ELECTRIC REACH TRUCKS FR-VI TRAINING TEXT TCM CORPORATIONCONTENTS . FEATURES . SPECIFICATION - OPERATION ON METER PANEL MOTOR - CONTROL PANEL . ACCELERATOR . MAIN CONTACTOR AND FUSE FAN . STEERING ANGLE POTENTIOMETER WOnNBTAwWNH- 10. ADJUSTMENT FOR CONTROLLER 10-1 EXPLANATION OF MPU BOARD 10-1 MAKING SURE AND ADJUSTING CONTROLLER 11. TROUBLESHOOTING 11-1 FUNCTION OF SELF-DEAGNOSIS 11-2 ERROR HISTORY MEMORY 12. CHARGER 12-1 RESOLUTION AND ASSEMBLE 12-2 INSPECTION AND REPLACEMENT 12-3 INSPECTION AFTER ASSEMBLED 12-4 TRANSFORMER TAP CHANGIN 13 BATTERY AND CHARGER 14. SYSTEM WIRING 21 23 25 27 30 30 31 32 38 67 1 83 86 88 89 75 91The TCM electric reach trucks, designed with new values. Introducing the new FR-VI series, the electric reach trucks equipped with new functions and performances to go beyond conventional reach trucks. With the new functions and improvements, we have upgraded traveling stability, operability, economical efficiency and operator comfort. TCM has redesigned this series based on customer requirements, which resulted in enhanced features. Improved traveling stability ‘*Auto-lock suspension control system ‘*Front whee! brakes AC drive control system ‘Improved frame rigidity Improved operator comfort ‘Wider operators compartment ist & hip support sy battery maintenance Cast stee! front whee! protector ‘Integrated dashboard design Improved operability ‘AC load handling control ‘system ©Small-diameter steering wheel ‘Reduced operating fatigue ‘Traction control system: Improved economical efficiency ‘Longer operating hours ‘Auto power off system ‘eTruck-mounted charger with timer (o3ton)Improved traveling stability and operability. Employs advanced functions to further evolve the electric reach trucks. Tmproved traveling Stability Auto-lock suspension control system ‘A controller constantly monitors the traveling and load han- dling concitions, and the rear wheel suspension is automat cally locked accoraingly Wider rear wheel tread ‘A wider rear wheel tread is adopted together with auto-lock ‘suspension con: wm Goa) 680mm trol system to ensure higher {% body stability.[ Front wheel brakes ] ‘The FR-I is equipped with electromagnetic-con- trolled front wheel brakes to ensure high level of brake performance when carying heavy Sec: loads and at slippery “ssc col locations. This. re- ‘duces stopping distance and prevents skid swaying during braking. Stopping tance slong and ski say Ena (Drive wneet brake ony) ‘Stopping stance Isshor ana stable braking. oth ave Wheel ana rent Whee! brakes} [ AC drive control system ] Drive whee slipping is controlled when starting or accelera: tion. This system automatically adjusts the traction of dive \whee! to the load and floor condition. AC motor also enables more precise con- trol than DC moter, _{ sostartup shock is j# \g=e=m=— creatly reduced. AC control also pro- vides regenerative braking when the accelerator lover is moved to the neu- tral while traveling, ing system. [ Improved frame rigidity ] ‘The frame structure was optimally designed using FEM(Finite Element Method) strength analy- sis and this improves the frame rigidity by 20% over conven: tional model AC load handling control system ‘AC motor enables more precise control and ensures top- class load handling performance. Lifting speed (1.5 ton mode!) Without iad ‘30m [ Small-diameter ] steering wheel The steering whee! is 95 mm smaller compared with con ventional model, and requires even less ‘operating strength, ‘and enhances ma: ewerabilly, [ Reduced operating fatigue ] Operating force of the control lever is 20% less than that ‘of conventional mod- fl. This significantly reduces operator fa- tigue during load hanating operation [ Traction control system ] When climbing slopes or got ting out of the cconcaves of the road, the con- troller automati- cally increases the traction of drive wheelA new appearance of electric reach trucks, with superior economical efficiency and operator comfort. "Improved economical efficiency [ Longer operating hours ] ‘The FR-W achieves &5 hours of operation per charge (Based on 85% work rato) by minimizing battery power con- ‘sumption during load handling operation. The tee types (ac cceleralor of, switen back, braking) of braking regeneration re tur the energy othe barry to lengtnen operating eure. [ Auto power off system ] ‘This systom wil automaticaly shutoff the main powar to save the battery power in ease the truck is nat oporated for 15 mi rules even if the main key svitchis "ON". The hour meter also ‘ops automaticaly to enable accurate operation management Truck-mounted charger with timer op%0n) This cha:ger enabies you to set the start time of charging beforehand. This enables the optimal charoing state when starting work after holcay Improved operator comfort Wider operators compartment ‘Changes inthe com pact AC motors layout ‘and compact design of the side cover en: larges operators com- partment. This com: partment is roomy ‘and provides ease of ‘access, Comparison of 18 tn mode eae ee |__ Floor depth Fioce width a FR-w |{ Waist & hip support ] The waist & hip support is optimal shape stud- ied from aD viewpoint and equip- edith ver tical slide adjustment by 30 mm, This design == firmly supports the operator's body, and enables work with a stable posture, { Easy battery maintenance ] Batteries are pulled forward, ut of the com. partment for easy access. This makes maintenance and replace. mont easy, uick and safe with ttle fat gue Cast steel front wheel protector “The edge of front wheel protector is rounded, and this provents reach-legs_ and pallets from scratching during reach retraction of pallets. ay Integrated dashboard design Functional dashboard panel is uniformly made and it pro- Vides better waterproofing property. Rubber boots are ap- plied for control levers to prevent splash of water and dust from going inside the panel (The pane! uses material with good recyciingetciency.) Turn signal with [ sett. -canceling ehonemeeal This mechanism detects steering wheel rotation and auto- matically cancels the turn signal OPTIONCOLOR Yellow A Ae eos and mprenisin po maybe eter. a)Teen rock wih ass gb ‘Auloiock suspension sysiom ‘Automate ant-sp contavcrve wneet Auta power of ‘Auto ruction coral Back-up buzzer lolojojojojo} 2O1An HTL 225An/SHAL b/plojololojolo| ‘250A. || D|> D> Y2AN/SHAL ‘S20Ah/SHR. >| > ‘STOARISHA b| > p| SODANSHA _4408n/SHR Bain charger(Truce-mounted) {ental greasing system (ChimetSuzzerorward raveing Battery fuel Clock wir calendar z ‘Hourmeter ‘Ovemeter ‘Saety monitor ‘Speedometer Documents chp “Bene power sieerng(EPS) Elecirormagnoic ton whe bake Head cht Newtal saely oyster (Operator tool kt (Overness quar Fear workin int ‘Acco-of brake lo] pJolo|ojojolojojoloojolo}o}p|o|p|p)p Brace Down-sope bavel ‘Swichrback '0\0/0/0}p ofololo|o}ojo|ojololojojo}pja}p| ‘Shock les eytnder (or VM) ‘Smalldia stg wnee! Spot ght ‘tational chargerwith MICON) ‘Stop & backup lamp “Turn aignal ights(vith sel-anceling) rail & hip suoporter lolo| >| >| polo! loop] >| plalojolololo|p|ojololojo|ojajojolojolojo|pjo}p loo} | >| plalojojofolo|p ajojojojo|olojajojojojojo| pjo}p loo >| >| pojojololalo|p jojojojojo|ojo|a|ojojolofo| pja}» loo] >] > |» Jalo}alola}o}>|alajojojojojo|ajojojojojo| pjo}r loo] p) >| pjolojojo| o|ofo|>|p|p|olalololo|o}p jojojojojojojojojolojojojo}ja}|»|> TSto A: Opteral pe i —_— eto Battery change stand) ‘Cenivalcloctratye rel system C-ug erive Tre Cod stage packagel-35C) Feo exinguishsn Fishery industry package Headight guard Mast guard Nonsmarking Tre (vemeac guarc canvas Polyuretnane Tire Rotating warning igh(Red, Yellow) Sido viow mirrors (ther on request eee ‘terative fork enaths| Fork extontone(Siooves) Load grabs Rotating clamps Side chiter ‘Wioe-ingerbar(or YM) ‘Wide view ul roe 2stage masi(VEM) ‘Wie view ul rae Setage maci(vFHM) Other on request‘STANDARD SPECIFICATIONS: Stand-up Rider Type - Electric Reach Trucks: Breronerce = eT a 755 a ons catey ea [om co a a Soe aes a snes Sra a a — = Seema ae aera [a fe ai Taare iba i oe rm fanostoad Sioa ae i se == om ge Stet ee 0 700 [ran =e 76 otrorsions& Weigh Overall tera ai fori om Te 2000, I 2a rT 2079, [2070 T2005, ana ‘e200 | 2225 2228 ot safe aa eee se on rh Penta aH t Bi Max. hight ok mwa’ | mm | waz0_ | 3820, 3620 | sexe ‘azo T4020, 3030 [4930 | 3830 [430 rama tenet Sars Sarno ae seonata0 tai aga oder] =e SD So Wreetinse Ce 15] es I 85 [tee [tse 1525, | 1901700] 1700, = = mE ae t 5 Fon (SEtaloewrteccton | mm |e 3 5 = 109 Sevrce waght [ah GT betery = yee —[1a7e [cao [ono | aan eso [eras [pian | gas —gare | pra] pen] am 1 a0 icine Mots & Garona & Dine oie = iow Canc | STOP] aves ee T asa Grewnacg [esse viene 0ST 1 Sov saan eee oe a eon — Seve a no conta bom er SS "eer eesaoe Tis Teesrogie dar re Wire 8 Sinang Sytem nereerbeneeh Teaver Trea Brie eae Soe oad aS I STs Bora ro os = ae t eT tant sa Sot To nboer soeEACH PART NAME AND FUNCTION ™@ INDICATOR PANEL Monitor dspiay Mode select switch foo4 3°44 . \/ 15 \ Blots mmm ese feet ECECONOMY> oorese EYTOTAL 83683. Sur EBS 3G-Oct SCREEN SELECTION BUTTONS If you runthe truck or operate the hydraulic controls when any of the above screen displayed, the display will return to the ba: screen. ®,° = fp Reserved charge sorech How to show the dslay page 26 Setup screen Refer to VARIOUS SETTING SPEED TRAVEL MODE in page 15. 9 SET TRAVEL ‘QuOMETER. «+ SET DISPLAY BRIGHTNESS {+ SET NEUTRAL REGENERATIVE FORCE, Press the@ button gp release within 3 seconds. Press the@ button (Date and time sereen Refer to VARIOUS SETTING over 3 seconds. + SET DATE, TIME AND DAY OF THE weeK)""" MODE in pore 18. see 'Refer to VARIOUS SETTING PRESS either of <| a> (MODE in page 12. or.Eleach PART NAME AND FUNCTION i MONITOR DISPLAY The forklift truck checks its own conditions and indicates the results via text and graphics on the LCD monitor E (Economy) 88888. BHR E (Economy) = % Gaui The safety monitor mark (@-40) show the function to explain. In fact, it doesn’t display state of the key switch ON.These marks blink only error. (Normally,it is not shown.) @ Battery discharge indicator The battery discharge indicator indicates the battery’s condition of charge. ‘ET CS ae Fully Battery charge | Battery charge Battery charge Battery charged evel 60% less than 20% less than 10% charge 0% F F F = - N > eS Ba JE E JE E When the battery charge If the level falls further to 10% level drops to 20% of the , one[RED] bar and the frame total capacity, the [GRE blink. EN] bars go out and the ‘two[RED] bars remain on. 10EACH PART NAME AND FUNCTION El Lift interrupt (Option) When all green segments are disappeared and two red segments are lit, the lit speed is reduced by hall At the same time," * Charge the battery * * message appears on the screen, When the truck is continued to use, only one red segment is started to flash and the lift function is interrupted. @ Slow speed mode monitor (Turtle mark) ‘When the turtle button is pushed, the turtle mark is indicated on the screen with the preset speed. @). Fork horizontal indicator (Option) This mark is indicated when the fork is horizontal and possible to use the laser pointer. @ Speed meter ‘The traveling speed is displayed on the scraen. © Reserve charge indication (Option) The reserved date and time to start charging the battery Is displayed. Refer the section of “Battery and charger" on FR-75 OPERATOR'S MANUAL or WORKSHOP MANUAL for detais @ Date and time (Calendar and clock) The current date and time are displayed. If the "2" button is pushed for more than 3 seconds, the display is Changed to the setting screen. Refer the page 30 for details W % Eedinectizgeline *Charge the battery 30-Oct(TH) ‘inking (RED autor so, 30-Oct(TH) antoesa E (Economy) 83, E (Economy) 28603, 0 snit a E (Economy) 30-Oct(TH) Fei & Hisiensteetient JEllcach PART NAME AND FUNCTION @ Hour meter The hour meter shows the total hours of turning on the key switch. (The actual operating hours can be displayed as option.) It is useful to know the total operating hours for the daily job management and scheduling of the periodical inspection. When pushing "<)" or ">" button, each individual hours for travel, hydraulic and total are displayed for 5 seconds, The normal screen and hour meter screen are changed by turn by pushing *<<]* or "(© * button, After 5 seconds, the normal screen is displayed. ‘The odometer can be displayed in the normat screen instead of hour meter. Refer the meter mode setting in the setting mode section. ACAUTION ‘The hour meter screen is returned to the normal screen even less than 5 seconds by operating traveling or hydraulic function. When the screen displays the odometer, the word of “TRAVEL’ is flashed while travelling, ® Safety monitor (for travel circuit) When fault is detected in the travel circuit, the travel icon flashes and the presumed defective part name is displayed. @© Safety monitor (for hydraulic circuit) When fault is detected in the hydraulic circuit, the hydraulic icon flashes and the presumed defective part name is displayed. @.Satety monitor (for steering circuit) ‘When fault is detected in the power steering circuit, the steering icon flashes and the presumed defective part name is displayed, 12 TTL '30-Oet CFD ‘After deplayed 5 sient SBSBOSBin-— TOTAL TRAVELING | ‘TOTAL TRAVELING DISTANCE: fesseiead E (Economy) 85298.84n aular 20 ciated z B10 : FUSE (Main) 30-Oct CTH) _ nit? Hidugiiused Got TRANSISTOR \, 34 ib 90-Oct (THY BED scoonds, Shift sttematiacally to basteEACH PART NAME AND FUNCTION @.Safety monitor (for battery electrolyte level) (for GS battery only) ‘When the electrolyte level is lower than the specific level, the battery icon flashes and ' Add purified water*" message is displayed. (2. Safety monitor (for overloading) (Option) When overioaded, the toad icon flashes and " Over load. Reduce load * message is displayed on the screen. (@EBNOTE When [name of a damaged part] or " REFILL FORK OIL :k" is lit, please contact the your local Nichiyu dealer. @®.Safety monitor (for hydraulic oil) (Option) It the hydraulic ol level is low, the icon is flashed and the message of * *Add lubrication oil** is displayed. The hydraulic oil level sensor detects the oil level for 2 seconds after turning on the key switch. So, the mast must be retracted completely and fork must be lowered on the ground before turning on the key switch. Otherwise, the warning message of "REFILL HYDRAULIC OIL." may be displayed even the quantity of oil is normal, @ Service icon The service icon wars the fault of the forklift truck to an operator. If any faults are detected, the spanner mark is flashed and the presumed defective part name is displayed. I some problems are occurred at the same time, each part name is scrolied alternatively for every 5 seconds, 13 Add purified waters, = fa 30 — Oct (TH) nat 2ZO_} ¢ Belaetzeleat ‘Over load. Reduce, 30 2 __20.= Oct (THD aut saatereiennberust ‘Add lubrication olf, 20 = ocr cnn aunt F iitaiescrienmiiont SES 90 ove crip" Hil'!S9Elleach PART NAME AND FUNCTION If any of the following errors occurs, the travel, hydraulic and EPS circuits will be interlocked B11: Transistor U (travel) B12: Transistor V (travel) B13: Transistor W (travel) C21: Transistor U (hydraulic) G22: Transistor V (hydraulic) 623: Transistor W (hydraulic) ‘Travel system clectric current error® Hydraulic system electric current error* The truck has made an emergency stop.* © While any error message is being indicated all the selection buttons @. @, <, Bare disabled (you cannot display the charge re— serve screen and others). @®.Mode select button Change the screen to each mode by pushing these buttons. © Slow speed mode button The slow speed mode is activates by pushing this button. Norma} traveling mode (When the siow speed button is off) The slow speed mode indicator (@) is not displayed. Slow speed mode (when the slow speed button is on) The turtle icon and preset speed are displayed on the screen. if the value of the slow speed mode is preset, the maximum traveling speed can be changed in the Normal mode and slow speed mode by pushing the turtle button. 14 Slow speed made button ‘Mode select bution ‘When the slow speed button i off ‘Ture mare's not cisplayed) cero) 8332 ‘When the slow speed bution is on ‘Turtle marks displayed)EACH PART NAME AND FUNCTION Eel [1] Slow speed setting [2] Travel mode setting [3] Meter mode setting [4] Display mode setting [5] Regeneration (Neutral) mode setting [6] How to set the date and time ACAUTION: © These settings are invalid while traveling or depressing the brake pedal. If traveling or hydraulic operation is done while setting, the display is returned to the normal screen immediately. When pushing the "@®)" button, the mode selection screen is displayed. If pushing the "3" button again, the normal screen is displayed again. GEANOTE When setting the mode of next [1] to [5] , each button works as below. o"<<|" and "[>" buttons : Move the cursor to select the value. ¢"(@®" button : Move the cursor to the next item. ©)" button : Back the cursor to the previous item, [1] Slow speed setting This mode sets the limited maximum travelling speed under the slow speed mode. ‘Make sure the turtle button is pushed and the turtle icon is flashed. Then, push *<=)" or "(@>* button to set the speed. ‘The maximum speed can be set to 7 steps of 2, 3, 4, 5, 6,7 and 8kmin. After setting, push "(R)" button to move the cursor to the travel mode setting. If push the "(5)" button, the normal screen is displayed. a = SPEED kwh * | ee i Solect low travel opeod by IB button no oer) rapa s [DTRAVEL CONTROL MODE SEREGTION 15Elleach PART NAME AND FUNCTION [2] Travel mode setting This screen is used to set the travel mode. Make sure that the current traveling mode indication is flashed. Push “ <=)" or * [£>" to select the mode. After selection, push "(R)" button to move the cursor to the meter mode setting. If pushing the "€=)" button, the cursor is moved to the slow speed mode setting The traveling mode can be set to the next three modes. E (ECONOMY) This mode is convenient for the slow speed inching. ‘This mode saves the battery energy consumption also. N (NORMAL) This is the normal traveling mode. The quick acceleration and smooth inching can be realized. P (POWER) This is the most powerful mode for acceleration. [3] Meter mode setting The hour meter or odometer can be selected by this mode on the normal screen. When the cursor is located on the meter mode, "HR" (hour meter) or *km* (odometer) can be selected by pushing "<<}* or ">" button. After selection, push "{R)" button to move the cursor to the display mode. If pushing the "€)" button, the cursor is réturned to the traveling mode area. The display is switched from the normal screen to the meter mode screen by pushing " <=)" or "(=> button. The meter mode screen has 2 kinds. Refer below for details. 16 TRAVEL MODE SELECTION SCREEN SELECT TRAVEL MODE BY a (ooler 8 fas] Bro SELECT HOUR METER, TRAVEL DISTAND HOUR METER AND ODOMETER SELECTION SCREEN. © Binkgusienortneny NETER = 7 SELEGT “METER MODE BY <{> BUTTON roe wir ©) Fines [JO DISPLAY BRIGHTNESS SETTING SCREENEACH PART NAME AND FUNCTION El | ‘SELECTING HOUR METER DISPLAYING PRESENT KEY SWITOH ON TIME METER MODE CONFIRMATION SCREEN ‘SELECTING ODOMETER "TRAVEL DISTANCE, TREE CTRAUEL™ Seese3.1 ant > Hise (ee > Gininstaatan | rove, gegence. TRAVEL 59955.5in— 33333. Se) TOTAL USING HYD HOURS TOTAL TRAVELING HouRs ‘TOTAL TRAVELING DISTANCE ———————— \ Traveling or Hydraulic. [4] Display mode setting ‘This mede sets the brightness ofthe screen, Make sure that the cursor is located on the brightness setting area. Push the * =) * button to select the biighiness forthe best. Itcan be selected 7 steps (rom 0 0) Alter setting, push "(R)" bution to get the coast mode setting scree. W pushing the “* button, the cursors returned to the view (contrast) setting. Refer the table bolow for the brightnoss sottings. [BRIGHTNESS (Intensity of backiigh) | 1 7 <= Dark Bright 7 = = HD. a ea Bessae l TRRUEL 983588, 810 TOTAL HOUR METE ora. uss nD TOTAL TRAvEuNG Hours! ‘TOTAL TRAVELING DISTANCE- ‘TOTAL HOUR MEE! 1% It will be raturn to basic eereen coon even if within 5 seconde, when operate ienarien ff ? BRIGHTNESS: SELECT BRIGHTNESS BY <> BUTTON! pase S) Preis] DITO NEUTRAL REGENERATIVE FORGE SETTING ‘SORENJEACH PART NAME AND FUNCTION Sot neutral regerative force display [5] Regeneration (Neutral) mode setting This mode can be set the regenerative braking force when releasing the accelerator pedel while travelling Make sure that the REGEN(NEUTRAL) mode screen is cisplayed. Then push *<)* or * [#>* button to select the strength, ‘SET NEUTRAL REGENERATIVE FORGE BY I> ‘The braking strength can be set to 4 steps of "NON" (No = braking), "LOW eos (Middle) and “tic ‘ [resale §) Fare] ‘TO BASIC SCREEN (EBNOTE| (‘itis set to "MID" (Middle) as detault. ) Alter setting, push *@®)" button to return to the normal screen. If pushing the *@)* button, the display mode setting screen is displayed. [6] How to set the date and When the *@)" button is pushed for more than 3 seconds, the date and time setting screen is displayed Push *@)* button to return to the normal screen. a SM arora 68888.80 EES 30-OctTH) AXCHUTION] [if traveling or hydraulic operation is done while setting, the display is returned to the normal screen immediately. GEBNOTE| { When setting the mode of next [1] to [6] , ‘each button works as below. "J" and "(2>" buttons : Move the cursor to select the value. #°@®" bution : Move the cursor to the next item. =)" button : Back the cursor to the previous 1. Set the year _ Make sure the cursor is located on the year area. etree Push" <=)" or *(#>" button to set the year. The year can B Gate eS CE SET “YEAR BY GD BUTTON be set from 2000 to 2998, After setting, push the " (®)* button to move the cursor to the month area, I push the " G3)" button, the normal screen is displayed. 18EACH PART NAME AND FUNCTION 2. Set the month Make sure the cursor is located on the month area. | Push "<<]" or "[3>" button to set the month. the month | Sle 30-oct () on1a#38 can be selected from 1 to 12. Bape 2003 } SET "MONT BY After setting, push "(R)" button for the date setting. If pushing " @ " button, the cursor is returned to the year area. 3. Set the date Make sure the cursor is located on the date area, push *<<]* or *(#>" button to set the date. The date can be set from 1 to 31. When setting the date, the day of the week is set automaticall After setting, push the "(R)" button to move the cursor to the AM/PM area. If pushing *@)* button, the cursor is returned to the month area. 4. Set the AM or PM Push the * <<)" or *[>" button to select the AM or PM. After setting, push the "(8)" button to move the cursor to the hour area If pushing " @) " button, the cursor is returned to the data area. 5. Set the hour Push the "<=]" or "(#>" button to set the hour. The hour can be set from 1 to 12, After setting, push the * (R)* button to move the cursor to the minute area. If pushing "@)* button, the cursor is returned to the AM or PM area. 19 anlar 8 fa [easier B Fa] PAGER E NIE ATE SH 30-0ct (TH) FES 2003 30-Oct (TH) 03 SET Te "BY <> waar PeEACH PART NAME AND FUNCTION 6. Set the minute Push the "" button to set the minute, The minute can be set from 00 t0 59. When pushing the " second is set to "00". ‘After setting the minute and push the button, the second is set to "00". ‘elf set the date and time, the reserve charge setting Is also renewed. 20 30-Oct (TH) mia 2003 — ssiedrsespeanbzs ome Ta Fer 30-Oct (TH) ani O?30 Eee eee “COMPLETE” |e displayed stimes wth BASIC SCREENHM motor ESRPOSITION AND EACH PART NAME [4-1-2] THE PARTS NAME OF PUMP MOTOR ‘This picture shows motor of FRIOH-18, 21Motor El [4-1-3. [THE PARTS NAME OF EPS MOTOR ‘©The main parts name of EPS motor Yone ASS ‘COVER (C), END [4-1-4] THE SPECIFICATION OF MOTOR DRIVE MOTOR ‘APPLICABLE MODEL TYPE NOTE FR10/13 AT26A1 2.6 kW, 15 V, 60 min FRIOH/13H,14/15/18 ATA3B2 4.9 KW, 30V, 60min FR20/25 AT50C2 5.0 kW, 30 V, 60 min * PUMP MOTOR ‘APPLICABLE MODEL TYPE NOTE FRIO/13 ‘AH6OA1D_ 15 V, 10 min FRIOH/13H, 14/15/18 "AH88B2D ‘8.8KW, 30V. 10min FR20/25 AH110B2D 11.0 kW, 30 V, 10 min. * EPS MOTOR APPLICABLE MODEL| P/N NOTE 0.15 kW, Do24 V FRIO/I3, S7410-01310 | 6.3 kW, O48 V) 37410-01460 _| 0.15 kW, DC24 V 37410-00890 _| 0.3 KW, DC48 V FRIOH/13H, 14-25 87410-01280 _| 0.3 KW, DC49 V 37410-01470 0.3 KW, DC48 V 22CONTROL PANEL RESOLUTION AND ASSEMBLE 5-1-1. RESOLUTION AND ASSEMBLE OF THE CONTROL PANEL Acamon| {@ Record connected position when you remove the lead line. © Pull out the battery plug. ‘© RESOLUTION AND ASSEMBLE OF THE CONTROL PANEL,CONTROL PANEL [5-1-2.|CAUTION OF ASSEMBLING * Use the turn prevention hole on reverse side of panel reinstall the each switch.(However, exclu— de the horn switch.) © The harness in the control panel does not come into right side of panel within 40mm. 24al ACCELERATOR RESOLUTION AND ASSEMBLE Acamon] [Pull out the battery plug before it works. 6-1-1. |RESOLUTION AND ASSEMBLE OF THE ACCELERATOR Apply LOCTITE a pemaa | WASHER (2) UApely LOCTITED Apply LOGTITE Note : Apply Shell Albania grease (RA) to both side of the washers (1) and to the spring side of the washers (2). 25AGCELARATOR [6-1-2] INSTALL LEVER © Match the direction of the sign (+) and the lever that exists in the shaft of Potentiometer as shown in the figure below. © Install lever |6-1-3.] ADJUST POTENTIOMETER © Refer to the chapter of the TROUBLE SHOOTING for the adjustment of the potentiometer. 26MAIN CONTACTOR AND FUSE EGR RESOLUTION AND ASSEMBLE Acumon|( @ Record connected position when you remove the lead line. © Pull out the battery plug. [7-1-1 REPLACING, REINSTALLING MAIN CONTACTOR AND FUSE 1, Remove the roulett knob and remove the front cover. © Remove the front coverIEA main contactor AND FUSES 2, Remove the main contactor and fuse. @Remove the main contactor and lead line for the wiring. @Referring to the figure below and remove main contactor and fuse. REMOVE MAIN CONTACTOR AND FUSE, +4) The glace bor tube and fuse becomes theve for @ Miah performance truck: 400 Use (EF) OJ 6.4-7.4N+m {0.65-0.75 kgf + m} Use the bolt with main contactor %¥ Install main contactor and fuse in the reverse order of detatching. 28MAIN CONTAGTOR AND FUSES CHECK AND EXCHANGE A CAUTION] (* Record connecter position when you remove the lead line. * Pull out the battery plug. |7-2-1.]| CHECK AND EXCHANGE MAIN CONTACTOR @ Check contact areas for excessive wear © CHECKING MAIN CONTACTOR or burns , and if any defect is found, Zz replace the mi a new one. The main contactor assembly must be replaced with a A. CAUTION] | jew one every two year, even if appeare normal © TYPE OF MAINCONTACTOR contact assembly with "APPLICABLE MODEL | _NAMUPAGTURE'S TYPE | VOLTAGE, FRIOH/134. 1 FRiowt HR-ISPAA av Ne (© MAIN TERMANAL (4a) = [Trane ror on 9] {0.65-0.75 kat - m) ( :inairenna Torque @ Apply the tightening torque in a right picture about main terminal (M8). [6d-2-2.|Replacing fuse When replacement of any fuse is requir a new fuse of the same capacity and he mounting nut securely Use Capacity Traveling Fi 225A EPS F2 40.A Transformer 100 A Control unit F3 10A Electomagnetic brake| F4 10 A ‘Accessories FS 10A 3 The glass fiber tube increases 3.(High performance truck) 29EM FAN RESOLUTION AND ASSEMBLE 8-1-1 REMOVE AND INSTALL FAN * REMOVE FAN Comp. FGM sTEERING ANGLE POTENTIOMETER IES RESOLUTION AND ASSEMBLE e-1-1] REMOVE AND INSTALL POTENTIOMETER © REMOVE THE STEERING ANGLE POTENTIOMETER 9-1-2. |ADJUST POTENTIOMETER © Refer the chapter of the trouble shooting for the adjustment of potentiometer. 30TROUBLE SHOOTING GUIDEADJUSTMENT FOR CONTROLLER EXPLANATION OF MPU BOARD -| BASIC CONTROL BOARD CONSTRUCTION As shown in the figure below, the SICOS-AC uses the display board as the central point for connecting all other boards for the exchange of data. In addition, all control boards use a one-chip CPU (with flash ROM) as their main CPUs, so their ROM can not be removed. Travel Hydraulic board Display unit || | Switch board Travelcircuit [ t >| control CPU Gate board | Motor . {¢——— Hydrauli , iydraulic circurt Display board fq > onal cpu Ey Gate board)—>{ Motor ‘Microcomputer EPS control charger >) board 32ADJUSTMENT FOR CONTROLLER BIO TRAVEL, HYDRAULIC BOARD © This board controls the traction motor and the hydraulic motor, (est) Rotary switch for [DS1f: Dip switch tor truck mode! selection specification selection End of the board eno vr Controter Sas ramess | Pore 2 2f]2] connector tor [SE 3115 |__pemona’ computer oF Ale 4 . Als t Sons jons Ft cnr Jone Body hamess 3] DISPLAY BOARD ‘* This board controls both the data exchanged between the other boards and the display. Lights when the 7V power sourea Is normal lashes whio the GPU is on Buzzer IRS!) : Rotary switch for monitor selection Connector or flourscent monitor Connector for mode select switch Backup battory Body names ALCHITION| { The voltage of the battery apply the di isconnect the battery plug before wor lay board. 33‘ADJUSTMENT FOR CONTROLLER 0-1-4. ROTARY SWITCH LIST OF TRAVEL, HYDRAULIC BOARD The rotary switch[RS1] of travel & hydraulic board is used to select the truck model. When you change the board, match the truck model in following chart. ®RSI setting " TAEPLIGABLE WODELTOR AWAY Rst| ONMeTER PANE ‘sD Hach NAST [DEPLAMING MODE AFPLOABLE WODEY| NOTE Tt 1 |RAS-HL Ri Zain RATA SiR 7 7 7 [BALE CRIT i 3_[Ra0-4 | f ToIRAZO-REE RIOT RAR t 3 [R251 rT r ‘A IRSO-H FRa0-7 79K [FRGO-7H | 79L B [RAIO-H_t f ‘Model display on the meter panel is available to push “R” of the switch board for long time. 1 DIP SWITCH LIST OF TRAVEL, HYDRAULIC BOARD The Dip Switch [DS1] is used for the spec selection. Please refer to the chart below when you replace the travel, hydraulic board. ® SPEC DS1 SETTING LIST st SETTING ‘CONTENTS YESH FUNCTION {STANDARD THIGH FUNGTION TRUCK MODE 1 ise OFF: ‘ON 2 SPEC W OFF : excepr specw ON: specw 3 DATA OF DINETER| OFF : NORMAL ON 7 GORPULSION SELF ABST TO 4 ‘SUS Loo ‘OFF © NORMAL \WETHOUT sus LOCK %*) Spec W of FBRIOH — 13H set the DS1-2 (SPEC W) to “ON”. (HIGH FUNCTION TRUCK) iP SVATGH FOR SPEC SELECTIONADJUSTMENT FOR CONTROLLER ROTARY SWTCH LIST OF DISPLAY BOARD Tne rotary switch [RS1] on the display board is used to select the display and the adjustment shown in the following table. RS1 FUNCTION LIST FUNCTION NOTE Mnitoring OK Displayed at a key switch on Usual monitor Battery capacity, Speed, Hour meter, Error, Clock, Reserve charge Making sure hour meter Displyaing hour meter for total, travel,and [Charge reservation screen Specify starting charge [Correction for date, time Low-speed set up [Power mode set up Change-over hour meter,distance Correcting date,time Speed setting at turtle switch on Setting economy, normal, or powerful Setting change-over switching hour meter, distance lof usual monitor Brightness control of VFD BRIGHTNESS level (0-7) [Adjustment for neutral regenerative [force at neutral (Accel off) Others for making sure service set up 4 levels including OFF Making sure truck model, soft ware number, buzzer mode, rotarySW mode setting [Symbol set up Screen character, TRAVEL, HYD, STEER, BRAKE, OIL, LOAD Displaying truck model Plugging force set up Displaying truck model of traveljhydraulic board set 0-32 [Pbrake force set up 10-32 [Anti-slip set up NON LOW MID HIGH Lift limit of Low-speed travel }0-32(HIGH SPEED) : 0-4km/h Lift limit of Mid-speed travel [0-32(HIGH SPEED) : 48km/h. Lift limit of High-speed travel ]0-32(HIGH SPEED) : km/h Lift 1 speed }0-32(HIGH SPEED) : Micro 1st step Lift 2 speed Tilt speed 10-32(HIGH SPEED) : Micro 2nd step [O-32(HIGH SPEED) Reach speed [0-33(HIGH SPEED) [Attachment 1 speed }0-34(HIGH SPEED) |Attachment 2 speed 0~35(HIGH SPEED) [Switch displaying language 6 foreign languages Option set up Set up option Displaying voltage,current, temperature Displaying RAM&I/O data Error histry memory 1 Displaying latest 10 cases Error histry memory 2 ‘All errors that occurred in the past are recorded Battery voltage set up Set up the voltage in capacity meter standard Speed limit at turning 0-16 [AOS set up 1 Set up lift end, tit end and Others AOS set up 2 [Checking leverSW Memory initial [Clearing error histry Standard screen 2 No error display on the soreen of RSO, Displaying hour meter when happening the error 35ADJUSTMENT FOR CONTROLLER (10-1-7| OTHERS, FOR MAKING SURE SERVICE SET UP [SETTING SCREEN When you keep pushing the (®) button for three seconds or more,the following screen is displayed. Chav & it 15 20) PEE LL F ee he model that made set up | the travel & board by RS1 si displayed. lo ti ARN HEMT AUNIA ERIS SOFTWARE cue TFO30G E £30100), [Displaying the software ta 8 0 L2q400 ber for T(Travel), minal T8030 eo H(Hydrauli), ECEPS), i D(Display). (© SCREEN GR ERATE RCRD TROT BRUCK SET UP MODE: une it = iti POULT LL (tan nun onan nEatt fea FUNCTION ay BUZZER o - gWalrovany sw Orr Bilt jomgmcems @! ' 3 Bushing B> or @ Disconnect the battery plug. connector (green black) of detecting battery electrolyte line in the control unit, ® Measure the insulation resistance each case betw “chassis body side battery plug [+] and the chassis and between “chassis body side battery plug [-] and the chassis”. NOTE : Measurement should be performed after discharging condenser. Srmanta WAL 38ADJUSTMENT FOR CONTROLLER BIO 10-2-2. |ADJUSTING BATTERY VOLTAGE © Pull the battery out, disconnect the plug. Measure the battery voltage at the main terminal direct from the battery line appeared. It automatically changes on the display for 24V and for 48V by the model set up. Specific gravity of battery fluid * 125 or more (20°C) Use the digital tester that can measure 1/100V. DG (Direct Current) mode © Set up the rotary switch RS1 on display board “A”. @ When turning the key switch on, the following screen “ST SITO"A is displayed. @ Adjusting battery voltage screen Fm Fah 1a 1S 2 * [tii E] VOLTAGE (BATTERY ) R CHARGE py 18: BEI SET VALUE OF BATTERY VOLTAGE( BLINKING) @ Set up the battery voltage as well as the measured value. Set it up within 0.1V or less. © Set value increases when you push the > © Set value decreases when you push the] . 39HM sosustwent ror conTROLLER 10-2: MAKING SURE CURRENT DETECTOR [i[Makina suRE DRIVE MOTOR CURRENT (UNLOADED,LOCK) IU :Drive motor current for U-phase (Even the V-phase or W-phase is acceptable) Specific gravity of : 1.25 or more (20°C) battery electrolyte Clamp ammeter AC (Alternating current) mode Haass, M HNBESS, CONTROLLER sLacKwaTe| SUE sous sxsrea < TALE, 109 OOOO DRIVE MOTOR U-PHASE [UT lz VI ve Wt Wa foxs[onr} [exelons} Mt a Boerdcomp., MPU bal CONTROL UNIT 40ADJUSTMENT FOR CONTROLLER DISPLAY BOARD @ Set up the rotary switch RS1on display board to”7”. “f, Dro Spite Sar @ When turning the key switch on, the following screen “Ets is displayed. 8 When the TRV doesn't blink, let blink “TRV” the! SET UP. RSI TO "7" before press the < button. @ SCREEN OF VOLTAGE. GRRENT. ‘TEMPERATURE CONFIRMATION. F gm, Ohi i 2 * |AAVAN ONAN aN GG E FHYO/EPS/0SP mares] 7 BATT - soy MOTOR 1 opa HYDSEPS/OSP BOARD °c pune @ At the state of no current flow, make sure to display for the drive motor current (MOTOR) is 000A. ® Jack up the drive wheels then perform the following, Tn cave of unloaded curent Keep rotating the wheels at full acceleration. Tr eave of the lock carver Release the brake pedal, with the brake micro on, make strong the brake spring (as stop rotation) and being accelerated. A warninc When measuring, jack up drive whe: © Make sure the drive motor current (IU) displays to be allowable ++20A in the meter reading (MOTOR). 41ADJUSTMENT FOR CONTROLLER i MAKING SURE HYDRAULIC CURRENT IU ‘Hydraulic motor current for U-phase (Even the V-phase or W-phase is acceptable Specific gravity of : 1.25 or more (20°C) battery electrolyte Clamp ammeter AC (Alternating current) mode anaos system. —] ‘CURMP AAETER HYDRAULIG MOTOR U-PHASE —] eran 126: 0N0 jeri a 42ADJUSTMENT FOR CONTROLLER (© DISPLAY BOARD @ Set up the rotary switch RS1on display board to”7”. @ When turning key switch on, the following screen displayed. SET THE RSI TO "7" @ Press either @>or @ Set up rotary switch RS1 on display board to “2”. ear @When turning the key switch on, the following screen BOd is displayed. oe @Make sure correct the truck model is set up. out SET UP RSI TO @Press ® button on the display for 5seconds. @ The following screen is displayed. @Make sure the truck model. @After making it sure, press the (®) button agai © SCREEN FOR MAKING SURE TRUCK MODEL When the rotary switch RS1 on the travel & hydraulic board is set to “2”.) 44 ADJUSTMENT FOR CONTROLLER BIO @SET UPTRUCK MODEL: Set the truck model by rotary switch on the travel & hydraulic board. ® RSILIST (travel & hydraulic board) I—BRAND RS! BRT Re 0_[RI-H 1 [RAQ-H (TCM: fa 2_[R13-H__}RA13-H 3_|RI4-H 7 | 7 _|ERTS=TH 6 7 8 |FR30-7 | 79K ay ERICSON eR ie pate B2t A essue a] 45ADJUSTMENT FOR CONTROLLER 10-2 ‘| SAFETY CIRCUIT FOR CONTROL (CONTACTOR TRIPPING) CHECK 1. Turn the key switch to OFF, and disconnect the battery plug. 2. Disconnect connectors of travel/hydraulic board (CN2 and CNA). tno >) [20 | t oy eel: Ni le | [ne t [po] Travel/hydraulic board ens | cne|_—| onz | cna! ontt fontz Disconnect CN2 and CN4 simultaneously. Do not travel or manipulate the hydraulic when only one end of CN2 or CN4 is disconnected. It may damage IGBT module. 3. Connect the battery plug and turn the key switch on. 4. Operate the accelerator, and make sure an alarm sounds, main contactor trips, and the error messages ‘comes on as shown below. Transistor U (travel) Transistor V (travel) Transistor W (travel) : *Emergency stop* : *Turn off key switch.* 46ADJUSTMENT FoR CONTROLLER BIDI [10-2-6 [HYDRAULIC SETTING CHECK AND ADJUSTMENT | @ Set up the rotary switch RS1 on the display board ‘* DISPLAY BOARD to “4”. @ Turn the key switch ON and the following screen appears. @® Make sure whether the set values for each item are set as specified specification SET UPRSI TO “4” © Hydraulic speed set up screen =F am Gini 5 io 1s 20 4 (MUM ARAD MERE GEER ESET THIT SPEEOCLIF TS HOMME TRAVEL O- A ksh Bein cette Hiaos| TRAVEL 8 tinth 26 | trial mses opocd achive speed O thru 4 km/h. (0-32) (N o| 16 =F i Fhnth 5 io 15 20) 7 TMA NRAEN MAUD GTERE Hen BBE @ Prose the & oJ . and set the hydraulic limited speed at drive Speed 4 thru 8 knvh. (0-32) E[LIMIT SPEEODCLIFTS WA TRAMEL O- dkmih 32 ian] TRAYEL a- 8 kmh Blinking set value 1 =e oS er i - lini value iar] TRAMEL B— kit cee ee aa at oe iM 10: BBY hydraulic limited speed at drive 5 Septet mera ea 5 E SP eee CHrD ) RCHRRERIL LET 1 BREF 4 8 — srinuing set vate HiecaslL IF T2 32 REACH i4 © proce the © ar. an oat te 1” RSS tei ®; {fe (NEXT PAGE) 47HIG) aowustwent For conTROLLER (FROM BEFORE PAGE) a =| 4 |NUUUE NARA DOUBRRBERE =I SPEED CHYD CHORAL ET 1 TILT 148 if isogfL 1 F TS BB Re RCH tt te an cot tho oF tS rere ted grag ive Sar om ivh Se =| “4 |ONNAANAEN ARBRE ERBEE =e SPEEDCHYO ) CURA CETL 14 TILT Piiheiotincine oot valve '* Proce the © or . and « Wigeae|L IF T2 32 REACH 14) Riedie unite apne ok ive CRLF TI i4 1a Blinking sot valuo ncaa | FT 2 j Ae Prove tha © or, and cot tha Fycraule lined eposd at crive Spoed for REACH (O22) = itn acta SPEED acre HYD a! 2 ite ear a 1 Beak: a Blinking set value © Press the © or) . and set the hydraulic limited speed at drive J, sped for ATT! (0-32) | Blinking set value # Press the D or. and sot the w= hydraulic limited speed at drive speed for ATT2(0-32) @ Press @ button or the @ button, blink the set value that want to change. @When pressing §& button, the set value is increased. @When pressing A set value according to the type of the attach ment is as follows. Type of attachment HYD ATTA set value SF 09 48ADJUSTMENT FOR CONTROLLER MIO 10-2-7. | DESCENDING REGENERATION CHECK @ Park the truck with the brake pedal at the suitable slop. @Make sure to slow down the slope by Ikm/h -£0.5 at free. SWITCH BACK (PLUGGING/REGENERATIVE) BRAKING FORCE ADJUSTMENT © Flat ground, unladen, and full speed © Specific gravity of the battery electrolyte : more than 1.25 at 20°C Set up the rotary switch RS1 on the display board to “3”. * DISPLAY BOARD AT Sue Sake PS SET UP RSI TO “3 @ When turning the key switch on, the following screen is displayed © Screen of strength level for plugging and brake STRENGTH PLUGGING BRAKE 12 SET VALUE FOR PLUGGING STRENGTH ceunacne) ® Make sure the “PLUGGING” is blinking. eS If “PLUGGING” is not blinked, press button. @When pressing (# button, the braking force becomes strong. @When pressing <) button, the braking force becomes strong. 49HI) awustment For conTROLLER 10-2-9.] REGENERATIVE BRAKING FORCE CHECK AND ADJUSTMENT © Cancel the neutral (released accelerator) regeneration. ea ee =| 5 (NUNDRDNERR RARER DRGER SS le[ REGENCHEUTRAL } WOM Lowe wine HIGH @ Travel forward at a moderate speed and return the accelerator lever to the neutral position. @ Lightly depress the brake pedal. @® Check if a light braking force (regenerative braking) is applied. ‘© DISPLAY BIARD © Set rotary switch RS1 on the display board to "3". 507, Yak ae @Turn the key switch ON and the following screen appears. SET RSI TO "3" @ SCREEN FOR SET UP STRENGTH OF PLUGGING AND BRAKE STRENGTH PLUGGING BRAKE @When pressing @ button, set value for “BRAKE” is blinked. @When pressing (> button, the braking becomes strong. ®When pressing <) button, the braking becomes weak. 50ADJUSTMENT FOR CONTROLLER MO {10-2-10. |ANTI-SLIP (FOR HIGH PERFORMANCE TRUCK)| * Only when you select the high performance mode, “ANTI SLIP” appears. @ Set up the rotary wsitch RS1 on the display board DISPLAY BOARD to “3”. ‘oy Saye sarees ii SET UP RSI TO "3" @ Turn the key switch ON and the following screen ‘appears. SSF em Ohh Sg © Ee STRENGTH aaa PLUGGING 32 Ht a:8B| BRAKE 12 Fm Ok Sto is aa ae ANTI-SLIP é asa NON‘ LOW? EMS HIGH & 3g ~ @ Press the ® button to display the "ANTI SLIP" screen. @Press the <} or button to set the slippage sensitivity. 51HG) adwustwent For conTROLLER FORONT WHEEL BRAKE (FOR HIGH PERFORMANCE TRUCK) @ Tum the key switch ON. ¢ Jack up a front wheel! and turn it with hand in the forward (reverse) direction. . @ Make sure that the brake is applied and the front wheel is locked. ® Check for both front wheels. 110-2-12. | MAKING SURE THE AUTO LOCK SUSPENTION © Puta load on the lift with the forks extended and move up and down the lif. @ Make sure that the drive wheel is locked on the truck ‘body by the lock cylinder. @ Check that no air enters the lock cylinder. '® When the air enters, the drive is not locked completely and it feels loose. 52ADJUSTMENT FoR CONTROLLER BIO 10-2-13.] SAFETY MONITOR SYMBOL CHECK AND ADJUSTMENT © Set rotary switch RS1 on the display board to "1". * DISPLAY BOARD @Turn the key switch ON and the following screen Alle, appears. sans @ Make sure it is correctly set with the truck specification. ooh SET UP RSI TO “1” (© SCREEN FOR MONITORING SYMBOL SET UP OSSILE TO CHANGE (BLINKING) F ity, Ghiv‘h ® I HAE ANE Te 4 tema {HYD Bg i ene BY Fa {sveen, fy e F/ i ‘parr Gia on : i = itn NEAT EAER EEA i =e SVHEOL fonake #OHARE co fig’ ow {LOAD ia on ' 53HI) adwustwent For conTROLLER @ Press either the (®) or ©) button to move the flashing icon to the iter you want to change. @ Press the > button to turn the item ON. @ Press the <} button to turn the item OFF, @ Turn the key switch OFF and return rotary switch RS1 t0"0". : ® Turn the key on again. The symbol indicating that the monitoring symbol setting screen is set to ON is displayed. Fmckvh § io 15 NOTE] ( When the display board is reset STEER are automatically turned ON. 54 * DISPLAY BOARD 507 Spe oaeke *eRY RETURN RSI TO “0”ADJUSTMENT FOR CONTROLLE! [10-2-14]DISPLAY LANGUAGE CHECK AND ADJUSTMENT] @ Set rotary switch RS1 on the display board to "5". DISPLAY BOARD 0 @Turn the key switch ON and the following screen & appears. @.Cheek if the display language is set to your preference. ‘SET UPTHE RSI TO “5” @ LANGUAGE OF DISPLAY SETTING SCREEN. ‘SET LANGUAGE (BLINGNG) Press either the [> or J button to select your preferred language. 55ADJUSTMENT FOR CONTROLLER 10-2-15. [OPTIONAL SETTING CHECK AND ADJUSTMENT @ Set rotary switch RS1 on the display board to "6 @ Turn the key switch ON and the following screen appears. ® Cheek if the opti © OPTIONAL SETTING SCREEN ions are set to your preferences. POSSIBLE TO CHANGE ON/OFF (BLINCING) hay & 1 15 20] QOUERAWOOO OREO SEES j IE OPTION ; RERBRGR PET LOCK ON | PliamlSPEED LIMIT On i F gm Chev Sai i 6 [ORSON GHRRD HREGRREBRE wieBe|POWER HODE i F ge 2 ; E OPTION : Batata 0S OG on OFF keh & Io is 20 PUTT F om. kav & io HAUUG REE F a0 fav 1o 15 20] ft HAURGTEREM RHODE RGRRE N i le DPTIO 4 Y RHA OUR WE TER ie HisagSPEED SWITCH ff 2 56 1620]: BRUEREGR | i E OPT IOH i | BEMGRa]C HAR GER ore ig | Ki-ajTILT STOP oH aoe © DISPLAY BOARD 607, s 2, & Ca m SET UPRSI TO “6”,OPTION SET MODE paral NOTE ADJUSTMENT FOR CONTROLLER MIO LIFT LOCK’ DISCHARGE FT Lock] OFF _| Tell is locked by one "FED BAR of tho battory SPEED LIMIT [HIGH LIFT HEIGHT [OFF] Ns mengeny tional Wie vate Trane SEATSWITCH | WITH SEAT SWITCH | OFF | Fixed OFF, for FB FINGERTIP | WITH FINGER TIP OFF | Easiped vith finger tip system hydro lover truck AOS WITH AOS OFF | AOS function installed truck POWER MODE | POSSE ToGHNGE | ON | Fixed on, for FB (Not set power mode) CHARGER | ROSSILETORESERVE | ON | rex auplay the reservation urge setting sree TILT STOP TEROMEOERS STO? |_OFF_| aro stor runcrion mSTALLED TRUGK 1: TIME DURING KEY SMITGH ON 2: TIME DURING WORKING HOUR METER 1 1 (OPERATING HRS FOR MOTOR) ‘SMTCHING DISPLAY (ENHER IS AVAILABLE TO COUNT Use the standard turtle switch ‘SPEED SWITCH 1 1 (EBNOTE| { All modes on standard forklifts other than POWER MODE are set to OFF. An optional mode can only be turned ON if that option has been installed on the forklift. @Press ® button or ) button, blink the item that want to change. @When press the (button, switch to”ON” or “2”. @ When press the button, switch to” OFF” or “1”. 57HQ) aowustwent For conTROLLER [10-2-16.[HOUR METER WORKING CHECK © Connect the following connector Connector terminal GEBNOTE]) Location: next to the charger control device in @® Make sure that the hourglass symbol on the display flashes when the hydraulic or travel controls are operated. After make sure, pull out the connector until A caval delivering it. the motor room Wire colors : Blue/black and black/white E (Economy) 939999. 9 uncey SANDGLASS (BLINKING) [eee Bonne al crm ACTUAL work i wan ov 10-2-17. JAUTO POWER OFF FUNCTION WORKING CHECK © Turn the key switch ON. @ Make sure that the key turns off automatically after about 15 minutes. 58ADJUSTMENT FOR CONTROLLER 10-2-18.| BATTERY ELECTROLYTE LEVEL WORKING CHECK @ Remove the battery electrolyte level sensor and make an electrolyte - level drop status. @Make sure +*Add purified water* flow right-to-left on the display @ BATTERY FLUID LEVEL =|" my. ah & 20 18 = ot 1g 15 (EARUE RNR ERURSEB BORE ==lc[*Add purified water* | Ie CHARGE early ei ia:as] 30-Octi (TU) ani 10-2-19.| TURN SIGNAL LAMP WORKING CHECK @ When the turn signal lever is operated, make sure that the turn signal lamp flashes and at the same time a buzzer sounds. @® When the turn signal lever is operated in one direction and the steering wheel is turned in the other direction within 12 seconds, make sure that the turn signal lamp goes off. However, if-the steering wheel is not turned within 12 seconds, the turn signal will go off automatically. [1-220 HYDRAULIC OIL LEVEL (OPTIONAL) WORKING CHECK © Fully lif-up the lift and turn the key switch to ON. @ Make sure *Add lubric: ion oil* on the display. « sunscanonon oni F gm. Oknh & 10 1s a z +> (AMBEOHNOBDEOQHA ATEBA E|*Add lubrication oitt, : 30-Oct (TU) ant oa i FLOW RIGHT TO LEFT BLINKING 59HQ) sdwustment ror conTROLLeR 10-2-21. [OVERLOAD (OPTIONAL) WORKING CHECK © Fully lift-up the fork and make a relief valve work. @ Make sure *Overload.Reduce load* flow from right to left onthe display. © OVERLOAD (OPTION) FLOW RIGHT-TOLEFT BLINKING |!0-2-22.| TRAVEL INHIBITOR (OPTIONAL) WORKING CHECK @.Connect [-lwire (Black,White) with connector[CN5-2 PIN] on the travel|hydraulic board. (Refer to “3-1.SYSTEM WIRING”) @ Make sure not running even if you operate the accelerator lever. COOLING FAN WORKING CHECK @ Make sure that the cooling fan is running at a high speed while in the traveling or hydraulic operation, or when the temperature in the control unit is 50 : or higher. @® While travel and hydraulic operation are stopped, make sure that the cooling fan stops when the temperature inside the control unit is 35: or less, and that it operates at low speed when the temperature inside the control unit is 40: or higher. (The cooling fan will operate at high speed when the temperature is 50: or higher.) (On FBR 10 series, the cooling fan will operate when key SW is turned on) 60ADJUSTMENT FOR CONTROLLER MIO 10-2-24. | LIFT LOCK AT OVER DISCHARGE (OPTION) @Set rotary switch RS1 on the display board to "6" # DISPLAY BOARD @ Turn the key switch ON. Ye @Set "LIFT LOCK” mode to "ON". Spates Refer to “1-2-15 MAKE SURE AND ADJUST OPTION See SET”. Be SET UPRSI TO “6”, © OPTION SETTING SCREEN SET TO “ON” (BLINKING) 10 MiaaSPEEO LIMIT Wna@ ON @ Turn the key switch OFF and return the rotary switch RS1 to "0". © Connect a 40 - 46V power supply to the battery plug. © Turn the key on again. @Measure the battery capacity meter light [RED], and flows *Recharge battery* flows right to left on the display board. ‘© DISPLAY BOARD RETURN RSI TO “0” The lift speed is decelerated to 50% in the above mentioned (two [RED]). One “RED” blinks and “Recharge battery” is displayed continuously and lift stops. (Especially, it is not necessary to confirm.) 61HI) sovustwent For conTROLLER 1-2-25. ADJUST TURNING DECELATION (OPTION) < @ Set the rotary switch RS1 on the display board to “B”. HOW TO ADJUST> @ DISPLAY BOARD. a Sef Se her ays @When you turn on the key switch, the following SET RSI TO "B”. screen is displayed. © SETTING SCREEN FOR LIMITED TRAVELING SPEED SET VALUE @Press the ® or <), and adjust set value (0-16km/h) © When you press the & button, the set value increases. When you press the © Put it into the state to turn steering wheel until end either right and left @ Operate an accelerator lever. @ Make sure the speed is limited, and is not accelerated. 62ADJUSTMENT FOR CONTROLLER 1-2-27.| ACCELERATOR POTENTIOMETER ADJUSTMENT ] @Set the rotary switch RS1 on the display board to “8”. © DISPLAY BOARD 827 23. So oes Ets ® When you turn on the key switch, the following screen is displayed. SET RS1 TO “8”. TMH VDFeEPs ose ADRRESS L OFFO ke @Press the ©, ® , & or J button, set to”1/0”, “TRV”,"WO012”. @ Loosen and adjust the screw on the accelerator potentiometer to set "DATA* to 200H +20H (01E0 - 6220) with the accelerator in the neutral position 38 The lever angle to disable the neutral switch should be ‘within 8 - 12° for both forward and backward directions. @ 1/0 check mode ee =| 5 |WERRURNDERUBODAGBRGR | =| 7 010/0000000111100000 IE AMY + ree HYD/EPS/OSP Ba] Be aa] ADRRESS = @B12 speero9c990 1000100000 = POTENTIO METER FOR ACCELERATOR corre! @ Provide 5 v power supply to the accelerator potentiometer ® Unplug the connector and insert the voltage [ measuring adaptor. re ® Measure the votage ofthe white cord by the tester. Lack @ Loosen and adjust the screw on the accelerator potentiometer to set output voltage to 2.5 0.1 V with the accelerator in the neutral position. 63HI) acwustwent For conTROLLER 10-2-28. | STEERING ANGLE POTENTIOMETER ADJUSTMENT, @Set the rotary switch RS1 on the display board to “8”. DISPLAY BOARD. £0 ee SXeES rte @ When you turn on the key switch, the following screen J is displayed. ‘SET RS1 TO "6" Hie:eay ADRRESS Lo OFFO © Pross ©, ®, &, or to select “vO", “TAV", and “WO0t6*. ® Loosen and adjust the screw on the steering angle potentiometer to set “DATA” to 200H + 10H (01FO 0210) with the steering wheel the drive mode. © 1/0 check mode DATA 01F0/0000000111110000 + HYD#EPS/OSP }000001000010000 w aeie | [700 ‘omRour, TESTER Provide 5 V power supply to.the steering angle potentiometer. @® Unplug the connector and insert the voltage measuring adaptor. @®Measure the voltage of the yellow/blue cord by the tester. @®Loosen and adjust the screw on the lift potentiometer to set output voitage to 2.5 + 0.15 V with the steering wheel in the drive mode.ADJUSTMENT FOR CONTROLLER MO 10—2-29. |TYRE DIAMETER DATA ADJUSTMENT (EBNOTE| (No setting is required for a new truck with standard tyres, ) Follow the directions below for diameter automatic adjustment after replacing tyres. (RBNOTE| ( The dry, flat road surface with length of 10 m or more available is desired for diameter automatic adjustment. @ Turn off the key switch with the steering wheel in the © DIP SWITCH drive mode. BIT9=ON @ Turn on the bit 3 of the Dip switch on the travel/ hydraulic board. @ Tum on the key switch. @® Maintain the steering wheel for the truck to stay in a straight line and travel forward and backward with the fully pressed down accelerator for more than 1 minute with no sudden acceleration or braking. © Turn off the key switch and the bit-3 the Dip switch on. the travel/hydraulic board, * Battery front loading mode! only @ Set the fork height and tilt to the reference position and restore the fork to the original position. @ Step on the battery front loading lever up to the middle of the stroke (do not push alll the way). @ Make sure that travel or hydraulic operations cannot be performed @ Make sure the message.(#Scure battery unit*) |!0-2-31. |NO SUSPENSION LOCK SYSTEM © Turn on the bit 4 of the Dip switch on the main board. ‘© Check if the suspension is not locked when operating hydraulic. 65 10-2-30.|BATTERY FRONT LOADING (TRAVEL/HYDRAULIC LOCK) ]I absustwent For conTROLLER 10-2-32. IEQUIPED CHARGER r Suro T GEARGE PASSED How to check eee REror| {ED a tS“ fa Tena 1 | insert the charge plu or | x | x | x | x | x 2 | insert the power plug into the OFF olo|x|x power supply Press'the automatic | Wty | orf | O | x | x | x | x 3| charge button more than 5 seconds Anerson a{x |x fofa When the “AUTO LED” start blinking, < 4 you release “AUTO BUTTON” OFF 4 x x Qo Oo You finish cheking after blinking 5 | “AUTO LED”, it is after Iminute OFF x x x ALTA 36 seconds Q: ware SX! uci ore Gi: case oF uoemne 2! eunedne AUTOMATIC CHARGE LAMP (GREEN) y-——. Lighting this LED means: full charged AUTO MATIC CHARGE BUTTON—t wey ‘UP RESERVED CHARGE LAMP (GREEN) —} 4 RMBLED 3 EQUALIZING CHARGE LAMP (ORANGE) —H} CHARGE PASSAGE LED (GREEN 2 inrespone teste of cere 2 non total timer fe operated Ly ‘Case of full charged battery, checking timer after hydraulic oprerate for rew minute: © When CAUTION bilink the charge passage LED, don’t pull out the battery plug. Make sure the ohm between connect of charging and body. GHB nore! ( Revered charge will be not function if “charger” of option set turn off. 66ER TROUBLESHOOTING [EESEFUNCTION OF SELF-DIAGNOSIS 11-1-1.| DISPLAY If abnormalities or errors are detected with the self- diagnosis function, the following symbols and error messages will be displayed on the screen. ‘© The applicable abnormality and/or error symbol will flash on the display. ‘* The applicable error message will be displayed. (If muitipie abnormalities andlor errors are detected, the applicable error messages will be displayed in order.) il TRAVEL SYSTEM ERRORS Fgmcknh & ie is ai aU E[B 10> Fuse (travel) CHAE lewis. 8 ia:20| U1 ERROR MESSAGE 30-Oct (TU) att SN ane samo cmaven | | HYDRAULIC (INCLUDING AOS) SYSTEM ERRORS J—"BLINGING SERVICE(SPANNER) MARK — ERROR MESSAGE }— BLINKING SYMBOL (HYDRALLIG) J— BUNKING SERVICE(SPARNER) MARK Eel ERROR MESSAGE S'S UT — sunane sywsot (see) ==IE (20> Fuse (EPS) iB CRARGE bev 1B BB] BH 1a: 8| ant 30-Oct (TU) 67Hi tRousLesHooTinc i MULTIPLE ABNORMALITIES AND/OR ERRORS OTHER ERRORS F am, ah © = POWER BEING SAVED lever BB] Bu 18:88] 30-Oct (TU) an1O2 30 F gm, Okt 5 10 Fy = 73 (AHEM WONAT AVENE F/O 30> Fuse (EPS), mai An 30-Oct (TU) ¢ If any of the following errors occurs, the travel, hydraulic and EPS circuits will be iterlocked. B11: Transistor U (travel) B12: Transistor V (travel) B13: Transistor W (travel) C21: Transistor U (hydraulic) C22: Transistor V (hydraulic) C23: Transistor W (hydraulic) *Travel system electric current error* ‘Each button of ©, ®, ©, is invailid while the self diagnosis. (It is not possible to shift to the charge reservation screen.) ‘Don't display the self-diagnosis, while the rotary switch RS1 on the display board is set to “F”. (Shift to basic screen) ¢ When becoming error-free, returns to the basic screen. 68 BLINGING SERVICE(SPANNER) MARK }— ERROR MESSAGETROUBLESHOOTING BE |! 1-1-2. | ERROR MESSAGES AND DISPLAY CONDITIONS. Error | Error 5 e ‘cmription marke carer, |Pror Frror messas Desert Remarks 1 | AL | Ate Contactor (main) oar contact of contactor 2 | Az | AD Current sensor (battery) Defective current sensor (fr checking traveling and hydraulic unit eurent) 10 | B10 | BID: Fuse (oiain) Fuse is blown out 11 [Bi | Bit: Traasister U (raved) Traveling motor U phase IGBT error Emergency stop* Turn ofkey switch? 12 | B12 | 812: Transistor V (travel) Traveling motor V phase IGBT error ‘Emergency stop* Tum off key switeh:* 13, | B13 | BIS: Transisor Wdiravel) ‘Traveling motor W phase IGBT exror Emergency stop" Tum oft key switch? 14 | Bid | Bid: Curent sensor (travel) Current sensor (traveling motor U and V phases) error 1s | Bis | Bis: Accelerator ‘Acoolerator error "Tum off key switeh.* 20 | C20 21 | C21 | C21: Transistor U (hydrate) ‘Hydraulic motor U phase IGBT error Emergency sop” “Tum of key switeh* 22 | 22 | C22: Transistor V dhydeanlic) Hydraulic motor V phase IGBY error ‘Emergency stop* Turn oft key switch? 23° | C23. | C23: Transistor W (hydraulic) Hydraulic motor W phase IGBT error Emergency stop* | #Tum off key switeh.* 24 | C24 | C24: Curent sensor (aya) | Current sensor (hydraulic motor U and V phases) error 25 |.€25 | C28: Micro-switeh (iN) Life lever micro-switeh error 28 | €26 | C26: Potenttometer (mast) ‘Tilt and lin potentiometer error 30 | D30 | 30: Fuse EPS) EPS fuse blown out (Accelerator input reduced 12) 31 | D31 | D3: Torque sensor (EPS) EPS sensor error (avcelerstor input reduced | *Tum off key switch * 12) 32 | ps2 | 32; Transistor EPS) EPS's FET error “Tum of key switeh* (Accelerator input reduced 1/2) 40 | e40 | E40; Transistor (AOS valve) Valve current error Tum offkey switeh* 41 | E41 | Bal: Potentiometer(AOS ever) — | AOS control potentiometer enor 42 | E42 | E42: Rotary encoder (AOS lit) | Lift height encoder err 50 | P50 | P50: Fuse (front brake) Front wheel brake power supply fuse blown out St | p51 | FSi:Potentiometer (steering angle) | Steering angle detection potentiometer enor 69HEI tRouBLESHOOTING Error Enor oer, | Emer Enor message Description Remarks 60 | G60 | *Curent enor Battery current error *Emergeney stop Tur off key switch* 61 | G61 | + Traveling motor current errort | Traveling motor curent enor Tum offkey switeh.* 62 | G62 | Hycraulicmotorcurrent error* | Hydraulic motor eweremt error ‘Tum off key switeh.* 63 | G63 | *Traveling motor voltage error ‘Traveling motor voltage error 64 | G64 | *Hydrautie motor vokage emer | Hydraulic motor voltage enor 68 | Gos | *Powerbeing saved: Control board temperature error 66 | G6S | *Powerbeing saved” Traveling motor IGBT temperature eror 67 | Ges | *Power being saved Hydraulic motor IGBT temperature eror 68 | G68 | *Communication exror* Display communication error * Tum off key switch? ‘Communigation error from lisplay to each CPL. 69, | G69 | *Muin board voltage ercor® Voltage err of IGBT gate power supply and | *Emergeney stop extemal 5V power supply “Tum ofrkey switch. 0 | G70) *Faneror* Fan power supply voltage error “Emergency stop* Traveling or hydraulic motor relay tripped Displayed together with ‘other erpar message. "Turn off key switeh.* ‘Any eritcal error in traveling or hydantic Displayed together with ‘other errr message. *Overlaad, Reduce Toa.” Overload ‘When overload occurs Add lubrication wilt Lubrication oi When lubrication il sensor satuates Add brake oit® Brake oil When brake ol sensor actuates © Add puritied water* Addition of purified water to battery ‘When battery electrolyte fevel sensor actuates ‘Recharge battery* Battery’s state of charge is low When baven’s state of charge is low: *Pasking brake is applied” Starting of tuck is tied with parking brake applied When staring oF rack is ied ‘wih parking brake upped, Tum off accelerator® Traveling with key switch ON. ‘When traveling CPU is in neutral safcty State “Tur oft hydraulic lever Hydraulic lever isin ON with key switeh turned ON. When hydraulic CPU is in neutral Safety state. *AOS emergency stop* AOS emergency stop switeh has been presse. AOS emergency stop switeh presed *Lift height setting eror* Lifting height setting is wrong Lifting height sting is wrong, "Apply parking rake Application of parking brake is forgotten Parking brake seat switch is off *Secune battery unit* ‘Traveling or hydraulic operation is performed with battery interfock switeh ON, 70TROUBLESHOOTING [I ERROR HISTORY MEMORY 1 1-2—1.]ERROR HISTORY MEMORY 1 screen is displayed. @® When turning the key switch on, the following ‘e To view less than the ten most recent errors/ @ Set, the rotary swtich RS1 on the display board to “9”, © DISPLAY BOARD SET UP RSI TO “9” abnormalities, place the flashing cursor on the last error/abnormality and press the (8) button to go to "Previously detected errors/abnormalities". ‘lf there are no errors/abnormalities, press the ® button to go to "Previously detected errors/ abnormalities". ‘© The 10 most recently detected errors! abnormalities ‘The most recent error/abnormality flashes as “A01" © Error/abnormality details ‘Number of imes the erorlabnonmality ogoutred when twas detected 20 ROR Aoi AgT E40 E40 FSi c20 B10 FSS ®; {'e - @®{i te = fay SG IS 2 Sl oe Gah Se =| 5] [RMUNAOEEUN RRNA OEE =| 5 |MAUURENERGUERD ant a ERROR al 3 cuente Big Agt AO E40 ey 0 iH 1a F51c20 B10 FSS ve 28 I 1 7 oe 4 as i ‘ Year, moray, and hte ®; 4e Ce ly atten dé toe distanco, and travel and hydraulic hour mete SF am. Gh is he 3 (ROUMUOBROH ERE: 20 aun eth Fo isan 3 | MRUER BSG ORDER GERE ERROR MAgT BiG AO1 AO E40 (ER a FS5 The ninth error/abnormality ashes as "B10". @! 4 @y +e {Tote next page) nHE tRouBLESHOOTING (From the previous page) F gam. hav 3 [RENE MRED ANEAH OME 30-Oct (TU) CHT= .2000 me 1 1. an 10°30 a =I & i ERROR Cuneo, Bid ADT AQT Meh E40 FS1 C20 B10 ‘The tenth arrorabnormalty flashes as FSS. ®;} toe i ‘The newt page is ‘Previously detected erorslabnormaitios (1) 11-2-2. ERROR HISTORY MEMORY 2 face i|g38 © DISPLAY BOARD © Rotary switch RS1 on display board : 9 hh GERNOTE 2. ‘if there are no previous errors/abnormalities displayed in the list, press the (®) button to go to "Previously detected errors/abnormalities (2)". if the same error/abnormality was detected multiple times previously, the data of the most recent detection will be displayed under “Errorfabnormality details". ‘# Flashing : Indicates the position of cursor. Highlighted : Only highlighted numbers are memorized as error items. © PREVIOUSLY DETECTED ERRORS/ABNORMALITIES (1) @ ERROR/ABNORNALITY DETAILS. ‘The previous page is “The 10 most recenty detected Sronsapnomains' @;} te feel ame hv Ie = 20} =| 9 iki init =| Bea ==le| = 355 Oct TU) ENT= PAG 1 fn open CHORE 2000 a ee Bis B18 IO Mw wio:3o 33:0m ef te - ” y i ahs 19 E ro ae S io 1s 20) 3 (Raga amen ENON | BEEN 02 GEM'8 141 Bi2 B13 B14 Sant 30- Get (TU) CUTS ais a 18 BB 12 Fel wiorso 48-88 ®; toe wn me ‘The next page is "Proviously detect errors!abnormaltis (4). 72TROUBLESHOOTING AE BY, TIS *:In case of detected multiple same errors in eat the past, the last detected data is displayed| t RSI=9 on detail of the error. © PREVIOUSLY DETECTED ERRORS/ABNORMALITIES (2) @ ERROR/ABNORMALITY DETAILS. ‘The previous page is “Previously detected “’eroisabnotmalies 1) [Number of times the errovfabnormalty ‘occurred when it was detected Erroriabnormailly messane display Fe Gknh & ioe Li t| SS 73 imal tore 30-Oct (TU) CHT= 0 R F51FS2 F753 F55 Se = fg] 0 Pr FS6 FS? F58 SJB Biel ators O12 HR 4 ~ 4 4 -_ ac) Errvionoralty detection data, time, travel ! ‘stance, anc travel end hydraulic or meter i 20} R BY FSt FS2 53 FSS FS6 FS? F58 73HB rRousLESHOOTING 1 1-2-3. | MEMORY INITIALIZATION @ Set rotary switch RSt on the display board to "E*. @ Tum the key switch ON. @® When the screen shown below is displayed, memory initialization is complete. @ Return rotary switch RS1 on the display board to "0" © MEMORY INITIALIZATION COMPLETION SCREEN Fam iv eo LOE EIMEMORY INITIALIZE COMPLETE! GRANOTE The following items are returned to their initial values: ‘© Slow speed (turtle) : Skmm/h Travel mode : N (NORMAL) ‘Meter mode : HR (hour meter) Accelerator released (neutral) regenerative force: MID Error history ; All clear © BRIGHTNESS (back light brightness): 5 14 © DISPLAY BOARD £07 Sake SABES ares SET UP RAI TO"E"BATTERY AND CHARGER MECHARGING THE BATTERY (TRUCK-MOUNTED CHARGER) > TRUCK -MOUNTED CHARGER ————_—_____ Se TRUOK SIDE S > MIGROPROGESSOR-CONTROLLED CHARGERBATTERY AND CHARGER > AUTOMATIC CHARGE (DAILY CHARGE) Automatic charge is used for recovering the battery after the day's work or your shift. OMove the truck to the specified charging place where the power supply equipment for the charger is installed. @Turn the key switch to OFF. @Open the battery cover. @Insert the charge plug into the mating receptacle on the truck side. 6 ®lnsert the power plug into the power supply. ‘The automatic charge lamp (green), the reserved charge lamp (green) and the equalizing charge lamp (orange) come on, 76BATTERY AND CHARGER @Press the automatic charge button. The automatic charge lamp (green) stays on while the reserved charge lamp (green) and equalizing charge lamp (orange) to go out. @The charge progress indication lamps come ‘on one by one as charge progresses, starting from the one at the bottom. When the lamp (green) at the top comes on, charging is com- pleted. @®Disconnect the charge plug and the power supply plug and store the charge cable. ‘The chatze stops automatically @Close the battery cover, and Jock to the battery clamp. Never disconnect the charge plug, the power supply plug or the battery plug while charging. When you want to stop charging halfway, press the stop button Make sure your hand is not wet when con necting or disconnecting charge plugs. Dry your hand or put on a glove, if it is wet. The charger is a high-voltage device.Never put your hand inside the equipment.Other wise, you might get injured. on>» RESERVED CHARGE You can give a reserved charge using the procedure given on pages that follow. Reserved charges are usually used charge the battery using cheap electrici during the night or when you want to have the battery fully charged before starting work after the truck has been out of service for a long period of time. © SETTING CHARGE START TIME elf you run the truck or operate the hyd raulic controls with the Reserved charge screen shown, the display will return to| the basic screen. ©The Reserved charge setup mode is dis abled while the truck is traveling or the brake pedal is being pressed. @Move the truck to the specified charging place where the power supply ea for the charger stalled. @With the basic screen shown on the display. press the @ button of the screen selection buttons to display the Reserved charge set up screen. (The Reserved charge screen sido appears when the charge plug is connected.) You can return to the basic by pressing the © button. @ "Set date”blinks on the screen. Press either the < button or the & button to select "Set date” or “Everyday”. When you select “Set date”: ‘The reserved charge time once specified on the screen will automatically be renewed every week (once every seven days) after the set deate has passed This function comes in handy when you want to charge the battery. When you select “Everyday” The reserved charge time once specified on the Screen will automatically be renewed everyday af ter the set time of day has passed ‘This function comes in handy for daily charge. Remember that the time that can be specified fon the screen ie the reserved charge “start” time, not the “end” time. 78 BATTERY AND CHARGER II (conor) eoem EJTOTAL 98893. S4r 30-Oct(TH) e101 30 sitsioieantient BREE < Divervaay B0-Oet CTH) HHBE30 m0 30 ee ey ee set ‘pioaestnasetnees date ID me 30-Oct (TH) atl OtSO ES patos seBATTERY AND CHARGER SELECTING “DATE” Press Shift to next item (blinkine) *@outon + Return to before item (blinkine) ® Setting “Month” After making sure that “Month” is selected (blinking), use Gand @ to set the month within the range from 1 to 12. After setting the month, press the @ button to select “Date any day of the week” You can return to the “Set date/Everyday” screen by pressing @ button. ® Setting “Date and day of the week” After, making sure that “Date and day of the week” is selected(blinking), use Gand &> to set.the month within the range from 1 to 31. ‘The day of the week changes as the date changes. After setting the date and day of the week, press the ® button to select “Date any day ‘of the week” - » . You can return to the “Set date/Everyday screen by pressing © button. ® Setting “AM/PM” After making sure “AM/PM” is selected (bli- nking), use QJ and © to set AM/PM. After selecting AM/PM, oress the ® button to select “Time of day”section. You can return to the “Date and day of the week” section by pressing @ button. 79 FE, wooetcnyy eiparsa wn acer free pet SET (WoNTHT WITH I> (asia ® Prairess] ~ Sialaet seineoe arora Lene ayo SET ~ Dato“ wii <> ole | Poairene aoe Pees© Setting “Time of day” After making sure that “Time of day” is sel ected (blinking), use <, and >i to set the time of day within the range from 1 to 12. After setting the time of day, press the ® button to select “Minute” You can return to the “AM/PM” section by pressing the @ button. ® Setting “Minuite” After making sure that “Minute” is selected (blinking), use <<) and &" to set the minute in four stages (00/15/30/45) You can return to the “Time of day” section by pressing the @ button. After all the data have been corectly enterd, press @: button. “COMPLETE” blinks three ‘times on screen before the display returns to the basic screen. BATTERY AND CHARGER SET” Time " vaTH (rencler 8 fraps) Binatone? _ = Set date 31-Oct (FR) Bay 2 SET" Minute” WITH > maser Frais Make sure that the reserved charge starting date and time have been correctly enter by looking at the date and time of day displayed at the left lower area of the eereen, © You cannot set any time of day inthe past as the reserved charge start time. [Exarote) Present sme oct 30,7008 + you enter: 021 30 ' The Final setting: Oot 3 PM 10:30 PM 10:90 (you eter a tne of cy the pt the same ane of ay ofthe fotning year abe set +The came holds true ifthe peo lime satting becomes tho “par the date and tine of day ot reserved charge ‘oe a romat that oof Ue deploy © The whole reserved charge setting will become void if you fail to enter any of the month. day and time of day. Example : If yoy do not enter data about the day, “such ac “(blank) October, PM 10:00,” ‘the whole setting will be void. If you mave to the next screen, leaving any item blank. the whole setting on the same screen will become void 80 relate fea Sot date Se si-oct eR) PEL “a 2:52 foowmerey * COMPLETE” pKuReaNG: | a Efieaitencian? 'E (Economy) SE roma _‘eeses.on 30-Oct (TH) de BASIC SCREENBATTERY AND CHARGER SELECTING EVERY DAY Press the 3 button or the®> button to display the “Everyday” screen. “Everyday ” blinks. The crrent settings are di layed. (No settings are displayed if any reserved charge is not set.) . . Press the @: button to select “AM/PM”. You canreturn to the basi pressing the © buttor ‘screen by ‘When you set next DG) mode. press the @, @, <, B button of mode select. 8d, & button > Set selected itemiblinking) ©B button + Shift to next item (blinking) Staton “> Retin to before item (blinking) © Setting “AM/PM” After making sure that ” AM/PM is selected (blinking), use ® Setting “Time of day” After making sure that ” Time of day” is sele — cted (bl 1g), use SJ and © to set the of day within the range of 1 to 12. After selecting the time of day, press the ® button to select the “Minute” section. You can return to the “AM/PM” section by pressing the @ button. [raaler Sl fhe] EBelegetisesiienst Everydey 7 30, SET”, Time” WH <> aie See Setting “Minutes” After making sure that “Minute” is selected (blinking), use to set the minutein four stages (00/15/30/45) . 81 [awoler@ Frais]BATTERY AND CHARGER J After all data haye been correctly entered, press @ button.”“COMPLETE” blinks three times on screen before the display returns to the basic screen. You can return to the”Time of day” section by pressing the ©: button. Make cure that the recerved charge starting date ‘and time have been correctly entered, by looking at the date and time of day displayed at the left lower area of the screen. © You cannot sot any time of day in the past as the reserved charge start Ure, sample) Prezent time 0:4 30.2008 PMIO0 oF day + 1 you enter PM 10:30 + ‘The final setting : Oct 3. 2009 PM 10:30 you eter in of dey of the ps the same tne f| (ay ofthe fae year beset ‘Tho same holds true if the prosent reserved chatag ime satting becomes Une “pact” ae 9 rogull tat he date and time of day sottings of the deplay are ‘© The whole reserved charge setting will become void if you fail to enter any of the month, Say and ‘ime of day. [Example ; If you do pot enter data about the day| |such ac “PM (blink)”, the whole setting will be If you move to the next coreen, leaving any item blink, the whole setting on the same screen will become Void, 82 "E (Economy) QTOTAL 88889. He 30-Oct (TH) ad? 3BEA CHARGER RESOLUTION AND ASSEMBLE -|RESOLUTION AND ASSEMBLE CHARGER ASS" ‘© When you assemble, take care that you don't mistake to connect ground wire. Make sure that you don't mistake connecting lead wire to each parts. © Tighten firmly so that the lead wire should not loosen. © The naked part such as the transformer terminals must not contact with other parts.Cover with the insulation tube, and separate with metallic part. ESOLUTION AND ASSEMBLE CHARGER ASS'Y * (Only the truck equiped with the gharger.) MAGNE |) romornccomern ES § TO BODY HARKESS 83|CHARGER 12-1-2.|DISMANTLING AND ASSEMBLING TRANSFORMER © DISMANTLING AND ASSEMBLING TRANSFORMER (Only the truck equiped with the charger) aie | — vrove e ro = OUTPUT TERMINAL (-), M8| —S SECONDARY COIL PRIMARY COIL 84CHARGER 12-1-3.|SPECIFICATION OF CHARGER <200V series> Battery | Charger | Capacity of | Capacity | Specification of capacly model power ‘of fuses | power supply- | Applicable (alvsny | ___{truoke supply or side plug of | truck model mount type) | equipment | breakers | charger cord 201 FR10-7(H) 220 | To224-1017| 3.0 kVA FR13-7(H) 225 FR10, 13-7C(H) 280 | To224-0328 | 4.3 KVA FRI4-7(4) FRIS-7(H) FR18-7(H) Grounding 3P, 320 20A, 250V 345 | 70224-0329] 5.2 kVA 370 4 20A FR20-7(H) 3390 FR25-7(H) 440 |11224-0317] 6.4kVA 445 <400V series in option> 2TaF2-6O2TIA 60201 =60244 5 Z 44 fea — Ba azna-so17)[2ezn2-co271 foaon?-60371 jezs |rRzo-7H BAY _|202R2-s0101 =60201 je2u _|rres—7H BAG feezne-coras_| 60241 85El charcer [Eaz4INSPECTION AND REPLACEMENT 1 INSPECTION FOR MAGNET CONTACTOR @Check the contact point for damage or burns. (© INSPECTION FOR MAGNET GONTAGTOR, 12-2-2.|INSPECTION REPLACING PLUG SOCKET @Check the plug socket for burns or discoloration. | » mspecTion anp EXCHANGING CONCENT "If there is something unusual, replace with both in set. @Check for looseness of the mounting nut for earth terminal. @Check for blowing the fuse or discolorration. @Check for looseness of the screw for fuse holder. 86CHARGER [12-2-4. INSPECTION FOR TRANSFORMER @Check for the damage and dirt. ™» If hard dirt is found, clean by compressed air. @Measure the insulation resistance, and check. Srerene nesistance | MORE THAN 5 MQ Zi CAUTION] (@ Disconnect the battery plug before measuring, ‘@ When you use the megger, never touch with measured terminals. @ Remove diode. ® Measuring the following point by megger. (BETWEEN PRIMARY COIL AND SECONDARY COIL © BETWEEN PRIMARY COIL AND CHASSIS. © BETWEEN SECONDARY COIL AND CHASSIS [12-2-5. INSPECTION FOR DIODE © Measure the resistance value, and check for © CHECK THE DIODE normality of the diode ci TESTER STANDARD RESISTANCE VALUE DIODE —————_____ Terminal ____| Resistance value 2 Pius side Minus side [ ‘Anode(A) — —_Kathode(k) a Kathode(K) — — Anode(A) 10-400k ©The above values are just reference measured by digital tester (KAISE SK 7711). ® Each resistance value are subject to tester type. © Adjust to set the range of resistance(Q) x1. ® With make a short circuited in tester sticks, adjust dit @ Apply the sticks to each point, and check for normality. to 0. 87GS cuarcer FESE}INSPECTION AFTER ASSEMBLED CAUTION]/ ® Make sure conductivity between earth terminal of plug socket and chassis body. (1 Qrange of tester : 0) © The inspection should be done in well ventilated area and kept flames away. 12-3-1. INSPECTION FOR TIMER MAGNET AUTO | RESERVE] EQUAL | LED. PASSED How to check ConTactor| LED | LED tro [1~2 | ona 1 Connect the battery plug 4 OFF x x 1 xX x x Gannect the power plug into 2} the poser socket OFF ° ° ° x x Press the “automatic | Wt, | orF | QO | x | x | x | x 3] charge button ” for more than 5 seconds. After oe ON a x x ao o When the “AUTO LED" etart blinking] OFF 4 you release “AUTO BUTTON™ OFF 4 x * Q o 3 | Betening seek oer om [x |x| xf la seconds L J AUTOMATIC CHARGE LAMP (GREEN) y— Lighting this LED means full charged. AUTOMATIC CHARGE BUTTON RESERVED CHARGE LAMP (GREEN): TereaNaTED| TED. 3 EQUALIZING CHARGE LAMP (ORANGE): PROGRESS OF CHARGE LED(GREEN) 1@ Inrecponce to state of charge. LED tehting 2 Wren total ine A CAUTION] fe In case of full charged battery use, checking the timer after operating hydraulics for few minute. case of blinking “Progress of charge LED”, it is continued until disconnecting the battery plug. 88CHARGER [ERZXTRANSFORMER TAP CHANGING 12-4-1 -|CHECKING THE SUPPLY VOLTAGE ame Nore] Measure the supply voltage of the facility without the charger operates. © After measuring it for one minute, specify the highest measured value as the supply voltage. © In case of 3@input source, measure the voltages between each phase (U-V,V-W,W-U) and specify the highest measured voltage in average as the supply voltage. CAUTION]! The measurement is done in recess of the facilities. [12-4-2. TAP CHANGING © Tap position Supply voltage (V) Indication of tap 199 or less. 200 V 200 = 209 210 V 210 = 219 220 V ‘Supply voltage (V) 379 or less 380 V 380 ~ 399 400 V 400 - 419 420 V 420 = 439 440 V Truck side > j— Three-core line A vinyl cap is put on a wen The tuck side and the tap which is not used traneformer cide are fastened togethor with 2 roynd crimp contact The tap voltage is in dicated by a marking band ‘Transformer sideCHARGER 2-4-3. [POINT OF TAP CHANGING A CAUTION] (© Turn off the key switch, and pull out the power supply plug.. ‘© Tighten screw enough. @Loosen the screw, replading pressed circle terminal. @® Connect to condiemed tap for power supply voltage, tighten the pressed circle terminal. © AT EX-FACTRY : 220V A CAUTION] | © Pull out the AC plug for power supply side. © If plug not tight enough it may result is bad contact and will cause trouble. DULY TIGHTEN SCREWS @Loosen screw, and change fuse with hook. FUSE WITH HOOK 90fbb} San WEES WES 67a -avLye gZ-uas 126 Pelyalel Be 2-4 Pata Rar 22255) 8 NS i eth Atle, Tuan ici", eX | ee HOR TER ti aFR-7 SERRE 93SPECIAL TOOL FOR REPLACING TRAIL WHEEL ON FR-7 SERIES Front brake is provided on FR-7 series. We suggest you to provide the special tool for replacing the Trail Wheel to introduce the below. P/No : 99500 ~ 00969 APPLICABLE MODEL : FR 10-25 -7, -7H IN SET PULLER 1 PCE PULLER BOLT 1 PCE BOLT(M6 x 40) 2PCS PUSHER A 1 PCE PUSHER B 1 PCE RING 1 PCE NUT, Lock (REPLACING PARTS FOR LOADWHEEL) BEARING SENSOR. PUSHER PF owes ro monte PULLER BoLT MOLE FORTHE CAP MATCH A SLIT OF THE PUSHER WITH THE GEARING SENSOR GUIDE 94