INTRODUCTION

sMost accident happens due to the disregard of basic safety rules or

precautions. In order to prevent accidents, the factors which may cause
accidents must be avoided beforehand.
For this reason, please read this manual and fully understand the
precautions for safety and the proper procedures and directions for
inspection and maintenance before starting operation.

Performing maintenance and repair without adequate knowledge may

cause inadvertent accidents.

sIt is not possible to cover all the possible cases of accidents in this
"SERVICE MANUAL". Therefore, attention should be given to
precautions other than the ones mentioned in this "SERVICE
MANUAL". Especially, when repair and maintenance work which are not
covered in this "SERVICE MANUAL" are carried out, always work under
the direction of an instructor who understands the matter.

See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters that
are not contained in this manual.
 USING THE "SERVICE MANUAL"
This Service Manual will give explanation on how to maintain and inspect NICHIYU forklift trucks of
FBT-67 series.
Since the parts used in this machine are subject to change for the sake of better quality, performance
enhancement, and safety, some portions of the contents and illustrations of the "SERVICE MANUAL"
may not be identified.
Directions with and marks are very important, and must be followed.

Indicates a potentially hazardous situation which, if not avoided,

DANGER could result in death or serious injury.
You shall observe this instruction.

Indicates a potentially hazardous situation which, if not avoided,

WARNING could result in death or serious injury.
You shall observe this instruction.

Indicates a potentially hazardous situation which, if not avoided, may

CAUTION result in minor or moderate injury.
You shall observe this instruction.

Indicates suggestions, tips and hints related to the safety of a

NOTE
operator and maintain of truck.

1. Personnel this "SERVICE MANUAL" is aimed at:

This "SERVICE MANUAL" is directed at personnel who possess sufficient knowledge and technical
expertise. If you do not understand any of the contents of this "SERVICE MANUAL", perform operation
under the guidance of personnel who does.

2. Conditions of a facility
The work conditions described in the "SERVICE MANUAL" are written on the assumption that the work
is performed at a shop where standard facilities and tools for the maintenance of NICHIYU ELECTRIC
LIFT TRUCKS are available.
For safe and reliable maintenance, the work should be performed at a shop where the facilities are
equivalent to these described in the "SERVICE MANUAL" or better, and the instructions described
should be strictly followed.

Copyright© 2000
NIPPON YUSOKI CO., LTD.
All Rights Reserved
 CONTENTS
See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters whose pages are not mentioned
in the "Contents".

SAFETY WORK 1 3. REAR AXLE (STEERING)

1. Precautions related to safe inspection 3-1. Disassembling and assembling

and maintenance work ....................................1 3-2. Adjustment
Conditions of a shop (location) for inspection 3-2-1. Micro switch adjustment
and maintenance 1 3-3. Precautions during assembling
Work clothing 2
Tools and gauges 2
Safety work 2
Parts 3 4. TIRE 21
Repair of electrical components 3
Hydraulics 4 4-1. Front tire.....................................................21
Tightening torque 4 4-1-1. Disassembling and assembling 21
2. Location of safety labels..................................5 4-1-2. Tire size (Front) 21
3. Model name and serial numbers .....................9 4-2. Rear tire .....................................................22
4. Cautions for maintenance..............................11 4-2-1. Disassembling and assembling 22
4-2-2. Tire size (Rear) 22
5. Tightening torque of bolts ..............................14
6. Stability of forklift truck ..................................15
7. Load center and load chart............................15
5 .STEERING LINKAGE

1. GENERAL 18 5-1. Disassembling and assembling

1-1. Appearance................................................18
1-2. Specifications .............................................19
6 .BRAKE LINKAGE

6-1. Foot brake

6-1-1. Disassembling and assembling
2. FRONT AXLE (DRIVE) 6-1-2. Master cylinder adjustment
6-1-3. Brake pedal adjustment
2-1. Front axle ass'y
6-2. Parking brake
2-1-1. Disassembling and assembling
6-2-1. Disassembling and assembling of parking brake
2-1-2. Adjustment
6-2-2. Disassembling and assembling of disk brake
2-2. Front axle comp.
6-3. Inspection and adjustment
2-2-1. Disassembling and assembling
6-3-1. Inspection of pad ass'y
2-2-2. Adjustment
6-3-2. Inspection of wheel cylinder
6-3-3. Micro switch adjustment
 See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters whose pages are not mentioned
in the "Contents".

7. HYDRAULIC SYSTEM 23 10. MOTOR

(TRACTION, HYDRAULIC, EPS)
7-1. Valve linkage
7-1-1. Disassembling and assembling 10-1. Disassembling and assembling
7-1-2. Micro switch adjustment 10-1-1. Traction motor
7-1-3. Lift (Fast) micro switch adjustment 10-1-2. Hydraulic motor
7-2. Control valve 10-1-3. Eps motor
7-2-1. Disassembling and assembling 10-2. Inspection
7-2-2. Relief pressure adjustment 10-2-1. Armature comp.
7-3. Oil tank 10-2-2. Carbon brush, carbon brush holder
7-3-1. Disassembling and assembling and spring
7-3-2. Fork oil and quantity 10-2-3. Field coil
7-4. Oil pump.....................................................23 10-2-4. Motor ass'y
7-4-1. Disassembling and assembling 23 10-2-5. Oil seal and permanent magnet
7-4-2. Gear pump type 23

11. ELECTRIC PARTS 27

8. CYLINDER 24
11-1. Location and name...................................27
8-1. Lift cylinder .................................................24 11-2. Control unit ...............................................28
8-1-1. Disassembling and assembling 24 11-2-1. Location and name 28
8-2. Tilt cylinder .................................................26 11-2-2. Hydraulic contactor 29
8-2-1. Disassembling and assembling 26 11-2-3. Disassembling and assembling 29
11-2-4. Precautions during inspection
and replacement
11-3. Forward/backward contactor ....................30
9. MAST
11-3-1. Disassembling and assembling 30
11-3-2. Fuse replacement procedure 31
9-1. Disassembling and assembling
11-3-3. Disassembling and assembling
9-1-1. Simplex mast
Fwd/Bwd contactor (M1, M2, M3, M4) 32
9-1-2. Triplex mast
11-4. Accelerator
9-2. Inspection and adjustment
11-4-1. Removal and installation of
9-2-1. Clearance between roller and mast
accelerator linkage
9-2-2. Mast, lift bracket, and roller shaft
11-4-2. Configuration and feature of accelerator
9-2-3. Back shoe
11-4-3. Adjustment procedure of accelerator linkage
9-2-4. Lift chain
9-2-5. Chain bolt
11-5. Indicator panel & directional switch
11-5-1. Disassembling and assembling
9-2-6. Chain wheel
of indicator panel
9-2-7. Hose pulley
11-5-2. Disassembling and assembling
9-2-8. Roller
of directional switch
9-2-9. Fork
11-6. Battery
11-6-1. Disassembling and assembling
11-6-2. Inspection of battery
11-6-3. Cleaning
11-7. Charger panel
11-7-1. Disassembling and assembling
11-7-2. Power tap switching procedure
 See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters whose pages are not mentioned
in the "Contents".

12. LASER POINTER 33 14. SERVICE DATA AND WIRING

(DIAGRAMS) 38
12-1. Adjustment ...............................................33
12-1-1. Fork level - adjustment 33 14-1. Standard work hours
12-1-2. Laser optical axis - adjustment 33
14-2. FBT-67 System wiring ..............................38
14-3. FBT-67 Body wiring..................................39
14-3-1. With Regen. 39
13. TROUBLESHOOTING 34 14-3-2. Without Regen. 40
14-4. FBT-67 Body harness ..............................41
13-1. Outline of FBT-67
14-5. FBT-67 Control unit harness ....................42
13-1-1. Change from FBT-67
14-5-1. With Regen. 42
13-1-2. Checking operation of auto power off function
14-5-2. Without Regen. 43
13-1-3. Checking display of warning
for battery electrolyte level
14-6. FBT-67 Control unit wiring........................44
13-1-4. Wiring connection of hour meter operation 14-7. FBT-67 Main controller ass'y....................45
13-2. How to adjust new SICOS60
(Major point only)
13-2-1. The name and function of mode select switch
13-2-2. How to set the each mode
13-2-3. Adjustment of starting current and
current limitation
13-2-4. Adjustment of other specifications
13-2-5. Check and adjustment for other functions
13-3. New eps system
13-3-1. Auto power off function
13-3-2. Checking and adjustment
13-4. List of settings for FBT-67 ........................34
13-5. Setting of volume and rotary switch .........35
13-5-1. Volume 35
13-5-2. Rotary switch 35
13-6. Self diagnosis history memory and
check and i/o check
13-6-1. Self diagnosis history memory
13-6-2. I/o check
13-6-3. Analysis of fault cause
 SAFETY WORK
1. Precautions related to safe inspection and
maintenance work
Conditions of a shop (location) for inspection and maintenance

CAUTION Facilities with adequate space and level

surfaces:
¡The floor area of the shop (location) where
inspection and maintenance are performed must
have adequate floor space, and have level
surfaces without holes.
aIf these conditions are not met, unexpected
accidents, such as a roll-over of the forklift
truck, may result.

CAUTION WELL-VENTILATED AREA

¡Work such as welding painted components or
sanding down coated parts should be carried
out in well-ventilated areas.
aIf this is not observed, harmful toxic gas or dust
may be inhaled.

CAUTION LOCATION EQUIPPED WITH FIRE

EXTINGUISHING EQUIPMENT
¡ Equipment such as first-aid boxes and fire
extinguishers should be nearby when work is
performed.

CAUTION SAFE AND WELL-LIGHTED AREA

¡The work area should be safe and well lighted.
When working inside the machine or underneath
of it, always use a safety lamp with a shielded
light bulb.
aIf this is not observed, leaked oil may catch fire
when a light bulb pops.

CAUTION PROPER ARRANGEMENT

¡Arrange and clean always at a working place to
work safety.
¡Especially, arrange disassembled parts well.

1
 SAFETY WORK

Work clothing

CAUTION ¡The worker should wear a hat, work clothes, and

safety shoes that are suitable for safe work. The
work clothes should be close-fitting.
a If this is not observed, loose clothing may
become caught in a machine, resulting in
serious injury.

Tools and gauges

CAUTION ¡Always use tools that are suitable for the work
being performed. Use proper size tools when
tightening and loosening the parts of the forklift
truck.
aFailure to observe the above could result in
serious injury or damage to machines.

CAUTION Prepare tools and gauges before starting to work.

Safety work

WARNING ¡ When hoisting a forklift truck or a heavy

component, use ropes or cable with correct
capacity.
¡Do not use ropes or cables which are kinked.

WARNING After lifting or jacking up a forklift truck, support it

with safety blocks or rigid stands.

WARNING Prevent tires from moving with wheel chocks etc.

WARNING When working under a forklift truck, use a pit or

proper safety precautions.

2
 SAFETY WORK

Parts

CAUTION When replacing any parts, be sure to use NICHIYU

genuine parts.

CAUTION When replenishing battery electrolyte, be sure to

use refined or distilled water.

Repair of electrical components

CAUTION Be sure to disconnect the battery plug when

replacing electrical component.

CAUTION Be sure to jack up the drive wheel when trouble

shooting electrical operations.

NOTE Record the places of lead wire connection when

disassembling.

CAUTION CHARGING BATTERY

¡ Batteries produce flammable gas during
charging. Do not allow batteries in the vicinity of
fire or flames.
aFailure to observe the above could result in an
explosion.

CAUTION ¡Diluted sulfuric acid is used as the battery's

electrolyte . Keep clothing and skin away from
contact with battery fluid.
aIf this is not observed, the fluid may corrode
clothing or cause burns.

3
 SAFETY WORK

Hydraulics

CAUTION When removing the hydraulic pipes, cap them to

prevent dust from entering into the hydraulic
components and pipes.

CAUTION When disassembling and assembling the hydraulic

components, work at clean place and do not
damage the parts.

Tightening torque

CAUTION Observe tightening torque specified in this

manual.
If not specified, refer to the table [Tightening
torque for bolts]. aSee page 15

4
 SAFETY WORK

2. Location of safety labels

The illustration below shows the location of safety labels for safe operation.
Always protect the safety labels from contamination and damage. If they are damaged or
lost, replace with new ones.

1
7

2
Name plate
(page 9)

1
8
3
9
10
4
5 11
6
215W011E

No. Parts No. Parts Name Q'ty Notes

1 0902-69774 Plate, Warning 2 Caution for fingers
2 0902-69814 Plate, Warning 2 No person on/under forks
0902-69964 Label, Tire 2 Air pressure (bar) FBT13, 15P
3
24700-09410 Label, Tire 2 Air pressure (bar) FBT18P
4 24700-04830 Plate, Warning 1 Precaution for Safety Operation
5 0902-68434 Plate, Lubrication 1 Lubrication
6 24700-01780 Plate, Caution 1 Operation of Gas spring lock
7 24700-01850 Plate, Caution 1 Caution for Braking
8 0902-68384 Plate, Precaution 1 Precaution for Safety Operation
9 0902-69794 Plate, Caution 1 No riding except Operator
10 38540-00630 Label, Caution 1 Caution for battery
24700-09410 Label, Tire 1 Air pressure (bar) FBT13, 15P
11
0902-69954 Label, Tire 1 Air pressure (bar) FBT20PN

5
 SAFETY WORK

6977F
3 (For EEC)
(FBT13, 15P)
2

(FBT18P)

(For pneumatic tire only)

6981F

4
Do Not Jump ! Lean Forward
Fasten Hold
Seatbelt On
Tight Lean
Truck can Away
TIP OVER ! Brace From
Risk of serious Feet Impact
INJURY
WARNING or DEATH IN CASE OF TIPOVER
exceeds the stability of the truck.
FOR SAFETY NOTICE FOLLOWING WARNINGS 4. Serious injury or death can occur to the operator if he / she is trapped
1. Lateral tipover can occur when unloaded if the combination of speed between the truck and the ground.
and sharpness of turn produces an overturning moment which exceeds
the stability of the truck.
2. Lateral tipover can occur if overloaded or loaded within capacity and the
IN CASE OF TIPOVER
load is elevated and if turning and / or braking when traveling rearward 1. The operator should stay with the truck if lateral or longitudinal tipover
or if turning and / or accelerating when traveling forward produces an occurs. The operator should hold on firmiy and lean away from the point
overturning moment which exceeds the stability of the truck. of impact.
Rearward tilt and / or off-center positioning of the load and / or uneven 2. The operator should stay with the truck if it falles off a loading dock or
ground conditions will further aggravate the above conditions. ramp. There are other situations where the environment of the landing
3. Longitudinal tipover can occur if overloaded or when loaded within area presents a severe hazard. In those incidents. it may be prudent for
capacity and the load is elevated if forward tilt. braking in forward travel. the operator to leave the truck.
or commencing rearward travel produces an overturning moment which 24700-04830

6
 SAFETY WORK

6 8

PRECAUTIONS FOR SAFETY OPERATION

1. DO NOT OVERLOAD.
OBSERVE ALLOWABLE LOAD (BLUE ZONE).
2. PRIOR TO OPERATION, CHECK PERFORM-
ANCE OF BRAKE.
3. DO NOT MAKE A SUDDEN START AND BRAKE
OR TURN QUICKLY.
4. DO NOT MAKE A SUDDEN VALVE LEVER
24700-01780
OPERATION AT A HIGH LIFT.
5.DO NOT RUN SIDEWAYS OR HANDLE ON AN
INCLINE.
6. WHEN THE RED LAMP OF BATTERY CAPACITY
INDICATOR TURNS ON, CHARGE BATTERY.
7. CHECK ELECTROLYTE EVERY WEEK AND
7 REPLENISH WATER.
8. BE SURE TO USE THE PRESCRIBED
FUSES.
6838 F

Apply parking brake before leav-

ing truck. Make adjustment to
provide adequate braking.
24700-01850

7
 SAFETY WORK

10

GASES produced by this battery can be explosive.

Cigarettes, flames or sparks could cause battery to explode.
Make sure batteries are stored and charged in a well—ventilayed area.
Batteries contain SULFURIC ACID can cause severe burns.
Avoid contact with skin, eyes or clothing.
In event of accident flush with water and call a physician immediately.
Wear rubber gloves to prevent ELECTRIC SHOCK during checking.
and maintaining.
Keep out of reach of children.
IMPORTANT POINT FOR MAINTENANCE
1. Keep the electrolyte level at proper height. (EX.) VENT PLUG
(When electrolyte decreased, fill purified water White
line
and stop filling immediately if confirmed the white line of the
float as shown herein, for over—filling causes overflow.)
2. Always give the battery an adequate charge and
FLOAT
do not use the battery at overdischarged condition.
3. Keep the surface of battery clean and dry.

11 (For EEC)
(FB13, 15P) (FB18P)

(For pneumatic tire only)

8
 SAFETY WORK

3. Model name and serial numbers

Model name
¡Name plate (For Standard)

LOAD CHART
MODEL LIFT HEIGHT

mm

CAPACITY kg
MAXIMUM mm kg / mm
LOAD/LC
LIFT HEIGHT mm kg / mm
SERIAL NO. MFG. YEAR
SERVICE WEIGHT
kg VOLTAGE V LOAD CENTER mm
W/O BATTERY

BATTERY WEIGHT MIN. kg MAX. kg 50001-60560

(For CE)

LOAD CHART
MODEL LIFT HEIGHT

mm

CAPACITY kg
MAXIMUM mm kg / mm
LOAD/LC
LIFT HEIGHT mm kg / mm
SERIAL NO. MFG. YEAR
SERVICE WEIGHT
kg VOLTAGE V LOAD CENTER mm
W/O BATTERY

BATTERY WEIGHT MIN. kg MAX. kg 50001-32831

T T : Three wheels

Capacity code 13 : 1250kg

15 : 1500kg
18 : 1750kg
20 : 2000kg

Classification P : Pneumatic tire

of tire PN : Pneumatic cushion tire
PC : Cushion tire

B : Large capacity battery equipped

C : Stationary charger
D : Dust resistant
Lift height [cm]

Mast type NO CODE : Two stage full visibility (simplex) mast

M : Three stage full free lift (triplex) mast
(Full visibility mast)
PFL : Full free lift (duplex) mast
(Full visibility mast)

CS : Cold storage use for -35:

WB : Wide bar lift bracket

: Attachment
Z : Special type

9
 SAFETY WORK

Serial numbers
No. Serial numbers Stamped position

1 Serial No. of a truck Stamped on the name plate.

2 Serial No. of a chassis Stamped on the battery compartment.

3 Serial No. of a mast Stamped on the mast name plate.

4 Serial No. of a front axle Stamped on the front axle.

5 Serial No. of a traction motor Stamped on the motor name plate.

6 Serial No. of a hydraulic motor Stamped on the motor name plate.

7 Serial No. of a EPS motor Stamped on the motor name plate.

8 Serial No. of lift cylinders Stamped on the lift cylinders.

¡Serial numbers

3
1

4
6

215W012E

10
 SAFETY WORK

4. Cautions for maintenance

General precautions
¡When replacing any parts, be sure to use genuine
NICHIYU parts.
¡ When parts are assembled, always replace old
packing and O-rings with new ones. In addition, be
sure to apply a light coat of grease on the O-rings and
oil seals before installing them.
¡As shown in the illustration, face the flat side of the C- Retainer for Retainer for
shape retainer in the direction the force is applied a groove a hole

when installed.

152E101

¡As shown in the illustration, face the slit side in the

direction the force is applied when driving in a spring
pin.

152E102

¡The split pin must be replaced with a new one and split
so it will not come out.

152E103

¡When using a thrust washer with oil grooves cut,

Oil grooves
observe the direction of installation.

152E104

¡ When connecting and disconnecting couplers of

electrical harnesses, always disconnect the battery
plug.
11
 SAFETY WORK

Using liquid packing

¡ Scraping before application of seal
Remove the sealer adhered on the mating surface of the
casing using a scraper or equivalent tool. Be careful not
to make scratches of 0.3 mm or deeper. If scratches are
Scraper
made, repair the area using an oil stone.

152E105

¡ Applying liquid packing

1.Wipe off the mating surfaces using a cloth soaked in
gasoline to remove oil and contamination.
* Do not use kerosene, light oil, or crude oil.

Cut the nozzle at the

2.Cut the nozzle of the liquid gasket tube at about the second section
second section so that the bead width will be 3 to 3.5
mm. 3 - 3.5 mm
Mating surface Liquid packing
152E106

3.Attach a key for rolling up the tube, and apply the liquid
gasket to the mating surface while rolling up the tube.
* Do not smooth out the bead; doing so may cause
leakage. Not Good

When applying the liquid gasket to bolt holes, apply it 3 -3.5 mm

Key to evacuate
on the internal portion of the mating surface. liquid packing
Good 152E107

4.Close the mating surfaces within 15 minutes after the

Apply liquid packing
liquid gasket is applied.
Within 15 minutes
5.When tightening the bolts, always tighten temporarily
Assembly
first, and then tighten them gradually, moving from one to
the next in a diagonal pattern. Wait for 30 minutes or more

Filling oil/Operation
6.Wait for more than 30 minutes before adding oil or
operating the machine.
* Failure to do so may cause oil leakage.

12
 SAFETY WORK

¡ Deterioration of liquid packing

1.Once the tube has been opened, the liquid gasket * If the oil has separated, the
packing has deteriorated.
anchoring the tip part of the nozzle might be cured and
deteriorated. Squeeze out that portion and discard it Squeeze out the
before reusing the gasket. bead about 20
mm and check.

152E108

2.If oil (filler) was separated from the liquid gasket and the
gasket appears shiny when it is squeezed out, this
indicates that the liquid gasket has deteriorated.
* Although the oil may have been separated from a liquid
gasket opened before its expiration date, this is not an
indication of deterioration.

CAUTION If the state of the gasket is normal, it will be

cured within approximately 2 hours. However, a
deteriorated gasket will not.

13
 SAFETY WORK

5. Tightening torque for bolts

Classification of bolt 4T 8T Brass Stainless

SCM435
Material of bolt SS400 BsBM2S-0 SUS304
(S55C)
Nominal Pitch *1
of bolt Tightening torque *2 Unit : N m{kgf m}
(mm) (mm)
0.6 1.3 0.4 0.5
M3 0.5 {0.06} {0.14} {0.04} {0.05}
1.4 3.2 1.0 1.0
M4 0.7 {0.14} {0.33} {0.10} {0.11}
2.7 6.4 1.8 2.0
M5 0.8 {0.28} {0.66} {0.19} {0.21}
4.7 10 3.1 3.6
M6 1.0 {0.48} {1.1} {0.32} {0.37}
11 26 7.8 9.0
M8 1.25 {1.1} {2.7} {0.80} {0.92}
22 55 15 18
M 10 1.25 {2.3} {5.7} {1.6} {1.9}
39 98 29 33
M 12 1.25 {4.0} {10} {3.0} {3.4}
62 150 47 53
(M 14) 1.5 {6.3} {16} {4.8} {5.4}
97 240 73 81
M 16 1.5 {9.9} {25} {7.5} {8.3}
180 500 140 150
M 20 1.5 {19} {51} {15} {16}
250 670 200 220
(M 22) 1.5 {26} {69} {21} {23}
320 840 250 280
M 24 2.0 {33} {86} {26} {29}
640 1600 530 570
M 30 2.0 {66} {170} {54} {58}

*1. In the table above, the thread pitches of bolt diameters M3 to M8 are for coarse
screw threads and those of bolt diameters M10 or larger are for fine threads
according to our specifications.
*2. The tolerance range of tightening torque is to be +/- 10% of the reference values
given above. (The tolerance range is determined according to experience, related
standards, and records provided by other companies.)

14
 SAFETY WORK

6. Stability of forklift truck

As shown in the figure, the counterbalanced forklift truck
will balance on its drive wheel with a full rated capacity
load on the forks. Consequently, careful attention should Load center
be paid to the load center so that truck does not
unbalance. If a load should exceed the rated capacity of
truck, or the rated load center, the rear steer tires will lift
off the ground and the possibility of toppling the truck
exists.

7. Load center and load chart

Distance from the center of gravity of a load on the forks
to the surface of the truck is called load center. The Bwd Fwd
LOAD CHART shows the relationship between load
center and load capacity of the truck. Do not drag forks
to the floor, lift up forks 150-200mm above floor when
traveling with mast tilted backward fully.
When traveling, do not lifting and tilting forward.
This could cause overturn by changing the center of
gravity for the load.

1300
FBT13P 1600
FBT15P 150-200mm
3700mm
1200 1500 3700mm
4000mm
1400 4000mm
1100
4500mm 1300
4500mm
Capacity (kg)

Capacity (kg)

1000 1200
900 5000mm 1100
5000mm
800 1000
900
700
800
600 700
500 600
500 600 700 800 900 1000 500 600 700 800 900 1000
Load center (kg) Load center (kg)

1800
FBT18P 2100
FBT20PN
3500mm
1700 2000 4000mm
1600 4000mm 1900 4300mm
1500 1800 4500mm
1400 4500mm 1700 4700mm
Capacity (kg)

Capacity (kg)

1300 1600 5000mm

1200 5000mm 1500
1100 1400
1000 1300
900 1200
800 1100
700 1000
500 600 700 800 900 1000 500 600 700 800 900 1000
Load center (kg) Load center (kg)

15
 SAFETY WORK

CAUTION 1) Completely insert the forks beneath the loading object.

2) Applying too much load on the front portion of the forks exerts force
beyond expectation and this may cause damage to the mast and forks
even if the load does not exceed the maximum allowable weight.
3) If the load is off-centered, it not only exerts force beyond expectation
on the truck, but also causes a side slide of the loading object. Thus,
off-centered loads in a lateral orientation should be avoided as well.
4) When loading an object, operate the valve lever carefully.
5) Abrupt operation during high stacking exerts great impacts on the
truck, and may result in a tip over accident.

16
 SAFETY WORK

MEMO

17
 1. GENERAL
1- 1. Appearance
2 FRONT AXLE

3 REAR AXLE

4 TIRE
9
5 STEERING
LINKAGE
8
6 BRAKE
LINKAGE
7 HYDRAULIC
*1 SYSTEM
6

7
8 CYLINDER

2 10 9 MAST

3 10 MOTOR
4
11 ELECTRIC
5
PARTS (*2)
4
12 LASER
POINTER
10
13 TROUBLE
SHOOTING
14 SERVICE DATA AND
WIRING (DIAGRAMS)
*1 : "ACCELERATOR LINKAGE" : See FBT-65.
*2 : 11. ELECTRIC PARTS : See page 27.
461E121

18
 1 GENERAL

1- 2. Specifications

(Seat height)
895

461E132

19
 GENERAL 1

Model FBT13P FBT15P FBT18P FBT20PN

Rated capacity kg 1250 1500 1750 2000
Load center A mm 500
Lift height B mm 3000
Free lift C mm 120
Lifting Laden mm/s 350 330 300 265
speed Unladen mm/s 540 465
Forward D 5
Tilt angle
Backward E 6
Travel Laden km/h 13.5 13 12.5 11
speed Unladen km/h 15.5 15 14.5 13
Minimum turning radius F mm 1400 1500 1545 1695
Overall length G mm 2830 2930 2975 3155
Overall width H mm 1070
Mast lifted I mm 4000
Height Mast lowered J mm 1960 1970
Overhead guard K mm 1985
Wheelbase L mm 1200 1300 1420
Tread (Front/Rear) mm 895/250 895/230
Service weight (Incl. battery) kg 2800 2970 3180 3560
Pneumatic 18 X 7-8-14PR X 2 18X7-8-16PRX2
Front

Pneumatic cushion 18X7-8X2

Tires Cushion 18X6X12 1/8X2
Pneumatic 15X4(1/2)-8-12PRX2 16X6-8-10PRX2
Rear

Pneumatic cushion 15X4(1/2)-8X2 16X6-8

Control system (Travel/Hydraulic) FET chopper
Traction 3.5X2 (60min)
Motor Hydraulic kw 8.8 (5min) 9.6 (5min)
EPS 0.3 (60min) 0.45 (60min)
Battery (48V) Ah/5HR 320 350 390
Automatic stationary charger (3 phase 200V)
Charger
kVA 5.2 6.4

*Subject to change without notice for improvement.

20
 4. TIRE
4- 1. Front tire
4-1-1. Disassembling and assembling

Tire

Rim, wheel

Rim bolt and Nut Tightening torque

88.2-108 N m
FBT13P-18P
{9-11 kgf m}
* FBT20PN : 1piece rim

Hub bolt and Nut Tightening torque

216-264 N m
{22.0-26.9 kgf m}
: Tightening torque
461E005

4-1-2. Tire size (Front)

Model Size Specified air pressure bar (kgf/cm2)

18x7-8-14PR
FBT13P, 15P 8.8 (9.0)
(18x7-8 SOLID : OPTION)
18x7-8-16PR
FBT18P 9.8 (10.0)
(18x7-8 SOLID : OPTION)

FBT20PN 18x7-8 SOLID -

21
 TIRE 4

4- 2. Rear tire
4-2-1. Disassembling and assembling
¡FBT13P-18P

Tightening torque
68.5-78.5 N m
Rim bolt and Nut
{7-8 kgf m}

Tightening torque
88.2-108 N m
Hub bolt and Nut
{9-11 kgf m}
461E036

¡FBT20PN

Rim bolt and Nut Tightening torque

88.2-108 N m
{9-11 kgf m}

Tightening torque
Hub bolt and Nut 216-264 N m
: Tightening torque {22-26.9 kgf m}
461E032

4-2-2. Tire size (Rear)

Model Size Specified air pressure bar (kgf/cm2)

FBT13P, 15P 15x4 1/2-8-12PR 9.8 (10.0)

FBT18P 15x4 1/2-8 SOLID -

FBT20PN 16x6-8-10PR 8.3 (8.5)

22
 7. HYDRAULIC SYSTEM
7- 4. Oil pump
7-4-1. Disassembling and assembling

Hydraulic motor

Bracket, motor

Cushion (1)

Pump, gear

Coupling, pump MG
Fill molybdenum grease up

MG : Apply molybdenum grease

461E042

7-4-2. Gear pump type

Model Type

FBT13-18P TMG1-17
FBT20PN DSG 05-18
23
 8. CYLINDER
8- 1. Lift cylinder
8-1-1. Disassembling and assembling
¡Main parts of lift cylinder for STD (simplex) mast

Valve, check
Bushing Head, cylinder

Bearing, cushion
Ring, snap
Gasket Spacer
Plug

Rod ass'y, piston

Tube ass'y, cylinder

215W008E

¡Main parts of lift cylinder for STD (simplex) mast of RP,

and lift cylinder 2nd for M (triplex) mast

Head, kit
Kit, repair

Spacer

Cylinder ass'y, lift Rod ass'y, piston

Bushing

Bearing, cushion
Ring, sanp

461E018
24
 8 CYLINDER

¡Main parts of lift cylinder 1st for M (triplex) and PFL (duplex) masts

Valve, check
Plate

Head, cylinder
Bearing, cushion
Ring, snap
Plug
Gasket

Tube ass'y, cylinder

Rod ass'y, piston

Valve, down safety

Plug

221W018E

¡Main parts of lift cylinder 2nd for PFL (duplex) mast

Ring, slide Ring, slide

Valve, check
Valve, check
Ring, snap
Ring, snap
Holder Spool, cushion Holder
Spool, cushion

Spring Spring

Tube ass'y Tube ass'y

cylinder cylinder

Rod(L), piston Rod(R), piston

Ring, wear Ring, wear
(MLH4300-5000) (MLH4300-5000)
Spacer Spacer
(MLH4300-5000) (MLH4300-5000)
Ring, snap Ring, snap

Piston Piston

121W071E

CAUTION ¡Care should be taken when installing packings and seals. Apply grease
on them.
¡Also apply a liberal amount of grease on the ground portion.

25
 CYLINDER 8

8- 2. Tilt cylinder
8-2-1. Disassembling and assembling

head, cylinder B
Apply THREEBOND[#1344] on
the threads when tightening.
Nipple,grease
Tightening torque
Head
Head 490 75 N m
FBT13P-18P
{50 7.5 kgf m}
490 49 N m
FBT20PN
{50 5 kgf m}

Head, cylinder

Bushing

Washer
Ring, snap

Spacer
Seal, KIT
Piston

Rod ASS'Y, piston

Cylinder sub ASS'Y

Bushing

Tightening torque
343 49 N m
FBT13P-18P
{35 5 kgf m}
: Tightening torque 735 74 N m
FBT20PN
B : Apply THREEBOND {75 7.5 kgf m}
N : Not reusable
215W001E

26
11. ELECTRIC PARTS
11- 1. Location and name
¡ Accelerator ¡ Indicator panel ¡ Directional switch ¡ Battery

a See FBT-65 a See FBT-65 a See FBT-65

¡ Charger panel a See FBT-65

a See FBT-65

¡ Front contactor
Fwd/
Bwd

a See page 30

¡ EPS controller
CU101-60 (48V/30A)

¡ Rear contactor
By-pass, Regenerator

¡ Control unit
CU101-51, 52

¡ EPS contactor ¡ MPU board

a See page 31

a See page 31 a See FBT-65 a See page 28

215W002E

27
 ELECTRIC PARTS 11

11- 2. Control unit

11-2-1. Location and name
¡CU101-51(with Regenerative function)
¡CU101-52
9. Sensor comp.,
current * Terminal

1. Contactor
3. Diode
Hyd. (M7)
Plugging (D2)

2. Diode
Flywheel (D1) 7. FET comp.
Travel

5. Diode
* Hyd. flywheel (D4)

8. Capacitor

4. Diode
Regenerative (D3)

6. FETcomp.
Hyd.
11. Board comp.,
printed
461E105

12. Resistor comp. 10. Board comp., MPU

No, Name Remarks

1 Contactor Hyd. (M7)

2 Diode Flywheel (D1)
3 Diode Plugging (D2)
4 Diode Regenerative (D3)
5 Diode Hyd. flywheel (D4)
6 FET comp. Hyd.
7 FET comp. Travel
8 Capacitor 100V, 2200 F
9 Sensor comp., current
10 Board comp., MPU
11 Board comp., printed PB83-64
12 Resistor comp.

NOTE ¡This illustration should be used for FBT-67 Regenerative function.

¡Therefore, the parts of 4, 111, 12, and *marked terminal should be used for
only the truck with Regenerative function.

28
11 ELECTRIC PARTS

11-2-2. Hydraulic contactor

Contactor Coil resistance

Hydraulic (M7) 51 - 54.5

11-2-3. Disassembling and assembling

FET comp. C
Apply conductive compound
TSK550 (Toshiba Silicones Co.,
Ltd) on all surfaces between the
"FET comp." and the insulator
FET comp. (Travel) sheet, and between the insulator
sheet and the base.
Diode C
Apply conductive compound
TSK550 (Toshiba Silicones Co.,
Ltd) on all surfaces between the
"Diode" and the heat sink, between
the heat sink and the insulator
FET comp. (Hyd.) sheet, and between the insulator
sheet and the base.

Tightening torque
Plugging diode (D2)
9.5-12.5 N m
{9.7-127 kgf m}
Base

Hyd. contactor (M7)

Heat sink

Plugging diode (D1)

Hyd. flywheel (D4)

Board comp., printed

(w/Regen.)
Tightening torque (M8 terminal)
8.75 N m 10%

Heat sink
89 kgf cm 10%
Only the truck with Hyd. chopper

Tightening torque
9.0-11.0 N m
Bracket (1), MPU board {92-112 kgf m}
Regenerative diode (D3)
(w/Regen.)
: Tightening torque
C : Apply compound
215W009E

29
 ELECTRIC PARTS 11

11- 3. Forward/backward contactor

Contactor Coil resistance

Forward/Backward (M1,M2,M3,M4) 34

By-pass (M5) 54

Regenerative (M6) 54

11-3-1. Disassembling and assembling

s1 Forward/backward contactor

Base, contactor

Cushion

Contactor (M3, M4)

(See 11-3-3)

M3

M4

M2
M1

Contactor (M1, M2)

(See 11-3-3)

Harness, contactor

Harness, CU
215W003

30
11 ELECTRIC PARTS

s2 Bypass, EPS, and regenerative contactor

Frame

Regenerative Tightening torque (M8 terminal)

Contactor (M6)
8.75 N m 10%
{89 kgf m 10%}

Bypass Contactor (M5)

Bracket, contactor

Fuse ass'y (See 11-3-2) G

EPS Contactor (M8) Apply grease

: Tightening torque
G : Apply grease
461E011

11-3-2. Fuse replacement procedure

CAUTION The battery plugs must be disconnected.

1. Fuse 40A (for EPS)

2. Fuse 40A (for Hydraulic)
3. Fuse 40A (for Travel)
4. Cartridge fuse 10A (for control circuit)
5. Cartridge fuse 10A (for accessory)
1
Type Replacement procedure 2
Loosen the fixing nuts and remove 3
Fuse
the fuse. 4
Open the glass case and remove the 5
Cartridge fuse
cartridge fuse.
If the nuts are not properly tightened, contact failure could 215W010E

result. causing malfunctioning.

CAUTION Use only the specified fuses.

31
 ELECTRIC PARTS 11

11-3-3. Disassembling and assembling

Fwd/Bwd contactor (M1, M2, M3, M4)

¡MSW44-23
1 Contact surface MG
(*2) Contact
2. Fitting bolt Apply a little grease with
molybdenum disulfide.

Fitting bolt (*2)

4. Solenoid

4. Core

3. Spring, return 1. Holder

(*2) Fitting nut
1. Spring

3. Armature 1. Holder

(*1) Pin, cotter

1. Contact comp.

MG : Apply molybdenum grease

215W004E

s1 Description of disassembling procedure

1. Remove the "pin, cotter" (*1), holders and the spring to

remove the "contact comp.".
2. Remove fitting bolts and nut (*2) to remove the
contact.
3. Remove the "spring, return" to remove the armature.
4. Remove the core and solenoid.

CAUTION Be careful not to damage the coil terminals.

* For replacement of contactor only, see disassembling

procedure 1.

32
12. LASER POINTER
12- 1. Adjustment
12-1-1. Fork level - adjustment
1. Raise forks to a height for easy work, and level them.
2. Adjust the positions of the leveling sensor and the Bracket, magnet Bracket, sensor

magnet so that they are struck by the laser beam. Magnet

a When the laser beam strikes the targets, the fork
leveling indicator lamp will light. Sensor

Adjustment position Within 1.25 degree of the

fork leveling position

<If the forks are not level>

Either loosen the fixing bolts of the sensor bracket to
215W007E
reposition it, or slightly adjust the magnet so that it is in
the center of the sensor sensing element when the forks
are level.

12-1-2. Laser optical axis - adjustment

1. With the forks positioned in level, adjust the height so
that the optical axis of the laser is aimed at the center
of the pallet insertion openings. Lift bracket

2. Set the distance between the fork edge and the end
face of the pallet to the distance used for loading work
(30mm or shorter), then park the forklift truck in line
with the pallet.
3. Irradiate the pallet with the laser optical axis. Adjust
the body adjustment screw so that, if a line type is
used, the light is aimed at the center area of the pallet
beam, and if a point type is used, at the top of the
deck board. ¡Laser pointer unit

Loosen the fixing bolts of the LASER POINTER UNIT, Laser optical axis
adjust the height by moving the case body up and
down. Also adjust the horizontal direction of the optical
axis by loosening the lock screw and rotating the unit Case
(the wire portion) inside the body.
Laser unit
After the adjustment is complete, securely tighten the
screw and fix it using a screw lock or equivalent item. Lock screw

4. Drive the forklift truck forward and make sure that the
461E050
forks do not hit the pallet. Also, when the forks are
inserted, make sure that they do not hit the deck
board. If they do, adjust the optical axis again.
33
 Rotary switch setting
[Verification]
RS0 RS1
Travel speed
Voltage 3 4 5 6 8 Laden/
Model Remarks
(V) Plugging PLUGG REGENE BRAKE TRAVEL HYD STEER BATT OIL LOAD BRAKE Unladen
Starting Current ING RATE TRQ
brake HYD HYD HYD HYD HYD [km/h]
current limitation
(A) distance LIFT-1 LIFT-2 TILT ATTAT-1 ATTAT-2 Switch back Regen REG-CHK
(A)

Language
brake brake LEVELS [Pneumatic type]

Model selection
(m)
FBT13 type A 55 5 390 10 4.5-5.5 1 50 64 40 32 32 083 083 045 1 20 15.5/13.5
FBT15 type A c c c 2 c c c c c c c c c c c c c c 15/13
FBT18 type A c c c 3 c c c c c c c c c c c c c c 14.5/12.5
FBT20 type A c c 4.0-5.0 4 c c c c c c c c c c c c c c 14/12
FBT13 type B c c 4.5-5.5 6 c c c c c c c c c c c c c c 15.5/13.5
FBT15 type B c c c 7 c c c c c c c c c c c c c c 15/13
48V
FBT18 type B c c c 8 c c c c c c c c c c c c c c 14.5/12.5
FBT20 type B c c 4.0-5.0 9 c c c c c c c c c c c c c c 14/12
FBT13 type C c c 4.5-5.5 B c c c c c c c c c c c c c c 15.5/13.5
13- 4. List of settings for FBT-67

FBT15 type C c c c C c c c c c c c c c c c c c c 15/13

FBT18 type C c c c D c c c c c c c c c c c c c c 14.5/12.5
FBT20 type C c c 4.0 -5.0 E c c c c c c c c c c c c c c 14/12

Plugging brake distance * Language should be as follows

GS battery only
¡TypeA: Equipped with no option ¡On smooth road, loaded, full speed unless otherwise specified:
13. TROUBLESHOOTING

¡TypeB: Equipped with regenerative Starting current/ ¡Gravity of electrolyte: more than 1.25 In Japan: Japanese [0]
braking, over discharge lift lock, Current limitation ¡Full accelerator. Overseas: English [1]
and seat switch ¡Motor current
¡TypeC: Not either type A or B ¡Power 100%
RS1-6 Language Display when key switch is ON
¡Gravity of electrolyte: more than 1.25
RS1-7 [Option set] RS1-5 [Safety monitor symbol] [0] Japanese OK
[1] English MONITORING OK
0 0 1 0 0 0 0 0 1 1 1 0 0 0 1 0
[2] French CONTROLEUR OK
Option board Monitoring TRAVEL
[3] Germany UEBERWACHUNG OK
Spare Sheet switch HYD. BRAKE
Hydraulic chopper Over discharge lift lock STEER LOAD [4] Spanish MONITOR OK
Regenerative contactor Spare BATT OIL [5] Dutch MONITOR OK
Set all figures of [Option set] at [0] at first.
Set all figures at [1] only when the options were installed.

34
13 TROUBLESHOOTING

13- 5. Setting of volume and rotary switch

When replacing MPU board, current sensor or when
necessary, adjust a volume and two rotary switches on
the MPU board. CFL (VR0) : Brightness adjustment of
back light of monitor

RS0 : Truck model selection

RS1 : Monitor selection

PB84-XX

CN1 CN2 CN3 CN4 CN5 CN6

MPU board

13-5-1. Volume
1. CFL (VR0) : Turning clockwise
Brightness adjustment of back light of bright contrast
monitor.
Make sure to see the display clearly even indoor. CFL
VR0

13-5-2. Rotary switch

1. RS0 : Truck model selection
The RS0 is for the truck model selection. If this selection
is not match with the actual model, the truck does not
operate correctly. When replacing the MPU board, the
original rotary switch settings should be recorded, or
refer to the setting table for RS0 to set to the correct
Model selection
positions. RS 0
Error history
memory clear
F01
CDE

23
456
AB

789

35
 TROUBLESHOOTING 13

Setting position Applicable truck model

0 Not used
1 FBT13 type A
2 FBT15 type A
3 FBT18 type A
4 FBT20 type A
5 Not used
6 FBT13 type B
7 FBT15 type B
8 FBT18 type B
9 FBT20 type B
A Not used
B FBT13 type C
C FBT15 type C
D FBT18 type C
E FBT20 type C
Clearing error history (turn the key
F
switch on under this condition)

*Type A : Equipped with no options.

Type B : Equipped with regenerative braking, over
discharge lift lock, and seat switch.
Type C : Not either type A or B.

*For the model other than type A or B, the options must

be set as type C.

CAUTION The "F" position of the RS0 is the clear function

for the error history memory. Pay attention not to
turn on/off the key switch to prevent the
accidental clear.

36
13 TROUBLESHOOTING

2. RS1 : Monitor selection

RS1 is used for the adjustments of current level, starting RS1 : Monitor selection
current, current limitation, I /O checking, …etc, for
F01
various adjustments.

CDE

23
456
Refer to the below table in details.

AB
789

Position Functions Remarks

0 Normal monitor Hour meter display (Total, Traveling, Hydraulic)
Current Level of If (Field) Adjust ; (-) minus value indication : Up button
Current Level of Ia (Armature) (+) plus value indication : Down button
1
Current Gain of If (Field) Adjust ; (Actual current) > (Displayed value) : Up button
Current Gain of Ia (Armature) (Actual current) < (Displayed value) : Down button

Starting current 0 - approx. 50A

2
Current limitation for travel 100 - 440A
Lift speed 1 0 a 64 (Fast) : Low speed (1st micro switch)
Lift speed 2 0 a 64 (Fast) : Hight speed (2nd micro switch)
3 Tilt speed 0 a 64 (Fast)
Attachment 1 speed 0 a 64 (Fast)
Attachment 2 speed 0 a 64 (Fast)
Plugging brake distance 0 - 100
4 Regenerative brake distance 0 - 100
Regenerative brake force 0 - 100
5 Monitor symbols TRAVEL, HYD, STEER, BATT. OIL, LOAD, BRAKE
6 Language selection Japanese, English, French, Germany, Spanish, Duch
7 Option set Regen. contactor / over discharge lift lock, etc
Level adjustment of
8 0 - 30
regenerative function
9 Setting letters on monitoring (Used in factory)
A Display of battery discharge (Used in factory)
Error history memory 1 Memory No : error No = Travel mode, Hyd mode ;
B
Error history memory 2 Same as SICOS 50, SICOS 60
C Display of selected model Display of model selection by RS0
D Address data (Used in factory)
E I/O memory data (Used in factory)
F Hour meter when troubled Display of hour meter when troubled

Each setting should be conforming to "List of setting values".

(See Page 34.)
37
 SERVICE DATA AND WIRING (DIAGRAMS) 14

14. SERVICE DATA AND WIRING (DIAGRAMS)

Battery
V N
3 3

F1 100V2200 F( 2) 2 4

NA
VA

BK/BKWH
Connetor
Connetor
Line
Pin

BK/BKWH
Line NO. CN

BU4
275A Pin NO.
NO. CN Connetor

RDWH
D1 NO. Line
Pin
NO. CN YEWH
NO. 80 3 15 Battery electrolyte level
D2 FC1
VC

left right Body earth (*GS battery only(OPT.))

NB 5 19 Control GND BUWH3
44 6 6 Lift 1 switch
BURD1
BK 75 5 7 Hour meter counting
M2 M4 BU E1 3 16 Travel FET source WHBU
45 6 14 Lift 2 switch
B1 3 6 Travel FET gate To connect : To start counting
GNBU 76 5 17 Hour meter (OPT.)
A A YEWH2
C5 3 19 Travel FET drain voltage BNWH1
46 6 7 Tilt switch BNWH2 Turn switch
* M6 IF C3 3 18 Contact (1) of For./Bwd. contactor 81 5 8
right IA YEBU2 (Turn on when turnning to right)
left 48 6 8 Attachment switch1 (OPT.) BUWH2 Turn switch
GNBU2 87 4 5
M1 M3 C4 3 9 Contact (2) of For./Bwd. contactor GNWH3 (Turn on when turnning to left)
49 6 16 Attachment switch2 (OPT.) YEWH4
82 5 18 Brake oil level
M5 BU4 OPT. GNWH1
* D3 43 6 13 Foot brake switch 83 4 3 Over load (OPT.)
Turn off when releasing brake pedal (w/Regen. or w/Rear combination lamp) OPT. WHBK1
*BU2 BNWH5 85 4 4 Travel inhibit
C1 4 15 Contact of Regen. contactor 90 4 13 Parking brake switch
30W

OPT. BUYE1
2.2

VB 2 7 Power supply for contactor 84 4 11 Seat switch (OPT.)

* PB83-63 * VH 2 6 Power supply for control
BK
Pre-energizing *WHRD1 w/ Laser pointer 1
3 4 16 Pre-energizing FET source Laser pointer
*BURD
B3 4 8 Pre-energizing FET gate
switch Turn signal
YERD4 DC/DC
lamp

RDBK
BNWH Converter
VC 2 1 Travel fuse right
w/ Level lamp RDGN5
BK BNWH6 TSL
100V2200 F( 2) NA 2 8 GND of contactor coil Level lamp
GNRD2
Tilt level 39 4 10 Turn signal lamp
D4 sensor Turn signal TSL
left
FC2 BNBK4 RD5
F2 Laser BURD5 switch
PA
BKRD 10E6
275A M7 E2 3 17 Hyd. FET source
BUWH B2 3 7 Hyd. FET gate Heater w/CS BNRD2
GNWH C6 3 10 Hyd. FET drain voltage
X3 96 4 14 Reverse signal
Back buzzer Load 200mA MAX.
BNRD C2 3 8 Contact of Hyd. contactor
GNBK RDGN3 RD4 BKWH
VD 2 5 Hyd. fuse P52 3 4 Power supply for accelerator BZ
GNBK1
BNYE
YEBU VE 2 2 EPS fuse BK1 GNBK1
C7 3 20 Contact of EPS contactor 13 4 2 Signal for accelerator(1) right

Combination lamp(OPT.)
Accelerator BKWH
BNYE1 BL

RDYE5
EPS motor PA RD4 12 3 5 Signal for accelerator(2) Back lamp
YE

BNYE1
25Wx2
GN

BKYE BKYE
F3 NB2 3 14 GND for accelerator(2)
BL
RD BU BKWH
EPS BUBK left
70 5 5 Abnomal of EPS chopper
40A M8 Controller YEWH1 71 5 15 Abnomal of EPS sensor Brained wire Brained wire BU4 25W right
4 BKWH
TL
RDYE4

BU3 RDGN4 GNBK2 or 10W

RD

RDWH

EPS P57 6 1 Power supply for directional switch Tail &

Key GNBU1 GNRD3
WH TS Sensor BNBK 10W
stop lamp
switch 40 6 4 Neutral TL
RDYE RDYE Directional BKWH
15 5 20 Battery voltage BN1 Lamp left
switch 41 6 12 Forward 25W
F4 RDGN X4
RDGN2
ST 5 10 Start for key switch WHRD2
switch
RD 42 6 Reverse
5 right
RD1 BKWH
10A X1 M1 20 2 3 Forward contactor (left) HL
WHBK Head
30 2 9 40Wx2
10A

lamp
F5

X4 HL
Mctt RDWH1 WH1 BKWH
M2
RDWH

21 2 4 Reverse contactor (left) Low speed left

WHGN1 BNWH1 GNWH2
31 2 10 58 5 12 Low speed
RDBK

RDYE1 GNBK3 BKWH

(w/Built-in cherger) M3 23 1 2 Forward contactor (right) M
YEWH3
BZ
BUWH1 56 5 11 Mode select
33 1 8 Mode select
1 RDWH2 switch YERD WHGN2
M4 26 1 5 Reverse contactor (right) 55 5 1 Up X5 95 4 6 Forward signal (OPT.)
BUYE
Low Forward buzzer(OPT.) Load 200mA MAX.
Accessory 36 1 13 speed YEBK1
RDBK1 57 5 2 Down 10E6 100V 22 F
M5 22 1 1 Travel bypass contactor BK
WHGN 32 1 7 WHBK2 BKWH
* RDGN1
H
M6 24 1 3 Regenerative contactor P53 4 1 Accelerator power supply
WHBU3 RDBK3 NB3 4 9 Accelerator (1) GND
34 1 9 BU1
P50 3 1 Power supply for current sensor (IA)
IA BKRD1
10 3 2 Signal for current sensor (IA)
YEBU1 BKWH 72 5 6 Speed sensitive EPS (SP1)
Reference: RD2 NB0 3 11 GND for current sensor (IA) X2
M7 25 1 4 Hyd. contactor Travel 73 5 16 Speed sensitive EPS (SP2)
Harness mark/color
Red RD WHRD3
35 1 12 current sensor RDYE2 AC0 6 2
YERD1
P51 3 3 Power supply for current sensor (IF) AC1 6 10 Accelerator
Black BK
RDYE3 IF BK2
11 3 12 Signal for current sensor (IF) Horn AC2 6 3
Green GN M8 27 1 6 EPS contactor NB1 3 13 GND for current sensor (IF) Available ports AC3 6 11
Yellow YE
GNRD switch NB7 6 9 Accelerator GND
White WH 37 1 14 (name for A-SICOS) 47 6 15 Reach switch
Brown BN Brained wire
RDBK2
Blue BU X1 28 1 10 Relay for power supply 60 5 3 Speed sensor 1 signal
Gray GY GNRD1 NB5 5 13 Speed sensor 1 GND
Pink PK 38 1 11
16P 61 5 4 Speed sensor 2 signal
Orange OG RDWH3 NB6 5 14 Speed sensor 2 GND
P12 5 9
Warning buzzer Flat
Ex) BKWH (=Black/White) BUWH1
97 4 7
Display unit cable 16P 7 86 4 12 Lift interrupt
Black colored harness with White line.

47 6 15 Lift limit (OPT.)

BK/BKWH

<Note>
White line 1. * Marking shows only for the truck with Regenerative braking.
RDWH

BK/BKWH

3
2
Black color

3
FBT-67 System wiring 14- 2.
54000-27690-0E

38
14 SERVICE DATA AND WIRING (DIAGRAMS)

Parking brake
Head swith Lift 2 Lift Tilt
lamp micro micro micro
Key switch Lamp switch switch switch switch Head
Turn lamp
signal Acceleration ST IG
lamp Indicator panel Turn
sensor signal
Foot brake lamp
B
micro switch

1
1

1
1
Horn switch Horn swith

1
1

1
1
(on handle post) (on valve lever)

1
1

1
1
Flat cable

WH
RD
GN
BK

RD

WH1

1
1

1
1
RDYE
RDGN2

RDBK

RD
GN
WH
BK
6P
2P
Water RD
resistant

Harness, adapter
w/ Laser pointer (Triplex mast)

1
1

1
Hanging on mast Harness, head guard

1
1

1
Harness, head gurad 2P

YEBU1
YEBU1
Harness, 4P 4P 3P 8P

RDBK

RDBK
mast(1) BK
Reference:
Water
2P WH 1 1
WH1 Water Water Water Water 6P 6P
resistant resistant resistant resistant Harness mark/color
resistant BK 1 1
BKWH WH BK BKWH 1 1
BK Red RD
RD 1 1
RD5 WH1 1 1
WH Black BK
Laser 2P GN GNRD2 RDGN5 RD Green GN
1 1 1 1
Harness, GNRD2 1 1
GN Yellow YE
Water
resistant mast(2) Harness, body RDWH White WH
*Refer to note 4 *Refer to note 4 1
RDBK 1
Brown BN
w/ Laser pointer (Simplex mast) Level sensor 2P GNBK2 1
Blue BU
Gray GY
Hanging on mast FL AL AR FR <Note> Pink PK
Harness, mast(1) w/ Laser pointer Water
resistant 8 8 8 8 1. <n> indicates the lead wire numbers.
Orange OG
Traction Traction

<9>
motor motor Ex) BKWH (=Black/White)
Laser 2P 2P 2. Symbol of terminal
Water
resistant
Water
resistant
(left) FFL AAL AAR FFR (right) Black colored harness with White line.
8 8 8 8 1 : Sure receptacle (with sleeve)
Contactor Ass’y, front
1 : Sure plug (with sleeve)

<3>
<6>
<5>

<4>

<7>
<8>
<17> 7 : Receptacle (with sleeve)
M3,M4 8 M34
Battery -+ White line
(right) plug n : Terminal
For./Rev. 8 R 3. Secure all wires so they do not contact
contactor movable parts, edged surfaces, or heat sources.
<2>
<1> Black color
FFR FR 4. When wiring the main terminals of the
8 8
<7> Wire, lead Traction motor, cover them with caps.
<8> WHBK2 7
Wire, lead w/ seat
BKWH Horn
7 switch 2P Hydraulic motor
M1,M2 8 M12 Water
(left) resistant
Seat switch PF PA
For./Rev. 8 L
contactor 8 8
<16>
FL FFL <11>
8 8 <10>
<6>
<5>

Wire, lead
4P
<11>

<10>

<16>

<17>
<2>

<4>

<1>
<3>
WH
6P 6P Water Water

RDYE5
BK WH Harness, CU <12> 3P 3P

BKWH
Harness, contactor resistant resistant
6P Water resistant
RD
10P

1
Harness,
4P 4P EPS

1
EPS sensor
turn switch
<13> RD WH 2PX controller

PK
BK
4P
CN6 CN5 CN4 CN3 CN2 CN1 XY EPS
Fly wheel 8 8 AAR 2PY motor
Hydraulic diode

BK
PF 8 Harness, EPS Back
FET Comp. D4 Harness, contactor buzzer
D1 8 D+ Current
MPU board

BUWH2

BNWH2
sensor
Capacitor 8 D2 RD
5 5 8 EPS
8 6 contactor
M8 Turn switch Turn switch

GNBK2

BURD1
AL

RDWH
5 5 5 5

BKWH
(Turn on when (Turn on when
Plugging 6 8 M6 8

BU4
Current RDGN turning to left) turning to right)

BK
5 5 diode 10A
RDBK Regen
sensor 10A
RDYE4 contactor

1
1
1
1
1

1
Capacitor
L
D3 8 Accessory
40A 275A
M7+M7- 8 EPS 8 Travel 8

BU
M6 DF Connect:
Travel FET Comp. D 8 8 8 M5- M5+ hour meter
8 <18> <15>
HF
275A 8 M5 8 counting
8 8 Hyd. 8 Bypass
contactor

Control unit <13>

Contactor unit, rear FBT-67 Body wiring 14- 3.
<14>

Wire, lead
With Regen. 14-3-1.
54000-27670-0E

39
 SERVICE DATA AND WIRING (DIAGRAMS) 14

Parking brake
Head swith Lift 2 Lift Tilt
lamp micro micro micro
Key switch Lamp switch switch switch switch Head
w/ Rear lamp
Turn combination
signal lamp ST IG
Acceleration Turn
lamp Indicator panel
sensor signal
Foot brake B lamp
switch

1
1

1
1
Horn switch Horn swith

1
1

1
1
Flat cable

1
1

1
1
RDYE
(on handle post)

RD
(on valve lever)

RDGN2

RDBK
RD

WH1
WH
BK
GN

1
1

1
1
WH
6P

RD
GN
BK
2P
Water RD
resistant

Harness, adapter
w/ Laser pointer (Triplex mast)

1
1

1
Hanging on mast Harness, head guard
Harness, head gurad

1
1

1
2P

YEBU1

YEBU1
Harness, 4P 4P 3P 8P

RDBK

RDBK
mast(1) BK
Reference:
Water
2P WH 1 1
WH1 Water Water Water 6P 6P
resistant resistant resistant Harness mark/color
resistant BK 1 1
BKWH WH BK BKWH 1 1
BK Red RD
RD 1 1
RD5 WH1 1 1
WH Black BK
Laser 2P GN GNRD2 RDGN5 RD Green GN
1 1 1 1
Harness, GNRD2 1 1
GN Yellow YE
Water
resistant mast(2) Harness, body RDWH White WH
*Refer to note 4 *Refer to note 4 1
RDBK 1
Brown BN
w/ Laser pointer (Simplex mast) Level sensor 2P GNBK2 1
Blue BU
Gray GY
Hanging on mast FL AL AR FR Pink PK
w/ Laser pointer Water <Note>
Harness, mast(1) resistant 8 8 8 8 Orange OG
Traction Traction 1. <n> indicates the lead wire numbers.

<9>
Laser 2P 2P motor motor Ex) BKWH (=Black/White)
Water
resistant
Water
resistant
(left) FFL AAL AAR FFR (right) 2. Symbol of terminal Black colored harness with White line.
8 8 8 8 1 : Sure receptacle (with sleeve)
Contactor Ass’y, front
1 : Sure plug (with sleeve)

<3>
<6>
<5>

<4>

<7>
<8>
<17> 7 : Receptacle (with sleeve)
M3,M4 8 M34 Battery -+ White line
(right) plug n : Terminal
For./Rev. 8 R 3. Secure all wires so they do not contact
contactor
<2> movable parts, edged surfaces, or heat sources.
<1> Black color
FFR FR 4. When wiring the main terminals of the
8 8
<7> Wire, lead Traction motor, cover them with caps.
<8> WHBK2 7
Wire, lead w/ seat
BKWH Horn
7 switch 2P Hydraulic motor
M1,M2
8 M12 Water
(left) resistant
For./Rev. PF PA
8 L Seat switch
contactor 8 8
<16>
FL FFL <11>
8 8 <10>
<6>
<5>

Wire, lead
4P
<11>

<10>

<16>

<17>
<2>

<4>

<1>
<3>
WH
6P 6P
Water Water

RDYE5
BK WH Harness, CU <12> 3P 3P

BKWH
Harness, contactor resistant resistant
6P Water resistant
RD
10P

1
EPS Harness,
4P 4P EPS

1
sensor turn switch
<13> RD WH 2PX controller

PK
BK
4P EPS
CN6 CN5 CN4 CN3 CN2 CN1 XY
Fly wheel 8 8 AAR 2PY motor
diode

BK
Hydraulic Harness, EPS Back
PF 8 buzzer
FET Comp. D4 Current Harness, contactor
MPU board D1 8 D+

BUWH2

BNWH2
sensor

RD
Capacitor 8 D2
5 5 8 EPS
8 6 contactor
M8 Turn switch Turn switch

GNBK2

BURD1
RDWH
5 5 5 5

BKWH
Plugging 6 (Turn on when (Turn on when

BU4
diode Current 10A RDGN turning to left) turning to right)

BK
5 5 RDBK
sensor 10A
RDYE4

1
1
1
1
1

1
Capacitor
L Accessory
8 40A 275A
M7+M7- 8 8 8
EPS Travel

BU
DF Connect:
D 8 8 8 M5- M5+ hour meter
Travel FET Comp. HF
<15> 275A 8 M5 8 counting
8 8 Bypass
Hyd.
contactor

Contactor unit, rear

Control unit <13>
<14> FBT-67 Body wiring 14- 3.
Wire, lead
Without Regen. 14-3-2.
54000-27660-0E

40
14 SERVICE DATA AND WIRING (DIAGRAMS)

AMP 174257-2 AMP 174982-2

K Horn relay Key & lamp O Indicator

panel AMP 174357-2
R DC/DC
M
2 1 4 3 2 1
4 3 8 7 6 5 Converter
switch
Reference:
Harness mark/color
Red RD
Relay
CA1a-DC48V-N
L Parking
switch
brake Switch
N (Laser pointer) Water resistant Water resistant Water resistant
3 2 1

Q Foot brake
1 2
S Valve micro switch
Black BK CA 1 2 3 Plug Plug Plug Plug switch 3 4
Green GN Relay 4 5 6 6P WH 4P 8P 3P
Yellow YE Plug 1 2 3
50D 29B Plug
White
Brown
Blue
Gray
WH
BN
BU
GY
Plug
4P WH
1 2
3 4
2P RD

1
Q,E
1
F
2
53B 32E
51C
D
16B
20C
E
2P BK 1
2
7B
3B
F
1B
2B
F
49A
12B
F
17B
11B
F
49C
18B
F
60B
61B
F
32I
52B
O
54A
P Horn
switch
Plug
2P BK
1
2
Plug
4P WH
4 5 6

Plug
2 1 1 62A 50D 50C 8B 62B 44B 63A 64A 6P BK
Pink PK F F E F E F T T
I,T K,P F R Q,L 32F 46B S,L W N T,K Z2 Z1

BNWH5
RDWH
Orange OG 32D 46A 44B 45B
1 2 3 4 5 6 1 2 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 M,U K,U 1 2 9B 6B 50B
D,M P T,I G 1 2 3 4
Ex) BKWH (=Black/White) 1 1
1 2 10E6 4 3 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 F F T,Q
Black colored harness with White line. or 4B 5B 10B

RDBK*
YEBU1

RDWH
BU4
BN1
WHRD2
RDGN4
BNBK

BK
YEBK1
YEWH3
YERD
BK
GNWH2
RDWH3
BUWH1

RDBK*
RD5
RDGN5

YERD4
BKWH*
BNWH6
BURD5
WH1
1 1 equivalent 1 1

RDYE

YERD4
RDBK*
RD*
RDGN2

RDWH
F F F
RDBK*
YEBU1

BKWH*
WHBK2
1 2 3 4 5 6
1 1 1 1 1 1
T Head guard(right)

BUWH3
WHBU
BNWH1
YEBU2
GNWH3
RDWH
White line
WH1
Front M 53C
GNRD2 Trun I 27C
signal
Black color RDGN5
Right O 54B
RDBK* U

H Acceleration sensor
P48 O 32H
RDWH

J Charger
KS S 50A
Clamp the horn Water

Y EPS controller
BKWH*
relay here.
X Relay BNYE1 2 1 E 56B
resistant AMP 174257-2 GND K 44A

YEBU1

RDBK*
RD4 E 55B
GNBK2
2 2 Spare W 59B

BK

BK
BKYE Plug
RDYE4 2 3 E 57B 2 1
4P
Plug 34B D 1 1 Relay GNBK1
2 4 F 22B 4 3 7 7 1
4P BK RDGN* AMP 174655-2 CA1a-DC48V-N
33B D 2 1 Water resistant 1 2 1

51B Y RD* CA V V P P,T

M 3
1 Plug
1 2
3 4 44D K
I
4 1
BKWH* 5 4 3 2 1 10P Relay

VSeat switch
62A 62B
Yazaki 6187-2171
46C 32G U Horn switch
(on valve lever)
W Accessory
10 9 8 7 6 (Back buzzer)
13B 19B 51A 41B 39B Water resistant
F F D B B 1 2 Plug Plug
Vinyl tube (BK) 50G 40B 3 4 4P WH 2P <Note>

53A M WH1 Write a M with undamped ink. Z1Laser 1 2 3 4 5 6 7 8 9 10

W B
32B 42B 32A
X,D C X
31B
F
50F
E,Y
8B 47A
F,Q C
59A 14B 48C
T F E,A
48A 28B
1

Yazaki 6180-2181
2 1. Symbol of terminal
Sure plug AMP170020-2
AMP 174352-2 2 2 2 2 2 2 2 E F
1 3 2 4 KS Brake GND Spare (With plating) Sleeve (for single wire) 170887-1

(Seal plug)
BUBK
(Seal plug)
YE1
(Seal plug)
RD*
RDWH
WH
GNBU1
BU3
1 2
Head guard
I (left) 27B F
T
GNRD2 BNBK4
BURD5
2
2
1 Z2 65A
2 R 64B
Plug
2P
2 1 1 1 1 10E6 1
or
7 7
Sleeve (for double wire)
Sure plug
170888-1
AMP170020-3 or

RDBK*

RDYE5

RDBK*

BNRD2

RDWH

BU4

BKWH*

GNBK2
BURD1
BK
1

BK

BUYE1
equivalent
RD5 (With plating)
52A O Water resistant 170002-5
BNBK4 2 Sleeve (for single wire) 170887-1
BKWH* 1 Z1 65B
44E J
G BNWH6 Plug
2 2 R 63B 2 1
2P Sure receptacle AMP170021-2
(With plating) Sleeve (for double wire) 170890-1
Water resistant AMP 174352-2
Sleeve (for single wire) 170889-1
Z2 Level sensor Put the sleeve
for shur plug rec.
1
(With plating)
Sure receptacle AMP170003-5 or
170021-3
Sleeve (for double wire) 170890-1
WHBK2 Vinyl tube (BK) Receptacle (with sleeve) AMP41729
45A K

G Horn Sleeve (for double wire) 1-170823-5

+

Sleeve (for single wire) 170823-2

44D IE
BKWH* 2 Receptacle AMP175061-2 or
Condenser
100V/22 F 173716-2
Clamp the + Receptacle AMP179461-5 or

BKWH*
1
relay here. 170032-5

BUWH2

BNWH2
GNBU1
RDYE5
RDBK*
2 Receptacle AMP173707-1 or

BU3
RD*

WH

BK
32C Condenser 171662-1 or
51B 100V, 4.7 F
X,K 2 2 2 2 2 2 172888-2
Y,M
1 2 3 1 2 3 2 Tab AMP173706-1 or
W,E X
47B 42A Y Y F W 171661-1

BK

BK
41A 39A 24B 48D 7 Terminal (F) Yazaki 1500-0110
GNWH2

GNWH3
WHRD1

RDWH3

WHRD2
BUWH2

BUWH1

BNWH5

BNWH2

BUWH3
BNWH1
YEWH3

YEWH1
GNRD2

REGN2
GNBK1

BNRD2

BURD1
BUYE1

YEBU2
YEBK1

RDGN

Y F
BURD

YERD

RDYE
BUBK

BNBK

Back Terminal (M) Yazaki 1600-0105

C 7
BU2

BN1
BU4

10A

10A
40A 15B
buzzer Terminal (pressed sleeve)FNC-2
WHRD1
BKWH*
BKWH*

Plug Cap
BNYE1
RDWH

BURD
RDYE

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
BKYE

3P 2. Lead wire
BK

BK
3P
RD4
BU2

1 2 9 4 5 6 7 8 16 3 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BK
BK

H E V L E O A M O E O S S O S S Water resistant Water resistant * : AVS0.85mm2

22A 25A 28A 29A 30A 12A 15A 16A 18A 20A 2A 4A 6A 7A 9A 10A 1 1 1 1 1 1 1 1 1 1 1 1
A O E I X O Y W O O Y O O S Q
For others : AVS0.5mm2
1 2 3 4 5 6 1 2 3 4 5 6
24A 61A 26A 27A 31A 11A 13A 14A 60A 17A 19A 1A 3A 5A 8A 8 3 2 1 1 2 3 Brained wire
F,M C O,O F F H 6. Fuses should be put
together like a concentric AMP 174357-2 AMP 174359-2
: Braddie wire under 25mm pitch.
Write a 4 with Write a 5 with Write a 6 with 20B 47C 49B 30B 25B 56A
CN5
undamped ink.
CN4
undamped ink. undamped ink. CN6
L,W
50E 44E
G V,W
48B 26B
F
55A
H
57A
H
D Fuse circle as below figure.
Fuse
10A B EPS sensor ATurn switch
3. Location of connector pin is looked from inserting side.
4. The mark bands in the figure are not necessary for
complete harnesses.

About 40
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10A

16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 5. When installing diodes and capacitors, solder them and

Plug
Plug cover them with insulating vinyl tubes.
E Control unit
6PWH 8
6PBK

F MPU board 1 2 3
4 5 6
1 2 3
4 5 6
70 40 Clamp
FBT-67 Body harness 14- 4.
54000-27532-0E

41
 SERVICE DATA AND WIRING (DIAGRAMS) 14

A Outer terminal B Contactor

unit
<Note>
1. Lead wire
: KIV2mm2
2 1 3 2 1 3 2 1 3 2 1 1 2 1 2 * : AV or AVS0.85mm2
4 3 6 5 4 6 5 4 6 5 4 3 4 3 4 # : AV or AVS0.3mm2
For others:AV or AVS0.5mm2
Cap Cap Cap Cap Plug Plug 2. Symbol of terminal
4PWH 6PRD 6PWH 6PBK 4PRD 4PWH 1 : Recptacle AMP 175027-6 or 173631-6
17B 22B 2B 40B 13B 43A 44A 45A 46A 48A 31B 1B 7B 6B 14B 2 : Recptacle AMP 175061-2 or 173716-2
E E E E E D H H G F E E E E E 1 : Tab AMP 179462-3 or 170340-3
18B 23B 5B 8B 37B 20B 44C 45C 47A 30B 32B 3B 9B 16B 42B
1 : Recptacle AMP 179461-5 or 170032-5
E E E E E D,E H H L E E E E E E
: Contact JST BXH-001G-P0.6 or SXH-001G-P0.6
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 : Recptacle AMP 41729
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8 : Terminal 1.25-8 or 2-8
3. Location of connector pin is looked from inserting side.
RD1
RDWH1

BNWH1

RDYE1
RDWH2
YEWH2
BUWH1
BUYE
GNBU2

RDYE

BKWH*
BKWH*
BK
BK

WHRD1
BURD
RD4
BNYE1
BKYE

RDBK1
RDGN1
WHGN
WHBU3

RDYE3
BNYE
GNRD
YEBU
BU2
RDWH
WHBK

4. The mark bands are not necessary for these harnesses.

5. The mark bands in the figure are not necessary for complete harnesses.
6. The wires shown below should be twisted in a pitch of 25mm or shorter.

Wires to be twisted
RDBK3-BU1-BKRD1
RDYE2-YERD1-BK2
RD4-BNYE1-BKYE
BUWH-BKRD
BU-BK

C Hydraulic
FET Comp.

BKRD Reference:
35B E 1 1
Cap GNWH Harness mark/color
2 1 38B E 2 1 Red RD
4P BUWH
4 3 34B E 3 1 Black BK
RD
4 Green GN
Yellow YE
White WH
Plug 49A J 1 1
RD Brown BN
1 Blue BU
2P
RDBK3#

BKRD1#
RDYE2#
YERD1#

RDWH1

RDWH2

WHRD3
BNWH1

BUWH1
WHBU3
YEWH2

RDGN1

GNRD1
Gray GY

RDBK1
RDYE1

RDYE3

RDBK2
2
BNYE1

BU

GNWH

WHGN
RDWH
RDWH
BUWH

BNWH

WHBK

GNRD
GNBU

GNBU
BNRD

GNBK
BKRD

YEBU

BNYE

BUYE
WH 50A F 2
BKYE

1
BU1#

BK2#

Pink PK
RD4

RD1

RD2
BU
BK

BK
Orange OG
BU
Write a 1 with
50B F 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 undamped ink. Ex) BKWH (=Black/White)
Plug BURD Black colored harness with White line.
1 2 48B A 2 1 1 2 11 3 12 13 4 5 14 6 16 7 17 8 9 10 15 18 19 20 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14
4P WH
3 4 51C L 3 1
GN L L L A A H C A H J A K D A B B A B B D A
4
24A 26A 28A 30A 32A 21A 35A 37A 41A 15A 17A 19A 20D 22A 1A 3A 5A 7A 9A 11A 13A
RDBK3# 1 E 24B
Pre-energizing
F
L L L A H C K C A B B A A H A A K B A D K B 2
BU1# 4P 1 2 3 4
25A 27A 29A 31A 33A 34A 36A 38A 40A 42A 16A 18A 20A 21C 23A 2A 4A 6A 8A 10A 12A 14A 3 E 25B
board resistor BKRD1# 4 E 26B
CN3(20P) CN2(10P) CN1(14P) Write a A with undamped ink. White line

10 9 8 7 6 5 4 3 2 1 4 3 2 1 6 5 4 3 2 1 RDYE2# 1 E 27B
20 19 18 17 16 15 14 13 12 11
Write a 3 with
undamped ink.
EMPU board
10 9 8 7 6 5 14 13 12 11 10 9 8 7

Write a 2 with
JTravel diode YERD1#
BK2#
2
3 E 28B
4 E 29B
4P 1 2 3 4 Black color

49B 15B
undamped ink.
F E Write a F with undamped ink.
RDYE
RDBK2
1
1
1 A 43B
2 E 10B
Plug
1 2 DRelay 8 8
WH
8 F 51B

BNWH
RDWH 4P
3 A

RD
1 E 20C 3 4 WHRD1
GNRD1 BK Clamp this properly. 8 A 47B
1 4 E 11B

L Current
sensor
G Regen. diode 46B A 8 BU2

WHRD3

GNBK

BNRD
RD2
BKWH*
BKWH*
GNBU

8 8
BU
BK

BK
BK

E E E E
1 1 1
4B 12B 19B 36B
1 2 3 4 8 8
FBT-67 Control unit harness 14- 5.
E,E
21B
E
E
33B
A,A
45B
A,A
44B
K Hyd.
contactor

41B
Travel
With Regen. 14-5-1.
2 1
4 3
Cap
4PGN H FET Comp. 24200-58061-3E

s CU101-51E/57E
42
14 SERVICE DATA AND WIRING (DIAGRAMS)

A Outer terminal B Contactor

unit
<Note>
1. Lead wire
: KIV2mm2
2 1 3 2 1 3 2 1 3 2 1 1 2 1 2 * : AV or AVS0.85mm2
4 3 6 5 4 6 5 4 6 5 4 3 4 3 4 # : AV or AVS0.3mm2
For others:AV or AVS0.5mm2
Cap Cap Cap Cap Plug Plug 2. Symbol of terminal
4PWH 6PRD 6PWH 6PBK 4PRD 4PWH 1 : Recptacle AMP 175027-6 or 173631-6
17B 22B 2B 40B 13B 43A 44A 45A 31B 1B 7B 6B 14B 2 : Recptacle AMP 175061-2 or 173716-2
E E E E E D H H E E E E E 1 : Tab AMP 179462-3 or 170340-3
18B 23B 5B 8B 37B 20B 44C 45C 30B 32B 16B 42B
1 : Recptacle AMP 179461-5 or 170032-5
E E E E E D,E H H E E E E
: Contact JST BXH-001G-P0.6 or SXH-001G-P0.6
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 : Recptacle AMP 41729
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8 : Terminal 1.25-8 or 2-8
3. Location of connector pin is looked from inserting side.

BKWH*
BKWH*
RD1

WHBK
BNWH1

RDYE1
RDWH2
YEWH2
BUWH1
BUYE
GNBU2

RDYE
RDWH

BK
BK

RD4
BNYE1
BKYE

RDBK1

WHGN

RDYE3
BNYE
GNRD
RDWH1

YEBU
4. The mark bands are not necessary for these harnesses.
5. The mark bands in the figure are not necessary for complete harnesses.
6. The wires shown below should be twisted in a pitch of 25mm or shorter.

Wires to be twisted
RDBK3-BU1-BKRD1
RDYE2-YERD1-BK2
RD4-BNYE1-BKYE
BUWH-BKRD
BU-BK

C Hydraulic
FET Comp.
Reference:
Harness mark/color
BKRD Red RD
35B E 1 1 Black BK
Cap GNWH
2 1 38B E 2 1 Green GN
4P BUWH Yellow YE
4 3 34B E 3 1
RD White WH
4
Brown BN
Blue BU
RDBK3#

BKRD1#
RDYE2#
YERD1#

RDWH1

RDWH2

WHRD3
BNWH1

BUWH1
YEWH2

GNRD1
GNBU2
Gray GY

RDBK1
RDYE1

RDYE3

RDBK2
BNYE1

GNWH

WHGN
RDWH
RDWH
BUWH

BNWH

WHBK

GNRD
GNBU
BNRD

GNBK
BKRD

YEBU

BNYE

BUYE
BKYE
BU1#

BK2#

Pink PK
RD4

RD1

RD2
BU
BK

BK
Orange OG

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ex) BKWH (=Black/White)

1 2 11 3 12 13 4 5 14 6 16 7 17 8 9 10 15 18 19 20 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Black colored harness with White line.

L L L A A H C A H J A K D A B A B D A
24A 26A 28A 30A 32A 21A 35A 37A 41A 15A 17A 19A 20D 22A 1A 5A 7A 11A 13A
RDBK3# 1 E 24B
L L L A H C K C A B B A A H A A K B A D K B 2
BU1# 4P 1 2 3 4
25A 27A 29A 31A 33A 34A 36A 38A 40A 42A 16A 18A 20A 21C 23A 2A 4A 6A 8A 10A 12A 14A 3 E 25B
BKRD1# 4 E 26B
CN3(20P) CN2(10P) CN1(14P) Write a A with undamped ink.
White line

Write a 3 with
10 9 8 7 6 5 4 3 2 1 4 3 2 1 6 5 4 3 2 1 RDYE2#
undamped ink. 1 E 27B
20 19 18 17 16 15 14 13 12 11

EMPU board
10 9 8 7 6 5 14 13 12 11 10 9 8 7

Write a 2 with
JTravel diode
Write a 1 with 15B
YERD1#
BK2#
2
3 E 28B
4 E 29B
4P 1 2 3 4 Black color

undamped ink. undamped ink. Write a F with undamped ink.

E

RDYE
RDBK2
1
1
1 A 43B
2 E 10B
Plug
1 2 DRelay 8

BNWH
RDWH 4P
1 3 A
E 20C 3 4
GNRD1 BK Clamp this properly.
1 4 E 11B

L Current
sensor

WHRD3

GNBK

BNRD
RD2
BKWH*
BKWH*
GNBU

8 8
BU
BK

BK
BK

E E E E
1 1 1
4B 12B 19B 36B
1 2 3 4 8 8
FBT-67 Control unit harness 14- 5.
E,E
21B
E
E
33B
A,A
45B
A,A
44B
K Hyd.
contactor

41B
Travel
Without Regen. 14-5-2.
2 1
4 3
Cap
4PGN H FET Comp. 24200-58071-3E

s CU101-52
43
 SERVICE DATA AND WIRING (DIAGRAMS) 14

Only with Regen.

2 1 3 2 1 3 2 1 3 2 1 1 2 1 2
4 3 6 5 4 6 5 4 6 5 4 3 4 3 4

Cap Cap Cap Cap Plug Plug

4PWH 6PRD 6PWH 6PBK 4PRD 4PWH
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

RDBK3#

BKRD1#
RDYE2#
YERD1#

RDWH1

RDWH2

WHRD3
BNWH1

BUWH1
WHBU3
YEWH2

RDGN1

GNRD1
GNBU2

RDBK1
RDYE1

RDYE3

RDBK2
BNYE1

GNWH

WHGN
RDWH
RDWH
BUWH

BNWH
YEWH2
RDWH1
WHBK
BNWH1

RDYE1
RDWH2

BUWH1
BUYE
GNBU2

RDYE
RDWH
BKWH*
BKWH*
BK
BK

BU2
WHRD1
BURD
RD4
BNYE1
BKYE

RDBK1
RDGN1

WHBU3

RDYE3

GNRD
YEBU

WHBK

GNRD
BNYE
RD1

GNBU
BNRD

GNBK
BKRD
WHGN

YEBU

BNYE

BUYE
BKYE
BU1#

BK2#
RD4

RD1

RD2
BU
BK

BK
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 11 3 12 13 4 5 14 6 16 7 17 8 9 10 15 18 19 20 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Only with
Regen.
CN3(20P) CN2(10P) CN1(14P)

10 9 8 7 6 5 4 3 2 1 4 3 2 1 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 14 13 12 11 10 9 8 7

MPU board
BKRD 1 1
GNWH 1 2 4P
BUWH 1 3 RD
4
Hydraulic
(9 1 2 3 4 Write a A with undamped ink.
2 1
) FET Comp.
1
2
4 3 - 1
RDBK3#
2
1 1
RD PA 4P
3
BU1#
2P 4
BKRD1#
Resistor WH
2 1
BU (8) Only with Regen.
WHRD1

(3
8 WH

)
Only with Regen. (1) D+
1 2
3 4 8 1
RDYE2#
1 1
BU 2
Pre- BURD 4P YERD1#
4P 2 1 3
energizing WH 1 2 BK2#
GN
(6)
3 1 4
PB RDYE 3 4

BNWH
4 1 1

RD
RDBK2 1 2 3 4 Write a F with undamped ink.
1 2 4P
RDWH Relay

)
BK

(7
1 3 Only with Regen.
GNRD1 1 4 Reference:

WHRD3
Harness mark/color

BNRD
Red RD

GNBK
RD2
Black BK
BK 1 1 2 1 Green GN
<Note> 4 3 Yellow YE
GNBU 1 2 White WH
1. Lead wire 4P
BU 1 3 RD Brown BN
: Main lead wire Blue BU
4 Gray GY
: Lead bar
: KIV2mm2 BK M7 Pink
Orange OG
PK

* : AV or AVS0.85mm2 BK 8 8
# : AV or AVS0.3mm2 BKWH*
Travel Ex) BKWH (=Black/White)
Black colored harness with White line.

For others:AV or AVS0.5mm2 BKWH* FET Comp. M7+ M7-

2. Symbol of terminal
1 : Recptacle AMP 175027-6 or 173631-6 A M6
2 : Recptacle AMP 175061-2 or 173716-2 BU2 8
Only with Regen. (2)
1 : Tab AMP 179462-3 or 170340-3 White line
1 : Recptacle AMP 179461-5 or 170032-5
Only with Regen.
: Contact JST BXH-001G-P0.6 or SXH-001G-P0.6 4. Recinnebded tightening torque for the Diode.
: Recptacle AMP 41729 Nihon inter Electronics make : 9.5-12.5 N m (97-127 kg cm) Black color
Semikron make : 9.0-11.0 N m(92-112kg cm)
8 : Terminal 1.25-8 or 2-8
3. Location of connector pin is looked from inserting side. 5. Recinnebded tightening torque of M8 terminal ALBRIGHT make contactor .
8.75N m 10% (89kg cm 10%)
6. <n> indicates the lead wire numbers.
FBT-67 Control unit wiring 14- 6.
24200-58100-2E

44
14 SERVICE DATA AND WIRING (DIAGRAMS)

34 35 33 34
1 4 32 33 14 30 31 11 9 15 14 30 31 6 37 22 13 7 31 8 15 14 30 20 35 17

54000-29310-0 54000-29300-0 54000-29320-0 54000-29330-0

Part No. CU101-52D CU101-51E CU101-56D CU101-57E
10 Without regen With regen Without regen CS With regen CS

21 Bracket(1), 24200-57681 24200-57561 24200-57681 24200-57561

MPU board
3 Contactor 35810-05590 35810-05590 35810-05630 35810-05630
SW80-643 SW80-643 SW80-704 SW80-704

29 Remarks Lead wire SHLV Lead wire SHLV Lead wire WL1 Lead wire WL1

27
- -
-
Upper
-
18 + +
+ + <Note>
36 1. Apply conductive compound TSK550(Toshiba
Silicones Co., Ltd) on all surfaces between the
"FET comp." , "Diode", "Sink, heat", "Sheet,
24 insulator", and the base.
2. Recinnebded tightening torque for the diode.
Nihon inter Electronics make : 9.5-12.5 N m (97-127 kg cm)
Semikron make : 9.0-11.0 N m(92-112kg cm)
3. Recinnebded tightening torque for the contactor M8 terminal.
25
8.75N m 10% (89kg cm 10%)

37 0077-05010 Screw, w/washer

36 24200-59260 Resistor comp.
35 0000-00008 Nut
34 0000-70008 Washer, lock
33 0000-72008 Washer, plain
30 14 15 9 31 6 11 32 33 19 26 16 14 30 5 12 31 33 2 3 29 28 20 35 32 0110-08020 Bolt
Only with Regen.
31 0016-08016 Bolt, w/washers
34 35 33 34 30 31010-02200 Bolt, w/washers
27 27
29 31010-03600 Bolt, w/washers
CU101- 28 31010-03590 Bolt, w/washers
Type
51E/52D/56D/57E 27 0075-04010 Screw, w/washers
26 0075-03006 Screw, w/washers
23
Applicable 25 35890-00030 Spacer
24200-64980 Board comp., printed
models FBT-65/67 24
23 54000-29200 Board comp., MPU
22 24200-58830 Bracket(1), MPU board
21 Bracket(1), MPU board
21 Power voltage 48 V 20 24200-63030 Terminal
19 24200-14910 Bar, capacitor
Current

Travel
limitation 390 A 18 24200-54830 Bar (2), lead
17 24200-54810 Sensor Comp., current
Maximum 16
39110-01180
or Capacitor
current 1000 A 39110-01120
15 24200-05570 Tube
(Main element)
14 25200-00450 Cup, insulator
13 8432-10020 Sheet, insulator
Power voltage 48 V 12 24200-19610 Sheet, insulator

Hydraulic
11 25200-00470 Sheet, insulator
Relief current 280 A 10 25200-00280 Sheet, insulator
9 35010-01700 Diode
Maximum 8 1911-59015 Diode
current 700 A 7 25200-01650 Sink, heat
(Main element) 6 24200-48090 Sink, heat
5 24200-36180 FET comp.
When installing, 4 24200-36170 FET comp.

Remarks make sure the 3 Contactor

2 24200-54801 Bracket, contactor
arrow points up. 1 24200-57921 Base, control unit

FBT-67 Main controller ass'y 14- 7.

1E-06168-12E

s CU101-51E/52D/56D/57E
45
 Reproduction prohibited
First printing : March 2004

Issued by : Nippon Yusoki Co., Ltd

Edited by : Overseas division
Nippon Yusoki Co., Ltd.