No.

SEB
・7E3AE

TC ⑮

SERVICEMANUAL

ELECTRICFORKLIFTTRUCK
(REACHTYPE)

FRSB唱4-8
FRSB唱6-8
FRSB20-8
FRSB25-8

TCMCORPORATION
 FOREWORD

TCM offers models FRSB14-8, FRSB16-8, FRSB20-8, and FRSB25-8 reach forklift trucks equipped
with an AC drive motor and controlled by an inverter controller. The AC motor does not have any parts
to wear out and does not require any mechanical adjustments, ensuring improved serviceability.
All of the trucks in this series come with electric power steering (EPS) as standard equipment. The
direction of the drive wheel is displayed on the LCD panel on the dashboard, for better controllability
and more safety.
This Service Manual describes the design and basic equipment parts of this series of trucks.
We encourage you to make practical use of the manual whenever servicing the truck.

December 2010
 SPECIFICATIONS
Truck Model FRSB14-8 FRSB16-8 FRSB20-8 FRSB25-8
Item
Performance
Max. load kg 1400 1600 2000 2500
Load center mm 600 ← ← ←
Max. lifting height mm 5000 ← ← ←
Reach stroke mm A 595 ← 590 705
Tilting angle (Fwd - Bwd) º 5–2 ← ← ←
Free lift mm B 1380 ← 1390 ←
Fork lifting speed mm/s
(Unloaded) 580 ← 480 ←
(Loaded) 340 ← 305 280
Travel speed km/h
Fwd (unloaded) 10.0 ← 11.0 ←
(loaded) 9.0 ← 9.5 ←
Bwd (unloaded) 10.0 ← 11.0 ←
(loaded) 9.0 ← 9.5 ←
Gradeability
(Unloaded) 1/9.5 (10.5%) ← 1/8 (12.5%) ←
(Loaded) 1/11 (9.0%) ← 1/10.5 (9.5%) ←
Min. turning radius mm C 1710 ← 1775 1930
Min. intersecting aisle width mm D 1790 ← 1850 1925
Dimensions mm
Overall length (including fork) E 2330 ← 2400 2440
Overall width F 1270 ← 1348 ←
Overall height (mast) G 2280 ← 2285 ←
Overall extended height H 5930 ← ← ←
Wheel base J 1445 ← 1495 1650
Tread
(Rear wheels) K 1160 ← 1200 ←
Fork overhang 180 ← ← ←
Front overhang L 230 ← 245 ←
Fork size
(Length x Width x Thickness M) 1070 x 122 x 40 ← 1070 x 122 x 45 ←
Fork spacing 245 – 735 ← ← ←
Backrest size 990 x 900 ← ← ←
Steering wheel height (from the floor) 1435 ← 1500 ←
Floor height 620 ← 685 ←
Minimum under clearance (Frame center) N 70 ← ← ←
Sideshift (each side) 75 ← ← ←
Weight
Service weight (w. standard battery) kg 3100 ← 3650 3865
Note: The figures are given for trucks with the standard battery unit.
 Unit: mm

245 - 735
K
F

122

D
2° 5°

A
H

5000

24

1070 M
N

180 J L
E

Fig. 1 External View

 STANDARD SETTINGS
Truck model *1 FRSB14-8 *1 FRSB20-8
Item *1 FRSB16-8 *2 FRSB25-8
Pump motor mm 27 (limit: 13) ←
Motor brush size and wear limit
Power steering motor mm 14.5 (limit: 8) ←
Pump motor N{kgf} 7.5 - 14.3 {0.76 - 1.46} ←
Motor brush spring force
Power steering N{kgf} 5 - 8 {0.5 - 0.8} ←
Electric system

Controller current limit value (pump motor lock current) 550 ←

Traveling system main circuit (A) 225 ←
Load handling system main circuit (A) 225 ←
Power steering main circuit (A) 40 ←
Fuse
Control circuit (A) 10 ←
Accessory circuit (A) 10 ←
Solenoid (A) 10 ←
Hub bolt torque (drive tire only) N-m{kgf-m} 63.7 {6.5} 88.2 {9.0}
Steering Wheels

Outer diameter of linkage pin and support pin (wear limit) mm ø30 (29.8) ø35 (34.8)
*1 1710 1775
system

Minimum turning radius

*2 – 1930
Brake pedal height mm 62 ←
Brake pedal play mm 0 ←
Brake pedal height when depressed fully mm 39 ←
Brake system

Braking distance (foot brake) less than 3.6 m less than 4.0 m
Clearance between electromagnetic brake discs (initial setting) mm 0.25 - 0.4 0.35 - 0.5
Electromagnetic brake disc thickness (limit) mm 0.65 - 0.75 0.9 - 1.0
Electromagnetic brake mounting bolt torque N-m{kgf-m} 29.7±3 {3±0.3} ←
Electromagnetic brake plate mounting bolt torque N-m{kgf-m} 26.1±5 {2.7±0.5} ←
Brake hub mounting nut torque N-m{kgf-m} 66.7 - 100 {6.8 - 10.2} ←
0
Fork thickness mm 40 -4 45-40
Load handling

Opening of fork tips mm less than 10 ←

system

Difference in height between right and left fork tips mm 10±5 ←

19.5/pitch
Chain length mm ←
(elongation 3%)
107.9±20.6
Lift cylinder piston rod bolt torque N-m{kgf-m} ←
{11.0±2.1}
Hydraulic system

Lift cylinder natural drop mm/min less than 60/10 ←

Tilt cylinder natural tilt (retraction of piston rod) mm/min less than 10/10 ←
2t : 305
Fork lifting speed (under load) mm/sec 340 2.5t : 280
Control valve relief pressure setting MPa{kgf/cm2} 18.1 {185} 19.1 {195}
Overhead guard mounting bolt torque N-m{kgf-m} 256±50 {26.1±5} ←
device
Safety

Load backrest mounting bolt torque N-m{kgf-m} 49.0 - 73.6 {5 - 7.5} ←

Drive wheel mm 290 345
Tires

Tire wear limit

Trail wheel mm 230 240
01. CAUTION TO TAKE WHEN SERVICING THE TRUCK

* Before servicing the truck, make sure to:

1. Park the truck on a level surface and jack up the drive wheel off the floor or ground.
Make sure there is no obstacle above and around the truck before operating the load handling
system.

* Caution to take when measuring, inspecting or repairing:

2. When connecting or disconnecting wire harness couplers or touching an electric component, make
sure the key switch is turned off, the battery receptacles are disconnected, and then wait for more
than 10 minutes until they are completely discharged.
3. When measuring the resistance of wire harness couplers with a multimeter, connect the probes to
the lead wire side of the coupler.
4. When inspecting the truck with the forks raised, support the forks to prevent them from falling
unexpectedly.
5. When inspecting the truck with the mast advanced, put a pallet between the mast and the front
guard of the truck to prevent the mast from retracting unexpectedly.
6. Inspection and repair of the truck must be performed only by qualified service personnel
authorized by TCM.

Counterbalanced model Reach model

 02. BASIC SERVICING KNOWLEDGE
1. Installing bearings
JIG
When installing a bearing onto a shaft, tap its
inner race with a mallet as shown in Figure 02.1.
When installing a bearing into a case, tap its outer
race.
When removing, use the same procedure as for
installing.

Fig. 02.1 Installing bearings

2. “O”-rings
① Use “O”-rings free from molding fault or damage.
② Clean “O”-rings and their mounting area and apply grease or hydraulic oil to them.
③ 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.
④ 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
the oil pressure. Pressure

Fig. 02.2 “O”-ring location

3. Oil seals
① Oil seals should be installed with the seal lip pointed toward the lubrication or hydraulic oil.
② When installing an oil seal on a housing, apply a thin coat of packing cementing agent on the
oil seal outer ring and inside the housing to prevent oil leakage through the fitting area. It is
recommended to use a suitable jig to apply uniform pressure when mounting oil seals.

JIG JIG JIG

Fig. 02.3 Installing Oil Seal

 ③ When installing an oil seal onto a shaft, apply
lubricating oil or grease to its seal lip and the JIG

mounting surface of the shaft. For a double-

lip type, fill grease by 1/3 to 1/2 of the space
between the lips.
When inserting an oil seal into a case, use care
to damage the seal lip. It is good practice to use
a suitable conical sleeve. SLEEVE

Fig. 02.4 Installing Oil Seal

4. Using LOCTITE
(1) Procedure for using LOCTITE
① Clean or degrease the surface of parts you are going to apply LOCTITE, using trichloroethylene,
acetone, ether or alkaline solution.
② Blow dry them with compressed air or allow to air dry at room temperature sufficiently.
③ 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 250°C 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

① 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.
② 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

① Clean parts thoroughly using cleaning fluid. It is recommended that parts be immersed in cleaning
fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned.
② Cast parts should be cleaned with cleaning solvent or steam cleaned.
③ 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.
④ 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.
⑤ 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.

⑥ 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.
⑦ After cleaning, parts must be thoroughly dried with compressed air.

2. Bearings
① 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.
② When drying bearings, be careful to direct air stream across bearing to avoid spinning.

3. Rubber parts
① When rubber parts need to be cleaned, use alcohol or wipe them clean with a soft cloth.
② Never use gasoline, diesel fuel or kerosene for cleaning. Use the same kind of oil for which the
rubber part will be used.
 04. STANDARD BOLT TIGHTENING TORQUE

See the section “0.4 STANDARD BOLT TIGHTENING TORQUE” for the torques of standard
bolts when they are used for general applications. Refer to the Shop Manual and Service Manual of
your truck model when:
1) Special nuts are used.
2) Synthetic resin or rubber is used for tightening.
3) Specified tightening torque is given.

• Division by strength

Strength Indication on bolt Material

SS400
4.6
(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.)
 Division by Surface
Name Shape Thread size Material Part number
strength treatment

SS400 4.6 Black 01101- Nominal symbol

SS400 4.6 01100- “

M4 - M8 coarse and S45C 6.8 01103- “
Normal
M10 - M39 fine Yellow
SCM435, Boron steel 8.8 01106- “
chromate
SCM435, Boron steel 10.9 01107- “
BsBME1 — 01108- “
SS400 4.6 Black 01112- “
SS400 4.6 01110- “
Coarse M10 - M39 coarse S45C 6.8 Yellow 01113- “
SCM435, Boron steel 8.8 Chromate 01116- “
SCM435, Boron steel 10.9 01119- “
SS400 4.6 Black 01115- “
Full thread SS400 4.6 01111- “
(normal, M10 - M39 coarse Yellow
coarse) S45C 6.8 01114- “
Chromate
Hex. head SCM435, Boron steel 8.8 01117- “
bolt SS400 4.6 Black 01121- “
SS400 4.6 01120- “
Full thread M4 - M8 coarse and S45C 6.8 01123- “
(normal) M10 - M39 fine Yellow
SCM435, Boron steel 8.8 01126- “
Chromate
SCM435, Boron steel 10.9 01127- “
BsBME1 — 01128- “
SS400 4.6 Black 01131- “
SS400 4.6 01130- “
w. socket M4 - M8 coarse and
S45C 6.8 Yellow 01133- “
head M10 - M39 fine
SCM435, Boron steel 8.8 Chromate 01136- “
SCM435, Boron steel 10.9 01137- “
SS400 4.6 Black 01161- “
SS400 4.6 01160- “
w. hole in M4 - M8 coarse and
S45C 6.8 Yellow 01163- “
threads M10 - M39 fine
SCM435, Boron steel 8.8 Chromate 01166- “
SCM435, Boron steel 10.9 01167- “

• Designation of screws: Each part number consists of a screw type designation and a nominal symbol.

Example: 01130-16050 (hex. bolt 4.6, M16 x 50, w. socket head)

 Tightening torque chart (Division by strength: 4.6)
Lubrication Dry LOCTITE262 Lubricant
condition
Target value Allowable value Target value Allowable value Target value Allowable value
Nominal
Class size Pitch 0࡮㨙 MIH࡮E㨙 0࡮㨙 MIH࡮E㨙 0࡮㨙 MIH࡮E㨙 0࡮㨙 MIH࡮E㨙 0࡮㨙 MIH࡮E㨙 0࡮㨙 MIH࡮E㨙
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             

Metric, fine system

/             
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             
/             

Metric, coarse system

/             
/             
/             
/             
/             
/             
/             
 Tightening torque chart (Division by strength: 6.8)
Lubrication Dry LOCTITE262 Lubricant
condition
Target value Allowable value Target value Allowable value Target value Allowable value
Nominal
Class size Pitch N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ
M 4 0.50 2.71 27.6 2.17 ‑ 3.26 22.1 ‑ 33.2 2.40 24.5 1.92 ‑ 2.87 19.6 ‑ 29.3 1.98 20.2 1.58 ‑ 2.38 16.1 ‑ 24.3
M 5 0.50 5.74 58.5 4.59 ‑ 6.87 46.8 ‑ 70.1 5.05 51.5 4.04 ‑ 6.06 41.2 ‑ 61.8 4.15 42.3 3.33 ‑ 4.98 33.9 ‑ 50.8
M 6 0.75 9.14 93.2 7.32 ‑ 11.0 74.6 ‑ 112 8.10 82.6 6.48 ‑ 9.72 66.1 ‑ 99.1 6.68 68.1 5.34 ‑ 8.01 54.4 ‑ 81.7
M 8 1.00 21.7 221 17.4 ‑ 26.0 177 ‑ 265 19.2 196 15.4 ‑ 23.0 157 ‑ 235 15.8 161 12.7 ‑ 19.0 129 ‑ 194
M 10 1.25 42.4 432 33.8 ‑ 50.9 345 ‑ 519 37.5 382 30.0 ‑ 45.0 306 ‑ 459 30.9 315 24.7 ‑ 37.1 252 ‑ 378
M 12 1.25 78.3 798 62.6 ‑ 93.9 638 ‑ 957 68.9 703 55.1 ‑ 82.7 562 ‑ 843 56.8 579 45.5 ‑ 68.2 464 ‑ 695
M 14 1.50 123 1250 98.1 ‑ 148 1000 ‑ 1510 109 1110 86.9 ‑ 129 886 ‑ 1320 89.4 912 71.6 ‑ 107 730 ‑ 1090
M 16 1.50 192 1960 153 ‑ 229 1560 ‑ 2340 169 1720 135 ‑ 202 1380 ‑ 2060 139 1420 111 ‑ 168 1130 ‑ 1700
M 18 1.50 282 2870 225 ‑ 337 2290 ‑ 3440 247 2520 198 ‑ 296 2020 ‑ 3020 203 2070 163 ‑ 244 1660 ‑ 2490
M 20 1.50 396 4040 317 ‑ 476 3230 ‑ 4850 347 3540 278 ‑ 416 2830 ‑ 4240 285 2910 229 ‑ 343 2330 ‑ 3500

Metric, fine system

M 22 1.50 537 5480 431 ‑ 645 4390 ‑ 6580 471 4800 376 ‑ 565 3830 ‑ 5760 386 3940 310 ‑ 465 3160 ‑ 4740
M 24 2.00 668 6810 534 ‑ 800 5440 ‑ 8160 585 5970 469 ‑ 702 4780 ‑ 7160 481 4910 385 ‑ 579 3930 ‑ 5900
M 27 2.00 978 9970 782 ‑ 1170 7970 ‑ 11900 855 8720 685 ‑ 1030 6980 ‑ 10500 704 7180 564 ‑ 845 5750 ‑ 8620
M 30 2.00 1370 14000 1100 ‑ 1650 11200 ‑ 16800 1200 12200 958 ‑ 1440 9770 ‑ 14700 991 10100 788 ‑ 1180 8040 ‑ 12000
M 33 2.00 1860 19000 1490 ‑ 2330 15200 ‑ 22700 1620 16500 1290 ‑ 1950 13200 ‑ 19900 1340 13700 1070 ‑ 1600 10900 ‑ 16300
M 36 3.00 2250 22900 1790 ‑ 2700 18300 ‑ 27500 1980 20200 1580 ‑ 2370 16100 ‑ 24200 1630 16600 1290 ‑ 1950 13200 ‑ 19900
M 39 3.00 2920 29800 2330 ‑ 3510 23800 ‑ 35800 2560 26100 2050 ‑ 3070 20900 ‑ 31300 2110 21500 1690 ‑ 2530 17200 ‑ 25800
M 4 0.70 2.29 23.3 1.82 ‑ 2.75 18.6 ‑ 28.0 2.06 21.0 1.65 ‑ 2.47 16.8 ‑ 25.2 1.70 17.3 1.36 ‑ 2.03 13.9 ‑ 20.7
M 5 0.80 4.72 48.1 3.77 ‑ 5.66 38.4 ‑ 57.7 4.21 42.9 3.36 ‑ 5.06 34.3 ‑ 51.6 3.47 35.4 2.78 ‑ 4.17 28.3 ‑ 42.5
M 6 1.00 7.95 81.1 6.36 ‑ 9.55 64.9 ‑ 97.4 7.13 72.7 5.70 ‑ 8.54 58.1 ‑ 87.1 5.87 59.9 4.70 ‑ 7.04 47.9 ‑ 71.8
M 8 1.25 19.6 200 15.7 ‑ 23.4 160 ‑ 239 17.5 178 14.0 ‑ 21.0 143 ‑ 214 14.4 147 11.5 ‑ 17.3 117 ‑ 176
M 10 1.50 38.6 397 31.2 ‑ 46.8 318 ‑ 477 34.8 355 27.8 ‑ 41.7 283 ‑ 425 28.6 292 22.9 ‑ 34.4 233 ‑ 351
M 12 1.75 68.4 697 54.6 ‑ 82.1 557 ‑ 837 60.9 621 48.6 ‑ 73.1 496 ‑ 745 50.2 512 40.1 ‑ 60.1 409 ‑ 613
M 14 2.00 110 1120 87.8 ‑ 132 895 ‑ 1350 97.6 995 78.1 ‑ 117 796 ‑ 1190 80.3 819 64.2 ‑ 96.4 655 ‑ 983
M 16 2.00 174 1770 139 ‑ 208 1420 ‑ 2120 154 1570 123 ‑ 185 1250 ‑ 1890 127 1290 101 ‑ 152 1030 ‑ 1550
M 18 2.50 235 2400 189 ‑ 282 1930 ‑ 2880 210 2140 168 ‑ 252 1710 ‑ 2570 173 1760 138 ‑ 208 1410 ‑ 2120
M 20 2.50 338 3450 271 ‑ 407 2760 ‑ 4150 300 3060 240 ‑ 360 2450 ‑ 3670 247 2520 198 ‑ 297 2020 ‑ 3030

Metric, coarse system

M 22 2.50 468 4770 374 ‑ 562 3810 ‑ 5730 413 4210 330 ‑ 495 3370 ‑ 5050 340 3470 272 ‑ 409 2770 ‑ 4170
M 24 3.00 585 5970 469 ‑ 702 4780 ‑ 7160 519 5290 414 ‑ 623 4220 ‑ 6350 428 4360 341 ‑ 513 3480 ‑ 5230
M 27 3.00 872 8890 697 ‑ 1050 7110 ‑ 10700 770 7850 616 ‑ 924 6280 ‑ 9420 634 6460 507 ‑ 760 5170 ‑ 7750
M 30 3.50 1180 12000 940 ‑ 1410 9580 ‑ 14400 1040 10600 831 ‑ 125 8470 ‑ 12700 855 8720 685 ‑ 1030 6980 ‑ 10500
M 33 3.50 1620 16500 1280 ‑ 1940 13100 ‑ 19800 1430 14600 1140 ‑ 1710 11600 ‑ 17400 1180 12000 940 ‑ 1410 9580 ‑ 14400
M 36 4.00 2070 21100 1650 ‑ 2480 16800 ‑ 25300 1820 18600 1460 ‑ 2190 14900 ‑ 22300 1500 15300 1200 ‑ 1790 12200 ‑ 18300
M 39 4.00 2700 27500 2160 ‑ 3240 22000 ‑ 33000 2380 24300 1900 ‑ 2840 19400 ‑ 29000 1960 20000 1570 ‑ 2340 16000 ‑ 23900
 Tightening torque chart (Division by strength: 8.8)
Lubrication Dry LOCTITE262 Lubricant
condition
Target value Allowable value Target value Allowable value Target value Allowable value
Nominal
Class size Pitch N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ
M 4 0.50 3.62 36.9 2.89 ‑ 4.34 29.5 ‑ 44.3 3.20 32.6 0.26 ‑ 0.39 26.1 ‑ 39.3 2.64 26.9 2.12 ‑ 3.17 21.6 ‑ 32.3
M 5 0.50 7.65 78.0 6.12 ‑ 9.18 62.4 ‑ 93.6 6.73 68.6 0.54 ‑ 0.81 55.0 ‑ 82.4 5.55 56.6 4.44 ‑ 6.66 45.3 ‑ 67.9
M 6 0.75 12.2 124 9.78 ‑ 14.7 99.7 ‑ 150 10.8 110 0.87 ‑ 1.30 88.2 ‑ 133 8.91 90.9 7.13 ‑ 10.7 72.7 ‑ 109
M 8 1.00 28.9 295 23.1 ‑ 34.7 236 ‑ 354 25.6 261 2.05 ‑ 3.08 209 ‑ 314 21.1 215 16.9 ‑ 25.3 172 ‑ 258
M 10 1.25 56.5 576 45.2 ‑ 67.9 461 ‑ 692 50.1 511 4.01 ‑ 6.01 409 ‑ 613 41.3 421 33.0 ‑ 49.5 337 ‑ 505
M 12 1.25 104 1060 83.6 ‑ 126 852 ‑ 1280 92.0 938 7.37 ‑ 11.0 751 ‑ 1120 75.8 773 60.6 ‑ 90.9 618 ‑ 927
M 14 1.50 164 1670 131 ‑ 197 1340 ‑ 2010 145 1480 11.6 ‑ 17.4 1180 ‑ 1770 119 1210 95.4 ‑ 143 973 ‑ 1460
M 16 1.50 256 2610 204 ‑ 307 2080 ‑ 3130 226 2300 18.0 ‑ 27.0 1840 ‑ 2750 185 1890 148 ‑ 222 1510 ‑ 2260
M 18 1.50 377 3840 301 ‑ 451 3070 ‑ 4600 330 3360 26.4 ‑ 39.5 2690 ‑ 4030 271 2760 217 ‑ 327 2210 ‑ 3330
M 20 1.50 529 5390 423 ‑ 635 4310 ‑ 6470 463 4720 37.0 ‑ 55.5 3770 ‑ 5660 381 3890 305 ‑ 457 3110 ‑ 4660

Metric, fine system

M 22 1.50 718 7320 574 ‑ 861 5850 ‑ 8780 629 6410 50.2 ‑ 75.3 5120 ‑ 7680 517 5270 413 ‑ 620 4210 ‑ 6320
M 24 2.00 890 9080 712 ‑ 1070 7260 ‑ 10900 782 7970 62.6 ‑ 93.8 6380 ‑ 9560 643 6560 514 ‑ 773 5240 ‑ 7870
M 27 2.00 1300 13300 1040 ‑ 1570 10600 ‑ 16000 1140 11600 91.3 ‑ 137 9310 ‑ 14000 940 9590 752 ‑ 1130 7670 ‑ 11500
M 30 2.00 1830 18700 1460 ‑ 2190 14900 ‑ 22300 1600 16300 128 ‑ 192 13100 ‑ 19600 1320 13500 1050 ‑ 1580 10700 ‑ 16100
M 33 2.00 2480 25300 1980 ‑ 2970 20200 ‑ 30300 2160 22000 173 ‑ 259 17600 ‑ 26400 1780 18200 1420 ‑ 2140 14500 ‑ 21800
M 36 3.00 3010 30700 2400 ‑ 3610 24500 ‑ 36800 2640 26900 211 ‑ 316 21500 ‑ 32200 2170 22100 1740 ‑ 2610 17700 ‑ 26600
M 39 3.00 3900 39800 3120 ‑ 4680 31800 ‑ 47700 3410 34800 273 ‑ 409 27800 ‑ 41700 2810 28700 2260 ‑ 3370 23000 ‑ 34400
M 4 0.70 3.06 31.2 2.45 ‑ 3.67 25.0 ‑ 37.4 2.7 27.9 2.19 ‑ 3.30 22.3 ‑ 33.6 2.27 23.1 1.81 ‑ 2.71 18.5 ‑ 27.6
M 5 0.80 6.30 64.2 5.03 ‑ 7.55 51.3 ‑ 77.0 5.6 57.3 4.49 ‑ 6.74 45.8 ‑ 68.7 4.63 47.2 3.70 ‑ 5.56 37.7 ‑ 56.7
M 6 1.00 10.6 108 8.50 ‑ 12.7 86.7 ‑ 130 9.5 96.9 7.60 ‑ 11.4 77.5 ‑ 116 7.85 80.0 6.28 ‑ 9.40 64.0 ‑ 95.9
M 8 1.25 26.1 266 20.9 ‑ 31.0 213 ‑ 319 23.3 238 18.6 ‑ 28.0 190 ‑ 286 19.2 196 15.4 ‑ 23.0 157 ‑ 235
M 10 1.50 52.1 531 41.6 ‑ 62.5 424 ‑ 638 46.4 473 37.1 ‑ 55.7 378 ‑ 568 38.2 390 30.6 ‑ 45.9 312 ‑ 468
M 12 1.75 91.2 930 73.1 ‑ 109 745 ‑ 1110 81.2 828 64.9 ‑ 97.4 662 ‑ 993 66.9 682 53.5 ‑ 80.3 546 ‑ 819
M 14 2.00 146 1490 117 ‑ 177 1190 ‑ 1800 130 1330 104 ‑ 156 1060 ‑ 1590 107 1090 85.8 ‑ 1290 875 ‑ 1320
M 16 2.00 232 2370 185 ‑ 279 1890 ‑ 2840 205 2090 164 ‑ 246 1670 ‑ 2510 169 1720 135 ‑ 203 1380 ‑ 2070
M 18 2.50 315 3210 252 ‑ 379 2570 ‑ 3860 280 2860 224 ‑ 336 2280 ‑ 3430 231 2360 185 ‑ 278 1890 ‑ 2830
M 20 2.50 452 4610 362 ‑ 543 3690 ‑ 5540 401 4090 320 ‑ 482 3260 ‑ 4910 330 3370 264 ‑ 396 2690 ‑ 4040

Metric, coarse system

M 22 2.50 624 6360 499 ‑ 749 5090 ‑ 7640 551 5620 441 ‑ 662 4500 ‑ 6750 454 4630 363 ‑ 545 3700 ‑ 5560
M 24 3.00 782 7970 626 ‑ 938 6380 ‑ 9560 692 7060 554 ‑ 831 5650 ‑ 8470 570 5810 456 ‑ 685 4650 ‑ 6980
M 27 3.00 1160 11800 931 ‑ 1400 9490 ‑ 14300 1030 10500 821 ‑ 123 8370 ‑ 12500 846 8630 678 ‑ 1020 6910 ‑ 10400
M 30 3.50 1570 16000 1260 ‑ 1880 12800 ‑ 19200 1390 14200 1110 ‑ 1660 11300 ‑ 16900 1140 11600 913 ‑ 1370 9310 ‑ 14000
M 33 3.50 2160 22000 1730 ‑ 2590 17600 ‑ 26400 1900 19400 1520 ‑ 2290 15500 ‑ 23300 1570 16000 1260 ‑ 1880 12800 ‑ 19200
M 36 4.00 2770 28200 2210 ‑ 3310 22500 ‑ 33800 2430 24800 1950 ‑ 2920 19900 ‑ 29800 2010 20500 1600 ‑ 2410 16300 ‑ 24600
M 39 4.00 3600 36700 2880 ‑ 4320 29400 ‑ 44100 3170 32300 2540 ‑ 3810 25900 ‑ 38900 2610 26600 2090 ‑ 3140 21300 ‑ 32000
 Tightening torque chart (Division by strength: 10.9)
Lubrication Dry LOCTITE262 Lubricant
condition
Target value Allowable value Target value Allowable value Target value Allowable value
Nominal
Class size Pitch N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ N・ｍ kgf・cｍ
M 4 0.50 5.33 54.3 4.26 ‑ 6.38 43.4 ‑ 65.1 4.71 48 3.77 ‑ 5.65 38.4 ‑ 57.6 3.87 39.5 3.11 ‑ 4.66 31.7 ‑ 47.5
M 5 0.50 11.3 115 9.00 ‑ 13.5 91.8 ‑ 138 9.91 101 7.92 ‑ 12.0 80.8 ‑ 122 8.15 83.1 6.52 ‑ 9.79 66.5 ‑ 99.8
M 6 0.75 17.9 183 14.3 ‑ 21.6 146 ‑ 220 15.9 162 12.7 ‑ 19.0 130 ‑ 194 13.0 133 10.5 ‑ 15.7 107 ‑ 160
M 8 1.00 42.6 434 34.1 ‑ 51.0 348 ‑ 520 37.7 384 30.1 ‑ 45.2 307 ‑ 461 31.1 317 24.9 ‑ 37.2 254 ‑ 379
M 10 1.25 83.1 847 66.5 ‑ 100 678 ‑ 1020 73.6 750 58.8 ‑ 88.4 600 ‑ 901 60.6 618 48.5 ‑ 72.8 495 ‑ 742
M 12 1.25 154 1570 123 ‑ 184 1250 ‑ 1880 135 1380 109 ‑ 162 1110 ‑ 1650 112 1140 89.0 ‑ 133 908 ‑ 1360
M 14 1.50 241 2460 193 ‑ 289 1970 ‑ 2950 213 2170 171 ‑ 255 1740 ‑ 2600 176 1790 140 ‑ 210 1430 ‑ 2140
M 16 1.50 376 3830 300 ‑ 450 3060 ‑ 4590 330 3370 265 ‑ 396 2700 ‑ 4040 272 2770 218 ‑ 327 2220 ‑ 3330
M 18 1.50 552 5630 442 ‑ 663 4510 ‑ 6760 484 4940 387 ‑ 582 3950 ‑ 5930 398 4060 319 ‑ 479 3250 ‑ 4880
M 20 1.50 777 7920 621 ‑ 933 6330 ‑ 9510 681 6940 544 ‑ 815 5550 ‑ 8310 560 5710 448 ‑ 672 4570 ‑ 6850

Metric, fine system

M 22 1.50 1060 10800 843 ‑ 1270 8600 ‑ 12900 922 9400 738 ‑ 1110 7530 ‑ 11300 759 7740 607 ‑ 912 6190 ‑ 9300
M 24 2.00 1300 13300 1050 ‑ 1570 10700 ‑ 16000 1150 11700 919 ‑ 1380 9370 ‑ 14100 946 9650 756 ‑ 1140 7710 ‑ 11600
M 27 2.00 1910 19500 1540 ‑ 2300 15700 ‑ 23500 1690 17200 1330 ‑ 2020 13600 ‑ 20600 1380 14100 1110 ‑ 1660 11300 ‑ 16900
M 30 2.00 2690 27400 2160 ‑ 3230 22000 ‑ 32900 2350 24000 1880 ‑ 2820 19200 ‑ 28800 1930 19700 1550 ‑ 2320 15800 ‑ 23700
M 33 2.00 3640 37100 2910 ‑ 4370 29700 ‑ 44600 3180 32400 2540 ‑ 3810 25900 ‑ 38900 2620 26700 2090 ‑ 3140 21300 ‑ 32000
M 36 3.00 4420 45100 3530 ‑ 5300 36000 ‑ 54000 3870 39500 3110 ‑ 4650 31700 ‑ 47400 3190 32500 2550 ‑ 3820 26000 ‑ 39000
M 39 3.00 5730 58400 4580 ‑ 6860 46700 ‑ 70000 5020 51200 4010 ‑ 6020 40900 ‑ 61400 4130 42100 3300 ‑ 4950 33700 ‑ 50500
M 4 0.70 4.49 45.8 3.60 ‑ 5.39 36.7 ‑ 55.0 4.03 41.1 3.22 ‑ 4.83 32.8 ‑ 49.2 3.32 33.9 2.66 ‑ 3.98 27.1 ‑ 40.6
M 5 0.80 9.24 94.2 7.40 ‑ 11.1 75.5 ‑ 113 8.26 84.2 6.60 ‑ 9.91 67.3 ‑ 101 6.81 69.4 5.44 ‑ 8.18 55.5 ‑ 83.4
M 6 1.00 15.6 159 12.6 ‑ 18.7 128 ‑ 191 14.0 143 11.2 ‑ 16.8 114 ‑ 171 11.5 117 9.21 ‑ 13.8 93.9 ‑ 141
M 8 1.25 38.3 391 30.7 ‑ 46.0 313 ‑ 469 34.3 350 27.4 ‑ 41.1 279 ‑ 419 28.2 288 22.6 ‑ 33.8 230 ‑ 345
M 10 1.50 76.5 780 61.2 ‑ 91.8 624 ‑ 936 68.2 695 54.5 ‑ 81.9 556 ‑ 835 56.1 572 44.9 ‑ 67.5 458 ‑ 688
M 12 1.75 133 1360 108 ‑ 161 1100 ‑ 1640 120 1220 95.4 ‑ 143 973 ‑ 1460 98.1 1000 78.8 ‑ 118 803 ‑ 1200
M 14 2.00 216 2200 173 ‑ 258 1760 ‑ 2630 191 1950 153 ‑ 230 1560 ‑ 2350 158 1610 127 ‑ 189 1290 ‑ 1930
M 16 2.00 341 3480 272 ‑ 409 2770 ‑ 4170 301 3070 241 ‑ 362 2460 ‑ 3690 249 2540 199 ‑ 298 2030 ‑ 3040
M 18 2.50 463 4720 370 ‑ 555 3770 ‑ 5660 412 4200 330 ‑ 493 3360 ‑ 5030 338 3450 272 ‑ 407 2770 ‑ 4150
M 20 2.50 665 6780 534 ‑ 797 5440 ‑ 8130 588 6000 471 ‑ 707 4800 ‑ 7210 485 4950 387 ‑ 583 3950 ‑ 5940

Metric, coarse system

M 22 2.50 918 9360 734 ‑ 1100 7480 ‑ 11200 810 8260 648 ‑ 972 6610 ‑ 9910 668 6810 534 ‑ 802 5450 ‑ 8180
M 24 3.00 1150 11700 919 ‑ 1380 9370 ‑ 14100 1020 10400 814 ‑ 1230 8300 ‑ 12500 838 8550 670 ‑ 1010 6830 ‑ 10300
M 27 3.00 1720 17500 1370 ‑ 2050 14000 ‑ 20900 1510 15400 1220 ‑ 1800 12400 ‑ 18400 1250 12700 991 ‑ 1490 10100 ‑ 15200
M 30 3.50 2300 23500 1840 ‑ 2770 18800 ‑ 28200 2040 20800 1630 ‑ 2440 16600 ‑ 24900 1690 17200 1330 ‑ 2020 13600 ‑ 20600
M 33 3.50 3170 32300 2540 ‑ 3810 25900 ‑ 38800 2800 28600 2240 ‑ 3350 22800 ‑ 34200 2300 23500 1840 ‑ 2760 18800 ‑ 28100
M 36 4.00 4060 41400 3240 ‑ 4860 33000 ‑ 49600 3580 36500 2860 ‑ 4300 29200 ‑ 43800 2950 30100 2360 ‑ 3530 24100 ‑ 36000
M 39 4.00 5290 53900 4240 ‑ 6350 43200 ‑ 64800 4660 47500 3740 ‑ 5590 38100 ‑ 57000 3830 39100 3070 ‑ 4610 31300 ‑ 47000
 05. LUBRICATION (1/2)
1. Hydraulic oil tank

HYDRAULIC OIL TANK CAP &

DIPSTICK

FRSB14-8 25 L
FRSB16-8 Wear-Resistant
FRSB20-8 TCM Hydraulic Oil
31.8 L
FRSB25-8
* Note: The capacity is given for trucks of standard
specifications.

2. Drive unit
3. Power steering actuator case
OIL FILL PORT (Remove breather and add oil)
OIL FILL PLUG
DRAIN PLUG

All models 0.35 L

TCM Gear Oil STD: SAE 90

DRAIN PLUG

FRSB14-8, FRSB16-8 2.1 L TCM Gear Oil

FRSB20-8, FRSB25-8 3.2 L STD: SAE90
 LUBRICATION (2/2)

4. Applying grease
4-1. Sideshift and finger bar................................................1

Apply grease.

4-2. Piston head guide

Apply grease to the guide indicated by arrows.

Inner mast
Middle mast channel channel

Outer mast channel

Apply grease.
 06. PARTS LIST

Part number
Item Part name FRSB14-8 FRSB20-8 Remarks
FRSB16-8 FRSB25-8
DC96V 225A
Fuses F1 and F2 181E2-62471
(DRIVE, PUMP)
Fuses
Fuse F3 181E2-62541 DC96V 40A (PS)
Fuse F4, F5 and F7 25592-42311 10A
Oil tank Suction filter 215E7-52031
Bulb 29502-42421 48V/40W
Head light
Assembly 29502-42401
Lights
Turn signal lights Bulb 27732-42331 48V/25W
(Option) Assembly 27912-42102
Brake Brake assembly 27E43-72001 27E53-72001
Trail wheel 27B04-40401 27B44-40401 Urethane
Tires
Drive wheel 27E44-40221 27E54-40221 Urethane

* Note: The part numbers shown above are subject to change without notice.
 INSPECTION AND MAINTENANCE

TABLE OF CONTENTS
1. BATTERY (OPTION) ............................................................................................................... 1
1.1 GENERAL DESCRIPTION...................................................................................................... 1
1.1.1 BATTERY (OPTION)....................................................................................................... 1

2. MOTORS ...................................................................................................................................... 9
2.1 GENERAL DESCRIPTION...................................................................................................... 9
2.1.1 DRIVE MOTOR.............................................................................................................. 10
2.1.2 PUMP MOTOR............................................................................................................... 12
2.1.3 ELECTRIC POWER STEERING (EPS) MOTOR......................................................... 14
2.2 MAINTENANCE................................................................................................................... 16
2.2.1 DRIVE MOTOR.............................................................................................................. 16
2.2.2 PUMP MOTOR............................................................................................................... 23

3. CONTROLLER ........................................................................................................................ 33
3.1 GENERAL DESCRIPTION.................................................................................................... 33
3.1.1 CONTROLLER............................................................................................................... 33
3.1.2 ACCELERATOR PEDAL............................................................................................... 36
3.1.3 LCD PANEL.................................................................................................................... 37

4. DRIVE UNIT .............................................................................................................................. 39

4.1 GENERAL DESCRIPTION................................................................................................... 39
4.2 MAINTENANCE.................................................................................................................... 41
4.2.1 REPLACING DRIVE WHEEL . .................................................................................... 41
4.2.2 ADJUSTMENT AFTER REASSEMBLY....................................................................... 43
4.2.3 TROUBLESHOOTING GUIDE..................................................................................... 45

5. STEERING SYSTEM . ........................................................................................................... 47

5.1 GENERAL DESCRIPTION.................................................................................................... 47
5.1.1 STEERING WHEEL....................................................................................................... 47
5.1.2 BEARING SENSOR....................................................................................................... 49
5.1.3 STEERING ANGLE SENSOR....................................................................................... 50
5.1.4 ACTUATOR.................................................................................................................... 51
5.1.5 REAR AXLE................................................................................................................... 52
5.1.6 TRAIL WHEEL............................................................................................................... 54
6. BRAKE SYSTEM .................................................................................................................... 55
6.1 GENERAL DESCRIPTION.................................................................................................... 55
6.1.1 BRAKE PEDAL.............................................................................................................. 56
6.1.2 ELECTROMAGNETIC BRAKE.................................................................................... 57

7. HYDRAULIC SYSTEM ......................................................................................................... 59

7.1 GENERAL DESCRIPTION.................................................................................................... 59
7.1.1 OIL TANK....................................................................................................................... 60
7.1.2 MAIN PUMP................................................................................................................... 61
7.1.3 CONTROL VALVE......................................................................................................... 61
7.1.4 VALVE CONTROL......................................................................................................... 63
7.1.5 LIFT CYLINDERS......................................................................................................... 64
7.1.6 FLOW REGULATOR VALVE........................................................................................ 67
7.1.7 SIDESHIFT CYLINDER................................................................................................ 69
7.1.8 TILT CYLINDER............................................................................................................ 70
7.1.9 REACH CYLINDER...................................................................................................... 71
7.2 MAINTENANCE.................................................................................................................... 72
7.2.1 HYDRAULIC OIL CHANGE........................................................................................ 72
7.2.2 REPLACING STRAINER ............................................................................................. 72
7.2.3 MEASURING AND ADJUSTING HYDRAULIC OIL PRESSURE............................ 73
7.2.4 ADJUSTING VALVE SWITCH .................................................................................... 74

8. LOAD HANDLING SYSTEM ............................................................................................. 77

8.1 GENERAL DESCRIPTION.................................................................................................... 78
8.1.1 MAST ASSEMBLY......................................................................................................... 78
8.1.2 FORK CARRIAGE......................................................................................................... 79
8.1.3 ROLLER LOCATIONS.................................................................................................. 80
8.2 MAINTENANCE.................................................................................................................... 82
8.2.1 ADJUSTING FRONT LIFT CYLINDER ROD WITH SHIMS.................................... 82
8.2.2 ADJUSTING FORK CARRIAGE HEIGHT ................................................................. 82
8.2.3 REPLACING FORK CARRIAGE ROLLERS . ............................................................ 84
8.2.4 REPLACING MAST ROLLERS ................................................................................... 86
8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS....................................... 87
8.2.6 ADJUSTING MAST SSC SWITCH............................................................................... 88
 1. BATTERY (OPTION)

1. BATTERY (OPTION)
Truck model FRSB14-8 FRSB20-8
Item FRSB16-8 FRSB25-8
Battery
Conformance DIN 43531C
Capacity range (standard) 420 - 465 Ah 560 - 620 Ah
(high capacity) 560 - 620 Ah 700 - 775 Ah
Rated voltage 48 V
Case size
(width x length x height)
(standard) 1223 x 283 x 784 mm 1223 x 355 x 784 mm
(high capacity) 1223 x 355 x 784 mm 1223 x 427 x 784 mm
Weight
(including case and electrolyte)
(standard) 750 - 785 kg 930 - 985 kg
(high capacity) 980 - 985 kg 1115 - 1175 kg

1.1 GENERAL DESCRIPTION

1.1.1 BATTERY (OPTION)
The battery assembly consists of 24 2-volt battery cells connected in series and is housed in a case.
Each battery cell has a cap on the top, inside which a float is located to indicate the electrolyte level
in the battery cell.
One of the 24 battery cells is used to monitor the battery electrolyte level, which is shown by the
battery electrolyte level indicator installed on the battery case.

-1-
1. BATTERY (OPTION)

BATTERY ELECTROLYTE
LEVEL INDICATOR (OPTION)

Fig. 1.1 Battery Assembly

-2-
 1. BATTERY (OPTION)

(1) Battery cell

The battery cell has a clad type pole plate as the anode. (It is a glass fiber or synthetic resin tube
filled with lead peroxide, having a lead alloy core which runs through the center).
The anode plate withstands a long cycle of use, and can stand up against overcharge and
overdischarge.
The negative plate consists of a lead frame filled up with lead peroxide in paste form. The two pole
plates are isolated by means of separators in order to prevent them from getting short-circuited.

The battery jar is made of resin. The electrolyte

BATTERY CAP
is high purity diluted sulfuric acid of 1.28 specific
gravity (at 20°C).
The battery cap is made of transparent resin,
having a float inside to monitor the electrolyte level
and to indicate when the fluid should be added.
FLOAT
On the side face of the battery case is an
electrolyte level indicator, which blinks when the
electrolyte level is low. A sensor for the indicator is
fitted on one of the 24 caps. Fig. 1.2 Float

-3-
1. BATTERY (OPTION)

(2) Battery case locking device

The battery assembly is housed in the frame using a battery tray.
The battery locking switch is turned on when the battery is housed properly in the frame and locked,
and turned off when the battery is removed from the frame or housed in an improper manner.

The battery case can be pulled out of the truck by advancing the mast forward.

A
SWITCH LOCK RELEASE
PEDAL

Operating
point:
22 mm

Detail of area A

SPRING HOOK

SLIDER BLOCK

Fig. 1.3 Battery Case Locking Device

-4-
 1. BATTERY (OPTION)

(3) Emergency shut-off switch

An emergency stop switch is installed between the truck-side receptacle (+) and the controller (+) to
allow the operator to shut off the battery power immediately in an emergency.

EMERGENCY
SHUT-OFF SWITCH

/& %0 %0 %0

㧼㧭
(

(

⵾ㅧ⇟ภ
/'+&'05*#%14214#6+10
6/&
(
#

(#0 (#0

to CONTROLLER (+)

to BATTERY
RECEPTACLE (+)

B
View looking from B

View looking from A

Fig. 1.4 Emergency Shut-off Switch

-5-
1. BATTERY (OPTION)

(4) Battery care

Cycles of charge
Service life

and discharge
The most important point in battery care is to
prevent overdischarge. The deeper the battery
discharges, the shorter its life becomes (See Fig.
1.5).
The approximate depth of discharge can be
known by measuring the specific gravity of the
electrolyte (See Fig. 1.6). Within
this range
Check the level of electrolyte every ten days. (Example)
Add distilled water if the level is found lower
than the specified level before recharging the
Depth of discharge (%)
battery.
Fig. 1.5 Relationship Between Depth of
Discharge and Service Life

SPECIFIC GRAVITY (20°C)

VOLTAGE
Usable

VOLTAGE

Alert
SPECIFIC GRAVITY
Overdischarge

(DISCHARGE DURATION)
(DISCHARGE RATE)

Fig. 1.6 Example of Specific Gravity Drop (5-hour rate discharge)

-6-
 1. BATTERY (OPTION)

■ Adding battery electrolyte

Battery electrolyte should be added as follows just before recharging the battery:
① Operate the reach lever to the retraction position to retract the mast.
② Press the battery lock release pedal.
③ Operate the reach lever to the advancement position so that the battery case comes out of the truck
body.
④ Disconnect the battery receptacles.
⑤ Clean all the cell caps and areas around them.
⑥ Open each cap and add distilled water into the cell.
Observe the float carefully not to add too much water. All the floats of the cells should be at the
same height.
⑦ Reinstall the caps and wipe dry the areas around them and the pole plates.
⑧ Connect the battery receptacles.
⑨ Press the battery lock release pedal while placing the reach lever in the retraction position, to
retract the mast.
⑩ Recharge the battery.
Note: Give an auxiliary charge to the battery after adding battery electrolyte.

Max. level Proper level Min. level

Red

White

Too much distilled water may cause an unclosed cap, It

may also let electrolyte overflow after recharging, causing
corrosion.

Fig. 1.7

-7-
1. BATTERY (OPTION)

■ Recharging the battery

When discharged, the battery should be recharged as soon as possible. Leaving the battery
discharged for a long time (longer than a day) may cause sulfation, which will result in the drop of
battery performance.
If the battery is kept out of service for a long time, it should be thoroughly charged before being put
in storage and an auxiliary charge is also required once a month.
If the amount of discharge is considered to be small, measure the specific gravity of the electrolyte.
Recharge the battery if the specific gravity is lower than 1.260.
An equalizing charge may be required if the specific gravity varies to a large extent among the cells
by the amount of 0.020 or larger. Such an equalizing charge should normally be performed one to four
times a month. If the specific gravity variation is not corrected by giving an equalizing charge, specific
gravity adjustment may be required.
Giving an equalizing charge more times than necessary will result in an overcharged battery, and the
battery’s service life will be shortened.
A microprocessor-controlled battery charger gives an equalizing charge automatically, but manual
equalizing charge may be required if the specific gravity varies to a large extent among the cells or the
cells are in a low state of charge.

[Caution to take when recharging the battery]

1. Do not recharge the battery if the electrolyte temperature is higher than 40°C. Leave the battery
for a while until the electrolyte temperature goes low.
2. Overdischarge or overcharge will raise the electrolyte temperature. While recharging the battery,
have good ventilation in order to let generated gas and heat get out.

[Specific gravity correction according to temperature]

The specific gravity of the electrolyte varies as the electrolyte temperature changes. The specific
gravity is generally based on the electrolyte temperature of 20°C. Therefore, if the specific gravity is
measured at the electrolyte temperature of other than 20°C, correct it using the following formula:
S20 = St + 0.0007 (t – 20)
Where
S20: Specific gravity for 20°C (1.280 in this model)
St: Specific gravity measured at t°C
t: Electrolyte temperature (measured value)

-8-
 2. MOTORS

2. MOTORS
Truck model
FRSB14-8 FRSB16-8 FRSB20-8 FRSB25-8
Item
Drive motor
Type 3-phase induction motor
Name VO-NR
Rating
Output 4.3 kW/60 min. 6.1 kW/60 min.
Speed 2600 rpm ←
Voltage 27.5 V 28.3 V
Current 125 A 160 A
Pump motor
Type DC series motor
Name VO-MRO
Rating
Output 11.0 kW/5 min.
Speed 1450 rpm
Voltage 35.9 V
Current 380 A
Electric Power Steering (EPS) motor
Type Magnet motor
Rating
Output 0.55 kW/60 min.
Speed 2900 rpm
Voltage 48 V
Current 14 A

2.1 GENERAL DESCRIPTION

The drive motor used for this series is a 3-phase induction motor consisting primarily of the parts
shown in Figures 2.1 and 2.2, and the drive motor speed is controlled by an inverter type controller.
The pump motor is a d.c. series-wound motor consisting primarily of the parts shown in Figures 2.3
and 2.4, and the pump motor speed is controlled by a d.c. chopper controller. The electric power
steering (EPS) motor is a magnet motor consisting primarily of the parts shown in Figure 2.3. The EPS
motor is fitted to the drive unit and the EPS motor speed is controlled by a controller.

-9-
2. MOTORS

2.1.1 DRIVE MOTOR

ROTATIONAL SPEED
SENSOR CONNECTOR THERMO-SENSOR
CONNECTOR

A B

View looking from A View looking from B

Fig. 2.1 Drive Motor (FRSB14-8, FRSB16-8)

- 10 -
 2. MOTORS

THERMO-SENSOR
CONNECTOR
ROTATIONAL SPEED
SENSOR CONNECTOR

A B

W U

View looking from A View looking from B

Fig. 2.2 Drive Motor (FRSB20-8, FRSB25-8)

- 11 -
2. MOTORS

2.1.2 PUMP MOTOR

1. ARMATURE ASSEMBLY 5. BRACKET (FRONT)

2. BALL BEARING 6. BRACKET (REAR)
3. BALL BEARING 7. BRUSH
4. YOKE ASSEMBLY 8. BRUSH COVER

Fig. 2.3 Pump Motor

- 12 -
 2. MOTORS

Apply Molykote on splines.

Tightening torque:
10 - 12 N-m {1 - 1.2 kgf-m}
Apply ThreeBond#1324.

to CONTROL VALVE

from TANK

View looking from A View looking from B

Fig. 2.4 Mounting of Pump Motor

- 13 -
2. MOTORS

2.1.3 ELECTRIC POWER STEERING (EPS) MOTOR

The EPS motor is a magnet type and fitted to the actuator section of the drive motor. The EPS motor
speed is controlled by an EPS controller.

ロ
ー
A惨 .
..口
B
h
い山川

White: (+) Black: (–)

口
View looking from A 口
View looking from B

Fig. 2.5 EPS Motor (FRSB14-8, FRSB16-8)

- 14 -
 2. MOTORS

FAN

A B

FAN LEAD WIRE

Red: (+) Black: (–)

View looking from A View looking from B

Fig. 2.6 EPS Motor (FRSB20-8, FRSB25-8)

- 15 -
2. MOTORS

2.2 MAINTENANCE
2.2.1 DRIVE MOTOR
(1) Checking with drive motor in operation

Item to be checked Service required Remedy

Motor frame Visually check that no excessive accumulation Shut off motor and clean.
of dust or dirt is found.Visually check that
no excessive rise of operating temperature is
found.
Motor frame Visually check that motor frame is not If contaminated, clean.
excessively contaminated with foreign matter
or liquid.
Motor frame, bearing Check that operating temperature below Repair if operating
specified value. temperature is higher than
Motor frame: 80°C specified.
Bearing: 55°C
Motor frame, bearing, Visually check there is no excessive vibration. Repair if vibration is beyond
cover and others allowable limit.
Motor frame, bearing, Check for an excessively high level of operating If operating noise level is
cover and others noise. It is good practice to use a stethoscopic extremely high, locate the
apparatus or other suitable devices. cause of the problem and
troubleshoot.

(2) Checking with drive motor shut off

Item to be checked Service required Remedy

Bolts and screws Visually or acoustically check bolts and screws Retighten, clean or paint.
for looseness, contamination or corrosion.
Connections Visually check for wrong or loose connection. Retighten or repair.
Visually check for proper insulation.
Lead wire Visually check for a damaged jacket. Ask a specialist to repair.

- 16 -
 2. MOTORS

(3) Periodic inspection

■ Inspection intervals
Perform periodic inspection at the intervals given below. If the truck is operated under a severer
working environment, an earlier inspection interval will be recommended.

Operating time More 12 hours per day 0 - 12 hours per day

Interval Once a year Once every two years

Item to be checked Service required Remedy

Roller bearing Check roller bearings for grease leakage, noise Replace if necessary.
(enclosed type) or accumulation of dust.
Joint surface Visually check damaged or corroded joint Clean or repair if required.
surface.
Bolts and screws Visually or acoustically check for loose, Retighten, apply anti-rust or
corroded or stuck bolt or screw. replace.
Terminal joint Visually check damage or roughness due to Retighten.
surfaces corrosion.
Connections Visually check for wrong or loose connection. Retighten or repair.
Visually check for proper insulation.
Lead wire Visually check for a damaged jacket. Ask a specialist to repair.
Stator and rotor Visually check iron core for accumulation of Clean as necessary.
assembly dust or dirt.
Check coil and connections for insulation using Clean. Dry by heating.
a 500 V megger. Apply insulating varnish.
Insulation resistance: 1 MΩ or higher
Truck speed sensor Check output waveform, referring to Fig. 2.7 Ask a specialist.
“Checking sensor for operation.”
Thermo-sensor Measure resistance. Ask a specialist.
Standard resistance: 13.04 kΩ ± 10% (20°C)
Painting Visually check painting for damage, Apply anti-rust.
discoloration, peeling or corrosion. Repaint.
Contamination Visually check for contamination, accumulation Clean or apply anti-rust.
of dirt, or corrosion. Repaint.

- 17 -
2. MOTORS

■ Inspection
Observe the following conditions when inspecting the drive motor:
① Select a dry, clean place.
② During disassembly, all the parts including the shaft should be marked properly so that they can be
reinstalled correctly. The screws and washers should be placed in order in an empty box.
③ Use a wooden mallet and lightly tap with even force to remove or reinstall brackets.
Do not use a metallic hammer; otherwise the drive motor might be damaged.
④ Handle the parts carefully not to give damage to them. In particular, use special caution not to
damage or contaminate the stator coil or bearings with water, dust or sand.
⑤ All the disassembled parts should be cleaned and inspected for damage. Any missing or damaged
part must be added or replaced with a new one.
⑥ To clean the coil, use a clean cloth or soft brush. The use of gasoline or other type of solvent might
impair the insulation.
⑦ If the coils shows a low insulation resistance, dry the coil by heating to 80 to 90°C until an
insulation resistance of 1 MΩ or more is attained. Use caution not to overheat locally.
⑧ Check all the bolts for looseness, retightening any loose bolts.
⑨ For inspection of the bearings, refer to paragraph (4) “Maintenance of bearings”.
⑩ If the paint is discolored or peeling, apply anti-rust or paint again.
⑪ Make sure all the terminals are securely tight, and insulate connections completely with insulation
tape.
⑫ After reassembly, check for any parts that have not been reinstalled. Make sure all the screws have
been tightened securely. Try to turn the shaft by hand to check that it turns smoothly, and then test
for the motor to ensure that it operates normally.
⑬ The drive motor should be stored in a dry, clean place where any harmful gas is not anticipated.
Apply a preservative to each end of the shaft and cover with oiled paper or vinyl cloth.
⑭ Checking the sensor removed from the truck for operation:
Using the following electric circuit, give an input voltage of +5 - 24 volts d.c. to the sensor to
rotate the inner ring of the bearing. Check the output waveform to see if it meets the specified
value.

Electric Output and accuracy

circuit +Vcc (red)
“B” phase output Output pulse count:
External connection (pull-up resistance) 64 pulses
“A” phase output (white)
“B” phase output (blue)
Sensor
Output pulse count:
“A” phase output 64 pulses
GND (black)

Connection of pull-up resistance:

Connect a pull-up resistance between the power supply (+Vcc) and
each sensor output.
The pull-up resistance should be set to ensure that the sink current 1. Pitch variation (%) = I (Tn – Tn + I) I/Tn x 100
of the transistors on the sensor output stage is 20 mA or less. 2. Duty (%) = Tp/Tn x 100
3. Advance angle (degree) = Tab/Tn x 360

Fig. 2.7

- 18 -
 2. MOTORS

(4) Servicing bearings

The life of bearings varies to a large extent with the magnitude of load and operating condition. If
the bearing causes undue heat or excessive noise, replace it with a new one.
The enclosed bearing is filled with high quality of lithium soap-based grease to provide effective
lubrication and prevent the entrance of dust into the bearing. It can be used for a long period of time
without adding grease.

The enclosed bearing should be replaced at the following intervals:

Operating time 0 - 12 hours per day More 12 hours per day

Replacement Once every 6 years Once every 3 years

If the truck is operated under a dusty area or any working environment where the grease inside
the bearing might deteriorate quickly due to harmful gases or solvents, an earlier replacement of the
bearing will be recommended.

■ Installing bearing
As shown in Figure 2.8, apply a pipe directly to the inner ring of the bearing or use an aluminum or
copper insert between the pipe and the inner ring.
If the bearing is heated using a heater, do not heat to over 60 to 80°C.

ALUMINUM OR
COPPER INSERT

Fig. 2.8

■ Removing bearing
Use a bearing puller to remove the bearing.

NUT

PULLER BOLT

BEARING COVER

BEARING

Fig. 2.9

- 19 -
2. MOTORS

(5) Troubleshooting guide

If the motor shows problems (no or slow rotation, heat buildup, excessive noise or vibration or
odor), troubleshoot it using the following troubleshooting guide:

Service required and

Problem probable cause
Remedy
Check battery,
inverter or wiring.
(Refer to section
No operating “battery and
sound inverter”.) Ask a specialist
to repair.
Broken wire
Motor won’t rotate without load

Broke stator coil

Poor connection due to

loose terminal Retighten.

Motor can be
turned in either Single-phase operation due Measure voltage with
direction by hand to failed wiring or inverter a voltmeter and repair.

A broken phase of the wires Replace wire.

between motor and inverter
Ask a specialist
A broken phase to repair.
of stator coil
Broken Replace
bearing bearing.
Motor hums,
but won’t rotate.
Rotating shaft is freewheeling Retighten bolts.
due to loose bolt

Rotating direction Wrong Change places of

is wrong. connection two lead wires.
Motor rotates without load.

Motor hums. Uneven between stator

iron core gap and rotor
iron core gap
Motor frame Ask a specialist
overheats. Stator coil short- to repair.
circuited

Bearing causes Defective Replace bearing

unusual noise. bearing with a new one.

- 20 -
 2. MOTORS

Check the voltage at inverter

The drive motor output terminal and lead wire
operates on a connections (as necessary)
shingle phase. using a voltmeter and repair.
Speed drops
suddenly Voltage Check the battery’s
drop condition of charge and
recharge battery if needed.
Overloading
Reduce load.
Motor overheats
Vent holes are
blocked with dust Remove dust.

Motor cannot be Burned Replace

turned easily by bearing bearing
hand.
Operation under load

Imbalanced resistance
Motor automatically Motor gives out between phases and low
stops. a foul smell. insulation resistance
(Measure the resistance Ask a specialist
with lead wires removed) to repair.

Lead wires broken

or short-circuited
Refer to section “Inverter”.
Inverter defective

Motor operates on a single phase

due to improper output terminal Connect motor lead
voltage of inverter or loose wires correctly.
Unusual noise or
connection of motor lead wires.
vibration during
operation
Bracket bolt, cooling
air guide, or sensor Retighten.
nut loose

Overheated Unusual noises from Replace

bearing bearing (check with bearing.
stethoscopic apparatus)

- 21 -
2. MOTORS

(6) Removing and reinstalling the drive motor

CAUTION
• Jack up the truck and use additional supports such as a rigid rack or sound timbers which
withstand the weight of the truck.
• Block the wheels securely.
• Tag all the lead wires before disconnecting.
• After removing pipes, cover the opening to prevent dirt or dust from entering the system.
• Disconnect the battery receptacles.

① Remove the bolts securing the hood and open the hood.
② Remove the motor cables (U, V and W) from the terminal on the bracket.
③ Disconnect the rotational speed sensor and thermo-sensor cable connectors.
④ Disconnect the electromagnetic brake cable connectors.
⑤ Remove the bolts securing the motor.
⑥ Attach a suitable lifting jig to the armature shaft of the motor and hoist the motor assembly to
remove from the truck.

TERMINAL

CONNECTOR

Fig. 2.10

- 22 -
 2. MOTORS

2.2.2 PUMP MOTOR

(1) Checking with pump motor in operation

Item to be checked Service required Remedy

Visually check that no excessive

Motor yoke Shut off motor and clean.
accumulation of dust or dirt is found.

Visually check that motor frame is not

Motor frame excessively contaminated with foreign If contaminated, clean.
matter or liquid.

Visually check that no unusual sparks

Interfacial surfaces of brush If unusual sparks are found, ask a
are produced on the interfacial surfaces
and commutator specialist to repair.
between brush and commutator.

Motor yoke, bearings, cover Visually check there is no excessive If vibration is beyond allowable
and others vibration. limit, shut off motor and repair.

Motor yoke, bearings, cover Acoustically check there are no unusual If noises are beyond allowable
and others noises using a stethoscopic appratus. limit, shut off motor and repair.

(2) Checking with pump motor shut off

Item to be checked Service required Remedy

Visually or acoustically check bolts and

Bolts and screws screws for looseness, contamination or Retighten, clean or paint.
corrosion.

Visually check for wrong or loose Retighten (10 - 12 N-m {1 - 1.2

Stud terminals connection. Visually check for proper kgf-m}) or measure insulation
insulation. resistance and repair if needed .

- 23 -
2. MOTORS

(3) Periodic inspection

■ Inspection intervals
Perform periodic inspection at the intervals given below. If the truck is operated under a severer
working environment, an earlier inspection interval will be recommended.

Operating time More 12 hours per day 0 - 12 hours per day

Interval Once a year Once every two years

It is advisable to inspect the brushes once a month or every two months.

Item to be checked Service required Remedy

Roller bearings Check roller bearings for grease leakage, noise or

Replace if necessary.
(enclosed type) accumulation of dust.

Joint surface Visually check damaged or corroded joint surface. Clean or repair if required.

Visually or acoustically check for loose, corroded or

Bolts and screws Retighten, apply anti-rust or replace.
stuck bolt or screw.

Visually check damaged or corroded joint surface. Clean or repair if required.

Retighten (10 - 12 N-m {1 - 1.2 kgf-m})

Visually check for wrong or loose connection. Visually
Stud terminals or measure insulation resistance and repair
check for proper insulation.
if needed.
Visually check that there are no brush powder or dust
Clean any brush powder or dust
at connections.
(compressed air or soft cloth) .

Visually check iron core for accumulation of brush Clean as necessary (compressed air or soft
powder or dust. cloth).
Stator and rotor
Check coil for accumulation of brush powder or dust.
assembly Clean as necessary (compressed air or soft
Check also connections for insulation using a 500 V
cloth)
megger.
Dry by heating.
Insulation resistance: 1 MΩ or higher

Check brush for useful limit.

Size of new brush: 12.5 mm x 40 mm x 27 mm If worn out beyond useful limit, replace
Material: 788 brush with a new one of same grade, size
Brush Useful limit: 13 mm (out of 27 mm) and material.
Check brush for breakage.

Check brush for seizure due to dust or corrosion. Clean (compressed air or soft cloth)

Repair any damage or wear or ask a

specialist to repair.
Allowable limit: about 1.5 mm at one side
Visually check commutator surface for smoothness, (from brush sliding surface)
Commutator
discoloration, damage or undue wear. If the surface is ground, the undercut
should be 0.5 mm or more. (The undercut
means the depth of mica from commutator
piece inserted between commutator pieces.)

Visually check painting for damage, discoloration, Apply anti-rust.

Painting
peeling or corrosion. Repaint.

Visually check for contamination, accumulation of Clean or apply anti-rust.

Contamination
dirt, or corrosion. Repaint.

- 24 -
 2. MOTORS

■ Inspection and servicing

Observe the following conditions when inspecting and servicing the pump motor:
① Select a dry, clean place.
② During disassembly, all the parts including the shaft should be marked properly so that they can be
reinstalled correctly. The screws and washers should be placed in order in an empty box.
③ Use a wooden mallet and lightly tap with even force to remove or reinstall brackets.
Do not use a metallic hammer; otherwise the pump motor might be damaged.
When removing the armature assembly from the yoke assembly, first remove the brush cover and
then keep the brush away from the commutator sliding surface.
④ Handle the parts carefully not to give damage to them. In particular, use special caution not to
damage or contaminate the the stator, armature coil, commutator, brush and bearings with water,
dust or sand.
⑤ All the disassembled parts should be cleaned with compressed air and inspected for damage. Any
missing or damaged part must be added or replaced with a new one.
Accumulation of brush powder or dust inside the motor will cause lowered insulation resistance or
poor insulation.
⑥ To clean the coil, commutator, or brush, use compressed air, a clean cloth or soft brush. The use of
gasoline or other type of solvent might impair the insulation.
⑦ If the coil shows a low insulation resistance, dry the coil by heating to 80 to 90°C until an
insulation resistance of 1 MΩ or more is attained. Use caution not to overheat unevenly.
⑧ Check all the bolts for looseness, retightening any loose bolts.
⑨ For inspection of the bearings, refer to paragraph (4) “Maintenance of bearings”.
⑩ If the paint is discolored or peeling, apply anti-rust or paint again.
⑪ Make sure stud terminals are securely tightened to the specified torque, and that the connections
are completely insulated.
⑫ After reassembly, check for any parts that have not been reinstalled. Make sure all the screws have
been tightened securely. Try to turn the shaft by hand to check that it turns smoothly, and then test
for the motor to ensure that it operates normally.
⑬ The pump motor should be stored in a dry, clean place where any harmful gas is not anticipated.
Apply a preservative to each end of the shaft and cover with oiled paper or vinyl cloth.

- 25 -
2. MOTORS

(4) Maintenance of bearings

The life of bearings varies to a large extent with the magnitude of load and operating condition. If
any of the bearings causes undue heat or excessive noise, replace it with a new one.
The enclosed bearing is filled with high quality of lithium soap-based grease to provide effective
lubrication and prevent the entrance of dust into the bearing. It can be used for a long period of time
without adding grease.

The enclosed bearing should be replaced at the following intervals:

Operating time 0 - 12 hours per day More 12 hours per day

Replacement Once every 6 years Once every 3 years

If the truck is operated under a dusty area or any working environment where the grease inside
the bearing might deteriorate quickly due to harmful gases or solvents, an earlier replacement of the
bearings will be recommended.

■ Installing the bearings

Prepare a soft-steel or brass cylindrical tool as shown in Figure 2.11. The tool should be designed to
come in contact with the bearing by only the side of the inner ring.
Heat the bearing to 60 to 80°C using a bearing heater and install the bearing onto the shaft as far as
it comes up against the abutting joint of the shaft.
If the bearing stops short and refuses to proceed, use the cylindrical tool and press fit or tap to install
with a wooden mallet, by applying force to the inner ring alone with care not to apply pressure to the
outer ring of the bearing. Application of force to the outer ring will cause a dent or scores to the balls
or raceway. Install the anti-load side bearing on the opposite side of the motor in the same manner.

FORCE

Fig. 2.11

- 26 -
 2. MOTORS

■ Removing bearings
Using a bearing puller, remove a bearing from the armature in the following manner:
Engage the jaws of the bearing puller on the outer periphery of the load-side bearing and tighten the
bolts which lock the spacing of the bearing puller jaws.
The motor shaft has a center hole in each end of the shaft. Protect this center hole with copper or
soft steel insert and then turn the bearing puller handle to push the motor shaft to remove the bearing.
(The center holes are used for maintenance.)
Remove the anti-load side bearing in the same manner.

Caution about bearing puller

Use a small-size bearing puller
as shown in Figure 2.12. A
large-size bearing puller might
give damage to the impeller or
commutator.

Fig. 2.12

(5) Replacing brushes

Remove the inspection cover of the motor Unit: mm
and check the remaining length of the brush. MOUNTING
BRUSH BRUSH LEAD WIRE
BOLT
The useful limit of the brush is 13 mm. Replace SPRING
Useful limit
of the brush
the brush in the following manner if the brush is
BRUSH HOLDER
worn to near the useful limit.
(1) Before trying to replace the brush, record
the connection of the brush lead wires to
13

insure correct reconnection. 34

13

(2) Remove the mounting bolts and brush lead

COMMUTATOR
wires.
(3) Lift the spring and remove the brush. If
the brush is removed, lifting the brush lead Fig. 2.13
wires without lifting the spring, the lead wires might be damaged.
(4) Lift the spring and install a new brush of the same part number, material and size as that replaced.
(5) Install the lead wires correctly as recorded in step (1) and secure with the mounting bolts. Make
sure the brush lead wires are kept away more than 7 mm from the yoke or inspection cover.
(6) Record the date on which the brush has been replaced with a new one, and use it for planning
subsequent brush changes.

- 27 -
2. MOTORS

(6) Troubleshooting guide

If the pump motor shows problems (no or slow rotation, heat buildup, excessive noise or vibration
or odor), troubleshoot it using the following troubleshooting guide:

Item Problem Possible cause Remedy

1 Motor won’t start (1) Low power supply voltage Check power supply.
Change power cable.
(2) Poor contact of brush Repair.
(3) Broken wire or poor connection Check terminal and repair.
(4) Broken wire or short-circuiting of Replace controller with a new one.
controller
(5) Field winding short-circuited or Ask a specialist.
broken
(6) Armature winding short-circuited or Ask a specialist.
broken
(7) Overloaded Reduce load.

2 Motor stats but (1) Starting resistor is not closed. Check switch.
speed won’t (2) Poor connection of armature circuit Reconnect.
increase. (3) Low power supply voltage Check power supply and change
power cable.

3 Winding (1) Overloading Reduce load.

overheating (2) Insufficient cooling or accumulation Clean.
of dust
(3) Winding short-circuited Ask a specialist to repair.
(4) Large current flow due to voltage drop Reduce terminal voltage to rated level.

4 Bearing overheating (1) Grease deteriorated Replace bearing with a new one.
(2) Bearing defective

5 Unusual noises (1) Loose parts Retighten.

(2) Foreign matter inside motor Remove foreign matter.
(3) Foreign matter inside bearing Replace bearing with a new one.
(4) Bearing defective Replace bearing with a new one.
(5) Improper installation Install properly. Retighten mounting
bolts securely.

6 Vibration (1) Improper installation Install properly.

Retighten mounting bolts securely.
(2) Bearing defective Replace bearing with a new one.
(3) Loose parts Retighten.
(4) Imbalance of armature Ask a specialist to repair.
(5) Poor centering Ask a specialist to repair.
(6) Effect of load applied Reduce vibration of load.

7 Defective (1) Overloading Reduce load.

commutation (2) Vibration Install properly.
Excessively worn (3) Armature winding short-circuited or Ask a specialist to repair.
brush Discolored broken
commutator Rough (4) Improper brush contact Repair.
commutator surface (5) Brush material improper Replace brush with a new one.
(6) Improper mica height Lower mica height.
(7) Corrosive gas atmosphere Avoid corrosive gas atmosphere.

8 Score marks on (1) Improper brush material Replace brush with a new one.
commutator surface (2) Dusty environment Prevent entrance of dust. (Cool with
clean air)
(3) Oily vapor Prevent entrance of oily vapor into
commutator. (Cool with clean air.)

- 28 -
 2. MOTORS

(7) Removing and reinstalling pump motor

1. Remove the following parts before trying to remove the pump motor from the truck:

CAUTION
Before trying to remove high-pressure pipes or hoses, operate the hydraulic levers several
times to release the hydraulic pressure from the circuit.
① Remove the high-pressure hoses and low-pressure hoses.
② Remove the hydraulic motor lead wires.

2. Remove the pump motor:

① Remove the mounting bolts (*1) securing the bracket.
② Hoist the pump motor together with the main pump and motor bracket.

* Removing pump motor (1)

BRACKET Tightening torque of mounting bolt (*1)
36 - 43 N-m {3.6 - 4.3 kgf-m}

CUSHION

PUMP MOTOR

CUSHION

MOUNTING BOLT (*1)

Tightening torque of mounting nut (*2)

10 - 12 N-m {1.0 - 1.2 kgf-m}
Apply ThreeBond #1342N or equivalent.

Fig. 2.14

- 29 -
2. MOTORS

3. Remove the cushion bolts and remove the cushion bracket from the pump motor.
4. Remove the bolts (*3) securing the main pump and remove the main pump from the pump motor.

CAUTION
Do not disassemble the main pump.
If the main pump fails to operate normally, replace the main pump assembly with a new one.

* Removing pump motor (2)

BRACKET

PUMP MOTOR

Apply molybdenum grease.

Tightening torque of
mounting bolts (*3)
20 - 24 N-m {2.0 - 2.4 kgf-m}

MAIN PUMP

Fig. 2.15

* The pump motor should be reassembled in the reverse order from disassembly.

- 30 -
 2. MOTORS

(8) EPS motor

1. Remove the connector from the EPS motor.
2. Remove the bolts (*1) securing the EPS motor, and then remove the EPS motor.

* Removing EPS motor

ESP MOTOR Tightening torque of

mounting bolts (*1)
17 - 28 N-m
{1.7 - 2.8 kgf-m}

SPLINES
Apply
molybdenum
grease.

EPS MOTOR COVER

Apply ThreeBond#1216E or
equivalent on the mating surfaces.

Fig. 2.16

* The EPS motor should be reassembled in the reverse order from disassembly.

- 31 -
2. MOTORS

NOTE

- 32 -
 3. CONTROLLER

3. CONTROLLER

Rated voltage 48V

Control method
Drive system Traveling: Vector controlled PWM inverter method
Plugging and regenerative braking: Torque control
Load handling system Chopper control
Power steering system Chopper control (H bridge)
Current limit
Load handling system 550A
Power steering system 35A
Protection • Main device error protection
• Main controller error protection
• Sensor input error protection
• Temperature protection
• Traveling and load handling system neutral safety
• Main FET short-circuit protection
• Low-voltage protection
• Continuous-current protection
Acceleration Resistance type

3.1 GENERAL DESCRIPTION

3.1.1 CONTROLLER
The controller consists primarily of the parts shown in Figure 3.1. It is fitted to the upper part of the
frame.

- 33 -
 Signal line PC
3. CONTROLLER

Pressure sensor
Power line

Communication line

Switch panel LCD panel

F/R potentiometer

Accelerator potentiometer

Controller
· Interlock switch Lift potentiometer
· Foot switch
· Battery position
detection switch
Main CPU Valve lever
· Mast SSC switch
· Brake switch

- 34 -
Fig. 3.1
Brake potentiometer

Steering angle
potentiometer

Module Sub CPU

Relay output:
Auxiliaries for forward travel
(option)
Auxiliaries for reverse travel
Speed alarm (option)

Solenoid output:
Front brake (option)
Lift lock
Electromagnetic brake

Steering wheel
Thermo-sensor Drive Pump sensor bearing
Rotation sensor motor motor EPS motor Battery
 3. CONTROLLER

① Main CPU board

② Sub CPU board
③ Contactor
④ Current sensor
⑤ Resistor
⑥ Fan
⑦ Fuse F1, 225 A (Drive motor)
⑧ Fuse F2, 225A (Pump motor)
⑨ Fuse F3, 40A (Power steering
motor)
⑩ Pump motor and EPS drive
module
⑪ Insulation sheet
⑫ Drive motor driving module
⑬ Insulation sheet

3
10,11

8
5
7
4

12,13

4 6 4

Fig. 3.2 Main Controller

- 35 -
3. CONTROLLER

3.1.2 ACCELERATOR PEDAL

The accelerator pedal assembly consists of the parts shown in Figure 3.3 and controls the travel
speed of the truck.
The operating angle of the pedal is converted by a potentiometer into voltage and it is outputted to
the controller.

95 41

93 41

93

95
23 mm

View looking from C

C
B

View looking from A

POTENTIOMETER

View looking from B

Fig. 3.3 Accelerator Pedal Assembly

- 36 -
 3. CONTROLLER

3.1.3 LCD PANEL

The LCD panel and switches are installed as shown in Figure 3.4.
The LCD panel has the following functions:
• Operating status of the truck
• Clock function
• Showing Error codes
• Controlling battery charging
• Setting parameters
Parameters can be entered and changed through the keypad.

TURN SIGNAL SWITCH

(OPTION)

LIGHTING SWITCH

HORN SWITCH

F/R SWITCH

KEY SWITCH

LCD PANEL

KEYPAD

Fig. 3.4 LCD Panel

- 37 -
3. CONTROLLER

■ LCD PANEL

1. PARKING BRAKE 4. TRAVEL SPEED 8. TIRE ANGLE INDICATOR 12. LOW-SPEED TRAVEL
INDICATING LIGHT METER 9. LOAD METER MARK (TURTLE)
2. INTERLOCK WARNING 5. HOUR METER 10. FORK POSITIONING LASER 13. S.P.E. MODE INDICATOR
LIGHT 6. DATE AND TIME 11. BATTERY DISCHARGE 14. SERVICE WRENCH ICON
3. NEUTRAL STATUS 7. KEYPAD INDICATOR
INDICATING LIGHT

Fig. 3.5

■ KEY PAD
① S.P.E. BUTTON
Every time the S.P.E. button is pressed, the operating
power mode changes, with the letter S, P or E appearing (S
→ P → E → S). Use this button to set the operating power
mode of the truck.
② SCREEN SELECTION “MODE” BUTTON
Screen selection Every time this button is pressed, the LCD
panel screen changes:
Main screen → Power consumption screen →
Hour meter → Main screen
Date and time If this button is pressed for more than 3
screen seconds, the Date and Time screen appears.

③ LOW-SPEED TRAVEL (TURTLE) BUTTON Fig. 3.6 Keypad

When you press the turtle mark button on the key pad, the
truck gets in the low-speed travel mode. To release the
low-speed travel mode, press the button again.
• Normal-speed travel mode
When the turtle mark button on the key pad is turned
off, the low-speed (turtle) mark on the LCD panel
disappears.
• Low-speed travel mode
When the turtle mark button on the key pad is turned
on, the low-speed (turtle) mark appears on the LCD
panel.
④ +/- BUTTONS
Change the date and time using the +/- buttons on the key
pad.

- 38 -
 4. DRIVE UNIT

4. DRIVE UNIT

Truck model
FRSB14-8 FRSB16-8 FRSB20-8 FRSB25-8
Item
Type Three-stage reduction ←
Model 7E4-25 7E5-25
Reduction ratio 22.566 23.952
Wheel dimensions 330 mm dia. x 145 mm 380 mm dia. x 165 mm

4.1 　GENERAL DESCRIPTION

Figure 4.1 shows the construction of the drive unit. The drive support unit is attached to the frame
through a link.
Each gear is incorporated into the gear case, efficiently transmitting the rotation of the motor.
The gear case is attached to the drive support unit by 2 taper roller bearings, and rotates to right and
left by means of the EPS motor.

- 39 -
4. DRIVE UNIT

EPS MOTOR

23. TAPER ROLLER 37. OIL SEAL

BEARING 38. OIL SEAL
24. NUT 39. GEAR
25. SHIM 40. BEARING
26. TAPER ROLLER 41. BEARING
1. MIDDLE CASE 12. BALL BEARING BEARING 42. OIL SEAL
2. GEAR 13. BEARING 27. COVER 43. TAPER ROLLER
3. BREATHER 14. GEAR 28. PLUG BEARING
4. PIN 15. TAPER ROLLER BEARING 29. OIL SEAL 44. TAPER ROLLER
5. "O"-RING 16. SPACER 30. UPPER CASE BEARING
6. LOWER CASE 17. NUT 31. COVER 45. SET SCREW
7. PLUG 18. RETAINER 32. GEAR 46. NUT
8. INPUT GEAR 19. SHIM 33. STEERING GEAR 47. WASHER
9. BALL BEARING 20. DRIVE PINION 34. BEARING 48. BUSHING
10. BALL BEARING 21. BEVEL GEAR 35. BEARING 49. SPACER
11. GEAR 22. DRIVE SHAFT 36. SNAP RING 50. PLUG

Fig. 4.1 Drive Unit

- 40 -
 4. DRIVE UNIT

4.2 MAINTENANCE
4.2.1 REPLACING DRIVE WHEEL
(1) Removing the drive wheel
① Jack the front part of the frame off the ground. (See Fig. 4.2)
② Turn the steering wheel to point the left side of the drive wheel to the front of the truck.
③ Remove all drive wheel mounting bolts. Remove the wheel.

BLOCKS This side points forward

BLOCKS
(both wheels) (both wheels)

Fig. 4.2

(2) Removing the hub

PRESS
Using a suitable press, remove the hub from the wheel.

WHEEL

HUB

Fig. 4.3

- 41 -
4. DRIVE UNIT

(3) Reassembling the drive wheel

PRESS
Using a suitable press, press the hub onto the wheel.

WHEEL

HUB

Fig. 4.4

(4) Reinstalling the drive wheel

① Aligning the bolt holes in the hub with the screw holes in the shaft, install the drive wheel.
② Install mounting bolts.
③ Tighten the bolts to specified torque.
Tightening torque: 104 N-m {10.6 kgf-m}
④ Turn the steering wheel to put the drive wheel in the straightforward position.
⑤ Lower the frame to the ground.

Tightening torque : 104 N-m {10.6 kgf-m}

Fig. 4.5

- 42 -
 4. DRIVE UNIT

4.2.2 ADJUSTMENT AFTER REASSEMBLY

(1) Adjusting the drive pinion LOCK NUT
(Stake lock nut after
① Reassemble the drive pinion as shown in Fig. 4.6. preload adjustment)
② Measure the preload and if necessary adjust with
the lock nut.
TAPER ROLLER
Preload: 1.2 to 1.5 N-m {0.12 to 0.15 kgf-m} BEARING

③ After preload adjustment, stake the lock nut.

RETAINER

TAPER ROLLER
BEARING

DRIVE PINION

Fig. 4.6

(2) Adjusting engagement and backlash between the drive pinion and bevel gear
① Install the drive shaft and bevel gear in the lower
case with a shim B (0.5 mm).
DRIVE PINION
The starting torque is adjusted by tightening the ASSEMBLY

nut.
Starting torque: DRIVE SHAFT

3.5 to 4.5 N-m {0.36 to 0.46 kgf-m} for

SHIM A
FRSB14-8, FRSB16-8
5.0 to 6.0 N-m {0.51 to 0.61 kgf-m} for
LOWER
FRSB20-8, FRSB25-8 CASE
② Install the drive pinion assembly in the lower
case with a shim A (0.5 mm).
Tightening torque: 41 to 45 N-m {4.2 to 4.6 kgf-m}
OIL SEAL

TAPER ROLLER
BEARING

BACKLASH ADJUSTING SHIM B

(0.1, 0.2 and 0.5 mm)

BEVEL GEAR

LOCK NUT
(Stake lock nut after
preload adjustment)

Fig. 4.7

- 43 -
4. DRIVE UNIT

③ Check the engagement between the bevel gear

and drive pinion gear.
Backlash: 0.2 to 0.3 mm
After the preload is adjusted, the backlash should
be proper and the engagement as shown in Fig.
4.8. If the backlash is not proper, adjust it with a
shim B .

Fig. 4.8 Correctly Engaged

Reduce the number of shims B to increase the backlash and increase the number of shims B to
reduce the backlash.
④ Stake lock nut after adjustment.

(3) Gear oil filling

Add gear oil into the drive unit in the following
manner:
① Add gear oil through the oil fill plug to fill area
OIL FILL PLUG
B.
② About 10 minutes later, check the oil level
through the level port. If the level is low, add
gear oil through the oil fill plug. LEVEL PORT

Unit: Liter

FRSB14-8, FRSB20-8,
FRSB16-8 FRSB25-8
Drive Unit 2.1 3.2
Actuator 0.35 ←

Fig. 4.9

- 44 -
 4. DRIVE UNIT

4.2.3 TROUBLESHOOTING GUIDE

No Problem Cause Remedy

① Poor engagement or wear of the gear teeth
between spiral bevel gear and spiral bevel Adjust or replace.
pinion
② Poor tooth contact or wear of the gear teeth
Replace.
between the counter gear and drive pinion
③ Poor contact or wear of the gear teeth
Loud repetitive Replace.
1 between the counter gear and driven gear
noises while driving
④ Incorrect adjustment or wear of the spiral
Adjust or replace.
bevel gear bearing
⑤ Incorrect adjustment or wear of the spiral
Adjust or replace.
bevel pinion bearing
⑥ Insufficient or contaminated oil in the gear
Clean or add.
case
① Damage to the bearings from excessive
Replace.
Gear case preload
2
overheating ② Insufficient backlash of the spiral bevel gear
Adjust.
and spiral bevel pinion
① A flat spot on the wheel Replace.
Excessive vibration ② A chipped wheel Replace.
3
while driving
③ Excessive gap between the link and drive
Adjust.
support

Irregular noises ① Wheels are peeling or deteriorating Replace.

4
while driving ② Irregular sounds coming from drive motor Inspect.
① Wear of the oil seal Replace.
② The bolt securing the gear case support is
Replace.
5 Gear oil leaks loose or the "O" ring is damaged
③ The bolt securing the gear case cover is
Replace.
loose or the gasket is damaged

Wheels slip while ① The control linkage is incorrectly adjusted Adjust.

6
accelerating ② The wheel is worn Replace.

- 45 -
4. DRIVE UNIT

NOTE

- 46 -
 5. STEERING SYSTEM

5. STEERING SYSTEM

Type Drive unit-rotating type

Power steering
Type Steer-by-wire type
Control Chopper control (H-bridge)
EPS motor
Type DC magnet type
Output 550 W (60 min.)
Actuator reduction ratio 23.1

5.1 GENERAL DESCRIPTION

The steering system is an electric power steering type consisting of a steering wheel, a bearing
sensor, a steering angle potentiometer, an EPS motor and an actuator.

5.1.1 STEERING WHEEL

The steering wheel is attached to the shaft with two bearing sensors which convert the operating
angle of the steering wheel into an electric signal and send to the controller. The controller controls the
EPS motor according to the electric signal it receives, and the output from the EPS motor is transmitted
to the actuator of the drive unit.

- 47 -
5. STEERING SYSTEM

LOCK LEVER
(for vertical direction)

LOCK LEVER
(for back-and-forth direction)

STEERING SHAFT View looking from A

Axial torque:
0.45 ±0.1 N-m
{4.6 ±1 kgf-cm}
(Adjust with concave nut.) BEARING SENSOR
(TOP)

BEARING SENSOR
(BOTTOM)

Tightening torque:
C 0.92 - 1.38 N-m
{9.4 - 14.1 kgf-cm}
Detail of area B

CONCAVE NUT

CONVEX NUT
Tightening torque:
21 ±3 N-m {214 kgf-cm}

Fig. 5.1

- 48 -
 5. STEERING SYSTEM

5.1.2 BEARING SENSOR

The bearing sensor has a structure as shown in Figure 5.2. Two bearing sensors are used to support
the steering shaft and convert the rotating direction and speed of the steering shaft into voltages and
send them to the controller.

Phase
A output Phase B output
(white) (blue)

SENSOR

Vcc (red) GND (black)

Fig. 5.2 Bearing Sensor

- 49 -
5. STEERING SYSTEM

5.1.3 STEERING ANGLE SENSOR

The steering angle sensor is installed in the position shown in Figure 5.3, and detects the steering
angle of the drive wheel. The information obtained is processed by the controller and displayed on the
LCD instrument panel as the tire angle. It is also used for controlling the travel speed of the truck when
making turns.
The controller adjusts speed controls according to the angle of the drive wheels.
The drive wheel angle display on the LCD panel is also based on the output of the steering angle
sensor. Incorrect neutral adjustment may result in the vehicle not being able to operate at its maximum
speed or irregular behavior when turning. (See TROUBLESHOOTING for how to adjust the neutral
position.)

STEERING ANGLE SENSOR

Fig. 5.3 Steering Angle Sensor

- 50 -
 5. STEERING SYSTEM

5.1.4 ACTUATOR
The actuator consists of gears and is incorporated
in the drive unit upper case. EPS MOTOR
The rotation of the motor is transmitted through
the gears A , B and C to the shaft, being reduced in
speed.
The gear D on the shaft is in mesh with the ring
gear fitted to the lower case.

GEAR A

GEAR B
GEAR C
GEAR D

Fig. 5.4 EPS Actuator

- 51 -
5. STEERING SYSTEM

5.1.5 REAR AXLE

The rear axle is mounted in the position shown in Figure 5.5 to support the drive unit.

UPPER LINK
DRIVE UNIT

Fig. 5.5 Rear Axle (FRSB14-8, FRSB16-8)

- 52 -
 5. STEERING SYSTEM

UPPER LINK
DRIVE UNIT

Fig. 5.6 Rear Axle (FRSB20-8, FRSB25-8)

- 53 -
5. STEERING SYSTEM

5.1.6 TRAIL WHEEL

As shown in Fig. 5.7, the trail wheel is installed on an outrigger. Optionally, a wheel featuring an
electromagnetic brake can be installed.

Standard truck

LOCK WASHER

LOCK NUT

BALL BEARING

TRAIL WHEEL

BALL BEARING

CAP

Truck with optional brakes

ELECTROMAGNETIC
BRAKE

COVER

LOCK WASHER

LOCK NUT
BALL BEARING

TRAIL WHEEL

BALL BEARING

CAP

Fig. 5.7

- 54 -
 6. BRAKE SYSTEM

6. BRAKE SYSTEM
6.1 GENERAL DESCRIPTION
The brake system uses both an electromagnetic brake and a regenerative brake, which are controlled
by the brake pedal.
The electromagnetic brake is installed on the drive motor, as shown in Figure 6.1, to brake the drive
motor armature shaft.

Tightening torque:
FRSB20-8 FRSB25-8 29.7 ± 3 N-m
FRSB14-8 FRSB16-8 {302.9 ± 30.6 kgf-cm}
1

ELECTROMAGNETIC
BRAKE

Tightening torque:
A 26.1 ± 5 N-m
Adjust the gap after replacement in the {266.2 ± 51.0 kgf-cm}
following manner:
Make sure that the gap “L” between the
armature and stator meets the following
Gap “L”

conditions at 3 points on the periphery of

the electromagnetic brake:
FRSB14-8 and FRSB16-8
● A thickness gauge of 0.2 mm can be
inserted.
● A thickness gauge of 0.45 mm cannot
be inserted.
FRSB20-8 and FRSB25-8
● A thickness gauge of 0.30 mm can be
inserted.
● A thickness gauge of 0.55 mm cannot
be inserted.
Detail of area A
If the gap “L” does not meet the above
conditions, adjust the gap “L” in the
following manner:
(1) Too wide a gap
Loosen the adjustment sleeve only
slightly and tighten the hex. bolt.
(2) Too narrow a gap
Loosen the hex. bolt and tighten the
sleeve into the mounting flange.

Fig. 6.1 Electromagnetic Brake

- 55 -
6. BRAKE SYSTEM

6.1.1 BRAKE PEDAL

The brake pedal has the construction shown in Figure 6.2. The amount of pedal effort is converted
into voltages by the potentiometer and sent to the controller.
When the brake pedal is bottomed, the brake switch is turned off to turn off the electromagnetic
brake, thus applying the mechanical brake immediately.

Adjustment procedure:
(1) Shift the brake switch to a position at which the brake switch roller is pushed in 3.0 ±0.5 mm with
the brake pedal depressed completely.
(2) Turn the potentiometer clockwise or counterclockwise so that the voltage between 93 and 186 is
2.05 ±0.05 V when 5 V is applied between 186 and 187 with the brake switch turned off.
(3) Adjust the lower stopper bolt so that the voltage between 93 and 186 is 2.35 ±0.05 V when the
brake pedal is depressed completely.
(4) Adjust the upper stopper bolt so that the voltage between 93 and 186 is 0.6 ±0.05 V when the
brake pedal is released.

3±0.5 mm

Detail of area A

LW187 BG186

LY93

187 93 186

View looking from B

62 mm
(reference value)

BRAKE SWITCH
UPPER
STOPPER BOLT

LOWER STOPPER BOLT

B

Fig. 6.2 Brake Pedal

- 56 -
 6. BRAKE SYSTEM

6.1.2 ELECTROMAGNETIC BRAKE

The electromagnetic brake consists of a stator, a coil, an armature, and a rotor, as shown in Figure 6.3.
When no current flows to the stator coil, the armature is locked up against the rotor by the spring
inside the stator, thus holding the rotor in place.
When current flows to the stator coil, the stator attracts the armature to release the rotor.

COIL
TORQUE
ADJUSTMENT RING
STATOR

FRSB14-8, FRSB16-8:
0.25 - 0.40 mm
FRSB20-8, FRSB25-8:
ARMATURE 0.35 - 0.50 mm

FLANGE
ROTOR

Note: The electromagnetic brake should be replaced with a new one every 10 years.

Fig. 6.3 Electromagnetic Brake

■ Check the gap in electromagnetic brake in the following manner:

(1) Turn the key switch off.
(2) Check the gap between the armature and stator of the electromagnetic brake. If the measured value
exceeds the specified limit, replace the electromagnetic brake with a new one.
unit: mm
Gap (limit)
FRSB14-8, FRSB16-8 0.65 - 0.75
FRSB20-8, FRSB25-8 0.90 - 1.00

(3) After replacement with a new one, check the gap in the manner shown in Figure 6.1 and adjust if
needed.

Note: Once the gap has been adjusted after replacing the electromagnetic brake with a new one,
do not try to adjust the gap in periodic inspections. If the gap is not proper, replace the
electromagnetic brake with a new one.

- 57 -
6. BRAKE SYSTEM

NOTE

- 58 -
 7. HYDRAULIC SYSTEM

7. HYDRAULIC SYSTEM

Truck model
FRSB14-8 FRSB16-8 FRSB20-8 FRSB25-8
Item
Pump
Type Gear connected directly to motor
Control valve
Type 3-spool sliding type
Name MSV04
Pressure setting 18.2 MPa {185 kgf/cm2} 19.1 MPa {195 kgf/cm2}
Lift cylinder
Rear cylinder
Type Single-acting piston type
Cylinder I.D. 65 mm 75 mm
Piston rod O.D. 50 mm 55 mm
Front cylinder
Type Single-acting piston type
Cylinder I.D. 45 mm 50 mm
Piston rod O.D. 35 mm 40 mm
Tilt cylinder
Type Double-acting piston
Cylinder I.D. 80 mm 90 mm
Piston rod O.D. 30 mm
Reach cylinder
Type Double-acting piston
Cylinder I.D. 50 mm
Piston rod O.D. 30 mm
Sideshift cylinder
Type Integral with the fork carriage
Cylinder I.D. 46 mm
Ram O.D. 40 mm

7.1 GENERAL DESCRIPTION

The hydraulic system consists of an oil tank, a pump, a control valve and cylinders.

- 59 -
7. HYDRAULIC SYSTEM

7.1.1 OIL TANK

The oil tank is installed under the floorboard and its construction is as shown in Fig. 7.1.
The breather cap has a filter to prevent dust in the air sucked due to a lowered oil level, from getting
into the tank.
The suction pipe has also a filter to prevent dust from entering the circuit.

OIL TANK CAP

to LIFT CYLINDER from CONTROL
VALVE AIR BREATHER

to PUMP

Capacity Oil level Oil level height

Mast lift height Models covered
(L) mark H mm
25 H 254 Up to VFHM600 FRSB14-8
27 S 274 Above VFHM650 FRSB16-8
31.8 H 323 Up to VFHM600 FRSB20-8
S 33.8 S 343 Above VFHM650 FRSB25-8
H
L

Fig. 7.1

- 60 -
 7. HYDRAULIC SYSTEM

7.1.2 MAIN PUMP

The main pump is a gear type as shown in Fig. 7.2.
The main pump consists of a pump body, a pair of gears, bushings and packings. To minimize the
gap between the gears’ side-faces, pressure-balanced type bearings and lubrication method are used.
The pressure-balanced type directs part of the oil discharged from the main pump into between the
pressure plate and pump body, to press the pressure plate toward the gear side.

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

Fig. 7.2 Main Pump

7.1.3 CONTROL VALVE

The control valve consists of four plunger sections, an outlet section and an inlet section with a
relief valve (as shown in Fig. 7.3), and is assembled with three bolts. The inlet section relief valve
is a cartridge type featuring that its pressure setting does not change even when it is reinstalled after
removed.
Between the inlet section and the lift plunger section and between the lift plunger section and the tilt
plunger section are check valves installed.
These check valves serve to prevent the back flow from a heavily loaded section to a lightly loaded
section when the lift and tilt levers are simultaneously operated.
A potentiometer installed on the plunger section at the lift side converts the movement of the
plunger into the voltage and sends it to the controller.

- 61 -
7. HYDRAULIC SYSTEM

SIDESHIFT SECTION

TILT SECTION

REACH SECTION

LIFT SECTION

GAUGE
PORT (G)
SOLENOID
VALVE
B2 B3 B4

A1 A2 A3 A4

INLET
SECTION

RELIEF VALVE

POTENTIOMETER

to LIFT CYLINDER

G A1 B2 A2 B3 A3 B4 A4

Fig. 7.3 Control Valve

- 62 -
 7. HYDRAULIC SYSTEM

7.1.4 VALVE CONTROL

The spools in the control valve are operated by the levers shown in Fig. 7.4. Each lever is installed
on a shaft and supported by a bracket on the valve assembly. The movement of each lever is detected
by each switch and transmitted to the controller.
The lift lever stroke length is detected by a potentiometer.

SPACER

Detail of area A

TILT LEVER
SIDESHIFT
LEVER REACH LEVER

LIFT LEVER

Tightening torque:
1.1 to 1.6 N-m
{11.2 to 16.3 kgf-m}

Fig. 7.4 Valve Control

- 63 -
7. HYDRAULIC SYSTEM

7.1.5 LIFT CYLINDERS

The truck has three lift cylinders; a rear cylinder, which is installed in the middle between the two
inner mast channels, and two front cylinders, which are located outside the right and left outer mast
channels.

(1) Rear cylinder

The rear cylinder has a construction as shown in Figure 7.5, with its cylinder tail bolted to the
bottom of the inner mast channel. The piston is secured to the rod with a lock ring. The rod has
multiple holes at its bottom and top to which the piston is attached. When the lift cylinder is extended
fully, the oil filled between the outside of the rod and the inside of the cylinder flows through these
holes into the space inside the piston rod. The amount of oil passing through these holes is so limited
that a cushioning effect is provided for the cylinder. When the lift cylinder is retracted, the oil inside
the piston rod flows, passing through the large holes in the rod, back to their respective places.

1. HOSE PULLEY
2. PISTON HEAD
Cylinder support
3. CHAIN SHEAVE
4. CHAIN
5. ANCHOR PIN
6. ADJUSTMENT NUT
7. LOCK NUT
8. DUST SEAL
9. PACKING
10. CYLINDER CAP
Hose pulley
11. BUSHING
12. O-RING
13. PLUG
14. ROD
15. CYLINDER
16. LOCK RING
17. PISTON
18. PACKING
19. WEAR RING
20. CHECK VALVE

Fig. 7.5 Lift Cylinder (rear)

- 64 -
 7. HYDRAULIC SYSTEM

(2) Front cylinder

The front cylinder has a construction shown in Figure 7.6, with its cylinder tail bolted to the bottom
of the outer mast channel. The piston is secured to the rod with a lock ring.
The piston has a cushioning device consisting of a pipe and a sleeve, which restricts the amount
of oil passing through the cylinder with the pipe’s periphery and the sleeve’s inner diameter, thus
providing a cushioning effect for the cylinder.

1. PISTON HEAD
2. CHAIN SHEAVE
3. DUST SEAL
4. PACKING
5. CYLINDER CAP
6. O-RING
7. BUSHING
8. ROD
9. CYLINDER
10. SPACER
11. LOCK RING
12. LOCK RING
13. PISTON
14. WEAR RING
15. PACKING
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. HOSE PULLEY

Left side Right side

Fig. 7.6 Lift Cylinder (front) for FRSB14-8 and FRSB16-8

- 65 -
7. HYDRAULIC SYSTEM

1. PISTON HEAD
2. CHAIN SHEAVE
3. DUST SEAL
4. PACKING
5. CYLINDER CAP
6. O-RING
7. BUSHING
8. ROD
9. CYLINDER
10. SPACER
11. LOCK RING
12. LOCK RING
13. PISTON
14. WEAR RING
15. PACKING
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. HOSE PULLEY

Left side Right side

Fig. 7.7 Lift Cylinder (front) for FRSB20-8 and FRSB25-8

- 66 -
 7. HYDRAULIC SYSTEM

7.1.6 FLOW REGULATOR VALVE

The flow regulator valve maintains a constant fork lowering speed, regardless of the load. It is
located at the position shown in Fig. 7.9.

■ Flow regulator valve operation

The oil returning from the lift cylinder flows into chamber G from which it then runs into the
control valve after flowing through the chambers F , E , D , C , B and A . In this step, when the oil
flowing through the orifice ⑥ exceeds the specified flow rate, the force that pushes the piston ④ is
greater than the force of the spring ⑧ , thus causing the piston ④ to move to the right.
Hole D is narrowed by hole C to limit the flow rate, and the fork lowering speed is thus controlled.
The oil flowing into the lift cylinder passes through chambers A , B , C , D , E , F and G , and is
not controlled.

Free flow
Regulated
flow

Lift cylinder side Control valve side

1. CASE 6. ORIFICE
2. SPRING 7. SNAP RING
3. BALL 8. SPRING
4. PISTON 9. “O”-RING
5. SLEEVE 10. NIPPLE

Fig. 7.8 Flow Regulator Valve

- 67 -
 PULLEY
INTERMEDIATE
MAST CHANNEL
FRONT LIFT
A CYLINDER, LEFT
Detail of area A
7. HYDRAULIC SYSTEM

Fig. 7.9

- 68 -
Mast Piping
to FRONT TILT
to FRONT TILT CYLINDER
CYLINDER to REAR TILT
CYLINDER
to REAR TILT to LEFT SIDESHIFT
CYLINDER CYLINDER
to LEFT SIDESHIFT to RIGHT SIDESHIFT
CYLINDER FLOW to OIL TANK CYLINDER
to RIGHT SIDESHIFT REGULATOR to LIFT CYLINDER
CYLINDER VALVE

CUT-OFF
VALVE FRONT LIFT
to FORK CYLINDER, RIGHT
CARRIAGE
REAR LIFT
CYLINDER

INNER MAST
CHANNEL
 7. HYDRAULIC SYSTEM

7.1.7 SIDESHIFT CYLINDER

Two sideshift cylinders of the ram type are incorporated into both sides of the upper guide of the
fork carriage. The ram is supported by a bushing fitted to the cylinder cap and secured to the upper
guide with an O-ring.
When oil enters the left sideshift cylinder, the left ram presses the carriage bar to the left while the
right ram is pushed into the carriage bar to allow the oil inside the right sideshift cylinder return back
into the oil tank.

“O”-RING

PACKING
BUSHING

RAM

DUST SEAL

UPPER GUIDE
CYLINDER CAP

Detail of area A

Fig. 7.10 Sideshift Cylinder

- 69 -
7. HYDRAULIC SYSTEM

7.1.8 TILT CYLINDER

The tilt cylinder of double-acting piston type is located under the fork carriage at right side of it.
The tilt cylinder consists of a piston, a rod, a cylinder tube and a cylinder cap as shown in Figure 7.11.
The piston and the rod are welded, with a wear ring and an O-ring attached to the circumference of
the piston.
The cylinder cap is provided with a dust seal, a bushing and a packing to provide oil tightness in the
cylinder. The piston rod end is ground spherical and pushes the fork tilt bracket to provide tilt operation
of the forks.

CYLINDER TUBE “O”-RING

PACKING

SNAP RING PISTON

DUST SEAL

ROD

CYLINDER CAP

BUSHING
WEAR RING
“O”-RING

Fig. 7.11 Tilt Cylinder

- 70 -
 7. HYDRAULIC SYSTEM

7.1.9 REACH CYLINDER

The reach cylinder moves the mast forward and backward. The reach cylinder assembly is mounted
under the frame at the center of the truck.
The piston and the cylinder cap are provided with seals which provide oil-tightness.
Note: Stroke values listed below are given for trucks with the standard battery.

Tightening torque:
274 to 411 N-m
{28 to 42 kgf-m}

Model Stroke (mm) 1. WIPE SEAL

2. SNAP RING
FRSB14-8
FRSB16-8 574 3. ROD PACKING
FRSB20-8 4. CYLINDER CAP
5. “O”-RING
FRSB25-8 686
6. BUSHING
7. CYLINDER
8. ROD
9. PISTON
10. PACKING
11. NUT
12. “O”-RING
13. PISTON
14. SPRING

Fig. 7.12 Reach Cylinder

- 71 -
7. HYDRAULIC SYSTEM

7.2 MAINTENANCE
7.2.1 HYDRAULIC OIL CHANGE
(1) Put an oil pan under the tank and remove the
drain plug. OIL TANK CAP
(2) After draining off oil, reinstall the drain plug
securely.
(3) Remove the oil cap and pour hydraulic oil.
Oil capacity: See Fig. 7.1.

STRAINER DRAIN PLUG

Fig. 7.13

7.2.2 REPLACING STRAINER

(1) Remove the suction hose from the tank suction pipe.
(2) Remove the suction pipe assembly from the tank.
Note: Remove the old gasket.
(3) Replace the suction strainer with a new one.
(4) Reinstall the suction pipe assembly on the tank with a new gasket.
Note: Apply the sealing agent (THREEBOND #4001 or #1101) to the both sides of the gasket before
installing.

- 72 -
 7. HYDRAULIC SYSTEM

7.2.3 MEASURING AND ADJUSTING HYDRAULIC OIL PRESSURE

(1) Oil pressure measurement
① Remove the check plug and install an oil
pressure gauge of 20 MPa {200 kgf/cm 2}
capacity.
② Move the tilt lever forward and read the
CHECK
pressure gauge. PLUG
③ If the measured pressure is not as specified,
adjust the relief valve.

Fig. 7.14 Oil Pressure Measurement

(2) Oil pressure adjustment

① Install an oil pressure gauge using the
RELIEF VALVE
procedure described above.
② Loosen the lock nut, taking care to prevent
the adjusting screw of the relief valve from
turning.
③ Move the tilt lever forward and set the pressure
to the specified value during the pressure
relief movement using the adjusting screw and
watching the pressure gauge.
④ After adjusting the pressure, tighten the lock
LOCK NUT
nut securely.
ADJUSTING SCREW

Specified pressure setting:

Fig. 7.15 Oil Pressure Adjustment
18.2 MPa {185 kgf/cm 2 } for FRSB14 -8 ,
FRSB16-8
19.1 MPa {195 kgf/cm 2 } for FRSB20 -8 ,
FRSB25-8

- 73 -
7. HYDRAULIC SYSTEM

7.2.4 ADJUSTING VALVE SWITCH 2 - 2.5 Unit: mm

(1) Loosen the valve switch mounting bolt and
move the switch away from the cam.
(2) Install a clearance gauge shown in Fig. 7.16
between the cam and the roller.

15 - 20
(3) Bring the switch slowly close to the cam and
lock the switch at the position where the switch
is turned ON. Thickness: 0.8±0.1
(4) Pull the gauge out, then make sure that the
switch is turned off. Fig. 7.16 Gauge Adjustment
Note: If the switch won’t turn off, readjust it.

0.8±0.1 mm

Fig. 7.17

- 74 -
 7. HYDRAULIC SYSTEM

CONTROL VALVE

View looking from A

MAIN PUMP

OIL TANK

① : from OIL TANK to PUMP ⑦ : to LIFT CYLINDER

② : from PUMP to CONTROL VALVE ⑧ : from CONTROL VALVE to OIL TANK
③ : to REACH CYLINDER CAP SIDE ⑨ : to LEFT SIDESHIFT CYLINDER
④ : to REACH CYLINDER TAIL SIDE (with black tape)
⑤ : to TILT CYLINDER CAP SIDE ⑩ : to RIGHT SIDESHIFT CYLINDER
(with red tape) (with yellow tape)
⑥ : to TILT CYLINDER TAIL SIDE ⑪ : from LIFT CYLINDER to OIL TANK
(with green tape)

Fig. 7.18 Hydraulic Piping (truck body side)

- 75 -
7. HYDRAULIC SYSTEM

NOTE

- 76 -
 8. LOAD HANDLING SYSTEM

8. LOAD HANDLING SYSTEM

Truck model
FRSB14-8 FRSB16-8 FRSB20-8 FRSB25-8
Item
Name VFHM-7E4 VFHM-7E5
Type Roller type 3-stage telescopic mast with free lift
Standard max. lifting height 5000 mm
Fork lifting system Hydraulic
Fork tilting system Hydraulic
Lift chain Leaf chain (front: BL534) Leaf chain (front: BL634)
(rear: BL834) (rear: BL834)
Mast rail dimensions
Cross section of outer mast
channel
62 mm
60 mm

144 mm
188 mm
124 mm
170 mm

104 mm

Cross section of inner and

intermediate mast channels
45 mm
119.5 mm
159.5 mm

76 mm

- 77 -
8. LOAD HANDLING SYSTEM

8.1 GENERAL DESCRIPTION

The load handling system uses three-stage type telescopic mast assembly consisting of outer,
intermediate and inner mast channels, and a fork carriage. The forks are raised and tilted by hydraulic
cylinders.

8.1.1 MAST ASSEMBLY

The mast assembly is of welded construction as shown in Figure 8.1, with the mast base attached to it.

1. INNER MAST
CHANNEL
2. SLIPPER
3. SHIM
4. SHIM
5. END ROLLER
6. INTERMEDIATE
MAST CHANNEL
7. OUTER MAST
CHANNEL
8. CAP
9. SNAP RING
10. SIDE ROLLER
11. SHIM
12. SPACER
13. HOOK
14. ECCENTRIC SHAFT
15. SPACER
16. ROLLER
17. SNAP RING
18. SNAP RING
19. BUSHING
20. PIN
21. SPACER
22. SPACER
23. ROLLER
24. SNAP RING

Fig. 8.1 Mast Assembly

- 78 -
 8. LOAD HANDLING SYSTEM

8.1.2 FORK CARRIAGE

The fork carriage has a fork tilt bracket, a carriage bar on which the forks are mounted, and end
rollers.
It travels inside the inner mast channels on the end rollers when the lift cylinders are extended or
retracted.

1. FORK CARRIAGE
2. SPACER
3. SHIM
4. SIDE ROLLER
5. SHIM
6. END ROLLER
7. PIN
8. SEGMENT
9. TILT BRACKET
10. BUSHING
11. BUSHING
12. "O"-RING
13. PACKING
14. CYLINDER CAP
15. DUST SEAL
16. ROD
17. LOWER GUIDE
18. SHIM
19. SEGMENT
20. CARRIAGE BAR

FRONT

Fig. 8.2 Fork Carriage

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8. LOAD HANDLING SYSTEM

8.1.3 ROLLER LOCATIONS

End rollers are installed on the following points: upper part (inside) of the outer mast channels, the
upper part (inside) of the intermediate mast channels, the lower part (outside) of the intermediate mast
channels, the lower part (outside) of the inner mast channels, and the upper and lower parts of each
side of the fork carriage. Side rollers are installed on the upper part of each side of the fork carriage
and the lower part (outside) of the intermediate mast channels.
All the end rollers and side rollers but those located at the lower part of the intermediate mast
channels are shim-adjusted to provide a proper clearance between the roller and the channel.
The end rollers support longitudinal load while the side rollers are supporting the lateral load, so
that the inner and intermediate mast channels and fork carriage can be raised and lowered smoothly.

Upper side Lower side

SIDE ROLLER
INNER MAST (Shim-adjusted)
INTERMEDIATE
MAST CHANNEL CHANNEL FORK CARRIAGE

END ROLLERS
(Shim-adjusted)

SIDE ROLLER
(Shim-adjusted)
OUTER MAST
CHANNEL

END ROLLERS
(Shim-adjusted) END ROLLER

SLIPPERS
(Shim-adjusted)

END ROLLER

Fig. 8.3 Roller Locations (VFHM-7E4)

- 80 -
 8. LOAD HANDLING SYSTEM

Upper side Lower side

SIDE ROLLER
INNER MAST (Shim-adjusted)
INTERMEDIATE
MAST CHANNEL CHANNEL FORK CARRIAGE

END ROLLERS
(Shim-adjusted)
SIDE ROLLER
(Shim-adjusted)

OUTER MAST
CHANNEL

END ROLLERS
(Shim-adjusted) END ROLLER

SLIPPERS
(Shim-adjusted)

END ROLLER

Fig. 8.4 Roller Locations (VFHM-7E5)

- 81 -
8. LOAD HANDLING SYSTEM

8.2 MAINTENANCE
8.2.1 ADJUSTING FRONT LIFT CYLINDER ROD WITH SHIMS
After the front lift cylinder, intermediate mast channel, or outer mast 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
PISTON HEAD
when the rod reaches the stroke end. SHIM

(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 1.0 mm
(4) Adjust the lift chain tension.

Fig. 8.5

8.2.2 ADJUSTING FORK CARRIAGE HEIGHT

(1) Park the truck on a level surface and put the
fork horizontally on the ground. TIRE
(2) Keep the fork bottom on the ground and adjust
the projected amount A of the fork carriage INNER MAST CHANNEL

lower end roller to 36 to 41 mm, using the

FORK CARRIAGE
chain anchor pin at the mast side. END ROLLER

FORK

Fig. 8.6

- 82 -
 8. LOAD HANDLING SYSTEM

(3) Check the clearance B between the fork

INNER MAST
carriage and the inner mast channel stoppers CHANNEL STOPPER
when the forks are raised to the maximum
lifting height.
Clearance B : 10 mm

FORK CARRIAGE
STOPPER

CHAIN ANCHOR PIN

AT MAST SIDE

Fig. 8.7

(4) Adjust the tension of the right and left chains

to the same value with the chain anchor pin at CHAIN

the mast side when the forks are at the bottom

position.

ANCHOR PIN

ADJUSTMENT NUT

LOCK NUT

Fig. 8.8

- 83 -
8. LOAD HANDLING SYSTEM

8.2.3 REPLACING FORK CARRIAGE ROLLERS

(1) Attach the pallet to the forks and stop the truck
on a level surface.
(2) Lower the forks with the pallet to the ground.
(3) Remove the joint link of the mast side anchor
pin and remove the chain from the sheave.
(4) Remove the tilt and attachment piping at the
fork carriage side.
(5) Extend the lift cylinder rod to raise the inner
channel.
(See ① in Fig. 8.9.)
(6) After the fork carriage is detached from the
inner channel, retract the mast. (See ② in Fig.
8.9.)
Fig. 8.9
(7) Replacing end rollers
① Remove the lower end roller with a puller,
keeping the shim.
② Install a new end roller with the shim removed
in step ① . Check the stamp S or SS and install Stamp (S or SS)

the roller which is marked the same stamp,

pointing the stamp side to the fork carriage
side.
③ Remove the snap ring and remove the upper
end roller with a puller.
④ Install a new end roller.

(8) Replacing side rollers

① Remove the side roller assembly. Keep the
numbers of the shims and their combination as Fig. 8.10
they were.
② Install a new roller with the shims removed in
step ① .
③ If there is excessive looseness between the side
SHIM
roller and inner mast channel, add the shims SIDE ROLLER

between the end roller and side roller, seeing

“8.2.5 PROCEDURE FOR ADDING OR SHIM
SUBTRACTING SHIMS”.

END
ROLLER

SHIM

Fig. 8.11

- 84 -
 8. LOAD HANDLING SYSTEM

(9) Extend the lift cylinder rod so that the inner

mast channel bottom projects the upper section
on the fork carriage.
(10) Bring the truck close to the fork carriage side
so that each roller enters inside of the outer
mast channel.
(11) Contract the lift cylinder rod to lower the inner
mast channels gradually. Place each roller of
the fork carriage into the inner mast channels.
(12) Engage the chain with the sheave and connect
the chain and anchor pin through the joint link.
(13) Engage one end of the tilt pipe with the hose
pulley and connect the other end to the fork
Fig. 8.12
carriage.
(14) Adjust the height of the fork carriage. (See 8.2.2.)

- 85 -
8. LOAD HANDLING SYSTEM

8.2.4 REPLACING MAST ROLLERS

(1) Remove the fork carriage from the inner mast
channel in the same procedure as described
in “8.2.3 REPLACING FORK CARRIAGE
ROLLERS”.
(2) Move the truck to a level surface and put the
rear end of each outrigger on a block 250 - 300
mm high.
(3) Block the drive wheel securely with blocks.
(4) Hoist the inner mast channel with a crane and BLOCK

remove the chain.

(5) Operate the crane to lower the inner mast 250 - 300 mm
channel gradually and remove the end rollers
from the lower part of the inner mast channel. Fig. 8.13
At the same time, the end roller at the upper
part of the intermediate mast channel can also
be removed.
(6) Replacing end rollers
① Remove end rollers using a puller. Keep the
shims in order.
② Install new end rollers with the shims removed
in step ① , without confusing between stamps
S or SS on the end roller (See Figure 8.10).
The stamp side must be pointed toward the
fork carriage.
(7) Remove the stopper bolt at the upper part of
the front lift cylinder and hoist both the inner
and intermediate mast channels with a crane.
Remove the front lift cylinder mounting bolts
and then remove the lift cylinder.
Lower the inner and intermediate mast
channels gradually and remove the end rollers
from the lower part of the intermediate mast
channels and from the outer mast channels.
Replace the end rollers with new ones in the 1. SLIPPER 4. END ROLLER
2. SHIM 5. SNAP RING
same manner as for those on the inner mast
3. SHIM 6. SIDE ROLLER
channels.
(8) Operate the crane to hoist the intermediate and
inner mast channels to house the rollers inside
each channel. Fig. 8.14
(9) Reinstall the fork carriage on the truck in a sequence opposite to disassembly.

- 86 -
 8. LOAD HANDLING SYSTEM

8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS

(1) Bring the inner mast channel and fork carriage close to one of the outer mast channels. Measure
the clearance between each of the mast channels and the end rollers opposite the side which has
been brought closer to the outer mast channel.
Clearance between end roller and mast channel: 0 to 0.5 mm

0 - 0.5 mm 0 - 0.5 mm

Make contact with

one side.
0 - 0.5 mm
(upper side)

Apply grease. Make contact

0 - 0.5 mm (2 places) with one side.

Procedure for adding or subtracting shims

Fig. 8.15
(2) Adjusting eccentric shaft
① Loosen the lock nut. MAST BASE

② Turn the adjustment bolt clockwise until the

upper part of the rearward guide roller comes
in contact with the inner part of the top of the
outrigger.
③ Secure with the lock nut. ECCENTRIC
SHAFT

(3) Adjusting mast base

Adjust the mast base with shims so that the mast
can be tilted back by 0.5 to 1 degree.
ADJUSTMENT BOLT
LOCK NUT

Fig. 8.16 Adjusting Eccentric Shaft

- 87 -
8. LOAD HANDLING SYSTEM

8.2.6 ADJUSTING MAST SSC SWITCH

If the SSC switch was removed from the mast base
and reinstalled, it needs to be adjusted and checked MAST

for proper operation in the following manner:

(1) Check if the SSC switch arm operates as shown DOG
in Figure 8.17 when the rear cylinders operate.
(2) If the SSC switch does not operate properly, ARM
move it to make the arm in contact with the dog.
SSC SWITCH
MAST BASE

Fig. 8.17

- 88 -
 TROUBLESHOOTING

TABLE OF CONTENTS
1. CONTROL CIRCUITS ............................................................................................................. 1
1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM....................................................... 1
1.2 LOAD HANDLING SYSTEM..................................................................................................... 3
1.3 POWER STEERING SYSTEM.................................................................................................... 4
1.4 BRAKE SYSTEM......................................................................................................................... 5
1.5 OTHERS........................................................................................................................................ 6
1.6 VOLTAGE CHECKPOINTS (FOR THE DRIVE SYSTEM)...................................................... 7
1.7 VOLTAGE CHECKPOINTS (FOR THE LOAD HANDLING SYSTEM)................................. 8
1.8 VOLTAGE CHECKPOINTS (FOR THE POWER STEERING SYSTEM)................................ 9

2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING . ....................... 11

2.1 PART LOCATIONS.................................................................................................................... 11
2.2 TERMINAL LOCATIONS......................................................................................................... 11
2.3 PROCEDURES FOR CHECKING............................................................................................. 12
2.3.1 MAIN CPU BOARD.......................................................................................................... 12
2.3.2 SUB CPU BOARD............................................................................................................. 13
2.3.3 CONTROLLER CPU INPUT AND OUTPUT.................................................................. 14
2.3.4 DRIVE MOTOR POWER MODULE (TMD)................................................................... 15
2.3.5 PUMP MOTOR POWER MODULE (TMP)..................................................................... 17
2.3.6 EPS MOTOR POWER MODULE (TMPS)....................................................................... 18
2.3.7 DRIVE MOTOR/PUMP MOTOR THERMOSENSORS.................................................. 19
2.3.8 HEAT-DISSIPATION SHEET............................................................................................ 20
2.3.9 MD CONTACTOR............................................................................................................. 21
2.3.10 CURRENT SENSOR......................................................................................................... 22
2.3.11 FUSES (F1, F2, F3)............................................................................................................ 23
2.3.12 ACCELERATOR POTENTIOMETER AND F/R SWITCH............................................. 25
2.3.13 BRAKE SWITCH.............................................................................................................. 26
2.3.14 LIFT POTENTIOMETER.................................................................................................. 27
2.3.15 LCD PANEL....................................................................................................................... 28
2.3.16 CONTROL PANEL............................................................................................................ 29
2.3.17 BRAKE POTENTIOMETER............................................................................................. 30
2.3.18 STEERING POTENTIOMETER....................................................................................... 31
2.3.19 SEAT SWITCH.................................................................................................................. 32
2.3.20 SENSOR BEARING (DRIVE MOTOR)........................................................................... 33
2.3.21 SENSOR BEARING (STEERING WHEEL).................................................................... 33

3. TROUBLESHOOTING GUIDE .......................................................................................... 35

3.1 HOW TO USE THIS GUIDE...................................................................................................... 35
3.2 CHECKING BEFORE TROUBLESHOOTING........................................................................ 36
 3.3 ERROR CODE TABLE.............................................................................................................. 38
3.4 TROUBLESHOOTING BY ERROR CODE.............................................................................. 41
3.5 TROUBLESHOOTING BY PROBLEM.................................................................................... 51
3.6 LCD PANEL SYSTEM ERRORS.............................................................................................. 56

4. PARAMETER SETTING ....................................................................................................... 57

4.1 SETTING THE PARAMETERS................................................................................................. 57
4.2 PARAMETER SETUP SCREEN................................................................................................ 57
4.3 KEY PAD.................................................................................................................................... 57
4.4 SCREEN OPERATION............................................................................................................... 58
4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING......................................... 62
4.6 SETTING THE PASSWORDS................................................................................................... 65

5. DESCRIPTION OF THE FUNCTIONS ........................................................................... 67

6. ELECTRIC WIRING . .............................................................................................................. 71

 1. CONTROL CIRCUITS

1. CONTROL CIRCUITS

1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM

Circuit Diagram Description

Main CPU board 1. Controller terminal CN5-6

Power Supply

When the key switch is turned on, 48 V

is applied to this terminal, activating the
controller.

2. Accelerator potentiometer (Accelerator

Main CPU
pedal)
board 4.8 V is supplied from CN2-8. The voltage
between CN2-7 and CN2-8 varies according
to the amount of pedal effort, as shown
below.
Accelerator pedal position
Released Fully depressed
Voltage (V)
between CN2-7 0.3 2.6
and CN2-8

3. F/R switch (Potentiometer)

CN2-1 CN2-2 4.8 V is applied from CN2-2. The voltage
Main CPU board at CN2-1 varies according to the switch
position, as shown in the table below.
WBr 53

WL 54

Switch position
Neutral Forward Reverse
Voltage (V)
Drive System

between CN2-1 2.3 0.1 3.0

and CN2-2

4. Speed control switch (“turtle” button)

(1) When the switch is pressed, the turtle mark
Switch panel appears on the LCD panel and the truck
speed limit control is activated.
Pressing the switch while the turtle mark is
displayed deactivates the truck speed limit
mode selection

Speed control

control.
S.P.E travel

(2) CN-1-1-16 terminal voltage

Switch pressed: 0 V
Switch released: 5 V

5. S.P.E mode selection switch

(1) Acceleration speed and top speed can
be switched over in 3 stages. The speed
control mode changes in turns from S, P, to
LCD panel E every time the switch is pressed.
(2) CN1-1-15 terminal voltage
Switch pressed: 0 V
Switch released: 5 V

-1-
1. CONTROL CIRCUITS

Circuit Diagram Description

6. Brake switch
Main CPU board
(1) Activates the electromagnetic brake and is
normally closed.
(2) Pressing the brake pedal fully turns off the
switch.
(However, the load handling system will
work.)
switch (3) Terminal voltage (V)
Terminal voltage
Brake

Brake switch status

CN5-4
ON 48
OFF 0
7. Backup buzzer relay
Sub CPU board (1) The coil of the relay which activates the
backup buzzer.
(2) When the F/R switch is placed in the R
position, the CN21-17 terminal voltage
becomes 0 V to activate the relay.
Drive System

8. Forward travel chime relay (option)

Sub CPU board
(1) The coil of the relay that activates the
forward travel buzzer.
(2) When the F/R switch is placed in the F
position, the CN21-16 terminal voltage
becomes 0 V to activate the relay.

Drive motor speed sensor 9. Drive motor speed sensor

(1) Detects the drive motor speed.
(2) When the drive motor runs, pulses are
generated.

Main CPU
board

-2-
 1. CONTROL CIRCUITS

Circuit Diagram Description

10. Drive motor thermosensor
Drive motor
thermosensor (1) Detects the drive motor temperature.
(2) When the sensor detects a temperature of
155°C, the symbol 206 appears on the
LCD panel and the motor output current is
restricted.
(3) When the sensor detects a temperature of
Main CPU 166°C, the symbol 205 appears on the
board
LCD panel and the motor output is stopped.
Drive System

11. Front brake solenoid (option)

Main CPU (1) Functions in conjunction with the brake
board
switch to control the front brakes. This helps
reduce truck skids and braking distances
while braking.
Front brake (right)

Front brake (left)

(2) CN21-19 and CN21-20 terminal voltage

Brake switch OFF: 48 V
Brake switch ON: approx. 24 V

BR 140

1.2 LOAD HANDLING SYSTEM

Circuit Diagram Description
1. Lift potentiometer
(1) Potentiometer power supply
Main CPU board 4.8 V is supplied from the CN1-10
terminal.
(2) Potentiometer signal
The CN1-9 terminal voltage varies as
follows according to the amount of
movement of the lever from neutral
position.
Load Handling System

Lever position
Down Neutral Up
CN1-9 1.1 V or 1.1 V or 2.4 to 4.5
terminal less less
2. Lift-down, reach, tilt, and side shift switches
Main CPU board (1) 4.6 V is supplied from CN1-4, CN1-13,
CN1-15, or CN1-12.
(2) When each lever is operated, the switch
turns on to operate the pump motor. (4.6
V → 0 V)

-3-
1. CONTROL CIRCUITS

Circuit Diagram Description

3 Lift lock solenoid
Main CPU board
(1) When the interlock switch is engaged, the
lift lock solenoid is activated.
(2) CN21-7 terminal voltage
Seat switch ON (key switch ON) : 36V

solenoid
Lift lock
Seat switch OFF (key switch ON) : 48 V
Load Handling System

4. Mast SSC switch

Main CPU board (1) When the mast is raised, the switch is turned
on, reducing the travel, reach, and side-
shifting speeds, and the truck speed.
(2) CN1-3 terminal voltage
Mast SSC switch ON: 0 V
Mast SSC switch OFF: 4.6 V

1.3 POWER STEERING SYSTEM

Circuit Diagram Description
1. Steering (angle) potentiometer
(1) The travel speed of the truck is controlled
Main CPU board according to the drive wheel steering angle.
(2) Power supply
4.8 V is supplied from the CN21-10 terminal.
(3) CN21-9 terminal voltage
Steering wheel
position
Left end Neutral Right end
(1 ton
Power Steering System

1.0 2.5 4.0

trucks)
CN21-9
(2 ton
0.9 2.5 4.2
trucks)
2. Steering wheel encoder
This is a sensor that detects the rotating
CN21-11
CN21-14
CN21-12
CN21-13

CN21-1

CN21-2
CN21-3
CN21-4

direction and speed of the steering wheel.

Main CPU board
GW 65
GR 64
GB 67

GY 66

YG 62
YR 60
YB 63
YL 61
ENCODER 2(A)
4(B)

ENCODER 2(A)
4(B)
STEERING 1(V)

STEERING 1(V)
3(-)

3(-)
WHEEL

WHEEL
(A)

(B)

Upper Lower
side side

-4-
 1. CONTROL CIRCUITS

1.4 BRAKE SYSTEM

Circuit Diagram Description
1. Brake pedal potentiometer
Main CPU board (1) Power supply
4.8 V is supplied from the CN2-16 terminal.
(2) Input voltage
The voltage at the CN2-15 terminal varies,
depending on the brake pedal effort as
shown below:
CN2-15 terminal voltage (V)
Brake pedal position
Released Maximum
CN2-15 0 2.0
2. Foot pedal switch
Main CPU board (1) 4.6 V is supplied from the CN1-7 terminal.
Brake system

(2) The battery switch turns on when the battery

is installed properly. When the foot pedal
is depressed with the battery switch on, the
Foot switch
foot pedal switch turns on to release the
parking brake (the electromagnetic brake).
Battery switch (4.6 V→0 V)

3. Electromagnetic brake
Main CPU board

Electromagnetic
Varistor brake

-5-
1. CONTROL CIRCUITS

1.5 OTHERS
Circuit Diagram Description
1. Seat switch
CN1-17 Main CPU board (1) 4.6 V is supplied from the CN1-17 terminal.
(2) When the operator sits on the operator’s
LB 34
seat, the seat switch turns on to release the
interlock.
Seat switch (4.6 V→0 V)

2. Auto power-off relay

Main CPU board Activates if no operation (traveling, load
Others

handling, or power steering) is performed for

15 minutes. This shuts off the power supply to
the main CPU board and turns off the power.
RY 101

LCD panel

-6-
 Unit (V)
CN (connector) No. Wire color/number F/R switch in F Foot switch ON
Brake pedal
Terminal name Key switch ON or R position Accelerator at Remarks
+ – + – ON Seat switch ON full throttle
Accelerator
CN2-8 N Terminal LW187 – potentiometer power 4.5 4.5 4.5 4.5
supply
Accelerator
CN2-7 N Terminal LY93 – 0.3 0.3 0.3 2.6
potentiometer signal
CN1-1-16 CN1-1-6 WL75 Gy80 S/C switch Switch pressed: 0 V Switch released: 5 V

CN1-1-15 CN1-1-6 W77 Gy80 S.P.E switch Switch pressed: 0 V Switch released: 5 V
Battery switch
CN5-4 N Terminal Br131 – Brake switch Brake pedal released: 48 V Brake pedal pressed: 0 V
ON
Controller power
CN5-6 N Terminal RW11 – 48 48 48 48
supply
F: 48
CN21-17 N Terminal WL179 – BB relay coil 48 48 48 R: 1 V or less

-7-
Drive motor speed
CN2-4 N Terminal RW31 – 0 or 4.4 0 or 4.4 0 or 4.4 0 → 5.6
sensor A
Drive motor speed
CN2-12 N Terminal RB32 – 0 or 4.4 0 or 4.4 0 or 4.4 2.2
sensor B
Voltage varies
Drive motor
CN5-1 CN5-7 WG16 WR17 3.1 3.1 3.1 3.1 with the
thermosensor temperature.
DU DV – – Drive motor cable 0 0 1.3 21 to 23 AC
DV DW – – Drive motor cable 0 0 1.3 21 to 23 AC
1.6 VOLTAGE CHECKPOINTS (FOR THE DRIVE SYSTEM)

DW DU – – Drive motor cable 0 0 1.3 21 to 23 AC

R: 0.1
CN2-2 CN2-1 WL54 WBr53 F/R switch 2.3 2.3 2.3 F: 3
Electromagnetic
CN21-6 RB140 Gy116 48 48 48 0
brake
CN1-7 N Terminal YW35 4.6 4.6 4.6 0
1. CONTROL CIRCUITS
 Unit (V)
CN (connector) No. Wire color/number Lever position
Terminal name Lever moved Lever moved Remarks
+ – + – Neutral
backward forward
Lift potentiometer
CN1-10 N Terminal LW95 – 4.8 4.8 4.8
1. CONTROL CIRCUITS

power supply

Lift potentiometer 2.4 or more

CN1-9 N Terminal YR94 – 1.1 or less 1.1 or less
signal 4.5 or less

CN1-4 CN2-9 BrW91 BR8 Lift-down switch 4.6 0 0

CN1-13 CN2-9 YB20 BR9 Tilt switch 4.6 0 0

CN1-15 CN2-9 YG21 BR9 Side shift switch 4.6 0 0

CN1-12 CN2-9 YL22 BR9 Reach switch 4.6 0 0

-8-
PA N Terminal – – PA terminal 48 43 to 48 43 to 48

Lift: 0
PF N Terminal – – PF terminal 48 20 to 48
Other: 20 to 35

CN21-7 N Terminal P117 – Lift lock solenoid 0 0 36 Seat switch ON

CN1-3 N Terminal WG135 – Mast SSC switch 4.6 – –

1.7 VOLTAGE CHECKPOINTS (FOR THE LOAD HANDLING SYSTEM)
 Unit (V)
CN (connector) No. Wire color/No. Steering wheel position
Terminal name Remarks
+ – + – Left end Straight ahead Right end
Brake
CN2-16 N Terminal W162 – potentiometer 4.8 4.8 4.8
power supply
Brake
CN2-15 N Terminal G161 – potentiometer 1.2 2.5 3.8
signal
Steering
CN21-10 N Terminal YR43 – potentiometer 4.8 4.8 4.8
power supply
Steering
CN21-9 N Terminal YL42 – potentiometer 1 2.5 4
signal
Steering wheel
CN21-2 CN21-4 YL61 YB63 0 or 4.4 0 or 4.4 0 or 4.4
sensor bearing A

-9-
CN21-3 CN21-4 YG62 YB63

Steering wheel
CN21-12 CN21-14 GW65 GB67 0 or 4.4 0 or 4.4 0 or 4.4
sensor bearing B

CN21-13 CN21-14 GY66 GB67

1.8 VOLTAGE CHECKPOINTS (FOR THE POWER STEERING SYSTEM)
1. CONTROL CIRCUITS
1. CONTROL CIRCUITS

NOTE

- 10 -
 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2. ELECTRICAL PARTS AND

PROCEDURES FOR CHECKING
2.1 PART LOCATIONS
EPS motor/pump
motor power module

Main contactor

Main CPU

Current sensor

Fuse

Sub CPU

Drive motor
power module

Current sensor

Current sensor

Fan

2.2 TERMINAL LOCATIONS

Positive “+”
terminal

PB terminal

Negative “-”
terminal

DU terminal DV terminal DW terminal

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2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3 PROCEDURES FOR CHECKING

2.3.1 MAIN CPU BOARD

CN1 (20P BLACK)

CN2 (16P BLACK)
CN5 (12P BLACK)

CN6 (4P WHITE)

CN12 (5P WHITE)
CN7 (14P WHITE)
MAIN CPU BOARD DIPSW1
CN9 (26P WHITE)
CN21 (4P WHITE)
CN8 (26P WHITE)
CN10 (2P WHITE)

The main CPU board is the brain of the control system.

The DSW1 switch on the main CPU board is used to set the board to work with each truck model.
The main CPU board controls the drive motor, pump motor and EPS motor, controls the LCD panel
display, and handle troubleshooting for the truck.
The same main CPU board is used in all truck models.
LED 1 on the main CPU board is lit continuously during normal operation. If an error occurs, LED
1 will blink in a pattern indicating the error (the error code).

Setting for 1.4 to 1.6 ton trucks Setting for 2 to 2.5 ton trucks

DSW-ON DSW-ON
DSW-OFF DSW-OFF

< Caution >

• Make sure that the DSW1-1 and 1-4 are always set to the OFF position.
• Otherwise, the main CPU board or other components may be damaged.

Procedure for checking

Look at the main CPU board to see if there is any damage, deformation or excessive discoloration.
In particular, check the connectors for poor contact due to corrosion or other reasons.

Caution
Do not touch the main CPU board with your bare hands. Electronic components mounted on the
printed circuit board may be damaged by static electricity. Hold the printed circuit board by its edges
when handling it.
Put the main CPU board in an antistatic bag when transporting or storing it. Protect it from
excessive vibration or shock.

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 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.2 SUB CPU BOARD

SUB CPU
BOARD CN23 (14P WHITE)

CN21 (20P BLACK)

The sub CPU board performs the following functions: steering wheel sensor bearing output, relay
output for auxiliary devices, electromagnetic brake output, lift lock solenoid output, front wheel brake
output, steering angle input, etc.
The same sub CPU board is used in all truck models.

Make sure that the DSW1 switches on the sub CPU board are all set to the OFF position.

DSW-ON

DSW-OFF

Procedure for checking

Look at the sub CPU board to see if there is any damage, deformation or excessive discoloration. In
particular, check the connectors for poor contact due to corrosion or other reasons.

Caution
Do not touch the sub CPU board with your bare hands. Electronic components mounted on the
printed circuit board may be damaged by static electricity. Hold the printed circuit board by its edges
when handling it.
Put the sub CPU board in an antistatic bag when transporting or storing it. Protect it from excessive
vibration or shock.

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2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.3 CONTROLLER CPU INPUT AND OUTPUT

Input/Output Main Function
Main CPU Sub CPU Main CPU Sub CPU
Pump motor output limit
Lift inching switch
control
Mast SSC Truck speed limit control
Lift-down switch Interlock control Lift lock control
Interlock switch Interlock control Lift lock control
Inverter control, interlock
Accelerator
control
Inverter control, interlock
F/R switch
control
Foot switch Inverter control, interlock
(Battery lock switch) control
Pump motor chopper
Lift VR Lift lock control
control, interlock control
Pump motor chopper
Reach Lift lock control
control, interlock control
Pump motor chopper
Tilt Lift lock control
control, interlock control
Pump motor chopper
Side shift switch Lift lock control
control, interlock control
PM temperature Thermal protection
P25 Output limit control
Drive motor sensor bearing
Inverter control
input
Brake potentiometer Inverter control
Drive motor temperature Output limit control
Brake switch Inverter control Front wheel brake control
Key switch Control power supply, etc. Control power supply
Drive motor inverter
Current sensor input control, pump motor current
limit control
Inverter temperature Output limit control
Steering wheel sensor
Steering control
bearing input
Steering angle sensor input Speed limit control Steering angle sensor input
Lift lock output Lift lock control
Electromagnetic brake Electromagnetic brake
output control
Output for forward travel Output for forward travel
components components
Output for reverse travel Output for reverse travel
components components
Speed alarm output Speed alarm output
Front brake output Front brake output

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 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.4 DRIVE MOTOR POWER MODULE (TMD)

Drive motor power module S1D2W

Thermosensor (W-phase OUT) Upper arm
connector

Upper arm

Gate drive circuit

Connector
S1D2U (U-phase OUT)
S1D2V (V-phase OUT)
S1D2W (W-phase OUT)

S1D2V
(V-phase OUT)
Lower arm
Connectors S1D2U
(U-phase OUT) Lower arm

Drive motor power board

Electrolytic
capacitor

Procedure for checking (using an analog multimeter)

① Look at the module to see if there is any damage, scratches, or excessive discoloration, and check
the connectors for corrosion.
② Disconnect all the cables and bus bars from the module.
③ Set the multimeter to measure resistance (kΩ range). Use the multimeter probes to contact the
terminals, according to the table below. Measure the resistance at each set of points.
④ Determine whether the module is defective or not according to the resistance values measured.
Multimeter Normal Value (R) Judgment
Measurement points
Red probe (+) Black probe (-) Approximate reading Good Not good
D1 (P) S1D2U Several kΩ Several kΩ 0 Ω and ∞Ω
D1-S1D2U
(Same for V, W) Several 10s of kΩ or
S1D2U D1 (P) 1* Several kΩ or less
more
S1D2U S2 (N) Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (U)-S2
(Same for V, W) Several 10s of kΩ or
S2 (N) S1D2U 1* Several kΩ or less
more
G1U-S1D2U G1U S1D2U Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
(Same for V, W) S1D2U G1U Approx. 50 kΩ Approx. 50 kΩ 0 Ω and ∞Ω
G2U-S2 G2U S2 (N) Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
(Same for V, W) S2 (N) G2U Approx. 50 kΩ Approx. 50 kΩ 0 Ω and ∞Ω
D1-G1U D1 (P) G1U Approx. 100 kΩ Approx. 100 kΩ 0 Ω and ∞Ω
(Same for V, W) G1U D1 (P) 1* Several 10s of kΩ or more Several kΩ or less
G2U-S1D2U S1D2U G2U Approx. 60 kΩ Approx. 60 kΩ 0 Ω and ∞Ω
(Same for V, W) G2U S1D2U 1* Several 10s of kΩ or more Several kΩ or less
* The resistance value will increase gradually (from several k-ohms to several hundreds of k-ohms) as the electrolyte capacitor charges.

• The values in the “Normal Value” column should be used as a rough guide. The normal value
readings may vary with the type of multimeter used and the internal battery’s state of charge.
The measured value is then treated as one of the following: “Resistance Present” (1 Ω or more), “No
Resistance” (0 Ω), or “Insulated” (∞Ω).
• When checking the gates (G1, G2), any FET elements in the same array can be used.

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2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

• Do not touch the module gate terminals (G1, G2) or any soldered areas on the printed circuit board
with bare hands. The components on the PCB and the FET module must be protected from static
electricity carried by your body.
• Put the power module in an antistatic bag when carrying or storing it. Do not subject it to shock or
vibration.

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 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.5 PUMP MOTOR POWER MODULE (TMP)

Pump motor/EPS
motor power module Upper arm
Upper arm
Lower arm

Gate drive circuit

Connector
Connectors Lower arm

Pump motor/EPS motor FET for pump motor

power module board

Electrolyte
capacitor for
EPS motor

Electrolyte
capacitor for
pump motor

FET for EPS motor

Procedure for checking (using an analog multimeter)

① Look at the module to see if there is any damage, scratches, or excessive discoloration, and check
the connectors for corrosion.
② Disconnect all the cables and bus bars from the module.
③ Set the multimeter to measure resistance (kΩ range). Use the multimeter probes to contact the
terminals, according to the table below. Measure the resistance at each set of points.
④ Determine whether the module is defective or not according to the resistance values measured.
Multimeter Normal Value (R) Judgment
Measurement points
Red probe (+) Black probe (-) Approximate reading Good Not good
D1 (PA) S1D2 (PB) Several kΩ Several kΩ 0 Ω and ∞Ω
D1-S1D2 (PB)
S1D2 (PB) D1 (PA) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (PB) S2 Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (PB)-S2
S2 S1D2 (PB) 1* Several 10s of kΩ or more Several kΩ or less
G1 S1D2 0Ω 0Ω 0 Ω or more
G1P-S1D2 (PB)
S1D2 (PB) G1 0Ω 0Ω 0 Ω or more
G2 S2 Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G2P-S2
S2 G2 Approx. 50 kΩ Approx. 50 kΩ 0 Ω and ∞Ω
D1 G1 Several kΩ Several kΩ 0 Ω and ∞Ω
D1-G1P
G1 D1 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (PB) G2 Approx. 100 kΩ Approx.100 kΩ 0 Ω and ∞Ω
G2P-S1D2 (PB)
G2 S1D2 (PB) ∞Ω ∞Ω ∞Ω or less
* The resistance value will increase gradually (from several k-ohms to several hundreds of k-ohms) as the electrolyte capacitor charges.

• The values in the “Normal Value” column should be used as a rough guide. The normal value
readings may vary with the type of multimeter used and the internal battery’s state of charge.
The measured value is then treated as one of the following: “Resistance Present” (1 Ω or more), “No
Resistance” (0 Ω), or “Insulated” (∞Ω).
• When checking the gates (G1, G2), any FET elements in the same array can be used.
• Do not touch the module gate terminals (G1, G2) or any soldered areas on the printed circuit board
with bare hands. They can be damaged by the static electricity in your body.
• Put the power module in an antistatic bag when carrying or storing it. Do not subject it to shock or
vibration.

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2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.6 EPS MOTOR POWER MODULE (TMPS)

Pump motor/EPS
motor power module Upper arm

Gate drive circuit

Connector
Lower arms

Lower arm
Connectors Upper arms

Pump motor/EPS motor FET for

power module board pump motor

Electrolyte
capacitor for
EPS motor

Electrolyte
capacitor for
pump motor

FET for EPS motor

Procedure for checking (using an analog multimeter)

① Look at the module to see if there is any damage, scratches, or excessive discoloration, and check the
connectors for corrosion.
② Disconnect all the cables and bus bars from the module.
③ Set the multimeter to measure resistance (kΩ range). Use the multimeter probes to contact the terminals,
according to the table below. Measure the resistance at each set of points.
④ Determine whether the module is defective or not according to the resistance values measured.
Multimeter Normal Value (R) Judgment
Measurement points
Red probe (+) Black probe (-) Approximate reading Good Not good
D1 (P22) S1D2 (24) Several kΩ Several kΩ 0 Ω and ∞Ω
D1 (P22)-S1D2 (P24)
S1D2 (P24) D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (P24) S2 Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (P24)-S2
S2 S1D2 (P24) 1* Several 10s of kΩ or more Several kΩ or less
G1T S1D2 (P22) Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G1T-S1D2 (P22)
S1D2 (P22) G1T Approx. 60 to 100 kΩ Approx. 10 kΩ or more 0 Ω and ∞Ω
G2T S2 Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G2T-S2
S2 G2T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
D1 (P22) G1T 1* Several 10s of kΩ or more Several kΩ or less
D1 (S22)-G1T
G1T D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (P24) G2T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
G2T-S1D2 (P24)
G2T S1D2 (P24) 1* Several 10s of kΩ or more Several kΩ or less
D1 (P22) S1D2 (P23) Several kΩ Several kΩ 0 Ω and ∞Ω
D1 (P22)-S1D2 (P23)
S1D2 (P23) D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (P23) S2 Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (P23)-S2
S2 S1D2 (P23) 1* Several 10s of kΩ or more Several kΩ or less
G3T S1D2 (P22) Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G3T-S1D2 (P22)
S1D2 (P22) G3T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
G4T S2 Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G4T-S2
S2 G4T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
D1 (P22) G3T 1* Several 10s of kΩ or more Several kΩ or less
D1 (P22)-G3T
G3T D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (P23) G4T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
G4T-S1D2 (P23)
G4T S1D2 (P23) 1* Several 10s of kΩ or more Several kΩ or less
* The resistance value will increase gradually (from several k-ohms to several hundreds of k-ohms) as the electrolyte capacitor charges.

• The values in the “Normal Value” column should be used as a rough guide. The normal value readings may vary with
the type of multimeter used and the internal battery’s state of charge. The measured value is then treated as one of the
following: “Resistance Present” (1 Ω or more), “No Resistance” (0 Ω), or “Insulated” (∞Ω).
• When checking the gates (G1, G2), any FET elements in the same array can be used.
• Do not touch the module gate terminals (G1, G2) or any soldered areas on the printed circuit board with bare hands. They
can be damaged by the static electricity in your body.
• Put the power module in an antistatic bag when carrying or storing it. Do not subject it to shock or vibration.

- 18 -
 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.7 DRIVE MOTOR/PUMP MOTOR THERMOSENSORS

Thermosensor

Each power module (the drive motor power module, and the pump motor/EPS motor power module)
has a built-in thermosensor that constantly monitors the power module temperature.
The drive motor power module thermosensor (THD) starts to limit the current when the module
temperature reaches 105°C and stops the drive motor when the module temperature reaches 120°C.
The pump motor/EPS motor power module thermosensor (THP) starts to limit the current when the
module temperature reaches 100°C and stops the pump motor when the module temperature reaches
115°C.

Checking method 1
(1) Remove the thermosensor (THD, THP) connector.
(2) Set the multimeter to measure resistance (x 1000). Put the test probes on the terminals according to
the table below and measure the resistance.
(3) Determine whether the thermosensor is defective or not according to the resistance values
measured.
Measurement Multimeter Normal Value (R)
points Red probe (+) Black probe (-) Approximate reading
THD THD-1 THD-2 0°C: approx. 66 kΩ, 10°C: approx. 40 kΩ
THP THP-1 THP-2 20°C: approx. 25 kΩ, 30°C: approx. 16 kΩ

Checking method 2
(1) Set the multimeter to measure voltage. Put the tester probes on the terminals according to the table
below and measure the resistance.
(2) Determine whether the thermosensor is defective or not according to the voltage values measured.
Normal Value
Measurement Multimeter
(R)
points
Red probe (+) Black probe (-) Approximate reading
Main CPU board Main CPU board
THD
CN8-7 CN8-8 25°C: 20 kΩ/4.0 V, 50°C: 7.2 kΩ/3.0 V
Main CPU board Main CPU board 80°C: 2.5 kΩ/1.7 V (Tolerance: ±10%)
THP
CN8-9 CN8-10

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2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.8 HEAT-DISSIPATION SHEET

Each module (the drive motor power module, and the pump motor/EPS motor power module) has
a single heat-dissipation sheet. It provides insulation between each module and its base plate, and
effectively transfers the heat generated from each module to the base plate.
Whenever a module is replaced, its heat-dissipation sheet must be replaced with a new one.

Procedure for checking

(1) Check the heat-dissipation sheet for scratches or cracks. Make sure that it is free from metal
particles or chips.
(2) When the module is removed or replaced with a new one, check the insulation between the
module and its base plate.

Caution
Handle the heat-dissipation sheets carefully. Heat-dissipation sheets are fragile because they are
designed to be thin, thus minimizing the sheet’s resistance to radiating heat. Do not use a sheet that has
any scratches or cracks.
Make sure that the sheet is free of metal particles or chips that could impair its radiating function
and cause a short circuit or ground fault that would damage the module. Install a sheet with care,
making sure that the hole in the module and the hole in the sheet are aligned.

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 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.9 MD CONTACTOR

MD contactor

Connector

Procedure for checking

(1) Checking the contactor coil
① Remove the coil wiring connector.
② Put the multimeter to measure resistance (100 Ω range). Put the test probes on the terminals and
measure the resistance.
③ Determine whether the coil is defective or not according to the resistance values measured.
Good: 20 Ω Defective: ∞Ω (coil broken)

(2) Performing mechanical checks

① Remove the contactor from the truck.
② Actuate the contact by pressing the armature with your finger. See if it operates smoothly.
③ Press it again after the contact has been closed. Make sure that the pressure spring is compressed
and pushes against the contact.
④ Set the multimeter to measure resistance (minimum range) and measure the resistance between
“a”-contact and the movable contact.
⑤ Determine whether the contactor is defective or not according to the resistance measured.
Good: 0 Ω

(3) Checking the contactor contacts

① Check the contacts for rough surface or wear.
② Replace a defective contactor with a new one.
Wear limit: 0.5 mm

Note: When the contacts are replaced with new ones, both fixed contacts and one movable contact must be
replaced simultaneously.

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2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.10 CURRENT SENSOR

Procedure for checking

(1) Checking the drive motor current sensor (CSDU, CSDW)
① Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on Pin Nos. 15, 16, 17, 18, 19, 20, and 21 on the CN8 terminal (26-pin
connector), which is on the main CPU board. Turn on the key switch and measure the voltage.
Determine whether the drive motor current sensor is defective or not according to the table below.

Voltage Table (Key switch is ON)

Measurement points
Normal voltage reading Measurement conditions
Pin No. Wire Color
CN8-21 15 V
R-B (Red-Black)
CN8-22 15 V
CN8-15
CN8-16 GR (Gray) 0V
CN8-17
CN8-18
Accelerator lever in neutral, and the brake pedal is up (the brake
7 V (0 A) pedal is not pressed)
CN8-20 Orange (0) 7 V → 6.5 V Measure the voltage change when the accelerator lever is moved
(CSDU)
(0 A → +90 A) all the way forward, with the brake pedal up (the brake pedal is
(approximate) not pressed).(The truck should not move.)
Accelerator lever in neutral, and the brake pedal is up (the brake
7 V (0 A) pedal is not pressed)
CN8-19 Pink (P) 7 V → 7.23 V Measure the voltage change when the accelerator lever is moved
(CSDW)
(0 A → -45 A) all the way forward, with the brake pedal up (the brake pedal is
(approximate) not pressed).(The truck should not move.)

(2) Checking the pump motor current sensor (CSP)

① Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on Pin Nos. 11, 12, 13, and 14 on the CN8 terminal (26-pin connector),
which is on the main CPU board. Turn on the key switch and measure the voltage. Determine
whether the pump motor current sensor is defective or not according to the table below.

Voltage Table (Key switch is ON)

Measurement points
Normal voltage reading Measurement conditions
Pin No. Wire Color
CN8-14 R-B (Red – Black) 15 V
CN8-11 GR (Gray) 0V
CN8-12
Load-handling levers in neutral, and the steering wheel not
7 V (0 A) moving
CN8-13 White (W)
7 V → 8.4 V Measure the voltage change when each load-handling lever is
(approximate) moved slowly to the fully forward or fully backward position.

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 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.11 FUSES (F1, F2, F3)

F2 left terminal
F1 upper terminal F2 right terminal

F1 lower terminal

F3 upper terminal

F3 lower terminal
Fuse Capacity
F1 (drive) 225 A
F2 (pump) 225 A
F3 (EPS) 40 A
F4 (control) 10 A
F5 (lamp) 10 A
F7 (solenoid) 10 A

Procedure for checking

(1) Checking the drive motor fuse (F1)
① Set the multimeter to measure voltage. Put the negative (-) test probe on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on the F1 fuse’s upper and lower terminals and measure the voltage.
Determine whether the fuse is defective or not according to the table below.

Voltage Table (Key switch is ON)

Measurement points Voltage value Judgment
BV Good
Lower terminal
0V Defective (Change the fuse)
Upper terminal BV Good
BV: Indicates battery voltage. (Measure the battery voltage before performing this check.)

(2) Checking the pump motor fuse (F2)

① Set the multimeter to measure voltage. Put the negative (-) test probe on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on the F2 fuse right and left terminals and measure the voltage.
Determine whether the fuse is defective or not according to the table below.

Voltage Table (Key switch is ON)

Measurement points Voltage value Judgment
BV Good
Right terminal
0V Defective (Change the fuse)
Left terminal BV Good
BV: Indicates battery voltage. (Measure the battery voltage before performing this check.)

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2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

(3) Checking the EPS motor fuse (F3)

① Set the multimeter to measure voltage. Put the negative (-) test probe on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on the F3 upper and lower terminals and measure the voltage. Determine
whether the fuse is defective or not according to the table below.

Voltage Table (Key switch is ON)

Measurement points Voltage value Judgment
BV Good
Lower terminal
0V Defective (Change the fuse)
Upper terminal BV Good
BV: Indicates battery voltage. (Measure the battery voltage before performing this check.)

- 24 -
 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.12 ACCELERATOR POTENTIOMETER AND F/R SWITCH

■ ACCELERATOR POTENTIOMETER

(2 kΩ)
B
95 41

LY
93

41 95
93

Procedure for checking

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
(2) Put the red test probe (+) on Pin No. 8 on the CN2 terminal (16-pin connector), which is on the
main CPU board. Measure the voltage.
Standard voltage: 4.8 V
(3) Put the red test probe (+) on Pin No. 7 on the CN2 terminal (16-pin connector), which is on the
main CPU board. Measure the voltage.
Standard voltage (without the accelerator pedal depressed) : 0.3 V
Standard voltage (with the accelerator pedal fully depressed) : 3.0 V

Adjustment procedure
(1) Turn the accelerator potentiometer to the left or right while in neutral, and apply 5 V between the
CN2-8 terminal (LW) and the CN2-6 terminal (BG).
(2) Adjust the potentiometer so that the voltage between the CN2-7 terminal (LY) and the CN2-6
terminal (BG) is 0.3±0.1 V. Then lock the potentiometer there.
(3) Move the lever several times, and check that the voltage falls within the range specified in step (2).
(4) Check that the voltage is 3.0±0.22 V when the accelerator is at full throttle.

■ F/R SWITCH
Procedure for checking
(1) Set the multimeter to measure voltage. Put the black test probe (-)
on the controller’s N terminal.
(2) Put the red test probe (+) on Pin No. 2 on the CN2 connector,
which is on the main CPU board. Measure the voltage.
Standard voltage: 4.8 V
(3) Put the red test probe (+) on Pin No. 1 on the CN2 connector,
which is on the main CPU board. Measure the voltage for each
switch position.
Fwd.: 3 V N: 2.25 V Rev.: 0.1 V

- 25 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.13 BRAKE SWITCH

Procedure for checking

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
(2) Put the red test probe (+) on Pin No. 4 on the CN5 terminal (12-pin connector), which is on the
main CPU board. Measure the voltage.
Brake switch is OFF : Battery voltage
Brake switch is ON : 0 V

Adjustment method
• Adjust the brake switch so that the switch roller is depressed by 3±0.5 mm when the brake pedal is
fully depressed.

Foot switch and battery lock switch

Foot switch

Battery lock switch

Foot switch
Battery lock switch

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s N terminal.
(2) Put the red test probe (+) on Pin No. 7 on the CN1 connector, which is on the main CPU board.
Measure the voltage.
Foot switch is depressed : 4.6 V
Foot switch is not depressed : 0 V

- 26 -
 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.14 LIFT POTENTIOMETER

The lift potentiometer is used to control the lift speed and outputs a signal according to the amount
that the lift lever is moved. The potentiometer is located in the lift section of the control valve.

Part No. Type

277H2-62701 EWK AIX R30 E53

Procedure for checking

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
(2) Put the red test probe (+) on Pin No. 10 on the CN1 terminal (20-pin connector), which is on the
main CPU board. Measure the voltage.
Standard voltage: 4.8 V
(3) Put the red test probe (+) on Pin No. 9 on the CN1 terminal (20-pin connector), which is on the
main CPU board. Measure the voltage.
Standard voltage (with the lift lever in the neutral position) : 1.1 V or less (An error will be output
at 0.2 V or less.)
Standard voltage (with the lift lever in the down position) : 1.1 V or less (An error will be output
at 0.2 V or less.)
Standard voltage (with the lift lever in the up position) : 2.4 to 4.5 V

- 27 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.15 LCD PANEL

The LCD panel features an hour meter and an error display which can display up to 5 errors at one
time (if more than 5 errors occur, the most serious 5 error codes will be displayed), a time clock, a “tire
angle indicator” that shows the angle of the drive wheel, an indicator that shows when the steering
wheel is in the neutral position, an hour meter screen that shows previous data and other detailed
information, a power consumption screen, and an auto power-off function.
The LCD panel also has a VTM board function that allows you to control battery charging,
overdischarge control, and make various other adjustments (by setting parameters).
The maintenance mode is used to display the temperature and voltage of the LCD panel.
By connecting a PC to the LCD panel, you can check the error history, battery charge history, and
other data.

- 28 -
 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.16 CONTROL PANEL

Procedure for checking

(1) Checking the truck speed control switch (“turtle” button)
• Measure the voltage between the CN1-1-16 terminal (WL) and the CN1-1-8 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 CN1-1-15 terminal (W) and the CN1-1-8 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 CN1-1-7 terminal (WG) and the CN1-1-8 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 CN1-1-14 terminal (Y) and the CN1-1-8 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 CN1-1-6 terminal (YW) and the CN1-1-8 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.

- 29 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.17 BRAKE POTENTIOMETER

BRAKE
POTENTIOMETER

BRAKE
POTENTIOMETER

Procedure for checking

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
(2) Put the red test probe (+) on Pin No. 16 on the CN2 terminal (16-pin connector), which is on the
main CPU board. Measure the voltage.
Standard voltage: 4.8 V
(3) Put the red test probe (+) on Pin No. 15 on the CN2 terminal (16-pin connector), which is on the
main CPU board. Measure the voltage.
Standard voltage (without the brake pedal depressed) : 0.95 V
Standard voltage (with the brake pedal fully depressed) : 2.3 V

Adjustment method
(1) Adjust the brake switch position (see section 2.3.13).
(2) Depress the brake pedal until the brake switch turns off. Hold that pedal position.
(3) Apply 5±0.05 V to Pin Nos. 1 (-) and 3 (+) on the connector for the potentiometer.
(4) Turn the potentiometer left and right, to adjust the voltage between Pin Nos. 2 and 3 (+) until it is
2.05±0.05 V, and lock the potentiometer there.
(5) Adjust the lower stopper so that the voltage between Pin Nos. 2 and 3 (+) is 2.35±0.05 V when the
brake pedal contacts the pedal’s lower stopper.
(6) Adjust the upper stopper so that the voltage between Pin Nos. 2 and 3 (+) is 0.6±0.05 V when the
brake pedal is not depressed.

- 30 -
 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.18 STEERING POTENTIOMETER

STEERING
POTENTIOMETER

Procedure for checking

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-) cable
terminal.
(2) Put the red test probe (+) on Pin No. 10 on the CN21 terminal (20-pin connector), which is on the main
CPU board. Measure the voltage.
Standard voltage: 4.8 V
(3) Put the red test probe (+) on Pin No. 9 on the CN21 terminal (20-pin connector), which is on the main CPU
board. Measure the voltage.
(FRSB 14 and 16) (FRSB 20 and 25)
Standard voltage
(with the steering wheel in the center position) : 2.5 V 2.5 V
Standard voltage
(with the steering wheel turned all the way to the left) : 1.0 V 0.8 V
Standard voltage
(with the steering wheel turned all the way to the right) : 4.0 V 4.2 V

Adjustment method 1
(1) Turn the drive wheels to the straight-ahead position.
(2) Apply 5 V to the CN21-10 terminal (YR) and the CN21-8 terminal (YB) on the CPU board.
(3) Adjust the potentiometer so that the voltage between the CN21-9 terminal (YL) and the CN21-8 terminal
(YB) is 2.5 V.

Adjustment method 2
(1) Lift the drive wheels off the ground. Turn on the key switch and turn the drive wheels to the
straight-ahead position.
(2) Turn off the key switch. Remove the steering potentiometer from the drive unit, with the
connectors installed.
(3) Turn on the key switch again. Press and hold the Mode button (for at least 3 seconds) to
display the calendar setting screen.
(4) Turn the steering potentiometer gear and find the position where the symbol is displayed
on the LCD panel.
(5) With the gear in the center position, where the symbol is displayed, turn off the key switch. Reinstall
the steering potentiometer on the drive unit while keeping the gear from turning.

Check after making the adjustment

(1) Lift the drive wheels off the ground and turn the drive wheels to the straight-ahead position.
(2) Move the F/R switch to the forward (or reverse) position and then depress the accelerator pedal fully.
Check the speed.
• When the drive wheel steering angle is within 30 degrees
(left or right of center) : Maximum speed
• When the drive wheel steering angle is 30 to 60 degrees to the left or right : The larger the steering angle, the
more the speed will decrease.
• When the drive wheel steering angle exceeds 60 degrees : approx. 5 km/h

- 31 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.19 SEAT SWITCH

SEAT SWITCH

Procedure for checking

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
(2) Put the red test probe (+) on Pin No. 7 on the CN1 terminal (20-pin connector), which is on the
main CPU board. Measure the voltage.
Seat switch ON : 4.6 V
Seat switch OFF : 0 V

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 2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.3.20 SENSOR BEARING (DRIVE MOTOR)

Procedure for checking

(1) Lift the drive wheels off the ground.
(2) Set the multimeter to measure voltage. Put the black test probe (-) on Pin No. 5 on the CN2
terminal (16-pin connector), which is on the main CPU board.
(3) Put the red test probe (+) on Pin No. 4 on the CN2 terminal (16-pin connector), which is on the
main CPU board.
Turn the drive motor manually. Check to see if the voltage changes from 0 to 5 V.
(4) Put the red test probe (+) on Pin No. 12 on the CN2 terminal (16-pin connector), which is on the
main CPU board.
Turn the drive motor manually. Check to see if the voltage changes from 0 to 5 V.

2.3.21 SENSOR BEARING (STEERING WHEEL)

A B

V(+) G(–)

Procedure for checking

(1) Set the multimeter to measure voltage. Put the black test probe (-) on Pin No. 4 on the CN21
connector, which is on the main CPU board.
(2) Put the red test probe (+) on Pin No. 2 on the CN21 connector, which is on the main CPU board.
Measure the voltage while turning the steering wheel left and right repeatedly:
Check whether the voltage changes from 0 V to 5 V and back to 0 V again.
(3) Put the red test probe (+) on Pin No. 3 on the CN21 connector, which is on the main CPU board.
Measure the voltage while turning the steering wheel left and right repeatedly:
Check whether the voltage changes from 0 V to 5 V and back to 0 V again.
(4) Put the black test probe (-) on Pin No. 14 on the CN21 connector, which is on the main CPU
board.
(5) Put the red test probe (+) on Pin No. 12 on the CN21 connector, which is on the main CPU board.
Measure the voltage while turning the steering wheel left and right repeatedly:
Check whether the voltage changes from 0 V to 5 V and back to 0 V again.
(6) Put the red test probe (+) on Pin No. 13 on the CN21 connector, which is on the main CPU board.
Measure the voltage while turning the steering wheel left and right repeatedly:
Check whether the voltage changes from 0 V to 5 V and back to 0 V again.

- 33 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

NOTE

- 34 -
 3. TROUBLESHOOTING GUIDE

3. TROUBLESHOOTING GUIDE
3.1 HOW TO USE THIS GUIDE
Check the LCD panel for any error codes.
If an error code is displayed on the LCD panel, see “3.4 TROUBLESHOOTING BY ERROR
CODE”. If no error code is displayed, see “3.5 TROUBLESHOOTING BY PROBLEM”.

Error code

Start trouble diagnosis

Perform the procedure in “3.2 CHECKING BEFORE TROUBLESHOOTING”.

Is any
error code shown on the
LCD panel?

Perform the procedure in Perform the procedure in

“3.4 TROUBLESHOOTING “3.5 TROUBLESHOOTING
BY ERROR CODE”. BY PROBLEM”.

Make repairs

Is the
truck properly
restored?

End

- 35 -
3. TROUBLESHOOTING GUIDE

3.2 CHECKING BEFORE TROUBLESHOOTING

(1) Checking wiring and terminals for looseness

If a bolt or nut of the controller gets loose, that part will be heated and burn out. When you find a
loosened bolt or nut or a heated area, polish the contacting areas and retighten the bolt/nut. Give
close watch especially on the parts where a large current flows such as the minus terminal, fuses,
motors, IGBT, contactors, etc. If the minus terminal is loosened, a large current will flow, which
may damage the board.

(2) Checking wire harness and cables visually

If any outer cover of wire harness or cables is damaged, insulate it with a vinyl tape. If any core
wire inside is damaged, replace it with a new one.

(3) Checking fuses

Check main fuse (in the controller) and the fuse in the fuse box.

(4) Checking the communication line

Check whether the LCD panel display looks correct.
When the P/E display changes by flipping the switch, the communication line is working correctly.
The hourglass symbol on the LCD panel should blink when normal.

(5) Leaks from body

The wiring of the electric truck is insulated from the frame. If there is any leak from the body,
various troubles will occur. Be sure to check for leaks.
It is recommended to wipe off dirt on the battery surface with a wet waste cloth or paper and dry
the cleaned surface by blowing air.
(Criteria)
Wiring side: If leak resistance is 100 k-ohm or more, the wiring condition in the wiring side is
judged as good.
Frame to body receptacle (+)
Frame to body receptacle (-)
Battery side: If the leak is 1 k-ohm impedance with 1 V or less, the wiring condition in the
battery side is judged as good.
Frame to battery (+)
Frame to battery (-)

- 36 -
 3. TROUBLESHOOTING GUIDE

< ERROR CODES SHOWN BY LED >

The error code numbers are displayed by an orange LED blinking on the controller CPU board.
Error codes are displayed as 2-digit numbers (decimal system). The 1’s digit and 10’s digit blink
at an interval of 0.5 seconds. The 100’s digit is not displayed for 3-digit error codes. The 1’s and 10’s
digits are separated by a 1-second OFF period. The 10’s digit is flashed first, and then the 1’s digit.
After flashing one error code, the LED will be OFF for 4 seconds before repeating the blinking
process.
If multiple errors occur, the last error code that was detected by the controller will be the one
displayed.
Because the error codes displayed on the LCD panel have a one-to-one correspondence with the
flashing LED error codes, the information described above is helpful if the LCD panel fails to display
the error codes.

(Example) Error code: 23 (Drive motor current sensor output abnormal)

Error code 23

LED blinks twice LED blinks 3 times

LED ON

LED OFF

The same process is repeated.

- 37 -
 Error code Error description Problem Reset method Error code conditions LED code Page
on display
Accelerator signal is present when key
blinks. Traveling neutral interlock Truck won’t travel. Put accelerator lever in neutral. 01 43
switch is turned ON.

Error will be cleared when no Load-handling signal is present when

blinks. Load handling neutral interlock Load handling system won’t work. 80 47
load-handling levers are operated. key switch is turned ON.

Low voltage detection Truck won’t travel and load handling Battery voltage drops below 28.2 V for
101 Turn key switch off. 09 41
(Low battery voltage) system won’t work. 0.2 sec.
< Error Code Index >
3. TROUBLESHOOTING GUIDE

Low voltage alarm Battery voltage drops to between 30

102 Low output of drive and pump motors Turn key switch off. 09 41
(Low battery voltage) and 40 V.

105 Interlock switch OFF detection Interlock switch: ON Interlock switch is OFF when key 87 42
(when key switch turned ON) Accelerator: Neutral switch is turned ON.
3.3 ERROR CODE TABLE

Truck won’t travel and load handling Lift: OFF

system won’t work. Tilt: OFF
106 Interlock switch ON detection Reach: OFF Interlock switch is ON when key switch
ATT: OFF 89 42
(when key switch turned ON) is turned ON.

The sensor is defective, and the stall

A and B lines broken: Low output
Drive motor sensor bearing Error will be cleared when the current is detected continuously for 68
201 A or B line broken: No outputLoad 45
defective input returns to normal. a minute with the accelerator lever 94
handling and EPS systems enabled

- 38 -
moved forward (or backward).

202 Drive controller temp. drops Truck stops if drive controller temp.
Drive controller temp. abnormal Truck stops running. 72 45
below 120°C. rises above 120°C.

203
Truck can travel. (However, the output Drive controller temp. drops Current is limited if drive controller
Drive controller temp. too high may drop due to the current being 71 45
temp. rises above 105°C.
limited, depending on the temperature.) below 105°C.
Drive controller temp. sensor Error will be cleared when the Thermosensor (THD) voltage drops
204 Truck can travel normally. 26 44
output defective output returns to normal. below 0.2 V, or rises above 4.95 V.

205 Drive motor temp. drops below

Drive motor temp. defective Truck stops running. Drive motor temp. rises above 166°C. 74 45
165°C.

206
Truck can travel. (However, the output Drive motor temp. drops below
Drive motor temp. too high may drop due to the current being Drive motor temp. rises above 155°C. 73 45
limited, depending on the temperature.) 145°C.
Drive motor thermosensor Error will be cleared when the Thermosensor voltage drops below 0.2
207 Truck can travel normally. 27 44
output defective output returns to normal. V, or rises above 4.95 V.
Drive motor main fuse (F1) Truck won’t travel.(MD contactor Fuse (F1) voltage (secondary-side) is
211 blownDetection circuit harness Turn key switch off. 14 43
closed) abnormal.
defective
Error will be cleared when the F/R switch output voltage exceeds 3.01
210 F/R switch defective Truck won’t travel. input returns to normal. V. 07 45
 Error code Error description Problem Reset method Error code conditions LED code Page
on display
Error will be cleared when the Accelerator output voltage drops below
212 Accelerator potentiometer defective Truck won’t travel. 06 43
input returns to normal. 0.2 V, or rises above 4.8 V.
213 Traveling FET module open- 213: U-phase open-circuited (broken wire) 16
Travel, load-handling, and EPS
214 circuited Turn key switch off. 214: V-phase open-circuited (broken wire) 17 43
systems inoperative.
215 U-, V-, or W-phase wire broken 215: W-phase open-circuited (broken wire) 18
Drive motor current sensor (CSDU, Sensor output drops below 1.6 V, or
216 CSDW) output abnormalCircuit Truck won’t travel. Turn key switch off. 23 44
rises above 13.3 V.
harness defective
Capacitor (CD, CP, CPS) charge
defective Travel, load-handling, and EPS
217 Turn key switch off. 28 45
(This code is also displayed when systems inoperative.
error code 218 occurs)
Traveling FET module short-
circuited Travel, load handling, and EPS
(Upper and lower FET modules
218 systems inoperative.(MD contactor Turn key switch off. 15 43
short-circuited)
not closed)
(This code is also displayed when
error code 217 occurs)
Traveling FET module short-
219 circuited Travel, load-handling, and EPS 219: Upper TR short-circuited 19
Turn key switch off. 44
220 (Upper or lower FET module short- systems inoperative. 220: Lower TR short-circuited 20
circuited)
Electromagnetic brake turns off; Sensor output drops below 1.5 V, or
221 Steering wheel SSC VR defective and the travel and EPS systems Turn key switch off. 63 49

- 39 -
rises above 4.85 V.
stop.
Brake potentiometer detection error Electromagnetic brake OFF; and Brake potentiometer output voltage
222 Turn key switch off. 129 45
due to inoperative brake switch travel system inoperative. drops below 0.2 V, or rises above 4.8 V.
Electromagnetic brake OFF and Brake potentiometer output voltage
223 Brake potentiometer detection error travel system inoperative Turn key switch off. drops below 0.2 V, or rises above 4.8 V. 29 45

Load handling controller temp. Load handling system stops Load handling controller temp. Load handling controller temp. rises
402 75 47
defective working. drops below 115°C. above 115°C.
The current is limited if load handling
Load handling system works.
Load handling controller temp. Load handling controller temp. controller temp. rises above 100°C, and
403 (Current being limited, depending 76 47
defective drops below 100°C. an alarm displayed if the temp. rises
on the temperature.) above 105°C.
Load handling controller temp. too
high
Pump motor power module (TMP) Load handling system won’t work.
open-circuited Turn key switch off. 36 46
406 Upper side (P11-P13) of pump motor (MD contactor closed)
power module (TMP) short-circuited
Pump motor short- or open-circuited
Load handling controller Error will be cleared when the Thermosensor (THP) voltage drops 37 46
thermosensor (THP) output abnormal Load handling system works. output returns to normal. below 0.2 V, or rises above 4.95 V.
Load handling system won’t work. Error will be cleared when the The current is limited when main CPU
404 Pump motor temp. abnormal 77 47
(Current being limited) input returns to normal. board CN1-18 is open-circuited
3. TROUBLESHOOTING GUIDE
 Error code Error description Problem Reset method Error code conditions LED code Page
on display
Pump motor main fuse (F2) Load handling system won’t work. Fuse (F2) voltage (secondary-side)
411 blownDetection circuit harness Turn key switch off. 32 46
(MD contactor closed) abnormal
defective
Load handling lift potentiometer Error will be cleared when the Lift potentiometer output voltage drops
412 Load handling system won’t work. 44 47
defective input returns to normal. below 0.2 V, or rises above 4.8 V.
Pump motor voltage sensor (CSP)
Sensor output drops below 1.47 V, or
416 output abnormalCircuit harness Pump motor output limited Turn key switch off. 43 47
rises above 12.5 V.
defective
Load handling FET module short- Travel, load handling, and EPS
418 Turn key switch off. 35 46
3. TROUBLESHOOTING GUIDE

circuited systems inoperative

Main contactor (MD) openDetection Travel, load handling, and EPS
501 Turn key switch off. 12 42
circuit harness defective systems inoperative
Main contactor (MD) short- Travel, load handling, and EPS
502 circuitedDetection circuit harness Turn key switch off. 11 41
systems inoperative
defective
EPS main fuse blown; and detection
505 EPS inoperative Turn key switch off. 52 48
circuit harness defective.
EPS FET module short-
circuited(upper and lower FET 55
modules short-circuited)EPS FET Travel, load handling, and EPS
506 Turn key switch off. 57 48
module short-circuited(P23 side)EPS systems inoperative. 58
FET module short-circuited(P24
side)Drive circuit harness defective

- 40 -
EPS FET module open-
507 circuited;Drive circuit harness EPS inoperative Turn key switch off. 54 48
defective;EPS motor open-circuited
Speed limit (speed while
600 turning),front wheel brake,forward/
CAN wire broken Turn key switch off. 81 49
reverse travel components,or speed
alarm function disabled.
EPS inoperative; electromagnetic An over current limiting (OCL)
EPS experiencing continuous over
508 current limiting (OCL) brake off, and travel system No operation required. condition (x 0.42A or higher) continues 91 49
inoperative for 10 seconds.
EPS inoperative; electromagnetic
EPS sensor bearing wire broken on
509 one side brake off, and travel system Turn key switch off. 61 49
inoperative
EPS inoperative; electromagnetic
Faulty detection of EPS sensor
510 bearing rotation direction brake off, and travel system Turn key switch off. 66 49
inoperative
512 Truck speed limited to 5 km/
EPS sensor bearing defective Turn key switch off. 60 49
h;Steering inoperative
EPS inoperative; electromagnetic
513 Error due to reversed connections on brake off, and travel system 54 50
the steering potentiometer inoperative
 3. TROUBLESHOOTING GUIDE

3.4 TROUBLESHOOTING BY ERROR CODE

This section explains how to perform troubleshooting using the error codes displayed on the
LCD panel.
< How to use this troubleshooting guide >
① Take Step ① and see if there is a problem. If a problem is found, take the corrective action in the
right column. If no problem is found, proceed to Step ② .
② Take Step ② and see if there is a problem. If a problem is found, take the corrective action in the
right column. If no problem is found, proceed to Step ③ .
③ Continue on the same way until the problem is resolved.

< Example: Main contactor (MD) open >

Upper: LCD panel error code

Lower: LED error code

1. General

(1) : Low voltage (Low battery voltage)

To clear the error code, turn the key switch off.
: Low voltage alarm (Low battery voltage)

① Check the battery voltage. Charge the battery.

② Check the harness between CN8-6 and P1 terminals

Repair or replace the harness.
on main CPU board.

(2) : Main contactor (MD) short-circuited To clear the error code, turn the key switch off.

① Turn the key switch OFF and remove the battery

receptacle.

② Check main contactor. See page 21. Replace the main contactor.

③ Check the harness between CN8-6 and P1 terminals

Repair or replace the harness.
on main CPU board.

④ Check the harness between CN9-6 on main CPU

board and CN19D-3 on the drive motor power Repair or replace the harness.
module (TMD).

⑤ Check the harness between CN8-25/8-26 on main

Repair or replace the harness.
CPU board and main contactor coil.

⑥ Replace CPU board.

- 41 -
3. TROUBLESHOOTING GUIDE

(3) : Main contactor (MD) open To clear the error code, turn the key switch off.

① Turn the key switch OFF and remove the battery

receptacle.

② Check the main contactor. See page 21. Replace the main contactor.

③ Check the harness between CN8-6 and P1

Repair or replace the harness.
terminals on main CPU board.

④ Check the harness between CN9-6 on main CPU

board and CN19D-3 on the drive motor power Repair or replace the harness.
module (TMD).

⑤ Check the harness between CN9-7 on main CPU

board and CN19P-4 on the pump motor/EPS Repair or replace the harness.
motor power module (TMD).

⑥ Check the harness between CN8-25/8-26 on main

Repair or replace the harness.
CPU board and main contactor coil.

⑦ Replace the CPU board.

(4) : Interlock switch OFF detected (after key To clear the error code, turn the interlock switch ON.
switch is turned ON)
Put the accelerator lever in neutral. Turn the lift, tilt,
: Interlock switch OFF detected (after key reach, and ATT switches OFF.
switch is turned ON)

① Turn the interlock switch ON. Put the accelerator

lever in neutral. Turn the key switch ON without
operating the load-handling levers.

② Check the interlock switch (seat switch). See

Replace the switch.
page 32.

③ Check the accelerator. See page 25. Replace the potentiometer.

④ Check the interlock switch and accelerator

Repair or replace the harness.
wiring.

⑤ Check the load-handling switch. Replace the switch.

⑥ Check the load-handling switch wiring. Repair or replace the harness.

- 42 -
 3. TROUBLESHOOTING GUIDE

2. Drive system
To clear the error code, put the accelerator lever in
(1) : Traveling neutral detection neutral.
① Put the accelerator lever in neutral and turn the
key switch ON.
② Check the accelerator potentiometer voltage. See
Replace the accelerator.
page 25.
③ Check the harness of accelerator potentiometer
Repair or replace the harness.
circuit.

This error will be cleared when the input returns to

(2) : Accelerator potentiometer defective normal.
① Check the harness between CN2-6/2-7/2-8 on
Repair or replace the harness.
main CPU board and accelerator.
② Check the accelerator. See page 25. Replace the potentiometer.

(3) : Drive motor main fuse (F1) blown To clear the error code, turn the key switch off.
① Check the drive motor fuse. See page 23. Replace the fuse (F1).
② Check the harness between CN8-6 and P1
Repair or replace the harness.
terminals on main CPU board.
③ Check the harness between CN9-6 on main CPU
board and CN19D-3 on the drive motor power Repair or replace the harness.
module board.

(4) : Traveling FET module short-circuited To clear the error code, turn the key switch off.
① Turn the key switch OFF and remove the battery
receptacle.
② Check the drive motor power module (TMD).
Replace the TMD.
See page 15.
③ Check the harness between CN7 on main CPU
Repair or replace the harness.
board and CN17D on the TMD.
④ Check the harness between CN9-6 on main CPU
Repair or replace the harness.
board and CN19D-3 on the TMD.

(5) : Traveling FET module open- To clear the error code, turn the key switch off.
circuited
① Turn the key switch OFF and remove the battery
receptacle.
② Check the drive motor power module (TMD).
Replace the TMD.
See page 15.
③ Check the harness between CN7 on main CPU
Repair or replace the harness.
board and CN17D on the TMD.
④ Check the output terminals (U, V and W phases)
Retighten.
for proper connection and any loose screws.

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3. TROUBLESHOOTING GUIDE

(6) : Traveling FET module short-circuited To clear the error code, turn the key switch off.

① Turn the key switch OFF and remove the battery

receptacle.
② Check the drive motor power module (TMD).
Replace the TMD.
See page 15.
③ Check the harness between CN7 on main CPU
Repair or replace the harness.
board and CN17D on the TMD.
④ Check the harness between CN9-8 on main CPU
Repair or replace the harness.
board and CN19D-4 on the TMD.
⑤ Check the harness between CN9-10 on main CPU
Repair or replace the harness.
board and CN19D-5 on the TMD.
⑥ Check the harness between CN9-12 on main CPU
Repair or replace the harness.
board and CN19D-6 on the TMD.
⑦ Check the harness between CN9-6 on main CPU
Repair or replace the harness.
board and CN19D-3 on the TMD.

(7) : Drive motor current sensor (CSDU, CSDW) To clear the error code, turn the key switch off.
output abnormal
① Check the harness between main CPU board and
current sensor.
Repair or replace the harness.
CSDU: CN8-16, -18, -20, -22
CSDW: CN8-15, -17, -19, -21
② Check the voltage of main CPU board current
sensor power supply.
Replace the main CPU board.
CSDU: CN8-22 to 8-16, and 8-18 Normal: 15 V
CSDW: CN8-21 to 8-15, and 8-17 Normal: 15 V
③ Check the current sensor. See page 22. Replace the current sensor.

(8) : Drive controller thermosensor output This error will be cleared when the output returns to
abnormal normal.
① Check the thermosensor (THD) voltage. See page
Replace the thermosensor.
19.
② Check the harness between CN8-7/8-8 on main
Repair or replace the harness.
CPU board and the thermosensor (THD).

This error will be cleared when the output returns to

(9) : Drive motor thermosensor output abnormal normal.

① Check the drive motor thermosensor voltage. See

Replace the current sensor.
page 19.
② Check the harness between CN5-1/5-7 on main
Repair or replace the harness.
CPU board and the drive motor thermosensor.

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 3. TROUBLESHOOTING GUIDE

(10) : Capacitor (CD, CP, CPS) charge abnormal To clear the error code, turn the key switch off.
① Check the harness between CN10 on main CPU
Repair or replace the harness.
board and the charge resistor (RQ).
② Check the drive motor power module (TMD), and
the pump motor/EPS motor power module (TMP, Replace the power module.
TMPS). See pages 15, 17, and 18.

(11) : Sensor bearing defective This error will be cleared when the input returns to normal.
① Check the harness between CN2-3/2-4/2-12 on
Repair or replace the harness.
main CPU board and sensor bearing.
② Check the sensor bearing. See page 38. Replace the sensor bearing.

(12) : Drive controller temp. too high The error codes will be cleared when the controller
temperature drops below 105°C and 120°C,
: Drive controller temp. abnormal respectively.
① Turn the key switch OFF and allow the controller
Reduce the load.
to cool down for about 30 minutes.
② Check the drive motor power module for loose screws. Retighten.
③ Check the thermosensor (THD). See page 19. Replace the thermosensor.
④ Check the the harness between CN8-7/8-8 on
Repair or replace the harness.
main CPU board and the thermosensor (THD).

(13) : Drive motor temp. too high The error codes will be cleared when the drive
motor temperature drops below 145°C and 165°C,
: Drive motor temp. abnormal respectively.
① Turn the key switch OFF and allow the drive
Reduce the load.
motor to cool down for about an hour.
② Check the drive motor thermosensor. See page 19. Replace the thermosensor.
③ Check the harness between CN5-1/5-7 on main
Repair or replace the harness.
CPU board and the drive motor thermosensor.

(14) : F/R potentiometer defective This error will be cleared when the input returns to normal.
① Check the harness between CN2-1/2-2 on main
Repair or replace the harness.
CPU board and F/R potentiometer.
② Check the F/R potentiometer. See page 25. Replace the F/R potentiometer.

(15) : Potentiometer not detecting the brake

switch turned off. To clear this error code, turn the key switch off.
: Brake potentiometer detection error
① Check the harness between CN2-14/2-15/2-16 on
Repair or replace the harness.
main CPU board and brake potentiometer.
② Check the harness between CN5-6 on main CPU
Repair or replace the harness.
board and brake switch.
③ Check the brake switch and brake potentiometer. Replace the brake switch and/or potentiometer.

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3. TROUBLESHOOTING GUIDE

3. Load handling system

(1) : Pump motor main fuse (F2) blown To clear the error code, turn the key switch off.

① Check the pump motor fuse (F2). See page 23. Replace the fuse.
② Check the harness between CN8-6 and P1
Repair or replace the harness.
terminals on main CPU board.
③ Check the harness between CN9-7 on main CPU
board and the pump motor/EPS motor power Repair or replace the harness.
module (TMP).

(2) : Load handling FET module short-circuited To clear the error code, turn the key switch off.

① Turn the key switch OFF and remove the battery

receptacle.
② Check the pump motor/EPS motor power module
Replace the TMP.
(TMP). See page 17.
③ Check the harness between CN9-7 on main CPU
board and the pump motor/EPS motor power Repair or replace the harness.
module (TMP).
④ Check the harness between CN7-3 on main CPU
board and the pump motor/EPS motor power Repair or replace the harness.
module (TMP).

(3) : Pump motor/EPS motor power module To clear the error code, turn the key switch off.
(TMP) open-circuited
① Turn the key switch OFF and remove the battery
receptacle.
② Check the pump motor/EPS motor power module
Replace the TMP.
(TMP). See page 17.
③ Check the harness between CN9-7 on main CPU
board and CN19P-4 on the pump motor/EPS Repair or replace the harness.
motor power module (TMP).
④ Check the harness between CN7-3 on main CPU
board and CN17P-2 on the pump motor/EPS Repair or replace the harness.
motor power module (TMP).

(4) : Load handling controller thermosensor This error will be cleared when the output returns to
(THP) output abnormal normal.
① Check the thermosensor (THP) voltage. See page
Replace the THP.
19.
② Check the harness between CN8-9/8-10 on main
Repair or replace the harness.
CPU board and the thermosensor (THP).

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 3. TROUBLESHOOTING GUIDE

(5) : Pump motor current sensor (CSP) output To clear the error code, turn the key switch off.
abnormal
① Check the harness between CN8-11 / 8-12 / 8-13
Repair or replace the harness.
/ 8-14 on main CPU board and the current sensor.
② C h e c k t h e v o l t a g e b e t w e e n C N 8 - 1 4 a n d
Replace the main CPU board.
CN8-11/8-12 on main CPU board. (Normal: 15 V)
③ Check the current sensor (CSP). See page 22. Replace the CSP.

This error will be cleared when the input returns to

(6) : Load-handling lift potentiometer defective normal.
① Check the harness between CN1-8/1-9/1-10 on
Repair or replace the harness.
main CPU board and the lift potentiometer.
② Check the lift potentiometer. See page 27. Replace the lift potentiometer.

(7) : Load handling controller temp. abnormal The error codes will be cleared when the controller
t e m p e r a t u r e d r o p s b e l o w 11 5 ° C a n d 1 0 0 ° C ,
: Load handling controller temp. too high respectively.

① Turn the key switch OFF and allow the controller

Reduce the load.
to cool down for about 30 minutes.
② Check the pump motor/EPS motor power module
Retighten.
(TMP) for loose screws.
③ Check the thermosensor (THP). See page 19. Replace the THP.
④ Check the harness between CN8-9/8-10 on main
Repair or replace the harness.
CPU board and the thermosensor (THP).

This error will be cleared when the input returns to

(8) : Pump motor temp. abnormal normal.
① Turn the key switch OFF and allow the pump
Reduce the load.
motor to cool down for about an hour.
② heck the harness between CN1-18 on main CPU
Repair or replace the harness.
board and the pump motor thermosensor.

This error will be cleared when no load-handling

(9) : Load-handling neutral detection levers are operated.
① Put the load-handling levers in neutral and turn
the key switch ON.
② Check the lift potentiometer and load-handling
Replace the potentiometer or switch.
lever switch harness. See page 27.
③ Check the lift potentiometer and load-handling
Repair or replace the harness.
lever switch harness.

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3. TROUBLESHOOTING GUIDE

4. EPS system

(1) : EPS main fuse open To clear the error code, turn the key switch off.
① Check EPS main fuse (F3). See page 23. Replace the fuse.
② Check the harness between CN9-5 on main CPU
board and the pump motor/EPS motor power Repair or replace the harness.
module (TMP).
③ Check the harness between CN8-6 and P1
Repair or replace the harness.
terminals on main CPU board.

(2) : EPS FET module open-circuited To clear the error code, turn the key switch off.
① Check the EPS motor (and brushes). Repair or replace the EPS motor.
② Check the EPS wiring. Repair or replace the harness.
③ Check the harness between CN7-5/7-7/7-9/7-11
on main CPU board and CN17P-3/17-4/17-5/17-6
Repair or replace the harness.
on the pump motor/EPS motor power module
(TMPS).
④ Check the pump motor/EPS motor power module
Replace the TMPS.
(TMPS). See page 18.

(3) : EPS FET module short-circuited (upper and

lower modules short-circuited)
: EPS FET module short-circuited (P23 side) To clear the error code, turn the key switch off.

: EPS FET module short-circuited (P24 side)

① Check the harness between CN7-5/7-7/7-9/7-11
on main CPU board and CN17P-3/17-4/17-5/17-6
Repair or replace the harness.
on the pump motor/EPS motor power module
(TMPS).
② Check the harness between CN21-1 on sub CPU
board and CN21P-4 on the pump motor/EPS Repair or replace the harness.
motor power module (TMPS).
③ Check the harness between CN21-2 on sub CPU
board and CN21P-3 on the pump motor/EPS Repair or replace the harness.
motor power module (TMPS).
④ Check the pump motor/EPS motor power module
Replace the TMPS.
(TMPS). See page 18.

(4) : Steering wheel SSC potentiometer defective To clear the error code, turn the key switch off.
① Check the harness between steering (angle)
potentiometer and CN21-8/21-9/21-10 on sub Repair or replace the harness.
CPU board.
② Check the steering (angle) potentiometer. See
Replace the potentiometer.
page 31.

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 3. TROUBLESHOOTING GUIDE

(5) : CAN wire broken To clear the error code, turn the key switch off.
① Check the harness between CN6/12 on main CPU
Repair or replace the harness.
board and CN21 on sub CPU board.

(6) : EPS experiencing continuous over current The steering wheel does not need to be turned to clear
limiting (OCL) the error code.
① Check the harness between EPS motor wiring and
Repair or replace the harness.
P23/P24.
② Check the harness between CN20-3 and CN9-21
Repair or replace the harness.
on main CPU board.
③ Check the harness between CN21-1 to -4 and -11
Repair or replace the harness.
to -14.
④ Check the load-handling and EPS drive modules
Replace the TMPS.
(TMPS).
⑤ Check the sub CPU board. Replace the sub CPU board.

(7) : Steering wheel sensor bearing wire broken

on one side
To clear the error code, turn the key switch off.
: Faulty detection of steering wheel sensor
bearing rotation direction
① Check the harness between CN21-1 to -4 / -11 to
Repair or replace the harness.
-14 on sub CPU board and steering wheel bearing.
② Check the steering wheel sensor bearing. Replace the steering wheel sensor bearing.

(8) : Steering wheel sensor bearing defective To clear the error code, turn the key switch off.
① Check the harness between CN21-1 to -4 / -11 to
Repair or replace the harness.
-14 and steering wheel sensor bearing.
② Check the steering wheel sensor bearing. Replace the steering wheel sensor bearing.
③ Check the harness between CN21-8/-9/-10 on sub
Repair or replace the harness.
CPU board and steering potentiometer.
④ Check the EPS motor wiring. Repair or replace the harness.
⑤ Check the pump motor/EPS motor power module
Replace the TMPS.
(TMPS).
⑥ Check the sub CPU board. Replace the sub CPU board.

⑦ Check the steering potentiometer. Replace the steering potentiometer.

⑧ Check the gears. Replace the gears.

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3. TROUBLESHOOTING GUIDE

(9) : Error due to reversed connections on the To clear the error code, turn the key switch off.
steering potentiometer
① Check the harness between CN21-8/-9/-10 and
Repair or replace the harness.
steering potentiometer.
② Check EPS motor wiring. Repair or replace the harness.
③ Check the load-handling/EPS drive module
Replace the TMPS.
(TMPS).
④ Check the sub CPU board. Replace the sub CPU board.

- 50 -
 3. TROUBLESHOOTING GUIDE

3.5 TROUBLESHOOTING BY PROBLEM

(1) The LCD panel is blank

• Key switch
Key switch ... Turn it ON. • Wire harness 101 , 100 or 5
Below
• Fuse F4
10 V
LCD panel
40 V or more

LCD panel

(2) MD contactor does not work (The travel, load handling, and EPS systems are inoperative)

Key switch ... Turn it ON. • Main CPU board

40 V or • PO relay
more
Main Below 40 V
CPU

Key switch ... Turn it ON. • Wire harness 11

40 V or • PO relay
more
Below 40 V

• Wire harness 101

Key switch ... Turn it ON.
40 V or • Key switch
more
Below 40 V

Key switch ... Turn it ON. • Wire harness 100

40 V or • Fuse F4
more
Below 40 V

• Wire harness 5
• Battery connector
• Battery

- 51 -
3. TROUBLESHOOTING GUIDE

(3) The load handling system works, but the truck won’t travel

Key switch....Turn it ON.

• Check the accelerator.
Brake pedal........Release. 40 V or
more
Main Below 40 V
CPU

Key switch....Turn it ON. • Wire harness 116

Brake pedal........Release. 40 V or • Check the electromagnetic brake.
more
Below 40 V

• Wire harness 110

Key switch....Turn it ON.
40 V or • Brake switch
more
Below 40 V

• Wire harness 11

Other
Key switch....Turn it ON. than 5 V • Foot switch
Foot switch.............Press. • Wire harness 35

Main 5V
CPU
Other
Key switch....Turn it ON. than 5 V • Battery switch
Foot switch.............Press. • Wire harness 131

Main
5V
CPU
Other
than 5 V
Key switch....Turn it ON. • Wire harness 9

5V

Main CPU board

- 52 -
 3. TROUBLESHOOTING GUIDE

(4) The truck travels, but does not gain speed

Is the
Turtle mark visible
turtle mark Key switch....Turn it ON.
invisible?

Key switch....Turn it ON.

Turtle mark Turtle button...........Press.
invisible

Switch panel

• LCD panel
Other
Key switch........ Turn it ON. than 5 V • Main CPU board
Accelerator pedal....Release.
• Wire harness 187
Foot switch..............Release.
Main CPU

Below
Key switch................. Turn it ON.
F/R switch........................F 3V • F/R switch
Foot switch................Press. • Wire harness 54
Accelerator pedal.......Release.
Main CPU
3 V or more

Key switch................. Turn it ON. 0.1 V or

F/R switch....................... R more • F/R switch
Accelerator pedal.......Release. • Wire harness 54
Foot switch................Press.
Main CPU
Below 0.1 V

Key switch.......Turn it ON. Below

Accelerator pedal......Press. 3.1 V • Accelerator
Foot switch................Press. • Wire harness 93
F/R switch ...............F or R
Main CPU 3.1 V or more

Other than
2.1-2.8 V • Wire harness 42
Key switch....Turn it ON.
• Steering potentiometer

Main CPU
2.1 to 2.8V

• Wire harness 135

Key switch....Turn it ON.
• Mast SSC

Main CPU

Main CPU board

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3. TROUBLESHOOTING GUIDE

(5) Only the lift lever does not work

Key switch..................Turn it ON. Other

Lift lever............................ Neutral than 5 V • Main CPU board
Tilt lever............................ Neutral
• Wire harness 95
Reach lever........................ Neutral
ATT lever.......................... Neutral
Main
CPU
Below
Key switch..................Turn it ON. 1.1 V • Lift potentiometer
Lift lever.........................Pull fully. • Wire harness 94
Main
1.2 V or more
CPU

Main CPU board

(6) Only one of the tilt lever, reach lever, and ATT levers does not work
(Tilt)

Key switch..................Turn it ON. • Tilt limit switch

Tilt lever.........................Pull fully. • Wire harness 20
Main CPU

(Reach)

Key switch..................Turn it ON. • Reach limit switch

Reach lever.....................Pull fully. • Wire harness 22
Main CPU

Key switch..................Turn it ON. • ATT1 limit switch

ATT1 lever.....................Pull fully. • Wire harness 21
Main CPU

Key switch..................Turn it ON. • ATT2 limit switch

ATT2 lever.....................Pull fully. • Wire harness 23
Main CPU

Main CPU board

- 54 -
 3. TROUBLESHOOTING GUIDE

(7) Lift speed is slow

Other
than 5 V • Wire harness 95
Key switch.... Turn it ON. • Main CPU board
Main CPU
Below
Key switch.... Turn it ON. 3.6 V • Lift potentiometer
Lift lever........... Pull fully. • Wire harness 94
Main CPU 3.6 V or more

Not
Check the “PARAMETER 1 - correct
No. 5” setting on the LCD panel. • Correct the setting.

Main CPU board

(8) Pump motor does not stop running

1.2 V or
more • Lift potentiometer
Key switch.... Turn it ON.
• Wire harness 94
Main CPU
Below 1.2 V
Other
than 5 V • Tilt limit switch
Key switch.... Turn it ON.
• Wire harness 20
Main CPU

Other
than 5 V • Reach limit switch
Key switch.... Turn it ON.
• Wire harness 22
Main CPU

Other
than 5 V • ATT1 limit switch
Key switch.... Turn it ON.
• Wire harness 21
Main CPU

Other
than 5 V • ATT2 limit switch
Key switch.... Turn it ON.
• Wire harness 23
Main CPU

Main CPU board

- 55 -
3. TROUBLESHOOTING GUIDE

3.6 LCD PANEL SYSTEM ERRORS

Error Description Cause Corrective Action
Code
This error code is displayed if a time-out has
occurred while receiving analog input data
074 AD conversion error (current draw or temperature readings).
Any of the indicators or wiring may be
defective.
Replace the LCD panel with a new one.
This error code is displayed if a time-out has
occurred while receiving data from the RTC
075 RTC error (real time clock).
The connections on the LCD panel board or the
RTC may be defective.
A time-out has occurred while reading memory Remove and reinstall the battery receptacle.
EEPROM access or writing to the LCD panel memory.
076 The connections on the LCD panel board or the If the problem is not solved, replace the LCD
error panel with a new one.
EEPROM may be defective.
077 Program sum error These error codes refer to errors that occur
while loading the program or when an incorrect Replace the LCD panel with a new one.
078 Version loading error program version was loaded.
Check to see if the controller operates properly
when the key switch is tuned ON (see if the
This error code is displayed if no signal is orange pilot lamp on the main CPU board is lit).
Communication received from the controller.
082 Check the communication lines (GW81, GR82,
error (controller) The controller or the controller communication GY83, GO84) between the LCD panel and the
lines may be defective. controller. If no problem is found, replace the
LCD panel with a new one.
Follow the instructions given by the fault
This error code is displayed if no signal is diagnosis program installed on a PC.
Communication received from PC.
083 Check the communication lines between the
error (PC) The communication line with PC may be LCD panel and PC. If no problem is found,
defective. replace the LCD panel with a new one.
This error will be cleared when the battery
Low battery voltage This indicates that the battery voltage detected
085 voltage returns to 26 V. When cleared, the key
by the LCD panel has dropped below 26 V. switch is forced OFF.

- 56 -
 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.

4.2 PARAMETER SETUP SCREEN

Program version
Battery voltage The actual temperature
Temperature detected detected is the displayed
(LCD panel) value minus 15.

Parameter group Parameter item Setting

4.3 KEY PAD

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 COM-
PLETE 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.

- 57 -
4. PARAMETER SETTING

4.4 SCREEN OPERATION

INITIAL PARAMETER SETUP SCREEN

FRB100 9/19(WED)

VOLT 50.2 12:34

TEMP 31 99999.9 h

PARAMETER

While pressing and holding the Mode button and the “+” button on the key pad, turn on the key
switch. The INITIAL PARAMETER SETUP screen shown above will be displayed.
Note that the contactor is not turned on 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

FRB100 9/19(WED)

VOLT 50.2 12:34

TEMP 31 99999.9 h

PARAMETER 1

Parameter group

PARAMETER 1 PARAMETER 1 and PARAMETER 2 are used when setting the

parameters for the controller.
PARAMETER 3 is used to set the LCD panel parameters.
PARAMETER 2 PC is the mode used when a PC (an electric truck fault-diagnosis
support system) is connected.

PARAMETER 3

PC
Press this turtle button to return to the INITIAL PARAM-
ETER SETUP screen.

- 58 -
 4. PARAMETER SETTING

PARAMETER GROUP SETUP SCREEN

FRB100 9/19(WED)

VOLT 50.2 12:34

TEMP 31 99999.9 h

PARAMETER 1

Press this turtle button to return to the

PARAMETER ITEM INITIAL PARAMETER SETUP screen.
SETUP SCREEN

FRB100 9/19(WED)

VOLT 50.2 12:34

TEMP 31 99999.9 h

PARAMETER 1
POWER
6

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.

- 59 -
4. PARAMETER SETTING

PARAMETER ITEM SETUP SCREEN

FRB100 9/19(WED)

VOLT 50.2 12:34

TEMP 31 99999.9 h

PARAMETER 1
POWER

Press and hold After setting a parameter item, press

PARAMETER SETUP this button. and hold the Mode button when the
COMPLETE SCREEN PARAMETER ITEM SETUP screen is
displayed.
The PARAMETER SETUP COMPLETE
FRB100 9/19(WED)
screen (shown on the left) will be dis-
VOLT 50.2 12:34 played.

TEMP 31 99999.9 h

TERMINATED

Press and hold Press and hold the Mode button when
DATA TRANSMISSION this button. the PARAMETER SETUP COMPLETE
SCREEN screen is displayed. The controller
contactor will be closed and the DATA
FRB100 9/19(WED) TRANSMISSION screen (shown on the
left) will be displayed. This screen indi-
VOLT 50.2 12:34 cates that the new setting is being sent
to the controller.
TEMP 31 99999.9 h
Note that the truck cannot be operated
during data transmission.
DATA IN TRANSMISSION
DO NOT TURN OFF THE KEY

DATA TRANSMISSION COMPLETE SCREEN

Once the data transmission is finished,
FRB100 9/19(WED)
the DATA TRANSMISSION COM-
VOLT 50.2 12:34 PLETE screen (shown on the left) will
be displayed. Then turn the key switch
TEMP 31 99999.9 h
OFF.

TERMINATED
TURN OFF THE KEY

- 60 -
 FRSB-8 Parameter Settings Table Factory settings
No. Screen display Item Description Unit Settings Remarks
1 POWER Travel speed acceleration level Drive acceleration mode numbers – 0 1 2 3 4 5 6 7 8 9 10
2 TRAVEL SPEED LIMIT Truck speed limit level Max. speed in “turtle” mode km/h 1 2 3 4 5 6 7 8 9
3 LIFT SPEED Lift level Lift limit rate % 50 55 60 65 70 75 80 85 90 95 100
4 LIFT INCING LEV. Lift inching level Lift inching limit rate % 0 5 10 15 20 25 30 35 40 45 50
5 TILT SPEED Tilt level Tilt limit rate % 0 10 20 30 40 50 60 70
6 ATT1 SPEED ATT1 level ATT1 limit rate % 0 5 10 15 20 25 30 35 40 45 50
7 ATT 2 SPEED ATT2 level ATT2 limit rate % 0 5 10 15 20 25 30 35 40 45 50
8 SWITCH BACK REG. Switchback regeneration level Switchback regeneration intensity % 0 10 20 30 40 50 60 70 80 90 100
9 ACCELERATOR OFF REG Accelerator-off regeneration level Accelerator-off regeneration intensity % 0 10 20 30 40 50 60 70 80 90 100
# ANTI ROLL BACK Anti-rollback regeneration level Anti-rollback regeneration intensity % 0 10 20 30 40 50 60 70 80 90 100

PARAMETER 1
# ACCELERATOR STAGE Accelerator stage level Accelerator stage mode numbers – 0 1 2 3 4 5 6 7 8 9 10
# SPEED ALARM OUTPUT SPEED Speed alarm output level Speed at which alarm output is stared km/h 1 2 3 4 5 6 7 8 9
with speed alarm output mode enabled
# REACH SPEED Reach level Reach limit rate % 0 5 10 15 20 25 30 35 40 45 50
# STEERING SSC SPEED Steering SSC level Lower speed limit when Steering SSC is activated. km/h 1 2 3 4 5 6 7 8 9
# STEERING LEVEL Steering level Steering sensitivity adjustment – 1 2 3 4 5
#
Traveling/load handling speed limiter,
2 TRAVEL AND LOAD SPEED LIMIT Flag setting (1)-2 to -4 – SL L N H
based on fork height and load weight
3 S MODE LIMIT Flag setting (3)-1 S mode disabled – OFF ON
4 NEUTRAL SAFTY LOCK PUMP LEV. Flag setting (3)-3 Load handling neutral safety lock enabled – OFF ON
5 OPPOSITE STEERING Flag setting (2)-1 Opposite steering enabled – OFF ON

- 61 -
6 PUMP ACCELERATION MODE Flag setting (2)-2 to -4 Lift acceleration mode: High, N, Low, Super Low – SL L N H
7 INTERLOCK SW DITECTION TIME Interlock switch detection time The time required for interlock switch OFF to be enabled sec 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 0: OFF is immediately enabled.
8 INTERLOCK SW OFF DELAY TIME Interlock switch OFF delay time The reset delay time after interlock switch OFF is detected sec 0 2 4 6 8 10 15 20 30 60 ∞ 0: Disabled
Truck speed limit rate during Truck speed limit rate when
9 SPEED LIMIT RATE % 0 10 20 30 40 50 60 70 80 90 100 0: The truck stops.
overdischarge overdischarge alarm signal is output
# PUMP UNIT LIMIT RATE Load handling limit rate during overdischarge Lift limit rate when overdischarge alarm signal is input % 0 10 20 30 40 50 60 70 80 90 100 100: No limit
# SLIP CONTROL Flag setting (4) Slip control mode: N, N, L, SL – SL L N H
discharge indicator level at Each number corresponds to each level
1 OVER DISCHARGE LEVEL Overdischarge output level Battery – 1 2 3 4 5 6 7 8 9 10 displayed on the battery discharge indicator
which overdischarge signal is output
The time required for auto power-off In increments of 1 minute
2 AUTO POWER OFF TIME Auto power-off time 0 1-14 15 16-90 Function disabled at 0.
function to be enabled
to be displayed on the hour
3 AH METER DISPLAY Hour meter display switchover Items TOTAL DRIVE PUMP WORK TRAVEL RATE
meter when key switch is turned ON
4 HEATER Heater ON/OFF control Not settable OFF ON Fixed to OFF
5 SPEED MODE LIMIT Fixed in the “turtle” mode Locked with the turtle switch pressed OFF ON
6 PASSWORD SET Password setting Password mode ON/OFF OFF ON
7 BATTERY CAPACITY Battery capacity Battery capacity selection 360 370 420 470 500 560 600 620 700 775 Set at the factory

PARAMETER 3
8 CONTRAST Contrast adjustment 1-44 45 46-90
0 and 3 to 10: No setting
9 CYLINDER Load meter constants Specify if a load meter (option) is fitted. 0 1 2 3-10 1: 7E3 and 7E4t, 2: 7E5 and 7E6
# MAST HEIGHT Mast height setting Fork height and load weight limit control 5000 5500 6000 6500 7000 7500 8000 8500
# CONTROL LOAD Load control setting Fork height and load weight limit control 100 200 300 400 500 600 700 800
# INT BUZZER TIME No. of times the interlock buzzer sounds No. of times the buzzer rings 1 2 3 4 5 6 7 8 9 10 10: Unlimited
4. PARAMETER SETTING
4. PARAMETER SETTING

4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING

(1) PARAMETER 1 - No. 4 “Lift inching level”
If the controller’s CN1-2 terminal is turned ON, the upper limit of the duty factor during lifting
operations will be adjusted to the setting of this parameter, thus slowing down the lifting speed.
Note: A standard harness does not have any wiring going to this terminal.

(2) PARAMETER 1 - No. 11 “Accelerator stage level”

You can specify the accelerator power curve to be used. The speed command to the motor varies
according to the angle at which the accelerator lever is tilted away from the neutral position.
N: Refers to a NICHIYU type power curve. Speed commands start being output at a lever angle of 6
degrees. The maximum speed command is output at a lever angle of 40 degrees.
T: Refers to a TOYOTA type power curve. Speed commands start being output at a lever angle of 4
degrees. The maximum speed command is output at a lever angle of 30 degrees.
The larger the number that follows the N or T, the steeper the curve.
Accelerator power curve

Level 0
Level 1
Level 2
Level 3
Speed command

Levels 4, 5 and 6
Levels 7 and 8
Levels 9 and 10

Accelerator voltage [V]

(3) PARAMETER 1 - No. 14 “Steering SSC level”

This function starts to gradually limit the truck speed when the wheel angle reaches 30 degrees left
or right from the center position. It eventually limits the truck speed to a preset level when the wheel
angle reaches 60 degrees.

Steering SSC characteristics for new FRSB models

FRSB 1-ton trucks

Steering wheel direction Counterclockwise (left turn) Clockwise (right turn)
Wheel angle [degrees] -95 -60 -45 -30 0 30 45 60 95
Steering SSC voltage [V] 0.99 1.54 1.78 2.02 2.50 2.98 3.22 3.46 4.01

- 62 -
 4. PARAMETER SETTING

FRSB 2-ton trucks

Steering wheel direction Counterclockwise (left turn) Clockwise (right turn)
Wheel angle [degrees] -95 -60 -45 -30 0 30 45 60 95
Steering SSC voltage [V] 0.80 1.43 1.70 1.96 2.50 3.04 3.30 3.57 4.20

The range, from the angle at which the speed limit function starts to the angle at which the maximum speed limit is imposed, is controlled
by a ramp function.
(When the steering wheel is turned counterclockwise from -30 to -60 degrees; clockwise from 30 to 60 degrees.)
The ramp angle is constant at each level.
The speed limit function is not engaged if the command speed (corresponding to the amount of accelerator pedal effort) is less than the
steering SSC speed that would be imposed as a limit.

(4) PARAMETER 1 – No. 15 “Steering level”

Steering Level 5 gives you the most sensitive steering response, while Steering Level 1 is the least
sensitive.

(5) PARAMETER 2 – No. 2 “Traveling and hydraulic system speed limiter, based on fork height
and load weight”
See the relevant section.

(6) PARAMETER 2 - No. 9 “Truck speed limit rate during overdischarge”

PARAMETER 2 - No. 10 “Pump motor speed limit rate during overdischarge”
PARAMETER 3 - No. 1 “Overdischarge output level”
If the battery discharge indicator level drops to a preset level, an overdischarge signal (GO 84) will
be output from the LCD panel to the controller, thus limiting the drive motor and pump motor speeds.
Use PARAMETER 3 – No.1 to set the battery discharge indicator level at which the overdischarge
signal is output. You can specify the speed limit rates (percentage) in PARAMETER 2 - Nos. 9 and 10.
Accelerator pedal effort
Command speed corresponding Steering SSC characteristics
to accelerator pedal effort
Speed limits [km/h]

Steering wheel turned Wheel angle Steering wheel turned

counterclockwise (left turn) [°] clockwise (right turn)

Factory setting: LV5

(8) PARAMETER 3 - No. 7 “Battery capacity”

Select the capacity of the battery installed in your truck. This setting will be used as the basis of the
calculations for the fuel consumption display.
This setting must be changed if the battery capacity is changed from the factory default setting.
If the capacity of the battery installed in your truck is not in the list, select the closest one.

- 63 -
4. PARAMETER SETTING

(9) PARAMETER 3 – No. 11 “Steering stability control when loaded”

When a lift truck is carrying a load, it reduces the weight on the drive wheels, which can make the
steering too sensitive.
Depending on the load weight, the truck will automatically adjust the steering sensitivity by
reducing the steering response output.

Traveling and hydraulic system speed limiter, based on fork height and load weight

Load handling speed limit control

Lift switch ON Speed limit function is activated.
Lift switch OFF No speed limit control

Truck speed limit control

Without a load With a load
Lift switch OFF No limit control No limit control
Mode N
Lift switch ON No limit control No limit control
Lift switch OFF No limit control No limit control
Mode H
Lift switch ON Limited to 6 km/h Limited to 4 km/h
Lift switch OFF No limit control No limit control
Mode L
Lift switch ON Limited to 5 km/h Limited to 3 km/h
Lift switch OFF No limit control No limit control
Mode SL
Lift switch ON Limited 4 km/h Limited to 2 km/h

- 64 -
 4. PARAMETER SETTING

4.6 SETTING THE PASSWORDS

Two different passwords can be specified. These two passwords are factory set to “0000”.

KEY PAD
Low-speed travel (turtle) button Switches between PASSWORD SETUP screens 1 and 2
(when pressed at the same time as the S.P.E button).

S.P.E button Switches between PASSWORD SETUP screens 1 and 2

(when pressed at the same time as the Low-Speed Travel
button).

Mode button Selects the digit to enter. Confirms the entered password.

+ button
- button Increases or decreases the number.

PASSWORD INPUT SCREEN

Set “PARAMETER 3 - No.6 PASSWORD SET” to ON.
For details on the setup procedure, refer to the PARAM-
ETER SETTING section.

Turn on the key switch to display the PASSWORD screen

(shown on the left).
Press and hold the low-speed travel (turtle) button and S.P.E
button at the same time.

Press and hold

these buttons
PASSWORD simultaneously.
SETUP SCREEN 1
PASSWORD SETUP screen 1 (shown on the left) will be
displayed.
To display PASSWORD SETUP screen 2, press and hold
the low-speed travel (turtle) button and S.P.E button simul-
taneously while PASSWORD SETUP screen 1 is being
displayed.
Use these buttons to toggle between PASSWORD SETUP
screens 1 and 2.

The zero on the screen indicates the selected digit.

The selected digit moves to the right each time the Mode
Press and hold button is pressed.
these buttons Pressing the Mode button when the selected digit is the last
simultaneously. digit on the right will select the digit on the far left.
PASSWORD Select a number (0 to 9) for each digit by pressing the “+”
button or the “–“ button.
SETUP SCREEN 2
After entering one or two 4-digit passwords, press and hold
the Mode button for 3 at least 3 seconds. Your password (or
passwords) will be confirmed and the Main screen will be
displayed.

You cannot specify “0000” as a valid password.

If you press and hold the Mode button when “0000” is dis-
played on PASSWORD SETUP screen 1, an error will be
displayed.
If you conform “0000” as your second password by press-
ing and holding the Mode button on PASSWORD SETUP
screen 2, the use of a second password will be canceled
and only the first password you specified on PASSWORD
SETUP screen 1 will be valid.

- 65 -
4. PARAMETER SETTING

NOTE

- 66 -
 5. DESCRIPTION OF THE FUNCTIONS

5. DESCRIPTION OF THE FUNCTIONS

(1) Travel speed control while turning (Steering SSC)
• Controls the motor speed so that the truck does not exceed the travel speed specified according
to the angle of the drive wheels (steering potentiometer voltage) while turning.
<Speed control for each steering angle range>
(a) Drive wheel steering angle 0 to 30 degrees: Maximum speed
(b) Drive wheel steering angle 30 to 60 degrees: The larger steering angle, the higher deceleration
rate.
(c) Drive wheel steering angle exceeding 60 degrees: As specified by the steering SSC level
setting

(2) Automatic torque boost control

• Automatically increases the torque output when the system detects that the truck is running
uphill or that a large load is applied.
<Activation conditions>
• All of the following conditions must apply: accelerator opening level: 90% or more, torque
command: 80% or more, and motor speed: 1,000 rpm or less
<When the boost control is active>
• The maximum torque in each travel mode (S, P, E) x 1.05
<Deactivation conditions>
• Any of the following conditions must be met: torque boost has been applied for 2 seconds, the
current torque is less than the maximum torque, or the motor speed of 1,000 rpm or higher

(3) Traveling neutral interlock

• Prevents the truck from starting suddenly when the key switch is turned ON while the F/R
switch is not in neutral.
<Activation conditions>
• The accelerator pedal or the F/R switch is not in neutral when the key switch is turned ON.
<Truck operation>
• The truck cannot be moved.
<Deactivation conditions>
• Accelerator lever OFF (in neutral)

(4) Load-handling neutral interlock

• Prevents the load handling system from starting suddenly when the key switch is turned ON
while a load handling lever is operated.
< Activation conditions>
• A load handling command (potentiometer switch) is present when the key switch is turned ON.
<Truck operation>
• Load handling system disabled
<Deactivation conditions>
• Load handling command (potentiometer switch) OFF

- 67 -
5. DESCRIPTION OF THE FUNCTIONS

(5) Interlock control

• The interlock system is a safety device that cuts off the power to the drive and load handling
circuits when the operator leaves the compartment during operation. This system helps prevent
an accident from happening if the operator is not in the correct driving position or if the controls
are moved unintentionally when no one is in the operator’s compartment.
<Activation conditions>
(a) When the key switch is turned ON:
• The interlock switch is OFF when the key switch is turned ON.
(b) After the key switch is turned ON:
• A predetermined period of interlock OFF time has passed while the key switch is ON
<Truck operation>
(a) The truck won’t travel and the load handling system won’t work. However, the EPS will
function.
(b) The truck won’t travel and the load handling system won’t work. However, the EPS will
function.
<Deactivation conditions>
(a) The key switch is turned ON while the interlock switch is ON
(b) Travel system: Accelerator pedal OFF and interlock switch ON
Load handling system: Load handling command OFF and interlock switch ON

(6) Traveling and hydraulic system speed limiter, based on fork heigh and load weight
• Limits the travel, reach, and side-shifting speeds, according to the fork height and the weight of
the load.
<Activation conditions>
• The lift switch is on (the rear cylinders are raised) and a load of 500 kg or more is being
carried.
• The lift switch is on (the rear cylinders are raised).
<Truck operation>
• Truck speed is limited.
• The reach and side-shifting speeds are limited.
<Deactivation conditions>
• The lift switch is turned off or the load is removed.
• The lift switch is turned off.

(7) Regenerative control

(a) Switchback regeneration
• Regenerative braking occurs during switchback operations when the F/R switch is resersed.
<Activation conditions>
See the table below.
(b) Braking regeneration
• The degree of regeneration varies with the amount of brake pedal effort.
< Activation conditions>
See the table below.
(c) Accelerator neutral regeneration (Accelerator-off regeneration)
• Regenerative braking occurs when the accelerator pedal is brought to the neutral position
while the truck is traveling.
< Activation conditions>
See the table below.

- 68 -
 5. DESCRIPTION OF THE FUNCTIONS

Powering and regenerating conditions for new FRSB models

Input conditions Controller drive mode
Accelerator ON OFF
Brake potentiometer signal 0 Output 0 Output
The direction of travel is
reversed while the accelerator - - Not reversed Reversed Not reversed Reversed
is OFF (Zero truck speed is
detected)
F/R switch Truck status
Braking Accelerator-off Anti-roll OFF
Forward travel Powering Braking regeneration
regeneration regeneration regeneration
Braking
F Stopped Powering Output OFF Braking regeneration
regeneration
Switchback Braking Accelerator-off Anti-roll OFF
Reverse travel Braking regeneration
regeneration regeneration regeneration regeneration
The seat switch
is on after the Braking
N Output OFF Output OFF Output OFF Braking regeneration
key switch is regeneration
turned on.
Switchback Braking Accelerator-off Anti-roll OFF
Forward travel Braking regeneration
regeneration regeneration regeneration regeneration
Braking
R Stopped Powering regeneration Output OFF Braking regeneration

Braking Accelerator-off Anti-roll OFF

Reverse travel Powering Braking regeneration
regeneration regeneration regeneration

(8) Front brake control (option)

• Functions in conjunction with the brake switch to control the front brakes. This helps reduce
truck skids and braking distances while braking.
<Activation conditions>
• The brake pedal is released while the truck is traveling.
<Deactivation conditions>
• The truck stops.
• The brake switch is turned ON.
• The truck is put in a travel mode.

- 69 -
5. DESCRIPTION OF THE FUNCTIONS

NOTE

- 70 -
 6. ELECTRIC WIRING

6. ELECTRIC WIRING
Red
Red
Red
Green Red
Green Red
Green Red
Green Red
Green Red
Green Red
Green Red
Green
Green Yellow
Green Yellow
Green Yellow
Yellow
Blue Yellow
Blue Yellow
Blue
Blue White
Blue White
Blue
Green
Blue

White-Green
White-Red

FOR PUMP/EPS MOTOR

THERMISTOR (THP)
POWER MODULE
THERMISTOR (THD)
FOR DRIVE MOTOR

Embedded in
POWER MODULE

Embedded in TMDV White-Blue TMPX

Purple
Gray Gray
Black
Black
Black
Black
DRIVE MOTOR
DRIVE BOARD

Red-Blue
Red-Black
Gray
Gray
Black

PUMP MOTOR
Orange
Black
Gray

Red-Black
Gray
DRIVE MOTOR

Orange
Gray
MAIN CONTACTOR

Yellow-Red
Red-Yellow
Yellow-Red
Yellow-Green

Yellow-Red
Note: No fans are provided for low-floor type vehicles.

White

EPS MOTOR
N1 (See Note)

P1 (See Note)

Gray
Blue

PUMP/PS MOTOR DRIVE BOARD

MAIN CPU BOARD
Black
MAIN CPU BOARD

Green
SUB CPU BOARD

Red-Black
Red
FAN 1
FAN 2

Fig. 6.1 Controller Internal Wiring (1) Fig. 6.2 Controller Internal Wiring (2)

- 71 -
6. ELECTRIC WIRING

to CONTROLLER, CN21 to CONTROLLER, CN5 to CONTROLLER, CN2 FUSE

10 1 1 8 1

YR YL YB P Gy - YB YG YL YR RW - W - - WG LW LY BG GB RW GW WL WBr
43 42 41 117 116 - 63 62 61 60 11 - 110 - - 16 29 31 28
187 93 186 54 53
LG LY WY WL LB - GB GY GW GR RL - GR GW GY WR WL G L - RB - - BR
115 114 168 179 180 - 67 66 65 64 100-2 - 82 81 83 17 162 161 160 - 32 - - 9-4

R 5-5
R 5-4

R 5-3
20 11 7 16 9

to CONTROLLER, to WIRE HARNESS,

CN4 UPPER COVER
to CONTROLLER,

F7 10A
F5 10A

F4 10A
to CONTROLLER (-) R CN3
146
to CONTROLLER, CN1 B
R
5-1
BR
9-5 to WIRE HARNESS,
to STEERING B(2
) 10 1
147 R
5-2
BR
9-6 VALVE SWITCH LIFT LOCK SOLENOID
- - - -
WHEEL SENSOR to WIRE HARNESS,
LW YR BG YW
- -
BrW WG
- -

140-F
RG

RB
102-F

100-F
95 94 96 35 91 135

RL
BEARING B HEAD GUARD GO
84
-
-
WR
175
LB
34
BrR
23
YL
22
-
-
YB
20
YG
21
-
-
YB
20
BrR
23
BrW
91
FIT (OPTION) P
117
Gy
68
20 11
BR YL YG
9-7 22 21
GR GW GR GY
64 65 105 106
to LIFT POTENTIOMETER

RG 102

RB 140
RL 100
GB GY WR B

R 5-6
R 5-1
R 5-2
67 66 107 2-5

BG YR LW
96 94 95
RW B
to STEERING WHEEL
RG GR G GY 11-2 2-3
102-2 105 104 106
SENSOR BEARING A YL
103
WR
107
WBr
53
WL
54 to PRESSURE SENSOR

LW BG
192 190
YR YL
WBr
60 61 191
YB YG LB WL YG
63 62 180 179 208
WBr WB Gy
97 98 68 B 2-1

to WIRE HARNESS, RW 11-3

RB - RELAY WB 98
140-3 -
- RB RL RG RW WY B 2-2
LY
- 140-1 100 102 11-1 168
114
RY G W B Gy
101 104 110-1 2-4 116-1 OPTIONAL ELECTRICAL
to WIRE HARNESS, COMPONENTS
BRAKE (RIGHT)
(OPTION) RB -
140-2
LG
-
- to HORN to PS MOTOR FAN
115 - RL
100-1
BR - BG GW GY (for FRSB20/25 only) to PS
9 - 190 81 83
to DRIVE MOTOR to DRIVE MOTOR
to WIRE HARNESS,
RY
101
YG
208
WBr
191
LW
192
GR
82
GO
84 MOTOR SPEED SENSOR THERMO SENSOR
BRAKE (LEFT) YL
B B 2-11
(OPTION) to WIRE HARNESS, 103
2
R GW RW
LCD PANEL RW 11-5
146 28 31 to ELECTROMAGNETIC WG
16
WR
17

B
GB
29
RB
32 BRAKE
147 Gy
- WR BR 116
- 175 9-3 RB
140

to STEERING
BY
37
RY
36 POTENTIOMETER
Y G
38 39

SHORT COUPLER
to LASER MARKER
(OPTION) RW 11-4 YR YL YB
RG 102-1 to FAN 43 42 41

B 2-7 LB - B 2-8
WBr 97 34 -
B 2-6 - -
- -
BR -
OPTION 9 -

to SEAT SWITCH

BR WG G
9-2 135 39
RY BY Y
36 37 38
W Br RW YW L Br BR
110 131 11 35 160 131 9-1
LY LW BG WL G
93 187 186 162 161
to WIRE HARNESS,
to BATTERY SWITCH MAST
to WIRE HARNESS,
FLOOR BOARD

Fig. 6.3 Wire Harness, Frame

- 72 -
 6. ELECTRIC WIRING

to WIRE HARNESS, FRAME

WBr
LB
180

97
WB
WL
179

98
YG
208
Gy
68
RB

RY
140

101
1 8
10

RL
1

100
- - -

G
104
YB BR YW WG Gy
- - - - - - - - - - - - - 196 9-1 79 76 80
- - - - - - - - - -

RG
102
W
110
L - - - - Y W WL
RY - - - - - - YG - - - - - -
174 78 77 75
101 - - - - - - 208 - -

RW

B
2
11
9 16
11 20

WY
168
Gy
116
to CN1-1
to CN5
1 1
BR - - -
BG WY W WB GO GR
9 - - -
190 224 226 228 84 82
RL - - -

RW
LW WBr WG WL GY GW

11-4
100 - - - 191 225 227
192 83 81
5
to CN8

RG

to VARISTOR
7
to CN1-2

102-4
OPTION

B
2-4
Y WG WL

RG
75

G
76

102-1
104
78

to FLASHER UNIT
WL WY W

RG

YR
102-5

12
227 224 226 YW W Gy
79 77 80

RB 140-1
WG - WB to SWITCH PANEL

to RELAY, RK

B
2-5
-
-
225 - 228

RW

B
11-3

Gy 116
to MONITOR

WY 168
RL 100-1
L 174

B 2-3
YR 12

to RELAY, PO
RY 101-1
YB 196

RG

WB 98-1
102-3

RW
97
WBr

11-1
-
B 2-2
to RELAY, RF

WL 113
to KEY SWITCH

WBr 97-1
OPTION

RY
101
-
-
RW

LB
180
11-2

YG
RL

208
100
to RELAY, BB
GY GW BG - BR RL
83 81 190 - 9 100

WB
RG
102

98
to RELAY, RB
GO GR LW WBr YG RY
84 82 192 191 208 101

RW

WL
179
11
to WIRE HARNESS, FRAME

to LIFT LOCK REGISTER

WL
RG

113
102-2
W
110
B
2-1

RB 140

Gy 68
Fig. 6.4 Wire Harness, LCD Panel Fig. 6.5 Wire Harness, Center Cover

- 73 -
6. ELECTRIC WIRING

ATT TILT
LIFT
YL 22
BR
to WIRE HARNESS, BrW 91
9-3
YB 20
FRAME
BR REACH
BrW - YB 9-2
91 - 20 BR
9-1 YG 21
YG YL BR
21 22 9

BR 9

Fig. 6.6 Wire Harness, Battery Switch Fig. 6.9 Wire Harness, Valve Switch

to BRAKE SWITCH
to ACCELERATOR to WIRE HARNESS, to HEAD LIGHT to TURN SIGNAL
NC
POTENTIOMETER FRAME (LEFT) LIGHT (LEFT)
COM
to BRAKE POTENTIOMETER BG LY LW B 2-3 GY 106 to HEAD LIGHT
W 110 186 93 187 GY GR (RIGHT)
106 105
L G WL RW 11 to WIRE HARNESS, FRAME B WR
160 161 162
2 107
WR 107-1 B 2-2 WR 107
L YW RW Br W
160
G
35
WL
11
BG
131
LW
110
LY
B 2-1
161 162 186 187 93

to FOOT SWITCH GR 105

B2

Br YW TURN SIGNAL LIGHT

131 35 (RIGHT)

Fig. 6.7 Wire Harness, Brake Switch Fig. 6.10 Wire Harness, Brake (Right)

to LIGHTING SWITCH
RG WR to HORN SWITCH
to SWITCH 102 107
to WIRE HARNESS,
to WIRE HARNESS, FRAME FRAME
W Br YL 103 RG 102-1
135 9
G W Br GY G GR RG
39 135 9-2 106 104 105 102
Y B R to TURN SIGNAL WL WBr WR YL
38 37 36
SWITCH (OPTION) 54 53 107 103

R B
36 37
GY G GR
G Y 106 104 105
39 38

to LASER MARKER
(OPTION)
WBr WL
53 54 to F/R SWITCH

Fig. 6.8 Wire Harness, Head Guard Fig. 6.11 Wire Harness, Brake (Left)

- 74 -
 6. ELECTRIC WIRING

HEAD LAMP CONTROLLER BATTERY

TURN SIGNAL (L.H.) TURN DISCONNECTING HEAD LAMP
LIGHTING SIGNAL SWITCH (R.H.) TURN SIGNAL
LAMP (L.H.)
SWITCH SWITCH LAMP (R.H.)
CN4 CN3

F3
2P 4P N.C
W W DW DV DU N.O
YG SOL.
COM
BR LIFT LOCK W W
B B
SIDE SIFT B B
GY B R W WR W WL
+ N.C LIFT GY B

2P
YB
B WR N.O POTENTIO
BR
CN21 2P 3P COM METER WR B
F/R

F1
STEERING WHEEL SW TILT
ENCODER(A)
N.C
N.O
YL FAN
F2
-
PB BR
B PA COM RW P

+
HORN PRESSURE
REACH

3P
4P N.C SWITCH 2P SENSOR
YL BR

F5
F7

F4
+ N.O COM
BrW
N.O
RG COM N.C B B
STEERING WHEEL
ENCODER(B) CN5 CN2 CN1 LIFT DOWN BACK

+
4P

3P
BUZZER

6P
MD 8P
4P
WB R

B B
4P

BRAKE L.H. BRAKE R.H.

RB R

LY L
R RB 4P
RB RK RF SWITCH PANEL ASS'Y
10P 6P (CONTROL)
L LG 4P 4P 4P

LCD PANEL

12P 16P
20P
CN5

-1
CN1
-2
CN8
8P

FLAS BATTERY
㧝㧟㧣
HER BB PO LOCK OPTION
6P
㧳
㨅
11-1 SWITCH
UNIT 4P 6P
(VARISTOR) 3P B RG FORWARD
RB RB
CHIME
Gy Gy
PC

㧳㨥
㧝㧟㧤
6P

WBr R
WL
R.W.L SPL

COM
SWITCH SWITCH

N.O
B

N.C
B
RL
3P

RW KEY B B
WB

W
Br
RY SWITCH
YR YR
OPTION
B HORN
R W R W
WY WL

B B
12P 2P YL
2P 2P

WG WR B

B B

SPOT
WG W LIGHT (4P)

B W
6P 2P
FRSB20/25 ONLY
REAR REAR
WORKING WORKING
LAMP LAMP BRAKE
SWITCH P RW

2P
(L.H) (R.H) ELECTRIC N.C
ACCELERATOR BRAKE W V U W
N.O
FLASH ASS'Y 10P 4P
LIGHT W
N.C B B B RW B
COM
N.O
3P

RW
COM
2P
2P SWITCH
BEARING
SENSOR LIFT SSC
2P B P
PA PF
W W W W W W
3P PUMP
U1 V1 W1 MOTOR SEAT
YR B WY B WY B BRAKE EPS SW.
3P

DRIVE
POT. MOTOR MOTOR

FOOT STEERING POT.

FAN
SWITCH 2P

Fig. 6.12 Wiring Diagram

- 75 -
 HORN YL 103 HORN SW
6. ELECTRIC WIRING

HEAD LAMP R.H. WR 107 HEAD LAMP SW

(40W)

Y 99
HEAD LAMP L.H.

RS
(40W)

TURN SIGNAL GR 105 FLASHER UNIT

LAMP R.H.(25W)
G104

TURN SIGNAL
LAMP L.H.(25W) GY 106

FORWARD CHIME WBr 97

RF
BACK BUZZER WB 98

BB
STEERING 1(V) CN21-11
BACK-UP LAMP GR 64
WHEEL 3(-) CN21-14
(25W) GB 67
ENCODER 2(A) CN21-12
GW 65
AT BBR (A) 4(B) CN21-13
GY 66
REVOLVING
LIGHT YR 12
AT STEERING 1(V) CN21-1
YR 60
KEY SW ON WHEEL 3(-) CN21-4

RK
2(A)
YB 63 CN21-2
ENCODER
4(B)
YL 61 CN21-3
5V

(B)
YG 62

W 110
CN5-4

RB
BRAKE SW
STOP LAMP WL 113 Gy116
SOL CN21-6
(15W)

RB
BRAKE (DRIVE)
SPOT LIGHT WG 111 SPL SW
(25W) LY 114
SOL CN21-19
FRONT
REAR WORKING WY 108 RWL SW
BRAKE R.H.
LIGHT (40W) LG 115
SOL CN21-20
FRONT
BRAKE L.H.
15
10

40W
30W

SOL
P 117 CN21-7
LIFT LOCK
Gy 69 Gy 68

RK
WY 168 CN21-18
RS

B 2
BR 9
LB 180
RF

CN21-16

WL 179
BB

CN21-17

CN8࡯1
5V

L 174

CN1-1-5
CN1-1-9 CN1࡯1࡯1

̪1
R 5
RXD
CN3࡯1
GW 81 TXD
CN1࡯2-12 CN5-9 CN3࡯3
GR 82 T.GND T.GND BATTERY
CN1࡯2-6 CN5-10
GY 83 RXD TXD DISCONNECTING SW
CN1࡯2-11 CN5-8
YB 196 GO 84 LOW VOLTAGE WARNING P
CN1-1-4 CN1࡯2࡯5 CN1-20

+12V
YG 197 CN1-1-11 WBr 53
CN2-1

OPTION
(INPUT˜3)
Y 198 CN1-1-3 CN1-1࡯8
Gy 80 F/R POT. WL 54
COM
CN2-2
YW 79 PB4 CN2-9
CN1࡯1࡯6
S1

BG 190 (UP) BrW 91

CONTROLLER

- 76 -
CN1-2-1 CN1-4
LW 192 CN1-2-7 LIFT DOWN
GW 191 Y 78 PB5 YL 22
S2

CN1-2-8 CN1࡯1࡯14 CN1-15

(DOWN)
F3(40A)

F1(225A)
F2(225A)

SENSOR PRESSURE REACH

YB 20 CN1-13
CN1࡯1࡯7
WG 76 PB7 TILT
S3

(MODE) WG 16
(CONTROL)

CN5࡯1 DM
WY 224 CN1-2-2 WR 17
CN5࡯7 THERMO SENSOR
SWITCH PANEL ASS'Y

WG 225 CN1࡯1࡯15 W 77 PB6 YG 21

S4

CN1-2-9 CN1-12

Fig. 6.13 Circuit Diagram

W 226 CN1-2-3
(S/P/E SIDE
WL 227 SELECT) SIFT DU
CN1-2-10

MONITOR
WB 228 WL 75 PB8 DV
CN1-2-4 CN1࡯1࡯16
S5
DIM

(SPEED
CONTROL) CN1-16 DW
Br 131 YW 35 CN1-7
BATTERY SW FOOT SW GW 28
CN5࡯13 CN2࡯3 1(V)
WG 135 DM REV.
CN1-3 CN2࡯5 GB 29 3(-) BEARING
MAST SSC1 CN2࡯4 RW 31 2(A) SENSOR
CN5࡯14 CN1-1 CN2࡯12 RB 32 4(B)

CN1-11
CN5࡯15
LB 34
LCD PANEL ASS'Y

CN1-17
SEAT
SW PA
CN5࡯5

WR 175 CN1-18
CN5࡯16 PM
THERMO PF
PM

CN5࡯4
YB 41 CN21-8
YR 43 CN21-10
+5V

CN5࡯11 STEER POT. YL 42 CN21-9

SENSOR

DETECTION
PM BRUSH

BG 96
WHEEL ANGLE

CN1-8
L 174

LW 95 CN1-10
LIFT POT. YR 94 CN1-9
YG 208
CN5࡯18
PO
̪1

BG 186 CN2-6
LW 187 CN2-8
ACCEL POT. LY 93 CN2-7
CN5࡯8
W 162 CN2-14
L 160
PSM

R 146 B 147
EFFORT

CN2-16
BRAKE POT. G 161
CN2-15
DETECTION
BRAKE PADAL

RW 11
MDࠦࠗ࡞౉㔚

CN5-6
CN8࡯5 CN5࡯12
CN8࡯6 CN3࡯2
CN8࡯4
CN8࡯8

CN3࡯4
PO
N

BATTERY 48V
F7
F4

F5

10A
10A
10A

RG 102

RB 140
RL 100
KEY SW
RY 101
No. SEB-7E3AE
Issued: December, 2010

MARKETING GROUP: 1-15-10, Kyomachi-bori, Nishi-ku, Osaka
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