TCM FB1O-8 - FB15-8 - FB18-8 - FB20-8 - FB25-8 - FB25-8LB - FB25-8v - FB30-8V - FB35-8S Forklift Truck Service Manual

https://truckmanualshub.
com/
No.SEB-7POBE
TCM⑮
@~æ.WD@国間A間切I&[S
FORKLIFTTRUCK
Counter8alanced
FB唱O
-S
FB唱5
-s
FB唱8
-s
FB
20-s
FB
25-s
FB
30-s
F
B25
-SLB
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B25-sv
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B30-sv
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B35-s
s
TCMCORPORATION
https://truckmanualshub.com/
FOREWORD
The new TCM’s FB-8 Series battery-powered forklift trucks are provided with a newly designed
speed control system and AC motors for both the traveling and load handling systems to assure
high performance operation.
The trucks of this series are also provided with a self-diagnosis function which keeps watching
the operating statuses of the main control systems of the truck. If the truck has a trouble, the
function detects the trouble and displays the result of diagnosis. The maintainability is thus
improved.
As for mobility, since the high capacity batteries and high power drive motor are used, the first-
class acceleration, gradeability, and traveling performance are achieved.
Controllability is also improved by the standard equipped power steering unit.
To save power, the acceleration and traveling speeds are selectable and made changeable
according to working conditions. Also for effective use of the battery, a regenerative device is
provided to send back counter electromotive force to the battery.
This Service Manual is intended to provide the maintenance personnel with helpful information
of the structures of the major components and with instructions on the maintenance and repair of
such components. We hope it will be much help for your servicing and maintenance operations.
December 2012
SPECIFICATIONS (1)
Truck model FB10-8 FB15-8 FB18-8 FB20-8
Item
Performance
Max. load kg [lbs] 1000 [2000] 1500 [3000] 1750 [3500] 2000 [4000]
Load center mm [in.] 500 [24] ← ← ←
Max. lifting height mm [in.] 3000 [118.1] ← ← ←
Tilting angle
Fwd ° 6 ← ← ←
Bwd ° 12 ← ← ←
Free lift A mm [in.] 155 [6.1] ← ← 110 [4.3]
Mast tilting time (Fwd - Bwd) s 2.0 - 1.4 ← ← 2.7 - 2.0
Fork lifting speed
Loaded mm/s [fpm] 390 [76.8] 350 [68.9] 330 [65.0] 290 [57.1]
Unloaded mm/s [fpm] 580 [114.2] ← ← 510 [100.4]
Travel speed
Loaded km/h [mph] 14 [8.7] ← ← ←
Unloaded km/h [mph] 16 [9.9] ← ← ←
Gradeability
(Starting on an uphill when loaded) 1/7 ← ← ←
Min. turning radius
(Outermost part of truck) EPS: B mm [in.] 1700 [66.9] ← 1790 [70.5] 1950 [76.8]
Orbitrol type: 1800 [70.9] ← 1890 [74.4] 2070 [81.5]
Min. intersecting aisle C mm [in.] 1690 [66.5] ← 1730 [68.1] 1895 [79.6]
Dimensions mm [in.]
Overall length (includ. fork) D 2875 [113.2] ← 2975 [117.1] 3315 [130.5]
Overall width E 1070 [42.1] ← ← 1150 [45.3]
Overall height (Overhead guard) F 2080 [81.9] ← ← 2125 [83.7]
EXN: 2140 [84.3] ← ← 2185 [86.0]
Overall extended height 4030 [158.7] ← ← ←
Wheel base G 1250 [49.2] ← 1350 [53.2] 1400 [55.1]
Tread
Front wheels H 910 [35.8] ← ← 955 [37.6]
Rear wheels J 900 [35.4] ← ← 950 [37.4]
Fork overhang K 375 [14.8] ← ← 435 [17.1]
Rear overhang L 330 [13.0] ← ← 410 [16.1]
Fork size 920x100x35 1070x122x40

(Length L x Width M x Thickness N) [36.2x3.9x1.4] ← ← [42.1x4.8x1.6]
200 - 920 245 -1020
Fork spacing Q [7.9 - 36.2] ← ← [9.6 - 40.2]
90 [3.5] 100 [3.9]
Minimum under clearance (Rear axle) ← ← (Rear axle)
Tow pin height 390 [15.4] ← ← 440 [17.3]
Weight
Service Weight with std. batteries kg [lbf] 2680 [5908] 2710 [5976] 3030 [6680] 3500 [7716]
The values in the Performance section are given for trucks operating in the Super mode.
SPECIFICATIONS (2)
Truck model FB25-8LB FB30-8
FB25-8 FB35-8S
Item FB25-8V FB30-8V
Performance
Max. load kg [lbs] 2500 [5000] ← 3000 [6600] 3500 [7000]
Load center mm [in.] 500 [24] ← ← ←
Max. lifting height mm [in.] 3000 [118.1] ← ← ←
Tilting angle
Fwd ° 6 ← ← ←
Bwd ° 12 ← ← 10
Free lift A mm [in.] 110 [4.3] ← 165 [6.5] 170 [6.7]
Mast tilting time (Fwd - Bwd) s 2.7 - 2.0 ← 2.5 - 2.0 3.5 - 2.5
Fork lifting speed
Loaded mm/s [fpm] 265 [52.2] ← 290 [57.1] 240 [47.2]
Unloaded mm/s [fpm] 510 [100.4] ← 490 [96.5] 410 [80.7]
Travel speed
Loaded km/h [mph] 14 [8.7] 13.5 [8.4] 14 [8.7] ←
Unloaded km/h [mph] 16 [9.9] 15.5 [9.6] 15 [9.3] ←
Gradeability
(Starting on an uphill when loaded) 1/7 1/8 ← 1/10
Min. turning radius
(Outermost part of truck) EPS: B mm [in.] 1970 [77.6] 2065 [81.3] 2140 [84.3] 2360 [92.9]
Orbitrol type: 2100 [82.7] 2200 [86.6] 2290 [90.2] 2500[98.4]
Min. intersecting aisle C mm [in.] 1905 [75.0] 1955 [76.9] 2050 [80.7] 2250 [88.6]
Dimensions mm [in.]
Overall length (includ. fork) D 3355 [132] 3460 [136] 3580 [140.9] 3805 [149.8]
Overall width E 1150 [45.3] ← 1225 [48.2] 1380 [54.3]
LB: 2250 [88.6] 2190 [86.2]
Overall height (Overhead guard) F 2125 [83.7] 2190 [86.2]
V: 2100 [82.7] V: 2100 [82.7]
Overall extended height 4030 [158.7] ← 4260 [167.7 ] ←
Wheel base G 1400 [55.1] 1545 [60.8] 1600 [63.0] 1800 [70.9]
Tread
Front wheels H 955 [37.6] ← 1000 [39.4] 1140 [44.9]
Rear wheels J 950 [37.4] ← ← ←
Fork overhang K 435 [17.1] ← 480 [18.9] 500 [19.7]
Rear overhang L 450 [17.7] 410 [16.1] 430 [16.9] ←
Fork size 1070x122x40 1070x125x45 1070x150x50

(Length L x Width M x Thickness N) [42.1x4.8x1.6] ← [42.1x4.9x1.8] [42.1x5.9x2.0]
245 - 1020 250 - 1090 300 - 1090
Fork spacing Q [9.6 - 40.2] ← [9.8 - 42.9] [11.8 - 42.9]
100 [3.9] 90 [3.5]
Minimum under clearance (Rear axle) (Rear axle) ← ←
Tow pin height 440 [17.3] ← 475 [18.7] ←
Weight
Service Weight with std. batteries kg [lbf] 3910 [8620] LB: 4400 [9700] 4640 [10200] 5240 [11600]
V: 4290 [9460]
The values in the Performance section are given for trucks operating in the Super mode.
1 - 2.5 t:1~2.5t 4030 3~3.5t
4030 :[158.7] 3 - 3.5: t:4260
4260 [167.7]
E
3000 [ 118.1]
3000 Q
H
N
A
M
P
K
D
Fig. 1 Overall Dimensions

C
L
B
F J
Unit: mm [in.]
Table 1. Maintenance Standard List

FB20-8
Truck model FB10-8 FB25-8 FB30-8
FB18-8 FB35-8S
Item FB15-8 FB25-8LB FB30-8V
FB25-8V
Traction mm [in.] * * * * *
Motor brush size and wear Pump mm [in.] * * * * *
limit Power steering
(EPS type only) mm [in.] 22 - 13 [0.87 - 0.51] ← ← ← ←
Traction N{kgf}[lbf] * * * * *
Motor brush spring force Pump N{kgf}[lbf] * * * * *
Power steering
(EPS type only) N{kgf}[lbf] 11.8 {1.2} [2.7] ← ← ← ←
Voltage relay check voltage (20°C) (V) 58.8±0.2 ← ← 87.0±0.2 ←
Electric system
Normal (h) 14 ← ← ← ←
Timer operating time
Fail (h) 16 ← ← ← ←
Controller current limit value P (A) * * * * *
(Traction motor lock current) E (A) * * * * *
Traveling system main circuit (A) 400 ← 500 400 ←
For control circuit
(battery power supply) (A) 10 ← ← ← ←
Lift lock (A) 2 ← ← ← ←
Battery charger primary side
Fuses (thermal relay) (A) 24 ← 34 40 ←
Battery charger secondary side (A) 130 ← 130/200 130 ←
For control circuit
(key switch power supply) (A) 10 ← ← ← ←
For accessory circuit (A) 10 ← ← ← ←
0.85±0.03 {8.5±0.3} 1.00±0.03 {10.0±0.3} ← 0.8±0.03 {8.0±0.3} 0.85±0.03 {8.5±0.3}
2
Front (single) MPa{kgf/cm }[psi] [123.3±4.35] [145.0±4.35] [116.0±4.35] [123.3±4.35]
Tire air (double) 0.7±0.03 {7.0±0.3} ← ← ← ←
pressure [101.5±4.4]
0.85±0.03 {8.5±0.3} 0.90±0.03 {9.0±0.3}
Rear MPa{kgf/cm2}[psi] ← ← *
[123.3±4.35] [130.5±4.35]
Steering axles and wheels
150-175 {15-17.5} 370-420 {37.8-42.8} 470.7-549.2

Front N-m{kgf-m}[lbf-ft] [110.6-129.1] ← [273-310] {48-56} [347-405] ←
Hub nut tightening torque
127.5-190.3 13.0-19.4}
Rear N-m{kgf-m}[lbf-ft] [94-140] ← ← ← ←
96.1-110.8 {9.8-11.3} 96.1-110.8 {9.8-11.3}
Axle shaft mounting bolt tightening torque N-m{kgf-m}[lbf-ft] [70.9-81.7] ← *
[70.9-81.7] ←
60.8-90.2 {6.2-9.2}
Front N-m{kgf-m}[lbf-ft] [44.8-66.5] ← * * *
Split rim assembly bolt
tightening torque 30.4-45.1 {3.1-4.6} 60.8-90.2 {6.2-9.2}
Rear N-m{kgf-m}[lbf-ft] [22.4-33.3] ← [44.8-66.5] ← ←
Steering axle gap in fore-and-aft direction mm [in.] less than 1 [0.039] ← ← ← ←
Steering axle center pin diameter (EPS type only) mm [in.] 40+0 +0
-0.1 [1.57-0.004 ] ← 50+0 +0
-0.1 [1.97 -0.004 ] ← ←
Steering axle bushing inner diameter mm [in.] +0.1 +0
40-0 [1.57-0.004 ] ← 50+0 +0
-0.1 [1.97 -0.004 ] ← ←
Steering wheel play in rotating direction mm [in.] 75±25 [2.95±0.98] ← ← ← ←
Steering system
Camber angle ° 1 ← ← ← ←
EPS type 1700+50-0 [66.9-0
+1.97
] 1790+50 +1.97
-0 [70.5-0 ] FB20: 1950+50 +1.97
-0 [76.8-0 ] 2140+50
-0 [84.3-0
+1.97
] 2360+50 +1.97
-0 [92.9-0 ]
+50 +1.97
Minimum turning radius EPS type FB25: 1970-0 [77.6-0 ]
mm [in.] FB20: 2070 [81.5]
Orbitrol type 1800 [70.9] 1890 [74.4] 2290 [90.2] 2500 [98.4]
FB25: 2100 [82.7]
Power steering relief pressure setting MPa{kgf/cm2}[psi] * * * * *
Brake pedal height mm [in.] 97 [3.8] ← ← 110 ←
Brake pedal play mm [in.] 10±5 [0.393±0.197] ← ← ← ←
Brake pedal height when depressed fully mm [in.] 60±10 [2.362±0.393] ← ← ← ←
Unloaded within 2.5 m ← ← ← ←
Foot pedal braking effect
Loaded within 2.5 m ← ← ← ←
Parking brake lever operating force N{kgf}[lbf] * * * * *
Brake system
Held in position on Held in position on

Unloaded 20% slope ← 16.7% slope ← ←
Parking brake braking effect
Loaded Held in position on ← ←
Held in position on
←
14.3% slope 12.5% slope
0.25-0.4
Clearance between brake drum and lining mm [in.] [0.0098-0.016] ← ← ← ←
Lining thickness mm [in.] 5-3 [0.197+0
+0
-0.118 ] ← 5.6+0 +0
-3.6 [0.22-0.142 ] 8+0 +0
-6 [0.31-0.236 ]] ←
Brake drum inner diameter mm [in.] 254+2 +0.079
-0 [10-0 ] ← 280+2 +0.079
-0 [11.0-0 ] 314+2-0 [12.4-0
+0.079
] ←
215.7-235.4 {22-24} 470.7-549.2 {48-56}
Brake drum mounting bolt tightening torque N-m{kgf-m}[lbf-ft] * * [159.1-173.6] [347.2-405.1] ←
117.7-137.3 205.9-225.6 {
Back plate mounting bolt tightening torque N-m{kgf-m}[lbf-ft] {12-14} [86.8-101.3] ← 21-23} [151.9-166.4] ← ←
←
dling system
Fork thickness mm [in.] 35+0 +0

-4 [1.38-0.157 ] 40+0 +0
-4 [1.57-0.157 ] 45+0 +0
-6 [1.77-0.236 ] 50+0 +0
-5 [1.97-0.197 ]
Load han-
Opening of fork tips mm [in.] within 10 [0.394] ← ← ← ←

Difference in height between right and left fork tips mm [in.] 0±5 [0±0.197] ← ← ← ←
Chain length mm [in.] 19.05+50-0 ← ← 25.4+50
-0 ←
Tilt cylinder piston rod lock bolt and nut 107.9±20.6 {11.0±2.1}
N-m{kgf-m}[lbf-ft] ← ← ← ←
Hydraulic system
tightening torque [79.6±15.2]

Lift cylinder natural drop mm [in.]/min less than 75 [2.95]/10 ← less than 60 [2.36]/10 less than 50 [1.97]/10 ←
Tilt cylinder natural tilt (extension of piston rod) mm [in.]/min less than 25 [0.98]/10 ← less than 20 [0.79]/10 ← ←
Fork lifting speed (Unloaded) mm [in.]/sec 580+50-0 [22.8-0
+1.97
] ← 510+50
-0 [20.1-0
+1.97
] 490+50 +1.97
-0 [19.3-0 ] 410 +50
-0 [16.1+1.97
-0 ]
+0.49 +5 +0.49 +5 +0.49 +5
13.7-0 {140-0 } 15.7-0 {160-0 } 17.2-0 {175-0 }
Control valve relief pressure setting MPa{kgf/cm2}[psi] +71.1 +71.1 +71.1 ← ←
[1990-0 ] [2277-0 ] [2495-0 ]
Overhead guard mounting bolt and nut 31.4-47.1 {3.2-4.8}
N-m{kgf-m}[lbf-ft] ← ← ← ←
device
Safety
tightening torque [23.2-34.7]

59.3±11.9 {6.05±1.21}
Load backrest mounting bolt tightening torque N-m{kgf-m}[lbf-ft] [43.7±8.8] ← ← ← ←
01. CAUTION TO TAKE WHEN SERVICING THE TRUCK
* Before servicing the truck, make sure to:

1. Park the truck on a level surface and jack up the drive wheel off the floor or ground.
Make sure there is no obstacle above and around the truck before operating the load handling
system.
* Caution to take when measuring, inspecting or repairing:

2. Before connecting or disconnecting wire harness couplers, make sure the key switch is turned off
and the battery receptacles are disconnected.
3. When measuring the resistance of wire harness couplers with a multimeter, connect the probes to
the lead wire side of the coupler.
4. When inspecting the truck with the forks raised, support the forks to prevent them from falling
unexpectedly.
5. When inspecting the truck with the mast advanced, put a pallet between the mast and the front
guard of the truck to prevent the mast from retracting unexpectedly.
6. Inspection and repair of the truck must be performed only by qualified service personnel
authorized by TCM.
Counterbalanced model Reach model

02. BASIC SERVICING KNOWLEDGE

1. Installing bearings
JIG
When installing a bearing onto a shaft, tap its
inner race with a mallet as shown in Figure 02.1.
When installing a bearing into a case, tap its outer
race.
When removing, use the same procedure as for
installing.
Fig. 02.1 Installing bearings
2. “O”-rings
① Use “O”-rings free from molding fault or damage.
② Clean “O”-rings and their mounting area and apply grease or hydraulic oil to them.
③ When installing “O”-rings, do not expand them so excessively that they suffer permanent
deformation. Also do not roll them when installing; otherwise they might stay twisted, causing oil
leakage.
④ When using an “O”-ring and back-up ring as
a set, such as when hydraulic pressure is high,
position the “O”-ring at the side which receives Pressure
the oil pressure.
Fig. 02.2 “O”-ring location
3. Oil seals
① Oil seals should be installed with the seal lip pointed toward the lubrication or hydraulic oil.
② When installing an oil seal on a housing, apply a thin coat of packing cementing agent on the
oil seal outer ring and inside the housing to prevent oil leakage through the fitting area. It is
recommended to use a suitable jig to apply uniform pressure when mounting oil seals.
JIG JIG JIG
Fig. 02.3 Installing Oil Seal

③ When installing an oil seal onto a shaft, apply

lubricating oil or grease to its seal lip and the JIG
mounting surface of the shaft. For a double-

lip type, fill grease by 1/3 to 1/2 of the space
between the lips.
When inserting an oil seal into a case, use care
to damage the seal lip. It is good practice to use
a suitable conical sleeve. SLEEVE
Fig. 02.4 Installing Oil Seal
4. Using LOCTITE
(1) Procedure for using LOCTITE
① Clean or degrease the surface of parts you are going to apply LOCTITE, using trichloroethylene,
acetone, ether or alkaline solution.
② Blow dry them with compressed air or allow to air dry at room temperature sufficiently.
③ Apply specified LOCTITE.
(2) Removing parts

When removing parts which were installed with the application of LOCTITE, use tools such as a
spanner, wrench, and pulley remover.
If you fear that a part may break due to the effect of LOCTITE if forcibly removed, heat the part to
200 to 250°C [392 to 482°F] with a soldering iron or gas burner.
Remember that parts are very hot after heating. Use caution not to get burnt when
removing them.
(3) Reinstalling parts

① When destroyed, LOCTITE remains as white powder on the threads of bolts. You can apply a
new coat of LOCTITE again over their surface.
Note: For example, if a bolt turns slightly due to bolt torque checking, remove the bolt and apply
LOCTITE again and reinstall.
② If LOCTITE is used for the surface of a flange, it is necessary to remove hardened LOCTITE with
a wire brush when reinstalling the flange.
5. How to use a power wrench

Power wrenches have their respective torque multiplying factors. Refer to the product catalog of
each power wrench.
It should be noted that a value obtained by multiplying the output torque of a torque wrench by the
multiplying factor of a power wrench is not necessarily an output torque.
Remember this especially when the tightening torque is strictly specified.
03. CLEANING
1. General metallic parts

① Clean parts thoroughly using cleaning fluid. It is recommended that parts be immersed in cleaning
fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned.
② Cast parts should be cleaned with cleaning solvent or steam cleaned.
③ If a part is severely contaminated, use a wire brush or a piece of wood or metal to scrape off
contaminants from the part. Wash it in cleaning fluid once, before cleaning it completely.
However, do not use a wire brush for cleaning sliding surfaces or machined surfaces.
④ Oil passages must be cleaned with a steam cleaner. After checking for clogging with a piece of
wire, they also should be cleaned with cleaning fluid or with compressed air.
⑤ Some parts may be cleaned in hot solution tanks with mild alkaline solution. Parts should remain
in solution long enough to be thoroughly cleaned and warmed.
This will aid the evaporation of the cleaning solution and rise water. Parts cleaned in solution
tanks must be thoroughly rinsed with clean water to remove all traces of alkali.
Care should be exercised to avoid skin rashes, fire hazards and inhalation of vapors when
using solvent type cleaners.
⑥ If alloy parts, such as bearing shells or bushings, are cleaned with alkaline solution, they are apt to
corrode due to ionization. Such parts should be cleaned with kerosene, Tricrene solvent vapor or
“Magnus” fluid.
⑦ After cleaning, parts must be thoroughly dried with compressed air.
2. Bearings
① To dislodge solidified particles of lubricant, immerse bearings in cleaning fluid and remove
them from the fluid. On a clean work bench, tap the bearing softly with a soft mallet to dislodge
solidified particles.
② When drying bearings, be careful to direct air stream across bearing to avoid spinning.
3. Rubber parts
① When rubber parts need to be cleaned, use alcohol or wipe them clean with a soft cloth.
② Never use gasoline, diesel fuel or kerosene for cleaning. Use the same kind of oil for which the
rubber part will be used.
04. STANDARD BOLT TIGHTENING TORQUE
See the section “04. STANDARD BOLT TIGHTENING TORQUE” for the torques of standard
bolts when they are used for general applications. Refer to the Shop Manual and Service Manual of
your truck model when:
1) Special nuts are used.
2) Synthetic resin or rubber is used for tightening.
3) Specified tightening torque is given.
Table 04.1 Strength

Strength Indication on bolt Material
SS400
4.6
(The number may be omitted.)
6.8 S45C
SCM435
8.8
Boron steel
(“B” may be omitted.)
SCM435
10.9
Boron steel
(“B” may be omitted.)
Table 04.2
Division by Surface
Name Shape Thread size Material Part number
strength treatment
SS400 4.6 Black 01101- Nominal symbol
SS400 4.6 01100- “

M4 - M8 coarse and S45C 6.8 01103- “
Normal
M10 - M39 fine Yellow
SCM435, Boron steel 8.8 01106- “
chromate
SCM435, Boron steel 10.9 01107- “
BsBME1 — 01108- “
SS400 4.6 Black 01112- “
SS400 4.6 01110- “
Coarse M10 - M39 coarse S45C 6.8 Yellow 01113- “
SCM435, Boron steel 8.8 Chromate 01116- “
SCM435, Boron steel 10.9 01119- “
SS400 4.6 Black 01115- “
Full thread SS400 4.6 01111- “
(normal, M10 - M39 coarse Yellow
coarse) S45C 6.8 01114- “
Chromate
Hex. head SCM435, Boron steel 8.8 01117- “
bolt SS400 4.6 Black 01121- “
SS400 4.6 01120- “
Full thread M4 - M8 coarse and S45C 6.8 01123- “
(normal) M10 - M39 fine SCM435, Boron steel 8.8
Yellow
01126- “
Chromate
SCM435, Boron steel 10.9 01127- “
BsBME1 — 01128- “
SS400 4.6 Black 01131- “
SS400 4.6 01130- “
w. socket M4 - M8 coarse and
S45C 6.8 01133- “
head M10 - M39 fine Yellow
SCM435, Boron steel 10.9 01137- “
SS400 4.6 Black 01161- “
SS400 4.6 01160- “
w. hole in M4 - M8 coarse and
S45C 6.8 01163- “
threads M10 - M39 fine Yellow
SCM435, Boron steel 10.9 01167- “
• Designation of screws: Each part number consists of a screw type designation and a nominal symbol.
Example: 01130-16050 (hex. bolt 4.6, M16 x 50, w. socket head)

Table 04.3 Tightening torque chart (Division by strength: 4.6)
Lubrication Dry LOCTITE262 Lubricant
condition
Target value Allowable value Target value Allowable value Target value Allowable value
Nominal
Class size Pitch 0࡮㨙 kgH࡮E㨙 0࡮㨙 kgH࡮E㨙 0࡮㨙 kgH࡮E㨙 0࡮㨙 kgH࡮E㨙 0࡮㨙 kgH࡮E㨙 0࡮㨙 kgH࡮E㨙
M 4 0.50 1.36 13.9 1.09 - 1.63 11.1 - 16.6 1.21 12.3 0.96 - 1.44 9.8 - 14.7 0.99 10.1 0.79 - 1.19 8.1 - 12.1
M 5 0.50 2.87 29.3 2.30 - 3.44 23.5 - 35.1 2.53 25.8 2.02 - 3.00 20.6 - 30.9 2.08 21.2 1.66 - 2.50 16.9 - 25.5
M 6 0.75 4.59 46.8 3.67 - 5.55 37.4 - 56.1 4.06 41.4 3.25 - 4.87 33.1 - 49.7 3.34 34.1 2.68 - 4.01 27.3 - 40.9
M 8 1.00 10.9 111 8.69 - 13.3 88.6 - 133 9.62 98.1 7.70 - 1.15 78.5 - 117 7.93 80.9 6.34 - 9.51 64.6 - 97.0
M 10 1.25 21.2 216 17.1 - 25.4 174 - 259 18.8 192 15.0 - 22.6 153 - 230 15.5 158 12.5 - 18.6 127 - 190
M 12 1.25 39.1 399 31.4 - 47.1 320 - 480 34.5 352 27.7 - 41.5 282 - 423 28.4 290 22.7 - 34.1 231 - 348
M 14 1.50 61.7 629 49.3 - 74.0 503 - 755 54.2 553 43.4 - 65.3 443 - 666 44.7 456 35.9 - 53.7 366 - 548
M 16 1.50 95.9 978 76.8 - 115 783 - 1170 84.3 860 67.5 - 100 1688 - 1030 69.5 709 55.5 - 83.4 566 - 850
M 18 1.50 141 1440 113 - 170 1150 - 1730 125 1270 99.1 - 148 1010 - 1510 102 1040 81.5 - 123 831 - 1250
M 20 1.50 198 2020 159 - 238 1620 - 2430 175 1780 139 - 208 1420 - 2120 143 1460 114 - 172 1160 - 1750
Metric, fine system

M 22 1.50 270 2750 216 - 324 2200 - 3300 235 2400 188 - 282 1920 - 2880 194 1980 155 - 233 1580 - 2380
M 24 2.00 334 3410 268 - 401 2730 - 4090 293 2990 234 - 351 2390 - 3580 241 2460 193 - 289 1970 - 2950
M 27 2.00 489 4990 391 - 587 3990 - 5990 429 4370 342 - 515 3490 - 5250 352 3590 282 - 424 2880 - 4320
M 30 2.00 686 7000 550 - 824 5610 - 8400 600 6120 480 - 720 4890 - 7340 493 5030 395 - 592 4030 - 6040
M 33 2.00 931 9490 744 - 1120 7590 - 11400 812 8280 650 - 974 6630 - 9930 669 6820 534 - 802 5450 - 8180
M 36 3.00 1130 11500 903 - 1350 9210 - 13800 991 10100 792 - 1190 8080 - 12100 815 8310 652 - 979 6650 - 9980
M 39 3.00 1460 14900 1170 - 1740 11900 - 17700 1280 13100 1020 - 1540 10400 - 15700 1050 10700 844 - 1270 8610 - 12900
M 4 0.70 1.15 11.7 0.92 - 1.38 9.4 - 14.1 1.03 10.5 0.82 - 1.24 8.4 - 12.6 0.8 8.66 0.68 - 1.02 6.9 - 10.4
M 5 0.80 2.36 24.1 1.89 - 2.82 19.3 - 28.8 2.11 21.5 1.70 - 2.53 17.3 - 25.8 1.7 17.8 1.39 - 2.08 14.2 - 21.2
30.0
M 6 1.00 3.98 40.6 3.20 - 4.79 32.6 - 48.8 3.56 36.3 2.85 - 4.29 29.1 - 43.7 2.9 2.35 - 3.53 24.0 - 36.0
M 8 1.25 9.81 100 7.84 - 11.7 79.9 - 119 8.74 89.1 7.00 - 10.5 71.4 - 107 7.2 73.5 5.77 - 8.65 58.8 - 88.2
M 10 1.50 19.5 199 15.6 - 23.4 159 - 239 17.5 178 13.9 - 20.9 142 - 213 14.3 146 11.5 - 17.3 117 - 176
M 12 1.75 34.2 349 27.5 - 41.1 280 - 419 30.4 310 24.4 - 36.6 249 - 373 25.1 256 20.1 - 30.1 205 - 307
M 14 2.00 55.0 561 43.9 - 65.9 448 - 672 48.8 498 39.0 - 55.8 398 - 597 40.2 410 32.3 - 48.3 329 - 493
M 16 2.00 86.9 886 69.5 - 104 709 - 1060 77.0 785 61.6 - 92.4 628 - 942 63.5 647 50.8 - 76.1 518 - 776
M 18 2.50 118 1200 94.6 - 142 965 - 1450 105 1070 84.1 - 127 858 - 1290 86.6 883 69.3 - 104 707 - 1060
M 20 2.50 171 1740 136 - 204 1390 - 2080 150 1530 121 - 180 1230 - 1840 125 1270 99.1 - 149 1010 - 1520
M 22 2.50 234 2390 187 - 252 1740 136 - 204 1390 - 2080
Metric, coarse system

1910 - 2570 207 2110 165 - 248 1680 - 2530 171
M 24 3.00 293 2990 234 - 352 2390 - 3590 259 2640 208 - 312 2120 - 3180 214 2180 172 - 257 1750 - 2620
M 27 3.00 436 4450 349 - 524 3560 - 5340 385 3930 308 - 463 3140 - 4720 318 3240 254 - 381 2590 - 3890
M 30 3.50 588 6000 471 - 706 4800 - 7200 521 5310 417 - 624 4250 - 6360 429 4370 342 - 515 3490 - 5250
M 33 3.50 810 8260 648 - 972 6610 - 9910 714 7280 572 - 857 5830 - 8740 588 6000 471 - 706 4800 - 7200
M 36 4.00 1030 10500 828 - 1250 8440 - 12700 914 9320 731 - 1100 7450 - 11200 753 7680 602 - 903 6140 - 9210
M 39 4.00 1350 13800 1080 - 1140 11000 - 11650 1190 12100 953 - 1430 9720 - 14600 981 10000 785 - 1180 8000 - 12000
condition
Nominal
M 4 0.50 2.71 27.6 2.17 - 3.26 22.1 - 33.2 2.40 24.5 1.92 - 2.87 19.6 - 29.3 1.98 20.2 1.58 - 2.38 16.1 - 24.3
M 5 0.50 5.74 58.5 4.59 - 6.87 46.8 - 70.1 5.05 51.5 4.04 - 6.06 41.2 - 61.8 4.15 42.3 3.33 - 4.98 33.9 - 50.8
M 6 0.75 9.14 93.2 7.32 - 11.0 74.6 - 112 8.10 82.6 6.48 - 9.72 66.1 - 99.1 6.68 68.1 5.34 - 8.01 54.4 - 81.7
M 8 1.00 21.7 221 17.4 - 26.0 177 - 265 19.2 196 15.4 - 23.0 157 - 235 15.8 161 12.7 - 19.0 129 - 194
M 10 1.25 42.4 432 33.8 - 50.9 345 - 519 37.5 382 30.0 - 45.0 306 - 459 30.9 315 24.7 - 37.1 252 - 378
M 12 1.25 78.3 798 62.6 - 93.9 638 - 957 68.9 703 55.1 - 82.7 562 - 843 56.8 579 45.5 - 68.2 464 - 695
M 14 1.50 123 1250 98.1 - 148 1000 - 1510 109 1110 86.9 - 129 886 - 1320 89.4 912 71.6 - 107 730 - 1090
M 16 1.50 192 1960 153 - 229 1560 - 2340 169 1720 135 - 202 1380 - 2060 139 1420 111 - 168 1130 - 1700
M 18 1.50 282 2870 225 - 337 2290 - 3440 247 2520 198 - 296 2020 - 3020 203 2070 163 - 244 1660 - 2490
M 20 1.50 396 4040 317 - 476 3230 - 4850 347 3540 278 - 416 2830 - 4240 285 2910 229 - 343 2330 - 3500
Metric, fine system

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

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

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

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

M 22 1.50 1060 10800 843 - 1270 8600 - 12900 922 9400 738 - 1110 7530 - 11300 759 7740 607 - 912 6190 - 9300
M 24 2.00 1300 13300 1050 - 1570 10700 - 16000 1150 11700 919 - 1380 9370 - 14100 946 9650 756 - 1140 7710 - 11600
M 27 2.00 1910 19500 1540 - 2300 15700 - 23500 1690 17200 1330 - 2020 13600 - 20600 1380 14100 1110 - 1660 11300 - 16900
M 30 2.00 2690 27400 2160 - 3230 22000 - 32900 2350 24000 1880 - 2820 19200 - 28800 1930 19700 1550 - 2320 15800 - 23700
M 33 2.00 3640 37100 2910 - 4370 29700 - 44600 3180 32400 2540 - 3810 25900 - 38900 2620 26700 2090 - 3140 21300 - 32000
M 36 3.00 4420 45100 3530 - 5300 36000 - 54000 3870 39500 3110 - 4650 31700 - 47400 3190 32500 2550 - 3820 26000 - 39000
M 39 3.00 5730 58400 4580 - 6860 46700 - 70000 5020 51200 4010 - 6020 40900 - 61400 4130 42100 3300 - 4950 33700 - 50500
M 4 0.70 4.49 45.8 3.60 - 5.39 36.7 - 55.0 4.03 41.1 3.22 - 4.83 32.8 - 49.2 3.32 33.9 2.66 - 3.98 27.1 - 40.6
M 5 0.80 9.24 94.2 7.40 - 11.1 75.5 - 113 8.26 84.2 6.60 - 9.91 67.3 - 101 6.81 69.4 5.44 - 8.18 55.5 - 83.4
M 6 1.00 15.6 159 12.6 - 18.7 128 - 191 14.0 143 11.2 - 16.8 114 - 171 11.5 117 9.21 - 13.8 93.9 - 141
M 8 1.25 38.3 391 30.7 - 46.0 313 - 469 34.3 350 27.4 - 41.1 279 - 419 28.2 288 22.6 - 33.8 230 - 345
M 10 1.50 76.5 780 61.2 - 91.8 624 - 936 68.2 695 54.5 - 81.9 556 - 835 56.1 572 44.9 - 67.5 458 - 688
M 12 1.75 133 1360 108 - 161 1100 - 1640 120 1220 95.4 - 143 973 - 1460 98.1 1000 78.8 - 118 803 - 1200
M 14 2.00 216 2200 173 - 258 1760 - 2630 191 1950 153 - 230 1560 - 2350 158 1610 127 - 189 1290 - 1930
M 16 2.00 341 3480 272 - 409 2770 - 4170 301 3070 241 - 362 2460 - 3690 249 2540 199 - 298 2030 - 3040
M 18 2.50 463 4720 370 - 555 3770 - 5660 412 4200 330 - 493 3360 - 5030 338 3450 272 - 407 2770 - 4150
M 20 2.50 665 6780 534 - 797 5440 - 8130 588 6000 471 - 707 4800 - 7210 485 4950 387 - 583 3950 - 5940
M 22 2.50 918 9360 6810 534 - 802 5450 - 8180

734 - 1100 7480 - 11200 810 8260 648 - 972 6610 - 9910 668
M 24 3.00 1150 11700 919 - 1380 9370 - 14100 1020 10400 814 - 1230 8300 - 12500 838 8550 670 - 1010 6830 - 10300
M 27 3.00 1720 17500 1370 - 2050 14000 - 20900 1510 15400 1220 - 1800 12400 - 18400 1250 12700 991 - 1490 10100 - 15200
M 30 3.50 2300 23500 1840 - 2770 18800 - 28200 2040 20800 1630 - 2440 16600 - 24900 1690 17200 1330 - 2020 13600 - 20600
M 33 3.50 3170 32300 2540 - 3810 25900 - 38800 2800 28600 2240 - 3350 22800 - 34200 2300 23500 1840 - 2760 18800 - 28100
M 36 4.00 4060 41400 3240 - 4860 33000 - 49600 3580 36500 2860 - 4300 29200 - 43800 2950 30100 2360 - 3530 24100 - 36000
M 39 4.00 5290 53900 4240 - 6350 43200 - 64800 4660 47500 3740 - 5590 38100 - 57000 3830 39100 3070 - 4610 31300 - 47000
05. LUBRICATION
1. Lubricating lift chains
Lubricate the lift chains with engine oil using an oiler or a brush.
To allow oil to enter between each pin and link plate of the lift chain, observe the following
conditions:
••Loosen the chains sufficiently.
••After applying engine oil, operate the lift cylinders at least ten times through full travel.
NOTE
If your lift truck is used near a port or coastal area, the lift chains might be damaged from salty
breezes. After a storm or typhoon, it is advisable to wash them with water before lubricating in the
above manner.
2. Mast and steering system
Fig. 05.1
■ Rear slippers of the mast
WARNING
Do not ride on the mast. Do not put your hand or
foot on the connecting member across the mast
or between the outer and inner mast channels;
otherwise you might get injured if the mast
accidentally moves.
Fig. 05.2
3. Checking hydraulic oil level

OIL DIPSTICK
レベルゲージ
Check the hydraulic oil level in the hydraulic oil
tank using the oil level dipstick.
Remove the dipstick of the tank cap, clean the rod
with a clean cloth and reinsert it. Remove the dipstick
again and check the oil level. If the level is low, add
hydraulic oil.
[How to read oil level]
“H” mark: Highest position of the standard truck
“L” mark: Lowest position of the standard truck
“S” mark: For trucks with a lift height of 6 m or more
or for special trucks, the oil level should be
HYDRAULIC
作動油タンクキャップOIL TANK CAP
within 10 mm above or below this mark.
Fig. 05.3
NOTE
••Too high oil level might cause oil leakage.
••The oil level check should be performed with the
mast vertical, the forks on the ground or floor
surface, and the truck parked on a level surface.
06. PARTS LIST
Part number
Item Part name FB10-8 FB30-8 Remarks

FB20-8 FB25-8V
FB15-8 FB30-8V
FB25-8 FB25-8LB
FB18-8 FB35-8S
283R2-63901 283T2-63901 283R2-63901
Fuse, F1 Controller
400A 500A 400A
27292-62272 27732-62091 27292-62272
Fuse, F6 Battery charger
130A 200A 130A
Fuses
Fuses, F4, F5, F9 25592-42311 10A
Fuse, F7 - 25592-42311 10A
Fuse, F8 27232-62111 2A
Oil tank Suction filter 216G7-52051
Bulb 271A2-42421 48V/40W
Head lights
Assembly 277H2-42001
Turn signal : 277H2-42361 48V/25W
Front Bulb
combination Side marker : 277H2-42371 48V/10W
Lights lights
Assembly 277H2-42011
(standard
trucks) Turn signal : 277H2-42361 48V/25W
Rear Bulb Side marker : 271A2-42441 48V/25W-10W
combination
lights Back-up : 277H2-42371 48V/10W
Assembly 280C2-42001
Relay unit 281E2-63252
* Note: The part numbers given below are subject to change without notice.
CONTENTS
1. BATTERY AND CHARGER (OPTION) . ...................................................................1
1.1 GENERAL DESCRIPTION..................................................................................................2
1.1.1 BATTERY.......................................................................................................................2
1.1.2 BATTERY CHARGER..................................................................................................4
1.1.3 CHARGING PROCEDURES........................................................................................9
1.1.4 CHARGER OPERATION............................................................................................ 11
2. MOTORS...............................................................................................................................13
2.1 GENERAL DESCRIPTION................................................................................................13
2.1.1 DRIVE MOTOR...........................................................................................................13
2.1.2 PUMP MOTOR............................................................................................................17
2.2 MAINTENANCE................................................................................................................19
2.2.1 DRIVE MOTOR...........................................................................................................19
2.2.2 PERIODIC INSPECTION...........................................................................................20
2.2.3 MAINTENANCE OF BEARINGS..............................................................................22
3. CONTROL SYSTEM........................................................................................................23
3.1.1 INVERTER UNIT........................................................................................................23
3.1.2 ACCELERATOR PEDAL............................................................................................30
4. DRIVE UNIT AND DRIVE AXLE.................................................................................31

4.1.1 DRIVE UNIT...............................................................................................................31
4.1.2 DRIVE AXLE...............................................................................................................35
5. BRAKE SYSTEM...............................................................................................................39
5.1.1 BRAKE PEDAL...........................................................................................................39
5.1.2 MASTER CYLINDER.................................................................................................41
5.1.3 WHEEL BRAKE..........................................................................................................42
5.1.4 PARKING BRAKE LEVER........................................................................................44
5.2 MAINTENANCE................................................................................................................47
5.2.1 DISASSEMBLING WHEEL BRAKE.........................................................................47
5.2.2 INSPECTION...............................................................................................................49
5.2.3 REASSEMBLING WHEEL BRAKE..........................................................................50
5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER.........................52
5.2.5 ADJUSTING BRAKE PEDAL....................................................................................53

5.2.6 TROUBLESHOOTING GUIDE..................................................................................54
6A. STEERING SYSTEM (ORBITROL type). ...........................................................55

6A.1 GENERAL DESCRIPTION................................................................................................55
6A.1.1 STEERING AXLE.......................................................................................................56
6A.1.2 STEERING WHEEL ASSEMBLY..............................................................................60
6A.1.3 ORBITROL..................................................................................................................62
6A.1.4 POWER CYLINDER...................................................................................................65
6B. STEERING SYSTEM (EPS type). ..........................................................................67

6B.1 GENERAL DESCRIPTION................................................................................................67
6B.1.1 OUTLINE OF STEERING SYSTEM..........................................................................68
6B.1.2 STEERING GEARBOX...............................................................................................69
6B.1.3 ACTUATOR.................................................................................................................72
6B.1.4 REAR AXLE................................................................................................................72
6B.1.5 ADJUSTING PRELOAD OF REAR WHEEL BEARING.........................................76
6B.2 MAINTENANCE................................................................................................................77
6B.2.1 MAINTENANCE FOR ACTUATOR..........................................................................77
7. HYDRAULIC SYSTEM....................................................................................................81
7.1.1 MAIN PUMP................................................................................................................82
7.1.2 CONTROL VALVE......................................................................................................82
7.1.3 VALVE CONTROL......................................................................................................84
7.1.4 HYDRAULIC OIL TANK...........................................................................................86
7.1.5 LIFT CYLINDER.........................................................................................................87
7.1.6 FLOW REGULATOR VALVE.....................................................................................92
7.1.7 TILT CYLINDER.........................................................................................................94
7.2 MAINTENANCE................................................................................................................97
7.2.1 MAINTENANCE OF PUMP.......................................................................................97
7.2.2 TRIAL RUN...............................................................................................................109
7.2.3 TROUBLESHOOTING GUIDE................................................................................ 110
8. LOAD HANDLING SYSTEM...................................................................................... 111

8.1 GENERAL DESCRIPTION.............................................................................................. 112
8.1.1 OUTER AND INNER CHANNELS.......................................................................... 112
8.1.2 CARRIAGE................................................................................................................ 113
8.1.3 LOCATIONS OF ROLLERS..................................................................................... 115
8.2 MAINTENANCE.............................................................................................................. 118

8.2.1 ADJUST LIFT CYLINDER ROD WITH SHIMS..................................................... 118
8.2.2 ADJUSTING HEIGHT OF CARRIAGE................................................................... 118
8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE....................120
8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE..............................122
8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS..................................123
9. ELECTRIC SYSTEM......................................................................................................125
9.1 SYSTEM DESCRIPTION................................................................................................125
9.1.1 RELAY UNIT.............................................................................................................126
9.1.2 LIGHTS......................................................................................................................128
https://truckmanualshub.com/ 1. BATTERY AND CHARGER (OPTION)
1. BATTERY AND CHARGER (OPTION)

The description in this section applies to our optional batteries and chargers. For other types of
batteries and chargers, refer to their respective instruction manuals.
Truck model
FB10-8 FB15-8 FB18-8 FB20-8 FB25-8
Item
Battery
Capacity 330 Ah/5 h 400 Ah/5 h 450 Ah/5 h 565 Ah/5 h
Name VSDX330M VSDX400M VSDX450M VSDX565M
Voltage 48V
pecific gravity of
S
electrolyte 1.280
Weight 650 kg [1430 lbs] 660 kg [1460 lbs] 930 kg [2050 lbs] 800 kg [1760 lbs] 880 kg [1940 lbs]
Charger
Type On-board type, 3-phase AC semiconstant voltage charger
Rated power 6.0 kVA 8.5 kVA
Rated current 17 A 24 A
Power supply voltage 205 / 390 / 440 V
pplicable battery
A
capacity 320 - 500 Ah/5 h 450 - 700 Ah/5 h
Output
Voltage 51 - 64 V
Current 80 - 20 A 115 - 29 A
Truck model FB30-8

FB25-8LB FB25-8V FB35-8S
FB30-8V
Item
Battery
Capacity 935Ah/5h 865Ah/5h 450Ah/5h
Name VSF935 VSF865 VSDX450MZ
Voltage 48 V 72 V
pecific gravity of
S
electrolyte 1.280
Weight 1440 kg [3170 lbs] 1325 kg [2920 lbs] 1110 kg [2450 lbs] 1225 kg [2700 lbs]
Charger
Type On-board type, 3-phase AC semiconstant voltage charger
Rated power 12 kVA 12 kVA
Rated current 34 A 34 A
Power supply voltage 205 / 390 / 440 V
pplicable battery
A
capacity 865 - 935 Ah/5 h 450 - 545 Ah/5 h
Output
Voltage 51 - 64 V 76.5 - 96 V
Current 160 - 40 A 105 - 26 A
-1-
1. BATTERY AND CHARGER (OPTION) https://truckmanualshub.com/
1.1 GENERAL DESCRIPTION

1.1.1 BATTERY
The battery unit consists of twenty-four 2-volt battery cells for the 48-volt electrical system
(thirty-six 2-volt battery cells for the 72-volt electrical system) connected in series. Figure 1.1
shows its construction.
LOCK PIN
ELECTROLYTE
LEVEL INDICATOR
BATTERY CELL WITH

ELECTROLYTE LEVEL SENSOR
Note: The sketch shows a 48-volt battery unit. The 72-volt battery unit has 36 battery cells.
Fig. 1.1 Battery Unit
(1) Battery care

charge and
Service life
discharge
Cycles of
The most important point in battery care is to

prevent overdischarge. The deeper the battery
discharges, the shorter its life becomes (See Figure
1.2).
The approximate depth of discharge can be
known by measuring the specific gravity of the
electrolyte (See Figure 1.3)
Check the level of electrolyte every ten days.
Add distilled water if the level is found lower than
the specified level before charging the battery.
Depth of discharge (%)
Fig. 1.2 R
elation Between Depth of Discharge
and Service Life (Example)
-2-
Specific gravity
(at 20°C)
Voltage (V)
Usable
Voltage
Alert !
Specific gravity
Overdischarge
(Discharge duration)
(Discharge rate)
Fig. 1.3 An Example of Specific Gravity Drop
(2) Charging the battery

When discharged, the battery should be recharged as soon as possible. Leaving the battery discharged for
a long time may cause sulfation, which will result in a drop of the battery performance.
If the battery is kept out of service for a long time, it should be thoroughly charged before put in storage.
An additional charge is also required once a month.
Do not leave a fully discharged battery longer than a day as it is. Be sure to recharge it as soon as
possible.
If the amount of discharge is considered to be small, measure the specific gravity of the electrolyte. If
lower than 1.260, recharge the battery.
Equalizing charge is required if the specific gravity varies among the cells by the amount of 0.020 or
larger. Equalizing charge is normally needed between one to four times a month.
If the specific gravity variation is not made smaller by equalizing charge, specific gravity adjustment will
be required.
Giving an equalizing charge more times than necessary will overcharge the battery, and its service life
will be shortened.
For a truck-mounted type charger, a microcomputer determines when an equalizing charge is required
and carries out equalizing charge automatically.
[Cautions on Charging the Battery]
① Do not start charging the battery if the electrolyte temperature is higher than 50°C. Leave the battery
for a while until the temperature goes low. Then charge it.
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. Therefore, if the specific gravity is measured at
the electrolyte temperature if other than 20°C, correct it using the following formula:
S20 = St + 0.0007 (t – 20)
where S20...........specific gravity for 20°C
St..............specific gravity measured at t
t................electrolyte temperature measured.
-3-
1.1.2 BATTERY CHARGER

The on-board battery charger is a computer-controlled, semiconstant-voltage type consisting of
a transformer, diodes, an operation panel, a CM contactor and a thermal relay.
Thermal relay current settings

Transformer model Setting (A)
Insulation tube BAND
M80B 24
M80C
13
M80D
M115B 34
M115C
18
M115D
M160B 40
Connection of M160C
secondary wire 26
M160D
Secondary wire CM%/ࠦࡦ࠲ࠢ࠲

Contactor
Primary wire Thermal relay
FB10-8 FB15-8 FB18-8
secondary wire CM Contactor

%/ࠦࡦ࠲ࠢ࠲
primary wire thermal relay
FB20-8 FB25-8 FB25-8LB FB25-8V
Fig. 1.4 Battery Charger (1- to 2.5-ton Trucks)
-4-
Thermal relay current settings

Transformer model Setting (A)
M105B 40
M105C
26
M105D
Secondary wire CM Contactor

CMコンタクタ
Primary wire Thermal relay
Fig. 1.5 Battery Charger (3- to 3.5-ton Trucks)
-5-
(1) Transformer
The transformer is located at the right side frame and converts input voltage to a voltage of the
level necessary for charging the battery.
There are three taps provided with a 10-volt difference from one to another. Make a selection
among them at the input side according to the input voltage level.
GROUND WIRE (GREEN)
PRIMARY WIRE
SECONDARY WIRE
■ Transformer tap changing

The supply voltage varies with the periods of time. Change therefore the taps from one to
another according to the average of supply voltages which to charger receives for the period of
time during which the battery is normally charged.
Supply Voltage (Average)
Symbol of Tap Note 1: Change all the three
205 V 390 V 440 V
phases as a set.
50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz Note 2: Give a terminal cap to
180 - 190 190 - 200 340 - 360 360 - 380 390 - 410 410 - 430 L each of the taps which are
not used, and fix them by
190 - 200 200 - 210 360 - 380 380 - 400 410 - 430 430 - 450 M
the wire binder.
200 - 210 210 - 220 380 - 400 400 - 420 430 - 450 450 - 470 H
Fig. 1.6 Transformer
-6-
(2) Diode
The diode, installed inside the right-side frame, is a 3-phase, full-wave rectification type which
converts AC to DC.
The current rectified by the diode flows through the fuse F6 to charge the battery.
DIODE
ダイオード
to TRANSFORMER
トランスへ
FUSE: 130
ヒューズ A
: 130A
Fig. 1.7 Diode
-7-
(3) Operation panel

The operation panel is located on the left side of the cabinet and equipped with charger control
switches, lamps and service power outlet.
Fig. 1.8 Operation Panel
-8-
1.1.3 CHARGING PROCEDURES

(1) Normal charge
① Turn off the key switch and apply the parking brake.
② Make sure that the power supply at the facility side is off and insert the plug into the
receptacle at the truck side.
The plug at the truck side is a locking type. Insert the plug securely until it reaches the locked
position. Then, insert the plug into the receptacle at the facility side when it is equipped with
the power service outlet.
③ When the power supply at the facility side is turned on and the START button at the charging
operation panel is pressed, the CHARGING lamp lights up and the charging is started. Then,
the humming is heard from the transformer, which shows that the charger is operating. The
charging state is also displayed on the LCD panel.
Note: If the battery is not connected or the power supply at the facility side is 0-volt, the
charging operation cannot be started.
④ The charging is automatically terminated after it continues for 8 to 10 hours (the charging
time varies with the amount of discharge). The battery is not so exhausted, the charging may
continue for a short time (a few minutes).
Note: If power failure occurs during charging and is remedied within 120 hours, battery
charging is automatically started again.
⑤ Make sure that the CHARGING lamp is turned off, turn off the power supply at the facility
side. Remove the plug at the truck side with its lock lever pressed.
⑥ After charging is finished, measure the specified gravity of the battery electrolyte to check if
the proper charging is carried out.
(2) Boosting charge

If the residual level gauge of the LCD panel is probable to indicate level 3 or less after
completing the day’s work, it is recommended that boosting charge is carried out by using a rest
period.
The starting procedure of the boosting charge is same as that of the normal charge, but be sure
to press the STOP button when terminating the boosting charge.
(3) Equalizing charge

Normally the battery does not need equalizing charge because when the battery needs it, the
microcomputer detects it and automatically puts the charger in equalizing charge operation.
However, manual equalizing charge is needed if:
••Purified water is added to the battery electrolyte
••The difference of the specific gravity in each cell is 0.02 or more.
••Overdischarge more than 100% occurs.
The procedure for carrying out the equalizing charge is as follows:
① Press the SUPER EQUALIZE button after taking the same steps as needed for normal charge,
so that the CHARGING lamp and SUPER EQUALIZE lamp light up.
-9-
② When equalizing charge is automatically terminated (the CHARGING lamp goes out), the
“SUPER EQUALIZE” lamp is turned off and equalizing charge is released by pressing the
“SUPER EQUALIZE” button or turning the key switch on.
While the battery is charged, equalizing charge can be released by pressing the STOP button.
(4) Super equalizing charge

① Super equalizing charge is used when you want to use 100% of the battery capacity after
consecutive holidays. The operation steps are the same as those described in “Equalizing
charge.”
② In super equalizing charge, both of equalizing charge and automatic proper boosting charge
during consecutive holidays are carried out, so that proper boosting charge is automatically
carried out every 24 hours after completing the charge. Therefore, 100% of the battery
capacity can be used after consecutive holidays. However, if 100 % of the battery capacity is
used, the battery service life will be short. It is recommended to adopt a high capacity battery
or to prepare a spare battery when super equalizing charge is so often used.
(5) Flickering CHARGING lamp

When charging voltage doesn’t rise up due to the deteriorated battery or other reasons, the timer
won’t operate properly, continuing to charge the battery.
However, for the truck-mounted type charger, the second timer is operated after charging the
battery for 15 to 17 hours, so that the charging is forcibly terminated and the CHARGING lamp
blinks. In such a case, inspect the cause and contact your TCM dealer.
Note: Have a helper for this procedure.
(1) Remove the battery connector.

(2) Having the helper keep the super equalizing charge button held down, reconnect the battery
connector.
(3) Make sure “Charging” lamp goes out.
- 10 -
1.1.4 CHARGER OPERATION

(1) When the power supply switch to the battery charger is turned on, the charging circuit inside
the LCD panel is activated.
(2) When the START button is pressed, a circuit consisting of the CM contactor, thermal relay TH
and CN1-8 terminals of the LCD panel is completed to activate the CM contactor.
(3) When the CM contactor is activated to connect the power supply to the transformer, the LED1
turns on and the fail timer starts counting down the time and thus charging operation starts.
The fail timer is usually set to 15 hours for normal charge.
(4) When the battery voltage rises up to the preset voltage, the control circuit inside the LCD
panel detects the voltage level and then timer starts counting down the time.
This timer is automatically set to a proper amount of time according to how much the battery
has been discharged.
(5) When the time set to the timer expires, the CM contactor opens to finishing charging.
to FUSE (F4) to KEY SWITCH
to CONTROLLER
to BATTERY TERMINAL (-)
ࡃ࠶࠹࡝
߳ to TRANSFORMER
ࡃ࠶࠹࡝
߳
F6
SWITCH PANEL ASS'Y
(CHARGE)
SR
TRANS
LR
204
EQUL)
(CHARGE)
LED1
LED2
(START)
(SUPER
PB1
PB2
PB3
(STOP)
(EQUL)
PO CM MN L MN L MN L
S1 S2 S3 L1 L2 COM CM
Gy
220
U V W
TH
TH
WG 209
WR 205
WY 206
BW 211
CN1-4 RG 203
YG 208
RB 202
CN1-11 RY 101
RL 100
LB 201
LY 212
CH
CN1-13
CN1-14
CN1-15
CN1-5
CN1-16
CN3-5
CN1-18
CN1-8
CN3-6
RESISTOR
ASS'Y
+5V CN3-8 W 213
R01
R03
LCD PANEL ASS'Y

R02
CN3-4 W 207
R S T
E
AC INPUT
Fig. 1.9 Charging Circuit
- 11 -
1. BATTERY https://truckmanualshub.com/
NOTE
- 12 -
https://truckmanualshub.com/ 2. MOTORS
2. MOTORS
Truck model FB10-8 FB15-8 FB20-8 FB25-8 FB30-8 FB35-8S
FB18-8 FB25-8LB FB25-8V FB30-8V
Item
Drive motor
Name HO-NR
Type Self-ventilated, 3-phase induction motor
Rated output 6.9 kW (60-min rate) 8.5 kW (60-min rate) 11.9 kW (60-min rate)
Rated voltage 26.5 V 26.3 V 43 V
Rated current 210 A 255 A 210 A
Weight 48 kg [106 lbs] 54 kg [119 lbs] 63 kg [139 lbs]
Pump motor
Name HO-NR
Type Self-ventilated, 3-phase induction motor
Rated output 8.6 kW (5-min rate) 9 kW (5-min rate) 14 kW (5-min rate)
Rated voltage 28 V 26 V 42 V
Rated current 260 A 280 A 260 A
Weight 34 kg [75 lbs] 43 kg [94.8 lbs] 47 kg [104 lbs]
Note: On trucks with an Orbitrol steering system, the pump motors of the 1-ton and 2-ton class
trucks are the same in design and specifications..

The drive and pump motor are located in positions shown in Figs 2.1 and 2.6, and controlled by
the controller inside the counterweight.
2.1.1 DRIVE MOTOR

The drive motor has a structure as shown Figure 2.2 and is installed on the drive unit, with the
rotation controlled by the inverter in the controller.
The rotation of the drive motor is sensed by the two sensors installed in the rear part of the
motor and sent to the controller.
- 13 -
2. MOTORS https://truckmanualshub.com/
DRIVE AXLE
DRIVE MOTOR
DRIVE UNIT
Fig. 2.1 Drive Motor Installation
- 14 -
Tightening
締付トルク torque:
10 10～12N
to 12 N-m
・m
[100 to 120 kgf-cm]
{7.4 to 8.9 lbf-ft}
ROTATION
回転センサBSENSOR B
ROTATION
回転センサASENSOR A
THERMO-SENSOR
CONNECTOR
U PHASE V PHASE W PHASE

TERMINAL
Ｕ相端子Ｖ相端子Ｗ相端子
TERMINAL TERMINAL
ViewBlooking from B
View looking from A
Fig. 2.2 Drive Motor
- 15 -
■ Operating principle of 3-phase induction motor

ion t
As shown in Figure 2.3, when the magnetic ec e)
g dir pol
in tic
poles N and S are rotated outside the rectangular tat ne
( Ro mag
oil, the coil side cuts the magnetic flux to induce of
electromotive force in the direction indicated in the (Rotating
figure, thus flowing circulating current inside the direction of coil)
coil. This causes rotating force in the same direction
as in which the magnetic poles rotates so that the
coil also rotates, following the magnetic poles.
Motors which operate in such a principle is called
an induction motor.
Three-phase alternating current is suitable for Fig. 2.3 Operating Principle of Induction Motor
rotating the magnetic coil. When 3-phase current is
passed into a 3-phase winding, a revolving magnetic
field which rotates a certain speed is created. It
is thus possible to perform the same action as the
purpose of rotating the magnetic poles N and S in
Figure 2.3. The 3-phase winding consists of an iron
core and three coils A, B, and C, spaced 120° apart,
installed in the iron core slots and connected in Y
or delta connection. The sketch “b” in Figure 2.4
shows a typical Y connection which is widely used
for the connection of induction motors.
When the directions (A → A’, B → B’, C → C’)
in which current flows into the coil are regarded Fig. 2.4 3-phase Winding
as the positive direction, the current of the coil in
each phase at the moment ① at (a), (b) and (c) in Figure 2.5, +Im flows into the coil A and –Im/2 flows into
both coils B and C. Therefore, the synthetic magnetic flux in the space becomes (c) to create a magnetic
field moving from right to left. This means that the magnetic pole is located at the right side and the S at the
left side. As such, each moment from ② - ⑥ is followed in order, the synthetic magnetic field created by
synthetic magnetic flux is a magnetic field which rotates by 60° clockwise. With time, it rotates to cause a
rotating magnetic field which makes a complete turn per one cycle of alternating current. The poles formed
at each moment are N and S, and thus this type of motor is called a 2-pole motor.
Fig. 2.5 Rotating Magnetic Field due to 3-phase Alternating Current
- 16 -
2.1.2 PUMP MOTOR

The pump motor is located on the left side frame and is used to drive the main pump.
Its rotation is controlled by the load handling inverter built in the speed controller only when the
lift lever is operated. Except that, the pump motor is used for starting or stopping the rotation of
the main pump.
MAIN PUMP
メインポンプ PUMP MOTOR
ポンプモータ
A
View looking from A
Fig. 2.6 Pump Motor
- 17 -
Tightening torque:
締付トルク
10 to 12 N-m
[100
10～12Nto ・
120
m kgf-cm]
THERMO-SENSOR {7.4 to 8.9 lbf-ft]
CONNECTOR
ROTATION
回転センサSENSOR
U PHASE V PHASE W PHASE

TERMINAL
Ｕ相端子Ｖ相端子Ｗ相端子
TERMINAL TERMINAL
View looking from A View B

looking from B
Fig. 2.7 Pump Motor
- 18 -
2.2 MAINTENANCE
2.2.1 DRIVE MOTOR
(1) Check the following points with the motor running
Check item Location Criteria Remedy
No remarkable deposit of dust allowed
If too much deposit of
compared with usual operation.
Environment
Dust Motor frame dust is found, stop the

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

Check item Location Criteria Remedy
No looseness, adherence of dust, or
Screws and Retighten, clean or
Tightened areas corrosion allowed.
nuts paint.
Check visually and by tapping.
Connections are correct and not loose.
Retighten.
Connections Proper insulation is ensured.
Check for insulation.
Terminals Visual check.
No damage to coating allowed.
Lead wires Ask specialist for repair.
Visual check.
- 19 -
2.2.2 PERIODIC INSPECTION

(1) Inspection criteria
Check the motor at periodic intervals, referring to the following troubleshooting chart. If the
motor is used under a severe working condition, earlier or more frequent preventive maintenance
is required.
Operation time more than 12 hours/day 8 – 12 hours/day
Inspection interval Once a year Once every two years
Location Check item Criteria Remedy

Check grease leaks, noise, adherence of
Roller bearing Bearing (sealed type) Replace.
dust visually or audibly.
Check for damage or rough surface due
Joined parts Clean.
to corrosion visually.
Tightened areas
Check for looseness, corrosion or seizure Retighten, apply
Fasteners
visually or by tapping. anti-rust or replace.
Check for damage or rough surface due
Joined areas Clean.
to corrosion visually.
Visually check that connections are
Terminals Connections correct and not loose, and that proper Retighten.
insulation is ensured.
Ask specialist for
Lead wire Check coating for damage visually.
repair.
Iron core Check for adherence of dust visually. Clean.
Stator and rotor Clean.
Coil and insulation Insulation resistance is more than 1 MΩ.
assembly Heat.
at connections (Use 500 V megger)
Varnish.
Measure resistance 620 ± 60 Ω (20°C or 68°F) Replace.
Rotation sensor Ask specialist for
Measure gap 0.7 ± 0.3 mm [0.028 ± 0.012 in.]
adjustment.
Ask specialist for
Thermo sensor Measure resistance 13.04 kΩ ± 10% (20°C or 68°F)
repair.
Check for damage, discoloration, peeling, Apply anti-rust.
Painting Damage
or corrosion visually. Paint again.
Clean or apply anti-
Deposit of Check for contamination, adherence of
Cleanliness rust.
contaminants or dust dust or corrosion visually.
Paint.
- 20 -
(2) Inspection procedure

Inspect the motors observing the following conditions:
① Select a place which is not dusty or humid.
② Parts which have been disassembled should be kept in order and the order of disassembly
recorded to ensure correct reassembly.
Screws and wave washers removed should be put in order in boxes.
③ When removing or reinstalling brackets with a wooden mallet, tap them evenly. Do not use a
metallic hammer.
④ Use caution not to damage parts, especially stator coil and bearings. Exercise caution not to
allow them to collect moisture, dust, or sand.
⑤ Disassembled parts should be cleaned and checked for damage. Any defective parts should be
replaced with new one.
⑥ Do not rub a contaminated coil forcefully. Do not use gasoline, petroleum or solvent for
cleaning; otherwise the insulation will be impaired. Use a dry cloth or soft brush for cleaning.
⑦ If the insulation resistance of the coil is lower than the specified value, dry the coil by heating
it to 80 to 90°C [176 to 194°F], avoiding local heating, until the insulation resistance is more
than 1 MΩ.
⑧ Check bolts for looseness, retightening any loose bolt.
⑨ For the procedure for checking and servicing the bearings, see (4) Maintenance of bearings.
⑩ If the coating is damaged, discolored or exfoliated, apply anti-rust or paint again.
⑪ Tighten the terminals securely. Connections must be completely insulated with insulation tape.
⑫ After reassembly, make sure that there is not any part left and the bolts and screws are
securely tightened. Turn the shaft by hand to make sure it turns smoothly. Run the motor on a
trial basis.
⑬ The motor should be stored in a dry, clean place free from alkaline or other harmful gases. The
shaft should be applied with anti-rust and covered with oilpaper or vinyl sheet.
- 21 -
2.2.3 MAINTENANCE OF BEARINGS

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

Replacement intervals Once every 6 years Once every 3 years
Earlier replacement may be required if the motor is used at a place which is dusty or might
cause the sealed grease to deteriorate or flow out due to the atmosphere of harmful gases or
solvent.
■ Installing bearing
Install the bearing onto the shaft using a pipe (with a patch, if needed), as shown in Figure 2.8.
When heating the bearing, do not heat to more than 60 to 80°C [140 to 176°F].
PATCH
Fig. 2.8
■ Removing bearing
Using a puller, remove the bearing.
NUT
PULLER BOLT
INTERNAL
BEARING COVER
BEARING
Fig. 2.9
- 22 -
https://truckmanualshub.com/ 3. CONTROL SYSTEM
3. CONTROL SYSTEM
The controller assembly consists of two inverter units which control the drive and the pump
motors, respectively (excluding trucks with an Orbitrol steering system), and an EPS controller
unit which controls the EPS motor, as shown in Figures 3.1 and 3.4.
3.1.1 INVERTER UNIT

The inverter unit is a device consisting of a CPU board and FET modules and converts direct
current to 3-phase alternating current.
The CPU board receives various electric signals through the operation of the accelerator pedal
and valve control levers to control the drive motor and the pump motor through the inverter’s FET
modules.
The operating status of the drive motor and the pump motor is detected by the rotation sensor,
thermo-sensor and current sensor to feed the information back to the CPU board.
- 23 -
MCコンタクタ EPSコントローラ
EPS CONTROLLER
MC CONTACTOR
3. CONTROL SYSTEM
16P
F1
2P 2P
WP VP UP
WD VD UD
- 24 -
36P 36P
インバータユニット
INVERTER UNIT
(ポンプ)
(PUMP MOTOR)
36P 36P
INVERTER UNIT
(ドライブ)
(DRIVE MOTOR)
Fig. 3.1 Controller (1.0 - to 1.8-ton Trucks (excluding those with an Orbitrol steering system))
https://truckmanualshub.com/ 3. CONTROL SYSTEM
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凶
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Fig. 3.2 Inverter Unit (drive motor) Circuit

(1.0 - to 1.8-ton Trucks (excluding those with an Orbitrol steering system))
- 25 -
The direction of current
at the time of the steering
wheel being turned
clockwise.
(1.0- to 1.8-ton Trucks (excluding those with an Orbitrol steering system))

Fig. 3.3 Inverter Unit (pump motor) Circuit
- 26 -
Truck model selection switch status
Model Model
selection selection
option 1 option 2 * Short-circuit “SIG” and “-“
terminals of the sensor not
1-ton class Opened Opened in use.
2-ton class Connected Connected
3. CONTROL SYSTEM

* Connected: To be connected to the
signal wire GND.
INVERTER UNIT (PUMP(ポンプ)
MOTOR)
EPSコントローラ
EPS CONTROLLER (Not available on trucks with Orbitrol steering system)
16P
WP
36P
36P
VP
UP
WD VD UD
- 27 -
2P 2P
F1
1-ton Class Trucks with an Orbitrol steering system)

36P 36P
INVERTER UNIT
Fig. 3.4 Controller (2.0- to 3.5-ton Trucks with an EPS steering system and
(ドライブ)
(DRIVE MOTOR)
MCコンタクタ
MC CONTACTOR
3. CONTROL SYSTEM
3. CONTROL SYSTEM https://truckmanualshub.com/
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Fig. 3.5 Inverter Unit (drive motor) Circuit (2.0- to 3.5-ton Trucks with an EPS steering system
and 1-ton Class Trucks with an Orbitrol steering system)
- 28 -
3. CONTROL SYSTEM
Fig. 3.6 Inverter Unit (pump motor) Circuit (2.0- to 3.5-ton Trucks with an EPS steering system
(Not available on trucks with Orbitrol steering
system)
The direction of current
at the time of the steering
wheel being turned
clockwise.
and 1-ton Class Trucks with an Orbitrol steering system)

- 29 -
Truck model selection switch status
Model Model
selection selection
option 1 option 2 * Short-circuit “SIG” and “-“
terminals of the sensor not
1-ton class Opened Opened in use.
* Connected: To be connected to the
signal wire GND.
3. CONTROL SYSTEM https://truckmanualshub.com/
3.1.2 ACCELERATOR PEDAL

The accelerator pedal is installed as shown in Figure 3.7, and the amount of accelerator pedal
effort is transmitted to the potentiometer.
The potentiometer converts pedal effort into voltage change and sends it to the controller.
186
93 185
92
187 184
ViewAlooking from A
18.5 mm
[0.73 in.] PEDAL 1. Apply a voltage of +5 ±0.01 V between 187 and 186.
1.187－186間に＋5±0.01Vの電圧を加える。
2. Turn potentiometer clockwise in neutral state and lock it at
2.中立時、ポテンショメータ本体を右方向に回し、93－186間
a position at which the voltage between 93 and 186 shows
の電圧が1.0±0.1Vとなる位置で固定する。
1.0 ± 0.1 V.
3. Move the lever a few times and make sure the voltage
3.２～３回レバーを動かし、全開時の93－186間の電圧が
between 186 and 93 shows 4.0 ± 0.2 V in full-throttle state.
4.0±0.2Vであることを確認する。
STOPPER
POTENTIOMETER
Fig. 3.7 Accelerator Pedal
- 30 -
https://truckmanualshub.com/ 4. DRIVE UNIT AND DRIVE AXLE
4. DRIVE UNIT AND DRIVE AXLE

FB18-8 FB25-8LB FB25-8V FB30-8V
Item
Drive unit
Type Three-stage reduction ← ←
Model 81E-25 81N-25 81U-25
Reduction ratio 25.1 ← 30.144
Drive axle
Type Full floating ← ←
6.00 x 9 – 10PR 21 x 8 – 9 16PR 28 x 9 – 15 14PR
Wheel dimensions Rib lug Rib lug Rib lug
Rim size 9 x 4.00E 9 x 6.00E 7.00T x 15
2 2
Air pressure 850 kPa {8.5 kgf/cm } 1000 kPa {10 kgf/cm } 800 kPa {8.0 kgf/cm2}
[120.9 psi] [142.2 psi] [100 psi]

4.1.1 DRIVE UNIT
The drive unit is a three-stage reduction type and located between the drive motor and the drive
axle as shown in Figs. 4.1 through 4.3.
The drive gear is splined to the output shaft of the drive motor, being in mesh with the counter
gear 1. The drive gear is supported by two ball bearings on the case. The rotation of the drive gear
is transmitted through the counter gears 1 and 2 to the ring gear.
The counter gear 2 of the 81N-25 and the 81U-25 is attached by two tapered roller bearings to
the case, with the starting torque adjusted with shims.
In the case the differential is installed by two ball bearings. The cross case has two side gears
and four pinions in it (Two pinions for the model 81E-25). For adjustment of the backlash between
each side gear and pinion, a washer is installed. These washers also work as bearings.
To the cross case a ring gear is fitted by a reamer bolt. The ring is in mesh with the final pinion
gear.
- 31 -
4. DRIVE UNIT AND DRIVE AXLE https://truckmanualshub.com/
RING GEAR PINION SHAFT

Tightening torque: 95 to 142 N-m
{970 to 1450 kgf-cm} WASHER
[840.8 to 1257 lbf-in.]
PINION GEAR
WASHER
Tightening torque: 44 to 54 N-m SIDE GEAR

{450 to 550 kgf-cm}
[389.4 to 477.9 lbf-in.]
COUNTER GEAR 2
カウンタギヤ2 TAPER PIN
Tightening torque:
34.3 to 44 N-m
{350 to 450 kgf-cm}
[303.6 to 389.4 lbf-in.]
O-RING
O-RING
O-RING
STOPPER
COUNTER
GEAR 1
カウンタギヤ1
MOTOR
DRIVE GEAR
Tightening torque: 278N・

締付トルク：278～416 tom416 N-m
{2800 kgf・
{2800～4200 to 4200
cm} kgf-cm}
[2460.5 to 3681.9 lbf-in.]
（ロックタイト＃262塗布）
(Apply LOCTITE #262)
Fig. 4.1 Drive Unit (1- to 1.8-ton Trucks)
- 32 -
https://truckmanualshub.com/ 4. DRIVE UNIT AND DRIVE AXLE
RING GEAR
SPIDER
WASHER SIDE GEAR

Tightening torque:
95 to 142 N-m
{970 to 1450 kgf-cm}
[840.8 to 1257 lbf-in.] PINION GEAR WASHER
Tightening torque:
44 to締付トルク：
54 N-m
{45044～54
to 550 kgf-cm}
N・m
[389.4 to 477.9 kgf
{450～550 lbf-in.]
・m}
TAPERED ROLLER
テーパローラベアリング
BEARING
COUNTER GEAR 2
カウンタギヤ2
Tightening torque:
34.3 to 44 N-m
SPACER
スペーサ {350 to 450 kgf-cm}
[303.6 to 389.4 lbf-in.]
TAPERED
テーパローラ
ROLLER
ベアリング
BEARING
STARTING TORQUE
起動トルク測定用ボルト
MEASUREMENT BOLT
(M12-1.25,長さ100mm)
(M12-1.25, LENGTH
O-RING 100 mm [3.9 in.])
Shim: 0.5 [0.0197]
(standard)
シム標準：0.5 O-RING
STOPPER
Starting torque: 1.5 to

起動トルク：1.5～3.5 N・3.5
m N-m
{15.3 to 35.7 kgf-cm}
[13.3 to 31.0 lbf-in.]
O-RING
COUNTER
カウンタギヤ1
GEAR 1
MOTOR
DRIVE GEAR
Tightening torque: 278N・m

締付トルク：278～416 to 416 N-m
{2800 to 4200 kgf-cm}
{2800～4200 kgfto
[2460.5 ・cm}
3681.9 lbf-in.]
Fig. 4.2 Drive Unit (2- to 2.5-ton Trucks)
- 33 -
Tightening torque:
137 to 177 N-m
RING GEAR {1400 to 1800 kgf-cm}
[1212.6 to 1566.6 lbf-in.]
SPIDER
Tightening torque:
95 to 142 N-m SIDE GEAR
WASHER
{970 to 1450 kgf-cm}
[840.8 to 1257 lbf-in.]
PINION GEAR WASHER
COUNTER GEAR 2
カウンタギヤ2
TAPERED ROLLER
テーパローラベアリング
SPACER
スペーサ BEARING
Tightening torque:
34.3 to 44 N-m
TAPERED ROLLER
テーパローラ {350 to 450 kgf-cm}
BEARING
ベアリング [303.6 to 389.4 lbf-in.]
O-RING STARTING TORQUE

起動トルク測定用ボルト
MEASUREMENT
(M12-1.25,長さ100mm)
BOLT (M12-1.25,
LENGTH 100 mm
[3.9 in.])
STOPPER
Shim: 0.5 [0.0197] (standard)
シム標準：0.5 O-RING
Starting torque: 1.5 toN・3.5
起動トルク：1.5～3.5 m N-m
{15.3 to 35.7 kgf-cm}
[13.3 to 31.0 lbf-in.]
O-RING
COUNTER
カウンタギヤ1
GEAR 1
MOTOR
DRIVE GEAR
Tightening torque: 278 Nto
締付トルク：278～416 ・m416 N-m
{2800kgf
{2800～4200 to ・cm}
4200 kgf-cm}
[2460.5 to 3681.9 lbf-in.]
Fig. 4.3 Drive Unit (3.0- to 3.5-ton Trucks)
- 34 -
axle shaft.
AXLE SHAFT TAPERED ROLLER BEARING
TAPERED ROLLER
AXLE HOUSING BEARING
4.1.2 DRIVE AXLE
OIL SEAL
front side of the frame.
OIL SEAL
ADJUSTMENT NUT
HUB & BRAKE DRUM
WHEEL BRAKE
LOCK NUT
- 35 -
Tightening torque:
98 to 113 N-m
{1000 to 1150 kgf-cm}
[870 to 1000 lbf-in.]
Tightening torque: 120 to 140 N-m (Apply LOCTITE#262)
{1220 to 1430 kgf-cm}
[ 1060 to 1240 lbf-in.]
At each end of the axle housing are a wheel hub and a wheel brake.
Fig. 4.4 Drive Axle (1- to 1.8-ton Trucks)

(Apply LOCTITE#270)
Tightening torque:
150 to 175 N-m
{1530 to 1780 kgf-cm}
Fill 50% of the space with grease [1330 to 1550 lbf-in.]
(100 cm3 at one side)
The drive axle is composed of an axle housing, wheel hub, and wheels. It is mounted at the
The wheel hub is supported on the spindle by two tapered roller bearings, and is driven by the
OIL SEAL
TAPERED ROLLER BEARING

AXLE SHAFT OIL SEAL
BRAKE DRUM HUB
AXLE HOUSING
WHEEL BRAKE
ADJUSTMENT NUT
LOCK NUT
- 36 -
Tightening torque: 140 to 160 N-m {1430 to 1630 kgf-cm}

[1240 to 1420 lbf-in.]
(Apply LOCTITE#270)
Fig. 4.5 Drive Axle (2- to 2.5-ton Trucks)

Tightening torque: 216 to 235 N-m {2200 to 2400 kgf-cm}
[1910 to 2080 lbf-in.] Tightening torque:
(Apply LOCTITE#270 or THREEBOND #1305N) 370 to 420 N-m
{3770 to 4280 kgf-cm}
[3275 to 3717 lbf-in.]
Fill 50% of the space with grease

{4800 to 5600 kgf-cm}
[4170 to 4860 lbf-in.]
HUB
AXLE SHAFT TAPERED ROLLER BEARING

TAPERED ROLLER BEARING
AXLE HOUSING
WHEEL BRAKE
OIL SEAL
ADJUSTMENT NUT
LOCK NUT
- 37 -

{2100 to 2300 kgf-cm}
[1820 to 1990 lbf-in.]
(Apply LOCTITE#270)
Tightening torque:
471 to 549 N-m
Fig. 4.6 Drive Axle (3.0- to 3.5-ton Trucks)

OIL SEAL
{4800 to 5600 kgf-cm}
[4170 to 4860 lbf-in.]
BRAKE DRUM
Fill 50% of the space with grease

■ Procedure for installing the wheel hub

(1) Put the specified amount of grease into the
space A of the wheel hub and install it
onto the spindle.
(2) Tighten the adjustment nut to approx. 98 A
N-m {1 kgf-m} [7.23 lbf-ft] torque and
loosen it by 1/2 turn.
ADJUSTMENT NUT
(3) Set the spring balancer to the stud bolt.
LOCK WASHER
Adjust the starting force of the hub while LOCK NUT
tightening the adjustment nut gradually.
Starting force: 4.9 to 6.9 N Fig. 4.7 Filling Grease
{0.5 to 0.7 kgf}
[43.4 to 61.1 lbf]
(4) Install the lock washers and the lock nuts,
and secure the lock nuts with the claws of
the lock washers.
Fig. 4.8 Measuring Starting Force
- 38 -
https://truckmanualshub.com/ 5. BRAKE SYSTEM
5. BRAKE SYSTEM

Item FB18-8 FB25-8LB FB25-8V FB30-8V
Type Front two wheel braking, internal expansion, hydraulic type
Pedal ratio 6.2 ← ←
Master cylinder bore 19.05 mm [0.75 in.] ← ←
Wheel brake
Type Duo-servo type ← ←
Wheel cylinder bore 22.22 mm [0.875 in.] 25.4 mm [1 in.] 28.58 mm [1.125 in.]
Brake drum inner dia. 254 mm [10 in.] 279.4 mm [in.] 314 mm [12.36 in.]
Lining size 279 x 48.5 x 5 mm 302 x 55 x 5.1 mm 348 x 76 x 7.67 mm
[10.98 x 1.91 x 0.20 in.] [11.9 x 2.2 x 0.2 in.] [13.7 x 3.0 x 0.31 in.]
Surface area 4 x 13530 mm2 4 x 16600 mm2 4 x 26400 mm2
[4 x 30 in.2] [4 x 25.7 in.2] [4 x 40.9 in.2]
Parking brake
Type Front two wheel braking, internal expansion, mechanical type

The brake system is a front two wheel braking, internal expansion, hydraulic type consisting of
a brake pedal, a master cylinder and wheel brakes.
5.1.1 BRAKE PEDAL

BRAKE PEDAL
The brake pedal is installed through a bracket
to the frame as shown in Figure 5.1.
Pedal movement pushes the piston of the
master cylinder by means of the push rod, which
converts pedal effort into hydraulic pressure.
MASTER CYLINDER
Fig. 5.1 Brake Pedal
- 39 -
5. BRAKE SYSTEM
RESERVE TANK MASTER CYLINDER

BRAKE SWITCH
BRAKE SWITCH OPERATION

DISTANCE:
5 – 10 mm [1.97 – 3.94 in.]
Height:
高さ：97 97mm（FB10～25）
mm [3.8 in.] (FB10 - 25)
110mm（FB30～35）
110 mm [4.3 in.] (FB30 - 35)
- 40 -
Fig. 5.2 Brake Pedal
View looking from A

5.1.2 MASTER CYLINDER

The master cylinder is installed on the bracket of the brake pedal unit as shown in Figure 5.3.
Built in the master cylinder are a check valve, spring and piston. They are kept in position by a
snap ring.
The primary and secondary cups installed on the piston slide inside the cylinder when brake
pedal is operated.
The check valve is operated so that the proper pressure remains in the wheel cylinder and brake
pipe. This pressure keeps pushing the piston cup of each wheel cylinder so as to prevent oil leakage
and also prevent vapor locking from occurring.
BLEEDER PLUG
from RESERVE TANK
CHECK
SNAP RING VALVE
YOKE
LOCK NUT
SPRING
BOOT
PUSH ROD PRIMARY CUP
PISTON
SECONDARY CUP
Fig. 5.3 Master Cylinder
- 41 -
5. BRAKE SYSTEM https://truckmanualshub.com/
5.1.3 WHEEL BRAKE

The wheel brake is duo-servo type, and is
mounted on each of the both ends of the drive
m tion
axle. ANCHOR PIN
dru rec
of n di
The wheel brake is composed of two pairs of
io
tat
brake shoes, a wheel cylinder and adjuster.
Ro
One end of the brake shoe is contacted with
the anchor pin and another end is contacted with
the adjuster. The brake shoes are pushed against
the backing plate through the shoe hold-down
spring and shoe hold-down pin. ADJUSTER
The parking brake mechanism and the
automatic clearance adjuster are also built in the Fig. 5.4 Braking Operation in Forward Travel
wheel brake.
(1) Wheel brake operation

The wheel cylinder pushes the primary and
secondary shoes against the brake drum with an
equal force. The shoes are kept turning with the
Working force
brake drum until the top of the secondary shoe
Secondary
Primary
comes in contact with the anchor pin.

When the secondary shoe comes in contact
with the anchor pin, the friction force is
generated between the brake lining and the
brake drum, and the primary shoe pushes the
secondary shoe with a stronger force than the
operation force of the wheel cylinder. Powerful Fig. 5.5 Braking Operation in Backward Travel
braking force is thus achieved. (See Figure 5.4)
In backward travel, the braking force works
in the reverse direction of forward travel. (See
Figure 5.5)
(2) Parking brake SECONDARY SHOE

PIN
The parking brake unit is built in the wheel
brake, and consists of a lever and strut. LEVER STRUT
The lever is installed on the primary shoe

side with a pin. Movement of the lever is also
transmitted to the secondary shoe side through
the strut.
PRIMARY SHOE
Fig. 5.6 Parking Brake
- 42 -
(3) Automatic clearance adjuster

The automatic clearance adjuster
automatically keeps the lining-to-drum
clearance properly. The components are as
CABLE
shown in Figure 5.7. It is put in action when the
brakes are applied while traveling backward. GUIDE
■ O peration of the automatic clearance

adjuster SPRING
LEVER
When the brake pedal is pressed down in ADJUSTER
reverse travel, the secondary shoe is slightly
turned together with the brake drum, and the
lever is turned clockwise around the section A
Fig. 5.7
shown in Figure 5.7.
At this step, the section B of the lever turns
the adjuster. As the braking force becomes
stronger, the more force is applied to the
threaded area of the adjuster, and the force of
the lever cannot turn the adjuster.
When the brake pedal is released, the brake
shoe returns to the initial position, the lever
turns counterclockwise around the section A ,
and the section B moves downward.
If a tooth of the adjuster is aligned with the
section B of the lever, the B is in mesh with
the next tooth and the clearance is adjusted
within the range from 0.25 to 0.4 mm [0.0098 to
0.0157 in.].
Expanding direction
Fig. 5.8 Automatic Clearance Adjuster
- 43 -
5.1.4 PARKING BRAKE LEVER

The parking brake lever is a toggle type and it is installed as shown in Figure 5.9. An adjuster
adjusting the braking force is located on the top of the lever.
RELEASE
BUTTON
PARKING
BRAKE LEVER
View looking from C

PARKING BRAKE SWITCH
RIGHT-SIDE CABLE
LEFT-SIDE CABLE
■ Adjusting lever pulling force

(1) Put the lever in the release position.
(2) Adjust the lever so that it is positioned as
shown in the figure when the point B of the
lever is pulled by a force of 147 to 167 N {15
to 17 kgf} [33 to 37.5 lbs].
Turn the point A clockwise when you want
a harder pulling force and counterclockwise
when you want a lighter pulling force.
Fig. 5.9 Parking Brake Lever
Parking brake alarm system

1. If the parking brake is released while the key switch
is in the OFF position:
Alarm
•• The alarm buzzer keeps sounding regardless of
whether the operator is in the seat or not.
How to release the alarm
•• Pull on the parking brake lever to set the brakes.
2. If the parking brake is released while the key switch
in the ON position:
Alarm SWITCH
•• The alarm buzzer will sound for one half second

if the parking brake is released and the operator
leaves the seat when the key switch is in the ON
position. If more than 3 seconds has passed after
the parking brake is released and the operator
leaves the seat, the alarm buzzer will keep
sounding.
How to release the alarm
•• Sit down or pull on the parking brake lever to set Fig. 5.10
the brakes.
Adjusting brake switch

① Loosen the two nuts securing the switch.
② Pull the brake lever.
③ Press the switch roller against the arm. After it clicks, press another 1 mm [0.0394 in.] and lock.
④ Release the brake and pull the brake lever again to see if the switch is turned ON.
- 44 -
Sectional view D - D Sectional view B - B

Sectional view E - E
Shoe expanding direction
Sectional view A - A
Sectional view of wheel cyl.
Sectional view C - C
1. BRAKE LEVER 8. SHOE HOLD-DOWN 1 4. PUSH ROD

2. SECONDARY SHOE PIN 15. BOOT
3. E RETAINER 9. PRIMARY SHOE 16. CYLINDER
4. WHEEL CYLINDER 10. SPRING 17. PISTON
5. RETURN SPRING 11. ADJUSTER LEVER 18. SPRING
6. STRUT 12. ADJUSTER 19. CUP
7. SPRING 13. SPRING
Fig. 5.11 Wheel Brake (1- to 2.5-ton Trucks)
- 45 -
Sectional view C - C Sectional view E - E
Sectional view D - D
Shoe expanding direction
Sectional view A - A
Sectional view of wheel cyl.
Sectional view B - B
1. BRAKE LEVER 8. SHOE HOLD-DOWN 1 4. PUSH ROD

2. SECONDARY SHOE PIN 15. BOOT
3. E RETAINER 9. PRIMARY SHOE 16. CYLINDER
4. WHEEL CYLINDER 10. SPRING 17. PISTON
5. RETURN SPRING 11. ADJUSTER LEVER 18. SPRING
6. STRUT 12. ADJUSTER 19. CUP
7. SPRING 13. SPRING
Fig. 5.12 Wheel Brake (3- to 3.5-ton Trucks)
- 46 -
5.2 MAINTENANCE
This section describes the procedure for disassembling, reassembling and adjusting the wheel
brake and the procedure for adjusting the brake pedal, with the wheel brake and hub removed.
5.2.1 DISASSEMBLING WHEEL BRAKE

(1) Remove the shoe hold-down pin, adjuster
lever, adjuster and spring from the
secondary shoe.
Fig. 5.13
(2) Remove the shoe return spring.
Fig. 5.14
(3) Remove the shoe hold-down spring from

the primary side.
Fig. 5.15
- 47 -
(4) Remove the primary and secondary shoes.

Also remove the adjuster and adjuster
spring at the same time.
Fig. 5.16
(5) Remove the brake pipe from the wheel

cylinder. Remove the bolts securing the
wheel cylinder. Remove the wheel cylinder
from the backing plate.
Fig. 5.17
(6) Remove the E retainer which secures the

parking brake cable to the backing plate.
After that, remove the bolt securing the
backing plate and remove the backing plate
from the axle.
Fig. 5.18
(7) Remove the boot and insert the piston to

remove one of the two wheel cylinders.
Then remove the other wheel cylinder by
pushing with a finger from the opposite
side.
Fig. 5.19
- 48 -
5.2.2 INSPECTION
Check each part and repair or replace any defective one.
(1) Check the wheel cylinder inner surface and

piston outer periphery for rust.
Measure the clearance between the piston
and cylinder.
Standard: 0.03 to 0.10 mm
[0.0012 to 0.0039 in.]
Limit: 0.15 mm [0.0059 in.]
Fig. 5.20
(2) Visually check the piston cup for damage or deformation and replace any damaged or
deformed one.
(3) Measure the free length of the wheel cylinder spring. If the length is out of the standard value,
replace the spring.
(4) Measure the brake lining thickness and

replace any excessively worn lining.
Unit: mm [in.]
1.0 – 1.8 t 2.0 – 3.5 t
Standard 4.87 [0.192] 7.67 [0.302]
Limit 2.5 [0.098] 5.0 [0.197]
Fig. 5.21
(5) Visually check the inner surface of the

brake drum. If any damage or uneven wear
is observed, grind it to repair. Replace an
excessively damaged or worn drum.
Unit: mm [in.]
1.0 – 1.8 t 2.0 – 2.5 t 3.0 – 3.5 t
254 279.4 314
Standard [10] [11] [12.36]
256 281.4 316
Limit [10.1] [11.1] [12.44]
Fig. 5.22
- 49 -
5.2.3 REASSEMBLING WHEEL BRAKE

(1) Apply brake fluid to the cup and piston of the wheel cylinder. Install the spring, piston cup,
piston and boot in this order.
(2) Install the wheel cylinder on the backing plate.
Tightening torque: 17.7 to 26.5 N-m {180 to 270 kgf-cm} [156.7 to 234.5 lbf-in.]
(3) Install the backing plate on the drive axle.
Tightening torque: 117.7 to 137.3 N-m {1200 to 1400 kgf-cm} [1042 to 1215 lbf-in.]
(4) Apply high-temperature grease to the points shown in Figure 5.23, using caution to keep
grease away from the lining.
(a) Shoe contacting surface on the

backing plate
(b) Anchor pin
(c) Cable guide surface contacting the
adjuster cable
(d) Parking brake lever pin
(e) Threaded area of the adjuster and the
other rotation areas
Fig. 5.23
(5) Install the parking brake cable with the E retainer.
(6) Install the shoe with the hold-down spring.
Fig. 5.24
(7) Insert the spring into the strut and attach the strut to the shoe.
- 50 -
(8) Install the shoe guide pin in the anchor pin,

and install the shoe return spring.
In this step, install the spring at first on the
primary side and then on the secondary
side.
Fig. 5.25
(9) Install the spring, adjuster, adjuster spring

and adjuster lever, paying attention to the
following items:
① Install the adjuster in such a way that the
left screw is used for the left brake, and that
the right screw is used for the right brake.
② Install the adjuster so that its teeth do not
make contact with the spring.
③ Install the return spring at the adjuster side,
with its longer hook attached to the adjuster Fig. 5.26
lever side.
④ After reassembling, check that the tip of the adjuster lever comes in contact with the adjuster
teeth.
(10) Install the brake pipe on the wheel cylinder.
(11) Measure the inner diameter of the brake

drum and the outer diameter of the shoe.
Adjust the adjuster so that the outer
diameter of the brake shoe is “the inner
diameter – 1.0 mm [0.0394 in.]”.
Fig. 5.27
- 51 -
5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER

(1) Set the outer diameter of the brake shoe to nearly the normal mounting dimension. Push up
the adjuster lever and adjust the diameter, turning the teeth of the adjuster.
When your finger is released, the teeth of the adjuster do not turn and the adjuster lever returns
to the original position.
Note: If the teeth of the adjuster return with the lever, they are adjusted properly after mounting
the brake system on the truck.
(2) If the operation described above does not occur by pushing up the adjuster lever, take the
following measures:
(a) Check that the adjuster lever, adjuster, adjuster spring, adjuster cable and shoe return spring
are securely installed.
(b) Check the shoe return spring and adjuster spring for deterioration, the adjuster for rotation,
damaged tooth or damage of the contact area with the teeth of the adjuster lever, and replace
any defective parts.
Expanding part
Fig. 5.28
- 52 -
5.2.5 ADJUSTING BRAKE PEDAL

(1) Shorten the push rod length of the master cylinder.
(2) Using the stopper bolt, adjust the pedal upheight to the value shown in Figure 5.29.
(3) Keeping the pedal pressed down by the pedal play, extend the push rod so that its tip contacts
the piston of the master cylinder.
(4) Securely tighten the push rod by its lock nut.
BRAKE SWITCH
Brake switch operating direction:

5 – 10 mm [0.2 – 0.4 in.]
Pedal height: 97 mm [3.8 in.] (FB10 - 25)

ペダル高さ：97mm（FB10～25）
110110mm（FB30～35）
mm [4.3 in.] (FB30 - 35)
Fig. 5.29
■ Adjusting brake switch

(1) Make sure that the pedal upheight is the value shown in Figure 5.29. Loosen the brake switch
lock nut.
(2) Remove the brake switch lead wire from the connector.
(3) While turning the brake switch and pressing down the brake pedal by 5 to 10 mm [0.2 to 0.4
in.], check and find the position where the switch turns ON.
(4) Secure the brake switch with the lock nut.
- 53 -
5.2.6 TROUBLESHOOTING GUIDE
Trouble Probable Cause Remedy

1. Brake fluid leaks from the brake system Repair.
2. Maladjustment of brake shoe clearance Check and adjust the adjuster.
3. Overheating brake Check for dragging.
Poor braking 4. Poor contact between brake drum and
Adjust contact.
force lining
5. Foreign matter sticking to lining Repair or replace.
6. Foreign matter mixed in brake fluid Check brake fluid.
7. Maladjustment of brake pedal Adjust.
1. Lining surface hardened or foreign
Repair or replace.
matter sticking to lining
2. Deformed backing plate or loose bolts Repair or replace.
Noisy brake
3. Shoes deformed or improperly installed Repair or replace.
4. Lining unevenly worn Replace.
5. Defective wheel bearing Replace.
1. Foreign matter adhering to lining Repair or replace.
2. Maladjusted brake shoe clearance Check and adjust the adjuster.
Uneven 3. Malfunctioning wheel cylinder Repair or replace.

braking 4. Shoe return spring defective Replace.
5. Deflected Drum Repair or replace.
6. Improper tire inflation pressure Adjust.
1. Brake fluid leaks from brake system Repair.
Soft or spongy 2. Maladjusted brake shoe clearance Check and adjust the adjuster.
brake 3. Air mixed in brake system Bleed air.
4. Pedal maladjusted. Adjust.
- 54 -
https://truckmanualshub.com/ 6A. STEERING SYSTEM (ORBITROL type)
6A. STEERING SYSTEM (ORBITROL type)
Truck model FB10-8 FB20-8 FB25-8V FB35-8S

FB15-8 FB25-8 FB25-8LB
Item FB18-8 FB30-8 FB30-8V
Steering axle
Center-pin supported, Elliot type with box-shaped
Type
cross section of weld construction
King pin spacing 735 mm [28.9 in.] 740 mm [29.1 in.]
King pin angle 0°
Toe-in 0 mm
Camber 1°
Caster 0°
Wheel dimension 16 x 6-8 10PR 18 x 7-8 14PR
Rim size 4.25 x DT ←
2
Air pressure 850 kPa {8.5 kgf/cm } 900 kPa {9.0 kgf/cm2}
Steering angle
Inner wheel 78.4° 75.3°
Outer wheel 53.3° 59.2°
Orbitrol
Type Open-centered, non-load reaction type
Discharge 96 cm3 [5.86 in.3]/rev
Power cylinder
Type Double-acting piston type
Cylinder bore 71 mm [2.8 in.]
Piston rod diameter 40 mm [1.57 in.]
Stroke 132 mm [5.20 in.] 146 mm [5.75 in.]
Flow divider valve
Flow rate 20 liters [5.28 U.S. gal]/min
Pressure setting 8.8 MPa {90 kgf/cm2} [1280 psi]
6A.1 GENERAL DESCRIPTION

The steering system consists primarily of a steering wheel, an orbitrol, and a power cylinder.
When the steering wheel is turned, the rotation is transmitted to the orbitrol; the oil passages in the
orbitrol are changed over to direct the hydraulic pressure from the flow divider valve to the power
cylinder, which extends or contracts depending on the hydraulic pressure, thereby steering the
truck.
- 55 -
6A. STEERING SYSTEM (ORBITROL type) https://truckmanualshub.com/
6A.1.1 STEERING AXLE

The steering axle is of steel-welded construction with a box-shaped cross section, incorporating
a power cylinder inside it. See Figures 6A.1 and 6A.3. The power cylinder is housed in the axle to
protect it from being damaged by obstacles on the road surface. The axle is installed onto the truck
frame through a center pin with bushing and cap, and it cradles around this center pin.
Tightening torque:
68 to 100 N-m
{7 to 10.2 kgf-m}
[50.6 to 73.8 lbf-ft]
Apply THREEBOND #1324
JOINT (LEFT)
POWER CYLINDER
JOINT (RIGHT)
D See Figure 6A.2.
B C See Figure 6A.2.

A
KNUCKLE
(LEFT) KNUCKLE
(RIGHT)
Point notched surface

toward knuckle’s shaft
POTENTIOMETER
KING PIN
Detail of A View looking from B
Fig. 6A.1 Steering Axle (for 1.0- to 1.8-ton Trucks) 1/2
- 56 -
PIN PIN
BUSHING
SPHERICAL
BUSHING
Detail of C
KING PIN
OIL SEAL
OIL SEAL
NEEDLE BEARING
TAPERED ROLLER
BEARING
THRUST BEARING
TAPERED ROLLER
BEARING
ADJUSTMENT NUT
COTTER PIN
CAP
Fill 50% of the

space with grease
“O”-RING
NEEDLE BEARING LOCK PIN
OIL SEAL
Detail of D
- 57 -
Tightening torque:
68 to 100 N-m
{7 to 10.2 kgf-m}
[50.6 to 73.8 lbf-ft]
Apply THREEBOND #1324
JOINT (LEFT)
POWER
CYLINDER
JOINT
(RIGHT)
D See Figure 6A.4.
B
A C See Figure 6A.4.
KNUCKLE
(LEFT) KNUCKLE
(RIGHT)
KING PIN
POTENTIOMETER
Detail of A View looking from B
- 58 -
PIN
PIN
BUSHING
SPHERICAL
BUSHING Detail of C KING PIN
OIL SEAL
OIL SEAL
TAPERED ROLLER
BEARING
NEEDLE BEARING
THRUST BEARING
TAPERED ROLLER
BEARING
ADJUSTMENT NUT
CAP
COTTER PIN
Fill 50% of the space

with grease
“O”-RING
NEEDLE BEARING
LOCK PIN
OIL SEAL
Detail of D

(1) Knuckle and king pin
The knuckle is supported with a king pin which in turn is secured at the knuckle side with a lock
pin. The top and bottom of the king pin are fitted to the axle boss with needle bearings.
Between the axle boss and the knuckle is a thrust bearing to let the knuckle smoothly rotate
around the king pin, sustaining load.
The top and bottom needle bearings and thrust bearing are lubricated by grease supplied through
the grease fittings at top and bottom of the king pin.
(2) Wheel hub

The wheel hub is mounted on the knuckle spindle with two tapered roller bearings and its
preload is adjusted with a nut.
- 59 -
6A.1.2 STEERING WHEEL ASSEMBLY

The steering wheel assembly is arranged as shown in Figure 6A.5. The orbitrol is located at the
bottom of the assembly. At the center of the steering wheel is the horn button.
The steering shaft is connected to the drive shaft of the orbitrol. The steering wheel can be
moved to a certain extent back and forth to suit the driver’s physique.
STEERING WHEEL
TILT LOCK LEVER
JOINT
View looking from A
ORBITROL
Fig. 6A.5 Steering Wheel Assembly
- 60 -
Front of COMBINATION SWITCH

the truck ASSEMBLY
Front of the truck
View looking from C
Front of
the truck
View looking from B

View looking from A
Fig. 6A.6 Steering Wheel
- 61 -
6A.1.3 ORBITROL
The orbitrol sends pressure oil from the pump selectively to the steering cylinder. It consists
primarily of a control valve and a metering device.
The control valve used in the orbitrol is not an ordinary spool valve whose spool moves in
the axial direction, but a rotary valve which consists of a sleeve and a spool that rotate together
forming different oil passages through the combination of their oil holes. The valve housing is
provided with four ports which lead to the pump, tank, right and left chambers of the cylinder.
Between the inlet port and return port is a check valve.
The metering device consists of an internally toothed stator and an externally toothed rotor.
During normal operation, it operates as an oil motor. In an emergency, it can be used as hand
pump. The rotor is mechanically linked with the sleeve through the drive shaft so that feedback
operation is possible.
The sleeve is interlocked with the motor’s rotor through the cross pin and drive shaft while the
spool is splined to the steering shaft.
ORBITROL
VP VALVE
L
R
T P EF
Oil pressure symbols
T PORT EF PORT
L PORT
R PORT
P PORT
Fig. 6A.7 Orbitrol
- 62 -
(1) Operation of orbitrol

(a) In “Neutral”
While the steering wheel is in straight
position, the oil from the pump flows through oil
passage ① to oil groove ② . The sleeve has 24
oil holes ③ which are now in line with the holes
④ in the spool so that the oil that flowed into
groove ② passes through oil holes ③ and ④ to
space ⑤ between the spool and drive shaft. Then
the oil flows through spool groove ⑥ and sleeve
groove ⑦ back to the oil tank.
Since cylinder ports ⑳ and 21 are respectively
open to oil holes ⑱ and ⑰ in the sleeve but not
to groove ⑯ nor ⑲ in the spool, the oil in the
cylinder does not go any where.
Oil passage ⑮ that leads to the hydraulic motor
is open to oil hole ⑭ in the sleeve which is used
as the inlet and outlet for the hydraulic motor, but
not to grooves ⑬ nor ⑯ in the spool and thus the
oil remain unmoved.
Fig. 6A.8
(b) When steering wheel is turned counterclock-

wise
As the steering wheel is turned counterclock-
wise, the grooves in the spool shift to the left in
relation with the holes and grooves in the sleeve
so that holes ④ in the spool get out of line with
holes ③ in the sleeve. The oil that has flowed into
groove ② thus far begins to flow into hole ⑫ in
the sleeve, passing through grooves 23 and ⑬ in
the spool, hole ⑭ in the sleeve, and oil passage
⑮ in the housing, to the hydraulic motor.
The hydraulic motor thus rotates in the
counterclockwise direction and the oil discharged
from the hydraulic motor flows through oil hole
⑭ in the sleeve, groove ⑯ in the spool, and oil
hole ⑱ in the sleeve to the cylinder port L in the
housing and thus actuates the steering cylinder.
Fig. 6A.9
- 63 -
The returning oil from the power cylinder flows, passing through the cylinder port R, groove ⑪
in the valve housing, oil hole ⑰ in the sleeve, groove ⑲ in the spool, oil hole 22 in the sleeve, and
groove ⑧ in the valve housing, back to the oil tank.
(c) When steering wheel is turned clockwise

As the steering wheel is turned clockwise, the
grooves in the spool shift to the right in relation to
the oil holes and grooves in the sleeve so that oil
holes ④ in the spool get out of line with holes ③
in the sleeve. The oil that has flowed into groove
② thus far begins to flow into oil hole ⑫ in the
sleeve and then flows through grooves 23 and
⑬ in the spool, oil hole ⑭ in the sleeve, and oil
passage ⑮ in the valve housing to the hydraulic
motor. The hydraulic motor thus rotates in the
clockwise direction and the oil discharged from
the hydraulic motor flows through oil hole ⑭ in
the sleeve, groove ⑯ in the spool, and oil hole ⑰
in the sleeve to the cylinder port R in the housing
and thus actuates the power cylinder.
The returning oil from the power cylinder
flows, passing through the cylinder port L, groove
⑩ in the housing, oil hole ⑱ in the sleeve, groove
⑲ in the spool, oil hole 22 in the sleeve and
groove ⑨ in the housing back to the oil tank.
Fig. 6A.10
(2) Relationship between the rotating speed and operating force of the steering wheel
The force required to operate the orbitrol is basically a valve operating force (the force
required to compress the centering spring: 2.9 N-m {0.3 kgf-m} [2.14 lbf-ft]). That is, there is
no mechanical linkage between the steering wheel and the tires, and thus the operating force of
the steering wheel remains constant regardless of the rotating speed of the steering wheel. The
discharge of oil from the orbitrol rotor to the steering cylinder is 80 cm3/revolution.
(3) Neutral feedback of orbitrol

The neutral feedback function of the orbitrol is performed by the valve switching over the oil
passages according to the reaction force of the centering spring. (If the steering wheel is turned and
then released with the engine turned off, it will automatically return to the straight-ahead position.)
Should the neutral feedback not function properly, the steering wheel might turn by itself when the
operator does not turn it.
- 64 -
(4) When the pump fails to operate normally

If the pump fails to supply pressure oil to the orbitrol, the orbitrol can serve as an emergency
manual steering device. Even if the orbitrol does not receive pressure oil from the pump, you can
rotate the spool by turning the steering wheel. However, when the spool turns 8°, it hits against
the cross pin, which in turn turns the rotor through the drive shaft. This way, the metering device
of the orbitrol works as a hand pump to send oil to the steering cylinder. At this time, the check
valve provided between the return port and the suction port opens to allow the oil to flow from the
cylinder to the suction side, making it possible to steer the truck manually.
6A.1.4 POWER CYLINDER

The power cylinder is attached to the steering axle and operated by oil from the orbitrol. The
cylinder body is secured to the axle, with both ends of the piston rod connected to the knuckles
with joints.
The cylinder cap has a bushing, an oil seal, and a dust seal, and is assembled on the cylinder
with two bolts.
22 mm [0.87 in.]: 1 to 1.8 ton Tightening torque:

15 mm [0.59 in.]: 2.0 to 3.5 ton 27.7 to 41.5 N-m
{28.3 to 42.3 kgf-m}
[20.43 to 30.6 lbf-ft]
BUSHING
BUSHING
BOLT
“O”-RING
PACKING
BUSHING
CAP PACKING
DUST SEAL
PISTON ROD
View looking from A
Fig. 6A.11 Power Cylinder
- 65 -
6. STEERING SYSTEM https://truckmanualshub.com/
NOTE
- 66 -
https://truckmanualshub.com/ 6B. STEERING SYSTEM (EPS type)
6B. STEERING SYSTEM (EPS type)
Truck model FB30-8

FB10-8 FB15-8 FB20-8 FB25-8 FB30-8V
FB18-8 FB25-8LB FB25-8V
Item FB35-8S
Steering system
Type Rear wheel steering, electric power steering
Steering gear
Type Ball nut type
Name PU41
Reduction ratio 18.9
Operating angle 92°
Worm returning angle Left
Handwheel dia. 360 mm [14.2 in.]
Actuator
Type Motor-driven, ball nut type
Rated voltage of motor 48 V ← 72 V
Rated output of motor 350 W 550 W ←
Stroke 235 mm [9.3 in.] ← ←
Controller
Type Voltage controlling type
Rated voltage 48 V ← 72 V
Current limit Max. ±40 A Max. ±45 A ←
Rear axle
Type Elliot type ← ←
Steering angle
(Inner wheel) 85.8° 83.5° ←
(Outer wheel) 55.6° 56.4° ←
King pin spacing 735 mm [28.9 in.] 740 mm [29.1 in.] ←
King pin tilt 0° ← ←
Camber 0° 1° ←
Caster 0 ← ←
Toe-in 0 ← ←
Trail 0 ← ←
Wheel
Tire size 16 x 6 – 8 10PR 18 x 7 – 8 14PR ←
Rim size 4.25 x DT ← ←
850 kPa {8.5 kgf/cm2} 900 kPa {9.0 kgf/cm2}
Inflation pressure ←
[120.9 psi] [128.0 psi]
6B.1 GENERAL DESCRIPTION

The steering system consists of a steering gear, actuator, controller, and axle. The steering
wheel operating force is boosted by the motor-driven actuator.
- 67 -
6B. STEERING SYSTEM (EPS type) https://truckmanualshub.com/
6B.1.1 OUTLINE OF STEERING SYSTEM

As shown in Figure 6B.1, the steering system is composed of a steering gearbox, actuator, and
controller.
The steering gearbox is provided with a potentiometer which detects the steering handwheel
operating force and sends to the controller a signal which corresponds to the strength and direction
of the force. The controller converts the signal from the potentiometer into the direction and
amount of electric current which flows into the motor. If an external force is applied to the steering
wheel, the potentiometer detects that force and the actuator generates a force of the same strength
in the reverse direction so that no shock is felt at the handwheel.
The controller is incorporated in the speed controller inside the counterweight.
EPS
CONTROLLER
POTENTIOMETER
EPS MOTOR
ACTUATOR
Fig. 6B.1 Steering System
- 68 -
6B.1.2 STEERING GEARBOX

The steering gearbox is constructed as shown in Figure 6B.2. Rotation of the steering wheel
is transmitted to the sector shaft by way of the ball nut screw. At the lower part of the steering
gearbox unit is located the potentiometer which converts slight up-and-down movement of the
steering shaft into a voltage and sends the voltage to the controller.
Ԙ
Tightening torque: ԙ
16.7 to 27.5 N-m
{170 to 280 kgf-cm}
[147.8 to 243.4 lbf-in.] Ԛ
ԛ
Ԝ
ԝ
Ԟ
ԟ
Ԡ
ԡ
Ԣ
ԣ
Ԥ
22 21 ԥ
Tightening torque: ԫ Ԫ ԩ B Ԩ ԧ Ԧ
19.6 to 29.4 N-m {200 to 300 kg-cm}
[173.5 to 260.2 lbf-in.] 1. SHAFT
2. DUST COVER
Tightening torque:
16.7 to 27.5 N-m 3. OIL SEAL
23 {170 to 280 kgf-cm} 4. NEEDLE BEARING
[147.8 to 243.4 lbf-in.] 5. REAR COVER
24 6. “O”-RING
7. GEARBOX
8. BALL NUT
25
9. NEEDLE BEARING
10. OIL SEAL
26 11. THRUST BEARING
12. SPRING
27 13. SENSOR HOUSING
Tightening torque: 37.3 to 53 N-m 14. “O”-RING
{380 to 540 kgf-cm} 15. THRUST BEARING
[330.1 to 469.1 lbf-in.]
16. LOCK NUT
17. FRONT COVER
18. SLIDE RING
Tightening torque: View looking from B
140 to 170 N-m 19. ARM
{1427.6 to 1733.5 kgf-cm} 20. ROLLER
[1239.1 to 1504.6 lbf-in.] 21. POTENTIOMETER
22. SHIMS
Sectional view A - A 23. LOCK NUT
24. ADJUSTMENT SCREW
25. SIDE COVER
26. SECTOR SHAFT
27. OIL SEAL
Fig. 6B.2 Steering Gearbox
- 69 -
STEERING
WHEEL
STEERING
WHEEL LOCK
LEVER
JOINT
STEERING
GEARBOX
View looking from A
DRAG LINK
ACTUATOR
Fig. 6B.3 Steering Linkage
- 70 -
COMBINATION
Front of SWITCH ASSEMBLY
the truck
Front of the truck
View looking from C
Front of the truck
View looking from B

View looking from A
Fig. 6B.4 Steering Wheel
- 71 -
6B.1.3 ACTUATOR
The actuator is a ball and nut screw type. The screw lengthens and shortens according to motor
operation.
Motor operation is transmitted to the ball and nut unit after its speed is reduced by two gears.
The ball and nut unit are supported by two tapered roller bearings on the gearbox.
The actuator is installed with its tube side fitted to the frame of the truck by a universal joint and
with its screw side fitted to the center arm of the axle by a ball joint.
EPS MOTOR
PINION GEAR
BREATHER IDLE GEAR
UNIVERSAL JOINT BALL NUT

BALL SCREW
Fig. 6B.5 Actuator
6B.1.4 REAR AXLE

The rear axle unit is of welded construction with a box-shaped cross section, consisting of an
axle, center arm, tie rods, and knuckles.
The rear axle support with a bushing press-fitted is attached to the support pins located at the
front and rear of the axle. The support is bolted to the rear frame. The axle is so mounted as to be
cradled with the front and rear support pins as an axis.
The knuckle attached to each end of the axle is so structured as can turn clockwise and
counterclockwise around the king pin. The rear wheel hub is mounted on the spindle of the
knuckle through two tapered roller bearings. On the hub installed is the wheel with hub bolts and
nuts. The tapered roller bearing at the king pin side has a single-side seal to keep tight the grease
filled between the hub and the knuckle.
- 72 -
CENTER ARM
TIE ROD (LEFT) TIE ROD (RIGHT)
KNUCKLE (LEFT) KNUCKLE (RIGHT)

POTENTIOMETER
KING PIN
View looking from B
Detail of A
Fig. 6B.6 Rear Axle (1- to 1.8-ton Trucks)
- 73 -
CENTER ARM
SUPPORT (FRONT)
TIE ROD (LEFT)

TIE ROD (RIGHT)
SUPPORT (REAR)
KNUCKLE (LEFT) KNUCKLE (RIGHT)

POTENTIOMETER
KING PIN
View looking from B
Detail of A
Fig. 6B.7 Rear Axle (2- to 3.5-ton Trucks)
- 74 -
(1) Knuckle and king pin

The king pin supporting the knuckle is secured to the knuckle side with the lock pin. Its upper
and lower ends are each installed on the axle boss through each needle bearing.
The thrust bearing is installed between the axle upper boss and the knuckle so that the knuckle
rotates smoothly around the king pin with its load.
The upper and lower needle bearings, and the thrust bearing are lubricated with grease through
the grease fittings located on the upper and lower sides of the king pin.
KING PIN
OIL SEAL TAPERED ROLLER
BEARING
NEEDLE BEARING
OIL SEAL
LOCK NUT
THRUST BEARING
COTTER PIN
CAP
OIL SEAL
HUB
NEEDLE BEARING
LOCK PIN
SHIM
OIL SEAL
Fig. 6B.8 Knuckle
(2) Wheel hub

The wheel hub is installed on the knuckle spindle unit with two tapered roller bearings. Its
preload is adjusted with the nut.
- 75 -
6B.1.5 ADJUSTING PRELOAD OF REAR WHEEL BEARING

(1) As shown in Figure 6B.8, apply grease to the hub, inner bearing, outer bearing, and cap. Also
apply grease to the oil seal lips.
(2) Set the bearings on the hub, then installed the hub on the knuckle spindle.
(3) Place a washer, then tighten the adjustment nut with a torque of 206 to 235 N-m {21 to 24
kgf-m} [1823 to 2080 lbf-in.]. Loosen the adjustment nut, then retighten it with a torque of 9.8
N-m {1 kgf-m} [86.7 lbf-in.].
(4) Gently tapping the hub with a mallet, make sure there is no looseness.
(5) Tighten the hub with a mallet, give it a few turns. Then measure the starting torque.
(6) Tapping the hub with a mallet, give it a few turns. Then measure the starting torque.
Starting torque: 1.67 to 1.96 N-m {17 to 20 kgf-cm} [14.8 to 17.4 lbf-in.]
(7) If the starting torque measured is beyond the standard range, replace the washer and
adjustment nut. Then, repeat the steps from (3) to (6) till the standard range is acquired.
(8) Lock the adjustment nut with cotter pin.
- 76 -
6B.2 MAINTENANCE
6B.2.1 MAINTENANCE FOR ACTUATOR
(1) Replacing the motor
① As shown in Figure 6B.9, securely hold the
actuator assembly by a vise.
Note: Be sure to hold it in a lying position.
Fig. 6B.9
② Remove the motor securing bolts, then

remove the motor.
Note: Do not give a strong shock to the motor.
Fig. 6B.10
③ Remove the packing from the motor fitting

surface.
Fig. 6B.11
④ Apply grease to the joint. Install the motor

with a new packing.
Tightening torque: 18.6 to 30.4 N-m
{1.9 to 3.1 kgf-m}
[13.7 to 22.4 lbf-ft]
Fig. 6B.12
- 77 -
(2) Replacing the ball joint

① Securely fix the ball joint with its connector BOOT
BALL JOINT
held in a vise.
Hold this section by vise
Fig. 6B.13
② Loosen the lock nut of the ball joint, then

remove the ball joint. BOOT
BALL JOINT
LOCK NUT
Fig. 6B.14
③ Apply LOCTITE#271 to the threaded areas

61 ± 2 mm
of the connector and lock nut. Then install CONNECTOR [2.4 ± 0.078 in.]
the ball joint.
Apply LOCTITE#271
LOCK NUT
BALL JOINT
Fig. 6B.15
(3) Replacing the boot BOOT

① Hold the connector section in a vise.
CONNECTOR BALL JOINT
Hold this section.
Fig. 6B.16
- 78 -
② Remove the clamp of the boot connector CLAMP LOCK NUT

side. Shift the position of the boot. Then BOOT CLAMP
loosen the connector lock nut, and remove

the connector.
Note: Fix the ball joint to prevent it from
turning. BALL JOINT
Shift to this position
Fig. 6B.17
③ Replace the boot with a new one. When
installing the new one, let its end of larger
outer diameter face the actuator.
Fig. 6B.18
④ Turn counterclockwise the ball screw till it
contracts the most.
Apply LOCTITE#271 to the threaded areas
of the connector and the lock nut, then install
the connector as specified in Figure 6B.19.
Tightening torque: 176.5 to 215.8 N-m Push it against actuator.
{18 to 22 kgf-m} 512 ± 2 mm [20.16 ± 0.078 in.]
[130 to 159 lbf-ft]
Fig. 6B.19
⑤ Clamp the both ends of the boot by wire.
Before clamping, align the position of the BOOT
joint, as shown in Figure 6B.21, to correct a
dislocation of the boot.
BALL JOINT
Fig. 6B.20
Breather plug direction 20°

(1 to 2.5 t)
20
MASTER HOLE
°
(3.0 to
3.5 t)
Fig. 6B.21
- 79 -
6. STEERING SYSTEM https://truckmanualshub.com/
NOTE
- 80 -
https://truckmanualshub.com/ 7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
Truck model FB20-8 FB25-8 FB30-8

FB10-8 FB15-8 FB18-8 FB35-8S
FB25-8LB FB25-8V FB30-8V
Item
Main pump
Type Gear type ← ← ← ←
Name TMG1A18 ← TMG1A20 TMG1A23 ←
Discharge 18.9 cm3/rev ← 21 cm3/rev 24.5 cm3/rev ←
Drive Directly connected ← ← ← ←
to motor
Control valve
Type Spool sliding type ← ← ← ←
Name MSV04 ← ← ← ←
Pressure setting 13.7 MPa 15.7MPa 17.2 MPa ← ←
{140 kgf/cm2} {160 kgf/cm2} {175 kgf/cm2}
[1987 psi] [2275 psi] [2489 psi]
Lift cylinder
Type Single-acting piston ← ← ← ←
type
Cylinder inner dia. 45 mm [1.77 in.] ← 50 mm [1.97 in.] 55 mm [2.17 in.] 60 mm [2.36 in.]
Rod outer dia. 35 mm [1.38 in.] ← 40 mm [1.58 in.] 45 mm [1.77 in.] 50 mm [1.97 in.]
Stroke 1495 mm [57.4 in.] ← ← ← ←
(when lifting height is
3000 mm [118.1 in.])
Tilt cylinder
Type Double-acting ← ← ← ←
piston type
Cylinder inner dia. 65 mm [2.56 in.] ← 70 mm [2.8 in.] ← ←
Rod outer dia. 30 mm [1.2 in.] ← ← ← ←
Stroke 120 mm [4.72 in.] ← 139 mm [5.47 in.] 151 mm [5.94 in.] ←
Hydraulic oil tank

Type Separate type ← ← ← ←
Capacity 18 L [4.8 US gal] ← 25 L [6.6 US gal] ← ←

The hydraulic system consists of a pump, control valve, tank, lift cylinders, and tilt cylinders.
Oil is supplied by the pump directly driven by a motor. The control valve is used for controlling
cylinders.
For the high-pressure piping, the O-ring fitting method that provides high sealing performance
is employed to improve hydraulic system serviceability.
For lifting operation, the load handling inverter is used to control the motor operation so as to
achieve the lifting speed that complies with the amount of lever operation.
- 81 -
7. HYDRAULIC SYSTEM https://truckmanualshub.com/
7.1.1 MAIN PUMP

The main pump is a gear type as shown in Figure 7.1.
The main pump consists of a pump body, a pair of gears, bushings and packings. To minimize
the gap between the gears’ side-faces, pressure-balanced type bearings and lubrication method are
used.
The pressure-balanced type directs part of the oil discharged from the main pump into between
the pressure plate and pump body, to press the pressure plate toward the gear side.
1. DRIVE GEAR
2. SNAP RING
3. OIL SEAL
4. GASKET
5. SIDE PLATE
6 PUMP BODY
7. REAR COVER
8. HYPSILOID
GASKET
9. DRIVEN GEAR
10. BUSHING
11. FRONT COVER
Fig. 7.1 Main Pump
7.1.2 CONTROL VALVE

The control valve consists of two plunger sections, an outlet section, and an inlet section with a
relief valve as shown in Figure 7.2. The inlet section relief valve is a cartridge type featuring that
its pressure setting does not change even when it is reinstalled after removed.
Between the inlet section and the lift plunger section and between the lift plunger section and
the tilt plunger section, check valves are installed (two in total).
These check valves serve to prevent the back flow from a heavily loaded section to a lightly
loaded section when the lift and tilt levers are simultaneously operated.
A potentiometer installed on the plunger section at the lift side converts the movement of the
plunger into the voltage and sends it to the controller.
- 82 -
A2
B2
PORT G
Ｇポート
A1
P T
LIFT SPOOL
リフトスプール
油圧回路図
Hydraulic circuit diagram
TILT SPOOL
ティルトスプール
LIFT-LOCK RELEASE
リフトロック解除スクリュ
SCREW
PORT
B2ポートB2
PORT T
Ｔポート
PORT A2
A2ポート
PORT P
Ｐポート
PORT A1
A1ポート
ソレノイドバルブ
SOLENOID VALVE
(FOR LIFT LOCK)
(リフトロック用)
POTENTIOMETER
ポテンショメータ
Fig. 7.2 Control Valve
- 83 -
7.1.3 VALVE CONTROL

The control valve plungers are operated with the levers shown in Figure 7.3, with each of the
levers installed on a single shaft.
The bracket supporting each shaft is attached to the cowl. The movement of each lever is
transmitted through the rod to the corresponding plunger.
TILT LEVER ATTACHMENT LEVERS

(OPTIONAL)
LIFT LEVER
VALVE SWITCH
VALVE SWITCH
CONTROL VALVE
コントロールバルブ
PLUNGER
0.8±0.1 mm
(0.031±0.0039 in.)
○ Installing the valve switch

Install the valve switch so that it turns on when the plunger is pushed in 0.8 ±0.1 mm
[0.031 ±0.0039 in.].
At this time, the center of switch’s plunger is aligned with the center of the cam.
Fig. 7.3 Valve control
- 84 -
■ Oil pressure adjustment

① Remove the plug of the check port (G) located in the inlet section of the control valve, then set
there a 20 MPa {200 kgf/cm2} [2901 psi] capacity oil pressure gauge.
② Operate the tilt lever till the cylinder piston reaches it stroke end. Then measure the hydraulic
pressure at that position.
③ If the pressure is not as specified, loosen the relief valve lock nut and adjust it by turning the
adjustment. If the measured pressure is higher than the specified, once lower it by turning the
adjustment screw counterclockwise till it goes down below the specified level. Then turn the
screw clockwise this time till the specified level is acquired.
④ When adjustment is complete, tighten the lock nut.
RELIEF VALVE
リリーフバルブ
LOCK NUT
ロックナット
ADJUSTMENT SCREW
アジャストスクリュ
Unit: MPa {kgf/cm2}[psi]

1 to 1.5 t 1.8 t 2.0 to 3.5 t
Pressure setting 13.7 {140} [1990] 15.7 {160} [2280] 17.2 {175} [2490]
Fig. 7.4
- 85 -
7.1.4 HYDRAULIC OIL TANK

The hydraulic oil tank is located at the center of the frame. In the tank, a suction filter and a
return filter are provided for the purpose of ensuring clean oil supply.
RETURN FILTER
リターンフィルタ
FB10-18 : 18 L [4.8 US gal]
FB20-35 : 25 L [6.6 US gal]
OIL FILL CAP
給油キャップ
from CONTROL VALVE

コントロールバルブから
BREATHER
ブリーザ
to MAIN PUMP
Ｌ
メインポンプへ
of part A
Detail部詳細
SUCTION FILTER
サクションフィルタ DRAIN
ドレンプラグPLUG
Fig. 7.5 Hydraulic Oil Tank
(1) Replacing filters

① Remove the drain plug and drain the oil tank.
② Clean the tank cover surrounding area. Then remove the cover securing bolts.
③ Remove the suction and return hoses.
④ Remove the tank cover.
⑤ Remove the return filter, then install a new return filter.
⑥ Remove the suction filter, then install a new suction filter.
⑦ Remove the packings from the cover and the tank, then apply sealing agent to the tank.
Sealing agent: THREEBOND#4001 or equivalent
⑧ Reinstall the tank cover, then connect the suction and return hoses.
- 86 -
7.1.5 LIFT CYLINDER

The two lift cylinders of single-acting type are located on the outer mast frame. Each lift
cylinder, consists 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 this 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 cylinders 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 A and B . In this step,
if the flow rate passing through the holes are
within a range of the flow rate which can be
controlled by the flow regulator, the pressure
difference between the front and rear of the
piston is less than the spring force so that the
piston does not move. PISTON
If the hose is ruptured and the oil passing SPRING

through the holes A and B exceeds the flow to
be controlled, the pressure difference between
the front and rear of the piston becomes larger
than the spring force, moving the piston to the
right. Fig. 7.6 In Below Control Flow Rate
The piston is thereby in firm contact the
section C of the case so that the oil in the
cylinder does not flow out, stopping the fork go
down.
CASE
Fig. 7.7 In Over Control Flow Rate
- 87 -
Cylinder support
1. PISTON HEAD
2. LOCK BOLT
3. WIPER SEAL
4. ROD PACKING
5. CYLINDER CAP
6. “O”-RING
7. BUSHING
8. ROD
9. CYLINDER
10. LOCK RING
11. WEAR RING
12. PACKING
13. PISTON
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT
NUT
19. LOCK NUT
20. COTTER PIN
Fig. 7.8 Lift Cylinder (1- to 1.8-ton Trucks)
- 88 -
Cylinder support
1. PISTON HEAD
2. LOCK BOLT
3. WIPER SEAL
4. ROD PACKING
5. CYLINDER CAP
6. “O”-RING
7. BUSHING
8. ROD
9. CYLINDER
10. LOCK RING
11. WEAR RING
12. PACKING
13. PISTON
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT
NUT
19. LOCK NUT
20. COTTER PIN
Fig. 7.9 Lift Cylinder (2- to 2.5-ton Trucks)
- 89 -
Cylinder support
1. PISTON HEAD
2. LOCK BOLT
3. WIPER SEAL
4. ROD PACKING
5. CYLINDER CAP
6. “O”-RING
7. BUSHING
8. ROD
9. CYLINDER
10. LOCK RING
11. WEAR RING
12. PACKING
13. PISTON
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT
NUT
19. LOCK NUT
20. COTTER PIN
Fig. 7.10 Lift Cylinder (3-ton Trucks)
- 90 -
Cylinder support
1. PISTON HEAD
2. LOCK BOLT
3. WIPER SEAL
4. ROD PACKING
5. CYLINDER CAP
6. “O”-RING
7. BUSHING
8. ROD
9. CYLINDER
10. LOCK RING
11. WEAR RING
12. PACKING
13. PISTON
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
Fig. 7.11 Lift Cylinder (3.5-ton Trucks)
- 91 -
7.1.6 FLOW REGULATOR VALVE

LIFT CYLINDER
The flow regulator valve is located at the (RIGHT)
position as shown in Figure 7.12. It not only

controls the fork lowering speed but works as LIFT CYLINDER (LEFT)
a safety device in case of a rupture of the high-

pressure hose.
The oil flowing from the control valve to
the lift cylinders is not controlled, but the oil to OIL TANK
returning from the lift cylinders is controlled.
to CONTROL
■ Flow regulator valve operation (1- to 3-ton VALVE
trucks) FLOW
REGULATOR
The oil returning from the lift cylinders VALVE
flows into the chamber G from which it flows CUT-OFF VALVE

カットバルブ
through the chambers D . E , D , C , B and A
back into the control valve.
In this step, the more the oil flow via the
This sketch shows the flow regulator valve and related
hole C in the piston ④ becomes, the larger the components for the 1- to 2.5-ton trucks. On 3- to 3.5-ton
pressure difference between the front and rear trucks, the positions of the flow regulator vale and cut-off
of the piston becomes. vale are reversed from this sketch.
When the force that pushes the piston ④ , Fig. 7.12 Mast Piping
produced by the pressure differential, is greater
than the spring force ⑦ , the piston ④ moves to the right. The hole D is narrowed by the hole C
to limit the flow rate, and the fork lowering speed is thus controlled.
When the forks are raised, the high-pressure oil from the control valve flows through the
chambers A , B , C , D , E , F , and G into the lift cylinders.
Free flow
自由流
Regulated
制限流
flow
Lift cylinder side

リフトシリンダ側
Control valve side
コントロールバルブ側
① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨
1. CASE 4. PISTON 7. SPRING

2. SPRING 5. SLEEVE 8. “O”-RING
3. BALL 6. ORIFICE 9. NIPPLE
Fig. 7.13 Flow Regulator Valve (1.0- to 3.0-ton Trucks)
- 92 -
■ Flow regulator valve operation (3.5-ton trucks)

The oil returning from the lift cylinder flows into the chamber F , past the chambers E , D , C ,
B , and A , and then back into the control valve.
In this step, the more the oil flows via the hole C in the piston ⑤ , the greater the pressure
differential across the piston ⑤ becomes to shift the piston ⑤ to the right. Therefore, the hole D
is narrowed by the hole C so that the quantity of oil flowing through the hole D is restricted to
reduce the forks lowering speed.
When the forks are raised, the high-pressure oil from the control valve flows through the
chambers A , B , C , D , E , and F to the lift cylinders.
Free
自由流 flow
Regulated
制御流
flow
Lift cylinder side

Control valve side
1. SPRING 6. SLEEVE
2. CASE 7. ORIFICE
3. SPRING 8. SPRING
4. BALL 9. “O”-RING
5. PISTON 10. NIPPLE
Fig. 7.14 Flow Regulator Valve (3.5-ton Trucks)
- 93 -
7.1.7 TILT CYLINDER

The tilt cylinder is a double-acting type. The piston rod end is supported by the mast, and the
cylinder tail by a pin on the frame. Two tilt cylinders are mounted on both sides of the truck, one at
each.
The tilt cylinder consists of a cylinder body, cylinder cap, piston and piston rod. The piston is
attached to the piston rod with a nut, and is provided with two packings and one wear ring on its
circumference. It is slid by hydraulic oil along the inner surface of the cylinder.
The cylinder cap is provided inside with a press-fitted bushing, packing, and dust seal which
provide oil tightness for the piston rod and in the cylinder cap, and also supports piston rod.
When the tilt lever is pushed forward, high-pressure oil flows into the tilt cylinder through its
tail. The oil then moves the piston forward, high-pressure oil flows into the tilt cylinder through its
tail. The oil then moves the piston forward, causing the mast to tilt forward by 6 degrees.
When it is pulled toward the operator, high-pressure oil enters the tilt cylinder from the cylinder
cap side. The oil then pushes back the piston, causing the mast to tilt backward by 12 degrees.
1. JOINT 8. LOCK RING

2. DUST SEAL 9. ROD
3. BUSHING 10. CYLINDER
4. “O”-RING 11. PACKING
5. PACKING 12. PISTON
6. CYLINDER CAP 13. LOCK NUT
7. “O”-RING
Fig. 7.15 Tilt Cylinder
- 94 -
TILT CYLINDER (RIGHT)
CONTROL VALVE
ORBITROL
to LIFT CYLINDER
- 95 -
TILT CYLINDER (LEFT)
OIL TANK
Fig. 7.16 Hydraulic Oil Piping (Orbitrol type)

MAIN PUMP
STEERING CYLINDER
7. HYDRAULIC SYSTEM
OIL TANK
TILT CYLINDER (RIGHT)
to LIFT CYLINDER
MAIN PUMP
CONTROL VALVE
TILT CYLINDER (LEFT)
Fig. 7.17 Hydraulic Oil Piping (EPS type)
- 96 -
7.2 MAINTENANCE
7.2.1 MAINTENANCE OF PUMP
■ Cautions
1. Before disassembling the pump, check for oil leaks from the oil seal, the mating section of
the pump body and cover, and other areas.
2. Remove rust, dust and dirt at the shaft end and the pump body. Failure to do so might
damage the parts or allow them to enter the inside of the pump during disassembly, thus
misleading your diagnosis about the pump.
3. The pump has some symmetrical parts. Before disassembling the pump, mark the parts in
the manner shown in the “disassembly procedure”, to ensure correct reassembly. For this
purpose, use oil paint not to damage the parts.
4. Disassembly is a means of finding out the cause of a trouble. Observe the procedure for
disassembling the pump.
5. Before disassembly, make sure you get new packings, gaskets, and oil seals.
(1) Disassembly
① Hold the front cover in a vice with the
input shaft side downward.
Notes: 1. The bolts will be loosened during
disassembly. Make sure to hold the
front cover in a vice securely as
shown in Figure 7.18, to prevent the
pump from the vice when a force is
applied on the pump.
2. Mark the rear and front covers and
the drive gear side of the pump body
with oil paint. Fig. 7.18
② Turn the four fitting bolts with a torque

wrench in the tightening direction, to check
whether they are properly tightened to 88.3
to 98 N-m {9 to 10 kgf-m} [782 to 867 lbf-
in.].
Fig. 7.19
- 97 -
③ Remove the four fitting bolts.
Fig. 7.20
④ Remove the rear cover by tapping the side

face of the pump body with a plastic mallet.
If the gaskets remain inside the pump body,
move them toward the rear cover side.
Fig. 7.21
⑤ Remove the pump body. If the gaskets

remain inside the pump body, move them
toward the front cover side.
Fig. 7.22
⑥ Put the mark “RV” the rear cover side plate

at the drive gear side before removing the
side plate.
Fig. 7.23
- 98 -
⑦ Put the mark “R” on the driven gear shaft

end and remove the drive gear.
Fig. 7.24
⑧ Holding the front side plate, remove the

drive gear.
Fig. 7.25
⑨ Put the mark “FV” on the front side plate

at the drive gear side, and remove the side
plate.
Fig. 7.26
⑩ Turn over the front cover and hold it again

in the vice. Remove the snap ring.
Fig. 7.27
- 99 -
⑪ Remove the oil seal from the front cover.
Fig. 7.28
- 100 -
CAUTION
1. Inspections are carried out to locate the cause of troubles and to determine whether parts
are reusable or not. Inspections must be carried out only by personnel with a certain
amount of knowledge and experience in hydraulic equipment.
2. The “useful limit” shown in this section should be used as a rough guide. We do not always
guarantee the performance of a part if it does not reach its useful limit.
Name of component Items to be checked Remarks (cause and others)

① Front cover (a) Check for cracks or damage. Oil pressure is too high.
CAUTION
The mating section between the front cover and the pump body looks black
in some parts. This is caused by the friction between aluminum parts and is
not a problem.
② Pump body (cast (a) Check for cracks or damage. Oil pressure is too high.
iron)
(b) Check wipe depth or wipe surface. Oil pressure is too high.
Useful limit
Wipe depth limit: less than 0.04 mm [0.0016 in]
(c) Check for signs of interference with Runout of gears

gear at discharge side. Pump’s performance is not affected if
there is a sign of interference.
③ Drive and (a) Check shaft ends and keyways for They might occur when gears are runout
driven gears cracks, damage or undue wear. or insufficiently lubricated, or when oil
pressure is too high.
(b) Check journal (in the area Contaminants in oil, too high oil
which slides on the bearing) for temperature (120°C [248°F] or higher),
discoloration, undue wear, or too frequently idle operations
roughness.
CAUTION
The shaft might have the following
OIL SEAL SIDE PLATE
BUSHING
scratches or scores on its outer
INPUT BUSHING
SHAFT diameter:
(a) Those caused by a hard object
between the shaft and bushing.
(b) Those caused by the oil seal’s main
lip
(c) Those caused by the oil seal’s dust
lip
Useful limit
Roughness on journal (a): 0.8S - 1.6S
Roughness on oil seals (b and c): 1.6S - 3.2S
- 101 -
Name of component Items to be checked Remarks (cause and others)

(continued from the (c) Check for discoloration, undue wear, Contaminants in oil, too high oil
preceding page) or roughness on the gears. temperature (120°C [248°F] or higher),
too frequently idle operations
Useful limit
0.1 mm [0.0040 in] or less
(d) Check gear teeth for roughness or Irregular rotation at high speeds
pitching.
(e) Check for missing or broken gear Too high oil pressure or a hard object
teeth caught in gear
④ Side plate (a) Check side plate in the gear sliding Fine dust between side plate and gears
area for wear or nicks or scores.
(b) Check the gears for erosion at or Cavitation or aeration
near the engagement area.
Useful limit
Wear limit: 0.15 mm (0.006 in) or less
LBC surface
These areas
might be worn
Discharge port Suction port

Erosion
might occur
here due to
cavitation.
⑤ Bushing Check the inner surfaces of bushings for The bushings are made of copper with
The bushings roughness or wear. the back plate made of lead brass. The
are fitted into back plate consists of porous and PTFE
front and rear
covers. (polytetrafluoro-ethylene) layers.
Useful limit
When the back plate of the bushing is exposed to view.
⑥ Gasket (a) Check gaskets for proper installation Too high oil temperature
or cut.
(b) Check rubber parts for swelling. Fire retardant hydraulic oil (phosphate)
or gasoline is used.
⑦ Oil seal (a) Check oil seal for round or peeled Wear occurs due to contaminants in oil,
edge. dust which enters oil due to undue external
CAUTION negative pressure, or rust due to moisture.
The oil seal might be
damaged when the drive (b) Check main lip for warping outward. Increased internal oil leaks or high oil
gear is disassembled
or when it is removed
pressure (0.2 - 0.3 MPa {2 - 3 kgf/cm2} [28.5
from the front cover. It - 42.7 psi] or more) applied on oil seal
is difficult to locate the
cause of damage when (c) Check rubber parts for swelling. Fire retardant hydraulic oil (phosphate)
removing it from the
front cover. or gasoline is used.
- 102 -
(2) Pump reassembly

① As shown in Figure 7.29, hold the front cover
in a vice.
Fig. 7.29
② Install a new gasket in the groove in the front

cover.
Fig. 7.30
③ Install a new “E” gasket in the groove in the

front cover, referring to Figure 7.32.
Fig. 7.31
”3”-shaped gasket
groove
The “E” gasket should
be installed with its flat Flat surface
surface pointing to the
bottom of the groove.
B-B section
Discharge Suction
side side
Flat surface
Discharge Suction
side side
A-A section C-C section
(b) “3”-shaped gasket
Fig. 7.32 Gasket Installation
- 103 -
④ Install the pump body on the front cover,

referring to Figure 7.34.
Fig. 7.33
Counterclockwise rotation: Drive side

Front side
Counterclockwise rotation: Clockwise rotation:
Rear side Rear side Suction port
Clockwise rotation: (larger radius)
Front side Discharge port
(smaller radius)
Projection (to be
always pointed to
drive side)
Driven side
Fig. 7.34
⑤ Install the front side plate on the front cover,

referring to Figure 7.36.
Fig. 7.35
LBC surface Back plate

LBC面(黄色)
(yellow) 裏金(SC材)
(SC material)
Discharge
吐出側 side Suction side
吸込側
(larger radius) Suction
吸込側 side Discharge side
吐出側
(smaller radius)
(小さいR) (大きいR)
常にLBC面を歯車面に
The LBS surface should be always
pointed to gear’s side face
対抗させます。
Fig. 7.36
- 104 -
⑥ Install the drive gear in the pump body, with its

splines pointed downward.
Fig. 7.37
⑦ Install the drive gear in the pump body, as

Fig. 7.38
CAUTION
The sketch shows the engagement of the left-rotation pump. Since the tooth profiles of
the two gears are asymmetric, install them with their larger pressure angle sides pointed
to each other. Failure to do so might damage the gear teeth.
Greater pressure angle side

(drive-side engagement surface)
Smaller pressure
angle side
Engagement surfaces
(shaded sections) Driven
side
Drive
side
Greater pressure angle side
(driven-side engagement surface)
(a) Engagement of 1st pump
Fig. 7.39
- 105 -
⑧ Install the rear side plate in the pump body, as

Fig. 7.40
⑨ Apply grease on a new gasket in some points

and install the gasket in the rear cover groove.
Fig. 7.41
Gasket groove
”E” gasket
Discharge side Suction side
The rear cover is commonly used for the “L”

(counterclockwise rotation) type and the “R”
(clockwise rotation) type. Align the discharge side
with the suction side.
Fig. 7.42
⑩ Install the “3”-shaped gasket in the rear

cover, as shown in Figure 7.32.
Fig. 7.43
- 106 -
⑪ Install the rear cover in the pump body with its

gasket pointed downward.
Fig. 7.44
⑫ Install the four bolts and tighten them to the

specified torque:
Tightening torque: 88.3 - 98 N-m
{9 - 10 kgf-m}
[782 - 867 lbf-in.]
Fig. 7.45
⑬ Remove the pump from the vice and put it on a

work bench.
Apply grease on the area between the lips
and on the outer diameter of a new oil seal.
Install it on the oil seal guide shown in Figure
7.51. Put it on the drive shaft of the pump, and
install the oil seal onto the front cover with an
oil seal snap.
Fig. 7.46
Direction in which oil

seal is installed. Apply a thin coat
of grease on outer
diameter of oil seal.
Dust lip
Oil seal
Main lip
Apply grease area
between oil seal lips.
Fig. 7.47 Fig. 7.48
- 107 -
⑭ Secure the oil seal with a snap ring and remove the oil seal guide.
Cross section of (Front

“C” lock ring cover)
Side at which corner is
chamfered.
Oil seal
Fig. 7.49 Fig. 7.50
ø4
[0.16] Unit: mm
ø17
2 [0.08]
ø4 [0.67]
[0.16]
20°
R2 R2
[0.08] [0.08]
R5
[0.2]
R2
115 [4.5]
100 [3.9]
[0.08]
92 [3.622]
62 [2.44]
71 [2.8]
22.05 +0.05
-0 [0.868 +0.002
-0 ]
23.0 0
-0.05 [0.906 0
-0.002 ] 23.1-0.05
0
[0.91-0.002
0 ]
35.5+0.5
0 [1.398+0.02
0 ]
Oil seal guide Oil seal snap
Fig. 7.51
- 108 -
7.2.2 TRIAL RUN

Trial runs should be performed to run in an assembled pump and to ensure that it delivers the
specified performance. Trial runs are preferably carried on a special test stand, but may be carried
out with the pump on the machine using the following manner:
(If the pump were disassembled because of a seized pump or an abnormally worn internal
component, be sure to change the hydraulic oil and replace the filters with new ones before trying
to make a trial run.)
(a) Install the pump on the truck. Install a pressure gauge on the oil pressure check port of the
control valve.
(b) Loosen the relief valve adjustment screw and operate the pump at 500 to 1000 rpm for about
10 minutes. Make sure the pressure is less than 0.98 MPa {10 kgf/cm2} [142 psi].
(c) Increase the pump speed to 1500 to 2000 rpm and let the pump operate for about 10 minutes.
(d) Keeping the pump speed at 1500 to 2000 rpm, increase the pressure by 2 - 3 MPa {20 to 30
kgf/cm2} [284 to 427 psi] up to 17.2 MPa {175 kgf/cm2} [2489 psi], letting the pump operate
at each pressure for about 5 minutes. Operate each circuit for 5 minutes and replace the return
filter with a new one.
While increasing the pressure, check the oil temperature and pump surface temperature.
Check also for operating noise. If the oil temperature or pump surface temperature rises
excessively, reduce the load and drop the temperature before continuing the test.
(e) After the test is over, set the oil pressure for 17.2 MPa {175 kgf/cm2} [2489 psi], perform a
discharge test. The pump discharge is checked by observing the lift speed.
- 109 -
7.2.3 TROUBLESHOOTING GUIDE

If any problem occurs in the hydraulic system, locate the cause of the problem and take
necessary measures, referring to the tables given below.
(1) Control valve

Problem Cause Remedy
The control flow is not a specified
Relief valve malfunctioning Readjust.
value.
Noisy control valve Relief valve malfunctioning Readjust.
Oil leaks (external) “O”-ring deteriorated or damaged Replace “O”-ring.
Replace spring.
Spring defective
Low pressure setting Readjust.
Set surface defective
Replace relief valve.
Oil leaks (internal) Seat surface damaged Correct seat surface.
Noisy control valve Sliding area too worn Replace relief valve.
Pressure setting rises Poppet stuck. Disassemble and clean.
(2) Main pump

Problem Cause Remedy
No oil discharged Low oil level in oil tank Add oil to specified level.
from gear pump Clogged suction tube or strainer Clean or change oil if necessary.
•• Worn pressure plate
•• Worn bearing
Replace with new one
•• Defective plate seal, bushing seal or back-
up
Gear pump pressure Adjust relief valve setting with a
Maladjusted relief valve
won’t rise pressure gauge.
•• Retighten suction side piping
connections.
Air being sucked
•• Add oil into oil tank.
•• Check pump oil seal.
Collapsed suction hose or clogged strainer
Check hose or service strainer.
causes cavitation
Air being sucked due to a loose suction side
Retighten a loose joint.
joint
Noisy gear pump
Change to oil of proper viscosity
Too viscous oil causes cavitation
Operate pump at proper temperature.
Find the cause of air bubbles and
Air bubbles in oil
take necessary measures.
Defective pump oil seal or plate seal Replace with new ones.
Oil leaks from pump
Defective pump Replace pump with a new one.
- 110 -
https://truckmanualshub.com/ 8. LOAD HANDLING SYSTEM
8. LOAD HANDLING SYSTEM
Truck model
FB10-8 FB15-8 FB20-8 FB25-8LB F30-8
FB35-8S
FB18-8 FB25-8 FB25-8V FB30-8V
Item
Name VM-7P1 VM-7P4 VM-7P5 VM-7P7 VM-7P9
Type Roller type 2-step telescopic mast with free lift
Max. standard 3000 mm ← ← ←
lifting height [118.1 in.]
Fork lifting system Hydraulic ← ← ←
Mast tilting system Hydraulic ← ← ←
Lift chain Leaf chain Leaf chain Leaf chain Leaf chain
BL534 BL634 BL823 BL834
Mast cross section
Outer mast
A: 44 mm A: 48 mm ← A: 60 mm
[1.73 in.] [1.89 in.] [2.36 in.]
B: 102.5 mm B: 119.5 mm ← B: 124 mm
[4.04 in.] [4.71 in.] [4.88 in.]
C: 134.5 mm C: 161.5 mm ← C: 170 mm
[5.30 in.] [6.36 in.] [6.69 in.]
Inner mast
A: 43 mm A: 45 mm ← ←
[1.69 in.] [1.77 in.]
B: 102.5 mm B: 119.5 mm ← ←
[4.04 in.] [4.71 in.]
C: 134.5 mm C: 159.5 mm ← ←
[5.30 in.] [6.28 in.]
D: 72 mm D: 76 mm ← ←
[2.83 in.] [2.99 in.]
- 111 -
8. LOAD HANDLING SYSTEM https://truckmanualshub.com/

The load handling system is of roller type having a two-staged telescopic mast. It consists of an
outer channel, inner channel, and carriage.
8.1.1 OUTER AND INNER CHANNELS

Outer and inner channels are of welded construction. The lower part of the outer channel is
provided with a support to be used for installing the mast assembly on the drive axle.
The center of the outer channel is supported by the frame via the tilt cylinders. The mast
assembly tilts forward and rearward by expanding and contracting the tilt cylinders.
At the inner channel, the end roller is installed on the lower outside. At the outer channel, it is
installed on the upper inside through shims.
1. INNER CHANNEL
2. OUTER CHANNEL
3. END ROLLER
4. SHIM
5. SNAP RING
6. END ROLLER
7. SHIM
8. SLIPPER
9. SHIM
10. PIN
11. CAP
12. BUSHING
Fig. 8.1 Outer and Inner Channels (VM-7P1)
- 112 -
1. INNER CHANNEL
2. OUTER CHANNEL
3. END ROLLER
4. SHIM
5. SNAP RING
6. END ROLLER
7. SHIM
8. SLIPPER
9. SHIM
10. PIN
11. CAP
12. BUSHING
Fig. 8.2 Outer and Inner Channels (VM-7P4, VM-7P7, VM-7P9)
8.1.2 CARRIAGE
The carriage has end rollers that roll along the inside of the inner channel, each installed on the
end roller shaft by bearings. The end roller shafts are welded to the carriage. The upper end rollers
are shim-adjusted while the lower end rollers are secured to the shafts with snap rings.
Longitudinal load is sustained by the end rollers. When the forks are raised to the maximum
height, the upper end rollers emerge from the mast top. Transverse load is sustained by the lower
side-rollers.
- 113 -
1. FORK
2. CARRIAGE
3. END ROLLER
4. SHIM
5. SNAP RING
6. SIDE ROLLER
7. SHIM
8. SPACER
VM-7P4, VM-7P7, VM-7P9
VM-7P1
Fig. 8.3 Carriage
- 114 -
8.1.3 LOCATIONS OF ROLLERS

End and side rollers are installed on the carriage.
The end rollers support longitudinal load and the side rollers support lateral load so that the
inner channel and carriage are raised and lowered smoothly.
END ROLLER
END ROLLER
Lower section
CARRIAGE
END ROLLER
SIDE ROLLER
Upper section
CHANNEL
INNER
END ROLLER
LIFT CYLINDER
CHANNEL
OUTER
SLIPPER
Fig. 8.4 Locations of Rollers (1- to 1.8-ton Trucks)
- 115 -
Upper section Lower section
INNER
END ROLLER CHANNEL
CARRIAGE
END ROLLER
END ROLLER
OUTER SIDE ROLLER
CHANNEL
- 116 -
SLIPPER
END ROLLER
LIFT CYLINDER
Fig. 8.5 Locations of Rollers (2- to 3.0-ton Trucks)

Upper section Lower section
INNER
END ROLLER CHANNEL
CARRIAGE
OUTER SIDE ROLLER

CHANNEL
END ROLLER
SIDE ROLLER
- 117 -
SLIPPER
END ROLLER
LIFT CYLINDER END ROLLER
Fig. 8.6 Locations of Rollers (3.5-ton Trucks)

8.2 MAINTENANCE
8.2.1 ADJUST LIFT CYLINDER ROD WITH SHIMS
After the lift cylinders, inner channel, or outer channel is replaced, the lift cylinder rod length
needs to be adjusted.
(1) Install a piston head on the rod of each lift

cylinder without using shims.
(2) Extend the rod of each lift cylinder slowly
and examine the difference in the rod
LOCK BOLT
ロックボルト
stopping time when the rod reaches the
stroke end between the two lift cylinders.
(3) Add shims to the space between the rod
and piston head of the lift cylinder whose
rod stops first. SHIM
シム PISTON HEAD
ピストンヘッド
Shim thickness: 0.2 and 0.5 mm LIFT CYLINDER

リフトシリンダ
[0.0079 and 0.0197 in.]
(4) Adjust the lift chain tension.
Fig. 8.7
8.2.2 ADJUSTING HEIGHT OF CARRIAGE

(1) Stop the truck on a level surface and put
the mast vertically.
(2) Keep the fork bottom on the ground and TIRE
adjust the projected amount A of the
carriage lower end roller to the value as INNER CHANNEL
shown in Table 8.1, using the chain anchor END ROLLER for
pin at the mast side. carriage
FORK
Table 8.1
Model Mast Type A (mm [in.])

1 – 1.8 t VM-7P1 36 – 41 [1.42 – 1.61] Fig. 8.8
2 – 2.5 t VM-7P4 24 – 29 [0.94 – 1.14]
3.0 t VM-7P7 44 – 49 [1.73 – 1.93]
3.5 t VM-7P9 37 – 42 [1.46 – 1.65]
- 118 -
(3) Make sure that the clearance between the INNER CHANNEL
carriage and the inner channel stoppers STOPPER
is 0 mm when the fork is raised to the

maximum lifting height
Note 1: When the mast lifting height is over
4000 mm [157.5 in.], the dimension CARRIAGE
STOPPER
B is +50 mm [1.97 in.].
CHAIN ANCHOR
PIN at mast side
Fig. 8.9
(4) Adjust the tension of the right and left

chains to the same value with the chain
anchor pin at the mast side when the fork is
CHAIN
at the bottom position and the mast is tilted
back all the way.
ANCHOR PIN
ADJUST NUT
LOCK NUT
Fig. 8.10
- 119 -
8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE

(1) Put a pallet to the fork and stop the truck
on a level surface.
(2) Lower the forks with the pallet to the
ground.
(3) Remove the joint link of the mast side
anchor pin and remove the chain from the
sheave.
(4) Extent the lift cylinder rods to raise the
inner channel. (See ① in Figure 8.11.)
(5) Move the truck backwards after making
sure that the carriage is removed from the
inner channel. (See ② in Figure 8.11.)
Fig. 8.11
(6) Replacing end rollers

① Remove the lower end rollers with a puller,
keeping the shims.
Stamp (S or SS)
② Install new end rollers with the shims
removed in step ① . Check the stamp of S
or SS and install the roller which is marked
the same stamp, pointing the stamp side to
the carriage side.
③ Remove the snap ring and remove the
upper end rollers with a puller.
④ Install new end rollers and secure them
with snap rings.
Fig. 8.12
(7) Replacing side rollers

① Remove the side roller assembly. Keep the
numbers of the shims and their combination
SHIM
as they were.
SHIM
② Install a new roller with the shims removed
SIDE
in step ① , pointing the groove for the balls ROLLER
to the shim side. (See Figure 8.14.)

③ If there is excessive looseness between
END
the side roller and inner channel, add the ROLLER
shims between the end roller and side
roller, seeing “8.2.5 PROCEDURE FOR
ADDING OR SUBTRACTING SHIMS”.
Fig. 8.13
- 120 -
(8) Extend the lift cylinder rods so that the

inner channel bottom projects the upper
section of the carriage.
(9) Bring the truck close to the carriage side Groove for balls
so that each roller enters inside of the outer

channel.
(10) Contract the lift cylinder rods to lower the
inner channels gradually. Place each roller
of the carriage into the inner channel.
(11) Engage the chain with the sheave and
connect the chain and anchor through the
joint link.
Fig. 8.14 Side Roller
(12) Adjust the height of the carriage. (See

8.2.2.)
Fig. 8.15
- 121 -
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
“8.2.3 PROCEDURE FOR REPLACING
ROLLERS AT CARRIAGE SIDE.”
(2) Move the truck to a level surface and put

the both rear wheels on the bench of 250 –
300 mm [9.8 – 11.8 in.] in height.
(3) Apply parking brake and block the rear

wheels securely.
(4) Remove the bolt securing the lift cylinders

to the inner channel, and hoist the inner
channel with a crane, keeping shims at the Fig. 8.16
end of the piston rod.
(5) Remove the lift cylinder mounting bolts at

the lower section of the outer channel and
cylinders support at the middle section,
SLIPPER
and remove the lift cylinder from the outer SHIM
channel. Remove the hydraulic hose with SHIM
two wrenches, using caution not to loosen END ROLLER
the fittings at the cylinder side.
(6) Operate the crane to lower the inner

channel gradually and remove the end
rollers from the lower section of the inner
channel. At the same time, the end rollers
at the upper section of the outer channel
can also be removed.
(7) Replacing end rollers

① Remove upper end rollers with a puller,
keeping shims.
② Install new end rollers with the shims
removed in step ① . Check for the stamp
of S or SS and install the roller which is
SHIM
marked the same stamp, pointing the stamp
END
side to the inner channel side. (See Figure ROLLER
8.12.)
③ Replace the lower end rollers, using same
procedure as above. In this step, point the
stamp side to the outer channel side.
Fig. 8.17
(8) Operate the crane to hoist the inner
channel. Place each roller into the channels.
(9) Install the lift cylinder and carriage in the reverse order of disassembly.
- 122 -
8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS

Move the inner channel and carriage 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 0.197 in.]
0 to 0.5 mm at upper side Make contact

SHIM SHIM with one side.
SHIM
SHIM SHIM
Make contact
0 to 0.5 mm [0 to 0.197 in.] with one side.
Note: Apply grease to the end roller contacting surface of each channel.
Procedure for Adding or Subtracting Shims
Fig. 8.18
- 123 -
NOTE
- 124 -
https://truckmanualshub.com/ 9. ELECTRIC SYSTEM
9. ELECTRIC SYSTEM
Headlights
Capacity 48 V - 40 W
Front combination lights
Capacity
Side marker lights 48 V - 10 W
Turn signal lights 48 V - 25 W
Rear combination lights
Capacity
Tail/brake lights 48 V - 10 W/25 W
Turn signal lights 48 V - 23 W
Back-up lights 48 V - 10 W
9.1 SYSTEM DESCRIPTION

The electric system components, excluding the speed controller and its related components, get
their electricity from a high-capacity battery installed in the truck. They include head lights and
front and rear combination lights, which are turned on and off via the relay unit.
- 125 -
9. ELECTRIC SYSTEM https://truckmanualshub.com/
9.1.1 RELAY UNIT

The relay unit is a semi-conductor switch that uses transistors to perform the switching. The
mechanical switch input signals cause the relay unit to turn the lights and electric devices on the
truck on and off.
CN
13 1
102 169 107 12 132 131 177 178 238 270 2 98 111
102 105 106 110 95 96 180 109 97 100 116 112 113
26 14
から見る
View looking from A
Fig. 9.1 Relay Unit
- 126 -
RR
50W
TURN SIGNAL, RIGHT
ターンシグナル右
RL
50W
TURN SIGNAL, LEFT
ターンシグナル左
RM
80W
HEADLIGHTS
ヘッドライト
RT
44W
TAIL/SIDE MARKER
テール、クリアランス
CR
3.5W＋0.1A
CHIME
チャイム
RB
BRAKE SIGNAL OUTPUT
ブレーキ信号出力
BB
20W
20 W
バックランプ
BACK-UP LIGHT
＋+
35 W
35W
BEACON LIGHT
パトライト
RF
*オプション装備
* OPTIONAL EQUIPMENT
チャイム
CHIME
0.15 A
0.15A
+
＋
35 W
35W
BEACON LIGHT
パトライト
RK
* OPTIONAL EQUIPMENT
*オプション装備
150 W
150W
(INTERLOCKED WITH THE
(キースイッチ連動)
KEY SWITCH OPERATION)
Fig. 9.2 Relay Unit Circuit (Ref.)
- 127 -
9.1.2 LIGHTS
The truck is equipped with headlights, front combination light assemblies, rear combination
light assemblies and a work light. They can be turned on and off with the integrated turn signal and
light switch lever, as shown in Figure 9.3
LIGHT SWITCH
F/R LEVER TURN SIGNAL

SWITCH
*1㧗
*1㧙
HORN
N VF ST VR
IG2 IG1 VF2 Ra
TB TR EL LH
TL LT
TURN SIGNALS AND LIGHTING TRAVELING DIRECTION INDICATOR
Fig. 9.3 Integrated Turn Signal and Light Switch
- 128 -
(1) Light Switch

The light switch is incorporated into the right lever of the integrated turn signal and light switch
assembly. The side marker lights, tail lights and head lights can be turned on and off by rotating the
lever.
■ 1st notch
When the lever is rotated to the 1st notch, terminals EL and LT in the light switch are
connected to each other to activate the RT relay inside the relay unit, thus turning on the side
marker lights in the front combination light assemblies, the tail lights in the rear combination light
assemblies and the LCD panel illumination.
■ 2nd notch
When the lever is rotated further to the 2nd notch, terminals EL , LT , and LH are connected to
each other to activate the RM relay inside the relay unit, in addition to the RT relay, thus turning on
the headlights.
RELAY UNIT
࡝࡟࡯࡙࠾࠶࠻
(RM) LIGHT SWITCH

࡜ࠗ࠹ࠖࡦࠣࠬࠗ࠶࠴
(RT)
OFF
T
F-13
F-26
F-10
F-22
F-19
F-11
F-6
F-7
H
EL LT LH
WG 109
WR 107
GY 178
RW12
R 177
RG 102
B2
KEY SWITCH F4
10A
RW12 R5
B+
F5
10A
RG 102
WG 109
(RIGHT)
MARKER LIGHT
MARKER LIGHT
(LEFT)
BATTERY
ࠢ࡝ࠕ࡜ࡦࠬ࡜ࡦࡊ
ࠢ࡝ࠕ࡜ࡦࠬ࡜ࡦࡊ
ࡃ࠶࠹࡝
ࡋ࠶࠼࡜ࡦࡊ
Ꮐ
ࡋ࠶࠼࡜ࡦࡊ
ฝ
࠹࡯࡞࡜ࡦࡊ
࠹࡯࡞࡜ࡦࡊ
TAIL LIGHT
LIGHT
HEADLIGHT
HEADLIGHT
(10W)
(10W)
(40W)
(40W)
(10W)
(10W)
TAIL
SIDE
SIDE
ࡈࡠࡦ࠻ ࡝ࡗ
FRONT COMBINATION REAR COMBINATION
ࠦࡦࡆࡀ࡯࡚ࠪࡦ
LIGHT (LEFT) LIGHT (LEFT)
࡜ࡦࡊ
Ꮐ ࡜ࡦࡊ
Ꮐ
ࡈࡠࡦ࠻
FRONT COMBINATION
࡝ࡗ
REAR COMBINATION
LIGHT (RIGHT)
࡜ࡦࡊ
ฝ
LIGHT (RIGHT)
࡜ࡦࡊ
ฝ
Fig. 9.4 Lighting Circuit
- 129 -
(2) Turn signal switch

The turn signal switch is incorporated into the right lever of the turn signal and light switch
assembly. When the lever is moved forward or backward, the left or right turn signal lights flash
accordingly.
When the lever is moved forward, terminals TB and TL are connected to each other, causing
the turn signals in the left front and rear combination light assemblies to flash; and when the lever
is moved backward, terminals TB and TR are connected to each other, and the turn signals in the
right front and rear combination light assemblies flash.
RELAY UNIT
࡝࡟࡯࡙࠾࠶࠻
TURN SIGNAL SWITCH

࠲࡯ࡦࠪࠣ࠽࡞ࠬࠗ࠶࠴
(RR)
(RL)
R
N
F-13
F-26
F-10
F-22
F-24
F-25
F-8
F-9
L
TB TR TL
RW12
RG 102
B2
GR 106
LW 132
L 131
G 105
KEY SWITCH F4
10A
RW12 R5
B+
F5
10A
RG 102
G 105
SIGNAL LIGHT
SIGNAL LIGHT
SIGNAL LIGHT
SIGNAL LIGHT
ࡃ࠶࠹࡝
BATTERY
࠲࡯ࡦࠪࠣ࠽࡞࡜ࡦࡊ
(25W)
(25W)
(25W)
(25W)
TURN
TURN
TURN
TURN
FRONT
ࡈࡠࡦ࠻ FRONT
ࡈࡠࡦ࠻ REAR
࡝ࡗ REAR
࡝ࡗ
COMBINATION
ࠦࡦࡆࡀ࡯࡚ࠪࡦ COMBINATION
LIGHT (LEFT)
࡜ࡦࡊ
Ꮐ LIGHT (RIGHT)
࡜ࡦࡊ
ฝ LIGHT (LEFT)
࡜ࡦࡊ
Ꮐ LIGHT (RIGHT)
࡜ࡦࡊ
ฝ
Fig. 9.5 Turn Signal Circuit
- 130 -
HEAD LIGHT
ヘッドランプ REAR COMBINATION LIGHT
リヤコンビネーションランプ
FRONT COMBINATION
フロント
LIGHT
コンビネーション
ランプ
1 - to 1～1.8t
1.8-ton trucks 2- to 2～3.5t
3.5-ton trucks
View looking
から見る from A
Fig. 9.6 Locations of lights
- 131 -
(3) Head lights

The head lights are installed on the upper part of the front legs of the overhead guard.
A A
④
1. LENS
③ 2. RIM
3. HOUSING
⑥ 4. REFLECTOR
5. GASKET
6. BULB
A - AA - A
断面 view
Sectional
Fig. 9.7 Head Lights
- 132 -
(4) Front and rear combination lights

The structures of the front and rear combination lights are shown in Figure 9.8.
The front combination light consists of a turn signal light and a side marker light.
The rear combination has a turn signal light, a brake light and a tail light incorporated in it.
■ Front combination light

■フロントコンビネーションランプ
TURN SIGNAL LIGHT

ターンシグナルランプ
SIDE MARKER LIGHT

ターンシグナル
GROUNDING
アース
TURN SIGNAL
クリアランス
から見る
View looking from A
SIDE MARKER
クリアランスランプ
■ Rear combination light

■リヤコンビネーションランプ
BACK-UP LIGHT
バックアップランプ TURN SIGNAL LIGHT
ターンシグナルランプ BRAKE/TAIL LIGHT
ブレーキ/テールランプ
TURN SIGNAL
BACK-UP
バックアップ GROUNDING
アース
BRAKE
ブレーキ TAIL
テール
から見る
View looking from A
Fig. 9.8 Combination Light
- 133 -
■ Replacing light bulbs

If you want to remove a bulb, push it into the
SCREW
スクリュ
reflector and then turn to the left.
REFLECTOR
リフレクタ
If you want to install a new bulb, push it into
the reflector and then turn to the right. 40W-48V
GASKET
ガスケット
(1) Head light and work light

① Remove the screw securing the rim and
housing, and remove the rim, lens, and
gasket.
LENS
レンズ
② Remove the bulb from the reflector and RIM

リム
install a new bulb. Fig. 9.9 Head Light (Work Light)
1. Use caution not to get burnt because the surface of a hot soon after it is turned off.
2. Use caution not to contaminate the bulb and reflector surfaces.
③ With the gasket, install the lens and reflector.

BACK-UP LIGHT
バックアップランプ
10W-48V 10W-48V
(2) Rear and front combination lights LENS

レンズ
① Remove the screws securing the lens and BODY
ボディ
body, and separate the lens from the body.
② Remove the the burned-out bulb you want to

replace and install a new bulb.
SCREW
スクリュ
STOP/
ストップ／ TURN SIGNAL
③ Reassemble the lens and body with the TAIL LIGHT
テールランプ LIGHT
ランプ
screws. 25W/10W-48V 25W-48V
25W/10W-48V 25W-48V
Fig. 9.10 Rear Combination Light
TURN SIGNAL LIGHT

ターンシグナルランプ
25W-48V 25W-48V
SCREW
スクリュ
BODY
ボディ
SIDE MARKER LIGHT

クリアランスランプ
10W-48V
10W-48V
LENS
レンズ
Fig. 9.11 Front Combination Light
- 134 -
TROUBLESHOOTING
TABLE OF CONTENTS
1. CONTROL CIRCUITS. ...................................................................................................... 1
1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM................................................ 1
1.2 LOAD HANDLING SYSTEM............................................................................................... 5
1.3 POWER STEERING SYSTEM............................................................................................. 8
1.4 OTHERS................................................................................................................................. 9
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING................... 11

2.1 PART LOCATION DIAGRAM AND TERMINAL LOCATIONS...................................... 11
2.2 PROCEDURE FOR CHECKING THE CONTROLLER ASSEMBLY SEPARATELY..... 13
2.2.1 CONTROLLER ASSEMBLY....................................................................................... 13
2.2.2 INVERTER UNIT......................................................................................................... 16
2.2.3 EPS MOTOR CONTROLLER..................................................................................... 18
2.2.4 HEAT-DISSIPATING SHEET....................................................................................... 19
2.2.5 MC CONTACTOR........................................................................................................ 20
2.2.6 FAST CHARGE RESISTANCE (RCH)........................................................................ 20
2.2.7 FUSE (F1)..................................................................................................................... 21
2.2.8 ACCELERATOR PEDAL............................................................................................. 21
2.2.9 MOTOR ROTATION SENSOR.................................................................................... 22
2.2.10 LIFT POTENTIOMETER............................................................................................. 23
2.2.11 STEERING POTENTIOMETER.................................................................................. 24
2.2.12 LCD PANEL.................................................................................................................. 25
2.2.13 CM CONTACTOR........................................................................................................ 26
2.2.14 CONTROL SWITCH PANEL....................................................................................... 27
2.2.15 BATTERY CHARGER SWITCH PANEL.................................................................... 28
2.2.16 CHARGE RECTIFICATION DIODE........................................................................... 29
2.2.17 CHECKING CHARGE TIMER.................................................................................... 30
2.2.18 MOTOR THERMO-SENSOR...................................................................................... 31
2.2.19 F/R SWITCH................................................................................................................. 32
2.2.20 CHECKING VOLTAGE ON THE LCD PANEL.......................................................... 33
3. TROUBLESHOOTING GUIDE.................................................................................... 35
3.1 HOW TO USE THIS GUIDE............................................................................................... 35
3.2 CHECKING BEFORE TROUBLESHOOTING.................................................................. 36
3.3 ERROR CODE TABLE........................................................................................................ 38
3.4 LCD PANEL SYSTEM ERRORS........................................................................................ 48
3.5 TROUBLESHOOTING BY ERROR CODE....................................................................... 49
3.6 TROUBLESHOOTING BY PROBLEM............................................................................. 66
4. PARAMETER SETTING................................................................................................. 73
4.1 SETTING THE PARAMETERS.......................................................................................... 73
4.2 PARAMETER SETUP SCREEN......................................................................................... 73
4.3 KEYPAD............................................................................................................................... 73
4.4 SCREEN OPERATION........................................................................................................ 74
4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING................................... 78
4.6 SETTING THE PASSWORDS............................................................................................ 80
5. DESCRIPTION OF THE FUNCTIONS..................................................................... 81
6. ELECTRIC WIRING.......................................................................................................... 83
1. CONTROL CIRCUITS
1. CONTROL CIRCUITS
1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM

Circuit Diagram Description
Drive motor inverter unit

走行コントローラ 1. Drive motor inverter unit CN1D-7 and
CN1D-8 terminals
CN1D-7 CN1D-8 When the key switch is turned on, the battery
Power Supply
voltage is applied to these terminals and the

inverter unit is energized.
RW11

走行コントローラ 2. Accelerator potentiometer
(1) Accelerator 1 potentiometer
アクセル1 1
Accelerator アクセル2 2
Accelerator 4.5 V is supplied from CN2D-32. The
Potentiometer Potentiometer
ポテンショメータポテンショメータ voltage at CN2D-8 varies according to the
amount of accelerator pedal effort.
CN2D-32
CN2D-20
CN2D-33
CN2D-21
(2) Accelerator 2 potentiometer

CN2D-8
CN2D-9
4.5 V is supplied from CN2D-33. The

voltage at CN2D-9 varies according to the
amount of accelerator pedal effort.
(3) Voltage at CN2D-8 and CN2D-9 terminals
Unit: V
WR 185
LW 187
BG 186
LB 184
LG 92
LY 93
Accelerator pedal Accelerator pedal

Terminal not pressed fully pressed
－－ Accelerator 1 1.0 ± 0.1 3.92 ± 0.2
CN2D-8
＋＋ Accelerator 2 0.5 ± 0.1 1.96 ± 0.2
CN2D-9
The voltage at CN2D-9 should be 50% of
Drive System
the voltage at CN2D-8. If not, it indicates

the signal wire is broken.
3. RB relay
Relay unit
リレーユニット
(1) This relay enables the inverter unit to know
(RB)
走行コントローラ
when the brake pedal is pressed.
(2) When the brake pedal is pressed, the
CN1D-4 brake switch is turned on and the CN1D-4
F-15
F-14
F-23
terminal voltage changes from 4.6 V to 0 V.

W110
WR 113
BW 112
ブレーキ
RG102 スイッチ
switch
Brake
to Brake light
ブレーキランプへ
to Fuse F5
ヒューズF5へ
-1-
1. CONTROL CIRCUITS
走行コントローラ 4. Parking brake switch

(1) When the parking brake lever is pulled, the
parking brake switch is turned on and the
“P” light on the LCD panel comes on. This
CN1D-5 CN1D-29 keeps the truck from moving.
(2) Voltage between CN1D-5 and CN1D-29
Parking brake lever pulled: 0V (switch
0 15
ON)
Parking brake lever released: 5V (switch
BR 9
Parking
パーキング
OFF)
switch
スイッチ
to LCD panel
メータパネルへ

走行コントローラ 5. F/R lever switch
(1) This switch tells the inverter unit whether
CN1D-19 CN1D-18 the F/R lever is in the forward or reverse
travel position.
F/Rレバースイッチ
F/R lever switch (2) Voltage between CN1D-18 and CN1D-19
F Unit: V
N
Lever position
WBr 53
WL 54
Drive System
R N F R
(Neutral) (Forward) (Reverse)
N IG1 IG2 VF VF2 ST VR Ra
CN1D-18 4.6 0 4.6
CN1D-19 4.6 4.6 0
GND

走行コントローラ 6. BB relay
Relay unit (1) Activates the back-up buzzer and light.
(2) When the F/R lever is placed in the R
(BB)
CN1D-34 position, the battery supplies voltage to the

CN1D-34 terminal. This activates the BB
F-22
F-21
F-2
relay, feeding power to the back-up light

LR 95
and buzzer.
WB 98
RW11
バックアップランプ，
to back-up light and
buzzer
バックアップブザーへ
-2-
1. CONTROL CIRCUITS
7. RF relay (option)
Relay unit (1) Activates the forward travel buzzer.
(2) When the F/R lever is placed in the F
(RF)
CN1D-33 position, the battery supplies voltage to the
CN1D-33 terminal. This activates the relay,
F-20 feeding power to the forward travel buzzer.
F-18
LB 180
WBr 97
to forward travel
前進チャイムへ
buzzer
Rotation
回転センサA sensor A Rotation
回転センサB sensor B 8. Drive motor rotation sensor
(1) Detects the drive motor speed.
(2) When the drive motor runs, a pulsed
(+) (S) (-) (+) (S) (-) voltage is present between CN2D-3 and
CN2D-15 and between CN2D-5 and
1 2 3 1 2 3
Drive System
CN2D-16.
GW 28
RW 31
GY 33
GB 29
RB 32
RY 34
走行
Drive motor
CN2D-27
CN2D-15
CN2D-29
CN2D-16
CN2D-3
CN2D-5
inverter unit
コントローラ
Drive motor thermosensor

走行モータサーモセンサ 9. Drive motor thermosensor
(1) Detects the drive motor temperature.
(2) When the sensor detects a temperature of
145°C [293°F] or above, the symbol
206 appears on the LCD panel, the
2 1
blinks, and the motor output is limited.
(3) When the sensor detects a temperature
WG 16
WR 17
of 156°C [312.9°F] or above, the symbol

走行コントローラ blinks, and the motor is stopped.
CN2D-17
CN2D-6
-3-
1. CONTROL CIRCUITS
スイッチパネル
Switch panel
10. Speed control switch (“turtle” button)
(1) When speed control switch is pressed, the
turtle mark appears on the LCD panel,
activating travel speed limit feature. If the
speed control switch is pressed with the
S.P.E スピード
S.P.E
セレクト
Speed
コントロール turtle mark appeared on the LCD panel,
selection control
switch
スイッチ switch
スイッチ travel speed limit feature is cancelled.
(2) Voltage between CN9-1-16 and CN9-1-8
COM S4 S5 terminals
Speed control switch pressed: 0 V
WL 75
CN9-1-8 Gy 80
W 77
Speed control switch released: 5 V

メータパネル
CN9-1-15
CN9-1-16 LCD panel

11. S.P.E mode selection switch
(1) Acceleration speed and top speed can
be switched over in 3 stages. The speed
control mode changes in turns from S, P, to
E every time the switch is pressed.
Drive System
(2) Voltage between CN9-1-15 and CN9-1-8

terminals
S.P.E selection switch pressed: 0 V
S.P.E selection switch released: 5 V
12. Steering potentiometer

CN2D-34
CN2D-23
CN2D-10
(1) Potentiometer power supply

4.8V is supplied from the CN2D-34
terminal.
(2) Voltage between CN2D-10 and CN2D-23
terminals
The voltage at the CN2D-10 terminal
varies according to the steering angle of the
YR 44
YB 42
wheels.
YL 43
Steering angle at neutral: 2.5 V

- Steering angle at left end: 3.5 V
Steering angle at right end: 1.8 V
+
-4-
1. CONTROL CIRCUITS
1.2 LOAD HANDLING SYSTEM

Pump motor inverter unit

荷役コントローラ 1. Pump motor inverter unit CN1P-7 and
CN1P-8 terminals
CN1P-8 CN1P-7 When the key switch is turned on, the battery
voltage is present at these terminals and the
inverter unit is energized.
RW11
Pump荷役コントローラ
motor inverter unit
2. Lift potentiometer
(1) Potentiometer power supply
4.8 V is supplied from the CN2P-32
CN2P-32
CN2P-20
CN2P-8
terminal.
(2) Potentiometer signal
The voltage between CN2P-8 and
CN2P-20 terminals varies as follows,
according to the amount of lever movement
Load Handling System
WR 188
GR 189
away from the neutral position.

YL 94
Lever position
-
Down Neutral Up
CN2P-8 1.1 V or 1.1 V or 2.4 to
+
terminal less less 4.5 V
Pump荷役コントローラ
motor inverter unit 3. Tilt and ATT1/ATT2 switches
(1) 4.6 V is supplied from CN1P-16,
CN1P-17, and CN1P-18.
(2) When each lever is operated, the switch
CN1P-16
CN1P-17
CN1P-18
CN1P-28
turns on to operate the pump motor. (4.6

V→ 0 V)
YG 21
YR 20
YL 22
BL 8
ATT2
ATT1
TILT
-5-
1. CONTROL CIRCUITS

荷役コントローラ 4 Lift lock solenoid
(1) When the seat switch and the load handling
CN1P-35 neutral safety switch are engaged, the lift
lock solenoid is energized.
(2) The voltage between the CN1P-35 terminal
2A P 139
and the negative (-) terminal.
Key switch ON (with seat switch ON): 36 V
F8
Key switch ON (with seat switch OFF): 48 V

O 138
LIFT LOCK
SOL
RL100
Pump motor rotation sensor

荷役モータ回転センサ 5. Pump motor rotation sensor
(1) Detects the pump motor speed.
(2) When the pump motor runs, a pulsed voltage
(+) (S) (-) is generated between CN2P-5 and CN2P-16
terminals.
1 2 3
W 40
Y 41
B 46
Pump motor controller

荷役コントローラ
CN2P-29
CN2P-16
CN2P-5
Pump motor thermosensor

荷役モータサーモセンサ 6. Pump motor thermosensor
(1) Detects the drive motor temperature.
(2) When the sensor detects a temperature of
145ºC [293ºF] or above, the symbol 406
appears on the LCD panel, the blinks,
2 1 and the motor output is limited.
(3) When the sensor detects a temperature
of 156ºC [312.8 ºF] or above, the symbol
YW 39
G 38
blinks, and the motor is stopped.

荷役コントローラ
CN2P-17
CN2P-6
-6-
1. CONTROL CIRCUITS
7 Truck model selection terminals

The relevant truck model is selected by turning
on or off each model selection switch.
CN1P-28
CN1P-5
CN1P-4
MODE SEL 1 MODE SEL 2
1 to 1.8 ton
OFF OFF
trucks
2 to 2.5 ton
ON OFF
trucks
3 to 3.5 ton
ON ON
trucks
BL 8
Note: The load handling unit differs depending
on the truck model. Therefore the load
handling unit is not interchangeable,
regardless of the truck model switch
MODE SEL 2
MODE SEL 1
selection.
Note: Although the circuit diagram on the
left shows some switch symbols, those
switches are not installed on the truck.
-7-
1. CONTROL CIRCUITS
1.3 POWER STEERING SYSTEM

PSPSコントローラ
motor controller 1. PS motor controller CN1E-17 terminal
When the key switch is turned on, the battery
CN1E-17 voltage is present at this terminal and the PS
motor controller is energized.
Power Steering System (EPS type)
RW11
PSPSコントローラ
motor controller 2. PS torque sensor
(1) Power supply
4.6 V is supplied from the CN1E-6 terminal.
CN1E-22
CN1E-23
CN1E-6
(2) Input voltage

(a) The EPS motor duty factor is controlled
according to the torque sensor CN1E-23
terminal voltage.
W 162
(b) The voltage between CN1E-23 and

L 160
G 161
CN1E-22 terminals:
-
In straight-ahead driving: 2.3 V
The voltage decreases when the steering
+
トルクセンサ
Torque sensor
(Potentiometer) wheel is turned counterclockwise and
(ポテンショメータ)
increases when it is turned clockwise.
1. Steering wheel sensor

GND
(1) The steering wheel sensor detects the

+15V
A
B
Z
number of rotations and the rotating

direction of the steering wheel.
(2) A pulse voltage develops between CN2P-1
and CN2P-25, and between CN2P-13 and
SSC
ESS
SS1
Power Steering System (Orbitrol type)
SS2
1G
Pump motor CN2P-25 according to the rotation of the

inverter unit
BG 243
BR 230
LG 246
BY 244
LY 249
steering wheel.
CN2P-25
CN2P-13
CN2P-14
CN2P-2
CN2P-1
Handle encoder
2. EPS/HPS switching terminal

The HPS and EPS units are switched over
CN2P-21
CN2P-29
by connecting or disconnecting the CN2P-21

and CN2P-29.
When CN2P-21
HPS (Orbitrol type power
LG 19
BL 18
is connected with
sttering) is available.
CN2P-29:
When CN2P-21 is
EPS (electric power
not connected with
steering) is available.
CN2P-29:
-8-
1. CONTROL CIRCUITS
1.4 OTHERS

走行コントローラ 1. Seat switch
(1) 4.6 V is supplied from CN1D-16.
(2) When the operator sits in the operator’s
CN1D-16
CN1D-29
seat, the seat switch turns on, releasing the
interlock.
(4.6 V→0 V)
YW181
BR 9
Drive motor Pump motor PS motor Excluding 2. Auto power-off relay

inverter unit inverter unit controller trucks with If no operation (traveling, load handling nor
an Orbitrol
steering power steering) is performed for more than
Others
system. 15 minutes, the auto power-off relay PO is

CN1E-17
CN1D-7
CN1D-8
CN1P-8
CN1P-7
energized to shut off the power supply to the

entire controller circuit.
RW11 PO RG216
RL 100
PO
RL 100
YG 208
LCD panel
䊜䊷䉺䊌䊈䊦
-9-
1. CONTROL CIRCUITS
11i Excluding
3. CN1D-24, CN1P-24, CN1P-22, and CN1E-34
Drive motor Pump motor PS motor trucks with terminals
inverter unit controller an Orbitrol
inverter unit When the battery is connected, the battery
]
[
steering
r' /〆一、 r、 system. voltage is present at these terminals.
CN1E-34
CN1D-24
CN1P-24
CN1P-22
These terminals are used to detect the battery
voltage.
冒4ど i .
.L
Others
L 」
RL100
- 10 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING

2.1 PART LOCATION DIAGRAM AND TERMINAL LOCATIONS
Note: Trucks with an Orbitrol steering system do not have an EPS unit.
■ 1- to 1.8-ton trucks (Excluding those with an Orbitrol steering system.)
Main contactor
メインコンタクタ Fast charge resistance (RCH)ヒューズ(F1)
急速充電抵抗(RCH) Fuse (F1) EPS unit
EPSユニット DW motor terminal
DWモータ端子
DV motor terminal
DVモータ端子
PU motor terminal
PUモータ端子
DU motor terminal
DUモータ端子
PV motor terminal
PVモータ端子
Inverter
インバータユニットunit
(drive
(ドライブ) motor)
PW motor terminal
PWモータ端子
Negative terminal
－端子
Inverter unit
(pump motor)
(ポンプ)
Positive terminal
＋端子 CN1P
CN1 CN2P
CN2 CN1D
CN1 Positive＋端子
terminal CN2
CN2D Negative terminal
－端子

PW PWモータ端子
motor terminal PV PVモータ端子
motor terminal PU motor terminal
PUモータ端子 EPS unit
EPSユニット DW motor terminal
DWモータ端子
CN1P
CN1
DV motor terminal
DVモータ端子
CN2P
CN2
DU motor terminal
DUモータ端子
Positive terminal
＋端子
Inverter
インバータユニットunit
(drive
(ドライブ) motor)
Negative terminal
－端子
Inverter unit (pump

(ポンプ) motor)
Fuse (F1)
ヒューズ(F1)
Positive terminal
＋端子 Fast charge resistance
Main contactor
メインコンタクタ (RCH)
急速充電抵抗(RCH) CN1D CN1 Negative
Positive terminal CN2
＋端子 CN2D －端子 terminal
- 11 -
PW motor terminal PV motor terminal PU motor terminal

DW motor terminal
CN1P DV motor terminal
CN2P DU motor terminal
Positive terminal
Inverter unit
(drive motor)
Negative terminal
Inverter unit (pump

motor)
Fuse (F1)
Positive terminal Fast charge resistance

Main contactor (RCH) CN1D Negative terminal
Positive terminal CN2D
- 12 -
2.2 P
ROCEDURE FOR CHECKING THE CONTROLLER ASSEMBLY
SEPARATELY
2.2.1 CONTROLLER ASSEMBLY
The controller assembly controls the drive, pump and power steering motors according to signals
from the F/R lever, accelerator pedal, load handling levers, and steering wheel.
It consist of a contactor which turns the battery power supply on and off, one EPS controller and
two inverter units. Each of the controller and converter units is connected by a CAN communications
network through which necessary information is sent and received.
The drive and pump motor inverter units each consist of a CPU printed-circuit board and a main
power circuit (FET boards and capacitor boards), which control the drive and pump motors.
The EPS (electric power steering) unit consists of a CPU printed-circuit board and main power
circuit assembly which controls the EPS motor. (excluding trucks with an Orbitrol steering system.)
The information stored in memory in the motor controller or inverter unit, including settings, can be
displayed on the LCD panel by operating the switch panel.
Checking procedure
■ Loose bolts and poor connector contacts
A loose nut or bolt, which secure a controllers’ power terminals, will generate heat or cause a fire.
Thoroughly clean any loose nuts or bolts with sand paper before retightening them.
Poor connector contacts will cause a system to fail to operate normally. If any poor contacts are
found, remove all dust, dirt or corrosion from the connectors and then connect and disconnect the
connectors a few times. In addition, check the lead wires for breaks and the terminals for deformation.
■ Checking the controllers on the machine

It is dangerous to work on the electric system of the truck with the key switch turned on and the
battery connectors connected. Make sure the battery connectors are disconnected and wait at least 15
minutes before touching any electrical part.
If you need to make measurements with the key switch turned on and the battery connected, lift the
drive wheel off the ground to prevent the truck from moving accidentally should the drive motor turn
suddenly.
Apply the parking brake, measure the maximum current while performing switch-back and load
handling operations.
- 13 -
■ Removing the inverter unit (1-ton class trucks excluding those with an Orbitrol steering
system)
Pass screws (M4 x 20 mm or longer) through
tapped through-holes in the aluminum inverter
base and remove the inverter unit from its
aluminum fin.
Top view
Thru holes
Do not hold the connectors. Do not hold the inverter unit by the
cover’s grooves.
Top view
■ Removing the inverter unit (2- and 3-ton class trucks excluding those with an Orbitrol
steering system)

aluminum fin.
Top view
Thru holes
Do not hold the inverter unit by the

cover’s grooves. Thru holes
Do not hold the connectors.
- 14 -
■ Removing the inverter unit (1-, 2- and 3-ton class trucks with an Orbitrol steering system)

aluminum fin.
Top view
Thru holes
Do not hold the inverter unit Thru holes

by the cover’s grooves.
Do not hold the connectors.
■ CAUTION
Do not hold the inverter unit by the cover’s grooves to detaching the inverter unit. Do not hold
the controller assembly by the connectors to lift it; otherwise there is a risk of damaging the cover or
boards or loosening the inverter seal.
- 15 -
2.2.2 INVERTER UNIT

The truck has two inverter units for the drive and pump motors, each having output terminals U, V
and W to the motor and power supply terminals (+) and (-).
The pump motor inverter unit of 1-ton class trucks (excluding those with an Orbitrol steering
system) is an S-type.
1. Main circuit terminal location and internal circuit diagram
Lタイプインバータ
L-type inverter
NN端子
terminal
U-phase motor
U相モータ端子
terminal
VB terminal
VB端子
V-phase motor
V相モータ端子
terminal
CN2D.P
W-phase motor CN1D.P

W相モータ端子
terminal
Internal circuit diagram

内部回路図
NN端子
terminal
S-type inverter
Sタイプインバータ
U-phase motor
U相モータ端子
terminal
CN2P
V-phase motor
V相モータ端子
terminal
W-phase motor CN1P

W相モータ端子
terminal
VB端子
VB terminal
2. Connector pin numbers
CN1D. P 1 12 CN2D. P 2 1
2
12
24
13
36
25
24
25 13 36
- 16 -
Checking procedure (using an analog multimeter)

① Measure the resistance of each terminal according to the table given below using an analog
multimeter with the resistance range set to x1000 ohms.
② Determine whether the inverter unit is defective or not according to the resistance value measured
at each terminal.
Standard value for each terminal on the inverter unit

Multimeter Normal value
Measurement
Approximate Judgment
point Red probe (+) Black probe (-) reading
VB U 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
VB-U The judgment varies according to charge
2 or 3 kΩ to
U VB status of the capacitors in the main
∞ Ω circuit; defective if 0 Ω is seen.
VB V 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
VB-V The judgment varies according to charge
2 or 3 kΩ to
V VB status of the capacitors in the main
∞ Ω
circuit; defective if 0 Ω is seen.
VB W 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
VB-W The judgment varies according to charge
2 or 3 kΩ to
W VB status of the capacitors in the main
U N 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
U-N The judgment varies according to charge
2 or 3 kΩ to
N U status of the capacitors in the main
V N 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
V-N The judgment varies according to charge
2 or 3 kΩ to
N V status of the capacitors in the main
W N 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
W-N The judgment varies according to charge
2 or 3 kΩ to
N W status of the capacitors in the main
*1. The values in the “Normal Value” column should be used as a rough guide, because they may vary with the type of multimeter used
and battery’s internal state of charge.
*2 If a digital multimeter is used, the resistance between each terminal will usually show a reading of 20 to 30 kΩ as a normal value.
However, in this case too, the value may vary with the type of multimeter and the battery’s internal state of charge.
If the resistance is 0 Ω, a digital multimeter will read between 0 and 20-30 Ω.
Notes
••Apply a heat-dissipating silicone compound (KS-609: Shinetsu Kagaku) over the whole back-surface
of the inverter unit.
••Make sure to apply the silicone compound whenever the inverter unit is replaced with a new one, to
allow the heat generated by the inverter unit to be transmitted to the aluminum base efficiently.
••Make sure there is no metal powder, cuts, damage or burrs on the mating surfaces of the aluminum
base and the inverter unit before applying the compound.
- 17 -
2.2.3 EPS MOTOR CONTROLLER (excluding trucks with an Orbitrol steering system)
Note: Trucks with an Orbitrol steering system do not have an EPS motor controller.
The EPS motor controller uses a motor-wire connector with a VB (+) wire and an N (-) wire as an
external harness.
1. Main circuit terminal location and internal circuit diagram

VB
CN1E
→ B
VB
N
N
内部回路図
Internal circuit diagram
Lock
ロック
2. Connector pin numbers
CN1E
17 1
34 18
- 18 -
Checking procedure (using an analog multimeter)

① Measure the resistance of each terminal according to the table given below using an analog
multimeter with the resistance range set to x1000 ohms.
② Determine whether the inverter unit is defective or not according to the resistance value measured
at each terminal.
Standard value for each terminal of the EPS motor controller
Multimeter Normal value
Measurement
Approximate Judgment
point Red probe (+) Black probe (-) reading
VB A 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
VB-A The judgment varies according to charge
2 or 3 kΩ to
A VB status of the capacitors in the main
VB B 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
VB-B The judgment varies according to charge
2 or 3 kΩ to
B VB status of the capacitors in the main
A N 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
A-N The judgment varies according to charge
2 or 3 kΩ to
N A status of the capacitors in the main
B N 2 or 3 kΩ Defective if 0 Ω or ∞ Ω
B-N The judgment varies according to charge
2 or 3 kΩ to
N B status of the capacitors in the main
*1. The values in the “Normal Value” column should be used as a rough guide, because they may vary with the type of multimeter used
and battery’s internal state of charge.
*2 If a digital multimeter is used, the resistance between each terminal will usually show a reading of 20 to 30 kΩ as a normal value.
However, in this case too, the value may vary with the type of multimeter and the battery’s internal state of charge.
If the resistance is 0 Ω, a digital multimeter will read between 0 and 20-30 Ω.
2.2.4 HEAT-DISSIPATING GREASE
Apply a heat-dissipating grease 250 g on the back of the controller base plate (all areas) to allow the
heat generated by the controller to be transmitted to the counterweight efficiently.
- 19 -
2.2.5 MC CONTACTOR
Checking procedure
① Check the mechanical action
••Check the contactors separately.
••Visually check the contacts, coil and connectors for damage
or remarkable discoloration.
••Replace any failed MC contactor with a new one.
② Checking the coil

••Remove the coil wiring connector. CONTACTOR
コンタクタ
••Set the multimeter to the resistance range of x100 Ω and

measure the resistance between the terminals.
••Determine whether the contactor is defective or not according to the resistance value measured.
Resistance value (key switch OFF, battery connectors disconnected, at 20°C [68°F])
Resistance Judgment
about 20 Ω Good
∞ Defective (replace contactor with a new one)
③ Checking the contacts

••Check the contacts visually, replacing any contactor with a new one if any of the contact has a
severely rough surface or serious wear.
Wear limit: 0.5 mm [0.0197 in.]
2.2.6 FAST CHARGE RESISTANCE (RCH)

The capacitor inside the inverter unit is charged through the fast
charge resistance (RCH) by the battery, to prevent erroneous detection
of a short-circuit in the main circuit.
Checking procedure
① Visually check the RCH for damage or remarkable discoloration.
② Set the multimeter to the resistance range of x100 Ω and measure
the resistance between the terminals.
③ Determine whether the RCH is defective or not according to the resistance value measured.
Resistance Judgment
about 39 Ω Good
0Ω Defective (short circuit)
∞ Defective (circuit open)
- 20 -
2.2.7 FUSE (F1)

If too large a current flows in the main circuit, the Cable side
ケーブル側
fuse (F1) will blow to prevent the controller from being Contact
コンタクタ側 side
damaged or catching fire.
Applicable truck model Symbol Type F1
1-ton and 3-ton class trucks F1 96LFB-400
2-ton class trucks F1 96LFB-500
Checking procedure
① Set the multimeter to measure voltage and connect the negative probe to the negative cable
connection terminal on the controller.
② Connect the positive probe to the F1 fuse. Measure the voltage and determine whether the fuse is
defective or not.
1 to 1.8-ton trucks
Measurement point Voltage Judgment
Cable-side terminal Battery voltage Good
Battery voltage Good
Contactor-side terminal
0 (V) Defective (Replace the fuse with a new one)
2- to 3.5-ton trucks
Measurement point Voltage Judgment
Cable-side terminal Battery voltage Good
Battery voltage Good
Contactor-side terminal
0 (V) Defective (Replace the fuse with a new one)
Note
If the fuse is blown, find the cause of the blown fuse (overloading, shorting or grounding) and take
the necessary repair measures before replacing the fuse.
2.2.8 ACCELERATOR PEDAL

The accelerator pedal controls the traveling speed. It outputs a
signal according to the angle at which the pedal is pressed.
Two accelerator potentiometers are installed to allow a broken
signal line to be detected.
Checking procedure
① Turn on the key switch in the truck. Lift the front wheels off
the ground.
② Press and hold the MODE button on the control panel for at
least 3 seconds.
CN2D-32
CN2D-20
CN2D-33
CN2D-21
③ Press and hold the SPE button on the control panel for at least
CN2D-8
CN2D-9
3 seconds.
A B
WR 185
LW 187
BG 186
LB 184
(Accelerator 1 (Accelerator 2
LG 92
LY 93
potentiometer potentiometer - -
output voltage) output voltage)
Accelerator pedal released 1.0 V 0.5 V
ACCEL1 POT.
ACCEL2 POT.
+
Accelerator pedal pressed fully 3.92 V 1.96 V

Note: The voltage at B is always supposed to be half of the voltage at A.
- 21 -
2.2.9 MOTOR ROTATION SENSOR

The motor rotation sensor is a magnetic induction
sensor which detects the alternating voltage generated by
the passing of the teeth in the rotor opposite the motor
shaft.
Two motor rotation sensors are installed on the drive
motor to detect the direction of rotation of the motor.
Checking procedure Sensor section

① Connect a 4.75-16 V power supply to both the Connector
Vcc terminal and the GND terminal of the motor
rotation sensor.
② Connect an analog multi-meter to both the Vout
(+) (S) (-)
terminal and the GND terminal.
③ Rotate the output shaft of the motor and make sure
the voltage at the Vout terminal should be about 1/2
1 2 3
of the power supply voltage.
■ How to rotate the output shaft of the motor

1. Jack up one of the front wheels and block the other
front wheel and the two rear wheels with blocks.
2. Turn the jacked-up front wheel with both hands.
This allows the output shaft of the motor to be
rotated.
Power
supply 4.75 - 16 V
- 22 -
2.2.10 LIFT POTENTIOMETER

The lift potentiometer is used to control the lift
speed of the forks and outputs a signal according to
the tilt angle of the lift lever. The potentiometer is
located in the lift section of the control valve.
Checking procedure
Control valve
Resistance (using a digital multimeter)

Measurement point (within the coupler) Normal value
Between brown and red 4.7 kΩ ±0.3 kΩ
Shaft status:
Between white and red Pushed in: 0.3 kΩ ±0.3 kΩ
Released: 4.7 kΩ ±0.3kΩ
- 23 -
2.2.11 STEERING POTENTIOMETER

The steering potentiometer is used to detect the
turning angle of the left rear wheel. It is located on
the top of the left-side king pin on the rear axle.
The motor speed is controlled according to the
angle at which the left rear wheel to prevent it from
exceeding the preset value.
1. Checking procedure
With the truck in the maintenance mode (See
2.2.20.), check the voltage at point D.
••When the left rear wheel is in the straight-ahead
position: 2.4 to 2.7 V
••When the left rear wheel is turned all the way left: about 3.6 V
••When the left rear wheel is turned all the way right: about 1.9 V
••Whenever the steering potentiometer or the drive motor inverter unit is replaced with a new one,
it will be necessary to set the center, right-end and left-end positions of the steering wheel into the
steering potentiometer in the following manner:
2. Operating procedure
■ Using the steering memory switch Steering memory switch
(1) With the key switch turned off, connect
a steering memory switch (part number:
280B2-60991) to the 3P coupler near the
center of the floorboard (on the side where
the truck-body harness is found).
(2) Press the steering memory switch while
turning the key switch on. Then, release the
steering memory switch to turn it off to put
the steering potentiometer in the read-in
mode. The buzzer will sound for 1 second.
(3) Turn the steering wheel counterclockwise
all the way and then press and release the
steering memory switch. The buzzer will
sound for 1 second. (The full left position will
have been stored in memory.)
(4) Return the steering wheel to the center. Then press and release the steering memory switch. The
buzzer will sound for 1 second. (The center position will have been stored in memory.)
(5) Turn the steering wheel clockwise all the way. Then press and release the steering memory switch.
The buzzer will sound for 1 second. (The full right position will have been stored in memory.)
(6) Return the steering wheel to the center and turn the key switch off.
(7) Remove the steering memory switch.
- 24 -
■ When you do not have a steering memory BR9
switch
(1) With the truck key switch off, connect Y7
one end of a wire to the 3P coupler (BR9 0.6 mm

[0.024 in.]
terminal) near the center of the floorboard. or less
0.6mm以下
(2) Connect the other end of the wire to the 3P
coupler (Y7 terminal). Turn the key switch on
and remove the end of the wire from the Y7
terminal. The buzzer will sound for 1 second.
(3) Turn the steering wheel counterclockwise all
the way and touch the free end of the wire briefly to the Y7 terminal. Remove it immediately. The
buzzer will sound for 1 second. (The full left position will have been stored in memory.)
(4) Turn the steering wheel to the center and touch the free end of the wire briefly to the Y7 terminal.
Remove it immediately. The buzzer will sound for 1 second. (The center position will have been
stored in memory.)
(5) Turn the steering wheel clockwise all the way and touch the free end of the wire briefly to the Y7
terminal. Remove it immediately. The buzzer will sound for 1 second. (The full right position will
have been stored in memory.)
(6) Return the steering wheel to the center and turn the key switch off.
(7) Remove the wire from the 3P coupler.
2.2.12 LCD PANEL

The LCD panel includes the hour meter, error code
display (up to 5 error codes, with the most serious
5 error codes displayed if more than 5 error codes
occur), run time clock, drive wheel angle indicator,
steering wheel in neutral display, an hour meter
screen which shows previous data and other detailed
information, fuel consumption screen and an auto
power-off function.
The LCD panel also has a VTM board function
that allows you to control the battery charging, over-
discharge control, and make various other adjustments
(by setting various parameters).
By connecting a PC to the LCD panel you can
check the error history, battery charge history and other data.
The maintenance mode is used to display voltages and other information (15 items). Without having
to connect a PC, you can also check the error history in the maintenance mode.
- 25 -
2.2.13 CM CONTACTOR
Coil
Contact B
3-phase AC
The CM contactor is used for the on-board battery charger. During charging, 3-phase AC is flowing
through the contactor to open the contact B, thus shutting off the control circuit power supply for the
controllers and other devices. Under normal conditions, it opens the 3-phase contacts to prevent the
charge current from flowing.
Applicable truck Thermal relay Thermal relay
CM contactor Input voltage
model setting setting range
FB10-8
FB15-8 281E2-62661 13A 9 to 13 A
FB18-8
FB20-8
281E2-62651 18A 12 to 18 A
FB25-8 3 ø 50/60Hz 380/390 V
FB25-8LB 430/440 V
FB25-8V
FB30-8 281U2-62661 26A 18 to 26 A
FB30-8V
FB35-8S
Checking procedure
(1) Checking coil resistance
Measure the resistance between points “a” and “b”.
The resistance should be 0.1 to 0.3 kΩ.
(2) Checking for continuity of contact B
Measure the resistance between points “c” and “d”.
There should be no continuity while the button “e” at the center
is being pressed.
- 26 -
2.2.14 CONTROL SWITCH PANEL
Checking procedure
(1) Checking the truck speed control switch (“turtle” button)
••Measure the voltage between the CN9-1-16 terminal (WL) and the CN9-1-8 terminal (Gy) on
the LCD panel.
The voltage reading must be as follows: 0 V when the turtle button is pressed and 5 V when the
button is not pressed.
(2) Checking the S.P.E switch
••Measure the voltage between the CN9-1-15 terminal (W) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the S.P.E button is pressed and 5 V when the
(3) Checking the “Mode” button
••Measure the voltage between the CN9-1-7 terminal (WG) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the Mode button is pressed and 5 V when the
(4) Checking the “-” button
••Measure the voltage between the CN9-1-14 terminal (Y) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the “-” button is pressed and 5 V when the
(5) Checking the “+” button
••Measure the voltage between the CN9-1-6 terminal (YW) and the CN9-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the “+” button is pressed and 5 V when the
- 27 -
2.2.15 BATTERY CHARGER SWITCH PANEL
Checking procedure
(1) Checking the power supply
••Measure the voltage between the CN1-4 (RG) and the CN9-1-5 (BR) on the LCD panel.
The voltage reading should be 5 V.
(2) Checking the start button
••Measure the voltage between the CN1-13 (WR) and the CN9-1-5 (BR) on the LCD panel.
The voltage should be as follows: 5 V when the start button is pressed and 0 V when the start
button is released.
(3) Checking the stop button
••Measure the voltage between the CN1-14 (WY) and the CN9-1-5 (BR) on the LCD panel.
The voltage should be as follows: 5 V when the stop button is pressed and 0 V when the stop
button is released.
(4) Checking SUPER EQUL button
••Measure the voltage between the CN1-15 (WG) and the CN9-1-5 (BR) on the LCD panel.
The voltage should be as follows: 5 V when the SUPER EQUL button is pressed and 0 V when
the SUPER EQUL button is released.
- 28 -
2.2.16 CHARGE RECTIFICATION DIODE
* The symbols are given on the product surface.
The diode is used to rectify the current in the charge circuit.

Part number Model Applicable truck model
177P2-62401 PT200S8 All models
Checking procedure
Resistance range x 1 Ω (Zero adjustment
should be made.)
Measurement point Probe Normal value
– Black
+ Red 60 ± 20 Ω
+ Black
– Red ∞
+ Black
U Red ∞
U Black
+ Red 15 ± 10 Ω
+ Black
V Red ∞
V Black
+ Red 15 ± 10 Ω
+ Black
W Red ∞
W Black
+ Red 15 ± 10 Ω
– Black
U Red 15 ± 10 Ω
U Black
– Red ∞
– Black
V Red 15 ± 10 Ω
V Black
– Red ∞
Note: Whenever the charge rectification diode – Black
W Red 15 ± 10 Ω
is replaced with a new one, apply silicone
grease (KS-609) on the fitting surface of a W Black
– Red ∞
new diode.
- 29 -
2.2.17 CHECKING CHARGE TIMER

Check the secondary timer for operation using the following procedure. If any fault is found, replace
the LCD panel with a new one.
○ : Lighting, △ : Flashing, × : Off

When the charge timer is normal:
Super equalizing Charge start LED CM contactor
Checking method charge LED operation
1 Connect power supply plug to wall outlet × × OFF
Press and hold super equalizing charge button
2 △ × OFF
for more than 3 seconds
when the button is pressed △ ○ ON
3 Press start button
31 seconds after pressing × × OFF
4 Checking is over (Timer counts up normally.) × × OFF
When the charge timer is defective:

Super equalizing Charge start LED CM contactor
Checking method charge LED operation
1 Connect power supply plug to wall outlet × × OFF
Press and hold super equalizing charge button
2 △ × OFF
for more than 3 seconds
when the button is pressed △ ○ ON
3 Press start button
more than 2 minutes pass △ × OFF
4 Checking is over (Charge error) △ × OFF
Charge start LED

充電開始LED
Start
開始ボタン button
Super equalizing
スーパー均等LED
charge LED
Super equalizing
スーパー均等ボタン
charge button
- 30 -
2.2.18 MOTOR THERMO-SENSOR

The drive and pump motors are provided with
thermo-sensors to check the motor temperature. If
the detection value of a thermo-sensor is judged to be
abnormal, the controller limits the electric current to
the corresponding motor.
Checking procedure
① Disconnect the motor sensor connectors.
② Set the multimeter to a resistance range of
x1000 Ω. Measure the resistance between the
terminals according to the table given below.
③ Determine whether the sensor is defective or not
according to the measured resistance.
Normal value (rough guide)
10°C [50°F]: about 20 kΩ
20°C [68°F]: about 13 kΩ
30°C [86°F]: about 9 kΩ
50°C [122°F]: about 4.4 kΩ
Voltage checking
Measurement terminals (wire color)
Drive motor Pump motor Normal value
+ – + –
CN11-4 CN11-3 CN1-22
N terminal 0.2 to 4.8 V
(WG) (WR) (LW)
- 31 -
2.2.19 F/R SWITCH
Checking procedure
Measure the resistance between terminals with the multimeter in the resistance range (minimum
range).
Standard value
IG1 (GND) ① 0 Ω for F

| ② ∞ for positions
VF (Inverter CN1-8) other than F
IG1 (GND) ① 0 Ω for R

| ② ∞ for positions Terminal position
VR (Inverter CN1-21) other than R
- 32 -
2.2.20 CHECKING VOLTAGE ON THE LCD PANEL

The FB-8 series trucks have controllers completely sealed with the couplers made into waterproof type. This
makes it difficult to measure the voltage of the controller system directly.
To make it easier to service the controller system of the truck, the trucks are provided with the maintenance
mode on the LCD panel to display the operating status information of the controllers.
The information of up to 15 items and error history can be displayed on the LCD panel using the following
procedure:
Main
通常画面 screen
Press and hold “MODE” button Press “turtle” button to

「MODE」ﾎﾞﾀﾝ３秒以上長押し
for more than 3 seconds. 「亀」ﾎﾞﾀﾝで戻る
return to Main screen.
Calendar
ｶﾚﾝﾀﾞ画面 screen
Press “turtle” button to

「亀」ﾎﾞﾀﾝで戻る
return to Main screen.
Press and hold “SPE” button Press “turtle” button to

「SPE」ﾎﾞﾀﾝ３秒以上長押し
for more than 3 seconds. 「亀」ﾎﾞﾀﾝで戻る
Maintenance return to Main screen.
ﾒﾝﾃﾅﾝｽ画面
screen
Press “SPE” button.

「SPE」ﾎﾞﾀﾝ短押し Press “SPE” button.
「SPE」ﾎﾞﾀﾝ短押し
Error history
故障表示画面
screen
New
新
Old
旧
JYU: Serious error CYU: Moderately serious error

JYU：重故障
Year/Month/Day Hour:Minute CYU：中故障
Error code: Year/Mont/ Day Hour: Minute Error code
The
error history
年/月/日時：分 is updated by pressing the SPE時：分
エラーコード年/月/日 button. エラーコード
Items to be displayed on the maintenance screen:

ｴﾗｰ履歴は、SPEﾎﾞﾀﾝを押すと更新されます。
A Accelerator 1 POT output voltage (V)
ﾒﾝﾃﾅﾝｽ画面の表示項目 F Drive motor current sensor 1 voltage (V) K Lift current sensor 1 voltage (V)
B Accelerator 2 POT output voltage (V) G Drive motor current sensor 2 voltage (V) L Lift current sensor 2 voltage (V)
C
A アクセル1POT.出力電圧(V)
Lift POT output voltage (V)
F ﾄﾞﾗｲﾌﾞｶﾚﾝﾄｾﾝｻ1電圧（V) K ﾘﾌﾄｶﾚﾝﾄｾﾝｻ1電圧（V)
H Pump motor inverter internal temp. (°C) M EPS motor current (A)
B アクセル2POT.出力電圧（V) G ﾄﾞﾗｲﾌﾞｶﾚﾝﾄｾﾝｻ2電圧（V) L ﾘﾌﾄｶﾚﾝﾄｾﾝｻ2電圧（V)
D Steering POT output voltage (V) I Drive motor inverter internal temp. (°C) N Drive motor speed (rpm)
C リフトPOT.出力電圧（V) H 荷役ｲﾝﾊﾞｰﾀ内部温度（℃) M EPSﾓｰﾀ電流(A)
E Torque sensor output voltage (V) J Power steering motor inverter internal temp. (°C) O Pump motor speed (rpm)
D ステアリングPOT.出力電圧（V) I 走行ｲﾝﾊﾞｰﾀ内部温度（℃) N 走行ﾓｰﾀ回転数（rpm)
On trucks
E withトルクセンサ出力電圧（V)
an Orbitrol steering system, the items E, J, and M are always displayed
J PSｲﾝﾊﾞｰﾀ内部温度（℃) O as “0”.
荷役ﾓｰﾀ回転数（rpm)
- 33 -
Drive system
Key switch Parking lever Forward switch Accelerator
No. Terminal Remarks
ON Released ON Full throttle
Accelerator 1 POT output common to all
A 0.97 0.97 0.97 4.08
voltage (V) models.
Accelerator 2 POT output common to all
B 0.51 0.51 0.51 2.04
voltage (V) models.
Drive motor current sensor common to all
F 2.49 2.49 2.49 2.49
1 voltage (V) models.
Drive motor current sensor common to all
G 2.49 2.49 2.49 2.49
2 voltage (V) models.
Drive motor inverter
I – – – –
internal temp. (°C)
1-ton class trucks
4085 (S mode)
2-ton class trucks
N Drive motor speed (rpm) 0 0 0 3829 (S mode)
3-ton class trucks
3407 (S mode)
Load handling system

Lever position
Lever pushed
No. Terminal Lever pulled Remarks
Neutral forward
back
during rotation
Lift POT output voltage common to all
C 4.27 1.05 0.9
(V) models
Pump motor inverter
H – – –
internal temp. (°C)
Lift current sensor 1 common to all
K 2.49 2.49 2.49
voltage (V) models
Lift current sensor 2 common to all
L 2.49 2.49 2.49
voltage (V) models
1.5-ton class trucks
2963 (S mode)
2.5-ton class trucks
O Pump motor speed (rpm) 0 0 2962 (S mode)
3-ton class trucks
2961 (S mode)
Power steering system (All the items except “D” are inapplicable to trucks with an Orbitrol
steering system.)
Steering wheel position
No. Terminal Remarks
Left end Center Right end
Steering POT output
D 3.63 2.5 1.9 common to all models
voltage (V)
Torque sensor output
E 1.04 2.4 3.8 common to all models
voltage (V)
PS motor inverter internal
J – – –
temp. (°C)
1-ton class trucks (MAX): The
40 0 40 current is limited when the steering
wheel is turned to each end.
M EPS motor current (A) 45 0 45 current is limited when the steering
38 0 38 current is limited when the steering
- 34 -
3. TROUBLESHOOTING GUIDE
3.1 HOW TO USE THIS GUIDE
Check the LCD panel for any error codes.
If an error code is displayed on the LCD panel, see “3.5 TROUBLESHOOTING BY ERROR
CODE”. If no error code is displayed, see “3.6 TROUBLESHOOTING BY PROBLEM”.
Error code
Start trouble diagnosis
2. Perform the procedure in “3.2 CHECKING BEFORE TROUBLESHOOTING”.
Is any
error code shown on the
LCD panel?
3. Perform the procedure in 4. Perform the procedure in

“3.5 TROUBLESHOOTING “3.6 TROUBLESHOOTING
BY ERROR CODE”. BY PROBLEM”.
Make repairs
Is the
truck properly
restored?
End
- 35 -
3.2 CHECKING BEFORE TROUBLESHOOTING
(1) Checking wiring and terminals for looseness

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

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

Check main fuse (in the controller) and the fuse in the fuse box.
(4) Checking the communication line

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

The wiring of the electric truck is insulated from the frame. If there is any leak from the body,
various troubles will occur. Be sure to check for leaks.
It is recommended to wipe off dirt on the battery surface with a wet waste cloth or paper and dry
the cleaned surface by blowing air.
(Criteria)
Wiring side: If leak resistance is 100 k-ohm or more, the wiring condition in the wiring side is
judged as good.
Frame to body receptacle (+)
Frame to body receptacle (-)
Battery side: If the leak is 1 k-ohm impedance with 1 V or less, the wiring condition in the
battery side is judged as good.
Frame to battery (+)
Frame to battery (-)
- 36 -
< ERROR CODES SHOWN BY LED >

The error code numbers are displayed by an orange LED blinking on the controller CPU board.
Error codes are displayed as 2-digit numbers (decimal system). The 1’s digit and 10’s digit blink
at an interval of 0.5 seconds. The 100’s digit is not displayed for 3-digit error codes. The 1’s and 10’s
digits are separated by a 1-second OFF period. The 10’s digit is flashed first, and then the 1’s digit.
After flashing one error code, the LED will be OFF for 4 seconds before repeating the blinking
process.
If multiple errors occur, the last error code that was detected by the controller will be the one
displayed.
Because the error codes displayed on the LCD panel have a one-to-one correspondence with the
flashing LED error codes, the information described above is helpful if the LCD panel fails to display
the error codes.
(Example) Error code: 23 (Drive motor current sensor output abnormal)
Error code 23
LED blinks twice LED blinks 3 times
LED ON
LED OFF
The same process

is repeated.
■ Locations of LEDs
For drive motor

inverter
For pump motor inverter
- 37 -
(1) Drive system (1/5)
Error code LED
Error description Problem Resetting Error code conditions Page
on display code
Turn the key switch ON
When the key switch is turned ON,
when:
blinks. Drive system neutral interlock The truck won’t travel. • an accelerator signal is present 01 49
• the accelerator is OFF
• a forward or reverse travel signal is present.
• the F/R lever is in neutral
Battery voltage:
28 V or less (for 48 V trucks)
The truck won’t travel, steering system
Low battery voltage detected 42 V or less (for 72 V trucks)

101 and the load handling system won’t Turn the key switch OFF. 09 49
(Battery voltage dropped) This error occurs if the voltage in the EPS
work.
system stays below 24 V (for 48 V trucks) or
36 V (for 72 V trucks) for at least 2 seconds.
3.3 ERROR CODE TABLE
Battery voltage:
Battery voltage (for travel and load-handling
• 28 V or less (for 48 V
Low battery voltage detected systems):
102 Lower output of drive and pump motors trucks) 95 49
(Low output) • 45 V or less (for 48 V trucks)
• 42 V or less (for 72 V
• 60 V or less (for 72 V trucks)
trucks)
103
The battery discharge
Battery The battery discharge indicator level drops
Low battery voltage detected indicator level rises above the
discharge Lower output of drive and pump motors below the warning level (factory set to Level - 49
- 38 -
(Overdischarge warning) warning level (factory set to
indicator 2).
Level 2).
blinks.
The truck won’t travel and the load Turn the seat switch ON. After the key switch is turned ON, the seat
blinks. Seat switch OFF detected handling system won’t work. (The operator must sit in the switch stays OFF for the preset period of 02 50
105 (after the key switch is turned ON)
Lift lock solenoid OFF. seat.) time, or longer.

The truck won’t travel and the load
blinks. Seat switch OFF detected The seat switch is ON when The seat switch is OFF when the key switch
handling system won’t work. 02 50
106 (When the key switch is turned ON) the key switch is turned ON. is turned ON.
Lift lock solenoid OFF.
Forward or reverse travel switch Automatically resets when The forward and reverse travel switches are
201 The truck won’t travel. 07 50
abnormal the input returns to normal. turned ON simultaneously.
The temp. drops to less than This error occurs when the temp. reaches
202 Drive motor inverter unit temp. abnormal The truck won’t travel. 34 50
109°C [228°F]. 109°C [228°F].
The truck can be driven (but the output The temp. drops to 90°C This error occurs when the temp. reaches
203 Drive motor inverter unit temp. too high 33 50
is limited). [194°F] or below. 94°C [201°F].
Error code LED
on display code
Drive motor inverter unit thermosensor 1
31
(TMD1) AD input range abnormal Automatically resets when The thermosensor voltage drops below 0.2 V
204 The drive output is limited. 48
Drive motor inverter unit thermosensor 2 the input returns to normal. or rises above 4.92 V
32
(TMD2) AD input range abnormal
The temp. drops below 155°C The thermosensor temp. reaches 155°C
205 Drive motor temp. abnormal The truck won’t travel. 37 49
[311°F]. [311°F].
The truck can be driven (but the current The temp. drops below 135°C The thermosensor temp. reaches 145°C
206 Drive motor temp. too high 36 49
is limited). [275°F]. [293°F].
Drive motor thermosensor abnormal Automatically resets when The thermosensor voltage drops below 0.15
207 The drive output is limited. 35 49
AD input range abnormal the input returns to normal. V or rises above 4.92 V
The truck won’t travel.
The brake switch remains ON for at least 10
(Limits the output to 80% when the
208 Excessive travel inching Accelerator output OFF seconds while the accelerator output is 70% 89 49
accelerator and brake are both turned
or more.
ON)
Rotation sensor defective After the accelerator is turned ON, if there
Automatically resets when
• The A or B phase pulse is missing. The truck won’t travel. is no speed pulse input and the electric 73 50
the input returns to normal.
- 39 -
• The A and B phase pulses are missing. current equivalent to the max. torque (i.e.,
209
Rotation sensor defective the torque command is for more than 60% of
Automatically resets when full current) remains present for at least 15
Bearing defective The drive output is limited. 74 50
(Stall signals detected continuously) seconds.
The truck can be driven normally.

Automatically resets when Accelerator voltage comparison:
210 Accelerator signal wire short-circuited Accelerator 1 or 2 signal wire short- - 51
the input returns to normal. Accelerator 1 – Accelerator 2 x 2 ≧ 0.5
circuited
The truck cannot be driven if this error Automatically resets when The output detected is not 1/2 of the
211 Accelerator 2 potentiometer defective 06 50
is detected together with Error Code the input returns to normal. accelerator 1 potentiometer output.
212.
Operated via accelerator 2 potentiometer.
The truck cannot be driven if this error Automatically resets when The output detected is not twice that of the
212 Accelerator 1 potentiometer defective 06 50
is detected together with Error Code the input returns to normal. accelerator 2 potentiometer output.
211.
Error code LED
on display code
U-phase upper side FET defective
213 The truck won’t travel. Turn the key switch OFF. 16 51
U-phase lower side FET defective
V-phase upper side FET defective
V-phase lower side FET defective

W-phase upper side FET defective
W-phase lower side FET defective
V-phase current detection abnormal, AD
input too low
The truck won’t travel. Turn the key switch OFF. 24 51
input too high
V-phase current offset abnormal, AD
input too low
input too high
- 40 -
216
W-phase current detection abnormal, AD
input too low
input too high
W-phase current offset abnormal, AD

input too low
input too high
Rapid charging of capacitor abnormal
The travel, load handling, and PS (power
(Improper charging of the capacitor
217 steering) systems are inoperative. Turn the key switch OFF. 23 52
between the P and N terminals)
Contactor OFF.
(Error Codes 218 and 418 also occur.)
Drive motor inverter unit upper/lower
FET short-circuited
(Error Code 418 also occurs because
the drive and load handling units are
connected with a copper bar.)
Contactor OFF.
(Error Code 217 is also triggered because
the capacitor between the P and N
terminals cannot be charged.)
Error code LED
on display code
Drive motor inverter unit upper FET
defective
Contactor OFF.
(Error Code 217 is also triggered
because the capacitor between the P and
N terminals cannot be charged.)
Drive motor inverter unit lower FET
defective
Contactor OFF.
221 Travel overspeed The truck can be driven normally. 94 54
- 41 -
When the key switch is turned ON:
Accelerator potentiometer not positioned Automatically resets when
307 The truck can be driven normally. • Accelerator 1: 0.8 V or less - 53
properly the input returns to normal.
• Accelerator 2: 0.4 V or less
Contactor coil broken The travel, load handling, and EPS

308 Turn the key switch OFF. 12 55
(Blown fuse) systems are inoperative.
The travel, load handling, and EPS
309 Contactor stuck Turn the key switch OFF. The contactor is stuck. 11 55
systems are inoperative.
Overvoltage
The truck won’t travel, and the load Automatically resets when 48 V trucks: More than 72 V
318 (Battery connectors disconnected during 86 55
handling and EPS systems won’t work. the input returns to normal. 72 V trucks: More than 118 V
regenerative braking)
Steering SSC Automatically resets when
503 Wheel angle sensor defective 52 55
Loss of control the input returns to normal.
LCD panel data reception error Automatically resets when
600 Mode selection is not possible. 65 56
(Communication wire broken) the input returns to normal.
Operates with default settings.
Error code LED
on display code
Load-handling data reception error
(Communication wire broken)
602 (The contactor does not operate when the The truck can be driven normally. 63 56
load-handling data has no errors when
the key switch is turned ON.)
EPS (power steering) data reception
error (Communication wire broken)

603 (The contactor does not operate when The truck can be driven normally. 64 56
the power steering data has no errors
when the key switch is turned ON.)
The travel, load-handling and PS (power 48 V trucks: More than 63 V
- Abnormal battery voltage detected Turn the key switch OFF. 08 56
steering) systems are inoperative. 72 V trucks: More than 94 V
Load short circuit (Motor interphase
- The truck won’t travel. Turn the key switch OFF. 22 57
short-circuited)
EEPROM SUM error The truck can be driven normally. 82

- (The parameters used for the drive Turn the key switch OFF. 57
EEPROM ACK error adjustments are the default settings.) 83
- 42 -
Overcurrent
- The truck won’t travel. Turn the key switch OFF. 91 57
(Hard OCL detected)
(2) Load-handling system (including trucks with an Orbitrol steering system) (1/3)
Error code LED
on display code
Turn the key switch ON
When the key switch is turned ON:
The load handling system won’t work. when:
blinks. Load-handling system neutral interlock • A load-handling signal is present (i.e., the 01 58
Lift lock solenoid OFF. • the load-handling levers are
seat switch is ON).
in neutral.
Pump motor inverter unit temp. The temp. drops to less than
402 The load handling system won’t work. The temp. rises above 109°C [228°F]. 34 58
abnormal 109°C [228°F].
The load handling system works (but The temp. drops to 90°C
403 Pump motor inverter unit temp. too high The temp. rises above 94°C [201°F]. 33 58
the output current is limited). [194°F] or below.
Pump motor inverter unit thermosensor
31
1 (TMD1) AD input range abnormal Automatically resets when The thermosensor voltage drops below 0.2 V
404 The load-handling output is limited. 58
Pump motor inverter unit thermosensor the input returns to normal. or rises above 4.92 V.
32
2 (TMD2) AD input range abnormal
The temp. drops to less than
405 Pump motor temp. abnormal The load handling system won’t work. The temp. rises above 155°C [311°F]. 37 58
115°C [311°F].
The load handling system works (but The temp. drops to 135°C
406 Pump motor temp. too high The temp. rises above 145°C [293°F]. 36 58
the output current is limited). [275°F] or below.
- 43 -
Pump motor thermosensor defective Automatically resets when The thermosensor voltage drops below 0.15
407 The load-handling output is limited. 35 59
AD input range abnormal the input returns to normal. V or rises above 4.92 V.
Rotation sensor defective A load-handling signal (including operation

• The A or B phase pulse is missing. The load handling system won’t work. of the steering wheel during OBT) is present 73 59
• The A and B phase pulses are missing. and speed pulse inputs (both A and B phases)
are absent.
410
Rotation sensor defective The current equivalent to the maximum
Automatically resets when torque (i.e., the torque command is for more
Bearing defective The load-handling output is limited. 74 59
the input returns to normal. than 60% of full current) continues for 15
(Stall signals detected continuously)
seconds or longer.
Automatically resets when The lift potentiometer output voltage drops
412 Lift potentiometer defective The load handling system won’t work. 06 59
the input returns to normal. below 0.2 V or rises above 4.8 V.
Error code LED
on display code
U-phase upper side FET defective
413 The load-handling system won’t work. Turn the key switch OFF. 16 60
U-phase lower side FET defective
V-phase upper side FET defective
V-phase lower side FET defective

W-phase upper side FET defective
W-phase lower side FET defective
input too low
The load-handling system won’t work. Turn the key switch OFF. 24 60
input too high
input too low
input too high
416
- 44 -
input too low
input too high
input too low

input too high
Pump motor inverter unit upper and
lower FET defective
(Error Code 218 also occurs because the
drive and pump motor inverter units are
Contactor OFF.
Pump motor inverter unit upper FET
defective (Error Code 218 also occurs
because the drive and pump motor
inverter units are connected with a copper
bar.)
Contactor OFF.
Error code LED
on display code
Pump motor inverter unit lower FET
defective
the drive drive and pump motor inverter
units are connected with a copper bar.)
Contactor OFF.
Load short-circuit (Motor interphase
- The load-handling system won’t work. Turn the key switch OFF. 22 61
short-circuited)
Drive data reception error
(Communication wire broken)
- (The contactor does not operate when The truck can be driven normally. 61 62
the drive data has no errors when the key
switch is turned ON.)
EEPROM SUM error The truck can be driven normally. 82

- (The parameters used for the drive Turn the key switch OFF. 62
EEPROM ACK error adjustments are the default settings.) 83
- 45 -
Overcurrent
- The load-handling system won’t work. Turn the key switch OFF. 91 61
(Hard OCL detected)
(3) EPS Power steering system (1/2)
Error code LED
on display code
The travel, load-handling and EPS
EPS transistor short-circuited (power steering) systems are inoperative. Turn the key switch OFF. 05 63
Contactor OFF.
EPS transistor short-circuited
(power steering) systems are inoperative. Turn the key switch OFF. 06 63
(after startup)
Contactor OFF.
506

(Lower)
Contactor OFF.
(Upper)
Contactor OFF.
The EPS power steering system won’t
507 EPS transistor open Turn the key switch OFF. 04 63
work.
1-ton class trucks: 3 2A or more continues for
at least 5 seconds.
The EPS power steering output is Automatically reset when the 2-ton class trucks: 3 6A or more continues for
Continuous energizing protection 1. 17 63
limited. input returns to normal. at least 6 seconds.
3-ton class trucks: 3 4A or more continues for
at least 7 seconds.
- 46 -
508
1-ton class trucks: 8 A or more continues for
at least 60 seconds.
The EPS power steering output is Automatically reset when the 2-ton class trucks: 8 A or more continues for
Continuous energizing protection 2. 19 63
limited. input returns to normal. at least 60 seconds.
3-ton class trucks: 7 A or more continues for

at least 60 seconds.
Torque sensor defective The EPS power steering system won’t 22
Turn the key switch OFF. 64
(Short-circuited) work. 25
509
Torque sensor defective The EPS power steering system won’t 23
Turn the key switch OFF. 64
(Open) work. 26
The EPS power steering system stops
- DM open Turn the key switch OFF. 09 64
working.
The EPS power steering output is The temp. drops below 95°C
- FET temp. too high The temp. rises above 100°C [212°F]. 11 64
limited. [203°F].
The EPS power steering system stops The temp. drops below 110°C
- FET temp. abnormal The temp. rises above 115°C [239°F]. 12 64
working. [230°F].
- FET1 thermosensor defective Only operates at ambient temperature. Turn the key switch OFF. 13 64
- FET2 thermosensor defective Only operates at ambient temperature. Turn the key switch OFF. 14 64
(3) EPS Power steering system (2/2)
Error code LED
on display code
If this error is detected before startup:
→ The EPS power steering system is
disabled. Automatically reset when the
- Data reception error 21 65
If this error is detected after startup: input returns to normal.
→ Speed detection is not possible.
Tire angle detection is not possible.
- 47 -
3.4 LCD PANEL SYSTEM ERRORS

Error Icon
Description Problem Cause Corrective Action
Code displayed
Check BW211 and LY212 between the
This error code is displayed when no current is
The travel, load- LCD panel and the CM contactor. Check the
being drawn by the CM contactor or the “a”-
CM relay handling and RL100 wire that goes to the CM contactor.
071 contact. Wrench
malfunction EPS systems are Also check any diodes connected in parallel.
The CM contactor, diodes, or their wiring may
inoperative. If no problem is found, replace the CM
be defective.
contactor with a new one.
Check YG 208 between the LCD panel and
This error code is displayed if there is no
PO relay short the PO relay. Check the RL100 wire that
072 Undefined current being drawn by the PO relay coil. Wrench
circuit leads to PO relay. If no problem is found,
The PO relay or its wiring may be defective.
replace the PO relay with a new one.
This error code is displayed if the CM Check BW211 and LY212 between the LCD
The travel, load- contactor does not work when the charge panel and the CM contactor, and the RL100
CM relay short handling and STOP button on the battery charger control wire that leads to the CM contactor. Also
073 Wrench
circuit EPS systems are panel is pressed. check any diodes connected in parallel. If no
inoperative. The CM contactor, diodes, or their wiring may problem is found, replace the CM contactor
be defective. with a new one
This error code is displayed if a time-out has
The travel, load-
occurred while receiving analog input data
AD conversion handling and
074 (current draw or temperature readings). Wrench
error EPS systems are
Any of the indicators or wiring may be
inoperative.
defective.
Replace the LCD panel with a new one.
This error code is displayed if a time-out has
The travel, load-
occurred while receiving data from the RTC
handling and
075 RTC error (real time clock). Wrench
EPS systems are
The connections on the LCD panel board or
inoperative.
the RTC may be defective.
The travel, load- A time-out has occurred while reading memory
Remove and reinstall the battery connectors.
EEPROM access handling and or writing to the LCD panel memory.
076 If the problem is not solved, replace the Wrench
error EPS systems are The connections on the LCD panel board or
LCD panel with a new one.
inoperative. the EEPROM may be defective.
Program sum
077 The travel, load- Wrench
error These error codes refer to errors that occur
handling and
while loading the program or when an Replace the LCD panel with a new one.
Version loading EPS systems are
078 incorrect program version was loaded.
error inoperative. Wrench
The travel, load-

This error code is displayed if the key switch
handling and
081 AC ON is turned ON while AC power supply is To reset, turn the key switch OFF. Wrench
EPS systems are
connected.
inoperative.
Check to see if the controller operates
properly when the key switch is tuned ON
The travel and This error code is displayed if no signal is
(see if the orange pilot lamp on the main
Communication load-handling received from the controller.
082 CPU board is lit). Check the communication Wrench
error (controller) systems can The controller or the controller communication
lines (GW81, GR82) between the LCD panel
work. lines may be defective.
and the controller. If no problem is found,
replace the LCD panel with a new one.
Follow the instructions given by the fault
The travel, load- This error code is displayed if no signal is
diagnosis program installed on a PC.
Communication handling and received from PC.
083 Check the communication lines between the Wrench
error (PC) EPS systems are The communication line with PC may be
LCD panel and PC. If no problem is found,
inoperative. defective.
replace the LCD panel with a new one.
The travel, load-
Another mode
handling and This error code is displayed if the key switch
084 was requested To reset, turn the key switch OFF. Wrench
EPS systems are is turned ON while charging.
while charging
inoperative.
The travel, load-
This error will be cleared when the battery
Low battery handling and This indicates that the battery voltage detected
085 voltage returns to 24 V. When cleared, the Wrench
voltage EPS systems are by the LCD panel has dropped below 26 V.
key switch is forced OFF.
inoperative.
This error code is displayed if the charging
The travel, load- process has not finished when the fail-safe
Connect the battery while pressing and
Abnormal handling and timer times out, or if an AC power failure lasts
087 holding the SUPER EQUALIZE switch on Wrench
charging EPS systems are for more than 120 hours while charging. The
the battery charger control panel.
inoperative. LED on the battery charger control panel will
keep blinking.
The travel, load- This error code is displayed if the AC power
AC power This error will be cleared when the AC
handling and goes OFF while charging.
088 failure during power is restored and then charging will Wrench
EPS systems are The truck is not operative because the battery
charging resume.
inoperative. is being charged.
- 48 -
3.5 TROUBLESHOOTING BY ERROR CODE
This section explains how to perform troubleshooting using the error codes displayed on the
LCD panel.
< How to use this troubleshooting guide >
① Take Step ① and see if there is a problem. If a problem is found, take the corrective action in the
right column. If no problem is found, proceed to Step ② .
② Take Step ② and see if there is a problem. If a problem is found, take the corrective action in the
right column. If no problem is found, proceed to Step ③ .
③ Continue on the same way until the problem is resolved.
<Example: Accelerator 1 sensor defective>

Upper: LCD panel error code
212
06 Lower: LED error code
1. Drive system
Resets when the accelerator pedal and F/R lever are
(1) N blinks
: Drive system neutral interlock
06
placed in neutral.
① Turn the key switch ON when the accelerator pedal

and the F/R lever are in neutral.
② Check the voltage of the potentiometer for

Repair the accelerator 1 potentiometer or wiring.
accelerator 1.
③ Check the voltage of the potentiometer for

accelerator 2.
④ Check the F/R lever switch voltage. Repair the F/R lever switch or wiring.
⑤ Replace the drive motor inverter unit.
(2) 101
09 : Low voltage (Low battery voltage) Resets when the key switch is turned OFF.
Resets when the battery voltage reaches:

102
95 : Low voltage (Low output) 48 V (for 48 V trucks)
72 V (for 72 V trucks)
Resets when the battery discharge indicator level

103
- : Low voltage (Over-discharge) rises above the warning level (factory set to Level
2).
① Check the battery voltage. Recharge the battery.
② Check the voltage at the CN1D-24 terminal on the

Correct the wiring.
drive motor inverter unit.
③ Replace the drive motor inverter unit.
- 49 -
(3) 105
02 :S
afety interlock (after the key switch is turned Resets when the seat switch is turned ON (i.e.,
on) when the operator is seated in the operator’s seat).
Resets when the key switch is turned ON while the

106
02 :S
afety interlock (when the key switch is turned seat switch is on (i.e., the operator is seated in the
on)
operator’s seat).
① Turn the seat switch ON, and put the accelerator

pedal and F/R lever in neutral. Then turn the key
switch ON.
② Check the voltage at the CN1D-16 terminal on the

Repair the seat switch or wiring.
(4) 201
07 :F
orward travel switch or reverse travel switch Automatically resets when the input returns to
abnormal normal.
① Check the voltage at the CN1D-18 and CN1D-19

Repair the combination switch or wiring.
terminals on the drive motor inverter unit.
② Replace the drive motor inverter unit.
Resets when the temperature drops below 109°C

(5) 202
: Drive motor inverter unit temp. too high
34
[228.2°F].
Resets when the temperature drops below 90°C

203
33 : Drive motor inverter unit temp. abnormal [194°F].
① Turn the key switch OFF and allow the controller to

cool down for at least 30 minutes.
② Check the drive and pump motor inverter units for

Retighten.
loose screws.
(6) 204
31 :D
rive motor inverter unit thermosensor 1 Automatically resets when the input returns to
(TMD1) AD input range abnormal normal.
204
32 :D
rive motor inverter unit thermosensor 2 Automatically resets when the input returns to
① Replace the drive motor inverter unit.
- 50 -
Resets when the temperature drops to less than

(7) 205
: Drive motor temp. abnormal
37
165°C [329°F].
Resets when the temperature drops to 145°C

206
36 : Drive motor temp. too high [293°F] or below.
① Turn the key switch OFF and allow the motor to cool
down for at least 30 minutes.
② Check the voltage between CD2D-6 and CD2D-17

Repair the drive motor or wiring.
on the drive motor inverter unit.
(8) 207
35 :D
rive motor thermosensor defective Automatically resets when the input returns to
AD input range abnormal normal.
① Check the drive motor thermosensor for proper

Install properly.
installation.

Repair the drive motor or wiring.
(9) 208
89 : Excessive travel inching Resets when the accelerator output is OFF.
① Check whether the accelerator and brake pedals have

been pressed for 10 seconds or longer.

③ Check the voltage between CD2D-9 and CD2D-21

④ Check the voltage at the CD2D-4 on the drive motor

Repair the relay unit or wiring.
inverter unit.
- 51 -
(10) 209
73 :R
otation sensor defective Automatically resets when the input returns to
The A or B phase pulse is missing.
normal.
The A and B phase pulses are missing.
209
74 :R
Bearing defective (Stall signals detected
normal.
continuously)
① Check the harness between the drive motor inverter

unit (CN2D-3, -5, -15, -16, -27, -29) and the rotation Correct the wiring.
sensor.
② Check the motor slit board. Repair the motor slit board.
③ Check the rotation sensor. Repair the rotation sensor.
④ Replace the drive motor inverter unit.
Automatically resets when the input returns to

(11) 211
: Accelerator 2 sensor defective
06
normal.
① Check the accelerator 2 sensor connector for proper

Connect properly.
connection.
② Check the harness between the drive motor inverter

Correct the wiring.
unit (CN2D-9, -21, -33) and the accelerator 2.
③ Check the accelerator 2 sensor. Repair the accelerator unit.

212
06 : Accelerator 1 sensor defective normal.
① Check the accelerator 2 sensor connector for proper

Connect properly.
connection.

Correct the wiring.
unit (CN2D-8, -20, -32) and the accelerator 1.
③ Check the accelerator 1 sensor. Repair the accelerator unit.
- 52 -

(12) 210
: Accelerator signal wire short-circuited
-
normal.
① Check the voltage at CN2D-8 and -9 terminals on

the drive motor inverter unit.
② Check the drive motor inverter unit (CN2D-8, -9)

Correct the wiring.
harness.
③ Check the accelerator unit. Repair the accelerator unit.
307
- : Accelerator potentiometer not positioned Automatically resets when the accelerator voltage
properly is 0.8 V or more.
① Check the voltage at the CN2D-8 and -9 terminals

Accelerator voltage should be 1.00 V in the neutral

② Check the accelerator unit for proper positioning.
position.
③ Replace the accelerator unit.
(13) 213
16 : Drive motor inverter unit U-phase FET open Resets when the key switch is turned OFF.
214
17 : Drive motor inverter unit V-phase FET open Resets when the key switch is turned OFF.
215
18 : Drive motor inverter unit W-phase FET open Resets when the key switch is turned OFF.
① Check the drive motor for loose terminals. Retighten.
② Check the drive motor cable. Correct the cable.
(14) 216
24 : V-phase current detection abnormal Resets when the key switch is turned OFF.
AD input too low, AD input too high
216
25 : V-phase current offset abnormal Resets when the key switch is turned OFF.
216
26 : W-phase current detection abnormal Resets when the key switch is turned OFF.
216
27 : W-phase current offset abnormal Resets when the key switch is turned OFF.
① Replace the drive motor inverter unit.
- 53 -
(15) 217
23 :R
apid charging of capacitor abnormal
(Improper charging of capacitor between P and Resets when the key switch is turned OFF.
N terminals)
① Troubleshoot the problem according to Error Code

218.
② Troubleshoot the problem according to Error Code

418.
(16) 218
15 :D
rive motor inverter upper/lower FET short- Resets when the key switch is turned OFF.
circuited
219
19 : Drive motor inverter upper FET short-circuited Resets when the key switch is turned OFF.
220
21 : Drive motor inverter lower FET short-circuited Resets when the key switch is turned OFF.
① Check the battery cable connection. (Check the

contactor secondary side for any negative (-) voltage Correct the cable.
leaks.)
② Remove the motor cables from U-, V-, and W phase. –
③ Check for any electrical leaks between the motor

Correct the cable.
cable, and the positive (+) and negative (-) terminals.
④ Check the bars and bolts that connect between the

Retighten.
drive and pump motor inverter units for looseness.
⑤ Check the harness for the CN1D-24 terminal on the

Correct the wiring.
⑥ Check the RCH (rapid charger resistor). Repair the RCH.
⑦ Check the harness between CN1D-11/CN1D-12 and

Correct the wiring.
CNCH on the drive motor inverter unit.
⑧ Replace the drive motor inverter unit.

(17) 221
: Travel overspeed
94
normal.
① Check the harness between the drive motor inverter

unit (CN2D-3, -5, -15, -16, -27, -29) and the rotation Correct the wiring.
sensor.
② Check the drive motor slit board. Repair the slit board.
- 54 -
(18) 308
12 :C
ontactor coil broken Resets when the key switch is turned OFF.
(Blown fuse)
① Check the contactor coil. Repair the contactor.
② Check the F1 fuse. Replace the F1 fuse, if needed.
③ Check the harness between CN1D-22/CN1D-35 and

CNMC (contactor coil connector) on the drive motor Correct the wiring.
inverter unit.
(19) 309
11 : Contactor coil short-circuited Resets when the key switch is turned OFF.
① Check the battery cable for proper connection.

(Check for any positive (+) voltage leak on the Correct the battery cable.
contactor secondary side.)
② Check the contactor coil. Repair the contactor.
③ Check the harness between CN1D-22/CN1D-35 and

CNMC (contactor coil connector) on the drive motor Correct the wiring.
inverter unit.
(20) 318
86 :O
vervoltage (Battery connectors disconnected Resets when the key switch is turned OFF.
during regenerative braking)
① Check the battery connectors for proper connection.
② Refer to the repair procedure for Error Code 308.

(21) 503
: Tire angle sensor defective
52
normal.
① Check the tire angle potentiometer connector for

Connect properly.
proper connection.

Correct the wiring.
unit (CN2D-10, -23, -24) and the tire angle sensor.
③ Check the tire angle potentiometer. Repair the tire angle potentiometer.
- 55 -
(22) 600
65 :L
CD panel data reception error Automatically resets when the input returns to
(Communication wire broken) normal.
① Check the connectors for the CN1D-1, -3, -13, -14,

and -15 terminals on the drive motor inverter unit for Install properly.
proper installation.
② Check the LCD panel connector for proper

Install properly.
installation.
③ Remove the EPS motor controller connector. –
④ Check the resistance between CN1E-9 and CN1E-12

Repair the EPS motor controller.
on the EPS motor controller.
(23) 602
63 :L
oad-handling data reception error Automatically resets when the input returns to
603
64 :E
PS data reception error Automatically resets when the input returns to
① Check the connectors for the CN1D-1, -3, -13, -14,

and -15 terminals on the drive motor inverter for Connect securely.
looseness.
② Check the connectors for the CN1P-1, -3, -13, -14,

and -15 terminals on the pump motor inverter unit Connect securely.
for looseness.
③ Check the connectors for the CN1E-8, -9, -10, -11,

and -12 terminals on the EPS motor controller for Connect securely.
looseness.
④ Check each harness of the connectors described in

Repair the harness.
items ① , ② , and ③ .
⑤ Remove the EPS motor controller connector. –
⑥ Check the resistance between CN1E-9 and CN1E-12

⑦ Replace the drive motor inverter unit.
(24) -
08 : Abnormal battery voltage Resets when the key switch is turned OFF.
① Check the charger connection. Connect properly.
② Check the battery voltage.
- 56 -
(25) -
22 :L
oad short circuit (Motor interphase short- Resets when the key switch is turned OFF.
circuit)
-
91 : Overcurrent (Hardware OCL detected) Resets when the key switch is turned OFF.
① Check the drive motor cable terminals U, V, and W

Remove the foreign matter.
for foreign matter.
② Check the drive motor cable for looseness. Retighten.
③ Check the drive motor cable for short circuit. Correct the cable.
④ Check the CN1D-24 terminal on the drive motor

Connect properly.
inverter unit for proper connection.
⑤ Check the harness for the CN1D-24 terminal on the

Correct the wiring.
⑥ Refer to the repair procedure for Error Code 308.
⑦ Refer to the repair procedure for Error Code 216.
⑧ Replace the drive motor.
⑨ Replace the drive motor inverter unit.
(26) -
82 : EEPROM SUM error Resets when the key switch is turned OFF.
-
83 : EEPROM ACK error Resets when the key switch is turned OFF.
① Replace the drive motor inverter unit if this error

occurs frequently.
- 57 -
2. Load handling system (including trucks with an Orbitrol steering system)

Resets when the load-handling levers are put in
(1) N点滅
: Load-handling system neutral interlock
01
neutral.
① Put the load-handling levers in neutral.
② Check the lift potentiometer voltage. Repair the lift potentiometer or wiring.
③ Check the voltage at the CN1P-16, -17, and -18

Repair the switch or wiring.
terminals on the pump motor inverter unit
④ Replace the pump motor inverter unit.

(2) 402
: Pump motor inverter unit temp. abnormal
34
109°C [228.2°F].
Resets when the temperature drops to 90°C [194°F]

403
33 : Pump motor inverter unit temp. too high or below.
① Turn the key switch OFF and allow the controller to

cool down for 30 minutes.
② Check the drive and pump motor inverter units for

Retighten.
loose screws.
③ Replace the pump motor inverter unit.
(3) 404
31 :P
ump motor inverter unit thermosensor 1 Automatically resets when the input returns to
404
32 :P
ump motor inverter unit thermosensor 2 Automatically resets when the input returns to
① Replace the pump motor inverter unit.

(4) 405
: Pump motor temp. abnormal
37
155°C [311°F].
Resets when the temperature drops to 135°C

406
36 : Pump motor temp. too high [275°F] or below.
① Turn the key switch OFF and allow the motor to cool
down for 30 minutes.
② Check the voltage between CN2P-6 and CN2P-17

Repair the pump motor or wiring.
on the pump motor inverter unit.
- 58 -
(5) 407
35 :P
ump motor thermosensor defective Automatically resets when the input returns to
AD input range abnormal normal.
① Check the pump motor thermosensor for looseness. Connect securely.
② Check the voltage between CN2P-6 and CN2P-17

Repair the pump motor or wiring.
on the pump motor inverter unit.
(6) 410
73 :R
The A or B phase pulse is missing.
normal.
The A and B phase pulses are missing.
410
74 :R
Abnormal bearing (Stall signals detected
normal.
continuously)
① Check the voltage between the pump motor inverter

Correct the wiring.
unit (CN2P-5, -16, -29) and the speed sensor
② Check the pump motor slit board. Repair the motor slit board.

(7) 412
: Lift potentiometer defective
06
normal.
① Check the lift potentiometer connector for looseness. Connect securely.
② Check the harness between the pump motor inverter

Correct the wiring.
unit (CN2P-8, -20, -32) and the lift potentiometer.
③ Check the lift potentiometer. Repair the lift potentiometer.
- 59 -
(8) 413
16 : Pump motor inverter unit U-phase FET open Resets when the key switch is turned OFF.
414
17 : Pump motor inverter unit V-phase FET open Resets when the key switch is turned OFF.
415
18 : Pump motor inverter unit W-phase FET open Resets when the key switch is turned OFF.
① Check the pump motor for loose terminals. Retighten.
② Check the pump motor cable. Correct the cable.
(9) 416
24 : V-phase current detection abnormal Resets when the key switch is turned OFF.
416
25 : V-phase current offset abnormal Resets when the key switch is turned OFF.
416
26 : W-phase current detection abnormal Resets when the key switch is turned OFF.
416
27 : W-phase current offset abnormal Resets when the key switch is turned OFF.
① Replace the pump motor inverter unit.
- 60 -
(10) 418
15 :P
ump motor inverter unit upper/lower FET Resets when the key switch is turned OFF.
short
419
19 :P
ump motor inverter unit upper FET short Resets when the key switch is turned OFF.
420
21 :P
ump motor inverter unit lower FET short Resets when the key switch is turned OFF.
① Check the battery cable connection (Check the

leaks).
② Remove the motor cables from the U, V and W

–
terminals.
③ Check for electrical leaks between the motor cable,

Correct the cable.
and the positive (+) and negative (-) terminals.
④ Check the bar and bolts that connect between the

Retighten.
drive and pump motor inverter units.
⑤ Check the harness for the CN1D-22 and -24

Correct the wiring.
terminals on the pump motor inverter unit.
⑥ Check the RCH (rapid charger resistor). Repair the RCH.
⑦ Check the harness between CN1D-11/CN1D-12 and

Correct the wiring.
CNCH on the drive motor inverter unit.
⑧ Replace the pump motor inverter unit.
(11) -
22 :L
oad short-circuit (Motor interphase short- Resets when the key switch is turned OFF.
circuited)
-
91 : Overcurrent (Hard OCL detected) Resets when the key switch is turned OFF.
① Check the pump motor cable U, V, and W terminals

Remove the foreign material.
and the areas around them for foreign material.
② Check the pump motor cable for looseness. Retighten.
③ Check the pump motor for short circuit. Correct the cable.
④ Check the pump motor inverter unit (CN1P-24, -22)

Connect properly.
for proper connection.
⑤ Check the harness for the CN1P-24 and -22

Correct the wiring.
terminals on the pump motor inverter unit.
⑥ Refer to the repair procedure for Error Code 308.
⑦ Refer to the repair procedure for Error Code 416.
⑧ Replace the pump motor.
⑨ Replace the pump motor inverter unit.
- 61 -
(12) -
61 :D
rive data reception error (Communication Resets when the key switch is turned OFF.
wire broken)
① Check the connectors for CN1D-1, -3, -13, -14, and

-15 terminals on the drive motor inverter unit for Connect securely.
looseness.
② Check the connectors for CN1P-1, -3, -13, -14, and

-15 terminals on the pump motor inverter unit for Connect securely.
looseness.
③ Check the connectors for the CN1E-8, -9, -10, -11,

and -12 terminals on the EPS motor controller for Connect securely.
looseness.
④ Check each harness for the connectors described in

Correct the wiring.
items ① , ② , and ③ .
⑤ Remove the EPS motor controller connector.
⑥ Check the resistance between CN1E-9 and CN1E-12

⑦ Replace the pump motor inverter unit.
(13) -
82 : EEPROM SUM error Resets when the key switch is turned OFF.
-
83 : EEPROM ACK error Resets when the key switch is turned OFF.
① Replace the pump motor inverter unit if this error

occurs frequently.
- 62 -
3. EPS Power steering system

(1) 506
05 : EPS transistor short-circuited (at startup) Resets when the key switch is turned OFF.
506
06 : EPS transistor short-circuited (after startup) Resets when the key switch is turned OFF.
506
07 : EPS transistor short-circuited (lower) Resets when the key switch is turned OFF.
506
08 : EPS transistor short-circuited (upper) Resets when the key switch is turned OFF.
① Check the battery cable connection. (Check the

leaks).
② Remove the EPS connector. –
③ Check for any electrical leaks between the frame-

side wires, and the positive (+) and negative (-) Correct the cable.
terminals.
④ Check the bar and bolts that connect between the

Retighten.
drive and pump motor inverter units for looseness.
⑤ Check the EPS motor controller’s positive (+) and

Correct the wiring.
negative (-) terminals and motor wiring.
⑥ Check the CN1E-34 terminal on the EPS motor

Connect properly.
controller for proper connection.
⑦ Check the harness for the CN1E-34 terminal on the

Correct the wiring.
EPS motor controller.
⑧ Replace the EPS motor controller.
(2) 507
04 : EPS transistor open Resets when the key switch is turned OFF.
① Check the EPS motor connector for looseness. Connect securely.
② Check the EPS motor wiring. Repair the harness.
③ Replace the EPS motor controller.

(3) 508
: Continuous energizing protection 1
17
normal.

508
19 : Continuous energizing protection 2 normal.
① Put the steering wheel in neutral.
② Replace the EPS motor controller.
- 63 -
(4) 509
22
509
25 : Torque sensor defective (shorted) Resets when the key switch is turned OFF.
509
23
509
26 : Torque sensor defective (open) Resets when the key switch is turned OFF.
① Check the torque sensor connector for looseness. Connect securely.
② Check the harness between the EPS motor controller

Correct the wiring.
(CN1E-6, -22, -23) and the torque sensor.
③ Check the torque sensor. Repair the torque sensor.
④ Replace the EPS motor controller.
(5) -
09 : DM open Resets when the key switch is turned OFF.
① Check the EPS motor connector for looseness. Connect properly.
② Check the EPS motor wiring. Correct the wiring.
③ Check the EPS motor. Repair the EPS motor.

(6) -
: FET temp. too high
11
normal.

-
12 : FET temp. abnormal normal.
① Put the steering wheel in neutral. –
② Turn the key switch OFF and allow the FET to cool
–
down.
③ Check the EPS motor controller for loose screws. Retighten.
(7) -
13 : FET1 thermosensor defective Resets when the key switch is turned OFF.
-
14 : FET2 thermosensor defective Resets when the key switch is turned OFF.
① Replace the EPS motor controller.
- 64 -

(8) -
: Data reception abnormal
21
normal.
① Check the connectors for the CN1E-8, -9, -10,

-11, -12 terminals on the EPS motor controller for Connect securely.
looseness.
② Check the harness for those connectors. Correct the wiring.
③ Remove the EPS motor controller connector. –
④ Check the resistance between CN1E-9 and CN1E-12

- 65 -
3.6 TROUBLESHOOTING BY PROBLEM

(1) The LCD panel is blank.
101(RY)
CN1-11
Key switch ... Turn it ON. LCD panel
LCD panel 40 V or
more
Below10 V
101(RY)
Key switch ... Turn it ON. RY101
Key switch 40 V or
more
Below10 V
100(RL)
Key switch ... Turn it OFF. Key switch
Key switch 40 V or
more
Below10 V
100(RL)
Key switch ... Turn it OFF. RL100
F4 40 V or
more
Below10 V
5(R)
Key switch ... Turn it OFF. F4
F4 40 V or
more
Below10 V
R5
- 66 -
(2) MC contactor does not work. (The travel, load handling, and EPS systems are inoperative.)
11(RW)
CN1D-7,8 Key switch ... Turn it ON.
Drive motor
inverter Drive motor inverter
11(RW) or
CN1D-7,8 Key switch ... Turn it ON. Pump motor inverter
Pump motor
inverter
All of these are or
40 V or more. EPS motor controller
11(RW)
PS1E-17
Key switch ... Turn it ON. RW11
EPS motor
controller Any of these is
below 10 V.
All of these are
below 10 V.
11(RW)
Key switch ... Turn it ON. RW11
PO relay 40 V or
more
Below 10 V
216(RG)
Key switch ... Turn it ON. PO relay
PO relay 40 V or
more
Below 10 V
216(RG)
MC Key switch ... Turn it ON. RG216
contactor 40 V or
more
Below 10 V
101(RY)
Key switch ... Turn it ON. MC contactor
MC
contactor 40 V or
more
Below 10 V
101(RY)
Key switch ... Turn it ON. RY101
Key switch 40 V or
more
Below 10 V
100(RL)
Key switch ... Turn it OFF. Key switch
Key switch 40 V or
more
Below 10 V
100(RL)
Key switch ... Turn it OFF. RL100
F4 40 V or
more
Below 10 V
5(R)
Key switch ... Turn it OFF. F4
F4 40 V or
more
Below 10 V
R5
- 67 -
(3) MC contactor works but the truck won’t travel.
15(O) Key switch .......................... Turn it ON.

F/R lever .................... Shift into F or R. • Parking brake switch
Parking brake lever .................. Release. 0 V • O 15
CN1D-5 • BR 9
Drive motor Accelerator pedal ............. Do not press.
inverter
5V
53 (WBr) in F
54 (WL) in R Key switch .......................... Turn it ON.
• Combination switch
CN1D-18 in F F/R lever .................... Shift into F or R.
• WBr 53
CN1D-19 in R Parking brake lever .................. Release. 0 V
• WL 54
Drive motor Accelerator pedal ............. Do not press.
inverter
5V
In maintenance mode:
A (Accelerator 1 Accelerator 1 potentiometer,
Key switch ................ Turn it ON. LY93
potentiometer output F/R lever .......... Shift into F or R. A: Below 0.5 V
voltage)
B (Accelerator 2 Parking brake lever ........ Release.
Accelerator pedal ....... Press fully. Accelerator 2 potentiometer,
potentiometer output LG92
voltage) B: Below 0.2 V
1.5 V or more
- 68 -
(4) The truck travels, but does not gain speed.
Is the “turtle” mark Key switch .......................... Turn it ON.

invisible? Turtle
mark
visible
“Turtle” mark 75(WL) Key switch ... Turn it ON.

Turtle button............Press. 5 V Switch panel
invisible LCD panel
CN9-1-16
0V
LCD panel
A (Accelerator 1 Key switch ................ Turn it ON.
potentiometer output F/R lever .......... Shift into F or R. • Accelerator
voltage) • LY93, LG92
B (Accelerator 2 Parking brake lever ........ Release. A: Below 3.1 V
potentiometer output Accelerator pedal ....... Press fully. B: Below 1.5 V
voltage)
3.1 V or more
In maintenance mode: • Steering angle potentiometer

D (Steering potentiometer Key switch ................ Turn it ON. • YL43
output voltage) Wheels .. Set them straight ahead. Other than • Adjust the neutral position
2.4 to 2.7 V of the wheels.
2.4 to 2.7V
- 69 -
(5) Only the lift lever does not work.

C (Lift potentiometer Key switch ................ Turn it ON. Lift potentiometer
output voltage) Below 0.2 V GR189
4.8 V or more WR188
0.5 to below 1.1 V YL94
In maintenance mode: Key switch ................ Turn it ON.

C (Lift potentiometer Lift potentiometer
Lift lever.........................Pull fully.
output voltage) Below 2.3 V YL94
4.6 V or more
2.4 to 4.5 V
Pump motor inverter
(6) Only the tilt lever does not work.
20(YR)
Key switch ............ Turn it ON. Pump motor inverter
Pump motor
inverter 0V YR20
BL9
5V
20(YR) Key switch ............ Turn it ON.

Tilt switch
Pump motor Tilt lever . .................. Tilt fully. 5 V
inverter YR20
BL9
0V
Pump motor inverter
(7) T
he pump motor is running when no load-handling operation is being performed.
(Applicable only to trucks with an EPS steering system)
Check the harness between the pump motor inverter GR189

unit (CN2P-8, -20, -32) and lift potentiometer. WR188
NG
YL94
OK
Check the lift potentiometer. Lift potentiometer
NG
OK
Check the harness between the pump motor

YR20
inverter unit (CN1P-16, -17, -18) and each switch. NG YG21
YL22
OK
Tilt switch, ATT1 and ATT2 switches
- 70 -
(8) Hard steering

■ EPS steering system
Key switch ................ Turn it ON.
D (Torque sensor output Torque sensor
Turn the steering wheel.
voltage) Below 0.2 V L160
4.8 V or more G161
1.0 to 3.8 V W162
EPS motor
Key switch ................ Turn it ON.
CN3E-1 Replace the EPS motor.
Turn the steering wheel.
CN3E-2 0A
0 to 40 V
EPS motor controller
■ Orbitrol steering system
In maintenance mode: Key switch ................ Turn it ON.

Steering wheel angle sensor
O (Pump motor rpm) Turn the steering wheel.
0 rpm BR 230
BG 243
0 to below 360 rpm LY 249
BY 244
LG 246
Below
In maintenance mode: Key switch ................ Turn it ON. 360 rpm
O (Pump motor rpm) When F/R switch is not in neutral. F/R swtich
WL 54
WBr 53
360 to 600 rpm
Below
Key switch ................ Turn it ON. 600 rpm
Turn the steering wheel clockwise Steering potentiometer
O (Pump motor rpm)
or counterclockwise to stop. YR 44
0 to 600 rpm
Pump motor inverter
- 71 -
NOTE
- 72 -
4. PARAMETER SETTING
4.1 SETTING THE PARAMETERS
Take the following considerations into account when changing the parameters.
1. Be careful when increasing the acceleration level or load-handling speed levels, because that may
reduce the number of hours you can operate the truck, the motor may overheat, or other problems
may occur.
2. Remember that increasing the levels of any parameter settings may adversely affect the operation
of the truck.
4.2 PARAMETER SETUP SCREEN
Program version
Battery voltage
The actual temperature
Temperature detected detected is the displayed
(LCD panel) value minus 15.
Parameter item Setting

Parameter group
4.3 KEYPAD
LOW-SPEED TRAVEL (TURTLE) BUTTON
If this button is pressed while the PARAMETER GROUP SETUP screen
is displayed, the display will return to the INITIAL PARAMETER SETUP
screen.
If this button is pressed while the PARAMETER ITEM SETUP screen is
displayed, the display will return to the PARAMETER GROUP SETUP
screen.
MODE BUTTON
Use this button to toggle between parameter items.
This button is also used to display the PARAMETER SETUP COM-
PLETE screen and the DATA TRANSMISSION screen.
+ BUTTON
- BUTTON
Use these buttons to increase or decrease the parameter group number
when selecting a parameter group, and to set a parameter value.
- 73 -
4.4 SCREEN OPERATION
INITIAL PARAMETER SETUP SCREEN
While pressing and holding the Mode button and the “+” button on the keypad, turn on the key
switch. The INITIAL PARAMETER SETUP screen shown above will be displayed.
Note that the MC contactor is not activated at this point.
Press the “+” button to display PARAMETER 1; press the “-” button to display PC.
Use the “+” button or the “-” button to toggle between the parameter groups, as shown below.
PARAMETER GROUP SETUP SCREEN
Parameter group
PARAMETER 1
PARAMETER 1 and PARAMETER 2 are used when setting the
parameters for the controller.
PARAMETER 3 is used to set the LCD panel parameters.
PARAMETER 2 PC is the mode used when a PC (an electric truck fault-diagnosis
support system) is connected.
PARAMETER 3
PC
Press this turtle button to return to the INITIAL
PARAMETER SETUP screen.
- 74 -
PARAMETER GROUP SETUP SCREEN
Press this turtle button to return to the INITIAL

PARAMETER ITEM PARAMETER SETUP screen.
SETUP SCREEN
Parameter item Setting
Press the Mode button when the PARAMETER GROUP SETUP screen is displayed. The first
parameter item in the selected parameter group will be displayed.
Each time the Mode button is pressed, another parameter item is displayed.
Pressing the Mode button on the last parameter item will return you to the first parameter item.
To cancel any changes to the settings and return to the INITIAL PARAMETER SETUP screen,
press the turtle button.
If the parameter item to be set has a range, press the “+” button or the “-” button to increase or
decrease the value within that range.
If the parameter item requires an ON or OFF setting, press the “+” button to select ON or the “-”
button to select OFF.
- 75 -
PARAMETER ITEM SETUP SCREEN
Press and hold After setting a parameter item, press

this button. and hold the Mode button when the
PARAMETER SETUP PARAMETER ITEM SETUP screen is
COMPLETE SCREEN displayed.
The PARAMETER SETUP COM-
PLETE screen (shown on the left) will
be displayed.
TERMINATED
Press and hold

DATA TRANSMISSION this button. Press and hold the Mode button when
SCREEN the PARAMETER SETUP COMPLETE
screen is displayed. The controller
MC contactor will be activated and the
DATA TRANSMISSION screen (shown
on the left) will be displayed. This
screen indicates that the new setting is
DATA IN TRANSMISSION being sent to the controller.
DO NOT TURN OFF THE KEY
Note that the truck cannot be operated
during data transmission.
DATA TRANSMISSION COMPLETE SCREEN

Once the data transmission is finished,
the DATA TRANSMISSION COM-
PLETE screen (shown on the left) will
be displayed. Then turn the key switch
TERMINATED OFF.
TURN OFF THE KEY
- 76 -
FB-8 Parameter Setting Table Factory settings
No. Screen display Item Description Unit 0 1 2 3 4 5 6 7 8 9 10 Remarks
1 POWER Travel speed acceleration level Travel speed acceleration mode numbers - 0 1 2 3 4 5 6 7 8 9 10
2 TRAVEL SPEED LIMIT Truck speed limit level Max. speed in the “turtle” mode km/h 3 4 5 6 7 8 9 10 12 14 16
3 LIFT SPEED Lift speed level Lift conduction ratio limit % 50 55 60 65 70 75 80 85 90 95 100
4 LIFT INCING LEV. Lift inching level Lift inching conduction ratio limit % 0 5 10 15 20 25 30 35 40 45 50
5 TILT SPEED Tilt speed level Tilt conduction ratio limit % 0 10 20 30 40 50 60 70 80 90 100
6 ATT1 SPEED ATT1 speed level ATT1 conduction ratio limit % 0 10 20 30 40 50 60 70 80 90 100
7 ATT2 SPEED ATT2 speed level ATT2 conduction ratio limit % 0 10 20 30 40 50 60 70 80 90 100
8 SWITCH BACK REG. Switchback regeneration level Switchback regeneration intensity % 0 10 20 30 40 50 60 70 80 90 100
9 ACCELERATOR OFF REG Accelerator-off regeneration level Accelerator-off regeneration intensity % 0 10 20 30 40 50 60 70 80 90 100
10 BRAKE REG. Brake OFF regeneration level Brake OFF regeneration intensity % 0 10 20 30 40 50 60 70 80 90 100
PARAMETER 1
11 ANTI ROLL BACK Anti-rollback regeneration level Anti-rollback regeneration intensity % 0 10 20 30 40 50 60 70 80 90 100
12 ACCELERATOR STAGE Accelerator stage level Accelerator stage mode numbers - 0 1 2 3 4 5 6 7 8 9 10
13 SPEED ALARM OUTPUT SPEED Speed alarm output level Speed at which alarm output is started with speed alarm output mode enabled km/h 3 4 5 6 7 8 9 10 12 14 16
14 STEERING SSC LEVEL Steering SSC level Lower speed limit when steering SSC is activated km/h 3 4 5 6 7 8 9 10 12 14 16
15
16 SPEED LIMIT LEVEL Max. speed limit level The speed obtained when the max. speed limit flag is enabled. km/h 3 4 5 6 7 8 9 10 12 14 16
1 SEAT SW Flag setting (1) Seat switch enabled OFF ON
2 SPEED㩷㪣㪠㪤㪠㪫䇭㪪㪠 Speed limit, vehicle inspection specifications 15 km/h or less OFF ON
3 S MODE LIMIT Flag setting (3)-1 S mode disabled OFF ON
- 77 -
4 NEUTRAL SAFTY LOCK ACCEL. Flag setting (3)-2 Accelerator pedal neutral safety enabled - OFF ON
5 NEUTRAL SAFTY LOCK PUMP LEV. Flag setting (3)-3 Load-handling neutral safety enabled - OFF ON
6 SPEED LIMIT Max. speed limit enabled Max. speed limit enabled - OFF ON
7 LIFT DOWN SWITCH Flag setting (2)-1 Lift-down switch ON OFF ON Note displayed. Always OFF.
8 PUMP ACCELERATION MODE Flag setting (2)-2 Lift acceleration mode: High/N/Low/Super Low - SL Low N H
PARAMETER 2
9 SEAT SW DETECTION TIME Seat switch detection time The time required for seat switch OFF to be enabled. sec 0 1 1 2 2 3 3 4 4 4.5 5
10 SEAT SW OFF DELAY TIME Seat switch OFF delay time The reset delay time after seat switch OFF is detected. sec 0 2 4 6 8 10 15 20 30 60 㺙
Truck speed limit rate that becomes effective Truck speed limit rate that becomes effective when the overdischarge alarm
11 SPEED LIMIT RATE BATT when the overdischarge alarm signal is present. signal is present. % 0 10 20 30 40 50 60 70 80 90 100
12 PUMP UNIT LIMIT RATE Load-handling operation limit rate during overdischarge Lift duty factor that is used when the overdischarge alarm signal is present. % 0 10 20 30 40 50 60 70 80 90 100
The numbers correspond to
1 OVER DISCHARGE LEVEL Overdischarge output level Battery discharge indicator level at which overdischarge signal is issued. - 1 2 3 4 5 6 7 8 9 10 the battery meter level.
2 AUTO POWER OFF TIME Auto power-off time The time required for auto power-off function to be enabled. 0 1-14 15 16-90 Settable in minutes. 0: OFF
3 AH䇭METER DISPLAY Hour meter display switching over Items to be displayed on hour meter when key switch is turned on. TOTAL DRIVE PUMP WORK TRAVEL RATE
4 HEATER Heater ON/OFF control Not settable OFF ON Fixed to OFF
5 SPEED MODE LIMIT Fixed in the “turtle” mode Locked with the turtle switch pressed OFF ON
6 PASS WORD SET Password setting Password mode ON/OFF OFF ON
7 BATTERY CAPACITY Battery capacity Battery capacity selection 330 400 450 485 545 565 600 700 865 935 Factory setting
8 CONTRAST Contrast adjustment 1-44 45 46-90
PARAMETER 3
0, 9, 10: OFF, 1: VM 1t, 2: VM 2t,
9 CYLINDER Load meter constants Specify if an optional load meter is installed. 0 1 2 3 4 5 6 7 8 9 10 3: VM 3t, 4: VM 3.5t, 5: VFHM 1t,
6: VFHM 2t, 7: VFHM 3t, 8: VFHM 3.5 t
11 INT BUZZER TIME Number of beeps made by interlock buzzer Number of beeps by buzzer 1 2 3 4 5 6 7 8 9 10 10: unlimited
4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING

(1) PARAMETER 1 - No. 4 “Lift inching level”
If the controller’s CN1P-20 terminal is turned ON, the upper limit of the conduction ratio during
lifting operations will be according to the setting of this parameter, thus slowing down the lifting speed.
Note: A standard harness does not have any wiring going to this terminal.
(2) PARAMETER 1 - No. 12 “Accelerator stage level”

You can specify the accelerator power curve to be used.
100
Accelerator power curve
アクセルステージ特性
Level 0
ﾚﾍﾞﾙ0
80
Level 1
ﾚﾍﾞﾙ1
Level 2
ﾚﾍﾞﾙ2
Level 3
[％] [%]
ﾚﾍﾞﾙ3
60
Level 4,5,6
command
ﾚﾍﾞﾙ4､5､6
Level 7,8
ﾚﾍﾞﾙ7､8
速度指令
40
Level 9,10
ﾚﾍﾞﾙ9､10
Speed
20
0
0.00 1.00 2.00 3.00 4.00 5.00
Accelerator
アクセル電圧 voltage
[Ｖ]
(3) PARAMETER 1 - No. 13 “Speed alarm output level” (option)

Sets the speed at which the speed alarm relay (RS) is turned on.
The output will be turned ON when the speed reaches the preset level and it is turned OFF when the
speed drops 0.5 km/h below that preset level.
If an additional RS relay is installed (inside the right side frame), 48 V can be output at Y99 (under
the floorboard).
- 78 -
(4) PARAMETER 1 - No. 14 “Steering SSC speed level”

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

ステアリングSSC特性
Command speed according the angle of
the accelerator lever
アクセルペダル踏み角に応じた指令速度
Speed limits
制限速度 (km/h)
[km/h]
Steering wheel turned Steering wheel turned

CCW (左旋回)
counterclockwise (to the left) Tireタイヤ切れ角
steering angle
[°][°] CW (右旋回)
clockwise (to the right)
(5) PARAMETER 2 - No. 11 “Truck speed limit rate during overdischarge”

PARAMETER 2 - No. 12 “Pump motor speed limit rate during overdischarge”
PARAMETER 3 - No. 1 “Overdischarge output level”
If the battery discharge indicator level drops to a preset level, an overdischarge signal will be output
from the LCD panel to the controller, thus limiting the drive motor and pump motor speeds.
Use PARAMETER 3 – No.1 to set the battery discharge indicator level at which the overdischarge
signal is output. You can specify the speed limit rates (percentage) in PARAMETER 2 - Nos. 11 and
12.
(6) PARAMETER 3 - No. 4 “Heater ON/OFF control”

This parameter item is displayed on the LCD panel, but its factory setting cannot be changed.
On LCD panels designed for use in a freezer, a heater is installed that maintains the correct LCD
temperature to keep the LCD panel functioning correctly.
This parameter item is factory set to OFF.
However, LCD panels for use in a freezer will switch the heater ON/OFF, according to the
temperature detected.
(7) PARAMETER 3 - No. 7 “Battery capacity”

Select the capacity of the battery installed in your truck. This setting will be used as the basis of the
calculations for the fuel consumption display.
This setting must be changed if the battery capacity is changed from the factory default setting.
If the capacity of the battery installed in your truck is not in the list, select the closest one.
- 79 -
4.6 SETTING THE PASSWORDS

Two different passwords can be specified. These two passwords are factory set to “0000”.
KEYPAD
Low-speed travel (turtle) button Switches between PASSWORD SETUP screens 1 and 2
(when pressed at the same time as the S.P.E button).
S.P.E button Switches between PASSWORD SETUP screens 1 and 2

(when pressed at the same time as the Low-Speed Travel
button).
Mode button Selects the digit to enter. Confirms the entered password.
+ button
- button Increases or decreases the number.
PASSWORD INPUT SCREEN
Set “PARAMETER 3 - No.6 PASSWORD SET” to ON.

For details on the setup procedure, refer to the PARAMETER
SETTING section.
Turn on the key switch to display the PASSWORD screen

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

these buttons
simultaneously.
PASSWORD
SETUP SCREEN 1
PASSWORD SETUP screen 1 (shown on the left) will be
displayed.
To display PASSWORD SETUP screen 2, press and
hold the low-speed travel (turtle) button and S.P.E button
simultaneously while PASSWORD SETUP screen 1 is being
displayed.
Use these buttons to toggle between PASSWORD SETUP
screens 1 and 2.
The zero on the screen indicates the selected digit.
The selected digit moves to the right each time the Mode
Press and hold button is pressed.
these buttons Pressing the Mode button when the selected digit is the last
simultaneously. digit on the right will select the digit on the far left.
Select a number (0 to 9) for each digit by pressing the “+”
PASSWORD button or the “–“ button.
SETUP SCREEN 2
After entering one or two 4-digit passwords, press and hold
the Mode button for at least 3 seconds. Your password (or
passwords) will be confirmed and the Main screen will be
displayed.
You cannot specify “0000” as a valid password.

If you press and hold the Mode button when “0000” is
displayed on PASSWORD SETUP screen 1, an error will be
displayed.
If you conform “0000” as your second password by pressing
and holding the Mode button on PASSWORD SETUP screen
2, the use of a second password will be canceled and only
the first password you specified on PASSWORD SETUP
screen 1 will be valid.
- 80 -
5. DESCRIPTION OF THE FUNCTIONS

(1) Travel speed control while turning (Steering SSC)
• Controls the motor speed so that the truck does not exceed the travel speed specified according to the
angle of the rear left wheel (steering potentiometer voltage) while turning.
<Speed control for each steering angle range>
(a) When the rear left wheel steering angle is 0 to 15 degrees while turning left, or 0 to -10 degrees while
turning right. ------ Maximum speed
(b) When the rear left wheel steering angle is 15 to 25 degrees while turning left, or -10 to -15 degrees
while turning right. ------ The larger the steering angle, the higher deceleration rate.
(c) When the rear left wheel steering angle is 25 to 45 degrees while turning left, or -15 to -30 degrees
while turning right. ------ Varies with the SSC steering level setting.
(2) Traveling neutral interlock

• Prevents the truck from suddenly lurching forward or back when the key switch is turned ON while the
accelerator pedal is pressed or the F/R lever is in the forward or reverse position.
<Activation conditions>
• If the accelerator pedal is pressed or the F/R lever is in the forward or reverse position when the key
switch is turned ON.
<Truck operation>
• The truck cannot be moved.
<Deactivation conditions>
• Accelerator pedal and F/R lever in neutral
(3) Load-handling system neutral interlock

• Prevents the load handling system from starting suddenly when the key switch is turned ON while a load
handling lever is operated.
< Activation conditions>
• If a load handling command (potentiometer switch or valve switch) is present when the key switch is
turned ON.
<Truck operation>
• Load handling system disabled
• Load handling command (potentiometer switch, valve switch) OFF
(4) Interlock control

• The interlock system is a safety device that cuts off the power to the drive and load handling circuits
when the operator leaves the compartment during operation. This system helps prevent an accident from
happening if the operator is not in the correct driving position or if the controls are moved unintentionally
when no one is in the operator’s compartment.
(a) When the key switch is turned ON:
• If the key switch is turned ON while the interlock switch is OFF
(b) After the key switch is turned ON:
• If a predetermined period of interlock OFF time has passed while the key switch is ON
<Truck operation>
(a) The truck won’t travel and the load handling system won’t work. However, the EPS will work.
(b) The truck won’t travel and the load handling system won’t work. However, the EPS will work.
(a) If the key switch is turned ON while the seat switch is ON
(b) Travel system: Accelerator lever OFF and seat switch ON
Load handling system: Load handling command OFF and seat switch ON
- 81 -
(5) Regenerative control

(a) Switchback regeneration
• Regenerative braking occurs when the F/R lever is switched from forward to reverse or vice versa
while the accelerator pedal is pressed.
See the table below.
(b) Brake OFF regeneration
• Regenerative braking occurs when the brake switch is turned OFF.
(c) Accelerator neutral regeneration (accelerator OFF regeneration)
• Regenerative braking occurs when the accelerator lever is moved to the neutral position while the
truck is traveling.
Table 1 Regenerative Control

Input conditions Controller drive mode
Accelerator ON OFF
Brake switch OFF ON OFF ON
Slope detected No Yes No Yes No Yes No Yes
Accelerator Truck – – – – – –
switch status
Accelerator
Forward Driving under Driving in Driving with Driving in Anti-roll OFF Brake OFF Anti-roll OFF
OFF
travel power slope mode *2 output limit *1 slope mode *2 regeneration regeneration regeneration
regeneration
Driving under Driving in Driving with Driving in
F Stopped Output OFF Output OFF
power slope mode *2 output limit *1 slope mode *2
Accelerator
Reverse Switchback Switchback Brake OFF Brake OFF Anti-roll OFF Brake OFF Anti-roll OFF
OFF
travel regeneration regeneration regeneration regeneration regeneration regeneration regeneration
regeneration
Accelerator Accelerator
Forward Anti-roll OFF Brake OFF Brake OFF Anti-roll OFF Brake OFF Anti-roll OFF
neutral neutral
travel regeneration regeneration regeneration regeneration regeneration regeneration
regeneration regeneration
N Stopped Output OFF Output OFF Output OFF Output OFF
Accelerator Accelerator
Reverse Anti-roll OFF Brake OFF Brake OFF Anti-roll OFF Brake OFF Anti-roll OFF
neutral neutral
travel regeneration regeneration regeneration regeneration regeneration regeneration
regeneration regeneration
Accelerator
Forward Switchback Switchback Brake OFF Brake OFF Anti-roll OFF Brake OFF Anti-roll OFF
OFF
travel regeneration regeneration regeneration regeneration regeneration regeneration regeneration
regeneration
Driving under Driving in Driving with Driving in
R Stopped Output OFF Output OFF
power slope mode *2 output limit *1 slope mode *2
Accelerator
Reverse Driving under Driving in Driving with Driving in Anti-roll OFF Brake OFF Anti-roll OFF
OFF
travel power slope mode *2 output limit *1 slope mode *2 regeneration regeneration regeneration
regeneration
*1: Driving with output limit: This refers to inching control. Limited to 80% of the maximum torque (Excessive Travel inching).
*2: Driving in slope mode: When a truck driving down a slope exceeds the speed that should normally be obtained by a given amount of accelerator pedal
pressure, the power output will be limited in order to maintain the speed that corresponds to that accelerator pedal effort.
(6) Output duty factor reduction when the rear wheels are at the maximum steering angle
(Excluding trucks with an Orbitrol steering system)
• The rear wheels are within 5 degrees of the maximum steering angle.
<Control applied>
• Limits the output duty factor to 10%.
• When the torque sensor voltage indicates that the wheels are in neutral (the straight-ahead position).
- 82 -
6. ELECTRIC WIRING
6. ELECTRIC WIRING
The electric components of the truck are wired using several types of wire harnesses and color
coded by circuit (wire number).
The wire harnesses are connected with connectors (2 types) or screws.
Table 6.1 Color symbols and examples
Y L 22 Wire
B Black R Red W 110 Wire
number number
G Green W White
L Blue Y Yellow
O Orange Lg Light green

Example: Wire number 22, Yellow coating Example: Wire number 110, White number
with a blue marking P Pink Sb Light blue 110, White coating without marking
Table 6.2 Connector symbol
Connecting type Plug-in side Receptacle side Remarks

Plug-in type
Housing
The numbers signify wire numbers.
The alphabetic letters mean colors.
Plug (Table 6.1)
Screw type
Two wires may have different wire numbers even though they have the same wire color. Before
trying to check the wires, refer to wire harness and circuit diagrams on pages that follow.
The dotted lines in the circuit diagrams are given for optional equipment.
- 83 -
6. ELECTRIC WIRING
NOTE
- 84 -
6. ELECTRIC WIRING
to LCD PANEL
䊜䊷䉺䊌䊈䊦䈻
1 10
1 RG LB BW P
W 203 201 211 176
B RG
2-7 102-1 207 RY WR WY WG RB YG
205 206 209 202 208
RL
100-1
LY
212
W
213 CN3 101-1
11 20
5
CN1
CN9-1 1 8
to㪝㪆㪩䉴䉟䉾䉼䈻
F/R SWITCH WY
108
GW
81
O
15
B
2-8
YW
79
WG
76
Gy
80
GR YB LB Y W WL
23 15
82 196 137 78 77 75
WL WBr BR 9 16
54 53 9
to 䉨䊷䉴䉟䉾䉼䈻
KEY SWITCH CN9-2
RY 1
(101) BG WY W WB
190 224 226 228
LW G WG WL
to HORN SWITCH
䊖䊷䊮䉴䉟䉾䉼䈻 192
7
191 225 227
RB RL
141-1 (100)
YL
103
to LIGHTING SWITCH
䊤䉟䊁䉞䊮䉫䉴䉟䉾䉼䈻 Y WG WL
78 76 75
to CONTROL SWITCH
䉮䊮䊃䊨䊷䊦䉴䉟䉾䉼
6
YW W Gy
PANEL
79 77 80
䊌䊈䊦䈻
R GY BR LW L BR
177 178 9-1 132 131 9-2
14
to REAR WORK LIGHT

ᓟㇱ૞ᬺἮ䉴䉟䉾䉼䈻 GW GR
SWITCH (OPTION)
81-1 82-1
㩿䉥䊒䉲䊢䊮㪀
WY RB B OPTION
䉥䊒䉲䊢䊮
108-1 141-2 2-3
GO RB B
111 141 2
to WIRE HARNESS,
䊪䉟䊟䊊䊷䊈䉴䊶
OVERHEAD
䊓䉾䊄䉧䊷䊄㩿Ꮐ㪀䈻 GUARD (LEFT)
GR WG
106 109-1
WIRE HARNESS,
GL WG
B WR 105 109 䊪䉟䊟䊊䊷䊈䉴䊶
OVERHEAD GUARD (RIGHT)
2-2 107-1 B
2-1
WR
107 䊓䉾䊄䉧䊷䊄㩿ฝ㪀䈻
Y
BW RG YB 104
(112) (102) (196) LG
2 1 WL WY W 24
227 224 226
WG WB
WR RG LB O BR 225 228
205 203 201 15-1 9-3
WG WY RB
to BRAKE SWITCH
ࡉ࡟࡯ࠠࠬࠗ࠶࠴߳ to EMERGENCY SWITCH
ࠛࡑ࡯ࠫࠚࡦࠪࠬࠗ࠶࠴߳
209 206 202
to PARKING SWITCH
䊌䊷䉨䊮䉫䉴䉟䉾䉼䈻 to PC MONITOR
2%ࡕ࠾࠲߳
to CHARGER
䉼䊞䊷䉳䊞 (for MAINTENANCE)

ࡔࡦ࠹࠽ࡦࠬ↪
SWITCH PANEL
䉴䉟䉾䉼䊌䊈䊦䈻
L G W
160 161 162
CAPACITOR
䉮䊮䊂䊮䉰
to㪜㪧㪪䉶䊮䉰䈻
EPS SENSOR
YL
(103)
to HORN
䊖䊷䊮䈻
B
(2-4)
LW G BG
192 191 190
to LOAD METER
䊨䊷䊄䊜䊷䉺䈻
(OPTION)
10 1 8 1
BW BR WL WBr LY LG O P LB RG GO R L RY RL GY GR
112 9 54 53 212 24 15 176 137 102 111 177 131 101 100 178 82
L G W GL GR WR WG WY B RB W W BW LW Y YG GW
160 161 162 105 106 107 109 108 2 141 213 207 211 132 104 208 81
20 11 16 9
to 䊪䉟䊟䊊䊷䊈䉴䊶䊐䊧䊷䊛䈻
WIRE HARNESS, FRAME
Fig. 6.1 Wire Harness, Front Guard (1- to 2.5-ton Trucks)
- 85 -
6. ELECTRIC WIRING
to LCD PANEL
䊜䊷䉺䊌䊈䊦䈻
1 10
1 10
RG LB BW P
203 201 211 176
1
CN3 CN1 RY
101-1
WR
205
WY
206
WG
209
RB
202
YG
208
B RG W 11 20
2-7 102-1 207
to STEERING
W
䊊䊮䊄䊦 RL
100-1
LY
212 213 CN9-1
ENCODER
1
䉣䊮䉮䊷䉻䈻
8
5
WY GW O B YW WG Gy
to F/R SWITCH
㪝㪆㪩䉴䉟䉾䉼䈻 BR BY
108 81
GR YB
15
LB
2-8 79
Y
76
W
80
WL
230 244 82 196 137 78 77 75
23 15
BG LY LG RY 9 16
WL WBr BR 243 249 246 (101)

54 53 9 RL
RG (100)
CN9-2
(102) 1
BG WY W WB
190 224 226 228
YR LW G WG WL
(117) 192 191 225 227
to HORN SWITCH
䊖䊷䊮䉴䉟䉾䉼䈻 7
RB
141-1
YL
to KEY SWITCH
䉨䊷䉴䉟䉾䉼䈻
103
to䊤䉟䊁䉞䊮䉫䉴䉟䉾䉼䈻
LIGHTING SWITCH Y
78
WG
76
WL
75
6 YW
79
W
77
Gy
80 to CONTROL SWITCH
䉮䊮䊃䊨䊷䊦䉴䉟䉾䉼
PANEL
䊌䊈䊦䈻
R GY BR LW L BR
177 178 9-1 132 131 9-2
14
to ᓟㇱ૞ᬺἮ䉴䉟䉾䉼䈻
REAR WORK LIGHT
SWITCH (OPTION)
㩿䉥䊒䉲䊢䊮㪀 GW
81-1
GR
82-1
WY RB B OPTION
䉥䊒䉲䊢䊮
108-1 141-2 2-3
GO RB B
111 141 2
to WIRE HARNESS,
OVERHEAD GUARD (LEFT)
䊓䉾䊄䉧䊷䊄㩿Ꮐ㪀䈻
GR WG
WIRE HARNESS,
GL WG
106 109-1 105 109
OVERHEAD GUARD (RIGHT)

B WR
2-2 107-1
B
2-1
WR
107 䊓䉾䊄䉧䊷䊄㩿ฝ㪀䈻
Y
BW 104
(112) RG YB
(102-2) (196) LG
24
WL WY W
227 224 226
WR RG LB BR O WG WB
205 203 201 9-3 15 225 228
WG WY RB
to BRAKE SWITCH
ࡉ࡟࡯ࠠࠬࠗ࠶࠴߳ toࠛࡑ࡯ࠫࠚࡦࠪࠬࠗ࠶࠴߳
EMERGENCY SWITCH
to 㪧㪚䊝䊆䉺䈻
PC MONITOR
209 206 202
to䊌䊷䉨䊮䉫䉴䉟䉾䉼䈻
PARKING SWITCH (for㩿䊜䊮䊁䊅䊮䉴↪㪀
MAINTENANCE)
to CHARGER
䉼䊞䊷䉳䊞
SWITCH PANEL
䉴䉟䉾䉼䊌䊈䊦䈻
L G W
160 161 162
CAPACITOR
䉮䊮䊂䊮䉰
to 㪜㪧㪪䉶䊮䉰䈻
EPS SENSOR YL
(103)
to HORN
䊖䊷䊮䈻
B
(2-4)
LW G BG
192 191 190
to LOAD METER
䊨䊷䊄䊜䊷䉺䈻
(OPTION)
1 2 3 9 1 4
BR LG R L
WBr WL BR GR B GL L 230 246 177 131
53 54 9 82 2 105 160 LY BG GY LW
RL GO
100 111 O LG GW WR RG G 249 243 178 132
RY RB 15 24 81 107 102 161 BY W W BW
101 141 244 213 207 211
BW LY WG LB GR W YR
112 109 137 106 117 P WY Y YG
212 162
176 108 104 208
16 17 18 24 13 16
to WIRE HARNESS, FRAME

䊪䉟䊟䊊䊷䊈䉴䊶䊐䊧䊷䊛䈻
Fig. 6.2 Wire Harness, Front Guard (3- to 3.5-ton Trucks)
- 86 -
6. ELECTRIC WIRING
toリレーRKへ
RELAY RK
RW RG
11-7 102-5 1 17
B GO
2-7 111-2 RG W GL GB RW
58 162 85 86 11-4
RG L G RL
58 160 161 100-7
18 34
to PARKING ALARM
パーキングアラームへ
toリレーPOへ
RELAY PO to CONTROLLER
コントローラ CN1E
LB(137) TERMINAL (P)
ターミナル(P)へ
RL RG
RG(102-3) 100-2 216 R(5)
YG RW
208 11
to WIRE HARNESS,
ワイヤハーネス・
to RELAY UNIT
リレーユニットへ
SEAT SWITCH
OPTION
オプション YB(30)
1 13
シートスイッチへ
GO WB BR GY R L LW RW WR RG
WY(168) 111-1 98-1 9-1 178 177 131 132 11-5 107 102-1 BR YW
WR BW WBr WG LB LR RW W GR GL RG 9-2 181
WG(169) 113 112 97 109-1 180 95 11-6 110 106-1 105-1 102-2
14 26
B(2-6)
toワイヤハーネス・CMへ
WIRE HARNESS, CM to WIRE HARNESS,
3 1 OPTION
オプションへ CNCH1
BW W W
211 207 213 WB P
LY RL WG RG GO 26 27
212 100-1 109-2 102-4 111
to LIFT POTENTIOMETER
リフトポテンショメータへ 6 4
WY
108
B
2-5
WB
98-2
B(2-4)
to LIFT LOCK
リフトロック RG (216)
Y G
GR
189
YL
94
WR
188 SOLENOID
ソレノイドへVALVE RY(101)
104 25
P(176) CNMC
O RL
138 100-3
to LEVEL
F4 10.
F5 10.
F9 10.
F8 2.
to BACK-UP BUZZER
バックアップブザーへバッテリ
SENSOR
レベルセンサへ
WB(98)
B(2)
toワイヤハーネス・
WIRE HARNESS,
VALVE SWITCH
バルブスイッチへ WBr(97) to FWD CHIME
前進チャイムへ
B(2-2) (OPTION)
(オプション)
YR YG CN1P
20 21
YL BL
22 8
1
12
GO GY RW RW
84 83 11-2 11-3
to ACCELERATOR
アクセレレータへ CN1D
GB GB GL YR YG YL
86 86-1 85 20 21 22
LG RL
19 100-5
RL
100-6
3 1
BL BL P
BG LY LG(19) 8 18 139
LW
186 93 187 25 36
WR LG LB BL(18)
185 92 184
6 4
3 2 1
to HPS/EPS
HPS/EPSへ CN2P
to DRIVE MOTOR CN2D
ドライブモータ
ROTATION RW RY RB BR Y
回転センサ(A)へ
SENSOR (A)
31 34 32 9-3 7
3 2 1
to DRIVE MOTOR to STEERING

ステアリングメモリ
ROTATION
GW
28
GY
33
GB
29
MEMORY
スイッチへ SWITCH
回転センサ(B)へ
SENSOR (B) 1
12
B(2) Y YL
BG BR YW
2 1 243 230 41 39 94
to DRIVE THERMO-
ドライブモータ LY BY B G WR
SENSOR サーモセンサへ
WG
16
WR
17
3 2 1
to CONTROLLER
コントローラ 249 244 46 38 188
GR
LG W
W Y B TERMINAL
ターミナル(N)へ(N) 246 40 189
2 1
40 41 46 25 36
G YW
38 39 to PUMP MOTOR
ポンプモータ
1 3
ROTATION
回転センサへSENSOR
BR
230
LY
249
BY
244
to PUMP MOTOR
ポンプモータ
BG LG THERMOSENSOR
サーモセンサへ
243 246
4 6 1 1
12
12
1 10 RY GY WR LY LG YL GR GW W O RW RW WB P
34 33 17 93 92 43 82 81 110 15 11-1 11 26 27
LB P O LG LY WBr WL BR BW GO GY YW YB WBr WL Y LG RL
137 176 15 212 54 9 112 RB GB WG BG LB YB
24 53 32 29 16 186 84 83 181 30 53 54 7 24
1 8 184 42 100-4
B WY WG WR GR GL W G L GW LW WR YR BR WY LB LR G WG
105 GR GY R WG B GL RW
2-1 108 109 107 106 162 161 160 RL RY L GO RG 31 28 187 185 44 9 168 180 95 25 169
82 178 100 101 131 177 111 102 109 2-3 105
11 20 YR YL YB WR WB GR 25 36 25 36
GW YG Y LW BW W W RB 44 43 42
81 113 98 106
208 104 132 211 207 213 141
9 16
to STEERING
ステアリング to WIRE HARNESS,
to WIRE HARNESS, FRONT GUARD
ワイヤハーネス・フロントガードへ POTENTIOMETER
ポテンショメータへ REAR COMBINATION LAMP
リヤコンビネーションランプへ
Note: The connector CN1E of trucks with Orbitrol steering system is connected to nowhere.
Fig. 6.3 Wire Harness, frame (1- to 1.8-ton Trucks)
- 87 -
6. ELECTRIC WIRING
to RELAY RK
リレーRKへ
RW RG
11-7 102-5
B GO
2-7 111-2
toリレーPOへ
RELAY PO
to PARKING ALARM
RL RG
100-2 216
LB(137) YG RW
RG(102-3) 208 11
to WIRE HARNESS,
to RELAY UNIT
リレーユニットへ SEAT SWITCH
OPTION
オプションシートスイッチへ
YB(30) 1 13
1 17
GO WB BR GY R L LW RW WR RG RG W GL GB RW
WY(168)
111-1 98-1 9-1 178 177 131 132 11-5 107 102-1 BR YW 58 162 85 86 11-4
WR BW WBr WG LB LR RW W GR GL RG 9-2 181 RL

WG(169) RG L G
113 112 97 109-1 180 95 11-6 110 106-1 105-1 102-2 161 100-7
58 160
14 26
18 34
B(2-6)
toワイヤハーネス・CMへ
WIRE HARNESS, CM toワイヤハーネス・
WIRE HARNESS,
1 3 OPTION
オプションへ CN1E
BW W W
211 207 213
LY RL WG RG GO
109-2 102-4 111
リフトポテンショメータへ 212 100-1
WY B WB to HPS/EPS
HPS/EPSへ
4 6 108 2-5 98-2
RG (216) B(2-4)
to LIFT LOCK
リフトロック
F4 10A
F5 10A
F9 10A
GR YL WR
F8 2A
189 94 188
SOLENOID VALVE
BL(18)
ソレノイドへ RY(101)
P(176)
LG(19)
CN1P
O RL
138 100-3 to BACK-UP BUZZER
バックアップブザーへ
to LEVEL
バッテリ
SENSOR
レベルセンサへ
WB(98)
B(2) CN2P
to WIRE HARNESS,
VALVE SWITCH WBr(97) to FWD CHIME
前進チャイム
バルブスイッチへ (OPTION)
(オプション)
B(2-2) to CONTROLLER
コントローラ
TERMINAL (P)
ターミナル(P)へ CNCH1
YR YG 1
12
20 21 R(5)
YL BL GO GY BL RW RW
22 8 84 83 8-1 11-2 11-3
Y G
104 25 GB GB GL YR YG YL LG RL RL
86 86-1 85 20 21 22 19 100-5 100-6
BL BL P
to ACCELERATOR
アクセレレータへ 8 18 139
36
25
3 1
BG LY LW WB P
186 93 187 26 27
WR LG LB CNMC
185 92 184
6 4
3 2 1
RW RY RB
to DRIVEドライブモータ
MOTOR 31 34 32
BR
9-3
Y
7
ROTATION SENSOR (A)
3 2 1
toステアリングメモリ
STEERING 1
12
GW GY GB MEMORY
スイッチへSWITCH B(2) CN1D BG BR Y YW YL
28 33 29 243 230 41 39 94
LY BY B G WR
to DRIVE MOTOR
249
LG
244 46 38
W
188
GR
ROTATION SENSOR (B)
回転センサ(B)へ
2 1
toコントローラ
CONTROLLER CN2D 246 40 189
36
TERMINAL (N)
25
WG
16
WR
17
3 2 1 ターミナル(N)へ
W Y B
to DRIVE THERMO-
ドライブモータ 40 41 46
SENSOR
2 1
G YW to PUMP MOTOR
ポンプモータ
3 1
38 39 ROTATION SENSOR
回転センサへ
BR
230
LY
249
BY
244 toポンプモータ
PUMP MOTOR
BG LG THERMOSENSOR
243 246
4 6
1 1
12 12
10 1
RY GY WR LY LG YL GR GW W O RW RW WB P
LB P O LG LY WBr WL BR BW 34 33 17 93 92 43 82 81 110 15 11-1 11 26 27
137 176 15 24 212 53 54 9 112 RB GB WG BG LB YB GO GY YW YB WBr WL Y LG RL
8 1
84 83 181 30 53 54 7 24
B WY WG WR GR GL W G L 32 29 16 186 184 42 100-4
2-1 108 109 107 106 105 162 161 160 GR GY RL RY L R GO RG LW WR YR BR WY LB LR G WG

RW GW
82 178 100 101 131 177 111 102 28 187 185 44 9 168 180 95 25 169
31
20 11 YB
GW YG Y LW BW W W RB YR YL 36 25 36
81 208 104 132 211 207 213 141 44 43 42 25
16 9
toステアリング
STEERING WG B GL
POTENTIOMETER
ポテンショメータへ 109 2-3 105
to WIRE HARNESS, FRONT GUARD
ワイヤハーネス・フロントガードへ WR WB GR
113 98 106
to WIRE HARNESS,
REAR COMBINATION LAMP
リヤコンビネーションランプへ Note: The connector CN1E of trucks with Orbitrol steering system is connected to
nowhere.
Fig. 6.4 Wire Harness, frame (2.0- to 2.5-ton Trucks)
- 88 -
6. ELECTRIC WIRING
toリレーPO2へ
RELAY PO2
to リレーRKへ
RELAY RK RL
100-8
L
116
YG RW
208-1 11
RW RG
to リレーPO1へ
RELAY PO1
F7 10A
F8 2A
11-2 102-5
B GO
2-7 111-2
RL RG 1 17
100-2 216
LW RG W GL GB LW
to PARKING ALARM
YG
208 115 58 162 85 86 115-4
RL
LB(137) to WIRE HARNESS,
ワイヤハーネス・ RG L G
100-7
to RELAY UNIT
リレーユニットへ 58 160 161
RG(102-3) 1 13
SEAT SWITCH
シートスイッチへ 18 34
F5 10A
F9 10A
GO WB BR GY R L LW RW WR RG
111-1 98-1 9-1 178 177 131 132 11 107 102-1 BR YW
WR BW WBr WG LB LR RW W GR GL RG 9-4 181
113 112 97 109-1 180 95 11-1 110 106-1 105-1 102-2
OPTION
オプション
RL 10O
CN1E
R5
O 138
P 139
14 26
YB(30)
WY(168) to ワイヤハーネス・CMへ
WIRE HARNESS, CM to WIRE HARNESS,
WG(169)
OPTION
オプションへ
B(2-6)
YR
117
RY
101
BW
211
W
207
W
213
to HPS/EPS
HPS/EPSへ
WG RG GO
L RG LY RL 109-2 102-4 111
BL(18)
RG 102
116 216 212 100-1
RB 141
リフトポテンショメータへ
Br 6-1
WY B WB
Br 6
108 2-5 98-2
B(2-4)
GR YL WR to LIFT LOCK
リフトロック
LG(19)
189 94 188 SOLENOID
ソレノイドへ VALVE
CN1P
P(176)
O RL
138 100-3 to BACK-UP BUZZER
バックアップブザーへ to LEVEL
バッテリ
SENSOR
レベルセンサへ CN2P
WB(98) toバッテリへ
BATTERY
to ワイヤハーネス・
WIRE HARNESS,
B(2) CNMC
to FWD Br to CONTROLLER
コントローラ
VALVE SWITCH
バルブスイッチへ WBr(97) 前進チャイム
CHIME 6 TERMINAL
ターミナル(P)へ(P)
B(2-2) (オプション)
(OPTION) R(5)
YR YG WB P
20 21 26 27
YL BL
22 8
Y G 1
12
CNCH1 104 25
GO GY BL BL LW LW
toステアリングメモリ
STEERING 84 83 8-1 8-2 115-2 115-3
3 1
MEMORY
スイッチへSWITCH GB GB GL YR YG YL
86 86-1 85 20 21 22
LG RL
19 100-5
RL
100-6
BG LY LW BL BL P
186 93 187 BR Y 8 18 139
WR LG LB to DRIVE MOTOR
ドライブモータ 9-3 7 25 36
92 184
185
6 4
ROTATION SENSOR (A)
3 2 1
toアクセレレータへ
ACCELERATOR RW RY RB
31 34 32
toコントローラ
CONTROLLER
TERMINAL (N)
ターミナル(N)へ
3 2 1
2 1
GW GY GB
28 33 29
WG WR
CN1D
16 17
to DRIVEドライブモータ
MOTOR B(2) 1
CN2D
12
ROTATION SENSOR (B)

回転センサ(B)へ to DRIVE THERMO-
ドライブモータ BG BR Y YW YL
SENSOR
サーモセンサへ 3 2 1 243 230 41 39 94
LY BY B G WR
W Y B 249 244 46 38 188
40 41 46 GR
2 1
LG W
246 40 189
to PUMP MOTOR
ポンプモータ 25 36
G YW
38 39
ROTATION SENSOR
1
回転センサへ
12
1
12
GR GW W O LW LW WB P
RY GY WR LY LG YL
9 3 2 1
to PUMP MOTOR
ポンプモータ 34 33 17 93 92 43
82
GO
81 110 15
GY YW YB WBr WL Y
115-1 115
LG
26 27
RL
L GL B GR BR WL WBr THERMOSENSOR
サーモセンサへ RB GB WG
32 29 16
BG LB
186 184
YB
42
84 83 181 30 53 54 7 24 100-4
160 105 2-1 82 9 54 53 RL BR WY LB LR G WG

GO 4 1 RW GW LW WR YR
G RG WR GW LG O 111 100 31 28 187 185 44
9 168 180 95 25 169
161 102 107 81 24 15 RB RY L R LG BR 25 36

36
141 101 131 177 246 230
25
YR W GR WG LB LY BW
117 162 106 109 137 212 112 LW GY BG LY
132 178 243 249
24 18 17 16
BW W W BY
211 207 213 244
YG Y WY P WG B GL
208 104 108 176 YR YL YB 109 2-3 105
44 43 42 WR WB GR
16 13 113 98 106
to STEERING
ステアリング to WIRE HARNESS,
toワイヤハーネス・フロントガードへ
WIRE HARNESS, FRONT GUARD POTENTIOMETER
ポテンショメータへ REAR COMBINATION LAMP
リヤコンビネーションランプへ
Note: The connector CN1E of trucks with Orbitrol steering system is connected to nowhere.
Fig. 6.5 Wire Harness, frame (3.0- to 3.5-ton Trucks)
- 89 -
6. ELECTRIC WIRING
WL RW
HEAD LIGHT OPTION
オプション
ヘッドランプ(右) PARKING ALARM
4P
3P
(RIGHT) パーキングアラーム
B B
REAR COMBINATION
リヤコンビネーション
エマージェンシ
EMERGENCY PO RK LIGHT
ランプ(右)(RIGHT)
8P
WY
W WR SWITCH
スイッチ
RY
RG
Insert when EGS.
EGS時のみ挿入する 6P 4P
W B (OPTION)
(オプション) LR Y
TRANSFORMER
トランス BEACON
回転灯LIGHT
RL
W
R
LG
B
6P
CONTROL SWITCH PANEL
コントロールスイッチパネル VALVE SWITCH
バルブスイッチ
N.C
YL M.C. RELAY
リレー
F6
N.O
ATT2 (OPTION) BY UNIT
ユニット
ATT2(オプション) COM GO
26P
6P
+
3P
N.C
ACCELERATOR
アクセレレータ TH. B
VALVE SWITCH
-
バルブスイッチ YG
FRONT COMBINATION
フロントコンビネーション
ATT1 (OPTION)
N.O
BY
LIGHT (RIGHT) ATT1(オプション) COM
WY
ランプ(右)
WM
UM
VM
WM
B
UM
VM
VALVE SWITCH
バルブスイッチ
N.C
N.O YB
G
GO
REAR後部作業灯
WORK LIGHT
RG
TILT COM BY (OPTION)
TILT B
WB
BW
WG B
BRAKE SWITCH
ブレーキスイッチ
6P
B LICENSE
リフト 4P
LIFT NUMBER
ライセンス
KEY SWITCH
キースイッチ POTENTIOMETER
ポテンショメータ PLATE
ランプ
LIGHT
RL (OPTION)
1P
RY EPS P B
EPSモータ
MOTOR
3P
1P
16P 12P
6P
LIFT LOCK
リフトロック
2P
CN9
F/R SWITCH
F/Rスイッチ SOLENOID
ソレノイド RW WL
BACK-UP
バックアップ CONTROLLER
コントローラ
18P
HORN SWITCH
ホーンスイッチ BUZZER
ブザー B B
RW WBr
2P
2P
+
FWD CHIME
前進チャイム
B B
16P
ELECTRO-
TURN SIGNAL
ターンシグナル (OPTION)
(オプション) - +
液面センサ
LYTE LEVEL SEAT SWITCH
シートスイッチ
SWITCH
スイッチ SENSOR
2P
14P
CN1 CN3
20P 8P
EPS EPSトルク
TORQUE BATTERY
バッテリ 2P PW PV PU
POTENTIOMETER
ポテンショメータ 3P 3P
2P 2P
DW DV DU
LCD PANEL
メータパネル
PRESSURE
プレッシャ DW DV DU -
SENSOR
センサ
36P 36P
2P
ドライブ
DRIVE 36P 36P
MOTOR
モータ
PARKING BRAKE
パーキングブレーキ RW COM
3P
Gy N.O
SWITCH
スイッチ
N.C
HORN
ホーン 3P F8
F9
REAR WORK LIGHT
後部作業灯スイッチ F5
SWITCH (OPTION)
2P
(オプション) F4
WY YL
+
RG B
COM1
NO WY
3P
B
HEAD LIGHT
ヘッドランプ(左)
-
(LEFT) BATTERY
チャージャCHARGER
SWITCH PANEL
20P
6P
W WR
16P
W B
6P
PW 6P
3P
PV
PU
6P
6P
3P
4P
REAR COMBINATION
FRONT COMBINATION
フロントコンビネーションポンプ
PUMP 2P LIGHT (LEFT)
ランプ(左)
LIGHT
ランプ(左)(LEFT) MOTOR
モータ 3P
STEERING
ステアリング
POTENTIOMETER
ポテンショメータ Note: Trucks with an Orbitrol steering system do not have an EPS motor.
Fig. 6.6 Wiring Diagram (1- to 1.8-ton Trucks)
- 90 -
6. ELECTRIC WIRING
WL RW
HEAD LIGHT OPTION
オプションパーキングアラーム
4P
3P
ヘッドランプ(右)
(RIGHT) PARKING ALARM
B B
REAR COMBINATION
EMERGENCY 8P PO RK LIGHT (RIGHT)
ランプ(右)
WY
W WR
RY
RG
SWITCH
スイッチ Insert when EGS.
EGS時のみ挿入する 6P 4P
W B (OPTION)
TRANSFORMER
トランス BEACON
回転灯 LIGHT
RL
W
R
LG
B
6P
コントロールスイッチパネル
N.C
YL M.C. リレー
RELAY
F6
N.O
VALVE SWITCH
バルブスイッチ COM BY ユニット
UNIT GO
ATT2 (OPTION)
ATT2(オプション)
26P
6P
+
3P
N.C
ACCELERATOR
アクセレレータ TH. - B
YG
FRONT COMBINATION
フロントコンビネーション VALVE SWITCH
バルブスイッチ N.O
COM BY
ATT1 (OPTION)
WY
WM
LIGHT (RIGHT) ATT1(オプション)
UM
VM
WM
ランプ(右)
B
UM
VM
N.C
YB
G
GO REAR WORK LIGHT
RG バルブスイッチ
N.O 後部作業灯
(OPTION)
VALVE SWITCH COM BY
TILT
TILT B
WB
BW
WG B
BRAKE SWITCH
6P
B
4P LICENSE
リフト
LIFT ライセンス
NUMBER
POTENTIOMETER
ポテンショメータ PLATE
ランプ
KEY SWITCH
キースイッチ
LIGHT
RL (OPTION)
1P
RY P B
EPS
EPSモータ
MOTOR
3P
1P
16P 12P
6P
LIFT LOCK
リフトロック
2P
CN9
F/R SWITCH
BACK-UP
バックアップ CONTROLLER
コントローラ
18P
BUZZER
ブザー B B
HORN SWITCH
ホーンスイッチ RW WBr
2P
2P
LIFT LOCK FWD CHIME

前進チャイム
B B
PW 16P
36P
ELECTRO-
TURN SIGNAL
ターンシグナル SOLENOID (OPTION)
(オプション) - + 液面センサ
LYTE LEVEL SEAT SWITCH
SWITCH SENSOR
2P
スイッチ
36P
14P
CN1 CN3 PV
20P 8P
EPSEPSトルク
TORQUE BATTERY
バッテリ 2P PU
POTENTIOMETER
ポテンショメータ 3P 3P DW DV DU
LCD PANEL
メータパネル PRESSURE
プレッシャ DW DV DU
-
SENSOR
センサ
2P
2P 2P
DRIVE
ドライブ + 36P 36P
MOTOR
モータ
RW COM
PARKING BRAKE
パーキングブレーキ Gy N.O 3P
SWITCH
スイッチ N.C HORN
ホーン 3P
F8
F9
F5
REAR WORK LIGHT
後部作業灯スイッチ
2P
SWITCH (OPTION)
(オプション) F4
WY YL
+
RG B
COM1
NO WY
3P
B
-
HEAD LIGHT
(LEFT) BATTERY
チャージャ CHARGER
SWITCH PANEL
20P
6P
W WR
16P
W B
6P
PW 6P
3P
PV
PU
6P
6P
STEERING
ステアリング
3P
4P
POTENTIOMETER
ポテンショメータ REAR COMBINATION
ポンプ 2P
PUMP LIGHT
ランプ(左)(LEFT)
FRONT COMBINATION
MOTOR 3P
LIGHT
ランプ(左)(LEFT) モータ
Note: Trucks with an Orbitrol steering system do not have an EPS motor.
Fig. 6.7 Wiring Diagram (2.0- to 2.5-ton Trucks)
- 91 -
6. ELECTRIC WIRING
WL RW
HEAD LIGHT OPTION
オプション PARKING ALARM
4P
3P
ヘッドランプ(右) パーキングアラーム
(RIGHT) B B
REAR COMBINATION
EMERGENCY PO PO RK LIGHT
ランプ(右)(RIGHT)
10P
WY
W WR SWITCH
スイッチ Insert when EGS.
EGS時のみ挿入する 6P 6P 4P
W B
(OPTION)
BEACON
回転灯 LIGHT
TRANSFORMER
トランス
RL
W
R
LG
B
6P
コントロールスイッチパネル N.C M.C. RELAY
リレー
バルブスイッチ YL
VALVE SWITCH
F6
N.O
BY UNIT
ユニット
ATT2 (OPTION)
ATT2(オプション) COM GO
26P
6P
+
3P
ACCELERATOR
アクセレレータ TH. B
N.C
-
VALVE SWITCH
バルブスイッチ N.O YG
FRONT COMBINATION
ATT1 (OPTION) COM BY
ATT1(オプション)
WY
WM
LIGHT (RIGHT)
UM
VM
ランプ(右)
WM
B
UM
VM
N.C
YB
G REAR WORK LIGHT
RG VALVE SWITCH
バルブスイッチ N.O
BY
GO 後部作業灯
(OPTION)
COM
TILT
TILT B
WB
BW
WG B
BRAKE SWITCH
6P
B LICENSE
4P ライセンス
リフト
LIFT NUMBER
POTENTIOMETER PLATE
ランプ
KEY SWITCH
キースイッチポテンショメータ LIGHT
GO RL (OPTION)
1P
RG RY P B
EPS
EPSモータ
MOTOR
3P
1P
16P 12P
6P
LIFT LOCK
リフトロック
2P
CN9
F/R SWITCH
BACK-UP CONTROLLER
コントローラ
18P
バックアップ
HORN SWITCH
ホーンスイッチ BUZZER
ブザー B B
RW WBr
2P
2P
FWD CHIME
前進チャイム PW 16P
B B
36P
TURN SIGNAL
ターンシグナル (OPTION)
(オプション) ELECTRO-
SEAT SWITCH
- + 液面センサ
LYTE LEVEL
SWITCH
スイッチ SENSOR
2P
36P
14P
CN1 CN3 PV
20P 8P
EPSEPSトルク
TORQUE BATTERY
バッテリ 2P PU
POTENTIOMETER
ポテンショメータ 3P 3P DW DV DU
-
LCD PANEL
メータパネル PRESSURE
プレッシャ DW DV DU 1P
SENSOR
センサ
2P
2P 2P
DRIVE
ドライブ + 36P 36P
MOTOR
モータ
RW COM
パーキングブレーキ
PARKING BRAKE Gy N.O 3P
SWITCH
スイッチ N.C F8
HORN
ホーン 6P
F9
F5
REAR WORK LIGHT
後部作業灯スイッチ
2P
F7
SWITCH
(オプション)(OPTION)
YL
+
RG B
COM1
NO WY
3P
B
-
HEAD LIGHT
(LEFT) BATTERY
チャージャ CHARGER
SWITCH
スイッチパネルPANEL
16P
6P
W WR
24P
W B
6P
PW 3P
PV
PU
6P
6P
STEERING
ステアリング
3P
4P
POTENTIOMETER
ポテンショメータ REAR COMBINATION
FRONT COMBINATION
フロントコンビネーションポンプ 2P
PUMP 3P LIGHT
ランプ(左)(LEFT)
LIGHT
ランプ(左)(LEFT) MOTOR
モータ
Note: Trucks with an Orbitrol steering system do not have an EPS motor.
Fig. 6.8 Wiring Diagram (3.0- to 3.5-ton Trucks)
- 92 -
RR
(GB 96) RG 102
F-13
RS F-26
(Y 99)
F-12
BR 9
FWD CHIME F-3
WBr 97
RW11
F-10
L 131
F-8
+
HORN SWITCH GR 106 (RL)
HORN F-24
YL 103
LW 132
RB 141
F-9
GL 105 (RR)
F-25
BEACON LIGHT GO 111 GO 111

AT KEY F-1 (RK)
࿁ォἮ㩿䉥䊒䉲䊢䊮㪀
(OPTION) SW ON
LIGHT
䊐䊨䊮䊃
FRONT
AT BBR LB 180
F-20
䊤䊮䊒㩿Ꮐ㪀
WBr 97 (RF)
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
TURN SIGNAL LIGHT GR 106
F-18
FET UNIT
(LEFT)
GL 105
RG 102
(25W)
䉮䊮䊎䊈䊷䉲䊢䊮
䊥䊧䊷䊡䊆䉾䊃
F-22
COMBINATION
LR 95
F-21 (BB)
䉪䊥䉝䊤䊮䉴䊤䊮䊒
SIDE-MARKER LIGHT WB 98
F-2
䊑䊧䊷䉨
BRAKE
䉴䉟䉾䉼SW BW 112
F-15
TURN SIGNAL LIGHT (RB)
F-14
(25W) WR 113
F-23
SIDE-MARKER LIGHT WG 109 WG 109
F-19
LIGHT
(RT)
FRONT
䊐䊨䊮䊃
F-6
䊤䊮䊒㩿ฝ㪀
䊓䉾䊄䊤䊮䊒㩿Ꮐ㪀 F-7
HEAD LIGHT (LEFT) WR 107 (RM)
F-11
(RIGHT)
COMBINATION
(40W)
䊓䉾䊄䊤䊮䊒㩿ฝ㪀
HEAD LIGHT (RIGHT)
(40W)
TURN SIGNAL LIGHT
T
H
(23W)
OFF
REAR
LIGHTING
䊁䊷䊦䊤䊮䊒
TAIL LIGHT (10W)
䊤䊮䊒㩿Ꮐ㪀
WR 113 GY 178
F
R
N
䊑䊧䊷䉨䊤䊮䊒
STOP LIGHT (25W)
R 177
EL LT LH
LIGHT (LEFT)
䊋䉾䉪䉝䉾䊒䊤䊮䊒
BACK-UP LIGHT WB 98
COMBINATION
䊤䉟䊁䉞䊮䉫䉴䉟䉾䉼
䊥䊟䉮䊮䊎䊈䊷䉲䊢䊮
F/R
TURN SIGNAL LIGHT
SWITCH TURN
L
R
N
(23W)
㪝㪆㪩䉴䉟䉾䉼
䊁䊷䊦䊤䊮䊒
SWITCH
TAIL LIGHT (10W) LW 132

STOP LIGHT (25W) L 131
REAR
TB TR TL
BACK-UP LIGHT
䊤䊮䊒㩿ฝ㪀
WL 54
WBr 53
SIGNAL SWITCH
䉺䊷䊮䉲䉫䊅䊦䉴䉟䉾䉼
LIGHT (RIGHT)
COMBINATION
WG 16
2
LR 95 CN2D-17
䊋䉾䉪䉝䉾䊒䊑䉱䊷
BACK-UP BUZZER CN1D-34 䊄䊤䉟䊑䊝䊷䉺
DRIVE MOTOR
LB 180 WR 17
1
CN1D-18
CN1D-19
CN1D-33 CN2D-6 䉰䊷䊝䉶䊮䉰

THERMO-SENSOR
W 110
REAR WORK CN1D-4
(WY 168) RW 31
1
WY 108
ᓟㇱ૞ᬺἮ䉴䉟䉾䉼
LIGHT SWITCH RS CN1D-32 CN2D-27
ᓟㇱ૞ᬺἮ
REAR WORK LIGHT RY 34 䊄䊤䉟䊑䊝䊷䉺
2
CN2D-3
DRIVE MOTOR
(WG 169) RB 32
3
(+) (S) (-)
(OPTION) RR CN1D-36 CN2D-15 ROTATION
࿁ォ䉶䊮䉰㪘SENSOR (A)
B 2
CN1D-7
GW 28
1
CN1D-8 CN2D-29
GY 33 䊄䊤䉟䊑䊝䊷䉺
2
CN2D-5 DRIVE MOTOR

CN1D-24
GB 29
3
(+) (S) (-)
CN2D-16 ROTATION
࿁ォ䉶䊮䉰㪙SENSOR (B)
GW 81 CANH(+) CANH(+) GW 81
CN9-1-2
120ǡ
CN1D-3
CN3-1
CANL(-)
CN9-1-5
GR 82
CN9-1-1
CANL(-) GR 82
CSDU
CN9-1-10 CN1D-1
CANH(+) GY 83 DU
CN1D-15
CANL(-) GO 84 DV 䊄䊤䉟䊑䊝䊷䉺
DRIVE MOTOR
+
DIM
CN1D-13
DW
CN9-1-4 0 15
YB 196 CN9-1-11 O 15 䊌䊷䉨䊮䉫 CN1D-5
PARKING SWITCH
CSDW
䉥䊒䉲䊢䊮㩿㪣㪪㪧㪀
OPTION (LSP) 䉴䉟䉾䉼
YW181
䉲䊷䊃䉴䉟䉾䉼
SEAT SWITCH CN1D-16
LW 192
CN9-2-7
BG 190 YB 30
- 93 -
+
䉴䉟䉾䉼
SIG CN9-2-1 㪟㪠㪞㪠䊙䉴䊃䉴䉟䉾䉼 CN1D-17

SWITCH
G 191
HIGH MAST SWITCH
CN9-2-8
䉥䊒䉲䊢䊮㩿㪣㪤㪀 Y7
OPTION (LM) 䉴䊁䉝䊥䊮䉫䊜䊝䊥
STEERING MEMORY CN1D-20
EMERGENCY
䉣䊙䊷䉳䉢䊮䉲
CN1D-28
WY 224 BR 9 Y
CN9-2-2 CN1D-29 104
(DRIVE)
P 176 LW 187
㩿䊄䊤䉟䊑㪀
WG 225 CN9-2-9 CN1-10 CN2D-32

-
G 25
INVERTER
W 226 CN9-2-3 + BG 186 CN1D-35

䉝䉪䉶䊦 CN2D-20
WL 227 Gy 80 LY 93 LG 24
MC
䊝䊆䉺
CNMC
2 1
CN9-2-10 CN9-1-8 ACCELERATOR

䊘䊁䊮䉲䊢䊜䊷䉺㪈 CN2D-8 CN1D-22
COM
WB 228 POTENTIOMETER 1 WR 185
MONITOR
CN9-2-4 CN2D-33
UNIT
-
䉟䊮䊋䊷䉺䊡䊆䉾䊃
䊡䊆䉾䊃
YW 79 PB4 P 27
UNIT
+ LB 184
S1
CN9-1-6 CN2D-21 CN1D-12

䉮䊮䉺䉪䉺
(UP) 䉝䉪䉶䊦
ACCELERATOR LG 92 WB 26
2 1
CNCH1
CN2D-9 CN1D-11
POTENTIOMETER
䊘䊁䊮䉲䊢䊜䊷䉺㪉2
CONTACTOR
YR 44 CN2D-34
-
Y 78 PB5 + YB 42 P
S2
CN9-1-14 CN2D-23
(DOWN) 䉴䊁䉝䊥䊮䉫
STEERING YL 43
F1
MD
CN2D-10
CONTROL
䊘䊁䊮䉲䊢䊜䊷䉺
POTENTIOMETER N
CN9-1-7 WG 76 PB7
S3
䊥䊐䊃䊨䉾䉪
LIFT LOCK F8
(MODE) 䉸䊧䊉䉟䊄
SOLENOID
Fig. 6.9 Circuit Diagram (1- to 2.5-ton trucks)

O 138 2A P 139
SOL CN1P-35
W 77 PB6
S4
CN9-1-15 CN1P-8
(S/P/E
SELECT) CN1P-7
䉮䊮䊃䊨䊷䊦䉴䉟䉾䉼䊌䊈䊦
CN1P-24
WL 75 PB8
SWITCH PANEL
S5
CN9-1-16 CN1P-22
(SPEED CANH(+) GY 83
CSPU
CONTROL) CN1P-3
CANL(-) GO 84 PU
CN1P-1
CANH(+) GL 85 PV
+
PIM
CN1P-15 䊘䊮䊒䊝䊷䉺
PUMP MOTOR
WR 205 PB1 CANL(-) GB 86 PW
S1
CN1-13 CN1P-13
(START)
CN1P-14
CSPW
䊥䊐䊃䉟䊮䉼䊮䉫
LIFTING SWITCH CN1P-20
WY 206 PB2 䉴䉟䉾䉼 G 38
2
S2
CN1-14 CN2P-17 䊘䊮䊒䊝䊷䉺

PUMP MOTOR
(STOP) YW 39
1
LCD PANEL
MODE SELECT SWITCH 2

*䊝䊷䊄䉶䊧䉪䊃䉴䉟䉾䉼㪉 CN1P-5 CN2P-6 䉰䊷䊝䉶䊮䉰
THERMOSENSOR
*䊝䊷䊄䉶䊧䉪䊃䉴䉟䉾䉼㪈
MODE SELECT SWITCH 1 CN1P-4
WG 209 PB3 YR 20 W 40
1
S3
CN1-15 䊋䊦䊑䉴䉟䉾䉼㩷㪫㪠㪣㪫
VALVE SWITCH TILT CN1P-16 CN2P-29
(SUPER YG 21 Y 41 䊘䊮䊒䊝䊷䉺
2
䊋䊦䊑䉴䉟䉾䉼㩷㪘㪫㪫㪈
VALVE SWITCH ATT1 CN1P-17 CN2P-5
PUMP MOTOR
EQUL) YL 22
3
B 46
(+) (S) (-)
䊋䊦䊑䉴䉟䉾䉼㩷㪘㪫㪫㪉 ROTATION
࿁ォ䉶䊮䉰 SENSOR
SWITCH PANEL
VALVE SWITCH ATT2 CN1P-18 CN2P-16

LB 201 LED1 BL 8
L1
CN1-5 CN1P-28
(CHARGE) LG 19 CN1P-21
BATTERY CHARGER
㩿䊘䊮䊒㪀
(PUMP)
EPS/HPSࠬࠗ࠶࠴
EPS/HPS SWITCH BL 18
CN1P-29
RB 202 LED2
L2
INVERTER
CN1-16
(EQUL) GR 189 CN2P-32
-
CN1-4 RG 203 + WR 188 CN2P-20

COM
䊥䊐䊃
UNIT
YL 94 CN2P-8
LIFT POTENTIOMETER
N
RG 102
+5V
CN3-2
LB 137 䊌䊷䉨䊮䉫䉝䊤䊷䊛
PARKING ALARM
CN9-1-12
CN1E-17
CN1-11 RY 101
CANH(+) CN1E-34
GL 85 CN1E-9
RL 100 CANL(-) GB 86 CN3E-2 㪜㪧㪪䊝䊷䉺
PS MOTOR
CN3-5 CN1E-11 +
CN3E-1
CN1E-4
YG 208 RG 58
PS
PO
CN1-18 CN1E-21
W 162 R 146 B 147
㪜㪧㪪
CN1E-6
PS
+ L 160 CN1E-22
㪜㪧㪪䊃䊦䉪
EPS TORQUE G 161
MOTOR
POTENTIOMETER CN1E-23
BW 211 N
䉮䊮䊃䊨䊷䊤
CN1-8
CM
CONTROLLER
TH
220
204
Gy
LR
RW11
LY 212 䊋䉾䊁䊥
BATTERY
CN3-4
CN3-8
CN3-6
(48V)
CM
R5
R5
R5
W 207
W 213
F9
F5
10A
10A
F4
PO
ELECTROLYTE
ᶧ㕙䉶䊮䉰
LEVEL SENSOR
an EPS torque potentiometer or an EPS motor.
10A RB 141
R03
RL100
RG 102
R02
R01
SR
RESISTOR
TRANSFORMER
MN L
CH
TH
U
AC
V
S
RG 216
MN L
W
DIODE
T
䉻䉟䉥䊷䊄
䌁䌃౉ജ
INPUT
F6
E
MN L
KEY SWITCH
RY101
Note: Trucks with an Orbitrol steering system have neither of an EPS motor controller,
6. ELECTRIC WIRING
6. ELECTRIC WIRING
RR
(GB 96) RG 102
F-13
RS F-26
(Y 99)
F-12
BR 9
FWD CHIME F-3
WBr 97
RW11
F-10
L 131
F-8
+
HORN SWITCH GR 106 (RL)
F-24
HORN YL 103
LW 132
F-9
RB 141 GL 105 (RR)
F-25
BEACON LIGHT GO 111 GO 111

AT KEY F-1 (RK)
࿁ォἮ㩿䉥䊒䉲䊢䊮㪀
(OPTION) SW ON
LIGHT
䊐䊨䊮䊃
FRONT
AT BBR LB 180
F-20
䊤䊮䊒㩿Ꮐ㪀
WBr 97 (RF)
GR 106
F-18
TURN SIGNAL LIGHT
GL 105
(LEFT)
(25W)
RG 102
FET UNIT
F-22
COMBINATION
䊥䊧䊷䊡䊆䉾䊃
LR 95
F-21 (BB)
SIDE-MARKER LIGHT WB 98
F-2
䊑䊧䊷䉨
BRAKE
䉴䉟䉾䉼SW BW 112
F-15
TURN SIGNAL LIGHT (RB)
F-14
(25W) WR 113
F-23
SIDE-MARKER LIGHT WG 109 WG 109
F-19
䊐䊨䊮䊃
(RT)
FRONT
F-6
䊤䊮䊒㩿ฝ㪀
F-7
䊓䉾䊄䊤䊮䊒㩿Ꮐ㪀
HEAD LIGHT (LEFT) WR 107 (RM)
F-11
LIGHT (RIGHT)
COMBINATION
(40W)
䊓䉾䊄䊤䊮䊒㩿ฝ㪀
HEAD LIGHT (RIGHT)
(40W)
TURN SIGNAL LIGHT
T
H
(23W)
OFF
REAR
LIGHTING
䊁䊷䊦䊤䊮䊒
TAIL LIGHT (10W)
WR 113
䊤䊮䊒㩿Ꮐ㪀
GY 178
F
R
N
STOP LIGHT (25W)
R 177
EL LT LH
LIGHT (LEFT)
BACK-UP LIGHT WB 98
COMBINATION
䊤䉟䊁䉞䊮䉫䉴䉟䉾䉼
F/R
TURN SIGNAL LIGHT
SWITCH TURN
L
R
N
(23W)
㪝㪆㪩䉴䉟䉾䉼
SWITCH
䊁䊷䊦䊤䊮䊒
TAIL LIGHT (10W) LW 132
STOP LIGHT (25W) L 131
REAR
LIGHT
TB TR TL
BACK-UP LIGHT
䊤䊮䊒㩿ฝ㪀
WL 54
WBr 53
SIGNAL SWITCH
䉺䊷䊮䉲䉫䊅䊦䉴䉟䉾䉼
(RIGHT)
COMBINATION
WG 16
2
LR 95 CN2D-17
䊋䉾䉪䉝䉾䊒䊑䉱䊷
BACK-UP BUZZER CN1D-34 䊄䊤䉟䊑䊝䊷䉺
DRIVE MOTOR
LB 180 WR 17
1
CN1D-18
CN1D-19
CN1D-33 CN2D-6 䉰䊷䊝䉶䊮䉰
THERMO-SENSOR
W 110
REAR WORK CN1D-4
(WY 168) RW 31
1
WY 108
ᓟㇱ૞ᬺἮ䉴䉟䉾䉼
LIGHT SWITCH RS CN1D-32 CN2D-27
ᓟㇱ૞ᬺἮ
REAR WORK LIGHT RY 34 䊄䊤䉟䊑䊝䊷䉺
2
CN2D-3 DRIVE MOTOR

(WG 169) RB 32
3
(+) (S) (-)
(OPTION) RR CN1D-36 CN2D-15 ROTATION
࿁ォ䉶䊮䉰㪘SENSOR (A)
B 2
CN1D-7
GW 28
1
CN1D-8 CN2D-29
GY 33 䊄䊤䉟䊑䊝䊷䉺
2
CN2D-5 DRIVE MOTOR

CN1D-24
GB 29
3
(+) (S) (-)
CN2D-16 ROTATION
࿁ォ䉶䊮䉰㪙SENSOR (B)
GW 81 CANH(+) CANH(+) GW 81
CN9-1-2
120ǡ
CN1D-3
CN3-1
CANL(-)
CN9-1-5
GR 82
CN9-1-1
CANL(-) GR 82
CSDU
CN9-1-10 CN1D-1
CANH(+) GY 83 DU
CN1D-15
CANL(-) GO 84 DV 䊄䊤䉟䊑䊝䊷䉺
DRIVE MOTOR
+
DIM
CN1D-13
O 15 DW
CN9-1-4
YB 196 CN9-1-11 0 15
䊌䊷䉨䊮䉫 CN1D-5
PARKING SWITCH
CSDW
䉥䊒䉲䊢䊮㩿㪣㪪㪧㪀
OPTION (LSP) CN1-10 P 176 䉴䉟䉾䉼
YW181
䉲䊷䊃䉴䉟䉾䉼
SEAT SWITCH CN1D-16
LW 192 Gy 80
CN9-2-7 CN9-1-8
COM
BG 190 YB 30
-
+ CN9-2-1 㪟㪠㪞㪠䊙䉴䊃䉴䉟䉾䉼
䉴䉟䉾䉼
SIG CN1D-17
SWITCH
- 94 -
G 191 YW 79 PB4 HIGH MAST SWITCH
S1
CN9-2-8 CN9-1-6
䉥䊒䉲䊢䊮㩿㪣㪤㪀
OPTION (LM) (UP) Y7
䉴䊁䉝䊥䊮䉫䊜䊝䊥
STEERING MEMORY CN1D-20
EMERGENCY
䉣䊙䊷䉳䉢䊮䉲
CN1D-28
WY 224 Y 78 PB5 BR 9
S2
CN9-2-2 CN9-1-14 CN1D-29

(DRIVE)
WG 225 (DOWN)
㩿䊄䊤䉟䊑㪀
CN9-2-9 LW 187
CN2D-32
-
CONTROL
INVERTER
W 226 CN9-2-3 + BG 186 G 25

䉝䉪䉶䊦 CN2D-20 CN1D-35
WL 227 WG 76 PB7 LY 93 LG 24
MC
CNMC
2 1
ACCELERATOR
䊘䊁䊮䉲䊢䊜䊷䉺㪈
䊝䊆䉺
CN9-1-7
S3
CN9-2-10 CN2D-8 CN1D-22 Y

WB 228 (MODE) POTENTIOMETER 1 WR 185 104
MONITOR
CN9-2-4 CN2D-33
UNIT
-
䊡䊆䉾䊃
P 27
UNIT
+
LB 184 CN2D-21 CN1D-12

䉮䊮䉺䉪䉺
W 77 PB6 䉝䉪䉶䊦
ACCELERATOR LG 92 WB 26
S4
2 1
CN9-1-15
CNCH1
CN2D-9 CN1D-11
(S/P/E POTENTIOMETER
䊘䊁䊮䉲䊢䊜䊷䉺㪉2
CONTACTOR
YR 44 CN2D-34
-
SELECT) + YB 42 P
CN2D-23
WL 75 䉴䊁䉝䊥䊮䉫
䉮䊮䊃䊨䊷䊦䉴䉟䉾䉼䊌䊈䊦
PB8 STEERING YL 43
F1
S5
MD
CN9-1-16 CN2D-10
SWITCH PANEL
(SPEED 䊘䊁䊮䉲䊢䊜䊷䉺
POTENTIOMETER N
CONTROL)
䊥䊐䊃䊨䉾䉪
LIFT LOCK F8
䉸䊧䊉䉟䊄
SOLENOID
WR 205 PB1 O 138 2A P 139
S1
CN1-13 SOL CN1P-35
Fig. 6.10 Circuit Diagram (3- to 3.5-ton trucks)

(START)
CN1P-8
CN1P-7
WY 206 PB2
S2
CN1-14 CN1P-24
(STOP)
CN1P-22
CANH(+) GY 83
CSPU
CN1P-3
WG 209 PB3 CANL(-) GO 84 PU
S3
CN1-15 CN1P-1
(SUPER CANH(+) GL 85 PV
+
PIM
EQUL) CN1P-15 䊘䊮䊒䊝䊷䉺

PUMP MOTOR
CANL(-) GB 86 CN1P-13 PW
LB 201 LED1
L1
CN1-5 CN1P-14
SWITCH PANEL
CSPW
(CHARGE) 䊥䊐䊃䉟䊮䉼䊮䉫
LIFTING SWITCH CN1P-20
䉴䉟䉾䉼 G 38
2
CN2P-17 䊘䊮䊒䊝䊷䉺
PUMP MOTOR
BATTERY CHARGER
RB 202 LED2 YW 39
1
L2
LCD PANEL
CN1-16 MODE SELECT SWITCH 2

䊝䊷䊄䉶䊧䉪䊃䉴䉟䉾䉼㪉 CN1P-5 CN2P-6 䉰䊷䊝䉶䊮䉰
THERMOSENSOR
(EQUL)
䊝䊷䊄䉶䊧䉪䊃䉴䉟䉾䉼㪈
MODE SELECT SWITCH 1 CN1P-4
RG 203 YR 20 W 40
1
CN1-4 䊋䊦䊑䉴䉟䉾䉼㩷㪫㪠㪣㪫
VALVE SWITCH TILT CN1P-16 CN2P-29
COM
YG 21 Y 41 䊘䊮䊒䊝䊷䉺
2
䊋䊦䊑䉴䉟䉾䉼㩷㪘㪫㪫㪈
VALVE SWITCH ATT1 CN1P-17 CN2P-5 PUMP MOTOR
YL 22 B 46
3
(+) (S) (-)
䊋䊦䊑䉴䉟䉾䉼㩷㪘㪫㪫㪉
VALVE SWITCH ATT2 CN1P-18 CN2P-16 ROTATION
࿁ォ䉶䊮䉰 SENSOR
+5V
CN3-2 BL 8 CN1P-28
LG 19
䊌䊷䉨䊮䉫䉝䊤䊷䊛 CN1P-21
㩿䊘䊮䊒㪀
PARKING ALARM
(PUMP)
LB 137 EPS/HPSࠬࠗ࠶࠴
EPS/HPS SWITCH BL 18
CN9-1-12 CN1P-29
INVERTER
GR 189 CN2P-32
-
+ WR 188 CN2P-20
䊥䊐䊃
UNIT
YL 94 CN2P-8
LIFT POTENTIOMETER
N
CN1-11 RY 101
RL 100
CN3-5 CN1E-17
CN1E-34
PO2
CANH(+) GL 85 CN1E-9 㪜㪧㪪䊝䊷䉺

PS MOTOR
CANL(-) GB 86 CN3E-2
CN1E-11 +
CN3E-1
CN1E-4
YG 208 RG 58
PS
CN1-18 CN1E-21
PO1
W 162 R 146 B 147

㪜㪧㪪
CN1E-6
PS
+ L 160 CN1E-22
㪜㪧㪪䊃䊦䉪
EPS TORQUE G 161
MOTOR
POTENTIOMETER CN1E-23
BW 211 N
䉮䊮䊃䊨䊷䊤
CN1-8
CM
CONTROLLER
TH
220
204
Gy
LR
LW115
LY 212 䊋䉾䊁䊥
BATTERY
CN3-4
CN3-8
CN3-6
(48V) (72V)
Br 6
CM
R5
W 207
W 213
PO2
F7
F9
F5
10A
10A
10A
L 116 ᶧ㕙䉶䊮䉰
ELECTROLYTE
YR 117 LEVEL SENSOR
an EPS torque potentiometer or an EPS motor.
R03
RB 141
RL100
䉨䊷䉴䉟䉾䉼
RG 102
KEY SWITCH
R02
R01
SR
TRANS-
RESISTOR
FORMER
MN L
CH
TH
U
AC
V
S
MN L
W
DIODE
T
PO1
䉻䉟䉥䊷䊄
䌁䌃౉ജ
INPUT
F6
E
MN L
KEY SWITCH
RG 216
RY101
Note: Trucks with an Orbitrol steering system have neither of an EPS motor controller,
No. SEB-7P0BE
Issued: July, 2012
Revised: December, 2012

MARKETING GROUP: 6-22-7, Minami-Oi, Shinagawa-ku Tokyo
140-0013, Japan
FAX:Japan +81-3-6730-3371
All rights reserved JB-1212010(HO) Printed in Japan
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TCMCORPORATION

TCM FB1O-8 - FB15-8 - FB18-8 - FB20-8 - FB25-8 - FB25-8LB - FB25-8v - FB30-8V - FB35-8S Forklift Truck Service Manual

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Copyright:

Available Formats

TCM FB1O-8 - FB15-8 - FB18-8 - FB20-8 - FB25-8 - FB25-8LB - FB25-8v - FB30-8V - FB35-8S Forklift Truck Service Manual

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Fork size 920x100x35 1070x122x40

Fork size 1070x122x40 1070x125x45 1070x150x50

Fig. 1 Overall Dimensions

Table 1. Maintenance Standard List

150-175 {15-17.5} 370-420 {37.8-42.8} 470.7-549.2

Held in position on Held in position on

Fork thickness mm [in.] 35+0 +0

Opening of fork tips mm [in.] within 10 [0.394] ← ← ← ←

tightening torque [79.6±15.2]

tightening torque [23.2-34.7]

01. CAUTION TO TAKE WHEN SERVICING THE TRUCK

* Before servicing the truck, make sure to:

* Caution to take when measuring, inspecting or repairing:

Counterbalanced model Reach model

02. BASIC SERVICING KNOWLEDGE

Fig. 02.1 Installing bearings

Fig. 02.2 “O”-ring location

JIG JIG JIG

Fig. 02.3 Installing Oil Seal

③ When installing an oil seal onto a shaft, apply

mounting surface of the shaft. For a double-

Fig. 02.4 Installing Oil Seal

(2) Removing parts

(3) Reinstalling parts

5. How to use a power wrench

1. General metallic parts

04. STANDARD BOLT TIGHTENING TORQUE

Table 04.1 Strength

SS400 4.6 Black 01101- Nominal symbol

SS400 4.6 01100- “

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

Metric, fine system

Metric, coarse system

Metric, fine system

Metric, coarse system

Metric, fine system

Metric, coarse system

Metric, fine system

Metric, coarse system

2. Mast and steering system

3. Checking hydraulic oil level

06. PARTS LIST

Item Part name FB10-8 FB30-8 Remarks

4. DRIVE UNIT AND DRIVE AXLE.................................................................................31

5.2.5 ADJUSTING BRAKE PEDAL....................................................................................53

6A. STEERING SYSTEM (ORBITROL type). ...........................................................55

6B. STEERING SYSTEM (EPS type). ..........................................................................67

8. LOAD HANDLING SYSTEM...................................................................................... 111

8.2 MAINTENANCE.............................................................................................................. 118

1. BATTERY AND CHARGER (OPTION)

Truck model FB30-8

1.1 GENERAL DESCRIPTION

BATTERY CELL WITH

(1) Battery care

The most important point in battery care is to

Fig. 1.3 An Example of Specific Gravity Drop

(2) Charging the battery

1.1.2 BATTERY CHARGER

Thermal relay current settings

Secondary wire CM%/ࠦࡦ࠲ࠢ࠲

Primary wire Thermal relay

FB10-8 FB15-8 FB18-8