TCM FB-8 Series Page 14 Service Manual Download

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Table 04.2

Name

Shape

Thread size

Material

Division by

strength

Surface

treatment

Part number

Hex. head

bolt

Normal

M4 - M8 coarse and

M10 - M39 fine

SS400

4.6

Black

01101-

Nominal symbol

SS400

4.6

Yellow
chromate

01100- “

S45C

6.8

01103- “

SCM435, Boron steel

8.8

01106- “

SCM435, Boron steel

10.9

01107- “

BsBME1

—

01108- “

Coarse

M10 - M39 coarse

SS400

4.6

Black

01112- “

SS400

4.6

Yellow
Chromate

01110- “

S45C

6.8

01113- “

SCM435, Boron steel

8.8

01116- “

SCM435, Boron steel

10.9

01119- “

Full thread

(normal,

coarse)

M10 - M39 coarse

SS400

4.6

Black

01115- “

SS400

4.6

Yellow
Chromate

01111- “

S45C

6.8

01114- “

SCM435, Boron steel

8.8

01117- “

Full thread

(normal)

M4 - M8 coarse and

M10 - M39 fine

SS400

4.6

Black

01121- “

SS400

4.6

Yellow
Chromate

01120- “

S45C

6.8

01123- “

SCM435, Boron steel

8.8

01126- “

SCM435, Boron steel

10.9

01127- “

BsBME1

—

01128- “

w. socket

head

M4 - M8 coarse and

M10 - M39 fine

SS400

4.6

Black

01131- “

SS400

4.6

Yellow
Chromate

01130- “

S45C

6.8

01133- “

SCM435, Boron steel

8.8

01136- “

SCM435, Boron steel

10.9

01137- “

w. hole in

threads

M4 - M8 coarse and

M10 - M39 fine

SS400

4.6

Black

01161- “

SS400

4.6

Yellow
Chromate

01160- “

S45C

6.8

01163- “

SCM435, Boron steel

8.8

01166- “

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)

Summary of Contents for FB-8 Series

Page 1: ...B 7 P O B E T C M WD A I S F O R K L I F TTRUCK C o u n t e r 8 a l a n c e d F B O S F B 5 s F B 8 s F B 2 0 s F B 2 5 s F B 3 0 s F B 2 5 S L B F B 2 5 s v F B 3 0 s v F B 3 5 s s TCMC O R P O R A...

Page 2: ......

Page 3: ...city batteries and high power drive motor are used the first class acceleration gradeability and traveling performance are achieved Controllability is also improved by the standard equipped power stee...

Page 4: ......

Page 5: ...aisle C mm in 1690 66 5 1730 68 1 1895 79 6 Dimensions mm in Overall length includ fork D 2875 113 2 2975 117 1 3315 130 5 Overall width E 1070 42 1 1150 45 3 Overall height Overhead guard F 2080 81...

Page 6: ...9 2050 80 7 2250 88 6 Dimensions mm in Overall length includ fork D 3355 132 3460 136 3580 140 9 3805 149 8 Overall width E 1150 45 3 1225 48 2 1380 54 3 Overall height Overhead guard F 2125 83 7 LB 2...

Page 7: ...Unit mm in Fig 1 Overall Dimensions E N J Q H B C A 1 2 5t 4030 3 3 5t 4260 3000 P F M K D G L 1 2 5 t 4030 158 7 3 3 5 t 4260 167 7 3000 118 1...

Page 8: ...6 8 1 97 0 2140 50 0 84 3 1 97 0 2360 50 0 92 9 1 97 0 EPS type FB25 1970 50 0 77 6 1 97 0 Orbitrol type 1800 70 9 1890 74 4 FB20 2070 81 5 FB25 2100 82 7 2290 90 2 2500 98 4 Power steering relief pre...

Page 9: ...ch 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...

Page 10: ...m when installing otherwise they might stay twisted causing oil leakage 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 rec...

Page 11: ...ibly 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 Reinstallin...

Page 12: ...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...

Page 13: ...efer to the Shop Manual and Service Manual of your truck model when 1 Special nuts are used 2 Synthetic resin or rubber is used for tightening 3 Specified tightening torque is given Table 04 1 Strengt...

Page 14: ...01111 S45C 6 8 01114 SCM435 Boron steel 8 8 01117 Full thread normal M4 M8 coarse and M10 M39 fine SS400 4 6 Black 01121 SS400 4 6 Yellow Chromate 01120 S45C 6 8 01123 SCM435 Boron steel 8 8 01126 SCM...

Page 15: ...5 15 0 22 6 27 7 41 5 43 4 65 3 67 5 100 99 1 148 139 208 188 282 234 351 342 515 480 720 650 974 792 1190 1020 1540 0 82 1 24 1 70 2 53 2 85 4 29 7 00 10 5 13 9 20 9 24 4 36 6 39 0 55 8 61 6 92 4 84...

Page 16: ...45 0 55 1 82 7 86 9 129 135 202 198 296 278 416 376 565 469 702 685 1030 958 1440 1290 1950 1580 2370 2050 3070 1 65 2 47 3 36 5 06 5 70 8 54 14 0 21 0 27 8 41 7 48 6 73 1 78 1 117 123 185 168 252 24...

Page 17: ...37 11 0 11 6 17 4 18 0 27 0 26 4 39 5 37 0 55 5 50 2 75 3 62 6 93 8 91 3 137 128 192 173 259 211 316 273 409 2 19 3 30 4 49 6 74 7 60 11 4 18 6 28 0 37 1 55 7 64 9 97 4 104 156 164 246 224 336 320 48...

Page 18: ...109 162 171 255 265 396 387 582 544 815 738 1110 919 1380 1330 2020 1880 2820 2540 3810 3110 4650 4010 6020 3 22 4 83 6 60 9 91 11 2 16 8 27 4 41 1 54 5 81 9 95 4 143 153 230 241 362 330 493 471 707 6...

Page 19: ...through full travel NOTE If your lift truck is used near a port or coastal area the lift chains might be damaged from salty breezes After a storm or typhoon it is advisable to wash them with water bef...

Page 20: ...l How to read oil level H mark Highest position of the standard truck L mark Lowest position of the standard truck S mark For trucks with a lift height of 6 m or more or for special trucks the oil lev...

Page 21: ...7 25592 42311 10A Fuse F8 27232 62111 2A Oil tank Suction filter 216G7 52051 Lights standard trucks Head lights Bulb 271A2 42421 48V 40W Assembly 277H2 42001 Front combination lights Bulb Turn signal...

Page 22: ......

Page 23: ...ENANCE OF BEARINGS 22 3 CONTROL SYSTEM 23 3 1 GENERAL DESCRIPTION 23 3 1 1 INVERTER UNIT 23 3 1 2 ACCELERATOR PEDAL 30 4 DRIVE UNIT AND DRIVE AXLE 31 4 1 GENERAL DESCRIPTION 31 4 1 1 DRIVE UNIT 31 4 1...

Page 24: ...REAR AXLE 72 6B 1 5 ADJUSTING PRELOAD OF REAR WHEEL BEARING 76 6B 2 MAINTENANCE 77 6B 2 1 MAINTENANCE FOR ACTUATOR 77 7 HYDRAULIC SYSTEM 81 7 1 GENERAL DESCRIPTION 81 7 1 1 MAIN PUMP 82 7 1 2 CONTROL...

Page 25: ...NG HEIGHT OF CARRIAGE 118 8 2 3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE 120 8 2 4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE 122 8 2 5 PROCEDURE FOR ADDING OR SUBTRACTING SHIMS 123 9 ELECTR...

Page 26: ......

Page 27: ...er Rated power 6 0 kVA 8 5 kVA Rated current 17 A 24 A Power supply voltage 205 390 440 V Applicable battery capacity 320 500 Ah 5 h 450 700 Ah 5 h Output Voltage 51 64 V Current 80 20 A 115 29 A Truc...

Page 28: ...ttery unit has 36 battery cells 1 Battery care The most important point in battery care is to prevent overdischarge The deeper the battery discharges the shorter its life becomes See Figure 1 2 The ap...

Page 29: ...ler by equalizing charge specific gravity adjustment will be required Giving an equalizing charge more times than necessary will overcharge the battery and its service life will be shortened For a tru...

Page 30: ...15 8 FB18 8 FB20 8 FB25 8 FB25 8LB FB25 8V Fig 1 4 Battery Charger 1 to 2 5 ton Trucks Insulation tube BAND Secondary wire CM Contactor Primary wire Thermal relay secondary wire primary wire thermal r...

Page 31: ...g 1 5 Battery Charger 3 to 3 5 ton Trucks Thermal relay current settings Transformer model Setting A M105B 40 M105C 26 M105D Secondary wire CM Contactor Primary wire Thermal relay 1 BATTERY AND CHARGE...

Page 32: ...aries with the periods of time Change therefore the taps from one to another according to the average of supply voltages which to charger receives for the period of time during which the battery is no...

Page 33: ...ght side frame is a 3 phase full wave rectification type which converts AC to DC The current rectified by the diode flows through the fuse F6 to charge the battery 130A Fig 1 7 Diode DIODE to TRANSFOR...

Page 34: ...Operation panel The operation panel is located on the left side of the cabinet and equipped with charger control switches lamps and service power outlet Fig 1 8 Operation Panel 1 BATTERY AND CHARGER O...

Page 35: ...ithin 120 hours battery charging is automatically started again Make sure that the CHARGING lamp is turned off turn off the power supply at the facility side Remove the plug at the truck side with its...

Page 36: ...Therefore 100 of the battery capacity can be used after consecutive holidays However if 100 of the battery capacity is used the battery service life will be short It is recommended to adopt a high cap...

Page 37: ...ol circuit inside the LCD panel detects the voltage level and then timer starts counting down the time This timer is automatically set to a proper amount of time according to how much the battery has...

Page 38: ...NOTE 1 BATTERY 12...

Page 39: ...28 V 26 V 42 V Rated current 260 A 280 A 260 A Weight 34 kg 75 lbs 43 kg 94 8 lbs 47 kg 104 lbs Note On trucks with an Orbitrol steering system the pump motors of the 1 ton and 2 ton class trucks are...

Page 40: ...14 Fig 2 1 Drive Motor Installation DRIVE UNIT DRIVE AXLE DRIVE MOTOR 2 MOTORS...

Page 41: ...m B B Tightening torque 10 to 12 N m 100 to 120 kgf cm 7 4 to 8 9 lbf ft ROTATION SENSOR A THERMO SENSOR CONNECTOR U PHASE TERMINAL V PHASE TERMINAL W PHASE TERMINAL View looking from A View looking...

Page 42: ...delta connection The sketch b in Figure 2 4 shows a typical Y connection which is widely used for the connection of induction motors When the directions A A B B C C in which current flows into the coi...

Page 43: ...ain pump Its rotation is controlled by the load handling inverter built in the speed controller only when the lift lever is operated Except that the pump motor is used for starting or stopping the rot...

Page 44: ...2 7 Pump Motor Tightening torque 10 to 12 N m 100 to 120 kgf cm 7 4 to 8 9 lbf ft U PHASE TERMINAL V PHASE TERMINAL W PHASE TERMINAL View looking from A View looking from B ROTATION SENSOR THERMO SENS...

Page 45: ...ation Motor frame bearing and cover No remarkable vibration or amplitude increase allowed compared with usual operation Visual and audible checks If allowable limit is exceeded stop the motor and remo...

Page 46: ...ned areas Check for damage or rough surface due to corrosion visually Clean Connections Visually check that connections are correct and not loose and that proper insulation is ensured Retighten Lead w...

Page 47: ...se the insulation will be impaired Use a dry cloth or soft brush for cleaning If the insulation resistance of the coil is lower than the specified value dry the coil by heating it to 80 to 90 C 176 to...

Page 48: ...ollowing table as a rough guide Operation time 8 12 hours day 12 hours day Replacement intervals Once every 6 years Once every 3 years Earlier replacement may be required if the motor is used at a pla...

Page 49: ...inverter unit is a device consisting of a CPU board and FET modules and converts direct current to 3 phase alternating current The CPU board receives various electric signals through the operation of...

Page 50: ...1 0 to 1 8 ton Trucks excluding those with an Orbitrol steering system MC 2P 2P 36P 36P 16P 36P 36P WP VP UP WD VD UD F1 EPS EPS CONTROLLER MC CONTACTOR INVERTER UNIT PUMP MOTOR INVERTER UNIT DRIVE M...

Page 51: ...excluding those with an Orbitrol steering system 3 CONTROL SYSTEM L J C S D W D R I V E I N V E R T E R U N I T W T O M T E M P S E N S O R D M R E V S E N S O R A O I M R E V S E N S O R B S T E E R...

Page 52: ...us Model selection option 1 Model selection option 2 1 ton class Opened Opened 2 ton class Connected Connected 3 ton class Connected Connected C onnected To be connected to the signal wire GND The dir...

Page 53: ...system and 1 ton Class Trucks with an Orbitrol steering system MC WP VP UP WD VD UD F1 2P 2P EPS 36P 16P 36P 36P 36P INVERTER UNIT PUMP MOTOR MC CONTACTOR INVERTER UNIT DRIVE MOTOR EPS CONTROLLER Not...

Page 54: ...Class Trucks with an Orbitrol steering system Batt DC48V Batt DC72V 48V For trucks with capacities from 3 to 3 5 tons For trucks with capacities from 3 to 3 5 tons 3 CONTROL SYSTEM j F f U K E Y i m l...

Page 55: ...steering wheel being turned clockwise S hort circuit SIG and terminals of the sensor not in use Truck model selection switch status Model selection option 1 Model selection option 2 1 ton class Opene...

Page 56: ...r The potentiometer converts pedal effort into voltage change and sends it to the controller 1 Apply a voltage of 5 0 01 V between 187 and 186 2 Turn potentiometer clockwise in neutral state and lock...

Page 57: ...4 1 through 4 3 The drive gear is splined to the output shaft of the drive motor being in mesh with the counter gear 1 The drive gear is supported by two ball bearings on the case The rotation of the...

Page 58: ...450 to 550 kgf cm 389 4 to 477 9 lbf in COUNTER GEAR 2 O RING STOPPER COUNTER GEAR 1 DRIVE GEAR RING GEAR PINION SHAFT WASHER PINION GEAR WASHER SIDE GEAR TAPER PIN Tightening torque 34 3 to 44 N m 3...

Page 59: ...SPACER TAPERED ROLLER BEARING STOPPER COUNTER GEAR 1 DRIVE GEAR RING GEAR SPIDER WASHER PINION GEAR SIDE GEAR WASHER TAPERED ROLLER BEARING Tightening torque 34 3 to 44 N m 350 to 450 kgf cm 303 6 to...

Page 60: ...ER PINION GEAR SIDE GEAR WASHER TAPERED ROLLER BEARING Tightening torque 34 3 to 44 N m 350 to 450 kgf cm 303 6 to 389 4 lbf in O RING O RING MOTOR Tightening torque 278 to 416 N m 2800 to 4200 kgf cm...

Page 61: ...gs and is driven by the axle shaft TAPERED ROLLER BEARING OIL SEAL ADJUSTMENT NUT LOCK NUT Tightening torque 98 to 113 N m 1000 to 1150 kgf cm 870 to 1000 lbf in Apply LOCTITE 262 Tightening torque 15...

Page 62: ...T Tightening torque 370 to 420 N m 3770 to 4280 kgf cm 3275 to 3717 lbf in Tightening torque 140 to 160 N m 1430 to 1630 kgf cm 1240 to 1420 lbf in Apply LOCTITE 270 Tightening torque 216 to 235 N m 2...

Page 63: ...M WHEEL BRAKE OIL SEAL TAPERED ROLLER BEARING OIL SEAL HUB ADJUSTMENT NUT LOCK NUT Tightening torque 471 to 549 N m 4800 to 5600 kgf cm 4170 to 4860 lbf in Fill 50 of the space with grease 100 cm 3 at...

Page 64: ...f m 7 23 lbf ft torque and loosen it by 1 2 turn 3 Set the spring balancer to the stud bolt Adjust the starting force of the hub while tightening the adjustment nut gradually Starting force 4 9 to 6 9...

Page 65: ...in 348 x 76 x 7 67 mm 13 7 x 3 0 x 0 31 in Surface area 4 x 13530 mm2 4 x 30 in 2 4 x 16600 mm2 4 x 25 7 in 2 4 x 26400 mm2 4 x 40 9 in 2 Parking brake Type Front two wheel braking internal expansion...

Page 66: ...5 110mm FB30 35 Fig 5 2 Brake Pedal BRAKE SWITCH RESERVE TANK MASTER CYLINDER BRAKE SWITCH OPERATION DISTANCE 5 10 mm 1 97 3 94 in Height 97 mm 3 8 in FB10 25 110 mm 4 3 in FB30 35 View looking from A...

Page 67: ...n the piston slide inside the cylinder when brake pedal is operated The check valve is operated so that the proper pressure remains in the wheel cylinder and brake pipe This pressure keeps pushing the...

Page 68: ...th the anchor pin When the secondary shoe comes in contact with the anchor pin the friction force is generated between the brake lining and the brake drum and the primary shoe pushes the secondary sho...

Page 69: ...Figure 5 7 At this step the section B of the lever turns the adjuster As the braking force becomes stronger the more force is applied to the threaded area of the adjuster and the force of the lever ca...

Page 70: ...ake is released and the operator leaves the seat the alarm buzzer will keep sounding How to release the alarm Sit down or pull on the parking brake lever to set the brakes Adjusting brake switch Loose...

Page 71: ...ctional view C C Shoe expanding direction Sectional view of wheel cyl 1 BRAKE LEVER 2 SECONDARY SHOE 3 E RETAINER 4 WHEEL CYLINDER 5 RETURN SPRING 6 STRUT 7 SPRING 8 SHOE HOLD DOWN PIN 9 PRIMARY SHOE...

Page 72: ...ctional view B B Shoe expanding direction Sectional view of wheel cyl 1 BRAKE LEVER 2 SECONDARY SHOE 3 E RETAINER 4 WHEEL CYLINDER 5 RETURN SPRING 6 STRUT 7 SPRING 8 SHOE HOLD DOWN PIN 9 PRIMARY SHOE...

Page 73: ...ocedure for adjusting the brake pedal with the wheel brake and hub removed 5 2 1 DISASSEMBLING WHEEL BRAKE 1 Remove the shoe hold down pin adjuster lever adjuster and spring from the secondary shoe Fi...

Page 74: ...eel cylinder Remove the wheel cylinder from the backing plate 6 Remove the E retainer which secures the parking brake cable to the backing plate After that remove the bolt securing the backing plate a...

Page 75: ...d or deformed one 3 Measure the free length of the wheel cylinder spring If the length is out of the standard value replace the spring 4 Measure the brake lining thickness and replace any excessively...

Page 76: ...backing plate Tightening torque 17 7 to 26 5 N m 180 to 270 kgf cm 156 7 to 234 5 lbf in 3 Install the backing plate on the drive axle Tightening torque 117 7 to 137 3 N m 1200 to 1400 kgf cm 1042 to...

Page 77: ...attached to the adjuster lever side After reassembling check that the tip of the adjuster lever comes in contact with the adjuster teeth 10 Install the brake pipe on the wheel cylinder 11 Measure the...

Page 78: ...uster return with the lever they are adjusted properly after mounting the brake system on the truck 2 If the operation described above does not occur by pushing up the adjuster lever take the followin...

Page 79: ...97mm FB10 25 110mm FB30 35 Fig 5 29 BRAKE SWITCH Brake switch operating direction 5 10 mm 0 2 0 4 in Adjusting brake switch 1 Make sure that the pedal upheight is the value shown in Figure 5 29 Loose...

Page 80: ...ining Repair or replace 2 Deformed backing plate or loose bolts Repair or replace 3 Shoes deformed or improperly installed Repair or replace 4 Lining unevenly worn Replace 5 Defective wheel bearing Re...

Page 81: ...eaction type Discharge 96 cm3 5 86 in 3 rev Power cylinder Type Double acting piston type Cylinder bore 71 mm 2 8 in Piston rod diameter 40 mm 1 57 in Stroke 132 mm 5 20 in 146 mm 5 75 in Flow divider...

Page 82: ...installed onto the truck frame through a center pin with bushing and cap and it cradles around this center pin A B C D Fig 6A 1 Steering Axle for 1 0 to 1 8 ton Trucks 1 2 JOINT LEFT JOINT RIGHT Tigh...

Page 83: ...SPHERICAL BUSHING BUSHING OIL SEAL NEEDLE BEARING THRUST BEARING O RING NEEDLE BEARING OIL SEAL KING PIN OIL SEAL TAPERED ROLLER BEARING TAPERED ROLLER BEARING ADJUSTMENT NUT COTTER PIN CAP Fill 50 of...

Page 84: ...tening torque 68 to 100 N m 7 to 10 2 kgf m 50 6 to 73 8 lbf ft Apply THREEBOND 1324 KNUCKLE LEFT KNUCKLE RIGHT View looking from B Detail of A POWER CYLINDER KING PIN POTENTIOMETER See Figure 6A 4 Po...

Page 85: ...bearing are lubricated by grease supplied through the grease fittings at top and bottom of the king pin 2 Wheel hub The wheel hub is mounted on the knuckle spindle with two tapered roller bearings an...

Page 86: ...At the center of the steering wheel is the horn button The steering shaft is connected to the drive shaft of the orbitrol The steering wheel can be moved to a certain extent back and forth to suit the...

Page 87: ...Fig 6A 6 Steering Wheel View looking from A View looking from B View looking from C Front of the truck Front of the truck Front of the truck COMBINATION SWITCH ASSEMBLY 6A STEERING SYSTEM ORBITROL ty...

Page 88: ...to the pump tank right and left chambers of the cylinder Between the inlet port and return port is a check valve The metering device consists of an internally toothed stator and an externally toothed...

Page 89: ...outlet for the hydraulic motor but not to grooves nor in the spool and thus the oil remain unmoved b When steering wheel is turned counterclock wise As the steering wheel is turned counterclock wise...

Page 90: ...der flows passing through the cylinder port L groove in the housing oil hole in the sleeve groove in the spool oil hole 22 in the sleeve and groove in the housing back to the oil tank 2 Relationship b...

Page 91: ...port and the suction port opens to allow the oil to flow from the cylinder to the suction side making it possible to steer the truck manually 6A 1 4 POWER CYLINDER The power cylinder is attached to th...

Page 92: ...NOTE 6 STEERING SYSTEM 66...

Page 93: ...35 mm 9 3 in Controller Type Voltage controlling type Rated voltage 48 V 72 V Current limit Max 40 A Max 45 A Rear axle Type Elliot type Steering angle Inner wheel 85 8 83 5 Outer wheel 55 6 56 4 King...

Page 94: ...e force The controller converts the signal from the potentiometer into the direction and amount of electric current which flows into the motor If an external force is applied to the steering wheel the...

Page 95: ...LL NUT 9 NEEDLE BEARING 10 OIL SEAL 11 THRUST BEARING 12 SPRING 13 SENSOR HOUSING 14 O RING 15 THRUST BEARING 16 LOCK NUT 17 FRONT COVER 18 SLIDE RING 19 ARM 20 ROLLER 21 POTENTIOMETER 22 SHIMS 23 LOC...

Page 96: ...70 Fig 6B 3 Steering Linkage STEERING WHEEL STEERING WHEEL LOCK LEVER JOINT STEERING GEARBOX DRAG LINK ACTUATOR View looking from A 6B STEERING SYSTEM EPS type...

Page 97: ...71 Fig 6B 4 Steering Wheel Front of the truck COMBINATION SWITCH ASSEMBLY Front of the truck Front of the truck View looking from A View looking from B View looking from C 6B STEERING SYSTEM EPS type...

Page 98: ...rods and knuckles The rear axle support with a bushing press fitted is attached to the support pins located at the front and rear of the axle The support is bolted to the rear frame The axle is so mo...

Page 99: ...Axle 1 to 1 8 ton Trucks KNUCKLE RIGHT TIE ROD RIGHT TIE ROD LEFT KNUCKLE LEFT CENTER ARM KING PIN POTENTIOMETER View looking from B Detail of A Point notched surface toward knuckle s shaft 6B STEERI...

Page 100: ...5 ton Trucks KNUCKLE RIGHT TIE ROD RIGHT TIE ROD LEFT KNUCKLE LEFT CENTER ARM KING PIN POTENTIOMETER View looking from B Detail of A Point notched surface toward knuckle s shaft SUPPORT FRONT SUPPORT...

Page 101: ...ing pin with its load The upper and lower needle bearings and the thrust bearing are lubricated with grease through the grease fittings located on the upper and lower sides of the king pin 2 Wheel hub...

Page 102: ...hten it with a torque of 9 8 N m 1 kgf m 86 7 lbf in 4 Gently tapping the hub with a mallet make sure there is no looseness 5 Tighten the hub with a mallet give it a few turns Then measure the startin...

Page 103: ...n a lying position Remove the motor securing bolts then remove the motor Note Do not give a strong shock to the motor Remove the packing from the motor fitting surface Apply grease to the joint Instal...

Page 104: ...e threaded areas of the connector and lock nut Then install the ball joint 3 Replacing the boot Hold the connector section in a vise Fig 6B 13 BOOT BALL JOINT Hold this section by vise Fig 6B 14 BOOT...

Page 105: ...threaded areas of the connector and the lock nut then install the connector as specified in Figure 6B 19 Tightening torque 176 5 to 215 8 N m 18 to 22 kgf m 130 to 159 lbf ft Clamp the both ends of th...

Page 106: ...NOTE 6 STEERING SYSTEM 80...

Page 107: ...ht is 3000 mm 118 1 in Tilt cylinder Type Double acting piston type Cylinder inner dia 65 mm 2 56 in 70 mm 2 8 in Rod outer dia 30 mm 1 2 in Stroke 120 mm 4 72 in 139 mm 5 47 in 151 mm 5 94 in Hydraul...

Page 108: ...7 1 2 CONTROL VALVE The control valve consists of two plunger sections an outlet section and an inlet section with a relief valve as shown in Figure 7 2 The inlet section relief valve is a cartridge...

Page 109: ...2 B2 A1 G P T Fig 7 2 Control Valve PORT G LIFT LOCK RELEASE SCREW PORT T PORT P SOLENOID VALVE FOR LIFT LOCK POTENTIOMETER LIFT SPOOL TILT SPOOL PORT B2 PORT A2 PORT A1 Hydraulic circuit diagram 7 HY...

Page 110: ...is transmitted through the rod to the corresponding plunger Fig 7 3 Valve control Installing the valve switch Install the valve switch so that it turns on when the plunger is pushed in 0 8 0 1 mm 0 03...

Page 111: ...fied loosen the relief valve lock nut and adjust it by turning the adjustment If the measured pressure is higher than the specified once lower it by turning the adjustment screw counterclockwise till...

Page 112: ...RAIN PLUG Detail of part A 1 Replacing filters Remove the drain plug and drain the oil tank Clean the tank cover surrounding area Then remove the cover securing bolts Remove the suction and return hos...

Page 113: ...e oil from the cylinder flows back to the tank via the piston holes A and B In this step if the flow rate passing through the holes are within a range of the flow rate which can be controlled by the f...

Page 114: ...LOCK BOLT 3 WIPER SEAL 4 ROD PACKING 5 CYLINDER CAP 6 O RING 7 BUSHING 8 ROD 9 CYLINDER 10 LOCK RING 11 WEAR RING 12 PACKING 13 PISTON 14 SNAP RING 15 SHEAVE 16 CHAIN 17 ANCHOR PIN 18 ADJUSTMENT NUT...

Page 115: ...LOCK BOLT 3 WIPER SEAL 4 ROD PACKING 5 CYLINDER CAP 6 O RING 7 BUSHING 8 ROD 9 CYLINDER 10 LOCK RING 11 WEAR RING 12 PACKING 13 PISTON 14 SNAP RING 15 SHEAVE 16 CHAIN 17 ANCHOR PIN 18 ADJUSTMENT NUT...

Page 116: ...CK BOLT 3 WIPER SEAL 4 ROD PACKING 5 CYLINDER CAP 6 O RING 7 BUSHING 8 ROD 9 CYLINDER 10 LOCK RING 11 WEAR RING 12 PACKING 13 PISTON 14 SNAP RING 15 SHEAVE 16 CHAIN 17 ANCHOR PIN 18 ADJUSTMENT NUT 19...

Page 117: ...OCK BOLT 3 WIPER SEAL 4 ROD PACKING 5 CYLINDER CAP 6 O RING 7 BUSHING 8 ROD 9 CYLINDER 10 LOCK RING 11 WEAR RING 12 PACKING 13 PISTON 14 SNAP RING 15 SHEAVE 16 CHAIN 17 ANCHOR PIN 18 ADJUSTMENT NUT 19...

Page 118: ...hen the force that pushes the piston produced by the pressure differential is greater than the spring force the piston moves to the right The hole D is narrowed by the hole C to limit the flow rate an...

Page 119: ...he piston to the right Therefore the hole D is narrowed by the hole C so that the quantity of oil flowing through the hole D is restricted to reduce the forks lowering speed When the forks are raised...

Page 120: ...itted bushing packing and dust seal which provide oil tightness for the piston rod and in the cylinder cap and also supports piston rod When the tilt lever is pushed forward high pressure oil flows in...

Page 121: ...95 Fig 7 16 Hydraulic Oil Piping Orbitrol type OIL TANK TILT CYLINDER RIGHT CONTROL VALVE to LIFT CYLINDER MAIN PUMP TILT CYLINDER LEFT STEERING CYLINDER ORBITROL 7 HYDRAULIC SYSTEM...

Page 122: ...96 Fig 7 17 Hydraulic Oil Piping EPS type OIL TANK TILT CYLINDER RIGHT CONTROL VALVE to LIFT CYLINDER MAIN PUMP TILT CYLINDER LEFT 7 HYDRAULIC SYSTEM...

Page 123: ...t not to damage the parts 4 Disassembly is a means of finding out the cause of a trouble Observe the procedure for disassembling the pump 5 Before disassembly make sure you get new packings gaskets an...

Page 124: ...mp body with a plastic mallet If the gaskets remain inside the pump body move them toward the rear cover side Remove the pump body If the gaskets remain inside the pump body move them toward the front...

Page 125: ...Fig 7 24 Fig 7 25 Fig 7 26 Fig 7 27 Holding the front side plate remove the drive gear Put the mark FV on the front side plate at the drive gear side and remove the side plate Turn over the front cov...

Page 126: ...100 Remove the oil seal from the front cover Fig 7 28 7 HYDRAULIC SYSTEM...

Page 127: ...pe surface Oil pressure is too high Useful limit Wipe depth limit less than 0 04 mm 0 0016 in c Check for signs of interference with gear at discharge side Runout of gears Pump s performance is not af...

Page 128: ...overs Check the inner surfaces of bushings for roughness or wear The bushings are made of copper with the back plate made of lead brass The back plate consists of porous and PTFE polytetrafluoro ethyl...

Page 129: ...ve Suction side The E gasket should be installed with its flat surface pointing to the bottom of the groove A A section Discharge side Suction side b 3 shaped gasket Flat surface B B section Flat surf...

Page 130: ...t side Counterclockwise rotation Front side Clockwise rotation Rear side Discharge port smaller radius Driven side Drive side Suction port larger radius Projection to be always pointed to drive side F...

Page 131: ...nstall them with their larger pressure angle sides pointed to each other Failure to do so might damage the gear teeth a Engagement of 1st pump Engagement surfaces shaded sections Smaller pressure angl...

Page 132: ...s shown in Figure 7 32 Fig 7 42 Discharge side Gasket groove E gasket Suction side The rear cover is commonly used for the L counterclockwise rotation type and the R clockwise rotation type Align the...

Page 133: ...seal Oil seal Main lip Install the four bolts and tighten them to the specified torque Tightening torque 88 3 98 N m 9 10 kgf m 782 867 lbf in Remove the pump from the vice and put it on a work bench...

Page 134: ...de at which corner is chamfered Front cover Oil seal Fig 7 51 Oil seal guide Oil seal snap 4 0 16 17 0 67 R2 0 08 20 R5 0 2 2 0 08 62 2 44 71 2 8 92 3 622 23 00 0 05 0 9060 0 002 22 05 0 05 0 0 868 0...

Page 135: ...nutes Make sure the pressure is less than 0 98 MPa 10 kgf cm2 142 psi c Increase the pump speed to 1500 to 2000 rpm and let the pump operate for about 10 minutes d Keeping the pump speed at 1500 to 20...

Page 136: ...ged from gear pump Low oil level in oil tank Add oil to specified level Clogged suction tube or strainer Clean or change oil if necessary Gear pump pressure won t rise Worn pressure plate Worn bearing...

Page 137: ...ydraulic Mast tilting system Hydraulic Lift chain Leaf chain BL534 Leaf chain BL634 Leaf chain BL823 Leaf chain BL834 Mast cross section Outer mast A 44 mm 1 73 in B 102 5 mm 4 04 in C 134 5 mm 5 30 i...

Page 138: ...the mast assembly on the drive axle The center of the outer channel is supported by the frame via the tilt cylinders The mast assembly tilts forward and rearward by expanding and contracting the tilt...

Page 139: ...of the inner channel each installed on the end roller shaft by bearings The end roller shafts are welded to the carriage The upper end rollers are shim adjusted while the lower end rollers are secure...

Page 140: ...114 VM 7P4 VM 7P7 VM 7P9 VM 7P1 1 FORK 2 CARRIAGE 3 END ROLLER 4 SHIM 5 SNAP RING 6 SIDE ROLLER 7 SHIM 8 SPACER Fig 8 3 Carriage 8 LOAD HANDLING SYSTEM...

Page 141: ...nd the side rollers support lateral load so that the inner channel and carriage are raised and lowered smoothly Fig 8 4 Locations of Rollers 1 to 1 8 ton Trucks LIFT CYLINDER OUTER CHANNEL INNER CHANN...

Page 142: ...5 Locations of Rollers 2 to 3 0 ton Trucks LIFT CYLINDER OUTER CHANNEL INNER CHANNEL SIDE ROLLER CARRIAGE SLIPPER END ROLLER END ROLLER END ROLLER END ROLLER Upper section Lower section 8 LOAD HANDLI...

Page 143: ...Locations of Rollers 3 5 ton Trucks LIFT CYLINDER OUTER CHANNEL INNER CHANNEL SIDE ROLLER CARRIAGE SLIPPER END ROLLER END ROLLER END ROLLER END ROLLER Upper section Lower section SIDE ROLLER 8 LOAD HA...

Page 144: ...e lift cylinder whose rod stops first Shim thickness 0 2 and 0 5 mm 0 0079 and 0 0197 in 4 Adjust the lift chain tension 8 2 2 ADJUSTING HEIGHT OF CARRIAGE 1 Stop the truck on a level surface and put...

Page 145: ...ver 4000 mm 157 5 in the dimension B is 50 mm 1 97 in 4 Adjust the tension of the right and left chains to the same value with the chain anchor pin at the mast side when the fork is at the bottom posi...

Page 146: ...oved in step Check the stamp of S or SS and install the roller which is marked the same stamp pointing the stamp side to the carriage side Remove the snap ring and remove the upper end rollers with a...

Page 147: ...r enters inside of the outer channel 10 Contract the lift cylinder rods to lower the inner channels gradually Place each roller of the carriage into the inner channel 11 Engage the chain with the shea...

Page 148: ...es using caution not to loosen the fittings at the cylinder side 6 Operate the crane to lower the inner channel gradually and remove the end rollers from the lower section of the inner channel At the...

Page 149: ...e opposite side and each channel Clearance between roller and channel 0 to 0 5 mm 0 to 0 197 in Fig 8 18 0 to 0 5 mm at upper side SHIM Make contact with one side 0 to 0 5 mm 0 to 0 197 in Note Apply...

Page 150: ...NOTE 8 LOAD HANDLING SYSTEM 124...

Page 151: ...lights 48 V 10 W 25 W Turn signal lights 48 V 23 W Back up lights 48 V 10 W 9 1 SYSTEM DESCRIPTION The electric system components excluding the speed controller and its related components get their el...

Page 152: ...102 100 110 CN Fig 9 1 Relay Unit 9 1 1 RELAY UNIT The relay unit is a semi conductor switch that uses transistors to perform the switching The mechanical switch input signals cause the relay unit to...

Page 153: ...2 Relay Unit Circuit Ref TURN SIGNAL RIGHT TURN SIGNAL LEFT HEADLIGHTS TAIL SIDE MARKER BRAKE SIGNAL OUTPUT CHIME 20 W BACK UP LIGHT 35 W BEACON LIGHT OPTIONAL EQUIPMENT CHIME 0 15 A 35 W BEACON LIGH...

Page 154: ...ed with headlights front combination light assemblies rear combination light assemblies and a work light They can be turned on and off with the integrated turn signal and light switch lever as shown i...

Page 155: ...nected to each other to activate the RT relay inside the relay unit thus turning on the side marker lights in the front combination light assemblies the tail lights in the rear combination light assem...

Page 156: ...when the lever is moved backward terminals TB and TR are connected to each other and the turn signals in the right front and rear combination light assemblies flash 25W 25W 25W 25W N R L TB TR TL F 9...

Page 157: ...131 2 3 5t 1 1 8t Fig 9 6 Locations of lights View looking from A HEAD LIGHT FRONT COMBINATION LIGHT REAR COMBINATION LIGHT 1 to 1 8 ton trucks 2 to 3 5 ton trucks 9 ELECTRIC SYSTEM...

Page 158: ...A 1 LENS 2 RIM 3 HOUSING 4 REFLECTOR 5 GASKET 6 BULB Fig 9 7 Head Lights 3 Head lights The head lights are installed on the upper part of the front legs of the overhead guard Sectional view A A 9 ELEC...

Page 159: ...ignal light and a side marker light The rear combination has a turn signal light a brake light and a tail light incorporated in it Front combination light TURN SIGNAL LIGHT SIDE MARKER LIGHT TURN SIGN...

Page 160: ...minate the bulb and reflector surfaces With the gasket install the lens and reflector 2 Rear and front combination lights Remove the screws securing the lens and body and separate the lens from the bo...

Page 161: ...2 2 6 FAST CHARGE RESISTANCE RCH 20 2 2 7 FUSE F1 21 2 2 8 ACCELERATOR PEDAL 21 2 2 9 MOTOR ROTATION SENSOR 22 2 2 10 LIFT POTENTIOMETER 23 2 2 11 STEERING POTENTIOMETER 24 2 2 12 LCD PANEL 25 2 2 13...

Page 162: ...TTING THE PARAMETERS 73 4 2 PARAMETER SETUP SCREEN 73 4 3 KEYPAD 73 4 4 SCREEN OPERATION 74 4 5 SUPPLEMENTARY INFORMATION ABOUT LEVEL SETTING 78 4 6 SETTING THE PASSWORDS 80 5 DESCRIPTION OF THE FUNCT...

Page 163: ...rom CN2D 33 The voltage at CN2D 9 varies according to the amount of accelerator pedal effort 3 Voltage at CN2D 8 and CN2D 9 terminals Unit V Terminal Accelerator pedal not pressed Accelerator pedal fu...

Page 164: ...itch 1 This switch tells the inverter unit whether the F R lever is in the forward or reverse travel position 2 Voltage between CN1D 18 and CN1D 19 Unit V Lever position N Neutral F Forward R Reverse...

Page 165: ...speed 2 When the drive motor runs a pulsed voltage is present between CN2D 3 and CN2D 15 and between CN2D 5 and CN2D 16 2 1 WR 17 WG 16 CN2D 17 CN2D 6 9 Drive motor thermosensor 1 Detects the drive m...

Page 166: ...tch 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 Voltage between CN9 1 15 and CN9 1 8 te...

Page 167: ...ied from the CN2P 32 terminal 2 Potentiometer signal The voltage between CN2P 8 and CN2P 20 terminals varies as follows according to the amount of lever movement away from the neutral position Lever p...

Page 168: ...motor rotation sensor 1 Detects the pump motor speed 2 When the pump motor runs a pulsed voltage is generated between CN2P 5 and CN2P 16 terminals CN2P 17 CN2P 6 2 1 YW 39 G 38 6 Pump motor thermosen...

Page 169: ...ch model selection switch MODE SEL 1 MODE SEL 2 1 to 1 8 ton trucks OFF OFF 2 to 2 5 ton trucks ON OFF 3 to 3 5 ton trucks ON ON Note The load handling unit differs depending on the truck model Theref...

Page 170: ...when it is turned clockwise Power Steering System Orbitrol type SS1 SS2 SSC ESS 1G B Z 15V A GND LY 249 LG 246 BG 243 BR 230 BY 244 CN2P 25 CN2P 2 CN2P 1 CN2P 13 CN2P 14 1 Steering wheel sensor 1 The...

Page 171: ...1D 7 RW11 PO RG216 CN1D 8 CN1P 8 CN1P 7 CN1E 17 PO YG 208 RL 100 RL 100 2 Auto power off relay If no operation traveling load handling nor power steering is performed for more than 15 minutes the auto...

Page 172: ...1P 24 CN1P 22 and CN1E 34 terminals When the battery is connected the battery voltage is present at these terminals These terminals are used to detect the battery voltage Drive motor inverter unit Pum...

Page 173: ...N1 DW motor terminal DV motor terminal DU motor terminal Inverter unit drive motor EPS unit Fuse F1 Fast charge resistance RCH Main contactor PU motor terminal PV motor terminal PW motor terminal Nega...

Page 174: ...Positive terminal Negative terminal Inverter unit pump motor Fuse F1 Positive terminal Main contactor Fast charge resistance RCH Positive terminal Negative terminal PW motor terminal PV motor termina...

Page 175: ...including settings can be displayed on the LCD panel by operating the switch panel Checking procedure Loose bolts and poor connector contacts A loose nut or bolt which secure a controllers power termi...

Page 176: ...ger through tapped through holes in the aluminum inverter base and remove the inverter unit from its aluminum fin Thru holes Top view Do not hold the inverter unit by the cover s grooves Do not hold t...

Page 177: ...erter base and remove the inverter unit from its aluminum fin Top view Thru holes Do not hold the inverter unit by the cover s grooves Do not hold the connectors Thru holes CAUTION Do not hold the inv...

Page 178: ...hose with an Orbitrol steering system is an S type 1 Main circuit terminal location and internal circuit diagram 2 Connector pin numbers CN1D P CN2D P 2 1 13 25 36 24 12 2 1 12 24 36 25 13 N N VB VB C...

Page 179: ...the main circuit defective if 0 is seen V N V N 2 or 3 k Defective if 0 or N V 2 or 3 k to The judgment varies according to charge status of the capacitors in the main circuit defective if 0 is seen W...

Page 180: ...rucks with an Orbitrol steering system do not have an EPS motor controller The EPS motor controller uses a motor wire connector with a VB wire and an N wire as an external harness 1 Main circuit termi...

Page 181: ...is seen A N A N 2 or 3 k Defective if 0 or N A 2 or 3 k to The judgment varies according to charge status of the capacitors in the main circuit defective if 0 is seen B N B N 2 or 3 k Defective if 0...

Page 182: ...udgment about 20 Good Defective replace contactor with a new one Checking the contacts Check the contacts visually replacing any contactor with a new one if any of the contact has a severely rough sur...

Page 183: ...ry voltage Good 0 V Defective Replace the fuse with a new one Note If the fuse is blown find the cause of the blown fuse overloading shorting or grounding and take the necessary repair measures before...

Page 184: ...er supply to both the Vcc terminal and the GND terminal of the motor rotation sensor Connect an analog multi meter to both the Vout terminal and the GND terminal Rotate the output shaft of the motor a...

Page 185: ...a signal according to the tilt angle of the lift lever The potentiometer is located in the lift section of the control valve Checking procedure Control valve Resistance using a digital multimeter Mea...

Page 186: ...Using the steering memory switch 1 With the key switch turned off connect a steering memory switch part number 280B2 60991 to the 3P coupler near the center of the floorboard on the side where the tru...

Page 187: ...efly to the Y7 terminal Remove it immediately The buzzer will sound for 1 second The full right position will have been stored in memory 6 Return the steering wheel to the center and turn the key swit...

Page 188: ...icable truck model CM contactor Thermal relay setting Input voltage Thermal relay setting range FB10 8 FB15 8 FB18 8 281E2 62661 13A 3 50 60Hz 380 390 V 430 440 V 9 to 13 A FB20 8 FB25 8 281E2 62651 1...

Page 189: ...button is pressed and 5 V when the button is not pressed 3 Checking the Mode button Measure the voltage between the CN9 1 7 terminal WG and the CN9 1 8 terminal Gy on the LCD panel The voltage reading...

Page 190: ...e voltage should be as follows 5 V when the start button is pressed and 0 V when the start button is released 3 Checking the stop button Measure the voltage between the CN1 14 WY and the CN9 1 5 BR on...

Page 191: ...Zero adjustment should be made Measurement point Probe Normal value Black Red 60 20 Black Red U Black Red U Black Red 15 10 V Black Red V Black Red 15 10 W Black Red W Black Red 15 10 U Black Red 15...

Page 192: ...charge button for more than 3 seconds OFF 3 Press start button when the button is pressed ON 31 seconds after pressing OFF 4 Checking is over Timer counts up normally OFF When the charge timer is def...

Page 193: ...procedure Disconnect the motor sensor connectors Set the multimeter to a resistance range of x1000 Measure the resistance between the terminals according to the table given below Determine whether the...

Page 194: ...ecking procedure Measure the resistance between terminals with the multimeter in the resistance range minimum range Standard value IG1 GND VF Inverter CN1 8 0 for F for positions other than F IG1 GND...

Page 195: ...voltage V F Drive motor current sensor 1 voltage V K Lift current sensor 1 voltage V B Accelerator 2 POT output voltage V G Drive motor current sensor 2 voltage V L Lift current sensor 2 voltage V C L...

Page 196: ...1 05 0 9 common to all models H Pump motor inverter internal temp C K Lift current sensor 1 voltage V 2 49 2 49 2 49 common to all models L Lift current sensor 2 voltage V 2 49 2 49 2 49 common to al...

Page 197: ...G BY ERROR CODE If no error code is displayed see 3 6 TROUBLESHOOTING BY PROBLEM Start trouble diagnosis 2 Perform the procedure in 3 2 CHECKING BEFORE TROUBLESHOOTING Is any error code shown on the L...

Page 198: ...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 co...

Page 199: ...fter 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 di...

Page 200: ...output of drive and pump motors The battery discharge indicator level rises above the warning level factory set to Level 2 The battery discharge indicator level drops below the warning level factory...

Page 201: ...tation sensor defective The A or B phase pulse is missing The A and B phase pulses are missing The truck won t travel Automatically resets when the input returns to normal After the accelerator is tur...

Page 202: ...input too low V phase current offset abnormal AD input too high The truck won t travel Turn the key switch OFF 25 51 W phase current detection abnormal AD input too low W phase current detection abnor...

Page 203: ...ically resets when the input returns to normal 94 54 307 Accelerator potentiometer not positioned properly The truck can be driven normally Automatically resets when the input returns to normal When t...

Page 204: ...the power steering data has no errors when the key switch is turned ON The truck can be driven normally Automatically resets when the input returns to normal 64 56 Abnormal battery voltage detected Th...

Page 205: ...andling system won t work The temp drops to less than 115 C 311 F The temp rises above 155 C 311 F 37 58 406 Pump motor temp too high The load handling system works but the output current is limited T...

Page 206: ...nt offset abnormal AD input too high The load handling system won t work Turn the key switch OFF 25 60 W phase current detection abnormal AD input too low W phase current detection abnormal AD input t...

Page 207: ...eering systems are inoperative Contactor OFF Turn the key switch OFF 21 61 Load short circuit Motor interphase short circuited The load handling system won t work Turn the key switch OFF 22 61 Drive d...

Page 208: ...r at least 5 seconds 2 ton class trucks 3 6A or more continues for at least 6 seconds 3 ton class trucks 3 4A or more continues for at least 7 seconds 17 63 Continuous energizing protection 2 The EPS...

Page 209: ...ing Error code conditions LED code Page Data reception error If this error is detected before startup T he EPS power steering system is disabled If this error is detected after startup S peed detectio...

Page 210: ...ms are inoperative These error codes refer to errors that occur while loading the program or when an incorrect program version was loaded Replace the LCD panel with a new one Wrench 078 Version loadin...

Page 211: ...when the accelerator pedal and the F R lever are in neutral Check the voltage of the potentiometer for accelerator 1 Repair the accelerator 1 potentiometer or wiring Check the voltage of the potentiom...

Page 212: ...when the input returns to normal Check the voltage at the CN1D 18 and CN1D 19 terminals on the drive motor inverter unit Repair the combination switch or wiring Replace the drive motor inverter unit 5...

Page 213: ...he drive motor thermosensor for proper installation Install properly Check the voltage between CD2D 6 and CD2D 17 on the drive motor inverter unit Repair the drive motor or wiring Replace the drive mo...

Page 214: ...tor inverter unit 11 211 06 Accelerator 2 sensor defective Automatically resets when the input returns to normal Check the accelerator 2 sensor connector for proper connection Connect properly Check t...

Page 215: ...inverter unit U phase FET open Resets when the key switch is turned OFF 214 17 Drive motor inverter unit V phase FET open Resets when the key switch is turned OFF 215 18 Drive motor inverter unit W ph...

Page 216: ...e the motor cables from U V and W phase Check for any electrical leaks between the motor cable and the positive and negative terminals Correct the cable Check the bars and bolts that connect between t...

Page 217: ...coil Repair the contactor Check the harness between CN1D 22 CN1D 35 and CNMC contactor coil connector on the drive motor inverter unit Correct the wiring Replace the drive motor inverter unit 20 318 8...

Page 218: ...ror Communication wire broken Automatically resets when the input returns to normal Check the connectors for the CN1D 1 3 13 14 and 15 terminals on the drive motor inverter for looseness Connect secur...

Page 219: ...short circuit Correct the cable Check the CN1D 24 terminal on the drive motor inverter unit for proper connection Connect properly Check the harness for the CN1D 24 terminal on the drive motor inverte...

Page 220: ...rn the key switch OFF and allow the controller to cool down for 30 minutes Check the drive and pump motor inverter units for loose screws Retighten Replace the pump motor inverter unit 3 404 31 Pump m...

Page 221: ...fective Abnormal bearing Stall signals detected continuously Automatically resets when the input returns to normal Check the voltage between the pump motor inverter unit CN2P 5 16 29 and the speed sen...

Page 222: ...or cable Correct the cable Replace the pump motor inverter unit 9 416 24 V phase current detection abnormal AD input too low AD input too high Resets when the key switch is turned OFF 416 25 V phase c...

Page 223: ...t Correct the wiring Check the RCH rapid charger resistor Repair the RCH Check the harness between CN1D 11 CN1D 12 and CNCH on the drive motor inverter unit Correct the wiring Replace the pump motor i...

Page 224: ...the connectors for the CN1E 8 9 10 11 and 12 terminals on the EPS motor controller for looseness Connect securely Check each harness for the connectors described in items and Correct the wiring Remove...

Page 225: ...r and bolts that connect between the drive and pump motor inverter units for looseness Retighten Check the EPS motor controller s positive and negative terminals and motor wiring Correct the wiring Ch...

Page 226: ...ned OFF Check the EPS motor connector for looseness Connect properly Check the EPS motor wiring Correct the wiring Check the EPS motor Repair the EPS motor Replace the EPS motor controller 6 11 FET te...

Page 227: ...the connectors for the CN1E 8 9 10 11 12 terminals on the EPS motor controller for looseness Connect securely Check the harness for those connectors Correct the wiring Remove the EPS motor controller...

Page 228: ...RL 5 R R5 RY101 RL100 F4 CN1 11 LCD panel Key switch Turn it ON Below10 V 40 V or more LCD panel Key switch Key switch Key switch Below10 V Below10 V Below10 V Below10 V 40 V or more 40 V or more 40...

Page 229: ...ve motor inverter or Pump motor inverter or EPS motor controller PO relay 40 V or more Below 10 V PO relay PO relay Key switch MC contactor Key switch Key switch 40 V or more 40 V or more 40 V or more...

Page 230: ...potentiometer LY93 Accelerator 2 potentiometer LG92 A Below 0 5 V B Below 0 2 V Key switch Turn it ON F R lever Shift into F or R Parking brake lever Release Accelerator pedal Press fully 53 WBr in F...

Page 231: ...Below 1 5 V Accelerator LY93 LG92 3 1 V or more In maintenance mode D Steering potentiometer output voltage Drive motor inverter 2 4 to 2 7V Other than 2 4 to 2 7 V Steering angle potentiometer YL43 A...

Page 232: ...4 8 V or more 0 5 to below 1 1 V 2 4 to 4 5 V Pump motor inverter Pump motor inverter Key switch Turn it ON Tilt lever Tilt fully Pump motor inverter YR20 BL9 Tilt switch YR20 BL9 OK NG GR189 WR188 Y...

Page 233: ...to 40 V Orbitrol steering system In maintenance mode O Pump motor rpm In maintenance mode O Pump motor rpm Steering wheel angle sensor BR 230 BG 243 LY 249 BY 244 LG 246 Pump motor inverter Key switc...

Page 234: ...72 3 TROUBLESHOOTING GUIDE NOTE...

Page 235: ...detected LCD panel The actual temperature detected is the displayed value minus 15 Parameter group Parameter item Setting BUTTON BUTTON Use these buttons to increase or decrease the parameter group n...

Page 236: ...ed 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...

Page 237: ...yed 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 th...

Page 238: ...P COMPLETE screen is displayed The controller MC contactor will be activated and the DATA TRANSMISSION screen shown on the left will be displayed This screen indicates that the new setting is being se...

Page 239: ...tput mode enabled Lower speed limit when steering SSC is activated The speed obtained when the max speed limit flag is enabled Seat switch enabled 15 km h or less S mode disabled Accelerator pedal neu...

Page 240: ...You can specify the accelerator power curve to be used 3 PARAMETER 1 No 13 Speed alarm output level option Sets the speed at which the speed alarm relay RS is turned on The output will be turned ON wh...

Page 241: ...d 12 6 PARAMETER 3 No 4 Heater ON OFF control This parameter item is displayed on the LCD panel but its factory setting cannot be changed On LCD panels designed for use in a freezer a heater is instal...

Page 242: ...P E button simultaneously while PASSWORD SETUP screen 1 is being displayed Use these buttons to toggle between PASSWORD SETUP screens 1 and 2 The zero on the screen indicates the selected digit The s...

Page 243: ...in neutral 3 Load handling system neutral interlock Prevents the load handling system from starting suddenly when the key switch is turned ON while a load handling lever is operated Activation condit...

Page 244: ...tion Anti roll OFF regeneration Brake OFF regeneration Anti roll OFF regeneration Stopped Output OFF Output OFF Output OFF Output OFF Reverse travel Accelerator neutral regeneration Anti roll OFF rege...

Page 245: ...g G Green W White L Blue Y Yellow O Orange Lg Light green P Pink Sb Light blue Table 6 2 Connector symbol Connecting type Plug in side Receptacle side Remarks Plug in type Housing The numbers signify...

Page 246: ...84 6 ELECTRIC WIRING NOTE...

Page 247: ...G 160 L R 177 BW 211 L 131 207 W 8 16 W 213 GY 178 108 WY 1 9 LW 132 Y 104 WBr 53 GW 81 BR 9 10 20 GR 82 G 161 LG 24 P 176 1 11 LB 137 GO 111 B 2 RG 102 RY 101 RL 100 YG 208 RB 141 WL 54 W 162 O 15 L...

Page 248: ...WY 108 P 176 16 13 4 1 178 177 R GY L LW 132 131 208 213 207 211 YG W W BW 104 Y 249 230 BR LY LG BG 243 246 244 BY B 2 LB 137 GR 112 BW 82 15 O GW 81 WBr WL 54 53 109 WG 107 WR GO 111 102 RG RL 100...

Page 249: ...16 B 2 1 R 177 BW 211 L 131 207 W W 213 GY 178 108 WY Y 104 GW 81 GR 82 YG 208 LW 132 WBr 53 BR 9 G 161 LG 24 P 176 LB 137 WL 54 W 162 O 15 L 160 GL 105 GR 106 WR 107 BW 112 LY 212 WG 109 3 6 1 4 100...

Page 250: ...3 YW 181 YB 30 RL 100 4 LG 24 BR 9 WY 168 LB 180 LR 95 G 25 WG 169 WBr 53 WL 54 Y 7 1 12 25 36 RW 31 GW 28 WR 17 LG 92 LY 93 YL 43 RB 32 GB 29 WG 16 BG 186 LB 184 YB 42 RY 34 GY 33 LW 187 WR 185 YR 44...

Page 251: ...97 WB 98 B 2 B 2 2 9 4 BR P 176 B 2 4 B 2 Y 7 WY 108 178 177 R GY L LW 132 131 208 213 207 211 YG W W BW 104 Y 13 16 4 1 249 230 BR LY LG BG 243 246 244 BY P 176 109 WG 107 WR 102 RG B 2 1 GL 105 106...

Page 252: ...UNIT PARKING ALARM EPS MOTOR EPS TORQUE POTENTIOMETER PRESSURE SENSOR STEERING POTENTIOMETER HEAD LIGHT RIGHT FRONT COMBINATION LIGHT RIGHT OPTION VALVE SWITCH ATT2 OPTION VALVE SWITCH ATT1 OPTION VAL...

Page 253: ...ING ALARM EPS MOTOR EPS TORQUE POTENTIOMETER PRESSURE SENSOR STEERING POTENTIOMETER HEAD LIGHT RIGHT FRONT COMBINATION LIGHT RIGHT OPTION VALVE SWITCH ATT2 OPTION VALVE SWITCH ATT1 OPTION VALVE SWITCH...

Page 254: ...AY UNIT PARKING ALARM EPS MOTOR EPS TORQUE POTENTIOMETER PRESSURE SENSOR STEERING POTENTIOMETER HEAD LIGHT RIGHT FRONT COMBINATION LIGHT RIGHT OPTION VALVE SWITCH ATT2 OPTION VALVE SWITCH ATT1 OPTION...

Page 255: ...2D 17 CN2D 6 CN1P 8 CN1P 7 CN1P 24 CN1P 22 CN1P 35 CN1P 3 CN1P 1 CN1P 15 CN1P 13 CN1P 20 CN1P 16 CN1P 17 CN1P 18 CN1P 28 CN2P 8 CN2P 32 CN2P 20 CN2P 17 CN2P 6 CN2P 5 CN2P 29 CN2P 16 CN1E 9 CN1E 11 CN1...

Page 256: ...20 CN1P 16 CN1P 17 CN1P 18 CN1P 28 CN2P 32 CN2P 20 CN2P 8 CN2P 17 CN2P 6 CN2P 29 CN2P 5 CN2P 16 CN1D 19 CN1D 18 CN1D 12 CN1D 11 CN1D 35 CN1D 22 CN9 1 11 CN3E 2 CN3E 1 CN1D 5 CN1D 16 CN1D 17 CN1D 28 C...

Page 257: ...No SEB 7P0BE Issued July 2012 Revised December 2012 MARKETING GROUP 6 22 7 Minami Oi Shinagawa ku Tokyo 140 0013 Japan FAX Japan 81 3 6730 3371 All rights reserved JB 1212010 HO Printed in Japan...

Page 258: ......

Page 259: ...n m o m Z C F H d o H H M 0 M Z 0 m O m C O R P O R A T I O N T C M...

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TCM FB-8 Series, Service Manual

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