PRODUCT BULLETIN – For technical & service purposes –

New Model Introduction

D01/D02 Series
 FOREWORD

This instruction manual describes the techniques used for the new 001 & 002
models. Please read this manual and following documents thoroughly for your
effective services.

Reference:
Service Manual for 001 & 002 models
(Publication No. SM99E-012SEO)
Service Manual and Technical Bulletin for J01 & J02 models
(Publication No. SM3E-J012GO)
Service Manual and Technical Bulletin for Model T027 and B030 engines
(Publication No. SM3E-J12EGO)

~ 1999 NISSAN MOTOR CO., LTD. Printed in Japan

CONTENTS

FEATURES 1
ENGINE CONTROL SYSTEM (GASOLINE/LPG ENGINE) 2
CREEP SPEED CONTROL (EN 1726-1) 14
ENGINE STOP SYSTEM (EN 1726-1) 20
JOYSTICK CONTROL SYSTEM
(ELECTRICAL LOADING CONTROL) 21
STEERING SySTEM 29
2W MAST (OUTSI DE PULLEY TYPE) 31
OTH ER CE REGULATIONS 33
HYDRAULIC SySTEM 34
 FEATURES

2W MAST
(Outside pulley type) Joystick control system

Engine control system

Steering system

Creep control system

Engine stop system
(EN1726-1)
(EN1726-1)

Other CE regulations
• Diesel engine exhaust gas control
• Battery disconnecting system (EN1175-1)
Hydraulic system
• Pump
• Control valve

-1-
 FEATURES
ENGINE CONTROL SYSTEM (GASOLINE/LPG
ENGINE)
FEED BACK CONTROL (EXHAUST GAS CONTROL)
DESCRIPTION
In this system, the controller judges the engine status and controls the solenoid valve in the carburetor (or the
mixer) in order to control the fuel feed rate (air-fuel ratio).

ps

A: Lambda-control
operation area

rpm

OPERATION AREA
A. Lambda-control operation: Control to the catalyst operation MR (theoretical mixture ratio: A = 1)
8. Full-open area: Priority is placed on output. (Enrich the mixture to obtain the maximum torque.)
Condition: [Vacuum SW is ON.]
C. Idling area: Fuel flow rate is fixed to the range where no odor occurs during idling. (Approx. A = 1)
Condition: [Throttle SW is OFF.]

-2-
 FEATURES
SYSTEM DIAGRAM

Power for controller

r"'"'y
Idle switch
(Carburetor) Idle judgement

Distributor

Revolution signal

Water Engine control unit

temperature (ECU)
sensor
Engine coolant temperature

Vacuum
switch
WOT (Wide open throttle) signal

Oxygen sensor
Fuel controller
(Muffler) Exhaust gas density (Operation signal)

Solenoid valve
(Carburetor or Mixer)

OPERATION FLOW
Oxygen sensor voltage ~ (Input of exhaust gas density) Control unit ~ (Operation command)
Feed back solenoid (Density setting to catalyst shift range) ~ Reduction of density by catalyst
Based on the lean or rich signal of the air-fuel ratio detected by the oxygen sensor, the energization time ratio
of the air-fuel ratio control solenoid (FIB SOL) is controlled, and the air-fuel ratio is controlled close to the ratio
of the three-way catalyst shift point.

-3-
 FEATURES
SYSTEM DIAGRAM
STD

(ij
c
0)

"w
c
.Q
T9o
cr

o
CJl
C
Q)
CJl
C
~(ij
>.c
)(0)

O"w

-4-
 FEATURES
LPG

eD
.0
E
o
CD

g
c:
(])
l/l
o f- "'eD
o a: ttl~
Cl::J
« ~ -0;
l/l~
en ::JeD
Ille.
.r::E
x(])
w_
(])
Cl
III
-"
9
<..> :z
III
e.
E 0;
::J
::J .2
<..>
c:
~ "(ij
::2:

-0
"0
c:
eD

0°
"_
0;.><
~<..>
l/l

-ttl
eD.o
::J
-~(]) -0
:«2

a;
c:
Cl
"iii
c:
o
~o
a:

-5-
 FEATURES
CIRCUIT DIAGRAM
--l I SHIELDING WIRE I
I ENGINE rpm ~---_.--. -~ jill
(Distributor)
~~-------

~.-.----. ----~-@j---------------l
IIDLE SW

[Q] !
~ISLOW CUT h I I
114(LPG)

I RS04MB I I I
I~R-S~?4-M-B~1
113 (GAS)

LPG & GASOLINE ~r-fEJ B A

FIB SOL ~ CD

I TEST SW I
A 17

I FAIL MONITOR LAMP I

B 107
E
I MONITOR LAMP
C 117
C

I E02MGY I I E02FGY I
I WATER TEMP SENSOR ~.---. rE4=i? 21
7
U

I OXYGEN SENSOR ~--.----.

11XO.5f

AV1.25
22
10

SELECT
GASOLINE or LPG
--------.. 14

I W02MB I I W02FB I
IVACUUM SW ~-------. ~ 15

I POWER SUPPLY ~--.----. 24

I ECU Terminal arrangement

D
t A

1 IGN PULSE 107 FAIL LAMP

3 -- 108 POWER GND
5 IDLE SW 113 FIB SOL (GASOLINE)
7 SENSOR GND 114 FIB SOL (LPG)
10 SYSTEM GND 117 MONITOR LAMP
13
14 SELECT SW (GAS or LPGl
15 VACUUM SW
17 TEST SW
21 WATER TEMP SENSOR
22 OXYGEN SENSOR
24 ECU POWER SUPPLY
EEMOO80
-6-
 FEATURES
ENGINE CONTROL PARTS CONNECTORS
Terminal
Part name Terminal configuration Remarks
No.

o
Engine control unit (ECU) 1 IGN PULSE

5 IDLE SW

t 7 SENSOR GND

10 SYSTEM GND
A B c 14 SELECT SW (GAS or LPG)
)1 T 15 BOOST SW

21 WATER TEMP SENSOR

A 22 OXYGEN SENSOR

11011102110311041'%"11051106110711081 24 ECU POWER SUPPLY

11~1110111111121113111411151116111711181 107 FAIL LAMP

10B POWER GND

B C
113 FIB SOL (GASOLINE)
1112131'X"14IslsT7Iar%"191101
114 FIB .SOL (LPG)
1111121131141151161171181191201211221231241
117 MONITOR LAMP
Distributor

2 Engine rpm

Carburetor or Mixer
1 V+ (Feed back solenoid)

2 V- (Feed back solenoid)

~3 4 3 -

4 V'N (Idle switch)

Water temperature sensor

1 V'N

~
2 GND

Oxygen sensor

@- 1 V'N

Vacuum switch

2 GND

-7-
 FEATURES
UNIT LAYOUT

Vacuum switch

Gasoline engine models

LPG engine models

Feedback
solenoid

Oxygen sensor

EEM0081

-8-
 FEATURES
Gasoline engine models GASOLINE CONTROL SPECIFICATIONS
Instead of the conventional carburetor, an electronic fuel flow
control (feed back solenoid: FIB SOL) system has been adopted.

LPG engine models

LPG CONTROL SPECIFICATIONS
A special mixer for LPG has been adopted, and the electronic
Feedback
solenoid
fuel flow control (FIB SOL) system has been introduced.

FEED BACK SOLENOID

Performs electrical control of the fuel feed.
IDLE SWITCH
Idle switch status Engine speed Throttle status
Switch OFF Idling Closed
Switch ON Other than idling Open (according to engine speed)

Oxygen sensor OXYGEN SENSOR

According to the change of voltage, the ECU judges the exhaust
gas density (rich or lean).
The sensor is a zirconia type.

-9-
 FEATURES
Vacuum switch VACUUM SWITCH
When vacuum pressure in the manifold decreases under high
load, the switch is turned on, and the ECU performs the fixed
flow rate control according to the engine speed. (It is used to
judge full-open.)
• Used to judge full-open.
• When turned on (when the vacuum pressure in the manifold
drops under high load), fixed flow rate control is performed
according to the engine speed.

Reference data
kPa (mbar, mmHg, inHg)

Vacuum pressure
Engine speed Remarks
kPa (mbar, mmHg, inHg)
From max. speed under no load to max.
-16.0 (-160, -120, -4.72) (Momentary) During tilt relief
speed under load

ECM (ENGINE CONTROL MODULE)

One module controls gasoline or LPG system by switching
signals.

Three way catalyst

CATALYST
Specifications

Capacity 1.0e (1-3/4 pt)

Substrate noble metal con-
15 9 (0.53 ozlqt)
tent
PtiRh 6/1

-10-
 FEATURES
SELF-DIAGNOSIS FUNCTION
This system can perform the self-diagnosis using the diagnostic monitoring device. The self-diagnosis is
performed by the presence of input signals from switches and sensors.

'Coupler
Clear UL with lamp-related RS03FB: Monitor side
lines connected. RS03MB: ECU side

I ECM I
I Monitor device

Resistance:
More than 510n

Test switch:
No cable between couplers

To instrument
harness

Usually Connected
~

ECU
BODY HARNESS

i Coo"," whO'
performing
self-diagnosis.
O .. To rear
harness

MONITOR FAIL TEST SW

Diagnostic monitor
Battery
EEMOO86

-11-
 FEATURES
DIAGNOSTIC MONITOR CONNECTION
1. Turn the ignition switch OFF, and disconnect the "-" terminal of battery cable.
2. Disconnect the connector @ and @ of body harness.
3. Connect the connector @ to the connector @ of diagnostic monitor.
4. Connect the "-" terminal of battery cable.
5. Perform the diagnosis in accordance with the table below. When the self-diagnosis is being performed, keep
the test switch OFF.
DIAGNOSTIC ITEMS
TEST SW Engine status Fail lamp Monitor lamp
After the IGN key is tumed ON, all fail lamps light
Stopped After the IGN key is turned ON, all fail lamps light
up for 3 seconds.
OFF (IGN ON) up for 3 seconds.
Then, the failure code display function is available.
Operation Failure code display function Rotation signal monitor function (Flash)

DIAGNOSTIC FUNCTIONS
Function Content
All lamps light up. • Turn on all lamps (fail and monitor lamps) to check fail and monitor lamps for open circuit.
Rotation monitor function • Flashes the monitor lamp depending on rotation signal pulses.
Failure code display function • Flashes the fail lamp, and outputs failure codes.

Self-diagnostic results
Failure detection condition
Failure code Device name When ENG is stopped
When ENG is running
(IGN ON)
09 Coolant temperature 0 0
15 Oxygen sensor 0
17 Oxygen sensor fixed 0
18 F/BSOL 1 0
19 FIBSOL2 0

-12-
 FEATURES
How to read the trouble code list

Example

Code: 09

2 3
ON --

OFF-~

Code: 15

I... p'' '1 ..

Tooth
1
~
1 2
First place

3 4 :1
Code shifts
~
Code shifts/repeats

ON --

0.4 0.4 4.0

EEM0085

Explanation of the flash codes

1. The codes are indicated in the order starting from the smallest number.
2. Explanation of flashing code
First-digit code:
The count of flashing corresponds to the code number.
It lights up/goes off for 0.4 seconds in turns in accordance with the code number.
Second-digit code:
In the tenth place, it lights up for 1.2 seconds, and goes off for 1.5 seconds. Then, it flashes for the first
place by the same method of the first digit.
Indication of shift/repeat:
The code shifts/repeats after it goes off for 4.0 seconds. Then it flashes in accordance with the code
number.

-13-
 FEATURES
CREEP SPEED CONTROL (EN1726-1)
DESCRIPTION
In this system, speed sensing system is used to detect the vehicle speed. When accel is released and the
vehicle speed falls below a set speed, controller set the transmission to the neutral position.
SYSTEM DIAGRAM

Ignition switch

I Battery ~~

Forward/Reverse ON/OFF signal Activation signal

Forward relay
switch

Solenoid valve
(AIT)
ON/OFF signal Activation signal
Accel switch Reverse relay

Creep controller

Speed sensor Engine starting

Neutral relay
circuit

Activation signal
Reverse relay Back buzzer

-
-

-14-
 FEATURES
COMPONENT LAYOUT
1 8
2 9
10
I~~ c---=-~]
4
5
6
13

H series engine

Switch stopper

BEM0135

-15-
 FEATURES

FIR LEVER POSITION SWITCH

This switch senses the position of the F/R lever.

1 8 Creep controller CREEP CONTROLLER

2 9
310
This controller detects the signals from the F/R switch, accel
11112 switch and speed sensor, and controls the ON/OFF signal to the
• 1----'
_____
-l
5 solenoid valve of the transmission.
6
713

-j'i=:::=~~----,L ATIOl16

H series engine ACCEL SWITCH

This switch detects the ON/OFF position of the accel pedal.

T027 engine

-16-
 FEATURES
SOLENOID VALVE
This solenoid valve switches the oil-pressure circuit of the
automatic transmission between forward and reverse.

SPEED SENSOR
Speed sensor
This sensor detects the vehicle speed.

~.

ATI0119

VEHICLE CONTROL
INHIBITOR FUNCTION
• The engine cannot start if the FIR lever is set to Forward or Reverse when the key is switched ON.
WHEN THE VEHICLE BEGINS TO MOVE (On a level road)
• When the FIR lever is set to Neutral, the vehicle doesn't move whether the accel is stepped ON or OFF.
• When the accel is stepped on (Accel ON) with the FIR lever set in Forward or Reverse position, the vehicle
begins to move.
• When the FIR lever is set to Forward or Reverse and the accel is not stepped on (Accel OFF), the vehicle
remains stopped.
WHEN THE VEHICLE IS MOVING (On a level road)
• When the FIR lever is set to Forward or Reverse, the vehicle continues to move if the accel remains ON.
• When the accel is released (Accel OFF) while the FIR lever is set to Forward or Reverse, the clutch is let
in to activate the engine brake if the vehicle speed is 4.5 kmlh (2.8 MPH) or over.
• When the accel is released (Accel OFF) while the FIR lever is set to Forward or Reverse, the clutch is set
in neutral if the vehicle speed is less than 4.5 kmlh (2.8 MPH).
• When the FIR lever is set to neutral, the clutch is set to neutral regardless of the vehicle speed.
CAUTION ON OPERATION
• The vehicle has no creeping phenomenon.
• Be sure to apply the parking brake before starting vehicle, even on a gentle slope.
• Be careful not to press the accel too rapidly (especially with a full load).
• Be sure to visually confirm the FIR lever position before starting the vehicle.

-17-
 FEATURES
RELATIONSHIP BETWEEN FIR LEVER AND ACCEL SWITCH
• When the vehicle starts to move (on a level road)
FIR lever
Accel switch
Neutral Forward or Reverse
OFF (when the accel pedal is not stepped on) The vehicle remains stopped. The vehicle remains stopped.
ON (when the accel pedal is stepped on) The vehicle remains stopped. The vehicle starts to move.

• When the vehicle is moving

FIR lever
Accel switch
Neutral Forward or Reverse
Vehicle speed: The automatic transmission stays in forward or re-
OFF (when the accel 4.5 kmlh (2.8 MPH) or over verse and the engine brake is activated.
pedal is not stepped on) Vehicle speed: The automatic
transmission is in The automatic transmission is in neutral.
less than 4.5 kmlh (2.8 MPH)
neutral.
ON (when the accel The automatic transmission stays in forward or re-
Regardless of vehicle speed
pedal is stepped on) verse and the vehicle continues to move.

-18-
 FEATURES
STRUCTURE AND OPERATION OF SOLENOID VALVE
WHEN NEUTRAL

AS

A: Port for forward clutch pressure

S: Port for reverse clutch pressure
~ P: Port for supply pressure
PT T: Drain (tank) port

CD SOL.a (Solenoid a) CID Plunger @ Spool valve

@ SOL.b (Solenoid b) @ Spring @ Manual operation pin

When the solenoid valve is not energized, the spool valve CID is held by the spring @ at the position shown
above, and the ports (A) and (8) are connected to the port (T) while the port (P) is blocked.
WHEN THE SOL.a IS ENERGIZED (Forward)

AS

tt]
PT
A:
B:
P:
T:
Port for forward clutch pressure
Port lor reverse clutch pressure
Port lor supply pressure
Drain (tank) port

When the SOL.a <D is energized, the plunger @ is moved to the right by magnetic force, and the spool valve
is switched to the right. The port (P) is connected to the port (A), and the port (8) is connected to the port (T).
Also, When the manual operation pin <ID on the left is pushed, the same passage is obtained as when the SOL.a
is energized. When the manual pin is released, it returns to the neutral position.
WHEN THE SOL.b IS ENERGIZED (Reverse)

AS

00
PT
A:
B:
P:
T:
Port lor forward clutch pressure
Port for reverse clutch pressure
Port for supply pressure
Drain (tank) port

When the SOL.b is energized, the plunger is moved to the left by the magnetic force, and the spool pin is
switched to the left. The port (P) is connected to the port (8), and the port (A) is connected to the port (T).

-19-
 FEATURES
ENGINE STOP SYSTEM
(EN1726-1)
DESCRIPTION
This system stops the engine when the top panel is opened while
the engine is running.
(A measure to correspond to the EN standard)
Also, it prevents the engine from starting when the top panel is
open.
To perform maintenance with the engine funning while the top
panel is open, connect the bypass connector.
However, be sure to disconnect the bypass connector after
finishing the maintenance.
WIRING DIAGRAM

~3.S
14

rfiE~
IGNITION SWITCH

1
2

(Body harness) --mo F.B- (Seat harness)

m
ENGINE STOP SWITCH

GY
L -rn I!fJ
I GY
L

(Instrument harness)
SlY
SlY ••

GY •• GY

FUSE BLOCK - BR -() co- w

~S~m --'~'"

~
llg

rooro
BYPASS
CONNECTOR
IJ~
IGNITION RELAY BATIERY -
m

-20-
 FEATURES
JOYSTICK CONTROL SYSTEM
(ELECTRICAL LOADING CONTROL)
DESCRIPTION
This system controls the mast speed (lift-tilt) according to the operation volume of the joystick lever using the
joystick controller. This system is also provided with the following controls (functions).
• When the engine is stopped, the lift is not lowered even if the joystick lever is operated.
(The lift can be lowered in the conventional model.)
• When the emergency stop switch is activated, the joystick operation is stopped.
When the emergency stop switch is reset, the loading and unloading operation can be restarted.
• When an abnormality (failure) occurs, the warning lamp "I" in the combination meter on the instrument panel
lights up, and the loading operation in the abnormal system is stopped.
SYSTEM DIAGRAM

Emergency switch
Ignition switch

Joystick ON/OFF signal

lever
Vcc (12V) Joystick
(Lift/Lower,
controller
Forward/backward
Output
- tilt, 3td, 4th)

GND

BEM0162

-21-
 FEATURES
UNIT LAYOUT

Joystick controller

-22-
 FEATURES
JOYSTICK LEVER
The output varies in accordance with the decline of the lever, and the controller defects such changes in output
to control the opening level of the control valve.

l-Iever type CENTER (NEUTRAL)

Switch output S.:t1.
ON (1 kQ max.)
OFF (100 MQ min.)
.!::
<Xl
Ol 100_8.1
o
o
POTENTIOMETER (50)
Ol
OUTPUT (%) 0+g.1
22.5" 22.5" '"
o
£
@\\ j@ E
E
ll)

C\l
I POTENTIOMETER OUTPUT

(OUTPUT)
\. I / RED
(GND)
BLACK

BEM0165

-23-
 FEATURES
2-lever type and
3rd, 4th types

CENTER (NEUTRAL)
Switch output 8":!:1"
ON (1 kQ max.)
OFF (100 MQ min.)

100_g.,

POTENTIOMETER 50
OUTPUT (%)

POTENTIOMETER OUTPUT

c
to
0
(OUTPUT)
0
RED
..q
0 (GND)
2- BLACK
E
E
N

BEM0166

-24-
 FEATURES
JOYSTICK CONTROL VALVE
The joystick controller judges the output signal of the joystick lever, and controls the joystick control valve using
the operation signal.
When the ignition key is set to the OFF position, the loading operation (lift/tilt) cannot be performed.
(With the conventional control valve, the lift can be lowered.)

BEM0168

-25-
 FEATURES
EMERGENCY SWITCH
When an error occurs in the system, making loading uncontrollable, the emergency switch forces the system
to stop.

(r==--==--\--~
!i Joystick cover

'
I, I Remove hole

~~
l'

~]-~'I r- Lock nut

Ii! 1.0 -1.9 Nom
STOP SW

L
, 'I
(0.1 - 0.2 kg-m, 9 -17 in-Ib) 2b

BEM0169

-26-
 FEATURES
JOYSTICK CONTROLLER
The joystick controller is provided with the following functions.
• When an abnormality occurs in the system, the loading operation in the faulty system is stopped.
• The abnormality (failure) in the system can be identified by the self-diagnosis system.
l;Jem0170z

Connector pin terminal arrangement

CN-A CN-S CN.C CN-D

876543216543211110987654321
61543111109 21110987 21 11 71615432

Connector Connector
CN name Pin number Signal name CN name Pin number Signal name
contact contact
1 Solenoid valve 1a + A 1 Sensor 4 Vcc B
2 Solenoid valve 1b + A 2 Sensor 3 GND B
3 Solenoid valve 2a + B 3 Sensor 3 Vcc B
4 Sotenoid valve 2b + B 4 Sensor 2 Vcc B
5 Solenoid valve 3a + B 5 Sensor 1 GND B
6 Solenoid valve 3b + B 6 Sensor 1 Vcc B
7 Solenoid valve 4a + B CN-C Sensor 4 sianal B
7
8 Solenoid valve 4b + B 8 Sensor 4 GND B
9 Solenoid valve 5a + B 9 Sensor 3 sional B
10 Solenoid valve 5b + B 10 Sensor 2 sianal B
11 Solenoid valve C1 + A 11 Sensor 2 GND B
12 A 12 Sensor 1 sianal B
13 A
CN-A Signal name Connector
14 Solenoid valve 1a - A CN name Pin number
contact
15 Solenoid valve 1b - A 1 Power + A
16 Solenoid valve 2a - B 2 Power A
17 Solenoid valve 2b B 3 Instruction 1 Vcc B
18 Solenoid valve 3a - B 4 Instruction 1 GND B
19 Solenoid valve 3b - B 5 Instruction 2 Vcc B
20 Solenoid valve 4a - B 6 Instruction 3 Vcc B
21 Solenoid valve 4b - B 7 Instruction 3 GND B
22 Solenoid valve 5a - B 8 Instruction 4 V cc B
23 Solenoid valve 5b - B 9 GND B
24 Solenoid valve C1 - A 10 Transmission) B
25 A CN-D 11 Transmission clock A
26 A 12 power + A
Connector 13 Power A
CN name Pin number Signal name contacl 14 Instruction 1 si nal B
1 Neutral sianal 3 B 15 Instruction 2 GND B
2 Neutral sianal 1 B 16 Instruction 2 si nal B
3 Back-uD switch 2 B 17 Instruction 3 si nal B
4 B 18 Instruction 4 GND B
5 GND B 19 Instruction 4 si nal B
6 Monitor lamD B 20 GND B
7 Seat switch B 21 IHeception) B
8 GND B 22 GND A
CN-B
9 Neutral sianal 4 B
10 Neutral sianal 2 B
11 Back-uD switch 3 B
12 GND B
13 GND B
14 Mode switchl B
15 Emeroencv shut down B
16 GND B

-27-
 FEATURES
SELF-DIAGNOSIS

CD TROUBLE DIAGNOSIS PROCEDURE

When the fail lamp in the monitor on the vehicle's instrument
panel (as shown in the figure at left) lights up, the controller stops

/ because of abnormalities. Perform the diagnosis procedures

below.
CAUTION:
Blinking of the fail lamp in the monitor on the instrument
\ ~( panel does not indicate abnormality. The blinking lamp
indicates that no operator is sitting in the forklift.

When removing the rubber plug attached to the controller cover,

an LED on the control board can be seen.

Joystick controller

The LED blinks at an interval of one second as shown in the

Number of blinks: Three figure at left, and the abnormality can be identified by counting
the number of blinks. Identify the type of abnormality by referring
Hi9J=h Norm~ILJlJ1JlJ1M~
to the table below.
output
Low CAUTION:
This system detects errors in the electrical system of the
poler
ON I~
~
see'-- Co
3 1-t:::!.-1see
see
-
loading. It does not detect errors resulting from mechanical
causes.
Instruction
signal sec: second
error

DIAGNOSTIC RESULTS
Flashing
Content of abnonnality Details (cause in electrical system)
count

Lit Normal No problem

• The seat switch is turned off. (Nobody on the seat)
2 Seat switch off signal
• Seat switch failure
• Joystick lever output abnormal
Command signal abnormal
3 • Harness is open.
(Operation lever signal abnormal)
• Joystick controller failure
• Solenoid valve output abnonnal
Output abnormal
4 (Solenoid valve abnormal)
• Hamess is open.
• Joystick controller failure

-28-
 FEATURES
STEERING SYSTEM
STEERING LINKAGE
STRUCTURE COMPARISON
001/002 Unit: mm

Size: 001 (17 dia.)

002 (20 dia.)
Round
bush

PS cylinder

Split pin Nut

J01/J02

Size: JOl (15 dia.)

J02 (17 dia.)
Clevis pin

PS cylinder

/
Grease holes (1 place): 2 dia.
1
Tie-bar

Split pin
Nut

-29-
 FEATURES
CHANGE CONTENT FROM J01/J02 MODEL
Change content Purpose

PS cylinder side Size: 17 mm (0.67 in) dia. +- 15 mm (0.59 in) dia. (1-ton series)
Increased allowable load
Rounded bush size increased Size: 20 mm (0.79 in) dia. +- 17 mm (0.67 in) dia. (2-ton series)
Clevis pin Hole diameter: 4 mm (0.16 in) dia. +- 2 mm (0.08 in) dia.
Grease hole diameter and Improved greasing easiness
number of holes increased Number of holes: 2 +- 1

Knuckle spindle side Increased wear resistance by

Material: Oiless #2000 (sintered oil impregnation metal)
Straight bush adopted material change

INTERCHANGEABILITY WITH THE CURRENT MODEL

The components marked by 0 in the table below have been changed. All the components marked by 0 are
interchangeable as a set with the current ones.
1-ton series 2-ton series
PS cylinder body 0 -

PS cylinder end 0 0
Knuckle spindle 0 0
Tie-bar 0 0
Clevis pin 0 0
Rounded bush 0 0

-30-
 FEATURES
2W MAST (OUTSIDE PULLEY TYPE)
The lift chain has been installed to the outside of the outer mast. Further, the chain guide has been installed to
prevent the lift chain from swinging.
CHANGE FROM J01102
Location Item

MAST • The lift chain has been installed to the outside of the outer mast.
• The chain guide has been installed .
• The chain anchor position has been changed .
Carriage • Backrest fixing bolt (8 pcs. ---> 4 pcs.)
• The notch position of the lower finger bar has been changed. (Abolition of the stopper bolt)
Fork Same as J01/02
• Flat steel type
Backrest
• Fixing bolt (8 pcs. ---> 4 pcs.)

-31-
 FEATURES
MAST ASSEMBLY

@:001
tcJ 93 - 127 (9.4 -13.0, 68 - 94)
002 (2.0, 2.5 ton)
tcJ 93 - 127 (9.4 - 13.0, 68 - 94)
G002 (3.0 ton)
tcJ 138 -192 (14.20,102 - 144)
Adjusting bolt

/,/'1

~.. /'1

Li (18-23,131-166) ,
I
tcJ 12.7 - 15.7 -0
i
(1.3 -1.6, I'
10-11) .

1 Inner

i mast

i
,) /
r ( Shim*
i

Side roller
i
i
I
)J
Mast roller m*
Low", b.. m

001
tcJ 21 - 26 i ~
",~
Fork
Anchor bolt

i~
(2.1-2.7,
16 - 19)
002 Shim*

,/'1 VJ1
tcJ 43.1 - 54.9
(4.4 - 5.5,
32 - 40)
L . i d?~~;:
1
i.~~!.A
~~.-1.'/ ,~I Carriage Tilt cylinder
1.75 - 3.0 ton
only ~x,,~ r tcJ 108 -147

rY/~ ~~
~' ,
(11 - 15, 80 -108)
Carriage roller * i
/. ~ Cot", plo 0
/ /" ~ Shim*
Thrust Carriage roller Carriage roller m*
metal (* 1.5 ton)
m :Apply grease.
tcJ : N'm (kg-m, ft-Ib)

~ : Always replace after every disassembly.

* : Select proper thickness.

LMM0143
-32-
 FEATURES
OTHER CE REGULATIONS
DIESEL ENGINE EXHAUST GAS CONTROL (TD27 ENGINE)
The injection pump used in the J01/02 is used as it is.
Specifications of injection pump
Maximum speed (rpm) 2,700:f:50 Under no load
3
Full load fuel (mm /st-cyl) 45:f:3 Engine speed: 2,300 rpm

BATTERY DISCONNECTING SYSTEM (EN117S-1)

The butterfly nut has been adopted instead of the disconnecting switch used in the J01 102 to connect the battery
negative cable in order to simplify the installation and removal of the cable.

Butterfly nut
~
I

~~o
Battery r<~nOO ,/
~~,/ [OJ 15-18(1.5-1.9,11-13)

,~~~~
~ ,~ b

~rr/iA'~
~

~
! J
-j" !
~ '----/'"1' ..... Battery fixing plate

F rame /---~A [OJ : N.m (kg-m, ft-Ib)

-33-
 FEATURES
HYDRAULIC SYSTEM
PUMP
PUMP LIST
DO series JO series
Load Engine
Type of pump Flow priority valve Type of pump Flow priority valve
KAYABA DGP22-19C ULTRA ISX190
H2O-II without installed
19.5cclrev. Dual gear 19.0cc/rev. Dual gear
1-ton
KAYABA DGP22.23C ULTRA IPX230
TD27 without installed
22.9cc/rev. Dual gear 23.0cc/rev. Single gear
H25 KAYABA DGP22-27C ULTRA IPX270
2-ton without without
TD27 26.5cc/rev. Dual gear 27.0cc/rev. Single gear

In both the 001 and 002, the duo (double gear) pump OGP22 series has been adopted.
The OGP22 series pump is a low pressure pulsation gear pump based on the single pump KFP22 series used
in the JO series.
The pressure pulsation amplitude has been reduced to 1/3 or 1/4 of that of the single pump. (Figure below)
STRUCTURE OF THE DUO (DOUBLE GEAR) PUMP

Duo (double gear) pump structural drawing

Front side gear

Rear side gear

Suction side

Front side pressure pUlsation

~ Overlapping pulse wave Discharge side

~
Double gear pump pressure pulse inertia
Reduces to 1/3, 1/4 of normal pump.

-34-
 FEATURES
CONTROL VALVE
GENERAL DESCRIPTION
The proportional solenoid control valve for the joystick lever has been adopted as standard equipment.
The conventional mechanical control valve is available as an option.
In the 001 model, the flow priority valve for PS which was built in the hydraulic pump is built into the control valve
(proportional solenoid type/mechanical type), and the hydraulic systems of the 001 and 002 models have been
unified.
CONTROL VALVE LIST
00 series JO series

Electrically controlled Mechanical Mechanical

001 002 001 002 J01 J02

Application STO STD OPT OPT STD STD

Number of valve section 2-4 2-4 2-4 2-4 2-4 2-4

6 - 12 6 - 12 6 - 12
Priority flow rate 9 (7-7/8) 9 (7-7/8) 9 (7-7/8)
(5-1/4 - 10-5/8) (5-114 - 10-5/8) (5-1/4 - 10-5/8)
f (Imp qt)/min. (fixed) (fixed) (fixed)
(demand) (demand) (demand)

Main relief pressure 16,672 18,143 16,672 18,143 16,672 18,143

kPa (bar, kg/cm2, psi) (166.7,170,2,417) (181.4,185,2,631) (166.7,170,2,447) (181.4,185,2.631) (166.7,170,2,417) (181.4,185,2,631)

Type name of supplier KVSF-65PSL KVSF-65VPF KVSF-65VPFOS KVS65-4 KVSF65VPFOS

Supplier KAYABA HUSCO

SYSTEM DESCRIPTION
The operating oil from the P-port enters the control valve where the flow-diverting valve diverts the oil flow to
supply a fixed amount from the PF-port to the PS circuit.
When the drive signals for the C1 solenoid valve are not transmitted from the controller (that is, when all the
joystick levers are in neutral position), all the oil diverted for the PS circuit flows through the C1 solenoid valve
and is supplied to the PS circuit.
When the drive signals for the C1 solenoid valve are transmitted from the controller (that is, when the joystick
levers are not in neutral position), the C1 solenoid valve is blocked, and all the oil diverted for the PS circuit flows
through the differential-pressure switching valve, and restricted by the orifice to be pressurized to the required
pressure level.
The pressure generated at this time is maintained at a constant level by the pressure reducing valve, and led
to the proportional solenoid control valves in individual sections (lift, tilt, attachment, etc.) to serve as the pilot
pressure.
A solenoid proportional valve is built-in at both ends of the spool of the proportional solenoid control valve. The
proportional solenoid valve restricts the pilot drain in accordance with the valve driving signals from the
controller to control the level of the pilot pressure.
The spool is shifted to a point where the controlled pilot pressure and the spring force of the spool are balanced.
The rate of operating oil flow directly fed from the P-port is controlled by the spool to give the telescopic
movements of the loading cylinder for operation.

-35-
 FEATURES
OPERATION OF CONTROL VALVE
INLET SECTION (001)

Structure and component name (Figure 1)

CD Flow priority valve for steering
@ Solenoid valve for unloading
Q) Pilot pressure switching valve for unloading
@ Unloading valve
@ Pressure reducing valve
@ Main relief valve
(J) Relief valve for steering
@ One-way damper (to prevent sticking of the steering)
@ Orifice
@ Piston
o Pilot pressure oil passage for unloading
@ Pressure-reducing valve secondary pressure oil passage
(supplied as the primary pressure to the proportional solenoid pressure-reducing valve of the spool section)
@ Low pressure passage
@ Excess flow land
@ Controlled oil passage

-36-
 FEATURES
Functions of parts
CD Flow priority valve for steering
• Diverts flow of priority for steering
@ Solenoid valve for unloading
• Normal-open-type; operated by signals from the joystick
With solenoid energized: On-load
With solenoid de-energized: Unload
• Shuts off the priority flow circuit when the joystick is operated (solenoid energized).
CID Pilot pressure switching valve for unloading
• Operates with differential pressure between the solenoid valve @.
• Controls the pressure in the spring chamber of the unloading valve @ .
• Raise the pressure at P-port to the required level, and closes the unloading valve.
@ Unloading valve
• Unloads excessive flow in the flow priority valve CD .
<ID Pressure reducing valve
• Regulates the primary pressure of the proportional solenoid pressure-reducing valve in the spool section.

Operation
When the joystick is in the neutral position: [Solenoid @ is de-energized.] (Figure 2)
The oil from the P-port is divided by the flow priority valve CD , and the excess flow is supplied to the spool section
from the land @.
The priority flow runs through the check valve @ via the solenoid valve @ to the PF-port.
At this time, the pilot pressure switching valve CID is held at the position shown in the figure, and the oil passage
@ is led to the low pressure passage @. Then the unloading valve @ opens, and the excess flow runs to the
unloading valve @ and the neutral passages of the spool section in parallel to return to the tank.

ToPS -

,
" '
'... _----------,

Figure 2

-37-
 FEATURES
When the joystick is operated: [The solenoid @ is energized.] (Figure 3)
When the joystick signal is input to the solenoid valve @ , the poppet of the solenoid valve @ is seated, and the
priority flow in the oil passage @ is cut off.
The priority flow runs through the orifice @ of the pilot pressure switching valve @ , pushes and opens the spool
@, and then runs to the PF-port.
At this time, the pilot pressure switching valve @ is moved to the left with the piston @ overcoming the spring
force, and the oil passage @ and the low pressure passage @ are shut off. Then the unloading valve @ is
closed.
When the solenoid valve @ operates, the P-port pressure increases to the pressure indicated below.'
P-port pressure = Steering (PS) circuit pressure + Piston @ back pressure + Orifice @ pressure difference +
Flow priority valve CD control pressure
When the P-port pressure increases to the given pressure, the pressure-reducing valve @) operates, and the
primary pressure supply to the proportional solenoid pressure-reducing valve in the spool section is regulated.

To ps_

~"",-----------,"/

Figure 3
Unload mechanism in an emergency
The unloading valve @ is constructed to be operated by switching the solenoid valve @ . When the joystick is
in the neutral position, the unload function operates.
Therefore even if the spool in the spool section is stuck and the neutral passage is shut off, the unload function
operates to prevent the increase of the P-port pressure when the joystick is returned to the neutral position.
Because the unloading valve @ unloads the excess flow circuit only (operating machine main circuit) in the flow
priority valve CD , the priority flow is secured in the steering circuit.

-38-
 FEATURES
LIFT SECTION
Structure and component name

Parallel feeder (high pressure passage)

Cap

Cap

~SOL.b

I
Proportion solenoid valve Proportion electric decompressor valve

Neutral passage
Secondary pressure oil passage
Low pressure passage

First pressure passage

Figure 4

-39-
 FEATURES
Operation (Lift)
When the joystick is in the neutral position: When the lift is in the neutral position (Figure 5)
(With the solenoid unloading valve de-energized)
Because no joystick signal is given to the proportional solenoid, the pressure inside the cap is led to the drain
circuit by the proportional solenoid pressure-reducing valve. The spool is held at the position shown in the figure
by the spring, and the cylinder port "A" is closed.
The excess flow divided by the flow priority valve in the inlet section runs through the neutral passage to the
tank.

Cylinder port "A"

Figure 5

-40-
 FEATURES
When the joystick is operated [SOL.a is energized.]: The lift moves up. (Figure 6)
(With the solenoid unloading valve energized)
When the proportional solenoid pressure-reducing valve on the SOL.a is energized, pilot pressure is generated
in the cap CD , overcoming the spring force in the cap @ , and this gives a rightward stroke to the spool.
The spool shuts off the flow in the neutral passage, and the oil pushes up the load check valve from the parallel
feeder to run to the cylinder port "A".

Cylinder port "A"

Load check valve

SOL. a

Figure 6

-41-
 FEATURES
When the joystick is operated [SOL.b is energized.]: The lift moves down. (Figure 7)
(With the solenoid unloading valve energized)
When the proportional solenoid pressure-reducing valve on the SOL.b is energized, the pilot pressure is
generated in the cap @ • overcoming the spring force in the cap <D , and this gives a leftward stroke to the spool.
At this time, the pilot pressure activates the lift lock valve in the spool (overcoming the spring force) moves to
the left, and then opens the pilot oil passage of the load check valve.
Because the pilot oil passage is opened to the low-pressure passage, the load check valve is lifted by the
pressure difference between the front and the rear of the orifices @ and @ . The oil in the cylinder port "A" runs
through the low pressure passage to the tank.
On the other hand, because the spool does not shut off the flow of the neutral passage even when a full stroke
is given, the excess flow runs directly to the tank.

Cylinder port "A"

Figure 7

-42-
 FEATURES
Lift locking mechanism in emergency (Figure 8)
If the spool is stuck when the proportional solenoid pressure-reducing valve on the SOL.b side is energized
(when the lift is lowered,) returning the joystick to neutral position depressurizes the pilot pressure in cap @ .
Following this, the spring force moves the lift lock valve to the position shown in the figure to shut off the pilot
oil passage.
Therefore, the pressure before and after the orifices @ and @ become equal, and the spring seats the load
check valve by moving it back, causing the cylinder to be locked.

Cylinder port "A"

Figure 8

-43-
 FEATURES
MANUAL LOWERING
When the fork stops at the lifted position and cannot be lowered by the joystick, perform the following procedure
to lower the fork.
1. Stop the engine, and remove the key.
2. Turn the lock nut CD counterclockwise on the upper area of the lift section of the proportional solenoid control
valve using a hexagon spanner 13 mm (0.51 in), and loosen the lock nut.
3. Turn the bolt @ counterclockwise slowly using a hexagon spanner 13 mm (0.51 in). When the bolt is
loosened, the mast is lowered.
4. When the fork is lowered to the desired height, loosen the bolt @ and fix it with the lock nut CD .
CAUTION:
• When the engine is running and the valve is pressurized by the pump, do not lower the fork
manually.
• When loosening the bolt @ , be sure to secure safety in the working area, turning the bolt slowly.
Sudden loosening may cause an abrupt lowering of the fork.
• When the fork is lowered once, it cannot be lifted unless the joystick is used. Be careful not to move
the fork to a position lower than desired.

Lift section

-44-
 FEATURES
Lowering lift by manual operation (Figure 9)
If the proportional solenoid pressure-reducing valve on the SOL.b side malfunctions and the lift cannot be
lowered, open the shut-off valve to form the pilot oil passage. Then, the load check valve can be opened or
closed.

Cylinder port "P\'

Figure 9

-45-
 FEATURES
TILT SECTION
Structure and component name (Figure 10)

Load check valve

Cylinder port "A" Cylinder port "S"

Parallelleeder (high pressure passage)

Cap G)

Low pressure
passage

SOL.a Neutral passage SOL.b

Figure 10

-46-
 FEATURES
Operation
When the joystick is in neutral position (Figure 11)
(With the solenoid valve for unload de-energized)
As no signals are sent to the proportional solenoids from the joystick, the proportional solenoid pressure-
reducing valve leads the pressure inside the cap to the drain passage. The spool is held by the spring at the
position shown in the figure, with cylinder ports A and B closed.
The excessive amount of oil, diverted by the flow priority valve in the inlet section, flows through the neutral
passage to the tank.
Note that because pressure is not transmitted to the damper chamber, the tilt lock valve is pushed to the right
by the spring.

Cylinder port "A" Cylinder port "8"

Figure 11

-47-
 FEATURES
When operating the joystick (SOL.a energized) (Figure 12)
(With solenoid valve for unload energized)
When the proportional solenoid pressure-reducing valve on the SOL.a side is energized, the pilot pressure is
generated in cap CD . The pilot pressure overcomes the force of the spring in cap @ to stroke and push the spool
to the right.
The spool blocks the flow of the neutral passage, and the oil, pushing up the load check valve from the parallel
feeder, flows from cylinder port "A" to the rod side of the tilt cylinder.
The oil on the bottom side flows from cylinder port liB" into the low pressure passage.
Note that because pressure is not transmitted to the damper chamber, the tilt lock valve is pushed to the right
by the spring.

Cylinder port "A" Cylinder port "8"

Figure 12

-48-
 FEATURES
When operating the joystick (SOL.b energized) (Figure 13)
(With solenoid valve for unload energized)
When the proportional solenoid pressure-reducing valve on the SOL.b side is energized, the pilot pressure is
generated in cap @ . The pilot pressure overcomes the force of the spring in cap <D to stroke and push the spool
to the left.
The spool blocks the flow of the neutral passage, and the oil, pushing up the load check valve from the parallel
feeder, flows from cylinder port liB" to the bottom side of the tilt cylinder.
At this time, as the pressure is transmitted from the high pressure passage to the damper chamber and
overcomes the force of the spring, the tilt lock valve is moved to the left. Then, the oil passage to the low
pressure passage is opened, and the oil on the rod side of the rod flows from cylinder port "A" to the low
pressure passage.

Cylinder port "A" Cylinder port "8"

Figure 13

-49-
 FEATURES
Tilt lock mechanism in emergency (Figure 14)
If the spool is stuck when the proportional solenoid pressure-reducing valve on the SOL.b side is energized
(when the tilt is inclined forward), returning the joystick to neutral position opens the unloading valve at the inlet
section. This causes the pilot pressure in the damper chamber to decrease to the level of the unloading
pressure. Then, the spring force moves the tilt lock valve to the position shown in the figure to close the passage
to the low pressure passage.
As the neutral passage is blocked, the excessive amount of oil flows to the low pressure passage from the
unloading valve at the inlet section.
When the engine runs at the rate of 1,000 rpm or over, the tilt lock mechanism will not work because the
unload pressure is higher than the spring force of the tilt lock valve.
In an emergency case, lower the engine speed to the level of idling.

Figure 14

-50-