11.

ELECTRIC DEVICES
11- 1. Name of parts
BATTERY

䝞 䝑䝔䝸  CONTROL
䝫䝔䞁䝅䝵䝯䞊䝍UNIT  Emergency
㠀ᖖ೵Ṇ䝪䝍䞁 switch  ACCELERATOR
䜰䜽䝉䝷䝺䞊䝍㻭㻿㻿䇻㼅ASS'Y

Refer㻖㻖䝨䞊䝆ཧ↷
to Page173 Refer㻖㻖䝨䞊䝆ཧ↷
to Page166

Refer㻖㻖䝨䞊䝆ཧ↷
to Page175

 Transformer

䝖䝷䞁䝇

Refer㻖㻖䝨䞊䝆ཧ↷
to Page183

 CONTROL
 UNIT
䝁䞁䝖䝻䞊䝹䝴䝙䝑䝖

 Traction

㉮⾜䝁䞁䝖䝻䞊䝷 controller  EPS controller
㻼㻿䝁䞁䝖䝻䞊䝷
㻱 STEERING
䝇 䝔䜰䝸䞁䜾ゅᗘANGLE
POTENTIOMETER
䚷㻌䝫䝔䞁䝅䝵䝯䞊䝍
CU104-90(24V/30A)

Refer㻖㻖䝨䞊䝆ཧ↷
to Page159

Refer㻖㻖䝨䞊䝆ཧ↷
to Page179

Refer㻖㻖䝨䞊䝆ཧ↷
to Page164 Refer㻖㻖䝨䞊䝆ཧ↷
to Page165

321S228

158
 11a. CONTROL UNIT
11a- 1. Name of parts
Main parts of Control unit
l

⑦ Fuse
② Contactor

④ Diode
⑥ Fuse
*F-7165
③ Fuse
*BN-275A

① Controller
⑤ Controller Ass'y, EPS

321S229

No. Part name number Remarks

① Controller 1 Curtis 1230-2302

② Controller 1

③ Fuse 1 Travel/Hydraulic 96V/275A

④ Diode 1

⑤ Controller Ass'y, EPS. 1

⑥ Fuse 1 for charger : 250V/15A

⑦ Fuse 1 Only 1-phase 100V for charger : 96V/50A

159
 CONTROL UNIT 11a

11a- 2. Disassembling and reassembling

CAUTION Apply wheel chocks to tyres to prevent the truck from moving.
l
Record places of lead wire connections before disassembling.
l
Be sure to disconnect the battery plug.
l

11a-2-1. Control unit - removal and installation

1. Remove "Cover, top" and "Cover, steering".

2. Remove the control unit as following procedure.

1. Disconnect the wiring of the control unit.
2. Remove the fitting bolts to remove the control unit.

Removing the control unit

l

Cover, top

Cover, steering

Control unit

Fitting bolt

321S202

* Install the control unit in reverse order when reassembling.

160
11a CONTROL UNIT

11a-2-2. Control unit - disassembling and reassembling

Disassembling and reassembling the control unit (1)
l
Main terminal (M8)
l
Tightening torque
8.75 N m 10%
Controller sub ass'y, panel
Controller sub ass'y, main Contactor Only 1-phase 100V

Diode

Fuse

Holder,
fuse

Main terminal (M5)

l
Fuse
Base
1 Tightening
Board torque
comp., MPU
1.5 - 2.5 N m

Fitting bolt (M6)

l
2 Tightening torque
2.5 - 3.9 N m

Controller Ass'y, EPS

Controller Main terminal (M5)

l
Tightening torque
9 N m 10%

: Tightening torque
321S203

161
 CONTROL UNIT 11a

Disassembling and reassembling the control unit (2)

l

Controller sub Ass'y, panel

BC Only 1-phase 100V
Holder,
fuse
Panel

Indicator, battery
Fuse

BC
Plate, name
Switch, push

Fuse

Switch, Receptacle
magnet Holder,
fuse

Socket
20A

Receptacle

Horn

321S204

Disassembling and reassembling the control unit (3)

l
lFitting nut (M18)
BC
Tightening torque
Metal Fitting 0.29 - 0.49 N m

Panel
Switch

Unit (case side)

Switch,
push

Fit side on the unit in case guide

ditch on the switch.
: Tightening torque 321S226

162
11a CONTROL UNIT

11a- 3. Inspection, replacement and attention

CAUTION Apply wheel chocks to tyres to prevent the truck from moving.
l
Be sure to disconnect the battery plug.
l
Record places of lead wire connections before disassembling.
l

11a-3-1. Contactor - check and replacement

CAUTION Be sure to disconnect the battery plug.
l lChecking the contactor
Record places of lead wire connections before
l
disassembling.

1 Checking procedure
1. Remove nut and washer to check the contactor for
damage, especially by burning. Main terminal

If it is damaged, replace it.

CAUTION To be safe, the assembly should be replaced

every 2 years even if there are no abnormalities.
Fitting bolt

< Type of contactor> 321S205

Applicable model Type Voltage Main terminal (M5)

l
Tightening torque
PLD•KLD10-30
FBD7-10 SW80-721 24V 1.5 - 2.5 N m
SBW7/9 Fitting bolt (M6)
l
Tightening torque
2.5 - 3.9 N m
2. As for main terminal (M5), apply the fitting torque
: Tightening torque
indicated in the right table.

CAUTION Be sure to check chassis insulation when parts

of the control unit are replaced.

163
 CONTROL UNIT 11a

2 Chassis insulation - check

1. Disconnect the battery plug. l Check for chassis insulation
2. Use a tester to measure the insulation resistance
between positive (+) terminal of the chassis battery
plug and chassis, and negative (-) terminal of the
chassis battery plug and chassis.

Specification 1M or greater

Chassis
battery Tester
plug

Fork side

Chassis
side

321S206

11a-3-2. Traction controller - specification

Current Traction controller
Applicable mode Type Voltage l
limitation
PLD KLD10-30 F+
FBD7-10 1230-2302 24V 150A B+
SBW7/9 B-

PLD KLD20-30
1230-2402 24V 200A
Center rider

V
W 321S207

lMain terminal (M5))

Tightening torque
9 N m 10%

: Tightening torque

164
11a CONTROL UNIT

11a-3-3. EPS controller - specification

Current EPS controller

Applicable model Type Voltage l
limitation
PLD KLD10-30
FBD7-10 CU104-90 24V 30A
SBW7/9

[Blue] : to traction
controller (B-)

[Red] : to traction To EPS motor

controller (B+) (2P-X)
321S314

165
 11b. ACCELERATOR ASS'Y
11b- 1. Name of parts
Main parts of Accelerator Ass'y (1)
l

Cover, controller

Switch
Comp., (EM)

Spring, return

Knob, speed

Shaft

Link
Bracket, controller

Potentiometer
Knob, speed

Arm Case,
CS controller

Register Comp.

Bracket,
controller

321S209

166
11b ACCELERATOR ASS'Y

Main parts of Accelerator Ass'y (2)

l

Switch Comp., (up/down)

Button, down
FBD7-10
(with tilt) Button, lift

Switch, Switch, Bracket,

push button(tilt) micro switch
Switch,
push button
(horn)

Switch,
micro

Key

Bracket, controller
Switch, key

Cap

Button,
emergency

Actuator

Handle

Case, controller

361S201

167
 ACCELERATOR ASS'Y 11b

11b- 2. Disassembling and reassembling

CAUTION Apply wheel chocks to tyres to prevent the truck from moving.
l
Record places of lead wire connections before disassembling.
l
Be sure to disconnect the battery plug.
l

11b-2-1. Accelerator Ass'y - removal and installation

1. Remove "Cover, controller".
1. Disconnect the wiring of the key, horn, and tilt ( only for
FBD7-10 with tilt).

CAUTION Record places of lead wire connections before disassembling.

2. Remove "Cover, controller"

3. Remove the switches.

Removing "Cover, controller".

l
Switch,
push button (tilt)

Key
Switch,
Switch, key
push button(horn)

Cap

Fitting screw

321S210

168
11b ACCELERATOR ASS'Y

2. Remove "Handle".
Removing the handle
l

Handle

321S211

(Refer the illustration on the next page.)

3. Remove "Knob, speed".

1. Disconnect the fitting screw (*1), (*2).
2. Remove "Link", the washer and "Spring, return".
3. Remove "Knob, speed", "shaft" and the bushing.

4. Remove "Bracket, controller".

1. Disconnect the wiring connecter.
2. Disconnect the fitting screw (*3) to remove "Bracket, controller".
3. Remove the each switch of EM, UP and DOWN.
4. Remove "Arm" and "potentiometer".

CAUTION Record places of lead wire connections before disassembling.

169
 ACCELERATOR ASS'Y 11b

5. Remove "Button, emergency".

1. Remove "Pin, spring".
2. Remove "Actuator", "Spring" and "Button, emergency".

Removing the accelerator Ass'y

l

Button, down

Button, lift Switch Comp., (Lift/Down)

Switch
Comp., (EM)
Fitting screw (*1)

Bushing
Spring, return Knob, speed

Shaft
Fitting screw (*2) Button,
Washer Bracket, emergency
controller
Actuator
Link
Pin, spring
Knob, speed

Bush
Potentiometer

Fitting screw (*1) Arm

Spring

Fitting screw (*3)

321S212

* Install the accelerator Ass'y in reverse order when reassembling.

170
11b ACCELERATOR ASS'Y

11b-2-2. Accelerator Ass'y - disassembling and reassembling

Disassembling and reassembling of Accelerator Ass'y (1)
l

1 Screw & Washer B

Degrease and apply THREEBOND
Cover, controller
[#1401] or equivalent product when
fitting.

Spring, return G
Apply grease

Switch Knob, speed

Comp., (EM)

Shaft

Bracket,
2 Knob, speed B
controller Degrease and apply CEMEDINE
Link [#575] or an equivalent product when
fitting.

Knob, speed

Potentiometer
Arm
Case, controller
CS

Register,
Comp.

Bracket,
controller

B : Apply bond
G : Apply grease
321S213

171
 ACCELERATOR ASS'Y 11b

Disassembling and reassembling of Accelerator Ass'y (2)

l

Switch Comp., (Lift/Down)

Button, down

FBD7-10 Button, lift

(tilt)
Bracket,
Switch, switch
micro
Switch,
push button,(tilt)
Switch,
push button,
(horn)
Switch,
micro

Bracket,
controller

Actuator B
Degrease and apply CEMEDINE
[#575] or an equivalent product on
fitting.
Key
Cap

Button,
Switch, key emergency

Handle

Case, controller

B : Apply bond
361S202

172
11b ACCELERATOR ASS'Y

11b- 3. Inspection and adjustment

CAUTION lApply wheel chocks to tyres to prevent the truck from moving.
lRecord places of lead wire connections before disassembling.
lBe sure to disconnect the battery plug.

11b-3-1. Shaft - inspection

1. Check for wear.
lInspection of shaft
<Specification> [mm]
Item Specific dimension Wear limit
D
Shaft [ D] 10 9.9

321S214

11b-3-2. Adjustment of the potentiometer

1 Adjustment procedure
1. Adjust the position of the potentiometer to get following
lAdjustment of potentiometer
voltage at the output wire (red) when the speed knob
is in the neutral position and D.C.5 volts is applied Neutral position Knob, speed

between white (IN) and black (GND).

<Specification>
Minimum (Reverse end) Maximum (Forward end) Bracket,
controller
1.5V or less 3.5V or greater
Potentiometer

2 Check of potentiometer output voltage

1. Turn off the key switch.
Arm
2.Tilt the handle to traction position.
3.Measure the voltage between White(IN) and
321S215

Black(GND), between Red(OUT) and Black(GND).

<Specification>
Steering arm is in neutral 2.5V 0.1V

Output voltage range 12 - 88% of the power supply voltage

CAUTION Be sure not to measure resistance of the

potentiometer directly.

173
 ACCELERATOR ASS'Y 11b

11b-3-3. Button, emergency - working check

Walkie Sub-step type
1. Tilt the accelerator Ass'y to the drive position. lButton, emergency - working check
2. Check that the travel direction is reversed by pressing
the emergency button while the truck moves forward Button, emergency
(sub-step : backward). Press

NOTE The reversal movement is ended within one

second.

CAUTION After releasing "Button, emergency", return the

accelerator to neutral. Then, you can operate the
truck again.
Accelerator Ass'y

321S216

Center-rider type (PLD KLD)

1. Check that the brake is applied by pressing "Button,

emergency".

NOTE The hydraulic operation is possible even in this

state.

174
11c. BATTERY
11c-1. Disassembling and reassembling
CAUTION Turn off the key switch and disconnect the battery plug before working.
l
Be careful not to touch with electrolyte to the body.
l
If the electrolyte is splashed into eye, wash out with water, and consult
l
physician immediately.
lThe inspection of the battery should be done in a place where is well
ventilated and kept away from fire.

PLD KLD
Removing and installation the battery
l
PLD . KLD

Battery Ass'y

Plug, battery

Case, battery

Lift Ass'y

321S217

175
 BATTERY 11c

FBD SBW
Removing and installation the battery
l
FBD . SBW
Bracket,
battery plug

Battery Ass'y
Plug, battery

Case, battery

Frame

361S203

176
11c BATTERY

11c-2. Inspection and adjustment

11c-2-1. Battery - inspection and adjustment
1 Inspection of quantity of electrolyte and Inspection of electrolyte level
l
replenishment
Appropriate
<Checking procedure> level
1. Disconnect the battery plug.
2. Open the battery cover and apply the stopper.
3. Check electrolyte level.

Proper level of electrolyte

<Specification>
If the red float can be seen, electrolyte level is normal.
l
If not, add refined or distilled water to the appropriate
level

Lowest level of electrolyte

Replenish refined water

<Adding refined water> lReplenishing procedure

1. Open the cap of the battery cell.
2. Add the distilled or refined water until the top of the Cap

red float is touched to the plate of the cap.

Float
White line

Battery

Level of
electrolyte

177
 BATTERY 11c

2 Measurement of specific gravity of electrolyte in each cell

<Reading hydrometer>
1. Take reading at contacting line of electrolyte and the Measurement of specific
l
gravity
tube.
2. Difference of specific gravity of each cell shall be less Thermo
Hydrometer
meter
温度計 比重計
than 0.05.
Difference between max. and min.
Less than 0.05
specific gravity

<Recharging procedure>
1. Carry out equalizing charging.
2. Check specific gravity at each cell after equalizing
charge and make sure the difference is within a
standard value. Conversion
l
The sta n d a rd specific gra v it y is b a s e d o n t h e
1.330
temperature with 20 . Convert the actual specific 1.310

Measured specific gravity

gravity to the value at 20 . 1.300 1.290

Specific gravity at 20
1.290
<How to convert to specific gravity at 20 > 1.280
1.270
1.270
1.260 1.250
1. Measure temperature of electrolyte. 1.250
1.240 1.230
1.230
1.210
CAUTION Use thermometer to measure. 1.220
1.210
1.190
1.200
1.190 1.170
2. Measure specific gravity of electrolyte. 1.180
1.170 1.150
3. Measured specific gravity shall be converted to the 1.160
1.150
value at 20 . 50 40 30 20 10 0 -10 -20
Temperature
[Conversion formula]
S20=St+0.0007(t-20)
S20:specific gravity converted at 20 .
St: Measured specific gravity
t : Temperature of electrolyte.

11c-2-2. Battery - cleaning

1 Cells, connectors and terminals
1. Keep dry. When they get wet, clean with a dry cloth or
blow out with compressed air.
2. If they are rusted, clean with a wire brush or a sand
paper.

2 Cleaning vent plug

1. Turn the vent plug counter-clockwise to remove.
2. Clean it with a detergent.
3. Securely fasten the vent plug on each cell.

NOTE If the cap damaged, replace with new one.

178
 11d. STEERING ANGLE POTENTIOMETER
11d- 1. Disassembling and reassembling
CAUTION Apply wheel chocks to tyres to prevent the truck from moving.
l
Record places of lead wire connections before disassembling.
l
Be sure to disconnect the battery plug.
l

11d-1-1. The steering angle potentiometer -

disassembling and reassembling
Removing and installation of steering angle potentiometer
l

Bracket,
potentiometer

Potentiometer
Steering angle
potentiometer

321S218

179
 STEERING ANGLE POTENTIOMETER 11d

11d- 2. Checking and adjustment

11d-2-1. Adjustment of the steering angle potentiometer
1 Check of potentiometer output voltage
1. Turn off the key switch.
2.Tilt the handle to traction position.
3.Measure the voltage between White(IN) and
Black(GND), between Red(OUT) and Black(GND).

<Specification>
l Check of potentiometer output
50% 2% of the power supply
Steering arm is in neutral voltage
voltage
12- 88% of the power supply Tester
Right and left ends of
steering voltage Potentiometer

Tester
NOTE The voltage (5V) is applied to the potentiometer stick
(+) 3P
circuit (between "White" and "Black") even if the
key switch is turned off.

Black(GND)
Blue(IN)
Red(OUT)
Tester stick (-)

CAUTION Be sure not to measure resistance of the

potentiometer.

2 Adjustment procedure
1. Provide 5V power supply to the accelerator
potentiometer.
2. Unplug the connector and insert the voltage measuring
adaptor.
3. Measure the output voltage between red and black
wires.

180
 11e. CHARGER
11e- 1. Disassembling and reassembling
11e-1-1. Charger - disassembling and reassembling

CAUTION Refer the wiring diagram when connecting and disconnecting wires.
l
Securely tighten all electric terminals.
l
Insert insulation tubes for terminals of lead wires in order to keep them
l
away from metal parts.

Removing and installation of charger(1) (only for trucks with built-in

l
charger)

Only 1-phase 100V Controller sub Ass'y, panel

Holder, fuse

Panel

Fuse

Indicator, battery

Plate, name
Switch, push

Fuse

Receptacle

Holder, fuse

Switch, magnet 20A

Receptacle
Socket

Horn

321S219

181
 CHARGER 11e

Removing and installation of charger(2) (only for trucks with built-in

l
charger)

Fuse

LY relay

To potentiometer To bearing To steering

To brake sensor To power supply
(drive)
To charger
To AC contactor switch

To condenser
To battery
To plug indicator To horn
To EPS controller To traction
To potentiometer
controller
(steering)
CA relay

Harness, CU

Diode Condenser

321S220

182
11e CHARGER

11e-1-2. Transformer - disassembling and reassembling

Removing and installation of transformer (only for trucks with built-in
l
charger)
Frame

Primary coil
Transformer
0V

90V
[+]
100V
[- ]
110V

[+]

Secondary coil

321S221

183
 CHARGER 11e

11e- 2. Inspection and replacement

11e-2-1. Switch, magnet- inspection
1. Check any burnings or damages. lInspection of Switch magnet

Terminal
Switch, magnet

321S222

11e-2-2. Plug comp. and receptacle - inspection and replacement

1. Check any burnings or discoloration on the receptacle. l Inspection of plug comp. and
If finding any abnormalities, replace both the plug comp. receptacle
Fitting nut
and the receptacle.
2. Check if the earth wire is tightened securely.
Receptacle

Earth wire

Plug comp.

321S223

11e-2-3. Fuse and Holder, fuse - inspection

1. Check fuse for blowing out or discoloration.
lInspection of fuse and holder fuse

Fuse

Holder, fuse
321S224

184
11e CHARGER

11e-2-4. Transformer - inspection

1 Checking procedure
1. Check for damage and dirt.
If the transformer is dirty, blow dusts away with
compressed air.
2. Measure the insulation resistance.
Specific parameter for insulation
5M or greater
resistance

2 Transformer insulation measurement lTransformer insulation measurement

Megger
CAUTION If using a megger, do not touch the measuring
terminals. Transformer

1. Use a megger to measure the following locations and

check the insulation.
lBetween the primary and secondary coils
lBetween the primary coil and the chassis
lBetween the secondary coil and the chassis

321S225

11e-2-5. Transformer - specification

Power supply
voltage Applicable model Battery capacity Capacity Transformer

PLD KLD10-20
FBD7-10 165-201Ah 1.6KVA T0111-0600
90V/100V/110V SBW7/9
PLD KLD30 250Ah 2.1KVA T0111-0610

185
 CHARGER 11e

11e- 3. Voltage tap

11e-3-1. Power supply voltage - check

NOTE lMeasure the power supply voltage at the charging section without running the
charger.
lMeasure the power supply voltage at the charging section without running the
charger.
lIf three-phase input power is used, the average of the highest voltages of
each phase (U-V, U-W, and V-W) is the power supply voltage.

CAUTION The measurement should be made when the peripheral facilities are not used,
such as during the lunch time or at night.

11e-3-2. Voltage tap - selection

lSelect a tap to match with the power supply voltage at
the charging place.

Power voltage [V] Voltage tap lLocation of the voltage top

90 or lower 90V
Secondary coil
91 － 100 100V Secondary coil
101 － 110 110V
Voltage
taps

Voltage is marked on each wire.

0 9 0
Isolation tubes are
placed on unused
1 0 0
taps.
321S315

1 1 0

3-core cable
0 9 0
(VCT)

Transformer
side
1 0 0 Body side
1 1 0

These wires must be

0 9 0
connected securely
1 0 0
with bolt and nut.
Bolt
1 1 0

Isolation tube Washer

Nut
321S316

186
11e CHARGER

11e-3-3. Voltage tap - changing

CAUTION lTurn off the key switch and disconnect the power supply plug and the battery
plug before proceeding the work.
lSecurely tighten the screw for the ring terminal to prevent from loosening.

1. Loosen the screw and remove the ring terminal. at 100V

2. Reconnect it to the tap fitting to the power supply at 90V
110V (Factory
voltage and secure the ring terminal together with bolts setting)
and nuts.
lFactory default setting:110V

090

100

110
321S317

187