Seb 7a0ae (FRB 8)

FOREWORD
TCM is offering a new series of FRB-8 reach type forklift trucks (capacities from 1.0 to 3.0 tons)
equipped with an AC drive motor and controlled by an inverter controller. The AC motor does not
have any parts to wear out and does not require any mechanical adjustments, ensuring improved
serviceability.
All of the trucks in this series come with electric power steering (EPS) as standard equipment. The
direction of the drive wheel is displayed on the LCD panel on the dashboard, for better controllability
and more safety.
This Service Manual describes the design and basic equipment parts of this series of trucks.
We encourage you to make practical use of the manual whenever servicing the truck.
November 2008
SPECIFICATIONS (1)
Truck Model
Item
Performance
Max. load kg [lbs]
Load center mm [in.]
Max. lifting height mm [in.]
Reach stroke mm [in.]
Tilting angle (Fwd - Bwd) º
Free lift mm [in.]
Fork lifting speed mm/s [ft/min]
(Loaded)
(Unloaded)
Travel speed km/h [mph]
Fwd (loaded)
(unloaded)
Bwd (loaded)
(unloaded)
Gradeability
(Unloaded)
(Loaded)
Min. turning radius mm [in.]
Min. intersecting aisle mm [in.]
(with a 1100 x 1100 mm [43 x 43 in.] pallet)
Dimensions mm [in.]
Overall length (include. fork)
Overall width
Overall height (Head guard)
Overall extended height
Wheel base
Tread
(Front wheels)
(Rear wheels)
Fork overhang
Rear overhang
Fork size
(Length Q x Width R x Thickness S)
Fork spacing
Backrest size
Steering wheel height (from the floor)
Floor height
Minimum under clearance (Frame center)
Weight
Service weight (w. standard battery) kg [lbs]
SPECIFICATIONS (2)
Truck Model
Item
Performance
Max. load kg [lbs]
Free lift mm [in.]
(Loaded)
(Unloaded)
Fwd (loaded)
(unloaded)
Bwd (loaded)
(unloaded)
Gradeability
(Unloaded)
(Loaded)
Dimensions mm [in.]
Overall width
Wheel base
Tread
(Front wheels)
(Rear wheels)
Fork overhang
Rear overhang
Fork size
Fork spacing
Backrest size
Floor height
Weight
SPECIFICATIONS (3)
Truck Model
Item
Performance
Max. load kg [lbs]
Free lift mm [in.]
(Loaded)
(Unloaded)
Fwd (loaded)
(unloaded)
Bwd (loaded)
(unloaded)
Gradeability
(Unloaded)
(Loaded)
Dimensions mm [in.]
Overall width
Wheel base
Tread
(Front wheels)
(Rear wheels)
Fork overhang
Rear overhang
Fork size
Fork spacing
Backrest size
Floor height
Weight
SPECIFICATIONS (4)
Truck Model
Item
Performance
Max. load kg [lbs]
Free lift mm [in.]
(Loaded)
(Unloaded)
Fwd (loaded)
(unloaded)
Bwd (loaded)
(unloaded)
Gradeability
(Unloaded)
(Loaded)
Dimensions mm [in.]
Overall width
Wheel base
Tread
(Front wheels)
(Rear wheels)
Fork overhang
Rear overhang
Fork size
Fork spacing
Backrest size
Floor height
Weight
Unit: mm [in.]
Fig. 1 External View

STANDARD SETTINGS
Truck model
Item
Motor brush size and Pump motor mm [in.] 27 [1.06] (limit: 13 [0.51]) ← ← ← ←
wear limit Power steering motor mm [in.] 14.5 [0.57] (limit: 8 [0.31]) ← ← ← ←
Motor brush Pump motor N{kgf}[lbf] 7.5 - 14.3 {0.76 - 1.46} [1.68 - 3.2] ← ← ← ←
spring force Power steering N{kgf}[lbf] 5 - 8 {0.5 - 0.8} [1.1 - 1.76] ← ← ← ←
Voltage relay check voltage (20°C) 60.5 ← ← ← ←
Normal 4.5 (6.5)
Timer operating time
Electric system
Fail 14 (16)
Controller current limit value (pump motor clock current) 425 ← ← 550 ←
Traveling system main circuit 225 ← ← ← ←
Load handling system main circuit 225 ← ← ← ←
Power steering main circuit 40 ← ← ← ←
Battery charger primary side (thermal relay) 13 18 18 19 27
Fuse
Battery charger secondary side 130 ← ← ← ←
Control circuit 10 ← ← ← ←
Accessory circuit 10 ← ← ← ←
Solenoid 10 ← ← ← ←
Wheels
Hub nut tightening torque (drive tire) N-m{kgf-m}[lbf-ft] 63.7 {6.5} [47] ← ← 88.2 {9.0} [65] ←
Outer diameter of linkage pin and support pin (wear limit) mm [in.] ø30 [1.18] (29.8 [1.17]) ← ← ø35[1.38](34.8[1.37]) ←
Steering wheel play in rotating direction mm [in.] 30 - 75 [1.18 - 2.95] ← ← ← ←
Steering system
1350 [53.2] 1560 [61.4] 1750 [68.9] 1795 [70.7] 2065 [81.3]
1335 [52.6] 1750 [68.9] 1965 [77.4]
Minimum turning radius
1480 [58.3]
1490 [58.7]
Steering chain deflection mm [in.]/N {kgf} [lbf] 5 [0.2]/49 {5} [11] ← ← ← ←
Brake pedal height mm [in.] 67 - 68 [2.64 - 2.68]
Brake pedal play mm [in.] 0
Brake pedal height when depressed fully mm [in.] 0
Brake system
Foot pedal braking force within 2.5 m ← ← ← ←

Brake pad thickness mm [in.] 11 [0.43] (limit 4 [0.16])
Brake disk thickness mm [in.] 10 [0.39]
Clearance between pad and disk mm [in.] 0.2 - 0.3 [0.008 - 0.012] (one side)
Clearance between brake cam and adjuster mm [in.] 0 ← ← ← ←
Brake spring fitted length mm [in.] 115 [4.5] ← ← 105 [4.1] ←
Brake disk mounting nut torque N-m{kgf-m}[lbf-ft] 66.7 - 100 {6.8 - 10.2} [49 - 73.8] ← ← ← ←
Fork thickness
Load handling
mm [in.] 35-6 [1.38-0.24] 35-4 [1.38-0.16] 38-4 [1.5-0.16] 40-4 [1.58-0.16] 45-4 [1.77-0.16]
system
Opening of fork tips mm [in.] within 10 [0.39] ← ← ← ←

Difference in height between right and left fork tips mm [in.] 10±5 [0.39±0.2] ← ← ← ←
Chain length mm [in.] 19.5 [0.77]/pitch (elongation 3%)
Lift cylinder piston rod bolt torque N-m{kgf-m}[lbf-ft] 107.9±20.6 {11.0±2.1}[80±15.2] ← ← ← ←
Hydraulic system
Lift cylinder natural drop mm [in.]/min less than 75 [2.95]/10 ← ← less than 60[2.36]/10 ←
Tilt cylinder natural tilt (extension of piston rod) mm [in.]/min less than 15 [0.59]/10 ← ← less than 10[0.39]/10 ←
10:330 [13.0] 20:270 [10.6]
Fork lifting speed (under load) mm [in.]/sec 310 [12.2] 290 [11.4] 210 [8.3]
13:320 [12.6] 25:250 [9.8]
Control valve relief pressure setting MPa {kgf/cm2} [psi] 12.3 {130} [1850] 13.7 {140} [1993] 15.7 {160} [2277] 17.2 {176} [2505] ←
device
← ← ← ←
Safety
Overhead guard mounting bolt and nut torque N-m{kgf-m}[lbf-ft] 256±50{26.1±5}[188.8±36.2]

Load backrest mounting bolt torque N-m{kgf-m}[lbf-ft] 49.0 - 73.6 {5 - 7.5} [36.2 - 54.3] ← ← ← ←
Drive wheel mm [in.] 275 [10.8] ← ← 320 [12.6] ←
Tires
Tire wear limit Caster wheel mm [in.] 150 [5.9] ← ← 172 [6.8] ←
Trail wheel mm [in.] 230 [9.1] ← ← 240 [9.5] ←
01. CAUTION TO TAKE WHEN SERVICING THE TRUCK
* Before servicing the truck, make sure to:

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

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

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

③ When installing an oil seal onto a shaft, apply
lubricating oil or grease to its seal lip and the JIG
mounting surface of the shaft. For a double-

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

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

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

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

① Clean parts thoroughly using cleaning fluid. It is recommended that parts be immersed in cleaning
fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned.
② Cast parts should be cleaned with cleaning solvent or steam cleaned.
③ If a part is severely contaminated, use a wire brush or a piece of wood or metal to scrape off
contaminants from the part. Wash it in cleaning fluid once, before cleaning it completely.
However, do not use a wire brush for cleaning sliding surfaces or machined surfaces.
④ Oil passages must be cleaned with a steam cleaner. After checking for clogging with a piece of
wire, they also should be cleaned with cleaning fluid or with compressed air.
⑤ Some parts may be cleaned in hot solution tanks with mild alkaline solution. Parts should remain
in solution long enough to be thoroughly cleaned and warmed.
This will aid the evaporation of the cleaning solution and rise water. Parts cleaned in solution
tanks must be thoroughly rinsed with clean water to remove all traces of alkali.
Care should be exercised to avoid skin rashes, fire hazards and inhalation of vapors when
using solvent type cleaners.
⑥ If alloy parts, such as bearing shells or bushings, are cleaned with alkaline solution, they are apt to
corrode due to ionization. Such parts should be cleaned with kerosene, Tricrene solvent vapor or
“Magnus” fluid.
⑦ After cleaning, parts must be thoroughly dried with compressed air.
2. Bearings
① To dislodge solidified particles of lubricant, immerse bearings in cleaning fluid and remove
them from the fluid. On a clean work bench, tap the bearing softly with a soft mallet to dislodge
solidified particles.
② When drying bearings, be careful to direct air stream across bearing to avoid spinning.
3. Rubber parts
① When rubber parts need to be cleaned, use alcohol or wipe them clean with a soft cloth.
② Never use gasoline, diesel fuel or kerosene for cleaning. Use the same kind of oil for which the
rubber part will be used.
04. STANDARD BOLT TIGHTENING TORQUE
See the section “0.4 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.
• 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.)
Division by Surface
Name Shape Thread size Material Part number
strength treatment
SS400 4.6 Black 01101- Nominal symbol
SS400 4.6 01100- “

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

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

M 22 1.50 270 2750 216 ‑ 324 2200 ‑ 3300 235 2400 188 ‑ 282 1920 ‑ 2880 194 1980 155 ‑ 233 1580 ‑ 2380
M 24 2.00 334 3410 268 ‑ 401 2730 ‑ 4090 293 2990 234 ‑ 351 2390 ‑ 3580 241 2460 193 ‑ 289 1970 ‑ 2950
M 27 2.00 489 4990 391 ‑ 587 3990 ‑ 5990 429 4370 342 ‑ 515 3490 ‑ 5250 352 3590 282 ‑ 424 2880 ‑ 4320
M 30 2.00 686 7000 550 ‑ 824 5610 ‑ 8400 600 6120 480 ‑ 720 4890 ‑ 7340 493 5030 395 ‑ 592 4030 ‑ 6040
M 33 2.00 931 9490 744 ‑ 1120 7590 ‑ 11400 812 8280 650 ‑ 974 6630 ‑ 9930 669 6820 534 ‑ 802 5450 ‑ 8180
M 36 3.00 1130 11500 903 ‑ 1350 9210 ‑ 13800 991 10100 792 ‑ 1190 8080 ‑ 12100 815 8310 652 ‑ 979 6650 ‑ 9980
M 39 3.00 1460 14900 1170 ‑ 1740 11900 ‑ 17700 1280 13100 1020 ‑ 1540 10400 ‑ 15700 1050 10700 844 ‑ 1270 8610 ‑ 12900
M 4 0.70 1.15 11.7 0.92 ‑ 1.38 9.4 ‑ 14.1 1.03 10.5 0.82 ‑ 1.24 8.4 ‑ 12.6 0.8 8.66 0.68 ‑ 1.02 6.9 ‑ 10.4
M 5 0.80 2.36 24.1 1.89 ‑ 2.82 19.3 ‑ 28.8 2.11 21.5 1.70 ‑ 2.53 17.3 ‑ 25.8 1.7 17.8 1.39 ‑ 2.08 14.2 ‑ 21.2
M 6 1.00 4.98 40.6 3.20 ‑ 4.79 32.6 ‑ 48.8 3.56 36.3 2.85 ‑ 4.29 29.1 ‑ 43.7 2.9 30.0 2.35 ‑ 3.53 24.0 ‑ 36.0
M 8 1.25 9.81 100 7.84 ‑ 11.7 79.9 ‑ 119 8.74 89.1 7.00 ‑ 10.5 71.4 ‑ 107 7.2 73.5 5.77 ‑ 8.65 58.8 ‑ 88.2
M 10 1.50 19.5 199 15.6 ‑ 23.4 159 ‑ 239 17.5 178 13.9 ‑ 20.9 142 ‑ 213 14.3 146 11.5 ‑ 17.3 117 ‑ 176
M 12 1.75 34.2 349 27.5 ‑ 41.1 280 ‑ 419 30.4 310 24.4 ‑ 36.6 249 ‑ 373 25.1 256 20.1 ‑ 30.1 205 ‑ 307
M 14 2.00 55.0 561 43.9 ‑ 65.9 448 ‑ 672 48.8 498 39.0 ‑ 55.8 398 ‑ 597 40.2 410 32.3 ‑ 48.3 329 ‑ 493
M 16 2.00 86.9 886 69.5 ‑ 104 709 ‑ 1060 77.0 785 61.6 ‑ 92.4 628 ‑ 942 63.5 647 50.8 ‑ 76.1 518 ‑ 776
M 18 2.50 118 1200 94.6 ‑ 142 965 ‑ 1450 105 1070 84.1 ‑ 127 858 ‑ 1290 86.6 883 69.3 ‑ 104 707 ‑ 1060
M 20 2.50 171 1740 136 ‑ 204 1390 ‑ 2080 150 1530 121 ‑ 180 1230 ‑ 1840 125 1270 99.1 ‑ 149 1010 ‑ 1520
Metric, coarse system

M 22 2.50 234 2390 187 ‑ 252 1910 ‑ 2570 207 2110 165 ‑ 248 1680 ‑ 2530 171 1740 136 ‑ 204 1390 ‑ 2080
M 24 3.00 293 2990 234 ‑ 352 2390 ‑ 3590 259 2640 208 ‑ 312 2120 ‑ 3180 214 2180 172 ‑ 257 1750 ‑ 2620
M 27 3.00 436 4450 349 ‑ 524 3560 ‑ 5340 385 3930 308 ‑ 463 3140 ‑ 4720 318 3240 254 ‑ 381 2590 ‑ 3890
M 30 3.50 588 6000 471 ‑ 706 4800 ‑ 7200 521 5310 417 ‑ 624 4250 ‑ 6360 429 4370 342 ‑ 515 3490 ‑ 5250
M 33 3.50 810 8260 648 ‑ 972 6610 ‑ 9910 714 7280 572 ‑ 857 5830 ‑ 8740 588 6000 471 ‑ 706 4800 ‑ 7200
M 36 4.00 1030 10500 828 ‑ 1250 8440 ‑ 12700 914 9320 731 ‑ 1100 7450 ‑ 11200 753 7680 602 ‑ 903 6140 ‑ 9210
M 39 4.00 1350 13800 1080 ‑ 1140 11000 ‑ 11650 1190 12100 953 ‑ 1430 9720 ‑ 14600 981 10000 785 ‑ 1180 8000 ‑ 12000
* 1 N-m = 0.7376 lbf-ft
condition
Nominal
M 4 0.50 2.71 27.6 2.17 ‑ 3.26 22.1 ‑ 33.2 2.40 24.5 1.92 ‑ 2.87 19.6 ‑ 29.3 1.98 20.2 1.58 ‑ 2.38 16.1 ‑ 24.3
M 5 0.50 5.74 58.5 4.59 ‑ 6.87 46.8 ‑ 70.1 5.05 51.5 4.04 ‑ 6.06 41.2 ‑ 61.8 4.15 42.3 3.33 ‑ 4.98 33.9 ‑ 50.8
M 6 0.75 9.14 93.2 7.32 ‑ 11.0 74.6 ‑ 112 8.10 82.6 6.48 ‑ 9.72 66.1 ‑ 99.1 6.68 68.1 5.34 ‑ 8.01 54.4 ‑ 81.7
M 8 1.00 21.7 221 17.4 ‑ 26.0 177 ‑ 265 19.2 196 15.4 ‑ 23.0 157 ‑ 235 15.8 161 12.7 ‑ 19.0 129 ‑ 194
M 10 1.25 42.4 432 33.8 ‑ 50.9 345 ‑ 519 37.5 382 30.0 ‑ 45.0 306 ‑ 459 30.9 315 24.7 ‑ 37.1 252 ‑ 378
M 12 1.25 78.3 798 62.6 ‑ 93.9 638 ‑ 957 68.9 703 55.1 ‑ 82.7 562 ‑ 843 56.8 579 45.5 ‑ 68.2 464 ‑ 695
M 14 1.50 123 1250 98.1 ‑ 148 1000 ‑ 1510 109 1110 86.9 ‑ 129 886 ‑ 1320 89.4 912 71.6 ‑ 107 730 ‑ 1090
M 16 1.50 192 1960 153 ‑ 229 1560 ‑ 2340 169 1720 135 ‑ 202 1380 ‑ 2060 139 1420 111 ‑ 168 1130 ‑ 1700
M 18 1.50 282 2870 225 ‑ 337 2290 ‑ 3440 247 2520 198 ‑ 296 2020 ‑ 3020 203 2070 163 ‑ 244 1660 ‑ 2490
M 20 1.50 396 4040 317 ‑ 476 3230 ‑ 4850 347 3540 278 ‑ 416 2830 ‑ 4240 285 2910 229 ‑ 343 2330 ‑ 3500
Metric, fine system

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

M 22 2.50 468 4770 374 ‑ 562 3810 ‑ 5730 413 4210 330 ‑ 495 3370 ‑ 5050 340 3470 272 ‑ 409 2770 ‑ 4170
M 24 3.00 585 5970 469 ‑ 702 4780 ‑ 7160 519 5290 414 ‑ 623 4220 ‑ 6350 428 4360 341 ‑ 513 3480 ‑ 5230
M 27 3.00 872 8890 697 ‑ 1050 7110 ‑ 10700 770 7850 616 ‑ 924 6280 ‑ 9420 634 6460 507 ‑ 760 5170 ‑ 7750
M 30 3.50 1180 12000 940 ‑ 1410 9580 ‑ 14400 1040 10600 831 ‑ 125 8470 ‑ 12700 855 8720 685 ‑ 1030 6980 ‑ 10500
M 33 3.50 1620 16500 1280 ‑ 1940 13100 ‑ 19800 1430 14600 1140 ‑ 1710 11600 ‑ 17400 1180 12000 940 ‑ 1410 9580 ‑ 14400
M 36 4.00 2070 21100 1650 ‑ 2480 16800 ‑ 25300 1820 18600 1460 ‑ 2190 14900 ‑ 22300 1500 15300 1200 ‑ 1790 12200 ‑ 18300
M 39 4.00 2700 27500 2160 ‑ 3240 22000 ‑ 33000 2380 24300 1900 ‑ 2840 19400 ‑ 29000 1960 20000 1570 ‑ 2340 16000 ‑ 23900
* 1 N-m = 0.7376 lbf-ft
condition
Nominal
M 4 0.50 3.62 36.9 2.89 ‑ 4.34 29.5 ‑ 44.3 3.20 32.6 0.26 ‑ 0.39 26.1 ‑ 39.3 2.64 26.9 2.12 ‑ 3.17 21.6 ‑ 32.3
M 5 0.50 7.65 78.0 6.12 ‑ 9.18 62.4 ‑ 93.6 6.73 68.6 0.54 ‑ 0.81 55.0 ‑ 82.4 5.55 56.6 4.44 ‑ 6.66 45.3 ‑ 67.9
M 6 0.75 12.2 124 9.78 ‑ 14.7 99.7 ‑ 150 10.8 110 0.87 ‑ 1.30 88.2 ‑ 133 8.91 90.9 7.13 ‑ 10.7 72.7 ‑ 109
M 8 1.00 28.9 295 23.1 ‑ 34.7 236 ‑ 354 25.6 261 2.05 ‑ 3.08 209 ‑ 314 21.1 215 16.9 ‑ 25.3 172 ‑ 258
M 10 1.25 56.5 576 45.2 ‑ 67.9 461 ‑ 692 50.1 511 4.01 ‑ 6.01 409 ‑ 613 41.3 421 33.0 ‑ 49.5 337 ‑ 505
M 12 1.25 104 1060 83.6 ‑ 126 852 ‑ 1280 92.0 938 7.37 ‑ 11.0 751 ‑ 1120 75.8 773 60.6 ‑ 90.9 618 ‑ 927
M 14 1.50 164 1670 131 ‑ 197 1340 ‑ 2010 145 1480 11.6 ‑ 17.4 1180 ‑ 1770 119 1210 95.4 ‑ 143 973 ‑ 1460
M 16 1.50 256 2610 204 ‑ 307 2080 ‑ 3130 226 2300 18.0 ‑ 27.0 1840 ‑ 2750 185 1890 148 ‑ 222 1510 ‑ 2260
M 18 1.50 377 3840 301 ‑ 451 3070 ‑ 4600 330 3360 26.4 ‑ 39.5 2690 ‑ 4030 271 2760 217 ‑ 327 2210 ‑ 3330
M 20 1.50 529 5390 423 ‑ 635 4310 ‑ 6470 463 4720 37.0 ‑ 55.5 3770 ‑ 5660 381 3890 305 ‑ 457 3110 ‑ 4660
Metric, fine system

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

M 22 2.50 624 6360 499 ‑ 749 5090 ‑ 7640 551 5620 441 ‑ 662 4500 ‑ 6750 454 4630 363 ‑ 545 3700 ‑ 5560
M 24 3.00 782 7970 626 ‑ 938 6380 ‑ 9560 692 7060 554 ‑ 831 5650 ‑ 8470 570 5810 456 ‑ 685 4650 ‑ 6980
M 27 3.00 1160 11800 931 ‑ 1400 9490 ‑ 14300 1030 10500 821 ‑ 123 8370 ‑ 12500 846 8630 678 ‑ 1020 6910 ‑ 10400
M 30 3.50 1570 16000 1260 ‑ 1880 12800 ‑ 19200 1390 14200 1110 ‑ 1660 11300 ‑ 16900 1140 11600 913 ‑ 1370 9310 ‑ 14000
M 33 3.50 2160 22000 1730 ‑ 2590 17600 ‑ 26400 1900 19400 1520 ‑ 2290 15500 ‑ 23300 1570 16000 1260 ‑ 1880 12800 ‑ 19200
M 36 4.00 2770 28200 2210 ‑ 3310 22500 ‑ 33800 2430 24800 1950 ‑ 2920 19900 ‑ 29800 2010 20500 1600 ‑ 2410 16300 ‑ 24600
M 39 4.00 3600 36700 2880 ‑ 4320 29400 ‑ 44100 3170 32300 2540 ‑ 3810 25900 ‑ 38900 2610 26600 2090 ‑ 3140 21300 ‑ 32000
* 1 N-m = 0.7376 lbf-ft
condition
Nominal
M 4 0.50 5.33 54.3 4.26 ‑ 6.38 43.4 ‑ 65.1 4.71 48 3.77 ‑ 5.65 38.4 ‑ 57.6 3.87 39.5 3.11 ‑ 4.66 31.7 ‑ 47.5
M 5 0.50 11.3 115 9.00 ‑ 13.5 91.8 ‑ 138 9.91 101 7.92 ‑ 12.0 80.8 ‑ 122 8.15 83.1 6.52 ‑ 9.79 66.5 ‑ 99.8
M 6 0.75 17.9 183 14.3 ‑ 21.6 146 ‑ 220 15.9 162 12.7 ‑ 19.0 130 ‑ 194 13.0 133 10.5 ‑ 15.7 107 ‑ 160
M 8 1.00 42.6 434 34.1 ‑ 51.0 348 ‑ 520 37.7 384 30.1 ‑ 45.2 307 ‑ 461 31.1 317 24.9 ‑ 37.2 254 ‑ 379
M 10 1.25 83.1 847 66.5 ‑ 100 678 ‑ 1020 73.6 750 58.8 ‑ 88.4 600 ‑ 901 60.6 618 48.5 ‑ 72.8 495 ‑ 742
M 12 1.25 154 1570 123 ‑ 184 1250 ‑ 1880 135 1380 109 ‑ 162 1110 ‑ 1650 112 1140 89.0 ‑ 133 908 ‑ 1360
M 14 1.50 241 2460 193 ‑ 289 1970 ‑ 2950 213 2170 171 ‑ 255 1740 ‑ 2600 176 1790 140 ‑ 210 1430 ‑ 2140
M 16 1.50 376 3830 300 ‑ 450 3060 ‑ 4590 330 3370 265 ‑ 396 2700 ‑ 4040 272 2770 218 ‑ 327 2220 ‑ 3330
M 18 1.50 552 5630 442 ‑ 663 4510 ‑ 6760 484 4940 387 ‑ 582 3950 ‑ 5930 398 4060 319 ‑ 479 3250 ‑ 4880
M 20 1.50 777 7920 621 ‑ 933 6330 ‑ 9510 681 6940 544 ‑ 815 5550 ‑ 8310 560 5710 448 ‑ 672 4570 ‑ 6850
Metric, fine system

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

M 22 2.50 918 9360 734 ‑ 1100 7480 ‑ 11200 810 8260 648 ‑ 972 6610 ‑ 9910 668 6810 534 ‑ 802 5450 ‑ 8180
M 24 3.00 1150 11700 919 ‑ 1380 9370 ‑ 14100 1020 10400 814 ‑ 1230 8300 ‑ 12500 838 8550 670 ‑ 1010 6830 ‑ 10300
M 27 3.00 1720 17500 1370 ‑ 2050 14000 ‑ 20900 1510 15400 1220 ‑ 1800 12400 ‑ 18400 1250 12700 991 ‑ 1490 10100 ‑ 15200
M 30 3.50 2300 23500 1840 ‑ 2770 18800 ‑ 28200 2040 20800 1630 ‑ 2440 16600 ‑ 24900 1690 17200 1330 ‑ 2020 13600 ‑ 20600
M 33 3.50 3170 32300 2540 ‑ 3810 25900 ‑ 38800 2800 28600 2240 ‑ 3350 22800 ‑ 34200 2300 23500 1840 ‑ 2760 18800 ‑ 28100
M 36 4.00 4060 41400 3240 ‑ 4860 33000 ‑ 49600 3580 36500 2860 ‑ 4300 29200 ‑ 43800 2950 30100 2360 ‑ 3530 24100 ‑ 36000
M 39 4.00 5290 53900 4240 ‑ 6350 43200 ‑ 64800 4660 47500 3740 ‑ 5590 38100 ‑ 57000 3830 39100 3070 ‑ 4610 31300 ‑ 47000
* 1 N-m = 0.7376 lbf-ft
05. LUBRICATION (1/2)
1. Hydraulic oil tank
HYDRAULIC OIL TANK CAP &

OIL DIPSTICK
L [U.S. gal]
16
[4.2] Wear-Resistant
TCM Hydraulic Oil
22 [5.8]
* Note: The capacity is given for trucks of standard

specifications.
2. Drive unit
3. Power steering actuator case

LINKAGE, UPPER OIL FILL PORT (Remove breather and add oil)
PIN, LINKAGE (3) DRAIN PLUG
All models 0.35 L [0.093 U.S. gal]
TCM Gear Oil (SAE#80W)
GREASE PIN, LINKAGE

PIPING (2)
L [U.S. gal]
TCM
2.1 Gear Oil
[0.56]
3.2 [0.85]
LUBRICATION (2/2)
4. Greasing
4-1. Drive unit support.........................................................1
4-2. Grease fitting block......................................................5
4-3. Steering shaft . .............................................................1
4-4. Lower linkage...............................................................1
4-5. Apply a thin coat of grease on the brake cam and steering chains.
4-6. Caster wheel (rear axle)................................................1
Apply grease through the grease fitting indicated by the arrow.
STEERING
SHAFT
DRIVE UNIT
SUPPORT
GREASE
FITTING BLOCK
4-7. Piston head guide

Apply grease on the guides indicated by arrows.
06. PARTS LIST
Part number
Item Part name Remarks
FRB10 - FRHB13 FRB14 - FRHB18 FRB20 - FRHB30
DC96V 225A
Fuses F1 and F2 181E2-62471
(DRIVE, PUMP)
Fuse F3 181E2-62541 DC96V 40A (PS)

Fuses
DC96V 130A
Fuse F6 27292-62272
(CHARGER)
Fuse F4, F5 and F7 25592-42311 10A
Oil tank Suction filter 215E7-52031
Bulb 29502-42421 48V/40W

Head light
Assembly 29502-42401
Lights
Turn signal Bulb 27732-42331 48V/25W
lights Assembly 27912-42102
Disk
Brake pad kit 282M3-65051 282M3-65051 282R3-65011
brake
27A04-40401 Rubber
Trail wheel
27B04-40401 27B44-40401 Urethane
Tires 27B04-42101 27B44-40301 Rubber

Caster wheel
Urethane
Drive wheel 27B04-40201 27B44-40201 Rubber
* Note: The part numbers shown above are subject to change without notice.
INSPECTION AND MAINTENANCE
TABLE OF CONTENTS
1. BATTERY AND BATTERY CHARGER (OPTION) .................................................... 1
1.1 GENERAL DESCRIPTION...................................................................................................... 1
1.1.1 BATTERY (OPTION)....................................................................................................... 1
1.1.2 BATTERY CHARGER (OPTION)................................................................................... 9
2. MOTORS .................................................................................................................................... 13
2.1 GENERAL DESCRIPTION.................................................................................................... 13
2.1.1 DRIVE MOTOR.............................................................................................................. 14
2.1.2 PUMP MOTOR............................................................................................................... 16
2.1.3 ELECTRIC POWER STEERING (EPS) MOTOR......................................................... 19
2.2 MAINTENANCE................................................................................................................... 20
2.2.1 DRIVE MOTOR.............................................................................................................. 20
2.2.2 PUMP MOTOR............................................................................................................... 30
3. CONTROLLER ........................................................................................................................ 39
3.1.1 CONTROLLER............................................................................................................... 39
3.1.2 ACCELERATOR............................................................................................................. 42
3.1.3 LCD PANEL.................................................................................................................... 43
4. DRIVE UNIT .............................................................................................................................. 45

4.1 GENERAL DESCRIPTION................................................................................................... 45
4.2 MAINTENANCE.................................................................................................................... 47
4.2.1 REPLACING DRIVE WHEEL . .................................................................................... 47
4.2.2 ADJUSTMENT AFTER REASSEMBLY....................................................................... 49
4.2.3 TROUBLESHOOTING GUIDE..................................................................................... 51
5. STEERING SYSTEM . ........................................................................................................... 53

5.1.1 STEERING WHEEL....................................................................................................... 53
5.1.2 TORQUE SENSOR......................................................................................................... 55
5.1.3 STEERING ANGLE SENSOR....................................................................................... 56
5.1.4 ACTUATOR.................................................................................................................... 57
5.1.5 REAR AXLE................................................................................................................... 58
5.1.6 LOCK CYLINDER......................................................................................................... 60
5.1.7 CASTER WHEEL........................................................................................................... 61
5.1.8 TRAIL WHEEL............................................................................................................... 62
5.2 MAINTENANCE.................................................................................................................... 63
5.2.1 REPLACING CASTER WHEEL .................................................................................. 63
5.2.2 REPLACING TORQUE SENSOR ................................................................................ 65
6. BRAKE SYSTEM .................................................................................................................... 67

6.1.1 BRAKE CALIPERS........................................................................................................ 67
6.1.2 BRAKE PEDAL.............................................................................................................. 68
6.2 MAINTENANCE.................................................................................................................... 71
6.2.1 ADJUSTING PEDAL HEIGHT .................................................................................... 71
6.2.2 ADJUSTING BRAKE CLEARANCE AND BRAKING FORCE................................. 71
6.2.3 REPLACING BRAKE PADS......................................................................................... 72
6.2.4 ADJUSTING BRAKE SWITCH ................................................................................... 72
7. HYDRAULIC SYSTEM ......................................................................................................... 73

7.1.1 OIL TANK....................................................................................................................... 74
7.1.2 MAIN PUMP................................................................................................................... 75
7.1.3 CONTROL VALVE......................................................................................................... 75
7.1.4 VALVE CONTROL......................................................................................................... 77
7.1.5 LIFT CYLINDER............................................................................................................ 78
7.1.6 FLOW REGULATOR VALVE........................................................................................ 82
7.1.7 TILT CYLINDER............................................................................................................ 85
7.1.8 REACH CYLINDER...................................................................................................... 86
7.2 MAINTENANCE.................................................................................................................... 87
7.2.1 HYDRAULIC OIL CHANGE........................................................................................ 87
7.2.2 REPLACING STRAINER ............................................................................................. 87
7.2.3 MEASURING AND ADJUSTING HYDRAULIC OIL PRESSURE............................ 88
7.2.4 ADJUSTING VALVE SWITCH .................................................................................... 89
8. LOAD HANDLING SYSTEM ............................................................................................. 91

8.1.1 OUTER AND INNER CHANNELS............................................................................... 92
8.1.2 CARRIAGE..................................................................................................................... 94
8.1.3 ROLLER LOCATION..................................................................................................... 96
8.2 MAINTENANCE.................................................................................................................... 98
8.2.1 ADJUSTING LIFT CYLINDER ROD WITH SHIMS................................................... 98
8.2.2 ADJUSTING CARRIAGE HEIGHT ............................................................................. 98
8.2.3 REPLACING CARRIAGE ROLLERS ....................................................................... 100
8.2.4 REPLACING MAST ROLLERS ................................................................................. 102
8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS..................................... 103
1. BATTERY AND BATTERY CHARGER (OPTION)

Truck model FRB10-8 FRHB10-8
FRB14-8 FRHB14-8
FRB10-8C FRHB10-8C FRB20-8 FRHB20-8 FRB30-8
FRB15-8 FRHB15-8
FRB13-8 FRHB13-8 FRB25-8 FRHB25-8 FRHB30-8
FRB18-8 FRHB18-8
Item FRB13-8C FRHB13-8C
Battery
Type Clad type lead accumulator
Name VSFL201M VSFL280 VSFL320 VSFL390
Capacity (5-hour rate) 201 Ah 280 Ah 320 Ah 390 Ah
Rated voltage 48 V
Case size 956 x 265 x 570 mm 956 x 375 x 570 mm 1125 x 395 x 570 mm ←
(width x length x height) [37.6 x 10.4 x 22.4 in.] [37.6 x 14.8 x 22.4 in.] [44.3 x 15.6 x 22.4 in.]
Weight (including case 360 kg [794 lbs] 495 kg [1087 lbs] 580 kg [1279 lbs] 665 kg [1466 lbs]
and electrolyte)
Battery charger
Type Truck-mounted, microprocessor controlled, 3-phase a.c. quasi-steady voltage type
Rated power 3 kVA 4.3 kVA 4.5 kVA 6.2 kVA
Rated current 8A 11 A 13 A 18 A
Power supply voltage 205 - 215 / 210 - 220 V

(50 Hz/60 Hz)
d.c. output
Voltage 50 - 62 V
Current 38 - 13 A 55 - 18 A 60 - 19 A 83 - 27A
1.1 GENERAL DESCRIPTION

1.1.1 BATTERY (OPTION)
The battery assembly consists of 24 2-volt battery cells connected in series and is housed in a case.
Each battery cell has a cap on the top, inside which a float is located to indicate the electrolyte level
in the battery cell.
One of the 24 battery cells is used to monitor the battery electrolyte level, which is shown by the
battery electrolyte level indicator installed on the battery case.
-1-
BATTERY
ELECTROLYTE
LEVEL INDICATOR
BATTERY CELL
BATTERY
CASE
COLLAR
Detail of area A
Fig. 1.1 Battery Assembly
-2-
(1) Battery cell

The battery cell has a clad type pole plate as the anode. (It is a glass fiber or synthetic resin tube
filled with lead peroxide, having a lead alloy core which runs through the center).
The anode plate withstands a long cycle of use, and can stand up against overcharge and
overdischarge.
The negative plate consists of a lead frame filled up with lead peroxide in paste form. The two pole
plates are isolated by means of separators in order to prevent them from getting short-circuited.
The battery jar is made of resin. The electrolyte

BATTERY CAP
is high purity diluted sulfuric acid of 1.28 specific
gravity (at 20°C [68°F]).
The battery cap is made of transparent resin,
having a float inside to monitor the electrolyte level
and to indicate when the fluid should be added.
FLOAT
On the side face of the battery case is an
electrolyte level indicator, which blinks when the
electrolyte level is low. A sensor for the indicator is
fitted on one of the 24 caps. Fig. 1.2 Float
-3-
(2) Battery case locking device

The battery assembly is housed in the frame using a battery tray.
The battery locking switch is turned on when the battery is housed properly in the frame and locked,
and turned off when the battery is removed from the frame or housed in an improper manner.
The battery case can be pulled out of the truck by advancing the mast forward.
SWITCH
LOCK RELEASE
PEDAL
Unlock
Operating point:
22 mm
Detail of switch
HOOK
SPRING
SLIDER BLOCK
View A Detail of area B
Fig. 1.3 Battery Case Locking Device
-4-
(3) Receptacle remover

The battery-side receptacle is located on the right side of the truck and connected to the truck-side
receptacle.
The truck-side receptacle is equipped with a receptacle remover which allows the operator to shut
off the battery power immediately in an emergency.
LEVER
OIL TANK
TRUCK-SIDE
RECEPTACLE
BATTERY-SIDE
RECEPTACLE
Fig. 1.4 Receptacle Remover
-5-
(4) BATTERY CARE
Cycles of charge
Service life
and discharge
The most important point in battery care is to
prevent overdischarge. The deeper the battery
discharges, the shorter its life becomes (See Fig.
1.5).
The approximate depth of discharge can be
known by measuring the specific gravity of the
electrolyte (See Fig. 1.6). Within
this range
Check the level of electrolyte every ten days. (Example)
Add distilled water if the level is found lower
than the specified level before recharging the
Depth of discharge (%)
battery.
Fig. 1.5 Relationship Between Depth of
Discharge and Service Life
SPECIFIC GRAVITY (20°C)
VOLTAGE
Usable
VOLTAGE
Alert
SPECIFIC GRAVITY
Overdischarge
(DISCHARGE DURATION)
(DISCHARGE RATE)
Fig. 1.6 Example of Specific Gravity Drop (5-hour rate discharge)
-6-
■ Adding battery electrolyte

Battery electrolyte should be added as follows just before recharging the battery:
① Operate the reach lever to the retraction position to retract the mast.
② Press the battery lock release pedal.
③ Operate the reach lever to the advancement position so that the battery case comes out of the truck
body
④ Disconnect the battery receptacles.
⑤ Clean all the cell caps and areas around them.
⑥ Open each cap and add distilled water into the cell.
Observe the float carefully not to add too much water. All the floats of the cells should be at the
same height.
⑦ Reinstall the caps and wipe dry the areas around them and the pole plates.
⑧ Connect the battery receptacles.
⑨ Press the battery lock release pedal while placing the reach lever in the retraction position, to
retract the mast.
⑩ Recharge the battery.
Note: Give an auxiliary charge to the battery after adding battery electrolyte.
Max. level Proper level Min. level
Red
White
Too much distilled water may cause an unclosed cap,

It may also let electrolyte overflow after recharging,
causing corrosion.
Fig. 1.7
-7-
■ Recharging the battery

When discharged, the battery should be recharged as soon as possible. Leaving the battery
discharged for a long time (longer than a day) may cause sulfation, which will result in the drop of
battery performance.
If the battery is kept out of service for a long time, it should be thoroughly charged before being put
in storage and an auxiliary charge is also required once a month.
If the amount of discharge is considered to be small, measure the specific gravity of the electrolyte.
Recharge the battery if the specific gravity is lower than 1.260.
An equalizing charge may be required if the specific gravity varies to a large extent among the cells
by the amount of 0.010 or larger. Such an equalizing charge should normally be performed one to four
times a month. If the specific gravity variation is not corrected by giving an equalizing charge, specific
gravity adjustment may be required.
Giving an equalizing charge more times than necessary will result in an overcharged battery, and the
battery’s service life will be shortened.
A microprocessor-controlled battery charger gives an equalizing charge automatically, but manual
equalizing charge may be required if the specific gravity varies to a large extent among the cells or the
cells are in a low state of charge.
[Caution to take when recharging the battery]

1. Do not recharge the battery if the electrolyte temperature is higher than 40°C [104°F]. Leave the
battery for a while until the electrolyte temperature goes low.
2. Overdischarge or overcharge will raise the electrolyte temperature. While recharging the battery,
have good ventilation in order to let generated gas and heat get out.
[Specific gravity correction according to temperature]

The specific gravity of the electrolyte varies as the electrolyte temperature changes. The specific
gravity is generally based on the electrolyte temperature of 20°C [68°F]. Therefore, if the specific
gravity is measured at the electrolyte temperature of other than 20°C [68°F], correct it using the
following formula:
S20 = St + 0.0007 (t-20)
Where
S20: Specific gravity for 20°C [68°F] (1.280 in this model)
St: Specific gravity measured at t°C [(1.8t + 32) °F]
t: Electrolyte temperature (measured value)
-8-
1.1.2 BATTERY CHARGER (OPTION)

The battery charger is a truck-mounted type consisting primarily of a transformer, diodes, an
operation panel and a contactor.
The control circuit of the battery charger is incorporated in the LCD panel. The transformer, to
which a diode assembly is attached, converts alternating current into direct current. See Figure 1.8.
to THERMAL RELAY TRANSFORMER
to BATTERY (-) HORN
to BATTERY (+)
Fig. 1.8 Transformer
-9-
(1) Battery charger operation panel

The battery charger operation panel is located, together with a battery charger receptacle and a
contactor, on the center cover.
WIRE HARNESS (FRAME)
RELAY (BACK-UP BUZZER) to SSC UNIT

RELAY FLASHER UNIT
(AUTO POWER-OFF)
BATTERY CHARGER
RECEPTACLE
PS SENSOR
WIRE HARNESS
(CENTER COVER)
WIRE HARNESS (FRAME) OPERATION PANEL
CONTACTOR
*RELAY (STOP LAMP)
*RELAY (INTERLOCKED WITH KEY SWITCH)
*RELAY (SPEED LIMITER)
*RELAY (FORWARD TRAVEL)
*FORWARD TRAVEL CHIME

(OPTION)
to PS MOTOR
BACK-UP BUZZER
Items with * are optional.
Fig. 1.9 Battery Charger & PS Panel
- 10 -
(2) Transformer and diodes

The transformer converts high-voltage 3-phase alternating current into direct current of a voltage
suitable for recharging the battery. See Figure 1.10.
All the diodes have the same shape, but remember that the positive and negative diodes have
different polarities respectively. Use caution especially when replacing them with new ones.
The primary coil of the transformer has a tap changer to keep the secondary voltage at a suitable
level according to the input voltage.
DIODE
OUTPUT TERMINAL
(–), M8
OUTPUT TERMINAL
(+), M8
SECONDARY COIL PRIMARY COIL
Fig. 1.10 Transformer and Diodes
- 11 -
■ Power supply tap changing procedure

1. Checking power supply voltage
• Measure the voltage of the power supply to which the battery charger is connected for one minute
and use the highest measurement as the power supply voltage.
• Voltage measurement should be performed between the three phases (U-V, V-W, and W-U), during
the specified operating time of the power supply
SECONDARY COIL
or when any other equipment is not connected PRIMARY COIL
to the said power supply.
2. Tap changing procedure

• Check the tap positions and the voltage
obtained by the taps currently being selected.
Make sure the measurement is within the
voltage range of each tap (See Figure 1.12.)
If the measurement is different from the
voltage range indicated on any of the taps, TAP POSITIONS
change taps in the following manner:
① Turn off the key switch. Make sure the power Fig. 1.11 Tap Positions
supply cable of the charging station is not connected to the battery charger receptacle.
② Displace the glass tube covering the tap being selected and remove the connecting bolt.
③ Remove the vinyl cap from the tap you want to use and install the glass tube onto it.
④ Connect the cable and bolt removed in step ② to the tap you want to use and cover with glass
tube.
⑤ Install the vinyl cap onto the tap, from which the cable has been removed.
Power supply voltage Supply voltage (V) Indication of tap
Voltage on tap
(V) 379 or less 380
Truck side
199 V or less 200 380 - 399 400
200 - 209 210 400 - 419 420
210 - 219 220 420 - 439 440
3-conductor cable
Taps not in use are (VCT)
Truck-side cable and the
covered with vinyl caps. transformer-side cable are
tightened together using a
round solderless terminal.
Bolt
Washer
Nut
Voltage is indicated on
each tap. Glass tube
Transformer side
Fig. 1.12
- 12 -
2. MOTORS
2. MOTORS
FRB10-8 FRB13-8 FRB14-8 FRB18-8
FRB20-8 FRHB20-8
Truck model FRB10-8C FRB13-8C FRHB14-8 FRHB18-8
FRB25-8 FRHB25-8
Item FRHB10-8C FRHB13-8C FRB15-8
FRB30-8 FRHB30-8
FRHB10-8 FRHB13-8 FRHB15-8
Drive motor
Type 3-phase induction motor
Name VO-NR VO-NR
Rating
Output 4.3 kW/60 min. 6.1 kW/60 min.
Speed 2600 rpm ←
Voltage 27.5 V 28.3 V
Current 125 A 160 A
Pump motor
Type DC series motor
Name VO-MRO VO-MRO
Rating
Output 8.0 kW/5 min. 11.0 kW/5 min.
Speed 1800 rpm 1450 rpm
Voltage 41.3 V 35.9 V
Current 250 A 380 A
Electric Power Steering
(EPS) motor
Type Magnet motor
Rating
Output 0.3 kW/60 min.
Speed 2900 rpm
Voltage 48 V
Current 8.2 A

The drive motor used for this series is a 3-phase induction motor consisting primarily of the parts
shown in Figures 2.1 and 2.2, and the drive motor speed is controlled by an inverter type controller.
The pump motor is a d.c. series-wound motor consisting primarily of the parts shown in Figures 2.3
and 2.4, and the pump motor speed is controlled by a d.c. chopper controller. The electric power
steering (EPS) motor is a magnet motor consisting primarily of the parts shown in Figure 2.3. The EPS
motor is fitted to the drive unit and the EPS motor speed is controlled by a controller.
- 13 -
2. MOTORS
2.1.1 DRIVE MOTOR
View A View B
1. FRAME 5. ROTOR FAN 9. WAVE SPRING

2. STATOR CORE 6. SHAFT 10. BEARING WITH ROTATIONAL
3. STATOR COIL 7. BRACKET SPEED SENSOR
4. ROTOR CORE 8. BEARING 11. THERMO-SENSOR
12. COLLAR
Fig. 2.1 Drive Motor (FRB10 - FRHB18)
- 14 -
2. MOTORS
V
U
W
View A View B
1. FRAME 5. ROTOR FAN 9. WAVE SPRING

2. STATOR CORE 6. SHAFT 10. BEARING WITH ROTATIONAL
3. STATOR COIL 7. BRACKET SPEED SENSOR
4. ROTOR CORE 8. BEARING 11. THERMO-SENSOR
12. COLLAR
Fig. 2.2 Drive Motor (FRB20 - FRHB30)
- 15 -
2. MOTORS
2.1.2 PUMP MOTOR
1. ARMATURE ASSEMBLY 5. BRACKET (FRONT)

2. BALL BEARING 6. BRACKET (REAR)
3. BALL BEARING 7. BRUSH
4. YOKE ASSEMBLY 8. BRUSH COVER
Fig. 2.3 Pump Motor (FRB10 - FRHB18)
- 16 -
2. MOTORS
1. ARMATURE ASSEMBLY 5. BRACKET (FRONT)

2. BALL BEARING 6. BRACKET (REAR)
3. BALL BEARING 7. BRUSH
4. YOKE ASSEMBLY 8. BRUSH COVER
Fig. 2.4 Pump Motor (FRB20 - FRHB30)
- 17 -
2. MOTORS
After installing a new motor

assembly, move the brush cover
latch to the position off the yoke
hole as indicated in the sketch.
Apply Molykote on splines.
Tightening torque: 10 - 12 N-m

[100 - 120 kgf-cm] {7.4 - 8.9 lbf-ft]
Apply ThreeBond#1324N
or equivalent.
from TANK
to CONTROL
VALVE
View A View B
Fig. 2.5 Mounting of Pump Motor
- 18 -
2. MOTORS
2.1.3 ELECTRIC POWER STEERING (EPS) MOTOR

The EPS motor is a magnet type and fitted to the actuator section of the drive motor. The EPS motor
speed is controlled by an EPS controller.
White: (+)
Black: (-)
Fig. 2.6 EPS Motor
- 19 -
2. MOTORS
2.2 MAINTENANCE
2.2.1 DRIVE MOTOR
(1) Checking with drive motor in operation
Item to be checked Service required Remedy

Motor frame Visually check that no excessive accumulation Shut off motor and clean.
of dust or dirt is found.Visually check that
no excessive rise of operating temperature is
found.
Motor frame Visually check that motor frame is not If contaminated, clean.
excessively contaminated with foreign matter
or liquid.
Motor frame, bearing Check that operating temperature below Repair if operating
specified value. Motor frame: 80°C [176°F] temperature is higher than
Bearing: 55°C [131°F] specified.
Motor frame, bearing, Visually check there is no excessive vibration. Repair if vibration is beyond
cover and others allowable limit.
Motor frame, bearing, Check for an excessively high level of operating If operating noise level is
cover and others noise. It is good practice to use a stethoscopic extremely high, locate the
apparatus or other suitable devices. cause of the problem and
troubleshoot.
(2) Checking with drive motor shut off

Bolts and screws Visually or acoustically check bolts and screws Retighten, clean or paint.
for looseness, contamination or corrosion.
Connections Visually check for wrong or loose connection. Retighten or repair.
Visually check for proper insulation.
Lead wire Visually check for a damaged jacket. Ask a specialist to repair.
- 20 -
2. MOTORS
(3) Periodic inspection

■ Inspection intervals
Perform periodic inspection at the intervals given below. If the truck is operated under a severer
working environment, an earlier inspection interval will be recommended.
Operating time 12 hours per day 0 - 12 hours per day

Interval Once a year Once every two years

Roller bearing Check roller bearings for grease leakage, noise Replace if necessary.
(enclosed type) or accumulation of dust.
Joint surface Visually check damaged or corroded joint Clean or repair if required.
surface.
Bolts and sscrews Visually or acoustically check for loose, Retighten, apply anti-rust or
corroded or stuck bolt or screw. replace.
Terminal joint Visually check damage or roughness due to Retighten.
surfaces corrosion.
Connections Visually check for wrong or loose connection. Retighten or repair.
Visually check for proper insulation.
Lead wire Visually check for a damaged jacket. Ask a specialist to repair.
Stator and rotor Visually check iron core for accumulation of Clean as necessary.
assembly dust or dirt.
Check coil and connections for insulation using Clean. Dry by heating.
a 500 V megger.Insulation resistance: 1 MΩ or Apply insulating varnish.
higher
Truck speed sensor Check output waveform, referring to Fig. 2.7 Ask a specialist.
“Checking sensor for operation.”
Thermo-sensor Measure resistance.Standard resistance: 13.04 Ask a specialist.
kΩ±10% (20°C [68°F])
Painting Visually check painting for damage, Apply anti-rust.Repaint.
discoloration, peeling or corrosion.
Contamination Visually check for contamination, accumulation Clean or apply anti-rust.
of dirt, or corrosion. Repaint.
- 21 -
2. MOTORS
■ Inspection
Observe the following conditions when inspecting the drive motor:
① Select a dry, clean place.
② During disassembly, all the parts including the shaft should be marked properly so that they can be
reinstalled correctly. The screws and washers should be placed in order in an empty box.
③ Use a wooden mallet and lightly tap with even force to remove or reinstall brackets.
Do not a metallic hammer; otherwise the drive motor might be damaged.
④ Handle the parts carefully not to give damage to them. In particular, use special caution not to
damage or contaminate the the stator coil or bearings with water, dust or sand.
⑤ All the disassembled parts should be cleaned and inspected for damage. Any missing or damaged
part must be added or replaced with a new one.
⑥ To clean the coil, use a clean cloth or soft brush. The use of gasoline or other type of solvent might
impair the insulation.
⑦ If the coils shows a low insulation resistance, dry the coil by heating to 80 to 90°C [176 to 194°F]
until an insulation resistance of 1 MΩ or more is attained. Use caution not to overheat locally.
⑧ Check all the bolts for looseness, retightening any loose bolts.
⑨ For inspection of the bearings, refer to paragraph (4) “Maintenance of bearings”.
⑩ If the paint is discolored or peeling, apply anti-rust or paint again.
⑪ Make sure all the terminals are securely tight, and insulate connections completely with insulation
tape.
⑫ After reassembly, check for any parts that have not been reinstalled. Make sure all the screws have
been tightened securely. Try to turn the shaft by hand to check that it turns smoothly, and then test
for the motor to ensure that it operates normally.
⑬ The drive motor should be stored in a dry, clean place where any harmful gas is not anticipated.
Apply a preservative to each end of the shaft and cover with oiled paper or vinyl cloth.
⑭ Checking the sensor removed from the truck for operation:
Using the following electric circuit, give an input voltage of +5 - 24 volts d.c. to the sensor to
rotate the inner ring of the bearing. Check the output waveform to see if it meets the specified
value.
Electric Output and accuracy

circuit +Vcc (red)
“B” phase output Output pulse count:
External connection (pull-up resistance) 64 pulses
“A” phase output (white)
“B” phase output (blue)
Sensor
Output pulse count:
“A” phase output 64 pulses
GND (black)
Connection of pull-up resistance:

Connect a pull-up resistance between the power supply (+Vcc) and
each sensor output.
The pull-up resistance should be set to ensure that the sink current 1. Pitch variation (%) = I (Tn – Tn + I) I/Tn x 100
of the transistors on the sensor output stage is 20 mA or less. 2. Duty (%) = Tp/Tn x 100
3. Advance angle (degree) = Tab/Tn x 360
Fig. 2.7
- 22 -
2. MOTORS
(4) Servicing bearings

The life of bearings varies to a large extent with the magnitude of load and operating condition. If
the bearing causes undue heat or excessive noise, replace it with a new one.
The enclosed bearing is filled with high quality of lithium soap-based grease to provide effective
lubrication and prevent the entrance of dust into the bearing. It can be used for a long period of time
without adding grease.
The enclosed bearing should be replaced at the following intervals:
Operating time 0 - 12 hours per day More 12 hours per day

Replacement Once every 6 years Once every 3 years
If the truck is operated under a dusty area or any working environment where the grease inside
the bearing might deteriorate quickly due to harmful gases or solvents, an earlier replacement of the
bearing will be recommended.
■ Installing bearing
As shown in Figure 2.8, apply a pipe directly to the inner ring of the bearing or use an aluminum or
copper insert between the pipe and the inner ring.
If the bearing is heated using a heater, do not heat to over 60 to 80°C [140 to 176°F].
ALUMINUM OR
COPPER INSERT
Fig. 2.8
■ Removing bearing
Use a bearing puller to remove the bearing.
NUT
PULLER BOLT
BEARING COVER
BEARING
Fig. 2.9
- 23 -
2. MOTORS
(5) Troubleshooting guide

If the motor shows problems (no or slow rotation, heat buildup, excessive noise or vibration or
odor), troubleshoot it using the following troubleshooting guide:
Service required and

Problem probable cause
Remedy
Check battery,
inverter or wiring.
(Refer to section
No operating “battery and
sound inverter”.) Ask a specialist
to repair.
Broken wire
Motor won’t rotate without load
Broke stator coil
Poor connection due to

loose terminal Retighten.
Motor can be
turned in either Single-phase operation due Measure voltage with
direction by hand to failed wiring or inverter a voltmeter and repair.
A broken phase of the wires Replace wire.

between motor and inverter
Ask a specialist
A broken phase to repair.
of stator coil
Broken Replace
bearing bearing.
Motor hums,
but won’t rotate.
Rotating shaft is freewheeling Retighten bolts.
due to loose bolt
Rotating direction Wrong Change places of

is wrong. connection two lead wires.
Motor rotates without load.
Motor hums. Uneven between stator

iron core gap and rotor
iron core gap
Motor frame Ask a specialist
overheats. Stator coil short- to repair.
circuited
Bearing causes Defective Replace bearing

unusual noise. bearing with a new one.
- 24 -
2. MOTORS
Check the voltage at inverter

The drive motor output terminal and lead wire
operates on a connections (as necessary)
shingle phase. using a voltmeter and repair.
Speed drops
suddenly Voltage Check the battery’s
drop condition of charge and
recharge battery if needed.
Overloading
Reduce load.
Motor overheats
Vent holes are
blocked with dust Remove dust.
Motor cannot be Burned Replace

turned easily by bearing bearing
hand.
Operation under load
Imbalanced resistance
Motor automatically Motor gives out between phases and low
stops. a foul smell. insulation resistance
(Measure the resistance Ask a specialist
with lead wires removed) to repair.
Lead wires broken

or short-circuited
Refer to section “Inverter”.
Inverter defective
Motor operates on a single phase

due to improper output terminal Connect motor lead
voltage of inverter or loose wires correctly.
Unusual noise or
connection of motor lead wires.
vibration during
operation
Bracket bolt, cooling
air guide, or sensor Retighten.
nut loose
Overheated Unusual noises from Replace

bearing bearing (check with bearing.
stethoscopic apparatus)
- 25 -
2. MOTORS
(6) Removing and reinstalling the drive motor

CAUTION
• Jack up the truck and use additional supports such as a rigid rack or sound timbers which withstand
the weight of the truck.
• Block the wheels securely.
• Tag all the lead wires before disconnecting.
• After removing pipes, cover the opening to prevent dirt or dust from entering the system.
• Disconnect the battery receptacles.
1. Before removing the drive motor from the truck, first remove the following components:
① Remove the steering wheel assembly.
② Remove the knob and boot of each lever.
③ Remove the wiring connectors and then remove the top cover assembly.
④ Remove the steering unit together with the bracket.
Note: After reinstalling, adjust the steering (angle) potentiometer according to the “STEERING (ANGLE)
POTENTIOMETER” on page 35 of the section “TROUBLESHOOTING”.
• Removing steering wheel assembly, top cover assembly and steering unit
TOP COVER ASSEMBLY
STEERING WHEEL ASSEMBLY
BRACKET
STEERING
UNIT
Fig. 2.10
- 26 -
2. MOTORS
2. Remove the cam rod from the cam lever.
• Removing cam rod

CAM LEVER
CAM ROD
Fig. 2.11
3. Remove the valve assembly and cylinder assembly used for the autolock suspension control
system:
① Disconnect the power cable of the valve assembly.
② Remove the cylinder assembly mounting pin.
③ Remove the valve assembly and cylinder assembly with the hydraulic pipes connected to them.
NOTE
Whenever the hydraulic piping for the autolock suspension control system is removed, bleed air out
of the system after reinstallation.
• Removing valve assembly and cylinder assembly
VALVE ASSEMBLY
CYLINDER ASSEMBLY
PIN
HYDRAULIC PIPING
Fig. 2.12
- 27 -
2. MOTORS
4. Remove the drive wheel.
• Removing drive wheel CONE WASHER SPRING WASHER
DRIVE WHEEL
Fig. 2.13
5. Remove drive unit:
① Remove the wiring and grease piping.
② Remove the linkage pins (2, 3).
③ Hoist the drive unit, together with the drive motor and upper linkage.
CAUTION
Tag all the lead wires for proper reconnection.
Hoist
• Removing drive unit
DRIVE MOTOR
HOISTING TOOL DRIVE MOTOR
HOISTING TOOL
LINKAGE PIN
GREASE PIPING
Fig. 2.14
- 28 -
2. MOTORS
6. Remove the drive motor: • Removing drive motor

• Remove the drive motor mounting bolts. Hoist
• Hoist the drive motor together with the disk
DRIVE MOTOR
brake unit. HOISTING TOOL
NOTE
MOUNTING
You can hoist the drive motor alone. In such BOLT DRIVE MOTOR
a case, remove other components connected
to the drive motor first.
Fig. 2.15
7. Remove the brake disk and brake assembly.
• Removing brake disk and brake assembly BRAKE

ASSEMBLY
BRAKE DISK MOUNTING

NUT
SHIM
BRAKE DISK
DRIVE MOTOR
Fig. 2.16
CAUTION
Record the number and thickness of shims before removing.
* The drive motor should be reassembled in the reverse order from disassembly.
CAUTION
When reassembling make sure to tighten the brake disk mounting nut securely.
NOTE
Whenever the hydraulic piping for the autolock suspension control system is removed, bleed air out
of the system after reinstallation.
- 29 -
2. MOTORS
2.2.2 PUMP MOTOR

(1) Checking with pump motor in operation
Visually check that no excessive

Motor yoke Shut off motor and clean.
accumulation of dust or dirt is found.
Visually check that motor frame is not

Motor frame excessively contaminated with foreign If contaminated, clean.
matter or liquid.
Visually check that no unusual sparks

Interfacial surfaces of brush If unusual sparks are found, ask a
are produced on the interfacial surfaces
and commutator specialist to repair.
between brush and commutator.
Motor yoke, bearings, cover Visually check there is no excessive If vibration is beyond allowable
and others vibration. limit, shut off motor and repair.
Motor yoke, bearings, cover Acoustically check there are no unusual If noises are beyond allowable
and others noises using a stethoscopic appratus. limit, shut off motor and repair.
(2) Checking with pump motor shut off
Visually or acoustically check bolts and

Bolts and screws screws for looseness, contamination or Retighten, clean or paint.
corrosion.
Retighten (10 - 12 N-m {1 -

Visually check for wrong or loose
1.2 kgf-m} [7.2 - 8.7 lbf-ft]) or
Stud terminals connection. Visually check for proper
measure insulation resistance and
insulation.
repair if needed .
- 30 -
2. MOTORS
(3) Periodic inspection

■ Inspection intervals
Perform periodic inspection at the intervals given below. If the truck is operated under a severer
working environment, an earlier inspection interval will be recommended.
Operating time 12 hours per day 0 - 12 hours per day
Interval Once a year Once every two years
It is advisable to inspect the brushes once a month or every two months.
Roller bearings Check roller bearings for grease leakage, noise or

Replace if necessary.
(enclosed type) accumulation of dust.
Joint surface Visually check damaged or corroded joint surface. Clean or repair if required.
Visually or acoustically check for loose, corroded or

Bolts and sscrews Retighten, apply anti-rust or replace.
stuck bolt or screw.
Visually check damaged or corroded joint surface. Clean or repair if required.
Retighten (10 - 12 N-m {1 - 1.2 kgf-m}

Visually check for wrong or loose connection. Visually
Stud terminals [7.2 - 8.7 lbf-ft]) or measure insulation
check for proper insulation.
resistance and repair if needed .
Visually check that there are no brush powder or dust
Clean any brush powder or dust
at connections.
(compressed air or soft cloth) .
Visually check iron core for accumulation of brush Clean as necessary (compressed air or soft
powder or dust. cloth).
Stator and rotor
Check coil for accumulation of brush powder or dust.
assembly Clean as necessary (compressed air or soft
Check also connections for insulation using a 500 V
cloth)
megger.
Dry by heating.
Insulation resistance: 1 MΩ or higher
Check brush for useful limit.

Size of new brush: 12.5 mm x 40 mm x 27 mm
If worn out beyond useful limit, replace
[0.5 in. x 1.6 in. x 1.06 in.]
brush with a new one of same grade, size
Material: 788
Brush and material.
Useful limit: 13 mm [0.51 in.] (out of 27 mm [1.06 in.])
Check brush for breakage.
Check brush for seizure due to dust or corrosion. Clean (compressed air or soft cloth)
Repair any damage or wear or ask a

specialist to repair.
Allowable limit: about 1.5 mm [0.06 in.] at
Visually check commutator surface for smoothness, one side (from brush sliding surface)
Commutator
discoloration, damage or undue wear. If the surface is ground, the undercut
should be 0.5 mm or more. (The undercut
means the depth of mica from commutator
piece inserted between commutator pieces.)
Visually check painting for damage, discoloration, Apply anti-rust.

Painting
peeling or corrosion. Repaint.
Visually check for contamination, accumulation of Clean or apply anti-rust.

Contamination
dirt, or corrosion. Repaint.
- 31 -
2. MOTORS
■ Pump motor maintenance

■ Inspection and servicing
Observe the following conditions when inspecting and servicing the pump motor:
① Select a dry, clean place.
② During disassembly, all the parts including the shaft should be marked properly so that they can be
reinstalled correctly. The screws and washers should be placed in order in an empty box.
③ Use a wooden mallet and lightly tap with even force to remove or reinstall brackets.
Do not a metallic hammer; otherwise the pump motor might be damaged.
When removing the armature assembly from the yoke assembly, first remove the brush cover and
then keep the brush away from the commutator sliding surface.
④ Handle the parts carefully not to give damage to them. In particular, use special caution not to
damage or contaminate the the stator, armature coil, commutator, brush and bearings with water,
dust or sand.
⑤ All the disassembled parts should be cleaned with compressed air and inspected for damage. Any
missing or damaged part must be added or replaced with a new one.
Accumulation of brush powder or dust inside the motor will cause lowered insulation resistance or
poor insulation.
⑥ To clean the coil, commutator, or brush, use compressed air, a clean cloth or soft brush. The use of
gasoline or other type of solvent might impair the insulation.
⑦ If the coil shows a low insulation resistance, dry the coil by heating to 80 to 90°C [176 to 194°F]
until an insulation resistance of 1 MΩ or more is attained. Use caution not to overheat unevenly.
⑧ Check all the bolts for looseness, retightening any loose bolts.
⑨ For inspection of the bearings, refer to paragraph (4) “Maintenance of bearings”.
⑩ If the paint is discolored or peeling, apply anti-rust or paint again.
⑪ Make sure stud terminals are securely tightened to the specified torque, and that the connections
are completely insulated.
⑫ After reassembly, check for any parts that have not been reinstalled. Make sure all the screws have
been tightened securely. Try to turn the shaft by hand to check that it turns smoothly, and then test
for the motor to ensure that it operates normally.
⑬ The pump motor should be stored in a dry, clean place where any harmful gas is not anticipated.
Apply a preservative to each end of the shaft and cover with oiled paper or vinyl cloth.
- 32 -
2. MOTORS
(4) Maintenance of bearings

The life of bearings varies to a large extent with the magnitude of load and operating condition. If
any of the bearings causes undue heat or excessive noise, replace it with a new one.
The enclosed bearing is filled with high quality of lithium soap-based grease to provide effective
lubrication and prevent the entrance of dust into the bearing. It can be used for a long period of time
without adding grease.
The enclosed bearing should be replaced at the following intervals:
Operating time 0 - 12 hours per day More 12 hours per day

Replacement Once every 6 years Once every 3 years
If the truck is operated under a dusty area or any working environment where the grease inside
the bearing might deteriorate quickly due to harmful gases or solvents, an earlier replacement of the
bearings will be recommended.
■ Installing the bearings

Prepare a soft-steel or brass cylindrical tool as shown in Figure 2.17. The tool should be designed to
come in contact with the bearing by only the side of the inner ring.
Heat the bearing to 60 to 80°C [140 to 176°F] using a bearing heater and install the bearing onto the
shaft as far as it comes up against the abutting joint of the shaft.
If the bearing stops short and refuses to proceed, use the cylindrical tool and press fit or tap to install
with a wooden mallet, by applying force to the inner ring alone with care not to apply pressure to the
outer ring of the bearing. Application of force to the outer ring will cause a dent or scores to the balls
or raceway. Install the anti-load side bearing on the opposite side of the motor in the same manner.
FORCE
Fig. 2.17
- 33 -
2. MOTORS
■ Removing bearings
Using a bearing puller, remove a bearing from the armature in the following manner:
Engage the jaws of the bearing puller on the outer periphery of the load-side bearing and tighten the
bolts which lock the spacing of the bearing puller jaws.
The motor shaft has a center hole in each end of the shaft. Protect this center hole with copper or
soft steel insert and then turn the bearing puller handle to push the motor shaft to remove the bearing.
(The center holes are used for maintenance.)
Remove the anti-load side bearing in the same manner.
Caution about bearing puller

Use a small-size bearing puller
as shown in Figure 2.18. A
large-size bearing puller might
give damage to the impeller or
commutator.
Fig. 2.18
(5) Replacing bearings

Remove the inspection cover of the motor Unit: mm [in.]
and check the remaining length of the brush. MOUNTING
BRUSH BRUSH LEAD WIRE
BOLT
The useful limit of the brush is 13 mm [0.5 in.]. SPRING
Useful limit
of the brush
Replace the brush in the following manner if the
BRUSH HOLDER
brush is worn to near the useful limit.
(1) Before trying to replace the brush, record
13[0.5] 13[0.5]
the connection of the brush lead wires to 34 [1.3]
insure correct reconnection.

(2) Remove the mounting bolts and brush lead
COMMUTATOR
wires.
(3) Lift the spring and remove the brush. If
the brush is removed, lifting the brush lead Fig. 2.19
wires without lifting the spring, the lead wires might be damaged.
(4) Lift the spring and install a new brush of the same part number, material and size as that replaced.
(5) Install the lead wires correctly as recorded in step (1) and secure with the mounting bolts. Make
sure the brush lead wires are kept away more than 7 mm [0.26 in.] from the yoke or inspection
cover.
(6) Record the date on which the brush has been replaced with a new one, and use it for planning
subsequent brush changes.
- 34 -
2. MOTORS
(6) Troubleshooting guide

If the pump motor shows problems (no or slow rotation, heat buildup, excessive noise or vibration
or odor), troubleshoot it using the following troubleshooting guide:
Item Problem Possible cause Remedy
1 Motor won’t start (1) Low power supply voltage Check power supply.
(2) Poor contact of brush Change power cable.
(3) Broken wire or poor connection Repair.
(4) Broken wire or short-circuiting of Check terminal and repair.
controller
(5) Field winding short-circuited or Replace controller with a new one.
broken
(6) Armature winding short-circuited or Ask a specialist.Ask a specialist.
broken
(7) Overloaded Reduce load.
2 Motor stats but (1) Starting resistor is not closed. Check switch.
speed won’t (2) Poor connection of armature circuit Reconnect.
increase. (3) Low power supply voltage Check power supply and change
power cable.
3 Winding (1) Overloading Reduce load.

overheating (2) Insufficient cooling or accumulation Clean.
of dust
(3) Winding short-circuited Ask a specialist to repair.
(4) Large current flow due to voltage drop Reduce terminal voltage to rated level.
4 Bearing overheating (1) Grease deteriorated Replace bearing with a new one.
(2) Bearing defective
5 Unusual noises (1) Loose parts Retighten.

(2) Foreign matter inside motor Remove foreign matter.
(3) Foreign matter inside bearing Replace bearing with a new one.
(4) Bearing defective Replace bearing with a new one.
(5) Improper installation Install properly. Retighten mounting
bolts securely.
6 Vibration (1) Improper installation Install properly.

(2) Bearing defective Retighten mounting bolts securely.
(3) Loose parts Replace bearing with a new one.
(4) Imbalance of armature Retighten.Ask a specialist to repair.
(5) Poor centering Ask a specialist to repair.
(6) Effect of load applied Reduce vibration of load.
7 Defective (1) Overloading Reduce load.

commutation (2) Vibration Install properly.
Excessively worn (3) Armature winding short-circuited or Ask a specialist to repair.
brush Discolored broken
commutator Rough (4) Improper brush contact Repair.
commutator surface (5) Brush material improper Replace brush with a new one.
(6) Improper mica height Lower mica height.
(7) Corrosive gas atmosphere Avoid corrosive gas atmosphere.
8 Score marks on (1) Improper brush material Replace brush with a new one.
commutator surface (2) Dusty environment Prevent entrance of dust.(Cool with
clean air)
(3) Oily vapor Prevent entrance of oily vapor into
commutator.(Cool with clean air.)
- 35 -
2. MOTORS
(7) Removing and reinstalling pump motor

1. Remove the following parts before trying to remove the pump motor from the truck:
CAUTION
Before trying to remove high-pressure pipes or hoses, operate the hydraulic levers several times to
release the hydraulic pressure from the circuit.
① Remove the high-pressure hoses and low-pressure hoses.
② Remove the hydraulic motor lead wires.
2. Remove the pump motor:

① Remove the mounting bolts (*1) securing the cushion bracket
② Hoist the pump motor together with the main pump and motor bracket.
* Removing pump motor (1)
Tightening torque of mounting bolt (*1)

36 - 43 N-m {3.6 - 4.3 kgf-m}
[26.6 - 31.7 lbf-ft]
CUSHION BRACKET
PUMP MOTOR
CUSHION (1)
Tightening torque of mounting nut (*2)

10 - 12 N-m {1.0 - 1.2 kgf-m}
[7.4 - 8.9 lbf-ft]
Apply ThreeBond #1342N or
equivalent.
MOUNTING BOLT (*1)
MOTOR BRACKET
Fig. 2.20
- 36 -
2. MOTORS
3. Remove the cushion bolts and remove the cushion bracket from the pump motor.
4. Remove the bolts (*3) securing the main pump and remove the main pump from the pump motor.
CAUTION
Do not disassemble the main pump.
If the main pump fails to operate normally, replace the main pump assembly with a new one.
* Removing pump motor (2)

CUSHION BRACKET
PUMP MOTOR
Apply molybdenum grease
MAIN PUMP Tightening torque of mounting bolts (*3)

20 - 24 N-m {2.0 - 2.4 kgf-m}
[14.8 - 17.7 lbf-ft]
Fig. 2.21
* The pump motor should be reassembled in the reverse order from disassembly.
- 37 -
2. MOTORS
(8) EPS motor

1. Remove the connector from the EPS motor.
2. Remove the bolts (*1) securing the EPS motor, and then remove the EPS motor.
* Removing EPS motor

ESP MOTOR
Tightening torque of mounting bolts (*1)
17 - 28 N-m {1.7 - 2.8 kgf-m} [12.5 - 20.7 lbf-ft]
SPLINES
Apply molybdenum grease.
EPS MOTOR COVER

Apply ThreeBond#1216E or
equivalent on the mating surfaces.
Fig. 2.22
* The EPS motor should be reassembled in the reverse order from disassembly.
- 38 -
3. CONTROLLER
3. CONTROLLER
Truck model FRB10-8 FRB13-8 FRB14-8

FRB20-8 FRHB20-8
FRB10-8C FRB13-8C FRHB14-8 FRB18-8
FRB20-8 FRHB25-8
FRHB10-8C FRHB13-8C FRB15-8 FRHB18-8
FRB30-7 FRHB30-8
Item FRHB10-8 FRHB13-8 FRHB15-8
Rated voltage 48V ←
Control method
Drive system Traveling: Vector controlled PWM inverter method
Plugging and regenerative braking: Torque control
Load handling system Chopper control
Power steering system Chopper control (H bridge)
Current limit
Load handling system 425A 550A
Power steering system 30A 35A
Protection * Main controller error protection ←
* Sensor input error protection
* Temperature protection
* Traveling and load handling system neutral safety
Acceleration Resistance type ←

3.1.1 CONTROLLER
The controller consists primarily of the parts shown in Figure 3.1. It is fitted to the upper part of the
frame.
- 39 -
Signal line PC
3. CONTROLLER
Power line
Communication line
Switch panel LCD panel
Accelerator potentiometer
Controller
Switches for: Lift potentiometer
Interlock
Foot brake
Battery position
sensor
Mast SSC (option) Main CPU Valve lever
Pump motor
- 40 -
temperature (option)
Fig. 3.1
EPS torque sensor
Steering angle
potentiometer
Module Sub CPU

Relay output:
Auxiliaries for forward travel
(option)
Auxiliaries for reverse travel
Speed alarm (option)
Solenoid output:
Front brake (option)
Lift lock
Suspension lock
Thermo-sensor Drive Pump

Rotation sensor motor motor EPS motor Battery
3. CONTROLLER
① Main CPU board

② Sub CPU board
③ Contactor
④ Current sensor
⑤ Resistor
⑥ Fan
⑦ Fuse F1, 225 A (Drive motor)
⑧ Fuse F2, 225A (Pump motor)
⑨ Fuse F3, 40A (Power steering
motor)
⑩ Pump motor and EPS drive
module
⑪ Insulation sheet
⑫ Drive motor driving module
⑬ Insulation sheet
⑭ Fuse F6 (battery charging),
130 A
Fig. 3.2 Main Controller
- 41 -
3. CONTROLLER
3.1.2 ACCELERATOR
The accelerator consists primarily of the parts shown in Figure 3.3 and controls the truck speed and
the direction of travel.
The operating angle of the lever is converted by a potentiometer into voltage and it is outputted to
the controller.
Apply ThreeBond#1324N.
1. BRACKET 5. SPRING 9. KNOB

2. BUSHING 6. WASHER
3. LEVER 7. POTENTIOMETER
4. PLATE 8. LEVER
Fig. 3.3 Accelerator
- 42 -
3. CONTROLLER
3.1.3 LCD PANEL

The LCD panel and switches are installed as shown in Figure 3.4.
The LCD panel has the following functions:
• Operating status of the truck
• Clock function
• Showing Error codes
• Controlling battery charging
• Setting parameters
Parameters can be entered and changed through the keypad.
1. LCD PANEL
2. KEYPAD
3. HORN SWITCH
4. LIGHTING SWITCH
5. WIRING HARNESS
6. TURN SIGNAL SWITCH
7. KEY SWITCH
Fig. 3.4 LCD Panel
- 43 -
3. CONTROLLER
■ LCD PANEL
1. PARKING BRAKE 4. TRAVEL SPEED 8. TIRE ANGLE INDICATOR 10. LOW-SPEED TRAVEL
INDICATING LIGHT METER 9. BATTERY DISCHARGE MARK (TURTLE)
2. INTERLOCK WARNING 5. HOUR METER INDICATOR 11. S.P.E. MODE
LIGHT 6. DATE AND TIME INDICATOR
3. NEUTRAL STATUS 7. KEY PAD
INDICATING LIGHT
Fig. 3.5
■ KEY PAD
① S.P.E. BUTTON
Every time the S.P.E. button is pressed, the operating
power mode changes, with the letter S, P or E appearing (S
→ P → E → S). Use this button to set the operating power
mode of the truck.
② SCREEN SELECTION “MODE” BUTTON
Screen selection Every time this button is pressed, the LCD
panel screen changes:
Main screen → Power consumption screen →
Hour meter → Main screen
Date and time If this button is pressed for more than 3
screen seconds, the Date and Time screen appears.
③ LOW-SPEED TRAVEL (TURTLE) BUTTON Fig. 3.6 Keypad

When you press the turtle mark button on the key pad, the
truck gets in the low-speed travel mode. To release the
low-speed travel mode, press the button again.
• Normal-speed travel mode
When the turtle mark button on the key pad is turned
off, the low-speed (turtle) mark on the LCD panel
disappears.
• Low-speed travel mode
When the turtle mark button on the key pad is turned
on, the low-speed (turtle) mark appears on the LCD
panel.
④ +/- BUTTONS
Change the date and time using the +/- buttons on the key
pad.
- 44 -
4. DRIVE UNIT
4. DRIVE UNIT

FRB20-8 FRHB20-8
FRB20-8 FRHB25-8
FRB30-7 FRHB30-8
Item FRHB10-8 FRHB13-8 FRHB15-8
Type Three-stage reduction ←
Model 7B0-25 7B4-25

Reduction ratio 22.954 23.952
Wheel dimensions 334 mm dia. x 145 mm [13.15 x 5.71 in.] 380 mm dia. x 165 mm
[14.96 x 6.5 in.]

Figure 4.1 shows the construction of the drive unit. The drive support unit is attached to the frame
through a link.
Each gear is incorporated into the gear case, efficiently transmitting the rotation of the motor.
The gear case is attached to the drive support unit by 2 taper roller bearings, and rotates to right and
left by means of the EPS motor.
- 45 -
4. DRIVE UNIT
EPS MOTOR
22. DRIVE SHAFT

23. TAPER ROLLER 38. OIL SEAL
BEARING 39. GEAR
24. NUT 40. BEARING
25. SHIM 41. BEARING
26. TAPER ROLLER 42. OIL SEAL
BEARING 43. TAPER ROLLER
1. MIDDLE CASE 12. BALL BEARING 27. COVER BEARING
2. GEAR 13. BEARING 28. PLUG 44. TAPER ROLLER
3. BREATHER 14. GEAR 29. OIL SEAL BEARING
4. PIN 15. TAPER ROLLER 30. UPPER CASE 45. SET SCREW
5. "O"-RING BEARING 31. COVER 46. NUT
6. LOWER CASE 16. SPACER 32. GEAR 47. WASHER
7. PLUG 17. NUT 33. STEERING GEAR 48. BUSHING
8. INPUT GEAR 18. RETAINER 34. BEARING 49. SPHERICAL BUSHING
9. BALL BEARING 19. SHIM 35. BEARING 50. SNAP RING
10. BALL BEARING 20. DRIVE PINION 36. SNAP RING 51. SPACER
11. GEAR 21. BEVEL GEAR 37. OIL SEAL 52. PLUG
Fig. 4.1
- 46 -
4. DRIVE UNIT
4.2 MAINTENANCE
4.2.1 REPLACING DRIVE WHEEL
(1) Removing the drive wheel.
① Jack the rear part of the frame off the ground. (See Fig. 4.2)
② Turn the steering wheel to face the drive wheel rearward.
③ Remove all drive wheel mounting bolts. Remove the wheel.
BLOCKS BLOCK This side points rearward.

(at both wheels)
Fig. 4.2
(2) Removing the hub

Using a suitable press, remove the hub from the wheel. PRESS
WHEEL
HUB
Fig. 4.3
- 47 -
4. DRIVE UNIT
(3) Reassembling the drive wheel

PRESS
Using a suitable press, press the hub onto the wheel.
WHEEL
HUB
Fig. 4.4
(4)Reinstalling the drive wheel

① Aligning the bolt holes in the hub with the screw holes in the shaft, install the drive wheel.
② Install mounting bolts.
③ Tighten the bolts to specified torque.
Tightening torque: 63.7 N-m {6.5 kgf-m} [563.8 lbf-in.] for 1 ton trucks
88.2 N-m {9.0 kgf-m} [780.6 lbf-in.] for 2 ton trucks
④ Turn the steering wheel to put the drive wheel in the straightforward position.
⑤ Lower the frame to the ground.
Tightening torque : 63.7 N-m {6.5 kgf-m}

[563.8 lbf-in.] for 1 ton trucks
: 88.2 N-m {9.0 kgf-m}
[780.6 lbf-in.] for 2 ton trucks
Fig. 4.5
- 48 -
4. DRIVE UNIT
4.2.2 ADJUSTMENT AFTER REASSEMBLY

(1) Adjusting the drive pinion LOCK NUT
(Stake lock nut after
① Reassemble the drive pinion as shown in Fig. 4.6. preload adjustment)
② Measure the preload and if necessary adjust with
the lock nut.
TAPER ROLLER
Preload: 1.2 to 1.5 N-m {0.12 to 0.15 kgf-m} BEARING
[10.621 to 13.276 lbf-in.]

RETAINER
③ After preload adjustment, stake the lock nut.
TAPER ROLLER
BEARING
DRIVE PINION
Fig. 4.6
(2) Adjusting engagement and backlash between the drive pinion and bevel gear
① Install the drive shaft and bevel gear in the lower
case with a shim B (0.5 mm or 0.0197 in).
DRIVE PINION
The starting torque is adjusted by tightening the ASSEMBLY
nut.
Starting torque: DRIVE SHAFT
3.5 to 4.5 N-m {0.36 to 0.46 kgf-m} [31.0 to

SHIM A
39.8 lbf-in.] for 1 ton trucks
5.0 to 6.0 N-m {0.51 to 0.61 kgf-m} [44.3 to
LOWER
53.1 lbf-in.] for 2 to 3 ton trucks CASE
② Install the drive pinion assembly in the lower
case with a shim A (0.5 mm or 0.197 in.).
Tightening torque: 41 to 45 N-m {4.2 to 4.6 kgf-m}
OIL SEAL
[362.9 to 398.3 lbf-in.]
TAPER ROLLER
BEARING
BACKLASH ADJUSTING SHIM B

(0.1, 0.2 and 0.5 mm or 0.0039,
0.0079 and 0.0197 in.)
BEVEL GEAR
LOCK NUT
(Stake lock nut after
preload adjustment)
Fig. 4.7
- 49 -
4. DRIVE UNIT
③ Check the engagement between the bevel gear

and drive pinion gear.
Backlash: 0.18 to 0.23 mm [0.0071 to 0.0091 in.]
After the preload is adjusted, the backlash should
be proper and the engagement as shown in Fig.
4.8. If the backlash is not proper, adjust it with a
shim B .
Fig. 4.8 Correctly Engaged
Reduce the number of shims B to increase the backlash and increase the number of shims B to
reduce the backlash.
④ Stake lock nut after adjustment.
(3) Gear oil filling

Add gear oil into the drive unit in the following
manner:
① Add gear oil through the oil fill plug to fill area
OIL FILL PLUG
B.
② About 10 minutes later, check the oil level
through the level port. If the level is low, add
gear oil through the oil fill plug. LEVEL PORT

Unit: Liter [U.S. gal]
1 ton trucks 2 to 3 ton trucks

Drive Unit 2.1 [0.555] 3.2 [0.845]
Actuator 0.35 [0.092] ←
Fig. 4.9
- 50 -
4. DRIVE UNIT
4.2.3 TROUBLESHOOTING GUIDE
No Problem Cause Remedy

① Poor engagement or wear of the gear teeth
between spiral bevel gear and spiral bevel Adjust or replace.
pinion
② Poor tooth contact or wear of the gear teeth
Replace.
between the counter gear and drive pinion
③ Poor contact or wear of the gear teeth
Loud repetitive Replace.
1 between the counter gear and driven gear
noises while driving
④ Incorrect adjustment or wear of the spiral
Adjust or replace.
bevel gear bearing
⑤ Incorrect adjustment or wear of the spiral
Adjust or replace.
bevel pinion bearing
⑥ Insufficient or contaminated oil in the gear
Clean or add.
case
① Damage to the bearings from excessive
Replace.
Gear case preload
2
overheating ② Insufficient backlash of the spiral bevel gear
Adjust.
and spiral bevel pinion
① A flat spot on the wheel Replace.
Excessive vibration ② A chipped wheel Replace.
3
while driving
③ Excessive gap between the link and drive
Adjust.
support
Irregular noises ① Wheels are peeling or deteriorating Replace.

4
while driving ② Irregular sounds coming from drive motor Inspect.
① Wear of the oil seal Replace.
② The bolt securing the gear case support is
Replace.
5 Gear oil leaks loose or the "O" ring is damaged
③ The bolt securing the gear case cover is
Replace.
loose or the gasket is damaged
Gears slip while ① The control linkage is incorrectly adjusted Adjust.

6
accelerating ② The wheel is worn Replace.
- 51 -
4. DRIVE UNIT
NOTE
- 52 -
5. STEERING SYSTEM
5. STEERING SYSTEM
Type Drive unit-rotating type with electric power steering unit

Power steering
Control Chopper control (H-bridge)
EPS motor
Type DC magnet type
Output 300 W (60 min.)
Actuator reduction ratio 23.1

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

The steering wheel is attached to the shaft supported by the ball bearing and a sprocket is welded to
the shaft.
The rotations of the steering wheel are transmitted through the sprocket and chain to the input shaft
of the steering sensor, and the output shaft connects to the drive unit actuator through the joint.
- 53 -
5. STEERING SYSTEM
View looking from A
JOINT
TORQUE SENSOR
CHAIN
Detail of area B
Fig. 5.1
- 54 -
5. STEERING SYSTEM
5.1.2 TORQUE SENSOR

Figure 5.2 shows the construction of the torque sensor. The torque sensor converts the rotational
direction and torque of the steering wheel into voltages and sends them to the main CPU of the
controller.
Stake 3 locations
PIN
PIN
INPUT SHAFT LOCK NUT

OIL SEAL ADJUSTING SCREW
POTENTIOMETER
SUN GEAR
INTERNAL GEAR
PINION GEAR
OIL SEAL
OUTPUT SHAFT
Fig. 5.2 Torque Sensor
- 55 -
5. STEERING SYSTEM
5.1.3 STEERING ANGLE SENSOR

The steering angle sensor is engaged with the chain that connects the sprocket of the steering wheel
and the sprocket of the torque sensor.
The steering angle sensor detects the angle of the drive wheel.
The controller adjusts speed controls and suspension locks according to the angle of the drive
wheels.
The drive wheel angle display on the LCD panel is also based on the output of the steering angle
sensor. Incorrect neutral adjustment may result in the vehicle not being able to operate at its maximum
speed or irregular behavior when turning. (See TROUBLESHOOTING for how to adjust the neutral
position.)
If the sensor is disconnected, the controller will register the wheels as straightforward, and the speed
control and suspension lock features will not function. Always connect the sensor.
REDUCTION GEAR
POTENTIOMETER
View looking from A

Connection Diagram
Fig. 5.3 Steering Angle Sensor
- 56 -
5. STEERING SYSTEM
5.1.4 ACTUATOR
The actuator consists of gears and is incorporated EPS MOTOR
in the drive unit upper case.

to TORQUE SENSOR
The rotation of the motor is transmitted through
the gears A , B and C to the shaft, being reduced in UPPER CASE
speed.
The gear D on the shaft is in mesh with the ring GEAR A
gear fitted to the lower case and is splined through a

joint to the torque sensor.
GEAR C
GEAR B
OIL SEAL
GEAR D
Fig. 5.4 EPS Actuator
- 57 -
5. STEERING SYSTEM
5.1.5 REAR AXLE

The rear axle supports the drive unit while minimizing reductions in contact pressure between
the ground and the drive wheel caused by rough road surfaces, thus preventing the drive wheel from
skidding.
If the castor and drive unit are secured to the frame, when the castor rides on a bulge in the road, the
drive unit floats together with the frame, thus causing the drive wheel to rotate in the air. To prevent
this, as shown in Fig. 5.5, with the aid of a spring, the drive unit is forced into the direction opposite
the direction in which the castor moves, maintaining the contact pressure between the drive wheel and
the road surface.
Tighten to 170 N-m {17.3 kgf-m} [1504.6

lbf-in.], and then back off 90 degrees.
DRIVE UNIT
35 mm
[1.39 in.]
UPPER LINKAGE
Spring installation size:

145 mm [5.71 in.]
LOWER LINKAGE
Fig. 5.5 Rear Axle (1.0- to 1.8-ton Trucks)
- 58 -
5. STEERING SYSTEM
Tighten to 170 N-m {17.3 kgf-m} [1504.6

lbf-in.], and then back off 90 degrees.
DRIVE UNIT
18 mm
[0.71 in.]
UPPER LINKAGE
Spring installation size:

165 mm [6.50 in.]
LOWER LINKAGE
Fig. 5.6 Rear Axle (2- to 3-ton Trucks)
- 59 -
5. STEERING SYSTEM
5.1.6 LOCK CYLINDER

The lock cylinder is a cylinder installed between the frame and drive unit.
The lock cylinder locks the rear axle when accelerating, decelerating, turning, or handling materials
to improve side-to-side and front-to-back stability.
Tightening torque:
15 N-m {1.53 kgf-m}
[132.76 lbf-in.]
Air bleeding instructions:
(1) Remove the cap, piston and plug from the valve. Do
not energize the solenoid valve. CAP
(2) Fully compress the cylinder and place the cylinder
so that the port is facing up, and the cylinder is level.
Place the valve above this so that the tank is on top. PLUG PISTON
(3) Fill the tank with hydraulic fluid. Use CS35 specified
hydraulic fluid (07012-02000), or an equivalent
product.
(4) Slowly lengthen the cylinder to its full length. TANK
(5) The fluid in the tank will decrease as the cylinder
lengthens. Add enough fluid to maintain the tank 1/4 to CYLINDER TAIL
full when the cylinder is at full length.
(6) Once the cylinder has been fully lengthened, slowly to CYLINDER ROD
compress it fully once again. Be careful of fluid
spillage from the tank.
(7) Once the cylinder is fully compressed, fill the tank
until it is 1/2 full with fluid.
(8) Repeat steps 4 to 7 until no bubbles escape from the SOLENOID
bottom of the tank. VALVE
(9) Once bubbles no longer escape, fully compress the
cylinder. Adjust the fluid level to 25 to 30 mm [1 to
1.18 in.]. Insert the piston until the R1/8 screws are
submerged, and fasten the plug. The piston should be
13 to 18 mm [0.51 to 0.71 in.] from the top of the tank.
(10) Fully expand the cylinder and install the cap when the
piston drops to the bottom of the tank.
Fig. 5.7 Lock Cylinder
- 60 -
5. STEERING SYSTEM
5.1.7 CASTER WHEEL

The caster wheel is a part of the rear axle and faces the direction the vehicle is moving when
steering.
The lower link is attached to the frame with a pin.
The shaft of the knuckle is attached to the lower link with 2 bearings.
CAP BALL
BEARING
KNUCKLE
BOLT
LOWER LINKAGE
WHEEL
CAP
BALL BEARING
Fig. 5.8 Caster Wheel (1- to 1.8-ton Trucks)
LOWER LINKAGE CAP
BALL BEARING
BALL BEARING
KNUCKLE
WHEEL BOLT
CAP
Fig. 5.9 Caster Wheel (2- to 3-ton Trucks)
- 61 -
5. STEERING SYSTEM
5.1.8 TRAIL WHEEL

As shown in Fig. 5.10, the trail wheel is installed on an outrigger. Optionally, a wheel featuring an
electromagnetic brake can be installed.
LOCK WASHER
LOCK NUT
BALL BEARING
TRAIL WHEEL
BALL BEARING
CAP
ELECTROMAGNETIC
BRAKE
COVER
LOCK WASHER
LOCK NUT
BALL BEARING
TRAIL WHEEL
BALL BEARING
CAP
Fig. 5.10
- 62 -
5. STEERING SYSTEM
5.2 MAINTENANCE
5.2.1 REPLACING CASTER WHEEL
(1) Removing the caster wheel
① Jack the rear part of the frame off the ground. (See Fig. 5.11)
② Remove the cap from the caster wheel.
③ Remove bolts and the wheel assembly.
WHEEL ASSEMBLY
WASHER
BOLT
CAP
BLOCKS BLOCK
(at both wheels) (Example)
Fig. 5.11
(2) Disassembling the caster wheel (for 2- to 3-ton trucks only)

Using a press, separate the hub from the wheel.
PRESS
WHEEL
HUB
Fig. 5.12
- 63 -
5. STEERING SYSTEM
(3) Reassembling the caster wheel (for 2- to 3-ton

trucks only) PRESS
Using a press, press the hub onto the wheel.

WHEEL
HUB
Fig. 5.13
(4) Reinstalling Caster Wheel

① Attach the wheel assembly to the shaft.
② Fasten washers and bolts.
③ Attach the cap. WASHER
BOLT
CAP
1- to 1.8-ton trucks
WASHER
BOLT
CAP
2- to 3-ton trucks Grease point
Fig. 5.14
- 64 -
5. STEERING SYSTEM
5.2.2 REPLACING TORQUE SENSOR

(1) Removing the potentiometer
① Clean the potentiometer and surrounding
area and cut the fastening band (See Fig.
FASTENING
5.15) BAND
② Remove the screws securing the
HARNESS
potentiometer. (See Fig. 5.16)
③ Remove the sealing agent from the cover POTENTIOMETER
and the shims.
④ Remove grease and oil, if any, from the Fig. 5.15
spring chamber with compressed air.
SCREW
SCREW
Fig. 5.16
(2) Installing the potentiometer

① Install the potentiometer with a shim (1.9
SPRING
mm or 0.075 in.)
Note: Pay attention to the direction of the harness. COVER (SHIM)
Care should be exercised not to bend the
needle.
POTENTIOMETER
Tightening torque: 0.5 to 1 N-m {5 to 10
kgf-cm} [4.4 to 8.9 lbf-in.]
Fig. 5.17
② Neutral adjustment
a. Connect the potentiometer to the connector
on the forklift body.
b. Set the tester to the 10V voltage range.
Connect the plus (+) terminal of the tester
to the CN2-15 (G) terminal on the main
CPU board and the minus (-) terminal of
the tester to the minus (-) terminal on the
controller.
Fig. 5.18
- 65 -
5. STEERING SYSTEM
c. Turn the key switch ON and measure the voltage.

Reference voltage: 2.5±0.08V
If the measured voltage is other than the reference voltage, change the cover (shims). Increase the
number of shims to increase the voltage and decrease the number of shims to decrease the voltage.
Types of cover (shims): 1.7, 1.8, 1.9, 2.0, and 2.1 mm [0.067, 0.071, 0.075, 0.079, and 0.083 in.]
A change of 0.1 mm [0.0004 in.] in shim thickness represents a change of 0.04 V in voltage.
③ After neutral adjustment, apply sealing

agent on the cover (shims) and secure with
screws.
Note: Sealing agent should be applied thinly and
evenly, and any excess sealing agent should
be removed.
Fig. 5.19
④ Install the potentiometer securely.

Tightening torque: 0.5 to 1 N-m {5 to 10
kgf-cm} [4.4 to 8.9 lbf-in.]
Fig. 5.20
⑤ Give the harness a little slack and secure

with the fastening band.
Fig. 5.21
- 66 -
6. BRAKE SYSTEM
6. BRAKE SYSTEM
FRB20-8 FRHB20-8
Item FRB25-8 FRHB25-8
FRB30-8 FRHB30-8
FRHB10-8 FRHB13-8 FRHB15-8
Type Motor-shaft-braking disk type

Pedal ratio 18.9
Brake disk outer diameter 210 mm [8.3 in.] 255 mm [10.0 in.]

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

The brake caliper assembly is made up of brake pads attached to levers on the top and bottom of the
assembly. The brake spring clamps the pads around the brake disc attached to the armature shaft of the
drive motor.
When the brake pedal is not being pressed, the cam lever is pulled upwards by the spring, keeping
the brake applied.
When the brake pedal is pressed, the cam lever turns through the linkage so that the cam forces the
top and bottom levers apart from each other, releasing the brake.
Install downwards for 2- to

3-ton trucks.
BRAKE SPRING
ADJUSTING
SCREW
LEVER (UPPER) PAD
CAM
ADJUSTING SCREW LEVER PAD

(LOWER)
Fig. 6.1 Brake Caliper Assembly
- 67 -
6. BRAKE SYSTEM
ADJUSTING SCREW
BRAKE DISC
BRAKE SWITCH
Brake switch adjustment

1. When installing the brake pedal, adjust the
shims so that the space between the disk and
the lower pad is 0.2 to 0.5 mm [0.007 to 0.019
in.]
2. Turn the adjusting screw to adjust the brake
pad gap (of the narrowest area) so that when
SHIM pressing the brake pedal, the gap on one side
is 0.2 to 0.3 mm [0.007 to 0.011 in.]).
DRIVE MOTOR 3. Adjust the brake switch so that the micro
switch is activated when the disk rotor is
rotated by hand.
Fig. 6.2 Brake Caliper Installation
6.1.2 BRAKE PEDAL

The brake pedal unit is installed as shown in Fig. 6.3. When the pedal is not pressed, the pedal is
pulled upwards by the spring.
When the pedal is pressed, the action is transmitted to the brake caliper cam lever through the link,
the crank arm, and the rod.
- 68 -
6. BRAKE SYSTEM
8.5 mm [0.33 in.]

6.5 mm [0.256 in.]
(compact trucks)
Pay attention to the
facing when installing
Detail of area A
Fig. 6.3 Brake Pedal (1/2)
- 69 -
6. BRAKE SYSTEM
(16 to 17 mm or
0.63 to 0.67 in.)
Detail of area A
(67 to 68 mm or
2.64 to 2.68 in.)
Trucks for cold storage and

freezer applications
Section B
Pedal height when the brake switch is ON

E mm [in.]
43 to 46
1.0- to 1.8-ton trucks
[1.69 to 1.81]
39 to 42
2- to 3-ton trucks
[1.54 to 1.65]
Fig. 6.4 Brake Pedal (2/2)
- 70 -
6. BRAKE SYSTEM
6.2 MAINTENANCE
6.2.1 ADJUSTING PEDAL HEIGHT
(1) Remove the ball joint from the lever. Loosen the
ball joint lock nut.
LOCK NUT
(2) Adjust the pedal height by turning the ball joint. BALL JOINT
Turn it clockwise to raise the pedal and turn
counterclockwise to lower it. With the pedal LEVER
adjusted, insert the lever into its installation hole

and measure the pedal height.
Pedal height: 67 to 68 mm [2.64 to 2.68 in.]
(3) After adjustment, secure the ball joint with the
lock nut and install it on the lever.
Fig. 6.5 Pedal Height
6.2.2 ADJUSTING BRAKE CLEARANCE AND BRAKING FORCE

(1) Adjusting brake clearance
① Press the brake pedal to the floor and secure it.
② Using the brake caliper adjustment screw, adjust
ADJUSTING SCREW
the clearances between the top and bottom pads
to the same clearance.
Clearance: 0.2 to 0.3 mm [0.007 to 0.011 in.]
ADJUSTING SCREW
Fig. 6.6 Brake Clearance

(2) Adjusting braking force
Adjust the length of the spring using the adjustment Note: The spring is
installed facing
nut to adjust the braking force. downwards for 2-
to 3-ton trucks.
115 mm [4.53 in.]

(1-ton trucks)
105 mm [4.13 in.]
(2- to 3-ton trucks)
Fig. 6.7 Adjusting Braking Force
- 71 -
6. BRAKE SYSTEM
6.2.3 REPLACING BRAKE PADS

(1) Turn the adjusting screw clockwise to give
clearances between pads and the brake disk.
(2) Remove the pad lock bolts and remove the pads. LOCK BOLT
LEVER
(3) Spread the gap between each lever and the (UPPER)
PAD
disk wide enough to insert a new pad with the

adjusting screws. Install new pads.
Tightening torque: 17.7 to 26.5 N-m {180 to
270 kgf-cm} [156.66 to 234.54 lbf-in.] LEVER (LOWER)
ADJUSTING SCREW
(4) After installing the pads, adjust the brake pad
clearance and the braking force. (See 6.2.2) Fig. 6.8
6.2.4 ADJUSTING BRAKE SWITCH

(1) Press the brake pedal until you can turn the
brake disk by hand. LOCK NUT NUT
(2) Loosen the brake switch lock nut. Set the nut
tightness at the point where the switch turns
ON. SWITCH
Fig. 6.9
- 72 -
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
Truck model FRB10-8 FRHB10-8 FRB14-8 FRB20-8

FRB13-8 FRHB13-8 FRB15-8 FRB18-8 FRHB20-8 FRB30-8
FRB10-8C FRHB10-8C FRHB14-8 FRHB18-8 FRB25-8 FRHB30-8
Item FRB13-8C FRHB13-8C FRHB15-8 FRHB25-8
Pump
Type Gear connected ← ← ← ←
directly to motor
Control valve
Type 3-spool sliding type ← ← ← ←
Name MSV04 ← ← ← ←
Pressure setting 12.3 MPa 13.7 MPa 15.7 MPa 17.2 MPa ←
{125 kgf/cm2} {140 kgf/cm2} {160 kgf/cm2} {175 kgf/cm2}
[1784 psi] [1987 psi] [2277 psi] [2495 psi]
Lift cylinder
Type Singe-acting ← ← ← ←
piston type
Cylinder bore 45 mm ← ← 50 mm 55 mm
[1.77 in.] [1.97 in.] [2.17 in.]
Rod outer dia. 35 mm ← ← 40 mm 45 mm
[1.38 in.] [1.58 in.] [1.77 in.]
Tilt cylinder
Type Double-acting ← ← ← ←
piston
Cylinder bore 50 mm ← ← 63 mm ←
[1.97 in.] [2.48 in.]
Rod outer dia. 25 mm ← ← 30 mm ←
[0.98 in.] [1.20 in.]
Reach cylinder
Type Double-acting ← ← ← ←
piston
Cylinder bore 45 mm ← ← ← ←
[1.77 in.]
Rod outer dia. 25 mm ← ← ← ←
[0.98 in.]

The hydraulic system consists of an oil tank, a pump, a control valve and cylinders.
- 73 -
7. HYDRAULIC SYSTEM
7.1.1 OIL TANK

The oil tank is installed on the upper side of the battery and its construction is as shown in Fig. 7.1.
The breather cap has a filter to prevent dust in the air sucked due to a lowered oil level, from getting
into the tank.
The suction pipe has also a filter to prevent dust from entering the circuit.
BREATHER to LIFT CYLINDER

OIL CAP
to PUMP
from CONTROL
VALVE
FILTER
Capacity Oil level Oil level height

Mast lift height Models covered
(L [US gal]) mark A mm [in.]
Up to V(F) M400
16 [4.2] H 254 [10]
Up to VFH M435
1.0- to 1.8-ton trucks
Above V(F) M400
17 [4.5] S 270 [10.6]
Above VFH M435
Up to V(F)(FH) M500 2- to 2.5-ton trucks
22 [5.8] H 285 [11.2]
Up to V(F)(FH) M450 3-ton trucks
Above V(F)(FH) M500 2- to 2.5-ton trucks
23 [6.1] S 298 [11.7]
Above V(F)(FH) M450 3-ton trucks
Fig. 7.1
- 74 -
7. HYDRAULIC SYSTEM
7.1.2 MAIN PUMP

The main pump is a gear type as shown in Fig. 7.2.
The main pump consists of a pump body, a pair of gears, bushings and packings. To minimize the
gap between the gears’ side-faces, pressure-balanced type bearings and lubrication method are used.
The pressure-balanced type directs part of the oil discharged from the main pump into between the
pressure plate and pump body, to press the pressure plate toward the gear side.
1. DRIVE GEAR
2. SNAP RING
3. OIL SEAL
4. GASKET
5. SIDE PLATE
6. PUMP BODY
7. REAR COVER
8. HYPSILOID GASKET
9. DRIVEN GEAR
10. BUSHING
11. FRONT COVER
Fig. 7.2 Main Pump
7.1.3 CONTROL VALVE

The control valve consists of three plunger sections, an outlet section and an inlet section with a
relief valve (as shown in Fig. 7.3), and is assembled with three bolts. The inlet section relief valve
is a cartridge type featuring that its pressure setting does not change even when it is reinstalled after
removed.
Between the inlet section and the lift plunger section and between the lift plunger section and the tilt
plunger section, check valves are installed.
These check valves serve to prevent the back flow from a heavily loaded section to a lightly loaded
section when the lift and tilt levers are simultaneously operated.
A potentiometer installed on the plunger section at the lift side converts the movement of the
plunger into the voltage and sends it to the controller.
- 75 -
7. HYDRAULIC SYSTEM
LIFT SECTION
TILT SECTION
SOLENOID
REACH VALVE
SECTION
GAGE PORT
OUTLET
SECTION
INLET
SECTION
RELIEF VALVE LIFT PORT (A3)
POTENTIOMETER
Hydraulic circuit diagram
Spool
position
Fig. 7.3 Control Valve
- 76 -
7. HYDRAULIC SYSTEM
7.1.4 VALVE CONTROL

The spools in the control valve are operated by the levers shown in Fig. 7.4. Each lever is installed
on a shaft and supported by a bracket on the valve assembly. The movement of each lever is detected
by each switch and transmitted to the controller.
The lift lever stroke length is detected by a potentiometer.
Reach switch
Tilt switch
Lift-down switch
Attachment switch
4-THROW VALVE (OPTIONAL)
3-THROW VALVE (STANDARD) 5-THROW VALVE (OPTIONAL)
Tightening torque:
1.08 to 1.57 N-m
{0.11 to 0.16 kgf-m}
[0.80 to 1.16 ft-lbs]
(Apply THREEBOND 1324N.)
View looking from A
Fig. 7.4 Valve Control
- 77 -
7. HYDRAULIC SYSTEM
7.1.5 LIFT CYLINDER

The two lift cylinders of single-acting type are located on the outer mast frame. Each lift cylinder
consists of cylinder body, rod, piston and cylinder cap.
The piston fastened to the rod with a snap ring is provided with a wear ring, and packing on its
circumference.
At the lower part of the cylinder body provided is a cut-off valve which works as a safety device
when the high-pressure hose connecting the right and left lift cylinders is broken.
The bushing and oil seal pressed into the cylinder cap serve to support the rod and protect the inside
of the cylinder from dust.
■ Cut-off valve operation

The oil from the cylinder flows back to the tank
via the piston holes A and B . In this step, if the
flow rate passing through the holes is within a range
of the flow rate which can be controlled by the flow
regulator, the pressure difference between the front
and rear of the piston is less than the spring force so
that the piston does not move.
If the hose is ruptured and the oil passing PISTON
through the holes A and B exceeds the flow to
SPRING
be controlled, the pressure difference between the
front and rear of the piston becomes larger than the
spring force, moving the piston to the right.
The piston is thereby in firm contact the section
C of the case so that the oil in the cylinder flows
Fig. 7.5 In Below Control Flow Rate
out only a little amount, lowering the fork slowly.
CASE
Fig. 7.6 In Over Control Flow Rate
- 78 -
7. HYDRAULIC SYSTEM
CYLINDER SUPPORT
(For the trucks having lift height
of 4,000 mm [157 in.] or more)
CYLINDER SUPPORT
of 3,750 mm [148 in.] or less)
1. SHIM
2. DUST SEAL
3. PACKING
4. CYLINDER CAP
5. “O”-RING
6. BUSHING
7. CYLINDER
8. ROD
9. LOCK RING
10. WEAR RING
11. PACKING
12. PISTON
13. HOSE PULLEY
14. CHAIN SHEAVE
15. CHAIN
16. ANCHOR PIN
17. ADJUSTMENT NUT
18. LOCK NUT
19. COTTER PIN
Fig. 7.7 Lift Cylinder (VM-7A0, VM-7A4, VM-7B0)
- 79 -
7. HYDRAULIC SYSTEM
1. SHIM 11. WEAR RING

2. DUST SEAL 12. PACKING
3. PACKING 13. HOSE PULLEY
4. CYLINDER CAP 14. CHAIN SHEAVE
5. “O”-RING 15. CHAIN
6. BUSHING 16. ANCHOR PIN
7. CYLINDER 17. ADJUSTMENT NUT
8. ROD 18. LOCK NUT
9. LOCK RING 19. COTTER PIN
10. PISTON
CYLINDER SUPPORT
CYLINDER SUPPORT
Fig. 7.8 Lift Cylinder (VM-7B4)
- 80 -
7. HYDRAULIC SYSTEM
1. SHIM 11. WEAR RING

2. DUST SEAL 12. PACKING
3. PACKING 13. HOSE PULLEY
4. CYLINDER CAP 14. CHAIN SHEAVE
5. “O”-RING 15. CHAIN
6. BUSHING 16. ANCHOR PIN
7. CYLINDER 17. ADJUSTMENT NUT
8. ROD 18. LOCK NUT
9. LOCK RING 19. COTTER PIN
10. PISTON
CYLINDER SUPPORT
CYLINDER SUPPORT
Fig. 7.9 Lift Cylinder (VM-7B8)
- 81 -
7. HYDRAULIC SYSTEM
7.1.6 FLOW REGULATOR VALVE

The flow regulator valve maintains a constant fork lowering speed, regardless of the load. It is
located at the position shown in Fig. 7.11.
■ Flow regulator valve operation

The oil returning from the lift cylinder flows into chamber G from which it then runs into the
control valve after flowing through the chambers F , E , D , C , B and A . In this step, when the oil
flowing through the orifice ⑥ exceeds the specified flow rate, the force that pushes the piston ④ is
greater than the force of the spring ⑧ , thus causing the piston ④ to move to the right.
Hole D is narrowed by hole C to limit the flow rate, and the fork lowering speed is thus controlled.
The oil flowing into the lift cylinder passes through chambers A , B , C , D , E , and F and is not
controlled.
Free flow
Regulated
flow
Lift cylinder side Control valve side
1. CASE 6. ORIFICE
2. SPRING 7. SNAP RING
3. BALL 8. SPRING
4. PISTON 9. “O”-RING
5. SLEEVE 10. NIPPLE
Fig. 7.10 Flow Regulator Valve
- 82 -
7. HYDRAULIC SYSTEM
LIFT CYLINDER
(right)
TILT CYLINDER
(left)
TILT CYLINDER
(right)
CUTOFF VALVE
LIFT CYLINDER
(left)
FLOW REGULATOR VALVE
Fig. 7.11 Mast Piping (VM-7A0, VM-7A4, VM-7B0)
- 83 -
7. HYDRAULIC SYSTEM
LIFT CYLINDER
(right)
TILT CYLINDER
(left)
TILT CYLINDER
(right)
CUTOFF VALVE
LIFT CYLINDER
(left)
FLOW REGULATOR VALVE
Fig. 7.12 Mast Piping (VM-7B4, VM-7B8)
- 84 -
7. HYDRAULIC SYSTEM
7.1.7 TILT CYLINDER

Two tilt cylinders of a double-acting type are located at the right and left side of the bracket. The tilt
cylinder consists of a piston, a piston rod, a cylinder tube and a cylinder cap as shown in Fig. 7.13.
The piston and piston rod are welded and a wear ring and piston packing are installed on the piston
circumference.
The cylinder cap is provided inside with a dust seal, bushing and packing which provide tightness
in the cylinder. The piston rod end is ground spherical and pushes the fork support carrying out the tilt
operation.
VM-7A0
VM-7A4
VM-7B0 CYLINDER PACKING
PACKING
WEAR RING
SNAP RING
DUST SEAL
CYLINDER CAP
BUSHING PISTON ROD
“O”-RING
VM-7B0
VM-7B8 CYLINDER PACKING
PACKING
WEAR RING
SNAP RING
DUST SEAL
CYLINDER CAP
BUSHING PISTON ROD
“O”-RING
Fig. 7.13 Tilt Cylinder
- 85 -
7. HYDRAULIC SYSTEM
7.1.8 REACH CYLINDER

The reach cylinder moves the mast forward and backward. The reach cylinder assembly is mounted
on the lower part of the frame at the truck center.
The piston and the cylinder cap are provided with seals which provide oil-tightness.
Note: Stroke values listed below are given for trucks with the standard battery.
Tightening torque:
58.8 to 68.6 N-m
{600 to 700 kgf-cm}
[520 to 607 lbf-in.]
FRB30
A collar is
provided for
the FRB30.
1. WIPE SEAL
2. SNAP RING
3. ROD PACKING
4. CYLINDER CAP
5. “O”-RING
6. BUSHING
7. CYLINDER
8. ROD
9. PISTON
10. PACKING
11. NUT
12. “O”-RING
13. PISTON
14. SPRING
Fig. 7.14 Reach Cylinder
- 86 -
7. HYDRAULIC SYSTEM
7.2 MAINTENANCE
7.2.1 HYDRAULIC OIL CHANGE
(1) Put an oil pan under the tank and remove the
drain plug. SUCTION PIPE
(2) After draining off oil, reinstall the drain plug

securely.
(3) Remove the oil cap and pour hydraulic oil.
Oil capacity: See Fig. 7.1.
DRAIN PLUG
Fig. 7.15
7.2.2 REPLACING STRAINER

(1) Remove the suction hose from the tank suction pipe.
(2) Remove the suction pipe assembly from the tank.
Note: Remove the old gasket.
(3) Replace the suction strainer with a new one.
(4) Reinstall the suction pipe assembly on the tank with a new gasket.
Note: Apply the sealing agent (THREEBOND #4001 or #1101) to the both sides of the gasket before
installing.
- 87 -
7. HYDRAULIC SYSTEM
7.2.3 MEASURING AND ADJUSTING HYDRAULIC OIL PRESSURE

(1) Oil pressure measurement
① Remove the check plug and install an oil
pressure gauge of 20 MPa {200 kgf/cm2} [2901
psi] capacity.
② Move the tilt lever forward and read the
CHECK
pressure gauge. PLUG
③ If the measured pressure is not as specified,
adjust the relief valve.
Fig. 7.16 Oil Pressure Measurement
(2) Oil pressure adjustment

① Install an oil pressure gauge using the
RELIEF VALVE
procedure described above.
② Loosen the lock nut, taking care to prevent
the adjusting screw of the relief valve from
turning.
③ Move the tilt lever forward and set the pressure
to the specified value during the pressure
relief movement using the adjusting screw and
watching the pressure gauge.
④ After adjusting the pressure, tighten the lock
LOCK NUT
nut securely.
ADJUSTING SCREW
Fig. 7.17 Oil Pressure Adjustment
- 88 -
7. HYDRAULIC SYSTEM
7.2.4 ADJUSTING VALVE SWITCH 2 - 2.5 [0.08 - 0.1] Unit: mm [in.]
(1) Loosen the valve switch mounting bolt and

move the switch away from the cam.
(2) Install a clearance gauge shown in Fig. 7.18
15 - 20 [0.6 - 0.8]
between the cam and the roller.
(3) Bring the switch slowly close to the cam and
lock the switch at the position where the switch
is turned ON. Thickness:
0.8±0.1 [0.03±0.004]
(4) Pull the gauge out, then make sure that the
switch is turned off. Fig. 7.18 Gauge Adjustment
Note: If the switch won’t turn off, readjust it.
0.8±0.1 mm
[0.03±0.004]
Fig. 7.19
- 89 -
7. HYDRAULIC SYSTEM
5-THROW
4-THROW, 5-THROW VALVE

4-THROW
OIL TANK
Detail of area A
MAIN PUMP
REACH CYLINDER
CONTROL VALVE
3-THROW VALVE
①: from OIL TANK to PUMP ⑥: TILT CYLINDER

②: from PUMP to CONTROL VALVE ⑦: LIFT CYLINDER
③: to REACH CYLINDER CAP SIDE ⑧: from CONTROL VALVE to OIL TANK
④: to REACH CYLINDER TAIL SIDE ⑨: from LIFT CYLINDER
⑤: TILT CYLINDER
Fig. 7.20 Hydraulic Piping (truck body side)
- 90 -
8. LOAD HANDLING SYSTEM
Truck model
FRB10-8 FRHB10-8 FRB14-8 FRHB14-8
FRB10-8C FRHB10-8C FRB20-8 FRHB20-8
FRB18-8 FRHB18-8
FRB13-8C FRHB13-8C
Item
Name VM-7A4 VM-7B0 VM-7B4 VM-7B8
(Compact trucks:
VM-7A0)
Type Roller type 2-stage telescopic mast with free lift
Standard max. lifting 3,000 mm 4,000 mm 3,000 mm 4,000 mm 3,000 mm 4,000 mm 3,000 mm 4,000 mm
height [118.1 in.] [157.5 in.] [118.1 in.] [157.5 in.] [118.1 in.] [157.5 in.] [118.1 in.] [157.5 in.]
Fork lifting system Hydraulic
Fork tilting system Hydraulic
Lift chain Leaf chain BL534 Leaf chain BL634 Leaf chain BL823
Mast rail dimensions
Cross section of A: 44 mm [1.73 in.] A: 48 mm [1.89 in.]
outer rail B: 102.5 mm [4.04 in.] B: 119.5 mm [4.71 in.]
C: 134.5 mm [5.30 in.] C: 161.5 mm [6.36 in.]
Cross section of A: 43 mm [1.69 in.] A: 45 mm [1.77 in.]

inner rail B: 102.5 mm [4.04 in.] B: 119.5 mm [4.71 in.]
C: 134.5 mm [5.30 in.] C: 159.5 mm [6.28 in.]
D: 72 mm [2.83 in.] D: 76 mm [2.99 in.]
- 91 -

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

The outer and inner channels are of welded construction shown in Fig. 8.1. The end roller shaft is
welded to the bottom of each channel. The right and left rails are connected with cross members.
1. OUTER CHANNEL
2. END ROLLER
3. SHIM
4. SHIM
5. SLIPPER
6. INNER CHANNEL
7. HOOK
8. ROLLER
9. SNAP RING
10. SHIM
11. SIDE ROLLER SHAFT
12. RETAINER
13. SIDE ROLLER
14. SNAP RING
15. SNAP RING
16. SHIM
Fig. 8.1 Outer and Inner Channels (VM-7A0, VM-7A4, VM-7B0)
- 92 -
1. OUTER CHANNEL
2. END ROLLER
3. SHIM
4. SHIM
5. SLIPPER
6. INNER CHANNEL
7. STOPPER
8. HOOK
9. ROLLER
10. SNAP RING
11. SHIM
12. SIDE ROLLER SHAFT
13. SIDE ROLLER
14. SNAP RING
15. SHIM
16. END ROLLER
Fig. 8.2 Outer and Inner Channels (VM-7B4, VM-7B8)
- 93 -
8.1.2 CARRIAGE
The carriage is provided with the fork installed through the shaft type fork support and the end roller
installed with the snap ring.
The carriage moves vertically through the end rail along the inside of inner mast frame by expansion
and contraction of the lift cylinder.
1. CARRIAGE
2. PIN
3. SPACER
4. SHIM
5. SIDE ROLLER
6. SHIM
7. END ROLLER
8. SNAP RING
9. SHAFT
10. FORK
11. FORK SUPPORT
Fig. 8.3 Carriage (VM-7A0, VM-7A4, VM-7B0)
- 94 -
1. CARRIAGE
2. PIN
3. SPACER
4. SHIM
5. SIDE ROLLER
6. SHIM
7. END ROLLER
8. SNAP RING
9. SHAFT
10. FORK
11. FORK SUPPORT
Fig. 8.4 Carriage (VM-7B4, VM-7B8)
- 95 -
8.1.3 ROLLER LOCATION

The load handling system has end and side rollers. They are installed on the inner and outer
channels, and carriage respectively.
Each roller can be adjusted with shims. It should be set to move the outer and inner channels and
carriage smoothly.
The end rollers support longitudinal load and the side rollers support lateral load so that the inner
channels and carriage are raised and lowered smoothly.
Upper side Lower side
FORK SUPPORT END ROLLER

OUTER RAIL INNER RAIL (shim adjusted)
CARRIAGE END ROLLER
(shim adjusted)
GUIDE ROLLER (front)
END ROLLER
(shim adjusted)
SIDE ROLLER
(shim adjusted)
SLIPPER
(shim adjusted)
END ROLLER
(shim adjusted)
LIFT CYLINDER
HOSE PULLEY
SIDE ROLLER
(shim adjusted)
GUIDE ROLLER
(rear)
Fig. 8.5 Roller Location (VM-7A0, VM-7A4, VM-7B0)
- 96 -
Upper side Lower side
FORK SUPPORT END ROLLER

OUTER RAIL INNER RAIL (shim adjusted)
CARRIAGE
END ROLLER
(shim adjusted)
GUIDE ROLLER (front)
END ROLLER
(shim adjusted)
SIDE ROLLER
(shim adjusted)
SLIPPER
(shim adjusted)
END ROLLER
(shim adjusted)
END ROLLER
(shim adjusted)
LIFT CYLINDER
HOSE PULLEY
SIDE ROLLER
(shim adjusted)
GUIDE ROLLER
(rear)
Fig. 8.6 Roller Location (VM-7B4, VM-7B8)
- 97 -
8.2 MAINTENANCE
8.2.1 ADJUSTING LIFT CYLINDER ROD WITH SHIMS
After the lift cylinder, inner channel, and outer channel are replaced, the lift cylinder rod length
needs to be adjusted.
(1) Install a piston head on the rod of each lift
SHIM
cylinder without using shims.
(2) Extend the rod of each lift cylinder slowly and
examine the difference in the rod stopping time
when the rod reaches the stroke end.
(3) Add shims to the space between the rod and
piston head of the lift cylinder whose rod stops
PISTON HEAD
first.
Shim thickness: 0.2 and 0.5 mm [0.0079 and
0.0197 in.]
(4) Adjust the lift chain tension.
Fig. 8.7
8.2.2 ADJUSTING CARRIAGE HEIGHT

(1) Stop the truck on a level surface and put the
mast vertically. TIRE
(2) Keep the fork bottom on the ground and adjust
the projected amount A of the carriage lower INNER CHANNEL
end roller to 36 to 41 mm [1.42 to 1.61 in.],

CARRIAGE END
using the chain anchor pin at the mast side. ROLLER
FORK
Fig. 8.8
- 98 -
(3) Check the clearance B between the carriage

INNER CHANNEL
and the inner channel stoppers when the fork is STOPPER
raised to the maximum lifting height.
Clearance B : 15 mm [0.59 in.] (VM)
0 mm [0 in.] (VMS)
CARRIAGE
STOPPER
CHAIN ANCHOR PIN

AT MAST SIDE
Fig. 8.9
(4) Adjust the tension of the right and left chains

to the same value with the chain anchor pin at CHAIN
the mast side when the fork is at the bottom

position and the mast is tilted back all the way.
ANCHOR PIN
ADJUST NUT
LOCK NUT
Fig. 8.10
- 99 -
8.2.3 REPLACING CARRIAGE ROLLERS

(1) Attach the pallet to the fork and stop the truck
on a level surface.
(2) Lower the fork with the pallet to the ground.
(3) Remove the joint link of the mast side anchor
pin and remove the chain from the sheave.
(4) Remove the tilt piping from the carriage side.
(5) Extend the lift cylinder rod to raise the inner
channel.
(See ① in Fig. 8.11.)
(6) After the carriage is detached from the inner
channel, retract the mast. (See ② in Fig. 8.11.)
(7) Replacing end rollers
① Remove the lower end roller with a puller,
Fig. 8.11
keeping the shim.
② Install a new end roller with the shim removed
in step ① . Check the stamp S or SS and install
the roller which is marked the same stamp,
pointing the stamp side to the carriage side. Stamp (S or SS)
③ Remove the snap ring and remove the upper

end roller with a puller.
④ Install a new end roller and secure it with the
snap ring.
(8) Replacing side rollers

① Remove the side roller assembly. Keep the
numbers of the shims and their combination as
they were.
② Install a new roller with the shims removed in Fig. 8.12
step ① .
③ If there is excessive looseness between the
side roller and inner channel, add the shims SHIM
SIDE ROLLER
between the end roller and side roller, seeing
“8.2.5 PROCEDURE FOR ADDING OR
SUBTRACTING SHIMS”. END ROLLER
SNAP RING
SHIM
Fig. 8.13
- 100 -
(9) Extend the lift cylinder rod so that the inner

channel bottom projects the upper section on
the carriage.
(10) Bring the truck close to the carriage side
so that each roller enters inside of the outer
channel.
(11) Contract the lift cylinder rod to lower the inner
channels gradually. Place each roller of the
carriage into the inner channels.
(12) Engage the chain with the sheave and connect
the chain and anchor pin through the joint link.
(13) Engage the tilt piping with the hose pulley.
(14) Adjust the height of the carriage. (See 8.2.2.)
Fig. 8.14
- 101 -
8.2.4 REPLACING MAST ROLLERS

(1) Remove the carriage from the inner channel
in the same procedure as described in “8.2.3
REPLACING CARRIAGE ROLLERS”.
(2) Move the truck to a level surface and put the
both front wheels on the bench of 250 - 300
mm [9.8 -11.8 in.] in height.
(3)Block the both rear wheels securely with blocks.
(4) Hoist the inner channel with a crane and
remove the down stopper bolt from the outer 250 - 300 mm
[98 - 11.8 in.] BLOCK
channel.
(5) Operate the crane to lower the inner channel
gradually and remove the end roller from the
lower section of the inner channel. At the same Fig. 8.15
time, the end roller at the upper section of the
outer channel can also be removed.
(6) Replacing end rollers SHIM
① Remove upper end roller with a puller, keeping SHIM

shims. END ROLLER
② Install a new end roller with the shims removes

SLIPPER
in step ① . Check the stamp S or SS and install
the roller which is marked the same stamp,
pointing the stamp side to the carriage side.
(See Fig. 8.12.)
③ Replace the lower end roller of the inner
channel, using the same procedure as above.
In this step, point the stamp side to the outer
channel side.
(7) Operate the crane to hoist the inner channel.
Place each roller into the channels.
(8) Install the carriage in the reverse order of
disassembly.
SHIM
END ROLLER
Fig. 8.16
- 102 -
8.2.5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS

(1) Move the inner channel and carriage to one side of the outer channel. Measure the clearance
between the end roller at the opposite side and each channel.
Clearance between roller and channel: 0 to 0.5 mm [0 to 0.197 in.]
0 - 0.5 mm 0 - 0.5 mm
[0 - 0.197 in.] [0 - 0.197 in.]
0 - 0.5 mm
[0 - 0. 197 in.] Apply grease.
(upper side) Make contact with one side.
Apply grease.
Make contact
with one side.
0 - 0.5 mm
[0 - 0.020 in.]
Fig. 8.17
- 103 -
NOTE
- 104 -
TROUBLESHOOTING
TABLE OF CONTENTS
1. CONTROL CIRCUITS ............................................................................................................. 1
1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM....................................................... 1
1.2 LOAD HANDLING SYSTEM..................................................................................................... 3
1.3 POWER STEERING SYSTEM.................................................................................................... 5
1.4 OTHERS........................................................................................................................................ 5
1.5 VOLTAGE CHECKPOINTS (FOR THE DRIVE SYSTEM)...................................................... 7
1.6 VOLTAGE CHECKPOINTS (FOR THE LOAD HANDLING SYSTEM)................................. 8
1.7 VOLTAGE CHECKPOINTS (FOR THE POWER STEERING SYSTEM)................................ 9
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING . ....................... 11

2.1 PART LOCATIONS.................................................................................................................... 11
2.2 TERMINAL LOCATIONS......................................................................................................... 11
2.3 PROCEDURES FOR CHECKING............................................................................................. 12
2.3.1 MAIN CPU BOARD.......................................................................................................... 12
2.3.2 SUB CPU BOARD............................................................................................................. 13
2.3.3 CONTROLLER CPU INPUT AND OUTPUT.................................................................. 14
2.3.4 DRIVE MOTOR POWER MODULE (TMD)................................................................... 15
2.3.5 PUMP MOTOR POWER MODULE (TMP)..................................................................... 17
2.3.6 EPS MOTOR POWER MODULE (TMPS)....................................................................... 19
2.3.7 DRIVE MOTOR/PUMP MOTOR THERMOSENSORS.................................................. 21
2.3.8 HEAT-DISSIPATION SHEET............................................................................................ 22
2.3.9 MD CONTACTOR............................................................................................................. 23
2.3.10 CURRENT SENSOR......................................................................................................... 24
2.3.11 FUSES (F1, F2, F3)............................................................................................................ 25
2.3.12 ACCELERATOR................................................................................................................ 27
2.3.13 BRAKE SWITCH.............................................................................................................. 28
2.3.14 LIFT POTENTIOMETER.................................................................................................. 29
2.3.15 LCD PANEL....................................................................................................................... 30
2.3.16 MAGNETIC CONTACTOR.............................................................................................. 31
2.3.17 CONTROL PANEL............................................................................................................ 32
2.3.18 BATTERY CHARGER CONTROL PANEL..................................................................... 33
2.3.19 TORQUE SENSOR............................................................................................................ 34
2.3.20 STEERING (ANGLE) POTENTIOMETER...................................................................... 35
2.3.21 FLOOR SWITCH............................................................................................................... 36
2.3.22 TRANSFORMER............................................................................................................... 37
2.3.23 DIODE................................................................................................................................ 37
2.3.24 SENSOR BEARING.......................................................................................................... 38
3. TROUBLESHOOTING GUIDE .......................................................................................... 39
3.1 HOW TO USE THIS GUIDE...................................................................................................... 39
3.2 CHECKING BEFORE TROUBLESHOOTING........................................................................ 40
3.3 ERROR CODE TABLE.............................................................................................................. 42
3.4 TROUBLESHOOTING BY ERROR CODE.............................................................................. 45
3.5 TROUBLESHOOTING BY PROBLEM.................................................................................... 54
3.6 LCD PANEL SYSTEM ERRORS.............................................................................................. 59
4. PARAMETER SETTING ....................................................................................................... 61

4.1 SETTING THE PARAMETERS................................................................................................. 61
4.2 PARAMETER SETUP SCREEN................................................................................................ 61
4.3 KEY PAD.................................................................................................................................... 61
4.4 SCREEN OPERATION............................................................................................................... 62
4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING......................................... 66
4.6 SETTING THE PASSWORDS................................................................................................... 68
5. DESCRIPTION OF THE FUNCTIONS ........................................................................... 69
6. ELECTRIC WIRING . .............................................................................................................. 73

1. CONTROL CIRCUITS
1. CONTROL CIRCUITS
1.1 CONTROLLER POWER SUPPLY AND DRIVE SYSTEM

Circuit Diagram Description
Main CPU board 1. Controller terminal CN5-6

Power Supply
When the key switch is turned on, 48 V is

applied to this terminal and the controller
operates.
2. Accelerator potentiometer (Accelerator lever)

4.8 V is supplied from CN2-8. The voltage at
Main CPU
board CN2-7 varies according to the direction and
angle the lever is moved as follows.
Accelerator Lever
Neutral Forward Reverse
Accelerator
potentiometer 2.5 2.5-4.3 0.6-2.5
CN2-7
3. Speed control switch (“turtle” button)

(1) When the switch is pressed, the turtle
Drive System
Switch panel mark appears on the LCD panel and the

truck speed limit control is activated.
Pressing the switch while the turtle mark is
displayed deactivates the truck speed limit
mode selection
Speed control
control.
S.P.E travel
(2) CN-1-1-16 terminal voltage

Switch pressed: 0 V
Switch released: 5 V
4. S.P.E mode selection switch

(1) Acceleration speed and top speed can
be switched over in 3 stages. The speed
control mode changes in turns from S, P, to
E every time the switch is pressed.
(2) CN1-1-15 terminal voltageSwitch pressed:
LCD panel
0V
Switch released: 5 V
-1-
1. CONTROL CIRCUITS

5. Brake switch and battery switch
(1) This circuit allows the controller to
determine the status of the brake switch
and the battery switch.
Main CPU board (2) The truck is allowed to move when the
brake switch and battery switch are turned
on.
(3) When the brake switch is on and the
Battery switch
battery switch is off, the truck won’t move.

(However, the load handling system will
work.)
(4) Terminal voltage (N)
Brake switch
Switch status Terminal voltage

Brake Battery CN5-4
ON ON 48
ON OFF 0
OFF ON 0
OFF OFF 0
6. Backup buzzer relay
Sub CPU board
(1) The coil of the relay which activates the
backup buzzer.
(2) When the accelerator lever is placed in the
R position, the CN21-17 terminal voltage
becomes 0 V to activate the relay.
Drive System
7. Forward travel chime relay (option)

Sub CPU board (1) The coil of the relay that activates the
forward travel buzzer.
(2) When the accelerator lever is placed in the
F position, the CN21-16 terminal voltage
becomes 0 V to activate the relay.
Drive motor speed sensor 8. Drive motor speed sensor

(1) Detects the drive motor speed.
(2) When the drive motor runs, pulses are
generated.
Main CPU
board
-2-
1. CONTROL CIRCUITS

9. Drive motor thermosensor
Drive motor (1) Detects the drive motor temperature.
thermosensor
(2) When the sensor detects a temperature of
155°C, the symbol 206 appears on the
LCD panel and the motor output current is
restricted.
(3) When the sensor detects a temperature of
166°C, the symbol 205 appears on the
Main CPU
board LCD panel and the motor output is stopped.
Drive System
10. Front brake solenoid (option)

(1) Functions in conjunction with the brake
Main CPU board switch to control the front brakes. This helps
reduce truck skids and braking distances
while braking.
Front brake (right)
(2) CN21-19 and CN21-20 terminal voltage

Front brake (left)
Brake switch OFF: 48 V

Brake switch ON: approx. 24 V
1.2 LOAD HANDLING SYSTEM

1. Lift potentiometer
Main CPU board
(1) Potentiometer power supply
4.8 V is supplied from the CN1-10
terminal.
(2) Potentiometer signal
The CN1-9 terminal voltage varies as
follows according to the amount of
movement of the lever from neutral
position.
Load Handling System
Lever position
Down Neutral Up
CN1-9 1.1 V or 1.1 V or 2.4 to 4.5
terminal less less
Main CPU board

2. Lift-down, tilt, reach, ATT1, and ATT2
switches
(1) 5 V is supplied from CN1-4, CN1-13,
CN1-15, CN1-12, or CN1-16.
(2) When each lever is operated, the switch
turns on to operate the pump motor. (4.4
V→ 0 V)
-3-
1. CONTROL CIRCUITS
Main CPU board

3 Lift lock solenoid
(1) When the interlock switch is engaged, the
lift lock solenoid is activated.
Lift lock solenoid

(2) CN21-7 terminal voltage
Floor switch ON (key switch ON): 36V
Floor switch OFF (key switch ON): 48 V
4. Mast SSC switch (option)

Main CPU board (1) When the mast is raised, the switch is turned
on and the truck travel speed is reduced.
Mast SSC switch ON: 0 V
Mast SSC switch OFF: 4.6 V
Load Handling System
5. Pump motor thermoswitch (option)

Main CPU board
(1) Detects the temperature of the pump motor.
(2) When the switch detects a temperature
of 120ºC [248ºF], the symbol 405 is
displayed on the LCD panel and the motor
thermoswitch
Pump motor
output current is restricted.
6. Pump motor brush sensor (option)

(1) Detects wear in the pump motor brushes.
(2) The switch is turned on when the brushes
Pump motor are worn out. 48 V is applied to the CN1-1-9
Pump
brush sensor terminal and the symbol is displayed on
motor the LCD panel.
LCD
panel
-4-
1. CONTROL CIRCUITS
1.3 POWER STEERING SYSTEM

1. PS torque sensor
Main CPU board (1) Power supply
4.8 V is supplied from the CN2-16 terminal.
(2) Input voltage
(a) The EPS motor conduction ratio is
controlled against the torque sensor input
voltage.
(b) CN2-15 terminal voltage
Steering wheel position
Power Steering System
Left end Neutral Right end

CN2-15 1.2 2.5 3.8
2. Steering (angle) potentiometer
(1) The travel speed of the truck is controlled
Main CPU board
according to the drive wheel steering angle.
(2) Power supply
4.8 V is supplied from the CN21-10
terminal.
Steering wheel
position
Left end Neutral Right end
(1.5 ton) 1.3 2.5 3.4
CN21-9
(2.5 ton) 1.1 2.5 3.6
1.4 OTHERS
1. Interlock switch
Main CPU board (1) 4.6 V is supplied from the CN1-7 terminal.
(2) When the operator stands on the floor
board, this switch turns on to deactivate the
interlock.
(4.4 V→0 V)
Others
2. Suspension lock solenoid

Main CPU board (1) Locks the drive unit suspension when the
truck is accelerating or decelerating, making
a turn, and during load handling operations.
This helps improve the fore and aft, left and
right stability of the truck.
Suspension lock OFF: 48 V
Suspension lock ON: 36 V
-5-
1. CONTROL CIRCUITS

3. Auto power-off relayActivates if no operation
Main CPU board (traveling, load handling, or power steering)
is performed for 15 minutes. This shuts off the
power supply to the main CPU board and turns
off the power.
Others
LCD panel
-6-
Unit (V)
CN (connector) No. Wire color/number
Brake switch Interlock Accelerator at
Terminal name Key switch ON Remarks
+ – + – ON switch ON full throttle
Accelerator
CN2-8 CN2-6 LW187 BG186 potentiometer power 4.5 4.5 4.5 4.5
supply
Accelerator R: 0.9 V or less
CN2-7 CN2-6 LY93 BG186 2.3 2.3 2.3
potentiometer signal F:4 V or more
CN1-1-16 CN1-1-6 WL75 Gy80 S/C switch Switch pressed: 0 V Switch released: 5 V
CN1-1-15 CN1-1-6 W77 Gy80 S.P.E switch Switch pressed: 0 V Switch released: 5 V
Battery switch
CN5-4 N Terminal Br131 – Brake switch Brake pedal released: 0 V Brake pedal pressed: 48 V
ON
Controller power
CN5-6 N Terminal RW11 – 48 48 48 48
supply
-7-
F: 48
CN21-17 N Terminal WL179 – BB relay coil 48 48 48
R: 1 V or less
Drive motor speed
CN2-4 CN2-5 RW31 GW28 0 or 4.4 0 or 4.4 0 or 4.4 0 → 5.6
sensor A
Drive motor speed
CN2-12 CN2-5 RB32 GW28 0 or 4.4 0 or 4.4 0 or 4.4 2.2
sensor B
Voltage varies
Drive motor
CN5-1 CN5-7 WG16 WR17 3.1 3.1 3.1 3.1 with the
1.5 VOLTAGE CHECKPOINTS (FOR THE DRIVE SYSTEM)
thermosensor
temperature.
DU DU – – Drive motor cable 0 0 0 21 to 23 AC
DV DV – – Drive motor cable 0 0 0 21 to 23 AC

DW DW – – Drive motor cable 0 0 0 21 to 23 AC
1. CONTROL CIRCUITS
Unit (V)
CN (connector) No. Wire color/number Lever position
Terminal name Lever moved Lever moved Remarks
+ – + – Neutral
backward forward
Lift potentiometer
CN1-10 CN1-8 LW95 BG96 4.8 4.8 4.8
1. CONTROL CIRCUITS
power supply
Lift potentiometer 2.4 or more

CN1-9 CN1-8 YR94 BG96 1.1 or less 1.1 or less
signal 4.5 or less
CN1-4 CN2-9 BrW91 BR8 Lift-down switch 4.6 0 0
CN1-13 CN2-9 YB20 BR9 Tilt switch 4.6 0 0
CN1-15 CN2-9 YG21 BR9 Reach switch 4.6 0 0
CN1-12 CN2-9 YL22 BR9 ATT1 switch 4.6 0 0
-8-
CN1-16 CN2-9 YL23 BR9 ATT2 switch 4.6 0 0
Pump motor
CN1-18 CN2-9 WR175 BR9 0 0 0 Option
thermosensor
PA N Terminal – – PA terminal 48 43 to 48 43 to 48
PF N Terminal – – PF terminal 48 0 48
CN21-7 N Terminal P117 – Lift lock solenoid 36 36 36 Floor switch ON
Mast SSC switch

CN1-3 N Terminal WG135 – 4.6 – –
1.6 VOLTAGE CHECKPOINTS (FOR THE LOAD HANDLING SYSTEM)
Unit (V)
CN (connector) No. Wire color/No. Steering wheel position
Terminal name Remarks
+ – + – Left end Straight ahead Right end
Power steering
CN2-16 CN2-14 W162 L160 torque sensor power 4.8 4.8 4.8
supply
Power steering
CN2-15 CN2-14 G161 L160 1.2 2.5 3.8
torque sensor signal
Steering
CN21-10 CN21-8 YR43 YB41 potentiometer 4.8 4.8 4.8
power supply
Steering
CN21-9 CN21-8 YL42 YB41 potentiometer 1.3 2.6 3.4
signal
-9-
1.7 VOLTAGE CHECKPOINTS (FOR THE POWER STEERING SYSTEM)
1. CONTROL CIRCUITS
1. CONTROL CIRCUITS
NOTE
- 10 -
2. ELECTRICAL PARTS AND PROCEDURES FOR CHECKING
2. ELECTRICAL PARTS AND

PROCEDURES FOR CHECKING
2.1 PART LOCATIONS
EPS motor/pump
motor power module
Main contactor
Main CPU
Current sensor
Fuse
Sub CPU
Drive motor
power module
Current sensor
Current sensor
Fan
2.2 TERMINAL LOCATIONS

Positive “+”
terminal
PB terminal
Negative “-”
terminal
DU terminal DV terminal DW terminal
- 11 -
2.3 PROCEDURES FOR CHECKING

2.3.1 MAIN CPU BOARD
CN1 (20P BLACK)

CN2 (16P BLACK)
CN5 (12P BLACK)
CN6 (4P WHITE)

CN12 (5P WHITE)
CN7 (14P WHITE)
MAIN CPU BOARD DIPSW1
CN9 (26P WHITE)
CN21 (4P WHITE)
CN8 (26P WHITE)
CN10 (2P WHITE)
The main CPU board is the brain of the control system.

The DSW1 switch on the main CPU board is used to set it for the truck model (1, 2, or 3 ton truck).
The main CPU board controls the drive motor, pump motor and EPS motor, controls the LCD panel
display, and handle troubleshooting for the truck.
The same main CPU board is used in all truck models.
LED 1 on the main CPU board is lit continuously during normal operation. If an error occurs, LED
1 will blink in a pattern indicating the error (the error code).
Setting for 1.4 to 1.8 ton trucks Setting for 2 to 3 ton trucks
DSW-ON DSW-ON
DSW-OFF DSW-OFF
Setting for 1 to 1.3 ton trucks

(including compact models) < Caution >
• Make sure that the DSW1-1 and 1-4 are always
DSW-ON
DSW-OFF
set to the OFF position.
• Otherwise, the main CPU board or other
components may be damaged.
Procedure for checking

Look at the main CPU board to see if there is any damage, deformation or excessive discoloration.
In particular, check the connectors for poor contact due to corrosion or other reasons.
Caution
Do not touch the main CPU board with your bare hands. Electronic components mounted on the
printed circuit board may be damaged by static electricity. Hold the printed circuit board by its edges
when handling it.
Put the main CPU board in an antistatic bag when transporting or storing it. Protect it from
excessive vibration or shock.
- 12 -
2.3.2 SUB CPU BOARD
SUB CPU
BOARD CN23 (14P WHITE)
CN21 (20P BLACK)
The sub CPU board performs the following functions: relay output for auxiliary devices, suspension
lock solenoid output, lift lock solenoid output, front wheel brake output, steering angle input, etc.
The same sub CPU board is used in all truck models.
Make sure that the DSW1 switches on the sub CPU board are all set to the OFF position.
DSW-ON
DSW-OFF

Look at the sub CPU board to see if there is any damage, deformation or excessive discoloration. In
particular, check the connectors for poor contact due to corrosion or other reasons.
Caution
Do not touch the sub CPU board with your bare hands. Electronic components mounted on the
printed circuit board may be damaged by static electricity. Hold the printed circuit board by its edges
when handling it.
Put the sub CPU board in an antistatic bag when transporting or storing it. Protect it from excessive
vibration or shock.
- 13 -
2.3.3 CONTROLLER CPU INPUT AND OUTPUT

Input/Output Main Function
Main CPU Sub CPU Main CPU Sub CPU
Pump motor output limit
Lift inching switch
control
Mast SSC Truck speed limit control
Lift-down switch Interlock control Lift lock control
Interlock switch Interlock control Lift lock control
Inverter control, interlock
Accelerator
control
Pump motor chopper Lift lock control, suspension
Lift VR
control, interlock control lock control
Pump motor chopper
ATT1 Lift lock control
control, interlock control
Pump motor chopper
Tilt Lift lock control
Pump motor chopper Lift lock control, suspension
Reach switch
control, interlock control lock control
Pump motor chopper
ATT2 Lift lock control
PM temperature Thermal protection
P25 Output limit control
Drive motor sensor bearing
Inverter control
input
EPS torque sensor EPS chopper control
Drive motor temperature Output limit control
Front wheel brake control,
Brake switch Inverter control
suspension lock control
Key switch Control power supply, etc. Control power supply
Drive motor inverter
Current sensor input control, pump motor current
limit control
Inverter temperature Output limit control
Front wheel sensor bearing
Not used
input
Steering angle sensor input Speed limit control Steering angle sensor input
Lift lock output Lift lock control
Suspension lock output Suspension lock control
Output for forward travel Output for forward travel
components components
Output for reverse travel Output for reverse travel
components components
Speed alarm output Speed alarm output
Front brake output Front brake output
- 14 -
2.3.4 DRIVE MOTOR POWER MODULE (TMD)
Drive motor power module S1D2W

Thermosensor (W-phase OUT) Upper arm
connector
Upper arm
Gate drive circuit

Connector
S1D2U (U-phase OUT)
S1D2V (V-phase OUT)
S1D2W (W-phase OUT)
S1D2V
(V-phase OUT)
Lower arm
Connectors S1D2U
(U-phase OUT) Lower arm
Drive motor power board

Electrolytic
capacitor
Procedure for checking (using an analog multimeter)

① Look at the module to see if there is any damage, scratches, or excessive discoloration, and check
the connectors for corrosion.
② Disconnect all the cables and bus bars from the module.
③ Set the multimeter to measure resistance (kΩ range). Use the multimeter probes to contact the
terminals, according to the table below. Measure the resistance at each set of points.
④ Determine whether the module is defective or not according to the resistance values measured.
Multimeter Normal Value (R) Judgment
Measurement points
Red probe (+) Black probe (-) Approximate reading Good Not good
D1 (P) S1D2U Several kΩ Several kΩ 0 Ω and ∞Ω
D1-S1D2U
(Same for V, W) Several 10s of kΩ or
S1D2U D1 (P) 1* Several kΩ or less
more
S1D2U S2 (N) Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (U)-S2
(Same for V, W) Several 10s of kΩ or
S2 (N) S1D2U 1* Several kΩ or less
more
G1U-S1D2U G1U S1D2U Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
(Same for V, W) S1D2U G1U Approx. 50 kΩ Approx. 50 kΩ 0 Ω and ∞Ω
G2U-S2 G2U S2 (N) Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
(Same for V, W) S2 (N) G2U Approx. 50 kΩ Approx. 50 kΩ 0 Ω and ∞Ω
D1-G1U D1 (P) G1U Approx. 100 kΩ Approx. 100 kΩ 0 Ω and ∞Ω
(Same for V, W) G1U D1 (P) 1* Several 10s of kΩ or more Several kΩ or less
G2U-S1D2U S1D2U G2U Approx. 60 kΩ Approx. 60 kΩ 0 Ω and ∞Ω
(Same for V, W) G2U S1D2U 1* Several 10s of kΩ or more Several kΩ or less
* The resistance value will increase gradually (from several k-ohms to several hundreds of k-ohms) as the electrolyte capacitor charges.
• The values in the “Normal Value” column should be used as a rough guide. The normal value
readings may vary with the type of multimeter used and the internal battery’s state of charge.
The measured value is then treated as one of the following: “Resistance Present” (1 Ω or more), “No
Resistance” (0 Ω), or “Insulated” (∞Ω).
• When checking the gates (G1, G2), any FET elements in the same array can be used.
- 15 -
There are two types of drive motor power modules: one for the 1-ton group of trucks (1, 1.3, 1.4, 1.5,
1,8 ton) and one for the 2 to 3 ton trucks. The size and appearance of the 1-ton truck type module is the
same as the 2-3 ton truck type module.
The difference between these two module is the number of the FET element parameters to be
specified (10 parameters for the 1-ton truck module; 14 parameters for the 2-3 ton truck module).
• Do not touch the module gate terminals (G1, G2) or any soldered areas on the printed circuit board
with bare hands. They can be damaged by the static electricity in your body.
• Put the power module in an antistatic bag when carrying or storing it. Do not subject it to shock or
vibration.
- 16 -
2.3.5 PUMP MOTOR POWER MODULE (TMP)

Pump motor/EPS
motor power module Upper arm
Upper arm
Lower arm
Gate drive circuit

Connector
Connectors Lower arm
Pump motor/EPS motor FET for pump motor

power module board
Electrolyte
capacitor for
EPS motor
Electrolyte
capacitor for
pump motor
FET for EPS motor

Measurement points
D1 (PA) S1D2 (PB) Several kΩ Several kΩ 0 Ω and ∞Ω
D1-S1D2 (PB)
S1D2 (PB) D1 (PA) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (PB) S2 Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (PB)-S2
S2 S1D2 (PB) 1* Several 10s of kΩ or more Several kΩ or less
G1 S1D2 0Ω 0Ω 0 Ω or more
G1P-S1D2 (PB)
S1D2 (PB) G1 0Ω 0Ω 0 Ω or more
G2 S2 Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G2P-S2
S2 G2 Approx. 50 kΩ Approx. 50 kΩ 0 Ω and ∞Ω
D1 G1 Several kΩ Several kΩ 0 Ω and ∞Ω
D1-G1P
G1 D1 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (PB) G2 Approx. 100 kΩ Approx.100 kΩ 0 Ω and ∞Ω
G2P-S1D2 (PB)
G2 S1D2 (PB) ∞Ω ∞Ω ∞Ω or less
- 17 -
Both the pump motor power module and EPS motor power module are contained in a single
module.
There are two types of pump motor/EPS motor power modules: one for the 1-ton group of trucks (1,
1.3, 1.4, 1.5, 1,8 ton) and one for the 2 to 3 ton trucks. The size and appearance of the 1-ton truck type
module is the same as the 2-3 ton truck type module.
The difference between these two module is the number of the FET element parameters to be
specified (10 parameters for the 1-ton truck module; 12 parameters for the 2-3 ton truck module).
vibration.
- 18 -
2.3.6 EPS MOTOR POWER MODULE (TMPS)

Pump motor/EPS
motor power module Upper arm
Gate drive circuit

Connector
Lower arms
Lower arm
Connectors Upper arms
Pump motor/EPS motor FET for

power module board pump motor
Electrolyte
capacitor for
EPS motor
Electrolyte
capacitor for
pump motor
FET for EPS motor

Measurement points
D1 (P22) S1D2 (24) Several kΩ Several kΩ 0 Ω and ∞Ω
D1 (P22)-S1D2 (P24)
S1D2 (P24) D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (P24) S2 Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (P24)-S2
S2 S1D2 (P24) 1* Several 10s of kΩ or more Several kΩ or less
G1T S1D2 (P22) Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G1T-S1D2 (P22)
S1D2 (P22) G1T Approx. 60 to 100 kΩ Approx. 10 kΩ or more 0 Ω and ∞Ω
G2T S2 Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G2T-S2
S2 G2T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
D1 (P22) G1T 1* Several 10s of kΩ or more Several kΩ or less
D1 (S22)-G1T
G1T D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (P24) G2T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
G2T-S1D2 (P24)
G2T S1D2 (P24) 1* Several 10s of kΩ or more Several kΩ or less
D1 (P22) S1D2 (P23) Several kΩ Several kΩ 0 Ω and ∞Ω
D1 (P22)-S1D2 (P23)
S1D2 (P23) D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
S1D2 (P23) S2 Several kΩ Several kΩ 0 Ω and ∞Ω
S1D2 (P23)-S2
S2 S1D2 (P23) 1* Several 10s of kΩ or more Several kΩ or less
G3T S1D2 (P22) Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G3T-S1D2 (P22)
G4T S2 Approx. 6 kΩ Approx. 6 kΩ 0 Ω and ∞Ω
G4T-S2
S2 G4T Approx. 60 to 100 kΩ Several 10s of kΩ or more 0 Ω and ∞Ω
D1 (P22) G3T 1* Several 10s of kΩ or more Several kΩ or less
D1 (P22)-G3T
G3T D1 (P22) 1* Several 10s of kΩ or more Several kΩ or less
G4T-S1D2 (P23)
G4T S1D2 (P23) 1* Several 10s of kΩ or more Several kΩ or less
- 19 -
Both the pump motor power module and EPS motor power module are contained in a single
module.
There are two types of pump motor/EPS motor power modules: one for the 1-ton group of trucks (1,
1.3, 1.4, 1.5, 1,8 ton) and one for the 2 to 3 ton trucks. The size and appearance of the 1-ton truck type
module is the same as the 2-3 ton truck type module.
The difference between these two module is the number of the capacitor parameters to be specified
(10 parameters for the 1-ton truck module; 12 parameters for the 2-3 ton truck module).
vibration.
- 20 -
2.3.7 DRIVE MOTOR/PUMP MOTOR THERMOSENSORS

Thermosensor
Each power module (the drive motor power module, and the pump motor/EPS motor power module)
has a built-in thermosensor that constantly monitors the power module temperature.
The drive motor power module thermosensor (THD) starts to limit the current when the module
temperature reaches 105°C [221°F] and stops the drive motor when the module temperature reaches
120°C [248°F].
The pump motor/EPS motor power module thermosensor (THP) starts to limit the current when the
module temperature reaches 100°C [212°F] and stops the pump motor when the module temperature
reaches 115°C [239°F].
Checking method 1
(1) Remove the thermosensor (THD, THP) connector.
(2) Set the multimeter to measure resistance (x 1000). Put the test probes on the terminals according to
the table below and measure the resistance.
(3) Determine whether the thermosensor is defective or not according to the resistance values
measured.
Measurement Multimeter Normal Value (R)
points Red probe (+) Black probe (-) Approximate reading
THD THD-1 THD-2 0°C [32°F]: approx. 66 kΩ, 10°C [50°F]: approx. 40 kΩ
THP THP-1 THP-2 20°C [68°F]: approx. 25 kΩ, 30°C [86°F]: approx. 16 kΩ
Checking method 2
(1) Set the multimeter to measure voltage. Put the tester probes on the terminals according to the table
below and measure the resistance.
(2) Determine whether the thermosensor is defective or not according to the voltage values measured.
Normal Value
Measurement Multimeter
(R)
points
Red probe (+) Black probe (-) Approximate reading
Main CPU board Main CPU board
THD
CN8-7 CN8-8 25°C [77°F]: 20 kΩ/4.0 V, 50°C [122°F]: 7.2 kΩ/3.0 V
Main CPU board Main CPU board 80°C [176°F]: 2.5 kΩ/1.7 V (Tolerance: ±10%)
THP
CN8-9 CN8-10
- 21 -
2.3.8 HEAT-DISSIPATION SHEET

Each module (the drive motor power module, and the pump motor/EPS motor power module) has
a single heat-dissipation sheet. It provides insulation between each module and its base plate, and
effectively transfers the heat generated from each module to the base plate.
Whenever a module is replaced, its heat-dissipation sheet must be replaced with a new one.

(1) Check the heat-dissipation sheet for scratches or cracks. Make sure that it is free from metal
particles or chips.
(2) When the module is removed or replaced with a new one, check the insulation between the
module and its base plate.
Caution
Handle the heat-dissipation sheets carefully. Heat-dissipation sheets are fragile because they are
designed to be thin, thus minimizing the sheet’s resistance to radiating heat. Do not use a sheet that has
any scratches or cracks.
Make sure that the sheet is free of metal particles or chips that could impair its radiating function
and cause a short circuit or ground fault that would damage the module. Install a sheet with care,
making sure that the hole in the module and the hole in the sheet are aligned.
- 22 -
2.3.9 MD CONTACTOR
MD contactor
Connector

(1) Checking the contactor coil
① Remove the coil wiring connector.
② Put the multimeter to measure resistance (100 Ω range). Put the test probes on the terminals and
measure the resistance.
③ Determine whether the coil is defective or not according to the resistance values measured.
Good: 20 Ω Defective: ∞Ω (coil broken)
(2)Performing mechanical checks

① Remove the contactor from the truck.
② Actuate the contact by pressing the armature with your finger. See if it operates smoothly.
③ Press it again after the contact has been closed. Make sure that the pressure spring is compressed
and pushes against the contact.
④ Set the multimeter to measure resistance (minimum range) and measure the resistance between
“a”-contact and the movable contact.
⑤ Determine whether the contactor is defective or not according to the resistance measured.
Good: 0 Ω
(3) Checking the contactor contacts

① Check the contacts for rough surface or wear.
② Replace a defective contactor with a new one.
Wear limit: 0.5 mm [0.019 in.]
Note: When the contacts are replaced with new ones, both fixed contacts and one movable contact must be
replaced simultaneously.
- 23 -
2.3.10 CURRENT SENSOR

(1) Checking the drive motor current sensor (CSDU, CSDW)
① Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on Pin Nos. 15, 16, 17, 18, 19, 20, and 21 on the CN8 terminal (26-pin
connector), which is on the main CPU board. Turn on the key switch and measure the voltage.
Determine whether the drive motor current sensor is defective or not according to the table below.
Voltage Table (Key switch is ON)

Measurement points
Normal voltage reading Measurement conditions
Pin No. Wire Color
CN8-21 15 V
R-B (Red-Black)
CN8-22 15 V
CN8-15
CN8-16 GR (Gray) 0V
CN8-17
CN8-18
Accelerator lever in neutral, and the brake pedal is up (the brake
7 V (0 A) pedal is not pressed)
CN8-20 Orange (0) 7 V → 6.5 V Measure the voltage change when the accelerator lever is moved
(CSDU)
(0 A → +90 A) all the way forward, with the brake pedal up (the brake pedal is
(approximate) not pressed).(The truck should not move.)
Accelerator lever in neutral, and the brake pedal is up (the brake
7 V (0 A) pedal is not pressed)
CN8-19 Pink (P) 7 V → 7.23 V Measure the voltage change when the accelerator lever is moved
(CSDW)
(0 A → -45 A) all the way forward, with the brake pedal up (the brake pedal is
(approximate) not pressed).(The truck should not move.)
(2) Checking the pump motor current sensor (CSP)

① Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on Pin Nos. 11, 12, 13, and 14 on the CN8 terminal (26-pin connector),
which is on the main CPU board. Turn on the key switch and measure the voltage. Determine
whether the pump motor current sensor is defective or not according to the table below.

Measurement points
Normal voltage reading Measurement conditions
Pin No. Wire Color
CN8-14 R-B (Red – Black) 15 V
CN8-11 GR (Gray) 0V
CN8-12
Load-handling levers in neutral, and the steering wheel not
7 V (0 A) moving
CN8-13 White (W)
7 V → 8.4 V Measure the voltage change when each load-handling lever is
(approximate) moved slowly to the fully forward or fully backward position.
- 24 -
2.3.11 FUSES (F1, F2, F3)
F2 left terminal
F1 upper terminal F2 right terminal
F1 lower terminal
F3 upper terminal
F3 lower terminal
Fuse Capacity
Truck Model FR (H) B10/13-8 FR (H) B14/15/18-8 FR (H) B20/25-8
Fuse Circuit FR (H) B10/13-8C
F1 (drive) 225 A 225 A 225 A
F2 (pump) 225 A 225 A 225 A
F3 (EPS) 40 A 40 A 40 A
F4 (control) 10 A 10 A 10 A
F5 (lamp) 10 A 10 A 10 A
F6 (charge) 130 A 130 A 130 A
F7 (solenoid) 10 A 10 A 10 A

(1) Checking the drive motor fuse (F1)
① Set the multimeter to measure voltage. Put the negative (-) test probe on the controller’s negative (-)
cable terminal.
② Put the red test probe (+) on the F1 fuse’s upper and lower terminals and measure the voltage.
Determine whether the fuse is defective or not according to the table below.

Measurement points Voltage value Judgment
BV Good
Lower terminal
0V Defective (Change the fuse)
Upper terminal BV Good
BV: Indicates battery voltage. (Measure the battery voltage before performing this check.)
(2) Checking the pump motor fuse (F2)

cable terminal.
② Put the red test probe (+) on the F2 fuse right and left terminals and measure the voltage.
Determine whether the fuse is defective or not according to the table below.

BV Good
Right terminal
Left terminal BV Good
- 25 -
(3) Checking the EPS motor fuse (F3)

cable terminal.
② Put the red test probe (+) on the F3 upper and lower terminals and measure the voltage. Determine
whether the fuse is defective or not according to the table below.

BV Good
Lower terminal
Upper terminal BV Good
- 26 -
2.3.12 ACCELERATOR

(1) Set the multimeter to measure voltage. Put the black test probe (-) on the controller’s negative (-)
cable terminal.
(2) Put the red test probe (+) on Pin No. 8 on the CN2 terminal (16-pin connector), which is on the
main CPU board. Measure the voltage.
Standard voltage: 4.8 V
Standard voltage (with the accelerator lever in the neutral position) : 2.5 V
Standard voltage (with the accelerator lever in the forward travel position) : 2.5 to 4.3 V (full throttle
should read 4.1 V or more)
Standard voltage (with the accelerator lever in the reverse travel position) : 0.6 to 2.5 V (full throttle
should read 0.9 V or less)
Adjustment procedure
(1) Apply 5 V between the CN2-8 terminal (LW) and the CN2-6 terminal (BG) when the accelerator
lever is in the neutral position.
(2) Adjust the potentiometer so that the voltage between the CN2-7 terminal (LY) and the CN2-6
terminal (BG) is 2.5±0.1 V.
- 27 -
2.3.13 BRAKE SWITCH

cable terminal.
Brake switch is ON: Battery voltage
Brake switch is OFF: 0V
Adjustment method
• Slowly press the brake pedal while turning the brake rotor. Adjust the brake switch so that the brake
rotor starts to turn at the same time that the brake switch is turned on.
- 28 -
2.3.14 LIFT POTENTIOMETER
The lift potentiometer is used to control the lift speed and outputs a signal according to the amount
that the lift lever is moved. The potentiometer is located in the lift section of the control valve.
Part No. Type Models Covered

277H2-62701 EWK AIX R30 E53 FRB10 to 30

cable terminal.
Standard voltage (with the lift lever in the neutral position) : 1.1 V or less (An error will be output
at 0.2 V or less.)
Standard voltage (with the lift lever in the down position) : 1.1 V or less (An error will be output
at 0.2 V or less.)
Standard voltage (with the lift lever in the up position) : 2.4 to 4.5 V
- 29 -
2.3.15 LCD PANEL
The LCD panel features an hour meter and an error display which can display up to 5 errors at one
time (if more than 5 errors occur, the most serious 5 error codes will be displayed), a time clock, a “tire
angle indicator” that shows the angle of the drive wheel, an indicator that shows when the steering
wheel is in the neutral position, an hour meter screen that shows previous data and other detailed
information, a power consumption screen, and an auto power-off function.
The LCD panel also has a VTM board function that allows you to control battery charging,
overdischarge control, and make various other adjustments (by setting parameters).
The maintenance mode is used to display the temperature and voltage of the LCD panel.
By connecting a PC to the LCD panel, you can check the error history, battery charge history, and
other data.
- 30 -
2.3.16 MAGNETIC CONTACTOR
Coil
“B” contact
3-phase AC
The magnetic contactor is used to control battery charging. While the battery is being charged,
3-phase AC current flows through the contactor so that the “B” contact opens, thus shutting off the
power supply to the control circuits (such as the MPU board). During normal truck operation, the
contactor opens the 3-phase AC contacts to prevent charging current from flowing into the circuit.
Thermal Relay
Models Covered AMG Contactor BThermal Relay Input Voltage Thermal Range
Set Value
FRB10 and 13 281E2-62661 --------- 13A 3φ50/60 Hz, 200/205 V 9 to 13
FRB 14 to 18 281E2-62651 --------- 18A 3φ50/60 Hz, 200/205 V 12 to 18
FRB14 to 18 (370 AH) 27912-62513 27042-63012 24A 3φ50/60 Hz, 200/205 V 24 to 34
FRB 20 to 25 27912-62513 27042-63012 24A 3φ50/60 Hz, 200/250 V 24 to 34
FRHB 20 to 25 (390AH) 27912-62513 27042-63012 28A 3φ50/60 Hz, 200/250 V 24 to 34
FRB30

(1) Checking the coil resistance
Measure the resistance between “a” and “b” in the
figure.
The measured resistance must be between 0.2 and 0.3
kΩ.
(2) Checking the “B” contact for continuity
Measure the resistance between “c” and “d” in the
figure.
There should be continuity between these points.
Make sure that no continuity is present when the “e”
button (located in the center of the figure) is pressed.
- 31 -
2.3.17 CONTROL PANEL

(1) Checking the truck speed control switch (“turtle” button)
• Measure the voltage between the CN1-1-16 terminal (WL) and the CN1-1-8 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 CN1-1-15 terminal (W) and the CN1-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the S.P.E button is pressed and 5 V when the
(3) Checking the “Mode” button
• Measure the voltage between the CN1-1-7 terminal (WG) and the CN1-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the Mode button is pressed and 5 V when the
(4) Checking the “-” button
• Measure the voltage between the CN1-1-14 terminal (Y) and the CN1-1-8 terminal (Gy) on the
LCD panel.
The voltage reading must be as follows: 0 V when the “-” button is pressed and 5 V when the
(5) Checking the “+” button
• Measure the voltage between the CN1-1-6 terminal (YW) and the CN1-1-8 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
- 32 -
2.3.18 BATTERY CHARGER CONTROL PANEL

(1) Checking the power supply
• Measure the voltage between the CN5-4 terminal (RG) and the CN1-1-5 terminal (BR) on the
LCD panel.
The voltage reading must be as follows: 5 V
(2) Checking the START button
• Measure the voltage between the CN5-13 terminal (WR) and the CN1-1-5 terminal (BR) on the
LCD panel.
The voltage reading must be as follows: 5 V when the START button is pressed and 0 V when
the button is not pressed.
(3) Checking the STOP button
• Measure the voltage between the CN5-14 terminal (WY) and the CN1-1-5 terminal (BR) on the
LCD panel.
The voltage reading must be as follows: 5 V when the STOP button is pressed and 0 V when the
(4) Checking the SUPER EQUL button
• Measure the voltage between the CN5-15 terminal (WG) and the CN1-1-5 terminal (BR) on the
LCD panel.
The voltage reading must be as follows: 5 V when the SUPER EQUL button is pressed and 0 V
when the button is not pressed.
- 33 -
2.3.19 TORQUE SENSOR

cable terminal.
Standard voltage (with the steering wheel in the center position) : 2.5 V
Standard voltage (with the steering wheel turned all the way to the left) : 1.2 V
Standard voltage (with the steering wheel turned all the way to the right) : 3.8 V
Adjusting the neutral position

(1) Put the multimeter test probes between the CN2-15 terminal (G) on the main CPU board and the
battery’s negative (-) terminal.
(2) Turn on the key switch and measure the voltage.
Standard voltage: 2.5±0.08 V
(3) If the voltage reading is not within the specification, replace the cover (shims).
• To increase the voltage, increase the shim thickness.
• To decrease the voltage, decrease the shim thickness.
• Available covers (shims): 1.7, 1.8, 1.9, 2.0, and 2.1 mm
• The voltage changes by approximately 0.04 V when the cover (shim) thickness changes by 0.1
mm.
- 34 -
2.3.20 STEERING (ANGLE) POTENTIOMETER

cable terminal.
Standard voltage (with the steering wheel in the center position) : 2.5 V
Standard voltage (with the steering wheel turned all the way to the left) : 1.3 V
Standard voltage (with the steering wheel turned all the way to the right) : 3.4 V
Adjustment method 1
(1) Move the drive wheels to the straight-ahead position.
(2) Apply 5 V to the CN21-10 terminal (YR) and the CN21-8 terminal (YB) on the CPU board.
(3) Adjust the potentiometer so that the voltage between the CN21-9 terminal (YL) and the CN21-8
terminal (YB) is 2.5 V.
Adjustment method 2
(1) Lift the drive wheels off the ground. Move these wheels to the straight-ahead
position and then turn on the key switch.
(2) Press and hold the Mode button (for at least 3 seconds) to display the calendar
setting screen.
(3) Remove the steering wheel shaft cover on the torque-sensor side and pull the
steering wheel shaft down.
(4) Turn the steering wheel and find a position when the symbol is displayed on the LCD panel.
(5) Stop turning the steering wheel at its center position when the symbol is displayed.
(6) Reinstall the steering wheel shaft that you removed in step (3).
Check after the adjustment

(1) Move the drive wheels to the straight-ahead position.
(2) Move the accelerator lever fully forward (and fully back) and check the speed.
• When the drive wheel steering angle is 30 degrees (to the left or right) : Maximum speed
• When the drive wheel steering angle is 30 to 60 degrees off center : The larger the steering angle,
the higher deceleration rate.
• When the drive wheel steering angle exceeds 60 degrees : approx. 5 km/h [3.1 miles/h]
- 35 -
2.3.21 FLOOR SWITCH

cable terminal.
Interlock switch ON : 4.5 V
Interlock switch OFF : 0 V
- 36 -
2.3.22 TRANSFORMER

(1) Check the transformer for damage or contamination.
(2) Measure the insulation resistance.
< Measuring method >

① Remove the diodes.
② Check for proper insulation by measuring the resistance:
• between the primary and secondary coils
• between the primary coil and the body
• between the secondary coil and the body
2.3.23 DIODE

① Remove the diodes.
② Put the multimeter test probes on the elements and measure the resistance. Determine whether the
diode is defective or not according to the table below.
• Standard Resistance
Terminal
Resistance Ω
Positive Negative
Anode (A) – Cathode (K) ∞
Cathode (K) – Anode (A) Several 10s to 100s of k-ohms
- 37 -
2.3.24 SENSOR BEARING

(1) Lift the drive wheels off the ground.
(2) Set the multimeter to measure voltage. Put the black test probe (-) on Pin No. 5 on the CN2
terminal (16-pin connector), which is on the main CPU board.
main CPU board.
Turn the drive motor manually. Check to see if the voltage changes from 0 to 5 V.
main CPU board.
Turn the drive motor manually. Check to see if the voltage changes from 0 to 5 V.
- 38 -
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 “3.4 TROUBLESHOOTING BY ERROR
CODE”. If no error code is displayed, see “3.5 TROUBLESHOOTING BY PROBLEM”.
Error code
Start trouble diagnosis
Perform the procedure in “3.2 CHECKING BEFORE TROUBLESHOOTING”.
Is any
error code shown on the
LCD panel?
Perform the procedure in Perform the procedure in

“3.4 TROUBLESHOOTING “3.5 TROUBLESHOOTING
BY ERROR CODE”. BY PROBLEM”.
Make repairs
Is the
truck properly
restored?
End
- 39 -
3.2 CHECKING BEFORE TROUBLESHOOTING
(1) Checking wiring and terminals for looseness

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

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

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

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

The wiring of the electric truck is insulated from the frame. If there is any leak from the body,
various troubles will occur. Be sure to check for leaks.
It is recommended to wipe off dirt on the battery surface with a wet waste cloth or paper and dry
the cleaned surface by blowing air.
(Criteria)
Wiring side: If leak resistance is 100 k-ohm or more, the wiring condition in the wiring side is
judged as good.
Frame to body receptacle (+)
Frame to body receptacle (-)
Battery side: If the leak is 1 k-ohm impedance with 1 V or less, the wiring condition in the
battery side is judged as good.
Frame to battery (+)
Frame to battery (-)
- 40 -
< ERROR CODES SHOWN BY LED >

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

Error code 23
LED blinks twice LED blinks 3 times
LED ON
LED OFF
The same process is repeated.
- 41 -
Error code Error description Problem Resetting Error code conditions LED code Page
on display
Accelerator signal is present when key
blinks. Traveling neutral interlock Truck won’t travel. Put accelerator lever in neutral. 01 47
switch is turned ON.
Error will be cleared when no Load-handling signal is present when

blinks. Load handling neutral interlock Load handling system won’t work. 80 51
load-handling levers are operated. key switch is turned ON.
Low voltage detection Truck won’t travel and load handling Turn key switch off and then on Battery voltage drops below 28.2 V for
101 09 45
(Low battery voltage) system won’t work. again. 0.2 sec.
< Error Code Index >
Low voltage alarm Turn key switch off and then on Battery voltage drops to between 30
102 Low output of drive and pump motors 09 45
(Low battery voltage) again. and 40 V.
105 Interlock switch OFF detection Interlock switch is OFF when key 87 46
(when key switch turned ON) Interlock switch: ON switch is turned ON.
3.3 ERROR CODE TABLE
Accelerator: Neutral
Truck won’t travel and load handling Lift: OFF
system won’t work. Tilt: OFF
Reach: OFF
106 Interlock switch ON detection ATT: OFF Interlock switch is ON when key switch 89 46
(when key switch turned ON) is turned ON.
The sensor is defective, and the stall

A and B lines broken: Low output
Drive motor sensor bearing Error will be cleared when the current is detected continuously for 68
- 42 -
201 A or B line broken: No outputLoad 49
defective input returns to normal. a minute with the accelerator lever 94
handling and EPS systems enabled moved forward (or backward).
202 Drive controller temp. abnormal Truck stops running. Drive controller temp. drops Truck stops if drive controller temp. 72 49
below 120°C [248°F]. rises above 120°C [248°F].
203
Truck can travel. (However, the output Drive controller temp. drops Current is limited if drive controller
Drive controller temp. too high may drop due to the current being 71 49
temp. rises above 105°C [221°F].
limited, depending on the temperature.) below 105°C [221°F].
Drive controller temp. sensor Error will be cleared when the Thermosensor (THD) voltage drops
204 Truck can travel normally. 26 48
output defective output returns to normal. below 0.2 V, or rises above 4.95 V.
205 Drive motor temp. drops below Drive motor temp. rises above 166°C
Drive motor temp. defective Truck stops running. 74 49
165°C [329°F]. [331°F].
206
Truck can travel. (However, the output Drive motor temp. drops below Drive motor temp. rises above 155°C
Drive motor temp. too high may drop due to the current being 73 49
[311°F].
limited, depending on the temperature.) 145°C [293°F].
Drive motor thermosensor Error will be cleared when the Thermosensor voltage drops below 0.2
207 Truck can travel normally. 27 48
output defective output returns to normal. V, or rises above 4.95 V.
Drive motor main fuse (F1) Truck won’t travel.(MD contactor Turn key switch off and then on Fuse (F1) voltage (secondary-side) is
211 blownDetection circuit harness 14 47
closed) again. abnormal.
defective
on display
Error will be cleared when the Accelerator output voltage drops below
212 Accelerator VR defective Truck won’t travel. 06 47
input returns to normal. 0.2 V, or rises above 4.8 V.
213 Traveling FET module open- 213: U-phase open-circuited (broken wire) 16
Travel, load-handling, and EPS Turn key switch off and then on
214 circuited 214: V-phase open-circuited (broken wire) 17 47
systems inoperative. again.
215 U-, V-, or W-phase wire broken 215: W-phase open-circuited (broken wire) 18
Drive motor current sensor (CSDU, Turn key switch off and then on Sensor output drops below 1.6 V, or
216 CSDW) output abnormalCircuit Truck won’t travel. 23 48
again. rises above 13.3 V.
harness defective
Capacitor (CD, CP, CPS) charge
defective Travel, load-handling, and EPS Turn key switch off and then on
217 28 49
(This code is also displayed when systems inoperative. again.
error code 218 occurs)
Traveling FET module short-
circuited Travel, load handling, and EPS
218 (Upper and lower FET modules key switch off and then on
systems inoperative.(MD contactor Turn 15 47
short-circuited) again.
not closed)
(This code is also displayed when
error code 217 occurs)
Traveling FET module short-
219 circuited Travel, load-handling, and EPS Turn key switch off and then on 219: Upper TR short-circuited 19 48
220 (Upper or lower FET module short- systems inoperative. again. 220: Lower TR short-circuited 20
circuited)
- 43 -
Turn key switch off and then on Sensor output drops below 1.5 V, or
221 Steering wheel SSC VR defective Speed not limited while turning 63 53
Load handling controller temp. Load handling system stops Load handling controller temp. Load handling controller temp. rises
402 defective working. drops below 115°C [239°F]. above 115°C [239°F]. 75 51
The current is limited if load handling

Load handling system works.
Load handling controller temp. Load handling controller temp. controller temp. rises above 100°C
403 (Current being limited, depending 76 51
defective drops below 100°C [212°F]. [212°F], and an alarm displayed if the
on the temperature.) temp. rises above 105°C [221°F].
Load handling controller temp. too
high
Pump motor power module (TMP) Load handling system won’t work. Turn key switch off and then on
open-circuited 36 50
again.
Upper side (P11-P13) of pump motor (MD contactor closed)
404 power module (TMP) short-circuited
Pump motor short- or open-circuited
Load handling controller Error will be cleared when the Thermosensor (THP) voltage drops 37 50
thermosensor (THP) output abnormal Load handling system works. output returns to normal. below 0.2 V, or rises above 4.95 V.
Load handling system won’t work. Error will be cleared when the The current is limited when main CPU
405 Pump motor temp. abnormal 77 51
(Current being limited) input returns to normal. board CN1-18 is open-circuited

on display
Pump motor main fuse (F2) Load handling system won’t work. Turn key switch off and then on Fuse (F2) voltage (secondary-side)
411 blownDetection circuit harness 32 50
(MD contactor closed) again. abnormal
defective
Error will be cleared when the Lift VR output voltage drops below 0.2
412 Load handling lift VR defective Load handling system won’t work. 44 51
input returns to normal. V, or rises above 4.8 V.
Pump motor voltage sensor (CSP) Turn key switch off and then on Sensor output drops below 1.47 V, or
416 output abnormalCircuit harness Pump motor output limited 43 51
defective
Load handling FET module short- Travel, load handling, and EPS Turn key switch off and then on
418 35 50
circuited systems inoperative again.
Main contactor (MD) openDetection Travel, load handling, and EPS Turn key switch off and then on
501 12 46
circuit harness defective systems inoperative again.
Main contactor (MD) short-

502 Travel, load handling, and EPS Turn key switch off and then on
circuitedDetection circuit harness 11 45
systems inoperative again.
defective
- 44 -
Power steering torque sensor output Turn key switch off and then on Torque sensor output voltage drops
503 Difficult to steer. 56 52
disabled again. below 0.2 V, or rises above 4.8 V
Power steering main fuse Turn key switch off and then on
505 blownDetection circuit harness Difficult to steer. 52 52
again.
defective
Power steering FET module short-
circuited (upper and lower FET
modules short-circuited) Travel, load handling, and EPS 55
Power steering FET module short- Turn key switch off and then on
506 systems inoperative.Difficult to 57 52
circuited (P23 side) again.
steer. 58
Power steering FET module short-
circuited (P24 side)
Drive circuit harness defective
Power steering FET module open-
circuited Turn key switch off and then on
507 Difficult to steer. 54 52
Drive circuit harness defective again.
Power steering motor open-circuited
Speed limit (speed while turning),
front wheel brake, suspension lock, Turn key switch off and then on
600 CAN wire broken 81 53
forward/reverse travel components, again.
or speed alarm function disabled.
3.4 TROUBLESHOOTING BY ERROR CODE
This section explains how to perform troubleshooting using the error codes displayed on the
LCD panel.
< How to use this troubleshooting guide >
① Take Step ① and see if there is a problem. If a problem is found, take the corrective action in the
right column. If no problem is found, proceed to Step ② .
② Take Step ② and see if there is a problem. If a problem is found, take the corrective action in the
right column. If no problem is found, proceed to Step ③ .
③ Continue on the same way until the problem is resolved.
< Example: Main contactor (MD) open >

Upper: LCD panel error code
Lower: LED error code
1. General
(1) : Low voltage (Low battery voltage) To clear the error code, turn the key switch off and
then on again.
: Low voltage alarm (Low battery voltage)
① Check the battery voltage. Charge the battery.
② Check the harness between CN8-6 and P1 terminals

Repair or replace the harness.
on main CPU board.
To clear the error code, turn the key switch off and
(2) : Main contactor (MD) short-circuited then on again.
① Turn the key switch OFF and remove the battery

receptacle.
② Check main contactor. See page 23. Replace the main contactor.
③ Check the harness between CN8-6 and P1 terminals

on main CPU board.
④ Check the harness between CN9-6 on main CPU

board and CN19D-3 on the drive motor power Repair or replace the harness.
module (TMD).
⑤ Check the harness between CN8-25/8-26 on main

CPU board and main contactor coil.
⑥ Replace CPU board.
- 45 -
(3) : Main contactor (MD) open then on again.

receptacle.
② Check the main contactor. See page 23. Replace the main contactor.
③ Check the harness between CN8-6 and P1

terminals on main CPU board.

module (TMD).
⑤ Check the harness between CN9-7 on main CPU

board and CN19P-4 on the pump motor/EPS Repair or replace the harness.
motor power module (TMD).
⑥ Check the harness between CN8-25/8-26 on main

CPU board and main contactor coil.
⑦ Replace the CPU board.
(4) : Interlock switch OFF detected (after key To clear the error code, turn the interlock switch ON.
switch is turned ON)
Put the accelerator lever in neutral. Turn the lift, tilt,
: Interlock switch OFF detected (after key reach, and ATT switches OFF.
switch is turned ON)
① Turn the interlock switch ON. Put the accelerator

lever in neutral. Turn the key switch ON without
operating the load-handling levers.
② Check the interlock switch (floor switch). See

Replace the switch.
page 36.
③ Check the accelerator. See page 27. Replace the potentiometer.
④ Check the interlock switch and accelerator

wiring.
⑤ Check the load-handling switch. Replace the switch.
⑥ Check the load-handling switch wiring. Repair or replace the harness.
- 46 -
1. Drive system
To clear the error code, put the accelerator lever in
(1) : Traveling neutral detection neutral.
① Put the accelerator lever in neutral and turn the
key switch ON.
② Check the accelerator potentiometer voltage. See
Replace the accelerator.
page 27.
③ Check the harness of accelerator potentiometer
circuit.
This error will be cleared when the input returns to

(2) : Accelerator VR defective normal.
① Check the harness between CN2-6/2-7/2-8 on
main CPU board and accelerator.
② Check the accelerator. See page 27. Replace the potentiometer.
(3) : Drive motor main fuse (F1) blown then on again.
① Check the drive motor fuse. See page 25. Replace the fuse (F1).
② Check the harness between CN8-6 and P1
③ Check the harness between CN9-6 on main CPU
module board.
(4) : Traveling FET module short-circuited then on again.
receptacle.
② Check the drive motor power module (TMD).
Replace the TMD.
See page 15.
③ Check the harness between CN7 on main CPU
board and CN17D on the TMD.
board and CN19D-3 on the TMD.
(5) : Traveling FET module open- To clear the error code, turn the key switch off and
circuited then on again.
receptacle.
Replace the TMD.
See page 15.
④ Check the output terminals (U, V and W phases)
Retighten.
for proper connection and any loose screws.
- 47 -
(6) : Traveling FET module short-circuited then on again.
receptacle.
Replace the TMD.
See page 15.
⑤ Check the harness between CN9-10 on main CPU
⑥ Check the harness between CN9-12 on main CPU
⑦ Check the harness between CN9-6 on main CPU
(7) : Drive motor current sensor (CSDU, CSDW) To clear the error code, turn the key switch off and
output abnormal then on again.
① Check the harness between main CPU board and
current sensor.
CSDU: CN8-16, -18, -20, -22
CSDW: CN8-15, -17, -19, -21
② Check the voltage of main CPU board current
sensor power supply.
Replace the main CPU board.
CSDU: CN8-22 to 8-16, and 8-18 Normal: 15 V
CSDW: CN8-21 to 8-15, and 8-17 Normal: 15 V
③ Check the current sensor. See page 24. Replace the current sensor.
(8) : Drive controller thermosensor output This error will be cleared when the output returns to
abnormal normal.
① Check the thermosensor (THD) voltage. See page
Replace the current sensor.
21.
② Check the harness between CN8-7/8-8 on main
CPU board and the thermosensor (THD).
This error will be cleared when the output returns to

(9) : Drive motor thermosensor output abnormal normal.
① Check the drive motor thermosensor voltage. See

Replace the current sensor.
page 21.
CPU board and the drive motor thermosensor.
- 48 -
To clear this error code, turn the key switch off and
(10) : Capacitor (CD, CP, CPS) charge abnormal then on again.
① Check the harness between CN10 on main CPU

board and the charge resistor (RQ).
② Check the drive motor power module (TMD), and

the pump motor/EPS motor power module (TMP, Replace the power module.
TMPS). See pages 15, 17, and 19.

(11) : Sensor bearing defective normal.

main CPU board and sensor bearing.
② Check the sensor bearing. See page 38. Replace the sensor bearing.
(12) : Drive controller temp. too high The error codes will be cleared when the controller
temperature drops below 105°C [221°F] and 120°C
: Drive controller temp. abnormal [248°F], respectively.
① Turn the key switch OFF and allow the controller

Reduce the load.
to cool down for about 30 minutes.
② Check the drive motor power module for loose

Retighten.
screws.
③ Check the thermosensor (THD). See page 21. Replace the thermosensor.
④ Check the the harness between CN8-7/8-8 on

main CPU board and the thermosensor (THD).
(13) : Drive motor temp. too high The error codes will be cleared when the drive motor
: Drive motor temp. abnormal [329°F], respectively.
① Turn the key switch OFF and allow the drive

Reduce the load.
motor to cool down for about an hour.
② Check the drive motor thermosensor. See page

Replace the thermosensor.
21.
③ Check the harness between CN5-1/5-7 on main

CPU board and the drive motor thermosensor.
- 49 -
3. Load handling system
(1) : Pump motor main fuse (F2) blown then on again.
① Check the pump motor fuse (F2). See page 25. Replace the fuse.
② Check the harness between CN8-6 and P1
board and the pump motor/EPS motor power Repair or replace the harness.
module (TMP).
(2) : Load handling FET module short-circuited then on again.
receptacle.
② Check the pump motor/EPS motor power module
Replace the TMP.
(TMP). See page 17.
module (TMP).
module (TMP).
(3) : Pump motor/EPS motor power module To clear the error code, turn the key switch off and
(TMP) open-circuited then on again.
receptacle.
Replace the TMP.
(TMP). See page 17.
motor power module (TMP).
motor power module (TMP).
(4) : Load handling controller thermosensor This error will be cleared when the output returns to
(THP) output abnormal normal.
① Check the thermosensor (THP) voltage. See page
Replace the THP.
21.
CPU board and the thermosensor (THP).
- 50 -
(5) : Pump motor current sensor (CSP) output To clear the error code, turn the key switch off and
abnormal then on again.
① Check the harness between CN8-11 / 8-12 / 8-13
/ 8-14 on main CPU board and the current sensor.
② Check the voltage between CN8-14 and
Replace the main CPU board.
CN8-11/8-12 on main CPU board. (Normal: 15 V)
③ Check the current sensor (CSP). See page 24. Replace the CSP.

(6) : Load-handling lift VR defective normal.
main CPU board and the lift potentiometer.
② Check the lift potentiometer. See page 29. Replace the lift potentiometer.
(7) : Load handling controller temp. abnormal The error codes will be cleared when the controller
: Load handling controller temp. too high [212°F], respectively.
① Turn the key switch OFF and allow the controller

Reduce the load.
to cool down for about 30 minutes.
Retighten.
(TMP) for loose screws.
③ Check the thermosensor (THP). See page 21. Replace the THP.
④ Check the harness between CN8-9/8-10 on main
CPU board and the thermosensor (THP).

(8) : Pump motor temp. abnormal normal.
① Turn the key switch OFF and allow the pump
Reduce the load.
motor to cool down for about an hour.
② heck the harness between CN1-18 on main CPU
board and the pump motor thermosensor.
This error will be cleared when no load-handling

(9) : Load-handling neutral detection levers are operated.
① Put the load-handling levers in neutral and turn
the key switch ON.
② Check the lift potentiometer and load-handling
Replace the potentiometer or switch.
lever switch harness. See page 29.
③ Check the lift potentiometer and load-handling
lever switch harness.
- 51 -
4. Power steering system
(1) : Power steering motor main fuse open then on again.
① Check power steering motor main fuse (F3). See
Replace the fuse.
page 25.
② Check the harness between CN9-5 on main CPU
module (TMP).
③ Check the harness between CN8-6 and P1
(2) : Power steering FET module open-circuited then on again.
① Check the power steering motor (and brushes). Repair or replace the power steering motor.
② Check the power steering motor wiring. Repair or replace the harness.
③ Check the harness between CN7-5/7-7/7-9/7-11
on main CPU board and CN17P-3/17-4/17-5/17-6
on the pump motor/EPS motor power module
(TMPS).
④ Check the pump motor/EPS motor power module
Replace the TMPS.
(TMPS). See page 19.
(3) : Power steering FET module short-circuited

(upper and lower modules short-circuited)
: Power steering FET module short-circuited To clear the error code, turn the key switch off and
(P23 side) then on again.
: Power steering FET module short-circuited
(P24 side)
① Check the harness between CN7-5/7-7/7-9/7-11
on main CPU board and CN17P-3/17-4/17-5/17-6
on the pump motor/EPS motor power module
(TMPS).
② Check the harness between CN21-1 on main CPU
motor power module (TMPS).
motor power module (TMPS).
④ Check the pump motor/EPS motor power module
Replace the TMPS.
(TMPS). See page 19.
(4) : Power steering torque sensor output To clear the error code, turn the key switch off and
abnormal then on again.
① Check the harness between torque sensor and
CN2-14/2-15/2-16 on main CPU board.
② Check the power steering torque sensor. See page
Replace the torque sensor.
34.
- 52 -
(5) : Steering wheel SSCVR defective then on again.
① Check the harness between steering (angle)

potentiometer and CN21-8/21-9/21-10 on main Repair or replace the harness.
CPU board.
② Check the steering (angle) potentiometer. See

Replace the potentiometer.
page 35.
(6) : CAN wire broken then on again.
① Check the harness between CN6/12 on main CPU

board and CN21 on sub CPU board.
- 53 -
3.5 TROUBLESHOOTING BY PROBLEM

(1) The LCD panel is blank
• Key switch
Key switch ... Turn it ON. • Wire harness 101 , 100 or 5
Below
• Fuse F4
10 V
LCD panel
40 V or more
LCD panel
(2) MD contactor does not work (The travel, load handling, and EPS systems are inoperative)
Key switch ... Turn it ON. • Main CPU board

40 V or
more
Main Below 40 V
CPU
• Wire harness 11
Key switch ... Turn it ON.
40 V or • PO relay
more
Below 40 V
Key switch ... Turn it ON. • Wire harness 216

40 V or • Magnetic contactor CM
more
Below 40 V
• Wire harness 101

Key switch ... Turn it ON.
40 V or • Key switch
more
Below 40 V
Key switch ... Turn it ON. • Wire harness 100

40 V or • Fuse F4
more
Below 40 V
• Wire harness 5
• Battery connector
• Battery
- 54 -
(3) The load handling system works, but the truck won’t travel
Key switch....Turn it ON.

• Check the accelerator.
Brake pedal............Press. 40 V or
more
Main Below 40 V
CPU
Key switch....Turn it ON. • Wire harness 131

Brake pedal............Press. 40 V or • Battery switch
more
Below 40 V

40 V or • Brake switch
more
Below 40 V
• Wire harness 11
- 55 -
(4) The truck travels, but does not gain speed
Is the
Turtle mark visible
turtle mark Key switch....Turn it ON.
invisible?

Turtle mark Turtle button...........Press.
invisible
Switch panel
• LCD panel
Other
Key switch........ Turn it ON. than 5 V • Main CPU board
Accelerator lever.....Neutral.
Brake pedal.............Release.
Main CPU
Below
Key switch................. Turn it ON.
3.1 V • Accelerator
Accelerator lever…Fully forward
Brake pedal………Release.
• Wire harness 93
Main CPU
3.1 V or more
Key switch................. Turn it ON. 1.8 V or

Accelerator lever….Fully reverse more • Brake switch
Brake pedal………Press • Wire harness 93
Main CPU Below 1.8 V
Other than
2.1-2.8 V • Wire harness 42
• Steering potentiometer
Main CPU
(For standard trucks) 2.1 to 2.8V

• Mast SSC
Main CPU
Main CPU board
- 56 -
(5) Only the lift lever does not work
Key switch..................Turn it ON. Other

Lift lever............................ Neutral than 5 V • Main CPU board
Tilt lever............................ Neutral
• Wire harness 95
Reach lever........................ Neutral
ATT lever.......................... Neutral
Main
CPU
Below
Key switch..................Turn it ON. 1.1 V • Lift potentiometer
Lift lever.........................Pull fully. • Wire harness 94
Main
1.2 V or more
CPU
Main CPU board
(6) Only one of the tilt lever, reach lever, and ATT levers does not work
(Tilt)
Key switch..................Turn it ON. • Tilt limit switch

Tilt lever.........................Pull fully. • Wire harness 20
Main CPU
(Reach)
Key switch..................Turn it ON. • Reach limit switch

Reach lever.....................Pull fully. • Wire harness 21
Main CPU
Key switch..................Turn it ON. • ATT1 limit switch

ATT1 lever.....................Pull fully. • Wire harness 22
Main CPU
Key switch..................Turn it ON. • ATT2 limit switch

ATT2 lever.....................Pull fully. • Wire harness 23
Main CPU
Main CPU board
- 57 -
(7) Lift speed is slow

Other
than 5 V • Wire harness 95
Key switch.... Turn it ON. • Main CPU board
Main CPU
Below
Key switch.... Turn it ON. 3.6 V • Lift potentiometer
Lift lever........... Pull fully. • Wire harness 94
Main CPU 3.6 V or more
Not
Check the “PARAMETER 1 - correct
No. 5” setting on the LCD panel. • Correct the setting.
Main CPU board
(8) Pump motor does not stop running

1.2 V or
more • Lift potentiometer
Key switch.... Turn it ON.
• Wire harness 94
Main CPU
Below 1.2 V
Other
than 5 V • Tilt limit switch
• Wire harness 20
Main CPU
Other
than 5 V • Reach limit switch
• Wire harness 21
Main CPU
Other
than 5 V • ATT1 limit switch
• Wire harness 21
Main CPU
Other
than 5 V • ATT2 limit switch
• Wire harness 23
Main CPU
Main CPU board
- 58 -
3.6 LCD PANEL SYSTEM ERRORS

Error Description Cause Corrective Action
Code
Check BW211 and LY212 between the LCD
This error code is displayed when no current is panel and the CM contactor. Check the RL100
being drawn by the CM contactor or the “a”-
CM relay wire that goes to the CM contactor. Also check
071 contact.
malfunction any diodes connected in parallel. If no problem
The CM contactor, diodes, or their wiring may is found, replace the CM contactor with a new
be defective. one.
Check YG 208 between the LCD panel and the
This error code is displayed if there is no
PO relay short PO relay. Check the RL100 wire that leads to
072 current being drawn by the PO relay coil.
circuit PO relay. If no problem is found, replace the
The PO relay or its wiring may be defective. PO relay with a new one.
Check BW211 and LY212 between the LCD
This error code is displayed if the CM contactor panel and the AM contactor, and the RL100
does not work when the charge STOP button on
CM relay short wire that leads to the CM contactor. Also check
073 the battery charger control panel is pressed.
circuit any diodes connected in parallel. If no problem
The CM contactor, diodes, or their wiring may is found, replace the CM contactor with a new
be defective. one
This error code is displayed if a time-out has
occurred while receiving analog input data
074 AD conversion error (current draw or temperature readings). Replace the LCD panel with a new one.
Any of the indicators or wiring may be
defective.
This error code is displayed if a time-out has
occurred while receiving data from the RTC
075 RTC error (real time clock).
The connections on the LCD panel board or the
RTC may be defective.
A time-out has occurred while reading memory
EEPROM access Remove and reinstall the battery receptacle.
076 or writing to the LCD panel memory.
The connections on the LCD panel board or the If
error the problem is not solved, replace the LCD
panel with a new one.
EEPROM may be defective.
077 Program sum error These error codes refer to errors that occur
while loading the program or when an incorrect Replace the LCD panel with a new one.
078 Version loading error program version was loaded.
This error code is displayed if the key switch is Turn the key switch OFF.Disconnect the AC
081 AC ON turned ON while AC power supply is connected. power supply and then turn the key switch ON
again.
Check to see if the controller operates properly
when the key switch is tuned ON (see if the
This error code is displayed if no signal is orange pilot lamp on the main CPU board is lit).
Communication received from the controller.
082 Check the communication lines (GW81, GR82,
error (controller) The controller or the controller communication GY83, GO84) between the LCD panel and the
lines may be defective. controller. If no problem is found, replace the
LCD panel with a new one.
Follow the instructions given by the fault
This error code is displayed if no signal is diagnosis program installed on a PC.
Communication received from PC.
083 Check the communication lines between the
error (PC) The communication line with PC may be LCD panel and PC. If no problem is found,
defective. replace the LCD panel with a new one.
Another mode was This error code is displayed if the key switch is Turn the key switch OFF. Stop charging the
084 requested while battery and disconnect the AC power supply.
turned ON while charging.
charging Then turn the key switch back ON.
This error will be cleared when the battery
Low battery voltage This indicates that the battery voltage detected
085 voltage returns to 26 V. When cleared, the key
by the LCD panel has dropped below 26 V. switch is forced OFF.
This error code is displayed if the charging
process has not finished when the fail-safe timer Connect the battery while pressing and holding
times out, or if an AC power failure lasts for
087 Abnormal charging more than 120 hours while charging. The LED the SUPER EQUALIZE switch on the battery
charger control panel.
on the battery charger control panel will keep
blinking.
AC power failure This error code is displayed if the AC power This error will be cleared when the AC power is
088 during charging goes OFF while charging. restored and then charging will resume.
- 59 -
NOTE
- 60 -
4. PARAMETER SETTING
4.1 SETTING THE PARAMETERS
Take the following considerations into account when changing the parameters.
1. Be careful when increasing the acceleration level or load-handling speed levels, because that may
reduce the number of hours you can operate the truck, the motor may overheat, or other problems
may occur.
2. Remember that increasing the levels of any parameter settings may adversely affect the operation
of the truck.
4.2 PARAMETER SETUP SCREEN

Program version
Battery voltage The actual temperature
Temperature detected detected is the displayed
(LCD panel) value minus 15.
Parameter group Parameter item Setting
4.3 KEY PAD

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.
- 61 -
4.4 SCREEN OPERATION
INITIAL PARAMETER SETUP SCREEN

FRB100 9/19(WED)
VOLT 50.2 12:34

TEMP 31 99999.9 h
PARAMETER
While pressing and holding the Mode button and the “+” button on the key pad, turn on the key
switch. The INITIAL PARAMETER SETUP screen shown above will be displayed.
Note that the contactor is not turned on at this point.
Press the “+” button to display PARAMETER 1; press the “-” button to display PC.
Use the “+” button or the “-” button to toggle between the parameter groups, as shown below.
PARAMETER GROUP SETUP SCREEN

FRB100 9/19(WED)
VOLT 50.2 12:34

TEMP 31 99999.9 h
PARAMETER 1
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 PARAM-
ETER SETUP screen.
- 62 -
PARAMETER GROUP SETUP SCREEN
FRB100 9/19(WED)
VOLT 50.2 12:34

TEMP 31 99999.9 h
PARAMETER 1
Press this turtle button to return to the

PARAMETER ITEM INITIAL PARAMETER SETUP screen.
SETUP SCREEN
FRB100 9/19(WED)
VOLT 50.2 12:34

TEMP 31 99999.9 h
PARAMETER 1
POWER
6
Parameter item Setting
Press the Mode button when the PARAMETER GROUP SETUP screen is displayed. The first
parameter item in the selected parameter group will be displayed.
Each time the Mode button is pressed, another parameter item is displayed.
Pressing the Mode button on the last parameter item will return you to the first parameter item.
To cancel any changes to the settings and return to the INITIAL PARAMETER SETUP screen,
press the turtle button.
If the parameter item to be set has a range, press the “+” button or the “-” button to increase or
decrease the value within that range.
If the parameter item requires an ON or OFF setting, press the “+” button to select ON or the “-”
button to select OFF.
- 63 -
PARAMETER ITEM SETUP SCREEN
FRB100 9/19(WED)
VOLT 50.2 12:34

TEMP 31 99999.9 h
PARAMETER 1
POWER
Press and hold After setting a parameter item, press

PARAMETER SETUP this button. and hold the Mode button when the
COMPLETE SCREEN PARAMETER ITEM SETUP screen is
displayed.
The PARAMETER SETUP COMPLETE
FRB100 9/19(WED)
screen (shown on the left) will be dis-
VOLT 50.2 12:34 played.
TEMP 31 99999.9 h
TERMINATED
DATA TRANSMISSION Press and hold the Mode button when

the PARAMETER SETUP COMPLETE
SCREEN screen is displayed. The controller
contactor will be closed and the DATA
FRB100 9/19(WED) TRANSMISSION screen (shown on the
left) will be displayed. This screen indi-
VOLT 50.2 12:34 cates that the new setting is being sent
to the controller.
TEMP 31 99999.9 h
Note that the truck cannot be operated
during data transmission.
DATA IN TRANSMISSION
DO NOT TURN OFF THE KEY
DATA TRANSMISSION COMPLETE SCREEN

Once the data transmission is finished,
FRB100 9/19(WED)
the DATA TRANSMISSION COM-
VOLT 50.2 12:34 PLETE screen (shown on the left) will
be displayed. Then turn the key switch
TEMP 31 99999.9 h
OFF.
TERMINATED
TURN OFF THE KEY
- 64 -
FRB-8 Parameter Settings Table Factory settings
Screen display Item Description Unit Settings Remarks

Travel speed acceleration level Drive acceleration mode numbers
Truck speed limit level Max. speed in “turtle” mode
Lift level Lift conduction ratio limit
Lift inching level Lift inching conduction ratio limit
Tilt level Tilt conduction ratio limit
ATT1 level ATT1 conduction ratio limit
ATT2 level ATT2 conduction ratio limit
Switchback regeneration level Switchback regeneration intensity
Accelerator off regeneration level Accelerator OFF regeneration intensity
Brake-pedal release regeneration level Brake-pedal release regeneration intensity
Anti-rollback regeneration level Anti-rollback regeneration intensity
Accelerator stage level Accelerator stage mode numbers T: Toyota, N: Nichiyu
Speed at which alarm output is started
Speed alarm output level with speed alarm output mode enabled
Reach level Reach conduction ratio limit
Steering SSC level Lower speed limit when Steering SSC is activated.
Mast SSC level Max. speed when mast SSC is activated.
Flag setting (1)-1 Interlock switch enabled
Flag setting (1)-2 Suspension lock enabled
Flag setting (3)-1 S mode disabled
Flag setting (3)-3 Load-handling neutral interlock enabled
- 65 -
Flag setting (2)-1 Lift-down switch ON
Flag setting (2)-2 to 4 Lift acceleration mode: High, N, Low, Super Low
Interlock switch detection time The time required for interlock switch OFF to be enabled 0: OFF is immediately enabled.
The reset delay time after interlock
Interlock switch OFF delay time switch OFF is detected 0: Disabled
Truck speed limit rate when overdischarge
Truck speed limit rate during overdischarge alarm signal is input 0: The trucks stops.
Lift limit conduction ratio when
Load handling limit rate during overdischarge overdischarge alarm signal is input 100: No limit
Flag setting (4) Slip control mode: H, N, L, SL

Each number corresponds to each level
Overdischarge output level Battery discharge indicator level at which overdischarge signal is output displayed on the battery discharge indicator.
In increments of 1 minute.
Auto power-off time The time required for auto power-off function to be enabled Function disabled at 0.
Hour meter display switchover Items to be displayed on the hour meter

when key switch is turned ON
Heater ON/OFF control Not settable Fixed to OFF.
Fixed in the “turtle” mode Locked with the turtle switch pressed
Password setting Password mode ON/OFF
Battery capacity Battery capacity selection Set at the factory.
Contract adjustment
Load meter constants Specify if a load meter (option) is fitted. 0: No setting, 1: 1 ton, 2: 2 tons, 3: 3 tons
4.5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING

(1) PARAMETER 1 - No. 4 “Lift inching level”
If the controller’s CN1-2 terminal is turned ON, the upper limit of the conduction ratio during lifting
operations will be according to the setting of this parameter, thus slowing down the lifting speed.
Note: A standard harness does not have any wiring going to this terminal.
(2) PARAMETER 1 - No. 12 “Accelerator stage level”

You can specify the accelerator power curve to be used. The speed command to the motor varies
according to the angle at which the accelerator lever is tilted away from the neutral position.
N: Refers to a NICHIYU type power curve. Speed commands start being output at a lever angle of 6
degrees. The maximum speed command is output at a lever angle of 40 degrees.
T: Refers to a TOYOTA type power curve. Speed commands start being output at a lever angle of 4
degrees. The maximum speed command is output at a lever angle of 30 degrees.
The larger the number that follows the N or T, the steeper the curve.
Accelerator power curve (N type)

Speed command [%]
Lever angle [°]
Accelerator power curve (T type)

Speed command [%]
Lever angle [°]
(3) PARAMETER 1 - No. 13 “Speed alarm output level”

Sets the speed at which the speed alarm relay (RS) is turned on.
The output will be turned ON when the speed reaches the preset level and it is turned OFF when the
speed drops 0.5 km/h below that preset level.
If an additional RS relay is installed (inside the center cover), 48 V can be output at Y99 (located at
the base of the HG leg).
- 66 -
(4) PARAMETER 1 - No. 15 “Steering SSC speed level”

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

angle of the accelerator lever
Speed limits (km/h)
Steering wheel turned Tire steering Steering wheel turned

counterclockwise (to the left) angle [°] clockwise (to the right)
(5) PARAMETER 1 - No. 16 “Mast SSC speed level”

If the mast SSC terminal (CN1-3, wire no. WG135) is turned ON, the maximum speed of the truck
will be limited to the level specified in this parameter.
4-way trucks use this parameter setting to limit the speed when the truck is driving sideways.
(6) PARAMETER 2 - No. 9 “Truck speed limit rate during overdischarge”

PARAMETER 2 - No. 10 “Pump motor speed limit rate during overdischarge”
PARAMETER 3 - No. 1 “Overdischarge output level”
If the battery discharge indicator level drops to a preset level, an overdischarge signal (GO 84) will
be output from the LCD panel to the controller, thus limiting the drive motor and pump motor speeds.
Use PARAMETER 3 – No.1 to set the battery discharge indicator level at which the overdischarge
signal is output. You can specify the speed limit rates (percentage) in PARAMETER 2 - Nos. 9 and 10.
(7) PARAMETER 3 - No. 4 “Heater ON/OFF control”

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

Select the capacity of the battery installed in your truck. This setting will be used as the basis of the
calculations for the fuel consumption display.
This setting must be changed if the battery capacity is changed from the factory default setting.
If the capacity of the battery installed in your truck is not in the list, select the closest one.
- 67 -
4.6 SETTING THE PASSWORDS

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

(when pressed at the same time as the Low-Speed Travel
button).
Mode button Selects the digit to enter. Confirms the entered password.
+ button
- button Increases or decreases the number.
PASSWORD INPUT SCREEN

Set “PARAMETER 3 - No.6 PASSWORD SET” to ON.
For details on the setup procedure, refer to the PARAM-
ETER SETTING section.
Turn on the key switch to display the PASSWORD screen

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

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

If you press and hold the Mode button when “0000” is dis-
played on PASSWORD SETUP screen 1, an error will be
displayed.
If you conform “0000” as your second password by press-
ing and holding the Mode button on PASSWORD SETUP
screen 2, the use of a second password will be canceled
and only the first password you specified on PASSWORD
SETUP screen 1 will be valid.
- 68 -
5. DESCRIPTION OF THE FUNCTIONS

(1) Travel speed control while turning (Steering SSC)
• Controls the motor speed so that the truck does not exceed the travel speed specified according
to the angle of the front wheels (steering potentiometer voltage) while turning.
<Speed control for each steering angle range>
(a) Drive wheel steering angle 0 to 30 degrees: Maximum speed
(b) Drive wheel steering angle 30 to 60 degrees: The larger steering angle, the higher deceleration
rate.
(c) Drive wheel steering angle exceeding 60 degrees: As specified by the steering SSC level
setting
(2) Automatic torque boost control

• Automatically increases the torque output when the system detects that the truck is running
uphill or that a large load is applied.
<Activation conditions>
• All of the following conditions must apply: accelerator opening level: 90% or more, torque
command: 80% or more, and motor speed: 1,000 rpm or less
<When the boost control is active>
• The maximum torque in each travel mode (S, P, E) x 1.05
<Deactivation conditions>
• Any of the following conditions must be met: torque boost has been applied for 2 seconds, the
current torque is less than the maximum torque, or the motor speed of 1,000 rpm or higher
(3) Traveling neutral interlock

• Prevents the truck from starting suddenly when the key switch is turned ON while the
accelerator lever is operated.
• If the accelerator lever is not in neutral (forward or reverse travel) when the key switch is turned
ON.
<Truck operation>
• The truck cannot be moved.
• Accelerator lever OFF (in neutral)
(4) Load-handling neutral interlock

• Prevents the load handling system from starting suddenly when the key switch is turned ON
while a load handling lever is operated.
< Activation conditions>
• If a load handling command (potentiometer switch) is present when the key switch is turned
ON.
<Truck operation>
• Load handling system disabled
• Load handling command (potentiometer switch) OFF
- 69 -
(5) Interlock control

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

• Locks the drive unit suspension when the truck is accelerating or decelerating, making a turn,
and during load-handling operations. This helps improve the fore and aft, left and right stability
of the truck.
(a) While traveling
• If the truck accelerates again after switchback regeneration has occurred. (However, if the
wheel steering angle is less than 60 degrees, switchback regeneration only refers to the case
where the accelerator lever is reversed while the truck is traveling backward.)
(b) While braking
• If regenerative braking occurs while the truck is traveling forward (the wheel steering angle
must be less than 30 degrees), or when the truck is traveling backward.
(c) While turning
• The travel speed of the truck while turning exceeds the speed specified according to the
steering angle.
• If the “accelerator off regeneration” speed setting is 2 km/h or less.
• If the “switchback regeneration” speed setting is 2 km/h or less.
• If the “brake-pedal release regeneration” speed setting is 2 km/h or less.
(d) During load handling (while the truck is stationary)
• Lift potentiometer voltage ON
• Lift-down switch ON
• Reach switch ON
(a) While traveling
• Two seconds after acceleration starts
(b) While braking
• If a travel speed of 0 km/h is detected once regenerative braking is complete.
(c) While turning
- 70 -
• One second after the drive wheels are moved to the straight-ahead position
• If the travel speed of the truck drops below the speed specified according to the steering angle
(the drive wheels must be steered at more than a specified angle).
• 0.5 seconds after a travel speed of 0 km/h is detected once regenerative braking is complete.
(d) While load-handling
• When the travel speed of the truck is 1 km/h or more, or if the interlock switch is turned OFF.
(7) Regenerative control

(a) Switchback regeneration
• Regenerative braking occurs during switchback operations or when the accelerator lever is
reversed.
See the table below.
(b) Brake-pedal release regeneration
• Regenerative braking occurs when the brakes are applied (the pedal is lifted) while the truck
is traveling.
(c) Accelerator neutral regeneration (accelerator OFF regeneration)
• Regenerative braking occurs when the accelerator lever is moved to the neutral position while
the truck is traveling.
Table 1 Regenerative Control

Input Conditions Regenerative Mode
Brake switch (Pedal) ON (pedal pressed) OFF (pedal released)
Accelerator lever Truck status
Forward travel - Brake-pedal release regeneration
Forward Stopped - -
(Accelerator ON)
Reverse travel Switchback regeneration Brake-pedal release regeneration
Forward travel Accelerator neutral regeneration Brake-pedal release regeneration
Neutral Stopped - -
(Accelerator OFF)
Reverse travel Accelerator neutral regeneration Brake-pedal release regeneration
Forward travel Switchback regeneration Brake-pedal release regeneration
Reverse
Stopped - -
(Accelerator ON)
Reverse travel - Brake-pedal release regeneration
(8) Front brake control (option)

• Functions in conjunction with the brake switch to control the front brakes. This helps reduce
truck skids and braking distances while braking.
• When the brake pedal is released while the truck is traveling.
• If the truck stops.
• If the brake switch turns ON.
• When the truck is put in a travel mode.
- 71 -
NOTE
- 72 -
6. ELECTRIC WIRING
6. ELECTRIC WIRING
Red
Red
Red
Green Red
Green Red
Green Red
Green Red
Green Red
Green Red
Green Red
Green
Green Yellow
Green Yellow
Green Yellow
Yellow
Blue Yellow
Blue Yellow
Blue
Blue White
Blue White
Blue
Green
Blue
White-Green
White-Red
Embedded in
Embedded in TMDV White-Blue TMPX
Purple
Gray Gray
Black
POWER MODULE
THERMISTOR (THP)
Black
POWER MODULE
FOR DRIVE MOTOR
THERMISTOR (THD)
FOR PUMP/EPS MOTOR
Black
Black
DRIVE BOARD
DRIVE MOTOR
Red-Blue
Red-Black
Gray
Gray
Black
Orange
Black
Gray
PUMP MOTOR
Red-Black
Gray
Orange
Gray
DRIVE MOTOR
Yellow-Red
Red-Yellow
Yellow-Red
Yellow-Green
Yellow-Red
MAIN CONTACTOR
White
Gray
Blue
EPS MOTOR
P1 (See Note)
N1 (See Note)
Black
Green
Red-Black
MAIN CPU BOARD
Red
MAIN CPU BOARD

FAN 1
FAN 2
SUB CPU BOARD

Note: No fans are provided for low-floor type vehicles.
PUMP/PS MOTOR DRIVE BOARD
Fig. 6.1 Controller Internal Wiring (1) Fig. 6.2 Controller Internal Wiring (2)
- 73 -
6. ELECTRIC WIRING
to CONTROLLER, CN2
8 1
LW LY BG GB RW GW
187 93 186 29 31 28
W G L RB BR
162 161 160 32 9-5
16 9
to WIRE HARNESS, to DM THERMOSENSOR
LCD PANEL to CONTROLLER, CN1 to CONTROLLER, CN5
1
10 1 WR
LW YR BG YW BrW WG RW Br WG 16 17
LB GW GY 11 131 16
94 96 35
GO WR BrR YG RL GR GW GY WR
82 84 175 23 21 100-2 82 81 83 17
20 11 7
to DM SPEED SENSOR
to ACCELERATOR
POTENTIOMETER to WIRE HARNESS, to WIRE
28
CENTER COVER HARNESS, GB
BG LY LW to WIRE HARNESS, LCD PANEL
R 5-5
R 5-4
R 5-3
186 93 187 WBr WB
97 98
LCD PANEL
RL
to LOCK SOLENOID
to HORN
to WIRE HARNESS, 12
HEAD GUARD (RIGHT) to CONTROLLER CN21 140 116
10 1
YL
F7 10A
F5 10A
F4 10A
YR YL YB P Gy 103
B 43 42 41 117 116
GR
105 2-8 LG LY WY WL LB B
WR B 115 114 168 179 180
20 11
107-1 2-9 2-2
to CONTROLLER,
RL
RB
RG
102-F
100-F
140-F
(-) TERMINAL CAPACITATOR
22μF (100V)
to MAST SSC
B(2)
GY B
R 5-6
R 5-1
R 5-2
RB 140
RG 102
RL 100
WG BR 106 2-3
135 9 WR B
107 2-4
to WIRE HARNESS, VALVE SW to WIRE HARNESS, HEAD GUARD (LEFT)

RB -
YB BrR BrW
23 91
LG -
BR YL YG 115 -
9-1 22 21
B 2-1
to WIRE HARNESS,
R BR
5-1 9-2 BRAKE BEARING SENSOR
Br W RW 11-1
R BR (LEFT) (OPTION)
5-2 9-3 131 110
SHORT COUPLER BG YR LW
96 94 95 to BATTERY SW (OPTION)
B B - - WR BR P RB
117 140-2 to CONTROLLER, CN3 WBr
2 2 - - 175 9-4 to LIFT POTENTIOMETER 97
BW YW BR WL 113
to LIFT LOCK SOLENOID 35 B 2-7 B 2-6
WB YR Y to WIRE HARNESS,
98 12 99
RG B BRAKE BEARING
to FLOOR SW 102-2 2
to BRAKE SW SENSOR (RIGHT)
to BATTERY CHARGER R (OPTION) (OPTION) (OPTION)
CONTROL PANEL 146
B
WR RG LB 147
WG WY RB
209 206 202 to CONTROLLER, CN4
to SSC POTENTIOMETER
YL
42
YB YR
41 43
to WIRE HARNESS, CM
W W RY
213 101
LY - RL RG
212 - 100 216
to EPS SENSOR
L G W
160 161 162
R
146
B
147
to EPS MOTOR
Fig. 6.3 Wire Harness, Frame
- 74 -
6. ELECTRIC WIRING
to WIRE HARNESS, FRAME
WB RG YG WBr
98 216 208 97-1
B G WL RL
2 104 179 100
Y WY WL BW
to LCD PANEL 99 168 113 112
RG RW LB YR
102 11 180 12
1 8
WY Y YB BR YW WG Gy
108 198 196 9-1 79 76 80
L YG Y W WL
174 197 78 77 75
9 16
1 10 1
RG LB BW BG WY W WB GO GR
203 211 190 224 226 228 84 82
RY WR WY WG RB YG LW GW WG WL GY GW
101-1 205 206 209 202 208 192 191 225 227 83 81
11 20 7
BR W to HORN SW
9 207
RL LY W
100 212 213 YL 103
5
RG 102
to TURN SIGNAL SW RL RG
to SWITCH PANEL 100 216
to RELAY, PO YG RW
G GR
104 105 208 11-6
Y WG WL
76 75
YW W Gy
79 77 80
RW RG
RG WR 11-2 102-1
to MONITOR 102-1 107 to RELAY, BB
WL WB
WL WY W to LIGHTING SW
227 224 226
179 98
WG - WB
225 - 228
RL 100-1
B G
L YG - 2-4 104
197 -
to KEY SW to FLASHER UNIT
WY Y YB RY 101
- RG
108 198 196 - 102-3
BG LW GW
190 192 191 RW RG
11-3 102-2
(OPTION) LB WBr
180 97
to RELAY, RF
GR RG (OPTION) BW RW
102
GY G 112 11
BW W W 104
107 211 207 213 B WL
LY YG RL BR 2-3 113
212 208 100 9 White tape
RW RG to RELAY, RB
(OPTION)
11-1 102
GY GW LB RG WY YL WY Y
81 201 203 206 103 Red tape WB 98-1
GO GR RB WR WG RY 168 99
84 82 202 205 209 101 B 2-2
to RELAY, RS
(OPTION) B 2-1 WBr 97
RW RW
to WIRE HARNESS, FRAME 11-4 11-5 Yellow tape to BACKUP
B YR to FORWARD BUZZER
TRAVEL CHIME
2 12 (OPTION)
RELAY, RK
(OPTION)
Fig. 6.4 Wire Harness, LCD Panel Fig. 6.5 Wire Harness, Center Cover
- 75 -
6. ELECTRIC WIRING
LIFT TILT
BrW 91 YB 20
BR 9-2
BR 9-1
REACH
YG 21
BR 9
BrW - YB
91 - 20
YG - BR
-
21 9
Fig. 6.6 Wire Harness, Battery Switch Fig. 6.9 Wire Harness, Valve Switch
LY 114
RB 140
- RB
- 140
- LY
- 114
Fig. 6.7 Wire Harness, Brake Switch Fig. 6.10 Wire Harness, Brake (Right)
to HEAD LIGHT
WR 107
B 2-1 LG 115
GY 106
RB 140
B2
- RB
- 140
- LG
B GY - 115
2 106 to TURN SIGNAL LIGHT
B WR
2-1 107
Fig. 6.8 Wire Harness, Head Guard Fig. 6.11 Wire Harness, Brake (Left)
- 76 -
6. ELECTRIC WIRING
SPOT HEAD LIGHT

TURN SIGNAL HEAD LIGHT (LEFT) REAR WORK (RIGHT) TURN SIGNAL
LIGHT SW LIGHT SW
LIGHT (LEFT) CONTROLLER (OPTION) SWITCH LIGHT (RIGHT)
(OPTON) PANEL
LIFT SSC SW TURN
(OPTION) LIGHTING
SW SIGNAL SW
HORN SW
LCD PANEL
BRAKE (RIGHT)
(OPTION)
HORN
BATTERY
LOCK SW OPTION
BRAKE (LEFT)
(OPTION)
KEY SW
ACCELERATOR
LIFT
LIFT
POTENTIOMETER
OPTION
TILT REACH
BRAKE SW
TRANSFORMER SSC UNIT
& DIODE LIFT LOCK
SOLENOID
BATTERY CHARGER
LOCK CONTROL PANEL
SOLENOID
VALVE
BATTERY
SPOT LIGHT
(OPTION)
BEARING SENSOR
BEACON LIGHT FLASHER
(OPTION) REAR WORK UNIT AC OUTLET
LIGHT STOP/BACKUP
(OPTION) LIGHT (OPTION) PUMP MOTOR
DRIVE MOTOR PS SENSER
OPTION
EPS
MOTOR
BACKUP
BUZZER
FORWARD
TRAVEL
FLOOR SW CHIME
(OPTION)
Fig. 6.12 Wiring Diagram
- 77 -
HORN SW
HORN
6. ELECTRIC WIRING
HEAD LIGHT (RIGHT) LIGHTING SW

(OPTION)
HEAD LIGHT (LEFT)
TURN SIGNAL LIGHT FLASHER UNIT
(RIGHT) (25W)
TURN SIGNAL LIGHT
(LEFT) (25W)
FORWARD TRAVEL CHIME (OPTION)
BACKUP BUZZER
BACKUP LIGHT
(OPTION) (25W)
BEACON LIGHT (OPTION)
KEY SW ON
BATTERY SW
BACKUP BUZZER
BRAKE SW
STOP LIGHT
SPOT LIGHT FRONT BRAKE
(OPTION) (25W) (RIGHT) (OPTION)
FRONT BRAKE
REAR WORK LIGHT (LEFT) (OPTION)
(OPTION) (40W)
LIFT LOCK
(OPTION)
UNIT LOCK
CONTROLLER
OPTION
(INPUTX3)
- 78 -
LIFT DOWN
OPTION
(ANALOG) TILT
REACH
ATT 1 (OPTION)
DM THERMOSENSOR
Fig. 6.13 Circuit Diagram

ATT 2 (OPTION)
CONTROL SWITCH PANEL
MONITOR
INTERLOCK
DRIVE MOTOR
MAST SSC
(OPTION)
SENSOR
BEARING
LCD PANEL
PM THERMO SW
STEERING
POTENTIOMETER
BATTERY CHARGER CONTROL PANEL

LIFT
POTENTIOMETER
(OPTION)
ACCELERATOR
POTENTIOMETER
PUMP MOTOR
PM BRUSH SENSOR
TORQUE SENSOR
MD COIL ENERGIZED
EPS MOTOR
TRANSFORMER
BATTERY 48 V
AC INPUT
KEY SW
No. SEB-7A0AE
Issued: November, 2008
MARKETING GROUP: 1-15-5, Nishi-shimbashi, Minato-ku, Tokyo

105-0003, Japan
FAX: Japan +81-3-35918154
All rights reserved JB-0811020(HO) Printed in Japan

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FOREWORD

Fig. 1 External View

Foot pedal braking force within 2.5 m ← ← ← ←

Opening of fork tips mm [in.] within 10 [0.39] ← ← ← ←

Overhead guard mounting bolt and nut torque N-m{kgf-m}[lbf-ft] 256±50{26.1±5}[188.8±36.2]

* Before servicing the truck, make sure to:

* Caution to take when measuring, inspecting or repairing:

Counterbalanced model Reach model

Fig. 02.1 Installing bearings

Fig. 02.2 “O”-ring location

JIG JIG JIG

Fig. 02.3 Installing Oil Seal

mounting surface of the shaft. For a double-

Fig. 02.4 Installing Oil Seal

(2) Removing parts

(3) Reinstalling parts

5. How to use a power wrench

1. General metallic parts

Strength Indication on bolt Material

SS400 4.6 Black 01101- Nominal symbol

SS400 4.6 01100- “

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

Metric, fine system

Metric, coarse system

Metric, fine system

Metric, coarse system

Metric, fine system

Metric, coarse system

Metric, fine system

Metric, coarse system

HYDRAULIC OIL TANK CAP &

* Note: The capacity is given for trucks of standard

3. Power steering actuator case

PIN, LINKAGE (3) DRAIN PLUG

All models 0.35 L [0.093 U.S. gal]

TCM Gear Oil (SAE#80W)

GREASE PIN, LINKAGE

4-7. Piston head guide

Fuse F3 181E2-62541 DC96V 40A (PS)

Fuse F4, F5 and F7 25592-42311 10A

Oil tank Suction filter 215E7-52031

Bulb 29502-42421 48V/40W

Tires 27B04-42101 27B44-40301 Rubber

Drive wheel 27B04-40201 27B44-40201 Rubber

4. DRIVE UNIT .............................................................................................................................. 45

5. STEERING SYSTEM . ........................................................................................................... 53

6. BRAKE SYSTEM .................................................................................................................... 67

7. HYDRAULIC SYSTEM ......................................................................................................... 73

8. LOAD HANDLING SYSTEM ............................................................................................. 91

1. BATTERY AND BATTERY CHARGER (OPTION)

Type Clad type lead accumulator

Name VSFL201M VSFL280 VSFL320 VSFL390

Capacity (5-hour rate) 201 Ah 280 Ah 320 Ah 390 Ah

Type Truck-mounted, microprocessor controlled, 3-phase a.c. quasi-steady voltage type

Rated power 3 kVA 4.3 kVA 4.5 kVA 6.2 kVA

Power supply voltage 205 - 215 / 210 - 220 V

1.1 GENERAL DESCRIPTION

Fig. 1.1 Battery Assembly

(1) Battery cell