Acroba SerManual FA15-30

No.
SEB-80BBE
R
FORKLIFT TRUCK
FA15B
FA20B
FA25B
FA30B
TCM CORPORATION
No. SEB-80BBE
FOREWORD
TCM’s ACROBA-ε series battery-powered lift trucks come equipped with an induction-motor drive
system to offer sideways travel which could not achieved by conventional lift trucks. In addition, this series
offers a variety of features, such as a substantially reduced minimum turning radius by “spin turn” and
reduced operator fatigue thanks to the turning driver’s seat which turns 45° to the right when the shift lever
is put into reverse.
This Service Manual is written to provide maintenance personnel with information about the design of the
Acroba series lift trucks and maintenance instructions for them. Read this manual thoroughly and become
completely familiar with the trucks before proceeding with servicing.
The specifications are subject to change without notice.
August 2001
No. SEB-80BBE
SPECIFICATIONS
Truck model
FA15B FA20B FA25B FA30B
Item
Performance
Max. load kg [lbs] 1500 [3307.5] 2000 [4410] 2500 [5512.5] 3000 [6615]
Basic load center mm [in] 500 [19.7]
Lift height mm [in] 3000 [118.1]
Tilt angle fwd-bwd (°) 6 - 10
Free lift mm [in] A 155 [6.1] 160 [6.3] 165 [6.5]
Lift speed*1 mm/s [ft/min]
(unloaded) 650 [128.0] 620 [122.1] 550 [108.3]
(loaded) 430 [84.7] 370 [72.9] 350 [68.9] 320 [63.0]
Traveling speed*1 km/h [mph]
(unloaded) 17.5 [10.9] 17.0 [10.6] 16.0 [9.9]
(loaded) 16.0 [9.9] 15.5 [9.7] 14.0 [8.7]
Gradeability
(loaded)*1 1/5 1/6 1/7 1/8
Minimum turning radius mm [in] B 1710 [67.3] 1900 [74.8] 2055 [80.9]
Dimensions
Overall length mm [in] C 3050 [120] 3275 [129] 3425 [135] 3620 [143]
Overall width mm [in] D 1115 [43.9] 1230 [48.4] 1290 [50.8]
Overall height
(at overhead guard) mm [in] E 2100 [82.7] 2150 [84.6]
Overall height
(with extended mast) mm [in] F 4030 [158.7] 4260 [168]
Wheel base mm [in] G 1390 [54.7] 1550 [61] 1640 [64.6]
Tread mm [in]
(front) mm [in] H 930 [36.6] 1020 [40.2] 1060 [41.7]
(rear) 950 [37.4] 1020 [40.2] 1080 [42.5]
Fork Overhang mm [in] J 420 [16.5] 455 [17.9] 495 [19.5]
Rear overhang mm [in] K 300 [11.8] 310 [12.2] 340 [13.4] 390 [15.4]
Fork size mm [in]
(length L x width M x thickness N) 920x100x35 920x122x40 1070x122x40 1070x125x45
[36.2x3.9x1.4] [36.2x4.8x1.6] [42.1x4.8x1.6] [42.1x4.9x1.8]
Fork spacing mm [in] P 200-920 [7.9-36.2] 245-1020 [9.6- 40.2] 250-1090 [9.8-42.9]
Under clearance (at frame) mm [in] Q 90 [3.5] 100 [3.9] 115 [4.5]
Weight
Operating weight kg [lbs] 3270 [7210] 3960 [8732] 4300 [9482] 5080 [11201]
*1 Values in the Super mode.

No. SEB-80BBE
Unit: mm [in]
A: Free lift
Fig. 1 External View

No. SEB-80BBE
TABLE OF CONTENTS
1. BATTERY ..................................................................................................................................... 1
1.1 GENERAL DESCRIPTION ......................................................................................................... 1
1.1.1 BATTERY CARE ..................................................................................................................... 2
1.1.2 CHARGING THE BATTERY.................................................................................................. 2
1.1.3 CHARGER ............................................................................................................................... 3
1.1.4 CHARGING PROCEDURE .................................................................................................... 18
2. MOTORS ...................................................................................................................................... 21
2.1.1 DRIVE MOTOR....................................................................................................................... 21
2.1.2 PUMP MOTOR ........................................................................................................................ 23
2.1.3 OPERATING PRINCIPLE OF 3-PHASE INDUCTION MOTOR.......................................... 25
2.2 MAINTENANCE.......................................................................................................................... 26
2.2.1 DAILY MAINTENANCE ........................................................................................................ 26
2.2.2 PERIODIC INSPECTION ........................................................................................................ 27
2.2.3 MAINTENANCE OF BEARINGS .......................................................................................... 29
3. CONTROL SYSTEM ............................................................................................................... 31

3.1.1 INVERTER ............................................................................................................................... 31
3.1.2 VALVE CONTROLLER .......................................................................................................... 35
3.1.3 ACCELERATOR PEDALS ..................................................................................................... 40
3.2 TROUBLESHOOTING ................................................................................................................ 42
3.2.1 CAUTIONS .............................................................................................................................. 42
3.2.2 HOW TO USE TROUBLESHOOTING GUIDE ..................................................................... 42
3.2.3 ERROR CODES SHOWN BY LED ........................................................................................ 43
3.2.4 CHECK BEFORE TROUBLESHOOTING ............................................................................. 43
3.2.5 TROUBLESHOOTING PROBLEMS KNOWN BY DISPLAY ............................................. 44
3.2.6 TROUBLESHOOTING INDIVIDUAL PROBLEMS ............................................................. 60
3.2.7 INSPECTING MAJOR COMPONENTS ................................................................................ 63
3.2.8 BOLT TORQUE FOR EACH PART ........................................................................................ 66
3.3 ADJUSTMENT............................................................................................................................. 67
3.3.1 CONTROLLER ........................................................................................................................ 67
4. DRIVE AXLE ............................................................................................................................... 69

4.1.1 FRONT AXLE ......................................................................................................................... 69
No. SEB-80BBE
4.1.2 FRONT SIDE-CYLINDER ...................................................................................................... 76

4.1.3 DRIVE UNIT ........................................................................................................................... 77
5. STEERING SYSTEM .............................................................................................................. 79

5.1.1 STEERING UNIT .................................................................................................................... 80
5.1.2 ORBITROL .............................................................................................................................. 82
5.1.3 PRIORITY VALVE .................................................................................................................. 83
5.1.4 POWER CYLINDER ............................................................................................................... 84
5.1.5 SHIFT CYLINDER .................................................................................................................. 85
5.1.6 STEERING AXLE ................................................................................................................... 86
5.1.7 FRONT WHEEL CONTROL LEVER .................................................................................... 90
6. BRAKE SYSTEM ...................................................................................................................... 93

6.1.1 BRAKE CALIPER ................................................................................................................... 93
6.1.2 MASTER CYLINDER ............................................................................................................. 95
6.1.3 PARKING BRAKE .................................................................................................................. 96
6.2 MAINTENANCE.......................................................................................................................... 97
6.2.1 ADJUSTING CLEARANCE ................................................................................................... 97
6.2.2 REPLACING PADS ................................................................................................................. 97
6.2.3 ADJUSTING BRAKE PEDALS .............................................................................................. 98
6.2.4 ADJUSTING PARKING BRAKE SWITCH ........................................................................... 99
7. HYDRAULIC SYSTEM ........................................................................................................... 101

7.1.1 MAIN PUMP............................................................................................................................ 101
7.1.2 CONTROL VALVE .................................................................................................................. 106
7.1.3 VALVE CONTROL .................................................................................................................. 107
7.1.4 LIFT CYLINDER ..................................................................................................................... 109
7.1.5 FLOW REGULATOR VALVE ................................................................................................. 112
7.1.6 TILT CYLINDER ..................................................................................................................... 114
7.1.7 OIL TANK ................................................................................................................................ 115
7.2 MAINTENANCE.......................................................................................................................... 116
7.2.1 PUMP MAINTENANCE ......................................................................................................... 116
7.2.2 TRIAL RUN ............................................................................................................................. 128
7.2.3 TROUBLE SHOOTING GUIDE ............................................................................................. 129
7.2.4 INSTALLING VALVE CONTROLLER .................................................................................. 130
No. SEB-80BBE
8. LOAD HANDLING SYSTEM ............................................................................................... 133

8.1.1 OUTER AND INNER CHANNELS ASSEMBLIES .............................................................. 134
8.1.2 CARRIAGE .............................................................................................................................. 135
8.1.3 LOCATIONS OF ROLLERS ................................................................................................... 136
8.2 MAINTENANCE.......................................................................................................................... 138
8.2.1 ADJUSTING LIFT CYLINDER ROD WITH SHIMS ............................................................ 138
8.2.2 ADJUSTING HEIGHT OF CARRIAGE ................................................................................. 138
8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE................................... 140
8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE ............................................ 142
8.2.5 PROCEDURE FOR SHIM ADJUSTING ................................................................................ 143
9. ELECTRIC WIRING ................................................................................................................. 145

1. BATTERY
1. BATTERY (OPTION)
Note: The batteries and truck-mounted charger are optional equipment for export trucks. For more
information about them, see their respective manuals supplied by the manufactures.
1.1 GENERAL DESCRIPTION

The battery assembly contains 36 battery cells connected in series and housed in a battery case
which is located in the position on the truck shown in Fig. 1.1.
The battery case has 10 rollers which makes it easy to getting the case in and out of the truck.
The battery assembly has a voltage of 72 V, but it can deliver 48 V to the controllers and electrical
components of the truck.
Note: The battery case comes equipped as standard.
Adjust the gap between the

roller and frame to 1 mm [0.039
in.] or less at each side BATTERY CASE
ROLLER
ELECTROLYTE LEVEL
MONITOR
HANDLE •
–
SPRING
STOPPER +
•
+48V
•
View looking from

View looking from
Fig. 1.1 Battery Unit
-1-
1. BATTERY
1.1.1 BATTERY CARE
discharges
Number of
Service
The most important point in battery care is to prevent
life
overdischarge. The deeper the battery discharges, the
shorter its life becomes (See Fig. 1.2).
The approximate depth of discharge can be known
by measuring the specific gravity of the electrolyte
(See Fig. 1.2)
Check the level of electrolyte every ten days. Add
distilled water if the level is found lower than the
specified level before charging the battery.
1.1.2 CHARGING THE BATTERY

Discharge depth (%)
When discharged, the battery should be recharged as
soon as possible. Leaving the battery discharged for a Fig. 1.2 Relation Between Depth of Discharge
long time may cause sulfation, which will result in a drop and Service Life (Example)
of the battery performance.
If the battery is kept out of service for a long time, it should be thoroughly charged before put in
storage. An additional charge is also required once a month.
Do not leave a fully discharged battery longer than a day as it is. Be sure to recharge it as soon as
possible.
If the amount of discharge is considered to be small, measure the specific gravity of the electrolyte.
If lower than 1.260, recharge the battery.
Equalizing charge is required if the specific gravity varies among the cells by the amount of 0.020
or larger. Equalizing charge is normally needed between one to four times a month.
If the specific gravity variation is not made smaller 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 truck-mounted type charger, a microcomputer determines when an equalizing charge is required
and carries out equalizing charge automatically.
[Cautions on Charging the Battery]

(1) Do not start charging the battery if the electrolyte temperature is higher than 50°C. Leave the
battery for a while until the temperature goes low. Then charge it.
(2) Overdischarge or overcharge will cause the electrolyte temperature to rise. Get a good ventilation during
charging to prevent the charging room from being filled with harmful gases, and to dissipate heat.
[Specific Gravity Correction According to Temperature]

The specific gravity of the electrolyte varies as the electrolyte temperature changes. The specific
gravity is generally based on the electrolyte temperature of 20°C. Therefore, if the specific gravity is
measured at the electrolyte temperature if other than 20°C, correct it using the following formula:
S = St + 0.0007(t-20)
where S20 .................. specific gravity for 20°C
St ..................... specific gravity measured at t
t ....................... electrolyte temperature measured.
-2-
1. BATTERY
1.1.3 CHARGER (OPTION)

The truck-mount charger consists of the transformer, charger control panel, VTM unit and operation panel
and is located at the left side of the frame.
OPERATION
PANEL
INVERTER
•
•
CHARGER DIODE
• VALVE
CONTROLLER
•
•
VTM UNIT
TRANSFORMER
• •
CHARGER
CONTROL
PANEL
Detail of area
Detail of operation panel with CHARGER
Fig. 1.3 Side Frame, Left (FA15B)

-3-
1. BATTERY
OPERATION
PANEL VALVE CONTROLLER
• •
CHARGER DIODE
INVERTER
•
•
VTM UNIT
•
• TRANSFORMER
•
CHARGER
CONTROL
PANEL
Detail of area
Detail of operation panel
with CHARGER
Fig. 1.4 Side Frame, Left (FA20B, FA25B, FA30B)
-4-
1. BATTERY
INVERTER
CONNECTOR
(for charge)
•
•
• VALVE
CONTROLLER
•
SHORT
COUPLER
VTM UNIT
•
CONTACTOR
without CHARGER (excluding EXA and EXE)

-5-
1. BATTERY
VALVE CONTROLLER
CONNECTOR
(for charge) •
•
INVERTER
•
VTM UNIT
•
SHORT
COUPLER
•
•
•
CONTACTOR
WEIGHT
(FA20B, FA25B only)
without CHARGER (excluding EXA and EXE)

-6-
1. BATTERY
INVERTER
CONNECTOR
(for charge)
•
•
• VALVE
CONTROLLER
•
VTM UNIT
CONTACTOR
without CHARGER for EXA

-7-
1. BATTERY
VALVE CONTROLLER
CONNECTOR
(for charge) •
•
INVERTER
•
VTM UNIT
•
•
•
WEIGHT
CONTACTOR (FA20B, FA25B only)
without CHARGER for EXA

-8-
1. BATTERY
VALVE CONTROLLER
CONNECTOR
(for charge) •
•
CONTACTOR
• INVERTER
•
VTM UNIT
SHORT
COUPLER
CHARGER CONTROL
PANEL
without CHARGER for EXE

-9-
1. BATTERY
VALVE CONTROLLER
CONNECTOR •
(for charge)
CONTACTOR INVERTER
• VTM UNIT
•
SHORT
COUPLER
• •
CHARGER CONTROL WEIGHT

PANEL (FA20B, FA25B only)
without CHARGER for EXE

- 10 -
1. BATTERY
(2) VTM Unit

The VTM unit sets the timers’ charging time intervals according to the battery’s state of charge.
(See Fig. 1.11)
The truck has two charging timers: the first timer and the second timer. The first timer’s time
interval is set by the microprocessor (up to 4 hours).
The second timer is usually set to a time interval of 15 hours for normal charge. If a single charge
time exceeds 15 hours, it is regarded as a charge error and the charge error lamp on the operation panel
blinks.
The VTM unit stores data on charges performed in the past in memory. The microprocessor
determines whether the battery needs equalizing charge, based on the data.
The VTM unit PWB also has an LED which displays data about the charger. It is possible to check
the adjustment and the status of the charger by selecting the setting switches on the PWB.
LED
• •
•
LD8 LD2
SETTING SWITCH
26P
BATTERY
Fig. 1.11 VTM Unit

- 11 -
1. BATTERY
The VTM unit also has a function which sets the limits of traveling speed and regeneration function. The limit
levels can be changed in the manner given below:
When changing the limit levels, observe the following conditions:
Note 1. When changing the limit levels of traveling speed and regeneration function, inform TCM’s
Quality Assurance of the model and chassis serial number of the truck you are going to
change its limit levels and the user name, and follow the instructions given by TCM’s Quality
Assurance.
Note 2. Do not adjust components other than the limit levels of traveling speed and regeneration.
Mode Factory set level Change
Traveling and lifting speed

They are increased by increasing the level.
Traveling speed change

No “turtle” mark
Traveling speed: 100%
“turtle” mark
Level 8: 90%
7: 80
6: 70
5: 60
4: 50
3: 40
2: 30
1: 20
Not changeable
Speed cannot be changed by changing the level.
Accelerator OFF regeneration

Regeneration force obtained while traveling with
accelerator OFF can be enhanced by increasing
the level.
Brake regeneration
Enabled when the brake switch is turned on.
- 12 -
1. BATTERY
[Procedure for changing limit levels]

Park the truck on a level surface and turn the key switch off.
Open the rear cover at the back of the truck and disconnect the battery connectors.
Remove the side cover at the left side of the truck.
Remove the VTM unit cover.
Make sure the setting switch on the VTM unit PWB is at position “D”. If it is not at “D”, use a
Phillips screwdriver to set it to the position “D”.
Connect the battery connectors. The 2-digit LED on the VTM PWB displays the present battery
voltage (the number is coded).
Turn the key switch on and set the setting switch to “8”.
Push the mode switch (SW2) to display “ ” on the 2-digit LED. Every time the SW2 is pressed,
the display changes “ ”, “ ”, “ ”, “ ” and “ ”. The 1st digit means the mode
symbol and the 2nd digit the level number.
Set the 1st digit to the mode symbol you want. Press SW3 or SW4 to set the level number to the
value you want.
After setting, turn the key switch off. The settings are stored in memory. Return the setting switch
to the position “D”.
Disconnect the battery connectors. Reinstall the VTM unit cover and side cover.
Connect the battery connectors and close the rear cover.
White
Setting mark
LOWER
DIGIT
SETTING SWITCH
UPPER
DIGIT
• • •
SW4 (L)
MODE SETTING
SWITCH SW2 SW3 (H)
Fig. 1.12 VTM Adjustment
- 13 -
1. BATTERY
[Transmitting hour meter data]

The hour meter data which show the operating time of the truck are recorded in the memory inside
the VTM unit. Therefore, before replacing the VTM unit, the hour meter data need to be transmitted to
the MPU board. The data to be transmitted are only the data of 10 hours or more.
1. Record the value of the hour meter on the meter panel and note it.
2. Perform the same operations as described in steps 1 to 3 of “Procedure for changing levels.”
3. Shift the preset switch to the position 9. After that, make sure that “ “ is displayed on the 2-
digit LED and turn the key switch on.
4. When the mode switch is pressed, “ “ is displayed on the LED, and after 2 to 3 seconds
“ .“ is displayed. And after 1 second is passed, the transmission is started.
When you want to stop the transmission, turn the key switch off before “ .“ is displayed.
When the transmission is started, the display changes from “ .“ to “ “ thru “ “ thru “ “ and
“ “ in this order. When the transmission is completed, the display returns to “ “
5. Turn the key switch off and remove the battery connector. After that, replace the VTM unit.
6. When the battery connector is connected after the replacement, “ “ is displayed on the LED.
Press the switch L and make sure that “ “ is displayed on the LED. After that, when the key
switch is turned on within 5 to 6 seconds, the transmission is started. The transmission is properly
terminated, the LED displays “ “
7. Return the preset switch to the position D, turn the key switch off.
Remove the battery connector and install the VTM unit cover and the counterweight cover.
Important: Be sure to remove the battery connector to prevent shortcircuit and reset the VTM
unit.
8. Connect the battery connector and turn the key switch on. Make sure that the value displayed in
this step is the same as that displayed on the hour meter in step 1.
Note: If there are any data less than 10 hours, the data are not transmitted and the different value
is displayed.
- 14 -
1. BATTERY
(3) Transformer (option)

The transformer is located at the left lower side of the frame and changes the input voltage to the
level necessary for charging the battery.
The primary side (input) voltage fluctuates to a large extent with time. Therefore, the taps of the
primary side can be switched over to minimized the fluctuations in voltage at the secondary side
(output).
Tap symbol
Note:
1. The three phases should be switched
over at the same.
2. Install a terminal cap to the tap not used,
and secure with a wire clamp.
Supply voltage (average) V
50 Hz 60 Hz
L 350 - 370 360 - 380
380 V
M 370 - 390 380 - 400
• • • H 390 - 410 400 - 420
L 400 - 420 410 - 430
440 V
M 420 - 440 430 - 450
H 440 - 460 450 - 470
SECONDARY
LINE
PRIMARY
LINE
•
Fig. 1.13 Transformer
(4) Diode (option)

The diode is installed as shown in Fig. 1.14. It converts alternating current to direct current.
Note: The fuse comes equipped as standard.
FUSE
130 A
DIODE
Fig. 1.14 Diode

- 15 -
1. BATTERY
(5) Charger control panel (option)

The charger control panel consists of a thermal relay, contactor, and resistors and turns on and off
the primary power supply of the transformer.
CONTACTOR
(CM)
D8
•
•
R
• THERMAL RELAY
(TH)
•
R64
•
• •
D10 R15
D10 (Pay attention

to polarity)
Detail of R15
Thermal relay current setting
Charger model
N80C N105C
N80D N105D
20A 27A
Wiring diagram
Fig. 1.15 Charger Control Panel

- 16 -
1. BATTERY
(6) Charger operation (for trucks with a charger)

When the power switch is turned on, the charger is made ready for operation by the photocoupler
in the VTM unit.
When the start button (PB1) is pressed, a circuit composed of the magnet switch CM, thermal
relay TH, and VTM unit V-25 terminal is formed, while the battery voltage is applied to the M-10
terminal of the meter panel, thus activating the magnet switch CM. However, the magnet switch
won’t work if the battery connectors are not connected.
When the power is connected to the transformer by the action of the magnet switch CM, LED 1
turns on; charging starts and the fail timer starts counting down the time.
The timer is usually set to 15 hours for normal charging.
When the battery voltage reaches the preset value, the microprocessor inside the VTM unit detects
the voltage and the normal timer starts counting down the time.
This timer is automatically set according to how much the battery has been discharged.
When the time set to the normal timer expires, the magnet switch CM opens to terminate charging
operation.
Fig. 1.16 Charging Circuit
- 17 -
1. BATTERY
1.1.4 CHARGING PROCEDURE (for trucks with a charger)

(1) Normal charge
Turn off the key switch and apply the parking brake.
Make sure that the power supply at the facility side is off and insert the plug into the receptacle at
the truck side.
The plug at the truck side is a locking type. Insert the plug securely until it reaches the locked
position. Then, insert the plug into the receptacle at the facility side when it is equipped with the
power service outlet.
When the power supply at the facility side is turned on and the START button at the charging
operation panel is pressed, the CHARGING lamp lights up and the charging is started. Then, the
humming is heard from the transformer, which shows that the charger is operating. The charging
state is also displayed on the meter panel.
Note: If the battery is not connected or the power supply at the facility side is 0-volt, the charging
operation cannot be started.
The charging is automatically terminated after it continues for 8 to 10 hours (the charging time
varies with the amount of discharge). The battery is not so exhausted, the charging may continue
for a short time (a few minutes).
Note: If power failure occurs during charging and is remedied within 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 lock lever pressed.
After charging is finished, measure the specified gravity of the battery electrolyte to check if the
proper charging is carried out.
(2) Boosting charge

If the residual level gauge of the meter panel is probable to indicate level 3 or less after completing
the day’s work, it is recommended that boosting charge is carried out by using a rest period.
The starting procedure of the boosting charge is same as that of the normal charge, but be sure to
press the STOP button when terminating the boosting charge.
(3) Equalizing charge

Normally the battery does not need equalizing charge because when the battery needs it, the
microcomputer detects it and automatically puts the charger in equalizing charge operation. However,
manual equalizing charge is needed if:
• Purified water is added to the battery electrolyte
• The difference of the specific gravity in each cell is 0.02 or more.
• Overdischarge more than 100% occurs.
The procedure for carrying out the equalizing charge is as follows:
Press the SUPER EQUALIZE button after taking the same steps as needed for normal charge, so
that the CHARGING lamp and SUPER EQUALIZE lamp light up.
When equalizing charge is automatically terminated (the CHARGING lamp goes out), the “SUPER
EQUALIZE” lamp is turn off and the equalizing charge is released by pressing the “SUPER
EQUALIZE” button or turning the key switch on.
While the battery is charged, the equalizing charge can be released by pressing the STOP button.
- 18 -
1. BATTERY
(4) Super equalizing charge

The super equalizing charge is used when you want to use 100% of the battery capacity after the
consecutive holidays. The operation steps are the same as those described in “Equalizing charge.”
In the super equalizing charge, both of the equalizing charge and the automatic proper boosting
charge during the consecutive holidays are carried out, so that the proper boosting charge is
automatically carried out every 24 hours after completing the charge. Therefore, 100% of the
battery capacity can be used after the 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 capacity
battery or to prepare a spare battery when the super equalizing charge is so often used.
(5) Flickering CHARGING lamp

When the charging voltage doesn’t rise up due to the deteriorated battery or other reasons, the timer
won’t operate properly, continuing to charge the battery.
However, for the truck-mounted type charger, the second timer is operated after charging the battery
for 15 to 17 hours, so that the charging is forcibly terminated and the CHARGING lamp blinks. In
such a case, inspect the cause and contact your TCM dealer.
Note: Have a helper for this procedure.
Remove the battery connector.

Having the helper keep the super equalizing charge button held down, reconnect the battery
connector.
Make sure “Charging” lamp goes out.
- 19 -
1. BATTERY
NOTE
- 20 -
2. MOTORS
2. MOTORS
Drive motor
Type 3-phase induction motor
Rating
Output 7.1 kW (2.5 min)
Speed 720 min-1
Frequency 27 Hz
Voltage 35.5 V
Current 195 A
Weight approx. 46 kg [101.4 lbs]
Pump motor
Type 3-phase induction motor
Rating
Output 18 kW (5 min)
Speed 1800 min-1
Frequency 62 Hz
Voltage 39 V
Current 372 A
Weight Approx. 60 kg [132.3 lbs]

The drive and pump motors are 3-phase induction motors consisting of a coil-wound frame, rotor
shaft, and brackets. The rear bracket has a rotation sensor incorporated.
2.1.1 DRIVE MOTOR

The drive motor is installed on the drive unit. (See Fig. 2.1.) One end of the drive motor shaft is
splined to the drive unit input gear A and thus the rotating force of the drive motor is transmitted to the
input gear A. The opposite end of the drive motor shaft has a slit plate which detect the rotation with
two sensors.
- 21 -
2. MOTORS
THERMO SENSOR
REAR BRACKET
• •
ROTATION SENSOR B
V PHASE
• U PHASE
W PHASE
• •
ROTATION
SENSOR A
• SLIT PLATE
• •
Detail of sensor
Align teeth and grooves

of two slip plates
WAVE WASHER
SNAP RING
•
•
View looking from
•
Detail of slit plate

Note: The front bracket is used also as the drive unit case.
Fig. 2.1 Drive Motor

- 22 -
2. MOTORS
2.1.2 PUMP MOTOR

The pump motor is installed in the position shown in Fig. 2.3 Figure 2.2 shows the appearance of
the pump motor. The pump motor drives the gear pump directly and the rotation is controlled by the
inverter. At the end opposite to the drive side is a slit plate which detects the rotation with the sensor.
REAR
BRACKET THERMO SENSOR FRONT BRACKET
• • •
V PHASE
W PHASE •
ROTATION U PHASE
SENSOR •
•
SLIT PLATE
(INSIDE COVER)
View looking from View looking from
Fig. 2.2 Pump Motor

- 23 -
2. MOTORS
PUMP MOTOR
PUMP
•
Front •
MAST SUPPORT
CUSHION
•
FA15B
PUMP
Front
MAST SUPPORT PUMP MOTOR
FA20B, FA25B, FA30B
Fig. 2.3 Pump Motor Location

- 24 -
2. MOTORS
2.1.3 OPERATING PRINCIPLE OF 3-PHASE INDUCTION MOTOR

As shown in Fig. 2.4, when the magnetic poles
N and S are rotated outside the rectangular oil, on
e cti e)
di pol
r
the coil side cuts the magnetic flux to induce it ng etic
a
electromotive force in the direction indicated in ot gn
(R ma
the figure, thus flowing circulating current inside of
(Rotating
the coil. This causes rotating force in the same direction of coil)
direction as in which the magnetic poles rotates
so that the coil also rotates, following the
magnetic poles. Motors which operate in such a
principle is called an induction motor.
Fig. 2.4 Operating Principle of Induction Motor
Three-phase alternating current is suitable for
rotating the magnetic coil. When 3-phase current ia
is passed into a 3-phase winding, a revolving 120° 120°
A
øC
magnetic field which rotates a certain speed is B’ C’ A’
created. It is thus possible to perform the same O
øA
action as the purpose of rotating the magnetic C
C’
ic
poles N and S in Fig. 2.4. The 3-phase winding C
B’
consists of an iron core and three coils A, B, and øB B ib B
C, spaced 120° apart, installed in the iron core A’
slots and connected in Y or delta connection. The 120°
sketch “b” in Fig. 2.5 shows a typical Y (a) (b)
connection which is widely used for the
Fig. 2.5 3-phase Winding
connection of induction motors.
When the directions (A A’, B B’, C C) in which current flows into the coil are regarded as
the positive direction, the current of the coil in each phase at the moment at (a), (b) and (c) in Fig.
2.6, +Im flows into the coil A and –Im/2 flows into both coils B and C. Therefore, the synthetic
magnetic flux in the space becomes (c) to create a magnetic field moving from right to left. This
means that the magnetic pole is located at the right side and the S at the left side. As such, each
moment from - is followed in order, the synthetic magnetic field created by synthetic magnetic
flux is a magnetic field which rotates by 60° clockwise. With time, it rotates to cause a rotating
magnetic field which makes a complete turn per one cycle of alternating current. The poles formed at
each moment are N and S, and thus this type of motor is called a 2-pole motor.
ia ib ic
Im
(a)
π 2π π 4π 5π
Im 3 3 3 3
2
Im Im Im Im
Im 2
2 2 Im
A A A A Im A Im A 2
C Im C Im C
(b) 2 2 Im
C
2
C 2 C Im
Im B B B B B B
Im Im Im Im
2 A 2 2
C’
B’ S S N N
(c) S N N S
C N N S S
B
A’
Fig. 2.6 Rotating Magnetic Field due to 3-phase Alternating Current

- 25 -
2. MOTORS
2.2 MAINTENANCE
2.2.1 DAILY MAINTENANCE
(1) Check the following points with the motor running
Check item Location Criteria Remedy
Dust Motor frame No remarkable deposit of dust allowed If too much deposit of
compared with usual operation. dust is found, stop the
Environment
Usual temperature rise. operation and clean.

Visual check.
Foreign Motor frame No remarkable change allowed compared Return to normal
matter, with usual operation. condition.
splash, liquid Visual check.
Temperature Motor frame, No remarkable rise in temperature allowed Return to normal

rise bearing compared with usual operation. condition.
Temperature is below specified values:
Motor frame: 80°C [176°F]
Bearing: 55°C [131°F]
Vibration Motor frame, No remarkable vibration or amplitude If allowable limit is

bearing, and increase allowed compared with usual exceeded, stop the
cover operation. operation and remove
Visual and audible checks. the cause.
Noise Motor frame, No remarkable noise or sound allowed If any defect is found,
bearing, compared with usual operation. stop the operation and
cover Using a sound-check rod, check against new remove the cause.
product.
Audible check.
(2) Check the following items with the motor stopped
Check item Location Criteria Remedy
Tightened areas Screws and No looseness, adherence of dust, or Retighten, clean or

nuts corrosion allowed. paint.
Check visually and by tapping.
Terminals Connections Connections are correct and not loose. Retighten.
Proper insulation is ensured. Check for insulation.
Visual check.
Lead wires No damage to coating allowed. Ask specialist for

Visual check. repair.
- 26 -
2. MOTORS
2.2.2 PERIODIC INSPECTION

(1) Inspection criteria
Check the motor at periodic intervals, referring to the following troubleshooting chart. If the motor
is used under a severe working condition, earlier or more frequent preventive maintenance is required.
Operation time more than 12 hours/day 8 – 12 hours/day

Inspection interval Once a year Once every two years
Location Check item Criteria Remedy
Roller Bearing (sealed Check grease leaks, noise, adherence of dust Replace.
bearing type) visually or audibly.
Tightened Joined parts Check for damage or rough surface due to Clean.
areas corrosion visually.
Fasteners Check for looseness, corrosion or seizure Retighten, apply anti-

visually or by tapping. rust or replace.
Terminals Joined areas Check for damage or rough surface due to Clean.
corrosion visually.
Connections Visually check that connections are correct Retighten.

and not loose, and that proper insulation is
ensured.
Lead wire Check coating for damage visually. Ask specialist for
repair.
Resistance For drive 0.0306Ω ± 5% (20°C or 68°F) Ask specialist for

between motor repair.
terminals
For pump 0.0502Ω ± 5% (20°C or 68°F)
motor
Stator Iron core Check for adherence of dust visually. Clean.

and rotor
assembly Coil and insulation Insulation resistance is more than 1MΩ. Clean.
at connections (Use 500 V megger) Heat.
Varnish.
Rotation Measure resistance 620 ± 60Ω (20°C or 68°F) Replace.

sensor
Measure gap 0.7 ± 0.3 mm [0.028 ± 0.012 in.] Ask specialist for
adjustment.
Thermo Measure resistance 13.04Ω ± 10% (20°C or 68°F) Ask specialist for
sensor repair.
Painting Damage Check for damage, discoloration, peeling, or Apply anti-rust.

corrosion visually. Paint again.
Cleanli- Deposit of Check for contamination, adherence of dust Clean or apply anti-
ness contaminants or dust or corrosion visually. rust.
Paint.
- 27 -
2. MOTORS
(2) Inspection procedure

Inspect the motors observing the following conditions:
Select a place which is not dusty or humid.
Parts which have been disassembled should be kept in order and the order of disassembly recorded
to ensure correct reassembly.
Screws and wave washers removed should be put in order in boxes.
When removing or reinstalling brackets with a wooden mallet, tap them evenly. Do not use a
metallic hammer.
Use caution not to damage parts, especially stator coil and bearings. Exercise caution not to allow
them to collect moisture, dust, or sand.
Disassembled parts should be cleaned and checked for damage. Any defective parts should be
replaced with new one.
Do not rub a contaminated coil forcefully. Do not use gasoline, petroleum or solvent for cleaning;
otherwise the insulation will be impaired. Use a dry cloth or soft brush for cleaning.
If the insulation resistance of the coil is lower than the specified value, dry the coil by heating it
to 80 – 90°C [176 – 194°F], avoiding local heating, until the insulation resistance is more than
1 MΩ.
Check bolts for looseness, retightening any loose bolt.
For the procedure for checking and servicing the bearings, see 2.2.3 MAINTENANCE OF
BEARINGS.
If the coating is damaged, discolored or exfoliated, apply anti-rust or paint again.
Tighten the terminals securely. Connections must be completely insulated with insulation tape.
After reassembly, make sure that there is not any part left and the bolts and screws are securely
tightened. Turn the shaft by hand to make sure it turns smoothly. Run the motor on a trial basis.
The motor should be stored in a dry, clean place free from alkaline or other harmful gases. The
shaft should be applied with anti-rust and covered with oilpaper or vinyl sheet.
- 28 -
2. MOTORS
2.2.3 MAINTENANCE OF BEARINGS

The service life of bearings varies with the magnitude of loads and operating conditions. Replace
the bearings with new ones when the temperature rises excessively or produces noise.
Sealed bearings sealing in lithium soap-based grease ensure effective lubrication and prevent the
entrance of dust. They can be used for a long period of time without adding grease.
The sealed bearing should be replaced using the following table as a rough guide.
Operation time 8 – 12 hours/day 12 hours/day

Replacement intervals Once very 6 years Once every 3 years
Earlier replacement may be required if the motor is used at a place which is dusty or might cause
the sealed grease to deteriorate or flow out due to the atmosphere of harmful gases or solvent.
(1) Installing bearing

Install the bearing onto the shaft using a pipe (with a patch, if needed), as shown in Fig. 2.7.
When heating the bearing, do not heat to more than 60 to 80°C [140 to 176°F].
PATCH
Fig. 2.7
(2) Removing bearing

Using a puller, remove the bearing.
NUT
PULLER BOLT
•
INTERNAL •
BEARING
COVER
BEARING
Fig. 2.8
- 29 -
2. MOTORS
NOTE
- 30 -
3. CONTROL SYSTEM
3. CONTROL SYSTEM
The control system consists of the inverter assembly which controls both the drive motor and pump motor,
and the valve controller which controls the control valve.
3.1.1 INVERTER
The inverter converts direct current into 3-phase alternating current. Figure 3.1 shows the outline of the
system.
The inverter consists of a CPU board, power supply board, and FET module. Figure shows the
construction of the inverter.
The CPU board, by receiving signals from accelerator and valve controller, controls the drive motor
and pump motor through the FET module. The operating status of each motor can be detected by the
thermo sensor and current sensor and fed back to the CPU board.
Control of induction motors by inverter
STEER
ACCELERATOR, SENSOR, DISPLAY
VALVE STEER VTM
CONTROLLER ENCODER BATTERY POWER
SUPPLY
DS, BK SW PWM INVERTER
CPU BOARD
POWER
SUPPLY
BOARD
CURRENT
SENSOR
DETERMINE TARGET VECTOR

VALUES: CONTROL PWM SIGNAL
SPEED, TORQUE OPERATION GENERATION
STEER KNOB
DISPLACE. COMP. ROTATION THERMO
SENSOR SENSOR
SOL.
OVERALL CONFIGURATION
FET MODULE x3 FET MODULE x3 FET MODULE x3
BATTERY
LEFT DRIVE RIGHT DRIVE
MOTOR MOTOR PUMP MOTOR
INTERME-
DIATE
ROTA- ROTA-
CAPACITOR ROTA- TION
BOARD TION TION
SEN- SEN-
SEN- SOR
SOR SOR
DISPLACE. COMPEN. SOL.
POWER SUPPLY BOARD CPU BOARD
Fig. 3.1 Outline of Inverter

- 31 -
3. CONTROL SYSTEM
PARTS AND TERMINAL LAYOUT
to PUMP MOTOR FET MODULES (9 pcs.)

PU PV PW
CURRENT
SENSORS
(6pcs.) •
RW
RV to DRIVE MOTOR
(RIGHT)
RU
LW
LV to DRIVE MOTOR
(LEFT)
LU
Fig. 3.2 Inverter Assembly

- 32 -
3. CONTROL SYSTEM
(1) CPU board and power supply board

The CPU board and power supply board are installed on the front side of the inverter assembly.
The CPU board receives the operating status of the accelerator and each switch and uses it to set the
speeds and torque values of the motors. In addition, it compares the settings against signals fed back
from the rotation sensor and current sensor of each motor, to drive the main circuit of the PWM
inverter by vector control method.
The CPU board has truck model setting switches and LED which shows error statuses on it.
The power supply board supplies power to the CPU board and FET module.
CPU BOARD
POWER SUPPLY
BOARD
MODEL SETTING SW
GREEN RED
LED LED
ERROR CODE DISPLAY LED
Note 1: Truck model setting switch (DSW2)
2 1 2 1 2 1
ON ON ON
FA15B FA20B FA30B
FA25B
Note 2: Error code display LED

• Green LED displays error codes for traveling system.
• Red LED displays error codes for load handling system.
Fig. 3.3 CPU Board and Power Supply Board

- 33 -
3. CONTROL SYSTEM
(2) FET Module

The FET module combines multiple current control FETs to control large current.
Each FET module consists of two FET aggregates, a Hi-side FET and a Lo-side FET, and three
FET modules are used for a single motor.
S2 (N)
D1 (P)
•
• •
S1D2 (OUT)
• •
CONNECTOR THERMO SENSOR CONNECTOR
(TMRV, TMLV, TMPV)
INSULATION SILICONE
SEAT
D1(P)
G1 G1 G1
GATE DRIVE
S1D2(OUT)
CONNECTOR
G2 G2 G2
S2(N)
Fig. 3.4 FET Module
- 34 -
3. CONTROL SYSTEM
3.1.2 VALVE CONTROLLER

The valve controller controls the solenoids of the main control valve and the pump motor.
The valve controller receives voltages (analog signals) which vary with the operation of the joystick
and the rotation of the drive unit, as well as the operating status (digital signal) of each switch. The
valve controller, based on such signals, controls the current passed to each solenoid and the rotation of
the pump motor.
ACRYLIC PLATE
• CN4
•
• CN3
• CN2
• CN1
Fig. 3.5 Valve Controller
- 35 -
3. CONTROL SYSTEM
LIFT SOL.
(PROPORTIONAL SOLENOID VALVE)
LIFT JOYSTICK
TILT SOL. TILT JOYSTICK
(ATTACHMENT 1 SOL) (ATTACHMENT 1 JOYSTICK)
REAR SOL (ATTACHMENT 2 JOYSTICK)
(ATTACHMENT 2 SOL)
FRONT RIGHT WHEEL SIDEWAYS TRAVEL CONTROL LEVER

SIDEWAYS TRAVEL SOL.
FRONT LEFT WHEEL
SIDEWAYS TRAVEL SOL SIDEWAYS TRAVEL SWITCH
F/R NEUTRAL SWITCH

UNLOAD SOL.
VALVE CONTROLLER
FRONT LEFT WHEEL ANGLE
SENSOR
FRONT LEFT WHEEL STRAIGHT
POSITION SWITCH
STEERING LOCK SOL
FRONT RIGHT WHEEL ANGLE
(REAR SOL) SENSOR
FRONT RIGHT WHEEL STRAIGHT
POSITION SWITCH
SIDEWAYS TRAVEL LAMP
REAR RIGHT WHEEL STRAIGHT POSITION

SWITCH
REAR RIGHT WHEEL SIDEWAYS TRAVEL
POSITION SWITCH
REAR LEFT WHEEL STRAIGHT POSITION
SWITCH
REAR LEFT WHEEL SIDEWAYS TRAVEL
POSITION SWITCH
STEERING NEUTRAL SWITCH
TRUCK DRIVING STATUS (STRAIGHT/
DRIVE MOTOR STATUS SIGNAL

DRIVE MOTOR STOP SIGNAL
PUMP MOTOR SPEED INDICATION
SIDEWAYS) SIGNAL
INVERTER
Fig. 3.6 Relationship between Valve Controller and each Component

- 36 -
3. CONTROL SYSTEM
(1) 4-digit LED

The valve controller has a 4-digit LED display
which checks the input and output of signals as well
as indicates circuit errors such as a broken wire. LED (4-DIGIT)
(2) Checking numbers •

Open the sight glass of the valve controller. After • • •
making sure the key switch is turn on, press the
SW1 (See Fig. 3.7.).
SW1 SW2 SW3
The 4-digit number has some points at the right
lower part of each figure, by which you can
interpret the indication.
Fig. 3.7 Valve Controller
(3) Meaning of each figure

[ 0 0 * * ]: Truck model
** = 01: FA15B1 ** = 02 : FA20B1 ** = 03 : FA25B1 ** = 04 : FA30B1
** = 51 : FA15B2 ** = 52 : FA20B2 ** = 53 : FA25B2 ** = 54 : FA30B2
Note 1: FAXXB1 stands for “without solenoid valve”.
FAXXB2 stands for “”with solenoid valve” (trucks with dual attachments)
[ * # $.] : Input check
Blank
Drive motor status signal, F/R neutral, steering neutral switch, sideways travel
switch status (See Table 3.1)
Rear wheel straight switch status (See Table 3.2)
Front wheel straight switch status (See Table 3.3)
Table 3.1 Input check 1 Table 3.2 Input check 2

Sideways F/R Steering Drive motor Rear wheel sideways Rear wheel straight
travel switch neutral neutral switch status signal travel status switch status switch NC NC
(Note 1) (Note 1) (Note 1) (Note 2) (Note 3) (Note 4)
#=0 OPEN OPEN OPEN OPEN *=0 OPEN OPEN OPEN OPEN
#=1 GND OPEN OPEN OPEN *=1 GND OPEN OPEN OPEN
#=2 OPEN GND OPEN OPEN *=2 OPEN GND OPEN OPEN
#=3 GND GND OPEN OPEN *=3 GND GND OPEN OPEN
#=4 OPEN OPEN GND OPEN *=4 OPEN OPEN GND OPEN
#=5 GND OPEN GND OPEN *=5 GND OPEN GND OPEN
#=6 OPEN GND GND OPEN *=6 OPEN GND GND OPEN
#=7 GND GND GND OPEN *=7 GND GND GND OPEN
#=8 OPEN OPEN OPEN GND *=8 OPEN OPEN OPEN GND
#=9 GND OPEN OPEN GND *=9 GND OPEN OPEN GND
#=A OPEN GND OPEN GND *=A OPEN GND OPEN GND
#=B GND GND OPEN GND *=B GND GND OPEN GND
#=C OPEN OPEN GND GND *=C OPEN OPEN GND GND
#=D GND OPEN GND GND *=D GND OPEN GND GND
#=E OPEN GND GND GND *=E OPEN GND GND GND
#=F GND GND GND GND *=F GND GND GND GND
Table 3.3 Input check 3

Front right wheel straight Front left wheel straight
status switch (Note 4) status switch (Note 4) Note 1: GND stands for sideways travel, F/R neutral, steering neutral
status.
= 0 OPEN OPEN Note 2: GND stands for drive motor speed at 0
= 1 GND OPEN Note 3: OPEN stands for sideways travel
= 2 OPEN GND Note 4: OPEN stands for straight travel
= 3 GND GND
- 37 -
3. CONTROL SYSTEM
[* # $.]: Output check

ON/OFF solenoid, LAMP status (See Table 3.4.)
Sideways travel, control status (See Table 3.5.)
Blank
Blank
Table 3.4 Output check 1 Table 3.5 Output check 2
Unload Steering Rear Sideways Truck operating status Drive motor
solenoid lock solenoid solenoid travel lamp (straight/sideways travel) signal stop signal NC
$=0 OFF OFF OFF OFF # = 0 OPEN OPEN OPEN
$=1 ON OFF OFF OFF # = 1 GND OPEN OPEN
$=2 OFF ON OFF OFF # = 2 OPEN GND OPEN
$=3 ON ON OFF OFF # = 3 GND GND OPEN
$=4 OFF OFF ON OFF # = 4 OPEN OPEN GND
$=5 ON OFF ON OFF # = 5 GND OPEN GND
$=6 OFF ON ON OFF # = 6 OPEN GND GND
$=7 ON ON ON OFF # = 7 GND GND GND
$=8 OFF OFF OFF ON
$=9 ON OFF OFF ON
$=A OFF ON OFF ON
$=B ON ON OFF ON
$=C OFF OFF ON ON
$=D ON OFF ON ON
$=E OFF ON ON ON
$=F ON ON ON ON
[ # * *.*.] Table 3.6 Error Code

Inputs 0-3FF from joystick *.*. = 0 Normal
*.*. = 1 Lift joystick wire broken
Neutral switch status inside joystick *.*. = 2 Tilt joystick wire broken
*.*. = 3 Attachment 1 joystick wire broken (Note 5)
[ # * *.* ] Input values 0 - 3FF from lift joystick *.*. = 4 Attachment 2 joystick wire broken (Note 6)
[ # * *.*. ] Input values 0 - 3FF from tilt joystick *.*. = 5 Sideways travel lever wire broken
[ # *.* * ] Input values 0 - 3FF from attachment 1 *.*. = 6 Front right wheel angle sensor wire broken
*.*. = 7 Front left wheel angle sensor wire broken
joystick *.*. = 8 Lift solenoid A wire broken
[ # *.* *.] Input values 0 - 3FF from attachment 2 *.*. = 9 Lift solenoid B wire broken
joystick *.*. = 10 Tilt solenoid A wire broken
*.*. = 11 Tilt solenoid B wire broken
[ 0 *.*.* ] Input values 0 - 3FF from Lever pot (302) *.*. = 12 Attachment 1 solenoid A wire broken (Note 5)
*.*. = 13 Attachment 1 solenoid B wire broken (Note 5)
[ 0 *.*.*.] Input values 0 - 3FF from F/RH angle pot (305) *.*. = 14 Front right wheel solenoid A wire broken
[ 0.* * * ] Input values 0 - 3FF from F/LH angle pot (308) *.*. = 15 Front right wheel solenoid B wire broken
*.*. = 16 Attachment 2 solenoid A wire broken
[ #.# *.* ] *.*. = 17 Attachment 2 solenoid B wire broken
*.*. = 18 Front left wheel solenoid A wire broken
Output values 0 - FF at proportional value A side *.*. = 19 Front left wheel solenoid B wire broken
*.*. = 20 Unload solenoid wire broken
Output values 0 - FF at proportional value B side *.*. = 21 Steer lock solenoid wire broken
*.*. = 22 Rear solenoid wire broken
[ #.# * *.] Lift solenoids A,B *.*. = 23 Sideways travel lamp wire broken
[ #. # *.*] Tilt solenoids A,B *.*. = 24 Lift solenoid A load short-circuited
[ #.# *.*.] Attachment solenoids A,B *.*. = 25 Lift solenoid B load short-circuited
*.*. = 26 Tilt solenoid A load short-circuited
[ #.#. * *] Front right wheel sideways travel solenoids A, B *.*. = 27 Tilt solenoid B load short-circuited
[ #.#.* *.] Attachment 2 solenoids A, B *.*. = 28 Attachment 1 solenoid A load short-circuited
[ #.#.*.* ] Front left sideways travel solenoids A, B *.*. = 29 Attachment 1 solenoid B load short-circuited
*.*. = 30 Front right wheel solenoid A load short-
[ #.#.*.*.] circuited
*.*. = 31 Front right wheel solenoid B load short-
Error code (See Table 3.6.) circuited
*.*. = 32 Attachment 2 solenoid A load short-circuited
Output values 0 - FF of Pump speed *.*. = 33 Attachment 2 solenoid B load short-circuited
*.*. = 34 Front left wheel solenoid A load short-circuited
Note 5: If the attachment 1 joystick is not connected, a broken *.*. = 35 Front left wheel solenoid B load short-circuited
wire or short-circuit of attachment 1 solenoids is not *.*. = 36 EEPROM write error
detected. *.*. = 37 EEPROM data error
Note 6: If the attachment 2 joystick is not connected, a broken
wire or short-circuit of attachment 2 solenoids is not
detected.
- 38 -
3. CONTROL SYSTEM
(4) Error detection and error prevention warning

1. Error detection
The unload solenoid, steering lock solenoid, rear solenoid, and sideways travel lamp are checked
for a broken wire immediately after the key switch is turned on. If a broken wire is detected, the
error code is set.
The lift, tilt, attachment 1 and attachment 2 joysticks and their respective solenoids are checked
for a broken wire between them for a certain period of time after the truck is started. If a broken
wire is detected, the error code is set. When the attachment 1 and 2 joysticks are not connected,
the attachment 1 and 2 solenoids are checked for a broken wire.
The front right and left wheel angle sensors, sideways travel lever, front right and left wheel
sideways travel solenoids are checked for a broken wire for a certain period of time after the truck
is started. If a broken wire is detected, the error code is set.
2. Error prevention check made immediately after the key switch is turned on.
The relationship between the truck’s status and the sideways travel switch is checked immediately
after the key switch is turned. This is to prevent the truck from taking the sideways travel position
suddenly when the key switch is turned on with the truck in straight travel position and the sideways
travel switch on.
If the truck is in straight position and the sideways travel switch is on when the key switch is
turned on, the sideways travel lamp blinks waiting for the sideways travel switch being turned
off. When the sideways travel switch is turned off, the warning lamp stops blinking.
Table 7 shows the relationship between the truck’s status, sideways travel switch and warning lamp.
The load handling system won’t operate if the key switch is turned on with the lift or tilt joystick
tilted. This prevents the forks or mast from operating abruptly when the key switch is turned on.
Return the tilt or lift joystick to neutral and then shift into an operating position.
Table 3.7 Error prevention as to sideways travel

Truck’s status Action taken immediately Lamp blinking after Remarks
key switch is turned on
Front wheel sideways Front wheel Sideways Truck’s status Sideways Sideways Sideways
travel lever is in control straight status travel switch travel lamp travel switch travel lamp
range? (Note 1) switch (Note 2) (Note 3)
Either right or left ON OFF Usual OFF –

wheel is out of range. straight travel
ON Truck stops Blinks OFF OFF
Both right and left OFF Truck stops Blinks ON Blinks Harness or
wheels are out of range. sensors are
ON Truck stops Blinks OFF Blinks defective (Note 4)
Either right or left OFF OFF Straight travel OFF – –

wheel is out of range. compensation
ON Truck stops Blinks OFF OFF
Both right and left OFF Truck stops Blinks ON Stays on

wheels are out of range.
ON Usual side- Stays on – –
ways travel
Note 1. Front wheel sideways travel lever control range: Range in which the front wheels are moved with the sideways travel
lever in sideways travel mode.
Note 2. Front wheel straight travel position switch: Straight travel position when the switch is turned on.
Note 3. Sideways travel switch: The sideways travel is indicated when the switch is turned on; straight travel is indicated when
turned off.
Note 4. Front wheel straight position switch broken or its wiring broken or front wheel angle sensor defective.
- 39 -
3. CONTROL SYSTEM
3.1.3 ACCELERATOR PEDALS

The truck has two accelerator pedals, main and sub accelerator pedals. They control the drive motor
speed.
The two accelerator pedals have the same design and pedal effort is transmitted through the
potentiometer to the inverter.
POTENTIOMETER
View looking from
ACCELERATOR PEDAL 2
Section -
34 mm
[1.34 in.]
ACCELERATOR
PEDAL 1
34 mm
[1.34 in.]
Fig. 3.8 Accelerator Pedals (FA15B)

- 40 -
3. CONTROL SYSTEM
POTENTIOMETER
View looking from
ACCELERATOR PEDAL 2
Section -
ACCELERATOR PEDAL 1
31 mm
[1.22 in.]
31 mm
[1.22 in.]
Fig. 3.9 Accelerator Pedals (FA20B, FA25B, FA30B)

- 41 -
3. CONTROL SYSTEM
3.2 TROUBLESHOOTING
3.2.1 CAUTIONS
(1) Caution to be taken when checking
Before touching any electric part with bare hand, disconnect the battery connectors and then discharge
the capacitor using a 22 Ω/20 - 30 W resistance.
The capacitor may store a voltage a few times greater than the battery voltage. Do not use a conducting
wire or screwdriver for discharging the capacitor; otherwise the terminal might melt or the capacitor
might be deteriorated.
The battery voltage is a high 72 V and thus use caution not to get an electrical shock accident.
When check electrical components, make sure lift the front wheels off the ground surface and block
the rear wheels.
When measuring the circuit, shut off the power supply and set measuring equipment. Then turn the
power supply on again.
(2) Caution to be taken when handling PWB

Observe the following conditions when handling the PWB removed from the truck.
• Do not touch adjustment knobs or switch on the PWB more than necessary.
• When carrying the PWB, put it in an anti-static bag to prevent damage due to static electricity.
(3) Caution to be taken when handling VTM

When handling the VTM, use caution not to allow the PWB to touch any metallic part; otherwise
the lithium battery which backs up memory may be short-circuited so that data be lost or there is fear
of setting on fire or malfunction.
(4) Caution to be taken when replacing PWB

• Record data on the hour meter before replacing the VTM PWB. See “Procedure for transmitting data”.
(5) Caution to be taken when measuring

When measuring the board coupler, use a small insulation probe. Do not apply the tester rods
directly to the coupler. The board might be damaged due to short-circuiting.
3.2.2 HOW TO USE TROUBLESHOOTING GUIDE

Check if any error code is displayed or how the problem occurs.
If any error code is displayed on the meter panel, see “3.2.5 TROUBLESHOOTING PROBLEMS
KNOWN BY DISPLAY”, and if no error code is displayed on the meter panel, see “3.2.6.
TROUBLESHOOTING INDIVIDUAL PROBLEMS”.
MOTOR OVERHEATING ERRORCODE

CONTROLLER OVERHEATING
NEUTRAL INTERLOCK
Fig. 3.10 Meter Panel

- 42 -
3. CONTROL SYSTEM
3.2.3 ERROR CODES SHOWN BY LED

Error codes (numbers) are shown by red and green LEDs on the controller CPU board.
Error codes are 2-digit numbers (decimal system) with the second and first digits blinking at an
interval of 0.5 seconds. The second and first digits are separated by 1-second OFF period.
(Example) Error code: 34 (load handling current detector defective)
Repeated hereafter
T10: Second digit blinks 3 times

T1: First digit blinks 4 times
Tb: 1-second separation
T0: 4-second blank before the above step is repeated.
3.2.4 CHECK BEFORE TROUBLESHOOTING

(1) Check wiring and terminals for looseness
A loose bolt or nut of the controller terminals will generate heat to cause a burned terminal. If any
looseness or heat build-up is found, polish the contact surface and retighten the bolt or nut securely.
Pay special attention to areas where a large current flows, such as the (P) and (N) terminals and
motor. Especially, a loose (N) terminal might allow a large current to pass through the PWB and in the
worst case it will be damaged.
(2) Check wire harness and cable visually
Check the outer covers of the wire harness and cable and if defective insulate with vinyl tape. If the
internal core wire is damaged, replace the harness or cable.
(3) Check fuses
Check the main fuse (inside the controller) and fuses in the fuse holder.
(4) Check communication line
Check if the communication line is displayed on the meter panel.
The communication line is normal if the mark P/E changes when the switch is switched over. If the
mark is not displayed, see “3.2.6 (1) METER PANEL DOES NOT WORK”.
(5) Check contactor chips
Polish any damaged contactor chip with a small file. If the chip is worn excessively, replace with a
new one.
Check the chip surface for any insulator.
(6) Leaks from the truck body
The wiring of the electric truck is insulated from the frame and thus any electric leak will cause
various problems. Check for electric leaks.
Wipe the battery case surface clean with a wet shop rag or paper and dry by blowing air.
(Criteria)
Wiringside: If the leak resistance is more than 100 kΩ, Frame – truck body receptacle (+)
the wiring condition in the wiring side is normal. Frame – truck body receptacle (-)
Battery side: If the electric leak is less than 1 V with 1 kΩ Frame – battery (+)
impedance, the wiring condition in the battery Frame – battery (-)
side is normal.
- 43 -
3. CONTROL SYSTEM
3.2.5 TROUBLESHOOTING PROBLEMS KNOWN BY DISPLAY

(1) Pictorial symbol on display
Controller overheating: blinks
Right drive controller temp. rise LED error code: 24
Right drive controller temp. abnormal LED error code: 26
Left drive controller temp. rise LED error code: 57
Left drive controller temp. abnormal LED error code: 56
Load handling controller temp. rise LED error code: 60
Load handling controller temp. abnormal LED error code: 39
Turn off key switch and hold for about 30 min. to cool
controller. [ • Reduce load.
Problem persists after key switch is turned on? NO
YES
FET module
Key switch
Check for a loose screw of
...................... Turn it OFF.
TMRU, TMRV, TMRW, [ • Retighten.
Battery connectors NG
T M L U , T M LV, T M LW,
....................... Disconnect.
TMPU, TMPV, and TMPW.
OK
Continuity Key switch

Check for continuity between ...................... Turn it OFF.
CN3R-1,7,2,8,3,9,4,10 and [ • Repair wiring.
Battery connectors NG
fan connectors CN8-13, and ....................... Disconnect.
CN1R-8.
OK
Check fan separately. [ • Fan

NG
OK
[ • CPU board
- 44 -
3. CONTROL SYSTEM
Motor overheating: blinks

Right drive motor temp. abnormal LED error code: 28
Left drive motor temp. abnormal LED error code: 58
Pump motor temp. abnormal LED error code: 65
Turn off key switch and hold for about 1 hour to cool the
motor. [ • Reduce load.
Problem persists when key switch is turned on? NO
YES
Continuity
Check for continuity
between:
CN2-5, 16 and right drive
motor and thermo sensor
connectors (18) and (19); Key switch ... Turn it OFF.
CN2-6, 17 and left drive Battery
motor and thermo sensor connectors ..... Disconnect.
connectors (16) and (17);
CN2-8, 19 and pump motor [ • Repair wiring.
and thermo sensor NG
connectors (22) and (23)
OK
Check thermo sensor separately. [• Thermo sensor

NG
OK
• Right drive motor

• Left drive motor
• Pump motor
• CPU board
Low voltage detection: blinks

Traveling low voltage detection LED error code: 21
Load handling low voltage detection LED error code: 44
Check battery voltage. [ • Charge
NG
OK
Continuity
Check for continuity Key switch ... Turn it OFF.
Battery [ • Repair wiring.
between CN9-1 and P NG
terminal. connectors ..... Disconnect.
OK
[ • CPU board
- 45 -
3. CONTROL SYSTEM
Neutral interlock: mark blinks

Traveling neutral interlock LED error code: 23
Interlock is released by shifting F/R lever in neutral or [ • Normal

turning accelerator OFF? YES
NO
Continuity
between: Key switch ... Turn it OFF.
CN1-22 and forward switch Battery [ • Repair wiring.
(53): connectors ..... Disconnect. NG
CN1-21 and reverse switch
(54) and F/R common (2).
OK
Check F/R switch separately. [ • F/R switch

NG
OK
Continuity
between:
CN1-10, 24, 23 and
Key switch ... Turn it OFF.
accelerator 1 (187), (93) [ • Repair wiring.
and (186); Battery
connectors ..... Disconnect. NG
CN1-12, 11, 25 and
accelerator 2 (189), (94)
and (188).
OK
Check accelerators 1 and 2 separately. [ • Accelerators

NG
OK
[ • CPU board
- 46 -
3. CONTROL SYSTEM
Load handling neutral lock LED error code: 66
Interlock is released without operating load handling

[ • Normal
levers?
YES
NO
Continuity
CN1-2, 16 and valve Battery [ • Repair wiring.
controller CN2-16, 15 connectors ..... Disconnect. NG
(145) (179)
OK
Check valve controller separately. [ • Valve controller

NG
OK
[ • CPU board
- 47 -
3. CONTROL SYSTEM
(2) Error code on display

Accelerator wire broken: 301 LED error code: 17, 18
Key switch .... Turn it ON.

F/R
lever ..... Shift into F or R.
(187) – (186) Parking brake • Power supply board
lever .................... Release. 0V • Wire harness (187), (186)
Accelerator
pedal ........ Leave released.
5V
Key switch .... Turn it ON.

F/R lever .............. Neutral
(93) – (186) Parking brake lever • Accelerator
............................. Release. • Wire harness (93) (186)
Accelerator pedal less
........................ Press fully. than
0.1 V
more than 2.5 V
[ • CPU board
Traveling current sensor abnormal: 302 LED error code: 19, 59
Check CSRU, CSRW or Key switch ... Turn it OFF.

CSLU, CSLW for damage Battery [ • Current sensor
or deformation. connectors ..... Disconnect. YES
NO
Continuity
between:
CN9-11, 10,9, 8 and CSRU
connector; Key switch ... Turn it OFF.
CN9-24, 22, 23, 21 and Battery [ • Repair wiring.
NG
CSRW connector; connectors ..... Disconnect.
CN9-7, 5, 6, 4 and CSLU
connector;
CN9-20, 18, 19, 17 and
CSLW connector.
OK
• Current sensor
• CPU board
- 48 -
3. CONTROL SYSTEM
Traveling FET module short-circuited: 303 LED error code: 1
Key switch ... Turn it OFF. [ • Fuses F1 and F2

Check fuses F1 and F2. Battery NG
connectors ..... Disconnect.
OK
Continuity
between:
CN10-3 and P2 terminal;
CN6R-5,4,12,13 and
TMRU connector;
CN7R-7,6,17,18 and
TMRU connector;
CN6R-2,1,9,10 and TMRV
connector;
CN7R-5,4,15, 16 and
TMRV connector;
CN7R-10,9,20,21 and
TMRW connector; Key switch ... Turn it OFF.
CN7R-3,2,13,14 and Battery [ • Repair wiring.
TMRW connector; connectors ..... Disconnect. NG
CN5R-13,12,25, 26 and
TMLU connector;
CN5R-4,3,16,17 and
TMLU connector;
CN5R-10,9,22,23 and
TMLV connector;
CN5R-2,1,14,15 and TMLV
connector;
CN5R-7,6,19,20 and
TMLW connector;
CN6R-8,7,15,16 and
TMLW connector;
CN4-1,2,3,4,5,6 and
CN11R-1,2,3,4,5,6;
CN6-1,2,3,4,5,6,7,8 and
CN10R-1,2,3,4,5,6,7,8.
OK
Check TMRU, Key switch ... Turn it OFF.

T M RV, T M R W, Battery [ • Replace damaged FET module with a new one.
TMLU, TMLV, and connectors ..... Disconnect. NG
TMLW separately.
OK
• Power supply board

• CPU board
- 49 -
3. CONTROL SYSTEM
Traveling FET module open: 304 LED error code: 2,52

Traveling fuse open: 307 LED error code: 20, 50

Check fuses F1 and F2. Battery [ • Fuses F1 and F2
OK
Continuity
between:
CN6R-5,4,12,13 and
TMRU connector;
CN7R-7,6,17,18 and
TMRU connector;
CN6R-2,1,9,10 and TMRV
connector;
CN7R-5,4,15,16 and
TMRV connector;
CN7R-10, 9, 20, 21 and
TMRW connector; Key switch ... Turn it OFF.
TMRW connector; connectors ..... Disconnect. NG
CN5R-13,12,25,26 and
TMLU connector;
CN5R-4,3,16,17 and
TMLU connector;
CN5R-10,9,22,23 and
TMLV connector;
CN5R-2,1,14,15 and
TMLV connector;
CN5R-7,6,19,20 and
TMLW connector;
CN6R-8,7,15,16 and
TMLW connector;
CN4-1,2,3,4,5,6 and
CN11R-1,2,3,4,5,6;
CN6-1,2,3,4,5,6,7,8 and
CN10R-1,2,3,4,5,6,7,8.
Check drive motor for Key switch ... Turn it OFF.

overloading, short- Battery [ • Repair motor.
circuiting or grounding. connectors ..... Disconnect. NG
OK
Remove TMRU, TMRV,

TMRW, TMLU, TMLV, Key switch ... Turn it OFF.
Battery [ • Replace damaged FET module with a new one.
T M LW f r o m t r u c k a n d NG
check. connectors ..... Disconnect.
OK

• CPU board
- 50 -
3. CONTROL SYSTEM
MD contactor short-circuited: 305 LED error code: 3

MD contactor open: 306 LED error code: 4
MD is closed or opened by turning ON and OFF the key [ • CPU board

switch? YES
NO
Continuity
CN10-13,2 and MD Battery [ • Repair wiring.
connector;
CN10-3 and P2 terminal.
OK
Remove MD from truck and check. [ • MD

NG
OK
[ • CPU board
- 51 -
3. CONTROL SYSTEM
Rotation sensor defective: 308 LED error code: 41, 42
Continuity
between:
CN13-2,1 and right drive
motor rotation sensor A
(37) (38);
CN13-3,11 and right drive Key switch ... Turn it OFF.
motor rotation sensor B Battery [ • Repair wiring.
(34) (35); connectors ..... Disconnect. NG
CN13-6, 14 and left drive
motor rotation sensor A
(31) (32);
CN13-8,16 and left drive
motor rotation sensor B
(28) (29).
OK
Remove check rotation sensor from truck and check. [ • Rotation sensor
NG
OK
Check rotation sensor and slit plate for installation. [ • Reinstall slit plate.
NG
OK
[ • CPU board
Pump motor speed command defective: 401 LED error code: 35
Continuity
CN1-2,16 and valve Battery [ • Repair wiring.
controller CN2-16, 15 connectors ..... Disconnect. NG
(145) (179)
OK
Remove check valve controller from truck and check. [ • Valve controller
NG
OK
[ • CPU board
- 52 -
3. CONTROL SYSTEM
Pump motor current sensor error: 402 LED error code: 34
Check CSPU, CSPW for Key switch ... Turn it OFF.

damage or deformation. Battery [ • Current sensor
connectors ..... Disconnect. YES
NO
Continuity
CN10-11,9,10,8 and CSPU Battery [ • Repair wiring.
connector; connectors ..... Disconnect. NG
CN10-22,20,21, 19 and
CSPW connector.
OK
• Current sensor
• CPU board
Loading handling system FET module short-circuited: 403 LED error code: 30
Pump motor FET module open: 404 LED error code: 31
Pump motor fuse open: 407 LED error code: 45
Check fuse F3. Battery [ • Fuse F3
OK
Continuity
between:
CN10-1 and P22 terminal;
CN8R-8,7,15,16 and
TMPU connector;
CN9R-9, 8, 19, 20 and
TMPU connector; Key switch ... Turn it OFF.
TMPV connector; connectors ..... Disconnect. NG
CN9R-6,5,16,17 and
TMPV connector;
CN8R-2,1,9,10 and TMPW
connector;
CN9R-3,2,13,14 and
TMPW connector;
CN5-1,2,3,4,5,6,7,8 and
CN12R-1,2,3,4,5,6,7,8
OK
Remove TMPU, TMPV, Key switch ... Turn it OFF.

TMPW from truck and Battery [ • Replace defective FET module with a new one.
check. connectors ..... Disconnect. NG
OK

• CPU board
- 53 -
3. CONTROL SYSTEM
MP contactor short-circuited: 405 LED error code: 33

MP contactor open: 406 LED error code: 37
MD is closed or opened by turning ON or OFF key switch? [ • CPU board

YES
NO
Continuity
CN10-15,4 and MP Battery [ • Repair wiring.
connector; connectors ..... Disconnect. NG
CN10-1 and P22 terminal.
OK
Remove MP from truck and check. [ • MP

NG
OK
[ • CPU board
Pump motor rotation sensor defective: 408 LED error code: 43
Continuity
CN13-5,13,12 and pump Battery [ • Repair wiring.
motor rotation sensor (40) connectors ..... Disconnect. NG
(41)
OK
Remove rotation sensor from truck and check. [ • Rotation sensor

NG
OK
Check rotation sensor and slit plate for installation. [ • Reinstall slit plate.
NG
OK
[ • CPU board.
- 54 -
3. CONTROL SYSTEM
Steering potentiometer error: 503 LED error code: 63
Continuity
CN7-1,2,7 and steering Battery [ • Repair wiring.
potentiometer (192) (92) connectors ..... Disconnect. NG
(190)
OK
Remove steering potentiometers from truck and check. [ • Potentiometers

NG
OK
[ • CPU board
Controller thermo sensor defective: 504 LED error code: 22, 53, 36
Continuity
between:
CN10-5, 16 and TMRV Key switch ... Turn it OFF.
thermo sensor; [ • Repair wiring.
Battery NG
C N 1 0 - 6 , 1 7 a n d T M LV connectors ..... Disconnect.
thermo sensor;
CN10-7,18 and TMPV
thermo sensor.
OK
Remove thermo sensors from truck and check. [ • Thermo sensor

NG
OK
[ • CPU board
Other serious error: 501 LED error code: 7, 38

MD, MP contactor drive TR, coil defective
Continuity
CN10-13,2 and MD [ • Repair wiring.
Battery
connector; NG
connectors ..... Disconnect.
CN10-15,4 and MP
connector.
OK
Remove contactors from truck and check. [ • Contactors

NG
OK
[ • CPU board
- 55 -
3. CONTROL SYSTEM
F/R switch defective LED error code: 16

Continuity
between:
CN1-22 and Forward Key switch ... Turn it OFF.
switch (53); [ • Repair wiring.
Battery NG
CN1-21 and Reverse connectors ..... Disconnect.
switch (54):
CN-21 and F/R switch
common (2).
OK
Remove F/R switch from truck and check. [ • F/R switch

NG
OK
[ • CPU board
EPROM sum error LED error code: 82

EPROMACK error LED error code: 83
Pump motor WDT error LED error code: 84
Drive motor WDT error LED error code: 85
Error is removed by turning the key switch OFF and then

ON? [ • Normal operation.
Normal operation is possible? YES
NO
[ • CPU board
Load dump error LED error code: 86
Check battery connectors and cable connections.

Check battery main circuit inside controller and retighten [ • Repair wiring.
if needed. NG
OK
Remove contactors MD and MP from truck and check. [ • Contactors

NG
OK
Remove fuses F1, F2 and F3 from truck and check. [ • Fuses

NG
OK
[ • CPU board
- 56 -
3. CONTROL SYSTEM
Other moderate error: 502

Right drive motor temperature rise LED error code: 25
Left drive motor temperature rise LED error code: 55
Pump motor temperature rise LED error code: 64
Turn key switch OFF and hold for about 1 hour to cool
the motor. [ • Reduce load.
Problem persists when key switch is turned ON? NG
YES
Continuity
between:
motor thermo sensor Key switch ... Turn it OFF.
connectors (18) (19); Battery [ • Repair wiring.
CN2-6,17 and left drive connectors ..... Disconnect. NG
motor thermo sensor
connectors (16) (17);
CN2-8,19 and pump motor
thermo sensor connectors
(22), (23)
OK
Remove thermo sensors from truck and check. [ • Thermo sensors

NG
OK
• Right drive motor

• Left drive motor
• Pump motor
• CPU board
Right drive motor thermo sensor defective LED error code: 27

Left drive motor thermo sensor defective LED error code: 51
Pump motor thermo sensor defective LED error code: 46
Continuity
between:
motor thermo sensor
connector (18) (19); Key switch ... Turn it OFF.
[ • Repair wiring.
CN2-6,17 and left drive Battery
NG
m o t o r t h e r m o s e n s o r connectors ..... Disconnect.
connector (16) (17);
CN2-8, 19 and pump motor
thermo sensor connector
(22) (23)
OK
Remove thermo sensors from truck and check. [ • Thermo sensor

NG
OK
[ • CPU board
- 57 -
3. CONTROL SYSTEM
Right inching over LED error code: 67

Left inching over LED error code: 68
Problem is automatically removed when F/R lever is

placed in neutral, accelerator is pressed without applying [ • Normal
brake? NG
NO
Continuity
between:
CN1-22 and forward switch Key switch ... Turn it OFF.
(53); Battery [ • Repair wiring.
CN1-21 and reverse switch connectors ..... Disconnect. NG
(54)
CN1-21 and F/R switch
common (2)
OK
Remove F/R switch from truck and check. [ • F/R switch

NG
OK
Continuity
between:
CN1-10, 24, 23 and
accelerator 1 (187) (93) [ • Repair wiring.
(186); Battery
CN1-12,11,25 and
accelerator 2 (189) (94)
(188).
OK
Remove accelerators 1 and 2 from truck and check. [ • Accelerator

NG
OK
Continuity
Battery [ • Repair wiring.
CN1-7 and brake switch
(110) connectors ..... Disconnect. NG
CN1-7 and common (2)
OK
Remove brake switch from truck and check. [ • Brake switch

NG
OK
[ • CPU board
- 58 -
3. CONTROL SYSTEM
Drive motor overspeed LED error code: 91

Pump motor overspeed LED error code: 92
Error code is removed when motor speed is reduced. [ • Normal
[ • CPU board
- 59 -
3. CONTROL SYSTEM
3.2.6 TROUBLESHOOTING INDIVIDUAL PROBLEMS

(1) Meter panel does not work
• Key switch
• Wire harness (11), (101), (100)
(11) Key switch ........................... Turn it ON.
less • Fuse F4
than • Magnet contactor CM
more than 60 V 10 V
[ • Meter panel
(2) Either MD or MP contactor does not work.
Key switch ........................... Turn it ON. • CPU board

(12) Emergency stop switch ............. Release. • Power supply board
more
than
less than 40 V 40 V
Key switch ........................... Turn it ON. • Wire harness (12)

(165) • Magnet contactor CM
Emergency stop switch ............. Release. more
than
less than 40 V 40 V

(99) Emergency stop switch ............. Release. • Key switch
more
than
less than 40 V 40 V
(115) Key switch ........................... Turn it ON. • Wire harness (99)

Emergency stop switch ............. Release. more • Emergency stop switch
than
less than 40 V 40 V

(6)
Emergency stop switch ............. Release. more • Fuse F5
than
less than 40 V 40 V
• Wire harness (115)

• Battery
• Battery connectors (center tap)
- 60 -
3. CONTROL SYSTEM
(3) MD or MP contactor does not work.

• CPU board
[• Power supply board
(4) MD contactor works but truck won’t travel.
Seat is in neutral and seat turn switch is pushed in? • Put seat in neutral.
• Adjust seat turn switch.
NO
YES
Key switch ............. Turn it ON.

Parking brake F/R lever ....... Shift into F or R. • Parking brake switch
indicator is OFF? Parking brake lever ...... Return.
ON • Wire harness (15)
Accelerator pedal ........ Release.
OFF

(53) in F F/R lever ....... Shift into F or R. • Combination switch
(54) in R Parking brake lever ...... Return. • Wire harness (53), (54) (2)
5V
Accelerator pedal ........ Release.
0V

F/R lever ....... Shift into F or R. • Seat turn switch
(24) Parking brake lever ...... Return. • Wire harness (24) (2)
Accelerator pedal ........ Release. 5V
0V

(187) - (186) F/R lever ....... Shift into F or R. • Power supply board
Parking brake lever ...... Return. • Wire harness (187) (186)
Accelerator pedal ........ Release. 0V
5V

(93) - (186) F/R lever ....... Shift into F or R. • Accelerator
Parking brake lever ...... Return. less • Wire harness (93) (186)
Accelerator pedal ... Press fully. than
0.1 V
more than 2.5 V
[ • CPU board
- 61 -
3. CONTROL SYSTEM
(5) MP contactor works but load handling system does not work.
Valve controller is turned

on? Key switch .... Turn it ON. • Valve controller
• Power LED ON Joystick lever ...... Neutral • Wire harness (12) (2)
NO
• Model code displayed
YES
Valve controller error is Key switch .... Turn it ON. [ • Remedy according to error code.
displayed ? Joystick lever ...... Neutral YES
NO
Input value from joystick Key switch .... Turn it ON. • Joystick lever
lever Joystick lever ...... Neutral Neutral • Wire harness
Neutral switch ON switch
Input value: 1FF OFF
Output value to propor- Key switch .... Turn it ON.

tional valve Joystick lever .. Pull fully. [ • Valve controller
0
FF
Pump speed output value Key switch .... Turn it ON.

Joystick lever .. Pull fully. [ • Valve controller
0
FF
• CPU board
• Wire harness (145) (143)
- 62 -
3. CONTROL SYSTEM
3.2.7 INSPECTING MAJOR COMPONENTS

(1) Inspecting FET modules
Place the analog tester into the resistance measurement mode (kΩ) and measure the continuity and
resistance between terminals.
The values shown in Table 3.8 should be used as a rough guide. Note that the values vary according
to the type of tester and internal battery state.
Note 1. Do not touch terminals or soldered parts on the FET device by bare hand because they are
fragile to static electricity.
Note 2. When carrying or storing the FET modules, put them in a destaticized bag to protect against
static electricity and vibration shock.
Table 3.8
No. Tester lead, red (+) Tester lead, black (-) Standard value
1 D1 S2D2 2 – 3 kΩ
S1D2 D1 Ω
2 S1D2 S2 2 – 3 kΩ
S2 S1D2 Ω
3 G1 S1D2 approx. 4 kΩ
S1D2 G1 approx. 12 kΩ
4 G2 S2 approx. 4 kΩ
S2 G2 approx. 12 kΩ
5 D1 G1 approx. 20 kΩ
G1 D1 Ω
6 S1D2 G2 approx. 20 kΩ
G2 S1D2 Ω
S2
D1
G1 •
•
S1D2
Fig. 3.11 FET Module

- 63 -
3. CONTROL SYSTEM
(2) Inspecting FET module thermosensor

Remove the thermosensor connector of the V-phase FET module and measure the resistance between
the terminals of the thermosensor connector.
Temperature °C [°F] Resistance (kΩ)

10 [50] approx. 40
20 [68] approx. 25
30 [86] approx. 16
(3) Inspecting contactors

Remove the contactor coil connector and PRESSURESPRING
measure the resistance between the
terminals of the contactor connector. ARMATURE MOVABLE
• CONTACT
Resistance: approx. 35 Ω. • • a CONTACT

COIL
Check the contact surfaces, armature •
•
action, and spring condition. Measure the
continuity resistance when the contacts are
closed.
•
Resistance: 0 Ω CONNECTOR
Fig. 3.12 Contactor
When perform a continuity test on the contactor removed from the truck, connect a flywheel
diode (200 V/1 A or more) to the coil terminal.
In addition, do not apply a voltage of 46 V to the coil continuously. When the armature is attracted,
reduce the voltage to 12 V within a few seconds.
- 64 -
3. CONTROL SYSTEM
(4) Inspecting fuses

Remove the fuse from the terminal or one of the fuse terminals and measure the resistance between
both fuse terminals.
Resistance: 0 Ω
If the tester reads (infinity), it indicates that the

fuse is blown out. Remove the cause and replace the
blown fuse with a new one.
Fig. 3.13 Fuse
(5) Inspecting motor-side thermo sensor

Remove the motor thermo sensor connector and measure the resistance between the terminals of
the thermo sensor connector.
Temperature Resistance (kΩ)

10 °C or 50 °F about 20
20 °C or 68 °F about 13
30 °C or 86 °F about 9
(6) Inspecting motor-side rotation sensor

Remove the motor-side rotation sensor connector and measure the resistance between the terminals
of the rotation sensor-side connector.
Resistance: about 620Ω (20°C or 68 °F)
SENSOR
•
•
CONNECTOR
Fig. 3.14 Rotation Sensor
- 65 -
3. CONTROL SYSTEM
3.2.8 BOLT TORQUE FOR EACH PART

The table given below shows screw torque and applicable screws for controller components and terminals.
Use a suitable torque screwdriver or wrench.
Screw Tightening torque

Component name Device symbol Location Screw type
size N-m [lbf-ft]
PWB CPU, power supply Fixing M4.5 1.0+0.5

0 4142 4.5 x 16
[0.738+0.369
0 ]
Power module TMRU/V/W Fixing M5 2.5 ± 0.5 47S 5 x 45-B

TMLU/V/W [1.844 ± 0.369]
TMPU/V/W
Power module Fixing M5 2.5 ± 0.5 47S 5 x 25-W

aluminum block [1.844 ± 0.369]
terminal
Terminal M8 9.8+0.5
-2 1S 8 x 16-B
[7.228-1.475
+0.369
]
Capacitor board CBR, CBL, CBP Fixing & M5 2.5 ± 0.5 47S 5 x 16, 20,25-B
terminal [1.844 ± 0.369]
Contactor MD, MP Fixing M5 2.5 ± 0.5 47S 5x18-B

[1.844 ± 0.369]
Terminal M8 9.8+0.5
-2 4213BS-8
[7.228-1.475
+0.369
]
Current sensor CSRU, CSRW, Fixing M4 1.5 ± 0.2

CSLU, CSLW, [1.106 ± 0.148]
CSPU, CSPW 47S 4x20-B
Terminal Fixing M8 12 ± 1
[8.851 ± 0.738]
Terminal M8 8.3 ± 1 4211BS-8

[6.122 ± 0.738]
Other screws are tightened to the following standard torque:

M4: 1.5 ± 0.2 N-m [1.106 ± 0.148 lbs-ft]
M5: 2.5 ± 0.5 N-m [1.844 ± 0.369 lbf-ft]
-2 N-m [7.228 -1.475 lbf-ft]
M8: 9.8+0.5 +0.369
- 66 -
3. CONTROL SYSTEM
3.3 ADJUSTMENT
3.3.1 CONTROLLER
(1) Model setting
When mounting the controller on the truck, it is necessary to set the truck model to the controller.
Whenever the controller or CPU board is replaced with a new one, it is also required to set the truck
model to the controller.
Remove the grommet at the front of the inverter cover.

Set the dip switches (see the figure below) for setting the truck model on the CPU board under the
hole.
Return the grommet onto the inverter cover.
Note:
1. The default is FA15B.
2. Make sure the power supply is turned OFF before setting the truck model.
TRUCK MODEL
SETTING SWITCH GROMMET
Dip switch
Truck model
Default
Detail of dip switch

for setting truck model
Do not touch the other dip switches; otherwise, the controller will fail to operate normally.
Fig. 3.15
- 67 -
3. CONTROL SYSTEM
(2) Storing the reading of the rear potentiometer in memory

It is necessary to store the reading of the rear potentiometer in memory when mounting the controller
onto the truck. This procedure is also required when the controller or the CPU board is replaced with
a new one or when the rear potentiometer is replaced with a new one or adjusted.
Store the readings (output values produced when the steering wheel is at the left end, center, and
right end) of the rear potentiometer into the inverter’s memory in the following manner:
Install the steer memory switch to the 3P coupler at the right side (truck body harness side) of the
inverter.
Press and hold the steer memory switch while turning on the key switch to enter the Adjustment
mode. The left-side turn signal blinks.
Turn the steering wheel to the left end. Press the steer memory switch. The sideways travel chime
sound to indicate that the left-end value has been stored in memory.
Put the rear wheels in straight position. Press the steer memory switch. The right-side turn signal
blinks to indicate that the center value has been stored in memory.
Turn the steering wheel to the right end. Press the steer memory switch. The right-side turn signal
goes out to indicate that the right-end value has been stored in memory.
Turn the key switch OFF. The adjustment procedure is completed.
Remove the steer memory switch.
INVERTER
PUSHBUTTON
SWITCH (Press to
turn it on)
CONNECTOR
Front of
the truck CONNECTOR :
SUMIKO
CL07D03M
STEER MEMORY SWITCH

Right side of the truck
Fig. 3.16
- 68 -
4. DRIVE AXLE
4. DRIVE AXLE
Truck model FA15B FA20B, FA25B FA30B
Item
Front axle
Side cylinder
Type Double-acting piston
Cylinder I.D. 63 mm [2.48 in.]
Rod O.D. 30 mm [1.18 in.]
Stroke 129 mm [5.08 in.] 156 mm [6.14 in.]
Drive unit
Type 3-stage reduction
Reduction ratio 15.021 17.168 20.065
Lubrication oil
Type Engine oil SAE 10W Class CD
Q’ty 2.2 liters [0.58 US gal] 2.8 liters [0.74 US gal] 4.0 liters [1.06 US gal]
Wheel
Tire size 18 x 7-8-14PR (I) 21 x 8-9-16PR(I) 23 x 9-10-16PR(I)
Inflation pressure 900 kPa [128 psi] 1000 kPa [142 psi] 900 kPa [128 psi]
4.1 DENERAL DESCRIPTION

The drive axle consists of the drive unit and front axle. The truck has two drive axles which are
mounted to the right and left sides of the front area of the frame.
4.1.1 FRONT AXLE

The front axle supports the drive unit and is supported on the frame by two tapered roller bearings.
The front axle has the side cylinder rod connected to the shaft through the arm and rotates 90° by the
side cylinder.
- 69 -
4. DRIVE AXLE
FRONT SIDE FRONT SIDE

CYLINDER (RIGHT) CYLINDER (LEFT)
•
•
POTENTIOMETER
POTENTIOMETER
• •
• •
DRIVE UNIT (RIGHT) DRIVE UNIT (LEFT)
Fig. 4.1 Front Axle (FA15B) 1/2

- 70 -
4. DRIVE AXLE
Turn 95°
Turn 90°
Turn 85°
69.2°
65.3°
61.3°
Tightening torque: 785 N-m

{8000 kgf-cm} [6948 lbf-in.]
Preload: 29 – 39 N-m
{300 – 400 kgf-cm}
[256.7 – 345.2 lbf-in.]
SPINDLE •
•
Seal in grease.
•
View looking from
TAPERED •
ROLLER
BEARING
•
•
“O”-RING
View looking from

- 71 -
4. DRIVE AXLE

• •
POTENTIOMETER
POTENTIOMETER
• •
• •
Fig. 4.3 Front Axle (FA20B, FA25B) 1/2

- 72 -
4. DRIVE AXLE
Turn 95°
Turn 90°
Turn 85°
69.2°
65.2°
61.0°
Tightening torque: 107.9 N-m
{11000 kgf-cm} [955 lbf-in.]
{450 – 500 kgf-cm}
[389.4 – 433.7 lbf-in.]
SPINDLE •
•
Seal in grease.
•
TAPERED
ROLLER •
BEARING
•
•
“O”-RING
View looking from
View looking from
Fig. 4.4 Front Axle (FA20B, FA25B) 2/2

- 73 -
4. DRIVE AXLE

• •
POTENTIOMETER
POTENTIOMETER
• •
• •

- 74 -
4. DRIVE AXLE
Turn 95°
Turn 90°
Turn 85°
69.2°
Tightening torque: 107.9 N-m
{11000 kgf-cm} [955 lbf-in.] 65.3°
{450 – 500 kgf-cm} 61.3°
[389.4 – 433.7 lbf-in.]
SPINDLE •
•
Seal in grease.
•
TAPERED
ROLLER •
BEARING
•
“O”-RING •
View looking from
View looking from

- 75 -
4. DRIVE AXLE
4.1.2 FRONT SIDE-CYLINDER

The front side-cylinder has the design as shown in Fig. 4.7. The cylinder tail is connected to the
axle support and the cylinder rod to the rotating shaft arm of the axle. When the cylinder rod extends,
the left-side axle turns clockwise while the right-side axle turns counter-clockwise. The rotation of
the axles is detected by the potentiometers and transmitted to the controller.
• •
• • • •
• •
• • • •
• •
•
•
Tightening torque:
372.7 – 559 N-m
{38 –57 kgf-m}
[274.9 – 412.3 lbf-ft]
RIGHT SIDE
CYLINDER TAIL END
LEFT SIDE-CYLINDER RIGHT SIDE-CYLINDER
View looking from
1. JOINT 6. BUSHING 11. “O”-RING

2. DUST SEAL 7. “O”-RING 12. WEAR RING
3. SNAP RING 8. CYLINDER 13. PACKING
4. PACKING 9. ROD 14. PISTON
5. CYLINDER CAP 10. PACKING 15. NUT
Fig. 4.7 Front Side-cylinder
- 76 -
4. DRIVE AXLE
4.1.3 DRIVE UNIT

The drive unit has the design as shown in Fig. 4.8 and it is installed to the front axle.
The drive unit case is also used as the drive motor front bracket on which the drive motor is located.
Gear A is engaged with the drive motor shaft and transmits the power from the drive motor to the
wheel through gears B, C, D and E.
The drive motor shaft has a disk brake which combines with the brake caliplers mounted on the
case cover to form a brake unit.
DRIVE MOTOR
GEAR A
•
BRAKE DISK
BRAKE •
CALIPERS
GEAR B
• •
GEAR D
TAPERED •
ROLLER
BEARING
GEAR C • •
•
•
GEAR E
•
TAPERED ROLLER
BEARING
OIL SEAL
Section –
Note 1. The sketches show the drive unit of the FA30B. Those of the FA15B, FA20B and
FA25B are similar.
Note 2. The sketches show the left-side drive unit. The right-side drive unit is symmetrical to it.
Fig. 4.8 Drive Unit

- 77 -
4. DRIVE AXLE
NOTE
- 78 -
5. STEERING SYSTEM
5. STEERING SYSTEM
Truck model FA20B
FA15B FA25B
Item FA30B
Type Hydrostatic power steering
Steering wheel diameter 360 mm [14.2 in]
Orbitrol
Type Non-load reaction, load sensing type
Capacity 184 cc/rev
Pressure setting 13.7 MPa {140 kgf/ cm2}[1987 psi]
Steering cylinder
Type Double-acting piston type
Cylinder bore 80 mm [3.15 in] 90 mm[ 3.54 in]
Cylinder rod diameter 45 mm [1.77 in] 50 mm [1.97 in]
Stroke 222 mm [8.7 in] 240 mm [9.45 in]
Shift cylinder
Type Double-acting piston type
Cylinder bore 63 mm [ 2.48 in] 71 mm [2.80 in]
Cylinder rod diameter 40 mm [1.58 in] 45 mm [1.77 in]
Stroke 89 mm [3.50 in] 95 mm [3.74 in]
Steering axle
Type Center pin supported, single-plate welded construction
Steering angle FA20B/25B FA30B
Inner wheels 107° 109° 107°
Outer wheels 73° 71° 73°
Wheel
Size 16 x 6-8-10PR(I) 18 x 7-8-14PR(I)
Inflation pressure 700 kPa [99.6 psi] 900 kPa [128 psi]

The steering system is a hydrostatic power steering unit consisting of a steering wheel, orbitrol,
steering cylinder, shift cylinder, and steering axle.
- 79 -
5. STEERING SYSTEM
5.1.1 STEERING UNIT

The steering wheel has a construction shown in Figs. 5.1 and 5.2 and consists of the steering wheel,
steering shaft and orbitrol.
The steering wheel is installed onto the steering shaft which is in turn connected to the orbitrol
drive shaft through the universal joint.
STEERING
WHEEL
LOCK LEVER
UNIVERSAL
JOINT
ORBITROL
Fig. 5.1 Steering Wheel Unit 1/2

- 80 -
5. STEERING SYSTEM
F/R LEVER
LIGHTING SWITCH
Front of the truck
COMBINATION
SWITCH
STEERING
SHAFT
Front of the truck
View looking from
Front of
the truck
View looking from
View looking from
Fig. 5.2 Steering Wheel Unit 2/2
- 81 -
5. STEERING SYSTEM
5.1.2 ORBITROL
The orbitrol sends pressure oil from the pump selectively to the steering cylinders. It consists
primarily of a control valve and a metering device.
The control valve used in the orbitrol is not an ordinary spool valve whose spool moves in the axial
direction, but a rotary valve which consists of a sleeve and a spool that rotate together forming different
oil passages through the combination of their oil holes. The valve housing is provided with four ports
which lead to the pump, tank, right and left chambers of the cylinder. Between the inlet port and return
port is a check valve.
The metering device consists of an internally toothed stator and an externally toothed rotor. During
normal operation, it operates as an oil motor. In an emergency, it can be used as a hand pump. The
rotor is mechanically linked with the sleeve through the drive shaft so that feedback operation is
possible.
The rotary valve switches over the oil passages using the grooves at the outer periphery of the spool
and the holes in the sleeve. The sleeve is interlocked with the motor’s rotor though the cross pin and
drive shaft while the spool is splined to the steering shaft.
•
••
•
•
•
•
• •
• • •
•
•
•
•
•
1. DUST SEAL 8. SLEEVE 15. SOLENOID VALVE

2. RETAINING RING 9. SPOOL 16. CHECK VALVE
3. SEAL GLAND BUSHING 10. SPACER PLATE 17. CHECK VALVE
4. NEEDLE BEARING 11. GEROTOR 18. VALVE BLOCK
5. CENTERING SPRING 12. END CAP 19. BALL
6. PIN 13. ADAPTER SCREW
7. HOUSING 14. RETAINER SCREW
Fig. 5.3 Orbitrol

- 82 -
5. STEERING SYSTEM
5.1.3 PRIORITY VALVE

The priority valve, located between the pump and orbitrol, suppresses changes in the pump discharge
due to changes in engine speed, thus keeping the steering force and speed always constant.
This valve has a load sensing function to deliver the necessary flow to supply the steering system
through the CF port.
to ORBITROL
(P port)
from PUMP
to CONTROL
VALVE (P port)
to TANK to ORBITROL
(LS port)
Fig. 5.4 Priority Valve

- 83 -
5. STEERING SYSTEM
5.1.4 POWER CYLINDER

The power cylinder is a double-acting piston type which has a piston at the center of the cylinder
rod with each end of the rod moving in and out of the cylinder.
The cylinder rod is supported through bushings to the cylinder caps at both ends and its oil tightness
is maintained by packings.
• • •
• •• • •
•
•
1. DUST SEAL 5. PACKING 9. BUSHING

2. SNAP RING 6. CYLINDER 10. CYLINDER CAP
3. BACK-UP SEAL 7. PISTON ROD
4. PACKING 8. “O”-RING
Fig. 5.5 Power Cylinder
- 84 -
5. STEERING SYSTEM
5.1.5 SHIFT CYLINDER

The shift cylinder is a double-acting piston type and is fitted to the shift plate.
Each end of the cylinder rod is connected through a joint to the rear wheel support arm.
• • • • • •
• •• • •
•
1. DUST SEAL 7. PACKING

2. SNAP RING 8. CYLINDER
3. BACK-UP SEAL 9. PISTON ROD
4. PACKING 10. “O”-RING
5. PACKING 11. BUSHING
6. WEAR RING 12. CYLINDER CAP View looking from
Fig. 5.6 Shift Cylinder
- 85 -
5. STEERING SYSTEM
5.1.6 STEERING AXLE

The steering axle is installed on the rear part of the frame. Figures 5.7 to 5.10 show its construction.
The wheel support is mounted on the axle by two taper roller bearings and is turned around the
shaft by the power cylinder.
When the truck is put in the sideways drive mode, the steering axle is turned about 90° from the
straight-ahead position by the shift cylinder.
Tightening torque:
785 N-m {8000 kgf-cm}
[579 lbf-ft]
Preload:
19.6 – 24.5
{200 – 250 kgf-cm}
[14.46 – 18.07 lbf-ft]
•
OIL SEAL
TAPERED •
ROLLER BEARING •
OIL SEAL
•
•
Fig. 5.7 Steering Axle (FA15B) 1/2

- 86 -
5. STEERING SYSTEM
View looking from
1. OIL SEAL
2. TAPERED ROLLER
BEARING
3. TAPERED ROLLER
BEARING
Seal in grease.
4. NUT
• 5. COTTER PIN
6. CAP
• •
• •
• •
Preload:
1.7 – 2.0 N-m {17 – 20 kgf-cm}
[15.05 – 15.05 lbf-in.]
Fig. 5.8 Steering Axle (FA15B) 2/2
- 87 -
5. STEERING SYSTEM
Tightening torque:
785 N-m {8000 kgf-cm}
[579 lbf-ft]
Preload:
24.5 – 29.4 N-m
{250 – 300 kgf-cm}
[216.8 – 260.2 lbf-in.]
OIL SEAL •
TAPERED ROLLER •
BEARING •
OIL SEAL
••
Fig. 5.9 Steering Axle (FA20B, FA25B, FA30B) 1/2
- 88 -
5. STEERING SYSTEM
View looking from
1. OIL SEAL
2. TAPERED ROLLER
BEARING
3. TAPERED ROLLER
BEARING
4. NUT
5. COTTER PIN
Seal in grease. 6. CAP
•
••
• •
••
Preload:
1.7 – 2.0 N-m {17 –20kgf-cm}
[15.05 – 15.05 lbf-in.]
Fig. 5.10 Steering Axle (FA20B, FA25B, FA30B) 2/2
- 89 -
5. STEERING SYSTEM
5.1.7 FRONT WHEEL CONTROL LEVER

The front wheel control lever corrects the path of the truck in the sideways travel mode. It is located
at the right side of the operator’s seat.
The operation of the lever is transmitted to the valve controller by the potentiometer in the form of
voltage change.
FRONT WHEEL
CONTROL LEVER SPRING
•
• •
POTENTIOMETER
• •
STOPPER
•
•
About 7 mm [0.276 in.]
Detail of the lever
POTENTIOMETER STABILIZED POWER SUPPLY: 5 ± 0.01 V
Volt meter
Adjustment circuit
Adjustment procedure:
1. Connect the power supply and voltmeter to the adjustment circuit as shown in the above figure.
2. Turn the potentiometer so that meter reads 5 ± 0.05 V when the lever is located at the position,
and lock.
3. Make sure the meter reads 4.5 ± 0.05 V when the lever is located at the position.
Fig. 5.11 Front Wheel Control Lever

- 90 -
5. STEERING SYSTEM
Sideways driving
When the sideways travel switch is pressed, the solenoids b3, b4, b5 and b6 of the control valve are
energized. (See Fig. 7.53)
Therefore, both the front and rear side cylinders operate to turn the four wheel supports 90°. When
the wheel supports are positioned for sideways driving, the cylinders stop their operation thanks to the
switch.
Note: You can select sideways drive mode only when the change lever is in neutral, the mast tilted
backward (EXA & EXE), and the steering wheel in the straight position. The driver can check
the operating status of the truck by seeing the monitor lamps on the dashboard.
The rotating status of the wheel supports is inputted to the controller by the potentiometer.
In the sideways driving mode, when the F/R lever is put in the reverse position, the truck travels to
the right and when the lever is put in the forward position, the truck travels to the left.
Straight travel Sideways driving
Fig. 5.12 Sideways Driving
- 91 -
5. STEERING SYSTEM
POWER CYLINDER
REAR SIDE-CYLINDER
POTENTIOMETER STRAIGHT TRAVEL

SWITCH
•
•
2 mm [0.079 in.]
SWITCH
•
2 mm [0.079 in.]
SWITCH
Adjust the switch to the value shown above in the

sideways travel mode and the switch to the value
shown above in the straight travel mode.
Detail of area
Adjusting potentiometer
1. Apply a voltage of 5 V DC between and .
2. With the truck in the straight travel mode, turn the potentiometer to ensure that the voltage between
and is 2.5 0.1 V.
Fig. 5.13 Cylinder Installation
- 92 -
6. BRAKE SYSTEM
6. BRAKE SYSTEM
Type Motor-shaft braking, hydraulic disk brake
Pedal ratio
Master cylinder I.D. 19.05 mm [0.75 in.]
Wheel cylinder I.D. 19.05 mm [0.75 in.]
Disk O.D. 200 mm [7.87 in.]

The brake system consists of the brake disk, brake calipers and master cylinder.
6.1.1 BRAKE CALIPER

The brake calipers has the construction as shown in Fig. 6.1 and consists of the wheel cylinder,
levers A, B, C, and D.
BRAKE DISK
• PAD
•
LEVER B
•
WHEEL CYLINDER
• CUP
LEVER A
• • •
•
PISTON
LEVER D BLEEDER
LEVER C
• •
Fig. 6.1 Brake Caliper
- 93 -
6. BRAKE SYSTEM
BRAKE PEDAL 2
MASTER CYLINDER
BRAKE SWITCH 2
BRAKE SWITCH 1
BRAKE PEDAL 1
Unit: mm [in.]
FA20B
FA15B FA25B FA30B
110 mm 105 mm
Pedal height [4.33 in.] [4.13 in.]
5 mm
Play [0.197 in.]
5 - 10 mm
Switch operating [0.197 -
distance 0.393 in.]
The sketches show the brake pedals for the FA20B and FA25B. The other truck models have similar
brake pedals.
Fig. 6.2 Brake Pedals
- 94 -
6. BRAKE SYSTEM
6.1.2 MASTER CYLINDER

The master cylinder is installed on the brake pedal bracket and has a cross sectional view as shown
in Fig. 6.3.
Inside the master cylinder are a check valve, spring and piston, all of which are secured with snap
ring.
The piston has primary and secondary cups attached and slides inside the cylinder as the brake
pedal is operated.
The check valve maintains an appropriate pressure in the wheel cylinder and brake piping. It also
blocks up the wheel cylinder piston cup to prevent oil leakage and the development of vapor lock.
from RESERVE
TANK
SNAP RING
to BRAKE
CALIPERS
LOCK NUT
YOKE
•
• •
• •
• • •
• •
PUSH ROD
BOOT
to BRAKE
CALIPERS
SECONDARY CUP
SPRING CHECK VALVE
PISTON
PRIMARY CUP
Fig. 6.3 Master Cylinder
- 95 -
6. BRAKE SYSTEM
6.1.3 PARKING BRAKE

The parking brake consists of the brake lever and cable as shown in Fig. 6.4. The brake calipers are
used also for the foot brake.
the cable is connected to the lever B of the brake calipers. When the brake lever is pulled, the cable
pulls the lever B outward.
• BRAKE LEVER
SWITCH
•
RIGHT-SIDE CABLE
• •
LEFT-SIDE CABLE
Fig. 6.4 Parking Brake

- 96 -
6. BRAKE SYSTEM
6.2 MAINTENANCE
Preparation
1. Park the truck on a level surface and put the front axle in the sideways travel mode.
2. Block the wheels and apply the parking brake.
6.2.1 ADJUSTING CLEARANCE

(1) Make sure the wheels are securely blocked
before releasing the parking brake.
(2) Loosen the lock nuts of the adjustment bolts
and .
(3) Adjust the clearance between the front end of
the bolt and lever to 2 mm [0.079 in.].
•
(4) Adjust the clearance between the front end of
the bolt and wheel cylinder to 1 mm [0.039
in.].
•
(5) Tighten the lock nuts of bolts and .
(6) Apply the parking brake.
Fig. 6.5
6.2.2 REPLACING PADS

(1) Make sure the wheels are securely blocked.
Release the parking brake.
(2) Loosen the bolts and and widen the PAD
clearance between the pad and disk. •

(3) Remove the brake calipers.
(4) Remove the old pad and install a new pad.
Tightening torque: 17.7 – 26.5 N-m

{180 – 270 kgf-cm}
[156.7 – 234.5 lbf-in.] •
Tightening torque:
(5) Reinstall the brake calipers. 17.7 – 26.5 N-m
(6) Adjust the clearance. (See 6.2.1.) {180 – 270 kgf-cm}
[156.7 – 234.5 lbf-in.]
Fig. 6.6
- 97 -
6. BRAKE SYSTEM
6.2.3 ADJUSTING BRAKE PEDALS

(1) Adjusting pedal height
ADJUSTER
Loosen the adjuster lock nut.
Turn the adjuster to adjust the pedal height to
the value shown in Fig. 6.2.
Secure the adjuster with the lock nut.
• •
LOCK
NUT
Fig. 6.7
(2) Adjusting brake pedal play
PUSH ROD
Loosen the push rod lock nut.
Make the front end of the push rod in contact MASTER CYLINDER
with master cylinder piston.

•
Adjust the push rod length so that the brake is •
•
applied when the pedal is pressed 5 mm [0.197
in.].
Secure the push rod with the lock nut. LOCK NUT
Fig. 6.8
(3) Adjusting brake switches
Remove the brake switch connector. BRAKE SWITCH 2 BRAKE SWITCH 1
Loosen the brake switch lock nut. •

• LOCK NUT
Put the tester in the resistance measurement mode
and connect it to the brake switch-side connector.
Press the brake pedal 5 mm [0.197 in.] and hold. •
Turn the entire switch to a position which turns
OFF the switch. Secure the switch with the lock
nut.
Remove the tester and connect the brake switch
connector to the harness correctly. Fig. 6.9
- 98 -
6. BRAKE SYSTEM
6.2.4 ADJUSTING PARKING BRAKE SWITCH

(1) Put the parking brake switch in an operating
position.
(2) Loosen the switch mounting bolts.
(3) Separate the switch roller from the cam and then
bring them closer to each other.
(4) Make the roller in contact with the cam and then
press further until the switch clicks. Press another
1 mm [0.039 in.] and secure in position.
(5) Put the brake lever in the release position. Make CAM
sure the switch operates when the brake lever is •
•
placed in the operating position. •
MOUNTING
BOLTS
Fig. 6.9
- 99 -
6. BRAKE SYSTEM
NOTE
- 100 -
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
Truck model FA15B FA20B, FA25B FA30B
Item
Main pump
Type Single-acting gear pump Dual gear pump
Model TMG1A23 TMG1A30 DSG1A32
Discharge 24.5 cc/rev 30.9 cc/rev 32.4 cc/rev
Control valve
Type 6-spool sliding type, hydraulic pilot proportional solenoid valve
Model KVSF-65PSL
Pressure setting 17.7 MPa [2560 psi]
Lift cylinder
Type Single-acting piston
Cylinder bore 45 mm [1.77 in.] 50 mm [1.97 in.] 55 mm [2.12]
Stroke 1495 mm [58.86 in.]
Tilt cylinder
Type Double-acting piston
Cylinder bore 63 mm [2.48 in.]
Rod O.D. 30 mm [1.18 in.]
Stroke 183 mm [7.21 in.] 191 mm [7.52 in.]
Oil tank
Type Welded construction, separately mounted.
Capacity 19.7 liters [5.2 US gal] 24.5 liters [6.5 US gal]

The hydraulic system consists of a main pump, control valve, lift cylinders and tilt cylinders. The
oil is supplied from the tank at the right of the frame.
7.1.1 MAIN PUMP

The main pump is a gear type driven by the motor.
The main pump consists of a pump body, a pair 2 pairs (for the FA30B) of gears, bushings and
packings. This pump uses pressure-balanced bearings and a special lubrication method to minimize
the clearance of the gear flank. The pressure-balanced method is to press the pressure plate toward
the gear side by introducing part of the discharge oil between the pressure plate and the pump body.
- 101 -
7. HYDRAULIC SYSTEM
DISCHARGE PORT
Rotating direction
SUCTION PORT
1. DRIVE GEAR
2. SNAP RING
• •
3. OIL SEAL
• •
• 4. GASKET
• 5. SIDE PLATE
6. VALVE BODY
7. REAR COVER
8. “3”-SHAPED GASKET
•
9. DRIVEN GEAR
• • •
10. BUSHING
•
11. FRONT COVER
Fig. 7.1 Main Pump (FA15B, FA20B, FA25B)
- 102 -
7. HYDRAULIC SYSTEM
DISCHARGE PORT
Rotating direction
SUCTION PORT
• •
•
•• • • 1. DRIVE GEAR
•
•
2. SNAP RING
• 3. OIL SEAL
4. FRONT COVER
5. BUSHING
6. GASKET
7. SIDE PLATE
• • 8. “3”-SHAPED
•
GASKET
9. BODY
10. DRIVE GEAR
11. REAR COVER
12. DRIVEN GEAR
13. DRIVEN GEAR
Fig. 7.2 Main Pump (FA30B)
- 103 -
7. HYDRAULIC SYSTEM
(1) Oil flow

The oil which has flowed through the inlet port in the rear cover then enters the area formed by the
tooth spaces of the gears, side plates, and the pump body, and flows along the peripheries of the gears
out of the discharge port.
TOOTH SPACE
DISCHARGE PORT SUCTION PORT
: Oil flow
Fig. 7.3 Hydraulic Oil Flow
(2) Pressure balance

While the pump is not operating or the discharge pressure is low, the side plates is pressed against
the gears’ side faces by the “3”-shaped rubber gasket. When the discharge pressure becomes high, a
force which repels the side plates acts on the shaded section in Fig. 7.4. At the same time, the oil
pressure also acts on the back side of the side plates, pressing the shaded section formed by the “3”-
shaped gasket in Fig. 7.5. The shapes and surface areas of both shaded sections are almost the same,
so that the side plates is always pressed against the sides faces of the gears with a constant elastic
force, regardless of the discharge pressure of the pump.
Fig. 7.4 Pressure Distribution on Side-Plate Side Fig. 7.5 Pressure Distribution on Gear Side
- 104 -
7. HYDRAULIC SYSTEM
(3) Body wipe

While the discharge pressure is low, the centers of the gears are almost aligned with the centers of
the pump body holes, maintaining the radial clearance which is determined by machined size. When
the discharge pressure increases, the gears are pushed toward the low-pressure side by the clearance
between the gear and bearing and a deflection of the shaft as shown in Fig. 7.6, to make the gear teeth
to contact with the pump body. During this process, the cast pump body is worn away, because the
gears, which are usually heat treated, are harder than the pump body. This is called “body wipe.”
In order to keep the optimum radial clearance of gears when loaded, the pump is run-in at a little
higher pressure than the rated pressure before it is delivered to the customer. Also, the pump is tested
for discharge and specified torque.
Wipe depth
Eccentricity 0.01 - 0.06 mm
[0.0004 - 0.0024 in.]
Center of
pump body
Discharge port Suction port
Trace of wipe
Fig. 7.6 Body Wipe
- 105 -
7. HYDRAULIC SYSTEM
7.1.2 CONTROL VALVE

The control valve consists of an inlet section, plunger section and outlet section. The inlet section
is provided with a relief valve to set the maximum pressure.
The plunger section is a solenoid proportional valve type whose plungers are operated by the pilot
oil pressure controlled by the solenoid valve.
SHUT-OFF VALVE
MAIN RELIEF VALVE (Release lift lock) REAR SHIFT
SECTION FRONT SHIFT
SECTION (Left)
FRONT SHIFT
SECTION (Right)
SOLENOID VALVE
PILOT OIL
PRESSURE
CHECK PORT
PORT DR
PILOT OIL
PRESSURE
RELIEF VALVE LIFT SECTION
TILT SECTION
ATT SECTION
Fig. 7.7 Control Valve
- 106 -
7. HYDRAULIC SYSTEM
7.1.3 VALVE CONTROL

The plungers of the control valve are controlled by the control lever and the valve controller installed
at the right side of the driver’s seat.
The control levers have the shape as shown in Fig. 7.9. It converts the movement of the lever into
a voltage and inputs into the valve controller.
The valve controller sends the amount of current corresponding to the input voltage to the solenoid
of the control valve to control the movement of the plungers.
CONTROL LEVER (LIFT)

CONTROL LEVER (TILT)
CONTROL LEVER (ATT 1)
CONTROL LEVER (ATT 2)
•
•
•
•
Fig. 7.8 Valve Controls
- 107 -
7. HYDRAULIC SYSTEM
POTENTIOMETER
Black
Red
ON (less than 1 k)
Blue
OFF (less than 100 M)
White
Switch output ( )
Wiring diagram
(neutral)
Potentiometer output (%)
Fig. 7.9 Control Levers
- 108 -
7. HYDRAULIC SYSTEM
7.1.4 LIFT CYLINDER

The lift cylinder is a single-acting piston type and consisting of a cylinder, rod, piston, and cylinder
cap. The truck is equipped with two lift cylinders on the outer channels of the mast assembly.
The piston is secured to the rod with a snap ring and has a wear ring and packing on its outer
diameter.
At the bottom of one cylinder is a cut-off valve which will act as a safety device if the high-pressure
hose connecting the right and left cylinders bursts for any reason.
The cylinder cap has a bushing and oil seal pressed to support the rod and provide dust proofness
for the cylinder.
Cut-off valve operation

When the oil in the cylinder returns into the oil tank, it passes through the holes and in the
piston. If the flow rate of the oil passing through those holes is less than the allowable rate, the piston
won’t move.
When the flow rate of oil passing through the holes and becomes greater than the allowable
rate, the pressure differential across the piston produces the force to move the piston to the right.
When this force becomes greater than the spring force, the piston moves to the right.
The oil in the cylinder is blocked by part and thus the oil does not flow out so that the forks stop
dropping.
CASE
CASE
•
• •
• •
•
•
PISTON SPRING
PISTON SPRING
Fig. 7.10 Cut-off Valve Operation
- 109 -
7. HYDRAULIC SYSTEM
Detail of Cylinder Support

• •
•
• •
•
• •
•
•
1. SHIM
2. DUST SEAL
3. PACKING
4. CYLINDER CAP
5. “O”-RING
• 6. BUSHING
CARRIAGE
SIDE ANCHOR
7. CYLINDER
8. ROD
9. LOCK RING
• 10. WEAR RING
• 11. PACKING
•
12. PISTON
• • 13. CHAIN SHEAVE
• 14. LIFT CHAIN
• 15. ANCHOR PIN
16. ADJUSTMENT NUT
17. LOCK NUT
18. COTTER PIN
Fig. 7.11 Lift Cylinder (FA15B)
- 110 -
7. HYDRAULIC SYSTEM
• • Detail of Cylinder Support

•
•
•
•
• CARRIAGE SIDE
ANCHOR
•
•
1. SHIM
2. DUST SEAL
3. PACKING
4. CYLINDER CAP
5. “O”-RING
• 6. BUSHING
7. CYLINDER
•
8. ROD
• 9. LOCK RING
• • 10. WEAR RING
•
•
• 11. PACKING
12. PISTON
13. CHAIN SHEAVE
14. LIFT CHAIN
15. ANCHOR PIN
16. ADJUSTMENT NUT
17. LOCK NUT
18. COTTER PIN
Note: The lift cylinder of the FA30B is similar to this sketch.
Fig. 7.12 Lift Cylinder (FA20B, FA25B, FA30B)
- 111 -
7. HYDRAULIC SYSTEM
7.1.5 FLOW REGULATOR VALVE

The flow regulator valve controls for descending speed and acts as a safety device if the high-
pressure hose bursts for any reason. It is located as shown in Figs 7.14 to 7.15.
The oil flowing from the control valve to the lift cylinders is not controlled, but the oil returning
from the lift cylinders is controlled.
Flow regulator valve operation

The oil returning from the lift cylinders enters the chamber , passing through chambers , ,
, and , back to the control valve.
The more the oil flows through the hole in the piston , the greater the pressure differential
across the piston becomes. When the force pressing the piston becomes greater than the force of
the spring , the piston moves to the right.
As the piston moves to the right, the hole is narrowed by the hole so that the oil flow is
restricted to slow the fork descending speed.
When the forks are raised, the oil from the control valve flows, passing through , , , , ,
and .
•
• •
•
• FREE
• FLOW
•
CONT-
ROLLED
• FLOW
• •
LIFT CYLINDER
• •
SIDE • • CONTROL VALVE SIDE
1. CASE 6. ORIFICE
2. SPRING 7. SPRING
3. BALL 8. “O”-RING
4. PISTON 9. NIPPLE
5. SLEEVE
Fig. 7.13 Flow Regulator Valve
- 112 -
7. HYDRAULIC SYSTEM
LIFT CYLINDER (RIGHT)
LIFT CYLINDER (LEFT)
to CONTROL VALVE
•
FLOW REGULATOR
VALVE
•
CUT-OFF VALVE
Fig. 7.14 Mast Piping (FA15B)
LIFT CYLINDER (RIGHT)
•
LIFT CYLINDER (LEFT)
• to CONTROL VALVE
FLOW REGULATOR
VALVE
•
CUT-OFF VALVE
Fig. 7.15 Mast Piping (FA20B, FA25B, FA30B)

- 113 -
7. HYDRAULIC SYSTEM
7.1.6 TILT CYLINDER

The tilt cylinder is a double-acting type, and its piston rod end is supported by the mast and the
cylinder tail is connected to the frame with a pin. This truck is provided with two tilt cylinders on both
sides of the front of the truck.
The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap, piston and piston
rod. The piston, secured to the piston rod with the nut, has two packings and one wear ring on the
circumference and moves along the inner surface of the cylinder by the force of hydraulic oil. Inside
the cylinder cap are a bushing press-fitted and a packing and dust seal installed to provide oil tightness
for the piston rod and cylinder cap, while supporting the piston rod. The cylinder cap, having an “O”-
ring at the outer diameter which comes in contact with the inner surface of the cylinder, is screwed
into the cylinder body.
When the tilt lever is pushed forward, the high-pressure oil enters the cylinder from the cylinder
cap side to move the piston backward, thus tilting the mast forward (6°).
When the tile lever is pulled backward, the high-pressure oil enters the cylinder body from the
cylinder tail side to move the piston forward, thus tilting the mast backward (10°).
•
• • • • • •
• • • •
•
•
• •
• •
Tightening torque:
147 - 196 N-m {15 - 20 kgf-m}
[ 108.5 - 144.7 ft-lbs]
Tightening torque:
373 - 559 N-m {38 - 57 kgf-m}
[274.9 - 412.3 ft-lbs]
1. JOINT 6. CYLINDER CAP 11. PACKING

2. DUST SEAL 7. “O”-RING 12. LOCK NUT
3. SNAP RING 8. BUSHING 13. WEAR RING
4. BACK-UP RING 9. CYLINDER 14. PISTON
5. PACKING 10. ROD 15. “O”-RING
Fig. 7.16 Tilt Cylinder
- 114 -
7. HYDRAULIC SYSTEM
7.1.7 OIL TANK

The oil tank is integral with the frame and located at the right side of the truck body. Figure 7.17
shows its construction.
Inside the oil tank are a suction filter and return filter to remove dust from the oil.
CAP (w/GAUGE)
from CONTROL •
VALVE
to PUMP
• •
SUCTION FILTER RETURN FILTER DRAIN PLUG
Fig. 7.17 Oil Tank
- 115 -
7. HYDRAULIC SYSTEM
7.2 MAINTENANCE
7.2.1 PUMP MAINTENANCE
Cautions
1. Before disassembling the pump, check for oil leaks from the oil seal, the mating section of the
pump body and cover, and other areas.
2. Remove rust, dust and dirt at the shaft end and the pump body. Failure to do so might damage
the parts or allow them to enter the inside of the pump during disassembly, thus misleading your
diagnosis about the pump.
3. The pump has some symmetrical parts. Before disassembling the pump, mark the parts in the
manner shown in the “disassembly procedure”, to ensure correct reassembly. For this purpose,
use oil paint not to damage the parts.
4. Disassembly is a means of finding out the cause of a trouble. Observe the procedure for
disassembling the pump.
5. Before disassembly, make sure you get new packings, gaskets, and oil seals.
(1) Disassembly
Hold the front cover in a vice with the input shaft
side downward.
Notes 1. The bolts will be loosened during
disassembly. Make sure to hold the
front cover in a vice securely as shown
in Figure 7.18, to prevent the pump
from the vice when a force is applied
on the pump.
2. Mark the rear and front covers and the
Fig. 7.18
drive gear side of the pump body with
oil paint.
Turn the four fitting bolts with a torque wrench

in the tightening direction, to check whether they
are properly tightened to 88 - 98 N-m {9 - 10
kgf-m} [65.1 - 72.3 ft-lbs].
Fig. 7.19
- 116 -
7. HYDRAULIC SYSTEM
Remove the four fitting bolts.
Fig. 7.20
Remove the rear cover by tapping the side face

of the pump body with a plastic mallet. If the
gaskets remain inside the pump body, move them
toward the rear cover side.
Fig. 7.21
Remove the pump body. If the gaskets remain

inside the pump body, move them toward the
front cover side.
Fig. 7.22
Put the mark “RV” the rear cover side plate at

the drive gear side before removing the side plate.
Fig. 7.23
- 117 -
7. HYDRAULIC SYSTEM
Put the mark “R” on the driven gear shaft end

and remove the drive gear.
Fig. 7.24
Holding the front side plate, remove the drive

gear.
Fig. 7.25
Put the mark “FV” on the front side plate at the

drive gear side, and remove the side plate.
Fig. 7.26
Turn over the front cover and hold it again in the

vice. Remove the snap ring.
Fig. 7.27
- 118 -
7. HYDRAULIC SYSTEM
Remove the oil seal from the front cover.
Fig. 7.28
- 119 -
7. HYDRAULIC SYSTEM
(2) Inspection
CAUTION
1. Inspections are carried out to locate the cause of troubles and to determine whether parts
are reusable or not. Inspections must be carried out only by personnel with a certain
amount of knowledge and experience in hydraulic equipment.
2. The “useful limit” shown in this section should be used as a rough guide. We do not always
guarantee the performance of a part if it does not reach its useful limit.
Name of component Items to be checked Remarks (cause and others)

Front cover (a) Check for cracks or damage. Oil pressure is too high.
CAUTION
The mating section between the front cover and the pump body looks black in some parts.
This is caused by the friction between aluminum parts and is not a problem.
Pump body (cast iron) (a) Check for cracks or damage. Oil pressure is too high.
(b) Check wipe depth or wipe surface. Oil pressure is too high.
Useful limit
Wipe depth limit: less than 0.04 mm [0.0016 in]
(c) Check for signs of interference with gear Runout of gears

at discharge side. Pump’s performance is not affected if there is
a sign of interference.
Drive and driven gears (a) Check shaft ends and keyways for cracks, They might occur when gears are runout or
damage or undue wear. insufficiently lubricated, or when oil pressure
is too high.
(b) Check journal (in the area which slides on Contaminants in oil, too high oil temperature
the bearing) for discoloration, undue wear, (120 [248 F] or higher), too frequently
or roughness. idle operations
CAUTION
OIL SEAL SIDE PLATE The shaft might have the following
INPUT BUSHING BUSHING scratches or scores on its outer diameter:
SHAFT (a) Those caused by a hard object
between the shaft and bushing.
(b) Those caused by the oil seal’s main
(a)
(c) (b) lip
(c) Those caused by the oil seal’s dust lip
Example of 1st pump drive shaft
Useful limit
Roughness on journal (a): 0.8S - 1.6S
Roughness on oil seals (b and c): 1.6S - 3.2S
- 120 -
7. HYDRAULIC SYSTEM
Name of component Items to be checked Remarks (cause and others)
(c) Check for discoloration, undue wear, or Contaminants in oil, too high oil temperature
roughness on the gears. (120 [248 F] or higher), too frequently idle
operations
Useful limit
0.1 mm [0.0040 in] or less
(d) Check gear teeth for roughness or Irregular rotation at high speeds
pitching.
(e) Check for missing or broken gear teeth Too high oil pressure or a hard object caught
in gear
Side plate (a) Check side plate in the gear sliding area Fine dust between side plate and gears
for wear or nicks or scores.
(b) Check the gears for erosion at or near the Cavitation or aeration
engagement area.
Useful limit
Wear limit: 0.15 mm (0.006 in) or less
Discharge port
These areas
might be worn
LBC surface Suction port

Erosion
might occur
here due to
cavitation.
Bushing Check the inner surfaces of bushings for The bushings are made of copper with the
The bushings are fitted roughness or wear. back plate made of lead brass. The back plate
into front and rear consists of porous and PTFE (polytetrafluoro-
covers. ethylene) layers.
Useful limit
When the back plate of the bushing is exposed to view.
Gasket (a) Check gaskets for proper installation or Too high oil temperature
cut.
Fire retardant hydraulic oil (phosphate) or
(b) Check rubber parts for swelling. gasoline is used.
Oil seal Wear occurs due to contaminants in oil, dust

(a) Check oil seal for round or peeled edge. which enters oil due to undue external
CAUTION negative pressure, or rust due to moisture.
The oil seal might be Increased internal oil leaks or high oil pressure
damaged when the drive (b) Check main lip for warping outward. (0.2 - 0.3 MPa {2 - 3 kgf/cm2} [28.5 - 42.7
gear is disassembled or psi] or more) applied on oil seal
when it is removed from
the front cover. It is Fire retardant hydraulic oil (phosphate) or
difficult to locate the cause (c) Check rubber parts for swelling. gasoline is used.
of damage when removing
it from the front cover.
- 121 -
7. HYDRAULIC SYSTEM
(3) Pump reassembly

As shown in Fig. 7.29, hold the front cover in a
vice.
Fig. 7.29
Install a new gasket in the groove in the front

cover.
Fig. 7.30
Install a new “E” gasket in the groove in the front

cover, referring to Fig. 7.32.
Fig. 7.31
”3”-shaped
gasket groove The “E” gasket should
be installed with its flat
surface pointing to the Flat surface
bottom of the groove.
B-B section
Discharge Suction
side side
Flat surface
Discharge Suction
side side
A-A section C-C section
(b) “3”-shaped gasket
Fig. 7.32 Gasket Installation

- 122 -
7. HYDRAULIC SYSTEM
Install the pump body on the front cover, referring

to Fig. 7.34.
Fig. 7.33
Counterclockwise
rotation: Drive side
Counterclockwise rotation: Front side
Rear side Clockwise rotation:
Clockwise rotation: Rear side Suction port
Front side Discharge port (larger radius)
(smaller radius)
Projection (to be always

Driven side pointed to drive side)
Fig. 7.34
Install the front side plate on the front cover,
referring to Fig. 7.36.
Fig. 7.35
LBC surface Back plate

(yellow) (SC material)
Discharge side Suction side Suction Discharge

(smaller radius) (larger radius) side side
The LBS surface should

be always pointed to
gear’s side face
Fig. 7.36
- 123 -
7. HYDRAULIC SYSTEM
Install the drive gear in the pump body, with its

splines pointed downward.
Fig. 7.37
Install the drive gear in the pump body, as shown

in Fig. 7.39.
Fig. 7.38
CAUTION
The sketch shows the engagement of an L-shaped pump. Since the tooth profiles of the two
gears are asymmetric, install them with their larger pressure angle sides pointed to each
other. Failure to do so might damage the gear teeth.
Greater pressure angle side

(driven-side engagement surface)
Smaller pressure
angle side
Engagement surfaces
(shaded sections) Drive
side
Driven
side
Greater pressure angle side
Smaller pressure angle side (drive-side engagement surface)
(a) Engagement of 1st pump (b) Engagement of asymmetric tooth profiles
Fig. 7.39
- 124 -
7. HYDRAULIC SYSTEM
Install the rear side plate in the pump body, as

shown in Fig. 7.36.
Fig. 7.40
Apply grease on a new gasket in some points and
install the gasket in the rear cover groove.
Fig. 7.41
Gasket groove
”E” gasket
Discharge side Suction side
The rear cover is commonly used for the

“L” (counterclockwise rotation) type and
the “R” (clockwise rotation) type. Align
the discharge side with the suction side.
Fig. 7.42
Install the “3”-shaped gasket in the rear cover,
as shown in Fig. 7.32.
Fig. 7.43
- 125 -
7. HYDRAULIC SYSTEM
Install the rear cover in the pump body with its

gasket pointed downward.
Fig. 7.44
Install the four bolts and tighten them to the

specified torque:
Tightening torque: 88 - 98 N-m {9 - 10 kgf-m}
[65.1 - 72.3 ft-lbs]
Fig. 7.45
Remove the pump from the vice and put it on a

work bench.
Apply grease on the area between the lips and
on the outer diameter of a new oil seal. Install it
on the oil seal guide shown in Fig. 7.51. Put it
on the drive shaft of the pump, and install the oil
seal onto the front cover with an oil seal snap.
Fig. 7.46
Direction in which
oil seal is Apply a thin coat of
installed. grease on outer
Dust lip diameter of oil seal.
Oil seal
Main lip
Apply grease area
between oil seal
lips.
Fig. 7.47 Fig. 7.48
- 126 -
7. HYDRAULIC SYSTEM
Secure the oil seal with a snap ring and remove the oil seal guide.
Cross section of
“C” lock ring (Front cover)
Side at which corner

is chamfered.
Oil seal
Fig. 7.48 Fig. 7.49
Unit: mm [in]
Oil seal guide Oil seal snap
Fig. 7.51
- 127 -
7. HYDRAULIC SYSTEM
7.2.2 TRIAL RUN

Trial runs should be performed to run in an assembled pump and to ensure that it delivers the
specified performance. Trial runs are preferably carried on a special test stand, but may be carried out
with the pump on the machine using the following manner:
(If the pump were disassembled because of a seized pump or an abnormally worn internal component,
be sure to change the hydraulic oil and replace the filters with new ones before trying to make a trial
run.)
(a) Install the pump on the truck. Install a pressure gauge on the oil pressure check port of the control
valve.
(b) Loosen the relief valve adjustment screw and operate the pump at 500 to 1000 rpm for about 10
minutes. Make sure the pressure is less than 0.98 MPa {10 kgf/cm2} [142 psi].
(c) Increase the pump speed to 1500 to 2000 rpm and let the pump operate for about 10 minutes.
(d) Keeping the pump speed at 1500 to 2000 rpm, increase the pressure by 2 - 3 MPa {20 to 30 kgf/
cm2} [284 to 427 psi] up to 17.7 MPa {180 kgf/cm2} [2560 psi], letting the pump operate at each
pressure for about 5 minutes. Operate each circuit for 5 minutes and replace the return filter with
a new one.
While increasing the pressure, check the oil temperature and pump surface temperature. Check
also for operating noise. If the oil temperature or pump surface temperature rises excessively,
reduce the load and drop the temperature before continuing the test.
(e) After the test is over, set the oil pressure for 17.7 MPa {180 kgf/cm 2} [2560 psi], perform a
discharge test. The pump discharge is checked by observing the lift speed.
- 128 -
7. HYDRAULIC SYSTEM
7.2.3 TROUBLE SHOOTING GUIDE

(1) Main pump
Problem Cause Remedy
No oil discharged from gear Low oil level in oil tank Add oil to specified level.
pump
Clogged suction tube or strainer Clean or change oil if necessary.
• Worn pressure plate

• Worn bearing
Replace with new one
• Defective plate seal, bushing seal
or back-up
Gear pump pressure won’t
rise Adjust relief valve setting with a
Maladjusted relief valve
pressure gauge.
• Retighten suction side piping

connections.
Air being sucked
• Add oil into oil tank.
• Check pump oil seal.
Collapsed suction hose or clogged

strainer causes cavitation Check hose or service strainer.
Air being sucked due to a loose

Noisy gear pump Retighten a loose joint.
suction side joint
Change to oil of proper viscosity

Too viscous oil causes cavitation Operate pump at proper
temperature.
Find the cause of air bubbles and

Air bubbles in oil
take necessary measures.
Oil leaks from pump Defective pump oil seal or plate seal Replace with new ones.
Defective pump Replace pump with a new one.
- 129 -
7. HYDRAULIC SYSTEM
7.2.4 INSTALLING VALVE CONTROLLER

When the valve controller is replaced with a new one or when it is removed for any reason, install
in the following manner:
(1) Know the truck model name by checking the name plate attached to the truck.
(2) Make sure the wire harness is correctly connected.
(3) Make sure the key switch is turned OFF before removing the acrylic plate of the valve controller.
(4) Press and hold the switch SW1 while turning on the key switch. Hold the switch SW1 for another
5 seconds and remove.
Note: Hold for about 5 seconds. If you release the switch SW1 earlier than specified, the controller
won’t enter the memory mode. In that case, repeat step (4).
When the controller gets into the memory mode, the 4-digit LED shows .
(5) Press the switch SW1. The 4-digit LED shows . The value stands for your truck
model.
(6) Press the switch SW2 or SW3 to set the model number.
(7) Turn the key switch OFF. Then, turn the key switch ON to make sure the mode number which has
been set in step (6) is displayed on the 4-digit LED.
Adjusting the front wheels

(1) Make sure the key switch is turned OFF.
(2) Press and hold the switch SW2 while turning the key switch ON. Hold the switch SW2 for another
5 seconds and then remove your finger.
Note: Hold for about 5 seconds. If you release the switch SW2 earlier than specified, the controller
won’t enter the front wheel adjustment mode. In that case, repeat step (2).
When the controller gets into the front wheel adjustment mode, the 4-digit LED shows .
(3) Make sure there is no obstacle around the front wheels before pressing the switch SW1. The front
wheels are put in the sideways travel position and then returns to the straight travel position. The
4-digit LED shows .
(4) Turn the key switch OFF. Then, turn the key switch ON and press the sideways travel switch to
put the front wheels in the sideways travel position. Operate the sideways travel lever to check to
see if the front wheels move properly.
- 130 -
7. HYDRAULIC SYSTEM
ACRYLIC PLATE 4-DIGIT LED
SW. 3
SW. 1
SW. 2
Truck model
Model number Rea solenoid (default)
name
1 FA15B 80B None
2 FA20B 80C None
3 FA25B 80E None
4 FA30B 80F None
51 FA15B 80B Provided
52 FA20B 80C Provided
53 FA25B 80E Provided
54 FA30B 80F Provided
Fig. 7.52 Adjusting Valve Controller
- 131 -
7. HYDRAULIC SYSTEM
CONTROL VALVE
LIFT CYL.
- 132 -
TILT CYL. PRIORITY VALVE
Fig. 7.53 Hydraulic Circuit

SOL
FRONT SIDE FRONT SIDE VALVE
CYL. (LEFT) CYL. (RIGHT)
PUMP
STEERING
SOL VALVE
ORBITROL
REAR SIDE CYL/ OIL TANK
STEERING CYL.
8. LOAD HANDLING SYSTEM

Truck model
FA15B FA20B, FA25B FA30B
Item
Name VM-80B VM-80C VM-80F

Type Roller type 2-stage telescopic mast
Standard max. lifting height 3000 mm [118.1 in]
Fork lifting system Hydraulic
Fork tilting system Hydraulic
Lift chain Leaf chain Leaf chain
Mast rail dimensions mm [in.]

Cross section of outer rail
Cross section of inner rail
- 133 -

The load handling system is a roller type having a two-staged telescopic mast. It consists of an
outer channel assembly, inner channel assembly and a carriage.
8.1.1 OUTER AND INNER CHANNEL ASSEMBLIES

The outer and inner channel assemblies are of welded construction. The outer channel assembly
has supports at both sides of its bottom for attaching the mast assembly to the frame.
The outer channel assembly also has the tilt cylinder piston rods connected so that the mast assembly
can be tilted forward and backward by the tilt cylinder extending and contracting.
End rollers are installed on the lower outside of the inner channel assembly with shims and on the
upper inside of the outer channel assembly with shims.
••
•
• • 1. OUTER CHANNEL
ASSEMBLY
• 2. END ROLLER
3. SHIM
4. SLIPPER
5. SHIM
6. BUSHING
7. CAP
8. PIN
• 9. INNER CHANNEL
ASSEMBLY
10. SHIM
11. END ROLLER
12. SNAP RING
•
• •
•
•
Fig. 8.1 Outer and Inner Channel Assembl

- 134 -
8.1.2 CARRIAGE
The carriage has end rollers installed by bearings on the end roller shaft. The end rollers roll along
inside the inner channel. The end roller shaft is welded to the carriage. The lower end rollers are
adjusted by adding or omitting the number of shims and both the upper and lower end rollers (lower
end rollers only for FA15B) are secured in place with snap rings. The back and forth load is sustained
by the end rollers and the lateral load is sustained by the side rollers.
1. FORK
2. STOPPER
3. SPRING
4. HANDLE
5. CARRIAGE
6. END ROLLER
7. SNAP RING
8. SIDE ROLLER
9. SHIM
10. SHIM
11. SPACER
12. LOAD BACKREST
Fig. 8.2 Carriage
- 135 -
8.1.3 LOCATIONS OF ROLLERS

End and side rollers are installed on the carriage. The inner channel assembly and carriage rise and
lower smoothly with the end rollers sustaining the back and forth load while the side rollers sustaining
the lateral load.
Upper section Lower section
INNER CHANNEL
ASSEMBLY
SIDE ROLLER CARRIAGE
(SHIM ADJUSTED)
•
OUTER CHANNEL • • END ROLLER
ASSEMBLY • (SHIM
• END ROLLER END ROLLER ADJUSTED)
(SHIM (SHIM
• •
ADJUSTED) ADJUSTED) •
END ROLLER
(SHIM ADJUSTED) •
SLIPPER
(SHIM ADJUSTED)
•
LIFT CYLINDER
Note: For the procedure for shim adjusting the end rollers, see Fig. 8.16.
Fig. 8.3 Location of Rollers (FA15B)
- 136 -
Upper section Lower section
OUTER
CHANNEL INNER CHANNEL
ASSEMBLY ASSEMBLY CARRIAGE
•
• •
END ROLLER
END ROLLER • (SHIM
(SHIM SIDE ROLLER • ADJUSTED)
END ROLLER • ADJUSTED) (SHIM
(SHIM ADJUSTED) ADJUSTED) •
•
SLIPPER •
(SHIM ADJUSTED) END ROLLER
(SHIM
ADJUSTED)
•
LIFT CYLINDER
Note: For the procedure for adjusting roller with shims, see Fig. 8.16.)
Fig. 8.4 Location of Rollers (FA20B, FA25B, FA30B)
- 137 -
8.2 MAINTENANCE
8.2.1 ADJUSTING LIFT CYLINDER ROD WITH SHIMS
After the lift cylinder, inner channel assembly, and outer channel assembly are replaced, the lift
cylinder rod length needs to be adjusted.
(1) Install a piston head on each rod of the right and
SHIM
left cylinders without shim. PISTON HEAD
(2) Extend the lift cylinder rod slowly and check the
difference of the time till each of the right and
left cylinder rods reaches the stroke end.
(3) Add shim between the rod and piston head which
stop first.
Shim thickness: 0.2 and 0.5 mm [0.008 and 0.02 in]
(4) Adjust the lift chain tension.
LIFT CYLINDER
Fig. 8.5
8.2.2 ADJUSTING HEIGHT OF CARRIAGE

(1) Stop the truck on a level surface and put the mast
upright. TIRE
(2) Keep the fork bottom on the ground and adjust
the projected amount of the carriage lower INNER CHANNEL
ASSEMBLY
end roller to the value as shown in Table 8-1,
CARRIAGE
using the chain anchor pin at the mast side. END
ROLLER
Table 8-1
Model Mast Type mm [in] FORK
FA15B VM-80B 36 - 41 [1.42 - 1.61]

FA20B VM-80C
FA25B 24 - 29 [0.95 - 1.14]
FA30B VM-80F Fig. 8.6
- 138 -
(3) Make sure that the clearance between the carriage INNER CHANNEL
and the inner channel stoppers is 0 mm when the STOPPER
fork is raised to the maximum lifting height.
Note 1: When the mast lifting height is over 4000 mm

[157.5 in], the dimension is + 50 mm [2
in]. CARRIAGE
STOPPER
CHAIN ANCHOR
PIN AT MAST
SIDE
Fig. 8.7
(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 position CHAIN
and the mast is tilted back all the way.
ANCHOR PIN
ADJUSTMENT NUT
LOCK NUT
Fig. 8.8
- 139 -
8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE

(1) Attach a pallet to the fork and stop the truck on a
level surface.
(2) Lower the fork with the pallet to the ground.
(3) Remove the joint link of the mast side anchor

pin and remove the chain from the sheave.
(4) Extend the lift cylinder rod to raise the inner

channel assembly. (See in Fig. 8.9.)
(5) Move the truck backwards after making sure that

the carriage is removed from the inner channel.
(See in Fig. 8.9.) Fig. 8.9
(6) Replacing end rollers

Remove the lower end roller with a puller,
keeping the shims.
Install a new end roller with the shims removed
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
roller with a puller.
Install a new end roller and secure it with the
snap ring.
(7) Replacing side rollers Fig. 8.10

Remove the side roller assembly. Keep the
number of the shims and their combination as
they were. SPACER
Install a new roller with the shims removed in SHIM
• SIDE
step , pointing the groove for the balls to the •
• ROLLER
shim side. (See Fig. 8.12.) •
If there is excessive looseness between the side SHIM
• END
roller and inner channel assembly, add shims • ROLLER
•
between the end roller and side roller, seeing
•
"8.2.5 PROCEDURE FOR SHIM
ADJUSTING".
•
•
END ROLLER SNAP
RING
Fig. 8.11
- 140 -
(8) Extend the lift cylinder rod so that the inner

channel bottom projects the upper section of the
carriage.
Groove for balls
(9) Bring the truck close to the carriage side so that
each roller enters inside of the outer channel
assembly.
(10) Contract the lift cylinder rod to lower the inner

channels gradually. Place each roller of the
carriage into the inner channels.
(11) Engage the chain with the sheave and connect

the chain and anchor through the joint link. Fig. 8.12 Side Roller Assembly
(12) Adjust the height of the lift bracket. (See 8.2.2.)
Fig. 8.13
- 141 -
8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE

(1) Remove the carriage from the inner channel
assembly in the same procedure as described in
"8.2.3 PROCEDURE FOR REPLACING
ROLLERS AT CARRIAGE SIDE".
(2) Move the truck to a level surface and put the both
front wheels on the bench of 250 - 300 mm [9.8 -
11.8 in] in height.
(3) Apply the parking brake and block the both rear
wheels securely with blocks.
(4) Remove the bolt securing the lift cylinder and inner
channel assembly, and hoist the inner channel
assembly with a crane, keeping shims at the end of Fig. 8.14
the piston rod.
(5) Remove the lift cylinder mounting bolt at the lower

section of the outer channel assembly and cylinder SHIM
SHIM
support at the middle section, and remove the lift SLIPPER

END
ROLLER
cylinder from the outer channel assembly. Remove
the hydraulic hose with two wrenches, using caution
not to loosen the fittings at the cylinder side.
(6) Operate the crane to lower the inner channel

assembly gradually and remove the end roller from
the lower section of the inner channel assembly.
At the same time, the end roller at the upper section
of the outer channel assembly can also be removed.
(7) Replacing end rollers

Remove upper end roller with a puller, keeping
shims.
Install a new end roller with the shims removed 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 inner channel side (Fig. 8.10).
Replace the lower end roller, using same procedure
as above. In this step, point the stamp side to the SHIM
outer channel side. END ROLLER
(8) Operate the crane to hoist the inner channel. Place

each roller into the channels assembly.
(9) Install the lift cylinder and carriage in the reverse Fig. 8.15
order of disassembly.
- 142 -
8.2.5 PROCEDURE FOR SHIM ADJUSTING

(1) Bring the inner channel assembly and carriage to one side of the outer channel assembly. Measure
the clearance between the end roller at the opposite side and each channel.
Clearance between roller and channel: 0 – 0.5 mm [0 – 0.02 in]
SHIM
Make contact with one side
SHIM
SHIM
SHIM
SHIM SHIM
Make contact with one side
: 0 – 0.5 mm [0 – 0.02 in]
Note: Apply grease to each channel in the end roller contacting area.
Procedure for shim adjusting
Fig. 8.16
- 143 -
NOTE
- 144 -
9. ELECTRIC WIRING
9. ELECTRIC WIRING
The electric components of the truck are wired through several types of wire harnesses and color
coded by circuit.
The wire harnesses are connected with connectors (2 types) or screws.
Table 9.1 Color symbols and examples
B Black R Red
G Green W White
L Blue Y Yellow
O Orange Lg Light green
Example: Yellow coating with a blue marking P Pink Sb Light blue Example: White coating without marking
Table 9.2 Connector symbols
Connection type Plug-in side Receptacle side Remarks
Housing The alphabetic letters means colors.

Plug-in type
(Table 9.1)
Plug
Screw type
The dotted lines in the circuit diagrams are given for optional equipment.
DANGER: Use due caution when handling the battery unit.

1. Never short the circuit, spark, smoke or use fire near the battery unit. Since flammable gas
is always released from the battery, there is a danger of causing an explosion.
2. The battery electrolyte is dilute sulfuric acid. It will cause burns if it gets on the skin. If
electrolyte comes in contact with the skin, flush with water. It can cause blindness if it gets
into eyes. If electrolyte gets into your eyes, flush our eyes out with water and get to a doctor.
- 145 -
to WIRE HARNESS,
OVERHEAD GUARD
(RIGHT)
to FORWARD
to BRAKE SWITCH 2
SWITCH to POTENTIOMETER
(FWD, RIGHT)
9. ELECTRIC WIRING
(FWD, RIGHT)
to BRAKE SWITCH 1
to STEERING SOLENOID
- 146 -
Connected to
in Fig. 9.5.
to WIRE HARNESS, STEERING to WIRE
Fig. 9.1 Wire Harness, Frame (1/2)

COLUMN (Fig. 9.16) HARNESS VALVE
to CHARGE
to POTENTIOMETER CONTROL PANEL to RELAY
(FWD, LEFT) to RESISTOR
ASSEMBLY to VTM UNIT ASSEMBLY
to FORWARD
SWITCH
(FWD, LEFT)
to WIRE HARNESS,
OVERHEAD GUARD
(LEFT)
For trucks manufactured in and before September 2001.

to WIRE HARNESS,
OVERHEAD GUARD
(RIGHT)
to FORWARD to BRAKE SWITCH 2
(FWD, RIGHT) (FWD, RIGHT)
to BRAKE SWITCH 1
Connected to
- 147 -
in Fig. 9.6.
to WIRE HARNESS, STEERING

COLUMN (Fig. 9.17)

to WIRE
to POTENTIOMETER to CHARGE HARNESS VALVE
(FWD, LEFT) CONTROL PANEL
to VTM UNIT
to RELAY ASSEMBLY
to FORWARD
SWITCH
(FWD, LEFT)
to RESISTOR
to WIRE HARNESS, ASSEMBLY
OVERHEAD GUARD
(LEFT)
For trucks manufactured in and after October 2001

(excluding trucks for EXA and EX)
9. ELECTRIC WIRING
to WIRE HARNESS,
OVERHEAD GUARD
(RIGHT)
to FORWARD
to BRAKE SWITCH 2
SWITCH
(FWD, RIGHT)
9. ELECTRIC WIRING
to POTENTIOMETER
(FWD, RIGHT)
to BRAKE SWITCH 1
Connected to
- 148 -
in Fig. 9.7.

COLUMN (Fig. 9.18) to WIRE

to POTENTIOMETER HARNESS VALVE
(FWD, LEFT)
to VTM UNIT
to RELAY ASSEMBLY
to FORWARD
SWITCH
(FWD, LEFT)
to RESISTOR
OVERHEAD GUARD
(LEFT)
For trucks manufactured in and after October 2001 (EXA)

to WIRE HARNESS,
OVERHEAD GUARD
(RIGHT)
to FORWARD to BRAKE SWITCH 2
(FWD, RIGHT) (FWD, RIGHT)

COLUMN (Fig. 9.19)
to BRAKE SWITCH 1
Connected to
in Fig. 9.8.
- 149 -
SHORT COUPLER A
to POTENTIOM-

ETER (FWD, to WIRE
LEFT) to CHARGER CONTROL HARNESS VALVE
PANEL
to VTM UNIT to RELAY ASSEMBLY

to FORWARD
SWITCH
(FWD, LEFT)
to RESISTOR
OVERHEAD GUARD
(LEFT)
For trucks manufactured in and after October 2001 (EXE)

9. ELECTRIC WIRING
to WIRE HARNESS,
JOYSTICK
to WIRE HARNESS, REAR AXLE

9. ELECTRIC WIRING
to WIRE HARNESS, INVERTER
to SOLENOID
to STEERING
POTENTIOMETER
to HANDLE
NEUTRAL SWITCH
to INVERTER
to TERMINAL (P)
- 150 -
to TERMINAL (N) to VALVE CONTROLLER
to REAR COMBINATION
to CHARGE PANEL LAMP (LEFT)

to FLASHER UNIT to FORWARD
TRAVEL CHIME to OPTIONAL
EQUIPMENT
to BACK-UP
BUZZER to SIDEWAYS
TRAVEL CHIME
For trucks manufactured in
Connected to in Fig. 9.1.
and before September 2001.
to WIRE HARNESS,
JOYSTICK
to WIRE HARNESS,
REAR AXLE
to STEERING
POTENTIOMETER to SOLENOID
to HANDLE
NEUTRAL SWITCH
to INVERTER
to TERMINAL (P)
- 151 -
to VALVE CONTROLLER
to TERMINAL (N)
to CHARGE
PANEL

to REAR COMBINATION
LAMP (LEFT)
to FLASHER UNIT to BACK-UP

BUZZER to FORWARD
TRAVEL CHIME
for OPTIONAL EQUIPMENT
to SIDEWAYS
TRAVEL CHIME A

(excluding EXA and EXE)
9. ELECTRIC WIRING
to WIRE HARNESS,
JOYSTICK
9. ELECTRIC WIRING
to WIRE HARNESS,
to WIRE HARNESS, INVERTER REAR AXLE
to STEERING
to HANDLE
NEUTRAL SWITCH
to INVERTER
to TERMINAL (P)
- 152 -
to VALVE CONTROLLER
to TERMINAL (N)
to REAR COMBINATION

LAMP (LEFT)
to FORWARD
to FLASHER UNIT TRAVEL CHIME
to BACK-UP
BUZZER
to SIDEWAYS
TRAVEL CHIME A
For trucks manufactured in and after October 2001 (EXA )

to WIRE HARNESS,
JOYSTICK
to WIRE HARNESS,
REAR AXLE
to STEERING
to HANDLE
NEUTRAL SWITCH
to INVERTER
to TERMINAL (P)
- 153 -
to VALVE CONTROLLER
to TERMINAL (N)
to REAR COMBINATION

LAMP (LEFT)
to FLASHER UNIT
to FORWARD
to BACK-UP TRAVEL CHIME
BUZZER
to SIDEWAYS
TRAVEL CHIME A

9. ELECTRIC WIRING
to WIRE HARNESS, DRIVE
MOTOR SENSOR
9. ELECTRIC WIRING
View looking from View looking from View looking from
to ACCELERATOR 1
For trucks
manufactured in and
before September 2001
For trucks manufactured

in and after October 2001
- 154 -
Fig. 9.9 Wire harness, Inverter (1/2)
to ACCELERATOR 2
to WIRE HARNESS,
DRIVE MOTOR SENSOR PUMP MOTOR
TILT
to WIRE HARNESS, FRAME LIFT
- 155 -
to SEAT SWITCH
LEVER
Fig. 9.10 Wire Harness, Joystick

to TURN SEAT SWITCH
9. ELECTRIC WIRING
9. ELECTRIC WIRING
UNLOAD
to VALVE CONTROLLER
Fig. 9.11 Wire Harness, Valve
- 156 -
9. ELECTRIC WIRING
to ROTATION SENSOR A
to WIRE HARNESS, FRAME
to ROTATION SENSOR B
to THERMO SENSOR
Fig. 9.12 Wire Harness, DM Sensor
WIRE HARNESS,
STEERING COLUMN
For trucks manufactured in and

before September 2001
Fig. 9.13 Wire Harness, Lamp Switch
- 157 -
9. ELECTRIC WIRING
to WIRE HARNESS,
STEERING COLUMN

(excluding EXE)
to WIRE HARNESS,
STEERING COLUMN
- 158 -
9. ELECTRIC WIRING
to STEERING WHEEL ENCODER

to HORN SWITCH
to F/R SWITCH
to LIGHTING SWITCH
to KEY SWITCH
to METER PANEL
to WIRE HARNESS,
LAMP SWITCH
to PARKING BRAKE SWITCH
CAPACITOR
to HORN
to ORBITROL

to WIRE HARNESS, FRAME (1/2) (Fig. 9.1) before September 2001.
Fig. 9.16 Wire Harness, Steering Column
- 159 -
9. ELECTRIC WIRING
to HORN SWITCH to STEERING WHEEL ENCODER
to F/R SWITCH
to LIGHTING SWITCH
to METER PANEL
to KEY SWITCH
to PARKING BRAKE SWITCH

to WIRE HARNESS,
LAMP SWITCH
CAPACITOR
to HORN
to ORBITROL
to WIRE HARNESS, FRAME (1/2) (Fig. 9.2)

(excluding EXA and EXE)
- 160 -
9. ELECTRIC WIRING
to HORN SWITCH to STEERING WHEEL ENCODER
to F/R SWITCH
to LIGHTING SWITCH
to METER PANEL
to KEY SWITCH
to PARKING BRAKE SWITCH to WIRE HARNESS,

LAMP SWITCH
CAPACITOR
to HORN
to ORBITROL

after October 2001 (EXA)
- 161 -
9. ELECTRIC WIRING
to HORN SWITCH
to STEERING WHEEL ENCODER
to F/R SWITCH
to LIGHTING SWITCH
to METER PANEL
to KEY SWITCH
to PARKING BRAKE SWITCH to WIRE HARNESS,

LAMP SWITCH
CAPACITOR
to HORN
to ORBITROL

after October 2001 (EXE)
- 162 -
9. ELECTRIC WIRING
Replacing bulbs
Removing and installing bulbs in the following
manner: SCREW
Removing: Push in the bulb and turn to the left. REFLECTOR
Installing: Push in the bulb and turn to the right. BULB
•
GASKET
(1) Head lamps and work light • •
Remove the screw securing the rim and housing.
Remove the rim, lens, and gasket.
•
Remove the bulb from the reflector and install a
• LENS
new bulb.
RIM
1. Use caution not to get your hand burnt

because the bulb is very hot immediately Fig. 9.20 Head Lamp (Work Light)
after the lamp is turned OFF.
2. Use caution not to allow the bulb and reflector surfaces to get contaminated with grease.
With the gasket, reinstall the lens and reflector.
(2) Rear and front combination lamps

Remove the screw and separate the lens from the BULB
(FLASHER)
body.
•
Remove the bulb you want to change and install BULB
(BRAKE, PARKING)
a new bulb.
Assemble the lens and body with the screw. •
SCREW • BODY
•
•
BULB
(BACK-UP LAMP)
•
LENS
Fig. 9.21 Rear Combination Lamp
BULB
(FLASHER)
•
SCREW BODY
•
•
•
BULB
(PARKING)
Fig. 9.22 Front Combination Lamp
- 163 -
9. ELECTRIC WIRING
Replacing fuses inside the controller

There are two fuses for the drive motor and one for the pump motor inside the controller.
If any fuse is blown out, remove the cause and replace it with a new one in the following manner:
1. Park the truck on a level surface.

2. Turn the key switch OFF and disconnect the battery connectors.
3. Open the hood and remove the inverter cover.
4. Loosen the mounting nut of the fuse you want to change.
5. Turn the fuse to the left and remove.
6. Install a new fuse in the reverse order of removing and secure with the nut.
Tightening torque: 8.3 ± 1 N-m {0.85 ± 0.1 kgf-m} [6.122 ± 0.738 lbf-ft]
Note 1. Make sure the fuse terminal is free from the adherence of lubricant, has no foreign matter
caught, and is not deformed.
Note 2. Position the opening in the right side. (See Fig. 9.23.)
Note 3. Tighten the fuse terminal with a plain washer and spring washer. (See Fig. 9.23.)
PLAIN WASHER FUSE TERMINAL

SPRING WASHER
NUT
•
• ••
The opening
should be pointed
to the right side.
Fig. 9.23
- 164 -
Fig. 9.25 Circuit Diagram
3P
ORBITROL
(2P)
No. SEB-80BBE
Issued: October 2001
INTERNATIONAL MARKETING DIVISION: 1-15-5, Nishi-shimbashi, Minato-ku, Tokyo

105-0003, Japan
FAX: JAPAN +81-3-35918152, 3-35918153
All rights reserved OT-1310050(HO) Printed in Japan

‘
-
n
塁
SERVICE MANUAL FA15B•FA20B•FA25B•FA30B No. SEB-80BBE

Acroba SerManual FA15-30

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No.

The specifications are subject to change without notice.

*1 Values in the Super mode.

Fig. 1 External View

3. CONTROL SYSTEM ............................................................................................................... 31

4. DRIVE AXLE ............................................................................................................................... 69

4.1.2 FRONT SIDE-CYLINDER ...................................................................................................... 76

5. STEERING SYSTEM .............................................................................................................. 79

6. BRAKE SYSTEM ...................................................................................................................... 93

7. HYDRAULIC SYSTEM ........................................................................................................... 101

8. LOAD HANDLING SYSTEM ............................................................................................... 133

9. ELECTRIC WIRING ................................................................................................................. 145

1.1 GENERAL DESCRIPTION

Note: The battery case comes equipped as standard.

Adjust the gap between the

View looking from

Fig. 1.1 Battery Unit

1.1.1 BATTERY CARE

1.1.2 CHARGING THE BATTERY

[Cautions on Charging the Battery]

[Specific Gravity Correction According to Temperature]

1.1.3 CHARGER (OPTION)

Detail of operation panel with CHARGER

Fig. 1.3 Side Frame, Left (FA15B)

Detail of operation panel

without CHARGER (excluding EXA and EXE)

Fig. 1.5 Side Frame, Left (FA15B)

without CHARGER (excluding EXA and EXE)

Fig. 1.6 Side Frame, Left (FA20B, FA25B, FA30B)

without CHARGER for EXA

Fig. 1.7 Side Frame, Left (FA15B)

without CHARGER for EXA

Fig. 1.8 Side Frame, Left (FA20B, FA25B, FA30B)

without CHARGER for EXE

Fig. 1.9 Side Frame, Left (FA15B)

CHARGER CONTROL WEIGHT

without CHARGER for EXE

Fig. 1.10 Side Frame, Left (FA20B, FA25B, FA30B)

(2) VTM Unit

Fig. 1.11 VTM Unit

Mode Factory set level Change

Traveling and lifting speed

Traveling speed change

Accelerator OFF regeneration

[Procedure for changing limit levels]

Fig. 1.12 VTM Adjustment

[Transmitting hour meter data]

(3) Transformer (option)

Fig. 1.13 Transformer

(4) Diode (option)

Note: The fuse comes equipped as standard.

Fig. 1.14 Diode

(5) Charger control panel (option)

D10 (Pay attention

Thermal relay current setting

Fig. 1.15 Charger Control Panel

(6) Charger operation (for trucks with a charger)

Fig. 1.16 Charging Circuit

1.1.4 CHARGING PROCEDURE (for trucks with a charger)

(2) Boosting charge

(3) Equalizing charge

(4) Super equalizing charge

(5) Flickering CHARGING lamp

Note: Have a helper for this procedure.

[ # * ..] Table 3.6 Error Code