Foreword

This manual includes explanations of the vehicle system, and

instructions for disassembly and assembly for Bobcat forklift models
B15/18/20T-7, B18/20TL-7, B15/18/20T-7 PLUS and B16/18/20X-7,
B16/18/20X-7 PLUS.

This manual has been developed for the purpose of helping the reader
understand and repair vehicles correctly. Bobcat do not take
responsibility for hazardous situations that may arise due to the
reader’s neglect to pay attention to the explanations and instructions in
this manual.

Bobcat reserve the right to change the content of this manual according
to the inclusion of updated components, new components, or
alterations made to the system. It is the responsibility of the service
man or mechanic to keep up to date with the most relevant information
for his lift truck, which is available from Bobcat dealers.

July 2023
Bobcat Company

* This document is the informational asset of Bobcat Company. Thus,

unauthorized access, revision, distribution and copying of this document are
strictly prohibited.
 DSB4449E00
B15/18/20T-7, B18/20TL-7, B15/18/20T-7 PLUS
B16/18/20X-7, B16/18/20X-7 PLUS
SERVICE MANUAL

CONTENTS
GENERAL l 1
ELECTRICAL SYSTEM l 2
DRIVE/BRAKE SYSTEM l 3
HYDRAULIC SYSTEM l 4
LIFT/TILT/AUX SYSTEM l 5
STEERING SYSTEM l 6
FRAME l 7
FINGERTIP OPTION l 8
ELECTRICAL SYSTEM(F-series) l 9
SCHEMATICS l 10
1 General

1-1 How to use this manual ...............................2

1-1-1 Construction of this manual .................................. 2
1-1-2 Warning label definition ........................................ 4

1-2 Glossary ........................................................5

1-3 Exterior and specifications..........................9

1-3-1
1-3-2
B15/18/20T-7 and B18/20TL-7 ............................. 9
B15/18/20T-7 PLUS ............................................15
1
1-3-3 B16/18/20X-7......................................................20

General
1-3-4 B16/18/20X-7 PLUS............................................24

1-4 Safety precautions .....................................27

1-5 Maintenance ................................................34

1-6 Lubricants ...................................................39

1-6-1 Recommended viscosities and capacities ...........39
1-6-2 Lubricant specifications .......................................40
1-6-3 Greasing points...................................................42

1-7 Disassembly/assembly instructions ........46

1-8 Standard torques ........................................55

1-8-1 Standard torques for bolts and nuts.....................55
1-8-2 Standard torques for tightening fittings ................57
1-1 How to use this manual

1-1-1 Construction of this manual

This Service Manual provides the information service
engineers and mechanics require for vehicle
maintenance and repair; it does not contain instructions
for vehicle operation.

The introductory section of this manual provides an

overview of the vehicle’s features, particularly focusing its
different components. The individual sections, which you
will find in the main body of the manual, provide more
specific details, including schematic diagrams of the
vehicle’s components, how they work, what to check,
service procedures, and data and information required for
repair and maintenance along with descriptions to aid the
reader.

To help the reader find the information they need for

service and training quickly and easily, the chapters are
classified according to the different systems that the
vehicle is comprised of (see the table below).

Section Title
1 General
2 Electrical system
3 Drive/Brake system
4 Hydraulic system
5 Lift/Tilt/Auxiliary systems
6 Steering system
7 Frame
8 Fingertip option
9 Schematics

To help you identify what information each page contains,

the current chapter title is shown at the middle right of
each odd numbered page and the subsection’s title and
the model name of the vehicle at the bottom of each
page.

How to use this manual 1-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
A typical example how each page is configured:

Part’s image

General
Chapter title

Work procedure

Applicable models Section title

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-3 How to use this manual
 1-1-2 Warning label definition
This manual uses the following three types of warning
labels: “DANGER,” “WARNING,” and “CAUTION.

Each label is designed to indicate to the reader the

severity of a potential hazard, its nature, its consequence,
and a precaution for preventing it. You will find these
labels throughout the manual. Ensure that you pay
careful attention to them as they have been included for
your safety.

DANGER
The label Danger indicates a hazardous
situation that will lead to death or severe
injury if not prevented.

WARNING
The label Warning indicates a
hazardous situation that may lead to
death or severe injury if not prevented.

CAUTION
The label Caution indicates a
hazardous situation that may lead to
minor injury if not prevented.

How to use this manual 1-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
1-2 Glossary
The following are terms used in this service manual and their descriptions.

Terms Descriptions
A device that converts mechanical movement into an analog voltage
Accelerator
pattern and sends it to the controller to control the vehicle’s drive speed
A device that converts hydraulic power into mechanical force and motion
Actuator
(e.g. hydraulic cylinders and motors)
The unit of measurement for current flow. The amount of current that one
Ampere (amp)
volt can push through a resistance of one ohm.
Anti-cavitation
A valve that helps prevent the effects of cavitation—metal erosion caused
valve

1
Battery Two or more cells connected together to supply an electric current.
(Battery Discharge Indicator) An electrically controlled display which
BDI
shows the operator the battery’s current charge level.
Bus bar A heavy electrical conductor to which other smaller wires are connected.

General
The CAN (Controller Area Network) is a standard for communication
CAN
between micro-controllers and/or devices.
Capacitor A device used to store electrical energy for short periods of time.
Carriage A support structure to which the forks are mounted
A valve that controls the charging of a hydraulic accumulator within an
Charging valve
adjustable switching range
Check valve A valve that allows oil to flow in one direction and not another
A path along which a current can travel from the positive (+) side to the
Circuit negative (-) side of an electrical power source. This can be through wires
and electrical components.
A component made from many circles or turns of wire that is used to
Coil
concentrate a magnetic field.
A part of a wire assembly or harness that connects with another wire
Connector assembly or harness that makes the task of disassembly and assembly
easier.
Contact tips or The portion of a switch, relay or contactor where the circuit can be opened
contacts or closed.
An electrical component consisting of an electromagnetic coil and a set of
Contactor
heavy contact tips. A control current passes through the coil, building a
assembly
magnetic field that closes or opens the contact tips.
An electromagnet used to open or close contact tips in a contactor
Contactor coil
assembly.
A valve unit comprised of several directional valve blocks, each with a
Control valve
corresponding actuator(s)
The main printed circuit board containing a microprocessor and circuits to
Controller condition the voltage signals that go into or come out of the logics. Its
function is to electronically monitor and controls the truck's functions.
A weight installed at the back of the forklift to ensure it is properly stable at
Counter weight
all times, especially when lifted heavy loads
The movement or flow of electricity through a conductor. A circuit must be
Current
complete for a current to flow.
The maximum allowable armature current of a stalled drive motor during
Current limit
pulsing.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-5 Glossary

 Terms Descriptions
A container that keeps pressurized oil and converts hydraulic power into
Cylinder
linear motion
DC-DC converter A device which converts DC battery voltage to DC 12 V.
A signal in which the elements may be either of two distinct values, for
Digital signal
example, high voltage and low voltage.
A semiconductor device that allows current to flow in one direction—from
Diode
the anode to the cathode.
A valve that determines the direction of oil flow based on the position of its
Directional valve
spool.
Display An electrical device that converts voltage inputs to a visual output.
Drift Motion of a cylinder or motor caused by a leakage in the hydraulic circuit.

Drive axle An axle that receives power from the drive motor

A control device for a drive motor, which is comprised of an inverter and

Drive controller
logic circuit.
(Electrically Assisted Braking) By using some electric signal from such as
EAB directional switch or service brake pedal, traction controller commands the
drive motor to rotate oppositely, to the direction of truck movement.
A service tool program designed for the calibration and diagnostics of
EasyView
trucks used by the CURTIS Controllers.
(Electric Foot Brake) The EFB is a type of service brake system replacing
mechanical brake system with master cylinder. By detecting the stroke of
EFB service brake pedal, traction controller manages electrically the direction
and power of drive motor so to decrease the travelling speed, by using the
logic of EAB.
A pair of brakes that are electromagnetically activated against their
EM parking brake
respective motors when the vehicle is stationary
A device which detects the direction and rotation speed of the motor to
Encoder
generate pulse signals.
Extension module A device used to extend the controller’s ports.
Fan A device that generates air flow to cool the motor and controller.
A mechanical device used to house a filter element, a straining device
Filter
used to prevent contaminants flowing through a system
A valve that blocks the control valve’ withdrawal of hydraulic oil from the
Flow protector lift cylinders when the hydraulic lines are unexpectedly broken. This
prevents a sudden drop of the mast.
A valve that reduces pressure by reducing the amount of flow travelling
Flow regulator
through a hydraulic line
Fork Two prong-shaped objects
Splined to the helical gear, friction discs stop the motion of the drive axle
Friction discs
when compressed by the steel plates
A component in an electrical circuit that opens the circuit if too much
Fuse
current it travelling through a given section of it.
Harness An assembly made of two or more wires that are held together.
Heat sink A mounting frame used for cooling the semiconductors.
Height option
A controller for measuring the height of the fork.
module
Hydraulic system A circuit of hydraulic components that transport oil pressure
Hydraulic tank A chamber that stores oil for the hydraulic system
Indicator A symbol that indicates the vehicle’s condition when it turns on or flashes.
Lift lock solenoid A valve that disables the lift lever when the operator leaves the seat.
Glossary 1-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Terms Descriptions
A large bracket mounted to the top of the carriage to protect the operator
Load backrest
when carrying large loads.
Main hydraulic A gear pump that, using mechanical power from a motor, pressurizes oil
pump stored in the tank to distribute it to a number of actuators.
A vertical structure at the front of the forklift that extends and retracts to lift
Mast
and lower a load.
Master cylinder A hydraulic cylinder responsible for actuating the service brake
A type of service brake system equipped with master cylinder. Operator’s
Mechanical
force and stroke to push the service brake pedal generates some
service brake
hydraulic force so that the device of service brake can work for decreasing
system
the travelling speed, eventually stopping the driving.
A semiconductor component used in electric forklift models as an
electronic switch. A MOSFET most often has three terminals, a GATE (G),
MOSFET a DRAIN (D), and a SOURCE (S). A MOSFET is a voltage-controlled
device and only requires a small input current. The switching speed is
very high. 1
A valve used to manually lower the mast when the lift lever is not
Needle valve
available.

General
A term used with a switch or relay. Their “normal condition” is when they
Normal condition are not controlled by the application of force, temperature, pressure, or
electricity.
The unit of resistance. The amount of resistance that will let one volt push
Ohm(Ω)
only one ampere of current through it.
On-time The amount of time it takes for a current to flow through a transistor.
Open circuit The wiring or components of a circuit that have no continuity.
A restricted passage in a hydraulic circuit included for the purpose of
Orifice limiting flow or creating pressure in a given chamber (e.g. a small drilled
hole)
Overhead guard An overhead frame structure that protects the operator from falling objects
The presence of a voltage or current which is greater than a given
Overload
electrical circuit or component’s capacity.
An oil pressure to shift a spool in a hydraulic device. Lower than regular
Pilot pressure
pump oil pressure, it is used as a command signal.
Piston A part that pushes the oil in a cylinder chamber
A portion of electrical braking where the generated current is directed
Plugging
back through the armature.
Port An input or output point on a hydraulic component
A connecting socket installed on a truck to supply 12 V power to external
Power socket
devices.
Pressure A force of fluid per unit area
A sensor able to detect the presence of nearby objects without any
Proximity sensor
physical contact.
A control device for the hydraulic motor, comprised of an inverter and
Pump controller
logic circuit.
An electrical component consisting of an electromagnetic coil and a set of
small contact tips. A control current passes through the coil, building a
Relay magnetic field which either closes or opens the contact tips. When the
contact tips are closed, a low current can flow in a separate isolated
circuit.
Relief valve A valve that limits hydraulic system pressure by releasing excess oil
Resistor A component made of a material with a specific resistance to current flow.
Return filter A filter that collects contaminants from oil returning to the hydraulic tank

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-7 Glossary

 Terms Descriptions
Rotor The part that rotates the motor.
A line drawing of an electrical or electronic assembly which uses symbols
Schematic to show how individual components, wires and connectors function
electrically.
Serial port A port for one-to-one communication with controller.
A pair of brakes each of which is built in a drive axle to hold the vehicle
Service brake
stationary when the operator applies the pedal
Short circuit An unwanted electrical connection between two or more components.
Sideshifter An attachment that moves forks and the loads on them to the left and right
The female contact of a connector that slips over a male contact (pin) of
Socket
another connector.
A directional valve whose spool shifts position when its solenoid coil is
Solenoid valve
electromagnetically charged.
A term that refers to semiconductor components, or circuits that use them,
Solid state
that have no moving parts, such as diodes and transistors.
Stator A fixed part in a motor
Steel plates activate the service brake function by compressing friction
Steel plate
discs at either side
Steer axle An axle to which the rear wheels of a vehicle are mounted
A column that connects the steering wheel to the steering unit, allowing
Steering column
the operator to control the unit by using the steering wheel
A circuit of hydraulic components comprised of a steering unit, lines and
Steering system
actuators
A hydraulic component which sends oil to the right or left side of steering
Steering unit
cylinder depending on the demands of the operator
Switch (SW) A component used to control an electric circuit by opening or closing it.
The electrical components, circuits, and connections that deliver power to
Systems
perform specific tasks.
Terminal An electrical connection point on an electrical component.
Thermal sensor A sensor that activates at a set temperature.
A valve that opens only when an external pressure reaches the set value
Unloading valve
of its precision spring
USB A connecting device that supplies 5 V power.
A part that controls the pressure, direction, or rate of flow within a
Valve
hydraulic system
The unit of measurement for electromotive force. One volt is the force
Voltage needed to make one ampere of current flow through one ohm of
resistance in a circuit.
The unit of measurement for power. The amount of power used when one
Watt volt pushes one ampere of current through a resistance of one ohm. The
result of amperes (current) multiplied by volts (voltage) is watts (power).
A conductor used to provide a path for a current to flow to and from
Wire
different electrical components.
A drawing that visual represents components the way they actually look. It
Wiring diagram is used to show the locations of components and the connections
between them.
A special diode used to regulate voltage or protect the system from over-
Zener diode
voltage.

Glossary 1-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

1-3 Exterior and specifications

1-3-1 B15/18/20T-7 and B18/20TL-7

Head lamp Overhead guard

Mast

Steering wheel

Lift cylinder

General
Battery
Forks Tilt cylinder

Drive wheel

Backup lamp

Load backrest

Instrument panel

Hydraulic levers

Control valve

Steer wheel 0800E

Fig. 1-1

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-9 Exterior and specifications
 36 V models
1 Manufacturer Bobcat
CHARACTERISTICS

2 Model B15T-7
3 Load Capacity at rated load center Q lb(kg) 3,000 (1,500)
4 Load center c in(mm) 24 (500)
5 Power type AC Electric
6 Operator type Driver Seated
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion E, C
8 Wheels (x=Driven) Number of front / rear x2/2
9 Max.Fork Height with STD 2-stage mast in(mm) 130 (3300)
10 Free Lift in(mm) 5.1 (130)
12 Fork carriage ISO Class CLASS Ⅱ
Thickness x Width x Length in(mm) 1.4x3.9x41.3 (35x100x1,050)
13 Fork
Fork Spacing (Min. x Max.) in(mm) 9.5x35.6 (240x905)
14 Tilt of Mast Forward / Backward deg 5/7
15 Length to Fork Face in(mm) 74.4 (1,891)
DIMENSIONS

16 Overall Width in(mm) 42.9 (1,090)

17 Mast Lowered Height in(mm) 78.7 (2,000)
Overall Dimensions
18 Mast Extended Height in(mm) 159.3 (4,045)
19 Overhead Guard Height in(mm) 79 (2,010)
20 Seat Height in(mm) 36.2 (919)
Outer Turning Radius in(mm) 59.6 (1,515)
21
Inner Turning Radius in(mm) 0
22 Load Moment Center Center of drive axle to fork face in(mm) 14.8 (376)
Right Angle Stacking Aisle Width Pallet 40in × 48in crossways in(mm) 126.6 (3,216)
23
(With Pallets & Clearance) Pallet 32in × 48in lengthways in(mm) 131.5 (3341)
24 Speed Travel Loaded / Unloaded mph(km/h) 8.7/8.7 (14.0/14.0)
PERFORMANCE

25 Lifting Loaded / Unloaded fpm(mm/s) 61/108 (310/550)

26 Lowering Loaded / Unloaded fpm(mm/s) 98/89 (500/450)
28 Max. Drawbar pull Loaded at 1.6km/h lb(kg) 2,734 (1,240)
30 Max. Gradeability Loaded at 1.6km/h % 24
32 Total weight with min. weight of battery lb(kg) 6,821 (3,094)
WEIGHT

33 Loaded , Front / Rear lb(kg) 8,858 / 1,269 (4,018 / 576)

Axle Load
34 Unloaded , Front / Rear lb(kg) 3,362 / 3,459 (1,525 / 1,569)
35 Number of Wheels (Front / Rear) 2/2
36 Tires Front 18x7x12.12
Size
37 Rear 15x6x11.25
38 Wheel Base Distance in(mm) 52 (1323)
CHASSIS

Front in(mm) 35.5 (902)

39 Tread Width
Rear in(mm) 7.8 (198)
40 at lowest in(mm) 3.4 (86)
Ground clearance Loaded
41 at center of wheel base in(mm) 3.9 (100)
42 Brakes Service Hydraulic (old) / Electric (new)
43 Parking Auto-Electric
Type Lead-acid
Voltage V 36
BS type AH 660
Capacity Normal
DIN type AH -
(5 Hours
45 Battery Rating) BS type AH 770
Max.
POWER TRAIN

DIN type AH -
Battery compartment sizes Normal / BS type in(mm) 20.8x39.1x27.5 (528x992x698)
(W x L x H) DIN type in(mm) -
Min. Weight lb(kgf) 1,543 (700)
47 Drive motor rating at S2 60 minute hp (kW) 8.0 (6.0) x 2
Electric Motors
48 Lifting motor rating at S3 15% hp (kW) 18.8 (14.0)
54 Control Type Drive and Hydraulic Type MOSFET Inverter
55 Drive Axle Brake Type Type ODB (old) / - (new)
System psi (kPa) 2,550 (17,600)
57 Relief Pressure
Attachment psi (kPa) 2,040 (14,000)

Exterior and specifications 1-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Bobcat Bobcat 1
B18T-7 B20T-7 2
3,500 (1,750) 4,000 (2,000) 3
24 (500) 24 (500) 4
AC Electric AC Electric 5
Driver Seated Driver Seated 6
E, C E, C 7
x2/2 x2/2 8
130 (3,300) 130 (3,300) 9
5.1 (130) 5.3 (135) 10
CLASS Ⅱ CLASS Ⅱ 12
1.4x3.9x41.3 (35x100x1,050) 1.6x3.9x41.3 (40x100x1,050)
13
9.5x35.6 (240x905) 9.5x35.6 (240x905)
5/7 5/7 14
78.4 (1,991) 79.9 (2,029) 15
42.9 (1,090)
78.7 (2,000)
159.3 (4,045)
42.9 (1,090)
78.7 (2,000)
159.4 (4,050)
16
17
18
1
79 (2,010) 79 (2,010) 19

General
36.2 (919) 36.2 (919) 20
63.6 (1,615) 64.9 (1,648)
21
0 0
14.8 (376) 15.0 (381) 22
130.5 (3,316) 132 (3,354)
23
135.5 (3,441) 137 (3,479)
8.7/8.7 (14.0/14.0) 8.7/8.7 (14.0/14.0) 24
61/108 (310/550) 61/108 (310/550) 25
98/89 (500/450) 98/89 (500/450) 26
2,734 (1,240) 2,734 (1,240) 28
23 22 30
7,072 (3,208) 7,910 (3,588) 32
9,673 / 1,256 (4,388 / 570) 10,785 / 1,534 (4,892 / 696) 33
3,439 / 3,633 (1,560 / 1,648) 3,688 / 4,221 (1,673 / 1,915) 34
2/2 2/2 35
18x7x12.12 18x7x12.12 36
15x6x11.25 15x6x11.25 37
56 (1,423) 57 (1,446) 38
35.5 (902) 35.5 (902)
39
7.8 (198) 7.8 (198)
3.4 (86) 3.4 (86) 40
3.9 (100) 3.9 (100) 41
Hydraulic (old) / Electric (new) Hydraulic (old) / Electric (new) 42
Auto-Electric Auto-Electric 43
Lead-acid Lead-acid
36 36
825 825
- -
970 970 45
- -
25.1x39.1x27.5 (638x992x698) 25.1x39.1x27.5 (638x992x698)
- -
1,764 (800) 2,315 (1,050)
8.0 (6.0) x 2 8.0 (6.0) x 2 47
18.8 (14.0) 18.8 (14.0) 48
MOSFET Inverter MOSFET Inverter 54
ODB (old) / - (new) ODB (old) / - (new) 55
2,880 (19,860) 3,125 (21,550)
57
2,040 (14,000) 2,040 (14,000)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-11 Exterior and specifications
 48 V models
1 Manufacturer Bobcat
CHARACTERISTICS

2 Model B15T-7
3 Load Capacity at rated load center lb(kg) 3,000 (1,500)
4 Load center in(mm) 24 (500)
5 Power type AC Electric
6 Operator type Driver Seated
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion E, C
8 Wheels (x=Driven) Number of front / rear x2/2
9 Max. Fork Height with STD 2-stage mast in(mm) 130 (3,300)
10 Free Lift in(mm) 5.1 (130)
12 Fork carriage ISO Class CLASS Ⅱ
Thickness x Width x Length in(mm) 1.4x3.9x35.4 (35 x 100 x 900)
13 Fork
Fork Spacing (Min. x Max.) in(mm) 9.5x35.6 (240x905)
14 Tilt of Mast Forward / Backward deg 5/7
15 Length to Fork Face in(mm) 74.4 (1,891)
DIMENSIONS

16 Overall Width in(mm) 42.9 (1,090)

17 Mast Lowered Height in(mm) 84.6 (2,150)
Overall Dimensions
18 Mast Extended Height in(mm) 171.1 (4,345)
19 Overhead Guard Height in(mm) 79 (2,010)
20 Seat Height in(mm) 36.2 (919)
Outer Turning Radius in(mm) 59.6 (1515)
21
Inner Turning Radius in(mm) 0
22 Load Moment Center Center of drive axle to fork face in(mm) 14.8 (376)
Right Angle Stacking Aisle Width Pallet 1000 x 1200 crossways in(mm) 126.6 (3,216)
23
(With Pallets & Clearance) Pallet 800 x 1200 lengthways in(mm) 131.5 (3,341)
24 Speed Travel Loaded / Unloaded mph(km/h) 10.6 / 10.6 (17 / 17)
PERFORMANCE

25 Lifting Loaded / Unloaded fpm(mm/s) 79 / 118 (400 / 600)

26 Lowering Loaded / Unloaded fpm(mm/s) 98 / 89 (500 / 450)
28 Max. Drawbar pull Loaded at 1.6km/h lb(kg) 2,866 (1,300)
30 Max. Gradeability Loaded at 1.6km/h % 26
32 Total weight with min. weight of battery lb(kg) 6,676 (3,028)
WEIGHT

33 Axle Load Loaded , Front / Rear lb(kg) 8,792 / 1,190 (3,988 / 540)
34 Unloaded , Front / Rear lb(kg) 3,296 / 3,380 (1,495 / 1,533)
35 Number of Wheels (Front / Rear) 2/2
36 Tires Front 18x7-81)
Size
37 Rear 15x4.5-82)
38 Wheel Base Distance in(mm) 52 (1,323)
CHASSIS

39 Tread Width Front in(mm) 35.5 (902)

Rear in(mm) 6.6 (167)
40 at lowest in(mm) 3.4 (86)
Ground clearance Loaded
41 at center of wheel base in(mm) 3.9 (100)
42 Brakes Service Hydraulic (old) / Electric (new)
43 Parking Auto-Electric
Type Lead-acid
Voltage V 48
BS type AH 440
Capacity Normal
DIN type AH 460
(5 Hours
Rating) BS type AH 575
45 Battery Max.
POWER TRAIN

DIN type AH 500

Normal in(mm) 20.8x39.1x27.5 (528x992x698)
Battery compartment sizes
BS type in(mm) 20.8x39.1x27.5 (528x992x698)
(W x L x H)
DIN type in(mm) 20.8x33.1x27.5 (528x842x698)
Min. Weight lb(kgf) 1,543 (700)
47 Drive motor rating at S2 60 minute hp (kW) 8.0 (6.0) x 2
Electric Motors
48 Lifting motor rating at S3 15% hp (kW) 18.8 (14.0)
54 Control Type Drive and Hydraulic Type MOSFET Inverter
55 Drive Axle Brake Type Type ODB (old) / - (new)
57 Relief Pressure System psi (kPa) 2,550 (17,600)

Exterior and specifications 1-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Attachment psi (kPa) 2,040 (14,000)

Bobcat Bobcat Bobcat Bobcat 1

B18T-7 B18TL-7 B20T-7 B20TL-7 2
3,500 (1,750) 3,500 (1,750) 4,000 (2,000) 4,000 (2,000) 3
24 (500) 24 (500) 24 (500) 24 (500) 4
AC Electric AC Electric AC Electric AC Electric 5
Driver Seated Driver Seated Driver Seated Driver Seated 6
E, C E, C E, C E, C 7
x2/2 x2/2 x2/2 x2/2 8
130 (3,300) 130 (3,300) 130 (3,300) 130 (3,300) 9
5.1 (130) 5.1 (130) 5.3 (135) 5.3 (135) 10
CLASS Ⅱ CLASS Ⅱ CLASS Ⅱ CLASS Ⅱ 12
1.4 x3.9x35.4 (35x100x900) 1.4 x3.9x35.4 (35x100x900) 1.6x3.9x35.4 (40x100x900) 1.6x3.9x35.4 (40x100x900)
13
9.5x35.6 (240x905) 9.5x35.6 (240x905) 9.5x35.6 (240x905) 9.5x35.6 (240x905)
5/7 5/7 5/7 5/7 14
78.4 (1,991) 83.9 (2,132) 79.9 (2,029) 84.1 (2,137) 15
42.9 (1,090)
84.6 (2,150)
171.1 (4,345)
42.9 (1,090)
84.6 (2,150)
171.1 (4,345)
44.1 (1,119)
84.6 (2,150)
171.3 (4,350)
44.1 (1,119)
84.6 (2,150)
171.3 (4,350)
16
17
18
1
79 (2,010) 79 (2,010) 79 (2,010) 79 (2,010) 19

General
36.2 (919) 36.2 (919) 36.2 (919) 36.2 (919) 20
63.6 (1,615) 69.1 (1,756) 64.9 (1,648) 69.1 (1,756)
21
0 0 0 0
14.8 (376) 14.8 (376) 15.0 (381) 15.0 (381) 22
130.5 (3,316) 136.1 (3,457) 132 (3,354) 136.3 (3,462)
23
135.5 (3,441) 141.0 (3,582) 137 (3,479) 141.2 (3,587)
10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 24
79 / 118 (400 / 600) 79 / 118 (400 / 600) 79 / 118 (400 / 600) 79 / 118 (400 / 600) 25
98 / 89 (500 / 450) 98 / 89 (500 / 450) 98 / 89 (500 / 450) 98 / 89 (500 / 450) 26
2,866 (1,300) 2,866 (1,300) 2,866 (1,300) 2,866 (1,300) 28
25 25 24 24 30
6,927 (3,142) 7,348 (3,333) 7,654 (3,472) 7,348 (3,333) 32
9,608 / 1,177 (4,358 / 534) 9,639 / 1,570 (4,372 / 712) 10,673 / 1,391 (4,841 / 631) 10,514 / 1,243 (4,769 / 564) 33
3,373 / 3,554 (1,530 / 1,612) 3,605 / 3,743 (1,635 / 1,698) 3,578 / 4,076 (1,623 / 1,849) 3,605 / 3,743 (1,635 / 1,698) 34
2/2 2/2 2/2 2/2 35
18x7-8 18x7-8 200x50-10 200x50-10 36
15x4.5-8 15x4.5-8 16x6-8 16x6-8 37
56 (1,423) 61 (1,554) 57 (1,446) 61 (1,554) 38
35.5 (902) 35.5 (902) 35.9 (912) 35.9 (912)
39
6.6 (167) 6.6 (167) 7.9 (201) 7.9 (201)
3.4 (86) 3.4 (86) 3.4 (86) 3.4 (86) 40
3.9 (100) 3.9 (100) 3.9 (100) 3.9 (100) 41
Hydraulic (old) / Electric (new) Hydraulic (old) / Electric (new) Hydraulic (old) / Electric (new) Hydraulic (old) / Electric (new) 42
Auto-Electric Auto-Electric Auto-Electric Auto-Electric 43
Lead-acid Lead-acid Lead-acid Lead-acid
48 48 48 48
510 600 585 600
525 690 575 690
690 - 690 -
45
625 750 625 750
25.1x39.1x27.5 (638x992x698) 29.4x39.1x27.5 (746x992x698) 25.1x39.1x27.5 (638x992x698) 29.4x39.1x27.5 (746x992x698)
23.9x39.1x27.5 (608x992x698) - 23.9x39.1x27.5 (608x992x698) -
25.1x33.1x27.5 (638x842x698) 29.4x33.1x27.5 (746x842x698) 25.1x33.1x27.5 (638x842x698) 29.4x33.1x27.5 (746x842x698)
1,764 (800) 2,205 (1,000) 2,205 (1,000) 2,205 (1,000)
8.0 (6.0) x 2 8.0 (6.0) x 2 8.0 (6.0) x 2 8.0 (6.0) x 2 47
18.8 (14.0) 18.8 (14.0) 18.8 (14.0) 18.8 (14.0) 48
MOSFET Inverter MOSFET Inverter MOSFET Inverter MOSFET Inverter 54
ODB (old) / - (new) ODB (old) / - (new) ODB (old) / - (new) ODB (old) / - (new) 55
2,886 (19,900) 2,886 (19,900) 3,133 (21,600) 3,133 (21,600)
57
2,040 (14,000) 2,040 (14,000) 2,040 (14,000) 2,040 (14,000)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-13 Exterior and specifications
 Fig. 1-2

Exterior and specifications 1-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 1-3-2 B15/18/20T-7 PLUS

36V models
1 Manufacturer Bobcat
CHARACTERISTICS

2 Model B15T-7 PLUS

3 Load Capacity at rated load center lb(kg) 3,000 (1,500)
4 Load center in(mm) 24 (500)
5 Power type Electric
6 Operator type Driver Seated
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion E, C
8 Wheels (x=Driven) Number of front / rear x2/2
9 Max.Fork Height with STD 2-stage mast in(mm) 130 (3,300)
10 Free Lift in(mm) 5.1 (130)
12 Fork carriage ISO Class CLASS Ⅱ
Thickness x Width x Length in(mm) 1.4 x 3.9 x 41.3 (35 x 100 x 1,050)
13 Fork

1
Fork Spacing (Min. x Max.) in(mm) 9.5 x 35.6 (240 x 905)
14 Tilt of Mast Forward / Backward deg 5/7
DIMENSIONS

15 Length to Fork Face in(mm) 74.4 (1,891)

16 Overall Width in(mm) 42.9 (1,090)
17 Mast Lowered Height in(mm) 78.7 (2,000)
Overall Dimensions

General
18 Mast Extended Height in(mm) 159.3 (4,045)
19 Overhead Guard Height in(mm) 79 (2,010)
20 Seat Height in(mm) 36.2 (919)
21 Outer Turning Radius in(mm) 59.6 (1,515)
Inner Turning Radius in(mm) 0
22
Load Moment Center Center of drive axle to fork face in(mm) 14.8 (376)
"Right Angle Stacking Aisle Width Pallet 40in × 48in crossways in(mm) 126.6 (3,216)
23
(With Pallets & Clearance)" Pallet 32in × 48in lengthways in(mm) 131.5 (3,341)
WEIGHT PERFORMANCE

24 Travel Loaded / Unloaded mph(km/h) 8.7/8.7 (14.0/14.0)

25 Speed Lifting Loaded / Unloaded fpm(mm/s) 61/108 (310/550)
26 Lowering Loaded / Unloaded fpm(mm/s) 98/89 (500/450)
28 Max. Drawbar pull Loaded at 1.6km/h lb(kg) 2,734 (1,240)
30 Max. Gradeability Loaded at 1.6km/h % 24
32 Total weight with min. weight of battery lb(kg) 6,821 (3,094)
33 Loaded , Front / Rear lb(kg) 8,858 / 1,269 (4,018 / 576)
Axle Load
34 Unloaded , Front / Rear lb(kg) 3,362 / 3,459 (1,525 / 1,569)
35 Number of Wheels (Front / Rear) 2/2
36 Tires Front 18x7x12.121)
Size
37 Rear 15x6x11.252)
38 Wheel Base Distance in(mm) 52 (1,323)
CHASSIS

Front in(mm) 35.5 (902)

39 Tread Width
Rear in(mm) 7.8 (198)
40 in(mm) in(mm) 3.4 (86)
Ground clearance Loaded
41 in(mm) in(mm) 3.9 (100)
42 Service Electric
Brakes
43 Parking Auto-Electric
Type Lead-acid
Voltage V 36
BS type AH 660
Normal
Capacity DIN type AH -
45 Battery (5 Hours Rating) BS type AH 770
Max.
POWER TRAIN

DIN type AH -
Battery compartment sizes Normal / BS type 20.8 x 39.1 x 27.5 (528 x 992 x 698)
(W x L x H) DIN type -
Min. Weight lb(kgf) 1,543 (700)
47 Drive motor rating at S2 60 minute hp (kW) 8.0 (6.0) x 2
Electric Motors
48 Lifting motor rating at S3 15% hp (kW) 18.8 (14.0)
54 Control Type Drive and Hydraulic Type MOSFET Inverter
55 Drive Axle Brake Type Type -
System psi (kPa) 2,550 (17,600)
57 Relief Pressure
Attachment psi (kPa) 2,040 (14,000)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-15 Exterior and specifications
 Bobcat Bobcat 1
B18T-7 PLUS B20T-7 PLUS 2
3,500 (1,750) 4,000 (2,000) 3
24 (500) 24 (500) 4
Electric Electric 5
Driver Seated Driver Seated 6
E, C E, C 7
x2/2 x2/2 8
130 (3,300) 130 (3,300) 9
5.1 (130) 5.3 (135) 10
CLASS Ⅱ CLASS Ⅱ 12
1.4 x 3.9 x 41.3 (35 x 100 x 1,050) 1.6 x 3.9 x 41.3 (40 x 100 x 1,050)
13
9.5 x 35.6 (240 x 905) 9.5 x 35.6 (240 x 905)
5/7 5/7 14
78.4 (1,991) 79.9 (2,029) 15
42.9 (1,090) 42.9 (1,090) 16
78.7 (2,000) 78.7 (2,000) 17
159.3 (4,045) 159.4 (4,050) 18
79 (2010) 79 (2,010) 19
36.2 (919) 36.2 (919) 20
63.6 (1,615) 64.9 (1,648)
21
0 0
14.8 (376) 15.0 (381) 22
130.5 (3,316) 132 (3,354)
135.5 (3,441) 137 (3,479) 23
8.7/8.7 (14.0/14.0) 8.7/8.7 (14.0/14.0) 24
61/108 (310/550) 61/108 (310/550) 25
98/89 (500/450) 98/89 (500/450) 26
2,734 (1,240) 2,734 (1,240) 28
23 22 30
7,072 (3,208) 7,910 (3,588) 32
9,673 / 1,256 (4,388 / 570) 10,785 / 1,534 (4,892 / 696) 33
3,439 / 3,633 (1,560 / 1648) 3,688 / 4,221(1,673 / 1,915) 34
2/2 2/2 35
18x7x12.121) 18x7x12.123) 36
15x6x11.252) 15x6x11.254) 37
56 (1,423) 57 (1,446) 38
35.5 (902) 35.5 (902)
39
7.8 (198) 7.8 (198)
3.4 (86) 3.4 (86) 40
3.9 (100) 3.9 (100) 41
Electric Electric 42
Auto-Electric Auto-Electric 43
Lead-acid Lead-acid
36 36
825 825
- -
970 970 45
- -
25.1 x 39.1 x 27.5 (638 x 992 x 698) 25.1 x 39.1 x 27.5 (638 x 992 x 698)
- -
1,764 (800) 2,315 (1,050)
8.0 (6.0) x 2 8.0 (6.0) x 2 47
18.8 (14.0) 18.8 (14.0) 48
MOSFET Inverter MOSFET Inverter 54
- - 55
2,880 (19,860) 3,125 (21,550)
57
2,040 (14,000) 2,040 (14,000)

1) Optional: Solid Soft Tires: 18 x 7-8

2) Optional: Solid Soft Tires: 15 x 4.5-8

Exterior and specifications 1-16 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 48V models
CHARACTERISTICS 1 Manufacturer Bobcat
2 Model B15T-7 PLUS
3 Load Capacity at rated load center kg 1,500
4 Load center mm 24
5 Power type Electric
6 Operator type Driver Seated
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion E, C
8 Wheels (x=Driven) Number of front / rear x2/2
9 Max.Fork Height with STD 2-stage mast mm 3,300
10 Free Lift mm 130
12 Fork carriage ISO Class CLASS Ⅱ
Thickness x Width x Length mm 35 x 100 x 900
13 Fork
Fork Spacing (Min. x Max.) mm 240 x 905
14 Tilt of Mast Forward / Backward deg 5/7
DIMENSIONS

15 Length to Fork Face mm 1,891

16 Overall Width mm 1,090

1
17 Mast Lowered Height mm 2,150
Overall Dimensions
18 Mast Extended Height mm 4,345
19 Overhead Guard Height mm 2,010
20 Seat Height mm 919
21 Outer Turning Radius mm 1,515

General
Inner Turning Radius mm 0
22
Load Moment Center Center of drive axle to fork face mm 376
"Right Angle Stacking Aisle Width Pallet 40in × 48in crossways mm 3,216
23
(With Pallets & Clearance)" Pallet 32in × 48in lengthways mm 3,341
WEIGHT PERFORMANCE

24 Travel Loaded / Unloaded km/h 17 / 17

25 Speed Lifting Loaded / Unloaded mm/s 400 / 600
26 Lowering Loaded / Unloaded mm/s 500 / 450
28 Max. Drawbar pull Loaded at 1.6km/h kg 1,300
30 Max. Gradeability Loaded at 1.6km/h % 26
32 Total weight with min. weight of battery kg 3,028
33 Loaded , Front / Rear kg 3,988 / 540
Axle Load
34 Unloaded , Front / Rear kg 1,495 / 1,533
35 Number of Wheels (Front / Rear) 2/2
36 Tires Front 18x7-81)
Size
37 Rear 15x4.5-82)
38 Wheel Base Distance mm 1,323
CHASSIS

Front mm 902
39 Tread Width
Rear Mm 198
40 at lowest mm 86
Ground clearance Loaded
41 at center of wheel base mm 100
42 Service Electric
Brakes
43 Parking Auto-Electric
Type Lead-acid
Voltage V 48
BS type AH 440
Normal
Capacity DIN type AH 460
(5 Hours Rating) BS type AH 575
45 Battery Max.
DIN type AH 500
POWER TRAIN

Normal mm 528 x 992 x 698

Battery compartment sizes
BS type mm 528 x 992 x 698
(W x L x H)
DIN type 528 x 992 (842)4) x 698
Min. Weight kg 700
47 Drive motor rating at S2 60 minute kW 6.0 x 2
Electric Motors
48 Lifting motor rating at S3 15% kW 14
54 Control Type Drive and Hydraulic Type MOSFET Inverter
55 Drive Axle Brake Type Type -
System kPa 17,600
57 Relief Pressure
Attachment kPa 14,000

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-17 Exterior and specifications
 Bobcat Bobcat 1
B18T-7 PLUS B20T-7 PLUS 2
1,750 2,000 3
500 500 4
Electric Electric 5
Driver Seated Driver Seated 6
E, C E, C 7
x2/2 x2/2 8
3,300 3,300 9
130 135 10
CLASS Ⅱ CLASS Ⅱ 12
35 x 100 x 900 40 x 100 x 900
13
240 x 905 240 x 905
5/7 5/7 14
1,991 2,029 15
1,090 1,119 16
2,150 2,150 17
4,345 4,350 18
2,010 2,010 19
919 919 20
1,615 1,648 21
0 0
22
376 381
3,316 3,354
23
3,441 3,479
17 / 17 17 / 17 24
400 / 600 400 / 600 25
500 / 450 500 / 450 26
1,300 1,300 28
25 24 30
3,142 3,472 32
4,358 / 534 4,841 / 631 33
1,530 / 1,612 1,623 / 1,849 34
2/2 2/2 35
18x7-8 200x50-10 36
15x4.5-8 16x6-8 37
1,423 1,446 38
902 912
39
167 201
86 86 40
100 100 41
Electric Electric 42
Auto-Electric Auto-Electric 43
Lead-acid Lead-acid
48 48
510 585
525 575
690 690
45
625 625
638 x 992 x 698 638 x 992 x 698
638 (608)3) x 992 x 698 638 (608)3) x 992 x 698
638 x 992 (842)4) x 698 638 x 992 (842)4) x 698
800 1,000
6.0 x 2 6.0 x 2 47
14 14 48
MOSFET Inverter MOSFET Inverter 54
- - 55
19,900 21,600
57
14,000 14,000
1) Optional: cushion Tires_18 x 7 - 12.12
2) Optional: cushion Tires_15 x 6 - 11.25
3) If operator using a BS Type Battery
(608mm length/ 575, 630, 690AH/5h capacity), special accessory (stopper) should be chosen.
4) If operator using a DIN Type Battery (842mm width), Special accessory (bracket) should be chosen.

Exterior and specifications 1-18 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 1

General

Fig. 1-3

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-19 Exterior and specifications
 1-3-3 B16/18/20X-7

Overhead guard

Head lamp

Mast

Steering wheel

Lift cylinder

Battery
Forks
Tilt cylinder

Drive wheel

Backup lamp

Load backrest

Instrument panel

Hydraulic levers

Control valve

Steer wheel

0802E
Fig. 1-4

Exterior and specifications 1-20 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B16/18/20X-7
1 Manufacturer Bobcat
CHARACTERISTICS

2 Model B16X-7
3 Load Capacity at rated load center lb(kg) 3,500 (1,600)
4 Load center in(mm) 24 (500)
5 Power type AC Electric
6 Operator type Driver Seated
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion P, E
8 Wheels (x=Driven) Number of front / rear x2/2
9 Max. Fork Height with STD 2-stage mast in(mm) 130 (3,300)
10 Free Lift in(mm) 5.1 (130)
12 Fork carriage ISO Class CLASS Ⅱ
Thickness x Width x Length in(mm) 1.4x3.9x35.4 (35x100x900)
13 Fork
Fork Spacing (Min. x Max.) in(mm) 9.5x35.6 (240x905)
14 Tilt of Mast Forward / Backward deg 5/7
15 Length to Fork Face in(mm) 83.5 (2,120)
DIMENSIONS

1
16 Overall Width in(mm) 42.9 (1,090)
17 Mast Lowered Height in(mm) 84.6 (2,150)
Overall Dimensions
18 Mast Extended Height in(mm) 171.1 (4,345)
19 Overhead Guard Height in(mm) 79 (2,010)

General
20 Seat Height in(mm) 36.2 (919)
Outer Turning Radius in(mm) 74.3 (1,886)
21
Inner Turning Radius in(mm) 19.4 (494)
22 Load Moment Center Center of drive axle to fork face in(mm) 14.8 (376)
Right Angle Stacking Aisle Width Pallet 1000 x 1200 crossways in(mm) 136.5 (3,466)
23
(With Pallets & Clearance) Pallet 800 x 1200 lengthways in(mm) 144.2 (3,662)
24 Travel Loaded / Unloaded mph(km/h) 10.6 / 10.6 (17 / 17)
PERFORMANCE

25 Speed Lifting Loaded / Unloaded fpm(mm/s) 79 / 118 (400 / 600)

26 Lowering Loaded / Unloaded fpm(mm/s) 98 / 89 (500 / 450)
28 Max. Drawbar pull Loaded at 1.6km/h lb(kg) 2,866 (1,300)
30 Max. Gradeability Loaded at 1.6km/h % 26
32 Total weight with min. weight of battery lb(kg) 7,031 (3,189)
WEIGHT

33 Loaded , Front / Rear lb(kg) 9,337 / 1,219 (4,235 / 553)

Axle Load
34 Unloaded , Front / Rear lb(kg) 3,743 / 3,287 (1,698 / 1,491)
35 Number of Wheels (Front / Rear) 2/2
36 Tires Front 18x7-8
Size
37 Rear 16x6-8
38 Wheel Base Distance in(mm) 59 (1,495)
CHASSIS

Front in(mm) 35.5 (902)

39 Tread Width
Rear in(mm) 35.0 (890)
40 at lowest in(mm) 3.4 (86)
Ground clearance Loaded
41 at center of wheel base in(mm) 3.9 (100)
42 Service Hydraulic (old) / Electric (new)
Brakes
43 Parking Auto-Electric
Type Lead-acid
Voltage V 48
BS type AH 585
Capacity Normal
DIN type AH 575
(5 Hours
Rating) BS type AH 690
45 Battery Max.
DIN type AH 625
POWER TRAIN

Normal in(mm) 25.1x39.1x27.5 (638x992x698)

Battery compartment sizes
BS type in(mm) 23.9x39.1x27.5 (608x992x698)
(W x L x H)
DIN type in(mm) 25.1x33.1x27.5 (638x842x698)
Min. Weight lb(kgf) 2,315 (1,050)
47 Drive motor rating at S2 60 minute hp (kW) 8.0 (6.0) x 2
Electric Motors
48 Lifting motor rating at S3 15% hp (kW) 18.8 (14.0)
54 Control Type Drive and Hydraulic Type MOSFET Inverter
55 Drive Axle Brake Type Type ODB (old) / - (new)
System psi (kPa) 2,886 (19,900)
57 Relief Pressure
Attachment psi (kPa) 2,040 (14,000)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-21 Exterior and specifications
 Bobcat Bobcat 1
B18X-7 B20X-7 2
4,000 (1,800) 4,400 (2,000) 3
24 (500) 24 (500) 4
AC Electric AC Electric 5
Driver Seated Driver Seated 6
E E 7
x2/2 x2/2 8
130 (3,300) 130 (3,300) 9
5.1 (130) 5.3 (135) 10
CLASS Ⅱ CLASS Ⅱ 12
1.4 x3.9x35.4 (35x100x900) 1.6x3.9x35.4 (40x100x900)
13
9.5x35.6 (240x905) 9.5x35.6 (240x905)
5/7 5/7 14
83.5 (2,120) 83.7 (2,125) 15
44.1 (1,119) 44.1 (1,119) 16
84.6 (2,150) 84.6 (2,150) 17
171.1 (4,345) 171.3 (4,350) 18
79 (2,010) 79 (2,010) 19
36.2 (919) 36.2 (919) 20
74.3 (1,886) 74.3 (1,886)
21
19.5 (496) 19.5 (496)
14.8 (376) 15.0 (381) 22
136.5 (3,466) 136.7 (3,471)
23
144.2 (3,662) 144.4 (3,667)
10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 24
79 / 118 (400 / 600) 79 / 118 (400 / 600) 25
98 / 89 (500 / 450) 98 / 89 (500 / 450) 26
2,866 (1,300) 2,866 (1,300) 28
25 24 30
7,233 (3,281) 7,630 (3,461) 32
10,033 / 1,168 (4,551 / 530) 10,739 / 1,301 (4,871 / 590) 33
3,739 / 3,494 (1,696 / 1,585) 3,730 / 3,900 (1,692 / 1,769) 34
2/2 2/2 35
200x50-10 200x50-10 36
16x6-8 16x6-8 37
58.9 (1,495) 58.9 (1,495) 38
35.9 (912) 35.9 (912)
39
35.0 (890) 35.0 (890)
3.4 (86) 3.4 (86) 40
3.9 (100) 3.9 (100) 41
Hydraulic (old) / Electric (new) Hydraulic (old) / Electric (new) 42
Auto-Electric Auto-Electric 43
Lead-acid Lead-acid
48 48
585 585
575 575
690 690
45
625 625
25.1x39.1x27.5 (638x992x698) 25.1x39.1x27.5 (638x992x698)
23.9x39.1x27.5 (608x992x698) 23.9x39.1x27.5 (608x992x698)
25.1x33.1x27.5 (638x842x698) 25.1x33.1x27.5 (638x842x698)
2315 (1050) 2315 (1050)
6.0 x 2 8.0 (6.0) x 2 47
18.8 (14.0) 18.8 (14.0) 48
MOSFET Inverter MOSFET Inverter 54
ODB (old) / - (new) ODB (old) / - (new) 55
2,886 (19,900) 3,133 (21,600)
57
2,040 (14,000) 2,040 (14,000)

Exterior and specifications 1-22 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 1

General

Fig. 1-5

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-23 Exterior and specifications
 1-3-4 B16/18/20X-7 PLUS
1 Manufacturer Bobcat
CHARACTERISTICS

2 Model B16X-7 PLUS

3 Load Capacity at rated load center kg 1,600
4 Load center mm 500
5 Power type Electric
6 Operator type Driver Seated
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion P, E
8 Wheels (x=Driven) Number of front / rear x2/2
9 Max.Fork Height with STD 2-stage mast mm 3,300
10 Free Lift mm 130
12 Fork carriage ISO Class CLASS Ⅱ
Thickness x Width x Length mm 35 X 100 X 900
13 Fork
Fork Spacing (Min. x Max.) mm 240 x 905
14 Tilt of Mast Forward / Backward deg 5/7
15 Length to Fork Face mm 2,120
DIMENSIONS

16 Overall Width mm 1,090

17 Mast Lowered Height mm 2,150
Overall Dimensions
18 Mast Extended Height mm 4,345
19 Overhead Guard Height mm 2,010
20 Seat Height mm 919
Outer Turning Radius 1,886
21
Inner Turning Radius 494
22 Load Moment Center Center of drive axle to fork face mm 376
"Right Angle Stacking Aisle Width Pallet 1000 x 1200 crossways mm 3,466
23
(With Pallets & Clearance)" Pallet 800 x 1200 lengthways mm 3,662
WEIGHT PERFORMANCE

24 Travel Loaded / Unloaded km/h 17 / 17

25 Speed Lifting Loaded / Unloaded mm/s 400 / 600
26 Lowering Loaded / Unloaded mm/s 500 / 450
28 Max. Drawbar pull Loaded at 1.6km/h kg 1,300
30 Max. Gradeability Loaded at 1.6km/h % 26
32 Total weight with min. weight of battery kg 3,189
33 Loaded , Front / Rear kg 4,235 / 553
Axle Load
34 Unloaded , Front / Rear kg 1,698 / 1491
35 Number of Wheels (Front / Rear) 2/2
36 Tires Front 18x7-81)
Size
37 Rear 16x6-82)
38 Wheel Base Distance mm 1,495
CHASSIS

Front mm 902
39 Tread Width
Rear mm 890
40 at lowest mm 86
Ground clearance Loaded
41 at center of wheel base mm 100
42 Service Electric
Brakes
43 Parking Auto-Electric
Type Electric
Voltage V 48
BS type AH 585
"Capacity Normal
DIN type AH 575
(5 Hours
BS type AH 690
45 Battery Rating)" Max.
DIN type AH 625
POWER TRAIN

Normal mm 638 x 992 x 698

"Battery compartment sizes
BS type mm 638 (608)3) x 992 x 698
(L x W x H)"
DIN type mm 638 x 992 (842)4) x 698
Min. Weight kg 1,050
47 Drive motor rating at S2 60 minute kW 6.0 x 2
Electric Motors
48 Lifting motor rating at S3 15% kW 14
54 Control Type Drive and Hydraulic Type MOSFET Inverter
55 Drive Axle Brake Type Type -
System kpa 19,900
57 Relief Pressure
Attachment kpa 14,000

Exterior and specifications 1-24 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Bobcat Bobcat 1
B18X-7 PLUS B20X-7 PLUS 2
1,800 2,000 3
500 500 4
Electric Electric 5
Driver Seated Driver Seated 6
E E 7
x2/2 x2/2 8
3,300 3,300 9
130 135 10
CLASS Ⅱ CLASS Ⅱ 12
35 x 100 x 900 40 x 100 x 900
13
240 x 905 240 x 905
5/7 5/7 14
2,120 2,125 15
1,119 1,119 16
2,150 2,150 17
4,345 4,350 18
2,010 2,010 19
919
1,886
496
919
1,886
496
20
21
1
376 381 22

General
3,466 3,471
23
3,662 3,667
17 / 17 17 / 17 24
400 / 600 400 / 600 25
500 / 450 500 / 450 26
1,300 1,300 28
25 24 30
3281 3461 32
4,551 / 530 4,871 / 590 33
1,696 / 1,585 1,692 / 1,769 34
2/2 2/2 35
200x50-10 200x50-10 36
16x6-8 16x6-8 37
1,495 1,495 38
912 912
39
890 890
86 86 40
100 100 41
Electric Electric 42
Auto-Electric Auto-Electric 43
Lead-acid Lead-acid
48 48
585 585
575 575
690 690
45
625 625
638 x 992 x 698 638 x 992 x 698
638 (608)3) x 992 x 698 638 (608)3) x 992 x 698
638 x 992 (842)4) x 698 638 x 992 (842)4) x 698
1,050 1,050
6.0 x 2 6.0 x 2 47
14 14 48
MOSFET Inverter MOSFET Inverter 54
- - 55
19,900 21,600
57
14,000 14,000
1) Optional: pneumatic Tires_18x7-8 16PR
2) Optional: pneumatic Tires_16x6-8 16PR
3) If operator using a BS Type Battery (608mm length/ 575, 630, 690AH/5h capacity), special accessory
(stopper) should be chosen.
4) If operator using a DIN Type Battery (842mm width), Special accessory (bracket) should be chosen.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-25 Exterior and specifications
 Fig. 1-6

Exterior and specifications 1-26 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
1-4 Safety precautions
The following safety section is comprised of the following
subsections: general, personal safety, maintenance
safety, compressed air hazards, hydraulic fluid hazards,
mechanical hazards, electrical hazards, and fire and burn
hazards. Under each title are listed the precautions you
should take to ensure that you remain safe when working
on your vehicle.

The reader is responsible for thoroughly reading,

understanding, and putting into practice all the

1
precautions listed below.

Also note that the safety instructions outlined below are

not only for the sake of the reader’s safety, but for those

General
around him, too. So for your own personal safety and the
safety of those around you, ensure that you read through
the following instructions thoroughly:

General

Safety notes

• Familiarize yourself with the safety instructions

immediately visible on your vehicle. These
include warning plates, stickers, engravings, and
so on. Make a note of reading them prior to
operating, lubricating or repairing the vehicle
(See Safety section of Operation and
Maintenance Manual).
Fig. 1-7

• Ensure you follow all the safety rules,

regulations, and instructions when performing
maintenance. Pay special attention to the
hazard warnings which occur throughout this
manual, which will notify you of potential
hazardous circumstances.

• Do not assume that you can perform the

Fig. 1-8
procedures outlined in this manual based on
previous maintenance experience from servicing
similar models. The weights and specifications
for different models vary respectively and should
be paid close attention to in order to avoid
hazardous situations, injury, and/or damage to
components.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-27 Safety precautions

 Personal safety

Fit for the job

• Do not operate the vehicle or perform License

maintenance on it if unauthorized or untrained.

• Do not operate the vehicle or perform

maintenance on it after the consumption of
alcohol or medication that impairs your judgment.

• Do not operate the vehicle or perform

maintenance on it if you have any illness or Fig. 1-9
condition that limits physical movement.

Work wear

• Do not operate the vehicle or perform

maintenance if you are wearing loose clothing or
if your hair is long and is not tied back. Both
have the potential to be caught in moving
components, causing severe injury.

• Wear the appropriate protective gear for the

maintenance task you are performing. Items
may include hard hat, glasses/visor, ear
defenders, gloves, and protective shoes.

• Wear a mask when sanding the body of the

vehicle, and wear an air-fed breathing apparatus
when spraying it with paint.

• Wear welder’s gloves, welding mask/goggles,

apron and other appropriate welding apparel
when welding.
Fig. 1-10
Maintenance safety

Pre-maintenance

• Ensure the vehicle is in a clear, open

environment, and free from traffic and other
people.

• Ensure that the vehicle is parked safely and that

the vehicle will not suddenly move. Place
wooden props before and after the wheels, and
make sure the parking brake is properly Fig. 1-11
engaged.

Safety precautions 1-28 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 • Ensure the vehicle is unloaded and unoccupied,
the forks are lowered, all hydraulic controls are
in the neutral position, and the key is switched to
OFF. Attach a "Do Not Operate" or similar
warning tag to the start switch or controls before
servicing or repairing the forklift.

• Make sure that the tools are in good condition.

Fig. 1-12

Mounting and dismounting

• Clean any mud or debris from steps, walkways

or work platforms before you mount the vehicle.

• Face the vehicle when using steps, ladders or

•
walkways to mount or dismount it.

Use the steps and grab the handles to mount or

1
dismount the vehicle. When you are not able to

General
use the steps, use ladders, scaffolds, or work
platforms to perform the repair operations safely.

Heavy lifting

• Check the weight of each component before

removing it. Some of the components on this
vehicle are extremely heavy and could cause
severe injury.

• Use proper lifting procedures when removing

Fig. 1-13
any components.

• To avoid back injury, use a hoist when lifting

components which weigh 23 kg (50 lb) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity.
Be sure hooks are positioned correctly. Lifting
eye bolts are not to be side loaded during a
lifting operation.

Fig. 1-14

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-29 Safety precautions

 Assembly/disassembly

• Ensure that the assembly/disassembly work site

is kept clean and in good order, and keep your
hands and tools clean.

• When you tighten/loosen bolts and nuts, use the

right-sized wrench and always pull toward your
body. Using a wrench the wrong size or pushing
away from your body to loosen/tighten bolts or
nuts may cause unexpected accidents due to a
slip of your grip.

• If two or more persons work, use signs or

signals for communication so that the work is
done with agility as if the work is done by one
man.

• Be careful when you remove a cover plate.

Slowly loosen the last bolt or the two nuts in the
opposite direction to each other from the cover
unit, twist the cover to loosen the tension or
other pressure, and then remove the last bolt or
the two nuts completely.

• Reinstall all the fasteners with the same part

number. If any fastener needs replacing, use a
quality fastener and be careful not to use the
metric system fasteners mixed with inch
fasteners.

Safety precautions 1-30 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Compressed air hazards
• Pressure air can cause personal injury. When
using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.

• The maximum air pressure must be below 205

kPa (30 psi) for cleaning purposes.

Hydraulic fluid hazards

Carefully follow the instructions below for safety tips

regarding the maintenance of the hydraulic system.
Escaping oil under pressure, even a pinhole size leak,
can penetrate body tissue, causing serious injury, and
possible death. Because it is toxic; hot, pressurized
1
hydraulic oil injected into the skin—although it may

General
appear benign at first—will infect the immediate area and
then spread, causing large cracks in the skin. If you think
you have been exposed to hydraulic oil in this way, seek
Fig. 1-15
medical attention immediately.

• Wear gloves, goggles, and make sure your arms

and legs are fully covered.

• Relieve all pressure from the hydraulic system

before any lines, fittings or related items are
disconnected or removed, and wait for the
system to cool if it has just been running.
 Even after you have completed the pressure
removal process, there is no guarantee
pressure has completely exited the system.
Exercise extreme caution.

• Never touch a pressurized hose with your hand

and do not bend or strike a hose.

• Never check for pinhole leaks with your hand;

this is how oil injection related injuries most
commonly occur! Use cardboard or another
solid surface instead.

• Hold a rag over ports when removing filler caps,

breathers and plugs to prevent being sprayed or
splashed by liquids under pressure.

• Have a container ready to catch any hydraulic

oil that might run out of the hoses/ports.

• Make sure all raised components are blocked

correctly.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-31 Safety precautions

 • When reinstalling the lines ensure they are
tightened to the correct torque (See Section 1-8).

• Make sure that all heat shields, clamps and

guards are installed correctly to avoid excessive
heat, vibration or friction with other parts during
operation.

• Shields that protect against oil spray onto hot

exhaust components in the event of a line, tube
or seal failure must be installed correctly.

Mechanical hazards
• Keep objects away from moving fan blades.
They will throw or cut any object or tool that falls
or is pushed into them.
Do not operate a machine if any rotating part is
damaged and contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.

• Support equipment and mounted components

properly when working beneath them. Do not
expect hydraulic cylinders will stay mounted.
Any attachment can fall if a control lever is
moved or if a hydraulic line breaks.

• Chips or other debris can fly off objects when

struck. Make sure no one will be injured by flying
debris before striking an object. Fig. 1-16

Electrical hazards
• Do not damage the wiring during removal
operations. When reinstalling the wiring, make
sure it is installed in such a way that it is
protected from being damaged by sharp corners,
friction with different objects, or hot surfaces.

• Do not connect wiring to a line containing oil.

• Do not smoke, or expose battery to sparks or

flame when checking, charging or servicing the
battery. Keep chains and metallic tools away
from the top of the battery. Electrolyte is an acid
and can cause personal injury if it contacts skin
or eyes. Fig. 1-17

Safety precautions 1-32 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Fire and burn hazards
• To avoid burns, be alert for hot parts on
machines which have just been stopped and hot
oils in lines, tubes and compartments.

• All fuels, most lubricants and some coolant

mixtures are flammable. If a pipe is loose or
damaged, a fire might occur.

• Keep all fuels and lubricants stored in properly

marked containers and away from unauthorized
persons.

• Store all oily rags or other flammable material in

a protective container, in a safe place.

• Do not weld or flame cut pipes or tubes that 1

contain flammable oils. Clean them thoroughly
with nonflammable solvent before welding or

General
flame cutting them.

• Remove all residual flammable materials on the

forklift, such as fuel and oil before they
accumulate.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-33 Safety precautions

1-5 Maintenance
Since the following table shows only some information in
Operation & Maintenance Manual (O & MM), please stick
to O & MM.

The following describes key items and replaceable parts

to inspect at maintenance intervals.

NOTICE: Except for the daily checkup made by the driver

of the vehicle, all maintenance and repair should be
carried out by qualified and authorized engineers.
NOTICE: Careless disposal of waste oil may not only
harm to the environment but also endanger human health.
Waste oil should always be placed in a container and
disposed by an authorized person at a designated site.

Inspection when required

Items Inspection criteria and method
• Press Enter down for 3 seconds

Instrument panel - By pressing this button with the key switch on, you can access
Diagnosis and Calibration modes.
- By pressing this button while driving, you can access Diagnosis mode.

• Measure the distance from the bottom of

the inner mast to the bottom of the carriage
bearing with the inner mast standing
upright, and then adjust the extrusion of
Carriage roller the roller.
Height of carriage roller extrusion (A)
STD mast FF mast FFT mast
-6 mm 8 mm 8 mm
(-0.2 in) (0.3 in) (0.3 in)

• Check the fuse for detached elements and replace if required.

- 5A: Backup/stop lamps, ISO relay/power supply, fan, fingertip, strobe,
flasher, rear/head lamps
Fuse box
- 10 A: Key switch
- 20 A: DC-DC converter and horn
- 500 A: Main fuse
• Check if the driver’s seat operates normally and then lightly lubricate the
Driver’s seat
slider track.

• Check the fastening of wheel bolts and nuts.

Wheel bolt - Standard rear wheel fastening torque: 113 N·m (85 lb·ft)
- Standard drive wheel fastening torque: 180 N·m (135 lb·ft)

Maintenance 1-34 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 • Conduct the parking brake test on 15% slope.
Parking Brake - Refer to parking brake test method in “Every 500 Service Hours or 3
Months”.

Drive axle gear • Check the gear box for lubrication.

box - Refill lubricant up to the plug opening for housing level inspection.

Inspection every 10 service hours or daily

Items Inspection criteria and method

• Check for loosened parts and fasteners.

• Check Instrument panel indicators for abnormality.
• Check if horns and other alarms operate normally.
• Check the mast and the lift chain for wear and pins/rollers for
1
abnormality.

General
• Check the carriage, fork, and attachments for damage and abnormality.
Daily inspection
• Check the tires, valves, and wheels for abnormality.
• Check the overhead guard for damage and abnormality.
• Check the hydraulic system for oil leaks and damage.
• Check the drive axle for oil leaks.
• With the driver’s seat adjusted and the control lever to neutral, turn on
the key switch and check the overall operation of the system.

Mast • Lubricate the beams on which rollers are seated.

• Inspect the battery’s installation position and check to see if it is properly

Battery placed, tightened, and cleaned.
- Check specific gravity of the battery (refill if it is 1.15 or lower).

Instrument panel • Check if the parking brake lamp works normally and if the battery is not
indicators discharged.

• Check tires and valve stems for wear, cut, groove, and contamination,
Tires and wheels
and check tire’s air pressure.

Inspection first 50–10 service hours or a week

Items Inspection criteria and method
Drive axles • Replace drive axle oil.

Inspection every 500 service hours or 3 months

Items Inspection criteria and method

• Lubricate the chassis and mast pivot eye bolt fittings.

Tilt cylinders
- Check pins for loose retainer bolts or wear.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-35 Maintenance

 • Measure and adjust the extension of the cylinder rods (up to 3.18
mm/0.13 in)
- Standard bolt fastening torque: 95±15 N·m (70±11 lb·ft)
• Check the cross head roller guard and retainer for damage.

• Operate the lift, tilt and attachment controls. Listen for unusual noises
• Inspect for loose bolts and nuts on the carriage and load backrest.
• Inspect the forks and attachments for free operation and damage.
Mast, Carriage, Lift
Chains and • Brush in a film of oil on all links of the chain.
Attachments • Raise and lower the carriage a few times to work lubricant into the chain
links.
• Inspect the chain anchors and individual links for wear, loose pins or
cracked leaves.

Mast Hinge Pins • Lubricate two fittings

• Replace drive axle oil on B15/18/20T-7, B18/20TL-7, B16/18/20X-7

truck.
Drive Axle Oil
- In case of B15/18/20T-7 PLUS and B16/18/20X-7 PLUS trucks, the
interval of changing drive axle oil is every 2000Hrs/Yearly.

Steering axle • Lubricate the fittings of the steering axle.

• Clean steer angle switches with 205 kPa (30psi) maximum air pressure
until dust is removed.
Steer Angle Switch
• Check the operation of steer angle switches and the tightness of bracket
Adjustment if needed.

• Check bolts for damage.

Overhead guard
- Standard bolt fastening torque: 60 ± 10 N·m (44±7 lb·ft)
• Check the tightness of the directional forward/reverse Switch mounting
Direction Control bracket. Adjust if needed.
forward/reverse • Check for ease of movement of directional forward/reverse Switch.
Switch Adjust if needed.
• Check for loose wiring. Secure wiring if needed.

• Clean the control panel with 205 kPa (30 psi) maximum air pressure,
until dust is removed from the control panel.
Control Panel • Inspect all wiring for loose connections, frayed cables and loose
mounting bolts.
• Inspect the fuses for looseness, corrosion and broken connections.

• Conduct the parking brake test on a 15% incline.

Parking Brake - If the parking brake fails to keep the lift truck at the parked position,
repair or replace the parking brake.
Hydraulic Oil • Maintain the oil level to the full mark on the breather/dipstick.

Maintenance 1-36 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Inspection every 1,000 service hours or 6 months
Items Inspection criteria and method
Air breather • Replace the air breather.

Drive and pump • Blow off the drive motor END SHIELD with 205 kPa (30 psi) maximum
motors air pressure, until dust is removed from the motor.

• Inspect tires for wear, cuts, gouges and foreign objects. Look for bent
rims and correct seating of locking ring.
• If equipped with pneumatic tires, check tires for proper inflation.
Tires and wheels
• When tires are changed be sure to clean all rim parts, and if necessary,
repaint to stop detrimental effects of corrosion.
• When installing the drive wheel, tightening torque is 180 N·m (135 lb·ft).

• Perform a lift chain abrasion test by measuring the wear of the chain 1
links and pins.
- Measure the distance in mm from the center of a pin to the 10th

General
chain link.
Lift chains
- Replace the chain if the wear rate is 2% or higher.
※ Chain’s wear rate (%) = [(measurement–15.88x10)/(15,88x10)]x100
• Check if tension is equal on the both sides of each lift chain set.
• Adjust the lift chain and carriage chain.
Hydraulic return • Replace the return filter in the hydraulic tank.
filter

Inspection every 2,000 service hours or yearly

Items Inspection criteria and method

• Replace oil and filters.

• Remove the breather / dipstick and the strainer. Wash them in clean,
Hydraulic, Power
steering systems nonflammable solvent and dry them.
• Maintain the oil level to the FULL mark on the breather / dipstick. Add
oil if necessary.

• After removing the hub group seal and the bearings, inspect the
bearings and the seal for wear or damage. Replace if necessary.
• When installing, lubricate the bearing and apply the proper procedures
in O&MM.
Steer Wheel
Bearings - While rotating the wheel, tighten the locknut to 34 N·m (24 lb·ft).
- Loosen the nut completely.
- Tighten the nut again to a torque of 11±3 N·m (8±2 lb·ft) and lock
within this range.
- Install the cover.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-37 Maintenance

 • Under normal conditions, perform regular inspections at least every 12
months. But if your type of work causes more labor and stress on the
vehicle (i.e. long operating hours, or heavy lifting) perform inspections
on a 6 month regular basis.
• Replace if any of the following conditions are found:
- Cracks on a fork’s heal, welding, bracket, etc.
- A fork is so worn that its thickness is lower than 90% of the initial
thickness.
Forks
- Angle between the top of the blade and the front face of the shank
exceeds 90±3º.
- The deviation from the straightness of the upper face of blade or the
front face of shank exceeds 0.5 percent of the length of the blade
and/or the height of the shank respectively 5 mm/1000 mm (0.18
in/36 in).
- Tolerance in the heights of two or more ends of the fork: 6.5 mm(0.3
in) (palette fork), 3.0 mm(0.1 in) (tapered fork)
※ The height tolerance between forks is 3% of the length of the blade.
• Replace the oil.
Hydraulic Oil • After replacing the oil, check for oil leaks and maintain the oil level to
the FULL mark on the dipstick. Add oil if necessary.

• Replace the oil on B15/18/20T-7 PLUS and B16/18/20X-7 PLUS.

Drive axle oil - In case of B15/18/20T-7 and B16/18/20X-7 trucks, the interval of
changing drive axle oil is every 500Hrs/6 months.

Maintenance 1-38 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

1-6 Lubricants
The following is a detailed explanation of the lubricants needed and the parts to be lubricated.

Some of the classifications and abbreviations used follow S.A.E. (Society of automotive Engineers)
J754 nomenclature while others follow S.A.E. J183. All MIL specifications are U.S.A. Military.

Greases are classified according to the National Lubricating Grease Institute (NLGI) based on ASTM
D217-68 worked penetration characteristics which give a defined consistency number.

1-6-1 Recommended viscosities and capacities

The SAE grade number indicates the viscosity of oil. A
proper SAE grade number should be selected according 1
to ambient temperature.

General
NOTICE: The amount of lubrication varies with the
remaining oil level. Therefore make sure to check the oil
gauge before lubrication.

Lubricant viscosities Refill

for ambient (outside) temperatures capacities
Compartment or
system Lubricant Temperatures (°C/°F)
Liters (l)
Viscosities Min. Max.
ISO VG 22 -30/-22 +20/+68
Hydraulic and power
steering ISO VG 32 -20/-4 +30/+86
18.0
system ISO VG 46 -10/+14 +40/+104
ISO 6743/4 HM
ISO VG 68 0/+32 +50/+122
API SAE 10 W -20/-4 +22/+71.6
Drive axle housing 1.1
CD/TO-2 SAE 30 +10/+50 +50/+122
Brake oil reservoir
only for the trucks with ISO VG 10 -30/-22 +50/+122 0.6
brake master cylinder

Note 1) For detailed information on lubricants, see Section 1-6-2.

Note 2) In case of PLUS models, brake oil is no longer used.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-39 Lubricants

 1-6-2 Lubricant specifications

Chain and linkage oils (DEO or EO)

The following engine oils are recommended for use on

the chains and linkages:

Items Spec.
European CCMC D3
API CD, CD/SF, CE
Military MIL-L-2104D or E
Fig. 1-16

Hydraulic oils (HYDO)

The following commercial classifications can be used in

the hydraulic system.

These oils should have antiwear, antifoam, antirust and

antioxidation additives for heavy duty use as stated by
the oil supplier. An ISO viscosity grade of 32 would
normally be selected.

Items Spec.
ISO 6743/4 HM
AFNOR NFE 48-603 HM
DIN 51524 TEIL 2 H-LP
Fig. 1-17
HAGGLUNDS DENISON HFO-HF2
CINCINNAT P68, 69, 70

NOTICE: Correct hydraulic oil should be used to achieve

the maximum life and performance from hydraulic system
components. The above hydraulic oil is recommended in
most hydraulic and hydrostatic systems.
Oil added to the hydraulic tank must mix with the oil
already in the system. Use only petroleum products
unless the system is equipped for use with a certain
special product.
If the hydraulic oil becomes cloudy, this means that water
or air has entered the system. Water or air in the system
will cause pump failure. Drain the oil, retighten all
hydraulic suction line clamps, and then purge and refill
the system.

Lubricants 1-40 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Drive axle oil

The following products are certificated as universal

transmission tractor oils (UTTO).

Suppliers Products
TOTAL TRANSMISSION MP
MOBIL MOBIL OIL 422 MOBIL OIL 425

MOTUL TRM 97
OPAL OPAL OIL TA/HIS

GS Caltex Bobcat DX 10W

Brake oil 1
Only for the trucks with brake master cylinder, use a

General
heavy duty hydraulic brake oil certified by the oil supplier
to meet ISO 6743/4 HM VG 10 latest revision.

Note: In case of B15/18/20T-7 PLUS series and

B16/18/20X-7 PLUS series trucks, brake oil is no longer
used.

Suppliers Products
TOTAL Azolla ZS 10
AGIP Acer 10
BP Energol HP 10 HLP 10
CALTEX Spindurn 10
ELF Spinelf 10
ESSO Nuto H 10 Spinesso 10
Fig. 1-18
FINA Hydran 10
MOBIL Velocite Oil No. 5 Velocite Oil E
SHELL Tllvs Oil C10 / Morlina 10

Lubricating grease (MPGM)

Use Multipurpose Molybdenum Grease (MPGM) for all

lubrication points. If MPGM grease cannot be used, a
multipurpose type grease which contains 3% to 5%
molybdenum disulfide can be used.

NLGI NO.2 grade is suitable for most temperatures. Use

NLGI No.1 or No.0 grade for extremely low temperature.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-41 Lubricants

 1-6-3 Greasing points
<Greasing points for B15/18/20T-7 and B18/20TL-7>

Fig. 1-19

Lubricants 1-42 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 <Greasing points for B15/18/20T-7 PLUS>

General

Fig. 1-20

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-43 Lubricants

 <Greasing points for B16/18/20X-7>

Fig. 1-21

Lubricants 1-44 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 <Greasing points for B16/18/20X-7 PLUS>

General

Fig. 1-22

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-45 Lubricants

1-7 Disassembly/assembly instructions
The following disassembly/assembly section is comprised
of the following subsections: preparations before
disassembly, check and test before disassembly,
precautions when disassembling, precautions after
disassembly, precautions when assembling, handling
general parts, and hydraulic line fittings. Under each title
are listed the precautions you should take to carry out the
disassembly/assembly work correctly.

Preparations before disassembly

• Wash off dust and contaminants from the
vehicle before you send it to the service center.
Dust or contaminants brought into the service
center may stain parts and get into them to
make scratches.

• An electric forklift operates based on the

electrical system. Do not let any water into the
system.

• To avoid unnecessary disassembly work,

prepare the necessary tools, a box to put the
parts in, and make it a priority to always keep
your worksite clean.

Check and test before disassembly

• Before you start disassembling, make sure to
record any problems. This may prevent
unnecessary disassembly, loss of replacement
parts, and repetitive failures caused by the same
problem.

• To prevent malfunction, keep a record of the

failure and the parts required for replacement.
Also make sure you check and record the
Fig. 1-21
following information:
 Vehicle’s model number, serial number, and
hours of operation
 Reason why the vehicle needs disassembling
 Check the symptom, location, and cause of the
failure (If needed, reproduce the same failure).
 Check if any parts are out of place.
 Check for damaged or loosened parts.
 Check how well the vehicle has been
maintained if possible.
Disassembly/assembly instructions 1-46 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Precautions when disassembling

Disassembly

• Identify how the parts are assembled (front/back,

left/right, and up/down connections) to
determine the order of disassembly.

• Before you start disassembling the parts, note

the connecting points of parts and mark them
using a punch to avoid misplacing the parts
during assembly.

• Use the right tools to remove specific parts.

• If any part is not dismounted and even the

mounting bolts and nuts were removed, do not
use excessive force. Check and find the cause.
1
• Put the disassembled parts to one side in the

General
order of their disassembly, putting a tag or mark
on those parts which similar in appearance.

• Store common parts such as bolts and nuts in

an orderly manner.

Check and test during disassembly

• Sometimes the cause of failure is found during

disassembly. Therefore, it is very important to
carefully check the state of the friction surface
and contacting parts.

• During disassembly, measure and record the

gap, distortion, projections, and other factors
that may cause the failure.

Maintaining gaps

• Make sure the shims and washers you install

produce the specified gap value required.

Link adjustment

• If the rod needs no readjustment, keep the initial

length. If you need to move the end of the rod,
measure and record its length before
disassembling.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-47 Disassembly/assembly instructions

 Disassembling press-fitted components

• Remove any dents or marks caused by

hammering and polish the area.

• If any press-fitted component is loosened,

identify and remove the cause to avoid problems
during assembly.

Disassembling bearings

• Do not remove bearings by force but use a

bearing puller as shown in Fig. 1-22.

Precautions after disassembly

Cleaning

• Clean the disassembled parts, arrange them by

assembly unit, and keep them away from
contaminants. Give particular attention to
removing contaminants from the oiling lines or
Fig. 1-22
the pipes of components.

• An efficient way of cleaning is to use two

vessels of detergent: one for washing dirty parts
and the other for rinsing them.

• When you clean special parts, increase the

number of detergent vessels and clean several
times.

• Kerosene or neutral acid anhydride diesel is

suitable for cleaning sticky oil in bearings.

• In the case of large castings, soak them in a pH

10 to 12 alkaline detergent, at 50°C to 70°C
(122°F to 158°F) and then rinse with water.

• When you use a hazardous chemical detergent,

be careful not to let your skin or eyes contact it.
Old oil should be disposed of at a designated
place using a specified container.

Dust prevention

• Keep cleaned parts free from dust and

contaminants using a dust cover and plug up the
ends of all pipes.

• Rustproof any parts you might store away

before installing again.

Disassembly/assembly instructions 1-48 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Precautions when assembling

Parts installation

• Keep all parts clean before you assemble them.

Check their surface for flaws and repair as
needed. Make sure not to stain the friction
surface with any contaminants that may reduce
the service life of the parts.

• Wash off the rust proofing agent from the parts

using a detergent before you start assembling.

• Identify the marks you have made for fitting

parts together before you start assembling.

• Use a press-fitting tool to assemble bearing,

bushing, and oil seal, and use designated tools
1
for specific parts.

General
• Before press-fitting parts, grease their surface
with molybdenum bisulfide.

Tightening bolts and nuts

• To ensure bolts and nuts are all torque evenly,

tighten them in the order shown in Fig. 1-23,
tightening one and then the other on the
opposite side. This method is called the
“template method” that repeats loosening and Fig. 1-23
tightening gradually to ensure even contact.

• Lubricating the screwing part of the bolts with

engine oil will make bolt tightening easier and
stronger.

• Use wire, cotter pins, lock washers, or other parts

shown in Fig. 1-24 to secure bolts, nuts, or other
important fastener that cannot be visually checked.
Fig. 1-24
Check during assembly

• At each step of the assembly procedure, check

and record gaps, free play, projections, and
distortion.

Reassembling shims

• Install shims and washers in the same places as

before and then check if the gaps are correct.

Assembling adjustment links

• If no adjustment is needed, assemble them to

make the same length as before.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-49 Disassembly/assembly instructions

 Assembling press-fitted parts

• Repair scratches and dents as required and

keep the parts clean before inserting them.

• Note that insufficiently tightened press-fitted

parts may become loose.

Assembling keys and keyways

• Check if keyways and keys are loosened and if

they contact the key head. If the key head
contacts the keyway, remove the remaining part
of the key head.

Handling general parts

Handling packing

• Packing, gaskets, and copper packing should all

be replaced as instructed. Assemble the gaskets
specified in this Service Manual after applying
an adhesive. When you apply an adhesive to a
gasket, note the following:
 Completely remove old adhesive, scratches,
dust, paint, and grease left on the surface of
the gasket.
 Evenly coat both sides of the gasket with an
appropriate sealant and wait for several
minutes until it dries.
 Once the sealant has dried to the extent that
when touched it does not stick to your hand,
assemble the parts.
 Soak leather packing in oil before use.

Handling O-rings

• Always remember to check the condition of O-

rings. Do not use O-rings that have become
hard from being stored away for a long time.

• Only use those O-rings that are specified in the

Parts List. For example, O-rings for engine oil
are made from special materials such as silicon
rubber and are resistant to heat and aging.
Installing a different type of O-ring in this case
could cause severe damage to a system and its
components.

• Lubricate O-rings to avoid scratching their

surface during installation. Silicon rubber O-
rings are easily damaged, so be careful not to
overstretch them.
Disassembly/assembly instructions 1-50 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Handling oil seal

• Prevent oil seals from gathering dust,

particularly in their lips, and make sure there is
no rust or scratches. Oil pressure

• Evenly lubricate the lip surface opposite to the

sealing of an oil seal.

• Check if the surface of the axle to which an oil

seal is mounted is contaminated, rusted, or Main lip Dust Sealing lip
0803E
scratched, then apply grease or lubricant so that
Fig. 1-25
the oil seal can be installed easily.

• Check the surface of the oil seal lip for scratches

by lightly rubbing a wire on the surface. If there
are any scratches, replace the oil seal. 1
• When you insert an oil seal, use a guide and jig
as shown in Fig. 1-26 to avoid damaging it.

General
• After you have inserted an oil seal, check the
inclination (tolerance of inclination: 0.2 mm/100
Guide Jig
mm, 0.008 in/3.937 in diameter). 0804E

Fig. 1-26
• When you apply adhesive to an oil seal, ensure
that no adhesive makes contact with the lip’s
surface. Completely remove residual adhesive
on the guide and jig before you insert another
seal.

Handling bearings

• To assemble a bearing correctly and avoid

damaging it, take note of the following:
 Completely remove dust and other
contaminants that might shorten the bearing’s
service life. Keep the bearing as packed until
its installation.
 Do not impact the bearing. Never turn the
bearing excessively in order to remove the
purifier by blowing in compressed air. Ensure
that the oil seal ring is installed in the right
direction.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-51 Disassembly/assembly instructions

 • Pay attention to the following when you install
bearings.
 Neither hit the outer race with a hammer to Jig
install it, nor hit the inner race to insert the
outer race. Hammering like this will cause
damage to the track of the bearing.
 When you insert the inner race of a bearing
with a reasonable tolerance, use a jig as
Pressure
shown in Fig. 1-27 and put pressure on the
inner race. When you perform thermal Fig. 1-27
insertion with a press-fitting tolerance, heat the Jig
bearing up to 120°C (248°F). Note, however,
that excessive heating may lower the hardness
of the surface of bearing.
 When you insert a non-split bearing with an
inner race and outer race at a reasonable Pressure
tolerance, use a jig as shown in Fig. 1-28 and 0805E

press in both the inner and outer races at the Fig. 1-28
same time.

Handling retaining rings

• When you remove or install a retaining ring, use

a pair of right ring pliers and be careful not to put
too much stress on the retaining ring.

• After you have installed the retaining ring, check

if it is correctly inserted into the groove.

Disassembly/assembly instructions 1-52 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Hydraulic line fittings

Hydraulic line installation

1. For a metal tube to hose installation, install the

tube and tighten all bolts finger tight.

2. Tighten the bolts at the rigid end.

3. Install the hose and tighten all bolts finger tight.

4. Put the hose in a position so that it does not

make contact with the machine or another hose.

5. Tighten the bolts on both connections.

6. Start the engine. 1

7. Move the implement control levers to all

General
positions.

8. Look at the hose during movement of the

implement. Make sure the hose is not in contact
with the machine or other hoses.

9. Shut off the engine.

10. If necessary, put the hose in a new position

where it will not make contact when the
implement is moved.

Assembly of fittings with straight threads and O-ring seals

(common to different applications)

1. Put locknut (3), backup washer (4) and O-ring (1) Connection to tube
seal (5) as far back on fitting body (2) as possible. (2) Fitting body

2. Turn the fitting into the part it is used on until

backup washer (4) just makes contact with the
face of the part.

3. To put the fitting assembly in its correct position,

(3) Locknut
turn fitting body (2) out (counterclockwise) a
maximum of 359°. (4) Backup washer

(5) O-ring seal

4. Tighten locknut (3) to the torque shown in the
correct chart for the fitting used.
(6) Connection to other part
5. If a fitting body’s tube end is shaped as shown in
0806E

Fig. 1-29
Fig. 1-29 (either an elbow or a straight body), put
a sleeve on the tube before connecting the tube
to the end.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-53 Disassembly/assembly instructions

 NOTICE: If the fitting is a connector (straight fitting), the
hex on the body takes the place of the locknut. To install
this type of fitting, tighten the hex against the face of the
part it goes into.

Tightening other fitting types

• Hi-duty (shear sleeve) tube fittings: After the

tube has been put through the nut and makes
contact against the tube shoulder in the fitting
body, turn the nut with a wrench until a small Fig. 1-30
decrease in torque is felt. This is an indication
that the sleeve has been broken off the nut.
Hold the tube to prevent turning and tighten the
nut 1-1/2 turns.

• Hi-seal fittings: Put the nut and the sleeve over

the tubing with the short heavy end of the sleeve
facing the end of the tubing. Put the tube end
against the counterbore in the body of the fitting
Fig. 1-31
and tighten until the nut is over the last thread
on the body. The remainder of space is used
whenever the fitting is removed and installed
again.

• Ermeto tube fittings: Put the nut and sleeve

over the tube with head or shoulder end of
sleeve next to the nut. Push the tube into Fig. 1-32
counterbore of fitting body as far as possible.
Turn the nut clockwise until sleeve holds the
tube and prevents movement. Tighten the nut 1-
1/4 turns more to seat sleeve and give a locking
action. When necessary to assemble again, put
sleeve over the tube and tighten the nut until a
sudden increase in torque is felt. Then tighten
1/6 to 1/3 turn more to seat the sleeve.

• Flex fittings: Put the nut and sleeve over the

tubing and push the tube in to counterbore of
fitting body as far as possible. Tighten the nut
until it is against the hex part of the fitting body. Fig. 1-33

Disassembly/assembly instructions 1-54 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

1-8 Standard torques

1-8-1 Standard torques for bolts and nuts

Be careful to avoid mixing metric and inch dimensioned
fasteners. Mismatched or incorrect fasteners can result in
vehicle damage or malfunction, or possible injury.
Exceptions to these torques are given in the Service
Manual where needed.

Prior to the installation of any hardware, be sure

components are in near new condition. Bolt and nut
threads must not be worn or damaged. Hardware must
be free of rust and corrosion. Clean hardware with a non- 1
corrosive cleaner and apply engine oil to threads and
bearing face. If thread lock or other compounds are to be

General
applied, do not apply engine oil.

After loosening fasteners, keep them well and reuse only

those in fine conditions. When replace with a new one,
make sure to select a fastener of the same size and class.

Usually, you can identify a bolt’s strength according to the

number marked on its head (e.g. 8.8 or 10.9) as shown in
Fig. 1-34. The table below lists the standard torques for
Fig. 1-34
standard bolts and nuts, and taperlock studs as shown in
Fig. 1-35.

Standard bolt

Taperlock stud 0807E

Fig. 1-35

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-55 Standard torques

 For metric fasteners

Thread size Metric nuts and bolts Metric taperlock studs

(mm) (N·m) (lb·ft) (N·m) (lb·ft)
M6 12 ± 3 9±2 8±3 6±2
M8 28 ± 7 20 ± 5 17 ± 5 13 ± 4
M10 55 ± 10 40 ± 7 35 ± 5 26 ± 4
M12 100 ± 20 75 ± 15 65 ± 10 48 ± 7
M14 160 ± 30 120 ± 22 - -
M16 240 ± 40 175 ± 30 110 ± 20 80 ± 15
M20 460 ± 60 340 ± 44 170 ± 30 125 ± 22
M24 800 ± 100 600 ± 75 400 ± 60 300 ± 45
M30 1600 ± 200 1200 ± 150 650 ± 80 480 ± 60
M36 2700 ± 300 2000 ± 225 870 ± 100 640 ± 75

For inch fasteners

Thread size Inch nuts and bolts Inch taperlock studs

(inch) (N·m) (lb·ft) (N·m) (lb·ft)
1/4 12 ± 3 9±2 8±3 6±2
5/16 25 ± 6 18.0 ± 4.5 17 ± 5 13 ± 4
3/8 47 ± 9 35 ± 7 35 ± 5 26 ± 4
7/16 70 ± 15 50 ± 11 45 ± 10 33 ± 7
1/2 105 ± 20 75 ± 15 65 ± 10 48 ± 7
9/16 160 ± 30 120 ± 20 - -
5/8 215 ± 40 160 ± 30 110 ± 20 80 ± 15
3/4 370 ± 50 275 ± 35 170 ± 30 125 ± 22
7/8 620 ± 80 460 ± 60 260 ± 40 190 ± 30
1 900 ± 100 660 ± 75 400 ± 60 300 ± 45
1-1/8 1300 ± 150 950 ± 100 500 ± 70 370 ± 50
1-1/4 1800 ± 200 1325 ± 150 650 ± 80 480 ± 60
1-3/8 2400 ± 300 1800 ± 225 750 ± 90 550 ± 65
1-1/2 3100 ± 350 2300 ± 250 870 ± 100 640 ± 75

Standard torques 1-56 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 1-8-2 Standard torques for tightening fittings

Standard torques for O-ring face seal fittings

Thread size Straight thread O-ring fitting O-ring

(inch) (N·m) (lb·ft)

O-ring groove

5/16-24 5.0 ± 1.5 45 ± 15

3/8-24 12 ± 2 110 ± 20
7-16-20 20 ± 4 15 ± 3
1/2-20 40 ± 5 30 ± 4 O-ring
9/16-18 40 ± 5 30 ± 4 O-ring face seal nut
3/4-16 100 ± 15 75 ± 10 Straight thread
O-ring port fitting end

1
7/8-14 135 ± 15 100 ± 10 0808E

1 1/16-12 200 ± 25 150 ± 20 Fig. 1-36

1 3/16-12 250 ± 25 185 ± 20
1 5/16-12 300 ± 40 225 ± 30

General
1 5/8-12 300 ± 40 225 ± 30
1 7/8-12 300 ± 40 225 ± 30
2 1/2-12 300 ± 40 225 ± 30

Thread size O-ring face seal fitting nut

(inch)
(N·m) (lb·ft)
9/16-18 16 ± 3 12 ± 2
11/16-16 30 ± 4 22 ± 3
13/16-16 50 ± 7 37 ± 5
1-14 90 ± 10 65 ± 7
1 3/16-12 120 ± 15 90 ± 10
1 7/16-12 160 ± 20 120 ± 15
1 11/16-12 190 ± 20 140 ± 15
2-12 215 ± 25 160 ± 20

Hose clamp-band type

Clamp Torque on new Retightening

width hose torque
7.9 mm 0.9 ± 0.2 N·m 0.7 ± 0.2 N·m
(0.312 in) (8 ± 2 lb·in) (6 ± 2 lb·in)
13.5 mm 4.5 ± 0.5 N·m 3.0 ± 0.5 N·m
(0.531 in) (40 ± 5 lb·in) (25 ± 5 lb·in)
15.9 mm 7.5 ± 0.5 N·m 4.5 ± 0.5 N·m
(0.625 in) (65 ± 5 lb·in) (40 ± 5 lb·in)

Fig. 1-37

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-57 Standard torques

 37°flared and straight thread O-ring fittings

37° flared O-ring fitting-plug Swivel nuts

Fig. 1-38

37° flared and straight thread O-ring fittings (except O-ring face seal fittings)
Nominal tube O.D. Thread size Standard torque
Metric Inch (inch) (N·m) (lb·ft)
3.18 0.125 5/16 5.0 ± 1.5 4±1
4.76 0.188 3/8 11.0 ± 1.5 8±1
6.35 0.250 7/16 16 ± 2 12 ± 1
7.94 0.312 1/2 20 ± 5 15 ± 4
9.52 0.375 9/16 25 ± 5 18 ± 4
9.52 0.375 5/8 35 ± 5 26 ± 4
12.70 0.500 3/4 50 ± 7 37 ± 5
15.88 0.625 7/8 65 ± 7 48 ± 5
19.05 0.750 1-1/16 100 ± 10 75 ± 7
22.22 0.875 1-3/16 120 ± 10 90 ± 7
25.40 1.000 1-5/16 135 ± 15 100 ± 11
31.75 1.250 1-5/8 180 ± 15 135 ± 11
38.10 1.500 1-7/8 225 ± 15 165 ± 11
50.80 2.000 2-1/2 320 ± 30 240 ± 22

Standard torques 1-58 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 45°flared and 45°inverted flare fittings

Inverted 45° flared 45° flared

Fig. 1-39

45° flared and 45° inverted flare fittings

Nominal tube O.D. Thread size Standard torque
Metric Inch (inch) (N·m) (lb·ft)
3.18
4.76
0.125
0.188
5/16
3/8
5.0 ± 1.5
8.0 ± 1.5
4±1
6±1 1
6.35 0.250 7/16 11 ± 2 8±1
7.94 0.312 1/2 17 ± 3 13 ± 2

General
9.52 0.375 5/8 30 ± 3 22 ± 4
11.11 0.438 11/16 30 ± 3 22 ± 2
12.70 0.500 3/4 38 ± 4 28 ± 3
15.88 0.625 7/8 50 ± 5 37 ± 4
19.05 0.750 1-1/16 90 ± 8 65 ± 6
22.22 0.875 1-1/4 100 ± 10 75 ± 7

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 1-59 Standard torques

 Air conditioning and tapered pipe thread fittings

O-ring 45° flare Fig. 1-40

Air conditioning fittings

45° flare fitting end
Thread size O-ring fitting end
Steel the tubes Aluminum the tubes
(inch)
N·m (lb·ft) N·m (lb·ft) N·m (lb·ft)
5/8-18 18 ± 4 13 ± 3 30 ± 3 22 ± 2 23 ± 3 17 ± 2
3/4-16 37 ± 4 27 ± 3 52 ± 5 38 ± 4 33 ± 4 24 ± 3
7/8-14 40 ± 4 30 ± 3 60 ± 7 44 ± 5 38 ± 4 28 ± 3
1 1/16-14 45 ± 5 33 ± 4 75 ± 8 55 ± 6 50 ± 5 37 ± 4

Tapered pipe thread fittings

Thread size Threads with 1e2200e sealant Threads without sealant

(inch) (N·m) (lb·ft) (N·m) (lb·ft)
1/16-27 15 11 20 15
1/8-27 20 15 25 18
1-14-18 25 18 35 26
3/8-18 35 26 45 33
1/2-14 45 33 60 45
3/4-14 60 45 75 55
1-11 1/2 75 55 90 65
1 1/4-11 1/2 95 70 110 80
1 1/2-11 1/2 110 80 130 95
2-11 1/2 130 95 160 120

Standard torques 1-60 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

2 Electrical system

2-1 Overview ........................................................2

2-1-1 Components ........................................................ 2
2-1-2 Communication protocol ...................................... 4

2-2 Battery ...........................................................6

2-2-1 Exterior and specifications ................................... 6
2-2-2 Functions ............................................................. 8
2-2-3 Wiring .................................................................10
2-2-4 Test ....................................................................11
2-2-5 Maintenance .......................................................14
2-2-6 Removal and installation .....................................16

2-3 Controllers and related devices ................17

2-3-1 Exterior and specifications ..................................17
2
2-3-2 Circuit and functions ...........................................18

Electrical system
2-3-3 Wiring .................................................................20
2-3-4 LED fault codes ..................................................23
2-3-5 Test ....................................................................24
2-3-6 Removal and installation .....................................26

2-4 Miscellaneous loads...................................29

2-4-1 Fuse box.............................................................29
2-4-2 DC-DC converter ................................................32
2-4-3 Lamp group ........................................................35
2-4-4 OSS controller ....................................................36
2-4-5 Horn ...................................................................38
2-4-6 Optional speed limit ............................................39

2-5 Instrument panel .........................................43

2-5-1 Display and buttons ............................................43
2-5-2 Diagnosis ............................................................48
2-5-3 Calibration ..........................................................52

2-6 Application “EasyView” .............................58

2-6-1 Installation and execution ....................................58
2-6-2 Controller firmware update ..................................64
2-6-3 “Administration” menu description .......................68
2-6-4 “Tools” menu description.....................................69
2-6-5 Main page – Test Menu ......................................78
2-6-6 Main page – Calibration Menu.............................86
2-6-7 Initial settings ....................................................110

2-7 Handling faults on instrument

panel/EasyView .........................................116
2-1 Overview

2-1-1 Components
Drive motor controller Pump motor

Pump motor controller Battery cover Horn Accelerator Drive motor

Line contactor F/R Unit DC-DC Converter EM Brake

Line fuse Control valve

(containing F/R switch and hydraulic switches) 0809E

Fig. 2-1

Overview 2-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 This model is equipped with an electrical system that
consists of the following components:

• Battery supplies power to the electrical system.

[Section 2-2]

• Motor, controllers, and related devices provide

the vehicle with necessary drive and pump power
based on their interaction with sensors, switches,
relays, and actuators as well as a number of
parameter settings. [Section 2-3]

• Fuse box protects all the DC loads from over

current by cutting off the power supply to a load
when the load is supplied with a current higher
than the limit. [Section 2-4-1]

• DC-DC converter converts the battery’s high

voltage to 12V for low voltage loads [Section 2-4-2]

• Other DC loads, activated by direct demand from

the operator, work independently from controllers.
2
Primarily, they are not regulated by controllers nor

Electrical system
is their purpose to signal them. However, they may
interact with them in some configurations. These
loads include the lamp group and horn. [Section 2-
4-3 to 2-4-5]

• Instrument panel monitors the vehicle to inform

the user of its conditions and provides basic
functions for mode setting, diagnosis, and
calibration [Section 2-5]

• Software for diagnosis and calibration provides

the same kinds of functions as the instrument
panel but in more specific detail [Section 2-6]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-3 Overview

 2-1-2 Communication protocol

Fig. 2-2
In order to enable all the electrical devices of a vehicle
and provide the user with diagnosis and parameter
calibration functions, data sharing between these
controllers and instrument devices is required. For this
purpose, CAN (Controller Area Network) is used as a
standard protocol.

A circuit diagram displaying communications between

major electrical devices using the CAN protocol is shown
above.

NOTICE: See Section 2-6 for how to install the

application to check the vehicle’s conditions and to
perform parameter calibration via CAN communication.

Overview 2-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Display
Drive
Controller Calibrating
PC Software

Pump
Controller

UART Fig. 2-3

Drive
Controller
Calibrating
PC Software
2

Electrical system
CAN

Display
Pump
Controller Fig. 2-4

This CAN communications effectively overcomes the

shortcomings of the point-to-point communication-based
UART (Universal Asynchronous Receiver/Transmitter)
system that has been widely used in the past. Due to
one-to-one communication between individual devices,
the UART system is limited in the number of available
communication devices and cabling as well as in
improving vehicle performance.

The diagrams above compare CAN and UART

communications.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-5 Overview

2-2 Battery

2-2-1 Exterior and specifications

Basic conditions
Items Spec.
Final discharge voltage 42.5 V
Electrolye Refined dilute sulfuric acid
Replenisher Distilled water
Insulation resistance Over 1 MΩ

Fig. 2-5
Specific gravity by temperature

Temperature
Charging
-15°C -5°C 0°C 5°C 15°C 25°C 35°C 45°C level
(5°F) (23°F) (32°F) (41°F) (59°F) (77°F) (95°F) (113°F)
1.108 1.101 1.098 1.094 1.087 1.08 1.073 1.066 0%
1.118 1.111 1.108 1.104 1.097 1.09 1.083 1.076 5%
1.128 1.121 1.118 1.114 1.107 1.1 1.093 1.086 10%
1.138 1.131 1.128 1.124 1.117 1.11 1.103 1.096 15%
1.148 1.141 1.138 1.134 1.127 1.12 1.113 1.106 20%
1.158 1.151 1.148 1.144 1.137 1.13 1.123 1.116 25%
1.168 1.161 1.158 1.154 1.147 1.14 1.133 1.126 30%
1.178 1.171 1.168 1.164 1.157 1.15 1.143 1.136 35%
1.188 1.181 1.178 1.174 1.167 1.16 1.153 1.146 40%
120% 1.191 1.188 1.184 1.177 1.17 1.163 1.156 45%
121% 1.201 1.198 1.194 1.187 1.18 1.173 1.166 50%
1.218 1.211 1.208 1.204 1.197 1.19 1.183 1.176 55%
1.228 1.221 1.218 1.214 1.207 1.2 1.193 1.186 60%
1.238 1.231 1.228 1.224 1.217 1.21 1.203 1.196 65%
1.248 1.241 1.238 1.234 1.227 1.22 1.213 1.206 70%
1.258 1.251 1.248 1.244 1.237 1.23 1.223 1.216 75%
1.268 1.261 1.258 1.254 1.247 1.24 1.233 1.226 80%
1.278 1.271 1.268 1.264 1.257 1.25 1.243 1.236 85%
1.288 1.281 1.278 1.274 1.267 1.26 1.253 1.246 90%
1.298 1.291 1.288 1.284 1.277 1.27 1.263 1.256 95%
1.308 1.301 1.298 1.294 1.287 1.28 1.273 1.266 100%

* Formula: D25 = Dt + 0.0007(t-25)

D25: converted specific gravity at 25°C (77°F)
Dt: specific gravity at t°C
t: temperature of the electrolyte when its specific gravity was measured (°C)

Battery 2-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Battery compartment dimension
Battery compartment dimension (mm)
Models
Length Width Height
B15T-7 528 992 (842) 2) 698
1) 2)
B18T-7 638 (608) 992 (842) 698
2)
B18TL-7 746 992 (842) 698
B20T-7 638 (608) 1) 992 (842) 2) 698
2)
B20TL-7 746 992 (842) 698
B16X-7 638 (608) 1) 992 (842) 2) 698
1) 2)
B18X-7 638 (608) 992 (842) 698
B20X-7 638 (608) 1) 992 (842) 2) 698
1)
When “BS type battery” is selected (choose a battery capacity that is compatible with the following capacities:
575/630/690 Ah)
2)
When “DIN type battery” is selected

Recommended battery dimension and weight

Min/max Dimension (mm) Capacity (Ah)
Models
B15T-7 (36V)
weight
(kg)
700/945
L
519
W
980
H1
610
H2
625
h
585
BS
Norminal / max
660/770 ( 850)3)
DIN
Norminal / max
-
2
B15T-7 (48V) 700/833 519 980 610 625 585 440/575 (600)3) 460/500

Electrical system
B18T-7 (36V) 800/1200 627 980 610 625 585 825/970 (1050)3) -
B18T-7 (48V) 800/1057 627 980 610 625 585 510/690 (750)3) 525/625
B18TL-7 (48V) 800/1057 738 980 610 625 585 600/ - 690/750
B20T-7 (36V) 1050/1200 627 980 610 625 585 825/970 (1050)3)
B20T-7 (48V) 1000/1250 627 980 610 625 585 585/690 (750)3) 575/625
B20TL-7 (48V) 1000/1250 738 980 610 625 585 600/ - 690/750
B16X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 3) 575/625
B18X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 3) 575/625
B20X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 3) 575/625
3)
When “special battery” is selected

Fig. 2-6

• Recommended cable length: 1000mm

• Recommended cable size: over 1/0 GA (50mm2)

• Battery connector (BS type): SB350 or SBE320

(confirm the vehicle connector type before installing),
BS connector handle: DIV Part No.D290575

• Battery connector (DIN type): DIN320 (confirm the

vehicle connector type before installing)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-7 Battery

 2-2-2 Functions

A. Characteristics of lead storage batteries

This model uses a lead storage battery as its power

supply to electrical systems.

A lead storage battery comprises the anode/cathode

plates to store electrical energy, a separator to prevent
short circuit in the plates, an electrolyte that acts as an
electrical conductor and agent within the battery, a
battery jar made of special plastics that houses these,
and a cover, plus an electrode that serves a gateway for
electrical energy, and various other fittings.

• Anode plate: The anode plate consists of tubes

inserted into each core metal of the lead alloy grid,
an active material (lead powder) filled between the
tube and the core metal, and a sealer that seals
the top and bottom of the tubes to prevent the
active material from getting out. This type of pole
plate is called a grid anode plate that features long
service life and high performance.

• Cathode plate: Having the lead alloy grid coated

with an active material (a paste made of lead
powder and a dilute sulfuric acid), this plate is
called a paste type cathode plate.

• Electrolyte: The electrolyte used in the battery is

a mixture of a high-purity, colorless and odorless
concentrated sulfuric acid (KSM 1203) and purified
water, of which the specific gravity is 1.280 (25°C,
77°F) at a specified level when fully charged.

• Separator: The separator features high

resistance to acid and oxidization, long longevity,
and low electrical resistance.

Battery 2-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 B. BDI (battery discharge indicator)

The BDI (battery discharge indicator) informs the

operator of the current charge level of the battery. In
proportion to this level, 1 to 10 segments are displayed
on the instrument panel.

BDI value determining process

Lead storage batteries have a large voltage drop in

driving and front end operations. And their voltages often
increase when they are not loaded. Given this voltage
fluctuation, the value on the BDI is determined as follows:

• Though the battery voltage is detected in real time,

the detection is not immediately reflected on the
BDI because the voltage continuously fluctuates.

• Only when the detected battery voltage has

remained lower than the BDI value for a specified 2
period of time (tens of seconds), the BDI

Electrical system
decreases its percentage value by 1%. This time
delay is make sure that the voltage decrease is
due to an actual battery discharge rather than a
temporary fluctuation. Thus the BDI value
continues to decrease by 1% at every elapse of the
seconds as long as higher than the actual voltage.

• The BDI value never increases unless the vehicle

is keyed off and on again. It is because, no matter
how frequently temporal voltage increases occur,
the battery is basically supposed not to be actually
recharged while the vehicle is keyed on.

BDI value reset after battery charge

The only way the BDI value increases is to reset it by

charging the battery under the following conditions:

• The BDI segments have not been more than 6

before the battery is charged.

• The battery has been fully charged before the

vehicle is keyed on.

In case you have charged a battery whose BDI segments

were 7 or more, the BDI leaves the value as it was before
the battery charge until the actual voltage becomes lower
than its BDI value.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-9 Battery

 2-2-3 Wiring
Terminal Wiring Terminal Wiring Connection
Connection (terminal no.)
no. color no. color (terminal no.)
F_CONN. A (FINGERTIP)
FUSE BOX (A) (10)
BATTERY (1)
RD
(+) F_CONN. A (FINGERTIP)
EMERGENCY SW (OPT)
(5)
F/R UNIT (6) POWER (OPT) (2)
F/R UNIT (7) DIODE-COMP. (2)
DC-DC CONVERTER (1) LIFT SOL VALVE (B)
BATTERY
DC-DC CONVERTER (6) BK FAN RELAY (OPT) (30)
(-)
FLASHER UNIT (OPT) (86) CONTROLLER FAN (2)
BATTERY EMERGENCY C (1) R-LAMP CONN (2)
BK
(-) BACK-UP BUZZER (OPT)
EMERGENCY C (3)
(2)
SERIAL PORT (1) HORN (2)
INSTRUMENT MONITOR (6) L-LAMP CONN (2)
BACK UP LAMP (OPT) (85) LICENCE LAMP (OPT) (2)
OPT LAMP CONN. (2)

Battery 2-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2-2-4 Test

A. Battery condition inspection

A weak battery can cause or contribute to problems in the

Logic Control Board and power circuits. Verify that the
battery is in good condition before troubleshooting other
areas.

Preliminary steps

1. Verify that there is proper polarity at the battery

connector and the control panel. The positive
cable should be at the line fuse and the negative
at the negative on the control panel.

When the vehicle is operational

<Battery load test> 2
1. Turn the range switch on the multimeter to read

Electrical system
battery voltage.

2. Connect the battery

3. Connect the multimeter leads between positive

(+) cable connection (1), and negative (-) cable
connection (2).

4. In a safe area, operate the hydraulic system,

(hold tilt lever to maximum position momentarily)
while reading the voltage indicated on the
multimeter.

5. If the indication is less than the limit (34.5 V for Fig. 2-7
a 36 V model; 45.6 V for a 48 V model), the
battery needs to be charged or repaired before
continuing to troubleshoot.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-11 Battery

 When the vehicle is not operational and the battery is the suspected cause
<Cell voltage test>

1. With the vehicle powered up and the pump (Idle)

motor running, measure the voltage at each cell.
 Normal voltage should be between 1.95V and
2.12V per cell. If the voltage on each cell is
below 1.95V, the battery must be charged or
repaired before continuing to troubleshoot.
 The indication between cells should not differ
more than 0.05 volts. If it does, the battery
must have an equalizing charge or be repaired.
<Hydrometer test>

1. Test each cell of the battery with a hydrometer.

 If the specific gravity indication is below 1.140,
the battery must be charged. The battery is
fully charged if the indication is 1.265 to 1.285
(See Section 2-2-1).
 The indication between cells should not differ
more than 1.020. If it does, the battery needs
an equalizing charge or needs to be repaired.

Battery 2-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 B. Resistance to chassis

Resistance between any point in the truck wiring and the

chassis should be a minimum of 10,000 Ω.

Many malfunctions are caused by shorts to chassis.

Usually, two shorts must exist before a malfunction will
occur. But, since batteries can have chassis leakage,
only one short to chassis in the truck wiring can cause
problems. To prevent problems because of shorts, do the
following:

1. Disconnect the battery and discharge the

controller.

2. Randomly measure any component connection

or wiring connection in respect to the lift truck

2
chassis for a minimum resistance of 10,000 Ω.
 Any test point with low resistance must have
the short to chassis removed.

Electrical system
3. Always keep batteries clean to minimize current
leakage to the chassis.

4. Routinely clean the brush dust from the motors.

5. Be sure that all attachments, such as horns and

lights are designed for no chassis connection (a
two wire system).

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-13 Battery

 2-2-5 Maintenance
The care and maintenance of batteries is most important
to maximize battery life and efficient vehicle operation.
Periodic inspection and service will increase the life of
batteries. Special attention should be given to the rules
that follow:

• Keep batteries clean at all times. Cleaning will

prevent corrosion, current leakage and shorts to
the chassis. Tighten all vent plugs, wash the
battery with water and a brush, then dry it with an
air hose. It may be necessary to use a baking soda
solution if water alone will not clean the top of the
battery.

• Add enough water to cover the plates before

charging. This will ensure the proper chemical
reaction over the entire plate surface. After
charging is complete, add water until it is about
12.7 mm (0.50 in) above the plates. Use distilled
water or water that has tested free from minerals.

• Charge the battery correctly. A battery should be Min. level Max. level
(refilling required) (normal)
discharged to 80% of its capacity then fully
recharged. It should cool four to eight hours to
allow the voltage to stabilize before being put back
into use. The battery should have an equalizing Float Float
charge (an extra three or four hour charge at a low 0810E

Fig. 2-8
finish rate) once a month to make sure all cells are
in a fully charged condition. Properly charged
batteries should be identified to prevent low
batteries from being installed in vehicles.

• Operation with a low battery must be prevented.

Low battery operation may damage the battery and
will cause a current in the electrical system that is
higher than normal. High current draw due to a low
battery will damage contactor tips and shorten
motor brush life.

Battery 2-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 • The battery's maximum temperature is critical. The
electrolyte temperature should never exceed 55°C
(131°F) either while operating or charging.
Overcharging a battery will cause it to overheat
and its plates to warp. Maximum battery life will
result from maintaining 25°C (77°F) electrolyte
temperature. Most of the charging equipment is
fully automatic but should be checked periodically
to ensure proper working order.

Electrolyte temp. Charging

5°C to 25°C
110%–125%
(41°F to 77°F)
-10°C to 5°C
125%–140%
(14°F to 41°F)
-15°C to -10°C
140%–150%

2
(5°F to 14°F)
Below -15°C (5°F) Not chargeable
• Keep accurate battery records. Regular battery

Electrical system
readings should be taken with a battery tester or
voltmeter and recorded. The specific gravity and
voltage of each cell should be checked and
recorded at least once a month. This inspection
should be made after an equalizing charge.
Readings should never be taken directly after
water has been added. Records of all battery
maintenance should be made and filed so it will be
known which batteries are being mistreated or
wearing out.

NOTICE: Repairs should be made immediately otherwise

the battery may become damaged. Batteries stored in a
discharged condition may be difficult to recharge due to
sulfate formation.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-15 Battery

 2-2-6 Removal and installation

WARNING
Careless use of the battery may
cause an electric shock.
Be sure to follow the safety precautions
given in Section 1-4.

CAUTION
A short-circuit may occur in the
course of removal, transport, and
installation of batteries.
Always ensure that the battery is
covered with an insulating material
(polywood) before removing and
installing it and no metallic material
contacts the top of battery cells.

1. Park the vehicle.

2. Lower the forks and tilt the mast forward until the
tips of the forks touch the ground.

3. Turn off the key switch. (1) Battery connector

4. Disconnect battery connector (1).

5. Place the steering column vertically and move

the seat back completely.
0811E

Fig. 2-9

6. Open hood latch lever (2) that holds the seat and
battery cover.

7. Raise the seat and battery cover.

8. Discharge the power supply module by keeping

the key switch on for approx. 30 seconds twice. (2) Hood latch lever

NOTICE: Failure to discharge the power supply module

0812E
may cause an electric shock. Fig. 2-10

9. Remove the battery using a hoist.

10. To install the battery, perform the procedure

above in the reverse sequence.

Battery 2-16 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

2-3 Controllers and related devices

2-3-1 Exterior and specifications

Line fuse

2
Line contactor Right drive motor controller Left drive motor controller Pump motor controller

Electrical system
0813E
Fig. 2-11

Items Spec.
Voltage 36/48 V
PWM frequency 10 kHz
Drive maximum current 450 A
Pump maximum current -40°C to +50°C (-40°F to 122°F)
Controller
Operating ambient temperature
-40°C to +95°C (-40°F to 203°F)
range
Maximum temperature +95°C (203°F)
IP degree (dust & water proof) IP65
Operating Voltage 36 VDC
Coil Resistance 94Ω (20°C, 68°F)
Line contactor Pull In Voltage 24 VDC
Drop Out Voltage 7.2 VDC
Coil Power Dissipation 21 W
Voltage rating 80 V
Line fuse Current rating 500 A
Cold Resistance 0.06 mΩ

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-17 Controllers and related devices
 2-3-2 Circuit and functions

Fig. 2-12

Controllers and related devices 2-18 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Key on  power supply to controller
This model is equipped with two drive motors and one
pump motor, which are controlled by their respective
controllers. Turning on the key switch causes the
controllers to be powered at their pins #1.

Current to line contactor  power supply to motor

Once the controllers are supplied with power, the magnetic

coil built in the line contactor (Fig. 2-13) is energized by
current flowing between pins 6 and 13 of the left drive
motor controller. The contactor’s two contacts then will
contact each other to close the circuit between the battery
and the three controller inverters. In this circuit, the battery
power is converted into a 3-phase AC power that runs the
motors through each set of U.V.W. connections. The line
contactor is equipped with a 500A fuse which prevents
overcurrent.
2
Motor controllers

Electrical system
The three controllers are connected with the following
sensors, switches, relays, and actuators.
• Key switch
• Emergency switch
• Forward/backward unit
Fig. 2-13
• Accelerator
• Seat switch
• Brake pedal switch
• Parking brake switch
• EM brake
• Steering angle sensor
• Hydraulic control switches
• Fan relay
• Backup relay
• Lift solenoid valve relay

Supplied with DC power, these devices interact with the

controllers, which based on a number of parameter settings
activate or receive data from them to control the motors.

In terms of hardware, the three motor controllers are

identical, but each is programmed with different kinds of
firmware for different functions.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-19 Controllers and related devices
 For detailed explanations of how the drive and pump
motors work, see Section 3-2-2 and 4-2-2 respectively.

2-3-3 Wiring
Drive motor controllers use a 35 pin AMP connector.

Controller connector Fig. 2-14

Left drive motor controller connector pins Harness Fig. 2-15

Wiring Wiring
Pin no. Connection (terminal no.) Pin no. Connection (terminal no.)
color color
Left Drive Controller (12) 8 VO LM Thermal (1)
Pump Controller (1) 10 OR Left Drive Controller (1)
Lift Sensor (1) 12 OR Left Drive Controller (1)
Auto Tilt SW3 (1) FAN Realy (86)
13 OR/RD
Mast Tilt SW2 (1) EM CONN A (4)
Height SW1 (1) Right Drive Controller (23)
Tilt Lever (1) Pump Controller (23)
DC-DC Converter (3) 23 GN CONN A (13)
1 OR
F_CONN A (6) CAN Port (7)
OSS Controller 2P (1) F_CONN A (3)
Pedal Brake SW (1) 24 GN Angle Sensor (2)
CONN A (1) CONN A (4)
25 RD/WH
F/R Unit (2) Angle Sensor (1)
Right Drive Controller (1) LM Encode (1)
26 RD
Right Drive Controller (11) Accelerator (3)
Left Drive Controller (10) 28 BU Serial Port (7)
2 RD/BK FAN Relay (85) 29 VO Serial Port (2)
3 YL Lift SOL Relay (85) 30 RD CONN A (5)
5 WH/RD EM CONN A (3) 31 LG LM Encode (3)
6 BR EM SW (1) 32 GY LM Encode (4)
Accelerator (1) Right Drive Controller (23)
CONN A (2) Pump Controller (23)
7 WH LM Encoder (2) 35 YL CONN A (13)
LM Thermal (2) CAN Port (7)
OSS Controller 8P (6) F_CONN A (3)

Controllers and related devices 2-20 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Wiring Wiring
Pin no. Connection (terminal no.) Pin no. Connection (terminal no.)
color color
Seat SW (2)
Seat Belt SW (2)
Angle Sensor (3)

Note) Consult the motor controller circuit in Fig. 2-13.

Right drive motor controller connector pins

Wiring Wiring
Pin no. Connection (terminal no.) Pin no. Connection (terminal no.)
color color
Left Drive Controller (12) 8 YL RM Thermal (1)
Pump Controller (1) EM CONN A (2)
13 YL/GN
Lift Sensor (1) F_CONN B (2)
Auto Tilt SW3 (1) Left Drive Controller 23)
Mast Tilt SW2 (1) Pump Controller (23)
Height SW1 (1)
Tilt Lever (1)
23 YL/BK CAN Port (7)
CONN A (13)
2
DC-DC Converter (3) F_CONN A (3)
1 OR

Electrical system
F_CONN A (6) 26 RD RM Encoder (1)
OSS Controller 2P (1) 28 BU/RD Serial Port (8)
Pedal Brake SW (1) 29 BU/WH Serial Port (3)
CONN A (1) 31 OR/RD RM Encoder (3)
F/R Unit (2) 32 YL RM Encoder (4)
Left Drive Controller (1) Left Drive Controller (23)
Right Drive Controller (11) Pump Controller (23)
Left Drive Controller (10) 35 YL CONN A (13)
2 YL/RD F_CONN B (1) CAN Port (7)
5 BK EM CONN A (1) F_CONN A (3)
RM Encoder (2)
7 WH
RM Thermal (2)

Note) Consult the motor controller circuit in Fig. 2-13.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-21 Controllers and related devices
 Pump motor controller connector pins
Wiring Wiring
Pin no. Connection (terminal no.) Pin no. Connection (terminal no.)
color color
Left Drive Controller (1) 14 WH/BK Height SW1 (2)
Left Drive Controller (12) 16 BK Accelerator (5)
Lift Sensor (1) 17 BR/YL Diode AS-Park (2)
Auto Tilt SW3 (1) 19 YL/GN Auto Tilt SW3 (2)
Mast Tilt SW2 (1) 20 YL/BU Tilt Lever (2)
Height SW1 (1) 21 OR/BK Pump Controller (34)
Tilt Lever (1) 22 YL Lift Sensor (6)
DC-DC Converter (3) Left Drive Controller 23)
1 OR
F_CONN A (6) Right Drive Controller (23)
OSS Controller 2P (1) 23 YL/BK CAN Port (7)
Pedal Brake SW (1) CONN A (13)
CONN A (1) F_CONN A (3)
F/R Unit (2) 24 GN/YL Lift Sensor (7)
Right Drive Controller (1) CONN A (9)
Right Drive Controller (11) 25 RD/GN Lift Sensor (2)
Left Drive Controller (10) Pressure Sensor (1)
2 BU/BK F_CONN B (3) PM Encoder (1)
26 RD
3 GN F_Back Up Relay (85) Accelerator (6)
4 WH/GN Tilt Solenoid (2) 28 BU Serial Port (9)
5 BU/GN F_CONN B (5) 29 VO Serial Port (4)
6 YL/WH Pressure Sensor (2) 31 GN/BK PM Encoder (3)
Lift Sensor (5) 32 BR PM Encoder (4)
Accelerator (4) 33 BK/WH Lift Sensor (8)
7 WH/BU CONN B (11) 34 OR/BK Pump Controller (21)
PM Encoder (2) Left Drive Controller (23)
PM Thermal (2) Right Drive Controller (23)
8 GN/RD PM Thermal (1) 35 YL CONN A (13)
9 BU Mast Tilt SW2 (2) CAN Port (7)
10 VO Lift Sensor (4) F_CONN A (3)
Tilt Solenoid (1)
13 BU/WH F_CONN B (4)
F_Back Relay (86)
Note) Consult the motor controller circuit in Fig. 2-13.

Controllers and related devices 2-22 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 2-3-4 LED fault codes
There is a way to see the current fault code without the
instrument panel and EasyView application: On each
controller, a pair of LEDs are installed, capable of
indicating the whole list of fault codes.

Each code consists of two digits. The red LED flashes

once to indicate that the first digit of the code will follow;
the yellow LED then flashes the appropriate number of
times for the first digit. The red LED flashes twice to
indicate that the second digit of the code will follow; the
yellow LED flashes the appropriate number of times for Fault code indicator
LEDs 0814E
the second digit. Fig. 2-16

If the current fault code is “23” for example, the LEDs will
display as follows:

RED YELLOW RED YELLOW 2

(first digit) (2) (second digit) (3)

Electrical system
0815E

The whole list of fault codes is described in Section 2-7.

The table below shows some other cases than indicating
a fault code:

Display Status
Neither LED Controller is not powered on; or vehicle
illuminated has dead battery; or severe damage.
Yellow LED
Controller is operating normally.
flashing
Yellow and
red LEDs Controller is in Flash program mode.
both on solid
No software loaded, or an internal
hardware fault detected by the
Red LED on
Supervisor or Primary microprocessor.
solid
Cycle KSI to clear. Reload software or
replace controller if necessary.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-23 Controllers and related devices
 2-3-5 Test

A. Controller

Measure the diode voltage of the AC MOSFET circuit

(Fig. 2-17) inside the controller to check for burnt
damages.

1. Remove the cables and harness connected to

the controller and discharge the internal
capacitor completely.

2. Using a multimeter, measure the voltage of the

diode (0.3–0.6V) and check if it is normal (Fig. 2-
18 and 2-19).

Diode Red lead Black lead Result

Approx.
Test 1 U, V, W B+
0.4–0.6 V
Approx.
Test 2 B- U, V, W
0.4–0.6 V

 Test 1: Measure voltage with the red lead to B- Fig. 2-17

and the black lead to U, V, and W.

○
W

○
V

-
○ ○
U ○
- ○
-

 Test 2: Measure voltage with the red lead to U, Fig. 2-18

V, and W, and the black lead to B+.

○
W

○
+
○ ○
+
+ ○
V

○
U

Fig. 2-19

Controllers and related devices 2-24 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Line contactor and fuse

Normal: 70 to 110 Ω
2

Electrical system
Fig. 2-20
Line contactor

Line fuse Fig. 2-21

1. For the line contactor and the line fuse, connect

an ohmmeter at the points shown in the figure
and check if it measures the values as specified.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-25 Controllers and related devices
 2-3-6 Removal and installation

A. Drive motor controller panel

(1) Drive motor controller panel (2) Connector (3) Bolt (4) Washer

B
A

0816E

Fig. 2-22
NOTICE: The controller contains ESD (Electro Static
Discharge) sensitive components. Use the appropriate
precautions when connecting, disconnecting or handling it.

Preliminary steps

1. Turn off the key switch.

2. Remove the top cover on the counterweight (See

Section 7-4).

Procedure

1. Remove connectors (2) from drive motor

controller panel (1).

2. Remove bolts (3) and washers (4) and then remove

drive motor controller panel (1) from the frame.

3. Follow the steps above in the opposite order to

install the drive motor controller.

Controllers and related devices 2-26 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Drive motor controllers, line contactor, and line fuse
(13) Bolt, Washer (14-1) Bracket
(1) Bolt
(12) Drive motor controller (14) Bracket (15) Bolt
(2) Nut
(3) Washer
(4) Line contactor
(5) Bracket

(6) Drive motor controller plate

(7) Bolt

(8) Bolt

(9) Fuse
(10) Washer
(11) Nut

(16) Drive motor controller panel

1. Remove nuts (2) and washers (3).

Fig. 2-23
0817E

Electrical system
2. Remove nuts (11) and washers using a 5 mm
socket wrench and then remove fuse (9).

3. Remove bracket (5) from line contactor (4).

4. Remove sets of bolts (7) and washers and sets

of bolts (8) and washers and then remove drive
motor controller plate (6) and line contactor (4).

5. Remove nuts (15) and washers using a 5 mm

socket wrench and then remove brackets (14)
and (14-1).
 Installation torque: 9.6±0.9 N·m (7.1±0.7 lb·ft)

6. Remove eight bolts (8) and washers and then

remove drive motor controller (12) from drive
motor controller ass’y (16).

7. Follow the steps above in the opposite order to

install the drive motor, line contactor, and line
fuse.
 Apply a small amount of D557047 Thermal
Joint Compound on the control panel plate and
mating surface prior to assembly.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-27 Controllers and related devices
 C. Pump motor controller

(1) Pump motor controller panel (2) Connector

(3) Bolt

(4) Bolt

(5) Pump motor controller

0818E

Fig. 2-24
The pump motor controller panel is located opposite to
the drive motor controller panel.

NOTICE: The controller contains ESD (Electro Static

Discharge) sensitive components. Use the appropriate
precautions when connecting, disconnecting or handling it.

Preliminary steps

1. Turn off the key switch.

2. Remove the top cover on the counterweight (See

Section 7-4).

Procedure

1. Remove connector (2) from pump motor

controller assembly (1)

2. Remove bolts (4) and washers and then remove

pump motor controller panel (1).

3. Remove bolts (3) and washers and then remove

pump motor controller (5).

4. Follow the steps above in the opposite order to

install the pump motor controller.

Controllers and related devices 2-28 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
2-4 Miscellaneous loads

2-4-1 Fuse box

A. Function and composition

To protect DC loads from overcurrent, the fuse box is

equipped with the following terminals:

Rated
Sets Items
capacity
DC-DC CONVERTER, HORN 20 A
KEY SWITCH 10 A
FAN, FINGERTIP (OPT) 5A
A
SOL VALVE, POWER (OPT) 5A
BACK-UP LAMP (OPT) 5A
5A
2
LEFT HEAD LAMP (OPT) 5A

Electrical system
10 A
OPT LAMP 5A
RIGHT HEAD LAMP,
B 5A
LICENCE LAMP (OPT)
STROBE, FLASHER LAMP
5A
(OPT)
Fig. 2-25
REAR LAMP 5A

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-29 Miscellaneous loads

 B. Wiring

FUSE BOX (A) FUSE BOX (B)

Terminal Wiring Terminal Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 (n/a) 1 GN/YL LIGHT SW (OPT) (7)
2 RD/YL F/R UNIT (4) 2 YL/WH FLASHER UNIT (OPT)
(85)
STOP LAMP SW (OPT) (2) OPT LAMP CONN. (8)
BACK UP LAMP (OPT) (30) 3 OR/RD DC-DC CONVERTER (5)
F_BACK UP RELAY (OPT) (30) LIGHT SW (OPT) (2)
3 OR/RD DC-DC CONVERTER (5) 4 YL/GN R-LAMP CONN. (1)
LIGHT SW (OPT) (2) LICENCE LAMP (OPT) (1)
4 (n/a) 5 BU/RD OPT LAMP CONN. (4)
5 (n/a) 6 BU/YL LIGHT SW (OPT) (3)
6 OR/RD DC-DC CONVERTER (5) 7 (n/a)
LIGHT SW (OPT) (2) 8 (n/a)
7 (n/a) 9 BU/GN L-LAMP CONN. (1)
8 (n/a) 10 BU/YL LIGHT SW (OPT) (3)
9 RD/BU DC-DC CONVERTER (2) 11 (n/a)
10 RD BATTERY (+) 12 (n/a)
11 (n/a)
12 (n/a)

Miscellaneous loads 2-30 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 C. Removal and installation

Preliminary steps

1. Turn off the key switch.

2. Remove the top cover on the counterweight (See

Section 7-4).

Procedure

1. Remove harness connectors (4) from fuse box

(1). (1) Fuse box
(2) Bolt
2. Remove bolts (2) and washers (3) and then (3) Washer

remove fuse box (1). (4) Connector

0819E
Fig. 2-26
2

Electrical system
3. To install the fuse box, perform the procedure
above in the reverse sequence.
 When you reconnect the connectors, note the
connection layout at the right.

Fig. 2-27

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-31 Miscellaneous loads

 2-4-2 DC-DC converter

A. Exterior and specifications

Fig. 2-28

Items Spec.
Part no. 300612-00121
Max Power 300 W
Supply Voltage 24/36/48 VDC
Output Voltage 12V ± 5%
Output Current Max. 25 A
Operating Temperature -30°C to +55°C (-22°F to 131°F)

Miscellaneous loads 2-32 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 B. Circuit and functions
12 FUSE BOX(A)
11
2/RD 10 D/D CONVERTER
98/RD/BU 9 20A HORN
8 KEY SWITCH
59/RD/WH 7 10A
43/OR/RD 6
5 FAN/FINGERTIP(OPT)
5A
4 SOL VALVE/POWER
5A
43/OR/RD 3
2/RD 2 BACK-UP
KEY SWITCH 5A
1 5A
ENABLE 3 3/OR
BATT + 2 98/RD/BU 12 FUSE BOX(B)
12V + 5 43/OR/RD 11
BATT - 1 1/BK 10
12V - 6 1/BK 9 L LAMP
5A
+ BATTERY 8
DC/DC CONVERTER 7 10A
6
5 OPT LAMP
5A
- BATTERY 4 R LAMP/LICENCE
5A
43/OR/RD 3

2
2 5A STROBE/FLASHER
1 REAR LAMP
5A
1/BK

Fig. 2-29

Electrical system
The DC-DC converter converts high voltage power from
the battery (48 V or 36 V) to a 12 V power that is suitable
for a number of loads.

Each of its terminals function as follows:

• Terminal 3 (ENABLE) receives power from the

battery to activate the DC-DC converter. It is also
connected with a key switch line to protect it from
an overcurrent higher than 10 A.

• Terminals 2 and 1 are connected to the positive

and negative poles of the battery respectively.
Unlike Terminal 3, these terminals are responsible
not to activate the converter but to resend battery
power to other loads. They are protected from an
overcurrent higher than 20 A

• Terminal 5 (12V+) is connected to the fuse box’s

terminals which cover the loads to be powered from
the converter. The power from the battery is
converted to 12 V and then sent through the fuse box
to the loads.

• Terminal 6 (12V-) is connected to the negative poles

of the loads that are to be applied at 12 V. Namely,
those currents which have passed through the loads
return to this terminal.

In this model, the terminals 1 (BATT+) and 6 (12V-) share

the same line.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-33 Miscellaneous loads

 C. Wiring

Terminal Wiring Terminal Wiring

Connection (terminal no.) Connection (terminal no.)
no. color no. color
F_CONN. A (FINGERTIP) (1) 4 (n/a)
1 BK F_CONN. A (FINGERTIP) (5) FUSE BOX (A) (6)
BATTERY (-) FUSE BOX (A) (3)
5 OR/RD
FUSE BOX (A) (9) FUSE BOX (B) (3)
2 RD/BU
F_CONN. A (FINGERTIP) (7) LIGHT SW (OPT) (2)
SAFETY RELAY (OSS) KEY SW F_CONN. A (FINGERTIP)
(1) (1)
3 OR 6 BK F_CONN. A (FINGERTIP)
F_CONN. A (FINGERTIP) (6)
(5)
PUMP CONTROLLER (P1-1) BATTERY (-)

NOTICE: Do not connect 12V output (-) terminal of the

convertor to the (-) tab of the battery. Incorrect power
supply may cause harm to related parts.

Miscellaneous loads 2-34 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2-4-3 Lamp group

HEAD LAMP (OPT)

FRONT COMB-R(OPT)

1/BK
130/YL/GN
94/YL/BU
R-LAMP CONN
2
T/S LAMP-R HEAD LAMP-R

Electrical system
1/BK 2
BACK-UP BUZZER (OPT)
85/RD/GN 1

This model is equipped with a variety of lamps, each with Fig. 2-30
different purpose.

• Head lamps (L/R) illuminate the path in front of the

vehicle

• Rear lamps illuminate the path behind the vehicle

• Backup lamp lights up during reverse drive

• Stop lamp lights up with the brake pedal pressed

• License lamp illuminates the license plate in dark

conditions

These are powered at 12 V from the DC-DC converter.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-35 Miscellaneous loads

 2-4-4 OSS controller
12 FUSE BOX(A)
11
2/RD 10
D/D CONVERTER
98/RD/BU 9 20A HORN

2/RD 4 3 4/YL/RD 4/YL/RD 8

KEY SWITCH
59/RD/WH 7 10A
LEFT 43/OR/RD 6
86/YL FAN/FINGERTIP(OPT)
TRACTION D1-3 56/OR/BK 5
5A
KEY SWITCH
89/RD/GN 4 SOL VALVE/POWER
D1-1 3/OR

D1-12 3/OR ENABLE 3 3/OR

2
BATT + 2 98/RD/BU
1
D1-17 18/BU/RD 17/GN/YL 17/GN/YL 12V + 5 43/OR/RD
1
D1-7 7/WH 7/WH 2 BATT - 1 1/BK
12V - 6 1/BK
SEAT SWITCH
DC/DC CONVERTER
D1-25 25/RD/WH

D1-23(CAN H) 23/YL/BK
D1-35(CAN L) 35/YL

RELAY-LIFT SOL VALVE

RIGHT 7/WH 2
86/YL 85
TRACTION 38/BU/GN 1 SEAT BELT SW 89/RD/GN 86
96/GN/RD 87
89/RD/GN 30
87a
103/BR/YL 2 S/B LAMP
D2-1 3/OR 4
3 BRAKE OIL J2
35/YL
23/YL/BK
6
5
CAN L
CAN H
DIODE-COMP.
D2-23(CAN H) 23/YL/BK 25/RD/WH 1 +12V
96/GN/RD 1
D2-35(CAN L) 35/YL
1 BRAKE OIL 1/BK 2
D2-11 3/OR 6 -12V

4 1/BK B
2 T/S LAMP
J1 96/GN/RD A
3 HEAD LAMP
25/RD/WH 8 +12V
7/WH 7 GND

5 LIFT SOL VALVE

INSTRUMENT MONITOR

PUMP

3 +12V
4 BUZZER
103/BR/YL 5 S/B LAMP

P1-35(CAN L) 35/YL 38/BU/GN 2 S/B SW

17/GN/YL 7 SEAT SW
59/RD/WH 1 B+
P1-23(CAN H) 23/YL/BK
7/WH 6 B-
8 PARKING

P1-1 3/OR 3/OR 1 KEY SW

2 +5

SAFETY RELAY
(OSS CONTROLLER)

Fig. 2-31

This model is equipped with an OSS (operator sensing

system), which keeps the operator from some dangerous
conditions:

Reaction to the operator’s absence from the seat

When the operator leaves the seat, the seat switch opens
and pin 17 on the left drive motor controller gets
ungrounded. Once this condition continues for more than
3 seconds (this period is adjustable with calibration code
11 on the instrument panel or the calibration parameter
Seat Switch Delay on EasyView), the left drive motor
controller signals the right drive motor and pump motor
controllers via CAN communications to stop all the three
motors. As a result, the accelerator pedal, steering wheel,
and all hydraulic controls are disabled to prevent an
unintended command to move the mast ass’y or wheels.

Since the lowering operation could be performed by the

gravitational force even when the pump motor is not
driven, there is another device to prevent this move

Miscellaneous loads 2-36 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 during the operator’s absence from the seat: lift lock
solenoid valve. Installed on the LIFT section block of the
control valve, this valve is opened at a signal from the
drive motor controller when the motor stop mentioned
above is triggered. When the lift lock solenoid is open,
the oil in the lift cylinders is not able to return and thus the
mast stands still even with the LIFT lever at the lowering
position. For a detailed explanation of hydraulic operation
in the LIFT section with this valve open, see Section 5-2-
2 B.

Warning on the seat belt’s release

While the seat belt is released, the seat belt switch is

open to unground pin 2 of the OSS controller’s 8-pin
connector. The controller then determines that the seat
belt is not fastened and gives a signal from its pin 5 to the
instrument panel, lighting up the seat belt indicator for 10
seconds.
2

Electrical system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-37 Miscellaneous loads

 2-4-5 Horn

Fig. 2-32
Connected to the fuse box’s terminal is the “DC-DC &
HORN [20A],” which is used to set off an alarm to warn
those nearby.

Miscellaneous loads 2-38 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2-4-6 Optional speed limit

2
②

Electrical system
Fig. 2-33
(1) Radar sensor (2) IAS Controller

A. Function

This option is a function to limit the maximum speed of

the vehicle by detecting the outside or inside, when the
vehicle is moving from outside to inside or from inside to
outside.

B. Specification of added components

1) Controller

Item Spec.

Voltage DC 9V - 32V

Rated voltage DC 12/24V

Current 500mA Max

Ambien temperature -20°C ~ +70°C

Storage temperature -30°C ~ +105°C

BAUD rate Auto

Fig. 2-34
IP grade IP 65

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-39 Miscellaneous loads

 1) Pin information

CONN Pin No. Description

1 Positive (9V-32V)
2 CAN H
3 CAN L
4 Tx
5 Rx
6 Serial GND
7 Serial Enable
P1 8 Negative (GND)
9 Sensor VDD
10 Sensor GND
Sensor Input (Active
11
High)
Sensor Input (Active
12
Low)
13 Digital Out (Attive High)
14 Digital Out (Attive HIgh)

2) Radar sensor

Item Spec.

Function Proximity switch

Range Max. 2,400 ㎝

Power ON LED, Green

Changing mode LED, Orange

Detection LED, Red

IP grade IP 67

Fig. 2-35

3) Pin and circuit information

Fig. 2-36 Fig. 2-37

Miscellaneous loads 2-40 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 C. Selection of speed limit

1. Press the Mode button.

Display
2. "8" is blinking in display.

3. Use the Up/Down buttons to select a mode.

4. If you press the Enter button, “0” is showing.

5. Press the Enter button or after a certain period of

time, “0” disappears and setting is finished.

D. Checking the current mode

1. Press the Enter button. Then, able to see the

Mode button Down button
current mode.

2. After a certain period of time, display turns off by Up button Enter button
itself.
Fig. 2-38 2
Model Mode Description

Electrical system
Mode 1 1500 rpm
Electric Mode 2 2000 rpm
Mode 3 2500 rpm

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-41 Miscellaneous loads

 E. Schematic

Fig. 2-39
The IAS (Indoor auto detection & Speed limit) sensor is
located on the top of the cabin to recognize the ceiling of
workshop, building or warehouse. When the vehicle
moves to the indoor, it generates a signal and
communicates directly with the IAS controller.

Then, the IAS controller generates a signal for speed limit

and communicates with the traction controller. Eventually,
it limits the rpm of the driving motor by sending a signal to
the driving controller through the CAN CONN terminal.

Miscellaneous loads 2-42 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

2-5 Instrument panel

2-5-1 Display and buttons

The instrument panel is located at the center of the
console cover. The symbols shown on the panel indicate
the values of the vehicle system’s essential analog and
digital parameters.

The indicator lamps and buttons are named as follows:

Vehicle speed and fault indicator

Vehicle speed level and F/R direction indicator

BDI (battery discharge indicator) EM brake indicator

2
Seat switch indicator
Brake oil level alarm indicator
Fault indicator
Travel lamp indicator

Electrical system
Turn signal indicator Over-temperature
Seat belt indicator alarm indicator

Brake oil level alarm indicator

[New model only]

Maintenance time
expiry indicator
Steering angle indicator
Message box DOWN button
E-S-H indicator ENTER button
Turtle mode indicator
UP/TURTLE button
E-S-H button 0820E
Fig. 2-33

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-43 Instrument panel

 Left LED Indicators

Located at the left side of the display are four LED

indicators that, when switched on, give the following
information:

0368K

Fig. 2-34

No. Indicators Descriptions

[Fault indicator]
• Lights up in red in the following situations:
- The instrument panel’s communication with the controllers is lost
for 3 seconds.
1
- The circuit board in the instrument panel is failed.
- A fault code appears due to a problem with the vehicle.
- Under normal conditions, the indicator briefly blinks when the key
switch is on or off.
[Travel lamp indicator]
2
• Lights up in green to indicate the vehicle is being driven.

[Turn signal indicator]

3
• Lights up in green to represent the indicated direction (option).

[Seat belt indicator]

4 • Lights up in red for 10 seconds after the seat belt is released
(option).

[Brake oil pressure alarm indicator] – New model only

5
• Lights up in red when the brake oil level is low

Instrument panel 2-44 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Indicator lamps in the display

Located at the center of the instrument panel are

indicator lamps that show the vehicle’s condition.

0368K

Fig. 2-35

No. Indicators Descriptions

[Seat switch indicator]

• This symbol indicates that the seat switch is open. At the appearance
of this symbol, fault code EE flickers and all the vehicle’s functions are
shut down.
• If the operator attempts to put the vehicle in forward or reverse before
6 the seat switch is on, fault code EE (Wrong Start) is displayed.
• If the LIFT/TILT/AUX1/AUX2 lever is activated before the seat switch is
on, fault code FL (Pump Sign On) is triggered.
• When fault code EE or FL occurs and the signal of the respective
function is deleted, the fault code disappears and the vehicle returns to
2
normal condition.

Electrical system
[Steering angle indicator]
7
• The steering angle is indicated in seven segments.
[E-S-H indicator]
• Lights up when shifting the curruent operation mode using the E-S-H
8
button at the bottom of the panel is enabled. The availity of this button
is set in the EasyView application.
[Turtle mode indicator]
9 • Indicates the vehicle is in the turtle mode, which limits its driving speed
to 10 km/h.
[Battery level indicator]
• Battery level, indicated by a 9 segment symbol.
Charge level BDI percent [%]
9 90%<
8 89%–80%
7 79%–70%
6 69%–60%

10 5 59%–50%
4 49%–42%
3 41%–34%
2 33%–26%
1 25%–20%
EL > 20%

• If the battery is completely discharged, the display will signal the alarm
code EL.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-45 Instrument panel

 No. Indicators Descriptions
[Vehicle speed and fault indicator]
• When the Key is in the On position, the vehicle model ID code appears
on the display for 3 seconds.
- Vehicle type (e.g.: C2 [CURTIS
Controller])
- Battery voltage (e.g.: 48V)
- Software program code (e.g.: 56)

11 • After that, the vehicle’s drive speed is displayed in kmh or mph

• Pressing the down button once will allow you to alternate between the
accumulated driving time (hour meter) and distance (odometer) on the
display.
• In the following conditions, the indicator shifts to display the
corresponding fault code (See Section 2-7):
- Seat switch open
- CAN communication between display and controllers is not active
- Main contactor open
[Vehicle speed level and F/R direction indicator]
• Each segment on the indicator dial represents a different speed level,
12
ranging from 0 (no speed) to 9 (maximum speed).
• The position of the F/R switch is displayed in the center.

[EM brake indicator]

13 • When the accelerator pedal is depressed, the indicator turns off; when
completely released, it lights up three seconds after.

[Brake oil pressure alarm indicator]

14
• Lights up in red when the brake oil level is low

[Over-temperature alarm indicator]

• Lights up when a motor or its controller is overheated at a temperature
15 higher than the alarm limit.
• A fault code among E1 to E6 (over-temperature) accompanies this
alarm, depending on which device is overheated.

[Maintenance time expiry indicator]

16
• Lights up to indicate the vehicle is due for maintenance.
[Message box]
17
• Displays the message.

Instrument panel 2-46 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Command and service menu buttons

Located at the bottom are four buttons: E-S-H,

UP/TURTLE, DOWN, and ENTER.

0368K
Fig. 2-36

No. Buttons Descriptions

[E-S-H button]
• With this key, you can shift the operation mode between Economic,
Standard, and High Performance modes in this order.
• This button is only available after it has been set to enabled on
18 EasyView; there are also some parameters applicable to the
respective modes which can be modified only on EasyView (See
Section 2-6).
• Pressing this key when you are in diagnostic mode allows you to see a
circular list of the 10 latest alarms.
[UP/TURTLE button]
2
• This button functions as TURTLE and UP buttons both.

Electrical system
• Pressing this button allows you to toggle between turtle and normal
drive modes.
• In calibration mode, you can adjust the speed at which the vehicle
19 travels in speed limitation mode (calibration no. 84: TURTLE SPEED,
range 500–3500 rpm).
• Pressing this button in calibration or diagnostic mode allows you to
choose the next parameter on display.
• After a parameter is selected in calibration mode, pressing this button
increases the parameter’s numeric value.
[ENTER button]
• Holding this button for 3 seconds simultaneously when the key switch
turns on gives you a selection between calibration and diagnostic
modes.
• Holding this button for 3 seconds while the vehicle is in normal
20
operation allows you to access to diagnostic mode.
• If the display is in diagnostic mode during normal operation, you can
exit this mode by pressing ENTER once more.
• After you choose a parameter or its setting value, pressing ENTER
confirms it.
[DOWN button]
• Pressing this button in calibration and diagnostic mode allows you to
choose the previous parameter on display.
• After a parameter is selected in calibration mode, pressing this button
21
decreases the parameter’s numeric value.
• When the button is held for one second during normal operation, the
display will alternate between showing the accumulated driving time
and distance.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-47 Instrument panel

 2-5-2 Diagnosis

A. Accessing diagnostic mode on the instrument panel

Parameter settings check

In diagnostic mode, you can check the main analog and

digital signals from the vehicle system as follows:

1. Hold ENTER for three seconds.

 If you have performed another task using the
instrument panel, it will enter immediately
diagnostic mode, displaying the symbol “d.” If it
is the first command after startup, the panel
will ask you to select between “c” and “d.”

Hold for 3 sec.

0821E

Fig. 2-37

2. Once you are given the two choices “c” and “d,”
press the down button to select “d” (diagnostic
mode).

Fig. 2-38
3. In diagnostic mode, use the up and down button
to select the parameter number you want to
check (See Section “B. Diagnosis codes”).
 In the speed and warning section, the
parameter’s number is shown (blinking).
 In the time and distance section, the current
value is shown.

4. Operate the vehicle, observing changes in the

parameter value, to test if the vehicle is in normal
Fig. 2-39
conditions.

NOTICE: You can quit the diagnostic mode at any time

even if you have not finished the diagnosis procedure.
NOTICE: If a warning occurs when you are in diagnostic
mode and the vehicle system is normal, the panel will
automatically change the display to show the warning.

Instrument panel 2-48 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Check of stored fault codes

You can see the last 10 faults as follows:

1. Press the E-S-H button to see the three types of

stored fault messages.

Hold for 3 sec.

0822E
Fig. 2-40

 If there is no fault code stored, the number “0”

will appear in the speed and warning section.

2
Fig. 2-41

Electrical system
2. Use the up and down button to choose the fault
code you wish to check.

Fig. 2-42

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-49 Instrument panel

 B. Diagnosis codes

Code Panel display Unit Description Remarks

DRIVE MOTOR
1 rpm Left drive motor’s speed
SPD
D-MOTOR REF
2 rpm Left drive motor’s reference speed
SPD
RIGHT MOTOR
3 rpm Right drive motor speed
SPD
R-MOTOR REF
4 rpm Right drive motor reference speed
SPD
LIFT SENSOR Throttle output
5 V Lift lever’s voltage
OUT for lifting
Voltage on the
6 BATT VOLTAGE V Battery’s voltage
key switch
D-INVERTER
7 °C (°F) Left drive motor controller’s temp.
TEMP
P-INVERTER
8 °C (°F) Pump motor controller’s temp.
TEMP
PUMP MOTOR
9 rpm Pump motor’s speed
SPD
P-MOTOR REF
10 rpm Pump motor’s reference speed
SPD
Throttle A
11 ACCEL 1ST OUT V Accelerator potentiometer voltage output for
driving
Throttle B
ACCEL 2ND Accelerator second potentiometer
12 V output for
OUT voltage
driving
STEER SENSOR Output from the
13 V Steer sensor’s voltage
OUT steer sensor
R-INVERTER
14 °C (°F) Right drive motor controller’s temp.
TEMP
15 D-MOTOR I-U mA Left drive motor’s U-phase current
16 D-MOTOR I-V mA Left drive motor’s V-phase current
17 D-MOTOR I-W mA Left drive motor’s W-phase current
18 R-MOTOR I-U mA Right drive motor’s U-phase current
19 R-MOTOR I-V mA Right drive motor’s V-phase current
20 R-MOTOR I-W mA Right drive motor’s W-phase current
21 P-MOTOR I-U mA Pump motor’s U-phase current
22 P-MOTOR I-V mA Pump motor’s V-phase current
23 P-MOTOR I-W mA Pump motor’s W-phase current
24 D-MOTOR TEMP °C (°F) Left drive motor’s temperature
25 R-MOTOR TEMP °C (°F) Right drive motor’s temperature
26 P-MOTOR TEMP °C (°F) Pump motor’s temperature

Instrument panel 2-50 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Code Panel display Unit Description Remarks
Time period
27 SEAT H METER Hour Seat switch hour meter while seat
switch is on
Time period
while drive
28 DRIVE H METER Hour Drive motor hour meter
motors are
working
Time period
while pump
29 PUMP H METER Hour Pump motor hour meter
motor is
working
30 SEAT SWITCH - Seat switch ON(1)/OFF(0)
31 PARK SWITCH - Parking brake switch ON(1)/OFF(0)
REV SELECT
33 - Reverse drive switch ON(1)/ OFF(0)
SW

34
FWD SELECT
SW
- Forward drive switch ON(1)/OFF(0) 2
PEDAL BRAKE
35 - Brake pedal switch ON(1)/OFF(0)

Electrical system
SW
37 AUX1 OUTPUT - AUX1 switch ON(1)/OFF(0)
38 AUX2 OUTPUT - AUX2 switch ON(1)/OFF(0)
Speed limit for high lift switch 1
40 HIGHT SW - ON(1)/OFF(0)
(GSS option selected)
TILT SWITCH
41 - Tilt switch ON(1)/OFF(0)
OUT
MAST TILT Tilt angle limit for high lift switch 2
42 - ON(1)/OFF(0)
SWITCH (GSS option selected)
43 CONTACTOR - Contactor switch ON(1)/OFF(0)
44 5V OUT - 5V output ON(1)/OFF(0)
45 12V OUT - 12V output ON(1)/OFF(0)
AUTO TILT Automatic tilt switch 3
46 - ON(1)/OFF(0)
SWITCH (GSS option selected)
48 FANS - Activation of fans ON(1)/OFF(0)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-51 Instrument panel

 2-5-3 Calibration

A. Accessing calibration mode on the instrument panel

Using the instrument panel, you can modify a number of

different parameter settings. And although it may only
allow you to set a limited number of parameters this
function is especially useful when the PC application
EasyView is not available.

To calibrate parameter settings:

1. Turn the key switch off and on again to initialize

the instrument panel.

2. Hold ENTER for three seconds until a page

loads that prompts you to select between “c” and
“d.”

Hold for 3 sec.

0821E

Fig. 2-43
3. Press the up button to select “c.”

NOTICE: If parameter calibration code 40 ENABLE

TURTLE is set to “disable,” the up button will be disabled,
preventing you from entering calibration mode. If this
happens, key the vehicle off and on again to restart.

Fig. 2-44

4. Use the up and down buttons to select

parameter calibration code number 10 and then
press ENTER.

Fig. 2-45

5. Use the up and down buttons to set the

parameter value to “4” and then press ENTER.

Fig. 2-46

Instrument panel 2-52 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 6. In the same way, set parameter calibration code
17 to “6.”

NOTICE: You can switch the order in which the two

parameter values are set. However, it is not possible to
modify other parameters before setting these two.

Fig. 2-47

7. Use the up and down buttons to select the

parameter you wish to set and then press
ENTER.

Fig. 2-48

8. Use the up and down buttons to modify the

selected parameter’s value and then press 2
ENTER.

Electrical system
 Using the E-S-H button, you can move the
cursor to another digit place.

NOTICE: Using the function that returns the parameter

settings to their default values will delete your current Fig. 2-49
settings.

The parameter code number is displayed in the speed

and warning section, and its setting value in the time and
distance section. If the number in the time and distance
changes, this means the selected parameter’s value has
been updated in the controller’s memory.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-53 Instrument panel

 B. Parameter calibration codes

Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
TURTLE ALARM 0–1
8 - 0
(Buzzer On Turtle Speed) (Off–On)
0–9
10 1st PASSWORD digit -
(not used)
SEAT SW DELAY
11 sec 3 1–9
(Seat Switch Delay)
CHAT TIME 1–9
12 sec 6
(Chat Time) (1–9)
IDLE TIME 10–20
13 sec 10
(Idle Time) (10–20)
MAINT TIME ON 0–1
14 - 0
(Maintenance Time Set) (Off–On)
0–9
17 2nd PASSWORD digit -
(not used)
HANDLE TURN-L 6.0–10.0
18 V 7.2
(Steering CCW) (0.00–10.00)
HANDLE TURN-R 0.5– 4.0
19 V 2.0
(Steering CW) (0.00–10.00)
WHEEL STRAIGHT 3.0 –7.0
20 V 4.5
(Steering Middle) (0.00–10.00)
ACCEL MIN VALUE 0.2–2.0
23 V 0.40
(Min Accelerator A) (0.20–2.00)
ACCEL MAX VALUE 2.0–5.0
24 V 2.93
(Max Accelerator A) (2.00–4.50)
SLOPE TIMER 3–10
26 sec 5
(Stop on a Slope Timer) (3–10)
LIFT PRI SPEED
0–1
27 (Lift Priority For Pump Reference - 1
(Off–On)
Speed)
FORWARD ALARM 0–1
30 - 0
(Buzzer On Forward Direction) (Off–On)
BACK UP ALARM 0–1
31 - 0
(Buzzer On Rerverse Direction) (Off–On)
LIFT MAX VALUE 3.0–10.0
32 V 9.81
(Lift Max) (0.00–10.00)
LIFT MIN VALUE 0–10.0
33 V 2.90
(Lift Min) (0.00–10.00)
START MOTOR FAN 0–100
35 °C (°F) 65(149)
(Motor Fan Starting Temp) (0–160)

Instrument panel 2-54 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
ENABLE TURTLE 0–1
40 - 1
(Enable Turtle Speed by Display) (Off–On)
DRIVE MAX I (Drive Max Current) 20–100
41 % See note
(See note) (20–100)
FWD MAX SPEED
1000–4500
42 (Drive Forward Max Speed) (See rpm See note
(0–4000/5000)
note)
REV MAX SPEED
1000–4500
43 (Drive Reverse Max Speed) rpm See note
(0–4000/5000)
See note
44 D LIMIT MAX SPD 500–3500
STEER LIMIT SPD 400–2000
47 rpm 1000
(Steering Limit Max Speed) (400–2000)

48
D ACCEL RATE H
(Acceleration Rate HS)
sec 6.0
0.1–30.0
(0.1–30.0)
2
D ACCEL RATE L 0.1–30.0
49 sec 6.5

Electrical system
(Acceleration Rate LS) (0.1–30.0)
D LOW ACCEL RATE 0.1–30.0
50 sec 10.0
(Low Accel Rate) (0.1–30.0)
D INVERS. RATE H 0.1–30.0
51 sec 5.0
(Inversion Rate HS) (0.1–30.0)
D INVERS. RATE L 0.1–30.0
52 sec 5.0
(Inversion Rate LS) (0.1–30.0)
D RELEASE RATE H 0.1–30.0
53 sec 6.0
(Release Rate HS) (0.1–30.0)
D RELEASE RATE L 0.1–30.0
54 sec 5.0
(Release Rate LS) (0.1–30.0)
D LOW BRAKE RATE 0.1–30.0
55 sec 5.0
(Low Inversion Rate) (0.1–30.0)
D SOFT STOP SPD 10–500
56 rpm 150
(Soft Stop Speed) (0–500)
START CONT. FAN 0–60
60 °C (°F) 65(149)
(Controller Fan Starting Temp) (0–160)
PARTIAL RELEASE 0.1–30.0
61 sec 30.0
(Partial Decel Rate) (0.1–30.0)
LOADED LIFT I 20.0–100.0
62 % See note
(Lift Current) See note (5.0–100.0)
LIFT MAX SPEED 1000–3500
64 rpm See note
(Lift Max Speed) See note (0–4000)
TILT SPEED 500–2000
65 rpm 800
(Tilt Backward Speed) (100–3000)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-55 Instrument panel

 Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
AUX1 SPEED 500–2000
66 rpm 800
(AUX1 Speed) (100–3000)
AUX2 SPEED 500–2000
67 rpm 800
(AUX2 Speed) (100–3000)
LIFT MIN SPEED 0–500
69 rpm 200
(Lift Min Speed) (0-500)
HYDRO SPEED 400–800
71 rpm 700
(Hydro Speed) (400–800)
IDLE SPEED 200–500
72 rpm 500
(Idle Speed) (400–800)
PUMP ACCEL RATE 0.1–30.0
73 sec 1.5
(Acceleration Rate) (0.1–30.0)
PUMP DECEL RATE 0.1–30.0
74 sec 1.5
(Deceleration Rate) (0.1–30.0)
TURTLE SPEED 500–3500
84 rpm 2000
(Max Speed in Turtle Mode) (500–3500)
BRITISH UNIT 0–1
85 - 0
(British Unit Enable) (Off–On)
E-S-H 0–1
87 - 1
(Enable EHS by Display) (Off–On)
TIMER-ODOMETER 0–1
88 -
(not used)
ENABLE FAN WORK 0–1
89 - 1
(Enable Working Fans) (Off–On)
ENABLE CHAT TIME 0–1
90 - 1
(Chat Time Enable) (Off–On)
ENABLE STR SENSR 0–1
91 - 1
(Enable Steer Angle Sensor) (Off–On)
MAITENANCE TIME 0–99990
92 hour 500
(Set Time) (100–65500)
0–1
93 EM BRAKE ENABLE - 1
(Off–On)
GSS ENABLE 0–1
94 - 0
(GSS Enable) (Off–On)
FINGERTIP ENABLE 0–1
95 - 0
(Fingertip enable) (Off–On)
AUTO CLAMP ENABLE 0–1
96 - 0
(Auto Clamp Enable) (Off–On)
AUTO TILT ENABLE 0–1
97 - 1
(Auto Tilt Enable) (Off–On)
TILT FWD SPEED 100–3000
98 rpm 800
(Tilt Forward Speed) (100–3000)

Instrument panel 2-56 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
LOWER SPEED 100–2000
99 rpm 600
(Lower Speed) (100–2000)
AUX2 ENABLE 0–1
A2 - 0
(Aux2 Enable) (Off–On)

Note: The default settings and adjustable ranges of EasyView’s calibration parameters for the instrument
panel parameter codes 41, 42, 43, 62, and 64 vary depending on which is selected from the E-H-S modes. For
a detailed explanation, see Section 2-6-6.

 Optional Guardian Stability System (GSS)

- Decrease of Travel Speed (50%) when the mast is raised above primary stage
- Available tilt-forward angle is restricted to 2° when the mast is raised above the primary stage
- Alarm when the mast, tilted more than 2°, is raised above primary stage

 Auto Tilt Leveling 2

- Returns the mast to vertical position easily by tilt angle sensing

Electrical system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-57 Instrument panel

2-6 Application “EasyView”

2-6-1 Installation and execution

As mentioned in the preceding section, electric vehicles
equipped with CURTIS controllers provide the functions
of diagnosis and parameter calibration not only on the
instrument panel but also on the PC application
EasyView.

To use EasyView, you will need to install it and the CAN

communications drivers on your laptop, and then connect
the PC to the vehicle with a communications cable
(A408026, Kvaser) and then carry out initial settings.

EasyView installation

1. Download the latest version of the application

EasyView from the bulletin board at the dealer’s
portal website: https://service.doosan-iv.co.kr

Fig. 2-50

Application “EasyView” 2-58 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2. Unpack the downloaded file, and execute the file
<setup.exe> to install the application on the PC.

3. Check that EasyView’s icon is created on the Fig. 2-51

desktop.

CAN communications drivers installation

1. Access Kvaser’s website and click Support 

Downloads  Kvaser Driver for Windows. 2
 Direct link:

Electrical system
http://www.kvaser.com/software/7330130980
013/V5_11_0/kvaser_drivers_setup.exe

Fig. 2-52

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-59 Application “EasyView”

 2. Once the Installation Wizard page appears, click
Next; then click Display Release Notes to read
the release notes or Next to proceed installation.

Fig. 2-53

Fig. 2-54

3. Select Kvaser CAN driver components to install

and then click Next.

Fig. 2-55

Application “EasyView” 2-60 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 4. Set the folder where Kvaser CAN Drivers will be
installed and then click Installation.

Fig. 2-56

Electrical system
Fig. 2-57

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-61 Application “EasyView”

 EasyView execution

1. Connect a CAN communications cable with one

end to your PC’s USB port and the other to the
vehicle’s CAN port near the controllers and then
turn on the key switch.

2. Double-click the EasyView icon to launch the

application.
 If the PC is not correctly connected to the
vehicle with the key switch on, a dialogue box
will appear and prompt you to select a vehicle
model as shown below:

Fig. 2-58
 When the boxes at right bottom are highlighted
in green, this means they are active, when the
PC and vehicle are correctly connected and
inactive in grey when they are not.

Fig. 2-59

Application “EasyView” 2-62 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3. When you are not logged in to the application,
only <Test Menu> is provided, which shows the
vehicle’s conditions. You can log in (password:
dbgby141) the application under the
Administration menu to access <Calibration
Menu>.

Electrical system
Fig. 2-60

Fig. 2-61

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-63 Application “EasyView”

 2-6-2 Controller firmware update
As the controllers’ performance and functions are updated,
so is the firmware. You can install an update on the
controllers using your PC. This process is referred to as
“flashing,” and it goes as follows:

1. Visit the dealer’s portal website:

https://service.doosan-iv.co.kr.

2. Under the menu of Board  Bulletin, search for

“easyview” and view the post of the latest
firmware version.

Fig. 2-62

3. Download xml.zip and the update file named

after your vehicle model such as B20TX-
7_48V_56_170825.zip.

Fig. 2-63
4. Unzip xml.zip into the Data folder under the path
of the EasyView application.
 Default: C:\Program Files (x86)\Curtis
Instruments\Easy View\Data

Application “EasyView” 2-64 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 5. On the EasyView application, select Flash under
the Tool menu.

Electrical system
Fig. 2-64
6. EasyView will display the vehicle model type and
current software version, for example, Truck type:
56 Current SW Data:2015/3/6. Click Browse and
find the downloaded update file specific to your
vehicle model.

Fig. 2-65

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-65 Application “EasyView”

 7. Click Flash and wait until the selected file is
completely loaded into the controllers.
 Flashing takes approx. 5–10 minutes.

NOTICE: While flashing is in progress, the PC must not

crash due to a system error, external interference, or the
removal of the communications cable. Make sure you use
AC power, not a battery, for the PC.

Fig. 2-66
8. Upon the completion of the flashing, a dialog box
will appear. Click Close to return to the main page.

Fig. 2-67

Application “EasyView” 2-66 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 9. Perform initial settings for the accelerator pedal,
lift sensor, and steering angle sensor (See each
relevant menu in Section 2-6-7).

Electrical system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-67 Application “EasyView”

 2-6-3 “Administration” menu description

Login

Once you log in to the application, you can access

Calibration Menu and Options Menu on the main page
(Compare Fig. 2-68 and Fig. 2-69). The password is
dbgby141.

• When you are not logged in, only Test Menu is

available.

• When you are logged in, you are allowed to access Fig. 2-68
Calibration Menu and Options Menu as well.

Fig. 2-69

Logout

Clicking this menu logs you out of the application.

Exit

Clicking this menu quits the application.

Application “EasyView” 2-68 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2-6-4 “Tools” menu description

Flash

As described above, Flash is for updating the controllers’

firmware. For a detailed explanation, see Section 2-6-2.

Electrical system
Fig. 2-70

Fig. 2-71

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-69 Application “EasyView”

 Save parameters

In this menu, you can store all parameter settings except

for the values of sensors (accelerator, lift, steering, etc.)
in the PC as follows:

Click Browse, choose a location on the computer where

you wish to store the parameter file, and then click Save.

Fig. 2-72

Application “EasyView” 2-70 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2
Fig. 2-73

Electrical system
Data Logging

This function records the vehicle’s operation history and

helps the operator analyze the vehicle’s conditions.

Enter a time scale in the time dialog box, which is set with
a default value to 0.5 seconds. Click Browse to select
where you wish to store the trace file and then click Start.
The data will then be logged at the selected file based on
the time scale specified. After clicking Stop, the operator
can check the data log file.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-71 Application “EasyView”

 Fig. 2-74

Fig. 2-75

Application “EasyView” 2-72 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Faults

This menu contains three submenus: Faults active,

Faults history, and Clear faults history.

• Faults active shows a list of the currently present

fault codes.

Fig. 2-76

• Faults history shows a list of the past fault codes

that have occurred since the last clearing of faults
history.

Electrical system
Fig. 2-77
• Clear faults history clears the current list of faults
history.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-73 Application “EasyView”

 Cloning

In this menu, you can either copy the parameter settings

applied to the vehicle to save them in the PC, or copy
parameter settings stored in the PC to apply them to the
vehicle.

• Browse/Open: Clicking this button enables you to

select a cloning file (*.csv). And then, parameter
settings from the selected file are displayed under
<File value>.

Fig. 2-78

Application “EasyView” 2-74 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 • Read controller: Clicking this button loads
parameter settings from the controllers and
displays them under <Controller value>.

Electrical system
Fig. 2-79
• Save: Clicking this button saves parameter values
from the controllers in the cloning file on the PC.

Fig. 2-80

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-75 Application “EasyView”

 • Clone: Clicking this button copies the parameter
settings from the cloning file to the controllers while
automatically running the following three steps:
Verify, Writing, and Reading.

Step 1: Verify

Fig. 2-81
Step 2: Writing

Fig. 2-82

Application “EasyView” 2-76 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Step 3: Reading

Electrical system
Fig. 2-83

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-77 Application “EasyView”

 2-6-5 Main page – Test Menu
<Test Menu> on the main page contains a list of
diagnostic parameters in groups.

Test Menu – Software Version Information

Fig. 2-84

No. Parameters Descriptions

1 Drive Left Software Type The model code to which the left drive software applies
2 Drive Left Software Year Left drive software revision year
3 Drive Left Software Month Left drive software revision month
4 Drive Left Software Day Left drive software revision day
5 Drive Right Software Type The model code to which the right drive software applies
6 Drive Right Software Year Right drive software revision year
7 Drive Right Software Month Right drive software revision month
8 Drive Right Software Day Right drive software revision day
9 Pump Software Type The model code to which the pump software applies
10 Pump Software Year Pump software revision year
11 Pump Software Month Pump software revision month
12 Pump Software Day Pump software revision day

Application “EasyView” 2-78 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Drive

Electrical system
Fig. 2-85

No. Parameters Descriptions

Left drive motor’s actual speed in revolutions per minute
1 Left Motor Speed
(rpm)
Left drive motor speed request in revolutions per minute
2 Left Motor Speed Request
(rpm)
Right drive motor’s actual speed in revolutions per minute
3 Right Motor Speed
(rpm)
Right Motor Speed Right drive motor speed request in revolutions per minute
4
Request (rpm)
5 Temp Left Drive Motor Left drive motor temperature (°C)
6 Temp Left Drive Module Left drive module temperature (°C)
7 Temp Right Drive Motor Right drive motor temperature (°C)
8 Temp Right Drive Module Right drive module temperature (°C)
9 Left Motor Current Left drive motor current in Amps RMS (A)
10 Right Motor Current Right drive motor current in Amps RMS (A)
11 Pedal Voltage A Pedal input voltage A (V)
12 Pedal Voltage B Pedal input voltage B (V)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-79 Application “EasyView”

 No. Parameters Descriptions
Steering Sensor Output
13 Steering sensor voltage (V)
Voltage
14 Seat Switch Seat switch state
15 Pedal Brake Switch Brake switch state
State of forward direction, received from F/R switch. On
16 Forward Switch
indicates that the forward direction is selected.
State of reverse direction, received from F/R switch. On
17 Reverse Switch
indicates that the reverse direction is selected.
State of buzzer relay output at drive module pin 30. On
18 Warning Buzzer indicates that the buzzer relay driver is active. When a fault
occurs, a buzzer will sound.
State of line contactor output at drive module pin 6. On
19 Main contactor
indicates that the line contactor driver is active.
20 Left Motor Encoder (5V) 5 V supply voltage at left drive module pin 26
Drive encoder phase A at left drive module pin 31. On
21 Left Motor Encoder A
indicates pulse activity on the encoder phase A.
Drive encoder phase B at left drive module pin 32. On
22 Left Motor Encoder B
indicates pulse activity on the encoder phase B.
23 Right Motor Encoder (5V) 5 V supply voltage at right drive module pin 26.
Drive encoder phase A at right drive module pin 31. On
24 Right Motor Encoder A
indicates pulse activity on the encoder phase A.
Drive encoder phase B at right drive module pin 32. On
25 Right Motor Encoder B
indicates pulse activity on the encoder phase B.
26 ISO Relay The state of ISO relay.
27 Left EM Brake EM Brake state of the left motor.
28 Right EM Brake EM Brake state of the right motor.

Application “EasyView” 2-80 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Pump

Fig. 2-86
2

Electrical system
No. Parameters Descriptions
1 Motor Speed Pump motor’s actual speed in revolutions per minute (rpm)
Pump motor speed request (from lift command input) in
2 Motor Speed Request
revolutions per minute (rpm)
3 Temp Pump Motor Pump motor temperature (°C, °F)
4 Temp Pump Module Pump module temperature (°C, °F)
5 Pump Motor Current Pump motor current in Amps RMS (A)
6 Lift Command Lift Command voltage (V) input from Analog1
7 Tilt Tilt switch command
8 Aux1 AUX1 switch command
9 Aux2 AUX2 switch command
10 Height Switch (SW1) [GSS] Height switch command
11 Mast Tilt Switch (SW2) [GSS] Mast Tilt switch command
12 Auto Tilt Switch (SW3) [GSS] Auto Tilt switch command
13 Pump Motor Encoder (5V) 5V supply voltage at pump module pin 26.
Pump encoder phase A at pump module pin 31. On
14 Pump Motor Encoder A
indicates pulse activity on the encoder phase A.
Pump encoder phase B at pump module pin 32. On
15 Pump Motor Encoder B
indicates pulse activity on the encoder phase B.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-81 Application “EasyView”

 Test Menu – Fingertip and Valve

Fig. 2-87

No. Parameters Descriptions

1 Knob Lift Command Lift command value from knob
2 Knob Lift (On/Off) State of lift signal from knob
3 Knob Lower (On/Off) State of lower signal from knob
4 Knob Tilt Backward (On/Off) State of tilt up signal from knob
5 Knob Tilt Forward (On/Off) State of tilt down signal from knob
6 Knob Aux1 Right (On/Off) State of AUX1 right signal from knob
7 Knob Aux1 Left (On/Off) State of AUX1 left signal from knob
8 Knob Aux2 Right (On/Off) State of AUX2 right signal from knob
9 Knob Aux2 Left (On/Off) State of AUX2 left signal from knob
10 Auto Tilt Mode Switch State of auto tilt signal from knob
11 Auto Clamp Mode Switch State of auto clamp signal from knob
12 Forward Switch State of drive forward signal from knob
13 Reverse Switch State of drive reverse signal from knob
14 Lift Sol Current Lifting valve solenoid current (mA)
15 Lower Sol Current Lowing valve solenoid current (mA)
16 Tilt Backward Sol Current Tilt back valve solenoid current (mA)
17 Tilt Forward Sol Current Tilt forward valve solenoid current (mA)
18 Aux1 Right Sol Current AUX1 right valve solenoid current (mA)
19 Aux1 Left Sol Current AUX1 left valve solenoid current (mA)

Application “EasyView” 2-82 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 No. Parameters Descriptions
20 Aux2 Right Sol Current AUX2 right valve solenoid current (mA)
21 Aux2 Left Sol Current AUX2 left valve solenoid current (mA)
22 Unload Valve State of unload valve
23 Back Up Buzzer State of backup alarm

Electrical system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-83 Application “EasyView”

 Test Menu – Battery

Fig. 2-88

No. Parameters Descriptions

1 Battery Voltage Battery voltage (V) measured at drive module pin 1
2 Inverter Voltage Inverter voltage (V) measured at drive module B+ stud
Battery level measured from the left drive motor
3 Battery Level
controller
4 BDI Percentage Battery discharge indicator level (%)

Application “EasyView” 2-84 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Timers

Fig. 2-89 2
No. Parameters Descriptions

Electrical system
Hour meter that counts the time that the seat switch is
1 Seat Switch Hour Meter applied (closed) (Hr). You can see this data on the
instrument panel.
Hour meter that counts the time that the drive motor is
2 Drive Motor Hour Meter
active (Hr)
Hour meter that counts the time that the pump motor is
3 Pump Motor Hour Meter active (Hr). You can see this data on the instrument
panel.
4 Odometer Vehicle distance traveled (km)
5 Odometer Vehicle distance traveled (km x 1000)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-85 Application “EasyView”

 2-6-6 Main page – Calibration Menu
<Calibration Menu> on the main page contains a list of
calibration parameters in groups. To access this menu,
you should log in to the application (Administration 
Login  Enter password: dbgby141).

Calibration Menu – Accel Pedal Set

Fig. 2-90
No. Parameters Descriptions
Pedal Voltage A
1 Voltage (V) at traction throttle pot wiper
(monitor variable)
Forward Switch
2 Forward switch state
(monitor variable)
Reverse Switch
3 Reverse switch state
(monitor variable)
4 Min Accelerator A Accelerator pedal voltage (V) with the pedal released.
5 Max Accelerator A Accelerator pedal voltage (V) with the pedal completely pressed.

NOTICE: See Section 2-6-7 for a detailed procedure of

using this submenu.

Application “EasyView” 2-86 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Brake Pedal Set

Fig. 2-91
2
No. Parameters Descriptions

Electrical system
1 Brake Pedal Voltage A Measured value between 0.00 and 5.50 V.
2 Brake Min Brake pedal voltage (V) with the pedal released.
Brake pedal voltage (V) with the pedal completely
3 Brake Max
pressed.
The percent of brake pedal’s stroke between 1 and
100% For reference, there are two stages during the
4 Brake Mid Percent
whole pedal stroke. Between the stages, there is some
stroke with slight different feeling.
The braking rate between 0.1 and 25.0 seconds when
the brake pedal is fully applied at vehicle’s high speed.
Increasing this setting results in a slower braking
5 Full Brake Rate HS
(longer stopping distance) at vehicle’s high speed and
decreasing this setting results in a faster braking
(shorter stopping distance) at vehicle’s high speed.
The braking rate between 0.1 and 25.0 seconds when
the brake pedal is fully applied at vehicle’s low speed.
Increasing this setting results in a slower braking
6 Full Brake Rate LS
(longer stopping distance) at vehicle’s low speed and
decreasing this setting results in a faster braking
(shorter stopping distance) at vehicle’s low speed.
The rate of braking between 0.1 and 25.0 seconds
when the brake pedal is slightly applied at vehicle’s low
speed. Increasing this setting results in a slower
7 Low Brake Rate
braking (longer stopping distance) and decreasing this
setting results in a faster braking (shorter stopping
distance).

NOTICE: See Section 2-6-7 for a detailed procedure of

using this submenu.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-87 Application “EasyView”

 Calibration Menu – Lift Set

Fig. 2-92

No. Parameters Descriptions

Lift Command (monitor
1 Lift command voltage (V) at pump module pin 24
variable)
2 Lift Min Lift command voltage (V) with the lift lever released.
Lift Command voltage (V) with the lift lever fully
3 Lift Max
applied.

NOTICE: See Section 2-6-7 for a detailed procedure of

using this submenu.

Application “EasyView” 2-88 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Steering Set

Fig. 2-93
2

Electrical system
No. Parameters Descriptions
Steer Sensor
1 Output Voltage Steer angle sensor voltage (V) at left drive module pin 24
(monitor variable)
Steer angle sensor voltage (V) when the rear wheels are fully
2 Steering Anticlock
turned counterclockwise.
3 Steering Middle Steer angle sensor voltage (V) when the rear wheels are in the middle.
Steer angle sensor voltage (V) when the rear wheels are fully
4 Steering Clock
turned clockwise.
Steering Limit Max Maximum drive motor speed when the steer angle is at full lock
5
Speed counterclockwise or clockwise.

NOTICE: See Section 2-6-7 for a detailed procedure of

using this submenu.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-89 Application “EasyView”

 Calibration Menu – Maintenance Timer

Fig. 2-94

No. Parameters Descriptions

Seat Switch Hour Meter Hour meter that counts the time that the seat switch
1
(monitor variable) is active (Hr)
When this parameter value is on, the maintenance
2 Maintenance Time Set function is enabled.

When the Drive Hour Meter exceeds this parameter

value, the wrench icon on the vehicle display lights
up, indicating that vehicle maintenance is needed.
3 Set Time Once the maintenance is performed, the value of this
parameter should be increased to a setting when the
next time maintenance is scheduled.

Application “EasyView” 2-90 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Timers

Fig. 2-95

No. Parameters Descriptions

2
The time delay since the driver leaves the seat and

Electrical system
1 Seat Switch Delay the seat switch is open until the controller enters
standby mode and inhibits drive and lift functions
If there is no command given (neither drive nor pump
action) during the amount of time set for this
2 Chat Time
parameter since the expiration of the idle time, the
display will show the “PP” message.
The time delay since no input has been received
3 Idle Time from LIFT, TILT, AUX1, AUX2, or steering until the
pump motor stops
Once the driver stops on a slope, the shafts of the
drive motors are locked while the vehicle is stationary
so it may hold its position regardless of whether the
4 Stop on a Slope Timer
EM parking brake is engaged or not. This function is
triggered by the release of the accelerator pedal by
the driver.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-91 Application “EasyView”

 Calibration Menu – Mode Selection (old software menu)

Fig. 2-96

No. Parameters Descriptions

Indicates if Economic mode is active on the instrument
1 E Mode (monitor variable)
panel.
Indicates if Standard mode is active on the instrument
2 S Mode (monitor variable)
panel.
Indicates if High Performance mode is active on the
3 H Mode (monitor variable)
instrument panel.
4 Max Speed in Turtle Mode Maximum drive motor speed allowed in turtle mode
Maximum drive motor current allowed in “E” power
mode. Setting this parameter to a higher value allows a
5 Drive Maximum Current E heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.
Maximum drive motor forward speed allowed in “E”
6 Drive Forward Max Speed E
power mode
Maximum drive motor reverse speed allowed in “E”
7 Drive Reverse Max Speed E
power mode
Maximum pump motor current allowed in “E” power
mode at the rated load pump speed (i.e. lift speed).
Small changes in this setting can result in big changes in
the rated load lift speed.
8 Lift Current E
Setting this parameter to a higher value increases the
loaded lift speed (and increase heating in the pump
motor and pump module). Setting this parameter to a
lower value lowers the loaded lift speed.

Application “EasyView” 2-92 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 No. Parameters Descriptions
Maximum pump motor speed allowed in “E” power mode
9 Lift Max Speed E as a result of a maximum lift command. This setting
controls the maximum lift speed with no load (unloaded).
Maximum drive motor current allowed in “S” power
mode. Setting this parameter to a higher value allows a
10 Drive Maximum Current S heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.
Maximum drive motor forward speed allowed in “S”
11 Drive Forward Max Speed S
power mode
Maximum drive motor reverse speed allowed in “S”
12 Drive Reverse Max Speed S
power mode
Maximum pump motor current allowed in “S” power
mode at the rated load pump speed (i.e. lift speed).
Small changes in this setting can result in big changes in

13 Lift Current S
the fully loaded lift speed.
Setting this parameter to a higher value increases the
loaded lift speed (and increase heating in the pump
2
motor and pump module). Setting this parameter to a

Electrical system
lowers value lower the loaded lift speed.
Maximum pump motor speed allowed in “S” power mode
14 Lift Max Speed S as a result of a maximum lift command. This setting
controls the maximum lift speed with no load (unloaded).
Maximum drive motor current allowed in “H” power
mode. Setting this parameter to a higher value allows a
15 Drive Maximum Current H heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.
Maximum drive motor forward speed allowed in “H”
16 Drive Forward Max Speed H
power mode
Maximum drive motor reverse speed allowed in “H”
17 Drive Reverse Max Speed H
power mode
Maximum pump motor current allowed in “H” power
mode at the rated load pump speed (i.e. lift speed).
Minor changes in this setting can result in significant
changes in the fully loaded lift speed.
18 Lift Current H
Setting this parameter to a higher value increases the
loaded lift speed (and increase heating in the pump
motor and pump module). Setting this parameter to a
lower value lowers the loaded lift speed.
Maximum pump motor speed allowed in “H” power mode
19 Lift Max Speed H as a result of a maximum lift command. This setting
controls the maximum lift speed with no load (unloaded).

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-93 Application “EasyView”

 Calibration Menu – Mode Selection for Traction (new software menu)

Fig. 2-97

No. Parameters Descriptions

Indicates if Economic mode is active on the instrument
1 E Mode (monitor variable)
panel.
Indicates if Standard mode is active on the instrument
2 S Mode (monitor variable)
panel.
Indicates if High Performance mode is active on the
3 H Mode (monitor variable)
instrument panel.
4 Max Speed in Turtle Mode Maximum drive motor speed allowed in turtle mode
Maximum drive motor current allowed in “E” power
mode. Setting this parameter to a higher value allows a
heavily loaded vehicle to reach higher speeds. Setting
5 Drive Maximum Current E
this parameter to a lower value limits the speed of a
heavily loaded vehicle.

Maximum drive motor forward speed allowed in “E”

6 Drive Forward Max Speed E
power mode
Maximum drive motor reverse speed allowed in “E”
7 Drive Reverse Max Speed E
power mode
Maximum drive motor current allowed in “S” power
mode. Setting this parameter to a higher value allows a
8 Drive Maximum Current S heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.
Maximum drive motor forward speed allowed in “S”
9 Drive Forward Max Speed S
power mode
Maximum drive motor reverse speed allowed in “S”
10 Drive Reverse Max Speed S
power mode

Application “EasyView” 2-94 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 No. Parameters Descriptions
Maximum drive motor current allowed in “H” power
mode. Setting this parameter to a higher value allows a
11 Drive Maximum Current H heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.
Maximum drive motor forward speed allowed in “H”
12 Drive Forward Max Speed H
power mode
Maximum drive motor reverse speed allowed in “H”
13 Drive Reverse Max Speed H
power mode

Electrical system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-95 Application “EasyView”

 Calibration Menu – Mode Selection for Pump (new software menu)

Fig. 2-98

No. Parameters Descriptions

Indicates if Economic mode is active on the instrument
1 E Mode (monitor variable)
panel.
Indicates if Standard mode is active on the instrument
2 S Mode (monitor variable)
panel.
Indicates if High Performance mode is active on the
3 H Mode (monitor variable)
instrument panel.

Application “EasyView” 2-96 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu –E/S/H MODE Performance (new software menu)

Fig. 2-99 2

Electrical system
No. Parameters Descriptions
Maximum pump motor speed allowed in “E” power mode
Lift Max Speed
1 as a result of a maximum lift command. This setting
(E MODE performance)
controls the maximum lift speed with no load (unloaded).
Maximum pump motor speed allowed in “S” power mode
Lift Max Speed
2 as a result of a maximum lift command. This setting
(S MODE performance)
controls the maximum lift speed with no load (unloaded).
Maximum pump motor speed allowed in “H” power mode
Lift Max Speed
3 as a result of a maximum lift command. This setting
(H MODE performance)
controls the maximum lift speed with no load (unloaded).

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-97 Application “EasyView”

 Calibration Menu – Drive Response

Fig. 2-100

No. Parameters Descriptions

The acceleration response to a full accelerator pedal
command (> 90%) when the vehicle is at a high speed (>
70% max speed). Increasing this setting results in a slower
Acceleration Rate HS
1 response; decreasing this setting results in a faster
(Full Accel Rate HS)
response. The Acceleration Rate HS parameter is typically
set higher (slower) than the Acceleration Rate LS
parameter.
The acceleration response to a full accelerator pedal
command (> 90%) when the vehicle is at a low speed (<
Acceleration Rate LS 30% max speed). Increasing this setting results in a slower
2
(Full Accel Rate LS) response; decreasing this setting results in a faster
response. The Acceleration Rate LS parameter is typically
set lower (faster) than the Acceleration Rate HS parameter.
The acceleration response to a low accelerator pedal
command (< 10%). Acceleration response for intermediate
(10% to 90%) accelerator pedal commands is scaled
between the Low Accel Rate and either the Acceleration
Rate LS or Acceleration Rate HS settings (depending on
3 Low Accel Rate
the vehicle’s speed). Increasing this setting results in a
slower response; decreasing this setting results in a faster
response. The Low Accel Rate parameter is typically set
higher (slower) than both the Acceleration Rate LS and
Acceleration Rate HS parameters.

Application “EasyView” 2-98 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 No. Parameters Descriptions
The deceleration response when the accelerator pedal
command is released (to neutral) while the vehicle is
travelling at high speeds. Increasing this setting results in a
Release Rate HS
4 slower deceleration response; decreasing this setting
(Neutral Decel Rate HS)
results in a faster deceleration response. The Release Rate
HS parameter is typically set higher (slower) than the
Release Rate LS parameter.
The deceleration response when the accelerator pedal
command is released (to neutral) while the vehicle is
travelling at low speeds. Increasing this setting results in a
Release Rate LS
5 slower deceleration response; decreasing this setting
(Neutral Decel Rate LS)
results in a faster deceleration response. The Release Rate
LS parameter is typically set lower (faster) than the Release
Rate HS parameter.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while

6
Inversion Rate HS
the vehicle is travelling at high speeds. Increasing this
setting results in a slower deceleration response;
2
(Full Brake Rate HS)
decreasing this setting results in a faster deceleration

Electrical system
response. The Inversion Rate HS parameter is typically set
higher (slower) than the Inversion Rate LS parameter.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while
the vehicle is travelling at low speeds. Increasing this
Inversion Rate LS
7 setting results in a slower deceleration response;
(Full Brake Rate LS)
decreasing this setting results in a faster deceleration
response. The Inversion Rate LS parameter is typically set
lower (faster) than the Inversion Rate HS parameter.
The response when the drive direction is reversed at low
(<10%) accelerator pedal command. Increasing this setting
results in slower deceleration response; decreasing this
8 Low Inversion Rate setting results in faster deceleration response. The Low
Inversion Rate parameter is typically set higher (slower)
than both the Inversion Rate HS and Inversion Rate LS
parameters.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-99 Application “EasyView”

 No. Parameters Descriptions
The speed below which a much slower deceleration rate is
used to give the vehicle a softer feel when coming to a stop
and also to reduce the amount of vehicle rollback on a
slope (before position hold takes control).
With vehicles that have fast deceleration, the driver may
find the final speed reduction to zero rpm uncomfortable;
the vehicle may even rock back as a result of tire wind-up.
Soft Stop Speed allows the vehicle to slow at the same fast
9 Soft Stop Speed rate until it reaches the set threshold, at which point it
changes to a slower (softer) deceleration rate. However, if
the threshold is set too high, the vehicle feels like it is
“running on.”
When throttle is released on a ramp, the vehicle may roll
back before Position Hold takes control. Soft Speed Stop
can be used to reduce the amount of rollback on a slope,
but shouldn’t be set so high the vehicle drives up the ramp
after the throttle is released.
The deceleration response when the accelerator pedal
command is released to a lower value (but not to neutral).
Increasing this setting results in slower deceleration
10 Partial Decel Rate response. Decreasing this setting results in faster
deceleration response. The Partial Decel Rate parameter is
typically set higher (slower) than both the Release Rate LS
and Release Rate HS parameters.

Application “EasyView” 2-100 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Pump Response (old software menu)

Fig. 2-101
2

Electrical system
No. Parameters Descriptions
Pump motor speed when tilt-forward/backward function is
1 Tilt Speed
active without the fingertip option
2 Aux1 Speed Pump motor speed when AUX1 function is active
3 Aux2 Speed Pump motor speed when AUX2 function is active
Pump motor idle speed when there is no steering input
4 Idle Speed
without the fingertip option
Pump motor speed during steering (excluding lift, tilt, etc.)
5 Hydro Speed
without the fingertip option
Pump motor minimum speed when lift function is active with
6 Lift Min Speed Fingertip
the fingertip option
Tilt Backward Speed Pump motor speed when tilt-backward function is active
7
Fingertip with the fingertip option
Tilt Forward Speed Pump motor speed when tilt-forward function is active with
8
Fingertip the fingertip option
Pump motor speed when lowering function is active with the
9 Lower Speed Fingertip
fingertip option
Pump motor idle speed when there is no steering input with
10 Idle Speed Fingertip
the fingertip option
Pump motor speed during steering (excluding lift, tilt, etc.)
11 Hydro Speed Fingertip
with the fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-101 Application “EasyView”

 Calibration Menu – Pump Motor RPM (new software menu)

Fig. 2-102

No. Parameters Descriptions

Pump motor speed when tilt-forward/backward function is
1 Tilt Speed Manually
active without the fingertip option
Pump motor speed at the secondary lifting span when tilt-
Tilt Secondary Speed
2 forward/backward function is active without the fingertip
Manually (PLUS only)
option
3 Aux1 Speed Manually Pump motor speed when AUX1 function is active
Aux1 Secondary Speed Pump motor speed at the secondary lifting span when
4
Manually (PLUS only) AUX1 function is active
5 Aux2 Speed Manually Pump motor speed when AUX2 function is active
Pump motor speed during steering (excluding lift, tilt, etc.)
6 Hydro Speed Manually
without the fingertip option
Pump motor idle speed when there is no steering input
7 Idle Speed Manually
without the fingertip option
Pump motor minimum speed when lift function is active with
8 Lift Min Speed Fingertip
the fingertip option

Application “EasyView” 2-102 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 No. Parameters Descriptions
Pump motor speed when the fingertip lift knob is placed
halfway to the lift command end. The three fingertip lift-
related parameters Lift Min Speed Fingertip, Lift Middle
Speed Fingertip, and Lift Max Speed determine the pattern
of fingertip lift acceleration as shown below:

2500 Lift Max

Speed
Lift Middle Speed 2000
9
Fingertip
1500

RPM
Lift Min Speed
1000 Fingertip

500
Lift Middle
Speed Fingertip
0
Knob command
2
Pump motor speed when lowering function is active with the
10 Lower Speed Fingertip
fingertip option

Electrical system
Pump motor minimum speed when tilt function is active with
11 Tilt Min Speed Fingertip
the fingertip option
Pump motor speed when tilt-backward function is active
12 Tilt BWD Speed Fingertip
with the fingertip option
Tilt BWD Secondary
Pump motor speed at the secondary lifting span when tilt-
13 Speed Fingertip (PLUS
backward function is active with the fingertip option
only)
Pump motor speed when tilt-forward function is active with
14 Tilt FWD Speed Fingertip
the fingertip option
Tilt FWD Secondary
Pump motor speed at the secondary lifting span when tilt-
15 Speed Fingertip (PLUS
forward function is active with the fingertip option
only)
AUX1 Min Speed Pump motor minimum speed when AUX1 function is active
16
Fingertip with the fingertip option
AUX1 FWD Speed Pump motor speed when AUX1-forward function is active
17
Fingertip with the fingertip option
AUX1 FWD Secondary Pump motor speed at the secondary lifting span when
18
Speed Fingertip AUX1-forward function is active with the fingertip option
AUX1 BWD Speed Pump motor speed when AUX1-backward function is active
19
Fingertip with the fingertip option
AUX1 BWD Secondary Pump motor speed at the secondary lifting span when
20
Speed Fingertip AUX1-backward function is active with the fingertip option
AUX2 Min Speed Pump motor minimum speed when AUX2 function is active
21
Fingertip with the fingertip option
AUX2 FWD Speed Pump motor speed when AUX2-forward function is active
22
Fingertip with the fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-103 Application “EasyView”

 No. Parameters Descriptions
AUX2 BWD Speed Pump motor speed when AUX2-backward function is active
23
Fingertip with the fingertip option
Pump motor idle speed when there is no steering input with
24 Idle Speed Fingertip
the fingertip option
Pump motor speed during steering (excluding lift, tilt, etc.)
25 Steering RPM Fingertip
with the fingertip option

In addition, tilt speed can be adjusted per the span of tilt load condition. Use the following two
menus.

Manual

Fig. 2-103
Fingertip

Fig. 2-104

Application “EasyView” 2-104 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Weight sensor

Fig. 2-105
2

Electrical system
No. Parameters Descriptions
When this parameter value is on, the weight sensor
1 Weight Sensor Enable
function is enabled.
2 Weight Sensor Output Weight sensor voltage (V)
3 No Load Pressure Voltage Weight sensor voltage without load (V)
4 Load Pressure Voltage Weight sensor voltage with load (V)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-105 Application “EasyView”

 Calibration Menu – Load weight British units ON

Fig. 2-106

No. Parameters Descriptions

1 Load Weight in Lbs Load weight in the British unit. [Lbs]
Tilt Speed Reduced By
2 Tilt speed reduction per the load
Weight in Lbs

Application “EasyView” 2-106 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Load weight British units OFF

2
Fig. 2-107

Electrical system
No. Parameters Descriptions
1 Load Weight in Kg Load weight in the British unit. [Kg]
Tilt Speed Reduced By
2 Tilt speed reduction per the load
Weight in Kg

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-107 Application “EasyView”

 Calibration Menu – Truck Setup

Fig. 2-108

No. Parameters Descriptions

Enable Working
1 When this parameter value is on, the cooling fans function is enabled.
Fans
Enable
When this parameter value is on, the vehicle display can be used to
2 Calibration by
view and change calibration parameters.
Display
Enable Turtle
When this parameter value is on, the Turtle Speed function can be
3 Speed by
turned On or Off from the vehicle display.
Display
Enable EHS by When this parameter value is on, the EHS mode function can be
4
Display selected though the vehicle display.
Enable Chat When this parameter value is on, the display is allowed to go to PP
5
Time mode.
Enable British
6 Enables the use of British units.
Units
Enables the use of fingertip option. For a fingertip vehicle, you should
7 Enable Fingertip
set this parameter to “1” after flashing.

Application “EasyView” 2-108 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 No. Parameters Descriptions
Enable Auto Defines whether auto clamp function is used on this vehicle or not
8
Clamp (fingertip only).
Determines whether AUX2 is used on this vehicle or not. When this
9 Enable Aux2
parameter is On, the system will check for valve presence.
10 Enable Auto Tilt Defines whether auto tilt function is used on this vehicle or not.
When this parameter value is on, the vehicle‘s GSS function is all
11 Enable GSS
enabled.
Buzzer On
When this parameter value is on, the vehicle buzzer sound when the
12 Forward
forward direction is selected.
Direction
Buzzer On
When this parameter value is on, the vehicle buzzer sound when the
13 Reverse
reverse direction is selected.
Direction
When this parameter value is on, turtle mode is active, and the
Buzzer On
14 vehicle speed equals the Max Speed in Turtle Mode the vehicle

2
Turtle Speed
buzzer will sound.
Buzzer On High When this parameter value is on, the vehicle buzzer sound when the
15
Speed Enable speed higher than the Buzzer On Speed.

Electrical system
Defines the buzzer on high speed level, when motor speed is higher
Buzzer On
16 than this value, and Buzzer On High Speed Enable is ON, buzzer
Speed
sound.
When this parameter value is on and the Lift function and any of the
other functions (Tilt, AUX1, AUX2) are operated simultaneously, the
Lift Priority For pump operates at a speed that is the lowest speed among the inputs
Pump (Tilt, AUX1, AUX2 or Lift).
17
Reference When this parameter value is off and the Lift function and any of the
Speed other functions (Tilt, AUX1, AUX2) are operated simultaneously, then
the pump operates at a speed that is the highest speed among the
inputs (Tilt, AUX1, AUX2 or Lift).
Controller Fan When controller temperature is higher than the value of this setting,
18
Starting Temp the cooling fan runs automatically.
Motor Fan When motor temperature is higher than the value of this setting, the
19
Starting Temp cooling fan runs automatically.
If there is no input on AUX2 during the amount of time set for this
Auto Clamp
20 parameter since the vehicle is keyed on, the auto clamp function will
First Delay
be automatically conducted (fingertip only).
If there is no input on AUX2 during the amount of time set for this
Auto Clamp
21 parameter since the last AUX2 operation, the auto clamp function will
Interval Delay
be automatically conducted (fingertip only).
Whether to include the status of the seat switch in the conditions for
22 Enable SG
vehicle operation.
Enable Mono
Whether to enable the F/R switch in a vehicle that uses the fingertip
23 pedal with
and mono pedal options.
fingertip

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-109 Application “EasyView”

 2-6-7 Initial settings
The output analog voltage of each accelerator, lift sensor,
steering sensor and brake sensor signals to inform the
controllers of their physical positions. In other words, the
electrical system recognizes these components’ positions
according to how high their output voltage is.

As there is a variation in voltage output versus physical

position among individual units, you must reset this
relationship once any of the aforementioned components
is replaced or the controller firmware is updated.

The initial setting procedure for each component is as

follows:

Accelerator initial settings

1. On EasyView, go to the Calibration Menu 

Pedal Set.

2. Check the value of the Pedal Voltage A

parameter (1) when the accelerator is not
pressed at all. Enter this value in the setting field
for the Min Accelerator A parameter (2), and
then press Save.

(1)

(2)

Fig. 2-109

Application “EasyView” 2-110 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3. Check the value of the Pedal Voltage A
parameter (1) when the accelerator is fully
pressed. Enter this value in the setting field for
the Max Accelerator A parameter (3), and then
press Save.

(1)

(3)

2
Fig. 2-110

Electrical system
Lift sensor initial setting

1. On EasyView, go to the Calibration Menu  Lift

Set.

2. Check the value of the Lift Command parameter

(1) when the lift lever is in neutral. Enter this
value in the setting field for the Lift Min
parameter (2), and then press Save.

(1)

(2)

Fig. 2-111

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-111 Application “EasyView”

 3. Check the value of the Lift Command parameter
(1) when the lift lever is fully pulled. Enter this
value in the setting field for the Lift Max
parameter (3), and then press Save.

(1)

(3)

Fig. 2-112
Steering sensor initial setting

1. On EasyView, go to the Calibration Menu 

Steering Set.

2. Check the value of the Steer Sensor Output

Voltage parameter (1) when the rear wheels are
fully turned left. Enter this value in the setting
field for the Steering Anticlock parameter (2),
and then press Save.

(1)

(2)

Fig. 2-113

Application “EasyView” 2-112 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3. Check the value of the Steer Sensor Output
Voltage parameter (1) when the rear wheels are
in the middle. Enter this value in the setting field
for the Steering Middle parameter (3), and then
press Save.

(1)

(3)

2
Fig. 2-114

Electrical system
4. Check the value of the Steer Sensor Output
Voltage parameter (1) when the rear wheels are
fully turned right. Enter this value in the setting
field for the Steering Clock parameter (4), and
then press Save.

(1)

(4)

Fig. 2-115

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-113 Application “EasyView”

 Brake pedal initial settings

1. Prior to this initial setting, conduct brake pedal

adjustment. [Refer to Chapter 3-7-4]

2. On EasyView, go to the Calibration Menu →

Brake Pedal Set.

3. Setting for Brake Min

3-1. Read the value of Brake Pedal Voltage A

parameter (1) when the brake pedal is not
pressed at all.

3-2. Click the row for Brake Min.

3-3. Enter the value read at 2-1 in the setting

field in box (2) and then, press the Save (3).
Compared to 0.50V in the box (1), a little bit of
higher value like 0.55V is recommended.

Fig. 2-116

Application “EasyView” 2-114 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 4. Setting for Brake Max

4-1. Read the value of Brake Pedal Voltage A

parameter (1) when the brake pedal is fully
pressed.

4-2. Click the row for Brake Max.

4-3. Enter the value read at 3-1 in the setting

field in box (2) and then, press the Save (3).
Compared to 4.50V in the box (1), a little bit of
lower value like 4.45V is recommended.

Electrical system
Fig. 2-117

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-115 Application “EasyView”

2-7 Handling faults on instrument panel/EasyView
A. Fault Levels

One function of the instrument panel is to display faults

that have occurred in the vehicle. In the case where more
than one fault has occurred, the most serious fault
(lowest level number) is displayed.

• Fault Level 1: Line contactor drops; both drive and

pump motors stop. (At this, the buzzer sounds and
the red alarm LED on the instrument panel lights up.)
• Fault Level 2: Drive or pump motors stop
individually or both stop together.
• Fault Level 3: Drive motor speed is limited to
2,000 rpm and pump motor speed to 800 rpm.
• Fault Level 4: Drive motor speed limited to 800 rpm.
• Fault Level 5: Drive motor torque reduced.
• Fault Level 6: Pump motor torque reduced.
• Fault Level 7: With the performance not limited,
only related component will stop functioning.

B. Curtis codes

In addition to the instrument panel and EasyView, the

drive and pump motor controllers also inform the operator
of the current faults using two fault code indicator LEDs
installed on each controller and the fingertip extension
module. Their fault indications are called “Curtis codes.”

Compared to other indicators, they have an advantage in

that the operator can easily identify which controller has a
trouble simply by seeing them—only the LEDs on
controllers detected faulty light up. The table below
shows which controller could set off a warning for each
fault code.

For an explanation of how to read Curtis codes, see

Section 2-3-4.

Handling faults on instrument panel/EasyView 2-116 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 C. Measures for fault codes

Panel Fault
Fault description
code level
CONTACTOR FAULT – Contactor not working properly
Curtis code 31/38/39 Drive
1. The line contactor coil is either open or shorted.
Cause 2. The line contactor contacts are welded closed.
3. There are faulty crimps and connections in the wires to the line contactor coil.
1. Check if the line contactor is normally wired.
2. Check if the line fuse has blown.
17 1 3. Check if the coil of the line contactor is open-circuit (its normal
resistance is 360 Ω at 25°C [77°F]).
4. Check its resistance and replace it if it is detected to be abnormal.
Solution
5. With the key switch off, measure the resistance between the two contact
tips using a multimeter to check if they are fused (If the battery voltage is
detected between the line contactor’s secondary tip and the controller's
"B-" pin with the key off, it indicates a fusion between the two tips. In that
case, replace the line contactor).
EXT VOLT FAULT – Extension module’s voltage faulty
(extension module disabled)
Curtis code 21/22 Pump F. Extension
2
Cause Overvoltage/undervoltage on the extension module
1. Measure the voltage between pins 1 and 3 on the harness connector of

Electrical system
the fingertip extension module to check if the measurement represents
the battery voltage.
2. If it is not measured the battery voltage, check if pin 1 on the left drive
Solution motor controller and pin 3 on the fingertip extension module connector
are correctly connected to one another. And also check if the battery's
21 7 negative terminal is correctly connected to pins 1 and 2 on the fingertip
extension module connector.
3. If it is not correctly connected, replace the harness.

10 14 24 35

Pin
1 5
position 1 12

[Harness conn. of fingertip module] [Harness conn. of controller]

EXT TIME FAULT – Extension module’s communications faulty (extension module

disabled)
Curtis code 67 Pump
Cause PDO timeout/SDO fault reported on Ext module; CAN communication fault
1. Check if pin 5 on the fingertip extension module is normally connected to
pin 23 on the left drive motor controller.
2. Check if pin 4 on the fingertip extension module is normally connected to
Solution pin 35 on the left drive motor controller.
3. Reinstall the latest software version.
51 7 4. If the steps above do not solve the problem, replace the pump motor
controller.

10 14 24 35

Pin
1 5
position 1 12

[Harness conn. of fingertip module] [Harness conn. of controller]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-117 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
R-INV SHUTDOWN – Right drive motor controller overheated (system halted)
Curtis code 16 Drive
The right drive motor controller has reached the shutdown temperature limit
Cause
(95°C, 203°F).
1. Check the temperature of the right drive motor controller in diagnostic
mode on the instrument panel or EasyView.
2. If the temperature is detected to be higher than 95°C (203°F), cool down
66 1 the vehicle for 15 minutes.
3. If the right drive motor controller is hotter than the other controllers,
Solution check its U.V.W. connections to the battery.
4. Check if the EM parking brake is engaged.
5. Check if the vehicle is excessively loaded.
6. Check if the right drive motor controller is improperly mounted,
preventing heat conduction.
7. If the problem persists, replace the right drive motor controller.
L-INV SHUTDOWN - Left drive motor controller overheated (system halted)
Curtis code 16 Drive
The left drive motor controller has reached the shutdown temperature limit
Cause
(95°C, 203°F).
1. Check the temperature of the left drive motor controller in diagnostic
mode on the instrument panel or EasyView.
2. If the temperature is detected to be higher than 95°C (203°F), cool down
67 1 the vehicle for 15 minutes.
3. If the left drive motor controller is hotter than the other controllers, check
Solution its U.V.W. connections to the battery.
4. Check if the EM parking brake is engaged.
5. Check if the vehicle is excessively loaded.
6. Check if the left drive motor controller is improperly mounted, preventing
heat conduction.
7. If the problem persists, replace the left drive motor controller.
P-INV SHUTDOWN – Pump motor controller overheated (system halted)
Curtis code 16 Pump
The pump motor controller has reached the shutdown temperature limit
Cause
(95°C, 203°F).
1. Check the temperature of the pump motor controller in diagnostic mode
on the instrument panel or EasyView.
2. If the temperature is detected to be higher than 95°C (203°F), cool down
68 1
the vehicle for 15 minutes.
3. If the pump motor controller is hotter than the other controllers, check its
Solution
U.V.W. connections to the battery.
4. Check if the vehicle is excessively loaded.
5. Check if the pump motor controller is improperly mounted, preventing
heat conduction.
6. If the problem persists, replace the pump motor controller.

Handling faults on instrument panel/EasyView 2-118 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
P-MOTOR ENCODER – Pump motor’s encoder failed
Curtis code 36/73/88/93 Pump
The phase A or B signal of the pump motor encoder is abnormal or not
Cause
detected, or indicates an abnormally fast speed.
1. Check if the connector of the pump motor encoder is normally
connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the pump
motor controller measures 5 V.
3. Check if pin 3 on the pump motor encoder is normally connected to pin
31 (phase A) on the pump motor controller.
4. Check if pin 4 on the pump motor encoder is normally connected to pin
Solution
76 1 32 (phase B) on the pump motor controller.
5. Check if the phases A and B on the pump motor encoder normally turn
on and off using EasyView.
- Test Menu  Pump  “Pump Motor Encoder A” & “Pump Motor
Encoder B”
If either phase is abnormal, replace the pump motor encoder.
6. If the problem persists, replace the pump motor controller.

Pin
24 35

35 24 2
position 4 1
1 12 12 1

Electrical system
[Harness conn. of encoder] [Harness conn. of controller] [Controller port]

R-M TEMP SENSOR – Right drive motor’s thermal sensor failed

(display only, no change in vehicle performance)
Curtis code 29 Drive
Right drive motor thermal sensor voltage is detected to be out of range
Cause (Continued operation with this fault may result in an overheated drive
motor, reducing its efficiency).
1. Check if the connector of the thermal sensor on the right drive motor is
normally connected.
2. Check if pin 1 on the thermal sensor of the right drive motor is normally
connected to pin 8 on the right drive motor controller.
Solution 3. Check if pin 2 on the thermal sensor of the right drive motor is normally
77 7
connected to pin 7 on the right drive motor controller.
4. Check if the resistance of the thermal sensor on the right drive motor
measures 603 Ω at 25°C (77°F).
5. Replace the thermal sensor of the right drive motor.
24 35

Pin
4 1
position 1 12

[Harness conn. of thermal sensor] [Harness conn. of controller]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-119 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
L-M TEMP SENSOR - Left drive motor’s thermal sensor failed
(display only, no change in vehicle performance)
Curtis code 29 Drive
The left drive motor thermal sensor voltage is detected to be out of range
Cause (Continued operation with this fault may result in an overheated drive
motor, reducing its efficiency).
1. Check if the connector of the thermal sensor on the left drive motor is
normally connected.
2. Check if pin 1 on the thermal sensor of the left drive motor is normally
connected to pin 8 on the left drive motor controller.
Solution 3. Check if pin 2 on the thermal sensor of the left drive motor is normally
78 7
connected to pin 7 on the left drive motor controller.
4. Check if the resistance of the thermal sensor on the left drive motor
measures 603 Ω at 25°C (77°F).
5. Replace the thermal sensor of the left drive motor.
24 35

Pin
4 1
position 1 12

[Harness conn. of thermal sensor] [Harness conn. of controller]

P-M TEMP SENSOR – Pump motor’s thermal sensor failed

(display only, no change in vehicle performance)
Curtis code 29 Drive
The pump motor thermal sensor voltage is detected to be out of range
Cause (Continued operation with this fault may result in an overheated drive
motor, reducing its efficiency).
1. Check if the connector of the thermal sensor on the pump motor is
normally connected.
2. Check if pin 1 on the thermal sensor of the pump motor is normally
connected to pin 8 on the left pump controller.
Solution 3. Check if pin 2 on the thermal sensor of the pump motor is normally
79 7
connected to pin 7 on the left pump controller.
4. Check if the resistance of the thermal sensor on the pump motor
measures 603 Ω at 25°C (77°F).
5. Replace the thermal sensor of the pump motor.
24 35

Pin
4 1
position 1 12

[Harness conn. of thermal sensor] [Harness conn. of controller]

Handling faults on instrument panel/EasyView 2-120 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
L-EM BRAKE – Left EM brake failed
Curtis code 32 Drive
The circuit from pin 5 or 13 of the left drive motor controller is open or
Cause
short, causing an abnormal current in the circuit detected by the controller.
1. Check if the connector of the EM brake on the left drive motor is
normally connected.
2. Check if the connectors labeled “EM CONN A” and “EM CONN B” are
properly connected.
3. Check if pin 1 of the left EM brake connector is normally connected to
Solution pin 5 of the left drive motor controller connector.
4. Check if pin 2 of the left EM brake connector is normally connected to
80 2 pin 13 of the left drive motor controller connector.
5. Swap the harness connectors for the left and right EM brakes, and check
which fault code is displayed.
6. If fault code 81 appears, replace the left drive motor's EM brake.

24 35

Pin
position 2 1
1 12 2
[Harness conn. of EM brake] [Harness conn. of controller]

Electrical system
R-EM BRAKE - Right EM brake failed
Curtis code 32 Drive
The circuit from pin 5 or 13 of the left drive motor controller is open or
Cause
short, causing an abnormal current in the circuit detected by the controller.
1. Check if the connector of the EM brake on the right drive motor is
normally connected.
2. Check if the connectors labeled “EM CONN A” and “EM CONN B” are
properly connected.
3. Check if pin 1 of the right EM brake connector is normally connected to
Solution pin 5 of the right drive motor controller connector.
4. Check if pin 2 of the right EM brake connector is normally connected to
81 2 pin 13 of the right drive motor controller connector.
5. Swap the harness connectors for the left and right EM brakes, and check
which fault code is displayed.
6. If fault code 80 appears, replace the right drive motor's EM brake.

24 35

Pin
position 2 1
1 12

[Harness conn. of EM brake] [Harness conn. of controller]

EM BRAKE WARN –EM BRAKE WARN

Curtis code N/A Drive
Triggered when Fault code 88 (EM BRAKE LOCKED) has happened to 20
82 3 Cause times.
- Phenomenon : The speed of drive motor is limited to 2,000 rpm.
1. After checking out that EM BRAKE is free from defect, conduct resetting
Solution
EM BRAKE COUNT.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-121 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
PAR CHANGE FAULT – Parameter change failed
Curtis code 49 Drive
83 1 Cause A change to a system parameter is detected that requires this safety fault.
1. This code appears when a parameter value has been changed. Turn off
Solution
the key switch and turn it on again.
DUAL TRA FAULT – Dual traction failed
Curtis code 74/75/99 Drive
When one of the drive motor controllers is troubled, the other drive motor
Cause
controller sets off this fault code.
84 1
1. Check the history of both drive controllers’ faults.
2. Clear all the faults on both controllers.
Solution
3. If the problem persists, identify which motor controller’s LEDs have lit up.
4. Replace the faulty motor controller.
D-INV SUPERVISOR – Some problem in the supervisor micro-process of drive
controller.
1. No drive.
2. No effect in Pump.
3. EM BRAKE is immediately engaged.
Curtis code 77 Drive EM BRAKE
85 2 1. Some mismatch in Supervisor's duplicate reading was detected.
2. Damage internally in Supervisor’s micro-process.
Cause 3. Switch input is greater than 100ms, between upper and lower
thresholds.
(If the error recurs, check the switch for moisture.)
1. After disconnecting the controller connector, clean and dry it. If a defect
Solution occurs, replace it.
2. Replace the drive motor controller.

Handling faults on instrument panel/EasyView 2-122 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
EM BRAKE LOCKED – EM BRAKE WARNING
Curtis codes 65 Drive
When the brake pedal is pushed more than 90% while driving motor speed
88 2 Cause exceeds 3,000 rpm, check the rpm for 1.7 seconds and then, force EM
brake when it does not fall below 2,700 rpm.
Solution 1. Turn the key switch off and again on.
CAP NOT CHARGED – Capacitor not charged
Curtis code 14 Drive Pump
The capacitor in one of the controllers has been discharged or charged
Cause
abnormally.
A 1
1. Turn the key switch off and again on.
2. Check that the line contactor is normally wired.
Solution
3. If the problem persists, identify which motor controller’s LEDs have lit up.
4. Replace the faulty motor controller.
DISPLAY CAN FAULT – Display CAN communications failed
Curtis code 62 Drive
Cause The instrument panel’s CAN communications is failed

2
1. Check if the instrument panel is correctly connected with the main
harness.
2. Check if the resistance between pins 2 and 7 on the CAN port connector
measures approx. 60 Ω when the harness is connected to the port and
Solution the key switch is off.

Electrical system
3. If the measurement falls short of 60 Ω, check if the resistance between
A7 1 pins 5 and 6 on the instrument panel’s P2 connector measures approx.
120 Ω.
4. If the measurement falls short of 120 Ω, replace the instrument panel.

3 2 1

Pin 6 9
6 5 4
position
1 5

[CAN port] [Instrument P2 connector]

EXT CUR FAULT – Extension module’s current faulty (extension module disabled)
Curtis code Pump F. Extension
Cause Total current exceeded 18 A
C1 7
1. Replace the fingertip harness.
Solution 2. Replace the fingertip extension module.
3. Replace the main harness.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-123 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
EXT POWER FAULT – Extension module controller’s power supply faulty (none)
Curtis code 13/14/15 Pump F. Extension
Cause Fingertip extension module fails to be correctly powered from the battery
1. Check if the fingertip fuse in fuse box A has been blown.
2. Check if the fingertip extension module is powered at the rated battery
voltage (36V/48V) by measuring the voltage between pins 5 and 6 on
Solution the F_CONN. A connector.
3. If the measurement falls short of the rated voltage, replace the fingertip
C2 7 harness.
4. If the problem persists, replace the fingertip extension module.

1 4

5 8
Pin
position

[Main harness F_CONN. A]

R-CONT CAN FAULT – Right CAN communications failed

Curtis code 72 Drive
Cause The right drive motor controller’s CAN communications is failed.
1. Check if the resistance between pins 2 and 7 on the CAN port connector
measures approx. 60 Ω when the harness is connected to the port and
the key switch is off.
2. If the measurement falls short of 60 Ω, check if pin 23 on the left drive
motor controller and pin 23 on the right drive motor controller are
Solution correctly connected to one another.
3. If their connection is normal, check if pin 35 on the left drive motor
C7 1 controller and pin 35 on the right drive motor controller are correctly
connected to one another.
4. Reinstall the software.
5. Replace the right drive motor controller.
24 35

6 9
Pin
position 1 5 1 12

[CAN port] [Harness conn. of controller]

R-INV OVERTEMP – Right drive motor controller overheated (performance

lowered)
Curtis code 22 Drive
The resistance of the thermal sensor inside the right drive motor controller
Cause represents an over-temperature of the controller above the specified limit of
85°C (185°F).
1. Check the temperature of the right drive motor controller in diagnostic
E1 5 mode on the instrument panel or EasyView.
2. If the temperature is detected to be higher than 85°C (185°F), cool down
the vehicle for 15 minutes.
Solution
3. If the right drive motor controller is hotter than the other controllers,
check its U.V.W. connections to the battery.
4. Check if the EM parking brake is engaged.
5. If the problem persists, replace the right drive motor controller.

Handling faults on instrument panel/EasyView 2-124 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
L-INV OVERTEMP – Left drive motor controller overheated (performance lowered)
Curtis code 22 Drive
The resistance of the thermal sensor inside the left drive motor controller
Cause represents an over-temperature of the controller above the specified limit of
85°C (185°F).
1. Check the temperature of the left drive motor controller in diagnostic
E2 5 mode on the instrument panel or EasyView.
2. If the temperature is detected to be higher than 85°C (185°F), cool down
the vehicle for 15 minutes.
Solution
3. If the left drive motor controller is hotter than the other controllers, check
its U.V.W. connections to the battery.
4. Check if the EM parking brake is engaged.
5. If the problem persists, replace the left drive motor controller.
P-INV OVERTEMP – Pump motor controller overheated (performance lowered)
Curtis code 22 Pump
The resistance of the thermal sensor inside the pump motor controller
Cause represents an over-temperature of the controller above the specified limit of
85°C (185°F).

E3 6
1. Check the temperature of the pump motor controller in diagnostic mode
on the instrument panel or EasyView. 2
2. If the temperature is detected to be higher than 85°C (185°F), cool down
Solution the vehicle for 15 minutes.

Electrical system
3. If the pump motor controller is hotter than the other controllers, check its
U.V.W. connections to the battery.
4. If the problem persists, replace the pump motor controller.
R-MOTOR OVERTEMP – Right drive motor overheated (performance lowered)
Curtis code 28 Drive
The controller has detected that the resistance of the thermal sensor inside
Cause the right drive motor represents an over-temperature of the motor above
the specified limit of 145°C (293°F).
1. Check the temperature of the right drive motor in diagnostic mode on the
instrument panel or EasyView.
2. If the temperature is detected to be higher than 145°C (293°F), cool
down the vehicle for 15 minutes.
3. Check if the connector of the thermal sensor on the right drive motor is
normally connected.
4. Check if pin 1 on the thermal sensor of the right drive motor is normally
Solution
connected to pin 8 on the right drive motor controller.
E4 5
5. Check if pin 2 on the thermal sensor of the right drive motor is normally
connected to pin 7 on the right drive motor controller.
6. Check if the resistance of the thermal sensor on the right drive motor
measures 603 Ω at 25°C (77°F).
7. Replace the thermal sensor of the right drive motor.
8. If the problem persists, replace the right drive motor controller.
24 35

Pin
4 1
position 1 12

[Harness conn. of thermal sensor] [Harness conn. of controller]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-125 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
L-MOTOR OVERTEMP – Left drive motor overheated (performance lowered)
Curtis code 28 Drive
The controller has detected that the resistance of the thermal sensor inside
Cause the left drive motor represents an over-temperature of the motor above the
specified limit of 145°C (293°F).
1. Check the temperature of the left drive motor in diagnostic mode on the
instrument panel or EasyView.
2. If the temperature is detected to be higher than 145°C (293°F), cool
down the vehicle for 15 minutes.
3. Check if the connector of the thermal sensor on the left drive motor is
normally connected.
4. Check if pin 1 on the thermal sensor of the left drive motor is normally
Solution
connected to pin 8 on the left drive motor controller.
E5 5
5. Check if pin 2 on the thermal sensor of the left drive motor is normally
connected to pin 7 on the left drive motor controller.
6. Check if the resistance of the thermal sensor on the left drive motor
measures 603 Ω at 25°C (77°F).
7. Replace the thermal sensor of the left drive motor.
8. If the problem persists, replace the left drive motor controller.
24 35

Pin
4 1
position 1 12

[Harness conn. of thermal sensor] [Harness conn. of controller]

P- MOTOR OVERTEMP – Pump motor overheated (performance lowered)

Curtis code 28 Pump
The controller has detected that the resistance of the thermal sensor inside
Cause the pump motor represents an over-temperature of the motor above the
specified limit of 145°C (293°F).
1. Check the temperature of the pump motor in diagnostic mode on the
instrument panel or EasyView.
2. If the temperature is detected to be higher than 20°C (293°F), cool down
the vehicle for 15 minutes.
3. Check if the connector of the thermal sensor on the pump motor is
normally connected.
4. Check if pin 1 on the thermal sensor of the pump motor is normally
Solution
connected to pin 8 on the left pump controller.
E6 6
5. Check if pin 2 on the thermal sensor of the pump motor is normally
connected to pin 7 on the left pump controller.
6. Check if the resistance of the thermal sensor on the pump motor
measures 603 Ω at 25°C (77°F).
7. Replace the thermal sensor of the pump motor.
8. If the problem persists, replace the pump motor controller.
24 35

Pin
4 1
position 1 12

[Harness conn. of thermal sensor] [Harness conn. of controller]

Handling faults on instrument panel/EasyView 2-126 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
WRONG START – Signal to move pump motor detected at startup
Curtis code 47/54 Drive
Accelerator pedal switch or forward/reverse direction signal is detected to
Cause
be active when the vehicle is first switched on.
1. Put the F/R switch in neutral.
2. Check if the accelerator pedal returns normally when released.
3. Calibrate the initial settings for the accelerator using EasyView or the
instrument panel.
Solution
4. Check if pins 2 and 3 on the F/R unit’s 4-pin connector are connected to
EE 2 one another in neutral. If so, replace the F/R unit.
5. Check if pins 1 and 2 on the F/R unit’s 4-pin connector are connected to
one another in neutral. If so, replace the F/R unit.

2 1
Pin
position 4 3

[F/R unit’s 4-pin connector]

SEAT SW OPEN – Seat switch opened 2

Curtis code 47/54 Drive
Cause The seat switch is open.

Electrical system
1. Sit down on the driver's seat.
2. If fault code EE stays blinking even when the operator is seated, check if
the connector of the seat switch is normally connected.
3. If the seat belt interlock option is applied, fasten the seat belt after you
Measure are seated.
EE 4. If the actions above do not solve the problem, disconnect the seat switch
(FLASH 1 connector and measure the resistance between pins 1 and 2 on the
ING) connector using a multimeter. If it measures an open circuit, it means the
seat switch is damaged. Replace the seat switch.

Pin 1 2
position

[Seat switch connector]

EXTENSION FAULT – Extension module internally faulty

Curtis code 68 Pump F. Extension
The fingertip extension module has a firmware error, or is overheated or
Cause
EF 7 overcooled.
1. Turn the key switch off and again on.
Solution 2. Leave the vehicle in a place warmer than 0°C (32°F) for 15 minutes.
3. If the problem persists, replace the fingertip extension model.
LOW BATT VOLT – Battery voltage insufficient (charge needed)
Curtis code 57 Drive
EL 3 Cause
The battery voltage is detected (at pin 1 of the drive motor controller) to be
below the minimum battery voltage set point.
Solution Charge the battery.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-127 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
EEPROM FAULT – Controller memory failed
Curtis code 46 Drive Pump
Cause The EEPROM memory on a motor controller has failed.
F 1
1. Reinstall the latest software version.
Solution 2. If the problem persists, identify which motor controller’s LEDs have lit up.
3. Replace the faulty motor controller.
MAX BATT VOLT – Battery voltage excessive
Curtis code 18 Drive Pump
The battery voltage between terminal B+ and B- on a motor controller has
Cause
F0 1 reached a severe overvoltage limit (70 V).
1. Measure the voltage between terminals B+ and B- on each controller
Solution using a multimeter to check if the measurement exceeds 70 V.
2. If a controller's voltage measures over 70 V, replace it.
MIN BATT VOLT – Battery voltage insufficient
Curtis code 17 Drive Pump
The battery voltage between terminal B+ on a motor controller has reached
Cause
F1 1 a severe undervoltage limit (20 V).
1. Measure the voltage between the terminals B+ and B- on each controller
Solution using a multimeter to check if the measurement falls short of 20 V.
2. If a controller's voltage measures below 20 V, replace it.
ACCEL FAULT – Signal from accelerator not received
Curtis code 55 Drive
One of the accelerator’s signal voltages is over the upper threshold or
Cause
below the lower threshold.
1. Check if the accelerator connector is normally connected to the main
harness. If so,
2. Check if both the left drive and pump motor controllers supply an approx.
5 V voltage to their respective encoders using EasyView.
- Left drive encoder: Test Menu  Drive  “Left Motor Encoder (5V)”
- Pump encoder: Test Menu  Pump  “Pump Motor Encoder (5V)”
If either controller fails 5 V voltage supply, replace that controller.
3. If both controllers normally output a 5 V voltage, check if the
accelerator’s two signals displayed on EasyView amount to approx. 5 V.
- Test Menu  Drive  “Pedal Voltage A” / “Pedal Voltage B”
Solution If the accelerator fails to output a total of 5 V voltage, replace it.
4. If they normally amount to approx. 5 V, check the connection of the
F2 2 accelerator to the controllers:
- Pin 2 on the accelerator to pin 16 on the left drive motor controller.
- Pin 1 on the accelerator to pin 7 on the left drive motor controller.
- Pin 3 on the accelerator to pin 26 on the left drive motor controller.
- Pin 5 on the accelerator to pin 16 on the pump motor controller.
- Pin 4 on the accelerator to pin 7 on the pump motor controller.
- Pin 6 on the accelerator to pin 26 on the pump motor controller.
If any part of the connection above is found open or short, replace the
main harness.

24 35
1 2 3
Pin 4 5 6
position 1 12

[Harness conn. of accelerator] [Harness conn. of controller]

Handling faults on instrument panel/EasyView 2-128 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
R-INVERTER FAULT – Right drive motor controller failed
Curtis code 12 Drive
Cause An overcurrent is detected on the right drive inverter.
1. Turn off the key switch and turn it on again.
2. Check if the U.V.W. terminals on the right drive motor are normally
F3 1 connected.
3. Check if the U.V.W. terminals on the right drive motor controller are
Solution
normally connected.
4. Check if the respective voltages of the U.V.W. terminals measure all
between 0.3–0.7 V using a multimeter.
5. Replace the right drive motor controller.
L-INVERTER FAULT – Left drive motor controller failed
Curtis code 12 Drive
Cause An overcurrent is detected on the left drive inverter.
1. Turn off the key switch and turn it on again.
2. Check if the U.V.W. terminals on the left drive motor are normally
F4 1 connected.
3. Check if the U.V.W. terminals on the left drive motor controller are
Solution
normally connected.
4. Check if the respective voltages of the U.V.W. terminals measure all
between 0.3–0.7 V using a multimeter.
2
5. Replace the left drive motor controller.

Electrical system
P-INVERTER FAULT – Pump motor controller failed
Curtis code 12 Pump
Cause An overcurrent is detected on the pump inverter.
1. Turn off the key switch and turn it on again.
F5 1 2. Check if the U.V.W. terminals on the pump motor are normally.
3. Check if the U.V.W. terminals on the pump motor controller are normally.
Solution
4. Check if the respective voltages of the U.V.W. terminals measure all
between 0.3–0.7 V using a multimeter.
5. Replace the pump motor controller.
R-MOTOR I OFFSET – Right drive motor current failed
Curtis code 13 Drive
Cause The current sensor offset reading from the right drive motor is invalid.
F6 1 1. Check for current leakage to the vehicle frame from the right drive motor
phase U, V or W.
Solution
2. If problems persist, the drive motor controller is defective and needs to
be replaced.
L-MOTOR I OFFSET – Left drive motor current failed
Curtis code 13 Drive
Cause The current sensor offset reading from the left drive motor is invalid.
F7 1 1. Check for current leakage to the vehicle frame from the left drive motor
phase U, V or W.
Solution
2. If problems persist, the drive motor controller is defective and needs to
be replaced.
P-MOTOR I OFFSET – Pump motor current failed
Curtis code 13 Pump
Cause The current sensor offset reading from the pump motor is invalid.
F8 1 1. Check for current leakage to the vehicle frame from the pump motor
phase U, V or W.
Solution
2. If problems persist, the pump motor controller is defective and needs to
be replaced.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-129 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
STEER SENSOR OUT – Steer sensor output failed
Curtis code 56 Drive
Analog 1 inputs are over the steering angle sensor’s higher threshold or
Cause
below its lower threshold.
1. Check if pin 1 on the steering sensor connector is normally connected to
pin 25 on the left drive motor controller.
2. Check if pin 2 on the steering sensor connector is normally connected to
pin 24 on the left drive motor controller.
3. Check if pin 3 on the steering sensor connector is normally connected to
Solution
pin 7 on the left drive motor controller.
F9 4 4. Check if the steering sensor is detected to output a normal signal on
EasyView.
5. If the measurement is not normal, replace the steering sensor;
otherwise, replace the left drive motor controller.
24 35

Pin
3 2 1
position 1 12

[Harness conn. of steer sensor] [Harness conn. of controller]

12V NOT OK – 12V output from a controller failed

Curtis code 69 Drive Pump
An overcurrent (over 200 mA) is detected in the drive or pump motor
Cause
controller’s 12V supply circuit.
1. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the left
drive controller measures 12 V.
2. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the right
Solution drive controller measures 12 V.
3. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the pump
FA 1
controller measures 12 V.
4. Replace any controller whose 12V output is not normal.
24 35

Pin
position 1 12

[Harness conn. of controller]

Handling faults on instrument panel/EasyView 2-130 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
R-MOTOR ENCODER – Right drive motor’s encoder failed
Curtis code 36/73/88/93 Drive
The phase A or B signal of the right drive motor encoder is abnormal or not
Cause
detected, or indicates an abnormally fast speed.
1. Check if the U.V.W. terminals on the right drive motor are normally
connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the right
drive motor measures 5 V.
3. Check if pin 3 on the right drive motor encoder is normally connected to
pin 31 (phase A) on the right drive motor controller.
4. Check if pin 4 on the right drive motor encoder is normally connected to
Solution
FC 4 pin 32 (phase B) on the right drive motor controller.
5. Check if phases A and B on the right drive motor encoder normally turn
on and off on EasyView.
- Test Menu  Drive  “Right Motor Encoder A” & “Right Motor
Encoder B”
If either phase is abnormal, replace the right drive motor encoder.
6. If the problem persists, replace the right drive motor controller.

Pin
24 35

35 24 2
position 4 1
1 12 12 1

Electrical system
[Harness conn. of encoder] [Harness conn. of controller] [Controller port]

L-MOTOR ENCODER – Left drive motor’s encoder failed

Curtis code 36/73/88/93 Drive
The phase A or B signal of the left drive motor encoder is abnormal or not
Cause
detected, or indicates an abnormally fast speed.
1. Check if the U.V.W. terminals on the left drive motor are normally
connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the left
drive motor measures 5 V.
3. Check if pin 3 on the left drive motor encoder is normally connected to
pin 31 (phase A) on the left drive motor controller.
4. Check if pin 4 on the left drive motor encoder is normally connected to
Solution
Fd 4 pin 32 (phase B) on the left drive motor controller.
5. Check if phases A and B on the left drive motor encoder normally turn on
and off using EasyView.
- Test Menu  Drive  “Left Motor Encoder A” & “Left Motor Encoder
B”
If either phase is abnormal, replace the left drive motor encoder.
6. If the problem persists, replace the left drive motor controller.
24 35

35 24
Pin
position 4 1
1 12 12 1

[Harness conn. of encoder] [Harness conn. of controller] [Controller port]

FINGERTIP FAULT – Fingertip faulty (pump stopped)

Curtis code 53 Pump F. Extension
FF 2 Cause A fingertip knob is out of range.
1. Check the output of each fingertip knob (Knob Command) in test menu
Solution
on EasyView. If any of the knobs is found abnormal, replace it.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-131 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
5V NOT OK – 5V output from a controller failed
Curtis code 25/69 Drive Pump
An overcurrent (over 200 mA) is detected in the drive or pump motor
Cause
controller’s 5V supply circuit.
1. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the left
drive controller measures 5 V.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the right
Solution drive controller measures 5 V.
3. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the pump
FH 1
controller measures 5 V.
4. Replace any controller whose 5V output is not normal.
24 35

Pin
position 1 12

[Harness conn. of controller]

PUMP SIGN ON – Signal to move pump motor detected at startup

Curtis code 47, (P-51,56) Pump
Cause A lever command (lift, lower, tilt, sideshift) is detected at startup.
1. Position all the hydraulic control levers in neutral.
FL 2 2. Calibrate the initial settings for the lift sensor using EasyView or the
instrument panel.
Solution
3. If the problem persists, make an adjustment of the clearance for the lift
sensor.
4. If the problem persists, replace the valve board.
R-INV UNDERTEMP- Right drive motor controller overcooled (-40°C, -40°F)
Curtis code 15 Drive
The right drive motor controller is below the lower temperature shutdown
Cause
H1 1 limit (-40°C, -40°F).
1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour. And
Solution then check if it is operational.
2. If the problems remains present, replace the right drive motor controller.
L-INV UNDERTEMP - Left drive motor controller overcooled (-40°C, -40°F)
Curtis code 15 Drive
The left drive motor controller is below the lower temperature limit (-40°C, -
Cause
H2 1 40°F).
1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour. And
Solution then check if it is operational.
2. If the problems remains present, replace the left drive motor controller.
P-INV UNDERTEMP – Pump motor controller overcooled (-40°C, -40°F)
Curtis code 15 Pump
The pump motor controller is below the lower temperature limit (-40°C,
Cause
H3 1 -40°F).
1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour. And
Solution then check if it is operational.
2. If the problems remains present, replace the pump motor controller.
R-MOTOR OPEN – Right drive motor circuit open
Curtis code 37 Drive
H4 1 Cause The U, V or W phase of the right drive motor is detected to be open.
1. Check for the U.V.W. connections of the right drive motor.
Solution
2. Replace the right drive motor.

Handling faults on instrument panel/EasyView 2-132 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
L-MOTOR OPEN - Left drive motor’s circuit open
Curtis code 37 Drive
H5 1 Cause The U, V or W phase of the left drive motor is detected to be open.
1. Check for the U.V.W. connections of the left drive motor.
Solution
2. Replace the left drive motor.
P-MOTOR OPEN – Pump motor’s circuit open
Curtis code 37 Pump
H6 1 Cause The U, V or W phase of the pump motor is detected to be open.
1. Check for the U.V.W. connections of the pump motor.
Solution
2. Replace the pump motor.
SOFTWARE ERROR – Software failed
Curtis code 68/71/91 Drive Pump
Cause Software error is detected.
1. Reinstall the latest software version.
2. Check that there is no switch input noise and instability at pin 6 on the
Solution pump motor controller.
3. If the problem persists, identify which motor controller’s LEDs have lit up.
H8 1
2
4. Replace the faulty motor controller.
24 35

Pin

Electrical system
position 1 12

[Harness conn. of controller]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-133 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
PEDAL SW FAULT - Brake pedal sensor signal fault
Curtis code 61 Drive
1. One of brake sensor’s signal voltages is over the range. (Phase A & B :
5V +/- 0.25V)
Cause
2. The sum of Phase A’s voltage and Phase B’s voltage is beyond 5.3V.
3. The harness wires to brake sensor are shorted or open.
1. Check if brake sensor connector is properly connected to the
main harness.
2. Check out if the harness wires to brake sensor are free from
open and short.
3. Since both left traction controller and pump controller normally
output 5 V voltage to brake sensor, check if brake sensor’s two
signals displayed on EasyView are to approx. 5 V.
- Test Menu → Drive → “Brake Pedal Voltage A” / “Brake
Pedal Voltage B”
If brake sensor fails to output the total of 5 V voltage, replace the
brake sensor.
Solution 4. If they normally amount to approx. 5 V, check the connection of
H9 1 the brake sensor to the controllers:
- Pin 3 on the brake sensor to pin 51 on the right drive motor
controller.
- Pin 5 on the brake sensor to pin 55 on the right drive motor
controller.
- Pin 1 on the brake sensor to pin 146 on the right drive motor
controller.
- Pin 2 on the brake sensor to pin 60 on the pump motor controller.
- Pin 4 on the brake sensor to pin 64 on the pump motor controller.
- Pin 6 on the brake sensor to pin 91 on the pump motor controller.
If any part of the connection above is found open or short,
replace the main harness.
24 35

Pin
position 1 12

[Harness conn. of Brake sensor] [Harness conn. of controller]

LIFT SOL FAULT – Lift solenoid valve faulty (pump stopped)
Curtis code 61 Pump F. Extension
Cause The circuit for the fingertip control valve’s lift solenoid (J1-12) is open/short.
1. Check if pin 8 on the main control valve connector A is normally
connected to pin 12 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 8 and 4
L1 2 on the main control valve connector A to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

10 14 1 4
4 1
Pin 5 8
8 5
1 5
position

[Harness conn. of fingertip module] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

Handling faults on instrument panel/EasyView 2-134 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
LOW SOL FAULT – Lowering solenoid valve faulty (pump stopped)
Curtis code 62 Pump F. Extension
The circuit for the fingertip control valve’s lowering solenoid (J1-13) is
Cause
open/short.
1. Check if pin 8 on the main control valve connector B is normally
connected to pin 13 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 8 and 4
L2 2 on the main control valve connector B to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

10 14 1 4
4 1
Pin 5 8
8 5
1 5
position

[Harness conn. of fingertip module] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

TILT FWD SOLFAU – Tilt-forward solenoid valve faulty (pump stopped)

2
Curtis code 64 Pump F. Extension
The circuit for the fingertip control valve’s tilt-forward solenoid (J1-9) is
Cause
open/short.
1. Check if pin 7 on the main control valve connector B is normally

Electrical system
connected to pin 9 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 7 and 3
L3 2 on the main control valve connector B to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

10 14 1 4
4 1
Pin 5 8
8 5
1 5
position

[Harness conn. of fingertip module] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-135 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
TILT BACK SOLFAU – Tilt-backward solenoid valve faulty (pump stopped)
Curtis code 59 Pump F. Extension
The circuit for the fingertip control valve’s tilt-backward solenoid (J1-11) is
Cause
open/short.
1. Check if pin 7 on the main control valve connector A is normally
connected to pin 11 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 7 and 3
L4 2 on the main control valve connector A to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

10 14 1 4
4 1
Pin 5 8
8 5
1 5
position

[Harness conn. of fingertip module] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

AUX1 L-SOLFAU – AUX1-left solenoid valve faulty (pump stopped)

Curtis code 63 (AUX1 FWD) Pump F. Extension
The circuit for the fingertip control valve’s AUX1-left solenoid (J1-14) is
Cause
open/short.
1. Check if pin 6 on the main control valve connector B is normally
connected to pin 14 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 2 and 6
L5 2 on the main control valve connector B to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

10 14 1 4
4 1
Pin 5 8
8 5
1 5
position

[Harness conn. of fingertip module] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

AUX1 R- SOLFAU – AUX1-right solenoid valve faulty (pump stopped)

Curtis code 65 (AUX1 BWD) Pump F. Extension
The circuit for the fingertip control valve’s AUX1-right solenoid (J1-10) is
Cause
open/short.
1. Check if pin 6 on the main control valve connector A is normally
connected to pin 10 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 2 and 6
L6 2 on the main control valve connector A to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

10 14 1 4
4 1
Pin 5 8
8 5
1 5
position

[Harness conn. of fingertip module] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

Handling faults on instrument panel/EasyView 2-136 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Panel Fault
Fault description
code level
AUX2 L-SOLFAU – AUX2-left solenoid valve faulty (shut down PD)
Curtis code 35 Pump F. Extension
The circuit for the fingertip control valve’s AUX2-left solenoid (P1-2) is
Cause
open/short.
1. Check if pin 5 on the main control valve connector B is normally
connected to pin 2 on the pump motor controller.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1 and 5
L7 7 on the main control valve connector B to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.
24 35
1 4
4 1
Pin 5 8
8 5
position 1 12

[Harness conn. of controller] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

AUX2 R-SOLFAU - AUX2-right solenoid valve faulty (shut down PD)

2
Curtis code 35 Drive
The circuit for the fingertip control valve’s AUX2-right solenoid (D2-2) is
Cause
open/short.
1. Check if pin 5 on the main control valve connector A is normally
connected to pin 2 on the right drive controller connector.

Electrical system
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1 and 5
L8 7 on the main control valve connector A to check if it measures approx. 30
Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.
24 35
1 4
4 1
Pin 5 8
8 5
position 1 12

[Harness conn. of controller] [Harness conn. of fingertip MCV] [Fingertip MCV connector A/B]

ISO/UNLOAD SOL – ISO/UNLOAD solenoid valve faulty (shut down driver)

Curtis code 31 Pump
Cause ISO (STD), unloading SOL (fingertip OPT) (P1-5) open/short
1. Check if pin 1 on the main control valve connector C is normally
connected to pin 5 on the pump motor controller.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1 and 2
L9 7 on the main control valve connector C to check if it measures approx.
28.5 Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.
24 35

Pin 1 2

position 1 12
2 1

[Harness conn. of controller] [Harness conn. of diverter] [Fingertip MCV connector C]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 2-137 Handling faults on instrument panel/EasyView
 Panel Fault
Fault description
code level
F-KNOB CAN FAULT – Fingertip CAN module CAN communications failed
Curtis code 52 Pump F. Extension
Cause The armrest CAN module’s CAN communications is failed.
1. Check if the armrest CAN module is correctly connected with the main
harness.
2. Check if pin 3 on the F_CONN. A connector and pin 23 on the left drive
motor controller are correctly connected to one another.
Solution 3. If their connection is normal, check if pin 2 on the F_CONN. A connector
and pin 35 on the left drive motor controller are correctly connected to
LL 1 one another.
4. Reinstall the software.
5. Replace the armrest CAN module.

24 35
1 4

5 8
Pin
position 1 12

[Main harness F_CONN. A] [Harness conn. of controller]

P-CONT CAN FAULT – Pump CAN communications failed

Curtis code 52 Drive
Cause The pump motor controller’s CAN communications is failed.
1. Check if the resistance between pins 2 and 7 on the CAN port connector
measures approx. 60 Ω when the harness is connected to the port and
the key switch is off.
2. If the measurement falls short of 60 Ω, check if pin 23 on the pump motor
controller and pin 23 on the left drive motor controller are correctly
connected to one another.
Solution 3. If their connection is normal, check if pin 35 on the pump motor controller
and pin 35 on the left drive motor controller are correctly connected to
P7 1 one another.
4. Check if the resistance between pins 21 and 34 on the pump motor
controller connector measures approx. 120 Ω.
5. Reinstall the software.
6. Replace the pump motor controller.
24 35

Pin 6 9
position 1 5 1 12

[CAN port] [Harness conn. of controller]

Handling faults on instrument panel/EasyView 2-138 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
3 Drive/brake system
3-1 Overview ........................................................2
3-1-1 Components ......................................................... 2
3-2 Drive motor ...................................................4
3-2-1 Exterior and specifications .................................... 4
3-2-2 How it works ......................................................... 6
3-2-3 Drive motor/axle/EM brake removal/installation ..... 8
3-2-4 Drive motor disassembly/assembly and test.........10
3-2-5 Drive wheel removal/installation ...........................12
3-3 Drive axle .....................................................13
3-3-1 Exterior and specifications ...................................13
3-3-2 How it works ........................................................14
3-3-3 Drive axle oil replacement....................................17
3-3-4 Adjustment ..........................................................18
3-3-5 Disassembly and assembly .................................19
3-4 Accelerator ..................................................24
3-4-1 Exterior and specifications ...................................24
3-4-2 How it works ........................................................25
3-4-3 Removal and installation ......................................26
3
3-5 F/R unit ........................................................27

Drive/brake system
3-5-1 Exterior and specifications ...................................27
3-5-2 How it works ........................................................28
3-5-3 Removal/Installation ............................................30
3-6 Service brake pedal ass’y ..........................31
3-6-1 Exterior and specifications ...................................31
3-6-2 How it works ........................................................32
3-6-3 Brake pedal adjustment .......................................36
3-6-4 Air removal in brake oil ........................................37
3-6-5 Brake pedal ass’y removal/installation .................39
3-6-6 Master cylinder disassembly/assembly ................41
3-7 Electric Foot Brake .....................................42
3-7-1 Exterior and specifications ...................................42
3-7-2 How it works ........................................................44
3-7-3 Brake pedal ass’y removal/installation .................46
3-7-4 Brake pedal adjustment .......................................48
3-8 EM parking brake ........................................51
3-8-1 Exterior and specifications ...................................51
3-8-2 How it works ........................................................52
3-8-3 Parking brake test ...............................................53
3-8-4 Manual release of braking....................................54
3-9 Troubleshooting .........................................55
3-9-1 Driving .................................................................55
3-9-2 Service brake ......................................................57
3-9-3 EM parking brake ................................................58
3-1 Overview

3-1-1 Components
Accelator pedal
Service brake pedal Drive wheel
Brake oil reservoir

Master cylinder

F/R unit
Controller group

EM Brake
(Parking)
Drive motor

Drive axle

0823E

Fig. 3-1

Battery

Electric Electric
power power

Magnetic
Digital power
signal EM (braking)

Accelerator parking
An brake
alo
gs Controller Drive
ign
al
motor Driving Driving
Digital signal power power
l
Drive Drive wheel
na axle
g sig
alo
An

F/R unit Mechanical Hydraulic Friction

power power (braking)
Brake Master Service
pedal cylinder brake

0824E

Fig. 3-2

Overview 3-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 The drive/brake system is comprised as follows:

• Drive motors, regulated by their respective

controllers, transfer a rotational force to the left and
right drive axles (electric power  mechanical
power). [Section 3-2]

• Drive axles convert the rotational forces transferred

from the drive motors to have a torque and velocity
appropriate for driving via their gear set, and send
them to the respective wheels (mechanical power
 mechanical power). They also contain service
brakes, which are actuated by the depressing of the
brake pedal to produce a braking power (hydraulic
power  friction force). [Section 3-3]

• Accelerator sends an electric signal to the left drive

motor controller to accelerate the motors (analog
signal  digital signal). [Section 3-4]

• F/R unit sends an electric signal to the left drive

motor controller to determine the driving direction of
the motors (analog signal  digital signal).
[Section 3-5] 3
• Service brake pedal ass’y injects brake fluid to the

Drive/brake system
drive axles to actuate the service brake in them
(hydraulic power  friction force). [Section 3-6]

• EM parking brakes, attached to the ends of both

drive motors, fix the motors’ shafts three seconds
after the vehicle is parked in order to ensure the
vehicle stands still (electric power  magnetic
power). [Section 3-7]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-3 Overview

3-2 Drive motor

3-2-1 Exterior and specifications

Fig. 3-3

Items Spec.
Part number 300503-00080
Voltage 48 VAC
Power 6.0 kW
Voltage 30 V
Current 152 A
Speed 2650 rpm
Max. speed 5000 rpm
Frequency 90 Hz
Protection degree IP 43
Weight 33.0 kg (72.8 lb)

Drive motor 3-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Encoder
Items Spec.
Part no. 301310-00007
PPR 64 pulses/rev.
Connector 4-pin AMP

Thermal sensor

Items Spec.
Part no. Included in the drive motor
Resistance 603 Ω ± 3% at 25°C (77°F)
Connector 2-pin AMP

Drive/brake system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-5 Drive motor

 3-2-2 How it works
EMERGENCY SW (OPT)

LEFT DRIVE MOTOR 8 +12V F/R UNIT F/R SWITCH

CONTROLLER -12V
6
12V OUT (BACKUP) 1 +5V

1
5
+12V 2 GND
4 3
vcc Forward
9/BU/YL BATT +
2 4 Revers
20/YL/GN 20/YL/GN FWD
9/BU/YL 6/BR D1-6 FWD D1-22 3
21/BR REV
LINE CTR REV D1-33 21/BR 1
1/BK BATT -
7
13/OR/RD D1-13

GND
7/WH D1-7 7/WH 1 GND
D1-26 26/RD/BK 26/RD/BK 3 +5V
D1-16 16/OR/BK 16/VO/BK 2 OUT A
THM1 GND
8/VO D1-8 4
B1 6 +5V
32/GY D1-32 5 OUT B
A1
31/GN D1-31
ACCELERATOR
+5V

2
1
26/RD/BK 26/RD/BK D1-26 D1-17 18/BU/RD 17/GN/YL 17/GN/YL 1
D1-7 7/WH 7/WH 2
2 7/WH
SEAT SWITCH
1 30/RD D1-30
D1-24 101/GN
PIOLOT BUZZER
D1-25 25/RD/WH FAN RELAY (OPT)
(WARNING)

31/GN 87
8/VO LEFT TRACTION MOTOR 71/RD/BK 71/RD/BK 85
7/WH
+

D1-13 13/OR/RD 13/OR/RD 86

32/GY
ENCODER

30
GND A

MR
D1-14 77/GN/WH 77/GN/WH 2
1
B

BRAKE PEDAL SWITCH

EM BRAKE-LEFT
THERMAL THERMAL
SENSOR SENDER 13/OR/RD 4 126/BU/WH 126/BU/WH 2
7/WH 12/WH/RD 125/BU/RD 1
D1-5 12/WH/RD 3 125/BU/RD
75/YL/GN 2 128/BR/YL 128/BR/YL 2
76/BK 1 127/BU/YL 127/BU/YL 1
D1-23(CAN H) 23/YL/BK
D1-35(CAN L) 35/YL EM CONN A EM CONN B EM BRAKE-RIGHT

RIGHT DRIVE MOTOR

CONTROLLER
GND
51/WH D2-7 7/WH 3
101/GN 2
25/RD/WH 1
THM1 D2-1
52/BU/BK D2-8 ANGLE SENSOR
B1
53/BU/GN D2-32
A1
54/OR/RD D2-31 23/YL/BK
D2-23(CAN H)
51/WH +5V D2-35(CAN L) 35/YL
53/BU/GN 55/RD D2-26 D2-11
52/BU/BK 55/RD
RIGHT TRACTION MOTOR D2-28 73/BU/RD
54/OR/RD 74/BU/WH
+

D2-29
ENCODER
GND A

MR

D2-13 75/YL/GN
B

D2-5 76/BK
D2-2
THERMAL THERMAL
SENSOR SENDER
51/WH

Fig. 3-4
Electrically powered, the drive motors turn their respective
drive wheels so that the vehicle can move
forward/backward.

Controlling by controllers

As shown in the schematic diagram, each drive motor is

wired by U, V, and W lines to a controller. The controller runs
the drive motor according to inputs from a number of switches
and sensors, as well as internal parameter settings.

The drive motors run when the following conditions are met:
• The key switch is connected, thus powering the
motors (See Section 2-2 for power supply),
• The operator is seated (seat switch),
• Driving direction is determined (F/R unit), and
• The accelerator pedal is pressed (accelerator).

Drive motor 3-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 When the motors are stopped, a pair of EM brakes
automatically engage with them and function as a parking
brake.

When you steer the vehicle, an angle sensor detects the

angle at which the rear wheels are turned and accordingly
the controllers regulate the vehicle’s drive speed. The
vehicle starts to decelerate when the angle reaches 5º, and
it travels at the set speed limit (2 km/h, 6562 ft/h) with a steer
angle of 90°. The default speed of the drive motor at this
angle is 1,500 rpm, and you can adjust this speed limit by
setting the value of the parameter “STEER LIMIT SPEED”
(instrument panel no.: 47 / range: 400–2000 rpm).
Fig. 3-5

Motor speed detection (encoder operation)

Each drive motor is equipped with an encoder, which

serves as a speed sensor for the motor. It includes two
hole sensors and has a gear installed on the drive shaft of
the motor to interact with these two hole sensors. This
gear’s concurrent rotation with the drive shaft makes the
gear teeth periodically pass the magnetic field of each hole 3
sensor. When a top land of the gear passes the magnetic Mechanical profile
field, it comes closer to the hole sensor and thus the

Drive/brake system
magnetic flux increases. On the other hand, when a
Magnetic profile
bottom land passes the magnetic field, the distance
increases and the magnetic flux decreases accordingly. Sensor electrical output profile 0825E

Fig. 3-6
This cycle recurs and the magnetic flux has a waveform to
produce a voltage pulse. The controller analyses the
amplitude of this pulse to compute the rpm of the motor. A
smaller amplitude means a higher rpm of the motor.

Like other sensors, the encoder also produces both a main Clockwise rotation
signal (signal A) and a reference signal (signal B) through
the two hole sensors. As shown in Fig. 3-7, the order of
the signals produced changes depending on the direction
of revolution.

Overheat protection (thermal sensor operation) Counterclockwise rotation 0826E

Fig. 3-7
Each drive motor is equipped with a thermal sensor to
protect it from overheating. Once the motor has been
heated up to 145°C (293°F), an overheat alarm is activated
and the working performance of the motors is limited.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-7 Drive motor

 3-2-3 Drive motor/axle/EM brake removal/installation
Line connections

(1) Thermal sensor connector

(2) Encoder connector
(4) EM brake cable
(3) U.V.W. terminals
(6) Bleeder tube

(5) Brake oil tube

(10) Drive motor

(9) Drive axle

(7) Axle assembling screw

(13) Hub (8) Motor assembling screw

(11) EM brake assembling screw

(12) EM brake

0827E

Fig. 3-8
WARNING
The vehicle’s movement or its moving
parts can cause injuries.
Before you begin this procedure, make
sure that the vehicle is parked on a level
surface where there is no need for the
parking brake, and that the key switch is
off with no risk of acciedental start-up.

Preliminary steps

1. Turn off the key switch.

2. Remove the mast (See Section 5-3-10 A).

3. Remove the drive wheels (See Section 3-2-5).

4. Remove the floor plates in the compartment so

that you may see drive motors (10) as shown in
Fig. 3-9.

Fig. 3-9

Drive motor 3-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Drive motor-axle removal/installation

1. Disconnect cables from thermal sensor

connector (1), encoder connector (2), and
U.V.W. terminals (3), and disconnect EM brake
cable (4).
 Mark the cables as a reference for reassembly.
 Installation torque for U.V.W. terminals: 15
N·m (11 lb·ft)

2. Disconnect brake oil tube (5) and bleeder tube

(6).

3. Loosen axle assembling screws (7) and remove

drive motor-axle assembly—(9) and (10)—from
the frame.
 Installation torque: 240±40 N·m (177±30 lb·ft)
 Installation sealant: Loctite #262

Axle, motor, and EM brake separation/coupling

1. Loosen motor assembling screws (8) and
remove drive motor (10) from drive axle (9).
3
 Installation torque: 240±40 N·m (177±30 lb·ft)

Drive/brake system
 Installation sealant: Loctite #262

2. Loosen EM brake assembling screws (11) and

then dismount EM brake (12).
 Installation torque: 9.5 N·m (7 lb·ft)

NOTICE: At installation, take care not to damage the

splines of the flange disc when you mount it onto hub (13).
And do not grease these parts, as it may hinder the brake’s
performance.
NOTICE: Water may be brought in through the encoder
connector line groove between drive motor (10) and EM
brake (12). Put grommets on the areas shown in Fig. 3-10,
or apply Loctite #5900 (part no.: 910101-00015) if
grommets are not available, to prevent water penetration.

3. Put the key into the shaft then remove hub (13)
from the shaft.

4. Follow the steps above in the reverse order for

installation.
 Operate the motor to check that all the moving
parts rotate smoothly.

Fig. 3-10

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-9 Drive motor

 3-2-4 Drive motor disassembly/assembly and test
(13) Retaining ring

(9-1) Nut (12) Encoder

(11) End bell

(9) Terminal block (10) Bearing (14) Sunk key

(12-1) Encoder

(8) Stator assembly

(9-2) Screw

(7) Rotor assembly

(6) Bearing
(4) End bell

(3) Oil seal

(2) O-ring
(5) Wave washer

(1) Bolt
0828E

Fig. 3-11

Disassembly/assembly

1. After removing the terminal protector, loosen nut

(9-1) and remove the terminals from terminal
block (9).

2. Loosen screw (9-2) and remove terminal block

(9).

3. Loosen bolts (12-1) and remove encoder (12).

4. When needed, remove retaining ring (13) and

sunk key (14).

5. Remove O-ring (2) and oil seal (3).

6. Loosen bolts (1) and remove end bell (4).

7. Remove stator assembly (8) by hand or using a

tool.

8. Remove wave washer (5) and bearing (6) from

rotor assembly (7).

Drive motor 3-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 9. Remove bearing (10) and rotor assembly (7)
from end bell (11).
 It is recommended to use a bearing puller as
shown in Fig. 3-12.

10. Follow the steps above in the opposite order to

assemble the drive motor.

NOTICE: Before you reassemble the motor, you may test

its parts as follows.
Fig. 3-12

Stator Test

1. Carefully wipe contaminants from the surface of

the stator using a clean cloth dampened with
alcohol.

NOTICE: Contaminants in the stator may cause damage

to the coil and consequently to the stator itself.

2. Measure resistance for each phase (U-V, V-W,

W-U) using a milli-ohmmeter.
 Rated resistance: 7.10 mΩ
3

Drive/brake system
Fig. 3-13

3. Test insulation at 1000 Vac and Min. 10 MΩ

using an insulation tester.
 If insulation is faulty, replace the stator with a
new one.

Fig. 3-14

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-11 Drive motor

 3-2-5 Drive wheel removal/installation
(2) Drive tire

(3) Wheel

(1) Nut

0829E

Fig. 3-15
1. Place a jack or wooden block under the forklift
and loosen nut (1).
 Installation torque: 105 N·m (77 lb·ft)

2. Remove nut (1) and drive tire (2).

3. Follow the steps above in the opposite order to

install the drive wheel.

Drive motor 3-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

3-3 Drive axle

3-3-1 Exterior and specifications

Fig. 3-16

3
Functions Items Spec. old Spec. new
Max. wheel load 2,800 kg (6,173 lb)
Max.input power 12.3 kW

Drive/brake system
Max. input torque 7.85 kg·m (56.78 lb·ft)
Driving Gear ratio 24.25
Weight (without oil) 49 kg (108 lb)
Oil volume 0.5 L
Oil type Automatic transmission fluid (RUBIA S10W)
N/A
Wet disc brake
Brake type (for reference, electric foot
(air cooled on the housing)
brake is incorporated)
Hydraulic oil
Braking Brake fluid N/A
(AZOLLA Z510)
Brake pressure on 31.5 N·m per 1 bar
N/A
piston (23.2 lb·ft per 14.5 psi)
Brake pressure limit 110 bar (1,595 psi) N/A

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-13 Drive axle

 3-3-2 How it works

A. Driving function

(6) Ring gear

(2) Pinion gear (5) Planetary gear

(1) Motor shaft (7) Pin

(3) Helical gear

(9) Drive shaft

(4) Sun gear

(8) Planetary carrier

0830E

Fig. 3-17
The drive axle is responsible for transferring the drive
motor’s output to the wheel, reducing the speed and
multiplying the torque based on a specific gear ratio
produced by its internal gear train. This is to fit the motor’s
high speed to driving and to gain an enough force to
endure the vehicle’s load and other external conditions.
Because heavy trucks such as forklifts require a large
traction force, rather than a high travel speed, they apply
a relatively high gear ratio to ensure the motor (or engine)
speed and torque are converted at a high rate, compared
to regular automobiles.

1st reduction and torque multiplication

When motor shaft (1) is turning, its attached pinion gear (2)
also turns and that in turn rotates helical gear (3), splined

Drive axle 3-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 to pinion gear (2). Since helical gear (3) has several times
more teeth than pinion gear (2), the first speed reduction
occurs between these two gears and the torque is
multiplied accordingly:

N of helical gear teeth

1st reduction torque multiplication ratio N of pinion gear teeth

2nd reduction and torque multiplication

Sun gear (4), meshed with helical hear (3), revolves

concurrently with the rotation of helical hear (3).

As shown in Fig. 3-18, the turning of sun gear (4) makes (6) Ring gear
three planetary gears (5) move around sun gear (4). As
encompassed by ring gear (6), planetary gears (5)
maintain their circular movement without becoming
unmeshed. These gears are named so because the way
in which they function together can be likened to the
orbiting of planets around the sun.
(5) Planetary gear
(4) Sun gear
0831E

3
Each of planetary gears (5) has a pin (7) inserted in its Fig. 3-18
center. As pins (7) are connected to planetary carrier (8),
planetary carrier (8) also revolves when planetary gears (5)
make a circular movement.

Drive/brake system
This specific combination of gears generates another
speed reduction and torque multiplication:

N of sun gear teeth

2nd reduction torque multiplication ratio N of ring gear teeth
𝟏

Effects

Planetary carrier (8) is splined to drive shaft (9) at its center,

and thus its turning leads to the revolving of the shaft and
ultimately the drive wheel. The speed and torque finally
transferred to the wheel are as follows:

𝐖𝐡𝐞𝐞𝐥 𝐢𝐧𝐩𝐮𝐭 𝐬𝐩𝐞𝐞𝐝 𝐦𝐨𝐭𝐨𝐫 𝐫𝐩𝐦 1st reduction ratio 𝟐𝐧𝐝 reduction ratio

𝐖𝐡𝐞𝐞𝐥 𝐢𝐧𝐩𝐮𝐭 𝐭𝐨𝐫𝐪𝐮𝐞 𝐦𝐨𝐭𝐨𝐫 𝐭𝐨𝐫𝐪𝐮𝐞 1st multiplication ratio 𝟐𝐧𝐝 multiplication ratio

In this way, power from the drive motor is transmitted to

the drive wheel via motor shaft (1)  pinion gear (2) 
helical gear (3) [1st speed reduction]  sun gear (4) 
planetary gears (5)  planetary carrier (8) [2nd speed
reduction]  drive shaft (9) so as to drive the vehicle at a
proper speed and torque.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-15 Drive axle

 B. Braking function
Lever plate
Neutral

Acruated

(11) Helical gear

(10) Friction disc
(7) Lever plate

(7) Lever plate

(8) Ball

(9) Steel plate

(5) Hook (4) Chamber

(6) Piston

(1) Master cylinder

(3) Brake cylinder

(2) Brake line

0832E
Fig. 3-19
When the brake is applied, pressurized oil flows from
master cylinder (1) through brake lines (2) to brake
cylinder (3) located at each drive axle. Once oil has
entered the brake cylinder, it fills chamber (4), causing
piston (6) and hook (5) to move forward.

The forward movement of the hook (5) moves lever plate

(7) slightly to the right, lifting it on its balls (8). As lever plate
(7) is lifted, it compresses rotating friction discs (10) in
between stationary steel plates (9).

Because friction discs (10) are splined to helical gear (11),

once their rotation is stopped, so is the motion/rotation of
the drive axle shaft and drive wheel.

Drive axle 3-16 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3-3-3 Drive axle oil replacement

Preliminary steps

1. Park the lift truck on a level ground. Check that

the parking brake lamp is on, and shift the
control lever to the neutral position.

Procedure

1. Raise the mast and block in place.

2. Turn the key switch to OFF.

3. Unscrew air breather (oil filling plug) (1), level

checking plug (2), and remove drain plug (3).
Allow the oil to drain.

4. Clean and install the drain plugs.

5. Fill the drive axle housing with oil through air

breather plug hole, the accurate amount of oil is
defined by the opening of level checking plug.
Fig. 3-20 3
6. Maintain the oil level.

Drive/brake system
7. Screw in level checking plug (2) and air breather
1
(1) with the seal ring.

8. Raise the mast and remove the blocking.

2
Fig. 3-21

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-17 Drive axle

 3-3-4 Adjustment
To determine the shim pack thickness required to achieve
the correct rolling torque of the drive axle ass’y, use the
formula D=B-C-(0 to 0.05mm, 0 to 0.002in)) and refer to
Fig. 3-22.

Example:
B = 2.58 mm (0.1 in) measured at the carrier and drive
shaft
C = 2.05 mm (0.08 in) measured at the lock nut B Distance between the surface of carrier
and the surface of drive shaft.
D = 2.58 mm - 2.05 mm (0–0.05) = 0.48 mm (0–0.53)
C Height of step in lock nut
Then 0.5 mm (0.02 in) thickness of shim pack can be
D Required thickness of shim pack
applied.
Fig. 3-22

Procedure

1. Tighten lock nut (1) to a torque of 80–110 N·m

(59–81 lb·ft) by hand in order to ensure the taper
roller bearing fitted to the drive shaft ass’y is in
the proper position.

2. Make the necessary measurements using the

formula:
 D = B - C (0–0.05 mm, 0-0.002 in)
Fig. 3-23
3. Remove locknut (1).

4. Install shims as required and then install locknut

(1), tightening it to a torque of 150–220 N·m
(110–162 lb·ft).

5. Check to see if the drive axle meets the rolling

torque specification of 4.5–6.5 N·m (3.3–4.8
lb·ft).
 Add or remove shims as required until you
have the correct rolling torque.

6. Remove locknut (1).

Fig. 3-24

Drive axle 3-18 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3-3-5 Disassembly and assembly

Tools needed
Names Figures Tool no.

Nut installer Bobcat tool no. T126

Bearing installer Bobcat tool no. T127

Oil seal installer Bobcat tool no. T128

Gamma seal installer Bobcat tool no. T129 3

Drive/brake system
Needle bearing
Bobcat tool no. T130
installer

Flat head bolt

Bobcat tool no. T131
installer

Preliminary steps
1. Remove the drive axle (see Section 3-2-3).
(2) Bolt
2. Remove hex socket bolts (1).
(1) Bolt
 Installation sealant: Loctite #277 to the threads
 Installation torque: 30±7 N·m (22±5 lb·ft)
3. Remove socket M8X25 bolts (2).
 Installation sealant: Loctite #277 to the threads
 Installation torque: 30±7 N·m (22±5 lb·ft)
4. Separate the housing ass’y from the housing 0833E

cover ass’y using M8 bolts. Fig. 3-25

 The housing cover areas must be cleaned and
degreased.
 Adhesive: Three Bond #1215 to the coat of one side.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-19 Drive axle

 (12) Lever plate

(11) Washer

(10) Steel plate

(9) Friction disc
(7) Washer

(4) Helical gear ass’y (6) End plate

(4-1) Retaining ring

(4-2) Retaining ring (8) Spring
(3-1) Retaining ring
(20) Breather
(4-4) Bearing (3-2) Bearing
(5) Bolt
(3-3) Pinion gear
(4-3) Sun gear
(17) Pin
(3) Piston gear ass’y

(16) Bearing
(22) Spring
(24) Shim (21) Plug
(15) Pin
(14) Steel ball (18) O-ring
(19) Plug

(23-1) Wear ring

(23-2) Back up ring
(23-3) Quad ring
(23-4) Quad ring
(13) Hook Piston rod
(23-5) Back up ring
(23-6) Wear ring

(23) Piston Rod ass’y

0834E

Fig. 3-26

Cover ass’y
1. Remove and disassembly pinion gear ass’y (3) in
the following order:
 Retaining ring (3-1)
 Ball bearings (3-2)
 Pinion gear (3-3)
 Grease: Total Multis EP2 to thrust bearing.
2. Remove and disassemble helical gear ass’y (4)
in the following order:
 Retaining ring (4-1)
 Retaining ring (4-2). The opening directions of
two snap rings opposite.
 Sun gear (4-3)
 Ball bearing (4-4)
 When assembling, make sure the teeth of the
friction discs are aligned before installing it.

Drive axle 3-20 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3. Remove bolts (5) using bolt installer.
 Installation sealant: Loctite #277
 Installation torque: 8±3 N·m (5.9±2.2 lb·ft)
4. Lift out end plate (6) carefully.
 At installation, put pressure on end plate (6) L (6) End plate
and check if the distance between the surface
of it and the housing cover’s bolting surface (L)
meets the specified measurement of 1.03–1.63
mm (0.041–0.064 in).
5. Remove washers (7). 0835E

Fig. 3-27
6. Pull out springs (8).
7. Lift out five friction discs (9) and four steel plates
(10).
8. Remove washers (11) located on top of the first
steel plate and then remove it, too.
 Before installing the friction discs, soak them in
transmission oil for a minimum of 12 hours.
9. Lift out lever plate (12) and hook (13).
 The split pin of hook (13) should be facing up if
installed correctly.
10. Remove steel balls (14)
 Grease: Total MULTIS EP2
3
11. Remove pins (15)

Drive/brake system
12. Remove ball bearing (16)
13. Remove parallel pin (17)
14. Remove and inspect O-ring (18).
15. Remove drain plug (19).
 Installation sealant: Loctite #572
16. Remove breather (20) and washer.
 Installation torque: 70±10 N·m (52±7 lb·ft).
17. Remove plug (21)
 Installation torque: 70±10 N·m (52±7 lb·ft).
18. Pull out spring (22).
19. Remove piston rod ass’y (23) and disassemble it.
 Wear ring (23-1)
 Back up ring (23-2)
 Quad ring (23-3)
 Quad ring (23-4)
 Back up ring (23-5)
 Wear ring (23-6)
 Lubricant: Total Azolla ZS 10 to all rings
 Grease: Total MULTIS EP2 to the protruding
end of the piston rod
 Ensure the backup rings are installed in the
correct position.
20. Remove shim (24).

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-21 Drive axle

 (31) Bearing

(36) Plug

(30) Bearing cup

(32) Drive shaft ass’y (35) Oil seal
(34) Bearing cup
(33) Seal
(25-1) Bolt

(32-1) Bearing cone

(32-2) Bolt

(25-7) Bolt
(25-2) Carrier cover
(25-8) Lock nut
(25-3) Ring
(25-9) Shim (25-4) Bearing
(25-5) Planetary gear
(25-6) Ring
(25-10) Parallel pin
(26) Bolt (25-11) Pin
(25-12) Spring pin
(25-13) Carrier housing
(25-14) Taper bearing

(25) Carrier ass’y

(27) Ring gear

(29) Plate
(28) Retaining ring 0836E

Fig. 3-28
Housing ass’y
1. Disassemble carrier ass’y (25) in the following
order:
 Socket head bolts (25-1) Apply Loctite #277 to
the threads of bolts (22-1) and then tighten
them to a torque of 30±7 N·m (22±5 lb·ft).
 Carrier cover (25-2)
 Rings (25-3)
 Needle rollers (25-4)
 Planetary gears (25-5)
 Rings (25-6)
 Stopping socket head bolt (25-7) Apply Loctite
#277 to the thread of bolt (22-7) and then
tighten it to a torque of 8±3 N·m (59±2.2 lb·ft).
 Lock nut (25-8) If the slot/bolt hole is not well
aligned with tap in carrier, rotate by one or two
splines until it is. Apply Loctite #277 to the
thread of lock nut (22-7) and then tighten it to a
torque of 150–220 N·m (110–162 lb·ft) using
the nut installer.
 Shims (25-9). See Section 3-3-4 before installing.
 Parallel pins (25-10)
 Pins (25-11)
 Spring pins (25-12)

Drive axle 3-22 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

  Carrier housing (25-13) with taper bearing
cone (25-14).
 When assembling, ensure the marks on the
carrier and carrier cover are aligned.
2. Separate the bearing cone (25-14) from the
carrier housing using the two armed
puller/bearing installer. Install the taper bearing
cone using the bearing installer and apply Total
MULTIS EP2 grease to the inner ring and the
space between the rollers.
3. Remove bolts (26) from ring gear (27)
 Installation torque: 55±10 N·m (40.6–7.4 lb·ft).
4. Remove retaining ring (28).
5. Remove plate (29).
6. Remove taper bearing cup (30).
7. Remove needle roller bearing (31). Install using
the needle bearing installer
8. Pull out drive shaft ass’y (32) and disassemble it
in the following order:
9. Taper bearing cone (32-1). Apply Total Multis
EP2 grease to the inner ring and the space
between the rollers and then install bearing cone
using the bearing installer.
10. Wheel bolts (32-2).
11. Remove gamma seal (33) Apply Three Bond
#1102 to the inner race, and then apply grease
to the rib.
3
12. Remove taper bearing cup (34),

Drive/brake system
13. Remove oil seal (35), Apply Three Bond #1102
to the outer race.
14. Remove oil level plug (36). Apply Loctite #572 on
the thread of the plug and tighten it to a torque:
70 ± 10 N·m (52 ± 7 lb·ft).
15. Follow the steps above in the opposite order to
assemble the drive axle.

During assembly
• Thoroughly clean all parts and remove all residual
Loctite.
• Check all the parts for wear and damage and
replace any if necessary.
• Finish sealing’s mating surface with an oil stone or
a fine finishing file.
• Lubricate the cleaned antifriction bearings before
installing.
• Be sure to replace all the sealing elements.
• Be sure to use mastic sealants (such as Loctite)
only.
DANGER
Corrosive detergents will cause
serious skin burns or even death if
inhaled or consumed.
Wear protective gloves, goggles, and a
mask.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-23 Drive axle

3-4 Accelerator

3-4-1 Exterior and specifications

Fig. 3-29

Item Spec.
Part number A401077
Initial pedal load 1 kgf (2.2 lbf)
Full stroke pedal load 3.0±0.5 kgf (6.6±1.1 lbf)
Input voltage 5 V±0.5%
Rated current 20 mA
Power 100 mW
Wire width 20 AWG
SIGNAL “A” 0.4±0.1 V
Voltage output at start point
SIGNAL “B” 4.5±0.1 V
SIGNAL “A” 3.60±0.15 V
Voltage output at end point
SIGNAL “B” 1.39±0.15 V
Insulation 10 mΩ @ 500 VDC
Operating temperature -40°C to +85°C (-40°F to +185°F)
Storate temperature -40°C to +100°C (-40°F to +212°F)

Accelerator 3-24 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3-4-2 How it works

Fig. 3-30
Electric vehicles such as the models B15/18/20T-7 and
B15/18/20T-7 run on power generated by the drive motor.
Therefore the accelerator that determines the travel speed
of the vehicle is connected to drive motor controllers.

Only the left motor controller is connected directly to the

accelerator, but it transmits inputs received from the
accelerator via the CAN protocol to the right motor
3
controller so that both motors may respond to those inputs.

Drive/brake system
As shown in the circuit diagram, the accelerator is powered
at 5 V from the left drive motor controller (at Terminal 3,
26/RD/BK) and produces Signal A (at Terminal 2,
16/VO/BK). This output determines the vehicle’s speed in
proportion to the angle at which the accelerator pedal is
pressed.

The accelerator is also powered at 5 V from the pump HALL IC output characteristics
motor controller (at Terminal 6, 64/RD) and produces SIGNAL “B”(+) SIGNAL “A”(-)
6
Signal B as a reference (at Terminal 6, 58/BK). These
4
Output (V)

Signals A and B transmitted by two different controllers, as 2

shown in the above, are shared by CAN communication.

0 1 3 5 7 9 11 13 15 17 19 21
In principle the values of these two signals should be the Accelerator pedal angle
same. If their difference exceeds the tolerance, it will be 0838E

Fig. 3-31
recognized as a problem in the electrical system or
accelerator and error code F2 will appear on the display.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-25 Accelerator

 3-4-3 Removal and installation

(2) Front floor plate

(5) Accelerator pedal

(4) Screw

(1) Rear floor plate (3) Connector

0839E

Fig. 3-32
Preliminary Steps

1. Turn off the key switch.

2. Remove the floor mat that covers floor plates

Procedure

1. Raise front floor plate (1) and disconnect the

connector of accelerator pedal (5) from main
harness connector (2).

2. Remove front floor plate (1)

3. Loosen three sets bolts (3) and nuts (4), and

remove accelerator pedal (5).

4. Follow the steps above in the opposite order to

reinstall the accelerator pedal.

5. Perform accelerator initial setting using the

EasyView application (See the Pedal Set menu
in Section 2-6-7).

Accelerator 3-26 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

3-5 F/R unit

3-5-1 Exterior and specifications

Drive/brake system
Fig. 3-33

Items Spec.
Part no. 300611-00882
Rated voltage 48 VDC/80 VDC
Operating voltage 24 to 90 VDC
Output current comsumption 1.5 A Max
FWD: close to common (BAT +)
Output (at input battery voltage)
REV: close to common (BAT +)
Operating temperature -40°C to +75°C (-40°F to +167°F)
Storage temperature -40°C to +100°C (-40°F to +212°F)
Protection grade IP65

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-27 F/R unit

 3-5-2 How it works

Fig. 3-34

The F/R (forward/reverse) unit is used to enable the

operator to select the vehicle’s travel direction by the use
of the F/R switch attached to the lift lever.

The F/R unit features two connectors (8-pin and 4-pin

connectors) to interact with a number of devices as follows:

F/R unit’s 8-pin connector wiring

• 8-pin connector’s pins 2 and 7 are connected with
the key switch circuit to get the battery power source.
This power input is used to give signals to the left
drive motor controller. See the next bullet item.

• 8-pin connector’s pins 3 and 1 are connected with

the left drive motor controller to send a command of
shifting the travel direction to forward (controller pin
22), reverse (controller pin 33), or neutral (no signal
to both controller pins). The left drive motor then
shares this command information across the entire
electrical system via the CAN communication lines.

• 8-pin connector’s pins 4 and 6 are connected with

the DC-DC converter circuit to get a 12V input
source. This power input is used to supply power to
the backup option (12 V) and the F/R switch (5 V).
See the next bullet item for the backup option and
the next subsection for the F/R switch.

• 8-pin connector’s pin 5 is connected with the

backup warning option, which lights up the backup
lamp and sounds the backup buzzer during reverse
travel.

F/R unit 3-28 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 F/R unit’s 4-pin connector wiring

The F/R unit’s 4-pin connector pins are all connected with
the F/R switch to supply it with 5V power and receive the
operator’s demand from the switch—forward, reverse, or
none.

When the switch is in neutral, it sends a voltage signal from

both the Forward and Reverse terminals. Once the switch
is shifted to forward, for example, the switch’s Forward
terminal stops signaling the F/R unit’s 4-pin connector pin
3. Unusually, this signal cutoff from the Forward terminal
signifies that the operator is demanding forward travel, and
thus the F/R unit gives a forward signal to the left controller
(8-pin connector 3  controller pin 22).

Conversely, when the F/R switch is shifted to reverse, the

process is performed for reverse travel: The signal from
the F/R switch’s Reverse terminal to the F/R unit’s 4-pin
connector pin 4 is cut off, and then the F/R unit’s 8-pin

3
connector pin 1 gives a signal to controller pin 33.

Drive/brake system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-29 F/R unit

 3-5-3 Removal/Installation

Preliminary steps

1. Lift up the seat and the hood.

F/R unit removal/installation

1. Disconnect main harness cable (2) and F/R

switch cable (3).

2. Remove bolts (4) and washers in both sides and

then remove F/R unit (1). (1) F/R unit

3. Follow the steps above in the opposite order to (4) Bolt and washer

reinstall the F/R unit.

(3) Cable to F/R switch
NOTICE: The F/R switch is attached onto the lift lever and (2) Cable to harness
0841E
cannot be removed separately. Fig. 3-35

F/R unit 3-30 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

3-6 Service brake pedal ass’y

3-6-1 Exterior and specifications

Fig. 3-36 3

Drive/brake system
Compoents Items Spec.
Part no. A501502
Max. use pressure 100 kg/cm2 (102 psi) or over
Master
Effective stroke 25 mm (1 in)
cylinder
Valve activating pressure 7 kg/cm2 (100 psi)
Cylinder pressure efficiency 90% or over
Rated voltage Up to DC 200 V
Brake oil Switching current 1A
reservoir Using temperature -40°C to +150°C (-40°F to +302°F)
Ploater Gauss 570±60 G

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-31 Service brake pedal ass’y
 3-6-2 How it works

A. Brake pedal
(1) Pedal (3) Reservoir
Once brake pedal (1) is pressed, the rod of master cylinder
(2) connected to the pedal is pushed to activate the (2) Master cylinder

cylinder. The activation of master cylinder (2) supplies oil

in reservoir (3) through tube (4) to the service brake in
drive axle (5) to generate a braking power. In this way,
pressing pedal (1) causes the immediate activation of the
brake by a hydraulic power through a process. For a
detailed explanation of the braking process in drive axle
(5), see Section 3-3-2.
(5) Drive axle
(4) Tube
0842E

Fig. 3-37
B. Master cylinder

(1) Reservoir

(2) Inlet port

(B) Secondary chamber (A) Primary chamber

(6) Residual pressure valve 0843E
Fig. 3-38

Neutral position

When the pedal is in the neutral position, oil flows back

and forth between reservoir (1) and primary chamber (A)
via inlet port (2). This is necessary to ensure that the
master cylinder’s oil level is always kept completely full so
that air cannot enter the system.

The outlet at secondary chamber (B) is equipped with

residual pressure valve (6) to prevent air inflow from the
disc brake and oil outflow from the cylinder.

Service brake pedal ass’y 3-32 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 High pressure
Low pressure

(2) Inlet port

(4-1) Primary piston cup seal

(6-1) Rod
(6) Residual
pressure valve
(B) Secondary chamber (A) Primary chamber (3) Push rod
(5) Secondary piston (4) Primary piston
0844E

Fig. 3-39

First depressed position

When the pedal is depressed, push rod (3) pushes primary

piston (4) forward until primary piston cup seal (4-1) seals 3
inlet port (2), trapping the oil in primary chamber (A). The

Drive/brake system
trapped oil then pushes secondary piston (5) for the oil in
secondary chamber (B) to flow in the disc brake through
residual pressure valve (6), consequently engaging the
service brake.

Rod (6-1) of residual pressure valve (6), when pressurized,

is pushed as indicated by the arrows so that oil is allowed
to flow out.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-33 Service brake pedal ass’y
 High pressure
Low pressure

(2) Inlet port

(C) Return chamber

(5-4) Adjusting bolt

(B) Secondary chamber (5-3) Joint spring
(5) Secondary piston (4) Primary piston
(5-2) Hole
(5-1) Joint rod
0845E

Fig. 3-40

Second depressed position

As the pedal is depressed even further, the oil pressure in

secondary chamber (B) increasingly overcomes the
pressure of joint spring (5-3) to push joint rod (5-1). The
move of joint rod (5-1) then forms a passage through which
the oil inflow through hole (5-2) can pass as indicated by
the arrows. Thus, oil in primary chamber (A) returns to
return chamber (C), on which inlet (2) is installed, and
subsequently goes back to the oil reservoir. From then on,
primary piston (4) is no longer pressurized, and only the oil
in secondary chamber (B) conveys its pressure to the disc
brake. This causes a great increase in the braking power
increment by a further pedal effort.

The pressure to push joint spring (5-3) determines the

pedal effort to enter this stage, it can be adjusted by
adjusting bolt (5-4).

Service brake pedal ass’y 3-34 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 (1) Reservoir

(2) Inlet port

(7) Orifice

(B) Secondary chamber (A) Primary chamber

(6) Residual pressure valve (5) Secondary piston (4) Primary piston
0846E

Fig. 3-41

Released position

Once the pedal is released, two springs that have pressed 3

by primary and secondary pistons (4, 5) in primary and

Drive/brake system
secondary chambers (A, B) respectively are relieved.
Primary chamber (A) again face inlet (2), allowing the oil
in it to flow back and forth between the chamber and
reservoir again.

Because the pistons (4, 5) return much quicker than the oil,
a low pressure area is created in primary chamber (A),
which could potentially allow air to enter the system. Small
orifices (7) are drilled into the back of both pistons to allow
the oil at the back of them to travel forward and fill the low
pressure area as a means to prevent this problem from
happening.

When the oil in the lines has returned to normal, the master
cylinder is kept at an atmospheric pressure by residual
pressure valve (6). The residual pressure helps prevent air
from entering at the wheel cylinder and it keeps fluid from
leaking out.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-35 Service brake pedal ass’y
 3-6-3 Brake pedal adjustment
The brake pedal must have enough free play to let the master
cylinder piston return to the release positon and open the relief outlet.
The master cylinder push rod must be adjusted so the brake pedal
has 3.0 to 8.0 mm (0.118 ± 0.315 in) of free play from the pedals
stop to the push rod contact point with the master cylinder piston.

Hydraulic pressure in the brake lines travels back through

the relief opening and releases the brakes. If there is no
pedal free play, the pressure cannot go back through the
relief opening, and the brakes will tighten and not release.

If there is too much free play, the brake pedal will be low
even with the correct brake adjustment.

1. Pull back rubber boot (1) to expose the

adjustment nuts.

2. Loosen nut (3).

3. Adjust rod (2) until there is 3.0 to 8.0mm (0.118 ±

0.315in.) of free play from the pedals stop to the
point where the push rod makes contact with the
master cylinder piston.
(1) Cover
4. Hold rod (2) and tighten nut (3). (2) Rod
(3) Nut
0847E

Fig. 3-42

Service brake pedal ass’y 3-36 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 3-6-4 Air removal in brake oil
(4) Brake pedal
(1) Bleed screw

(2) Bleeder hose

(5) Master cylinder

(3) Bottle
Axle housing

0848E
Fig. 3-43
If you depress the brake pedal and it feels spongy, this is
an indication that air has entered the brake’s hydraulic
system.

Bleeder wrench/appropriate wrench

3
Tools needed: Flexible hosing

Drive/brake system
Plastic bottle

Preliminary steps

1. Remove the carriage.

Procedure

1. Find bleeder screw (1) located at the back of the

drive axle housing.

2. Loosen the screw using the bleeder wrench (do

not force it), and then tighten it again moderately

3. Fit one end of a piece of clear tubing (2) over the

bleed screw and place the other in a plastic
bottle.

4. Have a partner pump the brake pedal and signal

to you “up” or “down”.

5. When your partner signals “down”, loosen the

bleed screw; allow the brake oil to flow into the
plastic bottle (3) and then tighten the screw
again.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-37 Service brake pedal ass’y
 6. Have your partner release the pedal (4).

7. Repeat steps 7–8 until the brake oil is free of air.

8. Refill the master cylinder (5) to the “Full” line and

then repeat steps 3–9 to bleed the brakes on the
opposite side of the drive axle.

9. Take the vehicle for a short drive and test the

brakes to see if they still feel spongy. If they do:
 Check the oil level in the master cylinder is
sufficient.
 Bleed the brakes once more.

Service brake pedal ass’y 3-38 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 3-6-5 Brake pedal ass’y removal/installation

(1) Port

3
(2) Bolt
Preliminary steps

Drive/brake system
0849E

Fig. 3-44
1. Remove floor plate (See Section 7-3).

2. Drain the reservoir.

3. Prepare an oil pan.

Procedure

1. Mark ports (1) and their corresponding hoses as

a reference for assembly.

2. Have the oil pan ready to catch any oil that will
come out of the hoses and cylinder ports.

3. Disconnect hoses from ports (1).

4. Remove bolts (2) and remove the brake ass’y

5. Follow the steps above in the opposite order to

install the brake ass’y.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-39 Service brake pedal ass’y
 (12) Bracket

(5) Pin

(11) Washer
(10-1) Pad
(16) Tube connector ass’y
(4) Washer
(3) Snap pin

(13) Washer
(14) Bolt

(15) Master cylinder (9) Spring

(8) Bearing
(10) Pedal ass’y
(7) Hard washer
(6) Bolt

0850E

Fig. 3-45

Brake pedal removal/installation

1. After removing snap pin (3), remove washer (4)

and pin (5).

2. Remove spring (9) if needed.

3. Unscrew bolt (6) and remove hard washer (7),

bearing (8), pedal assembly (10), and washer
(11) from bracket (12).

4. To assemble the brake pedal, perform the

procedure above in the reverse sequence.

Master cylinder removal/installation

1. After removing washers (13) and bolts (14),

remove master cylinder (15).

2. Remove/disassemble tube connector assembly

(16) if needed.

3. To assemble the master cylinder, perform the

procedure above in the reverse sequence.

Service brake pedal ass’y 3-40 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 3-6-6 Master cylinder disassembly/assembly

Fig. 3-46

Tools needed Vise

Preliminary steps
1. Remove the master cylinder (See Section 3-6-5)
3

Drive/brake system
Procedure
1. Position the cylinder in a vise

2. Remove head pin (1)

3. Remove boot (2)

4. Retaining ring (3)

5. Pull out primary piston ass’y (4) and secondary

piston ass’y (5) together and separate them.

6. Disassemble primary piston ass’y (4) in the

following order.
 Large spring (4-1)
 Primary cup 2 (4-2)
 Large spacer (4-3)

7. Disassemble secondary piston ass’y (5) in the

following order.
 Small spring (5-1)
 Retaining ring (5-2)
 Spring seat (5-3)
 Primary cup 1 (5-4)
 Small spacer (5-5)

8. Follow the steps above in the opposite order to

assemble the master cylinder

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-41 Service brake pedal ass’y
3-7 Electric Foot Brake
3-7-1 Exterior and specifications
A. Exterior

al Controller
Sign

Cou
nt
er e
Angle sensor

lectr
motio-
ve fo
rce
Brake pedal

INPUT
Braking
Brake sensor
Brake pedal ass’y
Drive motor
B15T73001

Fig. 3-47

Front view Side view

B15T73002

Fig. 3-48
B. Specifications
Items Specification
Brake pedal ass’y Part No. 130104-00563

Part No. 301308-01380

Input voltage 5 ± 0.1 V

Brake sensor Operating current under 25 mA

Operating temperature -30~+85 °C

IP grade 55

Electric Foot Brake 3-42 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 C. Detail of Brake sensor

Output versus Pedal travel

<Pedal Output Position>

5V
4.5V±0.15 4.5V±0.25
(SIGNAL 2) 4 (SIGNAL 1)

1
0.5V±0.15 0.5V±0.25
(SIGNAL 1) (SIGNAL 2)
0 50
Pedal Travel Position
50 ±2

B15T73003

Fig. 3-49

Pin location C B A 3
Pin
Description Color Wire
Location

Drive/brake system
A SIGNAL 1 Green

B SIGNAL 2 GND Violet

C SIGNAL 1 GND Black F E D

UL1007 B15T73004

D SIGNAL 2 DC5V White AWG20 Fig. 3-50

E SIGNAL 1 DC5V Red

F SIGNAL2 Orange

• AMP P/NO: 174264-2(CAP)

• COUNTER PART P/NO: 174262-2(PLUG)

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-43 Electric Foot Brake
 3-7-2 How it works

+ Battery

Left
Traction Motor +
MR Left Traction
-
D1-23(CAN H)
D1-35(CAN L)

Right
Traction Motor +
MR Right Traction
- D2-23(CAN H) Brake
D2-35(CAN L) Sensor
D2-7 3 GND
D2-26 5 +5V
D2-16 1 OUT A
2 GND
4 +5V
Pump Motor 6 OUT B
+ Pump
MR P1-26

- P1-35(CAN L)
P1-23(CAN H)

P1-17

- Battery

B15T73019

Fig. 3-51

Brake sensor receives 5 V from both the right traction

controller and pump controller. This implies that brake
sensor can work only under the operational controllers for
safety. When the brake pedal is pressed，its linear stroke
is converted mechanically to the rotational angle. This
turns the input shaft of brake sensor. Then, the brake
sensor generates the output signals. As shown in fig. 3-
49，there are two signal voltages from brake sensor.
These two signals provide much more precise detection of
pedal’s movement, like the accelerator pedal.

Signal out A is sent to the right traction controller and

signal out B is sent separately to the pump controller,
through the wire harness. Via CAN communication
between the right traction controller and the pump
controller, it decides that operator wants to use the
function of service brake and the direction and force of
braking the drive motors is calculated.

Electric Foot Brake 3-44 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Afterward, both the right traction controller and the left
traction controller send out the different direction and some
amount of current to each drive motor, respectively. Then,
this makes some reverse magnetic field in the drive motor
so to generate the reverse torque to achieve the braking
effect. This system is called EFB - Electric Foot Brake – by
using the function of EAB – Electrically Asssited Braking.

Electrical control diagram as follows : D2-26 is the power

input (+5V) and D2-7 is GND. P1-26 is the power input
(+5V) and P1-7 is GND. D2-16 receives Out A and P1-17
receives Out B.

Drive/brake system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-45 Electric Foot Brake
 3-7-3 Brake pedal ass’y removal/installation

Preliminary steps

1. Turn the key off..

Procedure

1. Remove the instrument cover by loosening two

bolts (1).
1

B15T73005

Fig. 3-52

2. Remove the section of instrument harness (2)

4
assembled to brake sensor (3).

Note: In reassembly, make sure to use the strap

2
(4) so to route the harness, as shown in the figure.

3 B15T73018

Fig. 3-53

Note: In case of the truck equipped with

combination lamp option, disconnect the other
5
harness also, assembled to the micro switch (5).

B15T73006

Fig. 3-54

Electric Foot Brake 3-46 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 3. Remove the brake ass’y (6) by loosening four 6
7
units of bolts (7).

B15T73007

Fig. 3-55

4. In case of replacing the brake sensor, make sure

to use the sealant on screw (8) and (9).
 Sealant: Loctite # 242.

B15T73008

Fig. 3-56

9
3

Drive/brake system
B15T73009

Fig. 3-57

5. For reference, when assembling the brake sensor

onto the bracket, the direction of brake sensor Initial position: 0
Pedal working angle: 20
should be zero degree, as shown in Fig. 3-xxx. (20
)

B15T73010
– Fig. 3-58

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-47 Electric Foot Brake
 3-7-4 Brake pedal adjustment

Preliminary steps

1. If the floor plate was removed, place it back to the

position.

2. Prepare the laptop with EasyView installed.

3. For reference, two steps of mechanical

adjustments and one step of electrical calibration
are required.

4. Prepare the ruler.

Procedure

Mechanical adjustment 1

1. Without pushing the service brake pedal, measure

the vertical distance (A) between the upper edge
of brake pedal and floor plate.
 Distance (A): 102 +3 / -0 mm A

(4.02 +0.12 / - 0 inch)

B15T73011

Fig. 3-59
2. If the distance (A) is out of range, adjust the
stopper bolt (1).

B15T73012

Fig. 3-60
 Distance (B) between the end of bolt and
bracket: Approx. 14 mm (0.55 inch)

Fig. 3-61

Electric Foot Brake 3-48 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 3. When pushing the service brake pedal fully, the
total stroke (C) should be more than 50 mm (1.97
inch). In case of less stroke, adjust the pedal
height (A) within the specified range.
C
 Stroke (C): 50 mm (1.97 inch)

B15T73014

Fig. 3-62
Mechanical adjustment 2

4. For reference, there are two stages during the

whole pedal stroke. Between the stages, there is
some slight difference. Before conducting the
following steps, this difference should be detected.
So, try to be familiar with this feeling.
D
5. Press the brake pedal until the different feeling is
noticed. At this moment, the distance (D) to this
travel is as below.
 Distance (D): 80 +3 / -0 mm
3
(3.15 +0.12 / - 0 inch)

Drive/brake system
B15T73015

Fig. 3-63

6. When the distance (D) is out of range, adjust the

stopper bolt (2).

B15T73016

Fig. 3-64

 Gap (E) between the end of stopper bolt and

the bracket: 9 mm (0.35 inch)

B15T73017

Fig. 3-65

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-49 Electric Foot Brake
 Electrical calibration
Conduct the calibration for Brake Pedal Set in Chapter 2-6-6.

Fig. 3-66

Electric Foot Brake 3-50 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
3-8 EM parking brake

3-8-1 Exterior and specifications

Drive/brake system
Fig. 3-67

Components 36 V spec. 48 V spec.

Part no. 130104-00300 130104-00301
Operating voltage 36 V 48 V
Power 30.9 W @ 20°C (68°F) 34.5 W @ 20°C (68°F)
Current 0.858 A @ 20°C (68°F) 0.718 A @ 20°C (68°F)
Resistance 41.9 Ω ± 5% 66.8 Ω ± 5%
Braking torque 42 N·m (31 lb·ft) 42 N·m (31 lb·ft)
Max. inclination at which
15° 15°
braking is effective

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-51 EM parking brake

 3-8-2 How it works
This model uses an EM (electromagnetic) brake pair as its
parking brake. (5) Flange (2) Spring

The EM brake is connected to the shafts in the backs of

(1) Inductor
the drive motors in both sides. The shafts in both sides are
(6) Hub
ultimately connected to the drive wheels and make the
(7) Motor shaft
entire drive system of the vehicle immovable when the EM
(3) Armature
brake is activated.
(4) Friction disc
If the operator stops the vehicle, spring (2) pushes
armature (3) and friction disc (4) so that flange (5) and
armature (3) contact both sides of friction disc (4), which
brings friction disc (4) and motor shaft (7) to a halt. If the
motor shaft (7) does not revolve, then the drive axle and 0852E

the wheel also will not revolve. Fig. 3-68

When the vehicle moves, electric current flows in inductor

(1) and generates magnetism to pull armature (3). Then a
free space is made among flange (5), friction disc (4), and
armature (3) so that friction disc (4) can rotates freely
without touching the front and rear sides, and thus motor
shaft (7), drive axle, and wheels connected to the friction
disc can revolves freely.

EM parking brake 3-52 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3-8-3 Parking brake test

WARNING
The vehicle will roll if the parking
brake is not adjusted correctly,
causing a hazardous circumstance:
Be prepared to operate the service brake
if the parking brake fails during this
procedure.

1. Put a rated load capacity on the forks

2. Drive the vehicle up a 15% incline.

3. Half way up the incline, stop the lift truck using

the service brake, and the EM brake will be
automatically engaged as the parking brake.

4. If the parking brake has been adjusted properly,

the vehicle should remain stationary (If the Fig. 3-69

vehicle descends see Section 3-8-3 EM parking

brake troubleshooting). 3

Drive/brake system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-53 EM parking brake

 3-8-4 Manual release of braking
The EM parking brake is automatically engaged three
seconds after the vehicle stops driving and disengaged
again once the accelerator pedal is pushed. Though this
gives convenience to the operator, in some cases such as
towing the vehicle you need to manually disengage the
brake when the vehicle is parked.

DANGER
When you disengage the EM parking
brake, the vehicle might move without
the operator seated.
Before you start the procedure below,
make sure to park the vehicle on a flat
ground and support the wheels with
wooden blocks.

Preliminary steps

1. Remove the top counterweight cover (see

Section 7-4).

Procedure

1. Disconnect the cables of EM CONN A and EM

CONN B beside the fuse box.
 The fault code 80 (L-EM Brake Fault) will be
displayed on the instrument panel and the
warning buzzer will sound.

2. Connect the cable of EM CONN B to the cable of

EMERGENCY C to release the EM parking
brake. < Location of cables > Fig. 3-70

< Cables zoomed in > Fig. 3-71

EM parking brake 3-54 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

3-9 Troubleshooting

3-9-1 Driving

Problems Probable causes

Switch not closed (battery connector, key switch, seat switch,

F/R switch or parking brake switch):
 Close the switch. If it still does not operate, test for
power to the control panel and power flow through each
switch with a voltmeter.
 But the service brake switch should be opened.
Bad connection. Fuse blown:
 Check battery connections. Check connections at battery
connector. Check fuses, drive and logics. Replace fuse if
blown.
 Check the Drive motor and control panel for possible
reasons for a blown fuse. Some causes are:
a. Operation under excessive MOSFET load, too high
current limit (C/L).
b. Possible short circuit in power unit.
Drive motor does not operate. Low battery voltage:
 Check battery terminal voltage. If too low, charge the
3
battery.

Drive/brake system
 Check all the cells for one or more that have defects.
 Check the specific gravity of each cell. The maximum
density difference from the highest to the lowest cell
must not be more than .020 SG (specific gravity).
Control panel operation not correct:
 See “Section 2-3-5 Motor controller test” and “2-7
Diagnosis/calibration/handling faults.”
Static return to off circuit (S.R.O.) actuated:
 If the static return to off is activated, the control will not
start again until the accelerator is released and the
directional control lever is returned to neutral.
Encoder is breakdown.
Brakes have a defect, cause a resistance (lack of free
movement). Heat increases, which causes the motor to stall:
 Check the brake adjustment.
Traction does not operate through a Too much heat in the control panel because:
a. Extra heavy traction loads.: Decrease the duty cycle
normal work period, but hydraulic
load.
operation is normal.
b. Faulty thermal sensor: See “Section 2-7 Handling
faults on instrument panel/EasyView.” These can
cause MOSFETS to become defective, control panel
failure or drive fuse to go bad.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-55 Troubleshooting

 Problems Probable causes
Too small a battery equipped in the lift truck:
 Use a larger battery for the complete work cycle and
normal work period.
Battery not being fully charged or equalized during the
battery charging operation:
 Check the battery cells for an equalization charge (a
charge to make the specific gravity the same in all cells).
 Check the battery charger for defects.
Battery change interval is too long or changed battery cooling
time is too short. This decreases the capacity and the ability
of the battery:
 Decrease the battery work duration before a change.
 Increase the battery cooling time after a charge before it
is put to use.
Battery has one or more defective cells which results in less
than the rated capacity and ability of the battery:
 Replace the battery.
Neither traction nor hydraulic does Traction system draws (makes a consumption of) too much
last through a complete normal battery power because of traction system faults. Operation of
work period. the duty cycle (complete working cycle) condition is not
correct:
 Check the brake adjustment. Check the mechanical
components such as wheel bearings, axles, etc., for
corrections to eliminate the faults. Change to a tire with
less friction.
Hydraulic system draws too much battery power because of
lifting and tilting arrangements, or hydraulic conditions are not
correct for the duty cycle:
 Decrease hydraulic relief valve setting to the capacity
that only will be used.
 Change to a smaller hydraulic pump.
 Check the mast for restriction during operation.
Lift truck working more than the capacity of its design with no
available power after one work shift:
 Have available an extra (exchange) battery. Decrease
the speed and work load required to complete the work
shift.
Dirty battery, electrolyte on top of cells and is in contact with
the frame. Current flows through battery box, which places a
voltage on the truck frame:
 Clean the battery with baking soda and water solution.
Low resistance to ground [battery Battery or control panel wire connections in contact with truck
polarity either positive (+) or frame:
negative (–) or a medium voltage is  Make a continuity test and move the wire from contact.
in direct contact with truck frame  Remove wires in sequence until the fault is cleared.
 The fault will be in the wire last disconnected.
(body) or drive motor body].
Dirty motor:
 Remove metallic or carbon dust with air pressure.
Wet motor:
 To dry the motor, heat it to 90°C (194°F).

Troubleshooting 3-56 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Problems Probable causes
Battery not fully charged or battery has bad cells:
 Charge the battery. Check for bad cells. Replace the
battery if necessary.
A fault either in the drive motor, control panel or drive train:
Lift truck does not get to top speed.
 Check lift truck speed in both directions. If the control
panel needs to be tuned up, make adjustments as shown
in the respective part of “Section 2 electrical system."
 If the drive motor is at fault, make tests of the motor components.
Unpolished or improperly positioned forks:
Lift truck does not have enough  Install tapered and polished forks. Position forks
correctly for load being lifted.
power to position itself under a
Lift truck equipped with tires that have poor traction:
load. Lift truck does not have
 Install tires that have good traction per recommendation
enough power on ramps or towing from Bobcat.
trailers. Lift truck work load is too heavy or the duty cycle too long:
 Decrease the work load and/or duty cycle.
Drive control overheated and the thermal switch opens.
Lift truck has slow acceleration. NOTE: The thermal switch will warning if the temperature is
145°C (293°F).

3-9-2 Service brake

3
Problems Probable causes

Drive/brake system
Leakage or low fluid level.
Pedal resistance is not solid
Air in the brake hydraulic system.
(spongy).
Master cylinder is loose.
Mechanical resistance on the brake pedal.
Extra (excessive) pedal pressure Restriction in the brake line.
needed for braking action. Bad master cylinder.
Discs look like glass (glazed) or are worn.
Leakage or low fluid level.
Pedal gradually goes to the floor.
Bad master cylinder.
Pedal adjustment is not correct.
Leakage or low fluid level.
Extra (excessive) pedal travel. Air in the brake hydraulic system.
Bad master cylinder.
Discs are worn.
Leakage or low fluid level.
Air in the brake hydraulic system.
Linkage is not in correct adjustment or is bent.
Brakes does not apply.
Discs look like glass (glazed) or worn.
Oil or brake fluid is on the lining.
Bad master cylinder.
Discs look like glass (glazed) or worn.
Oil or brake fluid is on the lining.
Not braking evenly or rough feeling Bad contact between the steel discs and friction discs.
during braking (chatter). Brake discs uneven (out of flat).
Loose pressure plate bearing.
Bad disc and friction disc assembly.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 3-57 Troubleshooting

 3-9-3 EM parking brake

Problems Possible causes

Power supply is too low.
Brake is not properly Power supply is too interrupted.
released. Disc is worn
Coil is damaged
Voltage is present afther the switch turned off.
Brake is not engaged.
Grease on the friction disc

Troubleshooting 3-58 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

4 Hydraulic system

4-1 Overview ........................................................2

4-1-1 Components ........................................................ 2
4-1-2 Oil flow ................................................................ 4

4-2 Pump motor ..................................................6

4-2-1 Exterior and specifications ................................... 6
4-2-2 How it works ........................................................ 8
4-2-3 Pump motor and main hydraulic pump
removal/installation .............................................10
4-2-4 Pump motor disassembly/assembly and test .......12

4-3 Main hydraulic pump..................................14

4-3-1 Exterior and specifications ..................................14
4-3-2 How it works .......................................................15
4-3-3 Removal and installation .....................................16

4-4 Priority valve ...............................................18

4-4-1
4-4-2
Exterior and specifications ..................................18
How it works .......................................................19
4
4-4-3 Removal and installation .....................................20

Hydraulic system
4-4-4 Disassembly and assembly .................................21

4-5 Hydraulic tank and filter.............................22

4-5-1 Exterior and specifications ..................................22
4-5-2 How it works .......................................................24
4-5-3 Hydraulic oil and filter replacement ......................26

4-6 Troubleshooting .........................................27

4-1 Overview

4-1-1 Components

Steering unit

Control valve

Load sensing line

Pump motor
Main pump Pump motor controller

Priority valve

Hydraulic tank
0854E

Fig. 4-1

Overview 4-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 The hydraulic system operates a number of actuators by
pressurized oil from the main hydraulic pump and
withdraws oil drained from those actuators.

• Pump motor, regulated by the controller, drives

the main hydraulic pump. [Section 4-2]

• Main hydraulic pump pressurizes oil in the

hydraulic tank using the rotatory force delivered
from the motor and sends the oil to the priority
valve. [Section 4-3]

• Priority valve determines to which device between

the steering unit and control valve it gives priority,
and then supplies the prioritized one with a
majority of pump oil. [Section 4-4]

• Hydraulic tank stores hydraulic oil that returns

from actuators. The stored oil is suctioned by the
main hydraulic pump for reuse. [Section 4-5]

Hydraulic system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-3 Overview

 4-1-2 Oil flow

(6) Steering unit (5) Control valve

Load sensing line

(4) Priority valve

(7) Return filter

(3) Main pump

Hydraulic line
Pilot line (2) Suction strainer
Drain line
(1) Hydraulic tank 0855E
Fig. 4-2

Overview 4-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Hydraulic oil circulation

Hydraulic tank (1) stores hydraulic oil, which is to be

supplied to main hydraulic pump (3) through suction
strainer (2). Main hydraulic pump (3) pressurizes the
supplied oil and distributes it to different systems
throughout the vehicle via priority valve (4). Upon
receiving hydraulic oil, these systems perform their
functions and then discharge the used oil to tank (1)
through return filter (7).

Hydraulically operated systems

The following systems are operated by the circulation of

hydraulic oil:

• Lift/tilt/auxiliary system: Control valve (5)

controls this system using a supply of hydraulic oil.
See Section 5 for more information.

• Steering system: Steering unit (6) controls this

system using a supply of hydraulic oil. See Section
6 for more information.

To ensure an efficient and safe use of the limited

hydraulic pressure, priority valve (4) determines which of
these two systems the majority of hydraulic oil will be
4
supplied to. When the steering mechanism is not being

Hydraulic system
operated, steering unit (6) is supplied with only little
hydraulic oil that passes through an orifice, and control
valve (5) is supplied with the rest.

However, once the operator turns the steering wheel,

priority valve (4) receives a pilot signal from steering unit
(6) through the load sensing line that shifts its spool,
increasing the hydraulic oil supply to steering unit (6).

For more information on the operations of individual

components that are involved in hydraulic oil circulation,
refer to the following sections.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-5 Overview

4-2 Pump motor

4-2-1 Exterior and specifications

Fig. 4-3

Items Spec.
Part number 300506-00353
Voltage 48 VAC
Power 14.0 kW
Voltage 30 V
Current 352 A
Speed 2140 rpm
Max. speed 4500 rpm
Frequency 74 Hz
Protection degree IP43
Weight 41.5 kg(91.5 lb)

Pump motor 4-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Encoder
Items Spec.
Part no. 301310-00010
PPR 64 pulses/rev.
Connector 4-pin AMP

Thermal sensor

Items Spec.
Part no. Included in the pump motor
Resistance 603 Ω ± 3% at 25°C (77°F)
Connector 2-pin AMP

Hydraulic system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-7 Pump motor

 4-2-2 How it works
PUMP MOTOR
CONTROLLER
GND
60/WH/BU P1-7

THM1
61/GN/RD P1-8
B1
63/BR P1-32
A1
62/GN/BK P1-31
60/WH/BU P1-9 65/BU 65/BU 2
63/BR +5V 1
64/RD P1-26
64/RD MAST TILT SW2 (OPT)
61/GN/RD
PUMP MOTOR 68/WH/GN 2
62/GN/BK P1-4 68/WH/GN
+

69/BU/WH 69/BU/WH 1
P1-13
ENCODER
GND A B

MR TILT SOLENOID (OPT)

P1-19 78/YL/GN 78/YL/GN 2
1
Auto tilt SW3 (OPT)
P1-20 79/YL/BU 79/YL/BU 2
1
THERMAL THERMAL
60/WH/BU TILT LEVER (OPT)
SENSOR SENDER
1
1 47/RD/GN P1-25 P1-25 47/RD/GN 47/RD/GN 2
2 117/YL/WH P1-6 44/VO 44/VO TILT
P1-10 4
45/YL 45/YL AUX1
PRESSURE SENSOR(OPT) P1-22 6
46/BK/WH
AUX2
P1-33 46/BK/WH 8
P1-7 60/WH/BU 60/WH/BU 5 GND+12V
P1-24 67/GN/YL 67/GN/YL 7 OUT

LIFT SENSOR

1
P1-14 24/WH/BK 24/WH/BK 2
HEIGHT SW1 (OPT)

Fig. 4-4
Electrically powered, the pump motor transmits power to
the main hydraulic pump so that it can pump hydraulic oil
for operating the hydraulic system.

Controlling by controllers

As shown in the schematic diagram, the pump motor is

wired by U, V, and W lines to a controller. The controller
runs the pump motor according to inputs from a number
of switches and sensors, as well as internal parameter
settings.

When the following conditions are all met, the pump

motor run:

• Key switch is closed.

• Operator is seated, closing the seat switch.

• One of the hydraulic control switches, F/R switch,

or accelerator switch is signaling the controller.

Turning the F/R switch to Forward or Reverse triggers the

pump motor to run at idle for six seconds. And then it
enters PP mode to stop running unless signaled from the
accelerator in the six seconds. To restart up the pump
motor, the operator should return the F/R switch to
neutral and then shift it to Forward or Reverse again, or

Pump motor 4-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 move one of the hydraulic control levers to turn on the
respective switch.

Unlike in tilting or other auxiliary operations, speed

matters when it comes to lifting. Therefore, via the lift
sensor, the input signal for lifting varies with the angle of
the lever; receiving this variable signal, the controller
regulates the pump motor’s speed in rpm. The motor’s
speed determines the pressure of the hydraulic oil sent to
the lift cylinders and consequently the lifting speed.

Motor speed detection (encoder operation)

The pump motor is equipped with an encoder, which

serves as a speed sensor for the motor. It includes two
hole sensors and has a gear installed on the drive shaft
of the motor to interact with these two hole sensors. This
gear’s concurrent rotation with the drive shaft makes the
gear teeth periodically pass the magnetic field of each
hole sensor. When a top land of the gear passes the Mechanical profile

magnetic field, it comes closer to the hole sensor and

thus the magnetic flux increases. On the other hand, Magnetic profile
when a bottom land passes the magnetic field, the

4
distance increases and the magnetic flux decreases Sensor electrical output profile 0825E

Fig. 4-5
accordingly.

This cycle recurs and the magnetic flux has a waveform

Hydraulic system
to produce a voltage pulse. The controller analyses the
amplitude of this pulse to compute the rpm of the motor.
A smaller amplitude means a higher rpm of the motor.
Clockwise rotation

Like other sensors, the encoder also produces both a

main signal (signal A) and a reference signal (signal B)
through the two hole sensors. As shown in Fig. 4-6, the
order of the signals produced changes depending on the
direction of revolution. Counterclockwise rotation 0826E

Fig. 4-6
Overheat protection (thermal sensor operation)

The pump motor is equipped with a thermal sensor to

protect it from overheating. Once the motor has been
heated up to 145°C (293°F), an overheat alarm is
activated and the working performance of the motors is
limited.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-9 Pump motor

 4-2-3 Pump motor and main hydraulic pump removal/installation

(4) Cable

(5) Encoder cable

(6) Thermal sensor cable

(3) Brake pedal ass’y

(1) Brake line

(10) Suction hose

(2) Brake line

(7) Suction hose

(8) Bulk hose

(9) Tube ass’y

(12) Bolt

(11) Strap

0857E

Fig. 4-7
NOTICE: When assembling and disassembling the
hydraulic pump, do not apply any pressure on the motor
nor damage the encoder (sensor bearing) cable.

Preliminary steps

1. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

Pump motor 4-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2. Remove the floor plates in the compartment so
that you may see the pump motor as shown in
Fig. 4-8.

3. Prepare and oil pan.

Procedure

1. Use a tie wrap or something similar to prevent

the brake oil from draining to the reservoir via Fig. 4-8
brake line (1).
 Have the oil pan ready to catch any brake fluid
that will come out of the lines and cylinder
ports.

2. Disconnect brake line (2) from the master

cylinder.

3. Dismount brake pedal ass’y (3) (See Section 3-

6-5).

4. Disconnect cables (4) from the UVW terminal.

5. Disconnect encoder cable (5) and thermal

sensor cable (6) from the main harness.

6. Disconnect suction hose (7) which connects the

priority valve to the control valve.
4

Hydraulic system
7. Disconnect bulk hose (8) from the hydraulic
pump.

8. Disconnect tube ass’y (9).

9. Disconnect suction hose (10) that runs from the

hydraulic pump to the priority valve.

10. Support the pump motor with straps (11) and

remove the motor and pump ass’y.

11. Remove bolts (12), washers, and hydraulic pump

from the hydraulic motor.
 Installation torque: 55±10 N·m(40±7 lb·ft).

12. Follow the steps above in the opposite order to

install the pump motor.

13. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-11 Pump motor

 4-2-4 Pump motor disassembly/assembly and test
(8-1) Nut (11) Encoder

(8) Terminal block

(8-2) Screw (11-1) Bolt

(10) End bell

(9) Bearing

(4) Bearing
(2) End bell
(3) Washer (7) Stator assembly

(6) Bolt
(5) Rotor assembly

(1) Nut
0858E
Fig. 4-9

Disassembly/assembly

1. After removing the terminal protector, loosen nut

(8-1) and remove the terminals from terminal
block (8).

2. Loosen screw (8-2) and remove terminal block

(8).

3. Loosen bolts (11-1) and remove encoder (11).

4. Loosen nuts (1) and remove bolts (6).

5. Remove end bell (4).

6. Remove stator assembly (7) by hand or using a

tool.

7. Remove washer (3) and bearing (4) from rotor

assembly (5).

Pump motor 4-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 8. Remove bearing (9) and rotor assembly (5) from
end bell (10).
 It is recommended to use a hand puller as
shown in Fig. 4-10.

9. Follow the steps above in the opposite order to

assemble the pump motor.

NOTICE: Before you reassemble the motor, you may test

its parts as follows.
Fig. 4-10
Stator Test

1. Carefully wipe contaminants from the surface of

the stator using a clean cloth dampened with
alcohol.

NOTICE: Contaminants in the stator may cause damage

to the coil and consequently to the stator itself.

2. Measure resistance for each phase (U-V, V-W,

W-U) using a milli-ohmmeter.
 Rated resistance: 3.50 mΩ

Hydraulic system
Fig. 4-11
3. Test insulation at 1000 Vac and Min. 10 MΩ
using an insulation tester.
 If insulation is faulty, replace the stator with a
new one.

Fig. 4-12

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-13 Pump motor

4-3 Main hydraulic pump

4-3-1 Exterior and specifications

Fig. 4-13

Items Spec.
Part number 400910-00078
Displacement 16.5 cc/rev
Rotation direction Counterclockwise
Rated pressure 21,000 kPa(3,046 psi)
Velocity at the maximum pressure 500 to 3000 rpm

Main hydraulic pump 4-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 4-3-2 How it works
(1) Driving gear

(2) Drive shaft Driving gear

Low High
Inlet pressure pressure Outlet

Rotated by the motor

Driven gear

(3) Driven gear

0859E

Fig. 4-14
This model uses a circumscribed gear pump as its main
hydraulic pump.

Gear operation

As shown in Fig. 4-14, driving gear (1) receives power

from the pump motor through drive shaft (2) and
transmits this power to engaged driven gear (3). These
two interlocked gears then revolve in the opposite
direction to each other.
4

Hydraulic system
Hydraulic oil flow

If the two gears revolve in the opposite direction to each

other, then the hydraulic oil in area A will be carried to
area D via areas B and C. Although the hydraulic oil in
area D tries to circulate by flowing between the two gears
back to area A, it remains in area D because there is no
space between the two gears for it to travel. Therefore, a
low pressure area is created in area A as the hydraulic oil
flows out, while a high pressure area is created in area D
as the oil is accumulated.

As a result, the low pressure area in area A causes

hydraulic oil in the tank to flow into the pump while the
high pressure area in area D causes its pressurized oil to
flow out of the pump via the outlet.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-15 Main hydraulic pump
 4-3-3 Removal and installation

Preliminary steps

1. Remove hydraulic pump.

Procedure
NOTICE: Identify and mark all sections of the hydraulic
pump for purposes of reassembly.

1. Remove four bolts (1) and washers (2) to remove

pump cover (3).

 Installation torque: 39–41 N·m(29-30 lb·ft)

Fig. 4-15
2. Remove O-ring seal (4) from the pump body

Fig. 4-16
3. Remove seal (5), back up-ring (6) and bushes (7)
from the pump gears.

4. Remove two gears (8) from the pump body and

Fig. 4-17
then separate the pump’s sections.

Fig. 4-18

Main hydraulic pump 4-16 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 5. Remove O-ring (9), seal (10), back up-ring (11)
and bush (12) from the pump body. Replace
seals, back up-ring, O-ring with new ones if
needed

Fig. 4-19
6. Remove seal (13) from the flange (14).
 When installing seal (13), make sure the lip of
the seal is positioned toward the inside of the
pump housing.

7. To assemble the main hydraulic pump, perform

the procedure in the reverse sequence.

Fig. 4-20

Hydraulic system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-17 Main hydraulic pump
4-4 Priority valve

4-4-1 Exterior and specifications

Fig. 4-21

Items Spec.
Part number D518223
Max. flow at “P” port 50 LPM
Max. pressure of excessive flow (EF) 21.6 MPa (3,129 psi)
Control pressure 0.46±0.05 MPa (67±7 psi)
Steering system Internal pilot dynamic signal type

Priority valve 4-18 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 4-4-2 How it works
As shown in Fig. 4-22 and 4-23, the priority valve meters
hydraulic oil to the control valve and the steering unit
after receiving oil from the main hydraulic pump so as to
always give priority to the steering system when
demanded for steering. It is because the steering speed
is more closely related to safety than the mast and
carriage speed.

A portion of the hydraulic oil that travels along the

steering unit line is distributed to lines A and B. Hydraulic
oil in line A has a higher pressure than spring (2) to push
spool (1) toward the opposite side of spring (2), but
pressure in line B varies depending on conditions of the
load sensing line.

When steering wheel is not turned

Control
When the steering wheel is not being turned, there is no
Load-sensing line
hydraulic oil (pilot pressure) sent from the steering unit Steering
unit
through the load sensing line. Therefore, as shown in Fig.
4-22, the hydraulic oil sent through line B flows out to the

4
load sensing line and gives nearly no pressure to spool
(1). Accordingly, spool (1) is pushed by the pressure from A B

line A, and the majority of pump oil is sent to the control (1) Spool Priority valve
valve while the steering unit is supplied with only a small (2) Spring

Hydraulic system
(1-1) Orifice
amount of oil that has passed orifice (1-1). This helps the
mast assembly operate at full performance. Main hydraulic pump 0860E
Fig. 4-22
When steering wheel is turned

When the steering wheel is being turned, a certain Control valve

pressure of hydraulic oil (pilot pressure) is sent from the
steering unit through the load sensing line and pushes Steering Load-sensing line
spool (1) together with the hydraulic oil in line B in the unit

opposite direction to the pressure of line A. As spring (2)

adds pressure, the pressure in line B exceeds the
A B
pressure in line A, pushing spool (1) in the direction (2) Spring
shown in Fig. 4-23. As a result, the steering unit is (1) Spool Priority valve

supplied with a greater amount of hydraulic oil sent

through the unrestraint passage in spool (1). Main hydraulic pump 0861E
Fig. 4-23

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-19 Priority valve

 4-4-3 Removal and installation

Preliminary steps

1. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

(1) Floor plate

2. Remove floor plate (1).

3. Prepare an oil pan.

0862E

Procedure Fig. 4-24

1. Mark connections (2) and their corresponding

hoses as a reference for assembly.
(3) Bolt
2. Have the oil pan ready to catch any oil that will
(4) Bracket
come out of the hoses and the priority valve’s
ports.

3. Disconnect the hoses at the connections and

(2) Connection
then plug and cap them.

4. Supporting the priority valve, remove bolts (3)

0863E
and washers and then lift out the priority valve Fig. 4-25
ass’y together with mounting bracket (4).

5. Follow the steps above in the opposite order to

install the priority valve.

6. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

Priority valve 4-20 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 4-4-4 Disassembly and assembly

(1) Plug
(2) Bushing
(3) Spool
(4) Spring

(5) Check valve

0864E
4
Fig. 4-26

Hydraulic system
Preliminary steps

1. Remove priority valve (See Section 4-4-3)

Procedure

1. Remove plug (1)

2. Remove bushing (2).

 Check the condition of the bushing and replace
it with a new one if worn or damaged.

3. Remove spool (3).

4. Remove spring (4).

5. Remove check valve (5).

6. Clean all the parts.

7. Follow the steps above in the opposite order to

assemble the priority valve

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-21 Priority valve

4-5 Hydraulic tank and filter

4-5-1 Exterior and specifications

Fig. 4-27

Hydraulic tank and filter 4-22 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Components Items Spec.
Hydraulic tank
Part no. 450105-00710
group
Part no. A215170
Air breather Filtration rating 40 µm
Pressure drop rating 1.0 kPa
Magnetic plug Part no. D700890
Part. No A155222
Operating temperature -20°C to +120°C (-4°F to +248°F)
Suction strainer
Filtration rating 149 µm (100 mesh)
Filtration area 31,500 mm2
Part no. D516976
Filtration rating Beta ratio ≥ 75 (98.7%)
Return filter
Initial pressure drop Max. 38 kPa @ 60 LPM, 40°C (104°F)
element
Final pressure drop Max. 262 kPa @ 60 LPM, 40°C (104°F)
Dust holding capacity More than 17 g @ pressure drop 2 kPa
Tank ass’y Part no. 450105-00711

Hydraulic system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-23 Hydraulic tank and filter
 4-5-2 How it works
(2) Air breather

(1) Hydraulic oil cap

R (3) Return filter

H Return line

(4) Suction strainer Supply line

(5) Magnetic plug

0865E
Fig. 4-28

The hydraulic tank and the filter that is installed in the

tank perform the following functions:

Storing hydraulic oil

The hydraulic tank retrieves and stores hydraulic oil

discharged from different components of the hydraulic
system in order that those discharges might be reused by
the main hydraulic pump. As shown in Fig. 4-28, the two
lines connected to the tank are responsible for receiving
and supplying hydraulic oil respectively.

Hydraulic tank and filter 4-24 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 The oil height (H) in the tank varies depending on the
contraction/expansion of various cylinders and the
opening/closing of different valves, and the remaining
space (R) changes accordingly. Air breather (2) is
installed to let external air flow into/out of this space so
that oil in the tank remains under constant atmospheric
pressure, and to prevent dust from entering the system a
filtering element is also installed.

You can open oil cap (1) and refill the tank with hydraulic
oil when needed.

Filtering impurities from hydraulic oil

As oil passes through the different components in the

hydraulic system, it collects various contaminants such
as moisture and air, which may lower the system
performance and cause component malfunction or failure.
For this reason, various devices have been installed in
the oil tank to filter these materials and protect the
system from failure.

Large, solid particles are the first of the contaminants to

be filtered by return filter (3) while the remaining particles
are separated into the lighter than oil, which float on the
surface, and the heavier, which settle at the bottom. Plug
4
(5), which is installed at the bottom of the oil tank,

Hydraulic system
facilitates the precipitation of the impurities.

And suction strainer (4) is installed in the discharge line

to the pump so that oil is filtered once more before it
flows back to the hydraulic system.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-25 Hydraulic tank and filter
 4-5-3 Hydraulic oil and filter replacement
1. Operate the vehicle a few minutes to warm the
oil.

2. Park the vehicle level, with the forks lowered,

parking brake engaged, F/R switch in neutral,
and the key switch to off.

Fig. 4-29

3. Remove the hydraulic tank drain plug. Allow the

oil to drain. Clean and install the plug.

Fig. 4-30

4. Remove and discard the hydraulic filter.

5. Remove the breather/dipstick and the strainer.

Wash them in clean, nonflammable solvent and
dry them.

6. Install the strainer. Fill the hydraulic tank (See

Section 1-6). Install the dipstick.
Fig. 4-31
7. Turn the key switch on and close the seat switch.
Operate the hydraulic controls and steering
system through a few cycles, to fill the filter and
lines.

8. Check for oil leaks.

9. Retract all cylinders.

10. Turn the key switch off.

11. Maintain the oil level to the FULL mark on the

breather/dipstick. Add oil if necessary.

Hydraulic tank and filter 4-26 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
4-6 Troubleshooting

Problems Probable causes

The oil level is low.

The oil is thick (viscosity too high).
The pump inlet line has a restriction in it.
Noise in the pump.
Worn parts in the pump.
Oil is dirty.
Air leaks into the inlet line.
The oil level is low.
There is a restriction in an oil passage.
The relief valve setting is too low.
The oil is too thin.
There is air leakage in the system.
The oil temperature is too high.
The pump has too much wear.
The system operates at too high a pressure.
a. Relief valve setting too high.
b. Attachment components cause a restriction during
movement.
c. Restrictions in flow control valve, check valve and in 4
oil lines.

Hydraulic system
The shaft seal is worn.
The inner parts of the pump body are worn.
Operation with too low oil level in tank causes suction on the
Leakage at the pump shaft seal. seal.
Seal cut on shoulder of pump or keyway during installation.
Seal lips are dry and hardened from heat.
Low level of the oil in the tank.
There is a restriction in the pump inlet line.
There is air leakage in the pump inlet line.
a. Loose bolts.
There is failure of the pump to b. Defects in suction line.
deliver fluid. The viscosity of the oil is wrong.
The pump has too much wear.
Failure of the pump shaft.
The bolts of the pump do not have the correct torque.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 4-27 Troubleshooting

5 Lift/tilt/auxiliary system
5-1 Overview........................................................2
5-1-1 Components ...........................................................2
5-1-2 Oil flow ....................................................................4

5-2 Control valve .................................................6

5-2-1 Exterior and specifications ......................................6
5-2-2 How it works............................................................7
5-2-3 Relief valve adjustment.........................................18
5-2-4 Needle valve for emergent lowering .....................21
5-2-5 Levers and switch group
adjustment/removal/installation ............................22
5-2-6 Control valve removal/installation .........................24
5-2-7 Control valve disassembly/assembly ....................26

5-3 STD/FFL/FFT Mast ......................................28

5-3-1 Exterior and specifications ....................................28
5-3-2 How it works..........................................................30
5-3-3 Forks service.........................................................38
5-3-4 Sideshifter service ................................................40
5-3-5 Chains service ......................................................46
5-3-6 Tilt cylinder service ...............................................52
5-3-7 Primary lift cylinder service ...................................60 5
5-3-8 Standard/secondary cylinder service ....................64

Lift/tilt/auxiliary system
5-3-9 Carriage service ....................................................74
5-3-10 Mast service ..........................................................78

5-4 Quad mast ...................................................84

5-4-1 Primary lift cylinder service ...................................84
5-4-2 Standard cylinder service .....................................87
5-4-3 Carriage service ....................................................99

5-5 Safety function and Optional Auto-tilt

leveling ......................................................100
5-5-1 Exterior and specifications ..................................100
5-5-2 How it works........................................................102
5-5-3 Height switch removal/installation ......................106
5-5-4 Mast tilt/auto-tilt switch ass’y removal/installation
............................................................................107
5-5-5 Hydraulic block ass’y removal/installation ..........109
5-5-6 Operator Safety Function.................................... 111

5-6 Troubleshooting ....................................... 112

5-1 Overview

5-1-1 Components

Fig. 5-1

Overview 5-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 The lift/tilt/auxiliary system is powered by the main
hydraulic pump, which consists of the following
components:

• Control valve, connecting the main hydraulic pump

and a number of actuator cylinders, supplies to or
returns pump oil from those cylinders. The positions
of the valve’s spools determine whether cylinders
are supplied with or drained of hydraulic oil; and
their positions are shifted by their respectively
corresponding levers. [Section 5-2]

• Mast ass’y is a group of devices that lift, lower, tilt

back and forward, and handle other operations with
loads. This ass’y is equipped with lift, tilt, and
auxiliary cylinders that the operator controls. These
cylinders are connected to the LIFT, TILT, and AUX
sections of the control valve.
 Forks: Two prong-shaped objects to support a load
[Section 5-3-3]
 Sideshifter: An attachment that moves the forks and
the loads on them to the left and right [Section 5-3-4]
 Chains: Parts that lift the carriage and mast [Section
5-3-5]
 Tilt cylinders: Double-acting cylinders that pull or
push the mast [Section 5-3-6]
 Primary lift cylinder: A single-acting cylinder that
pulls back the carriage’s chains [Section 5-3-7]
 Standard lift cylinders: Single-acting cylinders that
extend the inner mast [Section 5-3-8]
5
 Carriage: A support structure to which the forks are

Lift/tilt/auxiliary system
mounted [Section 5-3-9]
 Mast: A vertical structure at the front of the forklift
that extends and retracts to lift and lower a load
[Section 5-3-10]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-3 Overview

 5-1-2 Oil flow

Fig. 5-2
Priority valve operation
Priority valve (2) receives hydraulic oil from main hydraulic
pump (1) and distributes it to the steering unit and control
valve (3). When the steering wheel is not operated, as
shown in the circuit diagram priority valve (2) moves the
spool, and the steering unit receives low-pressure oil that
passes through the valve’s orifice, while control valve (3)
receives all the rest pump oil of a high pressure.
Accordingly, the mast, carriage, sideshifter, and other
attachments become able to work with the high pressure
oil required for their full performance.
Lifting/lowering
Lift cylinders (4) are connected to the LIFT block of control
valve (3) with hydraulic lines for one of the following jobs,
depending on the movement of the spool that is
mechanically connected to the lift lever.

Overview 5-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 • Lift is achieved as the cylinders receive hydraulic oil
to push their rods upward and consequently the
mast/carriage fastened to them.
• Lowering is achieved as the cylinders discharge oil
in their heads to retract the rods and consequently
the mast/carriage fastened to them by gravitational
force.
• Neutral is maintained as the cylinders neither
receive nor discharge oil so that their rods and the
mast/carriage fastened to them may stay in place.
Sudden lowering may lower work efficiency and threaten
safety. To control this there are many devices including
flow protectors (5) and flow regulator (6).

Tilt forward/backward
Tilt cylinders (4) are connected to the TILT block of control
valve (3) with hydraulic lines for one of the following jobs
depending on the movement of the spool that is
mechanically connected to the tilt lever.
• Tilt forward: is achieved as the cylinders receive
hydraulic oil at the pistons’ rear (B), which results in
the discharge of oil from the front (A), to extend the
cylinder rods and consequently to push the mast
fastened to them.
• Tilt backward is achieved as the cylinders receive
hydraulic oil at the pistons’ front (A), which results in
the discharge of oil from the rear (B), to retract the
cylinder rods and consequently to pull the mast
fastened to them.
• Neutral is maintained as the cylinders neither
receive nor discharge oil so that their rods and the
mast fastened to them may stay in place.
5
Anti-cavitation valve (3-6) is responsible for reducing

Lift/tilt/auxiliary system
cavitation (forming of air bubbles) in tilt cylinders (7).

Attachment
Sideshifter and various other attachments’ operations are
controlled by auxiliary cylinder (8) and can be made in both
directions depending on the spool’s position as with tilt
cylinders (7).

Pressure relief
If the hydraulic pressure sent to cylinders exceeds a set
limit, the excess portion of the oil will be discharged for the
purpose of safety. Overpressure in lift cylinder (4) is
controlled by main relief valve (3-1) while overpressure in
tilt cylinder (7) and auxiliary cylinder (8) is controlled by
auxiliary relief valve (3-2).
For detailed explanations of the control valve and mast
assembly, see Sections 5-2-2 and 5-3-2 respectively.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-5 Overview

5-2 Control valve

5-2-1 Exterior and specifications

Fig. 5-3

Items Spec.
A158140 (2-section)
Part no. A158141 (3-section)
A158142 (4-section)
Hydraulic oil -35°C to +100°C (-31°F to 212 °F)
Rated flow 53 L/min
Spool stroke 7 mm (0.28 in)
Main relief valve: 19.9±0.25 MPa (2,887±35.6 psi) at 40+3 L/min
Relief valve settings
Aux. relief valve: 13.8±0.25 MPa (2,005±35.6 psi) at 23+3 L/min
Spool operating
Max. 27 kgf (60 lbf)
force
LIFT spool: max. 5 cc/min at 19.6 MPa (2,845 psi)
TILT spool: max. 17.5 cc/min at 9.8 MPa (1,422 psi)
Leakage Other spools: max. 12.3 cc/min at 68.6 MPa (9,956 psi)
Load check leakage: max. 61.4 cc/min at 6.9 MPa (996 psi) (common to all ports)
Tilt lock leakage: max. 246 cc/min at 6.9 MPa (996 psi)
Coil type: 12 VDC / 14 W, male packard connector
Solenoid valve “B”
Solenoid valve B: normally colsed
performance
Internal leakage: 0.6 L/min at 20.6 MPa (2,987 psi)

Control valve 5-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 5-2-2 How it works

A. INLET section

Fig. 5-4

Hydraulic oil inflow

The pump oil that flows in the control valve through the
priority valve reaches the INLET section first.

Pressure relief

Once the oil pressure in the LIFT section has exceeded 5

the set limit, spring (1-1) is pushed to open main relief

Lift/tilt/auxiliary system
valve (1), allowing the hydraulic oil to exit to the tank until
the pressure returns to below the set limit.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-7 Control valve

 B. LIFT section

Fig. 5-5

Neutral

When the lift lever in the neutral position, the oil from the
pump flows to the TILT section, and the mast does not rise
since the pump oil supply line and lift cylinder line are
disconnected to one another.

The mast does not lower either because the oil remaining
in lift cylinders (2) is blocked from returning to the tank.

Control valve 5-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Fig. 5-6

Lift

Moving the lift lever to the lift position shifts spool (1) to
allow the oil from the pump to pass through spool (1) to the
line to lift cylinders (2), pushing their pistons up and raising
the mast.

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-9 Control valve

 Fig. 5-7

Lowering

Moving the lift lever to the lowering position shifts spool (1)
to allow the oil from the pump to pass through spool (1) to
the TILT section. At the same time, the oil in lift cylinders
(2) is pushed by the pistons under gravitational force to
return to the control valve and be drained through spool (1)
to the tank.

In the normal condition where the operator is seated, lift

lock solenoid valve (3) stays open, allowing the hydraulic
oil that reaches this valve to pass itself through.
Consequently the oil that has flowed out of lift cylinders (2)
through line A can hardly apply pressure to lift lock valve
(4), while the oil that reaches this valve through line B
retains a pressure to push on the valve and opens it. Thus
the oil from lift cylinders (2) could pass through spool (1)
and exit to the tank.

As the hydraulic oil that has supported the pistons of lift

cylinders (2) flows out, the mast is lowered. Through its
built-in orifice, flow regulator (6) never allows a large
amount of oil to exit lift cylinders (2) at once, preventing a
sudden drop of the mast.

If the line from the control valve to a lift cylinder (2) is

broken, the valve of protector (7) will be shifted to make
the oil in the cylinder pass through its orifice, preventing a
sudden drop of the mast.

Control valve 5-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Fig. 5-8
Limitation of lowering and manual lowering
For the purpose of safety, when the operator leaves the
seat, this forklift model stops the oil supply from the main
hydraulic pump in order to prevent the actuators from
working even when the levers are moved. However, there
needs to be another device to limit the lowering function in
this situation because lowering is not actuated by oil but
by gravitational force. 5
Once the operator leaves the seat, lift lock solenoid valve

Lift/tilt/auxiliary system
(3) is signaled by the left drive motor controller to close.
Then, the oil flow that has exited lift cylinders (2) and
passed through this valve starts to remain along line A to
be pressurized. The pressurized oil plus the spring of lift
lock valve (4) consequently overcomes the oil in line B to
close it. As a result, all the paths through which the
hydraulic oil in lift cylinders (2) can reach spool (1) are
blocked. It is in this way that moving the lift lever cannot
drain oil from cylinders (2) to lower the mast.

In this situation, if you were to manually lower the mast,

you should use needle valve (5). Open this valve and
move the lift lever to the lowering position to allow the
hydraulic oil that has held the pistons in place to be drained
with the mast being lowered.

NOTICE: When you use the needle valve, make sure to

follow the appropriate procedure in Section 5-2-4.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-11 Control valve

 C. TILT section

Fig. 5-9

Neutral

When the tilt lever is in the neutral position, the oil from the
pump flows to the AUX1 section and the mast neither tilts
forward nor back since the pump oil supply line and tilt
cylinder line are disconnected to one another.

Control valve 5-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Fig. 5-10

Tilt-forward

Once you push the tilt lever forward, spool (1) is shifted to
allow pump oil to flow in head chamber (A) of tilt cylinders
(2), and to allow oil in cylinder rod chamber (B) to be
drained through spool (1) to the tank. As a result, the mast
is pushed forward.

Tilt spool (1) is equipped with tilt lock valve (3) and thus
hydraulic oil in tilt cylinders (2) is not drained until pump oil
pushes this valve to open. Thus this valve keeps closed,
5
blocking the return passage of the oil in chamber B when

Lift/tilt/auxiliary system
pump oil is not supplied due to the operator’s absence
from the seat. As a result the tilt-forward function is
unavailable even when the lever is moved by mistake or
accident, preventing the load from unexpectedly dropping.

Also, there is cavitation valve (4) in the TILT section,

preventing cavitation in tilt cylinders (2), which might occur
during a forward tilt of the mast.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-13 Control valve

 Fig. 5-11

Tilt-backward

Once you pull the tilt lever back, spool (1) is shifted to allow
pump oil to flow in rod chamber (B) of tilt cylinders (2) and
to allow oil in cylinder head chamber (A) to be drained
through spool (1) to tank, pulling the mast back.

Control valve 5-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 D. AUX section

Fig. 5-12

Lift/tilt/auxiliary system

Fig. 5-13

Attachment movement

The movement of auxiliary cylinder (2) is similar to that of

the tilt cylinders. Depending on the position of spool (1),
the chamber to be supplied with hydraulic oil and the
chamber to be drained are switched within cylinder (2). In
this way any attachment mounted to the cylinder rod will
move with it together.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-15 Control valve

 E. OUTLET section

Fig. 5-14

Hydraulic oil outflow

The oil to be drained from the control valve passes through

the OUTLET section.

Pressure relief

Once the oil pressure in the TILT, AUX1, or AUX2 section

exceeds the set limit, spring (1-1) is pushed to open
auxiliary relief valve (1), allowing the hydraulic oil to exit to
the tank until the pressure decreases to the set limit.

Control valve 5-16 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 F. Valve control board

Fig. 5-15
In an electronic vehicle like this model, a switch is installed
in each hydraulic lever, which when pushed or pulled
signals the pump motor controller. These signals enable
hydraulic operations by activating the pump motor and the
main hydraulic pump.

Unlike other lever switches that can only perform switching

functions, the lift lever has a sensor that signals with a
voltage in proportion to the angle of the lift lever after
receiving 12 V of power from the controller. The further you
pull the lever, the higher the output from the pump motor
becomes, achieving a faster lift operation.

The valve board is connected to the key switch so that it

can respond immediately to the opening/closing of the
switch by moving a hydraulic lever when the key switch is
on. 5

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-17 Control valve

 5-2-3 Relief valve adjustment

Pressure-checking adapter
Tools needed Pressure tube
28,000 kPa (4061 psi) gauge

Preliminary steps
<Pressure-checking adapter>
1. Move the vehicle to a level surface where you
can fully extend the mast.

2. Remove the residual pressure in the hydraulic <Pressure tube>

system by moving the control levers back and
forth several times with the key off.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may <Pressure gauge>
even result in amputation. Fig. 5-16

Make sure the pressure is released from

the system before you perform the
following procedure.

3. Take out the floor plate (See Section 7-3).

4. With the key off, remove hose from pump port

(1).

5. Connect the 28,000 kPa (4061 psi) gauge to port

(1).

Fig. 5-17

Control valve 5-18 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Lift relief valve check and adjustment

1. Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating
temperature.

2. Without a load on the forks, extend the mast to

its maximum height.

3. Holding the control lever in position, watch the

gauge.
 The value the gauge indicates is the current
pressure at which the relief valve is opened at
the end of a cylinder stroke.

4. Check whether the reading on the gauge

matches the corresponding figure for your
vehicle model in the table.
 Note: PLUS model has the same pressure.

Main relief pressure

Models
kPa psi
B15T-7 17,600 2,550
B18T-7 19,900 2,886
B20T-7 21,600 3,133
B16/18X-7 19,900 2,886
B20X-7 21,600 3,133

5. If it does not, loosen jam nut (2) and then turn

setscrew (3) either clockwise to increase or
5
counterclockwise to decrease the pressure

Lift/tilt/auxiliary system
setting of the relief valve according to your need.

Fig. 5-18

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-19 Control valve

 Auxiliary relief valve check and adjustment

1. Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating
temperature.

2. Tilt the mast fully backward.

3. Holding the control lever in position, watch the

gauge.
 The gauge indicates is the current pressure at
which the relief valve is opened at the end of a
cylinder stroke.

4. Check whether the reading on the gauge

matches the corresponding figure for your
vehicle model in the table.
 Note: PLUS model has the same pressure

Auxiliary relief
Models pressure
kPa psi
B15/18/20T-7
14,000 2,031
B16/18/20X-7

5. If it does not, loosen jam nut (4) and then turn

setscrew (5) either clockwise to increase or
counterclockwise to decrease the pressure
setting of the relief valve according to your need.

Fig. 5-19

Control valve 5-20 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 5-2-4 Needle valve for emergent lowering
The needle valve is used to manually lower the mast when
the regular lowering operation by the lever is disabled.

DANGER
A sudden drop of the mast can cause
a serious accident.
Turn the needle valve slowly, looking at
the lowering of the mast.

1. Turn the key switch off and open the control

lever cover.

2. With the lift lever moved to the lowering position,

turn needle valve (1) 2–3 times counterclockwise
very slowly.

3. Once the carriage reaches the ground, lock

needle valve (1) again.

Fig. 5-20

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-21 Control valve

 5-2-5 Levers and switch group adjustment/removal/installation

Fig. 5-21
Lift sensor adjustment
1. Disconnect the battery and discharge the head
capacitor.

2. Loosen setscrew (4).

3. Adjust screw (3) so there is 1.0mm (0.039 in)

clearance (Y) between lift sensor (2) and magnet
(5) when the lift lever pulled all the way back.

NOTICE: If the magnet (5) makes contact with the plastic bracket
when the lift lever is activated, the lift sensor may be damaged.

4. Tighten setscrew (4).

 Check the lift sensor circuit to see if the valve
control card needs adjusting.

5. Set lift sensor initial setting using the EasyView

application (See the Lift Set menu in Section 2-6-7).

Control valve 5-22 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Tilt and auxiliary switches adjustment

1. Disconnect the battery and discharge the head

capacitor.

2. Disconnect all but connector (12) of the micro

switch that you wish to adjust.

3. With the corresponding spool for the connected

micro switch ass’y in neutral, loosen screws (13)
and adjust screw (17) to align switch roller (15)
with cam (14).

4. After obtaining the correct alignment, tighten

screws (13) and (17) to secure the micro switch
ass’y’s position.

5. Connect the battery, close the seat switch, and

then turn the key on.
 If needed, readjust the micro switch ass’y
being tested so the pump motor turns on
before the control valve spool opens. This
must be adjusted for each lever direction
(forward/back/neutral).
 A gap of at least 3mm (X) should always be
left between switch (16) and screw (17).

Levers and switch group removal/installation

1. Remove knob ass’y (1) from the top of levers

(18). 5
2. Disconnect connector (8).

Lift/tilt/auxiliary system
3. Loosen screws (7) and then remove board ass’y
(9).

4. Remove screws (10), and then remove micro

switch ass’ies (11) and lift sensor (2).

5. Follow the steps above in the opposite order to

install the levers and switch group

6. Perform the sensor and switch adjustment

procedures above.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-23 Control valve

 5-2-6 Control valve removal/installation

Fig. 5-22
Preliminary steps

1. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

Control valve 5-24 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2. Prepare an oil pan.

3. Lift the hood.

Procedure

1. Give each port and its connection, adaptor or

plug a corresponding mark as a reference for
assembly.

2. Referring to circle A, disconnect the connections,

adaptors or plugs and then plug and cap those
that are connected to hydraulic hoses.
 Have the oil pan ready to catch any oil that
will come out of the hoses and cylinder ports.

3. Pull out split pins (24) and pins (26) from the
AUX2, AUX1, and TILT spool’s cams (25) and
then remove them.

4. Pull out split pins (11) and pin (17), and then
loosen nut (12) from screw (16) to remove clip
ass’y (18).

5. Pull out split pins (6) and pins (5), remove

stopper (20) and nut (19), and then dismount the
valve ass’y bracket (4).

6. Loosen bolts (10) and bolt (3) from valve

mounting bracket (6). 5
7. Carefully remove pivot ass’y (9) while catching

Lift/tilt/auxiliary system
yokes (1) as they slide off pin ass’y (2).

8. Remove bolts (8) from the valve mounting

bracket (7) and remove it

9. Remove bolts (13) from bracket (14) and remove

it along with guide (15)

10. Supporting the control valve, remove bolts (23)

from the front of main mounting bracket (22) and
bolts (21) from the back.

11. Follow the steps above in the opposite order to

install the control valve.

12. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-25 Control valve

 5-2-7 Control valve disassembly/assembly

Fig. 5-23

Preliminary steps

1. Remove the control valve (See Section 5-2-6).

2. Mark the blocks according to their type.

3. Remove bolts (1) and separate the blocks.

4. Remove main relief valve ass’y (2) and auxiliary

relief valve ass’y (3).

5. Remove lift lock valve ass’y (4) and solenoid

valve ass’y (5) from the LIFT section.

Control valve 5-26 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 The different section blocks of the control valve all have similar disassembly and assembly procedures.
The illustration used for this section is of the tilt section block.

Procedure
1. Remove four bolts (6).
Fig. 5-24
5

Lift/tilt/auxiliary system
2. Remove return cap (7).

3. Pull out spool ass’y (8).

4. Remove dust wiper seal (9) and O-ring (10) at

both sides of the section block.

5. Unscrew the top of anti-cavitation valve (11) and

remove it.
 This step applies to the TILT section only

6. Remove plug (12) and O-ring (13).

7. Unscrew the top of check valve ass’y (14) and

remove it.

8. Remove O-ring (15).

9. Follow the steps above in the opposite order to

assemble the control valve.
 Inspect the condition of O-rings and install
new ones at assembly if worn or cracked

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-27 Control valve

5-3 STD/FFL/FFT Mast

5-3-1 Exterior and specifications

Fig. 5-25

STD/FFL/FFT Mast 5-28 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 The mast ass’y is comprised of various components and options. See the following part numbers to
check the specifications and information you need.

Items STD FFL FFT

Mast-vehicle joint parts A156562 A156634 A156562
Lift cylinder joint parts D583418 D583524 A156569
Attachment hydraulic
D583426 (3-way) D583428 (3-way) A156571 (3-way)
hoses (mounted on
D583427 (4-way) D583429 (4-way) A156572 (4-way)
mast)
D583432 (3-way, D583435 (3-way, A156573 (3-way, LH)
Attachment tubes LH) LH) A156574 (3-way,
(mounted on carriage) D583433 (3-way, RH) D583436 (3-way, RH) RH)
D583434 (4-way) D583437 (4-way) A156575 (4-way)
Sideshifter hydraulic
D584018 D584019
lines
Tilt cylinder groups A252107
Mast body D583572 D583573
Outer mast group 230218-02030 230218-02031 230218-02032
Inner mast group D583620 D583622 D583623
Intermediate mast group - - A156524
Chains D583413 D583414 A156560
Standard/secondary lift
D512374 D512388 D512394
cylinder group
Primary lift cylinder
- D501865 400321-00037
group
Carriage joint parts
Carriage body 230216-00432
160626-00451
230216-00433 230216-00434
5
Sideshifter body A156229

Lift/tilt/auxiliary system
Sideshift cylinder D144202
Load backrest D580046
Sideshifter-integrated
D800461 D800598 D801337
carriage
Fork positioner-
D800721 D801373 D801336
integrated carriage

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-29 STD/FFL/FFT Mast

 5-3-2 How it works

A. Mast tilt

Mast tilt operation is made by two double-acting cylinders.

In the case of each cylinder, one end is connected to the
vehicle’s chassis, while the other to the side of the mast.

Tilt forward

Pushing the tilt lever to shift the TILT spool of the control
valve will send hydraulic oil to the opposite chamber to
each cylinder rod (1-2), withdrawing oil from the rod’s
chamber. This leads piston (1-1) to be pushed forward,
tilting forward mast (2) mounted to cylinder rods (1-2) on
the axis of the connection to the vehicle (3).

Fig. 5-26
Tilt backward

Pulling the tilt lever to shift the TILT spool of the control
valve will send hydraulic oil to the chamber of each
cylinder rod (1-2), withdrawing oil from the opposite
chamber. This leads piston (1-1) to be pushed backward,
tilting back mast (2) mounted to cylinder rods (1-2) on the
axis of the connection to the vehicle (3).

Fig. 5-27

STD/FFL/FFT Mast 5-30 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 B. Standard mast lift

Standard (STD) mast assemblies use two masts and two

single-acting cylinders to lift a load.

Rollers (6) respectively installed inside and outside the

carriage and the mast facilitate these up/down
movements.

Lift Fig. 5-28

Upon receiving hydraulic oil from the control valve’s LIFT

section, standard cylinder (1) rod is extended, pushing up
inner mast (4) as shown in the Fig. 5-29.

At the same time carriage (5) is also pulled by lift chain (3)
that is connected to outer mast (2) to be lifted up together
with the chain. 5

Lift/tilt/auxiliary system
Lowering

If the operator controls the lever to open the oil outlet in

the lift block of the control valve, the oil sent in standard
cylinder (1) will start to flow out by gravitational force.

When the oil is discharged, the cylinder rod and the

attached inner mast (4) will retract.

When inner mast (4) is lowered, the tension of the lift chain
(3) will be loosened and carriage (5) will also be lowered.

Fig. 5-29

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-31 STD/FFL/FFT Mast

 C. FFL mast lift

Full Free Lift (FFL) mast assemblies use two masts and
two single-acting cylinders to lift a load. Primary cylinder
(5) is responsible for the lifting/lowering of carriage (7)
while two secondary cylinders (1) are responsible for
lifting/lowering of inner mast (4).

Rollers (8), installed inside and outside the carriage and

the mast respectively, facilitate their up/down movements.

Fig. 5-30

Carriage lifted

The schematic diagram shows that primary cylinder (5)

and secondary cylinders (1) are connected with each other.
Because the diameter of primary cylinder (5) is larger than
that of the secondary cylinder, upon recieveing hydraulic
oil from the control valve’s LIFT section, the primary
cylinder’s rod is extended first as shown in Fig. 5-31.

When the rod of primary cylinder (5) is lifted, free lift chain
(6) hung over the upper pulley is pulled, raising carriage
(7).

In this way, once the operator starts the lift operation,

carriage (7) is raised first while the mast remains in a
lowered position.

Fig. 5-31

STD/FFL/FFT Mast 5-32 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Mast lifted

If the operator keeps pulling the lift lever, thereby sending

oil even after primary cylinder (5) rod has been fully
extended, then secondary cylinder (1) will begin to extend.
As shown in Fig. 5-32, as secondary cylinder (1) rod
pushes the chain pulley attached to the upper part, the
inner mast (5) is pulled and lifted by secondary lift chain (3)
fastened to outer mast (2).

Lowering

If the operator controls the lever to open the oil outlet in

the lift block of the control valve, the oil sent in the lift
cylinder will start to flow out by gravitational force. Contrary
to the lift function, oil in secondary cylinder (1) is
discharged first, followed by the oil in primary cylinder (5).
Therefore, the carriage remains in a raised position until
the mast is fully lowered.

Fig. 5-32

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-33 STD/FFL/FFT Mast

 D. FFT mast lift

Full Free Triple (FFT) mast assemblies use three masts

and two single-acting cylinders to lift load. Primary cylinder
(6) is responsible for the lifting/lowering of carriage (8)
while secondary cylinders (1) are responsible for the
lifting/lowering of inner mast (5) and intermediate mast (6).

Rollers (9), installed inside and outside the carriage and

the mast respectively, facilitate their up/down movements.

Fig. 5-33

Carriage lifted

The schematic diagram shows that primary cylinder (6)

and secondary cylinder (1) are connected with each other.
Because the diameter of primary cylinder (6) is larger than
that of secondary cylinder (1), upon receiving hydraulic oil
from the control valve LIFT section, the primary cylinder
rod is extended first as shown in Fig. 5-34.

When primary cylinder (6) rod is extended, free lift chain

(7) hung over the upper pulley is pulled and thus raises
carriage (8).

In this way, once the operator starts the lift operation,

carriage (8) is lifted first up while the mast stays in lowered
position.

Fig. 5-34

STD/FFL/FFT Mast 5-34 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Mast lifted

If the operator keeps pulling the lift lever, sending oil even
after primary cylinder (6) rod has been fully extended, then
secondary cylinder (1) will start to extend. As shown in Fig.
5-35, as secondary cylinder (1) rod pushes intermediate
mast (4) upward, inner mast (5) is pulled upward and
extended by secondary lift chain (3) fastened to outer mast
(2).

As mentioned above, when intermediate mast (4) is lifted

by secondary cylinder (1) rod, inner mast (5) connected to
outer mast (2) via a chain is lifted together.

Lowering

If the operator controls the lever to open the oil outlet in

the lift block of the control valve, the oil sent in the lift
cylinder will start to flow out by gravitational force. On the
contrary to lift, oil in secondary cylinder (1) is discharged
first, and then followed by the oil in primary cylinder (6).
Therefore, the carriage remains in a raised position until
the mast is fully lowered.

Fig. 5-35
5

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-35 STD/FFL/FFT Mast

 E. Sideshifter and other attachments

Various attachments can be mounted to the carriage, and

it is using an auxiliary cylinder (double acting) that those
attachments operate in accordance with their
characteristics.

Sideshifter

The most basic attachment is the “sideshifter” that moves

the forks mounted to it left and right as shown in Fig. 5-36
and 5-37. For this purpose an auxiliary operation cylinder
called “sideshift cylinder” is used.

Move to the right

Pushing the sideshift lever to shift the AUX1 spool of the

control valve will send hydraulic oil to the left chamber of
cylinder piston (1-1), taking back the oil in the right
chamber. This leads piston (1-1) to be pushed forward
along with sideshifter (2) mounted to cylinder rod (1-2),
moving the forks attached thereto to the right also.

Move to the left Fig. 5-36

Pulling the sideshift lever to shift the AUX1 spool of the

control valve will send hydraulic oil to the right chamber of
cylinder piston (1-1), taking back the oil in the left chamber.
This leads piston (1-1) to be pushed backward along with
sideshifter (2) mounted to cylinder rod (1-2), moving the
forks attached thereto to the left also.

Fig. 5-37

STD/FFL/FFT Mast 5-36 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Other attachments

There are various other attachments than the sideshifter

that may be used with. All attachments are operated by the
auxiliary cylinders that are connected to the AUX1 and
AUX2 section blocks of the control valve. The number and
type of the auxiliary cylinders used for each attachment
may vary.

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-37 STD/FFL/FFT Mast

 5-3-3 Forks service

A. Forks alignment

After you make sure the carriage is correctly adjusted (See

Section 5-3-9 C), adjust the forks as follows:

1. Fully lower the carraige, and then use the tilt

lever to make the top surface of the forks parallel
with the ground.

2. Measure the distance from the forks’ heels to the

ground.
 The heels must be within 7 mm (0.28 in) of a level
surface.

Fig. 5-38
3. Raise the carriage to a good height and lay a
straight bar on the higher fork as shown in Fig. 5-
39.

4. Measure the vetical distance from the surface of

the lower fork to the straight bar.
 The measurement should fall within 3 mm (0.12 in) if
the forks are 1,500 mm (59 in) or shorter, and 4 mm if
they are longer than 1,500 mm (59 in). Replace
damaged forks. Fig. 5-39

NOTICE: Since the forks are made from a strong elastic

material, forcing them into position will only yield
temporary results before they return to their original
position.

STD/FFL/FFT Mast 5-38 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 B. Forks removal and installation

5
Fig. 5-40

Lift/tilt/auxiliary system
1. Disassemble latch ass’y (1) or pin.

2. Slide the fork to the center of the sideshifter and

remove it.

3. Repeat the steps above for the other fork.

4. Follow the steps above in the opposite order to

install the forks.

NOTICE: During disassembly, inspect the forks and fork

mounts and replace any components that may be
damaged, cracked, or excessively rusty.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-39 STD/FFL/FFT Mast

 5-3-4 Sideshifter service

A. Sideshifter and cylinder removal/installation

Fig. 5-41

Preliminary steps

1. Raise the carriage and position a wooden block

underneath it.

2. Lower the carriage onto the wooden block and

fasten a hoist to the load backrest.

3. Remove the forks (See Section 5-3-3 B).

4. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off.

DANGER Fig. 5-42

Pressurized hydraulic oil will cause

severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

5. Prepare an oil pan.

STD/FFL/FFT Mast 5-40 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Sideshifter body removal

1. Give hoses and ports (1) a corresponding mark

as a reference for assembly.

2. Disconnect hoses from ports (4-1) and then plug

and cap them.
 Have the oil pan ready to catch any oil that will
come out of the hoses and cylinder ports.

3. Remove shim (2) bracket ass’y (3) after

unscrewing bolts (1).

4. Remove bolts (10) and washers (9), and then

shim (8) and bar (7).

5. Remove the sideshifter from the carriage.

Sideshift cylinder removal

1. After removing two pins (5), pull out pin (6) and,
supporting sideshift cylinder (4), remove it.

Reassembly

1. Follow the steps above in the opposite order to

install the sideshifter body and sideshift cylinder.

2. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.
5

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-41 STD/FFL/FFT Mast

 B. Attachment hydraulic lines removal/installation

Fig. 5-43

STD/FFL/FFT Mast 5-42 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Preliminary steps

1. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

2. Prepare an oil pan.

Procedure

1. Remove brackets (3) from the side of the mast.

2. Disconnect hose A at connector (7) and pipe

ass’y (9) and drain the oil into the pan.
 After removing hose A, plug its ends to prevent debris
and foreign material from entering the hydraulic
system.

3. Unscrew bolt (1), dismount hose sheave (2), and

lay hose A to one side.

4. Remove brackets (7) and (6). 5

5. Disconnect hose B at pipe ass’y (9) and

Lift/tilt/auxiliary system
regulator (10) and drain the oil into the pan.
 After removing hose B, plug its ends to prevent debris
and foreign material from entering the hydraulic
system.

6. Remove pipe ass’y (9).

7. Unscrew bolts (4-1), dismount bracket ass’y (4)

with hose sheave (5) and hose B intact.

8. Disconnect hoses C and D at regulator (10) and at

sideshift cylinder (11) and drain the oil into the pan.

9. Dismount regulator (10).

10. Follow the steps above in the opposite order to

install the attachment hoses.

11. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-43 STD/FFL/FFT Mast

 C. Sideshift cylinder disassembly/assembly

Fig. 5-44

STD/FFL/FFT Mast 5-44 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Vise
Tools needed
Claw-type spanner wrench

Preliminary steps

1. Remove the sideshift cylinder (See Section 5-3-4

A).

Procedure

1. Position the sideshift cylinder in a vise and

remove the rod ass’y using a claw-type spanner
wrench.

2. Remove head ass’y.

3. Remove wiper seal (1).

 Install with lip facing outside head.

4. Remove U-cup (2).

5. Remove O-ring (3)

 Install so curved side of back up ring contacts.

6. Remove back up ring (4).

7. Remove bolt (5)..

8. Remove piston ass’y.

5
9. Remove seal (6).

Lift/tilt/auxiliary system
10. Follow the steps above in the opposite order to
assemble the sideshift cylinder.

NOTICE: Once you have completely assembled the

cylinder, make sure you reseal the ports with the dust cap
and plugs.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-45 STD/FFL/FFT Mast

 5-3-5 Chains service

A. Chain wear check

Tools needed Chain wear gauge

Finding chain pitch

To check chain wear, the chain pitch must be found first:

1. Lift the carriage enough to put tension on the lift

chains.

2. Put the stationary pointer of gauge (1) against

the upper pin of chain link (2).

3. Put the sliding pointer against the lower pin of

chain link (2).

4. Make sure to line the two pointers at the same

position on both pins to get an exact reading.

5. Hold the sliding pointer in position and read the Fig. 5-45
scale on gauge (1) to find out the chain pitch.

STD/FFL/FFT Mast 5-46 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Checking chain wear

Once you have found the chain pitch, start wear check:

1. Put the sliding pointer over one of the three

boxes at the bottom of the scale of gauge (1).

2. Put the window of the pointer over the square

that contains the chain pitch found above.

3. Hold gauge (1) against the other side of the lift

chain again with the stationary pointer against
the upper pin of one of the chain links.
Fig. 5-46
4. With the full length of gauge (1) against lift chain
(2), move the sliding pointer until it is aligned with
the upper pin of another chain link, keeping the
window of the pointer over the correct square
found in step 2.
 The colored line next to the white line on the
sliding pointer is the chain wear indication.
Each color stands for a degree in chain wear:
Green is 1%, orange 2%, red 3%, and blue
4%.

5. If the chain wear indication is 2% or greater,

replace the lift chain.

WARNING
An indication of 2% chain wear or
higher can lead to serious injury. 5
Do not operate the forklift if this reading

Lift/tilt/auxiliary system
is higher than 2%.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-47 STD/FFL/FFT Mast

 B. Chain tension check

Fig. 5-47

STD/FFL/FFT Mast 5-48 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 For safe operation, the tension of each pair of chains on
the mast should be the same.

Chains for STD

1. Raise the carriage to put weight on lift chains (1-

1).

2. Push lightly on both of lift chains (1-1) with your

hand to check the tension.
 If their tensions are uneven, follow the
adjustment procedure below.

3. With the carriage raised, position blocks

underneath.

4. Lower the carriage onto the blocks so that

Fig. 5-48
tension is released from the chains.

5. Tighten or untighten locknuts (2-1) at both sides

of the carriage to increase or decrease the chain
tensions as needed.

6. Put Loctite #242 on the threads of locknut (2-1)

after the adjustment is completed.

Chains for FFL/FFT

1. Perform the same precedure for STD on free lift chains

(1-2) and make adjustments with locknuts (2-2). 5
2. After fully raising the carriage, raise the mast

Lift/tilt/auxiliary system
even further to apply tension to secondary lift
chains (1-3).

3. Push lightly on both of secondary lift chains (1-3)

with your hand to check the tension.
 If their tensions are uneven, follow the
adjustment procedure below.

4. With the inner mast raised, position blocks

underneath.

5. Lower the inner mast onto the blocks so that

tension is released from the chains.

6. Tighten or untighten locknuts (2-3) at both sides

of the carriage to increase or decrease the chain
tensions as needed.

7. Put Loctite #242 on the threads of locknut (2-1)

after the adjustment is completed.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-49 STD/FFL/FFT Mast

 C. Chain removal/installation

Fig. 5-49

STD/FFL/FFT Mast 5-50 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Tools needed Pliers

Free lift chain removal

1. Unscrew chain anchor nuts (7) and then remove

the chain anchor from the free lift chain sheave
together with the chains and put them all to one
side.
 Installation torque: 270 ± 40 N·m
(200 ± 30 lb·ft)

2. Remove split pin (5) from the behind of the lower

panel of the carriage using the pair of pliers.

3. Remove retaining ring (5) and then dismount

chain sheave ass’y (6).

4. Perform the steps above for the other side.

Secondary lift chain removal

1. Unscrew chain anchor nuts (3) and then remove

the chain anchor from the secondary lift chain
sheave together with chains and put them all to
one side.
 Installation torque: 270±40 N·m (200 ± 30 lb·ft)

2. Remove split pin (4) from the inner mast using

the pair of pliers. 5
3. Remove retaining ring (2) and then dismount

Lift/tilt/auxiliary system
chain sheave ass’y (1).

4. Perform the steps above for the other side.

Free/secondary lift chain installation

1. Follow the steps above in the opposite order to

install the chains.

2. Check that the chains have the correct tension

(See Section 5-3-5 B).

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-51 STD/FFL/FFT Mast

 5-3-6 Tilt cylinder service

A. Tilt cylinder alignment

WARNING
Mast can fall and crush, causing
serious injury.
After you have finished adjusting, ensure
the cylinder rod is installed securely in
the clevis.

NOTICE: Cylinders which are out of alignment will cause

extra stress in the mast assembly and the mast hinge area.
To ensure the cylinders are aligned, follow the steps below:

Preliminary steps

Before you start the adjustment, check if:

• Both cylinders stop evenly at the end of the tilt back

and tilt forward strokes;

• Both cylinders extend and retract evenly;

• Both sides of the mast are not twisted;

• The tilt angles of the mast when tilted fully forward

and backward fall within the specifications stamped
on the truck’s identification plate (To measure them,
use a tilt indicator or protractor); and

• The difference in length between the cylinder rods

when fully extended is within 3.18 mm (0.125 in).
 If any of the conditions are not met, follow the
steps bellow to adjust the alignment of your tilt
cylinders.

STD/FFL/FFT Mast 5-52 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Procedure

1. Tilt the mast fully forward.

2. Loosen nut (2) that holds the cylinder rod in

clevis (1).

3. Twist the rod out of or into the clevis to achieve

the correct length for both cylinders.
 For tilt cylinders that include the tilt back
Fig. 5-50
limiting group option, you will need to move
spacer (5) back before you can adjust the rod.

4. Install nut (2) and tighten it to a torque of 95±15

N·m (70±10 lb·ft).
 Perform the following steps only if the tilt
cylinders on your vehicle include the tilt back
limiting group option.

5. Tilt the mast fully back.

6. Install shims (4) so there is no gap left between

spacer (5) and head (6).

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-53 STD/FFL/FFT Mast

 B. Tilt cylinder drift test

WARNING
Unexpected movement of the mast or
carriage can crush and cause serious
injury.
Use wood blocks and clamps to hold the mast in
position, and keep your hands and feet clear of
any moving parts.

Preliminary steps

1. Ensure that the chains tension is equal and that

the tilt cylinders are properly aligned.

2. Raise the mast 762 mm (30 in) and use blocks

and clamps to hold the mast in this position.

3. Check the mast hinge bolts to make sure they

are tight.

4. Remove the blocks and clamps and lower the

mast

Fig. 5-51

STD/FFL/FFT Mast 5-54 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Procedure

1. Position a load equal to the vehicle’s rated load

capacity on the forks

2. Run the forklift through a complete lift and tilt

cycle until the oil is at normal temperature for
operation 45°C–55 °C (113°F–131°F).

3. Put the mast in a vertical position.

4. Raise a rated load capacity to a height of 2.5 m

(8.2 ft).
 In the case of vehicles with less than 2.5 m
(8.2 ft) height extension, raise the load as high
as the vehicle is capable.

5. Place a tape measure between the cylinder tube

and head and measure how far the rod extends
(cylinder stroke) as the mast drifts forward over a
ten minute period. Fig. 5-52
 Drift should not exceed 35.5 mm (1.40 in). If
drifting exceeds this amount, it is possible that
you have a hydraulic leak at the cylinders or
control valve.

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-55 STD/FFL/FFT Mast

 C. Tilt cylinder removal/installation

Fig. 5-53

Preliminary steps

1. Prepare a hoist and tie straps to both sides of the

top of the mast ass’y.

STD/FFL/FFT Mast 5-56 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2. Remove the residual pressure in the hydraulic
system by moving the control levers back and
forth several times with the key off.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

3. Prepare an oil pan.

Procedure
1. Mark hoses and ports (1) as a reference for
assembly.

2. Disconnect hoses from ports and plug and cap them.

 Have the oil pan ready to catch any oil that will
come out of the hoses and cylinder ports.

CAUTION
The tilt cylinders can drop and crush
causing injury.
Support the tilt cylinder before you
perform the following procedure.

3. Remove bolt (2) and washer from the mast end

5
of the cylinder.

Lift/tilt/auxiliary system
 Installation torque: 105 N·m (77 lb·ft)
 Installation sealant: Loctite #242
4. Remove grease nipple (3).
5. Remove pin (4).
 At reinstallation, stand the mast upright using
a hoist and extract the tilt cylinders to align
their mounting holes with the mast’s holes as
shown in Fig. 5-54.
6. Remove bearing (5).
7. Repeat steps 2–6 for the mast end of the cylinder,
and remove bushing (6) that covers the pin
8. Remove the tilt cylinder.
9. Follow the steps above in the opposite order to
install the tilt cylinder.
10. Refill the tank with hydraulic oil according to the
specifications given in Section 1-6.
Fig. 5-54

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-57 STD/FFL/FFT Mast

 D. Tilt cylinder disassembly/assembly

Fig. 5-55

STD/FFL/FFT Mast 5-58 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Vise
Tools needed
Claw-type spanner wrench
NOTICE: During disassembly, be careful not to damage
the highly finished surface of the cylinder rod and the bore
of the cylinder body.

1. Position the tilt cylinder in a vise and remove the

rod ass’y using a claw-type spanner wrench.
 Installation torque: 270±30 N·m (200±22 lb·ft)

2. Remove eye (1) by loosening nut (2) and bolt (3).

 Installation torque: 95±15 N·m (70±11 lb·ft)

3. Remove head ass’y.

4. Remove DU bushing (4).

 Install with lip facing outside head.

5. Remove seal (5).

6. Remove back up ring (6).

7. Remove O-ring (7).

 Install so curved side of back up ring contacts.

8. Remove back up ring (8).

9. Remove seal (9).

 Install with lip facing inside head.

10. Remove nut (10).

5
 Installation sealant: Loctite #242

Lift/tilt/auxiliary system
 Installation torque: 270±30 N·m (200±22 lb·ft)

11. Remove piston ass’y

12. Remove slipper seal (11).

13. Remove O-ring (12).

NOTICE: Once you have completely assembled the tilt

cylinder, make sure you reseal the ports with dust cap.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-59 STD/FFL/FFT Mast

 5-3-7 Primary lift cylinder service

A. Primary lift cylinder removal/installation

The FTL/FFT primary lift cylinders have a similar removal and installation procedure. The illustration
used for this section is the FFT.

Fig. 5-56

STD/FFL/FFT Mast 5-60 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Preliminary steps

1. Remove the carriage (see Section 5-3-9 B), and

keep all residual pressure fully released.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is not left in the
system before you perform the following
procedure.

2. Fasten a hoist to the primary cylinder.

3. Prepare an oil pan.

Procedure

1. Remove clamp (5).

2. Lean primary cylinder (4) forward using the hoist

and then disconnect it from flow protector (6),
draining the oil from primary cylinder (4) and
hose (3) to the pan.

3. Once you have drained the oil, plug and cap

primary cylinder (4) and hose (3) to prevent
debris and foreign material from entering the
hydraulic system. 5
4. Disconnect hose (3) from the hose that connects

Lift/tilt/auxiliary system
with the control valve.

5. Remove clamp (2).

6. Unscrew bolts (1-1) and remove hose sheave

ass’y (1) together with hose (3) and flow
protector (6) intact.

7. Follow the steps above in the opposite order to

install the primary cylinder.

8. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-61 STD/FFL/FFT Mast

 B. Primary lift cylinder disassembly/assembly

The FFL and FFT primary cylinders have similar disassembly and assembly procedures. The
illustration used for this section is of the FFL primary cylinder.

Fig. 5-57

STD/FFL/FFT Mast 5-62 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Vise
Tools needed
Claw-type spanner wrench
NOTICE: During disassembly, be careful not to damage
the highly finished surface of the cylinder rod and the bore
of the cylinder body.

1. Position cylinder tube in a vise.

2. Remove rod ass’y using a claw-type spanner

wrench.
 Sealant: Loctite #262

3. Remove cover ass’y.

 Before you install the cover ass’y, inject 100
cc of hydraulic oil into the tube at the rod
cover end.

4. Remove stopper (1).

5. Remove wiper (2).

6. Remove packing (3).

7. Remove back up ring (4).

8. Remove O-ring (5).

9. Remove piston ass’y

10. Remove check valve (6).

11. Remove retaining ring (7).

5
12. Remove slipper seal (8).

Lift/tilt/auxiliary system
13. Remove wear ring (9).

14. Follow the steps above in the opposite order to

assemble the primary cylinder.

NOTICE: Once you have completely assembled the

cylinder, make sure you reseal the ports with dust cap.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-63 STD/FFL/FFT Mast

 5-3-8 Standard/secondary cylinder service

A. STD/SEC lift cylinder air removal

After the standard lift cylinder has been disassembled and

assembled, it may be necessary to remove the air (bleed)
from the cylinder.

1. Run the lift cylinders through one complete cycle

without any load.

2. With the forks on the floor, check the oil level in

the hydraulic tank and fill it to the full mark if not
full already.

3. Run the lift cylinders through four complete

cycles without any load.

4. Lift the forks high enough that weight is applied

all stages of the lift cylinders.

5. Locate setscrew (1) on each lift cylinder and

slowly open them no more than one turn.

WARNING
Forks will fall and can crush when the
bleed screws are loosened.
Keep your body away from the mast,
carriage and forks.
Fig. 5-58
6. Repeat steps 4 and 5 until there are no air
bubbles at the setscrews.

7. Tighten the setscrews to a torque of 5 to 7 N·m

(4 to 5 lb·ft) once all the air is removed.

8. Fill the hydraulic tank to the full mark.

9. Run lift cylinders through one last cycle.

10. Repeat steps 3 through 9 if the mast does not

operate smoothly.

STD/FFL/FFT Mast 5-64 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 B. Kick adjustment

To adjust the lift cylinder kick:

1. Adjust the outer chains so their tensions are

equal.

2. Raise the mast fully.

 If the mast does not kick to either side, no
shims are required. If the mast does kick to
one side, follow the steps below to shim the lift
cylinder.

3. Remove bolt (2) and, tilting the cylinder Fig. 5-59

forward,.add shims (1) as needed.
 The total number of shims must not exceed
three.

4. Reinstall the cylinder.

5. Adjust the outer chains so their tensions are

equal.

6. Raise the mast and check if either side of the

mast still kicks.

7. Repeat the procedure until the mast does not

kick, adding 3 mm (0.12 in) of shims (1) at the
most.

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-65 STD/FFL/FFT Mast

 C. STD/SEC lift cylinder drift test

WARNING
Unexpected movement of the mast or
carriage can crush and cause serious
injury.
Use wood blocks and clamps to hold the
mast in position, and keep your hands
and feet clear of any moving parts.

Preliminary steps

1. Ensure that the chain’s tension is equal and the

tilt cylinders are properly aligned.

2. Raise the mast 762 mm (30 in) and use blocks

and clamps to hold the mast in this position.

3. Check the mast hinge bolts to make sure they

are tight.

4. Remove the blocks and clamps and lower the

mast.

Fig. 5-60

STD/FFL/FFT Mast 5-66 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Procedure

1. Position a load equal to the vehicle’s rated load

capacity on the forks.

2. Run the forklift through a complete lift and tilt

cycle until the oil is at the normal temperature for
operation (45°C–55°C, 113°F–131°F).

3. Put the mast in a vertical position.

4. Raise a rated load capacity to a height of 2.5 m

(98.4 in).
 In the case of vehicles with less than 2.5 m
(98.4 in) height extension, raise the load as
high as the vehicle is capable.

5. Place a tape measure on the lift cylinder and

measure how far the rod retracts (cylinder
stroke) as the carriage drifts downward over a
ten minute period. Fig. 5-61

 Drift should not exceed 100.0 mm (3.94 in). If

drifting exceeds this amount, it is possible that
you have a hydraulic leak at the cylinders or
control valve.

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-67 STD/FFL/FFT Mast

 D. STD/SEC lift cylinder removal/installation

The illustration below is of the STD mast; the procedure is similar for all STD/FFL/FFT mast types.

Fig. 5-62

STD/FFL/FFT Mast 5-68 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Preliminary steps

1. Remove the chains (See Section 5-3-5 C).

2. Remove the carriage (See Section 5-3-9 B).

3. Remove the primary lift cylinder (See Section 5-

3-7 A).

4. Remove the mast (See Section 5-3-10 A).

5. Lay the mast on a flat ground

6. Prepare an oil pan.

Procedure

1. Disconnect hose ass’y (4) from the cylinder port

at one side and then drain the oil to the pan.

2. After removing hoses ass’y (4), plug each port to

prevent debris and foreign material from entering
the hydraulic system

3. Remove U bolt ass’y (2).

4. Remove plate ass’y (1) and dismount lift cylinder

(3).

5. Repeat the steps above for the other lift cylinder.

6. Follow the steps above in the opposite order to 5

install the lift cylinders.

Lift/tilt/auxiliary system
7. Refill the tank with hydraulic oil according to the
specifications given in Section 1-6.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-69 STD/FFL/FFT Mast

 E. STD/SEC lift cylinder disassembly/assembly

STD lift cylinder

Fig. 5-63

STD/FFL/FFT Mast 5-70 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Vise
Tools needed Hex wrench
Claw-type spanner wrench

NOTICE: During disassembly, be careful not to damage

the highly finished surface of the cylinder rod and the bore
of the cylinder body.

1. Position standard lift cylinder in a vise.

2. Remove screws (1) and steel balls using a hex

wrench.
 At installation, inject 100 cc hydraulic oil into
the head before mounting the steel balls.

 Installation torque: 6±1 N·m (4±0.7 lb·ft)

3. Remove head ass’y using a claw-type spanner

wrench.
 Installation sealant: Loctite #262

4. Remove U-packing (2).

 Install with lip facing outside.

5. Remove dust wiper seal (3).

6. Remove back up ring (4).

5
7. Remove glyd ring (5).

Lift/tilt/auxiliary system
8. Remove O-ring (6).
 Install so curved side of back up ring contacts.

9. Remove back up ring (7).

10. Remove rings (8).

11. Follow the steps above in the opposite order to

assembly the STD lift cylinder.

NOTICE: Once you have completely assembled the lift

cylinder, make sure you reseal the ports with the dust cap
and plugs.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-71 STD/FFL/FFT Mast

 FFL/FFT secondary lift cylinder
The FFL and FFT lift cylinders have a similar disassembly and assembly procedure. The illustration
used for this section is of the FFT.

Fig. 5-64

STD/FFL/FFT Mast 5-72 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Vise
Tools needed
Claw-type spanner wrench
NOTICE: During disassembly, be careful not to damage
the highly finished surface of the cylinder rod and the bore
of the cylinder body.

1. Position the secondary cylinder in a vise.

2. Remove screws (1) and steel balls using a hex

wrench.
 At installation, inject 100 cc hydraulic oil into
the head before mounting the steel balls.
 Installation torque: 6±1 N·m (4±0.7 lb·ft)

3. Remove cylinder rod ass’y with a claw-type

spanner wrench.
 Installation sealant: Loctite #262

4. Remove dust wiper seal (2)

 Install with lip facing outside head.

5. Remove back up ring (3).

6. Remove U-packing (4).

7. Remove glyd ring (5).

8. Remove back up ring (6)

9. Remove O-ring (7).

5
10. Remove the piston ass’y.

Lift/tilt/auxiliary system
11. Remove wear rings (8).

12. Remove retaining ring (9).

13. Remove ring (10).

14. Remove ring cushion (11).

15. Remove retaining ring (12).

16. Follow the steps above in the opposite order to

assembly the secondary FFL/FFT cylinders.

NOTICE: Once you have completely assembled the

cylinder, make sure you reseal the ports with the dust cap
and plugs.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-73 STD/FFL/FFT Mast

 5-3-9 Carriage service

A. Carriage and mast height adjustment

1. Put the mast in a vertical position.

2. Lower the carriage fully.

 The bottom of the inner mast on FFL and FFT
lift models must be even with the bottom of
the outer mast.

3. Measure the distance from the bottom of the

inner upright to the bottom of carriage bearing
(A).
 If your measurement of (A) does not match
those in the table below, adjust the chains
(See Section 5-3-5 B) and repeat this
procedure.

Height of carriage roller extrusion

STD FFL FFT
-6 mm 8 mm 8 mm
(-0.2 in) (0.3 in) (0.3 in)

B. Carriage removal/installation Fig. 5-65

Preliminary steps

1. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

2. Remove bolts (1) and washers, and then remove

load backrest.

3. Remove the forks (see Section 5-3-3 B).

Fig. 5-66

STD/FFL/FFT Mast 5-74 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 4. Raise the carriage and position a wooden block
underneath it.

5. Lower the carriage onto the wooden block and

fasten a hoist to it

6. Remove the sideshifter (See Section 5-3-4 A).

7. Prepare an oil pan.

8. Disconnect the chains connected tha carriage

from the inner mast.
Fig. 5-67

Procedure

1. Disconnect all hoses from the carriage ports (2),

and cap and plug them together
 Have the oil pan ready to catch any oil that
will come out of the hoses and ports.

Fig. 5-68
2. Remove stop bolt (3) and the retainers under the
bolt.
 As shown in Fig. 5-69, for the STD mast, stop
bolt (3) is installed on the foreside of the inner
mast; for the FFL and FFT masts, it is on the
rear side of the carriage.
 If stop bolt (3) is worn or damaged, replace it.
 At installation, adjust the number of the
5
retainers to obtain a 4.0 to 6.0 mm (0.16 to

Lift/tilt/auxiliary system
0.24 in) overlap between bolt (3) and carriage
stopper [STD] or inner mast upper stay
[FFL/FFT]. Fig. 5-69

3. Raise inner mast high and slide out carriage (5)

downwards.

4. Follow the opposite steps above to install the

carriage.

5. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

Fig. 5-70

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-75 STD/FFL/FFT Mast

 C. Carriage roller bearings adjustment

Fig. 5-71

You can adjust the clearance between the mast channel

and carriage rollers by adding or removing shims. All six
carriage roller bearings can be shimmed using the same
procedure.

Before and during adjustment:

• Make sure all parts are clean

• Check all parts for wear and replace those that are
worn.

• Perform the procedure one roller bearing set at a

time.

Preliminary steps

1. Remove the carriage (See Section 5-3-9 B).

Upper and lower roller bearing adjustment

1. Remove screw (1).

 Installation torque: 34±7 N·m (25±5 lb·ft).

2. Remove retainer (2).

3. Remove roller bearing ass’y (3 to 4).

STD/FFL/FFT Mast 5-76 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 4. Separate shims (3) from roller bearing (4).

5. If you are installing new roller bearings, refer to

the table below to choose those roller bearings
(4) which will help achieve “minimum clearance”
(clearance b) between the bearing and channel
leg for the full length of the mast; make sure you
use the same bearing in all six locations.

Part no. Bearing size Bearing O.D.*

D580006 Undersize 98.5mm (3.88 in)
D580007 Standard 99.0mm (3.90 in)
D580008 Oversize 99.5mm (3.92 in)
* Permissible tolerance ± 0.08 mm (0.003 in)

6. Measure across the width of the inner mast with

a ruler to find the narrowest point.

7. At this point, install shims (3) behind the

upper/lower carriage roller bearings (4) at both
sides until there is “zero clearance” between the
inner mast and the bearings.
Fig. 5-72
 Make sure an equal amount of shims is
installed for each corresponding side.
 Torque for screw (1): 34±7 N·m (25±5 lb·ft)

Side roller bearing adjustment

1. Unscrew bolts (5) and remove side roller bearing 5

ass’y (6 to 11).

Lift/tilt/auxiliary system
2. Install shims (8) on bolt connections at both ends
of pin (7) to achieve “minimum clearance”
(clearance c) between side roller bearings (11)
and the inner mast.

3. Reinstall side roller bearing ass’y (6 to 11).

Fig. 5-73

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-77 STD/FFL/FFT Mast

5-3-10 Mast service

A. Mast removal/installation

The STD, FFL and FFT mast ass’ies have a similar disassembly and assembly procedure. The
illustration used for this section is the FFT.

Fig. 5-74

Preliminary steps
1. Remove the forks (see Section 5-3-3 B).

2. Remove the carriage (see Section 5-3-9 B).

STD/FFL/FFT Mast 5-78 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3. Remove primary lift cylinder (see Section 5-3-7
A), and keep all residual pressure fully released.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is not left in the
system before you perform the following
procedure.

4. Prepare an oil pan.

Procedure
1. Disconnect hose (1), and cap and plug it.
 Have the oil pan ready to catch any oil that
will come out of the hoses
2. Remove bolt (2) and washer.
 Installation sealant: Loctite #242
3. Remove pin ass’y (3).
 At reinstallation, stand the mast upright using
a hoist and extract the tilt cylinders to align
their mounting holes with the mast’s holes as
shown in Fig. 5-75.

WARNING
The tilt cylinders can drop and crush
causing injury.
Support the tilt cylinder before you
5
perform this step

Lift/tilt/auxiliary system
4. Lean the mast assembly forward 8° using the
hoist
NOTICE: Loosen the tension of the straps connected to
the hoist when you tilt the mast forward. Straps that are
too tight can cause the mast assembly to slide off when
bolts (4) are removed.
5. Remove bolts (4)
 Installation sealant: Loctite #242
Fig. 5-75
 Installation torque: 160±30 N·m (118±22 lb·ft)
6. Remove the mast assembly using the hoist
7. Follow the steps above in the opposite order to
install the mast.
8. Refill the tank with hydraulic oil according to the
specifications given in Section 1-6.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-79 STD/FFL/FFT Mast

 B. Mast disassembly/assembly and roller bearing adjustment

Fig. 5-76

Preliminary steps

1. Remove mast ass’y (See Section 5-3-10 A).

2. Remove priamry and secondary (standard) lift

cylinders and their hydraulic hoses (See
Sections 5-3-7 A and 5-3-8 D).

STD/FFL/FFT Mast 5-80 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Disassembly

1. Hammer out mounting pins (1) on both sides of

the outer mast.

2. Check the condition of the bushings (2) inside

the mounting pin bore and replace them if too
worn.

3. Spread the masts apart so that all the roller

bearings are visible.

4. Remove all pads (3) and shims (4) and mark

them as a reference for assembly

5. Give each mast roller bearing ass’y a mark that

corresponds to its location on its mast.

6. Remove snap rings (5) and then remove mast

roller bearings (6) along with shims (7).
 Disassemble the mast roller bearings and
inspect the condition of mast roller bearings
(6), replacing any that are worn or damaged
as explained in the assembly procedure.
 For those bearings in good condition, clean
their parts, reassemble them, and then put
them to one side until installation.

7. Separate and mark shims (7) as a reference for

assembly.

8. Separate the masts from each other using a

5
hoist.

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-81 STD/FFL/FFT Mast

 Fig. 5-77
Assembly and roller bearing adjustment

For STD and FFL you need to perform the following steps
once with the inner and outer masts; and twice for FFT—
firstly with the intermediate and outer masts and secondly
with the inner and intermediate masts.

Before and during adjustment:

• Make sure all parts are clean

• Check all parts for wear and replace those that are
worn.

• Perform the procedure one roller bearing set at a

time.

1. Joint all the masts from each other using a hoist.

STD/FFL/FFT Mast 5-82 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 2. If you are installing new roller bearings, refer to
the table below to choose those roller bearings
(6) which will help achieve “minimum clearance”
(clearance a) between the bearing and channel
leg for the full length of the mast; make sure you
use the same bearing for the right and left side of
the mast location you are adjusting.

Part no. Bearing size Bearing O.D.*

D580006 Undersize 98.5 mm (3.878 in)
D580007 Standard 99.0 mm (3.898 in)
D580008 Oversize 99.5 mm (3.917 in)
Fig. 5-78
* Permissible tolerance ± 0.08 mm (0.003 in)
3. Within the section from the bottom of the wider
mast to the bottom of the channel lap (the area
where the masts overlap when fully extended),
measure across the width of the wider mast with
a ruler to find the narrowest point.

4. At this point, install 0.5 mm (0.02 in) or 1.0 mm (0.04

in) shims behind each roller bearing on both lower
outside ends of the narrower mast until they have
“zero clearance” (clearance b), securing bearing (6)
with snap ring (5). Fig. 5-79
NOTICE: Make sure the bearings are installed at the
correct locations by checking the marks you them, with an
equal amount of shims for each corresponding side.

5. Shim bearings (6) at both inside ends of the

wider mast in the same way to ensure “zero
clearance” (clearance b) there as well.

6. Use a hoist to fit the narrower mast inside the

5
wider mast.

Lift/tilt/auxiliary system
7. Make sure all roller bearings (6) are properly
shimmed by rolling the narrower mast inside of
the wider mast and moving it from side to side.

8. If clearance is detected or if the roller bearings

(6) are shimmed too tight, pull out the narrower
mast from the wider mast with a hoist, adding or
removing 0.5 mm or 1.0 mm shims as needed.
When the bearings have been shimmed
correctly, move on to the next step. Fig. 5-80

9. Install shims behind each pad (6) until there is “a

maximum of 0.80 mm (0.031 in) clearance” (clearance
c) between the pad and the narrower mast with the
mast ass’y at full extension. When the pads have been
shimmed correctly, move on to the next step.

NOTICE: Make sure an equal amount of shims is installed

for each side.

10. Install mounting pins (1) on both sides of the

wider mast.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-83 STD/FFL/FFT Mast

5-4 Quad mast

5-4-1 Primary lift cylinder service

A. Primary lift cylinder removal/installation

Preliminary steps

1. Remove the carriage chains (See Section 5-3-5

C).

2. Remove the carriage (see Section 5-3-9 B), and

keep all residual pressure fully released.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is not left in the
system before you perform the following
procedure.

3. Fasten a hoist to the primary cylinder.

4. Prepare an oil pan.

Procedure

1. Remove bolts (1) and washers.

Fig. 5-64

2. After pulling primary lift cylinder (3) out far

enough, disconnect hydraulic hose connector
(2).

3. Remove primary lift cylinder (3).

4. Follow the steps above in the opposite order to

install the lift cylinder.
Fig. 5-65
5. Refill the tank with hydraulic oil according to the
specifications given in Section 1-6.

Quad mast 5-84 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 B. Primary lift cylinder disassembly/assembly

Fig. 5-66
Vise
Tools needed
Claw-type spanner wrench
NOTICE: During disassembly, be careful not to damage
the highly finished surface of the cylinder rod and the bore
of the cylinder body.
5

Lift/tilt/auxiliary system
1. Position cylinder tube in a vise.

2. Remove cover ass’y.

 Before you install the cover ass’y, inject 100cc
of hydraulic oil into the cylinder tube at the rod
cover end.

3. Remove rod ass’y using the claw-type spanner

wrench.
 Installation sealant: Loctite #262

 Installation torque: 441 N∙m (325 lb∙m)

4. Remove retaining ring (1).

5. Remove dust wiper (2).

6. Remove U-packing (3).

7. Remove backup ring (5).

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-85 Quad mast

 8. Remove O-ring (4).

9. Remove piston ass’y.

10. Remove check valve (6).

11. Remove retaining ring (7).

12. Remove wear ring (9).

13. Remove piston seal (8).

14. Follow the steps above in the opposite order to

assemble the primary cylinder.

NOTICE: Once you have completely assembled the

primary lift cylinder, make sure you reseal the ports with
the dust cap and plugs.

Quad mast 5-86 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 5-4-2 Standard cylinder service
A. STD lift cylinder air removal
After the standard lift cylinder has been disassembled and
assembled, it may be necessary to remove the air (bleed)
from the cylinder.

1. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

2. Run the lift cylinders through one complete cycle

without any load.
3. With the forks on the floor, check the oil level in
the hydraulic tank and fill it to the full mark if not
full already.
4. Run the lift cylinders through four complete
cycles without any load.
5. Lift the forks high enough that weight is applied
all stages of the lift cylinders.
6. Locate setscrew (1) on each lift cylinder and 5
slowly open them no more than one turn.

Lift/tilt/auxiliary system
WARNING
Forks will fall and can crush when the
bleed screws are loosened.
Keep your body away from the mast,
carriage and forks.
Fig. 5-67
7. Repeat Steps 4 and 5 until there are no air
bubbles at the setscrews.
8. Tighten the setscrews to a torque of 5 to 7 N·m
(4 to 5 lb·ft) once all the air is removed.
9. Fill the hydraulic tank to the full mark.
10. Run lift cylinders through one last cycle.

11. Repeat steps 3 through 9 if the mast does not

operate smoothly.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-87 Quad mast

 B. Kick adjustment

To adjust the lift cylinder kick:

1. Adjust the outer chains so their tensions are

equal.

2. Raise the mast fully.

 If the mast does not kick to either side, no
shims are required. If the mast does kick to
(1) Shims
one side, follow the steps below to shim the lift
cylinder.
(2) Bolt
3. Remove bolt (2) and tilt the cylinder forward add
[Lift cylinder]
shims (1) as needed.
D25S95003

 The total number shims must not exceed Fig. 5-68

three.

4. Reinstall the cylinder.

5. Adjust the outer chains so their tensions are

equal.

6. Raise the mast and check if either side of the

mast still kicks.

7. Repeat the procedure until the mast does not

kick, adding 3 mm (0.12 in) of shims (1) at the
most.

Quad mast 5-88 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 C. Lift cylinder drift test

WARNING
Unexpected movement of the mast or
carriage can crush and cause serious
injury.
Use wood blocks and clamps to hold the
mast in position, and keep your hands
and feet clear of any moving parts.

Preliminary steps

1. Ensure that the chain’s tension is equal and the

tilt cylinders are properly aligned.

2. Raise the mast 762 mm (30 in) and use blocks

and clamps to hold the mast in this position.

3. Check the mast hinge bolts to make sure they

are tight.

4. Remove the blocks and clamps and lower the

mast.

Fig. 5-69

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-89 Quad mast

 Procedure

1. Position a load equal to the vehicle’s rated load

capacity on the forks.

2. Run the forklift through a complete lift and tilt

cycle until the oil is at the normal temperature for
operation 45°C–55°C, 113°F–131°F).

3. Put the mast in a vertical position.

4. Raise a rated load capacity to a height of 2.5 m

(98.4 in).
 In the case of vehicles with less than 2.5 m
(98.4 in) height extension, raise the load as
high as the vehicle is capable.

5. Place a tape measure on the lift cylinder and

measure how far the rod retracts (cylinder
stroke) as the carriage drifts downward over a
ten-minute period. Fig. 5-70

 Drift should not exceed 100.0 mm (3.94 in). If

drifting exceeds this amount, it is possible that
you have a hydraulic leak at the cylinders or
control valve.

Quad mast 5-90 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 D. STD lift cylinder removal/installation

Preliminary steps

1. Remove the chains (see Section 5-3-5 C).

2. Remove the carriage (see Section 5-3-9 B).

3. Remove the primary cylinder (see Section 5-3-7

A).

4. Remove the mast (see Section 5-3-10 A) and lay

the mast on a flat ground.

5. Prepare an oil pan.

Procedure

1. Disconnect hydraulic hose connectors (1).

Fig. 5-71
5
2. Remove top bolt (2) [STD/FFT] and washer or

Lift/tilt/auxiliary system
retaining ring [FFL].

3. Remove side bolts (3), washer, bracket and

rubber pad.

Fig. 5-72

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-91 Quad mast

 4. Fasten a nylon strap and a hoist to secondary
cylinder (4).

5. Slide up the inner mast and the intermediate

mast.

Fig. 5-73

6. Remove secondary cylinders (4) along with

shims.
 At installation, relocate bleeder screw (6) to
nearest port within ±45° to cylinder (4) as
shown in Fig. 5-74.

7. Follow the steps above in the opposite order to

install the lift cylinders.

8. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

Fig. 5-74

Quad mast 5-92 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 E. Quad mast lift

Quad mast assemblies use four masts and two types of

single-acting cylinders to lift load. Primary cylinders (8) are
responsible for the lifting/lowering of carriage (10) while
secondary cylinders (1) are responsible for the
lifting/lowering of inner mast (7) inner intermediate mast
(8), and outer intermediate mast (4).

Rollers (11), installed inside and outside the carriage and

the mast respectively, facilitate their up/down movements.

Fig. 5-75
Carriage lifted

The schematic diagram shows that primary cylinder (8)

and secondary cylinder (1) are connected with each other.
Because the diameter of primary cylinder (8) is larger than 5
that of secondary cylinder (1), upon receiving hydraulic oil

Lift/tilt/auxiliary system
from the control valve LIFT section, the primary cylinder
rod is extended first as shown in Fig. 5-36.

When primary cylinder (8) rod is extended, free lift chain

(9) hung over the upper pulley is pulled and thus raises
carriage (10).

In this way, once the operator starts the lift operation,

carriage (10) is lifted first up while the mast stays in
lowered position.

Fig. 5-76

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-93 Quad mast

 Mast lift

If the operator keeps pulling the lift lever, sending oil even
after primary cylinder (8) rod has been fully extended, then
secondary cylinder (1) will start to extend. As shown in Fig.
5-37, as secondary cylinder (1) rod pushes outer
intermediate mast (4) upward, inner intermediate mast (6)
is pulled upward and extended by outer lift chain (3)
fastened to outer mast (2). And the rise of inner
intermediate mast (6) pulls up inner lift chain (6), which in
turn lifts inner mast (7).

As mentioned above, when intermediate mast (4) is lifted

by secondary cylinder (1) rod, inner intermediate mast (6)
chained to outer mast (2), and inner mast (7) chained to
outer intermediate mast (4), are lifted together.

Lowering

If the operator controls the lever to open the oil outlet in

the lift block of the control valve, the oil sent in the lift
cylinder will start to flow out by gravitational force. On the
contrary to lift, oil in secondary cylinder (1) is discharged
first, and then followed by the oil in primary cylinder (8).
Therefore, the carriage remains in a raised position until
the mast is fully lowered.

Fig. 5-77

Quad mast 5-94 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 F. QUAD secondary cylinder disassembly/assembly

Right-hand cylinder disassembly/assembly

Fig. 5-78

Vise
Tools needed Claw-type spanner wrench
Pin-type spanner wrench
5
NOTICE: During disassembly, be careful not to damage

Lift/tilt/auxiliary system
the highly finished surface of the cylinder rod and the bore
of the cylinder body.

1. Position the right-hand secondary QUAD lift

cylinder in a vise and remove the actuator rod
using a claw-type spanner wrench.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-95 Quad mast

 2. Remove set screws (1).
 Installation torque: 24.5 N·m (18.1 lb·ft)
 Installation sealant: Loctite #242
 Make sure the set screws and set screw mounts
are clean before installation.

3. Remove and disassemble the rod cover ass’y

(2–7).
 Installation torque: 343 ~ 392 N·m
(253 ~ 289 lb·ft)
 Installation sealant: Loctite #242
 Before you install the rod cover ass’y, inject
100cc of hydraulic oil into the cylinder tube at
the rod cover end.

4. Disassemble rod end ass’y seals (8–10).

 Installation torque: 441 ~ 490 N·m
(325 ~ 361lb·ft)
 Installation sealant: Loctite #242
 Install O-rings (8/10) so the curved side of back
up ring (9) contacts.

5. Remove the piston ass’y (12–21) using a pin-

type spanner wrench.
 Installation torque: 343 ~ 392 N·m
(253 ~ 289 lb·ft)
 Installation sealant: Loctite #242

6. Follow the steps above in the opposite order to

assemble the right-hand secondary QUAD lift
cylinder.

NOTICE: Once you have completely assembled the

cylinder, make sure you reseal the ports with the dust caps.

Quad mast 5-96 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Left-hand cylinder disassembly/assembly

Vise
Tools needed Claw-type spanner wrench
Pin-type spanner wrench Fig. 5-79
NOTICE: During disassembly, be careful not to damage
the highly finished surface of the cylinder rod and the bore
of the cylinder body.

1. Position the left-hand secondary QUAD lift 5

cylinder in a vise and remove the actuator rod

Lift/tilt/auxiliary system
using a claw-type spanner wrench.

2. Remove and disassemble the rod cover ass’y

(1–6).
 Installation torque: 343 ~ 392 N·m
(253 ~ 289 lb·ft)
 Installation sealant: Loctite #242
 Before you install the rod cover ass’y, inject
100cc of hydraulic oil into the cylinder tube at
the rod cover end.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-97 Quad mast

 3. Remove set screw (7).
 Installation torque: 24.5 N·m (18.1 lb·ft)
 Installation sealant: Loctite #242

4. Remove the piston ass’y (8–15) using a pin-type

spanner wrench.
 Installation torque: 441 ~ 490 N·m
(325 ~ 361lb·ft)
 Installation sealant: Loctite #242

5. Follow the steps above in the opposite order to

assemble the right-hand secondary QUAD lift
cylinder.

NOTICE: Once you have completely assembled the

cylinder, make sure you reseal the ports with the dust caps.

Quad mast 5-98 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 5-4-3 Carriage service

A. Carriage and mast height adjustment

1. Put the mast in a vertical position.

2. Lower the carriage fully.

 The bottom of the inner mast must be even
with the bottom of the outer mast.

3. Measure the distance from the bottom of the

inner upright to the bottom of carriage bearing
(A). If your measurement of (A) does not match
those in the table below, adjust the chains (See
Section 5-3-5 B) and repeat this procedure.

Height of carriage roller extrusion

Fig. 5-80
STD FFL FFT QUAD
0 mm 41 mm 41 mm 41 mm
(0.00 in) (1.61 in) (1.61 in) (1.61 in)

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-99 Quad mast

5-5 Safety function and Optional Auto-tilt leveling

5-5-1 Exterior and specifications

Fig. 5-81

 Note: The mast height switch was

changed as above, to improve the
performance.

Safety function and Optional Auto-tilt leveling 5-100 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Components Items Spec.
Part no. 301411-00291
Contact capacity 125 Vac 15A (With the resistance loaded)
Height sensor (old) Min. 100 MΩ
Insulation resistance
(DC 500V insulation-resistance tester)
Allowable operating
1 mm/s–1 m/s
speed
Live part – For 1 min at 1,000 Vac (50/60)
Withstand voltage
Dead part – For 1 min at 2,000 Vac (50/60)
Contact resistance Min. 25 MΩ (initial)
Operating type Cam roller arm
IP rating IP40 (IEC529)
Part no. 301309-00420
Rated voltage DC 12/ 24V
Height sensor (new) Operating Voltage DC 9∼32V
Operating -30∼85 ℃
Temperature (-22∼185 ℉)
Temperature for -40∼85 ℃
storage (-40∼185 ℉)
IP Grade 67
Communication
CAN 2.0B, BITRATE 250K
method
Mast tilt & auto-tilt
Part no. D700116
switch
Maximum pressure 29,420 kPa (4,267 psi)
Maximum flow 50 L/min 5
Hydraulic block ass’y Counterbalance
10:1

Lift/tilt/auxiliary system
(for auto-tilt leveling) valve pilot ratio
Solenoid valve
12 Vdc (DIN connector)
voltage

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-101 Safety function and Optional Auto-tilt leveling
 5-5-2 How it works

A. Safety function

The Guardian Stability System (GSS) dynamically

stabilizes the operation of the mast ass’y to reduce the risk
of accidents to the operator and the load. With the circuit
shown in Fig. 5-82, this stabilization is rendered as follows:

• When the mast is raised above the primary section,

height switch (1) turns on to have the drive motor
controller decrease the travel speed by 50%.

• When the mast tilts forward by more than 2°, mast

tilt switch (2) turns off to set off an alarm at the lift
operation.

• When the mast is raised above the primary section,

Fig. 5-82
the forward-tilt angle is restricted to 2° as the status
of height switch (1) and mast tilt switch (2) activates
tilt solenoid (3) in the hydraulic system.

The operations of these components to render this GSS

functionality are discussed below in detail:

Height switch operations

Height switch (1) is mounted on the moving inner mast.

When the mast ass’y stays in the primary section, switch
bar (1-1) is pushed up by the switch’s internal spring as
shown in the first frame of Fig. 5-83. When the mast is
raised out of the primary section, switch bar (1-1) is
pushed down by the stationary bracket (4), as shown in
the second frame.

Height switch (1) turns off when switch bar (1-2) is pushed
up and on when the bar is pushed down.

As this switch’s status is reported to the pump motor

controller, the GSS can react to the height of the mast.

NOTICE: Fig. 5-83 illustrates the configuration for mast

MFH 2,700–3,700. See Section 5-4-1 for the configuration
for mast MFH 4,000–7,000.

Fig. 5-83

Safety function and Optional Auto-tilt leveling 5-102 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Operations of height switch with proximity sensor

Similar to the lever-type height switch, the proximity

switch detects the entry into the secondary section of the
mast.

Fig. 5-84

When replacing the proximity switch, adjustment of the

gap (C) is required.

Gap (C) : 5.0±1.5·mm (0.20±0.05·inch)

Adjustment method: Use a washer on the mounted

area.

How to check whether the switch is normal: If the

status and interval of the switch is normal, the
yellow indicator light on the switch will be on.

(A) Inner surface of mast Fig. 5-85

(B) Proximity switch

Mast tilt switch operations

Mast tilt switch (2) is mounted on the tilt cylinder tube, as 5

shown in Fig. 5-84. The position of auto-tilt sensing pin (5),

Lift/tilt/auxiliary system
which moves along with the tilt cylinder rod, determines
whether to turn mast tilt switch (2) on or off: When the
mast’s forward-tilt angle is not over 2°, the tip of mast tilt
switch (2) is pushed down by the pin’s (5) end, and mast
tilt switch (2) stays on (see the first frame). Once the mast
tilts forward by more than 2°, the switch tip is released, and
mast tilt switch (2) turns off (see the second frame).

As this switch’s status is reported to the pump motor

controller, the GSS can react to the tilting angle of the mast.
Fig. 5-86

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-103 Safety function and Optional Auto-tilt leveling
 Tilt solenoid operations

When the mast is raised above the primary section [height

switch (1) on] and tilts forward by 2° [mast tilt switch (2)
off], tilt solenoid valve (3) is energized to shift.

While tilt solenoid (3) is closed, a forward-tilt command

works normally, filling the tilt cylinders’ head chambers with
pressure oil from the control valve, as shown in the first
frame of Fig. 5-85. As a result, the tilt cylinder rods and
their attached mast are pushed forward.

However, once tilt solenoid valve (3) opens, the control

valve’s pressure oil is allowed to flow into the rod
chambers as well. This leads to an equilibrium between
the forces of the head and the rod chambers, stopping the
mast at the +2° position.

Fig. 5-87

Safety function and Optional Auto-tilt leveling 5-104 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Auto-tilt leveling

The auto-tilt leveling mechanism helps the operator return

a back-tilted mast to the exactly vertical position. This
system features two electric components, as seen in the
circuit in Fig. 5-88: an auto-tilt switch (1, attached to the
left tilt cylinder) and a tilt lever switch (2, mounted on the
tilt lever).

The activation of auto-tilt switch (1) is determined by the Fig. 5-88

mast’s position (whether it is vertical or not; see the next
subsection for its detailed process), while tilt lever switch
(2) turns on by the operator’s demand (by pressing the
button).

When the mast has reached the vertical position [auto-tilt

switch (1) off] and the operator is pressing the command
button on the tilt lever [tilt lever switch (2) on], the pump
motor controller stops running the pump to prevent the
mast from tilting further.

Determination of the mast’s position

Whether the mast is on the way or has already reached

the vertical position is determined by auto-tilt switch (1),
shown in Fig. 5-89. Like the mast tilt switch for the GSS,
this auto-tilt switch (1) is turned on and off based on the
position of auto-tilt sensing pin (3), but by its groove in the
middle and not by its end. When the mast is tilted back, 5
auto-tilt switch (1) is pushed down and stays on (see the

Lift/tilt/auxiliary system
first frame); when the mast returns to the vertical position,
the groove of pin (3) provides space for the tip of switch (1)
to be released upward and switch (1) turns off (see the
second frame).

Fig. 5-89

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-105 Safety function and Optional Auto-tilt leveling
 5-5-3 Height switch removal/installation

Switch cable disconnection

1. Unbolt and take out the floor plate (see Section

7-3).

2. Disconnect height switch connector (2), which is

labeled “HEIGHT SW1,” cut off straps (1).

Fig. 5-90

Switch ass’y removal (for MFH 2700–3700)

1. Remove straps (5).

2. Remove bolts (4) and their washers, and remove

bracket (3).

3. Remove bolts (1) and their washers, and remove

bracket (2).

4. Follow the steps above in the opposite order to

install the height switch, and then check if it
works properly.

Fig. 5-91
Switch ass’y removal (for MFH 4000–7000)

1. Remove straps (3).

 There is another strap at the lower part of the
mast not represented in Fig. 5-90.

2. Remove bolts (1) and their washers, and remove

bracket (2).

3. Follow the steps above in the opposite order to

install the height switch, and then check if it
works properly.
Fig. 5-92

Safety function and Optional Auto-tilt leveling 5-106 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 5-5-4 Mast tilt/auto-tilt switch ass’y removal/installation

Switch cable disconnection

1. Unbolt and take out the floor plate (see Section

7-3).

2. Disconnect mast tilt switch connector (2), labeled

“MAST TILT SW2,” or auto-tilt switch connector
(3), labeled “AUTO TILT SW3,” as needed, and
cut off straps (1).

Fig. 5-93

Switch ass’y removal

1. Unbolt and take out mast tilt switch (1) or auto-tilt

switch (2), as needed.
 You don’t have to screw the bolts completely out
of the switch.

Fig. 5-94

2. If you need to take out the whole switch bracket

ass’y from the tilt cylinder, remove bolt (3) and
5
pull out bracket (4).

Lift/tilt/auxiliary system
3. Follow the steps above in the opposite order to
install the mast tilt/auto-tilt switch, and then
check if it works properly (see the next
subsection).

Fig. 5-95

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-107 Safety function and Optional Auto-tilt leveling
 Switch adjustments

1. Check if the mast tilt switch and auto-tilt switch

are pushed and released at proper positions.
 The mast tilt switch must be released at the
point where the mast is tilted by 2°, as shown
in Fig. 5-96.

Fig. 5-96

 The auto-tilt switch must be released at the

point where the mast stands vertically, as
shown in Fig. 5-97.

Fig. 5-97
 Clearances and grease must be maintained as
presented in Fig. 5-98.

Fig. 5-98

2. If either switch moves improperly, make

horizontal adjustments of mast tilt switch (1) and
auto-tilt switch (2) and verical adjustments of
their mounting braket (3).

Fig. 5-99

Safety function and Optional Auto-tilt leveling 5-108 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 5-5-5 Hydraulic block ass’y removal/installation

Fig. 5-100

Preliminary steps

1. Remove the residual pressure in the hydraulic

5
system by moving the control levers back and

Lift/tilt/auxiliary system
forth several times with the key off.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

2. Prepare an oil pan.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-109 Safety function and Optional Auto-tilt leveling
 Procedure

1. Unbolt and take out the floor plate (see Section

7-3).

2. Disconnect the mast tilt switch connector,

labeled “TILT SOLENOID,” and cut off its binding
strap.

3. Disconnect all hose connectors (2) and their O-

rings from hydraulic block (4).

4. Remove bolts (7) and their washers, and remove

bracket ass’y (3).

5. Remove bolts (1), nuts (6), and washers (5), and

then sperate bracket (3) and hydraulic block (4).

6. Follow the steps above in the opposite order to

install the hydraulic block ass’y.

7. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

Safety function and Optional Auto-tilt leveling 5-110 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 5-5-6 Operator Safety Function
1. Neutral sensing function and its operating
principle

• When the lift lever is moved forward and

backward, the proximity sensor detects the
position of the bracket and detects whether the
attachment lever is in a neutral position.

• When the key is turned on, an error occurs if

the vehicle's attachment lever is not positioned
in the neutral position.

The installation location of the proximity sensor

is at the bottom of the lift lever as in Fig. 5-101
and, the detailed installation state is as in Fig.
5-102.
Fig. 5-101

Proximity sensor

Fig. 5-102 5

Lift/tilt/auxiliary system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-111 Safety function and Optional Auto-tilt leveling
5-6 Troubleshooting

Problems Probable causes

[Hydraulic cause]
There is an air leak, which lets air into the hydraulic system
on the inlet side of the hydraulic pump.
The relief valve opens at low oil pressure.
The hydraulic pump has too much wear.
The hydraulic system does not lift The load is not correct (too heavy).
the load.
[Mechanical cause]
The mast is not in alignment with the other lifting components
and does not move freely.
Not enough lubricant on the parts of the mast that move.
The carriage or mast rollers (bearings) are worn and do not
move (seized).
[Hydraulic cause]
Not enough oil supply to lift cylinder.
Defective lift cylinder seals.
[Mechanical cause]
Lift cylinder extends too slowly. The mast is not in alignment with the other lifting components
and does not move freely.
Not enough lubricant on the parts of the mast that move.
The carriage or mast rollers (bearings) are worn and do not
move (seized)
[Hydraulic cause]
Air in the hydraulic system.
Relief valve sticks or defective.
Mast does not move smoothly
[Mechanical cause]
Not enough lubricant on the parts of the mast that move
Load rollers (bearings) defective or not adjusted correctly.
[Electrical cause]
Nor to supply the electric power to solenoid valve in lift
section of control valve.
A broken solenoid valve in lift section of control valve.

Mast does not lower completely or [Hydraulic cause]

Lift poppet (lift lock) damaged and contaminated
does not lower at all.
[Mechanical cause]
Lift cylinder damaged or bent.
Load roller defective (bearing) or not adjusted correctly.
Not enough lubricant on the parts of mast which that moves.

Troubleshooting 5-112 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Problems Probable causes

[Electrical cause]
The electric switch (on-off) below a seat damaged.
The electric parts (relay and controller) related to a solenoid
Safety lift lock doesn’t work. valve in lift section of control valve damaged.
[Hydraulic cause]
Lift poppet (lift lock) damaged and contaminated.
Needle valve is loosened.
[Hydraulic cause]
There is an air leak, which lets air into the hydraulic system
on the inlet side of the hydraulic pump.
The relief valve opens at low oil pressure.
The mast does not tilt correctly or The hydraulic pump has too much wear.
moves too slowly.
The internal valve of the tilt spool is stuck.
Control valve tilt spool has a restriction
[Mechanical cause]
Damage or failure of the piston rods on the tilt cylinders.
[Hydraulic cause]
There are restrictions in the lift line.
The lift spool in the control valve has a restriction caused by
foreign material and does not operate freely.
The lift cylinder flow control valve has a restriction.
Lift cylinders excess flow protectors have a restriction.
The carriage does not lower
correctly.
Air in the hydraulic system. 5
[Mechanical cause]
The mast is not in alignment with the other lifting components

Lift/tilt/auxiliary system
and does not move freely.
Carriage chains need an adjustment.
Not enough lubricant on the part of the mast that moves.
The carriage or mast rollers (bearings) are worn and do not
move (seized).
The valve spools do not hold their positions because the
springs for the valve spools are weak or broken.
Control valve leakage caused by worn valve spools.
The lift or tilt cylinders do not hold
their position with the valve control The check valve or flow control valves in the control valve are
levers in neutral position. bad.
Leakage of the cylinder lines or piston seals.
There is foreign material in the control valve.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 5-113 Troubleshooting

6 Steering system

6-1 Overview ........................................................2

6-1-1 Components ........................................................ 2
6-1-2 Oil flow ................................................................ 4

6-2 Steering control group .................................6

6-2-1 Exterior and specifications ................................... 6
6-2-2 How it works ........................................................ 8
6-2-3 Steering system air removal ................................15
6-2-4 Steering system pressure check .........................16
6-2-5 Steering wheel cover removal/installation ............18
6-2-6 Steering wheel removal/installation .....................19
6-2-7 Steering wheel column removal/installation .........20
6-2-8 Steering unit disassembly/assembly....................22

6-3 Steering operation group [B15/18/20T (TL)]

24
6-3-1 Exterior and specifications ..................................24
6-3-2 How It works .......................................................26
6-3-3 Steer angle sensor removal/installation ...............28
6-3-4 Rear wheel and hub
adjustment/removal/installation ...........................29
6-3-5 Steer axle spindle

6-3-6
removal/installation/disassembly/assembly ............32
Steer axle housing ass’y disassembly/assembly..34
6
Steering system
6-4 Steering operation group [B16/18/20X] ....36
6-4-1 Exterior and specifications ..................................36
6-4-2 How it works .......................................................38
6-4-3 Steer angle sensor removal/installation ...............40
6-4-4 Rear wheel and hub
adjustment/removal/installation ...........................41
6-4-5 Steer axle removal/installation.............................44
6-4-6 Link ass’y removal/installation .............................46
6-4-7 Steering knuckle, king pin, and bearing
removal/installation .............................................47
6-4-8 Steering cylinder
removal/installation/disassembly/assembly ...........48

6-5 Troubleshooting .........................................50

6-1 Overview

6-1-1 Components
CONTROLLING GROUP

Steering wheel
Steering cylinder

Steering column
Steer axle

Steering unit

Load-sensing line
Rear wheel

ACTUATOR GROUP [ B15/18/20T, B18/20TL ]

Pump motor
Priority valve Hydraulic tank

Main hydraulic pump

Steer axle

Steering cylinder

Rear wheel

ACTUATOR GROUP [ B16/18/20X ]

0922E

Fig. 6-1

Overview 6-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 The steering system is a group of devices to steer the
vehicle to the left or right. In this model, the steering
system is hydraulically operated, consisting of a control
group and an actuator group:

• Control group determines the speed and direction

of steering and accordingly supplies hydraulic oil to
the operation group. This group includes a steering
wheel and a steering unit. [Section 6-2]

• Operation group converts hydraulic power

transmitted from the control section via hydraulic oil
into a mechanical power to steer the rear wheels.
This group includes a steering cylinder, steer axle,
and two rear wheel assemblies. [Section 6-3 (BT
model) and Section 6-4 (BX model)]

Unlike automobiles, forklifts use their rear wheels as steer

wheels because their priority lies not in driving speed but
in securing a wider steering angle in a narrow place. For
models B15/18/20T-7 and B18/20TL-7, the rear wheels
are positioned at very close distance to each other at the
center of the vehicle’s rear to achieve an even wider
steering.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-3 Overview

 6-1-2 Oil flow

(4) Steering cylinder

[B15/18/20T-7] [B16/18/20X-7]

(3) Steering unit

(5) Control valve

Load sensing line

(2) Priority valve

(1) Main
hydraulic
pump
Hydraulic line
Pilot line
Drain line
0923E

Fig. 6-2

Overview 6-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Main pump (1) sends oil through priority valve (3) to
steering unit (2) in proportion to the speed at which the
steering wheel is turned. This valve is defaulted to supply
oil to steering unit (3) first, and then main control valve (5).

Steering unit (3) uses a built-in spool splined to the

steering wheel to regulate the oil within the unit according
to the movement of the steering wheel.

Neutral position

When the steering wheel is in the neutral position, steering

unit (3) sends less pressure via the load sensing line, and
the spool of priority valve (2) is moved to the neutral
position, allowing a substantial amount of oil from main
pump (1) to travel to main control valve (5).

Turning

When the steering wheel is in a right or left position, an

increased load sensing pressure shifts the spool of priority
valve (2) to send oil to steering unit (3). During a right turn,
steering unit (3) sends the supplied oil to the left side of
steering cylinder (4). Once the oil reaches this cylinder, it
acts on the cylinder and moves its piston to the right. The
return oil from this cylinder drains back to hydraulic tank
through steering unit (3).

During a left turn, the same process takes place, only the
oil acts on the right side of steering cylinder (5) instead of
the left.
6
Pressure relief

Steering system
The relief valve in steering unit (3) opens when the
steering pressure rises above 10,3 MPa (1,493 psi).

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-5 Overview

6-2 Steering control group

6-2-1 Exterior and specifications

Fig. 6-3

Steering control group 6-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Components Items Spec.

Steering wheel Part no. 900141-00836

Part no. D512926

Max. impact pressure 17.2 MPa (2,489 psi)

Rated flow 22.7 l/min

Steering unit
Displacement 50 cc/rev

12.7–13.7 kPa (0.9–1 lb·ft)

Input torque
at 60 rpm

Relief valve pressure 10.3–10.8 MPa (1,493–1,564 psi)

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-7 Steering control group
 6-2-2 How it works

A. Steering control mechanism

(1) Steering wheel

(2-1) Left turn port

(2-2) Right turn port

Tank
Pump A
(2) Steering unit

(A) Control section

(B) Metering section

(5) Rear wheel

(4) Steer axle

(3) Steering cylinder A

0925E

Fig. 6-4
Once steering wheel (1) is turned, the spool inside steering
unit (2) also turns via the steering wheel column that is
splined between them. Turning the spool leads to the
steering unit regulating the amount of oil discharged to the
steering cylinder in the following ways:
• Control section (A), depending on the direction to
which the steering wheel is turned, this section
determines which side of the steering chamber the oil
will be assigned to and then delivers the oil supplied
from the hydraulic pump to metering section (B). Once
it passed metering section (B), the oil returns back to
control section (A) to exit through either left turn port
(2-1) or right turn port (2-2) according to the turning
direction of the steering wheel.
• Metering section (B) works as a small pump,
controlling the amount of oil the unit sends to the
steering cylinder. The turning angle of the vehicle
increases in proportion to the amount of oil sent to
the steering cylinder, which is determined by the
steering wheel’s rotational speed.

Oil discharged from left turn port (2-1) flows to the right of
steering cylinder (3), pushes the cylinder to the left, and
turns rear wheels (5) to the left. Oil discharged from right
turn port (2-2) flows the other way round and turns rear
wheels (5) to the right. For more information on the
cylinder and wheel’s different operations, see Section 6-3-
2 [BT model] and Section 6-4-2 [BX model].

Steering control group 6-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Neutral position
Steering cylinder

(A) Control section (B) Metering section

(3) Outlet
(2) Sleeve (4) Check valve (5) Inlet
(7) Stator
Steering unit
(1) Spool (6) Rotor

10.3 MPa
(8) Centering spring

(13) Drive
(9) Pin (11) Right turn port
(10) Left turn port (12) Housing T

Priority valve
P 0926E

Fig. 6-5
When the steering wheel is in neutral, oil grooves (21) of (21) Oil groove (1) Spool
spool (1) and oil holes (20) of sleeve (2) are not aligned to (18) Spring slot
each other and thus oil that reaches sleeve (2) is not able (2) Sleeve

6
(18) Spring slot
to enter spool (1), or the steering cylinder as a result.
Therefore, as the rear wheels can neither make a left nor (19) Pin hole
(20) Oil hole
right turn, the vehicle drives straight. (19) Pin hole

Steering system
0927E
Fig. 6-6
As the pump oil that travels along the LS line is all drained
with the spool in neutral, the priority valve is hardly pushed
by the LS pressure at its spring side so that it is opened up
by the pump oil pressure. Accordingly, most of pump oil is
sent to the control valve while the steering unit is supplied
with only some low pressure oil. This little supply results in
a weakened push of the check valve in inlet (5) and thus
only a small amount of the pumped oil passes through this
valve to the steering unit.

This amount fills the inside of the steering unit and enables
it to respond quickly to the steering wheel’s demands.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-9 Steering control group
 C. Left turn
Steering cylinder

PUMP OIL
METERED OIL:
RETURN OIL
(11) Right turn port
(10) Left turn port
(3) Outlet (5) Inlet Steering unit
(14) Passage
(15) Passage
(16) Gerotor
(1) Spool

10.3 MPa

(9) Pin (2) Sleeve (17) Passage

T

Priority valve
P 0928E

Fig. 6-7

When the steering wheel is turning (2) Sleeve

(1) Spool

As spool (1) is splined to the steering wheel, turning the

steering wheel makes spool (1) and its engaged pin (9) and (9) Pin
drive (13) turn also. Sleeve (2) is also engaged with pin (9),
but pin hole (19) in sleeve (2) has a larger diameter than pin
(9) itself; so for some time after spool (1) starts rotating,
sleeve (2) does not spin as shown in Fig. 6-8. Accordingly oil
holes (20) and oil grooves (21) that were not aligned with (13) Drive
0929E

each other in neutral now are, and the pumped oil outside Fig. 6-8
sleeve (2) flows into spool (1), bringing two changes.
(21) Oil groove (1) Spool
First, as spool (1) become full, it no longer drains the LS
(18) Spring slot
(load-sensing) line inflow and thus the pressure throughout (2) Sleeve
(18) Spring slot
LS line grows higher, closing the priority valve. At this, most
of pump oil is led to the steering unit as its passage to the (19) Pin hole
(20) Oil hole
control valve is blocked. This highly pressurized oil then (19) Pin hole
overcomes the resistance of the check valve’s spring 0927E
Fig. 6-9
inside inlet (5) and enters the steering unit.

Steering control group 6-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Second, the increasing pressure oil getting inside spool (1)
then flows through passage (15) into metering section (B).
Splined to drive (13), gerotor (16) in metering section (B)
turns together with the steering wheel to pump the oil
inflow. This pumped oil is discharged through oil passage
(17) to left turn port (10) and then to the right chamber of
the steering cylinder. The oil that enters the right chamber
pushes the piston to the left, turning the vehicle to the left.
Steering speed increases in proportion to the amount of oil
discharged and the rate at which it is pumped, which is
determined by the steering wheel’s rotational speed. The
pressure oil from the pump keeps flowing in via this
passage as long as the steering wheel is turning,
increasing the steering angle until the steering cylinder
reaches its limit.

When the steering wheel stands still

Once the operator stops turning the steering wheel, spool (2) Sleeve

(1), pin (9), drive (13), and stator (7) also stop turning, and (1) Spool

centering spring (8) returns spool (1) and sleeve (2) back
to their original positions. The pilot signal that was sent to (9) Pin
the priority valve through the load sensing line then stops
and only a small amount of pressurized oil is supplied.
Even this small amount is not able to enter spool (1) nor
can the oil inside spool (1) enter into metering section (B)
through passage (15). The oil in metering section (B) is not
(13) Drive
pumped out to left turn port (10) either, because the 0930E

steering wheel no longer turns. Thus all oil flow stops and Fig. 6-10
the steering angle of the wheels is maintained.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-11 Steering control group
 D. Right turn
Steering cylinder

PUMP OIL
METERED OIL
RETURN OIL
(10) Left turn port (5) Inlet
(3) Outlet (11) Right turn port Steering unit
(14) Passage
(15) Passage
(16) Gerotor

(1) Spool

10.3 MPa

(8) Centering
spring (9) Pin (2) Sleeve (13) Drive (17) Passage
T

(4) Check valve

Priority valve
P 0931E

Fig. 6-11

When the steering wheel is turning

(2) Sleeve

As spool (1) is splined to the steering wheel, turning the (1) Spool
steering wheel makes spool (1) and its engaged pin (9) and (9) Pin
drive (13) turn also. Sleeve (2) is also engaged with pin (9),
but pin hole (19) in sleeve (2) has a larger diameter than pin
(9) itself; so for some time after spool (1) starts rotating,
sleeve (2) does not spin as shown in Fig. 6-12. Accordingly
oil holes (20) and oil grooves (21) that were not aligned with
each other in neutral now are, and the pumped oil outside (13) Drive
0932E

sleeve (2) flows into spool (1), bringing two changes. Fig. 6-12

First, as spool (1) become full, it no longer drains the LS (21) Oil groove (1) Spool
(load-sensing) line inflow and thus the pressure throughout (18) Spring slot
LS line grows higher, closing the priority valve. At this, most (2) Sleeve
(18) Spring slot
of pump oil is led to the steering unit as its passage to the
control valve is blocked. This highly pressurized oil then (19) Pin hole
(20) Oil hole
overcomes the resistance of the check valve’s spring (19) Pin hole
0927E
inside inlet (5) and enters the steering unit. Fig. 6-13

Steering control group 6-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Second, the increasing pressure oil getting inside spool (1)
then flows through passage (17) into metering section (B).
Splined to drive (13), gerotor (16) in metering section (B)
turns together with the steering wheel to pump the oil
inflow. This pumped oil is then discharged through oil
passage (15) to right turn port (11) and then to the left
chamber of the steering cylinder. The oil that enters the left
chamber pushes the piston to the right, turning the vehicle
to the right. Steering speed increases in proportion to the
amount of oil discharged and the rate at which it is pumped,
which is determined by the steering wheel’s rotational
speed. The pressure oil from the pump keeps flowing in
via this passage as long as the steering wheel is turning,
increasing the steering angle until the steering cylinder
reaches its limit.

When the steering wheel stands still

(2) Sleeve
Once the operator stops turning the steering wheel, spool (1) Spool
(1), pin (9), drive (13), and stator (7) also stop turning, and
centering spring (8) returns spool (1) and sleeve (2) to their
(9) Pin
original positions. The pilot signal that was sent to the
priority valve through the load sensing line then stops and
only a small amount of pressurized oil is supplied. Even
this small amount is not able to enter spool (1) nor can the
oil inside spool (1) enter into metering section (B) through
passage (17). The oil in metering section (B) is not (13) Drive
0930E
pumped out to right turn port (11) either because the Fig. 6-14
steering wheel no longer turns. Thus all oil flow stops and
the steering angle of the wheels is maintained.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-13 Steering control group
 E. Relief
Steering cylinder

Steering unit

Spool
To relieve excessive pressure

10.3 MPa

Spool Priority valve

P 0933E
Fig. 6-15
Once the hydraulic oil fed to the steering cylinder reaches
the set pressure (10.3 MPa, 1,493 psi), a relief function is
triggered to lower the pressure to ensure safety.

As shown in Fig. 6-15, when the pumped oil pressure

exceeds the force of the spring, the spool is pushed
against the spring to allow the pressurized oil to exit the
steering unit to the hydraulic tank until its pressure falls
below the spring’s pressure setting.

Steering control group 6-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 6-2-3 Steering system air removal

WARNING
Driving the vehicle when there is air in
the steering system may result in a
crash.
Make sure air has been completely
removed from the system before driving
the vehicle.
If you have recently replaced a steering component or if
any part of the steering system has been opened, it may
be necessary to bleed the system.

Preliminary steps
1. Turn the motor off and wait for the vehicle to cool

2. Put a rated load capacity on the forks shift the

weight on the steer axle to the front of the vehicle.

3. Turn the steering wheel full lock to the left.

4. Fill the hydraulic tank to the full mark with the

appropriate oil (for details, see Section 1-6 Oil
specifications).

5. Check the hosing connections, hoses, and seal

fittings for openings where air might be let in to
the system, and replace those faulty parts.

Procedure
1. Have a partner keep an eye on the oil level in the

6
reservoir while you turn the steering wheel slowly
from lock to lock.

NOTICE: Do not turn the steering wheel too quickly as this

Steering system
will overflow the reservoir.
2. As you turn the steering wheel, have your
partner replenish the hydraulic tank with
hydraulic oil as the level drops.

NOTICE: Do not let the oil level in the hydraulic tank fall
below the pump outlet port.
 If the level does not drop immediately, this could
mean there is a large bubble in the system; oil
will not pass through until the bubble passes.

3. Repeat the previous step 15–20 times until the

oil level remains consistent, and the oil is clear
(i.e. not cloudy) and free of bubbles.
 If you perform the steps above and you are still
able to see bubbles, repeat the procedure.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-15 Steering control group
 6-2-4 Steering system pressure check
If the steering system does not work correctly, check the
hydraulic tank for the correct oil level and the hoses and
connections for leakage. If all these items are correct,
use the pressure gauge to check the steering hydraulic
system and its relief pressure setting.

Preliminary steps

1. Check the hydraulic tank is at the full mark.

2. Check hosing connections, hoses, and seal

fittings for opening.

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Release the pressure from the steering
system before you perform the following
procedure.

3. Turn the motor and the disconnect off.

Procedure

1. Remove plug from port (1) and connect a 28,000

kPa (4,000 psi) gauge as shown in Fig.6-16.

2. Turn the key switch to the ON position and

activate the hydraulic controls until the oil is at
the temperature for normal operation.

3. Turn the rear wheels left or right against the

stops and record the indication on the pressure
gauge. (1) Port

 The indication on the pressure gauge is the

pressure at which the priority valve’s relief valve
is opened—10.340–10.840 kPa (1,500–1,570
psi). 0934E
Fig. 6-16

Steering control group 6-16 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 4. Use the flowchart below to find out the
appropriate action for your pressure reading.

5. After making the necessary adjustments, repairs,

or replacements repeat steps 1–4 again to
ensure you have the correct pressure reading.

Pressure level check

Is the Yes Are you still Yes

Pressure experiencing
value problems?

Check the steering system’s

No mechanical connections for
No failure and make the necessary
repairs and adjustments.
See step 2

Is the
Yes See step 2
pressure
value
approximatel

Check the steering unit for

hydraulic failure and make the
necessary repairs and
adjustments.
No

Is the Yes
See step 2
6
pressure
value

Steering system
excessively

Replace the priority valve and its

components.
No

Check the steering cylinder for

hydraulic failure and make the See step 2
necessary repairs and
adjustments.

See step 5

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-17 Steering control group
 6-2-5 Steering wheel cover removal/installation

(2-1) Cover

(2-2) Cover

(2) Cover ass’y

(3) Key switch ass’y

(2-3) Cover
(2-4) Cover

(1) Screw

0935E

Fig. 6-17

1. Loosen 10 screws (1) and remove the washer,

cover (2-1 to 2-4), and key switch (3).

2. Follow the steps above in the opposite order to

install the cover.

Steering control group 6-18 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 6-2-6 Steering wheel removal/installation
(1) Cap
(2) Nut
(3) Washer
(4) Steering wheel ass’y

(5) Horn switch

0936E

Fig. 6-18

1. Remove cap (1) from the steering wheel.

2. Remove nut (2) and washer (3) from the steering

wheel.
6
Steering system
3. Remove knob (4).

4. Remove horn switch (5).

5. Remove the steering wheel ass’y using a

suitable puller.

6. Follow the steps above in the opposite order to

install the steering wheel cover.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-19 Steering control group
 6-2-7 Steering wheel column removal/installation

(12) Steering column

(4) Bolt
(11) Yoke

(10) Snap ring

(5) Washer

(9) Gas spring

(6) Cotter pin

(7) Washer

(8) Pin

(2) Load-sensing hose

(3) Bolt

(1) Hose

0937E

Fig. 6-19

Preliminary steps

1. Remove the residual pressure in the hydraulic

system by moving the control levers back and
forth several times with the key off

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Make sure the pressure is released from
the system before you perform the
following procedure.

Steering control group 6-20 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Procedure

1. Remove four hose assemblies (1) and load

sensing line (2) from steering unit (8).

NOTICE: As a reference for assembly mark the hoses and

then plug and cap each port to prevent debris and foreign
material from entering the hydraulic system.

2. Loosen four bolts (4) and four washers (5) from

the steering column ass’y and remove the
steering unit (8).

NOTICE: If you do not hold the steering unit when

loosening bolts (4), steering unit (8) may fall to the floor
and be damaged.

3. Pull out cotter pin (6) and then remove steering

column ass’y (9–12) while removing pin (8).

4. Remove retaining ring (10), and then remove

yoke (11) and gas spring (9).

5. Follow the steps above in the opposite order to

install the steering column.

6. Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-21 Steering control group
 6-2-8 Steering unit disassembly/assembly
(31) Plug
(30) Washer
(29) Fixed plug
(28) Spring
(25) Spring seat and ball assembly
(24) Ball seat
(23) Retaining ring
(22) Seal gland bushing
(21) Dust seal
(27) Spool (20) O-ring
(1) Housing
(26) Bushing

(17) Check valve ball

(16) Check valve pin
(15) Cap seal
(14) Bearing set

(13) Spool
(12) O-ring
(19) Check valve ball
(11) Distributor
(18) Threaded bush
(10) O-ring
(9) Shaft

(8) Spacer

(7) Inner gear

(6) Outer gear

(5) O-ring

(4) End cover

(3) Washer

(2) Bolt 0938E

Body disassembly/assembly Fig. 6-20

1. Mark housing (1) as a reference for assembly,

and then remove fittings and lines

2. Remove seven bolts (2) and washers (3).

 One of the bolts is a special bolt. Mark off its
position with a pin.
 At assembly, tighten bolts (2) in the sequence
shown in Fig. 6-21 to a first torque of 15±6 2nd 7th
N∙m (11±4 lb·ft), and then tighten them to a
second torque of 30±6 N∙m (22±4 lb·ft).
4th 5th
3. Remove end cover (4), O-ring (5), outer gear (6),
6th
inner gear (7), and spacer (8).
1st 3rd
4. Remove shaft (9), O-ring (10), and distributor
plate (11).
Fig. 6-21
 At assembly, make sure to engage the groove
of shaft (9) with the pin of spool assembly (13).

Steering control group 6-22 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 5. Remove O-ring (12).

6. Remove spool assembly (13), and remove

bearing set (14) and cap seal (15) from the
assembly.

7. Remove check valve pins (16) and balls (17).

8. Remove threaded bush (18) and check valve ball

(19).

9. Pry retaining ring (23).

10. Remove seal gland bushing (22) and O-ring (20),

and remove dust ring (21) from the bushing.

11. Remove three sets of plugs (31), washers (30),

fixed plugs (29), and springs (28).

12. Remove spools (27) and bushing (26).

13. Remove spring seat and ball assemblies (25)

and ball seats (24).

14. Follow the steps above in the opposite order to

assemble the steering unit.

Spool ass’y (13) disassembly/assembly

1. Remove the pin from the spool ass’y.

2. Pull the spool partially from the control end of the

sleeve, then remove the centering springs
carefully.

3. Push the spool back out of sleeve by rotating it

6
slowly.

4. Follow the steps above in the opposite order to Steering system

Fig. 6-22
assemble the spool ass’y.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-23 Steering control group
6-3 Steering operation group [B15/18/20T (TL)]

6-3-1 Exterior and specifications

A. Steer axle ass’y

Fig. 6-23

Items Spec.
190104-00126 (Solid Soft)
Part no. 190104-00128 (Cushion)
190104-001230 (Wide)
Output torqe 688.6 N·m at 7,400 kPa (507.9 lb·ft at 1,073 psi)
Piston area 28.27 cm2 (4.38 in2)
Pitch radius 33.02 mm (1.3 in)
Piston stroke (90° turn) 51.82 mm (2.04 in)
Volume (180° turn) 292.9 ml

Steering operation group [B15/18/20T (TL)] 6-24 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Steer sensor

Fig. 6-24

Characteristics Items Spec.

Part no. 301308-00553
Input voltage
Current consume
DC 12±0.2 V
10 mA
6
Electrical and Independent linearity ±3%

Steering system
mechanical Electrical angle 300±1°
Mechanical angle 360°
Service life 3 million cycles min (1 cycle = ±90°)
Operating temp. -30°C to +80°C(-22°F to +176°F)
High temp. exposure 100°C (212°F) 96 Hr
Low temp. exposure -40°C (-40°F) 96 Hr
Water resistance JIS D0203 S1
Environmental
Humidity 60°C (140°F), 90–95% RH, 500 Hr
10G, 50–250 Hz, 12 Hr
Vibration
each direction of X, Y, and Z
Shock 30G

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-25 Steering operation group [B15/18/20T (TL)]
 6-3-2 How It works

A. Steer axle operation

(1) Steering wheel
(2) Steering unit
Neutral position
P (2-1) L turn port
(2-2) R turn port
When steering wheel (1) is in neutral, steering unit (2)
T
discharges oil neither to left turn port (2-1) nor to right turn
port (2-2). Therefore pistons (3-1) stay at the center to
keep the wheels straight.
(3) Steering cylinder

(3-1) Piston
0939E
Fig. 6-25

Left turn
(1) Steering wheel
(2) Steering unit
When you are turning steering wheel (1) to the left,
steering unit (2) discharges oil through left turn port (2-1). P (2-1) L turn port
Accordingly, as oil fills the right chamber of steering (2-2) R turn port
T
cylinder (3), the oil in the left chamber is discharged to
steering unit (2), and thus both pistons (3-1) and rack gear (5) Rear wheel

(3-2) are pushed to the left. The shift of rack gear (3-2) to
the left causes pinion gear (4), which it is engaged with, to (4) Pinion gear

spin together with steering wheel (5) in the direction shown (3) Steering cylinder
in Fig. 6-26, turning the vehicle to the left. (3-1) Piston
0940E
Fig. 6-26

Right turn
(1) Steering wheel
When you are turning steering wheel (1) to the right,
(2) Steering unit
steering unit (2) discharges oil through the right turn port
(2-2). Accordingly, as oil fills the left chamber of the P (2-1) L turn port

steering cylinder (3), the oil in the right chamber is (2-2) R turn port
T
discharged to steering unit (2), and thus both pistons (3-1)
(5) Rear wheel
and rack gear (3-2) are pushed to the right. The shift of
rack gear (3-2) to the right causes pinion gear (4), which it
is engaged with, to spin together with steering wheel (5) in (4) Pinion gear

the direction shown in Fig. 6-27, turning the vehicle to the (3) Steering cylinder
right. (3-1) Piston
0941E
Fig. 6-27

Steering operation group [B15/18/20T (TL)] 6-26 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Steer sensor operation
Initial position: 0°

Left drive controller

D1-7 7/WH 3 GND

Signal out -150˚ 150˚

D1-24 101/GN 2
Voltage
VCC
D1-25 25/RD/WH 1
9±0.3V
Steer angle sensor

0+0.3V
-150±0.3˚ 0.3˚ 150±0.3˚ Angle
0942E

Fig. 6-28

The steer sensor monitors the angle at which the rear

wheels are turned and report it to the controller in real time.

Powered from the left motor controller at 12 V, this sensor

signals with a voltage which ranges from 9 V to 0 V in
inverse proportion to the rear wheels’ turning angle (-150°
to 150°).

The controller then converts this analog signal into angle

data and shares the converted data across the CAN
network: this data is then displayed on the instrument 6
panel and also used to control the electrical system in
accordance with the settings of a number of parameters.
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-27 Steering operation group [B15/18/20T (TL)]
 6-3-3 Steer angle sensor removal/installation

Preliminary steps Steer angle sensor ass’y

1. Open the counterweight top cover (See Section (1) Screw

7-4). (2) Washer
(3) Bolt

(4) Washer (5) Sensor

Removal

1. Disconnect the cable of steer angle sensor (5).

(7) Clip
2. Remove bolts (3) and washers (4), and then (6) Bracket

remove sensor-bracket ass’y (5 to 6), clip (7), (8) Hose

hose (8), and clip (9).
(9) Clip
3. Remove screw (1), washer (2), and then detach
sensor (5) from bracket (6).

Installation

1. Turn the rear wheels to make them straight.

0943E
2. Measure the resistance between P1 and P2, or Fig. 6-29
P2 and P3 of the steer angle sensor connector.
 The resistance should read 2.6 ± 0.1 kΩ.

3. If the resistance meets specification, then follow

the steps above in the opposite order to install
the steer angle sensor.

4. Perform sensor initial setting using the EasyView

application (See the Steering Set menu in
Section 2-6-7).

Steering operation group [B15/18/20T (TL)] 6-28 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 6-3-4 Rear wheel and hub adjustment/removal/installation

A. Rear wheel bearing adjustment

Tools needed: Torque wrench

Procedure (single wheel)

1. Slowly tighten nut (1) to a torque of 100 N·m (74 (2) Bearing
lb·ft).
(1) Nut

2. Turn the wheel at least one full rotation to secure

bearing (2) in the correct position.

3. Loosen nut (1) completely and then tighten it (3) Lock washer

again to a torque of 45 ± 3 N·m (33 ± 2 lb·ft). 0944E

Fig. 6-30

4. Bend forward the tabs of lock washer (3) to

secure it.

Procedure (double wheel)

1. Slowly tighten nut (1) to a torque of 133 N·m (98

lb·ft).

2. Turn the wheel at least one full rotation to secure

bearing (2) in the correct position.

3. Loosen nut (1) completely and then tighten again

to a torque of 45 to 55 N·m (33 to 41 lb·ft).

4. Bend forward the tabs of lock washer (3) to

secure it. 6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-29 Steering operation group [B15/18/20T (TL)]
 B. Rear wheel and hub removal/installation

(9) Bolt
(8) Hub

(11) Seal (7) Bearing

(10) Bearing (6) Tongue washer
(5) Lock washer
(4) Nut

(3) Wheel cap

(2) Rear wheel

(1) Nut
0945E

Fig. 6-31

Floor jack
Tools needed
Torque wrench

Preliminary steps

1. Raise the rear of the vehicle using a floor jack

and support it with wooden blocks.

2. Turn the rear wheels as much as 90 degrees as

shown in Fig. 6-31.

Rear wheel removal/installation

1. Remove nuts (1) that are connected with bolts

(9).

2. Remove rear wheel (2).

3. Follow the steps above in the opposite order to

install the wheel.

Rear wheel hub removal/installation

1. Remove wheel cap (3).

2. Clean hub ass’y (8) and make sure it is free of

grease.
 At installation, fully lubricate the inside of hub
ass’y (8).

3. Bend the tabs of lock washer (5) and then

remove nut (4) using a torque wrench.

Steering operation group [B15/18/20T (TL)] 6-30 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 4. Remove lock washer (5).
 At installation, perform the wheel bearing
adjustment procedure in the previous section.

5. Remove tongue washer (6) and the cone of

bearing (7) from hub (8).

6. Remove hub (8).

7. Remove the cups of bearing (7) and bearing (10)

from both sides of hub (8).
 At installation, lubricate the cups’ contact
surfaces with Multipurpose Grease.

8. Remove the cone of bearing (10) from the

vehicle.

9. Follow the steps above in the opposite order to

install the wheel hub.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-31 Steering operation group [B15/18/20T (TL)]
 6-3-5 Steer axle spindle removal/installation/disassembly/assembly

(3) Spindle ass’y

(2) Washer

(1) Bolt

0946E

Fig. 6-32

Steering operation group [B15/18/20T (TL)] 6-32 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Tools needed Floor jack

Preliminary steps

1. Remove both rear wheels and keep the rear of

the vehicle supported with wooden blocks (See
Section 6-3-4 B).

Procedure

1. Loosen bolts (1) and remove washers (2).

 Installation torque: 270±25 N·m (199±18 lb·ft).

 Installation sealant: Loctite #262

2. Remove spindle ass’y (3).

3. Follow the steps above in the opposite order to

install the spindle ass’y.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-33 Steering operation group [B15/18/20T (TL)]
 6-3-6 Steer axle housing ass’y disassembly/assembly
(1) Bolt
(2) Shaft
(3) Top plate
(4) Bolt
(5) Seal

(6) Bearing
(8) Bolt
(7) Overflow hose connector (12-2) Seal (12-3) Wear ring

(9) Washer (12-4) Piston

(16) Steer hose connector (12-1) O-ring seal

(8) Bolt

(9) Washer
(11) Rack hear

(12) Piston ass’y

(16) Steer hose connector
(20) Bearing (10) Hosing

(21) Seal (13) Washer

(14) Bolt

(22) Shim (15) O-ring seal

(17) Cap
(18) Washer
(23) Pinion gear (19) Bolt

0947E

Fig. 6-33
Preliminary steps

1. Remove the steer sensor (See Section 6-3-3).

2. Remove the steer axle spindle (See Section 6-3-5).

Housing ass’y removal/installation

1. Disconnect overflow hose (7) and two steer

hoses (16).

2. Remove three pairs of bolts (8) and washers (9)

fastened to the front/back of the housing ass’y.
 Installation torque: 460±60 N·m (339±44 lb·ft)

 Installation sealing: Loctite #262

3. Remove housing ass’y (10).

4. Follow the steps above in the opposite order to

reinstall the housing ass’y.

Top plate and shim removal

1. Loosen bolt (1) and remove top plate (3).

2. You may loosen bolt (4) and remove shaft (2)

from plate (3) if needed.

3. Remove shim pack (22) from pinion gear (23).

Steering operation group [B15/18/20T (TL)] 6-34 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Top plate and shim installation
1. Install top plate (3), and tighten bolts (1) to a
torque of 55 ± 10 N·m (41 ± 7 lb·ft) and then
loosen them again.
2. Measure distance (Y) from the surface of
housing (10) to the top of pinion gear (23) and
distance (X) from the surface of housing (10) to
the top of bearing (6). After you’ve recorded your
measurement, calculate the difference between
the two distances (X - Y).
3. Referring to the table below, determine the
required thickness of shims (22) according to the
value of (X – Y), and install them.

No. of shims 1 2 3 4
Thickness 0.05 0.125 0.35 0.75
mm, (in) (0.002) (0.005) (0.014) (0.030)
4. Reinstall top plate (1) and fasten bolt (1) to a
torque of 45±7 N·m (33 ± 5 lb·ft).
Main body disassembly/assembly
1. With the housing upside down, remove pinion gear (23).
 At assembly, with the rack gear (11) in the
center, install pinion gear (23) so that the “TOP”
hole is in the position shown in Fig. 6-34.
2. Remove the cone of bearing (20) from pinion
gear (23).
3. Remove bolts (19) and washers (18), and then
remove cap (17) and O-ring seal (15) at each side.
 Installation torque: 55 ± 10 N·m (40 ± 7 lb·ft).
Fig. 6-34
4. Remove rack gear piston ass’y (11 to 14).
5. Remove seal (9) and the cone and cup of bearing (6).
6. Remove seal (21) and the cup of bearing (20)
6
from housing (10).

Steering system
7. Follow the steps above in the opposite order to
assemble the body of the housing ass’y.
Piston-rack gear disassembly/assembly
1. Remove friction ring (12-3) from each piston (12-4).
2. Remove bolts (14) and washers (13), and then
remove both piston ass’ies and rack gear (11).
 Installation torque: 55 ± 10 N·m (40 ± 7 lb·ft)
 Apply lubricant NLGI #2 to rack gear (11).
3. Remove O-ring seal (12-1) and seal (12-2).
 At assembly, lightly apply Loctite #592 to where
the two seals touch in the piston.
4. Follow the steps above in the opposite order to
assemble the piston rack gear ass’y.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-35 Steering operation group [B15/18/20T (TL)]
6-4 Steering operation group [B16/18/20X]

6-4-1 Exterior and specifications

A. Steer axle ass’y

Fig. 6-35

Components Items Spec.

Part no. 190104-00093
Steer axle
Cramp angle 86°
Part no. A165090
Steering Use pressure 7.8 MPa (1,138 psi)
cylinder Test pressure 15.7 MPa (2,276 psi)
Allowable stroke 87±1.0

Steering operation group [B16/18/20X] 6-36 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Steer sensor

Fig. 6-36

Characteristics Items Spec.

Part no. 301308-00553
Input voltage
Current consume
DC 12±0.2 V
10 mA
6
Electrical and Independent linearity ±3%

Steering system
mechanical Electrical angle 300±1°
Mechanical angle 360°
Service life 3 million cycles min (1 cycle = ±90°)
Operating temp. -30°C to +80°C(-22°F to +176°F)
High temp. exposure 100°C (212°F) 96 Hr
Low temp. exposure -40°C (-40°F) 96 Hr
Water resistance JIS D0203 S1
Environmental
Humidity 60°C (140°F), 90–95% RH, 500 Hr
10G, 50–250 Hz, 12 Hr
Vibration
each direction of X, Y, and Z
Shock 30G

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-37 Steering operation group [B16/18/20X]
 6-4-2 How it works

A. Steer axle operation (1) Steering wheel

(2) Steering unit
Neutral position
P (2-1) L turn port
(2-2) R turn port
When steering wheel (1) is in neutral, steering unit (2) T
discharges oil neither to left turn port (2-1) nor to right turn (3) Steering cylinder

port (2-2). Therefore piston (3-1) stays at the center to

keep the wheels straight.

(3-1) Piston
0948E
Fig. 6-37
Left turn

When you are turning steering wheel (1) to the left, (1) Steering wheel
steering unit (2) discharges oil through left turn port (2-1). (2) Steering unit
Accordingly, as oil fills the right chamber of steering
P (2-1) L turn port
cylinder (3) the oil in the left chamber is discharged to (2-2) R turn port
steering unit (2), and thus piston (3-1) and the rods in both T (3) Steering cylinder
sides; links (4-1), which are connected to these rods; and (4) Pinion gear
(4-2) Knuckle
knuckles (4-2) are all pushed to the left. As a result,
knuckles (4-2) and rear wheels (5) turn on the axis of both
the ends of steer axle (4) as shown in Fig. 6-38, turning
the vehicle to the left.
(4-1) Link (3-1) Piston

(5) Rear wheel

0949E
Fig. 6-38
Right turn
(1) Steering wheel
When you are turning steering wheel (1) to the right, the
(2) Steering unit
steering unit (2) discharges oil through right turn port (2-2).
Accordingly, as oil fills the left chamber of steering cylinder P (2-1) L turn port
(3) the oil in the left chamber is discharged to steering unit (2-2) R turn port
T (3) Steering cylinder
(2), and thus piston (3-1) and the rods in both sides; links (4) Pinion gear
(4-1), which are connected to these rods; and knuckles (4-
2) are all pushed to the right. As a result, knuckles (4-2) (4-1) Link

and rear wheels (5) turn on the axis of both the ends of
steer axle (4) as shown in Fig. 6-39, turning the vehicle to
the right
(4-2) Knuckle (3-1) Piston
(5) Rear wheel
0950E

Fig. 6-39

Steering operation group [B16/18/20X] 6-38 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Steer sensor operation

Fig. 6-40

The steer sensor monitors the angle at which the rear

wheels are turned and reports it to the controller in real
time.

Powered from the left motor controller at 12 V, this sensor

signals with a voltage which ranges from 9 V to 0 V in
inverse proportion to the rear wheels’ turning angle (-150°
to 150°).

The controller then converts this analog signal into angle

data and shares the converted data across the CAN 6
network: this data is then displayed on the instrument
panel and also used to control the electrical system in
accordance with the settings of a number of parameters. Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-39 Steering operation group [B16/18/20X]
 6-4-3 Steer angle sensor removal/installation

(1) Screw

(2) Washer

(3) Sensor

(4) Plate

0951E

Fig. 6-41

Removal

1. Remove two screws (1) and washers (2).

2. Remove sensor (3) from the steer axle.

3. Remove plate (4).

Installation

1. Turn the rear wheels to make them straight.

2. Measure the resistance between P1 and P2, or

P2 and P3 of the steer angle sensor connector.
 The resistance should read 2.6 ± 0.1 kΩ.

3. If the resistance meets specification, then follow

the steps above in the opposite order to install
the steer angle sensor.

4. Perform sensor initial setting.

5. Perform sensor initial setting using the EasyView

application (See the Steering Set menu in
Section 2-6-7).

Steering operation group [B16/18/20X] 6-40 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 6-4-4 Rear wheel and hub adjustment/removal/installation

A. Wheel bearing adjustment

Tools needed Torque wrench

Procedure
(2) Bearing
(3) Lock washer
1. Tighten nut (1) slowly to 133 N·m (98 lb·ft).

2. Spin the wheel at least one full rotation to put (1) Nut
bearings (2) into position.

3. Loosen nut (1) completely and then tighten it

again to a torque of 45–55 N·m (33–41 lb·ft).

4. Bend lock washer (3) over nut (1) to hold it in 0952E

Fig. 6-42
position.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-41 Steering operation group [B16/18/20X]
 B. Rear wheel and hub removal/installation

(9) Bolt
(8) Washer
(11) Seal (7) Bearing
(10) Bearing (6) Tongue washer
(5) Lock washer
(4) Nut

(3) Wheel cap

(2) Rear wheel (1) Nut

0953E
Fig. 6-43
Floor jack
Tools needed
Torque wrench

Preliminary steps

1. Raise the rear of the vehicle using a floor jack

and support it with wooden blocks.

2. Turn the rear wheels as much as 90 degrees as

shown in Fig. 6-43.

Rear wheel removal/installation

1. Remove nuts (1) that are connected with bolts (9).

2. Remove rear wheel (2).

3. Follow the steps above in the opposite order to

install the wheel.

Rear wheel hub removal/installation

1. Remove wheel cap (3).

2. Clean hub ass’y (8) and make sure it is free of

grease.
 At installation, fully lubricate the inside of hub
ass’y (8).

3. Bend the tabs of lock washer (5) and then

remove nut (4) using a torque wrench.

Steering operation group [B16/18/20X] 6-42 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 4. Remove lock washer (5).
 At installation, perform the wheel bearing
adjustment procedure in the previous section.

5. Remove tongue washer (6) and the cone of

bearing (7) from hub (8).

6. Remove hub (8).

7. Remove the cups of bearing (7) and bearing (10)

from both sides of hub (8).
 At installation, lubricate the cups’ contact
surfaces with Multipurpose Grease.

8. Remove the cone of bearing (10) from the

vehicle.

9. Follow the steps above in the opposite order to

install the wheel hub.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-43 Steering operation group [B16/18/20X]
 6-4-5 Steer axle removal/installation

(1) Steer hoses

Steer axle ass’y

(5-2) Support (rear)
(6-2) Bushing (rear)
(7-2) Shims (rear)

(3-2) Spring washer (rear)

(2-2) Mounting bolt (rear)
(4-2) Grease nipple (rear)

(6-1) Bushing (front)

(5-1) Support (front)

(7-1) Shims (front)

(4-1) Grease nipple (front)

(3-1) Spring washer (front)

(2-1) Mounting bolt (front)

0954E
Fig. 6-44

Steering operation group [B16/18/20X] 6-44 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Tools needed Floor jack

Preliminary steps

1. Raise the rear of the vehicle using a floor jack

and support it with wooden blocks.
 Make sure the blocks are under the vehicle
frame, not the axle, so that the vehicle may stay
raised even after the floor jack.

2. Remove both rear wheels (See section 6-4-4 B).

Procedure

1. Disconnect steer hoses (1) and plug and cap

them together with their ports.

2. Loosen rear mounting bolts (2-2) until

approximately two bolt threads are left in the
mounting boxes.
 Installation torque: 270±40 N·m (199±30 lb·ft)

3. Lower the steer axle onto the heads of rear bolts

(2-2) with the floor jack.

4. Loosen front mounting bolts (2-1) and remove

washers (3-1) and support (5-1).
 Installation torque: 270±40 N·m (199 ± 30 lb·ft)

5. Slide the steer axle out of rear support (5-2), and

then remove the axle.
 Steer axle weight: 64 kg (141 lb)
6
6. You may remove front/rear grease nipple (4),
bushing (6), and shims (7) if needed.
 Shims (7) are to offset the gap between Steering system
front/rear supports (5) the steer axle.
 At installation, pay attention to the direction of
grease nipples (4) and pack (inject) sufficient
grease.

7. Follow the steps above in the opposite order to

install the steer axle.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-45 Steering operation group [B16/18/20X]
 6-4-6 Link ass’y removal/installation
In the illustration below, the axle covers are removed in order to show necessary components. In the
actual procedure, however, you may access those components without removing the covers by
steering the rear wheels to either side.

(1) Split pin

(2) Link [top]

(4) Bearing
(3) Washer

(5) Knuckle

(6) Washer

(7) Link [bottom]

(8) Washer

(9) Nut

(10) Snap pin

0955E
Fig. 6-45
1. Pull out snap pins (10), loosen nuts (9), and then
remove washers (8), bottom link (7), and
washers (6).

2. Remove split pins (1), top link (2), washers (3),

and bearing (4).

3. Follow the steps above in the opposite order to

install the link ass’y.

Steering operation group [B16/18/20X] 6-46 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 6-4-7 Steering knuckle, king pin, and bearing removal/installation
(1) Grease fitting

(2) Retaining ring

(3) Plug

(4) Needle bearing

(5) Thrust bearing

(6) Bolt

(7) Knuckle

(9) King pin

(4) Needle bearing

(8) Nut

(10) Shim

(3) Plug

(2) Retaining ring

(1) Grease fitting

0956E
Fig. 6-46

Preliminary steps

1. Remove the rear wheel and hub (See Section 6-

6
4-4 B).

2. Remove the link ass’y (See Section 6-4-6).

Steering system
Procedure

1. Remove grease fittings (1), retaining rings (2),

and plugs (3) from the top and bottom.

2. Loosen nut (8) and pull out bolt (6).

3. Pull out king pin (9) and remove knuckle (7),

thrust bearing (5), and shims (10).

4. Remove needle bearings (4) from the steer axle.

5. Follow the steps above in the opposite order to

install the steering knuckle, king pin, and
bearing.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-47 Steering operation group [B16/18/20X]
 6-4-8 Steering cylinder removal/installation/disassembly/assembly

A. Steering cylinder removal/installation

(2) Steering cylinder

(1) Bolt

0957E

Fig. 6-47

Preliminary steps

1. Remove the steer axle (See Section 6-4-5).

2. Remove both link ass’ies (See Section 6-4-6).

Procedure

1. Remove bolts (1) and washers.

2. Pull steering cylinder (2) to either side to remove

it.

3. Follow the steps above in the opposite order to

install the steering cylinder.

Steering operation group [B16/18/20X] 6-48 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 B. Steering cylinder disassembly/assembly

Tube Piston ass’y

Rod
(8) O-ring
(7) Slipper ring Rod cover ass’y
(6) Retaining ring
(5) O-ring
(4) DU-bushing
(3) O-ring seal
Piston (1) Dust wiper seal
Preliminary steps (2) U-packing

1. Remove the steer cylinder.

Rod cover

Procedure
Perform the following steps for both ends of the cylinder

1. Mark the position of the rod cover on the steering 0958E

Fig. 6-48
tube as a reference for installation.

2. Remove rod cover ass’y.

3. Remove the rod from the cylinder tube.

 Plate the rod with hard chrome before installing.

4. Remove dust wiper (1) and U-packing (2) from

6
the front side of the rod cover ass’y.

5. Remove O-ring (3) and DU-bushing (4) from the

back side

Steering system
6. Remove retaining ring (6) from the piston ass’y
on the cylinder rod.

7. Remove piston ass’y from the cylinder rod.

8. Remove O-ring (5) from the front side of the

piston.

9. Remove slipper seal (7) and O-ring (8).

10. Follow the steps above in the opposite order to

assemble the steering cylinder.
 Seal the port with a dust cap once you have
finished assembling.
 Adjust the rod’s stroke so that it reaches a
maximum of 87±1.0.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-49 Steering operation group [B16/18/20X]
6-5 Troubleshooting

Problems Probable causes

Priority valve (if equipped) releases pressure oil at a low

setting
Pump oil pressure is low, worn pump.
Steering gear covers are too tight.
Too much force needed to turn
steering wheel. Steering column not aligned with steering gear.
Priority valve spool is held in one position.
Steering gear without lubrication.
Low fluid level in the hydraulic supply tank.
Steering gear covers are too tight.
Steering column is not in correct alignment.
Steering wheel does not return to
center position correctly. Valve spool in the steering gear has a restriction.
Priority valve check valve permits lift and tilt hydraulic oil to
affect hydraulic circuit.
Loose hose connections.
Oil leakage at the pump.
Bad shaft seal.
Low oil level.
Priority valve (if equipped) relief valve spring weak.
Relief valve (priority valve) will not move from the open
Low oil pressure.
position.
Oil leakage inside or outside of the system.
Bad pump.
Air in the steering hydraulic circuit.
The pump has to much wear.
Pump makes noise when turning
the steering wheel and does not Loose connection of the oil line on the inlet side of the pump.
move smoothly. The viscosity of the oil is wrong.
The oil level in the hydraulic tank is low.
The oil level of the tank is low.
There is air in the steering system.
The pump operation is not correct.
Lift truck does not turn when
Dirt in the steering system.
steering wheel is slowly turned.
Steering gear operation is not correct.
Restriction in the steer axle linkage.
Steering cylinder has worn parts.

Troubleshooting 6-50 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Problems Probable causes

The viscosity of the oil is wrong.

The temperature of the oil is too Air is mixed with the oil.
hot. The relief valve is set too high (priority valve).
There is a restriction in the return line circuit.

6
Steering system

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 6-51 Troubleshooting

7 Frame

7-1 Hood removal/installation............................2

7-2 Overhead guard removal/installation .........4

7-3 Floor plates removal/installation ................5

7-4 Top cover and counterweight

removal/installation .......................................6

7-5 Modular cabin removal/installation ..............8

7-5-1 A type ....................................................................8
7-5-2 B type .................................................................. 10
7-5-3 C type .................................................................. 11
7-5-4 Electric schematic for cabin .................................. 12

7-6 Heater ...........................................................13

7-6-1 Exterior and Specifications ................................... 13
7-6-2 Operating condition .............................................. 13
7-6-3 Operating mode ................................................... 13
7-6-4 Maintenance information ...................................... 14
7-6-5 Troubleshooting ................................................... 15

7
Frame
7-1 Hood removal/installation

(5) Hoist

(4) Bolt

(2) Bolt

(3) Cylinder

(1) Harness connector

0959E
Fig. 7-1

Preliminary steps

1. Raise the hood and support it with a hoist.

Procedure

1. Disconnect harness connectors (1) for the seat.

2. Remove bolts (2) and washers from each support

cylinder (3) and then the cylinder rod from the
bracket.
WARNING
When the nuts are removed from the
support cylinder rod, the hood and
seat can fall and crush, causing
serious injury.
Support the seat and hood assembly
before removing the nut.

Hood removal/installation 7-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 3. After closing the hood and removing the top rear
cover, remove two bolts (4) and washers on each
side.

4. Use a hoist (5) to remove the hood and seat

assembly.

5. Follow the steps above in the opposite order to

install the hood.

7
Frame

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 7-3 Hood removal/installation

7-2 Overhead guard removal/installation

(3) Hoist (1) Plastic cover

(5) Cap (2) Harness connector

(6) Bolt (4) Bolt

0960E

Fig. 7-2

1. After loosening the two bolts, remove plastic cover

(1) from the cowl.

2. Disconnect harness connectors (2) from the

instrument panel’s connectors.

3. Support overhead guard with lifting straps and a

hoist (3).

4. Remove bolts (4) and washer from the inside of the

front leg on each side.

5. Remove cap (5) from the rear leg on each side.

6. Remove bolts (6) and washer from the rear leg on

each side and remove the overhead guard.

7. Follow the steps above in the opposite order to

install the overhead guard.

Overhead guard removal/installation 7-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
7-3 Floor plates removal/installation

(3) Bolt (1-3) Left floor plate

(4) Washer

(1-1) Front floor plate

(1-4) right floor plate

(3) Bolt
(4) Washer
(3) Bolt
(4) Washer

(1-2) Rear floor plate

(2) Harness connector

0961E

Fig. 7-3

Many of the procedures in this manual require the

removal and installation of certain hydraulic/electrical
components. Removing the floor plates is one of the most
convenient ways to access them.

Preliminary steps

1. Remove the floor mat.

Front floor plate

1. Slightly raise front floor plate (1-1) and disconnect 7

the accelerator’s harness connector (2). Frame

2. Remove front floor plate (1-1).

3. Follow the steps above in the opposite order to

install the front floor plate.

Other floor plates

1. Remove bolt (3) and washer (4) that secure the floor
plate you wish to remove.

2. Remove the plate.

3. Follow the steps above in the opposite order to

install the floor plate.
B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 7-5 Floor plates removal/installation
7-4 Top cover and counterweight
removal/installation
Though the illustration below shows models B16/18/20X-7, models B15/18/20T-7 and B18/20TL-7
have a similar removal/installation procedure.

(1) Bolt

(2) Top cover (7) Eyebolt

(8) Counterweight

(5) Washer
(6) Bolt

(3) Controller connector

(4) Bolt

0962E

Fig. 7-4

WARNING
Removing the counterweight of a
loaded vehicle may cause the vehicle
to tip over forward.
Put the forks on a stable surface when
removing the counterweight.

Tools needed Forged eyebolts

Top cover removal/installation

1. Loosen bolts (1) and remove top cover (2).

2. Follow the steps above in the opposite order to

install the top cover.

Top cover and counterweight removal/installation 7-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Counterweight removal/installation

1. Remove the steer axle joint parts:

 B15/18/20T and B18/20TL: Remove the steer
axle spindle (See Section 6-3-5), and
disconnect the three hoses from the steer axle
(See Section 6-3-6).
 B16/18/20X: Remove the mounting bolts and
caps from the steer axle (See Section 6-4-5).

2. Remove the battery (See Section 2-2-6).

3. Disconnect the cables from controller connectors (3).

 In the cases of models B15/18/20T and
B18/20T, you may disconnect the cable only
from the pump motor controller.

4. Loosen bolts (4) and washers.

 Installation sealant: Loctite #262
 Installation torque: 460±16 N·m (340±45 lb·ft)

5. Loosen bolts (6) and washers (5).

6. Install two forged eyebolts (7) at bolt holes and

attach a hoist.

7. Remove counterweight (2)

 Refer to the table below to confirm the weight
of your model’s counterweight. The weight
measurements represent the counterweight’s
net weight; you must take into consideration
the weight of other accessories. (PLUS model
has the same weight.)

Models Weight (kg) Weight (lb)

B15/18T-7 760 1,676
B20T-7
B18/20TL-7
900
750
1,984
1,653
7
B15X-7 588 1,296
Frame

B18X-7 671 1,479

B20X-7 850 1,874

8. Follow the steps above in the opposite order to

install the counterweight.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 7-7 Top cover and counterweight removal/installation
7-5 Modular cabin removal/installation

7-5-1 A type
1. Remove bolt (2) and washer (3) at top side.
(1) Top cover

A
Fig. 7-5
2. Remove top cover (1).

(2) Bolt
(3) Washer

Fig. 7-6
< Detail “A” >

3. Remove bolt (4) and washer (5) at front side.

4. Remove front plate (6).

(6) Front plate (4) Bolt

(5) Washer

Fig. 7-7

5. Remove clamp (7) at four places.

6. Remove plate (8).

(8) Plate B
Fig. 7-8

Modular cabin removal/installation 7-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 (7) Clamp

< Detail “B” > Fig. 7-9

7. Remove insulator (9). (9) Insulator

8. Follow the steps above in the opposite order to

install the A cabin.

Fig. 7--10

7
Frame

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 7-9 Modular cabin removal/installation
 7-5-2 B type
In addition to the procedure for A type,

1. Separate the connection between wiper switch (1)

and harness.
 NOTICE: Be careful not to damage the
harness.
(1) Wiper switch
Fig. 7-11

2. Remove clamp (2) at four places.

3. Remove front glass (3).

4. Follow the steps above in the opposite order to

install the B cabin.

(3) Front glass

A
Fig. 7-12

(2) Clamp

< Detail “A” >

Fig. 7-13

Modular cabin removal/installation 7-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 7-5-3 C type
In addition to the procedure for A type and B type,

1. If the rear glass (1) was open, close it.

2. Loosen nut (3) and remove gas spring (2) at both B

sides.

(2) Gas spring

(2) Gas spring
(1) Rear glass

(3) Nut

< Detail “A” > Fig. 7-14

3. Remove two pcs of screws (4) at both sides and

remove rear glass (1).
 NOTICE: Be careful not to miss the rear glass.

4. Follow the steps above in the opposite order to

(4) Screw
install the C cabin.

< Detail “B” >

7
Fig. 7-15

Frame

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 7-11 Modular cabin removal/installation
 7-5-4 Electric schematic for cabin

Fig. 7-16

Modular cabin removal/installation 7-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
7-6 Heater

7-6-1 Exterior and Specifications

Items Spec.

Heater voltage 48V, 80V

Air filter 20 PPI or 30 PPI

Heater Speed 2 speeds

Heating level 2 levels

Capacity 1500W

Fig. 7-17

7-6-2 Operating condition

(1) The heater location must insure fresh air inlet

(2) Free space of 20 mm minimum under the device must

be respected to insure air inlet Operating temperature
must be between -20°C and +50°C relative humidity is
to be lower than 85 %.

7-6-3 Operating mode

(1) Ventilation
7
1. The blower may run 2 different speeds, with or Frame
without heating.
(2) Heating

1. Heating mode cannot run when blower is switched

Off.

2. Heating lamp indicator is On only when heating

mode is On.

3. In case of overheating, the device is equipped with

an automatic safety thermostat.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 7-13 Heater

 7-6-4 Maintenance information
(1) Safety:

1. Turn the unit to OFF position and remove the plug.

Wait for the heater to cool down sufficiently.

(2) Cleaning:

1. You may clean the outside of the heater with a damp

cloth. Don't allow water to come into the appliance.

2. Don't use soap or chemicals, with may damage the

housing.

3. Allow sufficient time to dry before plugging the unit

back in the socket.

(3) Air filter maintenance:

1. To avoid any risk of clogging, every six weeks: clean

the air filter or replace if damaged.

2. Filter must be replaced yearly.

Heater 7-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 7-6-5 Troubleshooting
Defect Possible Cause Action
Check fuses position and size. Replace it if
Fuse (*) defective necessary. Always identify the cause before
replacing the defective fuse.

Turn on ignition and/or main battery switch.

The blower is inoperative No Power Make sure that electrical connections

between the battery and the device are
continuous.
Blower switch is defective.
Blower is blocked.
Replace heater.
The blower motor is
defective
Blower doesn't operate at low
The blower is defective Replace heater.
speed
Control the supply voltage on the connector.
Blower provide reduced Operating voltage is not
The voltage of the device and of the vehicle
airflow suitable
must be the same.

Internal short circuit in the Unplug the device (switch off battery power
The device can't be stopped
device supply) and contact your distributor.

ON the ventilation. (Heater element could be

The ventilation switch is
The heater is inoperative activated only when the blower is
OFF
functioning).
Control the supply voltage on the connector.
Operating voltage is not
The voltage of the device and of the vehicle
suitable
The heater works only at must be the same.
reduced power.
The air inlet/outlet is Free up if closed or covered.
closed or plugged. Clean if clogged or replace the air filter.

Check the electrical connection of the

No Power battery, the heater connector and make sure
that the ignition switch is turned ON.

Air is not warmed Check fuses position and size. Replace it if 7

Fuse (*) defective necessary. Always identify the cause before
replacing the defective fuse.
Frame

The Heating element is

Replace heater.
defective
The blown airflow is too
Refer to the blower's defects.
low

Heating power is insufficient The heater is under sized. Replace the device by a more powerful one.

The heating indicator lamp

Contact your distributor.
is defective.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 7-15 Heater

8 Fingertip option
8-1 Overview ........................................................2
Components and circuit ....................................... 2

8-2 Fingertip extension module.........................4

Exterior and specifications ................................... 4
Circuit configuration and key functions ................. 5
Wiring .................................................................. 6
Removal and installation ...................................... 7

8-3 Fingertip armrest unit ..................................8

Exterior and specifications ................................... 8
Circuit configuration and key functions ................10
Wiring .................................................................11
Hydraulic control knobs .......................................12
Forward/reverse switch .......................................13
Removal and installation .....................................14
Disassembly and assembly .................................15

8-4 Control valve – Kayaba (–Jul. 2018) .........19

Exterior and specifications ..................................19
Wiring .................................................................21
How it works .......................................................22
Relief valve adjustments .....................................34
Manual lowering ..................................................38
Removal and installation .....................................39
Disassembly and assembly .................................40

8-5 Control valve – Walvoil (Jul. 2018–) .........41

Exterior and specifications ..................................41
Wiring .................................................................43
How it works .......................................................44
Relief valve adjustments .....................................56
Manual lowering ..................................................58
Disassembly and assembly .................................59
8
Fingertip option

8-6 Steering pressure switch ass'y .................61

Exterior and specifications ..................................61
Wiring .................................................................61
Pump motor operation at steering .......................62

8-7 Fault diagnosis ...........................................64

Fault display .......................................................64
Troubleshooting ..................................................65
8-1 Overview

Components and circuit

To fingertip extension module

To F_CONN B of harness
To F_CONN A of harness

To control valve Solenoid A

To control valve Solenoid B
To control valve Solenoid C

To EM CONN of harness
To CAN CONN of armrest

To EM CONN of armrest

0963E
Fig. 8-1

Overview 8-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Fig. 8-2
The fingertip option makes using the hydraulic controls
easier by replacing the levers with electronic knobs that
add a wide range of functionality, including automatic
control, diagnosis, and calibration.

For this option, the vehicle is equipped with the following

components:

• Fingertip extension module operates actuators by

sending electronic signals to the control valve as the
operator operates the knobs and carries out various
automatic controls based on parameter settings.
[Section 8-2]
8
• Fingertip arm rest unit provides electronic knobs
Fingertip option

instead of the mechanically operating hydraulic

levers, which can be operated using your fingers.
[Section 8-3]

• Fingertip control valve is an electronically controllable

hydraulic control valve that is equipped with solenoids
at both sides of the spool for each section block.
[Section 8-4 for Kayaba / Section 8-5 for Walvoil]

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-3 Overview

8-2 Fingertip extension module

Exterior and specifications

14 10

9 6

5 1

Fig. 8-3

Items Spec.
Part no. 300611-01010
Input Voltage 36–80 V
Electrical isolation to Heatsink 500 VAC (minimum)
Storage Ambient Temperature Range -50°C to +90°C (-58°F to +194°F)
Operating Ambient Temperature Range -40°C to +50°C (-40°F to +122°F)
Enclosure protection rating IP65
Weight 0.4 kg (0.3 lbs)
Dimensions (W x L x H) 130 x 100 x 39 mm (5.2 x 3.9 x 1.5 in)

Fingertip extension module 8-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Circuit configuration and key functions

Fig. 8-4
The fingertip extension module connects the fingertip
armrest control knobs to the electrical system. Like the
three basic motor controllers, this module interacts with
several actuators to perform automatic control based on
parameter settings.

Connected to the other controllers and the instrument

panel via CAN, this module can exchange data and thus
you can perform diagnosis and calibration using the panel
or EasyView application.
8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-5 Fingertip extension module
 Wiring
The fingertip extension module uses a 14 pin AMP 14 10
connector (Fig. 8-5).
9 6

5 1

Extension module socket

Fig. 8-5

Harness connector
Fig. 8-6
Fingertip extension module connector pins
Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
F_CONN A (1) F_CONN A (2)
4 YL
F_CONN A (5) CAN CONN (4)
1 BK
1352 J1 (J1-2) F_CONN A (3)
5 YL/BK
CAN CONN (3) CAN CONN (1)

2 BK 1352 J1 (J1-1) 6 (N/A)

F_CONN A (6) 7 (N/A)

F_CONN A (2) 8 (N/A)

F_CONN A (3) 9 BR/YL CONN B (7)

3 RD F_CONN A (4) 10 WH CONN A (6)

F_CONN B (2) 11 BR CONN A (7)

F_CONN B (3) 12 VO CONN A (8)

F_CONN B (4) 13 OR CONN B (8)

14 WH/BK CONN B (6)

Fingertip extension module 8-6 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Removal and installation

Preliminary steps

Remove the left floor plate (See Section 7-3).

Procedure
(1) Fingertip extension module
Disconnect connector (2) from fingertip extension
module (1).

(2) Connector

0964E
Fig. 8-7

Loosen bolts (3) and remove fingertip extension (1) Fingertip extension module
module (1).

Follow the steps above in the opposite order to

install the fingertip extension module.
(3) Bolt

0965E
Fig. 8-8

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-7 Fingertip extension module
8-3 Fingertip armrest unit

Exterior and specifications

Auto tilt leveling switch (option)

F/R switch

Knob – LIFT

Knob –TILT

Knob – AUX1

Knob – AUX2

Auto clamp switch Emergency switch

Front cover

Harness ass’y

< Armrest ass’y >

< CAN module > Fig. 8-9

1503E

Fingertip armrest unit 8-8 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Components Items Spec.
220106-00078 (3 Way without horn SW)
220106-00081 (3 Way with horn SW)
Armrest ass’y Part no.
220106-00076 (4 Way without horn SW)
220106-00079 (4 Way with horn SW)
Part no. 300611-01006
Rated voltage DC 12V ± 0.5V
CAN module
Operating temp. -30°C to 80°C (-22°F to 176°F)
Storage temp. -40°C to 125°C (-40°F to 257°F)

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-9 Fingertip armrest unit
 Circuit configuration and key functions

Fig. 8-10
With the fingertip option, the fingertip armrest unit replaces
the hydraulic levers, enabling you to do the same jobs you
did using the hydraulic levers more easily by using your
fingertips.

Unlike the levers, this unit is connected to the fingertip

control valve by three cables since it uses electrical signals
to control hydraulic unit operations as well as
forward/reverse drive shift.

For more details of how the knobs work, see the followings
sections:

Fingertip armrest unit 8-10 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Wiring
The fingertip armrest uses a 6 pin EM connector (Fig. 8-
11) and a 4 pin CAN connector (Fig. 8-12). 3 2 1

6 5 4

EM connector
Fig. 8-11

2 1

4 3

CAN connector
Fig. 8-12
EM connector pins
Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 BU EM SWITCH A In 4 OR EM SWITCH B Out

2 RD EM SWITCH A Out 5 GN HORN

3 WH EM SWITCH B In 6 GY HORN COM

CAN connector pins

Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 YL CAN HI 3 BK GND

2 RD VCC +12V 4 BU CAN LOW

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-11 Fingertip armrest unit
 Hydraulic control knobs

V DC out

4.6V

8° FWD
REV2 28°
Signal “B”

4 YL(SIG2) 2 BK (GND)
2.5V
Signal “A”

0.4V
3YL (SIG1) 1RD (DC5V) 0
26° 26°
NORMAL
RVS 28° FWD 28°
POSITON
0967E

Fig. 8-13

The fingertip armrest includes four identical knobs. Each

knob has two input lines (+5 V and ground) and two output
lines (phases A and B). Both phases remain constant at
2.5 V in neutral, and vary from 0.4 V to 4.6 V, always
totaling 5 V. When their voltages do not make a total of 5
V, the fingertip extension detects the knobs are
malfunctioning and stops the control valve.

Fingertip armrest unit 8-12 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Forward/reverse switch

4 YL(SIG2) 2 BK (GND)

3YL (SIG1) 1RD (DC5V)

° RE
15 V
D
FW 15
°
FWD

NEU

REV

0968E
Fig. 8-14

The F/R (forward/reverse) knob has two input lines (+5 V

and ground) and two output lines (phases A and B).
Powered at 5 V, it signals with different analog voltages
according to the position of its angle: forward, neutral, and

8
reverse as shown in the graph above. The fingertip
extension module converts the signal from this knob into a
digital signal and shares it with other controllers across the
CAN network to determine the vehicle’s drive direction.
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-13 Fingertip armrest unit
 Removal and installation

Connecting harness

The manufacturers Daewon and Grammer supply seats

with differently structured joint parts, and thus they
require different installation/removal procedures.

Remove the EM cable and the CAN cable from CAN connector
the main harness. Main harness
EM connector

0969E
Fig. 8-15

If using a Daewon seat

Loosen hex bolt (4) and nut (2) and remove flat (2) Nut
(3) Flat washer
washers (3 and 5).
(1) Armrest
NOTICE: Be careful not to drop the armrest unit.

Remove armrest unit (1).

Follow the steps above in the opposite order to

install the armrest unit.

If using a Grammer seat (5) Flat washer (4) Hex bolt

0970E

Fig. 8-16
Loosen two hex bolts (3) and the bolt (4) and
then remove the hard washer (2).
(1) Armrest
NOTICE: Be careful not to drop the armrest unit.

Remove armrest unit (1) and rod (6).

(6) Rod (4) Bolt
Follow the steps above in the opposite order to (2) Hard washer
(5) Bracket (3) Hex bolt
install the armrest unit. 0971E
Fig. 8-17

Fingertip armrest unit 8-14 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Disassembly and assembly
You don’t need to all the steps below. Perform only the steps for the part you are working on.

A. Common

Loosen six bolts (1) from the fingertip armrest

unit and remove bottom cover (2).

Fig. 8-18

B. Hydraulic control knob or F/R switch replacement

Disconnect the cables connected to front cover

(1).
 Be careful in cabling when you install them.

Fig. 8-19

Remove hydraulic control knob (2) or F/R switch

(3).
 At installation, check the groove and fit the
front/back sides correctly.

Follow the steps above in the opposite order to 8

replace a new one.
Fingertip option

Fig. 8-20

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-15 Fingertip armrest unit
 C. Emergency button removal/installation

Remove cap (1) of the emergency button using a

thin flat-head screwdriver.

Fig. 8-21

Remove bolt (2) and then emergency button (3).

Fig. 8-22

 Align the emergency button cap with the

groove at installation.

Fig. 8-23

Remove the pin using a plier and remove inner

cap (4).

Fig. 8-24

Fingertip armrest unit 8-16 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Remove emergency button terminal block (5).
Disconnect the cables from the terminals by
removing the bolts.
 Cabling for installation
A – blue
B – red
C – white
D – orange

Follow the steps above in the opposite order to

install the emergency button.

Fig. 8-25

D. CAN module removal/installation

Disconnect all the cables from front cover (1).

Loosen all screws (2) and remove CAN module

(3).

Follow the steps above in the opposite order to

install the CAN module.

Fig. 8-26

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-17 Fingertip armrest unit
 E. Body removal/installation

Remove six larger bolts (1) and then six smaller

bolts (2) from the left cover.

Fig. 8-27

Loosen knob (3) and remove left cover (4).

 Make sure that no cables are pinched when
you reassemble.

Fig. 8-28

Remove bolt (5) and then bracket (6).

Fig. 8-29

Remove two sliding bars (7).

Fig. 8-30

Fingertip armrest unit 8-18 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
8-4 Control valve – Kayaba (–Jul. 2018)

Exterior and specifications

Solenoid B1 – lowering
Fork relief valve Solenoid B2 – tilt-forward
Solenoid C1 – unloading Solenoid B3 – Sideshift to the left

Solenoid B4 – AUX2

Emergency lowering valve

(needle valve)

INLET section

OUTLET section

LIFT
section TILT
AUX1
section
section AUX2
section

Solenoid A4 – AUX2
Solenoid A3 – Sideshift to the right
Solenoid A2 – tilt-back
Solenoid A1 – lift

OUTLET section

AUX2 AUX1
INLET section
8
section section TILT LIFT
section section
Fingertip option

0972E

Fig. 8-31

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-19 Control valve – Kayaba (–Jul. 2018)
 Control valve
Items Spec.
410105-01419 (3 way)
Part no.
410105-01420 (4 way)
Rated flow 85 L/min
Max. pressure 23 MPa (3,336 psi)
Max. back pressure Normal: 0.3 MPa (43.5 psi) / Peak: 1.0 MPa (145.0 psi)
Oil temperature Normal: -20°C to 80°C (-4°F to 176°F) / Peak: 100°C (212°F)

Solenoids

Proportional controlled
Items Unloading solenoid (C)
solenoid (A&B)
Rated voltage DC 24 V
Allowable voltage DC 16–32 V DC 20–32 V
Pulse width modulation control
Current Rating 0.71 A
0.6 A max.
Resistance 30 Ω at 20°C (-4°F) 28.5 Ω at 20°C (-4°F)
Watt consumption 7.5 W at 0.5 A, 20°C (-4°F) 20.2 W at 24V, 20°C (-4°F)
Coil insulation class JIS C 4008 class “H”
Water-proof class JIS D 0203 S2 JIS C 0920
Vibration-proof class JIS D 1601 class “3B”
Continual voltage 28V is allowed. 60%
Current rate Then coil surface temperature is ON: 3 min
under 90°C (194°F) OFF: 2 min

Control valve – Kayaba (–Jul. 2018) 8-20 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Wiring
The fingertip control valve is equipped with three sets of
solenoids A, B, and C, two of which use 8 pin connectors
and the rest one of which uses a 2 pin connector.

Solenoid A connector pins

Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 YL/GN F_CONN B (2) 5 RD/BU F_CONN B (1)

2 RD F_CONN A (6) 6 WH 1352 J1 (J1-10)

3 RD F_CONN A (6) 7 BR 1352 J1 (J1-11)

4 RD F_CONN A (6) 8 VO 1352 J1 (J1-12)

Solenoid B connector pins

Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 BU/BK F_CONN B (4) 5 GN/BK F_CONN B (3)

2 RD F_CONN A (6) 6 WH/BK 1352 J1 (J1-14)

3 RD F_CONN A (6) 7 BR/YL 1352 J1 (J1-9)

4 RD F_CONN A (6) 8 OR 1352 J1 (J1-13)

Solenoid C connector pins

Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 BU/BK F_CONN B (4) 2 GN/RD F_CONN B (5)

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-21 Control valve – Kayaba (–Jul. 2018)
 How it works

A. INLET section
CONTROL VALVE

AUX LIFT/TILT LIFT/TILT

spools spools Load-sensing (1) Compensator
Spool shifting (2) Main relief valve
pilot pressure

(3) Flow regulator

STEERING UNIT
2
25 kgf/cm

(4) Pilot relief vlave (5) Priority (7) Poppet

valve (6) Unloading valve

(8) Steering relief valve

PUMP MOTOR
CONTROLLER

Spring (i) Passage

(h) Chamber (3) Pilot relief valve
(4) Flow regulator Spring
(3-1) Adjuster

(1-1) Plate

(a) Chamber (d) Chamber Spring (b) passage

(e) Chamber (j) Passage (f) Chamber
SEC.E-E (h) Chamber Spring
(1) Compensator
(5) Priority valve B
B
Housing
Poppet (c) Outlet
Spring Set screw

Tank (b) Passage D

Steering relief

(d) Chamber Tank (g) Chamber

D

(2) Main relief valve Spring

Tank (6-1) Shuttle
(g) Chamber
(7) Poppet Spring (6) Unloading solenoid valve
SEC.D-D 0973E

Fig. 8-32

Control valve – Kayaba (–Jul. 2018) 8-22 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 The circuit diagram shows an overall operation in the control valve while the sectional view describes
oil flow in detail. Those components italicized in the text below will be found only in the sectional view.
For a complete understanding of the operation, it is recommended to consult both images when you
read the explanation below.

Flow priority

Oil from pump enters the valve through a passage in the

INLET section. From there it goes to chamber (a) of priority
valve (5). At steering, the spool slides to the right side
dependent on demanded steer flow. When steering wheel is
neutral on the other hand, priority valve (5) keeps the neutral
position and only standby flow goes to steer circuit, allowing
a majority of pump oil the lift/tilt/auxiliary system.

The excessive flow goes to chamber (d). Once its pressure

reaches the set point of steering relief valve (8), it is
released through passage (b) to outlet (c).

Compensator

Compensator (1) keeps the constant difference pressure between

chamber (e) pump pressure, and chamber (f), the higher pressure
of the LIFT or TILT section is selected by plate (1-1). And then, from
chamber (d), compensator (1) divides chamber (e) connecting with
the LIFT or TILT section as priority flow, and chamber (f) connecting
with the AUX section as excessive flow.

Unloading valve

When unloading solenoid valve (6) is de-energized, shuttle (5-1)

keeps the neutral position. As Chamber (g) of poppet (7) is
connected with the tank, poppet (7) opens connecting chamber
(d) to the tank to unload the pump pressure. This unloading
valve is closed when the operator leaves the seat more than
three seconds to disable the fingertip knobs for safety’s sake.

Once unloading solenoid valve (6) is energized, shuttle (5-

1) is shifted, and the pressure of chamber (g) becomes
that of chamber (d). Poppet (7) closes to maintain the
minimum pressure for solenoid source pressure.

Solenoid source pressure

Flow regulator (14) provides a small flow to solenoid source

8
passage (i) from chamber (h). The pressure of passage (i) then
Fingertip option

is supplied to each end of LIFT/TILT/AUX spools to facilitate

their shifting. The magnitude of the pressure is determined by
pilot relief valve (4), and you can set it using adjuster (4-1).

Excessive pressure relief

For safety, main relief valve (2) releases the excessive

pressure once the system pressure reaches its set point.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-23 Control valve – Kayaba (–Jul. 2018)
 B. Lift operation

2
155 kgf/cm

155 kgf/cm2

(1) Lift cylinders

(4) Lift lock poppet

(6) Spool

(8) Compensator

Line A
STEERING
UNIT
25 kgf/cm2

PUMP MOTOR
CONTROLLER

(d-1) Shuttle Sleeve

(5-1) Spring Spring
(4) Lift lock poppet (i) Chamber
(h) Outlet Spring (6) Spool (5) Valve
(l) Passage (m) Passage
(g) Chamber (7) Needle valve
k
(3a) Spring
(3b) Spring Detail “d”

(b) Chamber
(a1) Solenoid valve (b1) Solenoid valve
(fa) Chamber (a) Chamber (j) Oil (fb) Chamber
(c) Chamber
(d) Solenoid source pressure
(e) Drain passage

SEC.D-D 0974E
Fig. 8-33

Control valve – Kayaba (–Jul. 2018) 8-24 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 The circuit diagram shows an overall operation in the control valve while the sectional view describes
oil flow in detail. Those components italicized in the text below will be found only in the sectional view.
For a complete understanding of the operation, it is recommended to consult both images when you
read the explanation below.

LIFT spool shifted

When solenoid a1 is energized on LIFT spool (6), the push

rod of solenoid a1 pushes shuttle (d-1) in proportion with
the input current. The pressure of chamber (fa) then
balances with the force of solenoid a1. Spool (6) slides in
the opposition to solenoid a1 until the pressure of chamber
(fa) equals the force of spring (3a).

Once spool (6) is shifted, a path is opened between

chamber (a) and chamber (g), chamber (c) and chamber
(a). As a result, pump oil enters and opens lift lock poppet
(4) and flows from passage (g) to outlet (h).

Mast lifted

After the opening of lift lock poppet (4), pressure oil

eventually reaches lift cylinders (1) to move them up.

Compensator prioritizing

When LIFT spool (6) is positioned for the lift operation,

compensator (8) is held as shown in Fig. 8-33 since a
pressure along Line A supports the pushing force of the
compensator’s spring. This results in almost cutting off the
supply of pump oil to the AUX sections. Thus, the lift
operation takes priority over any auxiliary operation when
they are demanded at the same time.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-25 Control valve – Kayaba (–Jul. 2018)
 C. Lowering operation

2
155 kgf/cm

155 kgf/cm2

(1) Lift cylinders

(7) Needle valve
(5) Valve (6) Spool
(4) Lift lock
poppet

STEERING
UNIT
(2) Protector 25 kgf/cm2

(3) Flow regulator

PUMP MOTOR
CONTROLLER

(d-1) Shuttle Sleeve

(5-1) Spring Spring
(4) Lift lock poppet (i) Chamber
(h) Outlet Spring (6) Spool (5) Valve
(l) Passage (m) Passage
(g) Chamber (7) Needle valve
k
(3a) Spring
(3b) Spring Detail “d”

(b) Chamber
(a1) Solenoid valve (b1) Solenoid valve
(fa) Chamber (a) Chamber (j) Oil (fb) Chamber
(c) Chamber
(d) Solenoid source pressure
(e) Drain passage

SEC.D-D 0975E
Fig. 8-34

Control valve – Kayaba (–Jul. 2018) 8-26 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 The circuit diagram shows an overall operation in the control valve while the sectional view describes
oil flow in detail. Those components italicized in the text below will be found only in the sectional view.
For a complete understanding of the operation, it is recommended to consult both images when you
read the explanation below.

LIFT spool shifted

When solenoid b1 is energized on LIFT spool (6), the push rod of

solenoid b1 pushes shuttle (d-1) in proportion with the input current.
The pressure of chamber (fb) then balances with the force of
solenoid b1. Spool (6) slides in the opposition to solenoid b1 until
the pressure of chamber (fa) equals the force of spring (3b).

The pilot pressure of chamber (fb) goes into head chamber of valve
(5) through passage (k), moving valve (5) against the force of spring
(5-1) to open a path between passage (m) and passage (l). The
pressure of chamber (i) then is drained to the tank, weakening the
closing force of lift lock poppet (4)—the poppet opens.

Mast lowered

Now, spool (6) opens a path between outlet (h) and the
passage for return oil (j). Consequently, the hydraulic oil
that has supported the pistons of lift cylinders (1) flows out,
lowering the mast. Through its built-in orifice, flow
regulator (3) never allows a large amount of oil to exit lift
cylinders (1) at once, preventing a sudden drop of the mast.

Lift lock poppet closing for safety

If the pilot pressure is lost, for any reason, valve (5) will
return to the neutral position and the path for return oil is
closed. Then, lift lock poppet (4) closes the path for return
oil to stop lowering.

Protector in preparation for a line cutoff

If the line from the control valve to a lift cylinder (1) is

broken, the valve of protector (2) will be shifted to make
the oil in the cylinder pass through its orifice, preventing a
sudden drop of the mast. 8
Needle valve for an emergency lowering
Fingertip option

If the control valve is out of control, you can lower the mast
manually using needle valve (7).
NOTICE: Lowering speed is not controllable. Open the
valve carefully and as slow as possible.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-27 Control valve – Kayaba (–Jul. 2018)
 D. TILT-forward operation

2
155 kgf/cm

(1) Tilt cylinders

(2) Spool

(4) Relief valve

(3) Tilt-lock valve

155 kgf/cm2

Line A
(5) Check valve

(6) Compensator (7) Main relief valve

STEERING UNIT
2
25 kgf/cm

PUMP MOTOR
CONTROLLER

(3) Tilt lock valve (5) Check valve Spring (d-1) Shuttle
Sleeve
(m) Passage (h) Outlet (2) Spool (g) Passage Spring
(k) Orifice (i) Outlet
(l) Orifice
(n) Orifice
(3-1) Spring Relief valve cavity
(3a) Spring
(3b) Spring

Detail “d”

(a) Chamber
(a2) Solenoid (b2) Solenoid
(fa) Chamber (e) Drain passage (b) Chamber (fb) Chamber
(c) Chamber
(d) Solenoid source pressure (j) Passage
(d) Solenoid source pressure 0976E
Fig. 8-35

Control valve – Kayaba (–Jul. 2018) 8-28 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 The circuit diagram shows an overall operation in the control valve while the sectional view describes
oil flow in detail. Those components italicized in the text below will be found only in the sectional view.
For a complete understanding of the operation, it is recommended to consult both images when you
read the explanation below.

TILT spool shifted

When solenoid b2 is energized on TILT spool (2), the push rod of

solenoid b2 pushes shuttle (d-1) in proportion with the input current.
The pressure of chamber (fb) then balances with the force of
solenoid b2. Spool (2) slides in the opposition to solenoid b2 until
the pressure of chamber (fb) equals the force of spring (3b).

Once spool (2) is shifted, a path is opened between

passage (g) and outlet (i), chamber (c) and chamber (a).
Then pressure oil opens load check valve (5) and flows
from passage (g) to outlet (i).

Mast tilted forward

It then flows to the head ends of tilt cylinders (1) through

outlet and the mast tilts forward. Return oil from the rod
ends of tilt cylinders (1) flows through outlet (i) into
passage (j) and then to the tank.

Anti-cavitation

When pump oil passes through TILT spool (2), it goes into
the chamber of tilt lock valve (3) through orifice (k), and the
valve’s spring chamber is opened to the tank through
orifice (l). Tilt lock valve (3) moves against the force of
spring (3-1) and opens a path for return oil between
passage (m) and orifice (n). This has the effect of slowing
down the flow of oil from the rod ends of tilt cylinders (1)
and preventing cavitation in the head ends. If the pump
pressure is lost, for any reason, tilt lock valve (3) will return
to the neutral position and the path for return oil is closed.

Relief valve exclusive to tilt-forward

In the fingertip control valve, there is a relief valve (4) that

works only when tilt-forward is performed (see Fig. 8-35).
Set to a lower relief point than main relief valve (7), it
releases the excessive pressure during tilt-forward.
8
Compensator prioritizing
Fingertip option

When TILT spool (2) is positioned for the tilt-backward

operation, compensator (6) is held as shown in Fig. 8-35
since a pressure along Line A supports the pushing force
of the compensator’s spring. This results in almost cutting
off the supply of pump oil to the AUX sections. Thus, the
tilt-backward operation takes priority over any auxiliary
operation when they are demanded at the same time.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-29 Control valve – Kayaba (–Jul. 2018)
 E. TILT-backward operation

155 kgf/cm2

(1) Tilt cylinders

155 kgf/cm2

(2) Spool

(6) Compensator

STEERING UNIT
25 kgf/cm2

PUMP MOTOR
CONTROLLER

(3) Tilt lock valve (5) Check valve Spring (d-1) Shuttle
Sleeve
(m) Passage (h) Outlet (2) Spool (g) Passage Spring
(k) Orifice (i) Outlet
(l) Orifice
(n) Orifice
(3-1) Spring Relief valve cavity
(3a) Spring
(3b) Spring

Detail “d”

(a) Chamber
(a2) Solenoid (b2) Solenoid
(fa) Chamber (e) Drain passage (b) Chamber (fb) Chamber
(c) Chamber
(d) Solenoid source pressure (j) Passage
(d) Solenoid source pressure 0977E
Fig. 8-36

Control valve – Kayaba (–Jul. 2018) 8-30 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 The circuit diagram shows an overall operation in the control valve while the sectional view describes
oil flow in detail. Those components italicized in the text below will be found only in the sectional view.
For a complete understanding of the operation, it is recommended to consult both images when you
read the explanation below.

TILT spool shifted

When solenoid a2 is energized on TILT spool (2), the push

rod of solenoid a2 pushes shuttle (d-1) in proportion with
the input current. The pressure of chamber (fa) then
balances with the force of solenoid a2. Spool (2) slides in
the opposition to solenoid a2 until the pressure of chamber
(fa) equals the force of spring (3a).

Once spool (2) is shifted, a path is opened between

passage (g) and outlet (h), chamber (c) and chamber (a).
Then pressure oil opens load check valve (5) and flows
from passage (g) to outlet (h).

Mast tilted backward

It then flows to the rod ends of tilt cylinders (1) through

outlet and the mast tilts back. Return oil from the head
ends of tilt cylinders (1) flows through outlet (i) into
passage (j) and then to the tank.

Compensator prioritizing

When TILT spool (2) is positioned for the tilt-backward

operation, compensator (6) is held as shown in Fig. 8-36
since a pressure along Line A supports the pushing force
of the compensator’s spring. This results in almost cutting
off the supply of pump oil to the AUX sections. Thus, the
tilt-backward operation takes priority over any auxiliary
operation when they are demanded at the same time.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-31 Control valve – Kayaba (–Jul. 2018)
 F. AUX section
(2) Relief valve
155 kgf/cm2

(1) Auxilirary cylinder

(3) Spool
(4) Check valve

155 kgf/cm2

(5) Compensator
(6) Main relief valve

STEERING UNIT
2
25 kgf/cm

PUMP MOTOR
CONTROLLER

(4) Check valve Spring

(c) Chamber
(g) Passage (d-1) Shuttle Sleeve
(3) Spool (h) Outlet (i) Outlet Spring
(m) Passage

(3a) Spring
(3b) Spring

Detail “d”

(a3) Solenoid (b) Chamber (a) Chamber (b3) Solenoid

(fa) Chamber (d) Solenoid source pressure (fb) Chamber
(e) Drain passage (j) Passage 0978E
Fig. 8-37

Control valve – Kayaba (–Jul. 2018) 8-32 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 The circuit diagram shows an overall operation in the control valve while the sectional view describes
oil flow in detail. Those components italicized in the text below will be found only in the sectional view.
For a complete understanding of the operation, it is recommended to consult both images when you
read the explanation below.

AUX spool shifted

When solenoid a3 is energized on AUX spool (3), the push

rod of solenoid a3 pushes shuttle (d-1) in proportion with
the input current. The pressure of chamber (fa) then
balances with the force of solenoid a3. Spool (3) slides in
the opposition to solenoid a3 until the pressure of chamber
(fa) equals the force of spring (3a).

Once spool (3) is shifted, a path is opened between

passage (g) and outlet (i) and oil flow from chamber (b) to
chamber (a) is stopped. This causes the oil pressure to
increase and opens load check valve (4). The pressure oil
from the pump can now flow from passage (g) to outlet (h).
The path for return opens from outlet (i) to chamber (j).

Attachment operated

As a result, pump oil flows to the rod end of auxiliary

cylinder (1) and return oil is drained from the head end to
the tank, moving the attachment in the demanded way.

When solenoid b3 is energized, the attachment moves in

the opposite way.

Relief valve exclusive to attachment operations

In the fingertip control valve, there is a relief valve (2) that

works only when an axillary is operated (see Fig. 8-37).
Set to a lower relief point than main relief valve (6), it
releases the excessive pressure during attachment
operations.

Compensator prioritizing 8
When neither lifting nor tilting is operated, compensator (5)
Fingertip option

is held as shown in Fig. 8-37 since the pushing force of the

compensator’s spring could not be supported by pressure
oil. Thus the AUX sections are fully supplied with pump oil
while the LIFT and TILT sections receive a very small
amount of oil.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-33 Control valve – Kayaba (–Jul. 2018)
 Relief valve adjustments

Pressure-checking adapter
Tools needed Pressure tube
28,000 kPa (4061 psi) gauge

Preliminary steps
<Pressure-checking adapter>
Move the vehicle to a level surface where you
can fully extend the mast.

Take out the floor plate (See Section 7-3). <Pressure tube>

<Pressure gauge>

With the key off, remove hose from pump port

(1).

DANGER

Pressurized hydraulic oil will cause

severe burns, and infection that may
even result in amputation.
Be extremely careful not to allow the
disconnected hose and port to discharge
pressure oil onto your body.

Connect the 28,000 kPa (4061 psi) gauge to port

(1).
Fig. 8-38

Control valve – Kayaba (–Jul. 2018) 8-34 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Main relief valve check and adjustment

Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating
temperature.

Without a load on the forks, extend the mast to

its maximum height.

While holding the control knob in position, watch

the gauge.
 The value the gauge indicates is the current
pressure at which the relief valve is opened at
the end of a cylinder stroke.

Check whether the reading on the gauge

matches the corresponding figure for your
vehicle model in the table.

Main relief pressure

Models
kPa psi
B15/18/20T-7
21,550±250 3,125±35
B16/18/20X-7

If it does not, loosen jam nut (2) and then turn

setscrew (3) either clockwise to increase or
counterclockwise to decrease the pressure
setting of the relief valve according to your need.

(2) Jam nut (3) Setscrew

1517E
Fig. 8-39
8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-35 Control valve – Kayaba (–Jul. 2018)
 Tilt-forward relief valve check and adjustment

Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating
temperature.

Tilt the mast fully forward.

While holding the control knob in position, watch

the gauge.
 The gauge indicates is the current pressure at
which the relief valve is opened at the end of a
cylinder stroke.

Check whether the reading on the gauge

matches the corresponding figure for your
vehicle model in the table.

Tilt-forward relief pressure

Models
kPa psi
B15/18/20T-7
14,000±350 2,040±50
B16/18/20X-7

If it does not, loosen jam nut (4) and then turn

setscrew (5) either clockwise to increase or
counterclockwise to decrease the pressure
setting of the relief valve according to your need.

(5) Setscrew (4) Jam nut 1516E

Fig. 8-40

Control valve – Kayaba (–Jul. 2018) 8-36 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Secondary relief valve check and adjustment

Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating
temperature.

Sideshift the mast in either direction.

While holding the control knob in position, watch

the gauge.
 The gauge indicates is the current pressure at
which the relief valve is opened at the end of a
cylinder stroke.

Check whether the reading on the gauge

matches the corresponding figure for your
vehicle model in the table.

Secondary relief pressure

Models
kPa psi
B15/18/20T-7
14,000±350 2,040±50
B16/18/20X-7

If it does not, loosen jam nut (6) and then turn (7) Setscrew (6) Jam nut

setscrew (7) either clockwise to increase or

counterclockwise to decrease the pressure
setting of the relief valve according to your need.

1518E

Fig. 8-41

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-37 Control valve – Kayaba (–Jul. 2018)
 Manual lowering
The needle valve is used to manually lower the mast when
the regular lowering operation by the fingertip knob is
disabled.

Turn the key switch off and open the control

valve cover.

Loosen lock nut (1) using a spanner.

Turn screw (2) 2–3 times counterclockwise very

slowly using an L wrench.

DANGER

A sudden drop of the mast can cause

a serious accident.
Turn the adjusting screw slowly, looking Fig. 8-42
at the lowering of the mast.

Once the carriage reaches the ground, tighten

screw (2) and lock it with lock nut (1).

Control valve – Kayaba (–Jul. 2018) 8-38 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Removal and installation
Preliminary steps

Prepare an oil pan.

Remove the control valve cover.

Procedure

Give each port and its connection, adaptor or

plug a corresponding mark as a reference for
assembly.

Disconnect electrical connectors (1) and hose

adaptors (2) and then plug and cap those that
are connected to hydraulic hoses.
 Have the oil pan ready to catch any oil that will
come out of the hoses and cylinder ports. Fig. 8-43

DANGER

Pressurized hydraulic oil will cause

severe burns, and infection that may
even result in amputation.
Be extremely careful not to allow the
disconnected hoses and ports to
discharge pressure oil onto your body.

While supporting control valve (1), remove four

bolts (4) from the frame.

Follow the steps above in the opposite order to

install the control valve.

Refill the tank with hydraulic oil according to the

specifications given in Section 1-6.
Fig. 8-44

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-39 Control valve – Kayaba (–Jul. 2018)
 Disassembly and assembly

Preliminary steps

Remove the control valve (See Section 8-4-6).

Clean the valve using compressed air or cloth

before disassembly.

Removal/installation (1) Nuts

Loosen nuts (1) on the tie rods and take the

section blocks out.
 Be careful not to lose any parts between the
sections.
 Do not remove a spool before the section
block is taked out of the tie rods.

Follow the steps above in the reverse order to

assemble the control valve.

1502E

Fig. 8-45

Control valve – Kayaba (–Jul. 2018) 8-40 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
8-5 Control valve – Walvoil (Jul. 2018–)

Exterior and specifications

outlet section ass’y

Aux section ass’y

S/shift section ass’y

Tilt section ass’y

Lift section ass’y

Inlet section ass’y

1500E

Fig. 8-46

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-41 Control valve – Walvoil (Jul. 2018–)
 Control valve
Items Spec.
410105-01723 (3 way)
Part no.
410105-01724 (4 way)
Max. work port flow 90 L/min
Max. Inlet flow 120 L/min
Max. pressure 30,000 KPa (4,351 psi)
Max. backpressure 1,000 KPa (145 psi)
Stand-by pressure 1,400 KPa (203 psi)
Fluid Mineral based oil
Viscosity range 12 to 400 mm2/s
Seal material NBR-FPM
Temperature range of the fluid -20°C to +90°C (-4°F to + 194°F)
Environmental temperature -20°C to +50°C (-4°F to + 122°F)
Max. level of contamination of the fluid 18/15 ISO-4406
3
9 cm /min at 10,000 KPa (1,450 psi), 40°C
Internal leakage (A1)
(104°F) and 46mm2/s
14 cm3/min at 10,000 KPa (1,450 psi), 40°C
Internal leakage (A2,B2,A3,B3)
(104°F) and 46mm2/s
100 cm3/min at 10,000 KPa (1,450 psi), 40°C
Internal leakage check valve
(104°F) and 46mm2/s

Electrical features
Items Spec.
Nominal voltage DC 24 V
Electrical resistance coil at 20°C 20.8 Ohm
Max current 0.75 A
Hysteresis 20-30 mA
Suggested dither frequency 180 Hz
Suggested dither amplitude 200 mA
Starting current 350 mA
End stroke current 625 mA
Pilot pressure initial stroke 600 KPa (87 psi),
Pilot pressure end of stroke 2,200 KPa (319 psi),

Control valve – Walvoil (Jul. 2018–) 8-42 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Wiring
The fingertip control valve is equipped with three sets of
solenoids A, B, and C, two of which use 8 pin connectors
and the rest one of which uses a 2 pin connector.

Solenoid A connector pins

Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 YL/GN F_CONN B (2) 5 RD/BU F_CONN B (1)

2 RD F_CONN A (6) 6 WH 1352 J1 (J1-10)

3 RD F_CONN A (6) 7 BR 1352 J1 (J1-11)

4 RD F_CONN A (6) 8 VO 1352 J1 (J1-12)

Solenoid B connector pins

Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 BU/BK F_CONN B (4) 5 GN/BK F_CONN B (3)

2 RD F_CONN A (6) 6 WH/BK 1352 J1 (J1-14)

3 RD F_CONN A (6) 7 BR/YL 1352 J1 (J1-9)

4 RD F_CONN A (6) 8 OR 1352 J1 (J1-13)

Solenoid C connector pins

Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 BU/BK F_CONN B (4) 2 GN/RD F_CONN B (5)

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-43 Control valve – Walvoil (Jul. 2018–)
 How it works

A. Pressure-reducing valve and compensators

(5) Pressure-reducing valve (1) Compensator (2) Spool
Main load-sensing line

(4) Compensator

(3) Solenoid
valves

1513E

Dedicated to fingertip forklifts, this control valve features a Fig. 8-47

pressure-reducing valve (5) and main and sectional
compensators (1 & 4). These devices must be understood
to figure out how the control valve works.

Pressure-reducing valve to render pilot signals

Pressure-reducing valve (5) serves to reduce the pressure

of incoming pump oil to approximately 3,000–3,500 kPa
(435–508 psi) and such depressurized oil is used as pilot
pressure signals to shift spools (2).

This pilot oil is delivered to solenoid valves (3) at both ends

of each spool (2). If a solenoid valve (3) opens, the pilot oil
reaching there flows in to shift spool (2).

Main compensator to build up working pressure

When no hydraulic commands are inputted, main

compensator (4) is open to drain incoming pump oil. But
once a spool (2) is shifted to fill the main load-sensing line,
main compensator (4) is pushed to get closed and stops
draining pump oil. This results in building up pressure in
the control valve high enough for hydraulic operations.

Control valve – Walvoil (Jul. 2018–) 8-44 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Sectional compensators to ensure concurrent hydraulic operations

If the operator moves two knobs at the same time to

operate two different hydraulic actuators on the front end,
you may expect that the lighter-loaded actuator swiftly
takes most of pump oil to move while the heavier-loaded
one nearly stands still. This means failure in concurrent
hydraulic operations.

But the control valve is equipped with a compensator (1)

at each working section to ensure the concurrent operation
of two different actuators. Let us take as an example the
concurrent performance of the lift and tilt operations.
(1-2) Compensator
(1-1) Compensator
At first, both lift- and tilt-sectional compensators (1-1 & 1- Main load-sensing line

2) are shifted by the pump oil coming in through each spool Pump oil
(2-1 & 2-2) as shown in Fig. 8-48. This incoming oil fills the
main load-sensing line as this line is connected with the
compensators.
(2-1) Spool
Once the pump oil pressure in the control valve reaches
the pressure capable of acting on the tilt cylinders—which
require lower working pressure—the pressure build-up in
the tilt section is halted as the oil therein is about to move (2-2) Spool
the cylinder rods. Meanwhile, the pressure in the lift
section keeps building up (because the lift cylinders
require higher pressure) and the pressure in the main load-
sensing line builds up as well at the same rate. 1514E

Fig. 8-48

As a result, the main load-sensing line pressure becomes

(1-2) Compensator
stronger than the tilt section pressure to forcibly back tilt- (1-1) Compensator
sectional compensator (1-2) as shown in Fig. 8-49, which Main load-sensing line

then cuts off most of pump oil supply to the tilt cylinders. Pump oil

At this point, the oil out of tilt spool (2-2) pressurizes again
but its pressure remains weaker than the main load-
sensing line pressure and thus tilt-sectional compensator
(1-2) stays nearly closed. This prevents the oil (2-1) Spool

8
downstream of tilt-sectional compensator (1-2) from
pressurizing and thus the tilt cylinder rods stand still.

(2-2) Spool
This status is maintained until the main pressure becomes
Fingertip option

high enough to move the heavier-loaded lift cylinders.

Once this pressure is reached, the main load-sensing
pressure no longer builds up while the lift cylinder rods are
1515E
pushed up; consequently, tilt-sectional compensator (1-2) Fig. 8-49
is shifted by the oil flowing out of tilt spool (2-2) to let oil
into the tilt cylinders. At the moment, both the lift and tilt
cylinder rods are moved by pressure oil.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-45 Control valve – Walvoil (Jul. 2018–)
 B. Lift operation
[LIFT] [Inlet]

D
(1) Compensator

C
B (3) Main relief valve

(2) Spool
(2-1) Solenoid valve

(4) Lift cylinders

1508E

Fig. 8-50

Control valve – Walvoil (Jul. 2018–) 8-46 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 When lift command is inputted

Moving the lift knob to the lift position signals the lift
solenoid valve (2-1) to open. Pilot pressure oil then flows
in to shift spool (2) for the lift operation.

Consequently, pump oil is allowed through spool (2) and

reaches compensator (1). Oil in line A pushes the normally
closed compensator (1) to open, which in turn opens a
passage for the main oil in line B to travel into lift cylinders
(4). This inflowing oil pushes up the lift cylinder rods along
with the mast.

When lift command is stopped

When the lift command from the knob is stopped, spool (2)
drains pilot pressure oil and returns to neutral to cut off all
oil supply to compensator (1) and lift cylinders (4). Then,
the remaining oil in line D pushes compensator (1) back to
its original position.

Excessive pressure relief

A role of oil from line C is to convey the main working

pressure onto main relief valve (3). Once the pressure
reaches the set relief limit, main relief valve (3) opens to
relieve excessive pressure for the purpose of safety.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-47 Control valve – Walvoil (Jul. 2018–)
 C. Lower operation
[LIFT] [Inlet]

(1-1) Solenoid valve

(1) Spool

(2) Lift cylinders

(3) Flow
protector (4) Lift lock solenoid

(5) Flow regulator

1509E

Fig. 8-51

Control valve – Walvoil (Jul. 2018–) 8-48 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 When lower command is inputted

Moving the lift knob to the lower position signals the lower
solenoid valve (1-1) to open. Pilot pressure oil then flows
in to shift spool (1) for the lower operation.

Consequently, the oil held in lift cylinders (2) is allowed

through spool (1) to be withdrawn. The oil in lift cylinders
(2) is then pushed by the pistons under gravitational force
to return to the control valve and be drained into the tank.

Disablement of lower command for safety

For the purpose of safety, when the operator leaves the

seat, this forklift model stops the oil supply from the main
hydraulic pump in order to prevent the actuators from
working even if the knobs are moved. However, there
needs to be another device to limit the lower function in
this situation because lowering is not actuated by oil but
by gravitational force.

Once the operator leaves the seat for more than three
seconds, lift lock solenoid (4) is powered off to close. Then,
the oil inside lift cylinders (2) is no longer able to flow out
through lift lock solenoid valve (4) and therefore moving
the lift knob cannot drain oil from cylinders (2) to lower the
mast.

In this situation, if you are to manually lower the mast, you

should adjust spool (1) by hand to allow the hydraulic oil
that has held the pistons in place to be drained with the
mast being lowered.

NOTICE: When you use the needle valve, make sure to

follow the appropriate procedure in Section 5-2-4.

Other safety features

When the mast is lowered. flow regulator (5) uses its built-
in orifice to prevent lift cylinders (2) from draining a large 8
amount of oil at once, which otherwise causes a sudden
drop of the mast.
Fingertip option

If the line from the control valve to any lift cylinder (2) is
broken, protector’s (3) valve will be shifted to make the oil
in the cylinder pass through its orifice, preventing a sudden
drop of the mast.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-49 Control valve – Walvoil (Jul. 2018–)
 D. Tilt-forward operation
[TILT]

(2-1) Solenoid

D
(1) Compensator

C
B

(2) Spool

(3) Relief valve

(4) Counterbalance valve

(5) Tilt cylinders

1510E

Fig. 8-52

Control valve – Walvoil (Jul. 2018–) 8-50 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 When tilt-forward command is inputted

Moving the tilt knob to the forward position signals the tilt-
forward solenoid valve (2-1) to open. Pilot pressure oil then
flows in to shift spool (2) for the tilt-forward operation.

Consequently, pump oil is allowed through spool (2) and

reaches compensator (1). Oil in line A pushes the normally
closed compensator (1) to open. This opens a passage for
the main oil in line B to travel into tilt cylinders’ (5) head
chambers and another passage to allow the oil in the rod
chambers to get drained through spool (2). As a result, the
tilt cylinder rods are pushed forward along with the mast.

Anti-cavitation

A counterbalance valve (4) is built between the two tilt

cylinder lines. This ensures the oil in the rod chambers
remains held until a substantial pressure builds up in the
head chambers to open up counterbalance valve (4)
against its spring force, thereby preventing cavitation.

When tilt-forward command is stopped

When the tilt-forward command from the knob is stopped,

spool (2) drains pilot pressure oil and returns to neutral to
cut off all oil supply to compensator (1) and tilt cylinders
(5). Then, the remaining oil in line D pushes compensator
(1) back to its original position.

Excessive pressure relief

Once the pressure in the tilt section reaches the set relief
limit, relief valve (3) opens to relieve excessive pressure
for the purpose of safety.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-51 Control valve – Walvoil (Jul. 2018–)
 E. Tilt-backward operation
[TILT]

D
(1) Compensator

C (2-1) Solenoid valve

B

(2) Spool

(3) Relief valve

(5) Tilt cylinders

1511E

Fig. 8-53

Control valve – Walvoil (Jul. 2018–) 8-52 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 When tilt-backward command is inputted

Moving the tilt knob to the backward position signals the

tilt-backward solenoid valve (2-1) to open. Pilot pressure
oil then flows in to shift spool (2) for the tilt-backward
operation.

Consequently, pump oil is allowed through spool (2) and

reaches compensator (1). Oil in line A pushes the normally
closed compensator (1) to open. This opens a passage for
the main oil in line B to travel into tilt cylinders’ (5) rod
chambers and another passage to allow the oil in the head
chambers to get drained through spool (2). As a result, the
tilt cylinder rods are pushed backward along with the mast.

When tilt-backward command is stopped

When the tilt-backward command from the knob is stopped,

spool (2) drains pilot pressure oil and returns to neutral to
cut off all oil supply to compensator (1) and tilt cylinders
(5). Then, the remaining oil in line D pushes compensator
(1) back to its original position.

Excessive pressure relief

Once the pressure in the tilt section reaches the set relief
limit, relief valve (3) opens to relieve excessive pressure
for the purpose of safety.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-53 Control valve – Walvoil (Jul. 2018–)
 F. Auxiliary operations (sideshift/clamping)
[AUX]

(2-1) Solenoid valve

(1) Compensator

C
B

(2) Spool

(3) Relief valve

(4) Attachment cylinder

1512E

Fig. 8-54

Control valve – Walvoil (Jul. 2018–) 8-54 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Fig. 8-54 shows the hydraulic circuit when the left siedshift
operation is performed. But the description below can
apply to the operations in both directions in any auxiliary
section.

When a command is inputted

Moving the knob signals the corresponding solenoid valve

(2-1) to open. Pilot pressure oil then flows in to shift spool
(2) for the intended operation.

Consequently, pump oil is allowed through spool (2) and

reaches compensator (1). Oil in line A pushes the normally
closed compensator (1) to open. This opens a passage for
the main oil in line B to travel into one chamber of cylinder
(4) and another passage to allow the oil in the other
chamber to get drained through spool (2). As a result, the
cylinder rod is pushed along with the mast.

When a command is stopped

When a command from the knob is stopped, spool (2)

drains pilot pressure oil and returns to neutral to cut off all
oil supply to compensator (1) and cylinder (4). Then, the
remaining oil in line D pushes compensator (1) back to its
original position.

Excessive pressure relief

Once the pressure in the section reaches the set relief limit,
relief valve (3) opens to relieve excessive pressure for the
purpose of safety.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-55 Control valve – Walvoil (Jul. 2018–)
 Relief valve adjustments

Pressure-checking adapter
Tools needed Pressure tube
28,000 kPa (4061 psi) gauge

Preliminary steps
<Pressure-checking adapter>
Move the vehicle to a level surface where you
can fully extend the mast.

Take out the floor plate (See Section 7-3). <Pressure tube>

<Pressure gauge>
Fig. 8-55

With the key off, remove hose from pump port

(1).

DANGER

Pressurized hydraulic oil will cause

severe burns, and infection that may
even result in amputation.
Be extremely careful not to allow the
disconnected hose and port to discharge
pressure oil onto your body.
Fig. 8-56

Connect the 28,000 kPa (4061 psi) gauge to port

(1).

Control valve – Walvoil (Jul. 2018–) 8-56 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Main relief valve check and adjustment

Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating
temperature.

Without a load on the forks, extend the mast to

its maximum height.

While holding the control knob in position, watch

the gauge.
 The value the gauge indicates is the current
pressure at which the relief valve is opened at
the end of a cylinder stroke.

Check whether the reading on the gauge

matches the corresponding figure for your
vehicle model in the table.

Main relief pressure

Models
kPa psi
B15T-7 17,260±250 2,500±35
B18T-7
19,520±250 2,830±35
B16/18X-7
B20T-7
21,180±250 3,070±35
B20X-7

If it does not, loosen jam nut (2) and then turn

setscrew (3) either clockwise to increase or
counterclockwise to decrease the pressure
setting of the relief valve according to your need.

NOTICE: For this model, only the main relief valve is

adjustable.

Fig. 8-57 8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-57 Control valve – Walvoil (Jul. 2018–)
 Manual lowering
This procedure is used to manually lower the mast when
the regular lowering operation by the fingertip knob is
disabled.

Remove the control valve cover and floor plate.

Locate lift lock solenoid valve (0).

Fig. 8-58
Push and twist manual override button (2) on lift
lock solenoid valve (1) counterclockwise half a
turn until the knob pops out to open the lift lock
solenoid valve.

Fig. 8-59

Loosen lock nut (3) on the lift section using a 10

mm spanner.

Turn set screw (4) counterclockwise very slowly

to move the lift spool manually to neutral.

DANGER

A sudden drop of the mast can cause

a serious accident.
Turn the adjusting screw slowly, looking 19±1 mm
(when locked)
at the lowering of the mast.

Once the carriage reaches the ground, tighten

screw (2) and lock it with lock nut (1).
 When lock nut (1) is completely tightened, The
distance between lock nut (3) and the end of Fig. 8-60
set screw (4) must approximately 19±1 mm
(0.748±0.04 in).

Push and twist lift lock solenoid valve (0)

clockwise to the detented lock position.

Control valve – Walvoil (Jul. 2018–) 8-58 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 Disassembly and assembly

(4) Washers

(3) Tie rods

outlet section ass’y

Aux section ass’y

Sideshift section ass’y

Tilt section ass’y

(1) Nuts Lift section ass’y

(2) Washers Inlet section ass’y 1501E

Fig. 8-61

Preliminary steps

Remove the control valve (See Section 8-4-6).

Clean the valve using compressed air or cloth

before disassembly.

Disassembly

Unscrew mounting nuts (1) and remove washers

(2).

Carefully take out the section blocks from tie

rods (3) and keep them in a clean area with the
mounting holes at the bottom.

Close all the ports with protective plugs. 8

Assembly
Fingertip option

Check that the butting faces of each section

block are free of burrs, damages and rust.
 If any defect is found on the O-ring facing side,
replace the section block.

Blow the O-ring grooves on each section block

with compressed air.

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-59 Control valve – Walvoil (Jul. 2018–)
 Put the section blocks on tie rods (3) one by one
in the order shown in Fig. 8-61. Make sure that:
 Washers (4) are first put on tie rods (3).
 O-rings are properly fitted between blocks.
 All parts are put in place as shown in Fig. 8-61.

Put washers (2) and then tighten nuts (1) to a

torque of 35 N·m (25.8 lb·ft).
 The nuts must not be loosened by hand.

Control valve – Walvoil (Jul. 2018–) 8-60 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
8-6 Steering pressure switch ass'y

Exterior and specifications

Fig. 8-62

Items Spec.
Part no. A154432
Actuation pressure Max. 710 kPa
Deactuation pressure Min. 420 kPa
System pressure 140 to 6,900 kPa
Proof pressure 13,800 kPa
Burst pressure 34,500 kPa
Switch type Normally closed

Wiring
The steering pressure sensor uses a 2 pin connector to
connect it with the pump motor controller.
Pin Wiring Pin Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 RD/GN Pump motor controller (P1-25) 2 YL/WH Pump motor controller (P1-6)

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-61 Steering pressure switch ass'y
 Pump motor operation at steering

STEERING CYLINDER

STEERING UNIT

< Pump motor speed at steering and at no command received >

CONTROL VALVE

AUX LIFT/TILT LIFT/TILT

spools spools Load-sensing
Spool shifting
pilot pressure

25 kgf/cm2

(1) Priority
valve

(2) Steering relief valve

MAIN HYDRAULIC PUMP Load-sensing line

PUMP MOTOR
CONTROLLER

(3) Pressure switch ass’y

0979E
Fig. 8-63

Steering pressure switch ass'y 8-62 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS
 In the case of the manual type, if you turn the steering
wheel only without any other command, the pump motor
will become at the idle and then come to a stop in a number
of seconds, disabling even the steering operation. It is
because there is no way the pump motor controller detects
the operator’s steering demand. On the contrary, the
fingertip option enables such detection, so that the
controller may keep the pump motor rotating as long as
the operator is turning the steering wheel.

It is pressure switch ass’y (3) that is added to the steering

system for this function. The load-sensing pressure is sent
to pressure switch ass’y (3) in addition to priority valve (1).
This switch ass’y then convert the oil pressure signal to a
digital signal and transfer it to the fingertip extension
module, and this module to the pump motor controller via
the CAN protocol. Thus the pump motor controller
continues to rotate the pump motor at 500 rpm while the
steering wheel is turning as shown in the graph in Fig. 8-
63. Once the steering wheel stops turning, the controller
rotates the motor at the idle (200 rpm) for ten seconds and
then enters the PP mode (motor stops).

Note that you cannot make the pump motor restart from a
complete stop by turning the steering wheel in the fingertip
option either. It is because the signaling of switch pressure
ass’y (3) needs some pressure oil, which is supplied only
when the pump is operating.

The basic operations of the steering system are the same

as that of the manual type with the exception the location
of priority valve (1) and relief valve (2) in the control valve.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-63 Steering pressure switch ass'y
8-7 Fault diagnosis

Fault display
You can view the fault code and the fault text displayed in
the red area in Fig. 8-64:

Fig. 8-64

Fault
Description (Fingertip Controller PIN No.) Display Text
Code
Internal Fault (Curtis code 11)
EF EEPROM Fault (Curtis code 12) EXTENSION FAULT
Over/Under Temp (Curtis code 23, 24)
L1 Lift sol (J1-12) open/short LIFT SOL FAULT
L2 Lowering sol (J1-13) open/short LOW SOL FAULT
L3 Tilt Forward sol (J1-11) open/short TILT FWD SOLFAU
L4 Tilt Backward sol (J1-9) open/short TILT BACK SOLFAU
L5 AUX1 Left sol (J1-10) open/short AUX1 L-SOLFAU
L6 AUX1 Right sol (J1-14) open/short AUX1 R-SOLFAU
L7 AUX2 Left sol (P1-2) open/short AUX2 L-SOLFAU
L8 AUX2 Right sol (D2-2) open/short AUX2 R-SOLFAU
L9 ISO (STD), Unloading SOL (Fingertip OPT) (P1-5) open/short ISO/UNLOAD SOL
21 OverVoltager/UnderVoltage (Curtis code 21, 22) EXT VOLT FAULT
PDO Timeout/SDO Fault (Curtis code 51, 52)
51 CAN BUS Fault (Curtis code 53) EXT TIME FAULT

C1 Total Current Exceeded 18A (Curtis code 25) EXT CUR FAULT
C2 12V/5V Power supply fault (Curtis code 13, 14, 15) EXT POWER FAULT
FF Fingertip knobs out of range FINGERTIP FAULT
LL Fingertip CAN module CAN communicaion Fault F-KNOB CAN FAU

Fault diagnosis 8-64 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Troubleshooting

Knob does not move

From EasyView, check if the parameter Enable

Fingertip is enabled (1).

Fig. 8-65

Check if any errors have occurred.

If there is no error, check the output of <Fingertip

and Valve> from Test Menu and then replace the
knobs if there is no knobs signal.

8
Fingertip option

Fig. 8-66

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-65 Fault diagnosis

 Power supply fails

Check the PIN J1-3 of the fingertip extension

module.
 Measurements of J1-3 (Battery+) and J1-1
(GND) should equal the same voltage as the
battery.

If your measurement does not meet the specified

amount, check the fingertip harness for any
Fig. 8-67
faulty connection between 1352 J1 #3 and
F_CONN A #6; J1-1 and F_CONN A #1 or #5;
and J1-2 and F_CONN A #1 or #5.

Fault diagnosis 8-66 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Mast lifting is abnormal

If the error code L1 is displayed on the instrument panel:

Check if the connector is connected to the lifting

solenoid valve coil.

If the connection is fine, check the readings of the

Knob Lift Command and the Lift Sol Current when
the lift knob is completely held back.
 The maximum readings are: 1000 for Knob Lift
Command and 490–520 mA for Lift Sol
Current.

Fig. 8-68
If the Knob Lift Command reads “0,” change the
lift knobs.

Change the CAN module if the problem

continues even after you have replaced the lift
knob.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-67 Fault diagnosis

 If no error is displayed on the instrument panel:

If the pump motor operation fails, check if the

parameter Enable Fingertip is ON from <Truck
Setup>, Calibration, EasyView.

Fig. 8-69

Fault diagnosis 8-68 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Mast lowering is abnormal.

If the error code L2 is displayed on the instrument panel:

Check if the connector is normally connected to

the lowering solenoid valve coil.

If the connection is fine, check the readings of the

Knob Lower (On/Off) and the Lower Sol Current
when the lift knob is completely pushed forward.
 The specified readings are: 1 for Knob Lower
(On/Off) and 490mA for Lower Sol Current.

Fig. 8-70
If the Knob Lower (On/Off) reads “0,” change the
lift knob.

Change the CAN module if the problem persists

even after you have replaced the lift knob.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-69 Fault diagnosis

 If no error is displayed on the instrument panel:

If the pump motor operation fails, check if the

parameter Enable Fingertip is set to ON from
<Truck Setup>, Calibration, EasyView.

Fig. 8-71
If the problem persists, check from EasyView if
the unloading valve is in normal operation and if
the PWM reading is normal, i.e. 50%.

Fig. 8-72
If normal operation fails, check if the connector is
correctly connected.

If normal operation continues to fail even after

you have connected the connector, replace the
unloading valve.

Fault diagnosis 8-70 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Mast tilting is abnormal.

If an error code L3 (Tilt Forward) or L4 (Tilt Backward) is

displayed on the instrument panel:

Check if the connector is normally connected to

the tilt forward/backward solenoid valve coil.

If the connection is fine, check the readings of the

Knob Tilt Backward/Forward (On/Off) and the Tilt
Backward/Forward Sol Current when the tilt knobs
is pushed (forward) or pulled (backward) to the
full.
 The specified readings are: 1 for Knob Tilt
Backward/Forward (On/Off) and 490 mA for
Tilt Backward/Forward Sol Current.

Fig. 8-73
If normal operation fails, replace the tilt knobs.

Change the CAN module if the problem persists

even after you have replaced the tilt knobs.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-71 Fault diagnosis

 If no error is displayed on the instrument panel:

If the pump motor operation fails, check if the

parameter Enable Fingertip is set to ON from
<Truck Setup>, Calibration, EasyView.

Fig. 8-74

Fault diagnosis 8-72 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 AUX1 (Sideshift) operation is abnormal.

If an error code L5 (Shift to Left) or L6 (Shift to Right) is

displayed on the instrument panel:

Check if the connector is normally connected to the

AUX1 Left/Right shideshifting solenoid valve coil.

If the connection is fine, check the readings of

the Knob AUX1 Left/Right (On/Off) and the
AUX1 Left/Right Sol Current when the AUX1
knobs is pushed or pulled to the full.
 The specified readings are: 1 for Knob AUX1
Left/Right (On/Off) and 490mA for AUX1
Left/Right Sol Current.

Fig. 8-75
If normal operation fails, replace the AUX1
knobs.

Change the CAN module if the problem persists

even after you have replaced the AUX1 knobs.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-73 Fault diagnosis

 If no error is displayed on the instrument panel:

If the pump motor operation fails, check if the

parameter Enable Fingertip is set to ON from
<Truck Setup>, Calibration, EasyView.

Fig. 8-76

Fault diagnosis 8-74 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 AUX2 operation is abnormal.

If the error code L7 (Shift to Left) or L8 (Shift to Right) is

displayed on the instrument panel:

Check if the connector is connected to the AUX2

Left/Right shideshifting solenoid valve coil.

If the connection is fine, check the readings of

the Knob AUX2 Left/Right (On/Off) and the
AUX2 Left/Right Sol Current when the AUX2
knobs is pushed or pulled to the full.
 The specified readings are: 1 for Knob AUX2
Left/Right (On/Off) and 470mA for AUX2
Left/Right Sol Current.

Fig. 8-77
If normal operation fails, replace the AUX2 knob.

Change the CAN module if the problem persists

even after you have replaced the AUX2 knob.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-75 Fault diagnosis

 If no error is displayed on the instrument panel:

If the pump motor operation fails, check if the

parameter Enable Fingertip is set to ON from
<Truck Setup>, Calibration, EasyView.

Fig. 8-78

Fault diagnosis 8-76 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

 Auto tilt leveling is abnormal.

Check if the auto tilt leveling switch is operated

as shown in Fig. 8-79.
 LED turns on during switch operation.

From the menu <Truck Setup>, EasyView, check

if Enable Auto Tilt is set to 1. Fig. 8-79

 0: OFF, 1: ON

Fig. 8-80
Check if the auto tilt leveling switch operates
normally.

8
Fingertip option

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 8-77 Fault diagnosis

 Auto clamping is abnormal.

Press once the auto clamp switch as shown in

Fig.8-81 and check if it operates normally.
 The auto clamp switch is automatically
deactivated 3 seconds after Key ON and 10
seconds after the last operation.

Fig. 8-81

From the menu <Truck Setup>, EasyView, check

if Enable Auto Clamp is set to 1.
 0: OFF, 1: ON

Fig. 8-82
Check if the auto clamp switch operates
normally.

Fault diagnosis 8-78 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

9 Electrical System (F-series)
9-1 Overview ....................................................................2
9-1-1 Components…………………………………………………………2
9-1-2 Communication protocol…………………………………………...4

9-2 Battery .......................................................................6

9-2-1 Exterior and specifications………………………………………6
9-2-2 Functions………………………………………………………….8
9-2-3 Wiring…………………………………………………………….10
9-2-4 Test………………………………………………………………11
9-2-5 Maintenance…………………………………………………….14
9-2-6 Removal and installation………………………………………16

9-3 Controllers and related devices ...........................17

9-3-1 Exterior and specifications…………………………………….17
8
9-3-2 Circuit and functions……………………………………………18

Electrical System (F-series)

9-3-3 Wiring…………………………………………………………….20
9-3-4 LED fault codes…………………………………………………23
9-3-5 Test………………………………………………………………24
9-3-6 Removal and installation………………………………………26

9-4 Miscellaneous loads ..............................................29

9-4-1 Fuse box…………………………………………………………29
9-4-2 DC-DC Converter………………………………………………32
9-4-3 Lamp group……………………………………………………..35
9-4-4 Optional speed limit……………………………………………36

9-5 Instrument ................................................................... 40

9-5-1 Display and buttons…………………………………………….40
9-5-2 Diagnosis………………………………………………………..45
9-5-3 Calibration………………………………………………………49

9-6 Application “EasyView” ........................................54

9-6-1 Installing and execution………………………………………..54
9-6-2 Controller firmware update……………………………………60
9-6-3 “Administration” menu description……………………………64
9-6-4 “Tools” menu description………………………………………64
9-6-5 Main page – Test Menu (diagnostic parameters)…………..74
9-6-6 Main page – Calibration Menu…………………………….….82
9-6-7 Initial settings…………………………………………….……104

9-7 Handling faults on Instrument /EasyView ......... 110

9-1 Overview
9-1-1 Components

Fig. 9-1

(1) Pump motor controller (2) Drive motor controller (3) Battery (4) Horn

(5) Pump motor (6) Accelerator pedal (7) Drive motor (8) DC-DC Converter

(9) Control valve (10) Line contactor (11) Line fuse

(containing F/R switch
and hydraulic switches)

Overview 9-2 B20T-7 PLUS, B20X-7 PLUS

This information describes the electrical system composed of
the following parts related to the F-series controller.

• Battery supplies power to the electrical system.

[Section 9-2]

• Motor, controllers, and related devices provide the

vehicle with necessary drive and pump power
based on their interaction with sensors, switches,

relays, and actuators as well as a number of

parameter settings. [Section 9-3]

• Fuse box protects all the DC loads from over

current by cutting off the power supply to a load
when the load is supplied with a current higher
than the limit. [Section 9-4-1]

• DC-DC converter converts the battery’s high

•
voltage to 12V for low voltage loads. [Section 9-4-2]

Other DC loads, activated by direct demand from

8
the operator, work independently from controllers.

Electrical System (F-series)

Primarily, they are not regulated by controllers nor
is their purpose to signal them. However, they
may interact with them in some configurations.
These loads include the lamp group and horn.
[Section from 9-4-3 to 9-4-5]

• Instrument panel monitors the vehicle to inform the

user of its conditions and provides basic functions
for mode setting, diagnosis and calibration.
[Section 9-5]

• Software for diagnosis and calibration provides the

same kinds of functions as the instrument panel
but in more specific detail. [Section 9-6]

B20T-7 PLUS, B20X-7 PLUS 9-3 Overview

 9-1-2 Communication protocol

LEFT
TRACTION

RIGHT
TRACTION

PUMP
INSTRUMENT
MONITOR

Fig. 9-2
In order to enable all the electrical devices of a vehicle and
provide the user with diagnosis and parameter calibration
functions, data sharing between these controllers and
instrument devices is required. For this purpose, CAN
(Controller Area Network) is used as a standard protocol. For
this purpose, CAN (Controller Area Network) is used as a
standard protocol.

A circuit diagram displaying communications between major

electrical devices using the CAN protocol is shown above.
Note: See Section 8-6 for how to install the application to check
the vehicle’s conditions and to perform parameter
calibration via CAN communication.

Overview 9-4 B20T-7 PLUS, B20X-7 PLUS

 Display
Drive
Controller Calibrating
PC software

Pump
Controller

UART Fig. 9-3

Drive
Controller
Calibrating
PC software
8

Electrical System (F-series)

Display
Pump
Controller

Fig. 9-4
This CAN communications effectively overcomes the
shortcomings of the point-to-point communication-based UART
(Universal Asynchronous Receiver/Transmitter) system that has
been widely used in the past. Due to one-to-one communication
between individual devices, the UART system is limited in the
number of available communication devices and cabling as well
as in improving vehicle performance.

The diagrams above compare CAN and UART communications.

B20T-7 PLUS, B20X-7 PLUS 9-5 Overview

9-2 Battery
9-2-1 Exterior and specifications

Basic conditions

Items Spec.
Final discharge voltage 42.5 V
Electrolyte Refined dilute sulfuric acid
Replenisher Distilled water
Insulation resistance Over 1 MΩ

Fig. 9-5

Specific gravity by temperature

Temperature
Charging
-15°C -5°C 0°C 5°C 15°C 25°C 35°C 45°C Level
(5°F) (23°F) (32°F) (41°F) (59°F) (77°F) (95°F) (113°F)
1.108 1.101 1.098 1.094 1.087 1.08 1.073 1.066 0%
1.118 1.111 1.108 1.104 1.097 1.09 1.083 1.076 5%
1.128 1.121 1.118 1.114 1.107 1.1 1.093 1.086 10%
1.138 1.131 1.128 1.124 1.117 1.11 1.103 1.096 15%
1.148 1.141 1.138 1.134 1.127 1.12 1.113 1.106 20%
1.158 1.151 1.148 1.144 1.137 1.13 1.123 1.116 25%
1.168 1.161 1.158 1.154 1.147 1.14 1.133 1.126 30%
1.178 1.171 1.168 1.164 1.157 1.15 1.143 1.136 35%
1.188 1.181 1.178 1.174 1.167 1.16 1.153 1.146 40%
120% 1.191 1.188 1.184 1.177 1.17 1.163 1.156 45%
121% 1.201 1.198 1.194 1.187 1.18 1.173 1.166 50%
1.218 1.211 1.208 1.204 1.197 1.19 1.183 1.176 55%
1.228 1.221 1.218 1.214 1.207 1.2 1.193 1.186 60%
1.238 1.231 1.228 1.224 1.217 1.21 1.203 1.196 65%
1.248 1.241 1.238 1.234 1.227 1.22 1.213 1.206 70%
1.258 1.251 1.248 1.244 1.237 1.23 1.223 1.216 75%
1.268 1.261 1.258 1.254 1.247 1.24 1.233 1.226 80%
1.278 1.271 1.268 1.264 1.257 1.25 1.243 1.236 85%
1.288 1.281 1.278 1.274 1.267 1.26 1.253 1.246 90%
1.298 1.291 1.288 1.284 1.277 1.27 1.263 1.256 95%
1.308 1.301 1.298 1.294 1.287 1.28 1.273 1.266 100%

* Formula: D25 = Dt + 0.0007(t-25) D25: converted specific gravity at 25°C (77°F) Dt: specific gravity
at t°C t: temperature of the electrolyte when its specific gravity was measured (°C)

Battery 9-6 B20T-7 PLUS, B20X-7 PLUS

 Battery compartment dimension
Battery compartment dimension (mm)
Models
Length Width Height
B15T-7 528 992(842) 698
B18T-7 638(608) 992(842) 698
B18TL-7 746 992(842) 698
B20T-7 638(608) 992(842) 698
B20TL-7 746 992(842) 698
B16X-7 638(608) 992(842) 698
B18X-7 638(608) 992(842) 698
B20X-7 638(608) 992(842) 698
1) When “BS type battery” is selected (choose a battery capacity that is compatible with the following capacities:

575/ 630/ 690 Ah)

2) When “DIN type battery” is selected

Recommended battery dimension and weight

Min/max Dimension (mm) Capacity (Ah)
Models
weigh
(kg)
L W H1 H2 h
BS
Norminal / max
DIN
Norminal / max
8
B15T-7 (36V) 700/945 519 980 610 625 585 660 / 770 (850) -

Electrical System (F-series)

B15T-7 (48V) 700/833 519 980 610 625 585 440 / 575 (600) 460/500
B18T-7 (36V) 800/1200 627 980 610 625 585 825 / 970 (1050) -
B18T-7 (48V) 800/1057 627 980 610 625 585 510/690 (750) 525/625
B18TL-7 (48V) 800/1057 738 980 610 625 585 600/ - 690/750
B20T-7 (36V) 1050/1200 627 980 610 625 585 825/970 (1050)
B20T-7 (48V) 1000/1250 627 980 610 625 585 585 / 690 (750) 575/625
B20TL-7 (48V) 1000/1250 738 980 610 625 585 600 690/750
B16X-7 (48V) 1050/1250 627 980 610 625 585 585 / 690 (750) 575/625
B18X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 575/625
B20X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 575/625
3) When “Characteristics battery” is selected

Fig. 9-6

• Recommended cable length 1000mm

• Recommended cable size: over 1/0 GA (50mm2)

• Battery connector (BS Type): SB350 or SBE320

(confirm the device power vehicle connector type
before installing),
BS connector handle: Part no. D290575

• Battery connector (DIN type): DIN320 (confirm the

vehicle connector type before installing)

B20T-7 PLUS, B20X-7 PLUS 9-7 Battery

 9-2-2 Functions
A. Characteristics of lead storage batteries

This model uses a lead storage battery as its power

supply to electrical systems.

A lead storage battery comprises the anode/cathode

plates to store electrical energy, a separator to prevent
short circuit in the plates, an electrolyte that acts as an
electrical conductor and agent within the battery, a
battery jar made of special plastics that houses these,
and a cover, plus an electrode that serves a gateway for
electrical energy, and various other fittings.

• Anode plate: The anode plate consists of tubes

inserted into each core metal of the lead alloy grid,
an active material (lead powder) filled between the
tube and the core metal, and a sealer that seals
the top and bottom of the tubes to prevent the
active material from getting out. This type of pole
plate is called a grid anode plate that features long
service life and high performance.

• Cathode plate: Having the lead alloy grid coated

with an active material (a paste made of lead
powder and a dilute sulfuric acid), this plate is
called a paste type cathode plate.

• Electrolyte: The electrolyte used in the battery is

a mixture of a high-purity, colorless and odorless
concentrated sulfuric acid (KSM 1203) and purified
water, of which the specific gravity is 1.280 (25°C,
77°F) at a specified level when fully charged.

• Separator: The separator features high

resistance to acid and oxidization, long longevity,
and low electrical resistance.

Battery 9-8 B20T-7 PLUS, B20X-7 PLUS

B. BDI (battery discharge indicator)

The BDI (battery discharge indicator) informs the

operator of the current charge level of the battery. In
proportion to this level, 1 to 10 segments are displayed
on the instrument panel.

BDI value determining process

Lead storage batteries have a large voltage drop in

driving and front end operations. And their voltages often
increase when they are not loaded. Given this voltage
fluctuation, the value on the BDI is determined as follows:

• Though the battery voltage is detected in real time,

the detection is not immediately reflected on the
BDI because the voltage continuously fluctuates.

• Only when the detected battery voltage has

remained lower than the BDI value for a specified
8
period of time (tens of seconds), the BDI

Electrical System (F-series)

decreases its percentage value by 1%. This time
delay makes sure that the voltage decrease is due
to an actual battery discharge rather than a
temporary fluctuation. Thus the BDI value
continues to decrease by 1% at every elapse of the
seconds as long as higher than the actual voltage.

• The BDI value never increases unless the vehicle

is keyed off and on again. It is because, no matter
how frequently temporal voltage increases occur,
the battery is basically supposed not to be actually
recharged while the vehicle is keyed on.

BDI value reset after battery charge

The only way the BDI value increases is to reset it by

charging the battery under the following conditions:

• The BDI segments have not been more than 6,

before the battery is charged.

• The battery has been fully charged before the

vehicle is keyed on.

In case you have charged a battery whose BDI segments

were 7 or more, the BDI leaves the value as it was before
battery charging, until the actual voltage becomes lower
than its BDI value.

B20T-7 PLUS, B20X-7 PLUS 9-9 Battery

 9-2-3 Wiring
Terminal Wiring Terminal Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
F_CONN. A (FINGERTIP)
FUSE BOX (A) (10)
BATTERY (1)
RD
(+) F_CONN. A (FINGERTIP)
EMERGENCY SW (OPT)
(5)
F/R UNIT (6) POWER (OPT) (2)

F/R UNIT (7) DIODE-COMP. (2)

DC- DC CONVERTER (1) LIFT SOL VALVE (B)

DC- DC CONVERTER (6) FAN RELAY (OPT) (30)

FLASHER UNIT(OPT) (86) BATTERY CONTROLLER FAN (2)

BK
(-)
BATTERY EMERGENCY C (1) R-LAMP CONN (2)
BK
(-)
BACKUP BUZZER (OPT)
EMERGENCY C (3)
(2)
INSTRUMENT MONITOR (6) HORN (2)

BACK UP LAMP (OPT) (85) L-LAMP CONN (2)

LICENCE LAMP (OPT) (2)

OPT LAMP CONN. (2)
HEIGHT SENSOR
(OPT) (3)

Battery 9-10 B20T-7 PLUS, B20X-7 PLUS

 9-2-4 Test
A. Battery condition inspection

A weak battery can cause or contribute to problems in the

Logic Control Board and power circuits. Verify that the
battery is in good condition before troubleshooting other
areas. Before repairing failures in other area, check if the
battery is in good condition.

Preliminary steps

1. Verify that there is proper polarity at the battery

connector and the control panel. The positive
cable should be at the line fuse and the negative
at the negative on the control panel.

When the vehicle is operational

<Battery load test>
8

Electrical System (F-series)

1. Turn the range switch on the multimeter to read
battery voltage.

2. Connect the battery.

3. Connect the multimeter leads between positive

(+) cable connection (1), and negative (-) cable
connection (2).

4. In a safe area, operate the hydraulic system

(hold tilt lever to maximum position momentarily)
while reading the voltage indicated on the
multimeter.
Fig. 9-7
5. If the indication is less than the limit (34.5 V for a
36 V model; 45.6 V for a 48 V model), the battery
needs to be charged or repaired before
continuing to troubleshoot.

B20T-7 PLUS, B20X-7 PLUS 9-11 Battery

 When the vehicle is not operational and the battery is the suspected cause
<Cell voltage test>

1. With the vehicle powered up and the pump (Idle)

motor running, measure the voltage at each cell.

2. Normal voltage should be between 1.95V and

2.12V per cell. If the voltage on each cell is
below 1.95V, the battery must be charged or
repaired before continuing to troubleshoot.

3. The indication between cells should not differ

more than 0.05 volts. If it does, the battery must
have an equalizing charge or be repaired.

<Hydrometer test>

1. Test each cell of the battery with a hydrometer.

2. If the specific gravity indication is below 1.140,

the battery must be charged. The battery is fully
charged if the indication is 1.265 to 1.285. (See
Section 9-2-1)

3. The indication between cells should not differ

more than 1.020 volt. If it does, the battery needs
an equalizing charge or be repaired.

Battery 9-12 B20T-7 PLUS, B20X-7 PLUS

 B. Resistance to chassis

Resistance between any point in the truck wiring and the

chassis should be a minimum of 10,000Ω.

Many malfunctions are caused by shorts to chassis.

Usually, two shorts must exist before a malfunction will
occur. But, since batteries can have chassis leakage,
only one short to chassis in the truck wiring can cause
problems. To prevent problems because of shorts, do the
following:

1. Disconnect the battery and discharge the controller.

2. Randomly measure any component connection or

wiring connection in respect to the lift truck chassis
for a minimum resistance of 10,000Ω.
 Any test point with low resistance must have
the short to chassis removed. 8
3. Always keep batteries clean to minimize current

Electrical System (F-series)

leakage to the chassis.

4. Be sure that all attachments, such as horns and

lights are designed for no chassis connection (two
wire system).

B20T-7 PLUS, B20X-7 PLUS 9-13 Battery

 9-2-5 Maintenance
The care and maintenance of batteries is most important
to maximize battery life and efficient vehicle operation.
Periodic inspection and service will increase the life of
batteries. Special attention should be given to the rules
that follow:

• Keep batteries clean at all times. Cleaning will

prevent corrosion, current leakage and shorts to
the chassis. Tighten all vent plugs, wash the
battery with water and a brush, then dry it with an
air hose. It may be necessary to use a baking soda
solution if water alone will not clean the top of the
battery.

• Add enough water to cover the plates before

charging. This will ensure the proper chemical
reaction over the entire plate surface. After
charging is complete, add water until it is about
12.7 mm (0.50 in) above the plates. Use distilled
water or water that has tested free from minerals.
Min. level Max. level
• Charge the battery correctly. A battery should be
(refilling
discharged to 80% of its capacity then fully
recharged. It should cool four to eight hours to
allow the voltage to stabilize before being put back
into use. The battery should have an equalizing Float Float
charge (an extra three or four hour charge at a low
Fig. 9-8
finish rate) once a month to make sure all cells are
in a fully charged condition. Properly charged
batteries should be identified to prevent low
batteries from being installed in vehicles.

• Operation with a low battery must be prevented.

Low battery operation may damage the battery and
will cause a current in the electrical system that is
higher than normal. High current draw due to a
low battery will damage contactor tips and shorten
motor brush life.

Battery 9-14 B20T-7 PLUS, B20X-7 PLUS

 • The battery's maximum temperature is critical. The
electrolyte temperature should never exceed 55°C
(131°F) either while operating or charging.
Overcharging a battery will cause it to overheat
and its plates to warp. Maximum battery life will
result from maintaining 25°C (77°F) electrolyte
temperature. Most of the charging equipment is
fully automatic but should be checked periodically
to ensure proper working order. Most of the
charging equipment is fully automatic but should
be checked periodically to ensure proper working
condition.

Electrolyte temperature Charge

5℃~25℃
110%~125%
(41°F~77°F)
-10℃~5℃
(14°F~41°F)
-15℃~-10℃
125%~140%
8
140%~150%
(5°F~14°F)

Electrical System (F-series)

Below -15°C (5°F) Not chargeable
• Keep accurate battery records. Regular battery
readings should be taken with a battery tester or
voltmeter and recorded. The specific gravity and
voltage of each cell should be checked and
recorded at least once a month. This inspection
should be made after an equalizing charge.
Readings should never be taken directly after
water has been added. Records of all battery
maintenance should be made and filed so it will be
known which batteries are being mistreated or
wearing out.

Note: Repairs should be made immediately otherwise the

battery may become damaged. Batteries stored in
a discharged condition may be difficult to recharge
due to sulfate formation.

B20T-7 PLUS, B20X-7 PLUS 9-15 Battery

 9-2-6 Removal and installation
WARNING
Careless use of the battery may
cause an electric shock.
Be sure to follow the safety precautions
given in Section 1-4.

CAUTION
A short-circuit may occur in the
course of removal, transport, and
installation of batteries.
Always ensure that the battery is
covered with an insulating material
(polywood) before removing and
installing it and no metallic material
contacts the top of battery cells.

１. Park the vehicle.

２. Lower the forks and tilt the mast forward until

the tips of the forks touch the ground.

３. Turn the key switch off. Battery connector

４. Disconnect battery connector (1).

５. Place the steering column vertically and move

the seat back completely.
Fig. 9-9
６. Open hood latch lever (2) that holds the seat
and battery cover.

７. Raise the seat and battery cover.

８. Discharge the power supply module by

keeping the key switch on for approx. 30
seconds twice. Hood latch lever

NOTICE: Failure to discharge the power supply module

may cause an electric shock. Fig. 9-10

９. Remove the battery using a hoist.

10. To install the battery, perform the procedure

above in the reverse sequence.

Battery 9-16 B20T-7 PLUS, B20X-7 PLUS

9-3 Controllers and related devices
9-3-1 Exterior and specifications
Line contactor
Line fuse

Right drive Left drive

Pump motor controller
Fig. 9-11 8
motor controller motor controller

Electrical System (F-series)

Items Specification
Voltage 36/48 V
PWM frequency 10 kHz
Drive maximum current 450 A
Pump maximum current -40°C~+50°C (-40°F~122°F)
Controller
Internal heatsink operating
-40°C~+95°C (-40°F~203°F)
temperature
Maximum temperature +95°C (203°F)
IP degree (dust & water proof) IP65
Operating Voltage 36 VDC
Coil resistance 94Ω (20°C, 68°F)
Line contactor Pull-in voltage 24 VDC
Drop out voltage 7.2 VDC
Coil power dissipation 21 W
Rated voltage 80 V
Line fuse Rated current 500 A
Cold Resistance 0.06 mΩ

B20T-7 PLUS, B20X-7 PLUS 9-17 Controllers and related devices

 9-3-2 Circuit and functions

Key on  power supply to controller

This model is equipped with two drive motors and one

pump motor, which are controlled by their respective
controllers. Turning on the key switch causes the
controllers to be powered at their pins #1.

Current to line contactor  power supply to motor

Once the controllers are supplied with power, the

magnetic coil built in the line contactor (Fig. 2-13) is
energized by current flowing between pins 6 and 13 of
the left drive motor controller. Then, 2 contacts of the
contactor will contact each other to close the circuit
between the battery and three controllers. In this circuit,
the battery power is converted into a 3-phase AC power
that runs the motors through each set of U.V.W.
connections. The line contactor is equipped with a 500A
fuse which prevents overcurrent.

Motor controllers

The three controllers are connected with the following

sensors, switches, relays and actuators.
• Key Switch
• Emergency Switch
Fig. 9-12
• F/R unit
• Accelerator
• Seat switch
• Brake pedal switch
• Parking brake switch
• EM Brake
• Steering angle sensor
• Hydraulic control switches
• Fan relay
• Backup relay
• Lift solenoid valve relay

Controllers and related devices 9-18 B20T-7 PLUS, B20X-7 PLUS

 Supplied with DC power, these devices interact with the
controllers, which based on a number of parameter
settings activate or receive data from them to control the
motors.

In terms of hardware, the three motor controllers are

identical, but each is programmed with different kinds of
firmware for different functions.

For detailed explanations of how the drive and pump

motors work, see Section 3-2-2 and 4-2-2 respectively.

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-19 Controllers and related devices

 9-3-3 Wiring
Drive motor controllers use a 35 pin AMP connector.

Controller connector
Fig. 9-13

Harness Fig. 9-14

Left drive motor controller connector pins

Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
LEFT DRIVE CONTROLLER
FAN RELAY (86)
(12)
PUMP CONTROLLER (1) EM CONN A (4)
13 OR/RD
LIFT SENSOR (1) FORWARD RELAY (86)
AUTO TILT SW2 (1) LIFT SOL RELAY (86)
MAST TILT SW1 (1) SEAT BELT SW (1)
15 BU/GN
TILT LEVER (1) CONN B (6)
DC/ DC CONVERTER (3) 17 BU/RD SEAT SW (1)
1 OR
F_CONN A (6) 22 YL/GN F/R UNIT (3)
RIGHT DRIVE
CONN A (1)
CONTROLLER (23)
F/R UNIT (2) PUMP CONTROLLER (23)
RIGHT DRIVE 23 GN
CONN A (13)
CONTROLLER (1)
RIGHT DRIVE
F_CONN A (3)
CONTROLLER (11)
LEFT DRIVE CONTROLLER
24 GN ANGLE SENSOR (2)
(10)
2 RD/BK FAN RELAY (85) CONN A (4)
25 RD/WH
3 YL LIFT SOL RELAY (85) ANGLE SENSOR (1)
4 VO FORWARD RELAY (85) LM ENCODER (1)
26 RD
5 WH/RD EM CONN A (3) ACCELERATOR (3)
RIGHT DRIVE
6 BR EM SWITCH (1) 28 BU/YL
CONTROLLER (28)
RIGHT DRIVE
ACCELERATOR (1) 29 BU/WH
CONTROLLER (29)
CONN A (2) 30 RD CONN A (5)
LM ENCODER (2) 31 LG LM ENCODER (3)
7 WH
LM THERMAL SENSOR (2) 32 GY LM ENCODER (4)
SEAT SW (2) 33 BR F/R UNIT (1)
RIGHT DRIVE
SEAT BELT SW (2) 35 YL
CONTROLLER (35)

Controllers and related devices 9-20 B20T-7 PLUS, B20X-7 PLUS

 Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
ANGLE SENSOR (3) PUMP CONTROLLER (35)
8 VO LM THERMAL SENSOR (1) CONN A (14)
LEFT DRIVE CONTROLLER
10 OR F_CONN A (3)
(1)
LEFT DRIVE CONTROLLER
12 OR
(1)

Note) Refer to the motor controller circuit in Fig. 8-13.

Right drive motor controller connector pins

Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
LEFT DRIVE CONTROLLER RIGHT DRIVE
11 OR
(12) CONTROLLER (1)
PUMP CONTROLLER (1) EM CONN A (2)
13 YL/GN
LIFT SENSOR (1) F_CONN B (2)
AUTO TILT SW2 (1)
MAST TILT SW1 (1)
16
17
VO
VO
BRAKE SENSOR (1)
WEIGHT SENSOR (3)
8
LEFT DRIVE
TILT LEVER (1)

Electrical System (F-series)

CONTROLLER (23)
DC/ DC CONVERTER (3) PUMP CONTROLLER (23)
1 OR 23 YL/BK
F_CONN A (6) CONN A (13)
CONN A (1) F_CONN A (3)
F/R UNIT (2) RM ENCODER (1)
LEFT DRIVE CONTROLLER
26 RD BRAKE SENSOR (1)
(1)
RIGHT DRIVE CONTROLLER
WEIGHT SENSOR (2)
(11)
LEFT DRIVE CONTROLLER LEFT DRIVE
28 BU/YL
(10) CONTROLLER (28)
LEFT DRIVE
2 YL/RD F_CONN B (1) 29 BU/WH
CONTROLLER (29)
5 BK EM CONN A (1) 31 OR/RD RM ENCODER (3)
RM ENCODER (2) 32 YL RM ENCODER (4)
LEFT DRIVE
BRAKE SENSOR (3)
7 WH CONTROLLER (35)
RM THERMAL (2) PUMP CONTROLLER (35)
35 YL
WEIGHT SENSOR (1) CONN A (14)
8 YL RM THERMAL (1) F_CONN A (32)

Note) Refer to the motor controller circuit in Fig. 8-13.

B20T-7 PLUS, B20X-7 PLUS 9-21 Controllers and related devices

 Pump motor controller connector pins
Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
LEFT DRIVE CONTROLLER
14 WH/BK HEIGHT SENSOR (2)
(1)
LEFT DRIVE CONTROLLER
15 VO HEIGHT SENSOR (4)
(12)
LIFT SENSOR (1) 16 BK ACCELERATOR (5)

AUTO TILT SW2 (1) 17 BR/YL CONN B (14)

MAST TILT SW1 (1) 19 YL/GN AUTO TILT SW2 (2)

TILT LEVER (1) 20 YL/BU TILT LEVER (2)

DC- DC CONVERTER (3) 21 OR/BK PUMP CONTROLLER (34)

1 OR
F_CONN A (6) 22 YL LIFT SENSOR (6)
LEFT DRIVE
CONN A (1)
CONTROLLER (23)
RIGHT DRIVE
F/R UNIT (2)
CONTROLLER (23)
23 YL/BK
RIGHT DRIVE
CONN A (13)
CONTROLLER (1)
RIGHT DRIVE
F_CONN A (3)
CONTROLLER (11)
LEFT DRIVE CONTROLLER
24 GN/YL LIFT SENSOR (7)
(10)
2 BU/BK F_CONN B (3) CONN A (9)

3 GN F_BACK UP RELAY (85) 25 RD/GN LIFT SENSOR (2)

LIFT NEUTRAL SENSOR
4 WH/GN TILT SOLENOID (2)
(1)
5 BU/GN F_CONN B (5) PM ENCODER (1)

6 YL/WH PRESSURE SENSOR (2) 26 RD ACCELERATOR (6)

LIFT SENSOR (5) CONN B (10)

ACCELERATOR (4) 28 BU/YL F CAN2 (1)

CONN B (11) 29 BU/WH F CAN2 (2)

7 WH/BU
PM ENCODER (2) 31 GN/BK PM ENCODER (3)

PM THERMAL (2) 32 BR PM ENCODER (4)

LIFT NEUTRAL SENSOR (3) 33 BK/WH LIFT SENSOR (8)

8 GN/RD PM THERMAL (1) 34 OR/BK PUMP CONTROLLER (21)

9 BU MAST TILT SW1 (2)

LEFT DRIVE
10 VO LIFT SENSOR (4)
CONTROLLER (35)
RIGHT DRIVE
TILT SOLENOID (1)
35 YL CONTROLLER (35)
13 BU/WH F_CONN B (4) CONN A (14)

F_BACK RELAY (86) F_CONN A (2)

Note) Refer to the motor controller circuit in Fig. 8-13.

Controllers and related devices 9-22 B20T-7 PLUS, B20X-7 PLUS

 9-3-4 LED fault codes
There is a way to see the current fault code without the
instrument panel and EasyView application: On each Fault code Indicator
LEDs
controller, a pair of LEDs are installed, capable of
indicating the whole list of fault codes.

A pair of LEDs are red and yellow, each representing a

hexadecimal number. Red LED indicates the first digit
and yellow LED indicates the second digit.

Fig. 9-15

For example, if the error code is D4, the yellow LED will
blink 4 times after the red LED blinks 13 times. See the
table on the right for the hexadecimal table.
Decimal
number
Hexadecimal
number 8
1 1

Electrical System (F-series)

2 2

3 3
The whole list of fault codes is described in Section 8-7.
The table below shows some other cases than indicating 4 4
a fault code: 5 5

Display Status 6 6
Controller is not powered on; or 7 7
Neither LED
vehicle�
illuminated 8 8
has dead battery; or severe damage.
Yellow LED 9 9
Controller is operating normally.
flashing 10 A
Yellow and
11 B
red LEDs Controller is in Flash program mode.
both on solid 12 C
No software loaded, or an internal 13 D
hardware fault detected by the
Red LED on 14 E
Supervisor or Primary microprocessor.
solid
Cycle KSI to clear. Reload software or 15 F
replace controller if necessary.

B20T-7 PLUS, B20X-7 PLUS 9-23 Controllers and related devices

 9-3-5 Test
A. Controller

Measure the diode voltage of the AC MOSFET circuit (Fig.

8-17) inside the controller to check for burnt damages.

1. Remove the cables and harness connected to the

controller and discharge the internal capacitor
completely.

2. Using a multimeter, measure the voltage of the

diode (0.3–0.6V) and check if it is normal (Fig. 2-18
and 2-19).

Diode Red lead Black lead Result

Approx. 0.4 -
Test 1 U, V, W B+
0.6 V
Approx. 0.4 -
Test 2 B- U, V, W
0.6 V
Fig. 9-16

Test 1: Measure voltage with the red lead to Band

the black lead to U, V, and W.

Test 2: Measure voltage with the red lead to U, Fig. 9-17

V, and W, and the black lead to B+.

Fig. 9-18

Controllers and related devices 9-24 B20T-7 PLUS, B20X-7 PLUS

 B. Line contactor and Fuse

Normal: 70 ~ 110 Ω 8

Electrical System (F-series)

Fig. 9-19
Line contactor

Line fuse Fig. 9-20

1. For the line contactor and the line fuse, connect an

ohmmeter at the points shown in the figure and check
if it measures the values as specified.

B20T-7 PLUS, B20X-7 PLUS 9-25 Controllers and related devices

 8-3-6 Removal and installation
A. Drive motor controller panel

(Detail A-A)
Fig. 9-21
NOTICE: Remember the controller contains ESD (Electro
Static Discharge) sensitive components. Use
appropriate precautions in connecting,
disconnecting and handling it.

Preliminary steps
1. Turn the key switch off.
2. Remove the top cover on the counterweight
(See Section 7-4).

Procedure
1. Remove connectors (2) from drive motor
controller panel (1).
2. Remove the cable (5) by unscrewing the nut (6)
securing the cable (5) assembled on the
controller.
 If the identification label on the cable is
damaged, mark the terminals to which they
were connected to avoid confusion during
reassembly. (For example, CPW – Pump
controller W terminal)
 Installation torque: 10.2±1.1 N·m (7.5±0.8
lb·ft)
3. After removing the bolts (3) and washers (4),
remove the drive motor control panel (1) from
the frame.
4. Follow the steps above in the opposite order to
install the drive motor controller.
Apply a small amount of D557047 Thermal Joint
Compound on control panel plate and mating
surface, prior to assembly.

Controllers and related devices 9-26 B20T-7 PLUS, B20X-7 PLUS

 B. Drive motor controllers, line contactor, and line fuse

Drive motor controller panel

Fig. 9-22
8

Electrical System (F-series)

(1) Bolt (2) Nut (3) Washer (4) Line contactor
(5) Bracket (6) Screw (7) Line fuse (8) Washer
(9) Nut (10) Bolt (11) Bus bar (12) Drive motor controller

1. Remove nuts (2) and washers (3).

2. Remove the nuts (9) and washers (8) with a 5
mm socket wrench and remove the fuse (7).
3. Remove Bracket (5).
4. After removing Screw (6), remove line contactor (4).
5. Remove the nuts (13) and washer with 5 mm
socket wrench and remove the Bus bar (11).
 Installation torque: 10.2±1.1 N·m (7.5±0.8
lb·ft)

6. Remove the eight bolts (10) and washers and

then, dismount the motor controller (12).
7. Follow the steps above in the opposite order to
install the drive motor controller, line contactor
and line fuse.
 Apply a small amount of D557047 Thermal
Joint Compound on control panel plate and
mating surface, prior to assembly.

B20T-7 PLUS, B20X-7 PLUS 9-27 Controllers and related devices

C. Pump motor controller

(Detail B-B)

Fig. 9-23

The pump motor controller panel is located opposite the drive

motor controller panel.

NOTE: Remember the controller contains ESD (Electro Static

Discharge) sensitive components. Use appropriate
precautions in connecting, disconnecting and handling it.

Preliminary steps
1. Turn the key switch off.

2. Remove the top cover on the counterweight (See

Section 7-4).

Procedure
1. Remove the connector (2) from the pump motor
controller assembly (1).

2. Remove the cable (5) by unscrewing the nut (6)

securing the cable (5) assembled on the controller.
 If the identification label on the cable is damaged,
mark the terminals to which they were connected to
avoid confusion during reassembly. (For example,
CPW – Pump controller W terminal)
 Installation torque: 10.2±1.1 N·m (7.5±0.8 lb·ft)

3. After removing the bolts (3) and washers (4), remove

the Pump motor control panel (1) from the frame.

4. After removing bolts (3) and the washers, remove

Pump motor controller (5).

5. Follow the steps above in the opposite order to install

the pump motor controller.

Controllers and related devices 9-28 B20T-7 PLUS, B20X-7 PLUS

9-4 Miscellaneous loads
9-4-1 Fuse box
A. Function and composition

To protect DC loads from overcurrent, the fuse box is

equipped with the following terminals:

Rated
Set Items
capacity
DC- DC Converter, Horn 20 A

Key Switch 10 A

Fan, Fingertip (OPT) 5A

A SOL VALVE, POWER (OPT) 5A

BACK-UP LAMP (OPT) 5A 8

F/R unit 5A
Fig. 9-24

Electrical System (F-series)

Height Sensor 5A

LEFT HEAD LAMP (OPT) 5A

10 A

OPT LAMP 5A

B RIGHT HEAD LAMP, LICENCE

5A
LAMP (OPT)
STROBE, FLASHER LAMP
5A
(OPT)
REAR LAMP 5A

B20T-7 PLUS, B20X-7 PLUS 9-29 Miscellaneous loads

 B. Wiring
Fuse box (A) Fuse box (B)
Terminal� Wiring Terminal� Wiring Connection (terminal
Connection (terminal no.)
no. color no. color no.)
LIGHT SW (OPT) (7)
1 OR HEIGHT SENSOR (1) 1 GN/YL
FORWARD RELAY (30)
FLASHER UNIT (OPT)
F/R UNIT (4)
(85)
2 YL/WH
STOP LAMP SW (OPT) (2) OPT LAMP CONN. (8)
2 RD/YL
DC- DC CONVERTER
BACK UP LAMP (OPT) (30)
(5)
3 OR/RD
F_BACK UP RELAY (OPT)
LIGHT SW (OPT) (2)
(30)
DC- DC CONVERTER (5) R-LAMP CONN. (13)
3 OR/RD 4 YL/GN
LIGHT SW (OPT) (2) R-LAMP CONN. (3)

POWER (OPT) (1) 5 BU/RD OPT LAMP CONN. (4)

4 YL/GN
LIFT SOL RELAY (30) 6 BU/YL LIGHT SW (OPT) (3)

DOOR FAN (1) 7 (N/A)

DRIVE MOTOR FAN R (1) 8 (N/A)

5 OR/BK
DRIVE MOTOR FAN L (1) 9 (N/A)

PUMP MOTOR FAN (1) 10 BU/YL LIGHT SW (OPT) (3

DC- DC CONVERTER (5) 11 (N/A)

6 OR/RD
LIGHT SW (OPT) (2) 12 (N/A)

7 RD/WH CHARGER SW (1)

8 YL/RD EM SW (3)

DC- DC CONVERTER (2)

9 RD/BU HORN SW (4)

GRAB BAR SW (OPT) (2)

10 RD BATTERY (+)

11 (N/A)

12 (N/A)

Instrument 9-30 B20T-7 PLUS, B20X-7 PLUS

 C. Removal and installation

Preliminary steps
1. Turn the key switch off.

2. Remove the top cover on the counterweight (See

Section 7-4).

Procedure

1. Remove harness connectors (4) from fuse box (1).

Fuse Box
2. After removing the bolts (2) and washers (3), Bolt
remove the fuse box (1). Washer

Connector

Fig. 9-25
8

Electrical System (F-series)

3. Follow the steps above in the opposite order to
install the fuse box.
When you reconnect the connectors, note the
connection layout at the right.

WARNING: To reduce the risk of fire, replace only with

same type and ratings of fuse.

Fig. 9-26

B20T-7 PLUS, B20X-7 PLUS 9-31 Miscellaneous loads

 9-4-2 DC-DC Converter
A. Exterior and Specifications

Fig. 9-27

Items Specification
Part no. 300612-00250

Allowed Capacity 230 W

Supply Voltage 48 VDC

Output voltage 12V ± 5%

Operating temp. -30°C~+70°C (-22°F~158°F)

☞ Note: Since the external feature of DC-DC Converter above is same with the previous DC-DC
converter (part number: 300612-00121), be very careful of the part number when
exchanging with a new one.

Instrument 9-32 B20T-7 PLUS, B20X-7 PLUS

 B. Circuit and functions

DC-DC Converter
Horn

Key Switch

Fan/
Fingertip(OPT)
SOL
VALVE/POWER
Key Switch
BACK-UP

Fuse box (B)

L LAMP
Battery (+)
DC-DC Converter

OPT LMAP
Battery (-) R
LAMP/LICENCE

STROBE/FLASH
ER UNIT
8
Fig. 9-28

Electrical System (F-series)

The DC-DC converter converts high voltage power from
the battery (48 V or 36 V) to a 12 V power that is suitable
for a number of loads.

Each of its terminals function as follows:

• Terminal 3 (ENABLE) operates the DC-DC

converter by receiving battery power from terminal
P1-1 of the pump motor controller.

• Terminals 2 and 1 are connected to the positive and

negative poles of the battery respectively. Unlike
Terminal 3, these terminals are not responsible to
activate the DC-DC Converter but, responsible to
resend battery power to other loads. They are
protected from an overcurrent higher than 20 A.

• Terminal 5 (12V+) is connected to fuse box

terminal which covers the loads to be powered
from the converter. The power from the battery is
converted to 12 V and then sent to the loads
through the fuse box.

• Terminal 6 (12V-) is connected to the negative

poles of the loads that are to be applied at 12 V.
Namely, those currents which have passed through
the loads return to this terminal.

In this model, the terminals 1 (BATT -) and 6 (12V-) share

the same line.

B20T-7 PLUS, B20X-7 PLUS 9-33 Miscellaneous loads

 C. Wiring
Terminal Wiring Terminal Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
F/R UNIT (6) 4 (N/A)
FLASHER UNIT (86)
POWER(OPT) (2)
1 BK EMERGENCY C (3)
FAN RELAY (OPT) (86) FUSE BOX (A) (6)
OTHERS FUSE BOX (A) (3)
5 OR/RD
BATTERY (-) FUSE BOX (B) (3)
FUSE BOX (A) (9) LIFT SW(OPT) (2)
2 RD/BU HORN SW (4)
F_CONN. A (FINGERTIP) (7)
FLASHER UNIT (86)
POWER(OPT) (1)
EMERGENCY C (3)
FAN RELAY (30)
PUMP CONTROLLER (P1-1) CAN OPT (1)
3 OR 6 BK
F_CONN. A (FINGERTIP) (6) BACK UP LAMP(OPT) (85)
OPT LAMP CONN. (2)
F_CONN. A (FINGERTIP) (1)
F_CONN. A (FINGERTIP) (5)
BATTERY (-)

NOTICE: Do not connect 12V output (-) terminal of the

converter to the (-) tab of the battery. Incorrect
power supply may cause harm to related parts.
The simplified circuit diagram above is only for
the rough explanation.

Instrument 9-34 B20T-7 PLUS, B20X-7 PLUS

 9-4-3 Lamp group

Electrical System (F-series)

Fig. 9-29
This model is equipped with a variety of lamps, with different
purpose.
• Head lamps (L/R) illuminate the path in front of the
vehicle.
• Rear lamps illuminate the path behind the vehicle.
• Backup lamp lights up during reverse drive.
• Stop lamp lights up with the brake pedal pressed.
• License lamp illuminates the license plate in dark
condition.

These are powered at 12 V from the DC-DC converter.

B20T-7 PLUS, B20X-7 PLUS 9-35 Miscellaneous loads

 8-4-4 Optional speed limit

②
Fig. 9-30
(1) Radar sensor (2) IAS Controller

Function

This option is a function to limit the maximum speed of

the vehicle by detecting the outside or inside, when the
vehicle is moving from outside to inside or from inside to
outside.

Specification of added components

1) Controller

Items Specification

Operating voltage DC 9 - 32V

Rated voltage DC 12/ 24V

Current 500mA Max.

Operating
-20°C to +70°C
Temperature
Storage Temp. -30°C to +105°C

BAUD rate Auto

Fig. 9-31
IP grade IP 65

Instrument 9-36 B20T-7 PLUS, B20X-7 PLUS

 Pin No.

CONN Pin No. Connection

1 POSITIVE (9V-32V)
2 CAN H
3 CAN L
4 TX
5 RX
6 SERIAL GND
7 SERIAL ENABLE

P1 8 NEGATIVE (GND)
9 SENSOR VDD
10 SENSOR GND
SENSOR INPUT
11
(ACTIVE HIGH)
SENSOR INPUT
12

13
(ACTIVE LOW)
DIGITAL OUT (ATTIVE
HIGH)
8
DIGITAL OUT (ATTIVE

Electrical System (F-series)

14
HIGH)

2) Radar Sensor

Items Specification

Function Proximity switch

Range Max. 2400 ㎝

Power On LED, Green

Changing mode LED, Orange

Detection LED, Red

IP grade IP 67

Fig. 9-32
3). Pin and circuit information

Fig. 9-34 Fig. 9-33

B20T-7 PLUS, B20X-7 PLUS 9-37 Miscellaneous loads

 Selection of speed limit

1. Press the Mode button.

Indicato
2. "8" is blinking in display.

3. Use the Up/Down buttons to select a mode.

4. If you press the Enter button, “0” is showing.

5. Press the Enter button or after a certain period of

time, “0” disappears and setting is finished.

Checking the current mode

1. Press the Enter button. Then, able to see the

Mode button Down button
current mode.

2. After a certain period of time, display turns off by Up button Enter button
itself.

Model Mode Speed Limit Fig. 9-34

Mode 1 1500 rpm
Electric Mode 2 2000 rpm
Mode 3 2500 rpm

Instrument 9-38 B20T-7 PLUS, B20X-7 PLUS

 Schematic

Electrical System (F-series)

Fig. 9-35

The IAS (Indoor auto detection & Speed limit) sensor is

located on the top of the cabin to recognize the ceiling of
workshop, building or warehouse. When the vehicle
moves to the indoor, it generates a signal and
communicates directly with the IAS controller.

Then, the IAS controller generates a signal for speed limit

and communicates with the traction controller. Eventually,
it limits the rpm of the driving motor by sending a signal to
the driving controller through the CAN CONN terminal.

B20T-7 PLUS, B20X-7 PLUS 9-39 Miscellaneous loads

9-5 Instrument
9-5-1 Display and buttons
The instrument panel is located at the center of the
console cover. The symbols shown on the panel indicate
the values of the vehicle system’s essential analog and
digital parameters.

The indicator lamps and buttons are named as follows:

Vehicle speed and fault indicator

Vehicle speed level and F/R direction indicator

BDI (battery discharge indicator) EM brake indicator

Seat Switch Indicator Brake oil level alarm indicator

Fault indicator

Travel Lamp Indicator

Turn Signal Indicator Over-temperature
alarm indicator
Seat Belt Indicator

Brake oil level alarm indicator

[New model only]

Maintenance Time
Steering Angle Indicator Expiry Indicator
Message box DOWN button

E-S-H Indicator ENTER button

Turtle Mode Indicator

E-S-H Button UP/TURTLE button

Fig. 9-36

Instrument 9-40 B20T-7 PLUS, B20X-7 PLUS

 Left LED Indicators

Located at the left side of the display are four LED

indicators that, when switched on, give the following
information:

Fig. 9-37

No. Indicator Description

[Fault indicator]
• Lights up in red in the following situations:
- The instrument panel’s communication with the controllers is lost
for 3 seconds.
1
- The circuit board in the instrument panel is failed.
- A fault code appears due to a problem with the vehicle.
- Under normal conditions, the indicator briefly blinks when the key
switch is on or off.
8
[Travel Lamp Indicator]

Electrical System (F-series)

2
• Lights up in green to indicate the vehicle is being driven.

[Turn Signal Indicator]

3
• Lights up in green to represent the indicated direction (option).

[Seat Belt Indicator]

4 • Lights up in red for 10 seconds after the seat belt is released
(option).

[Brake oil Pressure alarm indicator]- New model only

5
• Lights up in red when the brake oil level is low.

B20T-7 PLUS, B20X-7 PLUS 9-41 Miscellaneous loads

 Indicator lamps in the display

Located at the center of the instrument panel are

indicator lamps that show the vehicle’s condition.

Fig. 9-38

No Indicator Description

[Seat Switch Indicator]

• This symbol indicates that the seat switch is open. At the appearance of this
symbol, EE Error Code flickers and all the functions of the truck are shut down.
• If the operator attempts to put the vehicle in forward or reverse before the seat
6 switch is on, fault code EE (Wrong Start) is displayed.
• If the LIFT/TILT/AUX1/AUX2 lever is activated before the seat switch is on,
fault code FL (Pump Sign On) is triggered.
• When fault code EE or FL occurs and the signal of the respective function is
deleted, the fault code disappears and the vehicle returns to normal condition.

[Steering angle Indicator]

7
• The steering angle is indicated in seven segments.
[E-S-H Indicator]
• Lights up when shifting the current operation mode using the E-S-H button at
8
the bottom of the panel is enabled. The availability of this button is set in the
EasyView application.
[Turtle mode indicator]
9 • Indicates the vehicle is in the turtle mode, which limits its driving speed
to 10 km/h.
[Battery level indicator]
• Battery charging level, indicated by a 9 segments symbol.
Charge level BDI percent [%]
9 90%<
8 89%~80%
7 79% ~70%
6 69% ~60%

10 5 59% ~50%
4 49% ~42%
3 41% ~34%
2 33% ~26%
1 25% ~20%
EL >20%

• If the battery is completely discharged, the display will signal the alarm
code EL.

Instrument 9-42 B20T-7 PLUS, B20X-7 PLUS

 No Indicator Description
[Vehicle speed and fault indicator]
• When the Key is in the On position, the vehicle model ID code appears on the
display for 3 seconds.
- Vehicle type (e.g.: C2 [CURTIS Controller])
- Battery voltage (e.g.: 48V)
- Software program code (e.g.: 56)

11 • After that, the vehicle’s drive speed is displayed in kmh or mph.

• Pressing the down button once will allow you to alternate between the
accumulated driving time (hour meter) and distance (odometer) on the display.
• In the following conditions, the indicator shifts to display the corresponding
fault code (See Section 2-7):
- Seat switch open
- CAN communication between display and controllers is not active.
- Main contactor open.
[Vehicle speed level and F/R direction indicator] 8
• Each segment on the indicator dial represents a different speed level, ranging
12

Electrical System (F-series)

from 0 (no speed) to 9 (maximum speed).
• The position of the F/R switch is displayed in the center.

[EM brake indicator]

13 • When the accelerator pedal is depressed, the indicator turns off; when
completely released, it lights up three seconds after.

[Brake oil pressure alarm indicator]

14
• Lights up in red when the brake oil level is low.

[Over-temperature alarm indicator]

• Lights up when a motor or its controller is overheated at a temperature higher
15 than the alarm limit.
• A fault code among E1 to E6 (over-temperature) accompanies this alarm,
depending on which device is overheated.

[Maintenance time expiry indicator]

16
• Lights up to indicate the vehicle is due for maintenance.
[Message box]
17
• Displays the message.

B20T-7 PLUS, B20X-7 PLUS 9-43 Miscellaneous loads

 Command and service menu buttons

Located at the bottom are four buttons: E-S-H,

UP/TURTLE, DOWN, and ENTER.

Fig. 9-39

No. Button Description

[E-S-H Button]
• With this key, you can shift the operation mode between Economic, Standard,
and High Performance modes in this order.
• This button is only available after it has been set to enabled on EasyView;
18
there are also some parameters applicable to the respective modes which can
be modified only on EasyView (See Section 2-6).
• Pressing this key when you are in diagnostic mode allows you to see a circular
list of the 10 latest alarms.
[UP/TURTLE button]
• This button functions as TURTLE and UP buttons both.
• Pressing this button allows you to toggle between turtle and normal drive
modes.
• In calibration mode, you can adjust the speed at which the vehicle travels in
19 speed limitation mode (calibration no. 84: TURTLE SPEED, range 500–3500
rpm).
• Pressing this button in calibration or diagnostic mode allows you to choose the
next parameter on display.
• After a parameter is selected in calibration mode, pressing this button
increases the parameter’s numeric value.
[ENTER button]
• Holding this button for 3 seconds simultaneously when the key switch turns on
gives you a selection between calibration and diagnostic modes.
• Holding this button for 3 seconds while the vehicle is in normal operation
20 allows you to access to diagnostic mode.
• If the display is in diagnostic mode during normal operation, you can exit this
mode by pressing ENTER once more.
• After you choose a parameter or its setting value, pressing ENTER
confirms it.
[DOWN button]
• Pressing this button in calibration or diagnostic mode allows you to choose the
previous parameter on display.
21 • After a parameter is selected in calibration mode, pressing this button
decreases the parameter’s numeric value.
• When the button is held for one second during normal operation, the display
will alternate between showing the accumulated driving time and distance.

Instrument 9-44 B20T-7 PLUS, B20X-7 PLUS

 8-5-2 Diagnosis
A. Accessing diagnostic mode on the instrument panel

Parameter setting check

In diagnostic mode, you can check the main analog and

digital signals from the vehicle system as follows:

1. Hold ENTER for three seconds.

If you have performed another task using the

instrument panel, it will enter immediately
diagnostic mode, displaying the symbol “d.” If it is
the first command after startup, the panel will ask
you to select between “c” and “d.”

Fig. 9-40

2. Once you are given the two choices “c” and “d,”
8
press the down button to select “d” (diagnostic

Electrical System (F-series)

mode).

Fig. 9-41
3. In diagnostic mode, use the up and down button
to select the parameter number you want to
check (See Section “B. Diagnosis codes”).
 In the speed and warning section, the
parameter’s number is shown (blinking).
 In the time and distance section, the current
value is shown.

4. Operate the vehicle, observing changes in the

parameter value, to test if the vehicle is in normal
Fig. 9-42
conditions.

NOTICE: You can quit the diagnostic mode at any time

even if you have not finished the diagnosis
procedure.
NOTICE: If a warning occurs when you are in
diagnostic mode and the vehicle system is
normal, the panel will automatically change the
display to show the warning.

B20T-7 PLUS, B20X-7 PLUS 9-45 Miscellaneous loads

 Check of stored fault codes

You can see the last 10 faults as follows:

1. Press the E-S-H button to see the three types of

stored fault messages.

Fig. 9-43

 If there is no fault code stored, the number “0”

will appear in the speed and warning section.

Fig. 9-44

2. Use the up and down button to choose the fault

code you wish to check.

Fig. 9-45

Instrument 9-46 B20T-7 PLUS, B20X-7 PLUS

 B. Diagnostic code

Code Panel display Unit Description Remarks

DRIVE MOTOR
1 rpm DRIVE MOTOR SPD
SPD
D-MOTOR REF
2 rpm D-MOTOR REF SPD
SPD
RIGHT MOTOR
3 rpm Right drive motor’s speed
SPD
R-MOTOR REF Right drive motor motor’s reference
4 rpm
SPD speed
LIFT SENSOR Throttle output
5 V LIFT SENSOR OUT
OUT for lifting
Voltage on the
6 BATT VOLTAGE V Battery’s voltage
key switch
D-INVERTER Left drive motor controller’s
7 °C (°F)

8
TEMP
P-INVERTER
°C (°F)
Temperature
Pump motor controller’s 8
TEMP Temperature

Electrical System (F-series)

PUMP MOTOR
9 rpm Pump motor speed
SPD
P-MOTOR REF
10 rpm Pump motor’s reference speed
SPD
Throttle A
11 ACCEL 1ST OUT V Accelerator potentiometer voltage output for
driving
Throttle B
Accelerator second potentiometer
12 ACCEL 2ND OUT V output for
voltage
driving
STEER
Output from the
13 SENSOR V Steering sensor’s voltage
steer sensor
OUT
R-INVERTER Right drive motor controller’s
14 °C (°F)
TEMP Temperature
15 D-MOTOR I-U mA Left drive motor’s U-phase current
16 D-MOTOR I-V mA Left drive motor’s V-phase current
17 D-MOTOR I-W mA Left drive motor’s W-phase current
18 R-MOTOR I-U mA Right drive motor’s U-phase current
19 R-MOTOR I-V mA Right drive motor’s V-phase current
20 R-MOTOR I-W mA Right drive motor’s W-phase current
21 P-MOTOR I-U mA Pump motor’s U-phase current
22 P-MOTOR I-V mA Pump motor’s V-phase current
23 P-MOTOR I-W mA Pump motor’s W-phase current
24 D-MOTOR TEMP °C (°F) Left drive motor’s s temperature
25 R- MOTOR TEMP °C (°F) Right drive motor s Temperature
26 P-MOTOR TEMP °C (°F) Pump motor temperature

B20T-7 PLUS, B20X-7 PLUS 9-47 Miscellaneous loads

 Code Panel display Unit Description Remarks
Time period
27 SEAT H METER Hour Seat switch hour meter while seat
switch is on
Time period
while drive
28 DRIVE H METER Hour Drive motor’s total hour meter
motors are
working
Time period
while Pump
29 PUMP H METER Hour Pump motor’s total hour meter
motors is
working
30 SEAT SWITCH - Seat switch ON(1)/OFF(0)
33 REV SELECT SW - Reverse drive switch ON(1)/ OFF(0)
34 FWD SELECT SW - Forward drive switch ON(1)/OFF(0)
35 Pedal brake switch - Brake pedal switch ON(1)/OFF(0)
37 AUX1 OUTPUT - AUX1 switch ON(1)/OFF(0)
38 AUX2 OUTPUT - AUX2 switch ON(1)/OFF(0)
Speed limit for high lift switch 1
40 HIGH LIFT 1 SW - ON(1)/OFF(0)
(GSS option selected)
TILT SWITCH
41 - Tilt switch ON(1)/OFF(0)
OUT
Tilting angle limit for high lift switch 2
42 Mast tilt switch - ON(1)/OFF(0)
(GSS option selected)
43 CONTACTOR - Contactor switch ON(1)/OFF(0)
44 5V OUT - 5V out ON(1)/OFF(0)
45 12V OUT - 12V out ON(1)/OFF(0)
AUTO TILT Automatic tilt switch 3
46 - ON(1)/OFF(0)
SWITCH (GSS option selected)
48 FANS - Activation of fans ON(1)/OFF(0)

Instrument 9-48 B20T-7 PLUS, B20X-7 PLUS

 9-5-3 Calibration
A. Accessing calibration mode on the instrument panel

Using the instrument panel, you can modify a number of

different parameter settings. And although it may only
allow you to set a limited number of parameters, this
function is especially useful when the PC application
EasyView is not available.

To calibrate parameter settings:

1. Turn the key switch off and on again to initialize

the instrument panel.

2. Hold ENTER for three seconds until a page loads

that prompts you to select between “c” and “d.”

8
Fig. 9-46

Electrical System (F-series)

3. Press the up button to select “c.”

NOTICE: If parameter calibration code 40 ENABLE

TURTLE is set to “disable,” the up button will
be disabled, preventing you from entering
calibration mode. If this happens, key the
vehicle off and on again to restart. Otherwise
Turn the key switch off and on again to
initialize the instrument panel. Fig. 9-47

4. Use the up and down buttons to select parameter

calibration code number 10 and then press
ENTER.

Fig. 9-48

5. Use the up and down buttons to set the parameter

value to “4” and then press ENTER.

Fig. 9-49

B20T-7 PLUS, B20X-7 PLUS 9-49 Miscellaneous loads

 6. In the same way, set parameter calibration code
17 to “6.”

NOTICE: You can switch the order in which the two

parameter values are set. However, it is not
possible to modify other parameters before
setting these two. Fig. 9-50

7. Use the up and down buttons to select the

parameter you wish to set and then press ENTER.

Fig. 9-51
8. Use the up and down buttons to select the
parameter you wish to set and then press ENTER.
 Using the E-S-H button, you can move the
cursor to another digit place.

NOTICE: Using the function that returns the parameter

settings to their default values will delete your
current settings.
Fig. 9-52
The parameter code number is displayed in the speed
and warning section, and its setting value in the time and
distance section. If the number in the time and distance
changes, this means the selected parameter’s value has
been updated in the controller’s memory.

Instrument 9-50 B20T-7 PLUS, B20X-7 PLUS

 B. Parameter calibration codes

Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
TURTLE ALARM 0–1
8 - 0
(Buzzer On Turtle Speed) (Off–On)
0–9
10 1st PASSWORD Digit -
(not used)
CHAT TIME 1-9
12 sec 6
(Chat Time) (1-9)
IDLE TIME 10-20
13 sec 10
(Idle Time) (10-20)
MAINT TIME ON 0–1
14 - 0
(Maintenance Time Set) (Off–On)
0–9
17 2nd PASSWORD Digit -
(not used)

18 WHEEL TURN-L V 7.2

6.0-10.0
(0.00-10.00)
8
0.5-4.0

Electrical System (F-series)

19 WHEEL TURN-R V 2.0
(0.00-10.00)
WHEEL STRAIGHT 3.0-7.0
20 V 4.5
(Steering Middle) (0.00-10.00)
0.2-2.0
23 (Min Accelerator A) V 0.40
(0.20-2.00)
2.0-5.0
24 (Max. Accelerator A) V 2.93
(2.00-4.50)
SLOPE TIMER 3-10
26 sec 5
(Stop on a Slope Timer) (3-10)
LIFT PRI SPEED
0–1
27 (Lift Priority For Pump Reference - 1
(Off–On)
Speed)
FORWARD ALARM 0–1
30 - 0
(Buzzer on Forward Direction) (Off–On)
BACK UP ALARM 0–1
31 - 0
(Buzzer on Reverse Direction) (Off–On)
LIFT MAX VALUE 3.0-10.0
32 V 9.81
(Lift Max) (0.00-10.00)
LIFT MIN VALUE 0-10.0
33 V 2.90
(Lift Min) (0.00-10.00)
START MOTOR FAN 0-100
35 °C (°F) 65(149)
(Motor Fan Starting Temp) (0-160)
ENABLE TURTLE 0–1
40 - 1
(Enable Turtle Speed by Display) (Off–On)
DRIVE MAX I (Drive Max Current) 20-100
41 % See note
(See note) (20-100)

B20T-7 PLUS, B20X-7 PLUS 9-51 Miscellaneous loads

 Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
(Drive Forward Max Speed) (See 1000-4500
42 rpm See note
note) (0 -4000 / 5000)
(Drive Reverse Max Speed) 1000-4500
43 rpm See note
See note (0 -4000 / 5000)
44 D LIMIT MAX SPD 500-3500
400-2000
47 (Steering Limit Max Speed) rpm 1000
(400-2000)
D ACCEL RATE H 0.1-30.0
48 sec 6.0
(Acceleration Rate HS) (0.1-30.0)
D ACCEL RATE L 0.1-30.0
49 sec 6.5
(Acceleration Rate LS) (0.1-30.0)
D LOW ACCEL RATE 0.1-30.0
50 sec 10.0
(Low Accel Rate) (0.1-30.0)
D INVERS. RATE H 0.1-30.0
51 sec 5.0
(Inversion Rate HS) (0.1-30.0)
D INVERS. RATE L 0.1-30.0
52 sec 5.0
(Inversion Rate LS) (0.1-30.0)
D RELEASE RATE H 0.1-30.0
53 sec 6.0
(Release Rate HS) (0.1-30.0)
D RELEASE RATE L 0.1-30.0
54 sec 5.0
(Release Rate LS) (0.1-30.0)
D LOW BRAKE RATE 0.1-30.0
55 sec 5.0
(Low Inversion Rate) (0.1-30.0)
D SOFT STOP SPD 10-500
56 rpm 150
(Soft Stop Speed) (0-500)
START CONT. FAN 0-60
60 °C (°F) 65(149)
(Controller Fan Starting Temp) (0-160)
PARTIAL RELEASE 0.1-30.0
61 sec 30.0
(Partial Decel Rate) (0.1-30.0)
DELTA RPM 20.0100.0
62 % See note
(Width of the delta increment) (5.0–100.0)
LIFT MAX SPEED 1000-3500
64 rpm See note
(Lift Max Speed) See note (0-4000)
TILT SPEED 500-2000
65 rpm 800
(Tilt Speed) (100-3000)
AUX1 SPEED 500-2000
66 rpm 800
(AUX1 Speed) (100-3000)
AUX2 SPEED 500-2000
67 rpm 800
(AUX2 Speed) (100-3000)
LIFT MIN SPEED
69 rpm 200 0- 500(0-500)
(Lift Min Speed)

Instrument 9-52 B20T-7 PLUS, B20X-7 PLUS

 Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
HYDRO SPEED 400-800
71 rpm 700
(Hydro Speed) (400-800)
IDLE SPEED 200-500
72 rpm 500
(Idle Speed) (400-800)
TURTLE SPEED 500-3500
84 rpm 2000
(Max Speed in Turtle Mode) (500-3500)
BRITISH UNIT 0–1
85 0. 0
(British Unit Enable) (Off–On)
E-S-H 0–1
87 - 1
(Enable EHS by Display) (Off–On)
ENABLE FAN WORK 0–1
89 - 1
(Enable Working Fans) (Off–On)
ENABLE CHAT TIME 0–1
90 - 1
(Chat Time Enable)
Maintenance Time
(Off–On)
0-99990
8
92 Hour 500
(Set Time) (100-65500)

Electrical System (F-series)

GSS ENABLE 0–1
94 - 0
(GSS Enable) (Off–On)
FINGERTIP ENABLE 0–1
95 - 0
(Fingertip enable) (Off–On)
0–1
96 (Auto Clamp Enable) - 0
(Off–On)
0–1
97 (Auto Tilt Enable) - 1
(Off–On)
LOWER SPEED 100–2000
99 (Lower Speed) rpm 600 (100– 2000)
0–1
A2 (Aux2 Enable) - 0
(Off–On)
Note: The default settings and adjustable ranges of EasyView’s calibration parameters for the
instrument panel parameter codes 41, 42, 43, 62, and 64 vary depending on which is
selected from the E-H-S modes. For a detailed explanation, see Section 2-6-6.

• Optional Guardian Stability System (GSS)

- Decrease of Travel Speed (50%) when the mast is raised above primary stage
- Available tilt-forward angle is restricted to 2° when the mast is raised above the primary stage
- Alarm when the mast, tilted more than 2°, is raised above primary stage

• Auto Tilt Leveling

- Returns the mast to vertical position easily by tilt angle sensing

B20T-7 PLUS, B20X-7 PLUS 9-53 Miscellaneous loads

9-6 Application “EasyView”
9-6-1 Installing and execution
As mentioned in the preceding section, electric vehicles
equipped with CURTIS controllers provide the functions
of diagnosis and parameter calibration not only on the
instrument panel but also on the PC application
EasyView.

To use EasyView, you will need to install it and the CAN

communications drivers on your laptop, and then connect
the PC to the vehicle with a communications cable
(A408026, Kvaser) and then carry out initial settings.

EasyView installation

1. Download the latest version of the application

EasyView from the bulletin board at the dealer’s
portal website: https://service.doosan-iv.co.kr

Fig. 9-53

EasyView Program 9-54 B20T-7 PLUS, B20X-7 PLUS

 2. Unpack the downloaded file, and execute the file
<setup.exe> to install the application on the PC.

3. Check that EasyView’s icon is created on the Fig. 9-54

desktop.

CAN communications drivers installation

1. Access Kvaser’s website and click Support

Downloads Kvaser Driver for Windows.
8
 Direct link:

Electrical System (F-series)

http://www.kvaser.com/software/73301309800
13/V5_11_0/kvaser_drivers_setup.exe

Fig. 9-55

B20T-7 PLUS, B20X-7 PLUS 9-55 EasyView Program

 2. Once the Installation Wizard page appears, click
Next; then click Display Release Notes to read
the release notes or Next to proceed installation.

Fig. 9-56

Fig. 9-57

3. Select Kvaser CAN driver components to install

and then click Next.

Fig. 9-58

EasyView Program 9-56 B20T-7 PLUS, B20X-7 PLUS

 4. Set the folder where Kvaser CAN Drivers will be
installed and then click Installation.

Fig. 9-59

Electrical System (F-series)

Fig. 9-60

B20T-7 PLUS, B20X-7 PLUS 9-57 EasyView Program

 EasyView execution

1. Connect a CAN communications cable with one

end to your PC’s USB port and the other to the
vehicle’s CAN port near the controllers and then
turn on the key switch.

2. Double-click the EasyView icon to launch the

application.

 If the PC is not correctly connected to the

vehicle with the key switch on, a dialogue
box will appear and prompt you to select a
vehicle model as shown below:

Fig. 9-61
 When the boxes at right bottom are highlighted
in green, this means they are active, when the
PC and vehicle are correctly connected and
inactive in grey when they are not.

Fig. 9-62

EasyView Program 9-58 B20T-7 PLUS, B20X-7 PLUS

 3. When you are not logged in to the application,
only <Test Menu> is provided, which shows the
vehicle’s conditions. You can log in (password:
dbgby141) the application under the
Administration menu to access <Calibration
Menu>.

Electrical System (F-series)

Fig. 9-63

Fig. 9-64

B20T-7 PLUS, B20X-7 PLUS 9-59 EasyView Program

 9-6-2 Controller firmware update
As the controllers’ performance and functions are updated,
so is the firmware. You can install an update on the
controllers using your PC. This process is referred to as
“flashing,” and it goes as follows:

1. Visit the dealer’s portal website:

https://service.doosan-iv.com

2. Under the menu of Board Bulletin, search for

“easyview” and view the post of the latest
firmware version.

Fig. 9-65

3. Download xml.zip and the update file named after

your vehicle model such as B20TX
7_48V_56_170825.zip.

Fig. 9-66
4. Unzip xml.zip into the Data folder under the path
of the EasyView application.

 Default: C:\Program Files (x86)\Curtis

Instruments\Easy View\Data

EasyView Program 9-60 B20T-7 PLUS, B20X-7 PLUS

 5. On the EasyView application, select Flash under
the Tool menu.

Electrical System (F-series)

Fig. 9-67
6. EasyView will display the vehicle model type and
current software version, for example, Truck type:
56 Current SW Data: 2015/3/6). Click Browse
and find the downloaded update file specific to
your vehicle model.

Fig. 9-68

B20T-7 PLUS, B20X-7 PLUS 9-61 EasyView Program

 7. Click Flash and wait until the selected file is
completely loaded into the controllers.
 Flashing takes approx. 5–10 minutes.

NOTICE: While flashing is in progress, the PC must not

crash due to a system error, external
interference, or the removal of the
communications cable. For this reason, it is
highly recommended that you use the laptop
PC plugged into an AC outlet rather than a
portable battery.

Fig. 9-69
8. Upon the completion of the flashing, a dialog box
will appear. Click Close to return to the main page.

EasyView Program 9-62 B20T-7 PLUS, B20X-7 PLUS

 Fig. 9-70
8
9. Perform initial settings for the accelerator pedal,

Electrical System (F-series)

lift sensor, and steering angle sensor (See each
relevant menu in Section 2-6-7).

B20T-7 PLUS, B20X-7 PLUS 9-63 EasyView Program

 9-6-3 “Administration” menu description

Login

Once you log in to the application, you can access

Calibration Menu and Options Menu on the main page
(Compare Fig. 9-68 and Fig. 9-69). The password is
dbgby141.

• When you are not logged in, only Test Menu is available.

• When you are logged in, you are allowed to access Calibration Fig. 9-71
Menu and Options Menu as well.

Fig. 9-72

Logout

Clicking this menu logs you out of the application.

Exit

Clicking this menu quits the application.

9-6-4 “Tools” menu description

EasyView Program 9-64 B20T-7 PLUS, B20X-7 PLUS
 Flash

As described above, Flash is for updating the controllers’

firmware. For a detailed explanation, see Section 9-6-2.

Electrical System (F-series)

Fig. 9-73

Fig. 9-74

B20T-7 PLUS, B20X-7 PLUS 9-65 EasyView Program

 Save parameter

In this menu, you can store all parameter settings except

for the values of sensors (accelerator, lift, steering, etc.)
in the PC as follows:

Click Browse, choose a location on the computer where

you wish to store the parameter file, and then click Save.

Fig. 9-75

EasyView Program 9-66 B20T-7 PLUS, B20X-7 PLUS

 8
Fig. 9-76

Electrical System (F-series)

Data Logging

This function records the vehicle’s operation history and

helps the operator analyze the vehicle’s conditions.

Enter a time scale in the time dialog box, which is set with
a default value to 0.5 seconds. Click Browse to select
where you wish to store the trace file and then click Start.
The data will then be logged at the selected file based on
the time scale specified. After clicking Stop, the operator
can check the data log file.

B20T-7 PLUS, B20X-7 PLUS 9-67 EasyView Program

 Fig. 9-77

Fig. 9-78

EasyView Program 9-68 B20T-7 PLUS, B20X-7 PLUS

 Faults

This menu contains three sub menus: Faults active,

Faults history, and Clear faults history.

• Faults Active : shows a list of the currently present

fault codes.

Fig. 9-79

• Faults History: shows a list of the past fault codes

that have occurred since the last clearing of faults
history.

Electrical System (F-series)

Fig. 9-80
• Clear Faults History: clears the current list of faults history.

B20T-7 PLUS, B20X-7 PLUS 9-69 EasyView Program

 Cloning

In this menu, you can either copy the parameter settings

applied to the vehicle to save them in the PC, or copy
parameter settings stored in the PC to apply them to the
vehicle.

• Browse/Open button: Clicking this button enables

you to select a cloning file (*.csv). And then,
parameter settings from the selected file are displayed
under <File value>.

Fig. 9-81

EasyView Program 9-70 B20T-7 PLUS, B20X-7 PLUS

 • Read controller button: Clicking this button loads
parameter settings from the controllers and
displays them under <Controller value>.

Electrical System (F-series)

Fig. 9-82
• Save button: Clicking this button saves parameter
values from the controllers in the cloning file on the
PC.

Fig. 9-83

B20T-7 PLUS, B20X-7 PLUS 9-71 EasyView Program

 • Clone button: Clicking this button copies the
parameter settings from the cloning file to the
controllers While automatically running the
following three steps: Verify, Writing, and Reading.

Step 1: Verify

Fig. 9-84
Step 2: Writing

Fig. 9-85

EasyView Program 9-72 B20T-7 PLUS, B20X-7 PLUS

 Step 3: Reading

Electrical System (F-series)

Fig. 9-86

B20T-7 PLUS, B20X-7 PLUS 9-73 EasyView Program

 9-6-5 Main page – Test Menu (diagnostic parameters)
<Test Menu> on the main page contains a list of
diagnostic parameters in groups.

Test Menu – Software Version Information

Fig. 9-87

No. Parameter Description

1 Drive Left Software Type The model code to which the left drive software applies.
2 Drive Left Software Type Left drive software revision year
3 Drive Left Software Month Left drive software revision month
4 Drive Left Software Day Left drive software revision day
The model code to which the right drive software
5 Drive Right Software Type
applies.
6 Drive Right Software Year Right drive software revision year
7 Drive Right Software Month Right drive software revision month
8 Drive Right Software Day Right drive software revision day
9 Pump Software Type The model code to which the pump software applies.
10 Pump Software Year Pump software revision year
11 Pump Software Month Pump software release month.
12 Pump Software Day Pump software revision day

EasyView Program 9-74 B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Drive

Electrical System (F-series)

Fig. 9-88

No. Parameter Description

Left drive motor’s actual speed in revolutions per minute�
1 Left Motor Speed
(rpm)
Left drive motor speed request in revolutions per minute�
2 Left Motor Speed Request
(rpm)
Right drive motor’s actual speed in revolutions per minute�
3 Right Motor Speed
(rpm)
Right Motor Speed Right drive motor speed request in revolutions per minute�
4
Request (rpm)
5 Temp Left Drive Motor Left drive motor temperature (°C)
6 Temp Left Drive Module Left drive module temperature (°C)
7 Temp Right Drive Motor Right drive motor temperature (°C)

B20T-7 PLUS, B20X-7 PLUS 9-75 EasyView Program

 No. Parameter Description
8 Temp Right Drive Module Right drive module temperature (°C)
9 Left Motor Current Left drive motor current in Amps RMS (A)
10 Right Motor Current Right drive motor current in Amps RMS (A)
11 Pedal Voltage A Accelerator pedal output voltage A (V).
12 Pedal Voltage B Accelerator pedal output voltage B (V).
Steering Sensor Output
13 Steering sensor voltage (V)
Voltage
14 Seat Switch Seat switch state
15 Pedal Brake Switch Brake switch state
State of forward direction, received from F/R switch. On�
16 Forward Switch indicates that the forward direction is selected. "On"
indicates that the forward direction is selected.
State of reverse direction, received from F/R switch. "On"
17 Reverse Switch
indicates that the reverse direction is selected.
State of buzzer relay output at drive module pin 30. "On"
indicates that the buzzer relay driver is active. When a
18 Warning Buzzer
fault�
occurs, a buzzer will sound.
State of line contactor output at drive module pin 6. “On”
19 Main contactor
indicates that the line contactor driver is active.
20 Left Motor Encoder (5V) 5 V supply voltage at left drive module pin 26
Drive encoder phase A at left drive module pin 31. "On"
21 Left Motor Encoder A
indicates pulse activity on the encoder phase A.
Drive encoder phase B at left drive module pin 32. "On"
22 Left Motor Encoder B
indicates pulse activity on the encoder phase B.
23 Right Motor Encoder (5V) 5 V supply voltage at right drive module pin 26
Drive encoder phase A at right drive module pin 31. "On"
24 Right Motor Encoder A
indicates pulse activity on the encoder phase A.
Drive encoder phase B at right drive module pin 32. "On"
25 Right Motor Encoder B
indicates pulse activity on the encoder phase B.
26 ISO Relay The state of ISO relay.
27 Left EM Brake EM Brake state of the left motor.
28 Right EM Brake EM Brake state of the right motor.

EasyView Program 9-76 B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Pump

Electrical System (F-series)

Fig. 9-89

No. Parameter Description

1 Motor Speed Pump motor’s actual speed (rpm).
The controller’s demanded pump motor speed (from lift
2 Motor Speed Request
command input) (rpm).
3 Temp Pump Motor Pump motor temperature (°C).
4 Temp Pump Module Pump module temperature (°C).
5 Pump Motor Current Pump motor current (A).
6 Lift Command Lift Command voltage (V) input from Analog1
7 Tilt Whether or not the TILT switch is on.
8 Aux1 Whether or not the AUX1 switch is on.
9 Aux2 Whether or not the AUX2 switch is on.
10 Height Switch NO (SW1) [GSS] Height switch command
11 Height Switch NC (SW1) [GSS] Mast Tilt switch command
12 Height Switch (SW1) [GSS] Height switch command
13 Mast Tilt Switch (SW2) [GSS] Mast Tilt switch command
14 Auto Tilt Switch (SW3) [GSS] Auto Tilt switch command
15 Pump Motor Encoder (5V) 5 V supply voltage at pump module pin 26
Pump encoder phase A at pump module pin 31. "On"
16 Pump Motor Encoder A
indicates pulse activity on the encoder phase A.
Pump encoder phase B at pump module pin 32. "On"
17 Pump Motor Encoder B
indicates pulse activity on the encoder phase B.

B20T-7 PLUS, B20X-7 PLUS 9-77 EasyView Program

 Test Menu – Fingertip and Valve

Fig. 9-90

No. Parameter Description

1 Knob Lift Command Lift command value from knob
2 Knob Lift (On/Off) State of lift signal from knob
3 Knob Lower (On/Off) State of lowering signal from knob
4 Knob Tilt Backward (On/Off) State of tilt backward signal from knob
5 Knob Tilt Forward (On/Off) State of tilt forward signal from knob
6 Knob Aux1 Right (On/Off) State of AUX1 right signal from knob
7 Knob Aux1 Left (On/Off) State of AUX1 left signal from knob
8 Knob Aux2 Right (On/Off) State of AUX2 right signal from knob
9 Knob Aux2 Left (On/Off) State of AUX2 left signal from knob
10 Auto Tilt Mode Switch State of auto tilt signal from knob
11 Auto Clamp Mode Switch State of auto clamp signal from knob
12 Forward Switch State of drive forward signal from knob
13 Reverse Switch State of drive reverse signal from knob
14 Lift Sol Current Lifting solenoid valve current (mA)
15 Lower Sol Current Lowing solenoid valve current (mA)

EasyView Program 9-78 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description
16 Tilt Backward Sol Current Tilt back solenoid valve current (mA)
17 Tilt Forward Sol Current Tilt forward solenoid valve current (mA)
18 Aux1 Right Sol Current AUX1 right valve solenoid current (mA)
19 Aux1 Left Sol Current AUX1 left valve solenoid current (mA)
20 Aux2 Right Sol Current AUX2 right valve solenoid current (mA)
21 Aux2 Left Sol Current AUX2 left valve solenoid current (mA)
22 Unload Valve State of unload valve
23 Back Up Buzzer State of backup alarm

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-79 EasyView Program

 Test Menu – Battery

Fig. 9-91

No. Parameter Description

1 Battery voltage Battery voltage (V) measured at drive module pin 1
Inverter voltage (V) measured at drive motor controller
2 Inverter Voltage
B+ stud
Battery level measured from the left drive motor�
3 Battery Level
controller
4 BDI Percentage Battery discharge indicate level (%)

EasyView Program 9-80 B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Timers

Fig. 9-92

No. Parameter Description

Hour meter that counts the time when the seat switch is
1 Seat Switch Hour Meter applied (closed) (Hr). You can see this data on the
instrument panel.

2 Drive Motor Hour Meter

Hour meter that counts the time that the drive motor is
active (Hr)
8
Hour meter that counts the time that the pump motor is

Electrical System (F-series)

3 Pump Motor Hour Meter active (Hr). You can see this data on the�
instrument panel.
4 Odometer Vehicle distance traveled (km)

B20T-7 PLUS, B20X-7 PLUS 9-81 EasyView Program

 9-6-6 Main page – Calibration Menu
< Calibration Menu> on the main page contains a list of
calibration parameters in groups. To access this menu,
you should log in to the application (Administration
Login Enter password: dbgby141).

Calibration Menu – Accel Pedal Set

Fig. 9-93

No. Parameter Description

Pedal Voltage A�
1 Output voltage (V) from the accelerator pedal
(monitor variable)
Forward Switch�
2 Forward switch state
(monitor variable)
Reverse Switch�
3 Reverse switch state
(monitor variable)
4 Min Accelerator A Accelerator pedal voltage (V) with the pedal released
5 Max Accelerator A Accelerator pedal voltage (V) with the pedal completely pressed

NOTICE: See Section 9-6-7 for a detailed procedure of using

this sub menu.

EasyView Program 9-82 B20T-7 PLUS, B20X-7 PLUS

 교정 메뉴 – 브레이크페달 세트

Fig. 9-94

No. Parameter Description

1 Brake Pedal Voltage A Measured value between 0.00 and 5.50 V.
2 Brake Min Brake pedal voltage (V) with the pedal released.
Brake pedal voltage (V) with the pedal completely�
3 Brake Max
pressed.
The percent of brake pedal’s stroke between 1 and
8
100%. For reference, there are two stages during the�

Electrical System (F-series)

4 Brake Mid Percent
whole pedal stroke. Between the stages, there is some
stroke with slight different feeling.

NOTICE: See Section 9-6-7 for a detailed procedure of using this

sub menu.

B20T-7 PLUS, B20X-7 PLUS 9-83 EasyView Program

 Calibration Menu – Lift Set

Fig. 9-95

No. Parameter Description

1 Lift Command (monitor variable) Lift command voltage (V) at pump module pin 24
2 Lift Min Lift command voltage (V) with the lift lever released.
Lift Command voltage (V) with the lift lever fully
3 Lift Max
applied.

NOTICE: See Section 9-6-7 for a detailed procedure of using this

sub menu.

EasyView Program 9-84 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Steering Set

Fig. 9-96

No. Parameter Description

Steer Sensor
1 Output Voltage Steering angle sensor voltage (V) at left drive module pin 24.
(monitor variable)
Steer angle sensor voltage (V) when the rear wheels are fully
8
2 Steering Anticlock
turned counterclockwise.

Electrical System (F-series)

Steer angle sensor voltage (V) when the rear wheels are in the
3 Steering Middle
middle.
Steer angle sensor voltage (V) when the rear wheels are fully
4 Steering Clock
turned clockwise.
Steer Middle Maximum drive motor speed at which the steering is turned to
5
Angle Max Speed about 45 degrees.
Steering Limit Max Maximum drive motor speed when the steer angle is at full lock
6
Speed counterclockwise or clockwise.

NOTICE: See Section 8-6-7 for a detailed procedure of using this

sub menu.

B20T-7 PLUS, B20X-7 PLUS 9-85 EasyView Program

 Calibration Menu – Maintenance Timer

Fig. 9-97

No. Parameter Description

Seat Switch Hour Meter (monitor Hour meter that counts the time when the seat switch
1
variable) is active. (Hr)
When this parameter value is on, the maintenance
2 Maintenance Time Set
function is enabled.
When the Drive Hour Meter exceeds this parameter
value, the wrench icon on the vehicle display lights
up, indicating that vehicle maintenance is needed.
3 Set Time
Once the maintenance is performed, the value of this
parameter should be increased to a setting when the
next time maintenance is scheduled.

EasyView Program 9-86 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu - Timers

Fig. 9-98

No. Parameter Description

The time delay since the driver leaves the seat and
1 Seat Switch Delay the seat switch is open until the controller enters
standby mode and inhibits drive and lift functions.

2 Chat Time
Chat Time If there is no command given (neither
drive nor pump action) during the amount of time set 8
for this parameter since the expiration of the idle

Electrical System (F-series)

time, the display will show the “PP” message.
The time delay since no input has been received
3 Idle Time from LIFT, TILT, AUX1, AUX2, or steering until the
pump motor stops.
Stop on a Slope Timer Once the driver stops on a
slope, the shafts of the drive motors are locked while
the vehicle is stationary so it may hold its position
4 Stop on a Slope Timer
regardless of whether the EM parking brake is
engaged or not. This function is triggered by the
release of the accelerator pedal by the driver.

B20T-7 PLUS, B20X-7 PLUS 9-87 EasyView Program

 Calibration Menu – Truck Setup

Fig. 9-99

No. Parameter Description

1 Li Battery enable When this parameter value is on, Lithium-ion Battery can be used.
2 Enable Geofence When this parameter value is on, the geofence lamp is enabled.
Enable Working When this parameter value is on, the cooling fan function is
3
Fans enabled.
Enable Calibration When this parameter value is on, the instrument panel can be
4
by Display used to view and change calibration parameters.
Enable Turtle When this parameter value is on, the Turtle Speed function can be
5
Speed by Display turned On or Off from the instrument panel.
Enable EHS by When this parameter value is on, the EHS mode function can be
6
Display selected though the vehicle display.
When this parameter value is on, the display is allowed to go to
7 Enable Chat Time
PP mode.

EasyView Program 9-88 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description
8 Enable British Units Enables the use of British units.
Enables the use of fingertip option. For a fingertip vehicle, you
9 Enable Fingertip
should� set this parameter to “1” after flashing.
10 Enable Auto Clamp Defines whether auto clamp function is used on this vehicle or not.
Enable Aux2 Determines whether AUX2 is used on this vehicle or
11 Enable Aux2 not. When this� parameter is On, the system will check for valve
presence.
12 Enable Auto Tilt Defines whether auto tilt function is used on this vehicle or not.
When this parameter value is on, the vehicle‘s GSS function is all
13 Enable GSS
enabled.
Buzzer On Forward When this parameter value is on, the vehicle buzzer sound when
14
Direction the� forward direction is selected.
Buzzer On Reverse When this parameter value is on, the vehicle buzzer sound when
15
Direction the reverse direction is selected.
When this parameter value is on, turtle mode is active, and the
Buzzer On Turtle
16 vehicle speed equals the Max Speed in Turtle Mode, the vehicle
Speed

Buzzer On High
buzzer will sound.
When this parameter value is on, the vehicle buzzer sounds when
8
17
Speed Enable the vehicle speed is higher than the Buzzer On Speed.

Electrical System (F-series)

Buzzer On Speed Defines the buzzer on high speed level, when
18 Buzzer On Speed motor speed is higher� than this value, and Buzzer On High
Speed Enable is ON, buzzer sound.
When this parameter value is on and the Lift function and any of
the other functions (Tilt, AUX1, AUX2) are operated
simultaneously, the pump operates at a speed that is the lowest
Lift Priority For
speed among the inputs (Tilt, AUX1, AUX2 or Lift).
19 Pump Reference
When this parameter value is off and the Lift function and any of
Speed
the� other functions (Tilt, AUX1, AUX2) are operated
simultaneously, then the pump operates at a speed that is the
highest speed among the� inputs (Tilt, AUX1, AUX2 or Lift).
Controller Fan When controller temperature is higher than the value of this
20
Starting Temp setting, the cooling fan runs automatically.
Motor Fan Starting When Motor is higher than the value of this setting, the cooling fan
21
Temp runs automatically.
If there is no input on AUX2 during the amount of time set for
Auto Clamp First
22 this� parameter since the vehicle is keyed on, the auto clamp
Delay
function will� be automatically conducted (fingertip only).
If there is no input on AUX2 during the amount of time set for this
Auto Clamp Interval
23 parameter since the last AUX2 operation, the auto clamp function
Delay
will be automatically conducted (fingertip only).
Whether or not to use the function to detect the operation order in
24 Enable Seat belt which the seat belt must be operated after the seat switch
operation.
Enable Mono Pedal Whether to enable the F/R switch in a vehicle that uses the
25
With Fingertip fingertip and mono pedal options.
Lift Lever neutral
26 Whether to enable the lift lever neutral switch in a vehicle.
SW Enable
Forward Light
27 Whether to enable the forward light relay in a vehicle.
Relay Enable

B20T-7 PLUS, B20X-7 PLUS 9-89 EasyView Program

 Calibration Menu – Mode Selection for Traction

Fig. 9-100

No. Parameter Description

Indicates if Economic mode is active on the instrument

1 E Mode (monitor variable)
panel.
Indicates if Standard mode is active on the instrument
2 S Mode (monitor variable)
panel.
Indicates if High Performance mode is active on the
3 H Mode (monitor variable) instrument�
panel.

4 Max Speed in Turtle Mode Maximum drive motor speed allowed in turtle mode.

Maximum drive motor current allowed in “E” power�

mode. Setting this parameter to a higher value allows
a heavily loaded vehicle to reach higher speeds.
5 Drive Maximum Current E Setting this parameter to a lower value limits the speed
of a heavily loaded vehicle. The higher value allows a
heavily loaded truck to reach higher speeds and lower
value limits the speed of a heavily loaded truck.
Maximum drive motor forward speed allowed in “E”
6 Drive Forward Max Speed E
power mode.
Maximum drive motor reverse speed allowed in “E”
7 Drive Reverse Max Speed E
power mode.
Maximum drive motor current allowed in “S” power
mode. Setting this parameter to a higher value allows a
8 Drive Maximum Current S heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.

EasyView Program 9-90 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description

Maximum drive motor forward speed allowed in “S”

9 Drive Forward Max Speed S
power mode.
Maximum drive motor reverse speed allowed in “S”
10 Drive Reverse Max Speed S
power mode.
Maximum drive motor current allowed in “H” power
mode. Setting this parameter to a higher value allows a
11 Drive Maximum Current H heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.
Maximum drive motor forward speed allowed in “H”
12 Drive Forward Max Speed H
power mode.
Maximum drive motor reverse speed allowed in “H”
13 Drive Reverse Max Speed H
power mode.

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-91 EasyView Program

 Calibration Menu – Mode Selection for Pump

Fig. 9-101

No. Parameter Description

Indicates if Economic mode is active on the instrument
1 E Mode (monitor variable)
panel.
Indicates if Standard mode is active on the instrument
2 S Mode (monitor variable)
panel.
Indicates if High Performance mode is active on the
3 H Mode (monitor variable)
instrument panel.

EasyView Program 9-92 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu –E/S/H MODE Performance

Fig. 9-102

No. Parameter Description

Lift Max Speed

Maximum pump motor speed allowed in “E” power mode
8
1 as a result of a maximum lift command. This setting
(E MODE performance)

Electrical System (F-series)

controls the maximum lift speed with no load (unloaded).
Maximum pump motor speed allowed in “S” power mode
Lift Max Speed�
2 as a result of a maximum lift command. This setting
(S MODE performance)
controls the maximum lift speed with no load (unloaded).
Maximum pump motor speed allowed in “H” power mode
Lift H Speed�
3 as a result of a maximum lift command. This setting
(H MODE performance)
controls the maximum lift speed with no load (unloaded).

B20T-7 PLUS, B20X-7 PLUS 9-93 EasyView Program

 Calibration Menu – Drive Response

Fig. 9-103

No. Parameter Description

The acceleration response to a full accelerator pedal
command (> 90%) when the vehicle is at a high speed
(> 70% max speed). Increasing this setting results in a
Acceleration Rate HS
1 slower� response; decreasing this setting results in a faster
(Full Accel Rate HS)
response. The Acceleration Rate HS parameter is typically
set higher (slower) than the Acceleration Rate LS
parameter.
The acceleration response to a full accelerator pedal
command (> 90%) when the vehicle is at a low speed
Acceleration Rate LS (< 30% max speed). Increasing this setting results in a
2
(Full Accel Rate LS) slower� response; decreasing this setting results in a faster
response. The Acceleration Rate LS parameter is typically
set lower (faster) than the Acceleration Rate HS parameter.
The acceleration response to a low accelerator pedal
command (< 10%). Acceleration response for intermediate
(10% to 90%) accelerator pedal commands is scaled
between the Low Accel Rate and either the Acceleration
Rate LS or Acceleration Rate HS settings (depending on
3 Low Accel Rate
the vehicle’s speed). Increasing this setting results in a
slower response; decreasing this setting results in a faster
response. The Low Accel Rate parameter is typically set
higher (slower) than both the Acceleration Rate LS and
Acceleration Rate HS parameters.

EasyView Program 9-94 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description
The deceleration response when the accelerator pedal
command is released (to neutral) while the vehicle is
traveling at high speeds. Increasing this setting results in
Release Rate HS
4 a slower deceleration response; decreasing this setting
(Neutral Decel Rate HS)
results in a faster deceleration response. The Release Rate
HS parameter is typically set higher (slower) than the
Release Rate LS parameter.
The deceleration response when the accelerator pedal
command is released (to neutral) while the vehicle is
traveling at low speeds. Increasing this setting results in a
Release Rate LS
5 slower deceleration response; decreasing this setting
(Neutral Decel Rate LS)
results in a faster deceleration response. The Release Rate
LS parameter is typically set lower (faster) than the Release
Rate HS parameter.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while
the vehicle is traveling at high speeds. Increasing this
setting results in a slower deceleration response;
8
6 Partial Decel Rate
decreasing this setting results in a faster deceleration

Electrical System (F-series)

response. The Partial Decel Rate parameter is typically set
higher (slower) than both the Release Rate LS and Release
Rate HS parameters.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while
the vehicle is traveling at high speeds. Increasing this
Inversion Rate HS
7 setting results in a slower deceleration response;
(Full Brake Rate HS)
decreasing this setting results in a faster deceleration
response. The Inversion Rate HS parameter is typically set
higher (slower) than the Inversion Rate LS parameter.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while
the vehicle is traveling at low speeds. Increasing this setting
Inversion Rate LS
8 results in a slower deceleration response; decreasing this
(Full Brake Rate LS)
setting results in a faster deceleration response. The
Inversion Rate LS parameter is typically set lower (faster)
than the Inversion Rate HS parameter.
The response when the drive direction is reversed at low
(<10%) accelerator pedal command. Increasing this setting
results in a slower deceleration response; decreasing this
9 Low Inversion Rate setting results in a faster deceleration response. The Low
Inversion Rate parameter is typically set higher (slower)
than both the Inversion Rate HS and Inversion Rate LS
parameters.

B20T-7 PLUS, B20X-7 PLUS 9-95 EasyView Program

 Calibration Menu – Pump Motor RPM_Manual

Fig. 9-104

No. Parameter Description

Pump motor speed when tilt-forward/backward function is
1 Tilt Speed Manually
active without the fingertip option.
Tilt Secondary Speed Pump motor speed at the secondary lifting span when tilt
2
Manually forward/backward function is active.
3 Aux1 Speed Manually Pump motor speed when AUX1 function is active.
Aux1 Secondary Speed Pump motor speed at the secondary lifting span when
4
Manually AUX1 function is active.
5 Aux2 Speed Manually Pump motor speed when AUX2 function is active.
6 Hydro Speed Manually Pump motor speed during steering (excluding lift, tilt, etc.).
7 Idle Speed Manually Pump motor idle speed when there is no steering input.

In addition, tilt speed can be adjusted per the span of tilt load condition. Use the following two
menus.

EasyView Program 9-96 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Pump Motor RPM_Fingertip

Fig. 9-105

No. Parameter Description

Pump motor minimum speed when lift function is active with
1 Lift Min Speed Fingertip
the fingertip option.
Pump motor speed when the fingertip lift knob is placed
8
halfway to the lift command end. The three fingertip lift-

Electrical System (F-series)

related parameters Lift Min Speed Fingertip, Lift Middle
Speed Fingertip, and Lift Max Speed determine the pattern
of fingertip lift acceleration as shown below:

2500 Lift Max

Speed
Lift Middle Speed 2000
2
Fingertip
1500
rpm

Lift Min Speed

1000 Fingertip

500
Lift Middle
Speed Fingertip
0
Knob command

Pump motor speed when lower function is active with the

3 Lower Speed Fingertip
fingertip option.
Pump motor minimum speed when tilt function is active with
4 Tilt Min Speed Fingertip
the fingertip option.
Motor speed when tilt backward function is active with the
5 Tilt BWD Speed Fingertip
fingertip option.
Tilt BWD Secondary Pump motor speed at the secondary lifting span when tilt
6
Speed Fingertip backward function is active with the fingertip option.
Motor speed when tilt forward function is active with the
7 Tilt FWD Speed Fingertip
fingertip option.
Tilt FWD Secondary Pump motor speed at the secondary lifting span when tilt
8
Speed Fingertip forward function is active with the fingertip option.

B20T-7 PLUS, B20X-7 PLUS 9-97 EasyView Program

 No. Parameter Description
AUX1 Min Speed Pump motor minimum speed when AUX1 function is active
9
Fingertip with the fingertip option.
AUX1 FWD Speed Pump motor speed when AUX1 and forward function are
10
Fingertip active with the fingertip option.
Pump motor speed at the secondary lifting span when
AUX1 FWD Secondary
11 AUX1 and forward function are active with the fingertip
Speed Fingertip
option.
AUX1 BWD Speed Pump motor speed when AUX1 and reverse function are
12
Fingertip active with the fingertip option.
AUX1 BWD Secondary Pump motor speed when AUX1 and reverse function are
13
Speed Fingertip active at the secondary lifting span with the fingertip option.
AUX2 Min Speed Pump motor minimum speed when AUX2 function is active
14
Fingertip with the fingertip option.
AUX2 FWD Speed Pump motor speed when AUX2 and forward function are
15
Fingertip active with the fingertip option.
AUX2 BWD Speed Pump motor speed when AUX2 and backward function are
16
Fingertip active with the fingertip option.
Pump motor idle speed when there is no steering input with
17 Idle Speed Fingertip
the fingertip option.
Pump motor speed during steering (excluding lift, tilt, etc.)
18 Steering RPM Fingertip
with the fingertip option.

EasyView Program 9-98 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Tilt Speed Reduction_Manual

Fig. 9-106

Tilt Speed Reduction_Fingertip

8

Electrical System (F-series)

Fig. 9-107

No. Parameter Description

Tilt Speed For 0∼20 Percent
1
Load
- Functions used in models with the weight scale option.
Tilt Speed For 21∼40
2 - When the load is in the range of XX % of the maximum
Percent Load
load, the tilt speed decreases by lowering the motor
Tilt Speed For 41∼60
3 RPM as much as the set value.
Percent Load
Example) When carrying a 1 ton load in the B20X
Tilt Speed For 61∼80
4 model, if the 41~60% setting value is 95, the motor RPM
Percent Load
decreases to 800 x 0.95 = 760 rpm.
Tilt Speed For 81∼100
5
Percent Load

B20T-7 PLUS, B20X-7 PLUS 9-99 EasyView Program

 Calibration Menu – Weight Sensor

Fig. 9-108

No. Parameter Description

When this parameter value is on, the weight sensor�
1 Weight Sensor Enable
function is enabled.
2 Weight Sensor Output Weight sensor voltage (V)
3 No Load Pressure Voltage Weight sensor voltage (V) without load.
4 Load Pressure Voltage Weight sensor voltage (V) with load.

EasyView Program 9-100 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Weight Sensor - Load weight British units ON

Fig. 9-109

No. Parameter Description

1 Load Weight in Lbs Load weight in the British unit. [Lbs]
Tilt Speed Reduced By
2 Tilt speed reduction per the load.
Weight in Lbs
8

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-101 EasyView Program

 Calibration Menu – Weight Sensor - Load weight British units OFF

Fig. 9-110

No. Parameter Description

1 Load Weight in Kg Load weight in the International unit. [Kg]
Tilt Speed Reduced By
2 Tilt speed reduction per the load. [Kg]
Weight in Kg

EasyView Program 9-102 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – EFB Advanced

Fig. 9-111

No. Parameter Description

EM Emergency Shut Down Counts the number of times operating the EM brake in
1
Counts an emergency situation.
If the number of using the EM brake in an emergency
2

3
EM Service Counts

EM Service Counts Reset

situation exceeds the set number, this function is limited.
Reset the EM service counts.
8
When the EM service counts reach the set value, an

Electrical System (F-series)

EM Service Counts Expired
4 error is displayed and the vehicle speed is limited to the
RPM
set value.

B20T-7 PLUS, B20X-7 PLUS 9-103 EasyView Program

 9-6-7 Initial settings
The output analog voltage of each accelerator, lift sensor,
steering sensor and brake sensor signals to inform the
controllers of their physical positions.

In other words, the electrical system recognizes these

components’ positions according to how high their output
voltage is. As there is a variation in voltage output versus
physical position among individual units, you must reset
this relationship once any of the aforementioned
components is replaced or the controller firmware is
updated.

The initial setting procedure for each component is as

follows:

Accelerator initial settings

1. On EasyView, go to the Calibration Menu 

Pedal Set.

2. Check the value of the Pedal Voltage A parameter

(1) when the accelerator is not pressed at all.
Enter this value in the setting field for the Min
Accelerator A parameter (2) and then, press
Save.

(1)

(2)

Fig. 9-112

EasyView Program 9-104 B20T-7 PLUS, B20X-7 PLUS

 3. Check the value of the Pedal Voltage A parameter
(1) when the accelerator is fully pressed. Enter
this value in the setting field for the Max
Accelerator A parameter (3) and then, press
Save.

(1)

(3)

8
Fig. 9-113

Electrical System (F-series)

Lift sensor initial setting

1. On EasyView, go to the Calibration Menu  Lift

Set.

2. Check the value of the Lift Command parameter

(1) when the lift lever is in neutral. Enter this value
in the setting field for the Lift Min parameter (2)
and then, press Save.

(1)

(2)

Fig. 9-114

B20T-7 PLUS, B20X-7 PLUS 9-105 EasyView Program

 3. Check the value of the Lift Command parameter
(1) when the lift lever is fully pulled. Enter this
value in the setting field for the Lift Max
parameter (3) and then, press Save.

(1)

(3)

Fig. 9-115

Steering sensor initial setting

1. On EasyView, go to the Calibration Menu 

Steering Set.

2. Check the value of the Steer Sensor Output

Voltage parameter (1) when the rear wheels are
fully turned left. Enter this value in the setting
field for the Steering Anti clock parameter (2) and
then, press Save.

(1)

(2)

Fig. 9-116

EasyView Program 9-106 B20T-7 PLUS, B20X-7 PLUS

 3. Check the value of the Steer Sensor Output
Voltage parameter (1) when the rear wheels are
in the middle. Enter this value in the setting field
for the Steering Middle parameter (3) and then,
press Save.

(1)

(3)

8
Fig. 9-117

Electrical System (F-series)

4. Check the value of the Steer Sensor Output
Voltage parameter (1) when the rear wheels are
fully turned right. Enter this value in the setting
field for the Steering Clock parameter (4) and
then, press Save.

(1)

(4)

Fig. 9-118

B20T-7 PLUS, B20X-7 PLUS 9-107 EasyView Program

 Brake pedal initial settings

1. Prior to this initial setting, conduct brake pedal

adjustment. [Refer to Chapter 3-7-4]

2. On EasyView, go to the Calibration Menu Brake

Pedal Set.

3. Setting for Brake Min.

3-1. Read the value of Brake Pedal Voltage A

parameter (1) when the brake pedal is not
pressed at all.

3-2. Click the row for Brake Min.

3-3. Enter the value read at 2-1 in the setting field

in box (2) and then, press the Save (3).
Compared to 0.50V in the box (1), a little bit
of higher value like 0.55V is recommended.

Fig. 9-119

EasyView Program 9-108 B20T-7 PLUS, B20X-7 PLUS

 4. Setting for Brake Max.

4-1. Read the value of Brake Pedal Voltage A

parameter (1) when the brake pedal is fully
pressed.

4-2. Click the row for Brake Max.

4-3. Enter the value read at 4-1 in the setting field

in box (2) and then, press the Save (3).
Compared to 4.50V in the box (1), a little bit
of lower value like 4.45V is recommended.

Electrical System (F-series)

Fig. 9-120

B20T-7 PLUS, B20X-7 PLUS 9-109 EasyView Program

9-7 Handling faults on Instrument/EasyView
A. Curtis code (LED code)

In addition to the instrument panel and EasyView, the

drive and pump motor controllers also inform the operator
of the current faults using two fault code indicator LEDs
installed on each controller and the fingertip extension
module. Their fault indications are called “Curtis code
(LED code)”.

Compared to other indicators, they have an advantage in

that the operator can easily identify which controller has a
trouble simply by seeing them— only the LEDs on the
faulty controllers light up. The table below shows which
controller could set off a warning for each fault code.

For an explanation of how to read Curtis codes, see

Section 9-3-4.

Handling faults on Instrument/EasyView 9-110 B20T-7 PLUS, B20X-7 PLUS

 B. Measures for fault codes

Panel
Fault description
code
LIB VOLT HIGHLOW - Lithium battery over voltage/low voltage warning
LED code TL-6E
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
01
1. Warning message from Lithium-ion battery BMS.
Cause
2. High/low voltage of the battery pack.

Solution 1. Check the lithium-ion battery.

LIB VOLT UNBALAN - Lithium battery voltage unbalancing warning

LED code TL-6F
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
02
Cause
1. Warning message from Lithium-ion battery BMS. 8
2. Unbalanced battery cells.

Electrical System (F-series)

Solution 1. Check the lithium-ion battery.

LIB VOLT UNBALAN - Lithium battery temperature unbalancing warning

LED code TL-7A
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
03
1. Warning message from Lithium-ion battery BMS.
Cause
2. The temperature of the battery is high or unbalanced.

Solution 1. Check the lithium-ion battery.

LIB OVER CURRENT - Lithium battery over current warning

LED code TL-7B
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
04
1. Warning message from Lithium-ion battery BMS.
Cause
2. Battery current too high.

Solution 1. Check the lithium-ion battery.

B20T-7 PLUS, B20X-7 PLUS 9-111 Handling faults on Instrument/EasyView

 LIB CAN Fault - Lithium battery CAN fault
LED code TL-7C
Traction Pump Extension EM Brake
Controller Action
Stop by EAB stop Work Stop by EAB

1. Cannot view CAN information from BMS or PDO timed out from
05 Cause
BMS.

1. Check the lithium-ion battery.

Solution 2. Check the canvas for 0X630 CAN message.
3. Check if CAN messages are stable.
CONTACTOR FAULT– Contactor not working properly
LED code 31/38/39
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Work
once

1. The line contactor coil is either open or shorted.

2. The line contactor contacts are welded closed.
Cause
3. There are faulty crimps and connections in the wires to the line
contactor coil.

17 1. Check that the line contactor is normally wired.

2. Check if the line fuse has blown.
3. Check if the coil of the line contactor is open-circuit (its normal
resistance is 360 Ω at 25°C [77°F]).

Solution 4. Check its resistance and replace it if it is detected to be abnormal.

5. With the key switch off, measure the resistance between the two
contact tips using a multi the metric to check if they are fused (If a
battery voltage is detected between the line contactor's secondary
tip and the controller's "B-" pin with the key off, it indicates a fusion
between the two tips. In that case, replace the line contactor).
EXT VOLT FAULT – Extension module’s voltage (extension module disabled)
LED code P-5A(EXM21,22)
Traction Pump Extension EM Brake
Controller Action
No action No action Shut down No action
Cause Over voltage/under voltage on the extension module

1. Measure the voltage between pins 1 and 3 on the harness

connector of the fingertip extension module to check if the
21 measurement represents the battery voltage.
2. If it is not measured the battery voltage, check if pin 1 on the left
Solution drive motor controller and pin 3 on the fingertip extension module
connector are correctly connected to one another. And also check if
the battery's negative terminal is correctly connected to pins 1 and
2 on the fingertip extension module connector.
3. If it is not correctly connected, replace the harness.

Handling faults on Instrument/EasyView 9-112 B20T-7 PLUS, B20X-7 PLUS

 EXT TIME FAULT – Extension module’s communications faulty (extension module
disabled)
LED code P-5B(EXM51,52,53),P-67
Traction Pump Extension EM Brake
Controller Action
No action No action Shut down No action
PDO timeout/SDO fault reported on Ext module; CAN Communication
Cause
fault

51 1. Check if pin 5 on the fingertip extension module is normally

connected to pin 23 on the left drive motor controller.
2. Check if pins 4 on the fingertip extension module is normally
connected to pin 35 on the left drive motor controller.
Solution
3. Reinstall the latest software version.
4. If the steps above do not solve the problem, replace the pump
motor�
controller.
BATT MISMATCH – Specifications of battery and controller do not match
LED code 61

Controller Action
Traction

Shut down
Pump

Shut down
Extension

Work
EM Brake
Shut down at
8
once

Electrical System (F-series)

1. The difference between the battery set voltage and the measured
60 voltage at KSI is large. Measure the voltage at KSI and check if it is
within the range below.
Cause 2. The voltage range of the battery for 36V is 26-46V.
3. The voltage range of the battery for 48V is 41.5-58V.
4. The voltage range of the battery for 80V is 64-96V.

Solution After setting the battery voltage to a normal state, cycle KSI.

B20T-7 PLUS, B20X-7 PLUS 9-113 Handling faults on Instrument/EasyView

 D-INV SHUTDOWN – Right drive motor controller overheated (system halted)
LED code 16
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once
The right drive motor controller has reached the shutdown temperature
Cause limit
(95°C, 203°F).

1. Check the temperature of the right drive motor controller in

diagnostic mode on the instrument panel or EasyView.

66 2. If the temperature is detected to be higher than 95°C (203°F), cool

down the vehicle for 15 minutes.
3. If the right drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
Solution
4. Check if the EM parking brake is engaged.
5. Check if the vehicle is excessively loaded.
6. Check if the right drive motor controller is improperly mounted,
preventing heat conduction.
7. If the problems remains present, replace the right drive motor
controller.

L-INV SHUTDOWN– Left drive motor controller overheated (system halted)

LED code 16
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once
The left drive motor controller has reached the shutdown temperature
Cause limit. (95 °C, 203 °F).

1. Check the temperature of the left drive motor controller in diagnostic

mode on the instrument panel or EasyView.
2. If the temperature is detected to be more than 95°C (185°F), cool
67 down the vehicle for 15 minutes.
3. If the Left drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
Solution
4. Check if the EM parking brake is engaged.
5. Check if the vehicle is excessively loaded.
6. Check if the left drive motor controller is improperly mounted,
preventing heat conduction.
7. If the problems remains present, replace the left drive motor
controller.

Handling faults on Instrument/EasyView 9-114 B20T-7 PLUS, B20X-7 PLUS

 P-INV SHUTDOWN – Pump motor controller overheated (system halted)
LED code 16
Traction Pump Extension
EM Brake
Controller Action Shut down at
No action Shut down Work
once
The pump motor controller has reached the shutdown temperature
Cause limit.(95°C, 203°F).

1. Check the temperature of the right drive motor controller in

diagnostic
mode on the instrument panel or EasyView.
68
2. If the temperature is detected to be more than 95°C (185°F), cool
down the vehicle for 15 minutes.

Solution 3. If the Pump motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
4. Check if the vehicle is excessively loaded.
5. Check if the pump motor controller is improperly mounted,
preventing heat conduction.
6. If the problems remains present, replace the pump motor controller.

P-MOTOR ENCODER – Pump motor’s encoder failed

8
LED code 36/73/88/93

Electrical System (F-series)

Traction Pump Extension EM Brake
Controller Action
No action Shut down Work No action
The phase A or phase signal of the Pump motor encoder is abnormal or
Cause not detected, or indicates an abnormally fast speed.

1. Check if the connector of the pump motor encoder is normally

connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the
pump motor controller measures 5 V.
76
3. Check if pin 3 on the pump motor encoder is normally connected to
pin 31 (phase A) on the pump motor controller.

Solution 4. Check if pin 4 on the pump motor encoder is normally connected to

pin 32 (phase B) on the pump motor controller.
5. Check if the phrases A and B on the pump motor encoder normally
turn on and off using EasyView. - Test Menu Pump “Pump
Motor Encoder A” & “Pump Motor Encoder B”
If either phrase is abnormal, replace the pump motor encoder.
6. If the problems remains present, replace the pump motor controller.

B20T-7 PLUS, B20X-7 PLUS 9-115 Handling faults on Instrument/EasyView

 R-M TEMP SENSOR – Right drive motor’s thermal sensor failed (display only, no
change in vehicle performance)
LED code 29
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
Right drive motor thermal sensor voltage is detected to be out of range.
Cause (Continued operation with this fault may result in an overheated drive
motor, reducing its efficiency.)

1. Check if the connector of the thermal sensor on the right drive

77 motor is normally connected.
2. Check if pin 1 on the thermal sensor of the right drive motor is
normally connected to pin 8 on the right drive motor controller.

Solution 3. Check if pin 2 on the thermal sensor of the right drive motor is
normally connected to pin 7 on the right drive motor controller.
4. Check if the resistance values of the thermal sensor on the right
drive motor measures 603 Ω at 25 °C (77 °F).
5. Replace the thermal sensor of the right drive motor.

L-M TEMP SENSOR– Left drive motor’s thermal sensor failed

(display only, no change in vehicle performance)
LED code 29
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
The left drive motor thermal sensor voltage is detected to be out of
Cause range. (Continued operation with this fault may result in an overheated
drive motor, reducing its efficiency.)

1. Check if the connector of the thermal sensor on the left drive motor
78 is normally connected.
2. Check if pin 1 on the thermal sensor of the left drive motor is
normally connected to pin 8 on the left drive motor controller.

Solution 3. Check if pin 2 on the thermal sensor of the left drive motor is
normally connected to pin 7 on the left drive motor controller.
4. Check if the resistance values of the thermal sensor on the left
drive motor measures 603 Ω at 25 °C (77 °F).
5. Replace the thermal sensor of the left drive motor.

Handling faults on Instrument/EasyView 9-116 B20T-7 PLUS, B20X-7 PLUS

 P-M TEMP SENSOR – Pump motor’s thermal sensor failed (display only, no
change in vehicle performance)
LED code 29
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
Pump motor thermal sensor voltage is detected to be out of range.
Cause Continued operation with this fault may result in an overheated drive
motor, reducing its efficiency.

1. Check if the connector of the thermal sensor on the pump motor is

79 normally connected.
2. Check if pin 1 on the thermal sensor of the pump motor is normally
connected to pin 8 on the pump motor controller.

Solution 3. Check if pin 2 on the thermal sensor of the pump motor is normally
connected to pin 7 on the pump motor controller.
4. Check if the resistance values of the thermal sensor on the pump
motor measures 603 Ω at 25 °C (77 °F).
5. Replace the thermal sensor of the pump motor.

L-EM BRAKE – Left EM brake failed

LED code 32/92
8
Traction Pump Extension EM Brake

Electrical System (F-series)

Controller Action Shut down at
Stop by EAB No action Work
once
The circuit from pin 5 or 13 of the left drive motor controller is open or�
Cause short, causing an abnormal current in the circuit detected by the
controller.

1. Check if the connector of the EM brake on the left drive motor is

normally connected.
80 2. Check if the connectors labeled “EM CONN A” and “EM CONN B”
are properly connected.
3. Check if pin 1 of the left EM brake connector is normally connected
Solution to pin 5 of the left drive motor controller connector.
4. Check if pin 2 of the left EM brake connector is normally connected
to pin 13 of the left drive motor controller connector.
5. Swap the harness connectors for the left and right EM brakes, and
check which fault code is displayed.
6. If fault code 81 appears, replace the left drive motor's EM brake.

B20T-7 PLUS, B20X-7 PLUS 9-117 Handling faults on Instrument/EasyView

 R-EM BRAKE - Right EM brake failed
LED code 32/92
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop by EAB No action Work
once
The circuit from pin 5 or 13 of the left drive motor controller is open or�
Cause short, causing an abnormal current in the circuit detected by the
controller.

1. Check if the connector of the EM brake on the right drive motor is

normally connected.

81 2. Check if the connectors labeled “EM CONN A” and “EM CONN B”

are
properly connected.
3. Check if pin 1 of the right EM brake connector is normally
Solution connected to pin 5 of the right drive motor controller connector.
4. Check if pin 2 of the right EM brake connector is normally
connected to pin 13 of the right drive motor controller connector.
5. Swap the harness connectors for the left and right EM brakes, and
check which fault code is displayed.
6. If fault code 80 appears, replace the right drive motor's EM brake.

EM BRAKE WARN –EM BRAKE WARN

LED code 5B
Traction Pump Extension EM Brake
Controller Action
Limited to 2000 No action Work No action

82 Triggered when Fault code 88 (EM BRAKE LOCKED) has happened to

Cause 20 times.
- Phenomenon : The speed of drive motor is limited to 2,000 rpm.

1. After checking out that EM BRAKE is free from defect, conduct

Solution
resetting EM BRAKE COUNT.

PAR CHANGE FAULT – Parameter change failed

LED code 49
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop Stop Work
83 once
A change to a system parameter is detected that requires this safety
Cause fault.

1. This code appears when a parameter value has been changed.

Solution
Turn off the key switch and turn it on again.

EM BRAKE LOCKED – EM BRAKE WARNING

LED code 63
Traction Pump Extension EM Brake
Controller Action
Shut down Work Work Shut down
88 When the brake pedal is pushed more than 90% while driving motor
Cause speed exceeds 3,000 rpm, check the rpm for 1.7 seconds and then, force
EM brake when it does not fall below 2,700rpm.

Solution 1. Turn the key switch off and again on.

Handling faults on Instrument/EasyView 9-118 B20T-7 PLUS, B20X-7 PLUS

 CAP NOT CHARGED – Capacitor not charged
LED code 14
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Work
once
The capacitor in one of the controllers has been discharged or charged�
Cause abnormally.
A
1. Turn the key switch off and again on.
2. Check that the line contactor is normally wired.
Solution 3. If the problem persists, identify which motor controller’s LEDs have
lit up.
4. Replace the faulty motor controller.
DISPLAY CAN FAULT – Display CAN Communication failed
LED code 59
Traction Pump Extension EM Brake
Controller Action
Work Work Work Work
Cause The instrument panel’s CAN Communication is failed.

1. Check if the instrument panel is correctly connected with the main

harness.
8
A7 2. Check if the resistance between pins 2 and 7 on the CAN port

Electrical System (F-series)

connector measures approx. 60Ω when the harness is connected to
the port and the key switch is off.
Solution
3. If the measurement falls short of 60Ω, check if the resistance
between pins 5 and 6 on the instrument panel’s P2 connector
measures approx.120Ω.
4. If the measurement falls short of 120 Ω, replace the instrument
panel.
FR UNIT OPEN – F/R unit is not connected
LED code T-6B
Traction Pump Extension EM Brake
Controller Action
Stop by EAB No action No action Stop by EAB
AF Cause Both forward and reverse are ON.

1. Check the harnesses to F/R unit.

Solution
2. Replace F/R unit.
AUTO TILT RELAY – Relay for P1-4 Driver3 Auto-tilt not working, due to no
fingertip
LED code P-A3
Traction Pump Extension EM Brake
Controller Action
No action no auto tilt No action No action

AL 1. The auto-tilt (P1-4) solenoid is disconnected or shorted (short

Cause
circuit).

1. Check reverse bsuzzer solenoid, wiring and connections.

Solution 2. Replace the relay.
3. Replace the pump motor controller.

B20T-7 PLUS, B20X-7 PLUS 9-119 Handling faults on Instrument/EasyView

 DSUPERVISION FLT – Checking the input/output of the right drive controller and
the redundancy status of the MCU.
LED code 77/79
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once

1. The Supervisor has detected a mismatch in redundant readings.

b1 2. Internal damage to Supervisor microprocessor.

Cause
3. Switch inputs allowed to be within upper and lower thresholds for
over 100 milliseconds.
(for recurring errors, check the switches for moisture)

1. Disconnect the controller connector then clean / dry the connnector

Solution or replace if defective.
2. Replace the drive controller.
LSUPERVISION FLT – Checking the input/output of the left drive controller and the
redundancy status of the MCU.
LED code 77/79
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once

1. The Supervisor has detected a mismatch in redundant readings.

b2 2. Internal damage to Supervisor microprocessor.

Cause
3. Switch inputs allowed to be within upper and lower thresholds for
over 100 milliseconds. (for recurring errors, check the switches for
moisture)

1. Disconnect the controller connector then clean / dry the connnector

Solution or replace if defective.
2. Replace the drive controller.
PSUPERVISION FLT – Checking the input/output of Pump controller and the
redundancy status of the MCU.
LED code 77/79
Traction Pump Extension EM Brake
Controller Action Shut down at
No action Shut down Work
once

1. The Supervisor has detected a mismatch in redundant readings.

b3 2. Internal damage to Supervisor microprocessor.

Cause
3. Switch inputs allowed to be within upper and lower thresholds for
over 100 milliseconds. (for recurring errors, check the switches for
moisture)

1. Disconnect the controller connector then clean / dry the connnector

Solution or replace if defective.
2. Replace the drive controller.

Handling faults on Instrument/EasyView 9-120 B20T-7 PLUS, B20X-7 PLUS

 DUNINTEND MOVING – Right Motor unintended moving (Speed Limit Supervision,
Motor Not Stopped, Motor Braking Impaired, Hazardous Movement, Interlock
braking supervision)
LED code 19/1A/84/D6
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop Work Work
once

1. Motor rpm has exceeded the Max Speed Limit setting for the Max
Speed Time Limit setting’s duration.
2. The purpose of this function is to detect hazardous movement when
the AC motor is stopped and expected to stay stopped.
3. Current cutback lowering than the setting for Over voltage and over
b4 temperature during Regen Condition.
Cause
4. This fault detects hazardous movement when the motor is
requested to be moving.
----The first hazard is a motor that is not able to slow down if the�
throttle goes to zero or the direction switch is not in the direction of
travel.
----The second hazard is a motor that accelerates the wrong way�
or goes too fast. 8
1. Checking the EM brake mechanical force.

Electrical System (F-series)

Solution 2. Checking if working condition can meet the truck's spec.
3. Battery or cable resistor is too high.
LUNINTEND MOVING – Left Motor unintended moving (Speed Limit Supervision,
Motor Not Stopped, Motor Braking Impaired, Hazardous Movement, Interlock
braking supervision)
LED code 19/1A/84/D6
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop Work Work
once

1. Motor rpm has exceeded the Max Speed Limit setting for the Max
Speed Time Limit setting’s duration.
2. The purpose of this function is to detect hazardous movement when
the AC motor is stopped and expected to stay stopped.
3. Current cutback lowering than the setting for Over voltage and over
b5 temperature during Regen Condition.
Cause
4. This fault detects hazardous movement when the motor is
requested to be moving.
----The first hazard is a motor that is not able to slow down if the
throttle goes to zero or the direction switch is not in the direction of
travel.
----The second hazard is a motor that accelerates the wrong way�
or goes too fast.

1. Checking the EM brake mechanical force.

Solution 2. Checking if working condition can meet the truck's spec.
3. Battery or cable resistor is too high.

B20T-7 PLUS, B20X-7 PLUS 9-121 Handling faults on Instrument/EasyView

 PUNINTEND MOVING – Pump Motor unintended moving (Speed Limit
Supervision, Motor Not Stopped, Motor Braking Impaired, Hazardous Movement,
Interlock braking supervision)
LED code 19/1A/84/D6
Traction Pump Extension EM Brake
Controller Action
Work Stop Work Work

1. Motor rpm has exceeded the Max Speed Limit setting for the Max
Speed Time Limit setting’s duration.
2. The purpose of this function is to detect hazardous movement when
the AC motor is stopped and expected to stay stopped.
3. Current cutback lowering than the setting for Over voltage and over
b6 temperature during Regen Condition.
Cause
4. This fault detects hazardous movement when the motor is
requested to be moving.
----The first hazard is a motor that is not able to slow down if the
throttle goes to zero or the direction switch is not in the direction of
travel.
----The second hazard is a motor that accelerates the wrong way�
or goes too fast.

1. Checking the EM brake mechanical force.

Solution 2. Checking if working condition can meet the truck's spec.
3. Battery or cable resistor is too high.
BACKBUZZER RELAY – Back buzzer relay fault if it is standard
LED code P-A4
Traction Pump Extension EM Brake
Controller Action
No action No action No action No action

bL Cause 1. Back buzzer relay (P1-3) solenoid is open or shorted.

1. Check reverse buzzer solenoid, wiring and connections.

Solution 2. Replace the relay.
3. Replace the pump motor controller.
EXT CUR FAULT – Extension module’s current faulty (extension module disabled)
LED code N/A
Traction Pump Extension EM Brake
Controller Action
Shut down
C1 Cause Total current exceeded 18 A.

1. Replace the fingertip harness.

Solution 2. Replace the fingertip extension module.
3. Replace the main harness.

Handling faults on Instrument/EasyView 9-122 B20T-7 PLUS, B20X-7 PLUS

 EXT POWER FAULT – Extension module controller’s power supply faulty (none)
LED code 13/14/15
Traction Pump Extension EM Brake
Controller Action
Shut down
Fingertip extension module failed to be correctly powered from the
Cause
battery

1. Check if the fingertip fuse in fuse box A has been blown.

C2
2. Check if the fingertip extension module is powered at the rated
battery voltage (36V/48V) by measuring the voltage between pins 5
Solution and 6 on the F_CONN. A connector.
3. If the measurement falls short of the rated voltage, replace the
fingertip harness.
4. If the problem persists, replace the fingertip extension module.
R-CONT CAN FAULT – Right CAN Communication failed
LED code 65/72
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Work
once
Cause The right drive motor controller’s CAN Communication is failed.

1. Check if the resistance between pins 2 and 7 on the CAN port

8
connector measures approx. 60 Ω when the harness is connected to

Electrical System (F-series)

the port and the key switch is off.
C7
2. If the measurement falls short of 60 Ω, check if pin 23 on the left
drive motor controller and pin 23 on the right drive motor controller
Solution are correctly connected to one another.
3. If their connection is normal, check if pin 35 on the left drive motor
controller and pin 35 on the right drive motor controller are correctly
connected to one another.
4. Reinstall the software.
5. Right the right drive motor controller.

R COIL POWER – R controller Coil supply (pin 13) fault

LED code TR-A9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Shut down
once

When doing KSI, the controller will check the coil power supply whether
can switch on or off. Fault may be caused by :

dC Cause 1. Coil is shorted to KSI.

2. Coil is shorted to GND.
3. The power supply circuit to the coil is damaged.

1. Check the solenoid connected to pin13 to see whether shorted to

KSI or GND.
Solution
2. Check whether B+ or B- voltage is leaked to pin13.
3. Replace the controller.

B20T-7 PLUS, B20X-7 PLUS 9-123 Handling faults on Instrument/EasyView

 R-CONT VOLTCUT – R controller high or low voltage cut back
LED code TL-23,24
Traction Pump Extension EM Brake
reduce driving
Controller Action
dU and Regen No action No action No action
current

Cause Battery voltage higher or lower than cutback point

Solution 1. Check the battery and cable.

R-INV OVERTEMP – Right drive motor controller overheated (performance

lowered)
LED code 22
Traction Pump Extension EM Brake
Controller Action
Limited to 2000 No action Work No action
The resistance of the thermal sensor inside the right drive motor
Cause controller represents an over-temperature of the controller above the
specified limit of 85°C (185°F).

E1 1. Check the temperature of the right drive motor controller in

diagnostic mode on the instrument panel or EasyView.
2. If the temperature is detected to be higher than 85°C (185°F), cool
down the vehicle for 15 minutes.
Solution
3. If the right drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
4. Check if the EM parking brake is engaged.
5. If the problem persists, replace the right drive motor controller.

L-INV OVERTEMP– Left drive motor controller overheated (performance lowered)

LED code 22
Traction Pump Extension EM Brake
Controller Action
Limited to 2000 No action Work No action
The resistance of the thermal sensor inside the left drive motor
controller�
Cause represents an over-temperature of the controller above the specified limit
of 85°C (185°F).

E2 1. Check the temperature of the left drive motor controller in diagnostic

mode on the instrument panel or EasyView.
2. If the temperature is detected to be more than 85°C (185°F), cool
down the vehicle for 15 minutes.
Solution
3. If the left drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
4. Check if the EM parking brake is engaged.
5. If the problem persists, replace the left drive motor controller.

Handling faults on Instrument/EasyView 9-124 B20T-7 PLUS, B20X-7 PLUS

 P-INV OVERTEMP – Pump motor controller overheated (performance lowered)
LED code 22
Traction Pump Extension EM Brake
Controller Action Limit current
No action Work No action
from 85C-95C
The resistance of the thermal sensor inside the pump motor controller
Cause represents an over-temperature of the controller above the specified limit
of 85°C (185°F).

E3 1. Check the temperature of the right drive motor controller in

diagnostic
mode on the instrument panel or EasyView.
2. If the temperature is detected to be more than 85°C (185°F), cool
Solution down the vehicle for 15 minutes.
3. If the Pump motor controller is hotter than the other controllers,
check its U.V.W. connections To the battery.
4. If the problems remains present, replace the pump motor controller.

R-MOTOR OVERTEMP – Right drive motor overheated (performance lowered)

LED code 28
Traction Pump Extension EM Brake
8
Controller Action Reduce driving
No action Work No action
current

Electrical System (F-series)

The controller has detected that the resistance of the thermal sensor
Cause inside the right drive motor represents an over-temperature of the motor
above the specified limit of 145°C (293°F).

1. Check the temperature of the right drive motor in diagnostic mode

on the instrument panel or EasyView.
2. If the temperature is detected to be more than 145°C (185°F), cool
down the vehicle for 15 minutes.
3. Check if the connector of the thermal sensor on the right drive motor
E4 is
normally connected.
4. Check if pin 1 on the thermal sensor of the right drive motor is
Solution normally
connected to pin 8 on the right drive motor controller.
5. Check if pin 2 on the thermal sensor of the right drive motor is
normally connected to pin 7 on the right drive motor controller.
6. Check if the resistance values of the thermal sensor on the right
drive motor measures 603 Ω at 25 °C (77 °F).
7. Replace the thermal sensor of the right drive motor.
8. If the problems remains present, replace the right drive motor
controller.

B20T-7 PLUS, B20X-7 PLUS 9-125 Handling faults on Instrument/EasyView

 L-MOTOR OVERTEMP – Left drive motor overheated (performance lowered)
LED code 28
Traction Pump Extension EM Brake
Controller Action Reduce driving
No action Work No action
current
The controller has detected that the resistance of the thermal sensor
Cause inside the left drive motor represents an over-temperature of the motor
above the specified limit of 145°C (293°F).

1. Check the temperature of the left drive motor in diagnostic mode on

the instrument panel or EasyView.
2. If the temperature is detected to be more than 145°C (185°F), cool
down the vehicle for 15 minutes.
E5
3. Check if the connector of the thermal sensor on the left drive motor
is normally connected.
4. Check if pin 1 on the thermal sensor of the left drive motor is
Solution normally connected to pin 8 on the left drive motor controller.
5. Check if pin 2 on the thermal sensor of the left drive motor is
normally connected to pin 7 on the left drive motor controller.
6. Check if the resistance values of the thermal sensor on the left drive
motor measures 603 Ω at 25 °C (77 °F).
7. Replace the thermal sensor of the left drive motor.
8. If the problem persists, replace the left drive motor controller.

P- MOTOR OVERTEMP – Pump motor overheated (performance lowered)

LED code 28
Traction Pump Extension EM Brake
Controller Action Reduce pump
Work No action
current
The controller has detected that the resistance of the thermal sensor
Cause inside the pump motor represents an over-temperature of the motor
above the specified limit of 145°C (293°F).

1. Check the temperature of the pump motor in diagnostic mode on the

instrument panel or EasyView.
2. If the temperature is detected to be higher than 20°C (203°F), cool
down the vehicle for 15 minutes.
E6
3. Check if the connector of the thermal sensor on the pump motor is
normally connected.
4. Check if pin 1 on the thermal sensor of the pump motor is normally
Solution connected to pin 8 on the pump controller.
5. Check if pin 2 on the thermal sensor of the pump motor is normally
connected to pin 7 on the pump controller.
6. Check if the resistance values of the thermal sensor on the pump
motor measures 603 Ω at 25 °C (77 °F).
7. Replace the thermal sensor of the pump motor.
8. If the problems remains present, replace the pump motor controller.

Handling faults on Instrument/EasyView 9-126 B20T-7 PLUS, B20X-7 PLUS

 SEAT SQN FAULT – Seat & Seat belt sequence fault (Key on -> Seat on -> Seat belt
on)
LED code 5C
Traction Pump Extension EM Brake
E8 Controller Action
Stop Stop Stop Stop by EAB

Cause Seat belt switch is not connected before seat switch.

Solution Check the seat switch and seat belt switch whether working properly.

SEAT SW OPEN – Seat belt switch open

LED code N/A
Traction Pump Extension EM Brake
E8 Controller Action
Stop Stop Stop Stop by EAB
(Flashing)
Cause Seat belt switch is not connected.

Solution Check the seat belt switch.

WRONG START – Signal to move pump motor detected at startup

LED code 47/52/53/5D/5E

Controller Action
Traction
Shut throttle
Pump
Shut down
Extension
Work
EM Brake
No action
8
Accelerator pedal switch or forward/reverse direction signal is detected to
Cause

Electrical System (F-series)

be active when the vehicle is first switched on.

1. Put the F/R switch in neutral.

EE 2. Check if the accelerator pedal returns normally when released.

3. Calibrate the initial settings for the accelerator using EasyView or
the instrument panel.
Solution
4. Check if pins 2 and 3 on the F/R unit’s 4-pin connector are
connected to one another in neutral. If so, replace the F/R unit. If so,
replace the F/R unit. Check if pins 1 and 2 on the F/R unit’s 4-pin
connector are connected to one another in neutral. If so, replace
the F/R unit.

SEAT SW OPEN – Seat switch opened

LED code
Traction Pump Extension EM Brake
Controller Action
Stop Stop Stop Stop by EAB
Cause The seat switch is open.

1. Sit down on the driver's seat.

EE 2. If fault code EE stays blinking even when the operator is seated,
(FLASHING) check if the connector of the seat switch is normally connected.
3. If the seat belt interlock option is applied, fasten the seat belt after
Solution you are seated.
4. If the actions above do not solve the problem, disconnect the seat
switch connector and measure the resistance between pins 1 and 2
on the connector using a multimeter. If it measures an open circuit, it
means the seat switch is damaged. Replace the seat switch.

B20T-7 PLUS, B20X-7 PLUS 9-127 Handling faults on Instrument/EasyView

 EXTENSION FAULT – Extension module internally faulty
LED code 66
Traction Pump Extension EM Brake
Controller Action
Work Work Stop Work
The fingertip extension module has a firmware error, or is overheated or�
Cause overcooled.
EF
1. Turn the key switch off and again on.
2. Leave the vehicle in a place warmer than 0 °C (32 °F) for 15
Solution
minutes.
3. If the problem persists, replace the fingertip extension model.

LOW BATT VOLT –Battery voltage insufficient (charge needed)

LED code 56
Traction Pump Extension EM Brake
EL Controller Action
limit to 2000 limit to 800 Work No action
The fingertip extension module has a firmware error, or is overheated or
Cause overcooled.
Solution Charge the battery.
MOTOR TEMP FAU – Large temperature difference between right and left drive
motors
LED code T-67
Traction Pump Extension EM Brake
Controller Action
Stop by EAB Work Work Stop by EAB
EP
1. The temperature difference between the left and right drive motors is
Cause
more than 30 degrees.

1. The temperature difference between the left and right drive motors is
Solution
less than 20 degrees.

EEPROM FAULT – Controller memory failed

LED code 46
Traction Pump Extension EM Brake
Shut down at
Controller Action
Shut down Stop Work once if fault on
traction
F Cause The EEPROM memory on a motor controller has failed.

1. Reinstall the latest software version.

2. If the problem persists, identify which motor controller’s LEDs have
Solution
lit up.
3. Replace the faulty motor controller.

Handling faults on Instrument/EasyView 9-128 B20T-7 PLUS, B20X-7 PLUS

 MAX BATT VOLT– Battery voltage excessive
LED code 18
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The battery voltage between terminal B+ and B- on a motor controller has
F0 Cause reached a severe over voltage limit (70 V).

1. Measure the voltage between terminals B+ and B- on each

controller using a multimeter to check if the measurement exceeds
Solution 70 V.
2. If a controller's voltage measures over 70 V, replace it.

MIN BATT VOLT – Battery voltage insufficient

LED code 17
Traction Pump Extension EM Brake
Controller Action
No Drving Stop Work Stop by EAB
The battery voltage between terminal B+ on a motor controller has
Cause
F1 reached a severe under voltage limit (20 V).

Solution
1. Measure the voltage between the terminals B+ and B- on each
controller using a multimeter to check if the measurement falls short
of 20 V.
8

Electrical System (F-series)

2. If a controller's voltage measures below 20 V, replace it.

ACCEL FAULT – Pedal trimmer fault

LED code 55
Traction Pump Extension EM Brake
Controller Action
Stop by EAB No action Work Stop by EAB
The battery voltage between terminal B+ on a motor controller has
Cause
F2 reached a severe under voltage limit (20 V).

1. Measure the voltage between the terminals B+ and B- on each

controller using a multimeter to check if the measurement falls short
Solution of 20 V.
2. If a controller's voltage measures below 20 V, replace it.

R-INVERTER FAULT – Right drive motor controller failed

LED code 13/12/83/DD/D2/54
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
Cause An over current is detected on the right drive inverter.

1. Turn the key switch off and turn it on again.

F3 2. Check if the U, V, W terminals on the right drive motor are normally
connected.
3. Check if the U, V, W terminals on the right drive motor controller are
Solution
normally connected.
4. Check if the respective voltages of the U, V, W terminals measure all
between 0.3–0.7 V using a multimeter.
5. Right the right drive motor controller.

B20T-7 PLUS, B20X-7 PLUS 9-129 Handling faults on Instrument/EasyView

 L-INVERTER FAULT – Left drive motor controller failed
LED code 13/12/83/DD/D2/6A
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
Cause An over current is detected on the left drive inverter.

1. Turn the key switch off and turn it on again.

F4 2. Check if the U, V, W terminals on the left drive motor are normally
connected.
3. Check if the U, V, W terminals on the left drive motor controller are
Solution
normally connected.
4. Check if the respective voltages of the U, V, W terminals measure all
between 0.3–0.7 V using a multimeter.
5. Replace the left drive motor controller.

P-INVERTER FAULT – Pump motor controller failed

LED code 13/12/83/DD/D2/5D
Traction Pump Extension EM Brake
Controller Action
Shut down Stop Work Stop by EAB
Cause An over current is detected on the pump inverter.

1. Turn the key switch off and turn it on again.

F5 2. Check if the U.V.W. terminals on the pump motor are normally.
3. Check if the U.V.W. terminals on the pump motor controller are
Solution normally.
4. Check if the respective voltages of the U, V, W terminals measure all
between 0.3–0.7 V using a multimeter.
5. Replace the pump motor controller.

R-MOTOR OFFSET – Right drive motor current failed

LED code 89/99/C9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
F6 Cause The current sensor offset reading from the right drive motor is invalid.

1. Check for current leakage to the vehicle frame from the right drive
motor phase U, V or W.
Solution
2. If problems persist, the drive motor controller is defective and needs
to be replaced.

L-MOTOR OFFSET – Left drive motor current failed

LED code 89/99/C9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
F7 Cause The current sensor offset reading from the left drive motor is invalid.

1. Check for current leakage to the vehicle frame from the left drive
motor phase U, V or W.
Solution
2. If problems persist, the drive motor controller is defective and needs
to be replaced.

Handling faults on Instrument/EasyView 9-130 B20T-7 PLUS, B20X-7 PLUS

 P-MOTOR OFFSET - Pump motor current failed
LED code 89/99/C9
Traction Pump Extension EM Brake
Controller Action
Stop by EAB Stop Work No action
Cause The current sensor offset reading from the pump motor is invalid.
F8
1. Check for current leakage to the vehicle frame from the pump motor
phase U, V or W.
Solution
2. If problems persist, the pump motor controller is defective and needs
to be replaced.

STEER SENSOR OUT – Steer sensor output failed

LED code 55/B9
Traction Pump Extension EM Brake
Controller Action
Limited to 800 No action Work No action
Analog 1 inputs are over the steering angle sensor’s higher threshold or�
Cause below its lower threshold.

1. Check if pin 1 on the steering sensor connector is normally

connected to pin 25 on the left drive motor controller.
F9 2. Check if pin 2 on the steering sensor connector is normally
connected to pin 24 on the left drive motor controller.
8
3. Check if pin 3 on the steering sensor connector is normally

Electrical System (F-series)

Solution
connected to pin 7 on the left drive motor controller.
4. Check if the steering sensor is detected to output a normal signal on
EasyView.
5. If the measurement is not normal, replace the steering sensor;
Otherwise, replace the left drive motor controller.
12V NOT OK – 12V output from a controller failed
LED code 69
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
An over current (over 200 mA) is detected in the drive or pump motor�
Cause
controller’s 12V supply circuit.

1. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the
FA left drive controller measures 12 V.
2. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the
Solution right drive controller measures 12 V.
3. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the
pump controller measures 12 V.
4. Replace any controller whose 12V output is not normal.

B20T-7 PLUS, B20X-7 PLUS 9-131 Handling faults on Instrument/EasyView

 R-MOTOR ENCODER – Right drive motor’s encoder failed
LED code 36/73/88/93
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The phase A or B signal of the right drive motor encoder is abnormal or
Cause not detected, or indicates an abnormally fast speed.

1. Check if the U, V, W terminals on the right drive motor are normally

connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the
right drive motor measures 5 V.

FC 3. Check if pin 3 on the right drive motor encoder is normally

connected to pin 31 (phase A) on the right drive motor controller.
4. Check if pin 4 on the right drive motor encoder is normally
Solution connected to pin 32 (phase B) on the right drive motor controller.
5. Check if the phrases A and B on the right drive motor encoder
normally turn on and off on EasyView.
- Test Menu  Drive  “Right Motor Encoder A” & “Right Motor
Encoder B”
If either phrase is abnormal, replace the right drive motor encoder.
6. If the problems remains present, replace the right drive motor
controller.
L-MOTOR ENCODER – Left drive motor’s encoder failed
LED code 36/73/88/93
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The phase A or B signal of the left drive motor encoder is abnormal or not
Cause detected, or indicates an abnormally fast speed.

1. Check if the U, V, W terminals on the left drive motor are normally

connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the
left
drive motor measures 5 V.
Fd 3. Check if pin 3 on the left drive motor encoder is normally connected
to pin 31 (phase A) on the left drive motor controller.
4. Check if pin 4 on the left drive motor encoder is normally connected
Solution to pin 32 (phase B) on the left drive motor controller.
5. Check if phases A and B on the left drive motor encoder normally
turn on and off using EasyView.
- Test Menu  Drive  “Left Motor Encoder A” & “Left Motor
Encoder B”
If either phrase is abnormal, replace the left drive motor encoder.
6. If the problems remains present, replace the left drive motor
controller.

Handling faults on Instrument/EasyView 9-132 B20T-7 PLUS, B20X-7 PLUS

 FINGERTIP FAULT – Fingertip faulty (pump stopped)
LED code 53/55/56/57
Traction Pump Extension EM Brake
Controller Action Stop the faulty Stop the faulty
No action No action
FF operation rpm operation valve
Cause A fingertip knob is out of range.

1. Check the output of each fingertip knob (Knob Command) in test menu
Solution
on EasyView. If any of the knobs is found abnormal, replace it.

5V NOT OK – 5V output from a controller failed

LED code 25
Traction Pump Extension EM Brake
Controller Action Stop 작용 없음 작용 없음 작용 없음
An over current (over 200 mA) is detected in the drive or pump motor�
Cause controller’s 5V supply circuit.

1. Check if the voltage between pin 26 (5V) and pin 7 (GND) on the left
drive controller measures 5 V.
FH
2. Check if the voltage between pin 26 (5V) and pin 7 (GND) on the

Solution
right
drive controller measures 5 V. 8
3. Check if the voltage between pin 26 (5V) and pin 7 (GND) on the
pump

Electrical System (F-series)

controller measures 5 V.
4. Replace any controller whose 5V output is not normal.

PUMP SIGN ON – Signal to move pump motor detected at startup

LED code 47,(P-51,54.6A)
Traction Pump Extension EM Brake
Controller Action STOP, ISO3691
No action Work No action
Shut down
Cause A lever command (lift, lower, tilt, sideshift) is detected at startup.

FL 1. Position all the hydraulic control levers in neutral.

2. Calibrate the initial settings for the lift sensor using EasyView or the
instrument panel.
Solution
3. If the problem persists, make an adjustment of the clearance for the
lift sensor.
4. If the problem persists, replace the valve board.

R-INV UNDERTEMP - Right drive motor controller overcooled (-40°C, -40°F)

LED code 15
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The right drive motor controller is below the lower temperature shutdown
H1 Cause limit (-40°C, -40°F).

1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour
and then check if it is operational.
Solution
2. If the problems remains present, replace the right drive motor
controller.

B20T-7 PLUS, B20X-7 PLUS 9-133 Handling faults on Instrument/EasyView

 L INV UNDERTEMP - Left drive motor controller overcooled (-40°C, -40°F)
LED code 15
Traction Pump Extension EM Brake
Contr oller Action Shut down at
Shut down Stop Work
once
The left drive motor controller is below the lower temperature limit (-40°C,
H2 Cause - 40°F).

1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour
and then check if it is operational.
Solution
2. If the problems remains present, replace the left drive motor
controller.

P INV UNDERTEMP - Pump controller overcooled (-40°C, -40°F)

LED code 15
Traction Pump Extension EM Brake
Controller Action
Stop Shut down Work No action
The pump motor controller is below the lower temperature limit (-40°C, -
H3 Cause 40°F).

1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour
Solution and then check if it is operative.
2. If the problems remains present, replace the pump motor controller.

R-MOTOR OPEN – Right drive motor circuit open

LED code 37
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
H4 once
Cause The U, V or W phase of the right drive motor is detected to be open.

1. Check for the U, V, W connections of the right drive motor.

Solution
2. Replace the right drive motor.

L-MOTOR OPEN– Left drive motor’s circuit open

LED code 37
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
H5 once
Cause The U, V or W phase of the left drive motor is detected to be open.

1. Check for the U, V, W connections of to the battery.

Solution
2. Replace the left drive motor.

P-MOTOR OPEN – Pump motor’s circuit open

LED code 37
Traction Pump Extension EM Brake
Controller Action
No action Shut down Work No action
H6 The U, V or W phase of the pump motor is detected to be open.
Cause
1. Check for the U, V, W connections of to the battery.
Solution
2. Replace the pump motor.

Handling faults on Instrument/EasyView 9-134 B20T-7 PLUS, B20X-7 PLUS

 PEDAL SW FAULT - Brake pedal sensor signal fault
LED code B1/51
Traction Pump Extension EM Brake
Controller Action
Stop by EAB Work Work Work

1. One of brake sensor’s signal voltages is over the range. (Phase A &
B : 5V +/- 0.25V)

Cause 2. The sum of Phase A’s voltage and Phase B’s voltage is beyond
5.3V.
3. The harness wires to brake sensor are shorted or open.

1. Check if brake sensor connector is properly connected to the main

harness.
2. Check out if the harness wires to brake sensor are free from open
and short.
3. Since both left traction controller and pump controller normally
H9 output 5 V voltage to brake sensor, check if brake sensor’s two
signals displayed on EasyView are to approx. 5 V.

- Test Menu → Drive → “Brake Pedal Voltage A” / “Brake

Pedal Voltage B”
8
If brake sensor fails to output the total of 5 V voltage, replace the

Electrical System (F-series)

Solution
brake sensor.
4. If they normally amount to approx. 5 V, check the connection of the
brake sensor to the controllers:
- Pin 3 on the brake sensor to pin 51 on the right drive motor controller.
- Pin 5 on the brake sensor to pin 55 on the right drive motor controller.
- Pin 1 on the brake sensor to pin 146 on the right drive motor
controller.
- Pin 2 on the brake sensor to pin 60 on the pump motor controller.
- Pin 4 on the brake sensor to pin 64 on the pump motor controller.
- Pin 6 on the brake sensor to pin 91 on the pump motor controller.
If any part of the connection above is found open or short, replace the
main harness.
LIFT SOL FAULT – Lift solenoid valve faulty (pump stopped)
LED code 61
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s lift solenoid (J1-12) is
Cause open/short.

L1 1. Check if pin 8 on the main control valve connector A is normally

connected to pin 12 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 8
and 4 on the main control valve connector A to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

B20T-7 PLUS, B20X-7 PLUS 9-135 Handling faults on Instrument/EasyView

 LOW SOL FAULT – Lowering solenoid valve faulty (pump stopped)
LED code 62
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s lowering solenoid (J1-13) is
Cause open/short.

L2 1. Check if pin 8 on the main control valve connector B is normally

connected to pin 13 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 8
and 4 on the main control valve connector B to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

TILT FWD SOLFAU – Tilt-forward solenoid valve faulty (pump stopped)

LED code 64
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s tilt-forward solenoid (J1-9) is
Cause open/short.

L3 1. Check if pin 7 on the main control valve connector B is normally

connected to pin 9 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 7
and 3 on the main control valve connector B to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

TILT BACK SOLFAU – Tilt-backward solenoid valve faulty (pump stopped)

LED code 59
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s tilt-backward solenoid (J1-11) is
Cause open/short.

L4 1. Check if pin 7 on the main control valve connector A is normally

connected to pin 11 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 7
and 3 on the main control valve connector A to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

Handling faults on Instrument/EasyView 9-136 B20T-7 PLUS, B20X-7 PLUS

 AUX1 L-SOLFAU – AUX1- left solenoid valve faulty (pump stopped)
LED code 63(AUX1 FWD)
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s AUX1-left solenoid (J1-14) is�
Cause open/short.

L5 1. Check if pin 6 on the main control valve connector B is normally

connected to pin 14 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 2
and 6 on the main control valve connector B to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

AUX1 R- SOLFAU – AUX1-right solenoid valve faulty (pump stopped)

LED code 65(AUX1 BACK)
Traction Pump Extension EM Brake
Controller Action
No action
Stop this
operation
Stop this
operation
No action 8
The circuit for the fingertip control valve’s AUX1-right solenoid (J1-10) is�
Cause open/short.

Electrical System (F-series)

L6 1. Check if pin 6 on the main control valve connector A is normally
connected to pin 10 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 2
and 6 on the main control A to check if it measures approx. 30Ω at
20°C (68°F).
4. If it is not measured so, replace the coil.

AUX2 L-SOLFAU – AUX2-left solenoid valve faulty (shut down PD)

LED code TR-A1
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s AUX2- left solenoid (P1-2) is
Cause open/short.
L7
1. Check if pin 5 on the main control valve connector B is normally
connected to pin 2 on the pump motor controller.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1 and
5 on the main control valve connector B to check if it measures approx.
30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

B20T-7 PLUS, B20X-7 PLUS 9-137 Handling faults on Instrument/EasyView

 AUX2 R- SOLFAU- AUX2-right solenoid valve faulty (shut down PD)
LED code TR-A1
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s AUX2-right solenoid (D2-2) is�
Cause open/short.

L8 1. Check if pin 5 on the main control valve connector A is normally

connected to pin 2 on the right drive controller connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1
and 5 on the main control valve connector A to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

ISO/UNLOAD SOL – ISO/UNLOAD solenoid valve faulty (shut down driver)

LED code P-A2, T-A4
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
Cause ISO (STD), unloading SOL (fingertip OPT) (P1-5) open/short

1. Check if pin 1 on the main control valve connector C is normally

L9
connected to pin 5 on the pump motor controller.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1
and 2 on the main control valve connector C to check if it measures
approx. 28.5Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

LED code
Traction Pump Extension EM Brake
LB Controller Action
Cause
Solution

Handling faults on Instrument/EasyView 9-138 B20T-7 PLUS, B20X-7 PLUS

 L COIL POWER – L controller coil supply (PIN13) faulty
LED code TL-A9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Shut down
once
When doing KSI, the controller will check the coil power supply
whether can switch on or off. Fault may be caused by :
1. Coil is shorted to KSI.
LC Cause
2. Coil is shorted to GND.
3. The power supply circuit to the coil is damaged.

1. Check the solenoid connected to PIN13 to see whether shorted to

KSI or GND.
Solution
2. Check whether B+ or B- voltage is leaked to PIN13.
3. Replace the controller.

F-KNOB CAN FAULT – Fingertip CAN module CAN Communication faulty

LED code TL-66, PU-52
Controller Action
Traction
Shut down
Pump
Shut down
Extension
Shut down
EM Brake
Stop by EAB 8
1. Abnormality is found in the CAN communication signals transmitted
Cause

Electrical System (F-series)

to and received from the fingertip CAN board.

1. Turn the key switch off and on again and, check if the fault code
LL disappears.
2. Update the firmware with the latest version (flashing). Upon
installation, turn the key switch off and on again and, check if the
fault code disappears.
Solution
3. Check connections of CAN H and CAN L. Measure the resistance
between pins 23 and 35 of each controller.
4. Repair or replace the harness.
5. Replace the drive controller.

L-CONT VOLTCUTL – L controller high or low voltage cut back

LED code TL-23,24
Traction Pump Extension EM Brake
Reduce driving
Controller Action
and Regen No action No action No action
LU
current

Cause Battery voltage is higher or lower than cutback point.

Solution 1. Check the battery and cable.

B20T-7 PLUS, B20X-7 PLUS 9-139 Handling faults on Instrument/EasyView

 WEIGHT SENSOR – weight sensor connected to TR D-17 is out of range (out of
0.5-5V)
LED code TR-BD
Traction Pump Extension EM Brake
P5 Controller Action
No action No action No action No action

Cause Weight sensor is out of range.

Solution 1. Check the weight sensor and harness.

P-CONT CAN FAULT – Pump CAN Communication failed
LED code TL-51,TR-53
Traction Pump Extension EM Brake
Controller Action
Shut down Shut down Work Work

Cause 1. The pump motor controller’s CAN communications is failed.

1. After connecting the main harness to the CAN port and turning off
the key switch, check if the measured resistance between pin 2 and
pin 7 of the CAN port connector is about 60Ω.
2. If the measured value is not 60, check if the connection between pin
P7 23 of the pump motor controller and pin 23 of the left drive motor
controller is normal.

Solution 3. If the connection between the two pins is normal, check if the
connection between pin 35 of the pump motor controller and pin 35
of the left drive motor controller is normal.
4. Check that the voltage between pins 21 and 34 of the pump motor
controller connector measures approximately 120Ω.
5. Reinstall the firmware.
6. Replace pump motor controller.
P COIL POWER – Pump controller coil supply (PIN13) faulty
LED code PU-A9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Shut down
once
When doing KSI, the controller will check the coil power supply whether
can switch on or off. Fault may be caused by :

Cause 1. Coil is shorted to KSI.

PC
2. Coil is shorted to GND.
3. The power supply circuit to the coil is damaged.

1. Check the solenoid connected to pin13 to see whether shorted to

KSI or GND.
Solution
2. Check whether B+ or B- voltage is leaked to pin13.
3. Replace the controller.

Handling faults on Instrument/EasyView 9-140 B20T-7 PLUS, B20X-7 PLUS

 P-CONT VOLTCUT – Pump controller high or low voltage cut back
LED code P-23,24
Traction Pump Extension EM Brake
Reduce driving
Controller Action
PU No action and Regen No action No action
current
Cause Battery voltage is higher or lower than cutback point.

Solution Check the battery and cable.

UNMATCH EXM PAR – Extension controller parameters and setting parameters are
unmatched
LED code 5F
Traction Pump Extension EM Brake
Controller Action
No action Stop Stop Stop

1. Pump controller will set the EXM parameters so the same EXM can
be used for different truck. When KSI on, the pump controller will
UE Cause read the parameters from EXM. If the reading parameters are not
the same with the Pump controller, will report the fault.
2.

1.
After KSI on, the EXM parameters are changed.

Cycle KSI.
8
Solution 2. Check the CAN messages between Pump and EXM.

Electrical System (F-series)

3. If problems persist, replace the extension model.
HEIGHT UNMATCH – Height sensor unmatched and Height sensor disconnected
LED code 5E
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work No action
800 800
UH 1. When GSS function is enabled, the mast switch becomes NC
(Normal Close) and NO (Normal Open) between Pump controller
Cause
P14 and P15) can not meet the redundant checking. So, it should be
ON-OFF, or OFF-ON. But, seen OFF-OFF or ON-ON.

조치 1. Check the mast height switch sensor and harness.

B20T-7 PLUS, B20X-7 PLUS 9-141 Handling faults on Instrument/EasyView

9 Electrical System (F-series)
9-1 Overview ....................................................................2
9-1-1 Components…………………………………………………………2
9-1-2 Communication protocol…………………………………………...4

9-2 Battery .......................................................................6

9-2-1 Exterior and specifications………………………………………6
9-2-2 Functions………………………………………………………….8
9-2-3 Wiring…………………………………………………………….10
9-2-4 Test………………………………………………………………11
9-2-5 Maintenance…………………………………………………….14
9-2-6 Removal and installation………………………………………16

9-3 Controllers and related devices ...........................17

9-3-1 Exterior and specifications…………………………………….17
9
9-3-2 Circuit and functions……………………………………………18

Electrical System (F-series)

9-3-3 Wiring…………………………………………………………….20
9-3-4 LED fault codes…………………………………………………23
9-3-5 Test………………………………………………………………24
9-3-6 Removal and installation………………………………………26

9-4 Miscellaneous loads ..............................................29

9-4-1 Fuse box…………………………………………………………29
9-4-2 DC-DC Converter………………………………………………32
9-4-3 Lamp group……………………………………………………..35
9-4-4 Optional speed limit……………………………………………36

9-5 Instrument ................................................................... 40

9-5-1 Display and buttons…………………………………………….40
9-5-2 Diagnosis………………………………………………………..45
9-5-3 Calibration………………………………………………………49

9-6 Application “EasyView” ........................................54

9-6-1 Installing and execution………………………………………..54
9-6-2 Controller firmware update……………………………………60
9-6-3 “Administration” menu description……………………………64
9-6-4 “Tools” menu description………………………………………64
9-6-5 Main page – Test Menu (diagnostic parameters)…………..74
9-6-6 Main page – Calibration Menu…………………………….….82
9-6-7 Initial settings…………………………………………….……104

9-7 Handling faults on Instrument /EasyView ......... 110

9-1 Overview
9-1-1 Components

Fig. 9-1

(1) Pump motor controller (2) Drive motor controller (3) Battery (4) Horn

(5) Pump motor (6) Accelerator pedal (7) Drive motor (8) DC-DC Converter

(9) Control valve (10) Line contactor (11) Line fuse

(containing F/R switch
and hydraulic switches)

Overview 9-2 B20T-7 PLUS, B20X-7 PLUS

This information describes the electrical system composed of
the following parts related to the F-series controller.

• Battery supplies power to the electrical system.

[Section 9-2]

• Motor, controllers, and related devices provide the

vehicle with necessary drive and pump power
based on their interaction with sensors, switches,

relays, and actuators as well as a number of

parameter settings. [Section 9-3]

• Fuse box protects all the DC loads from over

current by cutting off the power supply to a load
when the load is supplied with a current higher
than the limit. [Section 9-4-1]

• DC-DC converter converts the battery’s high

•
voltage to 12V for low voltage loads. [Section 9-4-2]

Other DC loads, activated by direct demand from

9
the operator, work independently from controllers.

Electrical System (F-series)

Primarily, they are not regulated by controllers nor
is their purpose to signal them. However, they
may interact with them in some configurations.
These loads include the lamp group and horn.
[Section from 9-4-3 to 9-4-5]

• Instrument panel monitors the vehicle to inform the

user of its conditions and provides basic functions
for mode setting, diagnosis and calibration.
[Section 9-5]

• Software for diagnosis and calibration provides the

same kinds of functions as the instrument panel
but in more specific detail. [Section 9-6]

B20T-7 PLUS, B20X-7 PLUS 9-3 Overview

 9-1-2 Communication protocol

LEFT
TRACTION

RIGHT
TRACTION

PUMP
INSTRUMENT
MONITOR

Fig. 9-2
In order to enable all the electrical devices of a vehicle and
provide the user with diagnosis and parameter calibration
functions, data sharing between these controllers and
instrument devices is required. For this purpose, CAN
(Controller Area Network) is used as a standard protocol. For
this purpose, CAN (Controller Area Network) is used as a
standard protocol.

A circuit diagram displaying communications between major

electrical devices using the CAN protocol is shown above.
Note: See Section 8-6 for how to install the application to check
the vehicle’s conditions and to perform parameter
calibration via CAN communication.

Overview 9-4 B20T-7 PLUS, B20X-7 PLUS

 Display
Drive
Controller Calibrating
PC software

Pump
Controller

UART Fig. 9-3

Drive
Controller
Calibrating
PC software
9

Electrical System (F-series)

Display
Pump
Controller

Fig. 9-4
This CAN communications effectively overcomes the
shortcomings of the point-to-point communication-based UART
(Universal Asynchronous Receiver/Transmitter) system that has
been widely used in the past. Due to one-to-one communication
between individual devices, the UART system is limited in the
number of available communication devices and cabling as well
as in improving vehicle performance.

The diagrams above compare CAN and UART communications.

B20T-7 PLUS, B20X-7 PLUS 9-5 Overview

9-2 Battery
9-2-1 Exterior and specifications

Basic conditions

Items Spec.
Final discharge voltage 42.5 V
Electrolyte Refined dilute sulfuric acid
Replenisher Distilled water
Insulation resistance Over 1 MΩ

Fig. 9-5

Specific gravity by temperature

Temperature
Charging
-15°C -5°C 0°C 5°C 15°C 25°C 35°C 45°C Level
(5°F) (23°F) (32°F) (41°F) (59°F) (77°F) (95°F) (113°F)
1.108 1.101 1.098 1.094 1.087 1.08 1.073 1.066 0%
1.118 1.111 1.108 1.104 1.097 1.09 1.083 1.076 5%
1.128 1.121 1.118 1.114 1.107 1.1 1.093 1.086 10%
1.138 1.131 1.128 1.124 1.117 1.11 1.103 1.096 15%
1.148 1.141 1.138 1.134 1.127 1.12 1.113 1.106 20%
1.158 1.151 1.148 1.144 1.137 1.13 1.123 1.116 25%
1.168 1.161 1.158 1.154 1.147 1.14 1.133 1.126 30%
1.178 1.171 1.168 1.164 1.157 1.15 1.143 1.136 35%
1.188 1.181 1.178 1.174 1.167 1.16 1.153 1.146 40%
120% 1.191 1.188 1.184 1.177 1.17 1.163 1.156 45%
121% 1.201 1.198 1.194 1.187 1.18 1.173 1.166 50%
1.218 1.211 1.208 1.204 1.197 1.19 1.183 1.176 55%
1.228 1.221 1.218 1.214 1.207 1.2 1.193 1.186 60%
1.238 1.231 1.228 1.224 1.217 1.21 1.203 1.196 65%
1.248 1.241 1.238 1.234 1.227 1.22 1.213 1.206 70%
1.258 1.251 1.248 1.244 1.237 1.23 1.223 1.216 75%
1.268 1.261 1.258 1.254 1.247 1.24 1.233 1.226 80%
1.278 1.271 1.268 1.264 1.257 1.25 1.243 1.236 85%
1.288 1.281 1.278 1.274 1.267 1.26 1.253 1.246 90%
1.298 1.291 1.288 1.284 1.277 1.27 1.263 1.256 95%
1.308 1.301 1.298 1.294 1.287 1.28 1.273 1.266 100%

* Formula: D25 = Dt + 0.0007(t-25) D25: converted specific gravity at 25°C (77°F) Dt: specific gravity
at t°C t: temperature of the electrolyte when its specific gravity was measured (°C)

Battery 9-6 B20T-7 PLUS, B20X-7 PLUS

 Battery compartment dimension
Battery compartment dimension (mm)
Models
Length Width Height
B15T-7 528 992(842) 698
B18T-7 638(608) 992(842) 698
B18TL-7 746 992(842) 698
B20T-7 638(608) 992(842) 698
B20TL-7 746 992(842) 698
B16X-7 638(608) 992(842) 698
B18X-7 638(608) 992(842) 698
B20X-7 638(608) 992(842) 698
1) When “BS type battery” is selected (choose a battery capacity that is compatible with the following capacities:

575/ 630/ 690 Ah)

2) When “DIN type battery” is selected

Recommended battery dimension and weight

Min/max Dimension (mm) Capacity (Ah)
Models
weigh
(kg)
L W H1 H2 h
BS
Norminal / max
DIN
Norminal / max
9
B15T-7 (36V) 700/945 519 980 610 625 585 660 / 770 (850) -

Electrical System (F-series)

B15T-7 (48V) 700/833 519 980 610 625 585 440 / 575 (600) 460/500
B18T-7 (36V) 800/1200 627 980 610 625 585 825 / 970 (1050) -
B18T-7 (48V) 800/1057 627 980 610 625 585 510/690 (750) 525/625
B18TL-7 (48V) 800/1057 738 980 610 625 585 600/ - 690/750
B20T-7 (36V) 1050/1200 627 980 610 625 585 825/970 (1050)
B20T-7 (48V) 1000/1250 627 980 610 625 585 585 / 690 (750) 575/625
B20TL-7 (48V) 1000/1250 738 980 610 625 585 600 690/750
B16X-7 (48V) 1050/1250 627 980 610 625 585 585 / 690 (750) 575/625
B18X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 575/625
B20X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 575/625
3) When “Characteristics battery” is selected

Fig. 9-6

• Recommended cable length 1000mm

• Recommended cable size: over 1/0 GA (50mm2)

• Battery connector (BS Type): SB350 or SBE320

(confirm the device power vehicle connector type
before installing),
BS connector handle: Part no. D290575

• Battery connector (DIN type): DIN320 (confirm the

vehicle connector type before installing)

B20T-7 PLUS, B20X-7 PLUS 9-7 Battery

 9-2-2 Functions
A. Characteristics of lead storage batteries

This model uses a lead storage battery as its power

supply to electrical systems.

A lead storage battery comprises the anode/cathode

plates to store electrical energy, a separator to prevent
short circuit in the plates, an electrolyte that acts as an
electrical conductor and agent within the battery, a
battery jar made of special plastics that houses these,
and a cover, plus an electrode that serves a gateway for
electrical energy, and various other fittings.

• Anode plate: The anode plate consists of tubes

inserted into each core metal of the lead alloy grid,
an active material (lead powder) filled between the
tube and the core metal, and a sealer that seals
the top and bottom of the tubes to prevent the
active material from getting out. This type of pole
plate is called a grid anode plate that features long
service life and high performance.

• Cathode plate: Having the lead alloy grid coated

with an active material (a paste made of lead
powder and a dilute sulfuric acid), this plate is
called a paste type cathode plate.

• Electrolyte: The electrolyte used in the battery is

a mixture of a high-purity, colorless and odorless
concentrated sulfuric acid (KSM 1203) and purified
water, of which the specific gravity is 1.280 (25°C,
77°F) at a specified level when fully charged.

• Separator: The separator features high

resistance to acid and oxidization, long longevity,
and low electrical resistance.

Battery 9-8 B20T-7 PLUS, B20X-7 PLUS

B. BDI (battery discharge indicator)

The BDI (battery discharge indicator) informs the

operator of the current charge level of the battery. In
proportion to this level, 1 to 10 segments are displayed
on the instrument panel.

BDI value determining process

Lead storage batteries have a large voltage drop in

driving and front end operations. And their voltages often
increase when they are not loaded. Given this voltage
fluctuation, the value on the BDI is determined as follows:

• Though the battery voltage is detected in real time,

the detection is not immediately reflected on the
BDI because the voltage continuously fluctuates.

• Only when the detected battery voltage has

remained lower than the BDI value for a specified
9
period of time (tens of seconds), the BDI

Electrical System (F-series)

decreases its percentage value by 1%. This time
delay makes sure that the voltage decrease is due
to an actual battery discharge rather than a
temporary fluctuation. Thus the BDI value
continues to decrease by 1% at every elapse of the
seconds as long as higher than the actual voltage.

• The BDI value never increases unless the vehicle

is keyed off and on again. It is because, no matter
how frequently temporal voltage increases occur,
the battery is basically supposed not to be actually
recharged while the vehicle is keyed on.

BDI value reset after battery charge

The only way the BDI value increases is to reset it by

charging the battery under the following conditions:

• The BDI segments have not been more than 6,

before the battery is charged.

• The battery has been fully charged before the

vehicle is keyed on.

In case you have charged a battery whose BDI segments

were 7 or more, the BDI leaves the value as it was before
battery charging, until the actual voltage becomes lower
than its BDI value.

B20T-7 PLUS, B20X-7 PLUS 9-9 Battery

 9-2-3 Wiring
Terminal Wiring Terminal Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
F_CONN. A (FINGERTIP)
FUSE BOX (A) (10)
BATTERY (1)
RD
(+) F_CONN. A (FINGERTIP)
EMERGENCY SW (OPT)
(5)
F/R UNIT (6) POWER (OPT) (2)

F/R UNIT (7) DIODE-COMP. (2)

DC- DC CONVERTER (1) LIFT SOL VALVE (B)

DC- DC CONVERTER (6) FAN RELAY (OPT) (30)

FLASHER UNIT(OPT) (86) BATTERY CONTROLLER FAN (2)

BK
(-)
BATTERY EMERGENCY C (1) R-LAMP CONN (2)
BK
(-)
BACKUP BUZZER (OPT)
EMERGENCY C (3)
(2)
INSTRUMENT MONITOR (6) HORN (2)

BACK UP LAMP (OPT) (85) L-LAMP CONN (2)

LICENCE LAMP (OPT) (2)

OPT LAMP CONN. (2)
HEIGHT SENSOR
(OPT) (3)

Battery 9-10 B20T-7 PLUS, B20X-7 PLUS

 9-2-4 Test
A. Battery condition inspection

A weak battery can cause or contribute to problems in the

Logic Control Board and power circuits. Verify that the
battery is in good condition before troubleshooting other
areas. Before repairing failures in other area, check if the
battery is in good condition.

Preliminary steps

1. Verify that there is proper polarity at the battery

connector and the control panel. The positive
cable should be at the line fuse and the negative
at the negative on the control panel.

When the vehicle is operational

<Battery load test>
9

Electrical System (F-series)

1. Turn the range switch on the multimeter to read
battery voltage.

2. Connect the battery.

3. Connect the multimeter leads between positive

(+) cable connection (1), and negative (-) cable
connection (2).

4. In a safe area, operate the hydraulic system

(hold tilt lever to maximum position momentarily)
while reading the voltage indicated on the
multimeter.
Fig. 9-7
5. If the indication is less than the limit (34.5 V for a
36 V model; 45.6 V for a 48 V model), the battery
needs to be charged or repaired before
continuing to troubleshoot.

B20T-7 PLUS, B20X-7 PLUS 9-11 Battery

 When the vehicle is not operational and the battery is the suspected cause
<Cell voltage test>

1. With the vehicle powered up and the pump (Idle)

motor running, measure the voltage at each cell.

2. Normal voltage should be between 1.95V and

2.12V per cell. If the voltage on each cell is
below 1.95V, the battery must be charged or
repaired before continuing to troubleshoot.

3. The indication between cells should not differ

more than 0.05 volts. If it does, the battery must
have an equalizing charge or be repaired.

<Hydrometer test>

1. Test each cell of the battery with a hydrometer.

2. If the specific gravity indication is below 1.140,

the battery must be charged. The battery is fully
charged if the indication is 1.265 to 1.285. (See
Section 9-2-1)

3. The indication between cells should not differ

more than 1.020 volt. If it does, the battery needs
an equalizing charge or be repaired.

Battery 9-12 B20T-7 PLUS, B20X-7 PLUS

 B. Resistance to chassis

Resistance between any point in the truck wiring and the

chassis should be a minimum of 10,000Ω.

Many malfunctions are caused by shorts to chassis.

Usually, two shorts must exist before a malfunction will
occur. But, since batteries can have chassis leakage,
only one short to chassis in the truck wiring can cause
problems. To prevent problems because of shorts, do the
following:

1. Disconnect the battery and discharge the controller.

2. Randomly measure any component connection or

wiring connection in respect to the lift truck chassis
for a minimum resistance of 10,000Ω.
 Any test point with low resistance must have
the short to chassis removed. 9
3. Always keep batteries clean to minimize current

Electrical System (F-series)

leakage to the chassis.

4. Be sure that all attachments, such as horns and

lights are designed for no chassis connection (two
wire system).

B20T-7 PLUS, B20X-7 PLUS 9-13 Battery

 9-2-5 Maintenance
The care and maintenance of batteries is most important
to maximize battery life and efficient vehicle operation.
Periodic inspection and service will increase the life of
batteries. Special attention should be given to the rules
that follow:

• Keep batteries clean at all times. Cleaning will

prevent corrosion, current leakage and shorts to
the chassis. Tighten all vent plugs, wash the
battery with water and a brush, then dry it with an
air hose. It may be necessary to use a baking soda
solution if water alone will not clean the top of the
battery.

• Add enough water to cover the plates before

charging. This will ensure the proper chemical
reaction over the entire plate surface. After
charging is complete, add water until it is about
12.7 mm (0.50 in) above the plates. Use distilled
water or water that has tested free from minerals.
Min. level Max. level
• Charge the battery correctly. A battery should be
(refilling
discharged to 80% of its capacity then fully
recharged. It should cool four to eight hours to
allow the voltage to stabilize before being put back
into use. The battery should have an equalizing Float Float
charge (an extra three or four hour charge at a low
Fig. 9-8
finish rate) once a month to make sure all cells are
in a fully charged condition. Properly charged
batteries should be identified to prevent low
batteries from being installed in vehicles.

• Operation with a low battery must be prevented.

Low battery operation may damage the battery and
will cause a current in the electrical system that is
higher than normal. High current draw due to a
low battery will damage contactor tips and shorten
motor brush life.

Battery 9-14 B20T-7 PLUS, B20X-7 PLUS

 • The battery's maximum temperature is critical. The
electrolyte temperature should never exceed 55°C
(131°F) either while operating or charging.
Overcharging a battery will cause it to overheat
and its plates to warp. Maximum battery life will
result from maintaining 25°C (77°F) electrolyte
temperature. Most of the charging equipment is
fully automatic but should be checked periodically
to ensure proper working order. Most of the
charging equipment is fully automatic but should
be checked periodically to ensure proper working
condition.

Electrolyte temperature Charge

5℃~25℃
110%~125%
(41°F~77°F)
-10℃~5℃
(14°F~41°F)
-15℃~-10℃
125%~140%
9
140%~150%
(5°F~14°F)

Electrical System (F-series)

Below -15°C (5°F) Not chargeable
• Keep accurate battery records. Regular battery
readings should be taken with a battery tester or
voltmeter and recorded. The specific gravity and
voltage of each cell should be checked and
recorded at least once a month. This inspection
should be made after an equalizing charge.
Readings should never be taken directly after
water has been added. Records of all battery
maintenance should be made and filed so it will be
known which batteries are being mistreated or
wearing out.

Note: Repairs should be made immediately otherwise the

battery may become damaged. Batteries stored in
a discharged condition may be difficult to recharge
due to sulfate formation.

B20T-7 PLUS, B20X-7 PLUS 9-15 Battery

 9-2-6 Removal and installation
WARNING
Careless use of the battery may
cause an electric shock.
Be sure to follow the safety precautions
given in Section 1-4.

CAUTION
A short-circuit may occur in the
course of removal, transport, and
installation of batteries.
Always ensure that the battery is
covered with an insulating material
(polywood) before removing and
installing it and no metallic material
contacts the top of battery cells.

１. Park the vehicle.

２. Lower the forks and tilt the mast forward until

the tips of the forks touch the ground.

３. Turn the key switch off. Battery connector

４. Disconnect battery connector (1).

５. Place the steering column vertically and move

the seat back completely.
Fig. 9-9
６. Open hood latch lever (2) that holds the seat
and battery cover.

７. Raise the seat and battery cover.

８. Discharge the power supply module by

keeping the key switch on for approx. 30
seconds twice. Hood latch lever

NOTICE: Failure to discharge the power supply module

may cause an electric shock. Fig. 9-10

９. Remove the battery using a hoist.

10. To install the battery, perform the procedure

above in the reverse sequence.

Battery 9-16 B20T-7 PLUS, B20X-7 PLUS

9-3 Controllers and related devices
9-3-1 Exterior and specifications
Line contactor
Line fuse

Right drive Left drive

Pump motor controller
Fig. 9-11 9
motor controller motor controller

Electrical System (F-series)

Items Specification
Voltage 36/48 V
PWM frequency 10 kHz
Drive maximum current 450 A
Pump maximum current -40°C~+50°C (-40°F~122°F)
Controller
Internal heatsink operating
-40°C~+95°C (-40°F~203°F)
temperature
Maximum temperature +95°C (203°F)
IP degree (dust & water proof) IP65
Operating Voltage 36 VDC
Coil resistance 94Ω (20°C, 68°F)
Line contactor Pull-in voltage 24 VDC
Drop out voltage 7.2 VDC
Coil power dissipation 21 W
Rated voltage 80 V
Line fuse Rated current 500 A
Cold Resistance 0.06 mΩ

B20T-7 PLUS, B20X-7 PLUS 9-17 Controllers and related devices

 9-3-2 Circuit and functions

Key on  power supply to controller

This model is equipped with two drive motors and one

pump motor, which are controlled by their respective
controllers. Turning on the key switch causes the
controllers to be powered at their pins #1.

Current to line contactor  power supply to motor

Once the controllers are supplied with power, the

magnetic coil built in the line contactor (Fig. 2-13) is
energized by current flowing between pins 6 and 13 of
the left drive motor controller. Then, 2 contacts of the
contactor will contact each other to close the circuit
between the battery and three controllers. In this circuit,
the battery power is converted into a 3-phase AC power
that runs the motors through each set of U.V.W.
connections. The line contactor is equipped with a 500A
fuse which prevents overcurrent.

Motor controllers

The three controllers are connected with the following

sensors, switches, relays and actuators.
• Key Switch
• Emergency Switch
Fig. 9-12
• F/R unit
• Accelerator
• Seat switch
• Brake pedal switch
• Parking brake switch
• EM Brake
• Steering angle sensor
• Hydraulic control switches
• Fan relay
• Backup relay
• Lift solenoid valve relay

Controllers and related devices 9-18 B20T-7 PLUS, B20X-7 PLUS

 Supplied with DC power, these devices interact with the
controllers, which based on a number of parameter
settings activate or receive data from them to control the
motors.

In terms of hardware, the three motor controllers are

identical, but each is programmed with different kinds of
firmware for different functions.

For detailed explanations of how the drive and pump

motors work, see Section 3-2-2 and 4-2-2 respectively.

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-19 Controllers and related devices

 9-3-3 Wiring
Drive motor controllers use a 35 pin AMP connector.

Controller connector
Fig. 9-13

Harness Fig. 9-14

Left drive motor controller connector pins

Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
LEFT DRIVE CONTROLLER
FAN RELAY (86)
(12)
PUMP CONTROLLER (1) EM CONN A (4)
13 OR/RD
LIFT SENSOR (1) FORWARD RELAY (86)
AUTO TILT SW2 (1) LIFT SOL RELAY (86)
MAST TILT SW1 (1) SEAT BELT SW (1)
15 BU/GN
TILT LEVER (1) CONN B (6)
DC/ DC CONVERTER (3) 17 BU/RD SEAT SW (1)
1 OR
F_CONN A (6) 22 YL/GN F/R UNIT (3)
RIGHT DRIVE
CONN A (1)
CONTROLLER (23)
F/R UNIT (2) PUMP CONTROLLER (23)
RIGHT DRIVE 23 GN
CONN A (13)
CONTROLLER (1)
RIGHT DRIVE
F_CONN A (3)
CONTROLLER (11)
LEFT DRIVE CONTROLLER
24 GN ANGLE SENSOR (2)
(10)
2 RD/BK FAN RELAY (85) CONN A (4)
25 RD/WH
3 YL LIFT SOL RELAY (85) ANGLE SENSOR (1)
4 VO FORWARD RELAY (85) LM ENCODER (1)
26 RD
5 WH/RD EM CONN A (3) ACCELERATOR (3)
RIGHT DRIVE
6 BR EM SWITCH (1) 28 BU/YL
CONTROLLER (28)
RIGHT DRIVE
ACCELERATOR (1) 29 BU/WH
CONTROLLER (29)
CONN A (2) 30 RD CONN A (5)
LM ENCODER (2) 31 LG LM ENCODER (3)
7 WH
LM THERMAL SENSOR (2) 32 GY LM ENCODER (4)
SEAT SW (2) 33 BR F/R UNIT (1)
RIGHT DRIVE
SEAT BELT SW (2) 35 YL
CONTROLLER (35)

Controllers and related devices 9-20 B20T-7 PLUS, B20X-7 PLUS

 Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
ANGLE SENSOR (3) PUMP CONTROLLER (35)
8 VO LM THERMAL SENSOR (1) CONN A (14)
LEFT DRIVE CONTROLLER
10 OR F_CONN A (3)
(1)
LEFT DRIVE CONTROLLER
12 OR
(1)

Note) Refer to the motor controller circuit in Fig. 8-13.

Right drive motor controller connector pins

Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
LEFT DRIVE CONTROLLER RIGHT DRIVE
11 OR
(12) CONTROLLER (1)
PUMP CONTROLLER (1) EM CONN A (2)
13 YL/GN
LIFT SENSOR (1) F_CONN B (2)
AUTO TILT SW2 (1)
MAST TILT SW1 (1)
16
17
VO
VO
BRAKE SENSOR (1)
WEIGHT SENSOR (3)
9
LEFT DRIVE
TILT LEVER (1)

Electrical System (F-series)

CONTROLLER (23)
DC/ DC CONVERTER (3) PUMP CONTROLLER (23)
1 OR 23 YL/BK
F_CONN A (6) CONN A (13)
CONN A (1) F_CONN A (3)
F/R UNIT (2) RM ENCODER (1)
LEFT DRIVE CONTROLLER
26 RD BRAKE SENSOR (1)
(1)
RIGHT DRIVE CONTROLLER
WEIGHT SENSOR (2)
(11)
LEFT DRIVE CONTROLLER LEFT DRIVE
28 BU/YL
(10) CONTROLLER (28)
LEFT DRIVE
2 YL/RD F_CONN B (1) 29 BU/WH
CONTROLLER (29)
5 BK EM CONN A (1) 31 OR/RD RM ENCODER (3)
RM ENCODER (2) 32 YL RM ENCODER (4)
LEFT DRIVE
BRAKE SENSOR (3)
7 WH CONTROLLER (35)
RM THERMAL (2) PUMP CONTROLLER (35)
35 YL
WEIGHT SENSOR (1) CONN A (14)
8 YL RM THERMAL (1) F_CONN A (32)

Note) Refer to the motor controller circuit in Fig. 8-13.

B20T-7 PLUS, B20X-7 PLUS 9-21 Controllers and related devices

 Pump motor controller connector pins
Wiring Wiring
Pin No. Connection (terminal no.) Pin No. Connection (terminal no.)
color color
LEFT DRIVE CONTROLLER
14 WH/BK HEIGHT SENSOR (2)
(1)
LEFT DRIVE CONTROLLER
15 VO HEIGHT SENSOR (4)
(12)
LIFT SENSOR (1) 16 BK ACCELERATOR (5)

AUTO TILT SW2 (1) 17 BR/YL CONN B (14)

MAST TILT SW1 (1) 19 YL/GN AUTO TILT SW2 (2)

TILT LEVER (1) 20 YL/BU TILT LEVER (2)

DC- DC CONVERTER (3) 21 OR/BK PUMP CONTROLLER (34)

1 OR
F_CONN A (6) 22 YL LIFT SENSOR (6)
LEFT DRIVE
CONN A (1)
CONTROLLER (23)
RIGHT DRIVE
F/R UNIT (2)
CONTROLLER (23)
23 YL/BK
RIGHT DRIVE
CONN A (13)
CONTROLLER (1)
RIGHT DRIVE
F_CONN A (3)
CONTROLLER (11)
LEFT DRIVE CONTROLLER
24 GN/YL LIFT SENSOR (7)
(10)
2 BU/BK F_CONN B (3) CONN A (9)

3 GN F_BACK UP RELAY (85) 25 RD/GN LIFT SENSOR (2)

LIFT NEUTRAL SENSOR
4 WH/GN TILT SOLENOID (2)
(1)
5 BU/GN F_CONN B (5) PM ENCODER (1)

6 YL/WH PRESSURE SENSOR (2) 26 RD ACCELERATOR (6)

LIFT SENSOR (5) CONN B (10)

ACCELERATOR (4) 28 BU/YL F CAN2 (1)

CONN B (11) 29 BU/WH F CAN2 (2)

7 WH/BU
PM ENCODER (2) 31 GN/BK PM ENCODER (3)

PM THERMAL (2) 32 BR PM ENCODER (4)

LIFT NEUTRAL SENSOR (3) 33 BK/WH LIFT SENSOR (8)

8 GN/RD PM THERMAL (1) 34 OR/BK PUMP CONTROLLER (21)

9 BU MAST TILT SW1 (2)

LEFT DRIVE
10 VO LIFT SENSOR (4)
CONTROLLER (35)
RIGHT DRIVE
TILT SOLENOID (1)
35 YL CONTROLLER (35)
13 BU/WH F_CONN B (4) CONN A (14)

F_BACK RELAY (86) F_CONN A (2)

Note) Refer to the motor controller circuit in Fig. 8-13.

Controllers and related devices 9-22 B20T-7 PLUS, B20X-7 PLUS

 9-3-4 LED fault codes
There is a way to see the current fault code without the
instrument panel and EasyView application: On each Fault code Indicator
LEDs
controller, a pair of LEDs are installed, capable of
indicating the whole list of fault codes.

A pair of LEDs are red and yellow, each representing a

hexadecimal number. Red LED indicates the first digit
and yellow LED indicates the second digit.

Fig. 9-15

For example, if the error code is D4, the yellow LED will
blink 4 times after the red LED blinks 13 times. See the
table on the right for the hexadecimal table.
Decimal
number
Hexadecimal
number 9
1 1

Electrical System (F-series)

2 2

3 3
The whole list of fault codes is described in Section 8-7.
The table below shows some other cases than indicating 4 4
a fault code: 5 5

Display Status 6 6
Controller is not powered on; or 7 7
Neither LED
vehicle�
illuminated 8 8
has dead battery; or severe damage.
Yellow LED 9 9
Controller is operating normally.
flashing 10 A
Yellow and
11 B
red LEDs Controller is in Flash program mode.
both on solid 12 C
No software loaded, or an internal 13 D
hardware fault detected by the
Red LED on 14 E
Supervisor or Primary microprocessor.
solid
Cycle KSI to clear. Reload software or 15 F
replace controller if necessary.

B20T-7 PLUS, B20X-7 PLUS 9-23 Controllers and related devices

 9-3-5 Test
A. Controller

Measure the diode voltage of the AC MOSFET circuit (Fig.

8-17) inside the controller to check for burnt damages.

1. Remove the cables and harness connected to the

controller and discharge the internal capacitor
completely.

2. Using a multimeter, measure the voltage of the

diode (0.3–0.6V) and check if it is normal (Fig. 2-18
and 2-19).

Diode Red lead Black lead Result

Approx. 0.4 -
Test 1 U, V, W B+
0.6 V
Approx. 0.4 -
Test 2 B- U, V, W
0.6 V
Fig. 9-16

Test 1: Measure voltage with the red lead to Band

the black lead to U, V, and W.

Test 2: Measure voltage with the red lead to U, Fig. 9-17

V, and W, and the black lead to B+.

Fig. 9-18

Controllers and related devices 9-24 B20T-7 PLUS, B20X-7 PLUS

 B. Line contactor and Fuse

Normal: 70 ~ 110 Ω 9

Electrical System (F-series)

Fig. 9-19
Line contactor

Line fuse Fig. 9-20

1. For the line contactor and the line fuse, connect an

ohmmeter at the points shown in the figure and check
if it measures the values as specified.

B20T-7 PLUS, B20X-7 PLUS 9-25 Controllers and related devices

 8-3-6 Removal and installation
A. Drive motor controller panel

(Detail A-A)
Fig. 9-21
NOTICE: Remember the controller contains ESD (Electro
Static Discharge) sensitive components. Use
appropriate precautions in connecting,
disconnecting and handling it.

Preliminary steps
1. Turn the key switch off.
2. Remove the top cover on the counterweight
(See Section 7-4).

Procedure
1. Remove connectors (2) from drive motor
controller panel (1).
2. Remove the cable (5) by unscrewing the nut (6)
securing the cable (5) assembled on the
controller.
 If the identification label on the cable is
damaged, mark the terminals to which they
were connected to avoid confusion during
reassembly. (For example, CPW – Pump
controller W terminal)
 Installation torque: 10.2±1.1 N·m (7.5±0.8
lb·ft)
3. After removing the bolts (3) and washers (4),
remove the drive motor control panel (1) from
the frame.
4. Follow the steps above in the opposite order to
install the drive motor controller.
Apply a small amount of D557047 Thermal Joint
Compound on control panel plate and mating
surface, prior to assembly.

Controllers and related devices 9-26 B20T-7 PLUS, B20X-7 PLUS

 B. Drive motor controllers, line contactor, and line fuse

Drive motor controller panel

Fig. 9-22
9

Electrical System (F-series)

(1) Bolt (2) Nut (3) Washer (4) Line contactor
(5) Bracket (6) Screw (7) Line fuse (8) Washer
(9) Nut (10) Bolt (11) Bus bar (12) Drive motor controller

1. Remove nuts (2) and washers (3).

2. Remove the nuts (9) and washers (8) with a 5
mm socket wrench and remove the fuse (7).
3. Remove Bracket (5).
4. After removing Screw (6), remove line contactor (4).
5. Remove the nuts (13) and washer with 5 mm
socket wrench and remove the Bus bar (11).
 Installation torque: 10.2±1.1 N·m (7.5±0.8
lb·ft)

6. Remove the eight bolts (10) and washers and

then, dismount the motor controller (12).
7. Follow the steps above in the opposite order to
install the drive motor controller, line contactor
and line fuse.
 Apply a small amount of D557047 Thermal
Joint Compound on control panel plate and
mating surface, prior to assembly.

B20T-7 PLUS, B20X-7 PLUS 9-27 Controllers and related devices

C. Pump motor controller

(Detail B-B)

Fig. 9-23

The pump motor controller panel is located opposite the drive

motor controller panel.

NOTE: Remember the controller contains ESD (Electro Static

Discharge) sensitive components. Use appropriate
precautions in connecting, disconnecting and handling it.

Preliminary steps
1. Turn the key switch off.

2. Remove the top cover on the counterweight (See

Section 7-4).

Procedure
1. Remove the connector (2) from the pump motor
controller assembly (1).

2. Remove the cable (5) by unscrewing the nut (6)

securing the cable (5) assembled on the controller.
 If the identification label on the cable is damaged,
mark the terminals to which they were connected to
avoid confusion during reassembly. (For example,
CPW – Pump controller W terminal)
 Installation torque: 10.2±1.1 N·m (7.5±0.8 lb·ft)

3. After removing the bolts (3) and washers (4), remove

the Pump motor control panel (1) from the frame.

4. After removing bolts (3) and the washers, remove

Pump motor controller (5).

5. Follow the steps above in the opposite order to install

the pump motor controller.

Controllers and related devices 9-28 B20T-7 PLUS, B20X-7 PLUS

9-4 Miscellaneous loads
9-4-1 Fuse box
A. Function and composition

To protect DC loads from overcurrent, the fuse box is

equipped with the following terminals:

Rated
Set Items
capacity
DC- DC Converter, Horn 20 A

Key Switch 10 A

Fan, Fingertip (OPT) 5A

A SOL VALVE, POWER (OPT) 5A

BACK-UP LAMP (OPT) 5A 9

F/R unit 5A
Fig. 9-24

Electrical System (F-series)

Height Sensor 5A

LEFT HEAD LAMP (OPT) 5A

10 A

OPT LAMP 5A

B RIGHT HEAD LAMP, LICENCE

5A
LAMP (OPT)
STROBE, FLASHER LAMP
5A
(OPT)
REAR LAMP 5A

B20T-7 PLUS, B20X-7 PLUS 9-29 Miscellaneous loads

 B. Wiring
Fuse box (A) Fuse box (B)
Terminal� Wiring Terminal� Wiring Connection (terminal
Connection (terminal no.)
no. color no. color no.)
LIGHT SW (OPT) (7)
1 OR HEIGHT SENSOR (1) 1 GN/YL
FORWARD RELAY (30)
FLASHER UNIT (OPT)
F/R UNIT (4)
(85)
2 YL/WH
STOP LAMP SW (OPT) (2) OPT LAMP CONN. (8)
2 RD/YL
DC- DC CONVERTER
BACK UP LAMP (OPT) (30)
(5)
3 OR/RD
F_BACK UP RELAY (OPT)
LIGHT SW (OPT) (2)
(30)
DC- DC CONVERTER (5) R-LAMP CONN. (13)
3 OR/RD 4 YL/GN
LIGHT SW (OPT) (2) R-LAMP CONN. (3)

POWER (OPT) (1) 5 BU/RD OPT LAMP CONN. (4)

4 YL/GN
LIFT SOL RELAY (30) 6 BU/YL LIGHT SW (OPT) (3)

DOOR FAN (1) 7 (N/A)

DRIVE MOTOR FAN R (1) 8 (N/A)

5 OR/BK
DRIVE MOTOR FAN L (1) 9 (N/A)

PUMP MOTOR FAN (1) 10 BU/YL LIGHT SW (OPT) (3

DC- DC CONVERTER (5) 11 (N/A)

6 OR/RD
LIGHT SW (OPT) (2) 12 (N/A)

7 RD/WH CHARGER SW (1)

8 YL/RD EM SW (3)

DC- DC CONVERTER (2)

9 RD/BU HORN SW (4)

GRAB BAR SW (OPT) (2)

10 RD BATTERY (+)

11 (N/A)

12 (N/A)

Instrument 9-30 B20T-7 PLUS, B20X-7 PLUS

 C. Removal and installation

Preliminary steps
1. Turn the key switch off.

2. Remove the top cover on the counterweight (See

Section 7-4).

Procedure

1. Remove harness connectors (4) from fuse box (1).

Fuse Box
2. After removing the bolts (2) and washers (3), Bolt
remove the fuse box (1). Washer

Connector

Fig. 9-25
9

Electrical System (F-series)

3. Follow the steps above in the opposite order to
install the fuse box.
When you reconnect the connectors, note the
connection layout at the right.

WARNING: To reduce the risk of fire, replace only with

same type and ratings of fuse.

Fig. 9-26

B20T-7 PLUS, B20X-7 PLUS 9-31 Miscellaneous loads

 9-4-2 DC-DC Converter
A. Exterior and Specifications

Fig. 9-27

Items Specification
Part no. 300612-00250

Allowed Capacity 230 W

Supply Voltage 48 VDC

Output voltage 12V ± 5%

Operating temp. -30°C~+70°C (-22°F~158°F)

☞ Note: Since the external feature of DC-DC Converter above is same with the previous DC-DC
converter (part number: 300612-00121), be very careful of the part number when
exchanging with a new one.

Instrument 9-32 B20T-7 PLUS, B20X-7 PLUS

 B. Circuit and functions

DC-DC Converter
Horn

Key Switch

Fan/
Fingertip(OPT)
SOL
VALVE/POWER
Key Switch
BACK-UP

Fuse box (B)

L LAMP
Battery (+)
DC-DC Converter

OPT LMAP
Battery (-) R
LAMP/LICENCE

STROBE/FLASH
ER UNIT
9
Fig. 9-28

Electrical System (F-series)

The DC-DC converter converts high voltage power from
the battery (48 V or 36 V) to a 12 V power that is suitable
for a number of loads.

Each of its terminals function as follows:

• Terminal 3 (ENABLE) operates the DC-DC

converter by receiving battery power from terminal
P1-1 of the pump motor controller.

• Terminals 2 and 1 are connected to the positive and

negative poles of the battery respectively. Unlike
Terminal 3, these terminals are not responsible to
activate the DC-DC Converter but, responsible to
resend battery power to other loads. They are
protected from an overcurrent higher than 20 A.

• Terminal 5 (12V+) is connected to fuse box

terminal which covers the loads to be powered
from the converter. The power from the battery is
converted to 12 V and then sent to the loads
through the fuse box.

• Terminal 6 (12V-) is connected to the negative

poles of the loads that are to be applied at 12 V.
Namely, those currents which have passed through
the loads return to this terminal.

In this model, the terminals 1 (BATT -) and 6 (12V-) share

the same line.

B20T-7 PLUS, B20X-7 PLUS 9-33 Miscellaneous loads

 C. Wiring
Terminal Wiring Terminal Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
F/R UNIT (6) 4 (N/A)
FLASHER UNIT (86)
POWER(OPT) (2)
1 BK EMERGENCY C (3)
FAN RELAY (OPT) (86) FUSE BOX (A) (6)
OTHERS FUSE BOX (A) (3)
5 OR/RD
BATTERY (-) FUSE BOX (B) (3)
FUSE BOX (A) (9) LIFT SW(OPT) (2)
2 RD/BU HORN SW (4)
F_CONN. A (FINGERTIP) (7)
FLASHER UNIT (86)
POWER(OPT) (1)
EMERGENCY C (3)
FAN RELAY (30)
PUMP CONTROLLER (P1-1) CAN OPT (1)
3 OR 6 BK
F_CONN. A (FINGERTIP) (6) BACK UP LAMP(OPT) (85)
OPT LAMP CONN. (2)
F_CONN. A (FINGERTIP) (1)
F_CONN. A (FINGERTIP) (5)
BATTERY (-)

NOTICE: Do not connect 12V output (-) terminal of the

converter to the (-) tab of the battery. Incorrect
power supply may cause harm to related parts.
The simplified circuit diagram above is only for
the rough explanation.

Instrument 9-34 B20T-7 PLUS, B20X-7 PLUS

 9-4-3 Lamp group

Electrical System (F-series)

Fig. 9-29
This model is equipped with a variety of lamps, with different
purpose.
• Head lamps (L/R) illuminate the path in front of the
vehicle.
• Rear lamps illuminate the path behind the vehicle.
• Backup lamp lights up during reverse drive.
• Stop lamp lights up with the brake pedal pressed.
• License lamp illuminates the license plate in dark
condition.

These are powered at 12 V from the DC-DC converter.

B20T-7 PLUS, B20X-7 PLUS 9-35 Miscellaneous loads

 8-4-4 Optional speed limit

②
Fig. 9-30
(1) Radar sensor (2) IAS Controller

Function

This option is a function to limit the maximum speed of

the vehicle by detecting the outside or inside, when the
vehicle is moving from outside to inside or from inside to
outside.

Specification of added components

1) Controller

Items Specification

Operating voltage DC 9 - 32V

Rated voltage DC 12/ 24V

Current 500mA Max.

Operating
-20°C to +70°C
Temperature
Storage Temp. -30°C to +105°C

BAUD rate Auto

Fig. 9-31
IP grade IP 65

Instrument 9-36 B20T-7 PLUS, B20X-7 PLUS

 Pin No.

CONN Pin No. Connection

1 POSITIVE (9V-32V)
2 CAN H
3 CAN L
4 TX
5 RX
6 SERIAL GND
7 SERIAL ENABLE

P1 8 NEGATIVE (GND)
9 SENSOR VDD
10 SENSOR GND
SENSOR INPUT
11
(ACTIVE HIGH)
SENSOR INPUT
12

13
(ACTIVE LOW)
DIGITAL OUT (ATTIVE
HIGH)
9
DIGITAL OUT (ATTIVE

Electrical System (F-series)

14
HIGH)

2) Radar Sensor

Items Specification

Function Proximity switch

Range Max. 2400 ㎝

Power On LED, Green

Changing mode LED, Orange

Detection LED, Red

IP grade IP 67

Fig. 9-32
3). Pin and circuit information

Fig. 9-34 Fig. 9-33

B20T-7 PLUS, B20X-7 PLUS 9-37 Miscellaneous loads

 Selection of speed limit

1. Press the Mode button.

Indicato
2. "8" is blinking in display.

3. Use the Up/Down buttons to select a mode.

4. If you press the Enter button, “0” is showing.

5. Press the Enter button or after a certain period of

time, “0” disappears and setting is finished.

Checking the current mode

1. Press the Enter button. Then, able to see the

Mode button Down button
current mode.

2. After a certain period of time, display turns off by Up button Enter button
itself.

Model Mode Speed Limit Fig. 9-34

Mode 1 1500 rpm
Electric Mode 2 2000 rpm
Mode 3 2500 rpm

Instrument 9-38 B20T-7 PLUS, B20X-7 PLUS

 Schematic

Electrical System (F-series)

Fig. 9-35

The IAS (Indoor auto detection & Speed limit) sensor is

located on the top of the cabin to recognize the ceiling of
workshop, building or warehouse. When the vehicle
moves to the indoor, it generates a signal and
communicates directly with the IAS controller.

Then, the IAS controller generates a signal for speed limit

and communicates with the traction controller. Eventually,
it limits the rpm of the driving motor by sending a signal to
the driving controller through the CAN CONN terminal.

B20T-7 PLUS, B20X-7 PLUS 9-39 Miscellaneous loads

9-5 Instrument
9-5-1 Display and buttons
The instrument panel is located at the center of the
console cover. The symbols shown on the panel indicate
the values of the vehicle system’s essential analog and
digital parameters.

The indicator lamps and buttons are named as follows:

Vehicle speed and fault indicator

Vehicle speed level and F/R direction indicator

BDI (battery discharge indicator) EM brake indicator

Seat Switch Indicator Brake oil level alarm indicator

Fault indicator

Travel Lamp Indicator

Turn Signal Indicator Over-temperature
alarm indicator
Seat Belt Indicator

Brake oil level alarm indicator

[New model only]

Maintenance Time
Steering Angle Indicator Expiry Indicator
Message box DOWN button

E-S-H Indicator ENTER button

Turtle Mode Indicator

E-S-H Button UP/TURTLE button

Fig. 9-36

Instrument 9-40 B20T-7 PLUS, B20X-7 PLUS

 Left LED Indicators

Located at the left side of the display are four LED

indicators that, when switched on, give the following
information:

Fig. 9-37

No. Indicator Description

[Fault indicator]
• Lights up in red in the following situations:
- The instrument panel’s communication with the controllers is lost
for 3 seconds.
1
- The circuit board in the instrument panel is failed.
- A fault code appears due to a problem with the vehicle.
- Under normal conditions, the indicator briefly blinks when the key
switch is on or off.
9
[Travel Lamp Indicator]

Electrical System (F-series)

2
• Lights up in green to indicate the vehicle is being driven.

[Turn Signal Indicator]

3
• Lights up in green to represent the indicated direction (option).

[Seat Belt Indicator]

4 • Lights up in red for 10 seconds after the seat belt is released
(option).

[Brake oil Pressure alarm indicator]- New model only

5
• Lights up in red when the brake oil level is low.

B20T-7 PLUS, B20X-7 PLUS 9-41 Miscellaneous loads

 Indicator lamps in the display

Located at the center of the instrument panel are

indicator lamps that show the vehicle’s condition.

Fig. 9-38

No Indicator Description

[Seat Switch Indicator]

• This symbol indicates that the seat switch is open. At the appearance of this
symbol, EE Error Code flickers and all the functions of the truck are shut down.
• If the operator attempts to put the vehicle in forward or reverse before the seat
6 switch is on, fault code EE (Wrong Start) is displayed.
• If the LIFT/TILT/AUX1/AUX2 lever is activated before the seat switch is on,
fault code FL (Pump Sign On) is triggered.
• When fault code EE or FL occurs and the signal of the respective function is
deleted, the fault code disappears and the vehicle returns to normal condition.

[Steering angle Indicator]

7
• The steering angle is indicated in seven segments.
[E-S-H Indicator]
• Lights up when shifting the current operation mode using the E-S-H button at
8
the bottom of the panel is enabled. The availability of this button is set in the
EasyView application.
[Turtle mode indicator]
9 • Indicates the vehicle is in the turtle mode, which limits its driving speed
to 10 km/h.
[Battery level indicator]
• Battery charging level, indicated by a 9 segments symbol.
Charge level BDI percent [%]
9 90%<
8 89%~80%
7 79% ~70%
6 69% ~60%

10 5 59% ~50%
4 49% ~42%
3 41% ~34%
2 33% ~26%
1 25% ~20%
EL >20%

• If the battery is completely discharged, the display will signal the alarm
code EL.

Instrument 9-42 B20T-7 PLUS, B20X-7 PLUS

 No Indicator Description
[Vehicle speed and fault indicator]
• When the Key is in the On position, the vehicle model ID code appears on the
display for 3 seconds.
- Vehicle type (e.g.: C2 [CURTIS Controller])
- Battery voltage (e.g.: 48V)
- Software program code (e.g.: 56)

11 • After that, the vehicle’s drive speed is displayed in kmh or mph.

• Pressing the down button once will allow you to alternate between the
accumulated driving time (hour meter) and distance (odometer) on the display.
• In the following conditions, the indicator shifts to display the corresponding
fault code (See Section 2-7):
- Seat switch open
- CAN communication between display and controllers is not active.
- Main contactor open.
[Vehicle speed level and F/R direction indicator] 9
• Each segment on the indicator dial represents a different speed level, ranging
12

Electrical System (F-series)

from 0 (no speed) to 9 (maximum speed).
• The position of the F/R switch is displayed in the center.

[EM brake indicator]

13 • When the accelerator pedal is depressed, the indicator turns off; when
completely released, it lights up three seconds after.

[Brake oil pressure alarm indicator]

14
• Lights up in red when the brake oil level is low.

[Over-temperature alarm indicator]

• Lights up when a motor or its controller is overheated at a temperature higher
15 than the alarm limit.
• A fault code among E1 to E6 (over-temperature) accompanies this alarm,
depending on which device is overheated.

[Maintenance time expiry indicator]

16
• Lights up to indicate the vehicle is due for maintenance.
[Message box]
17
• Displays the message.

B20T-7 PLUS, B20X-7 PLUS 9-43 Miscellaneous loads

 Command and service menu buttons

Located at the bottom are four buttons: E-S-H,

UP/TURTLE, DOWN, and ENTER.

Fig. 9-39

No. Button Description

[E-S-H Button]
• With this key, you can shift the operation mode between Economic, Standard,
and High Performance modes in this order.
• This button is only available after it has been set to enabled on EasyView;
18
there are also some parameters applicable to the respective modes which can
be modified only on EasyView (See Section 2-6).
• Pressing this key when you are in diagnostic mode allows you to see a circular
list of the 10 latest alarms.
[UP/TURTLE button]
• This button functions as TURTLE and UP buttons both.
• Pressing this button allows you to toggle between turtle and normal drive
modes.
• In calibration mode, you can adjust the speed at which the vehicle travels in
19 speed limitation mode (calibration no. 84: TURTLE SPEED, range 500–3500
rpm).
• Pressing this button in calibration or diagnostic mode allows you to choose the
next parameter on display.
• After a parameter is selected in calibration mode, pressing this button
increases the parameter’s numeric value.
[ENTER button]
• Holding this button for 3 seconds simultaneously when the key switch turns on
gives you a selection between calibration and diagnostic modes.
• Holding this button for 3 seconds while the vehicle is in normal operation
20 allows you to access to diagnostic mode.
• If the display is in diagnostic mode during normal operation, you can exit this
mode by pressing ENTER once more.
• After you choose a parameter or its setting value, pressing ENTER
confirms it.
[DOWN button]
• Pressing this button in calibration or diagnostic mode allows you to choose the
previous parameter on display.
21 • After a parameter is selected in calibration mode, pressing this button
decreases the parameter’s numeric value.
• When the button is held for one second during normal operation, the display
will alternate between showing the accumulated driving time and distance.

Instrument 9-44 B20T-7 PLUS, B20X-7 PLUS

 8-5-2 Diagnosis
A. Accessing diagnostic mode on the instrument panel

Parameter setting check

In diagnostic mode, you can check the main analog and

digital signals from the vehicle system as follows:

1. Hold ENTER for three seconds.

If you have performed another task using the

instrument panel, it will enter immediately
diagnostic mode, displaying the symbol “d.” If it is
the first command after startup, the panel will ask
you to select between “c” and “d.”

Fig. 9-40

2. Once you are given the two choices “c” and “d,”
9
press the down button to select “d” (diagnostic

Electrical System (F-series)

mode).

Fig. 9-41
3. In diagnostic mode, use the up and down button
to select the parameter number you want to
check (See Section “B. Diagnosis codes”).
 In the speed and warning section, the
parameter’s number is shown (blinking).
 In the time and distance section, the current
value is shown.

4. Operate the vehicle, observing changes in the

parameter value, to test if the vehicle is in normal
Fig. 9-42
conditions.

NOTICE: You can quit the diagnostic mode at any time

even if you have not finished the diagnosis
procedure.
NOTICE: If a warning occurs when you are in
diagnostic mode and the vehicle system is
normal, the panel will automatically change the
display to show the warning.

B20T-7 PLUS, B20X-7 PLUS 9-45 Miscellaneous loads

 Check of stored fault codes

You can see the last 10 faults as follows:

1. Press the E-S-H button to see the three types of

stored fault messages.

Fig. 9-43

 If there is no fault code stored, the number “0”

will appear in the speed and warning section.

Fig. 9-44

2. Use the up and down button to choose the fault

code you wish to check.

Fig. 9-45

Instrument 9-46 B20T-7 PLUS, B20X-7 PLUS

 B. Diagnostic code

Code Panel display Unit Description Remarks

DRIVE MOTOR
1 rpm DRIVE MOTOR SPD
SPD
D-MOTOR REF
2 rpm D-MOTOR REF SPD
SPD
RIGHT MOTOR
3 rpm Right drive motor’s speed
SPD
R-MOTOR REF Right drive motor motor’s reference
4 rpm
SPD speed
LIFT SENSOR Throttle output
5 V LIFT SENSOR OUT
OUT for lifting
Voltage on the
6 BATT VOLTAGE V Battery’s voltage
key switch
D-INVERTER Left drive motor controller’s
7 °C (°F)

8
TEMP
P-INVERTER
°C (°F)
Temperature
Pump motor controller’s 9
TEMP Temperature

Electrical System (F-series)

PUMP MOTOR
9 rpm Pump motor speed
SPD
P-MOTOR REF
10 rpm Pump motor’s reference speed
SPD
Throttle A
11 ACCEL 1ST OUT V Accelerator potentiometer voltage output for
driving
Throttle B
Accelerator second potentiometer
12 ACCEL 2ND OUT V output for
voltage
driving
STEER
Output from the
13 SENSOR V Steering sensor’s voltage
steer sensor
OUT
R-INVERTER Right drive motor controller’s
14 °C (°F)
TEMP Temperature
15 D-MOTOR I-U mA Left drive motor’s U-phase current
16 D-MOTOR I-V mA Left drive motor’s V-phase current
17 D-MOTOR I-W mA Left drive motor’s W-phase current
18 R-MOTOR I-U mA Right drive motor’s U-phase current
19 R-MOTOR I-V mA Right drive motor’s V-phase current
20 R-MOTOR I-W mA Right drive motor’s W-phase current
21 P-MOTOR I-U mA Pump motor’s U-phase current
22 P-MOTOR I-V mA Pump motor’s V-phase current
23 P-MOTOR I-W mA Pump motor’s W-phase current
24 D-MOTOR TEMP °C (°F) Left drive motor’s s temperature
25 R- MOTOR TEMP °C (°F) Right drive motor s Temperature
26 P-MOTOR TEMP °C (°F) Pump motor temperature

B20T-7 PLUS, B20X-7 PLUS 9-47 Miscellaneous loads

 Code Panel display Unit Description Remarks
Time period
27 SEAT H METER Hour Seat switch hour meter while seat
switch is on
Time period
while drive
28 DRIVE H METER Hour Drive motor’s total hour meter
motors are
working
Time period
while Pump
29 PUMP H METER Hour Pump motor’s total hour meter
motors is
working
30 SEAT SWITCH - Seat switch ON(1)/OFF(0)
33 REV SELECT SW - Reverse drive switch ON(1)/ OFF(0)
34 FWD SELECT SW - Forward drive switch ON(1)/OFF(0)
35 Pedal brake switch - Brake pedal switch ON(1)/OFF(0)
37 AUX1 OUTPUT - AUX1 switch ON(1)/OFF(0)
38 AUX2 OUTPUT - AUX2 switch ON(1)/OFF(0)
Speed limit for high lift switch 1
40 HIGH LIFT 1 SW - ON(1)/OFF(0)
(GSS option selected)
TILT SWITCH
41 - Tilt switch ON(1)/OFF(0)
OUT
Tilting angle limit for high lift switch 2
42 Mast tilt switch - ON(1)/OFF(0)
(GSS option selected)
43 CONTACTOR - Contactor switch ON(1)/OFF(0)
44 5V OUT - 5V out ON(1)/OFF(0)
45 12V OUT - 12V out ON(1)/OFF(0)
AUTO TILT Automatic tilt switch 3
46 - ON(1)/OFF(0)
SWITCH (GSS option selected)
48 FANS - Activation of fans ON(1)/OFF(0)

Instrument 9-48 B20T-7 PLUS, B20X-7 PLUS

 9-5-3 Calibration
A. Accessing calibration mode on the instrument panel

Using the instrument panel, you can modify a number of

different parameter settings. And although it may only
allow you to set a limited number of parameters, this
function is especially useful when the PC application
EasyView is not available.

To calibrate parameter settings:

1. Turn the key switch off and on again to initialize

the instrument panel.

2. Hold ENTER for three seconds until a page loads

that prompts you to select between “c” and “d.”

9
Fig. 9-46

Electrical System (F-series)

3. Press the up button to select “c.”

NOTICE: If parameter calibration code 40 ENABLE

TURTLE is set to “disable,” the up button will
be disabled, preventing you from entering
calibration mode. If this happens, key the
vehicle off and on again to restart. Otherwise
Turn the key switch off and on again to
initialize the instrument panel. Fig. 9-47

4. Use the up and down buttons to select parameter

calibration code number 10 and then press
ENTER.

Fig. 9-48

5. Use the up and down buttons to set the parameter

value to “4” and then press ENTER.

Fig. 9-49

B20T-7 PLUS, B20X-7 PLUS 9-49 Miscellaneous loads

 6. In the same way, set parameter calibration code
17 to “6.”

NOTICE: You can switch the order in which the two

parameter values are set. However, it is not
possible to modify other parameters before
setting these two. Fig. 9-50

7. Use the up and down buttons to select the

parameter you wish to set and then press ENTER.

Fig. 9-51
8. Use the up and down buttons to select the
parameter you wish to set and then press ENTER.
 Using the E-S-H button, you can move the
cursor to another digit place.

NOTICE: Using the function that returns the parameter

settings to their default values will delete your
current settings.
Fig. 9-52
The parameter code number is displayed in the speed
and warning section, and its setting value in the time and
distance section. If the number in the time and distance
changes, this means the selected parameter’s value has
been updated in the controller’s memory.

Instrument 9-50 B20T-7 PLUS, B20X-7 PLUS

 B. Parameter calibration codes

Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
TURTLE ALARM 0–1
8 - 0
(Buzzer On Turtle Speed) (Off–On)
0–9
10 1st PASSWORD Digit -
(not used)
CHAT TIME 1-9
12 sec 6
(Chat Time) (1-9)
IDLE TIME 10-20
13 sec 10
(Idle Time) (10-20)
MAINT TIME ON 0–1
14 - 0
(Maintenance Time Set) (Off–On)
0–9
17 2nd PASSWORD Digit -
(not used)

18 WHEEL TURN-L V 7.2

6.0-10.0
(0.00-10.00)
9
0.5-4.0

Electrical System (F-series)

19 WHEEL TURN-R V 2.0
(0.00-10.00)
WHEEL STRAIGHT 3.0-7.0
20 V 4.5
(Steering Middle) (0.00-10.00)
0.2-2.0
23 (Min Accelerator A) V 0.40
(0.20-2.00)
2.0-5.0
24 (Max. Accelerator A) V 2.93
(2.00-4.50)
SLOPE TIMER 3-10
26 sec 5
(Stop on a Slope Timer) (3-10)
LIFT PRI SPEED
0–1
27 (Lift Priority For Pump Reference - 1
(Off–On)
Speed)
FORWARD ALARM 0–1
30 - 0
(Buzzer on Forward Direction) (Off–On)
BACK UP ALARM 0–1
31 - 0
(Buzzer on Reverse Direction) (Off–On)
LIFT MAX VALUE 3.0-10.0
32 V 9.81
(Lift Max) (0.00-10.00)
LIFT MIN VALUE 0-10.0
33 V 2.90
(Lift Min) (0.00-10.00)
START MOTOR FAN 0-100
35 °C (°F) 65(149)
(Motor Fan Starting Temp) (0-160)
ENABLE TURTLE 0–1
40 - 1
(Enable Turtle Speed by Display) (Off–On)
DRIVE MAX I (Drive Max Current) 20-100
41 % See note
(See note) (20-100)

B20T-7 PLUS, B20X-7 PLUS 9-51 Miscellaneous loads

 Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
(Drive Forward Max Speed) (See 1000-4500
42 rpm See note
note) (0 -4000 / 5000)
(Drive Reverse Max Speed) 1000-4500
43 rpm See note
See note (0 -4000 / 5000)
44 D LIMIT MAX SPD 500-3500
400-2000
47 (Steering Limit Max Speed) rpm 1000
(400-2000)
D ACCEL RATE H 0.1-30.0
48 sec 6.0
(Acceleration Rate HS) (0.1-30.0)
D ACCEL RATE L 0.1-30.0
49 sec 6.5
(Acceleration Rate LS) (0.1-30.0)
D LOW ACCEL RATE 0.1-30.0
50 sec 10.0
(Low Accel Rate) (0.1-30.0)
D INVERS. RATE H 0.1-30.0
51 sec 5.0
(Inversion Rate HS) (0.1-30.0)
D INVERS. RATE L 0.1-30.0
52 sec 5.0
(Inversion Rate LS) (0.1-30.0)
D RELEASE RATE H 0.1-30.0
53 sec 6.0
(Release Rate HS) (0.1-30.0)
D RELEASE RATE L 0.1-30.0
54 sec 5.0
(Release Rate LS) (0.1-30.0)
D LOW BRAKE RATE 0.1-30.0
55 sec 5.0
(Low Inversion Rate) (0.1-30.0)
D SOFT STOP SPD 10-500
56 rpm 150
(Soft Stop Speed) (0-500)
START CONT. FAN 0-60
60 °C (°F) 65(149)
(Controller Fan Starting Temp) (0-160)
PARTIAL RELEASE 0.1-30.0
61 sec 30.0
(Partial Decel Rate) (0.1-30.0)
DELTA RPM 20.0100.0
62 % See note
(Width of the delta increment) (5.0–100.0)
LIFT MAX SPEED 1000-3500
64 rpm See note
(Lift Max Speed) See note (0-4000)
TILT SPEED 500-2000
65 rpm 800
(Tilt Speed) (100-3000)
AUX1 SPEED 500-2000
66 rpm 800
(AUX1 Speed) (100-3000)
AUX2 SPEED 500-2000
67 rpm 800
(AUX2 Speed) (100-3000)
LIFT MIN SPEED
69 rpm 200 0- 500(0-500)
(Lift Min Speed)

Instrument 9-52 B20T-7 PLUS, B20X-7 PLUS

 Adjustable
Instrument panel message
Code Unit Default range on panel
(EasyView message)
(EasyView)
HYDRO SPEED 400-800
71 rpm 700
(Hydro Speed) (400-800)
IDLE SPEED 200-500
72 rpm 500
(Idle Speed) (400-800)
TURTLE SPEED 500-3500
84 rpm 2000
(Max Speed in Turtle Mode) (500-3500)
BRITISH UNIT 0–1
85 0. 0
(British Unit Enable) (Off–On)
E-S-H 0–1
87 - 1
(Enable EHS by Display) (Off–On)
ENABLE FAN WORK 0–1
89 - 1
(Enable Working Fans) (Off–On)
ENABLE CHAT TIME 0–1
90 - 1
(Chat Time Enable)
Maintenance Time
(Off–On)
0-99990
9
92 Hour 500
(Set Time) (100-65500)

Electrical System (F-series)

GSS ENABLE 0–1
94 - 0
(GSS Enable) (Off–On)
FINGERTIP ENABLE 0–1
95 - 0
(Fingertip enable) (Off–On)
0–1
96 (Auto Clamp Enable) - 0
(Off–On)
0–1
97 (Auto Tilt Enable) - 1
(Off–On)
LOWER SPEED 100–2000
99 (Lower Speed) rpm 600 (100– 2000)
0–1
A2 (Aux2 Enable) - 0
(Off–On)
Note: The default settings and adjustable ranges of EasyView’s calibration parameters for the
instrument panel parameter codes 41, 42, 43, 62, and 64 vary depending on which is
selected from the E-H-S modes. For a detailed explanation, see Section 2-6-6.

• Optional Guardian Stability System (GSS)

- Decrease of Travel Speed (50%) when the mast is raised above primary stage
- Available tilt-forward angle is restricted to 2° when the mast is raised above the primary stage
- Alarm when the mast, tilted more than 2°, is raised above primary stage

• Auto Tilt Leveling

- Returns the mast to vertical position easily by tilt angle sensing

B20T-7 PLUS, B20X-7 PLUS 9-53 Miscellaneous loads

9-6 Application “EasyView”
9-6-1 Installing and execution
As mentioned in the preceding section, electric vehicles
equipped with CURTIS controllers provide the functions
of diagnosis and parameter calibration not only on the
instrument panel but also on the PC application
EasyView.

To use EasyView, you will need to install it and the CAN

communications drivers on your laptop, and then connect
the PC to the vehicle with a communications cable
(A408026, Kvaser) and then carry out initial settings.

EasyView installation

1. Download the latest version of the application

EasyView from the bulletin board at the dealer’s
portal website: https://service.doosan-iv.co.kr

Fig. 9-53

EasyView Program 9-54 B20T-7 PLUS, B20X-7 PLUS

 2. Unpack the downloaded file, and execute the file
<setup.exe> to install the application on the PC.

3. Check that EasyView’s icon is created on the Fig. 9-54

desktop.

CAN communications drivers installation

1. Access Kvaser’s website and click Support

Downloads Kvaser Driver for Windows.
9
 Direct link:

Electrical System (F-series)

http://www.kvaser.com/software/73301309800
13/V5_11_0/kvaser_drivers_setup.exe

Fig. 9-55

B20T-7 PLUS, B20X-7 PLUS 9-55 EasyView Program

 2. Once the Installation Wizard page appears, click
Next; then click Display Release Notes to read
the release notes or Next to proceed installation.

Fig. 9-56

Fig. 9-57

3. Select Kvaser CAN driver components to install

and then click Next.

Fig. 9-58

EasyView Program 9-56 B20T-7 PLUS, B20X-7 PLUS

 4. Set the folder where Kvaser CAN Drivers will be
installed and then click Installation.

Fig. 9-59

Electrical System (F-series)

Fig. 9-60

B20T-7 PLUS, B20X-7 PLUS 9-57 EasyView Program

 EasyView execution

1. Connect a CAN communications cable with one

end to your PC’s USB port and the other to the
vehicle’s CAN port near the controllers and then
turn on the key switch.

2. Double-click the EasyView icon to launch the

application.

 If the PC is not correctly connected to the

vehicle with the key switch on, a dialogue
box will appear and prompt you to select a
vehicle model as shown below:

Fig. 9-61
 When the boxes at right bottom are highlighted
in green, this means they are active, when the
PC and vehicle are correctly connected and
inactive in grey when they are not.

Fig. 9-62

EasyView Program 9-58 B20T-7 PLUS, B20X-7 PLUS

 3. When you are not logged in to the application,
only <Test Menu> is provided, which shows the
vehicle’s conditions. You can log in (password:
dbgby141) the application under the
Administration menu to access <Calibration
Menu>.

Electrical System (F-series)

Fig. 9-63

Fig. 9-64

B20T-7 PLUS, B20X-7 PLUS 9-59 EasyView Program

 9-6-2 Controller firmware update
As the controllers’ performance and functions are updated,
so is the firmware. You can install an update on the
controllers using your PC. This process is referred to as
“flashing,” and it goes as follows:

1. Visit the dealer’s portal website:

https://service.doosan-iv.co.kr

2. Under the menu of Board Bulletin, search for

“easyview” and view the post of the latest
firmware version.

Fig. 9-65

3. Download xml.zip and the update file named after

your vehicle model such as B20TX
7_48V_56_170825.zip.

Fig. 9-66
4. Unzip xml.zip into the Data folder under the path
of the EasyView application.

 Default: C:\Program Files (x86)\Curtis

Instruments\Easy View\Data

EasyView Program 9-60 B20T-7 PLUS, B20X-7 PLUS

 5. On the EasyView application, select Flash under
the Tool menu.

Electrical System (F-series)

Fig. 9-67
6. EasyView will display the vehicle model type and
current software version, for example, Truck type:
56 Current SW Data: 2015/3/6). Click Browse
and find the downloaded update file specific to
your vehicle model.

Fig. 9-68

B20T-7 PLUS, B20X-7 PLUS 9-61 EasyView Program

 7. Click Flash and wait until the selected file is
completely loaded into the controllers.
 Flashing takes approx. 5–10 minutes.

NOTICE: While flashing is in progress, the PC must not

crash due to a system error, external
interference, or the removal of the
communications cable. For this reason, it is
highly recommended that you use the laptop
PC plugged into an AC outlet rather than a
portable battery.

Fig. 9-69
8. Upon the completion of the flashing, a dialog box
will appear. Click Close to return to the main page.

EasyView Program 9-62 B20T-7 PLUS, B20X-7 PLUS

 Fig. 9-70
9
9. Perform initial settings for the accelerator pedal,

Electrical System (F-series)

lift sensor, and steering angle sensor (See each
relevant menu in Section 2-6-7).

B20T-7 PLUS, B20X-7 PLUS 9-63 EasyView Program

 9-6-3 “Administration” menu description

Login

Once you log in to the application, you can access

Calibration Menu and Options Menu on the main page
(Compare Fig. 9-68 and Fig. 9-69). The password is
dbgby141.

• When you are not logged in, only Test Menu is available.

• When you are logged in, you are allowed to access Calibration Fig. 9-71
Menu and Options Menu as well.

Fig. 9-72

Logout

Clicking this menu logs you out of the application.

Exit

Clicking this menu quits the application.

9-6-4 “Tools” menu description

EasyView Program 9-64 B20T-7 PLUS, B20X-7 PLUS
 Flash

As described above, Flash is for updating the controllers’

firmware. For a detailed explanation, see Section 9-6-2.

Electrical System (F-series)

Fig. 9-73

Fig. 9-74

B20T-7 PLUS, B20X-7 PLUS 9-65 EasyView Program

 Save parameter

In this menu, you can store all parameter settings except

for the values of sensors (accelerator, lift, steering, etc.)
in the PC as follows:

Click Browse, choose a location on the computer where

you wish to store the parameter file, and then click Save.

Fig. 9-75

EasyView Program 9-66 B20T-7 PLUS, B20X-7 PLUS

 9
Fig. 9-76

Electrical System (F-series)

Data Logging

This function records the vehicle’s operation history and

helps the operator analyze the vehicle’s conditions.

Enter a time scale in the time dialog box, which is set with
a default value to 0.5 seconds. Click Browse to select
where you wish to store the trace file and then click Start.
The data will then be logged at the selected file based on
the time scale specified. After clicking Stop, the operator
can check the data log file.

B20T-7 PLUS, B20X-7 PLUS 9-67 EasyView Program

 Fig. 9-77

Fig. 9-78

EasyView Program 9-68 B20T-7 PLUS, B20X-7 PLUS

 Faults

This menu contains three sub menus: Faults active,

Faults history, and Clear faults history.

• Faults Active : shows a list of the currently present

fault codes.

Fig. 9-79

• Faults History: shows a list of the past fault codes

that have occurred since the last clearing of faults
history.

Electrical System (F-series)

Fig. 9-80
• Clear Faults History: clears the current list of faults history.

B20T-7 PLUS, B20X-7 PLUS 9-69 EasyView Program

 Cloning

In this menu, you can either copy the parameter settings

applied to the vehicle to save them in the PC, or copy
parameter settings stored in the PC to apply them to the
vehicle.

• Browse/Open button: Clicking this button enables

you to select a cloning file (*.csv). And then,
parameter settings from the selected file are displayed
under <File value>.

Fig. 9-81

EasyView Program 9-70 B20T-7 PLUS, B20X-7 PLUS

 • Read controller button: Clicking this button loads
parameter settings from the controllers and
displays them under <Controller value>.

Electrical System (F-series)

Fig. 9-82
• Save button: Clicking this button saves parameter
values from the controllers in the cloning file on the
PC.

Fig. 9-83

B20T-7 PLUS, B20X-7 PLUS 9-71 EasyView Program

 • Clone button: Clicking this button copies the
parameter settings from the cloning file to the
controllers While automatically running the
following three steps: Verify, Writing, and Reading.

Step 1: Verify

Fig. 9-84
Step 2: Writing

Fig. 9-85

EasyView Program 9-72 B20T-7 PLUS, B20X-7 PLUS

 Step 3: Reading

Electrical System (F-series)

Fig. 9-86

B20T-7 PLUS, B20X-7 PLUS 9-73 EasyView Program

 9-6-5 Main page – Test Menu (diagnostic parameters)
<Test Menu> on the main page contains a list of
diagnostic parameters in groups.

Test Menu – Software Version Information

Fig. 9-87

No. Parameter Description

1 Drive Left Software Type The model code to which the left drive software applies.
2 Drive Left Software Type Left drive software revision year
3 Drive Left Software Month Left drive software revision month
4 Drive Left Software Day Left drive software revision day
The model code to which the right drive software
5 Drive Right Software Type
applies.
6 Drive Right Software Year Right drive software revision year
7 Drive Right Software Month Right drive software revision month
8 Drive Right Software Day Right drive software revision day
9 Pump Software Type The model code to which the pump software applies.
10 Pump Software Year Pump software revision year
11 Pump Software Month Pump software release month.
12 Pump Software Day Pump software revision day

EasyView Program 9-74 B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Drive

Electrical System (F-series)

Fig. 9-88

No. Parameter Description

Left drive motor’s actual speed in revolutions per minute�
1 Left Motor Speed
(rpm)
Left drive motor speed request in revolutions per minute�
2 Left Motor Speed Request
(rpm)
Right drive motor’s actual speed in revolutions per minute�
3 Right Motor Speed
(rpm)
Right Motor Speed Right drive motor speed request in revolutions per minute�
4
Request (rpm)
5 Temp Left Drive Motor Left drive motor temperature (°C)
6 Temp Left Drive Module Left drive module temperature (°C)
7 Temp Right Drive Motor Right drive motor temperature (°C)

B20T-7 PLUS, B20X-7 PLUS 9-75 EasyView Program

 No. Parameter Description
8 Temp Right Drive Module Right drive module temperature (°C)
9 Left Motor Current Left drive motor current in Amps RMS (A)
10 Right Motor Current Right drive motor current in Amps RMS (A)
11 Pedal Voltage A Accelerator pedal output voltage A (V).
12 Pedal Voltage B Accelerator pedal output voltage B (V).
Steering Sensor Output
13 Steering sensor voltage (V)
Voltage
14 Seat Switch Seat switch state
15 Pedal Brake Switch Brake switch state
State of forward direction, received from F/R switch. On�
16 Forward Switch indicates that the forward direction is selected. "On"
indicates that the forward direction is selected.
State of reverse direction, received from F/R switch. "On"
17 Reverse Switch
indicates that the reverse direction is selected.
State of buzzer relay output at drive module pin 30. "On"
indicates that the buzzer relay driver is active. When a
18 Warning Buzzer
fault�
occurs, a buzzer will sound.
State of line contactor output at drive module pin 6. “On”
19 Main contactor
indicates that the line contactor driver is active.
20 Left Motor Encoder (5V) 5 V supply voltage at left drive module pin 26
Drive encoder phase A at left drive module pin 31. "On"
21 Left Motor Encoder A
indicates pulse activity on the encoder phase A.
Drive encoder phase B at left drive module pin 32. "On"
22 Left Motor Encoder B
indicates pulse activity on the encoder phase B.
23 Right Motor Encoder (5V) 5 V supply voltage at right drive module pin 26
Drive encoder phase A at right drive module pin 31. "On"
24 Right Motor Encoder A
indicates pulse activity on the encoder phase A.
Drive encoder phase B at right drive module pin 32. "On"
25 Right Motor Encoder B
indicates pulse activity on the encoder phase B.
26 ISO Relay The state of ISO relay.
27 Left EM Brake EM Brake state of the left motor.
28 Right EM Brake EM Brake state of the right motor.

EasyView Program 9-76 B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Pump

Electrical System (F-series)

Fig. 9-89

No. Parameter Description

1 Motor Speed Pump motor’s actual speed (rpm).
The controller’s demanded pump motor speed (from lift
2 Motor Speed Request
command input) (rpm).
3 Temp Pump Motor Pump motor temperature (°C).
4 Temp Pump Module Pump module temperature (°C).
5 Pump Motor Current Pump motor current (A).
6 Lift Command Lift Command voltage (V) input from Analog1
7 Tilt Whether or not the TILT switch is on.
8 Aux1 Whether or not the AUX1 switch is on.
9 Aux2 Whether or not the AUX2 switch is on.
10 Height Switch NO (SW1) [GSS] Height switch command
11 Height Switch NC (SW1) [GSS] Mast Tilt switch command
12 Height Switch (SW1) [GSS] Height switch command
13 Mast Tilt Switch (SW2) [GSS] Mast Tilt switch command
14 Auto Tilt Switch (SW3) [GSS] Auto Tilt switch command
15 Pump Motor Encoder (5V) 5 V supply voltage at pump module pin 26
Pump encoder phase A at pump module pin 31. "On"
16 Pump Motor Encoder A
indicates pulse activity on the encoder phase A.
Pump encoder phase B at pump module pin 32. "On"
17 Pump Motor Encoder B
indicates pulse activity on the encoder phase B.

B20T-7 PLUS, B20X-7 PLUS 9-77 EasyView Program

 Test Menu – Fingertip and Valve

Fig. 9-90

No. Parameter Description

1 Knob Lift Command Lift command value from knob
2 Knob Lift (On/Off) State of lift signal from knob
3 Knob Lower (On/Off) State of lowering signal from knob
4 Knob Tilt Backward (On/Off) State of tilt backward signal from knob
5 Knob Tilt Forward (On/Off) State of tilt forward signal from knob
6 Knob Aux1 Right (On/Off) State of AUX1 right signal from knob
7 Knob Aux1 Left (On/Off) State of AUX1 left signal from knob
8 Knob Aux2 Right (On/Off) State of AUX2 right signal from knob
9 Knob Aux2 Left (On/Off) State of AUX2 left signal from knob
10 Auto Tilt Mode Switch State of auto tilt signal from knob
11 Auto Clamp Mode Switch State of auto clamp signal from knob
12 Forward Switch State of drive forward signal from knob
13 Reverse Switch State of drive reverse signal from knob
14 Lift Sol Current Lifting solenoid valve current (mA)
15 Lower Sol Current Lowing solenoid valve current (mA)

EasyView Program 9-78 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description
16 Tilt Backward Sol Current Tilt back solenoid valve current (mA)
17 Tilt Forward Sol Current Tilt forward solenoid valve current (mA)
18 Aux1 Right Sol Current AUX1 right valve solenoid current (mA)
19 Aux1 Left Sol Current AUX1 left valve solenoid current (mA)
20 Aux2 Right Sol Current AUX2 right valve solenoid current (mA)
21 Aux2 Left Sol Current AUX2 left valve solenoid current (mA)
22 Unload Valve State of unload valve
23 Back Up Buzzer State of backup alarm

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-79 EasyView Program

 Test Menu – Battery

Fig. 9-91

No. Parameter Description

1 Battery voltage Battery voltage (V) measured at drive module pin 1
Inverter voltage (V) measured at drive motor controller
2 Inverter Voltage
B+ stud
Battery level measured from the left drive motor�
3 Battery Level
controller
4 BDI Percentage Battery discharge indicate level (%)

EasyView Program 9-80 B20T-7 PLUS, B20X-7 PLUS

 Test Menu – Timers

Fig. 9-92

No. Parameter Description

Hour meter that counts the time when the seat switch is
1 Seat Switch Hour Meter applied (closed) (Hr). You can see this data on the
instrument panel.

2 Drive Motor Hour Meter

Hour meter that counts the time that the drive motor is
active (Hr)
9
Hour meter that counts the time that the pump motor is

Electrical System (F-series)

3 Pump Motor Hour Meter active (Hr). You can see this data on the�
instrument panel.
4 Odometer Vehicle distance traveled (km)

B20T-7 PLUS, B20X-7 PLUS 9-81 EasyView Program

 9-6-6 Main page – Calibration Menu
< Calibration Menu> on the main page contains a list of
calibration parameters in groups. To access this menu,
you should log in to the application (Administration
Login Enter password: dbgby141).

Calibration Menu – Accel Pedal Set

Fig. 9-93

No. Parameter Description

Pedal Voltage A�
1 Output voltage (V) from the accelerator pedal
(monitor variable)
Forward Switch�
2 Forward switch state
(monitor variable)
Reverse Switch�
3 Reverse switch state
(monitor variable)
4 Min Accelerator A Accelerator pedal voltage (V) with the pedal released
5 Max Accelerator A Accelerator pedal voltage (V) with the pedal completely pressed

NOTICE: See Section 9-6-7 for a detailed procedure of using

this sub menu.

EasyView Program 9-82 B20T-7 PLUS, B20X-7 PLUS

 교정 메뉴 – 브레이크페달 세트

Fig. 9-94

No. Parameter Description

1 Brake Pedal Voltage A Measured value between 0.00 and 5.50 V.
2 Brake Min Brake pedal voltage (V) with the pedal released.
Brake pedal voltage (V) with the pedal completely�
3 Brake Max
pressed.
The percent of brake pedal’s stroke between 1 and
9
100%. For reference, there are two stages during the�

Electrical System (F-series)

4 Brake Mid Percent
whole pedal stroke. Between the stages, there is some
stroke with slight different feeling.

NOTICE: See Section 9-6-7 for a detailed procedure of using this

sub menu.

B20T-7 PLUS, B20X-7 PLUS 9-83 EasyView Program

 Calibration Menu – Lift Set

Fig. 9-95

No. Parameter Description

1 Lift Command (monitor variable) Lift command voltage (V) at pump module pin 24
2 Lift Min Lift command voltage (V) with the lift lever released.
Lift Command voltage (V) with the lift lever fully
3 Lift Max
applied.

NOTICE: See Section 9-6-7 for a detailed procedure of using this

sub menu.

EasyView Program 9-84 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Steering Set

Fig. 9-96

No. Parameter Description

Steer Sensor
1 Output Voltage Steering angle sensor voltage (V) at left drive module pin 24.
(monitor variable)
Steer angle sensor voltage (V) when the rear wheels are fully
9
2 Steering Anticlock
turned counterclockwise.

Electrical System (F-series)

Steer angle sensor voltage (V) when the rear wheels are in the
3 Steering Middle
middle.
Steer angle sensor voltage (V) when the rear wheels are fully
4 Steering Clock
turned clockwise.
Steer Middle Maximum drive motor speed at which the steering is turned to
5
Angle Max Speed about 45 degrees.
Steering Limit Max Maximum drive motor speed when the steer angle is at full lock
6
Speed counterclockwise or clockwise.

NOTICE: See Section 8-6-7 for a detailed procedure of using this

sub menu.

B20T-7 PLUS, B20X-7 PLUS 9-85 EasyView Program

 Calibration Menu – Maintenance Timer

Fig. 9-97

No. Parameter Description

Seat Switch Hour Meter (monitor Hour meter that counts the time when the seat switch
1
variable) is active. (Hr)
When this parameter value is on, the maintenance
2 Maintenance Time Set
function is enabled.
When the Drive Hour Meter exceeds this parameter
value, the wrench icon on the vehicle display lights
up, indicating that vehicle maintenance is needed.
3 Set Time
Once the maintenance is performed, the value of this
parameter should be increased to a setting when the
next time maintenance is scheduled.

EasyView Program 9-86 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu - Timers

Fig. 9-98

No. Parameter Description

The time delay since the driver leaves the seat and
1 Seat Switch Delay the seat switch is open until the controller enters
standby mode and inhibits drive and lift functions.

2 Chat Time
Chat Time If there is no command given (neither
drive nor pump action) during the amount of time set 9
for this parameter since the expiration of the idle

Electrical System (F-series)

time, the display will show the “PP” message.
The time delay since no input has been received
3 Idle Time from LIFT, TILT, AUX1, AUX2, or steering until the
pump motor stops.
Stop on a Slope Timer Once the driver stops on a
slope, the shafts of the drive motors are locked while
the vehicle is stationary so it may hold its position
4 Stop on a Slope Timer
regardless of whether the EM parking brake is
engaged or not. This function is triggered by the
release of the accelerator pedal by the driver.

B20T-7 PLUS, B20X-7 PLUS 9-87 EasyView Program

 Calibration Menu – Truck Setup

Fig. 9-99

No. Parameter Description

1 Li Battery enable When this parameter value is on, Lithium-ion Battery can be used.
2 Enable Geofence When this parameter value is on, the geofence lamp is enabled.
Enable Working When this parameter value is on, the cooling fan function is
3
Fans enabled.
Enable Calibration When this parameter value is on, the instrument panel can be
4
by Display used to view and change calibration parameters.
Enable Turtle When this parameter value is on, the Turtle Speed function can be
5
Speed by Display turned On or Off from the instrument panel.
Enable EHS by When this parameter value is on, the EHS mode function can be
6
Display selected though the vehicle display.
When this parameter value is on, the display is allowed to go to
7 Enable Chat Time
PP mode.

EasyView Program 9-88 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description
8 Enable British Units Enables the use of British units.
Enables the use of fingertip option. For a fingertip vehicle, you
9 Enable Fingertip
should� set this parameter to “1” after flashing.
10 Enable Auto Clamp Defines whether auto clamp function is used on this vehicle or not.
Enable Aux2 Determines whether AUX2 is used on this vehicle or
11 Enable Aux2 not. When this� parameter is On, the system will check for valve
presence.
12 Enable Auto Tilt Defines whether auto tilt function is used on this vehicle or not.
When this parameter value is on, the vehicle‘s GSS function is all
13 Enable GSS
enabled.
Buzzer On Forward When this parameter value is on, the vehicle buzzer sound when
14
Direction the� forward direction is selected.
Buzzer On Reverse When this parameter value is on, the vehicle buzzer sound when
15
Direction the reverse direction is selected.
When this parameter value is on, turtle mode is active, and the
Buzzer On Turtle
16 vehicle speed equals the Max Speed in Turtle Mode, the vehicle
Speed

Buzzer On High
buzzer will sound.
When this parameter value is on, the vehicle buzzer sounds when
9
17
Speed Enable the vehicle speed is higher than the Buzzer On Speed.

Electrical System (F-series)

Buzzer On Speed Defines the buzzer on high speed level, when
18 Buzzer On Speed motor speed is higher� than this value, and Buzzer On High
Speed Enable is ON, buzzer sound.
When this parameter value is on and the Lift function and any of
the other functions (Tilt, AUX1, AUX2) are operated
simultaneously, the pump operates at a speed that is the lowest
Lift Priority For
speed among the inputs (Tilt, AUX1, AUX2 or Lift).
19 Pump Reference
When this parameter value is off and the Lift function and any of
Speed
the� other functions (Tilt, AUX1, AUX2) are operated
simultaneously, then the pump operates at a speed that is the
highest speed among the� inputs (Tilt, AUX1, AUX2 or Lift).
Controller Fan When controller temperature is higher than the value of this
20
Starting Temp setting, the cooling fan runs automatically.
Motor Fan Starting When Motor is higher than the value of this setting, the cooling fan
21
Temp runs automatically.
If there is no input on AUX2 during the amount of time set for
Auto Clamp First
22 this� parameter since the vehicle is keyed on, the auto clamp
Delay
function will� be automatically conducted (fingertip only).
If there is no input on AUX2 during the amount of time set for this
Auto Clamp Interval
23 parameter since the last AUX2 operation, the auto clamp function
Delay
will be automatically conducted (fingertip only).
Whether or not to use the function to detect the operation order in
24 Enable Seat belt which the seat belt must be operated after the seat switch
operation.
Enable Mono Pedal Whether to enable the F/R switch in a vehicle that uses the
25
With Fingertip fingertip and mono pedal options.
Lift Lever neutral
26 Whether to enable the lift lever neutral switch in a vehicle.
SW Enable
Forward Light
27 Whether to enable the forward light relay in a vehicle.
Relay Enable

B20T-7 PLUS, B20X-7 PLUS 9-89 EasyView Program

 Calibration Menu – Mode Selection for Traction

Fig. 9-100

No. Parameter Description

Indicates if Economic mode is active on the instrument

1 E Mode (monitor variable)
panel.
Indicates if Standard mode is active on the instrument
2 S Mode (monitor variable)
panel.
Indicates if High Performance mode is active on the
3 H Mode (monitor variable) instrument�
panel.

4 Max Speed in Turtle Mode Maximum drive motor speed allowed in turtle mode.

Maximum drive motor current allowed in “E” power�

mode. Setting this parameter to a higher value allows
a heavily loaded vehicle to reach higher speeds.
5 Drive Maximum Current E Setting this parameter to a lower value limits the speed
of a heavily loaded vehicle. The higher value allows a
heavily loaded truck to reach higher speeds and lower
value limits the speed of a heavily loaded truck.
Maximum drive motor forward speed allowed in “E”
6 Drive Forward Max Speed E
power mode.
Maximum drive motor reverse speed allowed in “E”
7 Drive Reverse Max Speed E
power mode.
Maximum drive motor current allowed in “S” power
mode. Setting this parameter to a higher value allows a
8 Drive Maximum Current S heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.

EasyView Program 9-90 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description

Maximum drive motor forward speed allowed in “S”

9 Drive Forward Max Speed S
power mode.
Maximum drive motor reverse speed allowed in “S”
10 Drive Reverse Max Speed S
power mode.
Maximum drive motor current allowed in “H” power
mode. Setting this parameter to a higher value allows a
11 Drive Maximum Current H heavily loaded vehicle to reach higher speeds. Setting
this parameter to a lower value limits the speed of a
heavily loaded vehicle.
Maximum drive motor forward speed allowed in “H”
12 Drive Forward Max Speed H
power mode.
Maximum drive motor reverse speed allowed in “H”
13 Drive Reverse Max Speed H
power mode.

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-91 EasyView Program

 Calibration Menu – Mode Selection for Pump

Fig. 9-101

No. Parameter Description

Indicates if Economic mode is active on the instrument
1 E Mode (monitor variable)
panel.
Indicates if Standard mode is active on the instrument
2 S Mode (monitor variable)
panel.
Indicates if High Performance mode is active on the
3 H Mode (monitor variable)
instrument panel.

EasyView Program 9-92 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu –E/S/H MODE Performance

Fig. 9-102

No. Parameter Description

Lift Max Speed

Maximum pump motor speed allowed in “E” power mode
9
1 as a result of a maximum lift command. This setting
(E MODE performance)

Electrical System (F-series)

controls the maximum lift speed with no load (unloaded).
Maximum pump motor speed allowed in “S” power mode
Lift Max Speed�
2 as a result of a maximum lift command. This setting
(S MODE performance)
controls the maximum lift speed with no load (unloaded).
Maximum pump motor speed allowed in “H” power mode
Lift H Speed�
3 as a result of a maximum lift command. This setting
(H MODE performance)
controls the maximum lift speed with no load (unloaded).

B20T-7 PLUS, B20X-7 PLUS 9-93 EasyView Program

 Calibration Menu – Drive Response

Fig. 9-103

No. Parameter Description

The acceleration response to a full accelerator pedal
command (> 90%) when the vehicle is at a high speed
(> 70% max speed). Increasing this setting results in a
Acceleration Rate HS
1 slower� response; decreasing this setting results in a faster
(Full Accel Rate HS)
response. The Acceleration Rate HS parameter is typically
set higher (slower) than the Acceleration Rate LS
parameter.
The acceleration response to a full accelerator pedal
command (> 90%) when the vehicle is at a low speed
Acceleration Rate LS (< 30% max speed). Increasing this setting results in a
2
(Full Accel Rate LS) slower� response; decreasing this setting results in a faster
response. The Acceleration Rate LS parameter is typically
set lower (faster) than the Acceleration Rate HS parameter.
The acceleration response to a low accelerator pedal
command (< 10%). Acceleration response for intermediate
(10% to 90%) accelerator pedal commands is scaled
between the Low Accel Rate and either the Acceleration
Rate LS or Acceleration Rate HS settings (depending on
3 Low Accel Rate
the vehicle’s speed). Increasing this setting results in a
slower response; decreasing this setting results in a faster
response. The Low Accel Rate parameter is typically set
higher (slower) than both the Acceleration Rate LS and
Acceleration Rate HS parameters.

EasyView Program 9-94 B20T-7 PLUS, B20X-7 PLUS

 No. Parameter Description
The deceleration response when the accelerator pedal
command is released (to neutral) while the vehicle is
traveling at high speeds. Increasing this setting results in
Release Rate HS
4 a slower deceleration response; decreasing this setting
(Neutral Decel Rate HS)
results in a faster deceleration response. The Release Rate
HS parameter is typically set higher (slower) than the
Release Rate LS parameter.
The deceleration response when the accelerator pedal
command is released (to neutral) while the vehicle is
traveling at low speeds. Increasing this setting results in a
Release Rate LS
5 slower deceleration response; decreasing this setting
(Neutral Decel Rate LS)
results in a faster deceleration response. The Release Rate
LS parameter is typically set lower (faster) than the Release
Rate HS parameter.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while
the vehicle is traveling at high speeds. Increasing this
setting results in a slower deceleration response;
9
6 Partial Decel Rate
decreasing this setting results in a faster deceleration

Electrical System (F-series)

response. The Partial Decel Rate parameter is typically set
higher (slower) than both the Release Rate LS and Release
Rate HS parameters.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while
the vehicle is traveling at high speeds. Increasing this
Inversion Rate HS
7 setting results in a slower deceleration response;
(Full Brake Rate HS)
decreasing this setting results in a faster deceleration
response. The Inversion Rate HS parameter is typically set
higher (slower) than the Inversion Rate LS parameter.
The deceleration response when the drive direction is
reversed at full (>90%) accelerator pedal command while
the vehicle is traveling at low speeds. Increasing this setting
Inversion Rate LS
8 results in a slower deceleration response; decreasing this
(Full Brake Rate LS)
setting results in a faster deceleration response. The
Inversion Rate LS parameter is typically set lower (faster)
than the Inversion Rate HS parameter.
The response when the drive direction is reversed at low
(<10%) accelerator pedal command. Increasing this setting
results in a slower deceleration response; decreasing this
9 Low Inversion Rate setting results in a faster deceleration response. The Low
Inversion Rate parameter is typically set higher (slower)
than both the Inversion Rate HS and Inversion Rate LS
parameters.

B20T-7 PLUS, B20X-7 PLUS 9-95 EasyView Program

 Calibration Menu – Pump Motor RPM_Manual

Fig. 9-104

No. Parameter Description

Pump motor speed when tilt-forward/backward function is
1 Tilt Speed Manually
active without the fingertip option.
Tilt Secondary Speed Pump motor speed at the secondary lifting span when tilt
2
Manually forward/backward function is active.
3 Aux1 Speed Manually Pump motor speed when AUX1 function is active.
Aux1 Secondary Speed Pump motor speed at the secondary lifting span when
4
Manually AUX1 function is active.
5 Aux2 Speed Manually Pump motor speed when AUX2 function is active.
6 Hydro Speed Manually Pump motor speed during steering (excluding lift, tilt, etc.).
7 Idle Speed Manually Pump motor idle speed when there is no steering input.

In addition, tilt speed can be adjusted per the span of tilt load condition. Use the following two
menus.

EasyView Program 9-96 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Pump Motor RPM_Fingertip

Fig. 9-105

No. Parameter Description

Pump motor minimum speed when lift function is active with
1 Lift Min Speed Fingertip
the fingertip option.
Pump motor speed when the fingertip lift knob is placed
9
halfway to the lift command end. The three fingertip lift-

Electrical System (F-series)

related parameters Lift Min Speed Fingertip, Lift Middle
Speed Fingertip, and Lift Max Speed determine the pattern
of fingertip lift acceleration as shown below:

2500 Lift Max

Speed
Lift Middle Speed 2000
2
Fingertip
1500
rpm

Lift Min Speed

1000 Fingertip

500
Lift Middle
Speed Fingertip
0
Knob command

Pump motor speed when lower function is active with the

3 Lower Speed Fingertip
fingertip option.
Pump motor minimum speed when tilt function is active with
4 Tilt Min Speed Fingertip
the fingertip option.
Motor speed when tilt backward function is active with the
5 Tilt BWD Speed Fingertip
fingertip option.
Tilt BWD Secondary Pump motor speed at the secondary lifting span when tilt
6
Speed Fingertip backward function is active with the fingertip option.
Motor speed when tilt forward function is active with the
7 Tilt FWD Speed Fingertip
fingertip option.
Tilt FWD Secondary Pump motor speed at the secondary lifting span when tilt
8
Speed Fingertip forward function is active with the fingertip option.

B20T-7 PLUS, B20X-7 PLUS 9-97 EasyView Program

 No. Parameter Description
AUX1 Min Speed Pump motor minimum speed when AUX1 function is active
9
Fingertip with the fingertip option.
AUX1 FWD Speed Pump motor speed when AUX1 and forward function are
10
Fingertip active with the fingertip option.
Pump motor speed at the secondary lifting span when
AUX1 FWD Secondary
11 AUX1 and forward function are active with the fingertip
Speed Fingertip
option.
AUX1 BWD Speed Pump motor speed when AUX1 and reverse function are
12
Fingertip active with the fingertip option.
AUX1 BWD Secondary Pump motor speed when AUX1 and reverse function are
13
Speed Fingertip active at the secondary lifting span with the fingertip option.
AUX2 Min Speed Pump motor minimum speed when AUX2 function is active
14
Fingertip with the fingertip option.
AUX2 FWD Speed Pump motor speed when AUX2 and forward function are
15
Fingertip active with the fingertip option.
AUX2 BWD Speed Pump motor speed when AUX2 and backward function are
16
Fingertip active with the fingertip option.
Pump motor idle speed when there is no steering input with
17 Idle Speed Fingertip
the fingertip option.
Pump motor speed during steering (excluding lift, tilt, etc.)
18 Steering RPM Fingertip
with the fingertip option.

EasyView Program 9-98 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Tilt Speed Reduction_Manual

Fig. 9-106

Tilt Speed Reduction_Fingertip

9

Electrical System (F-series)

Fig. 9-107

No. Parameter Description

Tilt Speed For 0∼20 Percent
1
Load
- Functions used in models with the weight scale option.
Tilt Speed For 21∼40
2 - When the load is in the range of XX % of the maximum
Percent Load
load, the tilt speed decreases by lowering the motor
Tilt Speed For 41∼60
3 RPM as much as the set value.
Percent Load
Example) When carrying a 1 ton load in the B20X
Tilt Speed For 61∼80
4 model, if the 41~60% setting value is 95, the motor RPM
Percent Load
decreases to 800 x 0.95 = 760 rpm.
Tilt Speed For 81∼100
5
Percent Load

B20T-7 PLUS, B20X-7 PLUS 9-99 EasyView Program

 Calibration Menu – Weight Sensor

Fig. 9-108

No. Parameter Description

When this parameter value is on, the weight sensor�
1 Weight Sensor Enable
function is enabled.
2 Weight Sensor Output Weight sensor voltage (V)
3 No Load Pressure Voltage Weight sensor voltage (V) without load.
4 Load Pressure Voltage Weight sensor voltage (V) with load.

EasyView Program 9-100 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – Weight Sensor - Load weight British units ON

Fig. 9-109

No. Parameter Description

1 Load Weight in Lbs Load weight in the British unit. [Lbs]
Tilt Speed Reduced By
2 Tilt speed reduction per the load.
Weight in Lbs
9

Electrical System (F-series)

B20T-7 PLUS, B20X-7 PLUS 9-101 EasyView Program

 Calibration Menu – Weight Sensor - Load weight British units OFF

Fig. 9-110

No. Parameter Description

1 Load Weight in Kg Load weight in the International unit. [Kg]
Tilt Speed Reduced By
2 Tilt speed reduction per the load. [Kg]
Weight in Kg

EasyView Program 9-102 B20T-7 PLUS, B20X-7 PLUS

 Calibration Menu – EFB Advanced

Fig. 9-111

No. Parameter Description

EM Emergency Shut Down Counts the number of times operating the EM brake in
1
Counts an emergency situation.
If the number of using the EM brake in an emergency
2

3
EM Service Counts

EM Service Counts Reset

situation exceeds the set number, this function is limited.
Reset the EM service counts.
9
When the EM service counts reach the set value, an

Electrical System (F-series)

EM Service Counts Expired
4 error is displayed and the vehicle speed is limited to the
RPM
set value.

B20T-7 PLUS, B20X-7 PLUS 9-103 EasyView Program

 9-6-7 Initial settings
The output analog voltage of each accelerator, lift sensor,
steering sensor and brake sensor signals to inform the
controllers of their physical positions.

In other words, the electrical system recognizes these

components’ positions according to how high their output
voltage is. As there is a variation in voltage output versus
physical position among individual units, you must reset
this relationship once any of the aforementioned
components is replaced or the controller firmware is
updated.

The initial setting procedure for each component is as

follows:

Accelerator initial settings

1. On EasyView, go to the Calibration Menu 

Pedal Set.

2. Check the value of the Pedal Voltage A parameter

(1) when the accelerator is not pressed at all.
Enter this value in the setting field for the Min
Accelerator A parameter (2) and then, press
Save.

(1)

(2)

Fig. 9-112

EasyView Program 9-104 B20T-7 PLUS, B20X-7 PLUS

 3. Check the value of the Pedal Voltage A parameter
(1) when the accelerator is fully pressed. Enter
this value in the setting field for the Max
Accelerator A parameter (3) and then, press
Save.

(1)

(3)

9
Fig. 9-113

Electrical System (F-series)

Lift sensor initial setting

1. On EasyView, go to the Calibration Menu  Lift

Set.

2. Check the value of the Lift Command parameter

(1) when the lift lever is in neutral. Enter this value
in the setting field for the Lift Min parameter (2)
and then, press Save.

(1)

(2)

Fig. 9-114

B20T-7 PLUS, B20X-7 PLUS 9-105 EasyView Program

 3. Check the value of the Lift Command parameter
(1) when the lift lever is fully pulled. Enter this
value in the setting field for the Lift Max
parameter (3) and then, press Save.

(1)

(3)

Fig. 9-115

Steering sensor initial setting

1. On EasyView, go to the Calibration Menu 

Steering Set.

2. Check the value of the Steer Sensor Output

Voltage parameter (1) when the rear wheels are
fully turned left. Enter this value in the setting
field for the Steering Anti clock parameter (2) and
then, press Save.

(1)

(2)

Fig. 9-116

EasyView Program 9-106 B20T-7 PLUS, B20X-7 PLUS

 3. Check the value of the Steer Sensor Output
Voltage parameter (1) when the rear wheels are
in the middle. Enter this value in the setting field
for the Steering Middle parameter (3) and then,
press Save.

(1)

(3)

9
Fig. 9-117

Electrical System (F-series)

4. Check the value of the Steer Sensor Output
Voltage parameter (1) when the rear wheels are
fully turned right. Enter this value in the setting
field for the Steering Clock parameter (4) and
then, press Save.

(1)

(4)

Fig. 9-118

B20T-7 PLUS, B20X-7 PLUS 9-107 EasyView Program

 Brake pedal initial settings

1. Prior to this initial setting, conduct brake pedal

adjustment. [Refer to Chapter 3-7-4]

2. On EasyView, go to the Calibration Menu Brake

Pedal Set.

3. Setting for Brake Min.

3-1. Read the value of Brake Pedal Voltage A

parameter (1) when the brake pedal is not
pressed at all.

3-2. Click the row for Brake Min.

3-3. Enter the value read at 2-1 in the setting field

in box (2) and then, press the Save (3).
Compared to 0.50V in the box (1), a little bit
of higher value like 0.55V is recommended.

Fig. 9-119

EasyView Program 9-108 B20T-7 PLUS, B20X-7 PLUS

 4. Setting for Brake Max.

4-1. Read the value of Brake Pedal Voltage A

parameter (1) when the brake pedal is fully
pressed.

4-2. Click the row for Brake Max.

4-3. Enter the value read at 4-1 in the setting field

in box (2) and then, press the Save (3).
Compared to 4.50V in the box (1), a little bit
of lower value like 4.45V is recommended.

Electrical System (F-series)

Fig. 9-120

B20T-7 PLUS, B20X-7 PLUS 9-109 EasyView Program

9-7 Handling faults on Instrument/EasyView
A. Curtis code (LED code)

In addition to the instrument panel and EasyView, the

drive and pump motor controllers also inform the operator
of the current faults using two fault code indicator LEDs
installed on each controller and the fingertip extension
module. Their fault indications are called “Curtis code
(LED code)”.

Compared to other indicators, they have an advantage in

that the operator can easily identify which controller has a
trouble simply by seeing them— only the LEDs on the
faulty controllers light up. The table below shows which
controller could set off a warning for each fault code.

For an explanation of how to read Curtis codes, see

Section 9-3-4.

Handling faults on Instrument/EasyView 9-110 B20T-7 PLUS, B20X-7 PLUS

 B. Measures for fault codes

Panel
Fault description
code
LIB VOLT HIGHLOW - Lithium battery over voltage/low voltage warning
LED code TL-6E
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
01
1. Warning message from Lithium-ion battery BMS.
Cause
2. High/low voltage of the battery pack.

Solution 1. Check the lithium-ion battery.

LIB VOLT UNBALAN - Lithium battery voltage unbalancing warning

LED code TL-6F
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
02
Cause
1. Warning message from Lithium-ion battery BMS. 9
2. Unbalanced battery cells.

Electrical System (F-series)

Solution 1. Check the lithium-ion battery.

LIB VOLT UNBALAN - Lithium battery temperature unbalancing warning

LED code TL-7A
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
03
1. Warning message from Lithium-ion battery BMS.
Cause
2. The temperature of the battery is high or unbalanced.

Solution 1. Check the lithium-ion battery.

LIB OVER CURRENT - Lithium battery over current warning

LED code TL-7B
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work Work
2000 800
04
1. Warning message from Lithium-ion battery BMS.
Cause
2. Battery current too high.

Solution 1. Check the lithium-ion battery.

B20T-7 PLUS, B20X-7 PLUS 9-111 Handling faults on Instrument/EasyView

 LIB CAN Fault - Lithium battery CAN fault
LED code TL-7C
Traction Pump Extension EM Brake
Controller Action
Stop by EAB stop Work Stop by EAB

1. Cannot view CAN information from BMS or PDO timed out from
05 Cause
BMS.

1. Check the lithium-ion battery.

Solution 2. Check the canvas for 0X630 CAN message.
3. Check if CAN messages are stable.
CONTACTOR FAULT– Contactor not working properly
LED code 31/38/39
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Work
once

1. The line contactor coil is either open or shorted.

2. The line contactor contacts are welded closed.
Cause
3. There are faulty crimps and connections in the wires to the line
contactor coil.

17 1. Check that the line contactor is normally wired.

2. Check if the line fuse has blown.
3. Check if the coil of the line contactor is open-circuit (its normal
resistance is 360 Ω at 25°C [77°F]).

Solution 4. Check its resistance and replace it if it is detected to be abnormal.

5. With the key switch off, measure the resistance between the two
contact tips using a multi the metric to check if they are fused (If a
battery voltage is detected between the line contactor's secondary
tip and the controller's "B-" pin with the key off, it indicates a fusion
between the two tips. In that case, replace the line contactor).
EXT VOLT FAULT – Extension module’s voltage (extension module disabled)
LED code P-5A(EXM21,22)
Traction Pump Extension EM Brake
Controller Action
No action No action Shut down No action
Cause Over voltage/under voltage on the extension module

1. Measure the voltage between pins 1 and 3 on the harness

connector of the fingertip extension module to check if the
21 measurement represents the battery voltage.
2. If it is not measured the battery voltage, check if pin 1 on the left
Solution drive motor controller and pin 3 on the fingertip extension module
connector are correctly connected to one another. And also check if
the battery's negative terminal is correctly connected to pins 1 and
2 on the fingertip extension module connector.
3. If it is not correctly connected, replace the harness.

Handling faults on Instrument/EasyView 9-112 B20T-7 PLUS, B20X-7 PLUS

 EXT TIME FAULT – Extension module’s communications faulty (extension module
disabled)
LED code P-5B(EXM51,52,53),P-67
Traction Pump Extension EM Brake
Controller Action
No action No action Shut down No action
PDO timeout/SDO fault reported on Ext module; CAN Communication
Cause
fault

51 1. Check if pin 5 on the fingertip extension module is normally

connected to pin 23 on the left drive motor controller.
2. Check if pins 4 on the fingertip extension module is normally
connected to pin 35 on the left drive motor controller.
Solution
3. Reinstall the latest software version.
4. If the steps above do not solve the problem, replace the pump
motor�
controller.
BATT MISMATCH – Specifications of battery and controller do not match
LED code 61

Controller Action
Traction

Shut down
Pump

Shut down
Extension

Work
EM Brake
Shut down at
9
once

Electrical System (F-series)

1. The difference between the battery set voltage and the measured
60 voltage at KSI is large. Measure the voltage at KSI and check if it is
within the range below.
Cause 2. The voltage range of the battery for 36V is 26-46V.
3. The voltage range of the battery for 48V is 41.5-58V.
4. The voltage range of the battery for 80V is 64-96V.

Solution After setting the battery voltage to a normal state, cycle KSI.

B20T-7 PLUS, B20X-7 PLUS 9-113 Handling faults on Instrument/EasyView

 D-INV SHUTDOWN – Right drive motor controller overheated (system halted)
LED code 16
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once
The right drive motor controller has reached the shutdown temperature
Cause limit
(95°C, 203°F).

1. Check the temperature of the right drive motor controller in

diagnostic mode on the instrument panel or EasyView.

66 2. If the temperature is detected to be higher than 95°C (203°F), cool

down the vehicle for 15 minutes.
3. If the right drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
Solution
4. Check if the EM parking brake is engaged.
5. Check if the vehicle is excessively loaded.
6. Check if the right drive motor controller is improperly mounted,
preventing heat conduction.
7. If the problems remains present, replace the right drive motor
controller.

L-INV SHUTDOWN– Left drive motor controller overheated (system halted)

LED code 16
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once
The left drive motor controller has reached the shutdown temperature
Cause limit. (95 °C, 203 °F).

1. Check the temperature of the left drive motor controller in diagnostic

mode on the instrument panel or EasyView.
2. If the temperature is detected to be more than 95°C (185°F), cool
67 down the vehicle for 15 minutes.
3. If the Left drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
Solution
4. Check if the EM parking brake is engaged.
5. Check if the vehicle is excessively loaded.
6. Check if the left drive motor controller is improperly mounted,
preventing heat conduction.
7. If the problems remains present, replace the left drive motor
controller.

Handling faults on Instrument/EasyView 9-114 B20T-7 PLUS, B20X-7 PLUS

 P-INV SHUTDOWN – Pump motor controller overheated (system halted)
LED code 16
Traction Pump Extension
EM Brake
Controller Action Shut down at
No action Shut down Work
once
The pump motor controller has reached the shutdown temperature
Cause limit.(95°C, 203°F).

1. Check the temperature of the right drive motor controller in

diagnostic
mode on the instrument panel or EasyView.
68
2. If the temperature is detected to be more than 95°C (185°F), cool
down the vehicle for 15 minutes.

Solution 3. If the Pump motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
4. Check if the vehicle is excessively loaded.
5. Check if the pump motor controller is improperly mounted,
preventing heat conduction.
6. If the problems remains present, replace the pump motor controller.

P-MOTOR ENCODER – Pump motor’s encoder failed

9
LED code 36/73/88/93

Electrical System (F-series)

Traction Pump Extension EM Brake
Controller Action
No action Shut down Work No action
The phase A or phase signal of the Pump motor encoder is abnormal or
Cause not detected, or indicates an abnormally fast speed.

1. Check if the connector of the pump motor encoder is normally

connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the
pump motor controller measures 5 V.
76
3. Check if pin 3 on the pump motor encoder is normally connected to
pin 31 (phase A) on the pump motor controller.

Solution 4. Check if pin 4 on the pump motor encoder is normally connected to

pin 32 (phase B) on the pump motor controller.
5. Check if the phrases A and B on the pump motor encoder normally
turn on and off using EasyView. - Test Menu Pump “Pump
Motor Encoder A” & “Pump Motor Encoder B”
If either phrase is abnormal, replace the pump motor encoder.
6. If the problems remains present, replace the pump motor controller.

B20T-7 PLUS, B20X-7 PLUS 9-115 Handling faults on Instrument/EasyView

 R-M TEMP SENSOR – Right drive motor’s thermal sensor failed (display only, no
change in vehicle performance)
LED code 29
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
Right drive motor thermal sensor voltage is detected to be out of range.
Cause (Continued operation with this fault may result in an overheated drive
motor, reducing its efficiency.)

1. Check if the connector of the thermal sensor on the right drive

77 motor is normally connected.
2. Check if pin 1 on the thermal sensor of the right drive motor is
normally connected to pin 8 on the right drive motor controller.

Solution 3. Check if pin 2 on the thermal sensor of the right drive motor is
normally connected to pin 7 on the right drive motor controller.
4. Check if the resistance values of the thermal sensor on the right
drive motor measures 603 Ω at 25 °C (77 °F).
5. Replace the thermal sensor of the right drive motor.

L-M TEMP SENSOR– Left drive motor’s thermal sensor failed

(display only, no change in vehicle performance)
LED code 29
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
The left drive motor thermal sensor voltage is detected to be out of
Cause range. (Continued operation with this fault may result in an overheated
drive motor, reducing its efficiency.)

1. Check if the connector of the thermal sensor on the left drive motor
78 is normally connected.
2. Check if pin 1 on the thermal sensor of the left drive motor is
normally connected to pin 8 on the left drive motor controller.

Solution 3. Check if pin 2 on the thermal sensor of the left drive motor is
normally connected to pin 7 on the left drive motor controller.
4. Check if the resistance values of the thermal sensor on the left
drive motor measures 603 Ω at 25 °C (77 °F).
5. Replace the thermal sensor of the left drive motor.

Handling faults on Instrument/EasyView 9-116 B20T-7 PLUS, B20X-7 PLUS

 P-M TEMP SENSOR – Pump motor’s thermal sensor failed (display only, no
change in vehicle performance)
LED code 29
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
Pump motor thermal sensor voltage is detected to be out of range.
Cause Continued operation with this fault may result in an overheated drive
motor, reducing its efficiency.

1. Check if the connector of the thermal sensor on the pump motor is

79 normally connected.
2. Check if pin 1 on the thermal sensor of the pump motor is normally
connected to pin 8 on the pump motor controller.

Solution 3. Check if pin 2 on the thermal sensor of the pump motor is normally
connected to pin 7 on the pump motor controller.
4. Check if the resistance values of the thermal sensor on the pump
motor measures 603 Ω at 25 °C (77 °F).
5. Replace the thermal sensor of the pump motor.

L-EM BRAKE – Left EM brake failed

LED code 32/92
9
Traction Pump Extension EM Brake

Electrical System (F-series)

Controller Action Shut down at
Stop by EAB No action Work
once
The circuit from pin 5 or 13 of the left drive motor controller is open or�
Cause short, causing an abnormal current in the circuit detected by the
controller.

1. Check if the connector of the EM brake on the left drive motor is

normally connected.
80 2. Check if the connectors labeled “EM CONN A” and “EM CONN B”
are properly connected.
3. Check if pin 1 of the left EM brake connector is normally connected
Solution to pin 5 of the left drive motor controller connector.
4. Check if pin 2 of the left EM brake connector is normally connected
to pin 13 of the left drive motor controller connector.
5. Swap the harness connectors for the left and right EM brakes, and
check which fault code is displayed.
6. If fault code 81 appears, replace the left drive motor's EM brake.

B20T-7 PLUS, B20X-7 PLUS 9-117 Handling faults on Instrument/EasyView

 R-EM BRAKE - Right EM brake failed
LED code 32/92
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop by EAB No action Work
once
The circuit from pin 5 or 13 of the left drive motor controller is open or�
Cause short, causing an abnormal current in the circuit detected by the
controller.

1. Check if the connector of the EM brake on the right drive motor is

normally connected.

81 2. Check if the connectors labeled “EM CONN A” and “EM CONN B”

are
properly connected.
3. Check if pin 1 of the right EM brake connector is normally
Solution connected to pin 5 of the right drive motor controller connector.
4. Check if pin 2 of the right EM brake connector is normally
connected to pin 13 of the right drive motor controller connector.
5. Swap the harness connectors for the left and right EM brakes, and
check which fault code is displayed.
6. If fault code 80 appears, replace the right drive motor's EM brake.

EM BRAKE WARN –EM BRAKE WARN

LED code 5B
Traction Pump Extension EM Brake
Controller Action
Limited to 2000 No action Work No action

82 Triggered when Fault code 88 (EM BRAKE LOCKED) has happened to

Cause 20 times.
- Phenomenon : The speed of drive motor is limited to 2,000 rpm.

1. After checking out that EM BRAKE is free from defect, conduct

Solution
resetting EM BRAKE COUNT.

PAR CHANGE FAULT – Parameter change failed

LED code 49
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop Stop Work
83 once
A change to a system parameter is detected that requires this safety
Cause fault.

1. This code appears when a parameter value has been changed.

Solution
Turn off the key switch and turn it on again.

EM BRAKE LOCKED – EM BRAKE WARNING

LED code 63
Traction Pump Extension EM Brake
Controller Action
Shut down Work Work Shut down
88 When the brake pedal is pushed more than 90% while driving motor
Cause speed exceeds 3,000 rpm, check the rpm for 1.7 seconds and then, force
EM brake when it does not fall below 2,700rpm.

Solution 1. Turn the key switch off and again on.

Handling faults on Instrument/EasyView 9-118 B20T-7 PLUS, B20X-7 PLUS

 CAP NOT CHARGED – Capacitor not charged
LED code 14
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Work
once
The capacitor in one of the controllers has been discharged or charged�
Cause abnormally.
A
1. Turn the key switch off and again on.
2. Check that the line contactor is normally wired.
Solution 3. If the problem persists, identify which motor controller’s LEDs have
lit up.
4. Replace the faulty motor controller.
DISPLAY CAN FAULT – Display CAN Communication failed
LED code 59
Traction Pump Extension EM Brake
Controller Action
Work Work Work Work
Cause The instrument panel’s CAN Communication is failed.

1. Check if the instrument panel is correctly connected with the main

harness.
9
A7 2. Check if the resistance between pins 2 and 7 on the CAN port

Electrical System (F-series)

connector measures approx. 60Ω when the harness is connected to
the port and the key switch is off.
Solution
3. If the measurement falls short of 60Ω, check if the resistance
between pins 5 and 6 on the instrument panel’s P2 connector
measures approx.120Ω.
4. If the measurement falls short of 120 Ω, replace the instrument
panel.
FR UNIT OPEN – F/R unit is not connected
LED code T-6B
Traction Pump Extension EM Brake
Controller Action
Stop by EAB No action No action Stop by EAB
AF Cause Both forward and reverse are ON.

1. Check the harnesses to F/R unit.

Solution
2. Replace F/R unit.
AUTO TILT RELAY – Relay for P1-4 Driver3 Auto-tilt not working, due to no
fingertip
LED code P-A3
Traction Pump Extension EM Brake
Controller Action
No action no auto tilt No action No action

AL 1. The auto-tilt (P1-4) solenoid is disconnected or shorted (short

Cause
circuit).

1. Check reverse bsuzzer solenoid, wiring and connections.

Solution 2. Replace the relay.
3. Replace the pump motor controller.

B20T-7 PLUS, B20X-7 PLUS 9-119 Handling faults on Instrument/EasyView

 DSUPERVISION FLT – Checking the input/output of the right drive controller and
the redundancy status of the MCU.
LED code 77/79
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once

1. The Supervisor has detected a mismatch in redundant readings.

b1 2. Internal damage to Supervisor microprocessor.

Cause
3. Switch inputs allowed to be within upper and lower thresholds for
over 100 milliseconds.
(for recurring errors, check the switches for moisture)

1. Disconnect the controller connector then clean / dry the connnector

Solution or replace if defective.
2. Replace the drive controller.
LSUPERVISION FLT – Checking the input/output of the left drive controller and the
redundancy status of the MCU.
LED code 77/79
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down No action Work
once

1. The Supervisor has detected a mismatch in redundant readings.

b2 2. Internal damage to Supervisor microprocessor.

Cause
3. Switch inputs allowed to be within upper and lower thresholds for
over 100 milliseconds. (for recurring errors, check the switches for
moisture)

1. Disconnect the controller connector then clean / dry the connnector

Solution or replace if defective.
2. Replace the drive controller.
PSUPERVISION FLT – Checking the input/output of Pump controller and the
redundancy status of the MCU.
LED code 77/79
Traction Pump Extension EM Brake
Controller Action Shut down at
No action Shut down Work
once

1. The Supervisor has detected a mismatch in redundant readings.

b3 2. Internal damage to Supervisor microprocessor.

Cause
3. Switch inputs allowed to be within upper and lower thresholds for
over 100 milliseconds. (for recurring errors, check the switches for
moisture)

1. Disconnect the controller connector then clean / dry the connnector

Solution or replace if defective.
2. Replace the drive controller.

Handling faults on Instrument/EasyView 9-120 B20T-7 PLUS, B20X-7 PLUS

 DUNINTEND MOVING – Right Motor unintended moving (Speed Limit Supervision,
Motor Not Stopped, Motor Braking Impaired, Hazardous Movement, Interlock
braking supervision)
LED code 19/1A/84/D6
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop Work Work
once

1. Motor rpm has exceeded the Max Speed Limit setting for the Max
Speed Time Limit setting’s duration.
2. The purpose of this function is to detect hazardous movement when
the AC motor is stopped and expected to stay stopped.
3. Current cutback lowering than the setting for Over voltage and over
b4 temperature during Regen Condition.
Cause
4. This fault detects hazardous movement when the motor is
requested to be moving.
----The first hazard is a motor that is not able to slow down if the�
throttle goes to zero or the direction switch is not in the direction of
travel.
----The second hazard is a motor that accelerates the wrong way�
or goes too fast. 9
1. Checking the EM brake mechanical force.

Electrical System (F-series)

Solution 2. Checking if working condition can meet the truck's spec.
3. Battery or cable resistor is too high.
LUNINTEND MOVING – Left Motor unintended moving (Speed Limit Supervision,
Motor Not Stopped, Motor Braking Impaired, Hazardous Movement, Interlock
braking supervision)
LED code 19/1A/84/D6
Traction Pump Extension EM Brake
Controller Action Shut down at
Stop Work Work
once

1. Motor rpm has exceeded the Max Speed Limit setting for the Max
Speed Time Limit setting’s duration.
2. The purpose of this function is to detect hazardous movement when
the AC motor is stopped and expected to stay stopped.
3. Current cutback lowering than the setting for Over voltage and over
b5 temperature during Regen Condition.
Cause
4. This fault detects hazardous movement when the motor is
requested to be moving.
----The first hazard is a motor that is not able to slow down if the
throttle goes to zero or the direction switch is not in the direction of
travel.
----The second hazard is a motor that accelerates the wrong way�
or goes too fast.

1. Checking the EM brake mechanical force.

Solution 2. Checking if working condition can meet the truck's spec.
3. Battery or cable resistor is too high.

B20T-7 PLUS, B20X-7 PLUS 9-121 Handling faults on Instrument/EasyView

 PUNINTEND MOVING – Pump Motor unintended moving (Speed Limit
Supervision, Motor Not Stopped, Motor Braking Impaired, Hazardous Movement,
Interlock braking supervision)
LED code 19/1A/84/D6
Traction Pump Extension EM Brake
Controller Action
Work Stop Work Work

1. Motor rpm has exceeded the Max Speed Limit setting for the Max
Speed Time Limit setting’s duration.
2. The purpose of this function is to detect hazardous movement when
the AC motor is stopped and expected to stay stopped.
3. Current cutback lowering than the setting for Over voltage and over
b6 temperature during Regen Condition.
Cause
4. This fault detects hazardous movement when the motor is
requested to be moving.
----The first hazard is a motor that is not able to slow down if the
throttle goes to zero or the direction switch is not in the direction of
travel.
----The second hazard is a motor that accelerates the wrong way�
or goes too fast.

1. Checking the EM brake mechanical force.

Solution 2. Checking if working condition can meet the truck's spec.
3. Battery or cable resistor is too high.
BACKBUZZER RELAY – Back buzzer relay fault if it is standard
LED code P-A4
Traction Pump Extension EM Brake
Controller Action
No action No action No action No action

bL Cause 1. Back buzzer relay (P1-3) solenoid is open or shorted.

1. Check reverse buzzer solenoid, wiring and connections.

Solution 2. Replace the relay.
3. Replace the pump motor controller.
EXT CUR FAULT – Extension module’s current faulty (extension module disabled)
LED code N/A
Traction Pump Extension EM Brake
Controller Action
Shut down
C1 Cause Total current exceeded 18 A.

1. Replace the fingertip harness.

Solution 2. Replace the fingertip extension module.
3. Replace the main harness.

Handling faults on Instrument/EasyView 9-122 B20T-7 PLUS, B20X-7 PLUS

 EXT POWER FAULT – Extension module controller’s power supply faulty (none)
LED code 13/14/15
Traction Pump Extension EM Brake
Controller Action
Shut down
Fingertip extension module failed to be correctly powered from the
Cause
battery

1. Check if the fingertip fuse in fuse box A has been blown.

C2
2. Check if the fingertip extension module is powered at the rated
battery voltage (36V/48V) by measuring the voltage between pins 5
Solution and 6 on the F_CONN. A connector.
3. If the measurement falls short of the rated voltage, replace the
fingertip harness.
4. If the problem persists, replace the fingertip extension module.
R-CONT CAN FAULT – Right CAN Communication failed
LED code 65/72
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Work
once
Cause The right drive motor controller’s CAN Communication is failed.

1. Check if the resistance between pins 2 and 7 on the CAN port

9
connector measures approx. 60 Ω when the harness is connected to

Electrical System (F-series)

the port and the key switch is off.
C7
2. If the measurement falls short of 60 Ω, check if pin 23 on the left
drive motor controller and pin 23 on the right drive motor controller
Solution are correctly connected to one another.
3. If their connection is normal, check if pin 35 on the left drive motor
controller and pin 35 on the right drive motor controller are correctly
connected to one another.
4. Reinstall the software.
5. Right the right drive motor controller.

R COIL POWER – R controller Coil supply (pin 13) fault

LED code TR-A9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Shut down
once

When doing KSI, the controller will check the coil power supply whether
can switch on or off. Fault may be caused by :

dC Cause 1. Coil is shorted to KSI.

2. Coil is shorted to GND.
3. The power supply circuit to the coil is damaged.

1. Check the solenoid connected to pin13 to see whether shorted to

KSI or GND.
Solution
2. Check whether B+ or B- voltage is leaked to pin13.
3. Replace the controller.

B20T-7 PLUS, B20X-7 PLUS 9-123 Handling faults on Instrument/EasyView

 R-CONT VOLTCUT – R controller high or low voltage cut back
LED code TL-23,24
Traction Pump Extension EM Brake
reduce driving
Controller Action
dU and Regen No action No action No action
current

Cause Battery voltage higher or lower than cutback point

Solution 1. Check the battery and cable.

R-INV OVERTEMP – Right drive motor controller overheated (performance

lowered)
LED code 22
Traction Pump Extension EM Brake
Controller Action
Limited to 2000 No action Work No action
The resistance of the thermal sensor inside the right drive motor
Cause controller represents an over-temperature of the controller above the
specified limit of 85°C (185°F).

E1 1. Check the temperature of the right drive motor controller in

diagnostic mode on the instrument panel or EasyView.
2. If the temperature is detected to be higher than 85°C (185°F), cool
down the vehicle for 15 minutes.
Solution
3. If the right drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
4. Check if the EM parking brake is engaged.
5. If the problem persists, replace the right drive motor controller.

L-INV OVERTEMP– Left drive motor controller overheated (performance lowered)

LED code 22
Traction Pump Extension EM Brake
Controller Action
Limited to 2000 No action Work No action
The resistance of the thermal sensor inside the left drive motor
controller�
Cause represents an over-temperature of the controller above the specified limit
of 85°C (185°F).

E2 1. Check the temperature of the left drive motor controller in diagnostic

mode on the instrument panel or EasyView.
2. If the temperature is detected to be more than 85°C (185°F), cool
down the vehicle for 15 minutes.
Solution
3. If the left drive motor controller is hotter than the other controllers,
check its U, V, W connections to the battery.
4. Check if the EM parking brake is engaged.
5. If the problem persists, replace the left drive motor controller.

Handling faults on Instrument/EasyView 9-124 B20T-7 PLUS, B20X-7 PLUS

 P-INV OVERTEMP – Pump motor controller overheated (performance lowered)
LED code 22
Traction Pump Extension EM Brake
Controller Action Limit current
No action Work No action
from 85C-95C
The resistance of the thermal sensor inside the pump motor controller
Cause represents an over-temperature of the controller above the specified limit
of 85°C (185°F).

E3 1. Check the temperature of the right drive motor controller in

diagnostic
mode on the instrument panel or EasyView.
2. If the temperature is detected to be more than 85°C (185°F), cool
Solution down the vehicle for 15 minutes.
3. If the Pump motor controller is hotter than the other controllers,
check its U.V.W. connections To the battery.
4. If the problems remains present, replace the pump motor controller.

R-MOTOR OVERTEMP – Right drive motor overheated (performance lowered)

LED code 28
Traction Pump Extension EM Brake
9
Controller Action Reduce driving
No action Work No action
current

Electrical System (F-series)

The controller has detected that the resistance of the thermal sensor
Cause inside the right drive motor represents an over-temperature of the motor
above the specified limit of 145°C (293°F).

1. Check the temperature of the right drive motor in diagnostic mode

on the instrument panel or EasyView.
2. If the temperature is detected to be more than 145°C (185°F), cool
down the vehicle for 15 minutes.
3. Check if the connector of the thermal sensor on the right drive motor
E4 is
normally connected.
4. Check if pin 1 on the thermal sensor of the right drive motor is
Solution normally
connected to pin 8 on the right drive motor controller.
5. Check if pin 2 on the thermal sensor of the right drive motor is
normally connected to pin 7 on the right drive motor controller.
6. Check if the resistance values of the thermal sensor on the right
drive motor measures 603 Ω at 25 °C (77 °F).
7. Replace the thermal sensor of the right drive motor.
8. If the problems remains present, replace the right drive motor
controller.

B20T-7 PLUS, B20X-7 PLUS 9-125 Handling faults on Instrument/EasyView

 L-MOTOR OVERTEMP – Left drive motor overheated (performance lowered)
LED code 28
Traction Pump Extension EM Brake
Controller Action Reduce driving
No action Work No action
current
The controller has detected that the resistance of the thermal sensor
Cause inside the left drive motor represents an over-temperature of the motor
above the specified limit of 145°C (293°F).

1. Check the temperature of the left drive motor in diagnostic mode on

the instrument panel or EasyView.
2. If the temperature is detected to be more than 145°C (185°F), cool
down the vehicle for 15 minutes.
E5
3. Check if the connector of the thermal sensor on the left drive motor
is normally connected.
4. Check if pin 1 on the thermal sensor of the left drive motor is
Solution normally connected to pin 8 on the left drive motor controller.
5. Check if pin 2 on the thermal sensor of the left drive motor is
normally connected to pin 7 on the left drive motor controller.
6. Check if the resistance values of the thermal sensor on the left drive
motor measures 603 Ω at 25 °C (77 °F).
7. Replace the thermal sensor of the left drive motor.
8. If the problem persists, replace the left drive motor controller.

P- MOTOR OVERTEMP – Pump motor overheated (performance lowered)

LED code 28
Traction Pump Extension EM Brake
Controller Action Reduce pump
Work No action
current
The controller has detected that the resistance of the thermal sensor
Cause inside the pump motor represents an over-temperature of the motor
above the specified limit of 145°C (293°F).

1. Check the temperature of the pump motor in diagnostic mode on the

instrument panel or EasyView.
2. If the temperature is detected to be higher than 20°C (203°F), cool
down the vehicle for 15 minutes.
E6
3. Check if the connector of the thermal sensor on the pump motor is
normally connected.
4. Check if pin 1 on the thermal sensor of the pump motor is normally
Solution connected to pin 8 on the pump controller.
5. Check if pin 2 on the thermal sensor of the pump motor is normally
connected to pin 7 on the pump controller.
6. Check if the resistance values of the thermal sensor on the pump
motor measures 603 Ω at 25 °C (77 °F).
7. Replace the thermal sensor of the pump motor.
8. If the problems remains present, replace the pump motor controller.

Handling faults on Instrument/EasyView 9-126 B20T-7 PLUS, B20X-7 PLUS

 SEAT SQN FAULT – Seat & Seat belt sequence fault (Key on -> Seat on -> Seat belt
on)
LED code 5C
Traction Pump Extension EM Brake
E8 Controller Action
Stop Stop Stop Stop by EAB

Cause Seat belt switch is not connected before seat switch.

Solution Check the seat switch and seat belt switch whether working properly.

SEAT SW OPEN – Seat belt switch open

LED code N/A
Traction Pump Extension EM Brake
E8 Controller Action
Stop Stop Stop Stop by EAB
(Flashing)
Cause Seat belt switch is not connected.

Solution Check the seat belt switch.

WRONG START – Signal to move pump motor detected at startup

LED code 47/52/53/5D/5E

Controller Action
Traction
Shut throttle
Pump
Shut down
Extension
Work
EM Brake
No action
9
Accelerator pedal switch or forward/reverse direction signal is detected to
Cause

Electrical System (F-series)

be active when the vehicle is first switched on.

1. Put the F/R switch in neutral.

EE 2. Check if the accelerator pedal returns normally when released.

3. Calibrate the initial settings for the accelerator using EasyView or
the instrument panel.
Solution
4. Check if pins 2 and 3 on the F/R unit’s 4-pin connector are
connected to one another in neutral. If so, replace the F/R unit. If so,
replace the F/R unit. Check if pins 1 and 2 on the F/R unit’s 4-pin
connector are connected to one another in neutral. If so, replace
the F/R unit.

SEAT SW OPEN – Seat switch opened

LED code
Traction Pump Extension EM Brake
Controller Action
Stop Stop Stop Stop by EAB
Cause The seat switch is open.

1. Sit down on the driver's seat.

EE 2. If fault code EE stays blinking even when the operator is seated,
(FLASHING) check if the connector of the seat switch is normally connected.
3. If the seat belt interlock option is applied, fasten the seat belt after
Solution you are seated.
4. If the actions above do not solve the problem, disconnect the seat
switch connector and measure the resistance between pins 1 and 2
on the connector using a multimeter. If it measures an open circuit, it
means the seat switch is damaged. Replace the seat switch.

B20T-7 PLUS, B20X-7 PLUS 9-127 Handling faults on Instrument/EasyView

 EXTENSION FAULT – Extension module internally faulty
LED code 66
Traction Pump Extension EM Brake
Controller Action
Work Work Stop Work
The fingertip extension module has a firmware error, or is overheated or�
Cause overcooled.
EF
1. Turn the key switch off and again on.
2. Leave the vehicle in a place warmer than 0 °C (32 °F) for 15
Solution
minutes.
3. If the problem persists, replace the fingertip extension model.

LOW BATT VOLT –Battery voltage insufficient (charge needed)

LED code 56
Traction Pump Extension EM Brake
EL Controller Action
limit to 2000 limit to 800 Work No action
The fingertip extension module has a firmware error, or is overheated or
Cause overcooled.
Solution Charge the battery.
MOTOR TEMP FAU – Large temperature difference between right and left drive
motors
LED code T-67
Traction Pump Extension EM Brake
Controller Action
Stop by EAB Work Work Stop by EAB
EP
1. The temperature difference between the left and right drive motors is
Cause
more than 30 degrees.

1. The temperature difference between the left and right drive motors is
Solution
less than 20 degrees.

EEPROM FAULT – Controller memory failed

LED code 46
Traction Pump Extension EM Brake
Shut down at
Controller Action
Shut down Stop Work once if fault on
traction
F Cause The EEPROM memory on a motor controller has failed.

1. Reinstall the latest software version.

2. If the problem persists, identify which motor controller’s LEDs have
Solution
lit up.
3. Replace the faulty motor controller.

Handling faults on Instrument/EasyView 9-128 B20T-7 PLUS, B20X-7 PLUS

 MAX BATT VOLT– Battery voltage excessive
LED code 18
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The battery voltage between terminal B+ and B- on a motor controller has
F0 Cause reached a severe over voltage limit (70 V).

1. Measure the voltage between terminals B+ and B- on each

controller using a multimeter to check if the measurement exceeds
Solution 70 V.
2. If a controller's voltage measures over 70 V, replace it.

MIN BATT VOLT – Battery voltage insufficient

LED code 17
Traction Pump Extension EM Brake
Controller Action
No Drving Stop Work Stop by EAB
The battery voltage between terminal B+ on a motor controller has
Cause
F1 reached a severe under voltage limit (20 V).

Solution
1. Measure the voltage between the terminals B+ and B- on each
controller using a multimeter to check if the measurement falls short
of 20 V.
9

Electrical System (F-series)

2. If a controller's voltage measures below 20 V, replace it.

ACCEL FAULT – Pedal trimmer fault

LED code 55
Traction Pump Extension EM Brake
Controller Action
Stop by EAB No action Work Stop by EAB
The battery voltage between terminal B+ on a motor controller has
Cause
F2 reached a severe under voltage limit (20 V).

1. Measure the voltage between the terminals B+ and B- on each

controller using a multimeter to check if the measurement falls short
Solution of 20 V.
2. If a controller's voltage measures below 20 V, replace it.

R-INVERTER FAULT – Right drive motor controller failed

LED code 13/12/83/DD/D2/54
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
Cause An over current is detected on the right drive inverter.

1. Turn the key switch off and turn it on again.

F3 2. Check if the U, V, W terminals on the right drive motor are normally
connected.
3. Check if the U, V, W terminals on the right drive motor controller are
Solution
normally connected.
4. Check if the respective voltages of the U, V, W terminals measure all
between 0.3–0.7 V using a multimeter.
5. Right the right drive motor controller.

B20T-7 PLUS, B20X-7 PLUS 9-129 Handling faults on Instrument/EasyView

 L-INVERTER FAULT – Left drive motor controller failed
LED code 13/12/83/DD/D2/6A
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
Cause An over current is detected on the left drive inverter.

1. Turn the key switch off and turn it on again.

F4 2. Check if the U, V, W terminals on the left drive motor are normally
connected.
3. Check if the U, V, W terminals on the left drive motor controller are
Solution
normally connected.
4. Check if the respective voltages of the U, V, W terminals measure all
between 0.3–0.7 V using a multimeter.
5. Replace the left drive motor controller.

P-INVERTER FAULT – Pump motor controller failed

LED code 13/12/83/DD/D2/5D
Traction Pump Extension EM Brake
Controller Action
Shut down Stop Work Stop by EAB
Cause An over current is detected on the pump inverter.

1. Turn the key switch off and turn it on again.

F5 2. Check if the U.V.W. terminals on the pump motor are normally.
3. Check if the U.V.W. terminals on the pump motor controller are
Solution normally.
4. Check if the respective voltages of the U, V, W terminals measure all
between 0.3–0.7 V using a multimeter.
5. Replace the pump motor controller.

R-MOTOR OFFSET – Right drive motor current failed

LED code 89/99/C9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
F6 Cause The current sensor offset reading from the right drive motor is invalid.

1. Check for current leakage to the vehicle frame from the right drive
motor phase U, V or W.
Solution
2. If problems persist, the drive motor controller is defective and needs
to be replaced.

L-MOTOR OFFSET – Left drive motor current failed

LED code 89/99/C9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
F7 Cause The current sensor offset reading from the left drive motor is invalid.

1. Check for current leakage to the vehicle frame from the left drive
motor phase U, V or W.
Solution
2. If problems persist, the drive motor controller is defective and needs
to be replaced.

Handling faults on Instrument/EasyView 9-130 B20T-7 PLUS, B20X-7 PLUS

 P-MOTOR OFFSET - Pump motor current failed
LED code 89/99/C9
Traction Pump Extension EM Brake
Controller Action
Stop by EAB Stop Work No action
Cause The current sensor offset reading from the pump motor is invalid.
F8
1. Check for current leakage to the vehicle frame from the pump motor
phase U, V or W.
Solution
2. If problems persist, the pump motor controller is defective and needs
to be replaced.

STEER SENSOR OUT – Steer sensor output failed

LED code 55/B9
Traction Pump Extension EM Brake
Controller Action
Limited to 800 No action Work No action
Analog 1 inputs are over the steering angle sensor’s higher threshold or�
Cause below its lower threshold.

1. Check if pin 1 on the steering sensor connector is normally

connected to pin 25 on the left drive motor controller.
F9 2. Check if pin 2 on the steering sensor connector is normally
connected to pin 24 on the left drive motor controller.
9
3. Check if pin 3 on the steering sensor connector is normally

Electrical System (F-series)

Solution
connected to pin 7 on the left drive motor controller.
4. Check if the steering sensor is detected to output a normal signal on
EasyView.
5. If the measurement is not normal, replace the steering sensor;
Otherwise, replace the left drive motor controller.
12V NOT OK – 12V output from a controller failed
LED code 69
Traction Pump Extension EM Brake
Controller Action
No action No action Work No action
An over current (over 200 mA) is detected in the drive or pump motor�
Cause
controller’s 12V supply circuit.

1. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the
FA left drive controller measures 12 V.
2. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the
Solution right drive controller measures 12 V.
3. Check if the voltage between pin 25 (12 V) and pin 7 (GND) on the
pump controller measures 12 V.
4. Replace any controller whose 12V output is not normal.

B20T-7 PLUS, B20X-7 PLUS 9-131 Handling faults on Instrument/EasyView

 R-MOTOR ENCODER – Right drive motor’s encoder failed
LED code 36/73/88/93
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The phase A or B signal of the right drive motor encoder is abnormal or
Cause not detected, or indicates an abnormally fast speed.

1. Check if the U, V, W terminals on the right drive motor are normally

connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the
right drive motor measures 5 V.

FC 3. Check if pin 3 on the right drive motor encoder is normally

connected to pin 31 (phase A) on the right drive motor controller.
4. Check if pin 4 on the right drive motor encoder is normally
Solution connected to pin 32 (phase B) on the right drive motor controller.
5. Check if the phrases A and B on the right drive motor encoder
normally turn on and off on EasyView.
- Test Menu  Drive  “Right Motor Encoder A” & “Right Motor
Encoder B”
If either phrase is abnormal, replace the right drive motor encoder.
6. If the problems remains present, replace the right drive motor
controller.
L-MOTOR ENCODER – Left drive motor’s encoder failed
LED code 36/73/88/93
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The phase A or B signal of the left drive motor encoder is abnormal or not
Cause detected, or indicates an abnormally fast speed.

1. Check if the U, V, W terminals on the left drive motor are normally

connected.
2. Check if the voltage between pin 26 (5 V) and pin 7 (GND) on the
left
drive motor measures 5 V.
Fd 3. Check if pin 3 on the left drive motor encoder is normally connected
to pin 31 (phase A) on the left drive motor controller.
4. Check if pin 4 on the left drive motor encoder is normally connected
Solution to pin 32 (phase B) on the left drive motor controller.
5. Check if phases A and B on the left drive motor encoder normally
turn on and off using EasyView.
- Test Menu  Drive  “Left Motor Encoder A” & “Left Motor
Encoder B”
If either phrase is abnormal, replace the left drive motor encoder.
6. If the problems remains present, replace the left drive motor
controller.

Handling faults on Instrument/EasyView 9-132 B20T-7 PLUS, B20X-7 PLUS

 FINGERTIP FAULT – Fingertip faulty (pump stopped)
LED code 53/55/56/57
Traction Pump Extension EM Brake
Controller Action Stop the faulty Stop the faulty
No action No action
FF operation rpm operation valve
Cause A fingertip knob is out of range.

1. Check the output of each fingertip knob (Knob Command) in test menu
Solution
on EasyView. If any of the knobs is found abnormal, replace it.

5V NOT OK – 5V output from a controller failed

LED code 25
Traction Pump Extension EM Brake
Controller Action Stop 작용 없음 작용 없음 작용 없음
An over current (over 200 mA) is detected in the drive or pump motor�
Cause controller’s 5V supply circuit.

1. Check if the voltage between pin 26 (5V) and pin 7 (GND) on the left
drive controller measures 5 V.
FH
2. Check if the voltage between pin 26 (5V) and pin 7 (GND) on the

Solution
right
drive controller measures 5 V. 9
3. Check if the voltage between pin 26 (5V) and pin 7 (GND) on the
pump

Electrical System (F-series)

controller measures 5 V.
4. Replace any controller whose 5V output is not normal.

PUMP SIGN ON – Signal to move pump motor detected at startup

LED code 47,(P-51,54.6A)
Traction Pump Extension EM Brake
Controller Action STOP, ISO3691
No action Work No action
Shut down
Cause A lever command (lift, lower, tilt, sideshift) is detected at startup.

FL 1. Position all the hydraulic control levers in neutral.

2. Calibrate the initial settings for the lift sensor using EasyView or the
instrument panel.
Solution
3. If the problem persists, make an adjustment of the clearance for the
lift sensor.
4. If the problem persists, replace the valve board.

R-INV UNDERTEMP - Right drive motor controller overcooled (-40°C, -40°F)

LED code 15
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
once
The right drive motor controller is below the lower temperature shutdown
H1 Cause limit (-40°C, -40°F).

1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour
and then check if it is operational.
Solution
2. If the problems remains present, replace the right drive motor
controller.

B20T-7 PLUS, B20X-7 PLUS 9-133 Handling faults on Instrument/EasyView

 L INV UNDERTEMP - Left drive motor controller overcooled (-40°C, -40°F)
LED code 15
Traction Pump Extension EM Brake
Contr oller Action Shut down at
Shut down Stop Work
once
The left drive motor controller is below the lower temperature limit (-40°C,
H2 Cause - 40°F).

1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour
and then check if it is operational.
Solution
2. If the problems remains present, replace the left drive motor
controller.

P INV UNDERTEMP - Pump controller overcooled (-40°C, -40°F)

LED code 15
Traction Pump Extension EM Brake
Controller Action
Stop Shut down Work No action
The pump motor controller is below the lower temperature limit (-40°C, -
H3 Cause 40°F).

1. Leave the vehicle in a place warmer than 0°C (32°F) for one hour
Solution and then check if it is operative.
2. If the problems remains present, replace the pump motor controller.

R-MOTOR OPEN – Right drive motor circuit open

LED code 37
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
H4 once
Cause The U, V or W phase of the right drive motor is detected to be open.

1. Check for the U, V, W connections of the right drive motor.

Solution
2. Replace the right drive motor.

L-MOTOR OPEN– Left drive motor’s circuit open

LED code 37
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Stop Work
H5 once
Cause The U, V or W phase of the left drive motor is detected to be open.

1. Check for the U, V, W connections of to the battery.

Solution
2. Replace the left drive motor.

P-MOTOR OPEN – Pump motor’s circuit open

LED code 37
Traction Pump Extension EM Brake
Controller Action
No action Shut down Work No action
H6 The U, V or W phase of the pump motor is detected to be open.
Cause
1. Check for the U, V, W connections of to the battery.
Solution
2. Replace the pump motor.

Handling faults on Instrument/EasyView 9-134 B20T-7 PLUS, B20X-7 PLUS

 PEDAL SW FAULT - Brake pedal sensor signal fault
LED code B1/51
Traction Pump Extension EM Brake
Controller Action
Stop by EAB Work Work Work

1. One of brake sensor’s signal voltages is over the range. (Phase A &
B : 5V +/- 0.25V)

Cause 2. The sum of Phase A’s voltage and Phase B’s voltage is beyond
5.3V.
3. The harness wires to brake sensor are shorted or open.

1. Check if brake sensor connector is properly connected to the main

harness.
2. Check out if the harness wires to brake sensor are free from open
and short.
3. Since both left traction controller and pump controller normally
H9 output 5 V voltage to brake sensor, check if brake sensor’s two
signals displayed on EasyView are to approx. 5 V.

- Test Menu → Drive → “Brake Pedal Voltage A” / “Brake

Pedal Voltage B”
9
If brake sensor fails to output the total of 5 V voltage, replace the

Electrical System (F-series)

Solution
brake sensor.
4. If they normally amount to approx. 5 V, check the connection of the
brake sensor to the controllers:
- Pin 3 on the brake sensor to pin 51 on the right drive motor controller.
- Pin 5 on the brake sensor to pin 55 on the right drive motor controller.
- Pin 1 on the brake sensor to pin 146 on the right drive motor
controller.
- Pin 2 on the brake sensor to pin 60 on the pump motor controller.
- Pin 4 on the brake sensor to pin 64 on the pump motor controller.
- Pin 6 on the brake sensor to pin 91 on the pump motor controller.
If any part of the connection above is found open or short, replace the
main harness.
LIFT SOL FAULT – Lift solenoid valve faulty (pump stopped)
LED code 61
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s lift solenoid (J1-12) is
Cause open/short.

L1 1. Check if pin 8 on the main control valve connector A is normally

connected to pin 12 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 8
and 4 on the main control valve connector A to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

B20T-7 PLUS, B20X-7 PLUS 9-135 Handling faults on Instrument/EasyView

 LOW SOL FAULT – Lowering solenoid valve faulty (pump stopped)
LED code 62
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s lowering solenoid (J1-13) is
Cause open/short.

L2 1. Check if pin 8 on the main control valve connector B is normally

connected to pin 13 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 8
and 4 on the main control valve connector B to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

TILT FWD SOLFAU – Tilt-forward solenoid valve faulty (pump stopped)

LED code 64
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s tilt-forward solenoid (J1-9) is
Cause open/short.

L3 1. Check if pin 7 on the main control valve connector B is normally

connected to pin 9 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 7
and 3 on the main control valve connector B to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

TILT BACK SOLFAU – Tilt-backward solenoid valve faulty (pump stopped)

LED code 59
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s tilt-backward solenoid (J1-11) is
Cause open/short.

L4 1. Check if pin 7 on the main control valve connector A is normally

connected to pin 11 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 7
and 3 on the main control valve connector A to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

Handling faults on Instrument/EasyView 9-136 B20T-7 PLUS, B20X-7 PLUS

 AUX1 L-SOLFAU – AUX1- left solenoid valve faulty (pump stopped)
LED code 63(AUX1 FWD)
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s AUX1-left solenoid (J1-14) is�
Cause open/short.

L5 1. Check if pin 6 on the main control valve connector B is normally

connected to pin 14 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 2
and 6 on the main control valve connector B to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

AUX1 R- SOLFAU – AUX1-right solenoid valve faulty (pump stopped)

LED code 65(AUX1 BACK)
Traction Pump Extension EM Brake
Controller Action
No action
Stop this
operation
Stop this
operation
No action 9
The circuit for the fingertip control valve’s AUX1-right solenoid (J1-10) is�
Cause open/short.

Electrical System (F-series)

L6 1. Check if pin 6 on the main control valve connector A is normally
connected to pin 10 on the fingertip extension module connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 2
and 6 on the main control A to check if it measures approx. 30Ω at
20°C (68°F).
4. If it is not measured so, replace the coil.

AUX2 L-SOLFAU – AUX2-left solenoid valve faulty (shut down PD)

LED code TR-A1
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s AUX2- left solenoid (P1-2) is
Cause open/short.
L7
1. Check if pin 5 on the main control valve connector B is normally
connected to pin 2 on the pump motor controller.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1 and
5 on the main control valve connector B to check if it measures approx.
30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

B20T-7 PLUS, B20X-7 PLUS 9-137 Handling faults on Instrument/EasyView

 AUX2 R- SOLFAU- AUX2-right solenoid valve faulty (shut down PD)
LED code TR-A1
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
The circuit for the fingertip control valve’s AUX2-right solenoid (D2-2) is�
Cause open/short.

L8 1. Check if pin 5 on the main control valve connector A is normally

connected to pin 2 on the right drive controller connector.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1
and 5 on the main control valve connector A to check if it measures
approx. 30Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

ISO/UNLOAD SOL – ISO/UNLOAD solenoid valve faulty (shut down driver)

LED code P-A2, T-A4
Traction Pump Extension EM Brake
Controller Action Stop this Stop this
No action No action
operation operation
Cause ISO (STD), unloading SOL (fingertip OPT) (P1-5) open/short

1. Check if pin 1 on the main control valve connector C is normally

L9
connected to pin 5 on the pump motor controller.
2. If it is not connected, replace the harness.
Solution 3. If it is normally connected, measure the resistance between pins 1
and 2 on the main control valve connector C to check if it measures
approx. 28.5Ω at 20°C (68°F).
4. If it is not measured so, replace the coil.

LED code
Traction Pump Extension EM Brake
LB Controller Action
Cause
Solution

Handling faults on Instrument/EasyView 9-138 B20T-7 PLUS, B20X-7 PLUS

 L COIL POWER – L controller coil supply (PIN13) faulty
LED code TL-A9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Shut down
once
When doing KSI, the controller will check the coil power supply
whether can switch on or off. Fault may be caused by :
1. Coil is shorted to KSI.
LC Cause
2. Coil is shorted to GND.
3. The power supply circuit to the coil is damaged.

1. Check the solenoid connected to PIN13 to see whether shorted to

KSI or GND.
Solution
2. Check whether B+ or B- voltage is leaked to PIN13.
3. Replace the controller.

F-KNOB CAN FAULT – Fingertip CAN module CAN Communication faulty

LED code TL-66, PU-52
Controller Action
Traction
Shut down
Pump
Shut down
Extension
Shut down
EM Brake
Stop by EAB 9
1. Abnormality is found in the CAN communication signals transmitted
Cause

Electrical System (F-series)

to and received from the fingertip CAN board.

1. Turn the key switch off and on again and, check if the fault code
LL disappears.
2. Update the firmware with the latest version (flashing). Upon
installation, turn the key switch off and on again and, check if the
fault code disappears.
Solution
3. Check connections of CAN H and CAN L. Measure the resistance
between pins 23 and 35 of each controller.
4. Repair or replace the harness.
5. Replace the drive controller.

L-CONT VOLTCUTL – L controller high or low voltage cut back

LED code TL-23,24
Traction Pump Extension EM Brake
Reduce driving
Controller Action
and Regen No action No action No action
LU
current

Cause Battery voltage is higher or lower than cutback point.

Solution 1. Check the battery and cable.

B20T-7 PLUS, B20X-7 PLUS 9-139 Handling faults on Instrument/EasyView

 WEIGHT SENSOR – weight sensor connected to TR D-17 is out of range (out of
0.5-5V)
LED code TR-BD
Traction Pump Extension EM Brake
P5 Controller Action
No action No action No action No action

Cause Weight sensor is out of range.

Solution 1. Check the weight sensor and harness.

P-CONT CAN FAULT – Pump CAN Communication failed
LED code TL-51,TR-53
Traction Pump Extension EM Brake
Controller Action
Shut down Shut down Work Work

Cause 1. The pump motor controller’s CAN communications is failed.

1. After connecting the main harness to the CAN port and turning off
the key switch, check if the measured resistance between pin 2 and
pin 7 of the CAN port connector is about 60Ω.
2. If the measured value is not 60, check if the connection between pin
P7 23 of the pump motor controller and pin 23 of the left drive motor
controller is normal.

Solution 3. If the connection between the two pins is normal, check if the
connection between pin 35 of the pump motor controller and pin 35
of the left drive motor controller is normal.
4. Check that the voltage between pins 21 and 34 of the pump motor
controller connector measures approximately 120Ω.
5. Reinstall the firmware.
6. Replace pump motor controller.
P COIL POWER – Pump controller coil supply (PIN13) faulty
LED code PU-A9
Traction Pump Extension EM Brake
Controller Action Shut down at
Shut down Shut down Shut down
once
When doing KSI, the controller will check the coil power supply whether
can switch on or off. Fault may be caused by :

Cause 1. Coil is shorted to KSI.

PC
2. Coil is shorted to GND.
3. The power supply circuit to the coil is damaged.

1. Check the solenoid connected to pin13 to see whether shorted to

KSI or GND.
Solution
2. Check whether B+ or B- voltage is leaked to pin13.
3. Replace the controller.

Handling faults on Instrument/EasyView 9-140 B20T-7 PLUS, B20X-7 PLUS

 P-CONT VOLTCUT – Pump controller high or low voltage cut back
LED code P-23,24
Traction Pump Extension EM Brake
Reduce driving
Controller Action
PU No action and Regen No action No action
current
Cause Battery voltage is higher or lower than cutback point.

Solution Check the battery and cable.

UNMATCH EXM PAR – Extension controller parameters and setting parameters are
unmatched
LED code 5F
Traction Pump Extension EM Brake
Controller Action
No action Stop Stop Stop

1. Pump controller will set the EXM parameters so the same EXM can
be used for different truck. When KSI on, the pump controller will
UE Cause read the parameters from EXM. If the reading parameters are not
the same with the Pump controller, will report the fault.
2.

1.
After KSI on, the EXM parameters are changed.

Cycle KSI.
9
Solution 2. Check the CAN messages between Pump and EXM.

Electrical System (F-series)

3. If problems persist, replace the extension model.
HEIGHT UNMATCH – Height sensor unmatched and Height sensor disconnected
LED code 5E
Traction Pump Extension EM Brake
Controller Action Speed limit to Speed limit to
Work No action
800 800
UH 1. When GSS function is enabled, the mast switch becomes NC
(Normal Close) and NO (Normal Open) between Pump controller
Cause
P14 and P15) can not meet the redundant checking. So, it should be
ON-OFF, or OFF-ON. But, seen OFF-OFF or ON-ON.

조치 1. Check the mast height switch sensor and harness.

B20T-7 PLUS, B20X-7 PLUS 9-141 Handling faults on Instrument/EasyView

10 Schematics

10-1 Hydraulic schematic

10-2 Hydraulic schematic (Fingertip-Kayaba)

10-3 Hydraulic schematic (Fingertip-Walvoil)

10-4 Electric schematic (Master Cylinder Brake)

10-5 Electric schematic (Electric Foot Brake)

10-6 Electric Schematic_Fingertip

10-7 Electric Schematic_STD (F-series)

10-8 Electric Schematic_Fingertip (F-series)

10-9 Harness_STD

10-10 Harness_Fingertip

10-11 Harness_STD (F-series)

10-12 Harness_Fingertip (F-series)

10-13 Harness_SLIO/SRIO

10-14 Harness_SLIO/SRIO (F-series)

10-15 Harness_NFC

10-16 Harness_NFC (F-series)

9
Schematics
 B15/18/20T, B18/20TL
S/A CYLINDER

SOLID SOFT 190104-00126 B16/18/20X TILT CYLINDER

CUSHION 190104-00128 P/S CYLINDER (A155010)
(190104-00093)
WIDE 190104-00130

LIFT CYLINDER
STANDARD D512374
PRIMARY D512413
FFT
SECONDARY D512394
PRIMARY D501865
FF
SECONDARY D512388

STEERING UNIT
(D512926)
PRIMARY
SECONDARY
or STANDARD

PROTECTOR
(D502539)
MAIN RELIEF V/V
PROTECTOR
(D501495)

FLOW REGULATOR
(D501493)

PRIORITY VALVE
RETURN FILTER (D518223)
(D516976) HYDRAULIC PUMP
(400910-00078)

SUCTION FILTER
(A155222)
● Hydraulic Schematic – Fingertip – Kayaba MODEL: B15/18/20T-7, B18/20TL-7, B16/18/20X-7

CONTROL VALVE
3 SECTION 410105-00973
4 SECTION 410105-00974

B15/18/20T, B18/20TL
TILT CYLINDER S/A CYLINDER
(A252110)
SOLID SOFT 190104-00126 B16/18/20X
CUSHION 190104-00128 P/S CYLINDER
(190104-00093)
LIFT CYLINDER WIDE 190104-00130

STANDARD D512374
PRIMARY D512413
FFT
SECONDARY D512394
PRIMARY D501865
FF
SECONDARY D512388

PRIMARY
SECONDARY
or STANDARD
STEERING UNIT
(D512926)

MAIN RELIEF V/V

PROTECTOR
(D502539)

PROTECTOR SWITCH AS-PRESSURE

(D501495) : “FINGERTIP” ONLY
FLOW REGULATOR (A154432)
(D501493)

FINGERTIP EXTENSION PUMP MOTOR

MODULE (300611-01010) CONTROLLER (300611-00991) HYDRAULIC PUMP
(400910-00078)

RETURN FILTER
(D516976)

D500067
950102-00571
●Electric Schematic (Master Cylinder Brake) MODEL: B15/18/20T-7, B18/20TL-7, B16/18/20X-7
12 FUSE BOX(A)
11
2/RD 10
D/D CONVERTER
98/RD/BU 9 20A HORN

2/RD 4 3 4/YL/RD 4/YL/RD 8

KEY SWITCH
59/RD/WH 7 10A
LEFT 43/OR/RD 6
EMERGENCY SW (OPT) TRACTION D1-3 86/YL 56/OR/BK 5 FAN/FINGERTIP(OPT)
KEY SWITCH 5A
89/RD/GN 4 SOL VALVE/POWER
D1-1 3/OR 5A
43/OR/RD 3

1
2/RD FUSE 84/RD/YL 2 BACK-UP
5A
500A 9/BU/YL 1
+12V F/R UNIT F/R SWITCH 5A
8 ENABLE 3 3/OR
-12V
+ BATTERY
1/BK 6
+5V BATT + 2 98/RD/BU
12
FUSE BOX(B)
12V OUT (BACK-UP) 1
85/RD/GN 5 12V + 5 43/OR/RD
9/BU/YL 6/BR D1-6 +12V 2 GND 11
LINE 84/RD/YL 4 3 BATT - 1 1/BK 131/BU/YL
vcc
Forward 10
BATT +
CTR D1-12 3/OR 3/OR 2 4 Revers
12V - 6 1/BK 129/BU/GN L LAMP
13/OR/RD D1-13 9 5A
FWD
FWD D1-22 20/YL/GN 20/YL/GN 3 8
REV DC/DC CONVERTER
REV D1-33 21/BR 21/BR 1 7 10A
GND BATT -
1/BK 7 131/BU/YL 6
7/WH D1-7 7/WH 1 GND
D1-26 26/RD/BK 26/RD/BK 3 +5V 82/BU/RD 5 OPT LAMP
D1-16 16/OR/BK 16/VO/BK 2 OUT A 5A
THM1 130/YL/GN 4 R LAMP/LICENCE
8/VO D1-8 60/WH/BU 4 GND
FLASHER UNIT (OPT) 5A
B1 64/RD 6 +5V
43/OR/RD
32/GY D1-32 3
58/BK 5 OUT B
A1 85 112/YL/WH 112/YL/WH 2 STROBE/FLASHER
31/GN D1-31 5A
ACCELERATOR 86 1/BK 113/GN/YL 1 REAR LAMP
+5V 5A

2
1
26/RD/BK 26/RD/BK 87 87/BK/RD
D1-26 D1-17 18/BU/RD 17/GN/YL 17/GN/YL 1 30
D1-7 7/WH 7/WH 2
86/YL 85
7/WH 89/RD/GN 86
2 SEAT SWITCH 96/GN/RD 87
1 30/RD D1-30 2 87/BK/RD RELAY-LIFT SOL VALVE
LEFT D1-24 101/GN 89/RD/GN 30
31/GN 87a
8/VO TRACTION MOTOR PILOT BUZZER D1-25 25/RD/WH 1 92/WH/GN
7/WH (WARNING) D1-28 28/BU/BK 3 94/YL/BU
+

32/GY 29/BU/GN 89/RD/GN 1

ENCODER

D1-29 POWER (OPT)

T/S SW (OPT) 1/BK 2
GND A

MR D1-2 71/RD/BK
D1-13 13/OR/RD 96/GN/RD 1 DIODE-COMP.
3/OR 1
3or4 wheel 1/BK
B

2
D1-10 3/OR 3/OR 2 open:4-Wheel,closed:3-wheel
98/RD/BU 4 1/BK B
LIFT SOL VALVE
THERMAL THERMAL D1-14 77/GN/WH 1/BK 3 96/GN/RD A
77/GN/WH 2
3/OR 1 98/RD/BU 2
7/WH SENSOR SENDER 1/BK 1 80/BK 87
PEDAL BRAKE SWITCH EMERGENCY C 71/RD/BK 85
FAN RELAY (OPT)
13/OR/RD 4 126/BU/WH 126/BU/WH 2
EM BRAKE-LEFT 13/OR/RD 86
D1-5 12/WH/RD 12/WH/RD 3 125/BU/RD 125/BU/RD 1
1/BK 30
75/YL/GN 2 128/BR/YL 128/BR/YL 2 EM BRAKE-RIGHT
76/BK 1 127/BU/YL 127/BU/YL 1
D1-23(CAN H) 23/YL/BK 89/RD/GN 1 HEAD LAMP (OPT)
EM CONN A EM CONN B 1/BK 2 CONTROLLER FAN
D1-35(CAN L) 35/YL 33/BK/WH 2
BRAKE OIL SW
34/BK/YL 1
56/OR/BK 1 FRONT COMB-R(OPT)
80/BK 2 DOOR FAN
RIGHT 7/WH 2

GND
TRACTION 38/BU/GN 1 SEAT BELT SW
56/OR/BK 1
51/WH D2-7 7/WH 3 80/BK 2 D/M FAN-R
101/GN 2
25/RD/WH 1 103/BR/YL 2 S/B LAMP 56/OR/BK 1
THM1 D2-1 3/OR 4 80/BK 2 D/M FAN-L
2 84/RD/YL
52/BU/BK D2-8 ANGLE SENSOR 34/BK/YL
B1 3 BRAKE OIL J2 1 93/GY
53/BU/GN D2-32 35/YL 6 CAN L 56/OR/BK 1
A1 23/YL/BK 5 CAN H 80/BK 2 P/M FAN
54/OR/RD D2-31 23/YL/BK
STOP LAMP SW (OPT)
D2-23(CAN H) 25/RD/WH 1 +12V
R-LAMP CONN
51/WH +5V D2-35(CAN L) 35/YL
33/BK/WH 1/BK
53/BU/GN 55/RD D2-26 D2-11 3/OR 1 BRAKE OIL
1/BK 6 -12V 130/YL/GN
52/BU/BK 55/RD RIGHT 4 94/YL/BU
TRACTION MOTOR D2-28 73/BU/RD 104/GN/WH 2 T/S LAMP
54/OR/RD
D2-29 74/BU/WH 82/BU/RD 3 HEAD LAMP
J1
T/S LAMP-R HEAD LAMP-R
+

25/RD/WH 8 +12V
ENCODER

7/WH GND
GND A

7
MR 5 1/BK 2

INSTRUMENT MONITOR 85/RD/GN 1 BACK-UP BUZZER (OPT)

D2-13 75/YL/GN
B

98/RD/BU 4
D2-5 76/BK
90/RD/BK 1
D2-2 114/YL/RD
THERMAL THERMAL 2
HORN SW
51/WH SENSOR SENDER 3
113/GN/YL 6 +12V
98/RD/BU 2
1/BK 1 GND
GRAB BAR SW (OPT)
28/BU/BK 7 L-S TX 90/RD/BK 1
29/BU/GN 2 L-S RX 94/YL/BU
73/BU/RD 8 R-S TX 104/GN/WH
74/BU/WH 3 R-S RX 92/WH/GN
48/BU 9 P-S TX
49/VO 4 P-S RX DIODE-DIR
10 90/RD/BK 1
5 2
1/BK
PUMP HORN
CAN PORT SERIAL PORT 87 110/WH/BU
1
85 1/BK
GND P1-26 64/RD VARISTOR
60/WH/BU P1-7 3 3 +12V 86 85/RD/GN
P1-16 58/BK 4 4 BUZZER 30 84/RD/YL
5 103/BR/YL 5 S/B LAMP

35/YL 35/YL 38/BU/GN 2 S/B SW

P1-35(CAN L) 2
17/GN/YL 7 SEAT SW
BACK UP LAMP (OPT)
THM1 6
61/GN/RD P1-8 59/RD/WH 1 B+
P1-23(CAN H) 23/YL/BK 23/YL/BK 7
B1 7/WH 6 B- 131/BU/YL 3
63/BR P1-32 11/BU/BK 8 PARKING 2 43/OR/RD
A1
62/GN/BK P1-31 3/OR 3/OR 1 KEY SW
OPT LAMP CONN. LIGHT SW(OPT)
P1-1 +5
7 113/GN/YL
2
60/WH/BU P1-9 65/BU 65/BU 2
63/BR +5V
64/RD P1-26 3/OR 1 SAFETY RELAY 1 81/RD 81/RD 8
MAST TILT SW2 (OPT) (OSS CONTROLLER) 3 93/GY
61/GN/RD 64/RD HEAD LAMP (OPT)
PUMP MOTOR 7 94/YL/BU
P1-4 68/WH/GN 68/WH/GN 2
62/GN/BK 5 L-LAMP CONN
+

69/BU/WH 69/BU/WH 1 110/WH/BU

P1-13
ENCODER

4 129/BU/GN
GND A

82/BU/RD 1
MR TILT SOLENOID (OPT)
2 1/BK 2
1/BK
P1-19 78/YL/GN 78/YL/GN 2
3/OR 1 6 92/WH/GN 92/WH/GN
HEAD LAMP-L
B

Auto tilt SW3 (OPT) 8 112/YL/WH T/S LAMP-L

P1-20 79/YL/BU 79/YL/BU 2
3/OR 1
THERMAL THERMAL
60/WH/BU TILT LEVER (OPT)
SENSOR SENDER
3/OR 1 FRONT COMB-L(OPT)
1 47/RD/GN P1-25 P1-25 47/RD/GN 47/RD/GN 2 56/OR/BK
117/YL/WH P1-6 TILT
2
P1-10 44/VO 44/VO 4
AUX1
P1-22 45/YL 45/YL 6
PRESSURE SENSOR(OPT) P1-33 46/BK/WH 46/BK/WH 8
AUX2
35/YL
P1-7 60/WH/BU 60/WH/BU 5 GND +12V
23/YL/BK
- BATTERY P1-24 67/GN/YL 67/GN/YL 7 OUT 90/RD/BK 1/BK 2
130/YL/GN 1
LIFT SENSOR 3/OR 98/RD/BU
LICENCE LAMP(OPT)
1/BK 1/BK

P1-28 48/BU
P1-29 49/VO 2 3 6 5 4 1 7 8

F_CONN. A
(FOR FINGERTIP)
2
1

60/WH/BU 2 PARKING BRAKE SW

91/BR/YL 11/BU/BK 1 (OPT FOR FR/LEVER) 6
P1-17 75/YL/GN 2
114/YL/RD 1
F_BACK UP RELAY (OPT) 69/BU/WH 4
124/BU/GN 5
86 69/GN/WH P1-13 3/OR 1
85 115/GN P1-3 118/BU/BK 3
87a P1-14 24/WH/BK 24/WH/BK 2
30 84/RD/YL
87 85/RD/GN HEIGHT SW1 (OPT) F_CONN. B
70/OR/BK P1-21 (FOR FINGERTIP)
P1-5 124/BU/GN
P1-34
P1-2 118/BU/BK

600123-00222
● Electric schematic (Electric foot brake) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS
A B C D E F G H I J

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

A B C D E F G H I J
600123-00535
● Electric schematic (Electric foot brake, 1/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS

A B C D E F

600123-00535
● Electric schematic (Electric foot brake, 2/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS

E F G H I J

600123-00535
● Electric schematic (Electric foot brake, 3/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS

A B C D E F

600123-00535
● Electric schematic (Electric foot brake, 4/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS

E F G H I J

600123-00535
• Electric Schematic_STD (F-series) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)
A B C D E F G H I J

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

A B C D E F G H I J
600123-00622
• Electric Schematic_STD (F-series)_(1/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

A B C D E F

600123-00622
• Electric Schematic_STD (F-series)_(2/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

E F G H I J

600123-00622
• Electric Schematic_STD (F-series)_(3/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

E F G H I J

600123-00622
• Electric Schematic_STD (F-series)_(4/4) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

E F G H I J

600123-00622
• Electric Schematic_Fingertip MODEL: B15/18/20T (PLUS), B16/18/20X-7 (PLUS)

600123-00367
• Electric Schematic_Fingertip (F-series) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

600123-00639
• Harness_STD (1/2) MODEL: B15/18/20T-7 (PLUS)

310207-12042
• Harness_STD (2/2) MODEL: B15/18/20T-7 (PLUS)

310207-12042
• Harness_Fingertip MODEL: B15/18/20T-7 (PLUS), B18/20TL-7, B16/18/20X-7 (PLUS)

310207-07212
• Harness_STD (F-series) (1/2) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

310207-12707
• Harness_STD (F-series) (2/2) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

310207-12707
• Harness_Fingertip (F-series) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

310207-12842
• Harness_SLIO/SRIO (1/2) MODEL: B15/18/20T-7 (PLUS)

310207-12206
• Harness_SLIO/SRIO (2/2) MODEL: B15/18/20T-7 (PLUS)

310207-12206
• Harness_SLIO/SRIO (F-series) (1/2) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

310207-12706
• Harness_SLIO/SRIO (F-series) (2/2) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

310207-12706
• Harness_NFC MODEL: B15/18/20T-7 (PLUS), B18/20TL-7, B16/18/20X-7 (PLUS)

310207-09046
• Harness_NFC (F-series) MODEL: B15/18/20T-7 PLUS, B16/18/20X-7 PLUS (F-series)

310207-12844
Index

# D

“Administration” menu description .................... 2-64 DC-DC converter ........................................... 2-32

“Tools” menu description.................................. 2-65 Diagnosis ...................................................... 2-44
Disassembly and assembly ....................................
A ....................................................................... 3-19
Disassembly and assembly ....................................
Accelerator ..................................................... 3-24 ..................................................... 8-15, 8-40, 8-59
Adjustment ..................................................... 3-18 Disassembly and assembly ............................. 4-21
Air removal in brake oil..................................... 3-37 Disassembly/assembly instructions ................ 1-36
Application “EasyView” .................................... 2-54 Display and buttons ....................................... 2-39
Drive axle ...................................................... 3-13
B Drive axle oil replacement .............................. 3-17
Drive motor........................................................ 3-4
B15/18/20T-7 and B18/20TL-7 ...........................1-9 Drive motor disassembly/assembly and test ... 3-10
B16/18/20X-7 ................................................... 1-15 Drive motor/axle/EM brake removal/installation 3-8
Battery .............................................................2-6 Drive wheel removal/installation ..................... 3-12
Brake pedal adjustment .......................... 3-36, 3-48 Drive/brake system .......................................... 3-1
Brake pedal ass’y removal/installation ..... 3-39, 3-46 Driving ............................................................. 3-55

C E

Calibration ............................................................ 2-48 Electric Foot Brake .......................................... 3-42

Carriage service ................................................... 5-74 Electrical system .............................................. 2-1
Chains service ....................................................... 5-46 EM parking brake ................................... 3-51, 3-58
Circuit and functions .............................................. 2-18 Exterior and specifications ......................................
Circuit configuration and key functions ...........8-10, 8-5 .................... 3-4, 3-13, 3-24, 3-27, 3-31, 3-42, 3-51
Communication protocol ........................................ 2-4 Exterior and specifications ......................... 2-6,2-17
Components ............................................................ 3-2 Exterior and specifications ......................................
Components ............................................................ 2-2 ........................................8-4, 8-8, 8-19, 8-41, 8-61
Components ............................................................ 4-2 Exterior and specifications ................................. 1-9
Components ............................................................ 5-2 Exterior and specifications ...... 4-6, 4-14, 4-18, 4-22
Components ............................................................ 6-2 Exterior and specifications ............. 5-6, 5-28, 5-84
Components and circuit ......................................... 8-2 Exterior and specifications ......................................
Construction of this manual ................................... 1-2 ....................................................... 6-6, 6-24, 6-36
Control valve – Kayaba (–Jul. 2018) ................... 8-19
Control valve – Walvoil (Jul. 2018–) .................... 8-41
Control valve............................................................ 5-6 F
Control valve disassembly/assembly ................... 5-26
Control valve removal/installation ........................ 5-24 F/R unit ........................................................... 3-27
Controller firmware update .................................. 2-60 Fault diagnosis ................................................ 8-64
Controllers and related devices ........................... 2-17 Fault display .................................................... 8-64
Fingertip armrest unit......................................... 8-8
Fingertip extension module ................................ 8-4
Fingertip option ................................................ 8-1
Floor plates removal/installation......................... 7-5
Forks service ................................................... 5-38
Forward/reverse switch.................................... 8-13
Frame .............................................................. 7-1

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 10-1 Index

Functions ........................................................... 2-8 Mast service .................................................... 5-78
Fuse box.......................................................... 2-29 Mast tilt/auto-tilt switch ass’y removal/installation ....
....................................................................... 5-90
Master cylinder disassembly/assembly ............ 3-41
G Miscellaneous loads ........................................ 2-29
Modular cabin removal/installation
General ............................................................ 1-1 ......................................................................... 7-5
Glossary ............................................................ 1-5
GSS and auto-tilt leveling options..................... 5-84 N
Needle valve for emergent lowering ................. 5-21
H
Handling faults on instrument panel/EasyView ........ O
...................................................................... 2-108
Height switch removal/installation..................... 5-89 Oil flow .............................................................. 4-4
Hood removal/installation ................................... 7-2 Oil flow .............................................................. 5-4
Horn ............................................................... 2-38 Oil flow .............................................................. 6-4
How it works . 3-6, 3-14, 3-25,3-28, 3-32, 3-44, 3-52 OSS controller ................................................. 2-36
How it works ........................................... 8-22, 8-44 Overhead guard removal/installation.................. 7-4
How it works ........................... 4-8, 4-15, 4-19, 4-24 Overview ........................................................... 3-2
How it works .................................... 5-7, 5-30, 5-86 Overview ........................................................... 2-2
How It works .................................... 6-8, 6-26, 6-38 Overview ........................................................... 8-2
How to use this manual .................................... 1-2 Overview ........................................................... 4-2
Hydraulic block ass’y removal/installation ....... 5-92 Overview ........................................................... 5-2
Hydraulic control knobs .................................... 8-12 Overview ........................................................... 6-2
Hydraulic oil and filter replacement ................... 4-26 Optional speed limit ......................................... 2-39
Hydraulic system .............................................. 4-1
Hydraulic tank and filter.................................... 4-22 P
Parking brake test ........................................... 3-53
I Primary lift cylinders service ........................... 5-60
Priority valve.................................................... 4-18
Initial settings ............................................... 2-102 Pump motor ...................................................... 4-6
Installation and execution ................................. 2-54 Pump motor and main hydraulic pump
Instrument panel .............................................. 2-39 removal/installation ........................................ 4-10
Pump motor disassembly/assembly and test ... 4-12
Pump motor operation at steering .................... 8-62
L
Lamp group ........................................................... 2-35 R
LED fault codes ..................................................... 2-23
Levers and switch group Rear wheel and hub adjustment/removal/installation
adjustment/removal/installation ............................. 5-22 .............................................................. 6-29, 6-41
Lift/tilt/auxiliary system ........................................... 5-1 Recommended viscosities and capacities ........ 1-31
Link ass’y removal/installation ............................... 6-46 Relief valve adjustment ................................... 5-18
Lubricant specifications ......................................... 1-32 Relief valve adjustments ......................... 8-34, 8-56
Lubricants .............................................................. 1-31 Removal and installation......................... 2-16, 2-26
Removal and installation.................................. 3-26
M Removal and installation.................. 8-14, 8-39, 8-7
Removal and installation......................... 4-16, 4-20
Main hydraulic pump ...................................... 4-14 Removal/Installation ........................................ 3-30
Main page – Calibration Menu ........................ 2-81
Main page – Test Menu .................................. 2-73
Maintenance .................................................... 2-14 S
Maintenance .................................................... 1-26
Manual lowering ...................................... 8-38, 8-58 Safety precautions........................................... 1-19
Manual release of braking ................................ 3-54 Service brake .................................................. 3-57
Mast ass’y ....................................................... 5-28 Service brake pedal ass’y ................................ 3-31

Index 10-2 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS

Sideshifter service .......................................... 5-40
Standard torques ............................................. 1-45
Standard torques for bolts and nuts.................. 1-45
Standard torques for tightening fittings ............. 1-47
Standard/secondary cylinders service .............. 5-64
Steer angle sensor removal/installation ... 6-28, 6-40
Steer axle housing ass’y disassembly/assembly6-34
Steer axle removal/installation.......................... 6-44
Steer axle spindle removal/installation/disassembly/
assembly ......................................................... 6-32
Steering control group ........................................6-6
Steering cylinder
removal/installation/disassembly/assembly
........................................................................ 6-48
Steering knuckle, king pin, and bearing
removal/installation .......................................... 6-47
Steering operation group [B15/18/20T (TL)]...... 6-24
Steering operation group [B16/18/20X] ............. 6-36
Steering pressure switch ass'y ......................... 8-61
Steering system ...............................................6-1
Steering system air removal ............................. 6-15
Steering system pressure check....................... 6-16
Steering unit disassembly/assembly ............... 6-22
Steering wheel column removal/installation ...... 6-20
Steering wheel cover removal/installation ......... 6-18
Steering wheel removal/installation .................. 6-19

T
Test ...................................................... 2-11, 2-24
Tilt cylinders service ....................................... 5-52
Top cover and counterweight removal/installation7-6
Troubleshooting ............................................... 3-55
Troubleshooting ............................................... 4-27
Troubleshooting ............................................... 5-94
Troubleshooting ............................................... 8-65
Troubleshooting ............................................... 6-50

W
Warning label definition ......................................1-4
Wiring ..................................................... 2-10, 2-20
Wiring ............................ 8-6, 8-11, 8-21, 8-43, 8-61

B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS 10-3 Index

 Version Page/
Modifications
(revision date) Chapter
SB4449E02
1-4 Deleted the asbestos.
(Oct, 2020)
1-5, 1-6 Revised for EPB
SB4449E02 3-3-1 Design change on drive axle.
(Dec, 2020) 3-7 Added Electric Foot Brake.
9-5 Added new electric schematic.
Foreword Added the PLUS model.
Added the specification for B15/18/20T-7 PLUS and
1-3
SB4449E04 B16/18/20X-7 PLUS
(Aug. 2021) 1-5 Revised the maintenance of changing drive axle oil.
Added the note on brake oil.
1-6
Added the greasing points for PLUS model.
2-3-1 Erased the part number.
2-4-6 Added the optional speed limit newly.
Updated several EasyView displays and parameters
2-6-6
SB4449E05 related with PLUS.
(Nov. 2021) 3-3-1 Erased the part number.
5-4 Added the Quad mast.
7-5 Added the modular cabin newly.
7-6 Added the heater newly.
SB4449E05
2-7 Added the new fault codes. (82, 85 & 88)
(Sep. 2022)
5-5 Revised the contents related with the functional safety.
Made this chapter newly, related with the F-series
SB4449E06 9
controller and electric components.
(Mar. 2023)
Added the new electric schematic and harnesses,
10
related with the functional safety.
Index 10-4 B20T-7, B20X-7, B20T-7 PLUS, B20X-7 PLUS