DETAILED GUIDANCE BATTERY-POWERED FORKLIFT TRUCKSCONTENTS 1. MAJOR ELECTRIC PARTS AND CHECKING PROCEDURES 1~31 2. PROCEDURES FOR OVERHAULING THE MOTORS/METER PANEL -----~ 32~41 3. TROUBLE SHOOTING - ATTACHED : 1 42~ 75 FB-6 CHECK POINTS 1/2~2/2 FRB-6 CHECK POINTS 1/2~2/2 CIRCUIT DIAGRAM FOR COUNTER BALANCE TYPE CIRCUIT DIAGRAM FOR REACH TYPE1. MAJOR ELECTRIC PARTS AND CHECKING PROCEDURES + PARKING BRAKE SWITCH « CHARGING SWITCH « CHARGING. CONNECTOR + DRIVE WOTOR + SPEED SENSOR + HORN + STOP LAP SH TOH POMP MOTOR 4 POTENTIOMETER FOR LIFTING “F/R SWITCH CONTROL VALVE SHITOHES «KEY SWITCH a ‘ * LIGHTING SWITCH « TURN SIGNAL SWITCH + HORN SWITCH ~ ACCELERATOR BACK BUZZER ~ TRANSFERIER “ EPS. CONTROLLER “MAGNET SWITCH PS CONTAGTON LOCATION FOR ELECTR! GA . L courovent «FS COTAll WETER PANEL KEY SWITCH LIGHTING SWITCH HORN SWITCH BATTERY LOCK SWITCH = BATTERY SWITCH * CHARGING SWITCHPU BOARD VTW UNIT F/R CONTACTOR DIODE FOR CHARGING & (COMMUTATION RB CONTACTOR BP. P, PB CONTACTOR CURRENT DETECTOR D.C CHOPPER UNIT (FB)THERMISTOR ASS’ DIODE FOR CHARGING & ‘COMMUTATION F/R CONTACTOR ‘CURRENT DETECTOR RB CONTACTOR BP. P. PB CONTACTOR D.C. CHOPPER UNIT (FRB)1GBT = CIRCUIT SYMBOL 2K GC & E ARE INDICATED ON IGBT BODY. Gc, EUs Riek 645%) ~ EXPLANATION 1GBT STANDS FOR | (INSULATED), G(GATE), B(BIPOLAR), T (TRANS! STOR) IT 1S MAIN ELEMENT FOR MOTOR DRIVING CIRCUIT AND TO CONTROL THE CURRENT PASSING RATE FOR wor 7779 9 Me $45), 77 BAF a2h0-0 FZ om heh PARTS NO. TYPE APPLICABLE MODEL 177H2-62201 | iMBi600NN-060| FEiO~30 17862-62081 |MGsoou1uss1 F820725. FRO10~25. FROL 17862-62041 | CM450HA-5F FRBIA/15716 1732-62071 | CMOOOHA-6F 20725. FRBIA7 15718 “INSPECTION FOR_1GBT wis RESISTANCE RANGE x19 BETWEEN E AND C 447th pret (SET ZERO(0) POSITION BEFORE USE) MEASURING POSITION | TESTER BAR] CORRECT VALUE 04z BRU 145 e BLACK | APPROX. 402 c RED Cc | BAX = E RED CNFINITY) RESISTANCES ON OTHERS BETAFFN F AND 6, G AND O ARF ALL INFINITY (co). (THERE ARE 4K1NDS) 19fe E-G , G-CR) Osta £7 00 (48) 5MAIN DIODE ~ CIRCUIT SYMBOL gieK Pitsh, ANODE KATHODE (A) (Kk) 3% A AND K ARE INDICATED ON THE BODY. AK eaet f REBES’) ~ EXPLANATION |T 1S USED FOR FLYWHEEL, PLUGGING AND REGENERATIVE CIRCUIT. EFAS TAR | 15TH REW EATS HRA PARTS NO. TYPE ‘APPLICABLE MODEL 1782-62061 | FRS300BA50 FB10~80, FRB10~25, FRBL 171H2-62381 | FRSSO0CASO Fe20726790 tee Tha 7% THON FOR MAIN DIODE thw RESISTANOE RANGE x1. (SET ZERO(0) POSITION BEFORE USE) (MEASURING POSITION | TESTER BAR VEER L 65 CORRECT VALUE A BLACK 5~10Q K RED K BLACK °° A RED (INFINITY)reRK HAS DIODE FOR CHARGING & COMMUTATION CIRCUIT SYMBOL Aca. 3 SYMBOL MARKS ARE INDICATED ON THE BODY. Rea Mie AES) ~ EXPLANATION IT 1S USED FOR COMMUTATION IN THE CHARGING CIRCUIT. REDM) SRW PARTS NO. TYPE APPLICABLE MODEL 1772-62211 | PTisose FB10718, FRBZO725 177P2-62401 | PT2008a FB207256730 17@M2—62051 | PT1018 FRE10~18. FRBL FOR THE DIODES RESISTANCE RANGE x19 (SET ZERO (0) POSITION BEFORE USE) MEASURING POSITION | TESTER BAR| CORREOT VALUE = Back =| 60+20Q Ee RED £ BLACK’ ~ = RED CINFINITY)44- tao DIODE FOR SURGE-KILLER = CIRCUIT SYMBOL 2% A & K ARE INDICATED ON THE BODY. Ack dEI~114 ALBA’) ~ EXPLANATION IT 1S USED TO COMBINE WITH CONDENSER OR RESISTOR FOR SURGE-KILLER CIRCUIT OF BOTH DRIVING AND LOADING | 6B. 26 RGR LOBT 9 4-747- DM FHI, UIZ2I Ue BROT EQ PARTS NO. TYPE. APPLICABLE MODEL 17 1A2-62071 | FRGZ5AA60 FB10~S0, FRB10~25, FRBL = INSPECTION FOR THE DIODE RESISTANCE RANGE x 19 (SET ZERO(O) POSITION BEFORE USE) [NEASURING POSITION] TESTER BAR] CORRECT VALUE A BLACK 13+2Q K RED K BLAGK Es Boe a RED (INFINITY)ARS it OES H, CONDENSER FOR SURGE-KILLER * CIRCUIT SYMBOL 9 () 1S INDICATED ON THE BoDY. C)eaete MERE S) * EXPLANATION IT 1S USED TO COMBINE WITH DIODE OR RESISTOR FOR SURGE-KILLER CIRCUIT OF BOTH DRIVING AND LOADING ISBT. 545 BAW IoBT 9 7A THK 297 BPR ER PARTS NO. CAPACITY RATED VOLTAGE APPLICABLE MODEL 171A2—62561 | 350v0C 680uF | FBIO~30 171A2—62571 | 850v0C 470uF | FB10~30 173A2—62111 | 160V0C 1000uF| F830, FRB10~25.FRBL | ~ INSPECTION FOR THE CONDENSER (b) Ce) 1. CHECKING FOR BROKEN WIRES CHECK THE TERMINALS BY RESISTANCE RANGE x 509 (SET ZERO(0) POSITION BEFORE USE) IT 1S NORMAL TO MOVE THE NEEDLE IN oo — APPROX. 1002 — co ORDER WHEN TESTER. BARS(RED - BLACK) ARE TOUCHED TO THE TERMINALS IN A MOMENT. CIN ORDER AS PHOTO (a) — (b) — (c) — (@)] PROVIDED THAT THE TESTER’ S NEEDLE MOVES ONLY ONE TIME AT THE SAME POLARITY (BLACK TO +, RED TO - AND SO ON) 2. CHECKING FOR SHORT-CIRCUI TED IT 1S NORMAL IF IN THE TERMINALS IS NOT INDICATED WITH SHORT-CIRCUITED (0)F/R CONTACTOR * CIRCUIT SYMBOL F ee oo. R nal Noo ae © CONTACT * EXPLANATION IT HAS 2 CONTACTORS FOR F(FORNARD) AND FOR R (REVERSE) IT 1S TO SHIFT THE ROTATING DERECTION OF THE MOTOR BY SHIFTING MOTOR CURRENT FLOW FOR Fe con, = KT EIR Auk sve ANZ SAT ya 79D RIM TERT PARTS. NO. TPE ‘APPLICABLE MODEL 271A2—621281 | CTTAISS4FRI42XN | FBIO71S, FREZO/25 271F2-62121 | CTTAGOSFRIG2XN | FB207E5 17772-62121 | sweoe-27 Fao [yreme-e2te1 | oceee-aest FRB10~18, FROL = INSPECTION FOR F/R CONTACTOR ain dhth 2 WEASURING COIL RESISTANCE (BY _WEANS OF DIGI TALTESTER) PARTS NO. COIL RESISTANCE 271A2-62121 29250 271F2-62121 20250 17772-62101 | 1802109 178M2—62011 55252 10F/R CONTACTOR + COMPOSED PARTS FOR F/R CONTACTORBP, P AND PB CONTACTOR CIRCUIT SYMBOL e*) COIL BP a CONTACT P, PB 3299919 25 w RIS 2% THE SYWBOL_IS DIFFERENT IN P_AND PB CONTACTOR, > EXPLANATION BP:BYPASS CONTACTOR FOR DRIVING C&O"4N'A 27779 ~ ) P :PUMP GONTACTOR FOR LOADING C#&™32999- ) PB:PUMP BYPASS CONTACTOR FOR LOADING (2 {i8) 41292999.) PARTS NO. TYPE, ‘APPLICABLE MODEL BP] P | PB 271A2—62131 |CTTA150AH142XN [FB10715 olfolo FReZ0725 ol[-|[- 271F2-62181 |CTTASOOAH142xKN |FB20725 Gijon | ue. FRe20725 =[ofo 17712-02141 |sw200-018 ruse ol|elo 17@M2—62021 |Swa0-901 FRIO~18. FRBL ol[- [= 178M2-62031 |[swao-900 FRIO~18. FRBL =[efo 3 MARKED ©: APPLICATION (2P, * INSPECTION FOR BP, P AND PB CONTACTOR MEASURING COIL RESISTANCE (USE DIGITAL TESTER) PARTS NO. COIL RESISTANCE E71AB 08107 2058 271F2-62131 g0280 17772-62141 1602102 17eM2—62021 osa50 178M2—62031 55250 12BP, P AND PB GONTAGTOR ~ COMPOSED PARTS FOR BP, P AND PB CONTAGTOR 324199 4 BhRB CONTACTOR * CIRCUIT SYMBOL @ [ns COIL b CONTACT = EXPLANATION RB:REGENERATIVE BRAKING, ad BY 29> J IT 1S THE CONTACTOR FOR THIS FUNCTION. THIS CONTACT 1S CLOSED (N.C) ON DRIVE USUALLY. WHEN OPERATING THE REGENERATIVE BRAKING, THE CONTACT 1S OPENED. SFA aA Cnc) WER HRY eID FI. PARTS NO. TYPE ‘APPLICABLE NODEL 177H2—62641 | Swise—s0 Fe107165 171F2—62181 | Sw2i10-120 FB20725, FRB10~25. FRBL 17772-62111 | Sw210-182 Fe30 * INSPECTION FOR RB CONTACTOR MEASURING COIL RESISTANCE (USE DIGITAL TESTER) PARTS NO. COIL RESISTANCE 177H2-62641 e025a 171F2—62181 S059 17772-62111 100%109= COMPOSED PARTS FOR RB CONTACTOR RB CONTACTORC/D_ASS'Y = CIRCUIT SYMBOL LI ~ EXPLANATION IT DETECTS A FLOWING CURRENT FOR DRIVE MOTOR(DM) TO BE CONVERTED VOLTAGE SIGNAL FOR OurPUT, FT E-7 COMPO RAL SRCRHL, SECT URI ENTS PARTS NO. OUTPUT FEATURE APPLICABLE MODCL T77H2-60801 TO00A7aV F810~30, FRB20/25 1792-60701 BOOA7 AV FRE1O~18. FROL INSPECTION FOR C/0 Ass’ y Lw 61 i C/D ASS'Y rr DRIVE MOTOR FAs LW 61 POWER Sotnte 1 W 62: ee ; ys Re, Meu Bag. (09 Sd Pt ESI) WETI eras Ee JUDGING TO CHECK THE VOLTAGE AT THE TERMINALS OF MPU BOARD SIDE. 4-Mo4 0H OSE ES) MEASURING POSITION | VOLTAGE AT THE KEY SWITCH ON (CORRECT VALUE) (2-35) — (2-36) 12+ (2-28) - (2-36) £0. 15V THAN LESS 164 2 THERMISTOR ASS’ Y + CIRCUIT SYMBOL. = EXPLANATION IT DETECTS A TEMPERATURE FOR FITTING FACE OF THE DRIVING GBT DETECTING CONTROLLER’ s TEMPERATURE) EW ZOD] $044 Hh 9 SRA FEHENS (2210-5 EMS) PRATS NO. THERNISTOR TYPE. ‘APPLICABLE MODEL 18502-62021 | S02AT-2 FB10~90. FRB10~25, FRBL ~ INSPECTION FOR THERWISTOR ASS’ Y AREDE WEASURING RESISTANCE (USE DIGITAL TESTER) 322kQ AT A NORMAL TEMPERATURE (CORRECT VALUE) 3 (24®)(re Sg #e% > RESISTOR ASS’ Y (FOR VOLTAGE ON FB30) * CIRCUIT SYMBOL RW 11 18KQ 470Q YB 18 + EXPLANATION IT 1S LOCATED AT A PART OF INPUT TERMINAL FOR DETECTING LOW VOLTAGE OF THE MPU BOARD, TO LOWER BATTERY VOLTAGE 72V TO 48V LEVEL FOR USING MICRO-COMPUTER CONTROL. FB 30m HPUA-F OO GEERHM rd HEPES) qv TISE t oev vv FHT TAD OPTI RY MSZ, PARTS NO. RESISTANCE VALUE ‘APPLICABLE MODEL 17772-62071 | 18K +4702 FBs0 ~ INSPECTION FOR RESISTOR ASS" Y bik) ze FB90 D.C CHOPPER UNIT MEASURING RESISTANCE (USE DIGITAL TESTER) D.¢ fart ae7b 18.5 + 0.9kS (CORRECT VALUE) 18gev-4 ACCELERATOR (FB) = CIROUIT SYMBOL (tv 3) x. B (POWER SOURCE 5¥) (774 $8) S (ACCELERATOR VOLTAGE) 2KQ -<—1 sh) (R) LR (GND) & fb * EXPLANATION IT 1S FOR CONTROL OF DRIVING SPEED, AND OUTPUT THE SIGNAL IN PROPORTION TO PRESSING ANGLE OF THE ACCELERATOR PEDAL. 452° 9 J>ha-W MT, PICK ATI hy reR EL RNID. POTENTIOMETER PARTS No. | TYPE APPLICABLE MODEL 271A2-62101 | ScFKSz008 FB10~30 ~ INSPECTION FOR ACCELERATOR MEASURING RESISTANCE (USE DIGITAL TESTER) MEASURING POSITION (IN COUPLER) CORRECT VALUE ®) — (LR) 1.9 +01kQ CONDITION OF THE ACCELERATOR PEDAL S72 RE a - aR AT FREE 01£0.1kQ AT PRESSING 1 kQ AND OVER 23K FOR ADJUSTING THE PRESSING VOLUME, IN APPLYING VOLTAGE OF 5 = 0.01V INTO (B) ~ (LR) AT FULL PRESSING IT, ADJUST THE STOPPER BOLT TO BECOME 2.7 + 0, 2V IN (LY) ~ (LR) HrorFo Ny. )- (MO Mr stocivg BEE G1 FIEMATIL t-#e Boreakel (BR) - HA) Ro Oe 272 0. 2y we ET ie Zh yn TIE PZ 19ACCELERATOR (FRB) * CIRCUIT SYMBOL a romn ¢ Soe 8 5Y) 8 lk gi TICS ) (ACCELERATOR VOLTAGE) 5KQ << — LW) FRO) B(GND) ~ EXPLANATION IT 18 FOR BOTH CONTROLS OF DRIVING SPEED AND DIRECTION, AND OUTPUT THE SIGNAL IN PROPORTION TO TILTING ANGLE OF THE ACCELERATOR LEVER. EG AETF SEW Fay 9M 1G SHO 7 THOU TTI UNA DAL RS Oe REL URIS, POTENT IONETER PARTS NO. TYPE ‘APPLICABLE MODEL ] 29502-62251 SCFKS200E FRE10~25. FRBL ~ INSPECTION FOR ACCELERATOR wd Ae (FURMAKD) (NEUTRAL) (REVERSE) MEASURING RESISTANCE (USE DIGITAL TESTER) rome POSITION(IN COUPLER) GORRECT VALUE ] ap - @ 4.70. KQ i (FORWARD) 3. 0KQ AND OVER | “n- ® (NEUTRAL) 25:40. 2k a = (REVERSE) 2. 0KQ THAN LESS 23K FOR ADJUSTING THE NEUTRAL, IN APPLYING VOLTAGE OF 5::0.O1V INTO (LR)-(B), ADJUST THE POTENTIOETER’ S SCREW TO BECOME 2.5-0.1V IN (LY)-@). SEMA AA) - Ms Stool v 9€E eit Ge (HR) - (2) OSE oD 2G f0dV CO3TF et ey ert eeF/R SWITCH + CIROUIT SYMBOL. = EXPLANATION IT 1S TO CONTROL THE DRIVING DIRECTION OF THE TRUCK. 2 MICRO SWITCHES FOR F (FORWARD) AND R(REVERSE) ARE PROVIDED WITH THIS SWITCH FHI2OK3H tee ZI. F: FORWARD ()@) Ri REVERSE (it) 02792472 AMF F MyRIN WS, PARTS NO. SPECIFICATION APPLICABLE MODEL 2772-60401 | STANDARD SPEC. (R.H) | Fe10~90 2772-60411 | LOL SPEC. (LH) | dee eh hy Pea ey MF OE Ln te 6G A) NEASURING POSITION | LEVER OPERATION | CONDUCTION ‘AT FORWARD Yes 4 Gr) - &Y) AAT NEUTRAL No = AT REVERSE NO = ‘AT FORWARD Noe © - en AT NEUTRAL NO te AT REVERSE Yes 4 3 IN CASE OF THE ABOVE RESULT 1S NOT OBTAINED. MAKF AN ADJUSTMENT OR REPLACEMENT OF THE MICRO SWITCH. Lt Hey WIE ny > ME sae DHT TFT 21LIFTING POTENTIOMETER ~ CIRCUIT SYMBOL z crv ER) Br (POWER SOURCE 5V) Cok @e > (LIFTING VOLTAGE) SK ey 8 R (GND) a * EXPLANATION IT 1S TO CONTROL LIFTING SPEED, AND OUTPUT THE SIGNAL IN PROPORTION TO OPERATING ANGLE OF THE LIFT LEVER. THE METER 1S PROVIDED IN LIFT SECTION OF THE HYDRAULIC CONTROL VALVE. DIRE Qazbew Aa, VIRVIN- BUR RAR ESE HROIT, Dew WRT OIE IL MESS, PARTS NO. TYPE. APPLICABLE MODEL 27742-62701 | EWT AIX R30 €53| FB10~90, FRB10~25. FRBL iE * INSPECTION FOR LIFTING POTENTIONETER (HYDRAULIC CONTROL VALVE) MEASURING RESISTANCE (USE DIGITAL TESTER) MEASURING POSITION (IN COUPLER) CORRECT VALUE % 60 = Ms 4.7 + 0.3 ko a aey SHAFT CONDITION 2-07} ERE m - ® AT PUSHING 0.3 + 0. 3k ® & AT FREE 4.7 + 0.3kQ me a2LIMIT SWITCH ) No I @ = CIRCUIT SYMBOL. () = EXPLANATION DEADWAN BRAKE, VALVE LEVER AND BATTERY). EMER ESD CT, EAT MTU, 97) OUR yet- 217 ORME IT 1 FOR DETECTING EACH CONDITION STATE OF THE POSITION ANO LOOK FOR THE. PAK PARTS NO, TYPE PART OF USE ‘APPLICABLE MODEL | WIRINGUUE IST) PARKING BRAKE | Fo 10~90 © VALVE Fe10~30 @ 27142-64002 | zc- TILT, ATT, REACH | FRe10~25. FRBL wazss | BATTERY LOOK FRB10~25. FRBL @ BATTERY 1 @ BRAKE (DEADNAN) 1 @ ~ INSPECTION FOR LIMIT SWITCH NEASURING POSITION [PLUNGER | CONDUCTION (Com = (NO) | AT FREECT@)&) NOR AT PUSHINGUFiG) YES [ony 0) | AT FREE CBR) YES 4 l AT PUSHING Noe CHLREFY 23STOP LAMP SWITCH (FB) CIRCUIT SYMBOL RG 102 Nc w 110 “EXPLANATION 7yb-7v-4 % WO ALES Zo G7 7° ER USC ee, HOGL CAS. 2499 OGG BHM Uc) TSIM, PETE EMO ME ZF " EAE T RAT TNT oF W902 WHEN PRESSING THE ‘oot BRAKE, IT INDICATES TO STOP THE TRUCK WITH STOP LAMP GOES ON ‘AS WELL AS TRANSMITS THE CONTROLLER. THE SWITCH IS WITH b CONTACT(N.C), IT IS INSTALLED TO PUSH THE SWITCH WHEN NO PRESSING THE FOOT BRAKE(IN STATE OF N.0). PRATS NO. TYPE APPLICABLE MODEL 27262-42101 | 118141 0001 FB10~s0 ~ INSPECTION FOR STOP LAMP SWITCH $a PART OF SWITCH] CONDUCTION AT FREE Pi Yes % | ‘AT PUSHING Noe Tet RESISTANCE RANGE = 1 kQ (SET ZERO(0) POSITION BEFORE USE) 24MAGNETIC SWITCH * CIRCUIT SYMBOL. cas | 1@ matatatt | EPUMTION GA Osho AR Hy SLAY AN BRAT PNR MPU IO BPE Rs Bay 33 IT IS FOR CONTROLLING CHARGE. 3 PHASE A.C FLONS IN CHARGE, AND CUT OFF THE POWER SOURCEFOR CONTROL CIRCUIT OF MPU BOARD AND E.1.C TO OPEN THE b CONTACT. USUALLY, IT IS OPENED WITH 3 PHASE A.C CONTACT NOT TO FLOW THE CHARGING CURRENT. PARTS NO. TYP ‘APPLICABLE MODEL 27912-62513 | SD-N21 FB10~25, FRB20725 27292-62213 | SD-N35 FB25BAH, FESO 27022-63103 | SD-N12 FRB10~18. FREL ~ INSPECTION FOR MAGNET SWITCH + COIL RESISTANCE (USE DIGITAL TESTER) NORMAL VALUE 0. 2~0. 3KQ CHARGER CONTROL PANEL (FB) “CONDUCTION IN b CONTACT VT 1S NORWAL IF THERE 1S NOT A CONDUCTION IN PUSH OF THE CENTRAL BUTTON. 1939 BR TS) TRO RPAUMCIN GA reynr ey CHARGER & PS PANEL 25SPEED SENSOR = CIRCUIT SYMBOL = EXPLANATION IT IS INSTALLED AT THE PART OF DRIVE UNIT TO DETECT THE DRIVING SPEED. KAT 22h Be BIA £1 RUE EK TT PARTS NO. TPE ‘APPLICABLE MODEL 278A2-62431 | x809-0308-0 F810~90. FRB10~25. FRBL ~ INSPECTION FOR SPEED SENSOR IN EITHER CASE OF THE FOLLOMINGS 1S ABNORMAL, |. TERMINALS OF THE SENSOR 1S SHORT-CIRCUITED. (02) 2.A NEEDLE OF THE TESTER 1S NOT NOVED WHEN PUTTING) DETECTOR OF THE SENSOR TO THE STEEL PLATE, THEN TAKE IT APART IN A MOMENT. €2F- OSIM 2 9-1 (02) FH Coy FERS AB ST. BGP THD 0) De N DNS BE 9KUSE ANALOGUE TESTER WITH SMALLER DC. V RANGE. : Prey FAILS Bb DCVO-Bdta Les 26MPU BOARD “EXPLANATION MPUAS HE Peek Uy aes-9 EME AL LEME R) MPU BOARD PROVIDES WITH 8 BITS MICRO COMPUTER TO CONTROL THE SYSTEM(DRIVING & LOADING) WITHOUT (CHARGING. ( of 2 | ve | eae | ied | 0. cHOPPER chassis eee eae CIRCUIT | UNIT 4 crm (a) © Thi G CABT MOP 5 | ea gl ae DRIVING GET CONTROL | SENSO 4oyt + k—8) ©- aan Lh ee | wy e) a a OR i— an Tete aie ‘CONTROL i 7 RELAY FOR Sea \ ls | CRS wae a | SIMPLIFIED CIRCUIT LOCATION ON MPU BOARD 27MPU BOARD It | 110} 1-9} 1-8] 1-7] 1-6] 1-8 J 4] sia] ia 1-22} 1-21 | 1-20 | 1-19 | 1-18 | 1-17 1-16 1-15] 1-14] 1-13] 112 + VIEW FROM COUPLER ¢ ‘SPEED SENSOR GND ‘SPEED SENSOR GND Br_131_ [DRIVING LOI PRONBITIVE SrIToH WUT P 169 [P/E SWITCH INPUT BY 250%) | (DW PM THERMO SENSOR INPUT) P/E SWITCH INPUT (G1) | (OM THERWO SENSOR INPUT) 1-5 [0 168 [SPEED LIMITING SWITCH INPUT 0 168 [SPEED LINITING SWITCH INPUT 1-6 |" Br 13 _|F SwiTOH INPUT 1-7 Ye 21__ [ATT 1 SWITCH INPUT Wo 22 [AIT 1, 2 SWITCH INPUT 1-8 [| 8 199 |EPS SPEED SIGNAL GND 1-0 [We 67 [EPS SPEED SIGNAL 2 OUTPUT BW 136 | (SSC POTENTIONETER INPUT) 110 [YR 94 | LIFTING POTENTIONETER INPUT a LY 93 [ACCELERATOR INPUT Wer 69 | SPEED SENSOR INPUT BY 25 [SWITCH GND (2) | (PW THERWO SENSOR INPUT) LY 93 [ACCELERATOR INPUT Wer 89 | SPEED SENSOR INPUT BY 25 | SWITCH GND G 132 _ | REACH RELEASE SWITCH INPUT 116 [RL 24 | (SCAT SWITOH INPUT) ie [4 [TR SWITCH INPUT 17 [22 [AT 2 SwiTon INPUT Ye 21 [REACH SWITCH INPUT 1-18 [YB 20 [TILTING SWITOH INPUT YB 20 | TILTING SWITCH INPUT Ce Wa 135 [LIFTING SSC SWITCH INPUT) 1-20 [BG 96 [LIFTING POTFNTIONETER GND BG 96 | LIFTING POTENTIONETER GND 1-21 [BG 96 [ACCELERATOR GND BG96 [ACCELERATOR GND 1-22 [UW 95 [ACCELERATOR, LIFT 25V UW 95 [ACCELERATOR LIFT +5v 1-28 | 1-27) 1-26 | 1-25] 1-24] 1-23 1-84 | 1-33] 1-92 | 1-31 | 1-30] 1-29 + VIEW FROM COUPLER D FS FORWARD CHIME OUTPUT) AIT | PONER SOURCE FOR ACCESSORY W110 [BRAKE SWITCH INPUT BY 41 [WAIN GND TT ORA)_| WATN POWER SOURCE +48 RH 11 | CoMTACTOR COIL PoNER Samra mT WS 97 _ [BACK BUZZER OUTPUT Gy 15 | PARKING SWITCH INPUT (OSCILLATION STOPS) BY 41 [WAIN GND 11 0X6) [LOW VOLTAGE DETECT INPUT 019 | Pine SHTGH WPUT oz ci roe RD CONTAGTOR COTL PONER SOURCE m= W110 [BRAKE SWITCH INPUT BY 41 [WAIN GND RW TT [WAIN POWER SOURCE +48 RW_TT | CONTAGTOR COTL POWER SOUROE wna Frere WB 97__|BACK BUZZER OUTPUT BY 41 [WAIN GND RW 11 [LOW VOLTAGE DETECT INPUT RW Ti [CONTACTOR COIL POWER SOURGE (FRC) RIL TT [CONTACTOR COIL POWER SOURCE ewe revo 28MPU BOARD +FB10/15 +FB20725 + VIEN FROM COUPLER A ~ ELECTRIC SEALED (CUSTOMERIZED SPEC.) : 3 WR 17 +3 TON SERIES: %4 RB 10,%5 YB 18 2-8 | 2-7] 2-6] 2-5 2-4 | 2-3 | 2-2] 2-1 2-16] 2-15 | 2-14 2-12 2-12| 2-11 [2-10] 2-9 wo [TERMINAL TRE COLOR no [ie RW 128 FB, FRE IN COMMON PU F6,_FRB_1W COMMON CONTACTOR COIL POWER SOURCE wp.) JURE NO. TERIINAL NAME CONTACTOR COIL. PORER SOURCE WF 8. F 70) 2-2 _| Br 129_[F CONTACTOR COIL OUTPUT ‘GONTACTOR COTL POWER SOURCE (R/C) 23 | 0 125 _[R CONTACTOR COIL OUTPUT ‘BP CONTACTOR COIL OUTPUT 2-4 | 6 126 [RB CONTACTOR COIL OUTPUT 25 | W122 _[P CONTACTOR COIL OUTPUT PB CONTACTOR COIL OUTPUT 26 | BY 41_[WAIN GND MAIN GND 2=T_| GW BT | presen cna Sm CxT TOTS) TRANSMISSION (TXD) 2-8 | GR 82_ [RECEPTION RXD) CORMUNTCATION. GND + VIEW FROM COUPLER B 2-29 2-28] 2-27]2-26 2-25 | 2-24 | 2-23 | 2-22 | 2-21 | 2-20| 2-19| 2-18 | 2-17 2-42 | 2-41 | 7-40 | 2-20 2-38 | 2-37 | 2-36 | 2-25 | 2-34 | 2-93 | 2-22 | 2-21 | 2-20 PU FB,_FRE_IN COMMON FB._FRB_IN COMMON ie TERWINAL NARE ‘a Peete TERMINAL NAME TOADING TGBT COLLECTOR LOADING T6BT EITTER(TS) 216 | GR 72 | LOADING 1GBT GATE (TS) ‘231_| GB 7 [LOADING (GBT ENITTER(T#D (FOR 2TON) 219 | GW 73 [LoADina vast GATE a) Fon 27 | 2-32 | YW 64 | LOADING SHUNT (>) 220 | YL 65 | LOADING SHUNT (-) 2-33 [We 46 [DRIVING 1e6T EMITTER) 221 | Wa 44 | DRIVING 1GBT GATE CTI) 234 re 2-35 | Wet [C/D +12v 2m | Wel | CD INPUT 296 | BY 62 | C/D GND 224 | P49 | THERWISTOR INPUT 237 | BW 50 _| THERWISTOR GND 2-25 | WR 43 [DRIVING 1GBT COLLECTOR 236 2-26 | R39 [DRIVING MOTOR DA 230 | ¥40_| DRIVE WOTOR AA 227 | G37 [initia excireo waneric resisron nif 2-40 | G37 __| WITIA BLCITED wimETiC RESISTOR mT 2-28 | Y40[IWiTiAL ExciTED waqieric outpuT [2-41 | ¥ 40 | INITIAL EXCITED MAGNETIC OUTPUT 229 | Br 36 | iwiviat excireo wie wesiston na [2-42 | Br 36 | WIVIA EXCITED waneTIC RESISTOR AMPU BOARD + FB WITH STANDARD SPECIFICATION PARTS. NO, i ae Paid WET tenes ir aia 17742-60301 ~ 00201 i -eowoe | rei0vis | ooz02 ~ orzie i aE usTOR THEO LOGIC 60303 o1219 ~ ERINTED BOARD TW CORON WITH FR 177P2-60301 ~ 00150 w | oD 60302 raons | St > ote : A. GWE NTE TWO LTE 60312 00341 ~ 00854 ies — WITH 2 coe oe ‘SPEC. 60313 0855 ~ re RENTED BOARD 18 COMMON WITH FRB 17772-60301 a3 ~ 00209 t inh 60302 00210 ~ pee BOARD IN COMMON WITH FRB (WOTE) NO INTERCHANGEABLE MPU BOARD 1. IN CASE OF THE WPU BOARD P/NO. 177H2-60301 1S INSTALLED ONTO THE TRUCKS SERIAL NO. 00202 AND AFTER. IN ANOTHER CASE OF THE MPU BOARD P/NO. 177P2-60301, P/NO. 177P2-60312 OR P/NO. 177P2-60313 1S INSTALLED ONTO THE TRUCK SERIAL NO. 00151 THRU 00340, = GUT OUT THE WIRES FOR EACH 1-4 AND 1-14 TERWINALS OF THE MPU BOARD. 2. IN GASE OF THE MPU BOARDS P/NO. 17H2-60302 OR P/NO. 177H2-60303 IS INSTALLED ONTO THE TRUCKS SERIAL NO.00201 AND BEFORE. IN ANOTHER CASE OF THE NPU BOARD P/NO. 177P2-60302 1S INSTALLED ONTO THE TRUCKS SERIAL NO. 00150 AND BEFORE OR SERIAL NO. 00341 AND AFTER. — WAKE SHORT-CIRCUITED BY WIRES FOR EACH 1~4 AND 1-14 TERMINALS TO GND OF THE MPU BOARD. 52. THE EFFECTIVE SERIAL NOS. APPLY CORRESPONDINGLY FB WITH(EO SPECIFICATIONS 10 THE TRUCKS WITH ST SPECIFICATION. PARTS NO. FOR Exe speo, | PARTS NO. FOR EXE SPEC. T] joy toy e | INTERCHAN (VIM LESS + WITH SEAT GEABILTY REMARKS (VIM LESS) mies WoDEL ao 177H2-60321 177H2-60331 FB10/15, f= PRINTED BOARD IN COMMON —60322 -60332 WITH FRB MODEL. 177P2-60321 177P2-60331 F820/25 $8 PRINTED BOARD IN COMMON 60322 —60332 ae 17772-60321 |177T2~-60331 Yes io i PRINTED BOARD 1W COMMON 60322 60332 WITH FRB MODEL 30MPU BOARD ‘FAB WITH STANDARD SPECIFICATION APPLICABLE TNTERGHAN PARTS NO. ee EFFECTIVE SERIAL wo. | Ta REMARKS 178A2-60301 x FRei0/19 —f— 60302 © (ABILITY uP 178M2-60301 x FRBI4~18 +f —60302 © fasiuity 178R2-60301 x FRB20/726 an -60302 © [ABILITY uP 178w2-60301 FRBL 31 eee ie2. PROCEDURES FOR OVERHAULING THE MOTORS/METER PANEL WORK ORDER POINT [2.1 OVERHAUL OF THE DRIVE MOTOR (1) REMOVE SNAP RING SECURING THE FAN FROM ARMATURE SHAFT. (2) USING 2 BOLTS AS THE PICTURE, REMOVE THE FAN FROM ARMATURE SHAFT. IN THIS WORK, SCREW THE BOLT ALTERNATIVELY IN EVEN TO SEPARATE THE FAN FROM IT, (3) TAKE BRUSH COVER UT AFTER RELEASING ITS LATCH. \ (4) LIFT BRUSH SPRING HALF THE WAY | DO NOT STRETCH FROM BRUSH HOLDER TOP BY USING [BRUSH WIRE BY BRUSH SPRING PULLER(AS BENT STEEL |FORCE. WIRE) AND ATTACH BRUSH SPRING TO BRUSH SIDE FACE AND LOCK. 32WORK ORDER POINT (5) PUT MOTOR UPRIGHT WITH BRACKET (F) UPWARD, AND REMOVE 6 BOLTS SECURING BRACKET (F) TO YOKE, (6) SEPARATE BRACKET (F) FROM YOKE BEFORE THAT. REMEMBER THE MARK POSITION NOT TO| SHIFT THE BRACKET (F) IN ASSEMBLY, AND WRAP VINYL TAPE AROUND ARMATURE SHAFT SPLINE FOR PREVENTING DAMAGE. (7) SEPARATE ARMATURE FROM YOKE, PAY ATTENTION CAREFULLY. INOT TO HIT JARMATURE TO FIELD COIL. (8) PRIOR TO SEPARATING BRACKET (R) FROM YOKE, TAKE SCREWS OUT FROM PART OF BRUSH HOLDER TO SECURE THE PIG TAIL (LEAD WIRE) OF BRUSH WITH FIELD COIL. 33WORK ORDER POINT (9) REMOVE 4 BOLTS, AND SEPARATE BRACKET (R) FROM YOKE, IF IT 1S TOO TIGHT TO SEPARATE THEM, GENTLY HIT BRACKET (R) AT THE INNER SIDE OF ‘SURROUNDING WITH A WOODEN HANMER OR THE LIKE. AT THIS TIME, DO NOT HIT THE PIGTAIL OF THE BRUSH. (10) SEPARATE BRUSH HOLDER FRON BRACKET (R) (4 SECURING BOLTS) CUDRENOVAL OF BEARING SHOULD BE PERFORMED ONLY WHEN ABNORMAL NOISE (OR JAMMING OF BEARING 1S NOTICED. FOR THIS PURPOSE, USE A SMALL PULLEY PULLER, AND APPLY A FORCE TO THE INNER RACE OF THE BEARING, IF YOUR NAIL 1S DIFFICULT TO CATCH THE INNER RACE, APPLY A FORCE ON THE OUTER RACE. DO NOT RE-USE THE REARING ONCE RENOVED. (12) IN CASE OF REMAINING KEY AT THE SHAFT, TAKE IT OUT, THEN REMOVE THE BEARING, WHEN ASSEMBLING IT, TEMPORARILY JCLAMP CABLES OF ITHE BRUSH HOLDER. 34WORK ORDER POINT (13) COMPOSED PARTS FOR DRIVE MOTOR. REASSEMBLE DRIVE MOTOR IN THE IREVERSE SEQUENCE OF DISASSEMBLY, JUSING CAUTION FOR THE FOLLOWING. (14) WHEN INSTALLING A NEW BEARING ON | BE SURE TO ‘ARMATURE SHAFT, USE A CYLINDRICAL |ROTATE IT JIG AND APPLY A FORCE TO THE INNER [SMOOTHLY AFTER RACE OF THE BEARING. INSTALLING, 35WORK ORDER. POINT 2.2 OVERHAUL OF THE PUNP NOTOR (1) TAKE BRUSH COVER OUT AFTER RELEASING ITS LATCH. (2) LIFT BRUSH SPRING HALF THE WAY FROM BRUSH HOLDER TOP BY USING BRUSH SPRING PULLER (AS BENT STEEL WIRE) AND ATTACH BRUSH SPRING TO BRUSH SIDE AND LOCK. (3) PUT MOTOR UPRIGHT WITH BRACKET (F) UPWARD, AND REMOVE 4 BOLTS SECURING BRACKET (F) TO YOKE. (4) SEPARATE BRACKET (F) FROM YOKE. BEFORE THAT, REMEMBER THE MARK POSITION NOT TO SHIFT THE BRACKET (F) IN ASSEMBLY. DO NOT STRETCH BRUSH WIRE BY FORCE. 36WORK ORDER POINT (5) SEPARATE ARMATURE FROM YOKE PAY ATTENTION CAREFULLY. INoT To HIT JARMATURE TO FIELD COIL, (6) PRIOR TO SEPARATING BRACKET (R) FROM YOKE, TAKE SCREWS OUT FROM PART OF BRUSH HOLDER TO SECURE THE PIG TAIL(LEAD WIRE) OF BRUSH WITH FIELD COIL, (7) REMOVE 4 BOLTS, AND SEPARATE BRACKET (R) FRON YOKE GENTLY TO HIT BRACKET (R) AT THE INNER SIDE OF SURROUNDING WITH A WOODEN HAMMER OR THE LIKE. AT THIS TIME, DO NOT HIT THE PIG TAIL OF THE BRUSH. (8) SEPARATE BRUSH HOLDER FROM BRACKET (R) (4 SECURING BOLTS) 37POINT (9) ONLY IN THE EVENT OF ABNORMAL NOISE OR JAWMING OF BALL BEARING, REPLACE IT WITH NEW ONE. WHEN REMOVING, USE A SMALL PULLER, AND APPLY A FORCE TO THE INNER RACE OF BEARING, DO NOT RE-USE THE BEARING ONCE REMOVED. (10) COMPOSED PARTS FOR REASSEWBIF PUMP MOTOR IN THE REVERSE |SEQUENCE OF DISASSEMBLY, USING JCAUTION FOR THE FOLLOWING, (TI)NHEN INSTALLING A NEW BEARING ON ARMATURE SHAFT, USE A CYLINDRICAL JIG AND APPLY A FORCE TO THE INNER RACE OF THE BEARING. BE SURE TO ROTATE. IT [SMOOTHLY AFTER INSTALL INGWORK ORDER. POINT 2.3 OVERHAUL OF THE METER PANEL. LOOSEN NUT SECURING HANDLE WHEEL. (D0 NOT SEPARATE IT YET) (2) AS SHOWN IN PHOTO, LIGHTLY HIT BY HAND FOR PUSHING UP THE HANDLE WHEEL AT BOTH END TO LOOSEN IT, THEN REMOVE IT WITH NUT. (3) REMOVE 8 SCRENS THE SEPARATE COVER(A) FROM HANDLE COLUMN. (4) REMOVE 4 BOLTS THEN SEPARATE METER PANEL FROM HANDLE COLUMN, (1) REMOVE CAP OF THE HORN SWITCH AND} 39WORK ORDER POINT (5) FALL METER PANEL DOWN SIDEWAYS WITH CARE OF THE HARNESS, (6) DISCONNECT COUPLER CONNECTING WITH LoD BOARD. (1) REMOVE 4 SCREWS (RIGHT AND LEFT EACH 2) AS POINTED IN PHOTO. (8) SEPARATE COVER(C) FROW COVER (B) 40WORK ORDER POINT (9) SEPARATE METER PANEL ASS’ Y FROM COVER(B) TO REMOVE 5 SCREMS. (10) REMOVE ALUMINUM PLATE (WITH 2 ‘SOREWS) AT THE BACK SIDE OF THE WETER PANEL ASS'Y, THEN SEPARATE LOD BOARD FROM IT(WITH 6 SCREWS) (11) REASSEMBLE IN THE REVERSE PROCEDURE OF DISASSEMBLY. 41vT™M MP US HEE 1 pele eee rey Pe] 8 121 8 Lee FB10~25 - 6 73vT™ MP Ud&4R MPU BOARD @ Pena aT PET or YU eet cleat a © 74 FB30 - 6BuBE-—6cog feeue wees SABES