Be30 (FB-11)

ELECTRIC LIFT TRUCK
FB10EX/14EX/15EX/18EX-11
FB15EXG /18EXG-11
SERIAL No.
807001 and up
FB20EX/25EX-11
FB20EXG /25EXG-11
SERIAL No.
814001 and up
FB30-11
SERIAL No.
814001 and up
SECTION INDEX
10. GENERAL AND SPECIFICATIONS
20. TESTING AND ADJUSTING
30. REMOVAL AND INSTALLATION
40. DISASSEMBLY AND ASSEMBLY
50. MAINTENANCE STANDARD
60. STRUCTURE AND FUNCTION
70. TROUBLESHOOTING
80. CRITERIA FOR YEARLY INSPECTION
BE30 Series 00-3

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

1 ton truck FB10EX
1.35 ton truck FB14EX
1.5 ton truck FB15EX / 15EXG
2 ton truck FB20EX / 20EXG
3 ton truck FB30
BE30 Series 00-5

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

The symbols described below are used in this manual for convenience and better understanding
Symbol Item Description
Special safety precautions are needed to perform the

Safety
work.
a Note
Special technical precautions are needed to perform the
work.
Fastening parts that require specified tightening force

Tightening torque
when assembling.
Weight of parts or systems.

Weight
Places to be coated with adhesives, etc. When assem-

Coat
bling.
00-6 BE30 Series

10. GENERAL AND SPECIFICATIONS
Outside view and specifications . . . . . . . . . . . . 10- 2

Periodic replacement of consumable parts . . . 10- 5
Safety items for maintenance. . . . . . . . . . . . . . 10- 6
Standard tightening torque for bolts . . . . . . . . . 10-12
Standard tightening torque for pipe joints . . . . 10-13
How to use loctite. . . . . . . . . . . . . . . . . . . . . . . 10-14
Conversion table . . . . . . . . . . . . . . . . . . . . . . . 10-15
BE30 Series 10-1

OUTSIDE VIEW AND SPECIFICATIONS GENERAL AND SPECIFICATIONS
OUTSIDE VIEW AND SPECIFICATIONS

FB10EX-11 – FB18EX-11
Item Unit FB10EX-11 FB14EX-11 FB15EX-11 FB18EX-11

• Performance
Rated capacity kg 1000 1350 1500 1750
Load center mm 500 500 500 500
Std. mast lift height A mm 3000 3000 3000 3000
Lifting speed (loaded) mm/s 360 350 340 340
Travel speed (unloaded) km/h 17 17 17 17
Max. gradeability % 22.0 20.0 19.0 17.0
(loaded) (degree) (12.5) (11.5) (11.0) (9.5)
• Dimensions, weight
Overall length (with std. forks) B mm 2775 2930 2930 2965
Overall width (at tire, single) C mm 1070 1070 1115 1115
Overall Mast lowered mm 1970 1970 1970 1970
height Overhead guard D mm 2095 2095 2095 2095
Free lift (overall mast height) E mm 135 140 140 140
Fork length F mm 770 920 920 920
Wheelbase G mm 1250 1250 1250 1250
Service weight (with standard battery) kg 2510 2715 2905 3080
• Motor output
Drive kw/h AC 7.3 AC 7.3 AC 7.3 AC 7.3
Pump kw/5min DC 9.0 DC 9.0 DC 9.0 DC 9.0
PS kw/h DC 0.4 DC 0.4 DC 0.4 DC 0.4
• Tire size
Front tires – 6.00-9-10PR 6.00-9-10PR 21x8-9-14PR 21x8-9-14PR
Rear tires – 5.00-8-8PR 5.00-8-8PR 5.00-8-8PR 5.00-8-10PR
10-2 BE30 Series

GENERAL AND SPECIFICATIONS OUTSIDE VIEW AND SPECIFICATIONS
Item Unit FB15EXG-11 FB18EXG-11

• Performance
Rated capacity kg 1500 1750
Load center mm 500 500
Std. mast lift height A mm 3000 3000
Lifting speed (loaded) mm/s 340 340
Travel speed (unloaded) km/h 17 17
Max. gradeability % 19.0 17.0
(loaded) (degree) (11.0) (9.5)
Overall length (with std. forks) B mm 3150 3150
Overall width (at tire, single) C mm 1115 1115
Overall Mast lowered mm 1970 1970
height Overhead guard D mm 2095 2095
Free lift (overall mast height) E mm 140 140
Fork length F mm 920 920
Wheelbase G mm 1470 1470
Service weight (with standard battery) kg 3105 3305
• Motor output
Drive kw/h AC 7.3 AC 7.3
Pump kw/5min DC 9.0 DC 9.0
PS kw/h DC 0.4 DC 0.4
• Tire size
Front tires – 21x8-9-14PR 21x8-9-14PR
Rear tires – 5.00-8-8PR 5.00-8-10PR
BE30 Series 10-3

OUTSIDE VIEW AND SPECIFICATIONS GENERAL AND SPECIFICATIONS
FB20EX-11 – FB30-11
Item Unit FB20EX-11 FB25EX-11 FB20EXG-11 FB25EXG-11 FB30-11

• Performance
Rated capacity kg 2000 2500 2000 2500 3000
Load center mm 500 500 500 500 500
Std. mast lift height A mm 3000 3000 3000 3000 3000
Lifting speed (loaded) mm/s 290 260 290 260 260
Travel speed (unloaded) km/h 16.5 16.0 16.5 16.0 14.0
Max. gradeability % 19.0 16.0 19.0 16.0 16.0
(loaded) (degree) (11.0) (9.0) (11.0) (9.0) (9.0)
Overall length (with std. forks) B mm 3175 3365 3325 3480 3590
Overall width (at tire, single) C mm 1165 1165 1165 1165 1235
Overall Mast lowered mm 1995 1995 1995 1995 2015
height Overhead guard D mm 2095 2095 2220 2220 2215
Free lift (overall mast height) E mm 150 155 150 155 155
Fork length F mm 920 1070 920 1070 1070
Wheelbase G mm 1400 1400 1550 1550 1600
Service weight (with standard battery) kg 3530 3960 4100 4230 5090
• Motor output
Drive kw/h AC 10.3 AC 10.3 AC 10.3 AC 10.3 AC 9.7
Pump kw/5min DC 10.0 DC 10.0 DC 10.0 DC 10.0 DC 12.6
PS kw/h DC 0.6 DC 0.6 DC 0.6 DC 0.6 DC 0.6
• Tire size
23x9-10- 23x9-10- 23x9-10- 23x9-10- 28x9-15-
Front tires – 16PR 16PR 16PR 16PR 14PR
Rear tires – 18x7-8-14PR 18x7-8-14PR 18x7-8-14PR 18x7-8-14PR 21x8-9-

10PR
10-4 BE30 Series

GENERAL AND SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS
PERIODIC REPLACEMENT OF CONSUMABLE PARTS
To operate the vehicle safely, replace periodically

the parts, which are especially related to safety
and fire, on the important replacement parts list
below.
Since the materials change as time goes, these
parts are subject to wear and degradation. But, it
is hard to judge the degree of deterioration in the
periodic maintenance.
Therefore, after a certain period of use, even if no
defect is observed, these parts should be re-
placed with new ones to maintain the vehicle in
the safe condition.
However, if any abnormality is found on these
parts before periodic maintenance, repair or re-
place them.
When replacing the hose, if the degradation of
hose clamp such as deformation and crack is
found, replace the hose clamp at the same time.
The periodic replacement is not covered by the
warranty.
Important Replacement Parts List
No. Part name Years
1 Master cylinder and wheel cylinder caps, dust seals 1
2 Brake hose or tube 1–2
3 Brake reserve tank, tube 2–4
4 Power sttering hose 2
5 Rubber parts of power steering 2
6 Lift chain 2–4
7 Hose of laod handling 1–2
BE30 Series 10-5

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS
SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION
USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE

• Only persons authorized by the owner or operator of the equipment and having proper certification (local or
national) may carry out inspection, maintenance and repairs of the lift truck.
If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.
MAINTENANCE LOCATION
• When carrying out inspection and maintenance, use a level, dry, dust-free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE

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

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the
lift truck before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks
and mast from dropping.
• When carrying out job with another worker, decide who is the leader and carry out the job in accordance
with instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been
fully corrected or that defective parts have not been removed.
10-6 BE30 Series

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS

• Avoid loose clothing, jewelry, and loose long hear.
They can catch control or in moving parts and cause serious injury
or death.
• Always wear a hard hat and safety boots.
• Depending on the working conditions, wear other safety equip-
ment in addition to the hard hat and safety boots.
USE SUITABLE TOOLS

• Always use tools that are suited for inspection and maintenance.
It is extremely dangerous to use broken tools or tools designed for
another purpose.
REPLACE SAFETY CRITICAL PARTS PERIODICALLY

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

• Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the filter
when the oil is hot. Hot oil may spurt out and cause burns.
• When carrying out inspection and maintenance, wait for the oil
temperature to go down, and carry out the operation in the order
given in this manual.
• Do not forget that the work equipment circuits are always under
pressure. Do not add oil, drain oil, or carry out maintenance or in-
spection before completely releasing the internal pressure.
• If oil is leaking under high pressure from small holes, it is danger-
ous if the jet of high-pressure oil hits your skin or eyes. Always
wear safety glasses and thick gloves, and use a piece of card-
board or a sheet of plywood to check for oil leakage.
• Release the internal pressure before checking the accumulator
piping.
• If you are hit by a jet of high pressure oil, consult a doctor imme-
diately.
BE30 Series 10-7

BE CAREFUL NOT TO GET CAUGHT OR FALL

• Never put your hands or feet into the mast structure. There is danger
that you will get caught in moving parts and be seriously injured.
• Do not use the mast as a ladder. If you slip, there is danger that you
will fall.
CHECKING AND INFLATING TIRES

• If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immediately.
The inflation pressure may have gone down because of damage to the rim. If the rim is damaged or cracked
and the tires are inflated, there is danger that the rim will break when the tire is under high pressure, and
this may cause personal injury or death.
• For safety, when checking tire pressure, place your body in front of the
tread face of the tire. Do not check from the side face of the tire.
• Suitable qualifications are needed for tire inflation work. Always have
the work carried out by properly qualified personnel.
• The tire inflation pressure on a forklift truck is several times higher than
the pressure on an automobile.
When the tires are being inflated, there is danger that dirt or dust may
be thrown up by the compressed air and enter your eyes, so always
wear safety glasses.
HANDLING OF TIRE
Leave disassembly and assembly of each tire to a specialist.
Since the tire inflation pressure is very high, you must han-
dle the tire carefully.
• Before removing the tire, release the inflation pressure
completely. To remove the tire from the chassis, loosen
hub nuts (2).
• Never touch rim nuts (1), since they are dangerous.
• After replacing the tire, perform a test run, then check the
mounting nuts for looseness. If the tightening torque of
the nuts is insufficient, retighten the nuts to the specified
torque.
• See the section of tightening torque: [20. TESTING AND
ADJUSTING, Service data].
10-8 BE30 Series

JACKING UP LIFT TRUCK (when checking or replacing tires)

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

• Lift truck slinging work should be carried out by a qualified person who
has completed a course in correct lifting methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes have ample strength
and are not damaged.
• Block the tires contacting the ground to prevent the lift truck from mov-
ing.
• Insert blocks to prevent the truck from coming down.
• Do not go under the lift truck during the lifting operation.
• If the specified lifting point is the counterweight, check that the counter-
weight mounting bolts are tightened to the specified torque before car-
rying out the lifting operation. check also that there is no damage to the
lifting portion on the counterweight.
SLINGING VEHICLE (for loading it on trailer, etc.)

• Never sling the vehicle by the head guard.
If the vehicle needs to be slung often, a special sling device
is necessary. In this case, consult your distributor.
• The vehicle shall be slung by a person who has completed a
course of slinging work.
• Install wires to the specified sling parts.
• Use wires which is free of defect and has sufficient strength
to sling the vehicle.
BE30 Series 10-9

CAUTION WHEN HANDLING BATTERY

Handling error of batteries may cause explosions, fires and
other critical injuries. Handle batteries after fully understanding
how to handle and their hazards.
• Batteries generate flammable hydrogen gas and may ex-
plode in contact with fire. Always keep the battery hood open
while charging batteries.
• Do not smoke or allow any flame near the battery.
• Sparks may ignite the gas. Do not place tools, parts or other
metal objects on the battery.
• To clean the battery surface, use wet piece of cloth. Dry
cloth may generate static and cause explosion.
• Depending on the weather, environmental, clothing material
and other conditions, human bodies may deposit and spark
statistics. Therefore, before touching lift truck being charged
or after charging, discharge statistic deposit in the human
bodies by grounding.
• Batteries for battery-driven lift trucks store large energy in
high-tension. Beware of the risk of electric shock and burns.
Be careful to keep human bodies from touching energized
portion during maintenance, inspection and/or installation or
removal.
• Battery electrolyte contains sulfuric acid, and can quickly
burn the skin and eat holes in clothing. Always wear protec-
tive glasses, rubber gloves and rubber sole shoes for main-
tenance inspection.
• If battery electrolyte gets into your eyes, flush them immedi-
ately with fresh tap water for 10 to 15 minutes continually
and consult a doctor.
• If you spill battery electrolyte on yourself, immediately take
off clothes and flush the contact portion of the skin with a
large quantity of tap water and consult a doctor.
• If one swallows battery electrolyte by mistake, drink a large
amount of water or milk mixed with white of raw eggs or sal-
ad oil and consult a doctor at once.
• If battery electrolyte is spilt or leaked in the surrounding ar-
ea, neutralize the area with neutralizing agents (baking so-
da, calcium hydroxide or sodium carbonate, etc.) and wash
it down with large amount of water. Or floor surfaces and
cargoes will be damaged.
• Do not drain battery electrolyte or disassemble or repair bat-
teries, which is dangerous.
• If the following abnormalities are detected, please call your
Komatsu Forklift distributor/dealer for service:
If battery plug and charging plug mating become loos-
ened or play is generated (Plug becomes abnormally
heated).
If battery electrolyte temperature is high or electrolyte lev-
el drops sharply.
If charging requires too long time (Charging is not com-
pleted although the battery was not used till late hours on
the preceding day).
10-10 BE30 Series

DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit and
start a fire.
PRECAUTIONS WHEN CHARGING

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change.
To prevent the danger of gas explosion, always do as follows.
• Carry out the charging operation in a well-ventilated place.
• Do not smoke or allow any flame.
• Start the charging operation when the temperature of the battery electrolyte is below 35°C (95°F). (If the
temperature goes above 50°C (122°F) during the charging operation, wait for it to go down below 35°C
(95°F) before starting charging operation again.)
• When using a battery charger to charge the battery, take the battery caps off.
HANDLING BRAKE FLUID

It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped. Always do
the following.
• Check the level of the brake fluid periodically.
• Always use the specified brake fluid.
• Check that the breather of the brake fluid reserve tank is not clogged.
• Be careful not to let dirt or dust get into the brake fluid reserve tank.
WASTE MATERIALS
• Obey appropriate laws and regulations when disposing of harmful objects
such as oil, filters, and batteries.
BE30 Series 10-11

STANDARD TIGHTENING TORQUE FOR BOLTS GENERAL AND SPECIFICATIONS
STANDARD TIGHTENING TORQUE FOR BOLTS

TIGHTENING TORQUE when using torque wrench or spanner shall be in accordance with Table. This torque
shall be used when TIGHTENING TORQUE of especially narrow range is required.
1. In the case of using impact wrenches or 2. In the case of using torque wrenches
spanners
Unit: kgm (Nm) [ft. lb] Unit: kgm (Nm) [ft. lb]
S43C, SMn34CH SMn40CH, S43C, SMn34CH SMn40CH,

Width across flats SCM3H
Width across flats mm
SCM3H
Thread mm (in) Thread (in)
or superior ones or superior ones
dia. dia.
mm (in) Conven- mm (in) Conven-
ISO ISO
tional threads
Range Torget tional threads
Range Torget
threads threads
6 10 10 0.9 – 1.5 1.2 6 10 10 1.2 – 1.5 1.35
(0.24) (0.39) (0.39) (8.8 – 15) (12) (0.24) (0.39) (0.39) (12 – 15) (13.2)
[6.5 – 11] [8.7] [8.7 – 11] [9.8]
8 14 13 1.5 – 3.5 2.5 8 14 13 2.8 – 3.5 3.2
(0.31) (0.55) (0.51) (15 – 34) (25) (0.31) (0.55) (0.51) (27 – 34) (31)
[11 – 25] [18] [20 – 25] [23]
10 17 17 3.5 – 7.5 5.5 10 17 17 6 – 7.5 6.7
(0.39) (0.67) (0.67) (34 – 74) (54) (0.39) (0.67) (0.67) (59 – 74) (66)
[25 – 54] [40] [43 – 54] [48]
12 19 19 5.5 – 12.5 9.0 12 19 19 10 – 12.5 11.5
(0.47) (0.75) (0.75) (54 – 123) (88) (0.47) (0.75) (0.75) (98 – 123) (113)
[40 – 90] [65] [72 – 90] [83]
14 21 22 8.5 – 20.0 14.0 14 21 22 16 – 20.0 18
(0.55) (0.83) (0.87) (83 – 196) (137) (0.55) (0.83) (0.87) (157 – 196) (177)
[61 – 145] [101] [116 – 145] [130]
16 23 24 15.0 – 31.5 23.5 16 23 24 25 – 31.5 28.5
(0.63) (0.91) (0.94) (147 – 309) (230) (0.63) (0.91) (0.94) (245 – 309) (279)
[108 – 228] [170] [181 – 228] [206]
18 26 27 20.5 – 43.5 32.0 18 26 27 35 – 43.5 39
(0.71) (1.02) (1.06) (201 – 427) (314) (0.71) (1.02) (1.06) (343 – 427) (382)
[148 – 315] [231] [253 – 315] [282]
20 29 30 32.5 – 62.0 47.0 20 29 30 50 – 62.0 56
(0.79) (1.14) (1.18) (319 – 608) (461) (0.79) (1.14) (1.18) (490 – 608) (549)
[235 – 448] [340] [362 – 448] [405]
22 32 32 48.0 – 84.5 66.5 22 32 32 67.5 – 84.5 76
(0.87) (1.26) (1.26) (471 – 829) (652) (0.87) (1.26) (1.26) (662 – 829) (745)
[347 – 611] [481] [488 – 611] [550]
24 35 36 60.0 – 105 82.5 24 35 36 84 – 105 94.5
(0.94) (1.38) (1.42) (588 – 1030) (809) (0.94) (1.38) (1.42) (824 – 1030) (927)
[434 – 759] [597] [608 – 759] [684]
27 41 41 90.0 – 150 120 27 41 41 120 – 150 135
(1.06) (1.61) (1.61) (883 – 1471) (1177) (1.06) (1.61) (1.61) (1177 – 1471) (1324)
[651 – 1085] [668] [868 – 1085] [976]
30 46 46 115 – 195 155 30 46 46 155 – 195 175
(1.18) (1.81) (1.81) (1128 – 1912) (1520) (1.18) (1.81) (1.81) (1520 – 1912) (1716)
[832 – 1410] [1121] [1121 – 1410] [1266]
33 50 50 150 – 250 200 33 50 50 200 – 250 225
(1.30) (1.97) (1.97) (1471 – 2452) (1961) (1.30) (1.97) (1.97) (1961 – 2452) (2206)
[1085 – 1808] [1447] [1447 – 1808] [1627]
36 54 55 190 – 310 250 36 54 55 250 – 310 280
(1.42) (2.13) (2.17) (1863 – 3040) (2452) (1.42) (2.13) (2.17) (2452 – 3040) (2746)
[1374 – 2242] [1808] [1808 – 2242] [2025]
39 58 60 230 – 370 300 39 58 60 295 – 370 335
(1.54) (2.28) (2.36) (2256 – 3628) (2942) (1.54) (2.28) (2.36) (2893 – 3628) (3285)
[1664 – 2676] [2170] [2134 – 2676] [2423]
a This table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to
be used, or which requir to tighten to otherwise specified torque.
Conventional screw threads ISO screw threads
10-12 BE30 Series

GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
Elbows, nipples and unions

Width across flats B mm 22 30 36
(inch) (0.866) (1.181) (1.417)
Width D mm 19 22 30
(inch) (0.748) (0.866) (1.181)
Tightening torque Nm {kgm} 29.4 – 39.2 {3 – 4} 78.5 – 103 {8 – 10.5} 117.7 – 161.8 {12 – 16.5}
[ft.Ib] [21.7 – 28.9] [57.9 – 75.9] [86.8 – 119.3]
Port size
3/4-16UNF 7/8-14UNF –
(inch)
Tightening torque Nm {kgm} 68.6 – 73.6 {7 – 7.5} 78.5 – 83.3 {8 – 8.5}

–
[ft.Ib] [50.6 – 54.2] [57.9 – 61.5]
High-pressure rubber hoses, pipes and sleeve nuts

Width across flats B (mm) 19 24 27 32 36
(inch) (0.748) (0.945) (1.063) (1.260) (1.417)
Bore A mm 14 18 22 24 30
(inch) (0.551) (0.709) (0.866) (0.945) (1.181)
Tightening torque Nm {kgm} 19.6 – 29.4 {2 – 3} 23.5 – 68.6 {3 – 7} 58.8 – 98.1 {6 – 10} 107.9 – 166.7 {11 – 17} 147– 206 {15–21}
[ft.Ib] [14.5 – 21.7] [21.7 – 50.6] [43.7 – 72.3] [79.6 – 122.9] [108.52 – 151.8]
BE30 Series 10-13

HOW TO USE LOCTITE GENERAL AND SPECIFICATIONS
HOW TO USE LOCTITE 4. Assembly

After applying LOCTITE, tighten the screw or fit
the shaft to the hole as usual. (When using LOC-
1. PROCEDURE FOR USING LOCTITE
TITE for structures or LOCTITE of instant glue
type, press the mating parts lightly (about 49 kPa
Male side {0.5 kgf/cm2}).
Degreasing Air drying
2. REMOVAL OF PARTS
Female
side
When screws and shafts are secured with LOC-
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pull-
Applying
Leaving Assembly ers, etc. If LOCTITE is so strong that a part may
LOCTITE
be broken when it is removed, heat it (to 200 –
250°C) with a soldering iron, gas torch, etc., and
1. Degreasing and cleaning you can remove it easily. It is generally difficult
(a) Clean the parts in trichloroethylene, ace- to dissolve LOCTITE in chemical solutions.
tone, ether, alkaline solution, etc. which are
highly volatile. 3. WHEN ASSEMBLING AGAIN
(b) Degrease the parts as perfectly as possible. (a) If a LOCTITE film on threads is broken, it is
(c) Since gasoline, light oil, kerosene, etc. are left as white powder on the threads. In this
not highly volatile, they are not recommend- case, you can apply LOCTITE again to the
ed. If it is obliged to use them, dry them threads without removing the white powder.
completely. (b) If shafts or flanges secured with LOCTITE
(d) If the mating parts are made of thermoset- are disconnected, LOCTITE remaining on
ting resin, treat them with LOQUICK PRIM- them may need to be removed to maintain
ER after degreasing them. dimensional accuracy. You can remove the
remaining LOCTITE easily, however, with a
2. Air drying wire brush, etc.
(a) Wait until the cleaning fluid dries out. (c) If plates secured with LOCTITE need to be
(b) If the parts are treated with LOQUICK PRIM- assembled again after they are separated,
ER, do not wipe them but dry them in air for be sure to remove all the hardened LOC-
5 – 10 minutes. (If LOCTITE is used before TITE and roughen the mating surfaces with
LOQUICK PRIMER dries out, its effect is sandpaper.
lowered.)
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads
or the shaft and hole to be fitted by amount to fill
the clearance between them by one of the fol-
lowing methods.
• Applying directly from LOCTITE container
nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving
pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
10-14 BE30 Series

MILLIMETERS TO INCHES
GENERAL AND SPECIFICATIONS INCHES TO MILLIMETERS
CONVERSION TABLE
MILLIMETERS TO INCHES
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.229 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
INCHES TO MILLIMETERS
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.141 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
BE30 Series 10-15

LITER TO U.S. GALLON
U.S. GALLON TO LITER GENERAL AND SPECIFICATIONS
LITER TO U.S. GALLON

1 l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
U.S. GALLON TO LITER

1 U.S. Gal = 3.7854 l
0 1 2 3 4 5 6 7 8 9
3.79 7.57 11.36 15.14 18.93 22.71 26.50 30.28 34.07
10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92
20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78
30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63
40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49
50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 253.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76
10-16 BE30 Series

LITTER TO U.K. GALLON
GENERAL AND SPECIFICATIONS U.K. GALLON TO LITER
LITTER TO U.K. GALLON

1 l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
U.K. GALLON TO LITER

1 U.K. Gal = 4.5461 l
0 1 2 3 4 5 6 7 8 9
4.55 9.09 13.64 18.18 22.73 27.28 31.82 36.37 40.92
10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38
20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84
30 136.28 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 341.88 436.42 440.97 445.52 450.06
BE30 Series 10-17

KILOGRAM TO POUND
POUND TO KILOGRAM GENERAL AND SPECIFICATIONS
KILOGRAM TO POUND
1 kg = 2.2046 Ib
0 1 2 3 4 5 6 7 8 9
2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
POUND TO KILOGRAM
1 Ib = 0.4536 kg
0 1 2 3 4 5 6 7 8 9
0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082
10 4.536 4.990 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154
30 13.608 14.061 14.515 14.969 15.422 15.876 16.329 16.783 17.237 17.690
40 18.144 18.597 19.051 19.505 19.958 20.412 20.865 21.319 21.772 22.226
50 22.680 23.133 23.587 24.040 24.494 24.948 25.401 25.855 26.308 26.762
60 27.216 27.699 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906
10-18 BE30 Series

GENERAL AND SPECIFICATIONS KG/CM² TO LB/IN²
KG/CM² TO LB/IN²
1 kg/cm² = 14.2233 lb/in²
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 996.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1123 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
BE30 Series 10-19

KGM TO FT. LB GENERAL AND SPECIFICATIONS
KGM TO FT. LB
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.6 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
10-20 BE30 Series

GENERAL AND SPECIFICATIONS TEMPERATURE
TEMPERATURE
Fahrenheit-Centigrade Conversion. –A simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column
of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.3 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.2 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 265.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
BE30 Series 10-21

20. TESTING AND ADJUSTING
Service data (1.0 - 1.75 ton models) . . . . . . . . 20- 2

Service data (2.0 - 3.0 ton models) . . . . . . . . . 20- 4
How to operate lift interrupt function . . . . . . . . 20- 6
How to reset electrolyte level indicator
function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 6
How to start hour meter . . . . . . . . . . . . . . . . . . 20- 7
Operation of meter panel . . . . . . . . . . . . . . . . . 20- 7
Adjusting lowering speed of fork . . . . . . . . . . . 20-14
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
Stationary charger . . . . . . . . . . . . . . . . . . . . . . 20-19
Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
Wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
Adjusting parking brake lever . . . . . . . . . . . . . . 20-22
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
Rear axle (Steering axle) . . . . . . . . . . . . . . . . . 20-24
Mast (1.0 - 1.75 ton models) . . . . . . . . . . . . . . 20-26
Mast (2.0 - 3.0 ton models) . . . . . . . . . . . . . . . 20-27
Fork carriage (1.0 - 1.75 ton models) . . . . . . . . 20-28
Fork carriage (2.0 - 3.0 ton models). . . . . . . . . 20-30
Measuring hydraulic drift of hydraulic cylinder
and hydraulic drift of leaning forward . . . . . . . 20-32
Bleeding air . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
BE30 Series 20-1

SERVICE DATA TESTING AND ADJUSTING
SERVICE DATA (1.0 – 1.75 TON MODELS)
Com- FB15EX FB18EX

ponent Inspection item Unit FB10EX / FB14EX
FB15EXG FB18EXG
Pump motor mm Min. 22 Min. 22 Min. 22

Brush height
Power steering mm Min. 13 Min. 13 Min. 13
motor
Pump motor N {kgf} Min. 7.35 {0.75} Min. 7.35 {0.75} Min. 7.35 {0.75}
Press force of
brush spring Power steering 4.9 –11.76 4.9 –11.76 4.9 –11.76
motor N {kgf} {0.5–1.2} {0.5–1.2} {0.5–1.2}
Motor
Outside diameter of
commutator Power steering
motor mm Min. 29.5 Min. 29.5 Min. 29.5
Pump motor mm Min. 0.2 Min. 0.2 Min. 0.2

Undercut depth
Power steering mm Min. 0.2 Min. 0.2 Min. 0.2
motor
Drive motor Mz Min. 3 Min. 3 Min. 3
Insulation of each
part
Pump motor Mz Min. 0.5 Min. 0.5 Min. 0.5
When discharged to 0 – 20% — 1.28 – 1.256 (at 20 °C)

Specific gravity

Battery
Input voltage V 48 48 48
Wear limit of contacts of contactors — Extreme unevenness must not be detected when checked visually.
For travel A 48LF-225A

For hydraulic A 48LF-225A
equipment
For power steer- A 48LF-40A
ing
Controller
Capacity of fuse
For charging A 48LF-225A
circuit
Control circuit of A 10
chassis
Accessory circuit A 15
Travel A 527 – 586

Cut-off current Hydraulic equip- A Min. 300
(Lock current) ment
Power steering A 45 ± 5
20-2 BE30 Series

TESTING AND ADJUSTING SERVICE DATA
Com- FB15EX FB18EX

Inspection item Unit FB10EX / FB14EX
ponent FB15EXG FB18EXG
Refill capacity of transfer case l 7 7 7
Depth of tire groove mm Min. 1.6 (At place of 1/4 of tread width)
Power train and travel device
Front wheel kPa 610 {6.25} 610 {6.25} 610 {6.25}

Tire inflation pres- {kgf/cm2}
sure kPa
Rear wheel {kgf/cm2} 780 {8} 780 {8} 780 {8}
Front wheel Nm 196 – 245 {20 – 25} 196 – 245 {20 – 25} 196 – 245 {20 – 25}
Tightening torque {kgm}
of hub nut Nm
Rear wheel {kgm} 98 – 147 {10 – 15} 98 – 147 {10 – 15} 98 – 147 {10 – 15}
Front wheel Nm 98 – 123 {10 – 12.5} 98 – 123 {10 – 12.5} 98 – 123 {10 – 12.5}
of rim fitting nut Nm
Rear wheel {kgm} 59 – 74 {6 – 7.5} 59 – 74 {6 – 7.5} 59 – 74 {6 – 7.5}
Play of steering wheel mm 30 – 60 30 – 60 30 – 60

Clearance of support mm Max. 0.5 Max. 0.5 Max. 0.5
thrust
Rear axle
Steering and braking devices
Min. turning radius mm 1,775 FB15EX: 1,775 FB18EX: 1,805

FB15EXG: 2,005 FB18EXG: 2,005
Play mm 2–6 2–6 2–6
Brake pedal
Height when pressed mm Min. 80 Min. 80 Min. 80
Refill quantity of brake l 0.4 0.4 0.4
fluid
Operating effort of park- N Min. 147 {15} Min. 147 {15} Min. 147 {15}
ing brake lever {kgf}
Brake
Tightening torque of back Nm 157 – 196 {16 – 20} 157 – 196 {16 – 20} 157 – 196 {16 – 20}
plate mounting bolt {kgm}
Thickness of lining mm Min. 2.0 Min. 2.0 Min. 2.0
Thickness of base mm 1.0-ton models: Min. 26 1.35-ton models: Min. 30

1.5-ton models: Min. 30 1.75-ton models: Min. 33
Fork Difference in height mm Max. 15 Max. 15 Max. 15
Cargo handling device
Increase of width at tips mm Max. 35 Max. 35 Max. 35
Chain Length of 17 links mm Max. 275.5 Max. 275.5 Max. 275.5
Hydraulic drift mm/15 At fork: Max. 60

min At cylinder: Max. 30
Cylinder
Hydraulic drift of lean- mm/15 Max. 23
ing forward min
Relief pressure MPa 17.6 {180} 17.6 {180} 17.6 {180}

Hydraulic {kgf/cm2}
system Refill capacity of
hydraulic tank l 25 ( 1.29) 26 ( 1.30) 26 ( 1.30)
1: A value in ( ) is total quantity of oil required when 3-m mast is installed.
BE30 Series 20-3

SERVICE DATA TESTING AND ADJUSTING
SERVICE DATA (2.0 – 3.0 TON MODELS)
Com- FB20EX FB20EXG

ponent Inspection item Unit FB30
FB25EX FB25EXG

Brush height
Power steering mm Min. 13 Min. 13 Min. 13
motor
Pump motor N {kgf} Min. 5.59 {0.57} Min. 5.59 {0.57} Min. 5.59 {0.57}
Press force of
brush spring Power steering 4.9 –11.76 4.9 –11.76 4.9 –11.76
motor N {kgf} {0.5–1.2} {0.5–1.2} {0.5–1.2}
Motor
Outside diameter of
commutator Power steering
motor mm Min. 29.5 Min. 29.5 Min. 29.5
Pump motor mm Min. 0.2 Min. 0.2 Min. 0.2

Undercut depth
Power steering mm Min. 0.2 Min. 0.2 Min. 0.2
motor
Drive motor Mz Min. 3 Min. 3 Min. 3
Insulation of each
part
Pump motor Mz Min. 0.5 Min. 0.5 Min. 0.5

Specific gravity

Battery
Input voltage V 48 48 72
Wear limit of contacts of contactors — Extreme unevenness must not be detected when checked visually.
For travel A 48LF-325 48LF-325 96LF-275A

For hydraulic A 48LF-225 48LF-225 96LF-200A
equipment
Controller
Capacity of fuse For power steer- A 48LF-40 48LF-40 96LF-40A

ing
Control circuit of A 10 10 10
chassis
Accessory circuit A 15 15 15
Travel A 674 – 746 674 – 746 450 – 520

Cut-off current Hydraulic equip- A Min. 340 Min. 340 220
(Lock current) ment
Power steering A 50 ± 25 50 ± 25 42 – 52
20-4 BE30 Series

TESTING AND ADJUSTING SERVICE DATA
Com- FB20EX FB20EXG

ponent Inspection item Unit FB30
FB25EX FB25EXG
Refill capacity of transfer case l 8 8 8
Depth of tire groove mm Min. 1.6 (At place of 1/4 of tread width)
Power train and travel device
Front wheel kPa 880 {9.0} 880 {9.0} 780 {8.0}

Tire inflation pres- {kgf/cm2}
sure kPa
Rear wheel {kgf/cm2} 880 {9.0} 880 {9.0} 610 {6.25}
Front wheel Nm 196 – 245 {20 – 25} 196 – 245 {20 – 25} 294 – 490 {30 – 50}
of hub nut Nm
Rear wheel {kgm} 196 – 245 {20 – 25} 196 – 245 {20 – 25} 196 – 245 {20 – 25}
Front wheel Nm — — —
of rim fitting nut Nm
Rear wheel {kgm} 157 – 196 {16 – 20} 157 – 196 {16 – 20} —
Play of steering wheel mm 30 – 60 30 – 60 30 – 60

Clearance of support mm Max. 0.5 Max. 0.5 Max. 0.5
thrust
Rear axle
Steering and braking devices
Min. turning radius mm FB20EX: 2,000 FB20EXG: 2,070 2.215

FB25EX: 2,015 FB25EXG: 2,130
Play mm 2–6 2–6 2–6
Brake pedal
Height when pressed mm Min. 60 Min. 60 Min. 60
Refill quantity of brake l 0.4 0.4 0.4
fluid
Operating effort of park- N Min. 196 {20} Min. 196 {20} Min. 196 {20}
ing brake lever {kgf}
Brake
Tightening torque of back Nm 157 – 196 {16 – 20} 157 – 196 {16 – 20} 157 – 196 {16 – 20}
plate mounting bolt {kgm}
Thickness of lining mm Min. 2.0 Min. 2.0 Min. 2.0
Thickness of base mm 2.0-ton models: Min. 33 Min. 44

2.5-ton models: Min. 36.5
Fork Difference in height mm Max. 15 Max. 15 Max. 15
Cargo handling device
Increase of width at tips mm Max. 35 Max. 35 Max. 35
Chain Length of 17 links mm Max. 330 Max. 330 Max. 550
Hydraulic drift mm/15 At fork: Max. 60

min At cylinder: Max. 30
Cylinder
Hydraulic drift of lean- mm/15 Max. 23 Max. 26 Max. 26
ing forward min
Relief pressure MPa 17.66 {180} 17.66 {180} 17.66 {180}

Hydraulic {kgf/cm2}
system Refill capacity of
hydraulic tank l 25 ( 1. 31) 26 ( 1. 31) 25 ( 1. 30)
1: A value in ( ) is total quantity of oil required when 3-m mast is installed.
BE30 Series 20-5

HOW TO OPERATE LIFT INTERRUPT FUNCTION,
HOW TO RESET ELECTROLYTE LEVEL INDICATOR FUNCTION TESTING AND ADJUSTING
HOW TO OPERATE LIFT INTERRUPT FUNCTION

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

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

FUNCTION
If the wires shown at right figure Br – YR are discon-
nected, the lift interrupt function operates. If those
wires are connected again, the lift interrupt function
does not operate.
HOW TO RESET ELECTROLYTE LEVEL INDICATOR FUNCTION

To reset the electrolyte level indicator function, dis-
connect yellow-blue wire B above the battery and
connect it to yellow-red wire A. When the electrolyte
level sensor is not necessary for some reason, con-
nect those wires.
20-6 BE30 Series

TESTING AND ADJUSTING HOW TO START HOUR METER, OPERATION OF METER PANEL
HOW TO START HOUR METER This illustration shows Japanese spec.
The hour meter is so set that it will not operate when

the lift truck is shipped. When delivering the lift truck
to a customer, remove its left side cover and connect
the wires to start the hour meter.
(Wire color: RB– BY)
1. Multi-controller
2. Charging mode switch connector
(Only in Japanese spec.)
3. Hour meter start connector
4. System controller
OPERATION OF METER PAN-

Standard display (Hour meter display)
EL
(Check of various set values, adjustment values,
and switches)
1. OPERATOR (USER) ADJUSTMENT MODE

1) Turn the key switch ON.
Set the forward-reverse lever, work equip-
ment control lever, and accelerator in neu-
tral.
2) Press mode button P3 to set the meter panel
in the operator adjustment mode.
• If the mode button is pressed, the meter
panel changes from the standard dis-
play (hour meter display) to the operator Operator adjustment mode display
adjustment mode display. Then, each
time the mode button is pressed, the
settable/adjustable items (settable val-
ues: data) are indicated by flashing in or-
der.
3) Press set value button P1, and the flashing
set value changes. When the set value is
decided, press mode button P3 to enter it
(and move to the next setting mode).
4) Repeat 2) and 3) above to set/adjust the 9
items (See the operator adjustment mode ta-
ble in the next page).
a Use item button P2 to set the year (the num-
ber of units and tens), month, date, day of
week, hour, minute, etc. for setting the cur-
rent time and time for starting charging which
will have multiple set values.
a If the meter panel is returned to the hour
meter display by a method other than press-
ing mode button P3, the set values are not
changed.
a In each example of display, if the italic item of
part A flashes thickly, that item is settable.
BE30 Series 20-7

OPERATION OF METER PANEL TESTING AND ADJUSTING
5) Returning to hour meter display (standard

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

Settable/Adjustable item Set/Adjusted data
1. Standard display (Hour meter display) ––
2. Travel power setting (ES control) Travel power (1 – 8)
3. Lift 1st speed setting Lift 1st speed (1 – 8)
4. Lift 2nd speed setting Lift 2nd speed (1 – 8)
5. Tilting speed setting Tilting speed (1 – 8)
6. Travel speed limit setting Travel speed limit (5 – 15 km/h, 10 steps)
7. Over-travel speed setting Overspeed (Set/Not set)
8. Accelerator neutral regeneration setting Accelerator neutral regeneration (Set/Not set)
9. Current time setting Current time (Year, month, date, day of week, time)
Note) Limit the overspeed to 15 km/h. (See the section 60 “STRUCTURE AND FUNCTIONS”.)
20-8 BE30 Series

TESTING AND ADJUSTING OPERATION OF METER PANEL
2. SERVICE (DISTRIBUTOR) MODE Standard display (Hour meter display)

• In this mode, various set values and adjust-
ment values (11 items in total), except the
operator (user) adjustment items, can be
changed.
a Condition for moving to service adjustment
mode
Set the forward-reverse lever, accelerator,
and work equipment control lever, in neutral.
1) With all of buttons P1, P2, and P3 pressed

(Pressing them simultaneously), turn the key
switch ON, and the screen is set in the ser-
vice adjustment mode.
2) Press mode button P3 to display a set/ad- Service adjustment mode display
justment item to be changed.
a The settable/adjustable item (data) is indicat-
ed by flashing.
3) Press set value button P1 to select a data
(value or letter) to be changed.
a If there are multiple settable data (Date, time,
characteristic, etc.), select one with item but-
ton P2.
4) After selecting a new data (the value or letter
selected finally is the selected value), press
mode button P3 to enter it (go to the next
item).
5) Repeat 2., 3., and 4. above to set/adjust the
11 items (See the service adjustment mode
table in the next page).
a After each item is set, it is lighted up for 2
seconds, then the next item is selected auto-
matically.
a If the meter panel is returned to the hour
meter display by a method other than press-
ing mode button P3, the set values are not
changed.
a In each example of display, if the italic item of
part A flashes thickly, that item is settable.
In service adjustment mode,
• Set the speed of the hydraulic/third valve.
ATT speed 1 (1 – 8)
Set value 8
• Change the accelerator characteristic.
Accelerator characteristic
Characteristic A
Characteristic A is reversed.
a Select characteristic B with button P2.
Characteristic B
Characteristic B is reversed.
After finishing setting, return to the standard
mode.
BE30 Series 20-9

6) Returning to standard display (hour meter

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

Settable/Adjustable item Set data in ( )
1. Standard display (Hour meter display) 1. —
2. Attachment speed 1 setting (3rd valve) 2. Attachment speed 1 (1 – 8)
3. Attachment speed 2 setting (4th valve) 3. Attachment speed 2 (1 – 8)
4. Attachment speed 3 setting (5th valve) 4. Attachment speed 3 (1 – 8)
5. FR regeneration current setting 5. Set value of FR regeneration current (0 – 100)
6. Brake regeneration current setting 6. Set value of brake regeneration current (0 – 100)
7. Neutral regeneration current setting 7. Set value of neutral regeneration current (0 – 100)
8. Slope regeneration current setting 8. Set value of slope regeneration current (0 – 100)
9. Soft start characteristic setting 9. Soft start characteristic setting (Characteristic A, B, C)
10. Accelerator characteristic setting 10. Accelerator characteristic setting (Characteristic A, B, C)
11. Trip meter display 11. Trip meter display (ON/OFF)
20-10 BE30 Series

(Contents of display in service adjustment mode)

Item Contents of display
Service adjustment
mode Item Display (24 characters , 2 lines) Display code
Attachment speed setting D01
Set value 8
Set value 8
Set value 8
FR regeneration current (0 – 100)
FR regeneration current setting D04
Set value 100
Brake regeneration current set- Brake regeneration (0 – 100)
D05
ting Set value 100
Neutral regeneration current set- Neutral regeneration (0 – 100)
D06
ting Set value 100
Slope regeneration current set- Slope regeneration (0 – 100)
D07
ting Set value 100
Soft start characteristic
Characteristics A
Characteristic A
Soft start
characteris- Characteristics B D08
Characteristic B
tic setting
Characteristics C
Characteristic C
Characteristics A
Characteristic A
Accelerator
characteris- Characteristics B D09
Characteristic B
tic setting
Characteristics C
Characteristic C
Trip meter
Trip meter OFF
Display OFF
display set- D10
ting Trip meter
ON
Display ON
3. CHECK IN SWITCH MONITOR MODE

Display and check the operating conditions
of switches and sensors on the display
• Condition for setting meter panel in

switch monitor mode
Pull the parking brake lever and set the for-
ward-reverse lever, work equipment control
lever, and accelerator in neutral.
1) Remove the floor plate.

(Keep the key switch in the OFF position.)
2) Disconnect switch monitor connector (1).

a Under the floor plate, there is a relay wiring
harness and there are lead wires (Color: P
→ BY) connected by a 1-P white connector
out of that harness as shown in the figure at
right. Disconnect (Open) those lead wires.
a Do not disconnect the wires (Color: YL →
BY) connected by the one-pin connector (2).
BE30 Series 20-11

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

erate it), and its state is displayed by ON
OFF on the display.
a See the example of the forward switch of the

forward-reverse lever which is displayed first Control button
in the switch monitor mode and shown in the
figure at right.
5) Press mode button P3 to display the next

switch (sensor).
6) Repeat 4) and 5) above to check the other

sensors.
7) Returning to standard display (hour meter

display)
(1) Turn the key switch OFF.
(2) Connect the switch monitor connector
(Wire color: P ← BY).
Operation of hydraulic tilt lever
(3) Install the floor plate.
(4) Turn the key switch ON.
Standard display (Display of hour meter)
20-12 BE30 Series

LIST OF SWITCHES (SENSORS) AND HOW TO CHECK THEM
No. Switch (Sensor) name How to check Remarks

Shift forward-reverse lever from N to F.
1 Directional F switch —
If indication changes from OFF to ON, this switch is normal.
Shift forward-reverse lever from N to R.
2 Directional R switch —
Press accelerator pedal.
3 Accelerator switch —
Press brake pedal by 28 mm.
4 Brake switch —
Pull lift lever. If indication changes from OFF to ON, this switch
5 Lift 1 switch
is normal.
Pull lift lever. If indication changes from OFF to ON, this switch
6 Lift 2 switch
is normal.
Pull tilt lever. If indication changes from OFF to ON, this switch
7 Tilt switch
is normal. Adjustable with
Pull 3-spool valve lever. potentiometer.
8 Attachment 1 switch
Pull 4-spool valve lever.
Pull 5-spool valve lever.
Pull parking brake lever.
11 Parking brake switch —
If this switch is normal, it is turned ON while lift interrupt function
12 Lift interrupt switch is not working and turned OFF while lift interrupt function is —
working.
Is seat switch is not
Sit in seat. If indication changes from OFF to ON, this switch is
13 Seat switch installed, circuit for
normal.
it is turned ON.
14 Spare ————— —
ON (above 15 km/h)
15 Travel speed limit 2 switch —
OFF (below 15 km/h) (Low-speed model, domestic market only)
If automatic lifting
This switch is turned ON while automatic lifting function is turned
function is not
16 Lifting height switch OFF, and turned OFF while automatic lifting function is turned
installed, circuit for
ON
it is turned ON.
When accelerator pedal is released: If accelerator switch No. 3
is turned OFF while indication is above 7%, this output is nor- If indication is
mal. below 64%, maxi-
17 Accelerator output
mum speed is not
When accelerator pedal is pressed: If indication is above 64 – obtained.
68%, this output is normal.
If indication is 45 – 55% when in neutral, 15 – 25% when at right
18 Torque sensor output —
end, and 75 – 85% when at left end, this output is normal.
BE30 Series 20-13

ADJUSTING LOWERING SPEED OF FORK TESTING AND ADJUSTING
ADJUSTING LOWERING SPEED OF FORK

(PROPORTIONAL SOLENOID VALVE)
The lowering speed of the fork cannot be adjusted
with the meter panel. Accordingly, if a user wants to
lower the lowering speed, apply the following method.
1. Work equipment control lever
2. Potentiometer
3. Bolt
4. Locknut
1. Apply the parking brake securely.
2. Remove the cover of work equipment control le-

ver (1) so that the lever device control will be
seen.
3. Loosen locknut (4) of bolt (3).
4. Tighten bolt (3) very gradually to adjust the low-

ering speed to a proper level.
5. Tighten locknut (4) securely.
6. Install the cover of work equipment control lever

(1).
Note) Do not loosen bolt (3), exceeding the standard

position. (If it is loosened so much, abnormal-
ity will be detected.)
a Check the set height of the bolt before ad-
justment.
a See the section 60 of the WORK EQUIP-
MENT CONTROL LEVER.
20-14 BE30 Series

TESTING AND ADJUSTING BATTERY
BATTERY
1. CHECKING ELECTROLYTE LEVEL
1) CHECKING WITH ELECTROLYTE LEVEL IN-

DICATOR
WARNING FOR ADDING DISTILLED WATER
The electrolyte level indicator (battery mark) lights up.

a If the above indicator lights up, add distilled water
immediately (See the method of adding distilled
water shown below).
a If the battery is used with insufficient electrolyte,
its lifespan is shortened extremely. Accordingly,
be sure to add distilled water.
a If a battery other than the standard or optional
one is used, the electrolyte level indicator cannot
be used.
2) CHECK WITH ELECTROLYTE LEVEL GAUGE
1. Stopper
2. Cap
3. Float (Red)
Before the float (red) indicates the lowest electrolyte

level, add distilled water (See the method of adding
distilled water to the battery shown below).
When the float (3) of stopper (1) touches the cap (2)
(When clearance a shown in the figure at right is 0),
the electrolyte level is at the lowest level.
a Caps of different battery manufacturers have dif-
ferent shapes.
2. METHOD OF ADDING DISTILLED WA-

TER TO BATTERY
A. While distilled water is added

B. After distilled water is added
1. Open the battery cap and add refined (distilled)

water.
2. Stop adding water immediately when the white

line of the float is seen.
a If you continue adding water after the white line is

seen, the water will spill. Accordingly, never do
so.
BE30 Series 20-15

FUSE TESTING AND ADJUSTING
FUSE
1. UNDER FLOOR PLATE
1. Turn the key switch OFF and disconnect the bat-

tery plug.
2. Remove the floor plate.
3. Open the fuse holder cap and replace the fuse.
Symbol Circuit where fuse is used Capacity
SF1 Control circuit on chassis 10A
SF2 Accessory circuit 15A
2. STATIONARY CHARGER
1. Disconnect the power cable of the charger from

the outlet.
2. Loosen the nut and replace the fuse.
3. Tighten the nut securely.
Symbol Voltage Battery capacity Capacity

330AH
BFS80A
400AH
485AH
BFS100A
545AH
48V 565AH
F5 600AH
700AH BFS150A
935AH
1,080AH
450AH
72V BF150A
545AH
20-16 BE30 Series

TESTING AND ADJUSTING FUSE
3. CONTROLLER
1. If any fuse is broken, a failure code is displayed

on the monitor at the operator's seat. Replace
the fuse according to the displayed failure code.
a When replacing F1 or F2, remove the printed
circuit card mounting bracket.
Failure
Corresponding fuse
code
E20 F1 (Fuse for travel circuit)
E33 F2 (Fuse for hydraulic circuit)
E52 F3 (Fuse for EPS circuit)
— F4 (Fuse for charging circuit)
2. Turn the key switch OFF and disconnect the bat-

tery plug.
3.
Circuit
Symbol where fuse Capacity
is used
1 – 1.75-ton models 48LF-275A
Travel
F1 2 – 2.5-ton models 48LF-325A
circuit
3-ton model 96LF-275A
Hydraulic
circuit
F3 EPS circuit 2 – 2.5-ton models 48LF-40A
Charging
circuit
4. Loosen the nut and replace the fuse.
5. Tighten the nut securely.
BE30 Series 20-17

TRANSFER CASE TESTING AND ADJUSTING
TRANSFER CASE
1. CHECKING OIL LEVEL
1. Remove oil level plug (2) and check the oil level.
2. If the oil level is near the lower line of the level

plug hole, it is normal.
3. If the oil is insufficient, remove oil filler plug (1)

and add gear oil.
2. REPLACING OIL
1. Remove the oil filler plug (1), and then remove

drain plug (3) to drain the oil.
2. Tighten drain plug (3) and add gear oil by the

specified quantity through the oil filler.
Refill capacity
FB10EX/14EX/15EX/18EX
7l
FB15EXG/18EXG
FB20EX/25EX
8l
FB20EXG/25EXG
FB30 8l
3. Check the oil level with the oil level plug (2) and
adjust it if necessary. (See the 1. CHECKING
OIL LEVEL shown above.)
20-18 BE30 Series

TESTING AND ADJUSTING STATIONARY CHARGER
STATIONARY CHARGER
1. Charging transformer
2. Electromagnetic switch
a The positional relationship between the charging

transformer and electromagnetic switch is differ-
ent from the above illustration.
1. ADJUSTING SOURCE VOLTAGE TAPS
1. Measure the source voltage to be used for charg- 3. Connect the selected wires to wires D coming
ing. from electromagnetic switch (2).
a The source voltage fluctuates between daytime If the charger is used for long hours with
and nighttime and between summer and winter. improper source voltage taps, it may
Measure the source voltage when it is highest. burn. Accordingly, be sure to adjust the
source voltage taps periodically.
2. Select 1 wire each corresponding to the mea-
sured source voltage from A, B, and C, accord-
ing to the following table.
Source voltage (V) Indication of wire
190 – 199 195
200 – 209 205
210 – 219 215
220 – 229 225
BE30 Series 20-19

BRAKE PEDAL TESTING AND ADJUSTING
BRAKE PEDAL
20-20 BE30 Series

TESTING AND ADJUSTING WHEEL BRAKE
WHEEL BRAKE
1. ADJUSTING WHEEL BRAKE
Jack up the chassis and fit the brake shoe to the

brake drum with adjustment screw (2). And then re-
turn adjustment screw (2) by 25 – 30 teeth.
a When returning adjustment screw (2), raise lever

(3) so that an excessive force will not be applied
to lever (3). If lever (3) is bent forcibly, it may not
operate normally. Take care.
2. OPERATION TEST OF AUTOMATIC

ADJUSTER
Pull cable (1) in the direction of the arrow with the fin-
gers under the normally adjusted condition, and the
lever (3) is engaged with the next tooth of the wheel.
Then, return cable (1), and it moves the wheel for-
ward by 1 tooth and the lever is returned.
When the cable (1) is pulled, if the lever (3) does

not operate normally, check the position of lever
(3) above the adjustment screw.
Normal position of lever

Lever (3) must touch the adjustment wheel when its
distance a from the center of the screw is 5 – 7 mm.
If distance a is out of this range, the lever is not en-
gaged with the wheel teeth normally and the wheel
does not rotate normally when the lever operates.
Actions to take when wheel brake does not work

1) Check that the cable guide fits to the specified
hole of the secondary shoe.
2) Check that the adjustment spring (4) is hooked
correctly on the specified hole of the primary
shoe.
3) Replace the cable.
4) Replace the lever.
5) Replace the adjuster assembly.
BE30 Series 20-21

ADJUSTING PARKING BRAKE LEVER TESTING AND ADJUSTING
ADJUSTING PARKING BRAKE

LEVER
When adjusting the parking brake lever, put chocks
under the front and rear wheels.
1. Press push button (1) to set parking brake lever

(2) in RELEASE position A from position B.
2. Pull the parking brake lever toward you by the

play of the cable.
3. Release the lever, and adjustment bolt (3) floats.

Tighten adjustment bolt (3) with a screwdriver,
etc. so that the operating effort of the lever is set
into the specified range.
4. Match the width across flats of adjustment bolt

(4) to stopper (5).
Operating effort of lever

FB10EX – 18EX Min. 147 Nm {15 kgm}
FB15EXG/18EXG Min. 196 Nm {20 kgm}
FB20, 25, 30 Min. 196 Nm {20 kgm}
5. Procedure for adjusting parking brake switch

Loosen the mounting screw of the parking brake
switch. Adjust the position of the parking brake
switch (6) so that it will be turned OFF (the switch
lever will be pressed) when the parking brake le-
ver is set in RELEASE position A. After finishing
adjustment, tighten the screw securely.
20-22 BE30 Series

TESTING AND ADJUSTING HYDRAULIC TANK
HYDRAULIC TANK
1. CHECKING OIL LEVEL
1. Open inspection cover (1) of the floor and pull out

oil level gauge (2).
2. Wipe oil off the oil level gauge with clean cloth,
then insert the oil level gauge in the tank.
3. Pull out the oil level gauge again and check that
the oiled part is in proper range L.
4.If the hydraulic oil is insufficient, add Komatsu

genuine oil through oil filler (3).
a Be sure to add Komatsu genuine oil.
2. REPLACING HYDRAULIC OIL AND

LINE FILTER AND CLEANING
STRAINER
1. Remove the drain plug to drain the oil. After

draining, tighten the drain plug securely.
2. Remove the cover and take out the strainer and
line filter.
3. Clean the strainer in cleaning oil. Then, blow air

from its inside to dry and install it.
4. Replace the line filter.
5. Install the cover.
6. Add hydraulic oil by the specified quantity

through the oil filler and check the oil level with
the oil level gauge.
7. Move the cylinders (lift, tilt, and attachment) to

the stroke ends 5 - 6 times to bleed air.
Refill capacity
FB10EX /14EX /15EX /18EX 20l
FB15EXG 20l
FB18EXG 20l
FB20EX /25EX 22l
FB20EXG /25EXG 22l
FB30 30l
BE30 Series 20-23

REAR AXLE TESTING AND ADJUSTING
REAR AXLE
(STEERING AXLE)
a Raise the rear part of the lift truck and place a
wood block under the rear part of the truck frame
to set the rear wheels free and stabilize the truck
body.
1. Tighten adjustment bolt (1) to eliminate clear-

ance A between the rear axle and bearing sup-
port (to eliminate the play in the front and rear of
the rear axle).
2. Check that you can swing the rear axle lightly

with your hands.
3. Tighten locknut (2) to lock adjustment bolt (1).
4. Check again that the rear axle does not have

play but swings lightly.
20-24 BE30 Series

MAST TESTING AND ADJUSTING
MAST
(1.0 – 1.75 TON MODELS)
1. SELECTING ROLLERS AND ADJUST-
ING SHIMS
OUTER MAIN ROLLE

1. Selecting roller size
Select a roller size (NS, NM, L, or NLL) so that
clearance a will be the same on both sides.
2. Adjusting shims
Insert shims (1) of the same thickness on both
sides so that b will be 0 – 0.3 mm at the maxi-
mum lifting height.
Insert shims (2) so that c will be 0.1 – 0.4 mm all
over the inner rail when the rollers are pressed
against the rails (Target: 0.1 mm).
INNER MAIN ROLLER

Select a roller size (NS, NM, L, or NLL) so that d
will be 0.2 – 0.7 mm.
2. Adjusting shims
Insert shims (3) of the same thickness on both
sides so that e will be 0 – 0.3 mm at the maximum
lifting height when the rollers are pressed against
the rails.
20-26 BE30 Series

TESTING AND ADJUSTING MAST
MAST
(2.0 – 3.0 TON MODELS)
1. SELECTING ROLLERS AND ADJUST-
ING SHIMS
OUTER MAIN ROLLER

Select a roller size (S, M, L, or O) so that clear-
ance b will be the same on both sides.
2. Adjusting shims
Adjust shims (2) so that a will be 0.1 – 0.4 mm.
Adjust shims (1) so that c will be 0 – 0.5 mm (at
the maximum lifting height).
INNER MAIN ROLLER

Select a roller size (S, M, or L,) so that d will be
0.2 – 0.7 mm.
2. Adjusting shims
Adjust shims (3) so that e will be 0 – 0.5 mm with
shims (3) (at the maximum lifting height).
BE30 Series 20-27

FORK CARRIAGE TESTING AND ADJUSTING
FORK CARRIAGE
(1.0 – 1.75 TON MODELS)
a Press the backrest of part A against the board
and tighten the bolts.
1. Section AA (3-roller type)

1) Select the rollers so that a1 will be 0.3 – 1.1
mm.
2) Insert shims of the same thickness on both
sides so that b1 will be 0.4 – 0.7 mm (when
the fork carriage is at the top end).
20-28 BE30 Series

TESTING AND ADJUSTING FORK CARRIAGE
2. Section BB
mm.
sides so that b2 will be 0.1 – 0.3 mm (3-roller
type) or 0 – 0.2 mm (2-roller type) (when the
fork carriage is at the top end).
3. Section CC
mm.
sides so that b3 will be 0 – 0.2 mm (when the
4. Projection B (When fork is lowered to ground)

1) Lower fork (2) to the ground and measure di-
mension B between bottom roller (4) of inner
rail (1) and fork carriage (3).
Projection of roller B (mm)
FB10 0
FB14 0
FB15 0
FB18 0
BE30 Series 20-29

FORK CARRIAGE TESTING AND ADJUSTING
FORK CARRIAGE
(2.0 – 3.0 TON MODELS)
a Press the backrest of part A against the board
and tighten the bolts.
1. Section BB
• Select the rollers so that a1 will be 0.2 – 0.7
mm.
Standard shim thickness: 2 mm
• Insert shims of the same thickness on both
20-30 BE30 Series

TESTING AND ADJUSTING FORK CARRIAGE
2. Section CC
• Select the rollers so that a2 will be 0.2 – 0.7
mm.
3. Section DD
• Select the rollers so that c will be 0.2 – 0.7
mm.
4. Section EE
sides so that d will be 0 – 0.2 mm (when the
5. Projection B (When fork is lowered to ground)

• Lower fork (2) to the ground and measure di-
mension B between bottom roller (4) of inner
rail (1) and fork carriage (3).
Projection of roller B (mm)
2 – 2.5 ton models 19
3.0 ton model 20
BE30 Series 20-31

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

AND HYDRAULIC DRIFT OF LEANING FORWARD
Precautions for measurement
1. When measuring, take care that any person will never be under the cargo.
2. Do not climb the mast stay or dashboard to measure hydraulic drift. If you do so, your hands or feet may be
caught in the mast. Be sure to use a sufficiently strong and stable step.
3. Before measuring, check that the hydraulic oil is not dirty and not a mixture of oils of different types and its
level is proper.
4. Be sure to measure the hydraulic drift on a level ground in front of a rack which can hold the lift truck when
the latter tips forward.
1. MEASURING METHOD
1. Stop the lift truck 500 mm before a rack.
2. Repeat lifting and tilting operations to raise the

hydraulic oil temperature to 50°C.
3. Put a cargo of the rated load on the lift truck and

secure it to the fin cover with wires.
4. Lift up the cargo until H is about 1,500 mm and

set mast (1) vertically.
[Hydraulic drift]
5. After 3 minutes, set ruler to the piston rod of

lift cylinder (2) and make mark A.
6. Measure the hydraulic drift after 15 minutes.

Hydraulic drift Max. 30 mm/15 min
[Hydraulic drift of leaning forward]
5. After 3 minutes, set ruler to the piston rod of

tilt cylinder (3) and make mark B.
6. Measure the hydraulic drift after 15 minutes.

Hydraulic drift of leaning Max. 23 mm/15 min
forward
20-32 BE30 Series

TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
1. BRAKE PIPING
1. Brake drum cover

2. Air bleed plug
3. Vinyl hose
4. Brake oil container
5. Brake drum
6. Lining
1. Remove the cap of air bleed plug (2) and install

one end of a vinyl hose (3) and put the other end
in a brake oil container (4).
2. Press the brake pedal to fit lining (6) to brake

drum (5), and then loosen air bleed plug (2)
about 3/4 turns to discharge the brake oil.
3. Tighten air bleed plug (2), and then release the

brake pedal.
4. Repeat 2. and 3. until no bubbles come out of

hose (3).
5. After bleeding all air, tighten plug (2) and install

the cap.
6. Remove cap (7) and inside cover of brake reser-

voir tank (8) and check the brake oil level. Add
new brake oil by the quantity discharged for
bleeding air and check that the brake oil level is
in proper range L (25 – 45 mm).
2. LIFT CYLINDER
1. Turn the key switch ON.
2. Lift up and down the fork.

a Stop the fork about 100 mm before the max-
imum lifting height and minimum height.
3. Repeat operation of 2. 4 – 5 times.
4. Lift up and down the fork to the maximum lifting

height and minimum height.
5. Repeat operation of 4. 4 – 5 times.
BE30 Series 20-33

30. REMOVAL AND INSTALLATION
Arrangement of units . . . . . . . . . . . . . . . . . . . . 30- 2

Weight of each unit (1.0 - 1.75 ton models) . . . 30- 3
Weight of each unit (2.0 - 3.0 ton models) . . . . 30- 4
General disassembly and assembly drawing. . 30- 5
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 7
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 9
Power train
(Front axle + Transfer + Drive motor). . . . . . . . 30-11
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
EPS actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Steering gear box. . . . . . . . . . . . . . . . . . . . . . . 30-20
Hydraulic pump + Pump motor. . . . . . . . . . . . . 30-21
BE30 Series 30-1

ARRANGEMENT OF UNITS REMOVAL AND INSTALLATION
ARRANGEMENT OF UNITS
1. Hydraulic control valve 8. EPS actuator

2. Drive motor 9. Front axle
3. Hydraulic pump 10. Steering gear box
4. Pump motor 11. Tilt cylinder
5. Tank 12. Brake master cylinder
6. Main controller 13. Lift cylinder
7. Rear axle 14. Mast
30-2 BE30 Series

REMOVAL AND INSTALLATION WEIGHT OF EACH UNIT
WEIGHT OF EACH UNIT (1.0 – 1.75 TON MODELS)

Unit: kg
Model
Unit name FB10EX FB14EX FB15EX FB18EX FB15EXG FB18EXG Remarks
Power train (Total) 246 246 246 246 246 246 —

Drive motor 60 60 60 60 60 60 —
Front axle 186 186 186 186 186 186 —
Pump motor 40 40 40 40 40 40 —
Rear axle 78 78 78 78 78 78 —
Front wheel 26 26 45 45 45 45 Per piece
Rear wheel 19 19 19 19 19 19 Per piece
Head guard 76 76 76 76 84 84 —
Counterweight 285 480 580 750 285 480 —
Mast (3 m, only inner and outer masts) 238 238 238 238 238 238 —
Lift cylinder (For 3-m mast) 20 20 20 20 20 20 Per piece
Tilt cylinder 17 17 17 17 17 17 Per piece
Fork carriage 69 69 69 70 69 70 —
Fork 32 34 34 34 34 34 Per piece
Backrest 17 17 17 17 17 17 —
Hydraulic pump 3 3 3 3 3 3 —
Tank, oil, and grease 48 48 48 48 52 52 —
Control valve + lever 20 20 20 20 20 20 —
Steering gear box 13 13 13 13 13 13 —
EPS actuator 17 17 17 17 17 17 —
a All of the above values are for the standard specification.
Battery
Model Capacity (Ah) Weight (kg) Voltage (V)
FB10EX/14EX 330 625
400 700
FB10EX/14EX
485 770 48
FB15EX/18EX
545 845
FB15EXG/18EXG 700 1,115
a Check the battery capacity by the manufacturer plate stuck to the front side
of the battery case.
BE30 Series 30-3

WEIGHT OF EACH UNIT REMOVAL AND INSTALLATION
WEIGHT OF EACH UNIT (2.0 – 3.0 TON MODELS)

Unit: kg
Model
Unit name FB20EX FB25EX FB20EXG FB25EXG FB30 Remarks
Power train (Total) 329 329 329 329 489 —

Drive motor 75 75 75 75 115 —
Front axle 254 254 254 269 374 —
Pump motor 49 49 49 49 53 —
Rear axle 78 78 78 78 130 —
Front wheel 72 72 72 105 72 Per piece
Rear wheel 34 34 34 46 34 Per piece
Head guard 84 84 95 93 95 —
Counterweight 650 950 550 680 995 —
Mast (3 m, only inner and outer masts) 344 344 344 344 401 —
Lift cylinder (For 3-m mast) 25 25 25 25 32 Per piece
Tilt cylinder 25 25 25 25 25 Per piece
Fork carriage 80 80 80 80 108 —
Fork 43 51 43 51 62 Per piece
Backrest 20 20 20 20 20 —
Hydraulic pump 6 6 6 6 3 —
Tank, oil, and grease 48 48 52 48 52 —
Control valve + lever 20 20 20 20 20 —
Steering gear box 13 13 13 13 13 —
EPS actuator 17 17 17 17 17 —
a All of the above values are for the standard specification.
Battery
Model Capacity (Ah) Weight (kg) Voltage (V)
FB20EX 450 820
565 925
FB20EX/25EX 600 945

48
700 1,035
935 1,375
FB20EXG/25EXG
1,080 1,605
450 1,500
FB30 72
545 1,500
a Check the battery capacity by the manufacturer plate stuck to the front side
of the battery case.
30-4 BE30 Series

REMOVAL AND INSTALLATION GENERAL DISASSEMBLY AND ASSEMBLY DRAWING
GENERAL DISASSEMBLY AND ASSEMBLY DRAWING
BE30 Series 30-5

GENERAL DISASSEMBLY AND ASSEMBLY DRAWING REMOVAL AND INSTALLATION
30-6 BE30 Series

REMOVAL AND INSTALLATION MAST
MAST
1. REMOVAL
1. Put blocks under the front and rear wheels.
2. Lower fork (1).
3. Raise fork carriage (2) with a crane so that the

hydraulic piping can be removed.
4. Put a block under the fork carriage.
5. Turn the key switch OFF and leave about 1

minute, and then disconnect hose (3) from the
part marked with an arrow.
a After disconnecting the hose, plug the adapters

immediately to prevent the hydraulic oil from
flowing out and dust from entering the system.
6. Raise the fork carriage a little with the crane and

remove the block from under the fork carriage.
7. Lower the fork carriage.
8. Install the crane hook to mast (4).
9. Remove the mast cap.
10. Remove tilt cylinder pin (5).
11. Lift off the mast with the crane.
Place the mast assembly horizontally on

wood blocks with the fork carriage up.
When placing the mast assembly, take care

extremely that the crane hook will not come
off the mast.
BE30 Series 30-7

MAST REMOVAL AND INSTALLATION
2. INSTALLATION
Carry out installation in the reverse order to removal
and observe the following points.
1. Tightening mast cap mounting bolts
157 – 196 Nm
1.0 – 1.75 ton models {16 – 20 kgm}
2.0 – 3.0 ton models 245 – 309 Nm

{25 – 31.5 kgm}
2. Driving in tilt cylinder pin

Secure the mast with the crane and align the
holes by operating the tilt lever, and then drive in
the tilt cylinder pin (5).
a A spherical bushing is used at the cylinder
head and it leans easily when the pin is driv-
en in. Accordingly, do not drive in the pin
forcibly.
30-8 BE30 Series

REMOVAL AND INSTALLATION LIFT CYLINDER
LIFT CYLINDER
1. REMOVAL
How to remove the cylinder on either side is ex-
plained below as an example.
1. Set mast (1) vertically and put chocks under the

front and rear wheels.
2. Raise fork carriage (2) about 300 mm with a

crane.
3. Remove cotter pin (3), pull out pin (4), disconnect

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

a The stopper bolts of different models are in-
stalled to different positions.
Stopper bolt (3a): 1.0 – 1.75 ton models
Stopper bolt (3b): 2.0 – 3.0 ton models
8. Lower the cylinder rod by operating the lift lever.
9. Turn the key switch OFF and leave about 1

minute, and then disconnect the piping.
a After disconnecting the piping, plug the adapters

to prevent the hydraulic oil from flowing out and
dust from entering the system.
10. Disconnect cylinder clamp (4).

a The different cylinder clamps are used of dif-
ferent models.
( 1 shows the cylinder clamp for 2.0 – 3.0
ton models.)
11. Using sling belts, raise the cylinder about 300

mm with the crane and pull it out downward.
BE30 Series 30-9

LIFT CYLINDER REMOVAL AND INSTALLATION
2. INSTALLATION
1. Inner mast 1.0 – 1.75 ton models
2. Outer mast
3. Cylinder rod
4. Shim (Right side)
5. Shim (Left side)
1. Adjusting vertical of mast
1) Raise the mast to the maximum lifting height.
2) Check the play on both sides of the mast.
3) Adjust the mast with a shim so that it will be

vertical when it is raised to the maximum lift-
ing height.
2.0 – 3.0 ton models
Insert shim (5) in left
If mast leans to left
cylinder.
Insert shim (4) in right

If mast leans to right
cylinder.
30-10 BE30 Series

REMOVAL AND INSTALLATION POWER TRAIN
POWER TRAIN (FRONT AXLE + TRANSFER + DRIVE MOTOR)

1. REMOVAL
1. Put chocks under the front and rear wheels.
2. Remove battery (1).

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

a Referring to the section of the MAST in this
chapter, remove the mast correctly and safe-
ly.
4. Disconnect drive motor cables U, V, and W.
5. Disconnect the brake pipes from the damping

cylinders (A and B in the figure at right) and
wheel cylinders (C and D in the figure at right).
6. Remove parking brake lever (3) together with the

cable.
BE30 Series 30-11

POWER TRAIN REMOVAL AND INSTALLATION
7. Set chocks both sides of the frame so that the

front wheels will be floated about 100 mm above
the ground, or using jack E, jack up the frame.
Remove the chocks from under the front wheels.
8. Set garage jack F under the power train (front

axle + transfer + drive motor) to support the pow-
er train.
9. Remove the front axle mounting bolts (4) on the

right side (4 pieces).
a The right side of the axle is secured with the
bolts and nuts through support (5).
10. Remove the front axle mounting bolts (6) on the

left side (4 pieces).
a The left side of the axle is secured directly to
the case with the bolts and nuts.
30-12 BE30 Series

REMOVAL AND INSTALLATION POWER TRAIN
11. Slowly pull the garage jack forward out of the

chassis to take out the power train assembly (7)
(front axle + transfer + drive motor).
BE30 Series 30-13

POWER TRAIN REMOVAL AND INSTALLATION
2. INSTALLATION
1. Tightening front axle mounting bolts
343 – 427 Nm
(Both sides) {35 – 43.5 kgm}
2. Tightening drive motor cable mounting bolts
10 – 12 Nm {102 – 122 kgcm}
3. Connecting cables
Bind the cables with tie-wraps so that they will
not touch a sharp edge of the lift truck body or will
not be caught in parts.
4. Tightening brake pipe nipples
10 – 13 Nm
Nipple (A, B, C, D) {102 – 133 kgcm}
30-14 BE30 Series

REMOVAL AND INSTALLATION REAR AXLE
REAR AXLE
1. REMOVAL
1. Sling the rear part of the frame with a crane and

put wood chocks under both sides of it.
2. Slinging counterweight (1) a little, remove its

mounting bolts to remove it.
3. Remove both rear wheels.
4. Remove ball joint (3) from bell crank (2).
5. Support the rear axle with garage jack A.
6. Remove 2 rear axle support bolts (4).
7. Pull out the rear axle in reverse.

Pull the garage jack in reverse until the center pin
of the rear axle comes off the support. After the
center pin comes off the support, lower the ga-
rage jack and pull the rear axle in reverse out of
the chassis.
BE30 Series 30-15

REAR AXLE REMOVAL AND INSTALLATION
2. INSTALLATION
1. Adjusting rear axle

1) Tighten adjustment bolt (1) until clearance a
between rear axle (3) and bearing support
(4) will be 0 (until play is eliminated).
2) Check that you can swing rear axle (3) with
your hand.
3) Tighten locknut (2) to lock adjustment bolt
(1).
4) Finally, check that rear axle (3) has no play
and you can swing it.
Tightening rear axle support bolt (5)
245 – 309 Nm
1.0 – 1.75 ton models {25 – 31.5 kgm}
2.0 – 3.0 ton models 490 – 608 Nm

{50 – 62 kgm}
2. Installation direction of rear axle support

bushing
Install the rear axle support bushing (6) with the
hole up.
30-16 BE30 Series

REMOVAL AND INSTALLATION BATTERY
BATTERY
1. REMOVAL
1. Disconnect battery plug (1).
2. Tilt the steering wheel forward.

Set steering wheel lock lever (2) in FREE posi-
tion A, tilt the steering wheel forward, and return
lock lever (2) to LOCK position B.
3. Open battery side covers (3) on both sides.
4. Remove battery hood catch (4).
BE30 Series 30-17

BATTERY REMOVAL AND INSTALLATION
5. Open the battery hood and check that it is fixed

with stopper (5) and will not close.
6. Pass a crane wire through cut C of the head

guard.
7. Install the hooks of the wire to holes D (4 places)

of the battery case and lift off battery (6) slowly.
2. INSTALLATION
Carry out installation in the reverse order to removal.
• Be sure to install crane wires to the 4 holes.

• The battery shall be lifted by a person who has finished the slinging work course and who is qualified for
using the crane.
Battery weight table
Capacity Voltage Capacity Voltage

Model (Ah) Weight (kg) (V) Model (Ah) Weight (kg) (V)
FB10EX/14EX 330 625 FB20EX 450 820
400 700 565 925

FB10EX/14EX
485 770 48 FB20EX/25EX 600 945
FB15EX/18EX 48
545 845 700 1,035
FB15EXG/18EXG 700 1,115 935 1,375

FB20EXG/25EXG
1,080 1,605
450 1,500
FB30 72
545 1,500
30-18 BE30 Series

REMOVAL AND INSTALLATION EPS ACTUATOR
EPS ACTUATOR
1. REMOVAL
1. Put chocks under the front wheels.
2. Disconnect battery plug and lift the battery off the

chassis with a crane.
(See REMOVAL OF BATTERY in this chapter.)
3. Remove the rear axle.

(See REMOVAL OF REAR AXLE in this chap-
ter.)
4. Remove ball joint (3) of drag link (2).
5. Disconnect EPS wiring connector (9).
6. Remove actuator mounting bolts (8).
7. Pull actuator (6) in reverse out of the chassis.
2. INSTALLATION
1. Pitman arm
1. Tightening actuator mounting bolts 2. Drag link
3. Ball joint
Bolt (8) 49 – 69 Nm {5 – 7 kgm}
4. Bell crank
5. Cotter pin
6. EPS actuator
7. Frame
2. Replacing and bending cotter pin 8. Actuator mounting bolt
9. EPS wiring connector
Cotter pin (5) Use a new cotter pin and bend it
securely after tightening the nut.
BE30 Series 30-19

STEERING GEAR BOX REMOVAL AND INSTALLATION
STEERING GEAR BOX
1. Floor plate 8. Pitman arm

2. Bell crank 9. Dashboard
3. Drag link 10. Mounting bolt
4. EPS actuator 11. Steering gear box
5. Frame 12. Stopper bolt
6. Ball joint 13. Universal joint
7. Connector
A. To controller
1. REMOVAL 2. INSTALLATION
1. Remove floor plate (1).
2. Disconnect wiring connector (7) for the EPS

torque sensor.
3. Remove ball joint (6) of the drag link from the pit-
man arm.
4. Remove stopper bolt (12) of the universal joint

spline.
5. Remove gear box mounting bolts (10) and spline

and pull out gear box (11) upward.
30-20 BE30 Series

REMOVAL AND INSTALLATION HYDRAULIC PUMP + PUMP MOTOR
HYDRAULIC PUMP + PUMP

MOTOR
1. REMOVAL
1. Remove right side cover.
2 Disconnect pump motor (8) wires A1 and D2 .
3. Disconnect wires (1) and (4) from hydraulic pump

(3).
4. Remove 3 bolts (6) of pump motor mounting

bracket (5).
5. Pull the hydraulic pump, pump motor, and pump

motor mounting bracket as a unit from floor frame
(9).
6. Remove pump mounting bolts (2) (only when re-

moving the pump).
7. Remove the motor mounting bracket (7) (only

when it needs to be removed).
2. INSTALLATION
1. Tightening mounting nuts of wires (A1) and

(D2)
Mounting nuts of wires 7.3 – 9.3 Nm

A1 and D2 {74 – 95 kgcm}
BE30 Series 30-21

Transfer (1.0 - 1.75 ton models). . . . . . . . . . . . 40- 2

Transfer (2.0 - 2.5 ton models). . . . . . . . . . . . . 40- 3
Transfer (3.0 ton model). . . . . . . . . . . . . . . . . . 40- 4
Differential (1.0 - 1.75 ton models). . . . . . . . . . 40-10
Differential (2.0 - 3.0 ton models) . . . . . . . . . . . 40-11
Front axle (1.0 - 1.75 ton models) . . . . . . . . . . 40-12
Front axle (2.0 - 2.5 ton models) . . . . . . . . . . . 40-13
Front axle (3.0 ton model) . . . . . . . . . . . . . . . . 40-14
Brake master cylinder . . . . . . . . . . . . . . . . . . . 40-15
Damping cylinder . . . . . . . . . . . . . . . . . . . . . . . 40-17
Wheel brake (1.0 - 1.75 ton models) . . . . . . . . 40-18
Wheel brake (2.0 - 2.5 ton models) . . . . . . . . . 40-19
Wheel brake (3.0 ton model) . . . . . . . . . . . . . . 40-20
Steering gear box. . . . . . . . . . . . . . . . . . . . . . . 40-21
EPS actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38
Rear axle (1.0 - 1.75 ton models). . . . . . . . . . . 40-45
Rear axle (2.0 - 3.0 ton models). . . . . . . . . . . . 40-49
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . 40-56
Control valve
(Proportional solenoid valve spec.) . . . . . . . . . 40-60
Control valve (Manual valve spec.) . . . . . . . . . 40-62
Drive motor (1.0 - 2.5 ton models) . . . . . . . . . . 40-71
Drive motor (3.0 ton model) . . . . . . . . . . . . . . . 40-72
Pump motor (1.0 - 1.75 ton models) . . . . . . . . 40-74
Pump motor (2.0 - 3.0 ton models) . . . . . . . . . 40-75
BE30 Series 40-1

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

Criteria
Symbol Inspection item Criteria Remedy
— Press-fitted parts of shaft and gear No clearance.
— Each gear Tooth surface must be free from damage, Replace

excessive wear, and bad contact.
— Bearing Must be free from play and flaw.
40-2 BE30 Series

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

Criteria

BE30 Series 40-3

TRANSFER (3.0 TON MODEL)

Criteria

40-4 BE30 Series

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

drain the oil.
2. Remove front wheels (3), torque shafts (4), hubs

(5), and wheel brakes (6) on both sides.
3. Remove drive motor mounting bolts (7) and drive

motor (8).
4. Set the transfer assembly securely and vertically

as shown in the figure at right so that it will fall
down.
BE30 Series 40-5

5. Remove cage (9) and plate (10).
6. Remove case mounting bolts, and then sling and

hold right-hand case (14) with a crane.
7. Gradually lift up right-hand case (14) about 30

mm.
a If bearing (16) of shaft (15) is not separated

from right-hand case (14), hit shaft (15) with
a bar. (The inner race of the bearing is re-
moved together with the shaft.)
8. Slinging right-hand case (14) about 30 mm, turn

(slide) it about 20 degrees from left-hand case
(17) and lift it off.
a If right-hand case (14) is lifted up straight, its

part P will interfere with the ring gear (26) of
the differential. Accordingly, turn (slide) it in
direction A about 20 degrees from left-hand
case (17) as shown in the figure, and then lift
it up.
9. Remove differential assembly (18), output shaft

(15), intermediate gear (19), and input gear (20)
from left-hand case (17).
40-6 BE30 Series

3. ASSEMBLY
1. Install bearing (21) to input gear (20).
(1.0 – 1.75 ton models) (2.0 – 3.0 ton models)

2. Install bearing (22) to intermediate gear (19).
a Install the roller bearings of the 2.0 – 3.0 ton

models so that their inner race flanges B will
be on the gear (19) side. (See the figure at
right.)

3. Install the bearing to output shaft (15).
a Install only the inner race of bearing (16) on

the small gear side. (See the figure at right.)
a Install bearing (23) on the large gear side in

the correct direction, referring to the figure at
right.
a Only bearing (23) on the large gear side of

the 1.0 – 1.75 ton models is secured with
snap ring (24).

4. Install bearing (25) to differential assembly (18).
BE30 Series 40-7

5. Set left-hand case (17) securely and vertically as

shown in the figure at right and install gasket
(26).
6. Install the following parts to left-hand case (17) in

order.
1. Input gear (20)
2. Intermediate gear (19)
3. Output shaft (15)
4. Differential assembly (18)
a If a bearing cannot be fitted to the case, hit it

lightly with a copper hammer.
7. Drive dowel pin (27) into left-hand case (17).
8. Sling right-hand case (14) with the crane and

hold it above left-hand case (17), and then lower
it gradually, turning it about 20 degrees as ex-
plained below.
a If right-hand case (14) is lowered straight, its

part P will interfere with ring gear (26) of the
differential. Accordingly, turn (slide) it in di-
rection A about 20 degrees from left-hand
case (17) as shown in the figure at right, and
then lower it.
40-8 BE30 Series

9. After the differential case is set in right-hand case

(14) and the distance between the right-hand
case (14) and left-hand case (17) becomes 30
mm, return right-hand case (14) to the original
position and lower it further.
10. Align the bolt holes of right-hand case (14) and

left-hand case (17) and set the guide bolts as
shown in the figure at right.
11. Hit right-hand case (14) with a hammer so that

each gear and each bearing will be set correctly.
12. Tighten case mounting bolts.
13. 1.5 – 1.75 ton models:

Drive in the outer race of roller bearing (16), in-
stall the inner race collar, and install plate (10)
with bolts (28).
2.0 – 3.0 ton models:

Drive in the outer race of roller bearing (16), in-
stall the inner race collar, drive in roller bearing
(16A), and install plate (10) with bolts (28).
Plate (10) LOCTITE #271 (Bolt hole)
Bolt (28) 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
14. Install cage (9) with bolts (29).
15. Install snap ring (30) and drive in cover (31).
BE30 Series 40-9

DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL (1.0 – 1.75 TON MODELS)

a Apply Grease (G2-LI) to rotary parts and sliding parts.
1. Hole side of threaded part.
Criteria Unit: mm
Criteria
Symbol Inspection item Remedy
Standard size Repair limit
A Differential pinion gear and differential side — When tooth surface is Replace gear
gear damaged. set
B Outside diameter of spider 21.959 – 21.980 21.75
C Inside diameter of differential pinion gear 22.0 – 22.2 22.3
D Thickness of bushing 1.54 – 1.66 1.3 Replace
E Thickness of bushing 1.54 – 1.66 1.3
— Inside diameter of brake drum 254.0 – 254.2 256
— Gasket, O-ring, seals — — Replace when

reassembling
40-10 BE30 Series

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

a Apply Grease (G2-LI) to rotary parts and sliding parts.
1. Hole side of threaded part.
Criteria Unit: mm
Criteria
A Differential pinion gear and differential side — When tooth surface is Replace gear
gear damaged. set
— Inside diameter of brake drum 279.4 – 279.6 281.4
— Gasket, O-ring, seals — — Replace when

reassembling
BE30 Series 40-11

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

1. Fill space with grease up to 1/2 – 2/3 of its volume.
1. DISASSEMBLY AND ASSEMBLY 2. Lip portion
3. Adjust with nut A.
4. Threaded portion
Criteria Unit: mm
Criteria
— Inside diameter of brake drum 254 – 254.2 256 Replace
— Play of hub 0 0 Replace bearing
— Front axle Distortion, crack, damage
— Shaft pipe Distortion, crack, damage Replace
— Brake drum Uneven wear and flaw of inside wall of brake

drum
40-12 BE30 Series

DISASSEMBLY AND ASSEMBLY FRONT AXLE
FRONT AXLE (2.0 - 2.5 TON MODELS)

1. DISASSEMBLY AND ASSEMBLY 1. Lip portion 4. Fill space with grease up to
2. Seat must be fitted to hub. 1/ 2 – 2/3 of its volume.
3. Threaded portion 5. Adjust with nut A.
Criteria Unit: mm
Criteria
— Inside diameter of brake drum 279.4 – 279.6 281.4 Replace

drum
BE30 Series 40-13

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

1. Fill space with grease up to 1/2 – 2/3 of its volume.
1. DISASSEMBLY AND ASSEMBLY 2. Lip portion
3. Adjust with nut A.
4. Threaded portion
Criteria Unit: mm
Criteria
— Inside diameter of brake drum 310.0 – 310.2.6 312 Replace

drum
40-14 BE30 Series

DISASSEMBLY AND ASSEMBLY BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER

1. Insert a screwdriver in the fitting groove of bel- 4. Loosen and remove clamp (5). Grip the cylinder
lows (2) of the cylinder to remove the bellows. body lightly in a vise and remove filler union (6)
with pliers.
2. Pull out push rod (1).
3. Remove snap ring (3) and take out piston assem-

bly (4). At this time, push in the piston a little, and
you can remove the snap ring.
a Take care not to damage the cylinder piston
and cup.
a Do not disassemble piston assembly (4).
Criteria Unit: mm
Criteria
A Clearance between cylinder and piston 0.020 – 0.104 0.15 Replace cylinder
assembly
Interference of cup (Outside diameter of cup P-cup: Approx. 0.8
B - Inside diameter of cylinder) S-cup: Approx. 1.3 0.3
Replace piston
assembly
C Spring Must be free from flaw, wear, and lean
BE30 Series 40-15

BRAKE MASTER CYLINDER DISASSEMBLY AND ASSEMBLY
2. ASSEMBLY
1. Apply rubber grease of brake oil evenly and suf-

ficiently to the inside surface of the cylinder and
outside surface of the piston.
2. Applying a guide or a cushion to filler union (6),

hit it lightly with a plastic hammer to fit the filler
union, and then tighten clamp (5).
CAUTION
• Use only alcohol or brake oil to clean the parts. In particular, never use mineral oil (kerosene, gaso-
line, etc.) (If mineral oil sticks to a rubber part, the latter swells and cannot be used.)
• After cleaning the parts, keep them in a clean place so that dust will not stick to them.
• Take care that impurities will not enter and damage the cylinder, piston, cup, etc.
40-16 BE30 Series

DISASSEMBLY AND ASSEMBLY DAMPING CYLINDER
DAMPING CYLINDER
1. DISASSEMBLY 2. ASSEMBLY
1. Remove end plug (3) and take out spring (2).
• Apply rubber grease to the piston end and spring.
2. Supply compressed air through the pipe joint to
take out piston assembly (1).
1. Apply rubber grease.
Criteria Unit: mm
Criteria
Replace cylinder
A Clearance between cylinder and piston 0.020 – 0.104 0.15 assembly
Interference of cup (Outside diameter of cup
B - Inside diameter of cylinder) Approx. 1.0 0.4
Replace piston
assembly
C Spring Must be free from flaw, wear, and lean
BE30 Series 40-17

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

Criteria Unit: mm
Criteria
A Lining Thickness of Lining 4.5 2.0
B1 97 105
Free length
B2 97 105
B1 2.6 2.0
B Return spring Thickness of hook
B2 2.6 2.0
Appearance Must be free from flaw and cracking.

Replace
Sliding surface Must be free from flaw.
C Wheel cylinder Inside diameter
Clearance between of cylinder: 0 – 0.05 0.2
wheel cylinder and piston 22.22
D Piston Clearance between pis- 0 – 0.05 0.2

ton and cylinder
E Cup Damage and fatigue Must be free from damage and fatigue
40-18 BE30 Series

DISASSEMBLY AND ASSEMBLY WHEEL BRAKE

Criteria Unit: mm
Criteria
Standard size Repair limi
A Lining Lining 5.1 2.0
B1 110 112
Free length
B2 106 108
B1 3.2 2.6
B2 2.6 2.0
Appearance Must be free from flaw and crack
Sliding surface Must be free from flaw Replace

Clearance between
cylinder and piston of cylinder: 0 – 0.05 0.2
25.40
Clearance between
D Piston piston and cylinder 0 – 0.05 0.2
BE30 Series 40-19

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

Criteria Unit: mm
Criteria
Standard size Repair limi
A Lining Lining 5.67 2.0
B1 124 136
Free length
B2 124 136
B1 2.9 2.0
B2 2.9 2.0
Appearance Must be free from flaw and crack
Sliding surface Must be free from flaw Replace

Clearance between
cylinder and piston of cylinder: 0 – 0.05 0.2
28.58
Clearance between
D Piston piston and cylinder 0 – 0.05 0.2
40-20 BE30 Series

DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX
STEERING GEAR BOX

1. NAME OF EACH PART
1. Gear box 9. Dust cover

2. Sector shaft 10. Side cover
3. Pitman arm 11. Spring
4. Ball nut 12. Sensor housing
5. Ball 13. Front cover
6. Ball tube 14. Potentiometer (Torque sensor)
7. Worm shaft 15. Potentiometer cover
8. Rear cover
BE30 Series 40-21

STEERING GEAR BOX DISASSEMBLY AND ASSEMBLY
2. DISASSEMBLY
1. Remove dust and stain.

a Do not use fuel oil, gasoline, paint thinner,
etc. for cleaning, since they can break the
potentiometer.
2. Grip pitman arm (1) in a vise and loosen the lock-

nut.
3. Grip the gear box in the vise with slit mark A at

the sector shaft end down.
a If the slit mark A is set down, its position is
the center of the steering angle.
4. Put block B to lock the pitman arm (1) and re-

move the pitman arm with pitman arm puller C.
a Do not hit the pitman arm with a hammer to

remove it.
a If you work at the end of the steering angle,

the internal parts may be broken. According-
ly, be sure to set the slit mark A down (work
at the center of the steering angle).
40-22 BE30 Series

5. Remove potentiometer cover (2) and potentiom-

eter.
a Remove the potentiometer only when it

needs to be removed.
6. Remove the front cover mounting bolts and front

cover (3).
7. Install set plate jig D (see page 40-37 SPECIAL

TOOLS) instead of the front cover with bolts D1.
Bolt D1 Approx. 44.1 Nm {4.5 kgm}
BE30 Series 40-23

8. Raise bent part E of the locknut with a screwdriv-

er.
9. Fix serrated part F of the worm shaft and remove

locknut (4).
a Keep the slit mark at the sector shaft end

down during the above work.
a Work with clean hands so that dirt will not

stick to the parts.
10. Remove the following parts, and then remove set

plat jig D installed in step 7.
1) Bearing ring ( 31 mm, t = 1.0mm)

2) Thrust needle roller bearing
40-24 BE30 Series

11. Taking care not to drop the spring, remove the

sensor housing, and then remove the following
parts.

4) O-ring at mounting face of sensor housing
12. Remove the side cover mounting bolts and side

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

set down.
13. Remove the dust cover, rear cover mounting

bolts, and recover.
14. Pull out worm shaft (6) without removing the ball
nut.
BE30 Series 40-25

3. ASSEMBLY
1. Grip the gear box in the vise and install worm

shaft (6) and ball nut with the tooth surface of the
ball nut up.
a Before starting the work, apply grease to

parts G shown in the figure at right.
Part G MITSUBISHI DIAMOND

GREASE CLS No. 1, No. 0
a Work in a clean place with the clean hands.

Never put on gloves.
2. Check that the lip of oil seal (1) is not rolled up.
3. Install rear cover (2) with the rear cover mounting

bolts.
16.7 – 27.4 Nm
Rear cover mounting bolt {1.7 – 2.8 kgm}
40-26 BE30 Series

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

Apply grease (MITSUBISHI DIAMOND GREASE
CLS No. 1, No. 0) to the T-groove and shim, and
then install adjustment screw (3) to sector shaft
(5).
5. Install side cover (8) to sector shaft (5).

1) Apply grease to the bearing of side cover (8)
and install it to sector shaft (5), and then
tighten adjustment screw (3) to the end.
2) Apply gasket sealant to the threads of adjust-
ment screw (3) and tighten locknut (7).
SEALEND No. 22 manu-
Gasket sealant factured by SEALEND
6. Set ball nut (9) so that its gear will be aligned with
the sector shaft mounting hole.
BE30 Series 40-27

7. Install the side cover packing, and then install

sector shaft assembly (10) so that its gear will be
aligned with the ball nut gear.
8. Install side cover (11) and tighten the side cover

mounting bolts.
16.7 – 27.4 Nm
Side cover mounting bolt {1.7 – 2.8 kgm}
9. Apply grease to O-ring (12) and set it to the O-

ring groove.
10. Install the bearing rings and thrust needle roller

bearing in the following order.
1) Bearing ring (13) ( 31 mm, t = 4.0 mm)

2) Thrust needle roller bearing (14)
3) Bearing ring (15) ( 40 mm, t = 4.0 mm)
a When installing these parts, apply grease to
them.
MULTEMP SC-W manufatured
Grease by KYODO-YUSHI
40-28 BE30 Series

11. Apply grease to the inside wall of slide ring (16)

and install sensor housing (17).
MULTEMP SC-W manufactured
Grease by KYODO-YUSHI
12. Install set plate jig D (See page 40-34 SPECIAL

TOOLS) with the mounting bolts.
Mounting bolt of set plate jig Approx. 44.1

Nm {4.5 kgm}
13. Install the bearing rings and thrust needle roller

bearing in the following order.
1) Bearing ring ( 40 mm, t = 4.0 mm)

3) Bearing ring ( 31 mm, t = 4.0 mm)
a When installing these parts, apply grease
(MULTEMP SC-W manufactured by KYO-
DO-YUSHI) to them.
BE30 Series 40-29

14. Tighten locknut (18) according to the following

procedure.
1) Set pitman arm (1) as shown in the figure at

right and secure sector shaft (5).
2) Turn the connecting part of the universal joint
of the worm shaft. (At this time, the worm
shaft slides about 1.6 mm.)
3) With the worm shaft turned, tighten locknut
(18) with the fingers so that axial play will not
be made.
15. Release the worm shaft and bend the locknut

with bending punch J (See page 40-37 SPE-
CIAL TOOLS). (2 places)
a After bending the locknut, check that part K

does not have play or a crack.
16. Turn the connecting part of the universal joint of

the worm shaft to the left. Check that locknut
(18) does not have circumferential play under
this condition.
a If the locknut has any play, bend it again.
17. Remove the pitman arm set to secure the sector

shaft.
18. Remove set plate jig D.
40-30 BE30 Series

19. Fit the O-ring in the O-ring groove of the mount-

ing face of front cover (3), and then install the
front cover with the mounting bolts.
Front cover mounting bolt 34.3 – 52.9 Nm

{3.5 – 5.4 kgm}
20. Determine the center of the operating angle ac-

cording to the following procedure.
1) Rotate the worm shaft from the left stroke

end to the right stroke end, and then set it to
the center of its rotation angle.
a The worm shaft must be rotated at least 4.8

turns to cover from the left stroke end to the
right stroke end. If it is not rotated so many
turns, the ball nut gear is not engaged prop-
erly with the sector shaft gear. In this case,
repeat the installation work of the sector
shaft.
21. Measure the backlash.
Set pitman arm (1) and dial gauge L as shown

in the figure at right, and then push and pull the
pitman arm in direction S with a force of 19.6 N
{2 kgf} and measure the backlash.
Backlash: If below 0.3 mm, normal.

If above 0.3 mm, adjust.
BE30 Series 40-31

22. Adjust the backlash.
Loosen the locknut and turn the adjustment

screw to reduce the backlash below 0.3 mm, and
then tighten the locknut.
Backlash Max. 0.3 mm
Locknut 19.6 – 29.4 Nm

{2.0 – 3.0 kgm}
a Be sure to adjust the backlash at the center

of the steering angle.
23. Supply grease (MITSUBISHI DIAMOND GREASE

CLS No. 1, No. 0) by 180 ± 2 g.
24. Check the operation.

1) Push and pull pitman arm (1) to check its op-
eration. If it is not hitched, it is normal.
2) Measure the turning torque of the worm
shaft.
Turning torque of Max. 0.49 Nm
worm shaft {5 kgcm}
25. Grip pitman arm (1) in vise M as shown in the fig-

ure at right.
a Do not grip the pitman arm near an end of the

steering angle.
40-32 BE30 Series

26. Apply grease to the roller at end of potentiometer

(torque sensor) (19) and fit the O-ring, and then
install the potentiometer.
Grease MULTEMP SC-W manufactured

by KYODO-YUSHI
a Install potentiometer (19) so that the roller at

part N will be in the arm.
27. Tighten the potentiometer mounting screw lightly

(temporarily).
28. Set stabilized power supply (5 V) P and digital

multimeter Q as shown in the circuit diagram to
measure the voltage of the potentiometer (torque
sensor).
BE30 Series 40-33

29. Measure and adjust the output voltage of the po-

tentiometer (torque sensor) when the steering
wheel is in neutral.
1) Turn worm shaft (20) to the right and release

it. Measure the voltage at this time (voltage
in neutral).
2) Turn worm shaft (20) to the left and release

it. Measure the voltage at this time (voltage
in neutral).
Main side 2.5 ± 0.1 V
Voltage in neutral
Sub side 2.5 ± 0.4 V
When main side is used When sub side is used
3) If the voltage in neutral is out of the above

range, adjust it with potentiometer (19). Af-
ter adjusting, tighten the mounting screw to
the specified torque.
Potentiometer 2.94 – 3.92 Nm
mounting screw {30 – 40 kgcm}
40-34 BE30 Series

a If the voltage is out of the specified range, the 31. Turn the steering wheel to the left and measure
mounting screw may be installed defectively. In the output voltage.
this case, remove the potentiometer and repeat
the work from temporary installation of the Turn the worm shaft to the left and measure the
mounting screw. output voltage.
Voltage when Main side 3.6 – 4.1 V

30. Turn the steering wheel to the right and measure
the output voltage. steered to left Sub side 3.3 – 4.4 V
Turn the worm shaft to the right end and measure 32. Measure the relationship between the input
the output voltage. torque and sensor output voltage with an XY re-
corder and check that the result is as follows.
Voltage when Main side 0.9 – 1.4 V
steered to right Sub side 0.6 – 1.7 V
Characteristic curves of torque sensor voltage (Main side)
BE30 Series 40-35

33. Install potentiometer cover (21) and secure it with

the bolts. Install clip (22) to the right bolt as
shown in the figure at right.
34. Clamp potentiometer wiring harness (23) with

clip (22).
a When clamping the wiring harness, slacken it

properly.
35. Match the slit marks A of the pitman arm and

sector shaft to each other as shown in the figure.
Grip pitman arm (1) in the vise and tighten the

locknut.
Locknut of pitman 17.7 – 21.5 Nm
arm {18 – 22 kgm}
36. Install the dust cover to the serrated part.
40-36 BE30 Series

4. SPECIAL TOOLS
Set plate jig D

1. Fitting side of set plate
Bending punch J
BE30 Series 40-37

EPS ACTUATOR DISASSEMBLY AND ASSEMBLY
EPS ACTUATOR
1. NAME OF EACH PART
1. EPS motor 7. Wire clamp

2. Actuator sub-assembly 8. Connector
3. Packing 9. Locknut
4. Motor mounting bolt 10. Ball joint
5. Bellows 11. Ball screw shaft
6. Wire clamp 12. Breather plug
40-38 BE30 Series

DISASSEMBLY AND ASSEMBLY EPS ACTUATOR
2. REPLACING EPS MOTOR
1. Grip actuator (1) in a vise horizontally as shown

in the figure at right.
a If the actuator is set vertically, the ball screw

assembly rotates automatically when the
bellows is removed. If the ball screw ex-
tends too much at this time, it may break the
ball tube.
2. Remove 3 motor mounting bolts (2) and EPS mo-

tor.
a If the motor cannot be separated, hit it lightly

with a plastic hammer.
3. Remove the used packing from the mounting

face of the motor and wipe the mounting face
with clean cloths.
a When removing the motor, take care not to

lose motor joint (3).
4. Apply grease to the inside tooth surfaces of the

motor joint and fit new packing, and then install
the motor.
Motor mounting bolt 18.7 – 230.3 Nm

{1.9 – 3.1 kgm}
BE30 Series 40-39

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

(1).
2. Loosen locknut (4) on the ball joint side and re-

move ball joint (5) from the connector.
a Since the threads are coated with LOCTITE,

the locknut and connector cannot be loos-
ened easily. Take care.
3. Apply LOCTITE #271 to connector (3) and

threads of locknut (4). Set new joint (5) as shown
in the right figure and tighten the locknut.
a After finishing work, check that bellows (2) is

not twisted.
Locknut LOCTITE #271
Locknut 177 – 215 Nm

{18 – 22 kgm}
40-40 BE30 Series

a Set breather plug A at 20 degrees from the

center of the bolt of the ball joint (5).
BE30 Series 40-41

4. REPLACING BELLOWS
1. Grip connector (1) in the vise to secure the actu-

ator.
2. Remove the wire clamp of bellows (2), and then

move bellows (2) and loosen locknut (3).
a Since the threads are coated with LOCTITE,

the locknut cannot be loosened easily. Take
care.
3. Secure ball screw shaft (4) and apply a spanner

to the spanner hook of connector (1), and the
turn connector (1) slowly to remove it.
a Be sure to secure ball screw shaft (4) side for

the above work. If the other side is secured
and the ball screw shaft extends, the ball
tube of the ball screw may be broken.
4. Remove the used bellows and install new bel-

lows (2).
a Install the bellows with the larger diameter

side a on actuator (5) side. Install the wire
clamp too, at this time.
40-42 BE30 Series

5. Grip actuator (5) in the vise again as shown in the

figure and install connector (1).
a When installing the connector, apply LOC-

TITE #271 to it and threads of the locknut.
Locknut LOCTITE #271
6. Turn ball screw shaft (4) to the left to press part

A against the bottom, and then adjust dimension
C into the following range.
Standard dimension C: 473.5 + 30 mm
7. After positioning the ball screw shaft, grip con-

nector (1) again as shown in the figure and tight-
en locknut (3).
177 – 215 Nm
Locknut {18 – 22 kgm}
8. Set the actuator, connector, and ball joint as

shown in the figure and clamp the bellows with
the wires (2 places).
a Set breather plug B at 20 degrees from the

center of the bolt of ball joint (6).
BE30 Series 40-43

a Wind the wire by 2 turns and twist it 4 – 5

times. Bellows must not be dragged. The
first and second turns of the wire must not
cross each other on the opposite side of the
twisted part. Correct twist of the bellows be-
fore clamping. Bend the wire so that it will
not interfere with the bellows and chassis.
40-44 BE30 Series

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

1. When installing the ball sockets (4 places), clean and
degrease their mounting faces and the holes of the
mating parts.
2. Lip portion
3. Fill bearing space with grease up to 1/2 – 2/3 of vol-
ume of space.
4. Adjust with nut E
BE30 Series 40-45

REAR AXLE DISASSEMBLY AND ASSEMBLY
2. TESTING AND INSPECTION

Unit: mm
Criteria
A Diameter of king pin 28 27.8 Replace
B Vertical play of knuckle — 0.2 Adjust shim
C Diameter of bell crank pin 28 27.8
D Diameter of center pin 50 49.5

Replace
• Crack
— Rear axle, hub, knuckle, bearing • Damage, flaking
• Seizure, defective rotation, abnormal noise
The symbols correspond to the alphabet letters in the figure on the previous page.
3. PRECAUTIONS FOR ASSEMBLY
1. Hub bearing
Fill hub bearing space A with grease (G2-LI) up
to 1/2 – 2/3 of volume of space.
2. Adjusting turning torque of hub

1) Tighten locknut (2) until it becomes difficult to
turn hub (1) with one hand.
2) Loosen locknut (2) by 1/4 turn.
3) Hook a spring balance to the hub bolt and

adjust the turning torque to 19.6 – 25.5 N {2
– 2.6 kgf} with locknut (2) to give preload to
taper roller bearing (3).
40-46 BE30 Series

3. Adjusting toe-in
1) Secure the bell crank with the bell crank pin
and connect the tie rod and knuckle.
2) Align the hole ( 22) at the center of the axle

with the hole ( 22) of the bell crank and in-
sert the pin to set the wheels in the straight
travel position, and then adjust the toe-in.
3) Loosen the locknut of the tie rod and turn the

tie rod to adjust the toe-in to 0.
Toe-in: L1 – L2 = 0 – --1
4) Tighten the locknut of the tie rod.

245 – 304 Nm
Locknutt {25 – 31 kgm}
BE30 Series 40-47

4. ASSEMBLY DRAWING FOR REAR AXLE

1. Be sure to bend cotter pin.
ume of space.
3. Adjust with nut A
4. Press fit bolt with jig.
5. Lip surface
40-48 BE30 Series


1. When installing the ball sockets (4 places), clean and
degrease their mounting faces and the holes of the
mating parts.
ume of space.
4. Press fit bolt with jig.
BE30 Series 40-49

2. TESTING AND INSPECTION

Unit: mm
Criteria
D Diameter of center pin 50 49.5

Replace
• Crack
• Seizure, defective rotation, abnormal noise
The symbols correspond to the alphabet letters in the figure on the previous page.
3. PRECAUTIONS FOR ASSEMBLY
1. Hub bearing
Fill hub bearing space A with grease (G2-LI) up
to 1/2 – 2/3 of volume of space.
2. Adjusting turning torque of hub

1) Tighten locknut (2) until it becomes difficult to
turn hub (1) with one hand.
2) Loosen locknut (2) by 1/4 turn.
3) Hook a spring balance to the hub bolt and

adjust the turning torque to 19.6 – 25.5 N {2
– 2.6 kgf} with locknut (2) to give preload to
taper roller bearing (3).
40-50 BE30 Series

3. Adjusting toe-in
1) Secure the bell crank with the bell crank pin
and connect the tie rod and knuckle.
2) Align the hole ( 22) at the center of the axle

with the hole ( 22) of the bell crank and in-
sert the pin to set the wheels in the straight
travel position, and then adjust the toe-in.
3) Loosen the locknut of the tie rod and turn the

tie rod to adjust the toe-in to 0.
Toe-in: L1 – L2 = 0 – --1
4) Tighten the locknut of the tie rod.

245 – 343 Nm
Locknutt {25 – 35 kgm}
4. Adjusting stopper bolts

1) Adjust stopper bolts (1) and (4) so that steer-
ing angles A (inside) and B (outside) of the
tires will be as follows.
A 57°
B 80°
2) Adjustment dimensions of stopper bolts.

Stopper (1), (4) C: 14 mm
Stopper (2), (3) D: 8 mm
BE30 Series 40-51

LIFT CYLINDER DISASSEMBLY AND ASSEMBLY
LIFT CYLINDER
1. 2.0 – 3.0 ton models
1. Cylinder 6. Wiper seal 11. Bearing

2. Piston rod 7. O-ring 12. Snap ring
3. Cylinder head 8. U-ring 13. Spacer
4. Bushing 9. Backup ring 14. O-ring
5. U-ring 10. Bushing
40-52 BE30 Series

DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
Criteria Unit: mm
Criteria
Clearance between 1.0 – 1.75 ton models 0.06 – 0.235 0.4
A piston rod and Replace
bushing bushing
2.0 – 3.0 ton models 0.04 – 0.023 0.35
Clearance between 1.0 – 1.75 ton models 0.05 – 0.30 0.5 Replace
B piston ring and piston
cylinder 2.0 – 3.0 ton models 0.05 – 0.035 0.5 ring
1.0 – 1.75 ton 2.0 – 2.5 ton 3.0 ton

models models model
C Outside diameter of cylinder
52 57 63
D Inside diameter of cylinder 45 50 55 — —
E Diameter of piston rod 35 40 45
F Stroke 1,505 1,505 1,505
Lifting height: 3 m
BE30 Series 40-53

TILT CYLINDER DISASSEMBLY AND ASSEMBLY
TILT CYLINDER (6°/12°)

1. DISASSEMBLY DRAWING
1. Cylinder 7. Snap ring 13. O-ring 19. Spring washer

2. Piston rod 8. Wiper ring 14. Backup ring 20. Nut
3. Cylinder head 9. O-ring 15. Piston nut 21. Fitting
4. Bushing 10. Backup ring 16. Rod head 22. Bushing
5. U-ring 11. O-ring 17. Bushing
6. Ring 12. Piston 18. Bolt
40-54 BE30 Series

DISASSEMBLY AND ASSEMBLY TILT CYLINDER
Criteria Unit: mm
Criteria
A Clearance between piston rod and bushing 0.04 – 0.167 0.3
Replace
bushing
B Clearance between rod head bushing and pin 0.05 – 0.23 0.5
1.0 – 1.75 ton 2.0 – 2.5 ton 3.0 ton
models models model
C Outside diameter of cylinder
73 84 84
D Inside diameter of cylinder 60 70 70 — —
E Diameter of piston rod 25 30 30
F Stroke 139 141 157
Lifting height: 3 m
2. DISASSEMBLY
1) Grip the bottom parallel part of cylinder tube (1)

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

to removal.
BE30 Series 40-55

HYDRAULIC PUMP DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
1. Flange 6. Bushing R assembly 11. Packing ring L

2. Body 7. Bushing L assembly 12. Oil seal
3. Cover 8. Bushing seal 13. Snap ring
4. Drive gear 9. Body seal 14. Hexagon socket head bolt
5. Driven gear 10. Packing ring R
40-56 BE30 Series

DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
2. DISASSEMBLY
1) When disassembling the pump, clean its surface and drive shaft thoroughly.
Place the removed parts on a clean sheet of paper or cloth and take care not to stain, scratch, or bruise
them. (Arrange the removed parts so that you can see their locations before disassembly.)
2) Grip mounting flange (1) of the pump in a vise with its surface down.
Apply pads made of wood, aluminum, copper, etc. to the vise to protect the flange.
3) Remove hexagon socket head bolts (14).
Caution
• Loosen the bolts gradually, taking care that the pump will not fall from the vise.
• Use a proper wrench which is not worn yet.
4) Remove cover (3).

5) Remove seals (8), (9) and (10).
6) Remove the pump from the vise and place it on a stand with the front pump side up, holding the parts in the
body with your hands.
7) Pull out flange (1) straight in the axial direction and remove seals (8), (9) and (11).
8) Pull up the spline of drive gear (4) a little and pull bushings (6) and (7) and gears (4) and (5) on the flange
side out of body (2).
9) Turn over body (2) and take out bushings (6) and
(7) on the cover side.
10) Remove snap ring (13) from flange (1), and then
remove oil seal (12). Remove oil seal (12) in the
direction of the arrow with flat-head screwdriver
A.
11) The pump is disassembled by the above work.
Arrange the removed parts so that you can see
their locations.
3. JUDGING PARTS
Referring to section 50 MAINTENANCE STANDARD,
judge the condition of the parts.
BE30 Series 40-57

HYDRAULIC PUMP DISASSEMBLY AND ASSEMBLY
4. ASSEMBLY
1) Clean each part.

2) Set body (2) on a flat stand with the cover side
up.
3) Insert 2 bushings (6) and (7) on the cover side in
body (2) simultaneously.
Insert the bushings so that their flat parts will
not deviate. If they lean and become hard to
insert, do not hit them but remove and insert
again carefully.
4) Turn over body (2) and set it with the cover side
down.
At this time, take care that the bushings in-
serted in step 3) will not fall.
5) Install gears (4) and (5). Install drive gear (4) and driven gear (5) as they are engaged.
6) Insert 2 bushings (6) and (7) on the flange side in body (2) by the method explained in step 3).
7) Install bushing seal (8), body seal (9), and packing rings (10) and (11).
8) Install flange (1). Since the holes of the flange are aligned with the shafts when assembled in the factory,
take care not to damage the flange.
9) Grip the body with flange (1) side down in the vise and install seals (8), (9) and (10) by the method explained
in 7).
10) Install cover (3) and tighten bolts (14).
Bolt 46.1 – 48.6 Nm

{4.7 – 5.0 kgm}
Bushing (6), (7) are carefully attached in suction
side A, discharge side B, and combination.
Caution
• Be sure to tighten the bolts to the specified
torque.
• If they are not tightened sufficiently or tight-
ened too strongly, they may be broken and
hydraulic oil may spouts out through the
mounting faces of the pump, and that can
cause an accident.
11) Remove the pump from the vise. Install oil seal
(12) and snap ring (13) to flange (1).
At this time, apply clean lithium grease thinly
to the lip of oil seal (12).
For the installation direction of oil seal (12),
see the figure at right.
When press fitting the oil seal, take care not
to damage its lip and not to lean it. The lip
can be protected by winding a seal tape onto
the end of the front drive gear shaft. After fit-
ting the oil seal, be sure to remove the seal
tape, however.
40-58 BE30 Series

DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12) Turn the drive gear shaft end with a tool. If you can turn it lightly with the hand, no impurities and seals are
caught in the pump. If the shaft is extremely hard to turn, something may be caught in the pump. In this
case, disassemble and assemble the pump again.
13) The pump is assembled by the above work. Check again that it is assembled correctly and its rotating di-
rection is correct before installing it to the chassis. When installing it, observe the following points.
1) Check that the spigot joint socket used as the base part for centering is free from flaws.
2) Check that the mounting face of flange (1) is free from flaw and dirt. (Take care particularly if the flange
was clamped strongly with the vise.)
3) Check that the piping flanges are free from flaw and dirt.
If there is any bruise or flaw, remove it with a fine oilstone.
Caution
• Install the body, gears, and bushings in the positions and directions before disassembly.
BE30 Series 40-59

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

1. Port relief valve
1. Lift spool
2. Tilt spool
3. Attachment spool
4. Attachment spool
5. Attachment spool
40-60 BE30 Series

DISASSEMBLY AND ASSEMBLY CONTROL VALVE
2. PRECAUTIONS
Clean each part carefully and blow compressed air against it to remove all cleaning liquid and dirt. Apply
hydraulic oil to it before installing.
Do not use cloths to remove cleaning liquid and dirt.
Use diesel fuel or trichloroethylene to clean the parts. Take extreme care of fire.
Replace all of the dust seals, U-packings, and O-rings with new ones. When installing the new ones, apply
grease them and take care not to damage them.
BE30 Series 40-61

CONTROL VALVE (Manual valve spec.)

1. Lift spool
2. Tilt spool
3. Attachment spool
4. Attachment spool
40-62 BE30 Series

BE30 Series 40-63

Attach tags, etc. to the disconnected parts so that

you can see their mounting positions when in-
stalling.
Take care not to damage the sealing surfaces of
the mating faces of each section.
As a rule, replace spools by the assembly, since
their clearances are controlled strictly.
2. DISASSEMBLY PROCEDURE
1. Remove port relief valve (3) and main relief valve

(4).
At this time, take care that the cap screw,
2. Loosen nut (1) and pull out stud bolt (2) to sepa- etc. will not be sent flying by the spring.
rate each block.
3. Disassembly of lift valve [Precautions for pulling out spool]

• Pull out each spool straight so that it will not be
4. Disassembly of lift spool assembly bruised or scratched.
• If it has a bruise, scratch, etc., it may damage the
1) Loosen socket head bolt (5) and remove cap body hole when pulled out and may not enter the
(6), and then pull the sub-assembly of spool body hole when inserted.
(7) out of valve housing (8). At this time, re- Even if it enters the body hole, it can cause a mal-
move seal plate (9) on the cap side, O-ring function.
(10), and wiper (11) without separating them • Attach tags, etc. to all the spools so that you can
from the spool. install them to the correct positions when assem-
bling.
2) Loosen screw (25) on the opposite side and • If a spool is installed to a wrong position, the ac-
remove the seal plate, O-ring, and wiper sim- tuator will malfunction, and that will be very dan-
ilarly. gerous.
3) Loosen the socket head bolt and solenoid

valve (12), and then remove the case, wave
washer, solenoid, and ring in order. Remove
the valve assembly by loosening its hexago-
nal part.
4) Remove plug (13), poppet (14), and spring

(15).
5) Remove plugs (16) and (17) on the side and

top of the housing.
6) Remove plug (18) from the bottom, and then

remove poppet (19) and spring (20).
7) Loosen and remove shut-off valve (21).
8) Grip spool (7) in a vise, padding it with hard

wood boards not to damage its outside.
Loosen cap screw (22) and remove spring
seats (23) and spring (24), and then remove
O-ring (10) and wiper (11).
40-64 BE30 Series

5. Disassembly of tilt spool assembly 4) Grip spool (31) in a vise, padding it with hard
1) Remove O-ring (26), poppet (27), and spring Loosen cap screw (37) and remove spring
(28) from the mating face of the valve. seat (38) and spring (39), and then remove
2) Loosen socket head bolt (30) and remove At this time, take care that the cap screw, etc.
cap (29), and then pull the sub-assembly of will not be sent flying by the spring.
spool (31) out of valve housing (32). At this
time, remove seal plate (33) on the cap side, 5) Remove spring (40) from inside of spool (31).
O-ring (34), and wiper (35) without separat- Pull valve (41) out of spool (31) by using the
ing them from the spool. M3 screw at the end face.
3) Loosen screw (36) on the opposite side and

remove the seal plate, O-ring, and wiper sim-
ilarly.
BE30 Series 40-65

6. Disassembly of attachment spool assembly 4) Grip spool (47) in a vise, padding it with hard
1) Remove O-ring (42), poppet (43), and spring Loosen cap screw (53) and remove spring
(44) from the mating face of the valve. seat (54) and spring (55), and then remove
2) Loosen socket head bolt (46) and remove At this time, take care that the cap screw, etc.
cap (45), and then pull the sub-assembly of will not be sent flying by the spring.
spool (47) out of valve housing (48). At this
time, remove seal plate (49) on the cap side, Attach tags, etc. to the disconnected parts by
O-ring (50), and wiper (51) without separat- section so that you can see their mounting posi-
ing them from the spool. tions when installing.
3) Loosen screw (52) on the opposite side and

remove the seal plate, O-ring, and wiper sim-
ilarly.
40-66 BE30 Series

3. CLEANING 5. ASSEMBLY
Clean the all removed parts thoroughly in pure miner- (1) When assembling, take the following care in han-
al oil, and then place them on clean sheets of paper dling the O-rings.
or cloth to dry them with compressed air and check
them. 1) Do not use an O-ring which has a forming de-
fect or a flaw made by improper handling.
4. CHECK 2) Apply grease or hydraulic oil to each O-ring

and the part to install it for sufficient lubrica-
Check the all surfaces of each part for a burr, scratch, tion.
notch, and other defects.
3) Do not expand an O-ring so much that it will
1) Check the periphery of the spool for a scratch, be deformed plastically.
bruise, etc. If there is a slight flaw, remove it with
an oilstone or a cloth coated with lapping com- 4) When installing an O-ring, do not roll it. Once
pound. it is twisted, it does not untwist easily by itself
after it is installed, and that can cause oil
2) Check that all the sliding parts move smoothly leakage.
and all the grooves and passages are free from
foreign matter. (2) Take the following care in handling the spools.
3) If a spring is broken, deformed, or worn, replace 1) Tightening the screw of a spool too strongly
it. can cause a malfunction. Be sure to tighten
it to the specified torque.
4) Check that the seal groove of the valve housing
is smooth and free from dirt, dent, rust, etc. 2) Combine each spool, spring, and spring end
as they were before disassembly.
5) If there is a dent or a flaw on the check seat sur-
face of the valve housing, remove it by lapping. (3) Take the following care in assembling each sec-
Take care that lapping compound will not be left tion assembly and valve assembly.
in the valve.
1) Check that the O-ring of the mating face of
6) If the relief valve does not operate normally, dis- the valve does not project from the O-ring
assemble and check it. groove.
7) Replace the all O-rings and backup rings. 2) Check that cleaning oil, hydraulic oil, etc.
does not stick to the following parts before
8) After removing a cap or a plug, check that any assembly.
paint flake is not left around the body hole or plug
seat. • The surface out of the O-ring groove on
If a paint flake enters the valve, it will be caught the mating face of each section.
in the internal parts and will cause a malfunction • The surface out of the O-ring groove on
or oil leakage. the mounting face of each cap.
9) Check that the solenoid valve filter is free from If the valve is assembled with any oil
dirt. If any dirt is caught in the filter, remove it. sticking to the above parts, that oil may
be mistaken for leaking oil during opera-
tion.
BE30 Series 40-67

1. Assembly of valve housing 3. Assembly of each spool (Lift spool is used as

example below)
1) Install the following poppets, springs, and O-
rings to the mating face of each section. 1) Set O-ring (10), wiper (11), and seal plate (9)
in spool (7) in order, and then place spring
Tilt: Poppet (27), spring (28), O-ring (26) (24) between spring seats (23) and install
Attachment: Poppet (43), spring (44), O-ring them to the spool with cap screw (22).
(42) When assembling the above parts, grip
spool (7) in a vise, padding it with hard wood
2) Drive tie rods (2a) and (2b) into the lift sec- boards not to damage its outside. Apply
tion until they stop and install the valve hous- grease to the periphery of spring (24). Take
ings of each section in order. Then, tighten care that wiper (11) must be installed in the
tie rods (2a) and (2b) with nuts (1a) and (1b) correct direction.
to the specified torque.
For a 2-spool valve, install the tilt housing to

the lift housing with bolts (2a) and (2b).
2. Assembly of lift spool section assembly
1) Fit the O-ring to each plug.
2) Insert poppet (19) and spring (20) in the bot-

tom and tighten plug (18).
3) Tighten plugs (16) and (17) on the side and

port surface.
2) For only the tilt section, put valve (41) and
4) Install shut-off valve (21) with the set screw spring (40) in spool cap screw (37) and fit the
loosened. Tighten the set screw and secure O-ring to cap screw (37) before assembling.
it with the locknut.
5) Insert poppet (15) and spring (14) and tight-

en plug (13).
6) Solenoid valve (12)

• Install valve assembly (12a) to the hous-
ing.
• Install ring (12b), solenoid (12c), wave
washer (12d), and case (12e) in order to
the valve assembly (12a) and set the
lead wires in positions, and then tighten
socket head bolt (12f).
40-68 BE30 Series

4. Completion of assembly and check

(Lift spool is used as example below)
1) Install the spool sub-assembly to the same

position in the same direction in valve hous-
ing (8) as before disassembly and secure
cap (6) with socket head bolt (5).
2) Install port relief valve (3) and main relief

valve (4).
[Precautions for inserting spool]

• Insert the spool slowly straight in the hole.
• After inserting the spool, slide it with the hand to
check that it has no abnormality.
• When inserting the spool, if you feel stiffness or
roughness, the spool may malfunction.
[Precautions for assembly]

• After completing assembly, check that the all re-
moved parts are installed and tightened again.
• If any part is not tightened, it may be loosened
and oil may leak.
BE30 Series 40-69

DISASSEMBLY AND ASSEMBLY DRIVE MOTOR
DRIVE MOTOR
1. NAME OF EACH PART (1.0 – 2.5 TON MODELS)
1. Sensor cover 5. Frame

2. Sensor gear 6. Stator
3. Speed sensor 7. Temperature sensor
4. Rotor 8. Terminal
BE30 Series 40-71

DRIVE MOTOR DISASSEMBLY AND ASSEMBLY
2. NAME OF EACH PART (3.0 TON MODEL)
46 ～ 55 Nm
{4.7 ～ 5.6 kgm} 46 ～ 55 Nm
{4.7 ～ 5.6 kgm}
6 Nm
{0.6 kgm}
125Nm
{12.7 kgm}
10 ～ 12 Nm
{1.0 ～ 1.2 kgm}
3 Nm
{0.3 kgm}
1. Sensor cover 10. Rear bracket

2. Sensor gear 11. Bolt
3. Speed sensor 12. Oil seal
4. Rotor 13. Nut
5. Frame 14. Front blacket
6. Stator 15. Bolt
7. Temperature sensor 16. Stud bolt
8. Terminal 17. Screw
9. Shaft 18. Bolt
40-72 BE30 Series

DISASSEMBLY AND ASSEMBLY DRIVE MOTOR
3. DISASSEMBLY
1. Remove the sensor cover (1) with a flat-head Cutout

screwdriver or the like.
2. Apply a flat-head screwdriver to the sensor gear Flat-head screwdriver
(2) through the bracket (10) cutout, and secure
the shaft not to rotate.
3. Remove the nut (13).
• Locking adhesive is applied to the thread. If the
nut is too tight, apply heat using a drier or the like
before loosening.
Forcibly applying torque can damage the
thread.
4. Remove the rear-side bolts (15) (M12 x 40, 4 bolts).
• Locking adhesive is applied to the thread. If the bolt is too tight, apply heat using a drier or the like before
loosening.
Forcibly applying torque can damage the bolt.
5. Remove the rear bracket (10) together with the sensor gear (2), by lightly tapping with a wooden hammer or
the like.
6. Pull out the shaft (9) together with the rotor (4).
Be careful not to bend or scratch the fins or balance shaft of the rotor (4).
Be careful not to damage the oil seal (12).
7. Remove the front-side bolts (11) (M12 x 40, 4 bolts).
• Locking adhesive is applied to the thread. If the bolt is too tight, apply heat using a drier or the like before
loosening.
8. Remove the front bracket (14).
• If it is difficult to remove, lightly tap with a wooden hammer or the like.
9. Pull out the lock screw (17), and remove the stud bolt (16).
4. ASSEMBLY
Assemble in the reverse order of disassembly procedure. Note the followings:
• When assembling the sensor gear (2), press it in to the stepped section by lightly tapping with a cylindri-
cal shape jig.
• When installing the stud bolt (16), do not tighten the lock bolt (17) with excessive torque so as not to
crack the resin.
BE30 Series 40-73

PUMP MOTOR DISASSEMBLY AND ASSEMBLY
PUMP MOTOR
1. NAME OF EACH PART (1.0 - 1.75 TON MODELS)
1. Front bracket 7. Field coil

2. Rear bracket 8. Pole core
3. Holder ring 9. Yoke
4. Brush 10. Fan
5. Brush spring 11. Brush band
6. Armature
40-74 BE30 Series

DISASSEMBLY AND ASSEMBLY PUMP MOTOR
2. NAME OF EACH PART (2.0 - 3.0 TON MODELS)
2 9
8
4
10
1. Front bracket 7. Field coil

2. Rear bracket 8. Pole core
3. Holder ring 9. Yoke
4. Brush 10. Fan
5. Brush spring
6. Armature
BE30 Series 40-75

3. DISASSEMBLY
1. Remove the screws of the lead wires (pigtails) of

brushes (4).
2. Remove brushes (4) from the brush holder.
3. Remove the front bracket mounting bolts and

front bracket (11).
4. Remove armature shaft assembly (6) slowly.
40-76 BE30 Series

5. Remove the rear bracket mounting bolts and re-

move rear bracket (2) from yoke (9).
6. Remove terminal bolt and nut of yoke (9).
7. Remove the mounting bolts of pole cores (8).
8. Remove pole cores (8) and field coils (7) from

yoke (9).
BE30 Series 40-77

9. Remove the mounting bolts of holder ring (3)
10. Remove holder ring (3) from rear bracket (2).
4. JUDGING PARTS
Referring to section 50 MAINTENANCE STANDARD,
judge the condition of the parts.
40-78 BE30 Series

5. ASSEMBLY

1. Installation of field coils and pole cores

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

Put the brushes in the brush holder and set the
brush springs, and make sure that the brushes
move smoothly in the holder.
3) Tightening torque of the bolt

(A) Holder ring mounting bolt M6 × 1:
5.1 – 6.6 Nm (52 – 67 kgcm)
(B) Terminal mounting bolt M6 × 1:
3.0 – 3.9 Nm (31 – 40 kgcm)
(C) Pole core mounting bolt M8 × 1.25:
9.5 – 12.3 Nm (97 – 125 kgcm)
(D) Bracket mounting bolt M6 × 1:
5.1 – 6.6 Nm (52 – 67 kgcm)
BE30 Series 40-79

INSPECTION AFTER ASSEMBLY
1) Rotation
Raise the brush (A) by pulling the brush lead wire
while the brush spring (B) is raised, then release
the brush spring to the state shown in the draw-
ing on the left.
Then, turn the armature shaft by hand while the
brush is not in contact with commutator (C) and
make sure it turns smoothly.
2) Insulation resistance
Connect the earth (-) side of the megohmeter
(DC500V) to the pole core mounting bolt (A) and
the line (+) side to the terminal (A1), then make
sure that the resistance is 0.5 MΩ and above.
3) No-load operation
With 12 V power supplied, perform no-load oper-
ation to check the points shown below.
(1) That the motor rotates smoothly.
(2) That no sparking is generated from the con-
tact faces of the brushes and commutator.
40-80 BE30 Series

50. MAINTENANCE STANDARD
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 2
Differential (1.0 - 1.75 ton models). . . . . . . . . . 50- 3
Differential (2.0 - 3.0 ton models) . . . . . . . . . . . 50- 4
Front axle (1.0 - 1.75 ton models) . . . . . . . . . . 50- 5
Front axle (2.0 - 2.5 ton models) . . . . . . . . . . . 50- 6
Front axle (3.0 ton model) . . . . . . . . . . . . . . . . 50- 7
Brake master cylinder . . . . . . . . . . . . . . . . . . . 50- 8
Damping cylinder . . . . . . . . . . . . . . . . . . . . . . . 50- 9
Wheel brake (1.0 - 1.75 ton models) . . . . . . . . 50-10
Wheel brake (2.0 - 2.5 ton models) . . . . . . . . . 50-11
Wheel brake (3.0 ton model) . . . . . . . . . . . . . . 50-12
Rear axle (1.0 - 1.75 ton models). . . . . . . . . . . 50-14
Rear axle (2.0 - 3.0 ton models). . . . . . . . . . . . 50-16
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
Control valve
(Proportional solenoid valve spec.) . . . . . . . . . 50-19
Control valve (Manual valve spec.) . . . . . . . . . 50-20
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . 50-22
Mast, fork carriage, and fork
(1.0 - 1.75 ton models) . . . . . . . . . . . . . . . . . . . 50-25
Mast, fork carriage, and fork
(2.0 - 3.0 ton models) . . . . . . . . . . . . . . . . . . . . 50-26
Drive motor (1.0 - 2.5 ton models) . . . . . . . . . . 50-27
Drive motor (3.0 ton model) . . . . . . . . . . . . . . . 50-28
Pump motor (1.0 - 1.75 ton models) . . . . . . . . 50-30
Pump motor (2.0 - 3.0 ton models) . . . . . . . . . 50-32
Power steering motor . . . . . . . . . . . . . . . . . . . . 50-34
BE30 Series 50-1

TRANSFER MAINTENANCE STANDARD
TRANSFER
A Fitted parts of shaft and gear No clearance
Tooth surface must be free from damage,

— Each gear excessive wear, and bat contact Replace
— Each bearing Must be free from play and flaw
50-2 BE30 Series

MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
Criteria
Differential pinion gear and differential side When tooth surface
A gear — Replace by set
has damage
— Inside diameter of brake drum 254.0 – 254.2 256

Replace when
— Gasket, O-ring, seals — — disassembling
and assembling
BE30 Series 50-3

DIFFERENTIAL MAINTENANCE STANDARD
Unit: mm
Criteria
Differential pinion gear and differential side When tooth surface
A gear — Replace by set
has damage
— Inside diameter of brake drum 279.4 – 279.6 281.4

Replace when
— Gasket, O-ring, seals — — disassembling
and assembling
50-4 BE30 Series

MAINTENANCE STANDARD FRONT AXLE
FRONT AXLE (1.0 – 1.75 TON MODELS)
1. Direct the bearing as shown in the drawing.
Unit: mm
Criteria
A Inside diameter of brake drum 254 – 254.2 256 Replace
B Play of hub 0 0 Replace bearing
C Front axle Distortion, cracking, damage
D Shaft pipe Distortion, cracking, damage Replace
E Brake drum Uneven wear and flaw of inside wall of brake

drum
BE30 Series 50-5

FRONT AXLE MAINTENANCE STANDARD
FRONT AXLE (2.0 – 2.5 TON MODELS)
Unit: mm
Criteria
A Inside diameter of brake drum 279.4 – 279.6 281.4 Replace

drum
50-6 BE30 Series

MAINTENANCE STANDARD FRONT AXLE
FRONT AXLE (3.0 TON MODEL)
Unit: mm
Criteria
A Inside diameter of brake drum 310.0 – 312 312 Replace

drum
BE30 Series 50-7

BRAKE MASTER CYLINDER MAINTENANCE STANDARD
BRAKE MASTER CYLINDER
Unit: mm
Criteria
Replace cylinder
Interference of cup (Outside diameter of cup P-cup: Approx. 0.8
B – Inside diameter of cylinder) S-cup: Approx. 1.3 0.3
Replace piston
assembly
C Spring Must be free from flaw, wear, and leaning
50-8 BE30 Series

MAINTENANCE STANDARD DAMPING CYLINDER
DAMPING CYLINDER
1. Apply rubber grease.
Unit: mm
Criteria
Replace cylinder
B Interference of cup (Outside diameter of cup Approx. 1.0 0.4

– Inside diameter of cylinder) Replace piston
assembly
C Spring Must be free from flaw, wear, and leaning
BE30 Series 50-9

WHEEL BRAKE MAINTENANCE STANDARD
Criteria Unit: mm
Criteria
A Lining Thickness of lining 4.5 2.0
B1 97 105
Free length
B2 97 105
B1 2.6 2.0
B2 2.6 2.0

Replace
Clearance between
wheel cylinder and piston of cylinder: 0 – 0.05 0.2
22.22

ton and cylinder
50-10 BE30 Series

MAINTENANCE STANDARD WHEEL BRAKE
Criteria Unit: mm
Criteria
B1 110 112
Free length
B2 106 108
B1 3.2 2.6
B2 2.6 2.0

Replace

ton and cylinder
BE30 Series 50-11

WHEEL BRAKE MAINTENANCE STANDARD
WHEEL BRAKE (3.0 TON MODEL)
Criteria Unit: mm
Criteria
B1 124 136
Free length
B2 124 136
B1 2.9 2.0
B2 2.9 2.0

Replace

ton and cylinder
50-12 BE30 Series

REAR AXLE MAINTENANCE STANDARD

1. When installing the ball sockets (4 places), clean and degrease
their mounting faces and the holes of the mating parts.
2. Lip portion
3. Fill bearing space with grease up to 1/2 – 2/3 of volume of space.
50-14 BE30 Series

MAINTENANCE STANDARD REAR AXLE
a For tightening torque of each part, see on the previous page.

Unit: mm
Criteria
D Inside diameter of bushing for bell crank pin 28 28.3
E Inside diameter of bushing for center pin 50 50.7 Replace
• Cracking
• Seizure, defective rotation, abnormal sound
BE30 Series 50-15

REAR AXLE MAINTENANCE STANDARD

1. When installing the ball sockets (4 places), clean and degrease
their mounting faces and the holes of the mating parts.
2. Fill bearing space with grease up to 1/2 – 2/3 of volume of space.
4. Press fit with jig.
50-16 BE30 Series

MAINTENANCE STANDARD REAR AXLE
a For tightening torque of each part, see on the previous page.

Unit: mm
Criteria
D Inside diameter of bushing for bell crank pin 28 28.3
E Inside diameter of bushing for center pin 50 50.7 Replace
• Cracking
• Seizure, defective rotation, abnormal sound
BE30 Series 50-17

LIFT CYLINDER, TILT CYLINDER MAINTENANCE STANDARD
LIFT CYLINDER
Unit: mm
Criteria
1.0 – 1.75 ton models 0.06 – 0.235 0.4
Clearance between
A piston rod and bushing Replace bushing
2.0 – 3.0 ton models 0.04 – 0.023 0.35
1.0 – 1.75 ton models 0.05 – 0.30 0.5

Clearance between Replace piston
B piston ring and cylinder ring
2.0 – 3.0 ton models 0.05 – 0.035 0.5
TILT CYLINDER
Unit: mm
Criteria Remedy
Symbol Inspection item
A Clearance between piston rod and bushing 0.04 – 0.167 0.3
Replace bushing
B Clearance between piston rod head bushing 0.05 – 0.23 0.5
and pin
50-18 BE30 Series

MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE (Proportional solenoid valve spec.)

1. Control valve with port relief valve is shown here.
BE30 Series 50-19

CONTROL VALVE MAINTENANCE STANDARD
CONTROL VALVE (Manual valve spec.)

1. Control valve with port relief valve is shown here.
1. Lift spool
2. Tilt spool
3. Attachment spool
4. Attachment spool
50-20 BE30 Series

MAINTENANCE STANDARD CONTROL VALVE
1. CHECK
Check the all surfaces of each part for a burr, scratch,

notch, and other defects.
1) Check the periphery of the spool for a scratch,

bruise, etc. If there is a slight flaw, remove it with
an oilstone or a cloth coated with lapping com-
pound.
2) Check that all the sliding parts move smoothly

and all the grooves and passages are free from
foreign matter.
3) If a spring is broken, deformed, or worn, replace

it.
4) Check that the seal groove of the valve housing

is smooth and free from dirt, dent, rust, etc.
5) If there is a dent or a flaw on the check seat sur-

face of the valve housing, remove it by lapping.
Take care that lapping compound will not be left
in the valve.
6) If the relief valve does not operate normally,

check the relief valve.
7) Replace the all O-rings and backup rings.
8) After removing a cap or a plug, check that any

paint flake is not left around the body hole or plug
seat.
If a paint flake enters the valve, it will be caught
in the internal parts and will cause a malfunction
or oil leakage.
9) Check that the solenoid valve filter is free from

dirt. If any dirt is caught in the filter, remove it.
BE30 Series 50-21

HYDRAULIC PUMP MAINTENANCE STANDARD
HYDRAULIC PUMP
1. Flange 8. Bushing seal

2. Body 9. Body seal
3. Cover 10. Packing ring R
4. Drive gear 11. Packing ring L
5. Driven gear 12. Oil seal
6. Bushing R assembly 13. Snap ring
7. Bushing L assembly 14. Hexagon socket head bolt
50-22 BE30 Series

MAINTENANCE STANDARD HYDRAULIC PUMP
1. INSPECTION AND REPAIR METHOD
Check the removed parts for stain and discoloration,

and then clean them in fuel oil. Do not soak rubber
parts in fuel oil, however.
Check each part for the following points, and then re-
pair or replace it if any defect is detected.
1) Body (2)
The tooth tips of the gears of the gear pump are
kept in contact with the inside wall of the gear
hole during operation to increase the volumetric
efficiency. Accordingly, once the pump is oper-
ated, there is contact mark A of the tooth tips
near the suction opening.
Contact mark B is less than 1/2 of the inside wall

of the gear hole and its depth a is about 0.05 mm,
if it is normal. If depth a is 0.15 mm or larger, re-
place the pump assembly.
2) Drive gar (4) and driven gear (5)

If the hydraulic oil is clean, the shafts and the
sides of the gears keep in smooth contact with
the mating parts. If the shafts or sides of the
gears are so roughened that your nails hitch on
them or tooth surfaces are worn unevenly abnor-
mally, replace them.
If shaft b is less than 18.935 mm, replace the

gear set.
BE30 Series 50-23

HYDRAULIC PUMP MAINTENANCE STANDARD
3) Bushings (6) and (7)

If the bushings are in ideal contact, their inside
sliding surfaces are smooth and about a half of
them on the suction side are glossy. If contact D
of the sides is normal, the suction side is in stron-
ger contact (blackish) and the high-pressure side
is in slight contact.
If any of the following conditions is detected, re-

place the bushings.
1. The whole inside sliding surfaces of the

bushings are in contact and roughened to a
degree that your nails hitch.
2. There are many flaws in the circumferential
direction on the sides of the bushings and
your nails hitch on them.
3. There are traces of foreign matter on the in-
side sliding surfaces and sides of the bush-
ings.
The service limits of the bushings are as follows.

If dimensions c or d is as follows, replace the
bushing assembly and gears by kit.
Inside diameter of bushing: 19.123 < c

Overall length of bushing: 26.411 > d
4) Be sure to replace bushing seal (8), body seal

(9), packing rings (10) and (11), oil seal (12), and
snap ring (13) each time the pump is disassem-
bled.
50-24 BE30 Series

MAINTENANCE STANDARD MAST, FORK CARRIAGE, AND FORK
MAST, FORK CARRIAGE, AND FORK (1.0 – 1.75 TON MODELS)
Unit: mm
Criteria
Inspection item Remedy
Left and right 0.1 – 0.3 Max. 2.0 Adjust shim
Clearance between outer mast
and inner mast Replace with
Front and rear 0.5 – 1.0 Max. 2.0 oversize roller

Clearance between inner mast
and fork carriage Replace with
Front and rear 0.5 – 1.0 Max. 2.0 oversize roller
Wear oil groove of bushing of mast support There is wear of oil groove Replace bushing
1.0 ton models 31 Min. 26

Thickness A of fork (base) Replace
BE30 Series 50-25

MAST, FORK CARRIAGE, AND FORK MAINTENANCE STANDARD
MAST, FORK CARRIAGE, AND FORK (2.0 – 3.0 TON MODELS)
Unit: mm
Criterion
Inspection item Remedy
Clearance between outer mast
and inner mast
Front and rear 0.2 – 0.7 Max. 2.0 Replace

Clearance between inner mast
and fork carriage
Front and rear 0.2 – 0.7 Max. 2.0
Wear oil groove of bushing of mast support There is wear of oil groove
2.0 ton models 36 Min. 33 Replace
Thickness A of fork (base) 2.5 ton models 40 Min. 36.5
3.0 ton model 44 Min. 39.5
50-26 BE30 Series

MAINTENANCE STANDARD DRIVE MOTOR
DRIVE MOTOR (1.0 – 2.5 TON MODELS)
5. Frame
1. Sensor cover 6. Stator
2. Sensor gear 7. Temperature sensor
3. Speed sensor 8. Terminal
4. Rotor
BE30 Series 50-27

DRIVE MOTOR MAINTENANCE STANDARD
DRIVE MOTOR (3.0 TON MODEL)

a The following illustration shows the 3 ton models.
46 ～ 55 Nm
{4.7 ～ 5.6 kgm} 46 ～ 55 Nm
{4.7 ～ 5.6 kgm}
6 Nm
{0.6 kgm}
125Nm
{12.7 kgm}
10 ～ 12 Nm
{1.0 ～ 1.2 kgm}
3 Nm
{0.3 kgm}
1. Sensor cover 10. Rear bracket

2. Sensor gear 11. Bolt
3. Speed sensor 12. Oil seal
4. Rotor 13. Nut
5. Frame 14. Front blacket
6. Stator 15. Bolt
7. Temperature sensor 16. Stud bolt
8. Terminal 17. Screw
9. Shaft 18. Bolt
50-28 BE30 Series

MAINTENANCE STANDARD DRIVE MOTOR
1. MAINTENANCE
1. Daily maintenance
(1) Maintenance during operation
Inspection item Part to be inspected Criterion Remedy
Must not change remarkably from
If dust is heaped
level in normal operation.
Dust Motor frame extremely, stop and
Temperature rise must be normal, too.
Environment clean.
Check visually.
Foreign matter, Must not change remarkably from

Motor frame Restore condition.
splash, liquid level in ordinary operation.
Temperature must not abnormally

above normal level and must be below
Temperature rise Motor frame, bearing specified level. Restore condition.
Motor frame: 80°C
Bearing: 55°C
There must not be abnormal vibration

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

If operation is troubled
and increase of noise level. Compare
Motor frame, bearing, with abnormal sound,
Abnormal sound current sound with sound of new
cover, etc. stop and remove
motor by using listening bar.
cause.
Check by listening.
(2) Maintenance at stop

Maintenance item Inspection item Criterion Remedy
Must be free from looseness, dust,
and rust. Retighten, clean, and
Clamping parts Clamping screws
Check visually. Check by hitting and paint.
listening sound.
Connection must be correct.

Connecting parts must not be loos-
Retighten.
Connecting parts ened.
Check insulation.
Terminals Insulation must be perfect.
Check visually.
Connecting parts of ter- Wire cover must not be damaged.

Repair in special factory.
minal and harness. Check visually.
BE30 Series 50-29

PUMP MOTOR MAINTENANCE STANDARD
PUMP MOTOR (1.0 – 1.75 TON MODELS)

A. Outside diameter of commutator
B. Depth of undercut
C. Bend of armature shaft

D. Insulation of armature
E. Insulation of field coil
50-30 BE30 Series

MAINTENANCE STANDARD PUMP MOTOR
Check insulation resistance between G. Pressing force of brush spring

2 of 3 terminals in 3 combinations.
Megger
Ground (–) side P1 P1 P2
Line (+) side P2 P3 P3
F. Insulation of holder ring
H. Height of brush
Unit: mm
Measuring Criteria
instrument Standard size Repair limit
Outside diameter of Slide calipers
A commutator 90 87 Replace
Undercut mica and
B Depth of undercut Slide calipers 0.65 ± 0.15 Min. 0.2 polish commutator sur-
face with sandpaper of
#400.
C Bend of armature shaft Dial gauge — Max. 0.2
D Insulation of armature Megger (DC 500 V) — Min. 0.5 Mz
E Insulation of field coil Megger (DC 500 V) — Min. 0.5 Mz

Replace
Insulation of holder
F ring Megger (DC 500 V) — Min. 0.5 Mz
Pressing force of brush
G spring Spring balance 11.1 N {1.13 kgf} 7.35 N {0.75 kgf}
H Height of brush Slide calipers 33 22
BE30 Series 50-31

PUMP MOTOR MAINTENANCE STANDARD
PUMP MOTOR (2.0 – 3.0 TON MODELS)

E
F
G
C, D
A, B

E. Insulation of field coil
50-32 BE30 Series

MAINTENANCE STANDARD PUMP MOTOR
Check insulation resistance between G. Pressing force of brush spring

Megger
F. Insulation of holder ring
H. Height of brush
Unit: mm
Measuring Criteria
A commutator 100 97 Replace
Undercut mica and
B Depth of undercut Slide calipers 0.8 – 1.2 0.2 polish commutator sur-
#400.
C Bend of armature shaft Dial gauge — Max. 0.2
E Insulation of field coil Megger (DC 500 V) — Min. 0.5 Mz

Replace
Insulation of holder
F ring Megger (DC 500 V) — Min. 0.5 Mz
Pressing force of brush 10.6 – 13.0 N
G spring Spring balance {1.1 – 1.3 kgf} 7.84 N {0.8 kgf}
H Height of brush Slide calipers 32 – 34 22
BE30 Series 50-33

POWER STEERING MOTOR MAINTENANCE STANDARD
POWER STEERING MOTOR


Check insulation resistance between E. Insulation of holder ring

Megger
50-34 BE30 Series

MAINTENANCE STANDARD POWER STEERING MOTOR
F. Pressing force of brush spring
G. Height of brush
Unit: mm
Measuring Criteria
A commutator 30.5 29.5 Replace
Undercut mica and
B Depth of undercut Slide calipers 0.6 – 0.8 Min. 0.2 polish commutator sur-
#400.
C Bend of armature shaft Dial gauge Max. 0.06 Max. 0.2
E Insulation of holder Min. 0.5 Mz

ring Megger (DC 500 V) — Replace
Pressing force of brush Spring balance 4.9 – 11.8 N 4.9 – 11.8 N

F
spring {0.5 – 1.2 kgf} {0.5 – 1.2 kgf}
G Height of brush Slide calipers 22 13
BE30 Series 50-35

60. STRUCTURE AND FUNCTION
Power train . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 3 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . 60-32

Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 3 Lift cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-32
System diagram of power train . . . . . . . . . . . . 60- 3 Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-33
Outside view and Cross section of power train Hydraulic circuit diagram . . . . . . . . . . . . . . . . . 60-35
(1.0 - 1.75 ton models) . . . . . . . . . . . . . . . . . . 60- 4 Work equipment control lever . . . . . . . . . . . . . 60-37
Outside view and Cross section of power train
(2.0 - 2.5 ton models) . . . . . . . . . . . . . . . . . . . 60- 6 Hydraulic control valve
Outside view and Cross section of power train (Proportional solenoid valve spec.) . . . . . . . . . 60-39
(3.0 ton model) . . . . . . . . . . . . . . . . . . . . . . . . 60- 8 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-39
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10 Section of proportional solenoid valve . . . . . . . 60-41
Explanation of operation . . . . . . . . . . . . . . . . . 60-42
Travel system . . . . . . . . . . . . . . . . . . . . . . . . 60-11 Outside view of hydraulic control valve
Front wheels and rear wheels . . . . . . . . . . . . . 60-11 (proportional solenoid valve) . . . . . . . . . . . . 60-53
Braking device . . . . . . . . . . . . . . . . . . . . . . . 60-12 Work equipment. . . . . . . . . . . . . . . . . . . . . . . 60-58

Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-12 Mast (1.0 - 1.75 ton models) . . . . . . . . . . . . . . 60-58
Wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . 60-14 Mast (2.0 - 2.5 ton models) . . . . . . . . . . . . . . . 60-60
Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-16 Mast (3.0 ton model) . . . . . . . . . . . . . . . . . . . . 60-62
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . 60-17
Parking brake lever . . . . . . . . . . . . . . . . . . . . . 60-18 Power connector for optional devices. . . . . 60-64
Steering system . . . . . . . . . . . . . . . . . . . . . . 60-20 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 60-65

Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . 60-20 Outline and features of control unit . . . . . . . . . 60-65
Electric power steering (EPS) . . . . . . . . . . . . . 60-20 Principle of change of motor speed . . . . . . . . . 60-66
EPS actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22 Connection diagram of motor power circuit . . . 60-66
EPS torque sensor and gear box . . . . . . . . . . 60-23 Outline of operation of travel motor . . . . . . . . . 60-66
Principle of operation of EPS . . . . . . . . . . . . . 60-24 Power module of controller . . . . . . . . . . . . . . . 60-68
Steering linkage . . . . . . . . . . . . . . . . . . . . . . . 60-26 Control functions of controller . . . . . . . . . . . . . 60-69
Electrical system circuit diagram . . . . . . . . . . 60-28
Rear axle (1.0 - 1.75 ton models) . . . . . . . . . . 60-30 Operating device
Rear axle (2.0 - 3.0 ton models) . . . . . . . . . . . 60-31 (Meter panel, switchs, etc.) . . . . . . . . . . . . 60-71
Name of each device . . . . . . . . . . . . . . . . . . . . 60-71
How to start hour meter . . . . . . . . . . . . . . . . . . 60-72
BE30 Series 60-1

How to turn electrolyte level indicator
function OFF . . . . . . . . . . . . . . . . . . . . . . . .60-72
How to operate lift interrupt function . . . . . . . .60-73
Reference for adjustment of travel
characteristic . . . . . . . . . . . . . . . . . . . . . . . .60-74
Mater panel display . . . . . . . . . . . . . . . . . . . . .60-75
Meter panel functions. . . . . . . . . . . . . . . . . . . .60-76
Display in each mode. . . . . . . . . . . . . . . . . . . .60-77
Ordinary A or B mode display . . . . . . . . . . .60-77
Operator adjustment mode display . . . . . . .60-82
Service adjustment mode display . . . . . . . .60-84
Switch monitor mode display . . . . . . . . . . . .60-87
Display list of meter panel dot section . . . . . . .60-88
60-2 BE30 Series

STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1. OUTLINE
The power train is made in one unit, containing from the motor to the front axle. The operable time is lengthened
by employing the high-efficiency structure to transmit the energy of the drive motor without wasting it and the
travel sound is lowered by employing the low-noise "high addendum helical gear" which has been employed for
the AR Series and evaluated high.
2. SYSTEM DIAGRAM OF POWER TRAIN
1. Drive motor 4. Wheel brake

2. Transfer 5. Brake drum
3. Front axle 6. Front tire
BE30 Series 60-3

POWER TRAIN STRUCTURE AND FUNCTION
1. Be sure to fill grease.

Install red cap.
3. OUTSIDE VIEW OF POWER TRAIN (1.0 – 1.75 TON MODELS) 2. Degrease mounting
bolts.
60-4 BE30 Series

4. CROSS SECTION OF POWER TRAIN (1.0 – 1.75 TON MODELS)
BE30 Series 60-5

1. Be sure to fill grease.

Install red cap.
2. Degrease mouting bolts.
5. OUTSIDE VIEW OF POWER TRAIN (2.0 – 2.5 TON MODELS) 3. Dimension after gasket is
clamped
60-6 BE30 Series

6. CROSS SECTION OF POWER TRAIN (2.0 – 2.5 TON MODELS)
BE30 Series 60-7

1. When mounting motor, check
that MOLY-PASTE is applied
to the gear hole side.
2. Be sure to fill grease Install red
7. OUTSIDE VIEW OF POWER TRAIN (3.0 TON MODEL) cap.
3. Degrease mouting bolts.
60-8 BE30 Series

8. CROSS SECTION OF POWER TRAIN (3.0 TON MODEL)
BE30 Series 60-9

9. FRONT AXLE
(1) 1.0 – 1.75 ton models
1. Install front axle to frame with bolts (Left).
(2) 2.0 – 3.0 ton models

1. Install front axle to frame with bolts (Left).
Specification Unit: mm
1.0, 1.4 ton models 1.5, 1.8 ton models 2.0, 2.5 ton models 3.0 ton model
Item
EX type
Type Fixed single-shaft full-float type
Type of reduction gears Helical gear
Tread 890 920 940 1,005
Overall width 1,050 1,115 1,165 1,235
Oil volume of wheel
7l 8l
(including transfer)
60-10 BE30 Series

STRUCTURE AND FUNCTION TRAVEL SYSTEM
TRAVEL SYSTEM
1. FRONT WHEELS AND REAR WHEELS
Standard tires
The wide tires having rib-lug mixed tread patterns for lower rolling resistance are installed as standard to lengthen
the operable time and stabilize the operability. (The wide tires are not installed to the front wheels of 1.0 – 1.4
tons models and rear wheels of 1.0 – 1.8 ton models.)
Kind Item 1.0/1.35 ton models 1.5/1.75 ton models 2.0/2.5 ton models 3.0 ton model
21×8-9-10PR(1) 23×8-9-16PR(1) 28×9-15-14PR(1)
Tire size 6.00-9-10PR(1)
Front wheel
Wide tire Wide tire Wide tire

Nominal rim size 9×4.00 E DT 9×6.00 E TB 10×6.50 F TB 15×7.00 T IR
Standard tire inflation 0.69MPa 0.61MPa 0.88MPa 0.78MPa
pressure {7.00 kgf/cm²} {6.25 kgf/cm²} {9.00 kgf/cm²} {8.00 kgf/cm²}
18×7-8-14PR(1) 21×8-9-10PR(1)
Tire size 5.00-8-8PR(1)
Rear wheel
Wide tire Wide tire

Nominal rim size 8×3.00 D DT 8×4.25 D DT 9×6.00 E TB
Standard tire inflation 0.78 MPa ⎧ Only 1.75 ton model 0.88MPa 0.61MPa
⎩
{8.00 kgf/cm²}⎩
⎧
pressure 0.88MPa {9 kgf/cm²} {9.00 kgf/cm²} {6.25 kgf/cm²}
Optional tires
A variety of optional tires are set to meet various customer needs.
(The structures of the wide tread tire, double tire, single-double tire, etc.)
In addition, the following optional tires are also set so that each of them will be selected for a different use or
purpose.
1) Deep tread patter tire having long lifespan
2) Cushion tire which will not be flattened
3) Color tire (white or green) which does not stain tiled floors, etc.
BE30 Series 60-11

BRAKING DEVICE STRUCTURE AND FUNCTION
BRAKING DEVICE
1. OUTLINE
The "regenerative brake + F/R regenerative brake +
neutral regenerative brake" system of multi-function
braking system is adopted and the braking force of
each brake unit of this system can be adjusted and
set freely.
Increase of operating hours

The braking energy of the mechanical brake is dis-
carded in the form of heat. On the other hand, the
braking energy of the regenerative brake is collected
in the form of electric energy into the battery. Accord-
ingly, the operating hours can be increased.
Reduction of pressing effort of brake pedal

If the brake pedal of the regenerative brake is pressed
lightly, the electric brake operates (it does not operat-
ed, however, when the travel speed is below 4 km/h).
If the brake pedal is pressed more, the mechanical
brake operates, too.
As a result, the regenerative brake requires only 60%
of the pressing effort of the mechanical brake to ob-
tain the same braking force. Accordingly, the opera-
tor is less fatigued.
Improvement of regenerative brake performance

Since the current "regeneration control + plugging
control" system is replaced with the new regenerative
brake control system, the regenerative brake func-
tions in the all acceleration range. Accordingly, the
time and distance required for a series of operations
New BE30
from changing of the travel direction (plugging opera-
tion) during travel to deceleration, stopping, and re-
starting are shortened. In addition, the time lag and
shocks are reduced. The braking force of each brake
can be adjusted and set freely.
Current BE30
60-12 BE30 Series

2. WHEEL BRAKE
New 1.0 – 1.75 ton models : Lining is thickened.

New 2.0 – 3.0 ton models : Same as BX.
• The brake lining is made of non-asbestos material for
higher durability and less environmental pollution.
Unit: mm
Sym-
Item 1.0 - 1.75 ton models 2.0, 2.5 ton models 3.0 ton model
bol
— Type Front wheel hydraulic internal expanding type (with built-in parking brake)
— Structure Duo-servo
A Material of lining Resin mold (Non-asbestos, sticking type)
B Inside diameter of brake drum 254(10”) 279(11”) 310(12.2”)
C Width of lining 48.5 55 60
D Thickness of lining 4.87 5.1 5.67
Inside diameter of wheel
E 22.22 25.4 28.58
cylinder
Wheel brake for 1.0 – 1.75 ton models 1. Turning direction of drum during forward travel
2. Turning direction of adjuster when shoe is expanded
60-14 BE30 Series

STRUCTURE AND FUNCTION BRAKING DEVICE
Wheel brake for 2.0 – 2.5 ton models
Wheel brake for 3.0 ton model
BE30 Series 60-15

3. BRAKE PEDAL
60-16 BE30 Series

4. PARKING BRAKE
FB20, 25EXG, FB30

FB15, 18EXG,
BE30 Series 60-17

5. PARKING BRAKE LEVER
60-18 BE30 Series

3.0
BE30 Series 60-19

STEERING SYSTEM STRUCTURE AND FUNCTION
STEERING SYSTEM
1. STEERING WHEEL
The tilt and telescopic steering wheel can be adjusted

by 70 mm in longitudinal direction A and by 30 mm in
vertical direction B. Accordingly, it can be properly for
each operator.
Quantity of adjustment in longitudinal direction A:
70 mm
Quantity of adjustment in vertical direction B: 30 mm
Since the levers, switches, and meters follow the
steering wheel, all positions of the control system can
be set to properly.
2. ELECTRIC POWER STEERING (EPS)
EPS : Electric Power Steering

Applicable models: All models
(1) EPS senses travel speed.
As shown in the graph at right, the steering effort of
the former EPS is reduced and the steering stability is
lowered as the travel speed is increased. On the oth-
er hand, the steering effort of the travel speed-sens-
ing EPS is lightest when the lift truck is steered while
it is stopped and it is increased properly as the travel
speed is increased. As a result, the steering is highly
stabilized.
In addition, the dead band of the electric signals is so
changed to reduce the play and improve the straight
travel performance.
60-20 BE30 Series

STRUCTURE AND FUNCTION STEERING SYSTEM
(2) Specifications and input and output characteristics
1) Specification
Gear module (Helix angle) 1.25(25°)
Gear ratio 4.917
Ball screw lead 8.731
Ball P.C.D. 28
Helix direction of ball screw Left
Rated voltage of motor assembly 48V 350W/H
Theoretical twisting force of shaft 10,980 N {1,120 kgf}: 40A
2) Input and output characteristics
BE30 Series 60-21

1. Component parts of 1079-025

2. Wind wire by 2 turns and twist it by 4 – 5 times.
3. EPS ACTUATOR It must not be dragged. Set ball stud 180° in opposite
direction.
60-22 BE30 Series

4. EPS TORQUE SENSOR AND GEAR BOX

1.Tightening phase of pitman arm
BE30 Series 60-23

5. PRINCIPLE OF OPERATION OF EPS

If the operator turns steering wheel (1), the steering The output voltage is converted into a current by the
torque of the steering wheel is applied to pitman arm controller and EPS motor (6) of actuator (7) rotates.
(4). Then, torque sensor (3) which is a part of steering As a result, the direction of rear wheels (10) is
gear box (2) outputs a voltage (a sensor voltage) in changed.
accordance with the steering torque and steering di-
rection to controller (11).
1. Steering wheel 7. Actuator

2. Steering gear box 8. Bell crank
3. Torque sensor 9. Tie rod
4. Pitman arm 10. Rear wheel
5. Drag link 11. Controller
6. EPS motor 12. Battery
1. Torque sensor (3) is a part of steering gear box 3. The controller (11) converts the signal from
(2), which is connect to actuator (7) through pit- torque sensor (3) into a current, which rotates
man arm (4) and drag link (5). EPS motor (6) to move actuator (7) in the same
direction as the steering direction.
2. If steering wheel (1) is turned, the input shaft
(worm shaft) of steering gear box (2) slides in the 4. Actuator (7) changes the direction of rear wheel
axial direction according to the steering effort. (10) through bell crank (8).
Torque sensor (3) converts the sliding distance of Commonality of parts
the input shaft into an electric signal and sends it The parts of the EPS system, except the controller
to controller (11). (11), EPS motor (6), and drag link (5), are common to
the 1 ton models to the 3 ton models.
60-24 BE30 Series

1. Mechanism to give proper steering effort to Steering gear box

steering wheel
1. Potentiometer 5. Pin
2. Bearing ring 6. Arm
3. Input shaft 7. Slide ring
(Worm shaft) 8. Coil spring
4. Output shaft 9. Thrust needle
(Sector shaft) 10. Locknut
1) In the steering gear box, there are input shaft

(worm shaft) (3), coil springs (8), slide ring (7),
and bearing ring (2). The input shaft is hung on
the coil springs (4 pieces).
2) If the steering wheel is turned, input shaft (3) ro-

tates.
3) As a load is applied to output shaft (sector shaft)

(4), the input shaft slides in the axial direction
(±1.6 mm). Since coil springs (8) are com-
pressed through bearing ring (2) at this time, the
reaction force becomes the steering effort.
2. Mechanism to generate electric signal in

torque sensor
1) While a load is applied to the output shaft, if the
steering wheel is rotated in direction A (e.g. to the
left), the input shaft slides in axial direction B (by
maximum of 1.6 mm).
2) As the input shaft slides, slide ring (7) moves, too.
3) Arm (6) and pin (5), which is used as a fulcrum of

the arm, are installed to the center of slide ring
(7). If the slide ring moves, the arm (6) turns
around the pin.
4) The sensor is installed to the end of arm (6).

Since the resistance of the potentiometer of the Torque sensor
sensor changes as the arm turns, the electric sig-
nal to the controller changes.
BE30 Series 60-25

6. STEERING LINKAGE (FOR 1.0 – 1.75 TON MODELS)
60-26 BE30 Series

BE30 Series 60-27

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

1.This illustration shows Japanese spec.
60-28 BE30 Series

1.This illustration shows Japanese spec.
BE30 Series 60-29

60-30
Type Center pin type
Structure of knuckle Elliot type
Toe-in 0mm
STEERING SYSTEM
Camber 1.5 degrees

Caster 4.0 degrees
King pin angle 6.0 degrees
Steering angle of tire
79.3 degrees
(inside)
Steering angle of tire
54.0 degrees
(outside)
Tread 893mm
8. REAR AXLE (1.0 – 1.75 TON MODELS, EX TYPE)
STRUCTURE AND FUNCTION
BE30 Series
BE30 Series
9. REAR AXLE (2.0 – 3.0 TON MODELS)
Type Center pin

type
Structure of
knuckle Elliot type
Toe-in 0mm
Camber 1.5 degrees
Caster 0 degrees
King pin angle 6.0 degrees
Steering angle 80 degrees
of tire (inside)
Steering angle
of tire (outside) 57 degrees
Tread 952mm
STEERING SYSTEM
60-31
HYDRAULIC SYSTEM STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
1. LIFT CYLINDER (1.0 – 1.75 TON MODELS)
Symbol Item Unit Specification 1. Wiper ring 8. Cushion bearing
2. U-ring 9. Snap ring
A Outside diameter of cylinder mm 52
3. Cylinder head 10. Bushing
B Inside diameter of cylinder mm 45 4. O-ring 11. Backup ring
C Disconnect of piston rod mm 35 5. Bushing 12. U-ring
6. Piston rod
D Stroke (Lifting height 3 m) mm 1,500
7. Cylinder
— Weight (Lifting height 3 m) kg 20
2. LIFT CYLINDER (2.0 – 3.0 TON MODELS)

Symbol Item Unit 2.0 – 2.5 ton models 3.0 ton model
A Outside diameter of cylinder mm 57 63
B Inside diameter of cylinder mm 50 55
C Disconnect of piston rod mm 40 45
D Stroke (Lifting height 3 m) mm 1,505 ± 15
— Weight (Lifting height 3 m) kg 24.7
60-32 BE30 Series

STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
3. TILT CYLINDER (1.0 – 1.75 TON MODELS)
Symbol Item Unit Specification 1. Wiper ring

2. Cylinder head
A Outside diameter of cylinder mm 73
3. O-ring
B Inside diameter of cylinder mm 60 4. Bushing
C Diameter of piston rod mm 25 5. U-ring
6. Packing header
D Stroke mm 139
7. Snap ring
E Retracted length mm 411±2 8. Backup ring
F Inside diameter of rod bushing mm 30 9. O-ring
10. Piston rod assembly
G Inside diameter of cylinder bottom bushing mm 30
11. Cylinder
— Weight kg 8.4 12. Backup ring
— Tilt angle ° 6°/12° 13. O-ring
BE30 Series 60-33

4. TILT CYLINDER (2.0 – 3.0 TON MODELS)
1. Wiper ring
2.0 – 2.5 ton
Symbol Item Unit 3.0 ton model 2. Cylinder head
models
3. O-ring
A Outside diameter of cylinder mm 84 84 4. Bushing
B Inside diameter of cylinder mm 70 70 5. U-ring
6. Packing header
C Diameter of piston rod mm 30 30
7. Snap ring
D Stroke mm 141 157 8. Backup ring
E Retracted length mm 435 445 9. O-ring
10. Piston rod assembly
F Inside diameter of rod bushing mm 35 35
11. Cylinder
Inside diameter of cylinder 12. Backup ring
G mm 35 35
bottom bushing 13. O-ring
— Weight kg 12.3 12.6
— Tilt angle ° 6°/12° 6°/12°
60-34 BE30 Series

5. HYDRAULIC CIRCUIT DIAGRAM

Proportional solenoid valve spec.
BE30 Series 60-35

6. HYDRAULIC CIRCUIT DIAGRAM

Manual valve spec.
60-36 BE30 Series

7. WORK EQUIPMENT CONTROL LEVER

Proportional solenoid valve spec.
BE30 Series 60-37

8. WORK EQUIPMENT CONTROL LEVER

Manual valve spec.
60-38 BE30 Series

STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE
HYDRAULIC CONTROL VALVE

(Proportional solenoid valve spec.)
1. OUTLINE
This valve is a bank-type multi-control valve developed for lift truck, which controls the operating direction and
speed of each actuator according to electrical inputs.
1) Indication of model name
KMC10L–3001A
Remodeling symbol
Rotation No.
Number of spools (Example: 3)
Proportional solenoid multi-control valve for lift trucks
2) Specifications
General Max. using pressure 24.5 MPa {250 kgf/cm²}
specifica- Max. flow rate 70 l/min
tions Allowable back pressure 0.9 MPa {10 kgf/cm²}
Applicable hydraulic oil Mineral hydraulic oil, ISO VG32 or equivalent
Allowable contamination level of hydraulic oil Max. NAS Class 10
Using temperature range -20 – +90 °C
Applicable visibility range 5 – 500mm²/s (cSt)
Electrical Rated current 0.7 A
specifica- Recommended dither 100 Hz, 180 – 200mApp
tions Coil resistance 17.5 ± 0.5 Ω
3) Hydraulic circuit diagram

(KMC10L-3001)
BE30 Series 60-39

HYDRAULIC CONTROL VALVE STRUCTURE AND FUNCTION
4) Component parts and their functions

No. Name Function
1 Main control valve Controls direction and flow rate to each actuator port and holds them in neutral.
2 Main relief valve Restricts maximum using pressure of circuit.
Lift lock valve
3 Prevents leakage while lift valve is held in neutral.
(Pilot spool)
Lift lock valve
4 Prevents leakage while lift valve is held in neutral.
(Main plunger)
5 Load check valve Prevents back-flow from load port.
Tilt lock valve
6 Prevents leakage while tilt valve is held in neutral.
(Pilot spool)
Tilt lock valve
7 Prevents leakage while tilt valve is held in neutral.
(Main plunger)
Proportional pressure Generates secondary pilot pressure according to electrical input and controls
8
reducing solenoid valve stroke of main control valve spool.
Pressure reducing Keeps primary pressure of proportional pressure reducing solenoid valve at
9
valve 1.5 MPa {15 kgf/cm²}.
10 Sequence valve Secures primary pressure of pressure reducing valve in unload state.
11 Port relief valve Restricts maximum using pressure of installation port (attachment).
5) Explanation of terms
Circuit to regulate oil flowing in a cylinder with a flow rate control valve (bleed-
Bleed-off circuit
off control section) installed in parallel with the cylinder.
Circuit to adjust flow rate on the inlet side of a cylinder to control the speed with
Meter-in circuit
a meter-in control section.
Circuit to adjust flow rate on the outlet side of a cylinder to control the speed
Meter-out circuit
with a meter-out control section.
High-frequency vibration given to the spool of a proportional solenoid valve to
Dither
reduce effects of friction and fixing to stabilize the performance.
1. Emergency manual lowering valve 3. Lift spool

2. Main relief valve 4. Tilt spool
60-40 BE30 Series

2. SECTION OF PROPORTIONAL SOLENOID VALVE
1. Main control valve 7. Tilt lock valve (Main puunger)

2. Main relief valve 8. Proportional pressure reducing
3. Lift lock valve (pilot spool) solenoid valve
4. Lift lock valve (Main plunger) 9. Pressure reducing valve
5. Load check valve 10. Sequence valve
6. Tilt lock valve (Pilot spool) 11. Port relief valve
BE30 Series 60-41

3. EXPLANATION OF OPERATION
(1) Operation of main control valve

The oil discharged from the hydraulic port is divided by end section (5) for bypass passage (1) and parallel
passage (4).
1) When in neutral
Bypass passage (1) is connected to the tank through sequence valve (3) of end section (2). At this time,
sequence valve (3) secures the unload pressure (2.0 MPa {20 kgf/cm²}). Parallel passage (4) passes
through each valve section and then it is blocked by end section (2). The main spool is held in neutral
by the force of the return spring.
60-42 BE30 Series

2) When fork is raised

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

2a. Solenoid B. B side
2b. Solenoid C. Parallel passage
3. Load check valve D. Meter-out control section
4a. Return spring E. Meter-in control section
4b. Return spring F. Bleed-off control section
5. Main spool (Lift) G. Bypass passage
6. Lift lock valve (Pilot spool)
7. Lift lock valve (Main plunger)
8. Screw (For emergency operation)
BE30 Series 60-43

3) When fork is lowered

• If the lift lever is operated (in the LOWER direction), a current flows in solenoid (2b) and the propor-
tional pressure reducing valve generates pilot pressure according to the command current (lever an-
gle), and then the pilot spool of lift lock valve (6) moves. If notch k1 of the pilot spool of lift lock valve
(6) is opened, the main plunger of lift lock valve (7) is pushed up. (For the operation of the lift lock
valve, see page 60-48.)
If the pilot spool of lift lock valve (6) moves, main spool (5) moves toward A side.
• As main spool (5) moves, port A1 is connected to the tank through meter-out control section D and
the oil in lift cylinder (1) returns to the tank.
The flow rate at this time is controlled by meter-out control section D, according to the input current
(lift lever angle).
• Connection to meter-out control section D is made after the main plunger of lift lock valve (7) is
opened.
60-44 BE30 Series

4) When mast is tilted backward

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

3. Load check valve Da. Meter-out control section
4a. Return spring Db. Meter-out control section
4b. Return spring Ea. Meter-in control section
5. Main spool Eb. Meter-in control section
6. Tilt lock valve (Pilot spool) F. Bleed-off control section
7. Tilt lock valve (Main plunger) G. Bypass passage
BE30 Series 60-45

5) When mast is tilted forward

• If the tilt lever is operated (in the FORWARD direction) and a current flows in solenoid (2b), the pro-
portional pressure reducing valve generates pilot pressure according to the command current (lever
angle), and then the pilot spool of tilt lock valve (6) moves. If the notch of the pilot spool of tilt lock
valve (6) is opened, the main plunger of tilt lock valve (7) is pressed in the direction of the arrow. (For
the operation of the tilt lock valve, see page 60-48.)
If the pilot spool of tilt lock valve (6) moves, main spool (5) moves toward A side.
Then, the parallel port C is connected to port B2 by meter-in control section Eb, and port A2 is con-
nected to the tank passage by meter-out control section Da. The oil from the parallel port C presses
the main plunger of tilt lock valve (7) in the direction of the arrow and it is discharged through port B2
into the bottom side of tilt cylinder (1). (Operation to tilt the mast forward)
• The oil returning from the tilt cylinder is discharged into the tank passage through port A2 and meter-
out control section Da. The flow rate at this time is controlled by bleed-off control section F, meter-
in control section Eb, and mater-out control section Da, according to the input current.
• Connection to the meter-in and meter-out control sections is made after the main plunger of tilt lock
valve (7) is opened.
60-46 BE30 Series

6) When attachment is operated

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

3. Load check valve Da. Meter-out control section
4a. Return spring Db. Meter-out control section
4b. Return spring Ea. Meter-in control section
5. Main spool Eb. Meter-in control section
F. Bleed-off control section
G. Bypass passage
BE30 Series 60-47

(2) Operation of lift lock valve

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

If the pump pressure rises and PP (= P13) exceeds load pressure PL, the main plunger of lift lock valve
(7) moves in the direction of the arrow to open the pot.
60-48 BE30 Series

3) When fork is lowered (Lift down)

• As the secondary pressure of the proportional pressure reducing valve rises, the pilot spool of lift lock
valve (6) moves in the direction of the arrow and port B is connected to port C of the tank passage.
As a result, load pressure PL applied to the area difference between D12 and D11 pushes up the
main plunger of lift lock valve (7) in the direction of the arrow.
a While the oil is flowing, the pressure on the narrower area ( D11) side is lower.
At this time, oil flows at a constant rate through orifice a of the main plunger of lift lock valve (7) to
port C.
4) Emergency operation
• When the fork cannot be lowered from a high position because of a trouble in the main spool (Hy-
draulic system), etc., it can be lowered by tightening screw (8) as an emergency measures. If screw
(8) is tightened, the pilot spool of lift lock valve (6) is moved to lower the fork.
• At this time, the main spool does not move and the oil flows through only orifice a. Accordingly, the
oil flow rate is kept constant, thus the lowering speed of the fork is kept constant.
Do not take this emergency measures against a mechanical trouble such as foreign matter caught in
the mast rails or rollers. When lowering the fork by this measures, check the condition of the cargo
and working place and take care of the safety extremely.
BE30 Series 60-49

(3) Operation of tilt lock valve

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

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

If the pump pressure rises and PP (= P23) exceeds load pressure PT, the main plunger of tilt lock valve
(7) moves in the direction of the arrow to open the pot.
60-50 BE30 Series

(4) Operation of pressure reducing valve and se-

quence valve
1) Operation of pressure reducing valve
The secondary pressure of the pressure re-
ducing valve, or the pressure in port A is ap-
plied through passage B to port C. Spool (1)
of the pressure reducing valve reduces the
primary pressure (pump pressure) so that the
pressure in port C applied to the sectional
area of the spool will be balanced with the
force of spring (2) of the pressure reducing
valve. That is, the secondary pressure of the
pressure reducing valve in port A will be kept
at a constant pressure (1.5 MPa {15 kgf/cm²})
decided by the spring force.
2) Operation of sequence valve
When the main control valve unloads or the
fork is "lowered", the sequence valve oper-
ates as described below to secure the prima-
ry pressure of the pressure reducing valve.
The pressure in port D is sent through pas-
sage E to port F. The secondary pressure of
the pressure reducing valve is sent through
passage H to spring port G. Accordingly,
when oil flows from port P through port D and
main spool (3) to port J, the pressure in port
D is kept as shown below even if main spool
(3) is unloading.
• Secondary pressure of pressure reduc-
ing valve (1.5 MPa {15 kgf/cm²}) + Force
of sequence valve spring (4) (0.5 MPa {5
kgf/cm²}) = 2.0 MPa {20 kgf/cm²})
BE30 Series 60-51

(5) Operation of proportional pressure reducing solenoid valve

• While a current is not flowing in proportional solenoid (5), pressure reducing valve spool (4) is kept in
contact with the end face of the proportional solenoid by spring force Fs. Under this condition, ports B
and A are shut off from each other by land 1 (2) of pressure reducing valve spool (4), and port A is con-
nected to port C which is connected to the drain passage. Accordingly, the pressure in the drain passage
is applied to port A.
• If a current flows in proportional solenoid (5) and attractive force Fi becomes larger than spring force Fs,
pressure reducing valve spool (4) moves. Ports B and A are connected to each other by notch 1 (3),
and the passages of ports A and C are choked by land 2 (1) and notch 2 (6). Accordingly, the pressure
(secondary pressure) in port A rises. Since diameter of D1 of land 1 (2) is larger than diameter D2 of
land 2 (1) at this time, the hydraulic pressure against attractive force Fi of the solenoid is applied to pres-
sure reducing valve spool (4).
• As pressure reducing spool (4) moves, Fh rises. When Fh + Fs = Fi, the spool is stopped and balanced.
In this way, secondary pressure P2 is kept in almost proportion to attractive force Fi of the solenoid.
1. Land 2 ( D2)
2. Land 1 ( D1)
3. Notch 1
4. Pressure reducing valve spool
5. Proportional solenoid
6. Notch 2
Fh: —
Fi: Attractive force
Fs: Spring force
P1: Primary pressure
P2: Secondary pressure
60-52 BE30 Series

4. OUTSIDE VIEW OF HYDRAULIC CONTROL VALVE

(PROPORTIONAL SOLENOID VALVE)
Emergency manual lowering valve

Main relief valve
Lift spool
Tilt spool
1.
2.
3.
4.
BE30 Series 60-53

Section of proportional solenoid valve (1)

1. Take care of the fitting direction.
60-54 BE30 Series

a This drawing is for understanding of the structure of

the proportional solenoid valve. The component
parts of the proportional solenoid valve will not be
supplied singly. .
Symbol Part name Symbol Part name
101 End section (1) 511 Plunger
102 End section (2) 512 Plunger
121 Casing L 513 Plunger
122 Casing T 521 Spring
123 Casing A 522 Spring
151 Plug 523 Spring
152 Plug 551 Plug
153 Plug 552 Plug
161 O-ring 561 O-ring
163 O-ring 601 Relief valve
166 O-ring 602 Relief valve
201 End cover 611 Sequence valve spool
202 Solenoid protective cover 612 Pressure reducing valve spool (1)
211 Adjusting screw 621 Spring
212 Pilot spool (1) 622 Spring
213 Sleeve 630 Rod
214 E-ring 651 Plug
215 Spring seat 661 O-ring
216 Spring 711 Pressure reducing valve spool (2)
251 Hexagon socket head set screw 712 Pilot spool (2)
252 Ball 713 Sleeve
254 Plug 721 Spring
261 O-ring 722 Spring
262 O-ring 731 Throttle
263 O-ring 751 Plug
271 Hexagon socket head bolt 763 O-ring
272 Hexagon nut 873 Double-end stud
273 Hexagon socket head bolt 879 Hexagon nut
301 Spool (L) 880 Spring washer
302 Spool 891 Nameplate
303 Spool (T) 892 Screw
321 Spring 901 Solenoid
331 Spring seat 949 Cap housing, 6P
950 Plate, 6P cap
951 Cap housing, 4P
952 Plate, 4P cap
953 Blind plug
Tightening torque table
Symbol Thread size Tightening torque (Nm{kgcm}) Remarks
151 PT1/4 20.0 – 24.0 {200 – 240}
152 NPTF1/16 5.9 – 7.8 {60 – 80}
153 9/16-18UNF 34.0 – 38.0 {350 – 390}
213 M14×1 27.0 – 33.0 {270 – 330}
251 M6×1 1.5 – 2.5 {15 – 25}
254 M22×1 39.0 – 49.0 {400 – 500}
271 M5 5.9 – 7.8 {60 – 80}
272 M8×1 6.9 – 8.8 {70 – 90} Adjusting screw locknut
273 M5 5.9 – 7.8 {60 – 80}
551 M18×1.5 49.0 – 59.0 {500 – 600}
552 M16×1.5 39.0 – 49.0 {400 – 500}
601 M20×1.5 41.0 – 47.0 {420 – 480} Relief valve
601 M8 6.9 – 8.8 {70 – 90} Adjusting screw locknut
602 M22×1.5 39.0 – 49.0 {400 – 500} Relief valve
651 PF3/8 69.0 – 78.0 {700 – 800}
731 M4 0.5 – 0.7 {5 – 7} Apply LOCTITE #241
751 M18×1.5 49.0 – 59.0 {500 – 600}
771 M5 5.90 – 7.8 {60 – 80}
879 M8 28.0 – 32.0 {280 – 320}
901 M22×1 39.0 – 49.0 {400 – 500} Solenoid
BE30 Series 60-55

Section of proportional solenoid valve (2)
60-56 BE30 Series

.
1. Main control valve
2. Main relief valve
3. Lift lock valve (Pilot spool)
4. Lift lock (Main plunger)
5. Load check valve
6. Tilt lock valve (Pilot spool)
7. Tilt lock valve (Main plunger)
8. Proportional pressure reducing solenoid valve
9. Pressure reducing valve
10. Sequence valve
BE30 Series 60-57

WORK EQUIPMENT STRUCTURE AND FUNCTION
WORK EQUIPMENT
1. MAST (FOR 1.0 – 1.75 TON MODELS)
60-58 BE30 Series

STRUCTURE AND FUNCTION WORK EQUIPMENT
BE30 Series 60-59

2. MAST (FOR 2.0 – 2.5 TON MODELS)
60-60 BE30 Series

BE30 Series 60-61

3. MAST (FOR 3.0 TON MODEL)
60-62 BE30 Series

FB30
BE30 Series 60-63

POWER CONNECTOR FOR OPTIONAL DEVICES STRUCTURE AND FUNCTION
POWER CONNECTOR FOR

OPTIONAL DEVICES
The power connectors for optional devices are in-
stalled to 2 places of the truck body. When adding
various devices, use these connectors.
The rated current of each connector is as follows.

1. Working lamp connector
1) This connector is not interlocked with the key
switch.
2) Rated current: 5 A ( 1)
2. Spare connector (Outside relay contact)

1) This connector is interlocked with the key
switch.
2) Rated current: 2 A
1. When using the spare connector and the working

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

YAZAKI, Type CN, 2P
Wire color: White and yellow/Black
Spare connector (2):
NIHON AMP, Econoseal J Series, 2P
Wire color: Yellow and red/Black
60-64 BE30 Series

STRUCTURE AND FUNCTION CONTROL UNIT
CONTROL UNIT
1. OUTLINE AND FEATURES OF CONTROL UNIT
This control unit is used for control of the speed of the travel motor, hydraulic motor, and EPS motor, control of
the hydraulic control valve (proportional solenoid valve), control of the charger, control display of the monitor pan-
el, troubleshooting, and control communication between controllers. It consists of the following devices.
1. Controller ......................... Divided into the invert control section, contactor (operation section), and com-
mand/signal communication control section. Used for control of the drive motor,
pump motor, EPS motor, and hydraulic control valve (proportional solenoid
valve), display of monitor panel, troubleshooting, etc.
2. Forward-reverse lever..... Has a switch to select forward and reverse travels.
3. Accelerator ...................... Controls the travel speed with the voltage which changes according to the press-
ing angle of the accelerator pedal.
4. Other devices .................. Control knobs, torque sensor, travel speed sensor, etc.
Features
1. Controller
The controller is divided into the main controller
and sub controller. The sub controller consists of
2 printed circuit boards; the multi-controller board
and system controller board (Only the multi-con-
troller is used for the manual valve specification,
however).
2. Meter panel
The meter panel has functions of indicators and
tools. It shows the current condition of the lift
truck and error codes when any trouble occurs.
In addition, it indicates the operations (ON/OFF)
of the switches and various adjustment data dur-
ing testing and adjusting.
3. Adjusting functions of meter panel and con-

trol switches
(1) Adjustment by operator
Each operator can set or adjust the date,
time, acceleration time, lifting speed, tilting
speed, and travel speed limit, and can turn
ON/OFF the speed limit operation and accel-
erator neutral regeneration.
(2) Adjustment by serviceman
Each serviceman can adjust the acceleration
mode, acceleration feeling, and regenerative
braking force, display the switch (ON/OFF)
monitor, and select the display language
(Japanese/English).
BE30 Series 60-65

CONTROL UNIT STRUCTURE AND FUNCTION
2. PRINCIPLE OF CHANGE OF MOTOR SPEED

The travel motor is a 3-phase induction motor, the speed of which is controlled with an AC inverter.
An inverter is a device which converts DC power into AC power at any voltage and frequency. It inverts the bat-
tery current (DC) into a 3-phase AC by operating 3 switches, then changes the wave form (frequency and height
of the wave) of the obtained 3-phase sine-wave AC to control the motor performance.
Control of induction motor speed with inverter
1. Device to convert AC power into DC power. This is the rectifier for a battery charger.
2. Device to convert DC power into AC power. This is mounted on an AC controller.
3. CONNECTION DIAGRAM OF MOTOR POWER CIRCUIT

(CIRCUIT OF TRAVEL, HYDRAULIC, AND EPS MOTORS)
In the following diagram, the contacts of the power modules and power transistors are expressed by mechanical
contacts, and fuses, current detectors, capacitors, etc. are omitted for simplification.
The drive contactor (MD), pump contactor (MP), and EPS contactor (MPS) are normally turned OFF. They are
turned ON when the key switch is turned ON.
1. An alternating current (AC) is generated by this switch (FET) to drive the AC motor. (Input signal)
60-66 BE30 Series

4. OUTLINE OF OPERATION OF TRAVEL MOTOR

Outline of operation of travel motor (AC)
Basic opera-
No. Measures Operations, signals, etc. for execution
tion item
1 Forward and Change the F-signal or R-signal of F/R lever Forward travel Reverse travel
reverse rota- order of the O
Sine-wave currents which are Sine-wave currents which are
tion of motor 3-phase cur- The CPU sends signals to the
shifted by 120 degrees from shifted by 120 degrees from
(Forward rents sup- power module according to the re-
each other are supplied in or- each other are supplied in or-
travel and re- plied to the ceived signal to change the order
der of coils U, V, and W. der of coils W, V, and U.
verse travel) stator. of the 3-phase currents.
Period of sine wave is 360 Period of sine wave is 360
degrees. degrees.
2 Heightening Change the Accelerator voltage Motor speed Chopping speed Period of motor current
and lower- frequency of O
Low
ing of motor the 3-phase The CPU sends
speed currents sup- signals to the pow-
(Heighten- plied to the er module accord-
ing and low- stator. ing to the received
ering of voltage to change
travel speed) the frequency of
the 3-phase cur- High
rents.
3 Increase and Change the Load condition Motor Small

decrease of strength of Pressing degree of torque
motor torque the 3-phase accelerator pedal
(when pow- currents sup- Present motor cur-
er is neces- plied to the rent
sary for stator. O
starting, ac- The CPU calcu-
celeration, or lates these data
Large
traveling up- and sends signals
hill) to the power mod-
ule to change the
strength of the 3-
phase currents and
generate neces-
sary torque.
BE30 Series 60-67

(Reference) Comparison of DC motor and AC motor

Comparison item DC motor AC motor
Structure of motor Complicated Relatively simple
Rectification (Commutation) Contact type with brushes and com- Non-contact type with semiconductor
mechanism mutator devices (Single-phase or multi-phase)
Increase of output power Generally difficult Easy
Heightening of speed Difficult Easy
Lowering of speed Generally easy Generally easy
Unevenness in rotation Generally much Generally little
Unevenness in torque Generally much Generally little
Output efficiency Generally high Generally low
Control circuit Relative simple Slightly complicated
Vibration and noise during ro- Generally much Generally little
tation
Cleanliness Low High
Maintenance Brushes and commutator need main- Maintenance-free
tenance
Lifespan Short Long
5. POWER MODULE OF CONTROLLER

The switching element for the travel motor is a MOS-FET
(Metal Oxide Semiconductor-Field Effect Transistor, hereinaf-
ter, referred to as FET). This FET works similarly to the con-
ventional IGBT, transistor, etc. It can switch faster, however,
and electric circuits can be reduced in size by using it. Since Circuit board (Detail of Y portion)
a large current cannot flow through each FET element, many
FET elements are connected in parallel so that the larger cur-
rent can flow through them. A set of these elements is called
a power module.
Although the hydraulic motor is a DC motor as ever, the
switching element is replaced with an FET.
• G1, G2, and S2 are the terminals of the FET's soldered to
the circuit board. It is required to measure at the terminal
of only 1 FET (All FET's are conected to each other in the
circuit board).
• Many FET's are soldered to the back side of the circuit
board.
Circuit board
60-68 BE30 Series

6. CONTROL FUNCTIONS OF CONTROLLER
1. Change of travel direction and control of speed

The travel direction of the lift truck is changed according to the tilting direction of the forward-reverse lever.
The travel speed can be controlled steplessly with the accelerator pedal.
2. Limiting of current
The current flowing in the motor is so controlled that it will not exceed the value saved in the CPU card to
prevent breakage of the motor, FET, and IGBT.
3. Protection from temperature

The temperature sensor installed near the power module monitors temperature rise. If the temperature ex-
ceeds 100 °C, the conduction ratio is lowered to limit the output and prevent overheating.
4. Runaway prevention circuit

If the travel power module has a short circuit, this circuit turns off the travel and cargo handling functions.
5. Low-voltage protection circuit

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

Start control : Prevents an excessive current at start.
Speed control : Controls the speed according to the type of work (lifting, tilting, etc.) and control lever angle.
Note) The chopper for hydraulic equipment can lengthen the lifespan of the brushes of the motor for hydrau-
lic equipment and save energy.
BE30 Series 60-69

7. Setup function for performance characteristics

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

(1) Travel power Set the max. travel speed and accel- • Power 7, 8: Max. speed is 17 km/h, 1 – 6: Max.
(1 – 8) eration performance. speed is 15.5 km/h.
• As the number increases, the acceleration and
current consumption are increased.
• Gradeability is kept constant at power 1
through 8.
(2) Soft start Set the starting shock level to soft (C) • A is hard and C is soft.
characteristic through hard (A). • When high production is required or the oper-
(A – C) ator is an expert, select A. When cargo is easy
to break or fine control is necessary, select C.
(3) Acceleration Set acceleration corresponding to • Set according to the feeling of each operator.
characteristic pressing depth of accelerator pedal
(A – C) to 3 patterns. By combining this char-
acteristic with the soft start character-
istic, 9 patterns can be set up.
(4) Plugging Set the braking force applied when • When quick response is necessary, set high.
regeneration the forward-reverse lever is shifted. When cargo is easy to break, set low.
characteristic
(1 – 100)
(5) Brake Set the strength of the electric brake • To shorten the stopping distance, set high.
regeneration applied when the foot brake is When handling cargo which tumbles easily,
characteristics pressed. set low.
(1 – 100)
(6) Lifting speed Set the lifting speed • When high lifting height or high production is
adjustment required or the operator is an expert, set high.
(1 – 8) When long operating time is required or cargo
is easy to break, set low.
(7) Tilting speed Set the tilting speed • When high lifting height is not required or high
adjustment production is required or the operator is an ex-
(1 – 8) pert, set high. When high lifting height is re-
quired or the operator is not skilled or cargo is
easy to break, set low.
(8) Slope Set slow or fast travel on a downhill • Set 2 = ON for safety, even if the slope is
regeneration road. gentle.
(ON/OFF) • When driving downhill by coasting, depending
on the type of work, set 1 = OFF.
• If 2 = ON is set, travel speed is limited to 1 – 2
km/h, regardless of position of the forward-re-
verse lever. (This does not function when the
forward-reverse lever is in neutral.)
(9) Accelerator neu- Set the strength of the electric brake • To apply the electric brake when the accelera-
tral regeneration applied when the accelerator pedal is tor pedal is released, set this characteristic.
characteristic released (equivalent to the strength • When quick response is necessary, set high.
(1 – 100) of an engine used as a brake). • When coasting is necessary or cargo is easy
to break, set low.
(10) Other characteristics
• Attachment speed, travel speed limit, and overspeed alarm
60-70 BE30 Series

STRUCTURE AND FUNCTION OPERATING DEVICE
OPERATING DEVICE (METER PANEL, SWITCHES, ETC.)

1. NAME OF EACH DEVICE
For detailed explanation of each device and how to operate it, see the operation manual.
Lift truck with proportional Lift truck with manual valve

solenoid valve specification specification
1. Key switch 7. Accelerator pedal

2. Forward-reverse lever 8. Brake pedal
3. Meter panel 9. Steering column lock lever
4. Parking brake lever 10. Lift lever
5. Horn button 11. Tilt lever
6. Combination switch 12. Emergency stop switch
BE30 Series 60-71

OPERATING DEVICE STRUCTURE AND FUNCTION
2. HOW TO START HOUR METER

The hour meter is turned OFF when the lift truck is
shipped. After the lift truck is delivered, remove the
left side cover of the truck body and connect the con-
nector for starting the hour meter shown below.
This illustration shows Japanese spec.
1. Wire color for 1 ton series.

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

LEVEL INDICATOR FUNCTION OFF
• If the electrolyte level indicator function is not
necessary, disconnect yellow/blue wire B on the
battery and connect it to yellow/red wire A.
• This is effective when a battery having no electro-
lyte level sensor is necessary for some reason.
60-72 BE30 Series

4. HOW TO OPERATE LIFT INTERRUPT

FUNCTION
What is lift interrupt function

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

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

If the wires Br – YR shown at right are discon-
nected, the lift interrupt function operates. If
those wires are connected again, the lift interrupt
function does not operate.
BE30 Series 60-73

5. REFERENCE FOR ADJUSTMENT OF TRAVEL CHARACTERISTIC
Reference data for adjustment of acceleration and deceleration of BE30 Series travel system
Travel operation
Adjustment value
BE30 Series Competitors
Truck characteristic and
Item to be adjusted
controller characteristic When car- During
When
go is easy power Toyota Nichiyu
shipped
to break travel
1) Travel power
(Set in operator 4 8 6 8 8
mode)
2) Soft start Shock and rise of speed at start

characteristic of truck can be changed by C A B A C
changing rise of output charac-
Start
(Set in dealer mode)

teristic of controller.
3) Accelerator
C A B C A
characteristic
Speed when accelerator pedal

is pressed halfway is adjusted.
4) Plugging regenerative 1 ton
55% 100% 100% 55% 100%
characteristic Series
Since data of 2 ton
2 ton
models of competitors Stopping distance 55% 100% 100%
Series
are not available, ad- by plugging is
just for each truck. changed.
(Current must not ex-
ceed range shown at
right.)
Stop
5) Brake regenerative 1 ton

30% 60% 60% 40% 56%
characteristic Series
Since data of 2 ton
models of competitors Stopping distance 2 ton
30% 60% 60%
Series
are not available, ad- by brake is
just for each truck. changed.
(Current must not ex-
ceed range shown at
right.)
60-74 BE30 Series

6. MATER PANEL DISPLAY
BE30 Series 60-75

7. METER PANEL FUNCTIONS

Meter panel analyzer functions and operations table
Q : STD E : If equipped
w : STD (User’s adjusting function) e : If equipped (Dealer’s adjusting function)
q : STD (Dealer’s adjusting function)
q : New function
Serviceability
Operability
No. Item No. Function/contents Operation/handling division

Visibility
Safety
Appearance
q q q 1 Display type Segment & partial dot type

2 Used for both counter and reach Q
Q 3 Back light Q
Q 4 Speed meter Q
q 5 Trip meter (integrated travel distance) e
Q 6 Key ON time Q
q 7 Travel motor power ON time Q (key SW: ON o Extinguished)
meter
Hour
q 8 Hydraulic motor power ON time Q (key SW: ON o Extinguished)

9
q 10 Date/time (calender & clock) w
Q 11 BDI (battery residual capacity meter) Q (10 steps)
Q Q 12 Acceleration time adjustment w (8 steps)
q 13 Acceleration mode adjustment q (10 choices)
q 14 Acceleration feeling adjustment q (10 choices)
Adjusting function
Q Q 15 Regenerative braking power adjustment q (8 steps)

Q 16 Lift speed adjustment w (8 steps)
Q 17 Tiltt speed adjustment w (8 steps)
Functional division
Q 18 ATT speed adjustment e (8 steps)

Q 19 Travel limit speed setting w
2 q 20 Overspeed alarm travel speed setting E
21
Q Q 22 Troubleshooting display Q
shooting
Trouble-
q q 23 Corrective measure message display Q

Q 24 SW (I/O) monitor display q
25
Q 26 Battery overdischarge alarm Q
cator
Indi-
Q 27 Battery liquid shortage Q

Q 28 Parking lever non-return alarm Q
Q 29 Battery oversidcharge alarm Q
Q 30 Battery liquid level Q
q 31 E
Alarm
Overspeed alarm
Q 32 Neutral return alarm Q
Q 33 Parking lever non-return alarm Q
34
Q Q 35 Speed limlt operation ON/OFF selection w
q 36 Accelerator neutral regeneration ON/OFF selection w
q q q 37 Language display selection q
60-76 BE30 Series

8. DISPLAY IN EACH MODE
Detailed contents of display
Mode Ordinary A or B mode display
BE30 Series
No. Item Contents of display Display example
1 Travel speed The travel speed is displayed according to When the travel speed is 9.1 km/h:
display the travel speed signal of the travel speed 1) When travel speed is 0 km:
sensor. (Display code: U07) Display: 0 km/h
2) The travel speed is displayed by rounding up. (7-
segment, 2-digit)
A. Lights up portion
B. Printed portion
2 Travel speed limit Display code: U08 On the standard screen:

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

screen, W1 or W2 is not displayed.
OPERATING DEVICE
60-77
60-78
3 BDI display Display code: U06 In the 50% discharged status: (S1 to S5 light
(Battery residual up.)
capacity display)
OPERATING DEVICE
Note: When the current mode is

changed into any adjustment
mode, this is not displayed.
4 Parking brake Display code: U10

display Part P, W2 is caused to blink by the parking brake SW signal.
1) Blinking interval: A When the travel speed is 0 km/h:
2) Parking brake switch: OFF o blinking Parking brake: ON
Parking brake switch: ON o extinguished Part P: Blinking
3) When part P, W2 blinks:
If the parking brake "ON" Eand the travel speed of 1
km/h or more are continued for 1 s or more, an alarm
sound will be output. (Interval: B)
To clear this status, reset the parking lever or accelerator
pedal to the original status.
Note: This is not displayed when the cur-

rent mode is changed into any
adjustment mode.
BE30 Series
BE30 Series
5 Travel power Display code: U09 Set travel power value: +4
display (T1 to T4 light up.)
Note: This is not displayed when the current

mode is changed into any adjustment
mode.
6 Clock and calendar Display code: U14 Date/time data is displayed in the dot matrix June 10, 1997, Tuesday, 17 hours and 00
display area shown in the figure at left. (Alphanu- minute
meric characters)
‘ 9 7 – 6 – 1 0 TUE 1 7 : 0 0
Display item
TOTAL 1 9 9 9 9 . 9 h
Year data: 00 to 99 (in units of year)
1st and 2nd digits of year to left a The lower row is used for the hour meter
Month data: 1 to 12 (in units of month) display.
Day data: 1 to 31 (in units of day)
Day does not need to be
adjusted at end of each month
and in leap years.
Data on the day of the week:
0: SUN 4: THU
1: MON 5: FRI
2: TUE 6: SAT
3: WED
Hour data: 0 to 23 (in units of hour)
Minute data:0 to 59 (in units of minute)
OPERATING DEVICE
60-79
60-80
7 Hour meter Display code: U01 to 04 Hour meter data is displayed in the dot matrix Total travel time: 19999.9 h
display area shown in the figure at left. (Character
(key ON time) display 8, alphanumeric characters) ‘ 9 7 – 6 – 1 0 TUE 1 7 : 0 0
Display item TOTAL 1 9 9 9 9 . 9 h
OPERATING DEVICE
Key ON time (U01): a The upper row is used for the calendar
0 to 19999.9 (in units of 0.1 h) display.
Travel time (U02):
0 to 19999.9 (in units of 0.1 h)
Material-handling time (U03):
0 to 19999.9 (in units of 0.1 h)
Integrated travel distance (U04):
0 to 19999.9 km (in units of 0.1 km)
Notes:
1. The portion marked denotes OP.
2. In the standard display (calendar/hour meter display) at the key ON time except in the portion
marked , the key ON time, travel time, and material-handling time are displayed in this order.
(Each data change is made at an interval of 1 second. After completion of one cycle, only the key
ON time is displayed.)
8 Battery residual Display code: U11

liquid quantity This is displayed by the battery liquid quantity signal.
display
When the quantity of battery liquid is insufficient, E5 shown in the above figure lights up.
8A Overspeed alarm Display code: U15

When Use of Overspeed Alarm is selected, the set overspeed value is compared with the current
travel speed. If the current travel speed exceeds the set value, an alarm sound will be output.
Notes:
1. The overspeed setting range is 5 to 15 km.
2. Alarm sound: B
3. Each setting is performed in the user mode. (Display code: A08, A09)
BE30 Series
BE30 Series
9 Error display Display code: E01 to 99
Displayed according to failure occurrence F A I L URE I N CON T . ( T ) E 0 1
signal (LC dot matrix section) CA L L YOUR S ERV I CE !
Liquid crystal dot matrix area,

24 characters x 2 lines
1) Upon occurrence of a failure, the contents corresponding to a failure position of E1, and E2 to E4
is displayed.
(All the other character display areas are extinguished.)
However, it blinks for 10 s after occurrence of an failure. (Blinking interval A, alarm sound A)
2) If another failure occurs in the blinking display status, blinking will be started anew for 10 s from the
moment.
3) When multiple failures occur, the contents of display will be switched at intervals of 1 s.
4) Regarding E99 (communication error), the display is made as follows:
KEY-ON
• When a communication error occurs, E99 is always displayed as an error display.
• When a recovery is made from the communication error status, E99 is changed into the display
of the contents of communication.
However, when a communication error is recovered within 2 s after occurrence of this error, E99
will be displayed for 2 s.
KEY-OFF
• When a recovery is made from the communication error status, E99 will be changed into the dis-
play of the contents of communication. However, when a communication error is recovered
within 2 s after occurrence of this error, E99 will be displayed for 2 s.
If a communication error is recovered even after all are extinguished, the contents of communi-
cation will be displayed.
If the communication is recovered, E99 changes to the display of the contents of the communica-
tion. If the communication is recovered within 2 seconds after occurrence of the error, however,
E99 is displayed for 2 seconds.
OPERATING DEVICE
60-81
Mode Operator adjustment mode display
60-82
1 Operator adjust- Conditions for changing the standard mode to The lift speed setting is changed from 1 into 2.
ment mode the user mode:
1. F/R lever: "N" L I F T S P E E D 1 ( 1 – 8 ) A 0 3
2. All work equipment levers: "OFF" S E T L E V E L 8
OPERATING DEVICE
Conditions for changing the user mode to the Press the e button (P1) 4 times.
standard mode:
1. No adjustment operation is performed for L I F T S P E E D 2 ( 1 – 8 ) A 0 4
60 seconds or more. S E T L E V E L 8
2. One of the F/R lever and work equipment Press the MODE button (P3). After the set
lever has been operated. value lights up for 2 sec., the current item is
3. The key switch is turned off. changed into the next item.
1. Press the MODE button (P3) and select a setting item.

2. The setting enable position will blink. (A blinks.)
2.1 Use the button (P1) to change any setting.
2.2 For an item having multiple setting positions (for example, date), select it by the button (P2).
2.3 After completion of setting, proceed to the next setting item by the MODE button (P3). Upon
completion of setting, the display is continued for 2 sec and then proceeds to the next item.
Adjustable item Setting data
1. Standard display –––
O
2. Travel power setting (ES control) DRIVE POWER (1–8)
O
3. Lift 1 speed setting LIFT SPEED1 (1–8)
O
4. Lift 2 speed setting LIFT SPEED2 (1–8)
O
5. Tilt speed setting TILT SPEED (1–8)
O
6. Travel speed limit value setting SPEED LIMIT (5–15km/h)
O
7. Travel overspeed setting OVER SPEED ALARM (ON/OFF)
O
8. Accelerator neutral regeneration setting NEUTRAL REGENE.BRAKE (ON/OFF)
O
9. Current time setting PRESENT TIME
(Year, month, day of the week, time)
Note: For travel overspeed setting, set 15 km/h max.

BE30 Series
Note 1) Italic letters and capital letters shall flash.
Note 2) When an abnormality is displayed, only the error code shall be displayed and justified to the right in the spare
section of the upper line.
Note 3) Items marked with "#" in the display item column are displayed for only the counterbalanced models and those
Mode Operator adjustment mode display
BE30 Series
marked with "*" are displayed for only the reach models.

Operator adjust- Display
Display item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
ment mode code
A01 Drive power adjustment D R I V E P O W E R ( 1 – 8 ) A 0 1
(ES control knob) S E T L E V E L 8
e
A02 Charging timer setting C H G . T I M E R S E T → A 0 2
(User adjustment mode) C H G . T I M E R S E T ? N O → M O D E
A03 Lifting speed 1 setting L I F T S P E E D 1 ( 1 – 8 ) A 0 3
S E T L E V E L 8
A04 Lifting speed 2 setting L I F T S P E E D 2 ( 1 – 8 ) A 0 4
S E T L E V E L 8
A05 Tilting speed setting T I L T S P E E D ( 1 – 8 ) A 0 5
S E T L E V E L 8
A06 Travel speed limit setting S P E E D L I M I T ( 5 – 1 5 k m / h ) A 0 6
S E T S P E E D 1 5 k m / h
A07 Overspeed alarm OFF O V E R S P E E D A L A R M A 0 7
setting S E T O F F
ON O V E R S P E E D A L A R M A 0 7
S E T O N 1 5 k m / h
A08 # Acceleration OFF N E U T R A L R E G E N E B R A K E A 0 8
neutral regen- S E T O F F
eration setting ON N E U T R A L R E G E N E B R A K E A 0 8
S E T O N
A09 Present time set- Year P R E S E N T T I M E A 0 9
ting ‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Month P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Day P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Day of P R E S E N T T I M E A 0 9
week ‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Hour P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Minute P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
A10 * Acceleration A A C C E L . P W R L E V E L ( A – C ) A 1 0
characteristic S E T L E V E L A
setting B A C C E L . P W R L E V E L ( A – C ) A 1 0
S E T L E V E L B
C A C C E L . P W R L E V E L ( A – C ) A 1 0
S E T L E V E L C
A11,13 * ON/OFF setting ON F U N C T I O N 1 1 ( O N / O F F ) A 1 1
15,17,19 11 – 20 S E T O N
21,23,25 OFF F U N C T I O N 1 1 ( O N / O F F ) A 1 1
27,29 S E T O F F
A12,14 * Analog setting A F U N C T I O N 1 1 ( 1 – 1 0 0 ) A 1 2
16,18,20 11 – 20 S E T L E V E L 1 0 0
22,24,26
OPERATING DEVICE
28,30
60-83
Mode Service adjustment mode display
60-84
1 Service adjustment Conditions for changing the standard mode to The accelerator characteristic is set in the
mode the service mode: dealer mode.
1. F/R lever: "N" A C C E L . PWR L E V E L ( A – C ) D 0 9
2. All work equipment levers: "OFF" S E T L E V E L A
OPERATING DEVICE
3. Key switch with all of P1 to P3 buttons Characteristic A is reversed.

pressed: "ON"
Conditions for changing the service mode to Select Characteristic B by the button.
e
the standard mode:

A C C E L . PWR L E V E L ( A – C ) D 0 9
1. One of the F/R lever and the work equip- S E T L E V E L B
ment lever has been operated. Characteristic B is reversed.
2. The key switch is turned off.
3. A single cycle of all adjustment items is After completion of setting, the mode is
completed. returned to the standard mode.
1. Press the MODE button (P3) and select a setting item.
2. The setting enable position will blink. (A blinks.)
2.1 Use the button (P1) to change any setting.
2.2 For an item having multiple setting positions (for example, date), select it by the button (P2).
2.3 After completion of setting, proceed to the next setting item by the MODE button (P3). Upon
completion of setting, the display is continued for 2 sec and then proceeds to the next item.
Adjustable item Setting data
1. Standard display 1. – – –
O
2. Attachment speed 1 setting 2. ATT SPEED1 (1–8)
O O
O O
O O
5. FR regenerative current setting 5. FR REGENE (0–100)
O O
6. Brake regenerative current setting 6. BRAKE REGENE (0–100)
O O
7. Neutral regenerative current setting 7. NEUTRAL REGENE (0–100)
O O
8. Slope regenerative current setting 8. SLOPE REGENE (0–100)
O O
9. Soft start characteristic setting 9. SOFT START LEVEL (A, B, C)
O O
10. Accelerator characteristic setting 10. ACCEL.PWR LEVEL (A, B, C)
O O
11. Trip meter display 11. TRIP METER (ON/OFF)
BE30 Series
Note 2) When an abnormality is displayed, only the error code shall be displayed and justified to the right in the spare
section of the upper line.
Note 3) Items marked with "#" in the display item column are displayed for only the counterbalanced models and those
BE30 Series
marked with "*" are displayed for only the reach models.

Service adjustment
Display
mode Display item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
code
D01 Attachment 1 speed setting A T T S P E E D 1 ( 1 – 8 ) D 0 1
S E T L E V E L 8
D02 Attachment 2 speed setting A T T S P E E D 2 ( 1 – 8 ) D 0 2
S E T L E V E L 8
D03 # Attachment 3 speed set- A T T S P E E D 3 ( 1 – 8 ) D 0 3

ting S E T L E V E L 8
D04 FR regenerated current set- F R R E G E N E . ( 1 – 1 0 0 ) D 0 4
ting S E T L E V E L 8
D05 # Brake regenerated cur- B R A K E R E G E N E . ( 1 – 1 0 0 ) D 0 5
rent setting S E T L E V E L 8
D06 # Neutral regenerated cur- N E U T R A L R
E G E N E ( 1 – 1 0 0 ) D 0 6
D07 # Slope regenerated cur- S L O P E R E G
E N E . ( 1 – 1 0 0 ) D 0 7
D08 Soft start charac- A S O F T S T A R
T L E V E L ( A – C ) D 0 8
teristic setting S E T L E V E L A
B S O F T S T A R
T L E V E L ( A – C ) D 0 8
S E T L E V E L B
C S O F T S T A R
T L E V E L ( A – C ) D 0 8
S E T L E V E L C
D09 Accelerator char- A A C C E L . P W R L E V E L ( A – C ) D 0 9
acteristic setting S E T L E V E L A
B A C C E L . P W R L E V E L ( A – C ) D 0 9
S E T L E V E L B
C A C C E L . P W R L E V E L ( A – C ) D 0 9
S E T L E V E L C
D10 Trip meter display OFF T R I P M E T E
R D 1 0
setting I N D I C A T I O
N O F F
ON T R I P M E T E
R D 1 0
I N D I C A T I O
N O N
D11 Travel time dis- OFF T R A V E L T I
M E I N D I C A T E D 1 1
play setting I N D I C A T I O
N O F F
ON T R A V E L T I
M E I N D I C A T E D 1 1
I N D I C A T I O
N O N
D12 Cargo handling OFF H Y D . T I M E I N D I C A T E D 1 2
time setting I N D I C A T I O N O F F
ON H Y D . T I M E I N D I C A T E D 1 2
I N D I C A T I O N O N
OPERATING DEVICE
60-85
60-86
1 Service adjustment
Display
mode Display item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
code
D14 * Reach speed setting R E A C H S P E E D ( 1 – 8 ) D 1 4
S E T L E V E L 8
OPERATING DEVICE
D15 * Reach END speed setting R E A C H E N D S P E E D ( 1 – 8 ) D 1 5

S E T L E V E L 8
D16 * Reach high mast speed R E A C H H M S P E E D ( 1 – 8 ) D 1 6
setting S E T L E V E L 8
D17 * Independent plugging cur- P L U G . C U R R E N T ( 1 – 1 0 0 ) D 1 7
rent setting S E T L E V E L 1 0 0
D18 * Travel speed limit 3 set- S P E E D L I M T 3 ( 5 – 1 5 k m / h ) D 1 8
ting S E T S P E E D 1 5 k m / h
D19,21 * ON/OFF setting ON F U N C T I O N 1 ( O N / O F F ) D 1 9
23,25,27 1 – 10 S E T O N
29,31,33 OFF F U N C T I O N 1 ( O N / O F F ) D 1 9
35,37 S E T O F F
D20,22 * Analog setting 1 – 10 A F U N C T I O N 1 ( 1 – 1 0 0 ) D 2 0
24,26,28 S E T L E V E L 1 0 0
30,32,34
36,38
BE30 Series
Mode Switch monitor mode display
BE30 Series
1 Switch monitor Conditions for changing the standard mode to The tilt switch is checked in the switch monitor
mode the switch monitor mode: mode.
1. When the connector in the body harness
is opened, the standard mode will be Tilt lever: OFF
changed to the switch monitor mode.
T I L T SW C 0 7
2. The current item is changed to the next
SW : O F F
item by the MODE button.
Condition for changing the switch monitor

mode to the standard mode: Tilt lever: ON
1. The key switch is turned off after comple-
T I L T SW C 0 7
tion of checking. SW : ON
Monitoring enable item Display data (display code)

1. Directional F-SW OFF/ON (C01)
2. Directional R-SW OFF/ON (C02)
3. Accelerator SW OFF/ON (C03)
4. Brake SW OFF/ON (C04)
5. Lift 1 SW OFF/ON (C05)
6. Lift 2 SW OFF/ON (C06)
7. Tilt SW OFF/ON (C07)
8. Attachment 1 SW OFF/ON (C08)
11. Parking brake SW OFF/ON (C11)
12. Lift interrupt SW OFF/ON (C12)
13. Seat SW OFF/ON (C13)
14. Unused OFF/ON (C14)
15. Travel speed limit 2 SW OFF/ON (C15)
16. Auto lift height SW (option) OFF/ON (C16)
17. Accelerator output 0 – 100% (C17)
18. Torque sensor output 0 – 100% (C18)
OPERATING DEVICE
60-87
9. DISPLAY LIST OF METER PANEL DOT SECTION

Note 2) When an abnormality is displayed, only the error code shall be displayed and justified to the right in the
spare section of the upper line.
Note 3) Items marked with "#" in the display item column are displayed for only the counterbalanced models and
those marked with "*" are displayed for only the reach models.
Display Display
No. Display item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Remarks
mode code
1 Stan- U01 Hour meter display ‘ 9 7 – 6 – 1 0 T U E 1 7 : 0 0 —
dard (Key ON time) T O T A L 1 9 9 9 9 . 9 h
mode
2 U02 Hour meter display ‘ 9 7 – 6 – 1 0 T U E 1 7 : 0 0 U 0 2 —
(Travel time) T R A V E L 1 9 9 9 9 . 9 h
(Cargo handling time) H Y D 1 9 9 9 9 . 9 h
(Travel distance) T O T A L T R I P 1 9 9 9 9 . 9 k m
5 U05 Automatic horizontal O N A U T O H O R I Z O N T A L —
6 User ad- A01 Drive power adjustment D R I V E P O W E R ( 1 – 8 ) A 0 1 Flashing point changes to "1" through
just- (ES control knob) S E T L E V E L 8 "8", depending on setting.
ment
7 A03 Lifting speed 1 setting L I F T S P E E D 1 ( 1 – 8 ) A 0 3 Transmission data (8 levels)
mode
S E T L E V E L 8 1. 01 – 1EH 2. 1F – 28H 3. 29 – 32H
4. 33 – 3CH 5. 3D – 46H 6. 47 – 50H
8 A04 Lifting speed 2 setting L I F T S P E E D 2 ( 1 – 8 ) A 0 4
7. 51 – 5AH 8. 5B – 64H
S E T L E V E L 8
9 A05 Tilting speed setting T I L T S P E E D ( 1 – 8 ) A 0 5 Transmission data (8 levels)
S E T L E V E L 8 1. 01 – 10H 2. 11 – 1CH 3. 1D – 28H
4. 29 – 34H 5. 35 – 40H 6. 41 – 4CH
7. 4D – 58H 8. 59 – 64H
10 A06 Travel speed limit settingS P E E D L I M I T ( 5 – 1 5 k m / h ) A 0 6 —
S E T S P E E D 1 5 k m / h
11 A07 Overspeed alarm OFF O V E R S P E E D A L A R M A 0 7 Flashing point changes between OFF
setting S E T O F F and ON, depending on setting.
ON O V E R S P E E D A L A R M A 0 7
S E T O N 1 5 k m / h
12 A08 # Acceleration OFF N E U T R A L R E G E N E B R A K E A 0 8 Flashing point changes between OFF
neutral regen- S E T O F F and ON, depending on setting.
eration setting
ON N E U T R A L R E G E N E B R A K E A 0 8
S E T O N
13 A09 Present time set- Year P R E S E N T T I M E A 0 9 —
ting ‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Month P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Day P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Day of P R E S E N T T I M E A 0 9
week ‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Hour P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
Minute P R E S E N T T I M E A 0 9
‘ 0 1 – 1 0 – 1 0 M O N 1 2 : 0 0
14 A10 * Acceleration A A C C E L . P W R L E V E L ( A – C ) A 1 0 —
characteristic S E T L E V E L A
setting
B A C C E L . P W R L E V E L ( A – C ) A 1 0
S E T L E V E L B
C A C C E L . P W R L E V E L ( A – C ) A 1 0
S E T L E V E L C
15 A11,13 * ON/OFF set- ON F U N C T I O N 1 1 ( O N / O F F ) A 1 1 • Flashing point changes between
15,17,19 ting S E T O N OFF and ON, depending on setting.
21,23,25 11 – 20 • Nos. 22 – 24 of upper line indicate
OFF F U N C T I O N 1 1 ( O N / O F F ) A 1 1
27,29 display code.
S E T O F F
16 A12,14 * Analog setting A F U N C T I O N 1 1 ( 1 – 1 0 0 ) A 1 2 • Nos. 22 – 24 of upper line indicate
16,18,20 11 – 20 S E T L E V E L 1 0 0 display code.
22,24,26
28,30
17 Switch C01 Directional ON D I R E C T I O N A L S W ( F ) C 0 1 ON or OFF is displayed, depending on
moniter F SW S W : O N state of SW.
mode
OFF D I R E C T I O N A L S W ( F ) C 0 1 ON or OFF is displayed, depending on
S W : O F F state of SW.
18 C02 Directional D I R E C T I O N A L S W ( R ) C 0 2 ON or OFF is displayed, depending on
R SW S W : O N state of SW.
60-88 BE30 Series

Display Display
mode code
19 Switch C03 Accelerator switch A C C E L E R A T O R S W C 0 3 ON or OFF is displayed, depending on
moniter S W : O N state of SW.
mode
20 C04 Brake switch B R A K E S W C 0 4 ON or OFF is displayed, depending on
S W : O N state of SW.
21 C05 Lift switch 1 L I F T 1 S W C 0 5 ON or OFF is displayed, depending on
22 C06 Lift switch 2 L I F T 2 S W C 0 6 ON or OFF is displayed, depending on
23 C07 Tilt switch T I L T S W C 0 7 ON or OFF is displayed, depending on
24 C08 Attachment 1 SW A T T 1 S W C 0 8 ON or OFF is displayed, depending on
25 C09 Attachment 2 SW A T T 2 S W C 0 9 ON or OFF is displayed, depending on
26 C10 # Attachment 3 SW A T T 3 S W C 1 0 ON or OFF is displayed, depending on
27 C11 Parking SW P A R K I N G B R A K E S W C 1 1 ON or OFF is displayed, depending on
28 C12 Lift interrupt SW L I F T I N T E R R U P T S W C 1 2 ON or OFF is displayed, depending on
29 C13 # Seat SW S E A T S W C 1 3 ON or OFF is displayed, depending on
30 C14 (Blank) C 1 4 ON or OFF is displayed, depending on
state of SW.
31 C15 Travel speed limit 2 T R A V E L S P E E D L I M I T 2 C 1 5 ON or OFF is displayed, depending on
32 C16 Lifting height SW L I F T H E I G H T S W C 1 6 ON or OFF is displayed, depending on
33 C17 Accelerator output A C C E L E R A T O R O U T P U T C 1 7 Changes to "0" through "100", depend-
O U T P U T : 1 0 0 % ing on condition of accelerator.
34 C18 Torque sensor output T O R Q U E S E N S O R O U T P U T C 1 8 Changes to "0" through "100", depend-
35 C19 * Reach (Reach IN) SW R E A C H S W C 1 9 ON or OFF is displayed, depending on
36 C20 * Reach OUT SW R E A C H O U T S W C 2 0 ON or OFF is displayed, depending on
37 C21 * Reach IN END SW R E A C H I N E N D S W C 2 1 ON or OFF is displayed, depending on
38 C22 * Reach OUT END SW R E A C H O U T E N D S W C 2 2 ON or OFF is displayed, depending on
39 C23 * Cargo handling high mast R E A C H H I G H M A S T S W C 2 3 ON or OFF is displayed, depending on
(Reach H. M) SW S W : O N state of SW.
40 C24 * Travel speed limit 3 SW T R A V E L S P E E D L I M I T 3 C 2 4 ON or OFF is displayed, depending on
41 C25 * Battery pull-out interlock B A T T E R Y I N T E R L O C K S W C 2 5 ON or OFF is displayed, depending on
SW S W : O N state of SW.
42 C26 * Tire wear prevention SW T I R E W E A R P R E V E N T S W C 2 6 ON or OFF is displayed, depending on
43 C27 * SW spare 1 SW S P A R E S W 1 C 2 7 ON or OFF is displayed, depending on
52 C36 * SW spare 10 SW S P A R E S W 1 0 C 3 6 ON or OFF is displayed, depending on
BE30 Series 60-89

Display Display
mode code
55 C39 * Analog spare 1 S P A R E A N A L O G S W 1 C 3 9 Changes to "0" through "100", depend-
56 C40 * Analog spare 2 S P A R E A N A L O G S W 2 C 4 0 Changes to "0" through "100", depend-
57 Dealer’s D01 Attachment 1 speed setting A T T S P E E D 1 ( 1 – 8 ) D 0 1 Flashing point changes to "1" through
adjust- S E T L E V E L 8 "8", depending on setting.
ment
58 D02 Attachment 2 speed setting A T T S P E E D 2 ( 1 – 8 ) D 0 2 Flashing point changes to "1" through
mode
S E T L E V E L 8 "8", depending on setting.
59 D03 # Attachment 3 speed set- A T T S P E E D 3 ( 1 – 8 ) D 0 3 Flashing point changes to "1" through
ting S E T L E V E L 8 "8", depending on setting.
60 D04 FR regenerated current set- F R R E G E N E . ( 1 – 1 0 0 ) D 0 4 Flashing point changes to "1" through
ting S E T L E V E L 8 "100", depending on setting.
61 D05 # Brake regenerated cur- B R A K E R E G E N E . ( 1 – 1 0 0 ) D 0 5 Flashing point changes to "1" through
rent setting S E T L E V E L 8 "100", depending on setting.
62 D06 # Neutral regenerated cur- N E U T R A L R E G E N E ( 1 – 1 0 0 ) D 0 6 Flashing point changes to "1" through
63 D07 # Slope regenerated cur- S L O P E R E G E N E . ( 1 – 1 0 0 ) D 0 7 Flashing point changes to "1" through
64 D08 Soft start charac- A S O F T S T A R T L E V E L ( A – C ) D 0 8 Flashing point changes to "A", "B", or
teristic setting S E T L E V E L A "C", depending on setting.
B S O F T S T A R T L E V E L ( A – C ) D 0 8
S E T L E V E L B
C S O F T S T A R T L E V E L ( A – C ) D 0 8
S E T L E V E L C
65 D09 Accelerator char- A A C C E L . P W R L E V E L ( A – C ) D 0 9 Flashing point changes to "A", "B", or
acteristic setting S E T L E V E L A "C", depending on setting.
B A C C E L . P W R L E V E L ( A – C ) D 0 9
S E T L E V E L B
C A C C E L . P W R L E V E L ( A – C ) D 0 9
S E T L E V E L C
66 D10 Trip meter display OFF T R I P M E T E R D 1 0 Flashing point changes between OFF
setting I N D I C A T I O N O F F and ON, depending on setting.
ON T R I P M E T E R D 1 0
67 D11 Travel time dis- OFF T R A V E L T I M E I N D I C A T E D 1 1 Flashing point changes between OFF
play setting I N D I C A T I O N O F F and ON, depending on setting.
ON T R A V E L T I M E I N D I C A T E D 1 1
68 D12 Cargo handling OFF H Y D . T I M E I N D I C A T E D 1 2 Flashing point changes between OFF
time setting I N D I C A T I O N O F F and ON, depending on setting.
ON H Y D . T I M E I N D I C A T E D 1 2
69 D14 * Reach speed setting R E A C H S P E E D ( 1 – 8 ) D 1 4 Flashing point changes to "1" through
70 D15 * Reach END speed setting R E A C H E N D S P E E D ( 1 – 8 ) D 1 5 Flashing point changes to "1" through
71 D16 * Reach high mast speed R E A C H H M S P E E D ( 1 – 8 ) D 1 6 Flashing point changes to "1" through
setting S E T L E V E L 8 "8", depending on setting.
72 D17 * Independent plugging cur- P L U G . C U R R E N T ( 1 – 1 0 0 ) D 1 7 Flashing point changes to "1" through
rent setting S E T L E V E L 1 0 0 "100", depending on setting.
73 D18 * Travel speed limit 3 set- S P E E D L I M T 3 ( 5 – 1 5 k m / h ) D 1 8 —
ting S E T S P E E D 1 5 k m / h
74 D19,21 * ON/OFF setting ON F U N C T I O N 1 ( O N / O F F ) D 1 9 Flashing point changes between OFF
23,25,27 1 – 10 S E T O N and ON, depending on setting.
29,31,33 OFF F U N C T I O N 1 ( O N / O F F ) D 1 9
35,37 S E T O F F
75 D20,22 * Analog setting 1 – 10 A F U N C T I O N 1 ( 1 – 1 0 0 ) D 2 0 —
24,26,28 S E T L E V E L 1 0 0
30,32,34
36,38
76 Failure F01 Failure record display F A I L U R E R E C O R D F 0 1 —
record (** is error code) E * * 1 9 9 9 9 . 9 h
mode
77 Failure E01 Failure display F A I L U R E I N C O N T . ( T ) E 0 1 —
mode C A L L Y O U R S E R V I C E !
60-90 BE30 Series

Display Display
mode code
78 Failure E02 Failure display F A I L U R E I N C O N T . ( T ) E 0 2 —
mode C A L L Y O U R S E R V I C E !
79 E03 Failure display F A I L U R E I N C O N T . ( T ) E 0 3 —
C A L L Y O U R S E R V I C E !
97 E21 Failure display B A T T E R Y P O W E R D O W N ( T ) E 2 1 —
C H A R G E B A T T E R Y !
99 E23 Failure display N E U T R A L S A F E T Y ( T ) E 2 3 —
R E T U R N A L L T O N E U T R A L !
100 E24 Failure display O V E R W O R K N G ( T ) E 2 4 —
C A U T I O N ! O V E R H E A T !
101 E25 Failure display O V E R W O R K N G ( T ) E 2 5 —
101A E26 Failure display C O N T . O V E R H E A T ( T ) E 2 6 —
S T O P O P E R A T ! C O O L C O N T . !
101B E27 Failure display F A I L U R E I N M O T O R ( T ) E 2 7 —
101C E28 Failure display M O T O R O V E R H E A T ( T ) E 2 8 —
S T O P O P E R A T ! C O O L M O T O R !
101D E29 Failure display F A I L U R E I N C O N T . ( T ) E 2 9 —
102 E30 Failure display F A I L U R E I N C O N T . ( P ) E 3 0 —
R E S E T E M E R G E N C Y S W
BE30 Series 60-91

Display Display
mode code
108 Failure E36 Failure display F A I L U R E I N C O N T .
P ) ( E 3 6 —
mode C A L L Y O U R S E R V I ! C E
109 E37 Failure display F A I L U R E I N C O N T .
P ) ( E 3 7 —
C A L L Y O U R S E R V I ! C E
P ) ( E 3 8 —
111 E39 Failure display C O N T . O V E R H E A T ) ( P E 3 9 —
S T O P O P E R A T ! C O O L
C O N T . !
T ) ( E 4 0 —
112A E41 Failure display F A I L U R E I N M O T O R
T ) ( E 4 1 —
112B E42 Failure display F A I L U R E I N M O T O R
T ) ( E 4 2 —
112C E43 Failure display F A I L U R E I N C O N T .
T ) ( E 4 3 —
112D E44 Failure display F A I L U R E I N C O N T .
T ) ( E 4 4 —
112E E45 Failure display F A I L U R E I N C O N T .
T ) ( E 4 5 —
112F E46 Failure display E R R O R ( P ) E 4 6 —
– E48 C A L L Y O U R S E R V I C E !
112G E49 Failure display O P E R A T I O N M I S T A K E ( P ) E 4 9 —
O P E R A T E A G A I N !
113 E50 Failure display F A I L U R E I N C O N T . ( E P S ) E 5 0 —
118 E55 Failure display O V E R W O R K N G ( P ) E 5 5 —
118A E56 Failure display F A I L U R E I N C O N T . ( P ) E 5 6 —
119 E57 Failure display E R R O R ( E P S ) E 5 7 —
119A E59 Failure display F A I L U R E I N C O N T . ( B D I ) E 5 9 —
120 E60 Failure display N E U T R A L S A F E T Y E 6 0 —
R E T U R N A L L T O N E U T R A L !
121 E61 Failure display F A I L U R E I N S U B C O N T . E 6 1 —
123 E63 Failure display O P E R A T I O N M I S T A K E E 6 3 —
124 E64 Failure display S T O P A N G L E I N C O R R E C T E 6 4 —
125 E65 Failure display O N T I L T H O R I Z O N T A L E 6 5 —

127 E68 Failure display O P E R A T I O N M I S T A K E E 6 8 —
128 E69 Failure display S T O P A T L O W E R H E I G H T E 6 9 —
129 E70 Failure display S T O P A T O V E R H E I G H T E 7 0 —
130 E71 Failure display H E I G H T L I M I T E R R O R E 7 1 —
131 E72 Failure display E R R O R ( S U B C O N T ) E 7 2 —
60-92 BE30 Series

Display Display
mode code
133 Failure E88 Failure display O N A U T O H O R I Z O N T A L E 8 8 —
mode N O F U N C T I O N E L S E
135 E90 Failure display F A I L U R E I N C H A R G E R E 9 0 —
142 E97 Failure display C O M M U N I C A T I O N E R R O R E 9 7 —
145 * E100 Failure display E R R O R E 1 0 0 Spare code (Nos. 21 – 24 of upper line
– E127 C A L L Y O U R S E R V I C E ! indicate display code.)
BE30 Series 60-93

70. TROUBLESHOOTING
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70- 2 Electric circuit diagram . . . . . . . . . . . . . . . . . 70-55

Self-diagnosis function . . . . . . . . . . . . . . . . . . .70- 2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-55
Action to take when failure code is displayed .70- 2 Proportional solenoid valve spec. . . . . . . . . . . 70-59
Control block diagram . . . . . . . . . . . . . . . . . . .70- 3 Manual valve spec. . . . . . . . . . . . . . . . . . . . . . 70-63
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .70- 4
Sub controller . . . . . . . . . . . . . . . . . . . . . . . . . 70-65
Main controller . . . . . . . . . . . . . . . . . . . . . . . .70- 6 Check before troubleshooting . . . . . . . . . . . . . 70-65
Checking electric parts of controller Troubles, the failure codes of which are not
(1.0 - 2.5 ton models) . . . . . . . . . . . . . . . . . . . .70- 6 displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-66
Checking electric parts of controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 70-67
(3.0 ton model) . . . . . . . . . . . . . . . . . . . . . . . . .70- 7
Looseness of fitting parts and defective Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 70-71
contact of connectors . . . . . . . . . . . . . . . . . . .70- 8 Precautions to take when failure code is
Checking parts installed to vehicle . . . . . . . . .70- 8 displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71
Removing CPU board . . . . . . . . . . . . . . . . . . .70- 8 Troubles that are not displayed . . . . . . . . . . . . 70-71
Preparing for checking voltage and current . . .70- 9 Failure codes list (1.0 - 2.5 ton models) . . . . . 70-73
Checking battery voltage . . . . . . . . . . . . . . . . .70- 9 Failure codes list (3.0 ton model) . . . . . . . . . . 70-84
Checking fuse for travel (F1), fuse for
hydraulic pressure (F2), fuse for EPS (F3) Self-diagnosis logic table
and fuse for charging (F4). . . . . . . . . . . . . . . .70-10 (1.0 - 3.0 ton models). . . . . . . . . . . . . . . . . . . 70-95
Checking current detectors for travel
(CSDU and CSDW) . . . . . . . . . . . . . . . . . . . .70-11 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . 70-101
CPU boad connector position and connector Troubles and remedy for them . . . . . . . . . . . 70-101
pin No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-12
Preparing for checking continuity . . . . . . . . . . .70-14 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-103
Main controller . . . . . . . . . . . . . . . . . . . . . . . . .70-15
Connector voltage check table
(1.0 - 2.5 ton models) . . . . . . . . . . . . . . . . . . . .70-22
Connector voltage check table
(3.0 ton model) . . . . . . . . . . . . . . . . . . . . . . . . .70-38
BE30 Series 70-1

CONTROLLER TROUBLESHOOTING
CONTROLLER
1. SELF-DIAGNOSIS FUNCTION
1. Battery capacity gauge
2. Travel system trouble occurrence
indicator
3. Hydraulic system trouble occur-
rence indicator
4. Speedometer
5. Battery fluid level indicator
6. Parking brake indicator
7. Travel speed limit indicator
8. Set value button
9. Set item button
10. Mode button
11. Travel power indicator
12. Trouble occurrence indicator
13. Power steering trouble occurrence
indicator
14. Display unit
• This controller has a self-diagnosis function, that • If a trouble occurs, check the troubled part and
it, it can check itself. cause of the trouble from the failure code dis-
• With this function, failure codes are displayed on played on the display unit of the meter panel, then
the display unit at the operator's seat to notify the repair the troubled part.
troubled parts.
2. ACTION TO TAKE WHEN FAILURE CODE IS DISPLAYED
1. Checking insulation resistance

If a trouble occurs, disconnect the battery connector first and check the insulation resistance between the
chassis and each terminal of the controller (+, –, A, B, E, F, PA, PB, BP, and CH) and between the chassis
and each electric part.
There is no continuity (cz): Normal.
There is continuity: Insulation is defective. Repair it.
2. Checking battery for leakage

Disconnect the battery connector, apply the black pin of the multimeter to the negative (–) side and the red
pin to the chassis, and measure the voltage.
There is no voltage (0 V): Normal
There is voltage : A current is leaking from the battery (Clean the inside of the battery).
3. Repairing according to failure codes list

a If multiple failure codes are displayed, repair for all of them.
70-2 BE30 Series

TROUBLESHOOTING CONTROLLER
3. CONTROL BLOCK DIAGRAM
a The following is the proportional solenoid valve specification.
1) Main controller: Installed in the main controller room at the rear of the chassis. The CPU card consists
of the main control section and the EPS control section (small circuit board).
2) Sub controller: Consists of the multi-controller board and system controller board (Sub controller of the
manual valve specification consists of the 2 multi-controllers, however).
[Installed at the front in the left side cover of the chassis (together with the transformer
of the on-board charger).]
BE30 Series 70-3

CONTROLLER TROUBLESHOOTING
4. TROUBLESHOOTING
1. Classification of failure codes

(1) Check the failure codes first.
(2) The failure codes are roughly classified by the sections as shown in the following table.
Failure code Controller Troubled section
E-01 – E-28, 41, 42, 45 Main controller Travel system
Cargo handling system
E-30 – E-38, 55, 56 Main controller
(excluding proportional solenoid valve)
E-50 – E-54 Main controller EPS system
E-60 – E-89 Sub controller (System controller)
(related to proportional solenoid valve)
E-59, E-90 – E-96 Sub controller (Multi-controller) Charger system
Abnormality in communication between
E-97 Sub controller (Multi-controller)
main controller and multi-controller
system controller and multi-controller
meter panel and multi-controller
For details, see the failure codes list on page 70-53.
(Note 1) When carrying out troubleshooting, disconnect the battery cable plug, unless otherwise spec-
ified in the failure codes list or testing and adjusting procedure. When checking the switches
or adjusting the data with the meter panel (by operating the monitor), keep the battery cable
plug connected, however.
(Note 2) When checking voltage with a multimeter, do not use the ordinary rods since they can short the
circuits (on the installed printed circuit cards).
(Note 3) Since water-resistant the wiring connectors are used, do not use the ordinary rods of a multim-
eter.
(Note 4) Before troubleshooting or repairing, put chocks under the front and rear wheels and take prop-
er safety measures since the vehicle (travel system, cargo handling system, EPS, etc.) may
move.
(Main controller)
Failure codes list

E01
See circuit
diagram, etc.
Troubleshooting (Testing and adjusting) Maintenance
70-4 BE30 Series

TROUBLESHOOTING CONTROLLER
2. Preparing for checking voltage and current

(1) Stop the vehicle on level ground and put chocks
under the rear wheels.
(2) Put wood blocks under both sides of the frame to
float the front wheel above the ground.
(3) Lower the fork to the ground, tilt the mast forward,
and apply the parking brake.
(4) Turn the key switch OFF.
(5) Remove door (1) for the controller at the rear part
of the counterweight.
When checking voltage or current, be sure to per-

form the above preparation.
BE30 Series 70-5

MAIN CONTROLLER TROUBLESHOOTING
MAIN CONTROLLER
1. CHECKING ELECTRIC PARTS OF CONTROLLER (1.0 - 2.5 TON MODELS)
1. Inspecting tools and measuring instruments

No. Name Specification/Remarks Use
Cross-head and flat-head screwdriv-
Tightening and removal of screws,
1 Set of screwdrivers ers (large, medium, and small), flat- setting of control knob
head screwdriver for machine screws
Set of spanners Tightening of removal of bolts and
2 (socket wrenches) 10 mm, 13 mm nuts
Mounting screws of power module, Measurement of tightening torque for
3 Torque wrench
etc., M4, M5 bolts and nuts
4 Tweezers and pliers – Installation and removal of small parts
5 Ammeter DC 500 A or 1000 A Measurement of current
Measurement of voltage
6 Digital multimeter and – 12V, – 30V, – 120 V (Digital voltmeter is applicable)
analogue multimeter
Range: ×1, ×100, ×1,000 Measurement of resistance
7 Synchroscope Check of transistor circuit, etc.
Stabilized power sup- Voltage: Variable from 0 to 50 V,
8 ply for control Capacity: 3 A Check of operation of each part
2. Tightening torque
Tightened part
Nomi- Tightening torque
Part name Item Symbol Model nal size (Nm{kgm}) Remarks
Printed circuit card Fixed – N61F30857 = 1 or 2 M4.5 1.0 – 1.5 {0.10 – 0.15} –
(CPU)
Printed circuit card Fixed – N61F30841 = 4 M4.5 1.0 – 1.5 {0.10 – 0.15} –
(Power supply)
Power module Fixed TMDU/V/W/ – M5 2.0 – 3.0 {0.20 – 0.30} Spread heat
TMP radiator sheet on
floor. For shape,
see a below.
Power module alumi- Fixed – N55F42549 M5 2.0 – 3.0 {0.20 – 0.30} –
num block terminal Terminal M8 7.5 – 10.8 {0.75 – 1.0} –
Capacitor board Fixed and CBD N61F30830 = 221/ M5 2.0 – 3.0 {0.20 – 0.30} –
terminal CBP N61F30831 = 215
Contactor Fixed MD CP30-MA M5 2.0 – 3.0 {0.20 – 0.30} –
(KYORITSU KEIKI) Terminal M8 8.8 – 10.8 {0.90 – 1.10} –
Contactor Fixed MPS CM2-ADC48V M4 1.3 – 1.7 {0.13 – 0.17} –
Current sensor Fixed CSDU/W 53CM7-800/4MD M4 1.3 – 1.7 {0.13 – 0.17} –
IGBT Fixed TMPS1/2 2MB1100N-60 M5 2.0 – 3.0 {0.20 – 0.30} –
Terminal M5 2.0 – 3.0 {0.20 – 0.30} –
Capacitor CPS Fixed CPS N71F41314 M4 1.3 – 1.7 {0.13 – 0.17} –
Shunt R Fixed SH MBP20A10MMJN M4 1.3 – 1.7 {0.13 – 0.17} –
Terminal M4 1.1 – 1.5 {0.11 – 0.15} –
FAN Fixed FAN1, 2 MMF-08D24ES-RND M4 1.3 – 1.7 {0.13 – 0.17} –
Terminal Fixed +, -, DU, DV, 1P-M8X40-M M8 14.0 – 16.0 {1.42 – 1.63} –
Terminal DW, PA, PB, M8 7.3 – 9.3 {0.74 – 0.95} –
CH
a Shape of heat radiator sheet (Upper and lower sides are the positions on the vehicle.)
1 ton models 2 ton models
Upper side Short and narrow Short and narrow Apply the standard tightening torque to the
TMP
Lower side Short and wide Short and wide parts that are not shown in the above table.
Upper side Short and wide Long and wide M4: 1.3 – 1.7 Nm {0.13 – 0.17 kgm}
TMDW
Lower side Short and wide Long and wide M5: 2.0 – 3.0 Nm {0.20 – 0.29 kgm}
Upper side Short and wide Long and wide M8: 8.8 – 10.8 Nm {0.90 – 1.10 kgm}
TMDU
Lower side Short and wide Long and wide
Upper side Short and wide Long and wide
TMDV
Lower side Short and narrow Long and narrow
70-6 BE30 Series

TROUBLESHOOTING MAIN CONTROLLER
2. CHECKING ELECTRIC PARTS OF CONTROLLER (3.0 TON MODEL)
1. Inspecting tools and measuring instruments

No. Name Specification/Remarks Use
Cross-head and flat-head screwdriv-
Tightening and removal of screws,
1 Set of screwdrivers ers (large, medium, and small), flat- setting of control knob
head screwdriver for machine screws
Set of spanners Tightening of removal of bolts and
2 (socket wrenches) 10 mm, 13 mm nuts
Mounting screws of power module, Measurement of tightening torque for
3 Torque wrench
etc., M4, M5 bolts and nuts
4 Tweezers and pliers – Installation and removal of small parts
5 Ammeter DC 500 A or 1000 A Measurement of current
Measurement of voltage
6 Digital multimeter and – 12V, – 30V, – 120 V (Digital voltmeter is applicable)
analogue multimeter
Range: ×1, ×100, ×1,000 Measurement of resistance
7 Synchroscope Check of transistor circuit, etc.
Stabilized power sup- Voltage: Variable from 0 to 50 V,
8 ply for control Capacity: 3 A Check of operation of each part
2. Tightening torque
Tightened part
Nomi- Tightening torque
Part name Item Symbol Model nal size (Nm{kgm}) Remarks
Printed circuit card Fixed – N61F30857 = 1 or 2 M4.5 1.0 – 1.5 {0.10 – 0.15} –
(CPU)
Printed circuit card Fixed – N61F30841 = 4 M4.5 1.0 – 1.5 {0.10 – 0.15} –
(Power supply)
Power module Fixed TMDU/V/W/ – M5 2.0 – 3.0 {0.20 – 0.30} Spread heat
TMP radiator sheet on
floor. For shape,
see a below.
Power module alumi- Fixed – N55F42549 M5 2.0 – 3.0 {0.20 – 0.30} –
num block terminal Terminal M8 7.5 – 10.8 {0.75 – 1.0} –
Capacitor board Fixed and CBD N61F30830 = 221/ M5 2.0 – 3.0 {0.20 – 0.30} –
terminal CBP N61F30831 = 215
Contactor Fixed MD CP30-MA M5 2.0 – 3.0 {0.20 – 0.30} –
Contactor Fixed MPS CM2-ADC48V M4 1.3 – 1.7 {0.13 – 0.17} –
Current sensor Fixed CSDU/W 53CM7-800/4MD M4 1.3 – 1.7 {0.13 – 0.17} –
IGBT Fixed TMPS1/2 2MB1100N-60 M5 2.0 – 3.0 {0.20 – 0.30} –
Terminal M5 2.0 – 3.0 {0.20 – 0.30} –
Capacitor CPS Fixed CPS N71F41314 M4 1.3 – 1.7 {0.13 – 0.17} –
Shunt R Fixed SH MBP20A10MMJN M4 1.3 – 1.7 {0.13 – 0.17} –
Terminal M4 1.1 – 1.5 {0.11 – 0.15} –
FAN Fixed FAN1, 2 MMF-08D24ES-RND M4 1.3 – 1.7 {0.13 – 0.17} –
Terminal Fixed +, -, DU, DV, 1P-M8X40-M M8 14.0 – 16.0 {1.42 – 1.63} –
Terminal DW, PA, PB, M8 7.3 – 9.3 {0.74 – 0.95} –
CH
a Shape of heat radiator sheet (Upper and lower sides are the positions on the vehicle.)
3 ton model
Upper side Short and narrow Apply the standard tightening torque to the
TMP
Lower side Short and wide parts that are not shown in the above table.
Upper side Long and wide M4: 1.3 – 1.7 Nm {0.13 – 0.17 kgm}
TMDW
Lower side Long and wide M5: 2.0 – 3.0 Nm {0.20 – 0.29 kgm}
Upper side Long and wide M8: 8.8 – 10.8 Nm {0.90 – 1.10 kgm}
TMDU
Lower side Long and wide
Upper side Long and wide
TMDV
Lower side Long and narrow
BE30 Series 70-7

3. LOOSENESS OF FITTING PARTS 5. REMOVING CPU BOARD

When removing the CPU board for inspection or re-
AND DEFECTIVE CONTACT OF
placement, remove the case cover, disconnect the
CONNECTORS wiring harness connector from the board, and remove
If a bolt or a nut of a power terminal fitting part of a the board mounting screws (CPU board mounting
controller is loosened, it may heat and cause a burn. screws: 9 pieces, power supply board mounting
Accordingly, if any fitting part is loosened or heated, screws: 9 pieces).
polish it carefully with sandpaper and retighten it. Hold the lock of the connector securely, pull the con-
If there is defective contact in a connector, the related nector.
parts do not operate normally. Accordingly, remove The CPU board and power supply board (including
dirt and rust from the connector to prevent defective EPS board) in the CPU box are connected by 3 ca-
contact, and then connect and disconnect the con- bles (CN8 and CN2R, CN9 and CN1R, and CN6 and
nector 2 – 3 times. At this time, check the lead wires CN1E).
for disconnection and terminals for deformation. After replacing the board, be sure to connect these 3
cables securely.
4. CHECKING PARTS INSTALLED TO
VEHICLE
It is dangerous to touch an electric part installed to the
vehicle while the power is applied to it.
When removing or touching a part, be sure to discon-
nect the battery connector and wait for at least 2 min-
utes.
There still may be some electric charge of 3 – 5 V in
the capacitors, however. In this case, if you short PS
to Ni, or P12 to N1, with a screwdriver, etc. you may
hear a snap of sudden discharge.
This snap does not cause an electric shock or a burn
of a part. It is recommended, however, to discharge
through a discharge resistor (100z – 1,000z).
When measuring with the power turned on, float the
drive wheels so that the vehicle will not start even if
the motor starts suddenly.
Under this condition, apply the brake, check the max-
imum current, and perform the switch-back operation
and hydraulic operation.
70-8 BE30 Series

6. PREPARING FOR CHECKING VOLT-

AGE AND CURRENT
1. Stop the vehicle on level ground and put chocks

under the rear wheels.
2. Put wood blocks under both sides of the frame to

float the front wheel above the ground.
3. Lower the fork to the ground, tilt the mast forward,

and apply the parking brake.
4. Turn the key switch off.
5. Remove door (1) for the controller at the rear part

When checking voltage or current, be sure to per-

form the above preparation.
7. CHECKING BATTERY VOLTAGE
1. Disconnect the battery plug.
2. Set the multimeter for measurement of voltage,

set the black rod (-) to the negative (-) side of the
battery plug, set the red rod (+) to the positive (+)
side of the battery plug, and measure the voltage.
3. Judge the measured voltage.

Measured voltage Judgment
Above battery voltage: Good
48 V
Below battery voltage: Bad
48 V (Charge battery)
3.0 ton model

Measured voltage Judgment
Above battery voltage: Good
72 V
Below battery voltage: Bad
72 V (Charge battery)
BE30 Series 70-9

8. CHECKING FUSE FOR TRAVEL (F1), FUSE FOR HYDRAULIC PRESSURE (F2),
FUSE FOR EPS (F3) AND FUSE FOR CHARGING (F4)
1. (-) cable connecting terminal
2. Terminal F2
3. Terminal F2
4. Terminal F3
5. Terminal F3, F4
6. Terminal F4
7. Terminal F1
8. Terminal F1
1. Checking fuse for travel (F1)

• Prepare for checking voltage and current, Voltage table (With key switch ON)
see P70-8. Measuring point Voltage Judgment
• Set the multimeter for measurement of
voltage and set the black rod (-) to nega- BV Good
Terminal (8)
tive (-) cable connecting terminal (1) of the 0V Bad (Replace fuse)
controller. Terminal (7) BV Good
• Set the red rod (+) to the (7) and (8) termi-
nals of fuse F1 and measure and judge the BV: Battery voltage
voltage. (Measure the battery voltage in advance)
2. Checking fuse for hydraulic pressure (F2) Voltage table (With key switch ON)
• Prepare for checking voltage and current,
Measuring point Voltage Judgment
see P70-8.
• Set the multimeter for measurement of BV Good
Terminal (2)
voltage and set the black rod (-) to nega- 0V Bad (Replace fuse)
tive (-) cable connecting terminal (1) of the
Terminal (3) BV Good
controller.
• Set the red rod (+) to the (3) and (2) termi- BV: Battery voltage
nals of fuse F2 and measure and judge the (Measure the battery voltage in advance)
voltage.
70-10 BE30 Series

3. Checking fuse for PS (F3)

• Prepare for checking voltage and current, see P70-9.
• Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting
terminal (1) of the controller.
• Set the red rod (+) to the (5) and (4) terminals of fuse F3 and measure and judge the voltage.
Voltage table (With key switch ON)
BV Good
Terminal (4)
0V Bad (Replace fuse)
BV: Battery voltage
(Measure the battery voltage in advance)
4. Checking fuse for CHARGING (F4)

• Prepare for checking voltage and current, see P70-9.
• Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting
terminal (1) of the controller.
• Set the red rod (+) to the (6) and (5) terminals of fuse F4 and measure and judge the voltage.
BV Good
Terminal (5)
0V Bad (Replace fuse)
BV: Battery voltage
(Measure the battery voltage in advance)
9. CHECKING CURRENT DETECTORS FOR TRAVEL (CSDU AND CSDW)

1. Prepare for checking voltage and current, see P70-9.
2. Set the multimeter for measurement of voltage and set the black rod (-) to negative (-) cable connecting ter-
minal (1) of the controller.
3. Set the red rod (+) to each measuring point (pin No. 3, 4, 5, 6, 14, 15, 16, and 17) of CN5 (22-pin connector),
turn the key switch ON, and measure and judge the voltage.
Precautions
• This voltage cannot be measured by one person. To measure it, two persons must work together;
one person must operate and the other must measure, making signals to each other.
• When setting the rods of the multimeter to the measuring points, be sure to turn the key switch OFF.
After checking that the rods are set correctly, turn the key switch ON and start measurement.
BE30 Series 70-11


Measuring point
Normal voltage (current) Measurement conditions
Pin No. Wire color
CN5-3 R–B 15V –
(Red – Black)
CN5-5 15V –
CN5-14 GR (Gray) 0V
CN5-15
CN5-16 –
CN5-17
CN5-4 Orange (O) 7V (0A) When F/R lever is in neutral and accelerator is OFF
(CSDU)
7V o 6.83V Set F/R lever in F or R and measure change of
1 ton
models (0A o +33A) voltage.
Value is for reference.
7V o 6.76V
2 ton
models (0A o +47.6A)
7V o 6.83V
3 ton
model (0A o +35A)
CN5-6 Pink (P) 7V o 7.08V Set F/R lever in F or R and measure change of
1 ton
(CSDW) models (0A o – 16.5A ) voltage.
7V o 7.12V
2 ton
models (0A o – 24A)
7V o 7.09V
3 ton
model (0A o – 17.5A)
10. CPU BOAD CONNECTOR POSITION AND CONNECTOR PIN NO.

1. CPU connector position
• CN1, 2, 4, 5, 7, 11, CN3R, 4R, and 8R are 040/070 Hybrid I/O Connector Series manufactured by NIHON
AMP.
• CN7R is XAD Series manufactured by JST.
70-12 BE30 Series

2. Connector pin No.
Power supply : CN7R
BE30 Series 70-13

11. PREPARING FOR CHECKING

CONTINUITY
1. Stop the vehicle on level ground, lower the fork to

the ground, tilt the mast forward, and apply the
parking brake.
2. Turn the key switch off and disconnect the battery

plug.
3. Remove the door for the controller at the rear part

4. Disconnect the wiring connector of the CPU

board.
• Connector of CPU board: CN1 – 5, CN7,
CN11
• Connector of power supply board: CN3R,
CN4R, CN7R, CN8R
a Pushing in the stopper at the center of the
connector, pull out the connector.
5. Remove the protective cover of the printed circuit

card.
6. With the printed circuit card installed, remove its

mounting bracket.
When checking continuity, be sure to perform

the above preparation.
70-14 BE30 Series

12. MAIN CONTROLLER

1. Parts arrangement of control section This illustration shows 1.0 ton to 2.5 ton models.
1. Sensor (CSB) 11. Diode (DPS)

2. Fuse (F2) 12. Transistor (TMS2)
3. Fuse (F3) 13. Transistor (TMS1)
4. Fuse (F4) 14. Sensor (CSDW)
5. Contactor (MD) 15. Sensor (CSDU)
6. Fuse (F1) 16. Power module (TMDW)
7. Capacitor board (CBP) 17. Power module (TMDV)
8. Power module (TMP) 18. Power module (TMDU)
9. Contactor (MPS) 19. Capacitor board (CBD)
10. Absorber (CPS)
This illustration shows 3.0 ton model.
BE30 Series 70-15

2. Checking power modules for travel/cargo handling (TMDU, TMDV, TMDW, TMP)
• Prepare for checking continuity.
• Disconnect the all wires, bus bars, and capacitor boards connected to the power modules. (Record their
wiring and locations so that you can connect and install them correctly again.)
• Set the multimeter for measurement of resistance (x1000), set its rods to the terminals according to the
following table to measure the resistance. (Use an analog multimeter.)
• Judge the condition of the power modules by the measured resistance.
Measuring Multimeter Normal value (R) Judgment
point Red rod (+) Black rod (-) Rough standard Good Bad
D1 S1D2 Few kz Above 1z 0z and cz
D1-S1D2
S1D2 D1 cz cz Below cz
S1D2 S2 Few kz Above 1z 0z and cz
D1D2-S2
S2 S1D2 cz cz Below cz
G1 S1D2 Approx. 4kz Above 1z 0z and cz
S1D2-S2
S1D2 G1 Approx. 12kz Above 1z 0z and cz
G2 S2 Approx. 4kz Above 1z 0z and cz
G2-S2
S2 G2 Approx. 12kz Above 1z 0z and cz
D1 G1 Approx. 20kz Above 1z 0z and cz
D1-G1
G1 D1 cz cz Below cz
S1D2 G2 Approx. 20kz Above 1z 0z and cz
G2-S1D2
G2 S1D2 cz cz Below cz
Since the normal values shown in the above table depend on the type of the multimeter used and the con-
dition of the battery in it, they are reference values. Accordingly, judge the condition of each power module
by whether the power module has resistance (above 1z) or not (0z) or it is insulated (cz).
• For check of the gates (G1 and G2), you may use gates of any FET's, as long as those FET's are in the same line.
• Do not touch the gate terminals (G1 and G2) of the power modules and the soldered parts of the printed
circuit boards with your bare hands, since they can be broken by static electricity.
• When carrying or storing the power modules, be sure to put them in anti-static bags and protect them
from large vibration and impacts.
Detail of Y portion
70-16 BE30 Series

3. Checking transistor for EPS

(1) Carry out to P70-13, PREPARATION FOR CHECKING CONTINUITY.
(2) Disconnect either wire of each terminal to be checked.
a Record the disconnected wires and their locations so that you can connect them correctly again.
(3) Set the multimeter for measurement of resistance (x100) and apply its rods to the terminals according
to the following table to measure the resistance.
(4) Judge the condition of the transistor by the measured resistance.
Black rod Red rod Normal value Judgment
Measuring point
(-) (+) (Rough standard) Good Bad
G1 C1 c c Other than c
G1 – C1
C1 G1 c c Other than c
G1 E1 c c Other than c
G1 – E1
E1 G1 c c Other than c
C1 E1 c c Other than c
G1 – E1
E1 C1 Approx. 650 z Above 1z 0z
G2 C2 c c Other than c
G2 – C2
C2 G2 c c Other than c
G2 E2 c c Other than c
G2 – E2
E2 G2 c c Other than c
C2 E2 Approx. 650z Above 1z 0z
C2 – E2
E2 C2 Approx. 1300z Above 1z 0z
Since the normal values shown in the above table depend on the multimeter used, they are reference
values. Accordingly, judge the condition of the transistor by whether the transistor has resistance (above
1z) or not (0z) or it is insulated (c).
EPS transister
BE30 Series 70-17

4. Checking contactor coil

(1) Carry out to P70-13, PREPARATION FOR CHECKING CONTINUITY.
(2) Disconnect all the lead wires from the coil wiring terminals.
a Record the disconnected wires and their locations so that you can connect them correctly again.
(3) Set the multimeter for measurement of resistance (x100) and apply its rods to the terminals to measure
the resistance.
(4) Judge the condition of the contactor coil by the measured resistance.
Note) The measuring method and standards are the same as those for the current BE30 Series. The MP
contactor is not installed, however.
Judgment
Contactor
Good Bad
MD contactor (1) (Travel) 20 – 50z (typ, 30z) cz (Coil is disconnected)
PS contactor (2) (Power steering) 120 – 380z (typ, 266z) cz (Coil is disconnected)
a Do not judge the condition of the contactor coil by measuring the resistance between the common
terminals.
70-18 BE30 Series

5. Checking contacts of contactor

Check the contacts of the contactor visually. If they
are free from extreme unevenness, they are nor-
mal. If their surfaces are uneven or worn extreme-
ly, replace them.
MD contactor Replace 2 fixed contacts and 1 moveable contact together.
PS contactor Replace contactor assembly.
6. Capacitor boards (CBD, CBP)

• Check capacitor board (1) visually for harmful flaw and deformation and extreme discoloration.
If it is free of those defects, it is normal.
7. Checking travel/cargo handling temperature sensors

• Carry out to P70-13, PREPARATION FOR CHECKING CONTINUITY.
• Disconnect temperature sensor connectors (THD, THP).
(When connecting, take care not mistake THD and THP for each other.)
• Set the multimeter for measurement of resistance (x1,000) and apply its rods according to the following
table to measure the resistance.
• Judge the measured resistance.
Measuring Multimeter Normal value (R)

point Red pin (+) Black pin (-) Standard
THD THD-1 THD-2 0°C Approx. 66kz
10°C Approx. 40kz
THP THP-1 THP-2 20°C Approx. 25kz
30°C Approx. 16kz
BE30 Series 70-19

8. Heat radiator insulation sheet

• Each power module uses 2 sheets. When replacing the power module, replace sheets with new ones,
too.
• Check the sheets visually for flaw, cracking, metal dust, metal chips, etc. If they are free of those defects,
they are normal.
• The heat radiator insulation silicone sheets are made thin to reduce the heat radiation resistance, thus
they are brittle.
Handle the sheets with extreme care. If they have any flaw or crack, do not use them.
Check carefully that metal dust, chips, are not sticking to the sheets.
These defects can lower the insulation and directly cause a short circuit and a grounding fault of the pow-
er module, and that can break the power module.
When installing, align the mounting holes of the power module with the holes of the sheets, then tighten
carefully so that the power module and sheets will not shift.
9. Cooling fan
• Disconnect fan connector (1).
• Prepare a stabilized power supply for control and set
its output voltage to about 24 V.
• Connect fan (2) according to the following table and
check that it operates.
Stabilized power
Fan connector Color of lead wire
supply
24V Pin 1 Red
0V Pin 3 Black
10. Checking limit current

• Stop the vehicle on level ground and put chocks under the rear wheels.
• Put wood blocks under both sides of the frame to float the front wheel above the ground (only when mea-
suring the travel limit current).
• Lower the fork to the ground, tilt the mast forward, and apply the parking brake.
• Disconnect the wiring of the brake switch (only when measuring the travel limit current).
• Set an ammeter (clamp tester) to the cable shown in the figure and measure the limit current under the
conditions shown in the following table.
Measuring Setting of
Motor Measurement conditions cable clamp Limit current
Set the forward-reverse lever in F po- DU, DV, DW DC 1,000 A 1 ton models 527 – 586A (peak)
sition, press the brake pedal and ac- peak range (373 – 412A (rms))
celerator pedal fully, and measure
the current at this time. 2 ton models 674 – 746A (peak)
Travel (475 – 525A (rms))
3 ton model 524 – 580A (peak)
(370 – 410A (rms))
Move the tilt lever forward fully to tilt PA, PB Same as (Specification values)
the mast forward and measure the model 8 1 ton models Min. 300 A
Hydraulic current at this time. 2 ton models Min. 340 A
3 ton model Min. 300 A, Max. 360 A
Steer fully to the left or right and mea- Cable of EPS Same as (Specification values)
EPS sure the current at this time. motor model 8 1 ton models 45±2.5A
2 ton models 50±2.5A
3 ton model Min. 45 A, Max. 50 A
• After finishing check, return the disconnected wiring of the brake switch (only after the travel limit current
is measured).
70-20 BE30 Series

VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS) TROUBLESHOOTING
13. CONNECTOR VOLTAGE CHECK TABLE

Voltage check table (1.0 - 2.5 ton models)
Use an analog multimeter. Set it for measurement of resistance (kz). Connect the negative (-)
voltage side (red rod side) to the negative (-) terminal of the panel and connect the positive (+)
voltage side (black rod side) to the terminal to be measured. When measuring, disconnect only
the connector housing that contains the terminal to be measured.
BV: Rough battery voltage.
CN1 (26-pole) P board connector
Resis-
Reference volt- Reference voltage when
Pin Signal Wire tance
Contents of signal Type age when key switch is ON and control knob Remarks
No. name color (Terminal
switch is ON (V) is operated (V)
– GND)
1 – (Not connected) – – 0z – – –
2 – (Not connected) – – >500kz – – –
3 REG Regenerating signal DO Sb 80kz (*1) Voltage ap- During regeneration: ON NchFET open drain output (Load * 5 V/2
output plied to multi-con- when below 0.5 V, Other mA/4.7z)
troller side state: OFF
4 SLMT2 Travel speed limit-2 SW DI BY ∞ 4.4 When switch is ON: 0 V OV short: Travel speed is not limited,
Open: Travel speed is limited
5 VS Control valve selection DI – ∞ 4.4 When switch is ON: 0 V Open: Proportional valve, OV short:
Manual valve
6 BRK Brake SW DI O ∞ 4.4 When switch is ON: 0 V OV short: Brake operates.
7 ACCLMT Lifting height SW DI Y ∞ 4.4 When switch is ON: 0 V Open: High lifting height (Acceleration
limiter operates)
8 LIFT1 Lift-1 SW DI LR ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
10 TILT Tilt SW DI GR ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
11 DSR Reverse SW DI WB 50kz 0 When DSR is operated: BV 48Vhigh side input
12 DSF Forward SW DI L 50kz 0 When DSR is operated: BV 48Vhigh side input
13 KEY Key SW (Control power Power Y 50kz BV 48 V control power supply in- –
supply input) supply put, When key is OFF: 0 V
(48 V)
14 OV O V (For SW input) OV Br 0z 0 0 –
15 – (Not connected) – – ∞ – – –
16 LICOM Lift interrupt command DI BrW ∞ 4.4 When switch is ON: 0 V Open: Cargo handling DUTY limit
input
17 LINT Lift interrupt SW DI YR ∞ 4.4 When switch is ON: 0 V Open: Interrupt is effective.
18 PB Parking SW DI RY ∞ 4.4 When switch is ON: 0 V Open: Parking brake is applied.

19 SEAT Seat SW DI Gr ∞ 4.4 When switch is ON: 0 V Open: Operator is out, OV short: Opera-
tor is seated
20 SWMONI SW monitor start input DI P ∞ 4.4 When switch is ON: 0 V Open: Monitor mode start
21 ATT1 ATT-1 SW DI BO ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
22 ATT2 ATT-2 SW DI GO ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
23 ATT3/ ATT-3 SW DI LO ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
RCH
24 EMG Main contactor (EMG) DI LB 30kz 0 When normal: BV, EMG 48Vhigh side input (MP contactor coil
state: 0 V current is supplied)
25 HORN Horn output DO – 15kz BV Horn operates: FETon (Max. NchFET open drain output (Max. 200 V/
0.6 V) 1.5 A)
(48 V)
70-22 BE30 Series

TROUBLESHOOTING VOLTAGE CHECK TABLE (1.0 - 2.5 TON MODELS)
OK: Device operates normally, or it has an error or cannot operate but it will not be broken.
NG: Device will be broken or damaged seriously.
All or one of codes concerned is displayed.

Key ON, SW ALL off" includes disconnection before Key ON.
Fault caused by disconnection, etc.

Just be- While When travel Just before While cargo
Code Key While travel Just
Pin Con- fore driv- travel motor is chopping for handling During
con- ON, SW motor is re- before Remarks
No. dition ing travel motor is loaded cargo han- motor is EPS
cerned ALL off generating EPS
motor driven heavily dling motor chopped
1 – – – – – – – – – – – –
2 – – – – – – – – – – – –
3 OK – OK OK OK OK OK OK OK OK OK –
4 OK – OK OK OK OK OK OK OK OK OK Travel speed is limited.
5 OK – OK OK OK OK OK OK OK OK OK Proportional valve operation

mode is selected.
6 OK – OK OK OK OK OK OK OK OK OK Regenerating brake cannot be
applied.
7 OK – OK OK OK OK OK OK OK OK OK High lifting height is limited.
8 OK – OK OK OK OK OK OK OK OK OK Cargo handling lift 1 does not op-

erate.
9 OK – OK OK OK OK OK OK OK OK OK Cargo handling lift 2 does not op-
erate.
10 OK – OK OK OK OK OK OK OK OK OK Cargo handling TILT does not
operate.
11 OK – OK OK OK OK OK OK OK OK OK Vehicle does not travel in re-
verse.
12 OK – OK OK OK OK OK OK OK OK OK Vehicle does not travel forward.
13 OK – OK OK OK OK OK OK OK OK OK Power is not supplied (when
CN1-26 is also disconnected).
15 – – – – – – – – – – – –
16 OK – OK OK OK OK OK OK OK OK OK Cargo handling DUTY is limited
(when LINT is effective).
17 OK – OK OK OK OK OK OK OK OK OK Cargo handling DUTY is limited
(when LICOMis open).
19 OK – OK OK OK OK OK OK OK OK OK Deadman function is turned ON.
20 OK – OK OK OK OK OK OK OK OK OK Monitor mode
21 OK – OK OK OK OK OK OK OK OK OK Cargo handling ATT-1 does not
operate.
operate.
operate.
24 OK 32 OK OK OK OK OK OK OK OK OK Cargo handling EGM SW is
turned ON.

BE30 Series 70-23


Resis-
Reference voltage Reference voltage when
Contents of signal Type when key switch is switch is ON and control knob Remarks
– GND) ON (V) is operated (V)
1 MCTXDP TXD (+) TXD WL ∞ (*2) Reference [Pull-up power supply side: (+) Data transmitted to display
(Source) cannot be set. side]
2 MCRXDP RXD (+) RXD W ∞ (*2) Reference [Photo coupler anode side: (+) Data received from display
3 PPDA-N Travel speed sensor A OV W 0z 0 Electromagnetic pickup input: –
(-) Common
4 PPDA-S Travel speed sensor A Pulse IN B 17kz 0 Electromagnetic pickup input: S1 = At 1358 Hz/10 km, S2 = At
(+) Signal 1253 Hz/ 10 km
5 ATIN Solenoid valve analogue AIN W 8.4kz (*1) Voltage ap- Input: Min. 4.25 V = DUTY min. –
signal plied to multi-con- 100%
troller side Max. 1.9 V = DUTY 0%
6 PSPT-S Torque sensor (S) AIN GW 10kz 0.4 – 4.6 If steering wheel is turned to –
right, VR wiper moves toward
PSPT-(-) side (Signal voltage
lowers).
When steering wheel is turned
to right end: 0.3 – 0.6 V
to left end: 4.4 – 4.7 V
7 PSPT-P Torque sensor (+) PSPT(+) LY 1kz 4.4 – 4.7 4.4 – 4.7 5V power supply with series R
8 ACCD-S Travel accelerator VR AIN GY 13.5kz 0.3 – 4.7 VR wiper moves toward (+) side –
(S) (Signal increases) o DUTY is
increased.
When accelerator is OFF: 0.3 –
0.9 V
When accelerator is ON: 3.2 –
4.7 V
9 ACCD-P Travel accelerator VR ACCD(+) RB ∞ 5 5 5V power supply with series R
(+)
10 ACCP-S Lift VR, (2) side (S) AIN YG 13.5kz 0.4 – 4.6 VR wiper moves toward (+) side –
(Signal increases) o DUTY is
increased.
When lift SW is OFF: 0.3 – 0.9 V
When lift SW is ON: 4.1 – 4.6 V
11 ACCP-P Lift VR, (3) side (+) LTVR(+) YG 1kz 4.1 – 4.6 4.1 – 4.6 5V power supply with series R
12 MCTXD TXD (-) TXDO OL ∞ (*2) Reference [Open drain power supply side: Data transmitted to display
N (Sync.) cannot be set. (-) side]
13 MCRXD RXD (-) RXDO B ∞ (*2) Reference [Photo coupler anode side: (-) Data received from display
N (Sync.) cannot be set. side]
14 MCCOM MC communication line OV BO 0z 0 0 –
shield (com)
15 PPDA- Travel sensor shield OV BW 0z 0 0 –
COM (com)
16 ATCOM Solenoid valve shield OV BG 0z 0 0 –
(com)
17 ATN Solenoid valve GND (0 V) OV B 0z 0 0V –
18 PSPT-N Torque sensor (-) PSPT (-) BY 200z 0.3 – 0.6 0.3 – 0.6 OV with series R
19 AC1 AC1 (Accelerator SW) DI RL ∞ 4.4 When switch is ON: 0 V OV short: Travel operation permis-
input sion
20 ACCD-N Travel accelerator VR, OV YB 0z 0 0V –
(-) side
21 ACCP-N LIFT VR1 side (-) OV BW 200z 0.3 – 0.9 0.3 – 0.9 OV with series R
22 – (Not connected) – – ∞ – – –
70-24 BE30 Series


Code Key While travel Just be-
con- ON, SW motor is re- fore Remarks
1 OK Trans- OK OK OK OK OK OK OK OK OK –
mission
error
3 OK 41 OK(41) OK(41) OK(41) OK(41) OK(41) OK(41) OK(41) OK(41) OK(41) Vehicle cannot travel.
6 OK – OK OK OK OK OK OK OK OK OK PS cannot operate.
7 OK 54 OK(54) OK(54) OK(54) OK(54) OK(54) OK(54) OK(54) OK(54) OK(54) Torque sensor is abnormal.
8 OK 17 OK(17) OK(17) OK(17) OK(17) OK(17) OK(17) OK(17) OK(17) OK(17) Travel accelerator is defective.
10 OK 35 OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) Cargo handling lift VR is defec-
tive (in manual valve mode)
mission
error
14 OK – OK OK OK OK OK OK OK OK OK Communication error may be

made.
15 OK – OK OK OK OK OK OK OK OK OK Travel speed may be sensed
wrongly.
16 OK – OK OK OK OK OK OK OK OK OK Cargo handling chopper DUTY
is unstable (in proportional
valve mode).
17 OK – OK OK OK OK OK OK OK OK OK Cargo handling chopper DUTY
is unstable (in proportional
valve mode).
19 OK – OK OK OK OK OK OK OK OK OK Vehicle does not travel.
22 – – – – – – – – – – – –
BE30 Series 70-25

CN3 (4-pole) relay connector: For power supply

Resis-
– GND) switch is ON (V) is operated (V)
1 Chassis power supply for control + VB48 W 7.8kz BV BV –

(+48 V)
2 Chassis power supply for control - VB- B 0z 0V 0V –
(+48 V)
CN4 (2-pole) relay connector: EPS motor (B)

Resis-
– GND)
1 EPS motor drive P24 R 24kz Unsettled Fluctuation when EPS rotates to Motor current direction when steer-
left: 0 – BV ing wheel is turned to right
CN4-2 o CN4-1
2 EPS motor drive P23 B 24kz Unsettled Fluctuation when EPS rotates to [= P23 o P24]
right: 0 – BV
For only this case, connect CN5-4 to red rod (0 V) of multimeter

and connect terminal to be measured to black rod (+ side).
Resis-
Pin Signal Wire tance Reference volt- Reference voltage when
– GND)
1 +VC power supply (+10 V ± 5%) +VC R 7.3kz 10.2V 10.2V –
2 OV GND B 0z 0V 0V –
3 Sensor output OUT W 5.6kz 0.6V Varies with battery current –
(0.6 – 8.6 Vmax)
4 OV GND B X 0V 0V –

Resis-
Pin Signal Reference volt- Reference voltage when
Contents of signal Type Wire tance age when key switch is ON and control knob Remarks
2 – (Not connected) – – ∞ – – –
3 DMTH Travel motor temperature 0V GY 0z 0 0 –
-N (-)
4 DMTH Travel motor temperature AIN LO 5.5kz Approx. 3.48 Varies with temperature –
-S (S) (at 25°C) (0.2 – 4.8).
5 PPDB- Travel speed sensor B (-) 0V W 0z 0 Electromagnetic pickup input: –
N Common
6 PPDB- Travel speed sensor B (+) Pulse B 16.5kz 0 Electromagnetic pickup input: S1 = At 1358 Hz/10 km, S2 = At
S IN Signal 1253 Hz/ 10 km
7 – (Not connected) – – 6.2kz – – –
8 – (Not connected) – – ∞ – – –
10 – (Not connected) – – ∞ – – –
11 – (Not connected) – – 0z – – –
12 – (Not connected) – – 5.5z – – –
13 PPDB- Travel sensor shield 0V BW 0z 0 0 –
COM (COM)
14 – (Not connected) – – 6.2kz – – –
15 – (Not connected) – – ∞ – – –
16 – (Not connected) – – ∞ – – –
70-26 BE30 Series



1 OK 50 OK(50) OK OK OK OK OK OK OK OK Opening of EPS transistor is
detected wrongly.
Operation of PS is defective.
detected wrongly.

Just be- While When travel While travel Just before While cargo Just be-
Pin Con- Code Key fore driv- travel motor is
motor is re- chopping
for handling During
con- ON, SW fore Remarks
No. dition ing travel motor is loaded
generating cargo han-
motor is EPS
cerned ALL off EPS
1 [Since this connector is used/controlled on multimeter side, ask the section in charge of your company.] –
2
3

Code Key Just be- While When travel While travel Just before While cargo Just be-
Pin Con- fore driv- travel motor is
for handling During
con- ON, SW ing
No. dition cerned travel motor is loaded cargo han- motor is fore EPS Remarks
ALL off generating EPS
1 – – – – – – – – – – – –
2 – – – – – – – – – – – –
3 OK 27 OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) OK(27) Travel motor temperature sensor
is defective (Vehicle can travel).
7 – – – – – – – – – – – –
8 – – – – – – – – – – – –
9 – – – – – – – – – – – –
10 – – – – – – – – – – – –
11 – – – – – – – – – – – –
12 – – – – – – – – – – – –
wrongly.
14 – – – – – – – – – – – –
15 – – – – – – – – – – – –
16 – – – – – – – – – – – –
BE30 Series 70-27


Resis-
1 SH+ Shunt resistance for detect- AIN Y-L 10.3kz 0 When EPS operates: Varies –
ing EPS current, (+) side largely with "ON" period ratio of
chopper
2 – (Not connected) – – ∞ – – –
3 – (Not connected) – – ∞ – – –
4 – (Not connected) – – ∞ – – –
5 THD+ Travel controller tempera- AIN W-BR 5.3kz Approx. 4.05 Varies with temperature –
ture sensor (at 25°C) (0.2 – 4.8).
6 THP+ Cargo handling controller AIN W-L 5.3kz Approx. 4.05 Varies with temperature –
temperature sensor (at 25°C) (0.2 – 4.8).
7 SH- Shunt resistance for detect- OV G-W 9.3kz 0 0 –
ing EPS current, (-) side
8 – (Not connected) – – ∞ – – –
9 – (Not connected) – – ∞ – – –
10 – (Not connected) – – 0z – – –
11 HTD- Travel controller tempera- OV GR 0z 0V 0V –
ture sensor 0 V
12 THP- Cargo handling controller OV GR 0z 0V 0V –
temperature sensor 0 V

Resis-
No. name Contents of signal Type color age when key
(Terminal switch switch is ON and control knob Remarks
is ON (V) is operated (V)
– GND)
1 P22 Main circuit: Secondary AIN W-G 80kz BV Before MPS contactor is turned –
side of MPS contactor ON: Approx. 35.2 V (When BV =
48 V)
After MPS contactor is turned ON:
BV
2 P3 Main circuit: Secondary AIN BR 33kz BV Before MD contactor is turned ON: 0
Before key SW is turned ON: 0 V – 39.5
side of fuse F1 V – 39.5 V V (When BV = 48 V)
After MD contactor is turned ON:
After key SW is turned ON: Boosting
BV charging until MD contactor is
turned ON
3 P4 Main circuit: Output termi- AIN L 49.8kz Approx. 24.5 V Varies largely when inverter oper- Vehicle stops, direction lever in neu-
nal of U-phase power mod- ates. tral, and accelerator is OFF.
ule
4 – (Not connected) – – ∞ – – –
5 MD (+) MD contactor coil power Power Y-R ∞ BV When chassis EMGsw operates: –
supply (+) supply 0 V, When normal: BV
(BV48)
6 MPS MPS contactor coil power Power R-L ∞ BV BV –

(+) supply (+) supply
(BV48)
7 – (Not connected) – – ∞ – – –
8 P1 Main circuit voltage (P1) AIN R 9.2kz BV BV –
9 P21 Main circuit: Secondary AIN W-R 80kz BV BV –

side of EPS fuse F3
10 P13 Main circuit: (PA) side of AIN L-R 45kz (*3) Before MP contactor is turned ON: 0 Before key SW is turned ON: 0 V –
cargo handling motor V – 39.5 V 39.5 V (When BV = 48 V)
After MP contactor is turned ON: After key SW is turned ON: Boosting
a) While cargo handling chopper is charging until MP contactor is
stopped: Approx. BV turned ON
b) While cargo handling chopper is
operating: Varies with "ON" period ra-
tio. Not fixed.
11 – (Not connected) – – ∞ – – –
12 – (Not connected) – – 45kz – – –
13 MD MD contactor coil drive FET OPEND Y-G 45kz BV When MP contactor is turned –
drain OFF: BV
When chassis EMGsw operates:
0 V, When normal: BV
When MP contactor is turned ON:
BV x 75% (*4)
14 MPS MPS contactor coil drive OPEND R-W 45kz BV o 0.2V When key SW is turned ON –
FET drain (When MPS contactor is turned
OFF): BV
When MPS contactor is turned
ON: 0.2 V
15 – (Not connected) – – ∞ – – –
16 N1 OV for contactor coil drive OV B 0z – – –
circuit
70-28 BE30 Series


1 OK – OK OK OK OK OK OK OK OK OK EPS overcurrent is detected
wrongly. PS is impossible.
2 – – – – – – – – – – – –
3 – – – – – – – – – – – –
4 – – – – – – – – – – – –
5 OK 22 OK(22) OK(22) OK(22) OK(22) OK(22) OK(22) OK(22) OK(22) OK(22) Temperature sensor is defec-
tive (Vehicle can travel).
tive (Vehicle can handle cargo).
7 NG 50 OK OK OK OK OK OK OK OK NG EPS current detector operates
wrongly.
EPS transistor is broken. PS is
impossible.
8 – – – – – – – – – – – –
9 – – – – – – – – – – – –
10 – – – – – – – – – – – –

Code Key
for handling During
No. dition cerned ALL off ing travel motor is loaded cargo han-
generating dling motor is EPS EPS
motor driven heavily motor chopped
1 OK 52 OK(52) OK(52) OK(52) OK(52) OK(52) OK(52) OK(52) OK(52) OK(52) –
4 – – – – – – – – – – – –
5 OK 7 OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7)Short circuit of MD contactor
drive TR is detected wrongly.
Defective contactor is detected
wrongly. Vehicle cannot travel
or handle cargo.
6 OK 53 OK(53) OK(53) OK(53) OK(53) OK(53) OK(53) OK(53) OK(53) OK(53) Short circuit of EPS drive TR is
detected wrongly. PS is impos-
sible.
7 – – – – – – – – – – – –
8 OK 21, 45, OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) –
56, 50
9 OK 52 OK OK OK OK OK OK OK OK(52) OK(52)
–
10 OK – OK OK OK OK OK OK OK OK OK
–
11 – – – – – – – – – – – –
12 – – – – – – – – – – – –
13 OK 7 OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) Short circuit of MD contactor
or handle cargo
sible.
15 – – – – – – – – – – – –
BE30 Series 70-29


Resis-
– GND)
2 – (Not connected) – – – – – –
3 CSDU(+) Travel U-phase current de- Power R-B 1.6kz 15 15 –
tector power supply, (+) supply
side
4 CSDU(S) Travel U-phase current de- AIN O 10.8kz 7 Varies with motor current: 3.0 – –
tector power supply, signal 11.0 Vmax
side
5 CSDW(+) Travel W-phase current de- Power R-B 1.6kz 15 15 –
side
6 CSDW(S) Travel W-phase current de- AIN P 10.8kz 7 Varies with motor current: 3.0 – –
side
8 – (Not connected) – – 10.8kz – – –
10 – (Not connected) – – 10.8kz – – –
11 P2 Main circuit: Secondary AIN Y 80kz BV BV
side of MD contactor
12 – (Not connected) – – 0z – – –
13 – (Not connected) – – 0z – – –
14 CSDU(-) Travel U-phase current detec- OV GR 0z 0 0 –
tor power supply, OV side
16 CSDW(-) Travel W-phase current detec- OV GR 0z 0 0 –
18 – (Not connected) – – 0z – – –
19 – (Not connected) – – 0z – – –
20 – (Not connected) – – 0z – – –
21 – (Not connected) – – 0z – – –
22 P12 Main circuit: Secondary AIN L-W 80kz BV BV –
side of cargo handling fuse
F2
70-30 BE30 Series


1 – – – – – – – – – – – –
2 – – – – – – – – – – – –
3 OK 19 OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) Travel current detector is defec-
tive. Vehicle cannot travel.
7 – – – – – – – – – – – –
8 – – – – – – – – – – – –
9 – – – – – – – – – – – –
10 – – – – – – – – – – – –
12 – – – – – – – – – – – –
13 – – – – – – – – – – – –
18 – – – – – – – – – – – –
19 – – – – – – – – – – – –
20 – – – – – – – – – – – –
21 – – – – – – – – – – – –
BE30 Series 70-31

CN3R (26-pole) P board connector

Resis-
– GND)
1 WVD Travel W-phase (Upper Gate R-B ∞ 11 – 13 11 – 13 –
FET of TMDW) gate power power (At CN3R-4) (At CN3R-4)
supply supply
2 GW1D Travel W-phase (Upper DO W-L ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
FET of TMDW) gate signal (At CN3R-4) turned OFF: 11 – 13 V turned ON: Varies largely with "ON"
1 period ratio.
3 GW2D Travel W-phase (Upper DO L-W ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
FET of TMDW) gate signal (At CN3R-4) turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON"
2 period ratio.
4 W0D Travel W-phase (Upper – GR-B ∞ – Measurement is impossible be- –
FET of TMDW) source cause of floating
5 V0D Travel V-phase (Upper FET – W-B ∞ – Measurement is impossible be- –
of TMDV) source cause of floating
6 GV2D Travel V-phase (Upper FET DO G-W ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
of TMDV) gate signal 2 (At CN3R-5) turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON"
period ratio.
7 GV1D Travel V-phase (Upper FET DO W-G ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
of TMDV) gate signal 1 (At CN3R-5) turned OFF: 11 – 13 V turned ON: Varies largely with "ON"
period ratio.
8 VVD Travel V-phase (Upper FET Gate R-W ∞ 11 – 13 11 – 13 –
of TMDV) gate power signal power (At CN3R-5) (At CN3R-5)
supply
9 – (Not connected) – – ∞ – – –
10 U0D Travel U-phase (Upper FET – GR ∞ Measurement is impossible be- –
of TMDU) source cause of floating
11 GU2D Travel U-phase (Upper FET DO G-Y ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
of TMDU) gate signal 2 (At CN3R-10) turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON"
period ratio.
12 GU1D Travel U-phase (Upper FET DO Y-G ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
of TMDU) gate signal 1 (At CN3R-10) turned OFF: 11 – 13 V turned ON: Varies largely with "ON"
period ratio.
13 UVD Travel U-phase (Upper FET Gate R-Y ∞ 11 – 13 11 – 13 –
of TMDU) gate power sup- power (At CN3R-10) (At CN3R-10)
ply supply
14 ZVD Travel Z-phase (Lower FET Gate R-L ∞ 11 – 13 11 – 13 –
of TMDW) gate power sup- power (At CN3R-17) (At CN3R-17)
ply supply
15 GZ1D Travel Z-phase (Lower FET DO O ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
of TMDW) gate signal 1 (At CN3R-17) turned OFF: 11 – 13 V turned ON: Varies largely with "ON"
period ratio.
16 GZ2D Travel Z-phase (Lower FET DO Y ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
of TMDW) gate signal 2 (At CN3R-17) turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON"
period ratio.
17 Z0D Travel Z-phase (Lower FET – B 0z – Measurement is impossible be- –
of TMDW) source cause of floating
18 Y0D Travel Y-phase (Lower FET – B 0z – Measurement is impossible be- –
19 GY2D Travel Y-phase (Lower FET DO L ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
20 GY1D Travel Y-phase (Lower FET DO G ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
21 YVD Travel Y-phase (Lower FET Gate R-L ∞ 11 – 13 11 – 13 –
of TMDV) gate power sup- power (At CN3R-18) (At CN3R-18)
ply supply
22 – (Not connected) – – ∞ – – –
23 X0D Travel X-phase (Lower FET – B 0z – Measurement is impossible be- –
24 GX2D Travel X-phase (Lower FET DO W ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
25 GX1D Travel X-phase (Lower FET DO P ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
of TMDU) gate signal 1 (At CN3R-23) turned OFF: 11 –13 V turned ON: Varies largely with "ON"
period ratio.
26 XVD Travel X-phase (Lower FET Gate R-L ∞ 11 – 13 11 – 13 –
ply supply
70-32 BE30 Series


1 NG Many NG NG NG NG NG NG NG NG NG –
3 NG Many NG NG NG NG NG NG NG NG NG
–
–
9 – – – – – – – – – – – –
22 – – – – – – – – – – – –
BE30 Series 70-33


Resis-
Pin Signal Wire tance Reference voltage Reference voltage when
Contents of signal Type when key switch switch is ON and control knob Remarks
– GND)
1 U0P Cargo handling U-phase – GR ∞ – Measurement is impossible be- –
(Upper FET of TMP) source cause of floating
2 GU2P Cargo handling U-phase DO G-Y ∞ 11 – 13 11 – 13 Normally OFF
(Upper FET of TMP) gate (At CN4R-1) (At CN4R-1)
signal 2
3 GU1P Cargo handling U-phase DO Y-G ∞ 11 – 13 11 – 13 Normally OFF
signal 1
4 UVP Cargo handling U-phase Gate R-Y ∞ 11 – 13 11 – 13 –
(Upper FET of TMP) gate power (At CN4R-1) (At CN4R-1)
power supply supply
5 – (Not connected) – – ∞ – – –
6 – (Not connected) – – ∞ – – –
7 X0P Cargo handling X-phase – B 0z – Measurement is impossible be- –
(Lower FET of TMP) source cause of floating
8 GX2P Cargo handling X-phase DO W ∞ 11 – 13 x 0.85 (At (*3) –
(Lower FET of TMP) gate CN4R-7)
signal 2
9 GX1P Cargo handling X-phase DO P ∞ 11 – 13 (*3) –
(Lower FET of TMP) gate (At CN4R-7)
signal 1
10 XVP Cargo handling X-phase Gate R-L ∞ 11 – 13 11 – 13 –
(Lower FET of TMP) gate power (At CN4R-7) (At CN4R-7)
power supply supply
11 – (Not connected) – – ∞ – – –
12 – (Not connected) – – 0z – – –
70-34 BE30 Series


1 NG 30, 31 NG NG NG NG NG NG NG NG NG Cargo handling power module
(30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) (30, 31) is broken, shorted, or open.


5 – – – – – – – – – – – –
6 – – – – – – – – – – – –


11 – – – – – – – – – – – –
12 – – – – – – – – – – – –
BE30 Series 70-35


Resis-
ON (V) is operated (V)
– GND)
1 N1 OV OV B 5.5kz 0 0 –
2 (Not connected) – – 0z – – –
3 N1 OV OV B 0z 0 0 –
4 (Not connected) – – ∞ – – –
5 VB4B Control power supply dur- Power R 80kz BV BV –
ing kickback + MPS supply
contactor power supply (48 V)
7 G3 EPS transistor (Upper side DO W ∞ 15V When EPS operates: 0 V – 12 V –
of TMPS2) gate signal (At CN8R-18) (Varies largely with "ON" period
ratio of chopper) (*3)
8 G4 EPS transistor (Lower side DO G 50kz 0 (At CN8R-19) When EPS operates: 0 V – 12 V –
of TMPS2) gate signal (Varies largely with "ON" period
9 G1 EPS transistor (Upper side DO Y ∞ 15V When EPS operates: 0 V – 12 V –
10 G2 EPS transistor (Lower side DO GR-B 56kz 0 (At CN8R-21) When EPS operates: 0 V – 12 V –
12 N1 OV OV B 5.5kz 0 0 –
13 (Not connected) – – 5.5kz – – –

14 N1 OV OV B 0z 0 0 –
16 (Not connected) – – 80kz – – –
18 E3 EPS transistor (Upper side DO O ∞ 0 (At CN8R-7) Measurement is impossible –
of TMPS2) emitter signal because of floating
19 E4 EPS transistor (Lower side DO W-L >500kz 0 (At CN8R-8) Measurement is impossible –
20 E1 EPS transistor (Upper side DO L-R ∞ 0 (At CN8R-9) Measurement is impossible –
21 E2 EPS transistor (Lower side DO G-W >500kz 0 (At CN8R-10) Measurement is impossible –
(*1) While the vehicle is not regenerating, the source voltage supplied by the multi-controller is the reference voltage.
(*2) A reference value cannot be set since the serial communication line is used.
(*3) A reference value cannot be set since the voltage varies largely with the outputting condition ("ON" period
ratio) while FED and IGBT are in operation.
(*4) Since the voltage is chopped, the reference value is about 75% of the battery voltage used as the control
power supply. The measured value may depends on the multimeter used.
70-36 BE30 Series


1 NG Many NG NG NG NG NG NG NG NG NG When CN8R-12 is also discon-
nected, connector may be broken.
OK – OK OK OK OK OK OK OK OK OK If only this line is disconnected,
there is no problem.
2 – – – – – – – – – – – –
4 – – – – – – – – – – – –
5 OK – OK OK OK OK OK OK OK OK OK PS kickback operation is impossi-
ble.
6 – – – – – – – – – – – –
7 NG 50 OK OK OK OK OK OK OK OK NG EPS transistor is broken. PS is
impossible.

impossible.

impossible.

impossible.
11 – – – – – – – – – – – –
12 NG Many NG NG NG NG NG NG NG NG NG When CN8R-1 is also disconnect-
ed, connector may be broken.
13 – – – – – – – – – – – –
15 – – – – – – – – – – – –
16 – – – – – – – – – – – –
17 – – – – – – – – – – – –
18 NG 50 OK OK OK OK OK OK OK OK OK EPS transistor is broken. PS is
impossible.
impossible.
impossible.
impossible.
22 – – – – – – – – – – – –
BE30 Series 70-37

VOLTAGE CHECK TABLE (3.0 TON MODEL) TROUBLESHOOTING
14. CONNECTOR VOLTAGE CHECK TABLE

Voltage check table (3.0 ton model)
Use an analog multimeter. Set it for measurement of resistance (kz). Connect the negative (-) volt-
age side (red rod side) to the negative (-) terminal of the panel and connect the positive (+) voltage
side (black rod side) to the terminal to be measured. When measuring, disconnect only the connector
housing that contains the terminal to be measured.
BV: Rough battery voltage.
Resis-
– GND)
2 – (Not connected) – – >500kz – – –
3 REG Regenerating signal DO Sb 80kz (*1) Voltage ap- During regeneration: ON NchFET open drain output (Load * 5 V/2
output plied to multi-con- when below 0.5 V, Other mA/4.7z)
troller side state: OFF
4 SLMT2 Travel speed limit-2 SW DI BY ∞ 4.4 When switch is ON: 0 V OV short: Travel speed is not limited,
Open: Travel speed is limited
5 VS Control valve selection DI – ∞ 4.4 When switch is ON: 0 V Open: Proportional valve, OV short:
Manual valve
6 BRK Brake SW DI O ∞ 4.4 When switch is ON: 0 V OV short: Brake operates.
7 ACCLMT Lifting height SW DI Y ∞ 4.4 When switch is ON: 0 V Open: High lifting height (Acceleration
limiter operates)
10 TILT Tilt SW DI GR ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
11 DSR Reverse SW DI WB 50kz 0 When DSR is operated: BV 48Vhigh side input
12 DSF Forward SW DI L 50kz 0 When DSR is operated: BV 48Vhigh side input
(48 V)
14 OV OV (For SW input) OV Br 0z 0 0 –
15 – (Not connected) – – ∞ – – –
16 LICOM Lift interrupt command DI BrW ∞ 4.4 When switch is ON: 0 V Open: Cargo handling DUTY limit
input
17 LINT Lift interrupt SW DI YR ∞ 4.4 When switch is ON: 0 V Open: Interrupt is effective.
18 PB Parking SW DI RY ∞ 4.4 When switch is ON: 0 V Open: Parking brake is applied.

19 SEAT Seat SW DI Gr ∞ 4.4 When switch is ON: 0 V Open: Operator is out, OV short: Opera-
tor is seated
20 SWMONI SW monitor start input DI P ∞ 4.4 When switch is ON: 0 V Open: Monitor mode start
21 ATT1 ATT-1 SW DI BO ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
22 ATT2 ATT-2 SW DI GO ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
23 ATT3/ ATT-3 SW DI LO ∞ 4.4 When switch is ON: 0 V OV short: Hydraulic chopper operates.
RCH
24 EMG Main contactor (EMG) DI LB 30kz 0 When normal: BV, EMG 48Vhigh side input (MP contactor coil
state: 0 V current is supplied)
25 HORN Horn output DO – 15kz BV Horn operates: FETon (Max. NchFET open drain output (Max. 200 V/
0.6 V) 1.5 A)
(48 V)
70-38 BE30 Series

TROUBLESHOOTING VOLTAGE CHECK TABLE (3.0 TON MODEL)
OK: Device operates normally, or it has an error or cannot operate but it will not be broken.
NG: Device will be broken or damaged seriously.
All or one of codes concerned is displayed.

Key ON, SW ALL off" includes disconnection before Key ON.

Just be- While When travel While trav- Just before While cargo
Code Key Just
Pin Con- fore driv- travel motor is el motor is chopping for handling During
con- ON, SW before Remarks
No. dition ing travel motor is loaded regenerat- cargo han- motor is EPS
cerned ALL off EPS
motor driven heavily ing dling motor chopped
1 – – – – – – – – – – – –
2 – – – – – – – – – – – –
4 OK – OK OK OK OK OK OK OK OK OK Travel speed is limited.
5 OK – OK OK OK OK OK OK OK OK OK Proportional valve operation mode is

selected.
6 OK – OK OK OK OK OK OK OK OK OK Regenerating brake cannot be ap-
plied.
7 OK – OK OK OK OK OK OK OK OK OK High lifting height is limited.
8 OK – OK OK OK OK OK OK OK OK OK Cargo handling lift 1 does not operate.

9 OK – OK OK OK OK OK OK OK OK OK Cargo handling lift 2 does not operate.
10 OK – OK OK OK OK OK OK OK OK OK Cargo handling TILT does not operate.
11 OK – OK OK OK OK OK OK OK OK OK Vehicle does not travel in reverse.
12 OK – OK OK OK OK OK OK OK OK OK Vehicle does not travel forward.
13 OK – OK OK OK OK OK OK OK OK OK Power is not supplied (when CN1-26
is also disconnected).
15 – – – – – – – – – – – –
16 OK – OK OK OK OK OK OK OK OK OK Cargo handling DUTY is limited (when
LINT is effective).
17 OK – OK OK OK OK OK OK OK OK OK Cargo handling DUTY is limited (when
LICOMis open).
19 OK – OK OK OK OK OK OK OK OK OK Deadman function is turned ON.
20 OK – OK OK OK OK OK OK OK OK OK Monitor mode
operate.
operate.
operate.
24 OK 32 OK OK OK OK OK OK OK OK OK Cargo handling EGM SW is turned
ON.
26 OK – OK OK OK OK OK OK OK OK OK Power is not supplied (when CN1-13

is also disconnected).
BE30 Series 70-39


Resis-
Reference voltage Reference voltage when
– GND) ON (V) is operated (V)
1 MCTXDP TXD (+) TXD WL ∞ (*2) Reference [Pull-up power supply side: (+) Data transmitted to display
2 MCRXDP RXD (+) RXD W ∞ (*2) Reference [Photo coupler anode side: (+) Data received from display
3 PPDA-N Travel speed sensor A OV W 0z 0 Electromagnetic pickup input: –
(-) Common
4 PPDA-S Travel speed sensor A Pulse IN B 17kz 0 Electromagnetic pickup input: 850 Hz/ 10 km
(+) Signal
5 ATIN Solenoid valve analogue AIN W 8.4kz (*1) Voltage ap- Input: Min. 4.25 V = DUTY min. –
signal plied to multi-con- 100%
troller side Max. 1.9 V = DUTY 0%
6 PSPT-S Torque sensor (S) AIN GW 10kz 0.4 – 4.6 If steering wheel is turned to –
right, VR wiper moves toward
PSPT-(-) side (Signal voltage
lowers).
to right end: 0.3 – 0.6 V
to left end: 4.4 – 4.7 V
7 PSPT-P Torque sensor (+) PSPT(+) LY 1kz 4.4 – 4.7 4.4 – 4.7 5V power supply with series R
8 ACCD-S Travel accelerator VR AIN GY 13.5kz 0.3 – 4.7 VR wiper moves toward (+) side –
(S) (Signal increases) o DUTY is
increased.
When accelerator is OFF: 0.3 –
0.9 V
When accelerator is ON: 3.2 –
4.7 V
9 ACCD-P Travel accelerator VR ACCD(+) RB ∞ 5 5 5V power supply with series R
(+)
10 ACCP-S Lift VR, (2) side (S) AIN YG 13.5kz 0.4 – 4.6 VR wiper moves toward (+) side –
(Signal increases) o DUTY is
increased.
When lift SW is OFF: 0.3 – 0.9 V
When lift SW is ON: 4.1 – 4.6 V
11 ACCP-P Lift VR, (3) side (+) LTVR(+) YG 1kz 4.1 – 4.6 4.1 – 4.6 5V power supply with series R
12 MCTXD TXD (-) TXDO OL ∞ (*2) Reference [Open drain power supply side: Data transmitted to display
N (Sync.) cannot be set. (-) side]
13 MCRXD RXD (-) RXDO B ∞ (*2) Reference [Photo coupler anode side: (-) Data received from display
N (Sync.) cannot be set. side]
14 MCCOM MC communication line OV (com) BO 0z 0 0 –
shield
15 PCCOM Travel sensor shield OV (com) BW 0z 0 0 –
16 ATCOM Solenoid valve shield OV (com) BG 0z 0 0 –
17 ATN Solenoid valve GND (0 V) OV B 0z 0 0V –
18 PSPT-N Torque sensor (-) PSPT (-) BY 200z 0.3 – 0.6 0.3 – 0.6 OV with series R
19 AC1 AC1 (Accelerator SW) DI RL ∞ 4.4 When switch is ON: 0 V OV short: Travel operation permis-
input sion
20 ACCD-N Travel accelerator VR, OV YB 0z 0 0V –
(-) side
21 ACCP-N LIFT VR, (1) side (-) OV BW 200z 0.3 – 0.9 0.3 – 0.9 OV with series R
22 – (Not connected) – – ∞ – – –
70-40 BE30 Series


mission
error
6 OK – OK OK OK OK OK OK OK OK OK PS cannot operate.
10 OK 35 OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) OK(35) Cargo handling lift VR is de-
fective (in manual valve mode)
mission
error
14 OK – OK OK OK OK OK OK OK OK OK Communication error may be

made.

wrongly.
16 OK – OK OK OK OK OK OK OK OK OK Cargo handling chopper
DUTY is unstable (in propor-
tional valve mode).
17 OK – OK OK OK OK OK OK OK OK OK Cargo handling chopper
DUTY is unstable (in propor-
tional valve mode).
19 OK – OK OK OK OK OK OK OK OK OK Vehicle does not travel.
22 – – – – – – – – – – – –
BE30 Series 70-41

CN3 (4-pole) relay connector: For power supply

Resis-

(+48 V)
(+48 V)

Resis-
– GND)
1 EPS motor drive P24 R 24kz Unsettled Fluctuation when EPS rotates to Motor current direction when steer-
left: 0 – BV ing wheel is turned to right
CN4-2 o CN4-1
2 EPS motor drive P23 B 24kz Unsettled Fluctuation when EPS rotates to [= P23 o P24]
right: 0 – BV
For only this case, connect CN5-4 to red rod (0 V) of multimeter

and connect terminal to be measured to black rod (+ side).
Resis-
– GND)
1 +VC power supply (+10 V ± 5%) +VC R 7.3kz 10.2V 10.2V –
2 OV GND B 0z 0V 0V –
3 Sensor output OUT W 5.6kz 0.6V Varies with battery current –
(0.6 – 8.6 Vmax)
4 OV GND B X 0V 0V –

Resis-
Pin Signal Reference volt- Reference voltage when
Contents of signal Type Wire tance age when key switch is ON and control knob Remarks
2 – (Not connected) – – ∞ – – –
3 DMTH Travel motor temperature 0V GY 0z 0 0 –
-N (-)
4 DMTH Travel motor temperature AIN LO 5.5kz Approx. 3.48 Varies with temperature –
-S (S) (at 25°C) (0.2 – 4.8).
5 PPDB- Travel speed sensor B (-) 0V W 0z 0 Electromagnetic pickup input: –
N Common
6 PPDB- Travel speed sensor B (+) Pulse B 16.5kz 0 Electromagnetic pickup input: 850 Hz/10 km
S IN Signal
8 – (Not connected) – – ∞ – – –
10 – (Not connected) – – ∞ – – –
11 – (Not connected) – – 0z – – –
12 – (Not connected) – – 5.5z – – –
13 PPDB- Travel sensor shield 0V BW 0z 0 0 –
COM (COM)
14 – (Not connected) – – 6.2kz – – –
15 – (Not connected) – – ∞ – – –
16 – (Not connected) – – ∞ – – –
70-42 BE30 Series



detected wrongly.
detected wrongly.

Pin Con- Code Key fore driv- travel motor is
for handling During
con- ON, SW ing fore Remarks
No. dition cerned travel motor is loaded
generating cargo han-
motor is EPS
ALL off EPS
1 [Since this connector is used/controlled on multimeter side, ask the section in charge of your company.] –
2
3

Code Key Just be- While When travel While travel Just before While cargo Just be-
for handling During
con- ON, SW ing
No. dition cerned travel motor is loaded cargo han- motor is fore EPS Remarks
ALL off generating EPS
1 – – – – – – – – – – – –
2 – – – – – – – – – – – –
7 – – – – – – – – – – – –
8 – – – – – – – – – – – –
9 – – – – – – – – – – – –
10 – – – – – – – – – – – –
11 – – – – – – – – – – – –
12 – – – – – – – – – – – –
wrongly.
14 – – – – – – – – – – – –
15 – – – – – – – – – – – –
16 – – – – – – – – – – – –
BE30 Series 70-43


Resis-
1 SH+ Shunt resistance for detect- AIN Y-L 10.3kz 0 When EPS operates: Varies –
ing EPS current, (+) side largely with "ON" period ratio of
chopper
2 – (Not connected) – – ∞ – – –
3 – (Not connected) – – ∞ – – –
4 – (Not connected) – – ∞ – – –
5 THD+ Travel controller tempera- AIN W-BR 5.3kz Approx. 4.05 Varies with temperature –
ture sensor (at 25°C) (0.2 – 4.8).
6 THP+ Cargo handling controller AIN W-L 5.3kz Approx. 4.05 Varies with temperature –
temperature sensor (at 25°C) (0.2 – 4.8).
7 SH- Shunt resistance for detect- OV G-W 9.3kz 0 0 –
ing EPS current, (-) side
8 – (Not connected) – – ∞ – – –
9 – (Not connected) – – ∞ – – –
10 – (Not connected) – – 0z – – –
11 HTD- Travel controller tempera- OV GR 0z 0V 0V –
ture sensor 0 V
12 THP- Cargo handling controller OV GR 0z 0V 0V –
temperature sensor 0 V

Resis-
No. name Contents of signal Type color age when key
(Terminal switch switch is ON and control knob Remarks
– GND)
1 P22 Main circuit: Secondary AIN W-G 80kz BV Before MPS contactor is turned –
side of MPS contactor ON: Approx. 53 V (When BV = 48
V)
After MPS contactor is turned ON:
BV
2 P3 Main circuit: Secondary AIN BR 33kz BV Before MD contactor is turned ON: 0
Before key SW is turned ON: 0 V – 47 V
side of fuse F1 V – 47 V (When BV = 72 V)
After MD contactor is turned ON:
After key SW is turned ON: Boosting
BV charging until MD contactor is
turned ON
3 P4 Main circuit: Output termi- AIN L 49.8kz Approx. 24.5 V Varies largely when inverter oper- Vehicle stops, direction lever in neu-
nal of U-phase power mod- ates. tral, and accelerator is OFF.
ule
4 – (Not connected) – – ∞ – – –
5 MD (+) MD contactor coil power Power Y-R ∞ BV When chassis EMGsw operates: –
supply (+) supply 0 V, When normal: BV
(BV48)
6 MPS MPS contactor coil power Power R-L ∞ BV BV –

(+) supply (+) supply
(BV48)
7 – (Not connected) – – ∞ – – –
8 P1 Main circuit voltage (P1) AIN R 9.2kz BV BV –
9 P21 Main circuit: Secondary AIN W-R 80kz BV BV –

side of EPS fuse F3
10 P13 Main circuit: (PA) side of AIN L-R 45kz (*3) Before MP contactor is turned ON: 0 Before key SW is turned ON: 0 V –
cargo handling motor V – 47 V 47 V (When BV = 72 V)
After MP contactor is turned ON: After key SW is turned ON: Boosting
a) While cargo handling chopper is charging until MP contactor is
stopped: Approx. BV turned ON
b) While cargo handling chopper is
operating: Varies with "ON" period ra-
tio. Not fixed.
11 – (Not connected) – – ∞ – – –
12 – (Not connected) – – 45kz – – –
13 MD MD contactor coil drive FET OPEND Y-G 45kz BV When MP contactor is turned –
drain OFF: BV
When chassis EMGsw operates:
0 V, When normal: BV
When MP contactor is turned ON:
BV x 75% (*4)
14 MPS MPS contactor coil drive OPEND R-W 45kz BV o 0.2V When key SW is turned ON –
FET drain (When MPS contactor is turned
OFF): BV
When MPS contactor is turned
ON: 0.2 V
15 – (Not connected) – – ∞ – – –
16 N1 OV for contactor coil drive OV B 0z – – –
circuit
70-44 BE30 Series


1 OK – OK OK OK OK OK OK OK OK OK EPS overcurrent is detected
wrongly. PS is impossible.
2 – – – – – – – – – – – –
3 – – – – – – – – – – – –
4 – – – – – – – – – – – –
7 NG 50 OK OK OK OK OK OK OK OK NG EPS current detector operates
wrongly.
EPS transistor is broken. PS is
impossible.
8 – – – – – – – – – – – –
9 – – – – – – – – – – – –
10 – – – – – – – – – – – –

Code Key
for handling During
No. dition cerned ALL off ing travel motor is loaded cargo han-
generating dling motor is EPS EPS
motor driven heavily motor chopped
4 – – – – – – – – – – – –
5 OK 7 OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7)
Short circuit of MD contactor
or handle cargo.
sible.
7 – – – – – – – – – – – –
8 OK 21, 45, OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) OK(21) –
56, 50
9 OK 52 OK OK OK OK OK OK OK OK(52) OK(52)
–
10 OK – OK OK OK OK OK OK OK OK OK
–
11 – – – – – – – – – – – –
12 – – – – – – – – – – – –
13 OK 7 OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) OK(7) Short circuit of MD contactor
or handle cargo
sible.
15 – – – – – – – – – – – –
BE30 Series 70-45


Resis-
– GND)
2 – (Not connected) – – – – – –
3 CSDU(+) Travel U-phase current de- Power R-B 1.6kz 15 15 –
side
4 CSDU(S) Travel U-phase current de- AIN O 10.8kz 7 Varies with motor current: 3.0 – –
side
5 CSDW(+) Travel W-phase current de- Power R-B 1.6kz 15 15 –
side
6 CSDW(S) Travel W-phase current de- AIN P 10.8kz 7 Varies with motor current: 3.0 – –
side
8 – (Not connected) – – 10.8kz – – –
10 – (Not connected) – – 10.8kz – – –
11 P2 Main circuit: Secondary AIN Y 80kz BV BV
side of MD contactor
12 – (Not connected) – – 0z – – –
13 – (Not connected) – – 0z – – –
18 – (Not connected) – – 0z – – –
19 – (Not connected) – – 0z – – –
20 – (Not connected) – – 0z – – –
21 – (Not connected) – – 0z – – –
22 P12 Main circuit: Secondary AIN L-W 80kz BV BV –
side of cargo handling fuse
F2
70-46 BE30 Series


1 – – – – – – – – – – – –
2 – – – – – – – – – – – –
3 OK 19 OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) OK(19) Travel current detector is de-
fective. Vehicle cannot travel.
7 – – – – – – – – – – – –
8 – – – – – – – – – – – –
9 – – – – – – – – – – – –
10 – – – – – – – – – – – –
12 – – – – – – – – – – – –
13 – – – – – – – – – – – –
18 – – – – – – – – – – – –
19 – – – – – – – – – – – –
20 – – – – – – – – – – – –
21 – – – – – – – – – – – –
BE30 Series 70-47


Resis-
– GND)
1 WVD Travel W-phase (Upper Gate R-B ∞ 11 – 13 11 – 13 –
FET of TMDW) gate power power (At CN3R-4) (At CN3R-4)
supply supply
2 GW1D Travel W-phase (Upper DO W-L ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
FET of TMDW) gate signal (At CN3R-4) turned OFF: 11 – 13 V turned ON: Varies largely with "ON"
1 period ratio.
3 GW2D Travel W-phase (Upper DO L-W ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
FET of TMDW) gate signal (At CN3R-4) turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON"
2 period ratio.
4 W0D Travel W-phase (Upper – GR-B ∞ – Measurement is impossible be- –
FET of TMDW) source cause of floating
5 V0D Travel V-phase (Upper FET – W-B ∞ – Measurement is impossible be- –
6 GV2D Travel V-phase (Upper FET DO G-W ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
7 GV1D Travel V-phase (Upper FET DO W-G ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
8 VVD Travel V-phase (Upper FET Gate R-W ∞ 11 – 13 11 – 13 –
of TMDV) gate power signal power (At CN3R-5) (At CN3R-5)
supply
9 – (Not connected) – – ∞ – – –
10 U0D Travel U-phase (Upper FET – GR ∞ Measurement is impossible be- –
11 GU2D Travel U-phase (Upper FET DO G-Y ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
12 GU1D Travel U-phase (Upper FET DO Y-G ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
of TMDU) gate signal 1 (At CN3R-10) turned OFF: 11 – 13 V turned ON: Varies largely with "ON"
period ratio.
13 UVD Travel U-phase (Upper FET Gate R-Y ∞ 11 – 13 11 – 13 –
ply supply
14 ZVD Travel Z-phase (Lower FET Gate R-L ∞ 11 – 13 11 – 13 –
of TMDW) gate power sup- power (At CN3R-17) (At CN3R-17)
ply supply
15 GZ1D Travel Z-phase (Lower FET DO O ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
of TMDW) gate signal 1 (At CN3R-17) turned OFF: 11 – 13 V turned ON: Varies largely with "ON"
period ratio.
16 GZ2D Travel Z-phase (Lower FET DO Y ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
of TMDW) gate signal 2 (At CN3R-17) turned OFF: (11 – 13) x 0.85 turned ON: Varies largely with "ON"
period ratio.
17 Z0D Travel Z-phase (Lower FET – B 0z – Measurement is impossible be- –
of TMDW) source cause of floating
18 Y0D Travel Y-phase (Lower FET – B 0z – Measurement is impossible be- –
19 GY2D Travel Y-phase (Lower FET DO L ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
20 GY1D Travel Y-phase (Lower FET DO G ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
21 YVD Travel Y-phase (Lower FET Gate R-L ∞ 11 – 13 11 – 13 –
of TMDV) gate power sup- power (At CN3R-18) (At CN3R-18)
ply supply
22 – (Not connected) – – ∞ – – –
23 X0D Travel X-phase (Lower FET – B 0z – Measurement is impossible be- –
24 GX2D Travel X-phase (Lower FET DO W ∞ 11 – 13 x 0.85 When FRSW and accelerator are When FRSW or accelerator is
period ratio.
25 GX1D Travel X-phase (Lower FET DO P ∞ 11 – 13 When FRSW and accelerator are When FRSW or accelerator is
of TMDU) gate signal 1 (At CN3R-23) turned OFF: 11 –13 V turned ON: Varies largely with "ON"
period ratio.
26 XVD Travel X-phase (Lower FET Gate R-L ∞ 11 – 13 11 – 13 –
ply supply
70-48 BE30 Series


–
–
9 – – – – – – – – – – – –
22 – – – – – – – – – – – –
BE30 Series 70-49


Resis-
Contents of signal Type when key switch switch is ON and control knob Remarks
– GND)
1 U0P Cargo handling U-phase – GR ∞ – Measurement is impossible be- –
(Upper FET of TMP) source cause of floating
2 GU2P Cargo handling U-phase DO G-Y ∞ 11 – 13 11 – 13 Normally OFF
signal 2
3 GU1P Cargo handling U-phase DO Y-G ∞ 11 – 13 11 – 13 Normally OFF
signal 1
4 UVP Cargo handling U-phase Gate R-Y ∞ 11 – 13 11 – 13 –
(Upper FET of TMP) gate power (At CN4R-1) (At CN4R-1)
power supply supply
5 – (Not connected) – – ∞ – – –
6 – (Not connected) – – ∞ – – –
7 X0P Cargo handling X-phase – B 0z – Measurement is impossible be- –
(Lower FET of TMP) source cause of floating
8 GX2P Cargo handling X-phase DO W ∞ 11 – 13 x 0.85 (At (*3) –
(Lower FET of TMP) gate CN4R-7)
signal 2
9 GX1P Cargo handling X-phase DO P ∞ 11 – 13 (*3) –
(Lower FET of TMP) gate (At CN4R-7)
signal 1
10 XVP Cargo handling X-phase Gate R-L ∞ 11 – 13 11 – 13 –
(Lower FET of TMP) gate power (At CN4R-7) (At CN4R-7)
power supply supply
11 – (Not connected) – – ∞ – – –
12 – (Not connected) – – 0z – – –
70-50 BE30 Series




5 – – – – – – – – – – – –
6 – – – – – – – – – – – –


11 – – – – – – – – – – – –
12 – – – – – – – – – – – –
BE30 Series 70-51


Resis-
ON (V) is operated (V)
– GND)
1 N1 OV OV B 5.5kz 0 0 –
2 (Not connected) – – 0z – – –
3 N1 OV OV B 0z 0 0 –
5 VB4B Control power supply dur- Power R 80kz BV BV –
ing kickback + MPS supply
contactor power supply (48 V)
7 G3 EPS transistor (Upper side DO W ∞ 15V When EPS operates: 0 V – 12 V –
8 G4 EPS transistor (Lower side DO G 50kz 0 (At CN8R-19) When EPS operates: 0 V – 12 V –
9 G1 EPS transistor (Upper side DO Y ∞ 15V When EPS operates: 0 V – 12 V –
10 G2 EPS transistor (Lower side DO GR-B 56kz 0 (At CN8R-21) When EPS operates: 0 V – 12 V –
12 N1 OV OV B 5.5kz 0 0 –
13 (Not connected) – – 5.5kz – – –

14 N1 OV OV B 0z 0 0 –
16 (Not connected) – – 80kz – – –
18 E3 EPS transistor (Upper side DO O ∞ 0 (At CN8R-7) (*3) –
of TMPS2) emitter signal
19 E4 EPS transistor (Lower side DO W-L >500kz 0 (At CN8R-8) (*3) –
20 E1 EPS transistor (Upper side DO L-R ∞ 0 (At CN8R-9) (*3) –
21 E2 EPS transistor (Lower side DO G-W >500kz 0 (At CN8R-10) (*3) –
(*1) While the vehicle is not regenerating, the source voltage supplied by the multi-controller is the reference voltage.
(*2) A reference value cannot be set since the serial communication line is used.
(*3) A reference value cannot be set since the voltage varies largely with the outputting condition ("ON" period
ratio) while FED and IGBT are in operation.
(*4) Since the voltage is chopped, the reference value is about 75% of the battery voltage used as the control
power supply. The measured value may depends on the multimeter used.
70-52 BE30 Series


Code Key While travel Just
con- ON, SW motor is re- before Remarks
2 – – – – – – – – – – – –
4 – – – – – – – – – – – –
5 OK – OK OK OK OK OK OK OK OK OK PS kickback operation is impossi-
ble.
6 – – – – – – – – – – – –
7 NG 50 OK OK OK OK OK OK OK OK NG EPS transistor is broken. PS is im-
possible.

possible.

possible.

possible.
11 – – – – – – – – – – – –
13 – – – – – – – – – – – –
15 – – – – – – – – – – – –
16 – – – – – – – – – – – –
17 – – – – – – – – – – – –
18 NG 50 OK OK OK OK OK OK OK OK OK EPS transistor is broken. PS is im-
possible.
possible.
possible.
possible.
22 – – – – – – – – – – – –
BE30 Series 70-53

TROUBLESHOOTING CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM

1. CONTROLLER(1.0 - 2.5 TON MODELS)
(2ton)
1
3
1
G-W
FAN
7
Y-L EPS CURRENT
1
W-L
11 5 12 6
GR BW
THP
13
W-BR SHIELD SOLENOID P.P.
W (-)
GR
CNPDB
5
TRAVEL SPEED SENSOR B
1 2
1
2
THD
B
CONTACTOR DRIVE CIRCUIT

CN7 (+) (TRAVEL MOTOR)
6
GY
TEMPERATURE SENSOR B
3
ANALOG INPUT CIRCUIT
Y-R LO (TRAVEL MOTOR)
4
14 6 13 5
Y-G CN11 THERMISTOR
MD
2
MD
R-L LY CLOCKWISE
[COIL CHOPPER] 5V
7
R-W ROTATION
(+)
MPS
MPS
GW
6
L BY
(SIG)
18
3
R TORQUE SENSOR
YG
(SIG)
(2.18KΩ ±0.45KΩ)
9 16 8
10
B
(+) UP
YG
(-)
5V
11
W-R LIFT VR
CONTROLLER
(-)
BW
BR (ACCELERATOR)
21
AUTO LIFT
1 10 2
L-R GY
(SIG)
CBD
(+) UP
W-G RB
5V TRAVEL ACCELERATOR POT
9
Y CN4
(-)
YB (4KΩ ±1.2KΩ)
3 14 4 15 5 16 6 17 22 11
20
L-W
ANALOG INPUT CIRCUIT

RL ACCELERATOR SWITCH
19
GR
4 3 2 1 W SOLENOID
OUT
P CPU
(P6)
5V VALVE GND
5
PHASE W CURRENT + B
GR
17
PERIPHERAL
R-B BG SHIELD
COMMUNICATION
CIRCUIT SOLENOID VALVE
16
GR ANALOG SIGNAL
B
CIRCUIT
O RXD(-) DATA RECEIVED
13
TMDW
1110 9 8 7 5 4 3 2 1 PHASE U CURRENT W

GR RXD(+) FROM DISPLAY
2
R-B OPEN DRAIN OL
15V TXD(-) DATA SENT
12
CN5 WL DISPLAY
5V TXD(+) TO DISPLAY
1
COUNTER REGENERATING
INPUT BO STATUS SIGNAL
SHIELD
OUT
(P5)
14
OPEN DRAIN BW
15
ON/OFF OUTPUT
W SHIELD (-) SOLENOID P.P.
(2ton)
CIRCUIT
CNPDA
3
TRAVEL SPEED SENSOR A
1 2
R R B B B (+) (TRAVEL MOTOR)
4
2 1 7 8
TMDV
1110 9 8 7 5 4 3 2 1 B CN2
4 14 15 16 17
Y
DW
CN7R
O 5V HORN OUTPUT
HORN
25
DIM
R-L Sb SWITCH
3
GR-B (MANUAL)
DV
L GZD
L-W
8 10 12
8 10 12
L GWD LO + -
3
4 3 2 1 W-L
OUT
ATT-3 SWITCH
23
(P4)
L GYD TRAVEL HORN
2
R-B GO
ATT-2 SWITCH
22
L GVD GATE
1
DU
B BO
6
L GXD CONTROL
TRAVEL IC GATE CIRCUIT

ATT-1 SWITCH
21
5 21 20 19 18
-
L
4
GR
F1
L GUD
(P3)
TILT SWITCH
10
G
2
LR
TMDU
1110 9 8 7 5 4 3 2 1 R-L LIFT-2 SWITCH
9
L GXP
ON/OFF INTPUT CIRCUIT

W-B LR
3
LOAD LIFT-1 SWITCH
8
G-W GATE YR
CN2R CN8
17
CONTROL LIFT INTERRUPT SWITCH
6
W-G BrW
7
16
R-W LIFT INTERRUPT COMMAND
CBP
Y
13 12 11 10 26 25 24 23 8
B FAN POWER LIFT HEIGHT SWITCH
7
SUPPLY CIRCUIT BY
W TRAVEL SPEED-2 SWITCH
4
P
Y CONTROL VALVE SELECTION
5
R-L
13 14 7 3 4 5 8 9 10 11 1 2 6
13 14 7 3 4 5 8 9 10 11 1 2 6
B O
BRAKE SWITCH
6
GR
(P13)
OUT
B RY
G-Y
18
B PARKING SWITCH
Gr
PA
Y-G
19
B SEAT SWITCH
P
PM
R-Y R-Y SWITCH MONITOR
20
(P12)
MD
F2
5V
(P2)
L Br STARTING SWITCH
CN3R TRAVEL GATE POWER SUPPLY
14
5V 0V (SW)
TMP
1110 9 8 7 5 4 3 2 1 LOAD GATE POWER SUPPLY W-B

B
W-L
7
LB HYDRAULIC CONTACTOR
PB
W
LOAD IC GATE CIRCUIT
24
R-B
8
P L
O DSF
1 10 9
12
R-L 15V WB
P
DSR
11
GR
R Y
G-Y
13
F4
CH
Y-G Y
CN1R CN9
G3
G4
E3
E4
26
3
R-Y CN1
MPS
L GATE IC CN1E
EPS MOTOR CN4R B
F3
2 4 6 8 10 12 14 16 9 11 13 15 7 5 3 1
2 4 6 8 10 12 14 16 9 11 13 15 7 5 3 1
GND
TMPS2
L
3
(Key)
CLOCKWISE L W
W
CN4
1 2 3 5 4
1 2 3 5 4
ROTATION L L OUT
9 20 10 21 19 8 18 7
3
(P21)
(P22)
O B
L L EPS GATE GND
R
2
G
L
23 24
R
1
L CONTROL
P P
PSM
W-L
SH
+Vc
1
L L
2
G-W CN5
B
L
I
GR-B B
L CN6
TMPS1
-
(P1)
L-R W
L
3
Y 5V 5V
L B B
1
R CONTROL POWER
2
SUPPLY (8V, 18V) L W
5
W
G1
G2
E1
E2
1
TRAVEL GATE POWER SUPPLY (VB48)
+
B CN3 FUSE EMERGENCY

L EPS GATE POWER SUPPLY
1 12 3 14
B LOAD GATE POWER SUPPLY SWITCH KEY SWITCH

L
B
EPS GATE POWER SUPPLY L
B
L
48V
Batt.
POWER SUPPLY CIRCUIT [EPS BOARD] [CPU BOARD]

CPS
CN2E
-
CN8R (POWER SUPPLY BOARD) CN6R

CSB
BE30 Series 70-55

2. CONTROLLER(3.0 TON MODEL)
BE30 Series 70-57

W W
11 1 Sensor +5V
Y Y
1 2 LED (1st layer)
L L
2 3 LED (2nd layer)
Br Br
3 4 LED (3rd layer)
YR YR
(L)/5W
4 5 LED (4th layer)
(R)/5W
LW
(L)/25W
(L)/45W
LW
(R)/25W
(R)/45W
5 6 LED (5st layer)
BrW BrW
Horn SW
8 7 LED (Memory)
Light SW
Offset SW
Head lamp
Head lamp
YB YB
6 8 LED (Putting up)
LR LR
Direction SW
Clearance lamp
7 9 LED (Putting down)
Clearance lamp
LIfting hight panel
Dimmer SW
Turn signal lamp
Turn signal lamp

BrR BrR
Lifting height reference SW
Tilting angle sensor

9 10 LED (Abnormal)
Turn signal SW
Lifting height (2) reference SW
(Steering column)
YG YG
Fork level display SW

10 25 Buzzer
BE30 Series
Buzzer
26
G G
F
F
Encoder specification
R
R
Lifting height (1) encoder
Lifting height (2) encoder
9 19 Memory SW
L
R
(26P)
P P
Charger control section

CN6S
7 20 Putting up SW
BW
BW
Sb Sb
Power supply unit of charger

8 21 Putting downSW
Lg Lg
2 14 Number-of-layer setting 1
GW GW
LgR LgR
Meter panel
Key SW
GR
External relay
GR
P
Y
S
5 24
T1
T2
Number-of-layer setting 4
Y
B
R
B
(12P)
RG
(20P)
LgY LgY
B
R
O
G
B
B
B
B
RW
0.85W
RG
17
Y
6 Number-of-layer setting 5
B
R
OW
B
RG
0.85RW
B
BrW
1 18 SW GND
(Number-of-layer display)
3
1
2
1
1
2
3
2
11
Automatic lifting height control panel
4
2
3
1
4
2
3
1
1
1
10
12
19
17
20
10
18
16
11
12
13
14
15
3
4
5
9
1
7
4
5
6
7
8
9
3
1
3
2
1
3
2
2
1
1
6
4
2
5
3
3
2
12
4
7
6
5
8
3
2
13
P
R
L
Y
G
W
L
Br
Gr
VW
PL
Sb
LW
PB
Br
BW
WB
TROUBLESHOOTING
Lg
BY
BY
22
GrL
WR
BW
GrR
DK1
1
4
3
2
6
5
1
4
3
2
6
5
0.85B
0.85G
23
0.85RW
0.85RG
0.85RG
0.85B
0.85B
0.85Y
0.85WG
RW CK1
0.85GL
0.85RW
Spare
0.85RG
GR FK1
LW EK1
RL AJ1
RG BJ1
RG BJ1
RL AJ1
RB CJ1
WL DJ1
WL DJ1
RB CJ1
0.85YG
GL GK1
B
R
B
R
BR HG1
G
G
Lg GG1
LA5
W
W
HA5
JE1
IE1
LE1
FE1
MA3
SE1
PE1
AF1
RE1
GW KE1
BE1
AE1
GY NE1
HE1
LgB DE1
CE1
7
QE1
OE1
GE1
WG ME1
0.85LR HK1
0.85WL BK1
0.85WG DK2
8
AK1
HA1
16
1
4
3
2
1
1
4
3
2
3
2
4
2
17
(22P)
CN5S
18
W
19
R
6 Encoder 2 (B-phase)
G
GR FK2
RW CK2
5 Encoder 2 (A-phase)
GL GK2
RW CK1
B
21
W
4 Encoder (GND)
Worming lamp
0.85Y HA6
0.85WL BK2
R
0.85B BC3A
0.85B BC4A
0.85WL BK1
0.85YR IK1
0.85YR IK1
0.85WG DK4
3 Encoder 1 (B-phase)
0.85B BC6A
0.85B BC5A
G
2 Encoder 1 (A-phase)
B
1
2
1 Encoder (Power supply)
For CH interlock
22
L
9 Lifting height reference SW
BY
10 SW GND
1.25B
Br
11 Lifting height reference (2)SW
0.85WG
WR
13 Sensor +5V
Lg
14 Tilting angle sensor
Y
To MGS auxiliary contact in charger

20 Fork leveling display SW
DK3
BC1A
12
BW
15 SW GND
P
7 Offset SW
1
2
0.85W
0.85WR
3
4
(17P)
CN3S
AC3
KK1
6
8
SHIELD WIRE
10
ASSSH 5SH050 GR
16
17
Chassis EMG.SW 31
30
0.85R 0.85LY ED1 G EG1A
1 22 Bit signal 1
0.85W 0.85YG AK1 Y DG1A
2 23 Bit signal 2
(31P)
CN1S
0.85Y 0.85WG DK5 B CG1A

3 24 Bit signal 3
0.85G 0.85LB IA1 W BG1A
4 25 Analog signal
R AG1A
26 Analog GND
7
IA2 0.85LB
8 Power supply for valve
BC2A 0.85B
Flasher unit 21 VB(-)
HA3 0.85Y
9 KEY SW
Y LW EK1 GA1 BO
2 5 ATT1 SW output
R WG DK6 FA1 GO
F 1 JADA BY 6 ATT2 SW output
19
RA1 LO
17 ATT3 SW output
FB1 W
YB JA3A 1 P-motor speed command signal
JAEA B
2 Analog GND
Charging mode SW DA3 GR
RL AD1 3 Tilt SW output
EA3 LR
(Open: Test mode) 4 Lift SW output
GB1 1
12
13
ASSSH
(22P)
14
CN7S
15
2SH050 BR
SHIELD WIRE
21
22
LR AH1 AH1A LR
1 16 Lift-up valve (+)
Lift up valve BW BH1 BH1A BW
3 3 Lift-up valve (-)
CH1A GW
18 Tilt-back valve (+)
GW CH1 DH1A G
2 7 Tilt valve (-)
Tilt back valve G DH1 EH1A Y
4 17 ATT1-A valve (+)
FH1A W
5 ATT1 valve (-)
Y EH1 GH1A WR
1 19 ATT2-A valve (+)
ATT1-A valve W FH1 HH1A BY
4 9 ATT2 valve (-)
IH1A GO
20 ATT3-A valve (+)
WR GH1 JH1A GY
System controller
2 11 ATT3 valve (-)

ATT2-A valve BY HH1 KH1A L
5 2 Lift-down valve (+)
LH1A GB
6 Tilt-forwad valve (+)
GO IH1 MH1A R
3 4 ATT1-B valve (+)
ATT3-A valve GY JH1 NH1A O
6 8 ATT2-B valve (+)
OH1A V
10 ATT3-B valve (+)
L KH1
1
Lift down valve BW BH2
3 7
GB LH1 8
2 9
Tilt forward valve G DH2
4 12
R MH1 13
1 16
ATT1-B valve W FH2
4 17
O NH1 20
2 21
ATT2-B valve BY HH2
(28P)
5 22
CN4S
V OH1 23
3 24
ATT3-B valve GY JH2
6 25
AI1 RB
26 Sensor +5V
BI1 L
3. PROPORTIONAL SOLENOID VALVE SPEC. (1.0 - 2.5 TON MODELS)
27 Lift pressure sensor

CI1 BY
28 Sensor GND
1 Sensor +5V
RB AI1 DI1 RY
1 2 Lift potentiometer
L BI1 3 Sensor GND
Lift pressure sensor 2
BY CI1 4
3 EI1 RW
6 ATT1 potentiometer
5
GW GW AI3 FI1 RL
1 10 Tilt potentiometer
Lift potentiometer RG RY DI1 11
2kΩ 2 GI1 LW
BY BY CI3 14 ATT2 potentiometer
8
GW RW EI1 15
4 HI1 LY
18 ATT3 potentiometer
ATT1 potentiometer RW RL FI1
2kΩ 3 19
BY LW GI1
5
GW LY HI1
6
Tilt potentiometer RL
2kΩ 7 AE1 Br
BY 21 RY1
BE1 W
GW 14 LED (Reservation of finish)
CE1 L
16 LED (Equalizing)
ATT2 potentiometer LW DE1 LgB
2kΩ 15 LED (Automatic)
BY FE1 G
17 LED (Abnormal)
GE1 PL
GW 9 LED (L6)
HE1 Sb
LY 10 LED (L5)
ATT3 potentiometer 2kΩ IE1 R
11 LED (L4)
BY JE1 LW
3 LED (L3)
KE1 GW
CN2
4 LED (L2)
(22P)
LE1 BW
BY JA1A 5 LED (L1)
3 20
YB JA3A ME1 WG
5 6 CH panel power supply (+8V)
BY JADA NE1 GY
2 13 AC connection signal (Outlet: ON)
BY JA4A
1 18
Joint connector BY JA7
8 12
BY JA2A
4 8
BY JA8 OE1 VW
7 7 Finish reservation SW
BY JA9 PE1 GrR
6 2 Equalizing charge SW
QE1 GrL
B B BC7A 1 Automatic charge SW
2 RE1 Gr
G 19 Start reservation SW
Horn 0.85LR HK1 SE1 P
1 22 CH panel power supply (GND)
AD1 RL
12 Charge mode SW
HA4 Y
EF3 25 KEY SW
KA1 Gr
RW GD3 3 Seat SW
VB(+) 12 JA1 Br
W BF1 4 SW_GND
TXD(+) 9 MA1 L
B CF1 15 F SW
TXD(-) 8 LA1 WB
16 R SW
7 JA3 Br
28 Controller selection SW
1 RA2 LO
Y HA7 8 ATT3 SW
KEY SW 10 EA1 LR
BR EF1 7 Lift SW
Meter panel GND 11 DA1 GR
YG FF1 23 Tilt SW
MODE SW 3 FA2 GO
LB GF1 24 ATT2 SW
Meter panel
UP SW 5 GA2 BO
WR HF1 1 ATT1 SW
SHIFT SW 4 30
BY IF1 BC4 0.85BL
SW GND 2 33 VB (-)
BG EJA BC3 0.85BL
Display changeover 6 34 VB (-)
CA1 Sb
CN1
18 Regenerating SW
(34P)
Display changeover EF2 0.85BR 0.85BG EJ1 BA1 BrW

27 Lift interrupt
AA1 RY
(Connector closed: English) 19 Parking SW
31
3(-) L BY JB1 32
3 ED1 0.85LY
RIGHT
5 G GW KB1 26 Charger interlock
2 2 FD1 0.85BrY
1(+) W LY LB1 17 Fault history SW
1 GD2 0.85RW
EPS torque sensor R 9 VB (+)
4 GD1 0.85RW
Y 10 VB (+)
5 HD1 RB
LEFT
(For standard specification) B 11 Hour meter start SW
6 ID1 0.85YB
2 Fluid level sensor
DB1A WL
5 Mashine controller receiving (+)
CB1A OL
5 6 Mashine controller receiving (-)
YB QB2 BB1A W
Multi-contoroller
4 4 13 Mashine controller transmission (+)

YB QB1 AB1A B
3 3 14 Mashine controller transmission (-)
RL RB1 EB3A EB2A
Accelerator 6 6 29
GY SB1 JD1A R
2 2 20 Current sensor power supply (+10V)
(4kΩ) RB TB1 KD1A W
1 21 Battery current (sig)
1 LD1A B
22 Current sensor power supply (GND)
LD4
AF1 PB
7 LED (Start reservation)
BF1A W
1 TXD (+)
OB1A CF1A B
2 TXD (-)
1 W MB1A 6
Travel speed sensor A 2 B NB1A 5
DF1 0.85YR
CL1A 4 8V (+)
EF1 BR
16 Meter panel GND
CN3
1 W AL1A FF1 YG
(16P)
10 MODE_SW
Travel speed sensor B 2 B BL1A GF1 LB
9 UP_SW
HF1 WR
8 SHIFT_SW
GY DL1A IF1 BY
1 15 SW_GND
Travel motor temperature sensor LO EL1A 14
2
13
12
0.85G BY JA9 3
(For regeneration) 3 11
0.85G O PA1 AG3
1
Brake SW 0.85R G JK1 AG1 R
4 4 Analog GND
0.85R WG DK7 BG1 W
2 9 Analog signal
(For lamp) CG1 B
5 Bit signal 3
DG1 Y
6 Bit signal 2
EG1 G
7 Bit signal 1
2
FG1 LB
SHIELD WIRE
Parking SW 0.85BW BY JA8 1

2 FG2 LB
0.85Br RY AA2 10
1 FG1 LB
(Lever pulled: SW OFF) 14 GND
GG1 Lg
ASSSH 2SH050 BR
8 Charger temperature sensor

HG1 BR
28 GND
3
JA2A BY RB HD1 11
CN4
(28P)
Hour meter start SW 12

(Connector shorted: Start) 13
JA7 BY P QA1 15
SHIELD WIRE
SHIELD WIRE
SW monitor mode 16
17
(Connector open: Monitor mode) 18
ASSSH 3SH050 BR
ASSSH 2SH050 BR
JA6 0.85Br 0.85BrY FD1 19

Fault history SW 20
21
(Connector open: History display) 22
10A 1.25W AC1 23
1 24
0.85RW GD1
2 25
15A 0.85WR KK1
Fuse 3 26
0.85WG DK1
4 27
SHIELD WIRE
SHIELD WIRE
SHIELD WIRE
ASSSH 2SH050 BR
ASSSH 2SH050 BR
ASSSH 2SH050 B
1
2
0A1
NA1
LD4
LA2
LK1
YR
BC2
BC1
AC1
AC2
BC9
BC1
BC2
BC7A
PA1
RA1
QA1
IB1
EL1
JB1
JA5A
BL1
AL1
TB1
LB1
DL1
CL1
SB1
EB1
RB1
KB1
BB1
AB1
NB1
HB2
HB1
DB1
CB1
QB1
OB1
MB1
MA2 0.85L
BC9 0.85B
FB1A
HA2 0.85Y
HA1 0.85Y
JD1
GB1A
LD1
LD3
KD1
MA1 L
P
NA1 Y
LK1 0.85WL
IA1 0.85LB
0.85WL
JA1 Br
0.85WB
1.25B
1.25B
KA1 Gr
EA2 LR
EA1 LR
CA1 Sb
AA1 RY
JA2 BY
0A1 YR
B
B
B
B
1.25W
1.25W
LO
GA1 BO
DA1 GR
AC4 1.25W
W
W
W
W
LA1 WB
FA1 GO
LY
RL
B0
BA1 BrW
YB
BY
LO
RB
OL
GY
GY
YG
YG
BG
WL
BC4 0.85BL
BC3 0.85BL
BW
BW
BW
R
B
B
GW
0.85B
BC1A 1.25B
BC6A 0.85B
1.25B
1.25B
W
Br
Br
1
1
2
5
6
4
7
9
8
3
9
8
7
2
4
3
6
5
9
8
4
3
7
6
5
1
2
B
15
23
20
25
17
12
11
19
14
24
26
13
21
22
10
16
18
16
15
14
12
11
10
13
22
19
20
15
18
21
10
11
16
17
14
12
13
JK1 G
JK1A G
ID1 0.85YB
DF1 0.85YR
LA3A WB
LA3 WB
GK1 GL
BC5C 0.85B
BC5B 0.85B
BC5 0.85B
CK3A RW
CK3 RW
FK1 GR
CK3B 0.85RW
1
1
1
6
5
8
1
7
3
4
2
2
4
2
3
3
4
2
Joint connector
1
1
4
2
5
6
3
4
2
5
6
3
JA5
JA4
GND
GR
F SW
R SW
VB(-)
VB(-)
TxD (-)
RxD (-)
VB(+)
VB(+)
Tilt SW
TxD (+)
RxD (+)
KEY SW
KEY SW
Seat SW
Lift 2 SW
Lift 1 SW
R
B
R
B
SW GND
ATT3 SW
ATT1 SW
ATT2 SW
B
Y
B
Brake SW
LW
LW
RB
RB
RW
RW
FWC output
Lift VR (+)
Parking SW
Horn output
Lift VR (sig)
Regenerating
Lift VR (GND)
Lift interrupt SW
SW monitor start
Lifting height SW
Current sensor (SIG)
Accelerator (+)
Accelerator SW
Torque sensor (+)
Current sensor (GND)
Current sensor (+10V)
Accelerator (sig)
Hydraulic contactor
Torque sensor (sig)
Connected for only 3-t model
Connected for only 1-t model
Communication shield
Travel speed sensor B

Travel speed sensor B
Travel speed sensor A
Travel speed sensor A
Accelerator (GND)
Torque sensor (GND)
Lift interrupt command

Travel speed sensor shield
Travel speed sensor shield
Battery connector
-
Work equipment selector SW
B
P-motor speed command shield
P-motor speed command signal
Travel motor temperature sensor

Travel motor temperature sensor
GR
Lift interrupt SW
Electrolyte level sensor
6V
GND for P-motor speed command signal
CN1
CN2
CN5
(26P)
(22P)
(4P)
(L)/25W
(R)/25W
(L)/25W
(L)/10W
(L)/25W
(R)/10W
(R)/25W
(L)/10W
(4P)
(R)/10W
CN3
Tail lamp
Tail lamp
1
(16P)
2
CN11
Stop lamp
Stop lamp
Backup lamp
Backup lamp
(Connector short circuit: Reset)
(Connector short circuit: Reset)
+
Turn signal lamp
Turn signal lamp
High Lifting height acceleration limit SW

Connected only when 3 or more control valves are used.
Main Controller
License plate lamp
Connected for only 72-V specification
Reverse travel buzzer

Travel speed limit 2 SW (Do not connect for small special truck spec.)
Forward/Reverse travel buzzer (Optional)
70-59
CIRCUIT DIAGRAM
4. PROPORTIONAL SOLENOID VALVE SPEC. (3.0 TON MODEL)
BE30 Series 70-61

5. MANUAL VALVE SPEC. (1.0 - 2.5 TON MODELS)

MULTI-CONTOROLLER
AC CONNECTION SIGNAL (OUTLET: ON)
CURRENT SENSOR POWER SUPPLY (+10V)

CONTROLLER SELECTION SW
MACHINE CONTROLLER TRANSMISSION (+)

MACHINE CONTROLLER RECEIVING (+)
CURRENT SENSOR POWER SUPPLY (GND)
CHARGER TEMPERATURE SENSOR

CH PANEL POWER SUPPLY (+8V)
CH PANEL POWER SUPPLY (GND)
MACHINE CONTROLLER TRANSMISSION (-)

MACHINE CONTROLLER RECEIVING (-)
CN1
LED (RESERVATION OF FINISH)

CN2 CN3 CN4
LED (START RESERVATION)

EQUALIZING CHARGE SW
AUTOMATIC CHARGE SW
FINISH RESERVATION SW
(34P)
START RESERVATION SW
(22P) (16P) (28P)
HOUR METER START SW
BATTERY CURRENT (sig)

CHARGER INTERLOCK
FLUID LEVEL SENSOR

WORK EQUIPMENT CONTROL LEVER SW
REGENERATING SW
FAULT HISTORY SW
CHARGE MODE SW
METER PANEL GND

LIFT INTERRUPT
LED (Equalizing)
LED (Automatic)
LED (Abnormal)
STARTING SW
PARKING SW
LIFT 2 SW
LIFT 1 SW
SW GND
MODE_SW
ATT1SW
ATT2SW
SHIFT_SW
TILT SW
LIFT 2 SW
LIFT 1 SW
SW_GND
SW_GND
SEAT SW
ATT2 SW
ATT1 SW
LED (L6)
LED (L5)
LED (L4)
LED (L3)
LED (L2)
LED (L1)
TILT SW
TXD (+)
UP_SW
TXD (-)
VB (+)
VB (+)
8V (+)
VB (-)
VB (-)
R SW
F SW
GND
GND
RY1 21
14
16
15
17
10
11
20
13
18
12
19
22
12
25
15
16
28
23
24
30
33
34
18
27
19
31
32
26
17
10
11
13
14
29
20
21
22
16
10
15
14
13
12
11
10
14
28
11
12
13
15
16
17
18
19
20
21
22
23
24
25
26
27
9
3
4
5
8
7
2
1
3
4
8
7
2
5
6
7
1
2
6
5
4
9
8
4
9
5
6
7
2
1
3
KD1A W
CONNECTED FOR ONLY 1-T MODEL
CB1A OL
HG1 BR
FG1 LB
FG2 LB
FG1 LB
DB1A WL
GG1 Lg
BB1A W
BA1 BrW
GO
LgB
JD1A R
LD1A B
PE1 GrR
BO
FF1 YG
QE1 GrL
LO
DF1 0.85YR
EF1 BR
GR
WB
HF1 WR
BC4 0.85BL
BC3 0.85BL
AF1 PB
IF1 BY
HD1 RB
AA1 RY
LR
CA1 Sb
GF1 LB
AB1A B
RL
GW
BF1A W
Gr
ME1 WG
NE1 GY
BW
ID1 0.85YB
Br
Br
LW
Sb
PL
W
GD2 0.85RW
GD1 0.85RW
OE1 VW
RE1 Gr
Br
ED1 0.85LY
CF1A B
FD1 0.85BrY
Y
L
G
SE1 P
L
EB2A
MA1
AD1
KA1
GA2
HA4
DA2
LA1
JA1
GE1
SA2
EA2
CE1
DE1
HE1
JA3
FA2
AE1
BE1
KE1
FE1
LE1
IE1
JE1
SHIELD WIRE SHIELD WIRE
CONNECTED FOR ONLY 3-T MODEL
LD4
ASSSH 2SH050 BR ASSSH 2SH050 BR
CONNECTED FOR ONLY 72V SPECIFICATION
EB3A
AC4 1.25W
SHIELD WIRE SHIELD WIRE BATTERY CONNECTOR
ASSSH 3SH050 BR ASSSH 2SH050 B
6
4
5
3
2
1
LD4 LD3 B
GO
BO
GR
LO
BY
2 CURRENT SENSOR (GND)
LR
LD1 B
4 GND CN5
GA1
DA1
SA1
EA1
FA1
KD1 W
JADA
3 CURRENT SENSOR (SIG)
JD1 R
1 CURRENT SENSOR (+10V)
(4P)
AB1 B
13 RxD (-)
BB1 W
2 RxD (+)
CB1 OL
12 TxD (-)
DB1 WL
1 TxD (+)
EB1 B0
14 COMMUNICATION SHIELD
17 GND FOR P-MOTOR SPEED COMMAND SIGNAL
5 P-MOTOR SPEED COMMAND SIGNAL
16 P-MOTOR SPEED COMMAND SHIELD
HB1 YG
SHIELD WIRE 2 11 LIFT VR (+)
HB2 YG
1 10 LIFT VR (sig)
ASSSH 2SH050 BR IB1 BW
21 LIFT VR (GND) CN2
JB1 BY
KB1 GW
18 TORQUE SENSOR (GND) (22P)
6 TORQUE SENSOR (sig)
LB1 LY
7 TORQUE SENSOR (+)
MB1 W
3 TRAVEL SPEED SENSOR A
NB1 B
4 TRAVEL SPEED SENSOR A
OB1 BW
15 TRAVEL SPEED SENSOR SHIELD
QB1 YB
SHIELD WIRE 20 ACCELERATOR (GND)
RB1 RL
19 ACCELERATOR SW
ASSSH 2SH050 BR SB1 GY
8 ACCELERATOR (sig)
TB1 RB
9 ACCELERATOR (+)
22 FWC OUTPUT
AL1 W
5 TRAVEL SPEED SENSOR B
BL1 B
6 TRAVEL SPEED SENSOR B
CL1 BW
13 TRAVEL SPEED SENSOR SHIELD
DL1 GY
3 TRAVEL MOTOR TEMPERATURE SENSOR
EL1 LO
4 TRAVEL MOTOR TEMPERATURE SENSOR CN11
1 (16P)
2
7
MAIN CONTROLLER
8
9
10
11
12
14
15
16
AA1 RY
18 PARKING SW
BA1 BrW
16 LIFT INTERRUPT COMMAND
CA1 Sb
3 REGENERATING
DA1 GR
10 TILT SW
EA1 LR
RL AJ1 8 LIFT 1 SW
T2 2 FA1 GO
RG BJ1 22 ATT2 SW
S 1 GA1 BO
RB CJ1 21 ATT1 SW
T1 3 SA1 LO
9 LIFT 2 SW
POWER SUPPLY UNIT OF CHARGER 0.85W AC3
HA1 0.85Y
13 STARTING SW
WL DJ1 HA2 0.85Y
26 STARTING SW
0.85WR KK1
IA1 0.85LB
JA1 Br
24 HYDRAULIC CONTACTOR CN1
FOR CH INTERLOCK 14 SW GND
WL DJ1 TO MGS AUXILIARY CONTACT IN CHARGER
KA1 Gr
19 SEAT SW
(26P)
(20P) 1 LA1 WB
Br AE1 11 R SW
3 MA1 L
W BE1 12 F SW
15 NA1 Y
L CE1 7 LIFTING HEIGHT SW
14 0A1 YR
LgB DE1 17 LIFT INTERRUPT SW
13 JA2 BY
G FE1 4 TRAVEL SPEED LIMIT 2 SW (DO NOT CONNECT FOR SMALL SPESIAL TRUCK SPEC.)
12 25 HORN OUTPUT
PL GE1 PA1 O
11 6 BRAKE SW
Sb HE1 QA1 P
9 20 SW MONITOR START
R IE1 JA10 Br
8 5 WORK EQUIPMENT SELECTOR SW
LW JE1
7 23 ATT3 SW
GW KE1
6 1
BW LE1
5 2
PB AF1
16 15
WG ME1
4
GY NE1 VB(+)
CHARGER CONTROL SECTION 18
Lg GG1
AC2 1.25W
1 VB(+)
10 AC1 1.25W
20
BR HG1
BC1 1.25B
3 VB(-) CN3
2
2
17
BC2 1.25B
4 VB(-)
(4P)
19
+
-
(12P) RB CJ1
12 BC2 1.25B
RG BJ1 2
7 BC1 1.25B
RL AJ1 4
1 BC3 0.85BL
3
VW OE1 BC4 0.85BL
9 7
GrR PE1 BC6A 0.85B
5 1
GrL QE1 BC1A 1.25B
4 8
Gr RE1 BC7A B
6V
10 5
P SE1 BC9 0.85B
3 6
WORKING LAMP JOINT CONNECTOR

0.85Y HA1 1.25B BC1A DF1 0.85YR
2
0.85YG AK1
2
0.85WG DK3 ID1 0.85YB ELECTROLYTE LEVEL SENSOR
STARTING SW 3 1 LIFT SOLENOID
1
IK2 YR
RG
2
0.85WL BK1 1 STOP-LAMP
BC10 B 2
RW
1
RW CK1
DK1 JK1 G
3
RB (R)/25W
LIGHT SW
0.85W
3
0.85WG BC5 0.85B
FK1 GR
6
B
R
TAIL LAMP
5
8 CK3 RW
1
RW (R)/10W
LA3 WB
2
4
LW TURN SIGNAL LAMP
(R)/25W
BACKUP LAMP
(R)/10W
B LW EK1
5
TURN SIGNAL SW
R B
6
GR FK1 CK3B 0.85RW Y LICENSE PLATE LAMP
L B GL GK1 BC5B 0.85B B
7 (L)/25W
0.85RW
4
DIMMER SW JK1A G RB
STOP-LAMP
3
BC5C 0.85B
6
B (L)/25W
GK1 GL R
R
B
1
Y
L
HA5
MA3 CK3A RW
5
RW TAIL LAMP
F 1
DIRECTION SW G
3
WB LA5 2 (L)/10W
R 5 LA3A WB LW
F
BrW
2
4 TURN SIGNAL LAMP
OW
R O
4 (L)/25W
6
BACKUP LAMP
HORN SW 0.85LR HK1 (L)/10W
0.85WG DK2
(STEERING COLUMN) 0A1 YR Br JA4
LIFT INTERRUPT SW
(CONNECTOR SHORT CIRCUIT: RESET)
NA1 Y Br JA5
HEAD LAMP B 0.85B 0.85B BC3A
(R)/45W RG
1
0.85RG
2
0.85WL BK2
HIGH LIFTING HEIGHT ACCELERATION LIMIT SW
2 1
(CONNECTOR SHORT CIRCUIT: RESET)
TURN SIGNAL LAMAP R
3
0.85RW
3
GR FK2 MA2 0.85L
Y 0.85G RW CK2
(R)/25W B
2
0.85RG
4 LK1 0.85WL GR
1 REVERSE TRAVEL BUZZER
FD1
RB HD1
CLEARANCE LAMP
JA3A
BC9 0.85B B
0.85RW GD1
0.85WG DK1
AK1
0.85WR KK1
ED1
RL AD1
DK5
IA1
P QA1
0.85LR HK1
2
(R)/5W
0.85BG EJ1
1.25W AC1
1
0.85BrY
LK1 0.85WL
JADA
B BC7A
GY DL1A
JA4A
1 W MB1A
WG DK7
O PA1
OB1A
G JK1
LO EL1A
1
2 B NB1A
LW EK1
WG DK6
CL1A
BY JA9
GF1
RW GD3
1 W AL1A
2 B BL1A
0.85WG
QB1
JA1A
JA3A
JA2A
B CF1
HF1
0.85YG
HA7
W BF1
GW KB1
RB1
RY AA2
EF1
YB
QB2
SB1
FF1
0.85LB
LY LB1
EJA
TB1
IF1
L
BY JB1
JA7
JA8
JA9
EF3
BY JA8
0.85LY
LA2 0.85WB
2
HEAD LAMP GR
YG
BR
WR
BY
BY
BY
BY
BY
BY
BY
BY
BG
GY
LB
RB
YB
YB
YB
RL
Y
(L)/45W RG 0.85RG 0.85WL BK1
3
1
4
2
2
1
2
2
2
3
2
4
5
6
2
3
4
5
4
3
6
2
2
3
4
B
3
5
2
1
8
4
7
6
9
8
3
5
4
2
6
7
12
10
11
1
1
1
1
1
1
1
1
BY
JA7 BY
B 0.85B 0.85B BC4A
JA6 0.85Br
2 2
TURN SIGNAL LAMAP
FORWARD/REVERSE TRAVEL
VB (+)
TXD (+)
TXD (-)
KEY SW
METER PANEL GND
MODE SW
UP SW
SHIFT SW
SW GND
DISPLAY CHANGEOVER
JA2A
0.85BR
G
0.85BW
B
0.85G
0.85G
(CONNECTOR OPEN: MONITOR MODE)

0.85R
0.85R
(CONNECTOR OPEN: HISTORY DISPLAY)

(L)/25W
0.85Br
R 0.85GL GL GK2
W
G
1 3
Y
L
CHARGER MODE SW
R
0.85G
Y
0.85W
0.85R
0.85Y
Y 0.85RW RW CK1
BUZZER (If equipped)
10A
15A
2 4
CHASSIS EMERGENCY SW
B 0.85B
(OPEN: TEST MODE)
FLASHER UNIT
CLEARANCE LAMP
1(+)
3
3(-)
(CONNECTOR SHORTED: START)

EF2
(L)/5W
2
F
JOINT CONNECTOR
HOUR METER START SW

(CONNECTOR CLOSED: ENGLISH)
0.85B BC5A
TRAVEL MOTOR TEMPERATURE SENSOR

TRAVEL SPEED SENSOR A
TRAVEL SPEED SENSOR B

2
3
SPARE 0.85YR IK1

5
1
4
SW MONITOR MODE
RIGHT LEFT
FUSE
FAULT HISTORY SW
(LEVER PULLED: SW OFF)
(FOR REGENERATION)
(FOR LAMP)
(FOR STANDARD SPECIFICATION)
ACCELERATOR
DISPLAY CHAGEOVER
BRAKE SW
METER PANEL
EPS TORQUE SENSOR
0.85YR IK1
4
0.85WG DK4
PARKING SW
2
EXTERNAL RELAY 1
0.85Y HA6
(4kΩ)
HORN
0.85B BC6A
3
BE30 Series 70-63

TROUBLESHOOTING SUB CONTROLLER
SUB CONTROLLER
(COMMON TO ALL MODELS: SYSTEM CONTROLLER AND MULTI-CONTROLLER)
(Note 1) When carrying out troubleshooting, disconnect the battery unless otherwise specified.
(Note 2) Pay attention to safety while you are carrying out troubleshooting, since the vehicle (travel sys-
tem, cargo handling system, EPS, etc.) may move.
(Note 3) If the vehicle is equipped with the manual valve specification, carry out troubleshooting for only
the multi-controller.
1. CHECK BEFORE TROUBLESHOOTING

Before troubleshooting, perform the following check.
• Checking controller source voltage
(1) Disconnect battery connector.
(2) Remove the side cover (left one seen from the counterweight).
(3) Set the multimeter for measurement of voltage and set its rods to the measuring points. Connect the battery
connector, turn the key switch on, and measure the voltage.
(4) Check that the voltage is in the normal range.
(5) Voltage check table
Red rod of multimeter Black rod of multimeter
Connector (+) (--)
Checked item Normal voltage
name
Pin No. Pin No.
CN1S 9 21 Battery voltage
System controller (2)
CN4S 26 28 4.9 – 5.1V
Multi-controller (1) CN1 10 34 Battery voltage
(Reference)
System controller adjustment function (Degree of shocks
made when lift is raised and lowered)
a Since this control knob is set properly when the vehicle is
shipped, do not adjust it usually.
1) VR-U: Shocks made when lift starts/stops rising
Adjust the degree of the shocks. (The knob is
set in neutral when the vehicle is shipped.)
Turning in direction A: Shocks are softened.
Turning in direction B: Shocks are hardened.
2) VR-D: Shocks made when lift starts/stops lowering
Adjust the degree of the shocks. (The knob is
set in neutral when the vehicle is shipped.)
Turning in direction A: Shocks are softened.
Turning in direction B: Shocks are hardened.
(Caution) Never touch the DIP switch and VR-L.
BE30 Series 70-65

SUB CONTROLLER TROUBLESHOOTING
2. TROUBLES, THE FAILURE CODES OF WHICH ARE NOT DISPLAYED
Contents of trouble Malfunction of vehicle Repair method

Charger interlock • Vehicle cannot travel or handle 1) Check charger interlock (sub) relay (in multi-
(sub) relay is open. cargo and EPS cannot operate. controller) and replace multi-controller board.
• Meters do not indicate.
Work equipment • Vehicle cannot handle cargo but 1) Check work equipment switch signal harness
switch signal is open. can do all other operations. (connected to connector CN1S of system con-
Drive Tr is open. • Pump motor does not rotate. troller) and repair or replace it.
2) If result of above check is normal, replace sys-
tem controller board.
(1) Troubleshooting for system controller

See failure codes list E-60 – E-89.
(2) Troubleshooting for multi-controller

See failure codes list E-59 and E-90 – E-99.
70-66 BE30 Series

3. TROUBLESHOOTING
1. Checking work equipment control lever and potentiometer
(See the sections of assembly drawing and section 60 STRUCTURE AND FUNCTION, work equipment con-
trol lever.)
(1) Checking voltage
1) Set a multimeter for measurement of voltage and set its black rod (-) to connector CN4S pin No. 28
of the system controller.
2) Set the red rod (+) according to the following table, connect the battery connector, and turn the key
switch ON to measure the voltage.
3) Check that the voltage is in the normal range shown in the following table.
(Note) Since the work equipment is operated for check, stop the vehicle on a place where there
is not an obstacle and take care particularly
while the work equipment is in operation.
Measuring point
Work equipment po- System controller con-

nector CN4S Pin No.
tentiometer for mea-
surement Red rod of Black rod of
multimeter multimeter
(+) (--)
Lift potentiometer 2
Tilt potentiometer 10
ATT1 potentiometer 6 28
ATT2 potentiometer 14
ATT3 potentiometer 18
Normal
When lever is operated
voltage
Neutral A 2.6 – 2.4V
Forward tilt end B 4.3 – 3.9V
Reverse tilt end C 1.1 – 0.7V
(2) Checking resistance of wiring harness

1) Remove the dashboard and disconnect the lever potentiometer intermediate connector.
2) Set a multimeter for measurement of resistance and set its rods to the measuring points to measure
the resistance according to the following table.
3) Check that the resistance is in the normal range.
(Note) If the rods of the multimeter are inserted from the fitting face of the connector, the contact
will be defective after the connector is connected. Accordingly, insert the rods from the
wiring harness side.
Measuring point Red rod of Black rod of

multimeter (+) multimeter (--) Normal resistance
Pin No. Pin No.
Connector on lift lever potentiometer side
Connector on tilt lever potentiometer side
Connector on ATT1 lever potentiometer side 1 2 2kz
Connector on ATT2 lever potentiometer side
Connector on ATT3 lever potentiometer side
BE30 Series 70-67

2. Checking dummy resistor

(1) Checking dummy resistor
1) Remove the dashboard and disconnect the dummy potentiometer intermediate connector.
(2) Measuring points and normal values Dummy resistance
Red rod of Black rod of
Measuring Normal
point multimeter multimeter
(+) (--) resis-
tance
Pin No. Pin No.
Connector on
dummy poten- 1 3 2 kz
tiometer side
2 3 1 kz
3. Checking lift pressure sensor

(1) Checking resistance of wiring harness
1) Disconnect the pressure sensor connector at the control valve.
2) Disconnect system controller connector CN4S.
(2) Measuring points and normal values
Measuring point Red rod of multimeter (+) Black rod of multimeter (--)
Normal resistance
CN4S pin No. Pressure sensor connector pin No.
26 1
Pressure sensor
27 2 0z
harness
28 3

1) Set a multimeter for measurement of voltage and set its black rod (-) to connector CN4S pin No. 28
of the system controller.
2) Set the red rod (+) to CN4S pin No. 27, connect the battery connector, and turn the key switch ON.
3) Lower the lift until the fork reaches the ground, and then measure the voltage.
4) Raise the lift to the stroke end and measure the voltage, keeping the lift at the stroke end.
5) Check that the resistance is in the normal range shown in the following table.
(Note) Since the work equipment is operated for check, stop the vehicle on a place where there
is not an obstacle and take care particularly while the work equipment is in operation.
When to measure pressure Red rod of multimeter (+) Black rod of multimeter (--)
Normal voltage
sensor voltage CN4S pin No. CN4S pin No.
When fork is on ground 0.37 – 0.63V
When fork is at rising 27 28
3.89 – 4.30V
stroke end
70-68 BE30 Series

4. Checking coil of proportional solenoid valve (hydraulic control valve)

(Note) A 4P connector and a 6P connector are installed respectively to the top and bottom of the propor-
tional valve.
(1) Checking coil resistance
1) Disconnect the connectors at the proportional valve.
Red rod of multimeter (+) Black rod of multimeter (--)
Normal
Measuring point Connector pin Nos. of Connector pin Nos. of resistance
proportional valve proportional valve
Lift raising end 4P 1 4P 3
Tilting back end 4P 2 4P 4
ATT1_Asol Lower connector 6P 1 Lower connector 6P 4 17.5 ± 0.5z
ATT2_Asol 6P 2 6P 5
ATT3_Asol 6P 3 6P 6
Lift lowering end 4P 1 4P 3
Tilting forward end 4P 2 4P 4
ATT1_Bsol Upper connector 6P 1 Upper connector 6P 4 17.5 ± 0.5z
ATT2_Bsol 6P 2 6P 5
ATT3_Bsol 6P 3 6P 6
(3) Checking wiring harness resistance

1) Disconnect the connectors at the proportional valve.
2) Disconnect system controller connector CN7S.
Measuring point Proportional valve connector Normal resistance
CN7S pin No.
pin No.
4P 1 16
Lift raising end
4P 3 3
4P 2 18
Tilting back end
4P 4 7
6P 1 17
ATT1_Asol Lower connector 0z
6P 4 5
6P 2 19
ATT2_Asol
6P 5 9
6P 3 20
ATT3_Asol
6P 6 11
BE30 Series 70-69


Measuring point Proportional valve connector Normal resistance
CN7S pin No.
pin No.
4P 1 2
Lift lowering end
4P 3 3
Tilting forward 4P 2 6
end 4P 4 7
6P 1 4
ATT1_Bsol Upper connector 0z
6P 4 5
6P 2 8
ATT2_Bsol
6P 5 9
6P 3 10
ATT3_Bsol
6P 6 11
5. Sub controller (System controller)

Checking work equipment control lever signal harness
1) Remove the side cover (left one seen from the counterweight).
2) Set the multimeter for measurement of voltage and set its rods to the measuring points.
3) Connect the battery connector, turn the key switch on, and measure the voltage.
4) Check that the voltage is in the normal range.

Work equipment Connector Red rod of multimeter (+) Black rod of multimeter (--) Normal voltage
switch name name Pin No. Pin No.
Lift switch 4
Tilt switch 3
ATT1 switch CN1S 5 2 Min. 4 V
ATT2 switch 6
ATT3 switch 17
70-70 BE30 Series

TROUBLESHOOTING TROUBLESHOOTING
TROUBLESHOOTING
1. PRECAUTIONS TO TAKE WHEN FAILURE CODE IS DISPLAYED
(1) When resetting a displayed failure code by turning the key switch OFF, wait at least 3 seconds before turning
the key switch ON again (since it takes 3 scones to turn the CPU OFF after the key switch is turned OFF).
(2) When checking the main controller, disconnect the battery plug and wait for at least 2 minutes.
(3) The following codes are displayed when mistakes are made in operation.
(Note) When the operation is repeated, if the same trouble occurs, see TROUBLESHOOTING.
• E-23: Travel neutral is detected
• E-60: Work neutral is detected
• E-68: Mistakes in operation of automatic lifting stopper device and automatic fork leveling device are displayed
• Abnormal operation LED in automatic lifting height indicator panel: A mistake in automatic lifting height
indication is displayed
(4) The following codes are displayed as warnings for Failure code Troubled part
safety 01 – 28, 41, 42, 45 Travel system
• E-64: Automatic fork leveling device does not
30 – 38, 55, 56 Cargo handling system (excluding
reach level position or exceeds level position proportional solenoid valve)
• E-69: Automatic lifting stopper device does not 50 – 54 PS system
reach set height
Cargo handling system (related to
• E-70: Automatic lifting stopper device exceeds 60 – 89 proportional solenoid valve)
set height 59, 90 – 96 Charger system
97 Communication between main
controller and multi-controller
Communication between system
98
controller and multi-controller
Communication between meter
99 panel and multi-controller
2. TROUBLES THAT ARE NOT DISPLAYED
Repair method Reset
No. Trouble in vehicle Contents of trouble (Execute 1) o 2) o ---) method Remarks
1 Vehicle cannot oper- • Control voltage Check and repair control voltage (key – –
ate at all (Travel, (key switch line) switch, EMG switch line).
cargo handling, is not applied.
EPS, display on • Relay in multi- Check charger interlock relay (sub) in – –
meters are impossi- controller: Open multi-controller, then replace multi-con-
ble) troller board if necessary.
2 Operations related – – – –
to main controller
1) When FR switch • Connectors of Check connection of connectors A and Reset Take care when replacing
(F or R) and ac- travel speed sen- B, then connect them correctly. normally. motor.
celerator are op- sors A and B are
erated, vehicle connected oppo-
does not travel. sitely.
• Accelerator 1) Repair or replace wiring harness be- Reset –
switch and its tween CN2-19 (CPU board) and normally.
signal circuit are travel accelerator.
disconnected. 2) Repair or replace wiring harness be-
tween CN2-8, 9, 20 (CPU board)
and travel accelerator.
3) Repair or replace travel accelerator
unit.
2) Vehicle stops • Accelerator and 1) Check and repair brake switch in Turn Vehicle may stop be-
traveling. brake are operat- OFF position. brake cause of mistake in oper-
ed simultaneous- 2) Repair or replace wiring harness be- switch ation (Mistake is detected
ly too long. tween CN-1-6 (CPU board) and OFF. when accelerator and
brake switch brake are operated for 10
seconds).
• Overvoltage pro- 1) Check battery connector for defec- Reset If battery connector has
tection works in tive contact. normally defective contact or is dis-
regeneration 2) Repair or replace wiring harness be- connected in regenera-
mode. tween CN4-2 (CPU board) and ter- tion mode, protection is
minal P3. applied.
3) Repair or replace wiring harness be-
tween CN4-10 (CPU board) and ter-
minal P13.
BE30 Series 70-71

TROUBLESHOOTING TROUBLESHOOTING
No. Trouble in vehicle Contents of trouble Repair method Reset Remarks

(Execute (1) o (2) o ---) method
2 (3) Cargo handling sys- Upper FED of cargo Check cargo handling power module – –
tem chops but does handling power module (TMP), then replace if necessary.
not have sufficient (TMP) is open.
power.
4) Vehicle stops travel- PS motor is shorted. Check PS motor and its wiring for short cir- – –
ing. cuit, then replace if necessary.
3 Troubles related to sys- – – – –
( 1) tem controller
1) P motor does not ro- Drive Tr power in sys- 1) Check voltage at system controller – –
tate. tem controller is open. CN1S-3, 4, 5, 6, 17, 18, and 19: If it is
Sensor circuit in main above 4 V, replace controller board.
controller is defective. 2) If voltage is below 4 V in 1) above, check
Work equipment switch voltage at main controller CN1-8, 9, 10,
signal harness is defec- 21, 22, and 23: If it s above 4 V, check
tive. wiring harness for disconnection.
3) If voltage is below 4 V in 2) above, check
wiring harness for short circuit.
4) If wiring harness is found normal in 3)
above, replace main controller board.
P motor DUTY signal 1) Check wiring harness between system – –
harness is shorted. controller CN1S-1 and main controller
Command IC in system CN2-5 for short circuit.
controller is defective. 2) Replace system controller.
2) When lever is oper- P motor DUTY signal 1) Check wiring harness between system – –
ated, P motor rotates harness is shorted. controller CN1S-1 and main controller
at full speed. Command IC in system CN2-5 for short circuit.
controller is defective. 2) Replace system controller.
3) When certain lever is Output of lever is lost. Check and repair Pot of lever operating sec- – Pot output:
operated, vehicle tion. Seems to be
does not respond kept at 2.5 V,
(and related propor- regardless of
tional valve coil does turning angle.
not drive).
4 Automatic lifting stopper – – – –
( 1) function
1) Automatic lifting FEP-ROM in system 1) Set automatic lifting stopping distance a – –
stopping position is controller is defective. little longer and apply automatic lifting
abnormal. (Below or stop to see if any trouble is displayed. If
above set position: any trouble is displayed, see trouble-
E-69 or E-78 is not shooting for it.
displayed) 2) If any trouble is not displayed, change
automatic lifting stopping position, turn
key switch OFF and ON, apply automat-
ic lifting stop. See if lifting stops at
changed position.
3) If lifting does not stop normally, replace
system controller board.
2) Automatic lifting is Following defects in au- 1) If all LED segments of automatic lifting – Memory
not displayed. tomatic lifting display display panel light up after key switch is switch is
panel: turned ON, replace system controller. shorted under
• Memory switch is 2) If all LED segments do not light up in 1) normal condi-
open. above, memory switch of automatic lift- tion.
• Memory switch wiring ing display panel is open or its wiring
harness is disconnect- harness is disconnected. Repair.
ed.
5 Automatic fork leveling – – – –
( 1) device
1) Fork cannot be tilted Automatic mode is not 1) Operate fork leveling display switch to – Switch at left
manually. reset (This is not trou- reset automatic mode. is an alternate
ble). switch, which
2) Fork cannot be tilted Fork leveling display 1) If fork leveling display switch cannot be – holds opera-
manually (Open). switch is defective. turned ON and OFF, replace it. tion. Each
Fork cannot be tilted Wiring harness of fork 2) If switch is normal, check its wiring har- time it is oper-
manually (Shorted). leveling display switch is ness for disconnection and short circuit, ated, its state
defective. then replace. is reversed.
3) If result of above check is normal, replace
system controller.
1. For proportional solenoid valve spec.
70-72 BE30 Series

TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS)
FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of Trouble in Repair method Reset
code trouble vehicle (Execute 1) o 2) o ---) method Remarks
01 Travel power mod- Vehicle cannot travel 1) If vehicle can travel, check code 45 Turn –
ule is shorted or handle cargo (MD first. key
(Upper and lower connector is not 2) Check travel power modules (TMDU, switch
FET's are short- closed). TMDV, and TMDW) and replace OFF.
ed). (This trouble is also them if necessary. (If a power mod-
detected when failure ule is defective, be sure to replace it
code 45 is displayed.) and power supply board as a set.)
3) Check wiring harness between CN3R
(Power supply board) and each pow-
er module, then repair or replace it.
4) Check wiring harness between CN4-
2 (CPU board) and terminal P3, then
repair or replace it.
6) If result of above check is normal, re-
place power supply board.
03 Main contactor Vehicle cannot travel 1) Check main contactor (MD) (for melt- Turn –
(MD) is shorted or or handle cargo. ing, mechanical hitching, etc. of con- key
open or its sensor tacts), then repair or replace it. switch
circuit harness is 2) Check wiring harness between CN5- OFF.
defective. 11 (CPU board) and terminal P2,
then repair or replace it.
05 Travel power mod- Vehicle cannot travel 1) Check travel power modules (TMDU, Turn Failure code 05:
11 ules are shorted or handle cargo. TMDV, TMDW) and replace them if key Detected when key
(Upper and lower necessary. (When replacing, be switch switch is turned ON.
modules are short- sure to replace them as a set, togeth- OFF. Failure code 11:
ed separately). er with power supply board.) Detected after key
2) Check wiring harness between switch and MD are
CN3R (Power supply board) and turned ON.
each power module, then repair or
replace it.
08 ule is open. or handle cargo. TMDV, TMDW) and replace them if key U-phase is open
09 U-, V-, or W-phase necessary. (When replacing, be switch (disconnected)
is disconnection. sure to replace them as a set, togeth- OFF. Failure code 08:
er with power supply board.) V-phase is open
2) Check wiring harness between (disconnected)
CN3R (Power supply board) and Failure code 09:
each power module, then repair or W-phase is open
replace it. (disconnected)
3) Check output terminals of U-, V-, and
W-phase for disconnection and
looseness of screws.
BE30 Series 70-73

FAILURE CODES LIST (1.0 - 2.5 TON MODELS) TROUBLESHOOTING

07 Main contactor Vehicle cannot travel 1) Check main contactor (MD) coil for Turn –
(MD) drive Tr is de- or handle cargo. disconnection of connector and coil, key
fective (In CPU then repair or replace it. switch
board: Tr4). 2) Check wiring harness between OFF.
Main contactor coil contactor coil and CN4-5, 13 (CPU
is open. board), then repair or replace it.
Sensor circuit har- 3) Replace CPU board (since drive Tr is
ness of main defective).
contactor coil is
defective.
16 F or R switch is de- Vehicle cannot travel.1) Check wiring harness between CN1- Reset Turn F switch and R
fective. 11, 12 (CPU board) and F/R switch normal- switch ON simulta-
for short circuit, then replace if nec- ly. neously.
essary.
2) Repair or replace F/R switch.
17 Travel accelerator Vehicle can travel at 1) Check wiring harness between CN2- Reset Normal source voltage of
output is defective. 40% of maximum 8, 9, 20 (CPU board) and travel ac- normal- accelerator: 5 V (Be-
speed. celerator, then repair or replace it. ly. tween CN2-9 and 20)
2) Check travel accelerator unit, then Output voltage of accel-
repair or replace it. erator when abnormality
is detected: Max. 0.2 V,
Min. 4.8 V (Between
CN2-8 and 20)
19 Output or wiring Vehicle cannot travel. 1) Check wiring harness between CPU Turn Normal sensor output
harness of travel board and current sensors, then re- key • During travel: 3.0 V
current sensor pair or replace it. switch – 11.0 V
(CSDU, CSDW) is CSDU: CN5-3, 4, 14, 15 OFF. • When FR switch is
defective. CSDW: CN5-5, 6, 16, 17 in neutral and accel-
2) Check source voltage of current sen- erator is OFF: Ap-
sor power supply of CPU board. prox. 7 V
CSDU: Between CN5-3 and 14, 15 CSDU: Between
CSDW: Between CN5-5 and 16, 17 CN5-4 and 14, 15
If source voltage is abnormal, re- CSDW: Between
place CPU board. CN5-6 and 16, 17
3) Check current sensors (CSDU, CS- Normal source volt-
DW), then replace it if necessary. age of sensor power
supply: 15 V
Sensor output when
abnormality is detect-
ed: Max. 1.5 V, Min.
12.5 V
20 Travel main fuse Vehicle cannot travel 1) Check travel fuse (F1) and replace it Turn Check voltage on sec-
(F1) is broken or its (MD contactor is if necessary. key ondary side of fuse
sensor circuit har- closed). 2) Check wiring harness between CN5- switch (F1).
ness is defective. 11 (CPU board) and terminal P2, OFF.
21 Undervoltage is Vehicle cannot travel 1) Charge battery. Turn This trouble is detect-
detected (Battery (MD/MPS connector 2) Check wiring harness between CN4- key ed when battery volt-
voltage is lower). is not closed). When 8 (CPU board) and terminal P1, then switch age is below 28.2 V for
key switch is turned repair or replace it. OFF. 0.8 seconds.
ON again, vehicle
can travel.
22 Output of travel Vehicle can travel 1) Check temperature sensor (THD), Reset Voltage of tempera-
controller tempera- normally (assuming and replace it if necessary. normal- ture sensor (THD)
ture sensor (THD) temperature is nor- 2) Check wiring harness between CN7-5, ly. when abnormality is
is defective. mal). 11 (CPU board) and temperature sen- detected: Max. 0.2 V,
sor (THD), then repair or replace it. Min. 4.95 V
23 Neutral is detect- Vehicle cannot travel. 1) Operate accelerator and direction Turn When both of acceler-
ed. switch normally. accel- ator and FR switch are
* Neutral caused 2) Check accelerator or direction switch erator turned ON, trouble is
by mistake in op- for short circuit, then repair or re- and FR reset when either of
eration is not place it. switch them is turned OFF.
trouble. 3) Check circuit of accelerator or direc- OFF.
tion switch for looseness of connec-
tor and defective wiring harness,
70-74 BE30 Series


24 Travel controller Vehicle can travel 1) Cool controller and stop vehicle. Con- Normal resistance/
temperature is (Current is limited by 2) Check mounting screws of TMDU, troller is voltage of tempera-
high. temperature rise and TMDV, and TMDW for looseness. reset ture sensor
Fan drive systemoutput is lowered). 3) Check resistance and voltage of tem- when 25°C: 20kz/4.0 V
is defective. perature sensor (THD), then replace temper- 50°C: 7.2kz/3.0 V
it if necessary. ature 80°C: 2.5kz/1.7 V
4) Check wiring harness between CN7- lowers Tolerance of these
5, 11 (CPU board) and temperature below values is ± 10%.
sensor, then repair or replace it. 100°C. 1 ton models: 1 fan
5) Check wiring harness between CN7R-2, 8
CN7R-1, 2, 7, 8 (Power supply 2 ton models: 2 fans
board) and each fan, then repair or CN7R-1, 7 added
replace it. Above 100°C: Current
6) Check wiring harness between CN9- is limited.
6 (CPU board) and CN1R-6, then re- Above 103°C: Warn-
pair or replace it. ing is displayed.
25 Travel motor tem- Vehicle can travel 1) Cool travel motor and stop vehicle. Travel Normal resistance/
perature rises. (Current is limited by 2) Check resistance and voltage of trav- motor is voltage of travel motor
temperature rise and el motor temperature sensor, then reset temperature sensor
output is lowered). replace it if necessary. when 25°C: 10.7kz/3.5 V
3) Check wiring harness between temper- 50°C: 4.4kz/2.4 V
CN11-3, 4 (CPU board) and travel ature 100°C: 1.0kz/0.9 V
motor temperature sensor, then re- lowers 150°C: 0.3kz/0.3 V
pair or replace it. below Tolerance of these
160°C. values is ± 10%.
Above 160°C: Current
is limited.
Above 163°C: Warn-
ing is displayed.
26 Travel controller Vehicle cannot travel. 1) Cool controller and stop vehicle. Con- Normal resistance/
temperature is ab- 2) Check mounting screws of TMDU, troller is voltage of tempera-
normal. TMDV, and TMDW for looseness. reset ture sensor
Fan drive system 3) Check resistance and voltage of tem- when 25°C: 20kz/4.0 V
sensor, then repair or replace it. 115°C. 1 ton: 2 fans
5) Check wiring harness between CN7R-2, 8
CN7R-1, 2, 7, 8 (Power supply 2 ton: 3 fans
board) and each fan, then repair or CN7R-1, 7 added
replace it. Above 115°C: Travel
6) Check wiring harness between CN9- is stopped.
6 (CPU board) and CN1R-6, then re-
pair or replace it.
27 Output of travel Vehicle can travel 1) Check voltage of travel motor tem- Reset Voltage of tempera-
motor temperature normally (assuming perature sensor, then replace sensor normal- ture sensor when ab-
sensor is defec- temperature is nor- if necessary. ly. normality is detected:
tive. mal). 2) Check wiring harness between Max. 0.2 V, Min. 4.95
CN11-3, 4 (CPU board) and travel V
motor temperature sensor, then re-
pair or replace it.
28 Travel motor tem- Vehicle cannot travel. 1) Cool travel motor and stop vehicle. Travel Normal resistance/
perature is abnor- 2) Check resistance and voltage of trav- motor is voltage of travel motor
mal. el motor temperature sensor, then reset temperature sensor
replace it if necessary. when 25°C: 10.7kz/3.5 V
pair or replace it. below Above 175°C: Travel
175°C. is stopped.
BE30 Series 70-75


30 Cargo handling Vehicle can handle 1) If vehicle can handle cargo, check Turn –
power module cargo. code 56 first. key
(TMPU) is shorted. (MP contactor is 2) Check cargo handling power module switch
closed.) (TMPU) and replace it if necessary. OFF.
(This trouble is also (If power module is defective, be
detected when failure sure to replace it and power supply
code 56 is displayed.) board as a set.)
3) Check wiring harness between
CN4R (Power supply board) and TM-
PU, then repair or replace it.
10 (CPU board) and terminal P13,
31 Cargo handling Vehicle cannot han- 1) Check cargo handling power module Turn –
power module dle cargo. (TMP) and replace it if necessary. (If key
(TMP) is open. (MP contactor is power module is defective, be sure to switch
Upper side of car- closed.) replace it and power supply board as OFF.
go handling power a set.)
module (TMP) (Be- 2) Check wiring harness between
tween P and OUT) CN4R (Power supply board) and car-
is shorted. go handling power module (TMP),
Cargo handling then repair or replace it.
motor is shorted or 3) Check wiring harness between CN8-
open. 3 (CPU board) and CN2R-3 (Power
supply board), then repair or replace
it.
4) Check cargo handling motor and its
wiring, then repair or replace it.
32 Chassis EMG Vehicle cannot oper- 1) Check chassis EMG switch. If it is Turn This trouble occurs
switch is defective ate work equipment. open, repair or replace it. EMG only when CN1-24 is
or its circuit har- (MP contactor is not 2) Check wiring harness between CN1- switch disconnected (and
ness is disconnect- closed.) 24 (CPU board) and EMG switch, and key does not occur while
ed. then repair or replace it. switch EMG switch is
OFF. pressed).
33 Cargo handling Vehicle cannot han- 1) Check cargo handling fuse (F2) and Turn Check voltage on sec-
main fuse (F2) is dle cargo (MP replace it if necessary. key ondary side of fuse
broken its sensor contactor is closed). 2) Check wiring harness between CN5- switch (F2).
circuit harness is 22 (CPU board) and terminal P12, OFF.
defective. then repair or replace it.
35 Cargo handling lift Vehicle operates with 1) Check wiring harness between CN2- Reset This code is applied to
VR is shorted or cargo handling "ON" 10, 11, 21 (CPU board) and cargo normal-
only vehicle equipped
open. period ratio at 100%. handling lift VR, then repair or re- ly. with manual valve lift
place it. VR.
2) Check cargo handling lift VR, then re- Output of lift VR when
place it if necessary. abnormality is detect-
4.8 V (Between CN2-
10 and 21)
36 Output of cargo Vehicle can handle 1) Check voltage of temperature sensor Reset Voltage of tempera-
handling controller cargo normally (as- (THP), then replace sensor if neces- normal- ture sensor when ab-
temperature sen- suming temperature sary. ly. normality is detected:
sor (THP) is defec- is normal). 2) Check wiring harness between CN7- Max. 0.2 V, Min. 4.95
tive. 6, 12 (CPU board) and temperature V (Between CN7-6
sensor (THP), then repair or replace and 12)
it.
41 Output of travel Vehicle cannot travel. 1) Check wiring harness between CN2- Reset –
speed sensor A is 3, 4 (CPU board) and travel speed normal-
defective. sensor A, then repair or replace it. ly.
2) Check travel speed sensor A, then
3) Replace travel motor. (Combination
of sensor and slit panel in motor is
defective.)
70-76 BE30 Series


42 Output of travel Vehicle cannot travel. 1) Check wiring harness between Reset –
speed sensor B is CN11-5, 6 (CPU board) and travel normal-
defective. speed sensor B, then repair or re- ly.
place it.
2) Check travel speed sensor B, then
defective.)
45 Capacitor of travel Vehicle can travel 1) If vehicle cannot travel, check code Turn Note) If this trouble is
capacitor port normally. When main 01 first. key left as it is, travel
(CBD) is charged contactor (MD) is 2) Replace CPU board (Resistance of switch contactor (MD) is
abnormally. turned ON, arc is boosting charge drive Tr is defec- OFF. worn quickly by arcs.
generated. (This tive). Repair it immediately.
trouble is also detect-
ed when failure code
01 is displayed.)
50 PS main Tr or its Steering wheel is 1) Check PS motor and its wiring for Turn –
drive circuit har- heavy. opening, then repair or replace it. key
ness are defective. i If short circuit is (Take care of defective contact of switch
EPS board is de- made, this trouble is brush, too.) OFF.
fective. detected before MPS 2) Check connectors and wiring har-
PS motor is open. contactor is turned ness between terminals G, E of main
ON. Tr (TMPS1, 2) and CN8R (Power
supply board) for short circuit, then
repair or replace them.
3) Check connectors and wiring har-
ness between CN6R (Power supply
board) and CN2E (EPS board), then
ness between CN6R (CPU board)
and CN1E (EPS board), then repair
or replace them.
5) Check main Tr (TMPS1, 2), then re-
place it if necessary.
(Note) Be sure to replace following
parts, if necessary.
• Replace set of main Tr (TMPS1,
2).
• Replace EPS board.
place EPS board.
51 PS contactor Vehicle operates nor- 1) Check PS contactor (MPS), then re- Turn Timing of displaying
(MPS) is shorted mally. place it if necessary. key trouble
or its sensor circuit (Error is kept dis- 2) Check wiring harness between CN4- switch When key is turned
harness is defec- played.) 9 (CPU board) and terminal P21, OFF. ON and when MPS
tive. then repair or replace it. drive is turned OFF
52 PS main fuse (F3) Steering wheel is 1) Check PS main fuse (F3), then re- Turn –
is open. heavy. place it if necessary. key
PS contactor (PS contactor (MPS) 2) Check PS contactor (MPS), then re- switch
(MPS) is open or is not closed.) pair or replace it. OFF.
its sensor circuit 3) Check wiring harness between CN4-
harness is defec- 9 (CPU board) and terminal P21,
tive. then repair or replace it.
53 PS contactor Steering wheel is 1) Check PS contactor (MPS) coil for Turn –
(MPS) coil drive Tr heavy. disconnection of connector and coil, key
or its sensor circuit then repair or replace it. switch
harness is defec- 2) Check wiring harness between OFF.
tive. contactor coil connector and CN4-6,
(In CPU board: 14 (CPU board), then repair or re-
Tr5) place it.
3) Replace CPU board (since drive Tr is
defective).
BE30 Series 70-77


54 Output of PS Steering wheel is 1) Check and repair connectors and Turn Output voltage of
torque sensor is heavy. wiring harness between torque sen- key torque sensor when
defective. sor and CN2-6, 7, 18 (CPU board). switchabnormality is detect-
2) Check PS torque sensor, then repair OFF. ed: Max. 0.2 V, Min.
or replace it. 4.8 V (Between CN2-6
and CN1-14)
55 Cargo handling Vehicle can handle 1) Cool controller and stop vehicle. Con- Normal resistance/
controller tempera- cargo ("ON" period 2) Check mounting screws of TMP for troller is voltage of tempera-
ture is high. ratio is limited by tem- looseness. reset ture sensor
Fan drive system perature rise). 3) Check resistance and voltage of tem- when 25°C: 20kz/4.0 V
is defective. perature sensor (THP), then replace temper- 50°C: 7.2kz/3.0 V
sensor (THP), then repair or replace 100°C.
it.
CN7R-1, 2, 7, 8 (Power supply
board) and each fan, then repair or
replace it.
pair or replace it.
56 Capacitor of cargo Vehicle can handle 1) When driving cargo handling motor Turn Note) If this trouble is
handling capacitor cargo. When main continuously, check code 30 first. key left as it is, main
port (CBP) is contactor (MD) is 2) Replace CPU board (Resistance of switch contactor (MD)
charged abnormal- turned ON, arc is boosting charge drive Tr is defec- OFF. is worn quickly
ly. generated. (This tive). by arcs. Repair
trouble is also detect- it immediately.
30 is displayed.)
60 • Key switch is • Only related opera- 1) Check input signal of work equip- Turn If E87 – E89 are also
( 2) turned ON while tions are impossi- ment Pot. key displayed, check them
work equipment ble. Error is • Measure voltage at system controller switch first. For repair meth-
control lever is displayed immedi- connector CN4S --- Normal: 2.4 - 2.6 V OFF. od, see each failure
not in neutral. ately after key 2) If result of check in (1) above is nor- code section.
(Note) This is not switch is turned ON. mal, replace system controller board.
trouble. 3) If result of check in (1) above is ab-
• Adjustment of normal, disconnect related Pot con-
work equipment nector and check its resistance, then
Pot is abnormal. replace if necessary.
• Work equipment Normal resistance --- Pin No. 1-3:
Pot is abnormal. 2kz Pin No. 2-3: 0 - 2kz
• Work equipment 4) If result of check in (1) above is ab-
Pot circuit har- normal but that in (3) is normal,
ness is defective. check and repair wiring harness be-
tween system controller and work
equipment Pot.
61 • Adjustment of • Only related opera- 1) Check and adjust control lever stop- Turn If E87 - E89 and E-60
( 2) work equipment tions are impossi- per. key are also displayed,
Pot is abnormal. ble. Error is • Measure voltage at work equipment switch check them first. For
• Work equipment displayed when le- control lever Pot connector CN4S. OFF. repair method, see
Pot is abnormal. ver is operated. Normal --- When lever is fully tilted each failure code sec-
• Work equipment forward: 3.9 – 4.3 V tion.
Pot circuit har- When lever is fully tilted back: 0.7 –
ness is defective. 1.1 V
2) If result of (1) above is normal, re-
place system controller board.
3) If result of (1) above is abnormal, dis-
connect related Pot connector and
check its resistance, then repair it.
Normal resistance --- Pin No. 1-3:
2kz
Pin No. 2-3: 0 – 2kz
4) If result of check in (1) above is ab-
normal but that in (3) is normal,
check and repair wiring harness be-
equipment Pot.
2. Displayed only proportional solenoid valve spec.
70-78 BE30 Series


61 • Output of lift • Vehicle can do all 1) Check input signal of lift pressure Turn
(Con- pressure sensor operations. Re- sensor. key
tinued) is abnormal. sponse is lowered, • Measure voltage at system controller switch
( 2) • Lift pressure however, and hunt- connector CN4S --- Normal: 0.37 – OFF.
sensor circuit ing prevention func- 4.3 V
harness is defec- tion does not work 2) If result of check in 1) above is nor-
tive. when lift lowers. mal, replace system controller board.
• Automatic lifting and 3) If result of check in 1) above is abnor-
automatic fork level- mal, check and repair pressure sen-
ing (if equipped) sor harness.
cannot be applied. 4) If result of check in 1) above is ab- (Output voltage of
Error is displayed normal but that in 3) is normal, repair pressure sensor: Out
immediately after pressure sensor. of 0.34 – 4.8 V)
key switch is turned
ON.
(If automatic fork • Automatic fork lev- 1) Check and repair mechanical opera- Set tilt
leveling device is eling cannot be ap- tion of tilting angle sensor. lever in
installed) plied. 2) Check that mast does not stop me- neutral.
• Output of tilting (• Fork can be chanically during automatic fork lev-
angle sensor is moved by manual eling operation, then repair mast if
abnormal. operation.) necessary.
• Tilting angle sen- Error is displayed 3) Check input signal from tilting angle sen-
sor circuit har- immediately after sor and adjust installation of sensor.
ness is defective. key switch is turned • Measure voltage at system controller
ON. connector CN5S.
Normal voltage: 0.4 – 4.6 V (Back-
ward tilting end - Forward tilting end) (Output voltage of tilt-
4) If result of 3) above is normal, re- ing angle sensor: Out
place system controller board. of 0.34 – 4.7 V)
5) If result of 3) above is abnormal, (Output of sensor
check and repair tilting angle sensor. does not change dur-
• Disconnect tilting angle sensor and ing fork leveling oper-
measure resistance of sensor. ation.)
62 • Proportional • Only related opera- 1) Check resistance of proportional Turn If E87 – E89, E-60,
( 2) valve coil is dis- tions are impossi- valve coil, then repair coil if neces- key and E-61 are also dis-
connected. ble. Error is sary. switch played, check them
• Wiring harness displayed when le- Normal resistance: 17 – 18z OFF. first. For repair meth-
between propor- ver is operated. 2) If result of above check is normal, od, see each failure
tional valve and (Pump motor ro- check and repair proportional valve code section.
system controller tates for a moment.) circuit harness. A1 --- Example: Main
has trouble of dis- 3) If results of 1) and 2) are normal, go transistor of main con-
connection, leak- to PROPORTIONAL VALVE DRIVE troller is shorted.
age, or defective CIRCUIT IS OPEN. A2 --- Example: EMG
contact. switch is operated mo-
• Relay, fuse, EMG • Vehicle cannot op- 1) Check proportional valve power sup- Turn mentarily or pushed
switch, or wiring erate at all. ply. key halfway.
harness is dis- Error is displayed • Check voltage between pins No. 8 switch
connected. when lever is oper- and No. 21 of system controller con- OFF.
• EMG relay in sys- ated. (Pump motor nector CN1S --- Normal voltage: Bat-
tem controller is rotates for a mo- tery voltage
open. ment.) 2) If result of 1) above is normal, re-
• Battery voltage place system controller board.
lowers while lever 3) If result of 1) above is abnormal,
is operated. A 1 check proportional valve power sup-
(Note) This is not ply circuit harness, CH interlock
trouble in system (main) relay, fuse, and EMG switch
controller. between battery and system control-
• EMG switch is ler for disconnection and leakage,
operated while then repair.
lever is operated,
then only propor-
tional valve pow-
er supply circuit
is broken. A 2
(Note) This is not
trouble in system
controller.
• Proportional • Only related opera- 1) Replace system controller board.
valve drive circuit tions are impossi-
in system con- ble. Error is
troller is open. displayed when le-
ver is operated.
(Pump motor ro-
tates for a moment.)
BE30 Series 70-79


62 • Proportional • Vehicle cannot op- 1) Check resistance of proportional Turn If E87 – E89, E-60,
(Con- valve coil is erate at all. valve coil, then repair coil if neces- key and E-61 are also dis-
tinued) shorted. Error is displayed sary. switch played, check them
( 2) when lever is oper- Normal resistance: 17 – 18z OFF. first. For repair meth-
ated. (Pump motor 2) If result of above check is normal, go od, see each failure
rotates for a mo- to PROPORTIONAL VALVE DRIVE code section.
ment.) CIRCUIT IS OPEN. A1 --- Example: Main
transistor of main con-
troller is shorted.
A2 --- Example: EMG
switch is operated mo-
mentarily or pushed
halfway.
• Proportional • Vehicle cannot op- 1) Replace system controller board. (Check output corre-
valve drive circuit erate at all. sponding to input.)
in system con- Error is displayed
troller is shorted. when lever is oper-
ated. (Pump motor
rotates for a mo-
ment.)
64 [If automatic fork • Automatic fork lev- 1) This phenomenon is not trouble. If it Leave (Fork is not in level po-
( 2) leveling device is eling device does occurs frequently, however, check lever in sition.)
installed] not reach level posi- for mechanical factor such as hitch- neutral.
• Automatic fork tion or exceeds lev- ing, then repair.
leveling device el position.
does not reach (• Fork can be tilted
level position or manually.)
exceeds level po-
sition.
(Note) This is not
trouble.
66 [If automatic lifting • Automatic lifting 1) Check input signal for automatic lift- Turn
( 2) device is installed] cannot be applied. ing operation. key
• Automatic lifting (• Lift can be raised • Measure input voltage for switches switch
control panel manually.) other than memory switch at connec- OFF.
switch is shorted Error is displayed tor CN6S of system controller.
before key switch immediately after Normal voltage: When switch is OFF:
is turned ON. key switch is turned Min. 4 V
ON. When switch is ON: 0 V
2) If result of 1) above is normal, re-
3) If result of (1) above is abnormal,
measure resistance of 9-pin connec-
tor of lifting display panel.
Normal resistance: When switch is
OFF: c
When switch is ON: 0z (when key switch is
(Excluding memory switch) turned ON, unloading,
4) If result of 3) above is abnormal, re- loading, or number-of-
pair lifting display panel. layer setting (1 - 5 lay-
5) If result of 1) above is abnormal but ers) switch is turned
that of (3) is normal, replace system ON.)
controller.
67 [If automatic lifting • Automatic lifting 1) Check encoder power supply circuit. Turn (Source voltage: Be-
( 2) device is installed] cannot be applied. • Disconnect system controller con- key low 4.77 V)
• Automatic lifting • If this trouble occurs nector CN5S and check voltage be- switch
encoder power in automatic lifting tween Pin No. 1 and No. 4. OFF.
supply in system mode, vehicle When normal: 10 V
controller is de- stops. 2) If result of above check is abnormal,
fective. (• Lift can be raised replace system controller board.
• Battery voltage is manually.)
low. Error is displayed
(Note) This is not immediately after
trouble in system key switch is turned
controller. ON.
(Example: Main tran-
sistor of main con-
troller is shorted.)
70-80 BE30 Series


67 [If automatic lifting • Vehicle stops lifting 1) Check that lifting encoder is operat- Turn (Note 1)
(Con- device is installed] operation, then it ing (wire is coming out or going in), key Encoder output pulses
tinued) • Lifting encoder is cannot start auto- then repair it if necessary. switch of 0 V and 5 V. If it is
( 2) defective. matic lifting opera- 2) Check that lift does not stop mechan- OFF. abnormal, its output
• Lifting encoder tion any more. ically during automatic lifting opera- only 0 V or 5 V.
circuit is defec- (• Lift can be raised tion, then repair lift if necessary. (Note 2)
tive. manually.) 3) Check input signal from lifting encod- Check encoder (2)
er while lift is rising. only when it is in-
• Check voltage at system controller stalled.
connector CN5S. (Note 3)
Voltage under abnormal condition In specification shown
(Note 1): 5 V or 0 V in standard connec-
(Note 2): Check A-phase and B- tion diagram, lifting
phase with encoders 1 and 2 respec- encoder wire is pulled
tively. out when lift is raised.
4) If result of 3) above is normal, replace In specification where
system controller board. wire is pulled in when
5) If result of 3) above is abnormal, check lift is raised, A-phases
lifting encoder harness, then repair it and B-phase are on
if necessary. opposite sides. Ac-
6) If result of 3) above is abnormal but cordingly, phases
that of 5) is normal, repair lifting en- must be confirmed.
coder.
[If automatic lifting • Vehicle stops lifting 1) Check that 1st and 2nd encoders are
device is installed] operation, then it connected correctly, then repair
[When 2 encoders cannot start auto- them if necessary.
are installed] matic lifting opera-
• 1st and 2nd en- tion any more.
coders are con- (• Lift can be raised
nected wrongly manually.)
(when 2 encod-
ers are installed).
[If automatic lifting • Vehicle stops lifting 1) Disconnect connector of lifting 2) ref- Turn If E87 – E89, E60 and
device is installed] operation, then it erence switch and measure voltage. key E61 are also dis-
[When 2 encoders cannot start auto- If voltage is above 4 V, check lifting switch played, check them
are installed] matic lifting opera- 2) reference switch, then repair it if OFF. first. For repair meth-
• Lifting 2) refer- tion any more. necessary. od, see each failure
ence switch is (• Lift can be raised 2) If voltage measured in 1) above is code section. (Pulses
defective. manually.) below 4 V, check wiring harness be- are not output from
• Circuit harness of tween system controller and lifting 2) encoder during lifting
lifting (2) refer- reference switch, then repair it if nec- operation.)
ence switch is essary.
defective. 3) If result of 2) above is normal, re-
[If automatic lifting • Vehicle stops lifting 1) Turn key switch ON and pass refer- Turn (Operating direction
device is installed] operation, then it ence switch. See if trouble occurs key does not conform to
• A-phase and B- cannot start auto- (buzzer sounds) 1 second after first switch output direction of en-
phase of lifting matic lifting opera- lifting operation is performed. OFF. coder.)
encoder are con- tion any more. 2) If trouble occurs by operation in 1)
nected opposite- (• Lift can be raised above, check and repair connections
ly. manually.) of A-phase and B-phase.
[If automatic lifting • Vehicle cannot op- 1) If trouble is not repaired by above Turn (Pulses are not output
device is installed] erate automatic lift- methods, replace system controller key from encoder during
• Lifting encoder ing work. board. switch lifting operation.)
input circuit in • Vehicle stops lifting OFF.
system control- operation.
ler is abnormal.
BE30 Series 70-81


68 [If automatic lifting • Vehicle cannot op- 1) Repeat operation correctly. Set [Fork leveling opera-
( 2) device is installed] erate automatic lift- lever in tion is abnormal]
or [If automatic fork ing work. neutral. • Operation is in re-
leveling device is • Vehicle cannot op- verse direction.
installed] erate fork leveling [Automatic lifting oper-
• Automatic lifting work. ation is abnormal]
operation and (• Fork can be lev- • Reference switch is
fork leveling op- eled manually.) not detected or num-
eration are de- ber of layers is not
fective. set.
[If automatic lifting • Vehicle cannot op- 1) Disconnect reference switch connec- Set • Number of layers is
device is installed] erate automatic lift- tor and measure voltage. If voltage lever in changed during op-
or [If automatic fork ing work. is above 4 V, check reference switch, neutral. eration or automatic
leveling device is (•Fork can be leveled then repair it if necessary. operation is started
installed] manually.) 2) If voltage measured in 1) above is in manual operation
• Automatic lifting below 4 V, check wiring harness be- mode.
reference switch tween system controller CN5S-9 and • Operation is in re-
is defective. reference switch, then repair it if nec- verse direction or it
• Wiring harness of essary. is performed at short
automatic lifting 3) If result of 2) above is normal, re- distance.
reference switch place system controller board.
is defective.
[If automatic fork • Fork cannot be tilt- 1) If fork leveling display switch cannot Set
leveling device is ed manually. be turned ON and OFF, replace it. lever in
installed] 2) If switch is normal, check its wiring neutral.
• Tilt display switch harness for short circuit, then repair.
is shorted. 3) If result of above check is normal, re-
• Tilt display switch place system controller.
harness is short-
ed.
69 [If automatic lifting • Fork stops before 1) This phenomenon is not trouble. If it Set After fork stops before
( 2) device is installed] set stop position in occurs frequently, however, check lever in set stop position, if it is
• Automatic lifting automatic lifting for mechanical factor such as hitch- neutral. moved to set stop po-
device does not mode. ing, then repair. sition manually, buzz-
reach set stop er sounds.
position.
(Note) This is not
trouble.
70 [If automatic lifting • Fork stops after set 1) This phenomenon is not trouble. If it Set After fork stops ex-
( 2) device is installed] stop position in au- occurs frequently, however, check lever in ceeding set stop posi-
• Automatic lifting tomatic lifting mode. for mechanical factor such as mal- neutral. tion, if it is moved to
device exceeds function of proportional solenoid set stop position man-
set stop position. valve, etc., then repair. ually, buzzer sounds.
(Note) This is not
trouble.
87 • Sensor power • Vehicle cannot op- 1) Disconnect connectors CN3S, 4S, Turn
( 2) supply in system erate at all. 5S, and 6S of the system controller key
controller is ab- Error is displayed and check voltage between pins No. switch
normal. immediately after 26 and 28 of CN4S. When it is nor- OFF.
• Battery voltage is key switch is turned mal, it is 5 V.
low. ON. 2) If result of 1) above is abnormal, re-
(Note) This is not place system controller board.
trouble in system 3) If result of 1) above is normal, check (Source voltage:
controller. SENS5V circuit harness and sensor Below 4.5 V)
(Example: Main for short circuit and leakage, then re-
transistor of main pair.
controller is short-
ed.)
70-82 BE30 Series


89 • Work equipment • Pump motor rotates 1) Check work equipment switch signal Turn
( 2) switch signal is at low speed. output. key
shorted to GND • Vehicle cannot op- • Measured voltage between pins No. switch
or it is leaking. erate at all. 4 and 2, 3 and 2, 5 and 2, 6 and 2, OFF.
• Work equipment Error is displayed and 17 and 2 of system controller
switch circuit of immediately after connector CN1S. If it is normal, it is
main controller is key switch is turned above 4 V.
abnormal. ON. 2) If result of 1) above is normal, re-
place system controller.
3) If result of 1) above is abnormal,
check work equipment switch signal
harness for leakage and short circuit
to GND, then repair.
measure voltage between pins No. 8
and 14, 10 and 14, 21 and 14, 22 and
14, 23 and 14 of main controller con- (When key switch is
nector CN1. If it is normal, it is 4 V - turned ON, hydraulic
5 V. chopper starts without
5) If result of 4) above is abnormal, re- receiving operation in-
place main controller board. put.)
• Proportional • Error is displayed 1) Replace system controller board. Turn (When key switch is
valve EMG relay immediately after key turned ON, EMG relay
in system con- key switch is turned switch in board is closed.)
troller is shorted. ON. OFF.
95 Multi-controller is • Error is displayed 1) Replace multi-controller board. Turn –
defective. immediately after batter
key switch is turned con-
ON. nector
(Vehicle operates OFF.
normally.)
97 Communication Error is displayed 1) Check continuity of wiring harnesses Per- Occasional occur-
between main con- when abnormality is of CN1-5, CN1-6, CN1-13, and CN1- form au- rence of this trouble is
troller and multi- detected. 14 of multi-controller, then repair tomatic caused by defective
controller is abnor- • Main controller can- them if necessary. reset- contact. In this case,
mal. not be adjusted. 2) Replace multi-controller board. ting nor- connect and discon-
• It cannot display fail- 3) Replace main controller board. mally. nect connector.
ure codes. (Vehicle
operates normally.)
( 2) between system when abnormality is of CN4-5, CN4-6, CN4-7, and CN4-9 form au- rence of this trouble is
controller and detected. of multi-controller, then repair them if tomatic caused by defective
multi-controller is System controller necessary. reset- contact. In this case,
abnormal. cannot display failure 2) Replace multi-controller board. ting nor- connect and discon-
codes. (Vehicle oper- 3) Replace system controller board. mally. nect connector.
ates normally.)
between meter when abnormality is of CN3-1 and CN3-2 of multi-control- form au- rence of this trouble is
panel and multi- detected. ler, then repair them if necessary. tomatic caused by defective
controller is abnor- • Main controller can- 2) Replace multi-controller board. reset- contact. In this case,
mal. not be adjusted. 3) Replace meter panel. ting nor- connect and discon-
• Main controller, sys- mally. nect connector.
tem controller, and
multi-controller can-
not display failure
codes. (Vehicle op-
erates normally.)
BE30 Series 70-83

FAILURE CODES LIST (3.0 TON MODEL) TROUBLESHOOTING
FAILURE CODES LIST (3.0 TON MODEL)

01 Travel power mod- Vehicle cannot travel 1) If vehicle can travel, check code 45 Turn –
ule is shorted or handle cargo (MD first. key
(Upper and lower connector is not 2) Check travel power modules (TMDU, switch
FET's are short- closed). TMDV, and TMDW) and replace OFF.
ed). (This trouble is also them if necessary. (If a power mod-
detected when failure ule is defective, be sure to replace it
code 45 is displayed.) and power supply board as a set.)
3) Check wiring harness between CN3R
(Power supply board) and each pow-
er module, then repair or replace it.
03 Main contactor Vehicle cannot travel 1) Check main contactor (MD) (for melt- Turn –
(MD) is shorted or or handle cargo. ing, mechanical hitching, etc. of con- key
open or its sensor tacts), then repair or replace it. switch
circuit harness is 2) Check wiring harness between CN5- OFF.
defective. 11 (CPU board) and terminal P2,
05 ules are shorted or handle cargo. TMDV, TMDW) and replace them if key Detected when key
11 (Upper and lower necessary. (When replacing, be switch switch is turned
12 modules are short- sure to replace them as a set, togeth- OFF. ON.(Upper)
ed separately). er with power supply board.) Failure code 05:
2) Check wiring harness between Detected when key
CN3R (Power supply board) and switch is turned
each power module, then repair or ON.(Lower)
replace it. Failure code 11:
3) Check wiring harness between CN4- Detected after key
3 (CPU board) and terminal P4, then switch and MD are
repair or replace it. turned ON.(Upper)
4) Check wiring harness between CN4- Failure code 12:
2 (CPU board) and terminal P3, then Detected after key
repair or replace it. switch and MD are
5) Check wiring harness between CN4- turned ON.(Lower)
08 ule is open. or handle cargo. TMDV, TMDW) and replace them if key U-phase is open
09 U-, V-, or W-phase necessary. (When replacing, be switch (disconnected)
is disconnection. sure to replace them as a set, togeth- OFF. Failure code 08:
er with power supply board.) V-phase is open
2) Check wiring harness between (disconnected)
CN3R (Power supply board) and Failure code 09:
each power module, then repair or W-phase is open
replace it. (disconnected)
3) Check output terminals of U-, V-, and
W-phase for disconnection and
looseness of screws.
70-84 BE30 Series

TROUBLESHOOTING FAILURE CODES LIST (3.0 TON MODEL)

07 Main contactor Vehicle cannot travel 1) Check main contactor (MD) coil for Turn –
(MD) drive Tr is de- or handle cargo. disconnection of connector and coil, key
fective (In CPU then repair or replace it. switch
board: Tr4). 2) Check wiring harness between OFF.
Main contactor coil contactor coil and CN4-5, 13 (CPU
is open. board), then repair or replace it.
Sensor circuit har- 3) Replace CPU board (since drive Tr is
ness of main defective).
contactor coil is
defective.
16 F or R switch is de- Vehicle cannot travel. 1) Check wiring harness between CN1- Reset Turn F switch and R
fective. 11, 12 (CPU board) and F/R switch normal- switch ON simulta-
for short circuit, then replace if nec- ly. neously.
essary.
2) Repair or replace F/R switch.
17 Travel accelerator Vehicle cannot travel. 1) Check wiring harness between CN2- Reset Normal source voltage of
output is defective. 8, 9, 20 (CPU board) and travel ac- normal- accelerator: 5 V (Be-
celerator, then repair or replace it. ly. tween CN2-9 and 20)
2) Check travel accelerator unit, then Output voltage of accel-
repair or replace it. erator when abnormality
is detected: Max. 0.2 V,
Min. 4.8 V (Between
CN2-8 and 20)
19 Output or wiring Vehicle cannot travel. 1) Check wiring harness between CPU Turn Normal sensor output
harness of travel board and current sensors, then re- key • During travel: 3.0 V
current sensor pair or replace it. switch – 11.0 V
(CSDU, CSDW) is CSDU: CN5-3, 4, 14, 15 OFF. • When FR switch is
defective. CSDW: CN5-5, 6, 16, 17 in neutral and accel-
2) Check source voltage of current sen- erator is OFF: Ap-
sor power supply of CPU board. prox. 7 V
CSDU: Between CN5-3 and 14, 15 CSDU: Between
CSDW: Between CN5-5 and 16, 17 CN5-4 and 14, 15
If source voltage is abnormal, re- CSDW: Between
place CPU board. CN5-6 and 16, 17
3) Check current sensors (CSDU, CS- Normal source volt-
DW), then replace it if necessary. age of sensor power
supply: 15 V
Sensor output when
abnormality is detect-
12.5 V
20 Travel main fuse Vehicle cannot travel 1) Check travel fuse (F1) and replace it Turn Check voltage on sec-
(F1) is broken or its (MD contactor is if necessary. key ondary side of fuse
sensor circuit har- closed). 2) Check wiring harness between CN5- switch (F1).
ness is defective. 11 (CPU board) and terminal P2, OFF.
21 Undervoltage is Vehicle cannot travel 1) Charge battery. Turn This trouble is detect-
detected (Battery (MD/MPS connector 2) Check wiring harness between CN4- key ed when battery volt-
voltage is lower). is not closed). When 8 (CPU board) and terminal P1, then switch age is below 42 V for
key switch is turned repair or replace it. OFF. 0.8 seconds.
ON again, vehicle
can travel.
22 Output of travel Vehicle can travel 1) Check temperature sensor (THD), Reset Voltage of tempera-
controller tempera- normally (assuming and replace it if necessary. normal- ture sensor (THD)
ture sensor (THD) temperature is nor- 2) Check wiring harness between CN7-5, ly. when abnormality is
is defective. mal). 11 (CPU board) and temperature sen- detected: Max. 0.2 V,
sor (THD), then repair or replace it. Min. 4.95 V
23 Neutral is detect- Vehicle cannot travel. 1) Operate accelerator and direction Turn When both of acceler-
ed. switch normally. accel- ator and FR switch are
* Neutral caused 2) Check accelerator or direction switch erator turned ON, trouble is
by mistake in op- for short circuit, then repair or re- and FR reset when either of
eration is not place it. switch them is turned OFF.
trouble. 3) Check circuit of accelerator or direc- OFF.
tion switch for looseness of connec-
tor and defective wiring harness,
BE30 Series 70-85


24 Travel controller Vehicle can travel 1) Cool controller and stop vehicle. Con- Normal resistance/
temperature is (Current is limited by 2) Check mounting screws of TMDU, troller is voltage of tempera-
high. temperature rise and TMDV, and TMDW for looseness. reset ture sensor
Fan drive systemoutput is lowered). 3) Check resistance and voltage of tem- when 25°C: 20kz/4.0 V
sensor, then repair or replace it. 100°C. Above 100°C: Current
5) Check wiring harness between is limited.
CN7R-1, 2, 7, 8 (Power supply Above 103°C: Warn-
board) and each fan, then repair or ing is displayed.
replace it.
pair or replace it.
25 Travel motor tem- Vehicle can travel 1) Cool travel motor and stop vehicle. Travel Normal resistance/
perature rises. (Current is limited by 2) Check resistance and voltage of trav- motor is voltage of travel motor
temperature rise and el motor temperature sensor, then reset temperature sensor
output is lowered). replace it if necessary. when 25°C: 10.7kz/3.5 V
pair or replace it. below Tolerance of these
160°C. values is ± 10%.
Above 160°C: Current
is limited.
Above 163°C: Warn-
ing is displayed.
26 Travel controller Vehicle cannot travel. 1) Cool controller and stop vehicle. Con- Normal resistance/
temperature is ab- 2) Check mounting screws of TMDU, troller is voltage of tempera-
normal. TMDV, and TMDW for looseness. reset ture sensor
Fan drive system 3) Check resistance and voltage of tem- when 25°C: 20kz/4.0 V
sensor, then repair or replace it. 115°C. Above 115°C: Travel
5) Check wiring harness between is stopped.
replace it.
pair or replace it.
27 Output of travel Vehicle can travel 1) Check voltage of travel motor tem- Reset Voltage of tempera-
motor temperature normally (assuming perature sensor, then replace sensor normal- ture sensor when ab-
sensor is defec- temperature is nor- if necessary. ly. normality is detected:
tive. mal). 2) Check wiring harness between Max. 0.2 V, Min. 4.95
CN11-3, 4 (CPU board) and travel V
motor temperature sensor, then re-
pair or replace it.
28 Travel motor tem- Vehicle cannot travel. 1) Cool travel motor and stop vehicle. Travel Normal resistance/
perature is abnor- 2) Check resistance and voltage of trav- motor is voltage of travel motor
mal. el motor temperature sensor, then reset temperature sensor
replace it if necessary. when 25°C: 10.7kz/3.5 V
pair or replace it. below Above 175°C: Travel
175°C. is stopped.
70-86 BE30 Series


30 Cargo handling Vehicle can handle 1) If vehicle can handle cargo, check Turn –
power module cargo. code 56 first. key
(TMPU) is shorted. (MP contactor is 2) Check cargo handling power module switch
closed.) (TMPU) and replace it if necessary. OFF.
(This trouble is also (If power module is defective, be
detected when failure sure to replace it and power supply
code 56 is displayed.) board as a set.)
CN4R (Power supply board) and
TMPU, then repair or replace it.
31 Cargo handling Vehicle cannot han- 1) Check cargo handling power module Turn –
power module dle cargo. (TMP) and replace it if necessary. (If key
(TMP) is open. (MP contactor is power module is defective, be sure to switch
Upper side of car- closed.) replace it and power supply board as OFF.
go handling power a set.)
module (TMP) (Be- 2) Check wiring harness between
tween P and OUT) CN4R (Power supply board) and car-
is shorted. go handling power module (TMP),
Cargo handling then repair or replace it.
motor is shorted or 3) Check wiring harness between CN8-
open. 3 (CPU board) and CN2R-3 (Power
supply board), then repair or replace
it.
4) Check cargo handling motor and its
wiring, then repair or replace it.
32 Chassis EMG Vehicle cannot oper- 1) Check chassis EMG switch. If it is Turn This trouble occurs
switch is defective ate work equipment. open, repair or replace it. EMG only when CN1-24 is
or its circuit har- (MP contactor is not 2) Check wiring harness between CN1- switch disconnected (and
ness is disconnect- closed.) 24 (CPU board) and EMG switch, and key does not occur while
ed. then repair or replace it. switch EMG switch is
OFF. pressed).
33 Cargo handling Vehicle cannot han- 1) Check cargo handling fuse (F2) and Turn Check voltage on sec-
main fuse (F2) is dle cargo (MP replace it if necessary. key ondary side of fuse
broken its sensor contactor is closed). 2) Check wiring harness between CN5- switch (F2).
circuit harness is 22 (CPU board) and terminal P12, OFF.
defective. then repair or replace it.
35 Cargo handling lift Vehicle operates with 1) Check wiring harness between CN2- Reset This code is applied to
VR is shorted or cargo handling "ON" 10, 11, 21 (CPU board) and cargo normal-
only vehicle equipped
open. period ratio at 100%. handling lift VR, then repair or re- ly. with manual valve lift
place it. VR.
2) Check cargo handling lift VR, then re- Output of lift VR when
place it if necessary. abnormality is detect-
4.8 V (Between CN2-
10 and 21)
36 Output of cargo Vehicle can handle 1) Check voltage of temperature sensor Reset Voltage of tempera-
handling controller cargo normally (as- (THP), then replace sensor if neces- normal- ture sensor when ab-
temperature sen- suming temperature sary. ly. normality is detected:
sor (THP) is defec- is normal). 2) Check wiring harness between CN7- Max. 0.2 V, Min. 4.95
tive. 6, 12 (CPU board) and temperature V (Between CN7-6
sensor (THP), then repair or replace and 12)
it.
41 Output of travel Vehicle cannot travel. 1) Check wiring harness between CN2- Reset –
speed sensor A is 3, 4 (CPU board) and travel speed normal-
defective. sensor A, then repair or replace it. ly.
2) Check travel speed sensor A, then
defective.)
BE30 Series 70-87


42 Output of travel Vehicle cannot travel. 1) Check wiring harness between Reset –
speed sensor B is CN11-5, 6 (CPU board) and travel normal-
defective. speed sensor B, then repair or re- ly.
place it.
2) Check travel speed sensor B, then
defective.)
45 Capacitor of travel Vehicle can travel 1) If vehicle cannot travel, check code Turn Note) If this trouble is
capacitor port normally. When main 01 first. key left as it is, travel
(CBD) is charged contactor (MD) is 2) Replace CPU board (Resistance of switch contactor (MD) is
abnormally. turned ON, arc is boosting charge drive Tr is defec- OFF. worn quickly by arcs.
generated. (This tive). Repair it immediately.
trouble is also detect-
01 is displayed.)
50 PS main Tr or its Steering wheel is 1) Check PS motor and its wiring for Turn –
drive circuit har- heavy. opening, then repair or replace it. key
ness are defective. i If short circuit is (Take care of defective contact of switch
EPS board is de- made, this trouble is brush, too.) OFF.
fective. detected before MPS 2) Check connectors and wiring har-
PS motor is open. contactor is turned ness between terminals G, E of main
ON. Tr (TMPS1, 2) and CN8R (Power
supply board) for short circuit, then
ness between CN6R (Power supply
board) and CN2E (EPS board), then
ness between CN6R (CPU board)
and CN1E (EPS board), then repair
or replace them.
5) Check main Tr (TMPS1, 2), then re-
place it if necessary.
(Note) Be sure to replace following
parts, if necessary.
• Replace set of main Tr (TMPS1,
2).
• Replace EPS board.
place EPS board.
51 PS contactor Vehicle operates nor- 1) Check PS contactor (MPS), then re- Turn Timing of displaying
(MPS) is shorted mally. place it if necessary. key trouble
or its sensor circuit (Error is kept dis- 2) Check wiring harness between CN4- switch When key is turned
harness is defec- played.) 9 (CPU board) and terminal P21, OFF. ON and when MPS
tive. then repair or replace it. drive is turned OFF
52 PS main fuse (F3) Steering wheel is 1) Check PS main fuse (F3), then re- Turn –
is open. heavy. place it if necessary. key
PS contactor (PS contactor (MPS) 2) Check PS contactor (MPS), then re- switch
(MPS) is open or is not closed.) pair or replace it. OFF.
its sensor circuit 3) Check wiring harness between CN4-
harness is defec- 9 (CPU board) and terminal P21,
tive. then repair or replace it.
53 PS contactor Steering wheel is 1) Check PS contactor (MPS) coil for Turn –
(MPS) coil drive Tr heavy. disconnection of connector and coil, key
or its sensor circuit then repair or replace it. switch
harness is defec- 2) Check wiring harness between OFF.
tive. contactor coil connector and CN4-6,
(In CPU board: 14 (CPU board), then repair or re-
Tr5) place it.
3) Replace CPU board (since drive Tr is
defective).
70-88 BE30 Series


54 Output of PS Steering wheel is 1) Check and repair connectors and Turn Output voltage of
torque sensor is heavy. wiring harness between torque sen- key torque sensor when
defective. sor and CN2-6, 7, 18 (CPU board). switchabnormality is detect-
2) Check PS torque sensor, then repair OFF. ed: Max. 0.2 V, Min.
or replace it. 4.8 V (Between CN2-6
and CN1-14)
55 Cargo handling Vehicle can handle 1) Cool controller and stop vehicle. Con- Normal resistance/
controller tempera- cargo ("ON" period 2) Check mounting screws of TMP for troller is voltage of tempera-
ture is high. ratio is limited by tem- looseness. reset ture sensor
Fan drive system perature rise). 3) Check resistance and voltage of tem- when 25°C: 20kz/4.0 V
is defective. perature sensor (THP), then replace temper- 50°C: 7.2kz/3.0 V
sensor (THP), then repair or replace 100°C.
it.
replace it.
pair or replace it.
56 Capacitor of cargo Vehicle can handle 1) When driving cargo handling motor Turn Note) If this trouble is
handling capacitor cargo. When main continuously, check code 30 first. key left as it is, main
port (CBP) is contactor (MD) is 2) Replace CPU board (Resistance of switch contactor (MD)
charged abnormal- turned ON, arc is boosting charge drive Tr is defec- OFF. is worn quickly
ly. generated. (This tive). by arcs. Repair
trouble is also detect- it immediately.
30 is displayed.)
60 • Key switch is • Only related opera- 1) Check input signal of work equip- Turn If E87 – E89 are also
( 2) turned ON while tions are impossi- ment Pot. key displayed, check them
work equipment ble. Error is • Measure voltage at system controller switch first. For repair meth-
control lever is displayed immedi- connector CN4S --- Normal: 2.4 - 2.6 V OFF. od, see each failure
not in neutral. ately after key 2) If result of check in (1) above is nor- code section.
(Note) This is not switch is turned ON. mal, replace system controller board.
trouble. 3) If result of check in (1) above is ab-
• Adjustment of normal, disconnect related Pot con-
work equipment nector and check its resistance, then
Pot is abnormal. replace if necessary.
• Work equipment Normal resistance --- Pin No. 1-3:
Pot is abnormal. 2kz Pin No. 2-3: 0 - 2kz
• Work equipment 4) If result of check in (1) above is ab-
Pot circuit har- normal but that in (3) is normal,
ness is defective. check and repair wiring harness be-
equipment Pot.
61 • Adjustment of • Only related opera- 1) Check and adjust control lever stop- Turn If E87 - E89 and E-60
( 2) work equipment tions are impossi- per. key are also displayed,
Pot is abnormal. ble. Error is • Measure voltage at work equipment switch check them first. For
• Work equipment displayed when le- control lever Pot connector CN4S. OFF. repair method, see
Pot is abnormal. ver is operated. Normal --- When lever is fully tilted each failure code sec-
• Work equipment forward: 3.9 – 4.3 V tion.
Pot circuit har- When lever is fully tilted back: 0.7 –
ness is defective. 1.1 V
2) If result of (1) above is normal, re-
3) If result of (1) above is abnormal, dis-
connect related Pot connector and
check its resistance, then repair it.
Normal resistance --- Pin No. 1-3:
2kz
Pin No. 2-3: 0 – 2kz
4) If result of check in (1) above is ab-
normal but that in (3) is normal,
check and repair wiring harness be-
equipment Pot.
BE30 Series 70-89


61 • Output of lift • Vehicle can do all 1) Check input signal of lift pressure Turn
(Con- pressure sensor operations. Re- sensor. key
tinued) is abnormal. sponse is lowered, • Measure voltage at system controller switch
( 2) • Lift pressure however, and hunt- connector CN4S --- Normal: 0.37 – OFF.
sensor circuit ing prevention func- 4.3 V
harness is defec- tion does not work 2) If result of check in 1) above is nor-
tive. when lift lowers. mal, replace system controller board.
• Automatic lifting and 3) If result of check in 1) above is abnor-
automatic fork level- mal, check and repair pressure sen-
ing (if equipped) sor harness.
cannot be applied. 4) If result of check in 1) above is ab- (Output voltage of
Error is displayed normal but that in 3) is normal, repair pressure sensor: Out
immediately after pressure sensor. of 0.34 – 4.8 V)
key switch is turned
ON.
(If automatic fork • Automatic fork lev- 1) Check and repair mechanical opera- Set tilt
leveling device is eling cannot be ap- tion of tilting angle sensor. lever in
installed) plied. 2) Check that mast does not stop me- neutral.
• Output of tilting (• Fork can be chanically during automatic fork lev-
angle sensor is moved by manual eling operation, then repair mast if
abnormal. operation.) necessary.
• Tilting angle sen- Error is displayed 3) Check input signal from tilting angle sen-
sor circuit har- immediately after sor and adjust installation of sensor.
ness is defective. key switch is turned • Measure voltage at system controller
ON. connector CN5S.
Normal voltage: 0.4 – 4.6 V (Back-
ward tilting end - Forward tilting end) (Output voltage of tilt-
4) If result of 3) above is normal, re- ing angle sensor: Out
place system controller board. of 0.34 – 4.7 V)
5) If result of 3) above is abnormal, (Output of sensor
check and repair tilting angle sensor. does not change dur-
• Disconnect tilting angle sensor and ing fork leveling oper-
measure resistance of sensor. ation.)
62 • Proportional • Only related opera- 1) Check resistance of proportional Turn If E87 – E89, E-60,
( 2) valve coil is dis- tions are impossi- valve coil, then repair coil if neces- key and E-61 are also dis-
connected. ble. Error is sary. switch played, check them
• Wiring harness displayed when le- Normal resistance: 17 – 18z OFF. first. For repair meth-
between propor- ver is operated. 2) If result of above check is normal, od, see each failure
tional valve and (Pump motor ro- check and repair proportional valve code section.
system controller tates for a moment.) circuit harness. A1 --- Example: Main
has trouble of dis- 3) If results of 1) and 2) are normal, go transistor of main con-
connection, leak- to PROPORTIONAL VALVE DRIVE troller is shorted.
age, or defective CIRCUIT IS OPEN. A2 --- Example: EMG
contact. switch is operated mo-
• Relay, fuse, EMG • Vehicle cannot op- 1) Check proportional valve power sup- Turn mentarily or pushed
switch, or wiring erate at all. ply. key halfway.
harness is dis- Error is displayed • Check voltage between pins No. 8 switch
connected. when lever is oper- and No. 21 of system controller con- OFF.
• EMG relay in sys- ated. (Pump motor nector CN1S --- Normal voltage: Bat-
tem controller is rotates for a mo- tery voltage
open. ment.) 2) If result of 1) above is normal, re-
• Battery voltage place system controller board.
lowers while lever 3) If result of 1) above is abnormal,
is operated. A 1 check proportional valve power sup-
(Note) This is not ply circuit harness, CH interlock
trouble in system (main) relay, fuse, and EMG switch
controller. between battery and system control-
• EMG switch is ler for disconnection and leakage,
operated while then repair.
lever is operated,
then only propor-
tional valve pow-
er supply circuit
is broken. A 2
(Note) This is not
trouble in system
controller.
• Proportional • Only related opera- 1) Replace system controller board.
valve drive circuit tions are impossi-
in system con- ble. Error is
troller is open. displayed when le-
ver is operated.
(Pump motor ro-
tates for a moment.)
70-90 BE30 Series


62 • Proportional • Vehicle cannot op- 1) Check resistance of proportional Turn If E87 – E89, E-60,
(Con- valve coil is erate at all. valve coil, then repair coil if neces- key and E-61 are also dis-
tinued) shorted. Error is displayed sary. switch played, check them
( 2) when lever is oper- Normal resistance: 17 – 18z OFF. first. For repair meth-
ated. (Pump motor 2) If result of above check is normal, go od, see each failure
rotates for a mo- to PROPORTIONAL VALVE DRIVE code section.
ment.) CIRCUIT IS OPEN. A1 --- Example: Main
transistor of main con-
troller is shorted.
A2 --- Example: EMG
switch is operated mo-
mentarily or pushed
halfway.
• Proportional • Vehicle cannot op- 1) Replace system controller board. (Check output corre-
valve drive circuit erate at all. sponding to input.)
in system con- Error is displayed
troller is shorted. when lever is oper-
ated. (Pump motor
rotates for a mo-
ment.)
64 [If automatic fork • Automatic fork lev- 1) This phenomenon is not trouble. If it Leave (Fork is not in level po-
( 2) leveling device is eling device does occurs frequently, however, check lever in sition.)
installed] not reach level posi- for mechanical factor such as hitch- neutral.
• Automatic fork tion or exceeds lev- ing, then repair.
leveling device el position.
does not reach (• Fork can be tilted
level position or manually.)
exceeds level po-
sition.
(Note) This is not
trouble.
66 [If automatic lifting • Automatic lifting 1) Check input signal for automatic lift- Turn
( 2) device is installed] cannot be applied. ing operation. key
• Automatic lifting (• Lift can be raised • Measure input voltage for switches switch
control panel manually.) other than memory switch at connec- OFF.
switch is shorted Error is displayed tor CN6S of system controller.
before key switch immediately after Normal voltage: When switch is OFF:
is turned ON. key switch is turned Min. 4 V
ON. When switch is ON: 0 V
2) If result of 1) above is normal, re-
3) If result of (1) above is abnormal,
measure resistance of 9-pin connec-
tor of lifting display panel.
Normal resistance: When switch is
OFF: c
When switch is ON: 0z (when key switch is
(Excluding memory switch) turned ON, unloading,
4) If result of 3) above is abnormal, re- loading, or number-of-
pair lifting display panel. layer setting (1 - 5 lay-
5) If result of 1) above is abnormal but ers) switch is turned
that of (3) is normal, replace system ON.)
controller.
67 [If automatic lifting • Automatic lifting 1) Check encoder power supply circuit. Turn (Source voltage: Be-
( 2) device is installed] cannot be applied. • Disconnect system controller con- key low 4.77 V)
• Automatic lifting • If this trouble occurs nector CN5S and check voltage be- switch
encoder power in automatic lifting tween Pin No. 1 and No. 4. OFF.
supply in system mode, vehicle When normal: 10 V
controller is de- stops. 2) If result of above check is abnormal,
fective. (• Lift can be raised replace system controller board.
• Battery voltage is manually.)
low. Error is displayed
(Note) This is not immediately after
trouble in system key switch is turned
controller. ON.
(Example: Main tran-
sistor of main con-
troller is shorted.)
BE30 Series 70-91


67 [If automatic lifting • Vehicle stops lifting 1) Check that lifting encoder is operat- Turn (Note 1)
(Con- device is installed] operation, then it ing (wire is coming out or going in), key Encoder output pulses
tinued) • Lifting encoder is cannot start auto- then repair it if necessary. switch of 0 V and 5 V. If it is
( 2) defective. matic lifting opera- 2) Check that lift does not stop mechan- OFF. abnormal, its output
• Lifting encoder tion any more. ically during automatic lifting opera- only 0 V or 5 V.
circuit is defec- (• Lift can be raised tion, then repair lift if necessary. (Note 2)
tive. manually.) 3) Check input signal from lifting encod- Check encoder (2)
er while lift is rising. only when it is in-
• Check voltage at system controller stalled.
connector CN5S. (Note 3)
Voltage under abnormal condition In specification shown
(Note 1): 5 V or 0 V in standard connec-
(Note 2): Check A-phase and B- tion diagram, lifting
phase with encoders 1 and 2 respec- encoder wire is pulled
tively. out when lift is raised.
4) If result of 3) above is normal, replace In specification where
system controller board. wire is pulled in when
5) If result of 3) above is abnormal, check lift is raised, A-phases
lifting encoder harness, then repair it and B-phase are on
if necessary. opposite sides. Ac-
6) If result of 3) above is abnormal but cordingly, phases
that of 5) is normal, repair lifting en- must be confirmed.
coder.
[If automatic lifting • Vehicle stops lifting 1) Check that 1st and 2nd encoders are
device is installed] operation, then it connected correctly, then repair
[When 2 encoders cannot start auto- them if necessary.
are installed] matic lifting opera-
• 1st and 2nd en- tion any more.
coders are con- (• Lift can be raised
nected wrongly manually.)
(when 2 encod-
ers are installed).
[If automatic lifting • Vehicle stops lifting 1) Disconnect connector of lifting 2) ref- Turn If E87 – E89, E60 and
device is installed] operation, then it erence switch and measure voltage. key E61 are also dis-
[When 2 encoders cannot start auto- If voltage is above 4 V, check lifting switch played, check them
are installed] matic lifting opera- 2) reference switch, then repair it if OFF. first. For repair meth-
• Lifting 2) refer- tion any more. necessary. od, see each failure
ence switch is (• Lift can be raised 2) If voltage measured in 1) above is code section. (Pulses
defective. manually.) below 4 V, check wiring harness be- are not output from
• Circuit harness of tween system controller and lifting 2) encoder during lifting
lifting (2) refer- reference switch, then repair it if nec- operation.)
ence switch is essary.
defective. 3) If result of 2) above is normal, re-
[If automatic lifting • Vehicle stops lifting 1) Turn key switch ON and pass refer- Turn (Operating direction
device is installed] operation, then it ence switch. See if trouble occurs key does not conform to
• A-phase and B- cannot start auto- (buzzer sounds) 1 second after first switch output direction of en-
phase of lifting matic lifting opera- lifting operation is performed. OFF. coder.)
encoder are con- tion any more. 2) If trouble occurs by operation in 1)
nected opposite- (• Lift can be raised above, check and repair connections
ly. manually.) of A-phase and B-phase.
[If automatic lifting • Vehicle cannot op- 1) If trouble is not repaired by above Turn (Pulses are not output
device is installed] erate automatic lift- methods, replace system controller key from encoder during
• Lifting encoder ing work. board. switch lifting operation.)
input circuit in • Vehicle stops lifting OFF.
system control- operation.
ler is abnormal.
70-92 BE30 Series


68 [If automatic lifting • Vehicle cannot op- 1) Repeat operation correctly. Set [Fork leveling opera-
( 2) device is installed] erate automatic lift- lever in tion is abnormal]
or [If automatic fork ing work. neutral. • Operation is in re-
leveling device is • Vehicle cannot op- verse direction.
installed] erate fork leveling [Automatic lifting oper-
• Automatic lifting work. ation is abnormal]
operation and (• Fork can be lev- • Reference switch is
fork leveling op- eled manually.) not detected or num-
eration are de- ber of layers is not
fective. set.
[If automatic lifting • Vehicle cannot op- 1) Disconnect reference switch connec- Set • Number of layers is
device is installed] erate automatic lift- tor and measure voltage. If voltage lever in changed during op-
or [If automatic fork ing work. is above 4 V, check reference switch, neutral. eration or automatic
leveling device is (•Fork can be leveled then repair it if necessary. operation is started
installed] manually.) 2) If voltage measured in 1) above is in manual operation
• Automatic lifting below 4 V, check wiring harness be- mode.
reference switch tween system controller CN5S-9 and • Operation is in re-
is defective. reference switch, then repair it if nec- verse direction or it
• Wiring harness of essary. is performed at short
automatic lifting 3) If result of 2) above is normal, re- distance.
reference switch place system controller board.
is defective.
[If automatic fork • Fork cannot be tilt- 1) If fork leveling display switch cannot Set
leveling device is ed manually. be turned ON and OFF, replace it. lever in
installed] 2) If switch is normal, check its wiring neutral.
• Tilt display switch harness for short circuit, then repair.
is shorted. 3) If result of above check is normal, re-
• Tilt display switch place system controller.
harness is short-
ed.
69 [If automatic lifting • Fork stops before 1) This phenomenon is not trouble. If it Set After fork stops before
( 2) device is installed] set stop position in occurs frequently, however, check lever in set stop position, if it is
• Automatic lifting automatic lifting for mechanical factor such as hitch- neutral. moved to set stop po-
device does not mode. ing, then repair. sition manually, buzz-
reach set stop er sounds.
position.
(Note) This is not
trouble.
70 [If automatic lifting • Fork stops after set 1) This phenomenon is not trouble. If it Set After fork stops ex-
( 2) device is installed] stop position in au- occurs frequently, however, check lever in ceeding set stop posi-
• Automatic lifting tomatic lifting mode. for mechanical factor such as mal- neutral. tion, if it is moved to
device exceeds function of proportional solenoid set stop position man-
set stop position. valve, etc., then repair. ually, buzzer sounds.
(Note) This is not
trouble.
87 • Sensor power • Vehicle cannot op- 1) Disconnect connectors CN3S, 4S, Turn
( 2) supply in system erate at all. 5S, and 6S of the system controller key
controller is ab- Error is displayed and check voltage between pins No. switch
normal. immediately after 26 and 28 of CN4S. When it is nor- OFF.
• Battery voltage is key switch is turned mal, it is 5 V.
low. ON. 2) If result of 1) above is abnormal, re-
(Note) This is not place system controller board.
trouble in system 3) If result of 1) above is normal, check (Source voltage:
controller. SENS5V circuit harness and sensor Below 4.5 V)
(Example: Main for short circuit and leakage, then re-
transistor of main pair.
controller is short-
ed.)
BE30 Series 70-93


89 • Work equipment • Pump motor rotates 1) Check work equipment switch signal Turn
( 2) switch signal is at low speed. output. key
shorted to GND • Vehicle cannot op- • Measured voltage between pins No. switch
or it is leaking. erate at all. 4 and 2, 3 and 2, 5 and 2, 6 and 2, OFF.
• Work equipment Error is displayed and 17 and 2 of system controller
switch circuit of immediately after connector CN1S. If it is normal, it is
main controller is key switch is turned above 4 V.
abnormal. ON. 2) If result of 1) above is normal, re-
place system controller.
check work equipment switch signal
harness for leakage and short circuit
to GND, then repair.
measure voltage between pins No. 8
and 14, 10 and 14, 21 and 14, 22 and
14, 23 and 14 of main controller con- (When key switch is
nector CN1. If it is normal, it is 4 V - turned ON, hydraulic
5 V. chopper starts without
5) If result of 4) above is abnormal, re- receiving operation in-
place main controller board. put.)
• Proportional • Error is displayed 1) Replace system controller board. Turn (When key switch is
valve EMG relay immediately after key turned ON, EMG relay
in system con- key switch is turned switch in board is closed.)
troller is shorted. ON. OFF.
95 Multi-controller is • Error is displayed 1) Replace multi-controller board. Turn –
defective. immediately after batter
key switch is turned con-
ON. nector
(Vehicle operates OFF.
normally.)
between main con- when abnormality is of CN1-5, CN1-6, CN1-13, and CN1- form au- rence of this trouble is
troller and multi- detected. 14 of multi-controller, then repair tomatic caused by defective
controller is abnor- • Main controller can- them if necessary. reset- contact. In this case,
mal. not be adjusted. 2) Replace multi-controller board. ting nor- connect and discon-
• It cannot display fail- 3) Replace main controller board. mally. nect connector.
ure codes. (Vehicle
operates normally.)
( 2) between system when abnormality is of CN4-5, CN4-6, CN4-7, and CN4-9 form au- rence of this trouble is
controller and detected. of multi-controller, then repair them if tomatic caused by defective
multi-controller is System controller necessary. reset- contact. In this case,
abnormal. cannot display failure 2) Replace multi-controller board. ting nor- connect and discon-
codes. (Vehicle oper- 3) Replace system controller board. mally. nect connector.
ates normally.)
between meter when abnormality is of CN3-1 and CN3-2 of multi-control- form au- rence of this trouble is
panel and multi- detected. ler, then repair them if necessary. tomatic caused by defective
controller is abnor- • Main controller can- 2) Replace multi-controller board. reset- contact. In this case,
mal. not be adjusted. 3) Replace meter panel. ting nor- connect and discon-
• Main controller, sys- mally. nect connector.
tem controller, and
multi-controller can-
not display failure
codes. (Vehicle op-
erates normally.)
70-94 BE30 Series

TROUBLESHOOTING SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)
SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS)

Error
Contents of trouble Trouble vehicle Trouble detection logic
No.
01 Travel power module is Vehicle cannot Detected only at time of start
shorted (Upper and lower travel or handle 1) Key is ON.
FET's are shorted). cargo (MD connec- 2) MD contactor OFF command is output.
tor is not closed). 3) P3 voltage (CN4-2) is below 3.0 V.
(This trouble is 4) Error code is displayed.
also detected 5) MD contactor OFF command.
when failure code
45 is displayed.)
03 Main contactor (MD) is Vehicle cannot <Detection of short circuit>
shorted or open. travel or handle Detected only at time of start
cargo. 1) Key is ON.
2) MD contactor OFF command is output.
3) Travel main circuit FET is normal.
4) P2 voltage (CN5-11) > P1 voltage (CN4-8) x 0.9
5) Error code is displayed.
6) MD contactor OFF command.
<Detection of opening>
At time of start or while stopped (Accelerator is OFF
and DS is in neutral)
1) MD contactor ON command is output.
2) P2 voltage (CN5-11) < P1 voltage (CN4-8) x 0.9
04 Upper FET of travel Vehicle cannot Detected only at time of start
power module is shorted. travel or handle 1) Key is ON.
cargo. 2) MD contactor OFF command is output.
3) P3 voltage (CN4-2) > 20 V
05 Lower FET of travel Vehicle cannot Detected only at time of start
power module is shorted. travel or handle 1) Key is ON.
cargo. 2) MD contactor OFF command is output.
3) P3 voltage (CN4-2) > 20 V
06 U-phase of travel power Vehicle cannot Detected only during operation
module is open. travel or handle 1) DS is in F/R and accelerator is ON.
cargo. 2) Current does not flow in U-phase.
BE30 Series 70-95

SELF-DIAGNOSIS LOGIC TABLE (1.0 - 3.0 TON MODELS) TROUBLESHOOTING
Error
No.
07 Main contactor (MD) drive Vehicle cannot <Detection of short circuit>
Tr is defective (In CPU travel or handle Detected only at time of start
board: Tr4). cargo. 1) Key is ON.
Main contactor coil is 2) MD contactor OFF command is output.
open. 3) Collector voltage of MD contactor coil drive TR in
printed circuit board is below 3.1 V.
Detected only at time of start
1) Key is ON.
3) Collector voltage of MD contactor coil drive TR in
printed circuit board is above 3.1 V.
08 V-phase of travel power Vehicle cannot Detected only during operation
cargo. 2) Current does not flow in V-phase.
09 W-phase of travel power Vehicle cannot Detected only during operation
cargo. 2) Current does not flow in W-phase.
11 Upper FET of travel Vehicle cannot Only while stopped (after key is turned ON).
power module is shorted. travel or handle 1) MD contactor ON command is output.
cargo. 2) Vehicle is stopped (DS is in Neutral and accelera-
tor is OFF).
12 Lower FET of travel Vehicle cannot Only while stopped (after key is turned ON).
power module is shorted. travel or handle 1) MD contactor ON command is output.
cargo. 2) Vehicle is stopped (DS is in Neutral and accelera-
tor is OFF).
16 F or R switch is defective. Vehicle cannot 1) Approx. 50 V is applied to CN1-11 and CN1-12 si-
travel. multaneously.
2) Error code is displayed. (MD is not turned OFF.)
17 Travel accelerator output Vehicle can travel 1) Accelerator output (Voltage between CN2-8 and
is defective. at 40% of maxi- CN1-14) is not 0.2 V – 4.8 V.
mum speed. 2) Error code is displayed. (MD is not turned OFF.)
70-96 BE30 Series

Error
No.
19 Output of travel current Vehicle cannot <Detection of current out of range>
sensor (CSDU, CSDW) is travel. 1) Current sensor output (U-phase: Voltage between
defective. CN5-4 and CN5-14, W-phase: Voltage between
CN5-6 and CN5-16) is not 1.5 V – 14.7 V.
<Detection of offset>
1) Vehicle is stopped (DS is in Neutral and accelera-
tor is OFF).
2) Current sensor output (U-phase: Voltage between
CN5-4 and CN5-14, W-phase: Voltage between
CN5-6 and CN5-16) is not 2.05 V – 2.49 V.
20 Travel main fuse (F1) Vehicle cannot 1) MD contactor ON command is output.
blows. travel. 2) Travel, cargo handling, or EPS operation is not per-
formed.
3) MD contactor is turned ON normally.
P3 voltage (CN4-2) < P2 voltage (CN5-11) x 0.9
21 Undervoltage is detected Vehicle cannot 1) P1 voltage (CN4-8) is below 28.2 V.
(Battery voltage is low). travel. 2) Error code is displayed.
3) MD contactor OFF command and MPS contactor
OFF command.
22 Output of travel controller Vehicle can travel 1) Output voltage of travel controller temperature sen-
temperature sensor is de- normally. sor (CN7-5) is not 0.2 V – 4.95 V.
fective. 2) Error code is displayed.
23 Neutral is detected. Vehicle cannot Detected only at time of start
travel. 1) Key is ON.
2) DS is F or R is ON.
24 Travel controller tempera- Vehicle can travel. 1) Output voltage of travel controller temperature sen-
ture is high. (As temperature sor (CN7-5) is below about 1.1 V. (Travel main cir-
rises, current is cuit temperature > 100°C)
limited and output 2) Error code is displayed. It is reset when tempera-
lowers.) ture lowers below 100°C.
25 Travel motor temperature Vehicle can travel. 1) Output voltage of travel motor temperature sensor
rises. (As temperature (CN11-4) is below 0.29 V. (Travel motor coil tem-
rises, current is perature > 160°C)
limited and output 2) Error code is displayed. It is reset when tempera-
lowers.) ture lowers below 160°C.
26 Travel controller tempera- Vehicle cannot 1) Output voltage of travel controller temperature sen-
ture is abnormal. travel. sor (CN7-5) is below about 0.79 V. (Travel main
circuit temperature > 115°C)
2) Error code is displayed. It is reset when tempera-
ture lowers below 115°C.
27 Output of travel motor Vehicle can travel 1) Output voltage of travel motor temperature sensor
temperature sensor is de- normally (assum- (CN11-4) is not 0.2 V – 4.95 V.
fective. ing temperature is 2) Error code is displayed.
normal).
BE30 Series 70-97

Error
No.
28 Travel motor temperature Vehicle cannot 1) Output voltage of travel motor temperature sensor
is abnormal. travel. (CN11-4) is below 0.22 V. (Travel motor coil tem-
perature: > 175°C)
30 Cargo handling power Vehicle can handle At time of start
module (TMP) is shorted. cargo. 1) Key is ON.
2) MD contactor OFF command is output.
3) P13 voltage (CN4-10) is below 3.0 V.
5) MD contactor ON command.
During operation
2) Chopper command is output.
3) P13 voltage (CN4-10) is below about 7.5 V.
5) MD contactor ON command. (MD is not turned
OFF.)
31 Cargo handling power Vehicle cannot 1) MD contactor ON command is output.
module (TMP) is open. handle cargo. 2) Chopper command is output.
Upper side of cargo han- 3) P13 voltage (CN4-10) is above about 7.5 V.
dling power module (TMP) 4) Error code is displayed.
(Between P and OUT) is 5) MD contactor ON command. (MD is not turned
shorted. OFF.)
Cargo handling motor is
shorted or open.
33 Cargo handling main fuse Vehicle cannot 1) MD contactor ON command is output.
(F2) is blows. handle cargo. 2) Travel, cargo handling, or EPS operation is not per-
formed.
3) MD contactor is turned ON normally.
P12 voltage (CN5-22) < P2 voltage (CN5-11) x 0.9
5) MD contactor ON command. (MD is not turned
OFF.)
35 Cargo handling lift VR is Vehicle operates 1) Lift VR output [Voltage between CN2-10 and CN1-
shorted or open. with "ON" period 14 (0 V)] is not 0.2 V – 4.8 V.
ratio for cargo han- 2) Error code is displayed. (MD is not turned OFF.)
dling at 100%.
36 Output of cargo handling Vehicle can handle 1) Output voltage of cargo handling controller temper-
controller temperature cargo normally. ature sensor (CN7-6) is not 0.2 V – 4.95 V.
sensor (THP) is defective. 2) Error code is displayed.
39 Cargo handling controller Vehicle cannot 1) Output voltage of cargo handling controller temper-
temperature is abnormal. handle cargo. ature sensor (CN7-6) is below about 0.79 V. (Car-
go handling main circuit temperature > 115°C)
41 Output of travel speed Vehicle cannot 1) Vehicle is stopped (Travel speed is 0).
sensor A is defective. handle cargo. Output voltage of travel speed sensor A (Voltage
between CN2-4 and CN2-3) is above 4.5 V.
70-98 BE30 Series

Error
No.
42 Output of travel speed Vehicle cannot 1) Vehicle is stopped (Travel speed is 0).
sensor B is defective. handle cargo. Output voltage of travel speed sensor B (Voltage
between CN11-6 and CN11-5) is above 4.5 V.
45 Capacitor of travel capaci- Vehicle cannot Detected only at time of start
tor board (CBD) is travel or handle 1) Key is ON.
charged abnormally. cargo. 2) MD contactor OFF command is output.
3) P3 voltage (CN4-2) is below 20 V.
50 PS main Tr is defective. Steering wheel is <Detection of short circuit>
heavy to turn. Detected only at time of start
1) Key is ON.
2) MPS contactor OFF command is output.
3) Test OFF command to steering TR.
4) Steering TR (collector) voltage (CN4-1) is below 5
V.
6) MPS contactor OFF command.
1) Key is ON.
3) Test ON command to steering TR.
4) Steering TR (collector) voltage (CN4-1) is above 10
V.
5) MPS contactor ON command.
6) Vehicle is steered.
7) Steering TR ON command (100% command).
8) Steering motor current does not flow.
51 PS contactor (MPS) is PS is possible. Detected only at time of start
shorted. (Error is kept dis- 1) Key is ON.
played.) 2) MPS contactor OFF command is output.
3) Test OFF command to steering TR.
4) Steering TR (collector) voltage (CN4-1) > P1 volt-
age (CN4-9) x 0.9
6) MPS contactor ON command. (MPS is not turned
OFF.)
52 PS main fuse is open. Steering wheel is At time of start
PS contactor (MPS) is heavy to turn. 1) Key is ON.
open. [PS contactor 2) MPS contactor ON command is output.
(MPS) is not 3) Steering TR (collector) voltage (CN4-1) < P1 volt-
closed.] age (CN4-9) x 0.9
While stopped
1) MPS contactor ON command is output.
2) Steering TR (collector) voltage (CN4-1) < P1 volt-
age (CN4-9) x 0.9
BE30 Series 70-99

Error
No.
53 PS contactor (MPS) coil Steering wheel is <Detection of short circuit>
drive Tr is defective. heavy to turn. Detected only at time of start
(In CPU board: Tr5) 1) Key is ON.
3) MPS contactor coil drive TR (collector) voltage
(CN4-14) is below 10.8 V.
1) Key is ON.
2) MPS contactor ON command is output.
3) MPS contactor coil drive TR (collector) voltage
(CN4-14) is above 10.8 V
54 Output of PS torque sen- Steering wheel is 1) Torque sensor voltage (between CN2-6 and CN1-
sor is defective. heavy to turn. 14) is below 0.2 V or above 4.8 V.
55 Cargo handling controller Vehicle can handle 1) Output voltage of cargo handling controller temper-
temperature is high. cargo. (As temperature sensor (CN7-6) is below about 1.1 V. (Cargo
ature rises, "ON" handling main circuit temperature > 100°C)
period ratio of 2) Error code is displayed. It is reset when tempera-
chopper is limited.) ture lowers below 100°C.
56 Capacitor of cargo han- Vehicle cannot Detected only at time of start
dling capacitor board travel or handle 1) Key is ON.
(CBP) is charged abnor- cargo. 2) MD contactor OFF command is output.
mally. 3) P12 voltage (CN5-22) is below 20 V.
70-100 BE30 Series

TROUBLESHOOTING DRIVE MOTOR
DRIVE MOTOR
a Perform inspection and maintenance according to failure codes list (E25, E27, and E28).
a If abnormality is not indicated by any failure code, perform inspection and maintenance according to the fol-
lowing explanation.
1. TROUBLES AND REMEDY FOR THEM
Cause of trouble Inspection order and cause Remedy
Abnormality in battery and

inverter or wiring
(See section of battery and
Rotating sound inverter.)
is not heard. Repair in special factory.
Motor does not rotate even if no load is applied.
Disconnection of connected wire
Disconnection of stator coil
Defective contact caused by

looseness of terminal Tighten securely.
connecting parts
Motor can be Single-phase operation caused
rotated in either Repair with voltmeter.
by trouble in wiring or inverter
direction by hand.
Disconnection of 1 phase Replace wire.
between motor and inverter
Disconnection of 1 phase of
stator coil Repair in special factory.
Breakage of bearing Replace bearing.

Hum is heard but
motor does not Interference of motor shaft
rotate. caused by looseness of Retighten bolts.
mounting bolts, etc.
Motor rotates if no load is applied.
Motor rotates in Wrong connection Exchange 2 of 3 terminal

reverse direction. connection.
Uneven gap between stator

Hum is heard. core and rotor core
Repair in special factory.
Motor frame is Short circuit of part of stator coil
heated abnormally.
Bearing makes Defective bearing Replace bearing.

abnormal sound.
BE30 Series 70-101

DRIVE MOTOR TROUBLESHOOTING
Cause of trouble Inspection order and cause Remedy
Check voltage at inverter

output terminals and, if
Single-phase operation necessary, motor lead wire
joints with voltmeter, then
eliminate cause of trouble.
Speed lowers
suddenly. Check charge level of
Lowering of voltage battery, then charge if
necessary.
Overloading Reduce load.

Motor overheats.
Clogging of air vent with dirt Remove dirt.
Motor cannot be Seizure of Replace bearing.

Loaded operation
rotated easily by hand. bearing
Unbalance of
resistance among
Motor smells phases or lowering of
Motor stops. abnormally. Repair in special factory.
insulation resistance
(with motor lead wires
disconnected)
Disconnection or short circuit of

lead wires
Trouble in inverter See section of inverter.
Check for possibility of

single-phase operation by Correct connection of
checking output terminal motor lead wires.
Motor makes voltage of inverter and
abnormal sound connection of motor lead wires.
or vibration during
operation. Looseness of bracket bolts, air
guides, or c-rings of sensors Retighten bolts, etc.
Bearing is Abnormal sound from bearing

overheated. (Check with sound tester rod) Replace bearing.
70-102 BE30 Series

TROUBLESHOOTING CHARGER
CHARGER
ELECTRIC CIRCUIT DIAGRAM FOR STATIONARY TYPE
MGS : Electromagnetic switch

D1 : Diode
D2 : Diode
BE30 Series 70-103

CHARGER TROUBLESHOOTING
Charge trouble inspection sheet

All the charge troubles are not caused by the charger. Some of them are caused by the condition of the battery
and operating environment. Describe the condition at the time of occurrence of each trouble and take proper
remedies.
Type-Model Serial No. User's name Hour meter Date of delivery Date of occurrence of trouble
Year: Month: Day: Year: Month: Day:
h
, , , ,
Contents of
trouble
Check items Date of inspection:
No. Check item Inspection result Remarks
Measured voltage (V)
Utility Time of measure-

1 :
voltage ment
Operation at time ON OFF
of measurement
2 Voltage tap of charger 195V 205V 215V
3 Abnormality lamp (LED) Lighting Flashing
4 Charge level lamp (LED) L1 L2 L3 L4 L5 L6
Automatic Equalizing
5 Operation lamp
Flashing Lighting
Specific gravity
Condition
6
of battery
Fluid temperature (°C)
7 Frequency of occurrence of Constant Frequent Occasional

trouble
8 Operating condition on previ-

ous day (Over-discharge, etc.)
Contents of remedy (Replace-
9 ment of charge controller, etc.)
Record after remedy is taken
10
(Re-occurrence of trouble)
11 Transformer No.
12 Charge controller No.
70-104 BE30 Series

80. YEARLY INSPECTION CRITERIA
Starting motor and pump motor . . . . . . . . . . . . 80- 2

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80- 3
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80- 6
Power train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-13
Travel system. . . . . . . . . . . . . . . . . . . . . . . . . . 80-14
Steering system . . . . . . . . . . . . . . . . . . . . . . . . 80-15
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20
Cargo handling system . . . . . . . . . . . . . . . . . . 80-24
BE30 Series 80-1

MOTOR YEARLY INSPECTION CRITERIA
Com-
Inspection item Contents of inspection
ponent
1. Abnormal sound Must be free from abnormal sound.

during rotation
2. Wear and sliding 1. Repair limit (Height of brush: H)

condition of brush
1 ton series 2 – 3 ton series
Motor
name 1 – 1.75 ton 2 – 3.0 ton
models models
Pump
Min. 22 mm Min. 22 mm
motor
EPS
Min. 13 mm Min. 13 mm
motor
2. Sliding condition
The brush must slide smoothly.
Starting motor and pump motor
3. Fatigue of brush 1. Pressing force of brush spring

spring
1 ton series 2 – 3 ton series
Motor
name 1 – 1.75 ton 2 – 3.0 ton
models models
Pump Min. 7.35N Min. 7.84N
motor {Min. 750gf} {Min. 800gf}
EPS 4.90 – 11.77N 4.90 – 11.77N

motor {500 – 1,200gf} {500 – 1,200gf}
Hitch a string to the brush spring and

measure the pressing force of the
brush spring with a spring balance.
4. Contact rate of 1. Contact with commutator

sliding surface of
brush 1. Brush
2. Commutator
A. Good
B. Bad
C. Bad
a If the contact is bad, fit the brush.
80-2 BE30 Series

YEARLY INSPECTION CRITERIA MOTOR, BATTERY
Com-
ponent
4. Contact rate of 2. Method of fitting brush

sliding surface of
brush 1) Insert rough sandpaper (#60 – #120) between the commutator and brush
with the sand side against the brush.
2) Hold both ends of the sandpaper and slide it along the commutator sur-
face in the circumferential direction until the brush fits to the commutator.
Starting motor and pump motor
3) Repeat the above work with fine sandpaper (#360) to finish.
4) Clean the brush and commutator by blowing air against them.
5. Commutator 1. Check of commutator surface

1. Sticking of carbon 2. Scratch 3. Stain of current collecting part
4. Uneven wear
6. Looseness of 1. Looseness of bolts

connecting parts 1. Internal connecting wire 2. Pigtail (Brush lead wire)
7 – 8. Electrolyte 1. Check of electrolyte level
1. Stopper
2. Cap
3. Float (Red)
Battery
• Before the float (red) (3) indicates the lowest electrolyte level, add dis-
tilled water (See the next page).
• When the float (3) stopper (1) touches the cap (2) (When clearance a
shown in the above figure is 0), the electrolyte level is at the lowest level.
a Caps (2) of different battery manufacturers have different shapes.
BE30 Series 80-3

BATTERY YEARLY INSPECTION CRITERIA
Com-
ponent
7 – 8. Electrolyte 2. Method of adding distilled water to battery
A. While distilled water

is added
B. After distilled water
is added
1) Open the battery cap and add refined (distilled) water.
2) Stop adding water immediately when the white line of the float is seen.
a If you continue adding water after the white line is seen, the water will spill.
Accordingly, never do so.
Precautions for handling battery
1. Actions to take when electrolyte sticks

Battery
If electrolyte sticks to your eyes, skins, or clothes, wash it away with

much water. If it enters your eyes, in particular, see a doctor immedi-
ately.
2. Prohibition of use of fire

Never make a short circuit or a spark or bring fire of a cigarette, etc.
near the battery.
3. Prevention of electric shock

When maintaining or inspecting the battery, put on rubber gloves.
4. Ventilation
Ventilate well while the battery is not used, as well as while it is used.
80-4 BE30 Series

YEARLY INSPECTION CRITERIA BATTERY
Com-
ponent
7 – 8. Electrolyte 3. Check of electrolyte specific

gravity
1. Rubber ball
2. Suction tube
3. Outer cylinder
4. Hydrometer
5. Electrolyte
1) Charge the battery. Then, set the

electrolyte level normally.
2) Using a hydrometer and a ther-

mometer, measure the specific
gravity and temperature of the
electrolyte.
3) Substitute the values obtained in

1) and 2) above for the following
formula to calculate S20.
S20 = St + 0.0007 (t – 20)
S20 : Specific gravity at 20°C

St : Specific gravity at t°C
(Measured value)
t : Temperature of electrolyte
Battery
(Measured value)
a Normal value:
S20 = 1.27 – 1.29
4) Carry out the above measurement

and calculation for every cell.
a After using the hydrometer, be

sure to wash it in water.
a Keep the measured data.
9. Terminal 1. Looseness 2. Stain 3. Damage

4. Corrosion and electrolytic corrosion
10. Battery case 1. Damage 2. Stain
11. Cell 1. Voltage

• Charge the battery. Then, measure the voltage of each cell with a DC
voltmeter. Check that the voltage is above the set value (2.0 V/cell) is
not extremely different from one cell to another.
2. Damage
BE30 Series 80-5

CONTROLLER YEARLY INSPECTION CRITERIA
Com-
ponent
15 – 20. Contactor 1. Contacts

(Electromagnetic If the contacts are roughened remarkably when checked visually, replace
switch) them.
Replace 2 fixed contacts and 1 moveable contact

MD contactor
together.
PS contactor Replace contactor assembly.
2. Coil resistance
1) Disconnect the lead wires of the coil terminals.
2) Set the multimeter for measurement of resistance and measure the resis-
tance between the coil terminals.
Resistance Judgment
(MD: Travel)
20 – 50 z
(PS: Power Good
steering)
120 – 380 z
c Defective
wiring
Short
0
circuit
Controller
a Do not judge the condi-

tion of the contactor
coil by measuring the
resistance between
the common terminals.
3. Connecting condition and looseness of lead wires of main circuit

Connect the lead wires correctly and tighten them securely.
80-6 BE30 Series

YEARLY INSPECTION CRITERIA CONTROLLER
Com-
ponent
21 – 22. 1. Timing, operating con-

• Potentiometer dition, and set voltage
(Proportional 1) Set the knobs of the all le-
solenoid valve vers in line when the work
specification) equipment control lever
(3) is in neutral with ad-
• Microswitch
justment bolts (1) and (2).
(Manual valve
1.Dimensions when lever
specification)
is in neutral
2.Adjustment range of the
potentiometer
Positions of lever
A. Neutral
B. Lean backward (Pull)
C. Lean forward (Push)
2) Procedure for
checking voltage
• Move work equipment
control lever (3) a little
(by the play) and adjust
the output of potentiom-
eter (4) into the set volt-
age range within the
play range (when the le-
ver is in neutral).
• Move work equipment
Controller
control lever (3) forward

and backward and ad-
just the output of poten-
tiometer (4) into each
set value range.
3)Adjustment
Loosen set bolt (5) of
potentiometer (4) and
turn the body of the po-
tentiometer little by little
to adjust the voltage.
a After adjusting, tighten
the set bolt securely.
4) Set voltage
Measuring point Set voltage
Section Multi-controller (Standard
Pin No. of CN4 value)
When lever is Lift 2
leaned for- Tilt 10 3.9 – 4.3V
ward (pushed) ATT 6, 14, 18
Lift 2
When lever is
Tilt 10 2.4 – 2.6V
in neutral
ATT 6, 14, 18
When lever is Lift 2
leaned back- Tilt 10 0.7 – 1.1V
ward (pushed) ATT 6, 14, 18
BE30 Series 80-7

Com-
ponent
21 – 22. Microswitch 1. Timing and operating condition
Press brake pedal (2), operate parking brake le-

ver (3), and adjust the positions of microswitches
(1) and (4) so that they will be turned ON at the
strokes (operating positions) shown in the follow-
ing table.
Must be turned ON when pedal

Brake pedal
is pressed by 22 – 28 mm.
Must be turned ON when park-
Parking brake
ing brake is applied
lever
(lever is pulled).
2. Check of voltage
See the TROUBLESHOOTING in Section 70.
3. Damage and looseness of fitting parts

Check that the microswitches are not damaged
and their fitting parts are tightened properly.
Controller
25 – 26. FR controller 1. Operating condition

(Sub controller) Check that the lever moves from the
neutral position to F and R securely.
F/R switch side: Male
2. Check of continuity
Check the internal wiring for discon-
nection by checking continuity.
Measuring method Judgment

Shift forward/ Connector on chassis side
reverse lever in F 0 z : Normal seen from inserting direction
and measure resis- c: Discon-
tance between pins nected
No. 1 and No. 3.
Shift forward/
reverse lever in R 0 z : Normal
and measure resis- c: Discon-
tance between pins nected
No. 1 and No. 5.
If disconnection is detected, re-
place the controller.
3. Damage and looseness of fitting parts
Check that the controller is not damaged
and its fitting parts are tightened properly.
80-8 BE30 Series

Com-
ponent
27. Cut-off current 1. Measuring cut-off current
1) Stop the lift truck on a level place and put chocks under the rear wheels.
2) Put wood blocks under both sides of the frame and float the front wheels
above the ground (only when measuring the travel cut-off current).
3) Lower the fork to the ground, lean the mast forward, and apply the parking
brake.
4) Disconnect the wires of the brake switch (only when measuring the travel
cut-off current).
5) Set an ammeter (clamp tester) to the cable to be measured and measure

the cut-off current under the conditions shown in the following table.
Measurement Cable to be Setting of

Motor Cut-off current
conditions measured clamp meter
DU, DV, DC 1,000 A 1ton- 527 – 568A
DW peak range models (peak)
(373 – 412A
Shift forward/re-
(rms))
verse lever in F
position and 2ton- 674 – 746A
press brake ped- models (peak)
Travel
al fully. Then, (475 – 525A
press accelerator (rms))
Controller
pedal fully and

3ton- 524 – 580A
measure current.
model (peak)
(370 – 410A
(rms))
PA, PB Same as (Specifica-
Lean tilt lever for- Model 8 tion values)
Hy- ward fully to lean 1ton-models Min. 300 A
draulic mast and mea- 2ton-models Min. 340 A
sure current. 3ton-model Min. 300 A
Max. 360 A
EPS motor Same as (Specifica-
Turn steering cable Model 8 tion values)
wheel fully to 1ton-models 45±2.5A
EPS
right or left and 2ton-models 50±2.5A
measure current. 3ton-model Min. 45A
Max. 50A
• After checking, connect the disconnected brake switch wires again (only
when measuring the travel cut-off current).
BE30 Series 80-9

Com-
ponent
28. Fuse 1. Under floor plate

1) Turn the key switch
OFF and disconnect
the battery plug.
2) Remove the floor

plate.
3) Open the fuse holder

cap and replace the
fuse.

SF1 Control circuit on chassis 10A
SF2 Accessory circuit 15A

Controller
80-10 BE30 Series

Com-
ponent
28. Fuse 2. Stationary charger

1) Disconnect the power
cable of the charger
from the outlet.
2) Loosen the nut and

replace the fuse.
3) Tighten the nut

securely.
Symbol Voltage Battery capacity Capacity

330AH
BFS80A
400AH
485AH
BFS100A
545AH
48V 565AH
F5 600AH
700AH BFS150A
Controller
935AH
1,080AH
450AH
72V BF150A
545AH
BE30 Series 80-11

Com-
ponent
28. Fuse 3.Controller

1)If any fuse is broken, a
failure code is dis-
played on the monitor
at the operator's seat.
Replace the fuse ac-
cording to the dis-
played failure code.
a When replacing F1 or
F2, remove the printed
circuit card mounting
bracket.
Failure code Corresponding fuse

E20 F1 (Fuse for travel circuit)
Controller
E32 F2 (Fuse for hydraulic circuit)

E52 F3 (Fuse for EPS circuit)
— F4 (Fuse for charging circuit)
a F4 for only 1.0 – 1.75 ton models
2) Turn the key switch OFF and disconnect the battery plug.
3)
1 – 1.75 ton models 48LF-225A
Travel
F1 2 – 2.5 ton models 48LF-325A
circuit
3.0 ton model 96LF-275A
Hydraulic
circuit
EPS
circuit
Charging
circuit
4) Loosen the nut and replace the fuse.
5) Tighten the nut securely.
80-12 BE30 Series

YEARLY INSPECTION CRITERIA CONTROLLER, POWER TRAIN
Com-
ponent
29 – 32. Wiring Check the following items visually and by feeling.

(including charging
cables) 1. Damage of wiring harnesses and looseness of clamps
2. Looseness of terminal connecting parts and condition of taped

Controller
parts
3. Contact condition of battery connectors and looseness of bolts
4. Damage of wiring harness covers
37 – 38. Transfer 1. Oil leakage

Check visually.
2. Checking oil level and replacing oil
Checking oil level

1) Remove level plug (2) and check
the oil level.
2) If the oil level is near the lower line
of the level plug hole, it is normal.
3) If the oil level is low, remove oil filler
plug (1) and add gear oil.
Replacing oil
1) Remove oil filler plug (1), then re-
move drain plug (3) to drain the oil.
2) After draining the oil, tighten drain
plug (3) and supply gear oil through
Power train
he oil filler by the specified quantity.
Refill capacity
Models Oil level (l)
FB10EX/14EX/15EX/18EX
7.0
FB15EXG/18EXG
FB20EX/25EX
8.0
FB20EXG/25EXG
FB30 8.0
3) After supplying oil, check the oil level with the level plug and adjust it if
necessary. (See CHECKING OIL LEVEL above.)
3. Looseness of bolts
Check that the bolts are tightened normally.
BE30 Series 80-13

TRAVEL SYSTEM YEARLY INSPECTION CRITERIA
Com-
ponent
41 – 45. Tire 1. Tire inflation pressure
1 – 1.35 ton 1.5 – 1.75 2 – 2.5 ton 3 ton

Items Unit
models ton models models model
Front kPa 610 610 880 780
wheel {kgf/cm²} {6.25} {6.25} {9.0} {8.0}
Rear kPa 780 780 880 610
wheel {kgf/cm²} {8.0} {8.0} {9.0} {6.25}
2. Cracking and damage of tire

Check the tread and side walls of each tire for cracking and breakage. If
cracking or breakage is serious, replace the tire.
3. Depth of groove
If pneumatic tire is used, measure
depth C of grooves at point B of 1/4
of tread width. Check that depth C is
1.6 mm or larger.
4. Abnormal wear of tire

Check the tire visually for abnormal
wear, uneven wear, and stepped
Travel system
wear.
5. Foreign matter caught or stuck in tire

Check the tire visually for metal pieces, stones, etc. caught or stuck in it.
46. Hub bolt and nut 1. Looseness

and rim fitting Check the nuts with a hub nut wrench and tighten them to the following
bolt and nut torque, if loosened.
1 – 1.75 ton 2 – 2.5 ton 3 ton

Items Unit
models models model
Front Nm 196 – 245 196 – 245 294 – 490
Tightening wheel {kgm} {20 – 25} {20 – 25} {30 – 50}
torque of
hub nut Rear Nm 98 – 147 196 – 245 196 – 245
wheel {kgm} {10 – 15} {20 – 25} {20 – 25}
Tightening Front Nm 98 – 123 {10 – 12.5}
–
torque of wheel {kgm} [Only 1.0 - 1.35 ton models]
rim fitting Rear Nm 59 – 74 157 – 196
nut –
wheel {kgm} {6 – 7.5} {16 – 20}
2. Damage
Check that the bolts and nuts are not damaged.
47. Rim 1. Damage, deformation, and cracking of side ring

Check the side ring visually or by a crack detection method.
80-14 BE30 Series

YEARLY INSPECTION CRITERIA TRAVEL SYSTEM, STEERING SYSTEM
Com-
ponent
48 – 49. Wheel Jack up the lift truck and check the following.
bearing
1. Play
Hold the top and bottom of each tire to check for play.
2. Abnormal sound
Turn each tire with the hands and check for abnormal sound while it is ro-
tating. Check the heaviness and inertia, too.
50. Front axle 1. Deformation, cracking, and damage

Check visually. If necessary, check by a crack detection method.
Travel system
2. Looseness of mounting bolts (1)

Check that mounting bolts (1) are tightened to the specified torque.
1.0 – 1.75 ton

models 343 – 427 Nm
2.0 – 3.0 ton {35 – 43.5 kgm}
models
52 – 55. Steering 1. Play in turning direction

wheel
Play L 30 – 60 mm
Steering system
2. Play in axial and radial directions

Move the steering wheel in the axial direction and radial direction to check
for play.
3. Operating condition
Drive the lift truck and operate the steering wheel actually to check for ab-
normality.
BE30 Series 80-15

STEERING SYSTEM YEARLY INSPECTION CRITERIA
Com-
ponent
56 – 57. Steering 1. Oil leakage

gear box Check visually.
(EX type) 2. Looseness of mounting bolts (1)
Check that the mounting bolts are tightened to the specified torque.
98 – 122 Nm
Mounting bolts (1)
{10.0 – 12.5 kgm}
1. Mounting bolts
2. Dashboard
3. Gear box
58 – 60. 1. Play and looseness of

Steering linkage fitting parts
Rod, arm, bell Have an assistant turn
crank, etc. the steering wheel and
check play of the moving
Steering system
parts, looseness of fitting

parts, and play of the
connecting parts. (Ball
joint (4) has a little play. If
the play is visible, howev-
er, it is abnormal.)
1. Steering gear box
2. Cotter pin
3. Castle nut
4. Ball joint
5. Frame
6. Castle nut
7. Castle nut
59 – 98 Nm
Castle nut (3), (6), (7)
{6 – 10 kgm}
2. Bend, damage, and wear

Check visually.
3. Breakage of cotter pin (2)
Check visually.
61. Knuckle 1. Play of kink pin

Jack up the rear wheels and hold the top and bottom of each tire to check
for play.
2. Damage and cracking of knuckle
Check visually or by a crack detection method.
80-16 BE30 Series

YEARLY INSPECTION CRITERIA STEERING SYSTEM
Com-
ponent
62. Rear axle 1. Camber angle

Apply a camber gauge to the hub
to measure the camber angle.
Camber angle A 1° 30’

Kink pin angle B 6°
2. Minimum turning radius

[1] Have an assistant drive the lift
truck with the minimum turning ra-
dius.
[2] Install a rod having a chalk at its
end to the outside of the counter-
weight to draw a circle on the
ground.
[3] Measure the radius drawn on the
ground.
[4] Measure in both turning direc-
tions.
FB10EX/14EX Within 1,760 ± 90 mm FB20EX Within 1,980 ± 100 mm

FB15EX Within 1,760 ± 90 mm FB25EX Within 2,000 ± 100 mm
FB18EX Within 1,790 ± 90 mm FB20EXG Within 2,050 ± 100 mm
FB15EXG Within 1,985 ± 90 mm FB25EXG Within 2,090 ± 100 mm
Steering system
FB18EXG Within 1,985 ± 90 mm FB30 Within 2,215 ± 110 mm
Difference between both direc-

Within ±100 mm
tions (Common to all models)
3. Thrust clearance
Press rear axle (3) forward and measure clearance a between it and axle
support (4).
Clearance a 0 – 0.1 mm
Adjusting: If clearance a is larger

than 0.3 mm, adjust it to 0
– 0.1 mm with adjustment
bolt (1). After adjusting,
tighten locknut (2) secure-
ly.
4. Support mounting bolt (5)

(1) 1.0 – 1.75 ton models
245 – 308.7 Nm {25 – 31.5 kgm}

(2) 2.0 – 2.5 ton models
490 – 607.6 Nm {50 – 62 kgm}
BE30 Series 80-17

STEERING SYSTEM YEARLY INSPECTION CRITERIA
Com-
ponent
63 – 65. 1. Checking voltage of EPS torque sensor

Power steering
system 1. Dashboard
(EX type) 2. Main
(EXG type) 3. Sub
Turn the key switch OFF and apply voltage of 5 V between terminals
and (Main side) ( is positive (+) and is negative (-)), and then
measure the voltage between terminals and .
When measuring the sub side, apply voltage of 5 V between terminals
and ( is positive (+) and is negative (-)), and then measure
the voltage between terminals and .
Steering system
a When the lift truck is shipped, the main side ( , , ) is used and
the sub side ( , , ) is not used. If the main side is defective,
wires may be connected to the sub side and used.
Normal voltage
State of steering wheel
Between and or between and
Neutral (Not turned at all) 2.5 ± 0.1 V
2.5 ± 0.1 V o 0.9 – 1.4 V
Turned to right
(Must change smoothly)
2.5 ± 0.1 V o 3.6 – 4.1 V
Turned to left
(Must change smoothly)
Judgment: If the voltage is always normal when the steering wheel is in neu-
tral, turned to the right, and turned to the left, the torque sensor is
normal.
80-18 BE30 Series

YEARLY INSPECTION CRITERIA STEERING SYSTEM
Com-
ponent
63 – 65. 2. EPS actuator

Power steering
system 1. Steering gear box
(EX type) 2. Mounting bolt
(EXG type) 3. Universal joint
4. Bellows
5. Ball joint
6. Castle nut
59 – 98 Nm
Castle nut (6)
{6 – 10 kgm}
Steering system
1) Universal joint (3)

Check the following visually and by feeling.
(1) Check that there is not play in the axial direction and turning direction.
(2) Check that the bearing has no play.
(3) Check that the spider is free from damage and cracking.
(4) Check that the bending torque is even and smooth.
2) Cracking and hardening of bellows (4)

Check visually.
3) Play of ball joint (5)

Check that the ball joint does not have visible play.
4) Looseness of actuator mounting bolts (2)

Check that the mounting bolts are tightened to the specified torque.
49 – 68.6 Nm {5 – 7 kgm}
BE30 Series 80-19

BRAKE SYSTEM YEARLY INSPECTION CRITERIA
Com-
ponent
67 – 72. Brake pedal 1. Play
Play (a) 2 – 6 mm
a. Play
b. Switch ON position
c. Stroke
2. Height of pedal (above floor plate)
Height of pedal (H1) 130 – 140 mm

Height of pedal 1 ton series Min. 81 mm
when pressed (H2) 2 – 3 ton series Min. 79 mm
3. Brake switch
After setting the height of the brake pedal, adjust the location of the mi-
croswitch so that it will operate when the pedal stroke (C) is 20 – 30 mm.
4. Entry of air in brake circuit

Press the pedal strongly to see if air is in the brake circuit.
Brake system
5. Braking force
Drive the lift truck at the maximum speed on a dry, flat, and paved road
and apply the brake sharply and check the following.
1) Swing of steering wheel 2) Operation of brake on only one side
3) Abnormal sound 4) Braking distance
With no load Max. 5 m

With load Max. 2.5 m
73 – 76. Parking 1. Operating effort of lever

brake
Model Operating effort of lever
FB10 – 18 147 – 196 Nm {15 – 20 kgm}
FB15/FB18EXG 196 – 245 Nm {20 – 25 kgm}
FB20 – 30 196 – 245 Nm {20 – 25 kgm}
2. Braking force
Check that the parking brake can holding the lift truck on the following
slopes.
With no load Slope of 20% (11.2°) or steeper

With load Slope of 15% (8.5°) or steeper
If there are not slopes, drive the lift truck at low speed and check the ef-
fect of the parking brake.
80-20 BE30 Series

YEARLY INSPECTION CRITERIA BRAKE SYSTEM
Com-
ponent
79 – 80. Brake piping 1. Damage, oil leakage, and interference

Check the pipes, hoses, and joints visually for damage, oil leakage, and
interference.
2. Looseness of connecting parts and clamps

Retighten.
81 – 85. Travel brake 1. Oil leakage

Check visually.
2. Brake oil level

Remove the inside cover under
the cap and check that oil level L
is proper. (25 – 45 mm)
1. Cap
2. Brake reservoir tank
3. Operating condition of master cylinder and wheel cylinder

Press and release the brake pedal and check the following.
1) Heaviness to press brake pedal
Brake system
2) Change of heaviness to press brake pedal

3) Change of position of pressed brake pedal
4) Returning condition of released brake pedal
4. Check the master cylinder and wheel cylinder visually for oil leakage and
damage.
5. Wear and damage of cylinder, piston, and cup

If any abnormality is detected in steps 3 and 4 above, disassemble the
cylinder to check.
Clearance between wheel cylinder and piston Max. 0.2 mm

Clearance between master cylinder and piston Max. 0.15 mm
BE30 Series 80-21

BRAKE SYSTEM YEARLY INSPECTION CRITERIA
Com-
ponent
86 – 93. 1. Looseness of drum fitting parts

Brake drum and Retighten the mounting nuts to 318.7 – 426.6 Nm {32.5 – 43.5 kgm}.
brake shoe If they are turned at this time, caulk them again.
2. Wear of lining
Measure the most worn part of the lining.
Thickness of lining Min. 2.0 mm
3. Operating condition of shoe

Holding the lining surface with a screwdriver, etc. so that the piston will
not come out, press the brake pedal and check the operating condition of
the shoe.
4. Rust of anchor pin

Remove the shoe from the anchor pin and check the anchor pin for rust
and wear.
a When installing the shoe, thinly apply special grease for brake to the
sliding parts.
5. Fatigue of return spring
1.0 – 1.75 ton models Free length: Max. 105 mm

Free length: Max. 112 mm (Longer one)
Free length: Max. 108 mm (Shorter one)
Brake system
3.0 ton model Free length: Max. 136 mm
6. Hook of return spring

Check visually for flaw.
7. Operation of automatic adjuster

See Section. 20. TESTING AND ADJUSTING.
8. Wear and damage of drum

If the inside wall of the drum is worn unevenly, tapered, or scratched bad-
ly, repair it by polishing.
1.0 – 1.75 ton models Max. 256 mm

Repair limit of brake drum
2.0 – 2.5 ton models Max. 281.4 mm
(Inside diameter of brake drum)
3.0 ton model Max. 312 mm
80-22 BE30 Series

YEARLY INSPECTION CRITERIA BRAKE SYSTEM
Com-
ponent
94 – 95. Back plate 1. Deformation and cracking

Check visually.
(Check the periphery of the back plate for deformation and the mounting
bolts for cracking, in particular.)
2. Looseness of mounting bolts

Apply LOCTITE (#271 or #601) to the mounting bolts and tighten them.
157 – 196 Nm {16 – 20 kgm}

Brake system
BE30 Series 80-23

CARGO HANDLING SYSTEM YEARLY INSPECTION CRITERIA
Com-
ponent
107 – 109. Fork 1. Damage and wear of fork and fork pin
2. Deformation of fork
Set the forks to the center of the lift truck
and check that their height difference C
and opening B are less than the speci-
fied values.
Height difference C Max. 15 mm

Opening B Max. 35 mm
3. Wear of fork
Check that thickness A of the base of the
fork is larger than the specified value.
1.0 ton models Min. 26 mm

1.35 – 1.5 ton models Min. 30 mm
2.5 ton models Min. 36.5 mm
3.0 ton model Min. 39.5 mm
4. Cracking of fork
Check the following parts by a crack de-
tection method, since stresses are con-
centrated on them particularly.
• Base of fork F
• Hooks of fork D and E
110 – 119. 1. Cracking

Mast and fork Check visually or by a crack detection method (Check the welded parts
carriage particularly).
• Each stay • Chain wheel shaft
• Tilt cylinder bracket • Each welded part of fork carriage
• Roller shaft
2. Play of roller bearing

Set the mast vertically and raise the fork about 100 mm above the ground.
At this time, check for change of the longitudinal and lateral clearances
between the inner mast and fork carriage and between the outer mast and
inner mast to judge the play between the roller and rail.
1.0 – 1.75 ton 2.0 – 3.0 ton

Items
models models
Clearance Clearance of
Max. 2.0 mm Max. 2.5 mm
between outer front and rear
mast and inner Clearance of
mast Max. 2.0 mm Max. 2.5 mm
left and right
Clearance Clearance of
Max. 2.0 mm Max. 2.0 mm
between fork car- front and rear
riage and inner Clearance of
mast Max. 2.0 mm Max. 2.5 mm
left and right
80-24 BE30 Series

YEARLY INSPECTION CRITERIA CARGO HANDLING SYSTEM
Com-
ponent
110 – 119. 3. Bushing of master support

Mast and fork Check that there is oil grooves on the bushing.
carriage
4. Cracking and damage of roller and roller pin
1) Visually check the rolling contact surface in the mast for abnormality.
2) Insert a steel rod about 200 mm long between the outer mast and inner
mast and pry the masts to check the roller and roller pin for cracking and
damage.
a If the welded parts of the roller pin seem to be cracked, disassemble
the mast and check by a crack detection method.
120 – 122. Chain 1. Tension

Set the mast vertically and raise the fork about 100 mm above the
ground. Press the center of the lift chain with the fingers and check that
the tension is not different.
Adjusting: Adjust with the chain stopper.
2. Elongation
Measure length L of 17 links and check that
it is in the specified range.
Length L of 17 links

2.0 – 2.5 ton models Max. 330 mm
3.0 ton model Max. 550 mm
3. Deformation, damage, lubrication, and

rust
Check visually.
4. Deformation and damage of chain stop-

per.
Check visually.
123 – 124. 1. Deformation and damage

Chain wheel Check visually.
2. Play of bearing
Turn the chain wheel with the hand and check the bearing for play.
125. Attachments 1. Looseness, deformation, cracking, damage, and wear

Operate the attachments and check visually.
2. Installation condition
Operate the attachments and check visually.
BE30 Series 80-25

Com-
ponent
126 – 129. Cylinder 1. Looseness, deformation, cracking, and damage

Check the piston rod, rod screw, and rod end for looseness, deformation,
cracking, and damage.
Important inspection items
1) Bend, flaw, and rust of piston rod (Visual check or feeling)
2) Cracking of piston rod screw (Visual check or dye penetrant test)
3) Looseness of lift cylinder mounting bolt
Lift cylinder mounting bolt 59 – 74 Nm {6 – 7.5 kgm}
2. Hydraulic drift and hydraulic drift of leaning forward
At fork Max. 60 mm/15 min

Hydraulic drift
At cylinder Max. 30 mm/15 min
Hydraulic drift of leaning forward At cylinder Max. 23 mm/15 min
a For the measuring method, see section 20, TESTING AND ADJUST-
ING.
Adjusting:If the hydraulic drift exceeds the specified value, replace
packings of the control valve and cylinder.
3. Oil leakage and damage

Check visually.
4. Clearance between head-side bushing of tilt cylinder rod and

mounting pin

Clearance
2.0 - 3.0 ton models Max. 0.6 mm
130. Hydraulic pump 1. Oil leakage and abnormal sound

Check visually and by listening.
80-26 BE30 Series

YEARLY INSPECTION CRITERIA CARGO HANDLING SYSTEM
Com-
ponent
131 – 132. 1. Oil level

Hydraulic tank
1. Oil level gauge
2. Oil filler
3. Inspection cover
Lower the fork and open inspec-

tion cover (3). Check that hydrau-
lic oil level gauge (1) shows the oil
level in proper range L. If oil level
is low, add hydraulic oil through
oil filler (2).
2. Replacing hydraulic oil, clean-

ing strainer, and replacing line
filter
See Section 20. TESTING AND
ADJUSTING.
133 – 134. 1. Play of connecting parts and movement of levers

Control lever Operate the levers and check by feeling.
BE30 Series 80-27

Com-
ponent
135 – 137. 1. Oil leakage

Control valve Check visually.
2. Operation of relief valve

Raise the fork to the maximum lifting height, and then check the operation
sound of the relief valve.
3. Relief pressure Proportional solenoid valve spec.

1) Proportional solenoid valve
spec.
Connect an oil pressure gauge
(for measuring maximum oil
pressure of 24.5 MPa {250 kgf/
cm²}) to relief oil pressure pick-
up plug (1) (plug at the sensor
fitting portion).
Manual valve spec.
Connect an oil pressure gauge
(for measuring maximum oil
pressure of 24.5 MPa {250 kgf/
cm²}) to relief oil pressure pick-
up plug (1) (plug at the control
valve P port portion).
2) Raise the fork to the maximum

lifting height and relieve the oil.
Check that the oil pressure at
this time is in the specified Manual valve spec.
range.
Specified 17.1 – 18.1 MPa

pressure {174 – 185 kgf/cm²}
a If a port valve is installed, lean

the attachment lever forward
when measuring.
80-28 BE30 Series

Be30 (FB-11)

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ELECTRIC LIFT TRUCK

10. GENERAL AND SPECIFICATIONS

20. TESTING AND ADJUSTING

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

80. CRITERIA FOR YEARLY INSPECTION

BE30 Series 00-3

Weight category Model name

BE30 Series 00-5

DESCRIPTION OF THE SYMBOLS

Symbol Item Description

Special safety precautions are needed to perform the

Fastening parts that require specified tightening force

Weight of parts or systems.

Places to be coated with adhesives, etc. When assem-

00-6 BE30 Series

Outside view and specifications . . . . . . . . . . . . 10- 2

BE30 Series 10-1

OUTSIDE VIEW AND SPECIFICATIONS

Item Unit FB10EX-11 FB14EX-11 FB15EX-11 FB18EX-11

10-2 BE30 Series

Item Unit FB15EXG-11 FB18EXG-11

BE30 Series 10-3

Item Unit FB20EX-11 FB25EX-11 FB20EXG-11 FB25EXG-11 FB30-11

Rear tires – 18x7-8-14PR 18x7-8-14PR 18x7-8-14PR 18x7-8-14PR 21x8-9-

10-4 BE30 Series

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

To operate the vehicle safely, replace periodically

Important Replacement Parts List

No. Part name Years

1 Master cylinder and wheel cylinder caps, dust seals 1

2 Brake hose or tube 1–2

3 Brake reserve tank, tube 2–4

4 Power sttering hose 2

5 Rubber parts of power steering 2

6 Lift chain 2–4

7 Hose of laod handling 1–2

BE30 Series 10-5

SAFETY ITEMS FOR MAINTENANCE

USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

10-6 BE30 Series

WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS

USE SUITABLE TOOLS

REPLACE SAFETY CRITICAL PARTS PERIODICALLY

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL

BE30 Series 10-7

BE CAREFUL NOT TO GET CAUGHT OR FALL

CHECKING AND INFLATING TIRES

10-8 BE30 Series

JACKING UP LIFT TRUCK (when checking or replacing tires)

LIFTING LIFT TRUCK (when checking tires)

SLINGING VEHICLE (for loading it on trailer, etc.)

BE30 Series 10-9

CAUTION WHEN HANDLING BATTERY

10-10 BE30 Series

DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

PRECAUTIONS WHEN CHARGING

HANDLING BRAKE FLUID