TCM FB-8 Series Service Manual
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TCM FB-8 Series Service Manual

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Summary of Contents for TCM FB-8 Series

  • Page 3 FOREWORD The new TCM’s FB-8 Series battery-powered forklift trucks are provided with a newly designed speed control system and AC motors for both the traveling and load handling systems to assure high performance operation. The trucks of this series are also provided with a self-diagnosis function which keeps watching the operating statuses of the main control systems of the truck.
  • Page 5 SPECIFICATIONS (1) Truck model FB10-8 FB15-8 FB18-8 FB20-8 Item Performance Max. load kg [lbs] 1000 [2000] 1500 [3000] 1750 [3500] 2000 [4000] ← ← ← Load center mm [in.] 500 [24] ← ← ← Max. lifting height mm [in.] 3000 [118.1] Tilting angle ←...
  • Page 6 SPECIFICATIONS (2) Truck model FB25-8LB FB30-8 FB25-8 FB35-8S Item FB25-8V FB30-8V Performance ← Max. load kg [lbs] 2500 [5000] 3000 [6600] 3500 [7000] ← ← ← Load center mm [in.] 500 [24] ← ← ← Max. lifting height mm [in.] 3000 [118.1] Tilting angle ←...
  • Page 7 Unit: mm [in.] Fig. 1 Overall Dimensions...
  • Page 8 Table 1. Maintenance Standard List FB20-8 Truck model FB10-8 FB25-8 FB30-8 FB18-8 FB35-8S Item FB15-8 FB25-8LB FB30-8V FB25-8V Traction mm [in.] Motor brush size and wear Pump mm [in.] limit Power steering ← ← ← ← mm [in.] 22 - 13 [0.87 - 0.51] (EPS type only) Traction N{kgf}[lbf]...
  • Page 9 When inspecting the truck with the mast advanced, put a pallet between the mast and the front guard of the truck to prevent the mast from retracting unexpectedly. Inspection and repair of the truck must be performed only by qualified service personnel authorized by TCM. Reach model Counterbalanced model...
  • Page 10 02. BASIC SERVICING KNOWLEDGE 1. Installing bearings When installing a bearing onto a shaft, tap its inner race with a mallet as shown in Figure 02.1. When installing a bearing into a case, tap its outer race. When removing, use the same procedure as for installing.
  • Page 11 ③ When installing an oil seal onto a shaft, apply lubricating oil or grease to its seal lip and the mounting surface of the shaft. For a double- lip type, fill grease by 1/3 to 1/2 of the space between the lips. When inserting an oil seal into a case, use care to damage the seal lip.
  • Page 12 03. CLEANING 1. General metallic parts ① Clean parts thoroughly using cleaning fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned. ②...
  • Page 13 04. STANDARD BOLT TIGHTENING TORQUE See the section “04. STANDARD BOLT TIGHTENING TORQUE” for the torques of standard bolts when they are used for general applications. Refer to the Shop Manual and Service Manual of your truck model when: 1) Special nuts are used. 2) Synthetic resin or rubber is used for tightening.
  • Page 14 Table 04.2 Division by Surface Name Shape Thread size Material Part number strength treatment Nominal symbol 01101- SS400 Black SS400 01100- “ M4 - M8 coarse and S45C 01103- “ Normal M10 - M39 fine Yellow SCM435, Boron steel 01106- “...
  • Page 19 05. LUBRICATION 1. Lubricating lift chains Lubricate the lift chains with engine oil using an oiler or a brush. To allow oil to enter between each pin and link plate of the lift chain, observe the following conditions: Loosen the chains sufficiently. •...
  • Page 20 3. Checking hydraulic oil level OIL DIPSTICK レベルゲージ Check the hydraulic oil level in the hydraulic oil tank using the oil level dipstick. Remove the dipstick of the tank cap, clean the rod with a clean cloth and reinsert it. Remove the dipstick again and check the oil level.
  • Page 21 06. PARTS LIST Part number FB10-8 FB30-8 Item Part name Remarks FB20-8 FB25-8V FB15-8 FB30-8V FB25-8 FB25-8LB FB18-8 FB35-8S 283R2-63901 283T2-63901 283R2-63901 Fuse, F1 Controller 400A 500A 400A 27292-62272 27732-62091 27292-62272 Fuse, F6 Battery charger 130A 200A 130A Fuses Fuses, F4, F5, F9 25592-42311 Fuse, F7 25592-42311...

  • Page 23: Table Of Contents

    CONTENTS 1. BATTERY AND CHARGER (OPTION) ..............1 GENERAL DESCRIPTION ....................2 1.1.1 BATTERY ........................2 1.1.2 BATTERY CHARGER ....................4 1.1.3 CHARGING PROCEDURES ..................9 1.1.4 CHARGER OPERATION ................... 11 2. MOTORS ..........................13 GENERAL DESCRIPTION ....................13 2.1.1 DRIVE MOTOR ......................13 2.1.2 PUMP MOTOR ......................17 MAINTENANCE .......................19 2.2.1 DRIVE MOTOR ......................19...
  • Page 24 5.2.5 ADJUSTING BRAKE PEDAL ...................53 5.2.6 TROUBLESHOOTING GUIDE .................54 6A. STEERING SYSTEM (ORBITROL type) ............55 6A.1 GENERAL DESCRIPTION ....................55 6A.1.1 STEERING AXLE ......................56 6A.1.2 STEERING WHEEL ASSEMBLY................60 6A.1.3 ORBITROL .........................62 6A.1.4 POWER CYLINDER ....................65 6B. STEERING SYSTEM (EPS type) ................67 6B.1 GENERAL DESCRIPTION ....................67 6B.1.1 OUTLINE OF STEERING SYSTEM .................68 6B.1.2 STEERING GEARBOX ....................69...
  • Page 25 MAINTENANCE ......................118 8.2.1 ADJUST LIFT CYLINDER ROD WITH SHIMS ............ 118 8.2.2 ADJUSTING HEIGHT OF CARRIAGE ..............118 8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE ....120 8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE ......122 8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS .........123 9.

  • Page 27: Battery And Charger (Option)

    1. BATTERY AND CHARGER (OPTION) 1. BATTERY AND CHARGER (OPTION) The description in this section applies to our optional batteries and chargers. For other types of batteries and chargers, refer to their respective instruction manuals. Truck model FB10-8 FB15-8 FB18-8 FB20-8 FB25-8 Item...

  • Page 28: General Description

    1. BATTERY AND CHARGER (OPTION) 1.1 GENERAL DESCRIPTION 1.1.1 BATTERY The battery unit consists of twenty-four 2-volt battery cells for the 48-volt electrical system (thirty-six 2-volt battery cells for the 72-volt electrical system) connected in series. Figure 1.1 shows its construction. LOCK PIN ELECTROLYTE LEVEL INDICATOR...
  • Page 29 1. BATTERY AND CHARGER (OPTION) Specific gravity (at 20°C) Voltage (V) Voltage Alert ! Specific gravity (Discharge duration) (Discharge rate) Fig. 1.3 An Example of Specific Gravity Drop (2) Charging the battery When discharged, the battery should be recharged as soon as possible. Leaving the battery discharged for a long time may cause sulfation, which will result in a drop of the battery performance.

  • Page 30: Battery Charger

    1. BATTERY AND CHARGER (OPTION) 1.1.2 BATTERY CHARGER The on-board battery charger is a computer-controlled, semiconstant-voltage type consisting of a transformer, diodes, an operation panel, a CM contactor and a thermal relay. Thermal relay current settings Transformer model Setting (A) BAND INSULATION TUBE M80B...
  • Page 31 1. BATTERY AND CHARGER (OPTION) Thermal relay current settings Transformer model Setting (A) M105B M105C M105D CM CONTACTOR CMコンタクタ SECONDARY WIRE THERMAL RELAY PRIMARY WIRE Fig. 1.5 Battery Charger (3- to 3.5-ton Trucks) - 5 -...
  • Page 32 1. BATTERY AND CHARGER (OPTION) (1) Transformer The transformer is located at the right side frame and converts input voltage to a voltage of the level necessary for charging the battery. There are three taps provided with a 10-volt difference from one to another. Make a selection among them at the input side according to the input voltage level.
  • Page 33 1. BATTERY AND CHARGER (OPTION) (2) Diode The diode, installed inside the right-side frame, is a 3-phase, full-wave rectification type which converts AC to DC. The current rectified by the diode flows through the fuse F6 to charge the battery. DIODE ダイオード...
  • Page 34 1. BATTERY AND CHARGER (OPTION) (3) Operation panel The operation panel is located on the left side of the cabinet and equipped with charger control switches, lamps and service power outlet. Fig. 1.8 Operation Panel - 8 -...

  • Page 35: Charging Procedures

    1. BATTERY AND CHARGER (OPTION) 1.1.3 CHARGING PROCEDURES (1) Normal charge ① Turn off the key switch and apply the parking brake. ② Make sure that the power supply at the facility side is off and insert the plug into the receptacle at the truck side.
  • Page 36 However, for the truck-mounted type charger, the second timer is operated after charging the battery for 15 to 17 hours, so that the charging is forcibly terminated and the CHARGING lamp blinks. In such a case, inspect the cause and contact your TCM dealer. Note: Have a helper for this procedure.

  • Page 37: Charger Operation

    1. BATTERY AND CHARGER (OPTION) 1.1.4 CHARGER OPERATION (1) When the power supply switch to the battery charger is turned on, the charging circuit inside the LCD panel is activated. (2) When the START button is pressed, a circuit consisting of the CM contactor, thermal relay TH and CN1-8 terminals of the LCD panel is completed to activate the CM contactor.
  • Page 38 1. BATTERY NOTE - 12 -...

  • Page 39: Motors

    2. MOTORS 2. MOTORS Truck model FB10-8 FB15-8 FB20-8 FB25-8 FB30-8 FB35-8S FB18-8 FB25-8LB FB25-8V FB30-8V Item Drive motor Name HO-NR Type Self-ventilated, 3-phase induction motor Rated output 6.9 kW (60-min rate) 8.5 kW (60-min rate) 11.9 kW (60-min rate) Rated voltage 26.5 V 26.3 V...
  • Page 40 2. MOTORS DRIVE AXLE DRIVE MOTOR DRIVE UNIT Fig. 2.1 Drive Motor Installation - 14 -...

  • Page 41: Drive Motor

    2. MOTORS Tightening torque: 締付トルク 10 to 12 N-m 10～12N ・ m [100 to 120 kgf-cm] {7.4 to 8.9 lbf-ft} ROTATION SENSOR B 回転センサB ROTATION SENSOR A 回転センサA THERMO-SENSOR CONNECTOR U PHASE V PHASE W PHASE TERMINAL Ｕ相端子 Ｖ相端子 Ｗ相端子 TERMINAL TERMINAL View looking from B...
  • Page 42 2. MOTORS ■ Operating principle of 3-phase induction motor As shown in Figure 2.3, when the magnetic poles N and S are rotated outside the rectangular oil, the coil side cuts the magnetic flux to induce electromotive force in the direction indicated in the (Rotating direction of coil) figure, thus flowing circulating current inside the...

  • Page 43: Pump Motor

    2. MOTORS 2.1.2 PUMP MOTOR The pump motor is located on the left side frame and is used to drive the main pump. Its rotation is controlled by the load handling inverter built in the speed controller only when the lift lever is operated.
  • Page 44 2. MOTORS Tightening torque: 10 to 12 N-m 締付トルク [100 to 120 kgf-cm] 10～12N ・ m THERMO-SENSOR {7.4 to 8.9 lbf-ft] CONNECTOR ROTATION SENSOR 回転センサ U PHASE V PHASE W PHASE TERMINAL Ｕ相端子 Ｖ相端子 Ｗ相端子 TERMINAL TERMINAL View looking from B View looking from A Fig.

  • Page 45: Maintenance

    2. MOTORS 2.2 MAINTENANCE 2.2.1 DRIVE MOTOR (1) Check the following points with the motor running Check item Location Criteria Remedy No remarkable deposit of dust allowed If too much deposit of compared with usual operation. Dust Motor frame dust is found, stop the Usual temperature rise.

  • Page 46: Periodic Inspection

    2. MOTORS 2.2.2 PERIODIC INSPECTION (1) Inspection criteria Check the motor at periodic intervals, referring to the following troubleshooting chart. If the motor is used under a severe working condition, earlier or more frequent preventive maintenance is required. Operation time more than 12 hours/day 8 –...
  • Page 47 2. MOTORS (2) Inspection procedure Inspect the motors observing the following conditions: ① Select a place which is not dusty or humid. ② Parts which have been disassembled should be kept in order and the order of disassembly recorded to ensure correct reassembly. Screws and wave washers removed should be put in order in boxes.

  • Page 48: Maintenance Of Bearings

    2. MOTORS 2.2.3 MAINTENANCE OF BEARINGS The service life of bearings varies with the magnitude of loads and operating conditions. Replace the bearings with new ones when the temperature rises excessively or produces noise. Sealed bearings sealing in lithium soap-based grease ensure effective lubrication and prevent the entrance of dust.

  • Page 49: Control System

    3. CONTROL SYSTEM 3. CONTROL SYSTEM 3.1 GENERAL DESCRIPTION The controller assembly consists of two inverter units which control the drive and the pump motors, respectively (excluding trucks with an Orbitrol steering system), and an EPS controller unit which controls the EPS motor, as shown in Figures 3.1 and 3.4. 3.1.1 INVERTER UNIT The inverter unit is a device consisting of a CPU board and FET modules and converts direct current to 3-phase alternating current.
  • Page 50 3. CONTROL SYSTEM Fig. 3.1 Controller (1.0 - to 1.8-ton Trucks (excluding those with an Orbitrol steering system)) - 24 -...
  • Page 51 3. CONTROL SYSTEM Fig. 3.2 Inverter Unit (drive motor) Circuit (1.0 - to 1.8-ton Trucks (excluding those with an Orbitrol steering system)) - 25 -...
  • Page 52 3. CONTROL SYSTEM Fig. 3.3 Inverter Unit (pump motor) Circuit (1.0- to 1.8-ton Trucks (excluding those with an Orbitrol steering system)) - 26 -...
  • Page 53 3. CONTROL SYSTEM Fig. 3.4 Controller (2.0- to 3.5-ton Trucks with an EPS steering system and 1-ton Class Trucks with an Orbitrol steering system) - 27 -...
  • Page 54 3. CONTROL SYSTEM Fig. 3.5 Inverter Unit (drive motor) Circuit (2.0- to 3.5-ton Trucks with an EPS steering system and 1-ton Class Trucks with an Orbitrol steering system) - 28 -...
  • Page 55 3. CONTROL SYSTEM Fig. 3.6 Inverter Unit (pump motor) Circuit (2.0- to 3.5-ton Trucks with an EPS steering system and 1-ton Class Trucks with an Orbitrol steering system) - 29 -...

  • Page 56: Accelerator Pedal

    3. CONTROL SYSTEM 3.1.2 ACCELERATOR PEDAL The accelerator pedal is installed as shown in Figure 3.7, and the amount of accelerator pedal effort is transmitted to the potentiometer. The potentiometer converts pedal effort into voltage change and sends it to the controller. View looking from A 18.5 mm 1.

  • Page 57: Drive Unit And Drive Axle

    4. DRIVE UNIT AND DRIVE AXLE 4. DRIVE UNIT AND DRIVE AXLE Truck model FB10-8 FB15-8 FB20-8 FB25-8 FB30-8 FB35-8S FB18-8 FB25-8LB FB25-8V FB30-8V Item Drive unit ← ← Type Three-stage reduction Model 81E-25 81N-25 81U-25 ← Reduction ratio 25.1 30.144 Drive axle Full floating...
  • Page 58 4. DRIVE UNIT AND DRIVE AXLE PINION SHAfT RING GEAR Tightening torque: 95 to 142 N-m WASHER {970 to 1450 kgf-cm} [840.8 to 1257 lbf-in.] PINION GEAR WASHER Tightening torque: 44 to 54 N-m SIDE GEAR {450 to 550 kgf-cm} [389.4 to 477.9 lbf-in.] TAPER PIN COUNTER GEAR 2...
  • Page 59 4. DRIVE UNIT AND DRIVE AXLE RING GEAR SPIDER SIDE GEAR WASHER Tightening torque: 95 to 142 N-m {970 to 1450 kgf-cm} PINION GEAR WASHER [840.8 to 1257 lbf-in.] Tightening torque: 締付トルク： 44 to 54 N-m {450 to 550 kgf-cm} 44～54 N ・...
  • Page 60 4. DRIVE UNIT AND DRIVE AXLE Tightening torque: 137 to 177 N-m {1400 to 1800 kgf-cm} RING GEAR [1212.6 to 1566.6 lbf-in.] SPIDER Tightening torque: 95 to 142 N-m SIDE GEAR WASHER {970 to 1450 kgf-cm} [840.8 to 1257 lbf-in.] PINION GEAR WASHER COUNTER GEAR 2...

  • Page 61: Drive Axle

    4. DRIVE UNIT AND DRIVE AXLE 4.1.2 DRIVE AXLE The drive axle is composed of an axle housing, wheel hub, and wheels. It is mounted at the front side of the frame. At each end of the axle housing are a wheel hub and a wheel brake. The wheel hub is supported on the spindle by two tapered roller bearings, and is driven by the axle shaft.
  • Page 62 4. DRIVE UNIT AND DRIVE AXLE Fig. 4.5 Drive Axle (2- to 2.5-ton Trucks) - 36 -...
  • Page 63 4. DRIVE UNIT AND DRIVE AXLE Fig. 4.6 Drive Axle (3.0- to 3.5-ton Trucks) - 37 -...
  • Page 64 4. DRIVE UNIT AND DRIVE AXLE ■ Procedure for installing the wheel hub (1) Put the specified amount of grease into the space of the wheel hub and install it onto the spindle. (2) Tighten the adjustment nut to approx. 98 N-m {1 kgf-m} [7.23 lbf-ft] torque and loosen it by 1/2 turn.

  • Page 65: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Truck model FB10-8 FB15-8 FB20-8 FB25-8 FB30-8 FB35-8S Item FB18-8 FB25-8LB FB25-8V FB30-8V Type Front two wheel braking, internal expansion, hydraulic type ← ← Pedal ratio ← ← Master cylinder bore 19.05 mm [0.75 in.] Wheel brake ←...
  • Page 66 5. BRAKE SYSTEM Fig. 5.2 Brake Pedal - 40 -...

  • Page 67: Master Cylinder

    5. BRAKE SYSTEM 5.1.2 MASTER CYLINDER The master cylinder is installed on the bracket of the brake pedal unit as shown in Figure 5.3. Built in the master cylinder are a check valve, spring and piston. They are kept in position by a snap ring.

  • Page 68: Wheel Brake

    5. BRAKE SYSTEM 5.1.3 WHEEL BRAKE The wheel brake is duo-servo type, and is mounted on each of the both ends of the drive ANCHOR PIN axle. The wheel brake is composed of two pairs of brake shoes, a wheel cylinder and adjuster. One end of the brake shoe is contacted with the anchor pin and another end is contacted with the adjuster.
  • Page 69 5. BRAKE SYSTEM (3) Automatic clearance adjuster T h e a u t o m a t i c c l e a r a n c e a d j u s t e r automatically keeps the lining-to-drum clearance properly.

  • Page 70: Parking Brake Lever

    5. BRAKE SYSTEM 5.1.4 PARKING BRAKE LEVER The parking brake lever is a toggle type and it is installed as shown in Figure 5.9. An adjuster adjusting the braking force is located on the top of the lever. RELEASE BUTTON PARKING BRAKE LEVER View looking from C...
  • Page 71 5. BRAKE SYSTEM Sectional view B - B Sectional view D - D Sectional view E - E Shoe expanding direction Sectional view A - A Sectional view of wheel cyl. Sectional view C - C 1. BRAKE LEVER 8. SHOE HOLD-DOWN 14.
  • Page 72 5. BRAKE SYSTEM Sectional view C - C Sectional view E - E Sectional view D - D Shoe expanding direction Sectional view A - A Sectional view of wheel cyl. Sectional view B - B 1. BRAKE LEVER 8. SHOE HOLD-DOWN 14.

  • Page 73: Maintenance

    5. BRAKE SYSTEM 5.2 MAINTENANCE This section describes the procedure for disassembling, reassembling and adjusting the wheel brake and the procedure for adjusting the brake pedal, with the wheel brake and hub removed. 5.2.1 DISASSEMBLING WHEEL BRAKE (1) Remove the shoe hold-down pin, adjuster lever, adjuster and spring from the secondary shoe.
  • Page 74 5. BRAKE SYSTEM (4) Remove the primary and secondary shoes. Also remove the adjuster and adjuster spring at the same time. Fig. 5.16 (5) Remove the brake pipe from the wheel cylinder. Remove the bolts securing the wheel cylinder. Remove the wheel cylinder from the backing plate.

  • Page 75: Inspection

    5. BRAKE SYSTEM 5.2.2 INSPECTION Check each part and repair or replace any defective one. (1) Check the wheel cylinder inner surface and piston outer periphery for rust. Measure the clearance between the piston and cylinder. Standard: 0.03 to 0.10 mm [0.0012 to 0.0039 in.] Limit: 0.15 mm [0.0059 in.]...

  • Page 76: Reassembling Wheel Brake

    5. BRAKE SYSTEM 5.2.3 REASSEMBLING WHEEL BRAKE (1) Apply brake fluid to the cup and piston of the wheel cylinder. Install the spring, piston cup, piston and boot in this order. (2) Install the wheel cylinder on the backing plate. Tightening torque: 17.7 to 26.5 N-m {180 to 270 kgf-cm} [156.7 to 234.5 lbf-in.] (3) Install the backing plate on the drive axle.
  • Page 77 5. BRAKE SYSTEM (8) Install the shoe guide pin in the anchor pin, and install the shoe return spring. In this step, install the spring at first on the primary side and then on the secondary side. Fig. 5.25 (9) Install the spring, adjuster, adjuster spring and adjuster lever, paying attention to the following items: ①...

  • Page 78: Operation Test Of Automatic Clearance Adjuster

    5. BRAKE SYSTEM 5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER (1) Set the outer diameter of the brake shoe to nearly the normal mounting dimension. Push up the adjuster lever and adjust the diameter, turning the teeth of the adjuster. When your finger is released, the teeth of the adjuster do not turn and the adjuster lever returns to the original position.

  • Page 79: Adjusting Brake Pedal

    5. BRAKE SYSTEM 5.2.5 ADJUSTING BRAKE PEDAL (1) Shorten the push rod length of the master cylinder. (2) Using the stopper bolt, adjust the pedal upheight to the value shown in Figure 5.29. (3) Keeping the pedal pressed down by the pedal play, extend the push rod so that its tip contacts the piston of the master cylinder.

  • Page 80: Troubleshooting Guide

    5. BRAKE SYSTEM 5.2.6 TROUBLESHOOTING GUIDE Trouble Probable Cause Remedy Brake fluid leaks from the brake system Repair. Maladjustment of brake shoe clearance Check and adjust the adjuster. Overheating brake Check for dragging. Poor braking Poor contact between brake drum and Adjust contact.

  • Page 81: Steering System (Orbitrol Type)

    6A. STEERING SYSTEM (ORBITROL type) 6A. STEERING SYSTEM (ORBITROL type) Truck model FB10-8 FB20-8 FB25-8V FB35-8S FB15-8 FB25-8 FB25-8LB Item FB18-8 FB30-8 FB30-8V Steering axle Center-pin supported, Elliot type with box-shaped Type cross section of weld construction King pin spacing 735 mm [28.9 in.] 740 mm [29.1 in.] King pin angle...

  • Page 82: 1.1 Steering Axle

    6A. STEERING SYSTEM (ORBITROL type) 6A.1.1 STEERING AXLE The steering axle is of steel-welded construction with a box-shaped cross section, incorporating a power cylinder inside it. See Figures 6A.1 and 6A.3. The power cylinder is housed in the axle to protect it from being damaged by obstacles on the road surface.
  • Page 83 6A. STEERING SYSTEM (ORBITROL type) BUSHING SPHERICAL BUSHING Detail of C KING PIN OIL SEAL OIL SEAL NEEDLE BEARING TAPERED ROLLER BEARING THRUST BEARING TAPERED ROLLER BEARING ADJUSTMENT NUT COTTER PIN fill 50% of the space with grease “O”-RING LOCK PIN NEEDLE BEARING OIL SEAL Detail of D...
  • Page 84 6A. STEERING SYSTEM (ORBITROL type) Tightening torque: 68 to 100 N-m {7 to 10.2 kgf-m} [50.6 to 73.8 lbf-ft] Apply THREEBOND #1324 JOINT (LEfT) POWER CYLINDER JOINT (RIGHT) See figure 6A.4. See figure 6A.4. KNUCKLE KNUCKLE (LEfT) (RIGHT) Point notched surface toward knuckle’s shaft KING PIN POTENTIOMETER...
  • Page 85 6A. STEERING SYSTEM (ORBITROL type) BUSHING SPHERICAL KING PIN BUSHING Detail of C OIL SEAL OIL SEAL TAPERED ROLLER BEARING NEEDLE BEARING THRUST BEARING TAPERED ROLLER BEARING ADJUSTMENT NUT COTTER PIN fill 50% of the space with grease “O”-RING NEEDLE BEARING LOCK PIN OIL SEAL Detail of D...

  • Page 86: 1.2 Steering Wheel Assembly

    6A. STEERING SYSTEM (ORBITROL type) 6A.1.2 STEERING WHEEL ASSEMBLY The steering wheel assembly is arranged as shown in Figure 6A.5. The orbitrol is located at the bottom of the assembly. At the center of the steering wheel is the horn button. The steering shaft is connected to the drive shaft of the orbitrol.
  • Page 87 6A. STEERING SYSTEM (ORBITROL type) COMBINATION SWITCH front of ASSEMBLY the truck front of the truck View looking from C front of the truck View looking from B View looking from A Fig. 6A.6 Steering Wheel - 61 -...

  • Page 88: 1.3 Orbitrol

    6A. STEERING SYSTEM (ORBITROL type) 6A.1.3 ORBITROL The orbitrol sends pressure oil from the pump selectively to the steering cylinder. It consists primarily of a control valve and a metering device. The control valve used in the orbitrol is not an ordinary spool valve whose spool moves in the axial direction, but a rotary valve which consists of a sleeve and a spool that rotate together forming different oil passages through the combination of their oil holes.
  • Page 89 6A. STEERING SYSTEM (ORBITROL type) (1) Operation of orbitrol (a) In “Neutral” While the steering wheel is in straight position, the oil from the pump flows through oil passage ① to oil groove ② . The sleeve has 24 oil holes ③ which are now in line with the holes ④...
  • Page 90 6A. STEERING SYSTEM (ORBITROL type) The returning oil from the power cylinder flows, passing through the cylinder port R, groove ⑪ in the valve housing, oil hole ⑰ in the sleeve, groove ⑲ in the spool, oil hole in the sleeve, and groove ⑧...

  • Page 91: 1.4 Power Cylinder

    6A. STEERING SYSTEM (ORBITROL type) (4) When the pump fails to operate normally If the pump fails to supply pressure oil to the orbitrol, the orbitrol can serve as an emergency manual steering device. Even if the orbitrol does not receive pressure oil from the pump, you can rotate the spool by turning the steering wheel.
  • Page 92 6. STEERING SYSTEM NOTE - 66 -...

  • Page 93: Steering System (Eps Type)

    6B. STEERING SYSTEM (EPS type) 6B. STEERING SYSTEM (EPS type) Truck model FB30-8 FB10-8 FB15-8 FB20-8 FB25-8 FB30-8V FB18-8 FB25-8LB FB25-8V FB35-8S Item Steering system Type Rear wheel steering, electric power steering Steering gear Type Ball nut type Name PU41 Reduction ratio 18.9 Operating angle...

  • Page 94: 1.1 Outline Of Steering System

    6B. STEERING SYSTEM (EPS type) 6B.1.1 OUTLINE OF STEERING SYSTEM As shown in Figure 6B.1, the steering system is composed of a steering gearbox, actuator, and controller. The steering gearbox is provided with a potentiometer which detects the steering handwheel operating force and sends to the controller a signal which corresponds to the strength and direction of the force.

  • Page 95: 1.2 Steering Gearbox

    6B. STEERING SYSTEM (EPS type) 6B.1.2 STEERING GEARBOX The steering gearbox is constructed as shown in Figure 6B.2. Rotation of the steering wheel is transmitted to the sector shaft by way of the ball nut screw. At the lower part of the steering gearbox unit is located the potentiometer which converts slight up-and-down movement of the steering shaft into a voltage and sends the voltage to the controller.
  • Page 96 6B. STEERING SYSTEM (EPS type) STEERING WHEEL STEERING WHEEL LOCK LEVER JOINT STEERING GEARBOX View looking from A DRAG LINK ACTUATOR Fig. 6B.3 Steering Linkage - 70 -...
  • Page 97 6B. STEERING SYSTEM (EPS type) COMBINATION front of SWITCH ASSEMBLY the truck front of the truck View looking from C front of the truck View looking from B View looking from A Fig. 6B.4 Steering Wheel - 71 -...

  • Page 98: 1.3 Actuator

    6B. STEERING SYSTEM (EPS type) 6B.1.3 ACTUATOR The actuator is a ball and nut screw type. The screw lengthens and shortens according to motor operation. Motor operation is transmitted to the ball and nut unit after its speed is reduced by two gears. The ball and nut unit are supported by two tapered roller bearings on the gearbox.
  • Page 99 6B. STEERING SYSTEM (EPS type) CENTER ARM TIE ROD (LEfT) TIE ROD (RIGHT) KNUCKLE (RIGHT) KNUCKLE (LEfT) Point notched surface toward knuckle’s shaft POTENTIOMETER KING PIN View looking from B Detail of A Fig. 6B.6 Rear Axle (1- to 1.8-ton Trucks) - 73 -...
  • Page 100 6B. STEERING SYSTEM (EPS type) CENTER ARM SUPPORT (fRONT) TIE ROD (LEfT) TIE ROD (RIGHT) SUPPORT (REAR) KNUCKLE (RIGHT) KNUCKLE (LEfT) Point notched surface toward knuckle’s shaft POTENTIOMETER KING PIN View looking from B Detail of A Fig. 6B.7 Rear Axle (2- to 3.5-ton Trucks) - 74 -...
  • Page 101 6B. STEERING SYSTEM (EPS type) (1) Knuckle and king pin The king pin supporting the knuckle is secured to the knuckle side with the lock pin. Its upper and lower ends are each installed on the axle boss through each needle bearing. The thrust bearing is installed between the axle upper boss and the knuckle so that the knuckle rotates smoothly around the king pin with its load.

  • Page 102: 1.5 Adjusting Preload Of Rear Wheel Bearing

    6B. STEERING SYSTEM (EPS type) 6B.1.5 ADJUSTING PRELOAD OF REAR WHEEL BEARING (1) As shown in Figure 6B.8, apply grease to the hub, inner bearing, outer bearing, and cap. Also apply grease to the oil seal lips. (2) Set the bearings on the hub, then installed the hub on the knuckle spindle. (3) Place a washer, then tighten the adjustment nut with a torque of 206 to 235 N-m {21 to 24 kgf-m} [1823 to 2080 lbf-in.].

  • Page 103: Maintenance

    6B. STEERING SYSTEM (EPS type) 6B.2 MAINTENANCE 6B.2.1 MAINTENANCE FOR ACTUATOR (1) Replacing the motor ① As shown in Figure 6B.9, securely hold the actuator assembly by a vise. Note: Be sure to hold it in a lying position. Fig. 6B.9 ②...
  • Page 104 6B. STEERING SYSTEM (EPS type) (2) Replacing the ball joint ① Securely fix the ball joint with its connector BOOT BALL JOINT held in a vise. Hold this section by vise Fig. 6B.13 ② Loosen the lock nut of the ball joint, then remove the ball joint.
  • Page 105 6B. STEERING SYSTEM (EPS type) ② Remove the clamp of the boot connector LOCK NUT CLAMP BOOT CLAMP side. Shift the position of the boot. Then loosen the connector lock nut, and remove the connector. Note: Fix the ball joint to prevent it from BALL JOINT turning.
  • Page 106 6. STEERING SYSTEM NOTE - 80 -...

  • Page 107: Hydraulic System

    7. HYDRAULIC SYSTEM 7. HYDRAULIC SYSTEM Truck model FB20-8 FB25-8 FB30-8 FB10-8 FB15-8 FB18-8 FB35-8S FB25-8LB FB25-8V FB30-8V Item Main pump ← ← ← ← Type Gear type ← ← Name TMG1A18 TMG1A20 TMG1A23 ← ← Discharge 18.9 cm /rev 21 cm /rev 24.5 cm...

  • Page 108: Main Pump

    7. HYDRAULIC SYSTEM 7.1.1 MAIN PUMP The main pump is a gear type as shown in Figure 7.1. The main pump consists of a pump body, a pair of gears, bushings and packings. To minimize the gap between the gears’ side-faces, pressure-balanced type bearings and lubrication method are used.
  • Page 109 7. HYDRAULIC SYSTEM PORT G Ｇポート LIfT SPOOL リフトスプール 油圧回路図 Hydraulic circuit diagram TILT SPOOL ティルトスプール LIfT-LOCK RELEASE リフトロック解除スクリュ SCREW PORT B2 B2ポート PORT T Ｔポート PORT A2 A2ポート PORT P Ｐポート A1ポート PORT A1 ソレノイドバルブ SOLENOID VALVE (fOR LIfT LOCK) (リフトロック用) POTENTIOMETER ポテンショメータ...

  • Page 110: Valve Control

    7. HYDRAULIC SYSTEM 7.1.3 VALVE CONTROL The control valve plungers are operated with the levers shown in Figure 7.3, with each of the levers installed on a single shaft. The bracket supporting each shaft is attached to the cowl. The movement of each lever is transmitted through the rod to the corresponding plunger.
  • Page 111 7. HYDRAULIC SYSTEM ■ Oil pressure adjustment ① Remove the plug of the check port (G) located in the inlet section of the control valve, then set there a 20 MPa {200 kgf/cm } [2901 psi] capacity oil pressure gauge. ②...

  • Page 112: Hydraulic Oil Tank

    7. HYDRAULIC SYSTEM 7.1.4 HYDRAULIC OIL TANK The hydraulic oil tank is located at the center of the frame. In the tank, a suction filter and a return filter are provided for the purpose of ensuring clean oil supply. RETURN fILTER リターンフィルタ...

  • Page 113: Lift Cylinder

    7. HYDRAULIC SYSTEM 7.1.5 LIFT CYLINDER The two lift cylinders of single-acting type are located on the outer mast frame. Each lift cylinder, consists of cylinder body, rod, piston, and cylinder cap. The piston fastened to the rod with a snap ring is provided with a wear ring and packing on its circumference.
  • Page 114 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. LOCK BOLT 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. “O”-RING 7. BUSHING 8. ROD 9. CYLINDER 10. LOCK RING 11. WEAR RING 12. PACKING 13. PISTON 14. SNAP RING 15.
  • Page 115 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. LOCK BOLT 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. “O”-RING 7. BUSHING 8. ROD 9. CYLINDER 10. LOCK RING 11. WEAR RING 12. PACKING 13. PISTON 14. SNAP RING 15.
  • Page 116 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. LOCK BOLT 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. “O”-RING 7. BUSHING 8. ROD 9. CYLINDER 10. LOCK RING 11. WEAR RING 12. PACKING 13. PISTON 14. SNAP RING 15.
  • Page 117 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. LOCK BOLT 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. “O”-RING 7. BUSHING 8. ROD 9. CYLINDER 10. LOCK RING 11. WEAR RING 12. PACKING 13. PISTON 14. SNAP RING 15.

  • Page 118: Flow Regulator Valve

    7. HYDRAULIC SYSTEM 7.1.6 FLOW REGULATOR VALVE LIfT CYLINDER (RIGHT) The flow regulator valve is located at the position as shown in Figure 7.12. It not only LIfT CYLINDER (LEfT) controls the fork lowering speed but works as a safety device in case of a rupture of the high- pressure hose.
  • Page 119 7. HYDRAULIC SYSTEM ■ Flow regulator valve operation (3.5-ton trucks) The oil returning from the lift cylinder flows into the chamber , past the chambers , and , and then back into the control valve. In this step, the more the oil flows via the hole in the piston ⑤...

  • Page 120: Tilt Cylinder

    7. HYDRAULIC SYSTEM 7.1.7 TILT CYLINDER The tilt cylinder is a double-acting type. The piston rod end is supported by the mast, and the cylinder tail by a pin on the frame. Two tilt cylinders are mounted on both sides of the truck, one at each.
  • Page 121 7. HYDRAULIC SYSTEM Fig. 7.16 Hydraulic Oil Piping (Orbitrol type) - 95 -...
  • Page 122 7. HYDRAULIC SYSTEM Fig. 7.17 Hydraulic Oil Piping (EPS type) - 96 -...

  • Page 123: Maintenance

    7. HYDRAULIC SYSTEM 7.2 MAINTENANCE 7.2.1 MAINTENANCE OF PUMP ■ Cautions Before disassembling the pump, check for oil leaks from the oil seal, the mating section of the pump body and cover, and other areas. Remove rust, dust and dirt at the shaft end and the pump body. Failure to do so might damage the parts or allow them to enter the inside of the pump during disassembly, thus misleading your diagnosis about the pump.
  • Page 124 7. HYDRAULIC SYSTEM ③ Remove the four fitting bolts. Fig. 7.20 ④ Remove the rear cover by tapping the side face of the pump body with a plastic mallet. If the gaskets remain inside the pump body, move them toward the rear cover side. Fig.
  • Page 125 7. HYDRAULIC SYSTEM ⑦ Put the mark “R” on the driven gear shaft end and remove the drive gear. Fig. 7.24 ⑧ Holding the front side plate, remove the drive gear. Fig. 7.25 ⑨ Put the mark “FV” on the front side plate at the drive gear side, and remove the side plate.
  • Page 126 7. HYDRAULIC SYSTEM ⑪ Remove the oil seal from the front cover. Fig. 7.28 - 100 -...
  • Page 127 7. HYDRAULIC SYSTEM CAUTION Inspections are carried out to locate the cause of troubles and to determine whether parts are reusable or not. Inspections must be carried out only by personnel with a certain amount of knowledge and experience in hydraulic equipment. The “useful limit”...
  • Page 128 7. HYDRAULIC SYSTEM Name of component Items to be checked Remarks (cause and others) (continued from the (c) Check for discoloration, undue wear, Contaminants in oil, too high oil preceding page) or roughness on the gears. temperature (120°C [248°F] or higher), too frequently idle operations Useful limit 0.1 mm [0.0040 in] or less...
  • Page 129 7. HYDRAULIC SYSTEM (2) Pump reassembly ① As shown in Figure 7.29, hold the front cover in a vice. Fig. 7.29 ② Install a new gasket in the groove in the front cover. Fig. 7.30 ③ Install a new “E” gasket in the groove in the front cover, referring to Figure 7.32.
  • Page 130 7. HYDRAULIC SYSTEM ④ Install the pump body on the front cover, referring to Figure 7.34. Fig. 7.33 Counterclockwise rotation: Drive side front side Counterclockwise rotation: Clockwise rotation: Rear side Rear side Suction port Clockwise rotation: (larger radius) front side Discharge port (smaller radius) Projection (to be...
  • Page 131 7. HYDRAULIC SYSTEM ⑥ Install the drive gear in the pump body, with its splines pointed downward. Fig. 7.37 ⑦ Install the drive gear in the pump body, as shown in Figure 7.39. Fig. 7.38 CAUTION The sketch shows the engagement of the left-rotation pump. Since the tooth profiles of the two gears are asymmetric, install them with their larger pressure angle sides pointed to each other.
  • Page 132 7. HYDRAULIC SYSTEM ⑧ Install the rear side plate in the pump body, as shown in Figure 7.36. Fig. 7.40 ⑨ Apply grease on a new gasket in some points and install the gasket in the rear cover groove. Fig. 7.41 Gasket groove ”E”...
  • Page 133 7. HYDRAULIC SYSTEM ⑪ Install the rear cover in the pump body with its gasket pointed downward. Fig. 7.44 ⑫ Install the four bolts and tighten them to the specified torque: Tightening torque: 88.3 - 98 N-m {9 - 10 kgf-m} [782 - 867 lbf-in.] Fig.
  • Page 134 7. HYDRAULIC SYSTEM ⑭ Secure the oil seal with a snap ring and remove the oil seal guide. Cross section of (front “C” lock ring cover) Side at which corner is chamfered. Oil seal Fig. 7.49 Fig. 7.50 ø4 [0.16] Unit: mm ø17 ø4...

  • Page 135: Trial Run

    7. HYDRAULIC SYSTEM 7.2.2 TRIAL RUN Trial runs should be performed to run in an assembled pump and to ensure that it delivers the specified performance. Trial runs are preferably carried on a special test stand, but may be carried out with the pump on the machine using the following manner: (If the pump were disassembled because of a seized pump or an abnormally worn internal component, be sure to change the hydraulic oil and replace the filters with new ones before trying...

  • Page 136: Troubleshooting Guide

    7. HYDRAULIC SYSTEM 7.2.3 TROUBLESHOOTING GUIDE If any problem occurs in the hydraulic system, locate the cause of the problem and take necessary measures, referring to the tables given below. (1) Control valve Problem Cause Remedy The control flow is not a specified Relief valve malfunctioning Readjust.

  • Page 137: Load Handling System

    8. LOAD HANDLING SYSTEM 8. LOAD HANDLING SYSTEM Truck model FB10-8 FB15-8 FB20-8 FB25-8LB F30-8 FB35-8S FB18-8 FB25-8 FB25-8V FB30-8V Item Name VM-7P1 VM-7P4 VM-7P5 VM-7P7 VM-7P9 Type Roller type 2-step telescopic mast with free lift ← ← ← Max. standard 3000 mm lifting height [118.1 in.]...

  • Page 138: General Description

    8. LOAD HANDLING SYSTEM 8.1 GENERAL DESCRIPTION The load handling system is of roller type having a two-staged telescopic mast. It consists of an outer channel, inner channel, and carriage. 8.1.1 OUTER AND INNER CHANNELS Outer and inner channels are of welded construction. The lower part of the outer channel is provided with a support to be used for installing the mast assembly on the drive axle.

  • Page 139: Carriage

    8. LOAD HANDLING SYSTEM 1. INNER CHANNEL 2. OUTER CHANNEL 3. END ROLLER 4. SHIM 5. SNAP RING 6. END ROLLER 7. SHIM 8. SLIPPER 9. SHIM 10. PIN 11. CAP 12. BUSHING Fig. 8.2 Outer and Inner Channels (VM-7P4, VM-7P7, VM-7P9) 8.1.2 CARRIAGE The carriage has end rollers that roll along the inside of the inner channel, each installed on the end roller shaft by bearings.
  • Page 140 8. LOAD HANDLING SYSTEM 1. FORK 2. CARRIAGE 3. END ROLLER 4. SHIM 5. SNAP RING 6. SIDE ROLLER 7. SHIM 8. SPACER VM-7P4, VM-7P7, VM-7P9 VM-7P1 Fig. 8.3 Carriage - 114 -...

  • Page 141: Locations Of Rollers

    8. LOAD HANDLING SYSTEM 8.1.3 LOCATIONS OF ROLLERS End and side rollers are installed on the carriage. The end rollers support longitudinal load and the side rollers support lateral load so that the inner channel and carriage are raised and lowered smoothly. Fig.
  • Page 142 8. LOAD HANDLING SYSTEM Fig. 8.5 Locations of Rollers (2- to 3.0-ton Trucks) - 116 -...
  • Page 143 8. LOAD HANDLING SYSTEM Fig. 8.6 Locations of Rollers (3.5-ton Trucks) - 117 -...

  • Page 144: Maintenance

    8. LOAD HANDLING SYSTEM 8.2 MAINTENANCE 8.2.1 ADJUST LIFT CYLINDER ROD WITH SHIMS After the lift cylinders, inner channel, or outer channel is replaced, the lift cylinder rod length needs to be adjusted. (1) Install a piston head on the rod of each lift cylinder without using shims.
  • Page 145 8. LOAD HANDLING SYSTEM (3) Make sure that the clearance between the INNER CHANNEL STOPPER carriage and the inner channel stoppers is 0 mm when the fork is raised to the maximum lifting height Note 1: When the mast lifting height is over 4000 mm [157.5 in.], the dimension CARRIAGE STOPPER...
  • Page 146 8. LOAD HANDLING SYSTEM 8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE (1) Put a pallet to the fork and stop the truck on a level surface. (2) Lower the forks with the pallet to the ground. (3) Remove the joint link of the mast side anchor pin and remove the chain from the sheave.
  • Page 147 8. LOAD HANDLING SYSTEM (8) Extend the lift cylinder rods so that the inner channel bottom projects the upper section of the carriage. Groove for balls (9) Bring the truck close to the carriage side so that each roller enters inside of the outer channel.

  • Page 148: Procedure For Replacing Rollers At Carriage Side

    8. LOAD HANDLING SYSTEM 8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE (1) Remove the carriage from the inner channel in the same procedure as described in “8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE.” (2) Move the truck to a level surface and put the both rear wheels on the bench of 250 –...

  • Page 149: Procedure For Adding Or Subtracting Shims

    8. LOAD HANDLING SYSTEM 8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS Move the inner channel and carriage to one side of the outer channel. Measure the clearance between the end roller at the opposite side and each channel. Clearance between roller and channel: 0 to 0.5 mm [0 to 0.197 in.] 0 to 0.5 mm at upper side Make contact with one side.
  • Page 150 8. LOAD HANDLING SYSTEM NOTE - 124 -...

  • Page 151: Electric System

    9. ELECTRIC SYSTEM 9. ELECTRIC SYSTEM Headlights Capacity 48 V - 40 W Front combination lights Capacity Side marker lights 48 V - 10 W Turn signal lights 48 V - 25 W Rear combination lights Capacity Tail/brake lights 48 V - 10 W/25 W Turn signal lights 48 V - 23 W Back-up lights...

  • Page 152: Relay Unit

    9. ELECTRIC SYSTEM 9.1.1 RELAY UNIT The relay unit is a semi-conductor switch that uses transistors to perform the switching. The mechanical switch input signals cause the relay unit to turn the lights and electric devices on the truck on and off. View looking from A から見る...
  • Page 153 9. ELECTRIC SYSTEM TURN SIGNAL, RIGHT ターンシグナル右 TURN SIGNAL, LEfT ターンシグナル左 HEADLIGHTS ヘッドライト TAIL/SIDE MARKER テール、クリアランス 3.5W＋0.1A CHIME チャイム BRAKE SIGNAL OUTPUT ブレーキ信号出力 20 W バックランプ BACK-UP LIGHT ＋ 35 W BEACON LIGHT パトライト *オプション装備 * OPTIONAL EQUIPMENT チャイム CHIME 0.15A 0.15 A ＋...

  • Page 154: Lights

    9. ELECTRIC SYSTEM 9.1.2 LIGHTS The truck is equipped with headlights, front combination light assemblies, rear combination light assemblies and a work light. They can be turned on and off with the integrated turn signal and light switch lever, as shown in Figure 9.3 LIGHT SWITCH TURN SIGNAL f/R LEVER...
  • Page 155 9. ELECTRIC SYSTEM (1) Light Switch The light switch is incorporated into the right lever of the integrated turn signal and light switch assembly. The side marker lights, tail lights and head lights can be turned on and off by rotating the lever.
  • Page 156 9. ELECTRIC SYSTEM (2) Turn signal switch The turn signal switch is incorporated into the right lever of the turn signal and light switch assembly. When the lever is moved forward or backward, the left or right turn signal lights flash accordingly.
  • Page 157 9. ELECTRIC SYSTEM HEAD LIGHT REAR COMBINATION LIGHT ヘッドランプ リヤコンビネーションランプ fRONT COMBINATION フロント LIGHT コンビネーション ランプ 1 - to 1.8-ton trucks 1～1.8t 2- to 3.5-ton trucks 2～3.5t View looking from A から見る Fig. 9.6 Locations of lights - 131 -...
  • Page 158 9. ELECTRIC SYSTEM (3) Head lights The head lights are installed on the upper part of the front legs of the overhead guard. ① ② ⑤ ④ 1. LENS ③ 2. RIM 3. HOUSING ⑥ 4. REFLECTOR 5. GASKET 6. BULB Sectional view A - A 断面...
  • Page 159 9. ELECTRIC SYSTEM (4) Front and rear combination lights The structures of the front and rear combination lights are shown in Figure 9.8. The front combination light consists of a turn signal light and a side marker light. The rear combination has a turn signal light, a brake light and a tail light incorporated in it. ■...
  • Page 160 9. ELECTRIC SYSTEM ■ Replacing light bulbs If you want to remove a bulb, push it into the SCREW スクリュ reflector and then turn to the left. REfLECTOR リフレクタ If you want to install a new bulb, push it into the reflector and then turn to the right.
  • Page 161 TROUBLESHOOTING TABLE OF CONTENTS 1. CONTROL CIRCUITS ....................... 1 1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM ..........1 1.2 LOAD HANDLING SYSTEM ....................5 1.3 POWER STEERING SYSTEM .................... 8 1.4 OTHERS ..........................9 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING ....
  • Page 162 4. PARAMETER SETTING ....................73 4.1 SETTING THE PARAMETERS ..................73 4.2 PARAMETER SETUP SCREEN ..................73 4.3 KEYPAD ..........................73 4.4 SCREEN OPERATION ....................... 74 4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING ........78 4.6 SETTING THE PASSWORDS.................... 80 5. DESCRIPTION OF THE FUNCTIONS ..............

  • Page 163: Control Circuits

    1. CONTROL CIRCUITS 1. CONTROL CIRCUITS 1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM Circuit Diagram Description 1. Drive motor inverter unit CN1D-7 and Drive motor inverter unit 走行コントローラ CN1D-8 terminals CN1D-8 CN1D-7 When the key switch is turned on, the battery voltage is applied to these terminals and the inverter unit is energized.
  • Page 164 1. CONTROL CIRCUITS Circuit Diagram Description 4. Parking brake switch 走行コントローラ Drive motor inverter unit (1) When the parking brake lever is pulled, the parking brake switch is turned on and the “P” light on the LCD panel comes on. This keeps the truck from moving.
  • Page 165 1. CONTROL CIRCUITS Circuit Diagram Description 7. RF relay (option) 走行コントローラ Drive motor inverter unit リレーユニット (1) Activates the forward travel buzzer. Relay unit (2) When the F/R lever is placed in the F position, the battery supplies voltage to the CN1D-33 CN1D-33 terminal.
  • Page 166 1. CONTROL CIRCUITS Circuit Diagram Description 10. Speed control switch (“turtle” button) スイッチパネル Switch panel (1) When speed control switch is pressed, the turtle mark appears on the LCD panel, activating travel speed limit feature. If the speed control switch is pressed with the S.P.E スピード...

  • Page 167: Load Handling System

    1. CONTROL CIRCUITS 1.2 LOAD HANDLING SYSTEM Circuit Diagram Description 1. Pump motor inverter unit CN1P-7 and Pump motor inverter unit 荷役コントローラ CN1P-8 terminals CN1P-8 CN1P-7 When the key switch is turned on, the battery voltage is present at these terminals and the inverter unit is energized.
  • Page 168 1. CONTROL CIRCUITS Circuit Diagram Description Lift lock solenoid Pump motor inverter unit 荷役コントローラ (1) When the seat switch and the load handling CN1P-35 neutral safety switch are engaged, the lift lock solenoid is energized. (2) The voltage between the CN1P-35 terminal and the negative (-) terminal.
  • Page 169 1. CONTROL CIRCUITS Circuit Diagram Description Truck model selection terminals The relevant truck model is selected by turning on or off each model selection switch. MODE SEL 1 MODE SEL 2 1 to 1.8 ton trucks 2 to 2.5 ton trucks 3 to 3.5 ton trucks...

  • Page 170: Power Steering System

    1. CONTROL CIRCUITS 1.3 POWER STEERING SYSTEM Circuit Diagram Description 1. PS motor controller CN1E-17 terminal PS motor controller PSコントローラ When the key switch is turned on, the battery CN1E-17 voltage is present at this terminal and the PS motor controller is energized. RW11 2.

  • Page 171: Others

    1. CONTROL CIRCUITS 1.4 OTHERS Circuit Diagram Description 1. Seat switch Drive motor inverter unit 走行コントローラ (1) 4.6 V is supplied from CN1D-16. (2) When the operator sits in the operator’s seat, the seat switch turns on, releasing the interlock. (4.6 V→0 V) 2.
  • Page 172 1. CONTROL CIRCUITS Circuit Diagram Description 3. CN1D-24, CN1P-24, CN1P-22, and CN1E-34 Excluding terminals PS motor trucks with Pump motor Drive motor controller an Orbitrol inverter unit When the battery is connected, the battery inverter unit steering voltage is present at these terminals. system.

  • Page 173: Electrical Parts And Procedures For Checking

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.1 PART LOCATION DIAGRAM AND TERMINAL LOCATIONS Note: Trucks with an Orbitrol steering system do not have an EPS unit. ■ 1- to 1.8-ton trucks (Excluding those with an Orbitrol steering system.) Fast charge resistance (RCH) Fuse (F1) 急速充電抵抗(RCH)
  • Page 174 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING ■ 1- to 3.5-ton trucks (Excluding those with an Orbitrol steering system.) PW motor terminal PV motor terminal PU motor terminal DW motor terminal CN1P DV motor terminal CN2P DU motor terminal Positive terminal Inverter unit (drive motor) Negative terminal...

  • Page 175: Procedure For Checking The Controller Assembly Separately

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2 PROCEDURE FOR CHECKING THE CONTROLLER ASSEMBLY SEPARATELY 2.2.1 CONTROLLER ASSEMBLY The controller assembly controls the drive, pump and power steering motors according to signals from the F/R lever, accelerator pedal, load handling levers, and steering wheel. It consist of a contactor which turns the battery power supply on and off, one EPS controller and two inverter units.
  • Page 176 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING ■  R emoving the inverter unit (1-ton class trucks excluding those with an Orbitrol steering system) Pass screws (M4 x 20 mm or longer) through tapped through-holes in the aluminum inverter base and remove the inverter unit from its aluminum fin.
  • Page 177 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING ■  R emoving the inverter unit (1-, 2- and 3-ton class trucks with an Orbitrol steering system) Pass screws (M4 x 20 mm or longer) through tapped through-holes in the aluminum inverter base and remove the inverter unit from its aluminum fin.

  • Page 178: Inverter Unit

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.2 INVERTER UNIT The truck has two inverter units for the drive and pump motors, each having output terminals U, V and W to the motor and power supply terminals (+) and (-). The pump motor inverter unit of 1-ton class trucks (excluding those with an Orbitrol steering system) is an S-type.
  • Page 179 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING Checking procedure (using an analog multimeter) ① Measure the resistance of each terminal according to the table given below using an analog multimeter with the resistance range set to x1000 ohms. ② Determine whether the inverter unit is defective or not according to the resistance value measured at each terminal.

  • Page 180: Eps Motor Controller

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.3 EPS MOTOR CONTROLLER (excluding trucks with an Orbitrol steering system) Note: Trucks with an Orbitrol steering system do not have an EPS motor controller. The EPS motor controller uses a motor-wire connector with a VB (+) wire and an N (-) wire as an external harness.
  • Page 181 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING Checking procedure (using an analog multimeter) ① Measure the resistance of each terminal according to the table given below using an analog multimeter with the resistance range set to x1000 ohms. ② Determine whether the inverter unit is defective or not according to the resistance value measured at each terminal.

  • Page 182: Mc Contactor

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.5 MC CONTACTOR Checking procedure ① Check the mechanical action Check the contactors separately. • Visually check the contacts, coil and connectors for damage • or remarkable discoloration. Replace any failed MC contactor with a new one. •...

  • Page 183: Fuse (F1)

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.7 FUSE (F1) If too large a current flows in the main circuit, the Cable side ケーブル側 fuse (F1) will blow to prevent the controller from being Contact side コンタクタ側 damaged or catching fire. Applicable truck model Symbol Type...

  • Page 184: Motor Rotation Sensor

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.9 MOTOR ROTATION SENSOR The motor rotation sensor is a magnetic induction sensor which detects the alternating voltage generated by the passing of the teeth in the rotor opposite the motor shaft. Two motor rotation sensors are installed on the drive motor to detect the direction of rotation of the motor.

  • Page 185: Lift Potentiometer

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.10 LIFT POTENTIOMETER The lift potentiometer is used to control the lift speed of the forks and outputs a signal according to the tilt angle of the lift lever. The potentiometer is located in the lift section of the control valve. Checking procedure Control valve Resistance (using a digital multimeter)

  • Page 186: Steering Potentiometer

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.11 STEERING POTENTIOMETER The steering potentiometer is used to detect the turning angle of the left rear wheel. It is located on the top of the left-side king pin on the rear axle. The motor speed is controlled according to the angle at which the left rear wheel to prevent it from exceeding the preset value.

  • Page 187: Lcd Panel

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING ■  W hen you do not have a steering memory switch (1) With the truck key switch off, connect one end of a wire to the 3P coupler (BR9 0.6 mm [0.024 in.] terminal) near the center of the floorboard.

  • Page 188: Cm Contactor

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.13 CM CONTACTOR Coil Contact B 3-phase AC The CM contactor is used for the on-board battery charger. During charging, 3-phase AC is flowing through the contactor to open the contact B, thus shutting off the control circuit power supply for the controllers and other devices.

  • Page 189: Control Switch Panel

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.14 CONTROL SWITCH PANEL Checking procedure (1) Checking the truck speed control switch (“turtle” button) Measure the voltage between the CN9-1-16 terminal (WL) and the CN9-1-8 terminal (Gy) on • the LCD panel. The voltage reading must be as follows: 0 V when the turtle button is pressed and 5 V when the button is not pressed.

  • Page 190: Battery Charger Switch Panel

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.15 BATTERY CHARGER SWITCH PANEL Checking procedure (1) Checking the power supply Measure the voltage between the CN1-4 (RG) and the CN9-1-5 (BR) on the LCD panel. • The voltage reading should be 5 V. (2) Checking the start button Measure the voltage between the CN1-13 (WR) and the CN9-1-5 (BR) on the LCD panel.

  • Page 191: Charge Rectification Diode

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.16 CHARGE RECTIFICATION DIODE * The symbols are given on the product surface. The diode is used to rectify the current in the charge circuit. Part number Model Applicable truck model 177P2-62401 PT200S8 All models Checking procedure Resistance range x 1 Ω...

  • Page 192: Checking Charge Timer

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.17 CHECKING CHARGE TIMER Check the secondary timer for operation using the following procedure. If any fault is found, replace the LCD panel with a new one. ○ : Lighting, △ : Flashing, × : Off When the charge timer is normal: Super equalizing CM contactor...

  • Page 193: Motor Thermo-Sensor

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.18 MOTOR THERMO-SENSOR The drive and pump motors are provided with thermo-sensors to check the motor temperature. If the detection value of a thermo-sensor is judged to be abnormal, the controller limits the electric current to the corresponding motor.

  • Page 194: F/R Switch

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.19 F/R SWITCH Checking procedure Measure the resistance between terminals with the multimeter in the resistance range (minimum range). Standard value IG1 (GND) ① 0 Ω for F ② ∞ for positions VF (Inverter CN1-8) other than F IG1 (GND) ①...

  • Page 195: Checking Voltage On The Lcd Panel

    2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING 2.2.20 CHECKING VOLTAGE ON THE LCD PANEL The FB-8 series trucks have controllers completely sealed with the couplers made into waterproof type. This makes it difficult to measure the voltage of the controller system directly.
  • Page 196 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING Drive system Key switch Parking lever Forward switch Accelerator Terminal Remarks Released Full throttle Accelerator 1 POT output common to all 0.97 0.97 0.97 4.08 voltage (V) models. Accelerator 2 POT output common to all 0.51 0.51 0.51...

  • Page 197: Troubleshooting Guide

    3. TROUBLESHOOTING GUIDE 3. TROUBLESHOOTING GUIDE 3.1 HOW TO USE THIS GUIDE Check the LCD panel for any error codes. If an error code is displayed on the LCD panel, see “3.5 TROUBLESHOOTING BY ERROR CODE”. If no error code is displayed, see “3.6 TROUBLESHOOTING BY PROBLEM”. Error code Start trouble diagnosis 2.

  • Page 198: Checking Before Troubleshooting

    3. TROUBLESHOOTING GUIDE 3.2 CHECKING BEFORE TROUBLESHOOTING (1) Checking wiring and terminals for looseness If a bolt or nut of the controller gets loose, that part will be heated and burn out. When you find a loosened bolt or nut or a heated area, polish the contacting areas and retighten the bolt/nut. Give close watch especially on the parts where a large current flows such as the minus terminal, fuses, motors, contactors, etc.
  • Page 199 3. TROUBLESHOOTING GUIDE < ERROR CODES SHOWN BY LED > The error code numbers are displayed by an orange LED blinking on the controller CPU board. Error codes are displayed as 2-digit numbers (decimal system). The 1’s digit and 10’s digit blink at an interval of 0.5 seconds.

  • Page 200: Error Code Table

    3. TROUBLESHOOTING GUIDE 3.3 ERROR CODE TABLE - 38 -...
  • Page 201 3. TROUBLESHOOTING GUIDE - 39 -...
  • Page 202 3. TROUBLESHOOTING GUIDE - 40 -...
  • Page 203 3. TROUBLESHOOTING GUIDE - 41 -...
  • Page 204 3. TROUBLESHOOTING GUIDE - 42 -...
  • Page 205 3. TROUBLESHOOTING GUIDE - 43 -...
  • Page 206 3. TROUBLESHOOTING GUIDE - 44 -...
  • Page 207 3. TROUBLESHOOTING GUIDE - 45 -...
  • Page 208 3. TROUBLESHOOTING GUIDE - 46 -...
  • Page 209 3. TROUBLESHOOTING GUIDE - 47 -...

  • Page 210: Lcd Panel System Errors

    3. TROUBLESHOOTING GUIDE 3.4 LCD PANEL SYSTEM ERRORS Error Icon Description Problem Cause Corrective Action Code displayed Check BW211 and LY212 between the This error code is displayed when no current is The travel, load- LCD panel and the CM contactor. Check the being drawn by the CM contactor or the “a”- CM relay handling and...

  • Page 211: Troubleshooting By Error Code

    3. TROUBLESHOOTING GUIDE 3.5 TROUBLESHOOTING BY ERROR CODE This section explains how to perform troubleshooting using the error codes displayed on the LCD panel. < How to use this troubleshooting guide > ① Take Step ① and see if there is a problem. If a problem is found, take the corrective action in the right column.
  • Page 212 3. TROUBLESHOOTING GUIDE Resets when the seat switch is turned ON (i.e., : Safety interlock (after the key switch is turned when the operator is seated in the operator’s seat). Resets when the key switch is turned ON while the : Safety interlock (when the key switch is turned seat switch is on (i.e., the operator is seated in the operator’s seat).
  • Page 213 3. TROUBLESHOOTING GUIDE Resets when the temperature drops to less than : Drive motor temp. abnormal 165°C [329°F]. Resets when the temperature drops to 145°C : Drive motor temp. too high [293°F] or below. ① Turn the key switch OFF and allow the motor to cool down for at least 30 minutes.
  • Page 214 3. TROUBLESHOOTING GUIDE (10) : Rotation sensor defective Automatically resets when the input returns to The A or B phase pulse is missing. normal. The A and B phase pulses are missing. : Rotation sensor defective Automatically resets when the input returns to Bearing defective (Stall signals detected normal.
  • Page 215 3. TROUBLESHOOTING GUIDE Automatically resets when the input returns to (12) : Accelerator signal wire short-circuited normal. ① Check the voltage at CN2D-8 and -9 terminals on the drive motor inverter unit. ② Check the drive motor inverter unit (CN2D-8, -9) Correct the wiring.
  • Page 216 3. TROUBLESHOOTING GUIDE (15) : Rapid charging of capacitor abnormal (Improper charging of capacitor between P and Resets when the key switch is turned OFF. N terminals) ① Troubleshoot the problem according to Error Code 218. ② Troubleshoot the problem according to Error Code 418.
  • Page 217 3. TROUBLESHOOTING GUIDE (18) : Contactor coil broken Resets when the key switch is turned OFF. (Blown fuse) Repair the contactor. ① Check the contactor coil. Replace the F1 fuse, if needed. ② Check the F1 fuse. ③ Check the harness between CN1D-22/CN1D-35 and CNMC (contactor coil connector) on the drive motor Correct the wiring.
  • Page 218 3. TROUBLESHOOTING GUIDE Automatically resets when the input returns to (22) : LCD panel data reception error (Communication wire broken) normal. ① Check the connectors for the CN1D-1, -3, -13, -14, and -15 terminals on the drive motor inverter unit for Install properly.
  • Page 219 3. TROUBLESHOOTING GUIDE (25) : Load short circuit (Motor interphase short- Resets when the key switch is turned OFF. circuit) Resets when the key switch is turned OFF. : Overcurrent (Hardware OCL detected) ① Check the drive motor cable terminals U, V, and W Remove the foreign matter.
  • Page 220 3. TROUBLESHOOTING GUIDE 2. Load handling system (including trucks with an Orbitrol steering system) Resets when the load-handling levers are put in : Load-handling system neutral interlock N点滅 neutral. ① Put the load-handling levers in neutral. ② Check the lift potentiometer voltage. Repair the lift potentiometer or wiring.
  • Page 221 3. TROUBLESHOOTING GUIDE Automatically resets when the input returns to : Pump motor thermosensor defective AD input range abnormal normal. Connect securely. ① Check the pump motor thermosensor for looseness. ② Check the voltage between CN2P-6 and CN2P-17 Repair the pump motor or wiring. on the pump motor inverter unit.
  • Page 222 3. TROUBLESHOOTING GUIDE Resets when the key switch is turned OFF. : Pump motor inverter unit U-phase FET open Resets when the key switch is turned OFF. : Pump motor inverter unit V-phase FET open Resets when the key switch is turned OFF. : Pump motor inverter unit W-phase FET open Retighten.
  • Page 223 3. TROUBLESHOOTING GUIDE (10) : Pump motor inverter unit upper/lower FET Resets when the key switch is turned OFF. short Resets when the key switch is turned OFF. : Pump motor inverter unit upper FET short Resets when the key switch is turned OFF. : Pump motor inverter unit lower FET short ①...
  • Page 224 3. TROUBLESHOOTING GUIDE (12) : Drive data reception error (Communication Resets when the key switch is turned OFF. wire broken) ① Check the connectors for CN1D-1, -3, -13, -14, and -15 terminals on the drive motor inverter unit for Connect securely. looseness.
  • Page 225 3. TROUBLESHOOTING GUIDE 3. EPS Power steering system : EPS transistor short-circuited (at startup) Resets when the key switch is turned OFF. Resets when the key switch is turned OFF. : EPS transistor short-circuited (after startup) Resets when the key switch is turned OFF. : EPS transistor short-circuited (lower) Resets when the key switch is turned OFF.
  • Page 226 3. TROUBLESHOOTING GUIDE Resets when the key switch is turned OFF. : Torque sensor defective (shorted) Resets when the key switch is turned OFF. : Torque sensor defective (open) ① Check the torque sensor connector for looseness. Connect securely. ② Check the harness between the EPS motor controller Correct the wiring.
  • Page 227 3. TROUBLESHOOTING GUIDE Automatically resets when the input returns to : Data reception abnormal normal. ① Check the connectors for the CN1E-8, -9, -10, -11, -12 terminals on the EPS motor controller for Connect securely. looseness. ② Check the harness for those connectors. Correct the wiring.

  • Page 228: Troubleshooting By Problem

    3. TROUBLESHOOTING GUIDE 3.6 TROUBLESHOOTING BY PROBLEM (1) The LCD panel is blank. 101(RY) Key switch ... Turn it ON. LCD panel CN1-11 40 V or LCD panel more Below10 V 101(RY) Key switch ... Turn it ON. RY101 Key switch 40 V or more Below10 V...
  • Page 229 3. TROUBLESHOOTING GUIDE (2) MC contactor does not work. (The travel, load handling, and EPS systems are inoperative.) 11(RW) Key switch ... Turn it ON. CN1D-7,8 Drive motor Drive motor inverter inverter 11(RW) Pump motor inverter Key switch ... Turn it ON. CN1D-7,8 All of these are Pump motor...
  • Page 230 3. TROUBLESHOOTING GUIDE (3) MC contactor works but the truck won’t travel. 15(O) Key switch ......Turn it ON. • Parking brake switch F/R lever ....Shift into F or R. • O 15 Parking brake lever ....Release. CN1D-5 •...
  • Page 231 3. TROUBLESHOOTING GUIDE (4) The truck travels, but does not gain speed. Is the “turtle” mark Key switch ......Turn it ON. Turtle invisible? mark visible 75(WL) Key switch .. Turn it ON. “Turtle” mark Switch panel Turtle button ...Press. invisible LCD panel CN9-1-16...
  • Page 232 3. TROUBLESHOOTING GUIDE (5) Only the lift lever does not work. In maintenance mode: Key switch ....Turn it ON. C (Lift potentiometer Lift potentiometer output voltage) Below 0.2 V GR189 4.8 V or more WR188 YL94 0.5 to below 1.1 V In maintenance mode: Key switch ....
  • Page 233 3. TROUBLESHOOTING GUIDE (8) Hard steering ■ EPS steering system In maintenance mode: Key switch ....Turn it ON. Torque sensor D (Torque sensor output Turn the steering wheel. Below 0.2 V L160 voltage) 4.8 V or more G161 W162 1.0 to 3.8 V EPS motor Key switch ....
  • Page 234 3. TROUBLESHOOTING GUIDE NOTE - 72 -...

  • Page 235: Parameter Setting

    4. PARAMETER SETTING 4. PARAMETER SETTING 4.1 SETTING THE PARAMETERS Take the following considerations into account when changing the parameters. 1. Be careful when increasing the acceleration level or load-handling speed levels, because that may reduce the number of hours you can operate the truck, the motor may overheat, or other problems may occur.

  • Page 236: Screen Operation

    4. PARAMETER SETTING 4.4 SCREEN OPERATION INITIAL PARAMETER SETUP SCREEN While pressing and holding the Mode button and the “+” button on the keypad, turn on the key switch. The INITIAL PARAMETER SETUP screen shown above will be displayed. Note that the MC contactor is not activated at this point. Press the “+”...
  • Page 237 4. PARAMETER SETTING PARAMETER GROUP SETUP SCREEN Press this turtle button to return to the INITIAL PARAMETER ITEM PARAMETER SETUP screen. SETUP SCREEN Parameter item Setting Press the Mode button when the PARAMETER GROUP SETUP screen is displayed. The first parameter item in the selected parameter group will be displayed.
  • Page 238 4. PARAMETER SETTING PARAMETER ITEM SETUP SCREEN After setting a parameter item, press Press and hold and hold the Mode button when the this button. PARAMETER SETUP PARAMETER ITEM SETUP screen is COMPLETE SCREEN displayed. The PARAMETER SETUP COM- PLETE screen (shown on the left) will be displayed.
  • Page 239 4. PARAMETER SETTING - 77 -...

  • Page 240: Supplementary Information About Level Setting

    4. PARAMETER SETTING 4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING (1) PARAMETER 1 - No. 4 “Lift inching level” If the controller’s CN1P-20 terminal is turned ON, the upper limit of the conduction ratio during lifting operations will be according to the setting of this parameter, thus slowing down the lifting speed. Note: A standard harness does not have any wiring going to this terminal.
  • Page 241 4. PARAMETER SETTING (4) PARAMETER 1 - No. 14 “Steering SSC speed level” This function starts to gradually limit the truck speed when the tire steering angle reaches 30 degrees left or right from the center position. It eventually limits the truck speed to a preset level when the tire steering angle reaches 60 degrees.

  • Page 242: Setting The Passwords

    4. PARAMETER SETTING 4.6 SETTING THE PASSWORDS Two different passwords can be specified. These two passwords are factory set to “0000”. KEYPAD Low-speed travel (turtle) button Switches between PASSWORD SETUP screens 1 and 2 (when pressed at the same time as the S.P.E button). S.P.E button Switches between PASSWORD SETUP screens 1 and 2 (when pressed at the same time as the Low-Speed Travel...

  • Page 243: Description Of The Functions

    5. DESCRIPTION OF THE FUNCTIONS 5. DESCRIPTION OF THE FUNCTIONS (1) Travel speed control while turning (Steering SSC) • Controls the motor speed so that the truck does not exceed the travel speed specified according to the angle of the rear left wheel (steering potentiometer voltage) while turning. <Speed control for each steering angle range>...
  • Page 244 5. DESCRIPTION OF THE FUNCTIONS (5) Regenerative control (a) Switchback regeneration • Regenerative braking occurs when the F/R lever is switched from forward to reverse or vice versa while the accelerator pedal is pressed. <Activation conditions> See the table below. (b) Brake OFF regeneration •...

  • Page 245: Electric Wiring

    6. ELECTRIC WIRING 6. ELECTRIC WIRING The electric components of the truck are wired using several types of wire harnesses and color coded by circuit (wire number). The wire harnesses are connected with connectors (2 types) or screws. Table 6.1 Color symbols and examples Black W 110 Wire...
  • Page 246 6. ELECTRIC WIRING NOTE - 84 -...
  • Page 247 6. ELECTRIC WIRING to LCD PANEL 102-1 101-1 100-1 CN9-1 to F/R SWITCH to KEY SWITCH CN9-2 (101) to HORN SWITCH (100) 141-1 to LIGHTING SWITCH to CONTROL SWITCH PANEL to REAR WORK LIGHT SWITCH (OPTION) 81-1 82-1 OPTION 108-1 141-2 to WIRE HARNESS, OVERHEAD GUARD (LEFT)
  • Page 248 6. ELECTRIC WIRING to LCD PANEL 101-1 102-1 to STEERING CN9-1 100-1 ENCODER to F/R SWITCH (101) CN9-2 (100) (102) (117) to HORN SWITCH 141-1 to KEY SWITCH to LIGHTING SWITCH to CONTROL SWITCH PANEL to REAR WORK LIGHT SWITCH (OPTION) 81-1 82-1 OPTION...
  • Page 249 6. ELECTRIC WIRING to RELAY RK リレーRKへ 11-7 102-5 111-2 11-4 100-7 to PARKING ALARM パーキングアラームへ to RELAY PO リレーPOへ to CONTROLLER コントローラ CN1E TERMINAL (P) ターミナル(P)へ LB(137) RG(102-3) 100-2 R(5) to WIRE HARNESS, ワイヤハーネス・ to RELAY UNIT リレーユニットへ SEAT SWITCH オプション...
  • Page 250 6. ELECTRIC WIRING to RELAY RK リレーRKへ 11-7 102-5 111-2 to RELAY PO リレーPOへ to PARKING ALARM パーキングアラームへ 100-2 LB(137) RG(102-3) to WIRE HARNESS, ワイヤハーネス・ to RELAY UNIT リレーユニットへ SEAT SWITCH OPTION シートスイッチへ オプション YB(30) WY(168) 111-1 98-1 11-5 102-1 11-4 WG(169) 109-1...
  • Page 251 6. ELECTRIC WIRING to RELAY PO2 リレーPO2へ to RELAY RK リレーRKへ 100-8 208-1 to RELAY PO1 リレーPO1へ 11-2 102-5 111-2 100-2 to PARKING ALARM パーキングアラームへ 115-4 to WIRE HARNESS, ワイヤハーネス・ LB(137) 100-7 to RELAY UNIT リレーユニットへ SEAT SWITCH シートスイッチへ RG(102-3) 111-1 98-1 102-1...
  • Page 252 6. ELECTRIC WIRING HEAD LIGHT OPTION ヘッドランプ(右) オプション PARKING ALARM パーキングアラーム (RIGHT) REAR COMBINATION リヤコンビネーション EMERGENCY エマージェンシ LIGHT (RIGHT) ランプ(右) SWITCH スイッチ Insert when EGS. EGS時のみ挿入する (OPTION) (オプション) BEACON LIGHT 回転灯 TRANSFORMER トランス RELAY CONTROL SWITCH PANEL リレー コントロールスイッチパネル VALVE SWITCH バルブスイッチ...
  • Page 253 6. ELECTRIC WIRING HEAD LIGHT OPTION オプション パーキングアラーム PARKING ALARM ヘッドランプ(右) (RIGHT) REAR COMBINATION リヤコンビネーション LIGHT (RIGHT) EMERGENCY エマージェンシ ランプ(右) SWITCH スイッチ Insert when EGS. EGS時のみ挿入する (OPTION) (オプション) BEACON LIGHT 回転灯 TRANSFORMER トランス リレー M.C. RELAY CONTROL SWITCH PANEL コントロールスイッチパネル VALVE SWITCH バルブスイッチ...
  • Page 254 6. ELECTRIC WIRING HEAD LIGHT OPTION オプション PARKING ALARM パーキングアラーム ヘッドランプ(右) (RIGHT) REAR COMBINATION リヤコンビネーション エマージェンシ EMERGENCY LIGHT (RIGHT) ランプ(右) SWITCH スイッチ Insert when EGS. EGS時のみ挿入する (OPTION) (オプション) BEACON LIGHT 回転灯 TRANSFORMER トランス RELAY リレー CONTROL SWITCH PANEL コントロールスイッチパネル M.C. VALVE SWITCH バルブスイッチ...
  • Page 255 6. ELECTRIC WIRING CONTACTOR UNIT KEY SWITCH RL100 RY101 (+) (S) (-) (+) (S) (-) (+) (S) (-) CNMC CNCH1 EMERGENCY SWITCH F/R SWITCH RG 102 PS MOTOR CONTROLLER RB 141 CSDU CSDW CSPU CSPW INVERTER UNIT (PUMP) N IG1 IG2 VF ST VR Ra INVERTER UNIT WL 54...
  • Page 256 6. ELECTRIC WIRING CONTACTOR UNIT KEY SWITCH RL100 RY101 (+) (S) (-) (+) (S) (-) (+) (S) (-) CNMC CNCH1 EMERGENCY SWITCH F/R SWITCH PS MOTOR CONTROLLER CSPU CSPW INVERTER UNIT CSDU CSDW (PUMP) RG 102 N IG1 IG2 VF ST VR Ra Br 6 INVERTER UNIT...
  • Page 257 No. SEB-7P0BE Issued: July, 2012 Revised: December, 2012 MARKETING GROUP: 6-22-7, Minami-Oi, Shinagawa-ku Tokyo 140-0013, Japan FAX:Japan +81-3-6730-3371 All rights reserved JB-1212010(HO) Printed in Japan...

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