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SERVICE MANUAL 65 SERIES FBT13P FBT15P FBT18P FBT20PN my 4 \s) z - ‘_ ~ I 2 ~ O iT = rT NICHISU NIPPON YUSOKI CO.1TO. KYOTO, JAPAN, atv #547 633 INTRODUCTION Most accident happens due to the disregard of basic safety rules or precautions. In order to prevent accidents, the factors which may cause accidents must be avoided beforehand. For this reason, please read this manual and fully understand the precautions for safety and the proper procedures and directions for inspection and maintenance before starting operation. Performing maintenance and repair without adequate knowledge may cause inadvertent accidents. Pit is not possible to cover all the possible cases of accidents in this “SERVICE MANUAL". Therefore, attention should be given to precautions other than the ones mentioned in this "SERVICE MANUAL", Especially, when repair and maintenance work which are not covered in this “SERVICE MANUAL" are carried out, always work under the direction of an instructor who understands the matter. MUSING THE "SERVICE MANUAL" This Service Manual will give explanation on how to maintain and inspect NICHIVU forklift trucks of FBT-65 series. ‘Since the parts used in this machine are subject to change for the sake of better quality, performance enhancement, and safety, some portions of the contents and illustrations of the "SERVICE MANUAL" may not be identified. Directions with d& and MB marks are very important, and must be followed. Indicates a potentially hazardous situation which, f not avoided, DANGER | could result in death or serious injury. ‘You shall observe this instruction. ( Indicates potentially hazardous situation which, it not avoided, WARNING | could resuit in death or serious injury. You shail observe this inetruction Indicates a potentially hazardous situation which, if not avoided, may CAUTION | result in minor or moderate injury You shall observe this instruction, Nore | Indicates suggestions, tips and hints related to the safety of a operator and maintain of truck. Personnel this "SERVICE MANUAL" is aimed at: This "SERVICE MANUAL" is directed at personnel who possess sulicient knowledge and technical expertise. If you do not understand any of the contents of this “SERVICE MANUAL’, perform operation ‘under the guidance of personnel who does. @Conditions of a facility “The work concitions deserbed inthe “SERVICE MANUAL" are writen on the assumption tha the work is pertormed at @ shop where standard facties and tools for the maintenance of NICHIYU ELECTRIC LIFT TRUCKS are avaiable For safe and reliable maintenance, the work should be performed at a shop where the faciities are equivalent to these described in the “SEAVICE MANUAL" or better, and the instructions described shouldbe sticty followed. Copyright® 2000, NIPPON YUSOKI CO., LTD. All Rights Reserved fete) LE ‘SAFETY WORK 1 Precautions related to sale inspection ‘and maintenance work *Conattions ofa shop (cation) for inspection ‘and maintenance... “WORK CLOTHING “TOOLS AND GAUGES. * SAFETY WORK... “PARTS. “REPAIR OF ELECTRICAL COMPONENTS * HYDRAULICS. “TIGHTENING TORQUE @ _ 2t0caTIon oF SAFETY LaaELs. MODEL NAME AND SERIAL NUMBERS. A.CAUTIONS FOR MAINTENANCE... S.TIGHTENING TORQUE OF BOLTS... STABILITY OF FORKLIFT TRUCK. 7.LOAD CENTER AND LOAD CHART 13 14 oN ECGS 1-1, APPEARANCE. 1-2.SPECIFICATIONS .. 16 17 PETS) mH 19 19 2A1.FRONT AXLE ASS'Y.. 21-1, DISASSEMBLING AND ASSEMBLING, @ 2 :200ustuent 2-2.FRONT AXLE COMP.. 2.2-1,DISASSEMBLING AND ASSEMBLING. 2 2.ADJUSTMENT... ERIE) '3+1.DISASSEMBLING AND ASSEMBLING... ‘3:2,ADJUSTMENT. ns 3-2-1 MICRO SWITCH ADJUSTMENT. ‘3-3, PRECAUTIONS DURING ASSEMBLING A 23 25 25 25 4 TYRE a 4-1,FRONT TYRE 26 1.DISASSEMBLING AND ASSEMBLING...26 41-2.TYRE SIZE (FRONT). 28 2.REAR TYRE a7 42+1.DISASSEMBLING AND ASSEMBLING....27 42.2.TVRE SIZE (REAR), ar ES 5-1.DISASSEMBLING AND ASSEMBLING .....28 Gene 6-1,FOOT BRAKE. — 6-1-1,DISASSEMBLING AND ASSEMBLING. 6:1-2MASTER CYLINDER ADJUSTMENT... 6-1-3. BRAKE PEDAL ADJUSTMENT 6-2.PARKING BRAKE. 6-2-1 DISASSEMBLING AND ASSEMBLING (OF PARKING BRAKE... : 6-2:2,DISASSEMBLING AND ASSEMBLING (OF DISK BRAKE. 6-3.NSPECTION AND ADJUSTMENT. {63+1.INSPECTION OF PAD ASSV.. 6-3-2 INSPECTION OF WHEEL CYLINDER 6-3-3MICRO SWITCH ADJUSTMENT. s8eee 8 eeeeey ‘TA.NALVE LINKAGE .. at 7-1-1.DISASSEMBLING AND ASSEMBLING. ..41 7-1-2MICRO SWITCH ADJUSTMENT. a2 ‘T-4-S.LIFT (FAST) MICRO SWITCH ‘ADJUSTMENT .. 42 T-2.CONTROL VALVE voor 43 7-2+1.DISASSEMBLING AND ASSEMBLING...43 7-2-2.RELIEF PRESSURE ADJUSTMENT. ...44 TOIL TANK . 45 7-941 DISASSEMBLING AND ASSEMBLING....25 17-3:2.FORK OIL AND QUANTITY, 48 7-4.01L PUMP a7 ‘7-4-1.DISASSEMBLING AND ASSEMBLING...47 "T-4-2.QEAR PUMP TYPE on a7 PEST a 841 ,LIFT CYLINDER 48 {8-1-1.DISASSEMBLING AND ASSEMBLING. .48 8-2 TILT CYLINDER . 49 {8-2-1,01SASSEMBLING AND ASSEMBLING. 49 PES 50 9-1, DISASSEMBLING AND ASSEMBLING.....50 19-1-1.SIMPLEX MAST, 50 9-2.TRIPLEX MAST. - 82 9.2.INSPECTION AND ADJUSTMENT 1c o0054 9-2-1. CLEARANCE BETWEEN ROLLER, ‘AND MAST. 54 9-2.2.MAST, LIFT BRACKET, AND ROLLER SHAFT onrnennninnnennnnnanane 9-2-3.BACK SHOE son 92-4.LIFT CHAIN, 58 9-2-6.CHAIN BOLT. 58 9-2-6. CHAIN WHEEL. 56 9-2-7 HOSE PULLEY $6 9-2-8,AOLLER.. 56 9-2-9.FORK... ST (eMC 10-1.0ISASSEMBLING AND ASSEMBLING.....58 40-1-1,TRACTION MOTOR 10-1-2.HYDRAULIC MOTOR 104-3.EPS MOTOR, 10:2 INSPECTION 10-2-1. ARMATURE COMP. 4102.2.CARGON BRUSH, CARBON BRUSH HOLDER [AND SPRING .. 63 10-2-3FIELD COIL... 65 10-2-4MOTOR ASSY. ss 5 10-2-5.01L SEAL AND PERMANENT MAGNET... nn sess Ga TAALLOCATION AND NAME 87 11-2.CONTROL UNIT 8 11-2-4.LOCATION AND NAME... sa 111-2:2.DISASSEMBLING AND ASSEMBLING.70 111-2-3.DISASSEMBLING AND ASSEMBLING. (OF HYDRAULIC CONTACTOR (M7)...7 +11-2-4, PRECAUTIONS DURING INSPECTION ‘AND REPLACEMENT, ne 11-3, FORWARDIBACKWARD CONTACTOR....76 11-3-1 DISASSEMBLING AND ASSEMBLING.76 411-9-2.FUSE REPLACEMENT PROCEDURE..77 11-4 ACCELERATOR: 78 “1-4-1, REMOVAL AND INSTALLATION OF ‘ACCELERATOR LINKAGE. 78 2.CONFIGURATION AND FEATURE OF ACCELERATOR, 7 11-43 ADJUSTMENT PROCEDURE OF | ACCELERATOR LINKAGE. oT 80 80 a1 11-5 INDICATOR PANEL & DIRECTIONAL, SWITCH 11-5-1.DISASSEMBLING AND ASSEMBLING OF INDICATOR PANEL... 4115-2,DISASSEMBLING AND ASSEMBLING. OF DIRECTIONAL SWITCH. at 11-6 BATTERY. . 82 ‘1-6-1 DISASSEMBLING AND ASSEMBLING. 11-6:2.INSPECTION OF BATTERY... 11-8.3.CLEANING..... 11-7. CHARGER PANEL... 1117-1 DISASSEMBLING AND ASSEMBLING... 2.POWER TAP SWITCHING PROCEDURE... a EEN mn 12-4. ADJUSTMENT PROCEDURE 412:4-1. HORIZONTAL ADJUSTMENT (OF FORKS: 42-1-2,LASER OPTICAL AXIS ADJUSTMENT. ..8 RES 13-1 OUTLINE OF FBT-65, 19-4-1 CHANGE FROM FBT-60. 1841-2. CHECKING OPERATION OF AUTO POWER OFF FUNCTION. 19-8. CHECKING DISPLAY OF WARNING FOR BATTERY ELECTROLYTE LEVEL, 194/-4.WIRING CONNECTION OF HOUR METER OPERATION.. 13-2How to adjust New SICOS60 (Major point ony) 13-24The name and function of ‘rode select switch .. 13.22 How to set the each mode 13.24.Adjustment of starting current ‘and current imation 13.2-4.Adjustment of ether spectications. 182.8.Check and adjustment for other functions. 13-3.NEW EPS SYSTEM 139-1,AUTO POWER OFF FUNCTION. 18:9:2. CHECKING AND ADJUSTMENT 1-4 LIST OF SETTINGS FOR FBT-65 1866.SETTING OF VOLUME AND ROTARY SWITCH... 135-1.VOLUME.... 135-2. ROTARY SWITCH. : 18-6.SELF DIAGNOSIS HISTORY MEMORY AND VO CHECK, ns 19.6-1.SELF DIAGNOSIS HISTORY MEMOAY 18.62.00 CHECK. 7. 19-83. ANALYSIS OF FAULT CAUSE, ISI 114-4.STANDARD WORK HOURS 14-2 FBT-65 SYSTEM WIRING, 14-3,FBT-65 BODY WIRING. 1434. WITHOUT HYD. CHOPPER AND REGEN : 148.2.WITH HYD. CHOPPER AND REGEN., 143.8 WITH HYD. CHOPPER AND WITHOUT REGEN. a 29 89 89 89 29 90 90 st 95 401 104 105 105 105 107 108 108 108 an am 7 21 122 130 131 131 N82 133 14.3-4.WITHOUT HYD. CHOPPER AND WITH REGEN. 14-4,FBT-65 BODY HARNESS... 14-8.FBT-85 CONTROL UNIT HARNESS. 145-1. WITHOUT HYD, CHOPPER AND. REGEN sevsnnnnne 14.5-2.WITH HYD. CHOPPER AND REGEN... . 145.3.WITH HYD. CHOPPER AND WITHOUT REGEN 14:5-4,WITHOUT HYD. CHOPPER AND WITH REGEN N88 195 136 196 198 139 Hil sarety work [EERIE Precautions related to safe inspection and maintenance work elo Bs) UWE cate (UeezWelt) RCclal ‘AcauToy] (Facilities with adequate space and level surfaces: The floor area of the shop (location) where Inspection and maintenance are performed must have adequate floor space, and have level surfaces without holes. If these conditions are not met, unexpected accidents, such as a roll-over of the forklift ‘truck, may result. “AcamTON] ( WELL-VENTILATED AREA # Work such as welding painted components or sanding down coated parts should be carried ‘out in well-ventilated areas. ‘$f this is not observed, harmful toxic gas or dust may be inhaled. ACATON] (LOCATION EQUIPPED WITH FIRE EXTINGUISHING EQUIPMENT ‘© Equipment such as first-aid boxes and fire extinguishers should be nearby when work is performed, “ACAMION] ( SAFE AND WELL-LIGHTED AREA ¢ The work area should be safe and well lighted. ‘When working inside the machine or underneath of it, always use a safety lamp with a shielded light bulb. ‘If this is not observed, leaked oil may catch fire ‘when a light bulb pops. ‘Acamon] ( PROPER ARRANGEMENT Arrange and clean always at a working place to work safety. Especially, arrange disassembied parts welt WORK CLOTHING SAFETY WORK ACHTON ‘¢ The worker should wear a hat, work clothes, and ‘safety shoes that are suitable for safe work. The ‘work clothes should be close-fitting, If this is not observed, loose clothing may become caught in a machine, resulting in TOOLS AND GAUGES ACAUTION ‘Always use tools that are suitable for the work being performed. Use proper size tools when tightening and loosening the parts of the forklift truck, "#Failure to observe the above could result in ‘serious injury or damage to machines. AcAUTION ‘© Prepare tools and gauges before starting to work, SAFETY WORK HARING ‘¢ When hoisting a forklift truck or a heavy ‘component, use ropes or cable with correct capacity. ‘#Do not use ropes or cables which are kinked. ————— “AWANNG] (6 ater titing oF jacking up a forklift truck, support iRtwith safety blocks or rigid stands. ALWRING] (” « Prevent tires from moving with whee! chocks te, ALAA] ("6 when working under a forklift truck, use a pit or proper safety precautions. | IB SAETY Work ACHITION] | © When replacing any parts, be sure to use NICHIYU genuine parts. A.CAITIN] («When replenishing battery electrolyte, be sure to use refined or distilled water. REPAIR ELECTRICAL COMPONEN ALCATION] ( © Be sure to disconnect the battery plug when replacing electrical component. ALCAITON} («Be sure to jack up the drive wheel when trouble ‘shooting electrical operations. \ MMBNOTE! | Record the places of tead wire connection when, disassembling. ACAITON| ( CHARGING BATTERY Batteries produce flammable gas during charging. Do not allow batteries in the vicinity of fire or flames. ‘Failure to observe the above could result in an. explosion. “ACAITON] (~© Diluted sulfuric acid is used as the battery's electrolyte . Keep clothing and skin away from contact with battery fluid. ‘If this is not observed, the fluid may corrode clothing or cause burns. ACAITION ‘® When removing the hydraulic pipes, cap them to Prevent dust from entering into the hydraulic ‘components and pipes. ACHUTION ‘When disassembling and assembling the hydraulic components, work at clean place and do not damage the parts. AcATTION| ‘© Observe tightening torque specified In this manual. I not specified, refer to the table {Tia torque for bolts). SAFETY WORK Ij Pend] p eNO eet) TIGHTENING TORQUE I s#reTy work [EESLLOCATION OF SAFETY LABELS ‘The illustration below shows the location of safety labels for safe operation Always protect the safety labels from contamination and damage. I they are damaged or lost, replace with new ones. Parts No. Parts Name | OW MEASURE ‘0902-69814 | Plato, Warning "No parson on/ under forks. ‘0902-6974 | Plate, Warning Caution for ingers @ | 2a700-07860 | Plate, Caution @ | 0902-68384 | Plate, Precaution @ [0802-69704 | Plate, Caution @ | 24700-01780 | Plate, Caution @ | 8540-00520__| Label, Danger Cauiion for Braking Precaution for Safety Operation No ring except Operator Operation of Gas spring lock Caution for Battery SAFETY WORK fap) pang tebe ee ing veer rode adequate braking. NICHIYU I svrcry work GASES produced by this batory can be explos AN |" Seerendetarcs 0 spate onde iy expe, DANGER|, Mave cue batters ae cored and cargedin a wel wurst area, «Bauer contain SULFURIC ACID can cause Sever Buna cid Lornct wah skin, yea or oting, thvevont of cident lush wih water adi call a physician immeciatery + War rubber gloves to prevent ELECTRIC SHOCK during checking ‘and maitainng. «+ Koep out of reach of chiléron IMPORTANT POINT FOR MAINTENANCE, ". owp te lcci evel at pe: ‘oper i Sari nfane pa wy ee rcuyeaney™ SAFETY WORK I ESEMODEL NAME AND SERIAL NUMBERS @ MODEL NAME NAME PLATE (For Std) (For CE) FB UL 650— T Three wheels Capacity code 13: 1250K9 15: 1500K9, 18: 1750K9 20: 2000kg Classification of tyre ‘© : Cushion tyre P : Pneumatic tyre PN :No puncture tyre ti t Litt height fem] B : Large capacty battery equipped! Stationary charger D : Electrical enclosure Mast type| [NO CODE : Two stage full visibifty mast M: Three stage ful roe fit mast (Fut vsbity mast) PEL: Ful ree ft mast (Ful vstity mast) é ‘CS : Col storage use for ~35 WB : Wide bar lt bracket ‘Attachment 2: Special ype electrical component SAFETY WORK lf SERIAL NUMBERS NO. ‘SERIAL NUMBERS: STAMPED POSITION @ | SeRIALNo, oF A TAUCK ‘Stamped on the name plato, @ | SERIALNO. OF ACHASSIS | Stamped on the battery compartment. @ | SERIAL NO. OF AMAST ‘Starmped on the mast name plate. @ | SERIAL NO. OF A DRIVE UNIT | Stamped on the name plat. | SERIAL NO.OF ATAACTINMOTOR | Stamped on the motor name plat. @ | SERIALNO. OF AHYD. MOTOR | Stamped on the motor name plate ‘SERIAL NO. OF A EPS MOTOR | Stamped on the motor name plate ‘SERIAL NO, OF LIFT CYLINDERS | Stamped on the it cytinders. ‘© SERIAL NUMBERS: pono0-0000 ‘SAFETY WORK EME CAUTIONS FOR MAINTENANCE 1 General precautions ‘* When replacing any parts, be sure to use genuine NICHIYU parts. ‘# When parts are assembled, always replace old packing and O-rings with new ones. In addition, be sure to apply a light coat of grease on the O-rings and cil seals before installing them. ‘As shown in hatin, fac the fat soot the C- [hearer pean shape retainer inthe cretion the force is applied | “Saene” “Sakis wn sal. = ML ‘*-As shown in the illustration, face the slit side in the recon the fre is epples wnen devngn aspen | ey ef HO pin. ‘© The split pin must be replaced with a new one and split ‘sot will not come out. ‘* When using a thrust washer with oll grooves cut, ‘observe the direction of installation. otanovon ‘© When connecting and disconnecting couplers of electrical hamesses, always disconnect the battery plug. 10 ‘SAFETY WORK " lf USING LIQUID GASKET © Scraping before application of seal Flemove the sealer adhered on the mating surface of the ceasing using a scraper or equivalent fool. Be careful not to make scratches of 0.3 mm or deeper. I scratches are made, repair the area using an ol stone. © APPLYING LIQUID GASKET 1. Wipe off the mating surfaces using a cloth soaked in gasoline to remove oil and contamination, %Do not use kerosene, light ci, or crude ol 2. Cut the nozzle of the liquid gasket tube at about the second section so that the bead width will be 3 to 3.6 3, Attach a key for rolling up the tube, and apply the liquid ‘gasket to the mating surface while rolling up the tube. 3#Do not smooth out the bead; doing so may cause leakage. When applying the liquid gasket to bolt holes, apply it (on the internal portion of the mating surface. 4, Close the mating surfaces within 16 minutes after the liquid gasket is applied. 5, When tightening the bolts, always tighten temporarily first, and then tighten them gradually, moving from one to the next in a diagonal pattern. 6, Wait for more than 30 minutes before adding oil or ‘operating the machine. 2i¢Fallure to do 50 may cause cil leakage. if \ Mees —— Noteeod 3.35mm Good ‘Apply nauid packing thin inter Taser J orton cna Filing operation SAFETY WORK I} © DETERIORATION OF LIQUID GASKET 1, Once the tube has been opened, the liquid gasket [ime ai has separated, be anchoring the tip part of the nozzie might be cured and | $#5H2thas étéorated deteriorated. Squeeze out that portion and discard it before reusing the gasket 2, If il (ler) was separated from the liquid gasket and the gasket appears shiny when it is squeezed out, this Indicates that the liquid gasket has deteriorated. X€Although the oil may have been separated from a e liquid gasket opened botre is expiration date, ths i ‘not an indication of deterioration lf the state of the gasket is normal, it will be ‘cured within approximately 2 hours. However, ‘a deteriorated gasket will not. or i s#rety work HEGSETIGHTENING TORQUE OF BOLTS 13 ‘lsstizaton of bt av ar Brass Stainless Materia of bott ssseoo SCM | seweso | suszos Nominal | Pitch” attot ‘nm Tightening torque"? Unit: N-mika-m ms os (00 er (608) (605) ma o7 or 039 oro) von Ms o8 eas) (oes) (ora) ean me te (esa) on (eo ean we 128 an en (20, (0%) mre 128 ey en 8) as mie es (toy 9, eo) 4 me ‘8 rey as a 6a mie 6 ea i a es wa | s vo, Ea 5) i (mz) 15 a oo a B Mes 20 as od fad @ woo | 20 3 vo |e a *1. In the table above, the thread pitches of bolt diameters M3 to MB are for coarse screw threads and those of bolt diameters M10 or larger are for fine threads according to our specifications. *2. The tolerance range of tightening torque is to be +/- 10% of the reference values given above. (The tolerance range is determined according to experience, related standards, and records provided by ‘other companies.) ‘SAFETY WORK HEGRE STABILITY OF FORKLIFT TRUCK ‘As shown in the figure, the counterbalanced forklift ‘ruck will balance on its drive wheel with a full rated ‘capacity load on the forks. Consequently, careful attention should be paid to the load center so that truck does not unbalance. Ifa load should exceed the rated capacity of truck, or the rated load center, the rear steer tyres will lift off the ground and the possibilty of toppling the truck exists. ° HEEABLLOAD CENTER AND LOAD CHART Distance from the center of gravity of a load on the forks to the surface of the truck is called load center. The LOAD CHART shows the relationship between load center and load capacity of the truck. Do not rag forks to the floor, lit up forks 150-200mm above floor when traveling with mast tilted backward fully. When traveling, do not lifting and titing forward. This could cause overturn by changing the center of ‘gravity forthe load. 4 SAFETY WORK 15 1) Completely insert the forks beneath the loading object. 2) Applying too much load on the front portion of the forks exerts force beyond expectation and this may cause damage to the mast and forks ‘even ifthe load does not exceed the maximum allowable weight. 3} Ifthe load is off-centered, it not only exerts force beyond expectation on the truck, but also causes a side slide of the loading object. Thus, off-centered loads in a lateral orientation should be avoided as well. 4) When loading an object, operate the valve lever carefully. 5) Abrupt operation during high stacking exerts great impacts on the truck, and may result ina tip over accident. IER Generat EEE APPEARANCE ‘ILLUSTRATION OF APPEARANCE 51 :"ACCELERATOR LINKAGE" : See page 78 32 : [ELECTRIC PARTS : See page 67. EFRONT AXLE IEBREAR AXLE IICYLINDER, Mast ELECTRIC PARTS (2) EBUsER POINTER ROUBLE ‘SHOOTING [TERSERVICE DATA AND ‘WIRING (DIAGRAMS) Mil cenera GREASPECIFICATIONS GENERAL at Forise | rovise | Ferien | Favzorn eens Tal _1250 | 1500 | 1750 | 2000 esdcerer tem 300 om rm 3000 ean rn 120 King —[sson | fame] are [308 | 208 [205 eet [nisen | [rma a wes | 8 [Tat angle [Forward 8 Boaward FL ri faa oon | af ass ef es owes _fonsson [onl a58 |e | as 8 luaeinisarg aus [mm] 1400 | vs0d | _r545_[v0e0 [owateogn——jnm| 25207 | _z7e0 | 2eas [2008 [ow win rn ior Moxcexaded [im 000 hi stoner m7 1370 Oveond pol mm a latase Km | aa08 100 az Fes Fontes) | [rom sere0 ‘esie00 eves verte [sa | — 2770 [2900 [| viao | _a820 ~ osu Taxa wPaKe [ewaiwnal = Epo tre Taxrexe yee | eR Toxexta ax neon iexanmerenne [= 5 veto hic wears TexaliayOxE essen = Ge in i FET chopper onion Traaen 3.52 (eomin) jr auc] © bmn 7 (Sin es 0.3 (eon Boney aw basal seo | aso a none Autopac saonaly charger phase 200) inal 52 mH “Subject te change without notie for improvement 18 BEAFRONT AXLE (DRIVE) E2EHIFRONT AXLE ASS'Y 2-1-1. [DISASSEMBLING AND ASSEMBLING Thing rue 720-560 N= m [46-56 kot - mj BTA -Casi Bok boson eo! ‘Acarion > |e Pay attention to diferent S}] Lbottenaths. FRONT AXLE (ORIVE) IE 2-1-2. [ADJUSTMENT “When tightening each plug and air breather, apply a seal matoral (LOCTITE #575) or seal tape, Fill Lubricant HE#BO or an equivalent product into the both sides. Right: 1.3L Left: 1.61, (Get the part upward position ang fil the lubricant to the level plug hole.) ‘®PLUG AND AIR BREATHER Plog and Air breather ‘Fooly LOCTITE[ES75 or Seal tape. Ph [aor asey one] ‘Banga Fay assy, ot ‘Airbroatner BA Aooly Loctite EE Fron axe onivey FRONT AXLE COMP. 2-2-1. DISASSEMBLING AND ASSEMBLING c Tightenieg true g Fron west TZN (1.8-2.2 kgf = my I Oisea po ‘Apply grease on paris of Lip and TineEeOND wtet6) around t Tarenng ore Te=22N i822 Ko Tightoning torque £ Kat m) Sees Ko SeAeSEMMLNGOF FRONT TRE: sng, bas Case (2), "s Tieng — [J SiiNem (09-17 Kgl mp Sac ofthe Goo case THREEBOND (#1215). i he contact surfaces with ‘Nat comp, hard lock Gear Tahienng rue [58-74 N= m (Conver side) [(6-7.5kaf mp TTghteangirue [118-127 N= m (Concave side) [712-8 kgl =m) aA OM e&. Gear ~o cons) | Best ‘1 N60 [A eewinapretces ) ‘WE | Measure at | 54-59 N postion A (hub 155-60 gH Thuong ove Apply threebona only grease gaog ai FRONT AXLE (ORE) EI BER, ‘© The bearing prevload should be 54-59N (5.5-6.0kgf) ‘when measured at the hub bolt ACAUTION ‘@ Apply THREEBOND (#1215) on the mating surface of the gear case. ALCALTION ‘Before inserting the oil seal, apply proper ‘grease on the seal. ‘© Apply gear oil on the serrated portions of the drive motor. FESREAR AXLE (STEERING) EEE DISASSEMBLING AND ASSEMBLING ® DISASSEMBLING AND ASSEMBLING OF REAR AXLE (1) Prete au Tahienngtome [2] ‘39-121 N- m (0-12 kgf = mp am / a a, a ® ‘Sensor assy EPS. ‘Spline shaft ‘Roply grease on he spine shalt erm [3/<] ‘Apply grease on parts of Lip anc STHREESOND [a 104) around Gover, EPS and EPS mete ine contact suraces wih Coat THREEBOND (#1212). o-0 ew rN —. Q-— © re “e-n Pinon, steering Tirening torque Spine shat Ta ree tinecoowo Arc gone TD normale ‘Apply grease on the (aoa 23 ‘ein case that OIL SEALS, O RINGS, BEARINGS were removed, they should be REAR AXLE (STEERING) © DISASSEMBLING AND ASSEMBLING OF REAR AXLE (2) Linn ome (e-8kgh m) X] Pre-ad Measure at | 95-13.5N estonia | nat late, cam ‘Suppor, rear ante Fil grease up between bearings. Plate Gear @), steering Taremnaere 19] B8-108N-m (eat kgm Hub, wheel Fill grease up between bearings Bracket comp. whoa! FOTO arn Thora ove, [Tetenngtame [7E-88N=m | Tipneng true | 79-88N= m see"REARTYRE” | (Convexside) [74-kgt- mj | (Convexsie) [7-4-9 = m) Tiiemngioqe [21-S1N-m | tgtteinguoqe [21-31 Nem (Concave side) [eizazgi= my_| (Concave sie) [2-02 gm) A [eam peed [OPA Benne rend QO} Wessurgat ” [aaccan | Measure | 249-09 sion A (UD ton aoe poston Alu Sasa [bot [ess Ko Bh -notmsate _. 24 REAR AXLE (STEERING) ADJUSTMENT 3-2-1. [MICRO SWITCH ADJUSTMENT ‘Adjust the gap between the smaller arc of the plato cam and the roller of the micro switch to 1 - 3 mm and lock the position Micro switch adjustment Specification | Dimension L procedure sto | 2stos esirp | 105 EES) PRECAUTIONS DURING ASSEMBLING (Apply THREEBOND (#1212) on the mating surface of (gear case and the motor mounting surface. @Add 0.5 of lubricant HEH80 or an equivalent product. @Apply seal tape to the air breathers and plugs. @Ater the micro switch is installed, apply THREEBOND (#1401) or an equivalent product on the both fixing nuts to lock the threads. 25 Raitvre EEHFRONT TYRE 4-1-1. [DISASSEMBLING AND ASSEMBLING Tieng ore 322-108 N-m __ FBTaUPN (-fhgt- mi) FBTZOBN 685-725N-m_FBTIaP16P WeBkGts my FBTISP-18P, {| Tratiening torque io] zi [22.0-26.9 Kgl . [TYRE SIZE (FRONT) Wedel Sie Spa presario ROTOR) Feriaprise | Tex7e- 4A 0.88 9.0) (1817-8 No puncture: OPTION) 18x7-8-16PR Ferree (1817-8 No puncture: OPTION) 9.98 (100) FBTZOPN | 16x78 No puncture = TyRE REAR TYRE 4-2-1. [DISASSEMBLING AND ASSEMBLING (© FBT13P-18P a & wm ) “a GS " 78.5 Nm Fim pat ana wut }9E S785 Sy ‘Tightening torque (7B kgf- mi) Tightening torque 132-162N Tightening torque 82-108 N>m (O-11 Kgl m i Tightening torque ‘up bot ana wut | 792—162 N= m 1135-165 kat 4-2-2. |TYRE SIZE (REAR) ‘Wodet Sa ‘Specie’ ar prossure MPa eave) FaTispise | t6x4 1/2.8-12PR 0.98 (10.0), FaTteP ‘6x4 1/2-8 No puncture = FBTZ0PN 16x6-8-10°R 0.83 (8.5) EES sTeEeRING LINKAGE DISASSEMBLING AND ASSEMBLING ‘© DISASSEMBLING AND ASSEMBLING OF STEERING LINKAGE (1) o ‘Wheel assy. steexing ~ Dntaction ed = Ferigp12=20 FRTI8/16P-14-2m é Se ) , 7 G:F aT ; A. ‘apy grease onthe nae ‘contact surface and the brush &F /\-counn ay ontact suriace. ¢ M TB Aoptaonse 28 IEBSTEERING LINKAGE * DISASSEMBLING AND ASSEMBLING OF STEERING LINKAGE (2) Spine shat ‘Apply grease on the spline shalt Bi :Acoy grease 20 STEERING LINKAGE * DISASSEMBLING AND ASSEMBLING OF STEERING LINKAGE (3) Spine shalt “Apply grease on The spine shat ‘Shaft comp. joint Sprocket (4) Gi hep grease BGS BRAKE LINKAGE FOOT BRAKE 6-1-1. [DISASSEMBLING AND ASSEMBLING Busting it Bi sAovygrase 31 BRAKE LINKAGE IE 6-1-2. MASTER CYLINDER ADJUSTMENT ACAITION ‘@ Apply assembling oil (MR#20) on the inner surface of the master cylinder during assembling. ‘© Bleed air after the master cylinder is disassembled or replaced. DISCHARGING AIR '¢ Discharge the air after installation of all brake ) | « paoceDURE OF AIR DISCHARGING parts, (Remove the cap on the wheel cylinder and connect a drain hose to the breather screw. The opposite end of fa drain hose should be connected to a container to receive brake fluid. Breather screw Depress the brake pedal several times and hold depressing, ‘@Loosen the breather screw and discharge the brake fluid with ait. Tighten the screw again before stopping to discharge. ALCAITION) ite Ca @Ater finishing to discharge the air, tighten the breather screw securely. Drain hose Broather screw ‘wheel eyindr ston @Make sure no brake fuid is leaked ACATON '¢ Use described brake fluid. Do not mix the different grade of fluid. eAlr discharging shall be done when disconnecting the brake piping. [J BRAKE LINKAGE [24 CYLINDER STROKE ADJUSTMENT. ipod tegen tho ed eng cote or | MASTERCTLIOER Shoe eto va sown oe on 29 of applied force". BRAKE LINKAGE [3 BRAKE PEDAL ADJUSTMENT (Dif the gap between the brake pedal and pedal bracket is tmm or larger at the both right and left sides, adjust the gap by placing a shim. Adjusting cod length of master cylinder With the rod lightly contacting the piston, adjust the rod length so A = 83+ 1.5mm is gained, then tighten the levis with the nut. ‘@Adjusting pedal height (1) Adjust height B of the pedal height adjusting bolt so that the play at the pedal end is 5 - 7mm when the pedal is released and the master cylinder is, completely retuned. (The specification of the pedal height is 17mm.) (2)Make sure that the distance between pedal height C ‘and the fioor is 87 5mm. ()If the pedal height is not within the above range, adjust the pedal height using the pedal height adjusting bolt. At the same time, change rod length A of the master cylinder to meet the condition described in (1) above. @Adjusting micro switch ‘Adjust dimension D (standard: 24mm) so that the miro switch switches ON/OFF when the pedal is pressed down 10 - 20mm. Nico switch Brake pedal 34 [Eb RAKE LINKAGE EESPARKING BRAKE 6- .|DISASSEMBLING AND ASSEMBLING OF PARKING BRAKE Frame: > 3 Lever assy, bake BRAKE LINKAGE DISASSEMBLING AND ASSEMBLING OF DISK BRAKE Disassemble the disk brake unit with referring to the illustration below. ‘¢ DISK BRAKE DISASSEMBLING PROCEDURE Pa LAgusing bat Peover — EMihocteyinder — Lover vt ‘© STRUCTURE AND DISASSEMBLING PROCEDURE 2 00 ® Procedure Paris (1) [Weeot (2) | @Piston assy @Soatpin (8) | @cap % Follow the opposite order of disassembling procedure. [J BRAKE LINKAGE 2 Discharging air. ‘ACAITON] (- © Discharge the air after installation of ail brake parts. Remove the cap on the wheel cylinder and connect a drain hose to the breather screw. The opposite end of ‘a drain hose should be connected to a container to receive brake fluid, @epress the brake pedal several times and hold depressing. Loosen the breather screw and discharge the brake ftid with ai. Tighten the screw again belore stopping to discharge ‘ACHTON] (~e Keep the bra ‘efilling. nk by @Ator finishing to discharge the air, tighten the breather screw securely. @Make sure no brake fluid is leaked. ‘ACHITON] (Use described brake fluid. Do not mix the different grade of fluid. Air discharging shall be done when disconnecting the brake piping. 37 ‘* PROCEDURE OF AR DISCHARGING Container Breather sorow cap DISCHARGING AIR, Loosen ly / Ya ZA /% cm oN | onrhe sear son tof sae BRAKE LINKAGE »3 Refer to the assembling procedure. ¢ ASSEMBLING PROCEDURE OF DISK BRAKE AND CAUTIONS po Tightening Torque g 77.65.26 48N- mr (82.7 Kolm) Tiahiening Tove. yg 2.94-588N-m fT 10.3.06Kgl-m) 5 | : | Pa &pi hoe ‘Roply molybdenum grease the pins and pin holes. ‘A.cuUTION [Never put grease on the lining and disk. Tightening rave TB: App moytaonum grease 38 BRAKE LINKAGE INSPECTION AND ADJUSTMENT 6-3-1. [INSPECTION OF PAD ASS'Y >1 MISSSaea ‘ Inspect the wearing of linings. If itis worn up to imitation, replace it. imm) ‘New ing ‘Wearing imitation [24 REPLACING PROCEDURE DSet the wheel stopper to prevent the forklift truck from ‘moving. ‘Loosen two adjusting bolts. Remove titing bolts and Pad assy. @install now Pad ass'y with bolts 39 ‘INSPECTION OF PAD ASS'Y ‘REPLACING OF PAD ASS'Y ‘Adjusting bot Fiting bots = =I ie Padassy same Fitting bolts Bi Ttienng rave [9] 1765-2648 Nm (1.827 Kolm) BRAKE LINKAGE I 6-3-2. |INSPECTION OF WHEEL CYLINDER “A.CHTON] (~* Clean inside of the cylinder and oil passing holes betore inspection. »>1 BNSC *# Cylinder body Check if not rusted or damaged inside of the cylinder body. [za INSPECTION 2 *Boot Check any damage or change of quality. @ > 3 EEE ‘© Piston Measure the clearance between the piston and cylinder body. Replace it if the clearance is more than the standard. ‘Standard of clearance within 0.15 mem [29 REPLACING PROCEDURE TEBNGTE] (Follow the opposite order of disassembling ‘© Apply molybdenum grease on the brake-pad pin and pin hote. “cu (“steer pat gente onthe ng ana ak) ‘INSPECTION OF WHEEL CYLINDER, Sprtin Boot Piston assy cap] 6-3-3. | MICRO SWITCH ADJUSTMENT ‘Adjust the micro switch so that it switches ON/OFF when 20 - 25 degrees from the position where the brake lever 's released. ‘@ MICRO SWITCH ADJUSTMENT PROCEDURE a@nyprautic system VALVE LINKAGE DISASSEMBLING AND ASSEMBLING Lover) camp. vaio e cover me tower Ss ®) LS _ ,e® y. Pana. Fe ) TB: Avoiygrease a HYORAULIC SYSTEM 7-1-2. | MICRO SWITCH ADJUSTMENT Tentatively set the adjustment gap of the micro switch 10 0.1-0.7mm when itis in a neutral position. ‘DAgjust the micro switch position to where the switch switches ON/OFF when the lever is inclined so much that the tip of the knob is 15 -30mm away from the center position, @atter the micro switch is adjusted, apply Threebond (#1401) or an equivalent product on the both fixing nuts, to lock the threads. re aie 0.19.76 ® 7-1-3. LIFT (FAST) MICRO SWITCH ADJUSTMENT ‘© Equipped with hydraulic chopper (option) Tentatively adjust the neutral micro switch to the position where it Is 24,0mm above the top face of the switch holder, and 0.7 - 1.0mm from the edge of the touch piece. Adjust the micro switch position to where the switch ‘switches ON/OFF when the lever is Inclined so much ‘that the tip of the knob is 70 - 80mm away from the center position. The spool stroke should be mm - 5.5mm from the center position e @Atter the micro switch is adjusted, apply Threebond (#1401) or an equivalent product on the both nuts to lock the threads. Toxen piece 071.00 Sstch nolder Mir ew a a2 HYDRAULIC SYSTEM CONTROL VALVE 7-2-1. DISASSEMBLING AND ASSEMBLING 43 Felc pressureasjsing ser ae. rt 7-2-2. [RELIEF PRESSURE ADJUSTMENT > 1 GEES ease [[ WecerT_ Pressure nPa rater _] retispise | 13.7140) FBT16P/20PN_ | 15.7 (160) [24 RELIEF PRESSURE ADJUSTMENT. It the pressure is deviated from the above specification, agjust the pre screw. ssure using the relief pressure adjusting + Loosening screw: Relief pressure increases. + Tightening screw: Relief pressure decreases. HYDRAULIC SYSTEM BI Ei *vorauuc system OIL TANK 7-3-1. [DISASSEMBLING AND ASSEMBLING Gauge comp, tevel 7. FORK OIL AND QUANTITY > 1 Monae Specification Fork it Shell: Telus Oils 32 si SSO : Powor lox 32 Mobile : Hydraute ol 28 ‘Shell: Tels T15 osres ESSO : Univis 43 “Accumon| ("+ 086 @ NICHIYU genuine product for the fork e oll, [4 PROCEDURE TO CHECK OIL QUANTITY. [MMBNOTE] (Tank capacity: 9610.6. (Lower the forks on a level ground. Tit the mast back completely. Te oil level should be between the marks on the level gauge. HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PUMP 7-4-1. [DISASSEMBLING AND ASSEMBLING 7-4-2. ar IB: Arty moybcenum grease Fil molybdenum grease up a] GEAR PUMP TYPE reris-teP | DG 05-145 FBT20PN DSG 05-18 KES cviinver [ESEHILIFT CYLINDER 8-1-1, [DISASSEMBLING AND ASSEMBLING ¢ SIMPLEX MAST “Acamton] (+ Cate should be taken when installing packings and seals. Apply grease on them, ‘Also apply a liberal amount of grease on the ground portion. 48 oytinder TILT CYLINDER 8-2-1. DISASSEMBLING AND ASSEMBLING Tightening rave gy SSN 35 kfm Head eyindr ki ‘Appy THREEBOND (71907) the treads before tightening IT, pair Tightening torque g 205 Nm iki m Space (For Bw 3 ‘Spacer (For Bd. Um) od assy, piston ‘Apply THREEBOND [#19245 i pn suncg —— termination No, ‘Sera No. ‘ee ean neve, gone 1B): Tigitoning torque Bi : Asply THREEBOND Eimast [EEN DISASSEMBLING AND ASSEMBLING 9-1-1, |SIMPLEX MAST ¢ DISASSEMBLING AND ASSEMBLING OF MAST 1 Mast ‘© DISASSEMBLING AND ASSEMBLING OF MAST 2 wst 9-1-2. [TRIPLEX MAST ¢ DISASSEMBLING AND ASSEMBLING OF MAST 1 Mideast Pate, ook Sot ajostor ie EERE INSPECTION AND ADJUSTMENT (9-2-1. [CLEARANCE BETWEEN ROLLER AND MAST [an INSPECTION 1 ‘e Measure and adjust the clearance between the roller ‘and the mast Move the inner mast to one side and measure the clearances A and B. Select a shim so the clearance meets the specification e Geararo peteton o-0.2mm ‘¢Clearance measurement of both sides @Remove each roller and install the shims to both sides evenly. (Shim types: 0.2t, 0.51, 1.0t, and 2.01.) >2 MR zee ‘@ Measure and adjust the clearance between the inner ‘and outer masts. Using a pry bar, lit up the inner mast and measure the clearance. Clearance specification 0-0.2mm - (Shim types: 0.5t and 4.01.) Select the shim meeting the specification and install it Shim instalation ack anos ternast sm [9-2-2. [MAST, LIFT BRACKET, AND ROLLER SHAFT LAD INSPECTION ] (color checkired check) Check welds for cracks using a dye penetrant material ‘© Mast material and welds Low hydrogen type should be used for the welding rods and ilminite type should be used for the other welding sections. Ey mast 9-2-3. [BACK SHOE >1 ENS '* Check the Back shoe for wear. {mm} ‘Standara thickness [AD Wear tim “INSPECTION OF BACK SHOE 110 105 9-2-4. |LIFT CHAIN [an INSPECTION 1 ‘© Check the Lift chains for stretch, Measure the length per 20 links at the part which are Used frequently. Imm} ‘Siandard thekness | Elongation lt | Preh [Py S75 wa 18875 [z4_ INSPECTION 2 ‘© Check the Lift chains for deformation and damage. IK itis joted, replace it. LAD INSPECTION 3 ‘© Check for lubrication. ‘Apply grease on chains. [9-2:5. [CHAIN BOLT m1 ‘* Check connecting part (3) for jolt. IRitis jolted, replace it Lad INSPECTION 2 ] ‘© Check for damage of threads. ‘sINSPECTION OF LIFT CHAIN ‘INSPECTION OF CHAIN BOLT B es =e 58 ast CHAIN WHEEL >1 DE ‘*INSPECTION OF CHAIN WHEEL '* Check the outer surface for deformation and the — je 8 9-2-7. [HOSE PULLEY DB > ‘INSPECTION OF HOSE PULLEY ‘© Check for wear, temm) Tem | Sandan Bameter[0]| —_ Wear it HOSE PULLEY 250 255 Ip 9-2-8. [ROLLER 1 >» ‘© Measure the clearance between outer diameter of rollers and inner width of mast channel, and between outer diameter and inner width of reach channel. over the specific clearance, replace it trom) “Tem ‘Specific clearance. ast ler Li rotor 15 [24 INSPECTION 2 ‘© Check for function and jot. Mast 929JFORK yt imena ‘* Check for transformation and leveling, (mm) Tenn Spastic Tearance ‘oval of Fork tips 70 Opening of Fork tips 5 ‘© Opening Bending [24 INSPECTION 2 ‘eWearing ‘© Check for wear and cracks. {mm} Wodet Specie hemes | _umtotwom +30 35-0 FBTIsPnsP 2 oon 330 Fariap eo 35 30 40-0 FBT2OPN, 7 ‘elf cracked, replace them and never use them after repairing. ‘© Check for cracks by using color check. 87 EIA Motor (TRACTION, HYDRAULIC, EPS) EEEEH DISASSEMBLING AND ASSEMBLING 10-1-1.| TRACTION MOTOR e SS Ter y MOTOR (TRACTION, HYORAULIC, EPS) [10-1-2. [HYDRAULIC MOTOR Core comp, ld -- Be. MOTOR (TRACTION, HYDRAULIC, £°S) KE] 10-1-3.[EPS MOTOR UZ ‘® NIKKO BRAND. Zeon, cover, & Yore assy ‘Cover (C), end ay, sony. © FUJII BRAND g HI) Motor iraacn HYDRAULIC, EPS) INSPECTION 10-2-1, [ARMATURE COMP. [an INSPECTION OF DAMAGE ‘© Check the armature for damage especially by high temperature, INit is damaged, replace it It the surface of Commutator is damaged, repair ot replace it, (Machine turn Commutator. ACATON (+e sure to center Gommutator when machining. 6 carry out the under cut (#400) Finish the surface of Commutator with a sand paper ‘© Repair limitation of Commutator ‘© CHECK OF SURFACE OF ‘COMMUTATOR O x (REPAIR LIMITATION Motor Standard (#)] Limitation (#0) Traction metor %0 65 Hyavle motor %0 5 EPS motor 49 7 1 Specitc under cut tm) | Gupen cur oF CoMNUTATOR Motor Specie under cut Traction motor 05-19 Hyaraute motor 5-10 © EPS motor 08-085 MOTOR (TRACTION, HYDRAUL| EPs) [24 INSPECTION OF INSULATION ‘* Measure the insulation between Commutator and ‘Armature shaft ‘* INSPECTION OF INSULATION “tan ("> can wp by compressed sir before messing) TOOL ‘SPECIFIC RESISTANCE, Tester © (Infinite at x1k A. range) Megger ‘Over 05M (OC500V) soe e > 3 IEG sae ‘© Check for wear of spline, and if itis extremely worn, | SiNSPECTION OF ARMATURE. replace it. SHAFT AND KEY ‘* Check the key whether it fis securaly in the groove of the shaft, and it jolted, replace it e > 4 EEE '* Check fitting part in COVER (C), END and COVER (0), END, and if loose, replace it. 6 BI Motor (TRACTION, HYDRAULIC, EPS) 10-2-2. | CARBON BRUSH, CARBON BRUSH HOLDER AND SPRING »1 BIRGER ‘© For those with a wear limit indicator, consider the indication line as the application limit. ‘© For those without an indication line, measure dimension A and consider it as the wear limit [mm Model ‘Basicaimenson | Wear Emit (A) ‘Traction motor 25 8 Hydraulic motor 25 7 EPS motor 25 15 le INSPECTION OF CARBON BRUSH WEAR a it [eed INSPECTION OF CLEARANCE BETWEEN CARBON BRUSH AND BRUSH HOLDER [mm Direction Clearance wiath 03-055 ‘Length (or 1 brush) 08-08 Length (for2 brushes) 1-18 ‘* INSPECTION OF CLEARANCE BETWEEN BRUSH AND HOLDER| [I Moron (TRACTION, HYDRAULIC, EPS) 10-2-3.]FIELD COIL [An INSPECTION OF INSULATION ‘¢ Measure the insulation between terminals and coil “A.cauTou] ("* Clean up by compressed air before measuring. TOOL ‘SPECIFIC RESISTANCE Tester © (Infinite at x19 range) Megger (Qver0.5 MA (0CS00V) ‘INSPECTION OF INSULATION Negative my) (+) Postive 10-2-4. [MOTOR ASS'Y 65 ‘© Inspect the following after assembling. [an ABNORMAL NOISE AND ARC '* Operate the motor. Then make sure that abnormal noise is not heard and are of brushes is not seen. (Be sure to secure Motor ass'y to a work bench. ‘Apply the battery of 1/4 voltage to carry out testing Connect wires as follows. ‘* TRACTION MOTOR 41) Connect (AA) terminal with (F) terminal 2) Connect (A) terminal with postive (+) terminal of battery. 3) Connect (FF) terminal with negative (-) terminal of battory ‘* HYDRAULIC MOTOR 4) Connect (A) terminal with positive (+) terminal of battory. 2) Connect (FF) terminal with negative (-) terminal of battery. ‘EPS MOTOR 1) Connect (GREEN or WHITE) wire with positive (+) terminal of battery. 2) Connect (YELLOW or BLACK] wire with negative () ‘terminal of battery. MOTOR (TRACTION, HYDRAULIC, €°S) KIO} [+4 INSPECTION OF INSULATION (Traction and Hydraulic motor) ‘¢ Measure the insulation between terminals and Yoke [wspecTion OF INSULATION with Megger. «Measuring procedure> DApply earth side (negative [-]) of Megger on the bolt of Yoke. @Apply line side (positive [+}) of Megger on each terminal (A), (AA), (F). (FF) e [10-2:5.[OIL SEAL AND PERMANENT MAGNET ‘¢ Ingpect the following parts regarding EPS motor. [an Ol SEAL © Check Oil seal for wear and damage. If worn or damaged, replace it. [7 PERMANENT MAGNET ‘* Check permanent magnets of Yoke for damage or sticking metallic dust. e Iticking metallic dust, remove it with compressed air. damaged, replace the assemble. 66 ERRELEctRic parts HEEEBLOCATION AND NAME ELECTRIC PARTS fj] CONTROL UNIT 11-2-1.| LOCATION AND NAME Dae WITHOUT HYDRAULIC CHOPPER @CU101—50 ‘@CU101—53(with Regenerative function) mers _. su yelyet Puaging 02) @ ose Se Ayano QFET COMP ue = seu wa “Hyd. (M7) Qoiete_ Sa r Boers comp., pret Resistor come, \eeou =e = a a a San @ | Diode ‘Regenerative (D3) (3) | FET COMP: Travel ‘® | Capacitor 1O0V, 2200 #F ® | Sensor comp., current ‘® | Board comp., MPU ® | Board comp., printed ‘PBB3-63 0 | Resistor comp. ‘e This illustration should be used for FBT-65 with Regenerative function. ‘e Therefore, the parts of @, @, (@, and "marked terminal should be Used for only the truck with Regenerative function. ELECTRIC PARTS. [ea WITH HYDRAULIC CHOPPER cuto1 52 \s8rsor care. hye bebeaoo © CU101—51 (with Regenerative function) ‘ie 7) ore comp Tre oa cp, nd 2s core oar comp. MPU No, Name Remarks @ | Contactor Hy. (07) @ | Diode Fiywhee! (Di) @ | Diose Plugging (02) @ | Bose Regenerative (03) @ | Diode Hyd. flywheel (04) @ | FET COMP Hyd @ | FETCOMP Travel @ | Capactior 100V, 2200 HF @ | Sensor comp, current (i | Board comp., MPU ‘w | Board comp., printed PEES-63 @ | Resistor comp. @EBNOTE Regenerative function. '¢ This illustration should be used for FBT-65 with Hydraulic chopper and ‘* Therefore, the parts of @, di (2, and *marked terminal should be Used for only the truck with Regenerative function. m4 if the contacting surface is not good, repair it as follows. «Repairing procedure> insert @ sand paper [#400] between COMMUTATOR ‘and BRUSH. (File surface toward BRUSH.) (Grind the contacting surface by moving a sand paper or rotating COMMUTATOR by hand. MOTOR (TRACTION, HYDRAULIC, EPS) KIO} [aq INSPECTION OF CONTACTING SURFACE OF BRUSH ‘Clean up with compresses air after repairing. INSPECTION OF FORCE OF SPRING ‘* Hook 2 spring scale to SPRING and pull towards arrow ‘mark. Then make sure of equal force on four springs. (2 springs in EPS motor ) “*INSPECTION OF CONTACTING. ‘SURFACE OF BRUSH Ox xX Good Not Good Not Good AAT ‘© REPAIRING SURFACE OF BRUSH ‘eINSPECTION OF FORCE OF SPRING | ALCAITION MOTOR ‘SPECIFIC FORCE Traction 46-99N | (047-095 kath Hydraulic aata7N | 045-15 koh EPS 49N (0.8 koh} elf SPRING and/or CARBON BRUSH HOLDER were rusted, replace them. ELECTRIC PARTS [DISASSEMBLING AND ASSEMBLING FET COMP. ‘Apply conductive compound "TSK550 (Toshiba Siscones Co., Uc) on all surfaces between the "FET comp." and the insulator sheet, and botween the insulator sheet and the base, FET come, (rave) ‘Apply conductive compound ‘T8K550 (Toshiba Silicones Co., Lia) on all surfaces between the "Diode" and the heat sink, between the heat sink and the Insulator sheet, and between the insulator shoot and the base. Tightening torque O5=125N«m 107-127 Kg Prange tos (03) happen) Fae aie 15 ee R ‘wihiye. choppen_ 222 A Ti nao rl Tig a TOTO] ® as SEN mE 89 kgf ems 10% ‘Only the truck with Hyd chopper Board son, pina Tween) Tightening torque BOT10N- m (92-112 gt Z a Fegenoraive dose (3) ‘wroaea [MSET—17]_Diassening procedure ‘Only the ruck wihoul Fd. chopper ao Bracket (1), MPU boars Gy :Tionteneg torque Gh Appiy compouns 7 ELECT >t Ic PARTS [DISASSEMBLING AND ASSEMBLING OF HYDRAULIC CONTACTOR {M7) eMss7=17 mw sot in Sing washer vir Washer G— pesncomna y— eter oe | Helder 3 nu —B 8050 sheet IB) Arniy molybdenum grease oom —conactam T] Contact surface ‘Appiy a ite grease with ‘molybdenum disulfide. contactor (Tea SSN (1}Remove the split pin, holder, pin, and nut to remove the contact arm. (2)Remove the nut, toothed washer, and washer. (a)Remove the bolt, spring washer, and washer to remove the contact post. Then, remove the contact. (4)Remove the bolt, nut, and return spring to remove the amateur. {5)Remove the screw at the bottom of the contact to remove the core and solenoid. (6)Remove the surge absorber. ACAITION ([¢ Be caretul not to damage the coil terminals.) n “For replacement of contactor only, see disassembling procedure (1). ELECTRIC PARTS BJ 11-2-4.| PRECAUTIONS DURING INSPECTION AND REPLACEMENT »1 [ero ‘A.CUTON] (© Prevent tyres from moving with wheel chocks ote. ‘© Be sure to disconnect the battery plug. ‘© Record the places of lead wire connection when disassembling. ‘© Discharge Capacitors on Control Unit. (OPrepare a resistor (20W, 50.2 or SOW, 10 2). @Fit the terminals of the resister to the terminals of the capacitors. >2 Ee Set the tester knob to register (x1 @Short the tester probes and adjust the pointer to 0. * DISCHARGING CAPACITORS. + CHECKING DIODE apply the testorprobos tothe element and check the | easy condition. " A SS tuoi] (“elt the diode is checked while is insialed onthe) | |, S| forklift truck, disconnect the battery pl XS A tconaconet caate an see i KK lal exer Wo, +]. Resistance 1 a] « ° 2 «x [A 10-100 B] ELECTRIC PARTS >9 ‘* Between drain {D) and source (S) DSet the tester knob to resistor (xk ‘BETWEEN 0 AND S @Apply the tester probe (+) to the source (S) of the FET COMP connector, and the tester probe (-} to the drain (0) of the FET COMP connector respectively. Resistance 1M orlarger (6) GEBNOTE| { Make sure that between the drain (D) and the source (S) is not conducting. ‘© Between gate (G) and source (S) (Sot the tester to resistance (K 2.) range. @Apply the probes to the gate (G) and the source (S) respectively. Resistance 100k 9 oF 10k [J ‘Between gate (G) and drain (D) @Sel the tester knob to resistance (2) xk A SBETWEENG AND D @Apply the tester probe (+) to the drain (0) of the FET COMP connector, and the tester probe (-) to the gate (G) of the FET COMP connector respectively. Resistance 1k 2 orlarger ree J Yeo #8, Wy = os a ELECTRIC PARTS I @EBNOTE (e Make sure that between the drain (D) and the gate (G) is not conducting. Je They should be checked while the FET printed board comp. is attached to aheat sink. /* Do not use @ megger. Resistance values vary depending on testers. > 4 oe ‘Visually check the outside. f no evidence of a leak is observed, check the following. [A cut] (= vse an anatog tester to check the capacitor. (Discharge the 8, For the discharge procedure, see "Precautions" Set the toster to resistance (11 )x1K O @Apply the tester prove (+) to the (+) pole of the capacitor, and the tester probe (-) to the (-) pole respectively. ‘@First, the tester reads a few K 0, then reads ‘CHECKING CAPACITOR ‘The above checking procedure is only a ‘simplified one. If the chance of capacitor fault is high, replace it. ALCHITION ™ LLECTRIC PARTS >s UEC «Adjustment and confirmation items of MPU board> Adjustment and confirmation items Confirmation items LED (12) os ght? OLED 1 (5) Does th? LED 2 (WO) ‘oes gh? @VRO(CFL) Back light density @rso Model seect ORSt Montor select (OP¥2 (LED 0) tt up wan he Y2V power sup i norma /2PS (LED 1) las vp wnen he SV power sup normal ,2 (LED 2) ight up when the mio emer erating (Gh (von indates te densy le ack gwen is ssid (24S 0 Mod slct BRS 1) Motor sect ‘one taal A UII ILL 3°) 2 8) ag 27} ow | one FO] cs [one cons | ove Fo ‘© For the details of VR 0, RS 0, and RS 1, see 13-5 SETTING OF VOLUMES AND ROTARY SWITCHES on pages 108 to 109. 5 ELECTRIC PARTS EE FORWARD/BACKWARD CONTACTOR Contactor Cait resistance ForwardBackward (M12) 44-4850 By pass (Ms) 18-250 Regenerative (Ma) 18-250 [134] DISASSEMBLING AND ASSEMBLING [an FORWARD/BACKWARD CONTACTOR RBS ia | saustin | ELECTRIC PARTS Lay INTERNAL STRUCTURE INTERNAL STRUCTURE OF ACCELERATOR SENSOR Hall element Magnet ‘Spin rote ‘eno hah Reaction force pring (eroront 11-4-3.[ADJUSTMENT PROCEDURE OF ACCELERATOR LINKAGE Adjust dimension “2 (115mm) s0 that dimension *1 (125mm) is obtained when the pedal is released. @Adjust the adjusting bolt (*4) so that dimension *3 (mm) is obtained when portion A of the pedal is pushed all the way down. ELECTRIC PARTS INDICATOR PANEL & DIRECTIONAL SWITCH 11-5-1 [DISASSEMBLING AND ASSEMBLING OF INDICATOR PANEL EB ctectaic pants [ns2] ..] DISASSEMBLING AND ASSEMBLING OF DIRECTIONAL SWITCH Ke ver at ELECTRIC PARTS BATTERY [11-6-1.|DISASSEMBLING AND ASSEMBLING ‘¢ Tum off the key switch and disconnect the battery plug. aretul not to be wet with electrolyte to the body. ACAITION] go to doctor The in ventilated and kept away from fire. 11-6-2./INSPECTION OF BATTERY > Seen er cy Pushes sealers - ‘@oisconnect the battery plug. ‘open the battery cover and set the stopper. rcamon] (~* Since @ gas spring (an assistant damper with selt-lock function) is used, the locking state should be checked. ‘check electrolyte level. ‘ei the electrolyte would come into eye, wash eye with fine water, and .cting battery should be done in a place which is well El ctectric pants 83 ‘the rd float can seen, electrolyte levels correct If not, eplenish with refined or disiled water. ‘INSPECTION OF ELECTROLYTE LEVEL. Aoponiste gy a i Remove the lid of the plastic tank, dip the hose with a lid into the tank deeply and tighten it up. (open the cap and put another end of the hose into the battery cel, ‘@Open the pinch-cock and press the tank at the both sides several times. @Retined water wil low into the cell by siphon action. Close the pinch-cock to stop replenishing just before the red-float touches the indicating plate of the cap. ‘s INSPECTION OF ELECTROLYTE LEVEL Botte ded nose '* REPLENISHING PROCEDURES ELECTRIC PARTS I [eg MEASUREMENT OF SPECIFIC GRAVITY OF ELECTROLYTE IN EACH CELL ‘DTake reading at the contacting tine of electrolyte and the tube. ‘tence ween max. andi. specie wavy sal bo kssttan0.s._ ® MEASUREMENT OF SPECIFIC GRAVITY ‘Bifarence Delwaen max land man. specie gravity Less than 0.05) Treo stone 4 DCamry out equalizing charging. Goneck specific gravity at each cell ater equalizing Ip charge and make sure the diference is within standard value. ‘As spect gravity of electrolyte is based on the value ‘at 20°, convert measured spect gravity. - (@Measure temperature of electrolyte. ‘* CONVERSION “Zrcurton] (+ Use mermometer to monsure ) ‘Measure specific gravity of electrolyte, 2 @Measured specific gravity shall be converted to the & value at 20°C. E [Conversion formula) i $20=S1+0,0007(+-20) i 20 : Specific gravity converted at 20°. Eerie tt St: Measured specitc gravity. "ongeanre © t 1 Temperature of electrolyte. 11-6-3.|CLEANING > einen keane (Keep dry. When they got wet, clean with a dry cloth or blow out wth compressed alr. @it they are rusted, clean with a wire brush or a sand Paper fq Cleaning vent plug (Turn the vent plug counter-ciockwise to remove, Clean it with a detergent so that the red-loatis visible. ‘Securely fasten the vent plug that it will ft well with the cell cover on installation. 1 ‘screw part is damag plug comp. with new one. replace the [i etectric pants ERERA CHARGER PANEL 85 11-7-1.[DISASSEMBLING AND ASSEMBLING @ ONLY THE TRUCK WITH BUILT-IN CHARGER: Magnetic Magnete Conactor(2) sonacter(t) Plug comp. Temioa! Harness, body TT & Op ELECTRIC PARTS I 11-7-2. IPOWER TAP SWITCHING PROCEDURE > 1 Resend eWe OENCTS @maNoTE ‘® Measure the power voltage at the charging section without running the charger. ‘© Measure the voltage for 1 minute. The highest voltage obtained is the power voltage. ‘ei three-phase input power is used, the average of the highest voltages in each phase (U-V, U-W, and V-W) is the power voltage. ‘e The measurement should be made when the peripheral facilities are b2 ot used, such as during the noon recess or while the charger is in tne SSeS ea Bower vatage (WV) ‘Wokage tap ‘* TAP CONNECTION POSITION Teearbne? a7 a ai ana aa of = Power votlage (V) Frame} |} ‘379 or lower ‘| ‘380-399 recom | a8 |sezesie . woe Re Resse ree seo Fon = — te == a Yorn rose \ po oon ee ELECTRIC PARTS [ey TAP SWITCHING PROCEDURE ‘Turn off the key switch and disconnect the power plug before proceeding with work. ‘© Securely tighten the screw for the ring-crimp terminal so it will not be loosened. ‘@Loosen the screw and remove the ring-crimp terminal, @Reconnect it to the tap conforming to the power voltage and crimp the ing-crimp terminal together. ‘© Factory setting: 220 > 4 DNS Sa “Aacumon] (—* Remove tha AC plug ofthe power side. ‘elf the screws are not securely tightened, contact failure could result, causing ‘malfunctioning. @ Loosen the screw and replace the link-fuse. Power vonage Type Battery capacity | FeTiP, 320-370 A 154, FETIP "350-565 AR BOR. FETIOP, 1300-865 An BOR, FET2OPN 300-628 AR BOR, 87 aes EEA Laser Pointer ADJUSTMENT PROCEDURE 12-1-1, [HORIZONTAL ADJUSTMENT OF FORKS: [12:1-2.]LASER OPTICAL AXIS ADJUSTMENT Raise the forks to a height for easy work, and level them. @Make the adjustment so that the actuator i inthe range ofthe sensing element ofthe leveling sonsor and itis iradiated withthe laser beam when the forks are level. ‘Adjustment positon: Within + 1.0 degree of the fork leveling positon Ii the forks are not lovel] Loosen the fixing bolts of the sensor bracket and reposition it, or slighty bend and adjust the actuator so that itis positioned to the center of the sensor sensing element when the forks are level ‘Owith the forks positioned in level, adjust the height so thatthe optical axis of the laser is aimed at the center ofthe pallet insertion openings. ‘@Set the distance between the fork edge and the end face of the palet tothe distance used for loading work (Gomm or shorter), then park the forkft truck in line with the pallet. @lrradiate the pallet with the laser optical axis. Adjust the body adjustment screw s0 that, if @ line type is used, the light is aimed at the center area of the pallet beam, and fa point type is used, at the top of the deck board. Loosen the fixing bolts of the LASER POINTER UNIT, adjust the height by moving the case body up and down. Also adjust the horizontal direction of the optical axis by loosening the lock screw and rotating the unit {the wire portion) inside the body. Ater the adjustment is complete, securely tighten the ssorew and fix itusing @ screw lock or equivalent iter. @Drive the fork truck forward and make sure that the forks do not hit the pallet. Also, when the forks are inserted, make sure that they do not hit the deck board. If they do, adjust the optical axis again. ToFrame ittracret_ ) EES TROUBLESHOOTING FESEH OUTLINE OF FBT-65 19-1-1, [CHANGE FROM FBT-60 '* FBTZOPN is added to the mode! setting, ‘© Model settings Typak | Equipped with no options Equipped wih regenerator, hydraule chopper, over lischarge lit lock, and seat switch Typed _| Not ether ype A or 8. Type3 ‘© The initial value of the “Battery electrolyte level” monitor display is set to of, ‘* Error messages related the EPS are added. ‘© Operation of auto power off function is changed. 13-1 -2. [CHECKING OPERATION OF AUTO POWER OFF FUNCTION ‘ (@Tum on the key switch. @Make sure that all contactors including the EPS are turned off if drivemhydraulic operation is not run for 30 seconds. @Make sure that the key is switched off in 15 minutes ater ths. '13-1-3. | CHECKING DISPLAY OF WARNING FOR BATTERY ELECTROLYTE LEVEL (only for GS battery) @Remove the level sensor to create a low level ~ condition. (@Make sure that the message “REPLENISH REFINED WATER FOR BATTERY* is displayed. 13-1-4, |WIRING CONNECTION OF HOUR METER OPERATION ‘Although, conventionally, the wiring connections of the hour meter have been located near the hydraulic valve, they are moved near the lft side ofthe hydraulic motor pump. Connection procedure> ‘Open the battery cover and connect the accessory wires *BUIRD 1" and “BK. ‘The hour meter starts counting. “ACAITON] (© For other items, see TROUBLESHOOTING of 98W-2101 FBT60. ‘TROUBLESHOOTING FE bow to adjust NEW SICOS60 (Major point only) 13-2-1. [The name and function of mode select switch @Slow speed mode button Change to traveling mode. When the stow speed mode button is tured fon, the speed is regulated to the preset ‘speed. (8094-80% of max speed), ‘*When the slow speed mode button is tumed on, the turtle mark is displayed on the monitor. (Mode select button. henge te sooct made 2p button (2 functions) Seeseane ne farsmate of each selected ow mode. 0) ~L_verten «shonin he tavel hour moter ——— B|6heaiaa SE =e BTRAVEL a. SHR Tmlhurnte @PDown button (2 functions). *Decoate he partnoer ofeach selected o mode Wy wr DOWN bution 90 TROUBLESHOOTING ‘© Showing the hydraulic hour meter. jow to set the each mode Press the mode select button @) 10 adjust the Mode eee button each mode. (@) *The each mode can be changed by pressing the mode select button @ as follows, TOTAL @.QHR] ‘(ermal iow specs, SPEED —_5@%] :specdseting mode POWER 188%) :Powersoting mode 2 [PCCEL STD) :pecetration tein moss © Speed setting mode SPEED Oe 4) The travel speed can be set at 30% through 180% by every 10% by pressing the Up button ® orDown bution ® . @ oe Og 9) ® © SoWWaen UP on ¢ 080%) 2) Tum the slow speed mode button on. 9 TROUBLESHOOTING IJ ‘When the slow speed is set, the preset speed (7), and the “turtle” mark is displayed on the monitor | GEBNOTE| ( When the slow speed mode button is off, the ‘travel speed can not be regulated even if it is set. Also no display of preset speed and the "turtle" mark, @Power setting mode ‘The power can be set at 3 steps, 100%, 75%, and 50% by pressing the Up button @) or Down button @ . @) aw Og \~ © © DOWNBuon = UP baton (60%6-75%-100%) The preset power is dlaplayed at the “POWER® column on the display. (ae cocci Acceleration feeling mode ‘The acceleration feeling mode can be set at 3|ACCEL SOFT] :essyinching ‘modes, Sof, Std (standard) and Full, ACCEL STD} :Nornas ACCEL FULL] ‘Qutereo IIBNOTE]( Boer inching operation can be achieved by ® owe ® ® ‘The preset accelerator fealing is displayed at > the "ACCEL" column on the display. © © DOWN baton UP bation (S0FT-STD-FULL) 92 EB TROUBLESHOOTING ®Option setting 1) Set the rotary switch RS1 to °7*, and tur the key switch on, 2) Press the mode select button @to shit the setting position. *The setting position which flashes can be moved to the right by pressing the mode select button @). ® 3) Press, ow the Up button @ to set: display "1" ®) the Down button @) to reset : display “0” {or each optional specification, Mode select ation [GEBNOTE] (Atter finishing to set or reset, be sure to return © > @ : the rotary switch ASI to "0". @ a © é> [EEBNOTE| (‘When replacing the MPU board, be sure to set) UPbutlon DOWN button the each function same as original setting. OhS6anigo 28 = HOPTION @@11 @118 egeratve contactor Opt) 3 @Language selection on LCD display “Each language can be selected by this operation. 1) Set the rotary switch RS1 to "6". 2) Choose the each language shown below by pressing Up button @) or Down button @ TROUBLESHOOTING * , og |» DOWN ton UP baton ~ Dipl when tuning kay eh on. @: JAPANESE ELI OK 1: ENGLISH MONITORING OK 2: FRENCH CONTROLEUR OK 3: GERMANY UEBERWACHUNG OK 4: SPANISH MONITOR OK 5:DUTCH MONITOR OK BEBNOTE] (Aftor finishing to set or the rotary switch RS1 to ee @Satety monitor symbol. BES “Each monitor symbol can be set by this Ss pe Tae operation. 41) Set the rotary switch RSI 10S" 2) Use the mode select button @ to shift the y> setting position, “tigen wt te a button @. @ ow OPN wo © © OWN bon UP bation EX Trova esooTine 3) Press, the Up button @ to set: display “1 the Down button @ to reset: display “0”. {or each safety monitor symbol == @EBNOTE ‘The aymbol for Travel, Hyd, Steerand) | SAFETY 1110 a01a Brake are presetted as a standard at the factory. (displayed "1") @aB NOTE 13-2-3. ‘After finishing to set or reset, be sure to return the rotary switch RS1 to "0". [Adjustment of starting current and current limitation The starting curent and current limitation can be set by using mode select @), Up @ or Down © button ‘There is no any volume for these adjustment. Zero (0) adjusting for installed current detector Zero (0) adjusting is required for the installed ‘current detector to adjust the starting current ‘and current imitation correctly as follows, 4) Park the truck against a wall, and touch the tip ‘of forks to a wall not to move the truck. Then apply the parking brake lever. 2) Tum the key switch on. Then initialize the mode settings by pressing the Up @) and Down @ button simultaneously for approx. three (3) sec- ‘onds. Each setting (SPEED, POWER, ACCEL) ‘will be initial setting mode with showing "INITIAL IZED" and a beep sound. ‘This “Initialize” operation is also accepted by each manual setting of, Park the truck agains the wal @ ress Up and Down button simultaneously for approx seconds. INITIALIZED ‘TROUBLESHOOTING BJ '3) Apply the clamp on meter (500 amps, ability) on the ‘main lead wire{AL) connected to "DF" or "AL" termi- nal from the traction motor. hou age vn Ragen soni snc ea ois rr tein net Condon on checking? 2 Spee gauty olhe batory elecwoyte more than 128 020°C pressing the mode select button (i) as olows, @) (CURR_START 626] (CURR LIMIT 620) *The “CURR START” will be shown ater key switch on. CURR START 830 TROUBLESHOOTING 3) Operate tho directional switch to forward, epress the foot brake. Then depress the accelerator pedal until the regenerative (forward) contactor just goes on, and hold at that position. Tn case of the truck without regenerative brake, depress the accelerator pedal until the forward contactor goes on. 4) Adjust the starting current on the monitor within specified range by pressing Up @ ‘or Down @ button. [roe] Loe | [rsp | a1 & o* ® Press Down buon when Press. Up baton hen rrondor inden stows monitor indeation shows Tighe en te species lower than the speci vaus. vue, 4 CURR START 9550] TROUBLESHOOTING Ba1usey dre pos xa vo dirs ac em Suu ou, Uoqesodo shoud ey (0) ual 248 "Yeu yey 2q 0a peeds Bunn “ese9 sx Ut {uous ou) uo sjepu Ayoedeo ‘saya ax uo no sau dv} pe: uayya =) pa eyop = one aut uoLIR ek@Spp SI + ANSLIVG SHL SOUVHO & Jo oDessau au eWR NINO fe ‘sbseypsip1010 ye ol Bu, orn somod oneuloiny {Uo 06 pinoys so1NEWeD ssedkg ofo}10) ‘vOUL (E "spuo098 2 JOYE LOH! weLino Jo sae Aq paseeiou aq prnoys wwauiNo ‘one Sunes pow szjenu} ge} uew sow fanes6 y900s0) ‘én antiovoiny | 2 13-2-5.|Check and adjustment for other functions| ‘uowng uNog & 10% dn Burssosd fq (1 18 poyooyo anven ewes eu 29 01 13037 BA. SU ISHIPY Cp => (noooscTanaT BM] nos < 30NL10n) + ‘uoung 10e}08 apow Sussseid Aq opow TAIT BA, 01105 (E "uo Us fey OU UIT] PUR AY, OF LSY LOHMS AveION ALTOS (2 "yun o.oo ‘24 Uyeuuen (=) srUY® _‘98nj PA: "Ye aBEyoA AleweR ou x20UD (L ‘unpeooid iwounsnipe puE x20 $21 vou o1ou Aines8 oypedscy Sanja 40; vopu09 {uonouny) won| on, EB TRouatesHooTING 13-2-4,[Adjustment of other specifications @Adjustment of switch back (plugging! hl, regenerative) braking distance. Spies 0 Sager een at wn Sok key switch on, ae Sa RSTO 2) Press the mode solect button @) to adjust the each mode. “The each mode can be changed by press- ing the mode select button (@) as follows. B®. we ©) Mode select button PLUGGING G83) 7 uapraxmenser REGENERATE G83) ‘(5 sev cctspemon BRAKE TRO 645 Mes, AERP Reversing > um <— ‘Shon back operated ‘Stop andstat revere Brekng distance by swith bck operation @:For the truck without regenerative PLUGGING a9! brake. 3) Set to "PLUGGING" mode by pressing mode ‘select button @) w 5 @ 4) Aatust the plugging braking distance by press- ||) Olas, ingUp @ or Down @ button. l® wy ‘The braking distance will be, UP button DOWN bution ‘shorten by pressing Up 4) button. For shorter distance, Forlonger stance. increased by pressing Down @ button. (100-088-200) Max. Min. 101 TROUBLESHOOTING BE] @®:For the truck with regenerative brake (Option). 3) Set to “REGENERATE” mode by pressing mode select buton 4) Adjust the regenerative braking distance by pressing Up @ orDown @ button, ‘The braking distance will be, ‘shorten by pressing Up @ button. increased by pressing Down @ button, EBNOTE| ( Be sure to check that the regenerative contactor goes off after switch back operation, Then, it goes on again when reversing. EBNOTE) ( Atter finishing the adjustment, be sure to return the rotary switch RS1 to “o" @Adjustment of regenerative braking force. (Option) 1) Set the rotary switch RS1 to "4", and tum the key switch on. ‘The each mode can be changed by press- ing the mode select button @ as follows. REGENERATE 083 ow @) ew ‘Wes © ® Wren Sonn Formcraronanc, Porlnget asuee (10-26-20 anaes PLUGGING 870 REGENERATE 870 BRAKE TRO 645) for Regenerative braking force. ‘by be Option of depressing brake peda 102 ‘TROUBLESHOOTING. ‘Brake peel ogres Sep Regenerative brag fore can be ated 2) Set to "BRAKE TRO” mode by pressing mode select button @) 3) Adjust the regenerative braking force by pressing Up @ or Down @ button. ‘The braking force willbe, ‘Strong by pressing Up @ button. ‘Poor by pressing Down @ button. NOTE Be sure to check thet the forward contactor goes off and the reverse contactor goes on instead with elec- tric braking effect when the brake Pedal is depressed. | BNOTE | 103 ‘After finishing the adjustment, be sure to return the rotary switch RS1 to “O @Level adjustment of regenerative func- tion (Opt.) ‘This adjustment is almost same as the adjustment of IP voltage for SICOS5OI60 control unit. The level adjustment of regenerative function can be adjusted by pressing Up @ or Down @ bution. ‘A: Specitic gravity of the battery electrolyte = more than 1.25 at 20C . 1) Set the rotary switch RS1 to *8*, and turn the ‘key switch on. BRAKE TRG G45) ® : oe |e Smt Sen scmntnny forsee vay me te toveuen oaare) Sa RSTO e REG-CHK LEVEL 26] TROUBLESHOOTING Ba1usey dre pos xa vo dirs ac em Suu ou, Uoqesodo shoud ey (0) ual 248 "Yeu yey 2q 0a peeds Bunn “ese9 sx Ut {uous ou) uo sjepu Ayoedeo ‘saya ax uo no sau dv} pe: uayya =) pa eyop = one aut uoLIR ek@Spp SI + ANSLIVG SHL SOUVHO & Jo oDessau au eWR NINO fe ‘sbseypsip1010 ye ol Bu, orn somod oneuloiny {Uo 06 pinoys so1NEWeD ssedkg ofo}10) ‘vOUL (E "spuo098 2 JOYE LOH! weLino Jo sae Aq paseeiou aq prnoys wwauiNo ‘one Sunes pow szjenu} ge} uew sow fanes6 y900s0) ‘én antiovoiny | 2 13-2-5.|Check and adjustment for other functions| ‘uowng uNog & 10% dn Burssosd fq (1 18 poyooyo anven ewes eu 29 01 13037 BA. SU ISHIPY Cp => (noooscTanaT BM] nos < 30NL10n) + ‘uoung 10e}08 apow Sussseid Aq opow TAIT BA, 01105 (E "uo Us fey OU UIT] PUR AY, OF LSY LOHMS AveION ALTOS (2 "yun o.oo ‘24 Uyeuuen (=) srUY® _‘98nj PA: "Ye aBEyoA AleweR ou x20UD (L ‘unpeooid iwounsnipe puE x20 $21 vou o1ou Aines8 oypedscy Sanja 40; vopu09 {uonouny) won| on, [Ml TROUBLESHOOTING EESES NEW EPS SYSTEM [13-34. [AUTO POWER OFF FUNCTION Make sure that all contactors including the EPS are turned of if drive/hydraulic operation is not run for 30 seconds, [13-3-2.] CHECKING AND ADJUSTMENT @Neutral adjustment of torque sensor «Checking procedure) 5S 1) Tum the key switch of. sontoter 2) Jack up the rear wheels from the ground. '8) Opana side cover at right side. 4) Put a clamp meter to a wre [yellow] or {green} § between EPS controller and EPS motor [DC range} al 5) Tum the key switch on and measure the indication at the clamp meter without steering operation. (= at neu- tral steet) Ifthe indication shows 0A, itis normal tee 6) If any current is flown, adjust the potentiometer by the following procedure. EPS moor | oo] s}o] a] >| a] o]= ‘Gloag error History arm he Key switch on Under this concition) “Type A: Equipped with no options. ‘Type B: Equipped with regenerator, hydraulic chopper, ‘over discharge lit lock, and seal switch. ‘Type ©: Not either type A or B. “For the model other than type A or B, the options must be set as type C. ACATON ‘The "F* position of the ASO is the clear function for the error 109 history memory. Pay attention not to turn on/otf the key switch ‘to prevent the accidental clear. @RS1 : Monitor selection SI is used for the adjustments of current level, starting current, current limitation, | /O checking, 00, for various adjustments, Refer to the below table in details. TROUBLESHOOTING I] RSL: Monitor setecton POSTION FUNCTIONS REMARKS 7 | Neral montor our meter display Tota, Travelng, Pyare) Curent Level of TFC) —_| agus; ) minus value ndeaton: Up ® patton | [earenttoer ora amen) (+) ps vale dation = Oown © burton Goren Gan of Fe) | aqua cal ca > Cited ae Up @ sen ‘Current Gain ot ta (Armature) (Actual current) < (Displayed value) Down ® button 7 [Sasa eure approx BOA Carentan for waved | 100-4408 speed 64 (Fas Law speed st mew aw Tieapoed? 264 (Fast Fgh speed (2nd miro swe). 2 Pratepees O64 Fast ‘achrrertt weed 0=64 Fast ‘Alachment2 seed Om 64 Fast Piogging brake dsiance [0-100 4 [Regenerative rake astarce | 0-100 Regeneralve bate force [0-100 3] Wenior symbole TRAVEL, HYD, STEER BATT OIL LOAD, BRARE 3 | Language sieoon efanese, Engh, French, Geman, Spanish, Dich 7 [option set Ty: Bypass Regen. conic | owt oaset tage ian | 0-30 3 | Seting letters on mentoring | (Usedin leony) 7A | Daspay of baery dscharge_| (Uregin acon). B LEor io meany + | Merry No: ror Ne = Tava de, Hrd nodD; Err history memoy@ | Same as SIGO8 60, SICOS 60 | Beaplay of etactod nodal — | Dspay of made stain by ASO | rere daia Gein acon) [00 memory cata ‘Usedin facon) =| Hourmeterwnen troubled | Dspiay of hour metorwhen waibied Each setting should be conforming to ‘List of setting values". (See Page 107) 110 ROUBLESHOOTING SELF DIAGNOSIS HISTORY MEMORY AND VO CHECK 13-6-1 [SELF DIAGNOSIS HISTORY MEMORY | 33 | cot :FuseePS Power sleeing fe @ Sain osm oso 4 35 [G80 CONTACTOREPS | EPS contactor, EPS contoter 96 | * REDUCE THE LOAD Ovetoaded “| on Ch ay [er | ner eance on © storage of bato ot on Fos | sreczocrencowserrrBvTE | shotge tbat sistas | (08) a {GIARGE THE BATTERY + | Nadi chro Eto eal RELEASE ACCEL TO NEUTRAL + | Asner epee bale poner on * OFF HYD. LEVER TO NEUTRAL » | Hye lovers operated belore power on "Tho folowing parts canna be dagnoved and cepayed 1 Dlodes "Di, 2,D3and04 8) Motors 2) Connectors 2} Capacitors for surge absorbing) Apartot MPU beard 10) Back conc of forward reverse contactor 2) Apa of outer sensor 7)Apartolmiceowiches —11)L\CD display 4) Apartotpre-anergzing boars 8) Wie harness "The eror messages forthe current sensor andthe pe-eneriing boa ae depend onthe deter conditions to dsp, 113 [3] Traveling motion mode No. ‘Traveling motion (condition) is displayed when the trouble has occurred. ‘TROUBLESHOOTING oe Cont (0] ode Contnt 30 Nowra rr] For or, Rogen, contactor ON ot | Fomard| Forfex, Ragon. cortactorON [22 [Let | Pugaing check 2 Fomara| aging check 25 [uatiwn | Speed cont as |Fwara] Sed cont 24 [Lt tum | Bypass contactor ON | Forward | Bypass contactor - ON 25 [ua tin| Bypass contacor= OFF 5 [Fowara Bypass conactor= OFF 26 [Let um | Bypass cont 06 [Forward | Bypass cont 27 [etm | Regenerave riacor~ OFF 07 [Foward] Regenerative covactor- OFF [28 Let wn | Regenerate coreacior—ON 08 |Fomwars | Reseneraveconactor-ON | 29|Lettum | Pre-enerong 09 | Forward | Pre-energing 1 _ 2A | Loft tu | Regenerative control aa Forward | Regereatve con 28 [Lat tum | Regen vate: ForRo coatr~ON 06 onward Beg. el Fv conader-ON |2C Let tun | Regun vated ForRo. coat -ON oC Forward | Rep, bald Foie centctor-ON ]20 ettun | Pre-eneting 2 00 | Fonard | Pre-enerona 2 2E Let tn| Repereraive commer? oc |romvara] Repererave contol 2 ar [Rotem | Foxe, Regen. contactor -ON 11 [Reverse | ForAev, Regen. contactor ON | 38 [Agttun | Plugging check 12 Reverse | Ping check 58 Agtun | Speed cont 13 [Reverso | Speed conto! 34 Ritu | Bypass contactor = ON 14 [Reverse | Bypass contador “ON 35 [Rept | Bypass contactor OFF 15 [ Reverso | Bypass contactor ~ OFF 26 wn | Bypass conte 16 [Reverse | Bypas coro! 27 | igen Regoerave contador ~ OFF 17 Reverse | Regenerate coracor= OFF |e [rghiun| Regenerate contactor ~ON 1 Revere | Regenerate contctr= ON |30[ Ritu | Pre-enerang 1 1 Reverse | Pre-nerong 1 aa gen | Regenerative contd 1a Reverse | Regenerative conc [Agha | Rogen, wae: cota ON 1B] Reverse | fgen. tae! Foxe conacar—ON [2c ghten| Regen. Watd Fee. contactor ON 1c] eves | Fegen. taka -Fooconactr—ON [20 Rat ten Pre-oeraing 2 10] Rovere | Pre-enaang 2 SE [Rtn | Repenerave cone a 1€ Reverse | Regenerate coral? [4] Hydraulic motion mode No. Hydraulic motion (condition) is displayed when the trouble has occurred. With hydrauic chopper Without hydraulic chopper © | Hydraulic neutral Hydraulic contactor - OFF 1. | Hydraulic contactor ~ ON Hydraulic contactor = ON 2 | Hydraulic contro! "4 ‘TROUBLESHOOTING ©: Format 2 of history memory 8) Press Up @ or Down @ button to change (call) the each Error memory No. It there has been a problem at least once, the bit shows “1” I not, it shows “0” on the monitor. “0” .. No trouble 1" . “Troubled (at least once) (@) oy ® ow w @) ‘SOWNDution ‘story memory No, can be changed (cated) ‘UP baton ‘by pressing UpfDown button. 15 Fret yne,| 7met | emer | shot | ame | aot | aden | totet | ove evo tl [SER [ees goon aR ERE rue enn Sr Eee [eos [fii |SSaron gE nae om ae (hie [MoemulSteer [Bircor Bi | Benn Bein (een (Si) (mer /neouce Sion ame lo (itl (REM. ‘TROUBLESHOOTING How to clear the error history memories. > 1) Turn the key switch OFF, 2) Set the rotary switch RSO to [F]. 3) Tum the key switch ON. (to START) (The memories are cleared.) 4) Tum the key switch OFF. 5) Set the rotary switch SO at the original pos!- tion, 116 FB rouseshooTIne 13-6-2. |W CHECK VO (InpuvOutput} check is the function that the input and ‘output signal for the microcomputer can be displayed on the Sot RS 110°" LCD by the binary code of [1] or [0] to check if each part is normal. Approx. 90 points of input/output signals can be checked, (Procedure of display > 1) Set the rolay switch RSt to [E]. and tum the Key switch on 2) Select the port (No. 00 through 03, No.0A through oF, | (@) ow No.10 through 18) by UP @) or DOWN © button. | a ‘) Rete tothe V0 table forthe ceil ofeach por, g %