FRB-8A Service Training

Challenge for Excellence
Training Text
Electric Forklift Model FR(H)B-8A
Copyright © 2013 UniCarriers Corporation. All Rights Reserved.

Contents
Summary
1. Control system and Parameter setting
2. Troubleshooting guide
3. Battery
4. Inspection of Major electric components
5. System wiring diagram

Summary Challenge for Excellence
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1. CONTROL SYSTEM Challenge for Excellence
1.1 BLOCK DIAGRAM
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1.2 GENERAL DESCRIPTION OF TRUCK CONTROL Challenge for Excellence
1. Connecting batteries to the truck

The batteries provide power for the electric components of the truck, such as the illumination
lights, and the power can be switched on or off using the respective component switches. In
addition, battery power is also provided to the battery connection terminals on the main
controller, EPS controller and meter panel, making everything ready for the truck to be
started.
2. Turning the key switch to ON

When the key switch is turned to the ON position, the controllers and the meter panel are
powered and turn on. The meter panel starts a self-check of the whole electrical system for
any problems or failures. If any errors are found, the meter panel displays the error codes
corresponding to those errors. The operation of the controllers and meter panel may be
disabled if
the error is serious.
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3. Travel speed control

When the accelerator lever is pushed forward or pulled back, the accelerator sensor converts
the tilt direction and angle of the lever into a corresponding voltage and outputs that voltage
to the drive module. The drive module controls the rotating speed and direction of the drive
motor, making it output the amount of power dictated by the voltage from the accelerator
sensor. The drive motor rotation is fed back to the drive module by the rotation sensor
incorporated in the bearing section, so that the operating status of the drive motor can be
monitored.
4. Lifting speed control

When the lift lever is tilted toward the lift side, the pump controller starts controlling the
pump motor using the voltage of the lift potentiometer. The amount the lever is moved is
converted by the lift sensor to a corresponding voltage, which is transmitted to the pump
module. The pump module controls the pump motor so that the greater movement of the lift
lever, the faster the pump motor will run.
The pump motor is only operating when the lift lever is tilted toward the lift side. It does not
run when the lift lever is tilted toward the lower side.
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5. Steering control
When the steering wheel is turned, two torque sensors transmit the rotating force and
direction of steering wheel to the EPS controller as voltages. The EPS controller drives the EPS
motor in the same direction as the steering wheel is rotated. The EPS motor keeps rotating as
long as the steering wheel is turned and the torque sensors detect rotational torque. When
the steering wheel stops turning, the torque sensors no longer detect any torque and the EPS
motor stops.
If the drive unit is turned by external force while the steering wheel is not being turned, the
torque sensors detect the rotational torque and cause the EPS controller to turn the EPS
motor in the direction opposite the direction in which the drive unit has been turned,
minimizing displacement of the drive unit by external forces.
The direction of the drive unit is sensed by an angle sensor and displayed on the meter panel.
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1.3 MAIN CONTROLLER Challenge for Excellence
1.3.1 Leading particulars
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1.3 MAIN CONTROLLER Challenge for Excellence
1.3.2 GENERAL DESCRIPTION

The main controller consists of a
drive module that controls the
drive motor, a pump module
that controls the pump motor, a
fuse unit and an MD contactor unit.
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1.3.2 GENERAL DESCRIPTION Challenge for Excellence
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DRIVE CONTROLLER DIAGRAM Challenge for Excellence
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CONNECTOR ARANGMENT (DRIVE) Challenge for Excellence
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LOAD HANDLING CONTROLLER DIAGRAM Challenge for Excellence
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CONNECTOR ARANGEMENT (LOAD HANDLING) Challenge for Excellence
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MAINTENANCE PROCEDURE Challenge for Excellence
CAUTION
Do not touch energized electric components.
• Turn off the key switch.
• Separate the battery connectors and wait more
than 15 minutes until they are completely
Discharged.
Drive and load handling controllers

Both the drive and load handling controllers
can be inspected in the same manner.
1. Remove the controller.
2. Measure the resistance between terminals.
3. Judge conformances to specifications based on
the measurements.
For the purpose of this inspection, use an analog
multimeter. Set the function for the measurement
of resistance and the range for 1000 .
If a digital multimeter is used, it should a resistance
of 20 to 30 Kohm between all terminal.
If there is a short-circuit between terminals, the
multimeter should read 0 to 20 or 30 Ohm. 15
Drive and load handling controllers Challenge for Excellence
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MD contactor
(Mechanical operation)
1. Visually check the general condition of the MD contactor for serious scratches, damage or
discoloration.
2. Visually check the surface of each contact for severe roughness.
Replace any MD contactor showing severe roughness or wear, with a new one.
<Coil>
1. Turn off the key switch.
2. Separate the battery connectors and wait
more than 15 minutes until they are
completely discharged.
3. Disconnect the coil wiring connector (1).
NOTE:
The range of the multimeter should be set for x100 Ohm.
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Fast charge resistor

1. Visually check the general condition of the
fast charge resistor for serious scratches,
damage or discoloration.
2. Turn off the key switch.
3. Separate the battery connectors and wait
4. Disconnect the wiring connector (1).
NOTE:
The range of the multimeter should be set for x100 Ohm.
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1.4 EPS CONTROLLER Challenge for Excellence

The EPS controller drives the EPS
motor according the signal from the
torque sensor.
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EPS CONTROLLER DIAGRAM Challenge for Excellence
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CONNECTOR ARRANGMENT (EPS) Challenge for Excellence
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CAUTION
Do not touch energized electric components.
Observe the following conditions when
disassembling electric components on the
truck.
Turn off the key switch.
Separate the battery connectors and wait
1. Disconnect all EPS controller wiring.

3. Judge conformances to specifications based
on the measurements.
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1.5 METER PANEL Challenge for Excellence
The meter panel indicates the operating

status of the truck and allows you to set its
display functions as well as their
parameters (to “enable” or “disable” each
function, set control limit values, etc.) using
the keypad. (More details see…)
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2. TROUBLESHOOTING GUIDE Challenge for Excellence
Trouble diagnosis flow chart HOW TO USE THIS GUIDE

If error code(s) are displayed on the meter
panel, refer to “LIST OF ERROR
CODES AND TROUBLESHOOTING”.
If the truck fails to operate normally
without displaying any error code on the
meter panel, refer to “FAILURE
PHENOMENA (WITHOUT ERROR CODES)
AND TROUBLESHOOTING”.
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TROUBLESHOOTING GUIDE Challenge for Excellence
Error codes shown by LED light

It is off in normal operating conditions, but
starts blinking when an error is detected.
Error codes are indicated as 2-digit numbers
(decimal system).
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2.3 LIST OF ERROR CODES AND TROUBLESHOOTING Challenge for Excellence
2.3.1 METER PANEL SYSTEM ERRORS
System errors are shown on the meter

panel, preferentially over error
information from the controllers.
System errors are divided into roughly
two categories: serious errors (the system
won’t be able to operate any longer) and
moderate ones (the system can be
restored by the user).
*1 Internal codes of serious and

moderate errors of the system
The internal codes are allocated in the
following ranges for each type of errors:
Serious system errors : 71 - 100
Moderate system errors: 171 - 200
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2.3 LIST OF ERROR CODES AND TROUBLESHOOTING Challenge for Excellence
*2 Controller communication error (CPU status error in the CAN communication mode)
When data is being transmitted or received through the controller area network (CAN) of the
CPU, the operating status of the communication line is checked by monitoring status changes
in the controller area network register.
controller communication error and displayed on the meter panel.
(In normal operating conditions, the register will change status in less than 100 ns.)
*3 Errors “P0 contactor short-circuited” and “CM contactor short-circuited” cannot be detected
by the hardware. Such errors are not actually output.
*4 The buzzer sounds repeatedly at 1 second intervals (0.5 seconds ON and 0.5 seconds OFF).
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2.3.2 LIST OF ERROR CODES FOR THE TRUCK Challenge for Excellence
1. Drive system (Replace the drive module if any problem cannot be solved by following as below)
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See more details in Service manual
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2.4 FAILURE PHENOMENA (WITHOUT ERROR CODES) AND
TROUBLESHOOTING Challenge for Excellence
2.4.1 Meter panel

IMPORTANT:
Before starting the troubleshooting
procedure, make sure that the battery
connectors are securely connected.
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2.4.2 MD CONTACTOR (TRAVEL,

LOAD HANDLING, STEERING)
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2.4.2 MD CONTACTOR (TRAVEL,

LOAD HANDLING, STEERING)
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2.4.3 MD CONTACTOR (TRAVEL)
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2.4.4 TRAVELING SYSTEM
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2.4.5 LOAD HANDLING (LIFT) Challenge for Excellence
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2.4.6 LOAD HANDLING (TILT) Challenge for Excellence
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2.4.7 LOAD HANDLING (REACH) Challenge for Excellence
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2.4.8 LOAD HANDLING OPERATION Challenge for Excellence
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2.4.9 STEERING OPERATION Challenge for Excellence
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3. Battery Challenge for Excellence

The battery consists of 24 two-volt battery cells connected in series and housed in the battery
case.
1. CELL
2. CONNECTOR
3. TERMINAL COVER
4. PLUG
5. CAP WITH FLOAT
6. CAP WITH FLOAT AND SENSOR 42
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4. INSPECTION OF MAJOR ELECTRIC COMPONENTS Challenge for Excellence
4.1.1 FRONT FRAME
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4.1.2 REAR FRAME
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4.1.3 UPPER COVER
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4.1.4 CENTER FRAME
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4.2.1 LEADING PARTICULARS Challenge for Excellence
4.2.1 LEADING PARTICULARS
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(1) DRIVE MOTOR
The drive motor is a 3-phase AC motor and its rotation is controlled by the drive inverter of the
main controller.
The drive motor has a rotation sensor incorporated into the bearing at the non-connection side,
to feed back its rotation to the drive inverter.
The motor frame ids fitted with a thermo-sensor which allows the drive inverter to monitor the
operating temperature of the drive motor
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(1) DRIVE MOTOR
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(2) PUMP MOTOR

The pump motor is a 3-phase AC
motor and its rotation is controlled
by the pump inverter of
the main controller.
The pump motor has a rotation
sensor incorporated into the
bearing at the non-connection
side to feed back its rotation to
the pump inverter.
The motor frame ids fitted with a

thermo-sensor which allows the
drive inverter to monitor the
operating temperature of the
pump motor.
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(3) EPS MOTOR

The EPS motor is a DC motor which is controlled by the EPS module.
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4.2.3 MAINTENANCE PROCEDURE Challenge for Excellence
Checking the drive motor

Measuring insulating resistance
1. Remove all of the wires leading to the
motor.
2. Measure the insulating resistance between
the frame and the coil.
Checking the thermo-sensor

1. Measure the resistance between two
terminals of the thermo-sensor.
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Checking the rotation sensor

1. Connect pull-up resistances between power
supply terminal (1) and output terminals (2
and 4).
NOTE:
The pull-up resistance value is set so that
the sink current of the transistor is 20 mA or
less.
2. Supply a voltage of +5 to +24 VDC to the

power supply terminal (1).
3. Turn the bearing inner ring and check the
output waveform to see if it meets the specified
value.
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Adjacent pitch tolerance = {|(Tn-Tn+1)|/ Tn} × 100

Duty (%) = (Tp/Tn) × 100
Advance (°) = (Tab/Tn) × 360
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(4) Checking the pump motor

1. Remove all of the wires leading to the
motor.
the frame and the coil.
Checking the thermo-sensor

1. Measure the resistance between two
terminals of the thermo-sensor.
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Checking the rotation sensor

1. Connect a pull-up resistance between power
supply terminal (1) and output terminal (2).
NOTE:
The pull-up resistance value is set so that the sink
current of the transistor is 20 mA or less.
2. Supply a voltage of +4.75 to +16 VDC to

the power supply terminal (1).
3. Turn the motor shaft to check the output

waveform to see if it meets the specified value.
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(5) Checking the EPS motor

1. Remove all of the wires leading to the motor.
the frame (1) and the coil (2).
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4.2.4 TROUBLESHOOTING GUIDE Challenge for Excellence
(1) Drive and pump motors
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4.2.4 TROUBLESHOOTING GUIDE Challenge for Excellence
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4.3 OTHER ELECTRIC COMPONENTS Challenge for Excellence
4.3.1 FUSES (F4, F5, F8 and F9)

(1) Inspection
1. Remove the each fuse from the fuse holder
and check them for continuity, using a
multimeter.
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4.3.2 ACCELERATOR Challenge for Excellence
(3) Checking and adjustment

1. With the key switch turned on, check the output voltage at the connector of the drive
module side.
2. When the accelerator lever is in neutral, the voltage at each of the terminals OUT 1 and
OUT 2 should be 2.5 ±0.1 V. If the measurement is not as specified, adjust the voltage by
turning the accelerator sensor (1) the right or left.
3. Tilt the accelerator lever back and forth to check to see if the output voltage varies
accordingly.
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4.3.2 ACCELERATOR Challenge for Excellence
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4.3.3 ANGLE SENSOR Challenge for Excellence
IMPORTANT:
Check whether the shaft makes 10 turns
from the right end to the left end. Stop the
rotation of the shaft at 5 turns from the right
or left end and reinstall the angle sensor.
(2) Inspection
1. Turn the shaft and measure the resistance
between the terminals (1 and 2).
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4.3.3 ANGLE SENSOR Challenge for Excellence
(3) Adjusting the mounting position

1. With the key switch turned on, check the output voltage at the connector of the drive
module side.
2. Turn the steering wheel to place the drive tire in the straight-ahead position.
3. Check that the angle sensor output voltage is 2.5 ±0.1 V.
4. If the measurement is not as specified,

remove the angle sensor and adjust the
voltage by turning the shaft.
5. After adjustment, check that tire angle
indicator on the meter panel indicates the
direction of the drive wheel correctly.
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4.3.4 TORQUE SENSOR Challenge for Excellence
Inspection
1. With the key switch turned on, check the
output voltage at the connector of the EPS
module side.
2. Turn the steering wheel to check to see if

The output voltage is as specified.
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4.3.5 LIFT SENSOR Challenge for Excellence
(1) Removal and reinstallation

Removal
1. Remove the bolts (1) and remove the lift
sensor (2) from the cap.
Reinstallation
1. Reinstall the lift sensor by reversing the
steps used to remove it.
(2) Inspection
1. With the key switch turned on, check the
output voltage at the connector of the pump
module side.
2. When the lift lever in in neutral, the OUT
voltage should be 2.5 ±0.1 V.
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4.3.5 LIFT SENSOR Challenge for Excellence
3. Tilt the lift lever back and forth to check to

see if the output voltage varies accordingly.
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4.3.6 LIFT LOCK SOLENOID Challenge for Excellence
(1) Removal and reinstallation

1. Disconnect the cable leading to the
solenoid (3) at the connector.
2. Remove the screw (4) and remove the
solenoid (3).
Reinstallation
1. Reinstall the lift lock solenoid by reversing
the steps used to remove it.
(2) Inspection
1. Measure the resistance between terminals
(1) and (2) of the connector.
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5. SYSTEM WIRING DIAGRAM Challenge for Excellence
5.1 POWER SUPPLY AND CHARGING SYSTEMS
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5.1 POWER SUPPLY AND CHARGING SYSTEMS Challenge for Excellence
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5.2 AUXILIARY SYSTEM (LIGHTING SYSTEM) Challenge for Excellence
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5.2 AUXILIARY SYSTEM (LIGHTING SYSTEM) Challenge for Excellence
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5.3 OPERATION AND CONTROL SYSTEM (METER PANEL) Challenge for Excellence
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5.3 OPERATION AND CONTROL SYSTEM (METER PANEL) Challenge for Excellence
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5.4 DRIVE SYSTEM Challenge for Excellence
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5.4 DRIVE SYSTEM Challenge for Excellence
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5.5 LOAD HANDLING SYSTEM Challenge for Excellence
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5.5 LOAD HANDLING SYSTEM Challenge for Excellence
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5.6 STEERING SYSTEM (POWER STEERING) Challenge for Excellence
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5.7 4-WAY TRUCKS Challenge for Excellence
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Wiring connection diagram Challenge for Excellence
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7. GENERAL WIRING DIAGRAM Challenge for Excellence
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CopyrightGeneral wiring diagram
© 2013 UniCarriers Corporation. All Rights Reserved.
Service data Challenge for Excellence



Service data (FRB-8A Parameter Setting Table) Challenge for Excellence
88

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Challenge for Excellence

Challenge for Excellence

Copyright © 2013 UniCarriers Corporation. All Rights Reserved.

Copyright © 2013 UniCarriers Corporation. All Rights Reserved.

1.1 BLOCK DIAGRAM

1. Connecting batteries to the truck

2. Turning the key switch to ON

3. Travel speed control

4. Lifting speed control

1.3.1 Leading particulars

1.3.2 GENERAL DESCRIPTION

Drive and load handling controllers

Fast charge resistor

1.4.1 GENERAL DESCRIPTION

1. Disconnect all EPS controller wiring.

The meter panel indicates the operating

Trouble diagnosis flow chart HOW TO USE THIS GUIDE

Error codes shown by LED light

2.3.1 METER PANEL SYSTEM ERRORS

System errors are shown on the meter

*1 Internal codes of serious and

See more details in Service manual

2.4.1 Meter panel

2.4.2 MD CONTACTOR (TRAVEL,

2.4.2 MD CONTACTOR (TRAVEL,

2.4.3 MD CONTACTOR (TRAVEL)

2.4.4 TRAVELING SYSTEM

3.1.2 GENERAL DESCRIPTION

4.1.1 FRONT FRAME

4.1.2 REAR FRAME

4.1.3 UPPER COVER

4.1.4 CENTER FRAME

4.2.1 LEADING PARTICULARS

4.2.2 GENERAL DESCRIPTION

(1) DRIVE MOTOR

(2) PUMP MOTOR

The motor frame ids fitted with a

(3) EPS MOTOR

Checking the drive motor

Checking the thermo-sensor

Checking the rotation sensor

2. Supply a voltage of +5 to +24 VDC to the

Adjacent pitch tolerance = {|(Tn-Tn+1)|/ Tn} × 100

(4) Checking the pump motor

Checking the thermo-sensor

Checking the rotation sensor

2. Supply a voltage of +4.75 to +16 VDC to

3. Turn the motor shaft to check the output

(5) Checking the EPS motor

(1) Drive and pump motors

4.3.1 FUSES (F4, F5, F8 and F9)

(3) Checking and adjustment

(3) Adjusting the mounting position

4. If the measurement is not as specified,

2. Turn the steering wheel to check to see if

(1) Removal and reinstallation

3. Tilt the lift lever back and forth to check to

(1) Removal and reinstallation

5.1 POWER SUPPLY AND CHARGING SYSTEMS

Copyright © 2013 UniCarriers Corporation. All Rights Reserved.

Copyright © 2013 UniCarriers Corporation. All Rights Reserved.

Copyright © 2013 UniCarriers Corporation. All Rights Reserved.

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