Service Manual for Forklift Chassis & Mast Components

Service Manual
Chassis & Mast

FBC15K, FBC18K, FBC18KL
A3BC1-10200-up
A3BC1-20200-up
A3BC1-30200-up
A3BC2-40200-up
FBC20K, FBC25K
A3BC2-10200-up
A3BC2-20200-up
A3BC2-30200-up
A3BC2-40200-up
A3BC2-80200-up
FBC25KE, FBC25KL, FBC30K
A3BC3-10200-up
A3BC3-20200-up
A3BC3-30200-up
A3BC3-40200-up
A3BC3-80200-up
FBC30KL
A3BC4-40200-up
99759-73110
TABLE OF CONTENTS
Chapter 1: General Information

Scope ................................................................................................................................ 1.1
Truck Models Covered ...................................................................................................... 1.1
Nameplate and Serial Number Locations ......................................................................... 1.2
Dimensions ........................................................................................................................ 1.3
Dimensions Chart .......................................................................................................... 1.4
General Information (Standard Models) ............................................................................ 1.5
Chapter 2: Front Axle & Reduction Differential

Front Axle
Description......................................................................................................................... 2.1
General Information....................................................................................................... 2.1
Front Wheels ..................................................................................................................... 2.2
Removal ........................................................................................................................ 2.2
Method 1 ................................................................................................................... 2.3
Method 2 ................................................................................................................... 2.3
Method 3 ................................................................................................................... 2.3
Installation ......................................................................................................................... 2.4
Disassembly ...................................................................................................................... 2.5
Removing Front Wheel Hub .......................................................................................... 2.6
Inspection after Disassembly ............................................................................................ 2.7
Reassembly ....................................................................................................................... 2.8
Axle Housing ................................................................................................................. 2.8
Front Wheel Hub ........................................................................................................... 2.8
Hub Bearing Preload ..................................................................................................... 2.9
Installation and Setting Preload ................................................................................ 2.9
Reduction Differential
Description......................................................................................................................... 2.10
Disassembly ...................................................................................................................... 2.11
Reduction Gear ............................................................................................................. 2.12
Differential...................................................................................................................... 2.12
Reassembly ....................................................................................................................... 2.13
Inspection and Adjustment ................................................................................................ 2.15
Side Bearing Preload .................................................................................................... 2.15
Reduction Gear Backlash.............................................................................................. 2.15
Reduction Gear Face Runout........................................................................................ 2.16
Tooth Contact ................................................................................................................ 2.16
Tooth Contact Adjustment ............................................................................................. 2.17
i
TABLE OF CONTENTS
Chapter 3: Transfer Assembly

Description......................................................................................................................... 3.1
Disassembly ...................................................................................................................... 3.2
Disassembly Sequence ..................................................................................................... 3.2
Inspection after Disassembly .......................................................................................... 3.2
Reassembly ....................................................................................................................... 3.5
Chapter 4: Rear Axle

Description......................................................................................................................... 4.1
Rear Wheels...................................................................................................................... 4.2

Removal ........................................................................................................................ 4.2
Installation ..................................................................................................................... 4.4
Rear Axle ........................................................................................................................... 4.7

Removal ........................................................................................................................ 4.7
Installation ..................................................................................................................... 4.8
Disassembly .................................................................................................................. 4.9
Inspection after Disassembly ........................................................................................ 4.11
Reassembly................................................................................................................... 4.12
Inspection and Adjustment ................................................................................................ 4.17

Minimum Turning Radius Adjustment............................................................................ 4.17
Chapter 5: Brake System

Description......................................................................................................................... 5.1
Automatic Adjusting Device........................................................................................... 5.1
General Information....................................................................................................... 5.1
Master Cylinder
Disassembly .................................................................................................................. 5.2
Reassembly................................................................................................................... 5.3
Service Brakes
Disassembly
(FBC15K - 18KL) ...................................................................................................... 5.4
(FBC20K - 30KL) ...................................................................................................... 5.5
Reassembly
(FBC15K - 18KL) ...................................................................................................... 5.8
(FBC20K - 30KL) ...................................................................................................... 5.9
Wheel Cylinders
Disassembly .................................................................................................................. 5.12
Reassembly................................................................................................................... 5.13
Inspection and Adjustment ............................................................................................ 5.14
ii
TABLE OF CONTENTS
Chapter 6: Steering System

Steering System
Description .................................................................................................................... 6.1
Steering System ...................................................................................................... 6.1
Oil Flow Sequence ............................................................................................... 6.1
General Information ............................................................................................. 6.1
Steering Gear
Steering Wheel
Removal.................................................................................................................... 6.2
Installation................................................................................................................. 6.2
Steering Gear ............................................................................................................... 6.3
Inspection after Removal .............................................................................................. 6.4
Disassembly.................................................................................................................. 6.5
Working Rules and Tips............................................................................................ 6.6
Suggestions .............................................................................................................. 6.6
Inspection after Disassembly.................................................................................... 6.6
Reassembly .................................................................................................................. 6.7
Suggestions ......................................................................................................... 6.8
Steer Pump
Removal........................................................................................................................ 6.9
Installation.....................................................................................................................6.10
Disassembly..................................................................................................................6.11
Sequence..................................................................................................................6.11
Working Rules and Tips............................................................................................6.12
Suggestions ..............................................................................................................6.12
Inspection after Disassembly....................................................................................6.14
Reassembly ..................................................................................................................6.15
Sequence..................................................................................................................6.15
Suggestions ..............................................................................................................6.16
Inspection after Reassembly ....................................................................................6.18
Chapter 7: Hydraulic System
Hydraulic System
Description......................................................................................................................... 7.1
Schematic ..................................................................................................................... 7.1
Hydraulic Tank ............................................................................................................... 7.2
Hydraulic Pump ............................................................................................................ 7.3
Control Valve ................................................................................................................. 7.5
Lift and Tilt Cylinders ..................................................................................................... 7.6
Flow Regulator Valve..................................................................................................... 7.7
Down Safety Valve ........................................................................................................ 7.8
Removal and Installation Warning..................................................................................... 7.9
iii
TABLE OF CONTENTS
Chapter 7: Hydraulic System, continued

Hydraulic Pump
Removal ............................................................................................................................ 7.10
Installation ......................................................................................................................... 7.11
Disassembly ...................................................................................................................... 7.12
Working Rules and Tips ................................................................................................ 7.13
Suggestions................................................................................................................... 7.14
Body .............................................................................................................................. 7.16
Mounting Flange Face................................................................................................... 7.16
Bushes and Balance Plate ............................................................................................ 7.16
Gears............................................................................................................................. 7.16
Reassembly ....................................................................................................................... 7.17
Inspection after Reassembly ............................................................................................. 7.22
Control Valve
Removal ............................................................................................................................ 7.23
Installation ......................................................................................................................... 7.24
Disassembly ...................................................................................................................... 7.25
Suggestions....................................................................................................................... 7.27
Reassembly ....................................................................................................................... 7.27
Lift and Tilt Cylinders

Removal
Lift Cylinders.................................................................................................................. 7.28
Tilt Cylinders .................................................................................................................. 7.31
Disassembly
Lift Cylinders.................................................................................................................. 7.33
Tilt Cylinders .................................................................................................................. 7.34
Flow Regulator Valve..................................................................................................... 7.35
Precautions for Reassembly ............................................................................................. 7.36
Inspection and Adjustment

Hydraulic Tank ................................................................................................................... 7.37
Control Valve ..................................................................................................................... 7.38
Lift and Tilt Cylinders ......................................................................................................... 7.40
Adjusting Method........................................................................................................... 7.41
Testing ........................................................................................................................... 7.42
iv
TABLE OF CONTENTS
Chapter 8: Mast and Forks

Description.................................................................................................................. 8.1
Removal and Installation ............................................................................................ 8.2
Disassembly .............................................................................................................. 8.4
Inspection after Disassembly...................................................................................... 8.6
Reassembly ................................................................................................................ 8.7
Inspection and Adjustment ......................................................................................... 8.8
Forks....................................................................................................................... 8.8
Chain Tension Adjustment ...................................................................................... 8.9
Clearance Adjustment on Lift Bracket .................................................................... 8.10
Mast Clearance Adjustment.................................................................................... 8.13
Main Roller Shim Replacement .............................................................................. 8.15
Mast Strip Adjustment............................................................................................. 8.15
Tilt Angle Adjustment .............................................................................................. 8.16
Lift Cylinder Stroke Adjustment .............................................................................. 8.17
Bleeding Lift Cylinders............................................................................................ 8.17
Service Data ............................................................................................................... 8.19
Troubleshooting .......................................................................................................... 8.20
Chapter 9: Troubleshooting Section

Front Axle and Reduction Differential ......................................................................... 9.1
Brake System ............................................................................................................. 9.2
Steering System ......................................................................................................... 9.4
Hydraulic System........................................................................................................ 9.6
Rear Axle .................................................................................................................... 9.8
Mast and Forks........................................................................................................... 9.9
v
TABLE OF CONTENTS
Chapter 10: Maintenance Service Data
Maintenance Service Data ................................................................................................ 10.1

Front Axle and Reduction Differential............................................................................ 10.1
Transfer Case ................................................................................................................ 10.3
Rear Axle ....................................................................................................................... 10.4
Brake System ................................................................................................................ 10.6
Steering System, ........................................................................................................... 10.11
Hydraulic System........................................................................................................... 10.13
Mast and Forks (Simplex Mast) .................................................................................... 10.16
Tightening Torques for Standard Bolts and Nuts .............................................................. 10.18
Fine Thread—With Spring Washer................................................................................ 10.18
Fine Thread—Without Spring Washer........................................................................... 10.19
Coarse Thread—With Spring Washer ........................................................................... 10.20
Coarse Thread—With Spring Washer ........................................................................... 10.21
Maintenance Chart ............................................................................................................ 10.22
Planned Replacement Parts.............................................................................................. 10.28

Lubrication Information ...................................................................................................... 10.29
Chart.............................................................................................................................. 10.29
Lubricant Specifications................................................................................................. 10.30
Recommended Brands of Lubrications ......................................................................... 10.30
Weight of Major Components (Approximate) .................................................................... 10.31
Special Service Tools ........................................................................................................ 10.32

Special Tool Illustrations ................................................................................................ 10.33
Inspection Guide................................................................................................................ 10.36
vi
Chapter 1: General Information
Scope......................................................................................................... 1.1
Truck Models Covered............................................................................... 1.1
Nameplate and Serial Number Locations.................................................. 1.2
Dimensions ................................................................................................ 1.3
Dimensions Chart ................................................................................... 1.4
General Information (Standard Models) .................................................... 1.5
GENERAL INFORMATION
Scope
This service manual deals with all components or systems of the Mitsubishi Forklift Trucks, except for the
electrical system, which is covered in a separate manual.
8609141A
Truck Models Covered

This service manual furnishes service and maintenance information for the following trucks.
Truck Model Serial Number

FBC15K, FBC18K, FBC18KL A3BC1-10200-up
A3BC1-20200-up
A3BC1-30200-up
A3BC2-40200-up
FBC20K, FBC25K A3BC2-10200-up

A3BC2-20200-up
A3BC2-30200-up
A3BC2-40200-up
A3BC2-80200-up
FBC25KE, FBC25KL, FBC30K A3BC3-10200-up
A3BC3-20200-up
A3BC3-30200-up
A3BC3-40200-up
A3BC3-80200-up
FBC30KL A3BC4-40200-up
1.1
GENERAL INFORMATION
Nameplate and Serial Number Locations
Mast
serial number
Power steering
motor serial number
Traction motor
Chassis serial number
serial number Hydraulic motor Nameplate
serial number
8609141
1.2
GENERAL INFORMATION
Dimensions
8609142
8609143
1.3
GENERAL INFORMATION
Dimensions Chart
Ref# Truck Model FBC15K, FBC18K FBC18KL FBC20K, FBC25K FBC25KE FBC25KL FBC30K FBC30KL
A Maximum Lift 3320 (130) 3320 (130) 3340 (131) 3340 (131) 3340 (131) 3310 (130) 3215 (126)
B Free Lift 115 (4.5) 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3) 135 (5.3)
Maximum Fork Spacing

C 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0)
(outside to outside)
D Fork Length 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42)
Tilt Angle
E 5°/6° 5°/6° 5°/6° 5°/6° 5°/6° 5°/6° 5°/6°
(forward/backward)
F Overall Length 3050 (120) 3123 (122.8) 3152 (124) 3252 (127.9) 3252 (127.9) 3325 (130.8) 3325 (130.8)
Overall Width
G 945 (37.2) 970 (38.2) 1054 (41.5) 1054 (41.5) 1103 (43.4) 1103 (43.4) 1103 (43.4)
(outside of tires)
Overall Height (to top of

H 2105 (83) 2105 (83) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5)
mast, lowered)

I 2180 (85.8) 2180 (85.8) 2207 (86.9) 2207 (86.9) 2207 (86.9) 2207 (86.9) 2207 (86.9)
overhead guard)

J 4560 (180) 4560 (180) 4570 (180) 4570 (180) 4570 (180) 4540 (179) 4540 (179)
mast, extended)
K Tread (front) 793 (31.2) 818 (32.2) 875 (34.4) 875 (34.4) 900 (35.4) 900 (35.4) 900 (35.4)
L Tread (rear) 826 (32.5) 826 (32.5) 897 (35.3) 897 (35.3) 897 (35.3) 897 (35.3) 897 (35.3)
M Wheelbase 1170 (46.1) 1170 (46.1) 1280 (50.4) 1380 (54.3) 1380 (54.3) 1380 (54.3) 1380 (54.3)
N Front Overhang 376 (14.8) 376 (14.8) 394 (15.5) 394 (15.5) 394 (15.5) 406 (15.9) 406 (15.9)
O Rear Overhang 434 (17) 507 (19) 408 (16) 408 (16) 408 (16) 469 (18.4) 469 (18.4)
Underclearance
P 118 (4.6) 118 (4.6) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9)
(at center of wheelbase)
Unit: mm (in.)
1.4
GENERAL INFORMATION
General Information (Standard Models)

Truck Model
Units FBC15K FBC18K FBC18KL FBC20K FBC25K FBC25KE FBC25KL FBC30K FBC30KL
Standard Controller GE SX Controller

Standard Simplex Mast Size meters 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Without 2095 2335 2595 2685 2870 2695 2865 3335 3502
Service Weight Battery (4620) (5140) (5720) (5920) (6330) (5940) (6320) (7353) (7721)
kg (lb)
(standard axle) With Max. 3298 3534 3797 4296 4482 4509 4681 5150 5317
Battery (7270) (7790) (8370) (9470) (9880) (9940) (10320) (11353) (11722)
Rated Capacity/ kg/mm 1500/500 1800/500 1800/500 2000/500 2500/500 2500/500 2500/600 3000/500 3500/500
Load Center (lb/in.) (3000/24) (3500/24) (4000/24) (4000/24) (5000/24) (5000/24) (5000/24) (6000/24) (6500/29)
Maximum Fork Height mm (in.) 3320 (130) 3340 (131) 3310 (130) 3215 (126)
Lift Speed 36V m/sec. .24 (48) .23 (45) .34 (67) .31 (61) .28 (56) .26 (51) .23 (45)
(Rated Load) 48V (fph) .34 (67) .32 (64) .47 (93) .40 (78) .38 (74) .36 (70) .31 (62)
Performance
Lowering Speed (rated load) .50 (99) .50 (98)
Tilt Angle (forward/backward) degrees 5° / 6°

Work
Free Lift mm (in.) 115 (4.5) 130 (5.1) 135 (5.3)
36V 12.9 (8.0) 14.3 (8.9) 11.6 (7.2) 11.1 (6.9) 10.8 (6.7) 13.2 (8.2)
Performance
Travel Speed km/h

Traveling
(Without Load) 48V (mph) DNA 17.9 (11.1) 14.8 (9.2) 14.5 (9.0) 14.2 (8.8) 16.4 (10.2)
Minimum Turning mm 1790 1840 1890 1990 2045

Radius (in.) (70.5) (72.5) (74.5) (78.5) (80.5)
Traction Motor 36V 60min. 8.2 (6.1) 9.6 (7.1) 8.3 (6.1)
Output 48V HP(kW) DNA 13.4 (10.0) 11.7 (8.7)
Transfer Type Spur

Gear Ratio 3.538 3.067
Reduction Type Bevel

Gear Ratio 4.571 5.0
Power Train
Axle Housing Banjo
Differential Gear Type/ Gears Straight Bevel/2
Number Pinions Straight Bevel/2
1.5
GENERAL INFORMATION
Truck Model
Type Dynamic Load Sense

Power Steering System
Inside 83° 83°

Turning Angle Degrees
Outside 54° 56°
Steering Wheel Diameter mm (in.) 328 (13)

2
Cylinder Minimum kgf/cm
107 (1522) [10,500] 163 (2320) [16,000]
Test Pressure (psi) [kPa]
Type Self-Adjusting Duo-Servo
Inside Drum +0 0.13(10.00 +0 0.0051)

mm (in.) 254
Diameter
Service Brake
Lining
mm (in.) 4.87 (0.19) 6 (0.24)
Thickness
Master 22.22 (0.8748)

mm (in.)
Cylinder ID
Wheel 22.22 (0.8748) 28.58 (1.1252)

Cylinder ID
Brake System
Type Mechanical, Mounted on Front Wheels
Park Brake Lever kgf 25 to 30

Operating (lbf) (55 to 66)
Effort [N] [245 to 294]
Front Wheels Fixed Type

Mounting
Traveling System
Rear Wheels Center Pivot Type
Wheel Oscillation 3°
Alignment Angle Degrees
Camber 1°
1.6
GENERAL INFORMATION
Truck Model
Type Gear
Hydraulic Pump Make Parker Hydraulics, Inc.
Model 1PX230 1SX250 1PX290 1SX250
Displacement cc (cu in.) 23.0 (1.403)/rev. 25.(1.526) 29(1.77) 25(1.526)
Make Husco International
Control Valve Model 5000CC Sectional Valve
Relief kgf /cm2
263 (3750) [25855]
Pressure (psi) [kPa]
Flow Regulator Type Variable
Valve Regulated liter 71(4332)
48(2929) 59 (3600)
Flow Rate (cu.in.) / min
Hydraulic System
Lift Cylinders ID 45 (1.77) 50 (1.97) 55 (2.17)

Stroke 1650 (64.96) 1600 (62.99)
mm (in.)
ID 63 (2.48) 70 (2.75) 80 (3.15)
Tilt Cylinders
Stroke 79 (3.11) 81 (3.19)
Hydraulic Tank Capacity liter 1 8 (4.8) 24 (6.3) 30 (7.9)
(Approx) (US gal.)
Mast Roller type CL
Mast 100 x 15 x 12 115 x 20 x 13 115 x 21 x 13
Outer
Dimensions (3.94 x 0.59 x 0.47) 4.53 x 0.79 x 0.51) (4.53 x 0.83 x 0.51)
(Flange Inside mm (in.)
Width x THK x 100 x 17 x 12 115 x 20 x 13
Inner
WEB THK) (3.94 x 0.67 x 0.47) (4.53 x 0.83 x 0.51)
Main Rollers Type #6308 Ball Bearing #6309 Ball Bearing
Diameter x Width 100 x 30 (3.94 x 1.18) 115 x 35 (4.53 x 1.58) 100 x 30 (3.94 x 1.18)
Side Rollers Type Lubricating type needle roller bearing
Diameter x
mm (in.) 42 x 36 (1.65 x 1.42)
Width
Mast and Forks
Lift Chains BL534 BL634 BL834

Forks (Lgth x Wdth x Thk) 1070x100x35 1070 x100 x40 1070 x 125 x 45
(36x4x1.3) (42 x 3.9 x 1.6) (42 x 5 x 1.8)
mm (in.)
Fork Spacing 240 / 818 (9.4/32) 284 / 958 (11.2/37.7)
(out to out) min/max
Voltage 36/48 36/48 36/48 36/48 36/48 36/48
Amp Hours (6 hr. rate) 36V 900 1300 1300
48V 700 800 1000
Compartment Height-Center 598 (23.6)
Dimensions Height-Edges 592 (23.3)
mm (in.)
Length 708 (27.9) 775 (30.5) 875 (34.4)
Battery
Width 906 (35.6) 1003 (39.5

Weight (Min/Max) kg (lb) 750/1200 1000/1600 1315/1600 1400/1800
(1650/2650) (2200/3550) (2900/3550) (3100/4000)
1.7
Chapter 2: Front Axle & Reduction Differential
Front Axle
Description.................................................................................................. 2.1
General Information ................................................................................ 2.1
Front Wheels .............................................................................................. 2.2
Removal .................................................................................................. 2.2
Method 1.............................................................................................. 2.3
Method 2.............................................................................................. 2.3
Method 3.............................................................................................. 2.3
Installation .................................................................................................. 2.4
Disassembly ............................................................................................... 2.5
Removing Front Wheel Hub.................................................................... 2.6
Inspection after Disassembly ..................................................................... 2.7
Reassembly................................................................................................ 2.8
Axle Housing ........................................................................................... 2.8
Front Wheel Hub ..................................................................................... 2.8
Hub Bearing Preload............................................................................... 2.9
Installation and Setting Preload........................................................... 2.9
Description ................................................................................................. 2.10
Disassembly ............................................................................................... 2.11
Inspection after Disassembly ..................................................................... 2.12
Reduction Gear....................................................................................... 2.12
Differential ............................................................................................... 2.12
Reassembly................................................................................................ 2.13
Inspection and Adjustment ......................................................................... 2.15
Side Bearing Preload .............................................................................. 2.15
Reduction Gear Backlash ....................................................................... 2.15
Reduction Gear Face Runout ................................................................. 2.16
Tooth Contact.......................................................................................... 2.16
Tooth Contact Adjustment ....................................................................... 2.17
FRONT AXLE: DESCRIPTION
Front Axle
Description
6 8
5
7
4 3 1
2
203658
1. Front wheel hub 5. Reduction pinion

2. Frame support 6. Reduction gear
3. Axle shaft 7. Differential case
4. Axle housing 8. Differential carrier
General Information
The frame supports hold the front axle housing in
such a manner as to allow a limited amount of
rotary motion of the housing, the rotary sliding
surfaces being lubricated with grease.
The cushion tire is press-fitted to the outer ring of
the wheel hub.
2.1
FRONT AXLE: REMOVAL & INSTALLATION
Removal
Front Wheels Suggestions
1. Park the truck on level floor with the parking
! WARNING
brake applied, the direction lever in neutral,
the forks lowered, and the key switch off.
Be sure to use the same size and brand tire 2. Prepare tools, jacks, and wheel blocks.
for replacement.
3. Block the rear wheels.
4. Loosen the wheel nuts about two turns.
Removal Sequence
2
Wheel nut
1
205952 100902B
1. Wheel Nuts NOTE

2. Front Wheel
Loosen, but do not remove, the wheel nuts.
5. Raise the front end of the truck. Use one of

the methods shown.
! WARNING
To prevent possible injury, do not replace

the tire when the truck is loaded.
Dismount the truck before raising the front
tire.
To prevent possible personal injury, raise
the truck only until the tire just clears the
ground.
Do not put any portion of your body under
the truck. Securely support the truck on
blocks after raising it.
2.2
Method 1 Method 3
Position the jack under the frame and raise the Fasten a hoist to the mast and lift the front end of
truck until the tire clears the floor. the truck as shown.
100828 202778A
Jack Capacities 6. Remove the wheel nuts (loosened in Step 4.)
FBC15K - 18KL 3000 kgf (6700 lbf)

FBC20K - 30KL 5000 kgf (12,000 lbf) ! CAUTION
Be careful not to damage the bolt threads when
removing the wheel.
Method 2
Tilt the mast all the way back, place wood blocks
under the mast, and tilt the mast forward.
7. Remove the wheel.
! CAUTION
After raising the front end, securely support it
NOTE
by blocks. Service Limit For Cushion Tires
Replace the tire if the height of the solid rubber
portion is 25.4 mm (1 in. or less). For tire
replacement, consult your Forklift Truck Dealer.
25.4 mm
200227 (1 inch)
100880
2.3
Installation
To install, reverse the removal sequence and do 2. Lower the truck until the tire touches the
the following steps. floor. Then tighten the wheel nuts in numbered
sequence shown below, in two or three steps,
to the specified torque.
! CAUTION
Use the same size and brand of tire. 1
Make sure the clamping surfaces of the wheel 6

nuts and counterbores in the rim are free of dirt. 3
4
1. Install the tire and tighten the wheel nuts.
Tighten each nut until its tapered portion is 5
in full-face contact with the counterbore in 2
the rim.
205953
Wheel Nut Tightening Torque For Wheel Nuts

FBC15K - 18KL FBC20K - 30KL
Counterbore
16 kgf•m 38.5 kgf•m
(116 lbf•ft) (278 lbf•ft)
[157 N•m] [378 N•m]
100835A
2.4
FRONT AXLE: DISASSEMBLY
Disassembly
6 7
5 205954
Sequence
1. Axle shaft 4. Tapered roller bearing (outer bearing), oil
2. Lock nut, lock washer, oil seal, and tapered seal, and oil deflector
roller bearing (inner bearing) 5. Tapered roller bearing (inner bearing), and
3. Hub & drum assembly [Front wheel hub, seal retainer
brake drum, wheel bolts, drum nuts, and 6. Brake assembly
tapered roller bearing (outer bearing)] 7. Frame support and axle housing
Start By:
1. Remove the mast. (For replacement of the 3. Support the front end of the truck at both sides
front axle housing and disassembly of the dif- with blocks or stands to keep the truck in a
ferential, refer to section, MAST AND FORKS.) horizontal position.
2. Jack up the truck. 4. Remove the front wheels.
NOTE
It is not necessary to remove the axle housing
or drain the oil for removal of the shaft only.
2.5
Suggestions
Removing the Lock Nut Removing Bearings
Use a lock nut wrench (Special Tool). The inner race of the tapered roller bearing re-
mains in the axle housing when the hub is drawn
out. Remove this race together with the seal
Tool FBC15K - 18KL FBC20K - 30KL retainer with a bearing puller.
Lock Nut Wrench 91268-00800 03703-59001
Special Tool
203651
200232
Removing Front Wheel Hub

Use a wheel hub puller (Special Tool).
Tool FBC15K - 18KL FBC20K - 30KL
Wheel Hub Puller 64309-40100 MH061017

(Puller seat) (64309-10601)
NOTE
It is not necessary to remove the oil seal from

the hub or to disassemble the oil deflector
unless the seal is defective.
Special Tool
200233
2.6
Inspection after Disassembly

Axle Shafts
Looseness of Mating Splines Runout
Mount the differential bevel gear on the splined Set a dial indicator at the middle part of the axle
end of the shaft and set a dial indicator as shown shaft. Turn the shaft and read the indicator to find
below. Turn the bevel gear and read the indicator. runout.
Runout of shaft
Face runout of flange

200235 200236
Free movement A 0.07 to 0.17 FBC15K -18KL FBC20K -

(0.0028 to 0.0067) 30KL
(looseness of
splines) B 0.5 (0.020) Runout of axle A 0.5 (0.020) 1.0 (0.039)
shaft (1/2 of dial maximum maximum
Unit: mm (in.) indicator reading B 1.0 (0.039) 2.0 (0.079)
A = Assembly Standard B = Repair or Service Limit
Unit: mm (in.)
Axle Housing A = Assembly Standard B = Repair or Service Limit
1. Check the surfaces of axle housing in contact
with the mast bearing for damage. Set a dial indicator against the flange of the axle
shaft as shown. Turn the shaft and read the indi-
2. Check the entire axle housing for distortion, cator to find face runout.
dents, and other defects, paying particular
attention to the welds to see if any weld is A 0.05 (0.0020)
Face runout of axle
cracked. shaft flange B 0.5 (0.020)
Oil Seals and Retainers Unit: mm (in.)
1. Check the outer surface of the oil seal retainer A = Assembly Standard B = Repair or Service Limit
for wear or damage.
2. Check the outer and inner oil seals for wear
and damage.
2.7
FRONT AXLE: REASSEMBLY
Reassembly
To reassemble, reverse the steps of the disas- 2. Install the inner race and oil seal retainer of
sembly sequence and do the following steps. the wheel hub bearing with an installer
(Special Tool).
Axle Housing
1. Install the O-ring in the outer groove (of the
two grooves in the bore of each frame sup-
port).
Special tool
2. Apply grease to the surfaces A of the support
and axle housing.
Frame support
O-ring A
203569
FBC20K-
Tool FBC15K - 18KL
30KL
Installer 64309-12300 91468-00300

200237
3. Apply retaining compound to the flange sur-

Front Wheel Hub faces of the axle shafts.
1. Fill the front wheel hub, especially the roller
holder and oil seal lip groove, with grease.
NOTE
Be careful not to apply grease to the brake
drum.
200238
2.8
FRONT AXLE: REASSEMBLY
Hub Bearing Preload Installation and Setting Preload

Tighten the inner nut to produce the required pre- 1. Fill the hub with the recommended grease as
load. Tighten the outer nut to the specified torque listed in the service manual.
and check the preload. Be sure that the preload 2. Pack the inner and outer bearing with the
noted after tightening the outer nut meets the recommended grease.
specification. This step is for new bearings. Where
the bearings removed in disassembly are reused, 3. Install the inner bearing to the back side of
try to produce the preload at the lower side of the the hub.
range. 4. Install the inner seal.
5. Clean the lining surface of the drum.
5 to 50 kgf•cm
Preload for hub bearing (0.4 to 3.6 lbf•ft) 6. Install the hub onto the axle.
[0.5 to 4.9 N•m] 7. Install the outer bearing, grease seal and pre-
Tightening torque 20 kgf•m load nut.
for (145 lbf•ft)
8. If the bearings are being reused, try to pro-
lock nuts [196 N•m]
duce the lower side of the applied force in
tangential direction.
9. For new bearings, tighten the preload nut to
14 kgf•m (101 lbf•ft) [137 N•m]. Slowly rotate
the hub slightly more than 3 turns, back the
nut off 80°, and set the applied force in tan-
gential direction.
10. For models with an outer lock nut, torque the
nut to 20 kgf•cm (145 lbf•ft) [196 N•m]. After
torquing the lock nut, check the force applied
in tangential direction again to insure the pre-
load did not change.
Inner nut Outer nut 200468
Bar
Spring
balancer
101653
2.9
REDUCTION DIFFERENTIAL: DESCRIPTION
Description
3
4 5 2 1
200240
Sequence
1. Lock plates 4. Reduction gear and differential gear assembly
(spring pins, pinion shafts, differential pinions,
2. Side bearing nuts
differential bevel gear, washers, and differen-
3. Differential carrier assembly (lock washers, tial case)
side bearing caps, and differential carrier)
5. Tapered roller bearings
Start By:
Remove the differential carrier from the transmis-
sion case.
2.10
REDUCTION DIFFERENTIAL: DISASSEMBLY
Disassembly
Suggestions Removing Bearing Inner Races
1. Before removing the differential carrier from Use a bearing puller to remove the inner races
the transmission case, measure the gear from the differential case.
backlash to aid in obtaining correct backlash
at the time of reassembly.
Backlash between reduction gear 0.15 to 0.25

and pinion (0.0059 to 0.0098)
Unit: mm (in.)
200242
200247
2. Put a mark across the bearing cap, adjusting

screw and carrier on each side.
The caps are not interchangeable.
200241
2.11
REDUCTION DIFFERENTIAL: DISASSEMBLY

Reduction Gear Differential
Check the teeth for wear, pitting, flaking, or chip- 1. Check the differential cases for damage.
ping. Minor flaws on the tooth surface can be Check in particular the seat formed of each
repaired by grinding with an oil stone or a hand case for carrying the side bearing inner race
grinder. Check the teeth for contact. If the gear is to see whether the seat surface is galled or
badly damaged and requires replacement, not.
replace the pinion too. Reduction gear and pinion 2. Check the sliding surfaces of the thrust wash-
are a matched set and must be changed at the ers and gears for wear or damage.
same time.
3. Check the teeth of the differential pinions and
bevel gears for wear, pitting, chipping, or
galling.
4. Check the fit of each pinion on the spider.
A 0.02 to 0.07
Fit of differential (0.0008 to 0.0028)
pinions on spider
B 0.35 (0.0138)
Unit: mm (in.)
A = Assembly Standard B = Repair or service limit
2.12
REDUCTION DIFFERENTIAL: REASSEMBLY
Reassembly
4 1
3 2
200243
Sequence
1. Tapered roller bearings 3. Spring pin
2. Differential gear assembly [differential case, 4. Reduction gear
thrust washers, bevel gears, pinions, and pin-
5. Differential carrier assembly [carrier, side
ion shaft]
bearing caps, side bearing nuts, and lock
washers]
2.13
Suggestions
Reassembling Differential Pinions Reassembling Differential Case
The thrust washers of the differential gears are to After putting the case assembly in place on the
be used for adjusting the backlash between the carrier, install the bearing caps tentatively by
differential gears and pinions. Measure the back- making the cap bolts snug tight. The caps are to
lash and, if it exceeds the limit, replace the thrust be secured tight after the bearing preload has
washers. been adjusted.
Backlash between A 0.18 to 0.23 Installing Bearing Caps

differential gears (0.0071 to 0.0091)
Be sure to know which are the left and right caps
and pinions B 0.5 (0.020) and to put each cap in place correctly.
Unit: mm (in.)
12.8 kgf•m
A = Assembly Standard B = Repair or service limit Tightening torque for
(93 lbf•ft)
bearing cap bolts
[126 N•m]
200244
200241
Installing Reduction Gear

Apply LOCTITE No. 271 to the bolts for holding
the reduction gear to the case. Be sure to tighten
these bolts evenly so as not to strain the gear.
12.0 kgf•m
Tightening torque for
(87 lbf•ft)
reduction gear bolts
[118 N•m]
2.14

Side Bearing Preload Reduction Gear Backlash
Tie a wire on the reduction gear tooth and hook a Adjust the backlash between the reduction gear
spring scale to the wire. Tighten the side bearing and pinion after installing the differential carrier
nuts while reading the spring scale until the speci- assembly to the transmission case. To measure
fied preload is obtained. the backlash, set a dial indicator with its spindle
pointing squarely to the tooth face of the reduc-
tion gear. With the pinion held, move the gear
NOTE back and forth to read the indicator. Adjust the
Before measuring the preload, tap the back backlash using the left and right side bearing
of the reduction gear with a copper hammer nuts and pinion shims.
while rotating the gear to center between
bearing. 0.15 to 0.25
Backlash between
(0.0059 to
reduction gear and pinion
0.0098)
Unit: mm (in.)
15 to 30 kgf
Min. (1.1 to 2.2 lbf)
[1.5 to 2.9 N]
Preload for differential 1.32 to 2.5 kgf•cm

case side bearings Max. (2.9 to 5.5 lbf•ft)
[13 to 25 N•m]
As force applied to
reduction gear in
tangential direction.
200247
Backlash
Increase
Decrease
Decrease
Increase
200246 Increase
Backlash
Decrease
200248
2.15
REDUCTION DIFFERENTIAL: INSPECTION
Reduction Gear Face Runout Tooth Contact

Using a dial indicator, check the reduction gear Check the gear reduction tooth contact. To check,
for face runout at the maximum radius position in apply a thin coat of bluing to several gear teeth
back of the gear. If the runout exceeds the limit, on both drive and coast sides. Press forward on
check the reduction gear bolts for tightness; the reduction pinion and rotate the reduction gear
retighten if necessary. Check the tapered roller back and forth until a contact pattern is noted on
bearings for condition. Readjust or replace them both concave and convex faces of the gear teeth.
if necessary. To adjust the tooth contact, refer to the chart.
Face runout of A 0.05 (0.0020) maximum

reduction gear B 0.05 (0.0020) maximum
Unit: mm (in.)
200250
200249
2.16
Tooth Contact Adjustment (FBC15K - 18KL)
Tooth Contact Adjustment

Extends from toe Correct tooth contact
to middle portion,
covering not less
1 than 50% of tooth
length.
203669-1
Short contact at 1. Move gear away from pinion.

toe of tooth. 2. Move pinion toward gear by increasing shim thick-
2 ness to secure correct backlash.
203669-2 203669-2A
Short contact at 1. Move gear toward pinion.

heel of tooth. 2. Move pinion away from gear by decreasing shim
3 thickness to secure correct backlash.
203669-3 203669-3A
Heavy contact 1. Move pinion toward gear by increasing shim thick-

on face or upper ness.
4 portion of tooth. 2. Move gear away from pinion to secure correct
backlash.
203669-4 203670-4A
Heavy contact on 1. Move pinion away from gear by decreasing shim

flank or lower thickness.
portion of tooth. 2. Move gear toward pinion to secure correct
5
backlash.
203669-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
2.17
Tooth Contact Adjustment (FBC20K - 30KL)
Tooth Contact Adjustment

Extends from toe Correct tooth contact
to middle portion,
covering not less
1 than 50% of tooth
length.
203670-1
Short contact at 1. Move pinion toward gear by increasing shim thick-

toe of tooth. ness.
2 2. Move gear away from pinion to secure correct
backlash.
203670-2 203670-2A
Short contact at 1. Move pinion away from gear by decreasing shim

heel of tooth. thickness.
3 2. Move gear toward pinion to secure correct
backlash.
203670-3 203670-3A
Heavy contact on 1. Move pinion toward gear by increasing shim

face or upper thickness.
portion of tooth. 2. Move gear away from pinion to secure correct
4
backlash.
203670-4 203670-4A
Heavy contact 1. Move pinion away from gear by decreasing shim

on flank or lower thickness.
5 portion of tooth. 2. Move gear toward pinion to secure correct
backlash.
203670-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
2.18
Chapter 3: Transfer Assembly
Description ...............................................................................................3.1
Disassembly.............................................................................................3.2
Disassembly Sequence ...........................................................................3.2
Inspection after Disassembly .................................................................3.2
Reassembly .............................................................................................3.5
TRANSFER ASSEMBLY
Description
Front axle center

1 8 2
6 Traction motor
5 9 4 6 209002
Main component
1 Transfer case 6 Taper roller bearing
2 Transfer cover 7 Lock nut
3 Input gear (13T) 8 Ball bearing
4 Output gear (48T) 9 Plug (standard) or pulse generator (option)
5 Bevel gear set
The transfer assemblies of all the 1 ton, 2 ton, and 3

ton class trucks share completely identical components
except the different bevel gear sets as shown below.
No. of teeth on No. of teeth on

bevel pinion bevel gear
1 ton class trucks 7 32
2 and 3 ton class
7 35
trucks
3.1
TRANSFER ASSEMBLY
Disassembly
Start by:
(1) Remove the drain plug on the front axle hous- (3) Remove the traction motor, reduction and dif-
ing to let the oil drain out. ferential assembly and transfer assembly as
(2) Disconnect the connectors of the traction motor one unit, from the front axle housing.
harnesses and pulse generator harness. (4) Separate the three assemblies removed in step
(3) from each other.
3 15 Liquid gasket
2
18 1
14
17
Plug (standard)
or 16
Pluse generator (option)
Staked
7
4
6
8 9
13 11 10 12
209002A
Disassembly sequence
1 Bolt 10 Output gear
2 Transfer cover 11 Spacer
3 Side cover with pulse generator, or plug 12 Bearing cup
4 Nut 13 Bearing cup
5 Shim 14 Snap ring
Remove parts 6 and 8 as a unit. Remove parts 15 to 17 as a unit.
6 Bevel pinion shaft 15 Input gear
7 Shim 16 Ball bearing
8 Bearing cone 17 Ball bearing
9 Bearing cone 18 Transfer case
3.2
TRANSFER ASSEMBLY
Suggestions for Disassembly
1. Remove the bevel pinion shaft 6 as follows:

Shaft locking
(1) Using a chisel, cut the staked portion of the nut 15 bar fixing bolt
4, taking care not to damage the bevel pinion Shaft locking
shaft. bar
18 Special
(2) Hold the input gear 15 with the special tool to tool
prevent the bevel pinion 6 from rotating, then
remove the nut 4 and shims 5. 6
Special tool needed

Staked
Transfer bearing tool 97E67 - 00100
4
(3) Using the bevel pinion puller (special tool), pull
5
the bevel pinion 6 out of the bearing cone 9
9
(See the drawing on the right). 12
8
13 10
Special tool needed 209003
Bevel pinion puller 91268 - 00300
(4) If the bearing cone 8 needs to be removed, use

a bearing puller and a press to pull it from the
bevel pinion 6.
(5) If the bearing cups 12 and 13 need to be
removed, use a bearing cup puller to pull them
out of the transfer case 18.
NOTE
205829
(1) The taper roller bearing cup and cone are an
exclusive pair. If either the cup or cone of a
pair is faulty, replace them as a set.
(2) The removed shims should be kept together
until they are reinstalled. (This only applies
when the bevel pinion and/or taper roller bear-
ing are/is reused.)
(3) The bevel pinion and bevel gear are an exclu-
sive pair. If either of them is defective, replace
them as a set.
205830
3.3
TRANSFER ASSEMBLY
2. Remove the input gear as follows:

(1) Remove the snap ring 14.
M14 × 1.5
(2) Using a sliding hammer, pull the input gear 15, 17 Thread 18
complete with the ball bearings out of the case
18.
14
(3) If the ball bearings 16 and 17 need to be
removed, use a puller to pull them out. Do not 15
attempt to tap them out. Rod of sliding
hammer
16
209004
Inspection after disassembly

(1) Check the output gear 10 and the input gear 15 for
damaged/worn teeth and worn splines.
(2) Check the bearings for wear or damage. Make
sure that they rotate freely without making noise.
(3) Check the transfer case for cracks or other dam-
age.
(4) Check the bevel pinion and the bevel gear for
incorrect tooth contact, damage and wear.
3.4
TRANSFER ASSEMBLY
Reassembly
Follow the disassembly sequence in reverse.
2 4 5
1
17
3
18
16 19
13
10
8 Staked
14
15
6 11 12 7
209002B
Reassembly sequence
1 Transfer case 11 Spacer
Assemble the parts 2 to 4 first, then install the 12 Output gear
assembly into the case 1. 13 Bearing cone
2 Input gear 14 Shim
3 Ball bearing 15 Nut
4 Ball bearing 16 Side cover with pulse generator (option)
5 Snap ring 17 Liquid gasket
Press-fit the parts 6 and 7 into the case 1. 18 Transfer cover
6 Bearing cup 19 Bolt
7 Bearing cup
Assemble the parts 8, 9 and 10.
8 Bevel pinion shaft
9 Shim
10 Bearing cone
3.5
TRANSFER ASSEMBLY
Suggestions for Reassembly
CAUTION Mark “b” is indicated here.
Ball bearings and taper roller bearings can be fit-
Axle center
ted onto shafts more easily when they are warmed
in hot oil. However, do not increase the oil tem-
perature above 120 °C (250 °F).
1. Install the input gear 2 as follows:

(1) Press-fit the ball bearings 3 and 4 into the input
gear 2. Force the assembly into the transfer
case 1.
(2) Install the snap ring 5.
2. Sub-assemble the bevel pinion shaft 8 as follows: B

(1) Place shim stock 9 and bearing cone 10 on the A
bevel pinion 8, then install these into place
using a press. The thickness C of shims 9 can
be calculated using the following equation. Mark “a” is indicated here.
C = 1.8 + a/100 - b (unit: mm) 209005
a: Machining error in the differential carrier

dimension A
b: Machining error in the bevel pinion dimen-
sion B
The machining error “a” is stamped on the top
surface of the differential carrier. (No stamping
is present if the error is within ± 0.05 mm.)
The machining error “b” is marked on the end
surface of the bevel pinion using electric mark-
ing pen. No mark is present if the error “b” is ±
0.
NOTE
When installing shim stock 9, be sure to locate the
1.0 mm (0.04 in.)
1.0 mm (0.04 in.) thick shim closest to the bevel thick shim Standard shim
C stock thickness
1.8 mm (0.071 in.)
209006
3.6
TRANSFER ASSEMBLY
(2) While inserting the bevel pinion shaft sub-

2 Attach spring
assembly into the case, install the spacer 11, scale hook here
output gear 12, bearing cone 13, and shim to measure the
tangential force.
stock 14. Reuse the originally installed shim
stock 14. Special
tool
Preload adjustment of taper roller bearing 8
(3) Hold the input gear 2 to prevent the bevel pin-
ion shaft 8 from rotating.
Special tool needed
14
Transfer bearing tool 97E67 - 00100
15
(4) Install a new nut 15 on the bevel pinion shaft 8.
Tighten and loosen the nut several times, each 13
time after rotating the shaft a little, so that the 12
11
bearing cups and cones settle completely on 209007
each other. Finally, tighten the nut to the torque
shown below. Do not give the bearings too
much preload.
294 ± 20 N·m
Tightening torque of nut 15 (30.0 ± 2.0 kgf·m)
[217 ± 14.5 lbf·ft]
(5) With the special tool installed on the input gear

2, measure the preload of the taper roller bear-
ing on the bevel pinion gear shaft 8. The pre-
(1) Stake the nut completely against the
load is measured in terms of the tangential bottom of the groove on the bevel pinion.
force required to start the input gear 2 rotating. (2) The staked portion should have a flat of
The measurement should meet the following φ 4 mm (φ 0.16 in.) or more.
specified value.
54 to 81 N
Tangential force required to
(5.5 to 8.3 kgf)
start input gear 2 rotating
[12.1 to 18.26 lbf]
(6) Adjust the preload as required by increasing or

Staking tool needed A screwdriver is not
decreasing the thickness of the shim stock 14. appropriate for staking.
The greater the shim stock thickness, the
smaller the preload. The smaller the shim
stock thickness, the greater the preload.
Repeat the steps (4) and (5) until the specified
preload is obtained.
R R
(7) After the specified preload is obtained, lock the φ 4 to 6 mm
nut 15 on the bevel pinion shaft 8 by staking to (φ 0.16 to 0.24 in.) 209008
prevent it from loosening. (See the drawing
shown on the right) 3.7
TRANSFER ASSEMBLY
3. Bolts to be tightened to special torques
Supply liquid gasket onto

the face of flange.
4
2
209009
Tightening torque
N·m kgf·m lbf·ft
1 Cover-to-traction motor 33 ± 2 3.4 ± 0.2 24.6 ± 1.4
2 Side cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9
3 Plug or pulse generator 54.0 ± 4.9 5.5 ± 0.5 39.7 ± 3.6
4 Case-to-cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9
5 Lock nut 294 ± 20 30.0 ± 2.0 217 ± 14.5
3.8
Chapter 4: Rear Axle
Description ................................................................................................. 4.1
Rear Wheels .............................................................................................. 4.2
Removal .................................................................................................. 4.2
Installation ............................................................................................... 4.4
Rear Axle.................................................................................................... 4.7
Removal .................................................................................................. 4.7
Installation ............................................................................................... 4.8
Disassembly............................................................................................ 4.9
Inspection after Disassembly .................................................................. 4.11
Reassembly ............................................................................................ 4.12
Inspection and Adjustment ......................................................................... 4.17
Minimum Turning Radius Adjustment ..................................................... 4.17
REAR AXLE: DESCRIPTION
Rear Axle
Description
3 2
1
7
3
6
B
8609001
1. Rear axle 5. Tie rods

2. Steering cylinder 6. Wheel rims
3. Steer knuckles 7. Shims
4. King pins
The truck is steered by the rear wheels. The rear

axle is connected to the frame by its center pivot
shaft. Because of the center pivoting feature, the
rear axle can oscillate up to 3° in each direction.
4.1
REAR WHEELS: REMOVAL & INSTALLATION
Rear Wheels
Removal Suggestions
1. Park the truck on level floor with the parking
! CAUTION brake applied, the direction lever in neutral,
Use the same size and brand of tire for the forks lowered, and the key switch off.
replacement. 2. Prepare the tools, parts, jack, and wheel
blocks.
Tools Needed: Spring scale, bearing
installer, and puller.
10
Parts Needed: Lock washer 3; oil seal 7;
7 cap 1 (when required); bearings 5, 8, 9, and
8 6 A 10 (when required); wheel assembly 6.
A
3. Cap 1 is press-fitted to the rim. Pry it off
9 5 4 3 2 1 using a chisel and hammer as shown.
Discard the removed cap. Use a new cap
when installing a replacement wheel.
207030
Removal Sequence
1. Cap
2. Outer nut
3. Lock washer
4. Inner nut 203614
5. Inner race bearing 4. Bend down lock washer 3.

6. Wheel assembly 5. Loosen nut 2.
7. Oil seal 6. Raise the wheels.
8. Outer race bearing
Hoist Capacities
9. Outer race bearing
3000 kgf
10. Inner race bearing FBC15/18KL
(6700 lbf)
FBC20/30KL 5000 kgf
(12,000 lbf)
4.2
Steering Cylinder
*: Parts contained in seal kit

12
*
11
* 14 13
17 * * 6
▲ ▲
▲
▲ ▲ ▲
9
8
16
10 * 7
▲
▲
▲
▲
▲
•▲ •
▲ ▲ •
5
▲ ▲
2 * 1
15
3 4
207168
1 Cylinder tube 10 Stopper ring

2 Piston rod 11 Wiper
3 Cylinder head 12 U-seal
4 Cylinder head 13 O-ring
5 Pivot joint 14 O-ring
6 Snap ring 15 Guide ring
7 Tie rod 16 Piston seal
8 Nut 17 Bushing
9 Spring washer
Double-action cylinder is used.
4.3
Suggestions, continued Inspection

7. Block the front wheels. 1. Oil seal
Check the oil seal of the rim for excessive wear or
8. Fasten a hoist to the counterweight and lift
damage.
the rear end of the truck.
2. Tires
9. Place the wood blocks under the side frames Check the height of the solid rubber portion and, if
to support the truck (with the left and right rear worn down to 25.4 mm (1 in.), replace the tire.
wheels slightly clearing the floor).
NOTE
Replace all tires if one tire is damaged. If new
and used tires are mixed, rapid tire wear will
result.
Installation
To install, follow the reverse the removal
Blocks sequence:
1. Using a puller, install bearings (outer) 8 and 9
100393B to the new wheel assembly 6.
2. Install oil seal 7 to the new wheel assembly 6.
10. Remove nut 2, lock washer 3 and nut 4.
11. Remove wheel assembly 6 from the rear
axle. Be careful not to cause damage to the
oil seal fitted to the rim. After removing the 10
assembly, raise the counterweight to a position
400 to 500 mm (16 to 20 in.) from the floor. 7
8 6 A
12. Using a puller, remove outer race bearings 8 A
and oil seal 7 from the wheel assembly.
9 5 4 3 2 1
NOTE
Replace the cap and bearings (inner and outer)
if defective.
207030
25.4 mm
(1 inch)
207029
4.4
3. Fill the rim and oil seal with grease. Do not

overfill the oil seal to prevent leakage.
Oil seal
4. Tighten nut 4 to 137 N·m (14 kgf·m) [101 lbf·ft]
torque and back it off 80°, then put lock wash-
▲
•
er 3. Install nut 2, tightening it to 157 N·m (16
kgf·m) [116 lbf·ft] torque. Check the hub bear- Fill with
grease
ing preload, making sure it is 2.5 to 6.4 N·m
(25 to 65 kgf·cm) [1.8 to 4.7 lbf·ft]. If the pre-
load is correct, bend lock washer 3.
207024
5. Check to make sure the preload is correct.

Insert a 24mm round bar into the cast hole of Bar
the rim. Attach a spring balance to the round
bar, and measure the tangential force.
▲
FBC15K FBC20K,FBC25K
FBC18K FBC25KE
FBC18KL FBC25KL,FBC30KL
Tangential 33.1 to 86 26.7 to 69.6
force (3.38 to 8.78) (2.73 to 7.10)
N (kgf) [lbf] [7.4 to 19.3] [6.0 to 15.6] 207025
Tighten the inner nut to achieve the specified
value.
Reference value Bar

2.5 to 6.4 N·m
Preload for hub
(25 to 65 kgf·cm)
bearings
[1.8 to 4.7 lbf·ft]
Spring scale
207026
4.5
6. After adjusting the preload, tighten a new lock

washer 3 and an outer nut 2 to the specified
torque.
Inside
nut
157N·m
Tightening torque for •• Outside
(16 kgf·m)
outer (lock) nut nut
[116 lbf·ft]
207024
7. Bend the lock washer to both sides (inward

and outward).
205436
8. Fill the cap with grease, and install the cap 1.

9. Raise the rear end of the truck and remove the
blocking from the side frames.
10 Lower the truck until the rear wheels just
touch the floor.
4.6
REAR AXLE: REMOVAL & INSTALLATION
Rear Axle
Removal
7
6
2 1
3
203613
Sequence
1. Cap 4. Rim and tire 7. Rear axle assembly
2. Nut and washer 5. Drag link
3. Bearing 6. Bearing support and bolts
Start By:
1. Apply the parking brake and block the front
wheels.
2. Raise the rear end of the truck with a jack and
place wood blocks under the side frames (with
the left and right rear wheels slightly clearing
the floor).
3. A hoist can be used instead of the jack to
raise the rear end (counterweight).
203622
4.7
Suggestions Installation
Removing Rear Axle Assembly To install, reverse the removal sequence and do
the following steps.
! WARNING
Adjusting Bearing Support Clearance
Be sure the pressure in the hydraulic system
is released before any lines or hoses are dis- Adjust the longitudinal clearance to 0.8 mm
connected. (0.031 in.) with the thrust washer and tighten the
bolts holding the bearing support to the specified
torque.
1. Put identification marks on the hoses, then
disconnect them. 14.8 kgf•m
2. Support the rear axle at its center with a (107 lbf•ft)
bearing support bolts
garage jack. [145 N•m]
3. Loosen and remove the axle mounting bolts.
Clearance:
0.8 mm
(0.031 in.)
203615 200257
Weight of Rear Axle
FBC15K-18KL 60kg
[132 lb]
FBC20K-30KL 85kg
[187 lb]
4.8
REAR AXLE: DISASSEMBLY
Disassembly
REAR AXLE ASSEMBLY
17
16
15
14 2
15 4
17
19
13
11
2
10
9 3
8
6
18
10 1
5
12
207028
Disassembly
1 Taper roller bearing (inner), Retainer 10 Oil seal
2 Tie rod pin, Bolt, Spring washer, Plain washer, 11 Cover, Retainer
Collar, Grease nipple 12 Boot
3 Spherical bushing, Ring, Retainer, Dust seal 13 Cover
4 Tie rod 14 Clamp, Bolt, Spring washer
5 Kingpin plate, Shim 15 Pipe (L.H., R.H.)
6 Kingpin, O-ring 16 Steering cylinder [Bolt, Spring washer, Nut]
Remove parts 7 through 12 as an assembly. 17 Elbow, O-ring
7 Knuckle 18 Stopper bolt, Lock nut
8 O-ring 19 Rear axle housing
9 Taper roller bearing
4.9
REAR AXLE: DISASSEMBLY
Suggestions
Removing Retainer and Bearing Mark Cylinder End Caps
Use a puller to remove the retainer and inner Mark the cylinder end caps for proper alignment
bearing from the knuckle. before they are disassembled from the cylinder.
Mark
Mark
203618 8609004
4.10
REAR AXLE: INSPECTION

Tie Rods and Pins Seals and O-rings
1. Make sure that the pins are free of any sur- Examine all seals and O-rings for damage such
face flaws such as grooving or stepped wear. as cuts and tears. Replace seals which show
Examine the keeper plate weld for cracking. signs of aging.
2. Examine the bearings for wear or damage.
Hydraulic Pipes
3. Examine the tie rods for damage and align-
ment. Inspect the welds for signs of cracks. Inspect the hydraulic pipes for cracks, especially
at the joints with the end fittings. Check for leaks.
NOTE Tires
If a pin must be replaced, replace its bearing Check the height of the solid rubber portion and,
as well. if worn down to 25.4 mm (1 in.), replace the tire.
NOTE
Kingpins
Check the kingpins for any surface flaws such as Replace all tires even if only one tire is damaged.
grooving or stepped wear. Inspect the pins for If new and used tires are mixed, rapid tire wear
cracks at the bearing shoulder. will result.
Kingpin Bearings
Examine the rollers and bearing races for groov-
ing, abrasive wear, pitting, bruising, or corrosion.
Replace both the cup and cone of damaged
bearings.
Knuckles 25.4 mm
Inspect the inside of each knuckle for wear or (1 inch)
damage. Be sure to examine for casting cracks.
Check the tie rod pin hole. Examine the wheel
nut threads for damage.
100880
Cylinder Rod
Examine the rod for surface or plating damage.
Inspect the rod for straightness. Examine the pis-
ton for damage. Check the tie rod pin hole for
damage or wear.
4.11
REAR AXLE: REASSEMBLY
Reassembly
3
2
4
5 17
4 16
3
1
15
11
17
10
9 7
8
13
18
10 19
14
12
207028
Assembly sequence
1 Rear axle housing 11 Cover, retainer
2 Steering cylinder [bolt, spring washer, 12 Boot
nut] 13 Kingpin, O-ring, bolt, spring washer
3 Elbow, O-ring 14 Kingpin plate, shim, bolt, spring washer
4 Pipe (L.H., R.H.) 15 Cover
5 Clamp, bolt, spring washer 16 Tie rod
6 Knuckle 17 Tie rod pin, bolt, spring washer, plain
7 Spherical bushing, ring, retainer, dust washer, collar, grease nipple
seal 18 Stopper bolt, lock nut
8 O-ring 19 Retainer, taper roller bearing
9 Taper roller bearing
10 Oil seal
4.12
Suggestions
Reassembling Steer Cylinder
1. Replace all seals and O-rings when reassem- 4. Pressure test cylinder reassembly for leaks.
bling the steer cylinder. Lubricate seals and
O-rings lightly with hydraulic fluid.
FBC15K-18KL FBC20K-30KL
2. Assemble wiper seal and U-seal as shown.
107 163
Minimum
(1522) (2320)
test pressure
[10,500] [16,000]
Unit: kgf/cm2 (psi) [kPa]
5. Use an alternating tightening pattern to tighten

the mounting bolts when attaching the cylinder
assembly to the axle beam.
Wiper seal U-Seal FBC15K-18KL FBC20K-30KL

8609006
17.9 kgf•m 26.7 kgf•m
Tightening torque
(130 lbf•ft) (193 lbf•ft)
for bolts
3. Align marks on the end caps to marks on the [176 N•m] [262 N•m]
cylinder body. Tighten nuts.
2.1 ± 0.2 kgf•m Reassembling Knuckles

(15.5 ± 1.5 lbf•ft) 1. Insert bearing cups into knuckles. Adequately
cylinder nuts
[21 ± 2 N•m] fill bearing cages with “AUTOLEX A” grease.
Apply a coat of grease to the oil seal groove.
Insert the bearing cages in the knuckles and
Mark
apply additional grease as required to meet
the recommended amount.
Quantity of grease 40cc (2.44 in3) 80 cc (4.88 in3)
2. Reassemble remaining components (seals,

Mark O-rings, covers, and boots).
8609004
3. Assemble parts, knuckle 6 through Boot 12, and
insert this sub-assembly into the rear axle
housing.
4.13
Reassembling Kingpins
1. Install the kingpins and measure the dis- 3. Measure the tangential force at point “C”.
tances “A” on both the left and right kingpins. When the tangential force is larger than the
values shown in the table below, add shims.
When the tangential force is smaller than the
values shown in the table below, remove
shims. Repeat this procedure until the values
in the table are attained.
1.6 to 2.6 kgf 2.5 to 4.5 kgf
Tangential force (3.5 to 5.7 lb.) (5.5 to 9.9 lb.)
15.7 to 25.5 N 24.5 to 44.1 N
A 8609007
2. Add shims to each side to within 0.1 mm

(0.004 in.) of the measured distance “A” and
C
tighten bolt “B”.
8609009
4. Tighten kingpin keeper plate bolts.
Kingpin Bolt Keeper Plate Bolts

1.7 kgf•m 3.4 kgf•m
Tightening torque
(12.3 lbf•ft) (24.6 lbf•ft)
for bolts
[16.7 N•m] [33.4 N•m]
Shims
Bolt B
8609008
4.14
Reassembling Tie Rods 3. Reassemble rear axle hubs. The inner race of
Replace dust seals. Tighten tie rod pin bolts to the inner bearing must be driven onto the
the specified torque. Grease the joints using the shaft using a special tool as shown below.
grease zerks.
0.7 kgf•m
Tightening torque for bolts (5 lbf•ft)
[6.9 N•m]
Zerk
205022
Dust
seals Rod 4. There is space between the two tapered
pin roller bearings inside the rear axle hub. Be
bolt
sure to fill this space with grease. Grease the
8609010 oil seal lip groove and roller retainers, too.
Do not overfill the oil seal lip groove as this
can cause leakage.
Reassembling Rear Axle Hub
1. Using Installation Tool #91268-01500 or
#64309-40400 install inner bearing races.
Using Tool #91268-01400 or 91268-00400 Oil
seal
install outer bearing races.
Fill
with
FBC15K-18KL FBC20K-30KL grease
Bearing installer 91268-01500 64309-40400
8609002A
2. Pack bearing cones.
5. Install wheel assembly carefully so as not to
damage the bearing or seal.
10
7
A 8 6 A
9 54 3 2 1
101744
4.15
6. Install outer bearing and nut 4.

NOTE
7. Tighten nut 4 to
14 kgf•m (101 lbf•ft) [137 N•m] torque and Preload for bearing is given in tangential force
back it off to 80°, then place lock washer 3. measurement and must be measured with a
Install nut 2, tightening it to spring scale. Apply force to spring scale as
16 kgf•m (116 lbf•ft) [157 N•m] torque. shown in graphic #101653, read scale. Adjust
nut 4 to achieve correct preload.
Check the hub bearing preload, making sure it is
25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m].
If the preload is correct, bend lock washer 3. 8. Check to make sure the preload is correct.
25 to 65 kgf•cm
Preload for hub bearings (1.8 to 4.7 lbf•ft)
[2.5 to 6.4 N•m]
Inside
nut
Outside
nut
Bar
8609002B
25 to 65 kgf•cm
Preload for hub bearings
(1.8 to 4.7 lbf•ft)
Tangential Force
[2.5 to 6.4 N•m]
8609002
16 kgf•m
(116 lbf•ft)
outer lock nut
[157 N•m]
Bar
Spring scale
101653
9. Install cap 1.
10. Raise the rear end of the truck and remove
the blocking from the side frames.
11. Lower the truck until the rear wheels are on
the floor.
4.16
REAR AXLE: INSPECTION

Minimum Turning Radius Adjustment
1. Using a turning radius gauge, measure the 3. Drive the machine at low speeds in such a
angular swing of rear wheels. way as to make the sharpest possible turn to
2. Setting the turning angle of each rear wheel to either side. Measure the radius of the track
the specification is not enough. The truck left by the outer wheel.
must be driven to make the sharpest possible 4. The minimum turning radius, R, is the dis-
turn to either side, and the radius of the track tance from the turning center to the center of
left behind by the outer wheel must be meas- tire contact with the surface while the truck is
ured for confirmation. The standard minimum executing its sharpest turn, plus the rear
turning radius is indicated below. overhang (distance from center of rear tire to
the outermost end of the counterweight).
FBC15K-18KL FBC20-30KL
Steering Angle FBC15K 1787 (70.4)
Inside 83° 83° FBC18K 1787 (70.4)
Outside 54° 56°
FBC18KL 1841 (72.5)
Tightening torque 6.8 kgf•m
FBC20K 1890 (74.4)
for knuckle stopper (49 lbf•ft)
bolt lock nut [67 N•m] FBC25K 1890 (74.4)
FBC25KE 1991 (78.4)
FBC25KL 1991 (78.4)
FBC30K 2045 (80.5)
FBC30KL 2045 (80.5)
202800
Turning radius [Unit: mm (in.)]
4.17
REAR AXLE: STEERING CYLINDER
STEERING CYLINDER
Disassembly
*: Parts contained in repair kit 10

*
11
9
A
11
3
*
4
5
2
* 1
6 *
7 7
A * 6
*
2
5
4
*
1 3
8
1
207036
1 Nut, Spring washer, Tie rod 6 Wiper
Remove parts 7 through 12 as assembly. 7 U-seal
2 Cylinder head 8 Cylinder tube
3 O-ring 9 Piston rod
4 Snap ring 10 Guide ring, Piston seal
5 Bushing 11 Stopper ring
NOTE
(1) Do not remove bushing 5 from the
cylinder head 2 if acceptable.
(2) Do not remove bearing 11 from piston
rod 9 if acceptable.
4.18
Suggestions
Mark Cylinder End Caps
Mark the cylinder end caps for proper align-
ment before they are disassembled from the Mark
cylinder.
Mark
207035
Inspection and Repair

1 Cylinder tube 8:
Check for wear, damage or rust inside the
cylinder.
2 Piston rod 9:
Check for rust, damage, scratches or
impact marks on the rod surface.
3 Rings and gaskets:
Replace the entire seal kit.
A: Standard value
Unit: mm (in.)
205439
FBC15K-18KL FBC20-30KL
Internal diameter of
A 63(2.480) 75(2.953)
cylinder tube 1
External diameter of
A 40(1.575) 50(1.968)
piston rod 2
2 1
207034
4.19
Reassembly
5 5
13
1 2 4 14
16 12
• •
•
15 9
8
6
7 3
10 11 207034
Assembly sequence
1 Piston rod 7 Snap ring 13 Spring washer
2 Piston seal 8 U-seal 14 Nut
3 Guide ring 9 Wiper 15 Pivot joint
4 Cylinder tube 10 O-ring 16 Stopper ring
5 Cylinder head 11 O-ring
6 Bushing 12 Tie rod
Suggestions
1. Replace all seals and O-rings whenever
reassembling steer cylinder. Lubricate
seals and O-rings lightly with hydraulic
fluid.
2. Assemble wiper seal and U-seal as
shown.
3. Align marks on the end caps to marks on
the cylinder body. Tighten nuts.
Wiper U-seal
207042
Unit: N·m (kgf·m) [lbf·ft]

Tightening torque for 21±2 Mark
cylinder nuts (2.1±0.2)
N·m (kgf·m) [lbf·ft] [15.5±1.5]
4. Pressure test cylinder reassembly for

leaks.
Unit: kPa (kgf/cm2) [psi]
Mark
FBC15-18KL FBC20-30KL
10500 16000 207035
Minimum
(107) (163)
test pressure
[1522] [2320]
4.20
Chapter 5: Brake System
Description .................................................................................................... 5.1
Automatic Adjusting Device ....................................................................... 5.1
General Information ................................................................................... 5.1
Master Cylinder
Disassembly............................................................................................... 5.2
Inspection after Disassembly..................................................................... 5.3
Reassembly ............................................................................................... 5.3
Service Brakes
Disassembly
(FBC15K - 18KL) ................................................................................... 5.4
(FBC20K - 30KL) ................................................................................... 5.5
Reassembly
(FBC15K - 18KL) ................................................................................... 5.8
(FBC20K - 30KL) ................................................................................... 5.9
Wheel Cylinders
Disassembly............................................................................................... 5.12
Reassembly ............................................................................................... 5.13
Inspection and Adjustment......................................................................... 5.14
BRAKE SYSTEM: DESCRIPTION
Description
Automatic Adjusting Device
205955
General Information
This device adjusts the drum-to-lining clearance
automatically. As the clearance increases due to
lining wear, the lever mechanism of this device
turns the adjusting screw by one notch or tooth
to reposition the shoes closer to the drum. This
corresponds to 1/24 of one rotation or 15°. In
the course of usage, the adjusting process
repeats itself at long intervals.
5.1
MASTER CYLINDER: DISASSEMBLY
Master Cylinder
Disassembly
9
8
4 7
10
6
5
*3
91484-37100 FBC15K - 18KL
91246-07200 FBC20K - 30KL
1
97146-10000A
1. Taper plug 6. Oil tank assembly

2. Master cylinder body 7. Push rod
3. Repair kit 8. Jam nut
4. Cap assembly 9. Clevis
5. Level sensor 10. Push rod assembly
NOTE
The parts* to be changed periodically are in-
cluded in the Repair Kit.
5.2
MASTER CYLINDER: INSPECTION & REASSEMBLY

Brake Fluid Level Sensor Piston
1. Fill the reservoir with brake fluid. Connect the Replace the piston if it is damaged. Check the
level sensor connector at the bottom of the piston clearance in the cylinder body. Replace
fluid reservoir and turn the key to ON. the cylinder body and piston if the clearance is in
excess of the service limit.
Clearance A 0.020 to 0.105

between piston (0.00079 to 0.00413)
and cylinder B 0.2 (0.008)
Unit: mm (in.)
DOWN = ON UP = OFF Return Spring

Replace the return spring every year.
200270
Primary Cup, Secondary Cup, and Valve
2. The sensor is satisfactory if the brake fluid Check these rubber parts for swelling, tearing,
level warning lamp on the monitor flashes and deterioration from aging. Replace them
when the reservoir filler is in the DOWN posi- every year.
tion and goes off when it is in the UP position.
Cylinder Body Reassembly

1. Check the bore of the cylinder for rust, corro- To reassemble, reverse the procedure for disas-
sion, and scoring. sembly and do the following steps.
2. Check the inlet port and relief ports for clean- 1. Clean all metal parts with a volatile cleaning
liness. Also check the threads in the screw solvent. Dry them with pressure air.
connection of each joint for damage. Make
sure the boot is free from defects. 2. Apply a thin coat of rubber grease (Metal
Rubber #20) or brake fluid to the piston cups
and the cylinder bore.
Master Cylinder Adjustment:

Adjust master cylinder only after pedal height
adjustment has been made (See pg. 5.18). With
master cylinder installed and push rod connected
to brake pedal, use the clevis pin to adjust the
master cylinder push rod so there is 0.5 to
2.8mm of free play between the end of the push
rod and cylinder position contact. Tighten jam nut
on push rod clevis assembly.
5.3
SERVICE BRAKES: DISASSEMBLY
Service Brakes
Disassembly (FBC15K - 18KL)
1
2
16 23 3 24 13 9 9 21
20
19
7
22
6
26
4 10
27 17
15
11
14
18 25
8
12
97146-11800A
Components
1. Service Brake Assembly 15. Spring
2. Wheel cylinder assembly 16. Pin
3. Backing plate 17. Spring
4. Primary shoe and lining assembly 18. Strut
5. Secondary shoe and lining assembly 19. Spring washer
6. Parking Lever 20. Retainer
7. Adjusting screw 21. Bolt with washer
8. Adjusting lever 22. Snap ring
9. Spring 23. Cover
10. Cable guide 24. Parking cable assembly
11. Fitting cable 25. Spring
12. Spring 26. Spring washer
13. Shoe guide plate 27. Bolt
14. Cup
5.4
Disassembly (FBC20K - 30KL)
2
16 23 10 3 24 13 27 28 29 21
26
9
20
19
7
22
6
31
30 4
14 17
15
14
18 11
12 8 25
97246-10900A
Components
1. Service Brake Assembly 10. Self-locking nut 21. Bolt with washer
2. Wheel cylinder assembly 11. Fitting cable 22. Snap ring
3. Backing plate 12. Spring 23. Cover
4. Primary shoe and lining 13. Shoe guide plate 24. Parking cable assembly
assembly 14. Cup 25. Spring
5. Secondary shoe and lining 15. Spring 26. Spring
assembly
16. Pin 27. Pin
6. Parking Lever
17. Spring 28. Sheave
7. Adjusting screw
18. Strut 29. Plain washer
8. Adjusting lever
19. Spring washer 30. Bolt
9. Spring
20. Retainer 31. Spring washer
Start By:
1. Remove the front wheel. 4. Disconnect the brake pipe from the wheel
2. Remove the wheel hub and brake drum. brake assembly.
3. Separate the parking brake lever and cable
at the bottom of the wheel brake.
5.5
Suggestions
Removing Return Springs Removing Hold-Down Springs
Use a special tool to remove the return springs. Use a special tool to remove the hold-down springs.
Special Tool Part Number Special Tool Part Number

Spring remover 64309-15411 Spring remover 64309-15412
200271 200272
5.6
SERVICE BRAKES: INSPECTION

Backing Plate Brake Drums
1. Check the backing plate for cracks. Check the inside (friction) surface of the drum for
2. Tighten the backing plate mounting bolts to abnormal wear, grooving, and other defects.
the specified torque. Minor grooving can be removed by grinding, pro-
vided that the service limit on the inside diameter
is not exceeded.
16 kgf•m
Tightening torque for backing
(116 lbf•ft)
plate mounting bolts
[157 N•m]
FBC15K - 18KL FBC20K-30KL
254 + 0.13 0 310 + 0.15 0
Inside
Shoes and Linings A 0.0051 0)
diameter of (10.0 + (12.2 + 0.0059 0)
1. Check each shoe and lining for cracks. brake drum
B 256 (10.08) 312 (12.28)
2. Replace the lining if it is dirty, greasy, burnt,
Unit: mm (in.)
or glazed.
A = Assembly standard B = Repair or service limit
3. Check the thickness of the lining. Replace
the lining if it exceeds the service limit.
Adjusting Screws
Check the wheel teeth for wear. Turn the screw
by hand to ensure its rotating parts turn freely.
203005
200274
4.87 6
A
Lining (0.19) (0.24)
thickness Parking Brake Cable
2.5 (0.10) 3 (0.12)
B Replace a cable if it is permanently stretched,
maximum maximum
rusted, or damaged.
Unit: mm (in.)
A = Assembly standard B = Repair or service limit Other:
1. Check the return springs for cracks or fatigue.
2. Check the adjusting springs for cracks or
fatigue.
3. Check the fitting cables for stretching.
5.7
SERVICE BRAKES: REASSEMBLY
Reassembly (FBC15K - 18KL)
6 10
A 3
12 1
8 12
13
5
8
4
7
1
11
9
9
14
16
2 Section A-A
15 A
205960
Sequence
1. Backing plate 9. Pin, hold-down spring, and cup
2. Parking brake cable 10. Shoe guide plate
3. Wheel cylinder 11. Fitting cable
4. Parking brake lever 12. Return spring
5. Shoe and primary lining 13. Cable guide
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Shoe and secondary lining 15. Adjusting screw
8. Strut and anti-rattle spring 16. Return spring
5.8
Reassembly (FBC20K - 30KL)
A
3 11
6 9
13 1
7
4
8
10
10
12
16
14
Section A-A
15
2 A
205961
Sequence
1. Backing plate 9. Strut and anti-rattle spring
2. Parking brake cable 10. Pin, hold-down spring, and cup
3. Wheel cylinder 11. Shoe guide plate
4. Parking brake lever 12. Fitting cable
5. Shoe and primary lining 13. Return spring
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Pin, sheave, and washer 15. Adjusting screw
8. Shoe and secondary lining 16. Return spring
5.9
Suggestions
Installing Wheel Cylinder Greasing
Apply retaining compound to the mounting face Apply a thin coat of the specified brake grease to
of the wheel cylinder before positioning the cylin- each of the following parts.
der in place. Secure it by tightening to the speci- 1. Shoe ledges (6 places):
fied torque: The ledges are the portions of the backing
plate in contact with the shoe.
2. Anchor pin surface in contact with the shoe
ends.
Tightening 0.8 to 1.2 1.8 to 2.7
torque for (6 to 9) (13 to 20) Installing Shoes
wheel cylinder [8 to 12] [18 to 26]
Make sure that each push rod of the wheel cylin-
Unit: kgf•m (lbf•ft) [N•m] der is snugly fitted to its shoe web.
Installing Return Springs

Use a special tool to install the return springs to
the backing plate pins
Special Tool Part Number

Spring installer 65309-15413
200275
200276
5.10
Installing Automatic Adjusting Device

1. Clean the adjusting screw and associated
parts, then grease the screw threads and
screw socket. Be sure the screw turns freely
when rotated by hand. If the screw is hard to
turn, replace it.
2. The right and left adjusting screws are color-
coded.
• Right-hand adjusting screw and lever (left-
hand thread) is yellow.
• Left-hand adjusting screw and lever (right-
hand thread) is white. 200277
NOTE
After reassembly, bleed air out of the brake
fluid lines. (Refer to INSPECTION AND
ADJUSTMENT, p. 5.15).
5.11
WHEEL CYLINDER: DISASSEMBLY
Wheel Cylinders
Disassembly
10
7
6 12
5 11
9
3
8
2
*
97246-10900B
Sequence
1. Connecting link 8. Spring
2. Boot 9. Cup
3. Piston 10. Piston
4. Piston cup 11. Boot
5. Body 12. Connecting Link
6. Bleeder screw
7. Cap
NOTE
The parts (*) to be changed periodically are
included in the repair kit.
5.12
WHEEL CYLINDER: INSPECTION & REASSEMBLY

Cylinder Bodies Piston Cups
1. Check the bore for rusting, corrosion, and Check for swelling or other defects. Replace the
scoring. cups at the time of overhaul and every year.
2. Check the threads of the bleeder screw and
oil pipe for damage. Boots
Replace the boots if they are hardened, damaged,
Pistons or otherwise deteriorated.
1. Check the sliding surface for rusting or
scratching. Reassembly
2. Check the piston clearance in the cylinder To reassemble, reverse the procedure for disas-
body. Replace the cylinder body and piston if sembly and do the following:
the clearance exceeds the service limit.
1. Coat the piston cups and the cylinder bore
with brake fluid.
2. Be careful not to damage the lips of the cups.
200280

0.040 to 0.125 0.020 to 0.105
Clearance A (0.00157 to (0.00079 to
between 0.00492) 0.00413)
piston and
cylinder B 0.15 (0.0059)
Unit: mm (in.)
A = Assembly standard B = Repair or service limit
5.13
BRAKE SYSTEM: INSPECTION

Automatic Adjusting Device
1. Have the service brake properly set with the 3. When the automatic adjusting device is sus-
drum-to-lining clearance adjusted to specifi- pected of malfunctioning during normal use of
cation. Pull the adjusting lever by giving a the machine, check for the following causes:
push to the cable, as shown, to see if the a. Adjusting spring is not correctly hooked to
lever turns the adjusting screw by one tooth the primary shoe.
and, as the push is released, returns to its
b. Any one of these parts is in bad condition
original position. If it does, the device is in
and needs replacing:
satisfactory condition.
1) fitting cable
2) adjusting lever
3) adjusting screw
Manual Adjustment
The drum-to-lining clearance can be adjusted by
rotating the adjusting screw with a screwdriver on
to the toothed wheel. The hole through which the
screwdriver tip can be inserted is in the backing
plate.
200281
2. If the lever fails or is sluggish to turn the

adjusting screw in the above test, the likely
cause is that the lever is not properly posi-
tioned relative to the toothed wheel. Be sure
that the lever is positioned so that its actuat-
ing tip touches the toothed wheel at about
9 mm (0.35 in.) under the center line of the
screw, as shown below. 200283
9 mm
(0.35 inch)
200282
5.14
BRAKE SYSTEM: INSPECTION
Brake Pedal Adjustment Bleeding Air Out of Brake Fluid Line

Set the dimensions A, B, and C to the specified Whenever any part of the brake fluid line is dis-
values. connected in servicing work, an air bleeding
After the shoe linings have been replaced, turn operation must be performed to complete the job.
the adjusting screw as far as it will go (until the Air trapped in any part of the fluid line will cause
clearance becomes zero) and back it off by the the brake pedal to feel spongy.
amount of rotation shown below. Air Bleeding Operation Procedure:
FBC15K - 18KL: 19 clicks 1. Tie a flexible tube, such as a vinyl pipe, to the
FBC20K - 30KL: 16 clicks bleeder screw on the wheel cylinder. Insert
the free end of the tube into a vessel filled
with brake fluid.
Height from floor to
98mm ± 3 mm 1 ton 2. Pump the brake pedal and depress it all the
pedal (A) 80mm ± 3mm 2/3 ton
way. While keeping the pedal depressed,
Stroke (to a point where
3 to 10 (0.12 to 0.4) loosen the bleeder screw. When air bubbles
brakes start to apply) (B)
cease to come out, tighten the screw. Repeat
Clearance between piston this process until nothing but brake fluid flows
0.5 to 2.8 (0.02 to 0.11)
and push rod (C) into the vessel.
Unit: mm (in.) 3. Repeat procedure at each wheel brake, and
fill up the brake fluid reservoir to level.
B
A
Push rod
200285
C
8609011
Stop bolt NOTE
Be sure that the reservoir never becomes
empty of fluid at any time during the procedure.
Use specified brake fluid. Avoid mixing different
brands of brake fluid before and after filling up
the reservoir.
Brake Test
After completion of necessary adjustments, test
the brake force by operating the truck at a speed
of 10 km/h (6.2 mph). Refer to Manual Adjustment
for necessary readjustment.
5.15
Chapter 6: Steering System
Steering System
Description ..................................................................................................6.1
Steering System ......................................................................................6.1
Oil Flow Sequence ...............................................................................6.1
General Information..............................................................................6.1
Steering Gear
Steering Wheel
Removal ...................................................................................................6.2
Installation ................................................................................................6.2
Steering Gear ..............................................................................................6.3
Inspection after Removal ............................................................................6.4
Disassembly ................................................................................................6.5
Working Rules and Tips ...........................................................................6.6
Suggestions .............................................................................................6.6
Inspection after Disassembly ...................................................................6.6
Reassembly.................................................................................................6.7
Suggestions..........................................................................................6.8
Steer Pump
Removal ......................................................................................................6.9
Installation ...................................................................................................6.10
Disassembly ................................................................................................6.11
Sequence .................................................................................................6.11
Working Rules and Tips ...........................................................................6.12
Suggestions .............................................................................................6.12
Inspection after Disassembly ...................................................................6.14
Reassembly.................................................................................................6.15
Sequence .................................................................................................6.15
Suggestions .............................................................................................6.16
Inspection after Reassembly....................................................................6.18
STEERING SYSTEM: DESCRIPTION
Steering System
Description
Steering System
6 4
1
8609044
Oil Flow Sequence

1. From hydraulic tank 4. Steering cylinder
2. Steering pump 5. Mast operating valve
3. Steer gear 6. To hydraulic tank
General Information
This steering system is an open-center type,
where the steering fluid is provided by a dedicat-
ed steering pump. The oil is constantly available
and flows through the steer gear and back to the
tank via the mast operating valve.
In this type of steering system, only the small
dedicated steer pump is pressurized, providing
an efficient, energy-conservation system.
6.1
STEERING GEAR: REMOVAL & INSTALLATION
Steering Gear
Removal
Steering Wheel
8609016
Sequence
1. Nut, washer
2. Wheel
Removal Installation
Use a special tool. To install, follow the reverse of the removal
sequence.
Special Tool Part Number
Wheel puller 91268-10600
Wheel puller
203466A
6.2
Steering Gear
Sequence
1. Column & Kick cover mounting hardware
! WARNING
2. Column & Kick covers
Hydraulic pressure can cause personal
3. Hoses, connectors and o-rings injury. Before any steering system hydraulic
4. Steer column mounting bolts lines or components are disconnected,
make sure all hydraulic pressure is released
5. Steer column in the steering system. Move the steer
6. Steer gear wheels to the left and right, then straight.
NOTE
For servicing the steer cylinder, see REAR
AXLE section.
6.3
Inspection after Removal

1. Inspect the grommets for cracks or tears in
the rubber or for signs of aging. Check the
O-rings for damage.
Installation
To install, follow the reverse order of the removal
sequence. Tighten bolts to the specified torque
2.9 ± 0.3 kgf•m

Tightening torque for bolts (20.9 ± 2.1 lbf•ft)
[28.4 ± 2.9 N•m]
6.4
STEERING GEAR: DISASSEMBLY
Disassembly
Steering Gear
9
5 7
8
16 6
4
3
2
15
14
13
12
1
11
10
Sequence
1. Mounting cap, cap screws, dust seal 9. Centering Springs
2. Pressure seal 10. O-ring
3. Thrust races, Thrust bearings & retaining ring 11. Gerotor
4. Spool 12. O-ring
5. Long Drive Pin 13. Housing
6. Drive Tube 14. O-ring
7. Short Drive Pin 15. Tank Plug
8. Sleeve 16. Manual Steering Balls
6.5
STEERING GEAR: DISASSEMBLY
Working Rules and Tips
3.Remove the Gerotor to gain access to the other
The steering gear, complete with the control valve, is
O-ring; remove.
a precision-machined component. As such, it must be
handled with extreme care. Cleanliness is imperative:
4.Slide the Thrust Races and Bearing off the spool.
work in a clean place and use clean tools.
1.Clean the disassembled parts with a volatile 5.Replace the worn components. See “Inspection
solvent such as trichlene or chlorobenzene, after Disassembly” section.
and dry them with compressed air. This does
not apply to rubber parts. 6.Reassemble the components from items 1-3 per
2.Oil seals, O-rings, and the like are rubber parts. the instructions given in the “Reassembly”
Never clean them with solvent. Blow dirt off rub- section.
ber parts with compressed air and keep them
immersed in a pool of hydraulic oil until they are 7.Remove the Tank Plug using Special Tool
ready for reassembly. A rubber part showing even 97E67-00200.
slight wear and tear must be replaced. Rubber
parts are expendable components that should be 8.Remove and, if necessary, replace the O-ring.
replaced once a year.
3.Parts to be installed by pressing or forcing need
special treatment. Inspection after Disassembly
a. Oil Seals
1.Check all mating surfaces. Replace any parts
Oil seals, once removed, must not be reused. that have scratches or burrs that could cause
After disassembly, examine the oil seals in leaks.
place (in the gear box and side cover). If they
are in good condition, leave them in place. 2.Clean all metal parts in clean solvent. Blow dry
When installing a replace-ment oil seal, be with air. Do not wipe dry with cloth or paper
careful not to score or scratch the lip area. towels because lint or other matter can get into
Suggestions: the hydraulic system and cause damage. Do not
use a coarse grit or try to file or grind these parts.
The Steer Gear is designed with very few serviceable
components. Only disassemble the steer gear if you
plan to replace one of the following:
1. Dust Seal
2. Pressure Seal
3. O-rings
4. Thrust Race and/or Bearings
If replacing these parts does not improve perform-
ance, you must replace the entire Steer Gear
Assembly. Refer to your Parts Manual for ordering
information.
IMPORTANT: Before you begin disassembly, scribe

a line across housing gerotor and mounting cap for
reference alignment when reassembling the unit.
1.Remove the five cap screws and the end cap.

Remove the dust and pressure seals from the
end cap using a thin-bladed screwdriver.
2.Remove the O-ring from the groove in the

housing.
6.6
STEERING GEAR: REASSEMBLY
Reassembly
Steering Gear
15 13 12
11
14
9
10
17 16
7
2
1
18 4
8
6 5
10
Sequence
1. O-ring 10. Spool
2. Tank Plug 11. Sleeve
3. Housing 12. Centering Springs
4. O-ring 13. Short Drive Pin
5. Gerotor 14. Drive Tube
6. Mounting cap 15. Long Drive Pin
7. Pressure seal 16. Retaining Ring
8. Dust Seal 17. Thrust Bearing and Races
9. Manual Steering Balls 18. Capscrews
6.7
STEERING GEAR: REASSEMBLY
Suggestions: 1 Install o-ring (82,6 [3.25 OD) on tank plug.

2 Assemble tank plug into housing. Torque tank plug to
NOTE: These instructions are more in depth
47,5 Nm [35 lb-ft].
than routine service should require. DO NOT 3 Install o-ring (82,6 [3.25 OD) into groove.
disassemble the steer gear further than 4 Lay gerotor on the housing,lining up bolt holes, check
required to replace serviceable components. alignment per scribed (mark) line..
Doing so may result in replacing entire gear. 5 Install pressure seal into inside cavity of mounting cap
(25,4 [1.00] OD x 3,2 [.12] W).
6 Install dust seal (25,4 [1.00] OD x 3,2 [.12] W) into
mounting cap.
7 Install manual steering balls (9) into spool. Grease
balls to retain in holes.
8 Insert spool into sleeve, lining up the spring slots.
9 Insert smaller centering spring onto spool/ sleeve
assembly.
10 Install larger centering spring onto spool/ sleeve
assembly.
11 Insert shorter drive pin.
12 Install drive tube assembly, wider groove downward.
13 Slide spool/sleeve/tube assembly into housing bore,
through the gerotor star. Before spool/sleeve/tube
reaches the tank plug,line up pin slot in gerotor with pin
slot in drive tube, insert longer drive pin, then continue
to slide spool/sleeve/tube into housing until the pin sets
into the gerotor.
14 Install the retaining ring into groove on spool.
15 Install bearing race-bearing-bearing race onto the
retaining ring.
16 Grease o-ring (82,6 [3.25] OD) and install into
mounting cap.
17 Carefully install mounting cap over spool so as not to
cut or damage seals. Lining up bolt holes, check
alignment per scribed (mark) line.
18 Install 5 bolts. torque to 23Nm [200 in-lb].
6.8
STEER PUMP: DESCRIPTION
Steer Pump
Removal
Sequence
1. Motor mounting bracket 3. Motor 5. Pump
2. Motor mounting hardware 4. Pump mounting hardware
Start By:
1. Remove the battery.
2. Remove the acid tray.
3. Disconnect the cables and wires from the
steer pump motor. Mark the wire leads and
cables so they can be correctly reconnected.
4. Disconnect the hydraulic lines from the pump.
6.9
STEER PUMP: DESCRIPTION
Suggestions Installation
Removing the Motor and Pump Assembly 1. To install, reverse removal sequence.
After disconnecting the steer pump hoses, motor
cables, and harness leads, remove the pump
and motor assembly by removing the motor
bracket mounting hardware where the bracket is
bolted to the frame.
Removing the Pump

Remove the pump from the motor.
6.10
STEER PUMP: DISASSEMBLY
Disassembly
4
2
6 7
3
5
1
Sequence
1. Cover and mounting bolts 5. Rotor and vanes
2. O-ring 6. Retaining ring
3. Spring and Pressure plate 7. Shaft and bearing
4. Ring and locating pins 8. Body, O-ring, and seal
6.11
Working Rules and Tips Suggestions

The steer pump is a precision-machined compo- Removing the Motor and Pump Assembly
nent and must be handled with extreme care.
Disconnect the steer pump hoses, motor cables,
Cleanliness is imperative: use clean tools and
and harness leads. Remove the pump and motor
work in a clean place.
assembly by removing the motor bracket mounting
1. Clean the disassembled parts with a volatile hardware where the bracket is bolted to the frame.
solvent such as trichlene or chlorobenzene
and dry them with compressed air. This does Removing the Pump
not apply to rubber parts. Remove the pump from the motor.
2. Oil seal, O-rings, and the like are rubber
Removing The Pump Cover
parts. Never wash them with solvent. Blow
dirt off rubber parts with compressed air and Remove the four bolts holding the rear cover on
keep immersed in a pool of hydraulic oil until the pump. Remove the cover. Remove the O-ring
they are ready for reassembly. A rubber part located in the groove of the cover.
showing even slight wear and tear must be
replaced. Rubber parts are expendable com-
ponents and should be replaced yearly.
3. Parts to be installed by pressing or forcing
need special treatment.
Oil Seals
An oil seal, once removed, must not be
reused. After disassembly, examine the oil
seal in place (in the housing) and, if in sound
condition, leave it in place. When installing a
replacement oil seal, be careful not to score 8609075
or scratch its lip portion.
Removing the Spring

Lift the spring off the pressure plate.
8609076
6.12
Removing the Pressure Plate Removing the Retaining Ring

Lift the pressure plate off of the ring and remove The shaft and bearing assembly is held in place
the two locating pins from the ring. by an internal retaining ring on the driven end of
the pump. Remove the retaining ring using a
standard retaining ring tool.
8609077
Retaining
Removing the Rotor and Vanes
Ring
Remove the rotor and the vanes. Take care not
to lose any of the vanes.
8609080
8609078
Removing the Ring

Lift the ring off of the pump body.
8609079
6.13
Removing the Shaft and Bearing Removing the Seal and O-ring
1. Tap the end of the shaft very lightly to 1. Examine the shaft seal in place in the housing.
remove it from the pump body. Take extreme If it is in sound condition, do not attempt to
care not to damage the end of the shaft. remove it. Instead, use it as part of the rebuilt
2. Remove the external retaining ring from the unit. If there is any damage to the seal, re-
shaft to allow removal of the bearing. Tap the move it and do not reuse it.
end of the shaft very lightly to separate the 2. Remove the O-ring from the slot in the body.
bearing from the shaft. Take extreme care
not to damage the end of the shaft.
8609082
8609081

1. Check all mating surfaces. Replace any parts
that have scratches or burrs that could cause
leaks.
2. Clean all metal parts in clean solvent. Blow
dry with air. Do not wipe dry with cloth or
paper towels because lint or other matter can
get into the hydraulic system and cause dam-
age. Do not use a coarse grit or try to file or
grind these parts.
6.14
STEER PUMP: REASSEMBLY
Reassembly
5
7
8
8609083
Sequence
1. Body and seal 5. Rotor and vanes
2. Shaft and bearing 6. Pressure plate
3. Retaining ring 7. Spring
4. Ring 8. Cover
6.15
Suggestions Reassembling the Shaft and Bearing

Press the bearing onto the shaft and secure it
with the external retaining ring.
NOTE
Replace all old seals with new seals.
Lubricate all seals with clean petroleum jelly
such as Vaseline.
Reassembling the Shaft Seal

1. Install the seal in the housing, orienting the
seal lip as shown. Take care not to damage
the seal during installation.
8609085
2. The seal must be bottomed against the
shoulder when installed.
Reassembling the Shaft and Body
Install the shaft and bearing assembly into the
body, taking care not to damage the shaft seal
during installation. Secure the shaft by installing
the retainer ring.
8609084
Retaining
ring
8609086
6.16
Reassembling the Ring Reassembling the Pressure Plate

Press the O-ring into the groove in the body. Install the pressure plate by slipping it over the
Place the ring on the body, aligning the bolt holes two pins
and the pin holes. Install the two pins through the
ring and into the body.
8609089
8609087
Reassembling the Spring

Slip the spring over the spring seat of the pres-
Reassembling the Rotor and Vanes
sure plate.
Slip the rotor over the splined portion of the shaft.
Insert a vane in each of the slots in the rotor.
8609090
8609088
6.17
Reassembling the Cover Inspection after Reassembly

1. Press the O-ring into the groove in the cover. Check the pump for smooth, free rotation. Check
Place the cover on the ring and align the four for leaks after reinstallation in the truck.
bolt holes. Take care to properly orient the
discharge port to its original position prior to
assembly.
2. Install and tighten the cover bolts.
8609091
4.8 to 6.2 kgf•m

Tightening torque for cover bolts (35 to 45 lbf•ft)
[47 to 61 N•m]
6.18
Chapter 7: Hydraulic System
Hydraulic System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
Removal and Installation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Hydraulic Pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Mounting Flange Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Bushes and Balance Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Control Valve
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
Removal
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
Disassembly
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
Adjusting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.42
HYDRAULIC SYSTEM: DESCRIPTION
Hydraulic System
Description
Schematic for Trucks
1. Hydraulic tank 4. Steer gear 7. Down safety valve 10. Steering cylinder
2. Hydraulic lift pump 5. Main control valve 8. Lift cylinder
3. Steer pump 6. Flow regulator valve 9. Tilt cylinder
General Information
The hydraulic pump draws oil from the oil tank
and delivers it to the main control valve, which
dispenses it for lift and tilt functions.
The steer gear and steer pump are covered in the
STEERING SYSTEM section and the steering
cylinder is covered in the REAR AXLE section.
7.1
Hydraulic Tank
1
6 5
4
3 8609093
1. Cap 3. Drain plug 5. Suction line strainer

2. Oil level gauge 4. Return line filter 6. Lift cylinder pipe
General Information
The tank contains internal filtering means including
a strainer on the suction line and a filter on the
return line.
The lift cylinder return pipe allows the cylinders to
draw fluid when they retract, providing the bore
walls with oil which inhibits corrosion.
7.2
Hydraulic Pump
8609094A
General Information
This gear pump is capable of developing very
high pressure on its discharge side. A special
arrangement is incorporated in the pump con-
struction for the purpose of keeping the side
clearances minimized between bushings on the
one side and pump gears on the other. Note, in
illustration 203585 (page 7.6), that discharge
pressure is applied to the back of each bushing
through internal oilways.
7.3
Hydraulic Pump Operation Pressure Loading Principle
Essentially the pump consists of two gears—the This pump is a self-balanced type based on the
drive gear and the driven gear—closely fitted in principle of pressure loading, balancing for equal
the housing. The oil is carried around the periph- pressure on all sides of the revolving gear. This
ery of the revolving gears from the suction to the reduces bushing and gear wear. In operation, the
discharge side. The teeth meshing between the high-pressure oil on the discharge side is fed
two gears prevents the return of oil from the dis- back to the suction side. On the suction side,
charge to the suction side. pressure is exerted equally on both sides of the
gears and shafts, thereby cancelling out unequal
pressure to balance the pump.
Driven Gear
Clearance
Drive Gear
203585
Discharge side
200333
7.4
Control Valve
7
6 8 9B
9A
1
3
12
11 10
1. Inlet Spool 8. To tank

2. Lift Spool 9A. Main relief valve, Auxiliary Valve (back)
3. Tilt Spool 9B. Auxiliary Relief Valve (front)
4. Auxiliary Attachment Spool 10. Tie bolt
5. Flow Control Screws 11. Nut
6. Pump port 12. Switches
7. From steering control valve
General Information
The control valve consists of three valve blocks,
all spool-type. The spools are finished by lap-
ping for their respective blocks and their combi-
nation should not be changed. The lift valve
assembly has a built-in load check valve. The tilt
valve spool has a built-in tilt lock valve. When
necessary, the attachment valve assembly has
a built-in overload relief valve. If the overload
relief valve is not used, a shutoff valve is
installed.
7.5
200345
205979
General Information
The left and right lift cylinders are single-acting
type.
The left and right tilt cylinders are double-acting
type. The piston rod carries a screw-on socket.
The socket is repositioned as necessary by
turning when the cylinder is connected to the
outer mast. This feature allows the tilt cylinders
to move in unison.
The tilt angle is increased or decreased with the
spacer and shim of each cylinder.
7.6
Flow Regulator Valve
From control valve To control valve
To lift cylinder From lift cylinder
203558
General Information
The flow regulator valve is located between each
lift cylinder and control valve. It limits the flow of
oil forced out of the cylinder when the loaded
forks are lowered to keep a safe constant lower-
ing speed regardless of load.
7.7
Down Safety Valve
Burst
Normal When hose burst

204971
General Information
The down safety valve is built in the oil pipe joint
at the bottom end of the lift cylinder. This valve is
internally provided with an orifice to prevent shock
when the valve is closed. In the valve having no
orifice, the oil leaks around the valve to prevent
shock.
Valve Types
Down safety valves are available in six types dif-
a
fering in terms of shutoff flow and identified by the
number punched on the flat (indicated as “a” on
illustration 201731A). The numbers are: 50, 70,
90, 100, 120, and 150. No. 90 and No. 120 valves
each come in two kinds differing in screw thread
size. a
Truck Dual stage Dual-stage full Triple-stage full

panoramic free-lift panoramic free-lift panoramic
1st lift 2nd lift 1st lift 2nd lift
cylinder cylinder cylinder cylinder 201731A
FBC15 K-18KL 70 90 70 90 70 Top View: • Dual-stage panoramic lift cylinder

FBC20K-25KE 70 120 70 120 70 • Dual-stage full free-lift panoramic,
FBC25K-30K
1st and 2nd cylinders
90 90 120 120 90
• Triple-stage full free-lift panoramic,
2nd lift cylinder
Bottom View: • Triple-stage full free-lift panoramic
1st lift cylinder
7.8
REMOVAL: GENERAL WARNING
Removal and Installation

Warning
! WARNING
Hydraulic oil under pressure can remain in

the hydraulic system after the truck and
pump have been stopped. To avoid person-
al injury, this pressure must be released
before any work is done on the hydraulic
system.
To prevent possible injury, lower the lift
bracket to the ground, turn the truck off,
and move the control levers to make sure
all hydraulic pressure is released before
any fitting, plug, or hose is loosened, tight-
ened, removed, or adjusted.
Always move the forklift truck to a clean
and level location away from the path of
other machines.
Be sure that no personnel are near the
machine when the truck is running and
tests or adjustments are being made.
7.9
HYDRAULIC PUMP: REMOVAL
Hydraulic Pump
Removal
1 8609094A
Sequence
1. Hardware
2. Pump
Start By:
1. Disconnect the battery from the truck. 5. Secure the motor from above with a crane,
hoist, or other adequate device, or support it
2. Disconnect the hoses attached to the pump
at its center with a garage jack.
fittings.
6. Remove the motor and pump assembly from
3. Disconnect the power cables and wire leads
the truck.
from the pump motor.
7. Remove the hydraulic fittings from the pump.
4. Raise the truck enough to allow the pump
and motor assembly to be removed from
below the truck. Make sure that the truck is
stable and secure in the raised position.
7.10
HYDRAULIC PUMP: INSTALLATION
Installation
1. To install, follow the reverse sequence of the
disassembly procedure. Before installing
hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace
them as required.
2. Tighten hose to the following specifications.
Tightening Torque for Hose
Supply hose from 6.5 ± 0.7 kgf•m 10.3 to 11.7 kgf•m

pump to mast (48 ± 5 lbf•ft) (74 to 85 lbf•ft)
operating valve [65 ± 7 N•m] [101 to 115 N•m]
8609137
3. Lube pump splines before installing into pump

motor. Use molybdenum disulfide grease.
HYDRAULIC PUMP APPLICATIONS

97E71-00030 97E71-00040 97F71-00020 9721-00700
23cc 25cc 29cc 29cc
Pump
Market Capacity UL Motor Voltage standard gear split gear standard gear split gear
15, 18 E 6 5/8" 36
No. Am.
25KL, 30 EE 9" 36/48
Europe 15, 18 N/A 8" 48
15, 18 EE 8" 36/48
15, 18 E 8" 48
18KL E, EE 8" 36/48
No. Am. 25KL, 30 E 8" 36/48
20, 25, 25KE E 8" 36/48
20, 25, 25KE E, EE 9" 36/48
25KL, 30 E 9" 36/48
20, 25, 25KE
Europe 25KL, 30 N/A 9" 48/80
7.11
HYDRAULIC PUMP: DISASSEMBLY
Disassembly
Premium Pump
1 5
9
4
7
6
Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes
Start By:
Externally clean the pump to make sure that it is
free of all matter that may contaminate the pump
parts during disassembly, inspection, or reassembly.
7.12
Disassembly
Standard Pump
5
3
1
4
7
9
6
Sequence
Working Rules and Tips

The hydraulic pump is a precision-machined com- Oil Seal
ponent and as such must be handled with extreme An oil seal, once removed, must not be reused.
care. Clean-liness is imperative: use clean tools After disassembly, examine the oil seal in place
and work in a clean place. (in the pump flange) and, if in good condition,
1. Clean the disassembled parts with a volatile leave it in place. When installing a replacement
solvent such as trichlene or chlorobenzene oil seal, be careful not to score or scratch its lip
and dry them with compressed air. This does portion.
not apply to rubber parts.
2. Oil seals, O-rings, and the like are rubber
parts. Never clean them with solvent. Blow
dirt off rubber parts with compressed air, and
keep them immersed in hydraulic oil until they
are ready for reassembly. A rubber part show-
ing even slight wear and tear must be
replaced. Rubber parts are expendable items
that should be replaced once a year.
3. Parts that are installed by pressing or forcing
need special treatment.
7.13
Suggestions
Removing the Flange
Removing the End Cover
Turn the unit over and lightly tap the mounting
1. Lightly mark the end cover, pump body, and flange to disengage it from the locating dowels.
mounting flange to ensure proper reassembly. Slide the flange squarely off the shaft.
2. Remove the rear bolts, spring washers, and
the end cover.
Removing the Seals

Remove the O-ring from the pump body. Remove
the bush seal and the backup seal from the rear
bushings.
8609101
Removing the Shaft Seal

Remove the internal retaining clip in the front of
the flange. Push the shaft seal squarely out of
the mounting flange.
8609100
8609102
7.14
Removing the O-ring and Seals Separating the Gear Pack

Remove the O-ring from the groove in the body 1. Separate the gears, key, and balance plate
of the pump. Remove the bush seal and the from the drive shaft and driven idler shaft.
backup seal from the front bushings. 2. Note the position of the balance plate to
ensure proper location during reassembly.
Removing the Rear Bushes

Remove the remaining rear bushes from the
body bore.
8609103
Removing the Bushings

Before removing the internal components, mark
the bushings to denote the location in the body
8609105
on a plain area away from the seal location mark.
FD = Bush on flange end of the drive shaft
FI = Bush on flange end of idler shaft
CD = Bush on the cover of priority valve end
of the drive shaft
CI = Bush on the cover end of the idler shaft
Removing the Drive Shaft

With the unit lying on its side, hold the drive shaft
and pull it squarely out of the body, bringing with
it the bushings and the complete gear pack.
8609104
7.15

Body 3. The bush bearing liners are acceptable if they
1. Inspect the body bore cut-in where gears wipe are not scored or do not show other damage.
into the body. The general outside area of the bush should
not show any prominent signs of wear.
2. The body can only be reused if the cut-in is
bright and polished in appearance and the Gears
depth does not exceed .08 mm.
1. The gear side faces should be examined for
3. The body should be replaced if the surface is
bushing or scoring. Often operation on con-
scored, has a matte appearance, or shows
taminated fluid shows scoring between the
signs that the tips of the gears have dug in and
root of the gear and the journal, which leaves
torn away the surface material.
a wear step. If a wear step can be felt, coinci-
4. The body should be inspected to ensure that dental with the root diameter, by drawing a
there is no superficial damage which may sharp-pointed tool across the surface from
adversely affect performance or sealing. Pay the journal outwards towards the tip of the
particular attention to the port threads and body gear, then the gear must be replaced.
O-ring seal recesses.
2. The gear teeth should be carefully examined
to ensure that there are no signs of bruising
Mounting Flange Face or pitting.
1. The inner surfaces should be inspected to en- 3. The journal bearing surfaces should be com-
sure that there is no unusual wear or scoring in pletely free from scoring or bruising. The sur-
the regions where the body O-rings and bush face should be highly polished and smooth to
seals contact, which could result in external leakage. the touch.
2. Check the shaft seal recess for scoring or dam- 4. Examine the area where the shaft seal lips
age that could result in oil leakage around the run on the drive shaft. This shows up as pol-
outer diameter of the shaft seal. A replacement ished ring or rings. If a noticeable groove can
shaft seal can be refitted with Loctite hydraulic be felt, or if there is scoring, the shaft should
sealant to overcome slight damage in this area. be replaced.
Bushes and Balance Plate 5. Examine drive keyway in driveshaft journal

extension to ensure it is not damaged or
1. The side faces which abut the gears should be chipped.
perfectly flat and show no signs of scoring.
6. If the driveshaft is not damaged from the
Characteristically there are bright polished
drive coupling and the gears have not been
areas on this surface caused by loading
harmed as described above, then the gears
against the gear side faces. This is often more
can be reused. If the gears are damaged,
pronounced on the low-pressure side. These
they must be replaced as a matched set.
should be replaced if there is any general
scoring or fine scoring with a matte appearance 7. As a matter of good practice, when pumps
or tearing of the surface material. have been dismantled, all the seals should be
replaced.
2. Often, the tips of the opposing gears have
wiped an overlap in a half-moon shape. There
must be no noticeable wear step as it is critical
that the bush side face and balance plate are
completely flat to the gear side face.
7.16
HYDRAULIC PUMP: REASSEMBLY
Reassembly
Trucks with Standard Hydraulic Pump
5
3
1
4
7
9
6
Sequence
Start By:
Ensure that all parts are perfectly clean. Lubricate
the bushes and gears with clean hydraulic fluid.
Ensure that the O-ring recess and end faces of
the body remain dry. This will assist the assembly
of the components with the body bores.
7.17
Reassembly
Trucks with Premium Hydraulic Pump
1 5
9
4
7
6
Sequence
Start By:
Ensure that all parts are perfectly clean. Lubricate
the bushes and gears with clean hydraulic fluid.
Ensure that the O-ring recess and end faces of
the body remain dry. This will assist the assembly
of the components with the body bores.
7.18
Reassembling the Rear Bushes
1. Install the rear bushes (marked CD and CI) Fixturing with the End Cover
into the undowelled end of the body. Use the end cover to temporarily fixture the parts
as they are reassembled. Place the end cover on
its back and set the undowelled end of the body
against it so that the dowels are pointing up.
Reassembling the Balance Plate

1. Hold the driveshaft and driven gear of the
idler shaft together and refit the balance plate
in its original position.
2. The two grooves in the plate must be to the
low-pressure side of the pump (the side
8609107
where the body bores meet in a point). With
the drive shaft nearest to you, these grooves
will be on the left-hand side as shown for the
2. The C-shaped cutout in the bushes must be counterclockwise rotation.
to the side of the body with the cusp removal
flat.
3. The diagram below shows the location of the
driveshaft and the front bushes and seals
installed.
Location Flange end

dowels
Cusp
Removal
Inlet
8609109
Position of
driveshaft
Counterclockwise Rotation
8609108
7.19
Reassembling the Gear Pack
Reassembling the O-ring and Seals
1. Fit the key into the keyway in the driveshaft
and then carefully fit the gear over the key. Fit a new O-ring, bush seal and backup seal,
Fit the second gear on the idler shaft. ensuring that the seals locate correctly in the
seal grooves.
2. Keeping the gear pack together, carefully feed
the assembly into the body bores with the
driveshaft positioned as previously shown.
8609112
8609110 Reassembling the Shaft Seal

Premium pump configuration 1. Fit a new shaft seal into the recess in the
mounting flange with the “garter” spring fac-
ing into the pump.
2. If the seal recess was scored, then Loctite
hydraulic sealant must be applied to the outer
diameter of the seal.
3. Apply a coat of high-melting-point grease to
the shaft seal lips.
4. Reinstall the retaining ring. Ensure that it is
located in its groove.
Standard pump configuration
Reassembling the Front Bushes

Refit the front bushes (FD and FI) into their origi-
nal bores, remembering that the C-cutout must
be to the side of the body with the cusp removal
flat. They must match the rear end bushes.
8609102
8609111
7.20
Reassembling the End Cover:
Reassembling the Flange
Slip the shaft seal and flange assembly over the
Replace end cover and refit the bolts and wash-
driveshaft and carefully refit the mounting flange,
ers. Tighten the bolts.
ensuring that it is positioned squarely onto the
dowels in the body.
End
cover
8609115A
8609113
Reassembling the Rear O-ring and Seals FBC15K - 18KL FBC20K-30KL

4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m
1. Hold the whole unit together and carefully Tightening torque (34 to 38 lbf•ft) (65 to 75 lbf•ft)
turn it over. Ensure that it is supported on the for bolts [46 to 51 N•m] [88 to 102 N•m]
mounting flange, not the driveshaft.
2. Remove the end cover and install a new O-
ring, bush seal, and backup seal.
NOTE
Lube splines before installing in pump motor.
Use molybdenum disulfide grease.
8609114
7.21
HYDRAULIC PUMP: INSPECTION
Inspection after Reassembly

Pour a small amount of clean hydraulic fluid into It is recommended that, initially, the unit is run in
a port and check that the shaft can be rotated at 1500 rpm at zero pressure for one minute. The
without undue force using a smooth-jawed vise. pressure should then be increased in intervals of
35 bars a minute until maximum pressure is
Running In After Reassembly reached. Check the system temperature frequent-
A unit which has been reassembled with either ly, ensuring that it does not exceed the maximum
new gears, bushes, or body, must be carefully run permissible temperature of 80°C. If the tempera-
in before it is subjected to full working conditions. ture exceeds the system or unit specification, the
test must be delayed and operated off-load until
Ideally, this should be done on a test rig, where
the temperature is lowered to an acceptable
pressure can be applied gradually and any wipings
range. Typical pump ratings are shown in the
from the body cut-in can be arrested by filters.
table below.
Pressure
Test gauge
unit Micronic Variable
filter restrictor
Flow
Strainer Relief meter
Tank
valve
Typical pump test circuit
8609116
Typical performance applicable when using

ISOVG 32 at 40°C (104°F)
Pump Part Test Speed Max. Flow Rate
Number Continuous
Pressure
97E71-00030 1500 rpm [185 bar] 9.11 GPM
(2683 psi) 34.5 L/min
204 kg/cm2
97E71-00040 1500 rpm [190 bar] 9.91 GPM
(2755 psi) 37.5 L/min
209 kg/cm2
97F71-00020 1500 rpm [247 bar] 11.49 GPM
(2900 psi) 43.5 l/min
220 kg/cm2
97271-00700 1500 rpm [185 bar] 11.49 GPM
(2683 psi) 43.5 l/min
204 kg/cm2
7.22
CONTROL VALVE: REMOVAL
Control Valve
Removal
Sequence
1. Auxiliary lines, connectors, and O-rings 5. Tilt lines, connectors, and O-rings
2. Steering return hose and connector 6. Return hose.
3. Lift pipe 7. Control valve
4. Delivery hose, connector, and O-ring 8. Switches
Start By:
1. Remove the floorplates and the dashboard cover.
2. Tilt the mast to vertical position, lower the forks all the way, and relieve the pressure in the
hydraulic lines.
3. Disconnect the battery
4. Disconnect the wire leads to the valve switches.
7.23
CONTROL VALVE: INSTALLATION
Control Valve
Installation
1. To install, follow the reverse of the disas- Tightening Torque for Hoses
sembly sequence. Before installing hydraulic
25 ± 0.5 N•m
fittings in the pump, inspect all O-rings for
A Tilt hoses 2.5 ± 0.5 kgf•m
damage or aging and replace them as 18 ± 3.6 lbf•ft
required.
65 ± 7 N•m
Delivery hose
2. Tighten hoses to the specifications shown in B 6.5 ± 0.7 kgf•m
FBC15K - 18K
the chart. 47 ± 5.1 lbf•ft
100 ± 10 N•m
Delivery hose
C 10 ± 0.1 kgf•m
FBC20-30K
72 ± 7.21 lbf•ft
50 ± 7 N•m
D Left Pipe 5.1 ± 0.7 kgf•m
36 ± 5.1 lbf•ft
48 ± 5 N•m
E Aux Hoses 5.0 ± 0.5 kgf•m
36.2 ± 3.6 lbf•ft
Steer Gear 25 ± 5 N•m
F Return Hose 2.5 ± 0.5 kgf•m
18 ± 3.6 lbf•ft
100 ± 10 N•m
G Return Hose 10 ± 1.0 kgf•m
72 ± 7.2 lbf•ft
7.24
CONTROL VALVE: DISASSEMBLY
Disassembly
7.25
CONTROL VALVE: DISASSEMBLY
Sequence
1. Aux Relief Valve 32. Seals
2. Main Relief Valve 33. Flow Control Screw
3. Tie Rod Nuts 34. Seals
4. Tie Rod Nuts 35. Lift Spool Section
5. Second Auxiliary Spool Section 36. Spring and Poppet
6. Spring and Poppet 37. O-ring
7. O-ring 38. Cap Screws
8. Cap Screws 39. Cap
9. Cap 40. Switch Assy
10. Switch Assy 41. Screws
11. Screws 42. Seals
12. Seals 43. Plugs
13. Flow Control Screw 44. O-rings
14. Seals 45. Connector
15. Auxiliary Spool Section 46. Inlet Section Spool
16. Spring and Poppet 47. Plug
17. O-ring 48. O-ring
18. Cap Screws 49. Plug
19. Cap 50. O-ring
20. Switch Assy 51. Tie Rods
21. Screws
22. Seals
23. Flow Control Screw
24. Seals
25. Tilt Spool Section
26. Spring and Poppet
27. O-ring
28. Cap Screws
29. Cap
30. Switch Assy
31. Screws
NOTE: Do Not remove spools from housing!
7.26
CONTROL VALVE: INSPECTION & REASSEMBLY
Suggestions Reassembly
Main Relief Valve Before Reassembly;

1. Wash all parts except for O-rings with solvent.
NOTE 2. Apply hydraulic oil to O-rings when installing them.
To remove main relief valve for cleaning or 3. Make sure that each spool moves freely.
inspection, loosen its plug. Loosening the
lock nut will disturb the pressure setting. 1. Lay out valve components on a clean, flat working
surface. The inlet assembly will include an o-ring,
and the spool sections include an o-ring, a load
Do not remove the main relief valve unless it is check poppet and a load check spring. Tools
required for basic valve assembly include 1/2” and
defective. This also applies to shut-off valve
9/16” open or box end wrenches and a torque
assembly. wrench with thin wall sockets.
Plug 2. Assemble tie rod nuts to one end of each tie rod
with one or two threads showing. Insert rods
through tie rod holes of inlet (larger tie rod at top).
Lay inlet on end with tie rods up, place o-ring into
position.
Lock nut 3. Place first spool section (o-ring side up) on inlet
section, position o-ring and insert load check
poppet (nose down) and spring (behind poppet)
205025
into load check cavity as shown. Repeat this
procedure for each spool section; the load check
springs are compressed by the following sections
during assembly.
Auxiliary Relief Valve
4. Position end section on last spool section and
NOTE hand tighten tie rod nuts. The end section is a
“turn around” section without ports. Universal outlet
To remove auxiliary relief valve for cleaning or
/ power beyond section and power beyond and
inspection, loosen its plug. Loosening the closed center sections are also used as end
lock nut will disturb the pressure setting. sections. These end sections do not have o-ring
grooves.
Do not remove the auxiliary relief valve unless it 5. Position valve assembly with the mounting pads of
is defective. This also applies to shut-off valve the end sections on a flat surface. To obtain proper
assembly. alignment of end sections relative to the spool
sections apply downward pressure to the end
sections; snug tie rod nuts to about 10 ft-lb.
Plug
Final torque the two 1.2” nuts to 14 ft-lb; final
torque the 9/16” nut to 33 ft-lb. check for proper
spool movement.
6. Install auxiliary valves and plugs and torque to

Lock nut proper specifications
205025
7.27
LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION

Removal
Lift Cylinders
5 4
1
207068
Sequence
1. Hose guard 4. Cylinder clamp (cushion, collar, and shims)
2. High-pressure hose 5. Lift cylinder and bracket
3. Set bolt and shims
7.28
Suggestions
1. Removing hose guard:
With the lift bracket raised to the maximum
height, remove each hose guard from the
front side of the mast.
! CAUTION
Be careful not to touch the lift control lever.
2. Lowering lift bracket:

Lower the lift bracket by carefully operating
the lift control lever.
3. Disconnecting high-pressure hoses:
Disconnect the high-pressure hoses at the
joints indicated by arrows. Use a container to
catch oil flowing out of the hoses.
Right-hand cylinder
Left-hand cylinder
204933
7.29
Removing Set Bolts Removing Lift Cylinders

1. Remove the set bolt at the top of each lift Attach a lift sling to the lift cylinder from the rear
cylinder. Lift the inner mast to separate the side of the mast and remove the cylinder. Attach
cylinder rod ends. To lift the inner mast, clove- the sling before removing the cylinder clamp.
hitch a sling to the mast with protective wad.
204935
204934
Installation
NOTE
Lift Cylinders
The rod end of either lift cylinder is shim-
adjusted to eliminate the difference in stroke To install, reverse the removal sequence and do
between the cylinders. Before removing the the following steps.
stopper bolts, make a record of the number of 1. Extend and retract the lift cylinders several
shims and the cylinder to which the shims are times under no-load conditions to expel air
fitted. from the cylinder circuits and to make sure
the cylinders move smoothly.
2. Check the oil level in the hydraulic tank with
2. Place wood blocks under the inner mast and
the oil level gauge.
detach the sling. Use blocks strong enough to
support the mast. 3. Check that the lift height is correct.
4. After the lift cylinders or piston rods have
been replaced, check for difference in stroke
between the two cylinders (refer to MAST
AND FORKS).
202983
7.30
Removal
Tilt Cylinders
3
1
206883
Sequence
1. Tilt socket pin (spacer)
2. Rubber hose (O-ring)
3. Cylinder pin (spacer)
4. Tilt cylinder
Start By:
1. Lower the forks all the way and tilt the mast
fully forward.
2. Hitch lifting slings to the top crossmember
of the outer mast by passing them through
the round holes. Take up the weight of the
mast with a hoist.
Suggestions
1. Retracting piston rod:
Remove tilt cylinder pin (item 1), and retract
207085
the piston rod all the way.
2. Disconnecting hoses:
Disconnect hoses (item 2) from the cylinder
at the connectors. Use a container to catch
oil from flowing out of the cylinder. Attach
caps to the connectors of the cylinder to
protect the threads of the connectors and to
prevent oil from flowing out of the cylinder
when the cylinder is removed.
7.31
Suggestions
Removing Tilt Socket
Later Version
! WARNING
If both tilt cylinders are to be removed at

the same time, make sure that the mast is
held either by a hoist or is securely sup-
ported and held in place by blocks.
1
4
2 3 206883
1. Rubber hose
2. Tilt socket pin, bolt, washer
3. Tilt cylinder pin, bolt, washer
4. Tilt cylinder
NOTE
When the tilt cylinders are to be replaced, it is
necessary to adjust the cylinder stroke and tilt.
7.32
LIFT & TILT CYLINDERS: DISASSEMBLY
Disassembly
Lift Cylinders
5
4
204948
Sequence
1. Bracket assembly 4. Piston rod, snap ring, holder, U-ring, nylon
heel, and piston ring
2. Holder, wiper ring, U-ring and O-ring
5. Cylinder tube
3. Bushing and bearing
Suggestions
Removing Piston Rod
Draw the piston rod out gently, taking care not to
damage the sealing members fitted to the piston.
200349
7.33
Disassembly
Tilt Cylinders
✱ Parts contained in seal kit
3
✱
1 ✱
✱
✱
1
207050
Sequence
1. Tilt socket, bushing, bolt, washer, nut, and 3. Piston rod, piston seal, and nut
grease fitting
4. Cylinder tube and bushing
2. Bushing, O-ring, dust seal, packing and
buffer ring
NOTE
Do not remove the tilt socket and cylinder tube
bushing unless they are defective.
Suggestions
Removing Bushing
1. Wrap the cylinder with a wad of cloth and
hold it in a vise. Using a wrench, remove the
bushing from the cylinder.
2. When removing the bushing from the piston
rod, be careful not to rub the buffer ring,
packing, etc., against the threads of the pis-
ton rod.
200351
7.34
LIFT & TILT CYLINDERS: FLOW REGULATOR VALVE

Disassembly
1
5
203559
Sequence Inspection after Disassembly

1. Lock nut 1. Check the springs for fatigue.
2. Plug and O-ring 2. Check the valve seats for damage. Check the
sliding surfaces for evidence of binding and
3. Spring and shims repair as necessary.
4. Piston, pin, washer, spring, and valve 3. Check the sliding surfaces of the piston and
valve body for damage.
5. Valve body
NOTE
Replace the flow regulator valve as an assem-
bly if any part is defective.
7.35
Inspection after Disassembly Precautions for Reassembly

Lift and Tilt Cylinders 1. Wash all parts clean, making sure that each
part is clear of any gritty particles.
Cylinder Tube
2. Before inserting the piston rod complete with
1. Check the bore wall for wear, grooving, the piston, apply hydraulic oil to the bore wall
scratch marks, and rusting. of the cylinder tube and to the sealing parts:
2. Check the welds for cracks. O-rings, U-rings, wiper rings, nylon heels, pis-
ton seals, dust seals, and packings—so they
Piston Rod will slide smoothly into the bore.
1. Check for deflection in the manner shown. 3. When clamping the cylinder tube in the vise
in order to run the head into the cylinder tube,
be careful not to distort the tube #4 and #117.
Before fitting the piston seal to the tilt cylinder
piston, squeeze the seal by hand 5 or 6 times
to soften it. Hold the piston steady by clamp-
ing the rod in a vise and apply a small
amount of hydraulic oil to the seal. Fit a por-
tion of the seal to the groove and push the
rest of the seal into place a little at a time
until the seal is in the groove.
4. Be sure to torque the nut, not the bolt when
200319 re-installing the tilt cylinder.
Torque to 108 to 118 N•m; 11 to 12 kgf•m.
2. Check for surface flaws such as grooving,
scratch marks, rusting, and wear. The rod
must be replaced if its threads show signs of
stripping or any other damage.
Packings and Rings

1. Check the packings and the lips of dust seals
for damage, distortion, and deterioration due
to aging.
2. Check each ring for deterioration due to aging.
200352
200353
7.36
HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Hydraulic Tank NOTE
Hydraulic Oil
A general rule: in any machine, regardless of
1. Check the hydraulic oil in the tank for cleanli- the mast-and-attachment combination, the oil
ness. Oil appearing dirty or whitish (showing level should not be above the “H” mark on the
more or less emulsification) must be changed. level gauge when the mast is all the way down.
2. Refill capacities in the amount of oil required.
! WARNING
Suction Strainer
Remove the hydraulic tank filler cap only Check the suction strainer for clogging or damage.
after the truck has been stopped and the
fill cap is cool enough to remove with your Return Filter
bare hand. Check the return filter for clogging or damage.
Hydraulic Tank Refill Capacities
FBC15K - 18KL FBC20K/25K FBC25KE/30KL
18 (4.8) 24 (6.3) 30 (7.9)
Unit: liter (U.S. gal)
7.37
Control Valve
External Leakage
1. Check for oil leaks from the joint between 2. Quickly disconnect the oil return hose and
adjacent valve housings sealed by O-ring. start collecting the oil coming out of the valve
2. Check for oil leaks from the scrapers sealed from the oil return port A.
by O-rings.
3. Check for oil leaks from the screw A
connections.
Internal Leakage
It is not practical to check the control valve alone
for internal leakage. The correct way to check the
control valve in place under normal operating
conditions follows.
The internal leakage to be checked includes
leakage occurring at the lift spool, tilt spool, tilt
lock valve, and check valves.
[Test oil temperature: approx. 50°C (122°F)]
Amount of oil collected 500 cc (30.5 cu. in.)
1. Pick up a load equal to the rated capacity. Lift for 15 minutes maximum
it approximately 1 meter (3 ft) high. Tilt the
mast forward 3° - 4° and stop the truck.
3° - 4°
3. If the tilt cylinders or lift cylinders drift (the
mast tilts forward or the fork lowers) exces-
sively even though the amount of oil collected
in 15 minutes is less than 500 cc (30.5 cu. in.),
measure the internal leakage of each cylinder.
(The measurement is the assembly standard
and not the service limit.)
approx.
1 meter
(3 feet)
203521A
7.38
Main Relief Valve Adjustment
1. Screw in special tool (6V3965) pressure port 4. If the setting is incorrect, loosen the lock nut
with o-ring into delivery hose port on valve(B). of the adjusting screw and, while observing
2. Attach a pressure gauge capable of measur- the pressure gauge reading, slowly turn the
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa] adjusting screw in either direction until the
to the pressure port. gauge indicates the prescribed set value.
3. Start the truck and move the control lever to 5. While holding the adjusting screw, tighten the
the backward tilt position and hold. If the relief lock nut to secure the adjusting screw.
pressure reading is 6. After securing the adjusting screw, recheck
185 ± 5 kgf/cm2 the setting.
(2631 ± 71 psi)
185 ± 5 kgf/cm2
[18,142 ± 490 kPa]
Main relief valve setting (2631 ± 71 psi)
when the tilt cylinders reach the end of their [18,142 ± 490 kPa]
stroke, the main relief valve setting is correct.
Main
relief
valve
Auxiliary Relief Valve Adjustment

1. Screw in special tool (6V3965) pressure port 4. If the setting is incorrect, loosen the lock nut
with o-ring into delivery hose port on valve(B). of the adjusting screw and, while observing
the pressure gauge reading, slowly turn the
2. Attach a pressure gauge capable of measur-
adjusting screw in either direction until the
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa]
gauge indicates the prescribed set value.
to the pressure port.
5. While holding the adjusting screw, tighten the
3. Start the truck and move the Auxiliary 1 con-
lock nut to secure the adjusting screw.
trol lever to the far right position and hold. If
the relief pressure reading is 6. After securing the adjusting screw, recheck
the setting.
158 ± 5 kgf/cm2
(2250 ± 71 psi)
158 ± 5 kgf/cm2
[15,513 ± 490 kPa] Auxiliary relief valve setting (2250 ± 71 psi)
the auxiliary relief valve setting is correct. [15,513 ± 490 kPa]
Auxiliary
relief
valve
7.39

Mast Tilt Angle Adjustment
NOTE
1. Place machine in a horizontal position.
It is not necessary to adjust the forward tilt
2. Tilt the mast all the way backward, and stop
angle, provided that the backward tilt angle is
the truck.
properly adjusted.
3. Measure the tilt angle of the mast at both sides.
4. To adjust the tilt angle, loosen bolt A of the tilt
cylinder socket, and adjust the cylinder stroke
by turning the rod on either cylinder so that
Forward/backward tilt angle 5° – 6°
there is no difference in stroke between the
cylinders.
Lift Cylinder Stroke Adjustment

1. Slowly raise the inner mast and check the
stopping manner of the left and right piston
rods at the moment the inner mast reaches
its maximum lift height.
207054
Tightening torque 127 to 152

for tilt cylinder (13 to 15.5)
socket bolt [94 to 112]
204698
2. If the top of the mast rocks at that moment, it

should be adjusted with shims. Abnormal
conditions will appear as a time lag in stop-
ping between right- and left-hand piston rods
and rocking of the rod with a longer cylinder
stroke.
7.40
Adjusting Method
1. Raise the inner mast, place blocks under the 3. Extend the piston rod and tighten the cylinder
right and left sides of the mast, and lower the stopper bolt. Remove the blocks from under
mast until it rests on the blocks. the inner mast.
4. Slowly lower the inner mast all the way to
make sure that the piston rods move smoothly.

Measure the lowering speed with rated load. If
the speed is out of specification, repair or replace
the flow regulator valve. For the specification of
lowering speed, refer to SERVICE DATA.
202983
1. Remove the stopper bolt at the top of the lift

cylinder which stopped first, retract the piston
rod, and insert the shims at the top of the pis-
ton rod end.
Stopper bolt
205972
Shims
200365
NOTE
To retract the piston rod, move the lift control
lever to the lowering position to let the oil
escape from the lift cylinder.
7.41
Testing
Lift Cylinder Drift Test Tilt Cylinder Drift Test
1. Pick up a load equal to the rated value, tilt the 1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks 1 mast to the vertical position, raise the forks
to 1.5 m (3.3 to 4.9 ft) and stop the truck. about 50 cm (20 in.) and stop the truck.
2. Scribe a line on the mast column and measure 2. Measure the drift extension of the tilt cylinder
the drift of the lift cylinder (drop for 15 minutes) for (extension) 15 minutes.
206891 207056
FBC15K - 25KE FBC25KL/30KL FBC15K-18KL FBC20-25KE FBC25KL/30KL
Lift cylinder drift 50 (2.0) 40 (1.6) Tilt cylinder drift 22 (0.9) 20 (0.8) 15 (0.6)
(rated load) maximum (rated load) maximum
Unit: mm (in.)/15 min Unit: mm (in.)/15 min
Piping
1. Check each hydraulic circuit for leaks.
2. Check to make sure that each hose is free
from twisting or excessive loops.
7.42
Chapter 8: Mast and Forks
Description ................................................................................................... 8.1
Removal and Installation.............................................................................. 8.2
Disassembly ................................................................................................ 8.4
Inspection after Disassembly ....................................................................... 8.6
Reassembly ................................................................................................. 8.7
Inspection and Adjustment........................................................................... 8.8
Forks ......................................................................................................... 8.8
Chain Tension Adjustment ........................................................................ 8.9
Clearance Adjustment on Lift Bracket ...................................................... 8.10
Mast Clearance Adjustment...................................................................... 8.13
Main Roller Shim Replacement ................................................................ 8.15
Mast Strip Adjustment............................................................................... 8.15
Tilt Angle Adjustment ................................................................................ 8.16
Lift Cylinder Stroke Adjustment................................................................. 8.17
Bleeding Lift Cylinders .............................................................................. 8.17
Service Data ................................................................................................ 8.19
Troubleshooting............................................................................................ 8.20
MAST AND FORKS: DESCRIPTION
Mast and Forks

Description
G
1
3
Forward Forward
B Detail of A Detail of F
D
Forward Forward
C
Detail of B, C Detail of D
E
4
Forward
F
Detail of E Detail of G
5
207081 207082
Components
1. Inner mast A. Main roller E. Main roller
2. Outer mast B. Main roller F. Main roller
3. Lift chain C. Main roller G. Mast strip
4. Lift bracket D. Side roller
5. Mast support bearing cap
Diam. of FBC20K/25K/
The simplex mast features two lift cylinders FBC15K - 18KL
main roller 25KE/25KL/30KL
placed behind the mast columns, right and left, to
provide maximum forward visibility. S 99 (3.90) 113.8 (4.48)
Mast strips are fitted to the top end parts of outer M 100 (3.94) 115 (4.53)
mast. These strips are for backing up the inner L 101 (3.98) 116 (4.57)
mast when the mast is tilted backward. LL 102 (4.016) 117 (4.606)
Unit: mm (in.)
8.1
MAST AND FORKS: REMOVAL & INSTALLATION
Removal and Installation

Mast and Lift Bracket Assembly
6
1 207083
Sequence
1. Nut 4. Tilt socket pins
2. Forks and lift bracket 5. Tilt cylinders
3. High-pressure hose for lift cylinders 6. Mast-support bearing caps and bushing
Suggestions
Removing Lift Bracket
1. Tilt the mast forward, and lower the inner mast
all the way. Slacken the lift chains, and
remove the nuts from the anchor bolts.
2. Tilt the mast back to vertical position. Secure
the lift bracket to prevent it from falling over.
Raise the inner mast until the lift bracket
becomes free. Then, back the truck away,
leaving the lift bracket and fork assembly
standing on the floor.
207084
8.2
MAST AND FORKS: REMOVAL & INSTALLATION
Removing Lift Cylinder High-Pressure Removing Mast Support Bearing Caps

Hoses 1. Scribe marks on the bearing caps before
With the mast in the lowest position, disconnect removing them.
the hoses at the flow regulator valve.
Removing Tilt Cylinders

1. Attach a sling to the holes, left and right in
the top cross member of the mast, and lift the
mast with a hoist.
Marks
207087
2. Remove the cap bolts and lift off the mast

assembly, laying it down flat on a level floor.
207085
NOTE
Lay the mast assembly on a floor large enough
for disassembly.
NOTE
Be sure to use a hoist having a capacity enough
to carry the weight of the mast assembly.
Weight of Components
FBC15K-18KL FBC20/25/ FBC30KL
25KE/25KL
Gross (Simplex 520 725 830
3.3 m mast) (1150) (1600) (1830)
Unit: kg (lb)
2. Remove the tilt socket pins, and separate the

masts from the tilt cylinders.
Tilt socket
pin
207086
8.3
MAST AND FORKS: DISASSEMBLY
Disassembly
12 10
15
3
11
10
13
9
2
16 17
2
6
6
7
6 14
1
4
5 207088
Sequence
1. Nut 10. Cylinder clamp, seat, shims, cushion, collar
and bolts
2. Forks and lift bracket
11. Bolt and shims
3. Backrest
12. Mast strip and shims
4. Main roller and shims
6. Side roller, bracket, and shims
15. Inner mast
7. Hose guard
16. Lift cylinders
8. Lift hose (high pressure)
(Rubber hose, T-joint and down safety valve) 17. Outer mast
9. Snap ring and chain wheel
8.4
Suggestions
Removing Mast Strips and Main Rollers
Remove bolts 10, 11 to free lift cylinder 16. Cross
the tops of the two lift cylinders. Slide inner mast
15 toward the bottom of outer mast 17, and
remove main rollers 13, 14 and mast strips 12.
Removing Inner Mast

After removing the main rollers, attach a sling to
the inner mast crossmember and slide the inner
mast toward the top of the outer mast until it gets
clear of the outer mast roller shafts. Sling the inner
mast again and remove it from the outer mast.
207089
8.5

Mast Lift Chains, Chain Wheels and Chain
Wheel Supports
1. Check each roller for wear, binding or other
defects. 1. Measure the length of each chain to be sure
that two chains are equal in length. Also
2. Check each roller for flat spots on rolling sur-
check the chains for wear, evidence of break-
face.
age, link binding and twist.
3. Check the mast member and the welds of
2. Check each chain anchor bolt for cracks or
crossmembers, shafts and supports for
damaged thread.
cracks.
3. Check each chain wheel support and chain
4. Check the mast support bushings for wear or
wheel for crack or wear. Check to be sure that
other damage.
the wheels are capable of smooth rotation.
4. Measure sections of chain that travel over the
chain wheel.
Length of Chain (Per 20 Links)

FBC15K-18K FBC20/25/ FBC30KL
18KL 25KE/25KL
A 318 (12.52) 381 (15.00) 508 (20.00)
B 327 (12.87) 392 (15.43) 523 (20.59)
Unit: mm (in.)
207090 A = Assembly standard B = Repair or service limit
Lift Bracket
Mast Strips
1. Check the main rollers and side rollers for
Check the mast strips for damage, wear or
smoothness of rotation. Inspect each roller for
wear and cracks. distortion.
2. Check the welds of the bracket for cracks.

3. Check the finger bar for bend or distortion.
Finger bar
207091
Distortion of 5 mm (0.2 in.)

A
finger bar maximum
A = Assembly standard
8.6
MAST AND FORKS: REASSEMBLY
Reassembly
To reassemble, follow the reverse of disassembly Mast Supports
sequence and do the following steps: 1. Check mast support bushing for wear.
Replace if worn.
Adjusting Mast and Lift Bracket Clearance
2. Apply a grease to the inside surfaces and
Rollers for mast and lift bracket are available in grooves of the caps.
three sizes (diameters) for selective use. Select
the size that will provide a longitudinal clearances 3. Install mast support bushings and caps with
of 1 mm (0.04 in.) and less. beveling toward the center of truck respective-
ly. Greasing will be facilitated if the mast is lift-
Clearance
ed by placing wooden blocks under it.
Mast cap
Bushing
Clearance
Lower roller Upper/middle roller

Apply grease
207096
Side with wider cut
203712
Roller Sizes
Diameter of FBC15K-18K FBC20K/25K/
main roller FBC18KL 25KE/25KL/30KL Precautions for Installing Chain Anchor Kit
Be careful not to install the center plate in the posi-
S 99 (3.90) 113.8 (4.48)
tion for link plate.
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
2
LL 102 (4.016) 117 (4.606) 3
Unit: mm (in.)
Cylinder Clamps
Install each lift cylinder in place (in vertical position)
by fitting to the support, and see if there is any
clearance between the outer mast and cylinder. 1
Reduce the clearance, if any, to zero by shimming.
4 Stamped mark
207094
1. Link plate (marked)

2. Center plate (not marked)
3. Link
4. Split pin
Shims
207093
8.7
MAST AND FORKS: REASSEMBLY

Forks
1. Carefully inspect the forks for cracks. Special 3. Check the fork blade D. The fork should be
attention should be given to the heel section withdrawn from service if the thickness is
A, all weld areas and B mounting brackets. reduced to less than the tolerant thickness.
Forks with cracks should be removed from Check the heel of fork. Fork blade length may
service. also be reduced by wear, especially on
tapered forks and platens. Remove the forks
“Wet Test” magnetic particle inspection is gen-
from service when the blade length is no
erally preferred due to its sensitivity and the
longer adequate for the intended loads.
ease of interpreting the results.
D Toe
A
101628 Heel 101630
2. Check the difference in height of one fork tip

Tolerant Thickness Standard Limit
to the other when mounted on the fork carrier.
A difference in fork tip height can result in FBC15K 40 (1.6) 31 (1.2)
uneven support of the load and cause prob-
FBC18K/18KL 40 (1.6) 33 (1.3)
lems when entering loads.
FBC20K 45 (1.8) 36 (1.4)
The maximum allowable difference in fork tip
elevation C is 5 mm (0.20 in.) for pallet forks. FBC25/25KE/25KL 45 (1.8) 39 (1.5)
FBC30KL 45 (1.8) 40 (1.57)
Replace one or both forks when the difference
in fork tip height exceeds the maximum allow- Unit: mm (in.)
able difference.
101629
8.8
MAST AND FORKS: INSPECTION & ADJUSTMENT
Chain Tension Adjustment

Tightening Torque
! WARNING
FBC15K-18K/18KL/20K/25K/25KE/25KL FBC30KL
Personal injury can be caused by sudden 57 84
Nut 2
movement of the mast and lift bracket. (5.8) (8.6)
Nut 3
Blocks must be used to prevent the mast [42.0] [62.2]
and lift bracket from any movement while 98 147
the adjustments are made. Keep hands and Nut 1 (10) (15.0)
feet clear of any parts that can move. [72.3] [108.5]
Unit: N•m (kgf•m) [lbf•ft]
1. Have the truck standing on a level floor, with
6. Adjust until tension is equal on both chains.
the mast vertical and the forks lowered to the
floor. Check to be sure that the lift cylinders
are fully retracted.
2. Set the anchor bolts with nut 3.
3. Raise the forks slightly and push the chains
inward midway between the chain wheel and
anchor alternately to check the tension. When
adjusting the chains by means of the nut 3,
tilt the mast forward to slacken the chains to
facilitate adjustment.
4. Turn nut 3 to adjust the chain tension. Then,
hold the anchor bolt in place with a wrench
and tighten nut 2 to the specified torque.
5. Hold nut 3 in place with a wrench, and tighten
nut 1 to the specified torque.
Anchor bolt
2 nut
3 nut
1 nut
102709
8.9
Clearance Adjustment on Lift Bracket

Longitudinal Clearance Adjustment on Lift
Bracket Main Rollers
1. Raise the forks a little from the floor. Roller Sizes
2. Insert a bar between the upper part of lift Diameter of FBC15K - 18KL FBC20K/25K/
bracket and the inner mast, and push the inner main roller 25KE/25KL/30KL
mast to one side. Using a feeler gauge, meas-
ure the clearance F between the main roller S 99 (3.90) 113.8 (4.48)
and inner mast on the opposite side. M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
F LL 102 (4.016) 117 (4.606)
Unit: mm (in.)
4. Lift bracket main rollers (upper and center

rollers).
The upper rollers should be the same in size
or 1-rank larger than the center rollers.
F
207095
0.1 to 1.0 mm
Clearance F
(0.004 to 0.039 in.)
3. If the clearance F is out of specification, use

oversize rollers.
Lower roller Upper/middle roller

207096
8.10
Lateral Clearance Adjustment on

Lift Bracket Main Rollers and Side Rollers
1. Raise the mast all the way. For the lift bracket upper main roller or center
2. Set a dial indicator on the inner mast with its main roller, to extend 0.5 mm (0.02 in.), insert
contact point rested on the side of the lift a 0.5 mm (0.02 in.) shim (a) on the inside
bracket. and remove the 0.5 mm (0.02 in.) shim (b)
from the lower stopper, then tighten the bolts.
3. Go over to the opposite side of the mast, and
push the lift bracket to one side with a bar.
Inner mast
Set the indicator to zero.
4. Insert a bar between the inner mast and lift
bracket on the indicator side, and push the lift
Shims (b)
bracket to the opposite side.
Shims (a)
207156
203818
5. Read the indicator.
0.1 to 0.5 mm
Clearance G
(0.004 to 0.020 in.)
6. Adjust clearance G1 between the middle main

roller and weld plate 2 at the maximum lift
position by increasing or decreasing the thick-
ness of the shim.
1 1
G1
2 2
202276
8.11

Lift Bracket Main Rollers and Side Rollers,
continued
7. Lower the lift bracket slightly below its maxi- 8. With the lift bracket at the maximum lift posi-
mum lift position, then adjust clearance G2 tion, adjust clearance G3 with shims.
between the side roller and mast by increas-
ing or decreasing the thickness of the shim.
G2
Side roller
Side Roller
G3
207158
202277
Adjust the side roller clearance by adding

shims under the roller bracket.
Shims
Shims
Roller 207157
Bracket
207098
8.12
Mast Clearance Adjustment

Longitudinal Clearance Adjustment on Lateral Clearance Adjustment on
Mast Main Rollers Inner Mast Main Rollers
1. Tilt the mast all the way backward. 1. Raise the mast all the way.
2. Using a feeler gauge, measure the clearance 2. Set a dial indicator on the inside of the outer
H between the inner mast lower roller and the mast with its contact point rested on the inner
outer mast. mast.
3. Go over to the opposite side of the mast, and
0.1 to 1.0 mm push the inner mast against the outer mast.
Clearance H
(0.004 to 0.039 in.) Set the indicator to zero.
3. If the clearance H is out of specification, use

oversize rollers.
Roller Sizes
Diameter of FBC15K - 18KL FBC20K/25K/
main roller 25KE/25KL/30KL
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53) J
L 101 (3.98) 116 (4.57) 204886
LL 102 (4.016) 117 (4.606)

4. Insert a bar between the outer and inner
Unit: mm (in.)
masts on the indicator side, and push the
inner mast to the opposite side.
H 0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)
207099
J
207101
8.13
6. If the clearance J is out of specification, adjust K
it by using shims.
Shims
207103
6. If the clearance K is out of specification, adjust

207102
it by using shims.
NOTE
Refer to Main Roller Shim Replacement.

Outer Mast Main Rollers Shims
1. Raise the mast all the way.
207104
2. Set a dial indicator on the outer mast with its
contact point rested on the inner mast.
3. Go over to the opposite side of the mast, and NOTE
push the outer mast against the inner mast
with a bar. Set the indicator to zero. Refer to Main Roller Shim Replacement.
4. Insert a bar between the outer and inner masts,
and push the inner mast to the opposite side.
0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.)
204889
8.14
Main Roller Shim Replacement Mast Strip Adjustment

1. Remove the lift bracket from the mast. 1. Check the clearance L with the clearance
between the outer mast rollers and inner mast
NOTE set to zero (0) in maximum lift position.
Refer to REMOVAL AND INSTALLATION, L

1. Lift Bracket Removal.
2. Lower the inner mast below the outer mast as

follows:
a. Raise the front end of the machine, and
block that end with a jack stand or the like.
b. Remove the upper set of bolts from the lift
200391
cylinders, and lift the inner mast with a
hoist. Remove the hose guard.
c. Remove the clamps from the lift cylinders. 0.1 to 0.5 mm
Pull the bottom ends of the cylinders from Clearance L
(0.004 to 0.020 in.)
the outer mast, tilt the cylinders to the cen-
ter of the mast, and tie them to the cross-
member of outer mast with rope. 2. If the clearance L is out of specification,
d. Slowly lower the inner mast until it comes adjust it by means of shims.
in contact with the lift cylinders.
e. Now the main rollers can be removed from
NOTE
the inner and outer masts. Remove the mast
strips and shims in advance because they Refer to Main Roller Shim Replacement.
are apt to come off under this condition.
3. After adjusting the all clearance, move the

mast and lift bracket slowly to make sure that
they move smoothly through their full stroke.
Shims
202961
200392
8.15
Tilt Angle Adjustment

1. Adjust the tire pressure correctly and keep 5. After adjusting the tilt angle, tighten the sock-
the truck level. et bolts to the specified torque.
2. Tilt the mast all the way backward and stop
the engine Tightening torque 127 to 152
for tilt cylinder (13 to 15.5)
3. Measure the backward tilt angle of the mast socket bolt [94 to 112]
at both sides.
Unit: N•m (kgf•m) [lbf•ft]
3. To adjust the tilt angle, loosen the bolt of tilt
cylinder socket, and adjust the cylinder stroke
by turning the rod on either cylinder so that
there is no difference in stroke between the
cylinders, left and right.
Bolt
207105
NOTE
It is not necessary to adjust the forward tilt
angle if the backward tilt angle is properly
adjusted.
Forward/backward tilt angle 5° to 6° (standard)
8.16
Lift Cylinder Stroke Adjustment

1. Slowly raise the inner mast, and check how 2. Remove the set bolt at the top of lift cylinder
the piston rods, left and right, stop at the which stopped first, retract the piston rod, and
moment the inner mast reaches its maximum insert shims at the top of piston rod end.
height. 3. Extend the piston rod, and tighten the cylinder
2. If the top of the inner mast rocks at that set bolt. Remove the blocks from under the
moment, make a shim adjustment. Abnormal inner mast.
condition can be told by a little time lag in
stopping between the piston rods, left and
right, and rocking of the rod with a longer Set bolt
cylinder stroke.
Shims
200365
4. Slowly lower the inner mast all the way to

make sure that the piston rods move smooth-
204698
ly and that the left and right lift cylinders
come to the end of stroke simultaneously.
Adjusting Method
1. Raise the inner mast, place blocks under the Bleeding Lift Cylinders
left and right sides of the inner mast, and
lower the mast until it rests on the blocks. When air and oil remaining inside the air chamber
of the rod and inside the rod chamber between
the tubes are compressed, they open the check
valve and flow out of the cylinder. Therefore,
there is no need to bleed the lift cylinders.
202983
8.17
MAST AND FORKS: SERVICE DATA
Service Data
Inner mast
F L
G1
G3
G2
B
F
Lift Bracket
A
C1
K
H E
J
C2
Outer mast D
207106
8.18
MAST AND FORKS: SERVICE DATA
Service Data
Item Truck Model FBC15K-18KL FBC20K-25KL FBC30K-30KL
Difference in height between fork tips A 5 (0.20)
100 x 40 100 x 40 125 x 45
A
(3.9 x 1.6) (3.9 x 1.6) (4.92 x 1.8)
Forks Chains
B FBC15K FBC20K
Thickness of forks 100 x 31 100 x 38
(3.9 x 1.2) (3.9 x 1.5) 125 x 39
FBC18K FBC25/25KE (4.92 x 1.53)
100 x 33 100 x 40
(width x thickness) (3.9 x 1.3) (3.9 x 1.57)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 101 (3.94) 115 (4.53)
Rollers
Diameter of main roller

L A 101 (3.98) 116 (4.57)
LL A 102 (4.016) 117 (4.606)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
A 523 (20.59) 575 (22.64)
(inside to inside) A
Distance between inner mast main rollers

A 581 (22.87) 639 (25.16)
(outside to outside) B
Distance between lift bracket main rollers

A 485 (19.09) 535 (21.06)
(outside to outside) C1

A 487 (19.17) 537 (21.14)

A 491 (19.33) 539 (21.22)
(outside to outside) D
Distance between lift bracket side rollers

Mast and Lift Bracket
A 496 (19.53) 546 (21.50)

(outside to outside) E
Longitudinal clearance of lift bracket middle rollers

A 0.1 to 1.0 (0.004 to 0.039)
(with forks slightly lifted) F
Lateral clearance of lift bracket middle main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G1
Lateral clearance of lift bracket side rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Lateral clearance of lift bracket lower main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G3
Longitudinal clearance of mast main rollers

A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H
Lateral clearance of inner mast main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) J
Lateral clearance of outer mast main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) K
Mast strip clearance

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) L
8.19
MAST AND FORKS: TROUBLESHOOTING
Troubleshooting
Complaint Possible Cause
Lift bracket and inner mast will a) Main rollers and side rollers having no proper clearance
not move smoothly b) Rollers involved binding on their shafts
c) Rollers damaged
d) Improper mast-to-strip clearance
Lift bracket or inner mast cocks a) Too much clearance on side rollers, or side rollers damaged
b) Lift chains unequally tensioned
c) Shim adjustments unequally made on left and right lift cylinders
(at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts, or damaged
Load drops (drifts) a) Lift cylinder packing damaged
b) Lift cylinder bore grooved
c) Control valve defective
Mast shakes entirely Mast-support bushing worn
Mast is distorted Improper loading or overload
Fork tips differ in height a) Finger bar bent
b) Forks bent
c) Distortion of mast due to off-center loading
8.20
Chapter 9: Troubleshooting Section
Front Axle and Reduction Differential ........................................................... 9.1
Brake System................................................................................................ 9.2
Steering System............................................................................................ 9.4
Hydraulic System .......................................................................................... 9.6
Rear Axle ...................................................................................................... 9.8
Mast and Forks ............................................................................................. 9.9
TROUBLESHOOTING: FRONT AXLE & REDUCTION DIFFERENTIAL
Troubleshooting Section
Front Axle and Reduction Differential
Complaint Possible Cause Remedy
Gear noise comes out Teeth worn excessively or tooth contact out Readjust or replace
continuously during of adjustment in spiral bevel drive
normal cruising run
Bearing preloads too much or too little, Readjust or replace
or bearings are worn excessively
Hub bearings broken Replace
Improper tooth contact between Readjust
reduction pinion (on output shaft) and
reduction gear
Irregular noise comes Bearings associated with spiral bevel Replace
out during normal travel drive or hub bearings broken
Differential side gears have broken teeth, Replace gears or washer
or thrust washers worn
Metal piece in axle housing Clean and replace oil
Bolts securing axle shaft or differential carrier Retighten
are loose
Abnormal noise comes Fit differential gears in differential case Replace worn parts
out when turning a are out of specification due to wear
corner
Broken teeth on differential pinions or Replace defective parts
side gears, or pinions seized on spiders
Differential overheats Bearings broken due to too large a Replace bearing and readjust
preload preload
Backlash between reduction pinion Replace bearings and readjust
(on output shaft) and reduction gear preload and backlash
too small
9.1
TROUBLESHOOTING: BRAKE SYSTEM
Brake System
Lack of Oil leaking past primary cup in master Replace piston cup if cylinder is worn.
braking force cylinder Replace cup and fluid if the cup is
distorted.
Oil leaking past cups in wheel cylinders Replace pipe and connector and
retighten
Oil leaking from oil pipe connection Retighten
Shoe linings excessively worn Replace
Linings dirty with oil or grease Clean or replace
Pedal stroke is Air trapped in brake oil line Bleed air at master cylinder and
too large wheel cylinder
Piston cup defective in master cylinder Replace
Not enough fluid in reservoir Refill
Push rod-to-piston clearance too large Readjust
in master cylinder
Service Brakes
Brake fluid leakage Replace piston cup if cylinder is worn.

Replace the cup and fluid if the cup is
distorted.
Automatic adjusting device out of order Check cable guide and adjusting
spring installation. If they are defective,
replace fitting cable, lever and
adjusting screw.
Uneven braking Lining or drum dirty with oil or grease in less Clean or replace
(machine pulls to effective brake
one side)
Wobbly or loose-mounted drum in less Replace drum. Readjust and retighten.
effective brake
Brake squeals Linings glazed Replace shoe & lining assembly
Linings badly worn Replace
Backing-plate securing bolts loose Retighten
Wheel bearings loose Readjust preload and retighten
Brake drum dirty Clean
Brake chatters Anchored ends of shoes rattling on anchor Repair or replace
or clatters
Shoe ledges badly worn Replace backing plate
Piston badly worn in wheel cylinder Replace
9.2
TROUBLESHOOTING: BRAKE SYSTEM
Lever stroke is Lining-to-drum clearance too small Readjust

too small
Squeals during Lining-to-drum clearance too small Readjust
traveling
Parking Brake
Brake drum badly distorted Repair or replace

Will not apply Parking brake cable longer than specified Check drum-to-lining clearance and,
if brake will not apply, turn adjusting
knob clockwise
Linings worn to service limit Replace shoe & lining assembly
Lining-to-drum clearance too small Readjust
Lack of brake lever operating effort Readjust to
25 to 30 kgf (55 to 66 lbf) [245 to 294 N]
Hard steering a) Overloaded steer axle Reduce load

b) Damaged mechanical linkage Replace
c) Dry mechanical linkage joints Lubricate
d) Mechanical joints too tight Readjust
e) Kingpin bearings improperly preloaded Readjust
Truck wanders a) Damaged or worn mechanical linkage Replace
b) Loose cylinder piston Replace cylinder rod
Steering System
Truck drifts a) Damaged or worn mechanical linkage Replace

b) Tire diameter differs between right and left Replace tire
Erratic steering Loose cylinder piston Replace cylinder rod
Excessive free play Damaged or worn linkage between cylinder Replace
at steered wheels and steered wheels
Axle shimmy a) Excessive clearance between the kingpin Repair or replace
and its bearings
b) Worn or damaged hub bearing Replace
Rear tires wear Tire on one side differs in kind or brand Replace tires
prematurely from that on the other side.
or unevenly
9.3
TROUBLESHOOTING: STEERING SYSTEM
Steering System
Slow steering, Worn or malfunctioning pump Replace

hard steering or
loss of steering Malfunctioning relief valve Readjust or replace
Worn or malfunctioning steer gear Replace
Pipe or tube flattened, or restriction in an oil line Clean or replace
Truck wanders Air in system Low level of oil Fill as required
Leaking joint Tighten joint
Pinched pipe or hose Straighten or replace
Worn steer gear Replace
Steering slip Worn steer gear Replace
Leakage of cylinder seals or at lines between steer gear Repair
and cylinder
Temporary hang-up in Thermal shock—caused by actuation of hydraulic lift and Correct operating
steering tilt for long periods of time without actuation of steering procedure
system, creating more than a 28°C (50° F) temperature
differential between the oil in the tank and the oil in the
steer gear.
Erratic steering Air in system Low level of oil Fill as required
Thermal shock damage to steer gear Replace
Spongy or soft steering Air in system Low level of oil Fill as required
Air trapped in cylinder Bleed air
9.4
TROUBLESHOOTING: STEERING SYSTEM
Steering wheel turns Problem with Column loose or damaged Repair or replace
with no axle response steering column
Column splines damaged or Repair or replace
disengaged from steer gear
Air in steer gear Starved at startup Temporary
Starved from long period of non-use Temporary
No flow to steer gear Low oil level Fill as required
Ruptured hose Replace
Thermal shock damage to steer gear Replace
Blown piston seal Replace
Steering instability or Air in lines Pump sucking air at inlet Check joints
oscillation
Components or lines contain air Bleed circuit
Improper relief setting Readjust
Steering wheel turns in Lines connected to wrong cylinder ports Correct connections
wrong direction
Excessive freeplay At steering wheel Loose steering wheel nut Tighten
Damaged or worn column shaft Replace
At steered wheels Leaky cylinder seals Replace
Binding or poor Binding or misalignment between column and steer gear Readjust steer gear
centering of steering mounting bracket or
wheel replace rubber mounting
grommets
High back pressure in tank return line Clear blockages
Contamination in steer gear unit Clean unit
Steer gear locks up Contamination in steer gear unit Clean unit
Insufficient hydraulic power Check pump and power
supply
Worn or damaged steer gear or steer gear pin Replace
9.5
TROUBLESHOOTING: HYDRAULIC SYSTEM
Hydraulic System
Will not lift or tilt Not enough oil in hydraulic tank Refill
Relief valve out of order because of:
1) Seized main valve Replace
2) Broken valve spring Replace relief valve
Oil pump defective Replace
Control valve switch misaligned or defective Readjust or replace
Will not lift rated Relief valve out or order because of:
load 1) Too low a relief valve setting Readjust
2) Defective plunger and poppet seat Replace relief valve
3) Weakened spring Replace relief valve
4) Damaged O-ring in valve case Replace O-ring
Oil pump defective Replace
Piston seals worn or damaged Replace
Lift speed is too low Rpm too low Adjust
Control lever installed loose, resulting in not Repair or replace
enough spool stroke
Tank strainer clogged Clean or replace

Pump not delivering enough oil Repair or replace
Lowering speed Sleeve seized in flow regulator valve Repair
is too low
Dirt in flow regulator valve Clean, repair system and replace
defective hose
Abnormal resistance to flow due to flattened Replace hose
hose or local clogging
Cylinder vibrates Piston rod distorted Repair or replace
when actuated Control lever installed loose, resulting in not Repair or replace
enough spool stroke
Air in oil circuit Bleed air by operation cylinder
through full stroke
Not enough oil in hydraulic tank Refill
Load will not hold Control valve spool leaking internally Replace
Lift connector on bottom of control valve Torque to 33 ± 3.5 ft•lbs
not tight
Sliding (inside) surface of cylinder tube Repair or replace cylinder assembly
slightly grooved
Sliding (inside) surface of tube badly grooved Replace
Piston seals broken or distorted Replace seal kit
Oil leakage from piping Repair or replace
9.6
TROUBLESHOOTING: HYDRAULIC SYSTEM

Lift and Tilt Cylinders, continued
Mast tilts forward Control valve spool leaking internally Replace

(drifts)
Foreign particles lodged between packing Replace packing
and mating surface
Piston seal damaged Repair
Cylinder distorted Repair or replace
Bushing leaks Foreign particles lodged between sealing Replace
members such as oil seals and dust seals
Oil seals and dust seals defective Replace
O-rings damaged Replace
Cylinder distorted Repair or replace
Hydraulic tank heats Oil viscosity improper Change oil
excessively
Overload Check working conditions and, if
overloaded, urge the operator to
stay within the load limit
Local overheating of oil line due to a large Repair or replace
restriction flow
Hydraulic Tank
Relief valve adjustment improper Readjust pressure setting

Pressure drop due to weakened or broken Repair or replace and readjust
springs
Hydraulic pump worn Replace
Outlet pipe or tube flattened, or restriction Repair or replace
to flow
Cylinders move Shortage of oil due to a natural loss Refill
too slowly
Oil leakage due to damaged oil line seals Repair or replace
Oil viscosity too high Change oil
Cylinders move too Hydraulic pump defective Check pump and piping; repair or
slowly replace
Oil leakage from oil line Check oil for level and condition;
and/or change oil
Abnormal rise in oil temperature Check control valve spools for
Hydraulic Pump
misalignment: repair or replace

Hydraulic pump leaking internally Replace pump
Noisy Poor pumping Refill
Cavitation 1. Check suction pipe for any flat
portion or loose connection;
retighten or replace
2. Check shaft oil seal for airtight-
ness; replace pump
3. Check pump body for any
outside interference; repair
9.7
TROUBLESHOOTING: REAR AXLE
Rear Axle
Hard steering Low pump pressure Check pressure, replace pump as needed
Damaged mechanical linkage Replace
Dry mechanical linkage joints Lubricate
Mechanical joints too tight Readjust
Kingpin bearings improperly preloaded Readjust
Truck wanders Damaged or worn mechanical linkage Replace
Loose cylinder piston Replace cylinder rod
Truck drifts Damaged or worn mechanical linkage Replace
Tire diameter differs between right and left Replace tire
Erratic steering Loose cylinder piston Replace cylinder rod
Excessive freeplay Damaged or worn linkage between cylinder Replace
at steered wheels and steered wheels
Axle shimmy Excessive clearance between the kingpin and Repair or replace
its bearings
Worn or damaged hub bearing Replace
Rear tires wear Tire on one side differs in kind or brand from Replace tires
prematurely or that on the other side
unevenly
9.8
TROUBLESHOOTING: MAST & FORKS
Mast and Forks

Complaint Possible Cause
Lift bracket and inner mast Main rollers and side rollers have proper clearance
do not move smoothly
Rollers involved are binding on their shafts
Rollers damaged
Improper mast-to-strip clearance
Lift bracket or inner mast Too much clearance on side rollers, or side rollers are damaged
cocks
Lift chains unequally tensioned
Shim adjustments unequally made on left and right lift cylinders
(at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts or are damaged
Load drops (drifts) Lift cylinder packing damaged
Lift cylinder bore grooved
Control valve defective
Entire mast shakes Mast-support bushing worn
Mast is distorted Improper loading or overload
Fork tips differ in height Finger bar bent
Forks bent
Distortion of mast due to off-center loading
9.9
Chapter 10: Maintenance Service Data
Maintenance Service Data .......................................................................... 10.1
Front Axle and Reduction Differential....................................................... 10.1
Transfer Case........................................................................................... 10.3
Rear Axle.................................................................................................. 10.4
Brake System ........................................................................................... 10.6
Steering System, ...................................................................................... 10.11
Hydraulic System ..................................................................................... 10.13
Mast and Forks (Simplex Mast) ............................................................... 10.16
Tightening Torques for Standard Bolts and Nuts ........................................ 10.18
Fine Thread—With Spring Washer .......................................................... 10.18
Fine Thread—Without Spring Washer ..................................................... 10.19
Coarse Thread—With Spring Washer...................................................... 10.20
Coarse Thread—With Spring Washer...................................................... 10.21
Maintenance Chart ...................................................................................... 10.22
Planned Replacement Parts........................................................................ 10.28
Lubrication Information ................................................................................ 10.29
Chart......................................................................................................... 10.29
Lubricant Specifications ........................................................................... 10.30
Recommended Brands of Lubrications .................................................... 10.30
Weight of Major Components (Approximate) .............................................. 10.31
Special Service Tools .................................................................................. 10.32
Special Tool Illustrations........................................................................... 10.33
Inspection Guide.......................................................................................... 10.36
SERVICE DATA: FRONT AXLE
Maintenance Service Data

Front Axle and Reduction Differential
Truck FBC15K- FBC20K-
Item
Model FBC18KL FBC30KL
A 0.05 (0.0020)
Face runout of axle shaft flange
B 0.5 (0.020)
Runout of axle shaft A 0.5 (0.020) max 1.0 (0.039) max
(1/2 of dial indicator reading)
B 1.0 (0.039) max 2.0 (0.079)
Preload for hub bearing 1,
A 5 to 50 (0.4 to 3.6) [0.5 to 4.9]
kgf•cm (lb•ft) [N•m]
Tightening Hub bearing lock nuts
A 20 (145) [196]
torque (outer) (2)
kgf•cm
(lbf•ft) Axle shaft bolts (3) A 8.8 (64) [86]
[N•m] Backing plate bolts (4) A 6 (43) [59] 18.5 (134) [181]
Hubs and Wheels
Hub bolt lock nuts (5) A 6 (43) [59] 18.5 (134) [181]
Frame support bolts (6) A 22.9 (166) [225]
Wheel nuts (7) A 16 (116) [157] 38.5 (278) [378]
6 1
4 7
203665

Unit: mm (in.)
10.1
SERVICE DATA: FRONT AXLE
Front Axle and Reduction Differential, continued

Item Truck FBC15K/18K/18KL/20K/25K/25KE/25KL/30KL
Model
Gear backlash (1) A 0.18 to 0.23 (0.0071 to 0.0091)
B 0.5 (0.020)
A 0.02 to 0.07 (0.0008 to 0.0028)

Fit of bevel pinion on spider (2)
B 0.35 (0.0138)
15 to 30 (1.1 to 2.2) [1.5 to 2.9]

Preload for differential case side bearings (3) A
kgf•cm (lbf•ft) [N•m] 1.3 to 2.5 kgf (2.9 to 5.5 lbf) [13 to 25 N]
as force applied to reduction gear in tangential direction
Hubs and Wheels
Face runout of reduction gear (4) A 0.05 (0.0020) max
B 0.05 (0.0020)
Backlash between reduction gear

A 0.15 to 0.25 (0.0059 to 0.0098)
and pinion (5)
Free movement (looseness) of A 0.07 to 0.17 (0.0028 to 0.0067)

axle shaft splines (6)
B 0.5 (0.020)
Tightening Reduction gear bolts (7) A 12 (87) [118]

torque
kgf•cm Side bearing cap bolts (8) A 12.8 (93) [126]
(lbf•ft)
[N•m] Carrier bolts (9) A 6.1 (44) [60]
Differential carrier cover

A 3.4 (25) [33]
bolts (10)
6 5 4
7
10
9
3
8
2 1
203664

Unit: mm (in.)
10.2
SERVICE DATA: TRANSFER CASE
Transfer Case
N•m kgf•m lbf•ft
1 Cover-to-traction motor 33±2 3.4±0.2 24.6±1.4

2 Side cover 39.2±3.9 4.0±0.4 29.0±2.9
3 Plug or pulse generator 54.0±4.9 5.5±0.5 39.7±3.6
4 case-to-cover 39.2±3.9 4.0±0.4 29.0±2.9
5 Lock nut 292±20 30.0±2.0 217±14.5
Supply liquid gasket onto

the face of flange.
Transfer Case
4
2
5
209009

Unit: mm (in.)
10.3
SERVICE DATA: REAR AXLE
Rear Axle
Item Truck FBC15K-18KL FBC20K- 30KL
Model
Oscillating angle A 3°
Toe-in A 0°
Caster A 0°
Camber A 1°
Total fore-aft play of axle at center pin (1) A 0.8 (0.031)
B 1.2 (0.047)
Turning Angle Inside (2) A 83° 83°
Outside (3) A 54° 56°
Tightening Support bolts (4) A 14.8 (107) [145]

torque, kgf•m
(lbf•ft) [N•m] Stopper bolt nuts (5) A 6.8 (49) [67]
Rear Axle
Cylinder minimum test pressure,

A 107 (1522) [10,500] 163 (2320) [16,000]
2
kgf•cm (psi) [kPa]
8609145

Unit: mm (in.)
10.4
SERVICE DATA: REAR AXLE
Rear Axle, continued

Item Truck FBC15K-18KL FBC20K- 30KL
Model
Tightening torque Outer locknut (6) A 16 (116) [157]

kgf•m (lbf•ft) [N•m]
Cylinder nuts (7) A 1.9 to 2.3 (14 to 17) [19 to 23]
Cylinder bolts (8) A 17.9 (130) [176] 26.7 (193) [262]
Kingpin bolts (9) A 1.7 (12.3) [16.7] 3.4 (24.6) [33.4]
Tie rod bolts (10) A 0.7 (5) [6.9]
Preload for hub bearing (11)

A 25 to 65 (1.8 to 4.7) [2.5 to 6.4]
8
Rear Axle
10
11
9
6
8609146

Unit: mm (in.)
10.5
SERVICE DATA: BRAKE SYSTEM
Brake System
Truck
Item FBC15K - 30KL
Model
Height of pedal (1) A 89 ± 3 (3.5 ± 0.12)
Stroke (to point where brakes start to apply) (2) A 3 to 10 (0.12 to 0.40)
Clearance between piston and push rod (3) A 0.5 to 2.8 (0.02 to 0.11)
2
1
Brake Pedal
8609147

Unit: mm (in.)
10.6
Brake System, continued
Truck FBC15K- FBC20K-30KL

Item
Model FBC18KL
19.05 + 0 0.052 22.22 + 0 0.052

Inside diameter of cylinder body (1) A
(0.7500 + 0 0.00205) (0.8748 +0 0.00205)
19.05 -0.020 -0.053 22.22 -0.020 -0.053

Diameter of piston (2) A
(0.7500 -0.0079 -0.00209) (0.8748 -0.0079 -0.00209)
Clearance between cylinder and piston 0.020 to 0.105 0.020 to 0.105

A
(0.00079 to 0.00413) (0.00079 to 0.00413)
B 0.2 (0.008) 0.2 (0.008)
Diameter of primary cup (lip side) (3) 20 0 -0.3 23.2 ± 0.25
A
(0.79 0 -0.012) (0.913 ± 0.0098)
B replace every year replace every year

Diameter of secondary cup (lip side) (4) 20.2 ± 0.2 23.2 ± 0.25
A
(0.795 ± 0.008) (0.913 ± 0.0098)
Free length of return spring (5) A 46.8 (1.843) 85 (3.35)
Master Cylinder
Earlier Version
204936
Later Version
2
4
1 3 5 91246-07200

Unit: mm (in.)
10.7

Item
Model FBC18KL
Inside diameter of cylinder body (1) A 22.22 + 0 0.052 28.58 + 0 0.052

(0.8748 - 0 0.00205) (1.1252 + 0 0.00205)
Diameter of piston (2) 22.22 - 0.040 - 0.073 28.58 - 0.020 - 0.058

A
(0.8748 - 0.00157 - 0.00287) (1.1252 - 0.00079- 0.00228)
Clearance between cylinder and piston 0.040 to 0.125 0.020 to 0.105

A
(0.00157 to 0.00492) (0.00079 to 0.00413)
B 0.15 (0.0059)
Diameter of piston cup (lip side) (3) 23.7 ± 0.2 30.5 ± 0.25
A
(0.933 ± 0.0079) (1.201 ± 0.0098)
B replace every year
Return Spring (4) Free length A 49.5 (1.95) 58 (2.28)
Length under test force A 20 (0.79) 23 (0.91)
1.2 ± 0.1 1.3 ± 0.1
A (2.6 ± 0.2) (2.9 ± 0.2)
Test force kgf (lbf) [N] [12 ± 1] [13 ± 1]
Wheel Cylinder
B replace every year

Tightening 0.8 to 1.2 1.8 to 2.7
torque, kgf•m Wheel cylinder bolts (5) A (6 to 9) (13 to 20)
(lbf•ft) [N•m] [8 to 12] [18 to 26]
Bleeder screw (6) A 0.6 to 0.9 (4 to 7) [6 to 9]
1 6 5
4 3 2
200426

Unit: mm (in.)
10.8

Item
Model FBC18KL
Inside diameter of brake drum (1) 254 + 0 1.3 310 + 0 0.15

A
(10.00 + 0 0.0051) (12.20 + 0 0.0059)
B 256 (10.08) 312 (12.28)
Thickness of lining (2) A 4.87 (0.19) 6 (0.24)
B 2.5 (0.098) max 3 (0.118) max

Wheel Brakes
Clearance between drum and lining (3) A 0.2 to 0.5 0.2 to 0.6
(one side) (0.0079 to 0.0197) (0.0079 to 0.0236)
Return spring 102 (4.02) Primary:120 (4.72)

Free length A
(4) Secondary: 139.3 (5.48)
111 (4.37) Primary: 134 (5.28)

Length under test force A
Secondary: 145.4 (5.72)
16 ± 1.6 23 ± 2.3
Test force, kgf (lbf) [N] A (35 ± 3.5) (51 ± 5.1)
[157 ± 16] [226 ± 23]

Unit: mm (in.)
10.9

Item
Model FBC18KL
Adjusting Free length A 79 (3.11) 104 (4.11)

spring (5)
Length under test force A 98.5 (3.88) 122 (4.80)
Test force, kgf (lbf) [N] A 14 ± 1.4 (31 ± 3) [137 ± 14] 8 ± 0.8 (18 ± 2) [78 ± 8]
Tightening torque for backing plate bolts (6) A 16 (116) [157]
Service Brakes
1
4
2 6
3
Secondary spring 4
5
Free length
203588
Locked position of lever A A 4° to 5°
Lever operating effort (F) A 25 to 30 (55 to 66) [245 to 294]
F
Parking Brake
204967

Unit: mm (in.)
10.10
SERVICE DATA: STEERING SYSTEM
Steering System
Item
Model FBC18KL
Steering effort (at rim with truck on)

A 1.3 (2.9) [12.8]
kgf (lbf) [N]
Tightening Tank Plug (1) A 4.8 (35) [47.5]

torque kgf•cm,
(lbf•ft) [N•m] Body cap screws (2) A 2.3 (17) [23]
Steering Gear

Unit: mm (in.)
10.11
SERVICE DATA: STEERING SYSTEM
Steering System

Item
Model FBC18KL
Inside diameter A 63 (2.48) 75 (2.95)
Diameter of piston rod A 40 (1.57) 50 (1.97)
Minimum test pressure for leaks, A 107 (1522) [10,500] 163 (2320) [16,000]
kgf•cm2 (psi) [kPa]
Tightening Cylinder nuts (1) A 2.1 ± 0.2 (15.5 ± 1.5) [21 ± 2]

Steering Cylinder
torque, kgf•cm,
(lbf•ft) [N•m] Mounting bolts (2) A 17.9 (130) [176] 26.7 (193) [262]
8609149

Unit: mm (in.)
10.12
SERVICE DATA: HYDRAULIC SYSTEM
Hydraulic System
Truck 15K 18K 18KL 20K 25K 25KE 25KL 30K-30KL
Item
Model
48 volt lift speed (rated load) mm/sec (fpm) A .34 (67) .32 (64) .47 (93) .40 (78) .38 (74) .32 (64)
Lowering speed (rated load) mm/sec (fpm) A .58 (115) .57 (113) .59 (116) .52 (102)
Forward tilt angle A 5°

Simplex Mast
Backward tilt angle A 6°
Lift cylinder drift (rated load)

mm (in.) / 15 min. A 50 (2.0) max 40 (1.6)
[Oil temperature 45°C (113°F)]
Tilt cylinder drift (forward) rated load

mm(in.) / 15 min. A 22 (0.9) 20 (0.8) 15 (0.6)
[Oil temperature 45°C (113°F)]
2
Main relief valve setting, kgf•cm , (psi) [kPa] A SAME
Power steering relief valve setting 51 (725)[5000] 81.5 (1160) [8000]

A
kgf•cm2, (psi) [kPa]
Output, liter (cu. in.) / min Standard 55.2(3360) 60(3913) 60(3913)2400rpm

Hydraulic Pump
A
2400 rpm 2400 rpm 69.6 (4549)
2400 rpm 69.6 (4539)
Premium A 60(3913)2400rpm DNA 2400rpm
Tightening torque for oil pump bolts

kgf•m (lbf•ft) [N•m] A 4.7 to 5.2 (34 to 38) [46 to 51]
Control Valve
Tightening Tie bolts (1/2 in.) A 1.9 (14) [19]

torque
kgf•m (lbf•ft)
[N•m] Tie bolts (9/16 in.) A 4.5 (33) [45]

Unit: mm (in.)
10.13
Hydraulic System, continued

Truck FBC15K- FBC20K- FBC25KL-
Item
Model FBC18KL FBC25KE FBC30KL
45 +0.2 50 +0.2 55 +0.2

[Piston] 0 0 0
A
Inside diameter of cylinder tube (1) (1.77 +0.008) (1.97 +0.008) (2.17 +0.008)
0 0 0
Diameter of piston ring (2) A 35 (1.38) 40 (1.57) 45 (1.77)
Thread diameter (3) A M49 x 1.5 M54 x 1.5 M59 x 1.5
Tightening torque (4) 170 to 240 200 to 270 270 to 304
A (17.3 to 24.5) (20.4 to 27.5) (27.5 to 31.0)
Lift Cylinder
N•m (kgf•m) [lbf•ft] [125 to 175] [150 to 200] [200 to 225]
3 2 1
4
207073
Return
Filter
Tightening torque
A 49 ± 10 (5 ± 1) [36 ± 7.2]
N•m (kgf•m) [lbf•ft]

Unit: mm (in.)
10.14
Hydraulic System, continued

Truck FBC15K- FBC20K- FBC25KL-
Item
63 +0.1 70 +0.1 80 +0.1

0 0 0
A
Inside diameter of cylinder tube (1) (2.48 +0.004) (2.76 +0.004) (3.15 +0.004)
0 0 0
B 63.12 (2.485 0) 70.12 (2.760 6) 80.12 (3.154 3)
-0.02
25 -0.05 30 -0.02 35 -0.025
[Guide bushing] A -0.05 -0.064
Diameter of piston rod (2) (1.0 -0.000 8) (1.18 -0.000 8) (1.38 -0.000 98)
-0.002 0 -0.002 0 -0.002 52
Inside diameter of mast-side socket bushing 0 0
A 35-0.012 (1.38-0.0005 )
(fitted) (3)
+0.085 +0.003)
Inside diameter of frame-side head bushing A 32 0 (1.26 0
(fitted) (4)
B 32.6 (1.283)
[Guide bushing] thread diameter (5) A M68 x 2 M75 x 2 M85 x 2
Tightening torque 265 ± 29 314 ± 31 373 ± 37

A (27 ± 3) (32 ± 3.2) (38 ± 3.8)
Tilt Cylinders
N•m (kgf•m) [lbf•ft] [195 ± 22] [231 ± 23] [275 ± 27]
[Socket] thread diameter (6) A M24 x 1.5 M27 x 1.5 M30 x 1.5
Tightening Socket bolt (7) A 127 to 152 (13 to 15.5) [94 to 112]
torque, N•m
(kgf•m) [lbf•ft] 127 ± 9.8 235 ± 19.6 39.2 ± 25
Self-locking nut (8) A (13 ± 1.0) (24 ± 2.0) (40 ± 2.5)
[94 ± 7.2] [174 ± 14.5] [289 ± 18.1]
Clearance between rod and A 0.06 to 0.111 0.075 to 0.139

guide bushing (9) (0.002 4 to 0.004 4) (0.003 0 to 0.005 5)
B 0.35 (0.013 8)
9
3
6 4
7 5 1 2 8 207033
Flow Regulator
Flow rate (no load)

Valve
A 50 (3051) 65 (3967) 75 (4577)

liter (cu. in.) / min

Unit: mm (in.)
10.15
SERVICE DATA: MAST AND FORKS
Mast and Forks (Simplex Mast)

Truck FBC15K- FBC20 - FBC25KL-
Item
Difference in height between fork tips A 5 (0.20)
Thickness of forks 100 x 40 100 x 45 125 x45
A (3.9 x 1.6) (3.9 x 1.8) (4.92 x 1.8)
Forks Chains
FBC15K FBC20K
100 x 31 100 x 38
B (3.9 x 1.2) (3.9 x 1.5) 125 X 39
FBC18K/KL FBC25K/KE/KL (4.92 x 1.53)
100 x 33 100 x 40
(width x thickness) (3.9 x 1.3) (3.9 X 1.57)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
Rollers
M A 100 (3.94) 115 (4.53)

Diameter of main roller
L A 101 (3.98) 116 (4.57)
LL A 102 (4.016) 117 (4.606)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
A 523 (20.59) 575 (22.64)
(inside to inside) A
Distance between inner mast main rollers
A 581 (22.87) 639 (25.16)
(outside to outside) B
A 485 (19.09) 535 (21.06)
A 487 (19.17) 537 (21.14)
A 491 (19.33) 539 (21.22)
(outside to outside) D
Mast and Lift Bracket
Distance between lift bracket side rollers

A 496 (19.53) 546 (21.50)
(outside to outside) E
Longitudinal clearance of lift bracket
A 0.1 to 1.0 (0.004 to 0.039)
middle rollers (with forks slightly lifted) F
Lateral clearance of lift bracket
A 0.1 to 0.5 (0.004 to 0.020)
middle main rollers (fully raised) G1
Lateral clearance of lift bracket side rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Lateral clearance of lift bracket lower main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Longitudinal clearance of mast main rollers
A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H
Lateral clearance of inner mast main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) J
Lateral clearance of outer mast main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) K
Mast strip clearance
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) L

Unit: mm (in.)
10.16
SERVICE DATA: MAST AND FORKS
Mast and Forks

Truck FBC15K FBC18K- FBC20K FBC30K
Item Model 18KL FBC25K FBC30KL
FBC25KE
F Inner mast
L
G1
G3
G2
B
Mast and Lift Bracket/Later Version
Lift Bracket
A C1
K
H
E
J
C2
D
Outer mast
207106
Tightening Mast support bolts A 7.5 (54) [74] 18.2 (132) [178]
torque, kgf•m
(lbf•ft) [N•m] Chain wheel support
A 9.9 (72) [97]
bolts
Distortion of finger bar A 5 (0.2)

Unit: mm (in.)
10.17
SERVICE DATA: GENERAL
Tightening Torques for Standard Bolts and Nuts

Fine Thread – With Spring Washer
With Spring Washer
Nominal Size Pitch
mm in. mm in. kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m
6 0.24 1 0.04 0.75 5.4 7.4 0.98 7.1 9.6 1.3 9.4 12.7
8 0.32 1.25 0.05 1.7 12.3 16.7 2.3 16.6 22.6 3.1 22.4 30.4
10 0.39 1.25 0.05 3.5 25.3 34.3 4.6 33.3 45.1 7.1 51.4 69.6
Metric Fine Thread
12 0.47 1.25 0.05 6.5 47.0 63.7 8.4 60.8 82.4 12.5 90.4 122.6
14 0.55 1.5 0.06 10.4 75.2 102.0 13.5 97.6 132.4 19.5 141.8 192.2
16 0.63 1.5 0.06 15.8 114.3 154.9 20.6 149.0 202.0 29.3 211.9 287.3
18 0.71 1.5 0.06 22.9 165.6 224.6 29.8 215.5 292.2 42.2 305.2 413.8
20 0.79 1.5 0.06 31.7 229.3 310.9 41.2 298.0 404.0 58.5 423.1 573.7
22 0.87 1.5 0.06 42.2 305.2 413.8 54.8 396.4 537.4 77.8 562.7 763.0
24 0.95 1.5 0.06 55.8 403.6 547.2 72.5 524.4 711.0 102.6 742.1 1006.2
27 1.06 1.5 0.06 81.0 585.9 794.3 105.3 761.6 1032.6 148.0 1070.5 1451.4
30 1.18 1.5 0.06 112.2 811.5 1100.3 145.9 1055.3 1430.8 205.2 1484.2 2012.3
33 1.30 1.5 0.06 149.6 1082.1 1467.1 194.5 1406.8 1907.4 273.3 1976.8 2680.2
36 1.42 1.5 0.06 195.6 1414.8 1918.2 254.3 1839.4 2493.8 356.6 2579.3 3497.1
39 1.54 1.5 0.06 251.0 1815.5 2461.5 326.2 2359.4 3198.9 455.8 3296.8 4469.9
Note
1. The tolerance on these torques is ± 10%.
2. These torques are for “dry” conditions.
10.18

Fine Thread – Without Spring Washer
Without Spring Washer
Nominal Size Pitch
6 0.24 1 0.04 0.88 6.4 8.6 1.1 8.0 10.8 1.5 10.8 14.7
8 0.32 1.25 0.05 2.0 14.5 19.6 2.7 19.5 26.5 3.7 26.8 36.3
10 0.39 1.25 0.05 4.2 30.4 41.2 5.4 39.1 53.0 8.3 60.0 81.4
Metric Fine Thread
12 0.47 1.25 0.05 7.6 55.0 74.5 9.9 71.6 97.1 14.7 106.3 144.2
14 0.55 1.5 0.06 12.2 88.2 119.6 15.9 115.0 155.9 23.1 167.1 226.5
16 0.63 1.5 0.06 18.6 134.5 182.4 24.2 175.0 237.3 34.5 249.5 338.3
18 0.71 1.5 0.06 26.9 194.6 263.8 35.0 253.2 343.2 49.7 359.5 487.4
20 0.79 1.5 0.06 37.3 269.8 365.8 48.5 350.8 475.6 68.8 497.6 674.7
22 0.87 1.5 0.06 49.6 358.8 486.4 64.5 466.5 632.5 91.5 661.8 897.3
24 0.95 1.5 0.06 65.6 474.5 643.3 85.3 617.0 836.5 120.7 873.0 1183.7
27 1.06 1.5 0.06 95.3 689.3 934.6 123.9 896.2 1216.0 174.1 1259.3 1707.3
30 1.18 1.5 0.06 132.0 954.8 1294.5 171.6 1241.2 1682.8 241.4 1746.0 2367.3
33 1.30 1.5 0.06 176.0 1273.0 1726.0 228.8 1654.9 2243.8 321.6 2326.1 3153.8
36 1.42 1.5 0.06 230.1 1664.3 2256.5 299.2 2164.1 2934.1 419.6 3035.0 4114.0
39 1.54 1.5 0.06 295.3 2135.9 2896.0 383.8 2776.0 3763.8 536.2 3878.3 5258.3
Note
10.19

Coarse Thread – With Spring Washer
With Spring Washer
Nominal Size Pitch
10 0.39 1.5 0.06 3.4 24.6 33.3 4.4 31.8 43.1 6.9 49.9 67.7
12 0.47 1.75 0.07 6.0 43.4 58.8 7.8 56.4 76.5 11.8 85.3 115.7
14 0.55 2 0.08 9.8 70.9 96.1 12.7 91.9 124.5 18.6 134.5 182.4
Metric Fine Thread
16 0.63 2 0.08 15.0 108.5 147.1 19.5 141.0 191.2 28.0 202.5 274.6
18 0.71 2.5 0.10 20.7 149.7 203.0 27.0 195.3 264.8 39.1 282.8 383.4
20 0.79 2.5 0.10 29.2 211.2 286.4 37.9 274.1 371.7 54.7 395.6 536.4
22 0.87 2.5 0.10 39.1 282.8 383.4 50.9 368.2 499.2 73.0 528.0 715.9
24 0.95 3 0.12 50.2 363.1 492.3 65.3 472.3 640.4 94.3 682.1 924.8
27 1.06 3 0.12 73.9 534.5 724.7 96.1 695.1 942.2 137.7 996.0 1350.4
30 1.18 3.5 0.14 98.9 715.3 969.9 128.4 928.7 1259.2 188.0 1359.8 1843.7
33 1.30 3.5 0.14 135.5 980.12 1328.8 176.1 1273.7 1727.0 252.6 1827.1 2477.2
36 1.42 4 0.16 170.9 1236.1 1676.0 222.3 1607.9 2180.0 326.3 2360.1 3199.9
39 1.54 4 0.16 226.3 1636.8 2219.2 294.1 2127.2 2884.1 420.0 3037.9 4118.8
42 1.65 4.5 0.18 280.9 2031.8 2754.7 365.2 2641.5 3581.4 523.9 3789.4 5137.7
Note
10.20

Coarse Thread – Without Spring Washer
Without Spring Washer
Nominal Size Pitch
10 0.39 1.5 0.06 4.0 28.9 39.2 5.2 37.6 51.0 8.1 58.6 79.4
12 0.47 1.75 0.07 7.1 51.4 69.6 9.2 66.5 90.2 13.8 99.8 135.3
14 0.55 2 0.08 11.5 83.2 112.8 14.9 107.8 146.1 22.0 159.1 215.7
Metric Fine Thread
16 0.63 2 0.08 17.6 127.3 172.6 22.9 165.6 224.6 33.0 238.7 323.6
18 0.71 2.5 0.10 24.4 176.5 239.3 31.8 230.0 311.9 46.0 332.7 451.1
20 0.79 2.5 0.10 34.3 248.1 336.4 44.6 322.6 437.4 64.3 465.1 630.6
22 0.87 2.5 0.10 40.0 289.3 392.3 59.9 433.3 587.4 85.9 621.3 842.2
24 0.95 3 0.12 59.0 426.7 578.6 76.8 555.5 753.2 111.0 802.9 1088.5
27 1.06 3 0.12 86.9 628.5 852.2 113.0 817.3 1108.2 162.0 1171.7 1588.7
30 1.18 3.5 0.14 116.3 841.2 1140.5 151.1 1092.9 1481.8 221.1 1599.2 2168.3
33 1.30 3.5 0.14 159.4 1153.0 1563.2 207.2 1498.7 2031.9 297.3 2150.4 2915.5
36 1.42 4 0.16 201.1 1454.6 1972.1 261.5 1891.4 2564.4 384.0 2777.5 3765.8
39 1.54 4 0.16 266.2 1925.4 2610.5 346.0 2502.6 3393.1 494.1 3573.8 4845.5
42 1.65 4.5 0.18 330.5 2390.5 3241.1 429.5 3107.3 4212.9 616.4 4458.4 6044.8
Note
10.21
Maintenance Chart
Use the service chart to determine servicing intervals. Calendar intervals shown (weekly, monthly, etc.)
may be used instead of service meter intervals if they provide more convenient servicing schedules and
approximate the indicated service meter reading. Recommended service should always be performed at
the interval that occurs first.
Perform service on items at multiples of the original requirement. For example, at every 1200 hours or 6
months, also service those items listed under every 200 hours or monthly, every 50 hours or weekly and
daily (pre-start).
● = Check or clean
★ = Change or adjust
Maintenance Intervals
Every 1200 hours
Every 2400 hours

Every 200 hours
Daily (pre-start)
Every 50 hours
Inspection Point How to Check Service Data
or 6 months
or monthly
or weekly
or 1 year
Motors Bearing lubrication, damage Visual ● ● Lubricate
Winding to case resistance Test ● ● Resistance to be > 1

Mega Ω
Armature to case resistance Test ● ●
Brush contact area Visual ● ● Change brush
Brush length Visual ● ● Change brush
Brush spring force Test ● ● Change spring
Commutator surface condition Visual ● ●
Commutator discoloration Visual ● ●
Interior, exterior cleanliness Visual ● ● ● Clean
Steering wheel Free-play, looseness, rattling Test ● ● ● ● ●
Operation Test ● ● ● ● ●
Steering gear Oil leaks Visual ● ● ● ● ●
Mounting bolts, tightness Wrench ● ● ●
Steering Beam structural damage Visual ●

linkage
Cylinder leaks Visual ● ● ● ● ●
Cylinder mounting bolts Wrench ●
Tie rod bearings and pins Visual ●
Kingpin looseness Test ●
Trunnion fore-aft looseness Test ● Nominal 0.8 mm

(0.031 in.) clearance
10.22
Every 2400 hours or

Every 1200 hours or
Every 200 hours or
Every 50 hours or
Daily (pre-start)
6 months
monthly
weekly
1 year
89 ± 3 mm
Brake pedal Height of pedal above floor Scale ● ● ● ● ● (3.5 ± 0.12 in.)
Stroke to point where brakes Scale ● ● ● ● ● 3 to 10 mm
start applying (0.12 to 0.4 in.)
Parking brake Lever lock position:

Performance Test/spring 4° - 5°
balancer ● ● ● ● ●
Operating effort:
25 to 30 kgf
(55 to 66 lb)
[245 to 294 N]
Brake hoses Fluid leaks, damage or Visual ● ● ● ● ●

and pipes installation
Brake fluid Level in reservoir Visual ● ● ● ● ★ 103cc (7.9 cu. in.)
Wheel brakes Master cylinder and wheel Overhaul/Visual

cylinders—operation, wear and ★
damage
Brakes drums FBC15K - 18KL

and shoes 0.2 to 0.5mm
Drum-to- lining clearance Feeler gauge ● ● ● (0.01 to 0.02)
FBC20K-30KL
0.2 to 0.6mm
(0.01 to 0.02)
FBC15K - 18K
Sliding surfaces of shoes and Disassemble/ ● 2.5mm (0.10 in.)
wear of lining calipers
FBC20K-30KL
3.0mm (0.12 in.)
Service Limit:
FBC15K - 18KL
254 + 0 0.13 mm
Drum—wear or damage Visual scale ● (10.00 + 0 0.0051 in.)
FBC20K-30KL
310 + 0 0.13 mm
(12.20 + 0 0.0051 in.)
Free length of return springs Scale ●
Operation of shoes Test ●
Anchor pins—seizure Visual ●
10.23
Every 1200 hours or
Every 2400 hours or

Every 200 hours or
Every 50 hours or
Daily (pre-start)
6 months
monthly
weekly
1 year
Backing plates Distortion, cracks, or damage Dye check ●
Fitting cables– Visual/scale ●

damage and length
Ratchet–wear or damage Visual ●
Front axle Cracks, distortion, Dye check/ ●

or other defects visual
Front wheel bearings–preload Spring balancer ● Hub bearing preload

5 to 50 kgf
(0.4 to 3.6 lbf•ft)
[0.5 to 4.9 N•m]
Fore-aft play Test ●
Cracks, distortion, or Visual ●

other defects
Differential Oil level and oil leaks Visual ● ● ● FBC15K - 18KL

5.7 liters (1.5 U.S. gal)
FBC20-30KL
6.1 liters (1.6 U.S. gal)
Mounting bolts Torque wrench ●
Rear axle Front wheel bearings–preload Spring balancer ● Hub bearing preload
Torque wrench 25 to 65 kgf
(1.8 to 4.7 lbf•ft)
[2.5 to 6.4 N•m]
Lock Nut (outside)

16 kgf•cm (116 lbf•ft)
[157 N•m]
Wheels Tires–cuts or gouges Visual ● ● ● ● ●
Tires–wear Depth gauge ● ● ● ● ●
Tires–imbedded objects Visual ● ● ● ● ●
Wheel nuts–tightness Torque wrench ● ● ●
Front Wheel Nuts:

FBC15K - 18KL
16 kgf•cm (116 lbf•ft) [157 N•m]
FBC20K-30KL
38.5 kgf•cm (278 lbf•ft) [378 N•m]
Rims–damage Visual ● ● ● ● ●
10.24
Every 2400 hours

Every 1200 hours
Every 200 hours
Daily (pre-start)
Every 50 hours
or 6 months
or monthly
or weekly
or 1 year
Hydraulic tank Oil level and contamination Visual ● ● ● ● ★
Strainer—clogging Visual ★
Return filter—clogging Visual ★
Hydraulic pump Oil leaks or abnormal noise Visual / listen ● ● ●
Control valve Oil leaks Visual ● ● ● ● ●
185 kgf/cm2
Main relief valve setting Pressure gauge ● (2631 psi)
[18,142 kPa]
Auxiliary relief valve setting Pressure gauge ● 158±5 kgf/cm2
2250±71psi
15,513 ± 490 kpa
Overload relief setting (optional) Pressure gauge ●
Control levers and links—rattle Test ● ● ● ● ●
Lift cylinders Cracks, distortion, or Visual ● ● ● ● ●
other defects
● ● ● ● ● FBC15K-25KE
Rod drift (rated load) Visual/watch/ 50 mm (2.0 in.)/15 min
scale FBC25KL-30KL
40 mm (1.6 in.)/15 min
Attachment ● ● ● ● ●
Mounting bolts—tightness Wrench ● ● ●
Oil Leaks Visual ● ● ● ● ●
Flow regulator Lowering speed Watch/scale ● ● ● Lowering speed
valve (rated load)
FBC15K-25KE
520 mm/sec (102 fpm)
FBC25KL-30KL
500 mm/sec (98 fpm)
10.25
Every 1200 hours

Every 200 hours
Daily (pre-start)
hours or 1 year
Every 50 hours
or 6 months
Every 2400
or monthly
or weekly
Tilt cylinders Cracks, distortion, Visual ● ● ● ● ●
or other defects
Oil leaks Visual ● ● ● ● ●
Forward rod drift (rated load) Watch/scale ● ● ● FBC15K - 18KL
22 mm (0.9 in.)/15 min
FBC20K-25KL
20 mm (0.8 in.)/15 min
FBC30KL
15 mm (0.6 in.)/15 min
Mounts—rattle or damage Visual/free ● ● ● ● ●
Rod socket nut—tightness Torque wrench ● ● ● ● ● FBC15K - 18KL
15 kgf·m
(108 lbf•ft)
[147 N•m]
FBC20K-30KL
40 kgf·m
(289 lbf·ft)
[392 N·m]
Piping Oil leaks Visual ● ● ● ● ●
Rubber hoses: damage Visual ● ● ●
Hose reels and swivel joint— Visual ● ● ●
distortion or other defects
Mast and Cracks, distortion, Visual/ ● ● ● ● ●
lift bracket or other defects dye check
Mast supports—rattle or ● ● ●
damage
Main rollers—clearance, Feeler gauge/ ● ● ● Each roller to
damage dial gauge mast clearance
(at max. height):
0.1 to 0.5 mm
(0.004 to 0.020 in.)
10.26
Every 1200 hours or

Every 200 hours or
Every 50 hours or
Every 2400 hours

Daily (pre-start)
6 months
or 1 year
monthly
weekly
Lift chains and Length of lift chains (20 links) Scale ● FBC15K - 18KL
chain wheels 318 mm (12.5 in.)
FBC20K-25KL
381 mm (15.0 in.)
FBC30KL
508 mm (20.0 in.)
Tension deflection of lift chains Scale ● ● ● ● ● Both chains to

equal in tension
Chains—damaged or rusting Visual ● ● ● ● ●
Chains wheels—wear, Visual ● ● ●
distortion, or other defects
Chain wheel bearings—rattle Feel ● ● ●
Chain anchor bolts—distortion Visual ● ● ●
or damage
Forks and Forks—wear and distortion Visual/scale ● ● ● ● ● Fork thickness—
backrest refer to Service Data
Forks stopper pins— Visual ● ● ● ● ●
damage or distortion
Backrest mounting bolts— Torque wrench ● ● ● ● ●
tightness
Backrest—distortion or damage Visual ● ● ● ● ●
Lights Operation Test/visual ● ● ● ● ●
Turn signals
Operation Test ● ● ● ● ●
(optional)
Rear view Rear vision Visual ● ● ● ● ●
mirrors (optional)
Overhead guard Installation and damage Visual/wrench ● ● ● ● ●
Chassis Loosen bolts or nuts Wrench ●
Operator’s seat— Visual ● ● ●
damage and installation
Lubricate mast supports
Lubrication points Lubricate ● ● ●
every 50 hours or weekly
Oil change Inspect ● ● ●
10.27
Periodic Replacement Parts

The parts listed below are important for the safe operation of the truck, and especially designed to be
replaced at specified periods. Each service shop is requested to adhere to the replacement schedule
given here on all trucks brought into its care.
Periodic Replacement Parts Service Period
1 month 1 month 6 months 1 year 2 years

after (200 hours) (1200 hours) (2400 hours) (4800 hours)
delivery
1 ★
Rubber parts for brake Replace ● ●
master cylinder
2 ★
Rubber parts for brake Replace ● ●
wheel cylinders
3 ★
Hydraulic hoses Replace ● ●
4 ★
Hoses for power steering Replace ●
5 ★
Rubber parts for Replace ●
steering cylinder
6 ★
Lift chains Replace ●
7 Hydraulic tank return filter Replace ● ● ● ●
8 Drum to lining clearance Check or replace ● ●
9 Motor brushes Check or replace ● ●

★
Indicates important safety-related parts
10.28
LUBRICATION AND MAINTENANCE CHART BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW
CHECK LUBRICATE
Lubrication Chart
EVERY 10 HR. OR DAILY EVERY 50 HR. OR WEEKLY

MULTIPURPOSE-TYPE GREASE
SPECIFIC GRAVITY OF BATTERY
ENGINE OIL
OIL LEAKS BOLTS, NUTS
EVERY 50 HR. OR WEEKLY
TIRES, WHEEL NUTS EVERY 200 HR. OR MONTHLY MAST SUPPORTS
DIFFERENTIAL OIL LEVEL EVERY 200 HR. OR MONTHLY
BRAKE FLUID LEVEL
MAST STRIPS, ROLLER
HYDRAULIC OIL LEVEL EVERY 600 HR. OR 3 MONTHS SURFACES (EACH SIDE)
CONTACTORS LIFT BRACKET SIDE
BATTERY ELECTROLYTE LEVEL MOTOR BRUSHES ROLLERS (EACH SIDE)
BATTERY RESTRAINT LIFT CHAIN (EACH SIDE)
MAST, FORKS, LIFT CHAINS TILT SOCKET (EACH SIDE)

CHANGE FRONT AXLE SUPPORT
SEAT BELT AND RAILS (EACH SIDE)
STEERING
OIL,
Filter TILT CYLINDER (EACH SIDE)
SERVICE BRAKES EVERY 1200 HR. OR 6 MONTHS
TRANSFER AND DIFFERENTIAL OIL BRAKE PEDAL
PARKING BRAKE HYDRAULIC TANK OIL FILTER TIE ROD ENDS (4 FITTINGS)
ACCELERATOR PEDAL REAR AXLE CENTER PIN
(FRONT/REAR)
HORN EVERY 2400 HR. OR 1 YEAR
HYDRAULIC OIL
DASH MONITOR BRAKE FLUID
NOTE: REDUCE SERVICING INTERVALS IN DUSTY OR SEVERE CONDITIONS. REFER TO OPERATION MANUAL 97182-12900
10.29
10.30
◆
Recommendation for ambient temperatures [°C (°F)]
Oil Recommendation (-22) (-4) (14) (32) (50) (68) (86)

-30 -20 -10 0 10 20 30
| | | | | | | | | | | | |
API service classification ISO Grade 32 ISO Grade 68
Gear oil multipurpose type GL-5 SAE 75W SAE 80W
(hypoid gear oil) AGMA-1EP AGMA-2EP
Hydraulic oil SAE 5W -30 to -10 SAE 10W
Brake fluid F.M.V.S.S. No. 116—DOT 3 or DOT4 (SAE J1703)

Wheel bearings NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295
Grease
Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340
• Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with the same
brand at successive service intervals.
Fuel and Lubricant Specifications
EP 68 Gear oil with borate additives are not recommended.
Gear Oil Greases Hydraulic oils

Specifications
API service classification GL-5 NLGI No. 1 NLGI No. 2
Visc
osity
SAE90W Consistency 310-340 Consistency 265-295 SAE5W SAE10W
Manufacturer
Mobil 90 Pegasus Gear Oil Mobil Grease JL 77 No. 1 Mobil Grease JL 77 No. 2 — Hydraulic oil 28 LP
Shell Shell Spirax EP90 Retinax A No. 1 Retinax A No. 2 Tellus oil 22 Tellus oil T-32
Exxon Gear Oil GX 80W90 ---- Ronex MP UNIVISN 22 Nuto H32
Castrol Castrol Hypoy Castrol LM Grease Castrol Spheerol API Castrol Hyspin Castrol Hyspin
AWS32 AWS68
■ Brands of oil are subject to change without notice.
■ When you buy oil, select recommended brands and check specifications.
Weight of Major Components (Approximate)

Component / Model FBC15K FBC18K FBC18KL FBC20K FBC25K FBC25KE FBC25KL FBC30K-
FBC30KL
Counterweight 470(1036) 625(1378) 910(2006) 540(1190) 730(1609) 540(1190) 730(1609) 1060(2337)
Power train 200 215

(Motor, transfer box, reduction (441) (474)
gear and differential)
Overhead guard 62.7 (138) 67.4 (149) 66.0 (146)
Rear axle 150 (331) 220 (485)
Mast (3.3 m simplex mast) 520 (1146) 725 (1598) 830 (1830)
Outer mast 140 (309) 190 (419) 205 (452)
Inner mast 135 (298) 180 (397) 190 (419)
Lift bracket (including backrest) 105 (231) 150 (331) 175 (386)
Forks (two) 80 (176) 130 (287) 165 (364)
Lift cylinder and related parts 60 (132) 75 (165) 95 (209)
Hydraulic motor 45 (99) 50 (110)
Traction motor 80 (176) 100 (220)
Unit: kg (lb)
10.31
SERVICE DATA: SPECIAL TOOLS
Special Service Tools

Truck Models
Ref. Part No. Part Name Application FBC FBC FBC

No. 15K-18KL 20K-25KL 30K-30KL
1 91268-00701 Socket wrench Removal and installation of rear wheel nuts ● ● ●
2 91268-00300 Bevel pinion Removal of bevel pinion assembly ● ● ●

(or 91268-02100) puller
3 64309-11701 Gauge kit Measurement of hydraulic pressure ● ● ●
4 91268-00800 Socket wrench Removal/installation of front wheel hub nuts ● ● ●
5 03703-59001 Socket wrench Removal/installation of front wheel hub nuts ● — —
6 91468-00300 Installer Installation of front axle wheel bearing inner — ● ●

races
94309-12300 ● — —
7 91268-01500 Installer Installation of rear axle inner bearing inner ● — —

races
8 64309-40400 Installer Installation of rear axle inner bearing inner — ● ●

races
9 91268-01400 Installer Install rear axle outer bearing inner races ● — —
10 91268-00400 Installer Install rear axle outer bearing inner races — ● ●
11 64309-15411 Spring remover Removal of return spring ● ● ●
12 64309-15412 Spring remover Removal/installation of brake shoes ● ● ●
13 64309-15413 Spring hook Installation of return spring ● ● ●
14 91268-10600 Steering wheel Removal of steering wheel ● ● ●

puller
15 91268-01600 Installer Installation of tilt cylinder tube bushing ● ● ●
16 09305-00680 ● — —
Hook wrench Remove / install tilt cylinder guide bushing
09305-00750 — ● —
09305-00800 — — ●
17 64309-16300 or Measurement of control valve main relief

F4540-06300 Pipe connector pressure & overload relief pressure (to be ● ● ●
used with 64309-17701 gauge kit)
18 97157-00100 Spring installer Install centering spring in steer gear ● ● ●
19 64309-40100 Wheel puller Removal of drive wheel hub ● — —
20 MH61017 Wheel puller Removal of drive wheel hub — ● ●
21 6V3965 Pressure Port Main Relief Valve Pressure Check ● ● ●
22 97E67-00100 Transfer Bearing Removal of Bevel Pinion Shaft ● ● ●

Tool
23 97E67-00200 Plug Assy Tool Torque or Steer Gear Tank ● ● ●
10.32
Special Tool Illustrations

1 2
M10 x 1.5
46
M14 x 1.5
164
95 17
250 10
22
155 91268-00300
91268-00701 91868-02100
3 4
64309-17701 91268-00800
5 6
90
91468-00300
03703-59001 64309-12300
7 8
91268-01500 64309-40400
10.33
9 10
ø31
ø48
ø68
ø71
30
40
10
91268-01400 91468-00400
11 12
64309-15411 64309-15412
13 14
M12 X 1.25
M8 X 1.25
45
55
64309-15413 91268-10600
10.34
15 16
ø32
ø35
30 45
Flame-hardened Hv >500,
depth 2mm (0.08 in.)
09305-00680
09305-00750
91268-01600 09305-00800
17 18
64309-16300
F4540-06300 97157-00100
19 20
64309-40100 MH061017
21 22
6V3965 97E67-00100
23
97E67-00200
10.35
Inspection Guide
Check For (item or defect) How
Antifriction bearings ITEMS Measure inside diameter with an indicator

hole gauge and shaft outside diameter with
a) Fit on shaft an indicating micrometer
b) Fit in housing Measure outside diameter with an indicat-

ing micrometer and housing inside
diameter with an indicator hole gauge
c) Preload (small initial load applied to As stated in service manual

absorb initial bearing deformation)
DEFECTS
a) High running temperature (caused by As shown

over lubrication)
b) Noise (humming), vibration, or rough

running
Radial bearing Thrust bearing
c) Creep (marks of circumferential slip 8609153

on inner ring’s surface in contact with Visually
shaft or on outer ring’s surface in
contact with housing due to loose fit
of bearing)
d) Corrosion Visually
8609151
e) True brineling (caused by careless

installation or removal)
8609152
10.36
Antifriction bearings f) False brineling (caused by a constant vibration Visually

or oscillation of non-rotating bearings through
small arc)
8609154
g) Cracked race (caused by forcing bearing or Visually

oversize shaft or by cooking race when installing
or removing)
8609155
h) Broken separator (caused by dirt, metal chips, Visually

or lack of lubricant)
8609156
i) Damaged seal (caused by improper use of tools) Visually
8609157
j) Spalled race (caused by too loose a fit) Visually
8609158
10.37
Antifriction bearings k) Bad discoloration (caused by overheating due to Visually

poor lubrication)
8609159
i) Craters (caused by passage of electric current) Visually
8609160
Bushings or sleeve ITEM

bearings Fit on shaft Determine by measuring inside
diameter of bushing and outside
diameter of shaft
DEFECTS
Nicks, burrs, or other flaws on bearing surface Hold bushing toward a light and look
through bore
Fasteners DEFECTS
a) Striped or otherwise damaged threads (bolts, Visually

nuts, screws, etc.)
b) Distortion or loss of tension (spring lock Examine by compressing

washers, snap rings, etc.)
Gears ITEMS
a) Fit on bearing, bushing, spline or key As stated in service manual
b) Backlash As stated in service manual
DEFECTS
a) Excessive wear on teeth, thrust faces, and end Visually

faces on hub
b) Scratching wear (caused by large particles other Visually

than associated with abrasive wear)
10.38
Gears c) Abrasive wear (caused by fine particles carried Visually

in lubricant)
d) Overload wear Visually
e) Pitting Visually
f) Spalling Visually
g) Overload breakage Visually
h) Fatigue breakage Visually
i) Corrosive wear Visually
10.39
Keys and keyways Wear on sides making parts not fit tightly Examine by placing
Oil seals Damage to lip Visually
Roller chains and a) Wear on pins, bushings, rollers, and plates in Visually
sprockets each link tending to increase in pitch.
b) Wear on sprocket teeth Visually
Chain load
Sprocket rotation
New Old
8609189
Rubber parts Hardening or softening, swelling, tackiness, Visually

tearing, and deterioration due to aging
Splines and serrations ITEM
Fit
DEFECTS
a) Nicks, burrs, chips, etc. Visually
b) Free movement (looseness) of mating splines Examine
c) Excessive wear polish on sides (sliding fit Visually

splines)
d) Ridge or edge left between worn and unworn Visually

areas (sliding fit spline)
8609170
10.40
Springs ITEMS See specification
a) Type called for Use a square
b) Squareness
8609171
c) Free length test Examine
d) Test force
DEFECTS
a) Excessive clearance space between coils Visually

(compression springs) in free state
b) Any clearance space between coils (tension

springs) in free state
8609172
8609173
c) Condition or ends or hooks Visually
d) Cracks or breakage Visually
10.41
TECHNICAL PUBLICATIONS FEEDBACK
(Please Print)
Dealer name: Submitted by:
Address: P. O. Box:
City: State:
Zip code: Country:
The following discrepancy or omission has been discovered in:
❏ Operation & Maintenance Manual ❏ Option Bulletin
❏ Part List/Manual ❏ Special Instruction
❏ Service Manual ❏ Service Data manual
❏ Electronic Manual ❏ Other:

Publication # Engine model #
Truck model # Issue date #
Truck serial # Page #
(Please print)
Explanation of discrepancy or omission:
Please fax or mail completed form to:

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2121 W. Sam Houston Parkway N. P.O. Box 30171
Houston, Texas 77043-2305 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695
Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-861-9277
FBC15K, FBC18K, FBC18KL, FBC20K, FBC25K,
Mitsubishi Forklift Trucks Service Manual 99759-73100
FBC25KE, FBC25KL, FBC30K, FBC30KL Forklift Trucks
Service Manual
GE SX Controls
FBC15K, FBC18K, FBC18KL
A3BC1-10200-up
A3BC1-20200-up
A3BC1-30200-up
A3BC1-40200-up
FBC20K, FBC25K
A3BC2-10200-up
A3BC2-20200-up
A3BC2-30200-up
A3BC2-40200-up
A3BC2-80200-up
FBC25KE, FBC25KL, FBC30K
A3BC3-10200-up
A3BC3-20200-up
A3BC3-30200-up
A3BC3-40200-up
A3BC3-80200-up
FBC30KL
A3BC4-40200-up
99759-74120
SAFETY PRECAUTIONS
Mitsubishi Forklift Trucks
Important Safety Information
Most accidents involving product operation, mainte- Mitsubishi Caterpillar Forklift America Inc. (MCFA)
nance and repair are caused by failure to observe cannot anticipate every possible circumstance that
basic safety rules and precautions. An accident can might involve a potential hazard. The warnings in this
often be avoided by recognizing potentially hazardous publication and on the product are therefore not all-
situations before an accident occurs. A person must inclusive. If a tool, procedure, work method or operat-
be alert to potential hazards. This person should also ing technique not specifically recommended by
have the necessary training, skills and tools to perform Mitsubishi Caterpillar Forklift America Inc. (MCFA) is
these functions properly. used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product
Improper operation, lubrication, maintenance or repair will not be damaged or made unsafe by the operation,
of this product can be dangerous and could result in lubrication, maintenance or repair procedures you
injury or death. choose.
Do not operate or perform any lubrication, maintenance The information, specifications, and illustrations in this
or repair on this product, until you have read and publication are on the basis of information available at
understood the operation, lubrication, maintenance the time it was written. The specifications, torques,
and repair information. pressures, measurements, adjustments, illustrations,
and other items can change at any time. These
Safety precautions and warnings are provided in this changes can affect the service given to the product.
manual and on the product. If these hazard warnings Obtain the complete and most current information
are not heeded, bodily injury or death could occur to before starting any job.
you or other persons.
Mitsubishi forklift truck dealers have the most current
The hazards are identified by the “Safety Alert Symbol” information available.
and followed by a “Signal Word” such as “CAUTION”
or “WARNING” as shown below.
! WARNING
The meaning of this “Safety Alert Symbol” is as follows:
Attention! Become Alert! Your Safety is involved.
The message that appears under the warning

explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are

identified by NOTICE labels on the product and in this
publication.
TABLE OF CONTENTS
1. GENERAL INFORMATION & FEATURES

Glossary............................................................................................................................... 1-1
Motor Options ...................................................................................................................... 1-5
Nameplate and Serial Number Locations............................................................................ 1-6
Features of the Control System........................................................................................... 1-7
Basics of Circuit Operation ................................................................................................. 1-8
Standard Display..................................................................................................................1-17
Premium Display..................................................................................................................1-18
Premium Display Set up Modes .........................................................................................1-19
Vehicle Monitoring System ..................................................................................................1-20
Traction Control Logic Flow Chart .......................................................................................1-21
General Maintenance Instructions .......................................................................................1-22
General Trouble Shooting Instructions ................................................................................1-24
2. PROGRAMMING
Handset .............................................................................................................................. 2-1
Operation ............................................................................................................................. 2-2
GE Sentry Set-up Procedures ............................................................................................. 2-2
Set-up Procedures............................................................................................................... 2-2
Function Settings ................................................................................................................. 2-4
Controller Setup...................................................................................................................2-15
Traction Controller Settings ................................................................................................2-16
Accelerator Setup ................................................................................................................2-23
Pump Controller Settings.....................................................................................................2-25
Memory Maps ......................................................................................................................2-30
Speedometer Setup.............................................................................................................2-34
3. CHECKS & REPAIRS

General Information ............................................................................................................. 3-1
Fuses .................................................................................................................................. 3-2
Exploded View of Contactor ................................................................................................ 3-3
Contactor Repair.................................................................................................................. 3-4
Truck Management Module ................................................................................................ 3-5
Thermal Transfer ................................................................................................................. 3-6
Traction Control ...................................................................................................................3-10
Trouble Shooting Tips (Motors) ..........................................................................................3-11
Unsatisfactory Brush Performance .....................................................................................3-12
Commutator Surfaces Conditions........................................................................................3-18
4. SX CONTROL CONNECTIONS & TROUBLESHOOTING

BY SYMPTOM
SX Control ........................................................................................................................... 4-1
Failures that Cause Reduced or No Motor Torque ............................................................. 4-2
Misoperation of Other Features .......................................................................................... 4-5
TABLE OF CONTENTS
5. WIRING
Traction Bypass with Pump Contactor Schematic ............................................................... 5-1
Pump Contactor Schematic.................................................................................................. 5-3
Traction Bypass with Pump Control Schematic ................................................................... 5-7
Pump Control Schematic...................................................................................................... 5-9
Traction Motor Controller with Pump motor Controller and Bypass.....................................5-11
Voltage Checks.....................................................................................................................5-13
TMM7A (Truck Management Module) .................................................................................5-16
Pump Driver..........................................................................................................................5-18
Pump Time Delay ................................................................................................................5-19
6. DIAGNOSTIC STATUS CODES

Basic Checks ....................................................................................................................... 6-1
Status Codes ........................................................................................................................ 6-2
GENERAL INFORMATION & FEATURES I
1. GENERAL INFORMATION & FEATURES

Glossary............................................................................................................................... 1-1
Motor Options ...................................................................................................................... 1-5
Nameplate and Serial Number Locations............................................................................ 1-6
Features of the Control System........................................................................................... 1-7
Basics of Circuit Operation ................................................................................................. 1-8
Display Standard. ................................................................................................................1-17
Display Premium..................................................................................................................1-18
Premium Display Set up Modes .........................................................................................1-19
Vehicle Monitoring System ..................................................................................................1-20
Traction Control Logic Flow Chart .......................................................................................1-21
General Maintenance Instructions .......................................................................................1-22
General Trouble Shooting Instructions ................................................................................1-24
GENERAL INFORMATION & FEATURES
Glossary
Accelerator Bypass (1A) Contactor, Traction

A device that converts mechanical movement into Switch that connects A2 traction motor cable to bat-
a voltage pattern to the logics for variable drive motor tery negative and bypasses the main power
speed. MOSFETs.
Activate Capacitor
A word used with a component or circuit. To change Device used to store electrical energy for short peri-
from the normal condition to the “activated” condition ods of time. Also used in filtering voltage noise and
because of an application of force or electricity. electrical spikes.
Cathode
Ammeter
The negative (–) side of a diode.
An electric meter used to measure current flow in
amperes. Circuit
Ampere (or Amp) A way for current to go from the positive (+) side of an
electrical power source to the negative (–) side of an
The unit of measure of current flow. The amount of electrical power source. This can be through wires
current that one volt can push through a resistance of and electrical components.
one ohm.
Closed Circuit
Anode
Wiring or components in a circuit that have continuity.
The positive (+) side of a diode.
Coil
Armature A component made from many circles or turns of wire
The rotating portion of an electric motor or generator. used to concentrate a magnetic field.
Battery Commutator
Two or more cells connected together for a supply of An armature component used to transfer current from
electric current. the brushes to the armature windings.
BDI (Battery Discharge Indicator) Compound Motor

An electrically controlled display showing the operator A motor which has a field winding in series with the
the state of battery charge. armature and a shunt field winding in parallel with the
series winding and armature.
BJT (Bipolar Junction Transistor)
Conduct
A transistor that is used to control voltage going to a
motor or other electrical device. To allow the flow of current.
Brush Conductor
A material that provides a path for current flow.
A conductor, normally a block of carbon, that makes
sliding contact between the stationary and moving part
Connector
of the motor or generator.
Part if a wire assembly or harness that connects with
Bus Bar another wire assembly or harness. Used for ease of
assembly and disassembly.
A heavy electrical conductor that carries high current
from one point to another and to which other smaller Contact Tips or Contacts
wires are connected.
The portion of a switch, relay or contactor where the
circuit can be opened or closed.
1-1
Glossary
Contactor Assembly Digital Signal

An electrical component consisting of an electro- A signal in which the elements may be either of two
magnetic coil and a set of heavy contact tips. Control distinct values. For example high voltage, low voltage.
current passes through the coil, building a magnetic
field which closes or opens the contact tips. Diode
A semiconductor device that allows current to flow in
Contactor Coil one direction, from the anode to the cathode.
An electromagnet used to close or open contact tips in
a contactor assembly. Display
An electrical device that converts voltage inputs to a
Continuity visual output.
Having the ability to allow current flow.
Drain
Control Circuits Terminal of a MOSFET through which the main cur-
The wires and components carrying low current used rent flows.
to signal the logics unit, turn on main components, or
support auxiliary circuits (indicated by thin lines on a Electric Motor
schematic). A device that changes electrical energy into
mechanical energy to do work.
Counter Electromotive
An opposing voltage set up by a collapsing or increas- Electrical Braking
ing magnetic field within a Force (CEMF) coil. Electrically trying to rotate the drive motor opposite to
the direction of truck movement.
Current
The movement or flow of electricity through a conductor. Electromagnet
A circuit must be complete for current to flow. A coil of wire, most often wound on an iron core,
which produces a strong magnetic filed when current
Current Limit is sent through the coil.
The maximum allowable current of a stalled drive
motor. Electromotive Force (EMF)
The force that causes an electric current to flow in a
Current Sensor circuit. This force is measured in volts.
A hall-effect sensor in the motor circuit that produces
an increasing voltage output as the motor current Field Effect Transistor (FET)
increases. A transistor in which the output current is varied by
varying the value of an electric field within a region of
Current Shunt the device.
A precision low-value resistor connected in series with
the armature of a motor. The logics uses the measured Field Windings
voltage drop across the shunt to control maximum The stationary coils that produce a magnetic field in
current allowed in selected power circuits. motors and generators.
Deactivate Filter
To change from the activated condition back to the An electrical device or component for restriction or
normal (deactivated) condition. It can be caused by suppression of undesired voltage spikes.
the application of force, the removal of force, or the
removal of electricity.
1-2
Glossary
Fuse Rotational Measure:

A component in an electrical circuit that will open the HP = Torque X Speed
circuit if too much current goes through it. 5252
• Torque in Foot - Pounds
Gate • Speed in revolutions per minute (RPM)
Terminal of a MOSFET to which voltage is applied to • 5252 is a Constant
turn the MOSFET on and off.
Indicator
Generator A lamp or LED that gives an indication of some vehi-
A device that transforms non-electric energy (such as cle condition when it turns on or flashes.
mechanical, thermal, etc...) into electrical energy.
Input
Grounded A voltage change at the incoming connection of a
A wire or wires that are in contact with the metal component.
chassis of the vehicle (ground). Can be caused by a
loss of insulation from the wire, or by connecting the Insulator
wire to the vehicle. A material that has a very large resistance so that it
will not let current flow through it.
Harness
An assembly made of two or more wires that are held LED
together. Light Emitting Diode - a diode that emits light (lights)
when current flows in the forward direction.
Heat Sink
A mounting frame used for semiconductor cooling. Logics or Logic Unit
The main printed circuit board containing a micro-
Heat Sink Pad processor and circuits to condition the voltage signals
Thin metal sheet sandwiched between the heatsink of that go into or come out of the logics. It electronically
a controller and the frame of the truck used to better monitors and controls the truck’s functions.
transfer the heat away from the controller.
Magnetic Field
Hour Meter The area around a magnet where magnetic forces can
An electrically activated device used to record the be detected.
amount of usage a truck receives.
Microprocessor
Horse Power A small computer chip preprogrammed to control the
A measure of the time-rate of doing work. 1 HP is various electrical functions on a lift truck.
defined as the equivalent of raising 33,000 pounds,
one foot, in one minute.
MOSFET
(Metal Oxide Semiconductor Field Effect
Linear Measure: Transistor)
A fast switching transistor that is used to control volt-
HP = Force X Distance age going to a motor or other electrical device.
33,000 X Time
• Force in Pounds Normal Condition
• Distance in Feet Words used with a switch or relay. Their normal condi-
• Time in Minutes tion is their condition when they are not controlled by
• 33,000 is a Constant the application of force, temperature, pressure, or elec-
tricity.
1-3
Glossary
Normally Closed (N.C.) Surface Voltage or Charge

Generally present just after the battery is unplugged
A switch or relay whose contacts are closed in the
from the charger.
normal condition.
Terminal
Normally Open (N.O.)
An electrical connection point on an electrical
A switch or relay whose contacts are open in the
component.
normal condition.
OFF-Time Transistor
The amount of time a current does not flow through a A semiconductor device used as an electronic
semiconductor. switch.
Ohm Torque
The unit of measurement of resistance. The amount of The turning force or effect required to do work.
resistance that will let one volt push only one ampere Torque = Force X Distance
of current through it, where R = E / I.
• Force in Pounds
• Distance in Feet to center of rotation
ON-Time
The amount of time current flows through a transistor.
Varistor
Open Circuit An electrical filter that is usually terminated across the
horn connections of a mechanical horn to eliminate
Wiring or components of a circuit that have no
voltage spikes when the horn is activated.
continuity.
Optical Switch Volt

An electronic device made up of an infrared light The unit of measurement of electromotive force. One
signal generator and photosensitive signal receiver volt is the force needed to make one ampere of cur-
that changes an input digital voltage into an electrical- rent flow through one ohm of resistance in a circuit.
ly isolated digital voltage output.
Watt
Output The unit of measurement of power. The amount of
The current flow from a component which initiated power used when one volt pushes one ampere of
from a voltage change at the component’s input. current through a resistance of one ohm. The result of
amperes (current) multiplied by volts (voltage) is watts
PTC (Positive Thermal Coefficient Resistor) (power).
A resistor that is used in parallel with the tips of the
line contactor to allow the main capacitors in the con- Wire
troller to charge quicker after the battery is plugged in. A conductor used to provide a path for current to flow
As the PTC conducts current, it heats up and its resis- to and from electrical components.
tance increases. Each controller has an internal PTC
that will slowly charge the main capacitors if the exter- Wiring Diagram
nal PTC fails. A drawing using visual representation of components
the way they actually look. It is used to show the
Resistance locations of components and the connections between
Opposition to the flow of current in a circuit. The unit them.
of electrical resistance is the OHM. The lower the
resistance, the greater the current flow for a given Zener Diode
voltage.
A special diode used to regulate voltage or as an
Source overvoltage protector.
Terminal of a MOSFET through which the main current
flows.
1-4
MOTOR OPTIONS
MODEL SERIAL # TRACTION MTR HYD PUMP MTR
FBC15K, FBC18K & FBC18KL A3BC1-10200-up 8" 6.62"
FBC15K, FBC18K & FBC18KL A3BC1-20200-up 9" 6.62"
FBC15K, FBC18K & FBC18KL A3BC1-30200-up 8" 8"
FBC15K, FBC18K & FBC18KL A3BC1-40200-up 9" 8"
FBC20/25K A3BC2-10200-up 9" 8"
FBC20/25K A3BC2-20200-up 11" 8"
FBC20/25K A3BC2-30200-up 9" 9"
FBC20/25K A3BC2-40200-up 11" 9"
FBC20/25K A3BC2-80200-up 11" 9"
FBC25KE/KL/30K A3BC3-10200-up 9" 8"
FBC25KE/KL/30K A3BC3-20200-up 11" 8"
FBC25KE/KL/30K A3BC3-30200-up 9" 9"
FBC25KE/KL/30K A3BC3-40200-up 11" 9"
FBC25KE/KL/30K A3BC3-80200-up 11" 9"
FBC30KL A3BC4-40200-up 11" 9"
1-5
Nameplate and Serial Number Locations
Nameplate
Chassis
Serial
Number
Mast Serial Number
Hydraulic Motor Power Steering Motor

Serial Number Serial Number
Traction Motor
Serial Number
For Illustrative Purposes Only
Before Servicing Forklift Truck
! WARNING
Before doing any maintenance or adjustments
on the Forklift Truck, be sure to always use correct
blocks to prevent the unit from rolling or falling.
Raise the drive wheels off the ground. This can be
done by tilting the mast all the way back, placing
hard wood blocks under the mast then tilting
the mast forward. Securely support with blocks.
1-6
◆ GE SX Control System Features
The GE SX control monitors over seventy dif-

ferent system functions. Run-time fault condi-
tions, when sensed, are indicated on the steer-
ing console display.
Mode/Fault Code Buttons
Fault Code Display Sequence
Run-time Diagnostics When the truck key is switched off, the display
shows truck hours, drive motor hours, and
pump motor hours for four seconds each. At
this point the mode buttons can be used to
activate a display sequence of faults that
caused the forklift truck to shut down. For
details see instrument panels sections for
both standard and premium displays.
Mode/Fault Code Button
During truck start up or operation, a diagnostic

code could appear on the display instead of the
battery state of charge. If the GE SX Control
Mode Buttons
System detects a problem, the ! symbol glows
in the monitoring system action lights at the
same time. The codes indicate an improper Programmable Truck Operating Modes
operating sequence or a defect in the truck The GE SX Control System also allows users
electrical system. to modify how the truck operates for condi-
tions where the truck is used. The operator
can select from four operating modes.:
Run-time diagnostics cover the following areas
of truck operation and protection: 1. Economy – slowest travel speed and
acceleration.
• Drive motor and pump motor hours
2. Moderate – travel speed and acceleration
• Service reminder hours
somewhat slower than standard.
• Battery discharge level
3. Standard – travel speed and acceleration
• Motor brush wear (Premium Display Only)
suitable for the broadest range of applica-
• Stall protection
tions.
• Over-temperature protection of drive motor,
4. High – Highest travel speed and accelera-
pump motor, and the control panel
tion.
• Brake fluid level
Each time the key is switched off then on
again the controller remains in the previously
selected mode.
Operating Mode details differ depending on
the display type. See the sections on Standard
and Premium Instrument Panels for more
information.
1-7
Basics of Circuit Operation
Motor Characteristics
Historically, most electric vehicles have relied on to normal full load on level ground is less than 10%.
series motor designs because of their ability to pro- For this reason, shunt motors are considered to be
duce very high levels of torque at low speeds. But, constant speed motors (Figure 2).
as the demand for high efficiency systems increases, In the separately excited motor, the motor is operated
i.e., systems that are more closely applied to cus-
tomers’ specific torque requirements, shunt motors
are now often being considered over series motors. SPEED
In most applications, by independently controlling the
NO LOAD CURRENT
field and armature currents in the separately excited
LOAD CURRENT
STARTING
CURRENT
motor, the best attributes of both the series and the
FULL
shunt wound motors can be combined.
As shown in from the typical performance curves of
TORQUE
ARMATURE CURRENT
NO LOAD CURRENT
SPEED
Figure 2
LOAD CURRENT
STARTING
CURRENT
FULL
as a fixed field shunt motor in the normal running

range. However, when additional torque is required,
TORQUE for example, to climb non-level terrain, such as
ramps and the like, the field current is increased to
ARMATURE CURRENT provide the higher level of torque. In most cases, the
Figure 1 armature to field ampere turn ratio can be very simi-
lar to that of a comparable size series motor (Figure
3.)
Figure 1, the high torque at low speed characteristic
of the series motor is evident.
In a shunt motor, the field is connected directly SPEED

across the voltage source and is therefore indepen-
LOAD CURRENT
dent of variations in load and armature current. If

NO LOAD CURRENT
FULL
field strength is held constant, the torque developed

will vary directly with the armature current. If the
STARTING
CURRENT
mechanical load on the motor increases, the motor

slows down, reducing the back EMF (which depends
on the speed, as well as the constant field strength). TORQUE
The reduced back EMF allows the armature current
to increase, providing the greater torque needed to ARMATURE CURRENT
drive the increased mechanical load. If the mechani- Figure 3
cal load is decreased, the process reverses. The
motor speed and the back EMF increase, while the
armature current and the torque developed decrease.
Thus, whenever the load changes, the speed Aside from the constant horsepower characteristics
changes also, until the motor is again in electrical described above, there are many other features that
balance. provide increased performance and lower cost. The
following description provides a brief introduction to
examples of some of these features.
In a shunt motor, the variation of speed from no load
1-8
Solid-State Reversing Flexible System Application
The direction of armature rotation on a shunt motor is Because the shunt motor controller has the ability to
determined by the direction in which current flows control both the armature and field circuits indepen-
through the field windings. Because the shunt motor dently, the system can normally be adjusted for maxi-
field only typically requires about 10% of the arma- mum system efficiencies at certain operating parame-
ture current at full torque, it is normally cost effective ters. Generally speaking, with the ability of indepen-
to replace the double-pole, double-throw reversing dent field and armature, the motor performance curve
contactor with a low power transistor H-Bridge circuit can be maximized through proper control application.
(Figure 4).
By energizing the transistors in pairs, current can be More Features with Fewer Components
Field weakening with a series wound motor is

LINE POS
accomplished by placing a resistor in parallel with the
FUSE
field winding of the motor. Bypassing some of the
Q5
Q3
current flowing in the field into the resistor causes the
A1 +
ARM F1 F2
field current to be less, or weakened. With the field
CAP Q2
A2 - weakened, the motor speed will increase, giving the
Q4 Q6 effect of “overdrive”. To change the “overdrive
Q1 speed”, it is necessary to change the resistor value.
In a separately excited motor, independent control of
the field current provides for infinite adjustments of
“overdrive” levels, between motor base speed and
NEG
maximum weak field. The desirability of this feature is
Figure 4
enhanced by the elimination of the contactor and
resistor required for field weakening with a series
made to flow in either direction in the field. The arma- motor.
ture control circuit typically operates at 12KHZ to
15KHZ, a frequency range normally above human With a separately excited motor, overhauling speed
hearing. This high frequency coupled with the elimi- limit, or downhill speed, will also be more constant.
nation of directional contactors, provides very quiet By its nature, the shunt motor will try to maintain a
vehicle operation. The field control circuits typically constant speed downhill. This characteristic can be
operate at 2 KHZ. enhanced by increasing the field strength with the
control. Overhauling load control works in just the
The line contactor is normally the only contactor opposite way of field weakening, armature rotation
required for the shunt motor traction circuit. This con- slows with the increase of current in the field.
tactor is used for both pre-charge of the line capaci-
tors and for emergency shut down of the motor cir- Regenerative braking (braking energy returned to the
cuit, in case of problems that would cause a full battery) may be accomplished completely with solid-
motor torque condition. The line can be energized state technology. The main advantage of regenera-
and de-energized by the various logic combinations tive braking is increased motor life. Motor current is
of the vehicle, i.e. activate on key, seat or start switch reduced by 50% or more during braking while main-
closure, and de-energize on time out of idle vehicle. taining the same braking torque as electrical braking
Again, these options add to the quiet operation of the with a diode clamp around the armature. The lower
vehicle. current translates into longer brush life and reduced
motor heating. Solid state regenerative braking also
eliminates a power diode, current sensor and contac-
tor from the circuit.
1-9
FEATURES OF SX FAMILY OF TRANSISTOR Handset. The C/L setting is based on the maximum
MOTOR CONTROLLERS thermal rating of the control. Because of the flyback
current through Q2, the motor current is usually
Standard Operation greater than battery current, except at 100% ON
time.
With the accelerator at maximum ohms or volts, the
creep speed can be adjusted by Function 2 of the
Handset or a trimpot. The field control section allows Regenerative Braking to Zero Speed
the adjustment of the field weakening level in order to
set the top speed of the motor. This top speed func- Slow down is accomplished
tion (Minimum Field Current) is enabled when the when reversing direction by
armature current is less than the value set by providing a small amount of
Function 24 and the accelerator pedal is fully retarding torque for decelera-
depressed. Top Speed can be adjusted by Function 7 Q2
tion. If the vehicle is moving,
of the Handset or a trimpot. ARM
and the directional lever is
The percent on-time has a range of approximately 0 moved from one direction to
to 100 percent. The SX controllers operate at a con- the other, the regen signal is
stant frequency and the percent on-time is controlled Q1
initiated. Once the regen signal
by the pulse width of the voltage / current applied to has been initiated, the field cur-
Figure 5
the motor circuits. rent is increased (armature cir-
cuit shown in Figure 5).
Creep Speed Armature current is regulated
to the regen current limit as set
With the accelerator at minimum volts, the creep by Function 9. As the vehicle slows down, the field
speed can be adjusted by Function 2 of the Handset. current continues to increase, and transistor Q2
At creep speed, the ON time can decrease to begins to chop. The field current will increase until it
approximately 5%, with the OFF time at approximate- reaches a preset value set by Function 10, and tran-
ly 95%. At full transistor operation, this condition will sistor Q2 on-time will increase until it reaches 100%
be reversed (short OFF time, long ON time). This on-time. Once both of the above conditions have
variation of ON and OFF time of the oscillator varies been met, and regen current limit can no longer be
the voltage applied to the motor, thereby varying the maintained, the braking function is canceled. The
speed of the motor for a given load. fields will then reverse, and the control reverts back
to motoring.
Control Acceleration Part of the energy produced by the motor during
regen is returned to the battery, and part is dumped
This feature allows for adjustment of the rate of time in the motor as heat.
it takes for the control to accelerate to 100% applied
battery voltage to the motor on hard acceleration. Pedal Position Regenerative Braking
Armature C/A is adjusted by Function 3 from 0.1 to
22 seconds. This feature allows control of the stopping distance
based on pedal position when there has been a
Current Limit “directional switch” change. Pedal position will reduce
the regenerative current to as the accelerator is
This circuit monitors motor current by utilizing sen- returned to the creep speed position. Maximum
sors in series with the armature and field windings. regenerative current is obtained with the accelerator
The information detected by the sensor is fed back to in the top speed position.
the card so that current may be limited to a pre-set
value. If heavy load currents are detected, this circuit
overrides the oscillator and limits the average current
to a value set by Function 4 and Function 8 of the
1-10
Auto Braking slowly down the grade when the accelerator or brake
is released. Because the vehicle can gain significant
This feature is enabled by initiating a “neutral posi- speed during roll-back, the torque needed to re-start
tion” using either the directional switch or the acceler- on the ramp is lower than an unrestricted roll-back
ator switch. Once activated, Auto Braking operates speed.
similar to Pedal Position Regenerative Braking and is
adjusted by using Function 21 of the Handset. Steer Pump Contactor Time Delay
Field Weakening This feature provides two options for SP time delay.
Option 1 provides a 0.5 to 63 second time delayed
This function allows the adjustment of the field weak- drop out of the steer pump contactor when the
ening level in order to set the top speed of the motor. Forward or Reverse directional switch is opened.
The function is enabled when the armature current is This is the default option for function 18. This Option
less than the value set by Function 24 and the accel- 1 is overridden by a 1.5 second time delayed drop
erator pedal is fully depressed. It is important to note out whenever the seat switch is opened. Option 2
that this function is used to optimize motor and con- provides a 0.5 to 63 second time delayed drop out of
trol performance, and this setting will be determined the SP contactor when the seat switch is opened.
by MCFA engineers at the time of vehicle develop-
ment. This setting must not be changed by field per- Static Return to Off (SRO)
sonnel, without the permission of MCFA Service
Engineering. This inherent feature of the control is designed to
require the driver to return the directional lever to the
Speed Limits neutral position anytime he leaves the vehicle and
returns. Additionally, if the seat switch or key switch
This feature provides a means to control speed by is opened, the control shuts off and cannot be
limiting motor volts utilizing three “adjustable speed restarted until the directional lever is returned to neu-
limits. This motor volt limit regulates top speed of the tral. A time delay of approximately 2 seconds is built
transistor controller, but actual truck speed will vary into the seat switch input to allow momentary open-
at any set point depending on the loading of the vehi- ing of the seat switch, if a bump is encountered.
cle. Each speed limit can be adjustable with the
Handset using Functions 11, 12, and 13.
Accelerator Volts Hold Off
Ramp Start
This feature checks the voltage level at the accelera-
This feature provides maximum control torque to tor input whenever the key switch or seat switch is
restart a vehicle on an incline. The memory for this activated. If, at start up, the accelerator is calling for
function is the directional switch. When stopping on more than 20% of full speed, the control will not
an incline, the directional switch must be left in its operate. This feature assures that the control is call-
original or neutral position to allow the control to initi- ing for low speed operation at start up.
ate full power when restarted. The accelerator poten-
tiometer input will modulate ramp start current.
Roll-Back Control
This feature provides retarding torque to limit rollback

speed in the non-travel direction when the accelera-
tor pedal is released when stopping on a grade, or
when the brake pedal is released when starting on a
grade. This feature forces the vehicle to roll very
1-11
Pulse Monitor Trip (PMT) Systems Diagnostics
The PMT design contains three features which shut The control detects the system’s present operating
down, or lock out, control operation if a fault condi- status and can be displayed to either the Dash
tions occurs that would cause a disruption of normal Display or the Handset. There are currently over 70
vehicle operation: status codes that are available with SX systems
using Traction and Pump controls and Truck
• Look ahead Management Module (TMM). Along with the status
• Look again code display from the TMM, the SX control is capable
• Automatic look again and reset of reducing the current to the motor, alerting the
operator of a critical fault condition.
The PMT circuit will not allow the control to start
under the following conditions:
Standard Status Codes
• The control monitors both armature and field FET’s
at start-up and during running. The SX traction control has over 30 Status Codes
• The control will not allow the line contactor to close that assist the service technician and operator in
at start-up, or will drop it out during running, if trouble shooting the vehicle. If mis-operation of the
either the armature or field FET’s are defective, so vehicle occurs, a status code will be displayed on the
as to cause uncontrolled truck movement. Dash Display for vehicles so equipped, or be avail-
able by plugging the Handset into the “P2 or P4” plug
Thermal Protector (TP) of the logic card.
With the status code number, follow the procedures
This temperature sensitive device is mounted to the outlined in DIAGNOSTIC STATUS CODES to deter-
heat sink of the power transistor (Q1). If the transis- mine the problem and a solution.
tor’s temperature begins to exceed the design limits,
the thermal protector will lower the maximum current Note: The Status Code Instruction Sheets do not
limit, and maintain the transistors within their temper- claim to cover all possible causes of the display of a
ature limits. Even at a reduced current limit, the vehi- “status code”. They do provide instructions for check-
cle will normally be able to reach sufficient speed. As ing the most direct inputs that can cause status
the control cools, the thermal protector will automati- codes to appear.
cally reset, returning the control to full power.
Stored Status Codes
This feature records the last 16 “Stored Status

Low Voltage Codes” that have caused a PMT controller shut down
and/or disrupted normal vehicle operation. (PMT type
Batteries under load, particularly if undersized or faults are reset by cycling the key switch). These sta-
more than 80 percent discharged, will produce low tus codes, along with the corresponding BDI and
voltages at the control terminals. The SX control is hourmeter readings, can be accessed with the
designed for use down to 50 percent of a nominal Handset, or by using the RS 232 communications
battery voltage of 36-84 volts, and 75 percent of a port and dumping the information to a Personal
nominal battery voltage of 24 volts. Lower battery Computer terminal.
voltage may cause the control to operate improperly,
however, the resulting PMT should open the Line
contactor, in the event of a failure. Hourmeter Readings
This feature will display the recorded hours of use of

the traction and pump control or contactor to the
Dash Display each time the key switch is turned off.
1-12
Maintenance Alert & Speed Limit tactor coils. On command from the control card,
these drivers initiate opening and closing the contac-
This feature is used to display Status Code 99 and/or tor coils. All driver modules are equipped with reverse
activate a speed limit when the vehicle operating battery protection, such that, if the battery is connect-
hours match the hours set into the maintenance alert ed incorrectly, the contactors can not be closed elec-
register. This feature is set with the Handset using trically.
Functions 19 and 20. The operator is alerted that
maintenance on the vehicle is required. This function Truck Management Module (TMM)
can be disabled be setting functions 19 & 20 to a
value of 255. The Truck Management Module is a multifunction
accessory card, or an integral function of the GE
Battery Discharge Indication (BDI) Pump controls when used with the SX Traction con-
trol. The Module provides the OEM the ability to initi-
The latest in microprocessor technology is used to ate status codes or operator warning codes to be dis-
provide accurate battery state of charge information played on the Dash Display, whenever a normally
and to supply passive and active warning signals to open switch or sensor wire provides a signal to the
the vehicle operator. Features and functions: Module.
• Displays 100 to 0 percent charge.
• Display blinks with 20% charge. Disables pump cir- The TMM Module can be used to display a separate
cuit with 10% charge. Auto ranging for 36/48 volt status code indicating over-temperature of traction
operation. Adjustable for use on 24 to 80 volts. motors, hydraulic motors, or any other device or sys-
tem that can activate a switch that closes.
Internal Resistance Compensation
The TMM Module can also be used as a Brush Wear
This feature is used when the Battery Discharge Indicator (BWI). The Brush Wear Indicator is
Indicator is present. Adjustment of this function will designed to detect a “worn out brush” and display a
improve the accuracy of the BDI. Improper adjust- fault code on the Dash Display to warn maintenance
ment can cause the battery to be over discharged. personnel that the motor brushes need to be
replaced before they wear to the point of causing
destructive damage to the motor commutator surface.
Display Modes
The Dash Display allows the operator to select the Hydraulic Pump Control
best vehicle performance for changing application
(task) conditions. There are four (4) modes that can This hydraulic motor controller consists of the follow-
be selected by depressing a push button on the dash ing features:
display.(SEE SECTION ON DISPLAY) • Four speeds, adjustable from 0 to 100% motor
volts. Fixed speeds actuated by switch closure to
From the Display, the operator may select any of four negative.
pre-set interactive modes consisting of (4) Controlled • Current limit and controlled acceleration adjustable.
Acceleration levels, (4) Auto Regen levels, (4) Lever • Battery Discharge Indicator interrupt compatible.
Regen Levels and (4) Speed Limits.
These interactive modes are “pre-set” using the Operation of voltage regulator card: This card pro-
Handset (Functions 48-63) or a personal computer vides the basic functions required for controlling the
(Functions 97-112). This feature allows the operator pump control, optional contactors, and PMT func-
to select the best vehicle performance for changing tions. Battery positive is applied through a main con-
application (task) conditions. trol fuse to the key switch, energizing the control card
power supply input to P1.
Circuit Board Coil Driver Modules When a pump line contactor (PL) is used, PMT oper-
ation is the same as outlined for the traction con-
Coil drivers are internal to the control card, and are trollers.
the power devices that operate the Line and SP con-
1-13
The four speed (motor volts) reference points P12,
P19, P20 and P21 are selected by connecting these
points independently to battery negative.
The speed for the Auxiliary functions (Aux1/Aux2) is

obtained by closing speed limit 1(SL1) at P1-12 to
control negative. SL1 is adjustable by Function 11
using the Handset to adjust motor voltage from 0 to
100%. The specified motor volts will be regulated,
however, the magnitude of motor current will vary
depending on the loading of the vehicle.
The speed for the first lift function (Lift0) is obtained

by closing Speed Limit 2 (SL2) at P1-19 to control
negative. SL2 is adjusted using the Handset and
Function 12, similar to SL1.
The speed for the tilt function (Tilt) is obtained by

closing speed limit 3 (SL3) at P1-20 to control nega-
tive. SL3 is adjusted using the Handset and Function
13, similar to SL1.
The speed for the second Lift function (Lift 1) is

obtained by closing speed limit 4 (SL4) at P1-21 to
control negative. SL4 is adjusted using the Handset
and Function 14, similar to SL1.
If more than one Speed Limit is activated, the select-

ed speed with the highest motor volts will override
the low motor volt speed. The current limit circuit is
adjustable and operates the same as the traction cur-
rent limit.
The controlled acceleration circuit is adjustable and

operates the same as the traction circuit. Adjustment
range is from 0.1 to 22.0 seconds.
The Battery Discharge Indicator (BDI) interrupt will

disable the hydraulic controller if the connection at
P10 loses the 12 volt signal from the traction control.
BDI interrupt can be disabled by Function 17 using
the Handset. Select card type with or without BDI
function.
1-14
GE Information for Separately Excited Controls
Example:
Part Number: IC3645 SE 4 D 33 2 C3

Argument Number: 01 02 03 04 05 06 07
Argument 01: Basic Electric Vehicle Control Number
Argument 02: Control Type:
SP = Series Control (Pump)

SH = Separately Excited Control (Plugging)
SR = Separately Excited Control (Regen to Zero)
Argument 03: Operating Voltage:
1 = 120 volts 4 = 48 volts

2 = 24 volts 5 = 36/48 volts
3 = 36 volts 6 = 24/36 volts
7 = 72/80 volts
Argument 04: Package Size:
D = 6.86" X 6.67"
R = 6.86" X 8.15"
U = 8.66" X 8.13"
W = 8.66" X 10.83"
Argument 05: Armature Current

(2 characters)
22 = 220 Amps
33 = 330 Amps
40 = 400 Amps
etc.
Argument 06: Field Current

(1 character)
2 = 20 Amps
3 = 30 Amps
4 = 40 Amps
etc.
Argument 07: Customer / Revision
A1 = Customer A / Revision 1
B1 = Customer B / Revision 1
etc.
1-15
Standard Display Operation: Premium Display Operation:
All segments on the display should turn on and the All segments on the LCD display and the Vehicle
Vehicle Monitoring System Action Lights should Monitoring System Action Lights should light in a
light in a left to right chaser pattern. Then the seat chaser pattern from left to right. The seat belt icon
belt icon should flash for 10 seconds (regardless of should flash for 10 seconds (regardless of whether
whether the seat belt is fastened or not). The 7-seg- the seat belt is fastened or not). The time display
ment display should show the currently selected area should show the currently selected operating
operating mode level, L1 through L4. mode for the drive motor controller and pump motor
controller, D1-4 and P1-4.
The 7-segment display should read the battery The battery charge display area should show the
state of charge in percentage format. This is a battery state of charge, and the time display area
numeric value between zero and one hundred should display either the time or date, whichever is
using the 3 rightmost digits. selected.
NOTE: When the battery reaches a 20% state of NOTE: When the battery reaches a 20% state of
charge the battery action light will flash continu- charge the battery action light will flash continu-
ously. At 10% charge the light remains on. ously. At 10% charge the light remains on.
For both the Premium and Standard display options: If the display shows a fault code instead of the battery
state of charge, this means a run-time fault has been detected. The fault must be corrected before you use the
the forklift truck. See the sections on the Premium and Standard Displays for more information on run time
fault codes.
1-16
STANDARD DISPLAY
Battery Discharge Indicator/

Hour Meter/Fault Code
Indicator (for Run-time
Diagnostics)
Monitoring
System Action
Lights
Mode/Fault History Button
Battery Discharge Indicator ed, the fault code, battery state of charge, and truck power
The 7-segment Light-Emitting Diode (LED) numeric display steering pump hours are displayed for 3 seconds each. If
indicates the percentage of battery charge. When the num- the Pump Controller History Folder is selected, the display
ber “100” appears, the battery is fully charged. cycles through the fault code and pump controller hours for
three seconds each. Pressing the Mode/fault History Button
cycles the display to the next fault. The displayed item blinks
Hour Meter briefly (to acknowledge the button having been depressed)
Immediately after the key is turned to the off position, the before changing to the next fault. Releasing the button
numeric display enters the Hour Display Mode for 12 sec- when the display is blank or turning the key switch to the on
onds. Truck hours, drive motor hours, and pump motor position, exits History Mode. If a pump controller is not
hours are consecutively displayed for 4 seconds each. installed, holding the button switches the display between
Once the Hour Meter display cycle is complete, the display “d” and a blank screen. Accessing the history folder for the
goes blank and enters Silent Mode. drive controller and exiting History Mode require the same
actions as if the unit was equipped with a pump controller.
Mode/ Fault History Button

Fault Code Indicator
Press and hold this button with the key switch on, to access
the performance mode. For the first 2 seconds the button is A fault code will be displayed if a run-time fault is detected
held, the current operating mode will be displayed in “Lx” by the monitoring system. In addition, the Fault Code
format using the 2 right most digits, where “x” is a numeric Indicator will light.
value between one and four. If the performance mode A drive controller fault is displayed in an “-xx” format(where
received from the controller is outside this range, the mode “x” is a number from 0 to 9). A pump controller fault is dis-
is displayed as “L=”. If the mode cannot be read at all, the played in a “-1xx” format. If the fault code received is out of
mode is displayed as “LC”. Continuing to hold the button will range “===” is displayed.
cycle the display through the 4 performance levels. To
select a new mode, release the button when the desired
mode is displayed. This button is also used to access and Monitoring System Action Lights
navigate History Mode. These symbols light when specific problems are detected.
The truck should be stopped and corrective action should
be taken immediately. These lights are identical for both the
History Mode Standard and Premium Instrument Panels and will be
While in Silent Mode, the user can access the history of the detailed later.
last 16 truck fault codes by pressing and holding the
Mode/fault History Button. Unit behavior is then dependent
on whether the truck is equipped with a pump controller or
not. If equipped with the pump controller, hold the button
cycles through a display of “d”, “P”, and a blank screen.
Releasing the button on the “d” or “P” accesses the history
folder for either the drive controller or pump controller
respectively. If the Drive Controller History folder is select-
1-17
◆ Premium Display
Drive Motor Icon

Brush Wear Indicator
Pump Motor Icon
Battery Discharge
Indicator
Speed Display/Performance
Mode Indicator/ Fault Code
Indicator
Truck Icon
Monitoring
System Action
Lights
History/Date/
Time Display
Right Mode Button
Left Mode
Button
Battery Discharge Indicator Hour Meter

The Battery Charge Display Area shows the current battery Immediately after the key is turned to the off position, the
state of charge on its bar graph in 10% increments. numeric display enters the Hour Display Mode for 12 sec-
onds. Truck hours, drive motor hours, and pump motor
hours are consecutively displayed along with their corre-
Time Display sponding icon for 4 seconds each.
The Time Display Area can either show the time or date.
Simultaneously depressing both Mode Buttons will switch
the display between the time and date. For details on how History Display
to set the time and date see the Setup Mode section. After the hour display cycle is complete the truck enters
Silent Mode. No activity is shown on the display or indica-
tors when the truck is in this mode. By pressing the left or
Speed Display right buttons, History Display can be accessed for either the
The Speed Display Area shows the current speed in either drive motor control or the pump motor control respectively.
MPH or KPH depending on the unit mode. The appropriate The corresponding motor icon illuminates to indicate which
MPH or KPH symbol is also lit to indicate which mode is history folder is being accessed. Regardless of which is
active. For details on how to select a desired system of accessed, the display behaves the same way. The Speed
units, see the Setup Mode section. Display Area displays the most recent fault code. The time
display area cycles through 4 different items: battery state
of charge, truck or pump hours, time, and date of the dis-
played fault. Pressing either button will cycle to the next
fault in the history folder, and the display will blink briefly
each time a button is pressed.
1-18
◆ Premium Display continued
Start-Up Setup Modes
Once the key is turned on, the display enters a self test Setup Mode is accessed by pressing both mode buttons
mode. All segments on the Liquid Crystal Display (LCD) and simultaneously while the display is in Silent Mode. If the but-
indicators are turned on in a left-to-right chaser pattern. After tons are released within 10 seconds, Regular Setup Mode
the self test is complete, the seat belt light will blink for 10 is accessed. If the buttons are held for longer than 10 sec-
seconds regardless of whether the seat belt is fastened. onds, the display blanks for 5 seconds and then enters
Also, the currently selected drive controller and pump con- Speed Sensor Setup Mode.
troller performance modes are displayed in an “dx_Py” for- In Regular Setup Mode the units system (imperial or metric)
mat where “x” and “y” are numeric values between 1 and 4. and the date and time can be set. Pressing the right button
If the performance mode information from either controller is toggles between metric (indicated by KPH icon) and imper-
outside of this range, “=” will be displayed instead of a num- ial (MPH icon). Pressing the left button selects the currently
ber. If the performance mode information cannot be read, flashing mode and advances to the time setup mode. The
“dC” or “PC” will be displayed. time is displayed in the Time Display Area with the hours
flashing. The right mode button changes the hour and the
Left Mode Button left mode button accepts the currently displayed hour. The
minutes will then flash and can be set in the same manner.
Pressing this button accesses the drive performance display AM and PM are set next if the unit is in imperial mode. Once
mode. The drive motor icon illuminates and the current drive the time is set, the display switches to the current date. Date
motor mode is displayed in the Speed Display Area. setup is identical to time setup, cycling through year, month,
Pressing this button a second time within 4 seconds access- and day respectively. To exit Regular Setup Mode, press
es the pump performance display mode and lights the pump both the left and right buttons simultaneously.
motor icon. To return to normal operating mode press this
button again. After 4 seconds, the performance display In Speed Sensor Setup Mode the current speed sensor set-
mode is exited automatically if no other buttons are ting flashes in the Speed Display Area. To scroll through the
depressed. This button also has several other functions available speed settings, press and release the right mode
described in other sections. button. Press the left mode button when the desired speed
setting is displayed. The selected setting will stop flashing
and both mode buttons must then be depressed to select
Right Mode Button the setting.
This button allows the user to change the current perfor- The Speed Sensor mode must be adjusted according to the
mance mode. By holding down this button while in either the gear ratio and tire diameter. Settings 1 through 12 are for
drive performance display mode or pump performance dis- the 2 or 3 ton gear ratio and settings 14 through 25 are for
play mode the unit will cycle through each available mode. the 1 ton gear ratio. If the truck has new, standard tires with
Releasing the button while the desired mode is displayed no wear yet, a setting of 5 should be used on 2 or 3 ton
will switch the unit to that mode. This button has several trucks and a setting of 18 should be used on 1 ton trucks.
other functions described in other sections.
Brush Wear Indicator Icon
Fault Code Indicator This icon lights if the system detects that either the drive or
A fault code will be displayed in the Speed Display Area if a pump motor brushes are worn and need to be replaced. The
run-time fault is detected by the monitoring system. In addi- corresponding motor icon (drive or pump) is illuminated with
tion, the Fault Code Indicator and any applicable icons will this icon.
light.
Monitoring System Action Lights

These symbols light when specific problems are detected.
The truck should be stopped and corrective action should
be taken immediately. These lights are identical for both the
Standard and Premium Instrument Panels and are detailed
following the Standard Instrument Panel section of this
manual.
1-19
◆ Vehicle Monitoring System – Action Lights
1 2 3 4 5 6 7
1. Service Due Action Light 5. Brake Fluid Action Light

The wrench symbol lights when it is time for planned main- The brake fluid symbol lights if the brake fluid reaches a
tenance. The maintenance interval can be programmed into predetermined low level.
the GE SX Control System tp provide reduced drive perfor-
mance when activated.
6. Park Brake Action Light
2. Seat Belt Warning Action Light The park brake symbol lights when the park brake is
applied. Do not drive the forklift truck with the park brake
The seat belt symbol flashes for the first 10 seconds after applied.
the key is turned on regardless of whether the seatbelt is
fastened.
7. Fault Detection Light
3. Over Temperature Action Light The fault code symbol lights whenever a fault code is being
displayed. When some faults are detected, the truck shuts
The thermometer symbol glows if an over-temperature con- downs and cannot be operated until the cause of the fault is
dition develops in the drive motor, pump motor, or the con- repaired.
troller. Reduced truck drive performance can be pro-
grammed into the GE SX Control System.
4. Battery Charge Action Light

The battery symbol flashes if the battery reaches the 20%
charge level. If the charge level drops below 10%, the sym-
bol glows solid. Reduced truck drive and/or lift performance
can be programmed into the GE SX Control System.
1-20
Traction Control Logic Flow Chart For Normal Operating Conditions

Connect
Battery
Battery Positive @
P1-1
Close Key Switch
Battery Positive @
P1-2
Close Seat Switch
Line contactor closes

and battery positive @
control P, A1, A2 and F1
Circuit is energized to
allow inputs from direc-
tion lever and accelerator
Select forward or
reverse
Power Steer contac-

tor closes
Depress accelerator
which closes acceler-
ator start switch
Voltage from accelerator

potentiometer is applied
to controller
The appropriate H-bridge

transistors are turned on to
apply voltage to the field
Q1 transistor turns on and

voltage is applied to the
armature
Truck moves in chosen

direction
1-21
General Maintenance Instructions 80 percent discharged with periodic equalizing
charges.
The transistor control, like all electrical apparati, does
have some thermal losses. The semiconductor junc- Visual inspection of GE contactors contained in the
tions have finite temperature limits, above which traction and pump systems is recommended to occur
these devices may be damaged. For these reasons, during every 160 hours of vehicle operation.
normal maintenance should guard against any action Inspection is recommended to verify that the contac-
which will expose the components to excessive heat tors are not binding and that the tips are intact and
and/or those conditions which will reduce the heat free of contaminants.
dissipating ability of the control, such as restricting air
flow. It is not recommend that any type of welding be per-
formed on the vehicle after the installation of the con-
The following Do’s and Don’t’s should be observed: trol(s) in the vehicle. MCFA will not honor control fail-
ures during the warranty period when such failures
Any controls that will be applied in ambient tempera- are attributed to welding while the control is installed
tures over 100° F (40° C) should be brought to the in the vehicle.
attention of MCFA Service Engineering.
Cabling for Vehicle Retrofits
All external components having inductive coils must
be filtered. Refer to vehicle manufacturer for specifi- If an additional control or electronic device is added
cations. to the vehicle in the field, only MCFA recommended
wires and cables should be used.
The wiring should not be directly steam cleaned. In
dusty areas, blow low-pressure air over the control to RF Interference
remove dust. In oily or greasy areas, a mild solution
of detergent or denatured alcohol can be used to To prevent radio frequency (RF) interference, care
wash the control, and then low-pressure air should should be taken in routing power cables in the vicinity
be used to completely dry the control. of radio-controlled devices.
For the control to be most effective, it must be Suppression

mounted against the frame of the vehicle. The metal
vehicle frame, acting as an additional heat sink, will Unless specifically noted otherwise, suppression (for
give improved vehicle performance by keeping the example, a snubber) is required on all inductive
control package cooler. Apply a thin layer of heat- devices. This suppression minimizes noise and pre-
transfer grease such as Dow Corning 340, and a vents damage caused by electrical surges.
metal heatsink pad between the control heat sink and
the vehicle frame.
Control wire plugs and other exposed transistor con-

trol parts should be kept free of dirt and paint that
might change the effective resistance between
points.
CAUTION: Electric braking should not be used

when the vehicle is jacked up and the drive
wheels are in a free wheeling position. The higher
motor speeds can create excessive voltages that
can be harmful to the control.
Do not hipot (or megger) the control.
Use a lead-acid battery with the voltage and ampere

hour rating specified for the vehicle. Follow normal
battery maintenance procedures, recharging before
1-22
Recommended Lubrication of Pins and Sockets
Prior to Installation
1. Disconnect plug from controller or mating plug.
WARNING: Before conducting maintenance on
the vehicle, jack up the drive wheels, disconnect 2. Locate the plug that contains the socket (female)
the battery and discharge the capacitors. To dis- terminals. Maintenance needs only to be per
charge the capacitors, connect a 150 ohm, 25 formed on the plug containing the socket (female)
watt resistor (Part No. 358280) between the posi- type terminals. Reconnecting the plugs will
tive and negative terminals on the control panel lubricate the pin (male) terminals.
for at least 20 seconds.
3. Clean each terminal using contact cleaner as
Cleaner and lubricant are provided in the terminal shown in Figure 1.
maintenance kit SE000003.
Fretting occurs during microscopic movement at

the contact points of the connection. This movement
exposes the base metal of the connector pin which, e ane
r
t cl
t ac
when oxygen is present, allows oxidation to occur. c on
r
Sufficient build up of the oxidation can cause intermit-
ane
tent contact and intermittent vehicle operation. This
C le
can occur at any similar type of connection, whether
at the control or in any associated vehicle wiring, and
the resultant intermittent contact can provide the
same fault indication as actual component failure.
The addition of lubricant will prevent the oxidation Figure 1

process by eliminating the access of oxygen to the
contact point. Add this lubricant to the 12 pin and 23 4. Lubricate each terminal using lubricant as shown
pin plugs of all new SX controls at the time of their in figure 2. Apply enough lubricant to each terminal
installation into a vehicle opening to completely fill each opening to a depth of
.125" minimum.
When servicing existing vehicles exhibiting symp-
toms of intermittent mis-operation or shutdown by the
control, add this lubricant to all 12 and 23 pin plugs,
after proper cleaning of the connectors, as a preven-
tative measure to insure fretting is not an issue
LU
B
before control replacement. Also, for long term reli-

R
IC
A
N
T
able control operation, the plug terminals must be

maintained per these instructions with the recom-
mended contact cleaner and lubricant which provides
a high degree of environmental and fretting protec-
tion.
New and re-manufactured control plugs are cleaned

and lubricated prior to shipment from the factory.
However, in applications where severe vibration or Figure 2
high temperature cycling and excessive humidity,
such as freezers are present, it is recommended that
5. Reconnect plugs.
the plug terminals be cleaned and lubricated every
year, per these instructions. In normal applications,
plug maintenance should be performed every two
years, unless intermittent problems arise with the
plugs, requiring more immediate attention.
Warning: Do not use any other cleaners or lubricants
other than the ones specified.
1-23
General Troubleshooting Instructions Tools and test equipment required are: clip leads,
volt-ohm meter (20,000 ohms per volt) and basic
Trouble-shooting the SX control should be quick and hand tools.
easy when following the instructions outlined in the
status code instruction sheets. BDI Operation: BDI is only monitored by the GE
Traction controller, not the pump controller. The sepa-
rate pump controller has no way of tracking the
! WARNING charge of battery. In order to tell the truck display
what the state of charge of the battery is so that it
Before trouble-shooting, jack up the drive
can show the operator, the traction controller uses a
wheels, disconnect the battery and discharge
specific algorithm to more accurately determine the
the capacitors. Capacitors should be dis-
voltage on the battery. The information that is sent to
charged by connecting a 150 ohm, 25 watt
resistor (Part No 358280) between the positive the display is just a percentage value, but this per-
and negative terminals on the control panel centage is linked to a specific battery voltage by the
for at least 20 seconds. Reconnect the battery controller.
as needed for specific checks.
The GE controller uses a value of 2.14 volts per cell
If mis-operation of the vehicle occurs, a status code or higher to indicate a fully charged battery (100%)
will be displayed on the Dash Display or made avail- and a value of 1.94 volts per cell or lower to indicate
able by plugging a Handset into the plug P2 location, a fully discharged battery (0%). As an example, a
and then reading the status code. 36V battery with 18 cells would have a fully charged
voltage of 38.52V and a fully discharged voltage to a
Note: Status code numbers from 00 to 99 are trac- percentage value that is then sent to the display.
tion control status codes. Status codes with the prefix
1 (101 to 199) are pump control status codes. The controller must know how many cells are present
to properly make this association, so there is a set-
With the status code number, follow the procedures ting (setting number 15) that can be adjusted to do
outlined in the status code instruction sheets to deter- this. Because the voltage difference is great enough
mine the problem. between a 36V and 48V battery, there is a value that
setting number 15 can be set to that allows the con-
Important Note: Due to the interaction of the controller to determine which of these two voltages is
troller with all vehicle functions, almost any status connected. If this setting is used, the controller can
code or control fault could be caused by the con- sometimes be fooled by a 36V battery with a high
troller. After all other status code procedures have surface voltage (generally present just after the bat-
been followed and no problem is found, the controller tery is unplugged from the charger) or an over dis-
should then be replaced as the last option to correct charged 48V battery. Another problem can arise if a
the problem. battery is plugged into the truck that has a different
voltage than the previous battery, without letting the
The same device designations have been maintained head capacitors in the controller discharge. Until the
on different controls but the wire numbers may vary. capacitors completely discharged, the controller still
Refer to the schematic for your specific control. The holds memory of the voltage of the first battery and
wire numbers shown on the schematic will have iden- will not automatically adjust to the new particular volt-
tical numbers on the corresponding wiring diagrams age of the battery to be used in the truck.
for a specific vehicle.
Whenever the controller is powered up and the key
Check resistance on R x 1000 scale from frame to switch is turned on after having the capacitors com-
power and control terminals. A resistance of less than pletely discharged, the controller must start with a
20,000 ohms can cause misleading symptoms. new battery discharge level based on the voltage that
Resistance less than 1000 ohms should be corrected is measured at that time. This discharged voltage is
first. stored and sent to the display to be shown to the
operator.
Before proceeding, visually check for loose wiring,
mis-aligned linkage to the accelerator switch, signs of
overheating of components, etc.
1-24
Once the controller knows how many cells the battery are at least 100 amps apart and extrapolate. The
should have and the current discharge state of the voltage drop that is given in the function 14 table is
battery, it must then start taking samples of the bat- based on how much the voltage with battery current
tery voltage to monitor any changes in the battery’s is assumed to be linear, so once the current and volt-
state of charge. These samples are taken only during age are known for any 2 points, any third point on the
operation of the traction motor by the traction con- same line can be calculated. If the third point is cho-
troller and only when the current in the traction motor sen as being exactly 100 amps above or below one
is between 50 amps and 400 amps. Each sample is of the other points, then the voltage difference
at least 4 seconds apart. As the values of the sample between should work for the function 14 table.
voltages start changing, the controller waits until the
measured voltage value is lower than the stored volt- Example:
age value 6 times in a row before it will decrement
the stored battery state of charge by 1%. This means Operated unloaded lift>36.5V on the battery with 120
that it will take a minimum of 4 minutes for the BDI to amps out of the battery
drop 10% Operated loaded lift>34.4V on the battery with 275
amps out of the battery
Function 14 Setting: In order for the controller to
know what the true state of discharge of the battery Find the voltage difference (X) for a current differ-
is by measuring the voltage while the battery is sup- ence of 100 amps.
plying current, there must be a relationship estab-
lished that will give the static voltage of the battery Slope= voltage difference / current difference = (36.5-
based on the voltage of the battery under a load. 34.4)/(275-120) = 0.0135 = X / 100
This relationship is based on the internal resistance
of the battery and can vary between different batter- X = 0.0135 * 100 = 1.35
ies based on battery quality, capacity and voltage.
This compensation factor can be adjusted using set- Since 1.35 is between a setting of 16 (1.43) and 17
ting 14 in the GE traction controller. (1.34), choose the higher setting (17) to be sure that
the battery is not over-discharged.
See Function 14 in the Handset section, there is a
table titled Internal Resistance Compensation Table. The setting for function 14 should be adjusted for
This table gives the appropriate setting for a given each different battery that is used in a truck to insure
voltage drop. This voltage drop value is the differ- the proper amount of discharge per cycle. If a battery
ence between the voltage on the battery while provid- is still not being discharged properly (over or under
ing 0 amps of current (static voltage) and the voltage discharged), even after properly adjusting function
on the battery while providing 100 amps of currents. 14, the function 14 setting can be raised to decrease
From this given voltage, the logic in the controller can the depth of discharge or lowered to increase the
determine the static voltage of the battery when the depth of discharge.
traction motor current is at any value between 50
amps and 400 amps.
To obtain the correct voltage drop for the function 14

table, the battery voltage when the battery current is
100 amps can be subtracted from the static battery
voltage. A true static voltage of the battery can be dif-
ficult to obtain if there is some surface charge still on
the battery right after charging or if the battery volt-
age is still rising after heavy usage. In addition, get-
ting the current to be exactly 100 amps out if the bat-
tery can be difficult as well. Because getting this
information is difficult, it can sometimes cause the
voltage measurement to be off by as much as a cou-
ple of volts.
A simpler method of obtaining the correct values that

1-25
PROGRAMMING
2. PROGRAMMING
Handset .............................................................................................................................. 2-1
Operation ............................................................................................................................. 2-2
GE Sentry Set-up Procedures ............................................................................................. 2-2
Function Settings ................................................................................................................. 2-4
Controller Setup...................................................................................................................2-15
Traction Controller Settings ................................................................................................2-16
Accelerator Setup ................................................................................................................2-23
Pump Controller Settings.....................................................................................................2-25
Memory Maps ......................................................................................................................2-30
Speedometer Setup.............................................................................................................2-34
PROGRAMMING
Handset — General Information

NOTE: The vehicle will operate with the Handset con-
nected, however, the adjustment knob MUST BE SET
FULLY CLOCKWISE to make sure the control can
operate at maximum speed.
This section has the control card checks and adjust-
ments that can be made using the Handset. The con-
trol card checks and adjustments are usually made
with the controller installed in the lift truck. Bench
checks and adjustments can also be made with the
control card connected. The checks show the stored
setting numbers that have been stored for the differ-
ent controller functions. This section also includes a
description of each of the different functions. Use the
adjustment knob on the Handset to adjust the function
settings. See FIGURE 1.
The Handset with a cord is available through your lift
truck dealer under part #97E57-00100. The handset is
the same for all GE controls, however, the cord is dif-
ferent for the SX series motor controllers. The SX
controller Handset cord is available from MCFA under
part # 97E57-00111.
Handset Functions
The purpose of the Handset is to permit authorized
personnel to perform checks and adjustments:
1. Adjustment Knob 4. Coil Cord ✦ Monitor existing system fault codes for both traction
and pump controllers.
2. LED Display 5. Plug P2 or P4 (12 Pin)
✦ Monitor intermittent random status codes
3. Keypad 6. Modular Plug (8 Pin Hand Set) ✦ Monitor battery state of charge
FIGURE 1. Handset ✦ Monitor hourmeter reading on traction and pump
controllers.
✦ Monitor or adjust the following control functions:
The Handset is a multifunctional tool to be used with
✧ Creep speed
the SX series motor controllers. The Handset ✧ Controlled acceleration and 1A time
is used to access the memory elements called ✧ Armature and field current limit.
“Registers” which have electronic data stored in them ✧ Steer pump time delay and define signal input
to control an operation. There are 128 Registers in the (seat switch or directional switch)
SX series of Control Cards. The Handset will access ✧ Regenerative braking current limit
the registers for the traction or pump motor functions, ✧ Speed limit points (SL1, SL2, and SL3)
indicate Status Codes (possible faults) and make ✧ Truck management fault speed limit
adjustments to the operating limits set in the Control ✧ Internal resistance compensation for battery
Cards. Some of the registers in the “SX” series of state of charge indication
✧ Battery voltage (36/48 volts can be auto ranging)
control cards can not be accessed with the Handset.
✦ Selection of card operation type:
The Handset can access the registers that control the
✧ Standard traction card selection:
operation of the lift truck. The values for the limits on ✧ 1A enabled/disabled
the control card functions must be set with either the ✧ Auto braking enabled/disabled
Handset or a PC. The Handset has a Light Emitting
Diode (LED) display, a keypad for data entry and an
adjustment knob for changing function values.
See FIGURE 1.
2-1
PROGRAMMING
Handset — Operation
! WARNING ! WARNING
Before connecting or disconnecting the Before making any adjustments to the control,
Handset tool, 1) Jack up the drive wheels of consult the function settings on page 4. Failure
the vehicle, 2) Turn off the key switch, 3) to use the proper settings could result in
Unplug the battery and 4) Discharge the misoperation or damage to the control system.
capacitors.
At the Traction Controller, unplug the P2 plug” and Function Set-Up Procedures
plug in the Handset to the plug location P2 on the
With the Handset connected, hold down the CONT
controller. After installing the Handset tool, plug in the
button while turning on the Key Switch. The Handset
battery and turn on the key switch. The following is will now show the segment checking display. This
the start-up display sequence that will occur: accesses the set up mode, ready to monitor or adjust
control function settings. If a fault code is displayed
START-UP DISPLAY SEQUENCE simply push the CONT button to clear.
Push down one of the function numbers on the keypad
Key Switch On to check that setting. For example, push down on
function key ➄ : the corresponding function code will
Verify each LED Segment be displayed.
8888 Example: U 05
After one second we will see the value which is stored
If Maintenance Code If Maintenance Code under this function:
is active is not active
Example: 105
If this value needs to be reset, push again on the
Display Code -99 for four CONT button and the value will blink. The number on
seconds and activate
speed limit (if selected)
the Handset will no longer be the original value but will
correspond to the position the adjustment knob was left.
Now turn the adjustment knob to the desired setting
(the values will continue to blink). When the desired
setting is reached, push STORE. This value will be
Diagnostics displayed but will no longer be blinking. Next push the
BDI Display override ESC button and get the Segment Check display
with fault again. This indicates the programming mode is still
accessed.Continue this process to check or set all the
Run Mode functions. Each time a value is changed, go back and
verify that the setting is correct. The value adjustment
range available on the Handset is 0 to 255. However,
Diagnostics some functions do not use the entire range.
BDI Display override
with fault There are 15 numbers on the keypad but many more
functions available. For the first 15 functions on the
keypad simply press the appropriate number. To
Key Switch Off access functions 16 through 30 press the CONT but-
ton and the appropriate number on the keypad at the
Display steer pump same time. For the traction controller, the seat switch
hourmeter for four seconds must be open and for the pump controller, the key
switch must be on.
Display traction
Hourmeter for four seconds Example for function 16: CONT and keypad #1
Display pump Example for function 18: CONT and keypad #3
Hourmeter for four seconds
FIGURE 2. Start up display

2-2
PROGRAMMING
To access functions 48 and up, the seat switch must be

closed. for the traction controller, and turn the key
switch off for the pump controller. Then press the CONT
button and the appropriate number on the keypad at the NOTE: For bench checks and adjustments,
same time. please see the GE Sentry for Windows sec-
Example for function 48: CONT and keypad #1 tion
When programming is finished, press the ESC button
when the (8888) is showing and press it again for 1 sec-
ond. The display now shows the battery state of charge.
This means the control is in run mode.
Accessing Stored Fault Codes

The SX Traction and Pump Motor Controllers have
function registers (31 through 47) that store the last
16 Status Codes that caused the operation of the lift
truck to stop, the battery charge and the power steer
hours at the time the fault occurred. A PMT fault is
reset by turning the key to the OFF position and then
to the ON position. The first of the 16 status codes will
be overwritten each time a new status code occurs.
The stored status can be cleared from the register by
using the Handset. Use the procedure in FIGURE 3
to access and clear the fault code registers for the
traction and pump controllers with the Handset.
Key to OFF position
Push ESC and CONT at the same time
Release ESC and CONT
hold both the ESC and

Push ESC to
Status Code Displayed CONT Keys down to
erase stored data
erase all 16 Stored codes
Push CONT Key
Displays Battery Stare-of

Push ESC to
Charge When Fault erase stored data
occurred
Push CONT Button
Display hourmeter reading Push ESC to

when fault occurred erase stored data
Push CONT Button
FIGURE 3. Accessing Fault Codes

2-3
PROGRAMMING
! WARNING
FUNCTION 3 ARMATURE CONTROLLED
Please contact MCFA before making changes to ACCELERATION
any function settings. Failure to properly adjust (Push 3)
the settings could result in misoperation or dam-
age to the motor and/or controller. This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration. This function
can be changed by the dash display mode selection but-
LX
HANDSET
ton.
g EVC
Range 0.025 to 6.3 seconds
Set 0 to 255
Resolution 0.025 seconds per set unit
Example: Setting of 20 = 0.5 seconds
FUNCTION 4 ARMATURE CURRENT LIMIT

(Push 4)
CON T ST ORE
This function should always remain set at 255 (maximum
current limit) for this family of controls.
1 2 3 4
+ +
FUNCTION 5 COUNTER EMF TRIP POINT FOR AUTO
5 6 7 BRAKING
(Push 5)
9 10 11 12
This function allows for the adjustment of the speed at
which the truck will activate auto braking, after the acceler-
13 14 15 ESC ator pedal is released. The truck speed correlates to the
amount of voltage produced by the traction motor when it
is coasting. The setting of this function represents the
motor voltage.
Setup Functions for Traction Controller Range 0 to 100 volts

Set 0 to 255
FUNCTION 1 MILE PER HOUR SCALING Resolution 0.392 volts per set unit
(Push 1) Example: Setting of 20 = 7.84 volts
This function is not used on a Standard Display. If the

premium display option is used, the speedometer should FUNCTION 6 AUTO CALIBRATION OF
be adjusted through the display. ACCELERATOR POTENTIOMETER
Factory Default Value 16 (Push 6)
This function allows for the auto calibration of the acceler-

FUNCTION 2 CREEP SPEED ator potentiometer. This function should be left set to a
(Push 2) value of zero during normal truck operation. To activate
accelerator the auto calibration routine, set this function to
This function allows for the adjustment of the creep speed a value between 15 and 20, and refer to accelerator setup
of the vehicle. Creep speed can add 13 % to the percent of this manual for detailed instructions covering the auto
on time at the slowest speed range. calibration procedure, on page 2.
Range 2% to 15% on time IMPORTANT NOTE: This function must be used to

Set 0 to 255 recalibrate the accelerator every time the traction
Resolution 0.05% per set unit controller or accelerator is replaced. The GE Sentry
Example: Setting of 20 = 3% on time cannot be used to calibrate the accelerator.
2-4
PROGRAMMING
FUNCTION 7 MIN FIELD CURRENT Important Note: This function is used to optimize
(Push 7) motor and control performance and this setting was
This function allows the adjustment of the field weakening determined by MCFA engineers at the time of vehicle
level in order to set the top speed of the motor. development. This setting must not be changed by
Resolution Example field personnel without the permission of MCFA
Volts Min Max Set Per unit value If set at 71 Service Engineering.
36/48 0 20 51 to 115 0.314 amps 6.28A
72/80 0 17 51 to 114 0.269 amps 5.38A FUNCTION 11 AUXILIARY SPEED LIMIT
(Push 11)
MIN IF = (VAL-51) X 0.314 (at 36/48 VOLTS)
MIN IF = (VAL-51) X 0.269 (at 72/80 VOLTS) This function allows for the adjustment of the motor speed
limit (maximum battery volts to the motor) based on the
Important Note: This function is used to optimize state of pin P1-12 of the controller. If pin P1-12 is pulled to
motor and control performance, and this setting was battery volts, the speed limit is deactivated. If pin P1-12 is
determined by MCFA engineers at the time of vehicle allowed to float, the speed limit will be active.
development. This setting must not be changed by
field personnel without the permission of MCFA Range 100% to 0% battery volts
Service Engineering. Set 46 to 180
Resolution 0.75% per set unit
Example Setting of 80 = 75% of
FUNCTION 8 MAX FIELD CURRENT battery volts
(Push 8) Factory Default Value 0
SPEED LIMIT = 100% - ((VAL-46) x 0.75%)
This function allows for the adjustment of the maximum
field current in order to obtain the maximum torque of the
motor. This function should always be set to 255. FUNCTION 12 TOP SPEED LIMIT
(Push 12)
FUNCTION 9 REGEN BRAKING CURRENT LIMIT This function allows for the adjustment of the motor speed
(Push 9) limit (maximum battery volts to the motor). This speed limit
is the same as function 11, however it is always active.
This function allows for the adjustment of the maximum This function can be changed by the dash display mode
current seen by the motor during regenerative braking; the selection button.
higher the current, the shorter the stopping distance. This
function can be changed by the dash display mode selec- Range 100% to 0% battery volts
tion button. Set 46 to 180
Resolution Example Resolution 0.75% per set unit
Volts Min Max Set Per unit value If set at 100 Example Setting of 80 = 75% of
36/48 182A 591A 0 to 255 1.625 344 amps battery volts
72/80 52A 409A 32 to 255 1.625 162 amps Factory Default Value 0
SPEED LIMIT = 100% - ((VAL-46) x 0.75%)
REGEN BRAKE IA = (VAL X 1.625) + 182 at 36/48 volts
REGEN BRAKE IA = (VAL X 1.625) at 72/80 volts
FUNCTION 13 MAINTENANCE AND TRUCK
MANAGEMENT SPEED LIMIT
FUNCTION 10 MAX FIELD CURRENT DURING REGEN (Push 13)
(Push 10)
This function is the same as function 11, however it is
This function allows for the adjustment of the maximum active based on maintenance hours (function 19 and 20),
field current attainable during the regenerative braking or traction motor overheating (Status Code 90) or on low
mode. BDI value.
Resolution Example
Volts Min Max Set Per unit value If set at 220 Range 100% to 0% battery volts
36/48 0 64 51 to 255 0.314 53 amps Set 46 to 180
72/80 0 55 51 to 255 0.269 45 amps Resolution 0.75% per set unit
Example Setting of 80 = 75% of
IF = (VAL-51) x 0.314 (at 36/48 volts) battery volts
IF = (VAL-51) x 0.269 (at 72/80 volts) SPEED LIMIT = 100% - ((VAL-46) x 0.75%)
2-5
PROGRAMMING
FUNCTION 14 INTERNAL RESISTANCE The following functions have function numbers larger
COMPENSATION than the numbers on the Handset keyboard. To access
(Push 14) these functions. Push the CONT key and the number
shown in the following instructions at the same time.
This function is used when the Battery Discharge Indicator THE SEAT SWITCH MUST BE OPEN.
is present. Adjustment of this function will improve the
accuracy of the BDI. In order to determine this setting the
voltage drop of the battery under load must first be calcu- FUNCTION 16 STALL PROTECTION % ON-TIME TRIP
lated by the following method. POINT
(Push CONT 1)
1. On a fully charged battery, record the open circuit volt-
age (Vo) by measuring the voltage at the control positive This function allows for the adjustment of the stall motor
and negative power terminals. protection, as well as the display and storing of an 82 fault
2. Load the traction motor to 100 amps in the battery cable code. This function adjusts the percent on time at which
and record the voltage (VL) at the control positive and the fault occurs when the accelerator is calling for greater
negative power terminal. than 50% speed and the armature current is above 500
3. Calculate voltage drop (VDrop) as follows: amps at 36/48V (or above 370 amps at 72/80V).
VDrop = VO - VL
4. Use the table below to determine the appropriate setting Range 100% to 0% battery volts
using the calculated VDrop as a reference. Set 46 to 180
(See Function 14 settings in General Information & Resolution 0.75% per set unit
Features) Example Setting of 125 = 41% on-time
INTERNAL RESISTANCE COMPENSATION TABLE % ON TIME = 100% - ((VAL-46) x 0.75%)
Setting VDrop Setting VDrop Important Note: This function is used to optimize
2 11.44 17 01.34 motor and control performance, and this setting will
3 07.60 18 01.27 be determined by MCFA engineers at the time of vehi-
4 05.72 19 01.20 cle development. This setting must not be changed by
5 04.57 20 01.14 field personnel without the permission of MCFA
6 03.81 21 01.09 Service Engineering.
7 03.27 22 01.04
8 02.86 23 00.99
9 02.54 24 00.95 FUNCTION 17 CARD TYPE SELECTION
10 02.28 25 00.91 (Push CONT 2)
11 02.08 26 00.88
12 01.90 27 00.85 This function allows the user to enable or disable the vehi-
13 01.76 28 00.82 cle’s auto braking routine by setting the function within the
14 01.63 29 00.79 ranges outlined below.
15 01.52 30 00.76
Control Function Setting
16 01.43 31 00.74
740A, 36/48V 1A enabled, auto braking enabled 128 to 255
740A, 36/48V 1A enabled, auto braking disabled 64 to127
740A, 36/48V Without 1A, auto braking enabled 50 to 63
740A, 36/48V Without 1A, auto braking disabled 0 to 49
FUNCTION 15 BATTERY VOLTS 600A, 36/48V Auto braking enabled 50 to 255
(Push l5) 600A, 36/48V Auto braking disabled 0 to 49
450A, 72/80V Auto braking enabled 50 to 255
This function allows for the adjustment of voltage range. In 450A, 72/80V Auto braking disabled 0 to 49
order for the BDI to operate properly, the setting as shown
in the table must be entered:
Battery volts Set units

36 volts Between 32 and 44 FACTORY DEFAULT
48 volts Between 45 and 69
36/48 volts Between 184 and 250
No BDI Between 251 and 255
2-6
PROGRAMMING
FUNCTION 18 STEER PUMP TIME DELAY FUNCTION 21 AUTO REGEN BRAKING CURRENT
(Push CONT 3) LIMIT
(Push CONT 6)
This function allows for the selection of steer pump contac-
tor pick up input, either seat switch or directional switch This function allows for the adjustment of the braking
closing, as well as the adjustment of the time delay for the torque applied when the start or directional switch is
contactor drop out. opened, and the counter EMF is above the setting of
Function 5. A higher current correlates to a shorter stop-
• Pick up steer pump contactor on seat switch closure
and drop out steer pump contactor on seat switch ping distance. This function can be changed by the dash
opening, after a delay determined by the following: display mode selection button.
Range 1.5 to 65 seconds Current = (Value of Setting /4) x 6.5

Setting Between 0 and 127
Resolution 0.5 seconds per set unit Note, if the result is less than 52 amps, the control will
default to 52 amps.
Example: Setting of 20 = (20 x 0.5) + 1.5 = 11.5 seconds
• Pick up steer pump contactor on directional switch clo- FUNCTION 22 NOT APPLICABLE
sure and drop out steer pump contactor on directional
switch opening, after a delay determined by the
following: This value changes with operating mode selected, and
should not be adjusted in the field.
Range 0.5 to 63 seconds
Setting Between 128 and 255 FUNCTION 23 REGEN CANCEL CURRENT
Resolution 0.5 seconds per set unit (Push CONT 8)
Example: Setting of 149 = ((149-128) x 0.5) + 1.5 = 11.5 This function allows for the adjustment of the armature
seconds current at which regenerative braking cancels, and is spe-
cific to each motor design.
Note: If the seat switch opens, the steer pump contactor
will open immediately. If a foot directional control option is
Important Note: This function is used to optimize
installed on a truck, only the settings for the seat switch
input should be used. motor and control performance, and this setting will
be determined by MCFA engineers at the time of vehi-
cle development. This setting must not be changed by
FUNCTION 19 MAINTENANCE CODE TENS AND field personnel without the permission of MCFA
UNITS HOURS SET Service Engineering.
(Push CONT 4)
This function allows for the adjustment of the tens and units FUNCTION 24 FIELD WEAKENING START
hours of the maintenance code activation time. If the replace- (Push CONT 9)
ment of the SX controller is required, record this value.
This function allows for setting the armature current at
Range 0 to 99 which minimum field current will be achieved.
Set 0 to 99
Example 9999 Hours Range 0 to 414 Amps
Disabled 255 Setting 0 to 255
Resolution 1.625 per set unit
FUNCTION 20 MAINTENANCE CODE THOUSANDS Example Setting of 20 = 32.5 amps
AND HUNDREDS HOURS SET
(Push CONT 5) I motor FWS = VAL. x 1.625
This function allows for the adjustment of the thousands Important Note: This function is used to optimize
and hundreds hours of the maintenance code activation motor and control performance, and this setting will
time. Same as Function 19. be determined by MCFA engineers at the time of vehi-
Range 0 to 240 field personnel without the permission of MCFA
Set 0 to 240 Service Engineering.
Example 9999 Hours
Disabled 255
2-7
PROGRAMMING
FUNCTION 25 MONITOR the Memory Map, match the “stored status code pointer
(Push CONT 10) number” [the number shown in the HS (Handset) number
column] on the memory map, with the number obtained
from Function 28. This will be the last stored status code
This function is not used. To ensure optimum opera- recorded.
tion of the control, this function must be left with zero
stored in this register. Note: When scrolling through the stored status code
register, the register always starts at status code 1
and scrolls to status code 16.
FUNCTION 26 FIELD TO ARMATURE CURRENT RATIO
(Push CONT 11)
FUNCTION 29 POWER STEERING HOURS
This function sets the ratio between armature and field (ONES AND TENS)
current when operating below the maximum field current (Push CONT 14)
and above the Field Weakening Start point. The setting
represents the quantity of field current changed for each 1 This register is only intended for storage of the ones and
amp of armature current changed. tens values of the hours of operation of the power steering
motor and should not be adjusted.
For a 36/48V control:
Range 0 to 0.314 field amps/armature amp
Setting 0 to 13 FUNCTION 30 POWER STEERING HOURS
Resolution 0.024 field amps/armature amp (HUNDREDS AND THOUSANDS)
Example Setting of 10 = 0.24 field (Push CONT 15)
amps/armature amp
This register is only intended for storage of the hundreds
For a 72/80V control: and thousands values of the hours of operation of the
Range 0 to 0.269 field amps/armature amp power steering motor and should not be adjusted.
Setting 0 to 13
Resolution 0.021 field amps/armature amp DASH DISPLAY MODES
Example Setting of 10 = 0.20 field The following functions (functions 48 through 63) are
amps/armature amp mode settings that are activated from the Dash Display.
Important Note: This function is used to optimize No mode should be set to values lower than the preceding
motor and control performance, and this setting will mode.
be determined by MCFA engineers at the time of vehi-
field personnel without the permission of MCFA The following functions have function numbers larger
Service Engineering. than the numbers on the Handset keyboard. To access
these functions. Push the CONT key and the number
shown in the following instructions at the same time.
FUNCTION 27 MINUTES REGISTER THE SEAT SWITCH MUST BE CLOSED AND KEY
(Push CONT 12) SWITCH OFF.
This register is only intended for storage of the minutes

value for proper operation of the hour meter and should FUNCTION 48 MODE 1 ARMATURE CONTROLLED
not be adjusted. ACCELERATION
(Push CONT 1)
FUNCTION 28 STORED STATUS CODE COUNT This function allows for the adjustment of the rate of time it
POINTER takes for the control to accelerate to 100% applied battery
(Push CONT 13) voltage to the motor on hard acceleration.
This register contains the location of the last stored status Range 1.0 to 25.5 seconds
code recorded of the 16 stored status codes. These stored Set 10 to 255
status codes have caused a PMT controller shutdown Resolution 0.10 seconds per set unit
and/or disruption of normal vehicle operation. Example: Setting of 20 = 2.0 seconds
To determine which stored status code was the last one This C/A takes effect when the Mode 1 settings are called
recorded, read the number stored in Function 28. Using for by the Dash Display.
2-8
PROGRAMMING
FUNCTION 49 MODE 1 REGEN CURRENT LIMIT FUNCTION 52 MODE 2 ARMATURE CONTROLLED
(Push CONT 2) ACCELERATION
(Push CONT 5)
This function allows for the adjustment of the maximum
current seen by the motor during regenerative braking; the Same as Function 48.
higher the current, the shorter the stopping distance.
Resolution Example This C/A takes effect when the Mode 2 settings are called
Volts Min Max Set Per unit value If set at 100 for by the Dash Display.
36/48 182A 591A 0 to 255 1.625 344 amps
72/80 52A 409A 32 to 255 1.625 162 amps
FUNCTION 53 MODE 2 REGEN CURRENT LIMIT
REGEN BRAKE IA = (VAL X 1.625) + 182 at 36/48 volts (Push CONT 6)
REGEN BRAKE IA = (VAL X 1.625) at 72/80 volts
Same as Function 49.
This REGEN CURRENT LIMIT takes effect when the
Mode 1 settings are called for by the Dash Display. This REGEN CURRENT LIMIT takes effect when the
Mode 2 settings are called for by the Dash Display.
FUNCTION 50 MODE 1 AUTO REGEN CURRENT LIMIT

(Push CONT 3) FUNCTION 54 MODE 2 AUTO REGEN CURRENT LIMIT
(Push CONT 7)
This function allows for the adjustment of the braking
torque applied when the start or directional switch is Same as Function 50.
opened, and the counter EMF is above the setting of
Function 5. A higher current correlates to a shorter stop- This AUTO REGEN CURRENT LIMIT takes effect when
ping distance. the Mode 2 settings are called for by the Dash Display.
Current = (Value of Setting /4) x 6.5

FUNCTION 55 MODE 2 SPEED LIMIT
Note, if the result is less than 52 amps, the control will (Push CONT 8)
default to 52 amps.
This AUTO REGEN CURRENT LIMIT takes effect when
the Mode 1 settings are called for by the Dash Display. This SPEED LIMIT 2 takes effect when the Mode 2 set-
tings are called for by the Dash Display.
FUNCTION 51 MODE 1 SPEED LIMIT

(Push CONT 4)
FUNCTION 56 MODE 3 ARMATURE CONTROLLED
This function allows for the adjustment of the motor speed ACCELERATION
limit (maximum battery volts to the motor. (Push CONT 9)
Range 100% to 0% battery volts Same as Function 48.

Set 46 to 180
Resolution 0.75% per set unit This C/A takes effect when the Mode 3 settings are called
Example Setting of 80 = 75% of for by the Dash Display.
battery volts
SPEED LIMIT = 100% - ((VAL-46) x 0.75%) FUNCTION 57 MODE 3 REGEN CURRENT LIMIT
(Push CONT 10)
This speed limit takes effect when the Mode 1 settings are
called for by the interactive Dash Display. Same as Function 49.

2-9
PROGRAMMING
(Push CONT 11)

the Mode 3 settings are called for by the Dash Display.
FUNCTION 59 MODE 3 SPEED LIMIT 2

(Push CONT 12)
called for by the Dash Display.
FUNCTION 60 MODE 4 ARMATURE CONTROLLED

ACCELERATION
(Push CONT 13)
This C/A takes effect when the Mode 4 settings are called
for by the Dash Display.
FUNCTION 61 MODE 4 REGEN CURRENT LIMIT

(Push CONT 14)


(Push CONT 15)

the Mode 4 settings are called for by the Dash Display.
FUNCTION 63 MODE 4 SPEED LIMIT 2

(Push CONT ESC)
called for by the Dash Display.
2-10
PROGRAMMING
The "maximum field current " setting is

adjusted by Function 8. This function, along
with the "armature current limit" , Function 4,
sets the maximum torque of the motor.
MAXIMUM
The " ratio " setting is adjusted by Function 26.

This function sets the ratio between armature
and field current when operating, IMOTOR is
above FWS and less than the full load
transistion point. Setting is the value of field
current changed for each 100 amps of
armature current changed.
FIELD CURRENT
The " minimum field

current " setting is adjusted
by Function 7. The function
sets the top speed of the
motor.
The " field weakening start "

setting is adjusted by Function
24. This function sets the
armature current at which
minimum field current will be
achieved .
ZERO
ARMATURE CURRENT
MAXIMUM
ZERO
The "full load transition point "
The "armature current limit "

setting is adjusted by Function 4.
The function along with the
"maximum field current",
Function 8, sets the maximum
torque of the motor.
2-11
PROGRAMMING
Setup Functions for Hydraulic Pump Control
Example: Setting of 20 = 0.032 seconds
FUNCTION 1 NOT APPLICABLE For example, if you had selected 2.08 volts from Function
16 to be added to the motor, it would take 0.18 seconds to
This function is not applicable to this type of control and add a total of 2.08 volts. (2.08/0.375)=0.032
should not be adjusted.
FUNCTION 11 AUX 1/AUX 2 SPEED LIMIT 1 (SL1)

FUNCTION 2 INTERNAL RESISTANCE (Push 11)
COMPENSATION START
(Push 2) This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL1 limit
This function allows for the adjustment of the current level switch input signal is received by the control card at pin
at which the internal resistance compensation feature P1-12. SL1 limit switch is a normally open switch connect-
(Function 16) will take effect. ed to battery negative, the switch closing enables speed
limit.
Range 0 to 1325 amps
Setting 52 to 255 Range 0 volts to 96 volts
Resolution 6.5 amps per set unit Setting 0 to 255
Resolution 0.375 volts per set unit
Example: Setting of 72 = (72-52) x 6.5 = 130 amps
Example: Setting of 50=18.75 volts
FUNCTION 3 CONTROLLED ACCELERATION

(Push 3) FUNCTION 12 LIFT 1 SPEED LIMIT 2 (SL2)
(Push 12)
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96% applied battery Same as Function 11 except using SL2 limit switch for
voltage to the motor on hard acceleration. input to control card at pin P1-19.

Setting 0 to 255 FUNCTION 13 TILT SPEED LIMIT 3 (SL3)
Resolution 0.021 seconds per set unit (Push 13)
Example: Setting of 20 = 0.52 seconds C/A Same as Function 11 except using SL3 limit switch for
input to control card at pin P1-20.
FUNCTION 4 ARMATURE CURRENT LIMIT

(Push 4) FUNCTION 14 LIFT 2 SPEED LIMIT (SL4)
(Push 14)
This function allows for the adjustment of the current limit
of the control. The setting for this function should always Same as Function 11 except using SL4 limit switch for
remain at 255 for this family of controls to achieve maxi- input to control card at pin P1-21.
mum current limit.
FUNCTION 15 NOT APPLICABLE

FUNCTION 7 INTERNAL RESISTANCE
COMPENSATION RATE This function is not applicable to this type of control and
(Push 7) should not be adjusted.
takes for the control to add the internal resistance com-
pensation voltage that is applied to the motor. This function Note: The following functions have function numbers
will add 0.375 volts to the motor at the rate of time adjust- larger than the numbers on the Handset keyboard. To
ed until the total IR compensation voltage has been access these functions, push the CONT key and the
added. number shown in the following instructions at the
same time. THE KEY SWITCH MUST BE ON.
Setting 0 to 255
Resolution 0.0015 seconds per set unit
2-12
PROGRAMMING
control panel used and the supporting electro-
FUNCTION 16 SPEED / TORQUE COMPENSATION mechanical devices. Failure to comply with proper
(Push CONT 1) application standards could result in mis-operation or
damage to the control and/or motors.
This function is used to stabilize pump speed at heavy
loads. The voltage selected will be added to the motor at
each 100 amp increment starting at the value set in FUNCTION 28: FAULT COUNT POINTER
Function 2. The voltage compensation selected will be (Push CONT 13)
added in increments of 0.375 volts until the entire voltage
is added. For example, a setting of 2 will be added in 30 This register contains the location of the last stored status
steps of 0.375 volts each whereas, a setting of 4 will be code recorded of the 16 stored status codes. These stored
added in 15 steps of 0.375 volts each. status codes have caused a PMT controller shutdown
and/or disruption of normal vehicle operation.
SPEED / TORQUE
VOLTAGE VOLTAGE To determine which stored status code was the last one
SETTING DROP SETTING DROP recorded, read the number stored in Function 28. Using
2 11.44 17 1.34 the Memory Map, match the “stored status code point-
3 7.60 18 1.27 er number” in the HS (Handset) number column) on the
4 5.72 19 1.20 memory map, with the number obtained from Function 28.
5 4.57 20 1.14 This will be the last stored status code recorded.
6 3.81 21 1.09
7 3.27 22 1.04 Note: When scrolling the stored status code register,
8 2.86 23 0.99 the register always starts at status code 1 and scrolls
9 2.54 24 0.95 to status code 16.
10 2.28 25 0.91
11 2.08 26 0.88 DASH DISPLAY MODES:
12 1.90 27 0.85 The Following functions (functions 48 through 63 are
13 1.76 28 0.82 mode settings that are activated from the Dash
14 1.63 29 0.79 Display.
15 1.52 30 0.76
16 1.43 31 0.74 Note: The following functions have function numbers
larger than the numbers on the Handset keyboard. To
COMPENSATION TABLE access these functions, push the CONT key and the
number shown in the following instructions at the
same time. THE KEY SWITCH MUST BE OFF.
FUNCTION 17 CARD TYPE SELECTION
(Push CONT 2)
FUNCTION 48 MODE 1 - CONTROLLED
This function should be set in accordance with the control ACCELERATION
type in use in the vehicle: (Push CONT 1)
Function Setting No BDI
Std C/L BDI Lockout 54 to 62 36 to 44 takes for the control to accelerate to 96% applied battery
High C/L BDI Lockout 63 to 71 45 to 53 voltage to the motor on hard acceleration.

BDI Lockout means that the BDI signal from the traction Setting 0 to 255
control must be present in order for the pump control to Resolution 0.084 seconds per set unit
operate. This control will stop operation when the battery
state of charge reaches 9%. Example: Setting of 20 = 1.8 seconds C/A
Settings for these functions should be made in between

the values shown.
Warning: This setting must be changed by authorized

personnel only, following instructions supplied by
MCFA Service Engineering. Card type selection must
be made within the capabilities of the TRANSISTOR
2-13
PROGRAMMING
FUNCTION 49 MODE 1 – LIFT 1 SPEED LIMIT (SL2) FUNCTION 54 MODE 2 – TILT SPEED LIMIT (SL3)
(Push CONT 2) (Push CONT 7)
This function allows for the adjustment of the speed limit Same as Function 50.
switch input signal is received by the control card. SL2
limit switch is a normally open switch connected to battery FUNCTION 55 MODE 2 – LIFT 2 SPEED LIMIT (SL4)
negative, the switch closing enables speed limit. (Push CONT 8)
Range 0 volts to 96 volts Same as Function 51.

Setting 0 to 255
FUNCTION 56 MODE 3 - CONTROLLED
Example: Setting of 50=18.75 volts ACCELERATION
(Push CONT 9)
FUNCTION 50 MODE 1 – TILT SPEED LIMIT (SL3)
(Push CONT 3) Same as function 48.
This function allows for the adjustment of the speed limit

(maximum battery volts to the motor) when the SL3 limit FUNCTION 57 MODE 3 – LIFT 1 SPEED LIMIT (SL2)
switch input signal is received by the control card. SL3 (Push CONT 10)
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit. Same as Function 49.
Range 0 volts to 96 volts

Setting 0 to 255 FUNCTION 58 MODE 3 – TILT SPEED LIMIT (SL3)
Resolution 0.375 volts per set unit (Push CONT 11)
Example: Setting of 50=18.75 volts Same as Function 50.
FUNCTION 51 MODE 1 – LIFT 2 SPEED LIMIT (SL4) FUNCTION 59 MODE 3 – LIFT 2 SPEED LIMIT (SL4)
(Push CONT 2) (Push CONT 12)
This function allows for the adjustment of the speed limit Same as Function 51.
switch input signal is received by the control card. SL4
limit switch is a normally open switch connected to battery FUNCTION 60 MODE 4 - CONTROLLED
negative, the switch closing enables speed limit. ACCELERATION
(Push CONT 13)
Range 0 volts to 96 volts
Setting 0 to 255 Same as function 48.
Example: Setting of 50=18.75 volts FUNCTION 61 MODE 4 – LIFT 1 SPEED LIMIT (SL2)
(Push CONT 14)
FUNCTION 52: MODE 2 - CONTROLLED Same as Function 49.

ACCELERATION
(Push CONT 5) FUNCTION 62 MODE 4 – TILT SPEED LIMIT 3 (SL3)
(Push CONT 15)
Same as function 48.
FUNCTION 53: MODE 2 – LIFT 1 SPEED LIMIT (SL2) FUNCTION 63 MODE 4 – LIFT 2 SPEED LIMIT (SL4)
(Push CONT 6) (Push CONT ESC)
Same as Function 49. Same as Function 51.
2-14
SETUP PROCEDURES
Controller Setup
Every controller has a basic number of settings that come with the controller. These basic settings are generic
and will not allow the truck to operate properly. After the controller is installed into a truck, the settings must
be changed to match the voltage of the truck, the size of the truck and the type of motor in the truck. All
trucks will have a traction controller that must be setup. Some trucks will have an optional pump controller
that will also need to be setup.
Before setting up any controller, the configuration of the truck must be determined. For the traction and pump
controller setup, 4 things must be determined; UL type (E or EE), truck voltage, truck size and motor size. The
UL type, truck voltage and size should be available on the build paperwork that comes with the truck. The
motor information is available in the serial number of the truck. The number in the sixth position of the serial
number (e.g. A3BC220053) gives the motor combination of the truck per the following table.
SN PREFIX MOTORS VOLTAGE

TRACTION PUMP
FBC15K A3BC11 8" 6.6" 36/48V
FBC18K A3BC12 9" 6.6" 36/48V
FBC18KL A3BC13 8" 8" 36/48V
A3BC14 9" 8" 36/48V
FBC20K A3BC21 9" 8" 36/48V
FBC25K A3BC22 11” 8" 36/48V
A3BC23 9" 9" 36/48V
A3BC24 11" 9" 36/48V
A3BC28 11" 9" 72/80V
FBC25KE A3BC31 9" 8" 36/48V
FBC25KL A3BC32 11" 8" 36/48V
FBC30K A3BC33 9" 9" 36/48V
A3BC34 11" 9" 36/48V
A3BC38 11" 9" 72/80V
FBC30KL A3BC44 11" 9" 36/48V
Once the configuration of the truck is known, the correct settings will need to be input into the traction and
pump controller (if the truck has a pump controller). Inputting the settings into the traction or pump controller
will require a GE controller handset with the proper cable.
2-15
TRACTION CONTROLLER SETTINGS
FOR FBC15K AND FBC18K
SN PREFIX: A3BC11 OR A3BC13
TRACTION MOTOR DIAMETER: 8"
SETTING DESCRIPTION SET# FBC15K (36V ONLY) FBC18K (36V ONLY)
MPH Scaling 1 16 16
Creep Speed 2 87 87
Controlled Acceleration 3 24 24
Armature Current Limit 4 255 255
Counter EMF Trip Point for Auto Regen 5 20 20
Auto Calibration of Accel. Potentiometer* 6 See Page 2-33 See Page 2-33
Min Field Current 7 86 86
Max Field Current 8 255 255
Regen Current Limit 9 45 30
Max Field Current for Regen 10 170 170
Speed Limit from Pin 12 on Negative (SL1) 11 0 0
Max Armature % On (SL2) 12 0 0
Speed Limit from Trac Mtr Temp/Maint/BDI 13 113 113
Internal Resistance Compensation 14 24 24
Battery Voltage 15 36 36
Traction Motor Stall Protection 16 130 130
Card Type Selection 17 57 57
Steer Motor Time Delay 18 149 149
Maint Code Hrs Tens and Ones 19 255 255
Maint Code Hrs Thousands and Hundreds 20 255 255
Auto Regen Current Limit 21 25 35
Truck Mode Set by Display 22 183 183
Regen Cancel Current 23 30 30
Field Weakening Start 24 64 64
Monitor 25 0 0
Field to Armature Current Ratio 26 6 5
Minutes Register for Hourmeter 27 0 0
Stored Fault Count Pointer 28 0 0
P/S Hourmeter Storage Register 29 0 0
MODE 1 - Controlled Acceleration [#3] 48 36 36
MODE 1 - Regen Current Limit [#9] 49 0 0
MODE 1 - Auto Regen Current Limit [#21] 50 0 0
MODE 1 - Max Armature % On (SL2) [#12] 51 80 83
*Valve changes to zero after calibration.
2-16
FOR FBC15K, FBC18K AND FBC18KL
SETTING DESCRIPTION SET# 36V 48V
MPH Scaling 1 16 16
Creep Speed 2 87 87
Auto Calibration of Accel. Potentiometer* 6 See Page 2-33
Monitor 25 0 0
2-17
FOR FBC20K, FBC25K AND FBC25KE
SN PREFIX: A3BC21, A3BC23, A3BC31 OR A3BC33
MPH Scaling 1 16 16
Creep Speed 2 87 87
Monitor 25 0 0
2-18
FOR FBC20K, FBC25K AND FBC25KE
SN PREFIX: A3BC22, A3BC24, A3BC32 OR A3BC34
MPH Scaling 1 16 16
Creep Speed 2 60 60
Monitor 25 0 0
2-19
FOR FBC25KL, FBC30K AND FBC30KL
SN PREFIX: A3BC32, A3BC34 OR A3BC44
MPH Scaling 1 16 16
Creep Speed 2 60 60
Monitor 25 0 0
2-20
FOR FBC25KL AND FBC30K
MPH Scaling 1 16 16
Creep Speed 2 87 87
Monitor 25 0 0
2-21
TRACTION CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION
FBC15K, FBC18K AND FBC18KL

MPH Scaling 1 16 16
Creep Speed 2 87 87
Monitor 25 0 0
2-22
TRACTION CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION
FBC20K, FBC25K, FBC25KE, FBC25KL, FBC30K AND FBC30KL
SN PREFIX: A3BC22, A3BC24, A3BC32, A3BC34 OR A3BC44

MPH Scaling 1 16 16
Creep Speed 2 60 60
Monitor 25 0 0
2-23
TRACTION CONTROLLER SETTINGS FOR
FBC20K, FBC25K, FBC25KE, FBC25KL AND FBC30K
MPH Scaling 1 16 16
Creep Speed 2 87 87
Monitor 25 0 0
2-24
PUMP CONTROLLER SETTINGS FOR
PUMP MOTOR DIAMETER: 8"
SETTING DESCRIPTION SET# 36V/48V

N/A 1 0
Internal Resistance Compensation Start 2 66
Controlled Acceleration 3 20
Armature Current Limit 4 255
N/A 5 255
N/A 6 255
Internal Resistance Compensation Rate 7 100
N/A 8 255
N/A 9 255
N/A 10 255
Aux1/Aux2 Speed Limit (SL1) 11 50
Lift 1 Speed Limit (SL2) 12 45
Tilt Speed Limit (SL3) 13 38
N/A 15 255
Speed Torque Compensation 16 20
Card Type Selection (500A/600A) 17 58
N/A 18 255
N/A 19 255
N/A 20 255
N/A 21 255
Truck Mode Set by Display 22 183
minutes 23 0
minutes seconds 24 0
N/A 25 0
Monitor 26 0
N/A 27 255
Stored Fault Count Pointer 28 0
Pump Hourmeter Storage Register 29 0
MODE 1 - Controlled Acceleration [#3] 48 27
MODE 1 - Lift 1 Speed Limit (SL2) [#12] 49 34
MODE 1 - Tilt Speed Limit (SL3) [#13] 50 31
2-25
FBC20K, FBC25K, FBC25KE, FBC25KL, FBC30KAND FBC30KL
SN PREFIX: A3BC23, A3BC24, A3BC33, A3BC34 OR A3BC44

N/A 1 0
N/A 5 255
N/A 6 255
N/A 8 255
N/A 9 255
N/A 10 255
N/A 15 255
N/A 18 255
N/A 19 255
N/A 20 255
N/A 21 255
minutes 23 0
N/A 25 0
Monitor 26 0
N/A 27 255
2-26
PUMP CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION
SN PREFIX: A3BC14

N/A 1 0
N/A 5 255
N/A 6 255
N/A 8 255
N/A 9 255
N/A 10 255
N/A 15 255
N/A 18 255
N/A 19 255
N/A 20 255
N/A 21 255
minutes 23 0
N/A 25 0
Monitor 26 0
N/A 27 255
2-27
PUMP CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION
FBC20K, FBC25K, FBC25KE, FBC25KL, FBC30K AND FBC30KL
SN PREFIX: A3BC24, A3BC34 OR A3BC44
N/A 1 0
N/A 5 255
N/A 6 255
N/A 8 255
N/A 9 255
N/A 10 255
N/A 15 255
N/A 18 255
N/A 19 255
N/A 20 255
N/A 21 255
minutes 23 0
N/A 25 0
Monitor 26 0
N/A 27 255
2-28
FBC20K, FBC25K, FBC25KE, FBC25KL AND FBC30K

N/A 1 0
N/A 5 255
N/A 6 255
N/A 8 255
N/A 9 255
N/A 10 255
N/A 15 255
N/A 18 255
N/A 19 255
N/A 20 255
N/A 21 255
minutes 23 0
N/A 25 0
Monitor 26 0
N/A 27 255
2-29
MEMORY MAPS
Traction Control
E2 Func No. HS Traction Control Access By Restrictions

No. Function
43 44 Hours (Thou/Hun) 3 PC Only Reset to Zero Only
45 46 BDI 4 PC Only Reset to Zero Only
46 47 Hours (Tens/Ones) 4 PC Only Reset to Zero Only
48 49 (26) Stored Status Code #5 PC Only Reset to Zero Only
62 63 Hours; (Tens/Ones) 8 PC Only Reset to Zero Only
73 ; 74 BDI 11 PC Only Reset to Zero Only
79 80 . Hours (Thou/Hun) 12 PC Only Reset to Zero Only
84 85 (44) Stored Status Code # 14 PC Only Reset to Zero Only
88 89 (46) Stored Status Code # 15 PC Only Reset to Zero Only
2-30
MEMORY MAPS
Traction Control

No. Function
0 1 1 MPH Scaling HS or PC None
1 2 2 Creep HS or PC None
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Armature Current Limit HS or PC None
4 5 5 Counter EMF Trip Point for Auto Braking HS or PC None
5 6 6 Auto Calibration of Accelerator Pot HS or PC None
6 7 7 Minimum Field Current HS or PC Contact service Engineering
7 8 8 Maximum Field Current HS or PC None
8 9 9 Regen Current Limit HS or PC None
9 10 10 Field Current for Regen HS or PC None
10 11 11 Speed Limit 1 HS or PC None
11 12 12 Top Speed Limit HS or PC None
12 13 13 Maintenance & Truck Mgmt Speed Limit HS or PC None
13 14 14 IR Compensation HS or PC None
14 15 15 Battery Volts Select HS or PC None
15 16 16 Stall Protection and % ON-Time Trip HS or PC None
16 17 17 Card Type Select HS or PC None
17 18 18 Steer Pump Time Delay HS or PC None
18 19 19 Maintenance Code HM (Tens/Units) HS or PC None
19 20 20 Maintenance Code HM (Thou/Hun) HS or PC None
20 21 21 Auto Regen Braking Current Limit HS or PC None
21 22 22 Mode Storage HS or PC For DD on power up
22 23 23 Regen Cancel Current HS or PC None
23 24 24 FW Start HS or PC Contact service Engineering
24 25 25 Monitor HS or PC Temporary Storage
25 26 26 Ratio HS or PC Contact service Engineering
26 27 27 Steer Pump Minutes HS or PC Temporary Storage
27 28 28 Fault Count Pointer HS or PC None
28 29 29 Steer Pump Hours (Tens/Ones) HS or PC None
29 30 30 Steer Pump Hours (Thou/Hun) HS or PC None
30 31 Traction Hours (Tens/Ones) PC Only None
31 32 Traction Hours (Thou/Hun) PC Only None
2-31
MEMORY MAPS
Traction Control

No. Function
96 67 48 Dash Display CA-1 HS or PC None
97 98 49 Dash Display Regen C/L-1 HS or PC None
98 99 50 Dash Display Auto Regen C/L-1 HS or PC None
99 100 51 Dash Display Speed Limit 2 - 1 HS or PC None
105 106 57 Dash Display Regen C/L -3 HS or PC None
112 113 Secure HM (Tens/Ones) Steer Pump PC Only Read Only
113 114 Secure HM (Thou/Hun) Steer Pump PC Only Read Only
114 115 Secure Aux HM (Tens/Ones) PC Only Read Only
115 116 Secure Aux HM (Thou/Hun) PC Only Read Only
116 117 Reserved PC Only GE Future Use
120 121 Truck Minutes PC Only None
121 122 Pump Minutes PC Only None
122 123 Pump Hours (Tens/Ones) PC Only None
123 124 Pump Hours (Thou/Hun) PC Only None
124 125 OEM Use PC Only None
125 126 OEM Use PC Only None
126 127 Accelerator Auto Calibration Slope PC Only None
127 128 Accelerator Auto Calibration Y-Intercept PC Only None
2-32
Accelerator Setup
The purpose of this setup procedure is to make the GE SX Traction controller learn the range of the accelerator
potentiometer. If this procedure is not done after new settings are installed into the controller, the display will
show a fault code – 08. The default settings are designed to require the accelerator setup every time new set-
tings are installed. Because of this, the accelerator setup should ALWAYS be done right after inputting the
settings into the traction controller.
This setup should be done any time the accelerator or traction controller is replaced for the production trucks.
This procedure can also be performed any time the accelerator appears to be out of adjustment. This adjust-
ment is possible only on traction software version M and higher.
1. Unplug the battery and blow the horn to discharge the capacitor.
2. Unplug the small black connector from the traction control and plug in the GE handset.
3. Make sure the battery is plugged in and the key switch is OFF.
4. Turn on the Key and while holding down the CONT key on the handset, then release the CONT key after
8888 appears on the handset. (The seat switch must be open)
5. Push 6 on the handset and change the value to 18 by pushing CONT, (the display will start flashing), turn
the knob when you see the 18, push store to save setting.
6. Sit on the seat to close the seat switch.
7. Leave the handset plugged in.
8. Make sure the directional lever is in neutral position and the seat switch is closed, Press the ESC key on
the handset.
9. If a – 83 appears, one of the above conditions has not been met. You will need to start over. ‘AAAA’
should appear on the handset display.
10. With your foot off of the accelerator pedal, the start switch in the “ON” position, push the directional lever
into forward and ‘AAA’ should now appear on the handset display.
11. Put the directional lever back into neutral and ‘AA’ should now appear on the handset display.
12. Depress the accelerator all the way down and hold it.
13. Push the directional lever into forward and ‘A’ should now appear on the handset display.
14. Put the directional lever back into neutral and – 11 should now appear on the handset display.
15. Release the accelerator and the truck should operate normally.
If during this procedure a fault code – 86 appears, there may be something wrong with the output of the
accelerator or there was just a glitch in the setup. Turn the key switch OFF then back ON to reset the proce-
dure and try again. If the procedure is unsuccessful more than 3 times, then there may be something wrong
with the output of the accelerator. The voltage output for the accelerator must not exceed 4.3V and the differ-
ence between the output voltage in the OFF position and the output voltage at full activation of the accelera-
tor must be between 2.5V and 4.2V. If any of these criteria are not met, a fault code – 86 will appear. One
possible cause for this is the incorrect adjustment of the accelerator pedal stop bolt. The distance from the top
of the threaded bolt to the flat surface of the floor plate should be 22 ± 2 mm X (26 ± 2 mm for foot direction
control).
If the accelerator range is set properly, function 6 will automatically change back to a value of 0. Because the
value of function 6 is defaulted to 255 when a controller is initially set up, the accelerator must also be set up
every time new settings are installed into the controller.
2-33
Premium Display Speedometer Setup (For Premium Display Option Only)
• The premium display has the ability to show the speed of the truck. Since the gear ratio is different
between a 1 ton truck and a 2-3 ton truck, the display must be set to show the right speed for the right
size truck.
• Plug the battery into the truck with the key switch OFF and make sure the display is blank.
• Once the display is blank, press and hold down both gray buttons on the display for 15 seconds.
• While holding down the buttons, the display will first show a blinking speed unit for 10 seconds, then it will
show nothing for 5 seconds.
• After 15 seconds a number will appear blinking on the right side of the display. At this time, release both
buttons.
• Now you are in the speed setup mode. The value of this setting can be changed from 1 to 25.
• If the truck is a 1 ton truck set the value to 18. If the truck is a 2 or 3 ton truck, set the value to 5.
• To set the value, press and hold down the right button. The number will start counting up. Once the
correct number is shown, release the right button.
• To input this value, press and release the left button once. The number should stop blinking if it is set.
• To exit this setup mode, press and release both buttons once.
• If the number does not seem like it is being set, exit this setup mode and reenter to try again.
2-34
CHECKS & REPAIRS
3. CHECKS & REPAIRS

General Information ............................................................................................................. 3-1
Fuses .................................................................................................................................. 3-2
Exploded View of Contactor ................................................................................................ 3-3
Contactor Repair.................................................................................................................. 3-4
Truck Management Module ................................................................................................ 3-5
Thermal Transfer ................................................................................................................. 3-6
Traction Control ...................................................................................................................3-10
Trouble Shooting Tips (Motors) ..........................................................................................3-11
Unsatisfactory Brush Performance .....................................................................................3-12
Commutator Surfaces Conditions........................................................................................3-18
CHECKS & REPAIRS
General Information
Pump fuse
(350 Amperes)
Traction Fuse
(350 Ampere for 600 Amp control)
(500 Ampere for 740 Amp control)
Traction and Pump Ampere rating is identified by the 11th, 12th and 13th
digit of the GE part number
example: 606 = 600 and 746 = 740 marked on the bottom of the controller
by the buses or bus bars.
! WARNING
Some adjustments in this section must be done with the battery connected and power applied to the
controller. When making these adjustments, make sure the drive wheels are raised from the floor.
Some voltage measurements must be made with the SRO circuit complete. Make sure the drive
wheels are raised from the surface before doing troubleshooting. If working alone, put a
weight in the seat to close the seat switch. Put the voltmeter so that you can see it from the operator
area. This will allow the controls to be operated while taking voltage measurements.
3-1
CHECKS & REPAIRS
General Information
! WARNING
Make sure to disconnect the battery and
separate the connector before disassembling
any part of the controller. The capacitor stores
electrical energy and can cause injury if a person
discharges a capacitor through parts of the
body. AFTER the battery is disconnected, make
sure to also discharge the capacitor by using a
p/n 358-280 Resistor across the positive and
negative terminals on the control panel for a
least 20 seconds.
☞ NOTICE ☞
The electronic controller in these lift trucks can not be
seen from the operator area. Some checks and
adjustments are difficult to do unless another person
can operate the controls.
☞ NOTICE ☞
The bolts and screws connected to the electronic
components are normally metric sizes. Make sure that
the correct fastener for the part that has been disas-
sembled is used.
Fuses
The fuses are found on the SX control panel. The
value of the power fuse for the traction controller is
350 amps for the 600 amp controller and 500 amps
for the 740 amp controller. The value of the power
fuse for the hydraulic pump controller is 350 amps
and the value for the hydraulic pump contactor is 500
amps. The value of the power fuse for the power
steering motor is 60 amps. The condition of the fuses
can be determined by looking at them or checking
with an ohmmeter.
3-2
CHECKS & REPAIRS
Contactor Repair Contactor Line

1 CONTACTOR
Make a location identification for the wires and cables 2 WASHER,PLAIN
then disconnect from the contactor assembly. Remove 3 TIP,SPRING
the mounting screws and remove the contactor TOP
assembly. 4 TIP,SPRING
Contactor Contacts. The contacts in a contactor 5 TIP, SPRING
are made of special silver alloy. The contacts will SEAT
look black and rough from normal operation. This 6 TIP,MOVABLE
condition does not cause problems with the 7 CLAMP,BUS
operation of the lift truck. Cleaning is not necessary. 8 SCREW
DO NOT USE A FILE ON THE CONTACTS. 9 WASHER,
DO NOT LUBRICATE THE CONTACTS. LOCK
10 TIP,CARRIER
11 BUSHING,
! WARNING PLUNGER
12 TIP,
STATIONARY
ALWAYS replace all of the contacts in a contac-
15 BASE,BUS
tor at the same time. Replace the contacts in
the contactor for the hydraulic pump after 1000 16 ARMATURE
hours of operation. Replace the contacts in the 17 SPRING,
other contactors when the thickness of any ARMATURE
area of a contact is less than 30% of the thick- 18 FRAME
ness of a new contact or if there is any transfer 19 COIL
of contact material. 20 MAGNET
BASE ASSY
21 KIT,SERVICE
TIP
22 NUT
Typical
Contactor Assembly
3-3
CHECKS & REPAIRS
Contactor Repair
Coil. Check the coil with an ohmmeter for an open circuit or a short-circuit. Replace if damaged. The coils in
the contactors for the hydraulic pump and 1A have an external suppressor. The coil and the suppressor can be
checked separately with an ohmmeter. A suppressor diode (and sometimes a resistor in series) is part of the
coil. The diode will cause the ohmmeter to indicate a difference in resistance in one direction. Reverse the probes
of the ohmmeter to the opposite terminals and measure the resistance. Use the highest resistance.
COIL RESISTANCE TEST SPECIFICATIONS

Line, Traction Line and Pump Line (36/48V) 59 ohms ± 10%
Line and Power Steering (72/80V) 161 ohms ± 10%
Power Steering (36/48V) 77 ohms ± 10%
Pump and 1A Bypass (36/48V) 33 ohms ±10%
Brush Wear Indicators Motor Thermal Switches

The brush wear indicator will illuminate on the premium The motor thermal switch will illuminate on both
display only, when the motor brushes must be replaced. displays. The switch is located in the motor and the
The sensor is located on the brush carrier and will over temperature action light will illuminate when the
come in contact with the brush holder when the brushes motor overheats. The thermal switch cannot be
have passed a serviceable limit. When the brush wears replaced if it is damaged. The thermal switch can only
within approximately 1.5 mm (0.060 in) of the brush be replaced by replacing the motor fields.
lead, the connection between the brush and the sensor
causes the indicator to illuminate on the premium display
The operation of the brush wear indicators can be
checked during periodic maintenance. The battery must ! WARNING
be removed from the lift truck for access to the
motors. To prevent damage and injury if the lift truck
Use a jumper cable so that the battery can be moves. Raise the drive wheels from the floor
connected for operation of the motors. See during these tests.
FIGURE 11. Disconnect the sensor wires from
the outside of the motor case. Touch the ends of each
sensor wire to the A1 terminal of the motor while it is Use a jumper cable so that the battery can be connected
in operation. The warning light will illuminate if the for operation of the motors. See FIGURE 11.
Disconnect the sensor wires from outside of the
motor case. Touch the ends of the sensor wire
1. RAISE DRIVE WHEELS together. The warning light will illuminate if the circuit
2. REMOVE BATTERY is operating correctly.
3. INSTALL JUMPER
Connect the battery so that the motor can be

operated. The battery must be removed for
access to the motor. Use a jumper cable to
connect the battery to the lift truck. Raise the
drive wheels. See “Before Servicing Forklift Truck”
in the GENERAL INFORMATION Section.
FIGURE 11. Connect Battery to Operate Motor

3-4
CHECKS & REPAIRS
Truck Management Module ☞ NOTE ☞

The Truck Management Module is a multi-function The microprocessor only checks for TMM status
accessory card or an auxiliary function of the SX codes 94 and 95 when a neutral signal is present (i.e.
Pump control used with the SX series Traction con- open start switch or open F/R switch), the status code
trols. The TMM card provides the status codes or is displayed and the speed limit enabled when the
operator warning codes, that will be displayed on the control is returned to the run mode.
dash display whenever a normally open switch or sen-
sor wire provides a signal to. The TMM is used to dis- The TMM is also used as a Brush Wear Indicator
play overtemperature of motors, hydraulic systems or (BWI) when the truck is equipped with a premium dis-
any other device or system than can activate a ther- play. The Brush Wear Indicator is designed to detect a
mostat type switch that closes at the desired tempera- worn-out brush and display a fault code on the dash
ture. Status code 90 not only displays the status code display to warn maintenance personnel that the motor
to the dash display but when activated can be pro- brushes need to be replaced before they wear to the
grammed with the Handset to reduce the speed of the point of causing destructive damage to the motor
truck from 100% to 0% percent on time. The TMM is commutator surface. The BWI is a sensor that short
also used to monitor and display motor brush wear circuits to the motor armature to signal limits of brush
warnings on the premium display when the motor wear.
brushes require replacement.
NOTE: Motor armature must be in the positive
side of the battery circuit.
Operation
The TMM card utilizes up to 6 input points and 3 output
points (See Wiring Section for connections). The 3
output points connect to the “P2” plug on the traction
Controller. The input to the TMM card is a switch wire ! WARNING
closure to battery negative or positive.
Before adjusting, servicing or making contact
The instructions for adjustment of the speed
with working components, raise the truck
limit function of status code 90 is described in
wheels off the floor, disconnect the battery and
detail in the instructions for the Handset. The
discharge the capacitor in the traction and pump
speed limit function will be enabled when the
controls
input switch supplies a negative signal to TB1.
3-5
CHECKS & REPAIRS
Thermal Transfer
Why is Thermal Transfer important?
Solid-state electronic devices are often considered
“lossless” as compared to their electro-mechanical
counterparts. However, these devices are not entirely
100% efficient and losses exist in the form of generated
heat which must be dissipated properly to insure
long-term reliability and performance.
The Control incorporates solid-state devices through-

out. It also incorporates heat sinking to provide proper
dissipation of the generated heat through these heat
sinks to the control base to be eventually dissipated in
the vehicle control mounting structure (i.e. bulkhead).
The Control heat sinks are designed to provide relief

from short-term thermal peak overloads, but long-term
cooling is dependent on proper thermal transfer from
the heat sink to the vehicle frame.
What determines
“Good” Thermal Transfer?
The primary factor for insuring “good” thermal transfer
is a good mechanical surface-to-surface interfacing
for flat and threaded surface mating. The effective-
ness of the thermal transfer is a function of the
amount of actual surface contact there is between a
heat “source” and a properly selected heat “sink”.
While most commercially prepared surfaces appear

flat and smooth, good thermal transfer of the heat
generated in solid-state devices requires the optimum
in surface contact. The smallest amount of surface
irregularity can be detrimental as it adds to the
thermal resistivity between the two surfaces and limits
thermal transfer.
“Good” thermal transfer is thus dependent on 3 factors:
1. Proper heat sinking.

2. Proper mechanical mating (mounting).
3. Optimum surface contact.
3-6
CHECKS & REPAIRS
Insuring Proper Thermal Transfer
Mounting Instructions for Motor Controls
In the design of this family of motor controls, performance assumptions were made based on heat transfer between the
control and the ambient environment. The vehicle mounting surface acts as a heat sink, which
increases the effective surface area for heat dissipation. If this assumed heat transfer is not
achieved during control installation and operation, the controllers will fall short of their antici-
pated performance. It should be noted that the condition of the mounting surface, and the
quality of the resulting interface between the control and the vehicle, can significantly hinder
heat transfer from the control.This why each control has a thin sheet of copper between the
control and the frame of the truck. The presence of contaminants, or of air voids created by
surface inconsistencies in either the vehicle or the control, degrade the control’s capacity for
heat transfer. The control’s performance is de-rated proportionally as its own thermal sensors
reduce its operation to protect it from damage due to excessive heating.
Contained within the software of the controls are several diagnostic status codes related to controller thermal perfor-
mance. Failure to follow these mounting recommendations increases the likelihood of encountering these status codes.
Careful surface preparation, including adequate application of thermal compound, as detailed in the following para-
graphs, must be completed during the installation of the controls. There are many techniques for applying thermal com-
pound, and one approach is outlined below that has shown to apply a consistent thickness of material.
Necessary Tools
Recommended use of the following components, or equivalent substitutions, during the control installation process:
a) Thermal compound, (5P9837), maintained per the manufacturer’s recommendations and free of
contaminants
b) 3/32" notched trowel, such as a adhesive spreader, model SE000049
c) Calibrated torque wrench (0 – 15 ft-lbs)
The Controls
During the manufacture of the control, the surface flatness is maintained at 0.005" per linear inch (not to exceed 0.025"
per 10.0 inches). The surface finish of the control has an Ra (average roughness) of 64 (microinches), or better. This fin-
ish is consistent with cold rolled or extruded aluminum.
Care should always be taken in the handling and storage of controllers. The base of the control should be free from
nicks, bumps, protrusions or any other foreign object that would prevent the control from sitting flush with the vehicle
mounting surface. Examine the base of the control to verify that it is in good condition and free from damage or contami-
nation.
Vehicle Mounting Surface

The quality of the vehicle mounting surface is critical for the optimum heat transfer between the control and the ambient
environment. Conduction through the base of the control is the control’s only means of heat rejection. While the controls
are highly efficient, a few percent of the electrical energy will be converted into heat. As previously mentioned, if this
energy is not dissipated through the base of the control, a thermal protector will reduce the performance of the control
until the temperature stabilizes. For optimal heat transfer from control to vehicle, the flatness of the vehicle mounting sur-
face should be equivalent to the flatness of the control surface (0.005" per linear inch). Use a straight edge or dial indi-
cator to verify the mounting surface.
The biggest hindrance to heat transfer is the presence of rust, scale, weld splatter or paint on the vehicle mounting sur-
face. If any of these items are noted, prepare the surface per the following guidelines:
a) Clean the mounting surface with a rotary wire brush until the metal surface is exposed.
b) Using 80-100 grit emery paper, sand the surface until the metal shines.
c) Flush the surface clean with an appropriate liquid de-greaser or parts cleaner.
3-7
CHECKS & REPAIRS
Application of Thermal Compound

Due to the minute differences in the control mounting surface and the vehicle mounting surface, small pockets of air will
be created. These air pockets will add to the overall thermal resistance of the interface. To avoid these air pockets and
improve thermal conductivity, thermal compound must be applied between the control base plate and the vehicle mount-
ing surface. The function of this compound is to conform to surface discrepancies, filling gaps and optimizing the metal-
to-metal contact of the control and the vehicle.
a) Prepare the two mounting surfaces (control and vehicle) as indicated above.
b) Using a triangular notched trowel of 3/32" (.09" ± .01), apply the grease to the vehicle mounting surface.
c) Use straight, non-crossing strokes of the trowel to apply the compound.
d) Make multiple vertical passes until a uniform consistency is achieved.
Adhesive spreader model SE000049 Vehicle surface after proper grease

application
Mounting the Control

a) After control mounting surface is prepared with heat sink grease, place the copper heat conducting pad on heat
sink grease and align holes as positioned.
b) After placing the copper pad, apply heat sink grease to the exposed side of the pad using the same method as
before.
c) Prepare mounting surface of truck.
d) Place the control unit with desired orientation on mounting surface of truck with mounting holes aligned.
e) Move the control slightly in all directions to eliminate voids and enhance the distribution of the thermal compound.
f) Insert all of the mounting hardware (6 or 8 bolts, M6, necessary for the mounting of the respective control).
g) Tighten these bolts (as per sequence shown in diagrams below) to half of the nominal torque value (4 ft-lb).
h) Lastly, tighten the bolts to the nominal torque value (8 ft-lb), following the same sequence.
Calibrated torque wrench for hardware installation
3-8
CHECKS & REPAIRS
Traction
8 5
Hydraulic
4 5
2 3
2 1
4 1
6 3
6 7
Proper sequence for use in tightening hardware during control mounting
Maintenance
If it is necessary to remove the control, careful consideration must be given to removing the old thermal compound from
the control and mounting surface, prior to replacement of the unit. Never re-use thermal compound. Use a putty knife or
similar straight edge to carefully remove all thermal compound residue without damaging either mounting surface. Flush
the surfaces with a liquid de-greaser or parts cleaner and allow them to dry, before re-applying the thermal compound
and mounting the control. Take care not to contaminate the surfaces with hydraulic fluid or battery acid.
If the copper heat conducting pad between the control and the truck shows signs of corrosion that cannot be cleaned,,
then the copper pad must be replaced. otherwise, carefully remove the old thermal compound and reapply it before
installing the new control.
3-9
CHECKS & REPAIRS
Traction Control
1 Traction Control 5 Bolt, Lockwasher Assembly

2 Pad, TR Heats 6 Washer, Plain
3 Bolt, Washer Assembly 7 Fuse
4 Washer, Plain 8 Washer, Spring
3-10
CHECKS & REPAIRS
Trouble Shooting Tips (Motors)
☞ COMMUTATION
SUCCESSFUL
REQUIREMENTS
☞ ☞ INSULATION SYSTEM ☞
• Insulation resistance - 0.10 Mega-ohm (or greater)
• Good contact between commutator and brush
• Less than 0.10 Mega-ohm, investigate:
• Mechanically true commutator
– Excessive dirt
• Brushes free to move in holders – Moisture
– Insulation break down
• Copper-Oxide-Carbon film (as opposed to pure
copper surface) noted by color variations For moisture, bake in an oven at 90 degrees C (190F)
• Commutator surface should be clean and smooth • 600V - 60HZ - 1 minute
• Clean commutator • Test older motors at 75% of above values
NOTE: Refer to the next following pages for charts

on “Unsatisfactory Brush Performance” and
illustrations of “Commutator Surfaces” which show
☞ ARMATURE WINDING PROBLEMS ☞
the main patterns of film build-up on commutators, • Open Circuit
and indicate the type of brush/commutator interaction – Thin red sparks encircling commutator
which give rise to each pattern.
– Blackens or flattens commutator bars,
especially at edges
☞ SPARKING AT BRUSHES ☞ • Short Circuit
• Commutator in poor condition – Blue spark in vicinity of brush holder
– Commutator bars oxidize or burn
• Eccentric or rough commutator
• Grounded
• Excessive vibration – High current draw
– Rapid brush wear
• Broken or sluggish spring
• Brushes to short
• Machine overloaded
• Short circuit in armature
Notes:
3-11
CHECKS & REPAIRS
Unsatisfactory Brush Performance
TABLE ONE
Primary Sources of Unsatisfactory Brush Performance
• Poor operation of commutator surface

• High mica
Preparation and Care of Motor • Side mica
• Need for periodic cleaning
• Clogged ventilating ducts
• Brushes tight in holders

• Brushes too loose in holders
• Brush holders loose at mounting
Mechanical Fault in Motor • Loose pole pieces
• Loose or worn bearings
• Dynamic imbalance
• Variable angular velocity
• Open or high resistance connection at commutator

• Connection at series terminal
Electric Fault in Motor • Short circuit in field or armature winding
• Ground in field or armature winding
• Reversed polarity on main pole
• Overload
• Dynamic braking
• Low average current density in brushes
• Contaminated atmosphere
Load or Service Condition • “Contact positions”
• Oil on commutator or oil mist in air
• Abrasive dust in air
• Humidity too high
• Humidity too low
• Silicone contamination
• Loose or damaged motor mounting

• External source of vibration
• External short circuit
• Contact drop of brushes too high
Disturbing External Condition • Contact drop of brushes too low
• Lack of film-forming properties in brush
• Lack of polishing action in brush
• Brushes too abrasive
• Lack of carrying capacity
3-12
CHECKS & REPAIRS
TABLE TWO
Indications Appearing at Brushes
INDICATION IMMEDIATE CAUSES PRIMARY FAULTS
Sparking Commutator surface condition • Poor operation of commutator surface

• High mica
• Side mica
• Low average current density in brushes
• Contaminated atmosphere
• Contact positions
• Lack of polishing action in brush
Mechanical fault in motor • Clogged ventilating ducts

• Brushes too loose at mounting
• Loose pole pieces
• Loose or worn bearings
• Dynamic unbalance
• Incorrect spring tension
Electrical fault in motor • Open or high resistance connection

at commutator
• Short circuit in field or armature winding
• Ground in field or armature winding
• Reversed polarity on main pole
Bad load condition • Overload

• Rapid change of load
Vibration • Loose or damaged motor mountings

Chattering of brushes • See Chattering or Noisy Brushes
Wrong brush grade for • Lack of film-forming properties in brush

application
Other • Silicone contamination
Etched or Burned Embedded copper • See Copper in Brush Face

Bands on Brush Face
Rapid Brush Wear Commutator surface condition • See specific surface fault in evidence
• Silicone contamination
Severe sparking • See Sparking

3-13
CHECKS & REPAIRS
TABLE TWO (cont’d)

Indications Appearing at Brushes
Rapid Brush Wear Imperfect contact w/commutator • Incorrect spring tension

(cont’d) • Brushes tight in holders
• Brushes too loose in holders
• Brushes holders loose at mounting
• Loose or damaged motor mountings
Wrong brush grade f/application • Lack of film-forming properties in brush
Copper in Brush Face Commutator surface condition • High mica

• Side mica
Bad service condition • Oil on commutator or oil mist in air


Chattering or Commutator surface condition • Raised Commutator Bars

Noisy Brushes
Looseness in motor • Brushes too loose in holders

• Incorrect spring tension
High friction • Clogged ventilating ducts

• Contact poisons
3-14
CHECKS & REPAIRS
TABLE THREE
Indications Appearing as Heating
Heating in Windings Severe load condition • Overload

(Field or Armature) • External short circuit
• Stalled motor
Unbalanced magnetic field • Loose or worn bearings

• Short circuit in field or armature winding
Lack of ventilation
Heating at Severe load condition • Overload

Commutator
Severe sparking • Contact positions
• See Sparking
High friction • Incorrect spring tension

• Contact poisons
Poor commutator surface • See specific surface fault in evidence
Depreciation • Clogged ventilating ducts
High contact resistance • Contact drop of brushes too high
Heating at Brushes Severe load condition • Overload
Faulty motor adjustment • Incorrect spring tension
Raw streaks on commutator • See Streaking or Threading of Surface
Embedded copper • See Copper in Brush Face
Wrong brush grade f/application • Contact drop of brushes too low

• Lack of carrying capacity
3-15
CHECKS & REPAIRS
TABLE FOUR
Indications Appearing at Commutator Surface

Brush Chipping or Commutator surface condition • See specific surface fault in evidence
Breakage
Looseness in motor • Brushes too loose in holders
Vibration • External source of vibration
Chattering • See Chattering or Noisy Brushes
Sluggish brush movement • Brushes tight in holders
Rough or uneven surface • Poor operation of commutator surface

• High mica
• Side mica
High Commutator Bar Sparking • Stalled motor
Low Commutator Bar Sparking • High mica

• Open or high resistance connection
at commutator
• Stalled motor
Streaking or Sparking • Low average current density in brushes

Threading of Surface • Contaminated atmosphere
• Contact positions
Copper or foreign material in • High mica

brush face • Side mica
Bar Etching or Sparking • High mica

Burning • Side mica
Bar Marking at Sparking • Open or high resistance connection

Pole Pitch Spacing at commutator
3-16
CHECKS & REPAIRS
TABLE FOUR (cont’d)

Indications Appearing at Commutator Surface
Bar Marking at Sparking • Lack of polishing action in brush

Slot Pitch Spacing • Lack of film-forming properties in brush
Flat Spot Sparking • Open or high resistance connection at

commutator
• Stalled motor
Discoloration of High temperature • See Heating at Commutator

Surface
Atmospheric condition • Contaminated atmosphere
• Oil in commutator or oil mist in air
Wrong brush grade for application • Lack of polishing action in brush

Raw Copper Surface Embedded copper • See Copper in Brush Face
Bad service condition • Contact positions

Wrong brush grade for application • Lack of film-forming properties in brush

Rapid Commutator Burning • High mica

Wear with • Side mica
Blackened Surface • Incorrect spring tension
Rapid Commutator Foreign material in brush face • Contact positions

Wear with • Abrasive dust in air
Bright Surface • Humidity too low
Wrong brush grade for application • Brushes too abrasive

• Lack of film-forming properties
Copper Dragging Brush Vibration • External source of vibration

3-17
CHECKS & REPAIRS
Commutator Surfaces
GOOD CONDITION UNSATISFACTORY CONDITION
LIGHT FILM UNEVEN FILM
Uniform coloring indicates Patchy colors of varying densities
satisfactory operation of and shape. Due to unclean
machine and brushes. Film color operating conditions or incorrect
is largely an effect of thickness, physical condition of commutator.
therefore provided the film is
uniform it is perfectly
acceptable.
SATISFACTORY CONDITION UNSATISFACTORY CONDITION

LIGHT AND DARK PATTERN FILM WITH DARK AREAS
This is not a good condition but These areas can be isolated or
in our experience it is known regular. Commutator out of
that machines having this round. This can be caused by
commutator pattern have vibration or mechanical
operated with satisfactory results deficiencies in equipment
for long periods of time. This operation, bearings, couplings,
condition can appear in etc.
alternating bars as shown or
every 3rd or 4th bar, etc. This is
related to the winding design of
the armature. Difficulty caused
from split windings crossing in
the same slot.
UNSATISFACTORY CONDITION UNSATISFACTORY CONDITION

STREAKY FILM WITH NO EXAMPLE OF POOR
COMMUTATOR WEAR COMMUTATOR
Frequently due to under-loaded MACHINING
operation, machine grossly Bars are low on entry and
over-brushed or brush grade leaving edges giving rise to the
incorrect for particular machine brushes riding on the middle of
application. Atmosphere and the bars.
environmental conditions can
contribute.
3-18
CHECKS & REPAIRS
Commutator Surfaces
EXAMPLE OF POOR BRUSH CONTACT MARK
COMMUTATOR Storage of machines, for lengthy
MACHINING periods, with brushes in position.
Bars are low in the middle giving This can also result from
rise to the brushes riding on operation of machine in
entry and leaving bar edges. prolonged stall conditions.
This and the previous illustration
indicate the need for better
maintenance.

STREAKY FILM WITH BAR EDGE BURNING
COMMUTATOR WEAR CAUSE HIGH MICA
This is a further development of Illustration shows high mica in
the third example, previous every slot. Same effect can
page. Brush grade, machine occur on one bar only. Similar
applications and working conditions can be caused by a
environment all suspect. Earlier high or low bar.
corrective action should have
been taken.

DOUBLE POLE PITCH SMALL BRIGHT SPOTS
Darkening of commutator in Related to over-loaded
sequences two pole pitches machines and low brush pres-
apart is due to armature fault, sure. Due to sparking under
defective coil, riser bars or brush which gives rise to spots
equalizer connections. being of a random distribution. If
not corrected, will result in
scored commutator.
3-19
SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM
4. SX CONTROL CONNECTIONS & TROUBLESHOOTING

BY SYMPTOM
SX Control ........................................................................................................................... 4-1
Failures that Cause Reduced or No Motor Torque ............................................................. 4-2
Misoperation of Other Features .......................................................................................... 4-5
SX Control
F1 F2
P2
Neg
GE Name Plate and

Part Number
P1 A1
A2 Positive
These troubleshooting instructions are intended as a Note:

method to check all outside devices and eliminate The settings for the controller must be set after
them as the source of the problem in order to installation. See Controller Setup in the Handset sec-
conclude that the SX Control is faulty. tion for the proper procedure.
Instructions for Removal of SX Control
1. Disconnect Battery, Discharge Cap, Raise drive

wheels.
2. Unplug main and Y plugs by pressing down on

tab and pulling straight out on connector. Never
use wires to pull out connector.
3. Remove power fuse and all Bus or cable

connections from control.
4-1
The primary method of diagnosing SX Control System
faults is to use the diagnostic features of the display and 1st Check is for Shorts to frame. Voltage on frame
handset. These, along with the preceding fault code tables, may cause many problems and codes.
aid in the resolution of the majority of faults encountered.
If a problem is readily identified through the built-in diag- 2nd Checks are always loose/dirty connections at
nostics feature, use the following tables as a secondary controller and harness connections.
guide to aid in the identification of the fault.
TABLE ONE
Failures that Cause Reduced or No Motor Torque
☞ NOTE ☞
Conduct all testing with drive wheels raised off the floor.
Symptom Probable Cause
1a. Line Contactor does not pick up. No • Check power and control fuses.
control voltage from positive to
negative. • Check battery for low specific gravity and connections
for looseness or broken connector.
1b. Line Contactor does not pick up. • Check PTC (Positive Temperature Coefficient) for
with control voltage positive to heating. If hot to touch, check for proper battery polarity
negative to control panel.
• Plug in the battery with the key switch OFF. Voltage on
should be battery volts at P1-1.
• Close key switch and check volts at P1-2; voltage should

be battery volts. If not check control fuse FU2
• With key switch and seat switch closed, check for battery
volts at P1-6. If zero, check control fuse, wiring or
faulty key switch. If low check for volt drop across circuit
from battery pos to P1-6.
• With key switch and seat switch closed, check for

battery volts at P1-2. If zero, check control wire #10
between key switch and seat switch and control card or fault
seat switch. If low check for volt drop across circuit to P1-2.
• Check for positive at line contact coil. P10-2 connection.
If not battery volts check line coil for open or possible loose
connections.
• Static Return to Off Fault.

If monitoring system warning light on display (!) comes on,
once the key switch and seat switch are closed:
• Check for fault in directional control switch.
• Check for fault in wiring to directional control switch
4-2
TABLE ONE (cont’d)

☞ NOTE ☞
1c. Line contact closes, truck • Check power fuse at positive on control. Should be
doesn’t move battery volts. If not, check power fuse by volt drop check
across fuse
• Check for over temperature condition on traction motor

or traction control.
• Check voltage at A1 and A2, should be battery volts. If

not, check motor cables and volts at A1 and A2 to locate
open circuit. Check motor brushes for sticking
• Check F1 to F2 for open field circuit. (loose connections)
• Check for voltage on F1 and F2, it should increase and

decrease by pressing accelerator and releasing.
• Check voltage at P1-7. Should be 0.5 volts with accelerator

at creep speed, increasing to 3.5 volts or more as the
accelerator is pressed down to top speed. If P1-7
remains at about 0.5 or less volts, check start switch
and accelerator potentiometer.
• Check circuit from accelerator start switch and

potentiometer to traction control for open wires.
• Check motor A1 to A2 for open circuit in motor armature.
• Check motor F1 to F2 for open circuit in motor fields.
• Check for direction switch inputs to control at P1-5 and

P1-6 for forward and reverse. If voltage not present,
check circuit to accelerator. Positive at P7-A and check for
circuit through switch at P7-B and P7-C.
• Replace the SX Traction control.
4-3
TABLE ONE (cont’d)

☞ NOTE ☞
1d. Line contactor closes, display powers • Check for direction switch positive to control at P1-4 and
up, Power steering contactor does not P1-5. If not present check direction switch and voltage to
close. switch.
• With direction switch input voltage to P1-4 or P1-5. Check

for positive voltage to power steering coil at P10-3 wire
21. If voltage is not present check coil for open by
resistance check. If Low voltage check for volt drop
across wire 10 from key switch and across key switch.
• If battery voltage is correct at P10-3 and all other voltage

are correct to traction control. The power steering driver
in the control has failed and SX controller must be
replaced.
4-4
TABLE TWO
Mis-operation of Other Features
☞ NOTE ☞
1a. 1A Bypass contact does not close • Check accelerator voltage to control at P1-7. Voltage
(If equipped) should start at below 0.5v and increase to above 3.5 volts
as accelerator is depressed
• Voltage from accelerator must go above 3.5V at P1-7 to

achieve 1A By Pass operation.
Warning: • Check Battery position voltage at 1A bypass coil to PID

Do Not use jumper wire on driver terminal 3 wire 30.
coil driver with motor in static
condition or Severe damage • Check for Battery Neg at PID driver terminal 2.
may occur to motor armature.
However controller protects • Check for signal voltage from control at P1-11 to PID
against this action and should driver terminal 1. Voltage should be less than 12.
produce a code
• If voltage is 12 or higher at P1-11 or PID driver terminal 1
then check for open PID driver.
• If voltage is 2 or less and terminal 2 and 3 do not

complete the circuit the PID driver may be shorted or
open and should be replaced.
4-5
TABLE THREE
☞ NOTE ☞
1a. 1A Bypass contactor close with key. • Check for short to negative on wire 45 from coil to
driver terminal 3.
• Check for signal voltage at P1-11 if present.

Replace SX controller
1b. Power Steering contact closes with • Check for voltage short to battery neg on wire 21
key switch between P10-3 and P1-18.
• Check Negative voltage at P10-3. If present replace SX

controller.
4-6
TABLE THREE (cont’d)

☞ NOTE ☞
3a. 1A Bypass contactor will not close at • Check voltage.

stall. (If equipped)
• Check Bypass contactor and driver and wiring.
• Replace SX Controller.
3b. 1A will not open until start switch • Check voltage at P1-7. Should be near 0.5 volts, or below
is opened. when accelerator is released. If not, check accelerator
output.
3c. Stiff Regen (severe reversal). • Check Regen adjustment setting on Controller.
• Check controller type setting.
• Check traction motor brushes.
• Check traction motor commotator for raised bars or

out of round..
3d. Very soft reversal during regen • Check for proper adjustment of regen.
braking mode.
• Check controller type setting
4-7
NOTES
4-8
WIRING
5. WIRING
Pump Contactor Schematic.................................................................................................. 5-3
Traction Bypass with Pump Control Schematic ................................................................... 5-7
Pump Control Schematic...................................................................................................... 5-9
Traction Motor Controller with Pump Motor Controller and Bypass.....................................5-11
Voltage Checks.....................................................................................................................5-13
TMM7A (Truck Management Module) .................................................................................5-16
Pump Driver..........................................................................................................................5-18
Pump Time Delay ................................................................................................................5-19
WIRING
Connections to Main Traction Plug P1 with Controller Hydraulics

Pin Wire COLOR PUMP INPUT/OUTPUT NORMAL ACTIVE TEST PROCEDURE
1 2 Blue Battery volts from battery B+ B+ Plug in Battery
2 10 Yellow Battery volts from key 0 B+ Key on
3 15 Yellow / BlackAccelerator Start Switch 0 B+ Push Accelerator
4 6 Green Forward Switch 0 B+ Move F/R to Forward
5 8 Green / Black Reverse Switch 0 B+ Move F/R to Reverse
6 7 Red Seat Switch 0 B+ Close Seat Switch
7 29 White Accelerator Input .3 - .8 V 3.4 – 4.2 v Push Accelerator
Voltage Signal to floor
8 28 Black Accelerator Negative 0 B- Checked to Battery +
9 56 Black Accelerator Pot + 4–5V 4.2 V Battery Plugged in
5 Volt Supply
10 17 Black / White BDI Interrupt for .5 V 12 V Seat switch closed
Lift Lockout 0V Low Battery (lift Lockout)
11 9 Blank
12 Blank
13 Blank
14 Blank
15 Blank
16 Blank
17 20 Black /Red LINE CONTACTOR B+ 0-1 V Line Contactor Closed
DRIVER AND
SUPPRESSION
18 21 Black / Green STEER PUMP CTR B+ 0-1 V Steer Contactor Closed
DRIVER AND
SUPPRESSION
19 Blank
20 Blank
21 10 K Yellow HOURMETER INPUT 0V B+ Key on
FOR PUMP CONTACTOR
22 Blank
23 Blank
Pins 1 & 2 Normal Voltage is Battery plugged in Key and Seat Switch open.
Pins 3 – 8 Normal Voltage is Battery plugged in Key Closed and Seat Switch open.
Pins 9 –23 Normal Voltage is Battery plugged in Key and Seat Switch Closed.
1 2 3 4 5 6 6 8 Input Pins 1-8

9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 Outputs & Signal Voltage Pins 9-23
WIRE HARNESS VIEW- MAIN PLUG
5-13
WIRING
Connections to Main Hydraulic Plug P5 with Controller Hydraulics

Pin Wire COLOR PUMP INPUT/OUTPUT NORMAL ACTIVE TEST PROCEDURE
1 2A Blue Battery volts from battery B+ B+ Plug in battery
2 10A Yellow Battery volts from key 0 volts B+ Key switch on
3 - - Blank
4 - - Blank
5 85 Blue / White BWI Traction Motor 0 volts Brushes worn
6 86 Yellow / White BWI Traction Motor 0 volts Brushes worn
7 - - Blank
8 87 Violet / White BWI Pump 0 volts Brushes worn
9 88 Green / Black BWI Pump 0 volts Brushes worn
10 17 Black / White Hyd. Enable signal 12 volts 0 volts Low Battery (lift cutout)
Seat switch closed
11 82 Red / White Pump Temperature 5 volts 0 volts Over Temp light on
12 52 Yellow / Blue Pump Aux 1 & 2 Switch 5 volts 0 volts Handle pulled
(switch closed)
13 24 Green To Plug 2 – 8 5 volts
14 23 Green To Plug 2 – 9 5 Volts
15 - - Blank
16 80 Brown / White Traction Temperature 5 Volts 0 Volts Over temp light on
17 - - Blank
18 - - Blank
19 53 Yellow / Black Hyd lift Switch # 2 5 Volts 0 Volts Pull lift lever full
(High Speed lift)
20 51 Yellow / Green Tilt Switch 5 Volts 0 Volts Push tilt lever
21 54 Yellow / Red Hyd lift Switch #1 5 Volts 0 Volts Pull lift lever back
(Low speed lift)
22 - - Blank
23 - - Blank
1 2 3 4 5 6 6 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
WIRE HARNESS VIEW- MAIN PLUG
5-14
WIRING
CONNECTIONS TO MAIN PLUG (23 PIN) AND P2 or P4 PLUG (12 PIN)

PIN TRACTION INPUT/OUTPUT (P1) PUMP INPUT/OUTPUT (P5)
1 Battery volts from battery Battery volts from battery
2 Battery volts from key Battery volts from key
3 Battery volts from start switch Status code 93 input
4 Battery volts from forward switch Status code 93 input
5 Battery volts from reverse switch Status code 94 input
6 Battery volts from seat switch Status code 94 input
7 Accelerator input voltage signal Potentiometer input voltage signal
8 Accelerator negative Status code 95 input
9 Accelerator pot +5 volts supply Status code 95 input
10 BDI interrupt for lift lockout Pump Enable signal 12v DC
11 1A Driver signal Status code 91 input
12 Optional switched speed limit set by function 11 Speed limit #1 input
13 Not used TMM brushwear indicator output
14 Hydraulic switch sensor TMM over temperature output
15 Not used Status code 92 input
16 Not used Status code 90 input
17 Line contactor driver and suppression Line contactor driver
18 Steer pump control driver and suppression 1 A contactor driver
19 TMM +5 volt supply Speed limit #2 input
20 Not used Speed limit #3 input
21 Hourmeter input for pump contactor Speed limit #4 input
22 Not used Not used
1 2 3 4 5 6 1 2 3 4 5 6 6 8
9 10 11 12 13 14 15
7 8 9 10 11 12
16 17 18 19 20 21 22 23
WIRE HARNESS VIEW P2 or P4 WIRE HARNESS VIEW- MAIN PLUG
Pin Traction P2 “Y” Plug Input/Output Pump “P4” Plug Input/Output

1 Not used Not used
2 Not used Not used
3 Not used Not used
4 Negative Negative
5 +5 volt supply +5 volt supply
6 Cont/Store(in) Handset Cont/Store(in) Handset
7 Not used Not used
8 Value Not used
9 Function Not used
11 Serial Receive Serial Receive
12 Serial Transmit Serial Transmit
5-15
WIRING
TMM7A (Truck Management Module)
CONNECTOR WIRE DESCRIPTION CONDITION NOMINAL

TERMINAL # VOLTAGE
No Fault 5V
1 73 Traction Motor Over Temperature
Traction Motor Over Temperature 0V
2 – Not Used
No Fault 5V
3 74 Pump Motor Over Temperature
Traction Motor Over Temperature 0V
4 – Not Used
No Fault 0V
5 75 Traction Motor BWI
Traction Motor Brushes Worn B+
No Fault 0V
6 76 Traction Motor BWI
Traction Motor Brushes Worn B+
7 70 P2-9 Traction Card –
No Fault 0V
8 77 Pump Motor BWI
Pump Motor Brushes Worn B+
9 71 P2-9 Traction Card –
No Fault 0V
10 78 Pump Motor BWI
Pump Motor Brushes Worn B+
13 72 P1 19 Traction Card – +5V
14 – Not Used
15 79 Battery Negative 0V
0V
5-16
WIRING
P11 PIN # ERROR TMM7A TMM7A TRUCK TRANSISTOR DESCRIPTION

TERMINAL # WIRE # HARNESS PUMP CONTROL
WIRE # PIN #
2 None TB7 70 23 P5-14 P2-9 On Traction Control
3 None TB9 71 24 P5-13 P2-8 On Traction Control
P1-19 On Traction Control
4 None TB13 72 25/17 P5-10 with pump contactor
P1-10 on Traction Control
with pump control
5 90 TB1 73 80 P5-16 Traction Motor Overtemp
6 91 TB3 74 82 P5-11 Pump Motor Overtemp
7 93 TB5 75 85 – Traction BWI
8 93 TB6 76 86 – Traction BWI
9 94 TB8 77 87 – Pump BWI
10 94 TB10 78 88 – Pump BWI
– 94 – – 85 P5-5 Traction BWI
– 94 – – 86 P5-6 Traction BWI
– 95 – – 87 P5-8 Pump BWI
– 95 – – 88 P5-9 Pump BWI
NOTE: TMM7A wires are all black with numbers stamped in white. Truck harness wires are multi colored
with wire numbers stamped 10mm from each terminal. Some TMM7A wire numbers are exactly
the same as truck harness wire numbers, but the wires are not connected.
5-17
WIRING
Pump Driver
FUNCTION: Controls the power supply to the contactor coil according to the control signal input.
TERMINAL TRUCK WIRE DESCRIPTION CONDITION VOLTAGE ON

# HARNESS # TERMINAL
WIRE #
Not Activated 0V
1 NA 52 Control Signal Input
Activated 5V
2 13 13 Battery Negative Always 0V
Contactor Not Activated BV
3 18 50-1 Contactor Coil Input
Contactor Activated 0 - 0.5V
4 N/A Not Used
BV = Battery Volt
5-18
WIRING
Pump Time Delay

FUNCTION: Controls the power supply to the pump driver according to the control signal input.
TERMINAL TRUCK CONTACTOR

DESCRIPTION CONDITION VOLTAGE ON
# WIRE PANEL TERMINAL
HARNESS # HARNESS #
Not Activated 0V
1 NA 52 Control Signal Output
Activated 5V
2 13 13 Battery Negative Always 0V
Contactor Not Activated 12V
3 52 53 Control Card Input to Delay
Contactor Activated 11V
BV
4 10 10 Battery Positive Key On
BV
BV = Battery Volt
5-19
WIRING
Shorted or Open Field or Armature FET Test

DESCRIPTION:
If a problem is suspected with the SX controller, the following test procedure will assist you in diagnosing field
and armature transistor (FET) failures in SX controllers. This test may be used for both the traction and pump
controllers.
NOTE: You must use a digital meter set to the DIODE TEST FUNCTION to perform these tests.
ARMATURE FET TEST:

1. Remove all cables and wire harnesses from the SX controller.
2. Verify the digital meter is set to the diode test function.
3. Attach the RED lead to the NEG terminal and attach the BLACK lead to the A2 terminal.
4. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If an armature FET
is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the
Controller.
5. Attach the RED lead to the A2 terminal and attach the BLACK lead to the POS terminal.
6. A properly function SX controller will have a reading between 0.3 and 0.6 volts. If an armature FET is
shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the
Controller.
FIELD FET TEST:

1. Attach the RED lead to NEG and attach the BLACK lead to F1.
2. A properly function SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted
or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.
3. Attach the BLACK lead to F2.
4. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is
Controller.
5. Attach the BLACK lead to POS and attach the RED lead to F1.
Controller.
7. Attach the RED lead to F2.
Controller.
5-20
Traction Bypass with Pump Contactor 5-1
yp
1
3 2
1. Controller, Traction
2. Contactor, Hydraulic Pump Motor
3. Fuse (Traction Circuit)
4. Fuse (Hydraulic Pump Circuit)
5. Fuse Panel (FU 1, FU 2, FU 3)
6. Fuse 5 (Steering Circuit)
7. Contactor, Power Steering Motor
5-3
Pump Contactor
1
1
2. Contactor, Hydraulic Pump Motor
3. Fuse 4 (Traction Circuit)
4. Fuse 6 (Hydraulic Pump Circuit)
8. Contactor, 1-A Bypass
9. Contactor, Line
2
2
3
3
8
8 7
7
5
4
4
9 9
6
6
5-5
Traction Bypass with Pump Contactor
5-7
Traction Bypass with Pump Control
2
1
2. Controller, Pump
3. Contactor , Line
5. Fuse 4 (Traction Circuit)
8. Fuse 6 (Hydraulic Pump Circuit
8
6
87
5
67
4
3
5-9
Pump Control
5-11
Traction Motor Controller with Pump Motor Controller and Bypass
SX DIAGNOSTIC STATUS CODES
6. DIAGNOSTIC STATUS CODES

Basic Checks ....................................................................................................................... 6-1
Status Codes ........................................................................................................................ 6-2
Basic Checks
The biggest mistake technicians can make is to • When you get the 8888 on the handset push
assume they know the problem before starting to work down on the key pad #1 button to double check
on a truck. Unfortunately while making our life easier the Status Code stored in the memory which
self-diagnostics also make us more susceptible to this should be the same as the dash display (if it
type of mistake. Never start to fix a truck based solely showed one).
on the number on the dash or handset display. Always
follow the basic troubleshooting steps. • Before proceeding check the card’s program-
ming.
• Talk to the operator. Always check each function and write down the
reading.
• Confirm their description of the problem with
an operational check. If the programming fails to match the specifications
reprogram the controller and check the truck opera-
tion before going any further. If repairs are required
• Visually inspect cables, connectors, contactor
turn the key switch off, then push the CONT and ESC
tips, etc.
keys at the same time to enter the History Folder.
These codes should only be zeroed out after the truck
• Perform basic battery cables to frame resistance is repaired and running properly.
tests. You should have at least 20,000 ohms.
Utilize the Status Codes in the following pages to find
the component or area to check for a fault. Status
• Check for any voltage on the frame. Codes can be the result of a defective controller, but
all voltage checks and testing should be performed
• Check the battery condition. before replacing.
Now we are ready to allow the self-diagnostics to give

us a starting point to repair the truck. Turn the key
switch on and check when the display goes through Display Codes
its boot up sequence to be sure all of the LEDs or Note – Shorts to frame may cause false codes.
LCD segments are functional. At this time note the CCCC – No activity detected on communication line
status (fault) code (if any) and then turn the key from display to controller. Check for shorts to
switch off so you can note the hours on the meter. frame by volts.
C– –C – Activity detected on communication line to
• Disconnect the battery and discharge the control, but does not make sense.
capacitor with the 150–25 watt resistor between PC – Pump controller information data cannot be
the Pos & Neg terminals on controller. read. Open in P4.
DC – Drive controller information data cannot be
• Remove the P2 plug which connects the dash read. Open in P2.
display to the card and insert the handset plug “=” – Fault Code Data from controller is outside of
connector. range
• Plug in the battery. Please see Display Section for proper setup of speed
sensor.
• While holding the CONT button down on the
handset turn on the key switch to enter the
programming mode.
6-1
TABLE OF CONTENTS
STATUS DESCRIPTION PAGE
CODE
Blank Segments do not illuminate on the Dash Display and/or the Handset. .6-4
-01 No seat switch input (no voltage to P1-6) . . . . . . . . . . . . . . . . . . . . . . . .6-4
-02 Forward directional switch is closed on initial power up . . . . . . . . . . . . .6-5
-03 Reverse directional switch is closed on initial power up . . . . . . . . . . . . .6-5
-05 Start switch or brake switch fails to close . . . . . . . . . . . . . . . . . . . . . . . .6-6
-06 Accelerator depressed with no direction selected . . . . . . . . . . . . . . . . .6-6
-07 Accelerator input voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
-08 Accelerator input speed too high on power up after initial key switch
closure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
-09 Both the forward and reverse directional switches are closed at the
same time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .6-8
-11 Start switch closed on power up after initial key switch closure . . . . . ..6-8
-15 Battery voltage is too low or control card is mis-adjusted . . . . . . . . . .. .6-9
-16 Battery voltage is too high or control card is mis-adjusted . . . . . . . . . .. 6-9
-21 Accelerator voltage is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
-23 Motor field current is too high on start up in the reverse direction . . . .6-10
-24 Motor field current is too high on start up in the forward direction . . . .6-11
-27 Control’s internal power supply is less than 10 volts DC . . . . . . . . . . .6-11
-28 Motor field current is too high during the run mode . . . . . . . . . . . . . . .6-12
-41 Shorted thermal protector (TP) or armature transistor
over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
-42 Motor armature offset voltage is too high . . . . . . . . . . . . . . . . . . . . . . .6-13
-43 Motor armature offset voltage is too low . . . . . . . . . .. . . . . . . . . . . . .6-13
-44 Armature transistor did not turn off properly . . . . . . . . . . . . . . . . . . . .6-14
-45 Armature transistor did not turn on properly . . . . . . . . . . . . . . . . . . . . .6-14
-46 Look Ahead test for A2 volts less than 12% of battery volts. . . . . . . . .6-15
-49 Motor field current is too low during the run mode. . . . . . . . . . . . . . .. 6-15
-51 Capacitor volts are low before the line contactor closes . . . . . . . . . . ..6-16
-57 Controller “motor current sensor” input too low during running . . . . . ..6-16
-64 The line driver input (P2-17) is less than 12% of battery volts . . . . . ..6-17
-65 The line coil is too high during the run mode . . . . . . . . . . . . . . . . . . .. 6-17
-66 The field current exceeds the current limit on the field transistor . . . .. 6-18
-67 The armature current exceeds the armature transistor limit . . . . . . . .. 6-18
-69 The power steering coil current is too high during the run mode. . . . .6-19
-76 Capacitor (1C) voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-19
-77 Motor current is detected during regenerative braking . . . . . . . . . . . .. 6-20
-82 If the armature motor current is greater than a preset value for
longer than 3.5 sec. The armature motoring current will be turned off . ..6-20
6-2
-83 A switch position is incorrect during the accelerator potentiometer
auto calibration routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-21
-86 Accelerator pot values obtained during the auto calibration routine
were not valid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
-89 Hydraulic lever is activated before the pump is enabled when key
switch is initially enabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
-89 Hydraulic lever is activated when truck is operating . . . . . . . . . . . . . ..6-22
-90 Traction motor temperature has exceeded maximum
temperature limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
-91 Pump motor temperature has exceeded maximum temperature limit. .6-24
-94 Traction motor brush wear indicator had detected a worn brush . . . . .6-25
-94 Traction motor brush wear indicator had detected a worn brush . . . . .6-25
-95 Pump motor brush wear indicator has detected worn brush . . . . . . . .6-26
-95 Pump motor brush wear indicator has detected worn brush . . . . . . . .6-26
-99 Maintenance alert and speed limit . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-27
-117 “Card Type” selection is invalid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-27
-127 Control logic card power supply is less than 10 VDC . . . . . . . . . . . . .6-28
-128 Armature current is too high during the lift mode . . . . . . . . . . . . . . . ..6-28
-141 Shorted thermal protector (TP1) or transistor is over temperature . . . .6-29
-142 Pump Controller “motor current sensor” input is missing . . . . . . . . . . .6-29
-143 Pump Controller “motor current sensor” input is too low . . . . . . . . . . ..6-30
-144 Power Transistor (Q1) did not turn off properly. . . . . . . . . . . . . . . . . . .6-30
-145 Power Transistor (Q1) did not turn o properly. . . . . . . . . . . . . . . . . . . ..6-31
-146 “Look Ahead” test for pump motor circuit volts less than 12% of
the battery volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
-150 Capacitor volts are low after the line contactor closes . . . . . . . . . . . . .6-32
-151 Capacitor volts are low before the line contactor closes.
(Internal card function during pre-charge) . . . . . . . . . . . . . . . . . . . . . .6-32
-157 Controller “motor current sensor” input voltage polarity check . . . . . ..6-33
-180 Voltage at capacitor (1C) is less than 14 volts . . . . . . . . . . . . . . . . . . .6-33
-181 Battery voltage is less than 14 volts . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
-189 Input switch closed before pump enable signal is received. . . . . . . . .6-34
6-3
TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Segments do not illuminate on the No input voltage to the Logic Card or the display
NONE Dash Display and/or the Handset. unit.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Display screen on Dash Display and/or
Handset is blank.
POSSIBLE CAUSE
Positive or negative control voltage is not present.
• Insure that the key switch is closed and voltage
Circuits valid is present between P1-1 & battery negative.
Also check for voltage between P1-2 and
for control negative.
Traction
Open circuit between control card AND the Dash
Controller Display or Handset.
• Check for an open circuit or loose connection
going from the control and the Dash Display
or Handset.
Defective Dash Display or Handset.

• Replace Dash Display or Handset.

STATUS CODE No seat switch input This status code will be displayed when P1-6 is
-01 (no voltage to P1-6). less than 50% battery volts.

NO Control will not operate.
POSSIBLE CAUSE
Mis-adjusted or defective seat or deadman
switch.
• Check to see that the seat switch closes
Circuits valid properly.
for
Open circuit between battery positive and P1-6.
Traction • Check for loose connections or broken wires:
Controller -Between the seat switch and P1-6.
-Between the key switch and the battery
positive side of the seat switch.
-Between the seat switch and P1-2.
• On vehicles without a seat/deadman switch,

check for a loose connection or broken wire
from P1-2 and/or P1-6.
6-4

STATUS CODE Forward directional switch is closed This status code will be displayed when P1-4 is
-02 on initial power up. greater than 60% of battery voltage at initial key
switch on.

NO Control will not operate because of Static
Return to Off (SRO) lock out.
POSSIBLE CAUSE
Forward directional switch is closed on initial
start up (i.e. closure of battery, key switch or
Circuits valid seat/deadman switch).
• Return directional switch lever to neutral and
for then return lever to forward position.
Traction
Forward directional switch is welded closed or
Controller mis-adjusted to be held closed.
• Replace or adjust directional switch to insure
that it opens when the directional switch is
returned to neutral.
Defective control.
• Replace the controller unit.

STATUS CODE Reverse directional switch is closed This status code will be displayed when P1-5 is
-03 on initial power up. greater than 60% of battery voltage at initial key
switch on.

NO Control will not operate because of Static
Return to Off (SRO) lock out.
POSSIBLE CAUSE
Reverse directional switch is closed on initial
start up (i.e. closure of battery, key switch or
Circuits valid seat/deadman switch).
• Return directional switch lever to neutral and
for then return lever to reverse position.
Traction
Reverse directional switch is welded closed or
Controller mis-adjusted to be held closed.
• Replace or adjust directional switch to insure
that it opens when the directional switch is
Defective control.
• Replace the controller unit.
6-5

STATUS CODE Start switch or brake switch fails to This status code will be displayed when P1-7 is
-05 close. calling for greater than 40% speed and P1-3 is
less than 60% of battery volts.

POSSIBLE CAUSE
Defective start switch circuit.
• Check start switch to insure closure with
accelerator pedal released.
Circuits valid • Check for open circuit or loose connection in
wiring from key switch to start switch and
for from P1-3 to start switch.
Traction
Controller Defective accelerator switch.
• Check accelerator switch potentiometer for
proper operation and ohmic value.

STATUS CODE Accelerator depressed with no This status code will be displayed when P1-4 &
-06 direction selected. P1-5 are less than 60% of battery volts, and P1-7
is calling for greater than 40% speed.

POSSIBLE CAUSE
Accelerator pedal is depressed before closing
forward or reverse directional switch.
• Status code will disappear when directional
Circuits valid switch is closed or when accelerator pedal is
released.
for
Traction Defective directional switch.
• Check forward or reverse switch to insure
Controller closure when direction is selected.
Open circuit between directional switch(es) and

battery positive or between directional
switch(es) and P1-4 or P1-5.
• Check all control wires and connections
shown in Trouble Shooting Diagram.
6-6

STATUS CODE Accelerator input voltage too high. This status code will be displayed when the accelerator
input voltage at P1-7 is 0.7 volts less than the zero
-07 speed auto calibration value for the accelerator.

NO Control will not operate when accelerator
pedal is depressed or status code -07 is dis-
played then disappears when the vehicle
starts to accelerate.
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
Circuits valid P1-9 P1-7 P1-8
for Open circuit between battery negative and P1-7
in accelerator input circuit. 56 29 28
Traction • Check for broken wires or loose connections
Controller or open potentiometer / voltage supply. P9-4 P9-1
Short circuit from battery positive to wiring in
accelerator input circuit.
P9-3
ACC. POT

STATUS CODE Accelerator input speed too high on This status code will be displayed when the
-08 power up after initial key switch accelerator input voltage at P1-7 is calling for greater
closure. than 20% speed, and any of the following connec-
tions are opened and closed: battery or key switch.
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
• Input voltage at P1-7 should be more than
20% speed.. Adjust or replace accelerator unit
Circuits valid to insure that the voltage at P1-7 is calling for
less than 20% before depressing pedal. P1-9 P1-7 P1-8
for
Traction • Repeat the auto calibration routine outlined in 56 29 28
Accelerator Controller Set-up Procedures of
Controller this manual.
P9-4 P9-1
• P1-7 or the accelerator pot negative have an
open circuit.
P9-3
• Defective Control ACC. POT
6-7

STATUS CODE Both the forward and reverse This status code will be displayed when P1-4 and
-09 directional switches are closed at the P1-5 are greater than 60% of battery volts at the
same time. same time.

POSSIBLE CAUSE
Forward or reverse directional switch welded
closed or mis-adjusted to be held closed.
• Replace or adjust directional switches to insure
Circuits valid that they open when directional switch is
for
Traction Short circuit between battery positive and P1-4
and / or P1-5.
Controller • Disconnect wires from P1-4 and P1-5 and
check wire for short circuit to positive side of
directional switch.
Defective card.
• Disconnect wires and measure voltage at
P1-4 and P1-5. Voltage should be less than
60% of battery volts.

STATUS CODE Start switch closed on power up after This status code will be displayed when P3 is
-11 initial key switch closure. greater than 60% of battery voltage when the key
switch is closed.

POSSIBLE CAUSE
Start switch input mis-adjusted or defective.
• Input voltage at P1-3 should be less than 60%
of battery volts at key switch closing. Adjust or
Circuits valid replace accelerator unit to insure that the
voltage at P1-3 is less than 60% of battery
for volts before closing the start switch.
Traction
Short circuit between battery positive and P1-3
Controller in start switch input circuit.
• Disconnect wire from P1-3. Check for short
circuit from wire to battery positive.
Defective card.
• Disconnect wire from P1-3. Measure voltage
from P1-3 to negative. Voltage should be zero,
if not, replace card.
6-8

STATUS CODE Battery voltage is too low or control This status code will be displayed when the battery
-15 card is mis-adjusted. volts are less than 1.95 volts per cell at initial key
switch on. See table below.

POSSIBLE CAUSE
Discharged battery.
• Check battery for proper open circuit voltage
as shown in “Trouble Shooting Diagram,
Circuits valid charge battery, if required.
for Defective battery.
Traction • Check each battery cell for proper voltage
(greater than 1.95 volts at cell). Replace or
Controller repair battery.
Incorrect control card adjustment.

• Check function 15 for proper adjustment for
battery being used. See Handset instruction
sheet for details. Adjust to proper settings.
Check “minimum” battery volts at P1-1 and

NEG.

STATUS CODE Battery voltage is too high or control This status code will be displayed when the bat-
-16 card is mis-adjusted. tery volts are greater than 2.40 volts per cell at ini-
tial key switch on. See table below.

POSSIBLE CAUSE
FU1 15A
Incorrect control card adjustment. 5
• Check function 15 for proper adjustment for
NOMINAL MAXIMUM
battery being used. See Handset instructions LIMIT VOLTS
Circuits valid for details. Adjust to proper setting. BATTERY
VOLTAGE
AT 2.4 VDC
PER CELL
for Battery over-charged or incorrect battery used. 24 28.8
Traction • Check battery for proper open circuit voltage 36 43.2
per table in trouble-shooting diagram. If voltage
Controller excessive, check battery charger for proper
48 57.6
72 86.4
output voltage. +
P1-1 80 100.8
Check “maximum” battery volts at P1-1 and

NEG. -
NEG
Traction
Control N
Terminal
6-9

STATUS CODE Accelerator voltage is too high. This status code will be displayed when the voltage
-21 at P1-7 is greater than 4.5 volts.

NO Controller will not operate.
POSSIBLE CAUSE
• Verify wire connection between accelerator pot
to P1-8.
Circuits valid • Verify wire connection between P1-7 to

P1-9 P1-7 P1-8
for accelerator pot.
56 29 28
Traction • Verify that the accelerator pot is adjusted
Controller properly. P9-4 P9-1
P9-3
ACC. POT

STATUS CODE Motor field current is too high on start This status code will be displayed when the cur-
-23 up in the reverse direction. rent draw in the motor field is too high at start up
in the reverse direction.

POSSIBLE CAUSE
Defective control
• Replace controller unit.
Circuits valid
for
Traction
Controller
6-10

STATUS CODE Motor field current is too high on This status code will be displayed when the current
-24 start up in the forward direction. draw in the motor field is too high at start up in the
forward direction.

Control does not operate.
NO
POSSIBLE CAUSE
Defective control.
Circuits valid
for
Traction
Controller

STATUS CODE Control’s internal power supply is This status code will be displayed when the control’s
-27 less than 10 Volts DC. power supply is less than 10 volts.

YES Line contactor opens and closes, then can
only be closed by opening and closing the KEY
key switch. FU2 SWITCH
12
POSSIBLE CAUSE 5
Discharged Battery. FU1
Circuits valid • Check battery to insure proper state of charge. 10
Voltage may be dropping below 10 Volts DC
for under load. + 2
Traction
Loose connection at P1-1.
Controller • Insure that the wire connection at P1-1 is tight. -
P1-1 should be at battery voltage. P1-1 P1-2
NEG
Defective control.
6-11

STATUS CODE Motor field current is too high dur- This status code will be displayed when the current
-28 ing the run mode. in the motor field is sustained above a preset limit
for longer than 70 seconds.

YES Control will not operate.
POSSIBLE CAUSE
Continued operation of vehicle in high motor cur-
rent condition.
• Operate vehicle at lower motor current THE PRESENCE OF THIS STATUS CODE
Circuits valid condition for 70 seconds.
IS NOT NECESSARILY INDICATIVE OF A
for Function 7 is mis-adjusted to allow higher than CONTROL ISSUE. IF FUNCTION 7 IS NOT
Traction normal motor filed current.
MIS-ADJUSTED, THE STATUS CODE INDI-
• Adjust function per OEM instructions.
Controller CATES AN APPLICATION ISSUE WHERE A
MOTOR IS BEING STALLED, ETC. DIS-
PLAY OF THIS STATUS CODE SHOULD
NOT TRIGGER THE RETURN OF A CON-
TROL FOR REPAIR OR REPLACEMENT.

STATUS CODE Shorted thermal protector (TP) or This status code will be displayed when the voltage
-41 armature transistor over temperature. at the thermal protector is too low.

YES Reduced or no power to traction motor in
transistor range.
POSSIBLE CAUSE
Control is in thermal cut-back.
• Allow control to cool, status code should THE PRESENCE OF THIS STATUS CODE
Circuits valid disappear.
IS NOT NECESSARILY INDICATIVE OF A
for Defective control. CONTROL ISSUE. IF FUNCTION 7 IS NOT
Traction • Replace controller unit. MIS-ADJUSTED, THE STATUS CODE INDI-
Controller NOTE: Thermal protector located in control is CATES AN APPLICATION ISSUE WHERE A
not serviceable. MOTOR IS BEING STALLED, ETC. DIS-
PLAY OF THIS STATUS CODE SHOULD
NOT TRIGGER THE RETURN OF A CON-
TROL FOR REPAIR OR REPLACEMENT.
6-12

STATUS CODE Motor armature offset voltage is too This status code will be displayed when the voltage
-42 high. at the current sensor input is greater than 2.6 volts
with no current flowing in the motor circuit.

POSSIBLE CAUSE
Defective control.
Circuits valid
for
Traction
Controller

STATUS CODE Motor armature offset voltage is too This status code will be displayed when the voltage
-43 low. at the current sensor input is less than 2.4 volts
with no current flowing in the motor circuit.

POSSIBLE CAUSE
Defective control.
Circuits valid
for
Traction
Controller
6-13

STATUS CODE Armature transistor did not turn off This status code will be displayed when, during
-44 properly. control operation, the armature transistor fails to
turn off. This will result in a PMT condition.

YES Line contactor opens and then can only be
closed by opening and closing the key
switch.
POSSIBLE CAUSE
Defective control.
Circuits valid • Replace controller unit.
for
Traction
Controller

STATUS CODE Armature transistor did not turn on This status code will be displayed when, during
-45 properly. control operation, the armature transistor fails to
turn on properly. This will result in a PMT condition.

YES Truck will not operate.
POSSIBLE CAUSE
Defective control.
Circuits valid
for
Traction
Controller
6-14

STATUS CODE “Look Ahead” test for A2 volts less This status code will be displayed when the volt-
-46 than 12% of battery volts. age at A2 is less than 12% of battery volts.

YES Line contactor will open.
POSSIBLE CAUSE
Check for short circuit from the motor armature
to the frame of the vehicle.
Circuits valid Check for welded 1A contactor (if used)

for Defective control.
Traction • Replace controller unit.
Controller

STATUS CODE Motor field current is too low during This status code will be displayed when the current
-49 the run mode. draw in the motor field is too low during the run
mode.

POSSIBLE CAUSE
Defective control or connection.

Circuits valid
• Open motor field winding.
for
Traction
Controller
6-15

STATUS CODE Capacitor volts are low before the line This status code will be displayed during “key on”
-51 contactor closes. when the capacitor volts is less than 85% of battery
volts at initial key switch on.

NO Line contactor does not close when capaci-
tor does not pre-charge.
POSSIBLE CAUSE
• Welded 1A contactor (if used)
• Check PTC for open circuit on line contactor.
Circuits valid • Check for conductivity across open 1A
contactor.
for
Traction Wiring error
• Insure that there is no device connected to
Controller load side of line contactor.
Defective control.
1A CTR 740Amp
control only

STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage
-57 too low during running. input from the current sensor is too low during run-
ning.

POSSIBLE CAUSE
• Line contactor power tips did not close.
• Volt drop across contactor tips.

Circuits valid
Defective control.
for • Replace controller unit.
Traction
Controller
6-16

STATUS CODE The line driver input (P2-17) is less This status code will be displayed when the control
-64 than 12% of battery volts. detects that the line driver input (P2-17) is less than
12% battery volts when the key switch is turned on.

NO Control does not operate. Line contactor
does not close.
POSSIBLE CAUSE
• Open wire connection to Pin P1-17.
• Shorted line Driver transistor in control.
Circuits valid • Possible open circuit in line contactor coil
for Defective control.
Traction • Replace controller unit.
Controller

This status code will be displayed when the current limit in the line
STATUS CODE The line coil is too high during the run coil driver is exceeded during the run mode. The line contactor will
-65 mode. drop out and the key switch will have to be recycled to reset the
control.

YES Control does not operate.
POSSIBLE CAUSE
• Shorted line contactor coil.
• Short between wires connected to line coil.
Circuits valid If line coil resistance is correct:

(59Ω for 36-48)
for (161Ω for 80V)
Traction
Defective control.
Controller • Replace controller unit.
6-17
TRACTION
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
This status code will be displayed when the field transistor
STATUS CODE The field current exceeds the current exceeds its specific current limit. The line contactor will
-66 limit on the field transistor. drop out and the key switch will have to be recycled to
restart the control.

• Line contactor opens.
POSSIBLE CAUSE
• Shorted field F1 to F2
Circuits valid • Open FU4 fuse

for • F1 or F2 terminals shorted to battery positive
Traction (B+)
Controller • F1 or F2 Terminals shorted to battery negative
(B-)
(The controller looks for a high change in current

over time to identify a short circuit in the field or
cables.)
TRACTION
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
STATUS CODE The armature current exceeds the This status code will be displayed when the armature tran-
armature transistor limit. sistor exceeds its specific current limit. The control is reset
-67 by recycling the key switch.

POSSIBLE CAUSE
• Shorted motor armature A1 to A2
• Power cables may be shorted to each other

Circuits valid (Measure at control terminals)
for • A1 to A2 terminals may be shorted to battery
Traction positive or negative.
Controller
6-18

STATUS CODE The power steering coil current is too This status code will be displayed when the current in the
high during the run mode. power steering driver circuit exceeds current limit during the
-69 run mode. The control is reset by recycling the key switch.

POSSIBLE CAUSE
• Shorted power steering control coil
• Short between wires connecting to the power
steering coil.
Circuits valid • Open FU4 fuse
for
Traction If the power steering coil resistance is correct
(59Ω for 36-48volt)
Controller (161Ω for 80 volt) then:
• Defective control. Replace control unit.

STATUS CODE Capacitor (1C) voltage too high. This status code will be displayed when the voltage on
the capacitor goes above limit voltage* during the
-76 regenerative braking cycle.

YES Line contactor opens and closes, then opens
and can only close by opening and closing the
key switch.
POSSIBLE CAUSE
• Unplugging the battery connector during LINE FU4
Circuits valid regenerative braking.
• Line contactor bouncing open during regen.
for • Main power fuse opening during regen. +
ARMATURE
Traction • Intermittent battery plug connection.

Battery
FIELD
Controller * Limit Voltage: -

POS A1 F1
POWER CONNECTIONS
Limit Batt. NEG A2 F2

50V 36V
70V 48V
96V 72/80V
6-19

STATUS CODE Motor current is detected during This status code will be displayed when motoring
-77 regenerative braking. current is detected during the regenerative braking
cycle.

YES Truck will not operate.
POSSIBLE CAUSE
Defective control.
• Replace controller unit
LINE FU1
Circuits valid
for +
ARMATURE
Traction Battery ACC POT
FIELD
POS A1 F1
Controller -
POWER CONNECTIONS
NEG A2 F2

STATUS CODE If the armature motor current is greater than a
This status code will be displayed when the armature
preset value for longer than 3.5 sec the armature
-82 motoring current will be turned off.
motor current exceeds a preset value for 3.5 sec and the
accelerator pedal is calling for maximum performance.

YES The Control will not operate, and can only be
reset by cycling the key switch.
*CODE WARNING*
POSSIBLE CAUSE:
• Continued operation of vehicle in high motor
THE PRESENCE OF THIS STATUS CODE
current condition IS NOT NECESSARILY INDICATIVE OF A
Circuits valid • Operating control at stall motor current for
CONTROL ISSUE. IF FUNCTION 16 IS
more than 3.5 seconds.
for • Function 16 is incorrectly adjusted for control NOT MIS-ADJUSTED, THE STATUS
Traction % on time.
CODE INDICATES AN APPLICATION
Adjust function
Controller • Function 16 is adjusted a level of 130 for all ISSUE WHERE A MOTOR IS BEING
controls except the 9"15K-18KL which is set to
120 and the EE’s are all set at 160.
STALLED, ETC. DISPLAY OF THIS STA-
• Possible mechanical resistance to motor TUS CODE SHOULD NOT TRIGGER THE
rotation.
RETURN OF A CONTROL FOR REPAIR
OR REPLACEMENT.
*Continued occurrence of this code could

lead to damage to motor assembly.
6-20

This status code will be displayed when the seat switch is
STATUS CODE A switch position is incorrect during the open, or the any of the forward, reverse or start switches
-83 accelerator potentiometer auto calibra- are closed at the beginning of the accelerator potentiome-
tion routine. ter auto calibration routine.

NO The auto calibration routine outlined in
Section 8 of this manual will not start.
POSSIBLE CAUSE:
• Seat switch is open
• Confirm switch wiring, or replace
Circuits valid switch, if required.
for • Any of the forward, reverse or start switches
Traction are closed
• Confirm switch wiring, or replace
Controller switch, if required.

STATUS CODE Refer to Section 8 of this manual for possible causes of
Accelerator pot values obtained during the
-86 auto calibration routine were not valid. this status code.

NO Accelerator potentiometer auto calibration
routine was not successfully completed.
POSSIBLE CAUSE:
• Misadjusted or defective accelerator
potentiometer assembly
Circuits valid • Verify the accelerator potentiometer operation.
• Open circuit on the accelerator potentiometer.
for P1-9 P1-7 P1-8
Traction
Controller 56 29 28
P9-4 P9-1
P9-3
ACC. POT
6-21

STATUS CODE Hydraulic lever is activated before the This status code will be displayed when the voltage
-89 pump is enabled when key switch is ini- at P14 is greater than 3 volts at pump enable
tially activated. (10ms).

NO The truck will not run or the pump will not
operate.
POSSIBLE CAUSE:
Shorted or welded hydraulic switch
Circuits valid • Verify connections to hydraulic switches
• Verify mechanical operation of hydraulic
for switches (check adjustment).
Traction
• Check for short between wire 50 and 52.
Controller
• Check for shorted switch.

STATUS CODE This status code will be displayed when the voltage
Hydraulic lever is activated when truck at P14 is greater than 3 volts at pump enable
-89 is operating (10ms).

NO Hydraulic functions do not operate.
POSSIBLE CAUSE:
• Battery voltage has dropped to Lift Lockout
conditions.
Circuits valid
for
Traction
Controller
6-22

STATUS CODE Traction motor temperature has This status code will be displayed when the voltage
-90 exceeded maximum temperature limit. at the respective terminal of the Pump Logic Card is
at zero volts.

YES Status code flashes “on and off”. Action
Light flashes.
POSSIBLE CAUSE
User defined status code is displayed by switch
closure to battery negative.
Circuits valid
• Defective temp switch (shorted). Traction
for motor.
Traction
• Defective TMM card.
Motor
Temperature • Wire 80 shorted to battery NEG.
(Contactor • Battery Neg @ TMM7A terminal 1 P11-5
Hydraulics)

STATUS CODE Traction motor temperature has This status code will be displayed when the voltage
-90 exceeded maximum temperature limit. at the respective terminal of the TMM is at zero
(with pump controller hyd.) volts.

YES Status code flashes “on and off”. Action light
flashes
POSSIBLE CAUSE
Circuits valid
• Defective temp switch (shorted). Traction
for motor.
Traction
• Defective pump card.
Motor
Temperature • Wire 80 shorted to battery NEG.
(Pump • Battery Neg @ pump control P5-16
Controller)
6-23

STATUS CODE Pump motor temperature has This status code will be displayed when the voltage
volts.

YES Status Code flashes “on and off”. Action
Light flashes
POSSIBLE CAUSE
Circuits valid
• Battery Neg at TMM7A terminal 3 P11-6.
for
Hydraulic • Wire 82 shorted to battery NEG.
Pump • Defective Temp switch (shorted).

Temperature
• Defective TMM card.
(Contactor
Hydraulics)

STATUS CODE Pump motor temperature has This status code will be displayed when the voltage
(with pump controller hyd.) volts.

YES Status Code flashes “on and off”.
POSSIBLE CAUSE
Circuits valid • Defective temp switch (shorted). Pump

motor.
for
Hydraulic • Defective pump card.
Pump • Wire 82 shorted to battery NEG.

Temperature • Battery Neg at P5-11
(Pump
Controller)
6-24

STATUS CODE Traction motor brush wear indicator This status code will be displayed when the voltage
-93 had detected worn brush. at terminal 8 and 10 of the TMM is at zero volts.

POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Circuits valid • Worn brushes.

• Terminal 5 or 6 is shorted to positive on the
for TMM7A card.
Traction Motor • Defective input switch (shorted) check for
proper adjustment of the BWI T-bar on brush
Brush Wear holder.
Indicator • Wire 85 or 86 shorted to positive.
• Defective TMM7A card.
(Contactor
Hydraulics)

STATUS CODE Traction motor brush wear indicator This status code will be displayed when the voltage
-94 had detected worn brush. at the respective terminal of the Pump Logic Card is
at zero volts.

POSSIBLE CAUSE

• P5-5 or P5-6 is shorted to positive on pump
for control card.
Traction Motor • Defective input switch (shorted) check for
proper adjustment of the BWI T-bar on brush
Brush Wear holder.
(Pump • Wire 85 or 86 shorted to positive.
• Defective pump control card.
Controller)
6-25

STATUS CODE Pump motor brush wear indicator has This status code will be displayed when the voltage
-94 detected worn brush. at the respective terminal of the TMM is at battery
volts.

POSSIBLE CAUSE

NEG
for • Terminal 8 or 10 is shorted to positive on the
Pump TMM7A card.
Motor • Defective input switch (shorted) check for

Brush Wear proper adjustment of the BWI T-bar on brush
holder.
Indicator
(Contactor • Wire 87 or 88 shorted to positive.
Hydraulics)

STATUS CODE Pump motor brush wear indicator has This status code will be displayed when the voltage
-95 detected worn brush. at the respective terminal of the Pump Logic Card is
at battery volts.

POSSIBLE CAUSE
for • P5-8 or 5-9 is shorted to positive.

Pump
• Defective input switch (shorted) check for
Motor proper adjustment of the BWI T-bar on brush
Brush Wear holder.
Indicator • Wire 87 or 88 shorted to positive.
(Pump
• Defective pump control card.
Controller)
NEG
6-26

STATUS CODE Maintenance alert and speed limit. This status code will be displayed when the “normal”
-99 hour meter exceeds the “maintenance alert hours”
setting for the vehicle.

YES Status code is displayed for 4 seconds when
the key switch is first turned on, and/or the
vehicle may run at a reduced speed.
CUSTOMER SELECTED SETTING WITH THE

HANDSET:
Circuits valid User defined status code is displayed when the
normal hour meter reading exceeds the pro-
for grammed “maintenance alert hours” setting
Traction selected by the user
NO DIAGRAM
• Maintenance Code Hour Meter, Functions 19
Control and 20, are programmed with the Handset and
command the display of status code -99.
USER SHOULD PERFORM THE
• If desired, Maintenance Code Speed Limit, DESIRED MAINTENANCE FUNCTION
Function 13, can be programmed with the
Handset.
User should perform the desired maintenance

function. Re-set maintenance alert hour meter
after maintenance is performed.
.

STATUS CODE “Card Type” selection is invalid. This status code will be displayed when the card
-117 type selection value is set to an invalid number.

POSSIBLE CAUSE
Invalid card type selection.
• Review function 17 in the Handset Instruction
sheets. Adjust and set card type value as
Circuits valid instructed by Service Manual.
for
Pump NO
Controller GRAPHIC
FOR THIS
STATUS CODE
6-27
HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Control logic card power supply is less This status code will be displayed when the logic
-127 than 10 VDC. card power supply is less than 10 volts.

POSSIBLE CAUSE
Discharged battery
• Check battery to insure proper state of charge.
• Check control fuse FU 11.
Circuits valid
for Loose connection at P1-1.
• Insure that the wire connection at P1-1 is tight.
Pump • Insure that wire connection at P5-1 is tight.
Controller • Check for Volt drop across wire 12 and wire 2.
Defective logic card..

• Replace control.

STATUS CODE Armature current is too high during the This status code will be displayed when the current
-128 lift mode in the armature circuit is sustained above 400A for
70 sec.

POSSIBLE CAUSE
Continued operation of vehicle in high motor cur-
rent condition.
• Operate vehicle at lower motor current condi-
Circuits valid tion for 70 seconds.
for • Check hydraulic pressure adjustment. NO
Pump GRAPHIC
Controller
FOR THIS
STATUS CODE
6-28

STATUS CODE Pump control is over Temperature This status code is displayed when the voltage at
-141 the thermal protector is less than 3.8 volts.

YES Reduced or no power to pump motor in con-
trol range.
POSSIBLE CAUSE
Control is in thermal cut-back.
• Allow control to cool, status code should
Circuits valid disappear.
for • Check wire 23, P5-14 and P2-9
Pump
• Check hydraulic pressure adjustment.
Controller
NOTE: Pump control thermal protection is locat-
ed inside of pump control and is not serviceable

STATUS CODE Pump Controller “motor current sensor” This status code is displayed when the voltage at
-142 input is missing. the current sensor is greater than 1.6 volts with no
current flowing in the motor circuit.

NO No power to pump motor in control range.
POSSIBLE CAUSE
Control is defective.
Circuits valid • Note: Pump motor current sensor is located

inside of pump control and testing is not possi-
for ble.
Pump
Controller
6-29

STATUS CODE Pump Controller “motor current sensor” This status code is displayed when the voltage at
-143 input is too low. the current sensor is less than 0.6 volts with no cur-
rent flowing in the motor circuit.

NO No power to pump motor in control range.
POSSIBLE CAUSE
Control is defective
Circuits valid • Note: Pump motor current sensor is located

inside of pump control and testing is not possi-
for ble.
Pump
NOTE: Pump control thermal protection is locat-
Controller ed inside of pump control and is not serviceable

STATUS CODE Power Transistor (Q1) did not turn off This status code is displayed when, during pump
-144 properly. control operation, the transistor fails to turn off.

YES Control may run continuously.
POSSIBLE CAUSE
• Check switch adjustment.
• Check for shorts to Neg on wires 51,52,53,54.
Circuits valid
• Replace controller.
for
Pump
Controller
6-30

STATUS CODE Power Transistor (Q1) did not turn on This status code is displayed when, during pump
-145 properly. control operation, the transistor fails to turn on.

YES Control may run continuously.
POSSIBLE CAUSE
Circuits valid • Check for proper negative voltage at N

for terminal on control.
• Check for shorts to Neg on wires 51,52,53,54.
Pump • Check for proper positive voltage to control at
P5-1. 19-20, 21 and 12
Controller
• Check for proper positive voltage at P5-1
• Check for proper Neg voltage at N terminal on

control

STATUS CODE “Look Ahead” test for Pump motor cir- This status code will be displayed when the voltage
-146 cuit volts less than 12% of battery in the pump motor is less than 12% of battery volts.
volts.

YES Pump contactor will operate. FU6
P
POSSIBLE CAUSE
• Check for short circuit from the motor armature
to the frame of the vehicle.
• Check for open circuit from A1 to A2 on control
Circuits valid through motor.
A1
for Control is defective
Pump • Replace controller.
ARMATURE
A1
Controller
P A1 *
PUMP CONTROL
A2
POWER
CONNECTION
N A2
FIELD
A2
6-31

STATUS CODE Capacitor volts are low after the line This status code will be displayed when the capacitor
-150 contactor closes. voltage is less than 85% of the battery voltage in the
run mode.

YES Pump control will not operate.
POSSIBLE CAUSE 325 amps

Defective line contactor. FU6
P
• Check for open line contactor power tips.
• Check for volt drop across line contactor.
Circuits valid • Check for loose or open connections in cables A1
for from battery positive to control positive circuit.
ARMATURE
A1
Pump P A1 *
Defective power fuse.
Controller • Check power fuse for open circuit.
PUMP CONTROL
POWER
CONNECTION
A2
N A2
FIELD
*
No battery voltage at P5-1.
A2
• Check for battery voltage at POS and P5-1.
N
• Check for loose connection at P5-1.

STATUS CODE Capacitor volts are low before the line This status code will be displayed during “key on”
-151 contactor closes. (Internal card func- when the capacitor volts is less than 85% of battery
tion during pre-charge) volts at initial key switch on.

NO Pump control will not operate.
POSSIBLE CAUSE
Note: Repeated “charging/discharging” the
capacitors during troubleshooting will cause sta-
tus code 51. Also “do not” connect any loads to
Circuits valid the load side of the line contactor.
• Check battery voltage.
for • Check for open PTC resistor.
Pump • Check for battery voltage at P5-1
Controller Defective control.
Note: PTC resistor is located across the line

contactor that is serviceable.
Note: There is also a PTC resistor that is in the

controller and it is not serviceable.
6-32

STATUS CODE “Controller motor current sensor” input This status code will be displayed when the voltage
-157 voltage polarity check. input to motor current sensor is of the wrong polarity.

POSSIBLE CAUSE
Circuits valid
for
Pump
Controller

STATUS CODE Voltage at capacitor (1C) is less This status code will be displayed when the voltage
-180 than 14 volts. at P1 is less than 14 volts. This occurs typically in
the run mode of operation.

NO Pump Control will not operate.
POSSIBLE CAUSE
(Line contactor controlled by traction control).
Line contactor opened up during run.
•Check connection from P5-17 to Line coil (-) for
Circuits valid loose connection.
•Check connection from battery (+) to Line coil
for (+) for loose connection.
Pump •Check for failed power fuse at pump control.
•Check for dirty contactor tips.
Controller
6-33

STATUS CODE Battery voltage is less than 14 volts. This status code will be displayed when the battery
-181 voltage measured at P1 is less than 14 volts.

POSSIBLE CAUSE
• Check connection from control fuse to pump
P1 for loose connections.
Circuits valid • Check for low battery volts under load.

for • Check for volt drop between pos. and P5-1.
Pump
Controller

STATUS CODE Input switch closed before pump This status code will be displayed when pin
-189 enable signal is received. 12,19,20 or 21 is pulled to negative before pin 10 is
greater than 5.0 volts.

NO Pump Control will not operate.
POSSIBLE CAUSE
• Hydraulic handle pulled before pump enable
signal given.
Circuits valid • Shorted hydraulic switch.

for • Check Hydraulic switch adjustment.
Pump
• Defective control.
Controller
6-34
TECHNICAL PUBLICATIONS FEEDBACK
(Please Print)
Dealer name: Submitted by:
Address: P. O. Box:
City: State:
Zip code: Country:
The following discrepancy or omission has been discovered in:
❏ Operation & Maintenance Manual ❏ Option Bulletin
❏ Part List/Manual ❏ Special Instruction
❏ Service Manual ❏ Service Data manual
❏ Electronic Manual ❏ Other:

Publication # Engine model #
Truck model # Issue date #
Truck serial # Page #
(Please print)
Explanation of discrepancy or omission:
Please fax or mail completed form to:

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2121 W. Sam Houston Parkway N. P.O. Box 30171
Houston, Texas 77043-2305 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695
Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-861-9277
FBC15K, FBC18K, FBC18KL, FBC20K, FBC25K,
Mitsubishi Forklift Trucks Service Manual 99759-74120
FBC25KE, FBC25KL, FBC30K, FBC30KL Forklift Trucks

Service Manual for Forklift Chassis & Mast Components

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Service Manual for Forklift Chassis & Mast Components

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Service Manual

Chassis & Mast

Chapter 1: General Information

Chapter 2: Front Axle & Reduction Differential

Chapter 3: Transfer Assembly

Chapter 4: Rear Axle

Rear Wheels...................................................................................................................... 4.2

Rear Axle ........................................................................................................................... 4.7

Inspection and Adjustment ................................................................................................ 4.17

Chapter 5: Brake System

Chapter 6: Steering System

Chapter 7: Hydraulic System, continued

Lift and Tilt Cylinders

Inspection and Adjustment

Chapter 8: Mast and Forks

Chapter 9: Troubleshooting Section

Brake System ............................................................................................................. 9.2

Steering System ......................................................................................................... 9.4

Hydraulic System........................................................................................................ 9.6

Rear Axle .................................................................................................................... 9.8

Mast and Forks........................................................................................................... 9.9

Chapter 10: Maintenance Service Data

Maintenance Service Data ................................................................................................ 10.1

Maintenance Chart ............................................................................................................ 10.22

Planned Replacement Parts.............................................................................................. 10.28

Weight of Major Components (Approximate) .................................................................... 10.31

Special Service Tools ........................................................................................................ 10.32

Inspection Guide................................................................................................................ 10.36

Truck Models Covered

Truck Model Serial Number

FBC20K, FBC25K A3BC2-10200-up

Nameplate and Serial Number Locations

Maximum Fork Spacing

Overall Height (to top of

Overall Height (to top of

Overall Height (to top of

General Information (Standard Models)

Standard Controller GE SX Controller

Lowering Speed (rated load) .50 (99) .50 (98)

Tilt Angle (forward/backward) degrees 5° / 6°

Free Lift mm (in.) 115 (4.5) 130 (5.1) 135 (5.3)

Travel Speed km/h

Minimum Turning mm 1790 1840 1890 1990 2045

Transfer Type Spur

Reduction Type Bevel

Axle Housing Banjo

Differential Gear Type/ Gears Straight Bevel/2

Number Pinions Straight Bevel/2

Type Dynamic Load Sense

Inside 83° 83°

Steering Wheel Diameter mm (in.) 328 (13)

Type Self-Adjusting Duo-Servo

Inside Drum +0 0.13(10.00 +0 0.0051)

Master 22.22 (0.8748)

Wheel 22.22 (0.8748) 28.58 (1.1252)

Type Mechanical, Mounted on Front Wheels

Park Brake Lever kgf 25 to 30

Front Wheels Fixed Type

Rear Wheels Center Pivot Type

Lift Cylinders ID 45 (1.77) 50 (1.97) 55 (2.17)

Lift Chains BL534 BL634 BL834

Width 906 (35.6) 1003 (39.5