Service Manual: No. SEB-83ACE

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No. SEB-83ACE
FOREWORD
This service manual has been written to provide service personnel with necessary information about
the design, operating principles and maintenance procedures of the TCM models FTB16‑7, FTB18‑7
and FTB20‑7 forklift trucks.
These forklifts feature a new FET controller, drive unit, OBT type power steering and low operating
noise.
The adoption of high-performance electric components provides dramatic energy savings. In addi‑
tion, a larger battery compartment allows the installation of a high capacity battery so that the truck can
be operated much longer on a single charge.
The front wheels can each be driven separately, making pivot turns with a smaller turning radius
possible.
The specifications presented in this manual are subject to change without notice.
July, 2009
No. SEB-83ACE
(Empty page)
No. SEB-83ACE
SPECIFICATIONS
Model
FTB16-7 FTB18-7 FTB20-7
Item
Performance
Maximum load kg [lbs] 1600 [3200]* 1750 [3500]* 2000 [4000]*
Load center mm [in.] 500 [24]* ← ←
Maximum lift height mm [in.] 3000 [118.1] ← ←
Mast tilt angle °
Fwd ° 5 ← ←
Bwd 6 ← ←
Free lift A mm [in.] 155 [6.1] ← 160 [6.3]
Fork lifting speed (S mode) mm/s [fpm]
Loaded (36 V) 330 [54.9] 310 [61] 280 [55.1]
(48 V) 410 [80.7] 400 [78.7] 370 [72.8]
Unloaded (36 V) 480 [94.4] ← 470 [92.5]
(48 V) 610 [120] ← 600 [118.1]
Traveling speed (S mode) km/h [mph]
Loaded (36 V) 12 [7.5] ← 10.5 [6.5]
(48 V) 15 [9.3] 14.5 [9.0] 13 [8.1]
Unloded (36 V) 14.5 [9.0] ← ←
(48 V) 16.5 [10.3] 16 [9.9] ←
Gradeability Loaded (48-V , S mode) 1/5 ← ←
Unloaded (48-V , S mode) 1/5 ← ←
Minimum turning radius, B mm [in.]
at outermost part of truck 1540 [60.6] 1650 [65] 1705 [67.1]
Minimum intersecting aisle mm [in.] 1910 [75.2] 1960 [77.2] 2010 [79.1]
Dimensions mm [in.]
Overall length, with forks C 2825 [111.2] 2935 [115.6] 3025 [119.1]
Overall width D 1075 [42.3] ← 1120 [44.1]
Overall height (head guard) 2080 [81.9] ← ←
Overall extended height 4030 [158.7] ← ←
Wheel base E 1355 [53.3] 1465 [57.7] 1530 [60.2]
Tread (front) 910 [35.8] ← ←
Fork overhang F 360 [14.2] ← 376 [14.8]
Rear overhang 190 [6.9] ← ←
Fork size 920 [36.2] x ← 1070 [42.1] x
length (G) x width (H) x thickness (J) 100 [3.9] x 35 [1.4] 122 [4.8] x 40 [1.6]
Fork spacing K 200 [7.9] - 920 [36.2] ← 245 - 950 [9.6 - 37.4]
Under clearance, at counter weight 75 [3.0] ← ←
Coupler height 520 [20.5] 530 [20.9] ←
Weight kg [lbs]
Service weight, with batteries 2910 [6420] 3030 [6680] 3400 [7500]
Note: The figures in brackets are given for EXA specification trucks.
The figures in brackets with an asterisk should not be converted to other units of measure.
4030 [158.7]
No. SEB-83ACE
3000 [118.1] D
A FREE LIFT H
G
J
5°
F
6°
Fig. 1
C
E
B
175
[6.9]
70 [2.8]
2080 [81.9]
Unit: mm [in.]
No. SEB-83ACE
CONTENTS
1. BATTERY (OPTION) ............................................................................................................... 1

1.1 GENERAL DESCRIPTION........................................................................................................... 1
1.1.1 BATTERY CARE...................................................................................................................... 1
1.1.2 CHARGING OF BATTERY..................................................................................................... 2
2. MOTORS ...................................................................................................................................... 5
2.1 GENERAL DESCRIPTION........................................................................................................... 5
2.1.1 DRIVE MOTOR....................................................................................................................... 5
2.1.2 PUMP MOTOR......................................................................................................................... 8
2.1.3 OPERATING PRINCIPLE OF 3-PHASE INDUCTION MOTOR........................................ 10
2.2 MAINTENANCE . ...................................................................................................................... 11
2.2.1 DAILY INSPECTION............................................................................................................. 11
2.2.2 PERIODIC INSPECTION...................................................................................................... 12
2.2.3 MAINTENANCE OF BEARINGS........................................................................................ 14
2.2.4 TROUBLESHOOTING GUIDE............................................................................................. 15
3. CONTROL SYSTEM ............................................................................................................. 17

3.1 GENERAL DESCRIPTION......................................................................................................... 17
3.1.1 CONTROLLER...................................................................................................................... 17
3.1.2 ACCELERATOR PEDAL....................................................................................................... 20
3.1.3 AUTO POWER-OFF SYSTEM (OPTION)........................................................................... 21
3.2 MAINTENANCE......................................................................................................................... 22
3.2.1 TROUBLESHOOTING.......................................................................................................... 22
3.2.2 CHECKING CONTROLLER COMPONENTS AND CONNECTIONS.............................. 32
4. DRIVE UNIT .............................................................................................................................. 59

5. BRAKE SYSTEM .................................................................................................................... 63

5.1.1 ACTUATOR............................................................................................................................ 63
5.1.2 MASTER CYLINDER........................................................................................................... 64
5.1.3 BRAKE PEDAL...................................................................................................................... 65
5.1.4 PARKING BRAKE................................................................................................................. 66
No. SEB-83ACE
6. STEERING SYSTEM . ........................................................................................................... 67

6.1.1 STEERING AXLE.................................................................................................................. 70
6.1.2 ORBITROL............................................................................................................................. 72
7. HYDRAULIC SYSTEM ......................................................................................................... 77

7.1.1 MAIN PUMP........................................................................................................................... 80
7.1.2 CONTROL VALVE................................................................................................................. 81
7.1.3 CONTROL VALVE (trucks with FIT).................................................................................... 87
7.1.4 LIFT CYLINDERS................................................................................................................. 92
7.1.5 FLOW REGULATOR VALVE............................................................................................... 95
7.1.6 TILT CYLINDER................................................................................................................... 96
7.1.7 OIL TANK............................................................................................................................... 97
8. LOAD HANDLING SYSTEM ............................................................................................. 99

8.1 GENERAL DESCRIPTION....................................................................................................... 100
8.1.1 OUTER & INNER CHANNELS.......................................................................................... 100
8.1.2 CARRIAGE.......................................................................................................................... 101
8.1.3 ROLLER POSITIONS.......................................................................................................... 102
9. ELECTRIC WIRING ............................................................................................................. 103

1. BATTERY (OPTION)
1. BATTERY (OPTION)
This truck does not have a battery unit as standard, because it is designed to use a battery unit
specified by the user.
This chapter, therefore, gives the information on the construction of typical batteries and
general rules and cautions to be used for them. For more information, see the Instruction Manual
supplied with the battery that is to be installed on the truck.
1.1 GENERAL DESCRIPTION

The battery unit consists of 24 2-volt batteries connected in series and is housed in an iron plate
case with a cover on which a driver’s seat is provided.
The cell employs a clad type anode plate (a glass fiber or synthetic resin tube filled with lead
peroxide, having a lead alloy core penetrated in the center). The pole plate withstands a long cycle
of use, and well endures overcharge and overdischarge.
The cathode plate is a lead frame filled with lead peroxide paste. These two plates are isolated by
a separator consisting of an ebonite plate, diatomaceous earth and porous rubber in order to prevent
short-circuiting of the plates.
The battery jar is made of resin, and the electrolyte is high purity diluted sulfuric acid having a
specific gravity of 1.28 (20°C) [68°F].
1.1.1 BATTERY CARE

The most important point in battery care is to prevent
overdischarge. The deeper the battery discharges, the
Service life
charge and
discharge
shorter its life becomes.

Cycle of
The approximate depth of discharge can be known

by measuring the specific gravity of the electrolyte.
Check the level of electrolyte every ten days. Add
distilled water if the level is found lower than the
specified level before charging the battery.
Depth of discharge (%)
Fig. 1.1
-1-
1. BATTERY (OPTION)
Specific gravity (20°C) [68°F]
Voltage (V)
Usable
Voltage
Alert !
Specific gravity
Overdischarge
(Discharge time)
(Discharge state)
Fig. 1.2
1.1.2 CHARGING THE BATTERY

When discharged, the battery should be recharged as soon as possible. Leaving the battery
discharged for a long time may cause sulfation, which will result in a drop of the battery
performance.
If the battery is kept out of service for a long time, it should be thoroughly charged before put in
storage. An additional charge is also required once a month.
Do not leave a fully discharged battery longer than a day as it is. Be sure to recharge it as soon as
possible.
If the amount of discharge is considered to be small, measure the specific gravity of the
electrolyte. If lower than 1.260, recharge the battery.
Equalizing charge is required if the specific gravity varies among the cells by the amount of 0.020
or larger. Equalizing charge is normally needed between one to four times a month.
If the specific gravity variation is not made smaller by equalizing charge, specific gravity
adjustment will be required.
Giving an equalizing charge more times than necessary will overcharge the battery, and its service
life will be shortened.
[Cautions on Charging the Battery]

(1) Do not start charging the battery if the electrolyte temperature is higher than 40°C [104°F].
Leave the battery for a while until the temperature goes low. Then charge it.
(2) Overdischarge or overcharge will cause the electrolyte temperature to rise. Keep the battery
compartment cover fully open and get a good ventilation during charging to prevent the charging
room from being filled with harmful gases, and to dissipate heat.
-2-
1. BATTERY (OPTION)
[Conversion of specific gravity at different temperatures]

The specific gravity of the electrolyte varies with the electrolyte temperature. Generally, the specific
gravity is expressed based on an electrolyte temperature of 20°C [68°F]. If the specific gravity is
measured at electrolyte temperatures other than 20°C [68°F], convert it using the following formula.
S20 = St + 0.0007 (t - 20)
where,
S20 : specific gravity at 20°C [68°F]
St : specific gravity at t°C (measured value)
t : electrolyte temperature (measured value)
Conversion from °F to °C:

5 (°F - 32)
°C =
9

Battery Voltage
The nominal battery voltage that can be used for the FTB16-7, FTB18-7 and FTB20-7 trucks is 48
volts or 36 volts. If a 48-volt battery is used, make sure that the battery does not have a short coupler.
-3-
1. BATTERY (OPTION)
NOTE
-4-
2. MOTORS
2. MOTORS
Drive motor
Type 3-phase induction motor
Rating 48 V 36 V
Output 5.5 kW (2 min) 3.7 kW (2 min)
Speed 850 min -1
715 min-1
Frequency 32 Hz 27.5 Hz
Voltage 24.7 V 19.5 V
Current 210 A 185 A
Weight approx. 40kg [88.2 lbs]
Pump motor
Type 3-phase induction motor
Rating 48 V 36 V
Output 10.4 kW (5 min) 8.2 kW (5 min)
Speed 1972 min-1 1568 min-1
Frequency 675 Hz 55 Hz
Voltage 26.5 V 20 V
Current 315 A 335 A
Weight approx. 45 kg [99.2 lbs]

The drive and pump motors are 3-phase induction motors consisting of a coil-wound frame, rotor
shaft, and brackets. The rear bracket has a motor speed sensor incorporated.
2.1.1 DRIVE MOTOR

The drive motor is installed on the drive unit. (See Fig. 2.1.) One end of the drive motor shaft is
splined to the drive unit input gear A and thus the rotating force of the drive motor is transmitted to the
input gear A. The opposite end of the drive motor shaft has a slit plate which detects the rotation with
two sensors.
-5-
2. MOTORS
Align grooves of
two slit plates
WAVE WASHER
SNAP RING
Detail of slit plate
ROTATION SENSOR B
W PHASE
V PHASE
U PHASE
MOTOR SPEED SENSOR A
THERMOSENSOR CONNECTOR
View looking from View looking from
Fig. 2.1 Drive Motor
-6-
2. MOTORS
DRIVE UNIT DRIVE MOTOR

(LEFT)
(LEFT)
DRIVE MOTOR (RIGHT)
DRIVE UNIT (RIGHT)
Motor mounting bolt Tightening torque:

Tightening torque: 135 N-m {1350 kgf-cm} [97.6 lbf-ft]
23 N-m {230 kgf-cm} [16.6 lbf-ft] (drive unit mounting bolt)
O-RING
LOWER NUT
Tightening torque:
KEY 45 N-m {450 kgf-cm}
[32.5 lbf-ft]
UPPER NUT
PINION GEAR Tightening torque:
45 N-m {450 kgf-cm}
[32.5 lbf-ft]
Detail of Detail of Pinion Gear
Fig. 2.2 Drive Motor Location
-7-
2. MOTORS
2.1.2 PUMP MOTOR

The pump motor is installed in the position shown in Fig. 2.4. Figure 2.3 shows the appearance of
the pump motor. The pump motor drives the gear pump directly and the rotation is controlled by the
inverter. At the end opposite to the drive side is a slit plate which detects the rotation with a sensor.
STATOR COIL
THERMOSENSOR LEAD WIRE
ROTATION SENSOR
SLIT PLATE
V PHASE
W PHASE U PHASE
Fig. 2.3 Pump Motor
-8-
2. MOTORS
OUT
IN
Apply Molycoat grease

to splines
MAIN PUMP
PUMP MOTOR
Fig. 2.4 Pump Motor Location
-9-
2. MOTORS
2.1.3 OPERATING PRINCIPLE OF 3-PHASE INDUCTION MOTOR

As shown in Fig. 2.5, when the magnetic f
no
poles N and S are rotated outside the c
e e
tio )
dir pol
rectangular coil, the coil side cuts the magnetic a t ing etic
ot gn
flux to induce electromotive force in the (R ma
direction indicated in the figure, thus flowing (Rotating direction
circulating current inside the coil. This causes of coil)
rotating force in the same direction as in which
the magnetic poles rotate so that the coil also
rotates, following the magnetic poles. Motors
which operate in such a principle is called an Fig. 2.5 Operating Principle of Induction Motor
induction motor.
Three-phase alternating current is suitable

for rotating the magnetic coil. When 3-phase
current is passed into a 3-phase winding, a
revolving magnetic field which rotates at a
certain speed is created. It is thus possible
to perform the same action as the purpose of
rotating the magnetic poles N and S in Fig. 2.5.
The 3-phase winding consists of an iron core
and three coils A, B, and C, spaced 120° apart, Fig. 2.6 3-phase Winding
installed in the iron core slots and connected in
Y or delta connection. The sketch “b” in Fig. 2.6 shows a typical Y connection which is widely used
for the connection of induction motors.
When the direction (A A’, B B’, C C’) in which current flows into the coil is regarded as the
positive direction, the current of the coil in each phase at the moment at (a), (b) and (c) in Fig. 2.6,
+Im flows into the coil A and –Im/2 flows into both coils B and C. Therefore, the synthetic magnetic
flux in the space becomes (c) to create a magnetic field moving from right to left. This means that the
magnetic pole N is located at the right side and the S at the left side. As such, each moment from –
is followed in order, the synthetic magnetic field created by synthetic magnetic flux is a magnetic
field which rotates by 60° clockwise. With time, it rotates to cause a rotating magnetic field which
makes a complete turn per one cycle of alternating current. The poles formed at each moment are N
and S, and thus this type of motor is called a 2-pole motor.
Fig. 2.7 Rotating Magnetic Field due to 3-phase Alternating Current
- 10 -
2. MOTORS
2.2 MAINTENANCE
2.2.1 DAILY INSPECTION
(1) Check the following points with the motors running
Check item Location Criteria Remedy

Dust Motor frame No remarkable deposit of dust allowed If too much deposit
compared with usual operation. of dust is found,
Environment
Usual temperature rise. stop operation and

Visual check. clean.
Foreign matter, Motor frame No remarkable change allowed compared with Return to normal
splash, liquid usual operation. condition.
Visual check.
Temperature rise Motor frame, No remarkable rise in temperature allowed Return to normal
bearing compared with usual operation. condition.
Temperature is below specified values:
Motor frame: 80°C [176°F]
Bearing: 55°C [131°F]
Vibration Motor frame, No remarkable vibration or amplitude increase If allowable limit
bearing, and allowed compared with usual operation. is exceeded, stop
cover Visual and audible checks. operation and
remove the cause.
Noise Motor frame, No remarkable noise or sound allowed If any defect
bearing, cover compared with usual operation. is found, stop
Using a sound-check rod, check against new operation and
product. remove the cause.
Audible check.
(2) Check the following items with the motors stopped
Check item Location Criteria Remedy

Fasteners Screws and No looseness, adherence of dust, or corrosion Retighten, clean or
nuts allowed. paint.
Check visually and by tapping.
Terminals Connections Connections are correct and not loose. Retighten.
Proper insulation is ensured. Check for
Visual check. insulation.
Lead wires No damage to coating allowed. Ask specialist for
Visual check. repair.
- 11 -
2. MOTORS
2.2.2 PERIODIC INSPECTION

(1) Inspection criteria
Check the motors at periodic intervals, referring to the following troubleshooting chart. If the
motors are used under a severe working condition, earlier or more frequent preventive maintenance is
required.
Operation time more than 12 hours/day 8 – 12 hours/day

Inspection interval Once a year Once every two years
Location Check item Criteria Remedy
Roller Bearing (sealed type) Check grease leaks, noise, adherence of dust Replace.
bearing visually or audibly.
Tightened Joined parts Check for damage or rough surface due to Clean.
areas corrosion visually.
Fasteners Check for looseness, corrosion or seizure Retighten, apply

visually or by tapping. anti-rust or replace.
Terminals Joined areas Check for damage or rough surface due to Clean.
corrosion visually.
Connections Visually check that connections are correct and Retighten.

not loose, and that proper insulation is ensured.
Lead wire Check coating for damage visually. Ask specialist for
repair.
Resistance For drive 0.0179Ω ±5% (20°C or 68°F) Ask specialist for
between motor repair.
terminals
For pump 0.0046Ω ±5% (20°C or 68°F)
motor
Stator Iron core Check for adherence of dust visually. Clean.

and rotor
assembly Coil and insulation at Insulation resistance is more than 1MΩ. Clean.
connections (Use 500 V megger) Heat.
Varnish.
Rotation Measure resistance 620 ± 60Ω (20°C or 68°F) Replace.

sensor
Measure gap 0.7 ± 0.3 mm [0.028 ± 0.012 in.] Ask specialist for
adjustment.
Thermo Measure resistance 13.04Ω ± 10% (20°C or 68°F) Ask specialist for
sensor repair.
Painting Damage Check for damage, discoloration, peeling, or Apply anti-rust.

corrosion visually. Paint again.
Cleanliness Deposit of Check for contamination, adherence of dust or

contaminants or dust corrosion visually.
- 12 -
2. MOTORS
(2) Inspection procedure

Inspect the motors observing the following conditions:
Select a place which is not dusty or humid.
Parts which have been disassembled should be kept in order and the order of disassembly recorded
to ensure correct reassembly.
Screws and wave washers removed should be put in order in boxes.
When removing or reinstalling brackets with a wooden mallet, tap them evenly. Do not use a
metallic hammer.
Use caution not to damage parts, especially stator coil and bearings. Exercise caution not to allow
them to collect moisture, dust, or sand.
Disassembled parts should be cleaned and checked for damage. Any defective parts should be
replaced with new one.
Do not rub a contaminated coil forcefully. Do not use gasoline, petroleum or solvent for cleaning;
otherwise the insulation will be impaired. Use a dry cloth or soft brush for cleaning.
If the insulation resistance of the coil is lower than the specified value, dry the coil by heating it
to 80 – 90°C [176 – 194°F], avoiding local heating, until the insulation resistance is more than
1 MΩ.
Check bolts for looseness, retightening any loose bolt.
For the procedure for checking and servicing the bearings, see 2.2.3 MAINTENANCE OF
BEARINGS.
If the coating is damaged, discolored or exfoliated, apply anti-rust or paint again.
Tighten the terminals securely. Connections must be completely insulated with insulation tape.
After reassembly, make sure that there is not any part left and the bolts and screws are securely
tightened. Turn the shaft by hand to make sure it turns smoothly. Run the motor on a trial basis.
The motor should be stored in a dry, clean place free from alkaline or other harmful gases. The
shaft should be applied with anti-rust and covered with oilpaper or vinyl sheet.
- 13 -
2. MOTORS
2.2.3 MAINTENANCE OF BEARINGS

The service life of bearings varies with the magnitude of loads and operating conditions. Replace
the bearings with new ones when the temperature rises excessively or produces noise.
Sealed bearings which seal in lithium soap-based grease ensure effective lubrication and prevent the
entrance of dust. They can be used for a long period of time without adding grease.
The sealed bearing should be replaced using the following table as a rough guide.
Operation time 8 – 12 hours/day 12 hours/day

Replacement intervals Once every 6 years Once every 3 years
Earlier replacement may be required if the motor is used at a place which is dusty or might cause
the sealed grease to deteriorate or flow out due to the atmosphere of harmful gases or solvent.
(1) Installing bearing

Install the bearing onto the shaft using a pipe (with a patch, if needed), as shown in Fig. 2.8.
When heating the bearing, do not heat to more than 60 to 80°C [140 to 176°F].
PATCH
Fig. 2.8
(2) Removing bearing

Using a puller, remove the bearing.
NUT
PULLER BOLT
INTERNAL
BEARING
COVER
BEARING
Fig. 2.9
- 14 -
2. MOTORS
2.2.4 TROUBLESHOOTING GUIDE

(1) Typical troubles with the motors include no rotation, slow rotation, heat build up, noise and
vibration, and foul smell. If a motor shows any of the above troubles, troubleshoot the motor
referring to (2) “Trouble-diagnosis chart” below.
If you ask your local dealer for troubleshooting, please give the model name, output, serial
number, operating condition, the total time of operation, and the state of the problem.
(2) Trouble-diagnosis chart
Problem Probable cause Remedy
Battery & inverter or

wiring defective
No rotating (See Battery & Inverter.)
sound Ask specialist for
repair
Broken wire
Motor won’t rotate without load
Broken stator coil
Poor connection due to

loose terminal connection Tighten securely
Motor can rotate in

either direction when Single phasing due to Ask specialist for
rotated by hand defective wiring or inverter repair
One phase of wires broken Replace wires.

between motor and inverter
Ask specialist for
One phase of stator
repair
coil broken
Broken Replace
bearing bearing.
Motor hums, but
won’t rotate
Rotating shaft twisted due Retighten bolts
to loose mounting bolt
Change connections
Reverse rotating Wrong
of two of the three
direction connections
lead wires.
Motor rotates only without load
Motor hums Unbalanced gap

between stator core
and rotor core
Motor frame Ask specialist for
shows excessive Part of stator coil repair
heat build up short-circuited
Noisy Defective Replace

bearing bearing bearing
- 15 -
2. MOTORS
Check for voltage at inverter

Single output terminal and if needed
phasing motor lead wire connections and
remove the cause.
Speed drops
suddenly Voltage Check battery condition of
drop charge and recharge if needed
Overloading
Reduce load
Motor overheating
Breather
clogged with Remove
contaminants contaminants
Motor shaft Burned Replace

cannot be easily bearing bearing
rotated by hand
Loaded operation
Imbalanced resistance
Motor stops Foul smell of each phase and low
from motor insulation resistance
(with motor lead wire Ask specialist for
removed) repair
Lead wire broken or

short-circuited
See “Inverter”.
Inverter defective
Check inverter for output Retighten

terminal voltage and motor connections of
lead wire for connection. motor lead wire
Noise or vibration
during operation
Check for bracket bolt,
sensor mounting nut for Retighten bolts
looseness.
Bearings Noise from bearings Replace

overheating (check with rod) bearings
- 16 -
3. CONTROL SYSTEM
3. CONTROL SYSTEM
The control system consists primarily of an inverter type controller, drive motors, VTM unit, and
pump motor.
3.1.1 CONTROLLER
The controller consists of the CPU, power supply unit, and main circuit (FET module, contactors
and fuses) and is installed at the rear part of the frame. Figure 3.1 shows its external appearance.
The CPU monitors the operating status of the F/R switch, accelerator pedal, load handling levers
and steering wheel to control the main circuit.
The power supply unit controls the power supply to be fed to the controller and the main circuit
controls the drive and pump motors.
The CPU has a range of self-check functions by which the control system is always monitored and
errors are displayed with LEDs.
Fig. 3.1 Controller
- 17 -
3. CONTROL SYSTEM
FAN
FAN
Fig. 3.2 Inside of Controller
- 18 -
3. CONTROL SYSTEM
DSF
DSR
TRAVEL SPEED LIMIT SW
ATT2 SW (TRAVEL STOP SIGNAL)
SPE SW
ATT1 SW
BRAKE SW
SEAT SW
PARKING BRAKE SW
INPUT VOLTAGE SELECT SW
STEERING WHEEL POSITION MEMORY
TILT SW
LEFT DRIVE MOTOR

ACCELERATOR POT
LIFT POT
(VTM ←
CONTROLLER SHIELD
DATA RECEIVED)
(VTM →
CONTROLLER
DATA TRANSMITTED)
LOW VOLTAGE SIGNAL
RIGHT DRIVE MOTOR

SHIELD
STEERING WHEEL ENCODER
PHASE A PHASE Z
PHASE B
LEFT DRIVE MOTOR

THERMOSENSOR
RIGHT DRIVE MOTOR

THERMOSENSOR
PUMP MOTOR
THERMOSENSOR
TRAVEL SPEED SENSOR B

(LEFT DRIVE MOTOR)
TRAVEL SPEED SENSOR A

(LEFT DRIVE MOTOR)

(PUMP MOTOR)
TRAVEL SPEED SENSOR B

(RIGHT DRIVE MOTOR)
PUMP MOTOR

(RIGHT DRIVE MOTOR)
OVERSPEED
WARNING OUTPUT
LIFT LOCK& UNLOAD
SPARE OUTPUT
SOL OUTPUT
OUTPUT FOR EQUIPMENT
RELATED TO REAR TRAVEL
OUTPUT FOR EQUIPMENT RELATED TO FWD TRAVEL
TURNING IN FWD TRAVEL
Others: AWG20
CN1-13.26:AWG18
Wire diameter:
DIRECTION OF TIRES IN
← STEERING SENSOR
(2.00 kΩ ±0.4kΩ)
Fig. 3.3 Controller Circuit Diagram
- 19 -
3. CONTROL SYSTEM
3.1.2 ACCELERATOR PEDAL

The accelerator pedal is installed as shown in Figure 3.4. When the accelerator pedal is pressed or
released, the movement of the pedal is transmitted to the potentiometer, which in turn converts the
mechanical movement into voltage change and send it to the controller.
Connection diagram
View looking from
LEVER
SPRING
View looking from
34.5 mm PEDAL 1. Apply a voltage of +5 ±0.01 V between 95 and 41.

1.36 in. 2. In neutral, turn potentiometer body clockwise and lock
when the potentiometer reads a voltage of 0.11 +0.167
- 0.099
between 93 and 41.

3. Move the lever a few times to make sure that the voltage
between 93 and 41 is 3.0 ±0.22 V when fully opened.
STOPPER
POTENTIOMETER
Fig. 3.4 Accelerator Pedal
- 20 -
3. CONTROL SYSTEM
3.1.3 AUTO POWER-OFF SYSTEM (OPTION)

The controller power supply is turned off automatically if no operation (traveling, load handling,
braking) is performed for 15 minutes while the key switch is turned on. Figure 3.5 shows the
configuration of the auto power-off system.
The operations including traveling, load handling and braking are constantly monitored by the VTM
unit.
100 14
1142
G Lg
11134 135
1 13
137
G 11-1
LL Y
Y(11)
Br(101)
A
- G
- 100
Lgg V -- V Y
142 211 136
36 11
L G P
134 137 139
B
PAO
O VLL
(AUTO POWER OFF)
F (LIFT LOCK)
Rear view of VTM unit

KEY SW
Y 11
2W 10
SHORT G 137 30W
COUPLER L 134 15
(AT 36V) 40W
AUTO
Gy 138
TO Y 11 FROM
W 135
CONTROLLER Br 101
CONTROLLER
LL
180 G 100
FROM F3 LLL
Lg 142
LIFT LOCK P 139
CONTROLLER V 136
SHORT 180
COUPLER 2W
(AT 36V)
SOL
V 211
(-)
TO VTM
CIRCUIT OF PAO(AUTO POWER OFF) CIRCUIT OF ISO(LIFT LOCK)
Fig. 3.5
- 21 -
3. CONTROL SYSTEM
3.2 MAINTENANCE
3.2.1 TROUBLESHOOTING
Error codes (2-digit decimal numbers) are displayed by the green LED (drive) or red LED (pump,
HPS) on the controller CPU board in the following manner:
The tens digit and ones digit are expressed by blinking at intervals of 0.5 seconds, respectively, with
the tens and ones digits separated by an 1-second OFF period. After a single error code is displayed,
the LED stays off for 4 seconds before starts blinking again.
If multiple errors occur, only the code of the error that has been detected most recently by the
controller is displayed.
Example:
Error code: 23 (drive neutral interlock detected)
Error code 23
LED blinks 2 times LED blinks 3 times
LED on
LED off
The same process

is repeated
Error codes are also displayed as 3-digit numbers on the meter panel. The table shown on the pages
that follow list the error code numbers that are indicated on the LED and those that are indicated on the
meter panel in the Error Code column. The error code numbers indicated on the meter panel are put in
brackets.
■ Caution
• When resetting the system by turning the key switch on/off after repairing errors, make sure to wait
for more than 1 second before turning the key switch from off to on. (The CPU takes 1 second to stop
functioning after the key switch is turned off.)
• When checking the controller, wait for more than 10 minutes after removing the battery connector.
Failure to observe the above requirement, some error codes might appear.
Neutral lock detected (If this error code appears, put DSF/DSR switch in neutral, accelerator in
OFF, load handling levers in OFF and then turn off the key switch, wait for more than 1 second
and then turn it on again.)
Seat switch not detected (If this error appears, turn the seat switch to ON, DSF/DSR switch in
neutral, accelerator in OFF, load handling levers in OFF and turn the key switch off, wait for
more than 1 second and then on again.)
• If the error code still appears, see “TROUBLESHOOTING.”
• If using the “Trouble diagnosis chart by error code” does not correct a problem, replace the CPU
board with a new one.
- 22 -
3. CONTROL SYSTEM
(1) Failures not shown by error codes

No. Problem Cause Remedy (Follow numerical order ) Resetting Remarks
1 When key switch is No power in key switch Check harness in key switch line. Repair or replace if Normal resetting
turned on, contactors line. needed.
won’t be closed and
green and red LEDs on Disconnected harness Check harnesses between CN1R (power supply board) and Normal resetting
controller CPU board between power supply CN8 (CPU board) and between CN2R (power supply board)
stay on, not blink. and CPU boards and CN8 (CPU board). Repair or replace if needed.
Malfunction of DSW1 Turn off DSW1 (D) and DSW3 (P) on CPU board. (DSW1 Normal resetting
and DSW3 and DSW3 are 2-bit switches.)
Power failure Check for disconnected battery connector. Normal resetting
2 Truck won’t move Speed sensor connectors Check connectors A and B of each drive motor for Normal resetting Do not
when DSF/DSR switch A and B are reversed. connections and reconnect correctly if needed. have wrong
(F or R) is placed in Check harnesses between CN101, CN102, CN103 and connections
a travel position and CN104 (drive motor) and CN13 (CPU board). Repair or when
accelerator pedal is replace if needed. replacing
pressed. motors.
Broken wire in Check for broken wire of harnesses between CN1-10, 23, Normal resetting
accelerator potentiometer 24 (CPU board) and accelerator and between CN1-10,
and its signal circuit. 24 (CPU board) and accelerator potentimeter. Repair or
replace, if needed.
Repair or replace drive accelerator unit.
3 Truck slows down and Overvoltage detected Check battery connector for poor connection. Norma resetting Poor
stops. Repair or replace harnesses between CN10 - 3, 14 (CPU connection
board) and P3 terminal. of battery
Repair and replace harnesses between CN10-1, 12 (CPU connector
board) and P23 terminal. during
regeneration
or protection
against
disconnected
battery
connector.
4 Pump motor rotates Lift lever signal wire Check for application of more than 1.40 V at CN1 - 11. Normal resetting
when neither lift lever leakage Replace valve controller unit.
or steering wheel is
operated Lift lever potentiometer Check for broken wires of harnesses between CN1-11,12 Normal resetting
and its signal circuit wire (CPU board) and lift lever potentiometer and between
broken CN1-11, 12, 25 (CPU board) and lift lever potentiometer.
Repair or replace if needed.
Repair or replace lift lever unit.
Steering wheel encoder Check for noise or application of voltage in CN2-10, 21. Normal resetting
signal wire leaking
Steering sensor signal With rear wheel in straight-ahead position, check for Normal resetting
wire leaking application of voltage of 1.27 V or 3.73 V in CN7-1.
5 Hard steering Steering wheel encoder Check harnesses between CN2-4, 10, 15, 21 and steering Normal resetting
wire broken, or encoder wheel encoder. Repair or replace if needed.
defective Check steering wheel encoder unit and replace if needed.
* If the electric system does not return to normal after the above steps have been followed, replace the CPU board or controller.
(2) Check procedure by error code.

■ Drive system
Error
Cause Problem Remedy (Follow numerical order ) Resetting Remarks
code
01 Upper and lower Drive motors, Check drive unit power modules (TMR, TML) and Turn off key Error code 30 (pump unit
[218] parts of drive unit pump motor, and replace if needed. switch power modules shorting)
power modules HPS inoperative. Check harness between CN10-3 (CPU board) and P3 is displayed because drive
shorting (Upper (main contactor terminal. Repair or replace if needed. unit power modules and
and lower parts of won’t be closed) Check harness between CN9-1 (CPU board) and P1 pump unit power module
TMR and TML terminal. Repair or replace if needed. are connected through
shorting) Check harness and gate wires between CN6R (power fuses. In addition, if any
supply board) and CNTMR. Repair or replace if power module is shorted,
needed. error codes 69 and 70
Check harness and gate wires between CN5R (power (drive and pump motor
supply board) and CNTML. Repair or replace if quick charge error) may
needed. also appear because no
Check harness and gate wires between CN4 (CPU charge is available for
board) and CN11R (power supply board). Repair or capacitor between P and
replace if needed. N.
Check harness and gate wires between CN6 (CPU
board) and CN10R (power supply board). Repair or
replace if needed.
See repair method for error code 30.
- 23 -
3. CONTROL SYSTEM
■ Drive system
Error
code
02 Lower parts of Drive motors, Check for loose screws or broken wire at ends of drive Turn off key
[316] power modules pump motor, and motors and pump motor. switch
open (TMR, TML, HPS inoperative Check all power modules and replace if needed.
TMP1, TMP2) (main contactor Check harness and gate wires between CN9R (power
won’t be closed) supply board) and CN17D (TMR). Repair or replace
if needed.
Check harness and gate wires between CN6R (power
supply board) and CNTMR. Repair or replace if
needed.
supply board) and CNTML. Repair or replace if
needed.
Check harnesses and gate wires between CN8R,
CN9R (power supply board) and CNTMP1, CNTMP2.
replace if needed.
replace if needed.
replace if needed.
05 Upper parts of Drive motors, Check drive motor power modules (TMR, TML) and Turn off key Error codes 31 and 32
[219] drive unit power pump motor, and replace if needed. switch. (Pump motor’s upper and
modules shorting HPS inoperative Check harness and P4 sensing wire between CN6R-14 lower power modules
(Upper parts of (Main contactor (power supply board) and round terminal in U phase shorting) appear because
TMR and TML won’t be closed) of TMR. Repair or replace if needed. two drive motors and
shorting) Check harness and P14 sensing wire between pump motor power
CN5R-14 (power supply board) and round terminal in modules are connected
06 Lower parts of U phase of TML. Repair or replace if needed. through fuses.
[220] drive unit power Check harness and P4 sensing wire between CN8-8
modules shorting (CPU board) and CN1R-1 (power supply board).
(Lower parts of Repair or replace if needed.
TMR and TML Check harness between CN10-3 (CPU board) and P3
shorting) terminal. Repair or replace if needed.
supply board) and CNTMR. Repair or replace if
needed.
supply board) and CNTML. Repair or replace if
needed.
replace if needed.
replace if needed.
See Repair method for error codes 31 and 32.
08 Right-side drive Drive motors, Check for loose screw or broken wire of right-side Turn off key
[313] unit power module: pump motor, and drive motor end. switch.
U-phase is open HPS inoperative Check right-side drive unit power module, and replace
(main contactor if needed.
09 Right-side drive off) Check harness and gate wires between CN6R (power
[314] unit power module: supply board) and CNTMR. Repair or replace if
V-phase is open needed.
12 Right-side drive Check harness and gate wires between CN4 (CPU
[315] unit power module: board) and CN11R (power supply board). Repair or
W-phase is open replace if needed.
Check harness and gate wires between CN8-13 (CPU
board) and CN1R-8 (power supply board). Repair or
replace if needed.
- 24 -
3. CONTROL SYSTEM
■ Drive system
Error
code
13 Left-side drive Drive motors, Check for loose screw or broken wire of left-side drive Turn key
[213] motor power pump motor, and motor end. switch off.
module: U-phase is HPS inoperative Check left-side drive unit power module, and replace
open (main contactor if needed.
off) Check harness and gate wires between CN5R (power
14 Left-side drive supply board) and CNTML. Repair or replace if
[214] motor power needed.
module: V-phase is Check harness and gate wires between CN6 (CPU
open. board) and CN10R (power supply board). Repair or
15 Left-side drive replace if needed.
[215] motor power Check harness and gate wires between CN8-13 (CPU
module: W-phase board) and CN1R-8 (power supply board). Repair or
is open replace if needed.
16 F/R switch Truck won’t travel Check harness between CN1-21, 22 (CPU board) and Normal Turn on DSF and DSR
[311] defective F/R switch. Repair or replace if needed. resetting switches of F/R switch
Repair or replace F/R switch. simultaneously.
17 Drive accelerator Truck won’t travel Check harness between CN1-10, 23, 24 (CPU board) Normal Accelerator power supply
[212] VR defective and drive accelerator VR. Repair or replace if needed. resetting voltage under normal
Check drive accelerator VR unit, and replace if condition: 4.5 V (between
needed. CN1-10 and N terminal)
An error code is issued
when accelerator output
voltage is more than 4.5
V (between CN1-24 and
N terminal)
19 Right-side drive Truck won’t travel Check harness between CPU board and right-side Turn off key Sensor output in normal
[317] current sensors drive current sensors. Repair or replace if needed. swithc. condition:
(CSRU, CSRW): CSRU: CN9-8, 9, 10, 11 * during traveling: 3.0 V
Defective output or CSRW: CN9-21,22,23,24 - 11.0 V
defective harness Check voltage of current sensor power supply on CPU * DSF/DSR switches =
in the circuit board. OFF, accelerator = OFF,
CSRU: CN9-11 and 8, 9 truck at rest: approx. 7 V
CSRW: CN9-24 and 21, 22 CRSU: between CN9-10
If not normal, replace CPU board. and 8, 9.
Check current sensors (CSRU, CSRW) and replace if CRSW: between CN9-23
needed. and 21, 22.
Sensor power supply
voltage under normal
condition: 15 V
20 Drive fuse (F1) Truck won’t travel Check drive fuse (F1) and replace if needed. Turn off key Check for secondary-side
[211] blown or defective Check harness between CN10-3 (CPU board) and P3 switch voltage of fuse (F1).
harness in detection terminal. Repair or replace if needed.
circuit Check harness between CN9-1 (CPU board) and P1
terminal. Repair or replace if needed.
21 Drive low-voltage Alarm: Low output Recharge battery. Turn off key • 48-V trucks
[101] detected (low Stop: Drive and Check harness between CN9-1 (CPU board) and P1 switch. Alarm occurs when
battery voltage) pump motors terminal. Repair or replace if needed. battery voltage drops to
inoperative (main Check harness and P25 for low voltage signal between 40 V or lower (alarm is
contactor cannot be CN2-3 (CPU board) and VTM unit. Repair or replace overridden when battery
turned off) if needed. voltage is 48 V or more.)
Truck stops when battery
voltage drops to lower
than 28 V for 0.8 sec.
• 36-V trucks
Alarm occurs when
battery voltage drops to
30 V or lower (alarm is
overridden when battery
voltage is 36 V or more.)
HPS continues to
function for safety sake,
but its performance is not
guaranteed.
- 25 -
3. CONTROL SYSTEM
■ Drive system
Error
code
22 Right-side drive Truck can Check thermosensor (THR) for voltage, and replace if Normal Error code is issued when
[304] unit power module travel normally needed. resetting thermosensor (THR) voltage
thermosensor (Temperature Check harness between CN10-5, 16 (CPU board) and is less than 0.2 V or more
(THR) defective reading is normal). thermosensor (THR). Repair or replace if needed. than 4.95 V.
23 Drive neutral Truck won’t travel. Operate accelerator, DSF and DSR switches properly. Turn off
interlock signal Check harness between CN1-10, 23, 24 (CPU board) accelerator
detected and accelerator VR. Repair or replace if needed. and DSF
* Error Check harness between CN1-21, 22 (CPU board) and switch.
code may also FR switch. Repair or replace if needed.
be issued due to Check the circuit for loose connector. Repair or
misoperation by replace if needed.
operator. Check drive accelerator VR unit and repair or replace
if needed.
Repair or replace FR switch.
24 Right-side drive Truck can travel Cool down controller and stop the truck. Truck returns Normal voltage range of
[303] unit power module (Current is limited Check thermosensor (THR) for resistance and voltage to normal thermosensor (THR):
temperature is high when temperature (between CN10-5 and 16) and replace if needed. when the 0.2 V - 4.95 V
is more than 105°C Check harness between CN10-5 , 16 (CPU board) and temperature Normal resistance and
[221°F]). thermosensor (THR). Repair or replace if needed. drops below voltage of thermosensor:
Check right-side drive unit power modules for loose 100°C 25°C : 100kΩ at
mounting bolt. [212°F]. 3.2V(±10%)
50°C: 36kΩ at
2.0V(±10%)
75°C: 15kΩ at
1.0V(±10%)
100°C: 6.5kΩ at
0.5V(±10%)
25 Right-side drive Truck can travel Cool down the drive motor and stop the truck. Truck returns Normal voltage range of
[306] motor temperature (Current is limited Check right-side drive motor thermosensor for to normal thermosensor: 0.2 V - 4.95V
is high when temperature resistance and voltage between CN2-5 and 16, and when the Normal resistance and
is more than 155°C replace if needed. temperature voltage of thermosensor:
[311°F]). Check harness between CN2-5, 16 (CPU board) and drops below 25°C : 10.7kΩ at
thermosensor of right-side drive motor. 145°C 3.5V(±10%)
[293°F]. 50°C: 4.4kΩ at
2.4V(±10%)
100°C: 1.0kΩ at
0.9V(±10%)
150°C: 0.3kΩ at
0.3V(±10%)
26 Right-side drive Truck won’t travel. Cool down controller and stop the truck. Truck Normal voltage range of
[302] unit power module (Error code is Check thermosensor for resistance and voltage returns to thermosensor:
temperature is not issued when between CN10-5 and 16 and replace if needed. normal when 0.2 V - 4.95V
normal temperature is Check harness between CN10-5, 16 (CPU board) and temperature Normal resistance and
115°C [239°F] or thermosensor (THR). Repair or replace if needed. drops below voltage of thermosensor:
more.) Check right-side drive unit power modules for loose 115°C 25°C : 100kΩ at
50°C: 36kΩ at
2.0V(±10%)
75°C: 15kΩ at
1.0V(±10%)
100°C: 6.5kΩ at
0.5V(±10%)
27 Right-side Truck can Check right-side drive motor thermosensor for voltage Normal Error code is issued when
[307] drive motor travel normally and replace if needed. resetting thermosensor voltage is
thermosensor (Temperature Check harness between CN2-5, 16 (CPU board) and less than 0.2 V or more
defective reading is normal) right-side drive motor thermosensor. Repair or replace than 4.95 V.
if needed.
28 Right-side drive Truck won’t Cool down drive motor and stop the truck. Truck Normal voltage range of
[305] motor temperature travel (Error code Check right-side drive motor thermosensor for returns to thermosensor:
is not normal is issued when resistance and voltage between CN2-5 and 16 and normal when 0.2 V - 4.95 V
temperature is replace if needed. temperature Normal resistance and
165°C [329°F] or Check harness between CN2-5, 16 (CPU board) and drops below voltage of thermosensor:
more) thermosensor (THR). Repair or replace if needed. 165°C 25°C : 10.7kΩ at
[329°F]. 3.5V(±10%)
50°C: 4.4kΩ at
2.4V(±10%)
100°C: 1.0kΩ at
0.9V(±10%)
150°C: 0.3kΩ at
0.3V(±10%)
41 Right-side drive Truck won’t travel Check harness between CN13-1, 2 (CPU board) and Normal
[301] motor speed sensor: phase A of right-side drive motor speed sensor. Repair resetting
Output error of or replace if needed.
phases A and B Check harness between CN13-3, 11 (CPU board) and
phase B of right-side drive motor speed sensor. Repair
or replace if needed.
Check phases A and B of right-side drive motor speed
sensor. Repair or replace if needed.
Replace right-side drive motor (improper engagement
between sensor and gears)
- 26 -
3. CONTROL SYSTEM
■ Drive system
Error
code
42 Left-side drive Truck won’t travel Check harness between CN13-6, 14 (CPU board) and Normal reset
[201] motor speed sensor: phase A of left-side drive motor speed sensor. Repair
Output error of or replace if needed.
phases A and B Check harness between CN13-8, 16 (CPU board) and
phase B of left-side drive motor speed sensor. Repair
Check phases A and B of left-side drive motor speed
sensor. Repair or replace if needed.
Replace left-side drive motor (improper engagement
between sensor and gears)
51 Left-side Truck can Check left-side drive motor thermosensor for voltage Normal Error code is issued when
[207] drive motor travel normally and replace if needed. resetting thermosensor voltage is
thermosensor (Temperature Check harness between CN2-6, 17 (CPU board) and less than 0.2 V and more
defective reading is normal) left-side drive motor thermosensor. Repair or replace than 4.95 V.
if needed.
53 Left-side drive Truck can Check thermosensor (THL) for voltage, and replace if Normal Error code is issued when
[204] unit power module travel normally needed. resetting thermosensor (THL)
thermosensor (Temperature Check harness between CN10-6, 17 (CPU board) and voltage is less than 0.2 V,
(THL) defective reading is normal) thermosensor (THL). Repair or replace if needed. more than 4.95 V.
55 Left-side drive Truck can travel Cool down the drive motor and stop the truck. Truck returns Normal voltage range of
[206] motor temperature (Current is limited Check left-side drive motor thermosensor for to normal thermosensor:
is high when temperature resistance and voltage between CN2-6 and 17, and when the 0.2 V - 4.95 V
is more than 155°C replace if needed. temperature Normal resistance and
[311°F]). Check harness between CN2-6, 17 (CPU board) and drops below voltage of thermosensor:
thermosensor of left-side drive motor. 145°C 25°C : 10.7kΩ at 3.5V(±10%)
[293°F]. 50°C: 4.4kΩ at 2.4V(±10%)
100°C: 1.0kΩ at 0.9V(±10%)
150°C: 0.3kΩ at 0.3V(±10%)
56 Left-side drive Truck won’t travel. Cool down controller and stop the truck. Truck Normal voltage range of
[202] unit power module (Error code is Check thermosensor (THL) for resistance and voltage returns to thermosensor (THL):
temperature is not issued when between CN10-6 and 17 and replace if needed. normal when 0.2 V - 4.95 V
normal temperature is Check harness between CN10-6, 17 (CPU board) and temperature Normal resistance and
115°C [239°F] or thermosensor (THL). Repair or replace if needed. drops below voltage of thermosensor:
more.) Check left-side drive unit power modules for loose 115°C 25°C : 100kΩ at 3.2V(±10%)
mounting bolt. [239°F]. 50°C: 36kΩ at 2.0V(±10%)
75°C: 15kΩ at 1.0V(±10%)
100°C: 6.5kΩ at 0.5V(±10%)
57 Left-side drive Truck can travel Cool down controller and stop the truck. Truck returns Normal voltage range of
[209] unit power module (Current is limited Check thermosensor (THL) for resistance and voltage to normal thermosensor (THL): 0.2 V -
temperature is high when temperature (between CN10-6 and 17) and replace if needed. when the 4.95 V
is more than 105°C Check harness between CN10-6, 17 (CPU board) and temperature Normal resistance and
[221°F]). thermosensor (THL). Repair or replace if needed. drops below voltage of thermosensor:
Check left-side drive unit power modules for loose 100°C 25°C : 100kΩ at
50°C: 36kΩ at 2.0V(±10%)
75°C: 15kΩ at 1.0V(±10%)
100°C: 6.5kΩ at
0.5V(±10%)
58 Left-side drive Truck won’t Cool down drive motor and stop the truck. Truck Normal voltage range of
[205] motor temperature travel (Error code Check left-side drive motor thermosensor for returns to thermosensor: 0.2 V - 4.95 V
is not normal is issued when resistance and voltage between CN2-6 and 17 and normal when Normal resistance and
temperature is replace if needed. temperature voltage of thermosensor:
165°C [329°F] or Check harness between CN2-6, 17 (CPU board) and drops below 25°C : 10.7kΩ at
more) left-side drive motor thermosensor. Repair or replace 165°C 3.5V(±10%)
if needed. [329°F]. 50°C: 4.4kΩ at 2.4V(±10%)
100°C: 1.0kΩ at 0.9V(±10%)
150°C: 0.3kΩ at 0.3V(±10%)
59 Left-side drive Truck won’t travel Check harness between CPU board and left-side drive Turn off key Normal sensor output:
[216] motor current motor current sensors. Repair or replace if needed. switch. • during traveling: 3.0V -
sensors (CSLU, CSLU: CN9-4, 5,6, 7 11.0V
CSLW) : Improper CSLW: CN9-17, 18, 19, 20 • DSF/DSRSW=OFF,
output. defective Check voltage of current sensor power supply on CPU accelerator=OFF, truck at
harness of the board: rest: about 7V
circuit CSLU: between CN9-7 and 4, 5 CSLU: between CN9-6
CSLW: between CN9-20 and 17, 18. and 4, 5
If defective, replace CPU board. CSLW: between CN9-19
Check current sensors (CSLU and CSLW) and replace and 17, 18
if needed. Normal sensor power supply
voltage: 15V
- 27 -
3. CONTROL SYSTEM
■ Drive system
Error
code
69 Drive unit Drive motors, See “Remedy for error code 01.” Turn off key
[217] rapid charge pump motor, and See “Remedy for error code 30.” switch.
error (capacitor HPS inoperative Replace CPU board (rapid charge drive transistor and
between P and (This error is resistance are defective)
N is improperly detected when
charged) error code 01 or
30 is caused. Main
contactor won’t be
closed.)
86 Load dump error Truck won’t travel Check battery connector and connection harness and Normal Drive unit power module
[318] (overvoltage repair if needed. resetting bridge voltage is too high.
detected) Check harness between P terminal and battery
connector and between N terminal and battery
connector. Repair or replace if needed.
Check P and N terminals for looseness, and retighten
if needed.
Check charger for wrong connection.
■ Pump motor and HPS system

Error
code
30 Upper and lower Drive motors, Check motor power modules (TMP1, TMP2) and Turn off key Error code 01 (drive unit
[418] parts of pump unit pump motor, HPS replace if needed. switch. power module shorting)
power modules inoperative Check harness between CN10-1 (CPU board) and P23 is displayed because
shorting (Main contactor terminal. Repair or replace if needed. drive unit power modules
(Upper and lower won’t be closed) Check harness between CN9-1 (CPU board) and P1 and pump motor power
parts of TMP1 and terminal. Repair or replace if needed. modules are connected
TMP2 shoring) Check harness and gate wires between CN8R, CN9R through fuses. In addition,
(power supply board) and CNTMP1, CNTMP2. if any power module is
Repair or replace if needed. shorted, error codes 69
Check harness and gate wires between CN5 (CPU and 70 (drive and pump
board) and CN12R (power supply board). Repair or unit quick charge error)
replace if needed. may also appear because
See “Remedy for error code 01.” no charge is available for
capacitor between P and
N.
31 Upper parts of Drive motors, Check pump unit power modules (TMP1 and TMP2) Turn off key Error codes 05 and 06
[419] pump unit power pump motor, HPS and replace if needed. switch. (upper and lower parts
modules shorting inoperative Check harness between CN8R-14 (power supply of drive unit power
(Upper parts of (Main contactor board) and U-phase round terminal of TMP1. Repair modules shorting) appear
TMP1 and TMP2 won’t be closed) or replace if needed. After replacement, check P24 because drive and pump
shorting) sensing wire. unit power modules are
Check harness and P4 sensing wires between CN8-8 connected through fuses.
32 Lower parts of (CPU board) and CN1R-1 (power supply board).
[420] pump unit power Repair or replace if needed.
modules shorting Check harness between CN10-1 (CPU board) and P23
(Lower parts of terminal. Repair or replace if needed.
TMP1 and TMP2 Check harness and gate wires beween CN8R, CN9R
shoring) (power supply board) and CNTMP1, CNTMP2.
board) and CN12R (power supply board). Repair
replace if needed.
See “Remedy for error codes 05 and 06.”
34 Pump current Pump motor and Check harness between CPU board and pump current Turn key Sensor output in normal
[416] sensor (CSP): HPS inoperative sensors. Repair or replace if needed. switch off condition:
Improper output, CSPU: CN10-8, 9, 10, 11 • during traveling: 3.0 V
defective harness CSPW: CN10-21,22, 23, 24 - 11.0 V
of the circuit Check voltage of current sensor power supply on CPU • truck at rest: about 7 V
board. CSPU: between
CSPU: between CN10-11 and 8, 9. CN10-10 and 8, 9
CSPW: between CN10-22 and 19, 20. CSPW: between
If defective, replace CPU board. CN10-21 and 19, 20
Check current sensors (CSPU, CSPW) and replace if Sensor power supply
needed. voltage under normal
condition: 15 V
- 28 -
3. CONTROL SYSTEM

Error
code
35 Lift VR defective Motor speed is Check harness between CN1-11, 12, 25 (CPU board) Normal Normal lift power supply
[412] limited to 50% of and lift VR. Repair or replace if needed. resetting voltage: 4.5 V (between
maximum speed. Check lift VR unit. Repair or replace if needed. CN1-12 and N terminal)
(Current is not Error code is issued when
limited.) lift output voltage is
4.5 V or more (between
CN1-11 and N terminal)
36 Pump unit Load handling Check thermosensor (THP) voltage, and replace if Normal Error code is issued
[404] power module operation possible needed. resetting when termosensor (THP)
thermosensor (Temperature Check harness beween CN10-7, 18 (CPU board) and voltage is less than 0.2 V
(THP) defective reading is normal.) thermosensor (THP). Repair or replace if needed. or more than 4.95 V
39 Pump unit Pump motor and Cool down controller and stop truck. Truck Normal voltage range of
[402] power module HPS inoperative Check thermosensor (THP) for resistance and voltage returns to thermosensor:
temperature error (when temperature (between CN10-7 and 18). Replace if needed. normal when 0.2 V - 4.95 V
is 115°C [239°F] or Check harness between CN10-7, 18 (CPU board) and temperature Normal resistance and
more.) thermosensor (THP). Repair or replace if needed. drops below voltage of thermosensor:
Check pump unit power modules (TMP1, TMP2) for 115°C 25°C : 100kΩ at
loose mounting bolt. [239°F]. 3.2V(±10%)
50°C: 36kΩ at
2.0V(±10%)
75°C: 15kΩ at
1.0V(±10%)
100°C: 6.5kΩ at
0.5V(±10%)
43 Pump motor speed Pump motor and Check harness between CN13-5, 13 (CPU board) Normal
[401] sensor: HPS inoperative and phase A of pump motor speed sensor. Repair or resetting
Output error of replace if needed.
phases A Check phases A of pump motor speed sensor. Repair
Replace pump motor (improper engagement between
sensor and gears)
44 Pump motor low- Alarm: Low output Recharge battery. Turn off key • 48-V trucks
[101] voltage detected Stop: Drive and Check harness between CN9-1 (CPU board) and P1 switch. Alarm occurs when
(low battery pump motors terminal. Repair or replace if needed. battery voltage drops to
voltage) inoperative (main Check harness and P25 for low voltage signal between 40 V or lower (alarm is
contactor won’t be CN2-3 (CPU board) and VTM unit. Repair or replace overridden when battery
turned off) if needed. voltage is 48 V or more.)
HPS continues to
guaranteed.
• 36-V trucks
Alarm occurs when
battery voltage drops to
30 V or lower (alarm is
overridden when battery
voltage is 36 V or more.)
HPS continues to
guaranteed.
45 Pump motor fuse Pump motor and Check pump motor fuse (F2) and replace if needed. Turn off key Check for secondary-side
[411] (F2) blown or HPS inoperative Check harness between CN10-1 (CPU board) and P23 switch voltage of fuse (F2).
defective harness terminal. Repair or replace if needed. Error code is ussed when
in detection circuit Check harness between CN9-1 (CPU board) and P1 thermosensor voltage is
terminal. Repair or replace if needed. less than 0.2 V or more
than 4.95 V.
46 Pump motor Load handling Check pump motor thermosensor for voltage and Normal Normal voltage range of
[407] thermosensor operation is normal replace if needed. resetting thermosensor (THP):
defective (Temperature Check harness between CN2-8, 19 (CPU board) 0.2 V - 4.95 V
reading is normal.) and pump motor thermosensor. Repair or replace if
needed.
- 29 -
3. CONTROL SYSTEM

Error
code
47 Pump unit power Drive motors, Check for loose screw or broken wire of pump motor Turn off key
[413] module: U-phase is pump motor, and end. switch.
open. HPS inoperative Check pump unit power modules, and replace if
(main contactor needed.
48 Pump unit power off) Check harness and gate wires between CN8R, CN9R
[414] module: V-phase is (power supply board) and CNTMP1, CNTMP2.
open. Repair or replace if needed.
49 Pump unit power Check harness and gate wires between CN5 (CPU
[415] module: W-phase board) and CN12R (power supply board). Repair or
is open. replace if needed.
Check harness and gate wires between CN8-13 (CPU
board) and CN1R-8 (power supply board). Repair or
replace if needed.
60 Pump unit Load handling Cool down controller and stop the truck. Truck returns Normal resistance and
[403] power module operation is Check thermosensor (THP) for resistance and voltage to normal voltage of thermosensor:
temperature is high possible (Current (between CN10-7 and 18) and replace if needed. when the 25°C : 100kΩ at
is limited when Check harness between CN10-7, 18 (CPU board) and temperature 3.2V(±10%)
temperature is thermosensor (THP). Repair or replace if needed. drops below 50°C: 36kΩ at 2.0V(±10%)
more than 105°C Check pump unit power modules (TMP1, TMP2) for 100°C 75°C: 15kΩ at 1.0V(±10%)
[221°F]). loose mounting bolts. [212°F]. 100°C: 6.5kΩ at
0.5V(±10%)
63 Steering angle HPS operative Check harness between CN7-1, 2, 7 (CPU board) Turn off key Normal steering angle
[312] potentiometer • Can travel with and steering angle potentiometer. Repair or replace if switch. potentiometer power supply
defective steering wheel in needed. voltage: 4.55 V (between
straight position Check steering angle potentiometer. Repair or replace CN7-1 and N terminal)
• Truck cannot turn if needed. Error code is issued when
(Speeds of right steering angle potentiometer
and left drive power supply voltage is less
motors cannot be than 0.3 V or more than 4.8
corrected.) V (between CN7-2 and N
• Steering terminal).
wheel knob If all wires between CN7-1,
displacement 2 and 7 are broken, steering
cannot be angle potentiometer input
corrected. voltage becomes 2.5 V.
(Ideal steering Therefore, any error code is
angle cannot be not generated.
calculated.)
64 Pump motor Load handling Cool down the pump motor and stop the truck. Truck returns Normal voltage range of
[406] temperature is high operation is Check pump motor thermosensor for resistance and to normal thermosensor:
possible. voltage (between CN2-8 and 19), and replace if when the 0.2 V - 4.95V
(Current is limited needed. temperature Normal resistance and
when temperature Check harness between CN2-8, 19 (CPU board) and drops below voltage of thermosensor:
is more than 155°C thermosensor of pump motor. 145°C 25°C : 10.7kΩ at 3.5V(±10%)
[311°F]). [293°F]. 50°C: 4.4kΩ at 2.4V(±10%)
100°C: 1.0kΩ at 0.9V(±10%)
150°C: 0.3kΩ at 0.3V(±10%)
65 Pump motor Load handling Cool down pump motor and stop the truck. Truck Normal voltage range of
[405] temperature is not operation is not Check pump motor thermosensor for resistance returns to thermosensor:
normal possible (Error and voltage between (CN2-8 and 19) and replace if normal when 0.2 V - 4.95 V
code is issued needed. temperature Normal resistance and
when temperature Check harness between CN2-8, 19 (CPU board) and drops below voltage of thermosensor:
is 165°C [329°F] or thermosensor. Repair or replace if needed. 165°C 25°C : 10.7kΩ at 3.5V(±10%)
more) [329°F]. 50°C: 4.4kΩ at 2.4V(±10%)
100°C: 1.0kΩ at 0.9V(±10%)
150°C: 0.3kΩ at 0.3V(±10%)
66 Pump motor neutral Load handling Operate lift lever properly. Turn off
interlock signal operation is not Check harness between CN1-11, 12, 25 (CPU board) lift, tilt,
detected possible. and lift VR. Repair or replace if needed. attachment
* Error Check lift VR unit. Repair or replace if needed. 1 and
code may also Check tilt, attachment 1, and attachment 2 switches. attachment 2
be issued due to Repair or replace if needed. switches.
misoperation by Check the circuit for loose connector and defective
operator. harness. Repair or replace if needed.
70 Pump system Drive motors, pump See “Remedy for error code 30.” Turn key
[417] rapid charge motor, and HPS See “Remedy for error code 01.” switch off.
error (capacitor inoperative Replace CPU board (rapid charge drive transistor and
between P and N is (This error is detected resistance defective)
defective) when error code 01
or 30 is caused. Main
contactor won’t be
closed.)
- 30 -
3. CONTROL SYSTEM
■ Whole system
Error
code
03 Main contactor Drive motors, Check main contactor. Repair or replace if needed. Turn off key
[502] shorting or pump motor and (contacts welded or stuck) switch.
sensing circuit HPS inoperative Check harness between CN9-1 (CPU board) and P1
harness defective (Main contactor’s terminal. Repair or replace if needed.
contacts are stuck.) Check harness between CN10-3 (CPU board) and P3
Check harness between CN10-1 (CPU board) and P23
04 Main contactor Drive motors, Check main contactor. Repair or replace if needed. Turn off key
[501] open, pump motor, and (foreign matter between contacts or contacts stuck.) switch.
all fuses open, HPS inoperative Check harness between CN9-1(CPU board) and P1
or sensing circuit (Error code is terminal. Repair or replace if needed.
harness defective issued when you Check harness between CN10-3 (CPU board) and P3
fail to operate terminal. Repair or replace if needed.
contactor properly Check harness between CN10-1 (CPU board) and P23
on your fifth try.) terminal. Repair or replace if needed.
Replace CPU board (drive transistor TR1 open)
07 Main contactor Drive motors, Check main contactor coil for disconnected connector Turn off key
[503] drive transistor pump motor and or broken wire. Repair or replace if needed. switch.
defective HPS inoperative. Check harness between CN10-2, 13 (CPU board) and
(on CPU board: TR1 shorted contactor coil connector. Repair or replace if needed.
TR1), contactor can be Replace CPU board (drive transistor TR1 shorted)
main contactor coil closed
open or sensing Coil open
circuit harness contactor won’t be
defective closed.
99 Battery voltage Current limit Check battery voltage and repair if needed. Turn off key
[110] setting error is added due to Check input voltage selection switch. switch.
(45 V is detected overvoltage Check harnesses of CN1-9 and selection connector
when battery is set Drive motor: (VTM unit side). Repair or replace if needed.
at 36 V setting.) Current is limited
to 50% at 45 V
Pump motor:
Current is limited
to 50% at 45 V.
■ Function
Error
code
67 Right-side drive Truck won’t travel Turn off DSF/DSR switches (neutral) and then turn off Turn off: Stall current x more than
[308] motor speed accelerator and brake switches. accelerator about 0.1 sec at 10 sec.
beyond inching Check accelerator and brake switches and DSF/DSR switch, DSF
range. switches for shorting. Repair or replace if needed. switch, DSR
68 Left-side drive Check the circuit for loose connector and defective switch, and
[208] motor speed harness. Repair or replace if needed. brake switch
beyond inching
range.
* Error code
may also be
issued due to
misoperation by
operator.
87 Seat switch not Truck won’t travel Turn seat switch on and accelerator switch, DSF/DSR Turn on seat
[105] detected (after key and load handling switches off. switch and
switch has been operation is not Turn off lift, tilt, attachment 1 and attachment 2 turn off the
turned on) possible. switches (neutral) and then turn key switch on and off. following
88 Seat switch not Check seat switch for opening. Repair or replace if switches:
[106] detected (after key needed. accelerator,
switch has been Check accelerator switch and DSF/DSR switches for DSF/DSR,
turned on) shorting. Repair or replace if needed. lift, tilt,
* Error code Check circuit for loose connector and defective attachment
may also be harness. Repair or replace if needed. 1, and
issued due to attachment 2.
misoperation by
operator.
- 31 -
3. CONTROL SYSTEM
3.2.2 CHECKING CONTROLLER COMPONENTS AND CONNECTIONS

Do not touch any electric component by bare hand with the truck in energized state. Make sure
the battery connector is disconnected and wait for more than 10 minutes before removing or touching
electric components. If checking parts and connections with the truck in energized state, raise the drive
wheel off the floor or ground surface to prevent the truck from moving accidentally when the motor
suddenly starts rotating for any reason. Use the same precaution when checking the truck for operations
including traveling, switchback, and load handling.
(1) Checking electric components of controller

■ Tools and measuring equipment
No. Name Specification and remarks Application
1 Screwdriver set Phillips and flat-bladed screwdrivers (large, medium, Tightening and removing screws, setting
small), flat-bladed screwdriver for small screws adjustment controls.
2 Wrench set (socket 8 mm, 13 mm, 17 mm Tightening and removing bolts, nuts, and
wrenches) studs
3 Torque drivers M4, M4.5, M5, M6 Measuring tightening torque of screws
4 Torque wrench M8 Tightening external terminal M8,
measuring tightening torque of M8 bolts
and nuts
5 Tweezers and pliers Installing and removing small parts
6 Ammeter DC500A or 1000A Measuring electric current
7 Digital tester, analog -12V, -30V, -120V Measure voltage
tester
Range x 1 Ω x 100 Ω x 1000 Ω Measure resistance (Do not use digital
tester)
8 Oscilloscope Diagnosis of transistor circuit
9 Stabilized power 0 - 50 V, variable, 3A conductable Checking operation of each component
supply for control
■ Component layout
1. Do not confuse polarity of wiring outside.

2. Tightening torque of nut to be 9.8 ± 1 N-m
[70.9 ± 7.2 lbf-ft].
Fig. 3.6
- 32 -
3. CONTROL SYSTEM
■ Tightening torque
Where to tighten Screw Torque
size (N-m)
Part name Item Symbol Truck Model [lbf-ft] Remarks
Printed circuit board Fixed Common N61F30836=5 M4.5 1.0+0.5

0
(CPU) [7.2+3.6
0 ]
Printed circuit board Fixed Common N61F30887=1 M4 1.5 ± 0.2 Lock bushing (NB-
(power supply) [10.8 ± 1.4] 400B) and collar
(NA-407B).
Power module Fixed Drive motor TMR Common FM400TU-02A M6 5.4 ± 0.5 Apply heat-
Drive motor TML [39.1 ± 3.6] dissipating silicone
Pump motor G-746 to mounting
TMP1, TMP2 surface.
Main contactor Fixed MD Common CP30M-A54 M5 2.5 ± 0.5
[18.1 ± 3.6]
Terminal M8 9.8 ± 1.0
[70.9 ± 7.2]
Current sensor Fixed CSRU/W Common L05Z800S15 M4 1.5 ± 0.2
CSLU/W [10.8 ± 1.4]
CSPU/CSPW
Terminal Fixed P.N.RU, RV, RW, Common IP-M8x363Nx10 M8 12 ± 1.0
LU, LV, LW, PU, IP-M8x31Nx12 [86.8 ± 7.2]
Terminal PV, PW
M8 9.8 ± 1.0
[70.9 ± 7.2]
Anchor mount Fixed Common CTAM1-HS M4 1.5 ± 0.2
[10.8 ± 1.4]
Screws whose tightening torque are not specified in the torque chart, are tightened to the following
standard torque:
M4: 1.5 ± 0.2 N-m [10.8 ± 1.4 lbf-ft]
M5: 2.5 ± 0.5 N-m [18.1 ± 3.6 lbf-ft]
M6: 5.4 ± 0.5 N-m [39.1 ± 3.6 lbf-ft]
M8: 9.8 ± 1.0 N-m [70.9 ± 7.2 lbf-ft]
CAUTION
If bolts or nuts for securing the controller power terminals become loose, heating will occur to cause
a burning accident. If a loose bolt or nut of heating is found, polish the said part with a sand paper and
retighten. In addition, a poor connection of the connectors will hamper normal operation. Remove dust
or corrosion of the connectors and insert and remove them a few times. Furthermore, check lead wires
for breakage and terminals for deformation.
- 33 -
3. CONTROL SYSTEM
(2) CPU board and power supply board

The CPU board controls the controller and the power supply board supplies control voltage and
drives the gates.
Visually check the CPU board and power supply board for scores, scratches, or undue discoloration,
and connectors for corrosion, observing the following conditions:
• Do not touch any components mounted on the surface of each printed circuit board with bare hand,
because it might be damaged by static electricity.
• Hold the edges of the printed circuit board when handling.
• Put them in an antistatic bag when transporting or storing.
■ Removing CPU board and power supply board

When inspecting or replacing the CPU board, remove the case cover first and then remove the
wire harness connector from the board. Remove the 9 screws securing the board. When inspecting or
replacing the power supply board, remove the 4 screws securing the CPU box and then remove the
CPU box. Remove the 7 screws (3 at the drive motor side, 4 at the pump motor side) securing the CPU
box locking plate and detach the CPU box locking plate. Remove wire harness connector from the
power supply board. Remove the 8 screws securing the power supply board and then remove the power
supply board.
When removing the wire harness connector, press the connector locks fully and remove the
connector.
There are several wire harnesses: one used between the CPU board and power supply board; ones
for detecting voltages inside the controller.
After replacing boards or checking wire harnesses, make sure to connect the wire harnesses
correctly and securely.
■ Composition of CPU board and power supply board
Power supply board CPU board
Fig. 3.7
- 34 -
3. CONTROL SYSTEM
CPU board
DSW2: For setting the model
刈1
( 0
C
制8
Power supply board
Fig. 3.8 Connector Locations
- 35 -
3. CONTROL SYSTEM
■ DSW default setting

The DSW2 is used for setting truck models that have the controller and the installation of SRS
feature.
The DSW1 (D) and DSW3 (P) are used for downloading software. Do not change their settings.
FTB16-7 FTB18-7 FTB20-7

Trucks with SRS Trucks with SRS
STD STD
DSW-OFF position feature feature
DSW-ON position
DSW2
SRS: Automatic correction of steering wheel knob deviation
Fig. 3.9
■ CPU board connector pin numbers

The CN1, CN13, CN7 and CN2 on the CPU board are used for connecting external wiring.
The CN11 and CN12 on the CPU board are used for downloading software and they are not used.
The other connectors are given for internal wiring to the power supply board, CS, thermistor, and
voltage detection terminal and N terminal.
26-pin connectors CN1, CN9 12-pin connector CN7
22-pin connectors CN2, CN10 16-pin connectors CN8, CN13
6-pin connector CN4 8-pin connector CN5 9-pin connector CN6
Fig. 3.10
- 36 -
3. CONTROL SYSTEM
■ Power supply board connector pin numbers

On the power supply board, the CN5R and CN6R are internal wiring connectors used to connect the
left drive unit power module TML and the right drive unit power module TMR. The CN8R and CN9R
are internal wiring connectors used to connect the pump unit power modules TMP1 and TMP2.
The connectors are internal wiring connectors used to connect the CPU board and N terminal.
12-pin connector CN9R 16-pin connector CN5R
20-pin connectors CN6R, CN8R
14-pin connector CN1R 5-pin connector CN4R 7-pin connector CN2R
6-pin connector CN11R 8-pin connector CN12R 9-pin connector CN10R
Fig. 3.11
- 37 -
3. CONTROL SYSTEM
■ Power module connector pin numbers
12-pin connectors CNTML - CNTMR - 2-pin connectors CNTHL - CNTHR -

CNTMP1 - CNTMP2 CNTHP
Fig. 3.12
■ Current sensor connector pin numbers
4-pin connectors CNCSLU - CNCSLW - CNCSRU -

CNCSRW - CNCSPU - CNCSPW
Fig. 3.13
■ Main contactor connector pin numbers
2-pin connectors CNMC
Fig. 3.14
- 38 -
3. CONTROL SYSTEM
(3) Checking power modules (drive unit TMR and TML, and pump unit TMP1 and TMP2)
■ Appearance of power module
The power module is a MOS FET module containing 6 elements with P and N terminals and U, V,
and W output terminals (3-phase inverter bridge circuit).
The gate signal and thermistor (thermosensor) are connected to the module with connectors.
Power module
N terminal
P terminal
Thermistor
Gate wire connector
connector
U terminal V terminal W terminal
* The numbers in parentheses represent

connector pin numbers.
(Indicated on the surface of the power
module case.)
Fig. 3.15
■ Power module arrangement
All the power modules

* The pump unit power modules are connected in are of the same type.
parallel (Connection of same characteristic rank)
Fig. 3.16
- 39 -
3. CONTROL SYSTEM
■ Checking power modules

Visually check each module for scores, scratches or excessive discoloration, and the connectors
for corrosion.
Disconnect all the cables, capacitor board and bus bar connected to the power module, and
measure the resistance of each terminal according to the table given below, using an analog tester
set to a resistance range of 1000 Ω.
Judge whether the module is defective or not, according to the measured values of resistance.
Location to be Tester Normal value Judgement
measured (+) (–) Rough guide Good Not good
P–U P U 2 - 3 kΩ 2 - 3 kΩ 0 Ω and ∞ Ω
(Same for V, W) U P ∞Ω ∞Ω 2 - 3 kΩ or less
U–N U N 2 - 3 kΩ 2 - 3 kΩ 0 Ω and ∞ Ω
(Same for V, W) N U ∞Ω ∞Ω 2 - 3 kΩ or less
U+ – U U+ (Pin 7) U ∞Ω ∞Ω 2 - 3 kΩ or less
(Same for V, W) U U+ (Pin 7) ∞Ω ∞Ω 2 - 3 kΩ or less
X+ – N X+ (Pin 10) N ∞Ω ∞Ω 2 - 3 kΩ or less
(Same for V, W) N X+ (Pin 10) ∞Ω ∞Ω 2 - 3 kΩ or less
P – U+ P U+ (Pin 7) ∞Ω ∞Ω 2 - 3 kΩ or less
(Same for V, W) U+ (Pin 7) P ∞Ω ∞Ω 2 - 3 kΩ or less
X+ – U P X+ (Pin 10) ∞Ω ∞Ω 2 - 3 kΩ or less
(Same for V, W) X+ (Pin 10) P ∞Ω ∞Ω 2 - 3 kΩ or less
*1 The “Normal value” given above should be used as a rough guide. The normal values vary with different
types of tester and the internal battery’s state of charge.
*2 When checking, observe the following conditions:
• Do not touch the gate terminals (U+, X+, others) on the power modules with bare hand; otherwise they
might be damaged due to static electricity.
• Put power modules in an antistatic bag when carrying or storing. Do not give shock or vibration.
■ Checking thermistor (thermosensor).

The power module has a thermistor (thermosensor) that monitors the power module temperature at
all times. If the thermistor senses a temperature above the setting, it limits the output current or reduces
it to zero.
Visually check the thermistors for scores, scratches, and excessive discoloration and the
connectors for corrosion.
Remove the thermistors (drive motor: THR, THL, pump motor: THP).
Set the tester to a resistance range of 1000 Ω and measure the resistance between terminals
according to the table given below.
Judge whether the thermistor is defective or not, according to the measured values of resistance.
Location to Tester Normal value

be measured (+) (–) Rough guide
THR THR–1 THR–2 25°C [77°F] : about 100 kΩ, 50°C [122°F]: about 36 kΩ
THL THL–1 THL–2 75°C [167°F] : about 15 kΩ, 100°C [212°F] : about 6.5 kΩ
THP THP–1 THP–2
■ Heat-dissipating silicone compound (G-746: Shin-Etsu Chemical)

The application of heat-dissipating silicone compound on the entire rear surface of the power
module will help dissipate the heat generated from the power module to the aluminum base efficiently.
When replacing the power module with a new one, check the mounting aluminum base and a new
power module for metallic powder, cuttings, damage or burrs before applying the heat-dissipating
silicone compound.
- 40 -
3. CONTROL SYSTEM
(4) Checking capacitor boards (CBD, CBP)

The capacitor board consists of multiple
aluminum electrolytic capacitors connected in Capacitor board
parallel, and installed just above the power module.
The capacitor board absorbs a surge voltage
generated from the power module to prevent
damage to the power module. (The same type of
capacitor board is used for drive and pump motors.)
Visually check for scores, scratches or
excessive discoloration.
Replace any defective capacitor board with a
new one.
Fig. 3.17
(5) Checking fuses
If an overcurrent flows through the main circuit, the fuses will blow to prevent damage to the
controller. When checking the fuses on the truck, measure the battery voltage in advance.
F2 upper terminal F1 upper terminal Symbol Part name Model

F1 Drive motor fuses 96LFB-275
• • F2 Pump motor fuses 96LFB-225
F2 F1
• •
F2 lower terminal F1 lower terminal
Fig. 3.18
■ Checking drive motor fuse (F1)

Set the tester to the voltage measurement range and attach the negative pole of the tester to the
negative cable connection terminal of the controller.
Attach the positive pole of the tester to the upper terminal of the F1 fuse and then to the lower
terminal to measure the voltage at each terminal.
Voltage table (key switch in ON)
Location Voltage value Judgement
Upper terminal Battery voltage Good
Battery voltage Good
Lower terminal
0V Defective (change fuse.)
■ Checking pump motor fuse (F2)

Attach the positive pole of the tester to the upper terminal of the F2 fuse and then to the lower
terminal to measure the voltage at each terminal.
Location Voltage value Judgement
Upper terminal Battery voltage Good
Battery voltage Good
Lower terminal
0V Defective (change fuse.)
- 41 -
3. CONTROL SYSTEM
(6) Checking current sensor

The current sensors detect the U-phase and W-phase current
of the right and left drive motors and the U-phase and W-phase
current of the pump motor, and generates a voltage corresponding
to the current.
A total of six current sensors are installed: four for the drive
unit power module output terminals and two for the pump unit
power module output terminals.
Visually check the sensors for scores, scratches damage or
excessive discoloration before checking their voltage. Current sensor (CS)
Fig. 3.19
■ Checking drive motor current sensors (CSRU, CSRW, CSLU, CSLW).
Attach the positive pole of the tester to each measurement point of the CN9 (26-pin connector)
and turn the key switch to ON to measure the voltage.

Current Location Normal
Measurement condition
sensor Pin No. Wire color voltage
CSRU CN9-11, 24 Red 15V
CSRW CN9-8, 9, 21, 22 Black 0V
CN9-10 Yellow 7 V (at 0 A) • DSF/DSRSW = OFF, accelerator in OFF
(CSRU) • The voltage varies in the range of 5.4 V - 8.6 V during
traveling.
CN9-23 White 7 V (at 0 A) • DSF/DSRSW = OFF, accelerator in OFF
(CSRW) • The voltage varies in the range of 5.4 V - 8.6 V during
traveling.
CSLU CN9-7, 20 Red 15V
CSLW CN9-4, 5, 17, 18 Black 0V
CN9-6 Green 7 V (at 0 A) • DSF/DSRSW = OFF, accelerator in OFF
(CSLU) • The voltage varies in the range of 5.4 V - 8.6 V during
traveling.
CN9-19 Blue 7 V (at 0 A) • DSF/DSRSW = OFF, accelerator in OFF
(CSLW) • The voltage varies in the range of 5.4 V - 8.6 V during
traveling.
■ Checking pump motor current sensors (CSPU, CSPW)

Attach the positive pole of the tester to each measurement point of the CN10 (22-pin connector)
and turn the key switch to ON to measure the voltage.

Current Location Normal
Measurement condition
sensor Pin No. Wire color voltage
CSPU CN10-11, 22 Red 15V
CSPW CN10-8, 9, 19, 20 Black 0V
CN10-10 Purple 6.8 V • Lift lever switch, TILTSW, ATT1SW, ATTSW2 in OFF,
(CSPU) (about -40 A) No steering wheel operation, the tire at center position.
CN10-21 Pink 7.1 V The voltage varies in the range of 4.1 V to 9.9 V during
(CSPW) (about 20A) load handling or steering.
- 42 -
3. CONTROL SYSTEM
(7) Checking main contactor (MD)

■ Mechanical action of the contactor Main contactor
Inspection should be performed on the contactor
Secondary
removed from the truck. contact
Visually check the contacts, coil and connector for (upper, fixed)
scores, scratches, damage or excessive discoloration. Secondary
Replace any defective contactor with a new one. contactor (lower,
movable)
■ Contactor coil
Remove the coil wiring connector. Coil
Set the tester to a resistance range of 100 Ω and Coil wiring connector
measure the resistance between terminals. Fig. 3.20
Judge whether the coil is defective or not according to
the measured value.
Judgement
Contactor
Good Defective
about 20 Ω
MD ∞ Ω (coil broken)
(20°C [68°F])
■ Contactor contacts
Motor speed sensor
Visually check the contacts for rough surface or wear.
Replace any defective contactor with a new one.
(8) Checking motor speed sensor

The magnetic induction sensor generates alternating
current per pitch of the toothed rotor attached to the side
opposite to the side which the motor shaft is directly
connected to. Three motor speed sensors are installed: two
for the right and left drive motors and one for the pump Pulse sensing
Connector section
motor.
Remove the connector. Fig. 3.21
Set the tester to a resistance range of 100 Ω and
measure the resistance between terminals.
Judge whether the sensor is defective or not according to the measured values.
Normal value about 620 Ω (20°C [68°F])
(9) Checking motor thermosensor

The right and left drive motors have thermosensors embedded to monitor the motor temperature at
all times.
If the temperature monitored by the sensor exceeds a certain level, the output current is restricted or
reduced to zero.
Remove the motor thermosensor connector.
Set the tester to a resistance range of 1000 Ω and measure the resistance between terminals using
the table given blow.
Judge whether the sensor is defective or not according to the measured values.
Normal value (rough guide)

10°C [50°F] : about 20 kΩ, 20°C [68°F] : about 13 kΩ
30°C [86°F] : about 9 kΩ, 50°C [122°F] : about 4.4 kΩ
100°C [212°F] : about 1.0 kΩ, 150°C [221°F] : about 0.3 kΩ
- 43 -
3. CONTROL SYSTEM
(10) How to change the controller settings

The VTM unit sets the traveling speed and regeneration feature. You can change the those settings
in the procedure given below. However, when trying to change them, observe the following conditions:
1. Notify TCM Quality Assurance Department about the truck model, serial number and user name
of the truck you want to change its controller settings and follow the instructions given by that
department.
2. The VTM unit contains some adjustable components other than those that can be used for
changing the above settings, but they must not be adjusted by users.
COMMUNICATION
LED
4-DIGIT LED
ROTARY SWITCH
SWITCHES (MODE, HIGH, LOW)
Setting
Mode symbol
Rotary switch
4-digit LED read-out
Fig. 3.22
[Changing controller settings]

Park the truck on a level surface and turn the key switch off.
Disconnect the battery connector.
Remove the left-side battery cover.
Remove the VTM unit cover.
Make sure that the VTM unit rotary switch is in the “D” position. If not, place the rotary switch in
the “D” position.
Connect the battery connector. Make sure the 4-digit LED shows “d**.*” (**.* is the battery
voltage).
Set the rotary switch to “8”. Make sure the 4-digit LED indicates “8P.10”.
Use the “MODE SW” to select the mode you want, and change the setting with the “H” and “L”
switches.
After setting, turn the key switch to “ON”.
The communication LED blinks for 5 seconds before going out.
After making sure the communication LED goes out, turn the key switch to “OFF” and place the
rotary switch in the “D” position to store the setting in memory.
Make sure the 4-digit LED shows “d**.*”.
Disconnect the battery connector and reinstall the covers.
- 44 -
3. CONTROL SYSTEM
VTM UNIT
BUZZER
B R
26P
FET UNIT
26P
View looking from
Fig. 3.23 VTM
- 45 -
3. CONTROL SYSTEM
VTM Settings Table (default settings)
No. Mode Unit Remarks

Drive acceleration, Drive/pump motor output
pump unit characteristics characteristics and acceleration
Truck speed limit Max. speed in “turtle” mode
Tilt speed Tilt
ATT1 speed Attachment 1
ATT2 speed Attachment 2
Plugging regeneration level Switchback regeneration level Disabled
Neutral regeneration level Regeneration level with accelerator turned off Disabled
Brake regeneration level Regeneration level with brake switch turned on Disabled
Anti-rollback control Anti-rollback control level Disabled
Accelerator operation Accelerator stage mode number

Speed at which alarm Speed at which the output of alarm is
is outputted started with speed alarm output mode enabled
Maximum permitted speed with
Speed limit speed limit mode enabled
Flag setting (1) Seat switch enabled Enabled
Speed limit enabled
Speed alarm output enabled
Flag setting (2) S mode disabled Enabled
Pump unit acceleration Hi mode
Pump unit acceleration Lo mode
Pump unit acceleration super-Lo mode
Flag setting (3) Neutral safety condition (accelerator pedal) Enabled
Neutral safety condition (lift or other lever)
Seat switch OFF delay time Seat switch OFF delay time
Speed limit rate (P25 ON) Speed limit rate at P25 ON Disabled
Pump unit limit rate (P25 ON) Pump unit limit rate at P25 ON 100: No limit
Overdischarge level (P25 ON) Overdischarge level at P25 ON Disabled
Mode LED Mode LED Mode LED Mode LED Mode LED
- 46 -
3. CONTROL SYSTEM
(11) Checking connector voltage

■ External connectors
CN1 (26-pin connector) on CPU board * VB represents battery voltage.

Pin Reference voltage with Reference voltage with
Signal name Remarks
No. key SW in ON (OFF) key SW and VR turned on
1 (Not connected)
2 (Not connected)
3 (Not connected)
4 SPE 4.4V Key SW in ON: 0 V SPE modes change from S, P, E, to S for each
occurrence of 0 V.
5 0V 0V
6 SLMT 4.4V Key SW in ON: 0 V 0V: Travel speed limited
7 BRK 4.4V Key SW in ON: 0 V 0V: Brake applied
8 PSCS 4.4V Key SW in ON: 0 V 0V: Steering wheel knob position memory in
action
9 VBSW 36V specification: 0 V Key SW shorted: 0 V
48V specification: 4.4 V Key SW open: 4.4 V
10 ACC-P 4.5 5V power supply with serial resistor
11 LFT-S 0 - 0.3 100% of max. motor speed is available When VR wiper is moved to (+) side, load-
at 1.4 V – 4.3 V or more handling command (signal) increases.
Error code is issued at 4.8 V or more
12 LFT-P 4.5 5V power supply with serial resistor
13 KEY VB VB=0 V with key SW in OFF 48V/36V control power supply input
14 (Not connected)
15 TILT 4.4V Key SW in ON: 0 V 0V: Tilt in action
16 (Not connected)
17 ATT1 4.4V Key SW in ON: 0 V 0V: Attachment 1 in action
18 ATT2 4.4V Key SW in ON: 0 V 0V: Attachment 2 in action
(DRVSTOP) (Open: Travel prohibited) (0: Travel permitted) (Travel prohibition SW in joystick mode)
19 PB 4.4V Key SW in ON: 0 V Open: Push in parking SW.
0V: Pull out parking SW.
20 SEAT 4.4V Key SW in ON: 0 V Open: Not seated
0V: Seated
21 DSR 4.4V Key SW in ON: 0 V 0V: Reverse travel allowed
22 DSF 4.4V Key SW in ON: 0 V 0V: Forward travel allowed
23 ACC-N 0V
24 ACC-S 0V - 0.3V 100% of max. motor speed is available When VR wiper is moved to (+) side, speed
at 0.3 V – 2.34 V or more command (signal) increases.
Error code is issued at 4.5 V or more
25 LFT-N 0V
26 KEY VB VB=0 V with Key SW in OFF 48V/36V control power supply input
CN13 (16-pin connector) on CPU board

Signal name Remarks
1 RDPA-N 0V Electromagnetic pickup input: common
2 RDPA-S 0V AC signal (within ±15 V) Electromagnetic pickup input: signal
3 RDPB-S 0V AC signal (within ±15 V) Electromagnetic pickup input: signal
4 RDPB-COM 0V Electromagnetic pickup input: shield
5 PPA-S 0V AC signal (within ±15 V) Electromagnetic pickup input: signal
6 LDPA-S 0V AC signal (within ±15 V) Electromagnetic pickup input: signal
7 LDPA-COM 0V Electromagnetic pickup input: shield
8 LDPB-S 0V AC signal (within ±15 V) Electromagnetic pickup input: signal
9 0V 0V
10 RDPA-COM 0V Electromagnetic pickup input: shield
11 RDPB-N 0V Electromagnetic pickup input: common
12 PPA-COM 0V Electromagnetic pickup input: shield
13 PPA-N 0V Electromagnetic pickup input: common
14 LDPA-N 0V Electromagnetic pickup input: common
15 LDPB-COM 0V Electromagnetic pickup input: shield
16 LDPB-N 0V Electromagnetic pickup input: common
- 47 -
3. CONTROL SYSTEM

Signal name Remarks
1 PSPOT-P 4.55V 5V power supply with serial resistor
2 PSPOT-S 2.5 V: steering wheel in 0.8 V - 3.6 V (movement range) When steering wheel is turned clockwise,
center position Error code is issued at less than 0.33 V VR wiper is moved to PSPOT (-) side (signal
(2.25 V - 2.75 V) or more than 4.77 V. voltage decreases).
3 (Not connected)
4 LLOCK VB During output: 0.5 V or less Open drain output
5 FWOUT VB During output: 0.5 V or less Open drain output
6 SARM VB During output: 0.5 V or less Open drain output
7 PSP0T-N 0.45V 0V power supply with serial resistor
8 (Not connected)
9 (Not connected)
10 (Not connected) (Reserved output)
11 SOL VB During output: 1.0 V or less Open drain output
12 RWOUT VB During output: 0.5 V or less Open drain output

Signal name Remarks
1 VTMTXDN 0V TXD GND
2 (Not connected)
3 P25 4.4V Key SW in ON: 0 V 0V: Motor speed limited, acceleration limited,
lift speed limited
4 HPNG-P 15V Power supply for steering wheel sensor (+15 V)
5 RDMTH-S approx. 3.48 V (at 25°C) Varies with temperature (0.2 V – 4.8 V)
6 LDMTH-S approx. 3.48 V (at 25°C) Varies with temperature (0.2 V – 4.8 V)
7 (Not connected)
8 PMTH-S approx. 3.48 V (at 25°C) Varies with temperature (0.2 V – 4.8 V)
9 HPNGCOM 0V
10 HPNGA 0V When steering wheel is operated: 0 – 5 V
(40 pulses/rev)
11 (Not connected)
12 VTMTXDP Reference setting not Data transmitted to display
allowed
13 VTMRXDN Reference setting not Data received from display
allowed
14 VTMCOM 0V
15 HPNG-N 0V
16 RDMTH-N 0V
17 LDMTH-N 0V
18 (Not connected)
19 PMTH-N 0V
20 HPNGZ 0V When steering wheel is operated: 0 – 5 V
(1 pulse/rev)
21 HPNGB 0V When steering wheel is operated: 0 – 5 V
(40 pulses/rev)
22 (Not connected)
- 48 -
3. CONTROL SYSTEM
■ Connectors for internal wiring

Signal name Remarks
1 0V 0V Energized when key SW turned to ON.
(5 V with gate in OFF)
2 GUP Varies between 0 – 5 V. Energized when key SW turned to ON.
(Gate in ON) (5 V with gate in OFF)
3 GXP Varies between 0 – 5 V. Energized when key SW turned to ON.
4 GVP Varies between 0 – 5 V. Energized when key SW turned to ON.
5 GYP Varies between 0 – 5 V. Energized when key SW turned to ON.
6 GWP Varies between 0 – 5 V. Energized when key SW turned to ON.
7 GZP Varies between 0 – 5 V. Energized when key SW turned to ON.
8 0V 0V

Signal name Remarks
1 GUDR 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
2 GXDR 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
3 GVDR 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
4 GYDR 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
5 GWDR 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
6 GZDR 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF

Signal name Remarks
1 0V 0V
2 GUDL 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
3 GXDL 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
4 GVDL 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
5 GYDL 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
6 GWDL 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
7 GZDL 5V Varies largely with output state. DSF/DSRSW=OFF and accelerator OFF
8 0V 0V
9 (Not connected)
- 49 -
3. CONTROL SYSTEM

Signal name Remarks
1 P23 MD contactor in ON: VB Before key SW is turned to ON: 0 V - VB
After key SW is turned to ON: Rapid charging
up to 20 V before contactor is closed.
2 MD (+) VB
4 (Not connected)
5 THR+ approx. 3.2 V (at 25°C) Varies with temperature. (0.2 V – 4.8 V) Built-in TMR
6 THL+ approx. 3.2 V (at 25°C) Varies with temperature. (0.2 V – 4.8 V) Built-in TML
7 THP+ approx. 3.2 V (at 25°C) Varies with temperature. (0.2 V – 4.8 V) Built-in TMP1
8 CSPU (-) 0V
9 CSPU (-) 0V
10 CSPU (S) 6.8V (-40A) Varies with motor current: 4.1 V – 9.9 V
11 CSPU (+) 15V
13 MD (-) MD contactor in ON: VB MD contactor in OFF: VB
Average voltage: 9 V MD contactor in ON: Approx. 80 – 75% of
control power supply voltage due to chopping
However, measured voltage varies with tester.
15 (Not connected)
16 THR- 0V Built-in TMR
17 THL- 0V Built-in TML
18 THP- 0V Built-in TMP1
19 CSPW (-) 0V
20 CSPW (-) 0V
21 CSPW (S) 7.1V (+20A) Varies with motor current: 4.1 V – 9.9 V
22 CSPW (+) 15V

Signal name Remarks
1 8V 8V For 5V generation
2 Vbkey VB VB=0 V with key SW in OFF 48 V/36V control power supply input
3 VB VB
4 0V 0V
5 Pon approx. 3.7 V
6 5V 5V
7 GND 0V
8 P4 Varies largely with motor Varies largely with motor output state. With MD contactor in OFF: approx. P3 x 3.7%
output state. (Motor output terminal voltage: approx. P3 x
58%)
9 18V 18V For 15V generation
10 Vbkey VB VB=0 V with key SW in OFF VB at all times while being connected to
battery
11 VB VB
12 0V 0V
13 PGon 0.5 V or less
14 0t 0V
15 GND 0V
16 0V 0V
- 50 -
3. CONTROL SYSTEM

Signal name Remarks
1 P1 VB
2 (Not connected)
3 (Not connected)
4 CSLU (-) 0V
5 CSLU (-) 0V
6 CSLU (S) 7V (0A) Varies with motor current: 5.4 – 8.6 V DSF/DSRSW=OFF and accelerator OFF
7 CSLU (+) 15V
8 CSRU (-) 0V
9 SCRU (-) 0V
10 CSRU (S) 7V (0A) Varies with motor current: 5.4 – 8.6 V DSF/DSRSW=OFF and accelerator OFF
11 CSRU (+) 15V
12 (Not connected)
13 (Not connected)
14 (Not connected)
15 P1 VB
16 (Not connected)
17 CSLW (-) 0V
18 CSLW (-) 0V
19 CSLW (S) 7V (0A) Varies with motor current: 5.4 – 8.6 V DSF/DSRSW=OFF and accelerator OFF
20 CSLU (+) 15V
21 CSRW (-) 0V
22 CSRW (-) 0V
23 CSRW (S) 7V (0A) Varies with motor current: 5.4 – 8.6 V DSF/DSRSW=OFF and accelerator OFF
24 CSRU (+) 15V
25 (Not connected)
26 (Not connected)
CN5R (16-pin connector) on power supply board

Signal name Remarks
1 GLU- 0V Varies largely with output state. (0 – 15 V) CNTML U- (1)
2 GLU+ 0V Varies largely with output state. (0 – 15 V) CNTML U+ (7)
3 GLX- 0V Varies largely with output state. (0 – 15 V) CNTML X- (4)
4 GLX+ 0V Varies largely with output state. (0 – 15 V) CNTML X+ (10)
5 GLV- 0V Varies largely with output state. (0 – 15 V) CNTML V- (2)
6 GLV+ 0V Varies largely with output state. (0 – 15 V) CNTML V+ (8)
7 GLY- 0V Varies largely with output state. (0 – 15 V) CNTML Y- (5)
8 GLY+ 0V Varies largely with output state. (0 – 15 V) CNTML Y+ (11)
9 GLW- 0V Varies largely with output state. (0 – 15 V) CNTML W- (3)
10 GLW+ 0V Varies largely with output state. (0 – 15 V) CNTML W+ (9)
11 GLZ- 0V Varies largely with output state. (0 – 15 V) CNTML Z- (6)
12 GLZ+ 0V Varies largely with output state. (0 – 15 V) CNTML Z+ (12)
13 CBD_P3 MD contactor in ON: VB Before key SW is turned to ON: 0 V – VB
14 CBD_P4 CBD_P3 x 58% Varies largely with output state.
- 51 -
3. CONTROL SYSTEM

Signal name Remarks
1 GRU- 0V Varies largely with output state. (0 – 15 V) CNTMR U- (1)
2 GRU+ 0V Varies largely with output state. (0 – 15 V) CNTMR U+ (7)
3 GRX- 0V Varies largely with output state. (0 – 15 V) CNTMR X- (4)
4 GRX+ 0V Varies largely with output state. (0 – 15 V) CNTMR X+ (10)
5 GRV- 0V Varies largely with output state. (0 – 15 V) CNTMR V- (2)
6 GRV+ 0V Varies largely with output state. (0 – 15 V) CNTMR V+ (8)
7 GRY- 0V Varies largely with output state. (0 – 15 V) CNTMR Y- (5)
8 GRY+ 0V Varies largely with output state. (0 – 15 V) CNTMR Y+ (11)
9 GRW- 0V Varies largely with output state. (0 – 15 V) CNTMR W- (3)
10 GRW+ 0V Varies largely with output state. (0 – 15 V) CNTMR W+ (9)
11 GRZ- 0V Varies largely with output state. (0 – 15 V) CNTMR Z- (6)
12 GRZ+ 0V Varies largely with output state. (0 – 15 V) CNTMR Z+ (12)
13 CBD_P13 MD contactor in ON: VB Before key SW is turned to ON: 0 V – VB
17 (Not connected)
18 (Not connected)
19 (Not connected)
20 (Not connected)

Signal name Remarks
1 GPU1- Varies between 0 – 15 V. CNTMP1 W- (3)
(Gate in ON)
2 GPU1+ Varies between 0 – 15 V. CNTMP1 W+ (9)
(Gate in ON)
3 GPX1- Varies between 0 – 15 V. CNTMP1 Z- (6)
(Gate in ON)
4 GPX1+ Varies between 0 – 15 V. CNTMP1 Z+ (12)
(Gate in ON)
5 GPV1- Varies between 0 – 15 V. CNTMP2 V- (2)
(Gate in ON)
6 GPV1+ Varies between 0 – 15 V. CNTMP2 V+ (8)
(Gate in ON)
7 GPY1- Varies between 0 – 15 V. CNTMP2Y- (5)
(Gate in ON)
8 GPY1+ Varies between 0 – 15 V. CNTMP2Y+ (11)
(Gate in ON)
9 GPW1- Varies between 0 – 15 V. CNTMP1 U- (1)
(Gate in ON)
10 GPW1+ Varies between 0 – 15 V. CNTMP1 U+ (7)
(Gate in ON)
11 GPZ1- Varies between 0 – 15 V. CNTMP1 X- (4)
(Gate in ON)
12 GPZ1+ Varies between 0 – 15 V. CNTMP1 X+ (10)
(Gate in ON)
13 CBP_P23 MD contactor in ON: VB Before key SW is turned to ON: 0 V – VB
14 CBP_P24 CBP_P23 x 58% Varies largely with output state.
17 (Not connected)
18 (Not connected)
19 (Not connected)
20 (Not connected)
- 52 -
3. CONTROL SYSTEM

Signal name Remarks
1 GPU2- Varies between 0 – 15 V. CNTMP1 V- (2)
(Gate in ON)
2 GPU2+ Varies between 0 – 15 V. CNTMP1 V+ (8)
(Gate in ON)
3 GPX2- Varies between 0 – 15 V. CNTMP1 Y- (5)
(Gate in ON)
4 GPX2+ Varies between 0 – 15 V. CNTMP1 Y+ (11)
(Gate in ON)
5 GPV2- Varies between 0 – 15 V. CNTMP2 U- (1)
(Gate in ON)
6 GPV2+ Varies between 0 – 15 V. CNTMP2 U+ (7)
(Gate in ON)
7 GPY2- Varies between 0 – 15 V. CNTMP2 X- (4)
(Gate in ON)
8 GPY2+ Varies between 0 – 15 V. CNTMP2 X+ (10)
(Gate in ON)
9 GPW2- Varies between 0 – 15 V. CNTMP2 W- (3)
(Gate in ON)
10 GPW2+ Varies between 0 – 15 V. CNTMP2 W+ (9)
(Gate in ON)
11 GPZ2- Varies between 0 – 15 V. CNTMP2 Z- (6)
(Gate in ON)
12 GPZ2+ Varies between 0 – 15 V. CNTMP2 Z+ (12)
(Gate in ON)

Signal name Remarks
1
2 0V 0V
3 0V 0V
4 GND 0V
5 GND 0V
- 53 -
DRIVE MOTOR (LEFT)
3. CONTROL SYSTEM
Controller main circuit

arrangement
MAIN CONTACTOR
- 54 -
Fig. 3.24
THERMISTOR
POWER SUPPLY BOARD CPU BOARD

DRIVE MOTOR (RIGHT)
- 55 -
Fig. 3.25
THERMISTOR

3. CONTROL SYSTEM
PUMP MOTOR
3. CONTROL SYSTEM
- 56 -
Fig. 3.26
THERMISTOR THERMISTOR

3. CONTROL SYSTEM
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- 57 -
3. CONTROL SYSTEM
NOTE
- 58 -
4. DRIVE UNIT
4. DRIVE UNIT
Model
FTB16-7 FTB18-7 FTB20-7
Item
Type: 2-stage speed reduction
Reduction ratio: 22.08
Wheel (pneumatic)
Tire size: 18 x 7 – 8 – 16PR –
Rim size: 4.33R x 8TB –
Tire inflation pressure: 1000 kPa {10 kgf/cm2} [142.2 psi] –
Wheel (cushion)
Tire size: 18 x 7 x 12 - 1/8 200/50-10 or 18 x 7 x 12-1/8
Rim size: 128 x 308 6.50F-10 or 128 x 308

Two drive units of 2-stage speed reduction type are located at the front right and left sides of the
frame. The right and left drive units have the same number of gears in different arrangements. (See
Fig. 4.1.)
Each drive unit has a multi-plate wet brake unit on its shaft.
- 59 -
4. DRIVE UNIT
• OIL FILL PLUG
• BRAKE ACTUATOR
• DRAIN PLUG
View looking from
Fig. 4.1 Drive Unit
- 60 -
4. DRIVE UNIT
■ Oil change
• Park the truck on a level surface and apply the
parking brake.
• Place a container of about 3-liter [0.79 U.S. gal]
capacity just under the drain plug and clean the
areas around the drain plug and oil fill plug.
• Remove the drain plug to drain off oil.
Fig. 4.2
• After draining oil thoroughly, reinstall the drain

plug with a new seal ring.
Tightening torque: 22 N-m {2.24 kgf-m}
[16.2 lbf-ft]
• Add specified oil through the oil fill port.
Q’ty of oil to added: 0.35 liters [0.092 U.S. gal]
• Reinstall the oil fill port plug with a new oil seal.
Tightening torque: 22 N-m {2.24 kgf-m}
[16.2 lbf-ft]
Fig. 4.3
■ Oil Brand
Mobil: Mobilube ATF
Mobilube ATF 220
Shell: DONAX TA
DONAX TG
DONAX TX
Esso: ATF D
ATF D2
ATF D3
- 61 -
4. DRIVE UNIT
NOTE
- 62 -
5. BRAKE SYSTEM
5. BRAKE SYSTEM
Wheel Brake
Type: Multi-plate wet, hydraulic type (built in drive unit)
Pedal ratio: 5.6
Master cylinder bore: 19.05 mm [3/4 in.]
Parking Brake
Type: Multi-plate wet, mechanical type (shared by wheel brake)

The brake unit is a multi-plate wet type consisting of a master cylinder, actuator, and brake disks
installed on the drive unit shaft.
5.1.1 ACTUATOR
The actuator operates the brake disks and is installed on the drive unit. When the oil enters the
cylinder of the actuator, the piston pushes the push rod due to its reaction force, the actuator cylinder
moves to the direction and thus the part pushes in the pin to lock up the brake disks.
PIN
ACTUATOR
from MASTER CYLINDER
PARKING BRAKE CABLE
PISTON
PUSH ROD
Fig. 5.1 Actuator
- 63 -
5. BRAKE SYSTEM
5.1.2 MASTER CYLINDER

The cylinder contains a spring, primary cup, piston, and secondary cup, which are all kept in place
with a snap ring. The exterior of the cylinder is protected from dust by means of a cover.
The piston is actuated through the push rod by operation of the brake pedal: First, as the brake
pedal is pressed, the push rod pushes the piston. The brake fluid in the cylinder flows back to the
reserve tank through the return port until the primary cup blocks up the return port. After the primary
cup passes the return port, the brake fluid in the cylinder is pressurized, flowing through the brake
pipe to the actuator cylinders. Thus, each actuator cylinder piston is forced outwards. This locks up
the brake disks to slow or stop the truck. Meanwhile, the cavity caused behind the piston is filled
with brake fluid led through the return port and inlet port to lubricate the piston.
When the brake disks are released, the piston is forced back by the return spring. At the same
time, the brake fluid in each actuator cylinder is pressurized by the force of the brake disk return
spring, returning into the master cylinder. With the piston in its original position, the fluid in the
master cylinder flows into the reserve tank throught the return port.
1. YOKE 6. PUSH ROD

2. LOCK NUT 7. CYLINDER
3. COVER 8. PISTON
4. SNAP RING 9. PRIMARY CUP
5. SECONDARY CUP 10. SPRING
Section -
from RESERVE TANK
Fig. 5.2 Master Cylinder
- 64 -
5. BRAKE SYSTEM
5.1.3 BRAKE PEDAL

The brake pedal assembly is installed on the bracket fitted to the driver’s cab as shown in Fig. 5.3.
The pedal is installed with bushings on the shaft which is in turn installed on the bracket. A grease
fitting is provided at its pipe section. Movement of the pedal is transmitted through the push rod
attached to the pipe with a clevis pin to move the piston of the master cylinder.
MASTER CYLINDER
BRAKE LAMP SWITCH
Detail of
View looking from Brake pedal play:

10 mm [0.394 in.]
Brake switch operation
RESERVE TANK (0.2 L) distance:
Grade: FMVSS 15 mm [0.591 in.]
DOT-3
in.]
95 mm
[3.740
Fig. 5.3 Brake Pedal
- 65 -
5. BRAKE SYSTEM
5.1.4 PARKING BRAKE

The parking brake consists of a brake lever and cables and is shown in Fig. 5.4. The brake disks
are used common for the service brakes.
Pulling force: 70 – 120N {7 – 12 kgf}

[15.4 – 26.5 lb]
PARKING BRAKE SWITCH
BRAKE CABLE (LEFT)
BRAKE CABLE (RIGHT)
View looking from
View looking from
Fig. 5.4 Parking Brake
- 66 -
6. STEERING SYSTEM
6. STEERING SYSTEM
Model
FTB16-7 FTB18-7 FTB20-7
Item
Type: Rear wheel steering type with power steering
Power steering
Type Hydraulic static type
Orbitrol
Type Load sensing non-load reaction
Discharge 69 cc/rev
Pressure setting 6.9 MPa {70 kgf/cm2} [996 psi]
Steering Axle
Steering angle: 90° to right and left
Wheel (unique)
Tire size: 15 x 4 · 1/2 – 8 –
Rim size: 3.00D x 8 –
Wheel (cushion)
Tire size: 15 x 5 x 11-1/4 ← or 140/55-9
Rim size: 100 x 285.75 ← or 4.00E-9

The steering system is a rear wheel steering type equipped with a power steering unit and consists
of a steering wheel, orbitrol, flow priority valve and rear axle.
The steering wheel can be tilted 2° to the front and rear, respectively. The rotation of the steering
wheel is transmitted through the universal joint to the orbitrol.
- 67 -
6. STEERING SYSTEM
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Fig. 6.1 Steering System 1/2
- 68 -
6. STEERING SYSTEM
STEERING WHEEL
View looking from
COMBINATION SWITCH
Detail of
LOCK LEVER
View looking from
JOINT
ORBITROL
View looking from

View looking from
Fig. 6.2 Steering System 2/2
- 69 -
6. STEERING SYSTEM
6.1.1 STEERING AXLE

The steering axle is shown in Fig. 6.3. The axle turns to the right and left 90°, respectively. The
axle is supported on the frame by two tapered roller bearings and has a spindle at the lower part. The
spindle has a hub held with two tapered roller bearings.
POTENTIOMETER
Engage with slit with tires

in straight-ahead position.
32010X
01
Detail of potentiometer mounting
Tightening torque: 264 - 395 N-m

{2690 - 4030 kgf-cm}
[195 - 292 lbs-ft]
Tightening torque:
135 N-m {1350 kgf-cm}
[98 lbs-ft]
CUSHION TIRE PNEUMATIC TIRE
Fig. 6.3 Steering Axle Mounting
- 70 -
6. STEERING SYSTEM
RACK-PINION
ADJUST NUT
OIL SEAL LOCK WASHER
TAPERED ROLLER
BEARING
OIL SEAL
TAPERED
ROLLER
BEARING CYLINDER PACKING
PISTON
Section -
COTTER PIN
CASTLE NUT
TAPERED ROLLER BEARING
OIL SEAL
HUB
Fig. 6.4 Steering Axle
- 71 -
6. STEERING SYSTEM
6.1.2 ORBITROL
The orbitrol sends pressure oil from the pump selectively to the steering cylinder. It consists
primarily of a control valve and a metering device.
The control valve used in the orbitrol is not an ordinary spool valve whose spool moves in the
axial direction, but a rotary valve which consists of a sleeve and a spool that rotate together forming
different oil passages through the combination of their oil holes. The valve housing is provided with
four ports which lead to the pump, tank, right and left chambers of the cylinder. Between the inlet
port and return port is a check valve.
The metering device consists of an internally toothed stator and an externally toothed rotor.
During normal operation, it operates as an oil motor. In an emergency, it can be used as hand pump.
The rotor is mechanically linked with the sleeve through the drive shaft so that feedback operation is
possible.
The sleeve is interlocked with the motor’s rotor through the cross pin and drive shaft while the
spool is splined to the steering shaft.
ORBITROL
VP VALVE
L
R
T P EF
Oil pressure symbols
T PORT EF PORT
L PORT
R PORT
P PORT
Fig. 6.5 Orbitrol
- 72 -
6. STEERING SYSTEM
(1) Operation of orbitrol

(a) In “Neutral”
While the steering wheel is in straight position, the
oil from the pump flows through oil passage to oil
groove . The sleeve has 24 oil holes which are
now in line with the holes in the spool so that the oil
that flowed into groove passes through oil holes
and to space between the spool and drive shaft.
Then the oil flows through spool groove and sleeve
groove back to the oil tank.
Since cylinder port and are respectively open
to oil holes and in the sleeve bur not the groove
or in the spool, the oil in the cylinder does not go
any where.
Oil passage that leads to the hydraulic motor
is open to oil hole in the sleeve which is used as
the inlet and outlet for the hydraulic motor, but not to
grooves or in the spool and thus the oil remain
unmoved.
Fig. 6.6
(b) When steering wheel is turned counterclockwise

As the steering wheel is turned counterclockwise,
the grooves in the spool shift to the left in relation to
the holes and grooves in the sleeve so that holes in
the spool get out of line with holes in the sleeve. The
oil that has flowed into groove thus far begins to
flow into hole in the sleeve, passing through grooves
and in the spool, hole in the sleeve, and oil
passage in the housing, to the hydraulic motor.
The hydraulic motor thus rotates in the
counterclockwise direction and the oil discharged
from the hydraulic motor flows through oil hole in
the sleeve, groove in the spool, and oil hole in
the sleeve to the cylinder port L and thus actuates the
steering cylinder.
The returning oil from the steering cylinder flows,
passing through the cylinder port R, groove in the
valve housing, oil hole in the sleeve, groove in
the spool, oil hole in the sleeve, and groove in the
valve housing, back to the oil tank. Fig. 6.7
- 73 -
6. STEERING SYSTEM
(c) When steering wheel is turned clockwise

As the steering wheel is turned clockwise, the
grooves in the spool shift to the right in relation to the
oil holes and grooves in the sleeve so that oil holes
in the spool get out of line with holes in the sleeve.
The oil that has flowed into groove thus far begins
to flow into oil hole in the sleeve and then flows
through grooves and in the spool, oil hole in
the sleeve, and oil passage in the valve housing to
the hydraulic motor. The hydraulic motor thus rotates
in the clockwise direction and the oil discharged from
the hydraulic motor flows through oil hole in the
sleeve, groove in the spool, and oil hole in the
sleeve to the cylinder port R in the housing and thus
actuates the steering cylinder.
The returning oil from the steering cylinder flows,
passing through the cylinder port L, groove in the
housing, oil hole in the sleeve, groove in the
spool, oil hole in the sleeve and groove in the
housing back to the oil tank. Fig. 6.8
(2) Relationship between rotating speed and operating force of steering wheel.
In principle, the force required to operate the orbitrol is only the force to change over the valve,
i.e. the force of compressing the centering spring or 2 N-m {0.2 kgf-m} [1.45 lbs-ft]. In other words,
since there are no mechanical connections between the steering wheel and the tires and only the
spring compressing force is required, constant steering force is kept even at increased rotational
speed. The discharge of oil supplied from the rotor of the orbitrol to the cylinder is 69 cc/revolution.
(3) Neutral feedback to orbitrol

The neutral feedback of the orbitrol is performed by changing-over in oil passages of the valve,
due to the reactions force of centering spring (When the steering wheel is turned and then released
the steering wheel returns to the initial position.)
Unless neutral feedback is completely performed, the steering wheel may be turned, even though
the operator does not turn the steering wheel.
- 74 -
6. STEERING SYSTEM
(4) Steering with defective pump

When the pump fails to supply hydraulic oil the orbitrol serves as an emergency hand steering
device. When the steering wheel is turned, the spool rotates. When turned about 8°, the spool contacts
the cross pin, which rotates the drive shaft, which in turn rotates the rotor. Thus, the metering device
serves as a hand pump to supply oil to the cylinder. In this case the check valve provided between the
return port and the suction port opens, so that oil flows from the cylinder to the suction side, thereby
effecting emergency steering.
- 75 -
6. STEERING SYSTEM
NOTE
- 76 -
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
Model
FTB16-7 FTB18-7 FTB20-7
Item
Main Pump
Type Gear type
Model TMG1A20
Discharge 21 cc/rev
Control Valve
Type 3-spool sliding type
Model MSV04
Pressure setting 15.7 MPa {160 kgf/cm2} [2276 psi] 17.2 MPa {175 kgf/cm2} [2489 psi]
Lift Cylinder
Type Single acting piston type
Cylinder bore 45 mm [1.77 in.]
Stroke 1495 mm [58.9 in.]
Tilt Cylinder
Type Double acting piston
Cylinder bore 70 mm [2.76 in.]
Stroke 69 mm [2.72 in.]
Oil tank
Capacity 18 liters [4.8 U.S. gal]
Grade ISO VG32
Brand Mobil: DTE Oil Light
Shell: Tellus Oil C-32
Esso: Teresso 32

The hydraulic system consists of a main pump, control valve, lift cylinders, tilt cylinders, and an
oil tank. Figure 7.1 shows the piping of the hydraulic system. The pump is driven with the motor and
sends the oil from the oil tank to the control valve. The lift and tilt cylinders are respectively actuated
for handling loads by changing over the two spools in the control valve. When the spools are not
operated, the oil flows through the control valve back into the oil tank.
- 77 -
7. HYDRAULIC SYSTEM
TILT CYLINDER
(RIGHT)
STEERING CYLINDER
(RIGHT)
to LIFT
CYLINDER
MAIN PUMP
ORBITROL STEERING CYLINDER
(LEFT)
TILT CYLINDER
OIL TANK
(LEFT)
View looking from
View looking from View looking from View looking from
Fig. 7.1 Piping Diagram
- 78 -
7. HYDRAULIC SYSTEM
TILT CYLINDER
(RIGHT) CONTROL VALVE
STEERING CYLINDER
(RIGHT)
to LIFT
CYLINDER
ORBITROL
MAIN PUMP
STEERING CYLINDER
(LEFT)
TILT CYLINDER OIL TANK

(LEFT)
View looking from
View looking from View looking from View looking from
Fig. 7.2 Piping Diagram with FIT
- 79 -
7. HYDRAULIC SYSTEM
7.1.1 MAIN PUMP

The main pump is driven by the motor and is attached on the front of the truck frame together
with the motor.
Intake
Discharge
View looking from
1. DRIVE GEAR
2. SNAP RING
3. OIL SEAL
4. GASKET
5. SIDE PLATE
6. BODY
7. REAR COVER
8. “3”-SHAPED GASKET
9. DRIVE GEAR
10. BUSHING
11. FRONT COVER
Fig. 7.3 Main Pump
- 80 -
7. HYDRAULIC SYSTEM
7.1.2 CONTROL VALVE

The control valve consists of three plunger sections, an outlet section, and an inlet section with
a relief valve, which are all assembled with three bolts. The inlet section relief valve is a cartridge
type featuring that its pressure setting does not change even if it is reinstalled after being removed.
Between the inlet and lift plunger sections, between the lift plunger and tilt plunger sections, and
between the tilt plunger and attachment plunger section, three check valves are installed one for each.
These check valves serve to prevent the back flow from the heavier load side to the lighter load side
when the lift, tilt and attachment levers are simultaneously operated.
The lift plunger section has a potentiometer which converts the movement of the plunger into a
voltage and outputs the voltage to the load handling controller which is turn controls the pump motor.
LIFT LOCK SOLENOID

TILT PLUNGER
VALVE (OPTION)
RELEAF
ATTACHMENT PLUNGER VALVE
LIFT PLUNGER
A1 PORT
A3 PORT
T1 PORT
T2 PORT
A2 PORT
P PORT
B3 PORT
B2 PORT LIFT LOCK

RELEASE SCREW
(FOR EMERGENCY)
POTENTIOMETER
T2
T1
A3 B3 A2 B2 A1
View looking from
Fig. 7.4 Control Valve
- 81 -
7. HYDRAULIC SYSTEM
SPOOL
ROLLER
■ Switch adjustment procedure
SWITCH PLUNGER 1. With the lever in neutral and the switch at the ON position,
adjust the distance between the roller end and the cam
contact surface to 0.8±0.1 mm [0.032±0.004 in.].
2. Align the center of the plunger with the center of the cam.
Detail of switch
SPACER
(Apply grease to both sides)
View looking from

Detail of
TILT LEVER
ATTACHMENT
LEVER LIFT LEVER
SWITCH
CONTROL VALVE
View looking from
Fig. 7.5 Valve Control
- 82 -
7. HYDRAULIC SYSTEM
(1) Lift section LOAD LIFT LOCK RELEASE

to PORT A1 CHECK SCREW (FOR
Note: The potentiometer is not shown. LOCK POPPET EMERGENCY USE)
SOLENOID VALVE PARALLEL PASSAGE
(a) Neutral
The oil discharged from the pump flows
through the unloading passage, back into the tank.
The port A is blocked and thus no oil pressure is
supplied to the lift cylinders. SPOOL
SPRING
(See Fig. 7.6.) TANK PASSAGE
UNLOADING
PASSAGE
Fig. 7.6
(b) Spool pulled out

When the spool is pulled out, the unloading
passage is closed and the oil discharged from the
pump flows through the parallel passage to open
the load check and then open the lock poppet,
passing through the port A1, into the lift cylinders.
The spool is returned to neutral by the spring.
(See Fig. 7.7.)
Fig. 7.7
(c) Spool pushed in Poppet won’t open because

cylinder pressure is applied on
With the spool pushed in, the unloading passage the back of the lock poppet.
is not blocked and thus the oil discharged from the

pump flows into the tank passage.
Solenoid valve not energized
The oil flow returning from the port A is
blocked by the lock poppet. Therefore, the oil
does not flow when the lift lever is placed in
the “down” position.
Fig. 7.8
(See Fig. 7.8.)
Solenoid valve energized

The oil returning from the port A flows
through the control orifice of the lock poppet
to the solenoid valve from which it flows
into the return passage. This flow generates
a pressure differential in the direction that
opens the lock poppet. The oil that has
passed through the lock poppet flows through
the spool land that opens towards the tank
Fig. 7.9
passage, back into the tank. The spool is
returned to neutral by the return spring.
(See Fig. 7.9.)
- 83 -
7. HYDRAULIC SYSTEM
(2) Tilt section LOAD CHECK

(a) Neutral PORT A1 PORT A2 PORT B2
The oil discharged from the pump flows through
PARALLEL
the unloading passage, back into the tank. The PASSAGE
ports A2 and B2 are blocked and no oil pressure is SPRING
supplied to the tilt cylinders.
(b) Spool pushed out (tilt back) SPOOL

With the unloading passage closed, the oil PILOT SPOOL UNLOADING
TANK PASSAGE PASSAGE
discharged from the pump flows through the
Fig. 7.10
parallel passage to open the load check, passing
through the port A2, into the tilt cylinders. The oil
returning from the tilt cylinders flows through the
port B2 and tank passage into the tank.
When the load inside the cylinders exceeds the
relief valve pressure setting, the relief valve opens
to return the oil into the tank passage. The spring
is returned to neutral by the spring.
(See Fig. 7.11.)
(c) Spool pushed in (tilt forward)

With the unloading passage blocked, the oil Fig. 7.11
through the port B2, into the tilt cylinders. The
oil returning from the tilt cylinders flows through
the port A2 and is blocked by the tilt lock valve.
However, as the oil pressure increases, the pilot
spool moves to push in the spring to allow the oil
at the port A2 to flow through the passage inside
the spool back into the tank.
When the load inside the cylinder exceeds the
to return the oil into the tank passage. The spool is Fig. 7.12
returned to neutral by the spring. (See Fig. 7.12.)
(d) Tilt lock mechanism

The tilt spool is provided with a tilt lock
mechanism which prevents the tilt cylinders from
moving when the tilt lever is operated with no oil
flow to the main valve.
If the spool is pushed in with no oil flow from
the pump (or if the tilt lever is placed in the “tilt
fwd” position, the oil at the loaded side of the tilt
cylinder tries to flow out the port A2. However, the
pilot pressure is not supplied to the pilot spool and Fig. 7.13
thus the return passage to the tank remains blocked
so that the tilt cylinders won’t move.
(See Fig. 7.13.)
- 84 -
7. HYDRAULIC SYSTEM
(3) Accessory section (option) LOAD CHECK

(a) Neutral PORT A PORT B PARALLEL
PASSAGE
The oil discharged from the pump flows SPRING
through the unloading passage back into the tank.

With the ports A and B blocked, no oil pressure is
supplied to the cylinder.
(See Fig. 7.14.) SPOOL
TANK PASSAGE UNLOADING
PASSAGE
Fig. 7.14
(b) Spool pulled out

With the unloading passage blocked, the oil
parallel passage to pen the load check, passing
through the port A, into the cylinder.
The oil returning from the cylinder flows
through the port B and tank passage back into the
tank.
Fig. 7.15
to return the oil into the tank passage. The spool is
(See Fig. 7.15.)
(c) Spool pushed in

With the unloading passage blocked, the oil
through the port B, into the cylinder. The oil
returning from the cylinder flows through the port
A and tank passage back into the tank.
Fig. 7.16
to return the oil into the tank passage. The spool is
(See Fig. 7.16.)
- 85 -
7. HYDRAULIC SYSTEM
(4) Main relief valve operation

(a) Relief valve not in operation PILOT
POPPET MAIN POPPET
When the circuit pressure is low enough SEAT SLEEVE
against the setting, the relief valve maintains
equilibrium. The oil at the port P flows through
the orifice inside the main poppet to fill the spring
chamber. The oil in the spring chamber acts on
the pilot poppet, but it is forced against the seat by
the spring force to block the oil flow to the tank
passage.
SPRING ORIFICE
The main poppet also blocks the passage to CHAMBER
the tank port, because it is forced against the seat
surface of the sleeve by the spring force and an Fig. 7.17 Main Relief Valve (before operation)
oil pressure created by the difference in area.
Therefore, all the oil supplied into the circuit is
sent to the operating section.
(See Fig. 7.17.)
(b) Relief valve in operation

When the circuit pressure increases enough to
reach the setting, the equilibrium is broken and
the relief valve operates. If the circuit pressure
reaches the pilot poppet pressure setting, the oil
pushes up the pilot poppet to flow into the tank
passage. This flow creates a pressure differential
across the orifice inside the main poppet to open
the main poppet to allow the oil to flow through
the port P into the tank passage, thus controlling
the maximum oil pressure.
(See Fig. 7.18.)
Fig. 7.18 Main Relief Valve (in operation)
- 86 -
7. HYDRAULIC SYSTEM
7.1.3 CONTROL VALVE (trucks with FIT)

The control valve consists of an inlet section, a plunger section and an outlet section.
The inlet section is provided with a relief valve that sets the maximum oil pressure.
The plunger section is a proportional electromagnetic type whose plunger is operated by the pilot
oil pressure controlled by the solenoid valve.
MAIN RELIEF VALVE SHUT-OFF VALVE

(FOR LIFT-LOCK RELEASE)
SHUT-OFF VALVE
b1 b2 b3
B2 B3
P
SOLENOID VALVE
A1 A2 A3
PILOT OIL
PRESSURE PORT DR
a1 a2 a3
CHECK PORT
PILOT OIL LIFT SECTION

PRESSURE
RELIEF VALVE TILT SECTION
ATT SECTION
(OPTION)
(LIFT) (TILT) (ATT)
Fig. 7.19 Control Valve (trucks with FIT)
- 87 -
7. HYDRAULIC SYSTEM
(1) Valve controls (trucks with FIT)

The plungers of the control valve are controlled with the control levers that are located on the
right side of the operator’s seat and a valve controller.
Figure 7.21 shows the control levers. The amount of movement of the lever is converted into
voltage and input to the valve controller, which in turn, passes the current corresponding to the input
voltage, to the solenoid to control the amount of movement of the plunger.
JOYSTICK FOR ATT2

JOYSTICK FOR ATT1 (RESERVED)
JOYSTICK FOR TILT
JOYSTICK FOR LIFT
Fig. 7.20 Valve Control (trucks with FIT)
- 88 -
7. HYDRAULIC SYSTEM
B A
POTENTIOMETER
2 4
1 3
Black
Red
Blue ON (1 k or less)
FF (100 M or less)
White
Switch output (Ω)

Wiring diagram
100 -0.1
0
50
0 +0.1
0
Neutral
40˚ ± 3˚
Potentiometer output (%)
Fig. 7.21 Control Lever
- 89 -
7. HYDRAULIC SYSTEM
(2) Valve controller

The valve controller controls the solenoids of the main control valve and the pump motor. The
valve controller receives the analog signal of voltages which vary according to the operation of
joysticks and the drive unit, and the digital signal of the operating status of each switch. According to
such signals, the valve controller controls the current to each solenoid and the rotation of the pump
motor.
VALVE CONTROLLER
VTM UNIT
Gy
Gy
Gy L Y
Fig. 7.22 Valve Controller
- 90 -
7. HYDRAULIC SYSTEM
(3) Installation of valve controller

When removing the valve controller for any reason or replacing it with a new one, follow the
procedure given below.
Check the truck model to which you want to install the valve controller.
Check that the wire harness is correctly connected.
Make sure the key switch is turned off before removing the valve controller acrylic plate.
Turn on the key switch. Press and hold down the SW1 for about 5 seconds and release it. The
system gets in the memory mode.
Note: Hold down the SW1 for about 5 seconds; otherwise the system won’t get in the memory
mode. If the system fails to get in the memory mode, turn off the key switch and repeat step .
When the system gets in the memory mode, the 4-digit LED displays [ ].
Press the SW1 again to display [ ] on the 4-digit.
Press the SW3 to change the display to [ ].
Press the SW1, and [ ] will appear in about 3 seconds on the 4-digit display.
Turn off the key switch.
(4) Saving the neutral status of joystick potentiometer in memory

A. Checking the neutral status of potentiometer
Turn off the key switch. Remove the transparent cover from the valve controller cover.
Turn the key switch on. [000*] is displayed on the 4-digit LED.
[1]: FTB16
[2]: FTB18, FTB20 Transparent cover
Press the SW2 on the board twice to display [*0.0] on 4-digit
LED
the 4-digit LED.
(Check the decimal point of each digit on the LED.)
If no decimal point is displayed, press the SW1 until a
decimal point appears. SW1
Check the value at the position of the asterisk (*) on the SW2
LED.
[0]: Not adjusted (Follow the procedure B.)
[1]: Adjusted
Turn off the key switch.
B. Saving neutral status of potentiometer in memory (Note 1)

Turn the key switch of. Move the levers to put them in free state.
Remove the transparent cover from the valve controller cover.
Hold down the SW2 on the board while turning the key switch on.
Hold down the SW2 for 5 seconds and release it. The 4-digit LED will display [c01]. (Note 2)
Press the SW1 to display [AAAA] on the 4-digit LED.
Press the SW1 again. The 4-digit LED displays [CCCC] for 3 seconds before displaying [c01].
Turn the key switch off. Reinstall the transparent cover.
Note 1: When saving the neutral status of potentiometers in memory, check the joystick for
connections.
Note 2: If the SW2 is released earlier than specified, the 4-digit LED does not display [c01]. If this
is the case, turn the key switch off and then repeat step 3.
- 91 -
7. HYDRAULIC SYSTEM
7.1.4 LIFT CYLINDERS

The two lift cylinders of single-acting type are located on the outer mast. Each lift cylinder
consists of a cylinder body, rod, piston, and holder.
The piston fastened to the rod with a snap ring is provided with a wear ring and a packing on its
circumference.
At the lower part of the cylinder provided is a cut-off valve which works as a safety device when
the high-pressure hose connecting the right and left lift cylinders breaks.
The bushing and oil seal pressed into the cylinder cap serve to support the rod and protect the
inside of the cylinder from dust.
■ Cut-off valve operation

The oil from the cylinders flows back to the
tank via the piston holes and . In this process,
if the flow rate passing through the holes are within
a range of the flow rate which can be controlled by
the flow regulator, the pressure difference across
the piston is less than the spring force so that the
piston does not move.
If the hose bursts and the oil passing through PISTON
the holes and exceeds the flow that can SPRING

be controlled, the pressure difference across
the piston becomes larger than the spring force,
moving the piston to the right.
The piston comes in contact with the section
of the case to the extent that a small amount of Fig. 7.23 Below Control Flow Rate
oil in the cylinder flows out to allow the forks to
lower slowly.
CASE
Fig. 7.24 Over Control Flow Rate
- 92 -
7. HYDRAULIC SYSTEM
Detail of cylinder support
1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. ROD PACKING
5. CYLINDER CAP
6. “O”-RING
7. BUSHING
8. ROD
9. CYLINDER
10. LOCK RING
11. WEAR RING
12. PACKING
13. PISTON
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
Fig. 7.25 Lift Cylinder (VM-83A)
- 93 -
7. HYDRAULIC SYSTEM
Detail of cylinder support
1. LOCK NUT
2. LOCK BOLT
3. PISTON HEAD
4. SHIM
5. WIPER SEAL
6. ROD PACKING
7. CYLINDER CAP
8. “O”-RING
9. BUSHING
10. ROD
11. CYLINDER
12. LOCK RING
13. WEAR RING
14. PACKING
15. PISTON
16. SNAP RING
17. SHEAVE
18. CHAIN
19. ANCHOR PIN
20. ADJUSTMENT NUT
21. LOCK NUT
22. COTTER PIN
Fig. 7.26 Lift Cylinder (VM-83C)
- 94 -
7. HYDRAULIC SYSTEM
7.1.5 FLOW REGULATOR VALVE

The flow regulator valve is installed at the
position shown in Figure 7.27 to control the fork LIFT CYLINDER
lowering speed and to work as a safety device (RIGHT)
when the high-pressure hose bursts for any reason.

LIFT CYLINDER
(LEFT)
■ Flow regulator valve operation
The oil returning from the lift cylinders flows from CONTROL
VALVE
into the chamber , passing through the chambers
, , , , and , back into the control valve.
At this time, the more the oil flows through
the hole in the piston , the greater the oil
pressure difference across the piston is created FLOW REGULATOR to OIL TANK
VALVE
and the piston moves to the right. The hole
is narrowed by the hole so that the flow rate is
regulated to control the fork lowering speed.
When the forks are raised, the high-pressure oil
from the control valve flows, passing through the
Fig. 7.27
chambers , , , , , , and , into the lift
cylinders.
Free flow
Controlled flow
Lift cylinder side Control valve side
1. CASE 4. PISTON 7. SPRING

2. SPRING 5. SLEEVE 8. “O”-RING
3. BALL 6. ORIFICE 9. GREASE FITTING
Fig. 7.28 Flow Regulator Valve
- 95 -
7. HYDRAULIC SYSTEM
7.1.6 TILT CYLINDER

The tilt cylinder is a double-acting type, with its piston rod end supported by the bottom of the
mast and the cylinder tail connected to the frame with a pin. This truck is provided with two tilt
cylinders, one on each side.
The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap, piston and rod.
The piston, installed onto the piston rod with a lock nut, has a packing on its circumference and
moves along the inner surface of the cylinder by the force of hydraulic oil. A bushing press-fitted to
the inside of the cylinder cap, with packing and wiper seal fitted thereto, provides oil tightness for
the rod and the cylinder cap, and also this bushing supports the rod. The cylinder cap, fitted with an
O-ring on the outer periphery, is screwed into the cylinder body.
When the tilt lever in the driver’s room is tilted forward, high-pressure oil enters the cylinder tail
side, moving the piston forward. This causes the mast to tilt forward 5 degrees. When the tilt lever is
tilted backward, high-pressure oil enters the cylinder cap side and moves the piston backward, tilting
the mast 6 degrees backward.
1. NUT 4. CYLINDER 7. CYLINDER CAP

2. PISTON 5. ROD 8. PACKING
3. PACKING 6. “O”-RING 9. DUST SEAL
Fig. 7.29 Tilt Cylinder
- 96 -
7. HYDRAULIC SYSTEM
7.1.7 OIL TANK

Figure 7.30 shows the oil tank, which is located at the left side of the truck frame.
The oil tank suction pipe is provided with a suction filter to prevent foreign matter from entering
the hydraulic circuit. The return pipe is equipped with a return filter to prevent foreign matter
generated in the hydraulic circuit from entering into the oil tank. These two devices keep the oil in
the hydraulic circuit clean, thus ensuring a long service life of the hydraulic system.
from ORBITROL
from CONTROL VALVE
to PUMP
from MAST PIPING

BREATHER
OIL FILL CAP
(W/ DIPSTICK)
RETURN FILTER
SUCTION FILTER DRAIN PLUG
Fig. 7.30 Oil Tank
- 97 -
7. HYDRAULIC SYSTEM
NOTE
- 98 -
8. LOAD HANDLING SYSTEM

Model
FTB16-7 FTB18-7 FTB20-7
Item
Name VM-83A VM-83C
Type Roller type 2-stage telecopic mast with free lift
Standard max. lifting height 3000 mm [118.11 in.]
Fork lifting system Hydraulic
Fork tilting system Hydraulic
Lift chain Leaf chain BL534
Mast rail dimensions
Cross section of outer rail
A : 44 mm [1.732 in.] ←
B : 102.5 mm [4.035 in.] ←
C : 134.5 mm [5.295 in.] ←
Cross section of inner rail
A : 43 mm [1.693 in.] ←
B : 102.5 mm [4.035 in.] ←
C : 134.5 mm [5.295 in.] ←
D : 72 mm [2.835 in.] ←
- 99 -

The hoist system uses a two-stage, roller type telescopic upright assembly consisting of outer and
inner channels and a carriage.
8.1.1 OUTER & INNER CHANNELS

The outer and inner channels are of welded construction. The bottom of the outer channel is
provided with a support by which the upright assembly is installed on the drive axle. The middle of
the outer channel is supported through tilt cylinders on the frame. The upright assembly can be tilted
forward and backward by operation of the tilt cylinders.
The outer channel has a ]-shaped section and is provided with end rollers at its upper part.
The inner channel has a J-shaped section and is provided with end rollers at its lower part.
1. OUTER CHANNEL
2. INNER CHANNEL
3. SHIM
4. END ROLLER
5. PIN
6. BUSHING
7. PIN
TILT CYLINDER
8. SHIM
9. END ROLLER
10. SHIM
11. SLIPPER
12. BUSHING
13. LOCK PLATE
Fig. 8.1 Outer & Inner Channels
- 100 -
8.1.2 CARRIAGE
The carriage has end rollers that roll along the inside of the inner channel, each installed on the
end roller shaft through a bearing with a snap ring. The end roller shafts are welded to the carriage.
The side rollers that roll along on the inside roller of each inner channel are bolt fitted, being shim
adjusted. To prevent rolling of the finger bar, two retaining rollers are used, which roll along the
outside of the inner channel. Longitudinal load is sustained by the end rollers of which the upper
one emerges from the channel top when the forks reach the maximum lift height. Transverse load is
sustained by both upper side rollers and the lower end rollers.
1. FORK
2. STOPPER
3. SPRING
4. HANDLE
5. CARRIAGE
6. END ROLLER
7. STOPPER BOLT
Z
8. SIDE ROLLER
9. SHIM
10. SHIM
Z [LF] 11. SPACER
[LFD]
[LFD]
Fig. 8.2 Carriage
- 101 -
8.1.3 ROLLER POSITIONS

There are two types of rollers: end rollers and side rollers. They are respectively installed on the
outer and inner channels and carriage.
The end rollers sustain forward-reverse load and the side rollers sustain side load to allow
movement of the inner channel and carriage.
Upper side Lower side
CARRIAGE
OUTER END ROLLER
CHANNEL INNER SIDE ROLLER (SHIM-ADJUSTED)
CHANNEL (SHIM-ADJUSTED)
END ROLLER
(SHIM-ADJUSTED)
END ROLLER
END ROLLER (SHIM-ADJUSTED)
(SHIM-ADJUSTED)
SLIPPER
(SHIM-ADJUSTED)
SHIM SHIM
SHIM
SHIM
SHIM
: Clearance 0 - 0.5 mm [0 - 0.02 in.]

: Contact at one side
: Apply grease (both sides)
Shim adjustment procedure
Fig. 8.3 Roller Positions
- 102 -
9. ELECTRIC WIRING
9. ELECTRIC WIRING
The electric components of the truck are wired using several types of wire harnesses and color
coded by circuit (wire number).
The wire harnesses are connected with connectors (2 types) or screws.
Table 9.1 Color symbols and examples
Wire B Black R Red Wire

number number
G Green W White
L Blue Y Yellow
O Orange Lg Light green

Example: Wire number 22, Yellow Example: Wire number 110, White
coating with a blue marking P Pink Sb Light blue coating without marking
Table 9.2 Connector symbol
Connection type Plug-in side Receptacle side Remarks
The numbers signify wire

Housing
Plug-in type
numbers.
The alphabetic letters mean
colors. (Table 9.1)
Plug
Screw type
Two wires may have different wire numbers even though they have the same wire color. Before
trying to check the wires, refer to wire harness and circuit diagrams on pages that follow.
The dotted lines in the circuit diagrams are given for optional equipment.
- 103 -
9. ELECTRIC WIRING
(Empty page)
- 104 -
9. ELECTRIC WIRING
G (111-3)
to FAM MOTOR
B (2-6) to BACK BUZZER

B (2-4)
Lg (98)
L 8))
O (97))
to LIFT LOCK SOL. B to FORWARD CHIME
B (2-5)
B V G
188 94 189
P B
139 2
to W/H.VALVE SW.
G 100
Gy 102
Lg 167
V 168
G B (9)
Br Gy G
B (2)) 111
O B Lg
108 2-3 98-1
G 100-F
Gy 102-F
Lg 167-F
V 168-F
to DM SENSOR (R.H) to W/H OPTION
to TERMINAL(N)
R R (5)
35 34
R (5-1))
F7 2A
F3 10A
F5 10A
to TERMINAL(P)
to STEERING POT.
Y
92
R 5
R 5-1
191 190
to ACCLE POT.
B Lg G
186 93 187
to BRAKE SW
B W
41 40
Gy (102-1)
to INVERTER CN2
to INVERTER CN7
1 11
1 6
Sb (112) O L R Br O V G
R Y V Br 81 230 18 16 22 243
to PM SENSOR 191 92 136 180 P Y B L P Sb L Y
B V R 83 82 25 19 17 23 246 249
12 22
168 95 CN2
7 12
1 8 CN7
B R W Gy Sb to INVERTER CN13
38 34 40 31 28
B B B B
35 41 32 29
9 16
O P
to INVERTER CN1
to SHORT COUPLER
to DM SENSOR (L.H)
1 13
B Sb
28 R B P Y G V G Y
151 86 150 110 183 30 187 94 189 11-7
to STEERING NEUTRAL SETTING SW
G L Br Lg
G Lg O Sb L Lg B Lg B Y
20 21 24 15 181 54 53 186 93 188 11
14 26
B Y -
86-2 183 -
CN1
to W/H REAR COMBINATION LAMP
Br B V
R Lg P
113 98-2 106
O(203-1)
WARNINNG BUZZER G (111-2)
Sb W G L
169 177 111 131 L(208)
Br Y O to VTM UNIT
101 132
Y (11-8) to FAM MOTOR
1 13
B (2-7)
Y G V P Br L Br
11-9 100-2 78 83 209 208 101-1 to AUTO POWER OFF
G W O O V B
P Gy B Y R 1
100-1 77 84 203 211 9-1
150 15 25 249 230 14 26
Br (101)
R B - L G
151 86-1 - 246 243 to OPTION EQUIPMENT DEVICE to FET UNIT
to W/H FRONT GUARD 1 13
G Lg B Y W L O Y L Sb Gy
111-1 98 86-3 178 177 131 132 11-2 107 169 102-2
R Sb O Br Br R Y W P V Gy
L Y V Gy B G 113 112 97 109-1 180 95 11-1 110 106-1 105-1 102-3
107 11 105 102 2-1 100 14 26 G -
Lg -
109 108 106 85 9 167 Lg
Y V - 142
-
P G Br
139 137 134
to RESISTOR & RELAY ASS'Y
Fig. 9.1 Wire Harness (Frame)
- 105 -
9. ELECTRIC WIRING
to W/H.OVER H.G. (R.H.)
V Br
105 109
B L
2 107
to METER PANEL
V R B Y B
78 79 9-1 11 9-2
W Gy B R
77 80 9 85
to OPTION EQUIPMENT DEVICE
G Gy B
111 102 2-1
to W/H SW
to HORN
B P R
86-1 150 151
to F/R SWITCH to FLASHER UNIT L(103) B(2-6)

23 15
L Lg B to KEY SW G(100)
54 53 86-2 Gy (102-4)
Br(101)
33
Sb (169)
to HANDLE ENCODER
R B
230 25 Lg 167 to W/H.FRAME
G Y L to ORBIT SOL.
243 249 246
35
Y 11-1
G B Gy V Y L
100 2 102 105 11 107
Lg B R P O Br
to HORN SWITCH 167 9 85 106 108 109
Gy
102-2
L
103
R Y B Gy P
B O 230 249 25 15 150
86 15 O Gy B
108 102-1 2-9 G L - B R
243 246 - 86 151
to PARKING SW
W Y B O L B
177 178 2-4 132 131 2-3 to RWL SW
14
to LIGHTING SWITCH
L G W Sb
P Br 131 111 177 169
106 109-1 O - Y Br
B L 132 - 178 101
2-5 107-1
to W/H.OVER H.G. (L.H.) W R Lg

77 79 53
V Gy L
78 80 54
Fig. 9.2 Wire Harness (Front Guard)
- 106 -
to SOL. 3B
(ATT1)
to SOL. 2B
Lg Sb to SOL. 4B
264 265
to RESISTOR
R V
120 121
O Y
45 46 271 11-1
Y 11
to SOL. 1A
13
(LIFT) Gy L Br Gy O R W Lg O Y
124 125 122 124 51 120 262 264 43 11
G L P V Y Sb Br Lg
G 123 125 52 121 263 265 44 261
14 26
to SOL. 1B
- 107 -
(LIFT)
to VALVE CONTROLLER CN1
O W Y to SOL. 4A
O P
(ATT2)
Fig. 9.3 Wire Harness, Valve (Trucks with FIT)

51 52
SOLENOID (ATT1)
(TILT)
9. ELECTRIC WIRING
9. ELECTRIC WIRING
to WIRE HARNESS, JOYSTICK
P R G R Lg
256 253 20 250 276
W B Y B O
254 255 251 252 272
to VALVE CONTROLLER CN4
1 11
Y B R W B R Y B B
11 2 253 254 255 250 251 252 2-2
Y B R G B R Br B
11-1 2-1 277 278 279 273 274 275
12 22
R G B
R B
- 108 -
1 8
P G Lg O B V
Y 11-2 256 20 276 272 94
9 16
Y B
11 2 to WIRE HARNESS,
VALVE
to WIRE HARNESS,
FRAME
- V B
- 94 188
Fig. 9.4 Wire Harness, Valve Control (Trucks with FIT)

to WIRE HARNESS, FRAME
to JOYSTICK FOR ATT1
G B
to WIRE HARNESS, 278 279
Lg
VALVE CONTROLLER 276 277
to JOYSTICK FOR TILT

to JOYSTICK FOR ATT2
B G
279 278 277 Y B
B Br B
251 252
275 274 273 274 275 G R
O R
20
272 273
to JOYSTICK FOR LIFT
- 109 -
W B
Lg R G R P
20
B Y B W
251 255
Fig. 9.5 Wire Harness, Joystick (Trucks with FIT)

9. ELECTRIC WIRING
9. ELECTRIC WIRING
■ FET unit
The FET unit consists of semiconductors (FET) and is used to turn on and off lamps.
The FET unit does not have any mechanical contacts and thus features low operating noise and
offers reliable switching function for a long period of time.
Terminal arrangement
Fig. 9.6 FET Unit
- 110 -
9. ELECTRIC WIRING
REAR COMBINATION LAMP
HEAD LAMP
FRONT COMBINATION LAMP
View looking from
Fig. 9.7 Lamp Mounting Position
- 111 -
9. ELECTRIC WIRING
■ Head lamp
The head lamp has a design shown in Figure 9.8 and is installed on the front supports of the
overhead guard.
1. LENS
2. RIM
3. HOUSING
4. REFLECTOR
5. GASKET
6. BULB
Section -
Fig. 9.8 Head Lamp
- 112 -
9. ELECTRIC WIRING
■ Replacing light bulbs SCREW

REFLECTOR
Remove the bulb by pushing in and then turning
to the left. BULB
48V - 40W
Reinstall the bulb by pushing in and then
GASKET
turning to the right.
(1) Head light and work light

Remove the screw securing the rim and
housing and remove the rim, lens and gasket.
LENS
Remove the bulb from the reflector and install
a new bulb. RIM
Fig. 9.9 Head Light (Work light)

1. Use caution not to get burnt because the surface of a bulb is hot soon after it is turned
off.
2. Use caution not to contaminate the bulb surface and reflector surface.
With the gasket, install the lens and reflector. BULB (FLASHER)
48V - 23W
BULB
(2) Rear and front combination lamps (BRAKE, PARKING)
48V - 25W, 48V - 10W
Remove the screw and separate the lens from
the body.
Remove the burned-out bulb and reinstall a SCREW
new one.
Reassemble the lens and body with the screw. BODY
BULB
(BACK-UP LAMP)
48V - 10W
LENS
Fig. 9.10 Rear Combination Lamp
BULB
(FLASHER)
48V - 25W
SCREW
BODY
BULB
(PARKING)
48V - 12W
Fig. 9.11 Front Combination Lamp
- 113 -
9. ELECTRIC WIRING
(Empty page)
- 114 -
HORN SW
HORN L 103
FAN MOTOR
(SIDE)
G 111
F-1
OPTION
KEY SWITCH-ON OUTPUT

COUPLER
FAN MOTOR
(UPPER)
O 97
F-18
L
R
N
B 2
TB
LICENCE PLATE
SWITCH
TURN SIGNAL
LAMP (10W) O 132

TR
F-9
LIGHT SWITCH INPUT
(TR)
L 131
TL
F-8
TURN SIGNAL LIGHT SWITCH INPUT
F-24 (TL)
(25W) TURN SIGNAL OUTPUT (L)
LAMP(L.H.)
FLASHER UNIT
CLEARRANCE
FRONT COMBINATION
(12W)
B 2
Sb 169
F-12
TURN SIGNAL POWER SUPPLY
T
H
OFF
B 2
EL
TURN SIGNAL
F-25
(25W)
LIGHTING SWITCH
TURN SIGNAL Y 178

LT
F-6
OUTPUT (R) LIGHT SWITCH INPUT
(LT)
LAMP(R.H.)
CLEARRANCE Br 109 W 177

LH
F-19 F-7
(12W) WIDTH LIGHT/TAIL LIGHT SWITCH INPUT
FRONT COMBINATION
LAMP OUT (R) (LH)

P 106
V 105
HEAD LAMP(L.H.)
( ) L 107
F-11 F-26
(40W) HEAD LIGHT OUTPUT
F-13
LAMP POWER SUPPLY
HEAD LAMP(R.H.)
( )
(40W)
BRAKE SW
F
Sb 112
R
N
F-15
BRAKE SWITCH INPUT
N
TURN SIGNAL
(23W)
1G1 1G2
F-23
BRAKE SIGNAL OUTPUT
TAIL(10W)
( ) R 113
VF
LAMP(L.H.) F-14 F-21

STOP(25W) STOP LAMP OUTPUT REVERSE TRAVEL
DIRECTION SWITCH
UNIT INPUT
REAR COMBINATION
F-20
VF2
BACK-UP Lgg 98
F-2
(10W) REVERSE TRAVEL
ST
F-5
UNIT OUTPUT
B 2
VR
Rc
TURN SIGNAL
GND
(23W)
F-3
F-22
KEY SWITCH F-10
TAIL(10W)
( )
LAMP(R.H.)
STOP(25W)
REAR COMBINATION
L 54
CN1-21 REVERSE SWITCH
BACK-UP Lgg 53
CN1-22 FORWARD SWITCH
(10W)
W 110 BRAKE SIGNAL
CN1-7
Y 11
BACK BUZZER
CN1-13
CN1-26
B 86
RWL SW CN1-5
REAR WORKING O 108 V 22
CN2-8 PM
LIGHT (40W) Gyy 15 Sb 23
PARKING CN1-19 CN2-19 THERMO SENSOR
LIFT LOCK
P 139 G 20
SOL TILT CN1-15 PU
- 115 -
Lg 21 PV
PIM
ATT1 CN1-17
O 24
PW
ATT2 CN1-18
1
Sb 181 W 40
M-9 GND SEAT CN1-20 CN13-5 PM
B 41
CNPPA
CN13-13
2
REV.SENSOR
STEER Y 183
M-3 CN1-8
Fig. 9.12 Circuit Diagram

ERROR SETTING SW
DISPLAY
ASS�Y
P 150
V-26 M-5 TRUCK SPEED LIMIT SWITCH CN1-6
METER PANEL
GND
R 151
F2
SPE SW CN1-4
Gyy 80 VOLTAGE CHANGE 225A
T.GND V-17 M-8 R.GND
R 79 W 30 SWITCH
TXD V-4 M-2 RXD M-4 CN1-9 F1
KEY P
W 77 SWITCH 275A
R.GND V-16 M-7 T.GND
V 78 0V B 186
RXD V-3 M-1 TXD CN1-23
Lgg 93 O 16
ACCEL1 POT. CN1-24 CN2-6 DM L.H.
+ G 187 P 17
CN1-10 CN2-17 THERMO SENSOR
0V B 188
CN1-25
36/48V
LU
V 94
M-10
LIFT POT CN1-11
+ G 189 LV
CN1-12
DIML
LW
O 84
GND V-19 CN2-1 GND
P 83
RXD V-6 CN2-12 TXD
1
Y 82 Gyy 31
TXD V-18 RXD CN13-6 DM L.H.
L 81 B 32
CNPDAL
P25 V-5 CN2-3 LOW VOLTAGE CN13-14

2
REV.SENSOR A
SIGNAL
R 85
1
R 230 Sb 28
1G CN2-4 CN13-8 DM L.H.
G 243 B 29
CNPDBL
SS1 CN2-10 CN13-16

2
REV.SENSOR B
Y 249
HANDLE
L 246
ENCODER SSC CN2-20
INVERTER
B 25
ESS CN2-15
Br 209
PB3 V-8
O 203
+5V V-22
0V B 190 Br 18
CN7-7 CN2-5 DM R.H.
Lg
L 208 Y 92 L 19
TM V-11 STEERING POT. CN7-2 CN2-16 THERMO SENSOR
L 134
g 142
G 137
(AT 36V)
+ R 191
SHORT
CN7-1
COUPLER
REVERSE TRAVEL UNIT RU
R 95
CN7-12
RV
DIMR
FORWARD TRAVEL UNIT Br 180

CN7-5 RW
180
2W
2W
CN7-6
1
Y 37
CN13-2 DM R.H.
W 135 LIFT LOCK V 136 B 38
LL
CNPDAR
CN7-4 CN13-1
2
REV.SENSOR A
VTM UNIT
1
R 34
15
10
CN13-3
40W
30W
LL ORBIT F7 DM R.H.
Gyy 138 Lgg 167 V 168 B 35
CNPDBR
SOL CN7-11 CN13-11

2
REV.SENSOR B
2A
B9
LIFT LOCK
B 2 N
PO
180
180
V 211
V-25
PO
BATTERY 48V/36V
R01
R 5
AUTO
V-1
POWER SUPPLY
POWE OFF
F5
F3
10A
10A
V-14
BATTERY VOLTAGE
DETECTION Gyy 102
G 100
MONITOR
V-12
KEY SW
Br 101
9. ELECTRIC WIRING
9. ELECTRIC WIRING
4P
N.C.
REAR
VALVE SW N.O. YL COMBINATION
W L BATTERY EXB
ASS2 COMM BY DISCONNECTING
LAMP (R.H.)
SWITCH 6P
W B
2P
+
N.C.
HEAD LAMP VALVE SW YG
(R.H.) ASS1 BY
O TAPING
N.C. F3 B
VALVE SW N.O. YB
SILS F5 BACK
COMM BY
3P
BUZZER
R
R
LIFS LOCK F7 Lg
g R
SOL.
+
FRONS COMBINASION LIFS
LAMP (R.H.) POSENSIOMESER (OP:VLL) B B
12P
4P 2P STD
2P
MESER
PANEL
HORN
3P
L 6P
B G
B
Lgg
Bg
MODE SPEED LIMIS B
NO
NC
COM
SW (
(L)
Sb 2P P N RW
(
(X)
G B
RV
RU
RW
Br
P
BY
Gy
DRIVE RV
MOTOR B
3P
P B RU
SURN SIGNAL 3P
SW W V U
FLASHER UNIS B A F1
LW
Br 2P 2P
F2 LV
O
B
G
STEERING
FAN LU POT. WORKING
KEY SW ACCEL. INVERTER LAMP
3P
2P
18P
Y
2P
2P W V U
RED SAPE SEAT SW
Lg BATTERY
6P
PUMP 3P
MOTOR
CN1 CN13 CN7 CN2
O
B
14P
ORBIS
SOL. 2P 2P 26P 16P 12P 22P
2P
A
U V W
KNOB SLIP REVERSE

F/R SW W/H SW (OP:SRS) BRAKE PU
PU
PV
PW
DRIVE S
SW Sb PV
V PW
W
LU
LV
LW
RW MOTOR
Gyy
W 2P
2P
SSEERING
PARKING
BRAKE SW
2
3P
Y 1
O
+
Gyy
COM1
3P
6P
O
NO
-
B WARNING SSD
BUZZER R O
REAR WORKING
LAMP SW B L
(12P)
W L
12P (2P))
G B
W B
VSM
10P
26P
HEAD LAMP UNIT
8P
(L.H.) P B
6P
6P
FET FAN
UNIT
26P (4P)) (6P))
3P
4P
6P
OPSION
Y
Br
FRONS COMBINASION PAO REAR COMBINASION

LAMP (L.H.) (AUSO POWER OFF) LAMP (L.H.)
VLL
(LIFS LOCK)
4P 6P
Y
Br
Fig. 9.13 Wiring Diagram
- 116 -
9. ELECTRIC WIRING
4P
N.C.
REAR
VALVE SW N.O. V COMBINATION
W L BATTERY
ATT2 COMM B DISCONNECTING
LAMP (R.H.)
SWITCH TAPING 6P
W B
+
N.C. BACK
HEAD LAMP VALVE SW P
(R.H.) ATT1 W BUZZER
COM
M B
Lg
g R
VALVE SW B B
G
TILT B
F5
3P
R
R
LIFT LOCK F7 O
SOL.
+
FRONT COMBINATION LIFT OPTION
LAMP (R.H.) POTENTIOMETER (OP:VLL) B
12P
4P 2P
2P
METER
PANEL
HORN
3P
6P
L
B G
B
Bg
MODE SPEED LIMIT B
NO
NC
SW SW (
(L)
Sb 2P P N RW
(
(X)
G B
RV
RU
RW
Br
O
B
P
B
Gy
DRIVE RV
MOTOR B
3P
P B RU
TURN SIGNAL 3P
SW W
FLASHER UNIT B A LW
Br 2P 2P
LV
O
B
G
STEERING REAR
FAN LU POT. WORKING
2P
18P
Y
2P
2P W V U
RED TAPE SEAT SW
Lg BATTERY
6P
PUMP 3P
MOTOR
CN1 CN13 CN7 CN2
O
B
14P
ORBIT
SOL. 2P 2P 26P 16P 12P 22P
2P
A B
U V W
KNOB SLIP REVERSE

F/R SW (OP:SRS) BRAKE PU
PU
PV
PW
DRIVE S
SW Sb PV
V PW
W
LU
LV
LW
COM
B MOTOR
NO
NC G 2P
2P
STEERING
PARKING NEUTRAL SET SW
BRAKE SW
B 3
3P
Y 1
O
+
Gyy
COM1
3P
6P
O
NO
-
B WARNING STD
BUZZER R O
B L
12P
LAMP SW
W L
12P (2P))
G B
W B
VTM
10P
26P
HEAD LAMP UNIT
8P
(L.H.) P B
6P
6P
FET FAN
UNIT
26P (4P)) (6P))
3P
4P
6P
OPTION
Y
Br
FRONT COMBINATION PAO REAR COMBINATION

LAMP (L.H.) (AUTO POWER OFF) LAMP (L.H.)
VLL
(LIFT LOCK)
4P 6P
Y
Br
Fig. 9.14 Wiring Diagram (for EXA)
- 117 -
HORN SW
HORN L 103
FAN MOTOR
(SIDE)
G 111
F-1
OPTION
KEY SWITCH-ON OUTPUT

COUPLER
FAN MOTOR
(UPPER)
9. ELECTRIC WIRING
GND
6.8Ω
40W
CN2-1 CN4-2
O 97
F-18 CN2-4 CN4-11
B 2
CN2-3 CN4-13
CN2-2 CN4-22
L
R
N
CN2-7 CN4-1
6.8Ω
40W
FOR 36V
CN4-12
B 2 Y 11
TB
CN1-11
LICENCE PLATE
CN2-5
LAMP (10W) O 132
TR
F-9 CN4-14
TURN SIGNAL SWITCH
LIGHT SWITCH INPUT

6.8Ω
40W
(TR) CN2-8 CN4-3

L 131
TL
F-8 CN4-4
TURN SIGNAL
F-24 (TL) CN2-6 UNLOAD
(25W) TURN SIGNAL OUTPUT (L) Lgg 261 O 271
CN1-24 SOL
LAMP(L.H.)
FLASHER UNIT CN2-14

CLEARRANCE
FRONT COMBINATION
CN3-9 CN1-7
(12W)
B 2
CN3-8
Sb 169
F-12 CN3-7 CN1-20
TURN SIGNAL POWER SUPPLY
CN1-8
T
H
OFF
CN3-4
CN3-5 CN1-21
B 2
EL
CN3-6 CN1-12
TURN SIGNAL
F-25
(25W)
LIGHTING SWITCH
TURN SIGNAL Y 178

LT
F-6 CN2-13 CN1-25

OUTPUT (R) LIGHT SWITCH INPUT
(LT) CN3-3 CN1-13
LAMP(R.H.)
CLEARRANCE Br 109 W 177

LH
F-19 F-7 CN3-2

(12W) WIDTH LIGHT/TAIL LIGHT SWITCH INPUT
FRONT COMBINATION
LAMP OUT (R) (LH) CN3-1 CN1-26

O 43 +
CN1-9
P 106
V 105
O 272
CN2-12 SOL A
GND B 275 Br 44 -
CN4-21 CN1-22
HEAD LAMP(L.H.) L 107 ATT2 POT. Br 274 G 45 ATT2
VALVE CONTROLLER
F-11 F-26 +
CN4-20 CN1-10
(40W) HEAD LIGHT OUTPUT (1KΩ) +5V R 273 (SOL4)
F-13 CN4-19
LAMP POWER SUPPLY Gyy 46 -
CN1-23
F
R
N
HEAD LAMP(R.H.) Lgg 276 W 262 +

CN2-11 CN1-5
(40W) GND B 279
Sb 112
BRAKE SW CN4-18 SOL A
ATT1 POT.
N
F-15 G 278 Y 263 -

CN4-17 CN1-18
BRAKE SWITCH INPUT (1KΩ) +5V R 277 Lgg 264 + ATT1
CN4-16 CN1-6
(SOL3)
G 20 Sb 265 -
CN2-10 CN1-19
GND B 252 O 51
1G1 1G2
CN4-10 CN1-3
TURN SIGNAL TILT POT. Y 251
CN4-9 SOL A
(23W) (1KΩ) +5V R 250 P 52
VF
F-23 CN4-8 CN1-16

DIRECTION SWITCH
BRAKE SIGNAL OUTPUT R 120 + TILT

CN1-4
TAIL(10W) R 113 P 256 (SOL2)
VF2
F-14 F-21 CN2-9 SOL B

LAMP(L.H.)
STOP(25W) STOP LAMP OUTPUT REVERSE TRAVEL GND B 255 V 121 -
UNIT INPUT CN4-7 CN1-17
REAR COMBINATION
LIFT POT. W 254 Br 122
ST
F-20 CN4-6 CN1-1

BACK-UP Lgg 98 (1KΩ) +5V R 253
F-2 CN4-5 SOL A
(10W) REVERSE TRAVEL G 123 -
VR
F-5 CN1-14
UNIT OUTPUT LIFT
Gyy 124 +
CN3-10 CN1-2
PUMP SPEED (SOL1)
Rc
V 94
B 2
CN2-16 SOL B
0V B 188 L 125 -
CN2-15 CN1-15
CN3-11
TURN SIGNAL
GND
CN3-12
(23W)
F-3
F-22
KEY SWITCH F-10
TAIL(10W)
LAMP(R.H.)
STOP(25W)
REAR COMBINATION
L 54
CN1-21 REVERSE SWITCH
BACK-UP Lgg 53
CN1-22 FORWARD SWITCH
(10W)
W 110 BRAKE SIGNAL
CN1-7
Y 11
BACK BUZZER
CN1-13
CN1-26
B 86
RWL SW CN1-5
REAR WORKING O 108 V 22
CN2-8 PM
LIGHT (40W) Gyy 15 Sb 23
PARKING CN1-19 CN2-19 THERMO SENSOR
LIFT LOCK
P 139
SOL CN1-15 PU
- 118 -
PV
PIM
CN1-17
PW
CN1-18
1
Sb 181 W 40
M-9 GND SEAT CN1-20 CN13-5 PM
B 41
CNPPA
CN13-13
2
REV.SENSOR
STEER Y 183
M-3 CN1-8
ERROR SETTING SW
DISPLAY
ASS�Y
P 150
V-26 M-5 TRUCK SPEED LIMIT SWITCH CN1-6
METER PANEL
GND
F2
R 151
SPE SW CN1-4
Gyy 80 VOLTAGE CHANGE
T.GND V-17 M-8 R.GND SWITCH
R 79 W 30
TXD V-4 M-2 RXD M-4 CN1-9 F1
P
Fig. 9.15 Circuit Diagram (Trucks with FIT)

KEY
W 77 SWITCH 275A
R.GND V-16 M-7 T.GND
V 78 0V B 186
RXD V-3 M-1 TXD CN1-23
Lgg 93 O 16
ACCEL1 POT. CN1-24 CN2-6 DM L.H.
+ G 187 P 17
CN1-10 CN2-17 THERMO SENSOR
0V
CN1-25
36/48V
LU
M-10
CN1-11
CN1-12
LV
DIML
LW
O 84
GND CN2-1 GND
P 83
RXD V-6 CN2-12 TXD
1
Gyy 31
TXD CN2-13 RXD CN13-6 DM L.H.
L 81 B 32
CNPDAL
P25 V-5 CN2-3 LOW VOLTAGE CN13-14

2
REV.SENSOR A
SIGNAL
R 85
1
R 230 Sb 28
1G CN2-4 CN13-8 DM L.H.
G 243 B 29
CNPDBL
SS1 CN2-10 CN13-16

2
REV.SENSOR B
Y 249
HANDLE SS2 CN2-21
L 246
ENCODER SSC CN2-20
INVERTER
B 25
ESS CN2-15
Br 209
PB3 V-8
O 203
+5V V-22
0V B 190 Br 18
CN7-7 CN2-5 DM R.H.
Lg
L 208 Y 92 L 19
TM V-11 STEERING POT. CN7-2 CN2-16 THERMO SENSOR
L 134
g 142
G 137
(AT 36V)
+ R 191
SHORT
CN7-1
COUPLER
REVERSE TRAVEL UNIT RU
R 95
CN7-12
RV
DIMR
FORWARD TRAVEL UNIT Br 180

CN7-5 RW
180
180
2W
2W
CN7-6
1
Y 37
CN13-2 DM R.H.
W 135 LIFT LOCK V 136 B 38
LL
CNPDAR
CN7-4 CN13-1
2
REV.SENSOR A
VTM UNIT
1
R 34
15
10
CN13-3
40W
30W
LL ORBIT F7 DM R.H.
Gyy 138 Lgg 167 V 168 B 35
CNPDBR
SOL CN7-11 CN13-11

2
REV.SENSOR B
2A
B9
LIFT LOCK
B 2 N
PO
180
2W
2W
V 211 W 143
V-25
PO
BATTERY 48V/36V
R02 R01
R 5
AUTO
V-1
POWE OFF
POWER SUPPLY
F5
F3
10A
10A
V-14
BATTERY VOLTAGE
DETECTION Gyy 102
G 100
MONITOR
V-12
KEY SW
Br 101
9. ELECTRIC WIRING
YELLOW TAPE
RED TAPE
4P
WHITE TAPE
REAR
2P
COMBINATION
W L RED TAPE BATTERY EXB
DISCONNECTING
LAMP (R.H.)
SWITCH A 6P
W B
2P
4P
+
HEAD LAMP JOYSTICK B
4P
(R.H.)
O
4P
TAPING
2P F3 B
F5 BACK
3P
BUZZER
R
R
10P
2P 2P
LIFT LOCK F7 Lg R
SOL.
+
FRONT COMBINATION
(OP:VLL)
6P
LAMP (R.H.) B B
12P
(4P) 2P STD
TAPING
YELLOW TAPE WHITE TAPE
2P
METER GRAY TAPE GREEN TAPE
PANEL
HORN
3P
6P
L
B G
B
Bg
MODE SPEED LIMIT B
NO
NC
SW SW (L)
Sb 2P P N RW
(X)
G B
RV
RU
RW
Br
O
BY
P
BY
Gy
DRIVE RV
MOTOR B
3P
P RU
TURN SIGNAL 3P
SW W V U
FLASHER UNIT A F1
LW
Br 2P
F2 LV
O
B
G
STEERING REAR
FAN LU POT. WORKING
3P
2P
18P
Y
2P
2P W V U
RED TAPE SEAT SW
Lg BATTERY
6P
PUMP 3P
MOTOR
CN1 CN13 CN7 CN2
O
14P
ORBIT
SOL. 2P 2P 26P 16P 12P 22P
2P
A B
U V W
KNOB SLIP REVERSE

PU
PV
PW
DRIVE SW Sb PV PW
LU
LV
LW
RW MOTOR
Gy
W 2P
2P
STEERING
PARKING
BRAKE SW
2
3P
1
O
+
Gy
COM1
3P
6P
NO
-
B
RESISTER
WARNING STD
2P
BUZZER R O
CN4
22P
REAR WORKING
LAMP SW O B L
(12P)
W L
12P
VALVE CN3 Gy L G B
12P
W B CONTROLLER
VTM
10P
AT 36V Y
26P
HEAD LAMP UNIT

AT 48V
CN2
16P
8P
(L.H.) P B
Y 6P
6P
FET FAN
2P
CN1
26P
UNIT
26P (4P) (6P)
3P
4P
6P
OPTION
Br

VLL
(LIFT LOCK)
4P 6P
Y
Br
Fig. 9.16 Wiring Diagram (Trucks with FIT)
- 119 -
9. ELECTRIC WIRING
RED TAPE
YELLOW TAPE
4P
WHITE TAPE REAR
2P
COMBINATION
W L RED TAPE
BATTERY
DISCONNECTING
LAMP (R.H.)
4P
SWITCH 6P
W B TAPING
4P
+
HEAD LAMP BACK
JOYSTICK W BUZZER
2P 2P
4P
(R.H.)
2P 2P Lg
g R
4P
2P 2P F3 B B
F5
3P
R
R
10P
2P 2P
LIFT LOCK F7 O
SOL.
+
FRONT COMBINATION OPTION
(OP:VLL)
8P
LAMP (R.H.) B
12P
( )
(4P) 2P
TAPING
YELLOW TAPE WHITE TAPE
2P
METER GRAY TAPE GREEN TAPE
PANEL
HORN
3P
L 6P
B G
B
Bg
MODE SPEED LIMIT B
NO
NC
SW SW (
(L)
Sb 2P P N RW
(
(X)
G B
RV
RU
RW
Br
O
B
P
B
Gy
DRIVE RV
MOTOR B
3P
P RU
TURN SIGNAL 3P
SW W V U
FLASHER UNIT A F1
LW
Br 2P
F2 LV
O
B
G
STEERING REAR
FAN LU POT. WORKING
3P
2P
18P
Y
2P
2P W V U
RED TAPE SEAT SW
Lg BATTERY
6P
PUMP 3P
MOTOR
CN1 CN13 CN7 CN2
O
14P
ORBIT
SOL. 2P 2P 26P 16P 12P 22P
2P
A B
U V W
KNOB SLIP REVERSE

PU
PV
PW
DRIVE S
SW Sb PV
V PW
W
LU
LV
LW
B MOTOR
Gyy
G 2P
2P
STEERING
PARKING
BRAKE SW
2
3P
Y 1
O
+
Gyy
COM1
3P
6P
NO
-
B
RESISTER
WARNING STD
2P
BUZZER R O
CN4
22P
REAR WORKING
O B L
12P
LAMP SW
W L
12P
VALVE Gy L G B
CN3
CONTROLLER 12P
W B
VTM
10P
AT 36V Y
26P
HEAD LAMP UNIT

AT 48V
CN2
16P
8P
(L.H.) P B
Y 6P
6P
FET FAN
2P
CN1
26P
UNIT
26P (4P)) (6P))
3P
4P
6P
OPTION
Br

VLL
(LIFT LOCK)
4P 6P
Y
Br
Fig. 9.17 Wiring Diagram (Trucks with FIT, for EXA)
- 120 -
No. SEB-83ACE
Issued: June, 2005
Revised: November, 2005
Revised: July, 2009
MARKETING GROUP: 1-15-5, Nishi-shimbashi, Minato-ku, Tokyo

105-0003, Japan
FAX: JAPAN +81-3-35918154
All rights reserved JB-0907005(HO) Printed in Japan

Service Manual: No. SEB-83ACE

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ド

ωm刃︿一Om 豆﹀Z C﹀﹁

1. BATTERY (OPTION) ............................................................................................................... 1

3. CONTROL SYSTEM ............................................................................................................. 17

4. DRIVE UNIT .............................................................................................................................. 59

5. BRAKE SYSTEM .................................................................................................................... 63

6. STEERING SYSTEM . ........................................................................................................... 67

7. HYDRAULIC SYSTEM ......................................................................................................... 77

8. LOAD HANDLING SYSTEM ............................................................................................. 99

9. ELECTRIC WIRING ............................................................................................................. 103

1.1 GENERAL DESCRIPTION

1.1.1 BATTERY CARE

shorter its life becomes.

The approximate depth of discharge can be known

Depth of discharge (%)

Specific gravity (20°C) [68°F]

1.1.2 CHARGING THE BATTERY

[Cautions on Charging the Battery]

[Conversion of specific gravity at different temperatures]

Conversion from °F to °C:

2.1 GENERAL DESCRIPTION

2.1.1 DRIVE MOTOR

Detail of slit plate

MOTOR SPEED SENSOR A

View looking from View looking from

Fig. 2.1 Drive Motor

DRIVE UNIT DRIVE MOTOR

DRIVE UNIT (RIGHT)

Motor mounting bolt Tightening torque:

View looking from View looking from

Detail of Detail of Pinion Gear

Fig. 2.2 Drive Motor Location

2.1.2 PUMP MOTOR

View looking from View looking from

Fig. 2.3 Pump Motor

Apply Molycoat grease

Fig. 2.4 Pump Motor Location

2.1.3 OPERATING PRINCIPLE OF 3-PHASE INDUCTION MOTOR

Three-phase alternating current is suitable

Fig. 2.7 Rotating Magnetic Field due to 3-phase Alternating Current

Check item Location Criteria Remedy

Usual temperature rise. stop operation and

(2) Check the following items with the motors stopped

Check item Location Criteria Remedy

2.2.2 PERIODIC INSPECTION

Operation time more than 12 hours/day 8 – 12 hours/day

Location Check item Criteria Remedy

Fasteners Check for looseness, corrosion or seizure Retighten, apply

Connections Visually check that connections are correct and Retighten.

Stator Iron core Check for adherence of dust visually. Clean.

Rotation Measure resistance 620 ± 60Ω (20°C or 68°F) Replace.

Painting Damage Check for damage, discoloration, peeling, or Apply anti-rust.

Cleanliness Deposit of Check for contamination, adherence of dust or

(2) Inspection procedure

Select a place which is not dusty or humid.

Check bolts for looseness, retightening any loose bolt.

If the coating is damaged, discolored or exfoliated, apply anti-rust or paint again.

2.2.3 MAINTENANCE OF BEARINGS

Operation time 8 – 12 hours/day 12 hours/day

(1) Installing bearing

(2) Removing bearing

2.2.4 TROUBLESHOOTING GUIDE

Problem Probable cause Remedy