Professional Documents
Culture Documents
Manuales de Servicio Serie FB-VIII
Manuales de Servicio Serie FB-VIII
Manuales de Servicio Serie FB-VIII
MEB-7P0AE
WORKSHOP MANUAL
WORKSHOP MANUAL
BATTERY ELECTRIC LIFT TRUCKS
FB10-8 - FB35-8S
Counter Balanced
FB10-8 FB25-8LB
FB15-8 FB25-8V
FB18-8 FB30-8V
FB20-8 FB35-8S
FB25-8
FB30-8
No. MEB-7P0AE
IMPORTANT
For detailed procedures about operating the lift truck, see the lift truck “OPERATION
AND MAINTENANCE MANUAL.” Improper operation of the lift truck might cause serious
bodily injury or death to you or fellow workers.
The decals on your lift truck indicate the level of hazard, such as “ CAUTION,”
“ WARNING,” and “ DANGER.” They are intended to alert the operator and service
personnel to potentially dangerous conditions in the operation and servicing of the lift truck.
Failure to follow the instructions in the message can lead to serious personal injury or death,
or damage to the lift truck or other property.
The “1. GENERAL DESCRIPTION” in this Workshop Manual describes basic safety
instructions for servicing the lift truck. Before starting study the safety instructions carefully
and become completely familiar with the procedures for servicing the lift truck as well as the
various points to be kept in mind. Improper techniques can lead to injury to oneself or others.
Service personnel must be completely familiar with the systems and components of the
lift truck, and the tools to be used, as well as the correct service procedures.
Read this Workshop Manual and the lift truck Service Manual thoroughly, and become
completely familiar with the lift truck.
The following safety symbol is used in this manual and on the decals found on the truck. If
you see this safety symbol, pay special attention to the instructions and messages. Otherwise
there is a likelihood of personal injury or death and of damaging the lift truck.
(Empty page)
INTRODUCTION
INDEX
TCM offers a wide variety of lift trucks which have
been enthusiastically welcomed by users all over the 1. GENERAL
world. The lift trucks covered in this Workshop Manual DESCRIPTION
have also been developed through years of research and
experience, and they feature high quality designs and parts.
2. REMOVING/
However, to get the most out of their performance, it
REINSTALLING
is necessary to service, inspect and adjust them at regular
intervals, as well as to operate them properly.
The purpose of this Workshop Manual is to serve 3. DISASSEMBLY/
as a guide to proper service, inspection and adjustment REASSEMBLY
techniques for the major components of your TCM lift
truck. Study this manual carefully before servicing or
inspecting the major components of your lift truck. For
details about the construction and operating principles
of the components, see the lift truck Service Manual.
We hope this manual will serve as a useful guide to your
service and inspection work.
Please note that the descriptions and specifications in
this manual are subject to change without prior notice.
February 2013
(Empty page)
1. GENERAL
1.1.1 Introduction
■ Lift trucks should only be operated by qualified operators
(1) A qualified operator must have training and possess any required
licenses to operate this truck.
(2) The operation of a crane or performing any welding must be only
attempted by qualified personnel.
(5) Keep sparks and open flames away from the work area. This is
especially important if your clothing is contaminated with a lubricant.
(6) Do not put a knife or any other sharp object in your pocket.
(7) Do not wear any jewelry, such as rings, pendants or bracelets, that
can become easily entangled in the machinery. Entanglement causes
serious personal injury. Do not wear a necktie or a watch.
(8) Do not wear gloves when checking rotating parts.
(9) Wear a safety belt when working in an elevated location.
(10) Keep your shoes clean, free of grease, oil, and mud.
1-1
(4) Clear away any obstructions or hazards from the work area.
(5) Do not stack unstable objects. Take any necessary measures to prevent
any stacks of objects from collapsing.
(6) Keep the areas around the switchboard, fire extinguisher, stairs, and
emergency exits clear of obstacles.
(7) Hazardous objects must only be stored in specified areas, surrounded
by a white line.
(8) Remove any waste or unnecessary objects from the work area
immediately.
(9) Do not bring any personal objects into the work area.
(10) Arrange the tools and replacement parts so they can be reached easily.
(3) Always attach a sign in the control area stating DO NOT OPERATE “Do not
operate”
when the truck is being repaired.
(4) In principle, you should not turn on the motors while servicing the
truck. Remove the key from the key switch when leaving the truck
unattended.
(5) Keep yourself in good shape before and during work. Block the
wheels
(6) If you are overworked, fatigued or feeling unwell, do not operate or
service the truck.
Report to the specified supervisor.
(7) Make sure there is good ventilation when working in an enclosed area.
(8) Before starting the service, make a work plan and make sure you
understand the work procedures well.
(9) Make certain you have all the necessary replacement parts, materials
and tools at hand.
(10) When working in a group, discuss the details with all personnel
involved and make sure everyone understands the meaning of any
hand signals and the communication methods that will be used.
(11) Check the equipment and tools you are going to use in advance. In
particular, wipe off any oil or grease. Check the power tools, such as
drills, for electrical cable problems.
(12) Take the necessary measures to prevent the directional and load
handling control levers and the load handling means from moving
unexpectedly.
(13) Read the caution decals carefully and obey the instructions written on
them.
(14) Use only TCM-approved replacement parts and lubricants.
1-2
1.1.5 Maintenance precautions (while working)
(1) Follow the specified work procedure. cedure
Work pro
(2) Do not remove any covers or components other than those necessary
to do the job.
(3) Do not allow people other than service personnel to enter the work
k!
area. t spea
Do no
Do not speak to service personnel while they are working.
(4) When working in a group, pay attention to the safety of your fellow
worker(s) as well as to your own safety. Do not try to perform tasks
other than the ones specified in advance.
(5) Sound an alarm immediately if you notice a danger.
(6) Do not toss tools or parts to a fellow worker. Hand them over with
care.
(7) When leaving the equipment unattended during maintenance, turn it
off.
If the power fails, turn off the power switch on the equipment. For
example,
• Lower any raised load to the ground.
• Turn off the switch to any power tools, such as drills, grinders or
welders.
(8) Do not use unstable objects, such as a box or a component, as a step-
ladder.
(9) Do not spill oil or grease on the floor. Wipe up any spilled oil or grease
on the floor right away.
(10) Clean the oil fill ports and grease fittings before adding oil or grease.
(11) Lubrication and oil level checks should always be performed with the
truck parked on a level surface.
(12) Do not stand or walk under raised forks, buckets or hoists.
When using a jack or hoist, do not exceed its rated capacity.
1-3
1.1.6 Maintenance precautions (after servicing)
(1) Clean the equipment and tools.
(2) After servicing, return the work bench, truck carriage, tools and pallets
to their designated positions.
(3) Wipe up any contaminants, spilled oil or grease in the work area.
(4) Discard waste such as waste oil, used waste cloth, and glass at the
specified place.
You should always have in mind that the environment must be
protected.
(5) Neutralize any spilt battery electrolyte with sodium bicarbonate or
wash it away with a large amount of water.
(6) Make certain all fires are out and all the switches on the electrical
equipment you used have been turned off.
(7) After servicing, make sure the truck operates properly.
Weight
1.1.8 When working in an elevated place
If you need to work in an elevated place, refer to the “Safety Instructions
for Working in Elevated Locations.”
1-4
1.1.10 Safety rules for maintenance
<Before starting maintenance>
Before starting maintenance service, make sure:
(1) The directional and load handling control levers are in neutral.
(2) The parking brake is securely applied.
(3) The key switch is turned off and the key is removed.
(4) The wheels are blocked.
(5) Put a sign stating “Do not operate” on the truck or mark the off-limits
area around the truck with traffic cones or chains to keep people away
from the work area.
(6) Lower the forks or bucket to the ground. If you need to work with
the forks or bucket raised, use supports to prevent the forks or bucket
operate
Do not
from lowering unexpectedly.
(7) Clean the floor surface and the truck steps, floorboard, battery hood
and tires of the truck before starting, to prevent an accident caused by
slipping.
(8) Do not try to repair the truck while it is on a trailer. erviced
Being s
(9) Do not try to work while sitting on a tire. Use a suitable step stool or
an elevating work platform.
(10) If you must go under the truck, use goggles or safety glasses to
prevent dust from getting into your eyes.
(11) Remove any caked-on mud from the truck and forks with a hammer
before cleaning the truck with water.
Work platform
1-5
(4) Use jack stands, supporting blocks or a bench suitable for supporting
Rectangular
the truck: cross section
· Do not use square timbers as supporting blocks.
· Use only specified jack stands, supporting blocks or platform.
· Use jack stands, supporting blocks and a bench that have enough
strength for the purpose.
· Test the jack stands, supporting blocks or bench before using them
and make sure you understand their weight limit. No projecting
bolts allowed
· Use hard timbers such as apitong or pine as supporting blocks.
Check them for cracks, deformation, or corrosion at regular
intervals, and replace them if necessary.
(5) When inserting jack stands or supporting blocks under the truck, use
caution not to get your hands or fingers pinched.
<Crane>
(1) Operation of cranes with a lifting capacity of 5 tons or more or mobile
cranes (excluding a floor type crane) must be only performed by a
qualified operator.
(2) Setting up a sling for a load of 1 ton or more must be performed by a
person qualified to do so.
(3) Basic rules of sling work:
· Do not exceed the rated capacity of the crane. As a rough guide,
assume the capacity of the crane is 20 percent less than the rated
capacity.
· Lift the truck from two points or more, never from a single point.
The lifting angle of the chains or cable must be less than 60 degrees
and the position of the center of gravity of the load must be low as
possible.
· Do not exceed the specified capacity for the wire ropes.
· Position the hook directly over the load you are going to lift.
· Attach pads to any sharp areas on the load where the wires might
come in contact with the load.
· Do not hook the lifting cables on a slippery area or any area from
which the hook can be easily disengaged.
· Do not lift at an angle and do not pull horizontally.
· Stop lifting the load when it is about 10 cm above its resting
position and check for stability and the center of gravity of the load.
· Have a guide at a position clearly visible by the worker, and let him Pads
give instructions for the work.
· Make sure everyone understands the meaning of any hand signals
and the communication methods that will be used.
· Do not ride on a load being lifted. Do not allow anyone to stand or
walk under a raised load.
· Use a guide rope when lifting a long load.
· Before lifting the load off the ground, reposition the main hook just
above the load’s center of gravity, to prevent the load from rolling.
1-6
(4) Chain blocks
· Do not toss or drag a chain block. If a block becomes wet, wipe Do not
drag!
away the moisture and lubricate it properly. An elongated or Do not
toss!
deformed hook should not be used.
· Make sure that the hook and other lifting equipment is working
properly before use.
· Do not use a chain block with any cracks or deformation in the
welds or shoulders.
Welded
part
Shoulder
(2) Put blocks under the root of the forks. Lower the forks to disengage
the forks from the carriage.
(3) Lift the tip of each fork prong to remove it from the carriage.
1-7
<Removing and reinstalling tires and rims>
(1) Deflate the tire before loosening the bolts connecting the rims (for the
split rim type) or before removing the side ring or lock ring (for the
side ring type).
(2) It is particularly dangerous if you try to remove an inflated tire from
the truck with the split-rim having a loose or missing rim connecting
bolt. When connecting the rims, tighten them to the specified torque
with the tire deflated.
Wow!
(3) Use a safety cage for inflating the tire. If one is not available, place the
tire on the ground or floor with the lock ring or side ring facing down.
(4) Do not weld or cut the rim while the tire is on the truck.
(5) Deflate the tire before trying to remove any nail or other foreign object
from the tire.
(6) Do not use a damaged tire or rim. Do not use a mismatched tire and
rim assembly.
Blown off!
(7) Inflate the tires to the specified pressure by using an air compressor.
1-8
<Precautions to take when overhauling cylinders>
(1) Do not try to overhaul cylinders while they are mounted on the truck.
Remove the cylinder assembly and overhaul it in a workshop.
(2) When removing a cylinder from the truck, secure it to a mast
connecting member with rope, to prevent it from falling. Do not try to
hold it in your hands. Lift cylinder
(3) Do not try to lift a cylinder by hand. Your hands might get crushed Boom and bucket cylinders
under the cylinder if you can’t hold it or if you lose your balance.
(4) Put the cylinder you are going to overhaul on a work bench and hold
in a vise. The work bench should be equipped with a V groove to
prevent the piston rod from rolling off the bench.
(5) Remove the piston rod from the cylinder. If the piston rod is hard
to remove by hand, apply compressed air from the tail side of the
cylinder to push the piston rod out.
(6) When using compressed air, fit a cylinder cap over the piston rod, to
prevent the piston rod from popping out. Be very careful not to be
injured by the piston rod extending unexpectedly.
(7) When removing the piston rod with a crane, the cylinder cap might
drop onto the piston. Use caution not to get your hands pinched. Hold
the side of the piston or hold the piston with a rope.
(8) For cylinders used in lift trucks with a capacity over 8 tons, secure the
cylinder tail to a pole in the room and remove the piston rod using a
sling hook and a lift truck.
(9) When replacing the piston seal with a new one, use a special spatula
to remove the old seal. (Do not use a prick punch. You might get
injured and you may damage the piston.)
1-9
<Mast inspection>
(1) Use a helper to inspect the mast operation: one person in the operator’s
seat operating the load handling levers and the other standing by the
side of the mast checking the mast operation. Do not climb between
the mast and the operator’s compartment.
(2) Use a mobile or fixed elevating work platform when working on
components at an elevated position. Do not climb between the mast
and the operator’s compartment.
WARNING
(3) If you need to inspect the truck with the forks raised, install the load INNER CHANNEL
handling lever stoppers and/or the inner mast stopper.
(4) Do not put your hands or feet on or near the mast rails or connecting CONNECTING
MEMBER
members of the mast.
(5) Never try to operate the hydraulic control levers in the operator’s
STOPPER
compartment from the mast side. In particular, do not try to operate
them from in between the truck body and the mast. OUTER
CHANNEL
(6) When working alone, use a crane to remove or reinstall the load
backrest.
SLOT Insert into
(7) When working with the mast raised, take the necessary steps to dashboard.
prevent the mast from falling unexpectedly, or install control lever PLATE WING NUT
stoppers.
(8) Apply genuine TCM Chain Coat chain lubricant to the lift chains from
the front of the mast with the forks lowered to the ground. (You can LEVER
1-10
<Electrical system>
(1) Precautions when recharging batteries
· Make sure the power cable is securely connected before turning on
the battery charger. Do not disconnect or reconnect the power cable
while the battery charger is on.
· Do not disconnect the battery connectors during recharging;
otherwise there is danger of causing sparks.
· Do not try to check the battery voltage by shorting the poles of the
battery.
· The battery must only be recharged in a well-ventilated space, with
no flammable materials in the area.
· Charge batteries on an acid-resistant floor surface that is well tric
Elec ck!
drained, because the battery electrolyte might spill on the floor sho
during recharging.
· Make sure that the charging equipment is equipped with a ground
fault interrupter. (it must be grounded). Danger!
Ele hock
s
ctr !
· Be careful not to drop a wire, tools or parts inside the truck. If you
ic
drop something, make sure to remove it.
(3) Do not touch any switch which has a warning sign attached to it. Use
special caution if you do need to touch it.
(4) Keep clear of broken wires.
(5) Always attach a sign to the battery charging unit stating “Do not
operate” when the electric system is being repaired.
(6) Write the name, rated voltage, and current of the power supply unit
and the name of the person in charge of the battery charging unit near
the power supply switch.
(7) Only use approved fuses for the power supply switch.
(8) If the battery charging unit fails to operate normally, turn off the
power switch immediately and report to the supervisor.
(9) Do not smoke near the battery. Do not use an open flame to check the
battery electrolyte level. Explosive gases are always being released
from the battery and there is a danger of causing an explosion.
(10) Keep the top surface of the battery case clean. If it is contaminated
with dust or water, there is a danger that an explosion may occur due
to an interfacial discharge occurring between the battery terminal and
the truck frame.
1-11
<Welding>
(1) Observe the following conditions when welding:
· When welding near a tire, note that there is a danger of the tire
ut!
wo
exploding if it is heated excessively.
Blo
· Do not try to weld or gas cut any container or pipe containing fuel
or oil. Remove the fuel or oil. It is good practice to put water in the
object before welding it.
(2) Wear a welding mask to protect your eyes.
(3) Using a welding mask will obstruct your sight. Organize the work Person in
area properly before starting to weld or cut. In particular, move away charge:
Mr. ______
<Press work>
(1) Make sure the hydraulic press workrest does not have any cracks.
(2) Do not bring your face or hand close to the press during operation.
(3) Place the platform in a stable position and keep it in place during
operation.
(4) Extend the ram as far as possible. Avoid using an intermediate jig.
1-12
<Grinding >
(1) Put the specified safety cover on the grinding wheel.
(2) The clearance between the workrest and the grinding wheel should be COVER SHIELD 3 mm
[0.118 in.]
less than 3 mm.
WORKREST
(3) Install a shield to prevent grinding powder from flying off.
(4) Make a dry run on the grinding wheel for at least 1 minute before
each use or for more than 3 minutes whenever the grinding wheel
is replaced with a new one. During the dry run, do not stand in line
with the grinding wheel direction of rotation; otherwise you could be
injured by flying pieces of wheel if it breaks.
(5) Make sure the sander switch is turned off before connecting the power
supply cable.
(6) Check the power tool cables for damage. Do not use any power tool
with a damaged cable.
(7) Make sure there are no flammable gas leaks or flammable articles
where grinding sparks will splash.
(8) Do not perform sanding with the sander switch locked.
(9) Wear safety glasses whenever you perform any sanding or grinding.
(10) Do not use the side of the grinding wheel.
<Drilling >
(1) When using a magnetic drill, remove any dust between the magnetic
base and the work.
(2) Install a power shut-off device, such as a power switch, in a position
where the worker can operate it without leaving his working position.
(3) Make sure the machine is turned off before cleaning, inspecting or
repairing the machine or cutter. VISE
(4) Use a suitable brush to remove cuttings from the cutter, or apply
lubricant to the cutter.
(5) Do not wear cloth work gloves when using devices such as a drill
mounted grinder.
(6) Hold the work in a vise when machining it with a drill mounted
grinder.
<Painting>
(1) Observe the following precautions when painting:
· Designate an organic solvent manager and put his or her name
(including this job description) in a conspicuous position.
· Put up a sign stating “No fire. Do not enter within 5 m of the
painting work area”. Install a fire extinguisher in the work area.
· Use explosion-proof fans and lights in a narrow space or an
enclosed area.
· Provide a local ventilation system, where necessary.
· Do not bring more paint than necessary into the work area.
· Reinstall the cap on any paint container not being used.
· Wear a gas mask to prevent organic gas poisoning.
· Do not install any electrical switches inside the painting work area.
· Check the electrical system in the painting work area as necessary.
(2) Do not incinerate used spray cans. Make a hole in the can when
disposing of it.
1-13
<Transporting>
(1) When a group is carrying a heavy load, make sure everyone
understands the meaning of any hand signals and the communication
methods that will be used. (Refer to “1.1.9. When working in a
group”.)
(2) Prevent back injuries. Use a diagonal foot position and get as close to
the load as possible. Lift the load, keeping it as close to the body as
possible while standing.
(3) Do not reduce the load suddenly or inadvertently.
(4) When loading or unloading the truck from a trailer, observe the
following precautions: Good Bad
· Wear gloves when handling a heavy load such as loading ramps.
· Check that the brake, tires and steering wheel are in good operating
condition before loading or unloading from a trailer.
· Check the loading ramps for corrosion or cracks before starting.
· Put supports below the loading ramps when loading or unloading a
heavy truck.
· When loading a forklift truck, drive it up backwards onto the trailer.
· When loading or unloading a forklift truck on a trailer by driving the
forklift truck yourself, use a guide to keep an eye out for problems.
(5) When towing a truck, pay attention to the traveling speed and keep
a safe distance from the truck being towed. It is necessary to have a
driver’s license even if the truck is towed. Look forward!
(6) Make sure there is no one around the truck when you are starting up or
operating the load handling equipment.
<Fire hazards>
(1) Do not carry loads which could cause a fire or explosion when they
come in contact with each other.
(2) Do not use open flame at places other than specified.
(3) Do not smoke at places other than specified. Do not
smoke!
(4) Keep a fire extinguisher nearby when welding or grinding. After work,
make sure the equipment is completely turned off.
(5) Before using an open flame, get permission to do so from your
supervisor.
(6) Observe the following precautions when handling flammable or
explosive materials :
· Put oily wastes in a non-combustible container and cover it.
· Do not heat an enclosed container containing flammable or
explosive materials.
· Handle hazardous materials carefully and store them in a specified
place.
· Do not use a heater or stove in a work area without prior permission.
· Handle solvents or chemicals carefully and make sure there is good Danger!
ventilation when using them.
· Do not use an electric device that can cause sparks, near flammable
or explosive materials.
(7) Do not use an open flame (match, lighter, etc.) to check an item in a
dark place, or to check the battery electrolyte level.
(8) Know where the fire extinguisher and fire hydrant are located. The
fire extinguisher or fire hydrant must not be blocked by equipment,
clothing or other objects that could interfere with access in an
emergency.
1-14
(9) If fire breaks out, observe the following precautions:
· If fire breaks out, give a loud warning to fellow workers
immediately.
· If an electrical device catches fire, turn off the power switch before
trying to fight fire.
· If an oil or lubricant catches fire, use a suitable fire extinguisher
such as ABC dry chemical fire extinguisher, or sand.
(10) Avoid burning waste or anything else in the work area.
<Others>
(1) Do not get on or off the truck while it is in motion. Do not grab the
load handling levers or steering wheel when getting on or off the
truck.
(2) Use the safety step(s) and safety handle when getting on or off a
stationary truck.
(3) After removing a large component, put it on a work bench.
(4) Before trying to remove hydraulic lines, shut off the engine and
operate the hydraulic control levers several times release any residual
pressure.
(5) Do not heat a hydraulic line that contains fluid. If the connector on a
corroded pipe sticks, loosen it using a penetrating agent, box wrench,
and a long spanner.
(6) When working in a group, make sure everyone understands the
meaning of any hand signals and the communication methods that will
be used. In particular, before you start the engine, let fellow workers
know you are going to start the engine.
(7) Shut off the engine before trying to check for water or oil leaks.
(8) Use jigs suitable for the job. Do not use an inappropriate jig. Check
the jig before use and repair any jig that is defective.
(9) Use screwdrivers suitable for the job.
(10) Do not connect two wrenches. If necessary, use a longer wrench or
weld them properly.
Bad
Bad
(11) A mallet should always have a wedge in the head. Do not wear a Bad
glove when using a mallet.
(12) Remove any burrs from the chisel head. Wear safety glasses when
chipping materials.
Bad
(13) Use a pressure gauge of suitable capacity to check the hydraulic
pressure.
(14) When using an impact wrench, make sure that the pin which locks the
socket has not come off.
1-15
(15) The drive shaft and planet carrier should be installed by turning them.
Do not push them or hit them. Be careful not to get your fingers
pinched.
(16) If you cannot engage the puller’s jaws properly on the hub bearing in BEARING PULLER
order to remove it, insert a bearing separator between the inner race
and the flange and pull out the separator using the puller. (Do not use a
chisel; otherwise the bearing might be damaged.)
BEARING SEPARATER
(17) Use a special jig with a handle to remove the king pin.
(18) Use a suitable tool with the correct diameter and a lock guide to install
bushings. GUIDE
(19) Use a round drift to install a quenched, or hardened pin. Do not hit the
pin directly.
(20) Do not check the alignment of pin holes by inserting your fingers into
the holes. Check by looking.
(21) Find out in advance where the waste disposal facility is located.
(22) Use non combustible solvents for cleaning. Do not use any flammable
solvent, including gasoline. Do not use the cleaning fluid tank to store
kerosene or diesel fuel.
(23) Make sure the nozzle valve is closed before turning on the car washer.
If you need to remove your hands from the hose while spraying, close
the nozzle valve.
1-16
1.2 BASIC KNOWLEDGE OF THE CHARGING STATION
YES. NO.
(We do not have a power supply
with a 3-phase AC outlet.)
Is there a power supply with a 3-phase AC outlet located
where it can be accessed by your electric lift truck (or a
battery charger)? Contact your local utility company to
supply the appropriate power and outlets.
YES. NO.
Check whether:
1. The rating, configuration, manufacturer,
and model (approval number) of the power Call an electrician and get the necessary power supply equipment installed *1.
supply socket are appropriate.
2. The capacity (in amperes) of the power
supply socket is greater than the battery
capacity of the electric lift truck you are
going to use.
Are you sure the power supply socket can be used to connect a battery charger
which will recharge the batteries in the electric lift truck you are going to use?
YES. NO.
(No socket is available for
Does the circuit breaker for the power supply socket have connecting the battery charger.)
sufficient capacity? NO.
(You should check that it is not shared with any other
piece of equipment.)
YES.
The manufacturer (distributor) will deliver the electric lift truck (or an optional on-board battery charger) equipped with
a cable that has a plug suitable for your power supply socket.
* Your present electricity service contract may need to be changed if you want to purchase a new electric truck, or add to
your lift truck fleet. Consult with your electrician and check with your local utility company.
* 1. For example, if the power supply equipment is a 3-phase AC 200 volt system, we need to know the
following:
On-board battery charger (optional)
FB-8
Truck model
10 - 18 20, 25 25LB, V 30, 30V, 35S
1. Power supply socket capacity Amperes 20 30 40 40
2. Power supply socket circuit breaker Amperes 20 30 40 40
capacity
3. On-board battery charger capacity kVA 6.0 8.5 12.0 12.0
4. Plug type on the end of the power Grounded 3P Grounded 3P *2 *2
supply cable supplied with the truck Straight cable 30A 30A None None
(standard accessory) 250V 250V
*2 The optional on-board battery charger cable will be delivered without a plug. It is recommended that you
connect the supply end of the cable directly to the circuit breaker or attach a plug appropriate for the socket
capacity: 50A or 60A ground 3P (4P). (Consult your local electrician.)
1-17
Stationary battery charger (optional)
FB-8
Truck model
10 - 18 20, 25 25LB, V 30, 30V, 35S
Charger model SA1G08 SA1G10 SA1G16 SAAG10
1. Capacity Amperes 20 30 50 50
2. Circuit breaker capacity Amperes 20 30 50 50
3. Battery charger capacity kVA 6.5 8.1 13.2 11.8
Grounded 3P Grounded 3P
4. Plug type on the end of the power Straight 20A 30A None None
supply cable supplied with the truck 250V 250V
Note: ① For details about charger models and specifications not provided in this table , such as charger
models or specifications for high-capacity batteries, refer to the Operation and Maintenance manual
or the Sales Manual for the FB-8 lift trucks.
② Attaching a plug to a charger cable should only be done according to the rules at your worksite and
only after consultation with our service personnel.
CAUTION
•• The power supply equipment must be installed under the supervision of a qualified electrician, or ask
a specialist authorized by your local utility company to do the work.
•• The power supply for the battery charger must be provided with a line switch (with a ground fault
interrupter) for each battery charger unit.
•• The power supply equipment, fuse and circuit breaker should be selected according to the capacity
of the battery charger you want to use. Use of improper power supply equipment, fuses or circuit
breakers will damage the battery and/or cause an accident.
•• Ground the power supply equipment securely. The ground line of the power supply socket must be
grounded without fail; otherwise there is a danger of electrocution.
Water-proof
防水型type
Embedded
埋込型type 露出型
Exposed type (There are many other
(他多数の形状)
configurations available.)
1-18
1.3 BASIC SERVICING KNOWLEDGE
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 the oil pressure.
Pressure
1-19
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
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.
Remember that parts are very hot after heating. Use caution not to get burnt when removing them.
1-20
5. CLEANING
■ 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.
■ 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.
■ 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.
1-21
6. STANDARD BOLT TIGHTENING TORQUE
See the bolt torque charts on page 1-22 to 1-25 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.
• Division by 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.)
1-22
Division by Surface
Name Shape Thread size Material Part number
strength treatment
• Designation of screws: Each part number consists of a screw type designation and a nominal symbol.
1-23
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 MIHE㨙 0㨙 MIHE㨙 0㨙 MIHE㨙 0㨙 MIHE㨙 0㨙 MIHE㨙 0㨙 MIHE㨙
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
1-24
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄
1-25
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
1-26
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
1-27
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
/ ̄ ̄ ̄ ̄ ̄ ̄
CAUTION
•• Do not mix lubricants of different brands; otherwise the performance of the lift truck might be
adversely affected.
1-28
1.5 PRE-OPERATION INSPECTION
Component Item to be checked Checking procedure
Master cylinder ① Brake oil level (A) Check brake oil level in reserve tank.
(brake oil tank)
Service brake ① Brake pedal freeplay and (A) Press brake pedal until some resistance is felt to
braking effect check for freeplay (normal freeplay: 5 to 10 mm).
(B) Press brake pedal to the bottom to check the
clearance between brake pedal and floorboard
surface. Check also for spongy brake, or air
trapped in the system.
(C) Drive slowly and press brake pedal to check for
braking effect and uneven braking.
Parking brake ① Operating force and (A) Pull the lever to the full to check that the lever is
application properly locked.
(B) Operating force should be between 150 to 170 N
{15 to 17 kgf}.
Tire ① Tire inflation pressure (A) Check tires for inflation pressure visually or using
a hammer.
(B) Check treads and side walls for excessive cracks,
damage or undue wear.
Steering wheel ① Excessive play or (A) With the engine running, turn steering wheel right
looseness and left to measure how far it moves before the
wheels begin to turn (normal play: 20 to 30 mm).
Excessive play check should be performed with
the key switch turned ON.
(B) Move steering wheel up and down, and back
and forth to check bearings for looseness and
horizontally to check main shaft and steering
column rubber and bushing for installation.
Steering wheel ① Wander, pull, hard (A) Run the truck at slow speed to check whether the
steering truck wanders or pulls to one side or has hard
steering.
Power steering ① Operation and oil leakage (A) Run the truck at slow speed and turn steering
wheel to the right and left to check power steering
for operation and oil leakage from piping.
Hub bolts and ① Damage or looseness (A) Using a test hammer or visually check hub bolts
nuts and nuts for damage or looseness.
Horn and turn ① Operation (A) Check horn and turn signal for proper operation.
signal
Rearview ① Full rear view (A) Check whether you can gain full rear view when
mirrors you are seated in operator’s seat.
Lights (head, ① Operation (A) Turn each of the light switches to check for
tail, license operation.
number plate, (B) Any light which interlocks with other device
brake, side should be checked in interlocked state. The back-
marker and up light should be checked for operation by
other) shifting the gears in reverse.
1-29
Component Item to be checked Checking procedure
Warning lights ① Operation (A) All warning lights on the instrument panel come
on when the key switch is turned ON and go out
shortly thereafter.
Pumps ① Oil leakages and noise (A) Turn the key switch to ON and operate the valve
levers to check for oil leaks and noise from the
pumps.
Control valve ① Lever operation (A) Turn the key switch ON and operate the valve
levers to check if the lift and tilt cylinders operate
normally.
Hydraulic piping ① Oil leakage and damage (A) Visually check the hydraulic lines and hoses for
oil leaks or damage.
Hydraulic ① Oil leakage (A) Turn the key switch ON and operate the valve
cylinders levers to check for oil leaks from the hydraulic
(lift, tilt) cylinders or lines.
② Damage to cylinder rod (A) Operate the hydraulic cylinders to check the
cylinder rods for contamination or damage.
Hydraulic oil ① Oil level (A) Remove the oil dipstick located inside the tank
tank and wipe it with a clean cloth.
Reinsert and remove to check the oil level by
viewing the oil on the end of the dipstick.
Lift chains ① Damage, deformation (A) Check lift chains for damage or deformation.
② Tension (A) Lift forks about 50 mm off ground and push
chain midway on the span with fingers. Normal
deflection: 40 to 50 mm.
(B) Check right and left lift chains for even tension.
Forks and mast ① Operation (A) Turn the key switch ON and operate the valve
levers to check for proper operation of the forks
and mast.
Battery ① Electrolyte level (A) Remove the vent caps on the battery and make
sure that the battery electrolyte fluid reaches the
level mark.
Any defects ① Repaired properly? (A) Check to see if defects found by previous
found by previous inspection have been correctly repaired and the
inspection truck operates normally.
1-30
1.6 PERIODIC INSPECTIONS
Note: It is necessary to service your forklift truck at periodic intervals, in order to keep it in good operating
condition and to prevent any problems from occurring.
Forklift trucks often play an important role in the production process and it is no exaggeration to
say that preventive maintenance of forklift trucks working in the facility is one of the key factors to
improvements in productivity.
1-31
PERIODICAL CHECK SCHEDULE
This check schedule is worked out on the assumption that the lift truck will be used under typical working
conditions. If the lift truck is used under severer working conditions, earlier check is required.
( ○ : Inspect and adjust, repair or change if necessary. ● : Change or addition.)
ELECTRIC SYSTEM
Checking Tool/remedy Before work Weekly Monthly Trimonthly Semiannualy Annually
Service Required
item or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check for contamination of battery case. Cleaning ○ ○ ○ ○ ○
Add if
Check electrolyte level. ○ ○ ○ ○ ○ ○
necessary
Battery
Check specific gravity. Adjust ○ ○ ○ ○ ○
Give equalizing charge. ○ ○ ○ ○
Check for insulation. Measure ○ ○
Check for contamination of the surface. Cleaning ○ ○ ○ ○
Check for rough contact points of Check ○ ○ ○ ○
contactor.
POWER TRAIN
Checking Tool/remedy Before work Weekly Monthly Trimonthly Semiannualy Annually
Service Required
item or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check for oil leaks. Visual ○ ○ ○ ○ ○ ○
1-32
STEERING SYSTEM
Checking Tool/remedy Before work Weekly Monthly Trimonthly Semiannualy Annually
Service Required
item or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check inflation pressure. Tire gauge ○ ○ ○ ○ ○ ○
Check tires for cracks. Visual ○ ○ ○ ○ ○ ○
Rims and Check for damage of rims, side rings, and Visual ○ ○ ○ ○ ○ ○
side rings disk wheels.
CONTROLS
Checking Tool/remedy Before work Weekly Monthly Trimonthly Semiannualy Annually
Service Required
item or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check for play. Operate ○ ○ ○ ○ ○ ○
Check for looseness in axial direction. Touch ○ ○ ○ ○ ○ ○
Steering
wheel
Check for looseness in radial direction. Touch ○ ○ ○ ○ ○ ○
Check for proper operation. Operate ○ ○ ○ ○ ○ ○
Steering gear Check for loose mounting bolts. Operate ○ ○ ○
box
1-33
BRAKE SYSTEM
Checking Tool/remedy Before work Weekly Monthly Trimonthly Semiannualy Annually
Service Required
item or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check for play. Operate ○ ○ ○ ○ ○ ○
Check for pedal travel. Scale ○ ○ ○ ○ ○ ○
Brake pedal
Check for braking effect or uneven Operate ○ ○ ○ ○ ○ ○
braking.
1-34
LOAD HANDLING SYSTEM
Checking Tool/remedy Before work Weekly Monthly Trimonthly Semiannualy Annually
Service Required
item or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check for damage, deformation, or wear. Visual ○ ○ ○ ○ ○ ○
Check fork stopper pin for damage or Visual ○ ○ ○
wear.
Forks
Check fork roots and teeth-welded area Visual ○ ○ ○ ○
for cracks or wear.
1-35
HYDRAULIC SYSTEM
Checking Tool/remedy Before work Weekly Monthly Trimonthly Semiannualy Annually
Service Required
item or shift (50 hrs.) (200 hrs.) (600 hrs.) (1200 hrs.) (2400 hrs.)
Check oil level and change oil if Visual ○ ○ ○ ○ ● ●
contaminated.
Hydraulic oil
tank Change suction strainer. ● ●
Change return filter. ● ●
Check control lever linkage for looseness. Operate ○ ○ ○ ○ ○ ○
Control
valve lever
Check for function of control lever. Touch ○ ○ ○ ○ ○ ○
1-36
2. REMOVING/REINSTALLING
(1)
FFFFFFFF
② Remove the nut (1) and then remove the head light
(3) from the overhead guard (2).
(3)
(2)
(1)
FFFFFFFF
■ Reinstallation
① Install the head light (2) on the overhead guard (1)
using the nut (3).
7.8 - 11.7 N-m {0.8 - 1.2 kgf-m} (2)
[5.8 - 8.6 lbf-ft]
(1)
(3)
FFFFFFFF
② Connect the connectors (2) of the head light to the
connectors of the wire harness (1) on the overhead
guard.
(2)
(1)
FFFFFFFF
2-1
2.1.2 FRONT COMBINATION LIGHT
■ Removal
① Disconnect the connector of each front combination
light from the connector of the wire harness (1) on
the overhead guard.
(1)
FFFFFFFF
② Remove the two screws (1) and then remove the
front combination light (3) from the overhead guard
(2).
(3)
(2)
(1)
■ Reinstallation FFFFFFFF
① Install the front combination light (2) on the
overhead guard (1) using the two screws (3).
1.9 - 2.8 N-m {0.2 - 0.3 kgf-m}
[1.4 - 2.1 lbf-ft] (2)
(1)
(3)
FFFFFFFF
② Connect the connector (2) of the front combination
light to the connector (1) of the wire harness on the
overhead guard.
(1)
(2)
FFFFFFFF
2-2
2.1.3 REAR COMBINATION LIGHT
■ Removal
① Remove the rear combination light cover (2) from
the overhead guard (1). (2)
(1)
FFFFFFFF
② Remove the screws (1) and then remove the rear
combination lights (2) from the overhead guard (3). (2)
(1)
(3)
FFFFFFFFF
③ Disconnect the connector of each rear combination
light (2) from the connector of each wire harness (1) (2)
on the overhead guard.
(1)
FFFFFFFFF
2-3
■ Reinstallation
① Connect the connectors of the wire harness (1) on
the overhead guard to the connectors (2) of the rear
combination lights. (2)
(1)
FFFFFFFFF
② Install the rear combination lights (2) on the
overhead guard (1) using the screws (3). (2)
1.9 - 2.8 N-m {0.2 - 0.3 kgf-m} (1)
(3)
[1.4 - 2.1 lbf-ft]
FFFFFFFFF
③ Install the rear combination light cover (2) on the
overhead guard (1). (2)
(1)
FFFFFFFFF
2-4
2.1.4 BATTERY
■ Removal
① Pull the battery connectors (1) apart.
(1)
FFFFFFFFF
② Release the battery hood latch (1) and open the
battery hood. (2)
CAUTION
•• After opening the battery hood, make sure the gas
damper stopper is securely engaged. (1)
•• Use caution not to get your fingers caught in the
battery hood when closing it.
FFFFFFFFF
③ Remove the knob bolts (1) and remove the right and
(2)
left battery side covers (2).
(1)
(2)
FFFFFFFFF
④ Pull apart the wire connector (1) for the battery
(1)
electrolyte level sensor.
FFFFFFFFF
2-5
⑤ Remove the battery lock pin (1). (1)
FFFFFFFFF
FFFFFFFFF
⑧ Before lifting the battery case, make sure there is no
one around the truck except a guide or helper. Lift
the battery case carefully, dismount it toward the
right side of the truck and drop on the ground. (See
Figure 2.21.)
2-6
■ Reinstallation
① Insert the four lifting hooks of a four-leg wire rope
sling into the four lifting eyes of the battery case.
FFFFFFFFF
② Make sure there is no one around the truck except
a guide or helper. Lift the battery case carefully,
mount it from the right side of the truck and put in
place. (See Figure 2.23.)
efer to the step
R of the Removal
procedure.
FFFFFFFFF
③ Attach the battery lock pin (1).
(1)
FFFFFFFFF
④ Connect the male and female wire connectors (1) for
(1)
the battery electrolyte level sensor.
FFFFFFFFF
2-7
⑤ Install the battery’s right and left side covers (1) and (1)
secure them with knob bolts (2).
(2)
(1)
FFFFFFFFF
⑥ Release the battery hood damper and close the
battery hood.
⑦ Lock the battery hood latch (1).
(1)
FFFFFFFFF
(1)
FFFFFFFFF
2-8
2.1.5 CONTROLLER
■ Removal
① Remove the battery from the truck. (Refer to
paragraph 2.1.4 BATTERY.)
② Remove the bolts (1) and caps (2) securing the
(3)
counterweight cover (3) and remove the cover.
(2)
(1)
FFFFFFFFF
③ Pull apart all the wire harness connectors attached to
the controller inside the counterweight.
1.0 - 1.8t
2.0 - 3.5t
FFFFFFFFF
2-9
④ Remove the nuts (1) and then take the controller (3)
away from the counterweight (2). (3)
(2)
(1)
FFFFFFFFF
■ Reinstallation
① Check that the rear side of the controller board
20
which contacts the counterweight is evenly coated
with thermally conductive silicone grease.
K S - 6 0 9 ( S h i n - E t s u C h e m i c a l ) o r
equivalent: 250 g [0.55 lbs]
20
20 20
FFFFFFFFF
② Install the controller (2) to the counterweight (1)
with nuts (3). (2)
(1)
7 .84 - 11.7 N-m {0.80 - 1.19 kgf-m}
[5.78 - 8.63 lbf-ft]
(3)
FFFFFFFFF
2-10
③ Attach all the wire harnesses to the controller.
9.8 N-m {1.0 kgf-m} [7.2 lbf-ft]
1.0 - 1.8t
2.0 - 3.5t
FFFFFFFFF
(4)
(3)
FFFFFFFFF
2-11
2.1.6 PUMP MOTOR
■ Removal
① Pull the battery connectors (1) apart..
② Release the battery hood latch (2) and open the
battery hood.
Make sure the battery hood damper is securely
locked.
(2)
(1)
FFFFFFFFF
③ Remove the knob bolt (1) and detach the battery’s
left-side cover (2).
(2)
(1)
FFFFFFFFF
④ Remove the screws (2) from the left-side frame
cover (1).
⑤ Remove the hole cap (3) and then remove the bolt (4)
(4). (3)
⑥ Remove the left-side frame cover (1). (2)
(1)
FFFFFFFFF
2-12
⑧ Remove the terminal caps (1). Remove the pump
(1) (4)
motor cable PU (2), PV (3) and PW (4). Disconnect
the wire harness connectors (5) from the pump
motor.
(2)
(3)
(5)
FFFFFFFFF
⑨ Remove the four nuts (1) and four spring washers (2).
Remove the pump motor (3) from the frame together (3)
with the bracket (4).
(2) (4)
(1)
FFFFFFFFF
⑩ Remove the four bolts (1) and separate the pump
(1)
motor (3) from the brackets (2).
(3)
(1)
(2)
FFFFFFFFF
2-13
■ Reinstallation
① Attach the brackets (1) to the pump motor (2) with (3)
the bolts (3). (2)
7 .8 - 11.7 N-m {0.8 - 1.2 kgf-m}
[5.8 - 8.6 lbf-ft]
(3)
(1)
FFFFFFFFF
② Install the pump motor and bracket assembly (1) to
the frame with the nuts (2) and spring washers (3). (1)
(3)
(2)
FFFFFFFFF
③ Connect the pump motor cables PU (1), PV (2), and
PW (3) to the pump motor using the washers (4), (7) (3)
spring washers (5) and nuts (6). Attach the terminal (6)
caps (7) to the terminals. Finally connect the wire (5)
harness connectors (8) to the pump motor. (4)
(8)
FFFFFFFFF
2-14
⑤ Attach the left-side frame cover (1) to the frame and
secure it with the screws (2) temporarily.
⑥ Install the bolts (3). Tighten the screws and bolts to (3)
the following torques: (4)
(2)
Screws (2): 3.20 - 4.79 N-m {0.3 - 0.5 kgf-m}
[2.36 - 3.53 lbf-ft]
Bolts (3): 15.6 - 23.4 N-m {1.6 - 2.4 kgf-m}
[11.5 - 17.3 lbf-ft] (1)
(1)
(2)
FFFFFFFFF
⑨ Unlock the battery hood damper and close the
battery hood.
⑩ Lock the battery hood latch (1).
⑪ Connect the battery connector halves (2).
(1)
(2)
FFFFFFFFF
2-15
2.1.7 TRANSFORMER
■ Removal
① Pull the battery connectors (1) apart..
② Release the battery hood latch (2) and open the
battery hood.
Make sure the battery hood damper is securely
locked.
(2)
(1)
FFFFFFFFF
③ Remove the knob bolt (1) and then detach the
battery’s right-side cover (2). (2)
(1)
FFFFFFFFF
④ Remove the screws (2) from the right-side frame (3)
cover (1). (4)
⑤ Remove the hole cap (3) and then take the bolt (4)
away. (2)
FFFFFFFFF
2-16
⑦ Cut the Insulock tie (2) on each of the three insulator (4)
tubes (1) of the transformer. (1)
⑧ Remove the three insulator tubes (1). (2)
⑨ Loosen the nuts (3) and bolts (4) to remove the
cables U (5), V (6) and W (7) from the transformer.
(3)
(5)
(6)
(7)
FFFFFFFFF
(2)
(1)
(5)
(6)
(4) (7)
(9)
(8)
(3)
FFFFFFFFF
(1)
FFFFFFFFF
2-17
■ Reinstallation
① Install the transformer (1) to the right-side frame
with bolts (2).
(1)
1 5.6 - 23.4 N-m {1.6 - 2.4 kgf-m}
[11.5 - 17.3 lbf-ft]
about 37 to 60 kg [81.6 to 132 lbs]
(2)
FFFFFFFFF
② Connect the cables U (3), V (4) and W (5) leading
(1)
from the thermal relays (2) to the transformer (1) (6)
using the bolts (6) and nuts (7). (2)
FFFFFFFFF
The transformer taps need to be changed according to the voltage of the power supply to be used
for battery recharging. (The transformer is factory set for the M tap.)
Tap changing
The power supply voltage may vary depending on the time of day. It is advisable to select the appropriate taps
based on the average voltage of the power supply during the time of day at which normal charge is given.
(2)
FFFFFFFFF
2-18
⑤ With an insulator tube (1) installed on each of the
cables U (3), V (4) and W (5) leading from the (3)
(6)
(4) (1)
rectifier, attach the cables to the transformer (2) (2)
using the bolts (6) and nuts (7). (5)
FFFFFFFFF
⑥ Slide the insulator tube (1) on each cable to cover
(1)
the cable connection with the transformer and secure
with an Insulock tie (2). (2)
FFFFFFFFF
⑦ Install the right-side cover (1) to the frame and (4)
secure it with the screws (2) temporarily. (3)
⑧ Install the bolt (3) and tighten both the bolt and
(2)
screws to the following torques:
(1)
Screws (2): 3.20 - 4.79 N-m {0.3 - 0.5 kgf-m}
[2.36 - 3.53 lbf-ft]
Bolt (3): 15.6 - 23.4 N-m {1.6 - 2.4 kgf-m}
[11.5 - 17.3 lbf-ft]
(2)
FFFFFFFFF
2-19
⑪ Unlock the battery hood damper and close the
battery hood.
⑫ Lock the battery hood latch (1).
⑬ Connect the battery connector halves (2).
(1)
(2)
FFFFFFFFF
2-20
2.2 OVERHEAD GUARD
■ Removal
① Park the truck on a level surface and apply the
parking brake.
(Refer to 1.1.10 Safety rules for maintenance
<Before starting maintenance>.)
(1)
FFFFFFFFF
③ Remove the right and left tilt cylinder covers (1).
④ Remove the right and left resin covers (2) from the (2)
cowling.
(1)
(2)
(1)
FFFFFFFFF
⑤ Pull apart the wire connectors (1) of the head lights
and front combination lights. (1)
FFFFFFFFF
2-21
⑥ Remove the rear combination light cover (1) (1)
⑦ Pull apart the wire connectors (2) of the rear
(2)
combination lights.
FFFFFFFFF
⑧ Remove the bolts (1) securing the ceiling of the
overhead guard to the rear legs. (1)
FFFFFFFFF
⑨ Remove the bolts (1) and washers (2) securing the
front legs to the cowling.
(2)
(1)
FFFFFFFFF
2-22
⑩ Hitch the three lifting hooks of a three-leg wire rope
sling to the three points (A) of the overhead guard A
A
shown in Figure 2.68 and remove the overhead
guard from the frame.
75 kg [165 lbs]
FFFFFFFFF
■ Reinstallation
① Hitch the three lifting hooks of a three-leg wire rope
sling to the three points (A) of the overhead guard A
shown in Figure 2.69 and place the overhead guard A
in position on the frame.
75 kg [165 lbs]
FFFFFFFFF
2-23
② Secure the front legs of the overhead guard to the
cowling temporarily, using the bolts (1) and washers
(2).
(2)
(1)
FFFFFFFFF
③ Secure the overhead guard ceiling to the rear legs
temporarily, using the bolts (1). (1)
FFFFFFFFF
FFFFFFFFF
2-24
⑦ Connect the male and female wire connectors (1) of
each of the head lights and front combination lights. (1)
FFFFFFFFF
⑧ Install the right and left resin covers (1) of the
cowling. (1)
⑨ Install the right and left tilt cylinder covers (2).
(2)
(1)
(2)
FFFFFFFFF
⑩ Connect the battery connector halves (1).
(1)
FFFFFFFFF
2-25
2.3 BATTERY HOOD
■ Removal
① Release the battery hood latch (1).
(1)
FFFFFFFFF
② Open the battery hood (1) and tie it to the rear legs (2)
of the overhead guard with string to prevent it from
closing unexpectedly. (1) (2)
FFFFFFFFF
③ Remove the nut (2) securing the battery hood
damper (1), and remove the battery hood damper.
(2)
(1)
FFFFFFFFF
2-26
⑤ Remove the bolts (1), spring washers (2), washers (3)
(1)
and collars (4) securing the battery hood to the rear (2)
(3)
legs of the overhead guard. (4)
FFFFFFFFF
⑥ Remove the battery hood from the battery case.
FFFFFFFFF
■ Reinstallation
① Put the battery hood on the battery case.
Use caution not to cause a short-circuit.
FFFFFFFFF
FFFFFFFFF
2-27
③ Open the battery hood and tie it to the rear legs of
the overhead guard with string. Install the battery
hood damper (1) with the nut (2).
7 .84 - 11.7 N-m {0.8 - 1.19 kgf-m}
[5.78 - 8.63 lbf-ft] (2)
(1)
FFFFFFFFF
④ Close the battery hood and lock it with the battery
hood latch (1).
(1)
FFFFFFFFF
2-28
2.4 COUNTERWEIGHT
■ Removal
① Disconnect the controller connection cables inside
the counterweight. (Refer to 2.1.5 CONTROLLER.)
After pulling the battery connector apart, wait
for more than 2 minutes before trying to remove
the counterweight. This will help prevent electric
shocks.
FFFFFFFFF
② Pass a wire rope (2) under the lifting bar (A) in the
counterweight (1) and hang both ends of the wire
(2)
rope on the crane hook.
A
(1)
FFFFFFFFF
③ Remove the bolts (1), spring washers (2), and
washers (3) securing the counterweight.
(1)
(2)
(3)
FFFFFFFFF
2-29
④ Hoist the counterweight (1) to remove it from the
frame (2).
kg [lbs]
1.0 t 550 [1210] (1)
FFFFFFFFF
■ Reinstallation
① Hoist the counterweight (1). Align the parts B on
the frame with the holes in the counterweight and
put the counterweight in place on the rear part of the
frame (2). (1)
kg [ lbs]
B
1.0 t 550 [1210]
2.0 t 750 [1650] (2)
2.5 t 1100 [2430]
3.0 t, 3.5 t 1170 [2580] B
FB25-8LB 850 [1870]
FFFFFFFFF
FFFFFFFFF
③ Connect the male and female wire connectors of the
controller inside the counterweight.
(Refer to 2.1.5 CONTROLLER.)
2-30
2.5 COWLING
■ Removal
① Remove the overhead guard.
(Refer to 2.2 OVERHEAD GUARD.)
② Pull the accelerator coupler (1) apart.
Note: The coupler is a lockable type. Unlock it before
pulling apart.
Lock
䝻䝑䜽
(1)
FFFFFFFFF
③ Remove the floor mat (1) and floor board (2).
(1)
(2)
FFFFFFFFF
(2)
(1)
FFFFFFFFF
2-31
⑥ Remove the resin covers (1) from the cowling.
(1)
(1)
FFFFFFFFF
(1)
FFFFFFFFF
⑧ Remove the bolts (1) and then remove the parking
brake lever (2) from the cowling.
(2)
(1)
FFFFFFFFF
2-32
⑩ Loosen the clamp (2) securing the brake oil reservoir
tank (1) and remove the brake oil reservoir tank. (1)
Note: Remove the tank with brake oil in it. (2)
FFFFFFFFF
⑪ Remove the bolts (1) and then remove the valve
levers (2).
(1) (2)
FFFFFFFFF
30 kg [66 lbs]
(2)
(1)
FFFFFFFFF
2-33
■ Reinstallation
① Hoist the cowling (1) and put it in place on the front (1)
part of the frame. (4)
30 kg [66 lbs]
② Secure the cowling (1) to the front plate (1) using
the bolts (3) and (4).
Tightening torque of bolts (3): (4)
27.5 - 41.4 N-m {2.8 - 4.2 kgf-m} [20.3 - 30.5lbf-ft] (3)
FFFFFFFFFF
FFFFFFFFFF
⑤ Install the valve levers (1) to the cowling using the
bolts (1).
7 .84 - 11.7 N-m {0.8 - 1.19 kgf-m} (2) (1)
[5.78 - 8.63 lbf-ft]
FFFFFFFFFF
2-34
⑥ Install the parking brake lever (1) to the cowling
using the bolts (2).
5.6 - 23.4 N-m {1.6 - 2.4 kgf-m}
1
[11.5 - 17.3 lbf-ft] (1)
(2)
FFFFFFFFFF
⑦ Connect the male and female connectors of the
parking brake switch wire harness (1).
(1)
FFFFFFFFFF
⑧ Install the resin covers (1) to the cowling.
(1)
(1)
(1)
FFFFFFFFFF
2-35
⑨ Connect the male and female connectors of the
cowling wire harness (1) and the frame wire harness
(2).
(2)
(1)
FFFFFFFFFF
(2)
FFFFFFFFFF
⑫ Connect the accelerator coupler halves (1).
(1)
FFFFFFFFFF
2-36
2.6 B
RAKE PEDAL AND BRAKE
MASTER CYLINDER
■ Removal
① Pull the accelerator coupler (1) apart.
Note: The coupler is a lockable type. Unlock it before
pulling apart
䝻䝑䜽
(1)
FFFFFFFFFF
② Remove the floor mat (1) and floor board (2).
(1)
(2)
FFFFFFFFFF
③ Remove the resin covers (1).
(1)
(1)
(1)
(1)
FFFFFFFFFF
2-37
④ Loosen the clamp (2) and remove the brake oil
reservoir tank (1). Empty the tank. (1)
(2)
FFFFFFFFFF
⑤ Remove the brake pipes (2) from the brake master
cylinder (1). (2)
(1)
(2)
(2)
FFFFFFFFFF
⑥ Remove the cotter pin (1) and washer (2). Remove (3)
the pin (3).
(2)
(1)
FFFFFFFFFF
2-38
⑦ Remove the bolts (1) and nuts (2). Remove the brake
master cylinder (3) from the cowling.
(1)
(3)
(2)
FFFFFFFFFF
⑧ Remove the bolt (1). Pull the shaft (2) out and
remove the brake pedal (3) from the cowling.
(2)
(1)
(3)
FFFFFFFFFF
2-39
■ Reinstallation
① Install the brake pedal (1) to the cowling. Install the (3)
shaft (2).
Note: Apply a thin coat of grease on the bushings of the
brake pedal (1) before installing the shaft. (2)
(3)
(1)
FFFFFFFFFF
② Secure the brake pedal with the bolt (1).
3.20 - 4.79 N-m {0.3 - 0.5 kgf-m}
[2.36 - 3.53 lbf-ft]
(1)
FFFFFFFFFF
③ Secure the brake oil reservoir tank (1) in the clamp
(2). (1)
(2)
FFFFFFFFFF
2-40
④ Install the brake master cylinder (1) to the cowling
using the bolts (2) and nuts (3).
5.6 - 23.4 N-m {1.6 - 2.4 kgf-m}
1
[11.5 - 17.3 lbf-ft]
(2)
(1)
(3)
FFFFFFFFFF
⑤ Connect the brake master cylinder (1) to the brake (3)
pedal (2) using the pin (3).
Secure them with the washer (4) and cotter pin (5). (4)
(2) (5)
(1)
FFFFFFFFFF
⑥ Connect the brake pipes (2) to the brake master
(2)
cylinder (1).
(1)
(2)
(2)
FFFFFFFFFF
⑦ Bleed air out of the brake unit and add brake oil into
the brake unit and brake oil reservoir tank.
2-41
⑧ Install the resin covers (1). (1)
(1)
(1)
(1)
FFFFFFFFFF
⑨ Install the floorboard (1) and floor mat (2) in place.
(2)
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
2-42
2.7 DRIVE MOTOR AND DRIVE UNIT
■ Removal
① Jack up the front of the truck and place jack stands (1)
under the truck.
Block the rear wheels with blocks (2).
(1) (2)
FFFFFFFFFF
(1)
(3)
(2)
FFFFFFFFFF
⑧ Remove the bolts (1) and then detach the front plate
(1)
(2) from the frame together with the control valve
(3).
(2)
(3)
(1)
FFFFFFFFFF
2-43
⑨ Disconnect the brake pipe (1) at each of the wheel
brakes (2).
(1)
(2)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
⑪ Remove the terminal caps (1) and disconnect the (2)
(3)
drive motor cables DU (2), DV (3) and DW (4) from
the drive motor. (1)
(4)
FFFFFFFFFF
⑫ Remove the drive motor thermo-sensor coupler and
rotation sensor coupler.
⑬ Remove the drive unit mount bolts (1), spring
washers (2) and washers (3). (1)
(2)
(3)
FFFFFFFFFF
2-44
⑭ Detach the axle support caps (3) by removing the
bolts (1) and spring washers (2).
(2)
(1)
(2)
(1)
(3)
(3)
FFFFFFFFFF
FFFFFFFFFF
■ Reinstallation
① Hoist the drive motor, drive unit and drive axle as
one unit and carefully lower them in place on the
frame.
350 kg [771.6 lbs]
FFFFFFFFFF
2-45
② Install the axle support caps (1) using the bolts (2)
and spring washers (3).
1.0 - 2.5 ton trucks: (3)
(2)
49 - 74 N-m {5 - 7.5 kgf-m} [36.1 - 54.6 lbf-ft]
3.0 - 3.5 ton trucks:
77 - 115 N-m {7.85 - 11.7 kgf-m} [56.8 - 84.8 lbf-ft] (3)
(2)
(1)
(1)
FFFFFFFFFF
③ Install the drive unit (1) on the frame, using the drive
(1)
unit mount bolts (2), spring washers (3) and washers (2)
(4).
(3)
2 78 - 416 N-m {28.3 - 42.4 kgf-m}
(4)
[205.0 - 306.8 lbf-ft]
Apply LOCTITE #262.
FFFFFFFFFF
④ Connect the drive motor thermo-sensor coupler and
rotation sensor coupler (identified with red tape) to
the drive motor.
⑤ Connect the cables DU (1), DV (2), and DW (3) to
(2) (1)
the drive motor, and then install the terminal caps (4).
(4)
(3)
FFFFFFFFFF
⑥ Connect the parking brake cables (2) to the brake
lever (1).
(1)
(2)
FFFFFFFFFF
2-46
⑦ Connect the brake pipe (2) to each of the wheel
brakes (1).
(2)
(1)
FFFFFFFFFF
⑧ Install the front plate (1) to the frame using the bolts
(2)
(2).
53 - 229 N-m {15.6 - 23.4 kgf-m}
1
[112.9 - 168.9 lbf-ft]
(1)
(2)
FFFFFFFFFF
⑨ Install the tilt cylinder pipe (2) to the front plate (1) (2) (4)
using the bolts (3) and clamps (4).
(3)
(1)
(4)
FFFFFFFFFF
2-47
2.8 DRIVE AXLE
■ Removal
① Jack up the front of the truck and rest the truck on
jack stands (1). Block the rear wheels with blocks (2).
(1) (2)
FFFFFFFFFF
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
2-48
⑦ Remove the under-plate (1).
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
⑨ Holding the drive unit side, remove the bolts (1) and
washers (2) securing the drive axle to the drive unit.
(1)
(2)
FFFFFFFFFF
FFFFFFFFFF
2-49
⑪ Remove the support caps (1) from the frame and
then remove the drive axle (2). (2)
150 kg [331 lbs]
(1)
FFFFFFFFFF
■ Reinstallation
① Place the drive axle (1) in position to the frame.
② With the gasket (2), install the drive axle (1) to the
drive unit (3).
1.0 - 2.5 ton trucks:
8.8T M10 45 - 68 N-m {4.6 - 6.9 kgf-m}
[33.2 - 50.2 lbf-ft]
3.0 – 3.5 ton trucks:
(3)
8.8T M12 84 - 126 N-m {8.6 - 12.8 kgf-m}
(2)
[62.0 - 92.9 lbf-ft] (1)
FFFFFFFFFF
FFFFFFFFFF
[1.0 – 1.8 ton and 3.0 – 3.5 ton trucks]
④ With a new gasket (1), install the axle shaft (2) into
the drive axle.
9 6 - 111 N-m {9.8 - 11.3 kgf-m}
[70.8 - 81.9 lbf-ft]
(1)
Apply LOCTITE #262.
2-50
⑤ Install the brake pipe (1) to each of the wheel brakes.
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
2-51
2.9 STEERING AXLE
2.9.1 STEERING AXLE (ORBITROL TYPE)
■ Removal
① Jack up the rear wheels and place jack stands (1)
under the truck.
Block the front wheels with blocks (2).
(2) (1)
FFFFFFFFFF
(2)
FFFFFFFFFF
FFFFFFFFFF
2-52
⑥ Place a garage jack under the steering axle (1) and
remove the bolts (3) and spring washers (4) securing (2) (1)
the axle supports (2).
(4)
(3)
FFFFFFFFFF
(1)
FFFFFFFFFF
■ Reinstallation
① Put the steering axle (1) on the garage jack, and (2)
place it in the installation “ready” position on the (1)
frame (2).
FFFFFFFFFF
2-53
③ Install the front and rear axle supports (1) to the
frame using the bolts (2) and spring washers (3) to (1) (4)
secure the steering axle (4) in position.
1.0 - 1.8 ton trucks:
44 - 65 N-m {4.5 - 6.6 kgf-m} [32.5 - 47.9 lbf-ft]
2.0 - 3.5 ton trucks:
68 - 100 N-m {6.9 - 10.2 kgf-m} [50.2 - 73.8 lbf-ft] (3)
Apply LOCKTITE #262.
(2)
FFFFFFFFFF
FFFFFFFFFF
(2)
FFFFFFFFFF
2-54
2.9.2 STEERING AXLE (EPS TYPE)
■ Removal
① Jack up the rear wheels and place jack stands (1)
under the truck.
Block the front wheels with blocks (2).
(2) (1)
FFFFFFFFFF
④ Remove the ball joint (3) from the center arm (1) at (1)
the side of the EPS actuator (2).
(2)
(3)
FFFFFFFFFF
⑤ Remove the ball joint (3) from the center arm (1) at
the side of the drag link (2). (1)
(3)
(2)
FFFFFFFFFF
2-55
⑥ Pull the steering wire harness connectors (1) apart
and remove the clamp (2).
(1)
(2)
FFFFFFFFFF
(4)
(3)
FFFFFFFFFF
FFFFFFFFFF
2-56
■ Reinstallation
① Put the steering axle (1) on the garage jack, and (2)
place it in the installation “ready” position on the (1)
frame (2).
FFFFFFFFFF
FFFFFFFFFF
FFFFFFFFFF
2-57
⑤ Install the ball joint (3) to the center arm (1) at the
drag link (2) side. (1)
(3)
(2)
FFFFFFFFFF
⑥ Install the ball joint (3) to the center arm (1) at the (1)
EPS actuator (2) side.
1 57 - 196 N-m {16.0 - 20.0 kgf-m}
[115.8 - 144.6 lbf-ft]
(2)
(3)
FFFFFFFFFF
⑦ Install the counterweight on the truck.
(Refer to 2.4 COUNTERWEIGHT.)
⑧ Install the wheel to each end of the steering axle.
2-58
2.10 STEERING WHEEL
■ Removal
① Remove the screws (1), (2) and (3) to detach the
cover A (4).
(6) (4)
② Remove the bolts (5) and displace the cover B
(1)
(6) and cover C (7) assembly toward the cowling (2)
(without disconnecting the wire harness connectors).
(5)
(7) (3)
FFFFFFFFFF
③ Disconnect the wire harness connectors (3) from the
(2)
instrument panel (1) and key switch (2).
(1)
(3)
FFFFFFFFFF
④ Disconnect the wire harness connectors from the
turn signal and lighting switch assembly (1).
(1)
(2)
FFFFFFFFFF
⑤ Remove the bolt (1) and washer (2) to detach the
steering wheel lock lever (3).
(3)
(2)
(1)
FFFFFFFFFF
2-59
⑥ Remove the lock bolt (1) and washer (2).
(2)
(1)
FFFFFFFFFF
(3)
(2)
(1)
FFFFFFFFFF
■ Reinstallation
① Install the universal joint (1) onto the splined shaft (2)
of the steering gear box.
Install the steering wheel assembly (5) to the (5)
cowling (6) using the bushing (3) and bolt (4).
21.2 N-m {2.16 kgf-m} [15.6 lbf-ft]
(6)
(3)
(4)
(1)
(2)
FFFFFFFFFF
2-60
② Install the lock bolt (1) and washer (2).
39.1 N-m {4.0 kgf-m} [28.8 lbf-ft]
(2)
(1)
FFFFFFFFFF
③ Attach the handle lock lever (2) to the lock bolt (1)
and secure with the washer (3) and bolt (4).
5.6 - 23.4 N-m {1.6 - 2.4 kgf-m}
1
[11.5 - 17.3 lbf-ft]
(1)
(2)
(3)
(4)
FFFFFFFFFF
(2)
FFFFFFFFFF
(2)
⑤ Connect the wire harness connectors (3) to the
(1)
instrument panel (1) and key switch (2).
(3)
FFFFFFFFFF
2-61
⑥ Install the cover B and cover C assembly (2) to the
steering wheel column (1) using the bolts (3).
(2) (1) (4)
⑦ Install the cover A (4) to the steering wheel column
(5)
using the screws (5), (6) and (7). (6)
(3)
(7)
FFFFFFFFFF
2-62
2.11 TILT CYLINDERS
■ Removal
① Remove the tilt cylinder cover (1) from each of the
tilt cylinders.
(1)
FFFFFFFFFF
② Disconnect the hoses (2) from each tilt cylinder (1). (2)
Before disconnecting the hoses, remove the residual
pressure completely from inside the tilt cylinder.
Caution must be taken when removing the hoses.
The oil may spurt.
(1)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
2-63
④ Remove the bolt (1) and take out the connecting pin
(2) at the frame side to remove the tilt cylinder (3)
from the frame.
(2)
(1)
(3)
FFFFFFFFFF
■ Reinstallation
① Make sure the oil ports (1) on each of the tilt
cylinders are pointed inside.
Place the tilt cylinders (2) in the installation “ready” (1)
position.
(2) (1)
FFFFFFFFFF
② Insert the connecting pin (1) into the hole in the end
of each tilt cylinder at the frame side and secure with
the bolt (2).
1 7.1 - 25.4 N-m {1.74 - 2.59 kgf-m} (1)
[12.6 - 18.7 lbf-ft] (2)
FFFFFFFFFF
③ Insert the connecting pin (1) into the hole in the end
of each tilt cylinder at the mast side and secure with
the bolt (2).
1 7.1 - 25.4 N-m {1.74 - 2.59 kgf-m}
[12.6 - 18.7 lbf-ft]
(1)
(2)
FFFFFFFFFF
2-64
④ connect the hydraulic hoses (2) to each of the tilt (2)
cylinders (1).
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
2-65
2.12 MAIN PUMP
■ Removal
① Drain the oil tank.
② Remove the screws (2) from the left-side frame
cover (1).
③ Remove the hole cap (3) and take the bolt (4) out. (4)
④ Remove the left-side frame cover (1). (3)
(2)
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
FFFFFFFFFF
2-66
⑦ Remove the bolts (1) securing the main pump to (3)
detach separate the main pump (2) from the pump
motor (3).
(1)
(2)
FFFFFFFFFF
■ Reinstallation
① Engage the main pump (1) onto the splined parts of (2)
the pump motor (2) and secure with the bolts (3).
7.1 - 25.4 N-m {1.74 - 2.59 kgf-m}
1
[12.6 - 18.7 lbf-ft] (3)
Note: T h e s p l i n e d p a r t s s h o u l d b e c o a t e d w i t h
molybdenum grease.
(1)
FFFFFFFFFF
② Connect the hose (1) leading from the oil tank to the
main pump (2).
(2)
(1)
FFFFFFFFFF
FFFFFFFFFF
2-67
④ Install the left-side frame cover (1) to the frame and
secure with the screws (2) temporarily.
⑤ Install the bolt (3) and tighten the screws and bolt to (3)
the following torques: (4)
(2)
Screws (2): 3.20 - 4.79 N-m {0.3 - 0.5 kgf-m}
[2.4 - 3.5 lbf-ft]
Bolt (3): 15.6 - 23.4 N-m {1.6 - 2.4 kgf-m}
[11.5 - 17.3 lbf-ft] (1)
⑥ Install the hole cap (4).
FFFFFFFFFF
2-68
2.13 CONTROL VALVE
■ Removal
① Remove the pin (1), washer (2), and cotter pin (3) to
detach the rod (4) from each spool.
(4) (3)
(2)
(1)
FFFFFFFFFF
(2)
(2)
FFFFFFFFFF
(1)
(2)
(2)
FFFFFFFFFF
2-69
④ Remove the bolts (1) and then detach the control
valve (3) from the front plate (2).
(3)
(1)
(2)
FFFFFFFFFF
■ Reinstallation
① Install the control valve (1) to the front plate (2) with
the bolts (3).
2 7.7 - 41.5 N-m {2.8 - 4.2 kgf-m} (1)
[20.4 - 30.6 lbf-ft]
Apply LOCTITE #262 or Scotch-Grip 2352 to
the threaded part of the bolts (3). (3)
(2)
FFFFFFFFFF
(2)
A1 (2)
FFFFFFFFFF
2-70
③ Connect the wire harness connectors (2) to the
control valve (1).
(1)
(2)
(2)
FFFFFFFFFF
FFFFFFFFFF
2-71
2.14 MAST ASSEMBLY
■ Removal
① Lightly hold the upper connecting member of the
outer mast channel with a crane.
② Remove the bolt (1) of each of the tilt cylinders (2)
and detach the mast-side connecting pin (3) of the
tilt cylinder (2).
(2)
(3)
(1)
FFFFFFFFFF
③ Disconnect the hoses (2) from the lift cylinders (1).
(1)
(2)
(1)
(2)
FFFFFFFFFF
(2)
(1)
(3)
FFFFFFFFFF
2-72
⑤ Hoist the mast using a crane to remove it from the
truck.
1.0 - 1.8 t 400 kg [882 lbs]
2.0 - 2.5 t 600 kg [1323 lbs]
3.0 - 3.5 t 800 kg [1764 lbs]
(The above figures are given for cases when hoisting
a standard mast of a lifting height of 3 m without a
lift carriage.)
■ Reinstallation
① Hoist the mast and fit the mast supports (1) into the
grooves in the drive axle (2) with bushings (3).
(1)
1.0 - 1.8 t 400 kg [882 lbs]
(2)
2.0 - 2.5 t 600 kg [1323 lbs]
3.0 - 3.5 t 800 kg [1764 lbs]
(The above figures are given for cases when hoisting
a standard mast of a lifting height of 3 m without a
lift carriage.)
Note: Apply grease to the bushings before installation. (3)
FFFFFFFFFF
② Install the mast support cap (1) and secure with the
bolts (2) and spring washers (3).
53 - 229 N-m {15.6 - 23.4 kgf-m}
1
[112.9 - 168.9 lbf-ft]
(3)
(2)
(1)
FFFFFFFFFF
③ Install the tilt cylinders (1) with the connecting pins
(2) and secure with the bolts (3).
7.1 - 25.4 N-m {1.74 - 2.59 kgf-m}
1
[12.6 - 18.7 lbf-ft]
(1)
(2)
(3)
FFFFFFFFFF
④ Remove the crane.
2-73
⑤ Connect the hoses (2) to the lift cylinders (1).
(1)
(2)
(1)
(2)
FFFFFFFFFF
2-74
3. DISASSEMBLY AND REASSEMBLY
■ Disassembly
① Remove the pushrod (1) and boot (2) from the brake
master cylinder.
(1)
(2)
FFFFFFFF
② Remove the snap ring (1) and then take the piston (1)
assembly (3), spring (4), and check valve (5) out of
the cylinder body (2).
Note: Use caution not to get injured because the parts
might pop out due to spring pressure. (2)
(3)
(4)
(5)
FFFFFFFF
(4)
(5)
(3)
(2) (1)
FFFFFFFF
3-1
■ Reassembly
① Install the spacer (2), primary cup (3), thimble (4)
and secondary cups (5) to the piston (1).
Note: Fill the clearance between the piston and the
(5)
secondary cup, and the groove (a) with rubber (3) (2)
(4)
grease.
(1)
(a)
FFFFFFFF
② Insert the check valve (2), spring (3) and piston (5)
assembly (4) into the cylinder body (1) in that order,
and then secure them with the snap ring (5).
(1)
(4)
(3)
(2)
FFFFFFFF
(1)
FFFFFFFF
3-2
3.2 DRIVE UNIT
Caution in disassembling and reassembling the drive unit
•• Use a workbench, a crane, bearing pullers and lifting hooks to disassemble the drive unit safely and efficiently.
•• Keep all parts in order as you disassemble so that they can be reinstalled correctly and efficiently.
Tag all the gears and shafts for proper reassembly.
•• The drive unit may vary slightly with different truck models.
FFFFFFFF
FFFFFFFF
3-3
③ Using a bearing puller, remove the two bearings (2)
from the cross-case assembly (1). (1)
(2)
(2)
FFFFFFFF
④ Remove the bolts (1) and nuts (2) and detach the
ring gear (3) from the cross case.
(3)
(1)
(2)
FFFFFFFFF
⑤ Remove the tapered pin (1) and then take the pinion
shaft (2) out of the cross case.
(2)
(1)
FFFFFFFFF
3-4
⑥ Rotate the gears inside the cross case (1) and then
remove the thrust washers (2) and pinion gears (3) (1)
through an opening of the cross case.
(2)
(3)
(3)
(2)
FFFFFFFFF
⑦ Remove the side gears (2) and thrust washers (3) (1)
from the cross case (1).
(3)
(2)
(3)
(2)
FFFFFFFFF
(2)
(4)
FFFFFFFFF
3-5
② Put the rear case (5) on a work bench with the cover
side downward. Remove the bolts (1) and (2) and
washers (3) and (4). Hoist the rear case (5) with a
crane to remove it from the cover.
about 29 kg [63.9 lbs]
(5) (3)
(1)
(4)
(2)
FFFFFFFFF
(2)
(1)
FFFFFFFFF
④ Remove the bolts (1) and key plate (2) and then pull
the shaft (3) out of the cover. Remove the O-ring (4)
from the shaft (3).
(2)
(3)
(1)
(4)
(4)
FFFFFFFFF
3-6
⑤ Remove the input gear assembly (2) and the R
(3) (2)
counter gear assembly (3) from the cover (1).
Note: The R counter gear assembly is interference with
the input gear assembly.
The procedure at step ④ releases the lock between
them. Rock the R counter gear assembly slightly
to detach it from the input gear assembly.
(1)
FFFFFFFFF
(2) (3)
FFFFFFFFF
(2) (2)
FFFFFFFFF
(2)
(2)
FFFFFFFFF
3-7
■ Reassembly
Note:
•• Replace all the O-rings with new ones.
•• Apply a small amount of grease to O-rings before installing. Use caution not to give damage to them when
installing.
(2)
(2)
FFFFFFFFF
(2) (2)
FFFFFFFFF
(2) (3)
FFFFFFFFF
3-8
④ Put the R counter gear assembly (2) in place in the
cover (1) and install the input gear assembly (3) in (2) (3)
the cover.
(1)
FFFFFFFFF
(1) (3)
(4)
FFFFFFFFF
⑥ Place the key plate (1) into the key groove in the
shaft (2) and secure with the bolt (3). Install a new (4)
O-ring (4) onto the rear case-side end of the shaft (2).
(2) (1)
(3)
FFFFFFFFF
3-9
⑦ Install the F counter gear assembly (2) into the cover
(1).
(2)
(1)
FFFFFFFFF
⑧ Install the rear case (2) to the cover (1) using the
bolts (3) and (4) and washers (5) and (6) and tighten
to the specified torque:
(1)
68 - 88 N-m {6.9 - 9.0 kgf-m}
[50.2 - 64.9 lbf-ft]
Note: Apply ThreeBond #1208D to the mating surfaces
of the cover and the rear case before assembling.
(2) (5)
(3)
(6)
(4)
FFFFFFFFF
⑨ With a new O-ring (2) on the bearing case (3), install (4) (3)
the bearing case to the rear case (1) using the bolts (4)
and washers (5).
(1)
34 - 44 N-m {3.5 - 4.5 kgf-m}
[25.1 - 32.5 lbf-ft] (5)
(2)
FFFFFFFFF
3-10
(2) Reassembling the differential
① Put the thrust washers (2) and side gears (3) in place (1)
in the cross case (1).
(2)
(3)
(2)
(3)
FFFFFFFFF
FFFFFFFFF
③ Insert the pinion shaft (1) into the cross case and
secure with the tapered pin (2).
(1)
(2)
FFFFFFFFF
3-11
④ Install the ring gear (2) onto the cross case (1) using
the bolts (3) and nuts (4). (2)
44 - 54 N-m {4.5 - 5.5 kgf-m} (3)
(4)
FFFFFFFFF
(2)
(2)
FFFFFFFFF
⑥ Put the cross case assembly (2) into the rear case
(1) in place and secure with the bearing caps (3) and (3) (4)
bolts (4).
95 - 142 N-m {9.7 - 14.5 kgf-m}
[70.1 - 104.7 lbf-ft]
Note: Apply LOCTITE #270 to the threads of each bolt
before installing. (2)
(1)
FFFFFFFFF
3-12
3.2.2 DRIVE UNIT (2.0 - 3.5 ton trucks)
■ Disassembly
(1) Disassembling the differential
① Place the drive unit on a work bench with the
flanged half of the differential case pointed upward, (2) (1)
and secure it to the work bench.
Remove the bolts (1) and then remove the bearing
caps (2) from the differential case.
FFFFFFFFF
(1)
FFFFFFFFF
(2)
(2)
FFFFFFFFF
3-13
④ <<2.0 - 2.5 ton trucks>>
(1)
Remove the bolts (1) and nuts (2) and detach the
ring gear (3) from the cross case.
(3)
(2)
FFFFFFFFF
(2)
(1)
FFFFFFFFF
(3)
(4)
(1)
FFFFFFFFF
3-14
⑥ Take the pinion gear assembly out of the cross case (2) (2)
half R and remove the thrust washers (2) and pinion
(1)
gears (3) from the spider (1).
(3) (3)
(2) (2)
FFFFFFFFF
⑦ Remove the side gear (2) and thrust washer (3) from
the cross case half R (1). (2)
(3)
(1)
FFFFFFFFF
(5)
FFFFFFFFF
3-15
② Remove the bearing case assembly (2) from the rear
case (1). (2)
(1)
FFFFFFFFF
(3)
FFFFFFFFF
(1)
(4)
(2)
FFFFFFFFF
3-16
⑤ Remove the F counter gear assembly (2) from the
cover (1).
(2)
(1)
FFFFFFFFF
⑥ Remove the bolts (1) and key plate (2) and then pull
the shaft (3) out of the cover. Remove the O-ring (4)
from the shaft (3).
(2)
(3)
(1)
(4)
(4)
FFFFFFFFF
(1)
FFFFFFFFF
3-17
⑧ Using a bearing puller, remove the bearing cones
(2) and (3) from both sides of the F counter gear (1)
assembly (1).
(2)
(3)
FFFFFFFFF
(2) (2)
FFFFFFFFF
(2)
(2)
FFFFFFFFF
(3)
(1)
FFFFFFFFF
3-18
■ Reassembly
Note:
•• Replace all the O-rings with new ones.
•• Apply a small amount of grease to O-rings before installing. Use caution not to give damage to them when
installing.
(2)
(1)
FFFFFFFFF
(2)
(2)
FFFFFFFFF
(2) (2)
FFFFFFFFF
3-19
④ Using a press, install the bearing cones (2) and (3) to
the F counter gear (1). (1)
(2)
(3)
FFFFFFFFF
(1)
FFFFFFFFF
(1) (3)
(4)
FFFFFFFFF
3-20
⑦ Place the key plate (1) into the key groove in the
shaft (2) and secure with the bolt (3). Install a new (4)
O-ring (4) onto the rear case-side end of the shaft (2).
(2) (1)
(3)
FFFFFFFFF
(2)
(1)
FFFFFFFFF
⑨ Install the rear case (2) to the cover (1) using the
bolts (3) and (4) and washers (5) and (6) and tighten
to the specified torque:
(1)
68 - 88 N-m {6.9 - 9.0 kgf-m}
[50.2 - 64.9 lbf-ft]
Note: Apply ThreeBond #1216E to the mating surfaces
of the cover and the rear case before assembling. (2) (5)
(3)
(6)
(4)
FFFFFFFFF
3-21
⑩ Install the bearing cup (2), spacer (3) and a new
O-ring (4) to the bearing case (1). (3) (1)
(4)
(2)
FFFFFFFFF
(1)
FFFFFFFFF
(1)
FFFFFFFFF
(2) Reassembling the differential
① Install the thrust washer (2) and the side gear (3)
into the cross case half R (1). (3)
(2)
(1)
FFFFFFFFF
3-22
② Install the pinion gears (2) and the thrust washers (3) (3) (3)
to the spider (1).
(1)
(2) (2)
(3) (3)
FFFFFFFFF
(1)
FFFFFFFFF
④ Install the side gear (2) and thrust washer (3) onto
the pinion gear assembly (1). (3)
(2)
(1)
FFFFFFFFF
3-23
⑤ <<2.0 - 2.5 ton trucks>>
(3)
Put the cross case half L (1) on the cross case half R.
Install the ring gear (2) using the bolts (3) and nuts
(4), and tighten to the specified torque.
(2)
44 - 54 N-m {4.5 - 5.5 kgf-m}
[32.5 - 39.8 lbf-ft]
Note: Apply LOCTITE #270 to the threads of each bolt
before installing.
(1)
(4)
FFFFFFFFF
(2)
(3)
FFFFFFFFF
(2)
(2)
FFFFFFFFF
3-24
⑦ Put the cross case assembly (2) in place in the rear
case (1) and secure with the bearing caps (3) and (3) (4)
bolts (4).
95 - 142 N-m {9.7 - 14.5 kgf-m}
[70.1 - 104.7 lbf-ft]
Note: Apply LOCTITE #270 to the threads of each bolt
before installing. (2)
(1)
FFFFFFFFF
(4) (2)
(1)
(5)
(3)
FFFFFFFFF
3-25
3.3 DRIVE AXLE
The cup and cone of each tapered roller bearing are in a matched set and need to be reinstalled in
the same pair. The disassembled tapered roller bearings should be kept as matched sets.
■ Disassembly
① Straighten the tabs on the lock washer (1) and
remove the lock nut (2) and lock washer (1).
(1)
(2)
FFFFFFFFF
② Remove the adjust nut (1) and the washer (2).
(2)
(1)
FFFFFFFFF
③ Using a bearing puller, remove the hub and drum
assembly (1) and bearing cone (2).
Remove the oil seal (3) from the detached bearing
cone (2).
about 17 kg [37.5 lbs] (1.0 - 1.8 ton)
(1)
about 22 kg [48.5 lbs] (2.0 - 2.5 ton)
about 31 kg [68.3 lbs] (3.0 - 3.5 ton)
Note: The weight of the hub varies with different truck
models.
Use a crane to remove the hub and drum assembly (2)
for safety’s sake. (3)
FFFFFFFFF
3-26
④ Remove the bearing cups (2) and (3) from the hub
and drum assembly (1). (1)
(2) (3)
FFFFFFFFF
(4)
(3)
(2)
(1)
FFFFFFFFF
(3)
(2)
FFFFFFFFF
3-27
<<3.0 - 3.5 ton trucks>>
Remove the nuts (1) and stud bolts (2) to separate (1)
the hub (3) from the drum (4).
(3)
(4) (2)
FFFFFFFFF
(3)
(1)
(2)
FFFFFFFFF
■ Inspection
For the procedure for inspecting the brake drum, refer to “Inspection” in “3.4 WHEEL BRAKE.”
3-28
■ Reassembly
Notes:
•• Replace the old seals with new ones.
•• When installing a new seal, apply a small amount of grease to its lip and use caution not to fit it the wrong way
round.
• Apply grease to the sliding part of bearings and pins before reinstalling.
•
•• The cup and cone of each tapered roller bearing are in a matched set and need to be reinstalled in the same pair.
FFFFFFFFF
FFFFFFFFF
3-29
<<3.0 - 3.5 ton trucks>>
Install the stud bolts (2) into the hub (1). Attach the (4)
drum (3) to the hub and secure with the nuts (4).
470 - 550 N-m {48 - 56 kgf-m} (1)
[346.7 - 405.7 lbf-ft]
(3) (2)
FFFFFFFFF
③ Install the bearing cups (2) and (3) to the hub and
drum assembly (1). (1)
(2) (3)
FFFFFFFFF
④ Install the bearing cone (2), oil seal (3) and retainer
(4) to the hub and drum assembly (1).
Note: Before installing, apply LOCTITE #575 to the (1)
(3)
oil seal at the hub side and to the retainer at the
(4)
spindle side (1.0 - 1.8 ton trucks and 3.0 - 3.5 ton
trucks). (2)
Apply LOCTITE #565 to the oil seal at the hub
side and to the retainer at the spindle side (2.0 - 2.5
ton trucks).
Use caution not to fit the oil seal the wrong way
round; otherwise there is a danger of grease FFFFFFFFF
leaking.
3-30
⑤ Install the hub and drum assembly onto the spindle
of the axle (1). Fill the space (a) 50% full with
(1)
grease:
(2)
about 100 cc (1.0 - 1.8 ton trucks)
about 30 cc (2.0 - 2.5 ton trucks)
about 100 cc (3.0 - 3.5 ton trucks)
(a)
FFFFFFFFF
⑥ Install the oil seal (2) to the bearing cone (1) and
then fit the bearing cone onto the spindle.
Use caution not to fit the oil seal the wrong way
round; otherwise there is a danger of grease
leaking.
(1)
(2)
FFFFFFFFF
3-31
⑧ Install the lock washer (1) and lock nut (2) to the
hub and bend the tabs on the lock washer (1) over
the nut.
(1)
(2)
FFFFFFFFF
3-32
3.4 WHEEL BRAKE
Note: The wheel brake can be disassembled, reassembled or inspected with the wheel brake mounted on the
axle housing.
■ Disassembly
① Remove the hold pins (1) from the primary and
secondary sides of the wheel brake unit. Remove the
cups (2) and springs (3). (1)
(2)
(3)
(2)
FFFFFFFFF
(1)
FFFFFFFFF
(1)
FFFFFFFFF
3-33
④ Remove the adjuster lever (1) and spring (2).
(1)
(2)
FFFFFFFFF
(1)
(2)
FFFFFFFFF
(2)
(1)
(3) (4)
FFFFFFFFF
3-34
⑦ Remove the retainer (1) and washers (2) and then
separate the brake lever (4) from the primary shoe
(3).
Note: The number and type of washers vary with (2)
different truck models. (1)
(4)
(3)
FFFFFFFFFF
(2)
FFFFFFFFFF
⑨ Disassemble the wheel cylinder assembly as
follows:
1. Remove the pushrod (1) and boot (2) from each
end of the cylinder.
(2) (1)
(1) (2)
FFFFFFFFFF
2. Force one piston (2) into one end of the cylinder
to remove the piston (2), cup (3) and spring (4)
(4)
from the other end of the cylinder.
(2)
(3)
(2)
(1)
(3)
FFFFFFFFFF
3-35
⑩ Remove the retainer (1) to detach the parking brake
cable (3) from the packing plate (2).
(2)
(1)
(3)
FFFFFFFFFF
■ Inspection
① Check the inner surface of the cylinder and the outer
diameter of the pistons (2) for corrosion.
(1)
② Measure the clearance between the cylinder (1) and
piston (2).
Standard clearance: 0.03 - 0.10 mm
[0.0012 - 0.0039 in.]
Limit: 0.15 mm [0.0059 in.]
③ Visually check the parts for damage or deformation,
replacing any defective part with a new one.
(2)
FFFFFFFFFF
FFFFFFFFFF
FFFFFFFFFF
3-36
■ Reassembly
Note: Prior to reinstallation, apply heat-resisting grease to the areas indicated in Figure 3.108, using caution
not to contaminate the lining with grease.
(b)
(d)
(a) (a)
(a)
(a)
(c)
(a) Backing plate in shoe contact area (c)
(b) Anchor pin
(c) Cable guide in areas which come in
contact with adjuster cable
(d) Parking brake lever pin (a)
(e) Adjuster threads and other rotating (a)
(e)
parts
FFFFFFFFFF
(3)
(2)
FFFFFFFFFF
(4)
(1)
(3)
FFFFFFFFFF
3-37
2. Fit the boots (1) and pushrods (2) to both sides
of the cylinder.
(1)
(2)
(2) (1)
FFFFFFFFFF
FFFFFFFFFF
(4)
(2)
(1)
FFFFFFFFFF
3-38
⑤ Install the primary shoe (2) and secondary shoe (3)
(1)
to the packing plate (1).
Attach the spring (4) and adjuster (5) between the
two shoes.
(3)
Note: The adjusters should be installed so that the left-
side wheel brake has a left-hand thread adjuster
and the right-side wheel brake has a right-hand
thread adjuster.
The adjuster spring should be installed with its
longer hook going to the adjuster lever side. Use
caution not to allow the adjuster teeth to come in
contact with the spring. (2)
(5) (4)
FFFFFFFFFF
⑥ Install the guide plate (1) and guide cable (2) to the
packing plate.
(1)
(2)
FFFFFFFFFF
(1)
(2)
FFFFFFFFFF
3-39
⑧ Install the spring (2) onto the strut (1) and install the
strut between the shoes.
(2)
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
(1)
(2)
(1)
FFFFFFFFFF
3-40
■ Adjustment and testing
(1) Adjusting the adjuster
① Measure the inner diameter (a) of the brake drum and outer diameter (b) of the brake shoe assembly. Adjust
the adjuster so that the size (a) - (b) equals 1.0.
FFFFFFFFFF
拡張方向of expansion
Direction
FFFFFFFFFF
3-41
3.5 STEERING AXLE
3.5.1 STEERING AXLE (Orbitrol type)
■ Disassembly
① Remove the wheel cap (2) from the hub (1).
(1)
(2)
FFFFFFFFFF
② Remove the cotter pin (1) and then remove the lock
nut (2) and washer (3) from the hub.
(2)
(1)
(3)
FFFFFFFFFF
③ Using a bearing puller, remove the hub (1) and
bearing cone (2) from the knuckle spindle.
(1)
(2)
FFFFFFFFFF
④ Remove the bearing cup (2) and bearing cup (3)
from the hub (1).
(1)
(3)
(2)
FFFFFFFFFF
3-42
⑤ Remove the bearing cone (2) and bearing cone seat
(3) from the spindle of the knuckle (1). Remove the
oil seal (4) from the detached bearing cone (2).
(1)
(2)
(3)
(4)
FFFFFFFFFF
⑥ Remove the bolt (1), spring washer (2), washer (3) (1)
and collar (4). Pull out the pin (7) connecting the (2)
yoke (5) and the knuckle (6). (3)
(5) (4)
(7)
(6)
FFFFFFFFFF
⑦ Remove the potentiometer in the following manner: (1)
(2)
Note: The potentiometer is located only at the left side
of the steering axle.
1. Remove the screws (1) and detach the cover (2)
and potentiometer and adapter assembly (3). (3)
FFFFFFFFFF
(4)
FFFFFFFFFF
3-43
3. Remove the screws (1) from the top of the
(1)
king pin and pull the spring (2) out of the
steering axle boss.
(2)
FFFFFFFFFF
⑧ Remove the nut (1), spring washer (2) and washer (3)
to pull out the lock pin (4). (1)
(2)
Note: The mounting direction of the lock pin varies (3)
with different truck models.
(4)
FFFFFFFFFF
⑨ Remove the king pin (1) from the bosses and then
remove the knuckle (2), thrust bearing (3) and shims (3)
(4) from between the two bosses.
(2)
(1)
(4)
FFFFFFFFFF
⑩ Remove the dust seal (2) (right side only) and the
bearing (3) from the upper boss at each end of the (2)
(3)
FFFFFFFFFF
3-44
⑪ Remove the dust seal (2), bearing (3), spacer (4) and
O-ring (5) from the lower boss at each end of the
steering axle (1).
Note: The spacer is provided only for 2.0 to 3.5 ton
trucks.
(1)
(5)
(4)
(3)
(2)
FFFFFFFFFF
(2)
(3)
FFFFFFFFFF
3-45
⑬ Detach one of the slings from the steering cylinder
(1) and move the steering cylinder sideways until (2)
just before it leaves the steering axle. Sling the
steering cylinder again at its end from which the
sling was detached and then remove the steering
cylinder from the steering axle (2).
(1)
(2)
(1)
FFFFFFFFFF
(6)
(7)
FFFFFFFFFF
3-46
■ Reassembly
Note:
•• Replace all the O-rings and seals with new ones.
•• Apply a small amount of grease to O-rings before installing.
Use caution not to give damage to them when installing.
• When installing a new seal, apply a small amount of grease to its lip and use caution not to fit it the wrong way
•
round.
•• Apply grease to the sliding part of bearings and pins before reinstalling.
FFFFFFFFFF
(3)
(4)
FFFFFFFFFF
3-47
③ Install the O-ring (2), the spacer (3), and bearing (4)
and the dust seal (5) into the lower boss at each end (1)
1.0~1.8 ton
of the steering axle (1).
Note: The spacer is provided only for 2.0 - 3.5 ton (2)
trucks.
(4)
(5)
2.0~3.5 ton
(3)
(2)
(4)
(5)
FFFFFFFFFF
④ Install the bearings (2) and the dust seal (3) into the
upper bosses of the steering axle (1). (1)
Note: The dust seal is provided only at the right end of
the steering axle.
(3)
(2)
(2)
FFFFFFFFFF
(1)
(2)
(4)
FFFFFFFFFF
3-48
⑥ Insert the king pin (2) through the upper and lower 1.0 - 1.8 ton
bosses at each end of the steering axle (1) aligning
with the notch of the king pin with the lock pin (3), (2)
and secure the king pin with the lock pin (3), washer
(4), spring washer (5) and nut (6).
(3)
(1) (5)
(6) (4)
(6)
(5)
(4)
(1) (3)
FFFFFFFFFF
FFFFFFFFFF
1. Install the spring (1) to the top of the king pin with
(2)
the screws (2)
Note; Apply ThreeBond #1324N to the threads of the
screws before installing. (1)
FFFFFFFFFF
3-49
2. (1.0 - 1.8 ton trucks)
(5)
Install the potentiometer (2) to the adapter (1) using (2)
the screws and washers (4).
(3)
(2.0 - 3.5 ton trucks)
Install the potentiometer (2) to the adapter (1) with
the bolts (5). (4)
(1)
FFFFFFFFFF
FFFFFFFFFF
⑧ Assemble the yoke (1) and the knuckle (2) and insert (4)
the pin (3) into the assembly. Secure the pin with the (5)
bolt (4), spring washer (5), washer (6) and collar (7). (6)
(1) (7)
(3)
(2)
FFFFFFFFFF
⑨ Install the seat (2) and the oil seal (3) to the bearing
cone (4). Install the bearing cone (4) onto the spindle
of the knuckle (1) at each end of the steering axle.
(1)
(4)
(2)
(3)
FFFFFFFFFF
3-50
⑩ Install the bearing cup (2) and bearing cup (3) to
each of the hubs (1).
(1)
(2)
(3)
FFFFFFFFFF
(2)
FFFFFFFFFF
3-51
5. After adjustment, secure the nut with the cotter pin
(1).
(1)
FFFFFFFFFF
⑫ Install the wheel cap (2) to the hub (1) at each end of
the steering axle.
Note: Fill grease in the wheel cap before installing. (1)
(2)
FFFFFFFFFF
3-52
3.5.2 STEERING AXLE (EPS type)
■ Disassembly
① Remove the wheel cap (2) from the hub (1) at each
end of the steering axle.
(1)
(2)
FFFFFFFFFF
② Remove the cotter pin (1), lock nut (2) and washer
(3).
(2)
(1)
(3)
FFFFFFFFFF
③ Using a bearing puller, remove the hub (1) and
bearing cone (3).
(1)
(2)
FFFFFFFFFF
④ Remove the bearing cup (2) and the bearing cup (3)
from the hub (1).
(1)
(3)
(2)
FFFFFFFFFF
3-53
⑤ Remove the bearing cone (2) from the spindle of the
knuckle (1).
Remove the oil seal (3) from the bearing cone (2).
(1)
(2)
(3)
FFFFFFFFFF
⑥ Remove the cotter pin (2) and nut (3) from each end
(2)
of the tie rod (1) and detach the tie rod (1) from the
steering axle. (3)
(2)
(3)
(1)
FFFFFFFFFF
⑦ Remove the potentiometer in the following manner:
(1)
Note: The potentiometer is located only at the left side (2)
of the steering axle.
1. Remove the screws (1) and detach the cover (2)
and potentiometer and adapter assembly (3). (3)
FFFFFFFFFF
(4)
FFFFFFFFFF
3-54
3. Remove the screws (1) from the top of the
(1)
king pin and pull the spring (2) out of the
steering axle boss.
(2)
FFFFFFFFFF
⑧ Remove the nut (1), spring washer (2) and washer (3)
to pull out the lock pin (4). (1)
Note: The mounting direction of the lock pin varies (2)
(3)
with different truck models.
(4)
FFFFFFFFFF
⑨ Remove the king pin (1) from the bosses and then
remove the knuckle (2), thrust bearing (3) and shims (3)
(4) from between the two bosses.
(2)
(1)
(4)
FFFFFFFFFF
⑩ Remove the dust seal (2) (right side only) and the (2)
bearing (3) from the upper boss at each end of the
steering axle (1). (3)
Note: The dust seal is provided only at the right side of (1)
the steering axle.
(3)
FFFFFFFFFF
3-55
⑪ Remove the dust seal (2), bearing (3), spacer (4) and
O-ring (5) from the lower boss at each end of the
steering axle (1).
Note: The spacer is provided only for 2.0 to 3.5 ton
trucks.
(1)
(5)
(4)
(3)
(2)
FFFFFFFFFF
⑫ Remove the bolts (1) and set plate (2) and the pull (1)
the pin (3) out of the steering axle.
(3) (2)
FFFFFFFFFF
⑬ Remove the center arm assembly (2) and shims (3) (1)
from the steering axle (1).
(2)
(3)
FFFFFFFFFF
⑭ Remove the dust seals (2), bearings (3) and spacer (4) (2)
from the center arm assembly (1).
(3)
(4)
(1)
(3)
(2)
FFFFFFFFFF
3-56
■ Reassembly
Note:
•• Replace all the O-rings and seals with new ones.
•• Apply a small amount of grease to O-rings before installing.
Use caution not to give damage to them when installing.
• When installing a new seal, apply a small amount of grease to its lip and use caution not to fit it the wrong way
•
round.
• Apply grease to the sliding part of bearings and pins before reinstalling.
•
① Install the spacer (2), bearings (3) and dust seals (4) (4)
into the center arm (1).
Note: The spacer should be installed aligning with the (3)
(2)
grease fitting of the center arm.
(1)
(3)
(4)
FFFFFFFFFF
(3)
(1)
FFFFFFFFFF
3-57
③ Install the O-ring (2), spacer (3), bearing (4) and
dust seal (5) into the lower boss at each end of the 1.0 - 1.8 ton
(1)
steering axle.
Note: The spacer is provided only for 2.0 - 3.5 ton (2)
trucks. (4)
(5)
(3)
(2)
(4)
(5)
FFFFFFFFFF
④ Install the bearing (2) and dust seal (3) into the
(1) (2)
upper boss at each end of the steering axle (1).
Note: The dust seal is provided only at the right-hand
end of the steering axle.
(3)
(2)
FFFFFFFFFF
(2)
(1)
(4)
FFFFFFFFFF
3-58
⑥ Insert the king pin (2) through the upper and lower
bosses at each end of the steering axle (1) aligning 1.0 - 1.8 ton
with the notch of the king pin with the lock pin (3), (2)
and secure the king pin with the lock pin (3), washer
(4), spring washer (5) and nut (6). (3)
(1) (5)
(6) (4)
(6)
(5)
(4)
(1) (3)
FFFFFFFFFF
FFFFFFFFFF
1. Install the spring (1) to the top of the king pin with
the screws (2) (2)
(1)
FFFFFFFFFF
3-59
2. (1.0 - 1.8 ton trucks)
Install the potentiometer (2) to the adapter (1) using (2) (5)
the screws (3) and washers (4).
(2.0 - 3.5 ton trucks) (3)
Install the potentiometer (2) to the adapter (1) with
the bolts (5).
(4)
(1)
FFFFFFFFFF
(2)
FFFFFFFFFF
⑧ Install the tie rods (1) in place and secure both ends
(3)
of each tie rod with the nuts (2) and cotter pins (3)
(2)
1 08 - 147 N-m {11.0 - 15.0 kgf-m}
[79.7 - 108.4 lbf-ft]
(3)
(2)
(1)
FFFFFFFFFF
⑨ Install the oil seal (2) to the bearing cone (1) and
install the bearing cone onto the spindle of the
knuckle (3).
(3)
(1)
(2)
FFFFFFFFFF
3-60
⑩ Install the bearing cup (2) and the bearing cup (3) to
the hub (1).
(1)
(2)
(3)
FFFFFFFFFF
(2)
FFFFFFFFFF
3-61
5. After adjustment, secure the nut with the cotter pin
(1).
(1)
FFFFFFFFFF
⑫ Install the wheel cap (2) to the hub (1) at each end
of the steering axle.
Note: Fill grease in the wheel cap before installing. (1)
(2)
FFFFFFFFFF
3-62
3.6 STEERING CYLINDER AND ACTUATOR
3.6.1 STEERING CYLINDER (Orbitrol type)
■ Disassembly
① Place the steering cylinder (1) on a work bench (1)
horizontally and secure it firmly.
FFFFFFFFFF
② Remove the bushing (2) from each end of the piston
rod (1).
(2)
(1)
FFFFFFFFFF
③ Remove the nut (2), spring washer (3) and washer
(4) from each of the assembly bolts (1) at one end,
(1) (4)
and pull the assembly bolts (1) from the cylinder cap
(3)
assemblies.
(2)
FFFFFFFFFF
④ Remove the cylinder cap assembly (2) f r o m e a ch
end of the cylinder body (1).
(2)
(1)
FFFFFFFFFF
3-63
⑤ Remove the piston rod assembly (2) from the
cylinder body (1). (1)
(2)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
(3)
(5) (2)
(4)
FFFFFFFFFF
3-64
■ Reassembly
Note:
•• Replace all the O-rings, back-up rings and seals with new ones.
•• Apply a small amount of grease to O-rings before installing.
Use caution not to give damage to them when installing.
• When installing a new oil seal, apply a small amount of grease to its lip and use caution not to fit it the wrong
•
way round.
① Install the packing (2), back-up ring (3), dust seal (4)
(4)
and bushing (5) into the cylinder cap (1).
(3)
(1)
(2)
(5)
FFFFFFFFFF
(1)
(2)
FFFFFFFFFF
(1)
FFFFFFFFFF
3-65
④ Install the piston rod assembly (2) into the cylinder
body (1). (1)
(2)
FFFFFFFFFF
FFFFFFFFFF
FFFFFFFFFF
(1)
FFFFFFFFFF
3-66
3.6.2 ACTUATOR (EPS type)
When disassembling or reassembling the actuator assembly, make sure to put it on its side.
FFFFFFFFFF
■ Disassembly
(1) Removing the motor
① Remove the bolts (1) securing the motor (2) to the (3)
(1)
actuator assembly, and detach the motor (2) and
O-ring (3) from the actuator assembly.
Note: Use caution not to give shock to the motor when
removing it.
(2)
FFFFFFFFFF
(2) Disassembling actuator rod
① Holding the connector rod (1) with a wrench (27 mm
[1.06 in.]) engaged on the two flats in the connector
rod, loosen the lock nut (2) and then remove the ball
joint (3) and lock nut (2) from the connector rod.
(2)
(3)
(1)
FFFFFFFFFF
3-67
② Remove the bands (1) and pull the boot (2) from the
connector rod.
(1)
(2)
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
■ Reassembly
(1) Assembling the actuator rod
① Turn the actuator rod counterclockwise to the most
retracted state, and install the lock nut (1) and
connector rod (2) onto the actuator rod.
Adjust the connector rod position so that the size
(a) is 508 mm and secure the connector rod with the
lock nut (1).
Size (a) = 508 mm [20 in.] (1)
(a)
FFFFFFFFFF
3-68
② Install the boot (2) onto the connector rod (1)
temporarily.
(2)
(1)
FFFFFFFFFF
③ Install the lock nut (1) and ball joint (2) to the
connector rod. Adjust the position of the ball joint (2)
so that the size (b) is as given below and secure the
ball joint with the lock nut (1).
Size (b) = 6 64 mm [26.1 in.] (1.0 - 2.5 ton trucks)
(1)
710 mm [28.0 in.] (3.0 - 3.5 ton trucks)
300 N-m {30.6 kgf-m} [221.3 lbf-ft] (2)
(b)
FFFFFFFFFF
3-69
④ Turn the actuator rod clockwise to extend 30 mm
1.0~2.5 ton
[1.18 in.] from the most retracted state to point the
direction of the ball joint (1) as shown in Figure 20°
3.211. 3.0~3.5 ton
Install the boot (2) in position and secure with the
20
bands (3).
°
(1)
(2)
(1)
(3) (3)
FFFFFFFFFF
(1)
FFFFFFFFFF
3-70
3.7 STEERING GEARBOX (EPS type)
■ Disassembly
(1) Removing the pitman arm
① Hold the pitman arm (1) in a vice and remove the
nut (2) and washer (3) from the pitman arm.
(3)
(2)
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
3-71
② Remove the spring (1), shaft (2) and bushing (3)
from inside the housing.
(3)
(2)
(1)
FFFFFFFFFF
③ Remove the bolts (1) and them remove the housing
(2) and gasket (3) from the gearbox. (1)
(2)
(3)
FFFFFFFFFF
3-72
■ Reassembly
(1) Reinstalling potentiometer
① Install the gasket (2) and housing (3) to the gearbox (4)
(1) with the bolts (4). (3)
.8 - 7.2 N-m {0.6 - 0.7 kgf-m}
5
[4.3 - 5.3 lbf-ft]
(1)
(2)
FFFFFFFFFF
② Insert the bushing (2), shaft (3) and spring (4) into
(1)
the housing (1). (2)
(3)
(4)
FFFFFFFFFF
③ Install the O-ring (1), spacer (2), shim (3) and
potentiometer (4) to the housing and secure them (1)
(2)
with screws (5). (3)
(4)
(5)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
3-73
② Hold the pitman arm (1) in a vise, install the washer
(2) and nut (3).
1 40 - 170 N-m {14.3 - 17.3 kgf-m}
(2)
[103.3 - 125.4 lbf-ft]
(3)
Note: Use caution not to drop the gearbox.
(1)
FFFFFFFFFF
■ Adjustment
The following adjustment is required if the potentiometer was disassembled and or replaced with a new one.
Green/red 2 V
Black/red 3
FFFFFFFFFF
3-74
3.8 TILT CYLINDER
■ Disassembly
① Hold the tail-side boss (a) of the tilt cylinder in a
vise (b) and place a block (c) under the cylinder to (a)
support it.
(b)
(c)
FFFFFFFFFF
② Loosen the lock nut (1) and remove the rod head (2)
from the piston rod.
(2)
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
3-75
④ Remove the piston assembly (2) from the cylinder
(1).
(2) (1)
FFFFFFFFFF
(2)
(1)
(3)
(2)
FFFFFFFFFF
(3)
FFFFFFFFFF
FFFFFFFFFF
3-76
■ Reassembly
Note:
•• Have a repair kit on hand and replace all seals with new ones when reassembling.
•• When installing new seals including O-rings and U-rings, apply a small amount of grease to them. Use caution
not to give damage to them.
(6)
(4)
(5)
(2) (3)
FFFFFFFFFF
② Install the back-up ring (2), O-ring (3) and O-ring (4)
onto the outer diameter of the cylinder cap (1). (1)
Note: On 1.0 – 1.8 ton trucks, the cylinder cap does not
have a back-up ring.
(2) (3)
(4)
FFFFFFFFFF
③ Install the back-up ring (2) and the O-ring (3) onto (2)
the piston (1).
(1)
(3)
FFFFFFFFFF
3-77
④ Insert the piston assembly (1) into the cylinder (2).
(1) (2)
FFFFFFFFFF
FFFFFFFFFF
⑥ Install the piston rod head (2) onto the piston rod (1)
and secure with the lock nut (3).
(1)
(2)
(3)
FFFFFFFFFF
3-78
3.9 MAIN PUMP
■ Disassembly
① Hold the flanged part of the front cover in a vise,
with the input shaft side pointed downward.
Note 1: Make sure to hold the front cover in a vise
firmly to prevent the pump from coming off the
vise when loosening the bolts.
Note 2: Mark the rear and front cover and the drive gear
side of the pump body for correct reassembly.
FFFFFFFFFF
② Using a torque wrench, turn the four bolts (1) in
the tightening direction, to check whether they are
properly torqued:
8- 98 N-m {9.0 - 10.0 kgf-m}
8 (1)
FFFFFFFFFF
③ Remove the bolts (1) and washers (2) from the pump
body.
(1)
(2)
FFFFFFFFFF
④ Detach the rear cover (2) from the pump body (1) by
tapping the side face of the pump body lightly with a
plastic mallet.
(2)
(1)
FFFFFFFFFF
3-79
⑤ Remove the gasket (2) and the “3”-shaped gasket (3)
(3)
from the rear cover (1). (2)
Note: If the gaskets remain inside the pump body,
remove them from the pump body.
(1)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
FFFFFFFFFF
FFFFFFFFFF
3-80
⑨ Remove the driven gear (1).
Note: Put the mark “R” on the rear-side end of the
driven gear shaft.
(1)
FFFFFFFFFF
FFFFFFFFFF
⑪ Remove the front side plate (1) from the front cover.
Note: Put the mark “FV” on the drive-gear side of the
front side plate.
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
3-81
⑬ Remove the bushings (2) from the front cover (1).
(2)
(1)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
⑮ Remove the oil seal (2) from the front cover (1).
(2)
(1)
FFFFFFFFFF
3-82
■ Inspection
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.
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 (a) Check for cracks or damage. Oil pressure is too high.
(cast 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]
CAUTION
Useful limit
Roughness on journal (a): 0.8S - 1.6S
Roughness on oil seals (b and c): 1.6S - 3.2S
3-83
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 [0.004 in] or less
(d) Check gear teeth for roughness or Irregular rotation at high speeds
pitching.
(e) Check for missing or broken gear teeth Too high oil pressure or a hard object
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 near Cavitation or aeration
the engagement area.
Useful limit
Wear limit: 0.15 mm (0.006 in) or less
LBC surface
These areas
might be worn
⑤ Bushing Check the inner surfaces of bushings for The bushings are made of copper with
roughness or wear. the back plate made of lead brass. The
The bushings back plate consists of porous and PTFE
are fitted into
front and rear (polytetrafluoro-ethylene) layers.
covers.
Useful limit
When the back plate of the bushing is exposed to view.
⑥ “3”-shaped (a) Check gaskets for proper installation or Too high oil temperature
Gasket 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 edge. Wear occurs due to contaminants in oil,
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 pressure
gear is disassembled or
when it is removed from the (0.2 - 0.3 MPa {2 - 3 kgf/cm2} [29.0 - 43.5 psi]
front cover. It is difficult to
locate the cause of damage or more) applied on oil seal
when removing it from the
front cover. (c) Check rubber parts for swelling. Fire retardant hydraulic oil (phosphate) or
gasoline is used.
3-84
■ Reassembly
Note:
1. Have a repair kit on hand. Replace all gaskets, oil seals and snap rings with new ones when reassembling
the main pump.
2. Before reinstalling a new gasket, apply a small amount of grease to it and use caution not to give damage.
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
(1)
FFFFFFFFFF
3-85
④ Install the “3”-shaped gasket (2) in the groove in the
front cover (1) as shown in Figure 3.256. (2)
(1)
FFFFFFFFFF
”3”-shaped gasket
groove The “3”-shaped gasket
should be installed
with its flat surface Flat 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
FFFFFFFFFF
(1)
FFFFFFFFFF
Counterclockwise rotation:
Front side Drive side
Counterclockwise rotation:
Rear side Clockwise rotation:
Clockwise rotation: Rear side
Suction port
Front side (larger radius)
Discharge port
(smaller radius)
Projection (to be
always pointed to
drive side)
Driven side
FFFFFFFFFF
3-86
⑥ Install the front side plate (1) on the pump body
according to the mark made during disassembly as
shown in Figure 3.260.
(1)
FFFFFFFFFF
吐出側
Discharge side Suction
吸込側side Suction side
(larger radius) 吸込側 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
対抗させます。to gear’s side face
FFFFFFFFFF
⑦ Insert the drive gear (1) into the pump body with the
splined end downward.
(1)
FFFFFFFFFF
FFFFFFFFFF
3-87
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.
Driven side
FFFFFFFFFF
(1)
FFFFFFFFFF
吐出側
Discharge side 吸込側 side
Suction Suction
吸込側side Discharge side
吐出側
(smaller radius)
(小さいR) (larger
(大きいR) radius)
常にLBC面を歯車面に
The LBS surface should be always
pointed
対抗させます。to gear’s side face
FFFFFFFFFF
3-88
⑩ Install the bushings (2) into the rear cover (1).
(2)
(1)
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(1)
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(1)
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B-B section
Discharge Suction
side side
Flat surface
Discharge Suction
side side
C-C section
A-A section
(b) “3”-shaped gasket
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3-89
⑬ Install the rear cover (2) onto the pump body (1)
according to the mark made during disassembly as
shown in Figure 3.271.
(2)
(1)
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Gasket groove
“3”-shaped gasket
Discharge side Suction side
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⑭ Install the washers (1) and bolts (2) to the rear cover.
Tighten them to the following torque:
8 8- 98 N-m {9.0 - 10.0 kgf-m}
[64.9 - 72.3 lbf-ft]
(2)
(1)
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3-90
⑮ Remove the pump from the vise and put it on the
work bench. Direction in which oil
Apply a thin coat
Apply grease on the area between the lips and on the seal is installed.
of grease on outer
outer diameter of a new oil seal and install it on the diameter of oil
Dust lip seal.
oil seal guide. Oil seal
Put oil seal guide onto the drive shaft of the pump
and insert the oil seal into the front cover (1) using
an insertion jig. Main lip
Apply grease area
between oil seal lips.
FFFFFFFFFF
(1)
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ø4 Unit: mm [in.]
[0.16] 単位: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 ]
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3-91
⑭ Secure the oil seal (1) with the snap ring (2).
Remove the oil seal guide. (2) (Front
cover)
(1)
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■ 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:
Note: 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.
① Install a pressure gauge on the oil pressure check port of the control valve.
② 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 1 MPa {10 kgf/cm2} [145 psi].
③ Increase the pump speed to 1500 to 2000 rpm and let the pump operate for about 10 minutes.
④ Keeping the pump speed at 1500 to 2000 rpm, increase the pressure by 2 to 3 MPa {20 to 30 kgf/cm2} [290
to 435 psi] up to 17.2 MPa {175 kgf/cm2} [2495 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.
⑤ After the test is over, set the oil pressure for 17.2 MPa {175 kgf/cm2} [2495 psi], perform a discharge test.
The pump discharge is checked by observing the lift speed.
3-92
3.10 CONTROL VALVE
■ Disassembly
Note:
1. Before disassembly, clean the exterior of the control valve to prevent the possibility of dirt and foreign
matter from entering the mechanism.
2. The control valve is a precision product. Handle the parts carefully. Use caution not to hit its parts against
each other or drop.
3. To insure accurate reassembly of the control valve, tag all disassembled parts by section.
(2)
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(1)
(5)
(3)
(5)
(2)
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3-93
③ Remove the springs (2) and the poppets (3) from
both side-faces of the outlet section (1).
(1)
(2)
(3) (3)
(2)
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④ Remove the solenoid valve assembly (2) from the
outlet section (1).
Note: This step applies only to trucks with an interlock (1)
unit.
(2)
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⑤ Detach the plug (2) from outlet section (1) to remove
the spring (3) and poppet (4). Remove the O-ring (5)
from the plug (2). (1)
(4)
(3)
(5)
(2)
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(2)
(1)
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3-94
② Remove the tilt spool assembly (2) from the valve
body (1), together with the cap-side seal plate (3)
and dust seal (4).
(1)
(2)
(4)
(3)
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③ Sandwich the tilt spool assembly (1) from both
side with hard wooden pieces using caution not to
damage its periphery as shown in Figure 3.285. Hold
the tilt spool assembly sandwiched with wooden
pieces in a vise. (1)
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④ Remove the screw (2), spring seats (3) and spring (4)
(2)
from the tilt spool assembly (1). Then, remove the
seal plate (5) and dust seal (6). (5)
Note: Use caution not to drop the parts because they (3)
might pop out from the tilt spool due to spring
(6)
pressure.
(4)
(1)
(3)
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3-95
⑤ Remove the spring (2) and pilot spool (3) from
(2)
inside the tilt spool assembly (1).
(1)
(3)
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⑥ Remove the bolts (1) and then take the bracket (3)
(1)
and dust seal (4) out from the valve body (2). (3)
(4)
(2)
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(4)
(3)
(1) (2)
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3-96
② Remove the bolts (1) and detach the cap (2).
(2)
(1)
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(2)
(4)
(3)
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(1)
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3-97
⑤ Remove the screw (2), spring seats (3) and
spring (4) from the lift spool assembly (1). Then, (2)
(5)
remove the seal plate (5) and dust seal (6).
Note: Use caution not to drop the parts because they (3)
might pop out from the tilt spool due to spring (6)
pressure.
(4)
(1)
(3)
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⑥ Remove the bolts (1) and then take the bracket (3)
(1)
and dust seal (4) out from the valve body (2). (3)
(4)
(2)
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■ After disassembly
(1) Cleaning
Clean all the disassembled parts thoroughly in clean mineral oil and dry with compressed air. Place them on a
clean sheet of paper or cloth for inspection.
(2) Inspection
Inspect all the disassembled parts for burrs, scratches, scores or other defect.
•• Any dent or nicks on the load check seat of the valve housing may be repaired by lapping. Use caution not to
leave behind the lapping agent inside the valve.
•• Inspect the spool for scratches or dent on the periphery. Minor scratches may be removed using oil stone or a
cloth and lapping agent.
•• Inspect the sliding parts for smooth movement and all grooves and passages for foreign material.
•• Inspect all the springs for deterioration, deformation or wear, replacing any defective spring with a new one.
•• Replace any relief valve that does not operate smoothly with a new one.
•• If the cap or plug was removed, inspect each hole and plug seat and around them for foreign matter.
3-98
■ Reassembly
1. Caution to take when reassembling the control valve
•• Too large torque to the threads will cause the malfunction of the spool. Observe the specified torque.
•• Spools, springs and spool ends should be reassembled in the same combination as before they were
removed.
• Replace all the O-rings and back-up rings should be replaced with new ones.
•
•• When installing new O-rings and back-up rings, apply a small amount of grease to them and use caution not
to damage.
•• Lubricate the sliding parts of the control valve before reassembly.
•• After reassembly of the control valve is completed, plug all the ports to prevent the entry of dust into the
mechanism.
(2)
(1)
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3-99
② Sandwich the lift spool (1) from both side with hard
wooden pieces, using caution not to damage its (1)
periphery as shown in Figure 3.296. Hold the lift
spool assembly sandwiched with wooden pieces in a
vise.
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③ Install the dust seal (2) and seal plate (3) onto the lift
spool (1). (4)
Then, install the spring seat (4) and spring (5) onto (2)
the lift spool and secure with the screw (6).
(1)
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④ Insert the list spool assembly (2) into the valve body
(1). (1)
(2)
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3-100
⑤ Install the cap (2) to the valve body (1) with the
bolts (3).
(1)
(2)
(3)
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⑥ Install the sensor plate (2) and spring (3) into the cap
(1). Install the potentiometer (4) to the cap (1) and
secure with the bolts (5). (1)
(2)
(3)
(4)
(5)
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(2)
(1)
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② Sandwich the tilt spool (1) from both side with hard
(1)
wooden pieces, using caution not to damage its
periphery as shown in Figure 3.302. Hold the lift
spool assembly sandwiched with wooden pieces in a
vise.
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3-101
③ Insert the pilot spool (2) and spring (3) into the tilt
(3)
spool (1).
(1)
(2)
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④ Insert the dust seal (2) and seal plate (3) into the tilt
spool (1). (4)
Then, install the spring seat (4) and spring (5) to the
(2)
tilt spool and secure them with the screw (6).
(1)
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⑤ Insert the tilt spool assembly (2) into the valve body
(1).
(1)
(2)
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3-102
⑥ Install the cap (2) to the valve body (1) with the
bolts (3).
(1)
(2)
(3)
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(2)
(3)
(4)
(5)
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(2)
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③ Fit the poppets (2) and springs (3) to both sides of
the outlet section (1).
(1)
(3)
(2) (2)
(3)
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3-103
④ Install the outlet section (3) to the inlet section (2)
with the O-ring (1) between both. Then, install the
rear cover (4) to the outlet section with the O-ring (2)
between both.
Secure them with the nuts (5).
(5)
(1)
(3)
(1)
(4)
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⑤ Install the relief valve assembly (2) into the inlet
section (1).
(1)
(2)
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3-104
■ Adjusting the relief valve
① Remove the check port (G) plug from the inlet section and install an oil pressure gauge with a capacity of at
least 20 MPa {200 kgf/cm2} [2900 psi] to the plug port.
② Operate the tilt lever and measure the oil pressure when the tilt cylinders reach the end of their stroke.
③ If the measured oil pressure is out of the specified value, loosen the lock nut of the relief valve and turn the
adjustment screw to the right or left to adjust for the specified value.
If the measured oil pressure is higher than the specified oil pressure setting, once turn the adjustment screw
all the way to the left to lower the oil pressure below the specified value, and then turn the adjustment screw
gradually to the right to increase to the specified oil pressure setting.
④ After adjustment, tighten the lock nut to secure the adjustment screw.
Unit: MPa {kgf/cm2} [psi]
1.0 - 1.5 ton trucks 1.8 ton trucks 2.0 - 3.5 ton trucks
Oil pressure setting 13.7 {140} [1987] 15.7 {160} [2277] 17.2 {175} [2495]
Relief valve
Adjustment screw
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3-105
3.11 DRIVE MOTOR
Do not disassemble or reassemble the drive motor in damp or wet locations.
■ Disassembly
① Remove the bolts (1) and detach the two rotation
sensors (2) from the drive motor.
(1)
(2)
(1) (2)
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② Remove the cover (1) and then detach the bolt (2),
washer (3) and sensor gear (4).
(1)
(2)
(3)
(4)
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③ Remove the bolts (1) and washers (2) and detach the
bracket (3) and waved washer (4).
(4)
(1)
(3)
(2)
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3-106
④ Remove the oil seal (2) from the bracket (1).
(1) (2)
FFFFFFFFFF
⑤ Pull out the rotor assembly (1) from the drive motor.
(1)
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3-107
■ Reassembly
① Install the bearings (2) and (3) onto the rotor (1).
(3) (1)
(2)
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(3)
(2)
(4)
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3-108
④ Install the oil seal (2) to the bracket (1).
Note: Use a new oil seal. Apply a thin coat of grease to
the lips of the new oil seal before installing.
(2)
(1)
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⑤ Install the sensor gear (1) to the drive motor with
bolt (2) and washer (3).
Install the cover (4).
(4)
(2)
(3)
(1)
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⑥ Install the two rotation sensors (1) to the drive motor
with the bolts (2).
(2)
(1)
(2)
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3-109
3.12 PUMP MOTOR
Do not disassemble or reassemble the pump motor in damp or wet locations.
■ Disassembly
① Remove the bolt (1) and detach the rotation sensor
(2) from the pump motor. (1)
(2)
FFFFFFFFFF
② Remove the cover (1) and then detach the bolt (2),
washer (3) and sensor gear (4).
(1)
(2)
(3)
(4)
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3-110
③ Remove the bolts (1) and washers (2) and detach the
bracket (3) and waved washer (4).
(4)
(1)
(2)
(3)
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④ Pull out the rotor assembly (1) from the pump motor.
(1)
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3-111
■ Reassembly
① Install the bearings (2) and (3) onto the rotor (1).
(3) (1)
(2)
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(1)
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(1)
(3)
(4)
(2)
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3-112
④ Install the sensor gear (1) to the pump motor with
bolt (2) and washer (3).
Install the cover (4).
(4)
(2)
(3)
(1)
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⑥ Install the sensor (1) to the pump motor with the bolt
(2).
(2)
(1)
FFFFFFFFFF
3-113
3.13 MAST ASSEMBLY
3.13.1 VM MAST
■ Disassembly
(1) Removing the carriage
① Park the truck on a level surface with a loaded pallet
on the forks.
Lower the carriage to the lowest position.
Note: The mast should be kept in an upright position
with the lift cylinders retracted fully.
FFFFFFFFFF
② Sling the lift chains at points near the sheaves with
wire ropes and remove the cotter pin (1) and nuts (2)
and detach the joint links (3) from the outer mast.
(3)
(2)
(1)
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③ Lower the chains gradually to remove them from the
sheaves and place on the pallet.
FFFFFFFFFF
3-114
④ Extend the piston rods of the lift cylinders to lift the
inner mast until the upper side rollers on the carriage
leave the inner mast.
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⑤ Drive back the truck to separate the carriage from
the mast assembly.
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3-115
② Disconnect the high-pressure hoses (2) and (3) from
the lift cylinders (1). (1)
Note: When disconnecting the hose leading from the
control valve, attach a plug to one end of the hose (1)
to minimize oil spillage from the hose.
(2)
(3)
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Note: The flow regulator valve regulates the oil flow
from the lift cylinders. The cut-off valve prevents to CONTROL VALVE
ࠦࡦ࠻ࡠ࡞ࡃ࡞ࡉ߳
the spillage of oil from the lift cylinders should
the oil pressure in the high-pressure hose drop (due FLOW REGULATOR
to a damaged or ruptured hose). VALVE
(The locations of the cut-off valve and relief
CUT-OFF
ࠞ࠶࠻ࡃ࡞ࡉ VALVE
valve vary with different truck models.)
FFFFFFFFFF
③ Remove the hoses (2) and (3) from the lift cylinders
(1).
(1)
(1)
(3)
(2)
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3-116
④ Loosen the lock nut (1) securing the cylinder rod to
the inner mast at each side of the mast assembly and
remove the lock bolt (2).
(1)
(2)
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(1)
(2)
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3-117
⑦ Remove the shims (2) from each of the lift cylinder
rods (1). (2)
Note: Record the number of shims removed at each of
the lift cylinder rods.
(1)
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(2)
(1)
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3-118
③ Remove the bolt (1) form each inner mast channel,
and then detach the side roller (2), shims (3) and
spacer (4).
Note: Record the thickness and number of shims
removed.
Some truck models may not have side rollers. (2)
(4)
(3)
(1)
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(3)
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3-119
■ Reassembly
Notes:
1. If the inner mast, outer mast, carriage, side rollers and end rollers were replaced with new ones, the
clearance between each part needs to be adjusted.
2. If the inner mast, outer mast and lift cylinders were replaced with new ones, the lift cylinder rod length
needs to be adjusted.
3. If the carriage and lift chains are removed, the carriage height needs to be adjusted.
FFFFFFFFFF
(3)
(2)
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3-120
③ Install the end roller (1) and shims (2) to the bottom
of each inner mast channel and to the upper part of
each outer mast channel.
(2)
Note: Apply grease to the end rollers and end roller
mounting parts of each channel before installing (1)
(2)
(1)
Larger radius
corner
“TCM” mark
Carriage side
Outside
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④ Install the spacer (2), shims (3) and side roller (4) to
the bottom of each inner mast channel (1) using the
bolt (5).
Note: Some truck models may not have side rollers.
(4)
(5)
(1)
(2)
(3)
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3-121
② Sling each cylinder (1) on a crane hook and secure
the bottom of the cylinder with the bolt (2). Put the (1) (4)
U-bolt (3) and stopper (4) in place and secure them
with the nuts (5) and washer (6) temporarily. (3) (5)
Note: The locations of the stopper and U-bolt may vary (6)
with different truck models.
(1)
(2)
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(2)
(1)
FFFFFFFFFF
(3)
(2)
(1)
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3-122
⑤ Adjust the clearance between the lift cylinder (2) (5)
and the stopper (3) with the adjuster (1) at each side (4)
(6)
of the inner mast. Tighten the U-bolt (4) with the
nuts (5).
Secure them with the lock nut (6).
(1)
Note: Do not overtighten the U-bolt; otherwise the
cylinder might be damaged.
(6)
(2)
(3)
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⑥ Connect the hoses (2) and (3) to the lift cylinders (1).
(1)
(1)
(3)
(2)
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(1)
(2)
(3)
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3-123
(3) Installing the carriage
① Put the mast assembly upright and extend the lift
cylinders to lift the inner mast until the bottom of
the inner mast is higher than the side rollers on the
carriage (See Figure 3.363.).
② Bring the truck close to the carriage and stop in a
position which allows the end roller at each side
of the carriage to come between both outer mast
channels.
③ Adjust the positions of the carriage and truck so that
the rollers on the carriage are positioned between
both inner mast channels and lower the inner mast to
the lowest position.
FFFFFFFFFF
(2)
(3)
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3-124
3.13.2 VFHM MAST
When trying to work on the mast assembly for adjustment or replacement of parts with the mast
assembly hoisted, make sure to take necessary measures to prevent the inner mast from falling
accidentally.
Do not rely too much on the hydraulic device alone for supporting the mast.
Chain or sling
wire rope
Upper connecting
member
Inner mast
Middle mast
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■ Disassembly
(1) Removing the carriage
① Park the truck on a level surface with a loaded pallet
on the forks.
Lower the carriage to the lowest position.
Note: The mast should be kept in an upright position
with the lift cylinders retracted fully.
FFFFFFFFFF
3-125
② Remove the bolt (2), washer (3) and stopper (4)
from the front lift cylinder (1). (2)
(3)
(4)
(1)
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(3)
(2)
(1)
FFFFFFFFFF
(2)
(1)
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3-126
⑤ Extend the piston rods of the rear lift cylinders to
lift the inner mast until the upper side rollers on the
carriage leave the inner mast.
FFFFFFFFFF
FFFFFFFFFF
(1)
(3)
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3-127
② Sling the front lift cylinder (1) on a crane hook and
remove the bolt (2) from the bottom of the cylinder.
Remove the bolts (3), washers (4) and support (5)
from the middle part of the cylinder. (5)
(1)
Hoist the front lift cylinder (1) with a crane to detach
from the inner mast (6).
(4)
(3) (6)
(2)
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(3) Removing the rear lift cylinders
① Move the truck to a level surface. Place the front
wheels on ramps 250 – 300 mm [9.84 - 11.8 in.]
high. Apply the parking brake and place wedges in
front of and behind the rear wheels to hold them in
place securely.
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3-128
② Sling the upper connecting member of the inner
mast on a crane hook to prevent the inner mast from (1)
falling accidentally.
Sling each lift chain (1) at a point near the sheave
with wire ropes and remove the cotter pin (2) and (4)
nuts (3) and pull out the joint links (4) from the
outer mast and inner mast, respectively.
Before removing the chains, make sure the inner
mast is supported securely to prevent it from (3)
falling.
Note: It is a good practice to hoist the inner mast a little (2)
to give a slack to the chains for easy operation.
(1)
(4)
(3)
(2)
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(1)
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3-129
④ Disconnect the high-pressure hoses (2) and (3) from
(2)
the rear lift cylinders (1). (1)
Note: When disconnecting the hoses, attach plugs to
their ends to minimize oil spillage from the hose. (1)
(3)
FFFFFFFFFF
⑤ Disconnect the hoses (2) and (3) from the rear lift
cylinders (1).
(1)
(1)
(3)
(2)
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⑥ Loosen the lock nut (1) securing each of the rear lift
cylinders to the middle mast, and remove the lock
bolt (2).
(2)
(1)
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3-130
⑧ Sling each rear lift cylinder (1) on a crane hook and
remove the bolt (2) from the bottom of the cylinder. (6)
Remove the nuts (3) and washer (4), U-bolt (5) and
stopper (6) from the middle part of the cylinder. (5) (3)
Hoist each lift cylinder (1) with a crane to remove (4)
from the mast assembly.
Before removing the rear lift cylinders, make
sure the middle mast is supported securely to
prevent it from falling accidentally.
Note: The locations of the stopper and U-bolt may vary (1)
with different truck models.
(2)
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(1)
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3-131
(4) Removing the rollers
Before trying to remove the rollers, make sure the inner and outer masts are secured properly to
prevent them from falling accidentally.
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3-132
① Using a puller, remove the end rollers (1) and shims
(2) from the bottom of each inner mast channel, the
upper and lower parts of each middle mast channel,
(2)
and the upper part of each outer mast channel.
Note: Record the number of shims removed from each (1)
part.
FFFFFFFFFF
② Remove the slipper (1) and shims (2) from the upper
part of each middle mast channel and those from the
upper part of each outer mast channel. (2)
Note: Record the number of shims removed from each
part. (1)
FFFFFFFFFF
(1)
(4)
(3)
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3-133
■ Reassembly
(1) Installing the rollers
Before trying to install the rollers, make sure the inner mast and outer mast are securely supported
to prevent them from falling accidentally.
Hold the middle mast in place and lower the inner mast with a crane. You can install the rollers at the bottom
of the inner mast and at the upper part of the middle mast.
Lower both the inner mast and middle mast together with a crane. You can install the rollers at the bottom of
the middle mast and at the upper part of the outer mast.
① Install the slipper (1) and shims (2) to the upper part
of each middle mast channel and to the upper part of
each outer mast channel. (2)
(1)
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② Install the the end roller (1) and shims (2) to the
bottom of each inner mast channel, to the upper and
lower part of each middle mast channel, and to the (2)
upper part of each outer mast channel. (1)
Note: Apply grease to the end rollers and end roller
mounting parts of each channel before installing
the end rollers. Use caution not to install them the
wrong way round.
Larger radius
corner
“TCM” mark
FFFFFFFFFF
3-134
③ Install the spacer (1) shims (2) and side roller (3)
to the bottom of each middle mast channel with the
bolt (4).
Note: Some truck models may have not side rollers.
(3)
(4)
(1)
(2)
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FFFFFFFFFF
(1)
(2)
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3-135
③ Install the shims (2) to each rear lift cylinder rod (1).
Lower the middle mast (3) gradually with a crane
to insert each cylinder rod into the mounting hole in
each of the middle mast channels (3). (3)
(2)
(1)
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④ Secure the upper part of each rear lift cylinder (1) to (4)
each of the middle mast channels (4) with the lock
bolt (2) and lock nut (3).
(2)
(3)
(1)
FFFFFFFFFF
FFFFFFFFFF
3-136
⑥ Install the hoses (2) and (3) to the rear lift cylinders
(1).
(1)
(1)
(3)
(2)
FFFFFFFFFF
(2)
FFFFFFFFFF
(1)
(2)
(3)
(4)
FFFFFFFFFF
3-137
(3) Installing the front lift cylinder
① Sling the front lift cylinder (1) on a crane hook and
put it in place inside the inner mast (2).
Secure the bottom of the cylinder with the bolt (4)
(1)
(3) and attach the support (4) to the middle of the
cylinder with the bolts (5) and washers (6).
(6)
(5) (2)
(3)
FFFFFFFFFF
② Connect the high-pressure hose (2) to the front lift
cylinder (1) with the bolt (3). Front前方
of the truck (2)
(1)
(3)
FFFFFFFFFF
FFFFFFFFFF
3-138
④ Install the piston head (2) to the top of the front lift
cylinder (1).
(2)
(1)
FFFFFFFFFF
(1)
(2)
(3)
FFFFFFFFFF
(3)
(4)
(1)
FFFFFFFFFF
3-139
3.13.3 INSPECTION AND ADJUSTMENT
■ Inspection
(1) Checking the inner and outer masts
① Check the inner and outer masts for bends and roller sliding areas of the masts for wear. If defective, repair
or replace.
② Visually check the connecting members of the inner and outer masts for cracked welds. If defective, replace
the connecting member with a new one. Check also the inner and outer masts for deformation or warping.
③ Measure the inner width of each of the inner and outer mast channels, along which the end roller rolls, and
calculate the distortion of each mast channel from the measured values. If the distortion is small, repair
using a press. If severely distorted, each mast assembly should be replaced with a new one.
④ Check the end rollers of the inner and outer masts for wear of their outer periphery. Replace any severely
worn end roller with a new one. Check their bearings for wear, too.
⑤ Check the outer mast support for cracks of the weld or wear and deformation of the bushing, replacing any
defective part with a new one.
① Using Color Check, check the upper and lower hangers of the forks for cracks at the welds. Check the forks
for squareness. Check the root of the hangers for damage. In addition, install the forks on the fork carrier
and check the tips of both forks for alignment. Check that the fork stoppers work properly.
② If the hangers have cracks at the welds, repair completely by welding. Replace any defective fork stopper
with a new one.
③ If the forks have poor squareness or their lengths are not the same, repair using a press. If the defect is too
severe, replace the forks with new ones.
3-140
■ Adjustment
(1) Adjusting the length of the lift cylinder rod
If the inner mast, outer mast or lift cylinders were replaced with new ones, the lift cylinder rod length needs to
be adjusted.
the two lift cylinders when the two piston rods reach
their respective stroke ends.
③ Add shims to the piston rod which stops first.
Note: Shim thickness: 0.2 mm [0.0079 in.], 0.5 mm
[0.0197 in.]
SHIM
PISTON ROD
LOCK BOLT
FFFFFFFFFF
stroke ends.
⑤ Adjust the tension of the right and left chains to the
same value using the chain anchor pin at the mast
side when the forks are at the bottom position and ANCHOR PIN
the mast is tilted back fully.
ADJUSTMENT NUT
LOCK NUT
FFFFFFFFFF
3-141
(2) Adjusting the carriage height (VM mast)
If the carriage and lift chains are removed, the carriage needs to be adjusted being reinstalled.
CLEARANCE
STOPPER
anchor pin at the mast side when the forks are at the
LOCK NUT
bottom position and the mast is tilted back fully.
FFFFFFFFFF
3-142
(3) Shim-adjusting the end rollers and side rollers
Note: Shim-adjustment of the end rollers and side rollers should be made when the forks are in the top lifting
position.
① Move the inner mast and carriage toward the left (or right) outer mast channel so that the end rollers on the
left (right) side of the inner mast come in contact with the left (or right) side outer mast channel and the end
rollers on the left (or right) side of the carriage with the left (or right) side inner mast channel, respectively.
② Measure the clearance between each end roller and each mast channel at the opposite side, and shim adjust
the clearance for 0 to 0.5 mm [0 to 0.02 in.].
③ Shim adjust the clearance between each side roller and each mast channel in the same way as above.
Note: The sketches given below show the shim-adjustment procedure for the VM mast.
Use the same procedure for the VFHM mast, although the number of rollers is somewhat different from
the VM mast.
SHIM
SHIM
SHIM SHIM
0 - 0.5 mm
[0 - 0.02 in.]
Move the carriage and inner mast
to one side of the outer mast.
FFFFFFFFFF
3-143
3.14 LIFT CYLINDER
Note:
•• Have a repair kit and replace all seals with new ones when reassembling the lift cylinder.
•• When installing new seals including O-rings, U-rings and seal rings, apply a small amount of grease to them
and use caution not to damage them.
(1)
FFFFFFFFFF
(2)
FFFFFFFFFF
(3)
(2) (4)
FFFFFFFFFF
3-144
④ Remove the piston rod assembly (2) from the
cylinder (1).
(2)
(1)
FFFFFFFFFF
(2) (1)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
(1)
(2)
(3)
FFFFFFFFFF
3-145
⑧ Remove the snap ring (2) from inside the piston (1)
and take out the cushion ring (3). (3)
(2)
(1)
FFFFFFFFFF
■ Reassembly
① Insert the cushion ring (2) into the piston (1) and
(1)
secure with the snap ring (3).
(3)
(2)
FFFFFFFFFF
(4)
FFFFFFFFFF
3-146
③ Install the spacer (2) and O-ring (3) onto the piston
rod (1). (1)
(VM400 - VM600, VFHM500 - VFHM650)
(2) (3)
FFFFFFFFFF
④ Install the wear ring (2) onto the piston rod (1).
(VFHM700, VFHM750) (1)
(2)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
3-147
⑥ Install the U-ring (2), wiper ring (3) and bushing (4)
into the inner diameter of the cylinder cap (1). (1) (2)
(3) (4)
FFFFFFFFFF
(2)
FFFFFFFFFF
3-148
3.14.2 FRONT LIFT CYLINDER (VFHM mast)
■ Disassembly
① Remove the cylinder cap assembly (2) from the
cylinder (1). (2)
(1)
FFFFFFFFFF
(1)
(2)
(3)
FFFFFFFFFF
(3)
(2) (4)
FFFFFFFFFF
④ Pull out the piston rod assembly (2) from inside the
cylinder (1).
(2)
(1)
FFFFFFFFFF
3-149
⑤ Remove the slide ring (2) and seal ring (3) from the
outer diameter of the piston (1).
(1)
(2)
(3)
FFFFFFFFFF
⑥ Remove the snap ring (2) from inside the piston (1)
and remove the check valve (3).
(1)
(2)
(3)
FFFFFFFFFF
3-150
■ Reassembly
① Insert the check valve (2) into the piston (1) and
secure with the snap ring (3). (1)
(3)
(2)
FFFFFFFFFF
② Install the seal ring (2) and slide ring (3) onto the
piston (1). (1)
(2)
(3)
FFFFFFFFFF
(2)
(1)
FFFFFFFFFF
3-151
④ Install the U-ring (2), wiper ring (3) and bushing (4)
into the cylinder cap (1). (2) (1) (4)
(3)
FFFFFFFFFF
⑤ Install the O-rings (2) and (3) onto the cylinder cap
(1)
(1).
(2) (3)
FFFFFFFFFF
3-152
3.15 CARRIAGE
The carriage and forks are heavy. You will be seriously injured if you are crushed under a fallen
carriage or forks. Make sure to sling them with wire ropes or chains to prevent them from falling
over.
■ Disassembly
① Remove the bolts (1) and washers (2) from the
carriage (3) and detach the load backrest (4) from (4)
the carriage.
(3)
(2)
(1)
FFFFFFFFFF
② Remove the bolt (1) and detach the side roller (2),
shims (3) and spacer (4). (4)
Note: Record the thickness and number of shims (3)
removed.
(2)
(1)
FFFFFFFFFF
③ Remove the snap rings (1).
(2)
Using a puller, remove the end rollers (2) and shims
(3) from each side of the carriage. (1)
Note: Record the thickness and number of shims
removed.
Some truck models may not have the snap ring or
shims for the end roller.
(3)
(2)
FFFFFFFFFF
3-153
■ Reassembly
Note: Apply grease to the sliding area of each part before installing.
(2)
(3)
“TCM” mark
Larger radius
corner
FFFFFFFFFF
② Install the spacer (2), shims (3) and side roller (4) (1)
with the bolt (5) to the carriage (1). (2)
(3)
3 4 - 51 N-m {3.5 - 5.2 kgf-m}
[25.1 - 37.6 lbf-ft]
(4)
(5)
FFFFFFFFFF
3-154
③ Install the load backrest (2) to the carriage (1) with
the bolts (3) and washers (4). (2)
(4)
(1)
(3)
FFFFFFFFFF
3-155
3.16 FORKS
The forks are heavy. You will be seriously injured if you are crushed under a fallen fork.
Make sure to sling them with wire ropes or chains to prevent it from falling over.
■ Removal
① Remove the fork lock bolt (1) and washer (2) from
the carriage.
(2)
(1)
FFFFFFFFFF
② Release the stopper (1) at the upper part of each fork
prong (2), bring both fork prongs to the center, and
(1)
remove them from the carriage.
(2)
(2)
FFFFFFFFFF
3-156
NOTE
3-157
No. MEB-7P0AE
Issued: February, 2013
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
F
B25-sv
F
B30-sv
F
B35-s
s
TCMCORPORATION
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]
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] ←
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
G
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
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
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.
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.
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.
Remember that parts are very hot after heating. Use caution not to get burnt when
removing them.
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.
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
• Designation of screws: Each part number consists of a screw type designation and a nominal symbol.
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.
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
* 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 GENERAL DESCRIPTION................................................................................................23
3.1.1 INVERTER UNIT........................................................................................................23
3.1.2 ACCELERATOR PEDAL............................................................................................30
5. BRAKE SYSTEM...............................................................................................................39
5.1 GENERAL DESCRIPTION................................................................................................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
7. HYDRAULIC SYSTEM....................................................................................................81
7.1 GENERAL DESCRIPTION................................................................................................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
9. ELECTRIC SYSTEM......................................................................................................125
9.1 SYSTEM DESCRIPTION................................................................................................125
9.1.1 RELAY UNIT.............................................................................................................126
9.1.2 LIGHTS......................................................................................................................128
1. BATTERY AND CHARGER (OPTION)
-1-
1. BATTERY AND CHARGER (OPTION)
LOCK PIN
ELECTROLYTE
LEVEL INDICATOR
Note: The sketch shows a 48-volt battery unit. The 72-volt battery unit has 36 battery cells.
Fig. 1.1 Battery Unit
discharge
Cycles of
Fig. 1.2 R
elation Between Depth of Discharge
and Service Life (Example)
-2-
1. BATTERY AND CHARGER (OPTION)
Specific gravity
(at 20°C)
Voltage (V)
Usable
Voltage
Alert !
Specific gravity
Overdischarge
(Discharge duration)
(Discharge rate)
-3-
1. BATTERY AND CHARGER (OPTION)
-4-
1. BATTERY AND CHARGER (OPTION)
-5-
1. BATTERY AND CHARGER (OPTION)
(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.
PRIMARY WIRE
SECONDARY WIRE
-6-
1. BATTERY AND CHARGER (OPTION)
(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
-7-
1. BATTERY AND CHARGER (OPTION)
-8-
1. BATTERY AND CHARGER (OPTION)
-9-
1. BATTERY AND CHARGER (OPTION)
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.
- 10 -
1. BATTERY AND CHARGER (OPTION)
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
R S T
E
AC INPUT
- 11 -
1. BATTERY
NOTE
- 12 -
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..
- 13 -
2. MOTORS
DRIVE AXLE
DRIVE MOTOR
DRIVE UNIT
- 14 -
2. MOTORS
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
ViewBlooking from B
View looking from A
- 15 -
2. MOTORS
- 16 -
2. MOTORS
MAIN PUMP
メインポンプ PUMP MOTOR
ポンプモータ
A
View looking from A
- 17 -
2. MOTORS
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
- 18 -
2. MOTORS
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
- 19 -
2. MOTORS
- 20 -
2. MOTORS
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.
⑨ For the procedure for checking and servicing the bearings, see (4) Maintenance of bearings.
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. MOTORS
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.
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 -
3. CONTROL SYSTEM
3. CONTROL SYSTEM
3.1 GENERAL DESCRIPTION
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.
- 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
インバータユニット
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))
3. CONTROL SYSTEM
「
認
〉
凶
T
記個瓜﹀
s
z
SENSORl
ACCEl
SENSOR2
ACCEし
STEER[NG
(W)
SENSOR
CSDW
ー一一一一一一一一一一一一寸
SENSORB
OIMREV
SENSORA
D
!MREV
DRIVEINVERTERUNIT
O[MTEMP
SENSOR
ー
L
J
- 25 -
The direction of current
at the time of the steering
wheel being turned
clockwise.
- 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
16P
WP
36P
36P
VP
UP
WD VD UD
- 27 -
2P 2P
F1
インバータユニット
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
fU$ε
V
b..
,t
一一一一一一一一---一一島民一一ー 一 一 つ
F
KEY
→
j│ず
ト
DC48V
Batt
DC72V
Batt
48V
from 3 to 3.5 tons
For trucks with capacities
For trucks with capacities from 3 to 3.5 tons
¥
1,
,,
怜
寸可了 iml
骨官了 iM
i
V
b,悦
、
m
一Z
yoO司﹁
ωoz-
ω山 一 回 一 同 ﹂
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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.
- 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.
2-ton class Connected Connected
3-ton class Connected Connected
* Connected: To be connected to the
signal wire GND.
3. CONTROL SYSTEM
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
- 30 -
4. DRIVE UNIT AND DRIVE AXLE
- 31 -
4. DRIVE UNIT AND DRIVE AXLE
WASHER
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
- 32 -
4. DRIVE UNIT AND DRIVE AXLE
RING GEAR
SPIDER
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
O-RING
COUNTER
カウンタギヤ1
GEAR 1
MOTOR
DRIVE GEAR
- 33 -
4. DRIVE UNIT AND DRIVE AXLE
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
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.]
- 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.
The wheel hub is supported on the spindle by two tapered roller bearings, and is driven by the
4. DRIVE UNIT AND DRIVE AXLE
OIL SEAL
AXLE HOUSING
4. DRIVE UNIT AND DRIVE AXLE
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)
HUB
ADJUSTMENT NUT
LOCK NUT
- 37 -
Tightening torque: 206 to 225 N-m
{2100 to 2300 kgf-cm}
[1820 to 1990 lbf-in.]
(Apply LOCTITE#270)
Tightening torque:
471 to 549 N-m
BRAKE DRUM
- 38 -
5. BRAKE SYSTEM
5. BRAKE SYSTEM
MASTER CYLINDER
- 39 -
5. BRAKE SYSTEM
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. BRAKE SYSTEM
BLEEDER PLUG
CHECK
SNAP RING VALVE
YOKE
LOCK NUT
SPRING
BOOT
PUSH ROD PRIMARY CUP
PISTON
SECONDARY CUP
- 41 -
5. BRAKE SYSTEM
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.
Secondary
Primary
- 42 -
5. BRAKE SYSTEM
Expanding direction
- 43 -
5. BRAKE SYSTEM
RELEASE
BUTTON
PARKING
BRAKE LEVER
RIGHT-SIDE CABLE
LEFT-SIDE CABLE
- 44 -
5. BRAKE SYSTEM
Sectional view A - A
Sectional view C - C
- 45 -
5. BRAKE SYSTEM
Sectional view D - D
Sectional view A - A
Sectional view B - B
- 46 -
5. BRAKE SYSTEM
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.
Fig. 5.13
Fig. 5.14
Fig. 5.15
- 47 -
5. BRAKE SYSTEM
Fig. 5.16
Fig. 5.17
Fig. 5.18
Fig. 5.19
- 48 -
5. BRAKE SYSTEM
5.2.2 INSPECTION
Check each part and repair or replace any defective one.
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.
Fig. 5.21
- 49 -
5. BRAKE SYSTEM
Fig. 5.23
Fig. 5.24
(7) Insert the spring into the strut and attach the strut to the shoe.
- 50 -
5. BRAKE SYSTEM
Fig. 5.25
Fig. 5.27
- 51 -
5. BRAKE SYSTEM
(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. BRAKE SYSTEM
BRAKE SWITCH
Fig. 5.29
- 53 -
5. BRAKE SYSTEM
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 -
6A. STEERING SYSTEM (ORBITROL type)
- 55 -
6A. STEERING SYSTEM (ORBITROL type)
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)
KNUCKLE
(LEFT) KNUCKLE
(RIGHT)
POTENTIOMETER
KING PIN
- 56 -
6A. STEERING SYSTEM (ORBITROL type)
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
OIL SEAL
Detail of D
- 57 -
6A. STEERING SYSTEM (ORBITROL type)
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)
B
A C See Figure 6A.4.
KNUCKLE
(LEFT) KNUCKLE
(RIGHT)
Point notched surface
toward knuckle’s shaft
KING PIN
POTENTIOMETER
- 58 -
6A. STEERING SYSTEM (ORBITROL type)
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
NEEDLE BEARING
LOCK PIN
OIL SEAL
Detail of D
- 59 -
6A. STEERING SYSTEM (ORBITROL type)
STEERING WHEEL
JOINT
View looking from A
ORBITROL
- 60 -
6A. STEERING SYSTEM (ORBITROL type)
Front of
the truck
- 61 -
6A. STEERING SYSTEM (ORBITROL type)
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
T PORT EF PORT
L PORT
R PORT
P PORT
- 62 -
6A. STEERING SYSTEM (ORBITROL type)
Fig. 6A.9
- 63 -
6A. STEERING SYSTEM (ORBITROL type)
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.
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.
- 64 -
6A. STEERING SYSTEM (ORBITROL type)
BUSHING
BUSHING
BOLT
“O”-RING
PACKING
BUSHING
CAP PACKING
DUST SEAL
PISTON ROD
- 65 -
6. STEERING SYSTEM
NOTE
- 66 -
6B. STEERING SYSTEM (EPS type)
- 67 -
6B. STEERING SYSTEM (EPS type)
EPS
CONTROLLER
POTENTIOMETER
EPS MOTOR
ACTUATOR
- 68 -
6B. STEERING SYSTEM (EPS type)
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
- 69 -
6B. STEERING SYSTEM (EPS type)
STEERING
WHEEL
STEERING
WHEEL LOCK
LEVER
JOINT
STEERING
GEARBOX
View looking from A
DRAG LINK
ACTUATOR
- 70 -
6B. STEERING SYSTEM (EPS type)
COMBINATION
Front of SWITCH ASSEMBLY
the truck
- 71 -
6B. STEERING SYSTEM (EPS type)
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
- 72 -
6B. STEERING SYSTEM (EPS type)
CENTER ARM
KING PIN
Detail of A
- 73 -
6B. STEERING SYSTEM (EPS type)
CENTER ARM
SUPPORT (FRONT)
KING PIN
Detail of A
- 74 -
6B. STEERING SYSTEM (EPS type)
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
- 75 -
6B. STEERING SYSTEM (EPS type)
- 76 -
6B. STEERING SYSTEM (EPS type)
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
Fig. 6B.10
Fig. 6B.11
Fig. 6B.12
- 77 -
6B. STEERING SYSTEM (EPS type)
Fig. 6B.13
LOCK NUT
Fig. 6B.14
Apply LOCTITE#271
LOCK NUT
BALL JOINT
Fig. 6B.15
Fig. 6B.16
- 78 -
6B. STEERING SYSTEM (EPS type)
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
MASTER HOLE
°
(3.0 to
3.5 t)
Fig. 6B.21
- 79 -
6. STEERING SYSTEM
NOTE
- 80 -
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
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.] ←
- 81 -
7. HYDRAULIC SYSTEM
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
- 82 -
7. HYDRAULIC SYSTEM
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
- 83 -
7. HYDRAULIC SYSTEM
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.)
- 84 -
7. HYDRAULIC SYSTEM
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
Fig. 7.4
- 85 -
7. HYDRAULIC SYSTEM
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
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
- 86 -
7. HYDRAULIC SYSTEM
CASE
- 87 -
7. HYDRAULIC SYSTEM
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
- 88 -
7. HYDRAULIC SYSTEM
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
- 89 -
7. HYDRAULIC SYSTEM
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
- 90 -
7. HYDRAULIC SYSTEM
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
- 91 -
7. HYDRAULIC SYSTEM
Free flow
自由流
Regulated
制限流
flow
① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨
- 92 -
7. HYDRAULIC SYSTEM
Free
自由流 flow
Regulated
制御流
flow
1. SPRING 6. SLEEVE
2. CASE 7. ORIFICE
3. SPRING 8. SPRING
4. BALL 9. “O”-RING
5. PISTON 10. NIPPLE
- 93 -
7. HYDRAULIC SYSTEM
- 94 -
TILT CYLINDER (RIGHT)
CONTROL VALVE
ORBITROL
to LIFT CYLINDER
- 95 -
TILT CYLINDER (LEFT)
OIL TANK
STEERING CYLINDER
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
CONTROL VALVE
- 96 -
to LIFT CYLINDER
OIL TANK
TILT CYLINDER (LEFT)
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
Fig. 7.19
- 97 -
7. HYDRAULIC SYSTEM
Fig. 7.20
Fig. 7.21
Fig. 7.22
Fig. 7.23
- 98 -
7. HYDRAULIC SYSTEM
Fig. 7.24
Fig. 7.25
Fig. 7.26
Fig. 7.27
- 99 -
7. HYDRAULIC SYSTEM
Fig. 7.28
- 100 -
7. HYDRAULIC SYSTEM
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.
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]
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 -
7. HYDRAULIC SYSTEM
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
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 -
7. HYDRAULIC SYSTEM
Fig. 7.29
Fig. 7.30
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
- 103 -
7. HYDRAULIC SYSTEM
Fig. 7.33
Projection (to be
always pointed to
drive side)
Driven side
Fig. 7.34
Fig. 7.35
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 -
7. HYDRAULIC SYSTEM
Fig. 7.37
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.
Fig. 7.39
- 105 -
7. HYDRAULIC SYSTEM
Fig. 7.40
Fig. 7.41
Gasket groove
”E” gasket
Discharge side Suction side
Fig. 7.42
Fig. 7.43
- 106 -
7. HYDRAULIC SYSTEM
Fig. 7.44
Fig. 7.45
Fig. 7.46
Main lip
Apply grease area
between oil seal lips.
- 107 -
7. HYDRAULIC SYSTEM
⑭ Secure the oil seal with a snap ring and remove the oil seal guide.
Oil seal
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 ]
Fig. 7.51
- 108 -
7. HYDRAULIC SYSTEM
(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. HYDRAULIC SYSTEM
- 110 -
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
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
- 112 -
8. LOAD HANDLING SYSTEM
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
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 -
8. LOAD HANDLING SYSTEM
1. FORK
2. CARRIAGE
3. END ROLLER
4. SHIM
5. SNAP RING
6. SIDE ROLLER
7. SHIM
8. SPACER
VM-7P1
- 114 -
8. LOAD HANDLING SYSTEM
END ROLLER
END ROLLER
Lower section
CARRIAGE
END ROLLER
SIDE ROLLER
Upper section
CHANNEL
INNER
END ROLLER
LIFT CYLINDER
CHANNEL
OUTER
SLIPPER
- 115 -
Upper section Lower section
8. LOAD HANDLING SYSTEM
INNER
END ROLLER CHANNEL
CARRIAGE
END ROLLER
END ROLLER
OUTER SIDE ROLLER
CHANNEL
- 116 -
SLIPPER
END ROLLER
LIFT CYLINDER
INNER
END ROLLER CHANNEL
CARRIAGE
END ROLLER
SIDE ROLLER
- 117 -
SLIPPER
END ROLLER
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.
Fig. 8.7
shown in Table 8.1, using the chain anchor END ROLLER for
pin at the mast side. carriage
FORK
Table 8.1
- 118 -
8. LOAD HANDLING SYSTEM
(3) Make sure that the clearance between the INNER CHANNEL
carriage and the inner channel stoppers STOPPER
CHAIN ANCHOR
PIN at mast side
Fig. 8.9
ANCHOR PIN
ADJUST NUT
LOCK NUT
Fig. 8.10
- 119 -
8. LOAD HANDLING SYSTEM
- 120 -
8. LOAD HANDLING SYSTEM
Fig. 8.15
- 121 -
8. LOAD HANDLING SYSTEM
(9) Install the lift cylinder and carriage in the reverse order of disassembly.
- 122 -
8. LOAD HANDLING SYSTEM
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.
Fig. 8.18
- 123 -
8. LOAD HANDLING SYSTEM
NOTE
- 124 -
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
- 125 -
9. ELECTRIC SYSTEM
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
- 126 -
9. ELECTRIC SYSTEM
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)
- 127 -
9. ELECTRIC SYSTEM
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
*1㧗
*1㧙
HORN
N VF ST VR
IG2 IG1 VF2 Ra
TB TR EL LH
TL LT
- 128 -
9. ELECTRIC SYSTEM
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
ࠢࠕࡦࠬࡦࡊ
ࠢࠕࡦࠬࡦࡊ
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
ࠦࡦࡆࡀ࡚ࠪࡦ
ࠦࡦࡆࡀ࡚ࠪࡦ
LIGHT (LEFT) LIGHT (LEFT)
ࡦࡊ
Ꮐ ࡦࡊ
Ꮐ
ࡈࡠࡦ࠻
FRONT COMBINATION
ࠦࡦࡆࡀ࡚ࠪࡦ
ࡗ
REAR COMBINATION
LIGHT (RIGHT)
ࡦࡊ
ฝ
ࠦࡦࡆࡀ࡚ࠪࡦ
LIGHT (RIGHT)
ࡦࡊ
ฝ
- 129 -
9. ELECTRIC SYSTEM
RELAY UNIT
࡙࠾࠶࠻
(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
࠲ࡦࠪࠣ࠽࡞ࡦࡊ
࠲ࡦࠪࠣ࠽࡞ࡦࡊ
࠲ࡦࠪࠣ࠽࡞ࡦࡊ
(25W)
(25W)
(25W)
(25W)
TURN
TURN
TURN
TURN
FRONT
ࡈࡠࡦ࠻ FRONT
ࡈࡠࡦ࠻ REAR
ࡗ REAR
ࡗ
COMBINATION
ࠦࡦࡆࡀ࡚ࠪࡦ COMBINATION
ࠦࡦࡆࡀ࡚ࠪࡦ COMBINATION
ࠦࡦࡆࡀ࡚ࠪࡦ COMBINATION
ࠦࡦࡆࡀ࡚ࠪࡦ
LIGHT (LEFT)
ࡦࡊ
Ꮐ LIGHT (RIGHT)
ࡦࡊ
ฝ LIGHT (LEFT)
ࡦࡊ
Ꮐ LIGHT (RIGHT)
ࡦࡊ
ฝ
- 130 -
9. ELECTRIC SYSTEM
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
- 131 -
9. ELECTRIC SYSTEM
A A
④
1. LENS
③ 2. RIM
3. HOUSING
⑥ 4. REFLECTOR
5. GASKET
6. BULB
A - AA - A
断面 view
Sectional
- 132 -
9. ELECTRIC SYSTEM
から見る
View looking from A
SIDE MARKER
クリアランスランプ
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
ターンシグナル
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
- 133 -
9. ELECTRIC SYSTEM
GASKET
ガスケット
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.
SCREW
スクリュ
BODY
ボディ
LENS
レンズ
- 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
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
6. ELECTRIC WIRING.......................................................................................................... 83
1. CONTROL CIRCUITS
1. CONTROL CIRCUITS
RW11
CN2D-20
CN2D-33
CN2D-21
CN2D-9
BG 186
LB 184
LG 92
LY 93
3. RB relay
Relay unit
リレーユニット
(1) This relay enables the inverter unit to know
Drive motor inverter unit
(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
to Brake light
ブレーキランプへ
to Fuse F5
ヒューズF5へ
-1-
1. CONTROL CIRCUITS
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
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
F-21
F-2
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
走行コントローラ
Drive motor inverter unit
7. RF relay (option)
リレーユニット
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
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
CN2D-23
CN2D-10
YB 42
wheels.
YL 43
-4-
1. CONTROL CIRCUITS
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
Lever position
-
Down Neutral Up
CN2P-8 1.1 V or 1.1 V or 2.4 to
+
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
YL 22
BL 8
ATT2
ATT1
TILT
-5-
1. CONTROL CIRCUITS
2A P 139
and the negative (-) terminal.
Key switch ON (with seat switch ON): 36 V
F8
RL100
terminals.
1 2 3
W 40
Y 41
B 46
CN2P-16
CN2P-5
CN2P-6
-6-
1. CONTROL CIRCUITS
CN1P-28
CN1P-5
CN1P-4
MODE SEL 1 MODE SEL 2
1 to 1.8 ton
OFF OFF
trucks
Load Handling System
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
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
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.
ESS
SS1
Power Steering System (Orbitrol type)
SS2
1G
BY 244
LY 249
steering wheel.
CN2P-25
CN2P-13
CN2P-14
CN2P-2
CN2P-1
Handle encoder
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
Circuit Diagram Description
CN1D-29
seat, the seat switch turns on, releasing the
interlock.
(4.6 V→0 V)
YW181
BR 9
CN1P-8
CN1P-7
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
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
インバータユニット
(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
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
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 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
Positive terminal
Inverter unit
(drive motor)
Negative terminal
Fuse (F1)
- 12 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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.
- 13 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
■ 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)
Top view
Thru holes
- 14 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
■ Removing the inverter unit (1-, 2- and 3-ton class trucks with an Orbitrol steering system)
Top view
Thru holes
■ 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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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
CN2P
V-phase motor
V相モータ端子
terminal
VB端子
VB terminal
CN1D. P 1 12 CN2D. P 2 1
2
12
24
13
36
25
24
25 13 36
- 16 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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.
CN1E
→ B
VB
N
N
内部回路図
Internal circuit diagram
Lock
ロック
CN1E
17 1
34 18
- 18 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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.
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)
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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.
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.
+
- 21 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
Power
supply 4.75 - 16 V
- 22 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
Checking procedure
Control valve
- 23 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
switch
(1) With the truck key switch off, connect Y7
- 25 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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
button is not pressed.
(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
button is not pressed.
(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
button is not pressed.
(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
button is not pressed.
- 27 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
Checking procedure
Measure the resistance between terminals with the multimeter in the resistance range (minimum
range).
Standard value
- 32 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
New
新
Old
旧
- 33 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
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)
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.
2-ton class trucks (MAX): The
M EPS motor current (A) 45 0 45 current is limited when the steering
wheel is turned to each end.
3-ton class trucks (MAX): The
38 0 38 current is limited when the steering
wheel is turned to each end.
- 34 -
3. TROUBLESHOOTING GUIDE
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
Is any
error code shown on the
LCD panel?
Make repairs
Is the
truck properly
restored?
End
- 35 -
3. TROUBLESHOOTING GUIDE
- 36 -
3. TROUBLESHOOTING GUIDE
Error code 23
LED ON
LED OFF
■ Locations of LEDs
- 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
3. TROUBLESHOOTING GUIDE
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].
(1) Drive system (2/5)
Error code LED
Error description Problem Resetting Error code conditions Page
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
the input returns to normal. seconds.
(Stall signals detected continuously)
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 can be driven normally.
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.
3. TROUBLESHOOTING GUIDE
(1) Drive system (3/5)
Error code LED
Error description Problem Resetting Error code conditions Page
on display code
Drive motor inverter unit
U-phase upper side FET defective
213 The truck won’t travel. Turn the key switch OFF. 16 51
Drive motor inverter unit
U-phase lower side FET defective
Drive motor inverter unit
V-phase upper side FET defective
214 The truck won’t travel. Turn the key switch OFF. 17 51
Drive motor inverter unit
3. TROUBLESHOOTING GUIDE
- 40 -
216
W-phase current detection abnormal, AD
input too low
The truck won’t travel. Turn the key switch OFF. 26 51
W-phase current detection abnormal, AD
input too high
W-phase current offset abnormal, AD
input too low
The truck won’t travel. Turn the key switch OFF. 27 51
W-phase current offset abnormal, AD
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 travel, load handling, and PS (power
the drive and load handling units are
218 steering) systems are inoperative. Turn the key switch OFF. 15 52
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.)
(1) Drive system (4/5)
Error code LED
Error description Problem Resetting Error code conditions Page
on display code
Drive motor inverter unit upper FET
defective
(Error Code 418 also occurs because
The travel, load handling, and PS (power
the drive and load handling units are
219 steering) systems are inoperative. Turn the key switch OFF. 19 54
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.)
Drive motor inverter unit lower FET
defective
(Error Code 418 also occurs because
The travel, load handling, and PS (power
the drive and load handling units are
220 steering) systems are inoperative. Turn the key switch OFF. 21 54
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.)
Automatically resets when
221 Travel overspeed The truck can be driven normally. 94 54
the input returns to normal.
- 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.
The truck can be driven normally.
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.
3. TROUBLESHOOTING GUIDE
(1) Drive system (5/5)
Error code LED
Error description Problem Resetting Error code conditions Page
on display code
Load-handling data reception error
(Communication wire broken)
Automatically resets when
602 (The contactor does not operate when the The truck can be driven normally. 63 56
the input returns to normal.
load-handling data has no errors when
the key switch is turned ON.)
EPS (power steering) data reception
3. TROUBLESHOOTING GUIDE
- 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
Error description Problem Resetting Error code conditions Page
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
Automatically resets when
• 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 input returns to normal.
• 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.
3. TROUBLESHOOTING GUIDE
(2) Load-handling system (including trucks with an Orbitrol steering system) (2/3)
Error code LED
Error description Problem Resetting Error code conditions Page
on display code
Pump motor inverter unit
U-phase upper side FET defective
413 The load-handling system won’t work. Turn the key switch OFF. 16 60
Drive motor inverter unit
U-phase lower side FET defective
Pump motor inverter unit
V-phase upper side FET defective
414 The load-handling system won’t work. Turn the key switch OFF. 17 60
Drive motor inverter unit
3. TROUBLESHOOTING GUIDE
- 44 -
input too low
The load-handling system won’t work. Turn the key switch OFF. 26 60
W-phase current detection abnormal, AD
input too high
W-phase current offset abnormal, AD
input too low
The load-handling system won’t work. Turn the key switch OFF. 27 60
W-phase current offset abnormal, AD
input too high
Pump motor inverter unit upper and
lower FET defective
(Error Code 218 also occurs because the
The travel, load handling, and PS (power
drive and pump motor inverter units are
418 steering) systems are inoperative. Turn the key switch OFF. 15 61
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.)
Pump motor inverter unit upper FET
defective (Error Code 218 also occurs
because the drive and pump motor
The travel, load handling, and PS (power
inverter units are connected with a copper
419 steering) systems are inoperative. Turn the key switch OFF. 19 61
bar.)
Contactor OFF.
(Error Code 217 is also triggered
because the capacitor between the P and
N terminals cannot be charged.)
(2) Load-handling system (including trucks with an Orbitrol steering system) (3/3)
Error code LED
Error description Problem Resetting Error code conditions Page
on display code
Pump motor inverter unit lower FET
defective
(Error Code 218 also occurs because
The travel, load handling, and PS (power
the drive drive and pump motor inverter
420 steering) systems are inoperative. Turn the key switch OFF. 21 61
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.)
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)
Automatically resets when
- (The contactor does not operate when The truck can be driven normally. 61 62
the input returns to normal.
the drive data has no errors when the key
switch is turned ON.)
- 45 -
Overcurrent
- The load-handling system won’t work. Turn the key switch OFF. 91 61
(Hard OCL detected)
3. TROUBLESHOOTING GUIDE
(3) EPS Power steering system (1/2)
Error code LED
Error description Problem Resetting Error code conditions Page
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.
The travel, load-handling and EPS
EPS transistor short-circuited
(power steering) systems are inoperative. Turn the key switch OFF. 06 63
(after startup)
Contactor OFF.
506
The travel, load-handling and EPS
3. TROUBLESHOOTING GUIDE
- 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
Error description Problem Resetting Error code conditions Page
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. TROUBLESHOOTING GUIDE
3. TROUBLESHOOTING GUIDE
- 48 -
3. TROUBLESHOOTING GUIDE
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.
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.
④ Check the F/R lever switch voltage. Repair the F/R lever switch or wiring.
(2) 101
09 : Low voltage (Low battery voltage) Resets when the key switch is turned OFF.
- 49 -
3. TROUBLESHOOTING GUIDE
(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).
(4) 201
07 :F
orward travel switch or reverse travel switch Automatically resets when the input returns to
abnormal normal.
(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
(TMD2) AD input range abnormal normal.
- 50 -
3. TROUBLESHOOTING GUIDE
① Turn the key switch OFF and allow the motor to cool
down for at least 30 minutes.
(8) 207
35 :D
rive motor thermosensor defective Automatically resets when the input returns to
AD input range abnormal normal.
(9) 208
89 : Excessive travel inching Resets when the accelerator output is OFF.
- 51 -
3. TROUBLESHOOTING GUIDE
(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
otation sensor defective Automatically resets when the input returns to
Bearing defective (Stall signals detected
normal.
continuously)
② Check the motor slit board. Repair the motor slit board.
- 52 -
3. TROUBLESHOOTING GUIDE
307
- : Accelerator potentiometer not positioned Automatically resets when the accelerator voltage
properly is 0.8 V or more.
(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.
(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.
AD input too low, AD input too high
216
26 : W-phase current detection abnormal Resets when the key switch is turned OFF.
AD input too low, AD input too high
216
27 : W-phase current offset abnormal Resets when the key switch is turned OFF.
AD input too low, AD input too high
- 53 -
3. TROUBLESHOOTING GUIDE
(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)
(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.
② Check the drive motor slit board. Repair the slit board.
- 54 -
3. TROUBLESHOOTING GUIDE
(18) 308
12 :C
ontactor coil broken Resets when the key switch is turned OFF.
(Blown fuse)
(19) 309
11 : Contactor coil short-circuited Resets when the key switch is turned OFF.
(20) 318
86 :O
vervoltage (Battery connectors disconnected Resets when the key switch is turned OFF.
during regenerative braking)
③ Check the tire angle potentiometer. Repair the tire angle potentiometer.
- 55 -
3. TROUBLESHOOTING GUIDE
(22) 600
65 :L
CD panel data reception error Automatically resets when the input returns to
(Communication wire broken) normal.
(23) 602
63 :L
oad-handling data reception error Automatically resets when the input returns to
(Communication wire broken) normal.
603
64 :E
PS data reception error Automatically resets when the input returns to
(Communication wire broken) normal.
(24) -
08 : Abnormal battery voltage Resets when the key switch is turned OFF.
- 56 -
3. TROUBLESHOOTING GUIDE
(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.
③ Check the drive motor cable for short circuit. Correct the cable.
(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.
- 57 -
3. TROUBLESHOOTING GUIDE
② Check the lift potentiometer voltage. Repair the lift potentiometer or wiring.
(3) 404
31 :P
ump motor inverter unit thermosensor 1 Automatically resets when the input returns to
(TMD1) AD input range abnormal normal.
404
32 :P
ump motor inverter unit thermosensor 2 Automatically resets when the input returns to
(TMD2) AD input range abnormal normal.
① Turn the key switch OFF and allow the motor to cool
down for 30 minutes.
- 58 -
3. TROUBLESHOOTING GUIDE
(5) 407
35 :P
ump motor thermosensor defective Automatically resets when the input returns to
AD input range abnormal normal.
(6) 410
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.
410
74 :R
otation sensor defective Automatically resets when the input returns to
Abnormal bearing (Stall signals detected
normal.
continuously)
② Check the pump motor slit board. Repair the motor slit board.
- 59 -
3. TROUBLESHOOTING GUIDE
(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.
(9) 416
24 : V-phase current detection abnormal Resets when the key switch is turned OFF.
AD input too low, AD input too high
416
25 : V-phase current offset abnormal Resets when the key switch is turned OFF.
AD input too low, AD input too high
416
26 : W-phase current detection abnormal Resets when the key switch is turned OFF.
AD input too low, AD input too high
416
27 : W-phase current offset abnormal Resets when the key switch is turned OFF.
AD input too low, AD input too high
- 60 -
3. TROUBLESHOOTING GUIDE
(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.
(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.
③ Check the pump motor for short circuit. Correct the cable.
- 61 -
3. TROUBLESHOOTING GUIDE
(12) -
61 :D
rive data reception error (Communication Resets when the key switch is turned OFF.
wire broken)
(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.
- 62 -
3. TROUBLESHOOTING GUIDE
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.
(2) 507
04 : EPS transistor open Resets when the key switch is turned OFF.
- 63 -
3. TROUBLESHOOTING GUIDE
(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.
(5) -
09 : DM open Resets when the key switch is turned OFF.
② Turn the key switch OFF and allow the FET to cool
–
down.
(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.
- 64 -
3. TROUBLESHOOTING GUIDE
- 65 -
3. TROUBLESHOOTING GUIDE
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 -
3. TROUBLESHOOTING GUIDE
(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. TROUBLESHOOTING GUIDE
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 -
3. TROUBLESHOOTING GUIDE
0V
LCD panel
In maintenance mode:
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
2.4 to 2.7V
- 69 -
3. TROUBLESHOOTING GUIDE
20(YR)
Key switch ............ Turn it ON. Pump motor inverter
Pump motor
inverter 0V YR20
BL9
5V
(7) T
he pump motor is running when no load-handling operation is being performed.
(Applicable only to trucks with an EPS steering system)
- 70 -
3. TROUBLESHOOTING GUIDE
EPS motor
Key switch ................ Turn it ON.
CN3E-1 Replace the EPS motor.
Turn the steering wheel.
CN3E-2 0A
0 to 40 V
Below
Key switch ................ Turn it ON. 600 rpm
In maintenance mode:
Turn the steering wheel clockwise Steering potentiometer
O (Pump motor rpm)
or counterclockwise to stop. YR 44
0 to 600 rpm
- 71 -
3. TROUBLESHOOTING GUIDE
NOTE
- 72 -
4. PARAMETER SETTING
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.
Program version
Battery voltage
The actual temperature
Temperature detected detected is the displayed
(LCD panel) value minus 15.
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. PARAMETER SETTING
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
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 -
4. PARAMETER 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 -
4. PARAMETER SETTING
TERMINATED
- 76 -
FB-8 Parameter Setting Table Factory settings
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. PARAMETER SETTING
4. PARAMETER SETTING
100
Accelerator power curve
アクセルステージ特性
Level 0
レベル0
80
Level 1
レベル1
Level 2
レベル2
Level 3
[%] [%]
レベル3
60
Level 4,5,6
command
レベル4、5、6
Level 7,8
レベル7、8
速度指令
40
Level 9,10
レベル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]
- 78 -
4. PARAMETER SETTING
- 79 -
4. PARAMETER SETTING
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).
Mode button Selects the digit to enter. Confirms the entered password.
+ button
- button Increases or decreases the number.
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.
- 80 -
5. DESCRIPTION OF THE FUNCTIONS
<Deactivation conditions>
(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. DESCRIPTION OF THE FUNCTIONS
(6) Output duty factor reduction when the rear wheels are at the maximum steering angle
(Excluding trucks with an Orbitrol steering system)
<Activation conditions>
• The rear wheels are within 5 degrees of the maximum steering angle.
<Control applied>
• Limits the output duty factor to 10%.
<Deactivation conditions>
• 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.
Y L 22 Wire
B Black R Red W 110 Wire
number number
G Green W White
L Blue Y Yellow
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
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
ࡉࠠࠬࠗ࠶࠴߳ to EMERGENCY SWITCH
ࠛࡑࠫࠚࡦࠪࠬࠗ࠶࠴߳
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)
㩿䉥䊒䉲䊢䊮㪀
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
- 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
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
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,
䊪䉟䊟䊊䊷䊈䉴䊶
OVERHEAD GUARD (LEFT)
䊓䉾䊄䉧䊷䊄㩿Ꮐ㪀䈻
GR WG
WIRE HARNESS,
䊪䉟䊟䊊䊷䊈䉴䊶
GL WG
106 109-1 105 109
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
ࡉࠠࠬࠗ࠶࠴߳ toࠛࡑࠫࠚࡦࠪࠬࠗ࠶࠴߳
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)
㩿䉥䊒䉲䊢䊮㪀
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
- 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,
ワイヤハーネス・
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
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,
ワイヤハーネス・
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.
- 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
パーキングアラームへ
RL RG
100-2 216
LB(137) YG RW
RG(102-3) 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 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
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
to LIFT POTENTIOMETER
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,
ワイヤハーネス・
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)
回転センサ(A)へ
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
ドライブモータ
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
サーモセンサへ
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
サーモセンサへ
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
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,
ワイヤハーネス・
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.
- 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
パーキングアラームへ
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,
ワイヤハーネス・
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
to LIFT POTENTIOMETER
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)
回転センサ(A)へ
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
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
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,
ワイヤハーネス・
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.
- 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
スイッチパネル
20P
6P
W WR
16P
W B
6P
PW 6P
3P
PV
PU
6P
6P
3P
4P
REAR COMBINATION
リヤコンビネーション
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.
- 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
リヤコンビネーション
エマージェンシ
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)
(オプション) LR Y
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
CONTROL SWITCH PANEL
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
ブレーキスイッチ
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
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
BUZZER
ブザー B B
HORN SWITCH
ホーンスイッチ RW WBr
2P
2P
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
シートスイッチ
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
ヘッドランプ(左)
(LEFT) BATTERY
チャージャ CHARGER
SWITCH PANEL
スイッチパネル
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
リヤコンビネーション
ポンプ 2P
PUMP LIGHT
ランプ(左)(LEFT)
FRONT COMBINATION
フロントコンビネーション
MOTOR 3P
LIGHT
ランプ(左)(LEFT) モータ
Note: Trucks with an Orbitrol steering system do not have an EPS motor.
- 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
リヤコンビネーション
エマージェンシ
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)
(オプション) LR Y
BEACON
回転灯 LIGHT
TRANSFORMER
トランス
RL
W
R
LG
B
6P
CONTROL SWITCH PANEL
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
フロントコンビネーション
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
ブレーキスイッチ
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
F/Rスイッチ SOLENOID
ソレノイド RW WL
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-
シートスイッチ
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
ヘッドランプ(左)
(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
リヤコンビネーション
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.
- 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
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
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
TURN SIGNAL LIGHT (RB)
F-14
(25W) WR 113
F-23
䉪䊥䉝䊤䊮䉴䊤䊮䊒
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
䉮䊮䊎䊈䊷䉲䊢䊮
(40W)
䊓䉾䊄䊤䊮䊒㩿ฝ㪀
HEAD LIGHT (RIGHT)
(40W)
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
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
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
TURN SIGNAL LIGHT
SWITCH TURN
L
R
N
(23W)
㪝㪆㪩䉴䉟䉾䉼
䊁䊷䊦䊤䊮䊒
SWITCH
REAR
TB TR TL
N IG1 IG2 VF VF2 ST VR Ra
䊋䉾䉪䉝䉾䊒䊤䊮䊒
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
䊥䊟䉮䊮䊎䊈䊷䉲䊢䊮
CN1D-18
CN1D-19
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) (-)
㩿䉥䊒䉲䊢䊮㪀
(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-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
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
G 25
INVERTER
䊝䊆䉺
CNMC
2 1
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
(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
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
LCD PANEL
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
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
-
䊥䊐䊃
UNIT
䉟䊮䊋䊷䉺䊡䊆䉾䊃
YL 94 CN2P-8
䊘䊁䊮䉲䊢䊜䊷䉺
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
䊘䊁䊮䉲䊢䊜䊷䉺
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
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
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
TURN SIGNAL LIGHT
GL 105
(LEFT)
(25W)
RG 102
FET UNIT
F-22
䉮䊮䊎䊈䊷䉲䊢䊮
COMBINATION
䊥䊧䊷䊡䊆䉾䊃
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
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
TURN SIGNAL LIGHT (RB)
F-14
(25W) WR 113
F-23
䉪䊥䉝䊤䊮䉴䊤䊮䊒
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)
䉮䊮䊎䊈䊷䉲䊢䊮
F-11
LIGHT (RIGHT)
COMBINATION
(40W)
䊓䉾䊄䊤䊮䊒㩿ฝ㪀
HEAD LIGHT (RIGHT)
(40W)
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
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
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
䉺䊷䊮䉲䉫䊅䊦䊤䊮䊒
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
䊑䊧䊷䉨䊤䊮䊒
STOP LIGHT (25W) L 131
REAR
LIGHT
TB TR TL
N IG1 IG2 VF VF2 ST VR Ra
䊋䉾䉪䉝䉾䊒䊤䊮䊒
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
䊥䊟䉮䊮䊎䊈䊷䉲䊢䊮
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
㩿䉥䊒䉲䊢䊮㪀
(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-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
WG 225 (DOWN)
㩿䊄䊤䉟䊑㪀
CN9-2-9 LW 187
CN2D-32
-
CONTROL
INVERTER
CNMC
2 1
ACCELERATOR
䊘䊁䊮䉲䊢䊜䊷䉺㪈
䊝䊆䉺
CN9-1-7
S3
MONITOR
CN9-2-4 CN2D-33
UNIT
-
䉟䊮䊋䊷䉺䊡䊆䉾䊃
䊡䊆䉾䊃
P 27
UNIT
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
CN1-14 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
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
CN1-4 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
䉟䊮䊋䊷䉺䊡䊆䉾䊃
YL 94 CN2P-8
䊘䊁䊮䉲䊢䊜䊷䉺
LIFT POTENTIOMETER
N
CN1-11 RY 101
RL 100
CN3-5 CN1E-17
CN1E-34
PO2
CN1-18 CN1E-21
PO1
CN1E-6
PS
+ L 160 CN1E-22
㪜㪧㪪䊃䊦䉪
EPS TORQUE G 161
MOTOR
䊘䊁䊮䉲䊢䊜䊷䉺
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
.
.
n
塁
TCMCORPORATION