Nichiyu 80 Series FBR9N to FBR18L Troubleshooting Manual SM15-002-R2

Data Size: 36.13 MB 
File Type: PDF 
Language: English 
Manufacturer: Nichiyu 
Applicable Machine: Forklift, Electric Forklift Truck 
Document: Troubleshooting Manual, Wiring Diagram, Error Code 
Machine Model: Nichiyu 80 Series FBR9N, FBR10N, FBR12N, FBR10, FBR12, FBR14, FBR15, 
FBR16, FBR18, FBR20, FBR25, FBR30, FBR35, FBR40, FBR9NL, FBR10NL, FBR12NL, FBR14L FBR15L FBR18L 
Book Number: SM15-002-R2 
Date: 2015 
Page: 173 Pages

List Contents:

1. Introduction 1 
1-1. Fbr-80 Control Overview 
1-2. Main Board Basic Configuration 
1-2-1. Main Board Basic Configuration 2 
1-2-2. Capacitor - Discharge 3 
1-3. Required Settings 
1-3-1. Settings For Main Board Replacing / Memory 
Initialization 4 
1-4. Reference 
1-4-1. Fuse 6 
1-4-2. Indication Of Display 7 
2. User And Manager Screen Setting 9 
2-1. Monitor Display Functions 
2-1-1. Indicator Panel 9 
2-1-2. Indication Of Display 10 
2-1-3. Function 10 
2-1-4. Sheet Switch 12 
2-2. Setting Screen 
2-2-1. Operation Setting 15 
1 Operation Feeling 15 
2 Neutral Reg Power 17 
2-2-2. Function Setting 18 
1 Speed Limit (Turtle Button) 18 
2 Tare Setting (Option) 19 
3 Reserved Charge 20 
4 Laser Pointer (Option) 20 
5 Count For Charge (Option) 21 
2-2-3. Display Setting 22 
1 Display Content 22 
2 Load Meter Size 23 
3 Clock Setting 24 
4 Brightness 25 
5 Contrast 25 
6 Display Type 26 
2-3. Manager Screen 
How To Access 
Press Button On The Normal Screen. 
Setting Screen Press Button For A While. 
2-3-1. Function Setting 29 
1 Speed Limit 29 
2 Speed Alarm 29 
3 Switchback Pwr 
4 Brake Power 30 
5 Neutral Res 
6 Antislip Func 
7 Lift (High) 32 
8 Lift (Low) 32 
9 Tilt 32 
10 Reach 33 
11 Att 1(Opt) 33 
12 Att 2(Opt) 33 
13 Function Reset 33 
2-3-2. Custom Feeling 34 
2-3-3. Fixed Feeling 35 
2-3-4. Password Change 36 
3. Model Check Screen Settings 37 
How To Access 
Press The Switch In Order Of While 
Pressing Switch On The Normal Screen. 
3-1. Function List And Description Of All Items 
3-2. Model Check/Setting Screen 
3-2-1. Type (Type Setting) 38 
3-2-2. Software (Program No. Check) 39 
3-2-3. Buzzer (Buzzer Setting) 40 
3-2-4. Hour Meter(Hour Meter Count Start) 40 
3-2-5. Tire Data Adjust (Tire Diameter Adjustment) 41 
3-2-6. Load Sensor Adjust (Load Sensor Setting) 42 
4. Service Dsp. Setting 45 
How To Access 
Press The Switch In Order Of 
While Pressing Switch On The 
Manager Screen. 
4-1. Settings List And Description Of Items 
4-2. Type Setting (Model Setting) 
4-3. Travel Setting 
4-3-1. Lmt. Speed (Turn) 
(Turn Speed Reduction Setting) 48 
4-4. Pump (Hyd) Setting 
4-4-1. Limited Lift-Spd. 
(Lift Speed Reduction Setting) 49 
4-4-2. Opr-Priority Set. 
(Hydraulic Simultaneous Operation Priority Setting) 50 
4-4-3. Opr-L/R Setting 
(Reach Valve Opening Amount Setting) 514-5. Language Setting 
4-6. Option Setting 
4-6-1. Hour Meter 
(Hour Meter Display Contents) 53 
4-6-2. Valve (Hydraulic Valve Number Setting) 54 
4-6-3. Accel. Angle (Accelerator Option Setting) 55 
4-6-4. Laser Pointer (Laser Pointer Option Setting) 56 
4-6-5. Lift Lock (Lift Interrupt Function Setting) 57 
4-6-6. Load Meter (Load Sensor Option Setting) 58 
4-6-7. Charger (Built-In Charger Option Setting) 59 
4-6-8. Wh Meter 
(Electricity Consumption Meter Option Setting) 59 
4-6-9. Batt. Lvl-Mtr 
(Battery Electrolyte Level Sensor Option Setting) 61 
4-6-10.Fl-Pump Oil 
(Fork Oil Level Sensor Option Setting) 62 
4-6-11.Fork Scale (Fork Scale Option Setting) 
(Special Spec.) 63 
4-6-12.Easy Pw-Entry 
(Easy Password Entry Setting) 64 
4-6-13.Buzzer Func. (Random Output Setting) 65 
4-6-14.Auto Pwr.-Off 
(Auto-Power-Off Function Setting) 66 
4-6-15.Suspens. Lock 
(Suspension Lock Function Setting) 67 
4-6-16.L-Remote Ctrl 
(Lift Remote Control Function Setting) 68 
4-6-17.Aos (Aos Setting) 69 
4-6-18.Spd-Lmt By H 
(Aos Travel Speed Reduction At High Lift Height Setting) 70 
4-6-19.Multi. Lever (Multi Lever Setting) 71 
4-6-20.Tilt-Hrzn 
(Automatic Tilt Horizontal Stop Function Setting) 72 
4-6-21.Charge Count 
(Total Charging Number Display Option Setting) 73 
4-6-22.Waiting(Chg) 
(Power Failure Error Detection Time Setting) 74 
4-6-23.Fan (Fan Setting) 75 
4-6-24.Horn(Chg) (Horn Setting) 76 
4-7. Other Settings 
4-7-1. For Level Meter 
(Battery Indicator Display Correction) 77 
4-7-2. For Ctl. / Chg (Control Voltage Adjustment) 78 
4-7-3. Mainte-Timer Set. (Maintenance Timer Setting) 79 
4-7-4. Error Dsp. Set. (Error Display Setting) 80 
4-7-5. Steering Torque (Steering Torque Setting) 81 
4-7-6. Steering Offset 
(Torque Sensor Neutral Voltage Adjustment) 82 
4-7-7. Steering End Stop 
(Steering End Stop Setting) 85 
5. Inspection And Adjustment Of Equipment/Functions 87 
5-1. Cautions When Inspecting And Adjusting 
5-2. How To Check And Adjust 
5-2-1. Chassis Insulation Check 88 
5-2-2. Body Ground Check 88 
5-2-3. Traction And Hydraulic Motor Insulationinspection 88 
5-2-4. Traction Motor Current Measurement 89 
5-2-5. Hydraulic Motor Current Measurement 91 
5-2-6. Eps Motor - Inspection 93 
5-2-7. Transformer - Inspection (For Built-In Charger) 93 
5-2-8. Diode - Inspection 94 
5-2-9. Descending Regeneration Check 94 
5-2-10.Auto-Power-Off Function Check 94 
5-2-11.Ois (Operation Interlock System) Check 95 
5-2-12.Turn Signal Lamp Check 95 
5-2-13.Travel Inhibitor Check (Option) 96 
5-2-14.Lift Lock (Lift Limit) Operation Check (Option) 96 
5-2-15.Cooling Fan Check 96 
5-2-16.Accelerator Sensor Adjustment 97 
5-2-17.Drive Angle Sensor Adjustment 98 
5-2-18.Torque Sensor Neutral - Check And Adjustment 99 
5-2-19.Ipm Module - Inspection And Replacement 102 
5-2-20.Battery Front Loading Travel/Hydraulic Interlock103 
5-2-21.Built-In Charger Function Check (Total Timer) 103 
6. Troubleshooting 105 
6-1. Caution For Electricity-Related Repairs 
6-2. Self Diagnosis Function 
6-2-1. Display 106 
6-2-2. Error Message List 107 
6-3. Trouble When An Error Message Does Not Appear 113 
6-3-1. Trouble Of Error Non-Occurrence 113 
6-4. Error History Memory 
6-4-1. Error History Memory (Latest 10) 114 
6-4-2. Error History Memory (All) 115 
6-4-3. Memory Initialize (Setting/Error History Reset) 116 
6-5. I / O Monitor Check 
6-5-1. Display Method 117 
6-5-2. Travel Cpu Monitor (Trv Cpu) 118 
6-5-3. Travel I/O Port Table 120 
6-5-4. Hydraulic Cpu Monitor (Hyd Cpu) 121 
6-5-5. Hydraulic Micro Switch I / O Monitor Check 123 
6-5-6. Hydraulic I/O Port Table 124 
6-5-7. Eps/Dsp Display Cpu Monitor (Eps/Dsp Cpu) 125 
6-5-8. Dsp I/O Port Table 1277. Wiring (Diagrams) 129 
7-1. Wiring, System 
7-1-1. Fbr-80 129 
7-2. Wiring, Body 
7-2-1. Fbr-80 130 
7-3. Harness, Body 
7-3-1. Fbr-80 Body Harness 131 
7-3-2. Fbr-H80 Body Harness (2) 132 
7-3-3. Fbr-80 Body Harness (3) 133 
7-3-4. Fbr-H80 Body Harness (3) 134 
7-4. Wiring, Controller 
7-4-1. Fbr-80 135 
7-5. Harness, Controller 
7-5-1. Fbr-80 136 
7-6. Wiring, Panel 
7-6-1. Fbr-80 137 
7-7. Harness, Panel 
7-7-1. Fbr9 - 40 - 80 138 
7-7-2. Fbr9n - 12n - 80 139 
7-8. Wiring, Charger Panel 
7-8-1. Fbr - 80 (3ø, 200v) 140 
7-8-2. Fbr - 80 (3ø, 200v) 6.4kva 141 
7-9. Harness, Bc 
7-9-1. Fbr - 80 Std 142 
7-9-2. Fbr - 80 W/Charging Monitoring System (Cms) 143 
7-9-3. Fbr - 80 W/Electric Power Usage Meter 144 
7-9-4. Fbr - 80 6.4kva Std 145 
7-9-5. Fbr - 80 6.4kva W/Charging Monitoring System (Cms) 146 
7-9-6. Fbr - 80 6.4kva W/Electric Power Usage Meter 147 
7-10.Wiring, Accessory 
7-10-1.Wiring For Strobe Light 148 
7-11.Wiring, Lamp 
7-11-1.Revolving Lamp 149 
7-11-2.Revolving Lamp Interlocking Reverse Travelling 150 
7-11-3.Working Lamp 151 
7-11-4.Back-Up Lamp (Reversing Lamp) 152 
7-11-5.Rear Lamp 153 
7-11-6.Rear Lamp Interlocking Reverse Travelling 154 
7-11-7 Rear Lamp 24v + 
Separately Interlocking Reverse Travelling 155 
7-11-8.Spot Lamp 156 
7-11-9.Spot Lamp 157 
7-11-10.Signal, Display Replenish Water Message 158 
7-12.Wiring, Chime 
7-12-1.Wiring, Chime 159 
7-12-2.Wiring, Chime (W/Back Buzzer) 160 
7-13.Wiring, Buzzer 
7-13-1.Wiring, Buzzer 161 
7-14.Wiring, Lift Limit 
7-14-1.P-Mast (2 Stage Mast) (High Lift Height Detection: 
Only When The Lift Height Is 4500 Mm Or More) 162 
7-14-2.M(Nm)/Pfl-Mast (2 Stage / 3 Stage Full Free Mast) 
(High Lift Height Detection: Only When The Lift Height Is 
4500 Mm Or More) 163 
7-14-3.Lift Limit (W/Release Switch) 164 
7-14-4.Lift Limit (W.O./Release Switch) 165 
7-15.Wiring, Fan 
7-15-1.Fbr - 80 6.4kva 166