70 SERIES

FBT13P
FBT15P
FBT18P
FBT20PN
 INTRODUCTION
Most 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.

It 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.
 USING THE "SERVICE MANUAL"
This Service Manual will give explanation on how to maintain and inspect NICHIYU forklift trucks of
FBT-70 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© 2005
NIPPON YUSOKI CO., LTD.
All Rights Reserved
 CONTENTS
SAFETY WORK 1 4 .TIRE 29

1.Precautions for safe inspection 4-1.Front tire ........................................................... 29

and maintenance work ....................................... 1 4-1-1.Disassembly and reassembly ..................... 29
Maintenance shops............................................. 1 4-1-2.Tire size (front) ............................................ 29
Work clothing ...................................................... 2 4-2.Rear tire............................................................ 30
Tools and gauges ............................................... 2 4-2-1.Disassembly and reassembly ..................... 30
Safety work ......................................................... 2 4-2-2.Tire size (rear) ............................................. 30
Parts ................................................................... 3
Repair of electrical components ............................ 3
Hydraulics ........................................................... 4
5 .STEERING LINKAGE 31
Tightening torque ................................................ 4
2.Safety labels ....................................................... 5 5-1.Disassembly and reassembly ........................... 31
3.Model name and serial numbers ........................ 9
4.Caution for maintenance .................................... 11
5.Tightening torque for bolts ................................ 14
6.Maintenance tools and inspection devices ....... 15
6 .BRAKE LINKAGE 34

6-1.Foot brake ........................................................ 34

1 .GENERAL 16 6-1-1.Disassembly and reassembly ..................... 34
6-1-2.Master cylinder and brake pedal - adjustment ... 35
1-1.Appearance ...................................................... 16 6-2.Parking brake ................................................... 37
1-2.Specifications ................................................... 17 6-2-1.Parking brake - disassembly and reassembly .... 37
6-2-2.Disk brake - disassembly and reassembly ........ 38
6-3.Inspection and adjusting................................... 40
2 .FRONT AXLE (DRIVE) 19 6-3-1.Discharge air from the brakes ..................... 40
6-3-2.Pad ass'y - Inspection ................................. 41
2-1.Front axle - disassenbly and reassembly ......... 19 6-3-3.Wheel cylinder - Inspection ......................... 42
2-1-1.Disassembly and reassembly ..................... 19 6-3-4.Microswitch - adjustment..............................42
2-1-2.Adjustment .................................................. 20
2-2.Front axle comp. . ............................................. 21 7 .HYDRAULIC SYSTEM 43
2-2-1.Disassembly and reassembly ..................... 21
2-2-2.Adjustment .................................................. 22 7-1.Valve linkage .................................................... 43
7-1-1.Disassembly and reassembly ..................... 43
7-1-2.Microswitch - adjustment ............................. 44
7-1-3.Lift (2nd) microswitch - adjustment ............. 44
3 .REAR AXLE (STEERING) 23 7-2.Control valve .................................................... 45
3-1.Disassembly and reassembly ........................... 23 7-2-1.Disassembly and reassembly ..................... 45
3-2.Adjustment ....................................................... 25 7-2-2.Relief pressure - adjustment ....................... 46
3-2-1.Angle sensor comp. - adjustment ................ 25 7-3.Oil tank ............................................................. 47
3-2-2.EPS torque sensor - adjustment ................. 25 7-3-1.Disassembly and reassembly ..................... 47
3-3.Precautions during assembling ........................ 28 7-3-2.Recommended oil and oil quantity .............. 48
7-4.Oil pump ........................................................... 49
7-4-1.Disassembly and reassembly ..................... 49
7-4-2.Gear pump type .......................................... 49
 8 .CYLINDER 50 11a .CONTROL UNIT 72
8-1.Lift cylinder ....................................................... 50 11a-1.Control unit ................................................... 72
8-1-1.Disassembly and reassembly ..................... 50 11a-1-1.Main controller - location and name ........ 72
8-2.Tilt cylinder ...................................................... 52 11a-2.Disassembly and reassembly ....................... 73
8-2-1.Disassembly and reassembly ..................... 52 11a-2-1.Main controller - disassembly and reassembly ... 73
11a-3.Inspection and replacement ......................... 76
11a-3-1.Main contactor - inspection and replacement ... 76
11a-3-2.FET module - inspection and replacement .... 77
9 .MAST 53
11a-3-3.Capacitor -check and replacement ......... 78
9-1.Disassembly and reassembly ........................... 53 11a-3-4.EPS controller - specification .................. 79
9-1-1.Simplex mast ............................................... 53
9-1-2.Triplex mast ................................................. 55
9-2.Inspection and adjustment ............................... 56 11b .ACCELERATOR 80
9-2-1.Clearance between roller and mast............... 56
9-2-2.Mast, lift bracket and roller shaft ................ 56 11b-1.Disassembly and reassembly ....................... 80
9-2-3.Back shoe ................................................... 57 11b-1-1.Accelerator linkage - removal and inspection ... 80
9-2-4.Lift chain ...................................................... 57 11b-2.Inspection and adjustment ........................... 81
9-2-5.Chain bolt .................................................... 57 11b-2-1.Potentiometer - adjustment ..................... 81
9-2-6.Chain wheel ................................................ 58 11b-2-2.Accelerator linkage - adjustment ............. 81
9-2-7.Hose pulley ................................................. 58
9-2-8.Roller ........................................................... 58
9-2-9.Fork ............................................................. 59
11c.INDICATOR PANEL &
DIRECTIONAL SWITCH 82

10.MOTOR 11c-1.Indicator panel - disassembly and reassembly .... 82

11c-2.Directional switch
(TRACTION, HYDRAULIC, EPS) 60
- disassembly and reassembly .................... 83
10-1.Disassembly and reassembly ......................... 60 11c-2-1.Disassembling procedure and parts name .... 83
10-1-1.Traction motor ........................................... 60 11c-2-2.Wiring ...................................................... 84
10-1-2.Hydraulic motor ......................................... 61
10-1-3.EPS motor ................................................. 62
10-2.Inspection and adjustment ............................. 63
11d .BATTERY 85
10-2-1.Roter comp. - inspection and replacement
(Traction and Hydraulic motor) ................ 63 11d-1.Disassembly and reassembly ....................... 85
10-2-2.Armature comp. (EPS motor) 11d-1-1.Battery - removal and installation ............ 85
- inspection and replacement ................... 64 11d-2.Inspection and adjustment ........................... 86
10-2-3.Brush, brush holder and spring (EPS motor) 11d-2-1.Battery - inspection ................................. 86
- inspection and replacement.................... 66 11d-2-2.Battery - cleaning .................................... 87
10-2-4.Motor ass'y - inspection
(Traction motor and Hydraulic motor) ...... 68
10-2-5.Motor ass'y (EPS motor) - inspection ........ 69
10-2-6.Oil seal and permanent magnet ................ 70 11e .CHARGER PANEL 88

11e-1.Disassembly and reassembly ....................... 88

11.ELECTRIC PARTS 71 11e-2.Inspection and adjustment ........................... 89
11e-2-1.Voltage tap - switching ............................ 89
11-1.Location and name ......................................... 71
 12 .LASER POINTER 91 13b .TROUBLESHOOTING 128

12-1.Adjustment ..................................................... 91 13b-1.Self diagnosis function ............................... 128

12-1-1.Fork level - adjustment .............................. 91 13b-1-1.Display .................................................. 128
12-1-2.Laser optical axis - adjustment.................. 91 13b-1-2.Error messages and Display conditions ... 130
13b-2.Error history memory.................................. 132
13b-2-1.Error history memory 1 ......................... 132
13b-2-2.Error history memory 2 ......................... 133
13a .ADJUSTMENT OF SICOS-AC 92
13b-2-3.Clearing the error history memory
13a-1.Explanation of the MPU board ..................... 92 (memory initialization) ............................... 135
13a-1-1.Basic control board construction ............. 92 13b-3. I/O Check................................................... 136
13a-1-2.Travel/Hydraulic board (MPU board) ............ 93 13b-3-1. I/O check mode display method ........... 136
13a-1-3.Display board .......................................... 93 13b-3-2. I/O port table ........................................ 138
13a-1-4.MPU board (COM) .................................. 94
13a-1-5.Rotary switch on the MPU board (COM) .... 95
13a-1-6.Rotary switch on the Display board ......... 96 14 .WIRING (DIAGRAMS) 142
13a-1-7.Adjustment Standards List for FBT-70 series .. 97
13a-1-8.Confirmation of other services ................ 98 14-1.FBT-70 System wiring .................................. 142
13a-2.SICOS-AC check and adjustment .............. 100 14-2.FBT-70 Body wiring ...................................... 143
13a-2-1.Chassis insulation check ....................... 100 14-3.FBT-70 Body wiring (2)
13a-2-2.Battery voltage adjustment.................... 101 (built-in charger for 3 phases 400V) ......... 144
13a-2-3.Current detector check .......................... 102 14-4.FBT-70 Body harness ................................... 145
13a-2-4.Forklift model setting check and adjustment ..107 14-5.FBT-70 Controller wiring ............................... 146
13a-2-5.Hydraulic setting check and adjustment.. 108 14-6.FBT-70 Main controller ................................. 147
13a-2-6.Switch back (plugging/regenerative) 14-7.FBT-70 Wiring, lamp ..................................... 148
braking force adjustment ............................ 110
13a-2-7.Regenerative braking force check
and adjustment .......................................... 111
13a-2-8.Safety monitor symbol check and adjustment .. 112
13a-2-9.Display language check and adjustment .. 113
13a-2-10.Optional setting check and adjustment .. 114
13a-2-11.Display brightness check and adjustment .. 116
13a-2-12.Hour meter working check .................. 117
13a-2-13.Checking the function of auto power off .. 117
13a-2-14.Battery electroyte level working
check (optional, only for GS battery) ......... 118
13a-2-15.Turn signal lamp working check .......... 118
13a-2-16.Hydraulic oil level (optional)
working check ........................................... 119
13a-2-17.Brake oil level (optional) working check .. 119
13a-2-18.Cooling fan working check .................. 119
13a-2-19.Lift interrupt (optional) working check .. 120
13a-2-20.Turning speed reduction (optional)
adjustment and working check .................. 121
13a-2-21.Accelerator potentiometer adjustment.. 122
13a-2-22.Potentiometer - steering angle sensor
adjustment ................................................. 123
13a-2-23.Seat switch (optional) working check .. 124
13a-2-24.Load sensor (optional) adjustment ...... 125
13a-2-25.Built-in charger (optional) working check .. 127
 SAFETY WORK
1. Precautions for safe inspection and maintenance work
Maintenance shops

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.
If 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.
If this is not observed, harmful toxic gas or dust
may be inhaled.

CAUTION L O C AT I O N E Q U I P P E D W I T H F I R E
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.
If 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.
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.
Failure 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 par ts, 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 and

discharge the capacitors in the control unit 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

 B a t t e r i e s p ro d u c e f l a m m a bl e g a s d u r i n g
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]. See page 13

4
 SAFETY WORK

2. 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.

2 8

10 9

5 6

4 11

461S100E

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
38540-00520 Label, Caution 1 Caution for battery, GS
(10)
38540-00630 Label, Caution 1 Caution for battery, Shinkobe, opt.
24700-09410 Label, Tire 1 Air pressure (bar) FBT13,15P
(11)
0902-69954 Label, Tire 1 Air pressure (bar) FBT20P

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
OPERATION AT A HIGH LIFT.
24700-01780
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)
(FBT13, 15P) (FBT20P)

(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
W/O BATTERY kg VOLTAGE V LOAD CENTER mm

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

FB 70

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
Maximum lifting 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°C

FCS : Cold storage use for -50°C
RP : Rust resistant

: Attachment
WB : Wide bar lift bracket
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 left 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 a lift cylinders Stamped on the lift cylinders.

Location of serial numbers

8
⑧

③
3 MODEL
LOAD CHART

LIFT HEIGHT

①
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

④
4
BATTERY WEIGHT MIN. kg MAX. kg 50001-60560

⑥
6

7
⑦

⑤
5

2
②

461S041

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 Retainer for Retainer for
C-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 first, Assembly
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
anchoring the tip part of the nozzle might be cured and gasket has deteriorated.

deteriorated. Squeeze out that portion and discard it Squeeze out the
bead about 20 mm
before reusing the gasket. 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. Maintenance tools and inspection devices

The table shows tools/devices required for inspection and maintenance.
Type No. Tool/Device name Detail
1 Doubleended spanner 6x7, 8x10, 11x13, 12x14, 17x19, 22x24
2 Single-ended spanner 24, 27, 30, 32
3 Offset wrench 10x12, 14x17, 22x24, 23x26
4 Extension bar 12.7x150mm
5 Box socket 12.7x10, 12, 13, 14, 17, 19, 21, 22, 23, 24, 26, 27, 30, 32
6 Adjust wrench 300mm
7 Hexangular wrench
8 Screwdriver (+)100, 150, 200, (-)100, 150, 200
9 Hammer 1P
10 Shockless hammer
11 Radio pliers 150mm
Maintenance
tools 12 Cutting pliers 150mm
13 Pliers 150mm
14 Nippers 150mm
15 Water pliers 250mm
16 Pressure pliers
17 Snap ring pliers
18 Gear puller For outward form 30～150mm
19 Pipe wrench 200, 350, 900
20 Scraper
21 Monkey wrench
22 Chisel
23 File
24 Thickness gauge 0.03～3mm
25 Measure 300mm、1000mm
26 Tape measure 10m
Resistor
27 (For discharging procedur) 20Wx50 or 50Wx10 or 10Wx15
28 Digital tester
29 Clamp tester
30 Analog clamp ammeter Hioki 3109-01
Inspection 31 Digital clamp ammeter Hioki 3209AC/DC high tester
devices 32 Megger
(For inspection of insulation)
33 Oil pressure gauge 25MPa
34 Thermometer Alcohol thermometer
35 Hydrometer Suction type
36 Color tester Color check
37 Stopwatch
38 Torque wrench 0.5～1.5, 3～15, 40～200, 150～800Nm（preset type）
39 Dial gauge
40 Spring scale

15
1. GENERAL
1- 1. Appearance
2. FRONT AXLE

3. REAR AXLE

4. TIRE

8
9 5. STEERING

6. BRAKE

7. HYDRAULIC
11 PUMP
6
7 8. CYLINDER

9. MAST
10
2
3 10. MOTOR

4 11. ELECTRIC
PARTS (*)
5
4 12. LASER
11
POINTER
10
13. TROUBLE
SHOOTING

14. WIRING

15. SERVICE DATA

* 11. ELECTRIC PARTS : See page 71.
461S025

16
1 GENERAL

1- 2. Specifications

E D

I
B
K

A
J
C

L
G

461S057

17
 GENERAL 1

Models FBT13P FBT15P FBT18P FBT20PN

Capacity kg 1250 1500 1750 2000
Load center A mm 500
Lift height B mm 3000
Free lift C mm 120
Laden mm/s 400 380 360 300
Lift speed
Unladen mm/s 610 500
Forward D deg 5
Tilt angle
Backward E deg 6
Laden km/h 15.0 14.5 14.0
Travel speed
Unladen km/h 16.5 16.5 16.0 15.5
Min. turning radius F mm 1400 1500 1545 1695
Max. gradeability
% 20 18 15 14
(3min. rating, 1.5km/h and over)
Overall length G mm 2830 2930 2975 3155
Overall width H mm 1070
Mast lifted I mm 4000
Overall
Mast lowered J mm 1960 1970
height
Overhead guard K mm 1985
Wheel base L mm 1200 1300 1420
Tread (Front/Rear) mm 895/250 895/230
Service weight (w.o battery) kg 2240 2260 2470 2850
Pneumatic 18 X 7-8-14PR 18X7–8–16PR
Front Solid 18 X 7-8
Tyres Cushion 18X6X12 (1/8)
Pneumatic 15X4 (1/2)-8-12PR 16X6-8-10PR
Rear
Solid 15 X 4 (1/2)-8 16X6-8
Control (Travel/Hydraulic) Inverter control
Travel 4.3 (2 pcs.)
Motor Hydraulic kw 9.5
EPS 0.3 0.45
Battery (48V) Ah/5HR 320 350 390
*Subject to change without notice for improvement.

18
 2. FRONT AXLE (DRIVE)
2- 1. Front axle - disassembly and reassembly
2-1-1. Disassembly and reassembly
Tightening torque

A 450-550 N m
[46-56 kgf m]
Frame B
Bolt A : L=65mm
B Bolt B : L=50mm
B
CAUTION
 Pay attention to different
bolt lengths.

B
B
B
Axle(R) ass'y, front
A B

B
B
Motor

Axle(L) ass'y, front

Motor
B
B

B
Upward

94

Upward

47

: Tightening torque
461E001

19
 FRONT AXLE (DRIVE) 2

2-1-2. Adjustment

1. When tightening each plug and air breather, apply a

seal material (LOCTITE #575) or seal tape.

2. Fill lubricant HE#80 or an equivalent product into the

both sides.
 Right: 1.3L
 Left: 1.6L
(Set the part upward position and fill the lubricant to the
level plug hole.)

Plug and air breather

Plug and Air breather L

Apply LOCTITE[#575], or Seal
tape.

Plug Axle(R) ass'y, front

(Oiling hole)

Plug
Axle(L) ass'y, front Plug
(Drain)

Air breather Motor

Plug
Plug (Level)
(Oiling hole)
Plug Plug

Plug
Plug
Plug
(Level)
(Drain)
Motor

Plug
(Level)
Plug

L : Apply LOCTITE
461E100

20
2 FRONT AXLE (DRIVE)

2- 2. Front axle comp.

2-2-1. Disassembly and reassembly

Case (1)

Tightening torque
18-22 N m
Front wheel
{1.8-2.2 kgf m}

Oil seal B G
Shaft, axle
Apply grease on parts of Lip and
THREEBOND [#1215] around it.
Hub bolt
Tightening torque
18-22 N m
{1.8-2.2 kgf m}
Tightening torque
See "ASSEMBLING AND
DISASSEMBLING OF FRONT TYRE".
Housing, bearing
Case (2)

Tightening torque
9-11 N m
{0.9-1.1 kgf m}

Surfaces of the Gear case B

Coat the contact surfaces with
THREEBOND (#1215).

Nut comp., hard lock

Tightening torque 59-74 N m
Gear (5) Gear (2) (Convex side) {6-7.5 kgf m}
Tightening torque 118-127 N m
(Concave side) {12-13 kgf m}
A Bearing pre-load
Gear (3)
Measure at 54-59 N
Gear (4) position A (hub
Gear (1) {5.5-6.0 kgf}
bolt)
: Tightening torque
B : Apply threebond
G : Apply grease
N : Not reusable
461E002

In case that OIL SEALS, O RINGS, BEARINGS

CAUTION
were removed, they should be replaced.

21
 FRONT AXLE (DRIVE) 2

2-2-2. Adjustment
 The bearing pre-load should be 54-59N (5.5-6.0kgf)
when measured at the hub bolt.

CAUTION Apply THREEBOND (#1215) on the mating

surface of the gear case.

CAUTION  Before inserting the oil seal, apply proper

grease on the seal.
 Apply gear oil on the serrated portions of the
drive motor.

22
 3. REAR AXLE (STEERING)
3- 1. Disassembly and reassembly
Disassembling and reassembling the rear axle(1)
Torque sensor
(Potentiometer)

Tightening torque
9.9-12.1 N m
{1.0-1.2 kgf m}

Sensor ass'y EPS Spline shaft G

Apply grease on the spline shaft.

EPS motor

Oil seal B G
Cover, EPS Apply grease on parts of Lip and
THREEBOND [#1104] around it.

Spacer
Cover, EPS and EPS motor B
Gear (2) Gear (1) Coat the contact surfaces with
THREEBOND (#1212).

Support, rear axle

Pinion, steering

: Tightening torque Spline shaft G

B : Apply THREEBOND Apply grease on the spline shaft.
G : Apply grease
N : Not reusable
461S029

In case that OIL SEALS, O RINGS, BEARINGS

CAUTION
were removed, they should be replaced.

23
 REAR AXLE (STEERING) 3

Disassembling and reassembling the rear axle(2)

Sensor Comp.,
angle
Support,
potentiometer Coupling L
Lever, Apply LOCTITE[#262] or an
potentiometer equivalent product.
Screw, set L
Apply LOCTITE[#262] or an
equivalent product at 2 places.
Tightening torque
39-59 N m
Washer
{4-6 kgf m}
Plate, cam X Pre-load
Measure at 9.5-13.5 N m
position X. {1.0-1.4 kgf m}
Support, rear axle
Support, rear axle G
Fill grease up between bearings.

Plate

Axle ass'y, rear Gear (2), steering

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

Stopper, rubber

Rear wheel Bracket comp., wheel

Hub, wheel G
Fill grease up between bearings.

A Bearing pre-load
Measure at 44-64 N
Tightening torque
position A (hub
See "REAR TYRE". bolt) {4.5-6.5 kgf}

: Tightening torque
G : Apply grease
L : Apply LOCTITE
N : Not reusable
461S002

24
3 REAR AXLE (STEERING)

3- 2. Adjustment
3-2-1. Angle sensor comp. - adjustment
Adjustment of "angle sensor comp."
1 Adjustment
Screw set Sensor comp., angle
Adjust the gap between the surface of "bracket
Comp., wheel" and "support, potentiometer" Support,
potentiometer
to L=24-26mm. Apply LOCTITE [#262] or an
equivalent product to screw set and tighten it.

L
(See page 123,124.)

(103)
75
Bracket comp.,
wheel
461S042

3-2-2. EPS torque sensor - adjustment

1 Check of neutral position Check neutral position of torque sensor

1. Turn off the key switch. EPS
EPS
2. Jack up rear wheels from the ground. controller
コントローラ

3. Put a clamp meter to a wire [yellow] or

[green] between EPS controller and EPS
motor [DC range]. �� �
yellow
�

green
4. Turn on the key switch and measure the
indication at the clamp meter without
steering operation(=at neutral position). If
把握電流計
Clamp meter
the indication shows 0A, it is normal.
��

black��
red

5. If it is not OA, check the voltage by the

following procedure.
EPS motor
EPSモータ
212E006

25
 REAR AXLE (STEERING) 3

2 Checking by voltage
1. Turn off the key switch.
2. Disconnect the connector of torque sensor and insert
the adapter for measuring voltage.

NOTE As the connector of the torque sensor is water proof

type, it is impossible to put the test probe. Make an
adapter by using the same type connector.

3. Turn on the key switch.

4. Check the voltage between [2] [Green/Red] and [3]
[Black/Red] by operating the steering handle from right
side end to left side end.

Position of steering handle Appropriate voltage

Right side end 0.6 - 1.8V

Neutral 2.4 - 2.6V

Left side end 3.2 - 4.4V

If the voltage values are not appropriate, adjust the

resistance value of the torque sensor.

From EPS [1] Orange [1] Blue

[2] Green/Red To EPS
sensor Tab [2] Green/Blue
Rece controller
(potentiometer) [3] Black/Red [3] White

3P water proof type connector

[1] pin
Rece [2] pin Tab Adaptor
[3] pin

Tab

+ probe - probe
to [2] pin to [3] pin
(output) (GND)

461S048

26
3 REAR AXLE (STEERING)

3 Adjustment procedure
1. Operate the steering at neutral position.
2. Turn off the key switch and disconnect the battery plug.
3. Disconnect the connector of torque sensor.

Adjustment of EPS torque sensor

3P water proof type
Torque sensor connector(tab side)
(potentiometer)

Sensor ass'y., EPS

461S004

4. Check the resistance value at the tab side.

<standard value>
 Between (1) pin [Orange] and (3) pin [Black/Red] = approx. 5k ......... (A)
 Between (1) pin [Orange] and (2) pin [Green/Red] = approx. 2.5k ..... (B) These shuold be
 Between (2) pin [Green/Red] and (3) pin [Black/Red] = approx. 2.5k . (C) at even value.

(1) Orange (1) Blue

From EP S
sensor (2) Green/Red Rece- (2) Green/Blue To EPS
Tab
(potentiometer) (3) Black/Red ptacle (3) White cont rolle r

3P water proof type connector

461S043

4. Adjust (B) and (C) to be at even value by removing or

Screw
inserting a shim.
5. After adjusting the resistance value, check the current
(3-2-2-1) and the voltage (3-2-2-2) again.
Potentiometer
6.If the current at the clamp meter without steering
operation (= at neutral position ) is not OA, check the
tension of the steering chain. (See page 31) Shim

461S049

27
3- 3. Precautions during assembling
1. Apply THREEBOND (#1212) on the mating surface of
gear case and the motor mounting surface.

2. Add 0.5R of lubricant HE#80 or an equivalent product.

3. Apply seal tape to the air breathers and plugs.

4. After adjusting "sensor comp., angle", tighten

"coupling" and "screw, set" by LOCTITE[#262] to
prevent looseness.

28
 4. TIRE
4- 1. Front tire
4-1-1. Disassembly and reassembly

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 -

29
 TIRE 4

4- 2. Rear tire
4-2-1. Disassembly and reassembly
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)
15x4 1/2-8-12PR
FBT13P, 15P 9.8 (10.0)
(15x4 1/2-8 SOLID : OPTION)
FBT18P 15x4 1/2-8 SOLID -
16x6-8-10PR
FBT20PN 8.3 (8.5)
(16x6-8 SOLID : OPTION)
30
 5. STEERING LINKAGE
5- 1. Disassembly and reassembly
Disassembling and reassembling the steering linkage (1)

Wheel ass'y, steering

Linkage comp., brake

Deflection
29.4N(3kgf) 4±2mm
Chain, roller Column ass'y, steering
Roller, comp.

29.4N(3kgf) Deflection
7±2mm

Chain, roller

Tensioner comp. sensor ass'y, EPS

Tube comp. Shaft

comp.,
joint

Chain, roller

29.4N(3kgf)
Deflection
Rear axle ass'y
14±2mm

Knob

 Inspection point
Specification of steering control force
Adjust the chain tension so the
steering control force becomes 14.7N
(15kgf) at the knob.
Column ass'y G
Apply grease on the plunger
contact surface and the brush
Column ass'y
contact surface.

G : Apply grease
461E019

31
 STEERING LINKAGE 5

Disassembling and reassembling the steering linkage (2)

Bolt, handle
Linkage comp., brake
Column ass'y

Screw, set
Handle

Joint

Sprocket (1)

Roller comp. Chain, roller 1 Spline shaft G

Tensioner
Apply grease on the spline shaft.
comp.

Sprocket (2)
Collar

Tube comp.

Sprocket (3)
Chain, roller Sprocket (4)

G : Apply grease
461E202

32
5 STEERING LINKAGE

Disassembling and reassembling the steering linkage (3)

Chain, roller

Sensor ass'y EPS

Sprocket (5)

Bracket,
sprocket
Chain adjusting
bolt

Case comp.,
sprocket
1 Spline shaft G
Apply grease on the spline shaft.

Shaft comp., joint

Sprocket (4)

G : Apply grease
461E021

33
 6. BRAKE LINKAGE
6- 1. Foot brake
6-1-1. Disassembly and reassembly

Frame

Pedal bracket

Pedal height
adjusting bolt
Microswitch

Tank comp., oil Bushing

Shim

Bushing

Brake
pedal

Pin G
Apply grease
Clevis
Nut

Push rod

Boot

Master Snap ring

cylinder

Piston
ass'y

Bushing
Union

Cylinder

G : Apply grease
461E026

34
6 BRAKE LINKAGE

6-1-2. Master cylinder and brake pedal - adjustment

CAUTION  Apply assembling oil (MR#20) on the inner
surface of the master cylinder during
assembling.
 Discharge air after the master cylinder is
disassembled or replaced. Refer to discharge
air from the brakes. See page 40

1 Adjustment
1. If the gap between the brake pedal and pedal bracket
is 1mm or larger at the both right and left sides, adjust

1.5
the gap by placing a shim.

A=83
2. After adjusting the rod length A=83 ± 1.5mm with the rod Master
contacting the psiton lightly, tighten the clevis with the nut. cylinder

3. Adjusting pedal height

(1) Adjust height B of the pedal height adjusting bolt so
461E128
that the play at the pedal end is 5 - 7mm
when the pedal is released and the master cylinder is
completely returned. (The specification of the pedal
height adjusting bolt is 17 ± 2mm.) Microswitch

(2)Make sure that the distance between the pedal and

the floor is in the following table.

Bolt
height (Play)

Applicable models Pedal height (C)

FBT13P - 18P 87±5 mm
Brake pedal
FBT20PN 91±5 mm

(3)If the pedal height is not within the above range, adjust
461S044
the pedal height using the pedal height adjusting bolt.
At the same time, change rod length A of the master
cylinder to meet the condition described in (1) above.

35
 BRAKE LINKAGE 6

(4)Adjusting micro switch

Adjust dimension D (specification : 24 ± 2mm) so that
the micro switch switches ON/OFF when the pedal is Microswitch

D=24±2mm
pressed down 10 - 20mm.

ON/OFF range)
(Microswitch
(5)Be sure to tighten each adjusting (fitting) bolt and nut
after adjusting brake linkage.

Brake pedal

461S045

36
6 BRAKE LINKAGE

6- 2. Parking brake
6-2-1. Parking brake - disassembly and reassembly

Frame

Lever ass'y, brake

Microswitch

Wire, brake

Disk

Brake ass'y

Brake ass'y

Disk

461E031

37
 BRAKE LINKAGE 6

6-2-2. Disk brake - disassembly and reassembly

1 Disassemble the disk brake unit with referring to the illustration below.

Disk brake disassembling procedure

(6) Pin (1) Adjusting bolt

(10) Pad
(4) Pin

(9) Bolt

(3) Pin

(1) Adjusting bolt (2) Spring

(7) Lever (8) Wheel cylinder (5) Lever 152E110

Structure and disassembling procedure

(2) (1) (3) (4)

Procedure Parts
<1> (1) Boot
<2> (2) Pistion ass'y
(3) Sprit-pin
152E111 <3>
(4) Cap

When the assembling, follow the opposite

order of disassembling procedure.

38
6 BRAKE LINKAGE

2 Refer to the disassembling procedure.

Reassembling procedure of disk brake and cautions

Tightening torque
17.65-26.48 N m
{1.8-2.7 Kgf m}

Tightening torque
2.94-5.88 N m
{0.3-0.6 Kgf m}

Pins & pin holes MG

Apply molybdenum grease on
the pins and pin holes.

CAUTION Never put grease on the lining and disk.

: Tightening torque
MG : Apply molybdenum grease

152E112

39
 BRAKE LINKAGE 6

6- 3. Inspection and adjusting

6-3-1. Discharge air from the brakes

CAUTION After assembling the master cylinder, wheel

cylinder, or brake piping, be sure to discharge
the air.

Discharge air from the wheel cylinder

<Air discharging procedure> Disk brake

1. Remove the breather cap on the wheel cylinder and

connect a drain hose to the breather screw. The
opposite end of the drain hose should be connected
to a container to receive the brake fluid.

2. Depress and hold the brake pedal several times. Breather screw
Breather cap
461S014

Air discharging procedure (1)

Container
Breather screw

3. Loosen the breather screw to discharge the brake

fluid and air. Tighten the screw again before the flow
Drain hose
stops.
Breather cap 152E115
4. Repeat steps 2. and 3. until there are no longer any air
bubbles in the discharged brake oil.
Air discharging procedure (2)

CAUTION Keep the brake fluid level in the tank by refilling. Loosen

5. After discharging the air, tighten the breather screw

securely.
Tighten
6. Make sure no brake fluid has leaked out.

CAUTION Use the specified brake fluid. Do not mix

different grades of fluid. Drain hose

Breather screw
Wheel cylinder 152E116

40
6 BRAKE LINKAGE

6-3-2. Pad ass'y - Inspection

1 Inspection
 Inspect the wearing of linings. Inspection of pad ass'y
If it is worn up to limitation, replace it.
Thickness
of lining Pad ass'y
<Thickness of lining> [mm]
Thickness
New lining 6
Wearing limitation 2

152E113

2 Replacing procedure
1. Set the wheel stopper to prevent the forklift truck from Replacing of pad ass'y
moving.
Adjusting bolt

Fitting bolts
2. Loosen two adjusting bolts.

3. Remove fitting bolts and pad ass'y.

Pad ass'y 152E114

4. Install new pad ass'y with bolts.

Fitting bolts
Tightening torque
17.65-26.48 N m
{1.8-2.7 Kgf m}

41
 BRAKE LINKAGE 6

6-3-3. Wheel cylinder - inspection

CAUTION Clean inside of the cylinder and oil passing
holes before the inspection.

1 Inspection 1
 Cylinder body Inspection fo wheel cylinder
Check if the inside of the cylinder body is not rusted or
damaged. Sprit-pin
Piston ass'y
2 Inspection 2 Boot
Cap

 Boot
Check whether there is no damage and deterioration.

3 Inspection 3
 Piston
Measure the clearance between the piston and
cylinder body. If it is over the specific value below,
replace the part. 152E111

Specific clearance within 0.15 mm

4 Replacing procedure

NOTE When the assembling, follow the opposite order of

disassembling procedure. See page 38

 Apply molybdenum grease on the brake-pad pin and

pin hole. See page 38

CAUTION Never put grease on the lining and disk.

6-3-4. Microswitch - adjustment Adjustment the microswitch

Adjust the microswitch so that it switches ON/OFF in the

range of 20 - 25 degrees from the position the brake lever
is released.

Brake
lever

461E041

42
 7. HYDRAULIC SYSTEM
7- 1. Valve linkage
7-1-1. Disassembly and reassembly

Lever (R) comp., valve

Cover

Boot, valve

Lever (L) comp., valve

Touch piece Panel (R), Front

Pin, pivot G
Apply grease.
Switch holder

Bracket, lever

Control valve

G : Apply grease
461E007

43
 HYDRAULIC SYSTEM 7

7-1-2. Microswitch - adjustment

1. Tentatively set the adjustment gap of the microswitch to Microswitch
0.1-0.7mm when it is in a neutral position.
2. Set the microswitch position so that the switch is
turned on when the tip of the valve lever knob is tilted
15-30mm from the neutral position.
3. After the microswitch is adjusted, apply Threebond
(#1401) or an equivalent product on the both fixing nuts
to lock the threads.

461E044

7-1-3. Lift (2nd) microswitch - adjustment

Touch piece
1. Tentatively adjust the neutral microswitch to the
position where it is 24.0mm above the top face of the
switch holder, and 0.7 - 1.0mm from the edge of the
touch piece.
2. Set the microswitch position so that the switch is
turned on when the tip of the lift lever knob is tilted
70-80mm from the neutral position. And the valve spool
stroke should be 5-5.5mm from the neutral position.
Switch holder
3. After the microswitch is adjusted, apply Threebond
(#1401) or an equivalent product on the both nuts to Microswitch 461E045

lock the threads.

44
7 HYDRAULIC SYSTEM

7- 2. Control valve
7-2-1. Disassembly and reassembly

Relief pressure adjusting screw

(Color)

Valve, relief

Ring, O
Wiper

Ring, O

Switch holder

Ring, O

Wiper

Plate, seal

Seat, spring

Spring

Seat, spring

Cap

461E006

45
 HYDRAULIC SYSTEM 7

7-2-2. Relief pressure - adjustment

1 Relief pressure specification

Model Pressure: MPa (kgf/cm2) color
FBT13P/15P 13.7 (140) Red

FBT18P/20PN 15.7 (160) Gray

2 Relief pressure adjustment

If the pressure is deviated from the above specification,
adjust the pressure using the relief pressure adjusting
screw.
• Loosening screw: Relief pressure increases.
• Tightening screw: Relief pressure decreases.

46
7 HYDRAULIC SYSTEM

7- 3. Oil tank
7-3-1. Disassembly and reassembly

Gauge comp., level

Pipe comp.

Gasket

Filter, oil

Filter, suction

Tank comp., oil

Plug

461E010

47
 HYDRAULIC SYSTEM 7

7-3-2. Recommended oil and oil quantity

1 Fork oil

Specification Recommended Oil

Shell : Tellus Oils 32
Standard ESSO : Power lex 32
Mobile : Hydraulic oil 28
Shell : Tellus T15
FCS
ESSO : Univis 43

2 Procedure to check oil quantity

NOTE Tank capacity: 9.6-10.6L

1. Lower the forks on a level ground.

2. Tilt the mast back completely.
3. The oil level should be between the marks on the level gauge.

48
7 HYDRAULIC SYSTEM

7- 4. Oil pump

7-4-1. Disassembly and reassembly

Disassembling and reassembling the oil pump
1 Tightening torque
Hydraulic 19.6-24.5 N m
motor
{2.0-2.5 Kgf m}

Pump, gear

Cushion (1)

Tightening torque
Bracket, motor
8.8-10.8 N m
{0.9-1.1 Kgf m}

: Tightening torque 461S016

7-4-2. Gear pump type

Model Type

FBT13 P- 20P TMG 1-18

49
 8. CYLINDER
8- 1. Lift cylinder
8-1-1. Disassembly and reassembly
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
50
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 Spool, cushion Holder

Spring Spring

Tube ass'y Tube ass'y

cylinder cylinder

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

Ring, snap Ring, snap

Piston Piston

461E208E

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.

51
 CYLINDER 8

8- 2. Tilt cylinder
8-2-1. Disassembly and reassembly

Head, cylinder B
Apply THREEBOND[#1344] on
the threads when tightening.
Nipple,grease
Tightening torque
Head
Head 490±75 N m
{50±7.5 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
{35±5 kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable
215W001E

52
 9. MAST
9- 1. Disassembly and reassembly
9-1-1. Simplex mast
Disassembling and reassembling the mast 1

Mast comp., outer

Shim
Roller
Back shoe

Shim, back shoe

Mast comp., outer
Lift cylinder

Plate, cover

Cushion, cylinder

Shim Band, cylinder Nipple,

grease
Roller

Bushing

Pin, tilt

Cap ,
pivot
Bolt, cylinder

Tilt cylinder

Pin, tilt

461E258

53
 MAST 9

Disassembling and reassembling the mast 2

Inner mast

Chain wheel

Cover (R) Chain comp.

Shim
Cover (L)

Chain comp.
Lift cylinder

Outer mast

Lift bracket

461E210

54
9 MAST

9-1-2. Triplex mast

Disassembling and reassembling the mast 1

Inner mast

Middle mast

Lift cylinder
(1st) Plate, lock
Shim Bolt, adjustor
Back shoe Roller Outer mast
Lift cylinder(2nd)

Shim

Clamp, cylinder Back

shoe Roller

Lift cylinder
(2nd)

Shim Cushion, cylinder

Band, cylinder Bracket, stopper
Roller

Shim Nipple,
grease
Roller
Pin, tilt Bushing
Cap,
pivot

Bolt, cylinder
Tilt cylinder

Pin, tilt

461E259

55
 MAST 9

9- 2. Inspection and adjustment

9-2-1. Clearance between roller and mast
1 Inspection 1
 Measure and adjust the clearance between the roller Clearance measurement of
both sides
and the mast.
<Measurement procedure>
Move the inner mast to one side and measure the
clearances A and B.
<Adjustment procedure>
1. Select a shim so the clearance meets the specification. Inner Outer mast
mast

Clearance specification 0-0.2mm

2. Remove each roller and install the shims to both sides

evenly.
[Shim types: 0.2t, 0.5t, 1.0t, and 2.0t.] 461E106

2 Inspection 2
Shim installation
 Measure and adjust the clearance between the inner
and outer masts.
Back shoe Outer mast
<Measurement procedure>
Using a pry bar, lift up the inner mast and measure the
clearance. Inner mast

Clearance specification 0-0.2mm

Shim

<Adjustment procedure> 461E107

Select the shim meeting the specification and install it.

[Shim types: 0.5t and 1.0t.]

9-2-2. Mast, lift bracket and roller shaft

1 Inspection
Check welds for cracks using a dye penetrant material
(color check/red check).

CAUTION Mast material and welds.

Low hydrogen type should be used for the
welding rods and ilminite type should be used
for the other welding sections.

56
9 MAST

9-2-3. Back shoe

1 Inspection Inspection of back shoe
Check the back shoe for wear.

<Specifications> [mm]
Standard thickness [A] Wear limit
11.0 10.5 A

152T022

9-2-4. Lift chain

1 Inspection 1
 Check the lift chains for stretch. Inspection of lift chain
Measure the length per 20 links at the part which are
used frequently.

<Specifications>
[mm]
Standard thickness Elongation limit Pitch [P]
317.5 324 15.875

2 Inspection 2
 Check the lift chains for deformation and damage.
If it is jolted, replace it.

3 Inspection 3 152T023

 Check for lubrication.

Apply grease on chains.

9-2-5. Chain bolt

1 Inspection 1 Inspection of chain bolt
 Check connecting part ( ) for jolt.
If it is jolted, replace it.

2 Inspection 2
 Check for damage of threads.

152T024

57
 MAST 9

9-2-6. Chain wheel

1 Inspection Inspection of chain wheel
 Check the outer surface for deformation and the
bearing for function.

152T025

9-2-7. Hose pulley

1 Inspection Inspection of hose pulley
 Check for wear.

<Specifications> [mm]
Item Standard Diameter [D] Wear limit
HOSE PULLEY 25.0 25.5
D

152T026

9-2-8. Roller
1 Inspection 1
 Measure the clearance between outer diameter of
rollers and inner width of mast channel, and between
outer diameter and inner width of reach channel.
If over the specific clearance, replace it.

<Specifications> [mm]
Item Specific clearance
Mast roller, Lift roller 1.5

2 Inspection 2
 Check for function and jolt.

58
9 MAST

9-2-9. Fork
1 Inspection 1 Leveling
 Check for transformation and leveling.

<Specifications> [mm]
Item Specific clearance
Leveling of Fork tips 10
Opening of Fork tips 15
461E123

Opening

461E124

Bending

461E125

2 Inspection 2 Wearing

 Check for wear and cracks.

<Specifications> [mm]
Model Specific thickness Limit of worn
+3.0
FBT13P/15P/18P 32 461E126
35-0
+3.0
FBT20PN 37
40-0

CAUTION  If cracked, replace them and never use them

after repairing.
 Check for cracks by using color check.

59
10. MOTOR (TRACTION, HYDRAULIC, EPS)
10- 1. Disassembly and reassembly
10-1-1. Traction motor

Bolt, w/washer L
Apply LOCTITE[#648], [#262] or
an equivalent product.
Tightening torque
13.5 N m±10%

Terminal comp.
ターミナルComp.

Housing, sensor
ハウジング、センサ
Bearing comp.,
ベアリングComp.,
sensor
センサ

Cover, end
カバー、エンド

Stator comp.
ステータComp.
Cover(D),
カバー(D)、エンドend

Rotor
ロータ sub ass'y
サブAss�y

Oil seal N B G
Oil seal is not reusable.
Periphery : Apply THREEBOND[#1104]
Lip : Apply grease

: Tightening torque
N : Not reusable
B : Apply THREEBOND
G : Apply grease
L : Apply LOCTITE 461S017

60
10 MOTOR (TRACTION, HYDRAULIC, EPS)

10-1-2. Hydraulic motor

Bolt & Cover, end L

Apply LOCTITE[#648], [#262] or
Terminal comp.
ターミナルComp. an equivalent product in tapped
holes of "Cover, end".
Tightening torque
13.5 N m±10%

Housing,
ハウジング、
sensor
センサ
Bearing comp.,
ベアリングComp.,
sensor
センサ

Cover(D),
カバー(D)、
end
エンド

Stator comp.
ステータComp.

Rotor サブAss�y
ロータ sub ass'y

: Tightening torque
N : Not reusable
L : Apply LOCTITE 461S018

61
 MOTOR (TRACTION, HYDRAULIC, EPS) 10

10-1-3. EPS Motor

FUJII (FBT13P-18P)
Cover, brush
Brush
comp.

Yoke ass'y
Bolt
Bearing
Wire comp.
Armature comp. lead

Bearing Holder comp.

brush
Oil seal
Cover (D)

461E213

Bolt
NIKKO (FBT20PN)
Spring
Brush

Cover, commutator

Yoke ass'y

Bearing
Cover (C)
Armature comp.
Holder sub ass'y
Bearing
Oil seal
Cover (D)

461E033

62
10 MOTOR (TRACTION, HYDRAULIC, EPS)

10-2. Inspection and adjustment

10-2-1. Rotor comp. - inspection and replacement
(Traction and Hydraulic motor)
1 Inspection of damage Rotor comp. (Traction motor)

1. Check the rotor comp. for damage, especially by

burning.
If it is damaged, replace it.

2 Inspection of spline
1. Check for wear of spline. Rotor comp.
If it is extremely worn, replace it. Spline 2210102

Rotor comp. (Hydraulic motor)

Rotor comp.
3 Inspection of ball bearing Spline 2210121

1. Check fitting part in "cover, end" and "cover(D), end".

If loose, replace it.

Inspection of fitting parts (Traction motor) Inspection of fitting parts (Hydraulic motor)
Bearing, radial ball Bearing, radial ball Bearing, radial ball Bearing, radial ball

Cover(D), end Cover, end Cover(D), end Cover, end

2210184 221W089E

CAUTION  When replacing the "bearing comp., sensor", Replacing the "Bearing comp.,
be very careful to not damage the sensor. sensor"
If the sensor is damaged, the motor will not
operate normally.
 Because you may generate the effect of static
electricity, do not touch directly connector Sensor

pins of lead wire terminal.

2210144

63
 MOTOR (TRACTION, HYDRAULIC, EPS) 10

10-2-2. Armature comp. (EPS motor) - inspection and replacement

1 Inspection of damage Inspection of armature comp.

1. Check the armature for damage, especially by burning. Armature comp.

If it is damaged, replace it.
If the surface of Commutator is damaged, repair or Spline
replace it.

2 Inspection of spline
1. Check for wear of spline. 152T038

If it is extremely worn, replace it. 221W087

Inspection of fitting parts

3 Inspection of ball bearing
Bearing, radial ball Bearing, radial ball
1. Check fitting part in "cover(C), end" and cover(D).
If loose, replace it.

Cover(C), end
Cover(D)

2210169

4 Inspection of commutator
 Check the armature for damage especially by high
temperature.
If it is damaged, replace it.
If the surface of Commutator is damaged, repair or
replace it.
Check of surface of commutator
<How to repair>
1. Machine turn Commutator.

CAUTION Be sure to center Commutator when machining.

Good Not Good

2. Carry out the under cut.

3. Finish the surface of Commutator with a sand paper
(#400). 152T035

64
10 MOTOR (TRACTION, HYDRAULIC, EPS)

Repair limitation
<Repair limitation>
 Repair limitation of Commutator [mm]
Motor Standard ( D) Limitation ( D)

EPS motor 49 47

152T036

 Specific under cut [mm] Under cut of commutator

Motor Specific under cut

EPS motor 0.8-0.85

152T037

5 Inspection of insulation
 Measure the insulation between Commutator and Inspection of insulation
Armature shaft.

CAUTION Clean up by compressed air before measuring. Positive

<Resistance>
TOOL SPECIFIC RESISTANCE
Negative
Tester (Infinite at x1k range)

Megger 0.5 M or greater (DC500V) 152T038

65
 MOTOR (TRACTION, HYDRAULIC, EPS) 10

10-2-3. Brush, brush holder and spring (EPS motor)

- inspection and replacement

1 Inspection of brush wear Inspection of brush wear

 Raise up the whirl spring (A) and then pull out the
B A
carbon brush (B) to check the length.
If the brush is worn more than the wearing limit (C),
replace all brushes of the motor.

 Power steering motor

Normal dimention Wearing limit B
Models Manufacuturer
(H) (C)
H C
FBT13P-18P 14.5 8 Fujii

FBT20PN 19 13 Nikko

461S059

2 Inspection of contacting surface of brush

 If the contacting surface is not good, repair it as Inspection of contacting

follows. surface of brush

Good Not Good Not Good

Brush

Commutator
152T042

<Repairing procedure> Repairing surface of brush

1. Insert a sand paper [#400] between COMMUTATOR
and BRUSH. Brush

(File surface toward BRUSH.) Sand paper

2. Grind the contacting surface by moving a sand paper
or rotating COMMUTATOR by hand.
3. Clean up with compresses air after repairing.

Commutator
152T059

66
10 MOTOR (TRACTION, HYDRAULIC, EPS)

3 Inspection of force of spring

 Hook a spring scale to SPRING and pull towards arrow Inspection of force of spring
mark. Then make sure of equal force on 2 springs.

<Specific force of SPRING>

Motor Specific force Spring

EPS motor
5-8 N (0.5-0.8 kgf)
(Nikko only)

CAUTION If SPRING and/or brush holder were rusted,

replace them. 152T060

67
 MOTOR (TRACTION, HYDRAULIC, EPS) 10

10-2-4. Motor ass'y - inspection

(Traction motor and Hydraulic motor)
Inspect the following after assembling.

1 Abnormal noise check

 Operate the motor. Make sure there is no abnormal
noise.

CAUTION When performing a motor test, be sure to

securely fix the motor to a work bench.
The motor will move suddenly when it is started.

<Checking procedure>
1. Be sure to secure the motor ass'y to a work bench.
2. Use the battery of the forklift truck to carry out testing.
3. Connect wires as follows.
4. Operate traction motor and hydraulic motor slowly at the
chassis side, and make sure the motors are performing
without abnormal noise.

 Traction motor
1) Connect the U1 cable from the chassis to the U1 terminal in the motor.
2) Connect the V1 cable from the chassis to the V1 terminal in the motor.
3) Connect the W1 cable from the chassis to the W1 terminal in the motor.
4) Connect the lead wire for the speed sensor from the chassis
(water proof type 4P) to the lead wire for the speed sensor in the motor
(water proof type 4P).
 Hydraulic motor
1) Connect the U2 cable from the chassis to the U2 terminal in the motor.
2) Connect the V2 cable from the chassis to the V2 terminal in the motor.
3) Connect the W2 cable from the chassis to the W2 terminal in the motor.
4) Connect the lead wire for the speed sensor from the chassis
(water proof type 4P) to the lead wire for the speed sensor in the motor
(water proof type 4P).

CAUTION If an extension cable is necessary, make one from the following parts:
1) Main cables for motor (3 cables)
2
1. Cable type : WTC, Cable size : 38 mm
2. Terminal : 38-S8
2) Lead wires for speed sensor (4 wires)
2
1. Lead wire : AVS- 0.5 mm
2. Receptacle : AMP171662-1
3. Tab : AMP173600-1
4. "Housing, cap 4P" : 37010-20940(AMP174259-2)
5. "Housing, plug 4P" : 37010-20890(AMP174257-2)
68
10 MOTOR (TRACTION, HYDRAULIC, EPS)

2 Inspection of insulation Inspection of insulation

 Measure the insulation between terminals and Terminal

stator comp. with Megger.

<Resistance>
Tool Specific resistance
Megger 0.5M or greater (DC500V)

<Measuring procedure>
1. Apply earth probe (negative [-]) of Megger to the Stator comp.
stator comp. 2210150

2. Apply line probe (positive [+]) of Megger to each

terminal.

10-2-5. Motor ass'y(EPS motor) - inspection

Inspect the following after assembling.

1 Abnormal noise and arc

 Operate the motor. Then make sure that abnormal
noise is not heard and arc of brushes is not seen.

CAUTION When performing a motor test, be sure to

securely fix the motor to a work bench.
The motor will move suddenly when it is started.

<Checking procedure>
1. Be sure to secure EPS motor ass'y to a work bench.
2. Apply 1/4 voltage of the battery (about 12V) to carry out testing.
3. Connect wires as follows.
1) Connect (GREEN or WHITE) wire with positive (+)
terminal of battery.
2) Connect (YELLOW or BLACK) wire with negative (-)
terminal of battery.

2 Inspection of insulation
 Measure the insulation between terminals and yoke Inspection of insulation
with Megger.

<Resistance>
Terminal
Tool Specific resistance Yoke

Megger 0.1M or greater (DC500V)

<Measuring procedure>
1. Apply earth probe (negative [-]) of Megger to the yoke.
2. Apply line probe (positive [+]) of Megger to each
152T058

terminal of connector plug.

69
 MOTOR (TRACTION, HYDRAULIC, EPS) 10

10-2-6. Oil seal and permanent magnet

Inspect the following parts regarding EPS motor.

1 Oil seal
 Check Oil seal for wear and damage. If worn or
damaged, replace it.

2 Permanent magnet
 Check permanent magnets of Yoke for damage or
sticking metallic dust.
If sticking metallic dust, remove it with compressed air.
If damaged, replace the assemble.

70
11. ELECTRIC PARTS
11-1. Location and name
� Acceletator
アクセラレータ � Indicator
インジケータパネル panel � Directional
ディレクショナル switch � Battery
バッテリ
スイッチ

See page 80
79ページ参照 See page 82
81ページ参照 See page 83
82ページ参照

See page 85
84ページ参照

� Charger
チャージャパネルpanel

See page 88
87ページ参照

MPU board
(COM)

� EPS controller
EPSコントローラ � Control unit
コントロールユニット
CU103-47(48V/30A) PB103-105

See page 79
78ページ参照

See page 72
71ページ参照
461S047

71
 ELECTRIC PARTS 11

11a. CONTROL UNIT

11a- 1. Control unit
11a-1-1. Main controller - location and name

Main parts of main controller

Battery[-] Battery[+]
line line
(8) Fuse
* BN-40A
(1) Contactor
BN-325A

(5) Board comp., MPU (2) FET module

* hydraulic

(3) Sensor, current

(6) Board comp., MPU No. Part name Remarks

* travel(left)
(1) Contactor
(2) FET module
(3) Sensor, current
(4) Condenser comp.
(4) Condenser comp. (5) Board comp., MPU Hydraulic
(6) Board comp., MPU Travel (left)
(7) Board comp., MPU Travel (right)
(7) Board comp., MPU Main:325A,
(8) Fuse
* travel(right) EPS:40A

461S019E

<The procedure of discharging the capacitors

(condensor comp.) in the control unit>
Discharging the capacitors

1. Disconnect the battery plug.

Battery[-]
バッテリ ［－］ Battery[+]
バッテリ ［＋］
2. Discharge the capacitors by using a line
ライン line
ライン
resistor (20W,50 or 50W,10 or 10W, 15
).

461S020

72
11 ELECTRIC PARTS

11a- 2. Disassembly and reassembly

11a-2-1. Main controller - disassembly and reassembly

CAUTION  Apply wheel chocks to tyres to prevent the truck from moving.
 Record places of lead wire connections before disassembling.
 Be sure to disconnect the battery plug and discharge the capacitors in
the control unit.

Disassembling and reassembling the main controller (1)

Tightening torque
3.5-4.5 N m
Heat sink
シンク, ヒート {0.36-0.49 kgf m}

For油圧用
hydraulic
1 Module comp., FET C
モジュール,
Module comp., FET
FET
(油圧)
(hydraulic)
Apply conductive compound
A [G-747](Shin-Etsu silicones) on all
Heat sink mating surfaces to "Heat sink".

Module comp., FET

モジュール, FET
(travel
(走行・左) - left)
D
走行用
For travel
B

Module comp., FET

モジュール, FET
(走行・右)
(travel - right) E
C
2 Terminal L
Apply LOCTITE [#242] or an
D equivalent product on threads.

A
Capacitor
コンデンサ
E

C
2

: Tightening torque
C : Apply compound
L : Apply LOCTITE
73 461S010
 ELECTRIC PARTS 11

Disassembling and reassembling the main controller (2)

Terminal L
コンタクタ
Contactor
Apply LOCTITE [#242] or an
equivalent product on threads.

A
Plate, ヒューズ
プレート, fuse
Tightening torque
Fuse(charger)
ヒューズ（チャージャ） 3.5-4.5 N m
{0.36-0.49 kgf m}

A
ヒューズ（EPS）
Fuse(EPS)

メインヒューズ（走行・油圧）
Main fuse(travel/hydraulic)

: Tightening torque
L : Apply LOCTITE 461S011

74
11 ELECTRIC PARTS

Disassembling and reassembling the main controller (3)

Sensor, カレント
センサ, current 1 Tightening torque
3.5-4.5 N m
A {0.36-0.49 kgf m}

B B C
C

Board
ボードComp,comp., MPU
MPU
(hydraulic)
(油圧)
油圧用
For hydraulic
Cover, board
カバー, ボード

Board comp., MPU

ボードComp, MPU
(travel
(走行・右) - left)
走行用
For travel

Board comp., MPU

ボードComp,
Base, board
ベース, ボード (travel - right)
(走行・左)

461S012
: Tightening torque

75
 ELECTRIC PARTS 11

11a- 3. Inspection and replacement

11a-3-1. Main contactor - inspection and replacement

CAUTION  Record places of lead wire connections before

disassembling.
 Be sure to disconnect the battery plug and
discharge the capacitors in the control unit.

1. Remove screws, and check for burns or wear in the Inpection of main contactor
contact area.
If there is an abnormality in the contact, replace the
assembly.

CAUTION To be safe, the assembly should be replaced

every 2 years even if there are no abnormalities.

 Main contactor type

Applicable model Type Voltage

Main terminal area (M8) M8
FBT13P-20P HR-404394 48V Tightening torque (M8)
6.4-7.4 N m
2. Use the tightening torque shown on the right for the
{0.65-0.75 kgf m}
main terminal area (M8).
: Tightening torque 121W226

76
11 ELECTRIC PARTS

11a-3-2. FET module - inspection and replacement

1. Perform a continuity test of the semiconductors, Inspection of "FET module"

at test points 1 - 6 in the following table, by using
continuity check mode of a digital tester. (Do not use D2-W
the resistance range because you can not get correct W

conclusion about the continuity.) D2-V

N V
When the circuit is conducting at any one test point,
the buzzer sounds. In this case, replace the "FET U D2-U
D1-U,V,W P
module" (Travel or Hydraulic). The "FET module" which
has the continuity is damaged.

* Plus side (+) * Minus side (-)

Terminals touched with Terminals touched with
the tester the tester G2-W
G2-V
1 P(D1-U) G1-U
G2-U
2 P(D1-V) G1-V G1-W
3 P(D1-W) G1-W G1-U G1-V
461S005

4 U(D2-U) G2-U
5 V(D2-V) G2-V
6 W(D2-W) G2-W
* Either plus (+) or minus (-) can be used.
Perform a continuity test.

Circuit of "FET module"

D1 D1 D1

G1 G1
G1

U V W

D2 D2 D2

G2 G2
G2

N
461S006

NOTE This is a simple check, and it is impossible to

conclude for details whether it is normal condition
or not.

77
 ELECTRIC PARTS 11

2. If you find the continuity at any one test point, check

Inspection of "FET module"
the MPU board (travel-left:PBC104-43, travel-right:
Main terminal area
PBC104-41, hydraulic:PBC104-42) at the same time
because there is a high possibility that the electric Installation area
devices in these boards are damaged by electric
surge.

3. When installing the "FET module" to the "heat sink",

be sure to apply conductive compound [G-747] (Shin-
Ethu silicones) evenly over the surface.
461S033

4. Apply the tightening torque shown on the right to the Main terminal area (M6)
Installation area (M6)
main terminal area (M6) and the installation area
Tightening torque (M6)
(M6).
3.5-4.5 N m
{0.36-0.49 kg m}
CAUTION Do not touch any of the FET module terminals
: Tightening torque
with your hand. Otherwise, the elements can be
destroyed by static electricity.

11a-3-3. Capacitor - check and replacement

<Appearance check> Checking the capacitor
Check for the damage such as bulge and burst. If you
find any problems at any one capacitor, replace the all Analog tester
capacitors (9pcs.) and in this case, check for the damage
of the capacitor (270µF) in the power steering controller,
too.

CAUTION Use an analog tester to check the capacitor.

1. Discharge the each capacitor by using a resistor.

461E115

For the discharge procedure, see the following

"<Capacitor - discharging procedure>".
2. Set the tester to resistance ( ) X 1k .
3. Apply the (+) tester probe to the (+) pole of the
capacitor, and the (-) tester probe to the (-) pole.
4. First, the tester reads a few k , then reads .

CAUTION This is a simple check, and it is impossible

to conclude for details whether it is normal
condition or not.

78
11 ELECTRIC PARTS

<Capacitor - discharging procedure>

1. Prepare a resistor (20W, 50 or 50W, 10 or 10W, Discharging the capacitor
15 ).

2. Fit terminals of the resistor to terminals of the capacitor.

152E118

11a-3-4. EPS controller - specification

Applicable model Type Voltage Current limitation EPS controller
FBT13P-18P CU103-47 48V 30A

FBT20P CU103-48 48V 38A

10P
[water proof]

2P-Y : Fuse, GND

2P-X : to EPS motor
from EPS sensor
to control unit
461S030

79
 ELECTRIC PARTS 11

11b. ACCELERATOR
11b- 1. Disassembly and reassembly
11b-1-1. Accelerator linkage - removal and installation
Removing and installing the accelerator linkage

Ball link

Pedal

Rod

1 Spring G
Apply Albania Grease[RA] on surface.

Plate floor (1)

Lever
Ball link

Plate
Bushing

Spacer

Spring
Spring
Potentiometer

Shaft & shim G

Apply Albania Grease[RA]
Bracket between shaft and shim.
Case
2 Spring G
Apply Albania Grease[RA] on hooks.

G : Apply grease 461S021

80
11 ELECTRIC PARTS

11b- 2. Inspection and adjustment

11b-2-1. Potentiometer - adjustment
1. Adjust the installation so that output voltage of
Adjusting the potentiometer
potentiometer is in the following table, when turning
Lever Neutral
lever with fixing potentiometer ass'y.
Lever position Output range

53
Neutral 0.85±0.1 V

.5
°
53.5 degree rotated 3.9 V - 4.5 V
* Each of them are voltage values which measured between
White(OUT1) and Black(GND), between Blue(OUT2) and
Black(GND), when applying DC5V between Red(+) and Potentiometer
Black(GND).
461S022

11b-2-2. Accelerator linkage - adjustment

<Adjustment procedure>
1. Adjust dimension *2 (119.5mm) so that dimention *1
(130.5±5mm) is fit when the pedal is released (neutral
position).
2. Adjust the adjusting bolt so that dimention *3 (46mm) is
fit when the pedal is depressed fully (12 degree). At this
time, check that the potentiometer is not reached 53.5
degree rotated position. If the potentiometer is reached
there before, adjust the adjusting bolt to stop the
accelerator pedal earlier to protect the potentiometer
from damage. (See page 124.)

Adjusting the accelator linkage

Neutral
12

Pedal, accelerator
1)

2)
130.5 5(

(
9.5

Adjusting bolt
11

Ball link
Floor
46( 3)

Rod

.5
53

Spring

Accelerator ass'y
81 461S023
 ELECTRIC PARTS 11

11c. INDICATOR PANEL & DIRECTIONAL SWITCH

11c- 1. Indicator panel - disassembly and reassembly
Disassembling and reassembling the indicator panel

Seat, switch
シート,スイッチ
Panel, display(1)
パネル,ディスプレイ(1)

Cap(1)
キャップ(1) Cap(2)
キャップ(2)
Cover, display(1)
カバー,ディスプレイ(1)
A

Cover, printed
カバー,プリンテッド

Board comp.,
ボードComp.,
display
プリンテッド

Support, display
サポート,ディスプレイ

Panel, display(3)
パネル,ディスプレイ(3)

Display
ディスプレイ
Switch, flasher
スイッチ,フラッシャ

ケース
Case

スイッチComp.,キー
Switch comp., key

Panel, display(2)
パネル,ディスプレイ(2)

461E220

82
11 ELECTRIC PARTS

11c- 2. Directional switch - disassembly and reassembly

11c-2-1. Disassembling procedure and parts name
Disassembling and reassembling the directional switch

Lever

Boss, lever
Knob, lever

Panel, display (1)

Case

Microswitch
DS1(forward)

Microswitch
DS2(backward)

Column ass'y
Microswitch
DS3(neutral)
Bushing
Spacer

Shaft
Spacer

Plate, switch
Roller

Arm
Cover, case
Cam (A)

Cam (B)

* This illustration indicates the right lever (DS100-20).

2210112

83
 ELECTRIC PARTS 11

11c-2-2. Wiring
<Type : DS100-20 (right lever)>
Case
DS1(Forward)
Red Green/White
Forward
DS2(Backward)
Red Blue/Yellow

DS3(Neutral)
Red White/Black

Backward

Insulation tube (black)

Length: 100 DS1
DS2
DS3
Green/White
Blue/Yellow

White/Black
Red

Microswitch location
2 2 2 2
1 2 3 4 Forward Neutral Backward
4P DS1 Conducting Not conducting Not conducting
Cap DS2 Not conducting Not conducting Conducting
1 2
3 4
DS3 Not conducting Conducting Not conducting 2210186

<Type : DS100-21 (left lever)>

Case
DS2(Backward)
Red Blue/Yellow

Forward
DS1(Forward)
Red Green/White

DS3(Neutral)
Red White/Black

Backward

Insulation tube (black)

Length: 100 DS2
DS1
DS3
Green/White
Blue/Yellow

White/Black
Red

Microswitch location
2 2 2 2
1 2 3 4 Forward Neutral Backward
4P
Cap DS2 Not conducting Not conducting Conducting
1 2 DS1 Conducting Not conducting Not conducting
3 4
DS3 Not conducting Conducting Not conducting
2210187

84
11 ELECTRIC PARTS

11d. BATTERY
11d- 1. Disassembly and reassembly
11d-1-1. Battery - removal and installation

Removing and installing the battery

Battery

Base, battery

Frame

461E261

CAUTION  Be sure to disconnect the battery plug and discharge the capacitors in
the control unit.
 Be careful not to be wet with electrolyte to the body.
 If the electrolyte would come into eye, wash eye with fine water, and go
to doctor.
 The inspecting battery should be done in a place which is well
ventilated and kept away from fire.

85
 ELECTRIC PARTS 11

11d- 2. Inspection and adjustment

11d-2-1. Battery - inspection
1 Inspection of quantity of electrolyte Inspection of electrolyte level
and replenishment Appropriate level

<Checking electrolyte level>

1. Disconnect the battery plug.
2. Open the battery cover and set the stopper.

CAUTION Since a gas spring (an assistant damper with

self-lock function) is used, the locking state Proper level of electrolyte

should be checked.

3. Check electrolyte level.

<Specification>
 If the red float can seen, electrolyte level is correct.
If not, replenish with refined or distilled water.

Lowest level of electrolyte

Refined water

<Replenishing with refined water> Replenishing procedure

1. Remove the lid of the plastic tank, dip the hose with a
Bottle Lidded hose
lid into the tank deeply and tighten it up.
2. Open the cap and put another end of the hose into the Hose
battery cell. Pinch-cock

3. Open the pinch-cock and press the tank at the both Cap
sides several times.
4. Refined water will flow into the cell by siphon action.
Vent plug
5. Close the pinch-cock to stop replenishing just before
the red-float touches the indicating plate of the cap.

Cap

Float
White line

Battery

Level of
electrolyte

86
11 ELECTRIC PARTS

2 Measurement of specific gravity of electrolyte in each cell

<Reading hydrometer>
1. Take reading at the contacting line of electrolyte and the tube.
2. Difference between max. and min. specific gravity shall be less than 0.05. MEASUREMENT OF
SPECIFIC GRAVITY
Difference between max. Less than 0.05
and min. specific gravity Thermo Hydrometer
meter
<Recharging procedures>
1. Carry out equalizing charging.
2. Check specific gravity at each cell after equalizing
charge and make sure the difference is within standard
value.
As specific gravity of electrolyte is based on the value
at 20 , convert measured specific gravity.

<How to convert to specific gravity at 20 >

1. Measure temperature of electrolyte.
CONVERSION

CAUTION  Use thermometer to measure 1.330

1.310
1.300 1.290
2. Measure specific gravity of electrolyte.
Specific gravity at 20

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

11d-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 so that the red-float is visible.
3. Securely fasten the vent plug that it will fit well with the
cell cover on installation.

NOTE If the swan screw part is damaged, replace the

plug comp. with new one.

87
 ELECTRIC PARTS 11

11e. CHARGER PANEL

11e- 1. Disassembly and reassembly
Only the truck with built-in charger

High voltage danger

while charging

Panel, charge

Contactor

Fuse ass'y

Connector, outlet

Magnetic Magnetic
Contactor(2) Contactor(1) Plug comp.
Terminal

Harness, BC
Harness, body

Fuse 0.5A

461E022

88
11 ELECTRIC PARTS

11e- 2. Inspection and adjustment

11e-2-1. Voltage tap - switching
1 Checking power supply voltage

NOTE  Measure the power supply voltage at the charging section without running the charger.
 Measure the voltage for 1 minute. The highest voltage obtained is the
power supply voltage.
 If three-phase input power is used, the average of the highest voltages
in 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 noon recess or while the charger is in use.

2 Selection of voltage tap

<Case of input power supply 200V>
Power supply voltage (V) Voltage Tap connection position
199 or lower 200V
200-209 210V
210-219 220V

<Case of input power supply 400V>

It is connected
Power supply voltage (V) Voltage Frame around here.

379 or lower 380V

380-399 400V Transformer
400-419 420V
420-439 440V 461E118

Body side

3-core cable
Vinyl caps are placed (VCT)
The body side and the
on for unused taps. transformer side are
secured together using
a ring by terminal.

Bolt

Washer
Nut
Mark band indicates
the tap voltage. Both Cartridge
60Hz/50Hz are written.
Transformer side
461E116

89
 ELECTRIC PARTS 11

CAUTION Before changing the voltage tap and replacing the link fuse, be sure to
disconnect the AC plug from the receptacle, disconnect the battery plug
and discharge the capacitors in the control unit.

3 Switching the voltage cap

CAUTION Securely tighten the screw for the ring terminal

so it will not be loosened.

1. Loosen the screw and remove the ring terminal.

2. Reconnect it to the tap conforming to the power 210V
200V
voltage and secure the ring terminal together with bolts Factory setting
(220V)
and nuts.
 Factory setting: 220V

Replacement of link fuse (three-phase voltage)

461E117

4

CAUTION If the screws are not securely tightened, contact

failure could result, causing malfunctioning.

1. Loosen the screw and replace the link fuse.

Power supply voltage Link fuse

爪付ヒューズ
Applicable model Battery capacity Securely
スクリューは確実にtighten
200V/220V the screw.
締付けてください。
FBT 13P 320-370 Ah 15A
FBT 15P 350-565 Ah 20A
461S013

FBT 18P 390-565 Ah 20A

FBT 20P 390-624 Ah 20A

90
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

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

Within 1.25 degree of the

Adjustment position
f o r k 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
(30 mm 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.

Loosen fixing bolts of the LASER POINTER UNIT,

adjust the height by moving the case body up and Laser pointer unit
down. Also adjust the horizontal direction of the optical
axis by loosening the lock screw and rotating the unit Laser optical axis Screw, set
(the wire portion) inside the body.

After the adjustment is complete, securely tighten the

screw and fix it using a screw lock or equivalent item. Support,
laser
4. Drive the forklift truck forward and make sure that
Laser pointer
the 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.
461E215

91
13a. ADJUSTMENT OF SICOS-AC
13a- 1. Explanation of the MPU board
13a-1-1. Basic control board construction
As shown in the figure below, the SICOS-AC uses the
display board as the central point for connecting all other
boards for the exchange of data. In addition, all control
boards use a one-chip CPU (with flash ROM) as their
main CPUs, so their ROM can not be removed.

EPS controller EPS motor

Microcomputer
charger Display board Load sensor (opt.)

(only for
Level potentiometer
built-in chager) (opt.) Laser pointer

Turtle switch
Parking switch
Brake oil switch(opt.)
Turn signal lamp switch
Key switch
Directional switch
Steering angle sensor
Seat switch (opt.)
MPU board (COM)
Brake switch
Accelerator
Hydraulic microswitch

Main contactor
Travel board Travel board Hydraulic board
Fan

Traction Traction Hydraulic

motor (L) Rotary encoder motor (R) Rotary encoder motor Rotary encoder

461S031

92
13a Adjustment of SICOS-AC

13a-1-2. Travel/ Hydraulic board (MPU board)

<Type : PB104-XX>
(P15) 15V power supply
(P15)15V電源正常時点灯
 This board controls the traction motor and the
(P7) 7V power supply
(P7)7V電源正常時点灯
hydraulic motor. (CPU) CPU drive
(CPU)CPU動作中点滅
Connector パソコン通信用コネクタ
for personal computer

CN5

CN3
Harness for
FETモジュール用
FET module
ハーネス
CN4

カレントセンサ用
Harness for
current sensor
ハーネス

CN1 CN2

Body harness (Connector

ボディハーネス for option)
（オプション用コネクタ）

13a-1-3. Display board

<Type : PB103-XXX>
 This board controls both the data exchanged between
the other boards and the display.
(P7) 7V power supply
(P7)7V電源正常時点灯

Buzzer
ブザー (CPU) CPU drive
(CPU)CPU動作中点滅
[RS1][RS1]
: Rotary switch for model selection
モニタセレクト用ロータリスイッチ
モードセレクト
Connector for Connector for
mode select switch
スイッチ用コネクタ flourscent monitor
蛍光管モニタ用コネクタ
F 0 12
B CDE

34 56

7 8 9A

Connector for
パソコン通信用コネクタ
personal computer

PB103-XXX CN2 CN1

Body harness
ボディハーネス

93
 Adjustment of SICOS-AC 13a

13a-1-4. MPU board (COM)

<Type : PB105-XXX>
 This board relays the travel/hydraulic board to the
display board.
[RS]:Rotary switch for model selection
機種セレクト用ロータリスイッチ (P7) 7V power supply
(P7)7V電源正常時点灯
Connector for (CPU) CPU drive
(CPU)CPU動作中点滅
personal computer
パソコン通信用コネクタ

[P7]
[CPU]
CN4

(LIFT) (VR1)
(TILT) (VR2)
Proportional
比例制御弁用
(ATT1) (VR3) valve adjustment
電流調整ボリューム
(ATT2) (VR4)

CN1 CN2 CN3 CN5 CN6

(Connector for option)

（オプション用コネクタ） 461E262

 The normal condition while turning on the key switch

Travel/Hydraulic board Display board MPU board (COM)
LED
(PB104-XX) (PB103-XX) (PB105-XX)
P7 lighting lighting lighting
P15 lighting
CPU blinking blinking blinking

CAUTION  When the MPU board (COM) or display board are replaced, specification such
as model setting and option setting has changed. After replacement of the
board, adjust the settings in accordance with this service manual.
 In case of changing the settings for the rotary switches, be sure to turn off the
key switch once before changing them.

94
13a Adjustment of SICOS-AC

13a-1-5. Rotary switch on the MPU board (COM)

The rotary switch on the MPU board (COM) is used to select forklift models.
When replacing the MPU board (COM), be sure to refer to the table below to match it with
the forklift.

 Rotary switch for model selection

RS Applicable model types
0 FBT13
1 FBT15/18
2 FBT20
3
4
5
6
7
8
9
A
B
C
D
E
F

Volume No. Function Remarks

Lift proportional control valve Turning the volume clockwise increases the
VR1
current adjustment current.

Tilt proportional control valve Turning the volume clockwise increases the
VR2 current.
current adjustment

Attachment 1 proportional control Turning the volume clockwise increases the

VR3
valve current adjustment current.

Attachment 2 proportional control Turning the volume clockwise increases the

VR4
valve current adjustment current.

Note: The standard board is not equipped with volumes.

Only fingertip control or AOS model is equipped.

95
 Adjustment of SICOS-AC 13a

13a-1-6. Rotary switch on the Display board

The rotary switch (RS1) on the display board is used for selecting the displays and
adjustments as following table.
 RS1 setting functions

RS1 Functions Remarks

MONITORING OK After turning on the key switch, this message is displayed.
Meters (Battery discharge, Speed, Hour, Error,
Normal monitor Clock, Battery charge reservation)
Hour meter check Total, travel, and hydraulic hour meters appear.
Date and time setting Set the date and time.
Set the maximum speed under the slow speed
Slow speed setting
0 mode. (4, 5, 6, 8, 10, 12, 15km/h)
Travel mode setting Select ECONOMY, NORMAL, or POWER.
Meter mode setting Select the hour meter or odometer.

Display mode setting VIEW (contrast)

BRIGHTNESS (0-7 intensity of back light)
Adjustment of regenerative power Select NON, LOW, MID, or HIGH
when accelerator is released
1 Monitor symbol setting STEER, BATT, OIL, LOAD, BRAKE
2 Forklift model check Displays the settings for the MPU board (COM)
Plugging strength setting 0 - 32
3
Brake strength setting 0 - 32
Maximum lift speed 1 0 - 32 (Fast) : For travel speeds of 0 - 5 Km/h
Maximum lift speed 2 0 - 32 (Fast) : For travel speeds of 5 - 10 Km/h
Maximum lift speed 3 0 - 32 (Fast) : For travel speeds of over 10 Km/h
Lift speed 1 0 - 32 (Fast) : 1st microswitch
4 Lift speed 2 0 - 32 (Fast) : 2nd microswitch
Tilt speed 0 - 32 (Fast)
Attachment 1 speed 0 - 32 (Fast)
Attachment 2 speed 0 - 32 (Fast)
Attachment 3 speed 0 - 32 (Fast)
5 Display language selection Six languages
6 Option setting Set the options.
7 Voltage, current, and temperature check
8 RAM and I/O memory data check
Error history memory 1 Displays the details of the 10 latest cases.
9
Error history memory 2 Records all past errors.
Battery voltage setting Voltage settings for capacity standards
A
Adjustment of Load sensor span Sets loaden/unloaden, overload value.
B Turning speed reduction 0 - 16
C AOS setting 1 Sets the lift/tilt end and others.
D AOS setting 2 Checks the lever switch.
E Memory initial Clears the error history.
F Normal screen 2 No errors are displayed on the screen

96
97
RS1 on display board
RS on
Voltage MPU 4 3 1 5
Model
[V] board HYD HYD HYD Travel speed Lift speed Plugging brake
(COM) SPD-L SPD-M SPD-H HYD HYD HYD ATTAT. ATTAT. ATTAT. PLUGG BRAKE TRAVEL HYD STEER BATT OIL LOAD BRAKE Language
LIFT LIFT LIFT LIFT-1 LIFT-2 TILT ING TRQ (km/h) (mm/sec) distance (m)
1 2 3
FBT13P 0 32 26 20 20 32 20 0 0 0 32 28 JAPAN 16.5/15.0 610/400 6.6
13a Adjustment of SICOS-AC

FBT15P 16.5/15.0 610/380 6.6

48V 1
FBT18P 16.0/14.5 610/360 6.6
FBT20P 2 15.5/14.0 500/300 6.9
3
4
5
6
7
8
9
A
B
C
D
E
F

�Memory initial (display board RS1=E) �Option setting (Display board RS1=6) Plugging brake distance
�Flat, unladen, and full speed
Slow speed (turtle speed) : 5km/h LIFT LOCK : OFF [Lift interrupt] �Specific gravity of electrolyte : more than 1.25 at 20
Travel mode : NORMAL SPEED LIMIT : OFF [Speed limit at high lifting height] �Full acceleration
BRIGHTNESS :5 SEAT SWITCH : OFF fixed [With seat switch]
Neutral regenerative power : MID FINGER TIP : OFF fixed [With finger tip] �Language selection (Display board RS1=5)
Meter mode : Hour meter AOS : OFF [With AOS]
JAPANESE > OK
Error history : Clear POWER MODE : ON fixed [Power mode]
ENGLISH > MONITORING OK
13a-1-7. Adjustment Standards List for FBT-70 series

CHARGER : ON [Charger]
When Japanese is not selected for display, "CHARGER" FRENCH > CONTROLEUR OK
TILT STOP : OFF [Automatic tilt leveling]
is automatically set to "OFF". GERMAN > UEBERWACHUNG OK
HOUR METER :1 [Hour meter count]
HOUR METER (hour meter count) setting SPANISH > MONITOR OK
SPEED SWITCH :1 [Slow speed mode switch]
1: Key switch ON DUTCH > MONITORING OK
2: Actual operation time (motor operation time)
 Adjustment of SICOS-AC 13a

13a-1-8. Confirmation of other services

Display

<Confirmation>
After pressing " " button for over 3 seconds, it is
displayed as follows.

 Model confirmation

The model set by rotary switch

on the MPU board (COM) is
461T020
displayed.

 Software number confirmation

The software program numbers

: TR (travel right), TL (travel left)
461T021 H (hydraulic)
C (MPU board (COM)
E (EPS), D (display)
 Buzzer mode, rotary SW mode setting are displayed.

Buzzer mode setting is

highlighted.
121T180
 Set buzzer mode by pressing
" " or " " button (OFF/
ON)
(continues on next page) ON: (Normal)
OFF: (turns off all the buzzer
except blinkers)

98
13a Adjustment of SICOS-AC

(continued from previous page)

 Rotary switch mode setting is

blinking.
121T181

 Set rotary switch mode by pressing

The setting number of rotary switch
is displayed. " " or " " button (OFF/
ON)
ON: normal
OFF:The rotar y switch is
disabled and the setting
number of rotary switch
is able to change by
mode select button.

CAUTION  When the connection is failure between

display board and TRV/HYD board, MPU board
(COM), EPS controller, software numbers are
not displayed.
 If buzzer mode is set to OFF, all buzzer sounds
are turned off except blinker sound.
 If rotary SW mode is set to OFF, the rotary
SW is disabled on the display board. You can
change the rotary SW setting by "keeping
pressing down button for over 3 seconds
while pressing bu t t o n " o r " k e e p i n g
pressing down button for over 3 seconds
while pressing button.

99
 Adjustment of SICOS-AC 13a

13a- 2. SICOS-AC check and adjustment

CAUTION  In case of changing the settings for the rotary

Display board
switch RS1, be sure to turn off the key switch
once before changing them. F01

CDE

23
 After finishing the setting, be sure to return

456
AB
rotary switch RS1 to "0". 789
 Before measuring current, change the mode
Return RS1 to "0".
depending on the objects.
Traction motor current
AC mode
Hydraulic motor current
Battery current
DC mode
EPS motor current

13a-2-1. Chassis insulation check

<Checking procedure>
1. Disconnect the battery plug.
2. Discharge the capacitors in the control unit.
(For the discharge procedure, see "11a-1. Capacitor -
discharging procedure".)
3. Remove the connector on the battery electrolyte level
detection line (green/black) in the control unit.
[Only models of electrolyte level detector is equipped]

4. Use a tester to measure the insulation resistance

between positive (+) terminal of the chassis battery
plug and chassis, between negative (-) terminal of the
chassis battery plug and chassis.

Specification 1M or greater

100
13a Adjustment of SICOS-AC

13a-2-2. Battery voltage adjustment

<Measuring points>
 Open the battery cover and measure the battery
voltage between positive terminal and negative
terminal.

<Measuring conditions>
Specific gravity of the battery electrolyte : over 1.25 at
20

<Measuring instrument>
Use a digital tester that can measure 1/100V.
Use Direct current (DC) mode.

<Adjusting procedure> Display board

1. Set rotary switch RS1 on the display board to "A". F01

CDE

23
456
AB
789

2. Turn on the key switch and the following screen

Set RS1 to "A".
appears.

 Battery voltage setting screen

121T127

Battery Voltage Parameter (flashing)

3. Set the parameter for battery voltage to the same as

the measured value for the tester.

NOTE The tolerance is within 0.1 V.

Press button to increase the parameter.

Press button to decrease the parameter.

101
 Adjustment of SICOS-AC 13a

13a-2-3. Current detector check

Traction motor current check
<Measuring point>
IU: traction motor (L/R) U phase electric current (V phase
or W phase is also possible.)

<Measuring conditions>
Specific gravity of the battery electrolyte : over 1.25 at 20

<Measuring instrument>
Alternating current (AC) mode
Control unit

contactor
Main

Board Comp., Harness, M

MPU
(Hyd)

Traction motor U phase

Board Comp.,
MPU
(Traction/L)

Analog clamp ammeter

Board Comp.,
MPU
(Traction/R)

461E216E

CAUTION When measuring AC motor current, use the

recommended ammeter below:
Recommended ammeter :
Hioki 3109-01 (Analog)
Hioki 3209 AC/DC high tester (Digital)

CAUTION When measuring travel/hydraulic motor current

using Hioki 3209 AC/DC (Digital), you need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response
102
13a Adjustment of SICOS-AC

<Checking procedure>
1. Set rotary switch RS1 on the display board to "7". Display board

F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
Set RS1 to "7".
NOTE If "TRL" or "TRR" is not blinking, press button
to make it blink.

 Voltage, current, and temperature checking screen.

Setting of TRL (Traction left) blinks.

Display
Battery voltage (travel CPU detection)
Traction motor current.
461S060

Setting of TRL (Traction left) blinks.

Display temperature of FET for traction left.

461T023

Setting of TRR (Traction right) blinks.

Display
Battery voltage (travel CPU detection)
461S061
Traction motor current.

Setting of TRR (Traction right) blinks.

Display temperature of FET for traction right.

461T025

103
 Adjustment of SICOS-AC 13a

3. Not depressing the accelerator pedal, check if the

traction motor current (MOTOR) shows 000A.

4. Jack up the drive wheel and depress the accelerator

pedal fully.

5. At this condition, check if the traction motor current

(MOTOR) shows a traction motor current (IU) meter
value within ±20A

104
13a Adjustment of SICOS-AC

Hydraulic motor current check

<Measuring point>
IU: hydraulic motor U phase electric current (V phase or
W phase is also possible.)

<Measuring conditions>
Specific gravity of the battery electrolyte : over 1.25 at 20

<Measuring instrument>
Alternating current (AC) mode
Control unit

contactor
Main

Hydraulic motor U phase

Board Comp.,
MPU Harness, M
(Hyd)

Board Comp.,
MPU
(Traction/L)

Analog clamp ammeter

Board Comp.,
MPU
(Traction/R)

461E217E

CAUTION When measuring AC motor current, use the

recommended ammeter below:
Recommended ammeter :
Hioki 3109-01 (Analog)
Hioki 3209 AC/DC high tester (Digital)

CAUTION When measuring travel/hydraulic motor current

using Hioki 3209 AC/DC (Digital), you need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response

105
 Adjustment of SICOS-AC 13a

<Checking procedure>
1. Set rotary switch RS1 on the display board to "7". Display board

F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
Set RS1 to "7".
3. Press either or button to make HYD blink.

 Voltage, current, and temperature checking screen.

Setting of HYD (Hydraulic) blinks.

Display
Battery voltage (hydraulic CPU detection)
hydraulic motor current.
461S062

Display temperature of FET for hydraulic.

461T027

4. Not operating the lift lever, check if the hydraulic motor

current (MOTOR) shows 000A.

5. Pull the lift lever (lift up) fully until lift relief position (lift
stroke end).

6. At this lift relief current, check if the hydraulic motor

current (MOTOR) shows a hydraulic motor current (IU)
meter value within 20A.

106
13a Adjustment of SICOS-AC

13a-2-4. Forklift model setting check and adjustment

<Checking procedure 1>
 Display board
1. Set rotary switch RS1 on the display board to "2".
2. Turn on the key switch and the following screen F01

CDE

23
appears.

456
AB
3. Confirm that the model type is set correctly.
789

Set RS1 to "2".

<Checking procedure 2>

1. Keep pressing button for 3 seconds.
2. The follwing screen appears.
3. Confirm that the model type is set correctly.

 Forklift model type checking screen

 MPU board (COM)
(In case of rotary switch for model selection on the MPU
board (COM) is set to "1") F01

CDE

23
456
AB
789

RS="1"

461S034

107
 Adjustment of SICOS-AC 13a

13a-2-5. Hydraulic setting check and adjustment

<Checking procedure>
1. Set rotary switch RS1 on the display board to "4".  Display board

F01
2. Turn on the key switch and the following screen

CDE

23
456
appears.

AB
789
3. Confirm that the parameter items are set to the same
as the values on the "Adjustment Standards List" on Set RS1 to "4".

page ??.

 Hydraulic speed setting screen

The parameter blinks.

 Set hydraulic speed limit of traveling
speed 0-5km/h by pressing or
221T002 button (0 - 32).

The parameter blinks.

 Set hydraulic speed limit of traveling
221T003
speed 5-10km/h by pressing or
button (0 - 32).

The parameter blinks.

 Set hydraulic speed limit of traveling
speed 10-km/h by pressing or
221T004 button (0 - 32).

The parameter blinks.

 Set LIFT1 hydraulic speed by pressing
or button (0 - 32).
221T005

(continues on next page)

108
13a Adjustment of SICOS-AC

(continued from previous page)

The parameter blinks.

221T006
 Set LIFT2 hydraulic speed by pressing
or button (0 - 32).

The parameter blinks.

 Set TILT hydraulic speed by pressing
or button (0 - 32).
221T007

The parameter blinks.

221T008
 Set ATT.1 hydraulic speed by pressing
or button (0 - 32).

The parameter blinks.

 Set ATT.2 hydraulic speed by pressing
or button (0 - 32).
221T009

The parameter blinks.

221T010
 Set ATT.3 hydraulic speed by pressing
or button (0 - 32).
<Adjusting procedure>
1. Press either or button to move the blinking
icon to the parameter you want to change.
2. Press button to increase the parameter.
3. Press button to decrease the parameter.
<Attachment parameter>
Parameter of attachment is listed below.
Attachment HYD ATTAT parameter
109 SF 09
 Adjustment of SICOS-AC 13a

13a-2-6. Switch back (plugging/ regenerative)

braking force adjustment

<Standard parameter>
 Refer to the Adjustment Standards List on page 97.

<Measuring conditions>
 Flat ground, unladen, and full speed
 Specific gravity of the battery electrolyte : 1.25 or over
(at 20°C)

<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "3".

2. Turn on the key switch and the following screen

appears.

 Plugging and braking strength setting screen

221T011

Plugging strength parameter (blinking)

3. Confirm that the "PLUGGING" parameter is blinking.

NOTE If the PLUGGING parameter is not blinking, press

button.

4. Press button to increase the braking force.

5. Press button to decrease the braking force.

110
13a Adjustment of SICOS-AC

13a-2-7. Regenerative braking force check

and adjustment

<Checking procedure>
1. Select the "NON" at the regenerative brake setting.

121T141

2. Travel forward in a moderate speed.

3. Release the accel pedal and depress the brake pedal
lightly.
4. Confirm that braking force (regenerative brake) is
applied lightly.
5. After checking, re-select the "MID" at the regenerative
brake setting.

<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "3".  Display board

CDE F01

23
456
AB

789
2. Turn on the key switch and the following screen
appears. Set RS1 to "3".

 Plugging and braking strength setting screen

221T012

Braking strength parameter (blinking)

3. Press button to move the blinking icon to the

"BRAKE" parameter.
4. Press button to increase the braking force
(regenerative brake).
5. Press button to decrease the braking force
(regenerative brake).
111
 Adjustment of SICOS-AC 13a

13a-2-8. Safety monitor symbol check and

adjustment

<Checking procedure>
1. Set rotary switch RS1 on the display board to "1".  Display board

F01
2. Turn on the key switch and the following screen

CDE

23
456
appears.

AB
789
3. Confirm that the parameter items are set to the same
as the values on the "Adjustment Standards List" on Set RS1 to "1".

page ??.

 Monitoring symbol setting screen

TRAVEL
HYD

STEER

BATT

BRAKE

LOAD

OIL

221T013

112
13a Adjustment of SICOS-AC

<Adjusting procedure>
1. Press either or button to move the blinking
icon to the item whitch you want to change.
2. Press button to turn the item "ON".
3. Press button to turn the item "OFF".
4. Turn off the key switch and return rotary switch RS1 to  Display board

"0".
F01
5. Turn on the key again.

CDE

23
456
It indicates the symbols set to "ON" at the monitoring

AB
789
symbol setting screen.
Return RS1 to "0".

121T145E

13a-2-9. Display language check and adjustment

<Checking procedure>
1. Set rotary switch RS1 on the display board to "5".  Display board

F01
2. Turn on the key switch and the following screen
CDE

23
456
appears.
AB

789
3. Confirm that the display language is set to your
preference. Set RS1 to "5".

 Display language setting screen.

121T146
Language (blinking)

<Adjusting procedure>
1. Press either or button to select your language.

113
 Adjustment of SICOS-AC 13a

13a-2-10. Optional setting check and adjustment

<Checking procedure>
1. Set rotary switch RS1 on the display board to "6".  Display board

F01
2. Turn on the key switch and the following screen

CDE

23
456
appears.

AB
789
3. Confirm that the options are set to your preferences.
Set RS1 to "6".

 Optional setting screen

121T147

114
13a Adjustment of SICOS-AC

Standard
Optional setting mode Remarks
setting
Lift locks when only one red segment is left
LIFT LOCK Lift interrupt OFF
on battery discharge indicator
SPEED LIMIT High lift height OFF Need to install the switch for detecting
SEAT SWITCH With seat switch OFF Need to install the switch type seat
Equipped with finger tip system hydraulic
FINGER TIP With finger tip OFF
lever models
AOS With AOS Equipped with AOS function models
POWER MODE Can change to travel mode ON ON fixed, for FB (disabled to set power mode)
CHARGER Can set a timer for charging OFF Equipped with built-in charger models
Equipped with Tilt Automatic Stop function
TILT STOP Automatic tilt leveling OFF
models

1: Key switch ON
HOUR METER 1 1 2: Actual operation time (motor operation time)
1: Using standard turtle switch
SPEED SWITCH 1 1
2: Using old turtle switch

NOTE If the relevant option has been equipped, adjust the

optional setting correctry.

<Adjusting procedure>
1. Press either or button to move the blinking
icon to the item you want to change.
2. Press button to turn the item "ON" or "2".
3. Press button to turn the item "OFF" or "1".

115
 Adjustment of SICOS-AC 13a

13a-2-11. Display brightness check and

adjustment

<Checking procedure>
 Confirm that the information on the display can be
read clearly even indoors.

<Adjusting procedure>
1. Press or button repeatedly till the display
adjustment screen appears.

 Display adjustment screen

221T016

Display brightness parameter (blinking)

2. Confir m that the "BRIGHTNESS" parameter is

blinking.
3. Press or button to adjust the brightness (0-7).
 Press button to increase the parameter.
 Press button to decrease the parameter.

116
13a Adjustment of SICOS-AC

13a-2-12. Hour meter working check

<Checking procedure>
1. Open the battery cover and connect "Blue/Red" wire
and Black/White" wire of the accessory terminal.
The hour meter starts counting.
Blue/Black
Black/White
2. Make sure that the hourglass symbol on the display
flashes when you turn on the key switch.

CAUTION  After completing the check, be sure that the

connector terminal is left unplugged until the
forklift is delivered to the customer.

461E122

121T148E

Hourglass (blinking)

Normal : key SW ON (white)

Option : actual operation (colored)

13a-2-13. Checking the function of auto power off

<Checking procedure>
1. Turn on the key switch.
2. Confirm that the main contactor is turned off by
keeping no operation for 15 minutes.

117
 Adjustment of SICOS-AC 13a

13a-2-14. Battery electrolyte level working

check (optional, only for GS battery)

<Checking procedure>
1. Remove the level sensor to make a low level condition.
2. Confirm that the message "*REPLENISH REFINED
WATER FOR BATTERY*" is displayed.

 Battery electrolyte level

121T149E

Scrolls from right to left Blinking

13a-2-15. Turn signal lamp working check

<Checking procedure>
1. When the turn signal lever is operated, confirm that
the turn signal lamp lights and a buzzer sounds at the
same time.
2. When the turn signal lever is operated in one direction
and the steering wheel is turned in the other direction
within 12 seconds, confir m that the tur n signal
lamp lights off. However, if the steering wheel is not
operated within 12 seconds, the turn signal lamp lights
off automatically.

118
13a Adjustment of SICOS-AC

13a-2-16. Hydraulic oil level (optional)

working check

<Checking procedure>
1. Fully lift up and turn on the key switch.
2. Confirm that the message "*REFILL HYDRAULIC
OIL*" is displayed.

 Hydraulic oil (optional)

121T150E

Scrolls from right to left Blinking

13a-2-17. Brake oil level (optional) working check

<Checking procedure>
1. Remove the level sensor to make a low level condition.
2. Confirm that the message "*REFILL BRAKE OIL*" is
displayed.

 Brake oil

221T015E

Scrolls from right to left Blinking

13a-2-18. Cooling fan working check

<Checking procedure>
1. Confirm that the cooling fan is working during travel or
hydraulic operation.
2. While travel and hydraulic operation are stopped,
confirm that the cooling fan is stopping when the
temperature inside the control unit is 35°C or lower,
and that it is working when the temperature inside the
control unit is 40°C or higher.
119
 Adjustment of SICOS-AC 13a

13a-2-19. Lift interrupt (optional) working check

<Checking procedure>
1. Set rotary switch RS1 on the display board to "6".  Display board

2. Turn on the key switch. F01

3. Set "LIFT LOCK" mode to "ON".

CDE

23
456
Refer to "13a-2-10. Optional setting check and

AB
789
adjustment" on page 114.
Set RS1 to "6".

 Option setting screen Set to ON (blinking)

121T152

4. Turn off the key switch and return the rotary switch  Display board
RS1 to "0".
F01
5. Connect a 40 - 46V power supply to the battery plug.

CDE

23
456
6. Turn on the key again.
AB
789
7. C o n f i r m t h a t t h e m e s s a g e " * C H A R G E T H E
BATTERY*" is displayed. Return RS1 to "0".

121T153E
"E" lights up Scrolls from right to left

NOTE In case of the above conditions("E" two segments),

the lift speed becomes 50% and the message
"*CHARGE THE BATTERY*" is displayed. If
t h e b a t t e r y d i s ch a rg e i n d i c a t o r l i g h t s o n ly
one segment, the lift operation is stopped
automatically.

120
13a Adjustment of SICOS-AC

13a-2-20. Turning speed reduction (optional)

adjustment and working check

<Adjusting procedure>
 Display board
1. Set rotary switch RS1 on the display board to "B".
F01

CDE

23
456
AB
2. Turn on the key switch and the following screen
789

appears.
Set RS1 to "B".

 Turning limit speed setting screen

121T154

Parameter (blinking)

3. Press either the or button to adjust the

parameter (0-16km/h).
 Press the button to increase the parameter.
 Press the button to decrease the parameter.

<Checking procedure>
1. Turn the steering wheel all the way to either the right
or the left.
2. Operate the accelerator lever.
3. Confirm that the speed limitation is applied and that
the forklift does not accelerate excessively.

CAUTION A turning detection limit switch and wire

harness must be installed in order to use this
option.

121
 Adjustment of SICOS-AC 13a

13a-2-21. Accelerator potentiometer adjustment

<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "8".  Display board

F01
2. Turn on the key switch and the following screen

CDE

23
456
appears.

AB
789

Set RS1 to "8".

461S039

3. Press , , , or to select "I/O", "COM",

and "W000C".
(See "13b-3. I/O check" on page 136 for setting.)

4. Adjust the potentiometer by loosing the screw. (See

page 80 and 81.)
The applicable "DATA" is as follows at the neutral
position and the full depressed position of accelerator
pedal.
 I/O check mode
neutral position

DATA
0099/0000000010011001

00C2/0000000011000010

461S036

full depressed position

DATA
0330/0000001100110000

0390/0000001110010000

461S037

W h e n t h e e r ro r m e s s ag e " AC C E L E R ATO R "

NOTE
is occured or replacing the potentiometer of
accelerator, perform the voltage adjustment, surely.
Use this I/O check as a confirmation.
<Voltage adjustment>
 See page 81.
122
13a Adjustment of SICOS-AC

13a-2-22. Potentiometer - steering angle sensor adjustment

<Adjusting procedure 1>
1. Set rotary switch RS1 on the display board to "8".  Display board

F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
Set RS1 to "8".

461S039

3. Press , , , or to select "I/O", "COM",

and "W0010".
(See "3c-3. I/O check" on page 136 for setting.)

4. Adjust the potentiometer by loosing the screw.

(See page 24 and 25.)
The applicable "DATA" is as follows at the neutral
position (steering angle of rear wheel is straight).

 I/O check mode

DATA
01F0/0000000111110000

0210/0000001000010000

461S040

461S038

NOTE When the error message "POTENTIO-STEERING

ANGLE" is occured or replacing the angle sensor,
perform the voltage adjustment, surely.
Use this I/O check as a confirmation.

123
 Adjustment of SICOS-AC 13a

<Adjusting procedure 2>

1. Disconnect the 3P plug and insert the adaptor for Tester
Sensor comp.,
measuring the voltage by tester. angle
2. Turn on the key switch to apply 5V power supply to the

RDYE
BN
BK
angle sensor comp.
3. Measure the voltage between brown [BN] line and black Tester
pole (+)
[BK] line by the tester.
4. Adjust the potentiometer by loosing the screw to
set output voltage 2.5±0.1V at the neutral position 3P
(steering angle of rear wheel is straight). Tester pole (-)

(See page 24 and 25.)

RDYE
BN
BK
461S032

13a-2-23. Seat switch (optional) working check

<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "6".  Display board

CDE F01

23
2. Turn on the key switch and the following screen 456
AB

789
appears.
Set RS1 to "6".

221T017

Set to ON (blinking)

3. Press or button to set "SEAT SWITCH" to

"ON".

<Checking procedure>
1. Operate the traveling without sitting on the seat.
2. Confirm that the truck is not traveling.
124
13a Adjustment of SICOS-AC

13a-2-24. Load sensor (optional) adjustment

<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "A".  Display board

2. Press to select the load sensor adjustment screen. F01

3. Set 110% of maximum lifting weight to "OVER" by

CDE

23
456
AB
using or button. 789

Set RS1 to "A".

461T029

NOTE When the over load is detected, the buzzer sounds. Control
コントロール
valve
バルブ Transmitter, ,
トランスミッタ
pressure
プレッシャ
((load sensor) )
ロードセンサ
4. After completing input operation, press and hold
button for 2 seconds until displaying "SET".
461E260

461T036E

CAUTION Do not do hydraulic operation during pressing

button.

5. Lift up about 50cm in unloaded condition and lift down

a little bit to release the hydraulic pressure.
6. Press and hold button for 2 seconds until
displaying "SET".

461T037E

125
 Adjustment of SICOS-AC 13a

7 Lift up about 50cm in loaded condition which the load

weight is found in advance and lift down a little bit to
release the hydraulic pressure.
8 Input the load weight by pressing or buttom.

461T030

9. Press and hold button for 2 seconds until

diaplaying "COMPLETE".

461T038

126
13a Adjustment of SICOS-AC

13a-2-25. Built-in charger (optional) working check

<Total timer>

Magnetic Auto Equal Indicating LED of charging state

Checking procedure Check Test
contactor LED LED 1-2 3-4
1 Disonnect the battery plug. OFF

2 Connect the AC plug to wall outlet. OFF

Press and hold the Auto When pressed ON

3 Button for at least 5
seconds. 5 seconds later ON

The check will end approximately 1 minute and

4 OFF
36 seconds after Auto Button begins flashing.

:On
:Off
:May be on

Chargeing state Indicator 4

Check LED

Auto charge LED

This LED is turned on when the

Equal charge LED battery is fully charged.

Chargeing state Indicator 3

Chargeing state Indicator 2

Chargeing state Indicator 1

TEST mode LED

461T012E

CAUTION  For a fully charged battery, check after performing approximately 2-3 minutes of
hydraulic operation.
 If the charging state LEDs blink, they will not stop until the battery plug is
unplugged.

<Earth check>
Make sure the conductivity (0 at "1x" range of the tester) between the chassis and the
earth terminal in the receptacle on the charger panel.

127
13b. TROUBLESHOOTING
13b- 1. Self diagnosis function
13b-1-1. Display
If abnormalities or errors are detected with the self-
diagnosis function, the following symbols and error
messages will be displayed on the screen.
 The applicable abnormality and/or error symbol will
flash on the display.
 The applicable error message will be displayed. (If
multiple abnormalities and/or errors are detected, the
applicable error messages will be displayed in order.)

Travel system errors

The service (spanner) mark flashes.

The travel system error message scrolls from

right to left.
The travel symbol flashes.
121T105E

Hydraulic (including AOS) system errors

The service (spanner) mark flashes.

The hydraulic system error message scrolls

from right to left.

The hydraulic symbol flashes.

244T075E

Steering (EPS) system errors

The service (spanner) mark flashes.

The steering (EPS) system error message

scrolls from right to left.

The steering symbol flashes.

244T071E

128
13b Troubleshooting

Other errors

121T108E

Multiple abnormalities and/or errors

The service (spanner) mark flashes.

The detected error messages are scrolled in

order from right to left.

All of the symbols for the abnormalities and/

or errors detected flash from the right in the
461S041 order they are detected.

NOTE  If the following abnormalities and/or errors

o c c u r, t r a v e l , h y d r a u l i c s a n d E P S a r e
interlocked.

B11 : FET -TRAVEL

C21 : FET -HYD.
FAIL -CURRENT TRAVEL
FAIL -CURRENT HYD
FAIL -OPERATION
TURN OFF KEY SWITCH

The , , , and buttons are disabled

while the self-diagnosis screen is displayed.
Display board
 If rotary switch RS1 on the display board is
set to F, the self-diagnosis screen will not F01
CDE

23

be displayed. (The normal screen will be

456
AB

displayed.) 789
 When the abnormalities and/or errors are
RS1="F"
resolved, the display will return to the normal
screen.

129
 Troubleshooting 13b

13b-1-2. Error messages and Display conditions

Error Message Probable Cause Note

A1 : CONTACTOR-MAIN Main contact is open circuit.

A2 : POTENTIO -STEERING Steering angle sensor is failure.

ANGLE When the key switch is turned on, the input
voltage (CN1-7) in the COM board is under
1.0V or over 4.0V.

B10 : FUSE-MAIN Blown main fuse

B11 : FET -TRAVEL *FAIL OPERATION*

Travel FET is failure. *TURN OFF KEY SWITCH*
B12 : SENSOR-CURRENT Current sensor U phase or W phase for
TRAVEL travel is failure.
When the key switch is turned on, the U
phase (CN4-2) or W phase (CN4-5) voltage
in the TRV board is out of 5 ± 0.976V.

B14 : ACCELERATOR Accelerator is failure.

The difference between input voltage 1
(CN1-5) and input voltage 2 (CN1-15) in the *TURN OFF KEY SWITCH*
COM board is over 0.62V.
Or, input voltage 1 or 2 is under 0.48 V.
Or, input voltage 1 or 2 is over 4.7 V.

B13 : DIRECTIONAL SWITCH Directional microswitch is failure.

C20 : FAIL, CAN-BUS SYSTEM The connection is failure between COM

board and TRV/HYD board.

C21 : FET -HYD. *FAIL OPERATION*

Hydraulic FET is failure. *TURN OFF KEY SWITCH*
C22 : SENSOR-CURRENT - HYD Current sensor U phase or W phase for
hydraulic is failure.
When the key switch is turned on, the U
phase (CN4-2) or W phase (CN4-5) voltage
in the HYD board is out of 5 ± 0.976V.

C23 : SWITCH-LIFT Lift lever microswitch is failure.

D30 : FUSE -EPS Blown EPS fuse (Decelerates by half)

D31 : SENSOR -EPS TORQUE EPS torque sensor is failure.

When the key switch is turned on, the input
voltage [GNRD line] is under 0.55V or over
*TURN OFF KEY SWITCH*
4.45V.

D32 : TR -EPS MAIN FET for Power Steering control is failure. *TURN OFF KEY SWITCH*
(Decelerates by half)

E40 : TR -AOS Valve current is out of range. *TURN OFF KEY SWITCH*

E41 : POTENTIO-HYD. - LEVER Potentiometer for AOS control lever is

failure
In the COM board,
When the lift SW (CN2-6) is turned off,
the input voltage is under 1.38V or over 3.62V.
When the lift SW (CN2-6) is turned on,
the input voltage is over 2.47V and under 2.53V.
When the tilt SW (CN2-7) is turned off,
the input voltage is under 1.38V or over 3.62V.
When the tilt SW (CN2-7) is turned on,
the input voltage is over 2.47V and under 2.53V.
When the ATT1 SW (CN2-15) is turned off,
the input voltage is under 1.38V or over 3.62V.
When the ATT1 SW (CN2-15) is turned on,
the input voltage is over 2.47V and under 2.53V.
When the ATT2 SW (CN2-8) is turned off,
the input voltage is under 1.38V or over 3.62V.
When the ATT2 SW (CN2-8) is turned on,
the input voltage is over 2.47V and under 2.53V.

E42 : ENCODER-HYD. - MAST Encoder for detecting lift height is failure.

Refer to the "FET Module inspection (P.77).
130
13b Troubleshooting

Error Message Probable Cause Note

*FAIL CURRENT-TRAVEL* Traction motor current is out of range. *TURN OFF KEY SWITCH*

*FAIL CURRENT-HYD* Hydraulic motor current is out of range. *TURN OFF KEY SWITCH*

*FAIL VOLTAGE-TRAVEL* Battery voltage is out of range.

When the key switch is turned on, the
batteryvoltage (CN5-20) in the MPU board is
under 36V.
(NOTE : Convert the measured voltage to 70V)

*FAIL VOLTAGE-HYD* Battery voltage is out of range.

When the key switch is turned on, the
batteryvoltage (CN5-20) in the MPU board is
under 36V.
(NOTE : Convert the measured voltage to 70V)

*REDUCE DUTY- OPERATION* The temperature sensor in the TRV/HYD

board is detecting over 90 .

*FAIL BUS SYSTEM* The connection is failure between display

board and COM board or between display *TURN OFF KEY SWITCH*
board and EPS controller.

*FAIL OPERATION* The main contatcor has tripped.

*TURN OFF KEY SWITCH*

*REDUCE THE LOAD* Overload

*REFILL HYDRAULIC OIL* Fork oil

*REFILL BRAKE OIL* Brake oil

*REPLENISH REFINED Replenish refined water to the battery

WATER FOR BATTERY*

*CHARGE THE BATTERY* The battery must be recharged.

*RELEASE PARKING
BRAKE*

*RELEASE ACCEL TO The accelerator was depressed when the

NEUTRAL* key was turned on.

*OFF HYD. LEVER TO The hydraulic lever was pulled or pushed

NEUTRAL* when the key was turned on.

*AOS FAIL OPERATION* The emergency switch has pressed.

(In case that the proportional control valve
is equipped)

*RACK MISSET* Lift location has set in the wrong way

*APPLY PARKING Dismounted from the truck without applying

BRAKE* the parking brake (In case that the seat
switch is equipped)

131
 Troubleshooting 13b

13b- 2. Error history memory

13b-2-1. Error history memory 1
<The 10 most recently detected errors/ abnormalities>
1. Set rotary switch RS1 on the display board to "9". Display board
2. Turn on the key switch and the following screen
F01
appears.

CDE

23
456
NOTE

AB
 To view less than the ten most recent errors/ 789
abnormalities, place the flashing cursor on the
Set RS1 to "9".
last error/abnormality and press button to go
to "Previously detected errors/abnormalities".
 If there are no errors/abnormalities, press
button to go to "Previously detected errors/
abnormalities".

 The 10 most recently detected errors/abnormalities  Error/abnormality details

The most recent error/abnormality flashes as "A01". Number of times the error/abnormality
occurred when it was detected

121T165E

121T159
Year, month, day, and the time of
the error occurrence
Error/abnormality detection date, time, travel
The second error/abnormality flashes as "B10". distance, and travel and hydraulic hour meter

121T160 121T166E

121T161 121T167E

The ninth error/abnormality flashes as "B10".

(To the next page)

132
13b Troubleshooting

(From the previous page)

121T162 121T168E

The tenth error/abnormality flashes as F55.

The next is "Previously detected errors/abnormalities (1)".

13b-2-2. Error history memory 2

<Previously detected errors/abnormalities (1)>
 Rotary switch RS1 on display board : 9 Display board

NOTE  If there are no previous errors/abnormalities F01

CDE

23
displayed in the list, press button to go to

456
AB
"Previously detected errors/abnormalities (2)". 789
 If the same error/abnormality was detected
RS1="9".
multiple times previously, the data of the
most recent detection will be displayed under
"Error/abnormality details".
 Flashing : Indicates the position of cursor.
Highlighted : Only highlighted numbers are
memorized as error items.

 Previously detected errors/abnormalities (1)  Error/abnormality details

The previous page is "The 10 most recently detected
errors/abnormalities".

121T163 121T165E

121T163 121T166E

133 The next page is "Previously detected errors/abnormalities (2)".

 Troubleshooting 13b

<Previously detected errors/abnormalities (2)>

 Rotary switch RS1 on display board : 9
Display board

F01
NOTE If the same error/abnormality was detected

CDE

23
456
multiple times previously, the data of the most

AB
789
recent detection will be displayed under "Error/
abnormality details". RS1="9"

 Previously detected errors/abnormalities (2)  Error/abnormality details

The previous page is "Previously detected errors/

abnormalities (1)". Number of times the error/abnormality
occurred when it was detected

Error/abnormality message display

121T164 121T169E

Error/abnormality detection date, time, travel

distance, and travel and hydraulic hour meter

121T164 121T168E

134
13b Troubleshooting

13b-2-3. Clearing the error history memory

(memory initialization)
1. Set rotary switch RS1 on the display board to "E". Display board
2. Turn on the key switch.
F01
3. The following screen appears and memory initialization

CDE

23
456
is complete.

AB
789
4. Return rotary switch RS1 on the display board to "0".
Set RS1 to "E".

 Memory Initialization Completion Screen

121T170

NOTE The following items are returned to their initial

values:
 Slow speed (turtle) : 5km/h
 Travel mode : N (NORMAL)
 Meter mode : HR (hour meter)
 Accelerator released (neutral) regenerative
force: MID
 Error history : All clear
 BRIGHTNESS (back light brightness): 5

135
 Troubleshooting 13b

13b- 3. I/O Check

13b-3-1. I/O check mode display method

1. Set rotary switch RS1 on the display board to "8". Display board
2. Turn on the key switch the following screen appears.
F01
3. Press button to enter the I/O check mode. The "I/O"

CDE

23
456
icon will flash.

AB
789

The RAM icon flashes. Set RS1 to "8".

CPU selection
COM : MPU board
EPS : Power steering
DSP : Display

461S039

 I/O check mode

The I/O icon flashes.

461S050

The I/O icon highlights.

 The selected CPU highlights.

 Press either or button to select a
CPU.
461S051

The I/O icon highlights.

The selected CPU highlights.

 The W icon (2 bytes) flashes.

461S052  (This can not be changed.)

(To the next page)

136
13b Troubleshooting

(From the previous page)

The I/O icon highlights.

The selected CPU highlights.
 The W icon (2 bytes) is displayed.
 The 0 icon flashes. (This can not be
461S053 changed.)

The I/O icon highlights.

The selected CPU highlights.
 The W icon (2 bytes) is displayed.
 The 0 icon flashes. (This can not be
461S054 changed.)

The I/O icon highlights.

The selected CPU highlights.
 The W icon (2 bytes) is displayed.
 The data address (first byte) setting
461S055 flashes.
 Press either or button to set the
data address (first byte).
(This is limited to the selected CPU.)

The I/O icon highlights.

The selected CPU highlights.
 The W icon (2 bytes) is displayed.
 The data address (first byte) setting
461S056 flashes.
 Press either or button to set the
data address (first byte).
(0-F)

The I/O icon and the selected CPU

highlight.
 The W icon (2 bytes) is displayed.
 The current data address setting is
displayed.

121T177
The data is displayed.

NOTE  The data length is set to W (2 bytes),

regardless of the CPU selected.
 The second byte of the data address is set to
00, regardless of the CPU selected.
137
 Troubleshooting 13b

13b-3-2. I/O port table

CPU in the MPU board (COM)
 I/O port table (1)
PortNO. Bit IN/OUT Contents Remarks
0 OUT Not used
1 OUT Not used
TCLKA IN Encoder A phase (Lift height)
TCLKB IN Encoder B phase
W0000
4 OUT Forward output
5 OUT Backward output
6 OUT Fan output
7 OUT Auxiliary output

W000C AN0 IN Accelerator signal 1

W000E AN1 IN Accelerator signal 2
W0010 AN2 IN Steering angle sensor
W0012 AN3 IN Tilt leveling potentiometer
W0014 AN4 IN Lift lever potentiometer
W0016 AN5 IN Tilt lever potentiometer
W0018 AN6 IN ATT 1 lever potentiometer
W001A AN7 IN ATT 2 lever potentiometer

W001C AN8 IN Lift valve electric current

W001E AN9 IN Tilt valve electric current
W0020 AN10 IN ATT 1 valve electric current
W0022 AN11 IN ATT 2 valve electric current

0 OUT CPU stop

Txd2 OUT Software input / debug
W0002
Rxd2 IN Software input / debug
3 OUT Not used

138
13b Troubleshooting

 I/O port table (2)

PortNO. Bit IN/OUT Contents Remarks
0 IN Directional -neutral
1 IN Directional -forward
2 IN Directional -backward
3 IN Brake switch
W0004
4 IN Rotary switch 1
5 IN Rotary switch 2
6 IN Rotary switch 3
7 IN Rotary switch 4

Txd0 OUT Travel output (display)

Rxd0 IN Travel input (display)
2 OUT Not used
Txd1 OUT Hydraulic output (display)
W0006
Rxd1 IN Hydraulic input (display)
5 IN Seat switch
6 IN Travel inhibitor
7 IN Turning speed reduction

0 IN Lift 1 switch
1 IN Lift 2 switch
2 IN Tilt switch
3 IN Lift 1 switch
W0008
4 IN Lift 2 switch
5 IN Auxiliary input
6 IN Auxiliary input
7 IN Auxiliary input

0 IN Lift up
1 IN Lift down
2 IN Tilt up
3 IN Tilt down
W000A
4 IN ATT 1A
5 IN ATT 1B
6 IN ATT 2A
7 IN ATT 2B

139
 Troubleshooting 13b

Display CPU
 I/O port table (1)
PortNo. Bit IN/OUT Contents Remarks
0 IN Switch 1 (up) L when on
1 IN Switch 2 (down) L when on
2 IN Switch 3 (mode) L when on
3 IN Switch 4 (Reserved setting) L when on
W0000
4 IN Hour meter count start Count starts when L
5 IN Key switch start H when on
6 IN Charging interlock relay <B-contact> H when charger plug is on
7 IN Switch 5 (Turtle) L when on

2 IN P5 power supply check CPU sleep when L

W0002
5 IN Battery electrolyte level When lowering 0/1=100/200ms

0 IN Rotary witch 1
1 IN Rotary witch 2
W0004
2 IN Rotary witch 3
3 IN Rotary witch 4

0 IN Tilt leveling L when level

1 IN Turn signal switch (right) L when on
2 IN Turn signal switch (left) L when on
3 IN Reserve charge start L when starting
W0006
4 IN Brake oil level H when normal condition
5 IN Hydraulic oil level H when normal condition
6 IN Overload L during overload
7 IN Parking brake L when on

 I/O port table (2)

PortNo. Bit IN/OUT Contents Remarks
0 OUT LCD reset Reset when H
1 OUT Power supply relay drive On when L
2 OUT Turn signal lamp (right) On when L
W0008 3 OUT Turn signal lamp (left) On when L
4 OUT Reserve charge Charging starts when L
5 OUT VFD power supply On when L
6 IN 5V power supply input H when there are 5V

0 OUT CPU stop CPU drive when the LED blinks

W000A 1 OUT Buzzer drive 4kHz when the buzzer is on
7 IN VFD icon flashing interval Lighting when H, off-lighting when L

W000C AN0 A/D Battery voltage 0-5V=0-55V

W000E AN1 A/D VFD power supply 0-5V=0-70V
W0010 AN2 A/D Pressure sensor 0-5V

140
13b Troubleshooting

EPS CPU
 I/O port table (1)

Port NO. Bit IN/OUT Contents Remarks

0 IN Motor current check 0: Electric current available

1: Electric current not available

1 IN K. S. check 0: K.S.ON 1: K.S.OFF

2 OUT Power source retention signal 0: Power source on

1: Power source off
0: Correct direction
(FET1:ON,FET3:OFF)
4 OUT FET1, 3 gate signal
W0000 1: Reverse direction
(FET1:OFF,FET3:ON)
0: Correct direction
(FET2:ON,FET4:OFF)
5 OUT FET2, 4 gate signal
1: Reverse direction
(FET2:OFF,FET4:ON)

6 OUT Lower level FET 1, 2 gate signal 0: Lower level FET off
1: Lower level FET chopper ok

7 OUT Upper level FET 3, 4 gate signal 0: Upper level FET off
1: Upper level FET chopper ok

TIOCA3 OUT Lower level FET 1, 2 gate signal 0: OFF 1: ON

W0002 Upper level FET power source chopper
TIOCA4 OUT signal

Abnormal electric current (overload

W0004 IRQ0 IN Interrupted at the startup edge
current x 2) check

W0006 AN0 A/D EPS motor current 0-2.25 ± 0.35V=0-40A

W0008 AN1 A/D EPS torque sensor 2.5V neutral

141
14. WIRING (DIAGRAMS)
V N COM
PBC105-50
Travel L
VA Battery(48V) NA PBC104-43 Line Connector
Line Connector Directional switch No. CN Pin No.
4
No. CN Pin No.
F1 + 125V 0.022 F Open when in Neutral DS3 WHBK
ADN 1 17 Neutral
MC 80V, 5600 F (×9) Travel L PBC104-43 RD
BK

325A RP 1 7 Power supply DS1 GNWH

Connector
Traction motor L BKRD RN 1 15 GND ADF 1 8 Forward
Line BUWH RA 1 8
No. speed sensor WH A phase signal DS2 BUYE
ADB 1 18 Backward
TLU CN Pin No. RB 1 16 B phase signal
RDYE

WH#
Traction FET module BU#
UE2 3 4 U phase gate output 1 RDBK# PU 4 1 Power supply
BUWH
motor UG2 3 3 U phase gate output 2 BU# HS1 2 6 Lift 1 switch
LU BK# UE1 3 2 U phase gate output 3 TLU IU 4 2 Signal WHBU
L RD# UG1 3 1 U phase gate output 4 Traction L BKRD# NU 4 3 GND HS2 2 14 Lift 2 switch
RDBK# BNWH
BNWH# current sensor PW 4 4 Power supply HS3 2 7 Tilt switch
HD 3 13 Thermistor input 2 BU# YEBU
LV THM BKWH# HN 3 14 GND TLW BKRD#
IW 4 5 Signal HS4 2 15 Attachment 1 switch
NW 4 6 GND GNWH
WH# HS5 2 8 Attachment 2 switch
VE2 3 8

RDWH
V phase gate output 1 RDWH BU
LW BU# VG2 3 7 V phase gate output 2 VB 1 1 Control power supply BS 1 10 Brake switch
BK# VE1 3 6 120 BK
RD# V phase gate output 3 RDGN HSN 1 9 Switch GND
VG1 3 5 V phase gate output 4 HP 1 6 CAN power supply
WHBU CANH 1 5 HS6 3 1 Auxiliary input
GNRD F 1 4 BUWH CAN BUS
BKWH Control voltage CANL 1 13 CAN BUS 1 3 HS7 3 5 Auxiliary input
NB 1 9 Control GND BK HN 1 14 HS8 3 2 Auxiliary input
TLW CAN GND

BKWH
WH# HSN 2 16 Auxiliary GND

RDBK
WE2 3 12 W phase gate output 1 MC1 1 2 Auxiliary output X3 + 100V RDGN
BU# WG2 3 11 W phase gate output 2 MC2 1 10 Auxiliary output 22 F 5 AP3 3 3 P5 power supply
BK# WHBK
RD#
WE1 3 10 W phase gate output 3 IO 1 3 Auxiliary input H AD3 3 6 Tilt level
WG1 3 9 W phase gate output 4 OF 1 11 Auxiliary output Horn AN3 3 7 GND
C 1 12 Auxiliary input
Travel R PBC104-41 YEBU
X3 BK
Connector
Travel R VN 1 11 Control GND
Line PBC104-41
TRU No. CN Pin No.
Traction Line Connector Horn switch
WH# UE2 3 4 U phase gate output 1 Rear combination lamp(right) RDGN
RU motor FET module BU# UG2 3 3 U phase gate output 2 125V 0.022 F No. CN Pin No.
GNWH Tail & BK HP 2 3 Power supply
BK# 25W
R RD#
UE1 3 2 U phase gate output 3 RDYE stop WHGN HN 2 11 GND
UG1 3 1 U phase gate output 4 RP 1 7 Power supply X6 lamp BUYE TXA 2 1 Traction Display
Traction motor R BKYE Data line
BNWH# HD 3 13 Thermistor input BUBK RN 1 15 GND TL WHRD RXA 2 9 Traction Display
RV THM BKWH# HN 3 14 GND speed sensor WHBK RA 1 8 A phase signal 10W YERD TXB 2 2 Hydraulic Display
RB 1 16 B phase signal Back RXB 2 10 Hydraulic Display
WH# VE2 3 8 lamp
V phase gate output 1 10W
RW BU# VG2 3 7 V phase gate output 2
RDBK# PU 4 1 Power supply BL Display
BK# BU#
RD#
VE1 3 6 V phase gate output 3 TRU BKRD# IU 4 2 Signal PBC103-56
VG1 3 5 V phase gate output 4 Traction R NU 4 3 GND 25W TSL
GNRD RDBK# Line Connector
BKWH
F 1 4 Control voltage current sensor BU# PW 4 4 Power supply No. CN Pin No.
TRW
NB 1 9 Control GND TRW BKRD# IW 4 5 Signal Rear combination lamp(left)
NW 4 6 GND YERD
WH# WE2 12
3 25W Tail & RXB 2 3 Display Hydraulic
BU# W phase gate output 1 RDWH stop WHRD
WG2 3
11 VB 1 1 TXB 2 13 Display Hydraulic

WHGN
BK# W phase gate output 2 Control power supply lamp BUYE
RXA 2 2 Display Traction Data line
RD#
WE1 10
3 W phase gate output 3 RDGN TL WHGN
TXA 2 12 Display Traction Traction Hydraulic
WG1 93 W phase gate output 4 WHBU HP 1 6 CAN power supply BK
CANH 1 5 CAN BUS 10W Back HNA 2 11 GND
Hydraulic PBC104-42 BUWH CANL 1 13 CAN BUS lamp
RDGN
HPA 2 1 Power supply
BK BN 10W
Line Connector HN 1 14 CAN GND BL
HIU No. CN Pin No. MC1 1 2 Auxiliary output
Hydraulic WH# MC2 1 10 Auxiliary output 25W TSL
FET module UE2 3 4 U phase gate output 1
motor BU# IO 1 3
HU BK#
UG2 3 3 U phase gate output 2
OF 1 11
Auxiliary input
X4 Reference:
UE1 3 2 U phase gate output 3 BNRD Auxiliary output
RD# UG1 3 1 U phase gate output 4 6 C 1 12 EPS fuse BN
BZ Harness mark/color
BNWH#
THM BKWH#
HD 3 13 Thermistor input Hydraulic Red RD
HV HN 3 14 GND PBC104-42 Back buzzer
40W Right Black BK
WH#
HW BU#
VE2 3 8 V phase gate output 1 Line Connector HL Green GN
BK#
VG2 3 7 V phase gate output 2 125V 0.022 F No. CN Pin No. Lamp switch Head lamp Yellow YE
VE1 3 6 V phase gate output 3
RD#
40W HL Left
VG1 3 5 V phase gate output 4 RDGN RP 1 7
White WH
GNRD BKRD Power supply
BKWH
F 1 4 Control voltage Hydraulic motor BUYE
RN 1 15 GND Brown BN
NB 1 9 Control GND GNBK
HIW speed sensor WHRD
RA 1 8 A phase signal
CH Blue BU
RB 1 16 B phase signal
WH# WE2 3 12 W phase gate output 1 X5 Gray GY
BU# WG2 3 11 W phase gate output 2 RDBK# PU 4 1
Forward chime Pink PK
BK# BU# Power supply
RD#
WE1 3 10 W phase gate output 3 HIU BKRD#
IU 4 2 Signal
25W TSL Right RDYE Orange OG
WG1 3 9 W phase gate output 4 Hydraulic NU 4 3 GND WL1 1 4 Turn signal lamp(right)
RDBK# Turn signal lamp
MC
WHBU
MC1 1 2 Main contactor
current sensor BU#
PV 4 4 Power supply
25W TSL Left BUYE Ex) BKWH (=Black/White)
EPS motor BNWH HIW BKRD#
IV 4 5 Signal WL2 1 12 Turn signal lamp(left)
Black colored harness with White line.
MC2 1 10 NV 4 6 GND
GN YE * Only for trucks with laser pointers
F3 6 PA RDWH
VB 1 1 Control power supply
40A RD BU RDGN RDGN Level lamp RD WHRD
WHBU HP 1 6 CAN power supply SW1 1 5 Tilt level
CANH 1 5 (OPT.) Laser pointer
EPS BUWH CAN BUS
switch
BKWH

WH Display BK CANL 1 13 CAN BUS HPD 2 6 Power supply

EPS GNBU
controller HN 1 14 5
sensor TS BU PBC103-56
BNRD
CAN GND Laser
Tilt level
HND
TXD
2
2
16
17
GND
Display
Data line
Line Connector M OF 1 11 Fan output sensor (Auxiliary)
RXD 2 7 Display
Charger panel No. CN Pin No. IO 1 3 Auxiliary input White line
BUBK
RDYE
HPC 2 5 Power supply 4 C 1 12 Contactor contact
* Only for trucks BKYE Data line
HNC 2 15 GND
with built-in chargers. WHBU
TXC 2 14 Display EPS (EPS) COM Lift pressure RDGN
BUWH
RXC 2 4 Display EPS PBC105-50 sensor (OPT.) HTM YEBK P50 2 8 Power supply
Charger, IO1 2 18 Signal
SW4 1 14 Reserve charge start Line Connector
controller CHG 2 20 Reserve charge No. CN Pin No. Turn signal lamp switch Black color
RD Right WHRD
VB 1 10 Battery voltage RDGN
YERD CNP 2 5 CAN power supply SW2 1 13 Turn signal lamp switch(right)
Mctt X1 RLP 1 3 Power supply relay WHBU
BUWH CNH 2 4 CAN BUS Left WHBU
X2 BNYE SW3 1 6 Turn signal lamp switch(left)
Key switch RLN 1 11 BK CNL 2 12 CAN BUS
F5 RDGN CNN 2 13 CAN GND BNBK
10A KSW 1 1 Control power supply SW5 1 7 Brake oil level
RDGN RD BKWH RDWH WHBK
VN 1 9 Control GND VP 1 1 Control power supply SW6 1 15 Hydraulic oil level
X2 X1 BURD BNBK
SW7 1 8
BN X5 OF2 1 12 Forward output Overload
F4 KST 2 19 Key switch start BUBK
10A RY 1 2 SW8 1 16 Parking brake switch
Charging interlock YEBK GNBK
BUBK
AH 2 10
X4 OB2 1 13 Backward output BWL 2 9 Battery electrolyte level
Hour meter counting
RDBK

RDWH

* Refer to note 2 BUBK

Body earth
X6 STP 1 2 Rear combination output
3 DWN 1 3 Auxiliary output WH HV 5 1
BK Back light power supply
Mode select switch RDYE GND 5 2 Back light GND
AP0 1 4 Power supply
1 2 WH AD0 1 5 Signal 1 22P
Accelerator
BS5 4 2 Low speed mode switch potentiometer BU
(turtle switch)
BS1 4 6 Up
GN BK AD1
AN0
1
1
15
14
Signal 2
GND
Display Flat cable
+ Body earth RDYE 3
- Flat cable BS2 4 5 Down BN AP2
AD2
1
1
6
7
P5 power supply 12P
Steering BK Signal
M
6P BS3 4 4 Mode select angle sensor AN2 1 16 GND <Note>
R
BS4 4 3 Reserved setting YEBU
SS 1 20 Seat switch 1. Lead wires marked with # or have different
GNBK
VN 4 1 Switch GND
BURD
TI 3 4 Travel inhibitor diameters.
SG 3 8 Turning speed reduction
BK
HSN 1 19 Switch GND 2. Connect and start the hourmeter countdown.

FBT-70 System wiring 14- 1.

54000-67741-0E

142
14 WIRING (DIAGRAMS)

Laser pointer Head guard(right) * Only for trucks with

built-in chargers Primary
* Only for trucks with laser pointers <12>
side
RD RD
L RDBK RD

resistant
1 1
1 1 WH BK HL
P mast

Water
Level WHGN WH 1 1
Transformer

2P
1 1
Harness, mast (1) Hanging on mast RDBK BK
M lamp RDYE
1 1
GN Harness, head guard
BK 1 1
BK <13>

resistant

resistant
1 1 GN GN TSL

Water

Water
RDWH 1 1

2P

2P
1
Laser BKWH 1
BNBK

resistant
1

Water
Level GNBK

2P
1
M mast Harness, mast (1) Hanging on mast sensor

resistant
Hydraulic motor

Water
Accelerator
EPS motor
Water

6P
resistant 2P 2P-X
Harness, mast (2) sensor
Control valve
Bearing
M

resistant
sensor

resistant

Water
Water
2P

2P
Laser
Only for when using optional equipment

BU

WH

RD
Battery 4P Water
Att.2 plug resistant

<1> HW HV HU
Att.1 RD <6>
RU <11> <9> <10> RDBK 1
<2> Blower YEBU
Tilt WH
RV <7> BKWH
1
Accessory
1
2P RDWH (rear)
RW <8>
BU WH
1
BNBK
Lift 1 1

6P
Battery GNBK
BUBK
1
1
Lift 2 R

resistant
RDGN BKWH
(48V)
BK Bearing sensor 1

Water
10A
RDYE Connect and start the

4P
RDBK <2> hourmeter countdown.
<Note> 10A
BN BK
1. <n> indicates the lead wire numbers. <13> 2 2
BU Back buzzer
2. Terminal symbols Traction motor(R) <1>
RDBK 2 2
RD

resistant
Pressure

Water
2 : Plug AMP 170020-3
<12>

3P
AMP 170002-5 sensor

resistant
Traction motor(L)

Water
160A

Contactor
1 : Plug AMP 170020-2 (opt.) Steering

resistant
L

Main
: Receptacle AMP 170021-3 RD

Water
2

3P
40A
AMP 170003-5 angle

4P
1 : Receptacle AMP 170021-1 325A
sensor
: Receptacle AMP 41729
Horn switch
7 Bearing sensor
RDBK

resistant
2 2
YEBU 6P

Water
3. When installing the charger panel on the truck body, use (valve lever) 2 2
BK
E
only bolts and spring washers. RD <3> EPS

3P
The reasons why only spring washers sould be used is that LU
they break the coating on the charger panel, enduring Laser pointer switch WH
LV <4> 2P
sensor
conductance between the frame and the charger panel. * Only for trucks with laser pointers WH
LW <5>
BU
4. Alphabets of the connectors indicate printed marks of the
connectors. 2P
<11>
BK H HW 4P Backward output
BK relay
CN1 Board Comp.,
Indicator panel MPU HV
<10>
CN2 (H) 4P Brake output
Lamp 2P WHBK 7 <9>
WH relay
Mode select CN4 CN2 switch WH
BKWH Horn HU
switch Board, 7

display CN1
L LW
<5>
Brake 2P
switch RD
CN1
Board Comp., <4>
CN5
MPU LV
Display CN2 (L)
CN3 <3>
LU
GN GN <8>
1 1 2P R RW Reference:
“K”
BK
Board Comp., MPU EPS CN1 Harness mark/color
Parking brake switch (COM) controller Board Comp., <7> Red RD
resistant

MPU RV Black BK
Water
3P

Key switch CN2 (R) Green

Yellow
GN
YE
<6>
Horn 4P RU
CN1

CN2

CN3

CN4

CN5

White WH
relay WH
+
Brown BN
Blue BU
Charger panel Gray GY
resistant
Water

Pink PK
Directional switch * Only for trucks with built-in chargers
Control
4P

Water Orange OG
2P-X 2P-Y
resistant 10P

Charger,
4P unit Ex) BKWH (=Black/White)
Black colored harness with White line.
resistant

BK
Water

controller
3P

Turn signal lamp switch Power supply 4P

relay BK
“W”
Magnetic Wire, lead(3)
contactor
Horn switch 2 2
RDBK
YEBU Head guard(left) White line
(handle post) 2 2

Harness, short circuit RD RD

RDBK RD 1 1
* Only when a charger is not mounted WHGN
1 1
WH
WH 1 1
BK HL
4P 1 1
Black color
BK RDBK BK
1 1 BK BK
BUYE 1 1
GN Harness, head guard GN
1 1
GN TSL
1 1
Body earth
(* Refer to note 3)
8

FBT-70 Body wiring 14- 2.

54000-67771-0E

143
 WIRING (DIAGRAMS) 14

Harness, BC(2)
Charger panel
2P
BK
Note) 1. Set the specification of the thermal relay to "8.2A".
Socket 4P 2. This diagram shows parts only relevant to the charger (3 400V).
Contactor BK
RD RD RD
1 2
WH WH WH
3 4
BK BK BK
5 6
<C>
<E>
Wire(2), lead
<D> Wire(3), lead

Reference:
Harness mark/color
Red RD Transformer
Black BK
Green GN
Yellow
White
YE
WH
Thermal relay U
4
RD
Brown BN
Blue BU RD RD
Gray GY 1 2
Pink PK V WH
Orange OG WH WH 4
3 4
Ex) BKWH (=Black/White)
Black colored harness with White line. BK BK W BK
5 6 4
* Refer to note 1
RD RD
96 95
White line

Black color
Harness, body

FBT-70 Body wiring (2) 14- 3.

(built-in charger for 3 phase 400V)
54000-28350-0E

144
14 WIRING (DIAGRAMS)

Reference:
<Note>
Harness mark/color 1. Terminal symbols
Red RD * Refer to note 8 1 Sure plug AMP 170020-2
Black BK (with plating) Sleeve(for single wire) 170887-1

RDWH

RDWH

RDWH
To I

To K
To J
Green GN Sleeve(for double wire) 170888-1

R sensor
Yellow YE Accelerator 2 Sure plug AMP 170020-3 or
(without plating) 170002-5
White WH Lead wire
30 Sleeve(for single wire) 170887-1
number : 1
Brown BN Sure receptacle AMP 170021-2
Switch Switch
P1 Q
Foot 1

Blue BU (lamp) P2 (laser pointer)

(with plating) Sleeve(for double wire) 170890-1

RDWH

RDWH
brake Water resistant

RDWH

RDWH
To F1

To F1
To F1

To E2
Plug 6P 3 2 1 Sleeve(for single wire) 170889-1

N relay
Gray GY Horn 6 5 4

Pink PK 5B 4B 83A Point "a" 2 Sure receptacle AMP 170003-5 or

(without plating) 170021-3

S Pressure
Parking
O Valve
V microswitch
1
Orange OG 1 1 J
2B
J
3B
M AMP 174262-2 Sleeve(for double wire) 170890-1
brake 2 2 2
J J Be careful of
sensor To U
BKWH2
To F2
BKWH2
CA relay DC48V
To J To F1 7 Receptacle(with sleeve) AMP 41729
1 2 3 5 6 4 the arrangement
Ex) BKWH (=Black/White) CA Plug Plug Plug
of terminals. Sumitomo 6189-0131
BKWH2
12
BKWH2 Sleeve(for double wire) 1-170823-5
Black colored harness with White line. relay 2P WH 2P BK 2P RD To F1 To F1 Sleeve(for single wire) 170823-2

4
4
4
4
4
BKWH2 BKWH2

(Stopper)
BU
RDYE
BK
WH
GN
Plug 69H 40B
3 1
Water resistant 1 2 3
Lead wire number : 12
2P BK 69I 81C 80B 46B 10C 11B
2
Plug 3P 4 5 6 6 Receptacle AMP 175061-2 or
Plug 1 2 N,P1 U Point "b" 173716-2
O,X M1,X L1,L2 U,L3 V,T3 J
4P WH 3 4 1 2 88B 12I Plug
1 1 2 1 2 1 2 Receptacle AMP 179461-5 or
3
Be careful of 2 6P BK Lead wire number : 24
the arrangement
3 3
3 3 3 3 3 3
U U 170032-5
72J 82A 69G 74B 89B BUWH BUWH

BUBK

RD3
BKWH

WHRD3
WHGN2
BKWH

BK3
of terminals.

BU2
M1,W W M2,O H U
30B 31B 10B To F1
BUWH 18 To F1
BUWH 4 Receptacle AMP 173707-1 or
1 2 1G6 or 4 3 J J J,Q To J To F1 171662-1 or
substitute 1 2 3 27B 28B 29B 172888-2(rubber plug)
3 3 parts 3 3 WHBU WHBU
15 15 15
J J J To F1 To F1 5 Tab AMP 917803-2 or

RDBK
18

YEBU2

BKWH
WHBK3
White line WHBU WHBU 917805-2

RDGN5
YEBK2
BKWH2
1 2 3 4 5 6 To J To F1
3 3 3 3 3 3 Lead wire number : 23 5 Receptacle AMP 179956-2 or
Point "c" 316041-2

BUWH2
WHBU2
BNWH
YEBU
GNWH2
BK3
WHGN2
1 P1,C2 81D
15 Receptacle Sumitomo 1500-0110
RDBK To T4 18 Pressed sleeve JST FNC-1.25
1 W,X 72L RD
To M2
RDWH 18 12 Pressed sleeve JST FNC-2
Black color 1 D 1K RD
To U
RDYE3
1 U,C1 34B RD 30 JST P-5.5
Point "d" RDBK
Lead wire number : 36 2. : Braided wires under 25mm pitch.
1 X,T1 72M Point "d" 3. The pin arrangements are all as viewed from the insertion side.
M2 Charger Clamp the
BKWH

BNBK
1
1 P1,L3

D
69J

70B
To C2
RDBK
To C2
To D
30 RDBK
4. All of the mark bands indicated in this diagram are not necessary for the
finished harness.
RDYE6
horn relay here. GNBK
1 D 71B RDBK To C1 5. When installing the diode, the capacitor and the resistance, solder and
To F2 RDBK
84B F2 1

YEBU
3

RDBK
Plug RDBK cover them with vinyl tube for insulation.
4P BK 85B F2 2 3
RDGN5 Cover with the vinyl tube(BK). Write or impress “M” Lead wire number : 72
RD with undamped ink. Point "e" 6. Fuses should be placed in a circle as shown in the figure below.
36C Point "d"3
Head guard
X (right)
3
1 2 H
I
BKWH M Fuse

L1 Laser
2 2 10A
69F N 4
3 4
3
RDGN4 1 J 79C Plug Pressed sleeve detailed drawing 10A
4 N,T1 N,X
RD3 2P Water
4 2 P2 80A
resistant 82B 72K
Write or impress “L”
L with undamped ink. 8

W
RDGN4
Horn switch
L2
WHGN2 4 1 J 79A Plug
81B C1,P1 1 RD3
2 Lamp (lever)
M1
4 P2 80C 2P Water Clamp
Head 72H F2,M1 1
RDBK
resistant
guard(left) RDBK WHRD3

L3 Level sensor
72I M1,N 1
4 1 P2 46C 7. The capacitor should be soldered to the speed sensor section, as shown
BKWH Plug
BUYE3 4 2 X 69K
38B U,C2 1 2P Water
resistant
in the figure below. The inside of the vinyl tube covering the capacitor
should be filled with silicon adhesive.
83B R
T1 8 GN Vinyl tube Capacitor Vinyl tube
2 1 Full the inside of the vinyl (Non polarized)
tube with silicon adhesive.

YEBU2
GN

BKWH2
WHBU3
WHRD2

GNWH
RDBK

BUYE
BK3
WHBK

RD
RDGN2
BN3

RDGN2

YERD2

WHBU3

BNYE
BUYE3
WHRD2

BUBK
RDYE3

YEBK2
WHRD3

BUGN5
BUBK2

BN3
AMP 174352-2
18
Tie wrap With solder Tie wrap

RDYE4
BKYE
Power supply

BUWH3
WHBU4
BK4
BUYE2

YERD
WHRD
RDGN

WHGN
4 4 4 4 4 4 4 4 4 4

K relay
2 2 1

RD
BKWH2
1 2 3 1 2 3 4 1 2 3
X M
72N 83C
D U J Q Point "d" U Or you can install the heat contraction tube after bonding. However cover
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
12D 39B 9B 10D 36B 47B 6
RDGN2
W
U J J K 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 7 8 9 10 16 17 18 19 20 one side of the lead wire with vinyl tube in order to maintain insulation.
3 1 U T4 32B
82C
YERD2
2 U 33B 4P 1 2
35B 16B 15B 32C K K P2 Point "b",S K T2 J J J I I S D T4
Be careful of the arrangement In addition at the contractile tube, be careful for the lead wire not to be
RDWH
3
Horn switch 32A 33A 46A 12H 37A 39A 21B 18B 20B 41A 43A 88A 45A 47A

T1 (post) of terminals.
E1 1F
BNYE
3 3 Point "a" BK 3 4 Water resistant Water resistant Water resistant
X T2 Point "d" M1 O J J J I I S damaged by the edge of the capacitor.
3 4 U 37B Plug 3P Plug 4P Plug 3P
89B
34A 35A 36A 38A 40A 22B 17B 19B 42A 44A
8. After bonding at terminal P, insulate by the heat contraction tube.
Write or impress “W” W K
CN1 CN2
C2
with undamped ink. 3 2 1 2 1 3 2 1 Control rear In addition even at places indicated to use FNC-2/1.25, you can insulate
4 3
lamp(left) by the heat contraction tube after bonding at terminal P.
19 20 19 20 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 9. Protect by the spiral tube or the corrugated tube.
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11
RD
RDWH

YE
GN

RD
BU

Turn signal Key

T2 T4
17 18 Water resistant
switch switch Plug 6P 3 2 1

U
D buzzer
6 5 4
Directional Display board Accessory
T3
72E 73C 38C
switch
RDYE4
BKYE
WHBU4
BUWH3

WH3
GNBU
BU3

WHBU2
GNWH2
BUWH2
BKWH2

Point "e"
BUYE2
RDYE2
BUBK5

GNWH

WHGN

BNWH
YEBU3
WHBK

WHRD

18
WHBU
BUWH
RDWH

E2 M1
RDGN

AMP 174262-2
YEBU
YEBK

BUYE

YERD
RDYE

81E 72F 68D

BK2

BK4
BK3
BU2

BKWH2
Stopper

Control rear
WH

Write or impress “K”

BN
BK
BU

C1
X Point "e" E1
with undamped ink. 68B 72B 25B 70A 45B
4 4 4 4 4 4 4 4 4 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 1 2 3 4 5 6
C1,E1 C1,D J X U Put the sleeve lamp(right)
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 14 15 6 7 16 8 9 10 11 12 13 17 18 19 20 1 9 2 10 3 11 4 12 5 13 6 7 8 14 15 16 1 2 3 4 5 6 7 8 4 4 4 4 4 4 for sure receptacle.
72C 1J 69A 71A 12E

RDBK
RDBK
U U Point "a" A2 F3 F2

WHGN2

GNWH3
BN4
BUYE3
Point "a" R R A1 T3 Q T3 U U U Point "c" V V L1,L2
V Be careful of the arrangement
1D 3A 5A 7A 9A 11A 15A 17A 19A 21A 23A 27A 29A 31A 79B of terminals. D,Point "e" F3,X E1 X T2,F2
43B 42B 1E 66B 75A 77A BKWH CA1a-DC48V Water resistant

E1
D,E2 69B
U U M2 A2 A2 F3 F2 Point "a"
E2
13A
R
2A
R
4A
A1
6A
A1
8A
V
10A
Point "b" E1
12G 14A
T3
16A
D U
18A 20A
U U
22A
Point "c"
24A 28A
V V
30A
RDWH
3
3
1
2 K,E2 1G
Plug
1 2
Relay 2 2 1 1 1 1 1 1 1 1
WHGN2
RDBK
4 1 M1 81A Plug 6P
25A D 72A
BN4 4P (backward) 4 2

BKWH

GNBK
BUBK2
BKWH2
BNBK
RDBK

RDWH
BN4

YEBU3
RDBK
44B 41B 36D 65B 67B 76A 78A 3 3 D,C2 68C 3 4 RDBK
YEBK BK 4 3 Point "e"72D
Write or impress “1” CN1 CN2 CN3 3 4 J 14B GNWH3
2P-X 2P-Y with undamped ink. 4 4 E2 73A
Water resistant BN4 3 2 1
Receptacle Receptacle BKWH CA1a-DC48V 4 5 D 68A

E2 Relay
EPS E1,F2 69C

I controller
Plug10P 3 1
Plug
RDYE3 4 6 X 34C 6 5 4
GNWH2
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 4 3 2 1 3 3 C1,C2 73B 1 2
RDWH 4P (rear combination)
3 2 E1,F3 1H 3 4
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 8 7 6 5 WH

J
BUBK5
5 4 3 2 1 3 4 J 13B
10 9 8 7 6
MPU board Clamp the relay here. 2 1
4 3
7
Be careful of the Condenser AMP 174257-2
WHBK3 arrangement of terminals. 125V 0.022 F

H Horn
74A N 7 RDGN3
4 1 F1 58B
BKRD2 3
4 F1 59B Water resistant
BUYE4
4 2 F1 60B Plug 4P
F2
69E M2 7
BKWH Point "b" Point "e" WHRD4
4 4 F1 61B
Point "c"
Condenser
100V 22 F
1/2W
120 B Speed sensor

BNRD
RDWH
(* Refer to note 7)
GNRD#
GNRD#

RDYE2
Point "e",
BUWH4

GNRD#

WHRD4
BKWH2

GNBU
BKWH2
BNWH2
WHBK2
BKWH2

WHBU5

RDGN3
BNRD2

BKRD2
BUYE4

BUBK4
BUBK3

WH3
RDYE5
BKYE2
WHBU
BUWH

WHBU5
BNWH2
RDWH

BU3
RDWH

BK2
WHBU
BUWH

BN
RDWH

BUWH
WHBU
BKRD

M2 M1 M2

BNRD
WH2
RD2

RDBK
RDGN5
Write or impress “R” 85A 72G 84A

GN
3 3

YE
with undamped ink. Condenser 1 2
125V 0.022 F 4 4 4 4 4 4
E2,D F1
R 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 3 3

GNRD#
6 6 6

BUBK4
BKWH
BNRD2
BKWH2
RD2 1I 63B
49B F1 1 4 1 2 1 2 3 1 2 3
BKRD 1 2 3 4 5 13 6 14 7 15 8 16 9 10 11 12 1 2 3 4 5 13 6 14 7 15 8 16 9 10 11 12 1 2 3 4 5 13 6 14 7 15 8 16 9 10 11 12 5 5

RD
BU
Water resistant 50B F1 3 4
BUWH4 F1 F1 18 12
Plug 4P 51B F1 2 4
WH2 Be careful of the arrangement Point "a" Point "c" G G Point "b" Point "a" Point "c" G G Point "b" Point "a" Point "c" B B Point "b" F3 1 2 I I J J
52B F1 4 4 57B 62B Plug

BK
I I
Write or impress “L” of terminals. 1C 23B 49A 51A 12C 1B 23C 53A 55A 12B 1A 23D 58A 60A 12A 63A 2P WH 65A 67A 6B 8B
75B 76B
with undamped ink. Condenser F2 Point "c" G G F2 F2 Point "c" G G F2 F2 Point "c" B B F2 F2
8 8 Plug 3 3 3 3 3
I J
125V 0.022 F 48B 24B 50A 52A 87A 48C 24C 54A 56A 57A 48D 24D 59A 61A 62A 64A 2P WH
L 1 2 3 4 5 6

10A
1

10A
RDYE5 I I F1,F1 2P-X 66A 7B
53B F1 1 4 D, Point "b" F1 F1 2

RDYE6
Water resistant 54B F1 3 4
BKYE2 77B 78B Tab
BUBK3 Write or impress “R” Write or impress “L” Write or impress “H” Water resistant Water resistant
Plug 4P 55B F1 2 4 CN.TR CN.TL CN.H 1 12F 87B 48A

BK

BK
WHBK2 2 Plug 3P Plug 3P
with undamped ink. with undamped ink. with undamped ink.

F3
56B F1 4 4
E2,H F1
2 1 69D 64B
Fan
4 3
8 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1
EPS motor E
8 8
Be careful of the arrangement Plug
AMP 174257-2

G Speed sensor of terminals. 16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9 8 3 2 1 3 2 1

6P BK Write or impress “E”
with undamped ink. AMP 174357-2 AMP 174357-2
(* Refer to note 7)
F1 MPU board
1 2 3

F2 fuse
Contactor 4 5 6
A2 EPS sensor A1 potentiometer
Steering

FBT-70 Body harness 14- 4.

54000-68323-0E

145
 WIRING (DIAGRAMS) 14

From above :
terminal, bar, Reference:
fuse and washer From above : Harness mark/color
Red RD
fuse, terminal Black
Green
BK
GN
and washer Yellow
White
YE
WH
Brown BN
Blue BU
Gray GY
6P Pink PK
Orange OG
BK
Ex) BKWH (=Black/White)
Black colored harness with White line.

N91100 N92100 N93100

White line

BKWH
BKWH
BUBK

GNRD

BNRD
Black color

8 8
(Only for trucks with
built-in chager)
P N P N P N 325A 40A 100A
6
2P

2P

2P

BUBK
12P

12P

12P
From above :
bar, fuse and
washer
U U V W U U V W U U V W

W W W (Only for trucks with

built-in chager)

From above :
bar, fuse and bar

<Note>
1. Be sure to wire the terminal connected BNRD line
under the fuse.

FBT-70 Controller wiring 14- 5.

54000-64071-1E

146
14 WIRING (DIAGRAMS)

Put the glass tube to prevent

26 scattering when blowing out.
34 35 34 35 34 35 34 35 34 35
12 33 22 20 23 38 24 12 33 15 5 33 9 6 33 4 32 7 33

25 27 21 28

16

325A 40A 100A

12 33
P N P N P N

34 35

7 8 9A 7 8 9A 7 8 9A
14 31
34 56

34 56

34 56
B CDE

B CDE

B CDE
F 012 F 012 F 012

U V W U V W U V W

13 31 13 31 18 17 19 13 31 17 19 11 30 33 10 31 2 31 3 31 1
29 29 34 35

Washer, Washer, 38 Condensor

Part No. Type 7 Fuse 8 Bar lead(1) 26 Tube, insulate 33
plain
34
lock
35 Nut
Comp., (2) Remarks
For trucks
54000-70640-0 CU106-30 1 piece 2 pieces 1 piece 20 pieces 21 pieces 18 pieces 0 pieces with charger
38 54000-76680 Condensor Comp., (2) EEC 19 39530-02180 Sensor, current HC-TN700V 6 Koshin
For trucks
54000-70010-0 CU106-31 0 piece 1 piece 0 piece 18 pieces 19 pieces 16 pieces 0 pieces without charger 37 54000-64071 Wiring, controller 1 18 54000-60771 Bar, lead(4) 3
36 54000-66351 Harness, contactor 1 17 54000-60761 Bar, lead(3) 6
For trucks
54000-76700-0 CU106-32 0 piece 1 piece 0 piece 18 pieces 19 pieces 16 pieces 3 pieces without charger (EEC) 35 0000-00008 Nut M8 16 54000-60752 Bar, lead(2) 1
34 0000-70008 Washer, lock M8 15 54000-60741 Bar, lead(1) 1
33 0000-72008 Washer, plain M8 14 54000-60713 Bracket, board(2) 1
32 0016-06020 Bolt, w/washers M6-20 2 Cross recessed 13 54000-60700 Bracket, board(1) 3
Condensor Comp.,(2) 31 0016-06012 Bolt, w/washers M6-12 25 Cross recessed 12 24200-63030 Terminal 3
Note) 1. When installing a “ 2 Module, FET” to the “ 1 Sink, heat”, be sure to apply condition 54000-76680 Silicon adhesive agent 30 0016-05012 Bolt, w/washers M5-12 6 Cross recessed 11 24180-00420 Terminal, Comp. 1P 3
compound[G-747] (Shin-Etsu silicones) to the entire cantact surface. 29 0075-04016 Screw, w/washers M4-16 6 10 54000-60840 Bracket, fuse 1
Refer to note 2 P N
28 0075-04010 Screw, w/washers M4-10 4 9 54000-15590 Bar, lead(2) 1
2. Insert washers in the “ 12 terminal”, as shown in Figure A, and then installing the 0070-03008 Screw, pan head 54000-15580 Bar, lead(1)
27 M3-8 5 8
“ 12 terminal”, apply LOCTITE[242] or a similar material to the screws to prevent 26 54000-68660 Tube, insulate 20x30 7 70000-15440 Fuse BNE-100A
looseness. 25 54000-70100 Cover, board 1 6 1995-32023 Fuse BN-40A 1
0.47 F 24 54000-70132 Board Comp., MPU PBC104-42C 1 Hydraulic 5 1995-32015 Fuse BN-325A 1
3. Recommended tightening torque for the FET.
54000-70122 Board Comp., MPU 70000-16930 Plate, fuse 3P-M 1
Main terminal(M6) and mounting(M6) : 3.5-4.5N.m(0.36-0.49kg.m)
23 PBC104-43C 1 Travel(left) 4 Kokonoe
22 54000-70112 Board Comp., MPU PBC104-41C 1 Trevel(right) 3 35810-63421 Contactor HR-404394 1 Hayakawa
4. Use the terminal bolt included for the “FET module”. Figure A 21 54000-70090 Base, board 1 2 70000-56750 Module, FET FM400TU-07A 3 Mitsubishi
5. Fix the Condensor Comp.,(2) to the FET module by a silicone adhesive agent not to U V W 20 54000-67731 Capacitor Comp. KMH80VNSN5600M35E 1 Nippon Chemi-con 1 54000-60813 Sink, heat A6063 1
remove by the vibration. Figure B SYM PART NO. PART NAME SIZE MATERIAL QTY MASS REMARKS

FBT-70 Main controller 14- 6.

E0000-12802-0E

147
 System wiring
RDBK

NOTE）１．Symbol of terminal
1 Sure plug
Key SW Sleeve (for single wire) AMP 170020-3
X4 X1
RDWH Sleeve (for double wire) AMP 170002-5
Sure plug AMP 170020-2
1 Sure receptacle
Sleeve (for single wire) AMP 170021-3
Sleeve (for double wire) AMP 170003-5
Sure receptacle AMP 170021-2

Reference:
Harness mark/color
Red RD
Black BK
Green GN
Revolving
Yellow YE

Battery
lamp
White WH
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG

BKWH Ex) BKWH (=Black/White)

Black colored harness with White line.

VKF 1.25mm2 2 pieces

FBT-70 Wiring, lamp

White line

Black color
BK BKWH
BK To harness, body
Revolving
lamp WH
WH RDWH
To harness, body
Install on the
head guard
Accessory

24800-89010-0E
WIRING (DIAGRAMS) 14

14- 7.

148
 Reproduction prohibited
First printing : July 2005

Issued by : Nippon Yusoki Co., Ltd

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