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Toyota Forklift 7FBMF16 7FBMF18 7FBMF20 7FBMF25 7FBMF30 7FBMF35 7FBMF40 7FBMF45 7FBMF50 Service Manual PDF
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Description
Toyota Forklift 7FBMF16 7FBMF18 7FBMF20 7FBMF25 7FBMF30 7FBMF35 7FBMF40 7FBMF45 7FBMF50 Service Manual – PDF DOWNLOAD
FILE DETAILS:
Toyota Forklift 7FBMF16 7FBMF18 7FBMF20 7FBMF25 7FBMF30 7FBMF35 7FBMF40 7FBMF45 7FBMF50 Service Manual – PDF DOWNLOAD
Language : English
Pages : 720
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Toyota Forklift 7FBMF16 7FBMF18 7FBMF20 7FBMF25 7FBMF30 7FBMF35 7FBMF40 7FBMF45 7FBMF50 Service Manual – PDF DOWNLOAD
FOREWORD:
- This manual covers the service procedures of the TOYOTA ELECTRIC
POWERED FORKLIFT 7FBMF16 to 50. - Please use these manuals for providing quick, correct servicing of the corresponding
forklift models. - This manual deals with the above models as of September 2002. Please
understand that disagreement can take place between the descriptions in the
manual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.
TABLE OF CONTENTS:
Toyota Forklift 7FBMF16 7FBMF18 7FBMF20 7FBMF25 7FBMF30 7FBMF35 7FBMF40 7FBMF45 7FBMF50 Service Manual – PDF DOWNLOAD
FOREWORD................................................................................................ 1 SECTION INDEX........................................................................................... 2 0E-Section.............................................................................................. 3 GENERAL............................................................................................. 3 EXTERIOR VIEWS...................................................................................... 4 16 ~ 35 Model................................................................................... 4 40 ~ 50 Model................................................................................... 5 VEHICLE MODELS...................................................................................... 6 FRAME NUMBER........................................................................................ 6 HOW TO USE THIS MANUAL.............................................................................. 7 EXPLANATION METHOD.............................................................................. 7 DISASSEMBLY•INSPECTION•REASSEMBLY............................................................... 7 TERMINOLOGY......................................................................................... 8 ABBREVIATIONS....................................................................................... 8 OPERATIONAL TIPS.................................................................................... 9 JACK-UP POINTS...................................................................................... 10 HOISTING THE VEHICLE................................................................................ 11 CAUTION FOR TOWING.................................................................................. 11 PARKING BRAKE RELEASE METHOD.................................................................... 11 ATTENTIVE POINTS ON SAS............................................................................. 12 CIRCUIT TESTER...................................................................................... 13 STANDARD BOLT & NUT TIGHTENING TORQUE............................................................... 15 BOLT STRENGTH TYPE IDENTIFICATION METHOD........................................................ 15 TIGHTENING TORQUE TABLE......................................................................... 16 PRECOATED BOLTS..................................................................................... 17 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE........................................................ 17 WIRE ROPE SUSPENSION ANGLE LIST..................................................................... 18 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE....................................................... 18 COMPONENTS WEIGHT................................................................................... 19 RECOMMENDED LUBRICANT QUANTITY & TYPES.............................................................. 20 LUBRICATION CHART................................................................................... 21 16 ~ 35 Model................................................................................... 21 40 ~ 50 Model................................................................................... 22 PERIODIC MAINTENANCE................................................................................ 23 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS........................................................ 27 1E-Section.............................................................................................. 28 BATTERY............................................................................................. 28 BATTERY COMPARTMENT AND REQUIRED WEIGHT............................................................. 29 SERVICE STANDARD.................................................................................... 30 DISPLAY............................................................................................. 30 TROUBLESHOOTING..................................................................................... 31 BATTERY ASSY........................................................................................ 32 REMOVAL•INSTALLATION............................................................................ 32 Removal Procedure........................................................................... 32 Installation Procedure...................................................................... 32 Point Operations............................................................................ 32 INSPECTION...................................................................................... 33 2E-Section.............................................................................................. 35 CONTROLLERS......................................................................................... 35 General............................................................................................. 36 SPECIFICATIONS...................................................................................... 37 COMPONENTS.......................................................................................... 38 Main controller................................................................................. 38 SAS (with PS) Controller (16 ~ 35 model)........................................................ 39 SAS controller (40 ~ 50 model).................................................................. 39 Contactor panel................................................................................. 40 Before starting repair work......................................................................... 41 Insulation Resistance Measurement............................................................... 41 DISASSEMBLY..................................................................................... 41 PRECAUTIONS FOR PARTS REPLACEMENT............................................................... 41 Connector Inspection List........................................................................... 42 Board Inspection................................................................................ 42 Main Controller............................................................................. 43 Traveling Controller........................................................................ 49 Material Handling Controller................................................................ 50 SAS Controller.............................................................................. 51 DC/SD Board................................................................................. 54 Main Controller..................................................................................... 56 REMOVAL•INSTALLATION............................................................................ 56 Removal Procedure............................................................................... 56 Installation Procedure.......................................................................... 56 TRAVELING/MATERIAL HANDLING CONTROLLER.............................................................. 57 REMOVAL•INSTALLATION (16•18 MODEL).............................................................. 57 Removal Procedure........................................................................... 57 Installation Procedure...................................................................... 57 Point Operations............................................................................ 58 REMOVAL•INSTALLATION (20 ~ 50 MODEL)............................................................ 59 Removal Procedure........................................................................... 59 Installation Procedure...................................................................... 59 Point Operations............................................................................ 60 Fan Inspection.................................................................................. 61 Motor Input Voltage Check....................................................................... 62 SAS (WITH PS) CONTROLLER (16 ~ 35 MODEL)............................................................ 64 REMOVAL•INSTALLATION............................................................................ 64 Removal Procedure........................................................................... 64 Installation Procedure...................................................................... 65 Point Operations............................................................................ 65 Inspection...................................................................................... 66 SAS Controller (40 ~ 50 MODEL)...................................................................... 68 REMOVAL•INSTALLATION............................................................................ 68 Removal Procedure............................................................................... 68 Installation Procedure.......................................................................... 68 Contactor Panel..................................................................................... 69 REMOVAL•INSTALLATION............................................................................ 69 Removal Procedure............................................................................... 69 Installation Procedure.......................................................................... 69 Point Operations................................................................................ 70 INSPECTION...................................................................................... 71 INSTALLATION.................................................................................... 72 Display............................................................................................. 73 Direction Switch.................................................................................... 74 REMOVAL•INSTALLATION............................................................................ 74 Removal Procedure........................................................................... 74 Installation Procedure...................................................................... 74 DISASSEMBLY•INSPECTION•REASSEMBLY................................................................... 75 Removal Procedure............................................................................... 75 Installation Procedure.......................................................................... 75 Point Operations................................................................................ 76 Accelerator Potentiometer Adjustment................................................................ 77 Brake Switch Adjustment............................................................................. 78 Foot Brake...................................................................................... 78 3E-Section.............................................................................................. 79 MULTI-DISPLAY FUNCTIONS............................................................................. 79 MULTIPLE DISPLAY.................................................................................... 80 GENERAL......................................................................................... 80 SPECIFICATIONS.................................................................................. 85 GENERAL FUNCTIONS............................................................................... 85 DISPLAY INDICATION LIST......................................................................... 86 ABBREVIATIONS DISPLAYED ON THE SCREEN........................................................... 87 NORMAL FUNCTION SCREEN.............................................................................. 88 OPERATION PROCEDURE............................................................................. 88 NORMALLY INDICATED SCREEN................................................................... 89 TRAVEL 2ND SPEED CONTROL LEVEL SETTING SCREEN............................................... 90 OVER SPEED ALARM SETTING SCREEN............................................................. 90 POWER CONTROL SET UP SELECTION SCREEN....................................................... 91 CLOCK SET UP SELECTION SCREEN............................................................... 92 MASK FUNCTIONS...................................................................................... 93 GENERAL......................................................................................... 93 Mask Function List.......................................................................... 93 Password........................................................................................ 95 ANALYZER........................................................................................ 97 GENERAL..................................................................................... 97 ANALYZER MENU SCREEN LIST................................................................... 98 Operation Procedure.........................................................................100 DIAG MEMORY.................................................................................101 Operation Procedure.........................................................................101 Vehicle Abnormalities Not Stored in Diag Memory.............................................102 I/O MONITOR Function........................................................................102 I/O MONITOR1................................................................................103 Operation Procedure.........................................................................103 I/O MONITOR2................................................................................106 Operation Procedure.........................................................................106 I/O MONITOR3................................................................................108 Operation Procedure.........................................................................108 I/O MONITOR4................................................................................111 Operation Procedure.........................................................................111 ACTIVE TEST.................................................................................113 Operation Procedure.........................................................................113 TUNING..........................................................................................115 GENERAL.....................................................................................115 Tuning Item List............................................................................115 TUNING Screen Operation Procedure...........................................................118 TUNING 1 FUNCTION Screen Operation Procedure................................................119 Low Remaining Battery Charge Alarm and Overdischarge Alarm Setting Levels (Tuning No. 3)....119 TUNING 2 LIFTV FUNCTION Screen Operation Procedure..........................................120 TUNING 3 TILTV FUNCTION Screen Operation Procedure..........................................121 TUNING 4 ATT1V FUNCTION Screen Operation Procedure.........................................122 TUNING 5 ATT2V FUNCTION Screen Operation Procedure.........................................123 OPTION SET......................................................................................124 Option Set Menu List........................................................................124 Operation Procedure Screen..................................................................126 MATCHING........................................................................................129 GENERAL.....................................................................................129 SAS Matching Menu List......................................................................129 MINI LEVER Matching Menu List...............................................................129 Before Starting Matching....................................................................130 Operation Procedure.........................................................................132 WHEEL DIA.......................................................................................134 Operation Procedure.........................................................................134 Tire Constant List..........................................................................134 DIAGNOSIS...........................................................................................135 DIAGNOSIS CODE LIST.............................................................................135 4E-Section..............................................................................................141 TROUBLESHOOTING.....................................................................................141 Before Troubleshooting..............................................................................142 Connector Handling..............................................................................142 Wire Harness and Connector Inspection Procedure.................................................142 Continuity check............................................................................142 Short circuit check.........................................................................143 Visual and contact pressure checks..........................................................143 Troubleshooting Method..............................................................................144 Explanation of boxes............................................................................144 TROUBLESHOOTING WITH ERROR CODES................................................................145 SST SETTING METHODS.................................................................................145 CPU BOARD CONNECTOR (16 ~ 35 MODEL).............................................................150 CPU BOARD CONNECTOR (40 ~ 50 MODEL).............................................................151 SCPU BOARD CONNECTOR (16 ~ 35 MODEL)............................................................152 SCPU BOARD CONNECTOR (40 ~ 50 MODEL)............................................................153 DC/SD board connector (16 ~ 35 MODEL)...........................................................154 DC/SD board connector (40 ~ 50 MODEL)...........................................................155 MAIN CONTROLLER CONNECTORCOMPONENT..............................................................156 SAS CONTROLLER CONNECTOR•COMPONENT (16 ~ 35 MODEL)..............................................157 SAS CONTROLLER CONNECTOR•COMPONENT (40 ~ 50 MODEL)..............................................158 TRAVELING CONTROLLER CONNECTOR•COMPONENT........................................................159 MATERIAL HANDLING CONTROLLER CONNECTOR•COMPONENT................................................159 CONTACTOR PANEL CONNECTOR•COMPONENT.............................................................160 OIL CONTROL VALVE CONNECTOR•COMPONENT...........................................................161 BRAKE CHANGE VALVE CONNECTORCOMPONENT...........................................................162 TROUBLESHOOTING.....................................................................................163 COMPOSITION LIST................................................................................163 MAIN CONTROLLER SYSTEM..............................................................................166 WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED........................................................166 • 61-1......................................................................................166 • 61-2......................................................................................167 • 62-1......................................................................................168 • 62-2......................................................................................169 • C4-1......................................................................................187 • C4-2......................................................................................188 • C4-3......................................................................................188 • C4-4......................................................................................188 • EE-1......................................................................................193 • EE-2......................................................................................193 • EE-3......................................................................................193 • FE-1......................................................................................195 • FE-2......................................................................................195 • G4-1......................................................................................197 • G4-2......................................................................................198 • G4-3......................................................................................198 • H1-1......................................................................................199 • H1-2......................................................................................203 • H2-1......................................................................................208 • H2-2......................................................................................212 • H3-1......................................................................................217 • H3-2......................................................................................221 • H3-5......................................................................................225 • H4-1......................................................................................226 • H4-2......................................................................................230 • H5-1......................................................................................235 • H5-2......................................................................................236 • H5-3......................................................................................236 • H5-4......................................................................................237 • H5-5......................................................................................237 • H6-1......................................................................................238 • H6-2......................................................................................239 • H6-3......................................................................................239 • H6-4......................................................................................240 • H6-5......................................................................................240 • H7-1......................................................................................241 • H7-2......................................................................................242 • H7-3......................................................................................242 • H7-4......................................................................................243 • H7-5......................................................................................243 • H8-1......................................................................................244 • H8-2......................................................................................245 • H8-3......................................................................................245 • H8-4......................................................................................246 • H8-5......................................................................................246 • H9-1......................................................................................247 • H9-2......................................................................................248 • H9-3......................................................................................248 TRAVELING CONTROLLER SYSTEM.........................................................................249 WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED........................................................249 MATERIAL HANDLING CONTROLLER SYSTEM.................................................................263 WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED........................................................263 SAS SYSTEM..........................................................................................276 WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED........................................................276 • 52-1, 2...................................................................................277 • 52-3......................................................................................277 • 54-1......................................................................................278 • 54-2......................................................................................279 • 71-1......................................................................................280 • 71-2......................................................................................281 • 72-1......................................................................................282 • 72-2......................................................................................283 • 72-3......................................................................................283 • 72-4......................................................................................284 • 73-1......................................................................................285 • 73-2......................................................................................286 • 74-1......................................................................................287 • AF-5, 6, 7, 8.............................................................................288 • EF-5, 6...................................................................................289 • FE-4, 5...................................................................................290 MULTI-DISPLAY COMMUNICATION SYSTEM..................................................................292 WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED........................................................292 WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED.......................................................293 5E-Section..............................................................................................298 MOTOR...............................................................................................298 DRIVE MOTOR.........................................................................................299 GENERAL.........................................................................................299 SPECIFICATIONS..................................................................................299 COMPONENTS......................................................................................300 REMOVAL•INSTALLATION............................................................................301 Removal Procedure...........................................................................301 Installation Procedure......................................................................301 Point Operations............................................................................302 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................303 Disassembly Procedure.......................................................................303 Reassembly Procedure........................................................................303 Point Operations............................................................................304 PUMP MOTOR..........................................................................................306 GENERAL.........................................................................................306 SPECIFICATIONS..................................................................................307 COMPONENTS......................................................................................307 REMOVAL•INSTALLATION............................................................................309 Removal Procedure...........................................................................310 Installation Procedure......................................................................310 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................311 Disassembly Procedure.......................................................................311 Reassembly Procedure........................................................................311 Point Operations............................................................................312 POWER STEERING MOTOR (16 ~ 35 model)................................................................314 GENERAL.........................................................................................314 SPECIFICATIONS..................................................................................314 COMPONENTS......................................................................................315 REMOVAL•INSTALLATION............................................................................316 Removal Procedure...........................................................................316 Installation Procedure......................................................................316 Point Operations............................................................................317 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................318 Disassembly Procedure.......................................................................318 Reassembly Procedure........................................................................318 Point Operations............................................................................319 6E-Section..............................................................................................322 DRIVE UNIT..........................................................................................322 GENERAL.............................................................................................323 16·18 model.....................................................................................323 20 ~ 35 model...................................................................................323 40 ~ 50 model...................................................................................324 SPECIFICATIONS......................................................................................324 COMPONENTS..........................................................................................325 16 ~ 35 model...................................................................................325 40 ~ 50 model...................................................................................325 16·18 model, 40 ~ 50 model......................................................................326 20 ~ 35 model...................................................................................326 DRIVE UNIT ASSEMBLY.................................................................................327 REMOVAL•INSTALLATION............................................................................327 16 ~ 35 model...............................................................................327 40 ~ 50 model...............................................................................328 Removal Procedure...........................................................................329 Installation Procedure......................................................................329 Point Operations............................................................................329 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................333 Disassembly Procedure.......................................................................333 Reassembly Procedure........................................................................333 Point Operations............................................................................334 DIFFERENTIAL CASE ASSEMBLY......................................................................336 DISASSEMBLY•INSPECTION•REASSEMBLY...........................................................336 16 • 18 model, 40 ~ 50 model............................................................336 20 ~ 35 model...........................................................................336 Disassembly Procedure.......................................................................337 Reassembly Procedure........................................................................337 Point Operations............................................................................337 7E-Section..............................................................................................340 FRONT AXLE..........................................................................................340 GENERAL.............................................................................................341 16•18 model.....................................................................................341 20•25 model.....................................................................................342 30•35 model.....................................................................................343 40 ~ 50 model...................................................................................344 SPECIFICATIONS......................................................................................345 COMPONENTS..........................................................................................345 16 ~ 35 model...................................................................................347 16 ~ 35 model...................................................................................346 40 ~ 50 model...................................................................................347 40 ~ 50 model...................................................................................348 TIRESWHEELS.........................................................................................349 FRONT AXLE ASSY (16 ~ 35 model).....................................................................350 REMOVALINSTALLATION.............................................................................350 Removal Procedure...........................................................................350 Installation Procedure......................................................................350 Point Operation.............................................................................351 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................352 Disassembly Procedure.......................................................................352 Reassembly Procedure........................................................................352 Point Operation.............................................................................353 FRONT AXLE ASSY (40 ~ 50 model).....................................................................355 REMOVAL•INSTALLATION............................................................................355 Removal Procedure...........................................................................355 Installation Procedure......................................................................355 Point Operation.............................................................................356 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................358 Disassembly Procedure.......................................................................358 Reassembly Procedure........................................................................358 Point Operation.............................................................................359 FRONT AXLE BRACKET..................................................................................362 REMOVAL•INSTALLATION (16 ~ 35 model)............................................................362 Removal Procedure...........................................................................362 Installation Procedure......................................................................363 Point Operations............................................................................363 REMOVALINSTALLATION (40 ~ 50 model).............................................................365 Removal Procedure...........................................................................366 Installation Procedure......................................................................366 Point Operations............................................................................366 8E-Section..............................................................................................369 REAR AXLE...........................................................................................369 GENERAL.............................................................................................370 16 ~ 25 model...................................................................................370 30·35 model.....................................................................................371 40 ~ 50 model...................................................................................372 Rear Axle Cylinder..............................................................................373 16 ~ 35 model...............................................................................373 40 ~ 50 model...............................................................................373 SPECIFICATIONS......................................................................................374 COMPONENTS..........................................................................................375 16 ~ 25 model...................................................................................375 30 • 35 model...................................................................................375 40 ~ 50 model...................................................................................376 16 ~ 35 model...................................................................................376 40 ~ 50 model...................................................................................377 TIRESWHEELS.........................................................................................378 Specified Inflating Pressure....................................................................378 REAR AXLE ASSY (16 ~ 35 MODEL)......................................................................379 REMOVAL•INSTALLATION............................................................................379 Removal Procedure...........................................................................379 Installation Procedure......................................................................379 Point Operations............................................................................380 REAR AXLE ASSY (40 ~ 50 MODEL)......................................................................381 REMOVAL•INSTALLATION............................................................................381 Removal Procedure...........................................................................381 Installation Procedure......................................................................381 Point Operations............................................................................382 REAR AXLE HUBSTEERING KNUCKLE (16 ~ 35 MODEL).......................................................383 REMOVAL•INSTALLATION............................................................................383 Removal Procedure...........................................................................383 Installation Procedure......................................................................383 Point Operations............................................................................384 REAR AXLE HUBSTEERING KNUCKLE (40 ~ 50 MODEL).......................................................388 REMOVAL•INSTALLATION............................................................................388 Removal Procedure...........................................................................388 Installation Procedure......................................................................388 Point Operations............................................................................389 REAR AXLE CYLINDER..................................................................................392 REMOVAL•INSTALLATION (16 ~ 35 MODEL)............................................................392 Removal Procedure...........................................................................392 Installation Procedure......................................................................392 Point Operations............................................................................393 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................394 Removal Procedure...........................................................................394 Installation Procedure......................................................................394 Point Operations............................................................................395 DISASSEMBLYINSPECTIONREASSEMBLY.................................................................396 16 ~ 35 model...............................................................................396 40 ~ 50 model...............................................................................396 Disassembly Procedure.......................................................................397 Reassembly Procedure........................................................................397 Point Operations............................................................................397 REAR WHEEL ALIGNMENT (16 ~ 35 MODEL)................................................................398 Toe-in Inspection...............................................................................398 Toe-in Adjustment...............................................................................398 REAR WHEEL ALIGNMENT (40 ~ 50 MODEL)................................................................400 Toe-in Inspection...............................................................................400 Toe-in Adjustment...............................................................................400 9E-Section..............................................................................................401 STEERING............................................................................................401 GENERAL.............................................................................................402 Hydrostatic Steering Valve......................................................................403 SPECIFICATIONS......................................................................................404 COMPONENTS..........................................................................................404 16 ~ 35 model...................................................................................405 40 ~ 50 model...................................................................................406 STEERING WHEEL•MAST JACKET..........................................................................407 REMOVAL•INSTALLATION............................................................................407 Removal Procedure...........................................................................408 Installation Procedure......................................................................408 Point Operations............................................................................409 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................411 Disassembly Procedure.......................................................................411 Reassembly Procedure........................................................................411 HYDROSTATIC STEERING VALVE ASSY.....................................................................412 TROUBLESHOOTING.................................................................................412 REMOVAL•INSTALLATION............................................................................413 Removal Procedure...........................................................................413 Installation Procedure......................................................................413 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................414 Disassembly Procedure.......................................................................414 Reassembly Procedure........................................................................414 Point Operations............................................................................415 RELIEF PRESSURE INSPECTION•ADJUSTMENT...........................................................418 POWER STEERING PUMP ASSY (16 ~ 35 MODEL)........................................................419 GENERAL.....................................................................................419 SPECIFICATIONS..............................................................................419 COMPONENTS..................................................................................419 REMOVAL•INSTALLATION........................................................................420 Removal Procedure.......................................................................420 Installation Procedure..................................................................420 Point Operations........................................................................421 10E-Section.............................................................................................422 BRAKE...............................................................................................422 GENERAL.............................................................................................423 Front Brake.....................................................................................423 16 ~ 25 model...............................................................................423 30 ~ 35 model...............................................................................423 40 ~ 50 model...............................................................................424 Parking Brake...............................................................................424 Brake Valve.....................................................................................425 16 ~ 35 model...............................................................................425 40 ~ 50 model...............................................................................425 Brake Change Valve..............................................................................426 X - X sectional view........................................................................426 Y - Y sectional view........................................................................426 Hydraulic circuit diagram...................................................................427 SPECIFICATIONS......................................................................................427 COMPONENTS..........................................................................................428 16 ~ 35 model...................................................................................428 40 ~ 50 model...................................................................................428 16 ~ 35 model...................................................................................429 40 ~ 50 model...................................................................................430 FRONT BRAKE.........................................................................................431 DISASSEMBLY•INSPECTION•REASSEMBLY (16 ~ 35 model)...............................................431 Disassembly Procedure.......................................................................431 Reassembly Procedure........................................................................431 Point Operations............................................................................432 DISASSEMBLYI•NSPECTION•REASSEMBLY (40 ~ 50 model)...............................................433 Disassembly Procedure.......................................................................433 Reassembly Procedure........................................................................433 Point Operations............................................................................434 PARKING BRAKE.......................................................................................436 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................436 Disassembly Procedure.......................................................................436 Reassembly Procedure........................................................................436 Point Operations............................................................................437 BRAKE VALVE.........................................................................................439 TROUBLESHOOTING.................................................................................439 REMOVAL•INSTALLATION............................................................................439 16 ~ 35 model...............................................................................439 40 ~ 50 model...............................................................................440 Disassembly Procedure.......................................................................440 Installation Procedure......................................................................440 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................441 Disassembly Procedure.......................................................................441 Reassembly Procedure........................................................................441 Point Operations............................................................................442 BRAKE CHANGE VALVE..................................................................................443 REMOVALI•NSTALLATION (16 ~ 35 model)............................................................443 Removal Procedure...........................................................................443 Installation Procedure......................................................................443 REMOVAL•INSTALLATION (40 ~ 50 model)............................................................444 Removal Procedure...........................................................................444 Installation Procedure......................................................................444 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................445 Disassembly Procedure.......................................................................445 Reassembly Procedure........................................................................445 Point Operations............................................................................445 BRAKE AIR BLEEDING..................................................................................446 BRAKING FORCE INSPECTION............................................................................446 Brake Hydraulic Pressure Inspection (16 ~ 35 model).................................................447 Brake Hydraulic Pressure Inspection (40 ~ 50 model).................................................448 PARKING BRAKE SWITCH INSPECTION.....................................................................449 BRAKE PEDAL INSPECTIONADJUSTMENT....................................................................450 11E-Section.............................................................................................451 BODY................................................................................................451 COMPONENTS..........................................................................................452 16 ~ 35 model...................................................................................452 16 ~ 35 model...................................................................................452 40 ~ 50 model...................................................................................453 40 ~ 50 model...................................................................................453 16 ~ 35 model...................................................................................454 40 ~ 50 model...................................................................................454 16 ~ 35 model...................................................................................455 40 ~ 50 model...................................................................................455 16 ~ 35 model...................................................................................456 40 ~ 50 model...................................................................................456 OPEN THE SEAT STAND METHOD..........................................................................457 16 ~ 35 model...................................................................................457 40 ~ 50 model...................................................................................457 SEAT STAND ASSY.....................................................................................458 REMOVAL•INSTALLATION............................................................................458 Removal Procedure...........................................................................458 Installation Procedure......................................................................458 SEAT STAND ADJUSTMENT...........................................................................459 COUNTERWEIGHT.......................................................................................460 REMOVALI•NSTALLATION............................................................................460 Removal Procedure...........................................................................460 Installation Procedure......................................................................460 DRIVER’S SEAT.......................................................................................461 REMOVAL•INSTALLATION............................................................................461 Removal Procedure...........................................................................461 Installation Procedure......................................................................461 Point Operation.............................................................................461 FUSE................................................................................................462 FUSE INSTALLATION POSITION......................................................................462 NAMES (APPLICABLE PORTIONS) AND CAPACITIES......................................................462 12E-Section.............................................................................................463 MATERAIAL HANDLING SYSTEM...........................................................................463 HYDRAULIC SYSTEM DIAGRAM............................................................................464 16 ~ 35 model...................................................................................464 40 ~ 50 model...................................................................................464 COMPONENTS..........................................................................................465 16 • 18 model...................................................................................465 20 ~ 35 model...................................................................................465 40 ~ 50 model...................................................................................466 40 ~ 50 model...................................................................................466 16 ~ 50 model (V)...............................................................................467 RETURN FILTER.......................................................................................468 REMOVALI•NSTALLATION (16 ~ 35 MODEL)............................................................468 Removal Procedure...........................................................................468 Installation Procedure......................................................................468 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................469 Removal Procedure...........................................................................469 Installation Procedure......................................................................469 SUCTION FILTER......................................................................................470 REMOVAL•INSTALLATION (16 ~ 35 MODEL)............................................................470 Removal Procedure...........................................................................470 Installation Procedure......................................................................470 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................471 Removal Procedure...........................................................................471 Installation Procedure......................................................................471 NATURAL DROP TEST...................................................................................472 NATURAL FORWARD TILT TEST...........................................................................472 OIL LEAK TEST.......................................................................................473 LIFT CYLINDER...................................................................................473 TILT CYLINDER...................................................................................474 13E-Section.............................................................................................475 MAST................................................................................................475 V MAST ASSY.........................................................................................476 COMPONENTS......................................................................................476 16 ~ 30 model...............................................................................476 35 model....................................................................................476 40 ~ 50 model...............................................................................476 16 • 18 model...............................................................................477 20 • 25 model...............................................................................477 30 model....................................................................................478 35 model....................................................................................478 40 • 45 model...............................................................................479 50 model....................................................................................479 16 ~ 25 model...............................................................................479 30 model....................................................................................479 35 model....................................................................................480 40 • 45 model...............................................................................480 50 model....................................................................................480 REMOVAL•INSTALLATION............................................................................481 Removal Procedure...........................................................................481 Installation Procedure......................................................................482 Point Operations............................................................................482 REMOVAL•INSTALLATION (W/LIFT BRACKET)...........................................................484 Removal Procedure...........................................................................484 Installation Procedure......................................................................484 Point Operations............................................................................485 MAST DISASSEMBLY•IINSPECTION REASSEMBLY.........................................................486 Disassembly Procedure.......................................................................486 Reassembly Procedure........................................................................486 Point Operations............................................................................487 LIFT BRACKET DISASSEMBLY•INSPECTIONREASSEMBLY...................................................489 16 ~ 35 model...............................................................................489 40 • 45 model...............................................................................489 50 model....................................................................................489 Disassembly Procedure.......................................................................490 Reassembly Procedure........................................................................490 Point Operations............................................................................490 MAST ADJUSTMENT (V MAST, 16 ~ 35 MODEL).........................................................491 Lift Roller Adjustment at Mast..............................................................491 Roller Adjustment at Lift Bracket...........................................................493 Mast Strip Adjustment.......................................................................495 MAST ADJUSTMENT (V MAST, 40 ~ 50 MODEL).........................................................496 Lift Roller Adjustment at Mast..............................................................496 Roller Adjustment at Lift Bracket...........................................................499 40·45 model.................................................................................499 50 model....................................................................................501 Mast Strip Adjustment.......................................................................502 MAST ROLLER REMOVAL•INSTALLATION................................................................503 CHAIN (16 ~ 35 MODEL)...............................................................................504 INSPECTION......................................................................................504 REASSEMBLY (V•FV•FSV)...........................................................................504 ADJUSTMENT......................................................................................505 CHAIN (40 ~ 50 MODEL)...............................................................................506 INSPECTION......................................................................................506 REASSEMBLY (V•FV•FSV)...........................................................................506 ADJUSTMENT......................................................................................509 FORK................................................................................................509 REMOVAL.........................................................................................509 INSTALLATION....................................................................................509 INSPECTION......................................................................................509 FV•FSV MAST ASSY....................................................................................510 COMPONENTS......................................................................................510 FV: 16 ~ 30 model...........................................................................510 FV: 40 ~ 50 model...........................................................................510 FSV: 16 ~ 30 model..........................................................................510 FSV: 35 model...............................................................................510 FSV: 40 • 45 model..........................................................................511 FSV: 50 model...............................................................................511 FV·FSV: 40 • 45 model.......................................................................511 FSV: 50 model...............................................................................511 FV: 16 ~ 25 model...........................................................................512 FV: 30 model................................................................................512 FV: 40 • 45 model...........................................................................512 FSV: 16 ~ 25 model..........................................................................513 FSV: 30 model...............................................................................513 FSV: 35 model...............................................................................513 FSV: 40 • 45 model (H3700 ~ H5500)..........................................................514 FSV: 40 • 45 model (H6000)..................................................................514 FSV: 50 model...............................................................................514 MAST ADJUSTMENT (FVFSV MAST, 16 ~ 35 MODEL).....................................................515 Lift Roller Adjustment at Mast..............................................................515 Lift/Side Roller Adjustment at Lift Bracket.................................................517 Mast Strip Adjustment.......................................................................518 MAST ADJUSTMENT (FVFSV MAST, 40 ~ 50 MODEL).....................................................519 Lift Roller Adjustment at Mast (FV).........................................................519 Lift Roller Adjustment at Mast (FSV)........................................................522 Adjustment Sequence.........................................................................523 Adjustment Sequence.........................................................................525 Lift Bracket Portion Lift/Side Roller Adjustment............................................527 Mast Strip Adjustment.......................................................................529 LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)....................................530 14E-Section.............................................................................................531 CYLINDER............................................................................................531 LIFT CYLINDER (V)REAR LIFT CYLINDER (FVFSV).........................................................532 GENERAL.........................................................................................530 Lift Cylinder (V/16 18 Model)...............................................................532 Lift Cylinder (V/20 25 Model)...............................................................532 Lift Cylinder (V/30 Model)..................................................................532 Lift Cylinder (V/35 Model)..................................................................533 Lift Cylinder (V/40 45 Model)...............................................................533 Lift Cylinder (FV/50 Model).................................................................534 Rear Lift Cylinder (FV/16 ~ 30 Model).......................................................534 Rear Lift Cylinder (FV/40 45 Model).........................................................535 Rear Lift Cylinder (FSV/16 ~ 30 Model)......................................................535 Rear Lift Cylinder (FSV/35 Model)...........................................................536 Rear Lift Cylinder (FSV/40 45 Model)........................................................536 Rear Lift Cylinder (FSV/50 Model)...........................................................537 SPECIFICATIONS..................................................................................538 Lift Cylinder (V/16 ~ 35 Model).............................................................538 Lift Cylinder (V/40 ~ 50 Model).............................................................538 Rear Lift Cylinder (FV/16 ~ 30 Model).......................................................538 Rear Lift Cylinder (FV/40 45 Model) •.......................................................539 Rear Lift Cylinder (FSV/16 ~ 35 Model)......................................................539 Rear Lift Cylinder (FSV/40 ~ 50 Model)......................................................539 COMPONENTS......................................................................................540 Lift Cylinder (V)...........................................................................540 16 • 18 model...........................................................................540 20 ~ 30 model...........................................................................540 35 model................................................................................541 40 • 45 model...........................................................................541 50 model................................................................................542 Rear Lift Cylinder (FV).....................................................................542 16 ~ 30 model...........................................................................542 40 • 45 model...........................................................................543 Rear Lift Cylinder (FSV)....................................................................543 16 • 18 model...........................................................................543 20 • 25 model...........................................................................544 30 model................................................................................544 35 model................................................................................545 40 • 45 model...........................................................................545 50 model................................................................................546 REMOVAL•INSTALLATION (16 ~ 35 MODEL)............................................................547 Removal Procedure...........................................................................547 Installation Procedure......................................................................548 Point Operations............................................................................548 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................549 Removal Procedure...........................................................................549 Installation Procedure......................................................................549 Point Operations............................................................................550 DISASSEMBLY•INSPECTION•REASSEMBLY (16 ~ 35 MODEL)...............................................551 Lift Cylinder (V)...........................................................................551 16 ~ 30 model...........................................................................551 35 model................................................................................551 Disassembly Procedure.......................................................................551 Reassembly Procedure........................................................................551 Point Operations............................................................................552 Rear Lift Cylinder (FV).....................................................................553 Disassembly Procedure.......................................................................553 Reassembly Procedure........................................................................553 Point Operations............................................................................554 Rear Lift Cylinder (FSV)....................................................................555 16 ~ 30 model...........................................................................555 35 model................................................................................555 Disassembly Procedure.......................................................................555 Reassembly Procedure........................................................................555 Point Operations............................................................................556 DISASSEMBLY•INSPECTIONREASSEMBLY (40 ~ 50 MODEL)................................................557 Lift Cylinder (V)...........................................................................557 Disassembly Procedure.......................................................................557 Reassembly Procedure........................................................................557 Point Operations............................................................................558 Rear Lift Cylinder (FV).....................................................................559 Disassembly Procedure.......................................................................559 Reassembly Procedure........................................................................559 Point Operations............................................................................560 Rear Lift Cylinder (FSV)....................................................................561 Disassembly Procedure.......................................................................561 Reassembly Procedure........................................................................561 Point Operations............................................................................562 FLOW REGULATOR VALVE................................................................................563 Lowering Speed Specifications...................................................................563 REMOVAL•INSTALLATION (16 ~ 35 MODEL)............................................................564 Removal Procedure...........................................................................564 Installation Procedure......................................................................564 Point Operations............................................................................564 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................565 Removal Procedure...........................................................................565 Installation Procedure......................................................................565 Point Operations............................................................................565 SAFETY DOWN VALVE...................................................................................566 Safety Down Valve Sectional View (for V) (for FV FSV Rear Lift Cylinder) •.....................566 V • FV FSV (35 ~ 50 model)..................................................................566 FSV (16 ~ 30 model).........................................................................566 Safety Down Valve Sectional View (for FV FSV Front Lift Cylinder) •............................566 REMOVAL INSTALLATION (16 ~ 35 MODEL) •.........................................................567 Removal Procedure...........................................................................567 Installation Procedure......................................................................568 Point Operations............................................................................568 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................569 Removal Procedure...........................................................................569 Installation Procedure......................................................................569 Point Operations............................................................................569 FRONT LIFT CYLINDER (FV•FSV)........................................................................570 GENERAL.........................................................................................570 FV: 16 ~ 30 model...........................................................................570 FSV: 16 ~ 30 model..........................................................................570 FSV: 35 model...............................................................................570 FV: 40 • 45 model...........................................................................571 FSV: 40 • 45 model..........................................................................571 FSV: 50 model...............................................................................571 SPECIFICATIONS..................................................................................572 16 ~ 30 Model (FV)..........................................................................572 16 ~ 35 Model (FSV).........................................................................572 40 ~ 50 Model (FV•FSV)......................................................................572 COMPONENTS......................................................................................573 Front Lift Cylinder (FV FSV)................................................................573 16 ~ 30 model (FV • FSV)................................................................573 35 model (FSV)..........................................................................573 40 • 45 model (FV • FSV)................................................................574 50 model (FSV)..........................................................................574 REMOVAL•INSTALLATION............................................................................575 Removal Procedure...........................................................................575 Installation Procedure......................................................................575 DISASSEMBLY•INSPECTION•REASSEMBLY (16 ~ 30 MODEL)...............................................576 Disassembly Procedure.......................................................................576 Reassembly Procedure........................................................................576 Point Operations............................................................................577 DISASSEMBLY•INSPECTION•REASSEMBLY (35 ~ 50 MODEL)...............................................578 FSV: 35 model...............................................................................578 FV: 40 • 45 model...........................................................................578 FSV: 40 ~ 50 model..........................................................................578 Disassembly Procedure.......................................................................578 Reassembly Procedure........................................................................578 Point Operations............................................................................579 TILT CYLINDER.......................................................................................580 GENERAL.........................................................................................580 16 ~ 35 model...............................................................................580 40 ~ 50 model...............................................................................580 SPECIFICATIONS..................................................................................580 COMPONENTS......................................................................................581 16 ~ 35 model...............................................................................581 40 ~ 50 model...............................................................................581 REMOVALINSTALLATION.............................................................................582 Removal Procedure...........................................................................582 Installation Procedure......................................................................582 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................584 16 ~ 35 model...............................................................................584 40 ~ 50 model...............................................................................584 Disassembly Procedure.......................................................................585 Reassembly Procedure........................................................................585 Point Operations............................................................................585 MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING)...................587 15E-Section.............................................................................................588 OIL PUMP............................................................................................588 GENERAL.............................................................................................589 Single gear pump (Kayaba).......................................................................589 16 ~ 35 model...................................................................................589 Double gear pump (Shimadzu).....................................................................589 40 ~ 50 model...................................................................................589 SPECIFICATIONS......................................................................................589 COMPONENTS..........................................................................................590 Single gear pump (Kayaba).......................................................................590 16 ~ 35 model...................................................................................590 Double gear pump (Shimadzu).....................................................................590 40 ~ 50 model...................................................................................590 OIL PUMP ASSY.......................................................................................591 REMOVAL•INSTALLATION............................................................................591 16 ~ 35 model...............................................................................591 40 ~ 50 model...............................................................................591 Removal Procedure...........................................................................592 Installation Procedure......................................................................592 DISASSEMBLY•INSPECTION•REASSEMBLY (16 ~ 35 MODEL)...............................................593 Disassembly Procedure.......................................................................593 Reassembly Procedure........................................................................593 Point Operations............................................................................594 DISASSEMBLY•INSPECTION•REASSEMBLY (40 ~ 50 MODEL)...............................................596 Disassembly Procedure.......................................................................596 Reassembly Procedure........................................................................596 Point Operations............................................................................597 TEST METHOD.........................................................................................600 Lifting Speed Table (Approx.value)..............................................................600 16E-Section.............................................................................................601 OIL CONTROL VALVE...................................................................................601 GENERAL.............................................................................................602 Oil Control Valve...............................................................................602 16 ~ 35 model...............................................................................602 Inlet Block Sectional View......................................................................603 16 ~ 35 model...............................................................................603 Lift Block Sectional View.......................................................................603 16 ~ 35 model...............................................................................603 Tilt Block Sectional View.......................................................................604 16 ~ 35 model...............................................................................604 Attachment Block Sectional View.................................................................604 16 ~ 35 model...............................................................................604 Hydraulic Circuit Diagram.......................................................................605 16 ~ 35 model...............................................................................605 Oil Control Valve...............................................................................606 40 ~ 50 model...............................................................................606 Inlet Block Sectional View......................................................................607 40 ~ 50 model...............................................................................607 Lift Block Sectional View.......................................................................607 40 ~ 50 model...............................................................................607 Tilt Block Sectional View.......................................................................608 40 ~ 50 model...............................................................................608 Attachment Block Sectional View.................................................................608 40 ~ 50 model...............................................................................608 Hydraulic Circuit Diagram.......................................................................609 40 ~ 50 model...............................................................................609 SPECIFICATIONS......................................................................................610 COMPONENTS..........................................................................................611 16 ~ 35 model...................................................................................611 40 ~ 50 model...................................................................................612 OIL CONTROL VALVE ASSY..............................................................................613 REMOVAL•INSTALLATION (16 ~ 35 MODEL)............................................................613 Removal Procedure...........................................................................613 Installation Procedure......................................................................613 Point Operations............................................................................614 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................615 Removal Procedure...........................................................................615 Installation Procedure......................................................................615 Point Operations............................................................................616 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................617 Disassembly Procedure.......................................................................618 Reassembly Procedure........................................................................618 Point Operations............................................................................619 MATERIAL HANDLING OPERATION START TIMING ADJUSTMENT.............................................621 RELIEF PRESSURE ADJUSTMENT..........................................................................622 16 ~ 35 model...................................................................................622 40 ~ 50 model...................................................................................622 Relief pressure standard value..................................................................623 LIFT LOCK RELEASE BOLT..............................................................................624 MINI LEVER BOX......................................................................................625 GENERAL.........................................................................................625 COMPONENTS......................................................................................626 16 ~ 35 model...............................................................................626 40 ~ 50 model...............................................................................626 REMOVAL•INSTALLATION............................................................................627 Removal Procedure...........................................................................627 Installation Procedure......................................................................627 Point Operations............................................................................627 DISASSEMBLY•INSPECTION•REASSEMBLY...............................................................628 Disassembly Procedure.......................................................................628 Reassembly Procedure........................................................................628 Point Operations............................................................................629 17E-Section.............................................................................................631 SAS FUNCTIONS.......................................................................................631 GENERAL.............................................................................................632 SAS (System of Active Stability) Configuration..................................................632 COMPONENTS..........................................................................................633 Speed sensor....................................................................................633 Yaw rate sensor.................................................................................633 16 ~ 35 model...................................................................................633 Yaw rate sensor.................................................................................634 40 ~ 50 model...................................................................................634 Tire angle sensor...............................................................................634 Swing lock cylinder.............................................................................635 16 ~ 25 model...................................................................................635 Swing lock cylinder.............................................................................635 30 • 35 model...................................................................................635 Swing lock cylinder.............................................................................636 40 ~ 50 model...................................................................................636 Steering wheel angle sensor.....................................................................636 Steering knob position correcting valve.........................................................637 Lifting height switch (V).......................................................................637 Lifting height switch...........................................................................638 (16 ~ 30 model: FV, 16 ~ 35 model: FSV).........................................................638 (40 • 45 model: FV, 50 model: FSV)..............................................................638 Lifting height switch (40 • 45 model: FSV)......................................................638 Tilt angle sensor (16 ~ 35 model)...............................................................639 Tilt angle sensor (40 ~ 50 model)...............................................................639 Load sensor (16 ~ 35 model: V, 16 ~ 30 model: FV, 40 ~ 50 model)................................640 Load sensor (16 ~ 35 model: FSV)................................................................640 BEFORE STARTING REPAIR WORK.........................................................................641 YAW RATE SENSOR.....................................................................................643 REMOVAL•INSTALLATION (16 ~ 35 MODEL)............................................................643 Removal Procedure...........................................................................643 Installation Procedure......................................................................643 Point Operations............................................................................644 REMOVALINSTALLATION (40 ~ 50 MODEL).............................................................645 Removal Procedure...........................................................................645 Installation Procedure......................................................................645 Point Operations............................................................................646 STEERING WHEEL ANGLE SENSOR.........................................................................647 REMOVAL•INSTALLATION............................................................................647 Removal Procedure...........................................................................647 Installation Procedure......................................................................647 Point Operations............................................................................648 STEERING KNOB POSITION CORRECTING VALVE.............................................................650 REMOVAL•INSTALLATION............................................................................650 Removal Procedure...........................................................................650 Installation Procedure......................................................................650 TIRE ANGLE SENSOR...................................................................................651 REMOVAL•INSTALLATION............................................................................651 Removal Procedure...........................................................................651 Installation Procedure......................................................................651 SWING LOCK CYLINDER.................................................................................652 REMOVAL•INSTALLATION............................................................................652 Removal Procedure...........................................................................652 Installation Procedure......................................................................652 Point Operations............................................................................653 TILT ANGLE SENSOR...................................................................................654 REMOVAL•INSTALLATION (16 ~ 35 MODEL)............................................................654 Removal Procedure...........................................................................654 Installation Procedure......................................................................654 Point Operations............................................................................655 REMOVAL•INSTALLATION (40 ~ 50 MODEL)............................................................656 Removal Procedure...........................................................................656 Installation Procedure......................................................................656 LOAD SENSOR.........................................................................................657 REMOVAL•INSTALLATION............................................................................657 V·FV mast...................................................................................657 FSV mast....................................................................................657 Removal Procedure...........................................................................657 V·FV mast...............................................................................657 FSV mast................................................................................657 Installation Procedure......................................................................657 SPEED SENSOR........................................................................................658 REMOVAL•INSTALLATION............................................................................658 Removal Procedure...........................................................................658 Installation Procedure......................................................................658 Point Operations............................................................................659 MAST LIFTING HEIGHT SWITCH..........................................................................660 REMOVAL•INSTALLATION............................................................................660 Removal Procedure...........................................................................660 Installation Procedure......................................................................660 MATCHING............................................................................................661 SAS MATCHING....................................................................................661 MINI LEVER MATCHING.............................................................................662 STANDARD STATE OF VEHICLE.......................................................................663 CAUTIONS ON MODIFYING VEHICLES......................................................................665 18E-Section.............................................................................................666 APPENDIX............................................................................................666 SST LIST............................................................................................667 SERVICE STANDARDS...................................................................................671 BATTERY (Reference).............................................................................671 CONTROLLER......................................................................................671 ACCELERATION POTENTIOMETER......................................................................671 DIRECTION SWITCH................................................................................671 BRAKE LIMIT SWITCH..............................................................................672 DRIVE MOTOR.....................................................................................672 PUMP MOTOR......................................................................................672 POWER STEERING MOTOR............................................................................672 DRIVE UNIT......................................................................................673 FRONT AXLE......................................................................................673 REAR AXLE.......................................................................................674 STEERING........................................................................................675 BRAKE...........................................................................................676 MATERIAL HANDLING SYSTEM........................................................................677 MAST............................................................................................677 CYLINDER........................................................................................678 OIL PUMP........................................................................................680 OIL CONTROL VALVE...............................................................................680 SAS.............................................................................................680 CONNECTOR DRAWING (16 ~ 35 MODEL)...................................................................681 CPU Boad Connector..............................................................................690 SCPU Board Connector............................................................................691 DC/SD Board Connector...........................................................................692 Main Controller Connector•Component.............................................................693 SAS Controller Connector•Component..............................................................694 Traveling Controller Connector•Component........................................................695 Material Handling Controller Connetor•Component.................................................695 Contactor Panel Connector•Component.............................................................696 Oil Control Valve Connector•Component...........................................................697 Brake Change Valve Connector•Component..........................................................697 CONNECTOR DRAWING (40 ~ 50 MODEL)...................................................................698 CPU Boad Connector..............................................................................707 SCPU Board Connector............................................................................708 DC/SD Board Connector...........................................................................709 Main Controller Connector•Component.............................................................710 SAS Controller Connector•Component..............................................................711 Traveling Controller Connector•Component........................................................712 Material Handling Controller Connector•Component................................................712 Contactor Panel Connector•Component.............................................................713 Oil Control Valve Connector•Component...........................................................714 Brake Change Valve Connector•Component..........................................................714 CONNECTING DIAGRAM (16 ~ 35 MODEL)..................................................................714 CONNECTING DIAGRAM (40 ~ 50 MODEL)..................................................................714 WIRING DIAGRAM (16 ~ 35 MODEL)......................................................................714 WIRING DIAGRAM (40 ~ 50 MODEL)......................................................................714 COLOPHON................................................................................................720
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