Professional Documents
Culture Documents
SEB-7POBE
TCM
@~.WD@AI&[S
FORKLIFTTRUCK
Counter8alanced
FBO
S
FB5
s
s
FB8
F
B
2
0
s
F
B
2
5
s
F
B
3
0
s
F
B
2
5
S
L
B
F
B
2
5
s
v
F
B
3
0
s
v
F
B
3
5
s
s
TCMCORPORATION
FOREWORD
The new TCMs 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. If the truck has a trouble, the
function detects the trouble and displays the result of diagnosis. The maintainability is thus
improved.
As for mobility, since the high capacity batteries and high power drive motor are used, the firstclass acceleration, gradeability, and traveling performance are achieved.
Controllability is also improved by the standard equipped power steering unit.
To save power, the acceleration and traveling speeds are selectable and made changeable
according to working conditions. Also for effective use of the battery, a regenerative device is
provided to send back counter electromotive force to the battery.
This Service Manual is intended to provide the maintenance personnel with helpful information
of the structures of the major components and with instructions on the maintenance and repair of
such components. We hope it will be much help for your servicing and maintenance operations.
December 2012
SPECIFICATIONS (1)
Truck model
FB10-8
Item
Performance
Max. load
kg [lbs] 1000 [2000]
Load center
mm [in.]
500 [24]
Max. lifting height
mm [in.] 3000 [118.1]
Tilting angle
Fwd
6
Bwd
12
Free lift
A mm [in.]
155 [6.1]
Mast tilting time (Fwd - Bwd)
s
2.0 - 1.4
Fork lifting speed
Loaded
mm/s [fpm] 390 [76.8]
Unloaded
mm/s [fpm] 580 [114.2]
Travel speed
Loaded
km/h [mph]
14 [8.7]
Unloaded
km/h [mph]
16 [9.9]
Gradeability
(Starting on an uphill when loaded)
1/7
Min. turning radius
(Outermost part of truck) EPS: B mm [in.] 1700 [66.9]
Orbitrol type:
1800 [70.9]
Min. intersecting aisle
C mm [in.] 1690 [66.5]
Dimensions
Overall length (includ. fork)
Overall width
Overall height (Overhead guard)
EXN:
Overall extended height
Wheel base
Tread
Front wheels
Rear wheels
Fork overhang
Rear overhang
FB15-8
FB18-8
FB20-8
1500 [3000]
1750 [3500]
2000 [4000]
110 [4.3]
2.7 - 2.0
350 [68.9]
330 [65.0]
290 [57.1]
510 [100.4]
1790 [70.5]
1890 [74.4]
1730 [68.1]
1950 [76.8]
2070 [81.5]
1895 [79.6]
2875 [113.2]
1070 [42.1]
2080 [81.9]
2140 [84.3]
4030 [158.7]
1250 [49.2]
2975 [117.1]
1350 [53.2]
3315 [130.5]
1150 [45.3]
2125 [83.7]
2185 [86.0]
1400 [55.1]
H
J
K
L
910 [35.8]
900 [35.4]
375 [14.8]
330 [13.0]
955 [37.6]
950 [37.4]
435 [17.1]
410 [16.1]
920x100x35
[36.2x3.9x1.4]
200 - 920
[7.9 - 36.2]
90 [3.5]
(Rear axle)
390 [15.4]
1070x122x40
[42.1x4.8x1.6]
245 -1020
[9.6 - 40.2]
100 [3.9]
(Rear axle)
440 [17.3]
2710 [5976]
3030 [6680]
3500 [7716]
mm [in.]
D
E
F
Fork size
(Length L x Width M x Thickness N)
Fork spacing
Minimum under clearance
Tow pin height
Weight
Service Weight with std. batteries
The values in the Performance section are given for trucks operating in the Super mode.
SPECIFICATIONS (2)
Truck model
FB25-8
Item
Performance
Max. load
kg [lbs] 2500 [5000]
Load center
mm [in.]
500 [24]
Max. lifting height
mm [in.] 3000 [118.1]
Tilting angle
Fwd
6
Bwd
12
Free lift
A mm [in.]
110 [4.3]
Mast tilting time (Fwd - Bwd)
s
2.7 - 2.0
Fork lifting speed
Loaded
mm/s [fpm] 265 [52.2]
Unloaded
mm/s [fpm] 510 [100.4]
Travel speed
Loaded
km/h [mph]
14 [8.7]
Unloaded
km/h [mph]
16 [9.9]
Gradeability
(Starting on an uphill when loaded)
1/7
FB25-8LB
FB25-8V
FB30-8
FB30-8V
FB35-8S
3000 [6600]
3500 [7000]
165 [6.5]
2.5 - 2.0
10
170 [6.7]
3.5 - 2.5
290 [57.1]
490 [96.5]
240 [47.2]
410 [80.7]
13.5 [8.4]
15.5 [9.6]
14 [8.7]
15 [9.3]
1/8
1/10
1970 [77.6]
2065 [81.3]
2140 [84.3]
2360 [92.9]
Orbitrol type:
Min. intersecting aisle
C mm [in.]
2100 [82.7]
1905 [75.0]
2200 [86.6]
1955 [76.9]
2290 [90.2]
2050 [80.7]
2500[98.4]
2250 [88.6]
Dimensions
Overall length (includ. fork)
Overall width
Overall height (Overhead guard)
Overall extended height
Wheel base
Tread
Front wheels
Rear wheels
Fork overhang
Rear overhang
mm [in.]
D
E
3355 [132]
1150 [45.3]
2125 [83.7]
4030 [158.7]
1400 [55.1]
H
J
K
L
955 [37.6]
950 [37.4]
435 [17.1]
450 [17.7]
410 [16.1]
1070x122x40
[42.1x4.8x1.6]
245 - 1020
[9.6 - 40.2]
100 [3.9]
(Rear axle)
440 [17.3]
Fork size
(Length L x Width M x Thickness N)
Fork spacing
Minimum under clearance
Tow pin height
3460 [136]
3580 [140.9]
1225 [48.2]
1545 [60.8]
1600 [63.0]
1000 [39.4]
480 [18.9]
430 [16.9]
3805 [149.8]
1380 [54.3]
2190 [86.2]
1800 [70.9]
1140 [44.9]
500 [19.7]
1070x125x45 1070x150x50
[42.1x4.9x1.8] [42.1x5.9x2.0]
250 - 1090
300 - 1090
[9.8 - 42.9]
[11.8 - 42.9]
90 [3.5]
(Rear axle)
475 [18.7]
Weight
Service Weight with std. batteries
The values in the Performance section are given for trucks operating in the Super mode.
5240 [11600]
3000
[ 118.1]
3000
1 - 2.5 t:1~2.5t
4030 :[158.7]
3 - 3.5: t:4260
4260 [167.7]
4030 3~3.5t
Unit: mm [in.]
Electric system
Steering system
Tire air
pressure
Front
(single)
(double)
Brake system
Load handling system
Hydraulic system
*
*
*
*
87.00.2
*
*
400
*
*
(A)
10
(A)
(A)
24
34
40
(A)
130
130/200
130
(A)
10
(A)
2
MPa{kgf/cm }[psi]
N-m{kgf-m}[lbf-ft]
N-m{kgf-m}[lbf-ft]
N-m{kgf-m}[lbf-ft]
mm [in.]
mm [in.]
mm [in.]
mm [in.]
EPS type
EPS type
Orbitrol type
10
[101.54.4]
0.850.03 {8.50.3}
[123.34.35]
150-175 {15-17.5}
[110.6-129.1]
127.5-190.3 13.0-19.4}
[94-140]
96.1-110.8 {9.8-11.3}
[70.9-81.7]
60.8-90.2 {6.2-9.2}
[44.8-66.5]
30.4-45.1 {3.1-4.6}
[22.4-33.3]
less than 1 [0.039]
+0
40+0
-0.1 [1.57-0.004 ]
+0.1
+0
40-0 [1.57-0.004 ]
7525 [2.950.98]
+1.97
+1.97
] 1790+50
]
1700+50
-0 [66.9-0
-0 [70.5-0
1800 [70.9]
1890 [74.4]
N-m{kgf-m}[lbf-ft]
*
*
*
*
500
Lining thickness
Brake drum inner diameter
*
*
*
*
*
*
58.80.2
14
16
*
*
400
MPa{kgf/cm2}[psi]
*
mm [in.]
97 [3.8]
mm [in.] 105 [0.3930.197]
mm [in.] 6010 [2.3620.393]
Unloaded
within 2.5 m
Loaded
within 2.5 m
N{kgf}[lbf]
*
Held in position on
Unloaded
20% slope
Loaded Held in position on
14.3% slope
0.25-0.4
mm [in.] [0.0098-0.016]
+0
mm [in.] 5-3 [0.197+0
-0.118 ]
+0.079
]
mm [in.] 254+2
-0 [10-0
FB35-8S
N-m{kgf-m}[lbf-ft]
*
*
FB30-8
FB30-8V
(V)
(h)
(h)
(A)
(A)
(A)
Rear
Rear
N{kgf}[lbf]
N-m{kgf-m}[lbf-ft]
*
*
*
*
Front
Front
*
*
FB20-8
FB25-8
FB25-8LB
FB25-8V
*
*
FB18-8
N{kgf}[lbf]
N{kgf}[lbf]
MPa{kgf/cm2}[psi]
Rear
Safety
device
mm [in.]
mm [in.]
FB10-8
FB15-8
N-m{kgf-m}[lbf-ft]
Fork thickness
Opening of fork tips
Difference in height between right and left fork tips
Chain length
Tilt cylinder piston rod lock bolt and nut
tightening torque
Lift cylinder natural drop
Tilt cylinder natural tilt (extension of piston rod)
Fork lifting speed (Unloaded)
mm [in.]
mm [in.]
mm [in.]
mm [in.]
mm [in.]/min
mm [in.]/min
mm [in.]/sec
MPa{kgf/cm2}[psi]
N-m{kgf-m}[lbf-ft]
N-m{kgf-m}[lbf-ft]
N-m{kgf-m}[lbf-ft]
0.900.03 {9.00.3}
[130.54.35]
370-420 {37.8-42.8}
470.7-549.2
[273-310]
{48-56} [347-405]
96.1-110.8 {9.8-11.3}
[70.9-81.7]
60.8-90.2 {6.2-9.2}
[44.8-66.5]
+0
50+0
+1.97
+1.97
FB20: 1950+50
] 2140+50
]
-0 [76.8-0
-0 [84.3-0
+50
+1.97
FB25: 1970-0 [77.6-0 ]
FB20: 2070 [81.5]
2290 [90.2]
FB25: 2100 [82.7]
*
*
110
*
*
Held in position on
16.7% slope
Held in position on
12.5% slope
+1.97
2360+50
]
-0 [92.9-0
2500 [98.4]
*
+0
+0
5.6+0
8+0
-3.6 [0.22-0.142 ]
-6 [0.31-0.236 ]]
+0.079
+0.079
280+2
]
314+2
]
-0 [11.0-0
-0 [12.4-0
215.7-235.4 {22-24} 470.7-549.2 {48-56}
[159.1-173.6]
[347.2-405.1]
205.9-225.6 {
21-23} [151.9-166.4]
+0
+0
40+0
45+0
-4 [1.57-0.157 ]
-6 [1.77-0.236 ]
25.4+50
-0
117.7-137.3
{12-14} [86.8-101.3]
+0
35+0
-4 [1.38-0.157 ]
within 10 [0.394]
05 [00.197]
19.05+50
-0
107.920.6 {11.02.1}
[79.615.2]
less than 75 [2.95]/10
less than 60 [2.36]/10 less than 50 [1.97]/10
+1.97
+1.97
+1.97
580+50
]
510+50
]
490+50
]
-0 [22.8-0
-0 [20.1-0
-0 [19.3-0
+0.49
+5
+0.49
+5
+0.49
+5
13.7-0 {140-0 } 15.7-0 {160-0 } 17.2-0 {175-0 }
+71.1
+71.1
+71.1
[1990-0 ]
[2277-0 ]
[2495-0 ]
31.4-47.1 {3.2-4.8}
[23.2-34.7]
59.311.9 {6.051.21}
[43.78.8]
+0
50+0
-5 [1.97-0.197 ]
+50
-0
410
[16.1+1.97
]
-0
Counterbalanced model
Reach model
JIG
2. O-rings
Use O-rings free from molding fault or damage.
Clean O-rings and their mounting area and apply grease or hydraulic oil to them.
When installing O-rings, do not expand them so excessively that they suffer permanent
deformation. Also do not roll them when installing; otherwise they might stay twisted, causing oil
leakage.
When using an O-ring and back-up ring as
a set, such as when hydraulic pressure is high,
position the O-ring at the side which receives
Pressure
the oil pressure.
JIG
JIG
JIG
JIG
SLEEVE
4. Using LOCTITE
(1) Procedure for using LOCTITE
Clean or degrease the surface of parts you are going to apply LOCTITE, using trichloroethylene,
acetone, ether or alkaline solution.
Blow dry them with compressed air or allow to air dry at room temperature sufficiently.
Apply specified LOCTITE.
(2) Removing parts
When removing parts which were installed with the application of LOCTITE, use tools such as a
spanner, wrench, and pulley remover.
If you fear that a part may break due to the effect of LOCTITE if forcibly removed, heat the part to
200 to 250C [392 to 482F] with a soldering iron or gas burner.
Remember that parts are very hot after heating. Use caution not to get burnt when
removing them.
(3) Reinstalling parts
When destroyed, LOCTITE remains as white powder on the threads of bolts. You can apply a
new coat of LOCTITE again over their surface.
Note: For example, if a bolt turns slightly due to bolt torque checking, remove the bolt and apply
LOCTITE again and reinstall.
If LOCTITE is used for the surface of a flange, it is necessary to remove hardened LOCTITE with
a wire brush when reinstalling the flange.
5. How to use a power wrench
Power wrenches have their respective torque multiplying factors. Refer to the product catalog of
each power wrench.
It should be noted that a value obtained by multiplying the output torque of a torque wrench by the
multiplying factor of a power wrench is not necessarily an output torque.
Remember this especially when the tightening torque is strictly specified.
03. CLEANING
1. General metallic parts
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.
Cast parts should be cleaned with cleaning solvent or steam cleaned.
If a part is severely contaminated, use a wire brush or a piece of wood or metal to scrape off
contaminants from the part. Wash it in cleaning fluid once, before cleaning it completely.
However, do not use a wire brush for cleaning sliding surfaces or machined surfaces.
Oil passages must be cleaned with a steam cleaner. After checking for clogging with a piece of
wire, they also should be cleaned with cleaning fluid or with compressed air.
Some parts may be cleaned in hot solution tanks with mild alkaline solution. Parts should remain
in solution long enough to be thoroughly cleaned and warmed.
This will aid the evaporation of the cleaning solution and rise water. Parts cleaned in solution
tanks must be thoroughly rinsed with clean water to remove all traces of alkali.
Care should be exercised to avoid skin rashes, fire hazards and inhalation of vapors when
using solvent type cleaners.
If alloy parts, such as bearing shells or bushings, are cleaned with alkaline solution, they are apt to
corrode due to ionization. Such parts should be cleaned with kerosene, Tricrene solvent vapor or
Magnus fluid.
After cleaning, parts must be thoroughly dried with compressed air.
2. Bearings
To dislodge solidified particles of lubricant, immerse bearings in cleaning fluid and remove
them from the fluid. On a clean work bench, tap the bearing softly with a soft mallet to dislodge
solidified particles.
When drying bearings, be careful to direct air stream across bearing to avoid spinning.
3. Rubber parts
When rubber parts need to be cleaned, use alcohol or wipe them clean with a soft cloth.
Never use gasoline, diesel fuel or kerosene for cleaning. Use the same kind of oil for which the
rubber part will be used.
Indication on bolt
Material
4.6
SS400
(The number may be omitted.)
6.8
S45C
SCM435
8.8
Boron steel
(B may be omitted.)
SCM435
10.9
Boron steel
(B may be omitted.)
Table 04.2
Name
Shape
Normal
Coarse
Full thread
(normal,
coarse)
Thread size
M4 - M8 coarse and
M10 - M39 fine
Hex. head
bolt
Full thread
(normal)
w. socket
head
w. hole in
threads
M4 - M8 coarse and
M10 - M39 fine
M4 - M8 coarse and
M10 - M39 fine
M4 - M8 coarse and
M10 - M39 fine
Material
Division by
strength
SS400
4.6
SS400
4.6
S45C
6.8
Surface
treatment
Black
Yellow
chromate
Part number
01101- Nominal symbol
01100-
01103-
01106-
8.8
10.9
01107-
BsBME1
01108-
SS400
4.6
01112-
SS400
4.6
01110-
S45C
6.8
01113-
8.8
01116-
10.9
01119-
SS400
4.6
01115-
SS400
4.6
01111-
01114-
01117-
01121-
01120-
01123-
01126-
S45C
6.8
8.8
SS400
4.6
SS400
4.6
S45C
6.8
Black
Yellow
Chromate
Black
Yellow
Chromate
Black
Yellow
Chromate
8.8
10.9
01127-
BsBME1
01128-
SS400
4.6
01131-
SS400
4.6
01130-
S45C
6.8
01133-
8.8
01136-
10.9
01137-
SS400
4.6
01161-
SS400
4.6
01160-
S45C
6.8
01163-
8.8
01166-
10.9
01167-
Black
Yellow
Chromate
Black
Yellow
Chromate
Designation of screws: Each part number consists of a screw type designation and a nominal symbol.
Class
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
Nominal
size
0.50
0.50
0.75
1.00
1.25
1.25
1.50
1.50
1.50
1.50
1.50
2.00
2.00
2.00
2.00
3.00
3.00
0.70
0.80
1.00
1.25
1.50
1.75
2.00
2.00
2.50
2.50
2.50
3.00
3.00
3.50
3.50
4.00
4.00
Pitch
Lubrication
condition
0
1.36
2.87
4.59
10.9
21.2
39.1
61.7
95.9
141
198
270
334
489
686
931
1130
1460
1.15
2.36
3.98
9.81
19.5
34.2
55.0
86.9
118
171
234
293
436
588
810
1030
1350
kgHE
13.9
29.3
46.8
111
216
399
629
978
1440
2020
2750
3410
4990
7000
9490
11500
14900
11.7
24.1
40.6
100
199
349
561
886
1200
1740
2390
2990
4450
6000
8260
10500
13800
Target value
Allowable value
kgHE
12.3
25.8
41.4
98.1
192
352
553
860
1270
1780
2400
2990
4370
6120
8280
10100
13100
10.5
21.5
36.3
89.1
178
310
498
785
1070
1530
2110
2640
3930
5310
7280
9320
12100
Target value
0
kgHE
0
1.09 - 1.63 11.1 - 16.6 1.21
2.30 - 3.44 23.5 - 35.1 2.53
3.67 - 5.55 37.4 - 56.1 4.06
8.69 - 13.3
88.6 133 9.62
17.1 - 25.4
174 259 18.8
31.4 - 47.1
320 480 34.5
49.3 - 74.0
503 755 54.2
76.8 - 115
783 - 1170 84.3
113 - 170
1150 - 1730 125
159 - 238
1620 - 2430 175
216 - 324
2200 - 3300 235
268 - 401
2730 - 4090 293
391 - 587
3990 - 5990 429
550 - 824
5610 - 8400 600
744 - 1120
7590 - 11400 812
903 - 1350
9210 - 13800 991
1170 - 1740 11900 - 17700 1280
0.92 - 1.38
9.4 - 14.1 1.03
1.89 - 2.82 19.3 - 28.8 2.11
3.20 - 4.79 32.6 - 48.8 3.56
7.84 - 11.7
79.9 119 8.74
15.6 - 23.4
159 239 17.5
27.5 - 41.1
280 419 30.4
43.9 - 65.9
448 672 48.8
69.5 - 104
709 - 1060 77.0
94.6 - 142
965 - 1450 105
136 - 204
1390 - 2080 150
187 - 252
1910 - 2570 207
234 - 352
2390 - 3590 259
349 - 524
3560 - 5340 385
471 - 706
4800 - 7200 521
648 - 972
6610 - 9910 714
828 - 1250
8440 - 12700 914
1080 - 1140 11000 - 11650 1190
Dry
0
kgHE
0.96 - 1.44
9.8 - 14.7
2.02 - 3.00 20.6 - 30.9
3.25 - 4.87 33.1 - 49.7
7.70 - 1.15 78.5 117
15.0 - 22.6
153 230
27.7 - 41.5
282 423
43.4 - 65.3
443 666
67.5 - 100
1688 - 1030
99.1 - 148
1010 - 1510
139 - 208
1420 - 2120
188 - 282
1920 - 2880
234 - 351
2390 - 3580
342 - 515
3490 - 5250
480 - 720
4890 - 7340
650 - 974
6630 - 9930
792 - 1190
8080 - 12100
1020 - 1540 10400 - 15700
0.82 - 1.24
8.4 - 12.6
1.70 - 2.53 17.3 - 25.8
2.85 - 4.29 29.1 - 43.7
7.00 - 10.5
71.4 107
13.9 - 20.9
142 213
24.4 - 36.6
249 373
39.0 - 55.8
398 597
61.6 - 92.4
628 942
84.1 - 127
858 - 1290
121 - 180
1230 - 1840
165 - 248
1680 - 2530
208 - 312
2120 - 3180
308 - 463
3140 - 4720
417 - 624
4250 - 6360
572 - 857
5830 - 8740
731 - 1100
7450 - 11200
953 - 1430
9720 - 14600
LOCTITE262
Allowable value
0
0.99
2.08
3.34
7.93
15.5
28.4
44.7
69.5
102
143
194
241
352
493
669
815
1050
0.8
1.7
2.9
7.2
14.3
25.1
40.2
63.5
86.6
125
171
214
318
429
588
753
981
kgHE
10.1
21.2
34.1
80.9
158
290
456
709
1040
1460
1980
2460
3590
5030
6820
8310
10700
8.66
17.8
30.0
73.5
146
256
410
647
883
1270
1740
2180
3240
4370
6000
7680
10000
Target value
0
0.79 - 1.19
1.66 - 2.50
2.68 - 4.01
6.34 - 9.51
12.5 - 18.6
22.7 - 34.1
35.9 - 53.7
55.5 - 83.4
81.5 - 123
114 - 172
155 - 233
193 - 289
282 - 424
395 - 592
534 - 802
652 - 979
844 - 1270
0.68 - 1.02
1.39 - 2.08
2.35 - 3.53
5.77 - 8.65
11.5 - 17.3
20.1 - 30.1
32.3 - 48.3
50.8 - 76.1
69.3 - 104
99.1 - 149
136 - 204
172 - 257
254 - 381
342 - 515
471 - 706
602 - 903
785 - 1180
kgHE
8.1 - 12.1
16.9 - 25.5
27.3 - 40.9
64.6 - 97.0
127 190
231 348
366 548
566 850
831 - 1250
1160 - 1750
1580 - 2380
1970 - 2950
2880 - 4320
4030 - 6040
5450 - 8180
6650 - 9980
8610 - 12900
6.9 - 10.4
14.2 - 21.2
24.0 - 36.0
58.8 - 88.2
117 176
205 307
329 493
518 776
707 - 1060
1010 - 1520
1390 - 2080
1750 - 2620
2590 - 3890
3490 - 5250
4800 - 7200
6140 - 9210
8000 - 12000
Lubricant
Allowable value
Class
Pitch
0.50
0.50
0.75
1.00
1.25
1.25
1.50
1.50
1.50
1.50
1.50
2.00
2.00
2.00
2.00
3.00
3.00
0.70
0.80
1.00
1.25
1.50
1.75
2.00
2.00
2.50
2.50
2.50
3.00
3.00
3.50
3.50
4.00
4.00
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
Nominal
size
Lubrication
condition
0
2.71
5.74
9.14
21.7
42.4
78.3
123
192
282
396
537
668
978
1370
1860
2250
2920
2.29
4.72
7.95
19.6
38.6
68.4
110
174
235
338
468
585
872
1180
1620
2070
2700
kgHE
27.6
58.5
93.2
221
432
798
1250
1960
2870
4040
5480
6810
9970
14000
19000
22900
29800
23.3
48.1
81.1
200
397
697
1120
1770
2400
3450
4770
5970
8890
12000
16500
21100
27500
Target value
kgHE
22.1 - 33.2
46.8 - 70.1
74.6 112
177 265
345 519
638 957
1000 - 1510
1560 - 2340
2290 - 3440
3230 - 4850
4390 - 6580
5440 - 8160
7970 - 11900
11200 - 16800
15200 - 22700
18300 - 27500
23800 - 35800
18.6 - 28.0
38.4 - 57.7
64.9 - 97.4
160 239
318 477
557 837
895 - 1350
1420 - 2120
1930 - 2880
2760 - 4150
3810 - 5730
4780 - 7160
7110 - 10700
9580 - 14400
13100 - 19800
16800 - 25300
22000 - 33000
Allowable value
0
2.17 - 3.26
4.59 - 6.87
7.32 - 11.0
17.4 - 26.0
33.8 - 50.9
62.6 - 93.9
98.1 - 148
153 - 229
225 - 337
317 - 476
431 - 645
534 - 800
782 - 1170
1100 - 1650
1490 - 2330
1790 - 2700
2330 - 3510
1.82 - 2.75
3.77 - 5.66
6.36 - 9.55
15.7 - 23.4
31.2 - 46.8
54.6 - 82.1
87.8 - 132
139 - 208
189 - 282
271 - 407
374 - 562
469 - 702
697 - 1050
940 - 1410
1280 - 1940
1650 - 2480
2160 - 3240
Dry
0
2.40
5.05
8.10
19.2
37.5
68.9
109
169
247
347
471
585
855
1200
1620
1980
2560
2.06
4.21
7.13
17.5
34.8
60.9
97.6
154
210
300
413
519
770
1040
1430
1820
2380
kgHE
24.5
51.5
82.6
196
382
703
1110
1720
2520
3540
4800
5970
8720
12200
16500
20200
26100
21.0
42.9
72.7
178
355
621
995
1570
2140
3060
4210
5290
7850
10600
14600
18600
24300
Target value
0
1.92 - 2.87
4.04 - 6.06
6.48 - 9.72
15.4 - 23.0
30.0 - 45.0
55.1 - 82.7
86.9 - 129
135 - 202
198 - 296
278 - 416
376 - 565
469 - 702
685 - 1030
958 - 1440
1290 - 1950
1580 - 2370
2050 - 3070
1.65 - 2.47
3.36 - 5.06
5.70 - 8.54
14.0 - 21.0
27.8 - 41.7
48.6 - 73.1
78.1 - 117
123 - 185
168 - 252
240 - 360
330 - 495
414 - 623
616 - 924
831 - 125
1140 - 1710
1460 - 2190
1900 - 2840
kgHE
19.6 - 29.3
41.2 - 61.8
66.1 - 99.1
157 235
306 459
562 843
886 - 1320
1380 - 2060
2020 - 3020
2830 - 4240
3830 - 5760
4780 - 7160
6980 - 10500
9770 - 14700
13200 - 19900
16100 - 24200
20900 - 31300
16.8 - 25.2
34.3 - 51.6
58.1 - 87.1
143 214
283 425
496 745
796 - 1190
1250 - 1890
1710 - 2570
2450 - 3670
3370 - 5050
4220 - 6350
6280 - 9420
8470 - 12700
11600 - 17400
14900 - 22300
19400 - 29000
LOCTITE262
Allowable value
0
1.98
4.15
6.68
15.8
30.9
56.8
89.4
139
203
285
386
481
704
991
1340
1630
2110
1.70
3.47
5.87
14.4
28.6
50.2
80.3
127
173
247
340
428
634
855
1180
1500
1960
kgHE
20.2
42.3
68.1
161
315
579
912
1420
2070
2910
3940
4910
7180
10100
13700
16600
21500
17.3
35.4
59.9
147
292
512
819
1290
1760
2520
3470
4360
6460
8720
12000
15300
20000
Target value
0
1.58 - 2.38
3.33 - 4.98
5.34 - 8.01
12.7 - 19.0
24.7 - 37.1
45.5 - 68.2
71.6 - 107
111 - 168
163 - 244
229 - 343
310 - 465
385 - 579
564 - 845
788 - 1180
1070 - 1600
1290 - 1950
1690 - 2530
1.36 - 2.03
2.78 - 4.17
4.70 - 7.04
11.5 - 17.3
22.9 - 34.4
40.1 - 60.1
64.2 - 96.4
101 - 152
138 - 208
198 - 297
272 - 409
341 - 513
507 - 760
685 - 1030
940 - 1410
1200 - 1790
1570 - 2340
kgHE
16.1 - 24.3
33.9 - 50.8
54.4 - 81.7
129 194
252 378
464 695
730 - 1090
1130 - 1700
1660 - 2490
2330 - 3500
3160 - 4740
3930 - 5900
5750 - 8620
8040 - 12000
10900 - 16300
13200 - 19900
17200 - 25800
13.9 - 20.7
28.3 - 42.5
47.9 - 71.8
117 176
233 351
409 613
655 983
1030 - 1550
1410 - 2120
2020 - 3030
2770 - 4170
3480 - 5230
5170 - 7750
6980 - 10500
9580 - 14400
12200 - 18300
16000 - 23900
Lubricant
Allowable value
Class
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
Nominal
size
0.50
0.50
0.75
1.00
1.25
1.25
1.50
1.50
1.50
1.50
1.50
2.00
2.00
2.00
2.00
3.00
3.00
0.70
0.80
1.00
1.25
1.50
1.75
2.00
2.00
2.50
2.50
2.50
3.00
3.00
3.50
3.50
4.00
4.00
Pitch
Lubrication
condition
0
3.62
7.65
12.2
28.9
56.5
104
164
256
377
529
718
890
1300
1830
2480
3010
3900
3.06
6.30
10.6
26.1
52.1
91.2
146
232
315
452
624
782
1160
1570
2160
2770
3600
kgHE
36.9
78.0
124
295
576
1060
1670
2610
3840
5390
7320
9080
13300
18700
25300
30700
39800
31.2
64.2
108
266
531
930
1490
2370
3210
4610
6360
7970
11800
16000
22000
28200
36700
Target value
kgHE
29.5 - 44.3
62.4 - 93.6
99.7 150
236 354
461 692
852 - 1280
1340 - 2010
2080 - 3130
3070 - 4600
4310 - 6470
5850 - 8780
7260 - 10900
10600 - 16000
14900 - 22300
20200 - 30300
24500 - 36800
31800 - 47700
25.0 - 37.4
51.3 - 77.0
86.7 130
213 319
424 638
745 - 1110
1190 - 1800
1890 - 2840
2570 - 3860
3690 - 5540
5090 - 7640
6380 - 9560
9490 - 14300
12800 - 19200
17600 - 26400
22500 - 33800
29400 - 44100
Allowable value
0
2.89 - 4.34
6.12 - 9.18
9.78 - 14.7
23.1 - 34.7
45.2 - 67.9
83.6 - 126
131 - 197
204 - 307
301 - 451
423 - 635
574 - 861
712 - 1070
1040 - 1570
1460 - 2190
1980 - 2970
2400 - 3610
3120 - 4680
2.45 - 3.67
5.03 - 7.55
8.50 - 12.7
20.9 - 31.0
41.6 - 62.5
73.1 - 109
117 - 177
185 - 279
252 - 379
362 - 543
499 - 749
626 - 938
931 - 1400
1260 - 1880
1730 - 2590
2210 - 3310
2880 - 4320
Dry
0
3.20
6.73
10.8
25.6
50.1
92.0
145
226
330
463
629
782
1140
1600
2160
2640
3410
2.7
5.6
9.5
23.3
46.4
81.2
130
205
280
401
551
692
1030
1390
1900
2430
3170
kgHE
32.6
68.6
110
261
511
938
1480
2300
3360
4720
6410
7970
11600
16300
22000
26900
34800
27.9
57.3
96.9
238
473
828
1330
2090
2860
4090
5620
7060
10500
14200
19400
24800
32300
Target value
0
0.26 - 0.39
0.54 - 0.81
0.87 - 1.30
2.05 - 3.08
4.01 - 6.01
7.37 - 11.0
11.6 - 17.4
18.0 - 27.0
26.4 - 39.5
37.0 - 55.5
50.2 - 75.3
62.6 - 93.8
91.3 - 137
128 - 192
173 - 259
211 - 316
273 - 409
2.19 - 3.30
4.49 - 6.74
7.60 - 11.4
18.6 - 28.0
37.1 - 55.7
64.9 - 97.4
104 - 156
164 - 246
224 - 336
320 - 482
441 - 662
554 - 831
821 - 123
1110 - 1660
1520 - 2290
1950 - 2920
2540 - 3810
kgHE
26.1 - 39.3
55.0 - 82.4
88.2 133
209 314
409 613
751 - 1120
1180 - 1770
1840 - 2750
2690 - 4030
3770 - 5660
5120 - 7680
6380 - 9560
9310 - 14000
13100 - 19600
17600 - 26400
21500 - 32200
27800 - 41700
22.3 - 33.6
45.8 - 68.7
77.5 116
190 286
378 568
662 993
1060 - 1590
1670 - 2510
2280 - 3430
3260 - 4910
4500 - 6750
5650 - 8470
8370 - 12500
11300 - 16900
15500 - 23300
19900 - 29800
25900 - 38900
LOCTITE262
Allowable value
kgHE
26.9
56.6
90.9
215
421
773
1210
1890
2760
3890
5270
6560
9590
13500
18200
22100
28700
23.1
47.2
80.0
196
390
682
1090
1720
2360
3370
4630
5810
8630
11600
16000
20500
26600
Target value
0
2.64
5.55
8.91
21.1
41.3
75.8
119
185
271
381
517
643
940
1320
1780
2170
2810
2.27
4.63
7.85
19.2
38.2
66.9
107
169
231
330
454
570
846
1140
1570
2010
2610
0
2.12 - 3.17
4.44 - 6.66
7.13 - 10.7
16.9 - 25.3
33.0 - 49.5
60.6 - 90.9
95.4 - 143
148 - 222
217 - 327
305 - 457
413 - 620
514 - 773
752 - 1130
1050 - 1580
1420 - 2140
1740 - 2610
2260 - 3370
1.81 - 2.71
3.70 - 5.56
6.28 - 9.40
15.4 - 23.0
30.6 - 45.9
53.5 - 80.3
85.8 - 1290
135 - 203
185 - 278
264 - 396
363 - 545
456 - 685
678 - 1020
913 - 1370
1260 - 1880
1600 - 2410
2090 - 3140
kgHE
21.6 - 32.3
45.3 - 67.9
72.7 109
172 258
337 505
618 927
973 - 1460
1510 - 2260
2210 - 3330
3110 - 4660
4210 - 6320
5240 - 7870
7670 - 11500
10700 - 16100
14500 - 21800
17700 - 26600
23000 - 34400
18.5 - 27.6
37.7 - 56.7
64.0 - 95.9
157 235
312 468
546 819
875 - 1320
1380 - 2070
1890 - 2830
2690 - 4040
3700 - 5560
4650 - 6980
6910 - 10400
9310 - 14000
12800 - 19200
16300 - 24600
21300 - 32000
Lubricant
Allowable value
Class
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
4
5
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
Nominal
size
0.50
0.50
0.75
1.00
1.25
1.25
1.50
1.50
1.50
1.50
1.50
2.00
2.00
2.00
2.00
3.00
3.00
0.70
0.80
1.00
1.25
1.50
1.75
2.00
2.00
2.50
2.50
2.50
3.00
3.00
3.50
3.50
4.00
4.00
Pitch
Lubrication
condition
0
5.33
11.3
17.9
42.6
83.1
154
241
376
552
777
1060
1300
1910
2690
3640
4420
5730
4.49
9.24
15.6
38.3
76.5
133
216
341
463
665
918
1150
1720
2300
3170
4060
5290
kgHE
54.3
115
183
434
847
1570
2460
3830
5630
7920
10800
13300
19500
27400
37100
45100
58400
45.8
94.2
159
391
780
1360
2200
3480
4720
6780
9360
11700
17500
23500
32300
41400
53900
Target value
kgHE
43.4 - 65.1
91.8 138
146 220
348 520
678 - 1020
1250 - 1880
1970 - 2950
3060 - 4590
4510 - 6760
6330 - 9510
8600 - 12900
10700 - 16000
15700 - 23500
22000 - 32900
29700 - 44600
36000 - 54000
46700 - 70000
36.7 - 55.0
75.5 113
128 191
313 469
624 936
1100 - 1640
1760 - 2630
2770 - 4170
3770 - 5660
5440 - 8130
7480 - 11200
9370 - 14100
14000 - 20900
18800 - 28200
25900 - 38800
33000 - 49600
43200 - 64800
Allowable value
0
4.26 - 6.38
9.00 - 13.5
14.3 - 21.6
34.1 - 51.0
66.5 - 100
123 - 184
193 - 289
300 - 450
442 - 663
621 - 933
843 - 1270
1050 - 1570
1540 - 2300
2160 - 3230
2910 - 4370
3530 - 5300
4580 - 6860
3.60 - 5.39
7.40 - 11.1
12.6 - 18.7
30.7 - 46.0
61.2 - 91.8
108 - 161
173 - 258
272 - 409
370 - 555
534 - 797
734 - 1100
919 - 1380
1370 - 2050
1840 - 2770
2540 - 3810
3240 - 4860
4240 - 6350
Dry
0
4.71
9.91
15.9
37.7
73.6
135
213
330
484
681
922
1150
1690
2350
3180
3870
5020
4.03
8.26
14.0
34.3
68.2
120
191
301
412
588
810
1020
1510
2040
2800
3580
4660
kgHE
48
101
162
384
750
1380
2170
3370
4940
6940
9400
11700
17200
24000
32400
39500
51200
41.1
84.2
143
350
695
1220
1950
3070
4200
6000
8260
10400
15400
20800
28600
36500
47500
Target value
0
3.77 - 5.65
7.92 - 12.0
12.7 - 19.0
30.1 - 45.2
58.8 - 88.4
109 - 162
171 - 255
265 - 396
387 - 582
544 - 815
738 - 1110
919 - 1380
1330 - 2020
1880 - 2820
2540 - 3810
3110 - 4650
4010 - 6020
3.22 - 4.83
6.60 - 9.91
11.2 - 16.8
27.4 - 41.1
54.5 - 81.9
95.4 - 143
153 - 230
241 - 362
330 - 493
471 - 707
648 - 972
814 - 1230
1220 - 1800
1630 - 2440
2240 - 3350
2860 - 4300
3740 - 5590
kgHE
38.4 - 57.6
80.8 122
130 194
307 461
600 901
1110 - 1650
1740 - 2600
2700 - 4040
3950 - 5930
5550 - 8310
7530 - 11300
9370 - 14100
13600 - 20600
19200 - 28800
25900 - 38900
31700 - 47400
40900 - 61400
32.8 - 49.2
67.3 101
114 171
279 419
556 835
973 - 1460
1560 - 2350
2460 - 3690
3360 - 5030
4800 - 7210
6610 - 9910
8300 - 12500
12400 - 18400
16600 - 24900
22800 - 34200
29200 - 43800
38100 - 57000
LOCTITE262
Allowable value
kgHE
39.5
83.1
133
317
618
1140
1790
2770
4060
5710
7740
9650
14100
19700
26700
32500
42100
33.9
69.4
117
288
572
1000
1610
2540
3450
4950
6810
8550
12700
17200
23500
30100
39100
Target value
0
3.87
8.15
13.0
31.1
60.6
112
176
272
398
560
759
946
1380
1930
2620
3190
4130
3.32
6.81
11.5
28.2
56.1
98.1
158
249
338
485
668
838
1250
1690
2300
2950
3830
0
3.11 - 4.66
6.52 - 9.79
10.5 - 15.7
24.9 - 37.2
48.5 - 72.8
89.0 - 133
140 - 210
218 - 327
319 - 479
448 - 672
607 - 912
756 - 1140
1110 - 1660
1550 - 2320
2090 - 3140
2550 - 3820
3300 - 4950
2.66 - 3.98
5.44 - 8.18
9.21 - 13.8
22.6 - 33.8
44.9 - 67.5
78.8 - 118
127 - 189
199 - 298
272 - 407
387 - 583
534 - 802
670 - 1010
991 - 1490
1330 - 2020
1840 - 2760
2360 - 3530
3070 - 4610
kgHE
31.7 - 47.5
66.5 - 99.8
107 160
254 379
495 742
908 - 1360
1430 - 2140
2220 - 3330
3250 - 4880
4570 - 6850
6190 - 9300
7710 - 11600
11300 - 16900
15800 - 23700
21300 - 32000
26000 - 39000
33700 - 50500
27.1 - 40.6
55.5 - 83.4
93.9 141
230 345
458 688
803 - 1200
1290 - 1930
2030 - 3040
2770 - 4150
3950 - 5940
5450 - 8180
6830 - 10300
10100 - 15200
13600 - 20600
18800 - 28100
24100 - 36000
31300 - 47000
Lubricant
Allowable value
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.
After applying engine oil, operate the lift cylinders at least ten times through full travel.
NOTE
If your lift truck is used near a port or coastal area, the lift chains might be damaged from salty
breezes. After a storm or typhoon, it is advisable to wash them with water before lubricating in the
above manner.
Fig. 05.1
Rear slippers of the mast
WARNING
Do not ride on the mast. Do not put your hand or
foot on the connecting member across the mast
or between the outer and inner mast channels;
otherwise you might get injured if the mast
accidentally moves.
Fig. 05.2
OIL DIPSTICK
HYDRAULIC
OIL TANK CAP
Fig. 05.3
NOTE
Too high oil level might cause oil leakage.
The oil level check should be performed with the
mast vertical, the forks on the ground or floor
surface, and the truck parked on a level surface.
Part name
FB10-8
FB15-8
FB18-8
FB20-8
FB25-8
283R2-63901
400A
Fuse, F1
283T2-63901
500A
27292-62272
130A
Fuse, F6
Fuses
27732-62091
200A
Oil tank
FB25-8V
FB25-8LB
FB30-8
FB30-8V
FB35-8S
283R2-63901
Controller
400A
27292-62272
130A
25592-42311
27232-62111
Suction filter
216G7-52051
Bulb
271A2-42421
Assembly
277H2-42001
Battery charger
10A
25592-42311
Fuse, F8
Remarks
10A
2A
48V/40W
Head lights
Lights
(standard
trucks)
Front
Bulb
combination
lights
Assembly
Rear
Bulb
combination
lights
Assembly
Relay unit
48V/25W
48V/10W
277H2-42011
Turn signal : 277H2-42361
48V/25W
48V/25W-10W
Back-up : 277H2-42371
280C2-42001
281E2-63252
* Note: The part numbers given below are subject to change without notice.
48V/10W
CONTENTS
1. BATTERY AND CHARGER (OPTION) . ...................................................................1
1.1 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
2.1 GENERAL DESCRIPTION................................................................................................13
2.1.1 DRIVE MOTOR...........................................................................................................13
2.1.2 PUMP MOTOR............................................................................................................17
2.2 MAINTENANCE................................................................................................................19
2.2.1 DRIVE MOTOR...........................................................................................................19
2.2.2 PERIODIC INSPECTION...........................................................................................20
2.2.3 MAINTENANCE OF BEARINGS..............................................................................22
3. CONTROL SYSTEM........................................................................................................23
3.1 GENERAL DESCRIPTION................................................................................................23
3.1.1 INVERTER UNIT........................................................................................................23
3.1.2 ACCELERATOR PEDAL............................................................................................30
5. BRAKE SYSTEM...............................................................................................................39
5.1 GENERAL DESCRIPTION................................................................................................39
5.1.1 BRAKE PEDAL...........................................................................................................39
5.1.2 MASTER CYLINDER.................................................................................................41
5.1.3 WHEEL BRAKE..........................................................................................................42
5.1.4 PARKING BRAKE LEVER........................................................................................44
5.2 MAINTENANCE................................................................................................................47
5.2.1 DISASSEMBLING WHEEL BRAKE.........................................................................47
5.2.2 INSPECTION...............................................................................................................49
5.2.3 REASSEMBLING WHEEL BRAKE..........................................................................50
5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER.........................52
7. HYDRAULIC SYSTEM....................................................................................................81
7.1 GENERAL DESCRIPTION................................................................................................81
7.1.1 MAIN PUMP................................................................................................................82
7.1.2 CONTROL VALVE......................................................................................................82
7.1.3 VALVE CONTROL......................................................................................................84
7.1.4 HYDRAULIC OIL TANK...........................................................................................86
7.1.5 LIFT CYLINDER.........................................................................................................87
7.1.6 FLOW REGULATOR VALVE.....................................................................................92
7.1.7 TILT CYLINDER.........................................................................................................94
7.2 MAINTENANCE................................................................................................................97
7.2.1 MAINTENANCE OF PUMP.......................................................................................97
7.2.2 TRIAL RUN...............................................................................................................109
7.2.3 TROUBLESHOOTING GUIDE................................................................................ 110
9. ELECTRIC SYSTEM......................................................................................................125
9.1 SYSTEM DESCRIPTION................................................................................................125
9.1.1 RELAY UNIT.............................................................................................................126
9.1.2 LIGHTS......................................................................................................................128
FB15-8
FB18-8
FB20-8
FB25-8
Item
Battery
Capacity
Name
330 Ah/5 h
400 Ah/5 h
450 Ah/5 h
565 Ah/5 h
VSDX330M
VSDX400M
VSDX450M
VSDX565M
Voltage
48V
pecific gravity of
S
electrolyte
1.280
650 kg [1430 lbs] 660 kg [1460 lbs] 930 kg [2050 lbs] 800 kg [1760 lbs] 880 kg [1940 lbs]
Weight
Charger
Type
Rated power
6.0 kVA
8.5 kVA
Rated current
17 A
24 A
Output
Voltage
51 - 64 V
Current
80 - 20 A
115 - 29 A
Truck model
FB30-8
FB30-8V
FB25-8LB
FB25-8V
935Ah/5h
865Ah/5h
450Ah/5h
VSF935
VSF865
VSDX450MZ
Item
FB35-8S
Battery
Capacity
Name
Voltage
48 V
pecific gravity of
S
electrolyte
Weight
72 V
1.280
1440 kg [3170 lbs] 1325 kg [2920 lbs] 1110 kg [2450 lbs] 1225 kg [2700 lbs]
Charger
Type
Rated power
12 kVA
12 kVA
Rated current
34 A
34 A
Voltage
51 - 64 V
76.5 - 96 V
Current
160 - 40 A
105 - 26 A
Output
-1-
ELECTROLYTE
LEVEL INDICATOR
Note: The sketch shows a 48-volt battery unit. The 72-volt battery unit has 36 battery cells.
Cycles of
charge and
discharge
Service life
Fig. 1.2 R
elation Between Depth of Discharge
and Service Life (Example)
-2-
Specific gravity
(at 20C)
Usable
Voltage (V)
Voltage
Alert !
Overdischarge
Specific gravity
(Discharge duration)
(Discharge rate)
-3-
Transformer model
M80B
M80C
M80D
M115B
M115C
M115D
M160B
M160C
M160D
BAND
Connection of
secondary wire
CM%/
Contactor
Secondary wire
Primary wire
Thermal relay
primary wire
CM
Contactor
%/
thermal relay
-4-
Setting (A)
24
13
34
18
40
26
Secondary wire
Primary wire
CM
Contactor
CM
Thermal relay
-5-
Setting (A)
40
26
(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.
PRIMARY WIRE
SECONDARY WIRE
390 V
440 V
-6-
(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
to TRANSFORMER
: 130A
FUSE: 130
A
-7-
-8-
-9-
When equalizing charge is automatically terminated (the CHARGING lamp goes out), the
SUPER EQUALIZE lamp is turned off and equalizing charge is released by pressing the
SUPER EQUALIZE button or turning the key switch on.
While the battery is charged, equalizing charge can be released by pressing the STOP button.
(4) Super equalizing charge
Super equalizing charge is used when you want to use 100% of the battery capacity after
consecutive holidays. The operation steps are the same as those described in Equalizing
charge.
In super equalizing charge, both of equalizing charge and automatic proper boosting charge
during consecutive holidays are carried out, so that proper boosting charge is automatically
carried out every 24 hours after completing the charge. Therefore, 100% of the battery
capacity can be used after consecutive holidays. However, if 100 % of the battery capacity is
used, the battery service life will be short. It is recommended to adopt a high capacity battery
or to prepare a spare battery when super equalizing charge is so often used.
(5) Flickering CHARGING lamp
When charging voltage doesnt rise up due to the deteriorated battery or other reasons, the timer
wont operate properly, continuing to charge the battery.
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.
(1) Remove the battery connector.
(2) Having the helper keep the super equalizing charge button held down, reconnect the battery
connector.
(3) Make sure Charging lamp goes out.
- 10 -
to FUSE (F4)
to CONTROLLER
to BATTERY
TERMINAL (-)
to TRANSFORMER
F6
S2
S3
L1
LR
204
LED2
(EQUL)
PB2
(STOP)
S1
PB3
(SUPER
EQUL)
LED1
(CHARGE)
PB1
(START)
TRANS
L2
PO
MN L
CM
COM
MN L
MN L
CM
Gy
220
TH
LY 212
CN3-8
+5V
CH
CN3-6
BW 211
CN1-8
YG 208
CN1-18
RL 100
CN3-5
CN1-11 RY 101
CN1-4 RG 203
RB 202
CN1-16
RESISTOR
ASS'Y
W 213
R01
R03
LB 201
CN1-5
WG 209
CN1-15
WY 206
CN1-14
CN1-13
WR 205
TH
W 207
R02
AC INPUT
- 11 -
1. BATTERY
NOTE
- 12 -
2. MOTORS
2. MOTORS
Truck model
FB10-8
FB15-8
FB18-8
Item
FB20-8
FB25-8LB
FB25-8
FB25-8V
FB30-8
FB30-8V
FB35-8S
Drive motor
Name
HO-NR
Type
Rated output
Rated voltage
26.5 V
26.3 V
43 V
Rated current
210 A
255 A
210 A
48 kg [106 lbs]
54 kg [119 lbs]
63 kg [139 lbs]
Weight
Pump motor
Name
HO-NR
Type
Rated output
9 kW (5-min rate)
14 kW (5-min rate)
Rated voltage
28 V
26 V
42 V
Rated current
260 A
280 A
260 A
34 kg [75 lbs]
43 kg [94.8 lbs]
47 kg [104 lbs]
Weight
Note: On trucks with an Orbitrol steering system, the pump motors of the 1-ton and 2-ton class
trucks are the same in design and specifications..
- 13 -
2. MOTORS
DRIVE AXLE
DRIVE MOTOR
DRIVE UNIT
- 14 -
2. MOTORS
Tightening
torque:
10 1012N
to 12 N-m
m
[100 to 120 kgf-cm]
{7.4 to 8.9 lbf-ft}
ROTATION
BSENSOR B
B
ASENSOR A
ROTATION
THERMO-SENSOR
CONNECTOR
U PHASE
TERMINAL
V PHASE
W PHASE
TERMINAL
TERMINAL
ViewBlooking from B
- 15 -
2. MOTORS
ion
t
ec e)
As shown in Figure 2.3, when the magnetic
dir pol
g
in tic
poles N and S are rotated outside the rectangular
tat ne
Ro mag
(
oil, the coil side cuts the magnetic flux to induce
of
electromotive force in the direction indicated in the
(Rotating
direction of coil)
figure, thus flowing circulating current inside the
coil. This causes rotating force in the same direction
as in which the magnetic poles rotates so that the
coil also rotates, following the magnetic poles.
Motors which operate in such a principle is called
an induction motor.
Three-phase alternating current is suitable for Fig. 2.3 Operating Principle of Induction Motor
rotating the magnetic coil. When 3-phase current is
passed into a 3-phase winding, a revolving magnetic
field which rotates a certain speed is created. It
is thus possible to perform the same action as the
purpose of rotating the magnetic poles N and S in
Figure 2.3. The 3-phase winding consists of an iron
core and three coils A, B, and C, spaced 120 apart,
installed in the iron core slots and connected in Y
or delta connection. The sketch b in Figure 2.4
shows a typical Y connection which is widely used
for the connection of induction motors.
When the directions (A A, B B, C C)
Fig. 2.4 3-phase Winding
in which current flows into the coil are regarded
as the positive direction, the current of the coil in
each phase at the moment at (a), (b) and (c) in Figure 2.5, +Im flows into the coil A and Im/2 flows into
both coils B and C. Therefore, the synthetic magnetic flux in the space becomes (c) to create a magnetic
field moving from right to left. This means that the magnetic pole is located at the right side and the S at the
left side. As such, each moment from - is followed in order, the synthetic magnetic field created by
synthetic magnetic flux is a magnetic field which rotates by 60 clockwise. With time, it rotates to cause a
rotating magnetic field which makes a complete turn per one cycle of alternating current. The poles formed
at each moment are N and S, and thus this type of motor is called a 2-pole motor.
- 16 -
2. MOTORS
PUMP
MOTOR
MAIN
PUMP
A
View looking
from A
- 17 -
2. MOTORS
Tightening torque:
10
to 12 N-m
[100
to
120
1012N
m kgf-cm]
{7.4 to 8.9 lbf-ft]
THERMO-SENSOR
CONNECTOR
SENSOR
ROTATION
U PHASE
TERMINAL
V PHASE W PHASE
TERMINAL
TERMINAL
View B
looking from B
- 18 -
2. MOTORS
2.2 MAINTENANCE
2.2.1 DRIVE MOTOR
(1) Check the following points with the motor running
Environment
Check item
Dust
Location
Motor frame
Foreign matter,
Motor frame
splash, liquid
Criteria
Remedy
Return to normal
condition.
Temperature rise
Motor frame,
bearing
Vibration
Motor frame,
bearing, and
cover
Noise
If allowable limit is
exceeded, stop the motor
and remove the cause.
Location
Tightened areas
Screws and
nuts
Retighten, clean or
paint.
Connections
Retighten.
Check for insulation.
Lead wires
Terminals
Criteria
- 19 -
Remedy
2. MOTORS
8 12 hours/day
Inspection interval
Once a year
Location
Check item
Criteria
Remedy
Replace.
Joined parts
Clean.
Fasteners
Joined areas
Clean.
Connections
Retighten.
Lead wire
Iron core
Clean.
Clean.
Heat.
Varnish.
Measure resistance
Replace.
Measure gap
Thermo sensor
Measure resistance
Painting
Damage
Cleanliness
Deposit of
Check for contamination, adherence of
contaminants or dust dust or corrosion visually.
Roller bearing
Tightened areas
Terminals
Rotation sensor
- 20 -
2. MOTORS
- 21 -
2. MOTORS
8 12 hours/day
12 hours/day
Replacement intervals
Earlier replacement may be required if the motor is used at a place which is dusty or might
cause the sealed grease to deteriorate or flow out due to the atmosphere of harmful gases or
solvent.
Installing bearing
Install the bearing onto the shaft using a pipe (with a patch, if needed), as shown in Figure 2.8.
When heating the bearing, do not heat to more than 60 to 80C [140 to 176F].
PATCH
Fig. 2.8
Removing bearing
Using a puller, remove the bearing.
NUT
PULLER BOLT
INTERNAL
BEARING COVER
BEARING
Fig. 2.9
- 22 -
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.
The CPU board receives various electric signals through the operation of the accelerator pedal
and valve control levers to control the drive motor and the pump motor through the inverters FET
modules.
The operating status of the drive motor and the pump motor is detected by the rotation sensor,
thermo-sensor and current sensor to feed the information back to the CPU board.
- 23 -
INVERTER UNIT
(PUMP MOTOR)
()
2P
2P
MC
MC CONTACTOR
WP
36P
VP
36P
UP
F1
- 24 36P
WD
16P
36P
VD
UD
EPS
CONTROLLER
EPS
INVERTER UNIT
(DRIVE MOTOR)
()
3. CONTROL SYSTEM
Fig. 3.1 Controller (1.0 - to 1.8-ton Trucks (excluding those with an Orbitrol steering system))
3. CONTROL SYSTEM
z
s
ACCEl
SENSORl
ACCE
SENSOR2
(W)
STEER[NG
SENSOR
O[MTEMP
SENSOR
DRIVEINVERTERUNIT
D
!MREV
SENSORA
L
J
CSDW
OIMREV
SENSORB
3. CONTROL SYSTEM
Model
selection
option 2
Opened
Connected
Connected
- 26 -
2P 2P
36P
F1
UP
VP
WP
MC
MC
CONTACTOR
INVERTER
UNIT (PUMP()
MOTOR)
16P
- 27 36P
WD
36P
VD
UD
INVERTER
UNIT
(DRIVE
MOTOR)
()
EPS
EPS
CONTROLLER (Not available on trucks with Orbitrol steering system)
3. CONTROL SYSTEM
36P
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)
3. CONTROL SYSTEM
fU$
V
b
.
.
---
F
KEY
Batt
DC72V
Batt
DC48V
48V
iml
iM
i
V
b
m
ozZ
yoO
i
i
RM
mzm02
mmM
z
o
40
}
zm
mmZO P
2 i ;
E
I
f
n
E i z
-.J
L _-1
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 -
3. CONTROL SYSTEM
Model
selection
option 2
Opened
Connected
Connected
- 29 -
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)
3. CONTROL SYSTEM
186
93
185
92
184
187
ViewAlooking from A
18.5 mm
[0.73 in.]
PEDAL
1.18718650.01V
1.
Apply a voltage of +5 0.01 V between 187 and 186.
2.
Turn potentiometer clockwise in neutral state and lock it at
2.93186
a position at which the voltage between 93 and 186 shows
1.00.1V
1.0 0.1 V.
3.93186
3.
Move the lever a few times and make sure the voltage
between 186 and 93 shows 4.0 0.2 V in full-throttle state.
4.00.2V
STOPPER
POTENTIOMETER
- 30 -
FB10-8
FB15-8
FB18-8
Item
FB20-8
FB25-8LB
FB25-8
FB25-8V
FB30-8
FB30-8V
FB35-8S
Drive unit
Type
Model
Reduction ratio
81E-25
81N-25
81U-25
25.1
30.144
Full floating
21 x 8 9 16PR
Rib lug
28 x 9 15 14PR
Rib lug
Three-stage reduction
Drive axle
Type
Wheel dimensions
Rim size
6.00 x 9 10PR
Rib lug
9 x 4.00E
9 x 6.00E
2
Air pressure
7.00T x 15
2
- 31 -
PINION SHAFT
RING GEAR
Tightening torque: 95 to 142 N-m
{970 to 1450 kgf-cm}
[840.8 to 1257 lbf-in.]
WASHER
PINION GEAR
WASHER
SIDE GEAR
TAPER PIN
2
COUNTER
GEAR 2
Tightening torque:
34.3 to 44 N-m
{350 to 450 kgf-cm}
[303.6 to 389.4 lbf-in.]
O-RING
STOPPER
O-RING
O-RING
COUNTER
1
GEAR 1
MOTOR
DRIVE GEAR
Tightening
torque: 278N
tom416 N-m
278416
{2800 kgf
to 4200
{28004200
cm} kgf-cm}
[2460.5 to 3681.9 lbf-in.]
262
(Apply LOCTITE #262)
- 32 -
RING GEAR
SPIDER
SIDE GEAR
WASHER
Tightening torque:
95 to 142 N-m
{970 to 1450 kgf-cm}
[840.8 to 1257 lbf-in.]
WASHER
PINION GEAR
Tightening torque:
44 to
54 N-m
Nm
{4504454
to 550 kgf-cm}
[389.4
to 477.9 kgf
lbf-in.]
{450550
m}
TAPERED ROLLER
BEARING
2
COUNTER
GEAR 2
Tightening torque:
34.3 to 44 N-m
{350 to 450 kgf-cm}
[303.6 to 389.4 lbf-in.]
SPACER
TAPERED
ROLLER
BEARING
STARTING
TORQUE
MEASUREMENT
BOLT
(M12-1.25,100mm)
(M12-1.25, LENGTH
100 mm [3.9 in.])
O-RING
Shim: 0.5 [0.0197]
(standard)
0.5
O-RING
STOPPER
Starting torque: 1.5 to
1.53.5
N3.5
m N-m
{15.3 to 35.7 kgf-cm}
[13.3 to 31.0 lbf-in.]
COUNTER
1
GEAR 1
O-RING
MOTOR
DRIVE GEAR
Tightening
torque: 278Nm
to 416 N-m
278416
{2800 to 4200 kgf-cm}
{28004200
kgfto
cm}
[2460.5
3681.9 lbf-in.]
- 33 -
Tightening torque:
137 to 177 N-m
{1400 to 1800 kgf-cm}
[1212.6 to 1566.6 lbf-in.]
RING GEAR
Tightening torque:
95 to 142 N-m
{970 to 1450 kgf-cm}
[840.8 to 1257 lbf-in.]
SPIDER
SIDE GEAR
WASHER
PINION GEAR
WASHER
COUNTER
GEAR 2
2
TAPERED ROLLER
BEARING
Tightening torque:
34.3 to 44 N-m
{350 to 450 kgf-cm}
[303.6 to 389.4 lbf-in.]
SPACER
TAPERED
ROLLER
BEARING
STARTING TORQUE
MEASUREMENT
(M12-1.25,100mm)
BOLT (M12-1.25,
LENGTH 100 mm
[3.9 in.])
O-RING
STOPPER
O-RING
Starting
torque: 1.5 toN3.5
1.53.5
m N-m
{15.3 to 35.7 kgf-cm}
[13.3 to 31.0 lbf-in.]
COUNTER
1
GEAR 1
O-RING
MOTOR
DRIVE GEAR
Tightening
torque: 278 Nto
278416
m416 N-m
{2800kgf
to cm}
4200 kgf-cm}
{28004200
[2460.5 to 3681.9 lbf-in.]
- 34 -
AXLE HOUSING
OIL SEAL
TAPERED ROLLER
BEARING
WHEEL BRAKE
AXLE SHAFT
Tightening torque:
150 to 175 N-m
{1530 to 1780 kgf-cm}
[1330 to 1550 lbf-in.]
Tightening torque:
98 to 113 N-m
{1000 to 1150 kgf-cm}
[870 to 1000 lbf-in.]
(Apply LOCTITE#262)
LOCK NUT
ADJUSTMENT NUT
OIL SEAL
WHEEL BRAKE
BRAKE DRUM
AXLE HOUSING
AXLE SHAFT
OIL SEAL
HUB
Tightening torque:
370 to 420 N-m
{3770 to 4280 kgf-cm}
[3275 to 3717 lbf-in.]
LOCK NUT
ADJUSTMENT NUT
OIL SEAL
AXLE HOUSING
WHEEL BRAKE
- 37 -
BRAKE DRUM
OIL SEAL
AXLE SHAFT
HUB
Tightening torque:
471 to 549 N-m
{4800 to 5600 kgf-cm}
[4170 to 4860 lbf-in.]
LOCK NUT
ADJUSTMENT NUT
OIL SEAL
ADJUSTMENT NUT
LOCK WASHER
LOCK NUT
- 38 -
5. BRAKE SYSTEM
5. BRAKE SYSTEM
Truck model
FB10-8
FB15-8
FB18-8
Item
Type
FB20-8
FB25-8LB
FB25-8
FB25-8V
FB30-8
FB30-8V
FB35-8S
Duo-servo type
25.4 mm [1 in.]
279.4 mm [in.]
Lining size
279 x 48.5 x 5 mm
[10.98 x 1.91 x 0.20 in.]
302 x 55 x 5.1 mm
[11.9 x 2.2 x 0.2 in.]
348 x 76 x 7.67 mm
[13.7 x 3.0 x 0.31 in.]
Surface area
4 x 13530 mm2
[4 x 30 in.2]
4 x 16600 mm2
[4 x 25.7 in.2]
4 x 26400 mm2
[4 x 40.9 in.2]
Pedal ratio
Master cylinder bore
Wheel brake
Type
Wheel cylinder bore
Brake drum inner dia.
Parking brake
Type
BRAKE PEDAL
MASTER CYLINDER
- 39 -
BRAKE SWITCH
RESERVE TANK
MASTER CYLINDER
Height:
mm [3.8 in.] (FB10 - 25)
97
97mmFB1025
110mmFB3035
110
mm [4.3 in.] (FB30 - 35)
5. BRAKE SYSTEM
- 40 -
5. BRAKE SYSTEM
BLEEDER PLUG
from RESERVE TANK
CHECK
VALVE
SNAP RING
YOKE
LOCK NUT
SPRING
BOOT
PUSH ROD
SECONDARY CUP
- 41 -
PRIMARY CUP
PISTON
ANCHOR PIN
Ro
tat
io
of n di
dru rec
m tion
5. BRAKE SYSTEM
ADJUSTER
PIN
Secondary
Primary
STRUT
LEVER
PRIMARY SHOE
- 42 -
5. BRAKE SYSTEM
CABLE
GUIDE
SPRING
LEVER
ADJUSTER
Fig. 5.7
Expanding direction
- 43 -
5. BRAKE SYSTEM
PARKING
BRAKE LEVER
SWITCH
Fig. 5.10
- 44 -
5. BRAKE SYSTEM
Sectional view B - B
Sectional view D - D
Sectional view E - E
Sectional view C - C
1. BRAKE LEVER
2. SECONDARY SHOE
3. E RETAINER
4. WHEEL CYLINDER
5. RETURN SPRING
6. STRUT
7. SPRING
8. SHOE HOLD-DOWN
PIN
9. PRIMARY SHOE
10. SPRING
11. ADJUSTER LEVER
12. ADJUSTER
13. SPRING
1 4. PUSH ROD
15. BOOT
16. CYLINDER
17. PISTON
18. SPRING
19. CUP
- 45 -
5. BRAKE SYSTEM
Sectional view C - C
Sectional view E - E
Sectional view D - D
Sectional view B - B
1. BRAKE LEVER
2. SECONDARY SHOE
3. E RETAINER
4. WHEEL CYLINDER
5. RETURN SPRING
6. STRUT
7. SPRING
8. SHOE HOLD-DOWN
PIN
9. PRIMARY SHOE
10. SPRING
11. ADJUSTER LEVER
12. ADJUSTER
13. SPRING
1 4. PUSH ROD
15. BOOT
16. CYLINDER
17. PISTON
18. SPRING
19. CUP
- 46 -
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.
Fig. 5.13
Fig. 5.14
Fig. 5.15
- 47 -
5. BRAKE SYSTEM
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.
Fig. 5.17
(6) Remove the E retainer which secures the
parking brake cable to the backing plate.
After that, remove the bolt securing the
backing plate and remove the backing plate
from the axle.
Fig. 5.18
(7) Remove the boot and insert the piston to
remove one of the two wheel cylinders.
Then remove the other wheel cylinder by
pushing with a finger from the opposite
side.
Fig. 5.19
- 48 -
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.]
Fig. 5.20
(2) Visually check the piston cup for damage or deformation and replace any damaged or
deformed one.
(3) Measure the free length of the wheel cylinder spring. If the length is out of the standard value,
replace the spring.
(4) Measure the brake lining thickness and
replace any excessively worn lining.
Unit: mm [in.]
Standard
Limit
1.0 1.8 t
2.0 3.5 t
4.87 [0.192] 7.67 [0.302]
2.5 [0.098] 5.0 [0.197]
Fig. 5.21
(5) Visually check the inner surface of the
brake drum. If any damage or uneven wear
is observed, grind it to repair. Replace an
excessively damaged or worn drum.
Unit: mm [in.]
1.0 1.8 t 2.0 2.5 t 3.0 3.5 t
Standard
Limit
254
[10]
279.4
[11]
314
[12.36]
256
[10.1]
281.4
[11.1]
316
[12.44]
Fig. 5.22
- 49 -
5. BRAKE SYSTEM
Fig. 5.23
(5) Install the parking brake cable with the E retainer.
(6) Install the shoe with the hold-down spring.
Fig. 5.24
(7) Insert the spring into the strut and attach the strut to the shoe.
- 50 -
5. BRAKE SYSTEM
Fig. 5.25
(9) Install the spring, adjuster, adjuster spring
and adjuster lever, paying attention to the
following items:
Install the adjuster in such a way that the
left screw is used for the left brake, and that
the right screw is used for the right brake.
Install the adjuster so that its teeth do not
make contact with the spring.
Install the return spring at the adjuster side,
Fig. 5.26
with its longer hook attached to the adjuster
lever side.
After reassembling, check that the tip of the adjuster lever comes in contact with the adjuster
teeth.
(10) Install the brake pipe on the wheel cylinder.
(11) Measure the inner diameter of the brake
drum and the outer diameter of the shoe.
Adjust the adjuster so that the outer
diameter of the brake shoe is the inner
diameter 1.0 mm [0.0394 in.].
Fig. 5.27
- 51 -
5. BRAKE SYSTEM
Expanding part
Fig. 5.28
- 52 -
5. BRAKE SYSTEM
BRAKE SWITCH
97mmFB1025
Pedal
height: 97 mm [3.8 in.] (FB10 - 25)
110110mmFB3035
mm [4.3 in.] (FB30 - 35)
Fig. 5.29
Adjusting brake switch
(1) Make sure that the pedal upheight is the value shown in Figure 5.29. Loosen the brake switch
lock nut.
(2) Remove the brake switch lead wire from the connector.
(3) While turning the brake switch and pressing down the brake pedal by 5 to 10 mm [0.2 to 0.4
in.], check and find the position where the switch turns ON.
(4) Secure the brake switch with the lock nut.
- 53 -
5. BRAKE SYSTEM
Poor braking
force
Probable Cause
Remedy
Repair.
3. Overheating brake
Repair or replace.
Adjust.
Uneven
braking
Soft or spongy
brake
Repair or replace.
Repair or replace.
Replace.
Replace.
Repair or replace.
Repair or replace.
Replace.
5. Deflected Drum
Repair or replace.
Adjust.
Repair.
Bleed air.
4. Pedal maladjusted.
Adjust.
- 54 -
FB10-8
FB15-8
FB18-8
FB20-8
FB25-8
FB30-8
FB25-8V
FB35-8S
FB25-8LB
FB30-8V
Steering axle
Type
King pin spacing
Toe-in
0 mm
Camber
Caster
Wheel dimension
16 x 6-8
10PR
18 x 7-8
14PR
Inner wheel
78.4
75.3
Outer wheel
53.3
59.2
Rim size
Air pressure
4.25 x DT
2
Steering angle
Orbitrol
Type
Discharge
Power cylinder
Type
Cylinder bore
71 mm [2.8 in.]
40 mm [1.57 in.]
Stroke
- 55 -
JOINT (LEFT)
POWER CYLINDER
JOINT (RIGHT)
KNUCKLE
(LEFT)
KNUCKLE
(RIGHT)
Point notched surface
toward knuckles shaft
POTENTIOMETER
KING PIN
Detail of A
- 56 -
PIN
PIN
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
CAP
O-RING
LOCK PIN
NEEDLE BEARING
OIL SEAL
Detail of D
- 57 -
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)
D See Figure 6A.4.
KNUCKLE
(LEFT)
Point notched surface
toward knuckles shaft
KING PIN
Detail of A
KNUCKLE
(RIGHT)
POTENTIOMETER
- 58 -
PIN
PIN
BUSHING
SPHERICAL
BUSHING
KING PIN
Detail of C
OIL SEAL
OIL SEAL
TAPERED ROLLER
BEARING
NEEDLE BEARING
THRUST BEARING
TAPERED ROLLER
BEARING
ADJUSTMENT NUT
CAP
COTTER PIN
OIL SEAL
Detail of D
- 59 -
STEERING WHEEL
ORBITROL
- 60 -
COMBINATION SWITCH
ASSEMBLY
Front of
the truck
Front of
the truck
- 61 -
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. The valve housing is
provided with four ports which lead to the pump, tank, right and left chambers of the cylinder.
Between the inlet port and return port is a check valve.
The metering device consists of an internally toothed stator and an externally toothed rotor.
During normal operation, it operates as an oil motor. In an emergency, it can be used as hand
pump. The rotor is mechanically linked with the sleeve through the drive shaft so that feedback
operation is possible.
The sleeve is interlocked with the motors rotor through the cross pin and drive shaft while the
spool is splined to the steering shaft.
ORBITROL
VP VALVE
L
R
EF
EF PORT
L PORT
R PORT
P PORT
- 62 -
Fig. 6A.8
- 63 -
The returning oil from the power cylinder flows, passing through the cylinder port R, groove
in the valve housing, oil hole in the sleeve, groove in the spool, oil hole 22 in the sleeve, and
groove in the valve housing, back to the oil tank.
(c) When steering wheel is turned clockwise
As the steering wheel is turned clockwise, the
grooves in the spool shift to the right in relation to
the oil holes and grooves in the sleeve so that oil
holes in the spool get out of line with holes
in the sleeve. The oil that has flowed into groove
thus far begins to flow into oil hole in the
sleeve and then flows through grooves 23 and
in the spool, oil hole in the sleeve, and oil
passage in the valve housing to the hydraulic
motor. The hydraulic motor thus rotates in the
clockwise direction and the oil discharged from
the hydraulic motor flows through oil hole in
the sleeve, groove in the spool, and oil hole
in the sleeve to the cylinder port R in the housing
and thus actuates the power cylinder.
The returning oil from the power cylinder
flows, passing through the cylinder port L, groove
in the housing, oil hole in the sleeve, groove
in the spool, oil hole 22 in the sleeve and
groove in the housing back to the oil tank.
Fig. 6A.10
(2) Relationship between the rotating speed and operating force of the steering wheel
The force required to operate the orbitrol is basically a valve operating force (the force
required to compress the centering spring: 2.9 N-m {0.3 kgf-m} [2.14 lbf-ft]). That is, there is
no mechanical linkage between the steering wheel and the tires, and thus the operating force of
the steering wheel remains constant regardless of the rotating speed of the steering wheel. The
discharge of oil from the orbitrol rotor to the steering cylinder is 80 cm3/revolution.
(3) Neutral feedback of orbitrol
The neutral feedback function of the orbitrol is performed by the valve switching over the oil
passages according to the reaction force of the centering spring. (If the steering wheel is turned and
then released with the engine turned off, it will automatically return to the straight-ahead position.)
Should the neutral feedback not function properly, the steering wheel might turn by itself when the
operator does not turn it.
- 64 -
Tightening torque:
27.7 to 41.5 N-m
{28.3 to 42.3 kgf-m}
[20.43 to 30.6 lbf-ft]
BUSHING
BUSHING
BOLT
O-RING
PACKING
BUSHING
PACKING
CAP
DUST SEAL
A
PISTON ROD
- 65 -
6. STEERING SYSTEM
NOTE
- 66 -
FB10-8
FB15-8
FB18-8
FB20-8
FB25-8
FB25-8LB FB25-8V
FB30-8
FB30-8V
FB35-8S
48 V
350 W
235 mm [9.3 in.]
550 W
72 V
48 V
Max. 40 A
Max. 45 A
72 V
Elliot type
85.8
55.6
735 mm [28.9 in.]
0
0
0
0
0
83.5
56.4
740 mm [29.1 in.]
16 x 6 8 10PR
4.25 x DT
850 kPa {8.5 kgf/cm2}
[120.9 psi]
18 x 7 8 14PR
- 67 -
EPS
CONTROLLER
POTENTIOMETER
EPS MOTOR
ACTUATOR
- 68 -
Tightening torque:
16.7 to 27.5 N-m
{170 to 280 kgf-cm}
[147.8 to 243.4 lbf-in.]
22
21
Tightening torque:
19.6 to 29.4 N-m {200 to 300 kg-cm}
[173.5 to 260.2 lbf-in.]
23
Tightening torque:
16.7 to 27.5 N-m
{170 to 280 kgf-cm}
[147.8 to 243.4 lbf-in.]
24
25
26
27
Tightening torque: 37.3 to 53 N-m
{380 to 540 kgf-cm}
[330.1 to 469.1 lbf-in.]
Tightening torque:
140 to 170 N-m
{1427.6 to 1733.5 kgf-cm}
[1239.1 to 1504.6 lbf-in.]
Sectional view A - A
- 69 -
1. SHAFT
2. DUST COVER
3. OIL SEAL
4. NEEDLE BEARING
5. REAR COVER
6. O-RING
7. GEARBOX
8. BALL NUT
9. NEEDLE BEARING
10. OIL SEAL
11. THRUST BEARING
12. SPRING
13. SENSOR HOUSING
14. O-RING
15. THRUST BEARING
16. LOCK NUT
17. FRONT COVER
18. SLIDE RING
19. ARM
20. ROLLER
21. POTENTIOMETER
22. SHIMS
23. LOCK NUT
24. ADJUSTMENT SCREW
25. SIDE COVER
26. SECTOR SHAFT
27. OIL SEAL
STEERING
WHEEL
STEERING
WHEEL LOCK
LEVER
JOINT
STEERING
GEARBOX
DRAG LINK
ACTUATOR
- 70 -
Front of
the truck
COMBINATION
SWITCH ASSEMBLY
- 71 -
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.
The actuator is installed with its tube side fitted to the frame of the truck by a universal joint and
with its screw side fitted to the center arm of the axle by a ball joint.
EPS MOTOR
PINION GEAR
IDLE GEAR
BREATHER
UNIVERSAL JOINT
BALL SCREW
BALL NUT
- 72 -
CENTER ARM
KNUCKLE (RIGHT)
KNUCKLE (LEFT)
POTENTIOMETER
KING PIN
View looking from B
Detail of A
- 73 -
CENTER ARM
SUPPORT (FRONT)
KNUCKLE (RIGHT)
KNUCKLE (LEFT)
POTENTIOMETER
KING PIN
Detail of A
- 74 -
OIL SEAL
KING PIN
NEEDLE BEARING
TAPERED ROLLER
BEARING
OIL SEAL
LOCK NUT
THRUST BEARING
COTTER PIN
CAP
OIL SEAL
NEEDLE BEARING
HUB
LOCK PIN
SHIM
OIL SEAL
- 75 -
- 76 -
6B.2 MAINTENANCE
6B.2.1 MAINTENANCE FOR ACTUATOR
(1) Replacing the motor
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
Remove the motor securing bolts, then
remove the motor.
Note: Do not give a strong shock to the motor.
Fig. 6B.10
Remove the packing from the motor fitting
surface.
Fig. 6B.11
Apply grease to the joint. Install the motor
with a new packing.
Tightening torque: 18.6 to 30.4 N-m
{1.9 to 3.1 kgf-m}
[13.7 to 22.4 lbf-ft]
Fig. 6B.12
- 77 -
BOOT
BALL JOINT
Fig. 6B.13
Loosen the lock nut of the ball joint, then
remove the ball joint.
BOOT
BALL JOINT
LOCK NUT
Fig. 6B.14
Apply LOCTITE#271 to the threaded areas
of the connector and lock nut. Then install
the ball joint.
61 2 mm
[2.4 0.078 in.]
CONNECTOR
Apply LOCTITE#271
LOCK NUT
BALL JOINT
Fig. 6B.15
(3) Replacing the boot
Hold the connector section in a vise.
BOOT
BALL JOINT
CONNECTOR
Fig. 6B.16
- 78 -
CLAMP
BOOT
LOCK NUT
CLAMP
BALL JOINT
Shift to this position
Fig. 6B.17
Replace the boot with a new one. When
installing the new one, let its end of larger
outer diameter face the actuator.
Fig. 6B.18
Turn counterclockwise the ball screw till it
contracts the most.
Apply LOCTITE#271 to the threaded areas
of the connector and the lock nut, then install
the connector as specified in Figure 6B.19.
Tightening torque: 176.5 to 215.8 N-m
{18 to 22 kgf-m}
[130 to 159 lbf-ft]
Clamp the both ends of the boot by wire.
Before clamping, align the position of the
joint, as shown in Figure 6B.21, to correct a
dislocation of the boot.
Fig. 6B.19
BOOT
BALL JOINT
Fig. 6B.20
Breather plug direction
(1 to 2.5 t)
20
20
MASTER HOLE
(3.0 to
3.5 t)
Fig. 6B.21
- 79 -
6. STEERING SYSTEM
NOTE
- 80 -
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
Truck model
FB18-8
FB20-8 FB25-8
FB25-8LB FB25-8V
FB30-8
FB30-8V
FB35-8S
Gear type
TMG1A18
18.9 cm3/rev
Directly connected
to motor
TMG1A20
21 cm3/rev
TMG1A23
24.5 cm3/rev
15.7MPa
{160 kgf/cm2}
[2275 psi]
17.2 MPa
{175 kgf/cm2}
[2489 psi]
Single-acting piston
type
45 mm [1.77 in.]
35 mm [1.38 in.]
1495 mm [57.4 in.]
(when lifting height is
3000 mm [118.1 in.])
FB10-8
FB15-8
Item
Main pump
Type
Name
Discharge
Drive
Control valve
Type
Name
Pressure setting
Lift cylinder
Type
Cylinder inner dia.
Rod outer dia.
Stroke
Tilt cylinder
Type
Cylinder inner dia.
Rod outer dia.
Stroke
Hydraulic oil tank
Type
Capacity
Double-acting
piston type
65 mm [2.56 in.]
30 mm [1.2 in.]
120 mm [4.72 in.]
70 mm [2.8 in.]
Separate type
18 L [4.8 US gal]
25 L [6.6 US gal]
- 81 -
7. HYDRAULIC SYSTEM
1. DRIVE GEAR
2. SNAP RING
3. OIL SEAL
4. GASKET
5. SIDE PLATE
6 PUMP BODY
7. REAR COVER
8. HYPSILOID
GASKET
9. DRIVEN GEAR
10. BUSHING
11. FRONT COVER
- 82 -
7. HYDRAULIC SYSTEM
A2
B2
PORT G
A1
G
P
LIFT SPOOL
Hydraulic
circuit diagram
TILT SPOOL
LIFT-LOCK RELEASE
SCREW
PORT
B2
B2
PORT T
A2
PORT A2
PORT P
A1
PORT A1
SOLENOID VALVE
(FOR LIFT LOCK)
()
POTENTIOMETER
- 83 -
7. HYDRAULIC SYSTEM
TILT LEVER
ATTACHMENT LEVERS
(OPTIONAL)
LIFT LEVER
VALVE SWITCH
VALVE SWITCH
PLUNGER
CONTROL VALVE
0.80.1 mm
(0.0310.0039 in.)
- 84 -
7. HYDRAULIC SYSTEM
RELIEF VALVE
LOCK NUT
ADJUSTMENT
SCREW
1.8 t
2.0 to 3.5 t
- 85 -
7. HYDRAULIC SYSTEM
OIL
FILL CAP
BREATHER
to MAIN PUMP
Detail
of part A
SUCTION
FILTER
DRAIN
PLUG
- 86 -
7. HYDRAULIC SYSTEM
PISTON
SPRING
CASE
- 87 -
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. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT
NUT
19. LOCK NUT
20. COTTER PIN
- 88 -
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. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT
NUT
19. LOCK NUT
20. COTTER PIN
- 89 -
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. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT
NUT
19. LOCK NUT
20. COTTER PIN
- 90 -
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. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
- 91 -
7. HYDRAULIC SYSTEM
LIFT CYLINDER
(RIGHT)
LIFT CYLINDER (LEFT)
to OIL TANK
to CONTROL
CUT-OFF VALVE
through the chambers D . E , D , C , B and A
back into the control valve.
In this step, the more the oil flow via the
This sketch shows the flow regulator valve and related
hole C in the piston becomes, the larger the
components for the 1- to 2.5-ton trucks. On 3- to 3.5-ton
pressure difference between the front and rear
trucks, the positions of the flow regulator vale and cut-off
vale are reversed from this sketch.
of the piston becomes.
When the force that pushes the piston ,
Fig. 7.12 Mast Piping
produced by the pressure differential, is greater
than the spring force , the piston moves to the right. The hole D is narrowed by the hole C
to limit the flow rate, and the fork lowering speed is thus controlled.
When the forks are raised, the high-pressure oil from the control valve flows through the
chambers A , B , C , D , E , F , and G into the lift cylinders.
Free flow
Regulated
flow
1. CASE
2. SPRING
3. BALL
4. PISTON
5. SLEEVE
6. ORIFICE
7. SPRING
8. O-RING
9. NIPPLE
- 92 -
7. HYDRAULIC SYSTEM
Free
flow
Regulated
flow
Lift cylinder side
1. SPRING
2. CASE
3. SPRING
4. BALL
5. PISTON
6. SLEEVE
7. ORIFICE
8. SPRING
9. O-RING
10. NIPPLE
- 93 -
7. HYDRAULIC SYSTEM
1. JOINT
2. DUST SEAL
3. BUSHING
4. O-RING
5. PACKING
6. CYLINDER CAP
7. O-RING
8. LOCK RING
9. ROD
10. CYLINDER
11. PACKING
12. PISTON
13. LOCK NUT
- 94 -
- 95 -
MAIN PUMP
ORBITROL
CONTROL VALVE
to LIFT CYLINDER
OIL TANK
STEERING CYLINDER
7. HYDRAULIC SYSTEM
CONTROL VALVE
MAIN PUMP
to LIFT CYLINDER
OIL TANK
7. HYDRAULIC SYSTEM
- 96 -
7. HYDRAULIC SYSTEM
7.2 MAINTENANCE
7.2.1 MAINTENANCE OF PUMP
Cautions
1. Before disassembling the pump, check for oil leaks from the oil seal, the mating section of
the pump body and cover, and other areas.
2. 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.
3. The pump has some symmetrical parts. Before disassembling the pump, mark the parts in
the manner shown in the disassembly procedure, to ensure correct reassembly. For this
purpose, use oil paint not to damage the parts.
4. Disassembly is a means of finding out the cause of a trouble. Observe the procedure for
disassembling the pump.
5. Before disassembly, make sure you get new packings, gaskets, and oil seals.
(1) Disassembly
Hold the front cover in a vice with the
input shaft side downward.
Notes: 1. The bolts will be loosened during
disassembly. Make sure to hold the
front cover in a vice securely as
shown in Figure 7.18, to prevent the
pump from the vice when a force is
applied on the pump.
2. Mark the rear and front covers and
the drive gear side of the pump body
with oil paint.
Fig. 7.18
Fig. 7.19
- 97 -
7. HYDRAULIC SYSTEM
Fig. 7.20
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. 7.21
Remove the pump body. If the gaskets
remain inside the pump body, move them
toward the front cover side.
Fig. 7.22
Put the mark RV the rear cover side plate
at the drive gear side before removing the
side plate.
Fig. 7.23
- 98 -
7. HYDRAULIC SYSTEM
Fig. 7.24
Holding the front side plate, remove the
drive gear.
Fig. 7.25
Put the mark FV on the front side plate
at the drive gear side, and remove the side
plate.
Fig. 7.26
Turn over the front cover and hold it again
in the vice. Remove the snap ring.
Fig. 7.27
- 99 -
7. HYDRAULIC SYSTEM
Fig. 7.28
- 100 -
7. HYDRAULIC SYSTEM
CAUTION
1.
2.
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 shown in this section should be used as a rough guide. We do not always
guarantee the performance of a part if it does not reach its useful limit.
Name of component
Front cover
Items to be checked
CAUTION
The mating section between the front cover and the pump body looks black
in some parts. This is caused by the friction between aluminum parts and is
not a problem.
Pump body (cast (a) Check for cracks or damage.
iron)
(b) Check wipe depth or wipe surface.
Useful limit
Wipe depth limit: less than 0.04 mm [0.0016 in]
Drive and
driven gears
Runout of gears
Pumps performance is not affected if
there is a sign of interference.
CAUTION
OIL SEAL
INPUT
SHAFT
SIDE PLATE
BUSHING
BUSHING
Useful limit
- 101 -
7. HYDRAULIC SYSTEM
Name of component
(continued from the
preceding page)
Items to be checked
(c) Check for discoloration, undue wear, Contaminants in oil, too high oil
or roughness on the gears.
temperature (120C [248F] or higher),
too frequently idle operations
Useful limit
0.1 mm [0.0040 in] or less
Side plate
Cavitation or aeration
Useful limit
Wear limit: 0.15 mm (0.006 in) or less
LBC surface
These areas
might be worn
Discharge port
Erosion
might occur
here due to
cavitation.
Bushing
The bushings
are fitted into
front and rear
covers.
Suction port
Useful limit
When the back plate of the bushing is exposed to view.
Gasket
Oil seal
CAUTION
The oil seal might be
damaged when the drive
gear is disassembled
or when it is removed
from the front cover. It
is difficult to locate the
cause of damage when
removing it from the
front cover.
(b) Check main lip for warping outward. Increased internal oil leaks or high oil
pressure (0.2 - 0.3 MPa {2 - 3 kgf/cm2} [28.5
- 42.7 psi] or more) applied on oil seal
(c) Check rubber parts for swelling.
- 102 -
7. HYDRAULIC SYSTEM
Fig. 7.29
Install a new gasket in the groove in the front
cover.
Fig. 7.30
Install a new E gasket in the groove in the
front cover, referring to Figure 7.32.
Fig. 7.31
3-shaped gasket
groove
Flat surface
Suction
side
B-B section
Flat surface
Discharge
side
Suction
side
C-C section
A-A section
(b) 3-shaped gasket
- 103 -
7. HYDRAULIC SYSTEM
Fig. 7.33
Counterclockwise rotation:
Rear side
Clockwise rotation:
Front side
Counterclockwise rotation:
Front side
Clockwise rotation:
Rear side
Drive side
Suction port
(larger radius)
Discharge port
(smaller radius)
Projection (to be
always pointed to
drive side)
Driven side
Fig. 7.34
Install the front side plate on the front cover,
referring to Figure 7.36.
Fig. 7.35
LBC surface
LBC()
(yellow)
Discharge
side
(smaller
radius)
(R)
Back plate
(SC)
(SC
material)
Suction side
(larger radius)
(R)
Suction
side
Discharge side
LBC
The LBS surface should be always
pointed to gears side face
Fig. 7.36
- 104 -
7. HYDRAULIC SYSTEM
Fig. 7.37
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. Failure to do so might damage the gear teeth.
Smaller pressure
angle side
Engagement surfaces
(shaded sections)
Drive
side
Driven
side
Fig. 7.39
- 105 -
7. HYDRAULIC SYSTEM
Fig. 7.40
Apply grease on a new gasket in some points
and install the gasket in the rear cover groove.
Fig. 7.41
Gasket groove
E gasket
Discharge side
Suction side
Fig. 7.42
Install the 3-shaped gasket in the rear
cover, as shown in Figure 7.32.
Fig. 7.43
- 106 -
7. HYDRAULIC SYSTEM
Fig. 7.44
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. 7.45
Remove the pump from the vice and put it on a
work bench.
Apply grease on the area between the lips
and on the outer diameter of a new oil seal.
Install it on the oil seal guide shown in Figure
7.51. Put it on the drive shaft of the pump, and
install the oil seal onto the front cover with an
oil seal snap.
Fig. 7.46
Main lip
Fig. 7.47
Fig. 7.48
- 107 -
7. HYDRAULIC SYSTEM
Secure the oil seal with a snap ring and remove the oil seal guide.
Cross section of
C lock ring
(Front
cover)
Oil seal
Fig. 7.49
Fig. 7.50
4
[0.16]
17
[0.67]
20
2 [0.08]
4
[0.16]
R2
[0.08]
R5
[0.2]
R2
[0.08]
+0.05
-0
0
-0.05
[0.868
[0.906
+0.002
-0
0
-0.002
100 [3.9]
115 [4.5]
92 [3.622]
62 [2.44]
71 [2.8]
R2
[0.08]
22.05
23.0
Unit: mm
]
]
23.1-0.05
0
[0.91-0.002
]
0
35.5+0.5
[1.398+0.02
]
0
0
Fig. 7.51
- 108 -
7. HYDRAULIC SYSTEM
- 109 -
7. HYDRAULIC SYSTEM
Cause
Remedy
Readjust.
Readjust.
Spring defective
Set surface defective
Replace spring.
Readjust.
Replace relief valve.
Poppet stuck.
Cause
Remedy
Defective pump
- 110 -
FB10-8 FB15-8
FB18-8
VM-7P1
3000 mm
[118.1 in.]
Hydraulic
Hydraulic
Leaf chain
BL534
FB20-8
FB25-8
FB25-8LB
FB25-8V
F30-8
FB30-8V
VM-7P4
VM-7P5
VM-7P7
Roller type 2-step telescopic mast with free lift
Leaf chain
BL634
FB35-8S
VM-7P9
Leaf chain
BL823
Leaf chain
BL834
A: 60 mm
[2.36 in.]
B: 124 mm
[4.88 in.]
C: 170 mm
[6.69 in.]
44 mm
[1.73 in.]
B: 102.5 mm
[4.04 in.]
C: 134.5 mm
[5.30 in.]
A:
48 mm
[1.89 in.]
B: 119.5 mm
[4.71 in.]
C: 161.5 mm
[6.36 in.]
A:
A:
A:
Inner mast
43 mm
[1.69 in.]
B: 102.5 mm
[4.04 in.]
C: 134.5 mm
[5.30 in.]
D:
72 mm
[2.83 in.]
45 mm
[1.77 in.]
B: 119.5 mm
[4.71 in.]
C: 159.5 mm
[6.28 in.]
D:
76 mm
[2.99 in.]
- 111 -
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
- 112 -
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
- 113 -
1.
2.
3.
4.
5.
6.
7.
8.
FORK
CARRIAGE
END ROLLER
SHIM
SNAP RING
SIDE ROLLER
SHIM
SPACER
- 114 -
END ROLLER
END ROLLER
CARRIAGE
SIDE ROLLER
LIFT CYLINDER
SLIPPER
OUTER
CHANNEL
INNER
CHANNEL
END ROLLER
Upper section
Lower section
END ROLLER
- 115 -
- 116 -
LIFT CYLINDER
SLIPPER
OUTER
CHANNEL
END ROLLER
INNER
CHANNEL
Upper section
END ROLLER
SIDE ROLLER
CARRIAGE
Lower section
END ROLLER
END ROLLER
- 117 -
LIFT CYLINDER
SLIPPER
OUTER
CHANNEL
END ROLLER
INNER
CHANNEL
Upper section
END ROLLER
SIDE ROLLER
CARRIAGE
Lower section
END ROLLER
END ROLLER
SIDE ROLLER
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.
(2) Extend the rod of each lift cylinder slowly
and examine the difference in the rod
stopping time when the rod reaches the
stroke end between the two lift cylinders.
(3) Add shims to the space between the rod
and piston head of the lift cylinder whose
rod stops first.
Shim thickness: 0.2 and 0.5 mm
[0.0079 and 0.0197 in.]
(4) Adjust the lift chain tension.
LOCK BOLT
PISTON HEAD
SHIM
LIFT CYLINDER
Fig. 8.7
8.2.2 ADJUSTING HEIGHT OF CARRIAGE
(1) Stop the truck on a level surface and put
the mast vertically.
(2) Keep the fork bottom on the ground and
adjust the projected amount A of the
carriage lower end roller to the value as
shown in Table 8.1, using the chain anchor
pin at the mast side.
INNER CHANNEL
END ROLLER for
carriage
FORK
Table 8.1
Model Mast Type
1 1.8 t VM-7P1
2 2.5 t VM-7P4
3.0 t
VM-7P7
3.5 t
VM-7P9
TIRE
A (mm [in.])
36 41 [1.42 1.61]
24 29 [0.94 1.14]
44 49 [1.73 1.93]
37 42 [1.46 1.65]
Fig. 8.8
- 118 -
INNER CHANNEL
STOPPER
CARRIAGE
STOPPER
CHAIN ANCHOR
PIN at mast side
Fig. 8.9
CHAIN
ANCHOR PIN
ADJUST NUT
LOCK NUT
Fig. 8.10
- 119 -
Stamp (S or SS)
Fig. 8.12
(7) Replacing side rollers
Remove the side roller assembly. Keep the
numbers of the shims and their combination
as they were.
Install a new roller with the shims removed
in step , pointing the groove for the balls
to the shim side. (See Figure 8.14.)
If there is excessive looseness between
the side roller and inner channel, add the
shims between the end roller and side
roller, seeing 8.2.5 PROCEDURE FOR
ADDING OR SUBTRACTING SHIMS.
SHIM
SHIM
SIDE
ROLLER
END
ROLLER
Fig. 8.13
- 120 -
Fig. 8.15
- 121 -
Fig. 8.16
SLIPPER
SHIM
SHIM
END ROLLER
SHIM
END
ROLLER
Fig. 8.17
(8) Operate the crane to hoist the inner
channel. Place each roller into the channels.
(9) Install the lift cylinder and carriage in the reverse order of disassembly.
- 122 -
SHIM
SHIM
Make contact
with one side.
SHIM
SHIM
Make contact
with one side.
Note: Apply grease to the end roller contacting surface of each channel.
Procedure for Adding or Subtracting Shims
Fig. 8.18
- 123 -
NOTE
- 124 -
9. ELECTRIC SYSTEM
9. ELECTRIC SYSTEM
Headlights
Capacity
Front combination lights
Capacity
Side marker lights
Turn signal lights
Rear combination lights
Capacity
Tail/brake lights
Turn signal lights
Back-up lights
48 V - 40 W
48 V - 10 W
48 V - 25 W
48 V - 10 W/25 W
48 V - 23 W
48 V - 10 W
- 125 -
9. ELECTRIC SYSTEM
CN
13
102
169
107
12
132
131
177
178
238
270
98
111
102
105
106
110
95
96
180
109
97
100
116
112
113
26
14
View looking
from A
- 126 -
9. ELECTRIC SYSTEM
RR
50W
RL
50W
RM
80W
HEADLIGHTS
RT
44W
TAIL/SIDE MARKER
CR
3.5W0.1A
CHIME
RB
BACK-UP LIGHT
+
35 W
35W
BEACON LIGHT
RF
*
* OPTIONAL EQUIPMENT
CHIME
0.15A
0.15 A
+
35 W
35W
BEACON LIGHT
RK
*
* OPTIONAL EQUIPMENT
150 W
150W
(INTERLOCKED WITH THE
()
KEY SWITCH OPERATION)
- 127 -
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
SWITCH
F/R LEVER
*1
*1
HORN
N
IG2
TR
TB
TL
VF
IG1
VR
ST
VF2
Ra
LH
EL
LT
- 128 -
9. ELECTRIC SYSTEM
RELAY UNIT
(RT)
(RM)
LIGHT SWITCH
OFF
F-19
F-6
F-11
F-7
F-10
F-22
F-13
F-26
T
H
R 177
WR 107
GY 178
WG 109
RW12
B2
RG 102
EL LT LH
KEY SWITCH
RW12
F4
10A
R5
B+
F5
10A
RG 102
FRONT
COMBINATION
LIGHT
(LEFT)
FRONT COMBINATION
LIGHT (RIGHT)
BATTERY
(10W)
TAIL
LIGHT
(10W)
TAIL LIGHT
(40W)
HEADLIGHT
(RIGHT)
(40W)
HEADLIGHT
(LEFT)
(10W)
SIDE
MARKER LIGHT
(10W)
SIDE
MARKER LIGHT
WG 109
REAR
COMBINATION
LIGHT
(LEFT)
REAR COMBINATION
LIGHT (RIGHT)
- 129 -
9. ELECTRIC SYSTEM
RELAY UNIT
(RL)
(RR)
TURN
SIGNAL SWITCH
N
F-25
F-9
F-24
F-8
F-10
F-22
F-13
F-26
R
L
G 105
LW 132
L 131
GR 106
RW12
B2
RG 102
TB TR TL
KEY SWITCH
RW12
F4
10A
R5
B+
F5
10A
RG 102
FRONT
COMBINATION
LIGHT (LEFT)
FRONT
COMBINATION
LIGHT (RIGHT)
BATTERY
REAR
COMBINATION
LIGHT (LEFT)
- 130 -
(25W)
TURN
SIGNAL LIGHT
(25W)
TURN
SIGNAL LIGHT
(25W)
TURN
SIGNAL LIGHT
(25W)
TURN
SIGNAL LIGHT
G 105
REAR
COMBINATION
LIGHT (RIGHT)
9. ELECTRIC SYSTEM
HEAD LIGHT
FRONT
COMBINATION
LIGHT
1 - to 11.8t
1.8-ton trucks
2- to 23.5t
3.5-ton trucks
View looking
from A
- 131 -
9. ELECTRIC SYSTEM
A - AA - A
view
Sectional
- 132 -
1. LENS
2. RIM
3. HOUSING
4. REFLECTOR
5. GASKET
6. BULB
9. ELECTRIC SYSTEM
GROUNDING
TURN SIGNAL
View looking
from A
SIDE MARKER
BACK-UP LIGHT
TURN
SIGNAL
BACK-UP
BRAKE
GROUNDING
TAIL
View looking
from A
Fig. 9.8
Combination Light
- 133 -
BRAKE/TAIL LIGHT
/
9. ELECTRIC SYSTEM
SCREW
REFLECTOR
40W-48V
GASKET
LENS
RIM
1. Use caution not to get burnt because the surface of a hot soon after it is turned off.
2. Use caution not to contaminate the bulb and reflector surfaces.
With the gasket, install the lens and reflector.
BACK-UP LIGHT
10W-48V 10W-48V
LENS
BODY
SCREW
TURN
SIGNAL
STOP/
LIGHT
TAIL
LIGHT
25W/10W-48V 25W-48V
25W-48V
25W/10W-48V
25W-48V
25W-48V
SCREW
BODY
SIDE
MARKER LIGHT
10W-48V
10W-48V
LENS
- 134 -
TROUBLESHOOTING
TABLE OF CONTENTS
1. CONTROL CIRCUITS. ...................................................................................................... 1
1.1
1.2
1.3
1.4
3. TROUBLESHOOTING GUIDE.................................................................................... 35
3.1
3.2
3.3
3.4
3.5
3.6
4. PARAMETER SETTING................................................................................................. 73
4.1
4.2
4.3
4.4
4.5
4.6
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
CN1D-8 terminals
When the key switch is turned on, the battery
voltage is applied to these terminals and the
inverter unit is energized.
Power Supply
Drive
motor inverter unit
CN1D-8
CN1D-7
RW11
Drive
motor inverter unit
CN2D-9
CN2D-21
Unit: V
LG 92
LB 184
CN2D-33
2 2
Accelerator
Potentiometer
WR 185
LY 93
CN2D-8
CN2D-20
BG 186
LW 187
CN2D-32
1 1
Accelerator
Potentiometer
2. Accelerator potentiometer
(1) Accelerator 1 potentiometer
4.5 V is supplied from CN2D-32. The
voltage at CN2D-8 varies according to the
amount of accelerator pedal effort.
(2) Accelerator 2 potentiometer
4.5 V is supplied from CN2D-33. The
voltage at CN2D-9 varies according to the
amount of accelerator pedal effort.
(3) Voltage at CN2D-8 and CN2D-9 terminals
Terminal
Accelerator 1
CN2D-8
Accelerator 2
CN2D-9
Drive System
Brake
switch
RG102
W110
F-14
CN1D-4
F-23
(RB)
Drive
motor inverter unit
WR 113
BW 112
F-15
Relay unit
to Brake light
F5
to Fuse F5
-1-
3.92 0.2
0.5 0.1
1.96 0.2
3. RB relay
(1) This relay enables the inverter unit to know
when the brake pedal is pressed.
(2) When the brake pedal is pressed, the
brake switch is turned on and the CN1D-4
terminal voltage changes from 4.6 V to 0 V.
1. CONTROL CIRCUITS
Circuit Diagram
Description
4. Parking brake switch
(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.
(2) Voltage between CN1D-5 and CN1D-29
Parking brake lever pulled: 0V (switch
ON)
Parking brake lever released: 5V (switch
OFF)
Drive
motor inverter unit
0 15
Parking
switch
BR 9
CN1D-29
CN1D-5
to LCD panel
Drive
motor inverter unit
CN1D-19
CN1D-18
F/R
F/R
lever switch
Unit: V
Lever position
WBr 53
WL 54
R
N IG1 IG2 VF VF2 ST VR Ra
N
(Neutral)
F
(Forward)
R
(Reverse)
CN1D-18
4.6
4.6
CN1D-19
4.6
4.6
GND
Drive
motor inverter unit
LR 95
F-2
CN1D-34
WB 98
F-21
F-22
(BB)
Relay unit
RW11
Drive System
F
N
-2-
6. BB relay
(1) Activates the back-up buzzer and light.
(2) When the F/R lever is placed in the R
position, the battery supplies voltage to the
CN1D-34 terminal. This activates the BB
relay, feeding power to the back-up light
and buzzer.
1. CONTROL CIRCUITS
Circuit Diagram
Description
Drive
motor inverter unit
(RF)
Relay unit
WBr 97
LB 180
F-20
F-18
CN1D-33
7. RF relay (option)
(1) Activates the forward travel buzzer.
(2) When the F/R lever is placed in the F
position, the battery supplies voltage to the
CN1D-33 terminal. This activates the relay,
feeding power to the forward travel buzzer.
CN2D-16
CN2D-5
RB 32
GW 28
RY 34
CN2D-29
CN2D-15
CN2D-3
Drive motor
inverter unit
CN2D-6
CN2D-17
WR 17
Drive
motor thermosensor
WG 16
RW 31
GB 29
Rotation
sensor B
B
GY 33
Rotation
sensor A
A
CN2D-27
Drive System
to
forward travel
buzzer
Drive
motor inverter unit
-3-
1. CONTROL CIRCUITS
Circuit Diagram
Description
Switch panel
S.P.E
S.P.E
selection
switch
S4
WL 75
S5
CN9-1-16
LCD
panel
CN2D-10
YL 43
CN2D-23
YB 42
YR 44
CN2D-34
Drive System
CN9-1-15
W 77
CN9-1-8 Gy 80
COM
Speed
control
switch
-4-
1. CONTROL CIRCUITS
Description
1. Pump motor inverter unit CN1P-7 and
CN1P-8 terminals
When the key switch is turned on, the battery
voltage is present at these terminals and the
inverter unit is energized.
Pump
motor inverter unit
CN1P-7
CN1P-8
RW11
2. Lift potentiometer
(1) Potentiometer power supply
4.8 V is supplied from the CN2P-32
terminal.
(2) Potentiometer signal
The voltage between CN2P-8 and
CN2P-20 terminals varies as follows,
according to the amount of lever movement
away from the neutral position.
CN2P-8
CN2P-20
YL 94
WR 188
GR 189
CN2P-32
Pump
motor inverter unit
Lever position
CN2P-8
terminal
CN1P-28
BL 8
CN1P-18
YL 22
ATT2
CN1P-17
YG 21
ATT1
CN1P-16
YR 20
Neutral
Up
1.1 V or
less
1.1 V or
less
2.4 to
4.5 V
Pump
motor inverter unit
TILT
Down
-5-
1. CONTROL CIRCUITS
Circuit Diagram
Description
4 Lift lock solenoid
(1) When the seat switch and the load handling
neutral safety switch are engaged, the lift
lock solenoid is energized.
(2) The voltage between the CN1P-35 terminal
and the negative (-) terminal.
Key switch ON (with seat switch ON): 36 V
Key switch ON (with seat switch OFF): 48 V
Pump
motor inverter unit
SOL
LIFT LOCK
O 138
F8
2A P 139
CN1P-35
RL100
Y 41
B 46
CN2P-5
CN2P-16
CN2P-29
W 40
Pump
motor controller
Pump
motor thermosensor
CN2P-6
YW 39
G 38
CN2P-17
Pump
motor rotation sensor
Pump
motor inverter unit
-6-
1. CONTROL CIRCUITS
CN1P-28
BL 8
CN1P-4
Description
OFF
ON
OFF
ON
ON
MODE SEL 1
MODE SEL 2
CN1P-5
Circuit Diagram
-7-
1. CONTROL CIRCUITS
Description
1. PS motor controller CN1E-17 terminal
When the key switch is turned on, the battery
voltage is present at this terminal and the PS
motor controller is energized.
PSPS
motor controller
RW11
2. PS torque sensor
(1) Power supply
4.6 V is supplied from the CN1E-6 terminal.
(2) Input voltage
(a) The EPS motor duty factor is controlled
according to the torque sensor CN1E-23
terminal voltage.
(b) The voltage between CN1E-23 and
CN1E-22 terminals:
In straight-ahead driving: 2.3 V
The voltage decreases when the steering
wheel is turned counterclockwise and
increases when it is turned clockwise.
G 161
L 160
CN1E-23
CN1E-6
CN1E-22
PSPS
motor controller
W 162
CN1E-17
Torque sensor
(Potentiometer)
()
SSC
1G
BG 243
SS1
LY 249
SS2
BY 244
ESS
BR 230
LG 246
Pump motor
inverter unit
CN2P-25
CN2P-2
CN2P-1
CN2P-13
CN2P-14
CN2P-29
BL 18
CN2P-21
Handle encoder
LG 19
Z
+15V
A
B
GND
-8-
When CN2P-21 is
not connected with
CN2P-29:
1. CONTROL CIRCUITS
1.4 OTHERS
Circuit Diagram
Description
1. Seat switch
(1) 4.6 V is supplied from CN1D-16.
(2) When the operator sits in the operators
seat, the seat switch turns on, releasing the
interlock.
(4.6 V0 V)
CN1D-29
BR 9
YW181
CN1D-16
Drive
motor inverter unit
CN1E-17
PS motor
controller
CN1P-7
RW11
PO
Excluding
trucks with
an Orbitrol
steering
system.
RG216
RL 100
RL 100
PO
YG 208
CN1P-8
CN1D-8
CN1D-7
Others
LCD panel
-9-
1. CONTROL CIRCUITS
Circuit Diagram
Others
11i
Excluding
trucks with
an Orbitrol
steering
system.
PS motor
controller
]
[
CN1E-34
CN1P-22
CN1D-24
r'
Pump motor
inverter unit
CN1P-24
Drive motor
inverter unit
Description
.
.
L
RL100
- 10 -
Main
contactor
EPS
EPS unit
DW
DW
motor terminal
DV
DV
motor terminal
PU
PU motor
terminal
DU
motor terminal
DU
PV motor
terminal
PV
Inverter
unit
(drive
motor)
()
PW motor
terminal
PW
Negative terminal
Inverter unit
(pump motor)
()
Positive terminal
CN1
CN1P
CN2P
CN2
CN1D
CN1
Positive
terminal CN2
CN2D
Negative terminal
PU
motor terminal
PU
EPS
EPS unit
DW
DW
motor terminal
CN1
CN1P
DV
DV
motor terminal
CN2
CN2P
DU
motor terminal
DU
Positive terminal
Inverter
unit
(drive
motor)
()
Negative terminal
Inverter
unit (pump
() motor)
Fuse (F1)
(F1)
Positive terminal
Main
contactor
- 11 -
Positive
terminal CN2
CN2D
Negative
terminal
PU motor terminal
DW motor terminal
CN1P
DV motor terminal
CN2P
DU motor terminal
Positive terminal
Inverter unit
(drive motor)
Negative terminal
Fuse (F1)
Positive terminal
Main contactor
- 12 -
Negative terminal
2.2 P
ROCEDURE FOR CHECKING THE CONTROLLER ASSEMBLY
SEPARATELY
- 13 -
Removing 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.
Top view
Thru holes
Removing the inverter unit (2- and 3-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.
Top view
Thru holes
- 14 -
Thru holes
Removing 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.
Top view
Thru holes
Thru holes
CAUTION
Do not hold the inverter unit by the covers grooves to detaching the inverter unit. Do not hold
the controller assembly by the connectors to lift it; otherwise there is a risk of damaging the cover or
boards or loosening the inverter seal.
- 15 -
U-phase motor
U
terminal
VB
VB
terminal
V-phase motor
V
terminal
CN2D.P
W-phase motor
W
terminal
CN1D.P
Internal
circuit diagram
NN
terminal
S-type inverter
S
U-phase motor
U
terminal
CN2P
V-phase motor
V
terminal
W-phase motor
CN1P
W
terminal
VB
VB
terminal
CN2D. P
12
12
24
13
36
25
24
25
13
36
- 16 -
VB-U
VB-V
VB-W
U-N
V-N
W-N
Multimeter
Normal value
Approximate
reading
VB
2 or 3 k
VB
2 or 3 k to
VB
2 or 3 k
VB
2 or 3 k to
VB
2 or 3 k
VB
2 or 3 k to
2 or 3 k
2 or 3 k to
2 or 3 k
2 or 3 k to
2 or 3 k
2 or 3 k to
Judgment
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
*1. The values in the Normal Value column should be used as a rough guide, because they may vary with the type of multimeter used
and batterys internal state of charge.
*2 If a digital multimeter is used, the resistance between each terminal will usually show a reading of 20 to 30 k as a normal value.
However, in this case too, the value may vary with the type of multimeter and the batterys internal state of charge.
If the resistance is 0 , a digital multimeter will read between 0 and 20-30 .
Notes
Apply a heat-dissipating silicone compound (KS-609: Shinetsu Kagaku) over the whole back-surface
of the inverter unit.
Make sure to apply the silicone compound whenever the inverter unit is replaced with a new one, to
allow the heat generated by the inverter unit to be transmitted to the aluminum base efficiently.
Make sure there is no metal powder, cuts, damage or burrs on the mating surfaces of the aluminum
base and the inverter unit before applying the compound.
- 17 -
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.
1. Main circuit terminal location and internal circuit diagram
VB
CN1E
B
A
VB
N
Internal
circuit diagram
Lock
B
CN1E
17
34
18
- 18 -
VB-A
VB-B
A-N
B-N
Multimeter
Normal value
Approximate
reading
VB
2 or 3 k
VB
2 or 3 k to
VB
2 or 3 k
VB
2 or 3 k to
2 or 3 k
2 or 3 k to
2 or 3 k
2 or 3 k to
Judgment
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
Defective if 0 or
The judgment varies according to charge
status of the capacitors in the main
circuit; defective if 0 is seen.
*1. The values in the Normal Value column should be used as a rough guide, because they may vary with the type of multimeter used
and batterys internal state of charge.
*2 If a digital multimeter is used, the resistance between each terminal will usually show a reading of 20 to 30 k as a normal value.
However, in this case too, the value may vary with the type of multimeter and the batterys internal state of charge.
If the resistance is 0 , a digital multimeter will read between 0 and 20-30 .
Apply a heat-dissipating grease 250 g on the back of the controller base plate (all areas) to allow the
heat generated by the controller to be transmitted to the counterweight efficiently.
- 19 -
2.2.5 MC CONTACTOR
Checking procedure
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.
Checking the coil
CONTACTOR
Remove the coil wiring connector.
Set the multimeter to the resistance range of x100 and
measure the resistance between the terminals.
Determine whether the contactor is defective or not according to the resistance value measured.
Resistance value (key switch OFF, battery connectors disconnected, at 20C [68F])
Resistance
about 20
Judgment
Good
Defective (replace contactor with a new one)
Judgment
Good
Defective (short circuit)
Defective (circuit open)
- 20 -
Symbol
Type
F1
96LFB-400
F1
96LFB-500
Cable side
Contact
side
F1
Checking procedure
Set the multimeter to measure voltage and connect the negative probe to the negative cable
connection terminal on the controller.
Connect the positive probe to the F1 fuse. Measure the voltage and determine whether the fuse is
defective or not.
1 to 1.8-ton trucks
Measurement point
Voltage
Judgment
Cable-side terminal
Battery voltage
Good
Battery voltage
Good
0 (V)
Measurement point
Voltage
Judgment
Cable-side terminal
Battery voltage
Good
Battery voltage
Good
0 (V)
Contactor-side terminal
2- to 3.5-ton trucks
Contactor-side terminal
Note
If the fuse is blown, find the cause of the blown fuse (overloading, shorting or grounding) and take
the necessary repair measures before replacing the fuse.
- 21 -
CN2D-9
CN2D-21
CN2D-8
CN2D-20
CN2D-33
LG 92
ACCEL2 POT.
1.96 V
LB 184
3.92 V
WR 185
0.5 V
LY 93
1.0 V
ACCEL1 POT.
BG 186
B
(Accelerator 2
potentiometer
output voltage)
A
(Accelerator 1
potentiometer
output voltage)
LW 187
Checking procedure
Turn on the key switch in the truck. Lift the front wheels off
the ground.
Press and hold the MODE button on the control panel for at
least 3 seconds.
Press and hold the SPE button on the control panel for at least
3 seconds.
CN2D-32
Sensor section
Connector
- 22 -
4.75 - 16 V
Checking procedure
Control valve
Resistance (using a digital multimeter)
Measurement point (within the coupler)
Between brown and red
Between white and red
Normal value
4.7 k 0.3 k
Shaft status:
Pushed in: 0.3 k 0.3 k
Released: 4.7 k 0.3k
- 23 -
- 24 -
- 25 -
2.2.13 CM CONTACTOR
Coil
3-phase AC
Contact B
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. Under normal conditions, it opens the 3-phase contacts to prevent the
charge current from flowing.
Applicable truck
model
CM contactor
Thermal relay
setting
FB10-8
FB15-8
FB18-8
281E2-62661
13A
FB20-8
FB25-8
281E2-62651
18A
FB25-8LB
FB25-8V
FB30-8
FB30-8V
FB35-8S
281U2-62661
26A
Input voltage
9 to 13 A
3 50/60Hz 380/390 V
430/440 V
Checking procedure
(1) Checking coil resistance
Measure the resistance between points a and b.
The resistance should be 0.1 to 0.3 k.
(2) Checking for continuity of contact B
Measure the resistance between points c and d.
There should be no continuity while the button e at the center
is being pressed.
- 26 -
Thermal relay
setting range
12 to 18 A
18 to 26 A
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.
(2) Checking the S.P.E switch
Measure the voltage between the CN9-1-15 terminal (W) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the S.P.E button is pressed and 5 V when the
button is not pressed.
(3) Checking the Mode button
Measure the voltage between the CN9-1-7 terminal (WG) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the Mode button is pressed and 5 V when the
button is not pressed.
(4) Checking the - button
Measure the voltage between the CN9-1-14 terminal (Y) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the - button is pressed and 5 V when the
button is not pressed.
(5) Checking the + button
Measure the voltage between the CN9-1-6 terminal (YW) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the + button is pressed and 5 V when the
button is not pressed.
- 27 -
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.
The voltage should be as follows: 5 V when the start button is pressed and 0 V when the start
button is released.
(3) Checking the stop button
Measure the voltage between the CN1-14 (WY) and the CN9-1-5 (BR) on the LCD panel.
The voltage should be as follows: 5 V when the stop button is pressed and 0 V when the stop
button is released.
(4) Checking SUPER EQUL button
Measure the voltage between the CN1-15 (WG) and the CN9-1-5 (BR) on the LCD panel.
The voltage should be as follows: 5 V when the SUPER EQUL button is pressed and 0 V when
the SUPER EQUL button is released.
- 28 -
Model
PT200S8
Checking procedure
Resistance range x 1 (Zero adjustment
should be made.)
Measurement point
Probe
Normal value
Black
Red
Black
Red
+
U
Black
Red
U
+
Black
Red
+
V
Black
Red
V
+
Black
Red
+
W
Black
Red
W
+
Black
Red
15 10
Black
Red
15 10
Black
Red
Black
Red
Black
Red
Black
Red
Black
Red
60 20
15 10
15 10
15 10
15 10
Checking method
CM contactor
operation
OFF
OFF
ON
OFF
OFF
Checking method
CM contactor
operation
OFF
OFF
ON
OFF
OFF
Start
button
Super equalizing
LED
charge LED
Super equalizing
charge button
- 30 -
Voltage checking
Measurement terminals (wire color)
Drive motor
Pump motor
+
CN11-4
CN11-3
CN1-22
N terminal
(WG)
(WR)
(LW)
- 31 -
Normal value
0.2 to 4.8 V
Checking procedure
Measure the resistance between terminals with the multimeter in the resistance range (minimum
range).
Standard value
IG1 (GND)
|
VF (Inverter CN1-8)
0 for F
for positions
other than F
IG1 (GND)
|
VR (Inverter CN1-21)
0 for R
for positions
other than R
Terminal position
- 32 -
Calendar
screen
Press
turtle button to
Maintenance
screen
Error history
screen
Press
turtle button to
New
Old
JYU
CYU
Year/Month/Day Hour:Minute
Error
code: Year/Mont/ Day Hour: Minute Error code
The
error history
is updated
by pressing the SPE
button.
//
//
Items to be displayed on the
maintenance screen:
SPE
A Accelerator
1 POT output voltage (V)
F Drive motor current sensor 1 voltage (V)
K Lift current sensor 1 voltage (V)
B
C
D
E
POT.V)
N rpm)
On trucks
an Orbitrol steering system, the items
E, J, and M are always displayed
0.
E withV)
J PS)
O as
rpm)
- 33 -
Drive system
Key switch
Parking lever
Forward switch
Accelerator
ON
Released
ON
Full throttle
0.97
0.97
0.97
4.08
common to all
models.
0.51
0.51
0.51
2.04
common to all
models.
2.49
2.49
2.49
2.49
common to all
models.
2.49
2.49
2.49
2.49
common to all
models.
No.
Terminal
Remarks
4085
3829
3407
Terminal
Lever pulled
back
Neutral
Lever pushed
forward
Remarks
during rotation
4.27
1.05
0.9
2.49
2.49
2.49
common to all
models
2.49
2.49
2.49
common to all
models
2963
2962
2961
common to all
models
Power steering system (All the items except D are inapplicable to trucks with an Orbitrol
steering system.)
No.
Terminal
Remarks
Left end
Center
Right end
3.63
2.5
1.9
1.04
2.4
3.8
40
40
45
45
38
38
- 34 -
3. TROUBLESHOOTING GUIDE
3. TROUBLESHOOTING GUIDE
3.1 HOW TO USE THIS GUIDE
Error code
Is any
error code shown on the
LCD panel?
- 35 -
3. TROUBLESHOOTING GUIDE
- 36 -
3. TROUBLESHOOTING GUIDE
LED ON
LED OFF
Locations of LEDs
- 37 -
Error description
- 38 -
203
Drive motor inverter unit temp. abnormal The truck wont travel.
202
201
33
34
07
02
02
103
Battery
discharge
indicator
blinks.
95
102
09
Battery voltage:
28 V or less (for 48 V trucks)
42 V or less (for 72 V trucks)
This error occurs if the voltage in the EPS
system stays below 24 V (for 48 V trucks) or
36 V (for 72 V trucks) for at least 2 seconds.
01
LED
code
Battery voltage:
28 V or less (for 48 V
Lower output of drive and pump motors trucks)
42 V or less (for 72 V
trucks)
Resetting
Turn the key switch ON
when:
the accelerator is OFF
the F/R lever is in neutral
Problem
101
Error code
on display
50
50
50
50
50
49
49
49
49
Page
3. TROUBLESHOOTING GUIDE
- 39 -
211
212
210
209
208
207
06
06
74
73
89
35
36
32
31
LED
code
The truck can be driven (but the current The temp. drops below 135C The thermosensor temp. reaches 145C
is limited).
[275F].
[293F].
206
37
Resetting
The temp. drops below 155C The thermosensor temp. reaches 155C
[311F].
[311F].
Problem
Error description
205
204
Error code
on display
50
50
51
50
50
49
49
49
49
48
Page
3. TROUBLESHOOTING GUIDE
- 40 -
218
217
216
215
214
213
Error code
on display
Error description
27
23
15
26
25
24
18
17
16
LED
code
Resetting
Problem
52
52
51
51
51
51
51
51
51
Page
3. TROUBLESHOOTING GUIDE
- 41 -
Travel overspeed
Contactor stuck
Overvoltage
The truck wont travel, and the load
(Battery connectors disconnected during
handling and EPS systems wont work.
regenerative braking)
220
221
307
308
309
318
Steering SSC
Loss of control
The truck can be driven normally.
Mode selection is not possible.
Operates with default settings.
503
600
219
Resetting
Problem
Error description
Error code
on display
65
52
86
11
12
94
21
19
LED
code
56
55
55
55
55
53
54
54
54
Page
3. TROUBLESHOOTING GUIDE
603
- 42 -
Overcurrent
(Hard OCL detected)
Resetting
Problem
602
Error description
Error code
on display
91
83
82
22
08
64
63
LED
code
57
57
57
56
56
56
Page
3. TROUBLESHOOTING GUIDE
- 43 -
412
410
407
406
405
403
404
Resetting
402
Problem
Error description
The load handling system wont work.
Lift lock solenoid OFF.
Error code
on display
(2) Load-handling system (including trucks with an Orbitrol steering system) (1/3)
06
74
73
35
36
37
32
31
33
34
01
LED
code
59
59
59
59
58
58
58
58
58
58
Page
3. TROUBLESHOOTING GUIDE
- 44 -
419
418
416
415
414
413
Error code
on display
Error description
15
19
26
25
27
24
18
17
16
LED
code
Resetting
Problem
(2) Load-handling system (including trucks with an Orbitrol steering system) (2/3)
61
61
60
60
60
60
60
60
60
Page
3. TROUBLESHOOTING GUIDE
- 45 -
Overcurrent
(Hard OCL detected)
420
Resetting
Problem
Error description
Error code
on display
(2) Load-handling system (including trucks with an Orbitrol steering system) (3/3)
Error code conditions
91
83
82
61
22
21
LED
code
61
62
62
61
61
Page
3. TROUBLESHOOTING GUIDE
- 46 -
DM open
Error description
509
508
507
506
Error code
on display
Problem
Resetting
14
13
12
11
09
22
25
23
26
19
17
04
08
07
06
05
LED
code
64
64
64
64
64
64
64
63
63
63
63
63
63
63
Page
3. TROUBLESHOOTING GUIDE
Error code
on display
Error description
Problem
If this error is detected before startup:
The EPS power steering system is
disabled.
If this error is detected after startup:
Speed detection is not possible.
Tire angle detection is not possible.
21
LED
code
65
Page
3. TROUBLESHOOTING GUIDE
- 47 -
3. TROUBLESHOOTING GUIDE
Description
Problem
Cause
Corrective Action
Icon
displayed
Wrench
071
CM relay
malfunction
072
PO relay short
circuit
Undefined
Wrench
073
CM relay short
circuit
Wrench
074
AD conversion
error
075
RTC error
076
077
Program sum
error
Wrench
Replace the LCD panel with a new one.
Wrench
078
Version loading
error
081
AC ON
082
083
Communication
error (PC)
084
Another mode
was requested
while charging
085
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Low battery
voltage
Wrench
087
Abnormal
charging
Wrench
088
AC power
failure during
charging
Wrench
- 48 -
3. TROUBLESHOOTING GUIDE
212
06
1. Drive system
(1)
N blinks
06
101
09
102
95
103
-
- 49 -
3. TROUBLESHOOTING GUIDE
(3)
105
02
106
02
:S
afety interlock (after the key switch is turned
on)
201
07
:F
orward travel switch or reverse travel switch
abnormal
(5)
202
34
203
33
Retighten.
204
31
:D
rive motor inverter unit thermosensor 1
(TMD1) AD input range abnormal
204
32
:D
rive motor inverter unit thermosensor 2
(TMD2) AD input range abnormal
- 50 -
3. TROUBLESHOOTING GUIDE
(7)
205
37
206
36
Turn the key switch OFF and allow the motor to cool
down for at least 30 minutes.
Check the voltage between CD2D-6 and CD2D-17
on the drive motor inverter unit.
207
35
:D
rive motor thermosensor defective
AD input range abnormal
Install properly.
208
89
- 51 -
3. TROUBLESHOOTING GUIDE
(10)
209
73
:R
otation sensor defective
The A or B phase pulse is missing.
The A and B phase pulses are missing.
209
74
:R
otation sensor defective
Bearing defective (Stall signals detected
continuously)
(11)
211
06
Connect properly.
212
06
Connect properly.
- 52 -
3. TROUBLESHOOTING GUIDE
(12)
210
-
307
-
213
16
214
17
215
18
Retighten.
216
24
216
25
216
26
216
27
- 53 -
3. TROUBLESHOOTING GUIDE
(15)
217
23
:R
apid charging of capacitor abnormal
(Improper charging of capacitor between P and Resets when the key switch is turned OFF.
N terminals)
218
15
:D
rive motor inverter upper/lower FET shortcircuited
219
19
: Drive motor inverter upper FET short-circuited Resets when the key switch is turned OFF.
220
21
: Drive motor inverter lower FET short-circuited Resets when the key switch is turned OFF.
Retighten.
(17)
221
94
: Travel overspeed
- 54 -
3. TROUBLESHOOTING GUIDE
(18)
308
12
:C
ontactor coil broken
(Blown fuse)
309
11
318
86
:O
vervoltage (Battery connectors disconnected
during regenerative braking)
(21)
503
52
Connect properly.
- 55 -
3. TROUBLESHOOTING GUIDE
(22)
600
65
:L
CD panel data reception error
(Communication wire broken)
Install properly.
602
63
:L
oad-handling data reception error
(Communication wire broken)
603
64
:E
PS data reception error
(Communication wire broken)
Connect securely.
Connect securely.
Connect securely.
08
Connect properly.
- 56 -
3. TROUBLESHOOTING GUIDE
(25)
22
:L
oad short circuit (Motor interphase shortcircuit)
91
Retighten.
Connect properly.
82
83
- 57 -
3. TROUBLESHOOTING GUIDE
N
01
(2)
402
34
403
33
Retighten.
404
31
:P
ump motor inverter unit thermosensor 1
(TMD1) AD input range abnormal
404
32
:P
ump motor inverter unit thermosensor 2
(TMD2) AD input range abnormal
(4)
405
37
406
36
Turn the key switch OFF and allow the motor to cool
down for 30 minutes.
Check the voltage between CN2P-6 and CN2P-17
on the pump motor inverter unit.
Replace the pump motor inverter unit.
- 58 -
3. TROUBLESHOOTING GUIDE
(5)
407
35
:P
ump motor thermosensor defective
AD input range abnormal
Connect securely.
410
73
:R
otation sensor defective
The A or B phase pulse is missing.
The A and B phase pulses are missing.
410
74
:R
otation sensor defective
Abnormal bearing (Stall signals detected
continuously)
(7)
412
06
- 59 -
3. TROUBLESHOOTING GUIDE
(8)
413
16
414
17
415
18
Retighten.
416
24
416
25
416
26
416
27
- 60 -
3. TROUBLESHOOTING GUIDE
(10)
418
15
:P
ump motor inverter unit upper/lower FET
short
419
19
:P
ump motor inverter unit upper FET short
420
21
:P
ump motor inverter unit lower FET short
Retighten.
22
:L
oad short-circuit (Motor interphase shortcircuited)
91
Retighten.
- 61 -
3. TROUBLESHOOTING GUIDE
(12)
61
:D
rive data reception error (Communication
wire broken)
Connect securely.
Connect securely.
Connect securely.
82
83
- 62 -
3. TROUBLESHOOTING GUIDE
506
05
506
06
506
07
506
08
Check for any electrical leaks between the frameside wires, and the positive (+) and negative (-)
terminals.
Retighten.
Connect properly.
507
04
Connect securely.
(3)
508
17
508
19
- 63 -
3. TROUBLESHOOTING GUIDE
(4)
509
22
509
25
509
23
509
26
Connect securely.
09
: DM open
Connect properly.
(6)
11
12
Turn the key switch OFF and allow the FET to cool
down.
Retighten.
13
14
- 64 -
3. TROUBLESHOOTING GUIDE
(8)
21
Connect securely.
- 65 -
3. TROUBLESHOOTING GUIDE
40 V or
more
LCD panel
Below10 V
101(RY)
Key switch
RY101
40 V or
more
Below10 V
100(RL)
Key switch
40 V or
more
Key switch
Below10 V
100(RL)
F4
40 V or
more
RL100
Below10 V
5(R)
F4
40 V or
more
F4
Below10 V
R5
- 66 -
3. TROUBLESHOOTING GUIDE
(2) MC contactor does not work. (The travel, load handling, and EPS systems are inoperative.)
11(RW)
CN1D-7,8
Drive motor
inverter
11(RW)
CN1D-7,8
Pump motor
inverter
11(RW)
PS1E-17
EPS motor
controller
11(RW)
PO relay
Below 10 V
216(RG)
PO relay
40 V or
more
40 V or
more
216(RG)
101(RY)
MC
contactor
101(RY)
Key switch
100(RL)
Key switch
100(RL)
F4
5(R)
F4
40 V or
more
40 V or
more
40 V or
more
40 V or
more
40 V or
more
40 V or
more
RW11
PO relay
RG216
MC contactor
RY101
Key switch
RL100
F4
R5
- 67 -
3. TROUBLESHOOTING GUIDE
5V
53 (WBr) in F
54 (WL) in R
CN1D-18 in F
CN1D-19 in R
Drive motor
inverter
Combination switch
WBr 53
WL 54
5V
In maintenance mode:
A (Accelerator 1
potentiometer output
voltage)
B (Accelerator 2
potentiometer output
voltage)
- 68 -
Accelerator 1 potentiometer,
LY93
Accelerator 2 potentiometer,
LG92
3. TROUBLESHOOTING GUIDE
Turtle
mark
visible
Turtle mark
invisible
LCD panel
CN9-1-16
Turtle button............Press. 5 V
Switch panel
0V
LCD panel
In maintenance mode:
A (Accelerator 1
potentiometer output
voltage)
B (Accelerator 2
potentiometer output
voltage)
Accelerator
LY93, LG92
3.1 V or more
In maintenance mode:
D (Steering potentiometer Key switch ................ Turn it ON.
Wheels .. Set them straight ahead.
output voltage)
2.4 to 2.7V
Drive motor inverter
- 69 -
Other than
2.4 to 2.7 V
3. TROUBLESHOOTING GUIDE
In maintenance mode:
C (Lift potentiometer
output voltage)
Below 0.2 V
4.8 V or more
Below 2.3 V
4.6 V or more
Lift potentiometer
GR189
WR188
YL94
Lift potentiometer
YL94
2.4 to 4.5 V
Pump motor inverter
0V
5V
Pump motor
inverter
Tilt switch
YR20
BL9
(7) T
he pump motor is running when no load-handling operation is being performed.
(Applicable only to trucks with an EPS steering system)
Check the harness between the pump motor inverter
unit (CN2P-8, -20, -32) and lift potentiometer.
NG
GR189
WR188
YL94
OK
Check the lift potentiometer.
NG
Lift potentiometer
OK
Check the harness between the pump motor
inverter unit (CN1P-16, -17, -18) and each switch. NG
YR20
YG21
YL22
OK
Tilt switch, ATT1 and ATT2 switches
- 70 -
3. TROUBLESHOOTING GUIDE
Torque sensor
L160
G161
W162
EPS motor
CN3E-1
CN3E-2
0A
0 to 40 V
EPS motor controller
0 rpm
In maintenance mode:
O (Pump motor rpm)
Below
360 rpm
In maintenance mode:
O (Pump motor rpm)
- 71 -
Below
600 rpm
Steering potentiometer
YR 44
3. TROUBLESHOOTING GUIDE
NOTE
- 72 -
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.
2. Remember that increasing the levels of any parameter settings may adversely affect the operation
of the truck.
Parameter item
Parameter group
Setting
4.3 KEYPAD
LOW-SPEED TRAVEL (TURTLE) BUTTON
If this button is pressed while the PARAMETER GROUP SETUP screen
is displayed, the display will return to the INITIAL PARAMETER SETUP
screen.
If this button is pressed while the PARAMETER ITEM SETUP screen is
displayed, the display will return to the PARAMETER GROUP SETUP
screen.
MODE BUTTON
Use this button to toggle between parameter items.
This button is also used to display the PARAMETER SETUP COMPLETE screen and the DATA TRANSMISSION screen.
+ BUTTON
- BUTTON
Use these buttons to increase or decrease the parameter group number
when selecting a parameter group, and to set a parameter value.
- 73 -
4. PARAMETER SETTING
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 + button to display PARAMETER 1; press the - button to display PC.
Use the + button or the - button to toggle between the parameter groups, as shown below.
PARAMETER GROUP SETUP SCREEN
Parameter group
PARAMETER 1
PARAMETER 2
PARAMETER 3
PC
Press this turtle button to return to the INITIAL
PARAMETER SETUP screen.
- 74 -
4. PARAMETER SETTING
PARAMETER ITEM
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.
Each time the Mode button is pressed, another parameter item is displayed.
Pressing the Mode button on the last parameter item will return you to the first parameter item.
To cancel any changes to the settings and return to the INITIAL PARAMETER SETUP screen,
press the turtle button.
If the parameter item to be set has a range, press the + button or the - button to increase or
decrease the value within that range.
If the parameter item requires an ON or OFF setting, press the + button to select ON or the -
button to select OFF.
- 75 -
4. PARAMETER SETTING
PARAMETER SETUP
COMPLETE SCREEN
TERMINATED
DATA TRANSMISSION
SCREEN
DATA IN TRANSMISSION
DO NOT TURN OFF THE KEY
TERMINATED
TURN OFF THE KEY
- 76 -
- 77 -
PARAMETER 3
PARAMETER 2
PARAMETER 1
Not settable
Locked with the turtle switch pressed
Password mode ON/OFF
Battery capacity selection
Truck speed limit rate that becomes effective when the overdischarge alarm
signal is present.
The speed obtained when the max. speed limit flag is enabled.
Speed at which alarm output is started with speed alarm output mode enabled
Load-handling operation limit rate during overdischarge Lift duty factor that is used when the overdischarge alarm signal is present.
Description
Travel speed acceleration mode numbers
Max. speed in the turtle mode
Lift conduction ratio limit
Lift inching conduction ratio limit
Tilt conduction ratio limit
ATT1 conduction ratio limit
ATT2 conduction ratio limit
Switchback regeneration intensity
Accelerator-off regeneration intensity
Brake OFF regeneration intensity
Anti-rollback regeneration intensity
Accelerator stage mode numbers
Item
POWER
TRAVEL SPEED LIMIT
LIFT SPEED
LIFT INCING LEV.
TILT SPEED
ATT1 SPEED
ATT2 SPEED
SWITCH BACK REG.
ACCELERATOR OFF REG
BRAKE REG.
ANTI ROLL BACK
ACCELERATOR STAGE
SPEED ALARM OUTPUT SPEED
Screen display
9 CYLINDER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
No.
4
5
5 6 7 8
OFF
OFF
OFF
OFF
OFF
OFF
OFF
SL
Low
sec 0 1 1 2 2 3
sec 0 2 4 6 8 10
%
0 10 20 30 40 50
%
0 10 20 30 40 50
1 2 3 4 5 6
0
15
1-14
TOTAL DRIVE PUMP
OFF
OFF
OFF
330 400 450 485 545 565
45
1-44
km/h
10 12
ON
ON
ON
ON
ON
ON
ON
14
16
10
16
100
50
100
100
100
100
100
100
100
10
16
16
10
Remarks
10
10
10: unlimited
N
H
3 4 4 4.5 5
15 20 30 60
60 70 80 90 100
60 70 80 90 100
The numbers correspond to
7 8 9 10
the battery meter level.
Settable in minutes. 0: OFF
16-90
WORK TRAVEL RATE
Fixed to OFF
ON
ON
ON
Factory setting
600 700 865 935
46-90
9
14
95
45
90
90
90
90
90
90
90
9
14
14
0 1 2 3 4 5 6 7 8
km/h 3 4 5 6 7 8 9 10 12
%
50 55 60 65 70 75 80 85 90
%
0 5 10 15 20 25 30 35 40
%
0 10 20 30 40 50 60 70 80
%
0 10 20 30 40 50 60 70 80
%
0 10 20 30 40 50 60 70 80
%
0 10 20 30 40 50 60 70 80
%
0 10 20 30 40 50 60 70 80
%
0 10 20 30 40 50 60 70 80
%
0 10 20 30 40 50 60 70 80
0 1 2 3 4 5 6 7 8
km/h 3 4 5 6 7 8 9 10 12
km/h 3 4 5 6 7 8 9 10 12
Unit
Factory settings
4. PARAMETER SETTING
4. PARAMETER SETTING
0
Level 0
1
Level 1
80
[] [%]
Speed
command
2
Level 2
3
Level 3
60
456
Level 4,5,6
78
Level 7,8
40
910
Level 9,10
20
0
0.00
1.00
2.00
3.00
4.00
5.00
voltage
[]
Accelerator
- 78 -
4. PARAMETER SETTING
[km/h]
Speed limits
(km/h)
the
accelerator lever
Tire
steering angle
[][]
- 79 -
4. PARAMETER SETTING
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
Mode button
+ button
- button
PASSWORD
SETUP SCREEN 1
- 80 -
<Deactivation conditions>
(a) If the key switch is turned ON while the seat switch is ON
(b) Travel system: Accelerator lever OFF and seat switch ON
Load handling system: Load handling command OFF and seat switch ON
- 81 -
Accelerator
ON
Brake switch
Slope detected
Accelerator
switch
Truck
status
OFF
OFF
No
ON
Yes
OFF
No
Yes
Stopped
Driving under
Driving in
Driving with
Driving in
power
slope mode *2 output limit *1 slope mode *2
ON
No
Yes
No
Yes
Accelerator
OFF
regeneration
Anti-roll OFF
regeneration
Brake OFF
regeneration
Anti-roll OFF
regeneration
Output OFF
Output OFF
Reverse
travel
Switchback
regeneration
Switchback
regeneration
Brake OFF
regeneration
Brake OFF
regeneration
Accelerator
OFF
regeneration
Anti-roll OFF
regeneration
Brake OFF
regeneration
Anti-roll OFF
regeneration
Forward
travel
Accelerator
neutral
regeneration
Anti-roll OFF
regeneration
Brake OFF
regeneration
Brake OFF
regeneration
Accelerator
neutral
regeneration
Anti-roll OFF
regeneration
Brake OFF
regeneration
Anti-roll OFF
regeneration
Stopped
Output OFF
Output OFF
Output OFF
Output OFF
Reverse
travel
Accelerator
neutral
regeneration
Anti-roll OFF
regeneration
Brake OFF
regeneration
Brake OFF
regeneration
Accelerator
neutral
regeneration
Anti-roll OFF
regeneration
Brake OFF
regeneration
Anti-roll OFF
regeneration
Forward
travel
Switchback
regeneration
Switchback
regeneration
Brake OFF
regeneration
Brake OFF
regeneration
Accelerator
OFF
regeneration
Anti-roll OFF
regeneration
Brake OFF
regeneration
Anti-roll OFF
regeneration
Stopped
Driving under
Driving in
Driving with
Driving in
power
slope mode *2 output limit *1 slope mode *2
Reverse
travel
Driving under
Driving in
Driving with
Driving in
power
slope mode *2 output limit *1 slope mode *2
Output OFF
Accelerator
OFF
regeneration
Anti-roll OFF
regeneration
Output OFF
Brake OFF
regeneration
Anti-roll OFF
regeneration
*1: Driving with output limit: This refers to inching control. Limited to 80% of the maximum torque (Excessive Travel inching).
*2: Driving in slope mode: When a truck driving down a slope exceeds the speed that should normally be obtained by a given amount of accelerator pedal
pressure, the power output will be limited in order to maintain the speed that corresponds to that accelerator pedal effort.
(6) Output duty factor reduction when the rear wheels are at the maximum steering angle
(Excluding trucks with an Orbitrol steering system)
<Activation conditions>
The rear wheels are within 5 degrees of the maximum steering angle.
<Control applied>
Limits the output duty factor to 10%.
<Deactivation conditions>
When the torque sensor voltage indicates that the wheels are in neutral (the straight-ahead position).
- 82 -
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
Y L
22 Wire
number
Black
Red
Green
White
Blue
Yellow
Orange
Lg Light green
Pink
Sb Light blue
W 110 Wire
number
Plug-in type
Connecting type
Plug-in side
Receptacle side
Remarks
Housing
The numbers signify wire numbers.
The alphabetic letters mean colors.
(Table 6.1)
Plug
Screw type
Two wires may have different wire numbers even though they have the same wire color. Before
trying to check the wires, refer to wire harness and circuit diagrams on pages that follow.
The dotted lines in the circuit diagrams are given for optional equipment.
- 83 -
6. ELECTRIC WIRING
NOTE
- 84 -
6. ELECTRIC WIRING
to
LCD PANEL
10
1
1
B
2-7
RL
100-1
RG
102-1
W
207
LY
212
W
213
RY
101-1
CN3
11
WR
205
RG
203
LB
201
WY
206
WG
209
BW
211
RB
202
P
176
YG
208
20
CN1
CN9-1
1
to
F/R SWITCH
23
WY
108
WBr
53
BR
9
YB
196
B
2-8
LB
137
YW
79
WG
76
Gy
80
Y
78
W
77
WL
75
16
to
KEY SWITCH
to HORN
SWITCH
O
15
GR
82
15
WL
54
GW
81
CN9-2
RY
(101)
BG
190
LW
192
WY
224
G
191
W
226
WB
228
WG
225
WL
227
RL
(100)
RB
141-1
YL
103
to
LIGHTING SWITCH
Y
78
YW
79
R
177
GY
178
LW
132
BR
9-1
L
131
WG
76
W
77
WL
75
Gy
80
to
CONTROL SWITCH
PANEL
BR
9-2
14
to REAR
WORK LIGHT
SWITCH
(OPTION)
WY
108-1
RB
141-2
GW
81-1
GR
82-1
OPTION
B
2-3
GO
111
RB
141
B
2
to
WIRE HARNESS,
OVERHEAD
GUARD (LEFT)
GR
106
B
2-2
WG
109-1
WR
107-1
GL
105
B
2-1
BW
(112)
RG
203
WY
206
O
15-1
LB
201
RB
202
to
CHARGER
SWITCH
PANEL
L
160
G
161
YB
(196)
WL
227
WR
205
WG
209
RG
(102)
WG
225
BR
9-3
to
BRAKE SWITCH
to
PARKING SWITCH
WY
224
W
226
to
PC MONITOR
2%
(for
MAINTENANCE)
CAPACITOR
YL
(103)
B
(2-4)
LW
192
G
191
to
HORN
BG
190
to
LOAD METER
(OPTION)
10
BR
9
WL
54
WBr
53
L
160
G
161
W
162
GL
105
20
BW
112
LY
212
GR
106
LG
24
O
15
WR
107
WG
109
P
176
WY
108
LB
137
RG
102
RB
141
B
2
11
16
GO
111
W
213
R
177
L
131
RY
101
RL
100
GY
178
GR
82
W
207
BW
211
LW
132
Y
104
YG
208
GW
81
9
to
WIRE HARNESS, FRAME
Y
104
LG
24
WB
228
W
162
to
EPS SENSOR
WG
109
WR
107
to EMERGENCY SWITCH
WIRE
HARNESS,
OVERHEAD
GUARD (RIGHT)
6. ELECTRIC WIRING
to
LCD PANEL
10
1
1
CN3
B
2-7
to STEERING
ENCODER
to
F/R SWITCH
23
15
WL
54
WBr
53
BR
9
BR
230
BG
243
RL
100-1
RG
102-1
W
207
LY
212
W
213
RY
101-1
WR
205
LB
201
WY
206
WG
209
RB
202
O
15
GW
81
GR
82
RY
(101)
LG
246
YB
196
GY
178
LW
132
BR
9-1
LB
137
YW
79
WG
76
Gy
80
Y
78
W
77
WL
75
16
CN9-2
RL
RG (100)
(102)
YR
(117)
LW
192
WY
224
G
191
W
226
WB
228
WG
225
WL
227
RB
141-1
to
KEY SWITCH
Y
78
YW
79
L
131
B
2-8
R
177
YG
208
CN9-1
WY
108
YL
103
to
LIGHTING SWITCH
P
176
20
BG
190
to HORN
SWITCH
10
BW
211
11
BY
244
LY
249
CN1
RG
203
WG
76
W
77
WL
75
Gy
80
to
CONTROL SWITCH
PANEL
BR
9-2
14
to
REAR WORK LIGHT
SWITCH
(OPTION)
WY
108-1
RB
141-2
GW
81-1
GR
82-1
OPTION
B
2-3
GO
111
RB
141
B
2
to WIRE
HARNESS,
OVERHEAD
GUARD (LEFT)
WG
109-1
WR
107-1
GR
106
B
2-2
GL
105
B
2-1
BW
(112)
RG
(102-2)
YB
(196)
WL
227
WR
205
WG
209
RG
203
WY
206
BR
9-3
LB
201
RB
202
to
CHARGER
SWITCH
PANEL
L
160
G
161
WG
225
O
15
to BRAKE SWITCH
to
PARKING SWITCH
W
162
WY
224
W
226
WB
228
to
PC MONITOR
(for
MAINTENANCE)
CAPACITOR
to
EPS SENSOR
YL
(103)
to
HORN
B
(2-4)
LW
192
G
191
BG
190
to LOAD
METER
(OPTION)
RL
100
RY
101
GO
111
RB
141
16
17
WBr
53
LG
24
O
15
BW
112
BR
9
WL
54
LY
212
LB
137
GR
106
18
L
160
G
161
RG
102
WR
107
GW
81
WG
109
GL
105
B
2
GR
82
W
162
YR
117
24
1
BR
230
LY
249
BY
244
P
176
13
LG
246
BG
243
W
213
WY
108
R
177
GY
178
W
207
Y
104
4
L
131
LW
132
BW
211
YG
208
16
to
WIRE HARNESS, FRAME
WG
109
WR
107
Y
104
LG
24
to
EMERGENCY SWITCH
WIRE
HARNESS,
OVERHEAD
GUARD (RIGHT)
6. ELECTRIC WIRING
toRK
RELAY RK
RW
11-7
B
2-7
RG
102-5
GO
111-2
17
RG
58
GL
GB
162
85
86
RG
58
160
161
RW
11-4
RL
100-7
18
to
PARKING ALARM
toPO
RELAY PO
LB(137)
RL
100-2
YG
208
RG(102-3)
OPTION
RG
216
to
CONTROLLER
(P)
TERMINAL
(P)
to
WIRE HARNESS,
SEAT
SWITCH
to
RELAY UNIT
1
GO
111-1
WR
113
WG(169)
13
WB
98-1
BW
112
CN1E
R(5)
RW
11
YB(30)
WY(168)
34
BR
9-1
GY
178
WG
WBr
97
109-1
R
177
LB
180
L
131
LR
95
LW
132
RW
11-6
RW
WR
11-5
107
GL
W
GR
110 106-1 105-1
14
RG
102-1
RG
102-2
BR
9-2
YW
181
26
B(2-6)
to
WIRE HARNESS,
OPTION
toCM
WIRE HARNESS, CM
3
BW
211
LY
212
to LIFT
POTENTIOMETER
to LIFT
LOCK
SOLENOID
VALVE
WG
RG
109-2 102-4
WY
B
108
2-5
CNCH1
WB
26
GO
111
WB
98-2
CNMC
P(176)
WB(98)
B(2)
WBr(97)
B(2-2)
YG
21
BL
8
F8 2.
to
LEVEL
SENSOR
to
BACK-UP BUZZER
to
WIRE HARNESS,
VALVE
SWITCH
G
25
Y
104
RY(101)
RL
100-3
P
27
B(2-4)
RG (216)
F9 10.
WR
188
O
138
YR
20
YL
22
W
213
RL
100-1
F5 10.
YL
94
W
207
F4 10.
GR
189
to
FWD CHIME
()
(OPTION)
CN1P
1
to
ACCELERATOR
3
LY
BG
186 93
WR LG
92
185
6
12
GO
84
GY
83
RW
31
RY
34
RB
32
BR
9-3
2
to DRIVE MOTOR
ROTATION
(B)
SENSOR
(B)
CN2D
GW
28
139
36
Y
7
to
STEERING
MEMORY
SWITCH
GB
29
GY
33
100-6
100-5
CN2P
HPS/EPS
to
HPS/EPS
19
25
BL(18)
RL
LG RL
BL BL
8 18
LG(19)
LW
187
LB
184
3
11-3
GB GB GL YR YG YL
86 86-1 85 20 21 22
CN1D
to DRIVE MOTOR
ROTATION
(A)
SENSOR
(A)
RW RW
11-2
B(2)
2
to DRIVE
THERMO
SENSOR
243
WG
16
WR
17
2
W
40
G
38
YW
39
BR
230
BG
243
LY
249
LG
246
to PUMP
MOTOR
THERMOSENSOR
BY
244
Y
41
B
46
249
P
176
O
15
LG
24
LY
212
WBr
53
WL
54
BR
9
BW
112
B
2-1
WY
108
WG
109
WR
107
GR
106
GL
105
W
162
G
161
L
160
11
20
GR
82
GW
81
9
to
WIRE HARNESS, FRONT GUARD
12
RY
GY
RB
GB WG
32
GY
178
YG
208
RL
100
Y
104
RY
101
LW
132
L
131
BW
211
R
177
W
207
GO
111
W
213
RG
102
RB
141
16
38
40
246
33
34
46
YW
39
YL
94
WR
188
GR
189
36
to
PUMP MOTOR
ROTATION
SENSOR
10
LB
137
BY
244
LG
41
230
25
LY
to
CONTROLLER
(N)
TERMINAL
(N)
12
BG BR
YR
44
YL
43
WG
109
WR
113
YB
42
to
STEERING
POTENTIOMETER
B
2-3
WB
98
GL
105
GR
106
RW
31
25
29
16
GW
28
WR
17
LY LG YL
93
92
YB
GO
GY YW YB WBr WL Y
84
42
184
185
81
83
W O
110
181
30
9
44
36
25
RW RW
15
BR
LW WR YR
187
12
GW
82
43
BG LB
186
GR
11-1
53
54
WB P
11
26
LG
24
WY LB LR
168
180
95
27
RL
100-4
G WG
25 169
36
to
WIRE HARNESS,
REAR
COMBINATION LAMP
Note: The connector CN1E of trucks with Orbitrol steering system is connected to nowhere.
6. ELECTRIC WIRING
to
RELAY RK
RK
RW
11-7
B
2-7
RG
102-5
GO
111-2
toPO
RELAY PO
to PARKING ALARM
RL
100-2
YG
208
LB(137)
RG(102-3)
RG
216
RW
11
to WIRE
HARNESS,
SEAT
SWITCH
to
RELAY UNIT
OPTION
YB(30)
GO
111-1
WR
113
WY(168)
WG(169)
13
WB
98-1
BW
112
BR
9-1
WBr
97
GY
178
WG
R
177
LB
180
109-1
L
131
LR
95
LW
132
RW
11-6
RW
WR
11-5
107
GL
W
GR
110 106-1 105-1
14
RG
102-1
RG
102-2
BR
9-2
17
YW
181
26
RG
GL
GB
RW
58
162
85
86
11-4
RL
RG
58
160
161
100-7
18
34
B(2-6)
toCM
WIRE HARNESS, CM
RG (216)
to LIFT
LOCK
SOLENOID
VALVE
WR
188
O
138
WG
RG
109-2 102-4
WY
B
108
2-5
GO
111
WB
98-2
to
HPS/EPS
HPS/EPS
B(2-4)
RY(101)
RL
100-3
WB(98)
B(2)
BL(18)
CN1P
LG(19)
P(176)
to BACK-UP BUZZER
to
WIRE HARNESS,
VALVE
SWITCH
YR
20
YL
22
CN1E
F8 2A
YL
94
W
213
RL
100-1
F9 10A
GR
189
W
207
F5 10A
BW
211
LY
212
to LIFT
POTENTIOMETER
to
WIRE HARNESS,
OPTION
F4 10A
to LEVEL
SENSOR
CN2P
WBr(97)
B(2-2)
to
FWD CHIME
(OPTION)
()
to CONTROLLER
TERMINAL
(P)
(P)
YG
21
BL
8
CNCH1
1
R(5)
G
25
Y
104
GY BL
83 8-1
RW RW
11-2
11-3
GB GB GL YR YG YL
86 86-1 85 20 21 22
19
WB
26
CNMC
100-6
100-5
139
36
25
LW
187
LB
184
RL
LG RL
BL BL
8 18
to ACCELERATOR
LY
BG
186 93
WR LG
92
185
12
GO
84
P
27
to DRIVE
MOTOR
ROTATION
SENSOR (A)
(A)
RW
31
RY
34
RB
32
BR
9-3
2
GW
28
GY
33
Y
7
to
STEERING
MEMORY
SWITCH
GB
29
CN1D
B(2)
243
LY
to DRIVE
MOTOR
ROTATION
SENSOR (B)
(B)
249
2
WG
16
WR
17
W
40
to DRIVE
THERMO
SENSOR
BR
230
BG
243
LY
249
LG
246
Y
41
CN2D
to
CONTROLLER
TERMINAL
(N)
(N)
LG
246
25
41
230
BY
244
46
38
40
YW
39
YL
94
WR
188
GR
189
36
B
46
G
38
to PUMP
MOTOR
ROTATION
SENSOR
YW
39
12
BG BR
to
PUMP MOTOR
THERMOSENSOR
BY
244
10
LB
137
P
176
O
15
LG
24
LY
212
WBr
53
WL
54
BR
9
BW
112
B
2-1
WY
108
WG
109
WR
107
GR
106
GL
105
W
162
G
161
L
160
20
11
33
34
GR
82
GY
178
RL
100
GW
81
YG
208
Y
104
16
to
WIRE HARNESS, FRONT GUARD
12
GY
RY
RY
101
LW
132
L
131
R
177
BW
211
W
207
GO
111
W
213
RB
RG
102
RW
32
RB
141
9
YR
44
YL
43
31
YB
42
to
STEERING
POTENTIOMETER
25
WG
109
WR
113
B
2-3
WB
98
29
93
92
BG LB
LW WR YR
187
84
42
184
185
GO
YB
186
GW
28
82
43
16
GR
LY LG YL
12
GW
81
110
83
181
30
9
36
25
11-1
WB P
11
26
GY YW YB WBr WL Y
BR
44
RW RW
15
53
54
LG
24
WY LB LR
168
180
95
27
RL
100-4
G WG
25 169
36
GL
105
GR
106
to
WIRE HARNESS,
REAR
COMBINATION LAMP
GB WG
WR
17
Note: The connector CN1E of trucks with Orbitrol steering system is connected to
nowhere.
6. ELECTRIC WIRING
toPO2
RELAY PO2
RW
11
GO
111-1
WR
113
WB
98-1
BW
112
13
BR
9-1
WBr
97
GY
178
WG
109-1
R
177
LB
180
L
131
LR
95
LW
132
RW
11-1
RW
WR
11
107
GL
W
GR
110 106-1 105-1
14
to CM
WIRE HARNESS, CM
LY
BG
186 93
WR LG
92
185
6
to FWD
CHIME
()
(OPTION)
WBr(97)
B(2-2)
BR
9-3
to DRIVE
MOTOR
ROTATION
SENSOR (A)
(A)
RW
31
85
86
115-4
RL
58
160
161
100-7
CN1E
RB 141
B(2-4)
BL(18)
CN1P
to
LEVEL
SENSOR
CN2P
CNMC
to
CONTROLLER
(P)
TERMINAL
(P)
Br
6
R(5)
WB
26
G
25
Y
104
CNCH1
to
STEERING
SWITCH
MEMORY
162
RG
HPS/EPS
to
HPS/EPS
GO
111
WB
98-2
Br 6
WG
RG
109-2 102-4
WY
B
108
2-5
to
BATTERY
WB(98)
B(2)
to
ACCELERATOR
W
213
RL
100-1
to
BACK-UP BUZZER
LW
P(176)
RL
100-3
YG
21
BL
8
LW
187
LB
184
GB
34
LG(19)
to
WIRE HARNESS,
VALVE
SWITCH
W
207
to LIFT
LOCK
SOLENOID
VALVE
O
138
YR
20
YL
22
BW
211
LY
212
RG 102
to LIFT
POTENTIOMETER
RY
101
RG
216
Br 6-1
YR
117
L
116
B(2-6)
WR
188
YW
181
GL
to
WIRE HARNESS,
OPTION
WG(169)
YL
94
BR
9-4
26
YB(30)
WY(168)
GR
189
RG
102-1
RG
102-2
18
P 139
to
RELAY UNIT
RG(102-3)
OPTION
58
to
WIRE HARNESS,
SEAT
SWITCH
R5
LB(137)
17
RG
LW
115
O 138
to
PARKING ALARM
RG
216
F9 10A
RL
100-2
YG
208
F8 2A
to PO1
RELAY PO1
RG
102-5
GO
111-2
F7 10A
L
116
F5 10A
RW
11-2
B
2-7
RL
100-8
YG
208-1
RL 10O
to RK
RELAY RK
P
27
12
LW LW
GY BL BL
83 8-1 8-2
GO
84
115-2 115-3
GB GB GL YR YG YL
86 86-1 85 20 21 22
Y
7
RL
LG RL
19
BL BL
8 18
100-6
100-5
139
36
25
RY
34
RB
32
to
CONTROLLER
TERMINAL
(N)
(N)
2
GW
28
1
2
GB
29
GY
33
WG
16
to DRIVE
MOTOR
(B)
ROTATION
SENSOR (B)
CN1D
WR
17
B(2)
to DRIVE
THERMO
SENSOR
L
160
GL
105
G
161
YR
W
117 162
24
B
2-1
RG
102
GR
82
WR
107
GR
106
WG
109
GW
81
O
15
LG
24
LB
137
WBr
53
WL
54
BR
9
LY
212
BW
112
18
GO
111
RB
141
RL
100
RY
101
17
16
L
131
LW
132
BW
211
YG
208
Y
41
243
LY
B
46
249
LG
246
to
PUMP MOTOR
ROTATION
SENSOR
R
177
GY
178
W
207
Y
104
LG
246
BG
243
W
213
WY
108
BR
230
LY
249
BY
244
P
176
13
RY
32
GY WR
33
17
RW
31
29
16
GW
28
WG
109
WR
113
YB
42
B
2-3
WB
98
LY LG YL
93
92
186
YB
GW
GO
GY YW YB WBr WL Y
84
42
184
GR
82
43
BG LB
185
81
83
110
181
30
9
44
25
LW LW
15
BR
LW WR YR
187
36
25
to
STEERING
POTENTIOMETER
BY
244
46
38
40
YW
39
YL
94
WR
188
GR
189
12
12
34
YL
43
41
230
25
1
RB GB WG
YR
44
12
BG BR
16
to
WIRE HARNESS, FRONT GUARD
YW
39
to
PUMP MOTOR
THERMOSENSOR
W
40
G
38
CN2D
115-1
53
54
WB P
115
26
LG
24
WY LB LR
168
180
95
27
RL
100-4
G WG
25 169
36
GL
105
GR
106
to WIRE HARNESS,
Note: The connector CN1E of trucks with Orbitrol steering system is connected to nowhere.
36
R
W
B
TH.
GO
26P
6P
8P
EPS EPS
TORQUE
POTENTIOMETER
LCD
PANEL
PRESSURE
SENSOR
RW
WL
B
RW
B
WBr
DW DV
CONTROLLER
2P
-
ELECTRO
LYTE LEVEL
SENSOR
+
16P
SEAT SWITCH
BATTERY
3P
6P
1P
2P
FWD
CHIME
(OPTION)
()
TURN
SIGNAL
SWITCH
EPS
EPS
MOTOR
3P
2P
18P
2P
CN3
BACK-UP
BUZZER
HORN SWITCH
14P
CN1
LIFT
LOCK
SOLENOID
3P
RY
20P
LICENSE
NUMBER
PLATE
LIGHT
(OPTION)
1P
RL
F/R
F/R
SWITCH
4P
LIFT
POTENTIOMETER
KEY
SWITCH
CN9
WB
WG
BRAKE
SWITCH
16P 12P
REAR
WORK LIGHT
(OPTION)
GO
BW
2P
2P
2P
PW PV
PU
DW
2P
36P
36P
F8
3P
F9
2P
F5
YL
F4
6P
WR
HORN
16P
36P
20P
HEAD
LIGHT
()
(LEFT)
BATTERY
CHARGER
SWITCH PANEL
WY
RG
WY
B
36P
3P
+
COM1
NO
DU
3P
N.C
6P
REAR
WORK LIGHT
SWITCH
(OPTION)
()
RW COM
Gy N.O
DV
DU
DRIVE
MOTOR
PARKING BRAKE
SWITCH
6P
PW
4P
6P
PU
2P
PUMP
MOTOR
FRONT
COMBINATION
LIGHT
(LEFT)
()
3P
STEERING
POTENTIOMETER
6P
3P
PV
3P
YB
BY
LIGHT
BEACON
WY
N.C
N.O
COM
ACCELERATOR
REAR
COMBINATION
LIGHT
(RIGHT)
()
WM
YG
BY
PARKING
ALARM
6P
RELAY
UNIT
UM
N.C
N.O
COM
TRANSFORMER
UM
VM
WM
3P
4P
M.C.
YL
BY
6P
VALVE
SWITCH
TILT
TILT
RG
6P
F6
N.C
N.O
COM
VALVE
SWITCH
ATT2
(OPTION)
ATT2()
VALVE
SWITCH
ATT1
(OPTION)
ATT1()
FRONT
COMBINATION
LIGHT
(RIGHT)
()
RK
VM
4P
LG
CONTROL
SWITCH PANEL
PO
RW
RL
8P
WL
WY
RY
WR
EMERGENCY
SWITCH
Insert
when EGS.
EGS
(OPTION)
() LR
Y
RG
OPTION
HEAD LIGHT
()
(RIGHT)
3P
6. ELECTRIC WIRING
REAR
COMBINATION
LIGHT
(LEFT)
()
Note: Trucks with an Orbitrol steering system do not have an EPS motor.
6. ELECTRIC WIRING
4P
R
W
B
RG
VALVE
SWITCH
TILT
TILT
BW
YB
BY
TH.
GO
26P
6P
4P
LIFT
POTENTIOMETER
1P
2P
LIFT LOCK
SOLENOID
TURN
SIGNAL
SWITCH
FWD
CHIME
(OPTION)
()
EPSEPS
TORQUE
POTENTIOMETER
LCD
PANEL
PRESSURE
SENSOR
RW
WL
B
RW
B
WBr
2P
-
ELECTRO
LYTE LEVEL
SENSOR
BATTERY
3P
3P
PW
SEAT SWITCH
16P
PV
PU
2P
DW
DV
DU
-
DU
2P
DW DV
6P
CONTROLLER
2P
18P
2P
HORN
SWITCH
14P
8P
BACK-UP
BUZZER
36P
CN3
LICENSE
NUMBER
PLATE
LIGHT
(OPTION)
36P
CN1
LIFT LOCK
SOLENOID
EPS
EPS
MOTOR
1P
3P
RY
20P
RL
F/R
F/R
SWITCH
WB
WG
KEY
SWITCH
CN9
(OPTION)
GO
B
BRAKE
SWITCH
16P 12P
N.C
N.O
COM
BEACON
LIGHT
WY
YG
BY
REAR
COMBINATION
LIGHT
(RIGHT)
()
WM
N.C
N.O
COM
ACCELERATOR
PARKING
ALARM
6P
RELAY
UNIT
M.C.
YL
BY
UM
N.C
N.O
COM
TRANSFORMER
UM
VM
WM
6P
3P
6P
F6
VALVE
SWITCH
ATT2
(OPTION)
ATT2()
VALVE
SWITCH
ATT1
(OPTION)
ATT1()
FRONT
COMBINATION
LIGHT
(RIGHT)
()
RK
VM
3P
4P
LG
CONTROL
SWITCH PANEL
PO
RW
RL
8P
WL
WY
RY
WR
EMERGENCY
Insert when EGS.
EGS
SWITCH
(OPTION)
Y
() LR
RG
OPTION
HEAD LIGHT
()
(RIGHT)
2P
DRIVE
MOTOR
WR
HORN
F8
3P
F9
2P
F5
F4
YL
6P
BATTERY
CHARGER
SWITCH PANEL
3P
N.C
16P
HEAD LIGHT
()
(LEFT)
WY
RG
WY
B
36P
20P
+
COM1
NO
36P
3P
REAR
WORK LIGHT
SWITCH
(OPTION)
()
RW COM
Gy N.O
6P
PARKING BRAKE
SWITCH
2P
6P
PW
2P
PUMP
MOTOR
FRONT
COMBINATION
LIGHT
(LEFT)
()
3P
6P
STEERING
POTENTIOMETER
6P
4P
3P
PU
3P
PV
REAR
COMBINATION
LIGHT
(LEFT)
()
Note: Trucks with an Orbitrol steering system do not have an EPS motor.
6. ELECTRIC WIRING
3P
4P
6P
4P
BEACON
LIGHT
N.C
N.O
COM
YB
BY
TH.
18P
F/R
F/R
SWITCH
2P
6P
HORN
SWITCH
TURN
SIGNAL
SWITCH
14P
8P
EPSEPS
TORQUE
POTENTIOMETER
LCD
PANEL
PRESSURE
SENSOR
3P
B
RW
B
WBr
CONTROLLER
2P
-
ELECTRO
LYTE LEVEL
SENSOR
BATTERY
3P
SEAT SWITCH
PW
16P
PV
PU
2P
DW
DV
1P
DU
DU
2P
DW DV
WL
6P
1P
FWD
CHIME
(OPTION)
()
RW
36P
CN3
BACK-UP
BUZZER
36P
CN1
20P
LIFT
LOCK
SOLENOID
EPS
EPS
MOTOR
2P
CN9
2P
16P 12P
LICENSE
NUMBER
PLATE
LIGHT
(OPTION)
1P
RY
4P
LIFT
POTENTIOMETER
3P
RL
WB
WG
KEY
SWITCH
RG
(OPTION)
GO
B
BRAKE
SWITCH
YG
BY
WY
N.C
N.O
COM
GO
26P
WM
ACCELERATOR
BW
GO
REAR
COMBINATION
LIGHT
(RIGHT)
()
6P
RELAY
UNIT
M.C.
YL
BY
VM
N.C
N.O
COM
UM
3P
6P
VALVE
SWITCH
TILT
TILT
RG
6P
PARKING
ALARM
F6
VALVE
SWITCH
ATT2
(OPTION)
ATT2()
VALVE
SWITCH
ATT1
(OPTION)
ATT1()
FRONT
COMBINATION
LIGHT
(RIGHT)
()
RK
TRANSFORMER
LG
CONTROL
SWITCH PANEL
PO
R
W
B
RL
PO
UM
VM
WM
10P
RW
WR
EMERGENCY
SWITCH
Insert
when EGS.
EGS
(OPTION)
() LR
Y
WL
WY
OPTION
HEAD
LIGHT
()
(RIGHT)
2P
DRIVE
MOTOR
WR
BATTERY
CHARGER
SWITCH
PANEL
3P
N.C
HORN
F8
6P
F9
2P
F5
F7
YL
24P
HEAD LIGHT
()
(LEFT)
RG
WY
B
36P
16P
+
COM1
NO
36P
3P
REAR
WORK LIGHT
SWITCH
(OPTION)
()
RW COM
Gy N.O
6P
PARKING BRAKE
SWITCH
2P
6P
PW
FRONT
COMBINATION
LIGHT
(LEFT)
()
2P
PUMP
MOTOR
3P
6P
STEERING
POTENTIOMETER
6P
4P
3P
PU
3P
PV
REAR
COMBINATION
LIGHT
(LEFT)
()
Note: Trucks with an Orbitrol steering system do not have an EPS motor.
REAR
COMBINATION
LIGHT (RIGHT)
-
- 93 -
120
MONITOR
SIGNAL SWITCH
LIGHTING
SWITCH TURN
ELECTROLYTE
LEVEL SENSOR
CN1E-17
CN1E-34
CN1E-9
CN1E-11
CN1E-4
CN1E-21
CN1E-6
CN1E-22
CN1E-23
CN2P-32
CN2P-20
CN2P-8
INVERTER
UNIT
(DRIVE)
CN3-8
CN3-4
(48V)
BATTERY
INVERTER
UNIT
(PUMP)
LY 212
PO
BW 211
EPS
TORQUE
POTENTIOMETER
RG 58
W 162
L 160
G 161
GL 85
GB 86
GR 189
WR 188
YL 94
CN3-6
RL 100
YG 208
CANH(+)
CANL(-)
CN1-8
LB 137
RY 101
PARKING
ALARM
LIFT
POTENTIOMETER
LG 19
BL 18
CN3E-2
CN3E-1
CN1-18
CN3-5
CN1-11
RG 102
COM
CN9-1-12
CN3-2
L2
RG 203
L1
CN1-4
EPS/HPS
EPS/HPS SWITCH
LED2
(EQUL)
CN2P-29
CN2P-5
CN2P-16
R 146
Y 41
B 46
W 40
CN1-16
S3
RB 202
BL 8
YG 21
YR 20
CSPW
YL 22
PUMP
MOTOR
SENSOR
ROTATION
PUMP
MOTOR
THERMOSENSOR
PUMP
MOTOR
B 147
PS
MOTOR
R03
LCD PANEL
LB 201
VALVE
SWITCH TILT
CN1-5
S2
PB3
(SUPER
EQUL)
LED1
(CHARGE)
CONTROL
SWITCH PANEL
WG 209
S1
G 38
YW 39
CN1-15
CN2P-17
CN2P-6
PV
PU
PW
PIM
CN1P-5
CN1P-4
CN1P-16
CN1P-17
CN1P-18
CN1P-28
CN1P-21
CN1P-29
CSPU
LIFTING SWITCH
*
MODE SELECT SWITCH 2
*
MODE SELECT SWITCH 1
CN1P-35
CN1P-8
CN1P-7
CN1P-24
CN1P-22
CN1P-3
CN1P-1
CN1P-15
CN1P-13
CN1P-14
CN1P-20
CNCH1
2 1
PB2
(STOP)
GY 83
GO 84
GL 85
GB 86
F8
2A P 139
WB 26
P 27
LG 24
MC
WY 206
O 138
Y
104
G 25
F1
PB1
(START)
CANH(+)
CANL(-)
CANH(+)
CANL(-)
SOL
CN1D-12
CN1D-11
CN1D-35
CN1D-22
DRIVE MOTOR
MD
CN1-14
WR 205
S5
CN1-13
S4
WL 75
PB6
(S/P/E
SELECT)
PB8
(SPEED
CONTROL)
LIFT
LOCK
SOLENOID
CSDW
CN9-1-16
S3
W 77
PB7
(MODE)
STEERING
POTENTIOMETER
CN9-1-15
S2
WG 76
S1
PB5
(DOWN)
LW 187
BG 186
LY 93
WR 185
LB 184
LG 92
YR 44
YB 42
YL 43
DV
DU
DW
DRIVE
MOTOR
ROTATION
SENSOR (B)
DRIVE
MOTOR
SENSOR (A)
ROTATION
DRIVE
MOTOR
THERMO-SENSOR
CONTACTOR
UNIT
CN9-1-7
COM
Y 78
ACCELERATOR
2
POTENTIOMETER
CN9-1-14
PB4
(UP)
ACCELERATOR
POTENTIOMETER 1
CN1D-20
CN1D-28
CN1D-29
CN2D-32
CN2D-20
CN2D-8
CN2D-33
CN2D-21
CN2D-9
CN2D-34
CN2D-23
CN2D-10
CN1D-17
CN1D-16
GW 28
GB 29
GY 33
CNMC
2 1
CN9-1-6
YW 79
Gy 80
P 176
Y7
YB 30
CN1D-5
RW 31
RB 32
RY 34
DIM
CN9-1-8
CN1-10
BR 9
STEERING
MEMORY
HIGH
MAST SWITCH
YW181
CN1D-19
CN1D-18
CN9-2-2
CN9-2-9
CN9-2-3
CN9-2-10
CN9-2-4
CN9-2-7
CN9-2-1
CN9-2-8
SEAT
SWITCH
CN2D-29
CN2D-5
CN2D-16
CN2D-27
CN2D-3
CN2D-15
EMERGENCY
SWITCH
WY 224
WG 225
W 226
WL 227
WB 228
CN3-1
CN9-1-5
CN9-1-1
PARKING
SWITCH
0 15
CN1D-3
CN1D-1
CN1D-15
CN1D-13
CSDU
CN9-1-11
GW 81
GR 82
GY 83
GO 84
CN1D-36
CN1D-7
CN1D-8
CN1D-24
O 15
CANH(+)
CANL(-)
CANH(+)
CANL(-)
(WG 169)
(WY 168)
CN9-1-4
CANH(+)
CANL(-)
RS
RR
WG 16
WR 17
GW 81
GR 82
B 2
WY 108
CN2D-17
CN2D-6
CN9-1-2
CN9-1-10
REAR
WORK LIGHT
(OPTION)
RG 102
REAR WORK
LIGHT SWITCH
CN1D-34
CN1D-33
CN1D-4
CN1D-32
TB TR TL
W 110
LR 95
LB 180
EL LT LH
BACK-UP
BUZZER
L 131
BACK-UP
LIGHT
LW 132
WL 54
OPTION
(LM)
REAR
COMBINATION
LIGHT (LEFT)
(23W)
GY 178
R 177
(RM)
(RT)
(RB)
(BB)
(RF)
OFF
TAIL
LIGHT (10W)
WB 98
F-7
F-11
F-19
F-6
F-15
F-14
F-23
F-22
F-21
F-2
(RK)
TURN
SIGNAL LIGHT
BACK-UP
LIGHT
WR 113
WG 109
WR 113
BW 112
WB 98
LR 95
WBr 97
F-20
F-18
F-1
(RR)
(RL)
WBr 53
LW 192
BG 190
G 191
(23W)
TAIL
LIGHT (10W)
STOP
LIGHT (25W)
BRAKE
SW
GO 111
LB 180
F-9
F-25
F-8
F-24
FET UNIT
TURN
SIGNAL LIGHT
(40W)
WR 107
WG 109
GL 105
GR 106
GO 111
GL 105
LW 132
GR 106
SIG
FRONT
COMBINATION
LIGHT
(RIGHT)
HEAD
LIGHT (RIGHT)
(40W)
HEAD
LIGHT (LEFT)
SIDE-MARKER
LIGHT
(25W)
TURN
SIGNAL LIGHT
AT KEY
SW ON
AT BBR
RB 141
HORN SWITCH
F-10
F-13
F-26
F-12
F-3
FRONT
COMBINATION
LIGHT
(LEFT)
SIDE-MARKER
LIGHT
(25W)
TURN
SIGNAL LIGHT
BEACON LIGHT
(OPTION)
YL 103
L 131
RW11
BR 9
RG 102
F/R
SWITCH
OPTION
(LSP)
HORN
WBr 97
RS
RR
YB 196
FWD CHIME
(Y 99)
(GB 96)
6. ELECTRIC WIRING
PS
R5
R5
PS
MOTOR
CONTROLLER
R5
RW11
Gy
220
10A
10A
W 207
RL100
KEY SWITCH
F4
RY101
F5
RG 102
10A RB 141
F9
PO
RG 216
BATTERY CHARGER
SWITCH PANEL
DIODE
CM
MN L
MN L
S
T
F6
SR
LR
204
TRANSFORMER
CM
MN L
TH
TH
CH
W 213
RESISTOR
R01
R02
AC
INPUT
Note: Trucks with an Orbitrol steering system have neither of an EPS motor controller,
an EPS torque potentiometer or an EPS motor.
REAR
COMBINATION
LIGHT
(RIGHT)
-
- 94 -
120
MONITOR
LY 212
116
KEY
SWITCH
PO2
ELECTROLYTE
LEVEL SENSOR
INVERTER
UNIT
(DRIVE)
(48V)
CN3E-2
CN3E-1
INVERTER
UNIT
(PUMP)
CN3-8
CN3-4
(72V)
BATTERY
R 146
PUMP
MOTOR
ROTATION
SENSOR
B 147
PS
MOTOR
R5
Br 6
SIGNAL SWITCH
LIGHTING
SWITCH TURN
Gy
220
10A
10A
10A
LW115
BATTERY CHARGER
SWITCH PANEL
DIODE
LR
204
CM
MN L
W 207
MN L
TH
TH
V
W
S
T
RG 216
CN1E-17
CN1E-34
CN1E-9
CN1E-11
CN1E-4
CN1E-21
CN1E-6
CN1E-22
CN1E-23
Y 41
PUMP
MOTOR
THERMOSENSOR
PUMP
MOTOR
PS
YR 117
RG 58
W 162
L 160
G 161
GL 85
GB 86
CN2P-32
CN2P-20
CN2P-8
PS
MOTOR
CONTROLLER
CN3-6
PO1
BW 211
EPS
TORQUE
POTENTIOMETER
CANH(+)
CANL(-)
CN1-8
PO2
YG 208
RL 100
GR 189
WR 188
YL 94
BL 18
LG 19
CN1-18
CN3-5
RY 101
LIFT
POTENTIOMETER
EPS/HPS SWITCH
EPS/HPS
B 46
W 40
CN1-11
COM
PARKING
ALARM
CN2P-29
CN2P-5
CN2P-16
R03
LCD PANEL
LB 137
CSPW
BL 8
YL 22
CN3-2
L2
CN9-1-12
YR 20
G 38
YW 39
YG 21
CN2P-17
CN2P-6
RG 203
L1
CN1P-5
CN1P-4
CN1P-16
CN1P-17
CN1P-18
CN1P-28
CN1P-21
CN1P-29
CSPU
LIFTING SWITCH
VALVE
SWITCH TILT
PV
PU
CN1-4
S3
PW
PIM
LED2
(EQUL)
Y
104
CNCH1
2 1
RB 202
GY 83
GO 84
GL 85
GB 86
CN1P-35
CN1P-8
CN1P-7
CN1P-24
CN1P-22
CN1P-3
CN1P-1
CN1P-15
CN1P-13
CN1P-14
CN1P-20
WB 26
P 27
MC
CN1-16
CANH(+)
CANL(-)
CANH(+)
CANL(-)
F8
2A P 139
G 25
LG 24
F1
LB 201
PB3
(SUPER
EQUL)
LED1
(CHARGE)
O 138
CN1D-12
CN1D-11
CN1D-35
CN1D-22
MD
CN1-5
S2
WG 209
SOL
LIFT LOCK
SOLENOID
CSDW
CN1-15
CN1-14
S1
PB2
(STOP)
PB1
(START)
CONTROL
SWITCH PANEL
WY 206
S5
WR 205
STEERING
POTENTIOMETER
CN1-13
WL 75
S4
ACCELERATOR
2
POTENTIOMETER
LW 187
BG 186
LY 93
WR 185
LB 184
LG 92
YR 44
YB 42
YL 43
CN1D-20
CN1D-28
CN1D-29
CN2D-32
CN2D-20
CN2D-8
CN2D-33
CN2D-21
CN2D-9
CN2D-34
CN2D-23
CN2D-10
CN1D-17
DRIVE MOTOR
DRIVE
MOTOR
ROTATION
SENSOR (B)
DRIVE
MOTOR
ROTATION
SENSOR (A)
DRIVE MOTOR
THERMO-SENSOR
CONTACTOR
UNIT
CN9-1-16
S3
PB6
(S/P/E
SELECT)
PB8
(SPEED
CONTROL)
W 77
ACCELERATOR
POTENTIOMETER 1
Y7
CN1D-16
CNMC
2 1
CN9-1-15
S2
PB7
(MODE)
BR 9
STEERING
MEMORY
HIGH
MAST SWITCH
YW181
YB 30
DV
DW
EMERGENCY
SWITCH
WG 76
PB5
(DOWN)
PB4
(UP)
SEAT
SWITCH
CN1D-5
DU
GB 29
GW 28
GY 33
DIM
CN9-1-7
Y 78
S1
CN9-1-14
YW 79
Gy 80
COM
CN9-2-2
CN9-2-9
CN9-2-3
CN9-2-10
CN9-2-4
CN9-1-6
CN9-1-8
P 176
0 15
CN1D-19
CN1D-18
WY 224
WG 225
W 226
WL 227
WB 228
CN9-2-7
CN9-2-1
CN9-2-8
CN1-10
PARKING
SWITCH
CN1D-3
CN1D-1
CN1D-15
CN1D-13
CSDU
LW 192
BG 190
G 191
CN3-1
CN9-1-5
CN9-1-1
CN9-1-4
GW 81
GR 82
GY 83
GO 84
CN2D-29
CN2D-5
CN2D-16
RB 32
RW 31
RY 34
CN9-1-11
CANH(+)
CANL(-)
CANH(+)
CANL(-)
CN1D-36
CN1D-7
CN1D-8
CN1D-24
CN2D-27
CN2D-3
CN2D-15
O 15
CANH(+)
CANL(-)
(WG 169)
(WY 168)
WG 16
WR 17
GW 81
GR 82
RR
RS
CN2D-17
CN2D-6
CN9-1-2
CN9-1-10
RG 102
REAR WORK
LIGHT SWITCH
TB TR TL
B 2
WY 108
WL 54
REAR
WORK LIGHT
(OPTION)
CN1D-34
CN1D-33
CN1D-4
CN1D-32
WBr 53
W 110
EL LT LH
LR 95
LB 180
BACK-UP
BUZZER
L 131
LW 132
(RM)
(RT)
(RB)
(BB)
BACK-UP
LIGHT
F-7
F-11
F-19
F-6
F-15
F-14
F-23
F-22
F-21
F-2
(RF)
(RK)
SIG
REAR
COMBINATION
LIGHT (LEFT)
(23W)
R 177
GY 178
WG 109
WR 113
BW 112
WB 98
LR 95
WBr 97
F-20
F-18
F-1
(RR)
(RL)
OFF
WR 113
WB 98
BRAKE
SW
GO 111
LB 180
F-9
F-25
F-8
F-24
TURN
SIGNAL LIGHT
BACK-UP
LIGHT
(23W)
TURN
SIGNAL LIGHT
(40W)
WR 107
WG 109
GL 105
GR 106
GO 111
GL 105
LW 132
GR 106
F/R
SWITCH
OPTION (LM)
FRONT
COMBINATION
LIGHT (RIGHT)
HEAD
LIGHT (RIGHT)
(40W)
HEAD
LIGHT (LEFT)
SIDE-MARKER
LIGHT
(25W)
TURN
SIGNAL LIGHT
AT KEY
SW ON
AT BBR
RB 141
HORN SWITCH
F-10
F-13
F-26
F-12
F-3
FRONT
COMBINATION
LIGHT
(LEFT)
SIDE-MARKER
LIGHT
(25W)
TURN
SIGNAL LIGHT
BEACON LIGHT
(OPTION)
YL 103
L 131
RW11
BR 9
RG 102
FET UNIT
OPTION (LSP)
HORN
WBr 97
RS
RR
YB 196
FWD CHIME
(Y 99)
(GB 96)
6. ELECTRIC WIRING
RL100
KEY SWITCH
F7
RY101
F5
RG 102
F9
RB 141
PO1
F6
TRANSFORMER
SR
CM
MN L
CH
W 213
RESISTOR
R01
R02
AC
INPUT
Note: Trucks with an Orbitrol steering system have neither of an EPS motor controller,
an EPS torque potentiometer or an EPS motor.
No. SEB-7P0BE
Issued:
Revised:
July, 2012
December, 2012
MARKETING GROUP:
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