of brake drum

B

Play of hub

C

Front axle

Distortion, cracking, damage

D

Shaft pipe

Distortion, cracking, damage

E

Brake drum

Uneven wear and flaw of inside wall of brake drum

BE30 Series

Remedy Replace Replace bearing

Replace

50-7

BRAKE MASTER CYLINDER

MAINTENANCE STANDARD

BRAKE MASTER CYLINDER

Unit: mm

Symbol

Inspection item

A

Clearance between cylinder and piston

B

Interference of cup (Outside diameter of cup – Inside diameter of cylinder)

C

Spring

50-8

Criteria Standard size

Repair limit

0.020 – 0.104

0.15

P-cup: Approx. 0.8 S-cup: Approx. 1.3

0.3

Must be free from flaw, wear, and leaning

Remedy Replace cylinder assembly Replace piston assembly

BE30 Series

MAINTENANCE STANDARD

DAMPING CYLINDER

DAMPING CYLINDER 1. Apply rubber grease.

Unit: mm

Symbol

Inspection item

A

Clearance between cylinder and piston

B

Interference of cup (Outside diameter of cup – Inside diameter of cylinder)

C

Spring

BE30 Series

Criteria Standard size

Repair limit

0.020 – 0.104

0.15

Approx. 1.0

0.4

Must be free from flaw, wear, and leaning

Remedy Replace cylinder assembly Replace piston assembly

50-9

WHEEL BRAKE

MAINTENANCE STANDARD

WHEEL BRAKE (1.0 – 1.75 TON MODELS)

Criteria Symbol A

Unit: mm

Inspection item Lining

Thickness of lining Free length

B

C

Return spring

Wheel cylinder

Thickness of hook

Repair limit

B1

4.5 97

2.0 105

B2 B1

97 2.6

105 2.0

B2

2.6

2.0

Appearance

Must be free from flaw and cracking.

Sliding surface

Must be free from flaw.

Inside diameter Clearance between wheel cylinder and piston of cylinder: 22.22

D

Piston

Clearance between piston and cylinder

E

Cup

Damage and fatigue

50-10

Criteria Standard size

0 – 0.05

0 – 0.05

Remedy

Replace

0.2 0.2

Must be free from damage and fatigue

BE30 Series

MAINTENANCE STANDARD

WHEEL BRAKE

WHEEL BRAKE (2.0 – 2.5 TON MODELS)

Criteria Symbol A

B

C

Unit: mm

Inspection item Lining

Return spring

Wheel cylinder

Thickness of lining

Repair limit

Free length

B1 B2

110 106

2.0 112 108

Thickness of hook

B1 B2

3.2 2.6

2.6 2.0

5.1

Appearance

Must be free from flaw and cracking.

Sliding surface

Must be free from flaw.

Inside diameter Clearance between of cylinder: wheel cylinder and piston 25.40

D

Piston

Clearance between piston and cylinder

E

Cup

Damage and fatigue

BE30 Series

Criteria Standard size

0 – 0.05

0 – 0.05

Remedy

Replace

0.2 0.2

Must be free from damage and fatigue

50-11

WHEEL BRAKE

MAINTENANCE STANDARD

WHEEL BRAKE (3.0 TON MODEL)

Criteria Symbol A

B

C

Unit: mm

Inspection item Lining

Return spring

Wheel cylinder

Thickness of lining

Repair limit

Free length

B1 B2

124 124

2.0 136 136

Thickness of hook

B1 B2

2.9 2.9

2.0 2.0

5.67

Appearance

Must be free from flaw and cracking.

Sliding surface

Must be free from flaw.

Inside diameter Clearance between of cylinder: wheel cylinder and piston 25.40

D

Piston

Clearance between piston and cylinder

E

Cup

Damage and fatigue

50-12

Criteria Standard size

0 – 0.05

0 – 0.05

Remedy

Replace

0.2 0.2

Must be free from damage and fatigue

BE30 Series

REAR AXLE

MAINTENANCE STANDARD

REAR AXLE (1.0 – 1.75 TON MODELS) 1. When installing the ball sockets (4 places), clean and degrease their mounting faces and the holes of the mating parts. 2. Lip portion 3. Fill bearing space with grease up to 1/2 – 2/3 of volume of space. 4. Adjust with nut E

50-14

BE30 Series

MAINTENANCE STANDARD

REAR AXLE

a For tightening torque of each part, see on the previous page. Unit: mm

Symbol

Inspection item

Criteria Standard size

Repair limit

Remedy

A

Diameter of king pin

28

27.8

Replace

B

Vertical play of knuckle

—

0.2

Adjust shim

C

Diameter of bell crank pin

28

27.8

D

Inside diameter of bushing for bell crank pin

28

28.3

E

Inside diameter of bushing for center pin

50

50.7

—

Rear axle, hub, knuckle, bearing

BE30 Series

Replace

• Cracking • Damage, flaking • Seizure, defective rotation, abnormal sound

50-15

REAR AXLE

MAINTENANCE STANDARD

REAR AXLE (2.0 – 3.0 TON MODELS) 1. When installing the ball sockets (4 places), clean and degrease their mounting faces and the holes of the mating parts. 2. Fill bearing space with grease up to 1/2 – 2/3 of volume of space. 3. Adjust with nut E 4. Press fit with jig.

50-16

BE30 Series

MAINTENANCE STANDARD

REAR AXLE

a For tightening torque of each part, see on the previous page. Unit: mm

Symbol

Inspection item

Criteria Standard size

Repair limit

Remedy

A

Diameter of king pin

28

27.8

Replace

B

Vertical play of knuckle

—

0.2

Adjust shim

C

Diameter of bell crank pin

28

27.8

D

Inside diameter of bushing for bell crank pin

28

28.3

E

Inside diameter of bushing for center pin

50

50.7

—

Rear axle, hub, knuckle, bearing

BE30 Series

Replace

• Cracking • Damage, flaking • Seizure, defective rotation, abnormal sound

50-17

LIFT CYLINDER, TILT CYLINDER

MAINTENANCE STANDARD

LIFT CYLINDER

Unit: mm

Symbol

A

B

Inspection item Clearance between piston rod and bushing

Clearance between piston ring and cylinder

Criteria Standard size

Repair limit

1.0 – 1.75 ton models

0.06 – 0.235

0.4

2.0 – 3.0 ton models

0.04 – 0.023

0.35

1.0 – 1.75 ton models

0.05 – 0.30

0.5

2.0 – 3.0 ton models

0.05 – 0.035

0.5

Remedy

Replace bushing

Replace piston ring

TILT CYLINDER

Unit: mm

Symbol

Inspection item

A B

50-18

Criteria Standard size

Repair limit

Clearance between piston rod and bushing

0.04 – 0.167

0.3

Clearance between piston rod head bushing and pin

0.05 – 0.23

0.5

Remedy

Replace bushing

BE30 Series

MAINTENANCE STANDARD

CONTROL VALVE

CONTROL VALVE (Proportional solenoid valve spec.) 1. Control valve with port relief valve is shown here.

BE30 Series

50-19

CONTROL VALVE

MAINTENANCE STANDARD

CONTROL VALVE (Manual valve spec.) 1. Control valve with port relief valve is shown here.

1. 2. 3. 4.

Lift spool Tilt spool Attachment spool Attachment spool

50-20

BE30 Series

MAINTENANCE STANDARD

CONTROL VALVE

1. CHECK Check the all surfaces of each part for a burr, scratch, notch, and other defects. 1)

Check the periphery of the spool for a scratch, bruise, etc. If there is a slight flaw, remove it with an oilstone or a cloth coated with lapping compound.

2)

Check that all the sliding parts move smoothly and all the grooves and passages are free from foreign matter.

3)

If a spring is broken, deformed, or worn, replace it.

4)

Check that the seal groove of the valve housing is smooth and free from dirt, dent, rust, etc.

5)

If there is a dent or a flaw on the check seat surface of the valve housing, remove it by lapping. Take care that lapping compound will not be left in the valve.

6)

If the relief valve does not operate normally, check the relief valve.

7)

Replace the all O-rings and backup rings.

8)

After removing a cap or a plug, check that any paint flake is not left around the body hole or plug seat. If a paint flake enters the valve, it will be caught in the internal parts and will cause a malfunction or oil leakage.

9)

Check that the solenoid valve filter is free from dirt. If any dirt is caught in the filter, remove it.

BE30 Series

50-21

HYDRAULIC PUMP

MAINTENANCE STANDARD

HYDRAULIC PUMP

1. 2. 3. 4. 5. 6. 7.

Flange Body Cover Drive gear Driven gear Bushing R assembly Bushing L assembly

50-22

8. 9. 10. 11. 12. 13. 14.

Bushing seal Body seal Packing ring R Packing ring L Oil seal Snap ring Hexagon socket head bolt

BE30 Series

MAINTENANCE STANDARD

HYDRAULIC PUMP

1. INSPECTION AND REPAIR METHOD Check the removed parts for stain and discoloration, and then clean them in fuel oil. Do not soak rubber parts in fuel oil, however. Check each part for the following points, and then repair or replace it if any defect is detected. 1)

Body (2) The tooth tips of the gears of the gear pump are kept in contact with the inside wall of the gear hole during operation to increase the volumetric efficiency. Accordingly, once the pump is operated, there is contact mark A of the tooth tips near the suction opening. Contact mark B is less than 1/2 of the inside wall of the gear hole and its depth a is about 0.05 mm, if it is normal. If depth a is 0.15 mm or larger, replace the pump assembly.

2)

Drive gar (4) and driven gear (5) If the hydraulic oil is clean, the shafts and the sides of the gears keep in smooth contact with the mating parts. If the shafts or sides of the gears are so roughened that your nails hitch on them or tooth surfaces are worn unevenly abnormally, replace them. If shaft b is less than 18.935 mm, replace the gear set.

BE30 Series

50-23

HYDRAULIC PUMP

3)

MAINTENANCE STANDARD

Bushings (6) and (7) If the bushings are in ideal contact, their inside sliding surfaces are smooth and about a half of them on the suction side are glossy. If contact D of the sides is normal, the suction side is in stronger contact (blackish) and the high-pressure side is in slight contact. If any of the following conditions is detected, replace the bushings. 1. The whole inside sliding surfaces of the bushings are in contact and roughened to a degree that your nails hitch. 2. There are many flaws in the circumferential direction on the sides of the bushings and your nails hitch on them. 3. There are traces of foreign matter on the inside sliding surfaces and sides of the bushings. The service limits of the bushings are as follows. If dimensions c or d is as follows, replace the bushing assembly and gears by kit. Inside diameter of bushing: 19.123 < c Overall length of bushing: 26.411 > d

4)

Be sure to replace bushing seal (8), body seal (9), packing rings (10) and (11), oil seal (12), and snap ring (13) each time the pump is disassembled.

50-24

BE30 Series

MAINTENANCE STANDARD

MAST, FORK CARRIAGE, AND FORK

MAST, FORK CARRIAGE, AND FORK (1.0 – 1.75 TON MODELS)

Unit: mm

Criteria

Inspection item Clearance between outer mast and inner mast

Clearance between inner mast and fork carriage

Repair limit

Left and right

0.1 – 0.3

Max. 2.0

Adjust shim

Front and rear

0.5 – 1.0

Max. 2.0

Replace with oversize roller

Left and right

0.5 – 2.0

Max. 2.5

Adjust shim

Front and rear

0.5 – 1.0

Max. 2.0

Replace with oversize roller

Wear oil groove of bushing of mast support

There is wear of oil groove

1.0 ton models

31

Min. 26

1.35 ton models

35

Min. 30

1.5 ton models

35

Min. 30

1.75 ton models

35

Min. 33

Thickness A of fork (base)

BE30 Series

Remedy

Standard size

Replace bushing

Replace

50-25

MAST, FORK CARRIAGE, AND FORK

MAINTENANCE STANDARD

MAST, FORK CARRIAGE, AND FORK (2.0 – 3.0 TON MODELS)

Unit: mm

Criterion Standard size Repair limit

Inspection item Clearance between outer mast and inner mast

Clearance between inner mast and fork carriage

Left and right

0.5 – 1.0

Max. 2.5

Adjust shim

Front and rear

0.2 – 0.7

Max. 2.0

Replace

Left and right

0.5 – 1.0

Max. 2.5

Adjust shim

Front and rear

0.2 – 0.7

Max. 2.0

Wear oil groove of bushing of mast support

Thickness A of fork (base)

50-26

Remedy

There is wear of oil groove

2.0 ton models

36

Min. 33

2.5 ton models

40

Min. 36.5

3.0 ton model

44

Min. 39.5

Replace

BE30 Series

MAINTENANCE STANDARD

DRIVE MOTOR

DRIVE MOTOR (1.0 – 2.5 TON MODELS)

1. 2. 3. 4.

Sensor cover Sensor gear Speed sensor Rotor

BE30 Series

5. 6. 7. 8.

Frame Stator Temperature sensor Terminal

50-27

DRIVE MOTOR

MAINTENANCE STANDARD

DRIVE MOTOR (3.0 TON MODEL) a The following illustration shows the 3 ton models.

46 ～ 55 Nm {4.7 ～ 5.6 kgm}

46 ～ 55 Nm {4.7 ～ 5.6 kgm}

6 Nm {0.6 kgm}

125Nm {12.7 kgm}

10 ～ 12 Nm {1.0 ～ 1.2 kgm}

3 Nm {0.3 kgm}

1. 2. 3. 4. 5. 6. 7. 8. 9.

Sensor cover Sensor gear Speed sensor Rotor Frame Stator Temperature sensor Terminal Shaft

50-28

10. Rear bracket 11. Bolt 12. Oil seal 13. Nut 14. Front blacket 15. Bolt 16. Stud bolt 17. Screw 18. Bolt

BE30 Series

MAINTENANCE STANDARD

DRIVE MOTOR

1. MAINTENANCE 1.

Daily maintenance (1) Maintenance during operation Inspection item

Dust

Part to be inspected

Criterion

Remedy

Must not change remarkably from If dust is heaped level in normal operation. extremely, stop and Temperature rise must be normal, too. clean. Check visually.

Motor frame

Environment Foreign matter, Motor frame splash, liquid

Must not change remarkably from level in ordinary operation.

Restore condition.

Temperature rise

Motor frame, bearing

Temperature must not abnormally above normal level and must be below specified level. Restore condition. Motor frame: 80°C Bearing: 55°C

Vibration

Motor frame, bearing, cover, etc.

There must not be abnormal vibration If vibration exceeds and increase of amplitude. allowable level, stop Check visually. Check by listening and remove cause. sound.

Motor frame, bearing, cover, etc.

There must not be abnormal sound and increase of noise level. Compare current sound with sound of new motor by using listening bar. Check by listening.

Abnormal sound

If operation is troubled with abnormal sound, stop and remove cause.

(2) Maintenance at stop Maintenance item

Clamping parts

Terminals

Inspection item

Criterion

Clamping screws

Must be free from looseness, dust, and rust. Check visually. Check by hitting and listening sound.

Retighten, clean, and paint.

Connecting parts

Connection must be correct. Connecting parts must not be loosened. Insulation must be perfect. Check visually.

Retighten. Check insulation.

Connecting parts of ter- Wire cover must not be damaged. minal and harness. Check visually.

BE30 Series

Remedy

Repair in special factory.

50-29

PUMP MOTOR

MAINTENANCE STANDARD

PUMP MOTOR (1.0 – 1.75 TON MODELS) A. Outside diameter of commutator

B. Depth of undercut

C. Bend of armature shaft D. Insulation of armature

E. Insulation of field coil

50-30

BE30 Series

MAINTENANCE STANDARD

PUMP MOTOR

G. Pressing force of brush spring

Check insulation resistance between 2 of 3 terminals in 3 combinations. Megger Ground (–) side

P1

P1

P2

Line (+) side

P2

P3

P3

F. Insulation of holder ring

H. Height of brush

Unit: mm

Symbol A

Inspection item Outside diameter of commutator

B

Depth of undercut

C

Measuring instrument Slide calipers

Standard size

Repair limit

90

87

0.65 ± 0.15

Min. 0.2

Bend of armature shaft Dial gauge

—

Max. 0.2

D

Insulation of armature

Megger (DC 500 V)

—

Min. 0.5 Mz

E

Insulation of field coil

Megger (DC 500 V)

—

Min. 0.5 Mz

F

Insulation of holder ring

Megger (DC 500 V)

—

Min. 0.5 Mz

G

Pressing force of brush Spring balance spring

11.1 N {1.13 kgf}

7.35 N {0.75 kgf}

H

Height of brush

33

22

BE30 Series

Slide calipers

Criteria

Slide calipers

Remedy Replace Undercut mica and polish commutator surface with sandpaper of #400.

Replace

50-31

PUMP MOTOR

MAINTENANCE STANDARD

PUMP MOTOR (2.0 – 3.0 TON MODELS) A. Outside diameter of commutator

E F G

H B. Depth of undercut

C, D A, B

C. Bend of armature shaft D. Insulation of armature

E. Insulation of field coil

50-32

BE30 Series

MAINTENANCE STANDARD

PUMP MOTOR

Check insulation resistance between 2 of 3 terminals in 3 combinations.

G. Pressing force of brush spring

Megger Ground (–) side

P1

P1

P2

Line (+) side

P2

P3

P3

F. Insulation of holder ring

H. Height of brush

Unit: mm

Symbol

Inspection item

Measuring instrument

Criteria Standard size

Repair limit

A

Outside diameter of commutator

Slide calipers

100

97

B

Depth of undercut

Slide calipers

0.8 – 1.2

0.2

C

Bend of armature shaft Dial gauge

—

Max. 0.2

D

Insulation of armature

Megger (DC 500 V)

—

Min. 0.5 Mz

E

Insulation of field coil

Megger (DC 500 V)

—

Min. 0.5 Mz

F

Insulation of holder ring

Megger (DC 500 V)

—

Min. 0.5 Mz

G

Pressing force of brush Spring balance spring

10.6 – 13.0 N {1.1 – 1.3 kgf}

7.84 N {0.8 kgf}

H

Height of brush

32 – 34

22

BE30 Series

Slide calipers

Remedy Replace Undercut mica and polish commutator surface with sandpaper of #400.

Replace

50-33

POWER STEERING MOTOR

MAINTENANCE STANDARD

POWER STEERING MOTOR A. Outside diameter of commutator

B. Depth of undercut

C. Bend of armature shaft D. Insulation of armature

Check insulation resistance between 2 of 3 terminals in 3 combinations.

E. Insulation of holder ring

Megger Ground (–) side

P1

P1

P2

Line (+) side

P2

P3

P3

50-34

BE30 Series

MAINTENANCE STANDARD

POWER STEERING MOTOR

F. Pressing force of brush spring

G. Height of brush

Unit: mm

Symbol

Inspection item

Measuring instrument

Criteria Standard size

Repair limit

A

Outside diameter of commutator

Slide calipers

30.5

29.5

B

Depth of undercut

Slide calipers

0.6 – 0.8

Min. 0.2

C

Bend of armature shaft Dial gauge

Max. 0.06

Max. 0.2

D

Insulation of armature

Megger (DC 500 V)

—

Min. 0.5 Mz

E

Insulation of holder ring

Megger (DC 500 V)

—

Min. 0.5 Mz

F

Pressing force of brush Spring balance spring

4.9 – 11.8 N {0.5 – 1.2 kgf}

4.9 – 11.8 N {0.5 – 1.2 kgf}

G

Height of brush

22

13

BE30 Series

Slide calipers

Remedy Replace Undercut mica and polish commutator surface with sandpaper of #400.

Replace

50-35

60. STRUCTURE AND FUNCTION

Power train . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 3 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 3 System diagram of power train . . . . . . . . . . . . 60- 3 Outside view and Cross section of power train (1.0 - 1.75 ton models) . . . . . . . . . . . . . . . . . . 60- 4 Outside view and Cross section of power train (2.0 - 2.5 ton models) . . . . . . . . . . . . . . . . . . . 60- 6 Outside view and Cross section of power train (3.0 ton model) . . . . . . . . . . . . . . . . . . . . . . . . 60- 8 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10 Travel system . . . . . . . . . . . . . . . . . . . . . . . . 60-11 Front wheels and rear wheels . . . . . . . . . . . . . 60-11

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . 60-32 Lift cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-32 Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-33 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . 60-35 Work equipment control lever . . . . . . . . . . . . . 60-37 Hydraulic control valve (Proportional solenoid valve spec.) . . . . . . . . . 60-39

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-39 Section of proportional solenoid valve . . . . . . . 60-41 Explanation of operation . . . . . . . . . . . . . . . . . 60-42 Outside view of hydraulic control valve (proportional solenoid valve) . . . . . . . . . . . . 60-53

Braking device . . . . . . . . . . . . . . . . . . . . . . . Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake lever . . . . . . . . . . . . . . . . . . . . .

60-12 60-12 60-14 60-16 60-17 60-18

Work equipment. . . . . . . . . . . . . . . . . . . . . . . 60-58 Mast (1.0 - 1.75 ton models) . . . . . . . . . . . . . . 60-58 Mast (2.0 - 2.5 ton models) . . . . . . . . . . . . . . . 60-60 Mast (3.0 ton model) . . . . . . . . . . . . . . . . . . . . 60-62

Steering system . . . . . . . . . . . . . . . . . . . . . . Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . Electric power steering (EPS) . . . . . . . . . . . . . EPS actuator . . . . . . . . . . . . . . . . . . . . . . . . . . EPS torque sensor and gear box . . . . . . . . . . Principle of operation of EPS . . . . . . . . . . . . . Steering linkage . . . . . . . . . . . . . . . . . . . . . . . Electrical system circuit diagram . . . . . . . . . . Rear axle (1.0 - 1.75 ton models) . . . . . . . . . . Rear axle (2.0 - 3.0 ton models) . . . . . . . . . . .

60-20 60-20 60-20 60-22 60-23 60-24 60-26 60-28 60-30 60-31

Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 60-65 Outline and features of control unit . . . . . . . . . 60-65 Principle of change of motor speed . . . . . . . . . 60-66 Connection diagram of motor power circuit . . . 60-66 Outline of operation of travel motor . . . . . . . . . 60-66 Power module of controller . . . . . . . . . . . . . . . 60-68 Control functions of controller . . . . . . . . . . . . . 60-69

BE30 Series

Power connector for optional devices. . . . . 60-64

Operating device (Meter panel, switchs, etc.) . . . . . . . . . . . . 60-71 Name of each device . . . . . . . . . . . . . . . . . . . . 60-71 How to start hour meter . . . . . . . . . . . . . . . . . . 60-72

60-1

How to turn electrolyte level indicator function OFF . . . . . . . . . . . . . . . . . . . . . . . .60-72 How to operate lift interrupt function . . . . . . . .60-73 Reference for adjustment of travel characteristic . . . . . . . . . . . . . . . . . . . . . . . .60-74 Mater panel display . . . . . . . . . . . . . . . . . . . . .60-75 Meter panel functions. . . . . . . . . . . . . . . . . . . .60-76 Display in each mode. . . . . . . . . . . . . . . . . . . .60-77 Ordinary A or B mode display . . . . . . . . . . .60-77 Operator adjustment mode display . . . . . . .60-82 Service adjustment mode display . . . . . . . .60-84 Switch monitor mode display . . . . . . . . . . . .60-87 Display list of meter panel dot section . . . . . . .60-88

60-2

BE30 Series

STRUCTURE AND FUNCTION

POWER TRAIN

POWER TRAIN 1. OUTLINE The power train is made in one unit, containing from the motor to the front axle. The operable time is lengthened by employing the high-efficiency structure to transmit the energy of the drive motor without wasting it and the travel sound is lowered by employing the low-noise "high addendum helical gear" which has been employed for the AR Series and evaluated high.

2. SYSTEM DIAGRAM OF POWER TRAIN

1. 2. 3.

Drive motor Transfer Front axle

BE30 Series

4. 5. 6.

Wheel brake Brake drum Front tire

60-3

POWER TRAIN

STRUCTURE AND FUNCTION

3. OUTSIDE VIEW OF POWER TRAIN (1.0 – 1.75 TON MODELS)

60-4

1. Be sure to fill grease. Install red cap. 2. Degrease mounting bolts.

BE30 Series

STRUCTURE AND FUNCTION

POWER TRAIN

4. CROSS SECTION OF POWER TRAIN (1.0 – 1.75 TON MODELS)

BE30 Series

60-5

POWER TRAIN

STRUCTURE AND FUNCTION

5. OUTSIDE VIEW OF POWER TRAIN (2.0 – 2.5 TON MODELS)

60-6

1. Be sure to fill grease. Install red cap. 2. Degrease mouting bolts. 3. Dimension after gasket is clamped

BE30 Series

STRUCTURE AND FUNCTION

POWER TRAIN

6. CROSS SECTION OF POWER TRAIN (2.0 – 2.5 TON MODELS)

BE30 Series

60-7

POWER TRAIN

7. OUTSIDE VIEW OF POWER TRAIN (3.0 TON MODEL)

60-8

STRUCTURE AND FUNCTION 1. When mounting motor, check that MOLY-PASTE is applied to the gear hole side. 2. Be sure to fill grease Install red cap. 3. Degrease mouting bolts.

BE30 Series

STRUCTURE AND FUNCTION

POWER TRAIN

8. CROSS SECTION OF POWER TRAIN (3.0 TON MODEL)

BE30 Series

60-9

POWER TRAIN

STRUCTURE AND FUNCTION

9. FRONT AXLE (1) 1.0 – 1.75 ton models 1. Install front axle to frame with bolts (Left).

(2) 2.0 – 3.0 ton models 1. Install front axle to frame with bolts (Left).

Specification Item

Unit: mm 1.0, 1.4 ton models 1.5, 1.8 ton models 2.0, 2.5 ton models EX type

Type

Fixed single-shaft full-float type

Type of reduction gears Tread Overall width Oil volume of wheel (including transfer)

60-10

3.0 ton model

Helical gear 890

920

940

1,005

1,050

1,115

1,165

1,235

7l

8l

BE30 Series

STRUCTURE AND FUNCTION

TRAVEL SYSTEM

TRAVEL SYSTEM 1. FRONT WHEELS AND REAR WHEELS Standard tires The wide tires having rib-lug mixed tread patterns for lower rolling resistance are installed as standard to lengthen the operable time and stabilize the operability. (The wide tires are not installed to the front wheels of 1.0 – 1.4 tons models and rear wheels of 1.0 – 1.8 ton models.)

Front wheel Rear wheel

Item

1.0/1.35 ton models 1.5/1.75 ton models 2.0/2.5 ton models

3.0 ton model

6.00-9-10PR(1)

21×8-9-10PR(1) Wide tire

23×8-9-16PR(1) Wide tire

28×9-15-14PR(1) Wide tire

Nominal rim size

9×4.00 E DT

9×6.00 E TB

10×6.50 F TB

15×7.00 T IR

Standard tire inflation pressure

0.69MPa {7.00 kgf/cm²}

0.61MPa {6.25 kgf/cm²}

0.88MPa {9.00 kgf/cm²}

0.78MPa {8.00 kgf/cm²}

5.00-8-8PR(1)

18×7-8-14PR(1) Wide tire

21×8-9-10PR(1) Wide tire

8×3.00 D DT

8×4.25 D DT

9×6.00 E TB

0.88MPa {9.00 kgf/cm²}

0.61MPa {6.25 kgf/cm²}

Tire size

Tire size Nominal rim size Standard tire inflation pressure

0.78 MPa ⎧ {8.00 kgf/cm²}⎩

Only 1.75 ton model 0.88MPa {9 kgf/cm²}

⎧ ⎩

Kind

Optional tires A variety of optional tires are set to meet various customer needs. (The structures of the wide tread tire, double tire, single-double tire, etc.) In addition, the following optional tires are also set so that each of them will be selected for a different use or purpose. 1) Deep tread patter tire having long lifespan 2) Cushion tire which will not be flattened 3) Color tire (white or green) which does not stain tiled floors, etc.

BE30 Series

60-11

BRAKING DEVICE

STRUCTURE AND FUNCTION

BRAKING DEVICE 1. OUTLINE The "regenerative brake + F/R regenerative brake + neutral regenerative brake" system of multi-function braking system is adopted and the braking force of each brake unit of this system can be adjusted and set freely. Increase of operating hours The braking energy of the mechanical brake is discarded in the form of heat. On the other hand, the braking energy of the regenerative brake is collected in the form of electric energy into the battery. Accordingly, the operating hours can be increased. Reduction of pressing effort of brake pedal If the brake pedal of the regenerative brake is pressed lightly, the electric brake operates (it does not operated, however, when the travel speed is below 4 km/h). If the brake pedal is pressed more, the mechanical brake operates, too. As a result, the regenerative brake requires only 60% of the pressing effort of the mechanical brake to obtain the same braking force. Accordingly, the operator is less fatigued. Improvement of regenerative brake performance Since the current "regeneration control + plugging control" system is replaced with the new regenerative brake control system, the regenerative brake functions in the all acceleration range. Accordingly, the time and distance required for a series of operations from changing of the travel direction (plugging operation) during travel to deceleration, stopping, and restarting are shortened. In addition, the time lag and shocks are reduced. The braking force of each brake can be adjusted and set freely.

New BE30

Current BE30

60-12

BE30 Series

BRAKING DEVICE

STRUCTURE AND FUNCTION

2. WHEEL BRAKE New 1.0 – 1.75 ton models : Lining is thickened. New 2.0 – 3.0 ton models : Same as BX. • The brake lining is made of non-asbestos material for higher durability and less environmental pollution. Unit: mm Symbol

Item

1.0 - 1.75 ton models

2.0, 2.5 ton models

3.0 ton model

—

Type

Front wheel hydraulic internal expanding type (with built-in parking brake)

—

Structure

A

Material of lining

B

Inside diameter of brake drum

C

Width of lining

48.5

55

60

D

Thickness of lining

4.87

5.1

5.67

E

Inside diameter of wheel cylinder

22.22

25.4

28.58

Wheel brake for 1.0 – 1.75 ton models

60-14

Duo-servo Resin mold (Non-asbestos, sticking type) 254(10”)

279(11”)

310(12.2”)

1. Turning direction of drum during forward travel 2. Turning direction of adjuster when shoe is expanded

BE30 Series

STRUCTURE AND FUNCTION

BRAKING DEVICE

Wheel brake for 2.0 – 2.5 ton models

Wheel brake for 3.0 ton model

BE30 Series

60-15

BRAKING DEVICE

STRUCTURE AND FUNCTION

3. BRAKE PEDAL

60-16

BE30 Series

STRUCTURE AND FUNCTION

BRAKING DEVICE

FB15, 18EXG, FB20, 25EXG, FB30

4. PARKING BRAKE

BE30 Series

60-17

BRAKING DEVICE

STRUCTURE AND FUNCTION

5. PARKING BRAKE LEVER

60-18

BE30 Series

STRUCTURE AND FUNCTION

BRAKING DEVICE

3.0

BE30 Series

60-19

STEERING SYSTEM

STRUCTURE AND FUNCTION

STEERING SYSTEM 1. STEERING WHEEL The tilt and telescopic steering wheel can be adjusted by 70 mm in longitudinal direction A and by 30 mm in vertical direction B. Accordingly, it can be properly for each operator. Quantity of adjustment in longitudinal direction A: 70 mm Quantity of adjustment in vertical direction B: 30 mm Since the levers, switches, and meters follow the steering wheel, all positions of the control system can be set to properly.

2. ELECTRIC POWER STEERING (EPS) EPS : Electric Power Steering Applicable models: All models (1) EPS senses travel speed. As shown in the graph at right, the steering effort of the former EPS is reduced and the steering stability is lowered as the travel speed is increased. On the other hand, the steering effort of the travel speed-sensing EPS is lightest when the lift truck is steered while it is stopped and it is increased properly as the travel speed is increased. As a result, the steering is highly stabilized. In addition, the dead band of the electric signals is so changed to reduce the play and improve the straight travel performance.

60-20

BE30 Series

STRUCTURE AND FUNCTION

STEERING SYSTEM

(2) Specifications and input and output characteristics 1) Specification Gear module (Helix angle)

1.25(25°)

Gear ratio

4.917

Ball screw lead

8.731

Ball P.C.D. Helix direction of ball screw

28 Left

Rated voltage of motor assembly

48V 350W/H

Theoretical twisting force of shaft

10,980 N {1,120 kgf}: 40A

2) Input and output characteristics

BE30 Series

60-21

STEERING SYSTEM

3. EPS ACTUATOR

60-22

STRUCTURE AND FUNCTION

1. Component parts of 1079-025 2. Wind wire by 2 turns and twist it by 4 – 5 times. It must not be dragged. Set ball stud 180° in opposite direction.

BE30 Series

STRUCTURE AND FUNCTION

4. EPS TORQUE SENSOR AND GEAR BOX

BE30 Series

STEERING SYSTEM

1.Tightening phase of pitman arm

60-23

STEERING SYSTEM

STRUCTURE AND FUNCTION

5. PRINCIPLE OF OPERATION OF EPS If the operator turns steering wheel (1), the steering torque of the steering wheel is applied to pitman arm (4). Then, torque sensor (3) which is a part of steering gear box (2) outputs a voltage (a sensor voltage) in accordance with the steering torque and steering direction to controller (11).

1. 2. 3. 4. 5. 6.

Steering wheel Steering gear box Torque sensor Pitman arm Drag link EPS motor

7. 8. 9. 10. 11. 12.

Actuator Bell crank Tie rod Rear wheel Controller Battery

1.

Torque sensor (3) is a part of steering gear box (2), which is connect to actuator (7) through pitman arm (4) and drag link (5).

2.

If steering wheel (1) is turned, the input shaft (worm shaft) of steering gear box (2) slides in the axial direction according to the steering effort. Torque sensor (3) converts the sliding distance of the input shaft into an electric signal and sends it to controller (11).

60-24

The output voltage is converted into a current by the controller and EPS motor (6) of actuator (7) rotates. As a result, the direction of rear wheels (10) is changed.

3.

The controller (11) converts the signal from torque sensor (3) into a current, which rotates EPS motor (6) to move actuator (7) in the same direction as the steering direction.

4.

Actuator (7) changes the direction of rear wheel (10) through bell crank (8). Commonality of parts The parts of the EPS system, except the controller (11), EPS motor (6), and drag link (5), are common to the 1 ton models to the 3 ton models.

BE30 Series

STRUCTURE AND FUNCTION

1.

STEERING SYSTEM

Mechanism to give proper steering effort to steering wheel 1. 2. 3. 4.

Potentiometer Bearing ring Input shaft (Worm shaft) Output shaft (Sector shaft)

5. 6. 7. 8. 9. 10.

Pin Arm Slide ring Coil spring Thrust needle Locknut

1)

In the steering gear box, there are input shaft (worm shaft) (3), coil springs (8), slide ring (7), and bearing ring (2). The input shaft is hung on the coil springs (4 pieces).

2)

If the steering wheel is turned, input shaft (3) rotates.

3)

As a load is applied to output shaft (sector shaft) (4), the input shaft slides in the axial direction (±1.6 mm). Since coil springs (8) are compressed through bearing ring (2) at this time, the reaction force becomes the steering effort.

2.

Mechanism to generate electric signal in torque sensor While a load is applied to the output shaft, if the steering wheel is rotated in direction A (e.g. to the left), the input shaft slides in axial direction B (by maximum of 1.6 mm).

1)

2)

As the input shaft slides, slide ring (7) moves, too.

3)

Arm (6) and pin (5), which is used as a fulcrum of the arm, are installed to the center of slide ring (7). If the slide ring moves, the arm (6) turns around the pin.

4)

The sensor is installed to the end of arm (6). Since the resistance of the potentiometer of the sensor changes as the arm turns, the electric signal to the controller changes.

BE30 Series

Steering gear box

Torque sensor

60-25

STEERING SYSTEM

STRUCTURE AND FUNCTION

6. STEERING LINKAGE (FOR 1.0 – 1.75 TON MODELS)

60-26

BE30 Series

STRUCTURE AND FUNCTION

BE30 Series

STEERING SYSTEM

60-27

STEERING SYSTEM

STRUCTURE AND FUNCTION

7. ELECTRICAL SYSTEM CIRCUIT DIAGRAM (FOR 1.0 – 1.75 TON MODELS)

1.This illustration shows Japanese spec.

60-28

BE30 Series

STRUCTURE AND FUNCTION

STEERING SYSTEM

1.This illustration shows Japanese spec.

BE30 Series

60-29

60-30 4.0 degrees 6.0 degrees 79.3 degrees 54.0 degrees

Caster King pin angle Steering angle of tire (inside) Steering angle of tire (outside)

893mm

1.5 degrees

Camber

Tread

0mm

Elliot type

Structure of knuckle Toe-in

Center pin type

Type

STEERING SYSTEM STRUCTURE AND FUNCTION

8. REAR AXLE (1.0 – 1.75 TON MODELS, EX TYPE)

BE30 Series

BE30 Series Structure of knuckle Toe-in Camber Caster King pin angle Steering angle of tire (inside) Steering angle of tire (outside) Tread

Type

952mm

57 degrees

80 degrees

0mm 1.5 degrees 0 degrees 6.0 degrees

Elliot type

Center pin type

STRUCTURE AND FUNCTION STEERING SYSTEM

9. REAR AXLE (2.0 – 3.0 TON MODELS)

60-31

HYDRAULIC SYSTEM

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM 1. LIFT CYLINDER (1.0 – 1.75 TON MODELS) Symbol

Item

Unit Specification

A

Outside diameter of cylinder

mm

52

B

Inside diameter of cylinder

mm

45

C

Disconnect of piston rod

mm

35

D

Stroke (Lifting height 3 m)

mm

1,500

—

Weight (Lifting height 3 m)

kg

20

1. 2. 3. 4. 5. 6. 7.

Wiper ring U-ring Cylinder head O-ring Bushing Piston rod Cylinder

8. 9. 10. 11. 12.

Cushion bearing Snap ring Bushing Backup ring U-ring

2. LIFT CYLINDER (2.0 – 3.0 TON MODELS) Symbol

Item

Unit

2.0 – 2.5 ton models

3.0 ton model

A

Outside diameter of cylinder

mm

57

63

B

Inside diameter of cylinder

mm

50

55

C

Disconnect of piston rod

mm

40

45

D

Stroke (Lifting height 3 m)

mm

1,505 ± 15

—

Weight (Lifting height 3 m)

kg

24.7

60-32

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

3. TILT CYLINDER (1.0 – 1.75 TON MODELS)

Symbol

Item

Unit

Specification

A

Outside diameter of cylinder

mm

73

B

Inside diameter of cylinder

mm

60

C

Diameter of piston rod

mm

25

D

Stroke

mm

139

E

Retracted length

mm

411±2

F

Inside diameter of rod bushing

mm

30

G

Inside diameter of cylinder bottom bushing mm

30

—

Weight

kg

8.4

—

Tilt angle

°

6°/12°

BE30 Series

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Wiper ring Cylinder head O-ring Bushing U-ring Packing header Snap ring Backup ring O-ring Piston rod assembly Cylinder Backup ring O-ring

60-33

HYDRAULIC SYSTEM

STRUCTURE AND FUNCTION

4. TILT CYLINDER (2.0 – 3.0 TON MODELS)

Symbol

Item

Unit

2.0 – 2.5 ton models

A

Outside diameter of cylinder

mm

84

84

B

Inside diameter of cylinder

mm

70

70

C

Diameter of piston rod

mm

30

30

D

Stroke

mm

141

157

E

Retracted length

mm

435

445

F

Inside diameter of rod bushing mm

35

35

G

Inside diameter of cylinder bottom bushing

mm

35

35

—

Weight

kg

12.3

12.6

—

Tilt angle

°

6°/12°

6°/12°

60-34

3.0 ton model

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Wiper ring Cylinder head O-ring Bushing U-ring Packing header Snap ring Backup ring O-ring Piston rod assembly Cylinder Backup ring O-ring

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

5. HYDRAULIC CIRCUIT DIAGRAM Proportional solenoid valve spec.

BE30 Series

60-35

HYDRAULIC SYSTEM

STRUCTURE AND FUNCTION

6. HYDRAULIC CIRCUIT DIAGRAM Manual valve spec.

60-36

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

7. WORK EQUIPMENT CONTROL LEVER Proportional solenoid valve spec.

BE30 Series

60-37

HYDRAULIC SYSTEM

STRUCTURE AND FUNCTION

8. WORK EQUIPMENT CONTROL LEVER Manual valve spec.

60-38

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

HYDRAULIC CONTROL VALVE (Proportional solenoid valve spec.) 1. OUTLINE This valve is a bank-type multi-control valve developed for lift truck, which controls the operating direction and speed of each actuator according to electrical inputs. 1)

Indication of model name KMC10L–3001A Remodeling symbol Rotation No. Number of spools (Example: 3) Proportional solenoid multi-control valve for lift trucks

2)

3)

Specifications General specifications

Max. using pressure Max. flow rate Allowable back pressure Applicable hydraulic oil Allowable contamination level of hydraulic oil Using temperature range Applicable visibility range

24.5 MPa {250 kgf/cm²} 70 l/min 0.9 MPa {10 kgf/cm²} Mineral hydraulic oil, ISO VG32 or equivalent Max. NAS Class 10 -20 – +90 °C 5 – 500mm²/s (cSt)

Electrical specifications

Rated current Recommended dither Coil resistance

0.7 A 100 Hz, 180 – 200mApp 17.5 ± 0.5 Ω

Hydraulic circuit diagram (KMC10L-3001)

BE30 Series

60-39

HYDRAULIC CONTROL VALVE

4)

Component parts and their functions No.

5)

STRUCTURE AND FUNCTION

Name

Function

1

Main control valve

Controls direction and flow rate to each actuator port and holds them in neutral.

2

Main relief valve

Restricts maximum using pressure of circuit.

3

Lift lock valve (Pilot spool)

Prevents leakage while lift valve is held in neutral.

4

Lift lock valve (Main plunger)

Prevents leakage while lift valve is held in neutral.

5

Load check valve

Prevents back-flow from load port.

6

Tilt lock valve (Pilot spool)

Prevents leakage while tilt valve is held in neutral.

7

Tilt lock valve (Main plunger)

Prevents leakage while tilt valve is held in neutral.

8

Proportional pressure Generates secondary pilot pressure according to electrical input and controls reducing solenoid valve stroke of main control valve spool.

9

Pressure reducing valve

Keeps primary pressure of proportional pressure reducing solenoid valve at 1.5 MPa {15 kgf/cm²}.

10 Sequence valve

Secures primary pressure of pressure reducing valve in unload state.

11 Port relief valve

Restricts maximum using pressure of installation port (attachment).

Explanation of terms Bleed-off circuit

Circuit to regulate oil flowing in a cylinder with a flow rate control valve (bleedoff control section) installed in parallel with the cylinder.

Meter-in circuit

Circuit to adjust flow rate on the inlet side of a cylinder to control the speed with a meter-in control section.

Meter-out circuit

Circuit to adjust flow rate on the outlet side of a cylinder to control the speed with a meter-out control section.

Dither

High-frequency vibration given to the spool of a proportional solenoid valve to reduce effects of friction and fixing to stabilize the performance.

1. 2.

60-40

Emergency manual lowering valve Main relief valve

3. 4.

Lift spool Tilt spool

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

2. SECTION OF PROPORTIONAL SOLENOID VALVE

1. 2. 3. 4. 5. 6.

BE30 Series

Main control valve Main relief valve Lift lock valve (pilot spool) Lift lock valve (Main plunger) Load check valve Tilt lock valve (Pilot spool)

7. Tilt lock valve (Main puunger) 8. Proportional pressure reducing solenoid valve 9. Pressure reducing valve 10. Sequence valve 11. Port relief valve

60-41

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

3. EXPLANATION OF OPERATION (1) Operation of main control valve The oil discharged from the hydraulic port is divided by end section (5) for bypass passage (1) and parallel passage (4). 1) When in neutral Bypass passage (1) is connected to the tank through sequence valve (3) of end section (2). At this time, sequence valve (3) secures the unload pressure (2.0 MPa {20 kgf/cm²}). Parallel passage (4) passes through each valve section and then it is blocked by end section (2). The main spool is held in neutral by the force of the return spring.

60-42

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

2) When fork is raised • If the lift lever is operated (in the RAISE direction) and a current flows in solenoid (2a), the proportional pressure reducing valve generates pilot pressure according to the command current (lever angle). With this pilot pressure, main spool (5) moves toward B side, pressing return spring (4b). • If main spool (5) moves, bypass passage G is blocked and the pressure in parallel passage C rises. If parallel port C is connected to port A1 by meter-in control section E, the oil from parallel passage C pushes up the main plunger of lift lock valve (7) and is discharged through port A1 into lift cylinder (1). (For the operation of the lift lock valve, see page 60-48.) • The flow rate at this time is controlled by bleed-off control section F and mater-in control section E, according to the input current. When the pump pressure (the pressure in parallel passage C) is lower than the load pressure, load check valve (3) prevents a back-flow.

1. 2a. 2b. 3. 4a. 4b. 5. 6. 7. 8.

Lift cylinder Solenoid Solenoid Load check valve Return spring Return spring Main spool (Lift) Lift lock valve (Pilot spool) Lift lock valve (Main plunger) Screw (For emergency operation)

BE30 Series

A. B. C. D. E. F. G.

A side B side Parallel passage Meter-out control section Meter-in control section Bleed-off control section Bypass passage

60-43

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

3) When fork is lowered • If the lift lever is operated (in the LOWER direction), a current flows in solenoid (2b) and the proportional pressure reducing valve generates pilot pressure according to the command current (lever angle), and then the pilot spool of lift lock valve (6) moves. If notch k1 of the pilot spool of lift lock valve (6) is opened, the main plunger of lift lock valve (7) is pushed up. (For the operation of the lift lock valve, see page 60-48.) If the pilot spool of lift lock valve (6) moves, main spool (5) moves toward A side. • As main spool (5) moves, port A1 is connected to the tank through meter-out control section D and the oil in lift cylinder (1) returns to the tank. The flow rate at this time is controlled by meter-out control section D, according to the input current (lift lever angle). • Connection to meter-out control section D is made after the main plunger of lift lock valve (7) is opened.

60-44

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

4) When mast is tilted backward • If the tilt lever is operated (in the BACKWARD direction), a current flows in solenoid (2a) and the proportional pressure reducing valve generates pilot pressure according to the command current (lever angle). With this pilot pressure, main spool (5) moves toward B side, pressing return spring (4b). • If main spool (5) moves, bypass passage G is blocked and the pressure in parallel passage C rises. Then, the parallel port C is connected to port A2 by meter-in control section Ea, and port B2 is connected to the tank passage by meter-out control section Db. The oil from the parallel port C presses the main plunger of tilt lock valve (7) in the direction of the arrow and it is discharged through port A2 into the rod side of tilt cylinder (1). (For the operation of the tilt lock valve, see page 60-48.) • The oil returning from the tilt cylinder is discharged into the tank passage through port B2 and meterout control section Db. The flow rate at this time is controlled by bleed-off control section F, meter-in control section Ea, and mater-out control section Db, according to the input current. • When the pump pressure (the pressure in the parallel passage C) is lower than the load pressure, load check valve (3) prevents a back-flow.

1. 2a. 2b. 3. 4a. 4b. 5. 6. 7.

Lift cylinder Solenoid Solenoid Load check valve Return spring Return spring Main spool Tilt lock valve (Pilot spool) Tilt lock valve (Main plunger)

BE30 Series

A. B. C. Da. Db. Ea. Eb. F. G.

A side B side Parallel passage Meter-out control section Meter-out control section Meter-in control section Meter-in control section Bleed-off control section Bypass passage

60-45

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

5) When mast is tilted forward • If the tilt lever is operated (in the FORWARD direction) and a current flows in solenoid (2b), the proportional pressure reducing valve generates pilot pressure according to the command current (lever angle), and then the pilot spool of tilt lock valve (6) moves. If the notch of the pilot spool of tilt lock valve (6) is opened, the main plunger of tilt lock valve (7) is pressed in the direction of the arrow. (For the operation of the tilt lock valve, see page 60-48.) If the pilot spool of tilt lock valve (6) moves, main spool (5) moves toward A side. • If main spool (5) moves, bypass passage G is blocked and the pressure in parallel passage C rises. Then, the parallel port C is connected to port B2 by meter-in control section Eb, and port A2 is connected to the tank passage by meter-out control section Da. The oil from the parallel port C presses the main plunger of tilt lock valve (7) in the direction of the arrow and it is discharged through port B2 into the bottom side of tilt cylinder (1). (Operation to tilt the mast forward) • The oil returning from the tilt cylinder is discharged into the tank passage through port A2 and meterout control section Da. The flow rate at this time is controlled by bleed-off control section F, meterin control section Eb, and mater-out control section Da, according to the input current. • Connection to the meter-in and meter-out control sections is made after the main plunger of tilt lock valve (7) is opened.

60-46

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

6) When attachment is operated • If the attachment lever is operated, a current flows in solenoid (2a) and the proportional pressure reducing valve generates pilot pressure according to the command current (lever angle). With this pilot pressure, main spool (5) moves toward B side, pressing return spring (4a). If main spool (5) moves, bypass passage G is blocked and the pressure in parallel passage C rises. • Then, the parallel port C is connected to the load port on the A side by meter-in control section Ea, and the load port on the B side is connected to the tank passage by meter-out control section Db. The oil from the parallel port C is discharged through port AX into the load port on the A side to cylinder (1). At this time, the oil returning from the hydraulic cylinder is discharged into the tank passage through the load port BX on the B side and meter-out control section Db. The flow rate at this time is controlled by bleed-off control section F, meter-in control section Ea, and mater-out control section Db, according to the input current (lever angle). • If solenoid (2b) is energized, the moving direction, discharge port, and return port of main spool (5) are inverted. When the pump pressure (the pressure in the parallel passage C) is lower than the load pressure, load check valve (3) prevents a back-flow.

1. 2a. 2b. 3. 4a. 4b. 5.

Hydraulic cylinder Solenoid Solenoid Load check valve Return spring Return spring Main spool

BE30 Series

A. B. C. Da. Db. Ea. Eb. F. G.

A side B side Parallel passage Meter-out control section Meter-out control section Meter-in control section Meter-in control section Bleed-off control section Bypass passage

60-47

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

(2) Operation of lift lock valve 1) When in neutral When in neutral, the pressures in ports A and B are kept at the same level (holding pressure) through orifice a of the main plunger of lift lock valve (7). Accordingly, the main plunger of lift lock valve (7) is pressed against the seat by load pressure PL applied to D12.

2) When fork is raised (Lift up) If the pump pressure rises and PP (= P13) exceeds load pressure PL, the main plunger of lift lock valve (7) moves in the direction of the arrow to open the pot.

60-48

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

3) When fork is lowered (Lift down) • As the secondary pressure of the proportional pressure reducing valve rises, the pilot spool of lift lock valve (6) moves in the direction of the arrow and port B is connected to port C of the tank passage. As a result, load pressure PL applied to the area difference between D12 and D11 pushes up the main plunger of lift lock valve (7) in the direction of the arrow. a While the oil is flowing, the pressure on the narrower area ( D11) side is lower. At this time, oil flows at a constant rate through orifice a of the main plunger of lift lock valve (7) to port C.

4) Emergency operation • When the fork cannot be lowered from a high position because of a trouble in the main spool (Hydraulic system), etc., it can be lowered by tightening screw (8) as an emergency measures. If screw (8) is tightened, the pilot spool of lift lock valve (6) is moved to lower the fork. • At this time, the main spool does not move and the oil flows through only orifice a. Accordingly, the oil flow rate is kept constant, thus the lowering speed of the fork is kept constant.

Do not take this emergency measures against a mechanical trouble such as foreign matter caught in the mast rails or rollers. When lowering the fork by this measures, check the condition of the cargo and working place and take care of the safety extremely.

BE30 Series

60-49

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

(3) Operation of tilt lock valve 1) When in neutral When in neutral, the pressures in ports A and B are kept at the same level (holding pressure) through the pilot spool of tilt lock valve (6). Accordingly, the main plunger of tilt lock valve (7) is pressed against the seat by load pressure PT applied to D22.

2) When mast is tilted forward As the secondary pressure of the proportional pressure reducing solenoid valve rises, the pilot spool of tilt lock valve (6) moves in the direction of the arrow. Then, port A becomes a block and port B is connected to tank passage C. As a result, load pressure PT applied to the area difference between D22 and D21 presses the main plunger of tilt lock valve (7) in the direction of the arrow.

3) When mast is tilted backward If the pump pressure rises and PP (= P23) exceeds load pressure PT, the main plunger of tilt lock valve (7) moves in the direction of the arrow to open the pot.

60-50

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

(4) Operation of pressure reducing valve and sequence valve 1) Operation of pressure reducing valve The secondary pressure of the pressure reducing valve, or the pressure in port A is applied through passage B to port C. Spool (1) of the pressure reducing valve reduces the primary pressure (pump pressure) so that the pressure in port C applied to the sectional area of the spool will be balanced with the force of spring (2) of the pressure reducing valve. That is, the secondary pressure of the pressure reducing valve in port A will be kept at a constant pressure (1.5 MPa {15 kgf/cm²}) decided by the spring force. 2) Operation of sequence valve When the main control valve unloads or the fork is "lowered", the sequence valve operates as described below to secure the primary pressure of the pressure reducing valve. The pressure in port D is sent through passage E to port F. The secondary pressure of the pressure reducing valve is sent through passage H to spring port G. Accordingly, when oil flows from port P through port D and main spool (3) to port J, the pressure in port D is kept as shown below even if main spool (3) is unloading. • Secondary pressure of pressure reducing valve (1.5 MPa {15 kgf/cm²}) + Force of sequence valve spring (4) (0.5 MPa {5 kgf/cm²}) = 2.0 MPa {20 kgf/cm²})

BE30 Series

60-51

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

(5) Operation of proportional pressure reducing solenoid valve • While a current is not flowing in proportional solenoid (5), pressure reducing valve spool (4) is kept in contact with the end face of the proportional solenoid by spring force Fs. Under this condition, ports B and A are shut off from each other by land 1 (2) of pressure reducing valve spool (4), and port A is connected to port C which is connected to the drain passage. Accordingly, the pressure in the drain passage is applied to port A. • If a current flows in proportional solenoid (5) and attractive force Fi becomes larger than spring force Fs, pressure reducing valve spool (4) moves. Ports B and A are connected to each other by notch 1 (3), and the passages of ports A and C are choked by land 2 (1) and notch 2 (6). Accordingly, the pressure (secondary pressure) in port A rises. Since diameter of D1 of land 1 (2) is larger than diameter D2 of land 2 (1) at this time, the hydraulic pressure against attractive force Fi of the solenoid is applied to pressure reducing valve spool (4). • As pressure reducing spool (4) moves, Fh rises. When Fh + Fs = Fi, the spool is stopped and balanced. In this way, secondary pressure P2 is kept in almost proportion to attractive force Fi of the solenoid.

60-52

1. 2. 3. 4. 5. 6.

Land 2 ( D2) Land 1 ( D1) Notch 1 Pressure reducing valve spool Proportional solenoid Notch 2

Fh: Fi: Fs: P1: P2:

— Attractive force Spring force Primary pressure Secondary pressure

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

1. 2. 3. 4.

Emergency manual lowering valve Main relief valve Lift spool Tilt spool

4. OUTSIDE VIEW OF HYDRAULIC CONTROL VALVE (PROPORTIONAL SOLENOID VALVE)

BE30 Series

60-53

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

Section of proportional solenoid valve (1) 1. Take care of the fitting direction.

60-54

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

a This drawing is for understanding of the structure of the proportional solenoid valve. The component parts of the proportional solenoid valve will not be . supplied singly. Symbol 101 102 121 122 123 151 152 153 161 162 163 166 201 202 211 212 213 214 215 216 251 252 254 261 262 263 264 265 271 272 273 301 302 303 321 331

Part name Symbol Part name End section (1) 511 Plunger End section (2) 512 Plunger Casing L 513 Plunger Casing T 521 Spring Casing A 522 Spring Plug 523 Spring Plug 551 Plug Plug 552 Plug O-ring 561 O-ring O-ring 562 O-ring O-ring 601 Relief valve O-ring 602 Relief valve End cover 611 Sequence valve spool Solenoid protective cover 612 Pressure reducing valve spool (1) Adjusting screw 621 Spring Pilot spool (1) 622 Spring Sleeve 630 Rod E-ring 651 Plug Spring seat 661 O-ring Spring 711 Pressure reducing valve spool (2) Hexagon socket head set screw 712 Pilot spool (2) Ball 713 Sleeve Plug 721 Spring O-ring 722 Spring O-ring 731 Throttle O-ring 751 Plug O-ring 761 O-ring O-ring 762 O-ring Hexagon socket head bolt 763 O-ring Hexagon nut 873 Double-end stud Hexagon socket head bolt 879 Hexagon nut Spool (L) 880 Spring washer Spool 891 Nameplate Spool (T) 892 Screw Spring 901 Solenoid Spring seat 949 Cap housing, 6P 950 Plate, 6P cap 951 Cap housing, 4P 952 Plate, 4P cap 953 Blind plug

Tightening torque table Symbol Thread size Tightening torque (Nm{kgcm}) 151 PT1/4 20.0 – 24.0 {200 – 240} 152 NPTF1/16 5.9 – 7.8 {60 – 80} 153 9/16-18UNF 34.0 – 38.0 {350 – 390} 213 M14×1 27.0 – 33.0 {270 – 330} 251 M6×1 1.5 – 2.5 {15 – 25} 254 M22×1 39.0 – 49.0 {400 – 500} 271 M5 5.9 – 7.8 {60 – 80} 272 M8×1 6.9 – 8.8 {70 – 90} 273 M5 5.9 – 7.8 {60 – 80} 551 M18×1.5 49.0 – 59.0 {500 – 600} 552 M16×1.5 39.0 – 49.0 {400 – 500} 601 M20×1.5 41.0 – 47.0 {420 – 480} 601 M8 6.9 – 8.8 {70 – 90} 602 M22×1.5 39.0 – 49.0 {400 – 500} 602 M8 6.9 – 8.8 {70 – 90} 651 PF3/8 69.0 – 78.0 {700 – 800} 731 M4 0.5 – 0.7 {5 – 7} 751 M18×1.5 49.0 – 59.0 {500 – 600} 771 M5 5.90 – 7.8 {60 – 80} 879 M8 28.0 – 32.0 {280 – 320} 901 M22×1 39.0 – 49.0 {400 – 500} 901 M6 6.9 – 7.8 {70 – 80}

BE30 Series

Remarks

Adjusting screw locknut

Relief valve Adjusting screw locknut Relief valve Adjusting screw locknut Apply LOCTITE #241

Solenoid Adjusting screw locknut

60-55

HYDRAULIC CONTROL VALVE

STRUCTURE AND FUNCTION

Section of proportional solenoid valve (2)

60-56

BE30 Series

STRUCTURE AND FUNCTION

HYDRAULIC CONTROL VALVE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

BE30 Series

Main control valve Main relief valve Lift lock valve (Pilot spool) Lift lock (Main plunger) Load check valve Tilt lock valve (Pilot spool) Tilt lock valve (Main plunger) Proportional pressure reducing solenoid valve Pressure reducing valve Sequence valve Port relief valve

.

60-57

WORK EQUIPMENT

STRUCTURE AND FUNCTION

WORK EQUIPMENT 1. MAST (FOR 1.0 – 1.75 TON MODELS)

60-58

BE30 Series

STRUCTURE AND FUNCTION

BE30 Series

WORK EQUIPMENT

60-59

WORK EQUIPMENT

STRUCTURE AND FUNCTION

2. MAST (FOR 2.0 – 2.5 TON MODELS)

60-60

BE30 Series

STRUCTURE AND FUNCTION

BE30 Series

WORK EQUIPMENT

60-61

WORK EQUIPMENT

STRUCTURE AND FUNCTION

3. MAST (FOR 3.0 TON MODEL)

60-62

BE30 Series

STRUCTURE AND FUNCTION

WORK EQUIPMENT

FB30

BE30 Series

60-63

POWER CONNECTOR FOR OPTIONAL DEVICES

STRUCTURE AND FUNCTION

POWER CONNECTOR FOR OPTIONAL DEVICES The power connectors for optional devices are installed to 2 places of the truck body. When adding various devices, use these connectors. The rated current of each connector is as follows. 1. Working lamp connector 1) This connector is not interlocked with the key switch. 2) Rated current: 5 A ( 1) 2.

Spare connector (Outside relay contact) 1) This connector is interlocked with the key switch. 2) Rated current: 2 A 1. When using the spare connector and the working lamp connector, note that the usable current is as follows. Rated usable current = Rated current (5 A) - Load of spare connector 2. Never add an optional device to a position other than specified ones. Doing so can break or burn the electric parts. 3. If a necessary current exceeds the rated value, add an outside relay, etc.

Working lamp connector (1): YAZAKI, Type CN, 2P Wire color: White and yellow/Black Spare connector (2): NIHON AMP, Econoseal J Series, 2P Wire color: Yellow and red/Black

60-64

BE30 Series

STRUCTURE AND FUNCTION

CONTROL UNIT

CONTROL UNIT 1. OUTLINE AND FEATURES OF CONTROL UNIT This control unit is used for control of the speed of the travel motor, hydraulic motor, and EPS motor, control of the hydraulic control valve (proportional solenoid valve), control of the charger, control display of the monitor panel, troubleshooting, and control communication between controllers. It consists of the following devices. 1.

2. 3. 4.

Controller ......................... Divided into the invert control section, contactor (operation section), and command/signal communication control section. Used for control of the drive motor, pump motor, EPS motor, and hydraulic control valve (proportional solenoid valve), display of monitor panel, troubleshooting, etc. Forward-reverse lever..... Has a switch to select forward and reverse travels. Accelerator ...................... Controls the travel speed with the voltage which changes according to the pressing angle of the accelerator pedal. Other devices .................. Control knobs, torque sensor, travel speed sensor, etc.

Features 1. Controller The controller is divided into the main controller and sub controller. The sub controller consists of 2 printed circuit boards; the multi-controller board and system controller board (Only the multi-controller is used for the manual valve specification, however). 2.

Meter panel The meter panel has functions of indicators and tools. It shows the current condition of the lift truck and error codes when any trouble occurs. In addition, it indicates the operations (ON/OFF) of the switches and various adjustment data during testing and adjusting.

3.

Adjusting functions of meter panel and control switches (1) Adjustment by operator Each operator can set or adjust the date, time, acceleration time, lifting speed, tilting speed, and travel speed limit, and can turn ON/OFF the speed limit operation and accelerator neutral regeneration. (2) Adjustment by serviceman Each serviceman can adjust the acceleration mode, acceleration feeling, and regenerative braking force, display the switch (ON/OFF) monitor, and select the display language (Japanese/English).

BE30 Series

60-65

CONTROL UNIT

STRUCTURE AND FUNCTION

2. PRINCIPLE OF CHANGE OF MOTOR SPEED The travel motor is a 3-phase induction motor, the speed of which is controlled with an AC inverter. An inverter is a device which converts DC power into AC power at any voltage and frequency. It inverts the battery current (DC) into a 3-phase AC by operating 3 switches, then changes the wave form (frequency and height of the wave) of the obtained 3-phase sine-wave AC to control the motor performance. Control of induction motor speed with inverter

1. Device to convert AC power into DC power. This is the rectifier for a battery charger. 2. Device to convert DC power into AC power. This is mounted on an AC controller.

3. CONNECTION DIAGRAM OF MOTOR POWER CIRCUIT (CIRCUIT OF TRAVEL, HYDRAULIC, AND EPS MOTORS) In the following diagram, the contacts of the power modules and power transistors are expressed by mechanical contacts, and fuses, current detectors, capacitors, etc. are omitted for simplification. The drive contactor (MD), pump contactor (MP), and EPS contactor (MPS) are normally turned OFF. They are turned ON when the key switch is turned ON.

1. An alternating current (AC) is generated by this switch (FET) to drive the AC motor. (Input signal)

60-66

BE30 Series

STRUCTURE AND FUNCTION

CONTROL UNIT

4. OUTLINE OF OPERATION OF TRAVEL MOTOR Outline of operation of travel motor (AC) No.

Basic operation item

Measures

Operations, signals, etc. for execution

1 Forward and reverse rotation of motor (Forward travel and reverse travel)

Change the order of the 3-phase currents supplied to the stator.

F-signal or R-signal of F/R lever O The CPU sends signals to the power module according to the received signal to change the order of the 3-phase currents.

2 Heightening and lowering of motor speed (Heightening and lowering of travel speed)

Change the frequency of the 3-phase currents supplied to the stator.

Accelerator voltage Motor speed O Low The CPU sends signals to the power module according to the received voltage to change the frequency of the 3-phase curHigh rents.

3 Increase and decrease of motor torque (when power is necessary for starting, acceleration, or traveling uphill)

Change the strength of the 3-phase currents supplied to the stator.

Load condition Motor Small Pressing degree of torque accelerator pedal Present motor current O The CPU calculates these data Large and sends signals to the power module to change the strength of the 3phase currents and generate necessary torque.

BE30 Series

Forward travel

Reverse travel

Sine-wave currents which are shifted by 120 degrees from each other are supplied in order of coils U, V, and W.

Sine-wave currents which are shifted by 120 degrees from each other are supplied in order of coils W, V, and U.

Period of sine wave is 360 Period of sine wave is 360 degrees. degrees.

Chopping speed

Period of motor current

60-67

CONTROL UNIT

STRUCTURE AND FUNCTION

(Reference) Comparison of DC motor and AC motor Comparison item

DC motor

AC motor

Structure of motor

Complicated

Relatively simple

Rectification (Commutation) mechanism

Contact type with brushes and commutator

Non-contact type with semiconductor devices (Single-phase or multi-phase)

Increase of output power

Generally difficult

Easy

Heightening of speed

Difficult

Easy

Lowering of speed

Generally easy

Generally easy

Unevenness in rotation

Generally much

Generally little

Unevenness in torque

Generally much

Generally little

Output efficiency

Generally high

Generally low

Control circuit

Relative simple

Slightly complicated

Vibration and noise during ro- Generally much tation

Generally little

Cleanliness

Low

High

Maintenance

Brushes and commutator need maintenance

Maintenance-free

Lifespan

Short

Long

5. POWER MODULE OF CONTROLLER The switching element for the travel motor is a MOS-FET (Metal Oxide Semiconductor-Field Effect Transistor, hereinafter, referred to as FET). This FET works similarly to the conventional IGBT, transistor, etc. It can switch faster, however, and electric circuits can be reduced in size by using it. Since Circuit board (Detail of Y portion) a large current cannot flow through each FET element, many FET elements are connected in parallel so that the larger current can flow through them. A set of these elements is called a power module. Although the hydraulic motor is a DC motor as ever, the switching element is replaced with an FET. • G1, G2, and S2 are the terminals of the FET's soldered to the circuit board. It is required to measure at the terminal of only 1 FET (All FET's are conected to each other in the circuit board). • Many FET's are soldered to the back side of the circuit board. Circuit board

60-68

BE30 Series

STRUCTURE AND FUNCTION

CONTROL UNIT

6. CONTROL FUNCTIONS OF CONTROLLER 1.

Change of travel direction and control of speed The travel direction of the lift truck is changed according to the tilting direction of the forward-reverse lever. The travel speed can be controlled steplessly with the accelerator pedal.

2.

Limiting of current The current flowing in the motor is so controlled that it will not exceed the value saved in the CPU card to prevent breakage of the motor, FET, and IGBT.

3.

Protection from temperature The temperature sensor installed near the power module monitors temperature rise. If the temperature exceeds 100 °C, the conduction ratio is lowered to limit the output and prevent overheating.

4.

Runaway prevention circuit If the travel power module has a short circuit, this circuit turns off the travel and cargo handling functions.

5.

Low-voltage protection circuit If the source voltage lowers below a certain level (the battery is overdischarged), this circuit stops the lift truck to protect the controller. Note) This circuit is not for protection of the battery. Check the battery for overdischarging with the "battery level gauge".

6.

Chopper for motor for hydraulic equipment Start control : Prevents an excessive current at start. Speed control : Controls the speed according to the type of work (lifting, tilting, etc.) and control lever angle. Note) The chopper for hydraulic equipment can lengthen the lifespan of the brushes of the motor for hydraulic equipment and save energy.

BE30 Series

60-69

CONTROL UNIT

7.

STRUCTURE AND FUNCTION

Setup function for performance characteristics The performance characteristics can be set up ideally on the metal panel, according to the type of handled cargo, working environment, feeling of the operator, etc. Set item

Purpose

Remarks

(1) Travel power (1 – 8)

Set the max. travel speed and accel- • Power 7, 8: Max. speed is 17 km/h, 1 – 6: Max. eration performance. speed is 15.5 km/h. • As the number increases, the acceleration and current consumption are increased. • Gradeability is kept constant at power 1 through 8.

(2) Soft start characteristic (A – C)

Set the starting shock level to soft (C) • A is hard and C is soft. through hard (A). • When high production is required or the operator is an expert, select A. When cargo is easy to break or fine control is necessary, select C.

(3) Acceleration characteristic (A – C)

• Set according to the feeling of each operator. Set acceleration corresponding to pressing depth of accelerator pedal to 3 patterns. By combining this characteristic with the soft start characteristic, 9 patterns can be set up.

(4) Plugging regeneration characteristic (1 – 100)

Set the braking force applied when the forward-reverse lever is shifted.

• When quick response is necessary, set high. When cargo is easy to break, set low.

(5) Brake regeneration characteristics (1 – 100)

Set the strength of the electric brake applied when the foot brake is pressed.

• To shorten the stopping distance, set high. When handling cargo which tumbles easily, set low.

(6) Lifting speed adjustment (1 – 8)

Set the lifting speed

• When high lifting height or high production is required or the operator is an expert, set high. When long operating time is required or cargo is easy to break, set low.

(7) Tilting speed adjustment (1 – 8)

Set the tilting speed

• When high lifting height is not required or high production is required or the operator is an expert, set high. When high lifting height is required or the operator is not skilled or cargo is easy to break, set low.

(8) Slope regeneration (ON/OFF)

Set slow or fast travel on a downhill road.

• Set 2 = ON for safety, even if the slope is gentle. • When driving downhill by coasting, depending on the type of work, set 1 = OFF. • If 2 = ON is set, travel speed is limited to 1 – 2 km/h, regardless of position of the forward-reverse lever. (This does not function when the forward-reverse lever is in neutral.)

(9) Accelerator neutral regeneration characteristic (1 – 100)

Set the strength of the electric brake applied when the accelerator pedal is released (equivalent to the strength of an engine used as a brake).

• To apply the electric brake when the accelerator pedal is released, set this characteristic. • When quick response is necessary, set high. • When coasting is necessary or cargo is easy to break, set low.

(10) Other characteristics • Attachment speed, travel speed limit, and overspeed alarm

60-70

BE30 Series

STRUCTURE AND FUNCTION

OPERATING DEVICE

OPERATING DEVICE (METER PANEL, SWITCHES, ETC.) 1. NAME OF EACH DEVICE For detailed explanation of each device and how to operate it, see the operation manual.

Lift truck with manual valve specification

Lift truck with proportional solenoid valve specification

1. 2. 3. 4. 5. 6.

Key switch Forward-reverse lever Meter panel Parking brake lever Horn button Combination switch

BE30 Series

7. 8. 9. 10. 11. 12.

Accelerator pedal Brake pedal Steering column lock lever Lift lever Tilt lever Emergency stop switch

60-71

OPERATING DEVICE

STRUCTURE AND FUNCTION

2. HOW TO START HOUR METER The hour meter is turned OFF when the lift truck is shipped. After the lift truck is delivered, remove the left side cover of the truck body and connect the connector for starting the hour meter shown below. This illustration shows Japanese spec.

1. Multi-controller 2. Connector for charge mode switch (Only in Japanese spec.) Wire color:Male side; BY ( 1. YB) Female side; OW ( 1. RL) 3. Charger transformer (Only in Japanese spec.) 4. Connector for starting hour meter Wire color: YW ( 1. RB) BY 5. System controller

1. Wire color for 1 ton series.

3. HOW TO TURN ELECTROLYTE LEVEL INDICATOR FUNCTION OFF • •

If the electrolyte level indicator function is not necessary, disconnect yellow/blue wire B on the battery and connect it to yellow/red wire A. This is effective when a battery having no electrolyte level sensor is necessary for some reason.

60-72

BE30 Series

STRUCTURE AND FUNCTION

OPERATING DEVICE

4. HOW TO OPERATE LIFT INTERRUPT FUNCTION What is lift interrupt function The lift interrupt function means a function of stopping the cargo handling work and warning the operator to charge the battery when the battery is discharged by 80% (at this time, 2 lower display portions A blink alternately and the warning buzzer sounds) so that the battery will not be deteriorated by overdischarge. If this function operates, the lift truck cannot handle cargo but can travel. Accordingly, the operator should return to the charging place and charge the battery. •

How to turn lift interrupt function OFF If the wires Br – YR shown at right are connected, the lift interrupt function does not operate. a The above wires are connected when the lift truck is shipped. Ask the operator if the lift interrupt function is necessary, then keep the wires connected or disconnect them.

•

How to turn lift interrupt function ON If the wires Br – YR shown at right are disconnected, the lift interrupt function operates. If those wires are connected again, the lift interrupt function does not operate.

BE30 Series

60-73

OPERATING DEVICE

STRUCTURE AND FUNCTION

5. REFERENCE FOR ADJUSTMENT OF TRAVEL CHARACTERISTIC Travel operation

Reference data for adjustment of acceleration and deceleration of BE30 Series travel system Adjustment value Item to be adjusted

Truck characteristic and controller characteristic

Start

1) Travel power (Set in operator mode)

2) Soft start characteristic (Set in dealer mode)

BE30 Series When car- During go is easy power to break travel

Competitors

When shipped

Toyota

Nichiyu

4

8

6

8

8

C

A

B

A

C

C

A

B

C

A

1 ton Series

55%

100%

100%

55%

100%

2 ton Series

55%

100%

100%

1 ton Series

30%

60%

60%

40%

56%

2 ton Series

30%

60%

60%

Shock and rise of speed at start of truck can be changed by changing rise of output characteristic of controller.

3) Accelerator characteristic

Stop

Speed when accelerator pedal is pressed halfway is adjusted. 4) Plugging regenerative characteristic Since data of 2 ton models of competitors Stopping distance are not available, ad- by plugging is changed. just for each truck. (Current must not exceed range shown at right.) 5) Brake regenerative characteristic Since data of 2 ton models of competitors Stopping distance are not available, ad- by brake is changed. just for each truck. (Current must not exceed range shown at right.)

60-74

BE30 Series

STRUCTURE AND FUNCTION

OPERATING DEVICE

6. MATER PANEL DISPLAY

BE30 Series

60-75

OPERATING DEVICE

STRUCTURE AND FUNCTION

7. METER PANEL FUNCTIONS Meter panel analyzer functions and operations table Q : STD w : STD (User’s adjusting function) q : STD (Dealer’s adjusting function)

E : If equipped e : If equipped (Dealer’s adjusting function)

Serviceability

q

q

q

Q q q Q Q Q Q

Q

Q

Q q Q q Q

Q q

Q Q Q Q Q q Q Q Q q q

60-76

Q q

q

Hour meter

Date/time (calender & clock) BDI (battery residual capacity meter) Acceleration time adjustment Acceleration mode adjustment Acceleration feeling adjustment Regenerative braking power adjustment Lift speed adjustment Tiltt speed adjustment ATT speed adjustment Travel limit speed setting Overspeed alarm travel speed setting Adjusting function

Functional division

Q

Operation/handling division

Segment & partial dot type Q Q Q e Q Q (key SW: ON o Extinguished) Q (key SW: ON o Extinguished) w Q (10 steps) w (8 steps) q (10 choices) q (10 choices) q (8 steps) w (8 steps) w (8 steps) e (8 steps) w E

Troubleshooting display Corrective measure message display SW (I/O) monitor display

Q Q q

Battery overdischarge alarm Battery liquid shortage Parking lever non-return alarm Battery oversidcharge alarm Battery liquid level Overspeed alarm Neutral return alarm Parking lever non-return alarm

Q Q Q Q Q E Q Q

Speed limlt operation ON/OFF selection Accelerator neutral regeneration ON/OFF selection Language display selection

w w q

Troubleshooting

q

Display type Used for both counter and reach Back light Speed meter Trip meter (integrated travel distance) Key ON time Travel motor power ON time Hydraulic motor power ON time

Indicator

q Q q q

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Alarm

Q Q

2

Function/contents

Safety

Operability

1

No.

Appearance

No. Item

Visibility

q : New function

BE30 Series

BE30 Series

Item

Travel speed display

Travel speed limit display

1

2

Note: Except on the ordinary A or B mode screen, W1 or W2 is not displayed.

Display code: U08

On the standard screen: 1) When the pushbutton [e] (P1) is pressed, the travel speed limit mode will be set. 2) When the mode is changed: [ ] (W1): Lights up. o [ ] (W1, W2): Lights up. 3) When the current mode is changed into the travel speed limit mode, the currently set value blinks. The set speed blinks. o 7-segment portion Blinking interval: A 2s 4) Settable speed: 5 to 15 km/h (10 steps)

1) When travel speed is 0 km: Display: 0 km/h 2) The travel speed is displayed by rounding up. (7segment, 2-digit)

Contents of display

The travel speed is displayed according to the travel speed signal of the travel speed sensor. (Display code: U07)

Ordinary A or B mode display

No.

Mode

Detailed contents of display

8. DISPLAY IN EACH MODE

A. Lights up portion B. Printed portion

When the travel speed is 9.1 km/h:

Display example

STRUCTURE AND FUNCTION OPERATING DEVICE

60-77

60-78

BDI display (Battery residual capacity display)

Parking brake display

4

Item

Contents of display

Note: This is not displayed when the current mode is changed into any adjustment mode.

1) Blinking interval: A 2) Parking brake switch: OFF o blinking Parking brake switch: ON o extinguished 3) When part P, W2 blinks: If the parking brake "ON" Eand the travel speed of 1 km/h or more are continued for 1 s or more, an alarm sound will be output. (Interval: B) To clear this status, reset the parking lever or accelerator pedal to the original status.

Display code: U10 Part P, W2 is caused to blink by the parking brake SW signal.

Note: When the current mode is changed into any adjustment mode, this is not displayed.

Display code: U06

Ordinary A or B mode display

3

No.

Mode

When the travel speed is 0 km/h: Parking brake: ON Part P: Blinking

In the 50% discharged status: (S1 to S5 light up.)

Display example

OPERATING DEVICE STRUCTURE AND FUNCTION

BE30 Series

Item

Travel power display

Clock and calendar display

5

6

BE30 Series

Display code: U14

Display code: U09

Ordinary A or B mode display

No.

Mode

Set travel power value: +4 (T1 to T4 light up.)

Display example

Date/time data is displayed in the dot matrix June 10, 1997, Tuesday, 17 hours and 00 area shown in the figure at left. (Alphanuminute meric characters) ‘ 9 7 – 6 – 1 0 TUE 1 7 : 0 0 Display item TOTAL 1 9 9 9 9 . 9 h Year data: 00 to 99 (in units of year) 1st and 2nd digits of year to left a The lower row is used for the hour meter Month data: 1 to 12 (in units of month) display. Day data: 1 to 31 (in units of day) Day does not need to be adjusted at end of each month and in leap years. Data on the day of the week: 0: SUN 4: THU 1: MON 5: FRI 2: TUE 6: SAT 3: WED Hour data: 0 to 23 (in units of hour) Minute data:0 to 59 (in units of minute)

Note: This is not displayed when the current mode is changed into any adjustment mode.

Contents of display

STRUCTURE AND FUNCTION OPERATING DEVICE

60-79

60-80

Hour meter display (key ON time)

Battery residual liquid quantity display

Overspeed alarm

8

8A

Item Hour meter data is displayed in the dot matrix area shown in the figure at left. (Character display 8, alphanumeric characters) Display item Key ON time (U01): 0 to 19999.9 (in units of 0.1 h) Travel time (U02): 0 to 19999.9 (in units of 0.1 h) Material-handling time (U03): 0 to 19999.9 (in units of 0.1 h) Integrated travel distance (U04): 0 to 19999.9 km (in units of 0.1 km)

Contents of display

Notes: 1. The overspeed setting range is 5 to 15 km. 2. Alarm sound: B 3. Each setting is performed in the user mode. (Display code: A08, A09)

Display code: U15 When Use of Overspeed Alarm is selected, the set overspeed value is compared with the current travel speed. If the current travel speed exceeds the set value, an alarm sound will be output.

When the quantity of battery liquid is insufficient, E5 shown in the above figure lights up.

Display code: U11 This is displayed by the battery liquid quantity signal.

Notes: 1. The portion marked denotes OP. 2. In the standard display (calendar/hour meter display) at the key ON time except in the portion marked , the key ON time, travel time, and material-handling time are displayed in this order. (Each data change is made at an interval of 1 second. After completion of one cycle, only the key ON time is displayed.)

Display code: U01 to 04

Ordinary A or B mode display

7

No.

Mode

TUE

1 7 : 0 0 1 9 9 9 9 . 9 h

a The upper row is used for the calendar display.

‘ 9 7 – 6 – 1 0 TOTAL

Total travel time: 19999.9 h

Display example

OPERATING DEVICE STRUCTURE AND FUNCTION

BE30 Series

Item

Error display

9

BE30 Series Displayed according to failure occurrence signal (LC dot matrix section)

Contents of display

1) Upon occurrence of a failure, the contents corresponding to a failure position of E1, and E2 to E4 is displayed. (All the other character display areas are extinguished.) However, it blinks for 10 s after occurrence of an failure. (Blinking interval A, alarm sound A) 2) If another failure occurs in the blinking display status, blinking will be started anew for 10 s from the moment. 3) When multiple failures occur, the contents of display will be switched at intervals of 1 s. 4) Regarding E99 (communication error), the display is made as follows: KEY-ON • When a communication error occurs, E99 is always displayed as an error display. • When a recovery is made from the communication error status, E99 is changed into the display of the contents of communication. However, when a communication error is recovered within 2 s after occurrence of this error, E99 will be displayed for 2 s. KEY-OFF • When a recovery is made from the communication error status, E99 will be changed into the display of the contents of communication. However, when a communication error is recovered within 2 s after occurrence of this error, E99 will be displayed for 2 s. If a communication error is recovered even after all are extinguished, the contents of communication will be displayed. If the communication is recovered, E99 changes to the display of the contents of the communication. If the communication is recovered within 2 seconds after occurrence of the error, however, E99 is displayed for 2 seconds.

Display code: E01 to 99

Ordinary A or B mode display

No.

Mode

Liquid crystal dot matrix area, 24 characters x 2 lines

F A I L URE I N CON T . ( T ) CA L L YOUR S ERV I CE !

Display example E 0 1

STRUCTURE AND FUNCTION OPERATING DEVICE

60-81

60-82

1

No.

Item Conditions for changing the standard mode to the user mode: 1. F/R lever: "N" 2. All work equipment levers: "OFF" Conditions for changing the user mode to the standard mode: 1. No adjustment operation is performed for 60 seconds or more. 2. One of the F/R lever and work equipment lever has been operated. 3. The key switch is turned off.

Contents of display

PRESENT TIME (Year, month, day of the week, time)

NEUTRAL REGENE.BRAKE (ON/OFF)

OVER SPEED ALARM (ON/OFF)

SPEED LIMIT (5–15km/h)

TILT SPEED (1–8)

LIFT SPEED2 (1–8)

LIFT SPEED1 (1–8)

DRIVE POWER (1–8)

Setting data –––

Note: For travel overspeed setting, set 15 km/h max.

Adjustable item 1. Standard display O 2. Travel power setting (ES control) O 3. Lift 1 speed setting O 4. Lift 2 speed setting O 5. Tilt speed setting O 6. Travel speed limit value setting O 7. Travel overspeed setting O 8. Accelerator neutral regeneration setting O 9. Current time setting

1. Press the MODE button (P3) and select a setting item. 2. The setting enable position will blink. (A blinks.) 2.1 Use the button (P1) to change any setting. 2.2 For an item having multiple setting positions (for example, date), select it by the button (P2). 2.3 After completion of setting, proceed to the next setting item by the MODE button (P3). Upon completion of setting, the display is continued for 2 sec and then proceeds to the next item.

Operator adjustment mode display

Operator adjustment mode

Mode

A 0 4

A 0 3

Press the MODE button (P3). After the set value lights up for 2 sec., the current item is changed into the next item.

L I F T S P E E D 2 ( 1 – 8 ) S E T L E V E L 8

Press the e button (P1) 4 times.

L I F T S P E E D 1 ( 1 – 8 ) S E T L E V E L 8

The lift speed setting is changed from 1 into 2.

Display example

OPERATING DEVICE STRUCTURE AND FUNCTION

BE30 Series

BE30 Series

No.

Item

A12,14 16,18,20 22,24,26 28,30

A11,13 15,17,19 21,23,25 27,29

A10

A09

A08

A07

4

5

V E L . . T L T L T L E D S R O R O T R O T R O S E – 1 S E – 1 S E – 1 S E – 1 S E – 1 S E – 1 E L L E L L E L L C T O C T O U N L P S F S N A F A N N 0 N 0 N 0 N 0 N 0 N 0 . E . E . E I N I F C E

E T T S E S E S E

6

8 O E M M E E E E E E I E E

E R 8 R R D 1 8 D 2 8 D ( 8 I T 1 D

1 2 1 2 1 2 1 2

N N N N

:

:

:

:

:

0 0

0 0

0 0

0 0

0 0

)

A 1 0

A 1 0

A 1 0

A 0 9

A 0 9

A 0 9

A 0 9

A 0 9

A 0 9

A 1 2

A 1 1

( A – C )

E V E L

O N / O F F

( A – C )

N 1 2 : 0 0 V E L ( A – C )

1 2

N

E V E L

E O E O E O E O E O E O E

O N 1 1 ( O N / O F F ) F T I O N 1 1 ( 1 – 1 0 0 V E L 1 0 0

I M M I M M I M M I M M I M M I M M L A L B L C 1 (

A 1 1

T 1 0 T 1 0 T 1 0 T 1 0 T 1 0 T 1 0 W R E L W R E L W R E L N 1

A 0 8

N E

B R A K E

A 0 8

A 0 7

A 0 7

) A 0 6

L A R M h N E B R A K E

h

A 0 5

A 0 4

)

T – T – T – T – T – T – P V P V P V O

)

( 5 – 1 5 k m / 5 k m / h A L A R M

1 – 8

1 – 8

)

A 0 1

(

)

→ A 0 2 N O → M O D E ) A 0 3

1 – 8

S E T S E T ? ( 1 – 8

(

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 W L E E E L E L E L M D E

E E D A 1 5 k m / L R E G E F L R E G E

P V I I P V P V P V L E P F P

7

Contents of display

e

A06

A05

A04

3

I T G G F T F T L T E T E T E T U T U T E 1 E 1 E 1 E 1 E 1 E 1 C T C T C T N T N T F E T

2 R E H H I E I E I E P E V E V E E E E E R 0 R 0 R 0 R 0 R 0 R 0 C E C E C E U E U E

1

D S C C L S Lifting speed 2 setting L S Tilting speed setting T S Travel speed limit setting S S Overspeed alarm OFF O setting S ON O S # Acceleration OFF N neutral regenS eration setting ON N S Present time set- Year P ting ‘ Month P ‘ Day P ‘ Day of P week ‘ Hour P ‘ Minute P ‘ * Acceleration A A characteristic S setting B A S C A S * ON/OFF setting ON F 11 – 20 S OFF F S * Analog setting A 11 – 20 S

Display Display item code A01 Drive power adjustment (ES control knob) A02 Charging timer setting (User adjustment mode) A03 Lifting speed 1 setting

Operator adjustment mode display

Operator adjustment mode

Mode Display example

Note 1) Italic letters and capital letters shall flash. Note 2) When an abnormality is displayed, only the error code shall be displayed and justified to the right in the spare section of the upper line. Note 3) Items marked with "#" in the display item column are displayed for only the counterbalanced models and those marked with "*" are displayed for only the reach models.

STRUCTURE AND FUNCTION OPERATING DEVICE

60-83

60-84

Item

Service adjustment mode

1

Conditions for changing the standard mode to the service mode: 1. F/R lever: "N" 2. All work equipment levers: "OFF" 3. Key switch with all of P1 to P3 buttons pressed: "ON" Conditions for changing the service mode to the standard mode: 1. One of the F/R lever and the work equipment lever has been operated. 2. The key switch is turned off. 3. A single cycle of all adjustment items is completed.

Contents of display

L E V E L ( A – C ) B

After completion of setting, the mode is returned to the standard mode.

Characteristic B is reversed.

A C C E L . PWR S E T L E V E L

Select Characteristic B by the

D 0 9

D 0 9

button.

L E V E L ( A – C ) A

Characteristic A is reversed.

A C C E L . PWR S E T L E V E L

The accelerator characteristic is set in the dealer mode.

Display example

e

1. Press the MODE button (P3) and select a setting item. 2. The setting enable position will blink. (A blinks.) 2.1 Use the button (P1) to change any setting. 2.2 For an item having multiple setting positions (for example, date), select it by the button (P2). 2.3 After completion of setting, proceed to the next setting item by the MODE button (P3). Upon completion of setting, the display is continued for 2 sec and then proceeds to the next item. Adjustable item Setting data 1. Standard display 1. – – – O 2. Attachment speed 1 setting 2. ATT SPEED1 (1–8) O O 3. Attachment speed 2 setting 3. ATT SPEED2 (1–8) O O 4. Attachment speed 3 setting 4. ATT SPEED3 (1–8) O O 5. FR regenerative current setting 5. FR REGENE (0–100) O O 6. Brake regenerative current setting 6. BRAKE REGENE (0–100) O O 7. Neutral regenerative current setting 7. NEUTRAL REGENE (0–100) O O 8. Slope regenerative current setting 8. SLOPE REGENE (0–100) O O 9. Soft start characteristic setting 9. SOFT START LEVEL (A, B, C) O O 10. Accelerator characteristic setting 10. ACCEL.PWR LEVEL (A, B, C) O O 11. Trip meter display 11. TRIP METER (ON/OFF)

Service adjustment mode display

No.

Mode

OPERATING DEVICE STRUCTURE AND FUNCTION

BE30 Series

BE30 Series

No.

Item

Display Display item 1 2 code D01 Attachment 1 speed setting A T S E D02 Attachment 2 speed setting A T S E D03 # Attachment 3 speed set- A T ting S E D04 FR regenerated current set- F R ting S E D05 # Brake regenerated cur- B R rent setting S E D06 # Neutral regenerated cur- N E rent setting S E D07 # Slope regenerated cur- S L rent setting S E D08 Soft start characA S O teristic setting S E B S O S E C S O S E D09 Accelerator charA A C acteristic setting S E B A C S E C A C S E D10 Trip meter display OFF T R setting I N ON T R I N D11 Travel time disOFF T R play setting I N ON T R I N D12 Cargo handling OFF H Y time setting I N ON H Y I N

Service adjustment mode display

Service adjustment mode

Mode

3

T A T U T O T F T F T F T C T C T C T I D I D A D A D D D D D

T T T T T T

5

L

L

S L S L S L E L E L R L E L

L E L L E L L E L L P I C P I C V E I C V E I C . T I C . T I C

T

T

T

P

T

K

R

4

6

E S E S E S E . E . E . E M A M A L A L A I A I A

E A E

P E P E P E G E

T M T M T

T

E V E V E V E V R V L V R V T V T V T V P V P V P V E T E T

7

E

.

3

2

1

N

N

E

E

)

)

)

(

(

O N I O F I O N D I O F D I O N

D 0 7

( A – C ) ( A – C )

L L

C A T E F C A T E

N D I C A T E F N D I C A T E

( A – C )

D 1 2

D 1 2

D 1 1

D 1 1

D 1 0

D 1 0

D 0 9

D 0 9

D 0 9

( A – C ) D 0 8

( A – C ) D 0 8

L

E L

)

) D 0 6

D 0 5

D 0 4

D 0 3

D 0 2

D 0 1

( A – C ) D 0 8

1 – 1 0 0

L E V E L

O F F

)

1 – 1 0 0

L E V E L

E .

)

1 – 1 0 0

E N E (

E .

1 – 1 0 0

1 – 8

1 – 8

1 – 8

L E V C L E V E A L E V E B L E V E C

B

A

( 8 ( 8 ( 8 ( 8 N 8 G 8 N 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 D L D L D L E L G L R L G L R L R L R L R L R L R L E O E O I O I O

E E E E E A T E A T E A T E W E W E W E T R I N T R I N T M I N T M I N E I I O N E I I O N

E E E E E E N E E E

8

Contents of display

Display example

Note 1) Italic letters and capital letters shall flash. Note 2) When an abnormality is displayed, only the error code shall be displayed and justified to the right in the spare section of the upper line. Note 3) Items marked with "#" in the display item column are displayed for only the counterbalanced models and those marked with "*" are displayed for only the reach models.

STRUCTURE AND FUNCTION OPERATING DEVICE

60-85

60-86

Item

Service adjustment mode

1 3

A T A T A T U T E T N T N T F E T

2 E E E E E E L E P E U E U E

1

R S D15 * Reach END speed setting R S D16 * Reach high mast speed R setting S D17 * Independent plugging cur- P rent setting S D18 * Travel speed limit 3 set- S ting S D19,21 * ON/OFF setting ON F 23,25,27 1 – 10 S 29,31,33 OFF F 35,37 S D20,22 * Analog setting 1 – 10 A 24,26,28 S 30,32,34 36,38

Display Display item code D14 * Reach speed setting

Service adjustment mode display

No.

Mode

4

5

C H L C H L C H L G . L E D S C T O C T O U N L P I N I F C E

E C E

E

E

6

8 P E N E M E R E I E N

)

( 0 5 k N

1 – 8

)

D 2 0

D 1 9

D 1 9

) D 1 8

– 1 5 k m / m / h / O F F )

D 1 6

D 1 5

D 1 7 h

)

D 1 4

)

)

1 – 8

1 – 1 0 0

E D (

E E D (

1 – 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 E E D ( L 8 D S P L 8 S P E L 8 R E N T L 1 0 M T 3 ( D 1 5 1 ( O

O N 1 ( O N / O F F ) F T I O N 1 ( 1 – 1 0 0 V E L 1 0 0

S V E V H V U V L E O

7

Contents of display

Display example

OPERATING DEVICE STRUCTURE AND FUNCTION

BE30 Series

1

No.

Item

Monitoring enable item 1. Directional F-SW 2. Directional R-SW 3. Accelerator SW 4. Brake SW 5. Lift 1 SW 6. Lift 2 SW 7. Tilt SW 8. Attachment 1 SW 9. Attachment 2 SW 10. Attachment 3 SW 11. Parking brake SW 12. Lift interrupt SW 13. Seat SW 14. Unused 15. Travel speed limit 2 SW 16. Auto lift height SW (option) 17. Accelerator output 18. Torque sensor output

Switch monitor mode display

Switch monitor mode

Mode

BE30 Series Display data (display code) OFF/ON (C01) OFF/ON (C02) OFF/ON (C03) OFF/ON (C04) OFF/ON (C05) OFF/ON (C06) OFF/ON (C07) OFF/ON (C08) OFF/ON (C09) OFF/ON (C10) OFF/ON (C11) OFF/ON (C12) OFF/ON (C13) OFF/ON (C14) OFF/ON (C15) OFF/ON (C16) 0 – 100% (C17) 0 – 100% (C18)

Conditions for changing the standard mode to the switch monitor mode: 1. When the connector in the body harness is opened, the standard mode will be changed to the switch monitor mode. 2. The current item is changed to the next item by the MODE button. Condition for changing the switch monitor mode to the standard mode: 1. The key switch is turned off after completion of checking.

Contents of display

T I L T SW SW : ON

Tilt lever: ON

T I L T SW SW : O F F

Tilt lever: OFF

C 0 7

C 0 7

The tilt switch is checked in the switch monitor mode.

Display example

STRUCTURE AND FUNCTION OPERATING DEVICE

60-87

OPERATING DEVICE

STRUCTURE AND FUNCTION

9. DISPLAY LIST OF METER PANEL DOT SECTION Note 1) Italic letters and capital letters shall flash. Note 2) When an abnormality is displayed, only the error code shall be displayed and justified to the right in the spare section of the upper line. Note 3) Items marked with "#" in the display item column are displayed for only the counterbalanced models and those marked with "*" are displayed for only the reach models. No. 1 2

Display mode Standard mode

3

7

User adjustment mode

18

60-88

6 T A 6 A V 6 D 6 L U T

– L – E –

1 0

I T F T F T L T

V E L T L T L T L

E S E S E S E

E T E T E T U T U T E 1 E 1 E 1 E 1 E 1 E 1 C T C T C T N T N T F E T

E D S R O R O T R O T R O S E – 1 S E – 1 S E – 1 S E – 1 S E – 1 S E – 1 E L L E L L E L L C T O C T O U N L

P S F S N A F A N N 0 N 0 N 0 N 0 N 0 N 0 . E . E . E I N I F C E

O N 1 1 ( O N / O F F ) F T I O N 1 1 ( 1 – 1 0 0 V E L 1 0 0

I W I W I W

E O E O E O

T

I O N A L

S W ( F )

C 0 1 ON or OFF is displayed, depending on state of SW.

T F T

I O N A L

S W ( F )

C 0 1 ON or OFF is displayed, depending on state of SW.

I O N A L

S W ( R )

C 0 2 ON or OFF is displayed, depending on state of SW.

P E V E V E E E E E R 0 R 0 R 0 R 0 R 0 R 0 C E C E C E U E U E

Drive power adjustment (ES control knob)

A06

Switch moniter mode

– O – R – Y – A A

S S A07 Overspeed alarm OFF O setting S ON O S A08 # Acceleration OFF N neutral regenS eration setting ON N S A09 Present time set- Year P ting ‘ Month P ‘ Day P ‘ Day of P week ‘ Hour P ‘ Minute P ‘ A10 * Acceleration A A characteristic S setting B A S C A S A11,13 * ON/OFF setON F 15,17,19 ting S 21,23,25 11 – 20 OFF F 27,29 S A12,14 * Analog setting A 16,18,20 11 – 20 S 22,24,26 28,30 C01 Directional ON D F SW S OFF D S C02 Directional D R SW S

A01

Tilting speed setting

17

‘

R E I E I E I E

Automatic horizontal

A05

16

8

D S L S L S T S

U05

9

15

7

‘ T O

Lifting speed 2 setting

14

6

Hour meter display (Travel distance)

A04

13

5

‘

8

12

4

Hour meter display (Cargo handling time)

Lifting speed 1 setting

11

3

‘

A03

10

2

Hour meter display (Travel time)

U02

U04

5

1

9 7 T 9 7 T 9 7 H 9 7 O T N

U03

4

6

Display Display item code U01 Hour meter display (Key ON time)

Travel speed limit setting

R : R : R :

C N C F C N

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 0 L 1 0

T U E

1 7 1 1 7 1 1 7 1 1 7 1 O N T

: 9 : 9 : 9 : 9 A

E R ( 1 – 8 8 D 1 ( 1 – 8 ) 8 D 2 ( 1 – 8 ) 8 D ( 1 – 8 ) 8

)

T U E T U E

– 1 0 T U E T R I P O H O R I Z W L E L E L E L

0 9 0 9 0 9 0 9 L

0 9 0 9 0 9 0 9

O E E E E E E E

L E P F P

I M I T ( 5 – 1 5 k m / E D 1 5 k m / h E E D A L A R M

T – T – T – T – T – T – P V P V P V O

T 1 0 T 1 0 T 1 0 T 1 0 T 1 0 T 1 0 W R E L W R E L W R E L N 1

I M M I M M I M M I M M I M M I M M L A L B L C 1 (

E O E O E O E O E O E O E

— 9 9 9 9

.

9 U . 9 U . 9 U . 9

h 0 h 0 h 0 k

2

—

3

—

4 m

— —

P V P V P V P V

E E D A 1 5 k m / L R E G E F L R E G E

Remarks

A 0 1 Flashing point changes to "1" through "8", depending on setting. A 0 3 Transmission data (8 levels) 1. 01 – 1EH 2. 1F – 28H 3. 29 – 32H 4. 33 – 3CH 5. 3D – 46H 6. 47 – 50H A 0 4 7. 51 – 5AH 8. 5B – 64H

h

A 0 5 Transmission data (8 levels) 1. 01 – 10H 2. 11 – 1CH 3. 1D – 28H 4. 29 – 34H 5. 35 – 40H 6. 41 – 4CH 7. 4D – 58H 8. 59 – 64H ) A 0 6 — A 0 7 Flashing point changes between OFF and ON, depending on setting.

L A R M h N E B R A K E

A 0 7

N E

A 0 8

B R A K E

A 0 8 Flashing point changes between OFF and ON, depending on setting.

A 0 9 N

1 2

:

0 0

N

1 2

:

0 0

N

1 2

:

0 0

N

1 2

:

0 0

N

1 2

:

0 0

—

A 0 9 A 0 9 A 0 9 A 0 9 A 0 9 N 1 2 : 0 0 V E L ( A – C )

A 1 0

E V E L

( A – C )

A 1 0

E V E L

( A – C )

A 1 0

O N / O F F )

—

A 1 1 • Flashing point changes between OFF and ON, depending on setting. • Nos. 22 – 24 of upper line indicate A 1 1 display code. )

A 1 2 • Nos. 22 – 24 of upper line indicate display code.

BE30 Series

STRUCTURE AND FUNCTION

No. 19 20

Display mode Switch moniter mode

Display Display item code C03 Accelerator switch

OPERATING DEVICE

1

2

3

4

5

A S B S L S L S T S A S A S A S P S L S S S

C W R W I W I W I W T W T W T W A W I W E W

C : A : F : F : L : T : T : T : R : F : A :

E O K O T O T O T O 1 O 2 O 3 O K O T O T O

L E R A T O R S W N E S W N 1 S W N 2 S W N S W N S W N S W N S W N I N G B R A K E S W N I N T E R R U P T S W N S W N

C04

Brake switch

21

C05

Lift switch 1

22

C06

Lift switch 2

23

C07

Tilt switch

24

C08

Attachment 1 SW

25

C09

Attachment 2 SW

26

C10

# Attachment 3 SW

27

C11

Parking SW

28

C12

Lift interrupt SW

29

C13

# Seat SW

30

C14

(Blank)

31

C15

32

C16

33

C17

34

C18

35

C19

36

C20

37

C21

38

C22

39

C23

40

C24

41

C25

42

C26

43

C27

44

C28

45

C29

46

C30

47

C31

48

C32

49

C33

50

C34

51

C35

52

C36

T S Lifting height SW L S Accelerator output A O Torque sensor output T O * Reach (Reach IN) SW R S * Reach OUT SW R S * Reach IN END SW R S * Reach OUT END SW R S * Cargo handling high mast R (Reach H. M) SW S * Travel speed limit 3 SW T S * Battery pull-out interlock B SW S * Tire wear prevention SW T S * SW spare 1 SW S S * SW spare 2 SW S S * SW spare 3 SW S S * SW spare 4 SW S S * SW spare 5 SW S S * SW spare 6 SW S S * SW spare 7 SW S S * SW spare 8 SW S S * SW spare 9 SW S S * SW spare 10 SW S S

BE30 Series

Travel speed limit 2

R W I W C U O U E W E W E W E W E W R W A W I W P W P W P W P W P W P W P W P W P W P W

A : F : C T R T A : A : A : A : A : A : T : R : A : A : A : A : A : A : A : A : A : A :

V O T O E P Q P C O C O C O C O C O V O T O E O R O R O R O R O R O R O R O R O R O R O

6

E L N H N L E U T U E U T H N H N H N H N H N E L N E R N W N E N E N E N E N E N E N E N E N E N E N

7

8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

S P E E D E

I G H T

R A T : 1 0 S E : 1 0 S W

O 0 N 0

C 0 4 ON or OFF is displayed, depending on state of SW. C 0 5 ON or OFF is displayed, depending on state of SW. C 0 6 ON or OFF is displayed, depending on state of SW. C 0 7 ON or OFF is displayed, depending on state of SW. C 0 8 ON or OFF is displayed, depending on state of SW. C 0 9 ON or OFF is displayed, depending on state of SW. C 1 0 ON or OFF is displayed, depending on state of SW. C 1 1 ON or OFF is displayed, depending on state of SW. C 1 2 ON or OFF is displayed, depending on state of SW. C 1 3 ON or OFF is displayed, depending on state of SW.

T 2

S W

C 1 4 ON or OFF is displayed, depending on state of SW. C 1 5 ON or OFF is displayed, depending on state of SW. C 1 6 ON or OFF is displayed, depending on state of SW.

R O U T P U T % S O R O U T P U T %

S W E N D

O U T H I G H

C 1 7 Changes to "0" through "100", depending on condition of accelerator. C 1 8 Changes to "0" through "100", depending on condition of accelerator.

C 2 0 ON or OFF is displayed, depending on state of SW. S W

E N D

C 2 1 ON or OFF is displayed, depending on state of SW.

S W

M A S T

S P E E D Y

I M I

C 0 3 ON or OFF is displayed, depending on state of SW.

C 1 9 ON or OFF is displayed, depending on state of SW.

O U T I N

L

Remarks

L

C 2 2 ON or OFF is displayed, depending on state of SW. S W

I M I

I N T E R L O C K

E A R

P R E V E N T

C 2 3 ON or OFF is displayed, depending on state of SW.

T 3

C 2 4 ON or OFF is displayed, depending on state of SW.

S W

C 2 5 ON or OFF is displayed, depending on state of SW.

S W

C 2 6 ON or OFF is displayed, depending on state of SW.

S W 1

C 2 7 ON or OFF is displayed, depending on state of SW.

S W 2

C 2 8 ON or OFF is displayed, depending on state of SW.

S W 3

C 2 9 ON or OFF is displayed, depending on state of SW.

S W 4

C 3 0 ON or OFF is displayed, depending on state of SW.

S W 5

C 3 1 ON or OFF is displayed, depending on state of SW.

S W 6

C 3 2 ON or OFF is displayed, depending on state of SW.

S W 7

C 3 3 ON or OFF is displayed, depending on state of SW.

S W 8

C 3 4 ON or OFF is displayed, depending on state of SW.

S W 9

C 3 5 ON or OFF is displayed, depending on state of SW.

S W 1 0

C 3 6 ON or OFF is displayed, depending on state of SW.

60-89

OPERATING DEVICE

No.

Display mode

53

Display Display item code C37 * SW spare 11 SW

54

C38

* SW spare 12 SW

55

C39

* Analog spare 1

56 57

C40

* Analog spare 2

D01

Attachment 1 speed setting

D02

Attachment 2 speed setting

59

D03

# Attachment 3 speed setting

60

D04

FR regenerated current setting

58

Dealer’s adjustment mode

STRUCTURE AND FUNCTION

61

D05

62

D06

63

D07

64

D08

# Brake regenerated current setting # Neutral regenerated current setting # Slope regenerated current setting A

Soft start characteristic setting

B C 65

D09

Accelerator characteristic setting

A B C

66

D10

Trip meter display setting

OFF ON

67

D11

Travel time display setting

OFF ON

68

D12

Cargo handling time setting

OFF ON

69

D14

70

D15

71

D16

* Reach speed setting * Reach END speed setting * Reach high mast speed setting

72

D17

* Independent plugging current setting

73

D18

* Travel speed limit 3 setting

74

75

76

77

Failure record mode Failure mode

60-90

D19,21 * ON/OFF setting ON 23,25,27 1 – 10 29,31,33 OFF 35,37 D20,22 * Analog setting 1 – 10 24,26,28 30,32,34 36,38 F01 Failure record display (** is error code) E01

Failure display

1

2

3

4

5

S S S S S O S O A S A S A S F S B S N S S S S S S S S S A S A S A S T I T I T I T I H I H I R S R S R S P S S S F S F S A S

P W P W P U P U T E T E T E R E R E E E L E O E O E O E C E C E C E R N R N R N R N Y N Y N E E E E E E L E P E U E U E

A : A : A T A T T T T T T T

R O R O R P R P

E N E N E U E U S L S L S L E L E L R L E L

T A T U T O T F T F T F T C T C T C T I D I D A D A D D D D D A T A T A T U T E T N T N T F E T

R K T P T

L T L T L E L L E L L E L L P I C P I C V E I C V E I C . T I C . T I C C H L C H L C H L G . L E D S C T O C T O U N L

6

T T P E P E P E G E E A E E S E S E S E . E . E . E M A M A L A L A I A I A E E E C E P I N I F C E

7

8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Remarks

S W 1 1

C 3 7 ON or OFF is displayed, depending on state of SW.

S W 1 2

C 3 8 ON or OFF is displayed, depending on state of SW.

A : A : E V E V E V E V R V L V R V T V T V T V P V P V P V E T E T T T M T M T S V E V H V U V L E O

N 1 N 1 E E E E E E N E E E E E E A E A E A E W E W E W E T I T I T I T I E I E I P E N E M E R E I E N

A 0 A 0 D L D L D L E L G L R L G L R L R L R L R L R L R L E O E O I O I O

L 0 L 0 1 2 3 . E E E

O % O % ( 8 ( 8 ( 8 ( 8 N 8 G 8 N 8

T

G

S W 1

C 3 9 Changes to "0" through "100", depending on condition of accelerator.

G

S W 2

C 4 0 Changes to "0" through "100", depending on condition of accelerator.

1 – 8

)

D 0 1 Flashing point changes to "1" through "8", depending on setting.

1 – 8

)

D 0 2 Flashing point changes to "1" through "8", depending on setting.

1 – 8

)

D 0 3 Flashing point changes to "1" through "8", depending on setting.

1 – 1 0 0 E

.

(

.

(

)

D 0 5 Flashing point changes to "1" through "100", depending on setting.

1 – 1 0 0

) D 0 6 Flashing point changes to "1" through "100", depending on setting.

1 – 1 0 0

)

D 0 7 Flashing point changes to "1" through "100", depending on setting.

L E V E L

( A – C ) D 0 8 Flashing point changes to "A", "B", or "C", depending on setting.

L E V E L

( A – C ) D 0 8

A T

D 0 4 Flashing point changes to "1" through "100", depending on setting.

1 – 1 0 0

E N E ( E

)

B T

R N R N M N M N I O N I O N E E L D L S L R E L M T D 1

L E V C L E V E A L E V E B L E V E C

E L

( A – C ) D 0 8

L

( A – C )

D 0 9 Flashing point changes to "A", "B", or "C", depending on setting.

L

( A – C )

D 0 9

L

( A – C )

D 0 9 D 1 0 Flashing point changes between OFF and ON, depending on setting.

O F F

D 1 0 E E N N D 8 S 8 P 8 N 1 3 1 (

O N I O F I O N D I O F D I O N ( 1

N D I C A T E F N D I C A T E C A T E F C A T E – 8

E E D ( T 0 ( 5 O

( 0 5 k N

D 1 1 D 1 2 Flashing point changes between OFF and ON, depending on setting. D 1 2

)

P E E D (

D 1 1 Flashing point changes between OFF and ON, depending on setting.

D 1 4 Flashing point changes to "1" through "8", depending on setting. 1 – 8

)

D 1 5 Flashing point changes to "1" through "8", depending on setting.

1 – 8

)

D 1 6 Flashing point changes to "1" through "8", depending on setting.

1 – 1 0 0

)

D 1 7 Flashing point changes to "1" through "100", depending on setting.

– 1 5 k m / m / h / O F F )

O N 1 ( O N / O F F ) F T I O N 1 ( 1 – 1 0 0 V E L 1 0 0

h

) D 1 8

—

D 1 9 Flashing point changes between OFF and ON, depending on setting. D 1 9

)

D 2 0

—

F A I L U R E R E C O R D E * * 1 9 9 9 9 . 9 h

F 0 1

—

F A I L U R E I N C O N T . ( T ) C A L L Y O U R S E R V I C E !

E 0 1

—

BE30 Series

STRUCTURE AND FUNCTION

No. 78

Display mode Failure mode

Display Display item code E02 Failure display

79

E03

Failure display

80

E04

Failure display

81

E05

Failure display

82

E06

Failure display

83

E07

Failure display

84

E08

Failure display

85

E09

Failure display

86

E10

Failure display

87

E11

Failure display

88

E12

Failure display

89

E13

Failure display

90

E14

Failure display

91

E15

Failure display

92

E16

Failure display

93

E17

Failure display

94

E18

Failure display

95

E19

Failure display

96

E20

Failure display

97

E21

Failure display

98

E22

Failure display

99

E23

Failure display

100

E24

Failure display

101

E25

Failure display

101A

E26

Failure display

101B

E27

Failure display

101C

E28

Failure display

101D

E29

Failure display

102

E30

Failure display

103

E31

Failure display

104

E32

Failure display

105

E33

Failure display

106

E34

Failure display

107

E35

Failure display

BE30 Series

OPERATING DEVICE

1

2

3

4

5

6

7

8

F C F C F C F C F C F C F C F C F C F C F C F C F C F C F C F C F C F C F C B C F C N R O C O C C S F C M S F C F C F C F R F C F C F C

A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A H A A E E V A V A O T A A O T A A A A A A A E A A A A A A

I L I L I L I L I L I L I L I L I L I L I L I L I L I L I L I L I L I L I L T A I L U T E U E U N O I L T O I L I L I L I S I L I L I L

L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L T R L L T U R T R T T P L L O P L L L L L L L E L L L L L L

U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y U R Y E R G E U R Y R A R N W I O W I O . O U R Y R O U R Y U R Y U R Y U R T U R Y U R Y U R Y

E O E O E O E O E O E O E O E O E O E O E O E O E O E O E O E O E O E O E O Y

I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R I U R P B A I U R S A L R K ! R K ! V E E R I U R V E E R I U R I U R I U R I M E I U R I U R I U R

E O L O N O N O P E O O P E O E O E O E E E O E O E O

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 N N N N N N N N N N N N N N N N N N N O T N A L N O N O R A N R A N N N N R N N N

C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E C S E W E T E C S E F E T G ( V E G ( V E H T ! M S E H T ! C S E C S E C S E C G E C S E C S E C S E

O R O R O R O R O R O R O R O R O R O R O R O R O R O R O R O R O R O R O R R R O R T O T R T R E O R E O R O R O R O N O R O R O R

N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V Y N V Y

T I T I T I T I T I T I T I T I T I T I T I T I T I T I T I T I T I T I T I D ! T I ( N

. C . C . C . C . C . C . C . C . C . C . C . C . C . C . C . C . C . C . C O

( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E ( E W

. C T E

( T ) E 2 E ! ) E 2 U T R A L ! E 2 A T ! E 2 A T ! T ) E 2 L C O N T . ( T ) E 2 E ! T ) E 2 L M O T O R ( T ) E 2 E ! ( P ) E 3 E ! ( P ) E 3 E ! ( P ) E 3 S W ( P ) E 3 E ! ( P ) E 3 E ! ( P ) E 3 E !

) H E ) A C T V A C N V N V N V N C N V N V N V

H T O O I T O T I T I T I T Y T I T I T I

E ( O R C ( O . C . C . C . . C . C . C

T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! T ! N

Remarks

)

E 0 2

—

)

E 0 3

—

)

E 0 4

—

)

E 0 5

—

)

E 0 6

—

)

E 0 7

—

)

E 0 8

—

)

E 0 9

—

)

E 1 0

—

)

E 1 1

—

)

E 1 2

—

)

E 1 3

—

)

E 1 4

—

)

E 1 5

—

)

E 1 6

—

)

E 1 7

—

)

E 1 8

—

)

E 1 9

—

)

E 2 0

—

( T ) E 2 1

—

2

—

3

—

4

—

5

—

6 ! 7

— —

8 ! 9

—

0

—

1

—

2

—

3

—

4

—

5

—

—

60-91

OPERATING DEVICE

Display mode 108 Failure mode No.

Display Display item code E36 Failure display

109

E37

Failure display

110

E38

Failure display

111

E39

Failure display

112

E40

Failure display

112A

E41

Failure display

112B

E42

Failure display

112C

E43

Failure display

112D

E44

Failure display

112E

E45

Failure display

112F

Failure display

112G

E46 – E48 E49

113

E50

Failure display

114

E51

Failure display

115

E52

Failure display

116

E53

Failure display

117

E54

Failure display

118

E55

Failure display

118A

E56

Failure display

119

Failure display

119A

E57 – E58 E59

Failure display

120

E60

Failure display

121

E61

Failure display

122

E62

Failure display

123

E63

Failure display

124

E64

Failure display

125

E65

Failure display

126

E67

Failure display

127

E68

Failure display

128

E69

Failure display

129

E70

Failure display

130

E71

Failure display

131

E72 – E86 E87

Failure display

132

60-92

Failure display

Failure display

STRUCTURE AND FUNCTION

1

2

3

4

5

6

7

8

F C F C F C C S F C F C F C F C F C F C E C O O F C F C F C F C F C O C F C E C F C N R F C F C O O S O O

A A A A A A O T A A A A A A A A A A A A R A P P A A A A A A A A A A V A A A R A A A E E A A A A P P T P N

I L I L I L N O I L I L I L I L I L I L R L E E I L I L I L I L I L E U I L R L I L U T I L I L E E O E

L L L L L L T P L L L L L L L L L L L L O L R R L L L L L L L L L L R T L L O L L L T U L L L L R R P R T

U R Y U R Y U R Y . O U R Y U R Y U R Y U R Y U R Y U R Y R ( Y A T A T U R Y U R Y U R Y U R Y U R Y W I O U R Y R ( Y U R Y R A R N U R Y U R Y A T A T A A T I L

E O E O E O O P E O E O E O E O E O E O P O I E E O E O E O E O E O O N E O E O E O L

I U R I U R I U R V E E R I U R I U R I U R I U R I U R I U R ) U R O N A I U R I U R I U R I U R I U R R K ! I U R P S U R I U R S A L I U R I U R O N A G L A H

F C O O S O S O H O E C F C

A A P P T P T P E P R A A A

I L E E O E O E I E R L I L

L L R R P R P R G R O L L L

U R Y A T A T A A T A A T H T A T R ( Y U R Y

E I N S U O U R S E R I O N M I S E A G A I N T L O W E R E A G A I N T O V E R E A G A I N L I M I T E A G A I N S U B C O N O U R S E R E I N S U O U R S E R

E O E O I E N E T

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 N N N R A N N N N N N

C S E C S E C S E H T ! C S E M S E M S E C S E C S E C S E

S E M I G A I N C S E N C S E N C S E N C S E N C S E N G ( O V E N C S E ) S E N C S E A F E L T N S S E N S S E M I G A I E I G A I O R I

O R O R O R E

N V N V N V A C N V T V T V N V N V N V

T I T I T I T O T I O I O I T I T I T I

P ) E 3 6 ! P ) E 3 7 ! P ) E 3 8 ! ) E 3 9 C O N T . ! O T ) E 4 0 R ! O T ) E 4 1 R ! O T ) E 4 2 R ! O T ) E 4 3 R ! O T ) E 4 4 R ! O T ) E 4 5 R ! E 4 6 R V I C E ! S T A K E ( P ) E 4 9 N ! O N T . ( E P S ) E 5 0 R V I C E ! O N T . ( E P S ) E 5 1 R V I C E ! O N T . ( E P S ) E 5 2 R V I C E ! O N T . ( E P S ) E 5 3 R V I C E ! O N T . ( E P S ) E 5 4 R V I C E ! P ) E 5 5 R H E A T ! O N T . ( P ) E 5 6 R V I C E ! E 5 7 R V I C E ! O N T . ( B D I ) E 5 9 R V I C E ! T Y E 6 0 O N E U T R A L ! U B C O N T . E 6 1 R V I C E ! U B C O N T . E 6 2 R V I C E ! S T A K E E 6 3 N ! N C O R R E C T E 6 4 N ! Z O N T A L E 6 5 B V I T A ! H ! H E ! E R ! T ) V I B V I

. C . C . C ( O . C R C R C . C . C . C

( E ( E ( E P L ( E ( E ( E ( E ( E ( E

C O N T C E ! K E

— — — — — — — — — — — — — — — — — — — — — — — — — — —

E 6 7

—

E 6 8

—

E 6 9

—

I G H T

E 7 0

—

R O R

E 7 1

—

E 7 2

—

E 8 7

—

E

.

Remarks

I G H T

C E ! C O N T C E !

.

BE30 Series

STRUCTURE AND FUNCTION

Display mode 133 Failure mode No.

134 135 136 137 138 139 140 141

Display Display item code E88 Failure display E89 E90 E91 E92 E93 E94 E95 E96

Failure display Failure display Failure display Failure display Failure display Failure display Failure display Failure display

142

E97

Failure display

143

E98

Failure display

144

E99

Failure display

145

* E100 Failure display – E127

BE30 Series

OPERATING DEVICE

1

2

O N F C F C F C F C F C F C F C F C C C C C C C E C

N O A A A A A A A A A A A A A A A A O A O A O A R A

3

4

5

6

7

I L I L I L I L I L I L I L I L M L M L M L R L

A F L L L L L L L L L L L L L L L L M L M L M L O L

U T O U N C U R E Y O U R E Y O U R E Y O U R E Y O U R E Y O U R E Y O U R E Y O U R E Y O U N I Y O U N I Y O U N I Y O R Y O

8 T U U U U U U U U C U C U C U

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 H I I R I R I R I R I R I R I R I R A R A R A R

U R

O R I O N N S S E N C S E N C S E N C S E N C S E N C S E N S S E N C S E T I O S E T I O S E T I O S E

Z E U R H R H R H R H R H R U R H R N R N R N R

O L B V A V A V A V A V A V B V A V

N T S E C I C R G I C R G I C R G I C R G I C R G I C C I C R G I C E R V I C E R V I C E R V I C

A L O E E E E E E E E E E E O E E E R E R E R E

N ! R ! R ! R ! R ! R ! N ! R ! O ! O ! O !

S E R V I C E !

Remarks

E 8 8

—

E 8 9

—

E 9 0

—

E 9 1

—

E 9 2

—

E 9 3

—

E 9 4

—

E 9 5

—

E 9 6

—

R

E 9 7

—

R

E 9 8

—

R

E 9 9

—

T

T

.

.

E 1 0 0 Spare code (Nos. 21 – 24 of upper line indicate display code.)

60-93

70. TROUBLESHOOTING Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70Self-diagnosis function . . . . . . . . . . . . . . . . . . .70Action to take when failure code is displayed .70Control block diagram . . . . . . . . . . . . . . . . . . .70Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .70-

2 2 2 3 4

Main controller . . . . . . . . . . . . . . . . . . . . . . . .70- 6 Checking electric parts of controller (1.0 - 2.5 ton models) . . . . . . . . . . . . . . . . . . . .70- 6 Checking electric parts of controller (3.0 ton model) . . . . . . . . . . . . . . . . . . . . . . . . .70- 7 Looseness of fitting parts and defective contact of connectors . . . . . . . . . . . . . . . . . . .70- 8 Checking parts installed to vehicle . . . . . . . . .70- 8 Removing CPU board . . . . . . . . . . . . . . . . . . .70- 8 Preparing for checking voltage and current . . .70- 9 Checking battery voltage . . . . . . . . . . . . . . . . .70- 9 Checking fuse for travel (F1), fuse for hydraulic pressure (F2), fuse for EPS (F3) and fuse for charging (F4). . . . . . . . . . . . . . . .70-10 Checking current detectors for travel (CSDU and CSDW) . . . . . . . . . . . . . . . . . . . .70-11 CPU boad connector position and connector pin No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-12 Preparing for checking continuity . . . . . . . . . . .70-14 Main controller . . . . . . . . . . . . . . . . . . . . . . . . .70-15 Connector voltage check table (1.0 - 2.5 ton models) . . . . . . . . . . . . . . . . . . . .70-22 Connector voltage check table (3.0 ton model) . . . . . . . . . . . . . . . . . . . . . . . . .70-38

BE30 Series

Electric circuit diagram . . . . . . . . . . . . . . . . . 70-55 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-55 Proportional solenoid valve spec. . . . . . . . . . . 70-59 Manual valve spec. . . . . . . . . . . . . . . . . . . . . . 70-63 Sub controller . . . . . . . . . . . . . . . . . . . . . . . . . 70-65 Check before troubleshooting . . . . . . . . . . . . . 70-65 Troubles, the failure codes of which are not displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-66 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 70-67 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 70-71 Precautions to take when failure code is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71 Troubles that are not displayed . . . . . . . . . . . . 70-71 Failure codes list (1.0 - 2.5 ton models) . . . . . 70-73 Failure codes list (3.0 ton model) . . . . . . . . . . 70-84 Self-diagnosis logic table (1.0 - 3.0 ton models). . . . . . . . . . . . . . . . . . . 70-95 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . 70-101 Troubles and remedy for them . . . . . . . . . . . 70-101 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-103

70-1

CONTROLLER

TROUBLESHOOTING

CONTROLLER 1. SELF-DIAGNOSIS FUNCTION 1. Battery capacity gauge 2. Travel system trouble occurrence indicator 3. Hydraulic system trouble occurrence indicator 4. Speedometer 5. Battery fluid level indicator 6. Parking brake indicator 7. Travel speed limit indicator 8. Set value button 9. Set item button 10. Mode button 11. Travel power indicator 12. Trouble occurrence indicator 13. Power steering trouble occurrence indicator 14. Display unit

• •

This controller has a self-diagnosis function, that it, it can check itself. With this function, failure codes are displayed on the display unit at the operator's seat to notify the troubled parts.

•

If a trouble occurs, check the troubled part and cause of the trouble from the failure code displayed on the display unit of the meter panel, then repair the troubled part.

2. ACTION TO TAKE WHEN FAILURE CODE IS DISPLAYED 1.

Checking insulation resistance If a trouble occurs, disconnect the battery connector first and check the insulation resistance between the chassis and each terminal of the controller (+, –, A, B, E, F, PA, PB, BP, and CH) and between the chassis and each electric part. There is no continuity (cz): Normal. There is continuity: Insulation is defective. Repair it.

2.

Checking battery for leakage Disconnect the battery connector, apply the black pin of the multimeter to the negative (–) side and the red pin to the chassis, and measure the voltage. There is no voltage (0 V): Normal There is voltage : A current is leaking from the battery (Clean the inside of the battery).

3.

Repairing according to failure codes list a If multiple failure codes are displayed, repair for all of them.

70-2

BE30 Series

TROUBLESHOOTING

CONTROLLER

3. CONTROL BLOCK DIAGRAM a The following is the proportional solenoid valve specification.

1)

Main controller:

2)

Sub controller:

BE30 Series

Installed in the main controller room at the rear of the chassis. The CPU card consists of the main control section and the EPS control section (small circuit board). Consists of the multi-controller board and system controller board (Sub controller of the manual valve specification consists of the 2 multi-controllers, however). [Installed at the front in the left side cover of the chassis (together with the transformer of the on-board charger).]

70-3

CONTROLLER

TROUBLESHOOTING

4. TROUBLESHOOTING 1.

Classification of failure codes (1) Check the failure codes first. (2) The failure codes are roughly classified by the sections as shown in the following table. Failure code

Controller

Troubled section

E-01 – E-28, 41, 42, 45 Main controller

Travel system

E-30 – E-38, 55, 56

Main controller

Cargo handling system (excluding proportional solenoid valve)

E-50 – E-54

Main controller

EPS system

E-60 – E-89

Sub controller (System controller)

Cargo handling system (related to proportional solenoid valve)

E-59, E-90 – E-96

Sub controller (Multi-controller)

Charger system

E-97

Sub controller (Multi-controller)

Abnormality in communication between main controller and multi-controller

E-98

Sub controller (Multi-controller)

Abnormality in communication between system controller and multi-controller

E-99

Sub controller (Multi-controller)

Abnormality in communication between meter panel and multi-controller

For details, see the failure codes list on page 70-53.

(Note 1) When carrying out troubleshooting, disconnect the battery cable plug, unless otherwise specified in the failure codes list or testing and adjusting procedure. When checking the switches or adjusting the data with the meter panel (by operating the monitor), keep the battery cable plug connected, however. (Note 2) When checking voltage with a multimeter, do not use the ordinary rods since they can short the circuits (on the installed printed circuit cards). (Note 3) Since water-resistant the wiring connectors are used, do not use the ordinary rods of a multimeter. (Note 4) Before troubleshooting or repairing, put chocks under the front and rear wheels and take proper safety measures since the vehicle (travel system, cargo handling system, EPS, etc.) may move. (Main controller)

Failure codes list E01 See circuit diagram, etc.

70-4

Troubleshooting (Testing and adjusting)

Maintenance

BE30 Series

TROUBLESHOOTING

2.

CONTROLLER

Preparing for checking voltage and current (1) Stop the vehicle on level ground and put chocks under the rear wheels. (2) Put wood blocks under both sides of the frame to float the front wheel above the ground. (3) Lower the fork to the ground, tilt the mast forward, and apply the parking brake. (4) Turn the key switch OFF. (5) Remove door (1) for the controller at the rear part of the counterweight. When checking voltage or current, be sure to perform the above preparation.

BE30 Series

70-5

MAIN CONTROLLER

TROUBLESHOOTING

MAIN CONTROLLER 1. CHECKING ELECTRIC PARTS OF CONTROLLER (1.0 - 2.5 TON MODELS) 1.

Inspecting tools and measuring instruments No. Name Specification/Remarks Cross-head and flat-head screwdriv1 Set of screwdrivers ers (large, medium, and small), flathead screwdriver for machine screws Set of spanners 2 (socket wrenches) 10 mm, 13 mm Mounting screws of power module, 3 Torque wrench etc., M4, M5 4 Tweezers and pliers – 5 Ammeter DC 500 A or 1000 A 6 7 8

2.

Digital multimeter and – 12V, – 30V, – 120 V analogue multimeter Range: ×1, ×100, ×1,000 Synchroscope Stabilized power sup- Voltage: Variable from 0 to 50 V, ply for control Capacity: 3 A

Use Tightening and removal of screws, setting of control knob Tightening of removal of bolts and nuts Measurement of tightening torque for bolts and nuts Installation and removal of small parts Measurement of current Measurement of voltage (Digital voltmeter is applicable) Measurement of resistance Check of transistor circuit, etc. Check of operation of each part

Tightening torque Tightened part Part name

Printed circuit card (CPU) Printed circuit card (Power supply) Power module

Item

Symbol

Model

Fixed

–

N61F30857 = 1 or 2

Fixed

–

N61F30841 = 4

Fixed

TMDU/V/W/ TMP

Power module alumi- Fixed num block terminal Terminal Capacitor board Fixed and terminal Contactor Fixed (KYORITSU KEIKI) Terminal Contactor Fixed (KYORITSU KEIKI) Terminal Current sensor Fixed IGBT Fixed Terminal Capacitor CPS Fixed Shunt R Fixed Terminal FAN Fixed Terminal Fixed Terminal

–

NomiTightening torque nal size (Nm{kgm}) M4.5 1.0 – 1.5 {0.10 – 0.15}

Remarks –

M4.5

1.0 – 1.5 {0.10 – 0.15}

–

–

M5

2.0 – 3.0 {0.20 – 0.30}

N55F42549

M5 M8 M5

2.0 – 3.0 {0.20 – 0.30} 7.5 – 10.8 {0.75 – 1.0} 2.0 – 3.0 {0.20 – 0.30}

Spread heat radiator sheet on floor. For shape, see a below. – – –

M5 M8 M4 M4 M4 M5 M5 M4 M4 M4 M4 M8 M8

2.0 – 3.0 {0.20 – 0.30} 8.8 – 10.8 {0.90 – 1.10} 1.3 – 1.7 {0.13 – 0.17} 1.1 – 1.5 {0.11 – 0.15} 1.3 – 1.7 {0.13 – 0.17} 2.0 – 3.0 {0.20 – 0.30} 2.0 – 3.0 {0.20 – 0.30} 1.3 – 1.7 {0.13 – 0.17} 1.3 – 1.7 {0.13 – 0.17} 1.1 – 1.5 {0.11 – 0.15} 1.3 – 1.7 {0.13 – 0.17} 14.0 – 16.0 {1.42 – 1.63} 7.3 – 9.3 {0.74 – 0.95}

CBD CBP MD

N61F30830 = 221/ N61F30831 = 215 CP30-MA

MPS

CM2-ADC48V

CSDU/W TMPS1/2

53CM7-800/4MD 2MB1100N-60

CPS SH

N71F41314 MBP20A10MMJN

FAN1, 2 MMF-08D24ES-RND +, -, DU, DV, 1P-M8X40-M DW, PA, PB, CH

– – – – – – – – – – – – –

a Shape of heat radiator sheet (Upper and lower sides are the positions on the vehicle.) Upper side TMP Lower side Upper side TMDW Lower side Upper side TMDU Lower side Upper side TMDV Lower side

70-6

1 ton models Short and narrow Short and wide Short and wide Short and wide Short and wide Short and wide Short and wide Short and narrow

2 ton models Short and narrow Short and wide Long and wide Long and wide Long and wide Long and wide Long and wide Long and narrow

Apply the standard tightening torque to the parts that are not shown in the above table. M4: 1.3 – 1.7 Nm {0.13 – 0.17 kgm} M5: 2.0 – 3.0 Nm {0.20 – 0.29 kgm} M8: 8.8 – 10.8 Nm {0.90 – 1.10 kgm}

BE30 Series

TROUBLESHOOTING

MAIN CONTROLLER

2. CHECKING ELECTRIC PARTS OF CONTROLLER (3.0 TON MODEL) 1.

Inspecting tools and measuring instruments No. Name Specification/Remarks Cross-head and flat-head screwdriv1 Set of screwdrivers ers (large, medium, and small), flathead screwdriver for machine screws Set of spanners 2 (socket wrenches) 10 mm, 13 mm Mounting screws of power module, 3 Torque wrench etc., M4, M5 4 Tweezers and pliers – 5 Ammeter DC 500 A or 1000 A 6 7 8

2.

Digital multimeter and – 12V, – 30V, – 120 V analogue multimeter Range: ×1, ×100, ×1,000 Synchroscope Stabilized power sup- Voltage: Variable from 0 to 50 V, ply for control Capacity: 3 A

Use Tightening and removal of screws, setting of control knob Tightening of removal of bolts and nuts Measurement of tightening torque for bolts and nuts Installation and removal of small parts Measurement of current Measurement of voltage (Digital voltmeter is applicable) Measurement of resistance Check of transistor circuit, etc. Check of operation of each part

Tightening torque Tightened part Part name

Printed circuit card (CPU) Printed circuit card (Power supply) Power module

Item

Symbol

Model

Fixed

–

N61F30857 = 1 or 2

Fixed

–

N61F30841 = 4

Fixed

TMDU/V/W/ TMP

Power module alumi- Fixed num block terminal Terminal Capacitor board Fixed and terminal Contactor Fixed (KYORITSU KEIKI) Terminal Contactor Fixed (KYORITSU KEIKI) Terminal Current sensor Fixed IGBT Fixed Terminal Capacitor CPS Fixed Shunt R Fixed Terminal FAN Fixed Terminal Fixed Terminal

–

NomiTightening torque nal size (Nm{kgm}) M4.5 1.0 – 1.5 {0.10 – 0.15}

Remarks –

M4.5

1.0 – 1.5 {0.10 – 0.15}

–

–

M5

2.0 – 3.0 {0.20 – 0.30}

N55F42549

M5 M8 M5

2.0 – 3.0 {0.20 – 0.30} 7.5 – 10.8 {0.75 – 1.0} 2.0 – 3.0 {0.20 – 0.30}

Spread heat radiator sheet on floor. For shape, see a below. – – –

M5 M8 M4 M4 M4 M5 M5 M4 M4 M4 M4 M8 M8

2.0 – 3.0 {0.20 – 0.30} 8.8 – 10.8 {0.90 – 1.10} 1.3 – 1.7 {0.13 – 0.17} 1.1 – 1.5 {0.11 – 0.15} 1.3 – 1.7 {0.13 – 0.17} 2.0 – 3.0 {0.20 – 0.30} 2.0 – 3.0 {0.20 – 0.30} 1.3 – 1.7 {0.13 – 0.17} 1.3 – 1.7 {0.13 – 0.17} 1.1 – 1.5 {0.11 – 0.15} 1.3 – 1.7 {0.13 – 0.17} 14.0 – 16.0 {1.42 – 1.63} 7.3 – 9.3 {0.74 – 0.95}

CBD CBP MD

N61F30830 = 221/ N61F30831 = 215 CP30-MA

MPS

CM2-ADC48V

CSDU/W TMPS1/2

53CM7-800/4MD 2MB1100N-60

CPS SH

N71F41314 MBP20A10MMJN

FAN1, 2 MMF-08D24ES-RND +, -, DU, DV, 1P-M8X40-M DW, PA, PB, CH

– – – – – – – – – – – – –

a Shape of heat radiator sheet (Upper and lower sides are the positions on the vehicle.) Upper side TMP Lower side Upper side TMDW Lower side Upper side TMDU Lower side Upper side TMDV Lower side

BE30 Series

3 ton model Short and narrow Short and wide Long and wide Long and wide Long and wide Long and wide Long and wide Long and narrow

Apply the standard tightening torque to the parts that are not shown in the above table. M4: 1.3 – 1.7 Nm {0.13 – 0.17 kgm} M5: 2.0 – 3.0 Nm {0.20 – 0.29 kgm} M8: 8.8 – 10.8 Nm {0.90 – 1.10 kgm}

70-7

MAIN CONTROLLER

3. LOOSENESS OF FITTING PARTS AND DEFECTIVE CONTACT OF CONNECTORS If a bolt or a nut of a power terminal fitting part of a controller is loosened, it may heat and cause a burn. Accordingly, if any fitting part is loosened or heated, polish it carefully with sandpaper and retighten it. If there is defective contact in a connector, the related parts do not operate normally. Accordingly, remove dirt and rust from the connector to prevent defective contact, and then connect and disconnect the connector 2 – 3 times. At this time, check the lead wires for disconnection and terminals for deformation.

4. CHECKING PARTS INSTALLED TO VEHICLE

TROUBLESHOOTING

5. REMOVING CPU BOARD When removing the CPU board for inspection or replacement, remove the case cover, disconnect the wiring harness connector from the board, and remove the board mounting screws (CPU board mounting screws: 9 pieces, power supply board mounting screws: 9 pieces). Hold the lock of the connector securely, pull the connector. The CPU board and power supply board (including EPS board) in the CPU box are connected by 3 cables (CN8 and CN2R, CN9 and CN1R, and CN6 and CN1E). After replacing the board, be sure to connect these 3 cables securely.

It is dangerous to touch an electric part installed to the vehicle while the power is applied to it. When removing or touching a part, be sure to disconnect the battery connector and wait for at least 2 minutes. There still may be some electric charge of 3 – 5 V in the capacitors, however. In this case, if you short PS to Ni, or P12 to N1, with a screwdriver, etc. you may hear a snap of sudden discharge. This snap does not cause an electric shock or a burn of a part. It is recommended, however, to discharge through a discharge resistor (100z – 1,000z). When measuring with the power turned on, float the drive wheels so that the vehicle will not start even if the motor starts suddenly. Under this condition, apply the brake, check the maximum current, and perform the switch-back operation and hydraulic operation.

70-8

BE30 Series

TROUBLESHOOTING

MAIN CONTROLLER

6. PREPARING FOR CHECKING VOLTAGE AND CURRENT 1.

Stop the vehicle on level ground and put chocks under the rear wheels.

2.

Put wood blocks under both sides of the frame to float the front wheel above the ground.

3.

Lower the fork to the ground, tilt the mast forward, and apply the parking brake.

4.

Turn the key switch off.

5.

Remove door (1) for the controller at the rear part of the counterweight. When checking voltage or current, be sure to perform the above preparation.

7. CHECKING BATTERY VOLTAGE 1.

Disconnect the battery plug.

2.

Set the multimeter for measurement of voltage, set the black rod (-) to the negative (-) side of the battery plug, set the red rod (+) to the positive (+) side of the battery plug, and measure the voltage.

3.

Judge the measured voltage. 1.0 – 2.5 ton models Measured voltage

Judgment

Above battery voltage: Good 48 V Below battery voltage: Bad 48 V (Charge battery) 3.0 ton model Measured voltage

Judgment

Above battery voltage: Good 72 V Below battery voltage: Bad 72 V (Charge battery)

BE30 Series

70-9

MAIN CONTROLLER

TROUBLESHOOTING

8. CHECKING FUSE FOR TRAVEL (F1), FUSE FOR HYDRAULIC PRESSURE (F2), FUSE FOR EPS (F3) AND FUSE FOR CHARGING (F4) 1. 2. 3. 4. 5. 6. 7. 8.

1.

2.

Checking fuse for travel (F1) • Prepare for checking voltage and current, see P70-8. • Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting terminal (1) of the controller. • Set the red rod (+) to the (7) and (8) terminals of fuse F1 and measure and judge the voltage. Checking fuse for hydraulic pressure (F2) • Prepare for checking voltage and current, see P70-8. • Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting terminal (1) of the controller. • Set the red rod (+) to the (3) and (2) terminals of fuse F2 and measure and judge the voltage.

70-10

(-) cable connecting terminal Terminal F2 Terminal F2 Terminal F3 Terminal F3, F4 Terminal F4 Terminal F1 Terminal F1

Voltage table (With key switch ON) Measuring point Terminal (8) Terminal (7)

Voltage

Judgment

BV

Good

0V

Bad (Replace fuse)

BV

Good

BV: Battery voltage (Measure the battery voltage in advance) Voltage table (With key switch ON) Measuring point Terminal (2) Terminal (3)

Voltage

Judgment

BV

Good

0V

Bad (Replace fuse)

BV

Good

BV: Battery voltage (Measure the battery voltage in advance)

BE30 Series

TROUBLESHOOTING

3.

MAIN CONTROLLER

Checking fuse for PS (F3) • Prepare for checking voltage and current, see P70-9. • Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting terminal (1) of the controller. • Set the red rod (+) to the (5) and (4) terminals of fuse F3 and measure and judge the voltage. Voltage table (With key switch ON) Measuring point Voltage Terminal (4) Terminal (5)

Judgment

BV

Good

0V

Bad (Replace fuse)

BV

Good

BV: Battery voltage (Measure the battery voltage in advance) 4.

Checking fuse for CHARGING (F4) • Prepare for checking voltage and current, see P70-9. • Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting terminal (1) of the controller. • Set the red rod (+) to the (6) and (5) terminals of fuse F4 and measure and judge the voltage. Voltage table (With key switch ON) Measuring point Voltage Terminal (5) Terminal (6)

Judgment

BV

Good

0V

Bad (Replace fuse)

BV

Good

BV: Battery voltage (Measure the battery voltage in advance)

9. CHECKING CURRENT DETECTORS FOR TRAVEL (CSDU AND CSDW) 1. 2. 3.

Prepare for checking voltage and current, see P70-9. Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting terminal (1) of the controller. Set the red rod (+) to each measuring point (pin No. 3, 4, 5, 6, 14, 15, 16, and 17) of CN5 (22-pin connector), turn the key switch ON, and measure and judge the voltage.

Precautions • This voltage cannot be measured by one person. To measure it, two persons must work together; one person must operate and the other must measure, making signals to each other. • When setting the rods of the multimeter to the measuring points, be sure to turn the key switch OFF. After checking that the rods are set correctly, turn the key switch ON and start measurement.

BE30 Series

70-11

MAIN CONTROLLER

TROUBLESHOOTING

Voltage table (With key switch ON) Measuring point Pin No. CN5-3 CN5-5

Normal voltage (current)

Wire color

R–B 15V (Red – Black) 15V

CN5-14 CN5-15 CN5-16 CN5-17

GR (Gray)

CN5-4 (CSDU)

Orange (O)

Measurement conditions – –

0V – 7V (0A)

When F/R lever is in neutral and accelerator is OFF

7V o 6.83V Set F/R lever in F or R and measure change of 1 ton (0A o +33A) voltage. models Value is for reference. 7V o 6.76V 2 ton models (0A o +47.6A) Value is for reference. 3 ton model

CN5-6 (CSDW)

Pink (P)

7V o 6.83V (0A o +35A) Value is for reference.

7V o 7.08V Set F/R lever in F or R and measure change of 1 ton (0A o – 16.5A ) voltage. models Value is for reference. 7V o 7.12V 2 ton models (0A o – 24A) Value is for reference. 3 ton model

7V o 7.09V (0A o – 17.5A) Value is for reference.

10. CPU BOAD CONNECTOR POSITION AND CONNECTOR PIN NO. 1.

• •

CPU connector position

CN1, 2, 4, 5, 7, 11, CN3R, 4R, and 8R are 040/070 Hybrid I/O Connector Series manufactured by NIHON AMP. CN7R is XAD Series manufactured by JST.

70-12

BE30 Series

TROUBLESHOOTING

2.

MAIN CONTROLLER

Connector pin No.

Power supply : CN7R

BE30 Series

70-13

MAIN CONTROLLER

TROUBLESHOOTING

11. PREPARING FOR CHECKING CONTINUITY 1.

Stop the vehicle on level ground, lower the fork to the ground, tilt the mast forward, and apply the parking brake.

2.

Turn the key switch off and disconnect the battery plug.

3.

Remove the door for the controller at the rear part of the counterweight.

4.

Disconnect the wiring connector of the CPU board. • Connector of CPU board: CN1 – 5, CN7, CN11 • Connector of power supply board: CN3R, CN4R, CN7R, CN8R a Pushing in the stopper at the center of the connector, pull out the connector.

5.

Remove the protective cover of the printed circuit card.

6.

With the printed circuit card installed, remove its mounting bracket. When checking continuity, be sure to perform the above preparation.

70-14

BE30 Series

TROUBLESHOOTING

MAIN CONTROLLER

12. MAIN CONTROLLER 1.

Parts arrangement of control section

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Sensor (CSB) Fuse (F2) Fuse (F3) Fuse (F4) Contactor (MD) Fuse (F1) Capacitor board (CBP) Power module (TMP) Contactor (MPS) Absorber (CPS)

This illustration shows 1.0 ton to 2.5 ton models.

11. 12. 13. 14. 15. 16. 17. 18. 19.

Diode (DPS) Transistor (TMS2) Transistor (TMS1) Sensor (CSDW) Sensor (CSDU) Power module (TMDW) Power module (TMDV) Power module (TMDU) Capacitor board (CBD)

This illustration shows 3.0 ton model.

BE30 Series

70-15

MAIN CONTROLLER

2.

TROUBLESHOOTING

Checking power modules for travel/cargo handling (TMDU, TMDV, TMDW, TMP) • Prepare for checking continuity. • Disconnect the all wires, bus bars, and capacitor boards connected to the power modules. (Record their wiring and locations so that you can connect and install them correctly again.) • Set the multimeter for measurement of resistance (x1000), set its rods to the terminals according to the following table to measure the resistance. (Use an analog multimeter.) • Judge the condition of the power modules by the measured resistance. Measuring point D1-S1D2 D1D2-S2 S1D2-S2 G2-S2 D1-G1 G2-S1D2

Multimeter Red rod (+) Black rod (-) D1 S1D2 S1D2 D1 S1D2 S2 S2 S1D2 G1 S1D2 S1D2 G1 G2 S2 S2 G2 D1 G1 G1 D1 S1D2 G2 G2 S1D2

Normal value (R) Rough standard Few kz cz Few kz cz Approx. 4kz Approx. 12kz Approx. 4kz Approx. 12kz Approx. 20kz cz Approx. 20kz cz

Judgment Good Above 1z cz Above 1z cz Above 1z Above 1z Above 1z Above 1z Above 1z cz Above 1z cz

Bad 0z and cz Below cz 0z and cz Below cz 0z and cz 0z and cz 0z and cz 0z and cz 0z and cz Below cz 0z and cz Below cz

Since the normal values shown in the above table depend on the type of the multimeter used and the condition of the battery in it, they are reference values. Accordingly, judge the condition of each power module by whether the power module has resistance (above 1z) or not (0z) or it is insulated (cz). • For check of the gates (G1 and G2), you may use gates of any FET's, as long as those FET's are in the same line. • Do not touch the gate terminals (G1 and G2) of the power modules and the soldered parts of the printed circuit boards with your bare hands, since they can be broken by static electricity. • When carrying or storing the power modules, be sure to put them in anti-static bags and protect them from large vibration and impacts. Detail of Y portion

70-16

BE30 Series

TROUBLESHOOTING

3.

MAIN CONTROLLER

Checking transistor for EPS (1) Carry out to P70-13, PREPARATION FOR CHECKING CONTINUITY. (2) Disconnect either wire of each terminal to be checked. a Record the disconnected wires and their locations so that you can connect them correctly again. (3) Set the multimeter for measurement of resistance (x100) and apply its rods to the terminals according to the following table to measure the resistance. (4) Judge the condition of the transistor by the measured resistance. Measuring point G1 – C1 G1 – E1 G1 – E1 G2 – C2 G2 – E2 C2 – E2

Judgment

Black rod (-)

Red rod (+)

Normal value (Rough standard)

Good

Bad

G1

C1 G1

G1

E1

E1

G1

C1

E1

c c c c c

Other than c

C1

c c c c c

E1

C1

Approx. 650 z

Above 1z

0z

G2

C2 G2

G2

E2

E2

G2

c c c c

Other than c

C2

c c c c

C2

E2

Approx. 650z

Above 1z

0z

E2

C2

Approx. 1300z

Above 1z

0z

Other than c Other than c Other than c Other than c

Other than c Other than c Other than c

Since the normal values shown in the above table depend on the multimeter used, they are reference values. Accordingly, judge the condition of the transistor by whether the transistor has resistance (above 1z) or not (0z) or it is insulated (c). EPS transister

BE30 Series

70-17

MAIN CONTROLLER

4.

TROUBLESHOOTING

Checking contactor coil (1) Carry out to P70-13, PREPARATION FOR CHECKING CONTINUITY. (2) Disconnect all the lead wires from the coil wiring terminals. a Record the disconnected wires and their locations so that you can connect them correctly again. (3) Set the multimeter for measurement of resistance (x100) and apply its rods to the terminals to measure the resistance. (4) Judge the condition of the contactor coil by the measured resistance. Note) The measuring method and standards are the same as those for the current BE30 Series. The MP contactor is not installed, however. Contactor

Judgment Good

MD contactor (1) (Travel)

20 – 50z (typ, 30z)

PS contactor (2) (Power steering)

120 – 380z (typ, 266z)

Bad

cz (Coil is disconnected) cz (Coil is disconnected)

a Do not judge the condition of the contactor coil by measuring the resistance between the common terminals.

70-18

BE30 Series

TROUBLESHOOTING

5.

MAIN CONTROLLER

Checking contacts of contactor Check the contacts of the contactor visually. If they are free from extreme unevenness, they are normal. If their surfaces are uneven or worn extremely, replace them. MD contactor Replace 2 fixed contacts and 1 moveable contact together. PS contactor Replace contactor assembly.

6.

Capacitor boards (CBD, CBP) • Check capacitor board (1) visually for harmful flaw and deformation and extreme discoloration. If it is free of those defects, it is normal.

7.

Checking travel/cargo handling temperature sensors • Carry out to P70-13, PREPARATION FOR CHECKING CONTINUITY. • Disconnect temperature sensor connectors (THD, THP). (When connecting, take care not mistake THD and THP for each other.) • Set the multimeter for measurement of resistance (x1,000) and apply its rods according to the following table to measure the resistance. • Judge the measured resistance. Multimeter

Measuring point

Red pin (+)

Black pin (-)

THD

THD-1

THD-2

THP

THP-1

THP-2

BE30 Series

Normal value (R) Standard 0°C 10°C 20°C 30°C

Approx. 66kz Approx. 40kz Approx. 25kz Approx. 16kz

70-19

MAIN CONTROLLER

TROUBLESHOOTING

8. Heat radiator insulation sheet • Each power module uses 2 sheets. When replacing the power module, replace sheets with new ones, too. • Check the sheets visually for flaw, cracking, metal dust, metal chips, etc. If they are free of those defects, they are normal. • The heat radiator insulation silicone sheets are made thin to reduce the heat radiation resistance, thus they are brittle. Handle the sheets with extreme care. If they have any flaw or crack, do not use them. Check carefully that metal dust, chips, are not sticking to the sheets. These defects can lower the insulation and directly cause a short circuit and a grounding fault of the power module, and that can break the power module. When installing, align the mounting holes of the power module with the holes of the sheets, then tighten carefully so that the power module and sheets will not shift. 9. Cooling fan • Disconnect fan connector (1). • Prepare a stabilized power supply for control and set its output voltage to about 24 V. • Connect fan (2) according to the following table and check that it operates. Stabilized power Fan connector Color of lead wire supply 24V

Pin 1

Red

0V

Pin 3

Black

10. Checking limit current • Stop the vehicle on level ground and put chocks under the rear wheels. • Put wood blocks under both sides of the frame to float the front wheel above the ground (only when measuring the travel limit current). • Lower the fork to the ground, tilt the mast forward, and apply the parking brake. • Disconnect the wiring of the brake switch (only when measuring the travel limit current). • Set an ammeter (clamp tester) to the cable shown in the figure and measure the limit current under the conditions shown in the following table. Motor

Travel

Measuring cable

Setting of clamp

Set the forward-reverse lever in F po- DU, DV, DW sition, press the brake pedal and accelerator pedal fully, and measure the current at this time.

DC 1,000 A peak range

Measurement conditions

Limit current 1 ton models 527 – 586A (peak) (373 – 412A (rms)) 2 ton models 674 – 746A (peak) (475 – 525A (rms)) 3 ton model

Move the tilt lever forward fully to tilt PA, PB the mast forward and measure the Hydraulic current at this time.

EPS

•

70-20

Steer fully to the left or right and mea- Cable of EPS sure the current at this time. motor

524 – 580A (peak) (370 – 410A (rms))

Same as model 8

(Specification values) 1 ton models Min. 300 A 2 ton models Min. 340 A 3 ton model Min. 300 A, Max. 360 A

Same as model 8

(Specification values) 1 ton models 45±2.5A 2 ton models 50±2.5A 3 ton model Min. 45 A, Max. 50 A

After finishing check, return the disconnected wiring of the brake switch (only after the travel limit current is measured).

BE30 Series

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

13. CONNECTOR VOLTAGE CHECK TABLE Voltage check table (1.0 - 2.5 ton models)

Use an analog multimeter. Set it for measurement of resistance (kz). Connect the negative (-) voltage side (red rod side) to the negative (-) terminal of the panel and connect the positive (+) voltage side (black rod side) to the terminal to be measured. When measuring, disconnect only the connector housing that contains the terminal to be measured. BV: Rough battery voltage.

CN1 (26-pole) P board connector Pin No.

Signal name

Contents of signal

Type

1 – 2 – 3 REG

(Not connected) (Not connected) Regenerating signal output

4 SLMT2

Travel speed limit-2 SW DI

5 VS

Control valve selection

DI

6 BRK

Brake SW

DI

∞ ∞

4.4

When switch is ON: 0 V

O

∞

4.4

When switch is ON: 0 V

DI

Y

∞

4.4

When switch is ON: 0 V

DI DI DI DI DI Power supply (48 V) OV – DI

LR LR GR WB L Y

∞ ∞ ∞

4.4 4.4 4.4 0 0 BV

Br – BrW

0z

∞ ∞

0 – 4.4

0 – When switch is ON: 0 V

– – Open: Cargo handling DUTY limit

DI

YR

∞

4.4

When switch is ON: 0 V

Open: Interrupt is effective.

DI DI

RY Gr

∞ ∞

4.4 4.4

When switch is ON: 0 V When switch is ON: 0 V

20 SWMONI SW monitor start input 21 ATT1 ATT-1 SW

DI DI

P BO

∞ ∞

4.4 4.4

When switch is ON: 0 V When switch is ON: 0 V

Open: Parking brake is applied. Open: Operator is out, OV short: Operator is seated Open: Monitor mode start OV short: Hydraulic chopper operates.

22 ATT2

ATT-2 SW

DI

GO

∞

4.4

When switch is ON: 0 V

OV short: Hydraulic chopper operates.

23 ATT3/ RCH 24 EMG

ATT-3 SW

DI

LO

∞

4.4

When switch is ON: 0 V

OV short: Hydraulic chopper operates.

Main contactor (EMG)

DI

LB

30kz

0

25 HORN

Horn output

DO

15kz

BV

26 KEY

Key SW (Control power Power Y supply input) supply (48 V)

50kz

BV

When normal: BV, EMG state: 0 V Horn operates: FETon (Max. 0.6 V) 48 V control power supply input, When key is OFF: 0 V

48Vhigh side input (MP contactor coil current is supplied) NchFET open drain output (Max. 200 V/ 1.5 A) –

LIFT1 LIFT2 TILT DSR DSF KEY

14 OV 15 – 16 LICOM

Lift-1 SW Lift-2 SW Tilt SW Reverse SW Forward SW Key SW (Control power supply input)

17 LINT

O V (For SW input) (Not connected) Lift interrupt command input Lift interrupt SW

18 PB 19 SEAT

Parking SW Seat SW

70-22

0z >500kz 80kz

BY –

Remarks

– – During regeneration: ON when below 0.5 V, Other state: OFF When switch is ON: 0 V

8 9 10 11 12 13

– – Sb

Reference voltReference voltage when age when key switch is ON and control knob switch is ON (V) is operated (V) – – (*1) Voltage applied to multi-controller side 4.4

7 ACCLMT Lifting height SW

– – DO

ResisWire tance color (Terminal – GND)

–

50kz 50kz 50kz

– – NchFET open drain output (Load * 5 V/2 mA/4.7z) OV short: Travel speed is not limited, Open: Travel speed is limited Open: Proportional valve, OV short: Manual valve OV short: Brake operates.

Open: High lifting height (Acceleration limiter operates) When switch is ON: 0 V OV short: Hydraulic chopper operates. When switch is ON: 0 V OV short: Hydraulic chopper operates. When switch is ON: 0 V OV short: Hydraulic chopper operates. When DSR is operated: BV 48Vhigh side input When DSR is operated: BV 48Vhigh side input 48 V control power supply in– put, When key is OFF: 0 V

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

OK: Device operates normally, or it has an error or cannot operate but it will not be broken. NG: Device will be broken or damaged seriously. All or one of codes concerned is displayed. Key ON, SW ALL off" includes disconnection before Key ON. Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just travel motor is chopping for handling During motor is rebefore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped – – – – – – – – – – – – – – – – OK OK OK OK OK OK OK – OK OK OK OK OK OK OK Travel speed is limited.

1 2 3 4

– – OK OK

– – – –

– – OK OK

Just before driving travel motor – – OK OK

5

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

6

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

7

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

8

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

9

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

10

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

11

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

12 13

OK OK

– –

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

14 15 16

OK – OK

– – –

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

17

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

18 19

OK OK

– –

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

20 21

OK OK

– –

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

22

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

23

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

24

OK

32

OK

OK

OK

OK

OK

OK

OK

OK

OK

25

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

26

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

Code Key Pin Concon- ON, SW No. dition cerned ALL off

BE30 Series

Proportional valve operation mode is selected. Regenerating brake cannot be applied. High lifting height is limited. Cargo handling lift 1 does not operate. Cargo handling lift 2 does not operate. Cargo handling TILT does not operate. Vehicle does not travel in reverse. Vehicle does not travel forward. Power is not supplied (when CN1-26 is also disconnected). – – Cargo handling DUTY is limited (when LINT is effective). Cargo handling DUTY is limited (when LICOMis open). – Deadman function is turned ON. Monitor mode Cargo handling ATT-1 does not operate. Cargo handling ATT-2 does not operate. Cargo handling ATT-3 does not operate. Cargo handling EGM SW is turned ON. – Power is not supplied (when CN1-13 is also disconnected).

70-23

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

CN2 (22-pole) P board connector Pin No.

Signal name

Contents of signal

Type

ResisReference voltage Wire tance when key switch is color (Terminal ON (V) – GND)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

1 MCTXDP TXD (+)

TXD WL (Source)

∞

(*2) Reference cannot be set.

[Pull-up power supply side: (+) Data transmitted to display side]

2 MCRXDP RXD (+)

RXD W (Source) OV W

∞

(*2) Reference cannot be set. 0

Data received from display

3 PPDA-N Travel speed sensor A (-) 4 PPDA-S Travel speed sensor A Pulse IN B (+) 5 ATIN Solenoid valve analogue AIN W signal

17kz 8.4kz

S1 = At 1358 Hz/10 km, S2 = At 1253 Hz/ 10 km – –

AIN

7 PSPT-P Torque sensor (+) 8 ACCD-S Travel accelerator VR (S)

PSPT(+) LY AIN GY

1kz 13.5kz

9 ACCD-P Travel accelerator VR (+) 10 ACCP-S Lift VR, (2) side (S)

ACCD(+) RB

∞

11 ACCP-P Lift VR, (3) side (+)

LTVR(+) YG

12 MCTXD N

TXD (-)

TXDO (Sync.)

OL

∞

(*2) Reference cannot be set.

[Open drain power supply side: Data transmitted to display (-) side]

13 MCRXD RXD (-) N 14 MCCOM MC communication line shield 15 PPDATravel sensor shield COM 16 ATCOM Solenoid valve shield

RXDO (Sync.) OV (com) OV (com) OV (com)

B

∞

BO

0z

(*2) Reference cannot be set. 0

[Photo coupler anode side: (-) side] 0

BW

0z

0

0

–

BG

0z

0

0

–

B

0z

0

0V

–

200z

∞

0.3 – 0.6 4.4

–

70-24

YG

Solenoid valve GND (0 V) OV

18 PSPT-N Torque sensor (-) 19 AC1 AC1 (Accelerator SW) input 20 ACCD-N Travel accelerator VR, (-) side 21 ACCP-N LIFT VR1 side (-) 22

AIN

(Not connected)

PSPT (-) BY DI RL

10kz

–

6 PSPT-S Torque sensor (S)

17 ATN

GW

0z

[Photo coupler anode side: (+) side] Electromagnetic pickup input: Common 0 Electromagnetic pickup input: Signal (*1) Voltage apInput: Min. 4.25 V = DUTY min. plied to multi-con- 100% troller side Max. 1.9 V = DUTY 0% 0.4 – 4.6 If steering wheel is turned to right, VR wiper moves toward PSPT-(-) side (Signal voltage lowers). When steering wheel is turned to right end: 0.3 – 0.6 V When steering wheel is turned to left end: 4.4 – 4.7 V 4.4 – 4.7 4.4 – 4.7 0.3 – 4.7 VR wiper moves toward (+) side (Signal increases) o DUTY is increased. When accelerator is OFF: 0.3 – 0.9 V When accelerator is ON: 3.2 – 4.7 V 5 5

13.5kz

0.4 – 4.6

1kz

4.1 – 4.6

0.3 – 0.6 When switch is ON: 0 V

YB

0z

0

0V

OV

BW

200z

0.3 – 0.9

0.3 – 0.9

∞

–

–

–

5V power supply with series R

VR wiper moves toward (+) side – (Signal increases) o DUTY is increased. When lift SW is OFF: 0.3 – 0.9 V When lift SW is ON: 4.1 – 4.6 V 4.1 – 4.6 5V power supply with series R

OV

–

5V power supply with series R –

Data received from display –

OV with series R OV short: Travel operation permission – OV with series R –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped OK OK OK OK OK OK OK

OK

OK

Transmission error –

Just before driving travel motor OK

OK

OK

OK

OK

OK

OK

OK

3

OK

41

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41) OK(41) Vehicle cannot travel.

4

OK

41

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41) OK(41) Vehicle cannot travel.

5

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

6

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

7 8

OK OK

54 17

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(54) Torque sensor is abnormal. OK(17) OK(17) Travel accelerator is defective.

9

OK

17

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17) OK(17) Travel accelerator is defective.

10

OK

35

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35) OK(35) Cargo handling lift VR is defective (in manual valve mode)

11

OK

35

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

12

OK

OK

OK

OK

OK

OK

OK

OK

13

OK

Transmission error –

OK(35) OK(35) Cargo handling lift VR is defective (in manual valve mode) OK OK –

OK

OK

OK

OK

OK

OK

OK

OK

OK

14

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

15

OK

–

OK

OK

OK

OK

OK

OK

OK

16

OK

–

OK

OK

OK

OK

OK

OK

OK

17

OK

–

OK

OK

OK

OK

OK

OK

OK

18 19

OK OK

54 –

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

Communication error may be made. OK OK Travel speed may be sensed wrongly. OK OK Cargo handling chopper DUTY is unstable (in proportional valve mode). OK OK Cargo handling chopper DUTY is unstable (in proportional valve mode). OK(54) OK(54) Torque sensor is abnormal. OK OK Vehicle does not travel.

20

OK

17

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17) OK(17) Travel accelerator is defective.

21

OK

35

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

22

–

–

–

–

–

–

–

–

–

OK(35) OK(35) Cargo handling lift VR is defective (in manual valve mode) – – –

Code Key Pin Concon- ON, SW No. dition cerned ALL off 1

OK

2

BE30 Series

OK

OK

Remarks – –

– PS cannot operate.

–

70-25

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

CN3 (4-pole) relay connector: For power supply Pin Signal No. name 1 2 3 4

Contents of signal

Chassis power supply for control + (+48 V) Chassis power supply for control Chassis power supply for control + (+48 V) Chassis power supply for control -

Type

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

VB48

W

7.8kz

BV

BV

–

VBVB48

B W

0z 7.8kz

0V BV

0V BV

– –

VB-

B

0z

0V

0V

–

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

CN4 (2-pole) relay connector: EPS motor (B) Pin No.

Signal name

Contents of signal

Type

ResisWire tance color (Terminal – GND)

1

EPS motor drive

P24

R

24kz

Unsettled

2

EPS motor drive

P23

B

24kz

Unsettled

CN5 (4-pole) relay connector: EPS motor (B) Pin Signal No. name

Contents of signal

Type

Fluctuation when EPS rotates to Motor current direction when steerleft: 0 – BV ing wheel is turned to right CN4-2 o CN4-1 Fluctuation when EPS rotates to [= P23 o P24] right: 0 – BV

For only this case, connect CN5-4 to red rod (0 V) of multimeter and connect terminal to be measured to black rod (+ side).

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

1 2 3

+VC power supply (+10 V ± 5%) OV Sensor output

+VC GND OUT

R B W

7.3kz 0z 5.6kz

10.2V 0V 0.6V

4

OV

GND

B

X

0V

Reference voltage when switch is ON and control knob is operated (V) 10.2V 0V Varies with battery current (0.6 – 8.6 Vmax) 0V

Remarks – – – –

CN11 (16-pole) P board connector Pin Signal No. name 1 – 2 – 3 DMTH -N 4 DMTH -S 5 PPDBN 6 PPDBS 7 – 8 – 9 – 10 – 11 – 12 – 13 PPDBCOM 14 – 15 – 16 –

70-26

Contents of signal (Not connected) (Not connected) Travel motor temperature (-) Travel motor temperature (S) Travel speed sensor B (-)

Type – –

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

– – 0

– – 0

– – –

0z

0V

– – GY

AIN

LO

5.5kz

0V

W

0z

Approx. 3.48 (at 25°C) 0

B

16.5kz

0

– – – – – – BW

6.2kz

– – – – – – 0

– – –

6.2kz

Travel speed sensor B (+) Pulse IN (Not connected) – (Not connected) – (Not connected) – (Not connected) – (Not connected) – (Not connected) – Travel sensor shield 0V (COM) (Not connected) – (Not connected) – (Not connected) –

∞

0z

∞

0z

∞

0z 5.5z 0z

∞ ∞

– – –

Varies with temperature (0.2 – 4.8). Electromagnetic pickup input: Common Electromagnetic pickup input: Signal – – – – – – 0 – – –

– – S1 = At 1358 Hz/10 km, S2 = At 1253 Hz/ 10 km – – – – – – – – – –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

1

OK

–

OK

Just before driving travel motor OK

2 3

OK OK

– –

OK OK

OK OK

4

OK

–

OK

OK

Pin ConNo. dition

Code Key conON, SW cerned ALL off

1

OK

50

OK(50)

Just before driving travel motor OK

2

OK

50

OK(50)

OK

Pin ConNo. dition

Code Key conON, SW cerned ALL off

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped OK OK OK OK OK OK OK Power is not supplied (when CN3-3 is also disconnected). OK OK OK OK OK OK OK – OK OK OK OK OK OK OK Power is not supplied (when CN3-3 is also disconnected). OK OK OK OK OK OK OK –

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped OK OK OK OK OK OK OK Opening of EPS transistor is detected wrongly. Operation of PS is defective. OK OK OK OK OK OK OK Opening of EPS transistor is detected wrongly. Operation of PS is defective.

Fault caused by disconnection, etc. Just beWhile When travel While travel Just before While cargo Just bePin Confore drivtravel motor is for handling During motor is re- chopping fore No. dition ing travel motor is loaded motor is EPS generating cargo hanEPS motor driven heavily dling motor chopped 1 [Since this connector is used/controlled on multimeter side, ask the section in charge of your company.] 2 3 Code Key conON, SW cerned ALL off

Remarks –

4

Fault caused by disconnection, etc. Just beWhile When travel While travel Just before While cargo Just beCode Key Pin Confore drivtravel motor is for handling During con- ON, SW ing motor is re- chopping fore Remarks No. dition cerned travel motor is loaded cargo hanmotor is EPS ALL off generating EPS motor driven heavily dling motor chopped 1 – – – – – – – – – – – – 2 – – – – – – – – – – – – 3 OK 27 OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) Travel motor temperature sensor is defective (Vehicle can travel). 4 OK 27 OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) Travel motor temperature sensor is defective (Vehicle can travel). 5 OK 42 OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) Vehicle cannot travel. 6

OK

42

OK(42)

OK(42)

OK(42)

OK(42)

OK(42)

OK(42)

OK(42)

7 8 9 10 11 12 13

– – – – – – OK

– – – – – – –

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

14 15 16

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

BE30 Series

OK(42) OK(42) Vehicle cannot travel. – – – – – – Travel speed may be sensed wrongly. – – –

70-27

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

CN7 (12-pole) P board connector Pin Signal No. name

Contents of signal

Type

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

10.3kz

0

∞ ∞ ∞

– – – Approx. 4.05 (at 25°C) Approx. 4.05 (at 25°C) 0

When EPS operates: Varies largely with "ON" period ratio of chopper – – – Varies with temperature (0.2 – 4.8). Varies with temperature (0.2 – 4.8). 0

–

Remarks

1 SH+

Shunt resistance for detect- AIN ing EPS current, (+) side

Y-L

2 – 3 – 4 – 5 THD+

(Not connected) – (Not connected) – (Not connected) – Travel controller tempera- AIN ture sensor Cargo handling controller AIN temperature sensor Shunt resistance for detect- OV ing EPS current, (-) side

– – – W-BR

5.3kz

W-L

5.3kz

G-W

9.3kz

∞ ∞

OV

– – – GR

0z 0z

– – – 0V

– – – 0V

– – – –

OV

GR

0z

0V

0V

–

Reference voltage when switch is ON and control knob is operated (V)

Remarks

6 THP+ 7 SH-

8 – 9 – 10 – 11 HTD12 THP-

(Not connected) (Not connected) (Not connected) Travel controller temperature sensor 0 V Cargo handling controller temperature sensor 0 V

– – –

– – – – – –

CN4 (16-pole) P board connector Pin Signal No. name

Contents of signal

Type

Wire color

ResisReference volttance age when key (Terminal switch is ON (V) – GND)

1 P22

Main circuit: Secondary side of MPS contactor

AIN

W-G

80kz

BV

2 P3

Main circuit: Secondary side of fuse F1

AIN

BR

33kz

BV

3 P4

Main circuit: Output termi- AIN L nal of U-phase power module 4 – (Not connected) – – 5 MD (+) MD contactor coil power Power Y-R supply (+) supply (BV48) 6 MPS (+)

MPS contactor coil power supply (+)

7 – 8 P1

(Not connected) Main circuit voltage (P1)

9 P21

Main circuit: Secondary side of EPS fuse F3 Main circuit: (PA) side of cargo handling motor

49.8kz

Before MPS contactor is turned ON: Approx. 35.2 V (When BV = 48 V) After MPS contactor is turned ON: BV Before MD contactor is turned ON: 0 V – 39.5 V After MD contactor is turned ON: BV

–

Before key SW is turned ON: 0 V – 39.5 V (When BV = 48 V) After key SW is turned ON: Boosting charging until MD contactor is turned ON Approx. 24.5 V Varies largely when inverter oper- Vehicle stops, direction lever in neuates. tral, and accelerator is OFF.

∞ ∞

– BV

– When chassis EMGsw operates: 0 V, When normal: BV

– –

∞

BV

BV

–

Power R-L supply (BV48) – – AIN R

9.2kz

∞

– BV

– BV

– –

AIN

W-R

80kz

BV

BV

–

AIN

L-R

45kz

(*3)

11 – 12 – 13 MD

(Not connected) – – (Not connected) – – MD contactor coil drive FET OPEND Y-G drain

45kz 45kz

∞

– – BV

14 MPS

MPS contactor coil drive FET drain

45kz

BV o 0.2V

15 – 16 N1

(Not connected) – OV for contactor coil drive OV circuit

∞

– –

10 P13

70-28

OPEND R-W

– B

0z

Before MP contactor is turned ON: 0 Before key SW is turned ON: 0 V – V – 39.5 V 39.5 V (When BV = 48 V) After MP contactor is turned ON: After key SW is turned ON: Boosting a) While cargo handling chopper is charging until MP contactor is stopped: Approx. BV turned ON b) While cargo handling chopper is operating: Varies with "ON" period ratio. Not fixed. – – – – – When MP contactor is turned OFF: BV When chassis EMGsw operates: 0 V, When normal: BV When MP contactor is turned ON: BV x 75% (*4) When key SW is turned ON – (When MPS contactor is turned OFF): BV When MPS contactor is turned ON: 0.2 V – – – –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped OK OK OK OK OK OK OK EPS overcurrent is detected wrongly. PS is impossible.

1

OK

–

OK

Just before driving travel motor OK

2 3 4 5

– – – OK

– – – 22

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

6

OK

36

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

7

NG

50

OK

OK

OK

OK

OK

OK

OK

8 9 10 11

– – – OK

– – – 22

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

12

OK

36

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

Code Key Pin Concon- ON, SW No. dition cerned ALL off

– – – – – – – – – OK(22) OK(22) Temperature sensor is defective (Vehicle can travel). OK(36) OK(36) Temperature sensor is defective (Vehicle can handle cargo). OK NG EPS current detector operates wrongly. EPS transistor is broken. PS is impossible. – – – – – – – – – OK(22) OK(22) Temperature sensor is defective (Vehicle can travel). OK(36) OK(36) Temperature sensor is defective (Vehicle can handle cargo).

Fault caused by disconnection, etc. While When travel While travel Just before While cargo Just betravel motor is for handling During motor is re- chopping fore motor is loaded cargo hanmotor is EPS generating dling EPS driven heavily motor chopped OK(52) OK(52) OK(52) OK(52) OK(52) OK(52) OK(52)

1

OK

52

OK(52)

Just before driving travel motor OK(52)

2

OK

20

OK(20)

OK(20)

OK(20)

OK(20)

OK(20)

OK(20)

OK(20)

3

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

4 5

– OK

– 7

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

6

OK

53

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

7 8

– OK

– OK(21)

– OK(21)

– OK(21)

– OK(21)

– OK(21)

– OK(21)

– OK(21)

9

OK

– 21, 45, 56, 50 52

OK

OK

OK

OK

OK

OK

OK

10

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

11 12 13

– – OK

– – 7

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

14

OK

53

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53) OK(53) Short circuit of EPS drive TR is detected wrongly. PS is impossible.

15 16

– OK

– –

– OK

– OK

– OK

– OK

– OK

– OK

– OK

Code Key Pin Concon- ON, SW No. dition cerned ALL off

BE30 Series

OK(20) OK(20)

Remarks –

–

–

– Short circuit of MD contactor drive TR is detected wrongly. Defective contactor is detected wrongly. Vehicle cannot travel or handle cargo. OK(53) OK(53) Short circuit of EPS drive TR is detected wrongly. PS is impossible. – – – OK(21) OK(21) – OK(52) OK(52)

– OK

– OK

– –

– – Short circuit of MD contactor drive TR is detected wrongly. Defective contactor is detected wrongly. Vehicle cannot travel or handle cargo

– –

70-29

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

CN5 (22-pole) P board connector Pin No.

Signal name

Contents of signal

1 – (Not connected) 2 – (Not connected) 3 CSDU(+) Travel U-phase current detector power supply, (+) side 4 CSDU(S) Travel U-phase current detector power supply, signal side 5 CSDW(+) Travel W-phase current detector power supply, (+) side 6 CSDW(S) Travel W-phase current detector power supply, signal side 7 – (Not connected) 8 – (Not connected) 9 – (Not connected) 10 – (Not connected) 11 P2 Main circuit: Secondary side of MD contactor 12 – (Not connected) 13 – (Not connected) 14 CSDU(-) Travel U-phase current detector power supply, OV side 15 CSDU(-) Travel U-phase current detector power supply, OV side 16 CSDW(-) Travel W-phase current detector power supply, OV side 17 CSDW(-) Travel W-phase current detector power supply, OV side 18 – (Not connected) 19 – (Not connected) 20 – (Not connected) 21 – (Not connected) 22 P12 Main circuit: Secondary side of cargo handling fuse F2

70-30

Type

Wire color

ResisReference volttance age when key (Terminal switch is ON (V) – GND)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

– – 15

– – –

– – Power supply

– – R-B

1.6kz – 1.6kz

– – 15

AIN

O

10.8kz

7

Power supply

R-B

1.6kz

15

AIN

P

10.8kz

7

1.6kz 10.8kz 1.6kz 10.8kz 80kz

– – – – BV

– – – – BV

– – – –

OV

– – GR

0z 0z 0z

– – 0

– – 0

– – –

OV

GR

0z

0

0

–

OV

GR

0z

0

0

–

OV

GR

0z

0

0

–

– – – – AIN

– – – – L-W

0z 0z 0z 0z 80kz

– – – – BV

– – – – BV

– – – – –

– – – – AIN – –

– – – – Y

Varies with motor current: 3.0 – 11.0 Vmax 15 Varies with motor current: 3.0 – 11.0 Vmax

– – –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped – – – – – – – – – – – – – – – – OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

1 2 3

– – OK

– – 19

– – OK(19)

Just before driving travel motor – – OK(19)

4

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

5

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

6

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

7 8 9 10 11

– – – – OK

– – – – –

– – – – OK

– – – – OK

– – – – OK

– – – – OK

– – – – OK

– – – – OK

– – – – OK

12 13 14

– – OK

– – 19

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

15

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

16

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

17

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

18 19 20 21 22

– – – – OK

– – – – 33

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

Code Key Pin Concon- ON, SW No. dition cerned ALL off

BE30 Series

– – – – OK

– – – – OK

– – – – –

– – – – – – OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. – – – – – – – – – – – – OK(33) OK(33) –

70-31

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

CN3R (26-pole) P board connector Pin Signal No. name

Contents of signal

Type

Wire color

ResisReference volttance age when key (Terminal switch is ON (V) – GND)

Gate power supply DO

R-B

∞

11 – 13 (At CN3R-4)

W-L

∞

11 – 13 (At CN3R-4)

DO

L-W

∞

11 – 13 x 0.85 (At CN3R-4)

–

GR-B

∞

–

–

W-B

∞

–

DO

G-W

∞

11 – 13 x 0.85 (At CN3R-5)

7 GV1D

Travel V-phase (Upper FET DO of TMDV) gate signal 1

W-G

∞

11 – 13 (At CN3R-5)

8 VVD

Travel V-phase (Upper FET Gate of TMDV) gate power signal power supply (Not connected) – Travel U-phase (Upper FET – of TMDU) source Travel U-phase (Upper FET DO of TMDU) gate signal 2

R-W

∞

11 – 13 (At CN3R-5)

– GR

∞ ∞

–

G-Y

∞

11 – 13 x 0.85 (At CN3R-10)

1 WVD

Travel W-phase (Upper FET of TMDW) gate power supply 2 GW1D Travel W-phase (Upper FET of TMDW) gate signal 1 3 GW2D Travel W-phase (Upper FET of TMDW) gate signal 2 4 W0D Travel W-phase (Upper FET of TMDW) source 5 V0D Travel V-phase (Upper FET of TMDV) source 6 GV2D Travel V-phase (Upper FET of TMDV) gate signal 2

9 – 10 U0D 11 GU2D 12 GU1D

Travel U-phase (Upper FET DO of TMDU) gate signal 1

Y-G

∞

11 – 13 (At CN3R-10)

13 UVD

Travel U-phase (Upper FET of TMDU) gate power supply Travel Z-phase (Lower FET of TMDW) gate power supply Travel Z-phase (Lower FET of TMDW) gate signal 1

R-Y

∞

11 – 13 (At CN3R-10)

R-L

∞

11 – 13 (At CN3R-17)

O

∞

11 – 13 (At CN3R-17)

14 ZVD 15 GZ1D

Gate power supply Gate power supply DO

16 GZ2D

Travel Z-phase (Lower FET DO of TMDW) gate signal 2

Y

∞

11 – 13 x 0.85 (At CN3R-17)

17 Z0D

Travel Z-phase (Lower FET – of TMDW) source Travel Y-phase (Lower FET – of TMDV) source Travel Y-phase (Lower FET DO of TMDV) gate signal 2

B

0z

–

B

0z

–

L

∞

11 – 13 x 0.85 (At CN3R-18)

20 GY1D

Travel Y-phase (Lower FET DO of TMDV) gate signal 1

G

∞

11 – 13 (At CN3R-18)

21 YVD

Travel Y-phase (Lower FET of TMDV) gate power supply (Not connected) Travel X-phase (Lower FET of TMDU) source Travel X-phase (Lower FET of TMDU) gate signal 2

R-L

∞

11 – 13 (At CN3R-18)

18 Y0D 19 GY2D

Gate power supply – –

B

0z

∞

– –

DO

W

∞

11 – 13 x 0.85 (At CN3R-23)

25 GX1D

Travel X-phase (Lower FET DO of TMDU) gate signal 1

P

∞

11 – 13 (At CN3R-23)

26 XVD

Travel X-phase (Lower FET Gate of TMDU) gate power sup- power ply supply

R-L

∞

11 – 13 (At CN3R-23)

22 – 23 X0D 24 GX2D

70-32

–

Reference voltage when switch is ON and control knob is operated (V) 11 – 13 (At CN3R-4)

Remarks –

When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. Measurement is impossible be– cause of floating Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-5) – – Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-10) 11 – 13 (At CN3R-17)

–

When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. Measurement is impossible be– cause of floating Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-18) – – Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 –13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-23)

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped NG NG NG NG NG NG NG

1

NG

Many

NG

Just before driving travel motor NG

2

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

3

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

4

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

5

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

6

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

7

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

8

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

9 10

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– –

11

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

12

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

13

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

14

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

15

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

16

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

17

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

18

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

19

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

20

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

21

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

22 23

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– –

24

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

25

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

26

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

Pin ConNo. dition

Code Key conON, SW cerned ALL off

BE30 Series

Remarks – –

–

–

70-33

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

CN4R (12-pole) P board connector Pin Signal No. name 1 U0P 2 GU2P 3 GU1P 4 UVP 5 – 6 – 7 X0P 8 GX2P 9 GX1P 10 XVP 11 12

– –

70-34

Contents of signal

Type

Cargo handling U-phase – (Upper FET of TMP) source Cargo handling U-phase DO (Upper FET of TMP) gate signal 2 Cargo handling U-phase DO (Upper FET of TMP) gate signal 1 Cargo handling U-phase Gate (Upper FET of TMP) gate power power supply supply (Not connected) – (Not connected) – Cargo handling X-phase – (Lower FET of TMP) source DO Cargo handling X-phase (Lower FET of TMP) gate signal 2 Cargo handling X-phase DO (Lower FET of TMP) gate signal 1 Cargo handling X-phase Gate (Lower FET of TMP) gate power power supply supply (Not connected) – (Not connected) –

ResisWire tance Reference voltage when key switch color (Terminal is ON (V) – GND)

Reference voltage when switch is ON and control knob is operated (V)

GR

∞

–

G-Y

∞

11 – 13 (At CN4R-1)

Y-G

∞

11 – 13 (At CN4R-1)

11 – 13 (At CN4R-1)

R-Y

∞

11 – 13 (At CN4R-1)

11 – 13 (At CN4R-1)

– –

∞ ∞

– – –

Measurement is impossible because of floating 11 – 13 (At CN4R-1)

– – Measurement is impossible because of floating 11 – 13 x 0.85 (At (*3) CN4R-7)

Remarks – Normally OFF Normally OFF – – – –

B

0z

W

∞

P

∞

11 – 13 (At CN4R-7)

R-L

∞

11 – 13 (At CN4R-7)

11 – 13 (At CN4R-7)

–

– –

0z

∞

– –

– –

– –

(*3)

– –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped NG NG NG NG NG NG NG Cargo handling power module (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) is broken, shorted, or open. NG NG NG NG NG NG NG Cargo handling power module (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) is broken, shorted, or open.

NG (30, 31) NG (30, 31)

Just before driving travel motor NG (30, 31) NG (30, 31)

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

NG

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

5 6 7

– – NG

– – 30, 31

8

NG

30, 31

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – – – NG NG (30, 31) (30, 31) NG NG (30, 31) (30, 31)

9

NG

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

10

NG

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

11 12

– –

– –

– –

– –

– –

– –

– –

– –

– –

Pin ConNo. dition

Code Key conON, SW cerned ALL off

1

NG

30, 31

2

NG

30, 31

3

NG

4

BE30 Series

– –

– –

– – Cargo handling power module is broken, shorted, or open. Cargo handling power module is broken, shorted, or open.

– –

70-35

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

TROUBLESHOOTING

CN8R (22-pole) P board connector Pin Signal No. name

Contents of signal

Type

1 N1

OV

OV

2 3 N1

(Not connected) OV

OV

4 5 VB4B

(Not connected) Control power supply during kickback + MPS contactor power supply (Not connected) EPS transistor (Upper side of TMPS2) gate signal

6 7 G3

ResisWire tance Reference voltage when key switch is color (Terminal ON (V) – GND) B

0

0

–

0z 0z

– 0

– 0

– –

∞

– BV

– BV

– –

W

∞ ∞

– 15V (At CN8R-18)

– B

– R

80kz –

8 G4

EPS transistor (Lower side DO of TMPS2) gate signal

G

50kz

9 G1

EPS transistor (Upper side DO of TMPS1) gate signal

Y

∞

10 G2

EPS transistor (Lower side DO of TMPS1) gate signal

GR-B

11 12 N1

(Not connected) OV

OV

13 14 N1

(Not connected) OV

OV

15 16 17 18 E3

(Not connected) (Not connected) (Not connected) EPS transistor (Upper side of TMPS2) emitter signal EPS transistor (Lower side of TMPS2) emitter signal EPS transistor (Upper side of TMPS1) emitter signal EPS transistor (Lower side of TMPS1) emitter signal (Not connected)

19 E4 20 E1 21 E2 22

–

– B

–

–

– – –

56kz

∞

5.5kz

B

– – –

– 0

∞

– – – 0 (At CN8R-7)

80kz

∞ ∞

O

DO

W-L

>500kz

DO

L-R

∞

DO

G-W

>500kz

–

– When EPS operates: 0 V – 12 V (Varies largely with "ON" period ratio of chopper) (*3) 0 (At CN8R-19) When EPS operates: 0 V – 12 V (Varies largely with "ON" period ratio of chopper) (*3) 15V When EPS operates: 0 V – 12 V (At CN8R-20) (Varies largely with "ON" period ratio of chopper) (*3) 0 (At CN8R-21) When EPS operates: 0 V – 12 V (Varies largely with "ON" period ratio of chopper) (*3) – – 0 0

5.5kz 0z

DO

–

Remarks

5.5kz

–

– Power supply (48 V) – DO

Reference voltage when switch is ON and control knob is operated (V)

∞

– 0

– – – Measurement is impossible because of floating 0 (At CN8R-8) Measurement is impossible because of floating 0 (At CN8R-9) Measurement is impossible because of floating 0 (At CN8R-10) Measurement is impossible because of floating – –

– – – – – – –

– –

– – – – – – – –

(*1) While the vehicle is not regenerating, the source voltage supplied by the multi-controller is the reference voltage. (*2) A reference value cannot be set since the serial communication line is used. (*3) A reference value cannot be set since the voltage varies largely with the outputting condition ("ON" period ratio) while FED and IGBT are in operation. (*4) Since the voltage is chopped, the reference value is about 75% of the battery voltage used as the control power supply. The measured value may depends on the multimeter used.

70-36

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped NG NG NG NG NG NG NG When CN8R-12 is also disconnected, connector may be broken. OK OK OK OK OK OK OK If only this line is disconnected, there is no problem. – – – – – – – – NG NG NG NG NG NG NG When CN8R-14 is also disconnected, connector may be broken. OK OK OK OK OK OK OK If only this line is disconnected, there is no problem. – – – – – – – – OK OK OK OK OK OK OK PS kickback operation is impossible.

NG

Many

NG

Just before driving travel motor NG

OK

–

OK

OK

– NG

– Many

– NG

– NG

OK

–

OK

OK

4 5

– OK

– –

– OK

– OK

6 7

– NG

– 50

– OK

– OK

– OK

– OK

– OK

– OK

– OK

– OK

– NG

– EPS transistor is broken. PS is impossible.

8

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

NG

EPS transistor is broken. PS is impossible.

9

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

NG

EPS transistor is broken. PS is impossible.

10

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

NG

EPS transistor is broken. PS is impossible.

11 12

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

15 16 17 18

– – – NG

– – – 50

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

19

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

OK

20

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

OK

21

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

OK

22

–

–

–

–

–

–

–

–

–

–

–

– When CN8R-1 is also disconnected, connector may be broken. If only this line is disconnected, there is no problem. – When CN8R-3 is also disconnected, connector may be broken. If only this line is disconnected, there is no problem. – – – EPS transistor is broken. PS is impossible. EPS transistor is broken. PS is impossible. EPS transistor is broken. PS is impossible. EPS transistor is broken. PS is impossible. –

Code Key Pin Concon- ON, SW No. dition cerned ALL off 1

2 3

13 14

BE30 Series

70-37

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

14. CONNECTOR VOLTAGE CHECK TABLE Voltage check table (3.0 ton model)

Use an analog multimeter. Set it for measurement of resistance (kz). Connect the negative (-) voltage side (red rod side) to the negative (-) terminal of the panel and connect the positive (+) voltage side (black rod side) to the terminal to be measured. When measuring, disconnect only the connector housing that contains the terminal to be measured. BV: Rough battery voltage.

CN1 (26-pole) P board connector Pin No.

Signal name

Contents of signal

Type

1 – 2 – 3 REG

(Not connected) (Not connected) Regenerating signal output

4 SLMT2

Travel speed limit-2 SW DI

5 VS

Control valve selection

DI

6 BRK

Brake SW

DI

∞ ∞

4.4

When switch is ON: 0 V

O

∞

4.4

When switch is ON: 0 V

DI

Y

∞

4.4

When switch is ON: 0 V

DI DI DI DI DI Power supply (48 V) OV – DI

LR LR GR WB L Y

∞ ∞ ∞

4.4 4.4 4.4 0 0 BV

Br – BrW

0z

∞ ∞

0 – 4.4

0 – When switch is ON: 0 V

– – Open: Cargo handling DUTY limit

DI

YR

∞

4.4

When switch is ON: 0 V

Open: Interrupt is effective.

DI DI

RY Gr

∞ ∞

4.4 4.4

When switch is ON: 0 V When switch is ON: 0 V

20 SWMONI SW monitor start input 21 ATT1 ATT-1 SW

DI DI

P BO

∞ ∞

4.4 4.4

When switch is ON: 0 V When switch is ON: 0 V

Open: Parking brake is applied. Open: Operator is out, OV short: Operator is seated Open: Monitor mode start OV short: Hydraulic chopper operates.

22 ATT2

ATT-2 SW

DI

GO

∞

4.4

When switch is ON: 0 V

OV short: Hydraulic chopper operates.

23 ATT3/ RCH 24 EMG

ATT-3 SW

DI

LO

∞

4.4

When switch is ON: 0 V

OV short: Hydraulic chopper operates.

Main contactor (EMG)

DI

LB

30kz

0

25 HORN

Horn output

DO

15kz

BV

26 KEY

Key SW (Control power Power Y supply input) supply (48 V)

50kz

BV

When normal: BV, EMG state: 0 V Horn operates: FETon (Max. 0.6 V) 48 V control power supply input, When key is OFF: 0 V

48Vhigh side input (MP contactor coil current is supplied) NchFET open drain output (Max. 200 V/ 1.5 A) –

LIFT1 LIFT2 TILT DSR DSF KEY

14 OV 15 – 16 LICOM

Lift-1 SW Lift-2 SW Tilt SW Reverse SW Forward SW Key SW (Control power supply input)

17 LINT

OV (For SW input) (Not connected) Lift interrupt command input Lift interrupt SW

18 PB 19 SEAT

Parking SW Seat SW

70-38

0z >500kz 80kz

BY –

Remarks

– – During regeneration: ON when below 0.5 V, Other state: OFF When switch is ON: 0 V

8 9 10 11 12 13

– – Sb

Reference voltReference voltage when age when key switch is ON and control knob switch is ON (V) is operated (V) – – (*1) Voltage applied to multi-controller side 4.4

7 ACCLMT Lifting height SW

– – DO

ResisWire tance color (Terminal – GND)

–

50kz 50kz 50kz

– – NchFET open drain output (Load * 5 V/2 mA/4.7z) OV short: Travel speed is not limited, Open: Travel speed is limited Open: Proportional valve, OV short: Manual valve OV short: Brake operates.

Open: High lifting height (Acceleration limiter operates) When switch is ON: 0 V OV short: Hydraulic chopper operates. When switch is ON: 0 V OV short: Hydraulic chopper operates. When switch is ON: 0 V OV short: Hydraulic chopper operates. When DSR is operated: BV 48Vhigh side input When DSR is operated: BV 48Vhigh side input 48 V control power supply in– put, When key is OFF: 0 V

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (3.0 TON MODEL)

OK: Device operates normally, or it has an error or cannot operate but it will not be broken. NG: Device will be broken or damaged seriously. All or one of codes concerned is displayed. Key ON, SW ALL off" includes disconnection before Key ON. Fault caused by disconnection, etc. Just beWhile When travel While trav- Just before While cargo Code Key Just Pin Confore driv- travel motor is el motor is chopping for handling During con- ON, SW before No. dition ing travel motor is loaded regenerat- cargo hanmotor is EPS cerned ALL off EPS motor driven heavily ing dling motor chopped 1 – – – – – – – – – – – 2 – – – – – – – – – – – 3 OK – OK OK OK OK OK OK OK OK OK

Remarks – – –

4

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

Travel speed is limited.

5

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

6

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

7

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

Proportional valve operation mode is selected. Regenerating brake cannot be applied. High lifting height is limited.

8 9 10 11 12 13

OK OK OK OK OK OK

– – – – – –

OK OK OK OK OK OK

OK OK OK OK OK OK

OK OK OK OK OK OK

OK OK OK OK OK OK

OK OK OK OK OK OK

OK OK OK OK OK OK

OK OK OK OK OK OK

OK OK OK OK OK OK

OK OK OK OK OK OK

Cargo handling lift 1 does not operate. Cargo handling lift 2 does not operate. Cargo handling TILT does not operate. Vehicle does not travel in reverse. Vehicle does not travel forward. Power is not supplied (when CN1-26 is also disconnected).

14 15 16

OK – OK

– – –

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

OK – OK

17

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

18 19

OK OK

– –

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

– – Cargo handling DUTY is limited (when LINT is effective). Cargo handling DUTY is limited (when LICOMis open). – Deadman function is turned ON.

20 21

OK OK

– –

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

OK OK

22

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

23

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

24

OK

32

OK

OK

OK

OK

OK

OK

OK

OK

OK

25

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

26

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

BE30 Series

Monitor mode Cargo handling ATT-1 does not operate. Cargo handling ATT-2 does not operate. Cargo handling ATT-3 does not operate. Cargo handling EGM SW is turned ON. – Power is not supplied (when CN1-13 is also disconnected).

70-39

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

CN2 (22-pole) P board connector Pin No.

Signal name

Contents of signal

Type

ResisReference voltage Wire tance when key switch is color (Terminal ON (V) – GND)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

1 MCTXDP TXD (+)

TXD WL (Source)

∞

(*2) Reference cannot be set.

[Pull-up power supply side: (+) Data transmitted to display side]

2 MCRXDP RXD (+)

RXD W (Source) OV W

∞

(*2) Reference cannot be set. 0

Data received from display

3 PPDA-N Travel speed sensor A (-) 4 PPDA-S Travel speed sensor A Pulse IN (+) 5 ATIN Solenoid valve analogue AIN signal

0z

B

17kz

W

8.4kz

6 PSPT-S Torque sensor (S)

AIN

GW

10kz

7 PSPT-P Torque sensor (+) 8 ACCD-S Travel accelerator VR (S)

PSPT(+) AIN

LY GY

1kz 13.5kz

9 ACCD-P Travel accelerator VR (+) 10 ACCP-S Lift VR, (2) side (S)

ACCD(+) RB

11 ACCP-P Lift VR, (3) side (+)

LTVR(+) YG

12 MCTXD N

TXDO (Sync.)

TXD (-)

13 MCRXD RXD (-) N 14 MCCOM MC communication line shield 15 PCCOM Travel sensor shield 16 ATCOM Solenoid valve shield 17 ATN

–

70-40

YG

(Not connected)

13.5kz

0.4 – 4.6

1kz

4.1 – 4.6

– 850 Hz/ 10 km – –

5V power supply with series R –

5V power supply with series R

VR wiper moves toward (+) side – (Signal increases) o DUTY is increased. When lift SW is OFF: 0.3 – 0.9 V When lift SW is ON: 4.1 – 4.6 V 4.1 – 4.6 5V power supply with series R

OL

∞

(*2) Reference cannot be set.

[Open drain power supply side: Data transmitted to display (-) side]

RXDO B (Sync.) OV (com) BO

∞ 0z

(*2) Reference cannot be set. 0

[Photo coupler anode side: (-) side] 0

OV (com) BW OV (com) BG

0z 0z

0 0

0 0

– –

0z

0

0V

–

200z

∞

0.3 – 0.6 4.4

Solenoid valve GND (0 V) OV

18 PSPT-N Torque sensor (-) 19 AC1 AC1 (Accelerator SW) input 20 ACCD-N Travel accelerator VR, (-) side 21 ACCP-N LIFT VR, (1) side (-) 22

AIN

∞

[Photo coupler anode side: (+) side] Electromagnetic pickup input: Common 0 Electromagnetic pickup input: Signal (*1) Voltage apInput: Min. 4.25 V = DUTY min. plied to multi-con- 100% troller side Max. 1.9 V = DUTY 0% 0.4 – 4.6 If steering wheel is turned to right, VR wiper moves toward PSPT-(-) side (Signal voltage lowers). When steering wheel is turned to right end: 0.3 – 0.6 V When steering wheel is turned to left end: 4.4 – 4.7 V 4.4 – 4.7 4.4 – 4.7 0.3 – 4.7 VR wiper moves toward (+) side (Signal increases) o DUTY is increased. When accelerator is OFF: 0.3 – 0.9 V When accelerator is ON: 3.2 – 4.7 V 5 5

B

PSPT (-) BY DI RL

0.3 – 0.6 When switch is ON: 0 V

OV

YB

0z

0

0V

OV

BW

200z

0.3 – 0.9

0.3 – 0.9

∞

–

–

–

–

Data received from display –

OV with series R OV short: Travel operation permission – OV with series R –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (3.0 TON MODEL)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped OK OK OK OK OK OK OK

OK

OK

Transmission error –

Just before driving travel motor OK

OK

OK

OK

OK

OK

OK

OK

3

OK

41

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41) OK(41) Vehicle cannot travel.

4

OK

41

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41)

OK(41) OK(41) Vehicle cannot travel.

5

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

6

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

7 8

OK OK

54 17

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(17)

OK(54) OK(54) Torque sensor is abnormal. OK(17) OK(17) Travel accelerator is defective.

9 10

OK OK

17 35

OK(17) OK(35)

OK(17) OK(35)

OK(17) OK(35)

OK(17) OK(35)

OK(17) OK(35)

OK(17) OK(35)

OK(17) OK(35)

OK(17) OK(17) Travel accelerator is defective. OK(35) OK(35) Cargo handling lift VR is defective (in manual valve mode)

11

OK

35

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

12

OK

OK

OK

OK

OK

OK

OK

OK

13

OK

Transmission error –

OK(35) OK(35) Cargo handling lift VR is defective (in manual valve mode) OK OK –

OK

OK

OK

OK

OK

OK

OK

OK

OK

–

14

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

Communication error may be made.

15

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

16

OK

–

OK

OK

OK

OK

OK

OK

OK

17

OK

–

OK

OK

OK

OK

OK

OK

OK

18 19

OK OK

54 –

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

OK(54) OK

Travel speed may be sensed wrongly. OK OK Cargo handling chopper DUTY is unstable (in proportional valve mode). OK OK Cargo handling chopper DUTY is unstable (in proportional valve mode). OK(54) OK(54) Torque sensor is abnormal. OK OK Vehicle does not travel.

20

OK

17

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17)

OK(17) OK(17) Travel accelerator is defective.

21

OK

35

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

OK(35)

22

–

–

–

–

–

–

–

–

–

OK(35) OK(35) Cargo handling lift VR is defective (in manual valve mode) – – –

Pin ConNo. dition 1

OK

2

Code Key conON, SW cerned ALL off

BE30 Series

OK

OK

Remarks – –

– PS cannot operate.

70-41

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

CN3 (4-pole) relay connector: For power supply Pin Signal No. name 1 2 3 4

Contents of signal

Chassis power supply for control + (+48 V) Chassis power supply for control Chassis power supply for control + (+48 V) Chassis power supply for control -

Type

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

VB48

W

7.8kz

BV

BV

–

VBVB48

B W

0z 7.8kz

0V BV

0V BV

– –

VB-

B

0z

0V

0V

–

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

CN4 (2-pole) relay connector: EPS motor (B) Pin No.

Signal name

Contents of signal

Type

ResisWire tance color (Terminal – GND)

1

EPS motor drive

P24

R

24kz

Unsettled

2

EPS motor drive

P23

B

24kz

Unsettled

CN5 (4-pole) relay connector: EPS motor (B) Pin Signal No. name

Contents of signal

Type

Fluctuation when EPS rotates to Motor current direction when steerleft: 0 – BV ing wheel is turned to right CN4-2 o CN4-1 Fluctuation when EPS rotates to [= P23 o P24] right: 0 – BV

For only this case, connect CN5-4 to red rod (0 V) of multimeter and connect terminal to be measured to black rod (+ side).

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

1 2 3

+VC power supply (+10 V ± 5%) OV Sensor output

+VC GND OUT

R B W

7.3kz 0z 5.6kz

10.2V 0V 0.6V

4

OV

GND

B

X

0V

Reference voltage when switch is ON and control knob is operated (V)

Remarks

10.2V 0V Varies with battery current (0.6 – 8.6 Vmax) 0V

– – – –

CN11 (16-pole) P board connector Pin Signal No. name 1 – 2 – 3 DMTH -N 4 DMTH -S 5 PPDBN 6 PPDBS 7 – 8 – 9 – 10 – 11 – 12 – 13 PPDBCOM 14 – 15 – 16 –

70-42

Contents of signal (Not connected) (Not connected) Travel motor temperature (-) Travel motor temperature (S) Travel speed sensor B (-)

Type – –

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

– – 0

– – 0

– – –

0z

0V

– – GY

AIN

LO

5.5kz

0V

W

0z

Approx. 3.48 (at 25°C) 0

B

16.5kz

0

– – – – – – BW

6.2kz

– – – – – – 0

– – –

6.2kz

Travel speed sensor B (+) Pulse IN (Not connected) – (Not connected) – (Not connected) – (Not connected) – (Not connected) – (Not connected) – Travel sensor shield 0V (COM) (Not connected) – (Not connected) – (Not connected) –

∞

0z

∞

0z

∞

0z 5.5z 0z

∞ ∞

– – –

Varies with temperature (0.2 – 4.8). Electromagnetic pickup input: Common Electromagnetic pickup input: Signal – – – – – – 0 – – –

– – 850 Hz/10 km – – – – – – – – – –

BE30 Series

TROUBLESHOOTING

Code Key Pin Concon- ON, SW No. dition cerned ALL off 1

OK

–

OK

2 3

OK OK

– –

OK OK

4

OK

–

OK

Pin ConNo. dition

Code Key conON, SW cerned ALL off

1

OK

50

OK(50)

2

OK

50

OK(50)

VOLTAGE CHECK TABLE (3.0 TON MODEL)

Fault caused by disconnection, etc. Just beWhile When travel Just before While cargo While travel Just before drivtravel motor is chopping for handling During motor is refore Remarks ing travel motor is loaded cargo hanmotor is EPS generating EPS motor driven heavily dling motor chopped OK OK OK OK OK OK OK OK Power is not supplied (when CN3-3 is also disconnected). OK OK OK OK OK OK OK OK – OK OK OK OK OK OK OK OK Power is not supplied (when CN3-3 is also disconnected). OK OK OK OK OK OK OK OK –

Fault caused by disconnection, etc. Just beWhile When travel Just before While cargo While travel Just before drivtravel motor is chopping for handling During motor is refore Remarks ing travel motor is loaded cargo hanmotor is EPS generating EPS motor driven heavily dling motor chopped OK OK OK OK OK OK OK OK Opening of EPS transistor is detected wrongly. Operation of PS is defective. OK OK OK OK OK OK OK OK Opening of EPS transistor is detected wrongly. Operation of PS is defective.

Fault caused by disconnection, etc. Just beWhile When travel While travel Just before While cargo Just beCode Key Pin Confore drivtravel motor is for handling During con- ON, SW ing motor is re- chopping fore No. dition cerned travel motor is loaded motor is EPS ALL off generating cargo hanEPS motor driven heavily dling motor chopped 1 [Since this connector is used/controlled on multimeter side, ask the section in charge of your company.] 2 3

Remarks –

4

Fault caused by disconnection, etc. Just beWhile When travel While travel Just before While cargo Just beCode Key Pin Confore drivtravel motor is for handling During con- ON, SW ing motor is re- chopping fore Remarks No. dition cerned travel motor is loaded cargo hanmotor is EPS ALL off generating EPS motor driven heavily dling motor chopped 1 – – – – – – – – – – – – 2 – – – – – – – – – – – – 3 OK 27 OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) Travel motor temperature sensor is defective (Vehicle can travel). 4 OK 27 OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) Travel motor temperature sensor is defective (Vehicle can travel). 5 OK 42 OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) OK(42) Vehicle cannot travel. 6

OK

42

OK(42)

OK(42)

OK(42)

OK(42)

OK(42)

OK(42)

OK(42)

7 8 9 10 11 12 13

– – – – – – OK

– – – – – – –

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

– – – – – – OK

14 15 16

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

BE30 Series

OK(42) OK(42) Vehicle cannot travel. – – – – – – Travel speed may be sensed wrongly. – – –

70-43

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

CN7 (12-pole) P board connector Pin Signal No. name

Contents of signal

Type

ResisWire tance color (Terminal – GND)

Reference voltage when key switch is ON (V)

Reference voltage when switch is ON and control knob is operated (V)

10.3kz

0

∞ ∞ ∞

– – – Approx. 4.05 (at 25°C) Approx. 4.05 (at 25°C) 0

When EPS operates: Varies largely with "ON" period ratio of chopper – – – Varies with temperature (0.2 – 4.8). Varies with temperature (0.2 – 4.8). 0

–

Remarks

1 SH+

Shunt resistance for detect- AIN ing EPS current, (+) side

Y-L

2 – 3 – 4 – 5 THD+

(Not connected) – (Not connected) – (Not connected) – Travel controller tempera- AIN ture sensor Cargo handling controller AIN temperature sensor Shunt resistance for detect- OV ing EPS current, (-) side

– – – W-BR

5.3kz

W-L

5.3kz

G-W

9.3kz

∞ ∞

OV

– – – GR

0z 0z

– – – 0V

– – – 0V

– – – –

OV

GR

0z

0V

0V

–

Reference voltage when switch is ON and control knob is operated (V)

Remarks

6 THP+ 7 SH-

8 – 9 – 10 – 11 HTD12 THP-

(Not connected) (Not connected) (Not connected) Travel controller temperature sensor 0 V Cargo handling controller temperature sensor 0 V

– – –

– – – – – –

CN4 (16-pole) P board connector Pin Signal No. name

Contents of signal

Type

Wire color

ResisReference volttance age when key (Terminal switch is ON (V) – GND)

1 P22

Main circuit: Secondary side of MPS contactor

AIN

W-G

80kz

BV

2 P3

Main circuit: Secondary side of fuse F1

AIN

BR

33kz

BV

3 P4

Main circuit: Output termi- AIN L nal of U-phase power module 4 – (Not connected) – – 5 MD (+) MD contactor coil power Power Y-R supply (+) supply (BV48) 6 MPS (+)

MPS contactor coil power supply (+)

7 – 8 P1

(Not connected) Main circuit voltage (P1)

9 P21

Main circuit: Secondary side of EPS fuse F3 Main circuit: (PA) side of cargo handling motor

49.8kz

Before MPS contactor is turned ON: Approx. 53 V (When BV = 48 V) After MPS contactor is turned ON: BV Before MD contactor is turned ON: 0 V – 47 V After MD contactor is turned ON: BV

–

Before key SW is turned ON: 0 V – 47 V (When BV = 72 V) After key SW is turned ON: Boosting charging until MD contactor is turned ON Approx. 24.5 V Varies largely when inverter oper- Vehicle stops, direction lever in neuates. tral, and accelerator is OFF.

∞ ∞

– BV

– When chassis EMGsw operates: 0 V, When normal: BV

– –

∞

BV

BV

–

Power R-L supply (BV48) – – AIN R

9.2kz

∞

– BV

– BV

– –

AIN

W-R

80kz

BV

BV

–

AIN

L-R

45kz

(*3)

11 – 12 – 13 MD

(Not connected) – – (Not connected) – – MD contactor coil drive FET OPEND Y-G drain

45kz 45kz

∞

– – BV

14 MPS

MPS contactor coil drive FET drain

45kz

BV o 0.2V

15 – 16 N1

(Not connected) – OV for contactor coil drive OV circuit

∞

– –

10 P13

70-44

OPEND R-W

– B

0z

Before MP contactor is turned ON: 0 Before key SW is turned ON: 0 V – V – 47 V 47 V (When BV = 72 V) After MP contactor is turned ON: After key SW is turned ON: Boosting a) While cargo handling chopper is charging until MP contactor is stopped: Approx. BV turned ON b) While cargo handling chopper is operating: Varies with "ON" period ratio. Not fixed. – – – – – When MP contactor is turned OFF: BV When chassis EMGsw operates: 0 V, When normal: BV When MP contactor is turned ON: BV x 75% (*4) When key SW is turned ON – (When MPS contactor is turned OFF): BV When MPS contactor is turned ON: 0.2 V – – – –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (3.0 TON MODEL)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped OK OK OK OK OK OK OK EPS overcurrent is detected wrongly. PS is impossible.

1

OK

–

OK

Just before driving travel motor OK

2 3 4 5

– – – OK

– – – 22

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

6

OK

36

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

7

NG

50

OK

OK

OK

OK

OK

OK

OK

8 9 10 11

– – – OK

– – – 22

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

– – – OK(22)

12

OK

36

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

OK(36)

Pin ConNo. dition

Code Key conON, SW cerned ALL off

– – – – – – – – – OK(22) OK(22) Temperature sensor is defective (Vehicle can travel). OK(36) OK(36) Temperature sensor is defective (Vehicle can handle cargo). OK NG EPS current detector operates wrongly. EPS transistor is broken. PS is impossible. – – – – – – – – – OK(22) OK(22) Temperature sensor is defective (Vehicle can travel). OK(36) OK(36) Temperature sensor is defective (Vehicle can handle cargo).

Fault caused by disconnection, etc. While When travel While travel Just before While cargo Just betravel motor is for handling During motor is re- chopping fore motor is loaded cargo hanmotor is EPS generating dling EPS driven heavily motor chopped OK(52) OK(52) OK(52) OK(52) OK(52) OK(52) OK(52)

1

OK

52

OK(52)

Just before driving travel motor OK(52)

2

OK

20

OK(20)

OK(20)

OK(20)

OK(20)

OK(20)

OK(20)

OK(20)

3

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

4 5

– OK

– 7

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

– OK(7)

6

OK

53

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

7 8

– OK

– OK(21)

– OK(21)

– OK(21)

– OK(21)

– OK(21)

– OK(21)

– OK(21)

9

OK

– 21, 45, 56, 50 52

OK

OK

OK

OK

OK

OK

OK

10

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

11 12 13

– – OK

– – 7

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

– – OK(7)

14

OK

53

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53)

OK(53) OK(53) Short circuit of EPS drive TR is detected wrongly. PS is impossible.

15 16

– OK

– –

– OK

– OK

– OK

– OK

– OK

– OK

– OK

Code Key Pin Concon- ON, SW No. dition cerned ALL off

BE30 Series

OK(20) OK(20)

Remarks –

–

–

– Short circuit of MD contactor drive TR is detected wrongly. Defective contactor is detected wrongly. Vehicle cannot travel or handle cargo. OK(53) OK(53) Short circuit of EPS drive TR is detected wrongly. PS is impossible. – – – OK(21) OK(21) – OK(52) OK(52)

– OK

– OK

– –

– – Short circuit of MD contactor drive TR is detected wrongly. Defective contactor is detected wrongly. Vehicle cannot travel or handle cargo

– –

70-45

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

CN5 (22-pole) P board connector Pin No.

Signal name

Contents of signal

1 – (Not connected) 2 – (Not connected) 3 CSDU(+) Travel U-phase current detector power supply, (+) side 4 CSDU(S) Travel U-phase current detector power supply, signal side 5 CSDW(+) Travel W-phase current detector power supply, (+) side 6 CSDW(S) Travel W-phase current detector power supply, signal side 7 – (Not connected) 8 – (Not connected) 9 – (Not connected) 10 – (Not connected) 11 P2 Main circuit: Secondary side of MD contactor 12 – (Not connected) 13 – (Not connected) 14 CSDU(-) Travel U-phase current detector power supply, OV side 15 CSDU(-) Travel U-phase current detector power supply, OV side 16 CSDW(-) Travel W-phase current detector power supply, OV side 17 CSDW(-) Travel W-phase current detector power supply, OV side 18 – (Not connected) 19 – (Not connected) 20 – (Not connected) 21 – (Not connected) 22 P12 Main circuit: Secondary side of cargo handling fuse F2

70-46

Type

ResisReference voltWire tance age when key color (Terminal switch is ON (V) – GND)

Reference voltage when switch is ON and control knob is operated (V)

Remarks

– – 15

– – –

– – Power supply

– – R-B

1.6kz – 1.6kz

– – 15

AIN

O

10.8kz

7

Power supply

R-B

1.6kz

15

AIN

P

10.8kz

7

1.6kz 10.8kz 1.6kz 10.8kz 80kz

– – – – BV

– – – – BV

– – – –

OV

– – GR

0z 0z 0z

– – 0

– – 0

– – –

OV

GR

0z

0

0

–

OV

GR

0z

0

0

–

OV

GR

0z

0

0

–

– – – – AIN

– – – – L-W

0z 0z 0z 0z 80kz

– – – – BV

– – – – BV

– – – – –

– – – – AIN – –

– – – – Y

Varies with motor current: 3.0 – 11.0 Vmax 15 Varies with motor current: 3.0 – 11.0 Vmax

– – –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (3.0 TON MODEL)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped – – – – – – – – – – – – – – – – OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

1 2 3

– – OK

– – 19

– – OK(19)

Just before driving travel motor – – OK(19)

4

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

5

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

6

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel.

7 8 9 10 11

– – – – OK

– – – – –

– – – – OK

– – – – OK

– – – – OK

– – – – OK

– – – – OK

– – – – OK

– – – – OK

12 13 14

– – OK

– – 19

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

– – OK(19)

15

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

16

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

17

OK

19

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

OK(19)

18 19 20 21 22

– – – – OK

– – – – 33

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

– – – – OK(33)

Pin ConNo. dition

Code Key conON, SW cerned ALL off

BE30 Series

– – – – OK

– – – – OK

– – – – –

– – – – – – OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. OK(19) OK(19) Travel current detector is defective. Vehicle cannot travel. – – – – – – – – – – – – OK(33) OK(33) –

70-47

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

CN3R (26-pole) P board connector Pin Signal No. name

Contents of signal

Type

Wire color

ResisReference volttance age when key (Terminal switch is ON (V) – GND)

Gate power supply DO

R-B

∞

11 – 13 (At CN3R-4)

W-L

∞

11 – 13 (At CN3R-4)

DO

L-W

∞

11 – 13 x 0.85 (At CN3R-4)

–

GR-B

∞

–

–

W-B

∞

–

DO

G-W

∞

11 – 13 x 0.85 (At CN3R-5)

7 GV1D

Travel V-phase (Upper FET DO of TMDV) gate signal 1

W-G

∞

11 – 13 (At CN3R-5)

8 VVD

Travel V-phase (Upper FET Gate of TMDV) gate power signal power supply (Not connected) – Travel U-phase (Upper FET – of TMDU) source Travel U-phase (Upper FET DO of TMDU) gate signal 2

R-W

∞

11 – 13 (At CN3R-5)

– GR

∞ ∞

–

G-Y

∞

11 – 13 x 0.85 (At CN3R-10)

1 WVD

Travel W-phase (Upper FET of TMDW) gate power supply 2 GW1D Travel W-phase (Upper FET of TMDW) gate signal 1 3 GW2D Travel W-phase (Upper FET of TMDW) gate signal 2 4 W0D Travel W-phase (Upper FET of TMDW) source 5 V0D Travel V-phase (Upper FET of TMDV) source 6 GV2D Travel V-phase (Upper FET of TMDV) gate signal 2

9 – 10 U0D 11 GU2D 12 GU1D

Travel U-phase (Upper FET DO of TMDU) gate signal 1

Y-G

∞

11 – 13 (At CN3R-10)

13 UVD

Travel U-phase (Upper FET of TMDU) gate power supply Travel Z-phase (Lower FET of TMDW) gate power supply Travel Z-phase (Lower FET of TMDW) gate signal 1

R-Y

∞

11 – 13 (At CN3R-10)

R-L

∞

11 – 13 (At CN3R-17)

O

∞

11 – 13 (At CN3R-17)

14 ZVD 15 GZ1D

Gate power supply Gate power supply DO

16 GZ2D

Travel Z-phase (Lower FET DO of TMDW) gate signal 2

Y

∞

11 – 13 x 0.85 (At CN3R-17)

17 Z0D

Travel Z-phase (Lower FET – of TMDW) source Travel Y-phase (Lower FET – of TMDV) source Travel Y-phase (Lower FET DO of TMDV) gate signal 2

B

0z

–

B

0z

–

L

∞

11 – 13 x 0.85 (At CN3R-18)

20 GY1D

Travel Y-phase (Lower FET DO of TMDV) gate signal 1

G

∞

11 – 13 (At CN3R-18)

21 YVD

Travel Y-phase (Lower FET of TMDV) gate power supply (Not connected) Travel X-phase (Lower FET of TMDU) source Travel X-phase (Lower FET of TMDU) gate signal 2

R-L

∞

11 – 13 (At CN3R-18)

18 Y0D 19 GY2D

Gate power supply – –

B

0z

∞

– –

DO

W

∞

11 – 13 x 0.85 (At CN3R-23)

25 GX1D

Travel X-phase (Lower FET DO of TMDU) gate signal 1

P

∞

11 – 13 (At CN3R-23)

26 XVD

Travel X-phase (Lower FET Gate of TMDU) gate power sup- power ply supply

R-L

∞

11 – 13 (At CN3R-23)

22 – 23 X0D 24 GX2D

70-48

–

Reference voltage when switch is ON and control knob is operated (V) 11 – 13 (At CN3R-4)

Remarks –

When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. Measurement is impossible be– cause of floating Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-5) – – Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-10) 11 – 13 (At CN3R-17)

–

When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. Measurement is impossible be– cause of floating Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 – 13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-18) – – Measurement is impossible be– cause of floating When FRSW and accelerator are When FRSW or accelerator is turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON" period ratio. When FRSW and accelerator are When FRSW or accelerator is turned OFF: 11 –13 V turned ON: Varies largely with "ON" period ratio. 11 – 13 – (At CN3R-23)

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (3.0 TON MODEL)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped NG NG NG NG NG NG NG

1

NG

Many

NG

Just before driving travel motor NG

2

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

3

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

4

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

5

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

6

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

7

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

8

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

9 10

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– –

11

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

12

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

13

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

14

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

15

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

16

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

17

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

18

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

19

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

20

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

21

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

22 23

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– –

24

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

25

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

26

NG

Many

NG

NG

NG

NG

NG

NG

NG

NG

NG

–

Pin ConNo. dition

Code Key conON, SW cerned ALL off

BE30 Series

Remarks – –

–

–

70-49

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

CN4R (12-pole) P board connector Pin Signal No. name 1 U0P 2 GU2P 3 GU1P 4 UVP 5 – 6 – 7 X0P 8 GX2P 9 GX1P 10 XVP 11 12

– –

70-50

Contents of signal

Type

Cargo handling U-phase – (Upper FET of TMP) source Cargo handling U-phase DO (Upper FET of TMP) gate signal 2 Cargo handling U-phase DO (Upper FET of TMP) gate signal 1 Cargo handling U-phase Gate (Upper FET of TMP) gate power power supply supply (Not connected) – (Not connected) – Cargo handling X-phase – (Lower FET of TMP) source DO Cargo handling X-phase (Lower FET of TMP) gate signal 2 Cargo handling X-phase DO (Lower FET of TMP) gate signal 1 Cargo handling X-phase Gate (Lower FET of TMP) gate power power supply supply (Not connected) – (Not connected) –

ResisWire tance Reference voltage when key switch color (Terminal is ON (V) – GND)

Reference voltage when switch is ON and control knob is operated (V)

GR

∞

–

G-Y

∞

11 – 13 (At CN4R-1)

Y-G

∞

11 – 13 (At CN4R-1)

11 – 13 (At CN4R-1)

R-Y

∞

11 – 13 (At CN4R-1)

11 – 13 (At CN4R-1)

– –

∞ ∞

– – –

Measurement is impossible because of floating 11 – 13 (At CN4R-1)

– – Measurement is impossible because of floating 11 – 13 x 0.85 (At (*3) CN4R-7)

Remarks – Normally OFF Normally OFF – – – –

B

0z

W

∞

P

∞

11 – 13 (At CN4R-7)

R-L

∞

11 – 13 (At CN4R-7)

11 – 13 (At CN4R-7)

–

– –

0z

∞

– –

– –

– –

(*3)

– –

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (3.0 TON MODEL)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just betravel motor is chopping for handling During motor is refore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped NG NG NG NG NG NG NG Cargo handling power module (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) is broken, shorted, or open. NG NG NG NG NG NG NG Cargo handling power module (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) is broken, shorted, or open.

NG (30, 31) NG (30, 31)

Just before driving travel motor NG (30, 31) NG (30, 31)

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

NG

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

5 6 7

– – NG

– – 30, 31

8

NG

30, 31

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – NG (30, 31) NG (30, 31)

– – – – NG NG (30, 31) (30, 31) NG NG (30, 31) (30, 31)

9

NG

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

10

NG

30, 31

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG (30, 31)

NG NG Cargo handling power module (30, 31) (30, 31) is broken, shorted, or open.

11 12

– –

– –

– –

– –

– –

– –

– –

– –

– –

Pin ConNo. dition

Code Key conON, SW cerned ALL off

1

NG

30, 31

2

NG

30, 31

3

NG

4

BE30 Series

– –

– –

– – Cargo handling power module is broken, shorted, or open. Cargo handling power module is broken, shorted, or open.

– –

70-51

VOLTAGE CHECK TABLE (3.0 TON MODEL)

TROUBLESHOOTING

CN8R (22-pole) P board connector Pin Signal No. name

Contents of signal

Type

1 N1

OV

OV

2 3 N1

(Not connected) OV

OV

4 5 VB4B

(Not connected) Control power supply during kickback + MPS contactor power supply (Not connected) EPS transistor (Upper side of TMPS2) gate signal

6 7 G3

ResisWire tance Reference voltage when key switch is color (Terminal ON (V) – GND) B

0

0

–

0z 0z

– 0

– 0

– –

∞

– BV

– BV

– –

W

∞ ∞

– 15V (At CN8R-18)

– B

– R

80kz –

8 G4

EPS transistor (Lower side DO of TMPS2) gate signal

G

50kz

9 G1

EPS transistor (Upper side DO of TMPS1) gate signal

Y

∞

10 G2

EPS transistor (Lower side DO of TMPS1) gate signal

GR-B

11 12 N1

(Not connected) OV

OV

13 14 N1

(Not connected) OV

OV

15 16 17 18 E3

(Not connected) (Not connected) (Not connected) EPS transistor (Upper side of TMPS2) emitter signal EPS transistor (Lower side of TMPS2) emitter signal EPS transistor (Upper side of TMPS1) emitter signal EPS transistor (Lower side of TMPS1) emitter signal (Not connected)

19 E4 20 E1 21 E2 22

Remarks

5.5kz

–

– Power supply (48 V) – DO

Reference voltage when switch is ON and control knob is operated (V)

–

– B

–

∞

5.5kz

– B

– – –

56kz

– – –

– When EPS operates: 0 V – 12 V (Varies largely with "ON" period ratio of chopper) (*3) 0 (At CN8R-19) When EPS operates: 0 V – 12 V (Varies largely with "ON" period ratio of chopper) (*3) 15V When EPS operates: 0 V – 12 V (At CN8R-20) (Varies largely with "ON" period ratio of chopper) (*3) 0 (At CN8R-21) When EPS operates: 0 V – 12 V (Varies largely with "ON" period ratio of chopper) (*3) – – 0 0

– – – – – – –

5.5kz 0z

– 0

– 0

– –

∞ ∞ ∞

– – – 0 (At CN8R-7)

– – – (*3)

– – – –

80kz

DO

O

DO

W-L

>500kz

0 (At CN8R-8)

(*3)

–

DO

L-R

∞

0 (At CN8R-9)

(*3)

–

DO

G-W

>500kz

0 (At CN8R-10)

(*3)

–

∞

–

–

–

–

–

(*1) While the vehicle is not regenerating, the source voltage supplied by the multi-controller is the reference voltage. (*2) A reference value cannot be set since the serial communication line is used. (*3) A reference value cannot be set since the voltage varies largely with the outputting condition ("ON" period ratio) while FED and IGBT are in operation. (*4) Since the voltage is chopped, the reference value is about 75% of the battery voltage used as the control power supply. The measured value may depends on the multimeter used.

70-52

BE30 Series

TROUBLESHOOTING

VOLTAGE CHECK TABLE (3.0 TON MODEL)

Fault caused by disconnection, etc. While When travel Just before While cargo While travel Just travel motor is chopping for handling During motor is rebefore Remarks motor is loaded cargo hanmotor is EPS generating EPS driven heavily dling motor chopped NG NG NG NG NG NG NG When CN8R-12 is also disconnected, connector may be broken. OK OK OK OK OK OK OK If only this line is disconnected, there is no problem. – – – – – – – – NG NG NG NG NG NG NG When CN8R-14 is also disconnected, connector may be broken. OK OK OK OK OK OK OK If only this line is disconnected, there is no problem. – – – – – – – – OK OK OK OK OK OK OK PS kickback operation is impossible.

NG

Many

NG

Just before driving travel motor NG

OK

–

OK

OK

– NG

– Many

– NG

– NG

OK

–

OK

OK

4 5

– OK

– –

– OK

– OK

6 7

– NG

– 50

– OK

– OK

– OK

– OK

– OK

– OK

– OK

– OK

– NG

– EPS transistor is broken. PS is impossible.

8

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

NG

EPS transistor is broken. PS is impossible.

9

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

NG

EPS transistor is broken. PS is impossible.

10

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

NG

EPS transistor is broken. PS is impossible.

11 12

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

– NG

– Many

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

– NG

OK

–

OK

OK

OK

OK

OK

OK

OK

OK

OK

15 16 17 18

– – – NG

– – – 50

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

– – – OK

19

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

OK

20

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

OK

21

NG

50

OK

OK

OK

OK

OK

OK

OK

OK

OK

22

–

–

–

–

–

–

–

–

–

–

–

– When CN8R-1 is also disconnected, connector may be broken. If only this line is disconnected, there is no problem. – When CN8R-3 is also disconnected, connector may be broken. If only this line is disconnected, there is no problem. – – – EPS transistor is broken. PS is impossible. EPS transistor is broken. PS is impossible. EPS transistor is broken. PS is impossible. EPS transistor is broken. PS is impossible. –

Pin ConNo. dition 1

2 3

13 14

Code Key conON, SW cerned ALL off

BE30 Series

70-53

TROUBLESHOOTING

CIRCUIT DIAGRAM

ELECTRIC CIRCUIT DIAGRAM

7

1 2 CNPDB

13 5 6 3 4

(+) (SIG)

7 6

YB

AUTO LIFT CONTROLLER

LIFT VR (ACCELERATOR)

(-)

(SIG)

TORQUE SENSOR (2.18KΩ ±0.45KΩ)

(SIG) (-)

(+) UP

9

RL

TRAVEL ACCELERATOR POT (4KΩ ±1.2KΩ)

ACCELERATOR SWITCH SOLENOID VALVE GND

W B SHIELD

BG B

2

OL WL

SOLENOID VALVE ANALOG SIGNAL

RXD(-) DATA RECEIVED RXD(+) FROM DISPLAY

14

BO

15

TXD(-) DATA SENT TXD(+) TO DISPLAY

BW

SHIELD

(-) SOLENOID P.P. TRAVEL SPEED SENSOR A (TRAVEL MOTOR)

SHIELD

3

W

DISPLAY

REGENERATING STATUS SIGNAL

B 4

(+)

1 2 CNPDA

5 17 16 13

(-)

(+) UP

18 10 11 21

GY

20

4 14 15 16 17

CN2

25

HORN OUTPUT

HORN SWITCH (MANUAL)

3 LOAD GATE POWER SUPPLY EPS GATE POWER SUPPLY

POWER SUPPLY CIRCUIT CN6R CN8R (POWER SUPPLY BOARD)

9

ATT-1 SWITCH

GR

TILT SWITCH

LR

LIFT-2 SWITCH

17

8

LIFT-1 SWITCH

YR

LIFT INTERRUPT SWITCH

BrW

LIFT INTERRUPT COMMAND

Y

LIFT HEIGHT SWITCH TRAVEL SPEED-2 SWITCH

6

RY

14

20

19

18

5

CONTROL VALVE SELECTION O

12

24

5V

13

11

15V

CN9

BRAKE SWITCH PARKING SWITCH

Gr

SEAT SWITCH SWITCH MONITOR STARTING SWITCH 0V (SW)

P Br

HYDRAULIC CONTACTOR

LB L

DSF

WB

DSR

Y Y

CN1E

B 4

GND

W

OUT

3

EPS GATE CONTROL

2

B

GND

R

+Vc

CN5 B 4

CN6

-

L L L L L

1 2 3 5 4

1 2 3 5 4

3

W 5V

B

B 2

5V

W 1

L L L L L L L L L L L L L L L L

(Key)

CN1 GATE IC 2 4 6 8 10 12 14 16 9 11 13 15 7 5 3 1

CONTROL POWER SUPPLY (8V, 18V)

BO

BY

26

CN1R

13 14 7 3 4 5 8 9 10 11 1 2 6

13 14 7 3 4 5 8 9 10 11 1 2 6

LOAD IC GATE CIRCUIT

7 8 1 10 9 2

Y B B B B R-Y L W-B W-L R-B O P R

16

CN8

HORN

ATT-2 SWITCH

LR

7

LOAD GATE CONTROL

ATT-3 SWITCH

4

3

3

ON/OFF INTPUT CIRCUIT

GXP

+

LO GO

-

23 22 21 10

8 10 12 6 4

6 2

4

TRAVEL IC GATE CIRCUIT

2

8 10 12

3 5 21 20 19 18 6 7 13 12 11 10 26 25 24 23 8

TRAVEL GATE POWER SUPPLY

5V

TRAVEL GATE POWER SUPPLY

1 12 3 14

OPEN DRAIN

GZD GWD GYD TRAVEL GVD GATE GXD CONTROL GUD

FAN POWER SUPPLY CIRCUIT

3 5

E2

E1 G2

G1 CPS

CN2R

2 4 6 8 10 12 14 16 9 11 13 15 7 5 3 1

TMPS2 SH TMPS1

2

1

G-W GR-B L-R Y R

L L L L L L

4

E4

E3 G4 4 P P 23 24

(P22)

(P21)

3

F3

MPS

G3

F4 R B (P1) CSB

BW

5V

L

CN4R W O G W-L

YG

W OPEN DRAIN

CLOCKWISE ROTATION

Sb

LOAD GATE POWER SUPPLY

9 20 10 21 19 8 18 7

TMP

B W P R-L GR G-Y Y-G R-Y

ON/OFF OUTPUT CIRCUIT

(2ton)

CN7R

CN3R 1110 9 8 7 5 4 3 2 1

PB CH CN4

5V

5V

1

OUT (P4) OUT (P13)

CBP

TMDU

F1 (P3) (P12)

MD (P2)

F2

PA

R-Y

1

BY YG

19

15V

2

DV DU

B L G R-L W-B G-W W-G R-W B W P R-L GR G-Y Y-G

1110 9 8 7 5 4 3 2 1

+

LY

12

PHASE U CURRENT

SOLENOID P.P. TRAVEL SPEED SENSOR B (TRAVEL MOTOR) TEMPERATURE SENSOR B (TRAVEL MOTOR)

GW

1

CPU + PERIPHERAL CIRCUIT

(-) (+)

8

1 14 6 13 5 3 9 16 8 1 10 2

PHASE W CURRENT

OUT (P5) TMDV DW

B Y O R-L GR-B L-W W-L R-B

B B B B

-

LO

SHIELD

RB

5V

R R B B 2 1 7 8

1110 9 8 7 5 4 3 2 1

2

PSM I Batt. 48V

BE30 Series

GY

COUNTER INPUT

DIM PM

EPS MOTOR CLOCKWISE ROTATION

B

THERMISTOR

5V

CN4

CN5

4 3 2 1

W

CN11

5V

ANALOG INPUT CIRCUIT

OUT (P6)

1110 9 8 7 5 4 3 2 1

BW

1

TMDW

4 3 2 1

Y L-W GR P GR R-B GR O GR R-B

3 14 4 15 5 16 6 17 22 11

CBD

L R B W-R BR L-R W-G

[COIL CHOPPER]

ANALOG INPUT CIRCUIT

2 2 2

MPS

MD

2

Y-R Y-G R-L R-W

COMMUNICATION CIRCUIT

1 1

CONTACTOR DRIVE CIRCUIT

THP THD

1

MD

CN7

1

MPS

EPS CURRENT

11 5 12 6

1 1

(2ton)

3

G-W Y-L W-L GR W-BR GR

FAN

3

1. CONTROLLER(1.0 - 2.5 TON MODELS)

CN3

EPS GATE POWER SUPPLY

CN2E

[EPS BOARD]

W (VB48)

FUSE

EMERGENCY SWITCH KEY SWITCH

[CPU BOARD]

70-55

TROUBLESHOOTING

CIRCUIT DIAGRAM

2. CONTROLLER(3.0 TON MODEL)

BE30 Series

70-57

BE30 Series Clearance lamp (L)/5W

External relay RG B 0.85RG 1 0.85B 2 0.85WL BK1 1 0.85B BC4A 2

R Y B 0.85GL 1 0.85RW 2 0.85B 3 GL GK2 3 RW CK1 4

Spare 2 1

4 2 1 3 0.85B BC5A 0.85YR IK1

0.85YR IK1 0.85WG DK4 0.85Y HA6 0.85B BC6A

Tilt potentiometer

2kΩ

2kΩ

2kΩ

VB(+) TXD(+) TXD(-)

B G

Meter panel RIGHT

2 1

3

2

0.85G 0.85G 0.85R 0.85R

15A

10A

QB2 QB1 RB1 SB1 TB1

G JK1 WG DK7

BY JA9 O PA1

FD1

1.25W AC1 1 0.85RW GD1 2 0.85WR KK1 3 0.85WG DK1 4

0.85BrY

P QA1

BY JA8 2 RY AA2 1

3 1 4 2

GY DL1A 1 LO EL1A 2

BY

0.85Br

YB YB RL GY RB

RB HD1

0.85BG EJ1

HA7 EF1 FF1 GF1 HF1 IF1 EJA

OB1A 1 W MB1A 2 B NB1A CL1A 1 W AL1A 2 B BL1A

5 4 3 6 2 1

JA7 BY

JA2A

Y BR YG LB WR BY BG

EF3 RW GD3 W BF1 B CF1

BY JB1 3 GW KB1 2 LY LB1 1 4 5 6

12 9 8 7 1 10 11 3 5 4 2 6

RB CJ1 RG BJ1 RL AJ1

-

ASSSH 2SH050 BR

SHIELD WIRE

RL Y Gr Br L WB Br LO LR GR GO BO

AD1 HA4 KA1 JA1 MA1 LA1 JA3 RA2 EA1 DA1 FA2 GA2

12 25 3 4 15 16 28 8 7 23 24 1 30 BC4 0.85BL 33 BC3 0.85BL 34 CA1 Sb 18 BA1 BrW 27 AA1 RY 19 31 32 ED1 0.85LY 26 FD1 0.85BrY 17 GD2 0.85RW 9 GD1 0.85RW 10 HD1 RB 11 ID1 0.85YB 2 DB1A WL 5 CB1A OL 6 BB1A W 13 AB1A B 14 EB2A EB3A 29 JD1A R 20 KD1A W 21 LD1A B 22 LD4 AF1 PB 7 BF1A W 1 CF1A B 2 6 5 DF1 0.85YR 4 EF1 BR 16 FF1 YG 10 GF1 LB 9 HF1 WR 8 IF1 BY 15 14 13 12 3 11 AG3 AG1 R 4 BG1 W 9 CG1 B 5 DG1 Y 6 EG1 G 7 2 FG1 LB 1 FG2 LB 10 FG1 LB 14 GG1 Lg 8 HG1 BR 28 3 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27

Br W L LgB G PL Sb R LW GW BW

AE1 BE1 CE1 DE1 FE1 GE1 HE1 IE1 JE1 KE1 LE1

21 14 16 15 17 9 10 11 3 4 5 20 ME1 WG 6 NE1 GY 13 18 12 8 OE1 VW 7 PE1 GrR 2 QE1 GrL 1 RE1 Gr 19 SE1 P 22

HI1 LY

GI1 LW

FI1 RL

EI1 RW

DI1 RY

AI1 RB BI1 L CI1 BY

7 8 9 12 13 16 17 20 21 22 23 24 25 26 27 28 1 2 3 4 6 5 10 11 14 15 18 19

1 12 13 14 15 21 22 AH1A LR 16 BH1A BW 3 CH1A GW 18 DH1A G 7 EH1A Y 17 FH1A W 5 GH1A WR 19 HH1A BY 9 IH1A GO 20 JH1A GY 11 KH1A L 2 LH1A GB 6 MH1A R 4 NH1A O 8 OH1A V 10

GB1

SHIELD WIRE

SHIELD WIRE

SHIELD WIRE

ASSSH 2SH050 BR

ASSSH 3SH050 BR LD4

Meter panel (Number-of-layer display)

ASSSH 2SH050 BR

SHIELD WIRE

2 1

W R G B

W R G B SHIELD WIRE

ASSSH 2SH050 BR

L BY

RL AJ1 RG BJ1 RB CJ1

WL DJ1 Br AE1 W BE1 L CE1 LgB DE1 FE1 G PL GE1 Sb HE1 R IE1 JE1 LW GW KE1 LE1 BW PB AF1 WG ME1 GY NE1 Lg GG1 BR HG1

OE1 PE1 QE1 RE1 SE1

1.25B BC1A 0.85WG DK3

LK1 LA2

LD3 LD1 KD1 JD1 B B W R

AB1 BB1 CB1 DB1 EB1 JA5A FB1A GB1A HB1 HB2 IB1 JB1 KB1 LB1 MB1 NB1 OB1 QB1 RB1 SB1 TB1 B W OL WL B0 B W BG YG YG BW BY GW LY W B BW YB RL GY RB

AL1 BL1 CL1 DL1 EL1 W B BW GY LO

Br BY

WR Lg BW

AA1 RY BA1 BrW CA1 Sb DA1 GR EA1 LR FA1 GO GA1 BO EA2 LR HA1 0.85Y HA2 0.85Y IA1 0.85LB JA1 Br KA1 Gr LA1 WB MA1 L NA1 Y 0A1 YR JA2 BY PA1 QA1 O P

RA1 LO

AC2 AC1 BC1 BC2

DK1 0.85WG

LW EK1 5 GR FK1 6 GL GK1 7

HA5 MA3 LA5

0.85WL 0.85WB

13 2 12 1 14 17 5 16 11 10 21 18 6 7 3 4 15 20 19 8 9 22

RxD (-) RxD (+) TxD (-) TxD (+) Communication shield GND for P-motor speed command signal P-motor speed command signal P-motor speed command shield Lift VR (+) Lift VR (sig) Lift VR (GND) Torque sensor (GND) Torque sensor (sig) Torque sensor (+) Travel speed sensor A Travel speed sensor A Travel speed sensor shield Accelerator (GND) Accelerator SW Accelerator (sig) Accelerator (+) FWC output

5 6 13 3 4 1 2 7 8 9 10 11 12 14 15 16

Travel speed sensor B Travel speed sensor B Travel speed sensor shield Travel motor temperature sensor Travel motor temperature sensor

18 16 3 10 8 22 21 9 13 26 24 14 19 11 12 7 17 4 25 6 20 5 23 1 2 15 Parking SW Lift interrupt command Regenerating Tilt SW Lift 1 SW ATT2 SW ATT1 SW Lift 2 SW KEY SW KEY SW Hydraulic contactor SW GND Seat SW R SW F SW Lifting height SW Lift interrupt SW Travel speed limit 2 SW (Do not connect for small special truck spec.) Horn output Brake SW SW monitor start Work equipment selector SW ATT3 SW

Main Controller

SHIELD WIRE

Fuse

L G W R Y B

0.85BW 0.85Br

1(+)

3(-)

JA1A JA3A JADA JA4A JA7 JA2A JA8 JA9

7 1 2 3 4 5 6 8 10 16 17 31 30 G 22 Y 23 B 24 W 25 R 26 7 IA2 0.85LB 8 BC2A 0.85B 21 HA3 0.85Y 9 GA1 BO 5 FA1 GO 6 JADA BY 19 RA1 LO 17 W FB1 1 JAEA B 2 DA3 GR 3 EA3 LR 4 EG1A DG1A CG1A BG1A AG1A

P

BW

L BY Br WR Lg Y

W R G B

R G

ATT3 SW output P-motor speed command signal Analog GND Tilt SW output Lift SW output

Power supply for valve VB(-) KEY SW ATT1 SW output ATT2 SW output

Bit signal 1 Bit signal 2 Bit signal 3 Analog signal Analog GND

Offset SW

SW GND

Lifting height reference SW SW GND Lifting height reference (2)SW Sensor +5V Tilting angle sensor Fork leveling display SW

Encoder (GND) Encoder 1 (B-phase) Encoder 1 (A-phase) Encoder (Power supply)

Encoder 2 (B-phase) Encoder 2 (A-phase)

Lift-up valve (+) Lift-up valve (-) Tilt-back valve (+) Tilt valve (-) ATT1-A valve (+) ATT1 valve (-) ATT2-A valve (+) ATT2 valve (-) ATT3-A valve (+) ATT3 valve (-) Lift-down valve (+) Tilt-forwad valve (+) ATT1-B valve (+) ATT2-B valve (+) ATT3-B valve (+)

GND Charger temperature sensor GND

Analog GND Analog signal Bit signal 3 Bit signal 2 Bit signal 1

8V (+) Meter panel GND MODE_SW UP_SW SHIFT_SW SW_GND

LED (Start reservation) TXD (+) TXD (-)

Current sensor power supply (+10V) Battery current (sig) Current sensor power supply (GND)

Charger interlock Fault history SW VB (+) VB (+) Hour meter start SW Fluid level sensor Mashine controller receiving (+) Mashine controller receiving (-) Mashine controller transmission (+) Mashine controller transmission (-)

VB (-) VB (-) Regenerating SW Lift interrupt Parking SW

Charge mode SW KEY SW Seat SW SW_GND F SW R SW Controller selection SW ATT3 SW Lift SW Tilt SW ATT2 SW ATT1 SW

Finish reservation SW Equalizing charge SW Automatic charge SW Start reservation SW CH panel power supply (GND)

CH panel power supply (+8V) AC connection signal (Outlet: ON)

RY1 LED (Reservation of finish) LED (Equalizing) LED (Automatic) LED (Abnormal) LED (L6) LED (L5) LED (L4) LED (L3) LED (L2) LED (L1)

ATT3 potentiometer

ATT2 potentiometer

Tilt potentiometer

ATT1 potentiometer

Sensor +5V Lift pressure sensor Sensor GND Sensor +5V Lift potentiometer Sensor GND

CN3 (16P)

Hour meter start SW (Connector shorted: Start) SW monitor mode (Connector open: Monitor mode) JA6 Fault history SW (Connector open: History display)

Parking SW (Lever pulled: SW OFF)

(For regeneration) Brake SW (For lamp)

Travel motor temperature sensor

Travel speed sensor B

Travel speed sensor A

6

4

LEFT

Accelerator (4kΩ)

5

BY YB BY BY BY BY BY BY

B BC7A 2 0.85LR HK1 1

3 5 2 1 8 4 7 6

7

FI1 GI1 HI1

W

Memory SW Putting up SW Putting downSW Number-of-layer setting 1 Number-of-layer setting 2 Number-of-layer setting 3 Number-of-layer setting 4 Number-of-layer setting 5 SW GND

Sensor +5V LED (1st layer) LED (2nd layer) LED (3rd layer) LED (4th layer) LED (5st layer) LED (Memory) LED (Putting up) LED (Putting down) LED (Abnormal) Buzzer

CN1 (34P)

EPS torque sensor (For standard specification)

EF2 0.85BR Display changeover (Connector closed: English)

KEY SW Meter panel GND MODE SW UP SW SHIFT SW SW GND Display changeover

Joint connector

ATT3 potentiometer

ATT2 potentiometer

2kΩ

GR FK2 3 RW CK2 4

ATT1 potentiometer

0.85RW 0.85G 0.85RG

AI3 DI1 CI3 EI1

0.85B BC3A 2 0.85WL BK2 1

CN2 (22P)

Horn

Turn signal lamp (L)/25W 3 2 1 0.85B 0.85RG

2kΩ

Head lamp (L)/45W 1 2

GW RY 2 BY 8 RW 4 RL 3 LW 5 LY 6

Horn SW (Steering column)

1

R Y B Y 1 L 3 WB 5 2 4 6

GW RG BY GW RW BY GW RL BY GW LW BY GW LY BY

R B G BrW OW O

Lift pressure sensor

Dimmer SW

Lift potentiometer

0.85RW

CN4S (28P)

RB AI1 1 L BI1 2 BY CI1 3

B B B

V OH1 3 GY JH2 6

Turn signal lamp (R)/25W 3 8

ATT3-B valve

0.85W

2 1

O NH1 2 BY HH2 5

B RG 2 1

Worming lamp

ATT2-B valve

RG RW

HA1 AK1

ATT1-B valve

Head lamp (R)/45W 0.85Y 2 0.85YG 3 1

R MH1 1 W FH2 4

Key SW

GB LH1 2 G DH2 4

9 5 4 10 3 VW GrR GrL Gr P

Tilt forward valve

F R F R 12 7 1 KK1

L KH1 1 BW BH2 3

(12P) AC3

0.85WR

GO IH1 3 GY JH1 6

Charger control section 1 3 15 14 13 12 11 9 8 7 6 5 16 4 18 10 20 2 17 19 0.85W

Lift down valve

(20P)

For CH interlock To MGS auxiliary contact in charger

ATT3-A valve

WL DJ1

WR GH1 2 BY HH1 5

R L 2 1 3

ATT2-A valve

Light SW T2 S T1

Y EH1 1 W FH1 4

Power supply unit of charger

ATT1-A valve

Direction SW P

7 8 16 17 18 19 6 5 21 4 3 2 1 22 9 10 11 13 14 20 12 15

1 2 3 4 5 6 7 8 9 10 25 26 19 20 21 14 15 16 24 17 18 11 12 13 22 23

System controller

ASSSH 2SH050 BR

AC4 1.25W

2 4 3 1

1.25W 1.25W 1.25B 1.25B

BC2 1.25B 1.25B BC1 BC3 0.85BL BC4 0.85BL BC6A 0.85B BC1A 1.25B B BC7A BC9 0.85B

LK1 0.85WL

MA2 0.85L

BC9 0.85B

1 2

Current sensor (GND) GND Current sensor (SIG) Current sensor (+10V)

2 4 3 7 1 8 5 6

0.85WL BK1 RW CK1

ID1 0.85YB

4 JK1 G 3 BC5 0.85B 6 FK1 GR 5 CK3 RW 1 2 LA3 WB 4 RB B R RW

CK3B 0.85RW BC5B 0.85B Y B

JK1A G 3 BC5C 0.85B 6 GK1 GL 5 CK3A RW 1 2 LA3A WB 4 RB B R RW

0A1 YR Br JA4

NA1 Y Br JA5

LW

LW

0.85LR HK1 0.85WG DK2

GR

+

Turn signal SW Y

BW

GW CH1 2 G DH1 4

Fork level display SW BW

Tilt back valve

Offset SW

LR AH1 1 BW BH1 3

ASSSH 5SH050 GR

CN7S (22P)

Lift up valve

1 2 3

JA3A

Tilting angle sensor

RL AD1

1 3 2 4

YB

Lifting height (2) reference SW

Charging mode SW (Open: Test mode)

Lifting height reference SW 1 3 2 4

LW EK1 2 WG DK6 1

Lifting height (1) encoder 5 6 2 3 4 1

Y R

Encoder specification 5 6 2 3 4 1

CN1S (31P)

F

Automatic lifting height control panel Lifting height (2) encoder

CN3S (17P)

Flasher unit

B

G P Sb Lg GW LgR GR LgY B

W Y L Br YR LW BrW YB LR BrR YG

3. PROPORTIONAL SOLENOID VALVE SPEC. (1.0 - 2.5 TON MODELS)

6V

Clearance lamp (R)/5W ED1 AK1 DK5 IA1

Buzzer

0.85LY 1 0.85YG 2 0.85WG 3 0.85LB 4

LIfting hight panel

CN5S (22P)

0.85R 0.85W 0.85Y 0.85G

G P Sb Lg GW LgR GR LgY B

W Y L Br YR LW BrW YB LR BrR YG

CN6S (26P)

Chassis EMG.SW

9 7 8 2 3 4 5 6 1

11 1 2 3 4 5 8 6 7 9 10

TROUBLESHOOTING CIRCUIT DIAGRAM

Multi-contoroller CN4 (28P) Connected only when 3 or more control valves are used.

Connected for only 1-t model

Connected for only 3-t model

SHIELD WIRE

Connected for only 72-V specification Battery connector

ASSSH 2SH050 B

CN5 (4P)

CN2 (22P)

CN11 (16P)

CN1 (26P)

VB(+) 1 VB(+) 3 VB(-) 2 4 VB(-)

CN3 (4P)

Joint connector DF1 0.85YR

Electrolyte level sensor Stop lamp (R)/25W Tail lamp (R)/10W Turn signal lamp (R)/25W Backup lamp (R)/10W License plate lamp (L)/25W

Stop lamp (L)/25W Tail lamp (L)/10W Turn signal lamp (L)/25W Backup lamp (L)/10W

Lift interrupt SW (Connector short circuit: Reset) High Lifting height acceleration limit SW (Connector short circuit: Reset)

B

Reverse travel buzzer L 2 1

GR

Forward/Reverse travel buzzer (Optional)

B

70-59

TROUBLESHOOTING

CIRCUIT DIAGRAM

4. PROPORTIONAL SOLENOID VALVE SPEC. (3.0 TON MODEL)

BE30 Series

70-61

TROUBLESHOOTING

CIRCUIT DIAGRAM

5. MANUAL VALVE SPEC. (1.0 - 2.5 TON MODELS)

SHIELD WIRE

SHIELD WIRE

ASSSH 2SH050 BR

ASSSH 2SH050 BR SHIELD WIRE

ASSSH 3SH050 BR

ASSSH 2SH050 B LD3 LD1 KD1 JD1

GND CHARGER TEMPERATURE SENSOR GND

JADA GA1 FA1 DA1 SA1 EA1

BY BO GO GR LO LR

LD4

SHIELD WIRE

ASSSH 2SH050 BR

2 1

SHIELD WIRE

ASSSH 2SH050 BR

WL DJ1

CHARGER CONTROL SECTION

0.85W

AC3

0.85WR

KK1

FOR CH INTERLOCK TO MGS AUXILIARY CONTACT IN CHARGER

WL DJ1 Br AE1 W BE1 L CE1 LgB DE1 G FE1 GE1 PL Sb HE1 R IE1 LW JE1 GW KE1 BW LE1 PB AF1 WG ME1 GY NE1 Lg GG1 BR HG1

2 1

0.85RW

18 16 3 10 8 22 21 9 13 26 24 14 19 11 12 7 17 4 25 6 20 5 23 1 2 15

PARKING SW LIFT INTERRUPT COMMAND REGENERATING TILT SW LIFT 1 SW ATT2 SW ATT1 SW LIFT 2 SW STARTING SW STARTING SW HYDRAULIC CONTACTOR SW GND SEAT SW R SW F SW LIFTING HEIGHT SW LIFT INTERRUPT SW TRAVEL SPEED LIMIT 2 SW (DO NOT CONNECT FOR SMALL SPESIAL TRUCK SPEC.) HORN OUTPUT BRAKE SW SW MONITOR START WORK EQUIPMENT SELECTOR SW ATT3 SW

1.25W 1.25W 1.25B 1.25B

1 3 2 4

VB(+) VB(+) VB(-)

CN3 (4P)

VB(-)

2 4 3 7 1 8 5 6

ELECTROLYTE LEVEL SENSOR

ID1 0.85YB

DK1 0.85WG

JK1 G 3 BC5 0.85B 6 FK1 GR 5 CK3 RW 1 2 LA3 WB 4

RB B R RW

CK3B 0.85RW BC5B 0.85B

Y B

LW

RB B R RW

JK1A G 3 BC5C 0.85B 6 GK1 GL 5 CK3A RW 1 2 LA3A WB 4

HA5 MA3 LA5

LW

JA4

Br

JA5

1.25W AC1 1 0.85RW GD1 2 0.85WR KK1 3 0.85WG DK1 4 15A

10A

FD1 P QA1

LK1 0.85WL LA2 0.85WB

LICENSE PLATE LAMP (L)/25W STOP-LAMP (L)/25W TAIL LAMP (L)/10W TURN SIGNAL LAMP (L)/25W BACKUP LAMP (L)/10W

LIFT INTERRUPT SW (CONNECTOR SHORT CIRCUIT: RESET) HIGH LIFTING HEIGHT ACCELERATION LIMIT SW (CONNECTOR SHORT CIRCUIT: RESET) GR

BC9 0.85B

STOP-LAMP (R)/25W TAIL LAMP (R)/10W TURN SIGNAL LAMP (R)/25W BACKUP LAMP (R)/10W

REVERSE TRAVEL BUZZER B 2 1

1 2

L GR B

FORWARD/REVERSE TRAVEL BUZZER (If equipped)

FUSE

JA2A

HOUR METER START SW (CONNECTOR SHORTED: START) JA7 BY SW MONITOR MODE (CONNECTOR OPEN: MONITOR MODE) JA6 0.85Br FAULT HISTORY SW (CONNECTOR OPEN: HISTORY DISPLAY)

0.85BrY

RB HD1

PARKING SW (LEVER PULLED: SW OFF)

(FOR REGENERATION) BRAKE SW (FOR LAMP)

TRAVEL MOTOR TEMPERATURE SENSOR

TRAVEL SPEED SENSOR B

TRAVEL SPEED SENSOR A

1 6

LEFT

4

RIGHT

2

5

3

2

0.85BW 0.85Br

BY

BY JA8 2 RY AA2 1

G JK1 WG DK7

BY JA9 O PA1

3 1 4 2 0.85G 0.85G 0.85R 0.85R

GY DL1A 1 LO EL1A 2

OB1A 1 W MB1A 2 B NB1A CL1A 1 W AL1A 2 B BL1A

QB2 QB1 RB1 SB1 TB1 YB YB RL GY RB 5 4 3 6 2 1

BY JB1 3 GW KB1 2 LY LB1 1 4 5 6 L G W R Y B 1(+)

0.85BR EF2

KEY SW METER PANEL GND MODE SW UP SW SHIFT SW SW GND DISPLAY CHANGEOVER

3(-)

0.85BG EJ1

HA7 EF1 FF1 GF1 HF1 IF1 EJA Y BR YG LB WR BY BG

EF3 RW GD3 W BF1 B CF1

12 9 8 7 1 10 11 3 5 4 2 6

VB (+) TXD (+) TXD (-)

B BC7A 2 0.85LR HK1 1

JA1A JA3A JADA JA4A JA7 JA2A JA8 JA9 BY YB BY BY BY BY BY BY 3 5 2 1 8 4 7 6

B G

METER PANEL

ACCELERATOR (4kΩ)

0.85YR IK1 0.85WG DK4 0.85Y HA6 0.85B BC6A

EPS TORQUE SENSOR (FOR STANDARD SPECIFICATION)

4 2 1 3

0.85B BC5A 0.85YR IK1

DISPLAY CHAGEOVER (CONNECTOR CLOSED: ENGLISH)

EXTERNAL RELAY

2 1

HORN

SPARE

Y R

GL GK2 3 RW CK1 4

LW EK1 2 WG DK6 1

ED1 AK1 DK5 IA1

0.85WL BK1 1 0.85B BC4A 2

0.85GL 1 0.85RW 2 0.85B 3

0.85LY 1 0.85YG 2 0.85WG 3 0.85LB 4

0.85RG 1 0.85B 2

R Y B

JOINT CONNECTOR

CLEARANCE LAMP (L)/5W

RG B

CHASSIS EMERGENCY SW

HEAD LAMP (L)/45W

Br

NA1 Y

LK1 0.85WL

CLEARANCE LAMP (R)/5W

TURN SIGNAL LAMAP (L)/25W

0A1 YR

MA2 0.85L

RL AD1

GR FK2 3 RW CK2 4 JA3A

0.85RW 0.85G 0.85RG

YB

3 2 1

CHARGER MODE SW (OPEN: TEST MODE)

R Y B

0.85B BC3A 2 0.85WL BK2 1

F

TURN SIGNAL LAMAP (R)/25W

1 2

0.85B 0.85RG

CN11 (16P)

CN1 (26P)

0.85LR HK1 0.85WG DK2

B RG

BE30 Series

TRAVEL SPEED SENSOR B TRAVEL SPEED SENSOR B TRAVEL SPEED SENSOR SHIELD TRAVEL MOTOR TEMPERATURE SENSOR TRAVEL MOTOR TEMPERATURE SENSOR

DF1 0.85YR

LIFT SOLENOID IK2 YR 1 BC10 B 2

0.85WL BK1 RW CK1

Y 1 L 3 WB 5 2 4 6

R B G BrW OW O

HORN SW (STEERING COLUMN) HEAD LAMP (R)/45W

5 6 13 3 4 1 2 7 8 9 10 11 12 14 15 16

CN2 (22P)

JOINT CONNECTOR 1.25B BC1A 0.85WG DK3

FLASHER UNIT

DIRECTION SW

RxD (-) RxD (+) TxD (-) TxD (+) COMMUNICATION SHIELD GND FOR P-MOTOR SPEED COMMAND SIGNAL P-MOTOR SPEED COMMAND SIGNAL P-MOTOR SPEED COMMAND SHIELD LIFT VR (+) LIFT VR (sig) LIFT VR (GND) TORQUE SENSOR (GND) TORQUE SENSOR (sig) TORQUE SENSOR (+) TRAVEL SPEED SENSOR A TRAVEL SPEED SENSOR A TRAVEL SPEED SENSOR SHIELD ACCELERATOR (GND) ACCELERATOR SW ACCELERATOR (sig) ACCELERATOR (+) FWC OUTPUT

4

DIMMER SW F R F R

2 1

LW EK1 5 GR FK1 6 GL GK1 7

B B B

R L

TURN SIGNAL SW

HA1 AK1

0.85R 0.85W 0.85Y 0.85G

LIGHT SW

3 8

W B BW GY LO

13 2 12 1 14 17 5 16 11 10 21 18 6 7 3 4 15 20 19 8 9 22

BC2 1.25B BC1 1.25B BC3 0.85BL BC4 0.85BL BC6A 0.85B BC1A 1.25B B BC7A BC9 0.85B

WORKING LAMP

0.85W

AL1 BL1 CL1 DL1 EL1

AC2 AC1 BC1 BC2

OE1 PE1 QE1 RE1 SE1

0.85Y 2 0.85YG 3 1 RG RW

YG YG BW BY GW LY W B BW YB RL GY RB

CN5 (4P)

6V

VW 9 GrR 5 GrL 4 Gr 10 P 3

STARTING SW

HB1 HB2 IB1 JB1 KB1 LB1 MB1 NB1 OB1 QB1 RB1 SB1 TB1

PA1 O QA1 P JA10 Br

RB CJ1 12 RG BJ1 7 RL AJ1 1

(12P)

B W OL WL B0

CURRENT SENSOR (GND) GND CURRENT SENSOR (SIG) CURRENT SENSOR (+10V)

+

1 3 15 14 13 12 11 9 8 7 6 5 16 4 18 10 20 2 17 19

AB1 BB1 CB1 DB1 EB1

2 4 3 1

-

(20P)

B B W R

AA1 RY BA1 BrW CA1 Sb DA1 GR EA1 LR FA1 GO GA1 BO SA1 LO HA1 0.85Y HA2 0.85Y IA1 0.85LB JA1 Br KA1 Gr LA1 WB MA1 L NA1 Y 0A1 YR JA2 BY

RL AJ1 RG BJ1 RB CJ1

2 1 3

T2 S T1

POWER SUPPLY UNIT OF CHARGER

CONNECTED FOR ONLY 72V SPECIFICATION BATTERY CONNECTOR

AC4 1.25W SHIELD WIRE

MAIN CONTROLLER

RL Y Gr Br L WB Br LO LR GR GO BO AD1 HA4 KA1 JA1 MA1 LA1 JA3 SA2 EA2 DA2 FA2 GA2

CN4 (28P)

4 9 5 6 7 2 FG1 LB 1 FG2 LB 10 FG1 LB 14 GG1 Lg 8 HG1 BR 28 3 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27

8V (+) METER PANEL GND MODE_SW UP_SW SHIFT_SW SW_GND

LED (START RESERVATION) TXD (+) TXD (-)

CURRENT SENSOR POWER SUPPLY (+10V) BATTERY CURRENT (sig) CURRENT SENSOR POWER SUPPLY (GND)

CHARGER INTERLOCK FAULT HISTORY SW VB (+) VB (+) HOUR METER START SW FLUID LEVEL SENSOR MACHINE CONTROLLER RECEIVING (+) MACHINE CONTROLLER RECEIVING (-) MACHINE CONTROLLER TRANSMISSION (+) MACHINE CONTROLLER TRANSMISSION (-)

VB (-) VB (-) REGENERATING SW LIFT INTERRUPT PARKING SW

CHARGE MODE SW STARTING SW SEAT SW SW_GND F SW R SW CONTROLLER SELECTION SW LIFT 2 SW LIFT 1 SW TILT SW ATT2 SW ATT1 SW

CN3 (16P)

12 25 3 4 15 16 28 8 7 23 24 1 30 BC4 0.85BL 33 BC3 0.85BL 34 CA1 Sb 18 BA1 BrW 27 AA1 RY 19 31 32 ED1 0.85LY 26 FD1 0.85BrY 17 GD2 0.85RW 9 GD1 0.85RW 10 HD1 RB 11 ID1 0.85YB 2 DB1A WL 5 CB1A OL 6 BB1A W 13 AB1A B 14 EB2A EB3A 29 JD1A R 20 KD1A W 21 LD1A B 22 LD4 AF1 PB 7 BF1A W 1 CF1A B 2 6 5 DF1 0.85YR 4 EF1 BR 16 FF1 YG 10 GF1 LB 9 HF1 WR 8 IF1 BY 15 14 13 12 3 11

FINISH RESERVATION SW EQUALIZING CHARGE SW AUTOMATIC CHARGE SW START RESERVATION SW CH PANEL POWER SUPPLY (GND)

CH PANEL POWER SUPPLY (+8V) AC CONNECTION SIGNAL (OUTLET: ON)

CN1 (34P)

6 4 5 3 2 1

CONNECTED FOR ONLY 3-T MODEL

Br W L LgB G PL Sb R LW GW BW

CONNECTED FOR ONLY 1-T MODEL

AE1 BE1 CE1 DE1 FE1 GE1 HE1 IE1 JE1 KE1 LE1

21 14 16 15 17 9 10 11 3 4 5 20 ME1 WG 6 NE1 GY 13 18 12 8 OE1 VW 7 PE1 GrR 2 QE1 GrL 1 RE1 Gr 19 SE1 P 22

SW GND ATT1SW ATT2SW TILT SW LIFT 2 SW LIFT 1 SW

WORK EQUIPMENT CONTROL LEVER SW

RY1 LED (RESERVATION OF FINISH) LED (Equalizing) LED (Automatic) LED (Abnormal) LED (L6) LED (L5) LED (L4) LED (L3) LED (L2) LED (L1)

MULTI-CONTOROLLER CN2 (22P)

70-63

TROUBLESHOOTING

SUB CONTROLLER

SUB CONTROLLER

(COMMON TO ALL MODELS: SYSTEM CONTROLLER AND MULTI-CONTROLLER) (Note 1) When carrying out troubleshooting, disconnect the battery unless otherwise specified. (Note 2) Pay attention to safety while you are carrying out troubleshooting, since the vehicle (travel system, cargo handling system, EPS, etc.) may move. (Note 3) If the vehicle is equipped with the manual valve specification, carry out troubleshooting for only the multi-controller.

1. CHECK BEFORE TROUBLESHOOTING Before troubleshooting, perform the following check. • Checking controller source voltage (1) Disconnect battery connector. (2) Remove the side cover (left one seen from the counterweight). (3) Set the multimeter for measurement of voltage and set its rods to the measuring points. Connect the battery connector, turn the key switch on, and measure the voltage. (4) Check that the voltage is in the normal range. (5) Voltage check table Checked item

System controller (2) Multi-controller (1)

Connector name

Red rod of multimeter Black rod of multimeter (+) (--)

Normal voltage

Pin No.

Pin No.

CN1S

9

21

Battery voltage

CN4S

26

28

4.9 – 5.1V

CN1

10

34

Battery voltage

(Reference) System controller adjustment function (Degree of shocks made when lift is raised and lowered) a Since this control knob is set properly when the vehicle is shipped, do not adjust it usually. 1) VR-U: Shocks made when lift starts/stops rising Adjust the degree of the shocks. (The knob is set in neutral when the vehicle is shipped.) Turning in direction A: Shocks are softened. Turning in direction B: Shocks are hardened. 2) VR-D: Shocks made when lift starts/stops lowering Adjust the degree of the shocks. (The knob is set in neutral when the vehicle is shipped.) Turning in direction A: Shocks are softened. Turning in direction B: Shocks are hardened. (Caution) Never touch the DIP switch and VR-L.

BE30 Series

70-65

SUB CONTROLLER

TROUBLESHOOTING

2. TROUBLES, THE FAILURE CODES OF WHICH ARE NOT DISPLAYED Contents of trouble Charger interlock (sub) relay is open.

Malfunction of vehicle

Repair method

• Vehicle cannot travel or handle cargo and EPS cannot operate. • Meters do not indicate.

1) Check charger interlock (sub) relay (in multicontroller) and replace multi-controller board.

Work equipment • Vehicle cannot handle cargo but switch signal is open. can do all other operations. Drive Tr is open. • Pump motor does not rotate.

1) Check work equipment switch signal harness (connected to connector CN1S of system controller) and repair or replace it. 2) If result of above check is normal, replace system controller board.

(1) Troubleshooting for system controller See failure codes list E-60 – E-89. (2) Troubleshooting for multi-controller See failure codes list E-59 and E-90 – E-99.

70-66

BE30 Series

TROUBLESHOOTING

SUB CONTROLLER

3. TROUBLESHOOTING 1.

Checking work equipment control lever and potentiometer (See the sections of assembly drawing and section 60 STRUCTURE AND FUNCTION, work equipment control lever.) (1) Checking voltage 1) Set a multimeter for measurement of voltage and set its black rod (-) to connector CN4S pin No. 28 of the system controller. 2) Set the red rod (+) according to the following table, connect the battery connector, and turn the key switch ON to measure the voltage. 3) Check that the voltage is in the normal range shown in the following table. (Note) Since the work equipment is operated for check, stop the vehicle on a place where there is not an obstacle and take care particularly while the work equipment is in operation. Measuring point Work equipment potentiometer for measurement

System controller connector CN4S Pin No. Red rod of Black rod of multimeter multimeter (+) (--)

Lift potentiometer

2

Tilt potentiometer

10

ATT1 potentiometer

6

ATT2 potentiometer

14

ATT3 potentiometer

18

When lever is operated

28

Normal voltage

Neutral

A

2.6 – 2.4V

Forward tilt end

B

4.3 – 3.9V

Reverse tilt end

C

1.1 – 0.7V

(2) Checking resistance of wiring harness 1) Remove the dashboard and disconnect the lever potentiometer intermediate connector. 2) Set a multimeter for measurement of resistance and set its rods to the measuring points to measure the resistance according to the following table. 3) Check that the resistance is in the normal range. (Note) If the rods of the multimeter are inserted from the fitting face of the connector, the contact will be defective after the connector is connected. Accordingly, insert the rods from the wiring harness side. Measuring point

Red rod of multimeter (+)

Black rod of multimeter (--)

Pin No.

Pin No.

1

2

Normal resistance

Connector on lift lever potentiometer side Connector on tilt lever potentiometer side Connector on ATT1 lever potentiometer side

2kz

Connector on ATT2 lever potentiometer side Connector on ATT3 lever potentiometer side BE30 Series

70-67

SUB CONTROLLER

2.

TROUBLESHOOTING

Checking dummy resistor (1) Checking dummy resistor 1) Remove the dashboard and disconnect the dummy potentiometer intermediate connector. 2) Set a multimeter for measurement of resistance and set its rods to the measuring points to measure the resistance according to the following table. 3) Check that the resistance is in the normal range. (Note) If the rods of the multimeter are inserted from the fitting face of the connector, the contact will be defective after the connector is connected. Accordingly, insert the rods from the wiring harness side. (2) Measuring points and normal values Dummy resistance Measuring point

Red rod of Black rod of multimeter multimeter (+) (--)

Connector on dummy potentiometer side

3.

Normal resistance

Pin No.

Pin No.

1

3

2 kz

2

3

1 kz

Checking lift pressure sensor (1) Checking resistance of wiring harness 1) Disconnect the pressure sensor connector at the control valve. 2) Disconnect system controller connector CN4S. 3) Set a multimeter for measurement of resistance and set its rods to the measuring points to measure the resistance according to the following table. 4) Check that the resistance is in the normal range. (Note) If the rods of the multimeter are inserted from the fitting face of the connector, the contact will be defective after the connector is connected. Accordingly, insert the rods from the wiring harness side. (2) Measuring points and normal values Measuring point

Red rod of multimeter (+)

Black rod of multimeter (--)

CN4S pin No.

Pressure sensor connector pin No.

26

1

27

2

28

3

Pressure sensor harness

Normal resistance

0z

(3) Checking voltage 1) Set a multimeter for measurement of voltage and set its black rod (-) to connector CN4S pin No. 28 of the system controller. 2) Set the red rod (+) to CN4S pin No. 27, connect the battery connector, and turn the key switch ON. 3) Lower the lift until the fork reaches the ground, and then measure the voltage. 4) Raise the lift to the stroke end and measure the voltage, keeping the lift at the stroke end. 5) Check that the resistance is in the normal range shown in the following table. (Note) Since the work equipment is operated for check, stop the vehicle on a place where there is not an obstacle and take care particularly while the work equipment is in operation. When to measure pressure Red rod of multimeter (+) Black rod of multimeter (--) sensor voltage CN4S pin No. CN4S pin No. When fork is on ground When fork is at rising stroke end

70-68

Normal voltage 0.37 – 0.63V

27

28

3.89 – 4.30V

BE30 Series

TROUBLESHOOTING

SUB CONTROLLER

4. Checking coil of proportional solenoid valve (hydraulic control valve) (Note) A 4P connector and a 6P connector are installed respectively to the top and bottom of the proportional valve. (1) Checking coil resistance 1) Disconnect the connectors at the proportional valve. 2) Set a multimeter for measurement of resistance and set its rods to the measuring points to measure the resistance according to the following table. 3) Check that the resistance is in the normal range. (Note) If the rods of the multimeter are inserted from the fitting face of the connector, the contact will be defective after the connector is connected. Accordingly, insert the rods from the wiring harness side. (2) Measuring points and normal values Measuring point

Red rod of multimeter (+)

Black rod of multimeter (--)

Connector pin Nos. of proportional valve

Connector pin Nos. of proportional valve

Lift raising end

4P 1

4P 3

Tilting back end

4P 2

4P 4

ATT1_Asol

Lower connector

6P 1

Lower connector

6P 4

ATT2_Asol

6P 2

6P 5

ATT3_Asol

6P 3

6P 6

Lift lowering end

4P 1

4P 3

Tilting forward end

4P 2

4P 4

ATT1_Bsol

Upper connector

6P 1

Upper connector

6P 4

ATT2_Bsol

6P 2

6P 5

ATT3_Bsol

6P 3

6P 6

Normal resistance

17.5 ± 0.5z

17.5 ± 0.5z

(3) Checking wiring harness resistance 1) Disconnect the connectors at the proportional valve. 2) Disconnect system controller connector CN7S. 3) Set a multimeter for measurement of resistance and set its rods to the measuring points to measure the resistance according to the following table. 4) Check that the resistance is in the normal range. (Note) If the rods of the multimeter are inserted from the fitting face of the connector, the contact will be defective after the connector is connected. Accordingly, insert the rods from the wiring harness side. (4) Measuring points and normal values Measuring point

Red rod of multimeter (+)

Black rod of multimeter (--)

Proportional valve connector pin No.

CN7S pin No.

Lift raising end Tilting back end ATT1_Asol ATT2_Asol ATT3_Asol

BE30 Series

Lower connector

4P 1

16

4P 3

3

4P 2

18

4P 4

7

6P 1

17

6P 4

5

6P 2

19

6P 5

9

6P 3

20

6P 6

11

Normal resistance

0z

70-69

SUB CONTROLLER

Measuring point

TROUBLESHOOTING

Red rod of multimeter (+)

Black rod of multimeter (--)

Proportional valve connector pin No.

CN7S pin No.

Lift lowering end Tilting forward end ATT1_Bsol

Upper connector

ATT2_Bsol ATT3_Bsol 5.

4P 1

2

4P 3

3

4P 2

6

4P 4

7

6P 1

4

6P 4

5

6P 2

8

6P 5

9

6P 3

10

6P 6

11

Normal resistance

0z

Sub controller (System controller) Checking work equipment control lever signal harness (1) Checking voltage 1) Remove the side cover (left one seen from the counterweight). 2) Set the multimeter for measurement of voltage and set its rods to the measuring points. 3) Connect the battery connector, turn the key switch on, and measure the voltage. 4) Check that the voltage is in the normal range. (2) Measuring points and normal values Work equipment switch name Lift switch

4

Tilt switch

3

ATT1 switch

70-70

Connector Red rod of multimeter (+) Black rod of multimeter (--) name Pin No. Pin No.

CN1S

5

ATT2 switch

6

ATT3 switch

17

2

Normal voltage

Min. 4 V

BE30 Series

TROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTING 1. PRECAUTIONS TO TAKE WHEN FAILURE CODE IS DISPLAYED (1) When resetting a displayed failure code by turning the key switch OFF, wait at least 3 seconds before turning the key switch ON again (since it takes 3 scones to turn the CPU OFF after the key switch is turned OFF). (2) When checking the main controller, disconnect the battery plug and wait for at least 2 minutes. (3) The following codes are displayed when mistakes are made in operation. (Note) When the operation is repeated, if the same trouble occurs, see TROUBLESHOOTING. • E-23: Travel neutral is detected • E-60: Work neutral is detected • E-68: Mistakes in operation of automatic lifting stopper device and automatic fork leveling device are displayed • Abnormal operation LED in automatic lifting height indicator panel: A mistake in automatic lifting height indication is displayed (4) The following codes are displayed as warnings for Failure code Troubled part safety 01 – 28, 41, 42, 45 Travel system • E-64: Automatic fork leveling device does not Cargo handling system (excluding 30 – 38, 55, 56 reach level position or exceeds level position proportional solenoid valve) • E-69: Automatic lifting stopper device does not 50 – 54 PS system reach set height Cargo handling system (related to • E-70: Automatic lifting stopper device exceeds 60 – 89 proportional solenoid valve) set height 59, 90 – 96 Charger system 97 98 99

2. TROUBLES THAT ARE NOT DISPLAYED

Communication between main controller and multi-controller Communication between system controller and multi-controller Communication between meter panel and multi-controller

Repair method Reset (Execute 1) o 2) o ---) method 1 Vehicle cannot oper- • Control voltage Check and repair control voltage (key – ate at all (Travel, (key switch line) switch, EMG switch line). cargo handling, is not applied. EPS, display on • Relay in multiCheck charger interlock relay (sub) in – meters are impossicontroller: Open multi-controller, then replace multi-conble) troller board if necessary. 2 Operations related – – – to main controller 1) When FR switch • Connectors of Check connection of connectors A and Reset (F or R) and actravel speed sen- B, then connect them correctly. normally. celerator are opsors A and B are erated, vehicle connected oppodoes not travel. sitely. • Accelerator 1) Repair or replace wiring harness be- Reset switch and its tween CN2-19 (CPU board) and normally. signal circuit are travel accelerator. disconnected. 2) Repair or replace wiring harness between CN2-8, 9, 20 (CPU board) and travel accelerator. 3) Repair or replace travel accelerator unit. 2) Vehicle stops • Accelerator and 1) Check and repair brake switch in Turn traveling. brake are operatOFF position. brake ed simultaneous- 2) Repair or replace wiring harness be- switch ly too long. tween CN-1-6 (CPU board) and OFF. brake switch

No.

Trouble in vehicle

Contents of trouble

Remarks – – – Take care when replacing motor.

–

Vehicle may stop because of mistake in operation (Mistake is detected when accelerator and brake are operated for 10 seconds). • Overvoltage pro- 1) Check battery connector for defec- Reset If battery connector has tection works in tive contact. normally defective contact or is disregeneration 2) Repair or replace wiring harness beconnected in regeneramode. tween CN4-2 (CPU board) and tertion mode, protection is minal P3. applied. 3) Repair or replace wiring harness between CN4-10 (CPU board) and terminal P13.

BE30 Series

70-71

TROUBLESHOOTING

TROUBLESHOOTING

Repair method Reset Remarks (Execute (1) o (2) o ---) method 2 (3) Cargo handling sys- Upper FED of cargo Check cargo handling power module – – tem chops but does handling power module (TMP), then replace if necessary. not have sufficient (TMP) is open. power. 4) Vehicle stops travel- PS motor is shorted. Check PS motor and its wiring for short cir– – ing. cuit, then replace if necessary. 3 Troubles related to sys– – – – ( 1) tem controller 1) P motor does not ro- Drive Tr power in sys- 1) Check voltage at system controller – – tate. tem controller is open. CN1S-3, 4, 5, 6, 17, 18, and 19: If it is Sensor circuit in main above 4 V, replace controller board. controller is defective. 2) If voltage is below 4 V in 1) above, check Work equipment switch voltage at main controller CN1-8, 9, 10, signal harness is defec21, 22, and 23: If it s above 4 V, check tive. wiring harness for disconnection. 3) If voltage is below 4 V in 2) above, check wiring harness for short circuit. 4) If wiring harness is found normal in 3) above, replace main controller board. P motor DUTY signal 1) Check wiring harness between system – – harness is shorted. controller CN1S-1 and main controller Command IC in system CN2-5 for short circuit. controller is defective. 2) Replace system controller. 2) When lever is oper- P motor DUTY signal 1) Check wiring harness between system – – ated, P motor rotates harness is shorted. controller CN1S-1 and main controller at full speed. Command IC in system CN2-5 for short circuit. controller is defective. 2) Replace system controller. – Pot output: 3) When certain lever is Output of lever is lost. Check and repair Pot of lever operating secoperated, vehicle tion. Seems to be does not respond kept at 2.5 V, (and related proporregardless of tional valve coil does turning angle. not drive). 4 Automatic lifting stopper – – – – ( 1) function 1) Automatic lifting FEP-ROM in system 1) Set automatic lifting stopping distance a – – stopping position is controller is defective. little longer and apply automatic lifting abnormal. (Below or stop to see if any trouble is displayed. If above set position: any trouble is displayed, see troubleE-69 or E-78 is not shooting for it. displayed) 2) If any trouble is not displayed, change automatic lifting stopping position, turn key switch OFF and ON, apply automatic lifting stop. See if lifting stops at changed position. 3) If lifting does not stop normally, replace system controller board. 2) Automatic lifting is Following defects in au- 1) If all LED segments of automatic lifting – Memory not displayed. tomatic lifting display display panel light up after key switch is switch is panel: turned ON, replace system controller. shorted under • Memory switch is 2) If all LED segments do not light up in 1) normal condiopen. above, memory switch of automatic lifttion. • Memory switch wiring ing display panel is open or its wiring harness is disconnectharness is disconnected. Repair. ed. 5 Automatic fork leveling – – – – ( 1) device 1) Fork cannot be tilted Automatic mode is not 1) Operate fork leveling display switch to – Switch at left manually. reset (This is not troureset automatic mode. is an alternate ble). switch, which holds opera2) Fork cannot be tilted Fork leveling display 1) If fork leveling display switch cannot be – tion. Each manually (Open). switch is defective. turned ON and OFF, replace it. time it is operFork cannot be tilted Wiring harness of fork 2) If switch is normal, check its wiring harated, its state manually (Shorted). leveling display switch is ness for disconnection and short circuit, is reversed. defective. then replace. 3) If result of above check is normal, replace system controller. 1. For proportional solenoid valve spec. No.

Trouble in vehicle

70-72

Contents of trouble

BE30 Series

TROUBLESHOOTING

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

FAILURE CODES LIST (1.0 - 2.5 TON MODELS) Failure Contents of code trouble 01 Travel power module is shorted (Upper and lower FET's are shorted).

03

Main contactor (MD) is shorted or open or its sensor circuit harness is defective.

05 11

Travel power modules are shorted (Upper and lower modules are shorted separately).

06 08 09

Travel power module is open. U-, V-, or W-phase is disconnection.

BE30 Series

Trouble in Repair method vehicle (Execute 1) o 2) o ---) Vehicle cannot travel 1) If vehicle can travel, check code 45 or handle cargo (MD first. connector is not 2) Check travel power modules (TMDU, closed). TMDV, and TMDW) and replace (This trouble is also them if necessary. (If a power moddetected when failure ule is defective, be sure to replace it code 45 is displayed.) and power supply board as a set.) 3) Check wiring harness between CN3R (Power supply board) and each power module, then repair or replace it. 4) Check wiring harness between CN42 (CPU board) and terminal P3, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 6) If result of above check is normal, replace power supply board. Vehicle cannot travel 1) Check main contactor (MD) (for meltor handle cargo. ing, mechanical hitching, etc. of contacts), then repair or replace it. 2) Check wiring harness between CN511 (CPU board) and terminal P2, then repair or replace it. 3) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. Vehicle cannot travel 1) Check travel power modules (TMDU, or handle cargo. TMDV, TMDW) and replace them if necessary. (When replacing, be sure to replace them as a set, together with power supply board.) 2) Check wiring harness between CN3R (Power supply board) and each power module, then repair or replace it. 3) Check wiring harness between CN43 (CPU board) and terminal P4, then repair or replace it. 4) Check wiring harness between CN42 (CPU board) and terminal P3, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 6) If result of above check is normal, replace power supply board. Vehicle cannot travel 1) Check travel power modules (TMDU, or handle cargo. TMDV, TMDW) and replace them if necessary. (When replacing, be sure to replace them as a set, together with power supply board.) 2) Check wiring harness between CN3R (Power supply board) and each power module, then repair or replace it. 3) Check output terminals of U-, V-, and W-phase for disconnection and looseness of screws. 4) If result of above check is normal, replace power supply board.

Reset method Turn key switch OFF.

Turn key switch OFF.

Remarks –

–

Turn key switch OFF.

Failure code 05: Detected when key switch is turned ON. Failure code 11: Detected after key switch and MD are turned ON.

Turn key switch OFF.

Failure code 06: U-phase is open (disconnected) Failure code 08: V-phase is open (disconnected) Failure code 09: W-phase is open (disconnected)

70-73

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of Trouble in code trouble vehicle 07 Main contactor Vehicle cannot travel (MD) drive Tr is de- or handle cargo. fective (In CPU board: Tr4). Main contactor coil is open. Sensor circuit harness of main contactor coil is defective. 16 F or R switch is de- Vehicle cannot travel. fective.

17

Repair method (Execute 1) o 2) o ---) 1) Check main contactor (MD) coil for disconnection of connector and coil, then repair or replace it. 2) Check wiring harness between contactor coil and CN4-5, 13 (CPU board), then repair or replace it. 3) Replace CPU board (since drive Tr is defective).

1) Check wiring harness between CN111, 12 (CPU board) and F/R switch for short circuit, then replace if necessary. 2) Repair or replace F/R switch. Travel accelerator Vehicle can travel at 1) Check wiring harness between CN2output is defective. 40% of maximum 8, 9, 20 (CPU board) and travel acspeed. celerator, then repair or replace it. 2) Check travel accelerator unit, then repair or replace it.

19

Output or wiring Vehicle cannot travel. 1) Check wiring harness between CPU harness of travel board and current sensors, then recurrent sensor pair or replace it. (CSDU, CSDW) is CSDU: CN5-3, 4, 14, 15 defective. CSDW: CN5-5, 6, 16, 17 2) Check source voltage of current sensor power supply of CPU board. CSDU: Between CN5-3 and 14, 15 CSDW: Between CN5-5 and 16, 17 If source voltage is abnormal, replace CPU board. 3) Check current sensors (CSDU, CSDW), then replace it if necessary.

20

Travel main fuse Vehicle cannot travel 1) Check travel fuse (F1) and replace it (F1) is broken or its (MD contactor is if necessary. sensor circuit har- closed). 2) Check wiring harness between CN5ness is defective. 11 (CPU board) and terminal P2, then repair or replace it. 3) Check wiring harness between CN42 (CPU board) and terminal P3, then repair or replace it. Undervoltage is Vehicle cannot travel 1) Charge battery. detected (Battery (MD/MPS connector 2) Check wiring harness between CN4voltage is lower). is not closed). When 8 (CPU board) and terminal P1, then key switch is turned repair or replace it. ON again, vehicle can travel. Output of travel Vehicle can travel 1) Check temperature sensor (THD), controller tempera- normally (assuming and replace it if necessary. ture sensor (THD) temperature is nor2) Check wiring harness between CN7-5, is defective. mal). 11 (CPU board) and temperature sensor (THD), then repair or replace it. Neutral is detect- Vehicle cannot travel. 1) Operate accelerator and direction ed. switch normally. * Neutral caused 2) Check accelerator or direction switch by mistake in opfor short circuit, then repair or reeration is not place it. trouble. 3) Check circuit of accelerator or direction switch for looseness of connector and defective wiring harness, then repair or replace it.

21

22

23

70-74

TROUBLESHOOTING

Reset method Turn key switch OFF.

Remarks –

Reset Turn F switch and R normal- switch ON simultaly. neously. Reset Normal source voltage of normal- accelerator: 5 V (Bely. tween CN2-9 and 20) Output voltage of accelerator when abnormality is detected: Max. 0.2 V, Min. 4.8 V (Between CN2-8 and 20) Turn Normal sensor output key • During travel: 3.0 V switch – 11.0 V OFF. • When FR switch is in neutral and accelerator is OFF: Approx. 7 V CSDU: Between CN5-4 and 14, 15 CSDW: Between CN5-6 and 16, 17 Normal source voltage of sensor power supply: 15 V Sensor output when abnormality is detected: Max. 1.5 V, Min. 12.5 V Turn Check voltage on seckey ondary side of fuse switch (F1). OFF.

Turn key switch OFF.

This trouble is detected when battery voltage is below 28.2 V for 0.8 seconds.

Reset Voltage of temperanormal- ture sensor (THD) ly. when abnormality is detected: Max. 0.2 V, Min. 4.95 V Turn When both of acceleraccel- ator and FR switch are erator turned ON, trouble is and FR reset when either of switch them is turned OFF. OFF.

BE30 Series

TROUBLESHOOTING

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of code trouble 24 Travel controller temperature is high. Fan drive system is defective.

25

26

27

28

Trouble in Repair method vehicle (Execute 1) o 2) o ---) Vehicle can travel 1) Cool controller and stop vehicle. (Current is limited by 2) Check mounting screws of TMDU, temperature rise and TMDV, and TMDW for looseness. output is lowered). 3) Check resistance and voltage of temperature sensor (THD), then replace it if necessary. 4) Check wiring harness between CN75, 11 (CPU board) and temperature sensor, then repair or replace it. 5) Check wiring harness between CN7R-1, 2, 7, 8 (Power supply board) and each fan, then repair or replace it. 6) Check wiring harness between CN96 (CPU board) and CN1R-6, then repair or replace it. Travel motor tem- Vehicle can travel 1) Cool travel motor and stop vehicle. perature rises. (Current is limited by 2) Check resistance and voltage of travtemperature rise and el motor temperature sensor, then output is lowered). replace it if necessary. 3) Check wiring harness between CN11-3, 4 (CPU board) and travel motor temperature sensor, then repair or replace it.

Reset method Controller is reset when temperature lowers below 100°C.

Travel controller Vehicle cannot travel. 1) Cool controller and stop vehicle. temperature is ab2) Check mounting screws of TMDU, normal. TMDV, and TMDW for looseness. Fan drive system 3) Check resistance and voltage of temis defective. perature sensor (THD), then replace it if necessary. 4) Check wiring harness between CN75, 11 (CPU board) and temperature sensor, then repair or replace it. 5) Check wiring harness between CN7R-1, 2, 7, 8 (Power supply board) and each fan, then repair or replace it. 6) Check wiring harness between CN96 (CPU board) and CN1R-6, then repair or replace it. Output of travel Vehicle can travel 1) Check voltage of travel motor temmotor temperature normally (assuming perature sensor, then replace sensor sensor is defectemperature is norif necessary. tive. mal). 2) Check wiring harness between CN11-3, 4 (CPU board) and travel motor temperature sensor, then repair or replace it. Travel motor tem- Vehicle cannot travel. 1) Cool travel motor and stop vehicle. perature is abnor2) Check resistance and voltage of travmal. el motor temperature sensor, then replace it if necessary. 3) Check wiring harness between CN11-3, 4 (CPU board) and travel motor temperature sensor, then repair or replace it.

Controller is reset when temperature lowers below 115°C.

BE30 Series

Travel motor is reset when temperature lowers below 160°C.

Remarks Normal resistance/ voltage of temperature sensor 25°C: 20kz/4.0 V 50°C: 7.2kz/3.0 V 80°C: 2.5kz/1.7 V Tolerance of these values is ± 10%. 1 ton models: 1 fan CN7R-2, 8 2 ton models: 2 fans CN7R-1, 7 added Above 100°C: Current is limited. Above 103°C: Warning is displayed. Normal resistance/ voltage of travel motor temperature sensor 25°C: 10.7kz/3.5 V 50°C: 4.4kz/2.4 V 100°C: 1.0kz/0.9 V 150°C: 0.3kz/0.3 V Tolerance of these values is ± 10%. Above 160°C: Current is limited. Above 163°C: Warning is displayed. Normal resistance/ voltage of temperature sensor 25°C: 20kz/4.0 V 50°C: 7.2kz/3.0 V 80°C: 2.5kz/1.7 V Tolerance of these values is ± 10%. 1 ton: 2 fans CN7R-2, 8 2 ton: 3 fans CN7R-1, 7 added Above 115°C: Travel is stopped.

Reset Voltage of temperanormal- ture sensor when ably. normality is detected: Max. 0.2 V, Min. 4.95 V Travel motor is reset when temperature lowers below 175°C.

Normal resistance/ voltage of travel motor temperature sensor 25°C: 10.7kz/3.5 V 50°C: 4.4kz/2.4 V 100°C: 1.0kz/0.9 V 150°C: 0.3kz/0.3 V Above 175°C: Travel is stopped.

70-75

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 30 Cargo handling Vehicle can handle 1) If vehicle can handle cargo, check power module cargo. code 56 first. (TMPU) is shorted. (MP contactor is 2) Check cargo handling power module closed.) (TMPU) and replace it if necessary. (This trouble is also (If power module is defective, be detected when failure sure to replace it and power supply code 56 is displayed.) board as a set.) 3) Check wiring harness between CN4R (Power supply board) and TMPU, then repair or replace it. 4) Check wiring harness between CN410 (CPU board) and terminal P13, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 6) If result of above check is normal, replace power supply board. 31 Cargo handling Vehicle cannot han- 1) Check cargo handling power module power module dle cargo. (TMP) and replace it if necessary. (If (TMP) is open. (MP contactor is power module is defective, be sure to Upper side of car- closed.) replace it and power supply board as go handling power a set.) module (TMP) (Be2) Check wiring harness between tween P and OUT) CN4R (Power supply board) and caris shorted. go handling power module (TMP), Cargo handling then repair or replace it. motor is shorted or 3) Check wiring harness between CN8open. 3 (CPU board) and CN2R-3 (Power supply board), then repair or replace it. 4) Check cargo handling motor and its wiring, then repair or replace it. 32 Chassis EMG Vehicle cannot oper- 1) Check chassis EMG switch. If it is switch is defective ate work equipment. open, repair or replace it. or its circuit har(MP contactor is not 2) Check wiring harness between CN1ness is disconnect- closed.) 24 (CPU board) and EMG switch, ed. then repair or replace it. 33

Cargo handling main fuse (F2) is broken its sensor circuit harness is defective.

Vehicle cannot handle cargo (MP contactor is closed).

1) 2) 3) 4)

35

Cargo handling lift Vehicle operates with 1) VR is shorted or cargo handling "ON" open. period ratio at 100%. 2)

36

41

Output of cargo handling controller temperature sensor (THP) is defective.

Vehicle can handle cargo normally (assuming temperature is normal).

1) 2)

Output of travel Vehicle cannot travel. 1) speed sensor A is defective. 2) 3)

70-76

TROUBLESHOOTING

Reset method Turn key switch OFF.

Turn key switch OFF.

Turn EMG switch and key switch OFF. Check cargo handling fuse (F2) and Turn replace it if necessary. key Check wiring harness between CN5- switch 22 (CPU board) and terminal P12, OFF. then repair or replace it. Check wiring harness between CN410 (CPU board) and terminal P13, then repair or replace it. Check wiring harness between CN511 (CPU board) and terminal P2, then repair or replace it. Check wiring harness between CN2- Reset 10, 11, 21 (CPU board) and cargo normalhandling lift VR, then repair or rely. place it. Check cargo handling lift VR, then replace it if necessary.

Remarks –

–

This trouble occurs only when CN1-24 is disconnected (and does not occur while EMG switch is pressed). Check voltage on secondary side of fuse (F2).

This code is applied to only vehicle equipped with manual valve lift VR. Output of lift VR when abnormality is detected: Max. 0.2 V, Min. 4.8 V (Between CN210 and 21) Check voltage of temperature sensor Reset Voltage of tempera(THP), then replace sensor if neces- normal- ture sensor when absary. ly. normality is detected: Check wiring harness between CN7Max. 0.2 V, Min. 4.95 6, 12 (CPU board) and temperature V (Between CN7-6 sensor (THP), then repair or replace and 12) it. Check wiring harness between CN2- Reset – 3, 4 (CPU board) and travel speed normalsensor A, then repair or replace it. ly. Check travel speed sensor A, then repair or replace it. Replace travel motor. (Combination of sensor and slit panel in motor is defective.)

BE30 Series

TROUBLESHOOTING

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 42 Output of travel Vehicle cannot travel. 1) Check wiring harness between speed sensor B is CN11-5, 6 (CPU board) and travel defective. speed sensor B, then repair or replace it. 2) Check travel speed sensor B, then repair or replace it. 3) Replace travel motor. (Combination of sensor and slit panel in motor is defective.) 45 Capacitor of travel Vehicle can travel 1) If vehicle cannot travel, check code capacitor port normally. When main 01 first. (CBD) is charged contactor (MD) is 2) Replace CPU board (Resistance of abnormally. turned ON, arc is boosting charge drive Tr is defecgenerated. (This tive). trouble is also detected when failure code 01 is displayed.) 50 PS main Tr or its Steering wheel is 1) Check PS motor and its wiring for drive circuit harheavy. opening, then repair or replace it. ness are defective. i If short circuit is (Take care of defective contact of EPS board is de- made, this trouble is brush, too.) fective. detected before MPS 2) Check connectors and wiring harPS motor is open. contactor is turned ness between terminals G, E of main ON. Tr (TMPS1, 2) and CN8R (Power supply board) for short circuit, then repair or replace them. 3) Check connectors and wiring harness between CN6R (Power supply board) and CN2E (EPS board), then repair or replace them. 4) Check connectors and wiring harness between CN6R (CPU board) and CN1E (EPS board), then repair or replace them. 5) Check main Tr (TMPS1, 2), then replace it if necessary. (Note) Be sure to replace following parts, if necessary. • Replace set of main Tr (TMPS1, 2). • Replace EPS board. 6) If result of above check is normal, replace EPS board. 51 PS contactor Vehicle operates nor- 1) Check PS contactor (MPS), then re(MPS) is shorted mally. place it if necessary. or its sensor circuit (Error is kept dis2) Check wiring harness between CN4harness is defec- played.) 9 (CPU board) and terminal P21, tive. then repair or replace it. 3) Check wiring harness between CN41 (CPU board) and terminal P22, then repair or replace it. 52 PS main fuse (F3) Steering wheel is 1) Check PS main fuse (F3), then reis open. heavy. place it if necessary. PS contactor (PS contactor (MPS) 2) Check PS contactor (MPS), then re(MPS) is open or is not closed.) pair or replace it. its sensor circuit 3) Check wiring harness between CN4harness is defec9 (CPU board) and terminal P21, tive. then repair or replace it. 4) Check wiring harness between CN41 (CPU board) and terminal P22, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 53 PS contactor Steering wheel is 1) Check PS contactor (MPS) coil for (MPS) coil drive Tr heavy. disconnection of connector and coil, or its sensor circuit then repair or replace it. harness is defec2) Check wiring harness between tive. contactor coil connector and CN4-6, (In CPU board: 14 (CPU board), then repair or reTr5) place it. 3) Replace CPU board (since drive Tr is defective).

BE30 Series

Reset method Reset normally.

Remarks –

Turn key switch OFF.

Note) If this trouble is left as it is, travel contactor (MD) is worn quickly by arcs. Repair it immediately.

Turn key switch OFF.

–

Turn key switch OFF.

Timing of displaying trouble When key is turned ON and when MPS drive is turned OFF

Turn key switch OFF.

–

Turn key switch OFF.

–

70-77

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of code trouble 54 Output of PS torque sensor is defective.

55

Cargo handling controller temperature is high. Fan drive system is defective.

Trouble in vehicle Steering wheel is heavy.

Repair method (Execute 1) o 2) o ---) 1) Check and repair connectors and wiring harness between torque sensor and CN2-6, 7, 18 (CPU board). 2) Check PS torque sensor, then repair or replace it.

Vehicle can handle 1) cargo ("ON" period 2) ratio is limited by temperature rise). 3) 4)

5)

6) 56

Capacitor of cargo handling capacitor port (CBP) is charged abnormally.

Vehicle can handle cargo. When main contactor (MD) is turned ON, arc is generated. (This trouble is also detected when failure code 30 is displayed.) 60 • Key switch is • Only related operaturned ON while tions are impossi( 2) work equipment ble. Error is control lever is displayed immedinot in neutral. ately after key (Note) This is not switch is turned ON. trouble. • Adjustment of work equipment Pot is abnormal. • Work equipment Pot is abnormal. • Work equipment Pot circuit harness is defective.

1) 2)

Reset method Turn key switch OFF.

Remarks

Output voltage of torque sensor when abnormality is detected: Max. 0.2 V, Min. 4.8 V (Between CN2-6 and CN1-14) Cool controller and stop vehicle. ConNormal resistance/ Check mounting screws of TMP for troller is voltage of temperalooseness. reset ture sensor Check resistance and voltage of tem- when 25°C: 20kz/4.0 V perature sensor (THP), then replace temper- 50°C: 7.2kz/3.0 V it if necessary. ature 80°C: 2.5kz/1.7 V Check wiring harness between CN7- lowers Tolerance of these 6, 12 (CPU board) and temperature below values is ± 10%. sensor (THP), then repair or replace 100°C. it. Check wiring harness between CN7R-1, 2, 7, 8 (Power supply board) and each fan, then repair or replace it. Check wiring harness between CN96 (CPU board) and CN1R-6, then repair or replace it. When driving cargo handling motor Turn Note) If this trouble is continuously, check code 30 first. key left as it is, main Replace CPU board (Resistance of switch contactor (MD) boosting charge drive Tr is defecOFF. is worn quickly tive). by arcs. Repair it immediately.

1) Check input signal of work equipment Pot. • Measure voltage at system controller connector CN4S --- Normal: 2.4 - 2.6 V 2) If result of check in (1) above is normal, replace system controller board. 3) If result of check in (1) above is abnormal, disconnect related Pot connector and check its resistance, then replace if necessary. Normal resistance --- Pin No. 1-3: 2kz Pin No. 2-3: 0 - 2kz 4) If result of check in (1) above is abnormal but that in (3) is normal, check and repair wiring harness between system controller and work equipment Pot. 61 • Adjustment of • Only related opera- 1) Check and adjust control lever stopwork equipment tions are impossiper. ( 2) Pot is abnormal. ble. Error is • Measure voltage at work equipment • Work equipment displayed when lecontrol lever Pot connector CN4S. Pot is abnormal. ver is operated. Normal --- When lever is fully tilted • Work equipment forward: 3.9 – 4.3 V Pot circuit harWhen lever is fully tilted back: 0.7 – ness is defective. 1.1 V 2) If result of (1) above is normal, replace system controller board. 3) If result of (1) above is abnormal, disconnect related Pot connector and check its resistance, then repair it. Normal resistance --- Pin No. 1-3: 2kz Pin No. 2-3: 0 – 2kz 4) If result of check in (1) above is abnormal but that in (3) is normal, check and repair wiring harness between system controller and work equipment Pot. 2. Displayed only proportional solenoid valve spec.

70-78

TROUBLESHOOTING

Turn key switch OFF.

If E87 – E89 are also displayed, check them first. For repair method, see each failure code section.

Turn key switch OFF.

If E87 - E89 and E-60 are also displayed, check them first. For repair method, see each failure code section.

BE30 Series

TROUBLESHOOTING

Failure Contents of Trouble in code trouble vehicle 61 • Output of lift • Vehicle can do all (Conpressure sensor operations. Retinued) is abnormal. sponse is lowered, however, and hunt( 2) • Lift pressure sensor circuit ing prevention funcharness is defec- tion does not work tive. when lift lowers. • Automatic lifting and automatic fork leveling (if equipped) cannot be applied. Error is displayed immediately after key switch is turned ON. (If automatic fork • Automatic fork levleveling device is eling cannot be apinstalled) plied. • Output of tilting (• Fork can be angle sensor is moved by manual abnormal. operation.) • Tilting angle sen- Error is displayed sor circuit harimmediately after ness is defective. key switch is turned ON.

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Repair method (Execute 1) o 2) o ---) Check input signal of lift pressure sensor. Measure voltage at system controller connector CN4S --- Normal: 0.37 – 4.3 V If result of check in 1) above is normal, replace system controller board. If result of check in 1) above is abnormal, check and repair pressure sensor harness. If result of check in 1) above is abnormal but that in 3) is normal, repair pressure sensor.

Reset method Turn key switch OFF.

1) Check and repair mechanical operation of tilting angle sensor. 2) Check that mast does not stop mechanically during automatic fork leveling operation, then repair mast if necessary. 3) Check input signal from tilting angle sensor and adjust installation of sensor. • Measure voltage at system controller connector CN5S. Normal voltage: 0.4 – 4.6 V (Backward tilting end - Forward tilting end) 4) If result of 3) above is normal, replace system controller board. 5) If result of 3) above is abnormal, check and repair tilting angle sensor. • Disconnect tilting angle sensor and measure resistance of sensor. 62 • Proportional • Only related opera- 1) Check resistance of proportional valve coil is distions are impossivalve coil, then repair coil if neces( 2) connected. ble. Error is sary. • Wiring harness displayed when leNormal resistance: 17 – 18z between proporver is operated. 2) If result of above check is normal, tional valve and (Pump motor rocheck and repair proportional valve system controller tates for a moment.) circuit harness. has trouble of dis3) If results of 1) and 2) are normal, go connection, leakto PROPORTIONAL VALVE DRIVE age, or defective CIRCUIT IS OPEN. contact. • Relay, fuse, EMG • Vehicle cannot op- 1) Check proportional valve power supswitch, or wiring erate at all. ply. harness is disError is displayed • Check voltage between pins No. 8 connected. when lever is operand No. 21 of system controller con• EMG relay in sys- ated. (Pump motor nector CN1S --- Normal voltage: Battem controller is rotates for a motery voltage open. ment.) 2) If result of 1) above is normal, re• Battery voltage place system controller board. lowers while lever 3) If result of 1) above is abnormal, is operated. A 1 check proportional valve power sup(Note) This is not ply circuit harness, CH interlock trouble in system (main) relay, fuse, and EMG switch controller. between battery and system control• EMG switch is ler for disconnection and leakage, operated while then repair. lever is operated, then only proportional valve power supply circuit is broken. A 2 (Note) This is not trouble in system controller. • Proportional • Only related opera- 1) Replace system controller board. valve drive circuit tions are impossiin system conble. Error is troller is open. displayed when lever is operated. (Pump motor rotates for a moment.)

Set tilt lever in neutral.

1) • 2) 3) 4)

Remarks

(Output voltage of pressure sensor: Out of 0.34 – 4.8 V)

Turn key switch OFF.

Turn key switch OFF.

(Output voltage of tilting angle sensor: Out of 0.34 – 4.7 V) (Output of sensor does not change during fork leveling operation.) If E87 – E89, E-60, and E-61 are also displayed, check them first. For repair method, see each failure code section. A1 --- Example: Main transistor of main controller is shorted. A2 --- Example: EMG switch is operated momentarily or pushed halfway.

2. Displayed only proportional solenoid valve spec.

BE30 Series

70-79

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of code trouble 62 • Proportional (Con- valve coil is tinued) shorted. ( 2)

Trouble in Repair method vehicle (Execute 1) o 2) o ---) • Vehicle cannot op- 1) Check resistance of proportional erate at all. valve coil, then repair coil if necesError is displayed sary. when lever is operNormal resistance: 17 – 18z ated. (Pump motor 2) If result of above check is normal, go rotates for a moto PROPORTIONAL VALVE DRIVE ment.) CIRCUIT IS OPEN.

• Proportional • Vehicle cannot op- 1) Replace system controller board. valve drive circuit erate at all. in system conError is displayed troller is shorted. when lever is operated. (Pump motor rotates for a moment.) 64 [If automatic fork • Automatic fork lev- 1) This phenomenon is not trouble. If it eling device does occurs frequently, however, check ( 2) leveling device is installed] not reach level posifor mechanical factor such as hitch• Automatic fork tion or exceeds leving, then repair. leveling device el position. does not reach (• Fork can be tilted level position or manually.) exceeds level position. (Note) This is not trouble. 66 [If automatic lifting • Automatic lifting 1) Check input signal for automatic liftcannot be applied. ing operation. ( 2) device is installed] • Automatic lifting (• Lift can be raised • Measure input voltage for switches control panel manually.) other than memory switch at connecswitch is shorted Error is displayed tor CN6S of system controller. before key switch immediately after Normal voltage: When switch is OFF: is turned ON. key switch is turned Min. 4 V ON. When switch is ON: 0 V 2) If result of 1) above is normal, replace system controller board. 3) If result of (1) above is abnormal, measure resistance of 9-pin connector of lifting display panel. Normal resistance: When switch is OFF: c When switch is ON: 0z (Excluding memory switch) 4) If result of 3) above is abnormal, repair lifting display panel. 5) If result of 1) above is abnormal but that of (3) is normal, replace system controller. 67 [If automatic lifting • Automatic lifting 1) Check encoder power supply circuit. cannot be applied. • Disconnect system controller con( 2) device is installed] • Automatic lifting • If this trouble occurs nector CN5S and check voltage beencoder power in automatic lifting tween Pin No. 1 and No. 4. supply in system mode, vehicle When normal: 10 V controller is destops. 2) If result of above check is abnormal, fective. (• Lift can be raised replace system controller board. • Battery voltage is manually.) low. Error is displayed (Note) This is not immediately after trouble in system key switch is turned controller. ON. (Example: Main transistor of main controller is shorted.) 2. Displayed only proportional solenoid valve spec.

70-80

TROUBLESHOOTING

Reset method Turn key switch OFF.

Remarks If E87 – E89, E-60, and E-61 are also displayed, check them first. For repair method, see each failure code section. A1 --- Example: Main transistor of main controller is shorted. A2 --- Example: EMG switch is operated momentarily or pushed halfway. (Check output corresponding to input.)

Leave (Fork is not in level polever in sition.) neutral.

Turn key switch OFF.

(when key switch is turned ON, unloading, loading, or number-oflayer setting (1 - 5 layers) switch is turned ON.) Turn key switch OFF.

(Source voltage: Below 4.77 V)

BE30 Series

TROUBLESHOOTING

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 67 [If automatic lifting • Vehicle stops lifting 1) Check that lifting encoder is operat(Con- device is installed] operation, then it ing (wire is coming out or going in), tinued) • Lifting encoder is cannot start autothen repair it if necessary. defective. matic lifting opera- 2) Check that lift does not stop mechan( 2) • Lifting encoder tion any more. ically during automatic lifting operacircuit is defec(• Lift can be raised tion, then repair lift if necessary. tive. manually.) 3) Check input signal from lifting encoder while lift is rising. • Check voltage at system controller connector CN5S. Voltage under abnormal condition (Note 1): 5 V or 0 V (Note 2): Check A-phase and Bphase with encoders 1 and 2 respectively. 4) If result of 3) above is normal, replace system controller board. 5) If result of 3) above is abnormal, check lifting encoder harness, then repair it if necessary. 6) If result of 3) above is abnormal but that of 5) is normal, repair lifting encoder. [If automatic lifting • Vehicle stops lifting 1) Check that 1st and 2nd encoders are device is installed] operation, then it connected correctly, then repair [When 2 encoders cannot start autothem if necessary. are installed] matic lifting opera• 1st and 2nd ention any more. coders are con(• Lift can be raised nected wrongly manually.) (when 2 encoders are installed). [If automatic lifting • Vehicle stops lifting 1) Disconnect connector of lifting 2) refdevice is installed] operation, then it erence switch and measure voltage. [When 2 encoders cannot start autoIf voltage is above 4 V, check lifting are installed] matic lifting opera2) reference switch, then repair it if • Lifting 2) refertion any more. necessary. ence switch is (• Lift can be raised 2) If voltage measured in 1) above is defective. manually.) below 4 V, check wiring harness be• Circuit harness of tween system controller and lifting 2) lifting (2) referreference switch, then repair it if necence switch is essary. defective. 3) If result of 2) above is normal, replace system controller board. [If automatic lifting • Vehicle stops lifting 1) Turn key switch ON and pass referdevice is installed] operation, then it ence switch. See if trouble occurs • A-phase and Bcannot start auto(buzzer sounds) 1 second after first phase of lifting matic lifting operalifting operation is performed. encoder are con- tion any more. 2) If trouble occurs by operation in 1) nected opposite- (• Lift can be raised above, check and repair connections ly. manually.) of A-phase and B-phase. [If automatic lifting • Vehicle cannot op- 1) If trouble is not repaired by above device is installed] erate automatic liftmethods, replace system controller • Lifting encoder ing work. board. input circuit in • Vehicle stops lifting system controloperation. ler is abnormal. 2. Displayed only proportional solenoid valve spec.

BE30 Series

Reset method Turn key switch OFF.

Remarks (Note 1) Encoder output pulses of 0 V and 5 V. If it is abnormal, its output only 0 V or 5 V. (Note 2) Check encoder (2) only when it is installed. (Note 3) In specification shown in standard connection diagram, lifting encoder wire is pulled out when lift is raised. In specification where wire is pulled in when lift is raised, A-phases and B-phase are on opposite sides. Accordingly, phases must be confirmed.

Turn key switch OFF.

If E87 – E89, E60 and E61 are also displayed, check them first. For repair method, see each failure code section. (Pulses are not output from encoder during lifting operation.)

Turn key switch OFF.

(Operating direction does not conform to output direction of encoder.)

Turn key switch OFF.

(Pulses are not output from encoder during lifting operation.)

70-81

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 68 [If automatic lifting • Vehicle cannot op- 1) Repeat operation correctly. erate automatic lift( 2) device is installed] or [If automatic fork ing work. leveling device is • Vehicle cannot opinstalled] erate fork leveling • Automatic lifting work. operation and (• Fork can be levfork leveling opeled manually.) eration are defective. [If automatic lifting • Vehicle cannot op- 1) Disconnect reference switch connecdevice is installed] erate automatic lifttor and measure voltage. If voltage or [If automatic fork ing work. is above 4 V, check reference switch, leveling device is (•Fork can be leveled then repair it if necessary. installed] manually.) 2) If voltage measured in 1) above is • Automatic lifting below 4 V, check wiring harness bereference switch tween system controller CN5S-9 and is defective. reference switch, then repair it if nec• Wiring harness of essary. automatic lifting 3) If result of 2) above is normal, rereference switch place system controller board. is defective. [If automatic fork • Fork cannot be tilt- 1) If fork leveling display switch cannot leveling device is ed manually. be turned ON and OFF, replace it. installed] 2) If switch is normal, check its wiring • Tilt display switch harness for short circuit, then repair. is shorted. 3) If result of above check is normal, re• Tilt display switch place system controller. harness is shorted. 69 [If automatic lifting • Fork stops before 1) This phenomenon is not trouble. If it set stop position in occurs frequently, however, check ( 2) device is installed] • Automatic lifting automatic lifting for mechanical factor such as hitchdevice does not mode. ing, then repair. reach set stop position. (Note) This is not trouble. 70 [If automatic lifting • Fork stops after set 1) This phenomenon is not trouble. If it stop position in auoccurs frequently, however, check ( 2) device is installed] • Automatic lifting tomatic lifting mode. for mechanical factor such as maldevice exceeds function of proportional solenoid set stop position. valve, etc., then repair. (Note) This is not trouble. 87 • Sensor power • Vehicle cannot op- 1) Disconnect connectors CN3S, 4S, supply in system erate at all. 5S, and 6S of the system controller ( 2) controller is abError is displayed and check voltage between pins No. normal. immediately after 26 and 28 of CN4S. When it is nor• Battery voltage is key switch is turned mal, it is 5 V. low. ON. 2) If result of 1) above is abnormal, re(Note) This is not place system controller board. trouble in system 3) If result of 1) above is normal, check controller. SENS5V circuit harness and sensor (Example: Main for short circuit and leakage, then retransistor of main pair. controller is shorted.) 2. Displayed only proportional solenoid valve spec.

70-82

TROUBLESHOOTING

Reset Remarks method Set [Fork leveling operalever in tion is abnormal] neutral. • Operation is in reverse direction. [Automatic lifting operation is abnormal] • Reference switch is not detected or number of layers is not set. • Number of layers is Set lever in changed during opneutral. eration or automatic operation is started in manual operation mode. • Operation is in reverse direction or it is performed at short distance.

Set lever in neutral.

Set After fork stops before lever in set stop position, if it is neutral. moved to set stop position manually, buzzer sounds.

Set After fork stops exlever in ceeding set stop posineutral. tion, if it is moved to set stop position manually, buzzer sounds. Turn key switch OFF.

(Source voltage: Below 4.5 V)

BE30 Series

TROUBLESHOOTING

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 89 • Work equipment • Pump motor rotates 1) Check work equipment switch signal switch signal is at low speed. output. ( 2) shorted to GND • Vehicle cannot op• Measured voltage between pins No. or it is leaking. erate at all. 4 and 2, 3 and 2, 5 and 2, 6 and 2, • Work equipment Error is displayed and 17 and 2 of system controller switch circuit of immediately after connector CN1S. If it is normal, it is main controller is key switch is turned above 4 V. abnormal. ON. 2) If result of 1) above is normal, replace system controller. 3) If result of 1) above is abnormal, check work equipment switch signal harness for leakage and short circuit to GND, then repair. 4) If result of 1) above is abnormal, measure voltage between pins No. 8 and 14, 10 and 14, 21 and 14, 22 and 14, 23 and 14 of main controller connector CN1. If it is normal, it is 4 V 5 V. 5) If result of 4) above is abnormal, replace main controller board. • Proportional • Error is displayed 1) Replace system controller board. valve EMG relay immediately after in system conkey switch is turned troller is shorted. ON. 95 Multi-controller is • Error is displayed 1) Replace multi-controller board. defective. immediately after key switch is turned ON. (Vehicle operates normally.) 97 Communication Error is displayed 1) Check continuity of wiring harnesses between main con- when abnormality is of CN1-5, CN1-6, CN1-13, and CN1troller and multidetected. 14 of multi-controller, then repair controller is abnor- • Main controller canthem if necessary. mal. not be adjusted. 2) Replace multi-controller board. • It cannot display fail- 3) Replace main controller board. ure codes. (Vehicle operates normally.) 98 Communication Error is displayed 1) Check continuity of wiring harnesses when abnormality is of CN4-5, CN4-6, CN4-7, and CN4-9 ( 2) between system controller and detected. of multi-controller, then repair them if multi-controller is System controller necessary. abnormal. cannot display failure 2) Replace multi-controller board. codes. (Vehicle oper- 3) Replace system controller board. ates normally.) 99 Communication Error is displayed 1) Check continuity of wiring harnesses between meter when abnormality is of CN3-1 and CN3-2 of multi-controlpanel and multidetected. ler, then repair them if necessary. controller is abnor- • Main controller can- 2) Replace multi-controller board. mal. not be adjusted. 3) Replace meter panel. • Main controller, system controller, and multi-controller cannot display failure codes. (Vehicle operates normally.) 2. Displayed only proportional solenoid valve spec.

BE30 Series

Reset method Turn key switch OFF.

Turn key switch OFF. Turn batter connector OFF.

Remarks

(When key switch is turned ON, hydraulic chopper starts without receiving operation input.) (When key switch is turned ON, EMG relay in board is closed.) –

Perform automatic resetting normally.

Occasional occurrence of this trouble is caused by defective contact. In this case, connect and disconnect connector.

Perform automatic resetting normally.

Occasional occurrence of this trouble is caused by defective contact. In this case, connect and disconnect connector.

Perform automatic resetting normally.

Occasional occurrence of this trouble is caused by defective contact. In this case, connect and disconnect connector.

70-83

FAILURE CODES LIST (3.0 TON MODEL)

TROUBLESHOOTING

FAILURE CODES LIST (3.0 TON MODEL) Failure Contents of code trouble 01 Travel power module is shorted (Upper and lower FET's are shorted).

03

Main contactor (MD) is shorted or open or its sensor circuit harness is defective.

04 05 11 12

Travel power modules are shorted (Upper and lower modules are shorted separately).

06 08 09

Travel power module is open. U-, V-, or W-phase is disconnection.

70-84

Trouble in Repair method vehicle (Execute 1) o 2) o ---) Vehicle cannot travel 1) If vehicle can travel, check code 45 or handle cargo (MD first. connector is not 2) Check travel power modules (TMDU, closed). TMDV, and TMDW) and replace (This trouble is also them if necessary. (If a power moddetected when failure ule is defective, be sure to replace it code 45 is displayed.) and power supply board as a set.) 3) Check wiring harness between CN3R (Power supply board) and each power module, then repair or replace it. 4) Check wiring harness between CN42 (CPU board) and terminal P3, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 6) If result of above check is normal, replace power supply board. Vehicle cannot travel 1) Check main contactor (MD) (for meltor handle cargo. ing, mechanical hitching, etc. of contacts), then repair or replace it. 2) Check wiring harness between CN511 (CPU board) and terminal P2, then repair or replace it. 3) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. Vehicle cannot travel 1) Check travel power modules (TMDU, or handle cargo. TMDV, TMDW) and replace them if necessary. (When replacing, be sure to replace them as a set, together with power supply board.) 2) Check wiring harness between CN3R (Power supply board) and each power module, then repair or replace it. 3) Check wiring harness between CN43 (CPU board) and terminal P4, then repair or replace it. 4) Check wiring harness between CN42 (CPU board) and terminal P3, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 6) If result of above check is normal, replace power supply board. Vehicle cannot travel 1) Check travel power modules (TMDU, or handle cargo. TMDV, TMDW) and replace them if necessary. (When replacing, be sure to replace them as a set, together with power supply board.) 2) Check wiring harness between CN3R (Power supply board) and each power module, then repair or replace it. 3) Check output terminals of U-, V-, and W-phase for disconnection and looseness of screws. 4) If result of above check is normal, replace power supply board.

Reset method Turn key switch OFF.

Turn key switch OFF.

Remarks –

–

Turn key switch OFF.

Failure code 04: Detected when key switch is turned ON.(Upper) Failure code 05: Detected when key switch is turned ON.(Lower) Failure code 11: Detected after key switch and MD are turned ON.(Upper) Failure code 12: Detected after key switch and MD are turned ON.(Lower)

Turn key switch OFF.

Failure code 06: U-phase is open (disconnected) Failure code 08: V-phase is open (disconnected) Failure code 09: W-phase is open (disconnected)

BE30 Series

TROUBLESHOOTING

Failure Contents of Trouble in code trouble vehicle 07 Main contactor Vehicle cannot travel (MD) drive Tr is de- or handle cargo. fective (In CPU board: Tr4). Main contactor coil is open. Sensor circuit harness of main contactor coil is defective. 16 F or R switch is de- Vehicle cannot travel. fective.

17

FAILURE CODES LIST (3.0 TON MODEL)

Repair method (Execute 1) o 2) o ---) 1) Check main contactor (MD) coil for disconnection of connector and coil, then repair or replace it. 2) Check wiring harness between contactor coil and CN4-5, 13 (CPU board), then repair or replace it. 3) Replace CPU board (since drive Tr is defective).

1) Check wiring harness between CN111, 12 (CPU board) and F/R switch for short circuit, then replace if necessary. 2) Repair or replace F/R switch. Travel accelerator Vehicle cannot travel. 1) Check wiring harness between CN2output is defective. 8, 9, 20 (CPU board) and travel accelerator, then repair or replace it. 2) Check travel accelerator unit, then repair or replace it.

19

Output or wiring Vehicle cannot travel. 1) Check wiring harness between CPU harness of travel board and current sensors, then recurrent sensor pair or replace it. (CSDU, CSDW) is CSDU: CN5-3, 4, 14, 15 defective. CSDW: CN5-5, 6, 16, 17 2) Check source voltage of current sensor power supply of CPU board. CSDU: Between CN5-3 and 14, 15 CSDW: Between CN5-5 and 16, 17 If source voltage is abnormal, replace CPU board. 3) Check current sensors (CSDU, CSDW), then replace it if necessary.

20

Travel main fuse Vehicle cannot travel 1) Check travel fuse (F1) and replace it (F1) is broken or its (MD contactor is if necessary. sensor circuit har- closed). 2) Check wiring harness between CN5ness is defective. 11 (CPU board) and terminal P2, then repair or replace it. 3) Check wiring harness between CN42 (CPU board) and terminal P3, then repair or replace it. Undervoltage is Vehicle cannot travel 1) Charge battery. detected (Battery (MD/MPS connector 2) Check wiring harness between CN4voltage is lower). is not closed). When 8 (CPU board) and terminal P1, then key switch is turned repair or replace it. ON again, vehicle can travel. Output of travel Vehicle can travel 1) Check temperature sensor (THD), controller tempera- normally (assuming and replace it if necessary. ture sensor (THD) temperature is nor2) Check wiring harness between CN7-5, is defective. mal). 11 (CPU board) and temperature sensor (THD), then repair or replace it. Neutral is detect- Vehicle cannot travel. 1) Operate accelerator and direction ed. switch normally. * Neutral caused 2) Check accelerator or direction switch by mistake in opfor short circuit, then repair or reeration is not place it. trouble. 3) Check circuit of accelerator or direction switch for looseness of connector and defective wiring harness, then repair or replace it.

21

22

23

BE30 Series

Reset method Turn key switch OFF.

Remarks –

Reset Turn F switch and R normal- switch ON simultaly. neously. Reset Normal source voltage of normal- accelerator: 5 V (Bely. tween CN2-9 and 20) Output voltage of accelerator when abnormality is detected: Max. 0.2 V, Min. 4.8 V (Between CN2-8 and 20) Turn Normal sensor output key • During travel: 3.0 V switch – 11.0 V OFF. • When FR switch is in neutral and accelerator is OFF: Approx. 7 V CSDU: Between CN5-4 and 14, 15 CSDW: Between CN5-6 and 16, 17 Normal source voltage of sensor power supply: 15 V Sensor output when abnormality is detected: Max. 1.5 V, Min. 12.5 V Turn Check voltage on seckey ondary side of fuse switch (F1). OFF.

Turn key switch OFF.

This trouble is detected when battery voltage is below 42 V for 0.8 seconds.

Reset Voltage of temperanormal- ture sensor (THD) ly. when abnormality is detected: Max. 0.2 V, Min. 4.95 V Turn When both of acceleraccel- ator and FR switch are erator turned ON, trouble is and FR reset when either of switch them is turned OFF. OFF.

70-85

FAILURE CODES LIST (3.0 TON MODEL)

TROUBLESHOOTING

Failure Contents of code trouble 24 Travel controller temperature is high. Fan drive system is defective.

25

26

Trouble in Repair method vehicle (Execute 1) o 2) o ---) Vehicle can travel 1) Cool controller and stop vehicle. (Current is limited by 2) Check mounting screws of TMDU, temperature rise and TMDV, and TMDW for looseness. output is lowered). 3) Check resistance and voltage of temperature sensor (THD), then replace it if necessary. 4) Check wiring harness between CN75, 11 (CPU board) and temperature sensor, then repair or replace it. 5) Check wiring harness between CN7R-1, 2, 7, 8 (Power supply board) and each fan, then repair or replace it. 6) Check wiring harness between CN96 (CPU board) and CN1R-6, then repair or replace it. Travel motor tem- Vehicle can travel 1) Cool travel motor and stop vehicle. perature rises. (Current is limited by 2) Check resistance and voltage of travtemperature rise and el motor temperature sensor, then output is lowered). replace it if necessary. 3) Check wiring harness between CN11-3, 4 (CPU board) and travel motor temperature sensor, then repair or replace it.

Travel controller Vehicle cannot travel. 1) temperature is ab2) normal. Fan drive system 3) is defective. 4) 5)

6) 27

28

Output of travel motor temperature sensor is defective.

Vehicle can travel normally (assuming temperature is normal).

1) 2)

Travel motor tem- Vehicle cannot travel. 1) perature is abnor2) mal. 3)

70-86

Reset method Controller is reset when temperature lowers below 100°C.

Remarks Normal resistance/ voltage of temperature sensor 25°C: 20kz/4.0 V 50°C: 7.2kz/3.0 V 80°C: 2.5kz/1.7 V Tolerance of these values is ± 10%. Above 100°C: Current is limited. Above 103°C: Warning is displayed.

Travel motor is reset when temperature lowers below 160°C.

Normal resistance/ voltage of travel motor temperature sensor 25°C: 10.7kz/3.5 V 50°C: 4.4kz/2.4 V 100°C: 1.0kz/0.9 V 150°C: 0.3kz/0.3 V Tolerance of these values is ± 10%. Above 160°C: Current is limited. Above 163°C: Warning is displayed. Cool controller and stop vehicle. ConNormal resistance/ Check mounting screws of TMDU, troller is voltage of temperaTMDV, and TMDW for looseness. reset ture sensor Check resistance and voltage of tem- when 25°C: 20kz/4.0 V perature sensor (THD), then replace temper- 50°C: 7.2kz/3.0 V it if necessary. ature 80°C: 2.5kz/1.7 V Check wiring harness between CN7- lowers Tolerance of these 5, 11 (CPU board) and temperature below values is ± 10%. sensor, then repair or replace it. 115°C. Above 115°C: Travel Check wiring harness between is stopped. CN7R-1, 2, 7, 8 (Power supply board) and each fan, then repair or replace it. Check wiring harness between CN96 (CPU board) and CN1R-6, then repair or replace it. Check voltage of travel motor tem- Reset Voltage of temperaperature sensor, then replace sensor normal- ture sensor when abif necessary. ly. normality is detected: Check wiring harness between Max. 0.2 V, Min. 4.95 CN11-3, 4 (CPU board) and travel V motor temperature sensor, then repair or replace it. Cool travel motor and stop vehicle. Travel Normal resistance/ Check resistance and voltage of trav- motor is voltage of travel motor el motor temperature sensor, then reset temperature sensor replace it if necessary. when 25°C: 10.7kz/3.5 V Check wiring harness between temper- 50°C: 4.4kz/2.4 V CN11-3, 4 (CPU board) and travel ature 100°C: 1.0kz/0.9 V motor temperature sensor, then re- lowers 150°C: 0.3kz/0.3 V pair or replace it. below Above 175°C: Travel 175°C. is stopped.

BE30 Series

TROUBLESHOOTING

FAILURE CODES LIST (3.0 TON MODEL)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 30 Cargo handling Vehicle can handle 1) If vehicle can handle cargo, check power module cargo. code 56 first. (TMPU) is shorted. (MP contactor is 2) Check cargo handling power module closed.) (TMPU) and replace it if necessary. (This trouble is also (If power module is defective, be detected when failure sure to replace it and power supply code 56 is displayed.) board as a set.) 3) Check wiring harness between CN4R (Power supply board) and TMPU, then repair or replace it. 4) Check wiring harness between CN410 (CPU board) and terminal P13, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 6) If result of above check is normal, replace power supply board. 31 Cargo handling Vehicle cannot han- 1) Check cargo handling power module power module dle cargo. (TMP) and replace it if necessary. (If (TMP) is open. (MP contactor is power module is defective, be sure to Upper side of car- closed.) replace it and power supply board as go handling power a set.) module (TMP) (Be2) Check wiring harness between tween P and OUT) CN4R (Power supply board) and caris shorted. go handling power module (TMP), Cargo handling then repair or replace it. motor is shorted or 3) Check wiring harness between CN8open. 3 (CPU board) and CN2R-3 (Power supply board), then repair or replace it. 4) Check cargo handling motor and its wiring, then repair or replace it. 32 Chassis EMG Vehicle cannot oper- 1) Check chassis EMG switch. If it is switch is defective ate work equipment. open, repair or replace it. or its circuit har(MP contactor is not 2) Check wiring harness between CN1ness is disconnect- closed.) 24 (CPU board) and EMG switch, ed. then repair or replace it. 33

Cargo handling main fuse (F2) is broken its sensor circuit harness is defective.

Vehicle cannot handle cargo (MP contactor is closed).

1) 2) 3) 4)

35

Cargo handling lift Vehicle operates with 1) VR is shorted or cargo handling "ON" open. period ratio at 100%. 2)

36

41

Output of cargo handling controller temperature sensor (THP) is defective.

Vehicle can handle cargo normally (assuming temperature is normal).

1) 2)

Output of travel Vehicle cannot travel. 1) speed sensor A is defective. 2) 3)

BE30 Series

Reset method Turn key switch OFF.

Turn key switch OFF.

Turn EMG switch and key switch OFF. Check cargo handling fuse (F2) and Turn replace it if necessary. key Check wiring harness between CN5- switch 22 (CPU board) and terminal P12, OFF. then repair or replace it. Check wiring harness between CN410 (CPU board) and terminal P13, then repair or replace it. Check wiring harness between CN511 (CPU board) and terminal P2, then repair or replace it. Check wiring harness between CN2- Reset 10, 11, 21 (CPU board) and cargo normalhandling lift VR, then repair or rely. place it. Check cargo handling lift VR, then replace it if necessary.

Remarks –

–

This trouble occurs only when CN1-24 is disconnected (and does not occur while EMG switch is pressed). Check voltage on secondary side of fuse (F2).

This code is applied to only vehicle equipped with manual valve lift VR. Output of lift VR when abnormality is detected: Max. 0.2 V, Min. 4.8 V (Between CN210 and 21) Check voltage of temperature sensor Reset Voltage of tempera(THP), then replace sensor if neces- normal- ture sensor when absary. ly. normality is detected: Check wiring harness between CN7Max. 0.2 V, Min. 4.95 6, 12 (CPU board) and temperature V (Between CN7-6 sensor (THP), then repair or replace and 12) it. Check wiring harness between CN2- Reset – 3, 4 (CPU board) and travel speed normalsensor A, then repair or replace it. ly. Check travel speed sensor A, then repair or replace it. Replace travel motor. (Combination of sensor and slit panel in motor is defective.)

70-87

FAILURE CODES LIST (3.0 TON MODEL)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 42 Output of travel Vehicle cannot travel. 1) Check wiring harness between speed sensor B is CN11-5, 6 (CPU board) and travel defective. speed sensor B, then repair or replace it. 2) Check travel speed sensor B, then repair or replace it. 3) Replace travel motor. (Combination of sensor and slit panel in motor is defective.) 45 Capacitor of travel Vehicle can travel 1) If vehicle cannot travel, check code capacitor port normally. When main 01 first. (CBD) is charged contactor (MD) is 2) Replace CPU board (Resistance of abnormally. turned ON, arc is boosting charge drive Tr is defecgenerated. (This tive). trouble is also detected when failure code 01 is displayed.) 50 PS main Tr or its Steering wheel is 1) Check PS motor and its wiring for drive circuit harheavy. opening, then repair or replace it. ness are defective. i If short circuit is (Take care of defective contact of EPS board is de- made, this trouble is brush, too.) fective. detected before MPS 2) Check connectors and wiring harPS motor is open. contactor is turned ness between terminals G, E of main ON. Tr (TMPS1, 2) and CN8R (Power supply board) for short circuit, then repair or replace them. 3) Check connectors and wiring harness between CN6R (Power supply board) and CN2E (EPS board), then repair or replace them. 4) Check connectors and wiring harness between CN6R (CPU board) and CN1E (EPS board), then repair or replace them. 5) Check main Tr (TMPS1, 2), then replace it if necessary. (Note) Be sure to replace following parts, if necessary. • Replace set of main Tr (TMPS1, 2). • Replace EPS board. 6) If result of above check is normal, replace EPS board. 51 PS contactor Vehicle operates nor- 1) Check PS contactor (MPS), then re(MPS) is shorted mally. place it if necessary. or its sensor circuit (Error is kept dis2) Check wiring harness between CN4harness is defec- played.) 9 (CPU board) and terminal P21, tive. then repair or replace it. 3) Check wiring harness between CN41 (CPU board) and terminal P22, then repair or replace it. 52 PS main fuse (F3) Steering wheel is 1) Check PS main fuse (F3), then reis open. heavy. place it if necessary. PS contactor (PS contactor (MPS) 2) Check PS contactor (MPS), then re(MPS) is open or is not closed.) pair or replace it. its sensor circuit 3) Check wiring harness between CN4harness is defec9 (CPU board) and terminal P21, tive. then repair or replace it. 4) Check wiring harness between CN41 (CPU board) and terminal P22, then repair or replace it. 5) Check wiring harness between CN48 (CPU board) and terminal P1, then repair or replace it. 53 PS contactor Steering wheel is 1) Check PS contactor (MPS) coil for (MPS) coil drive Tr heavy. disconnection of connector and coil, or its sensor circuit then repair or replace it. harness is defec2) Check wiring harness between tive. contactor coil connector and CN4-6, (In CPU board: 14 (CPU board), then repair or reTr5) place it. 3) Replace CPU board (since drive Tr is defective).

70-88

TROUBLESHOOTING

Reset method Reset normally.

Remarks –

Turn key switch OFF.

Note) If this trouble is left as it is, travel contactor (MD) is worn quickly by arcs. Repair it immediately.

Turn key switch OFF.

–

Turn key switch OFF.

Timing of displaying trouble When key is turned ON and when MPS drive is turned OFF

Turn key switch OFF.

–

Turn key switch OFF.

–

BE30 Series

TROUBLESHOOTING

Failure Contents of code trouble 54 Output of PS torque sensor is defective.

55

Cargo handling controller temperature is high. Fan drive system is defective.

FAILURE CODES LIST (3.0 TON MODEL)

Trouble in vehicle Steering wheel is heavy.

Repair method (Execute 1) o 2) o ---) 1) Check and repair connectors and wiring harness between torque sensor and CN2-6, 7, 18 (CPU board). 2) Check PS torque sensor, then repair or replace it.

Vehicle can handle 1) cargo ("ON" period 2) ratio is limited by temperature rise). 3) 4)

5)

6) 56

Capacitor of cargo handling capacitor port (CBP) is charged abnormally.

Vehicle can handle cargo. When main contactor (MD) is turned ON, arc is generated. (This trouble is also detected when failure code 30 is displayed.) 60 • Key switch is • Only related operaturned ON while tions are impossi( 2) work equipment ble. Error is control lever is displayed immedinot in neutral. ately after key (Note) This is not switch is turned ON. trouble. • Adjustment of work equipment Pot is abnormal. • Work equipment Pot is abnormal. • Work equipment Pot circuit harness is defective.

1) 2)

Remarks

Output voltage of torque sensor when abnormality is detected: Max. 0.2 V, Min. 4.8 V (Between CN2-6 and CN1-14) Cool controller and stop vehicle. ConNormal resistance/ Check mounting screws of TMP for troller is voltage of temperalooseness. reset ture sensor Check resistance and voltage of tem- when 25°C: 20kz/4.0 V perature sensor (THP), then replace temper- 50°C: 7.2kz/3.0 V it if necessary. ature 80°C: 2.5kz/1.7 V Check wiring harness between CN7- lowers Tolerance of these 6, 12 (CPU board) and temperature below values is ± 10%. sensor (THP), then repair or replace 100°C. it. Check wiring harness between CN7R-1, 2, 7, 8 (Power supply board) and each fan, then repair or replace it. Check wiring harness between CN96 (CPU board) and CN1R-6, then repair or replace it. When driving cargo handling motor Turn Note) If this trouble is continuously, check code 30 first. key left as it is, main Replace CPU board (Resistance of switch contactor (MD) boosting charge drive Tr is defecOFF. is worn quickly tive). by arcs. Repair it immediately.

1) Check input signal of work equipment Pot. • Measure voltage at system controller connector CN4S --- Normal: 2.4 - 2.6 V 2) If result of check in (1) above is normal, replace system controller board. 3) If result of check in (1) above is abnormal, disconnect related Pot connector and check its resistance, then replace if necessary. Normal resistance --- Pin No. 1-3: 2kz Pin No. 2-3: 0 - 2kz 4) If result of check in (1) above is abnormal but that in (3) is normal, check and repair wiring harness between system controller and work equipment Pot. 61 • Adjustment of • Only related opera- 1) Check and adjust control lever stopwork equipment tions are impossiper. ( 2) Pot is abnormal. ble. Error is • Measure voltage at work equipment • Work equipment displayed when lecontrol lever Pot connector CN4S. Pot is abnormal. ver is operated. Normal --- When lever is fully tilted • Work equipment forward: 3.9 – 4.3 V Pot circuit harWhen lever is fully tilted back: 0.7 – ness is defective. 1.1 V 2) If result of (1) above is normal, replace system controller board. 3) If result of (1) above is abnormal, disconnect related Pot connector and check its resistance, then repair it. Normal resistance --- Pin No. 1-3: 2kz Pin No. 2-3: 0 – 2kz 4) If result of check in (1) above is abnormal but that in (3) is normal, check and repair wiring harness between system controller and work equipment Pot. 2. Displayed only proportional solenoid valve spec.

BE30 Series

Reset method Turn key switch OFF.

Turn key switch OFF.

If E87 – E89 are also displayed, check them first. For repair method, see each failure code section.

Turn key switch OFF.

If E87 - E89 and E-60 are also displayed, check them first. For repair method, see each failure code section.

70-89

FAILURE CODES LIST (3.0 TON MODEL)

Failure Contents of Trouble in code trouble vehicle 61 • Output of lift • Vehicle can do all (Conpressure sensor operations. Retinued) is abnormal. sponse is lowered, however, and hunt( 2) • Lift pressure sensor circuit ing prevention funcharness is defec- tion does not work tive. when lift lowers. • Automatic lifting and automatic fork leveling (if equipped) cannot be applied. Error is displayed immediately after key switch is turned ON. (If automatic fork • Automatic fork levleveling device is eling cannot be apinstalled) plied. • Output of tilting (• Fork can be angle sensor is moved by manual abnormal. operation.) • Tilting angle sen- Error is displayed sor circuit harimmediately after ness is defective. key switch is turned ON.

TROUBLESHOOTING

Repair method (Execute 1) o 2) o ---) Check input signal of lift pressure sensor. Measure voltage at system controller connector CN4S --- Normal: 0.37 – 4.3 V If result of check in 1) above is normal, replace system controller board. If result of check in 1) above is abnormal, check and repair pressure sensor harness. If result of check in 1) above is abnormal but that in 3) is normal, repair pressure sensor.

Reset method Turn key switch OFF.

1) Check and repair mechanical operation of tilting angle sensor. 2) Check that mast does not stop mechanically during automatic fork leveling operation, then repair mast if necessary. 3) Check input signal from tilting angle sensor and adjust installation of sensor. • Measure voltage at system controller connector CN5S. Normal voltage: 0.4 – 4.6 V (Backward tilting end - Forward tilting end) 4) If result of 3) above is normal, replace system controller board. 5) If result of 3) above is abnormal, check and repair tilting angle sensor. • Disconnect tilting angle sensor and measure resistance of sensor. 62 • Proportional • Only related opera- 1) Check resistance of proportional valve coil is distions are impossivalve coil, then repair coil if neces( 2) connected. ble. Error is sary. • Wiring harness displayed when leNormal resistance: 17 – 18z between proporver is operated. 2) If result of above check is normal, tional valve and (Pump motor rocheck and repair proportional valve system controller tates for a moment.) circuit harness. has trouble of dis3) If results of 1) and 2) are normal, go connection, leakto PROPORTIONAL VALVE DRIVE age, or defective CIRCUIT IS OPEN. contact. • Relay, fuse, EMG • Vehicle cannot op- 1) Check proportional valve power supswitch, or wiring erate at all. ply. harness is disError is displayed • Check voltage between pins No. 8 connected. when lever is operand No. 21 of system controller con• EMG relay in sys- ated. (Pump motor nector CN1S --- Normal voltage: Battem controller is rotates for a motery voltage open. ment.) 2) If result of 1) above is normal, re• Battery voltage place system controller board. lowers while lever 3) If result of 1) above is abnormal, is operated. A 1 check proportional valve power sup(Note) This is not ply circuit harness, CH interlock trouble in system (main) relay, fuse, and EMG switch controller. between battery and system control• EMG switch is ler for disconnection and leakage, operated while then repair. lever is operated, then only proportional valve power supply circuit is broken. A 2 (Note) This is not trouble in system controller. • Proportional • Only related opera- 1) Replace system controller board. valve drive circuit tions are impossiin system conble. Error is troller is open. displayed when lever is operated. (Pump motor rotates for a moment.)

Set tilt lever in neutral.

1) • 2) 3) 4)

Remarks

(Output voltage of pressure sensor: Out of 0.34 – 4.8 V)

Turn key switch OFF.

Turn key switch OFF.

(Output voltage of tilting angle sensor: Out of 0.34 – 4.7 V) (Output of sensor does not change during fork leveling operation.) If E87 – E89, E-60, and E-61 are also displayed, check them first. For repair method, see each failure code section. A1 --- Example: Main transistor of main controller is shorted. A2 --- Example: EMG switch is operated momentarily or pushed halfway.

2. Displayed only proportional solenoid valve spec.

70-90

BE30 Series

TROUBLESHOOTING

Failure Contents of code trouble 62 • Proportional (Con- valve coil is tinued) shorted. ( 2)

FAILURE CODES LIST (3.0 TON MODEL)

Trouble in Repair method vehicle (Execute 1) o 2) o ---) • Vehicle cannot op- 1) Check resistance of proportional erate at all. valve coil, then repair coil if necesError is displayed sary. when lever is operNormal resistance: 17 – 18z ated. (Pump motor 2) If result of above check is normal, go rotates for a moto PROPORTIONAL VALVE DRIVE ment.) CIRCUIT IS OPEN.

• Proportional • Vehicle cannot op- 1) Replace system controller board. valve drive circuit erate at all. in system conError is displayed troller is shorted. when lever is operated. (Pump motor rotates for a moment.) 64 [If automatic fork • Automatic fork lev- 1) This phenomenon is not trouble. If it eling device does occurs frequently, however, check ( 2) leveling device is installed] not reach level posifor mechanical factor such as hitch• Automatic fork tion or exceeds leving, then repair. leveling device el position. does not reach (• Fork can be tilted level position or manually.) exceeds level position. (Note) This is not trouble. 66 [If automatic lifting • Automatic lifting 1) Check input signal for automatic liftcannot be applied. ing operation. ( 2) device is installed] • Automatic lifting (• Lift can be raised • Measure input voltage for switches control panel manually.) other than memory switch at connecswitch is shorted Error is displayed tor CN6S of system controller. before key switch immediately after Normal voltage: When switch is OFF: is turned ON. key switch is turned Min. 4 V ON. When switch is ON: 0 V 2) If result of 1) above is normal, replace system controller board. 3) If result of (1) above is abnormal, measure resistance of 9-pin connector of lifting display panel. Normal resistance: When switch is OFF: c When switch is ON: 0z (Excluding memory switch) 4) If result of 3) above is abnormal, repair lifting display panel. 5) If result of 1) above is abnormal but that of (3) is normal, replace system controller. 67 [If automatic lifting • Automatic lifting 1) Check encoder power supply circuit. cannot be applied. • Disconnect system controller con( 2) device is installed] • Automatic lifting • If this trouble occurs nector CN5S and check voltage beencoder power in automatic lifting tween Pin No. 1 and No. 4. supply in system mode, vehicle When normal: 10 V controller is destops. 2) If result of above check is abnormal, fective. (• Lift can be raised replace system controller board. • Battery voltage is manually.) low. Error is displayed (Note) This is not immediately after trouble in system key switch is turned controller. ON. (Example: Main transistor of main controller is shorted.) 2. Displayed only proportional solenoid valve spec.

BE30 Series

Reset method Turn key switch OFF.

Remarks If E87 – E89, E-60, and E-61 are also displayed, check them first. For repair method, see each failure code section. A1 --- Example: Main transistor of main controller is shorted. A2 --- Example: EMG switch is operated momentarily or pushed halfway. (Check output corresponding to input.)

Leave (Fork is not in level polever in sition.) neutral.

Turn key switch OFF.

(when key switch is turned ON, unloading, loading, or number-oflayer setting (1 - 5 layers) switch is turned ON.) Turn key switch OFF.

(Source voltage: Below 4.77 V)

70-91

FAILURE CODES LIST (3.0 TON MODEL)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 67 [If automatic lifting • Vehicle stops lifting 1) Check that lifting encoder is operat(Con- device is installed] operation, then it ing (wire is coming out or going in), tinued) • Lifting encoder is cannot start autothen repair it if necessary. defective. matic lifting opera- 2) Check that lift does not stop mechan( 2) • Lifting encoder tion any more. ically during automatic lifting operacircuit is defec(• Lift can be raised tion, then repair lift if necessary. tive. manually.) 3) Check input signal from lifting encoder while lift is rising. • Check voltage at system controller connector CN5S. Voltage under abnormal condition (Note 1): 5 V or 0 V (Note 2): Check A-phase and Bphase with encoders 1 and 2 respectively. 4) If result of 3) above is normal, replace system controller board. 5) If result of 3) above is abnormal, check lifting encoder harness, then repair it if necessary. 6) If result of 3) above is abnormal but that of 5) is normal, repair lifting encoder. [If automatic lifting • Vehicle stops lifting 1) Check that 1st and 2nd encoders are device is installed] operation, then it connected correctly, then repair [When 2 encoders cannot start autothem if necessary. are installed] matic lifting opera• 1st and 2nd ention any more. coders are con(• Lift can be raised nected wrongly manually.) (when 2 encoders are installed). [If automatic lifting • Vehicle stops lifting 1) Disconnect connector of lifting 2) refdevice is installed] operation, then it erence switch and measure voltage. [When 2 encoders cannot start autoIf voltage is above 4 V, check lifting are installed] matic lifting opera2) reference switch, then repair it if • Lifting 2) refertion any more. necessary. ence switch is (• Lift can be raised 2) If voltage measured in 1) above is defective. manually.) below 4 V, check wiring harness be• Circuit harness of tween system controller and lifting 2) lifting (2) referreference switch, then repair it if necence switch is essary. defective. 3) If result of 2) above is normal, replace system controller board. [If automatic lifting • Vehicle stops lifting 1) Turn key switch ON and pass referdevice is installed] operation, then it ence switch. See if trouble occurs • A-phase and Bcannot start auto(buzzer sounds) 1 second after first phase of lifting matic lifting operalifting operation is performed. encoder are con- tion any more. 2) If trouble occurs by operation in 1) nected opposite- (• Lift can be raised above, check and repair connections ly. manually.) of A-phase and B-phase. [If automatic lifting • Vehicle cannot op- 1) If trouble is not repaired by above device is installed] erate automatic liftmethods, replace system controller • Lifting encoder ing work. board. input circuit in • Vehicle stops lifting system controloperation. ler is abnormal. 2. Displayed only proportional solenoid valve spec.

70-92

TROUBLESHOOTING

Reset method Turn key switch OFF.

Remarks (Note 1) Encoder output pulses of 0 V and 5 V. If it is abnormal, its output only 0 V or 5 V. (Note 2) Check encoder (2) only when it is installed. (Note 3) In specification shown in standard connection diagram, lifting encoder wire is pulled out when lift is raised. In specification where wire is pulled in when lift is raised, A-phases and B-phase are on opposite sides. Accordingly, phases must be confirmed.

Turn key switch OFF.

If E87 – E89, E60 and E61 are also displayed, check them first. For repair method, see each failure code section. (Pulses are not output from encoder during lifting operation.)

Turn key switch OFF.

(Operating direction does not conform to output direction of encoder.)

Turn key switch OFF.

(Pulses are not output from encoder during lifting operation.)

BE30 Series

TROUBLESHOOTING

FAILURE CODES LIST (3.0 TON MODEL)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 68 [If automatic lifting • Vehicle cannot op- 1) Repeat operation correctly. erate automatic lift( 2) device is installed] or [If automatic fork ing work. leveling device is • Vehicle cannot opinstalled] erate fork leveling • Automatic lifting work. operation and (• Fork can be levfork leveling opeled manually.) eration are defective. [If automatic lifting • Vehicle cannot op- 1) Disconnect reference switch connecdevice is installed] erate automatic lifttor and measure voltage. If voltage or [If automatic fork ing work. is above 4 V, check reference switch, leveling device is (•Fork can be leveled then repair it if necessary. installed] manually.) 2) If voltage measured in 1) above is • Automatic lifting below 4 V, check wiring harness bereference switch tween system controller CN5S-9 and is defective. reference switch, then repair it if nec• Wiring harness of essary. automatic lifting 3) If result of 2) above is normal, rereference switch place system controller board. is defective. [If automatic fork • Fork cannot be tilt- 1) If fork leveling display switch cannot leveling device is ed manually. be turned ON and OFF, replace it. installed] 2) If switch is normal, check its wiring • Tilt display switch harness for short circuit, then repair. is shorted. 3) If result of above check is normal, re• Tilt display switch place system controller. harness is shorted. 69 [If automatic lifting • Fork stops before 1) This phenomenon is not trouble. If it set stop position in occurs frequently, however, check ( 2) device is installed] • Automatic lifting automatic lifting for mechanical factor such as hitchdevice does not mode. ing, then repair. reach set stop position. (Note) This is not trouble. 70 [If automatic lifting • Fork stops after set 1) This phenomenon is not trouble. If it stop position in auoccurs frequently, however, check ( 2) device is installed] • Automatic lifting tomatic lifting mode. for mechanical factor such as maldevice exceeds function of proportional solenoid set stop position. valve, etc., then repair. (Note) This is not trouble. 87 • Sensor power • Vehicle cannot op- 1) Disconnect connectors CN3S, 4S, supply in system erate at all. 5S, and 6S of the system controller ( 2) controller is abError is displayed and check voltage between pins No. normal. immediately after 26 and 28 of CN4S. When it is nor• Battery voltage is key switch is turned mal, it is 5 V. low. ON. 2) If result of 1) above is abnormal, re(Note) This is not place system controller board. trouble in system 3) If result of 1) above is normal, check controller. SENS5V circuit harness and sensor (Example: Main for short circuit and leakage, then retransistor of main pair. controller is shorted.) 2. Displayed only proportional solenoid valve spec.

BE30 Series

Reset Remarks method Set [Fork leveling operalever in tion is abnormal] neutral. • Operation is in reverse direction. [Automatic lifting operation is abnormal] • Reference switch is not detected or number of layers is not set. • Number of layers is Set lever in changed during opneutral. eration or automatic operation is started in manual operation mode. • Operation is in reverse direction or it is performed at short distance.

Set lever in neutral.

Set After fork stops before lever in set stop position, if it is neutral. moved to set stop position manually, buzzer sounds.

Set After fork stops exlever in ceeding set stop posineutral. tion, if it is moved to set stop position manually, buzzer sounds. Turn key switch OFF.

(Source voltage: Below 4.5 V)

70-93

FAILURE CODES LIST (3.0 TON MODEL)

Failure Contents of Trouble in Repair method code trouble vehicle (Execute 1) o 2) o ---) 89 • Work equipment • Pump motor rotates 1) Check work equipment switch signal switch signal is at low speed. output. ( 2) shorted to GND • Vehicle cannot op• Measured voltage between pins No. or it is leaking. erate at all. 4 and 2, 3 and 2, 5 and 2, 6 and 2, • Work equipment Error is displayed and 17 and 2 of system controller switch circuit of immediately after connector CN1S. If it is normal, it is main controller is key switch is turned above 4 V. abnormal. ON. 2) If result of 1) above is normal, replace system controller. 3) If result of 1) above is abnormal, check work equipment switch signal harness for leakage and short circuit to GND, then repair. 4) If result of 1) above is abnormal, measure voltage between pins No. 8 and 14, 10 and 14, 21 and 14, 22 and 14, 23 and 14 of main controller connector CN1. If it is normal, it is 4 V 5 V. 5) If result of 4) above is abnormal, replace main controller board. • Proportional • Error is displayed 1) Replace system controller board. valve EMG relay immediately after in system conkey switch is turned troller is shorted. ON. 95 Multi-controller is • Error is displayed 1) Replace multi-controller board. defective. immediately after key switch is turned ON. (Vehicle operates normally.) 97 Communication Error is displayed 1) Check continuity of wiring harnesses between main con- when abnormality is of CN1-5, CN1-6, CN1-13, and CN1troller and multidetected. 14 of multi-controller, then repair controller is abnor- • Main controller canthem if necessary. mal. not be adjusted. 2) Replace multi-controller board. • It cannot display fail- 3) Replace main controller board. ure codes. (Vehicle operates normally.) 98 Communication Error is displayed 1) Check continuity of wiring harnesses when abnormality is of CN4-5, CN4-6, CN4-7, and CN4-9 ( 2) between system controller and detected. of multi-controller, then repair them if multi-controller is System controller necessary. abnormal. cannot display failure 2) Replace multi-controller board. codes. (Vehicle oper- 3) Replace system controller board. ates normally.) 99 Communication Error is displayed 1) Check continuity of wiring harnesses between meter when abnormality is of CN3-1 and CN3-2 of multi-controlpanel and multidetected. ler, then repair them if necessary. controller is abnor- • Main controller can- 2) Replace multi-controller board. mal. not be adjusted. 3) Replace meter panel. • Main controller, system controller, and multi-controller cannot display failure codes. (Vehicle operates normally.) 2. Displayed only proportional solenoid valve spec.

70-94

TROUBLESHOOTING

Reset method Turn key switch OFF.

Turn key switch OFF. Turn batter connector OFF.

Remarks

(When key switch is turned ON, hydraulic chopper starts without receiving operation input.) (When key switch is turned ON, EMG relay in board is closed.) –

Perform automatic resetting normally.

Occasional occurrence of this trouble is caused by defective contact. In this case, connect and disconnect connector.

Perform automatic resetting normally.

Occasional occurrence of this trouble is caused by defective contact. In this case, connect and disconnect connector.

Perform automatic resetting normally.

Occasional occurrence of this trouble is caused by defective contact. In this case, connect and disconnect connector.

BE30 Series

TROUBLESHOOTING

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS) Error No.

Contents of trouble

Trouble vehicle

Trouble detection logic

01

Travel power module is Vehicle cannot shorted (Upper and lower travel or handle FET's are shorted). cargo (MD connector is not closed). (This trouble is also detected when failure code 45 is displayed.)

Detected only at time of start 1) Key is ON. 2) MD contactor OFF command is output. 3) P3 voltage (CN4-2) is below 3.0 V. 4) Error code is displayed. 5) MD contactor OFF command.

03

Main contactor (MD) is shorted or open.

Detected only at time of start 1) Key is ON. 2) MD contactor OFF command is output. 3) Travel main circuit FET is normal. 4) P2 voltage (CN5-11) > P1 voltage (CN4-8) x 0.9 5) Error code is displayed. 6) MD contactor OFF command.

Vehicle cannot travel or handle cargo.

At time of start or while stopped (Accelerator is OFF and DS is in neutral) 1) MD contactor ON command is output. 2) P2 voltage (CN5-11) < P1 voltage (CN4-8) x 0.9 3) Error code is displayed. 4) MD contactor OFF command. 04

Upper FET of travel power module is shorted.

Vehicle cannot travel or handle cargo.

Detected only at time of start 1) Key is ON. 2) MD contactor OFF command is output. 3) P3 voltage (CN4-2) > 20 V 4) P2 voltage (CN5-11) < P1 voltage (CN4-8) x 0.9 5) P4 voltage (CN4-3) > P3 voltage (CN4-2) x 0.8 6) Error code is displayed. 7) MD contactor OFF command.

05

Lower FET of travel power module is shorted.

Vehicle cannot travel or handle cargo.

Detected only at time of start 1) Key is ON. 2) MD contactor OFF command is output. 3) P3 voltage (CN4-2) > 20 V 4) P2 voltage (CN5-11) < P1 voltage (CN4-8) x 0.9 5) P4 voltage (CN4-3) < P3 voltage (CN4-2) x 0.2 6) Error code is displayed. 7) MD contactor OFF command.

06

U-phase of travel power module is open.

Vehicle cannot travel or handle cargo.

Detected only during operation 1) DS is in F/R and accelerator is ON. 2) Current does not flow in U-phase. 3) Error code is displayed. 4) MD contactor OFF command.

BE30 Series

70-95

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)

Error No. 07

Contents of trouble

Trouble vehicle

Main contactor (MD) drive Vehicle cannot travel or handle Tr is defective (In CPU cargo. board: Tr4). Main contactor coil is open.

TROUBLESHOOTING

Trouble detection logic

Detected only at time of start 1) Key is ON. 2) MD contactor OFF command is output. 3) Collector voltage of MD contactor coil drive TR in printed circuit board is below 3.1 V. 4) Error code is displayed. 5) MD contactor OFF command.

Detected only at time of start 1) Key is ON. 2) MD contactor ON command is output. 3) Collector voltage of MD contactor coil drive TR in printed circuit board is above 3.1 V. 4) Error code is displayed. 5) MD contactor OFF command.

08

V-phase of travel power module is open.

Vehicle cannot travel or handle cargo.

Detected only during operation 1) DS is in F/R and accelerator is ON. 2) Current does not flow in V-phase. 3) Error code is displayed. 4) MD contactor OFF command.

09

W-phase of travel power module is open.

Vehicle cannot travel or handle cargo.

Detected only during operation 1) DS is in F/R and accelerator is ON. 2) Current does not flow in W-phase. 3) Error code is displayed. 4) MD contactor OFF command.

11

Upper FET of travel power module is shorted.

Vehicle cannot travel or handle cargo.

Only while stopped (after key is turned ON). 1) MD contactor ON command is output. 2) Vehicle is stopped (DS is in Neutral and accelerator is OFF). 3) P4 voltage (CN4-3) > P3 voltage (CN4-2) x 0.8 4) Error code is displayed. 5) MD contactor OFF command.

12

Lower FET of travel power module is shorted.

Vehicle cannot travel or handle cargo.

Only while stopped (after key is turned ON). 1) MD contactor ON command is output. 2) Vehicle is stopped (DS is in Neutral and accelerator is OFF). 3) P4 voltage (CN4-3) < P3 voltage (CN4-2) x 0.2 4) Error code is displayed. 5) MD contactor OFF command.

16

F or R switch is defective. Vehicle cannot travel.

1) Approx. 50 V is applied to CN1-11 and CN1-12 simultaneously. 2) Error code is displayed. (MD is not turned OFF.)

17

Travel accelerator output is defective.

1) Accelerator output (Voltage between CN2-8 and CN1-14) is not 0.2 V – 4.8 V. 2) Error code is displayed. (MD is not turned OFF.)

70-96

Vehicle can travel at 40% of maximum speed.

BE30 Series

TROUBLESHOOTING

Error No. 19

Contents of trouble

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)

Trouble vehicle

Output of travel current Vehicle cannot sensor (CSDU, CSDW) is travel. defective.

Trouble detection logic

1) Current sensor output (U-phase: Voltage between CN5-4 and CN5-14, W-phase: Voltage between CN5-6 and CN5-16) is not 1.5 V – 14.7 V. 2) Error code is displayed. (MD is not turned OFF.)

1) Vehicle is stopped (DS is in Neutral and accelerator is OFF). 2) Current sensor output (U-phase: Voltage between CN5-4 and CN5-14, W-phase: Voltage between CN5-6 and CN5-16) is not 2.05 V – 2.49 V. 3) Error code is displayed. (MD is not turned OFF.)

20

Travel main fuse (F1) blows.

Vehicle cannot travel.

1) MD contactor ON command is output. 2) Travel, cargo handling, or EPS operation is not performed. 3) MD contactor is turned ON normally. P3 voltage (CN4-2) < P2 voltage (CN5-11) x 0.9 4) Error code is displayed. (MD is not turned OFF.)

21

Undervoltage is detected (Battery voltage is low).

Vehicle cannot travel.

1) P1 voltage (CN4-8) is below 28.2 V. 2) Error code is displayed. 3) MD contactor OFF command and MPS contactor OFF command.

22

Output of travel controller Vehicle can travel temperature sensor is de- normally. fective.

1) Output voltage of travel controller temperature sensor (CN7-5) is not 0.2 V – 4.95 V. 2) Error code is displayed.

23

Neutral is detected.

Detected only at time of start 1) Key is ON. 2) DS is F or R is ON. 3) Error code is displayed.

24

Travel controller tempera- Vehicle can travel. ture is high. (As temperature rises, current is limited and output lowers.)

1) Output voltage of travel controller temperature sensor (CN7-5) is below about 1.1 V. (Travel main circuit temperature > 100°C) 2) Error code is displayed. It is reset when temperature lowers below 100°C.

25

Travel motor temperature Vehicle can travel. rises. (As temperature rises, current is limited and output lowers.)

1) Output voltage of travel motor temperature sensor (CN11-4) is below 0.29 V. (Travel motor coil temperature > 160°C) 2) Error code is displayed. It is reset when temperature lowers below 160°C.

26

Travel controller tempera- Vehicle cannot ture is abnormal. travel.

1) Output voltage of travel controller temperature sensor (CN7-5) is below about 0.79 V. (Travel main circuit temperature > 115°C) 2) Error code is displayed. It is reset when temperature lowers below 115°C.

27

Output of travel motor Vehicle can travel temperature sensor is de- normally (assumfective. ing temperature is normal).

1) Output voltage of travel motor temperature sensor (CN11-4) is not 0.2 V – 4.95 V. 2) Error code is displayed.

BE30 Series

Vehicle cannot travel.

70-97

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)

Error No.

Contents of trouble

Trouble vehicle

28

Travel motor temperature Vehicle cannot is abnormal. travel.

30

Cargo handling power module (TMP) is shorted.

TROUBLESHOOTING

Trouble detection logic 1) Output voltage of travel motor temperature sensor (CN11-4) is below 0.22 V. (Travel motor coil temperature: > 175°C) 2) Error code is displayed. It is reset when temperature lowers below 175°C.

Vehicle can handle At time of start cargo. 1) Key is ON. 2) MD contactor OFF command is output. 3) P13 voltage (CN4-10) is below 3.0 V. 4) Error code is displayed. 5) MD contactor ON command. During operation 1) MD contactor ON command is output. 2) Chopper command is output. 3) P13 voltage (CN4-10) is below about 7.5 V. 4) Error code is displayed. 5) MD contactor ON command. (MD is not turned OFF.)

31

Vehicle cannot Cargo handling power handle cargo. module (TMP) is open. Upper side of cargo handling power module (TMP) (Between P and OUT) is shorted. Cargo handling motor is shorted or open.

1) 2) 3) 4) 5)

33

Cargo handling main fuse Vehicle cannot (F2) is blows. handle cargo.

1) MD contactor ON command is output. 2) Travel, cargo handling, or EPS operation is not performed. 3) MD contactor is turned ON normally. P12 voltage (CN5-22) < P2 voltage (CN5-11) x 0.9 4) Error code is displayed. 5) MD contactor ON command. (MD is not turned OFF.)

35

Cargo handling lift VR is shorted or open.

36

Output of cargo handling Vehicle can handle 1) Output voltage of cargo handling controller tempercontroller temperature cargo normally. ature sensor (CN7-6) is not 0.2 V – 4.95 V. sensor (THP) is defective. 2) Error code is displayed.

39

Cargo handling controller temperature is abnormal.

Vehicle cannot handle cargo.

1) Output voltage of cargo handling controller temperature sensor (CN7-6) is below about 0.79 V. (Cargo handling main circuit temperature > 115°C) 2) Error code is displayed. It is reset when temperature lowers below 115°C.

41

Output of travel speed sensor A is defective.

Vehicle cannot handle cargo.

1) Vehicle is stopped (Travel speed is 0). Output voltage of travel speed sensor A (Voltage between CN2-4 and CN2-3) is above 4.5 V. 2) Error code is displayed. (MD is not turned OFF.)

70-98

MD contactor ON command is output. Chopper command is output. P13 voltage (CN4-10) is above about 7.5 V. Error code is displayed. MD contactor ON command. (MD is not turned OFF.)

1) Lift VR output [Voltage between CN2-10 and CN1Vehicle operates 14 (0 V)] is not 0.2 V – 4.8 V. with "ON" period ratio for cargo han- 2) Error code is displayed. (MD is not turned OFF.) dling at 100%.

BE30 Series

TROUBLESHOOTING

Error No.

Contents of trouble

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)

Trouble vehicle Vehicle cannot handle cargo.

Trouble detection logic

42

Output of travel speed sensor B is defective.

45

Capacitor of travel capaci- Vehicle cannot travel or handle tor board (CBD) is charged abnormally. cargo.

Detected only at time of start 1) Key is ON. 2) MD contactor OFF command is output. 3) P3 voltage (CN4-2) is below 20 V. 4) Error code is displayed. 5) MD contactor OFF command.

50

PS main Tr is defective.

Detected only at time of start 1) Key is ON. 2) MPS contactor OFF command is output. 3) Test OFF command to steering TR. 4) Steering TR (collector) voltage (CN4-1) is below 5 V. 5) Error code is displayed. 6) MPS contactor OFF command.

Steering wheel is heavy to turn.

1) Vehicle is stopped (Travel speed is 0). Output voltage of travel speed sensor B (Voltage between CN11-6 and CN11-5) is above 4.5 V. 2) Error code is displayed. (MD is not turned OFF.)

Detected only at time of start 1) Key is ON. 2) MPS contactor OFF command is output. 3) Test ON command to steering TR. 4) Steering TR (collector) voltage (CN4-1) is above 10 V. 5) MPS contactor ON command. 6) Vehicle is steered. 7) Steering TR ON command (100% command). 8) Steering motor current does not flow. 9) Error code is displayed. 10) MPS contactor OFF command. 51

PS contactor (MPS) is shorted.

PS is possible. (Error is kept displayed.)

Detected only at time of start 1) Key is ON. 2) MPS contactor OFF command is output. 3) Test OFF command to steering TR. 4) Steering TR (collector) voltage (CN4-1) > P1 voltage (CN4-9) x 0.9 5) Error code is displayed. 6) MPS contactor ON command. (MPS is not turned OFF.)

52

PS main fuse is open. PS contactor (MPS) is open.

Steering wheel is heavy to turn. [PS contactor (MPS) is not closed.]

At time of start 1) Key is ON. 2) MPS contactor ON command is output. 3) Steering TR (collector) voltage (CN4-1) < P1 voltage (CN4-9) x 0.9 4) Error code is displayed. While stopped 1) MPS contactor ON command is output. 2) Steering TR (collector) voltage (CN4-1) < P1 voltage (CN4-9) x 0.9 3) Error code is displayed.

BE30 Series

70-99

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)

Error No. 53

Contents of trouble PS contactor (MPS) coil drive Tr is defective. (In CPU board: Tr5)

Trouble vehicle Steering wheel is heavy to turn.

TROUBLESHOOTING

Trouble detection logic

Detected only at time of start 1) Key is ON. 2) MPS contactor OFF command is output. 3) MPS contactor coil drive TR (collector) voltage (CN4-14) is below 10.8 V. 4) Error code is displayed. 5) MPS contactor OFF command.

Detected only at time of start 1) Key is ON. 2) MPS contactor ON command is output. 3) MPS contactor coil drive TR (collector) voltage (CN4-14) is above 10.8 V 4) Error code is displayed. 5) MPS contactor OFF command.

54

Output of PS torque sensor is defective.

Steering wheel is heavy to turn.

55

Cargo handling controller temperature is high.

Vehicle can handle 1) Output voltage of cargo handling controller temperature sensor (CN7-6) is below about 1.1 V. (Cargo cargo. (As temperhandling main circuit temperature > 100°C) ature rises, "ON" 2) Error code is displayed. It is reset when temperaperiod ratio of ture lowers below 100°C. chopper is limited.)

56

Capacitor of cargo handling capacitor board (CBP) is charged abnormally.

Vehicle cannot travel or handle cargo.

70-100

1) Torque sensor voltage (between CN2-6 and CN114) is below 0.2 V or above 4.8 V. 2) Error code is displayed. 3) MPS contactor OFF command.

Detected only at time of start 1) Key is ON. 2) MD contactor OFF command is output. 3) P12 voltage (CN5-22) is below 20 V. 4) Error code is displayed. 5) MD contactor OFF command.

BE30 Series

TROUBLESHOOTING

DRIVE MOTOR

DRIVE MOTOR a Perform inspection and maintenance according to failure codes list (E25, E27, and E28). a If abnormality is not indicated by any failure code, perform inspection and maintenance according to the following explanation.

1. TROUBLES AND REMEDY FOR THEM

Motor does not rotate even if no load is applied.

Cause of trouble

Rotating sound is not heard.

Abnormality in battery and inverter or wiring (See section of battery and inverter.)

Remedy

Repair in special factory.

Disconnection of connected wire Disconnection of stator coil Defective contact caused by looseness of terminal connecting parts

Tighten securely.

Single-phase operation caused by trouble in wiring or inverter

Repair with voltmeter.

Disconnection of 1 phase between motor and inverter

Replace wire.

Disconnection of 1 phase of stator coil

Repair in special factory.

Breakage of bearing

Replace bearing.

Interference of motor shaft caused by looseness of mounting bolts, etc.

Retighten bolts.

Motor rotates in reverse direction.

Wrong connection

Exchange 2 of 3 terminal connection.

Hum is heard.

Uneven gap between stator core and rotor core

Motor can be rotated in either direction by hand.

Hum is heard but motor does not rotate.

Motor rotates if no load is applied.

Inspection order and cause

Motor frame is heated abnormally.

Short circuit of part of stator coil

Bearing makes abnormal sound.

Defective bearing

BE30 Series

Repair in special factory.

Replace bearing.

70-101

DRIVE MOTOR

Cause of trouble

TROUBLESHOOTING

Inspection order and cause

Remedy

Single-phase operation

Check voltage at inverter output terminals and, if necessary, motor lead wire joints with voltmeter, then eliminate cause of trouble.

Lowering of voltage

Check charge level of battery, then charge if necessary.

Overloading

Reduce load.

Clogging of air vent with dirt

Remove dirt.

Speed lowers suddenly.

Loaded operation

Motor overheats.

Motor cannot be rotated easily by hand.

Motor stops.

Motor smells abnormally.

Seizure of bearing

Unbalance of resistance among phases or lowering of insulation resistance (with motor lead wires disconnected)

Replace bearing.

Repair in special factory.

Disconnection or short circuit of lead wires

Motor makes abnormal sound or vibration during operation.

Bearing is overheated.

70-102

Trouble in inverter

See section of inverter.

Check for possibility of single-phase operation by checking output terminal voltage of inverter and connection of motor lead wires.

Correct connection of motor lead wires.

Looseness of bracket bolts, air guides, or c-rings of sensors

Retighten bolts, etc.

Abnormal sound from bearing (Check with sound tester rod)

Replace bearing.

BE30 Series

TROUBLESHOOTING

CHARGER

CHARGER ELECTRIC CIRCUIT DIAGRAM FOR STATIONARY TYPE

MGS : Electromagnetic switch D1 : Diode D2 : Diode

BE30 Series

70-103

CHARGER

TROUBLESHOOTING

Charge trouble inspection sheet All the charge troubles are not caused by the charger. Some of them are caused by the condition of the battery and operating environment. Describe the condition at the time of occurrence of each trouble and take proper remedies. Type-Model Serial No. User's name Hour meter

Date of delivery Year:

h

Month:

Day:

,

,

Date of occurrence of trouble Year:

Month: ,

Day: ,

Contents of trouble Check items No.

Date of inspection: Check item

Inspection result

Measured voltage 1

Utility voltage

(V)

Time of measurement

:

Operation at time of measurement 2

Voltage tap of charger

3

Abnormality lamp (LED)

4

Charge level lamp (LED)

5

Operation lamp

6

Condition of battery

Remarks

ON

OFF

195V

205V

215V

Lighting L1

Flashing

L2

L3

L4

L5

L6

Automatic

Equalizing

Flashing

Lighting

Specific gravity Fluid temperature

7

Frequency of occurrence of trouble

8

Operating condition on previous day (Over-discharge, etc.)

9

Contents of remedy (Replacement of charge controller, etc.)

10

Record after remedy is taken (Re-occurrence of trouble)

(°C) Constant

Frequent

Occasional

11 Transformer No. 12 Charge controller No.

70-104

BE30 Series

80. YEARLY INSPECTION CRITERIA Starting motor and pump motor . . . . . . . . . . . . 80- 2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80- 3 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80- 6 Power train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-13 Travel system. . . . . . . . . . . . . . . . . . . . . . . . . . 80-14 Steering system . . . . . . . . . . . . . . . . . . . . . . . . 80-15 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20 Cargo handling system . . . . . . . . . . . . . . . . . . 80-24

BE30 Series

80-1

MOTOR

Component

YEARLY INSPECTION CRITERIA

Inspection item 1. Abnormal sound during rotation

Contents of inspection Must be free from abnormal sound.

2. Wear and sliding 1. Repair limit (Height of brush: H) condition of brush 1 ton series 2 – 3 ton series Motor 2 – 3.0 ton name 1 – 1.75 ton models models Pump motor

Min. 22 mm

Min. 22 mm

EPS motor

Min. 13 mm

Min. 13 mm

Starting motor and pump motor

2. Sliding condition The brush must slide smoothly.

3. Fatigue of brush spring

1. Pressing force of brush spring Motor name Pump motor

1 ton series

2 – 3 ton series

1 – 1.75 ton models

2 – 3.0 ton models

Min. 7.35N {Min. 750gf}

Min. 7.84N {Min. 800gf}

EPS 4.90 – 11.77N 4.90 – 11.77N motor {500 – 1,200gf} {500 – 1,200gf} Hitch a string to the brush spring and measure the pressing force of the brush spring with a spring balance.

4. Contact rate of sliding surface of brush

1. Contact with commutator 1. Brush 2. Commutator A. Good B. Bad C. Bad a If the contact is bad, fit the brush.

80-2

BE30 Series

YEARLY INSPECTION CRITERIA

Component

Inspection item 4. Contact rate of sliding surface of brush

Starting motor and pump motor

MOTOR, BATTERY

5. Commutator

Contents of inspection 2.

Method of fitting brush

1)

Insert rough sandpaper (#60 – #120) between the commutator and brush with the sand side against the brush.

2)

Hold both ends of the sandpaper and slide it along the commutator surface in the circumferential direction until the brush fits to the commutator.

3)

Repeat the above work with fine sandpaper (#360) to finish.

4)

Clean the brush and commutator by blowing air against them.

1. Check of commutator surface 1. Sticking of carbon 2. Scratch 4. Uneven wear

6. Looseness of connecting parts

1. Looseness of bolts 1. Internal connecting wire

7 – 8. Electrolyte

1. Check of electrolyte level

3. Stain of current collecting part

2. Pigtail (Brush lead wire)

Battery

1. Stopper 2. Cap 3. Float (Red)

• Before the float (red) (3) indicates the lowest electrolyte level, add distilled water (See the next page). • When the float (3) stopper (1) touches the cap (2) (When clearance a shown in the above figure is 0), the electrolyte level is at the lowest level. a Caps (2) of different battery manufacturers have different shapes.

BE30 Series

80-3

BATTERY

Component

YEARLY INSPECTION CRITERIA

Inspection item 7 – 8. Electrolyte

Contents of inspection 2.

Method of adding distilled water to battery A. While distilled water is added B. After distilled water is added

1)

Open the battery cap and add refined (distilled) water.

2)

Stop adding water immediately when the white line of the float is seen.

a If you continue adding water after the white line is seen, the water will spill. Accordingly, never do so.

Battery

Precautions for handling battery 1. Actions to take when electrolyte sticks If electrolyte sticks to your eyes, skins, or clothes, wash it away with much water. If it enters your eyes, in particular, see a doctor immediately. 2. Prohibition of use of fire Never make a short circuit or a spark or bring fire of a cigarette, etc. near the battery. 3. Prevention of electric shock When maintaining or inspecting the battery, put on rubber gloves. 4. Ventilation Ventilate well while the battery is not used, as well as while it is used.

80-4

BE30 Series

YEARLY INSPECTION CRITERIA

Component

BATTERY

Inspection item 7 – 8. Electrolyte

Contents of inspection 3.

Check of electrolyte specific gravity 1. Rubber ball 2. Suction tube 3. Outer cylinder 4. Hydrometer 5. Electrolyte

1)

Charge the battery. Then, set the electrolyte level normally.

2)

Using a hydrometer and a thermometer, measure the specific gravity and temperature of the electrolyte.

3)

Substitute the values obtained in 1) and 2) above for the following formula to calculate S20. S20 = St + 0.0007 (t – 20)

Battery

S20 : Specific gravity at 20°C St : Specific gravity at t°C (Measured value) t : Temperature of electrolyte (Measured value) a 4)

Normal value: S20 = 1.27 – 1.29

Carry out the above measurement and calculation for every cell.

a After using the hydrometer, be sure to wash it in water. a Keep the measured data. 9. Terminal

1. Looseness 2. Stain 3. Damage 4. Corrosion and electrolytic corrosion

10. Battery case

1. Damage

11. Cell

1.

Voltage • Charge the battery. Then, measure the voltage of each cell with a DC voltmeter. Check that the voltage is above the set value (2.0 V/cell) is not extremely different from one cell to another.

2.

Damage

BE30 Series

2. Stain

80-5

CONTROLLER

Component

YEARLY INSPECTION CRITERIA

Inspection item 15 – 20. Contactor (Electromagnetic switch)

Contents of inspection 1.

2. 1) 2)

Contacts If the contacts are roughened remarkably when checked visually, replace them. MD contactor

Replace 2 fixed contacts and 1 moveable contact together.

PS contactor

Replace contactor assembly.

Coil resistance Disconnect the lead wires of the coil terminals. Set the multimeter for measurement of resistance and measure the resistance between the coil terminals. Resistance

Judgment

(MD: Travel) 20 – 50 z

Controller

(PS: Power steering) 120 – 380 z

c

Defective wiring

0

Short circuit

a Do not judge the condition of the contactor coil by measuring the resistance between the common terminals.

3.

80-6

Good

Connecting condition and looseness of lead wires of main circuit Connect the lead wires correctly and tighten them securely.

BE30 Series

YEARLY INSPECTION CRITERIA

Component

CONTROLLER

Inspection item 21 – 22. • Potentiometer (Proportional solenoid valve specification)

Controller

• Microswitch (Manual valve specification)

Contents of inspection 1.

Timing, operating condition, and set voltage 1) Set the knobs of the all levers in line when the work equipment control lever (3) is in neutral with adjustment bolts (1) and (2). 1.Dimensions when lever is in neutral 2.Adjustment range of the potentiometer Positions of lever A. Neutral B. Lean backward (Pull) C. Lean forward (Push) 2) Procedure for checking voltage • Move work equipment control lever (3) a little (by the play) and adjust the output of potentiometer (4) into the set voltage range within the play range (when the lever is in neutral). • Move work equipment control lever (3) forward and backward and adjust the output of potentiometer (4) into each set value range. 3)

Adjustment Loosen set bolt (5) of potentiometer (4) and turn the body of the potentiometer little by little to adjust the voltage. a After adjusting, tighten the set bolt securely. 4)

Set voltage Section When lever is leaned forward (pushed) When lever is in neutral When lever is leaned backward (pushed)

BE30 Series

Lift Tilt ATT Lift Tilt ATT Lift Tilt ATT

Measuring point Multi-controller Pin No. of CN4 2 10 6, 14, 18 2 10 6, 14, 18 2 10 6, 14, 18

Set voltage (Standard value) 3.9 – 4.3V

2.4 – 2.6V 0.7 – 1.1V

80-7

CONTROLLER

Component

YEARLY INSPECTION CRITERIA

Inspection item 21 – 22. Microswitch

Contents of inspection 1.

Timing and operating condition Press brake pedal (2), operate parking brake lever (3), and adjust the positions of microswitches (1) and (4) so that they will be turned ON at the strokes (operating positions) shown in the following table. Brake pedal

Must be turned ON when pedal is pressed by 22 – 28 mm.

Controller

Must be turned ON when parkParking brake ing brake is applied lever (lever is pulled). 2.

Check of voltage See the TROUBLESHOOTING in Section 70.

3.

Damage and looseness of fitting parts Check that the microswitches are not damaged and their fitting parts are tightened properly.

25 – 26. FR controller 1. (Sub controller)

Operating condition Check that the lever moves from the neutral position to F and R securely. F/R switch side: Male

2.

Check of continuity Check the internal wiring for disconnection by checking continuity. Measuring method

Judgment

Shift forward/ reverse lever in F 0 z : Normal and measure resis: Discontance between pins nected No. 1 and No. 3.

c

Connector on chassis side seen from inserting direction

Shift forward/ reverse lever in R 0 z : Normal and measure resis: Discontance between pins nected No. 1 and No. 5. If disconnection is detected, replace the controller.

c

3.

80-8

Damage and looseness of fitting parts Check that the controller is not damaged and its fitting parts are tightened properly.

BE30 Series

YEARLY INSPECTION CRITERIA

Component

CONTROLLER

Inspection item 27. Cut-off current

Contents of inspection 1.

Measuring cut-off current

1)

Stop the lift truck on a level place and put chocks under the rear wheels.

2)

Put wood blocks under both sides of the frame and float the front wheels above the ground (only when measuring the travel cut-off current).

3)

Lower the fork to the ground, lean the mast forward, and apply the parking brake.

4)

Disconnect the wires of the brake switch (only when measuring the travel cut-off current).

5)

Set an ammeter (clamp tester) to the cable to be measured and measure the cut-off current under the conditions shown in the following table.

Motor

Measurement conditions

Cable to be Setting of measured clamp meter DU, DV, DW

527 – 568A (peak) (373 – 412A (rms))

2tonmodels

674 – 746A (peak) (475 – 525A (rms))

3tonmodel

524 – 580A (peak) (370 – 410A (rms))

Same as Model 8

(Specification values) 1ton-models Min. 300 A 2ton-models Min. 340 A 3ton-model Min. 300 A Max. 360 A

EPS motor Same as cable Model 8 Turn steering wheel fully to EPS right or left and measure current.

(Specification values) 1ton-models 45±2.5A 2ton-models 50±2.5A 3ton-model Min. 45A Max. 50A

Controller

Lean tilt lever forHy- ward fully to lean draulic mast and measure current.

•

BE30 Series

DC 1,000 A 1tonpeak range models

Shift forward/reverse lever in F position and press brake pedTravel al fully. Then, press accelerator pedal fully and measure current.

PA, PB

Cut-off current

After checking, connect the disconnected brake switch wires again (only when measuring the travel cut-off current).

80-9

CONTROLLER

Component

YEARLY INSPECTION CRITERIA

Inspection item 28. Fuse

Contents of inspection 1.

Under floor plate

1)

Turn the key switch OFF and disconnect the battery plug.

2)

Remove the floor plate.

3)

Open the fuse holder cap and replace the fuse.

2.0 – 3.0 ton models

Symbol

Circuit where fuse is used

Capacity

SF1

Control circuit on chassis

10A

SF2

Accessory circuit

15A

Controller

1.0 – 1.75 ton models

80-10

BE30 Series

YEARLY INSPECTION CRITERIA

Component

CONTROLLER

Inspection item 28. Fuse

Contents of inspection 2. 1)

Stationary charger Disconnect the power cable of the charger from the outlet.

2)

Loosen the nut and replace the fuse.

3)

Tighten the nut securely.

Symbol Voltage Battery capacity 330AH 400AH 485AH 545AH 48V

BFS80A BFS100A

565AH 600AH

F5 Controller

700AH

BFS150A

935AH 1,080AH 72V

BE30 Series

Capacity

450AH 545AH

BF150A

80-11

CONTROLLER

Component

YEARLY INSPECTION CRITERIA

Inspection item 28. Fuse

Contents of inspection 3. 1)

Controller If any fuse is broken, a failure code is displayed on the monitor at the operator's seat. Replace the fuse according to the displayed failure code. a When replacing F1 or F2, remove the printed circuit card mounting bracket.

Failure code

Controller

E20

Corresponding fuse F1 (Fuse for travel circuit)

E32

F2 (Fuse for hydraulic circuit)

E52

F3 (Fuse for EPS circuit)

—

F4 (Fuse for charging circuit)

a F4 for only 1.0 – 1.75 ton models 2)

Turn the key switch OFF and disconnect the battery plug.

3) Symbol F1

F2

F3

F4

80-12

Circuit where fuse is used Travel circuit

Hydraulic circuit

EPS circuit

Charging circuit

Capacity

1 – 1.75 ton models

48LF-225A

2 – 2.5 ton models

48LF-325A

3.0 ton model

96LF-275A

1 – 1.75 ton models

48LF-225A

2 – 2.5 ton models

48LF-225A

3.0 ton model

96LF-200A

1 – 1.75 ton models

48LF-40A

2 – 2.5 ton models

48LF-40A

3.0 ton model

96LF-40A

1 – 1.75 ton models

48LF-225A

2 – 2.5 ton models

48LF-225A

3.0 ton model

96LF-200A

4)

Loosen the nut and replace the fuse.

5)

Tighten the nut securely. BE30 Series

YEARLY INSPECTION CRITERIA

Component

CONTROLLER, POWER TRAIN

Inspection item

Controller

29 – 32. Wiring (including charging cables)

37 – 38. Transfer

Contents of inspection Check the following items visually and by feeling. 1.

Damage of wiring harnesses and looseness of clamps

2.

Looseness of terminal connecting parts and condition of taped parts

3.

Contact condition of battery connectors and looseness of bolts

4.

Damage of wiring harness covers

1.

Oil leakage Check visually.

2.

Checking oil level and replacing oil

1) 2) 3)

1)

Power train

2)

Checking oil level Remove level plug (2) and check the oil level. If the oil level is near the lower line of the level plug hole, it is normal. If the oil level is low, remove oil filler plug (1) and add gear oil. Replacing oil Remove oil filler plug (1), then remove drain plug (3) to drain the oil. After draining the oil, tighten drain plug (3) and supply gear oil through he oil filler by the specified quantity.

Refill capacity Models

BE30 Series

Oil level (l)

FB10EX/14EX/15EX/18EX FB15EXG/18EXG

7.0

FB20EX/25EX FB20EXG/25EXG

8.0

FB30

8.0

3)

After supplying oil, check the oil level with the level plug and adjust it if necessary. (See CHECKING OIL LEVEL above.)

3.

Looseness of bolts Check that the bolts are tightened normally.

80-13

TRAVEL SYSTEM

Component

Inspection item 41 – 45. Tire

Travel system

YEARLY INSPECTION CRITERIA

46. Hub bolt and nut and rim fitting bolt and nut

Contents of inspection 1.

Tire inflation pressure

Front wheel

kPa {kgf/cm²}

610 {6.25}

610 {6.25}

880 {9.0}

780 {8.0}

Rear wheel

kPa {kgf/cm²}

780 {8.0}

780 {8.0}

880 {9.0}

610 {6.25}

2.

Cracking and damage of tire Check the tread and side walls of each tire for cracking and breakage. If cracking or breakage is serious, replace the tire.

3.

Depth of groove If pneumatic tire is used, measure depth C of grooves at point B of 1/4 of tread width. Check that depth C is 1.6 mm or larger.

4.

Abnormal wear of tire Check the tire visually for abnormal wear, uneven wear, and stepped wear.

5.

Foreign matter caught or stuck in tire Check the tire visually for metal pieces, stones, etc. caught or stuck in it.

1.

Looseness Check the nuts with a hub nut wrench and tighten them to the following torque, if loosened.

Tightening torque of hub nut Tightening torque of rim fitting nut

80-14

3 ton model

Unit

Unit

1 – 1.75 ton models

2 – 2.5 ton models

3 ton model

Front wheel

Nm {kgm}

196 – 245 {20 – 25}

196 – 245 {20 – 25}

294 – 490 {30 – 50}

Rear wheel

Nm {kgm}

98 – 147 {10 – 15}

196 – 245 {20 – 25}

196 – 245 {20 – 25}

Front wheel

Nm {kgm}

Rear wheel

Nm {kgm}

Items

47. Rim

1 – 1.35 ton 1.5 – 1.75 2 – 2.5 ton models ton models models

Items

98 – 123 {10 – 12.5} [Only 1.0 - 1.35 ton models] 59 – 74 {6 – 7.5}

157 – 196 {16 – 20}

2.

Damage Check that the bolts and nuts are not damaged.

1.

Damage, deformation, and cracking of side ring Check the side ring visually or by a crack detection method.

– –

BE30 Series

YEARLY INSPECTION CRITERIA

Component

TRAVEL SYSTEM, STEERING SYSTEM

Inspection item 48 – 49. Wheel bearing

Travel system

50. Front axle

Contents of inspection Jack up the lift truck and check the following. 1.

Play Hold the top and bottom of each tire to check for play.

2.

Abnormal sound Turn each tire with the hands and check for abnormal sound while it is rotating. Check the heaviness and inertia, too.

1.

Deformation, cracking, and damage Check visually. If necessary, check by a crack detection method.

2.

Looseness of mounting bolts (1) Check that mounting bolts (1) are tightened to the specified torque.

1.0 – 1.75 ton models 2.0 – 3.0 ton models

52 – 55. Steering wheel

1.

Play in turning direction

Steering system

Play L

BE30 Series

343 – 427 Nm {35 – 43.5 kgm}

30 – 60 mm

2.

Play in axial and radial directions Move the steering wheel in the axial direction and radial direction to check for play.

3.

Operating condition Drive the lift truck and operate the steering wheel actually to check for abnormality.

80-15

STEERING SYSTEM

Component

YEARLY INSPECTION CRITERIA

Inspection item 56 – 57. Steering gear box (EX type)

Contents of inspection 1. 2.

Oil leakage Check visually. Looseness of mounting bolts (1) Check that the mounting bolts are tightened to the specified torque. Mounting bolts (1)

98 – 122 Nm {10.0 – 12.5 kgm}

1. Mounting bolts 2. Dashboard 3. Gear box

1.

Steering system

58 – 60. Steering linkage Rod, arm, bell crank, etc.

Play and looseness of fitting parts Have an assistant turn the steering wheel and check play of the moving parts, looseness of fitting parts, and play of the connecting parts. (Ball joint (4) has a little play. If the play is visible, however, it is abnormal.) 1. Steering gear box 2. Cotter pin 3. Castle nut 4. Ball joint 5. Frame 6. Castle nut 7. Castle nut

Castle nut (3), (6), (7) 2. 3.

61. Knuckle

1. 2.

80-16

59 – 98 Nm {6 – 10 kgm}

Bend, damage, and wear Check visually. Breakage of cotter pin (2) Check visually. Play of kink pin Jack up the rear wheels and hold the top and bottom of each tire to check for play. Damage and cracking of knuckle Check visually or by a crack detection method.

BE30 Series

YEARLY INSPECTION CRITERIA

Component

STEERING SYSTEM

Inspection item 62. Rear axle

Contents of inspection 1.

Camber angle Apply a camber gauge to the hub to measure the camber angle. Camber angle A

1° 30’

Kink pin angle B

6°

Steering system

2. Minimum turning radius [1] Have an assistant drive the lift truck with the minimum turning radius. [2] Install a rod having a chalk at its end to the outside of the counterweight to draw a circle on the ground. [3] Measure the radius drawn on the ground. [4] Measure in both turning directions. FB10EX/14EX Within 1,760 ± 90 mm

FB20EX

Within 1,980 ± 100 mm

FB15EX

Within 1,760 ± 90 mm

FB25EX

Within 2,000 ± 100 mm

FB18EX

Within 1,790 ± 90 mm

FB20EXG

Within 2,050 ± 100 mm

FB15EXG

Within 1,985 ± 90 mm

FB25EXG

Within 2,090 ± 100 mm

FB18EXG

Within 1,985 ± 90 mm

FB30

Within 2,215 ± 110 mm

Difference between both directions (Common to all models) 3.

Within ±100 mm

Thrust clearance Press rear axle (3) forward and measure clearance a between it and axle support (4). Clearance a

0 – 0.1 mm

Adjusting: If clearance a is larger than 0.3 mm, adjust it to 0 – 0.1 mm with adjustment bolt (1). After adjusting, tighten locknut (2) securely.

4.

Support mounting bolt (5) (1) 1.0 – 1.75 ton models 245 – 308.7 Nm {25 – 31.5 kgm} (2) 2.0 – 2.5 ton models 490 – 607.6 Nm {50 – 62 kgm}

BE30 Series

80-17

STEERING SYSTEM

Component

Inspection item 63 – 65. Power steering system (EX type) (EXG type)

Steering system

YEARLY INSPECTION CRITERIA

Contents of inspection 1.

Checking voltage of EPS torque sensor 1. Dashboard 2. Main 3. Sub

Turn the key switch OFF and apply voltage of 5 V between terminals and (Main side) ( is positive (+) and is negative (-)), and then measure the voltage between terminals and . When measuring the sub side, apply voltage of 5 V between terminals and ( is positive (+) and is negative (-)), and then measure the voltage between terminals and . a When the lift truck is shipped, the main side ( , , ) is used and the sub side ( , , ) is not used. If the main side is defective, wires may be connected to the sub side and used. State of steering wheel

Normal voltage Between

and

or between

Neutral (Not turned at all)

2.5 ± 0.1 V

Turned to right

2.5 ± 0.1 V o 0.9 – 1.4 V (Must change smoothly)

Turned to left

2.5 ± 0.1 V o 3.6 – 4.1 V (Must change smoothly)

and

Judgment: If the voltage is always normal when the steering wheel is in neutral, turned to the right, and turned to the left, the torque sensor is normal.

80-18

BE30 Series

YEARLY INSPECTION CRITERIA

Component

STEERING SYSTEM

Inspection item 63 – 65. Power steering system (EX type) (EXG type)

Contents of inspection 2.

EPS actuator 1. Steering gear box 2. Mounting bolt 3. Universal joint 4. Bellows 5. Ball joint 6. Castle nut 59 – 98 Nm {6 – 10 kgm}

Steering system

Castle nut (6)

1)

Universal joint (3) Check the following visually and by feeling. (1) Check that there is not play in the axial direction and turning direction. (2) Check that the bearing has no play. (3) Check that the spider is free from damage and cracking. (4) Check that the bending torque is even and smooth.

2)

Cracking and hardening of bellows (4) Check visually.

3)

Play of ball joint (5) Check that the ball joint does not have visible play.

4)

Looseness of actuator mounting bolts (2) Check that the mounting bolts are tightened to the specified torque. 49 – 68.6 Nm {5 – 7 kgm}

BE30 Series

80-19

BRAKE SYSTEM

Component

YEARLY INSPECTION CRITERIA

Inspection item 67 – 72. Brake pedal

Contents of inspection 1.

Play Play (a)

2 – 6 mm

a. Play b. Switch ON position c. Stroke

2.

Height of pedal (above floor plate) Height of pedal (H1)

Brake system

Height of pedal when pressed (H2)

73 – 76. Parking brake

130 – 140 mm 1 ton series

Min. 81 mm

2 – 3 ton series Min. 79 mm

3.

Brake switch After setting the height of the brake pedal, adjust the location of the microswitch so that it will operate when the pedal stroke (C) is 20 – 30 mm.

4.

Entry of air in brake circuit Press the pedal strongly to see if air is in the brake circuit.

5.

Braking force Drive the lift truck at the maximum speed on a dry, flat, and paved road and apply the brake sharply and check the following. 1) Swing of steering wheel 2) Operation of brake on only one side 3) Abnormal sound 4) Braking distance

1.

With no load

Max. 5 m

With load

Max. 2.5 m

Operating effort of lever Model

2.

Operating effort of lever

FB10 – 18

147 – 196 Nm {15 – 20 kgm}

FB15/FB18EXG

196 – 245 Nm {20 – 25 kgm}

FB20 – 30

196 – 245 Nm {20 – 25 kgm}

Braking force Check that the parking brake can holding the lift truck on the following slopes. With no load

Slope of 20% (11.2°) or steeper

With load

Slope of 15% (8.5°) or steeper

If there are not slopes, drive the lift truck at low speed and check the effect of the parking brake.

80-20

BE30 Series

YEARLY INSPECTION CRITERIA

Component

BRAKE SYSTEM

Inspection item

Contents of inspection

79 – 80. Brake piping 1.

2.

81 – 85. Travel brake 1. 2.

Damage, oil leakage, and interference Check the pipes, hoses, and joints visually for damage, oil leakage, and interference. Looseness of connecting parts and clamps Retighten.

Oil leakage Check visually. Brake oil level Remove the inside cover under the cap and check that oil level L is proper. (25 – 45 mm)

Brake system

1. Cap 2. Brake reservoir tank

3.

Operating condition of master cylinder and wheel cylinder Press and release the brake pedal and check the following. 1) Heaviness to press brake pedal 2) Change of heaviness to press brake pedal 3) Change of position of pressed brake pedal 4) Returning condition of released brake pedal

4.

Check the master cylinder and wheel cylinder visually for oil leakage and damage.

5.

Wear and damage of cylinder, piston, and cup If any abnormality is detected in steps 3 and 4 above, disassemble the cylinder to check. Clearance between wheel cylinder and piston

Max. 0.2 mm

Clearance between master cylinder and piston Max. 0.15 mm

BE30 Series

80-21

BRAKE SYSTEM

Component

YEARLY INSPECTION CRITERIA

Inspection item 86 – 93. Brake drum and brake shoe

Contents of inspection 1.

Looseness of drum fitting parts Retighten the mounting nuts to 318.7 – 426.6 Nm {32.5 – 43.5 kgm}. If they are turned at this time, caulk them again.

2.

Wear of lining Measure the most worn part of the lining. Thickness of lining

Min. 2.0 mm

3.

Operating condition of shoe Holding the lining surface with a screwdriver, etc. so that the piston will not come out, press the brake pedal and check the operating condition of the shoe.

4.

Rust of anchor pin Remove the shoe from the anchor pin and check the anchor pin for rust and wear. a When installing the shoe, thinly apply special grease for brake to the sliding parts.

5.

Fatigue of return spring

Brake system

1.0 – 1.75 ton models Free length: Max. 105 mm 2.0 – 2.5 ton models

Free length: Max. 112 mm (Longer one) Free length: Max. 108 mm (Shorter one)

3.0 ton model

Free length: Max. 136 mm

6.

Hook of return spring Check visually for flaw.

7.

Operation of automatic adjuster See Section. 20. TESTING AND ADJUSTING.

8.

Wear and damage of drum If the inside wall of the drum is worn unevenly, tapered, or scratched badly, repair it by polishing. 1.0 – 1.75 ton models Max. 256 mm Repair limit of brake drum 2.0 – 2.5 ton models Max. 281.4 mm (Inside diameter of brake drum) 3.0 ton model Max. 312 mm

80-22

BE30 Series

YEARLY INSPECTION CRITERIA

Component

Inspection item 94 – 95. Back plate

BRAKE SYSTEM

Contents of inspection 1.

Deformation and cracking Check visually. (Check the periphery of the back plate for deformation and the mounting bolts for cracking, in particular.)

2.

Looseness of mounting bolts Apply LOCTITE (#271 or #601) to the mounting bolts and tighten them.

Brake system

157 – 196 Nm {16 – 20 kgm}

BE30 Series

80-23

CARGO HANDLING SYSTEM

Component

YEARLY INSPECTION CRITERIA

Inspection item 107 – 109. Fork

Contents of inspection 1.

Damage and wear of fork and fork pin

2.

Deformation of fork Set the forks to the center of the lift truck and check that their height difference C and opening B are less than the specified values. Height difference C Max. 15 mm Opening B

3.

Max. 35 mm

Wear of fork Check that thickness A of the base of the fork is larger than the specified value. 1.0 ton models

Min. 26 mm

Cargo handling system

1.35 – 1.5 ton models Min. 30 mm

110 – 119. Mast and fork carriage

1.75 ton models

Min. 33 mm

2.0 ton models

Min. 33 mm

2.5 ton models

Min. 36.5 mm

3.0 ton model

Min. 39.5 mm

4.

Cracking of fork Check the following parts by a crack detection method, since stresses are concentrated on them particularly. • Base of fork F • Hooks of fork D and E

1.

Cracking Check visually or by a crack detection method (Check the welded parts particularly). • Each stay • Chain wheel shaft • Tilt cylinder bracket • Each welded part of fork carriage • Roller shaft

2.

Play of roller bearing Set the mast vertically and raise the fork about 100 mm above the ground. At this time, check for change of the longitudinal and lateral clearances between the inner mast and fork carriage and between the outer mast and inner mast to judge the play between the roller and rail. Items

80-24

1.0 – 1.75 ton 2.0 – 3.0 ton models models

Clearance between outer mast and inner mast

Clearance of Max. 2.0 mm Max. 2.5 mm front and rear

Clearance between fork carriage and inner mast

Clearance of Max. 2.0 mm Max. 2.0 mm front and rear

Clearance of Max. 2.0 mm Max. 2.5 mm left and right

Clearance of Max. 2.0 mm Max. 2.5 mm left and right BE30 Series

YEARLY INSPECTION CRITERIA

Component

CARGO HANDLING SYSTEM

Inspection item 110 – 119. Mast and fork carriage

Cargo handling system

120 – 122. Chain

123 – 124. Chain wheel

125. Attachments

BE30 Series

Contents of inspection 3.

Bushing of master support Check that there is oil grooves on the bushing.

4. 1) 2)

Cracking and damage of roller and roller pin Visually check the rolling contact surface in the mast for abnormality. Insert a steel rod about 200 mm long between the outer mast and inner mast and pry the masts to check the roller and roller pin for cracking and damage. a If the welded parts of the roller pin seem to be cracked, disassemble the mast and check by a crack detection method.

1.

Tension Set the mast vertically and raise the fork about 100 mm above the ground. Press the center of the lift chain with the fingers and check that the tension is not different. Adjusting: Adjust with the chain stopper.

2.

Elongation Measure length L of 17 links and check that it is in the specified range. Length L of 17 links 1.0 – 1.75 ton models

Max. 275.5 mm

2.0 – 2.5 ton models

Max. 330 mm

3.0 ton model

Max. 550 mm

3.

Deformation, damage, lubrication, and rust Check visually.

4.

Deformation and damage of chain stopper. Check visually.

1.

Deformation and damage Check visually.

2.

Play of bearing Turn the chain wheel with the hand and check the bearing for play.

1.

Looseness, deformation, cracking, damage, and wear Operate the attachments and check visually.

2.

Installation condition Operate the attachments and check visually.

80-25

CARGO HANDLING SYSTEM

Component

YEARLY INSPECTION CRITERIA

Inspection item 126 – 129. Cylinder

Contents of inspection 1.

Looseness, deformation, cracking, and damage Check the piston rod, rod screw, and rod end for looseness, deformation, cracking, and damage. Important inspection items 1) Bend, flaw, and rust of piston rod (Visual check or feeling) 2) Cracking of piston rod screw (Visual check or dye penetrant test) 3) Looseness of lift cylinder mounting bolt Lift cylinder mounting bolt

2.

59 – 74 Nm {6 – 7.5 kgm}

Hydraulic drift and hydraulic drift of leaning forward At fork

Max. 60 mm/15 min

At cylinder

Max. 30 mm/15 min

Hydraulic drift of leaning forward At cylinder

Max. 23 mm/15 min

Hydraulic drift

Cargo handling system

a For the measuring method, see section 20, TESTING AND ADJUSTING. Adjusting:If the hydraulic drift exceeds the specified value, replace packings of the control valve and cylinder. 3.

Oil leakage and damage Check visually.

4.

Clearance between head-side bushing of tilt cylinder rod and mounting pin Clearance

130. Hydraulic pump 1.

80-26

1.0 – 1.75 ton models Max. 0.5 mm 2.0 - 3.0 ton models

Max. 0.6 mm

Oil leakage and abnormal sound Check visually and by listening.

BE30 Series

YEARLY INSPECTION CRITERIA

Component

CARGO HANDLING SYSTEM

Inspection item 131 – 132. Hydraulic tank

Contents of inspection 1.

Oil level 1. Oil level gauge 2. Oil filler 3. Inspection cover

Cargo handling system

Lower the fork and open inspection cover (3). Check that hydraulic oil level gauge (1) shows the oil level in proper range L. If oil level is low, add hydraulic oil through oil filler (2).

133 – 134. Control lever

BE30 Series

2.

Replacing hydraulic oil, cleaning strainer, and replacing line filter See Section 20. TESTING AND ADJUSTING.

1.

Play of connecting parts and movement of levers Operate the levers and check by feeling.

80-27

CARGO HANDLING SYSTEM

Component

Inspection item 135 – 137. Control valve

Cargo handling system

YEARLY INSPECTION CRITERIA

Contents of inspection 1.

Oil leakage Check visually.

2.

Operation of relief valve Raise the fork to the maximum lifting height, and then check the operation sound of the relief valve.

3. 1)

Proportional solenoid valve spec. Relief pressure Proportional solenoid valve spec. Connect an oil pressure gauge (for measuring maximum oil pressure of 24.5 MPa {250 kgf/ cm²}) to relief oil pressure pickup plug (1) (plug at the sensor fitting portion). Manual valve spec. Connect an oil pressure gauge (for measuring maximum oil pressure of 24.5 MPa {250 kgf/ cm²}) to relief oil pressure pickup plug (1) (plug at the control valve P port portion).

2)

Manual valve spec.

Specified 17.1 – 18.1 MPa pressure {174 – 185 kgf/cm²} a

80-28

Raise the fork to the maximum lifting height and relieve the oil. Check that the oil pressure at this time is in the specified range.

If a port valve is installed, lean the attachment lever forward when measuring.

BE30 Series