Fr15,18,10,25 7h Service Manual

No.
SEB-82ABE
ELECTRICAL FORKLIFT TRUCK

Reach Type
FR10-7C FR10-7 FR10-7H
FR13-7C FR13-7 FR13-7H
FR10-7CH FR14-7 FR14-7H
FR13-7CH FR15-7 FR15-7H
FR18-7 FR18-7H
FR20-7 FR20-7H
FR25 -7 FR25 -7H
FR30 -7 FR30 -7H
TCM CORPORATION
No. SEB-82ABE
FOREWORD
is offering a new FR-7 series of reach-type battery forklift trucks (1.0- to 3.0-ton models) equipped
with induction current traveling and load handling motors.
These motors are controlled by an inverter controller, which has eliminated abrasion and the need of
mechanical adjustment, thus making servicing easier.
All of the trucks in this series come with electric power steering as standard equipment. The electromagnetic
brake built in the trail wheel has improved safety and made load handling easier.
This Service Manual describes the design and basic equipment elements of the trucks mentioned above.
We encourage you to make practical use of the manual during servicing activities.
April 2008
SPECIFICATIONS (1)
Truck model
FR10-7C FR10-7CH FR13-7C FR13-7CH
Item
Performance
Max. load kg [lbf] 1000 [2200] 1250 [2750]
Basic load center mm [in.] 500 [19.7]
Max. lifting height A mm [in.] 3000 [118.1] 4000 [157.5] 3000 [118.1] 4000 [157.5]
Reach stroke B mm [in.] 405 [15.9] 555 [21.9]
Tilt angle (fwd – rev) ° 3–5
Free lift C mm [in.] 410 [16.1]
Fork lifting speed
(Unloaded) mm/s [fpm] 570 [112.3]
(Loaded) mm/s [fpm] 350 [69.0] 340 [67.0]
Travel speed
Fwd (unloaded) km/h [mph] 10.5 [6.5]
(loaded) km/h [mph] 9.5 [5.9]
Bwd (unloaded) km/h [mph] 10.5 [6.5]
(loaded) km/h [mph] 9.5 [5.9]
Gradeability
(Unloaded) 1/7 (14.3%)
(Loaded) 1/10 (10%)
Min. turning radius D mm [in.] 1335 [52.6] 1480 [58.3]
Min. intersecting aisle E mm [in.] 1550 [61.0] 1600 [63.0]
Dimensions
Overall length (include. Fork) F mm [in.] 2000 [78.7]
Overall width G mm [in.] 990 [39.0]
Overall height (at overhead guard) H mm [in.] 2260 [89.0]
Overall height with extended mast J mm [in.] 3845 [151.4]
Wheel base K mm [in.] 1095 [43.1] 1245 [49.0]
Tread
(Front wheels) L mm [in.] 875 [34.4]
(Rear wheels) M mm [in.] 600 [23.6]
Fork overhang N mm [in.] 170 [6.7]
Rear overhand P mm [in.] 220 [8.7]
Fork size mm [in.] 920 x 100 x 35
(Length Q x Width R x Thickness S) [36.2 x 3.9 x 1.4]
Fork spacing T mm [in.] 250 x 620 [9.8 x 24.4]
Backrest size mm [in.] 980 x 820 [38.6 x 32.3]
Steering wheel height (from floor) mm [in.] 1050 [41.3]
Floor height mm [in.] 310 [12.2]
Minimum under clearance (at mast) U mm [in.] 70 [2.8]
Weight
Service weight (with standard battery) kg [lbf] 1820 [4015] 1920 [4235] 1900 [4190] 1980 [4365]
No. SEB-82ABE
SPECIFICATIONS (2)
Truck model
FR10-7 FR13-7 FR14-7 FR15-7 FR18-7 FR20-7 FR25-7
Item
No. SEB-82ABE
Performance
Max. load kg [lbf] 1000 [2200] 1250 [2750] 1350 [2950] 1500 [3300] 1750 [3950] 2000 [4400] 2500 [5500]
Max. lifting height A mm [in.] 3000 [118.1]
Reach stroke B mm [in.] 405 [15.9] 555 [21.9] 580 [22.8] 725 [28.5] 650 [25.6] 795 [31.3]
Free lift C mm [in.] 410 [16.1] 415 [16.3] 410 [16.1]
Fork lifting speed
(Unloaded) mm/s [fpm] 570 [112.3] 480 [94.6]
(Loaded) mm/s [fpm] 350 [69.0] 340 [67.0] 330 [65.0] 310 [61.1] 270 [53.2] 250 [49.3]
Travel speed
Fwd (unloaded) km/h [mph] P:10.5[6.5]/N.E:9.5[5.9] 11.5 [7.1]
(loaded) km/h [mph] P:9.5[5.9]/N.E:8.5[5.3] 9.5 [5.9]
Bwd (unloaded) km/h [mph] P:10.5[6.5]/N.E:9.5[5.9] 11.5 [7.1]
Gradeability
(Unloaded) 1/7 (14.3%)
(Loaded) 1/10 (10%)
Min. turning radius D mm [in.] 1350 [53.2] 1490 [58.7] 1560 [61.4] 1750 [68.9] 1795 [70.7] 1965 [77.4]
Min. intersecting aisle E mm [in.] 1580 [62.2] 1630 [64.2] 1680 [66.1] 1750 [68.9] 1850 [72.8] 1910 [75.2]
Dimensions
Overall length (include. Fork) F mm [in.] 2000 [78.7] 2070 [81.5] 2110 [83.1] 2200 [86.6] 2225 [87.6]
Overall width G mm [in.] 1090 [42.9] 1200 [47.2]
Overall height (at overhead guard) H mm [in.] 2260 [89.0] 2315 [91.1]
Overall height with extended mast J mm [in.] 3845 [151.4] 3930 [154.7]
Wheel base K mm [in.] 1095 [43.1] 1245 [49.0] 1345 [52.9] 1525 60.0] 1530 [60.2] 1700 [66.9]
Tread
(Front wheels) L mm [in.] 975 [38.4] 1065 [41.9]
(Rear wheels) M mm [in.] 680 [26.8] 725 [28.5]
Fork overhang N mm [in.] 170 [6.7] 165 [6.5] 170 [6.7] 165 [6.5]
Rear overhand P mm [in.] 220 [8.7] 240 [9.4]
Fork size mm [in.] 920 x 100 x 35 920 x 100 x 38 920 x 122 x 40
(Length Q x Width R x Thickness S) [36.2 x 3.9 x 1.4] [36.2 x 3.9 x 1.5] [36.2 x 4.8 x 1.6]
Fork spacing T mm [in.] 250 x 720 [9.8 x 28.3] 290 x 735 [11.4 x 28.9]
Floor height mm [in.] 310 [12.2] 355 [14.0]
Weight
Service weight (with standard battery) kg [lbf] 1860 [4100] 1940 [4580] 2050 [4520] 2160 [4760] 2230 [4915] 2740 [6040] 2880 [6350]
SPECIFICATIONS (3)
Truck model
FR10-7H FR13-7H FR14-7H FR15-7H FR18-7H FR20-7H FR25-7H
Item
Performance
Max. load kg [lbf] 1000 [2200] 1250 [2750] 1350 [2950] 1500 [3300] 1750 [3950] 2000 [4400] 2500 [5500]
Max. lifting height A mm [in.] 4000 [1575]
Reach stroke B mm [in.] 555 [21.9] 580 [22.8] 725 [28.5] 795 [31.3]
Free lift C mm [in.] 410 [16.1] 415 [16.3] 410 [16.1]
Fork lifting speed
(Unloaded) mm/s [fpm] 570 [112.3] 480 [94.6]
(Loaded) mm/s [fpm] 350 [69.0] 340 [67.0] 330 [65.0] 310 [61.1] 270 [53.2] 250 [49.3]
Travel speed
Fwd (unloaded) km/h [mph] P:10.5[6.5]/N.E:9.5[5.9] 11.5 [7.1]
Bwd (unloaded) km/h [mph] P:10.5[6.5]/N.E:9.5[5.9] 11.5 [7.1]
Gradeability
(Unloaded) 1/7 (14.3%)
(Loaded) 1/10 (10%)
Min. turning radius D mm [in.] 1490 [58.7] 1560 [61.4] 1750 [68.9] 1965 [77.4]
Min. intersecting aisle E mm [in.] 1630 [64.2] 1680 [66.1] 1750 [68.9] 1910 [75.2]
Dimensions
Overall length (include. Fork) F mm [in.] 2000 [78.7] 2070 [81.5] 2105 [82.9] 2110 [83.1] 2225 [87.9]
Overall width G mm [in.] 1090 [42.9] 1200 [47.2]
Overall height (at overhead guard) H mm [in.] 2260 [89.0] 2315 [91.1]
Wheel base K mm [in.] 1245 [49.0] 1345 [52.9] 1525 [60.0] 1700 [66.9]
Tread
(Front wheels) L mm [in.] 975 [38.4] 1065 [41.9]
(Rear wheels) M mm [in.] 680 [26.8] 725 [28.5]
Fork overhang N mm [in.] 170 [6.7] 165 [6.9] 170 [6.7] 165 [6.5]
Rear overhand P mm [in.] 220 [8.7] 240 [9.4]
Fork size mm [in.] 920 x 100 x 35 920 x 100 x 38 920 x 122 x 40
(Length Q x Width R x Thickness S) [36.2 x 3.9 x 1.4] [36.2 x 3.9 x 1.5] [36.2 x 4.8 x 1.6]
Fork spacing T mm [in.] 250 x 720 [9.8 x 28.3] 290 x 735 [11.4 x 28.9]
Floor height mm [in.] 310 [12.2] 355 [14.0]
Weight
Service weight (with standard battery) kg [lbf] 1970 [4345] 2020 [4455] 2130 [4695] 2140 [4720] 2310 [5090] 2890 [6370] 3000 [6615]
No. SEB-82ABE
SPECIFICATIONS (4)
Truck model
FR30-7 FR30-7H
Item
No. SEB-82ABE
Performance
Max. load kg [lbf] 3000 [2200]
Max. lifting height A mm [in.] 3000 [118.1] 4000 [157.5]
Reach stroke B mm [in.] 555 [21.9]
Free lift C mm [in.] 410 [16.1]
Fork lifting speed
(Unloaded) mm/s [fpm] 400 [112.3]
(Loaded) mm/s [fpm] 220 [69.0]
Travel speed
Fwd (unloaded) km/h [mph] P:11.0[6.8]/N.E:10.0[6.2]
(loaded) km/h [mph] P:9.0[5.6]/N.E:8.0[5.0]
Bwd (unloaded) km/h [mph] P:11.0[6.8]/N.E:10.0[6.2]
(loaded) km/h [mph] P:9.0[5.6]/N.E:8.0[5.0]
Gradeability
(Unloaded) 1/7 (14.3%)
(Loaded) 1/10 (10%)
Min. turning radius D mm [in.] 2065 [81.3]
Min. intersecting aisle E mm [in.] 1970 [77.6]
Dimensions
Overall length (include. Fork) F mm [in.] 2575 [101.4]
Overall width G mm [in.] 1200 [47.2]
Overall height (at overhead guard) H mm [in.] 2315 [91.1]
Wheel base K mm [in.] 1800 [70.9]
Tread
(Front wheels) L mm [in.] 1065 [41.9]
(Rear wheels) M mm [in.] 725 [28.5]
Fork overhang N mm [in.] 165 [6.5]
Rear overhand P mm [in.] 240 [9.5]
Fork size mm [in.] 1070 x 125 x 45
(Length Q x Width R x Thickness S) [42.1 x 4.9 x 1.8]
Fork spacing T mm [in.] 290 x 735 [11.4 x 28.9]
Floor height mm [in.] 355 [14.0]
Weight
Service weight (with standard battery) kg [lbf] 3210 [7078] 3320 [7321]
No. SEB-82ABE
Unit: mm [in.]
Fig. 1 External View

No. SEB-82ABE
No. SEB-82ABE
TABLE OF CONTENTS
1. BATTERY AND CHARGER (OPTION) ............................................................................. 1
1.1 GENERAL DESCRIPTION ........................................................................................................... 1
1.1.1 BATTERY .................................................................................................................................. 1
1.1.2 CHARGER ................................................................................................................................. 9
2. MOTOR ........................................................................................................................................... 13
2.2 MAINTENANCE............................................................................................................................ 16
2.2.1 DRIVE MOTOR AND PUMP MOTOR MAINTENANCE ..................................................... 16
2.2.2 EPS MOTOR MAINTENANCE................................................................................................ 17
3. CONTROLLER ............................................................................................................................ 19
3.1.1 CONTROLLER .......................................................................................................................... 19
3.1.2 ACCELERATOR........................................................................................................................ 23
3.1.3 EPS CONTROLLER .................................................................................................................. 24
3.2 MAINTENANCE............................................................................................................................ 25
3.2.1 INSPECTING AND REPLACING IGBT MODULES.............................................................. 25
3.2.2 INSPECTING AND REPLACING CAPACITORS ................................................................... 26
3.2.3 MAIN CONTACTOR AND FUSE ............................................................................................ 27
3.2.4 ERROR CODES ......................................................................................................................... 29
4. DRIVE UNIT .................................................................................................................................. 31

4.2 MAINTENANCE............................................................................................................................ 34
4.2.1 REMOVING DRIVE WHEEL REPLACEMENT..................................................................... 34
5. STEERING SYSTEM ................................................................................................................ 39

5.1.1 STEERING WHEEL .................................................................................................................. 39
5.1.2 REAR AXLE .............................................................................................................................. 43
5.1.3 CASTOR .................................................................................................................................... 45
5.1.4 TRAIL WHEEL.......................................................................................................................... 47
5.2 MAINTENANCE............................................................................................................................ 48
5.2.1 CASTOR REPLACEMENT ...................................................................................................... 48
No. SEB-82ABE
6. BRAKE SYSTEM ........................................................................................................................ 49

6.1.1 BRAKE CALIPER ..................................................................................................................... 49
6.1.2 BRAKE PEDAL ......................................................................................................................... 50
6.2 MAINTENANCE............................................................................................................................ 53
6.2.1 PEDAL HEIGHT ADJUSTMENT ............................................................................................ 53
6.2.2 ADJUSTMENT OF BRAKE CLEARANCE AND BRAKING FORCE .................................. 53
6.2.3 PAD REPLACEMENT .............................................................................................................. 54
6.2.4 BRAKE SWITCH ADJUSTMENT ........................................................................................... 54
6.2.5 ELECTROMAGNETIC BRAKE INSPECTION ...................................................................... 55
7. HYDRAULIC SYSTEM ............................................................................................................. 57

7.1.1 OIL TANK .................................................................................................................................. 57
7.1.2 MAIN PUMP.............................................................................................................................. 59
7.1.3 CONTROL VALVE .................................................................................................................... 60
7.1.4 VALVE CONTROL .................................................................................................................... 61
7.1.5 LIFT CYLINDER ....................................................................................................................... 62
7.1.6 FLOW REGULATOR VALVE ................................................................................................... 65
7.1.7 TILT CYLINDER ....................................................................................................................... 68
7.1.8 REACH CYLINDER ................................................................................................................. 69
7.2 MAINTENANCE............................................................................................................................ 70
7.2.1 HYDRAULIC OIL CHANGE.................................................................................................... 70
7.2.2 STRAINER REPLACEMENT................................................................................................... 70
7.2.3 OIL PRESSURE MEASUREMENT AND ADJUSTMENT .................................................... 71
7.2.4 VALVE SWITCH ADJUSTMENT ............................................................................................ 72
8. LOAD HANDLING SYSTEM ................................................................................................. 75

8.1.1 OUTER AND INNER CHANNELS .......................................................................................... 76
8.1.2 CARRIAGE ................................................................................................................................ 78
8.1.3 ROLLER LOCATION ................................................................................................................ 80
8.2 MAINTENANCE............................................................................................................................ 82
8.2.1 ADJUSTING LIFT CYLINDER ROD WITH SHIMS .............................................................. 82
8.2.2 ADJUSTING HEIGHT OF CARRIAGE ................................................................................... 82
8.2.3 PROCEDURE FOR REPLACING ROLLER AT CARRIAGE SIDE ....................................... 84
8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE .............................................. 86
8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING THE NUMBE R OF SHIM ................... 87
9. ELECTRIC WIRING ................................................................................................................... 89

1. BATTERY AND CHARGER
1. BATTERY AND CHARGER (OPTION)

Truck Model FR10-7 FR13 -7 FR14 -7 FR14-7H FR20-7 FR20-7H FR30 -7
FR10-7C FR13 -7C FR15 -7 FR15-7H FR25-7 FR25-7H FR30-7H
FR10-7CH FR13-7CH FR18 -7 FR18-7H
Item FR10-7H FR13-7H
Battery
Type Clad type lead accumulator
Name VCF201ML VCF280L VCF320L VCF390
Capacity 201 Ah/5h 280 Ah/5h 320 Ah/5h 390 Ah/5h
Voltage 48 V
Case dimension 956 x 265 x 570 mm 956 x 265 x 570 mm 1125 x 395 x 570 mm
(Length x height x width) [37.6 x 10.4 x 22.4 in.] [37.6 x 10.4 x 22.4 in.] [44.3 x 15.6 x 22.4 in.]
Weight (including case and fluid) 360 kg 495 kg 580 kg 660 kg
[794 lbs.] [1092 lbs.] [1279 lbs.] [1455 lbs.]
Battery charger
Type Microprocessor-controlled, 3-phase AC semiconstant voltage,
truck-mounted type
Rated power 3 kVA 4.3 kVA 5.2 kVA 6.4 kVA
Rated current 8A 11 A 13 A 18 A
Rated voltage (50 Hz/60 Hz) 205 – 215/210 – 220 V
Output
Voltage 50 – 62 V
Current 38 – 13 A 55 – 18 A 60 – 20 A
1.1 GENERAL DESCRIPTION

1.1.1 BATTERY
The battery assembly consists of 24 2-volt battery cells connected in series and is housed in a case.
A batter cap is on each battery cell, having a float inside. The float indicates the electrolyte level.
One of the 24 battery cells is set for the battery electrolyte level monitor and the level is indicated in the indicator
fitted on the battery case.
-1-
ELECTROLYTE
LEVEL
INDICATOR
CELL
CASE
COLLAR
Detail of section
Fig. 1.1 Battery Assembly
-2-
(1) Cell structure

The cell has a clad type pole as the anode. (It is a glass fiber or synthetic resin tube filled with lead peroxide,
having a lead alloy core which runs through the center).
This pole plate withstands a long cycle of use, and can stand up against overcharge and overdischarge.
The negative plate is a lead frame filled up with lead peroxide in paste form. The two plates are isolated by
means of separators in order to prevent the plates from getting short-circuited.
The battery jar is made of resin. The electrolyte is high BATTERY CAP
purity diluted sulfuric acid of 1.28 specific gravity (at
20°C [68°F]).
The battery cap is made of transparent resin, having a

float inside, to monitor the electrolyte level and to indicate
FLOAT
when the fluid should be added.
On the side face of the battery case is an electrolyte
level indicator, which blinks when the electrolyte level
is low. A sensor for the indicator is fitted on the cap.
Fig. 1.2 Float
-3-
(2) Battery lock device

The battery assembly is stored in the frame through the battery tray.
When the battery is stored in the frame properly, the battery is locked and the switch turns on. The switch
turns off, when the battery is either pulled out from the frame or installed improperly.
To pull out the battery, advance the mast assembly.
SWITCH
LOCK RELEASE
PEDAL
20 mm [0.79 in.]
Working point LOCK
Detail of switch area
HOOK
SPRING
SLIDER BLOCK
Detail of area
View looking from
Fig. 1.3 Battery Lock Device
-4-
(3) Receptacle remover

The battery side receptacle is mounted on the right-hand side of the truck body and connected to the receptacle
at the truck side.
The receptacle remover installed in the receptacle area at the truck side shuts off the battery power source
in an emergency.
LEVER
OIL TANK
TRUCK SIDE
RECEPTACLE
BATTERY
SIDE
RECEPTACLE
Fig. 1.4 Receptacle Remover
-5-
(4) Battery care
Service life
discharge
charge and
Cycles of
The most important point in battery care is to prevent
overdischarge. The deeper the battery discharges, the
shorter its life becomes (See Fig. 1.5).
The approximate depth of discharge can be known by
measuring the specific gravity of the electrolyte (See
Fig.1.6).
Check the level of electrolyte every ten days. Add
distilled water if the level is found lower than the specified Within this
range
level before charging the battery.
Depth of discharge (%)
Fig. 1.5 Relation Between Depth of Discharge

and Service Life (Example)
SPECIFIC
GRAVITY (20°C)
VOLTAGE (V)
Usable
VOLTAGE
Alert
SPECIFIC
GRAVITY
Overdischarge
(DISCHARGE DURATION)
(DISCHARGE RATE)
Fig. 1.6 Example of Specific Gravity Drop (Example of 5-hour rate discharge)
-6-
Adding battery electrolyte

Battery electrolyte should be added as follows just before charging the battery:
Operate the reach lever to the retraction position to retract the mast.
Step on the battery lock release pedal.
Operate the reach lever to the advancement position, and pull out the battery with the mast.
Disconnect the battery receptacle.
Clean all cell caps and areas around them.
Open the caps and add distilled water.
Observe each float carefully not to add too much water. All floats should have the same height.
Reinstall the caps and wipe the areas around them and the poles.
Connect the battery receptacle.
Operate the reach lever to the retraction position while stepping on the battery lock release pedal, and
retract the mast.
Charge the battery.
Note: Charge the battery after adding battery electrolyte.
Max. level Proper level Min. level
Red
White
Too much distilled water may cause

an unclosed cap. It may also let
electrolyte overflow after charging,
causing corrosion.
Fig. 1.7
-7-
Charging the battery

When discharged, the battery should be recharged as soon as possible. Leaving the battery discharged for a long
time (longer than a day) may cause sulfation, which will result in the drop of battery performance.
If the battery is kept out of service for a long time, it should be thoroughly charged before being put in
storage and an additional charge is also required once a month.
If the amount of discharge is considered to be small, measure the specific gravity of the electrolyte. If it is
lower than 1.260, recharge the battery.
Equalizing charge is required if the specific gravity varies among the cells by the amount of 0.010 or
larger. Equalizing charge is normally needed between one to four times a month. If the specific gravity
variation is not corrected by equalizing charge, specific gravity adjustment may be required.
Giving an equalizing charge more times than necessary will overcharge the battery, and its service life will
be shortened.
A microprocessor-controlled charger gives automatic equalizing charge, but manual equalizing charge is
required if the specific gravity varies among the cells or the cells are in a low state of charge.
[Cautions on charging battery]

1. Do not charge the battery if the electrolyte temperature is higher than 40°C [104°F]. Leave the battery
for a while until the temperature goes low.
2. Overdischarge or overcharge raises the electrolyte temperature. While charging the battery, be sure to
keep the battery cover fully open in order to let the generated gas and heat get out.
[Specific gravity correction according to temperature]

The specific gravity of the electrolyte varies as the electrolyte temperature changes. The specific gravity is
generally based on the electrolyte temperature of 20°C [68°F]. Therefore, if the specific gravity is measured
at the electrolyte temperature of other than 20°C [68°F], correct it using the following formula:
S20=St+0.0007 (t-20)
Where
S20: Specific gravity for 20°C [68°F] (1.280 in this model)
St: Specific gravity measured at t°C [(1.8t+32)°F]
t: Electrolyte temperature measured
-8-
1.1.2 CHARGER
The charger is truck-mounted type consisting of a transformer, diode and control unit.
The transformer is provided with a diode assembly as shown in Fig. 1.8, and converts alternating current
to direct current.
DIODE (- side)
CONTACTOR
DIODE (+ side) TRANSFORMER to BATTERY
to PRIMARY WINDING WIRE
to AC RECEPTACLE
View looking from
Fig. 1.8 Transformer Installing Position
-9-
(1) Charger controller

The charger controller is mounted to the center cover, together with the charging receptacle and contactor.
The charger controller is controlled by microcomputer, which makes it easy to charge the battery properly.
A fuse is provided between the contactor and receptacle.
KEY SWITCH
View looking from

View looking from
Detail of key switch area CHARGER
CONTROLLER
CONTACTOR FUSE
FORWARD
CHIME
(OPTION)
BACK-UP
BUZZER
RELAY (BB)
RELAY (RF)
RELAY (x1) RELAY (x2)
AC RECEPTACLE
(CHARGER)
Fig. 1.9 Charger Controller
- 10 -
(2) Transformer and diode

The transformer and diode have the designs as shown in Fig. 1.10. They serve to convert the high-voltage 3-
phase alternating current to the voltage suitable for charging the battery.
Use caution when replacing the diodes, since the diode for (+) and that for (-) have different polarity
though they are the same in shape.
The primary coil of the transformer is provided with a voltage switch tap to keep the secondary voltage at
a proper level according to the input voltage.
DIODE
OUTPUT TERMINAL (-), M8
OUTPUT TERMINAL (+), M8
SECONDARY COIL PRIMARY COIL
Fig. 1.10 Transformer and Diodes
- 11 -
Transformer tap changing

1. Checking the supply voltage
• Measure the supply voltage of the facility by which the battery is normally charged for one minute and
specify the highest measured value as the supply voltage.
• Measure the voltages between each phase (U-V, V-W, W-U) either for the period of time during which
the battery charger is to be used or while peripheral equipment is not operated.
2. Tap changing
• Check the positions of taps and the voltage indicated
by the tap currently connected. Make sure the SECONDARY COIL
measured voltage is within the specified voltages of PRIMARY COIL
the tap. (See Fig. 1.12)

If the measured voltage is not within the specified
values, change the voltage as follows.
Turn off the key switch, and make sure that the power
supply cable is not connected to the charger
receptacle.
Move the glass fiber tube covering the currently
connected tap out of place, and remove the
connecting bolt.
Remove the vinyl cap of the tap you want to convert
Fig. 1.11 Tap position
and run the glass fiber tube through the tap.
Connect the cable removed in step to the tap you want to change , with a bolt and a nut, and cover the tap
with the glass fiber tube.
Put a vinyl cap on the tap removed in step .
Supply voltage (V) Indication of tap Supply voltage (V) Indication of tap
199 or less 200 379 or less 380
Truck side
200 – 209 210 380 – 399 400
210 – 219 220 400 – 419 420
420 – 439 440
Three-core line
A vinyl cap is put on a (VCT)
tap which is not used. The truck side and the transformer
side are fastened together with a
round crimp contact.
BOLT
WASHER
NUT
The tap voltage is indicated

by a marking band. GLASS FIBER TUBE
Transformer side
Fig. 1.12
- 12 -
2. MOTOR
2. MOTOR
Truck Model FR10-7 FR13-7 FR14-7 FR18-7 FR20-7 FR20-7H
FR10-7C FR13-7C FR14-7H FR18-7H FR25-7 FR25-7H
FR10-7CH FR13 -7CH FR15-7 FR30-7 FR30-7H
Item FR10-7H FR13-7H FR15-7H
Drive motor
Type 3-phase induction motor
Name AT43B2 AT50C2
Rating
Output 4.3 kW/60 min. 5.0 kW/60 min.
Speed 1500 rpm
Voltage 30 V
Current 120.5 A 130 A
Pump motor
Type 3-phase induction motor
Name AH88B2D AH110BB2D
Rating
Output 8.8 kW/10 min. 11.0 kW/10 min.
Speed 1800 rpm 2000 rpm
Voltage 30 V
Current 238 A 290 A
EPS motor
Type Magnet motor
Rating
Output 0.3 kW/60 min.
Speed 2900 rpm
Voltage 48 V
Current 8.2 A

The drive and pump motors are 3-phase induction motors consisting of the parts shown in Figs. 2.1 and
2.2.
The rotation of the drive and pump motors is controlled by an inverter-type controller. The drive motor
drives the drive unit and the pump motor drives, the main pump.
The EPS motor is a magnet motor consisting of the parts shown in Fig. 2.3.
The rotation of the EPS motor is controlled by an EPS controller. The EPS motor is mounted to the drive
unit.
- 13 -
2. MOTOR
TERMINAL
SENSOR
COVER
STATOR
COVER (D)
ROTOR
Fig. 2.1 Drive Motor
TERMINAL
COVER
COVER (D) STATOR
ROTOR
Fig. 2.2 Pump Motor
- 14 -
2. MOTOR
BRUSH
ARMATURE
COVER (C)
YOKE
COVER (D)
Fig. 2.3 EPS Motor
Tightening torque: 36 – 43 N-m {360 – 430 kgf-cm}

[313 – 373 lbf-in.]
Tightening torque: 36 – 43 N-m {360 – 430 kgf-cm}

[313 – 373 lbf-in.]
Apply MOLYCOAT
to the spline.
View looking from
MAIN PUMP
Tightening torque:
10 – 12 N-m {100 – 120 kgf-cm}
[87 – 104 lbf-in.]
Fig. 2.4 Pump Motor Installing Position
- 15 -
2. MOTOR
2.2 MAINTENANCE • ROTOR (DRIVE MOTOR)

2.2.1 DRIVE MOTOR AND PUMP MOTOR
MAINTENANCE
(1) Rotor inspection and maintenance
Check the rotor for damage or burns. If there is
something unusual in the rotor, replace.
Check the spline for wear. If the spline is worn
ROTOR
extremely, replace.
SPLINE
• ROTOR (PUMP MOTOR)
ROTOR
SPLINE
Fig. 2.5
(2) Ball bearing inspection
Check the end cover and the end cover (D) bearing mounting area for fit of ball bearings. Replace any
loose bearing with a new one.
• Fitting area inspection (drive motor) • Fitting area inspection (pump motor)
BALL BEARING BALL BEARING BALL BEARING BALL BEARING
END COVER (D) END COVER END COVER (D) END COVER
• “Bearing sensor” replacement
When changing the “bearing sensor”, use due

caution not to damage the sensor. If the sensor
is damaged, the motor does not operate normally.
SENSOR
Fig. 2.6
- 16 -
2. MOTOR
2.2.2 EPS MOTOR MAINTENANCE

(1) Checking armature
• Check armature
Check the commutator for damage or burns, and if
any defect is found, replace the armature with a new one.
ARMATURE
Also check the splines for excessive wear and if
unsatisfactory, replace the armature with a new one. SPLINES
COMMUTATOR
Fig. 2.7
(2) Checking ball bearings
• Check for fit
Check for fit of the ball bearing of each cover. Replace
any loose-fit bearing with a new one. BALL BEARING BALL BEARING
END COVER (C)

END COVER (D)
Fig. 2.8
(3) Check brush
Measure brush size A and if the value is smaller • Check brush
than specified, replace the brush with a new one. BRUSH
Limit: 13 mm [0.51 in.] (Nikko Electric)
9 mm [0.35 in.] (TD DRIVE)
WEAR LIMIT
BRUSH HOLDER
BRUSH
SPRING
COMMUTATOR
Fig. 2.9
- 17 -
2. MOTOR
If the brush shows roughness in its commutator contact

• Check brush in commutator contact area
area, repair as follows:
• Insert sandpaper (#400) between the commutator and
brush with the abrasive side pointed to the brush.
• Turn the commutator or move the sandpaper to the
right and left. Good Not good Not good
• After repairing, clean with compressed air.

BRUSH
COMMUTATOR
Fig. 2.10
• Repair brush’s commutator contact area
BRUSH
SAND PAPER
COMMUTATOR
Fig. 2.11
Engage a spring balance into the spring and pull the spring
• Check pulling force of spring
balance into the direction indicated by the arrow to
measure the pulling force.
Pulling force: 5 – 8 N {0.5 – 0.8 kgf}
SPRING
Fig. 2.12
- 18 -
3. CONTROLLER
3. CONTROLLER
Drive motor
Type IGBT inverter type
Name CU104-17A CU104-14A
Rating
Voltage 48V
Protective device: • IGBT error protection
• Motor voltage error protection
• Temperature protection
• Traveling, load handling neutral safety
Accelerator Resistance type

3.1.1 CONTROLLER
The controller consists primarily of the components shown in Fig. 3.1, and it is installed on the upper part
of the frame.
Six IGBT modules are used for the traveling and load handling systems, three for each system, and installed
on a single heat sink.
- 19 -
3. CONTROLLER
BATTERY [+]
LINE
BATTERY [–]
LINE
1. HEAT SINK 6. IGBT MODULE (V PHASE OF

2. IGBT MODULE (U PHASE OF HYDRAULIC SYSTEM)
TRAVELING SYSTEM) 7. IGBT MODULE (W PHASE OF
3. IGBT MODULE (V PHASE OF HYDRAULIC SYSTEM)
TRAVELING SYSTEM) 8. HEAT SENSOR
4. IGBT MODULE (W PHASE OF 9. CURRENT SENSOR
TRAVELING SYSTEM) 10. CAPACITOR (80 V x 4700 µF x 9 pcs.)
5. IGBT MODULE (U PHASE OF 11. MPU
HYDRAULIC SYSTEM) 12. IGBT BOARD (GATE SIGNAL)
Fig. 3.1 Controller (Traveling and Hydraulic Systems)
- 20 -
3. CONTROLLER
3.5 – 4.5 N-m

{0.36 – 0.49 kgf-m}
[2.58 – 3.32 lbf-ft]
CURRENT SENSOR
Apply heat-conductive compound to

the surface which comes in contact
with the heat sink.
HYDRAULIC SYSTEM
IGBT MODULE
(HYDRAULIC)
HEAT SINK
HEAT SENSOR
3.5 – 4.5 N-m
{0.36 – 0.49 kgf-m}
[2.58 – 3.32 lbf-ft]
IGBT BOARD IGBT MODULE (TRAVELING)
TRAVELING SYSTEM
Fig. 3.2 Parts Layout (1/2)
- 21 -
3. CONTROLLER
MPU BOARD
3.5 – 4.5 N-m

{0.36 – 0.49 kgf-m}
[2.58 – 3.32 lbf-ft]
CAPACITOR
(TRAVELING)
CAPACITOR
(HYDRAULIC)
Apply LOCTITE#242 to threaded

area of heat side.
Fig. 3.3 Parts Layout (2/2)
- 22 -
3. CONTROLLER
3.1.2 ACCELERATOR
The accelerator is composed of the components shown in Fig. 3.4. It controls the traveling speed and
direction of the truck. The operating angle of the lever is converted by the potentiometer into voltages which
is turn outputted to the controller.
Apply LOCTITE
KNOB
SPRING
WASHER (1)
LEVER
WATER (2)
SPRING
WASHER (1)
14.7 – 16.7 N-m
SHAFT {1.5 – 1.7 kgf-m}
WASHER (2) [10.8 – 12.3 lbf-ft]
LEVER (Apply LOCTITE)
ACCELERATOR
POTENTIOMETER
CASE
Apply LOCTITE.
MICROSWITCH
Do not exceed 0.49 N-m [5 kgf-m]
COVER [0.36 lbf-ft].
Apply LOCTITE.
Note: Apply Shell Albania grease (RA) to both sides of the washers (1) and to the spring side of
the washers (2).
Fig. 3.4 Accelerator
- 23 -
3. CONTROLLER
3.1.3 EPS CONTROLLER

The EPS controller controls the EPS motor speed. Its configuration and location are shown in Fig. 3.5.
• EPS CONTROLLER
10P
(Water-proof)
Lead wire [green]: to EPS motor
Lead wire [yellow]: to EPS motor
Lead wire [blue]: to control unit (-)
Lead wire [red]: to control unit (+)
Fig. 3.5 Battery Unit
- 24 -
3. CONTROLLER
3.2 MAINTENANCE
3.2.1 INSPECTING AND REPLACING IGBT MODULES
CAUTION
1. Park the truck on a level surface and block the
wheels.
2. Disconnect the battery receptacles.
3. Discharge the capacitors using the procedure given
in Fig. 3.6.
Resistor: 50 Ω/20 W or 10 Ω/50 W enameled resistor
Fig. 3.6
Perform a conduction test on the test points shown in Table 3.1, using a digital tester preset to the
semiconductor conduction range. You cannot obtain a correct result if the tester is set to the resistance
range.
Table 3.1
Plus side (+) Minus side (-)
Terminals to which Terminals to which
tester rod is applied tester rod is applied
1 C1 E1
2 C2 E2
1 C1 G1
1 G1 C1
2 C2 G2
2 G2 C2
If there is continuity between any combination of

Fig. 3.7
terminals, replace the module (traveling and hydraulic)
with a new one. In addition, if any module is replaced
with a new one, all the capacitors should be replaced MOUNTING AREA MAIN TERMINAL
with a new 9-piece set.
If you suspect that any IGBT module is defective,

visually check the IGBT board for burns.
Apply a heat-conductive compound [G-747]
(Shietsu Silicone) to the entire contact area of IGBT
modules before installing them to the heat sink.
When tightening the main terminals and mounting 3.5 – 4.5 N-m
area, use the tightening torque shown on the right. {0.36 – 0.49 kgf-m}
[2.58 – 3.32 lbf-ft]
Fig. 3.8
- 25 -
3. CONTROLLER
3.2.2 INSPECTING AND REPLACING CAPACITORS

Check the general condition of capacitors for deformation, discoloration and fluid leakage.
If there is no problem with the general condition, perform the following checks:
CAUTION
Use an analog tester to inspect the capacitors.
ANALOG TESTER
Discharge the capacitors (See Fig. 3.6.)
Set the tester to the resistance measurement mode
(x 1 kΩ).
Apply tester’s (+) rod to the (+) pole of the capacitor
and the tester’s (–) rod to the (–) pole of the capacitor.
Make sure that pointer swings much and then
gradually comes to indicate ∞.
CAUTION
1. The above checking method is a simplified one. If
Fig. 3.9
you suspect that any capacitor is defective for any
reason, replace it with a new one.
2. If it is suspected that the IGBT is defective, replace all the capacitors with a new 9-piece set.
- 26 -
3. CONTROLLER
3.2.3 MAIN CONTACTOR AND FUSES
CONNEC-
TOR
MAIN CONTACTOR GLASS TUBE

FUSE
(F4 – F6)
WIRE HARNESS,
FRAME
100A, TRANSFORMER FUSE
40A, EPS FUSE 6.4 – 7.4 N-m

(F3) {0.65 – 0.75 kgf-m}
[4.72 – 5.46 lbf-ft]
325A, TRAVELING
AND HYDRAULIC
SYSTEM FUSE (F1)
Fig. 3.10 Main Contactor and Fuses
- 27 -
3. CONTROLLER
(1) Inspecting main contactor

• Check main contactor
Check contact areas for excessive wear or burns, and
if any defect is found, replace the main contact assembly
with a new one.
CAUTION
The main contactor assembly must be replaced with a
new one every two year, even if it appears normal.
Tightening torque:
6.4 – 7.4 N-m {0.65 – 0.75 kgf-m}
[4.72 – 5.46 lbf-ft]
Fig. 3.11
(2) Replacing fuses

• Type of fuse
When replacement of any fuse is required, use a new
fuse of the same capacity and tighten the mounting nut
securely.
100 A,
TRANSFORMER
• Type of fuse FUSE
Use Capacity
Traveling F1 325A 40 A,
EPS FUSE (F3)
EPS F3 40 A
10 A,
Transformer 100 A 325 A,
GLASS TUBE FUSE
(F4 – F6)
TRAVELING AND
Control unit F4 10 A HYDRAULIC
SYSTEM FUSE (F1)
Electromagnetic brake F5 10 A
Accessories F6 10 A
Fig. 3.12
- 28 -
3. CONTROLLER
3.2.4 ERROR CODES

Error Error Error message Description Remarks
code No. code
1 A1 A1: Contactor (main) Poor contact of contactor
2 A2 A2: Current sensor (battery) Defective current sensor (for checking

traveling and hydraulic unit current)
10 B10 B10: Fuse (main) Fuse is blown out
11 B11 B11: Transistor U (travel) Traveling motor U phase IGBT error *Emergency stop*
*Turn off key switch.*
12 B12 B12: Transistor V (travel) Traveling motor V phase IGBT error *Emergency stop*
13 B13 B13: Transistor W (travel) Traveling motor W phase IGBT error *Emergency stop*
14 B14 B14: Current sensor (travel) Current sensor (traveling motor U and V
phases) error
15 B15 B15: Accelerator Accelerator error *Turn off key switch.*
20 C20
21 C21 C21: Transistor U (hydraulic) Hydraulic motor U phase IGBT error *Emergency stop*
22 C22 C22: Transistor V (hydraulic) Hydraulic motor V phase IGBT error *Emergency stop*
23 C23 C23: Transistor W (hydraulic) Hydraulic motor W phase IGBT error *Emergency stop*
24 C24 C24: Current sensor (hydraulic) Current sensor (hydraulic motor U and V
phases) error
25 C25 C25: Micro-switch (lift) Lift lever micro-switch error
25 C26 C26: Potentiometer (mast) Tilt and lift potentiometer error
30 D30 D30: Fuse (EPS) EPS fuse blown out (Accelerator input reduced
1/2)
31 D31 D31: Torque sensor (EPS) EPS sensor error (accelerator input reduced *Turn off key switch.*
1/2)
32 D32 D32: Transistor (EPS) EPS’s FET error *Turn off key switch.*
(Accelerator input reduced 1/2)
40 E40 E40: Transistor (AOS valve) Valve current error *Turn off key switch.*
41 E41 E41: Potentiometer (AOS lever) AOS control potentiometer error
42 E42 E42: Rotary encoder (AOS lift) Lift height encoder error
50 F50 F50: Fuse (front brake) Front wheel brake power supply fuse blown out
51 F51 F51: Potentiometer (steering angle) Steering angle detection potentiometer error
- 29 -
3. CONTROLLER
Error Error Error message Description Remarks

code No. code
60 G60 *Current error* Battery current error *Emergency stop*

61 G61 * Traveling motor current error* Traveling motor current error *Turn off key switch.*
62 G62 *Hydraulic motor current error* Hydraulic motor current error *Turn off key switch.*
63 G63 *Traveling motor voltage error* Traveling motor voltage error
64 G64 *Hydraulic motor voltage error* Hydraulic motor voltage error
65 G65 *Power being saved: Control board temperature error
66 G65 *Power being saved* Traveling motor IGBT temperature error
67 G65 *Power being saved* Hydraulic motor IGBT temperature error
68 G68 *Communication error* Display communication error * Turn off key switch.*
Communication error from
display to each CPU.
69 G69 *Main board voltage error* Voltage error of IGBT gate power supply and *Emergency stop*
external 5V power supply *Turn off key switch.*
70 G70 *Fan error* Fan power supply voltage error
*Emergency stop* Traveling or hydraulic motor relay tripped. Displayed together with
other error message.
*Turn off key switch.* Any critical error in traveling or hydraulic Displayed together with
system other error message.
*Overload. Reduce load.* Overload When overload occurs
*Add lubrication oil* Lubrication oil When lubrication oil sensor

actuates
*Add brake oil* Brake oil When brake oil sensor actuates
* Add purified water* Addition of purified water to battery When battery electrolyte
level sensor actuates
*Recharge battery* Battery’s state of charge is low When battery’s state of

charge is low.
*Parking brake is applied* Starting of truck is tried with parking brake When starting of truck is tried
applied. with parking brake applied.
*Turn off accelerator* Traveling with key switch ON. When traveling CPU is in
neutral safety state.
*Turn off hydraulic lever* Hydraulic lever is in ON with key switch turned When hydraulic CPU is in
ON. neutral safety state.
*AOS emergency stop* AOS emergency stop switch has been pressed. AOS emergency stop switch
pressed
*Lift height setting error* Lifting height setting is wrong. Lifting height setting is wrong.
*Apply parking brake* Application of parking brake is forgotten Parking brake&seat switch
is off.
*Secure battery unit* Traveling or hydraulic operation is performed

with battery interlock switch ON.
- 30 -
4. DRIVE UNIT
4. DRIVE UNIT
Type Three-step reduction
Model 82M-25 82R-25
Reduction ratio 17.95 18.74
Wheel dimension ø330 x 145 mm ø380 x 165 mm
[ø13 x 5.7 in.] [ø15 x 6.5 in.]

The drive unit consists of the parts shown in Fig. 4.1, with the drive support linked to the frame.
Each gear incorporated in the gear case transmits rotation of the drive motor effectively.
The gear case is mounted to the drive support by two tapered roller bearings and rotates to the right and left by
means of the EPS motor.
- 31 -
4. DRIVE UNIT
EPS MOTOR
DRIVE MOTOR
1. TAPERED ROLLER BEARING 15. BUSHING

2. STEERING GEAR (2) 16. OIL SEAL
3. BREATHER 17. OIL SEAL
4. GEAR CASE SUPPORT 18. SNAP RING
5. PLUG 19. SNAP RING
6. “O”-RING 20. BALL BEARING
7. GEAR CASE 21. BREATHER
8. LEVEL GAUGE 22. COVER
9. GASKET 23. SPACER 29. BALL BEARING
10. COVER 24. GEAR 30. DRIVE SUPPORT
11. PLUG 25. BALL BEARING 31. PLUG
12. NUT 26. OIL SEAL 32. GREASE FITTING
13. TAPERED ROLLER BEARING 27. BALL BEARING 33. BUSHING
14. SNAP RING 28. GEAR 34. STEERING GEAR (1)
Fig. 4.1 Drive Unit (1/2)
- 32 -
4. DRIVE UNIT
1. NUT
2. HOUSING
3. SHIM
4. SLEEVE
5. BEARING
6. SPIRAL BEVEL
PINION GEAR
7. DRIVEN GEAR
8. BEARING
9. SHIM
10. BEARING
11. COUNTERGEAR
12. BEARING
13. COUPLING
14. SPACER
15. BEARING
16. DRIVE PINION
GEAR
17. BEARING
18. NUT
19. BEVEL GEAR
20. BEARING
21. SHIM
22. BEARING
23. OIL SEAL
24. DRIVE WHEEL
SHAFT
25. CONE WASHER
Fig. 4.2 Drive Unit (2/2)
- 33 -
4. DRIVE UNIT
4.2 MAINTENANCE
4.2.1 REMOVING DRIVE WHEEL REPLACEMENT
(1) Removing drive wheel
Jack the rear part of the frame off the ground. (See Fig.4.3)
Turn the steering wheel to make the drive wheel side face to point rearward.
Remove all drive wheel mounting bolts to remove the wheel.
BLOCKS BLOCK This side points rearward.

(at both wheels)
Fig. 4.3
(2) Removing hub

PRESS
Using a suitable press, remove the hub from the wheel.
WHEEL
HUB
Fig. 4.4
- 34 -
4. DRIVE UNIT
(3) Reassembling drive wheel PRESS

Using a suitable press, press hub into wheel.
WHEEL
HUB
Fig. 4.5
(4) Reinstalling drive wheel

Aligning the bolt holes in the hub with the screw holes in the shaft, install the drive wheel.
Install mounting bolts.
Tighten the bolts to specified torque.
Tightening torque: 90 – 100 N-m {9 – 10 kgf-m} [66.4 – 73.8 lbf-ft]
Turn the steering wheel to put the steering wheel in the straight-forward position.
Lower the rear part of the frame and remove the jack.
Tightening torque:
90 – 100 N-m {9 – 10 kgf-m} [66.4 – 73.8 lbf-ft]
Fig. 4.6
- 35 -
4. DRIVE UNIT
(5) Assembly criteria
EPS MOTOR
17 – 28 N-m {1.7 – 2.8 kgf-m}
[12.6 – 20.7 lbf-ft]
Apply THREEBOND #1104

COVER to the circumference.
Apply grease to the lip.
17 – 28 N-m {1.7 – 2.8 kgf-m}

GEAR (1) [12.6 – 20.7 lbf-ft]
GEAR (2)
to the mating surfaces.
DRIVE SUPPORT

to the circumference.
Apply grease to the lip.
Pour gear oil into the

EPS gear box.
SAE #80W: 0.35 L
STEERING GEAR (2)
STEERING GEAR
Note: When the oil seal, “O”-ring and bearing were removed,
replace all of them with new ones.
Fig. 4.7 Assembly Criteria (1/3)
- 36 -
4. DRIVE UNIT
82M-25: 200 – 220 N-m {20 – 22 kgf-m}

[147.5 – 162.3 lbf-ft]
82R-25: 294 – 314 N-m {30 – 32 kgf-m}
[216.9 – 231.6 lbf-ft]
Preload: 55 – 65 N-m
{5.5 – 6.5 kgf-m}
[40.6 – 47.9 lbf-ft]
(Measure at position .)
Fill grease between bearing rollers.
DRIVE SUPPORT
STEERING GEAR (2)

82M-25: 90 – 100 N-m {9 – 10 kgf-m}
[66.4 – 73.8 lbf-ft]
82R-25: 78 – 98 N-m {7.9 – 9.8 kgf-m}
[57.5 – 72.3 lbf-ft]
GEAR CASE SUPPORT
Apply grease.
Apply THREEBOND #1104.
Fill the gear case with gear oil.

SAE #80W: 2.2 L (82M-25)
3.6 L (82R-25)
GEAR CASE
COVER
Note: When the oil seal, “O”-ring and bearing were removed, replace all of them with new ones.
- 37 -
4. DRIVE UNIT
Apply grease to the spline.
GEAR CASE SUPPORT
180 – 200 N-m {18 – 20 kgf-m}

[132.8 – 147.5 lbf-ft]
DRIVEN GEAR
DRIVE PINION
90 – 100 N-m {9 – 10 kgf-m}

COUNTER [66.4 – 73.8 lbf-ft]
GEAR
SHIM
SHIM
{3.5 – 4.5 kgf-m}
[2.6 – 3.3 lbf-ft]
Measure at the circumference
of the driven gear.
SPIRAL BEVEL PINION
GEAR CASE
Backlash:
SHIM 0.1 – 0.3 mm [0.004 – 0.012 in.]
SPIRAL BEVEL GEAR

{17 – 18 kgf-m}
[125.4 – 132.8 lbf-ft]
Measure at position .
DRIVE WHEEL SHAFT

70 – 80 N-m {7 – 8 kgf-m}
[51.6 – 59.0 lbf-ft]
120 – 130 N-m {12 – 13 kgf-m}
[88.5 – 95.9 lbf-ft]
Apply LOCTITE #242.
Note: When the oil seal, “O”-ring and bearing were removed,
replace all of them with new ones.
- 38 -
5. STEERING SYSTEM
5. STEERING SYSTEM
Type Drive unit rotating type with electric power steering unit
Power steering
Control PWM control
EPS motor
Type DC magnet type
Output 300 W (one hour)
Actuator reduction ratio 23.1

The steering system is a drive unit rotating type with power steering, consisting of a steering wheel, a
steering sensor, an EPS motor and an actuator.
5.1.1 STEERING WHEEL

The steering wheel is mounted on a shaft supported by a ball bearing. Sprockets are installed to the shaft
with keys.
The rotation of the steering wheel is transmitted through the sprocket and chain to the input shaft of the
steering sensor whose output shaft is jointed to the drive unit actuator.
- 39 -
5. STEERING SYSTEM
STEERING WHEEL
POTENTIOMETER
STEERING SENSOR
DRIVE UNIT
Fig. 5.1 Steering System
- 40 -
5. STEERING SYSTEM
STEERING WHEEL
STEERING SENSOR
ASSEMBLY
SHIM
POTENTIOMETER
SNAP RING
ROLL PIN
JOINT
to DRIVE UNIT
Fig. 5.2 Steering Sensor
- 41 -
5. STEERING SYSTEM
Power steering operation

When the steering wheel is rotated, the input shaft won’t rotate because ground resistance is applied
through the drive unit on the output shaft, to transmit the steering wheel torque to the steering sensor.
The steering sensor in turn converts this torque into a voltage and sends it to the EPS controller.
The voltage output from the steering sensor is converted by the EPS controller to a motor rotation control
signal to rotate the motor.
The motor continues to rotate as long as there is steering wheel torque.
If the truck gets a shock from the road, the motor generates a torque corresponding to the external force,
thus alleviating the shock.
STEERING WHEEL
SPROCKET (B)
SPROCKET (A)
STEERING SENSOR
EPS CONTROLLER
OUTPUT SHAFT
DRIVE MOTOR
EPS MOTOR
to BATTERY
DRIVE UNIT
DRIVE WHEEL
Fig. 5.3 Outline of Steering System
- 42 -
5. STEERING SYSTEM
5.1.2 REAR AXLE

The rear axle supports the drive unit while minimizing the reduction in ground contact of the drive wheel
due to a rough road surface, thus preventing the drive wheel from skidding.
With the castor and drive unit are secured on the frame, if the caster rides on a bulge on the road, the drive
unit floats together with the frame, thus causing the drive wheel to rotate in the air. To prevent this, as shown
in Fig.5.4, with the aid of a spring, the drive unit is forced into the direction opposite the direction in which
that the caster moves, so that the drive wheel is kept in contact with the road surface.
Tighten with torque of 170 N-m

{17 kgf-m} [125.3 lbf-ft], and
back off by 90°.
LOCK CYLINDER
DRIVE UNIT
32 mm
[1.26 in.]
UPPER LINK
Spring setting length:

160 mm [6.3 in.]
(170 mm [6.7 in.] for compact models)
LOWER LINK
Fig. 5.4 Rear Axle (1.0- to 1.75-ton trucks)
- 43 -
5. STEERING SYSTEM
Tighten with torque of 170 N-m

{17 kgf-m} [125.3 lbf-ft], and
back off by 90°.
DRIVE UNIT
35 mm
[1.39 in.]
UPPER LINK
Spring setting length:

150 mm [5.9 in.]
LOWER LINK
Fig. 5.5 Rear Axle (2.0- to 3.0-ton trucks)
- 44 -
5. STEERING SYSTEM
5.1.3 CASTOR
The castor wheel is a part of the rear axle and rotates in the direction of travel of the truck.
The castor link is pinned to the frame, and its movement is transmitted through a spring to the rear axle.
The knuckle shaft is mounted on the castor link with two bearings.
CAP
BALL BEARING
KNUCKLE
BOLT
CASTOR LINK
WHEEL CAP
BALL BEARING
Fig. 5.6 Castor Wheel (1.0- to 1.75-ton trucks)
- 45 -
5. STEERING SYSTEM
CASTOR LINK CAP

BALL BEARING
BALL BEARING
KNUCKLE
BOLT
WHEEL
CAP
Fig. 5.7 Castor Wheel (2.0- to 3.0-ton trucks)
- 46 -
5. STEERING SYSTEM
5.1.4 TRAIL WHEEL

The trail wheel has a built-in electromagnetic brake as shown in Fig. 5.8, and is mounted to the outrigger.
It also has a built-in sensor to detect the rotating condition of the wheel.
SHIM
BUSHING
WASHER
SPRING
WASHER
BRAKE
SENSOR
When disassembling NUT

and reassembling the
sensor, use special jig
and use caution not to WHEEL
give a shock. RING
SNAP RING
BEARING WASHER
CAP
Fig. 5.8 Trail Wheel
- 47 -
5. STEERING SYSTEM
5.2 MAINTENANCE
5.2.1 CASTOR REPLACEMENT
(1) Removing castor wheel
Jack the rear of the frame off the ground. (See Fig.5.9)
Remove the castor wheel cap.
Remove the bolt and remove the wheel assembly.
WHEEL
WASHER
BOLT
CAP
BLOCK BLOCK
(at both sides)
Fig. 5.9
(2) Reinstalling caster wheel

WHEEL
Install the wheel assembly on the shaft.
Install the washer and lock washer. Secure with the BEARING
bolt.
Reinstall the cap.
WASHER
SNAP RING
CAP
Fig. 5.10
- 48 -
6. BRAKE SYSTEM
6. BRAKE SYSTEM
Type Motor-shaft-braking disk type
Pedal ratio 14.88
Brake disk outer dia 210mm [8.27 in.]

The brake system is composed of a brake caliper, a brake disk and a link. The brake caliper and the brake
disk are mounted on the drive motor.
6.1.1 BRAKE CALIPER

The upper and lower levers of the brake caliper assembly clamp the brake disk installed on the armature
shaft of the drive motor by the force of the brake spring.
When the brake pedal is not pressed, the cam lever is drawn closer to the disk brake by the spring so that
the brake is applied.
When the brake pedal is pressed, the cam lever turns through the link to extend the distance between the
two levers to release the brake.
BRAKE
SPRING
ADJUSTING
SCREW
LEVER
(UPPER) PAD
CAM
ADJUSTING LEVER PAD

SCREW (LOWER)
Fig. 6.1 Brake Caliper Assembly
- 49 -
6. BRAKE SYSTEM
BRAKE DISK
BRAKE SWITCH
DRIVE MOTOR
Fig. 6.2 Brake Caliper Arrangement
6.1.2 BRAKE PEDAL

The brake pedal unit is installed as shown in Fig.6.3. When the pedal is not pressed, the pedal is pulled
upwards by the spring.
When the pedal is pressed, the action is transmitted to the cam lever in the brake caliper assembly through
the link, the crank arm and the rod.
- 50 -
6. BRAKE SYSTEM
BRAKE PEDAL
ROD
6.5 mm
[0.26 in.]
Pay attention to the

mounting direction.
Detail of area
LINK
Fig. 6.3 Brake Pedal (1/2)
- 51 -
6. BRAKE SYSTEM
1.0- to 1.75-ton trucks
16 – 17 mm
[0.63 – 0.67 in.]
View looking from
ROD
Detail of area
LINK
67 – 68 mm
[2.64 – 2.68 in.]
Fig. 6.4 Brake Pedal (2/2)
- 52 -
6. BRAKE SYSTEM
6.2 MAINTENANCE
6.2.1 PEDAL HEIGHT ADJUSTMENT
(1) Remove the ball joint from the lever. Loosen the
ball joint lock nut.
(2) Adjust the pedal height by turning the ball joint. Turn BALL JOINT
it clockwise to raise the pedal and turn LEVER
counterclockwise to lower it. With the pedal
adjusted, insert the lever into its installation hole
and measure the pedal height.
Pedal height: 67 to 68 mm [2.64 to 2.68 in.]
(3) After adjustment, secure the ball joint with lock nut
and install it on the lever.
Fig. 6.5 Pedal Height
6.2.2 ADJUSTMENT OF BRAKE CLEARANCE AND BRAKING FORCE

(1) Adjusting brake clearance
Keep the pedal pressed down to the floor. ADJUSTING
Adjust clearance between the pads and the disk with SCREW
the brake caliper adjusting screws so that the upper

and the lower clearances have the same value.
Clearance: 0.2 to 0.3 mm [0.0079 to 0.0118 in.]
ADJUSTING SCREW
Fig. 6.6 Brake Clearance
(2) Adjusting braking force

Adjust the setting length of the spring with the
adjusting nut to get the adequate braking force.
115 mm
[4.53 in.]
Fig. 6.7 Adjustment of brake Force
- 53 -
6. BRAKE SYSTEM
6.2.3 PAD REPLACEMENT

(1) Turn the adjusting screw clockwise to give
clearances between pads and the brake disk.
(2) Remove the pad lock bolts and remove the pads. LOCK
BOLT LEVER
(3) Spread the distance between each lever and the disk (UPPER)
PAD
wide enough to insert a new pad with the adjusting
screws. Install new pads.
Tightening torque: 17.7 to 26.5 N-m {180 to 270
kgf-cm}
(4) After installing the pads, adjust the brake pad LEVER (LOWER)
ADJUSTING
clearance and the braking force. (See 6.2.2.) SCREW
Fig. 6.8
6.2.4 BRAKE SWITCH ADJUSTMENT

(1) Step on the brake pedal to a position where the brake
disk can be turned manually. LOCK NUT NUT
(2) Loosen the nut securing the switch. Move the switch
in the position where the switch turns on, and secure
it with the nut. SWITCH
Fig. 6.9
- 54 -
6. BRAKE SYSTEM
6.2.5 ELECTROMAGNETIC BRAKE INSPECTION

(1) Press the part indicated by the arrow (four locations
• Movement margin inspection
on one side) as shown in Fig. 6.10 to make sure that
the movement margin is within the standards.
Standard values: 0.5 to 0.7 mm [0.020 to 0.028 in.]
Fig. 6.10
(2) When the movement margin is not within the standard • Shim for adjusting clearance
values, adjust the margin by increasing or decreasing
the number of shims. ø
[0 8 . 5 m
.3 m m .]
When the movement margin is larger than the 35 m 0 7 in
in. ø 2 .78
] [0
standards, decrease the number of shims. When the
margin is smaller than the standards, increase the
number.
t = 0.2 mm
[0.008 in.]
Brake operation inspection
Turn off the key switch and block the wheels.
Jack the front wheel off the ground.
Turn on the key switch.
Turn the trail wheel by hand to make sure that the
brake is applied.
If the trail wheel turns wobbly, the brake is actuating
normally, since the brake is repeatedly applied and
released.
Inspect the other brake in the same way.
Fig. 6.11
- 55 -
6. BRAKE SYSTEM
NOTE
- 56 -
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
Truck Model FR10-7C FR10-7CH FR14-7 FR20-7
FR13-7C FR13-7CH FR15-7 FR18-7 FR25-7 FR30-7
FR10-7 FR10-7H FR14-7H FR18-7H FR20-7H FR30-7H
Item FR13-7 FR13-7H FR15-7H FR25-7H
Pump
Type Gear connected
directly to motor
Control valve
Type 3-spool sliding type
Name MSV04
Pressure setting 12.7 MPa 13.7 MPa 15.7 MPa 17.2 MPa
{130 kgf/cm2} {140 kgf/cm2} {160 kgf/cm2} {176 kgf/cm2}
[1849 psi] [1991 psi] [2276 psi] [2503 psi]
Liftcylinder
Type Single-acting piston type
Cylinder bore 45 mm [1.77 in.] 50 mm [1.97 in.] 55mm[2.17in.]
Rod outer dia. 35 mm [1.38 in.] 40 mm [1.58 in.] 45mm[1.77in.]
Tiltcylinder
Type Double-acting piston
Cylinder bore 50 mm [1.97 in.] 63 mm [2.48 in.]
Rod outer dia. 25 mm [0.98 in.] 30 mm [1.18 in.]
Reach cylinder
Type Double-acting piston
Cylinder bore 45 mm [1.77 in.]
Rod outer dia. 25 mm [0.98 in.]

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

The oil tank is installed on the upper side of the rear axle and its construction is as shown in Fig.7.1.
The breather cap has a filter to prevent dust in the air sucked due to a lowered oil level, from getting into
the tank.
- 57 -
7. HYDRAULIC SYSTEM
to LIFT CYLINDER
to PUMP
from CONTROL
VALVE
DRAIN PLUG FILTER
Fig. 7.1 Oil Tank
- 58 -
7. HYDRAULIC SYSTEM
The suction pipe has also a filter to prevent dust from entering the circuit.
PUMP MOTOR
Apply MOLYCOAT
to the spline.
SUCTION MAIN PUMP

PORT DISCHARGE PORT
Fig. 7.2 Pump Drive
- 59 -
7. HYDRAULIC SYSTEM
7.1.2 MAIN PUMP

7.1.3 CONTROL VALVE
The control valve consists of three plunger sections, an outlet section, and an inlet section with a relief valve, and
they are assembled with three bolts.
The inlet section relief valve is a cartridge type featuring that its pressure setting does not change even
when it is reinstalled after removed.
Check valves between the outlet section and each plunger section serve to prevent the oil from flowing
back from a heavily loaded section to a lightly loaded section two levers simultaneously operated.
TILT PLUNGER
LIFT PLUNGER
REACH PLUNGER
GAUGE PORT
OUTLET SECTION
INLET SECTION
RELIEF VALVE
Fig. 7.3 Control Valve
- 60 -
7. HYDRAULIC SYSTEM
7.1.4 VALVE CONTROL

The spools of the control valve are operated with the levers shown in Fig.7.4. Each lever is installed on a shaft and
supported by the bracket on the valve assembly.
Movement of each lever is detected by the switch and transmitted to the controller.
LIFT SWITCH 1 LIFT SWITCH 2
TILT SWITCH
REACH SWITCH
ATTACHMENT SWITCH
4-THROW VALVE (OPTION)
LIFT SWITCH 2
LIFT SWITCH 2
3-THROW VALVE (STANDARD)

5-THROW VALVE (OPTION)
Tightening torque:
1.08 – 1.57 N-m
{11 – 16 kgf-cm}
[0.80 – 1.16 lbf-in.]
(Apply LOCTITE #242.)
View looking from
Fig. 7.4 Valve Control
- 61 -
7. HYDRAULIC SYSTEM
7.1.5 LIFT CYLINDER

The two lift cylinders of single-acting type are located on the outer mast frame, consisting of cylinder body, rod,
piston and cylinder cap.
The piston fastened to the rod with a snap ring is provided with a wear ring, and packing on its circumference.
At the lower part of the cylinder body provided is a cut-off valve which works as a safety device when the high-
pressure hose connecting the right and left lift cylinder is broken.
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 cylinder flows back to the tank via the
piston holes and . In this step, if the flow rate passing through
the holes are within a range of the controlled flow rate, the
pressure difference between the front and rear of the piston
is less than the spring force so that the piston does not move.
If the hose is ruptured and the oil passing through the
holes and exceeds the flow to be controlled, the
PISTON
pressure difference between the front and rear of the piston
becomes larger than the spring force, moving the piston to SPRING
the right.
The piston is thereby in firm contact the section of the
case so that the oil in the cylinder flows out only a little amount,
lowering the fork slowly.
Fig. 7.5 In Below Control Flow Rate
CASE
Fig. 7.6 In Over Control Flow Rate
- 62 -
7. HYDRAULIC SYSTEM
CYLINDER SUPPORT
(For the trucks having lift height
of 4000 mm [157.5 in.] or more)
CYLINDER SUPPORT (For

the trucks having lift height of
3750 mm [147.6 in.] or less)
1. SHIM
2. DUST SEAL
3. PACKING
4. CYLINDER CAP
5. “O”-RING
6. BUSHING
7. CYLINDER
8. ROD
9. LOCK RING
10. WEAR RING
11. PACKING
12. PISTON
13. HOSE PULLEY
14. CHAIN SHEAVE
15. CHAIN
16. ANCHOR PIN
17. ADJUSTING NUT
18. LOCK NUT
19. COTTER PIN
Fig. 7.7 Lift Cylinder (VM-82A, VM-82F, VM-82M)
- 63 -
7. HYDRAULIC SYSTEM
1. SHIM 11. PACKING

2. DUST SEAL 12. PISTON
3. PACKING 13. HOSE PULLEY
4. CYLINDER CAP 14. CHAIN SHEAVE
5. “O”-RING 15. CHAIN
6. BUSHING 16. ANCHOR PIN
7. CYLINDER 17. ADJUSTING NUT
8. ROD 18. LOCK NUT
9. LOCK RING 19. COTTER PIN
10. WEAR RING
CYLINDER SUPPORT
of 4000 mm [157.5 in.] or more)

3750 mm [147.6 in.] or less)
Fig. 7.8 Lift Cylinder (VM-82R)
- 64 -
7. HYDRAULIC SYSTEM
1. SHIM 11. PACKING

2. DUST SEAL 12. PISTON
3. PACKING 13. HOSE PULLEY
4. CYLINDER CAP 14. CHAIN SHEAVE
5. “O”-RING 15. CHAIN
6. BUSHING 16. ANCHOR PIN
7. CYLINDER 17. ADJUSTING NUT
8. ROD 18. LOCK NUT
9. LOCK RING 19. COTTER PIN
10. WEAR RING
CYLINDER SUPPORT
of 4000 mm [157.5 in.] or more)

3750 mm [147.6 in.] or less)
Fig. 7.9 Lift Cylinder (VM-79K)
- 65 -
7. HYDRAULIC SYSTEM
7.1.6 FLOW REGULATOR VALVE

The flow regulator valve is located at the position as shown in Fig. 7.11. It keeps the fork lowering speed at a
certain level, regardless of the load.
Flow regulator valve operation

The oil returning from the lift cylinder flows into the chamber from which it then runs into the control
valve after flowing through the chambers , , , , and . In this step, the amount of oil flowing
through the orifice exceeds the preset amount, the force pressing the piston becomes greater than that
of the spring , and the piston moves to the right. The hole is narrowed to limit the flow rate through
the hole . The fork lowering speed is thus controlled.
The oil flowing into the lift cylinder passes through chambers , , , , , and , and is not
controlled.
Free flow
Regulated
flow
Control valve side
Lift cylinder side
1. CASE 6. ORIFICE
2. SPRING 7. SNAP RING
3. BALL 8. SPRING
4. PISTON 9. “O”-RING
5. SLEEVE 10. NIPPLE
Fig. 7.10 Flow Regulator Valve
- 66 -
7. HYDRAULIC SYSTEM
LIFT CYLINDER (RIGHT)
TILT CYLINDER
(LEFT)
TILT CYLINDER
(RIGHT)
CUT-OFF VALVE
LIFT CYLINDER
(LEFT)
FLOW REGULATOR
VALVE
Fig. 7.11 Mast Piping (VM-82A, VM-82F, M-82M)
- 67 -
7. HYDRAULIC SYSTEM
LIFT CYLINDER (RIGHT)
TILT CYLINDER
(LEFT)
TILT CYLINDER
(RIGHT)
CUT-OFF VALVE
LIFT CYLINDER
(LEFT)
FLOW REGULATOR
VALVE
Fig. 7.12 Mast Piping (VM-82R, VM-79K)
- 68 -
7. HYDRAULIC SYSTEM
7.1.7 TILT CYLINDER

Two tilt cylinders of a double-acting type are located at the right and left side of the bracket. The tilt cylinder
consists of a piston, a piston rod, a cylinder tube and a cylinder cap as shown in Fig.7.13.
The piston and piston rod are welded and a wear ring and piston packing are installed on the piston
circumference.
The cylinder cap is provided inside with a dust seal, bushing and packing which provide tightness in the
cylinder. The piston rod end is ground spheric and pushes the fork support carrying out the tilt operation.
VM-82A
VM-82F CYLINDER
PACKING
VM-82M PACKING
WEAR RING
SNAP RING
DUST SEAL
CYLINDER CAP
BUSHING PISTON ROD
“O”-RING
VM-82R
VM-79K
CYLINDER PACKING
PACKING
WEAR RING
SNAP RING
DUST SEAL
CYLINDER CAP
BUSHING PISTON ROD
“O”-RING
Fig. 7.13 Tilt Cylinder
- 69 -
7. HYDRAULIC SYSTEM
7.1.8 REACH CYLINDER

The reach cylinder moves the mast forward and backward. The reach cylinder assembly is mounted on the lower
part of the frame at the truck center.
The piston and the cylinder cap are provided with seals which provide oil-tightness.
Note: Stroke valves listed below are given for trucks with the standard battery.
Tightening torque:
58.8 – 68.6 N-m
{600 – 700 kgf-cm}
[521 – 608 lbf-in.]
Model Stroke mm [in.]
406 [16]
556 [21.9]
1. WIPER SEAL
2. SNAP RING
3. ROD PACKING
4. CYLINDER CAP
581 [22.9] 5. “O”-RING
6. BUSHING
7. CYLINDER
725 [28.5]
8. ROD
9. PISTON
650 [25.6]
10. PACKING
795 [31.3] 11. NUT
700 [27.6]
Fig. 7.14 Reach Cylinder
- 70 -
7. HYDRAULIC SYSTEM
7.2 MAINTENANCE
7.2.1 HYDRAULIC OIL CHANGE
(1) Put an oil pan under the tank and remove the drain plug.
SUCTION PIPE
(2) After draining off oil, reinstall the drain plug securely.
(3) Remove the breather cap and pour hydraulic oil.
Oil capacity: 18 L [4.8 US gal]
(1.0- to 1.75-ton trucks)
22 L [5.8 US gal]
(2.0- to 3.0-ton trucks)
DRAIN PLUG
Fig. 7.15
7.2.2 STRAINER REPLACEMENT

(1) Remove the suction hose from the tank suction pipe.
(2) Remove the suction pipe assembly from the tank.
Note: Remove the old gasket.
(3) Replace the suction strainer with a new one.
(4) Reinstall the suction pipe assembly on the tank with a new gasket.
Note: Apply the sealing agent (THREEBOND #4001) to the both sides of the gasket before installing.
- 71 -
7. HYDRAULIC SYSTEM
7.2.3 OIL PRESSURE MEASUREMENT AND ADJUSTMENT

(1) Oil pressure measurement
Remove the check plug and install an oil pressure gauge
of 20 MPa {200 kgf/cm2} [3000 psi] capacity.
Move the tilt lever forward and read the pressure
gauge.
If the measured pressure is not as specified, adjust
CHECK
the relief valve. PLUG
Fig. 7.16 Oil Pressure Measurement
(2) Oil pressure adjustment

Install an oil pressure gauge in the same procedure RELIEF VALVE
shown above.
Loosen the lock nut, using caution to prevent the
adjusting screw of the relief valve from turning.
Move the tilt lever forward and adjust the pressure
to the specified value with the adjusting screw,
observing the pressure gauge.
When adjusting is complete, tighten the lock nut
securely.
LOCK NUT
ADJUSTING SCREW
Fig. 7.17 Oil Pressure Adjustment
Unit: MPa {kgf/cm2} [psi]

FR10-7 FR10-7C FR20-7 FR20-7H
FR13-7 FR13-7C FR14-7 FR14-7H FR18-7 FR25-7 FR25-7H
FR10-7H FR10-7CH FR15-7 FR15-7H FR18-7H FR30-7 FR30-7H
FR13-7H FR13-7CH
12.7 {130} [1842] 13.7 {140} [1987] 15.7 {160} [2277] 17.2 {176} [2495]
- 72 -
7. HYDRAULIC SYSTEM
7.2.4 VALVE SWITCH ADJUSTMENT

(1) Loosen the valve switch mounting bolt and move the 2 – 2.5
[0.08 – 0.10] Unit: mm
switch away from the cam. [in.]
(2) Install a clearance gauge shown in Fig.7.18 between
the cam and the roller.
(3) Bring the switch slowly close to the cam and lock
[0.59 – 0.79]
the switch at the position where the switch is turned
15 – 20
ON.
(4) Pull the gauge out, then make sure that the switch is Thickness:
0.8 ± 0.1
turned off. [0.03± 0.004]
Note: If the switch won’t turn off, readjust it.
Fig. 7.18 Gauge Adjustment
0.8 ± 0.1
[0.03± 0.004]
Fig. 7.19
- 73 -
7. HYDRAULIC SYSTEM
5-THROW
4-THROW and 5-THROW VALVES
OIL TANK
4-THROW
Detail of section
MAIN PUMP
REACH CYLINDER
CONTROL VALVE
3-THROW VALVE
: from OIL TANK to

PUMP
: from PUMP to
CONTROL VALVE
: to REACH CYLINDER
CAP SIDE
: to REACH CYLINDER
TAIL SIDE
: TILT CYLINDER
: TILT CYLINDER
: to LIFT CYLINDER
: from CONTROL
VALVE to OIL TANK
: from LIFT CYLINDER
Fig. 7.20 Hydraulic Piping (truck body side)
- 74 -
8. LOAD HANDLING SYSTEM

Truck Model FR10-7 FR10-7H FR14-7 FR14-7H FR20 -7 FR20-7H FR30-7 FR30-7H
FR10-7C FR10-7CH FR15-7 FR15-7H FR25 -7 FR25-7H
FR13-7 FR13-7H FR18-7 FR18-7H
Item FR13-7C FR13-7CH
Name VM-82F(C:VM-80A) VM-82M VM-82R VM-79K
Type Roller type 2-stage telescopic mast wit free lift
Standard max. lifting height 3000 mm 4000 mm 3000 mm 4000 mm 3000 mm 4000 mm 3000 mm 4000 mm
[118.1 in.] [157.5 in.] [118.1 in.] [157.5 in.] [118.1 in.] [157.5 in.] [118.1 in.] [157.5 in.]
Fork lifting system Hydraulic
Fork tilting system Hydraulic
Reaching system Hydraulic
Lift chain Leaf chain BL623 Leaf chain BL623 Leaf chain BL823
Mast rail dimensions
Cross section of outer rail
A: 44 mm [1.7 in.] A: 48 mm [1.9 in.]
B: 102.5 mm [4.0 in.] B: 119.5 mm [4.7 in.]
C: 134.5 mm [5.3 in.] C: 161.5 mm [6.4 in.]
Cross section of inner rail

A: 43 mm [1.7 in.] A: 45 mm [1.8 in.]
B: 102.5 mm [4.0 in.] B: 119.5 mm [4.7 in.]
C: 134.5 mm [5.3 in.] C: 159.5 mm [6.3 in.]
D: 72 mm [2.8 in.] D: 76 mm [3.0 in.]
- 75 -

The load handling system uses two-stage type telescopic mast assembly consisting of an outer channel, an
inner channel and a lift bracket.
8.1.1 OUTER AND INNER CHANNELS

The outer and inner channels are of welded construction shown in Fig.8.1. The end roller shaft is welded
to the bottom of each channel. The right and left rails are connected with cross members.
1. OUTER CHANNEL
2. END ROLLER
3. SHIM
4. SHIM
5. SLIPPER
6. INNER CHANNEL
7. STOPPER
8. HOOK
9. SPACER
10. SHIM
11. SIDE ROLLER
12. ROLLER
13. SNAP RING
14. SHIM
15. SHIM
16. END ROLLER
17. SNAP RING
Fig. 8.1 Outer and Inner Channels (VM-82A, VM-82F, VM-82M)
- 76 -
1. OUTER CHANNEL
2. END ROLLER
3. SHIM
4. SHIM
5. SLIPPER
6. INNER CHANNEL
7. STOPPER
8. HOOK
9. ROLLER
10. SNAP RING
11. SHIM
12. SIDE ROLLER
SHAFT
13. SIDE ROLLER
14. SNAP RING
15. SHIM
16. END ROLLER
17. SNAP RING
Fig. 8.2 Outer and Inner Channels (VM-82R, VM-79K)
- 77 -
8.1.2 CARRIAGE
The carriage has the forks installed through the shaft type fork support and the end rollers installed with
snap rings.
The carriage moves vertically through the end rollers along the inside of the inner mast frame by expansion
and contraction of the lift cylinders.
1. CARRIAGE
2. PIN
3. SPACER
4. SHIM
5. SIDE ROLLER
6. SHIM
7. END ROLLER
8. SNAP RING
9. SHAFT
10. FORK
11. FORK SUPPORT
Fig. 8.3 Carriage (VM-82A, VM-82F, VM-82M)
- 78 -
1. CARRIAGE
2. PIN
3. SPACER
4. SHIM
5. SIDE ROLLER
6. SHIM
7. END ROLLER
8. SNAP RING
9. SHAFT
10. FORK
11. FORK SUPPORT
Fig. 8.4 Carriage (VM-82R, VM-79K)
- 79 -
8.1.3 ROLLER LOCATION

The load handling system has end and side rollers. They are installed on the inner and outer channels, and
lift bracket respectively.
Each roller can be adjusted with shims. It should be set to move the outer and inner channels and lift
bracket smoothly.
The end rollers support longitudinal load and the side rollers support lateral load so that the inner channels
and lift bracket are raised and lowered smoothly.
Upper side Lower side
END ROLLER
OUTER INNER FORK SUPPORT (shim adjusted)
RAIL RAIL
END ROLLER
CARRIAGE (shim adjusted)
GUIDE ROLLER (front)
END ROLLER SIDE ROLLER

(shim adjusted) (shim adjusted)
SLIPPER END ROLLER

(shim adjusted) (shim adjusted)
LIFT CYLINDER
HOSE PULLEY
SIDE ROLLER
(shim adjusted)
GUIDE ROLLER
(rear)
Fig. 8.5 Roller Location (VM-82A, VM-82F, VM-82M)
- 80 -
OUTER INNER FORK SUPPORT END ROLLER

RAIL RAIL (shim adjusted)
CARRIAGE END ROLLER
(shim adjusted)
END ROLLER
(shim adjusted) SIDE ROLLER
(shim adjusted)
SLIPPER
(shim adjusted) END ROLLER
(shim adjusted)
LIFT CYLINDER
HOSE PULLEY
SIDE ROLLER
(shim adjusted)
GUIDE ROLLER
(rear)
Fig. 8.6 Roller Location (VM-82R)
- 81 -
OUTER INNER FORK SUPPORT END ROLLER

RAIL RAIL (shim adjusted)
CARRIAGE END ROLLER
(shim adjusted)
END ROLLER
(shim adjusted)
SLIPPER
(shim adjusted) END ROLLER
(shim adjusted)
LIFT CYLINDER
HOSE PULLEY
SIDE ROLLER
(shim adjusted)
GUIDE ROLLER
(rear)
Fig. 8.7 Roller Location (VM-79K)
- 82 -
8.2 MAINTENANCE
8.2.1 ADJUSTING CYLINDER ROD WITH SHIMS
Whenever the lift cylinder, inner channel, and outer
channel are replaced, the lift cylinder rod length needs to PISTON HEAD SHIM
be adjusted.
(1) Install the piston head on each rod of the right and
left cylinders without shim.
(2) Extend the lift cylinder rod slowly and check the
difference of the time till each of the right and left
cylinder rods reaches the stroke end.
(3) Add shims between the rod and piston head of the
cylinder stop first.
Shim thickness: 0.2 mm [0.008 in.] and 0.5 mm
[0.02 in.] LIFT CYLINDER
(4) Adjust the lift chain tension.

Fig. 8.8
8.2.2 ADJUSTING HEIGHT OF CARRIAGE

(1) Stop the truck on a level surface and put the mast
vertically.
TIRE
(2) Keep the fork bottom on the ground and adjust the
projected amount of the carriage lower end roller
INNER CHANNEL
to 36 – 41 mm [1.42 – 1.61 in.], using the chain
anchor pin at the mast side. CARRIAGE
END ROLLER
FORK
Fig. 8.9
- 83 -
(3) Make sure that the clearance between the lift

carriage and the inner channel stoppers is 0 mm [0 INNER CHANNEL
in.] when the forks are raised to the maximum lifting
height.
CARRIAGE
STOPPER
CHAIN ANCHOR
PIN AT THE MAST
Fig. 8.10
(4) Adjust the tension of the right and left chains to the
same value with the chain anchor pin at the mast
CHAIN
side when the forks are at the bottom position and
the mast is tilted back all the way.
ANCHOR PIN
ADJUSTMENT NUT
LOCK NUT
Fig. 8.11
- 84 -
8.2.3 PROCEDURE FOR REPLACING ROLLER AT CARRIAGE SIDE

(1) Attach the pallet to the fork and stop the truck an a
level surface.
(2) Lower the forks with the pallet to the ground.
(3) Remove the joint link of the mast side anchor pin
and remove the chain from the sheave.
(4) Remove the tilt piping from the carriage side.
(5) Extend the lift cylinder rod to raise the inner channel.
(See in Fig. 8.12.)
(6) After the carriage is detached from the inner channel,

retract the mast. (See in Fig. 8.12.) Fig. 8.12
(7) Replacing end rollers

Remove the lower end roller with a puller, keeping
the shim.
Stamp (S or SS)
Install a new end roller with the shim removed in
step . Check the stamp S or SS and install the
roller which is marked the same stamp, pointing the
stamp side to the carriage side.
Remove the snap ring and remove the upper end
roller with a puller.
Install a new end roller and secure it with the snap
ring.
(8) Replacing side rollers

Remove the side roller assembly. Do not change the Fig. 8.13
numbers of the shims and their combination as they
were. SHIM SIDE
ROLLER
Install a new roller with the shims removed in step
, pointing the groove for the balls to the shim side.
If there is excessive looseness between the side roller
END
and inner channel, add the shims between the end ROLLER
roller and side roller, seeing “PROCEDURE FOR
ADJUSTING SHIMS”.
SNAPRING
SHIM
Fig. 8.14
- 85 -
(9) Extend the lift cylinder rod so that the inner channel
bottom projects the upper section on the carriage.
(10) Bring the truck close to the carriage side so that each
roller enters inside of the outer channel.
(11) Contract the lift cylinder rod to lower the inner

channels gradually. Place each roller of the carriage
into the inner channels.
(12) Engage the chain with the sheave and connect the
chain and anchor pin through the joint link.
(13) Engage the tilt piping with the hose pulley.

Fig. 8.15
(14) Adjust the height of the carriage. (See 8.2.2)
- 86 -
8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE

(1) Remove the carriage from the inner channel in the
same procedure as described in “8.2.2
PROCEDURE FOR REPLACING ROLLERS AT
CARRIAGE SIDE”.
(2) Move the truck to a level surface and put both ends
of the outriggers on blocks, 250 – 300 mm [10 – 12
in.] high.
(3) Block both rear wheels securely.

250 – 300 mm
[9.8 – 11.8 in.] BLOCK
(4) Hoist the inner channel with a crane and remove the
stopper from the outer channel.
(5) Operate the crane to lower the inner channel Fig. 8.16
gradually and remove the end roller from the lower section of the inner channel. At the same time, the
end roller at the upper section of the inner channel will come off.
(6) Replacing end rollers

Remove the lower end roller with a puller. Keep the SHIM
shims. SHIM
Install a new end roller with the shims removed in END ROLLER
step . Check the stamp S or SS and install the
roller which is marked the same stamp, pointing the SLIPPER
stamp side to the carriage side. (See Fig.8.13)
Replace the lower end rollers of the inner channel,
using same procedure as above. In this step, point
the stamp side to the outer channel side.
(7) Operate the crane to hoist the inner channel. Place

rollers into the channels.
(8) Install the carriage in the reverse order of

disassembly.
SHIM
END ROLLER
Fig. 8.17
- 87 -
8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING THE NUMBER OF SHIMS

(1) Move the inner channel and lift bracket to one side of the outer channel. Measure the clearance between
the end roller at the opposite side and each channel.
Clearance between roller and channel: 0 to 0.5 mm [0 to 0.020 in.]
0 – 0.5 mm
[0 – 0.02 in.]
0 – 0.5 mm
Make contact with one side. [0 – 0.02 in.]
(Only left side)
0 – 0.5 mm 0 – 0.5 mm
[0 – 0.02 in.] [0 – 0.02 in.]
2.0- to 3-ton trucks

0 – 0.5 mm Apply grease.
[0 – 0.02 in.]
(Upper side) Make contact with one side.
Apply grease.
Make contact with one side.
0 – 0.5 mm
[0 – 0.02 in.]
Fig. 8.18
- 88 -
9. ELECTRIC WIRING
9. ELECTRIC WIRING
The electric components of the truck are wired using several types of wire harness 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 Wire
number B Black R Red number
G Green W White
L Blue Y Yellow
O Orange Lg Light green
Example: Yellow coating with a blue marking P Pink Lb Light blue Example: White coating without marking
Table 9.2 Connector symbol
Connection type Plug-in side Receptacle side Remarks
Housing The alphabetic letters means colors.

Plug-in type
(Table 9.1)
Plug
Screw type
Two wires may have different wire numbers even through 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.
- 89 -
9. ELECTRIC WIRING
to TURN SIGNAL SWITCH

(OPTION)
WL B WR
48 78 49
to LIGHTING SWITCH
WB - B WL
77 - 78 48 RB 82-1
RB WG - WR
82 73 - 49 WG 73
RB 82
WB 77
to WIRE HARNESS,
FRAME to HORN SWTICH
Fig. 9.1 Wire Harness, Meter Panel
to TILT SWITCH
to LIFT SWITCH 2 to LIFT SWITCH 1
BrR 92
BrW BrR YB YG 21 YB 20
91 92 20
YG - BY BY 23-2
21 - 23 BY 23 BY 23-1
BrW 91
BY 23-3
to WIRE HARNESS,
FRAME
to REACH SWITCH
Fig. 9.2 Wire Harness, Valve (for 3-throw valve)
- 90 -
9. ELECTRIC WIRING
N.C.
RW LW W W 112
83 177 112
LW 177
N.O.
to WIRE HARNESS, RW 83
FRAME
COM.
to BRAKE SWITCH
Fig. 9.3 Wire Harness, Brake Switch
to WIRE HARNESS FRAME

to BATTERY SWITCH
Fig. 9.4 Wire Harness, Battery Switch
to HEAD LAMP
LY RW
46 83
B WG WG 73
78 73
B 78
to WIRE HARNESS, RW 83
FRAME
LY 46
to TURN SIGNAL LAMP

(OPTION)
Fig. 9.5 Wire Harness, Overhead Guard
- 91 -
9. ELECTRIC WIRING
to BRAKE SENSOR
(RIGHT)
RY LB GW
169 171 163
BY WB WG
170 172 164 WG 164
GW 163
to WIRE HARNESS,
FRAME
RY LB
169 171
BY WB
170 172
to BRAKE SENSOR
(LEFT)
R LW GW
165 167 161
BR W WG
166 168 162 WG 162
GW 161
to WIRE HARNESS,
FRAME
R LW
165 167
BR W
166 168
Fig. 9.6 Wire Harness, Brake Sensor
- 92 -
9. ELECTRIC WIRING
1 10
1 8
WG WR RG R LW R W R YR YL
26 28 24 30 32 165 11 12 9 14 15
LY YR B BR W BR BY YB WB
27 29 25 31 33 166 13 16 10
11 20
9 16
1 10
RW
1 83-6
WR RY BY YB R
RY 80 3 169 170 2 4 76-1
11 20
RY 80-2
RY 80-1
L 56
L 56-1
R
F6 10A
F4 10A
BrR 60
59
F5 10A
1 8
RB 82-F
RG 81-F
GR BrW YL to CONTROLLER to DISPLAY BOARD
58 91 22
YG BY L WL 1 8
92 21 23 56 54 GW R RG YL YR RY WL
BrR GR BrW
R 160-F
9 16
71 43 45
59 58 55 GW BW R Br LY WR YB
163 79 76-2 44 46 49 42
9 16
to CONTACT COIL
RG 81
RB 82
For optional equipment
1 10
L 68
RG LY YR WL RY LB
R 160
24 27 29 50 52 39
B 78 B WG WR LW Br BW
RW RB
83 25 26 28 51 53 40 41
83-1 11 20
BW 79
B WL
Br 75 54
B 78-10 BrW
W 112 55
B 78-11
to WIRE HARNESS,
to EPS CONTROLLER METER PANEL
G Y
67 66 WL B - WB
-
L R WR - WG
RW LY
68 60 49 - 73-1 to WIRE HARNESS, VALVE SWITCH
46
WG B to BRAKE SWITCH
73
RW 83-11 BrW
W LW RW 91
to WIRE HARNESS, 112 177 83-2 B 78-15 YG
21
LW WL
OVERHEAD GUARD 53 51 50 -
RW W GW L
(LEFT) 83-7 65 64 63
GW
161
LW R CAPACITOR
WG BW RY
W
162 41 80
LW WR YB BrW
177 3 42 210 78-4
to WIRE HARNESS,
BRAKE SENSOR WB(77)
RW RY
83-5 45
(LEFT) to HORN to FORWARD CHIME WG B
LW
32 GW
RED TAPE B(78-5) 73 78-6
LB RY R
76-3
RG
72
Br
40
(OPTION)
31 WG
164
WB
172
BY
170
to WIRE HARNESS,
GW 74
to BEARING SENSOR OVERHEAD GUARD
to WIRE HARNESS, to WIRE HARNESS, B 78-1
(DRIVE) to BACK-UP BUZZER (RIGHT)
KEY SWITCH Br 75-1
BRAKE SENSOR (RIGHT)
78-2
RB 4
to LOCK
RW RB
SOLENOID RW 83-9
83-4 82-2
YB Br
2 75
RW RB
83-3 82-3
WBr GW
1 74
YR YL YB
14 15 16
to STEERING SENSOR
to ANGLE POTENTIOMETER L GW W
Br
65
RG YL
LB 39 81-1 81 71
BrW R
210 76
B 78-3
to RELAY
Y
66
G
67
to HOUR METER
TOR
Fig. 9.7 Wire Harness, Frame
- 93 -
9. ELECTRIC WIRING
MODE SWITCH TURN SIGNAL HEAD LAMP

LIGHTING SWITCH SWITCH HORN (RIGHT) TURN SIGNAL
TURN SIGNAL HEAD LAMP (LEFT)
LAMP (LEFT) FUSE and CONTACTOR SWITCH LAMP (RIGHT)
CN1 CN2
DISPLAY
N.C
WB
N.O
RB
CN4
CN5 CN3
W W L R 2P RB WG W W
EPS COM
W W CONTROLLER RY DISPLAY BOARD W B
RW L
3P RW LY
16P 20P
WG B WG
BRAKE (LEFT) BRAKE (RIGHT)

R GW F1 F3 F7 GW R
F5
F6
F4
8P 4P
L WG WG L
4P 4P 10P
4P 4P
GR
BEARING SENSOR 6P BEARING

(LEFT) SENSOR (RIGHT)
LIFT 2 LIFT 1 ATT 2 ATT 1 TILT REACH
N.C N.C N.C
BrW YL YL
6P N.O N.O N.O N.O
BY BY BY
COM COM 6P
For optional equipment
ACCELERATOR
3P
Br
B
RW B FAN
W 2P B
BW
4P 6P L P B
RW
B FAN RG LB U1 U2 V1 V2 W1 W2
NA
3P
2P
16P 20P 16P 20P

(B)
T+ KEY SWITCH + -
FAN RG LB CONTROLLER Br
6P 6P ST
T
R RG
B IG
R Br
FORWARD CHIME BACK-UP
(OPTION) BUZZER
(+)
TRANSFORMER WB
and DIODE
B
B R B R
LOCK SOLENOID
WM
UM
VM
RW 3P
STEERING BATTERY
(-) HORN B GW B Br
RB SENSOR
6P CHARGER
BRAKE SWITCH R
4P
BB
W
B
3P PUMP MOTOR M.C.
3P
DRIVE MOTOR
4P
X1
2P
6P
B X2
W2 V2 U2
RELAY
LB 12P
W1 V1 U1
EPS MOTOR
ANGLE
POTENTIOMETER BATTERY SWITCH
Fig. 9.8 Wiring Diagram
- 94 -
MB R 160
BRAKE (LEFT) GW 161 (1-8)
SOL MB1
10A
(1-10) F5
WG 162
MB2
(1-9)
BRAKE (RIGHT) GW 163
SOL MB3
(1-20)
HIU
WG 164
MB4
(1-19) U2
+
YB 16
AN3
(6-15) V2
PM
YR 14 PUMP MOTOR
AP3
HIV
(6-7) W2
YL 15
AD3
(6-8)
1(V)
R 165 RPA (6-1)
WB 77
HORN SWITCH BEARING BR 166 RNA
LW 167 RA4 (6-2)
HORN
(LEFT) W 168 RB4 (6-10)
MC
RPA (5-13)
F1
BEARING
325A
LIGHTING BY 170 RNA (5-14)
TIU
HEAD LAMP (LEFT) SWITCH RA5 (6-3)
WG 73 (RIGHT) WB 172 U1
RB5 (6-11) +
(40W)
V1
DM
HEAD LAMP (RIGHT) BY 23 DRIVE MOTOR

HSN
(40W) (8-16) TIV W1
LIFT1 BrW 91
HS1
(8-4) R 30
(7-5) RPA
LIFT2 BrR 92 BR 31 REV. SENSOR
HS2
CNPDAL
(8-12) LW 32
(7-6) (DRIVE MOTOR)
TILT YB 20 W 33
HS3 (7-16)
(8-5)
REACH YG 21
RF
FORWARD CHIME (OPTION) HS4
GW 74 (8-13) GR 58
F1
ATT1 YL 22 (3-9)
HS5
CONTROLLER
(8-6) L 56
C1
ATT2 (3-18)
F3
(3-10)
BB
BACK-UP BUZZER Br 75
(5-20)
ACCELERATOR MC
(3-6)
BACK-UP LAMP BY 13 BrW 55
AN1
(25W) (6-12) (3-16)
FAM MOTOR
ACC. RY 11
AP1 (SIDE)
(6-4) RG 69
PV
AT BBR W 12 (1-6)
AD1
REVOLVING LIGHT (6-5)
WB 10
ADN
AT KEY SW ON (6-16)
R9
AP2
(6-6) LB 70
PVN
OPTION (1-16)
LOCK SOLENOID
LCK RB 4 SOL
(5-16)
SPOT LIGHT WR 111 SPL SW HS7 (Load handling WBr 1
OF2 RF
(25W) operation is
possible when OB2 YB 2 BB
opened.) (5-15)
REAR WORK LIGHT WL 61 RWL SW N
VB
(40W) (5-10)
BATTERY SWITCH
BRAKE
(Traveling is possible (normal working status)
WR 3 LW 177
SWITCH
(7-3)
(7-2)
(7-4)
(7-13)
(7-12)
(7-14)
BS1
HP
HN
TXB
TXA
RXB
RXA
when closed.) (5-12)
STOP LAMP W 112

(25W)
- 95 -
B 25
LY 27
YR 29
RG 24
WR 28
WG 26
Y 66 G 67
PS
FAN MOTOR
(CENTER) L 68 L 63
GW 64
SENSOR
Fig. 9.9 Circuit Diagram

STEERING
TXB
TXA
HPA
RXB
RXA
HNA
(2-3)
(2-2)
(2-1)
(2-13)
(2-12)
(2-11)
W 65
HPC RY 52
(2-5)
VN
HNC BY 53 R 60
+
(2-15)
BS1
F3
LW 51
40A
TXC
-
(2-14)
EPS CONTROLLER
BS2
RXC WL 50
M
(2-4)
BS3
R
BS4 TURN SIGNAL LAMP (LEFT)

MODE SWITCH
BS4 WL2 LY 46
(1-12) (25W)
TURN SIGNAL LAMP (RIGHT)
M-4 HV WL1 RY 45
(1-4) (25W)
M-10 GND
RLP YR 43 X1
(1-3)
RLN Br 44
(1-11)
22P
DISPLAY
FLAT
RW 83
CABLE
R 76
DISPLAY BOARD
RY YL 71
TURN SIGNAL LAMP (1-2)
SWITCH (LEFT) VB
WL 48 (1-10)
SW3
(1-6) KST Br 40
WR 49 (2-19) X2
SW2
(1-13) RG 81 RY 80
TURN SIGNAL LAMP
F4
10A
SWITCH (RIGHT) X1
KEY
KSW RG 72 BrW 210 X2

10A
(1-1)
SWITCH
F6
BW 79 VN
(1-9)
HOUR METER SWITCH CHG BW 41
LB 39 (2-20) RY 80
CHS
(2-10) YB 42
SW4
(1-14)
CHARGE
B 78
CONTROLLER
B 208
TRANSFORMER
R 207
W 211
CM
U
R
V
AC INPUT
W
T
CM
E
100A
B+
F7
BATTERY
RB 82
9. ELECTRIC WIRING
9. ELECTRIC WIRING
- 96 -
No. SEB-82ABE
Issued: May, 2004
Reviced: April, 2008
INTERNATIONAL MARKETING DIVISION: 1-15-5, Nishi-shimbashi, Minato-ku, Tokyo

105-0003, Japan
FAX: JAPAN +81-3-35918152, 3-35918153
All rights reserved JB-0804005(HO) Printed in Japan

SERVICE MANUAL FR10-7 – FR30-7H · FR10-7C – FR13-7CH No. SEB-82ABE

Fr15,18,10,25 7h Service Manual

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Fr15,18,10,25 7h Service Manual

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No.

ELECTRICAL FORKLIFT TRUCK

Fig. 1 External View

4. DRIVE UNIT .................................................................................................................................. 31

5. STEERING SYSTEM ................................................................................................................ 39

6. BRAKE SYSTEM ........................................................................................................................ 49

7. HYDRAULIC SYSTEM ............................................................................................................. 57

8. LOAD HANDLING SYSTEM ................................................................................................. 75

9. ELECTRIC WIRING ................................................................................................................... 89

1. BATTERY AND CHARGER (OPTION)

1.1 GENERAL DESCRIPTION

Fig. 1.1 Battery Assembly

(1) Cell structure

The battery cap is made of transparent resin, having a

(2) Battery lock device

To pull out the battery, advance the mast assembly.

Detail of switch area

Fig. 1.3 Battery Lock Device

(3) Receptacle remover

Fig. 1.4 Receptacle Remover

(4) Battery care

Depth of discharge (%)

Fig. 1.5 Relation Between Depth of Discharge

Adding battery electrolyte

Max. level Proper level Min. level

Too much distilled water may cause

Charging the battery

[Cautions on charging battery]

[Specific gravity correction according to temperature]

DIODE (+ side) TRANSFORMER to BATTERY

to PRIMARY WINDING WIRE

View looking from

Fig. 1.8 Transformer Installing Position

(1) Charger controller

View looking from

Fig. 1.9 Charger Controller

(2) Transformer and diode

OUTPUT TERMINAL (-), M8

OUTPUT TERMINAL (+), M8

SECONDARY COIL PRIMARY COIL

Fig. 1.10 Transformer and Diodes

Transformer tap changing

the tap. (See Fig. 1.12)

The tap voltage is indicated

2.1 GENERAL DESCRIPTION

Fig. 2.1 Drive Motor

COVER (D) STATOR

Fig. 2.2 Pump Motor

Fig. 2.3 EPS Motor

Tightening torque: 36 – 43 N-m {360 – 430 kgf-cm}

Tightening torque: 36 – 43 N-m {360 – 430 kgf-cm}

Fig. 2.4 Pump Motor Installing Position

2.2 MAINTENANCE • ROTOR (DRIVE MOTOR)

• ROTOR (PUMP MOTOR)

• “Bearing sensor” replacement

When changing the “bearing sensor”, use due

2.2.2 EPS MOTOR MAINTENANCE

END COVER (C)

If the brush shows roughness in its commutator contact

• After repairing, clean with compressed air.

• Repair brush’s commutator contact area

3.1 GENERAL DESCRIPTION

1. HEAT SINK 6. IGBT MODULE (V PHASE OF

Fig. 3.1 Controller (Traveling and Hydraulic Systems)

15 B15 B15: Accelerator Accelerator error Turn off key switch.

60 G60 Current error Battery current error Emergency stop

63 G63 Traveling motor voltage error Traveling motor voltage error

64 G64 Hydraulic motor voltage error Hydraulic motor voltage error

66 G65 Power being saved Traveling motor IGBT temperature error

67 G65 Power being saved Hydraulic motor IGBT temperature error

70 G70 Fan error Fan power supply voltage error

Overload. Reduce load. Overload When overload occurs

Add lubrication oil Lubrication oil When lubrication oil sensor

Recharge battery Battery’s state of charge is low When battery’s state of

Secure battery unit Traveling or hydraulic operation is performed