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INTRODUCTION sMost accident happens due to the disregard of basic safety rules or precautions. In order to prevent accidents, the factors which may cause accidents must be avoided beforehand. For this reason, please read this manual and fully understand the precautions for safety and the proper procedures and directions for inspection and maintenance before starting operation. Performing maintenance and repair without adequate knowledge may cause inadvertent accidents. sIt is not possible to cover all the possible cases of accidents in this "SERVICE MANUAL". Therefore, attention should be given to precautions other than the ones mentioned in this "SERVICE MANUAL". Especially, when repair and maintenance work which are not covered in this "SERVICE MANUAL" are carried out, always work under the direction of an instructor who understands the matter.
See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters that are not contained in this manual.
USING THE "SERVICE MANUAL" This Service Manual will give explanation on how to maintain and inspect NICHIYU forklift trucks of FBT-67 series. Since the parts used in this machine are subject to change for the sake of better quality, performance enhancement, and safety, some portions of the contents and illustrations of the "SERVICE MANUAL" may not be identified. Directions with and marks are very important, and must be followed.
DANGER
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. You shall observe this instruction.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. You shall observe this instruction.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. You shall observe this instruction.
NOTE
Indicates suggestions, tips and hints related to the safety of a operator and maintain of truck.
1. Personnel this "SERVICE MANUAL" is aimed at: This "SERVICE MANUAL" is directed at personnel who possess sufficient knowledge and technical expertise. If you do not understand any of the contents of this "SERVICE MANUAL", perform operation under the guidance of personnel who does.
2. Conditions of a facility The work conditions described in the "SERVICE MANUAL" are written on the assumption that the work is performed at a shop where standard facilities and tools for the maintenance of NICHIYU ELECTRIC LIFT TRUCKS are available. For safe and reliable maintenance, the work should be performed at a shop where the facilities are equivalent to these described in the "SERVICE MANUAL" or better, and the instructions described should be strictly followed.
Copyright© 2000 NIPPON YUSOKI CO., LTD. All Rights Reserved
CONTENTS See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters whose pages are not mentioned in the "Contents".
SAFETY WORK
1
1. Precautions related to safe inspection and maintenance work ....................................1 Conditions of a shop (location) for inspection and maintenance Work clothing Tools and gauges Safety work Parts Repair of electrical components Hydraulics Tightening torque
3. REAR AXLE (STEERING) 3-1. Disassembling and assembling 3-2. Adjustment 3-2-1. Micro switch adjustment
1 2 2 2 3 3 4 4
2. Location of safety labels..................................5 3. Model name and serial numbers .....................9 4. Cautions for maintenance..............................11 5. Tightening torque of bolts ..............................14 6. Stability of forklift truck ..................................15 7. Load center and load chart............................15
3-3. Precautions during assembling
4. TIRE
21
4-1. Front tire.....................................................21 4-1-1. Disassembling and assembling 4-1-2. Tire size (Front)
21 21
4-2. Rear tire .....................................................22 4-2-1. Disassembling and assembling 4-2-2. Tire size (Rear)
22 22
5 .STEERING LINKAGE 1. GENERAL
18
1-1. Appearance................................................18 1-2. Specifications .............................................19
5-1. Disassembling and assembling
6 .BRAKE LINKAGE 6-1. Foot brake
2. FRONT AXLE (DRIVE) 2-1. Front axle ass'y 2-1-1. Disassembling and assembling 2-1-2. Adjustment
2-2. Front axle comp. 2-2-1. Disassembling and assembling 2-2-2. Adjustment
6-1-1. Disassembling and assembling 6-1-2. Master cylinder adjustment 6-1-3. Brake pedal adjustment
6-2. Parking brake 6-2-1. Disassembling and assembling of parking brake 6-2-2. Disassembling and assembling of disk brake
6-3. Inspection and adjustment 6-3-1. Inspection of pad ass'y 6-3-2. Inspection of wheel cylinder 6-3-3. Micro switch adjustment
See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters whose pages are not mentioned in the "Contents".
7. HYDRAULIC SYSTEM
23
10. MOTOR (TRACTION, HYDRAULIC, EPS)
7-1. Valve linkage 7-1-1. Disassembling and assembling 7-1-2. Micro switch adjustment 7-1-3. Lift (Fast) micro switch adjustment
10-1. Disassembling and assembling 10-1-1. Traction motor 10-1-2. Hydraulic motor 10-1-3. Eps motor
7-2. Control valve 7-2-1. Disassembling and assembling 7-2-2. Relief pressure adjustment
10-2. Inspection
7-3. Oil tank 7-3-1. Disassembling and assembling 7-3-2. Fork oil and quantity
7-4. Oil pump.....................................................23 7-4-1. Disassembling and assembling 7-4-2. Gear pump type
23 23
10-2-1. Armature comp. 10-2-2. Carbon brush, carbon brush holder and spring 10-2-3. Field coil 10-2-4. Motor ass'y 10-2-5. Oil seal and permanent magnet
11. ELECTRIC PARTS 8. CYLINDER
24
8-1. Lift cylinder .................................................24 8-1-1. Disassembling and assembling
24
8-2. Tilt cylinder .................................................26 8-2-1. Disassembling and assembling
9. MAST 9-1. Disassembling and assembling 9-1-1. Simplex mast 9-1-2. Triplex mast
9-2. Inspection and adjustment 9-2-1. Clearance between roller and mast 9-2-2. Mast, lift bracket, and roller shaft 9-2-3. Back shoe 9-2-4. Lift chain 9-2-5. Chain bolt 9-2-6. Chain wheel 9-2-7. Hose pulley 9-2-8. Roller 9-2-9. Fork
27
26
11-1. Location and name...................................27 11-2. Control unit ...............................................28 11-2-1. Location and name 11-2-2. Hydraulic contactor 11-2-3. Disassembling and assembling 11-2-4. Precautions during inspection and replacement
28 29 29
11-3. Forward/backward contactor ....................30 11-3-1. Disassembling and assembling 11-3-2. Fuse replacement procedure 11-3-3. Disassembling and assembling Fwd/Bwd contactor (M1, M2, M3, M4)
11-4. Accelerator 11-4-1. Removal and installation of accelerator linkage 11-4-2. Configuration and feature of accelerator 11-4-3. Adjustment procedure of accelerator linkage
11-5. Indicator panel & directional switch 11-5-1. Disassembling and assembling of indicator panel 11-5-2. Disassembling and assembling of directional switch
11-6. Battery 11-6-1. Disassembling and assembling 11-6-2. Inspection of battery 11-6-3. Cleaning
11-7. Charger panel 11-7-1. Disassembling and assembling 11-7-2. Power tap switching procedure
30 31 32
See the "FBT-65 SERVICE MANUAL" (00W-2101) for the chapters whose pages are not mentioned in the "Contents".
12. LASER POINTER
33
14. SERVICE DATA AND WIRING (DIAGRAMS)
38
12-1. Adjustment ...............................................33 12-1-1. Fork level - adjustment 12-1-2. Laser optical axis - adjustment
13. TROUBLESHOOTING
33 33
34
13-1-1. Change from FBT-67 13-1-2. Checking operation of auto power off function 13-1-3. Checking display of warning for battery electrolyte level 13-1-4. Wiring connection of hour meter operation
14-5-1. With Regen. 14-5-2. Without Regen.
13-2-1. The name and function of mode select switch 13-2-2. How to set the each mode 13-2-3. Adjustment of starting current and current limitation 13-2-4. Adjustment of other specifications 13-2-5. Check and adjustment for other functions
13-3. New eps system 13-3-1. Auto power off function 13-3-2. Checking and adjustment
13-4. List of settings for FBT-67 ........................34 13-5. Setting of volume and rotary switch .........35
13-6-1. Self diagnosis history memory 13-6-2. I/o check 13-6-3. Analysis of fault cause
39 40
42 43
14-6. FBT-67 Control unit wiring........................44 14-7. FBT-67 Main controller ass'y....................45
13-2. How to adjust new SICOS60 (Major point only)
13-6. Self diagnosis history memory and check and i/o check
14-3-1. With Regen. 14-3-2. Without Regen.
14-4. FBT-67 Body harness ..............................41 14-5. FBT-67 Control unit harness ....................42
13-1. Outline of FBT-67
13-5-1. Volume 13-5-2. Rotary switch
14-1. Standard work hours 14-2. FBT-67 System wiring ..............................38 14-3. FBT-67 Body wiring..................................39
35 35
SAFETY WORK 1.
Precautions related to safe inspection and maintenance work Conditions of a shop (location) for inspection and maintenance
CAUTION
Facilities with adequate space and level surfaces: ¡The floor area of the shop (location) where inspection and maintenance are performed must have adequate floor space, and have level surfaces without holes. aIf these conditions are not met, unexpected accidents, such as a roll-over of the forklift truck, may result.
CAUTION
WELL-VENTILATED AREA ¡Work such as welding painted components or sanding down coated parts should be carried out in well-ventilated areas. aIf this is not observed, harmful toxic gas or dust may be inhaled.
CAUTION
LOCATION EQUIPPED WITH EXTINGUISHING EQUIPMENT
FIRE
¡ Equipment such as first-aid boxes and fire extinguishers should be nearby when work is performed.
CAUTION
SAFE AND WELL-LIGHTED AREA ¡The work area should be safe and well lighted. When working inside the machine or underneath of it, always use a safety lamp with a shielded light bulb. aIf this is not observed, leaked oil may catch fire when a light bulb pops.
CAUTION
PROPER ARRANGEMENT ¡Arrange and clean always at a working place to work safety. ¡Especially, arrange disassembled parts well.
1
SAFETY WORK
Work clothing CAUTION
¡The worker should wear a hat, work clothes, and safety shoes that are suitable for safe work. The work clothes should be close-fitting. a If this is not observed, loose clothing may become caught in a machine, resulting in serious injury.
Tools and gauges CAUTION
¡Always use tools that are suitable for the work being performed. Use proper size tools when tightening and loosening the parts of the forklift truck. aFailure to observe the above could result in serious injury or damage to machines.
CAUTION
Prepare tools and gauges before starting to work.
Safety work WARNING
¡ When hoisting a forklift truck or a heavy component, use ropes or cable with correct capacity. ¡Do not use ropes or cables which are kinked.
WARNING
After lifting or jacking up a forklift truck, support it with safety blocks or rigid stands.
WARNING
Prevent tires from moving with wheel chocks etc.
WARNING
When working under a forklift truck, use a pit or proper safety precautions.
2
SAFETY WORK
Parts CAUTION
When replacing any parts, be sure to use NICHIYU genuine parts.
CAUTION
When replenishing battery electrolyte, be sure to use refined or distilled water.
Repair of electrical components CAUTION
Be sure to disconnect the battery plug when replacing electrical component.
CAUTION
Be sure to jack up the drive wheel when trouble shooting electrical operations.
NOTE
Record the places of lead wire connection when disassembling.
CAUTION
CHARGING BATTERY ¡ Batteries produce flammable gas during charging. Do not allow batteries in the vicinity of fire or flames. aFailure to observe the above could result in an explosion.
CAUTION
3
¡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.
SAFETY WORK
Hydraulics CAUTION
When removing the hydraulic pipes, cap them to prevent dust from entering into the hydraulic components and pipes.
CAUTION
When disassembling and assembling the hydraulic components, work at clean place and do not damage the parts.
Tightening torque CAUTION
Observe tightening torque specified in this manual. If not specified, refer to the table [Tightening torque for bolts]. aSee page 15
4
SAFETY WORK
2.
Location of safety labels The illustration below shows the location of safety labels for safe operation. Always protect the safety labels from contamination and damage. If they are damaged or lost, replace with new ones.
1 7
2 Name plate (page 9)
1 8
3
9 10
4 5
11
6 215W011E
No.
Parts No.
Parts Name
Q'ty
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
24700-09410
Label, Tire
2
Air pressure (bar) FBT18P
4
24700-04830
Plate, Warning
1
Precaution for Safety Operation
5
0902-68434
Plate, Lubrication
1
Lubrication
6
24700-01780
Plate, Caution
1
Operation of Gas spring lock
7
24700-01850
Plate, Caution
1
Caution for Braking
8
0902-68384
Plate, Precaution
1
Precaution for Safety Operation
9
0902-69794
Plate, Caution
1
No riding except Operator
10
38540-00630
Label, Caution
1
Caution for battery
24700-09410
Label, Tire
1
Air pressure (bar) FBT13, 15P
0902-69954
Label, Tire
1
Air pressure (bar) FBT20PN
3
11
5
Notes
SAFETY WORK
1
6977F
3 (For EEC) (FBT13, 15P)
2
(FBT18P)
(For pneumatic tire only)
6981F
4 Do Not Jump ! Fasten Seatbelt
WARNING
Truck can TIP OVER ! Risk of serious INJURY or DEATH
FOR SAFETY NOTICE FOLLOWING WARNINGS 1. Lateral tipover can occur when unloaded if the combination of speed 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 load is elevated and if turning and / or braking when traveling rearward or if turning and / or accelerating when traveling forward produces an overturning moment which exceeds the stability of the truck. Rearward tilt and / or off-center positioning of the load and / or uneven ground conditions will further aggravate the above conditions. 3. Longitudinal tipover can occur if overloaded or when loaded within capacity and the load is elevated if forward tilt. braking in forward travel. or commencing rearward travel produces an overturning moment which
Lean Forward Hold On Tight Brace Feet
Lean Away From Impact
IN CASE OF TIPOVER exceeds the stability of the truck. 4. Serious injury or death can occur to the operator if he / she is trapped between the truck and the ground.
IN CASE OF TIPOVER 1. The operator should stay with the truck if lateral or longitudinal tipover occurs. The operator should hold on firmiy and lean away from the point of impact. 2. The operator should stay with the truck if it falles off a loading dock or ramp. There are other situations where the environment of the landing area presents a severe hazard. In those incidents. it may be prudent for the operator to leave the truck. 24700-04830
6
SAFETY WORK
5
8
6
PRECAUTIONS FOR SAFETY OPERATION
24700-01780
7
1. DO NOT OVERLOAD. OBSERVE ALLOWABLE LOAD (BLUE ZONE). 2. PRIOR TO OPERATION, CHECK PERFORMANCE 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. 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 REPLENISH WATER. 8. BE SURE TO USE THE PRESCRIBED FUSES. 6838 F
Apply parking brake before leaving truck. Make adjustment to provide adequate braking. 24700-01850
7
SAFETY WORK
9
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. (When electrolyte decreased, fill purified water 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 do not use the battery at overdischarged condition. 3. Keep the surface of battery clean and dry.
(EX.) VENT PLUG White line
FLOAT
11 (For EEC) (FB13, 15P)
(FB18P)
(For pneumatic tire only)
8
SAFETY WORK
3.
Model name and serial numbers Model name ¡Name plate
(For Standard) LOAD CHART
MODEL
LIFT HEIGHT
mm mm
SERIAL NO.
kg /
mm
kg /
mm
CAPACITY kg
mm MAXIMUM LOAD/LC LIFT HEIGHT
MFG. YEAR
SERVICE WEIGHT W/O BATTERY
kg
BATTERY WEIGHT MIN.
kg
VOLTAGE MAX.
LOAD CENTER mm
V kg
50001-60560
(For CE) LOAD CHART
MODEL
LIFT HEIGHT
mm mm
SERIAL NO.
kg /
mm
kg /
mm
CAPACITY kg
mm MAXIMUM LOAD/LC LIFT HEIGHT
MFG. YEAR
SERVICE WEIGHT W/O BATTERY
kg
BATTERY WEIGHT MIN.
kg
VOLTAGE MAX.
T
LOAD CENTER mm
V kg
50001-32831
T : Three wheels
Capacity code
13 : 1250kg 15 : 1500kg 18 : 1750kg 20 : 2000kg
Classification of tire
P : Pneumatic tire PN : Pneumatic cushion tire PC : Cushion tire B : Large capacity battery equipped C : Stationary charger
Lift height [cm] Mast type
D : Dust resistant
NO CODE : Two stage full visibility (simplex) mast M : Three stage full free lift (triplex) mast (Full visibility mast) PFL : Full free lift (duplex) mast (Full visibility mast) CS : Cold storage use for -35: WB : Wide bar lift bracket : Attachment Z : Special type
9
SAFETY WORK
Serial numbers No.
Serial numbers
Stamped position
1
Serial No. of a truck
Stamped on the name plate.
2
Serial No. of a chassis
Stamped on the battery compartment.
3
Serial No. of a mast
Stamped on the mast name plate.
4
Serial No. of a front axle
Stamped on the front axle.
5
Serial No. of a traction motor
Stamped on the motor name plate.
6
Serial No. of a hydraulic motor
Stamped on the motor name plate.
7
Serial No. of a EPS motor
Stamped on the motor name plate.
8
Serial No. of lift cylinders
Stamped on the lift cylinders.
¡Serial numbers
8 3 1 4 6 7 5
2
215W012E
10
SAFETY WORK
4.
Cautions for maintenance General precautions ¡When replacing any parts, be sure to use genuine NICHIYU parts. ¡ When parts are assembled, always replace old packing and O-rings with new ones. In addition, be sure to apply a light coat of grease on the O-rings and oil seals before installing them. ¡As shown in the illustration, face the flat side of the Cshape retainer in the direction the force is applied when installed.
Retainer for a groove
Retainer for a hole
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, observe the direction of installation.
Oil grooves
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 made, repair the area using an oil stone.
Scraper
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.
2.Cut
the nozzle of the liquid gasket tube at about the second section so that the bead width will be 3 to 3.5 mm.
Cut the nozzle at the second section 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. When applying the liquid gasket to bolt holes, apply it on the internal portion of the mating surface.
Not Good 3 -3.5 mm Key to evacuate liquid packing Good
4.Close
the mating surfaces within 15 minutes after the liquid gasket is applied.
152E107
Apply liquid packing Within 15 minutes
5.When
tightening the bolts, always tighten temporarily first, and then tighten them gradually, moving from one to the next in a diagonal pattern.
6.Wait
for more than 30 minutes before adding oil or operating the machine. * Failure to do so may cause oil leakage.
Assembly Wait for 30 minutes or more Filling oil/Operation
12
SAFETY WORK
¡ Deterioration of liquid packing
1.Once
the tube has been opened, the liquid gasket anchoring the tip part of the nozzle might be cured and deteriorated. Squeeze out that portion and discard it before reusing the gasket.
* If the oil has separated, the packing has deteriorated. Squeeze out the bead about 20 mm and check.
152E108
2.If oil (filler) was separated from the liquid gasket and the gasket appears shiny when it is squeezed out, this indicates that the liquid gasket has deteriorated. * Although the oil may have been separated from a liquid gasket opened before its expiration date, this is not an indication of deterioration.
CAUTION
13
If the state of the gasket is normal, it will be cured within approximately 2 hours. However, a deteriorated gasket will not.
SAFETY WORK
5.
Tightening torque for bolts Classification of bolt
4T
8T
Brass
Stainless
Material of bolt
SS400
SCM435 (S55C)
BsBM2S-0
SUS304
Nominal of bolt (mm)
Pitch *1
M3
0.5
0.6 {0.06}
1.3 {0.14}
0.4 {0.04}
0.5 {0.05}
M4
0.7
1.4 {0.14}
3.2 {0.33}
1.0 {0.10}
1.0 {0.11}
M5
0.8
2.7 {0.28}
6.4 {0.66}
1.8 {0.19}
2.0 {0.21}
M6
1.0
4.7 {0.48}
10 {1.1}
3.1 {0.32}
3.6 {0.37}
M8
1.25
11 {1.1}
26 {2.7}
7.8 {0.80}
9.0 {0.92}
M 10
1.25
22 {2.3}
55 {5.7}
15 {1.6}
18 {1.9}
M 12
1.25
39 {4.0}
98 {10}
29 {3.0}
33 {3.4}
(M 14)
1.5
62 {6.3}
150 {16}
47 {4.8}
53 {5.4}
M 16
1.5
97 {9.9}
240 {25}
73 {7.5}
81 {8.3}
M 20
1.5
180 {19}
500 {51}
140 {15}
150 {16}
(M 22)
1.5
250 {26}
670 {69}
200 {21}
220 {23}
M 24
2.0
320 {33}
840 {86}
250 {26}
280 {29}
M 30
2.0
640 {66}
1600 {170}
530 {54}
570 {58}
Tightening torque *2
Unit : N m{kgf m}
(mm)
*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
Stability of forklift truck As shown in the figure, the counterbalanced forklift truck will balance on its drive wheel with a full rated capacity load on the forks. Consequently, careful attention should be paid to the load center so that truck does not unbalance. If a load should exceed the rated capacity of truck, or the rated load center, the rear steer tires will lift off the ground and the possibility of toppling the truck exists.
7.
Load center and load chart Distance from the center of gravity of a load on the forks to the surface of the truck is called load center. The LOAD CHART shows the relationship between load center and load capacity of the truck. Do not drag forks to the floor, lift up forks 150-200mm above floor when traveling with mast tilted backward fully. When traveling, do not lifting and tilting forward. This could cause overturn by changing the center of gravity for the load.
1200
Capacity (kg)
1100
FBT13P
1500 3700mm
4000mm
1400 4000mm
4500mm
1300
1000 900 5000mm 800 700
1800
1100
5000mm
1000 900
700 600
500 600 700 800 900 1000 Load center (kg)
FBT18P
500 600 700 800 900 1000 Load center (kg)
FBT20PN
2100
3500mm
1600 4000mm
2000 4000mm 1900 4300mm
1500
1800 4500mm
1400 4500mm
1700 4700mm
1300 1200 5000mm 1100
Capacity (kg)
1700
Capacity (kg)
4500mm
1200
800
600 500
FBT15P
1600
3700mm
Capacity (kg)
1300
1600 5000mm 1500 1400
1000
1300
900
1200
800
1100
700
15
Load center
500 600 700 800 900 1000 Load center (kg)
1000
500 600 700 800 900 1000 Load center (kg)
Bwd
Fwd
150-200mm
6.
SAFETY WORK
CAUTION
1) Completely insert the forks beneath the loading object. 2) Applying too much load on the front portion of the forks exerts force beyond expectation and this may cause damage to the mast and forks even if the load does not exceed the maximum allowable weight. 3) If the load is off-centered, it not only exerts force beyond expectation on the truck, but also causes a side slide of the loading object. Thus, off-centered loads in a lateral orientation should be avoided as well. 4) When loading an object, operate the valve lever carefully. 5) Abrupt operation during high stacking exerts great impacts on the truck, and may result in a tip over accident.
16
SAFETY WORK
MEMO
17
1. GENERAL 1- 1. Appearance 2 FRONT AXLE 3 REAR AXLE 4 TIRE 9
5 STEERING LINKAGE
8
6 BRAKE LINKAGE *1
7 HYDRAULIC SYSTEM
6 7
2
10
3
8 CYLINDER 9 MAST 10 MOTOR
4
11 ELECTRIC PARTS (*2)
5 4
10
12 LASER POINTER 13 TROUBLE SHOOTING 14 SERVICE DATA AND WIRING (DIAGRAMS)
*1 : "ACCELERATOR LINKAGE" : See FBT-65. *2 : 11. ELECTRIC PARTS : See page 27. 461E121
18
1 GENERAL
895 (Seat height)
1- 2. Specifications
461E132
19
GENERAL 1
Model kg
Rated capacity
FBT13P
FBT15P
FBT18P
FBT20PN
1250
1500
1750
2000
300
265
Load center
A mm
500
Lift height
B mm
3000
Free lift
C mm
120
Lifting
Laden
mm/s
speed
Unladen
mm/s
Tilt angle
350
330 540
465
Forward
D
5
Backward
E
6
Travel
Laden
km/h
13.5
13
12.5
11
speed
Unladen
km/h
15.5
15
14.5
13
Minimum turning radius
F mm
1400
1500
1545
1695
Overall length
G mm
2830
2930
2975
3155
Overall width
H mm
1070
I mm
4000
Mast lifted Height Mast lowered
J mm
1970
1960
Overhead guard K mm L mm
Wheelbase Tread (Front/Rear) Service weight (Incl. battery)
kg
Rear
1420
895/250 2800
895/230
2970
3180
18 X 7-8-14PR X 2
Pneumatic cushion
18X7-8-16PRX2
18X6X12 1/8X2 15X4(1/2)-8-12PRX2
Pneumatic
16X6-8-10PRX2
15X4(1/2)-8X2
Pneumatic cushion
16X6-8
Control system (Travel/Hydraulic)
FET chopper
Traction
3.5X2 (60min)
Motor
Hydraulic
kw
EPS Battery (48V)
3560
18X7-8X2
Cushion
Tires
1300
1200
mm
Pneumatic Front
1985
Ah/5HR
320
8.8 (5min)
9.6 (5min)
0.3 (60min)
0.45 (60min)
350
390
Automatic stationary charger (3 phase 200V) Charger kVA
5.2
6.4 *Subject to change without notice for improvement.
20
4. TIRE 4- 1. Front tire 4-1-1. Disassembling and assembling
Tire
Rim, wheel
Rim bolt and Nut
Tightening torque FBT13P-18P
88.2-108 N
{9-11 kgf * 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 FBT13P, 15P
21
Size 18x7-8-14PR (18x7-8 SOLID : OPTION)
FBT18P
18x7-8-16PR (18x7-8 SOLID : OPTION)
FBT20PN
18x7-8 SOLID
Specified air pressure bar (kgf/cm2) 8.8 (9.0) 9.8 (10.0) -
m m}
TIRE 4
4- 2. Rear tire 4-2-1. Disassembling and assembling ¡FBT13P-18P
Tightening torque 68.5-78.5 N
Rim bolt and Nut
{7-8 kgf
m
m}
Tightening torque 88.2-108 N
Hub bolt and Nut
{9-11 kgf
m m}
461E036
¡FBT20PN
Rim bolt and Nut
Tightening torque 88.2-108 N {9-11 kgf
m m}
Tightening torque Hub bolt and Nut
216-264 N
m
{22-26.9 kgf
: Tightening torque
m}
461E032
4-2-2. Tire size (Rear) Size
Model
Specified air pressure bar (kgf/cm2)
FBT13P, 15P
15x4 1/2-8-12PR
9.8 (10.0)
FBT18P
15x4 1/2-8 SOLID
-
FBT20PN
16x6-8-10PR
8.3 (8.5)
22
7. HYDRAULIC SYSTEM 7- 4. Oil pump 7-4-1. Disassembling and assembling Hydraulic motor
Bracket, motor
Cushion (1) Pump, gear
Coupling, pump Fill molybdenum grease up
MG : Apply molybdenum grease 461E042
7-4-2. Gear pump type Model
23
Type
FBT13-18P
TMG1-17
FBT20PN
DSG 05-18
MG
8. CYLINDER 8- 1. Lift cylinder 8-1-1. Disassembling and assembling ¡Main parts of lift cylinder for STD (simplex) mast Valve, check Bushing
Head, cylinder
Bearing, cushion Ring, snap Spacer
Gasket Plug
Rod ass'y, piston
Tube ass'y, cylinder
215W008E
¡Main parts of lift cylinder for STD (simplex) mast of RP, and lift cylinder 2nd for M (triplex) mast
Head, kit Kit, repair Spacer
Cylinder ass'y, lift
Rod ass'y, piston
Bushing Bearing, cushion Ring, sanp 461E018
24
8 CYLINDER
¡Main parts of lift cylinder 1st for M (triplex) and PFL (duplex) masts Valve, check Plate
Head, cylinder Bearing, cushion Ring, snap Plug Gasket
Tube ass'y, cylinder Rod ass'y, piston
Valve, down safety Plug 221W018E
¡Main parts of lift cylinder 2nd for PFL (duplex) mast
Ring, slide Valve, check Ring, snap Holder
Spool, cushion Spring
Tube ass'y cylinder Rod(L), piston Ring, wear (MLH4300-5000) Spacer (MLH4300-5000) Ring, snap Piston
Ring, slide Valve, check Ring, snap Spool, cushion
Holder
Spring
Tube ass'y cylinder
Rod(R), piston Ring, wear (MLH4300-5000) Spacer (MLH4300-5000) Ring, snap Piston
121W071E
CAUTION
25
¡Care should be taken when installing packings and seals. Apply grease on them. ¡Also apply a liberal amount of grease on the ground portion.
CYLINDER 8
8- 2. Tilt cylinder 8-2-1. Disassembling and assembling B
head, cylinder Apply THREEBOND[#1344] on the threads when tightening. Nipple,grease Head
Tightening torque
Head
FBT13P-18P FBT20PN
490 {50
75 N 7.5 kgf
m m}
490
49 N
m
{50
5 kgf
m}
Head, cylinder
Bushing
Washer Ring, snap
Spacer Seal, KIT Piston Rod ASS'Y, piston Cylinder sub ASS'Y
Bushing
Tightening torque FBT13P-18P : Tightening torque B : Apply THREEBOND N : Not reusable
FBT20PN
343
49 N
m
{35
5 kgf
m}
735
74 N
m
{75
7.5 kgf
m}
215W001E
26
11. ELECTRIC PARTS 11- 1. Location and name ¡ Accelerator
¡ Indicator panel
a See FBT-65
a See FBT-65
¡ Directional switch
¡ Battery
a See FBT-65
¡ Charger panel
a See FBT-65
a See FBT-65 ¡ Front contactor Fwd/ Bwd
a See page 30 ¡ EPS controller CU101-60 (48V/30A) ¡ Rear contactor By-pass, Regenerator
¡ Control unit CU101-51, 52 ¡ EPS contactor
a See page 31
¡ MPU board
a See FBT-65
a See page 31
a See page 28 215W002E
27
ELECTRIC PARTS 11
11- 2. Control unit 11-2-1. Location and name ¡CU101-51(with Regenerative function) ¡CU101-52 9. Sensor comp., current
* Terminal
1. Contactor Hyd. (M7)
3. Diode Plugging (D2) 2. Diode Flywheel (D1)
7. FET comp. Travel
5. Diode * Hyd. flywheel (D4) 8. Capacitor
4. Diode Regenerative (D3) 6. FETcomp. Hyd.
11. Board comp., printed 461E105
10. Board comp., MPU
12. Resistor comp.
No,
NOTE
Name
Remarks
1
Contactor
Hyd. (M7)
2
Diode
Flywheel (D1)
3
Diode
Plugging (D2)
4
Diode
Regenerative (D3)
5
Diode
Hyd. flywheel (D4)
6
FET comp.
Hyd.
7
FET comp.
Travel
8
Capacitor
100V, 2200
9
Sensor comp., current
10
Board comp., MPU
11
Board comp., printed
12
Resistor comp.
F
PB83-64
¡This illustration should be used for FBT-67 Regenerative function. ¡Therefore, the parts of 4, 111, 12, and *marked terminal should be used for only the truck with Regenerative function.
28
11 ELECTRIC PARTS
11-2-2. Hydraulic contactor Coil resistance
Contactor Hydraulic (M7)
51
- 54.5
11-2-3. Disassembling and assembling C
FET comp. Apply conductive compound TSK550 (Toshiba Silicones Co., Ltd) on all surfaces between the "FET comp." and the insulator sheet, and between the insulator sheet and the base.
FET comp. (Travel)
C
Diode
Apply conductive compound TSK550 (Toshiba Silicones Co., Ltd) on all surfaces between the "Diode" and the heat sink, between the heat sink and the insulator sheet, and between the insulator sheet and the base.
FET comp. (Hyd.)
Tightening torque Plugging diode (D2)
9.5-12.5 N {9.7-127 kgf
m m}
Base
Hyd. contactor (M7)
Heat sink Plugging diode (D1) Hyd. flywheel (D4)
Board comp., printed (w/Regen.)
Tightening torque (M8 terminal)
Heat sink
8.75 N
m
10%
89 kgf
cm
10%
Only the truck with Hyd. chopper
Tightening torque Bracket (1), MPU board : Tightening torque
Regenerative diode (D3) (w/Regen.)
9.0-11.0 N
m
{92-112 kgf
m}
C : Apply compound 215W009E
29
ELECTRIC PARTS 11
11- 3. Forward/backward contactor Coil resistance
Contactor Forward/Backward (M1,M2,M3,M4)
34
By-pass (M5)
54
Regenerative (M6)
54
11-3-1. Disassembling and assembling s1 Forward/backward contactor
Base, contactor Cushion
Contactor (M3, M4) (See 11-3-3)
M3 M4
M2 M1
Contactor (M1, M2) (See 11-3-3)
Harness, contactor
Harness, CU 215W003
30
11 ELECTRIC PARTS
s2 Bypass, EPS, and regenerative contactor
Frame Regenerative Contactor (M6)
Tightening torque (M8 terminal) 8.75 N
m
10%
{89 kgf
m
10%}
Bypass Contactor (M5)
Bracket, contactor
Fuse ass'y (See 11-3-2) EPS Contactor (M8) Apply grease
G
: Tightening torque G : Apply grease 461E011
11-3-2. Fuse replacement procedure The battery plugs must be disconnected.
CAUTION 1. 2. 3. 4. 5.
Fuse 40A (for EPS) Fuse 40A (for Hydraulic) Fuse 40A (for Travel) Cartridge fuse 10A (for control circuit) Cartridge fuse 10A (for accessory) 1
Type Fuse Cartridge fuse
Replacement procedure Loosen the fixing nuts and remove
3
the fuse.
4
Open the glass case and remove the
5
cartridge fuse.
If the nuts are not properly tightened, contact failure could result. causing malfunctioning.
CAUTION 31
2
Use only the specified fuses.
215W010E
ELECTRIC PARTS 11
11-3-3. Disassembling and assembling Fwd/Bwd contactor (M1, M2, M3, M4) ¡MSW44-23 (*2) Contact 2. Fitting bolt
1 Contact surface Apply a little grease with molybdenum disulfide.
MG
Fitting bolt (*2)
4. Solenoid 4. Core
3. Spring, return
1. Holder
(*2) Fitting nut
1. Spring 1. Holder
3. Armature
(*1) Pin, cotter 1. Contact comp.
MG : Apply molybdenum grease 215W004E
s1 Description of disassembling procedure 1. Remove the "pin, cotter" (*1), holders and the spring to remove the "contact comp.". 2. Remove fitting bolts and nut (*2) to remove the contact. 3. Remove the "spring, return" to remove the armature. 4. Remove the core and solenoid.
CAUTION
Be careful not to damage the coil terminals. * For replacement of contactor only, see disassembling procedure 1.
32
12. LASER POINTER 12- 1. Adjustment 12-1-1. Fork level - adjustment 1. Raise forks to a height for easy work, and level them. 2. Adjust the positions of the leveling sensor and the magnet so that they are struck by the laser beam. a When the laser beam strikes the targets, the fork leveling indicator lamp will light. Adjustment position
Bracket, magnet
Bracket, sensor
Magnet
Sensor
Within 1.25 degree of the fork leveling position
Either loosen the fixing bolts of the sensor bracket to reposition it, or slightly adjust the magnet so that it is in the center of the sensor sensing element when the forks are level.
215W007E
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. 2. Set the distance between the fork edge and the end face of the pallet to the distance used for loading work (30mm or shorter), then park the forklift truck in line with the pallet. 3. Irradiate the pallet with the laser optical axis. Adjust the body adjustment screw so that, if a line type is used, the light is aimed at the center area of the pallet beam, and if a point type is used, at the top of the deck board. Loosen the fixing bolts of the LASER POINTER UNIT, adjust the height by moving the case body up and down. Also adjust the horizontal direction of the optical axis by loosening the lock screw and rotating the unit (the wire portion) inside the body.
Lift bracket
¡Laser pointer unit Laser optical axis
Case Laser unit
After the adjustment is complete, securely tighten the screw and fix it using a screw lock or equivalent item. 4. Drive the forklift truck forward and make sure that 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. 33
Lock screw
461E050
c
c
c
c
c
c
FBT15 type C
FBT18 type C
FBT20 type C
0
1
0
c
0
RS1 5
TRAVEL HYD. STEER BATT
1
1
1
0
0
0
1
RS1-5 [Safety monitor symbol]
0 BRAKE LOAD OIL
RS1-6 [0] [1] [2] [3] [4] [5]
Remarks
Language Japanese English French Germany Spanish Dutch
OK MONITORING OK CONTROLEUR OK UEBERWACHUNG OK MONITOR OK MONITOR OK
Display when key switch is ON
unless otherwise specified: In Japan: Japanese [0] Overseas: English [1]
* Language should be as follows
14/12
c c c c
c
c
c
c
c
c
c
c
GS battery only
14.5/12.5
15/13
c
c c
c c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c c
15.5/13.5
c c c
c
c
c
c
c
c
c
c
c c
14/12
c c c
c
c
c
c
c
c
c
c
c
c
14.5/12.5
c
c
15/13
c c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
15.5/13.5
c c
c
c
14/12
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
14.5/12.5
c
c
c
15/13
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
[Pneumatic type]
15.5/13.5
REG-CHK LEVELS
Travel speed Laden/ Unladen [km/h]
20
8
6
1
083 083 045
32
32
40
Plugging brake distance ¡On smooth road, loaded, full speed ¡Gravity of electrolyte: more than 1.25 ¡Full accelerator.
c
c
c
c c
c
c
c
c
c
c
c
c
64
c
c
c
c
c
c
c
c
50
Monitoring Sheet switch Over discharge lift lock Spare
0
4
PLUGG REGENE BRAKE TRAVEL HYD STEER BATT OIL LOAD BRAKE ING RATE TRQ HYD HYD HYD HYD HYD LIFT-1 LIFT-2 TILT ATTAT-1 ATTAT-2 Switch back Regen brake brake
Set all figures of [Option set] at [0] at first. Set all figures at [1] only when the options were installed.
Option board Spare Hydraulic chopper Regenerative contactor
0
RS1-7 [Option set]
D E
C
c
c
4.0 -5.0
B
9
8
7
6
4
3
2
1
4.5-5.5
4.0-5.0
c
c
4.5-5.5
4.0-5.0
c
c
4.5-5.5
Plugging brake distance (m)
3
Rotary switch setting
Language
RS0 Model selection
Starting current/ Current limitation ¡Motor current ¡Power 100% ¡Gravity of electrolyte: more than 1.25
10
0
c
c
0
c
c
FBT18 type B
FBT20 type B
c
c
FBT15 type B
FBT13 type C
c
c
FBT13 type B
c
c
c
FBT20 type A
c
c
c
c
390
c
5
Current limitation (A)
FBT18 type A
55
Starting current (A)
FBT15 type A
FBT13 type A
Model
¡TypeA: Equipped with no option ¡TypeB: Equipped with regenerative braking, over discharge lift lock, and seat switch ¡TypeC: Not either type A or B
48V
Voltage (V)
[Verification]
13. TROUBLESHOOTING
13- 4. List of settings for FBT-67
34
13 TROUBLESHOOTING
13- 5. Setting of volume and rotary switch When replacing MPU board, current sensor or when necessary, adjust a volume and two rotary switches on the MPU board.
CFL (VR0) : Brightness adjustment of back light of monitor RS0 : Truck model selection RS1 : Monitor selection
PB84-XX
CN1
CN3
CN2
CN4
CN5
CN6
MPU board
13-5-1. Volume 1. CFL (VR0) : Brightness adjustment of back light of monitor.
Turning clockwise bright contrast
CFL VR0
Make sure to see the display clearly even indoor.
13-5-2. Rotary switch 1. RS0 : Truck model selection The RS0 is for the truck model selection. If this selection is not match with the actual model, the truck does not operate correctly. When replacing the MPU board, the original rotary switch settings should be recorded, or refer to the setting table for RS0 to set to the correct positions.
Model selection RS 0
F01
789
35
456
AB
23
CDE
Error history memory clear
TROUBLESHOOTING 13
Setting position
Applicable truck model
0
Not used
1
FBT13 type A
2
FBT15 type A
3
FBT18 type A
4
FBT20 type A
5
Not used
6
FBT13 type B
7
FBT15 type B
8
FBT18 type B
9
FBT20 type B
A
Not used
B
FBT13 type C
C
FBT15 type C
D
FBT18 type C
E
FBT20 type C
F
Clearing error history (turn the key switch on under this condition)
*Type A : Equipped with no options. Type B : Equipped with regenerative braking, over discharge lift lock, and seat switch. Type C : Not either type A or B. *For the model other than type A or B, the options must be set as type C.
CAUTION
The "F" position of the RS0 is the clear function for the error history memory. Pay attention not to turn on/off the key switch to prevent the accidental clear.
36
13 TROUBLESHOOTING
2. RS1 : Monitor selection F01
AB
789
Position 0
Functions
456
CDE
RS1 : Monitor selection
23
RS1 is used for the adjustments of current level, starting current, current limitation, I /O checking, …etc, for various adjustments. Refer to the below table in details.
Remarks
Normal monitor
Hour meter display (Total, Traveling, Hydraulic)
Current Level of If (Field)
Adjust ; (-) minus value indication : Up (+) plus value indication
Current Level of Ia (Armature)
: Down
button button
1 Current Gain of If (Field)
Adjust ; (Actual current) > (Displayed value) : Up
button
(Actual current) < (Displayed value) : Down
Current Gain of Ia (Armature)
button
Starting current
0 - approx. 50A
Current limitation for travel
100 - 440A
Lift speed 1
0 a 64 (Fast) : Low speed (1st micro switch)
Lift speed 2
0 a 64 (Fast) : Hight speed (2nd micro switch)
Tilt speed
0 a 64 (Fast)
Attachment 1 speed
0 a 64 (Fast)
Attachment 2 speed
0 a 64 (Fast)
Plugging brake distance
0 - 100
Regenerative brake distance
0 - 100
Regenerative brake force
0 - 100
5
Monitor symbols
TRAVEL, HYD, STEER, BATT. OIL, LOAD, BRAKE
6
Language selection
Japanese, English, French, Germany, Spanish, Duch
7
Option set
Regen. contactor / over discharge lift lock, etc
8
Level adjustment of regenerative function
0 - 30
9
Setting letters on monitoring
(Used in factory)
A
Display of battery discharge
(Used in factory)
Error history memory 1
Memory No : error No = Travel mode, Hyd mode ;
Error history memory 2
Same as SICOS 50, SICOS 60
C
Display of selected model
Display of model selection by RS0
D
Address data
(Used in factory)
E
I/O memory data
(Used in factory)
F
Hour meter when troubled
Display of hour meter when troubled
2
3
4
B
Each setting should be conforming to "List of setting values". (See Page 34.) 37
SERVICE DATA AND WIRING (DIAGRAMS) 14
14. SERVICE DATA AND WIRING (DIAGRAMS) Battery
N 3
2
VC
right
left
M2
A
* M6
left
FC1 BK BU GNBU YEWH2
M4
A IF
right IA
M1
GNBU2
M3
NB
5
19
Control GND
BUWH3
E1 B1 C5 C3
3 3 3 3
16 6 19 18
Travel FET source Travel FET gate Travel FET drain voltage Contact (1) of For./Bwd. contactor
WHBU BNWH1
C4
3
9
Contact (2) of For./Bwd. contactor
GNWH3
YEBU2
M5
* D3
BU4
2.2 30W
C1
4
15
BNWH5
Contact of Regen. contactor
6
6
Lift 1 switch
45
6
14
Lift 2 switch
PB83-63 * Pre-energizing
*WHRD1 *BURD BNWH
100V2200
F(
BK
2)
3
4
16
Pre-energizing FET source
B3
4
8
Pre-energizing FET gate
VC
2
1
Travel fuse
NA
2
8
GND of contactor coil
Laser pointer switch
Tilt switch
BNWH2
6
8
Attachment switch1 (OPT.)
BUWH2
6
16
Attachment switch2 (OPT.)
YEWH4
6
13
Foot brake switch (w/Regen. or w/Rear combination lamp)
6
48 49 43
F2
w/ Level lamp Level lamp
BKRD BUWH GNWH
M7
BNRD GNBK BNYE YEBU
GN
M8 RD
RDGN
X4
Key switch
BUBK YEWH1
BU3 GNBU1 WH
BNWH6
RD1 WHBK
RDWH
WHGN1
RDWH1 BNWH1
(w/Built-in cherger)
RDYE1
M3
BUWH1
1
RDWH2
M4
Accessory M5
17 7 10
Hyd. FET source Hyd. FET gate Hyd. FET drain voltage
C2 VD
3 2
8 5
Contact of Hyd. contactor Hyd. fuse
VE C7
2 3
2 20
EPS fuse Contact of EPS contactor
*
70 71
5 5
5 15
15
5
20
Heater
Battery voltage
5
10
Start for key switch
20
2
3
Forward contactor (left)
30
2
9
21
2
4
Reference:
8
1
5
32
1
7
24
1
3
34
1
9
25
1
4
35
1
12
27
1
6
M8
RDYE3
X1
RDBK2
w/CS
BK/BKWH
3
8
87
4
5
82
5
18
Hour meter (OPT.) Turn switch (Turn on when turnning to right) Turn switch (Turn on when turnning to left) Brake oil level
83
4
3
Over load (OPT.)
85
4
4
Travel inhibit
84
4
11
Seat switch (OPT.)
TSL
RD5
39
4
10
Turn signal lamp
96
4
14
Reverse signal Load 200mA MAX.
95
4
6
Forward signal (OPT.) Load 200mA MAX.
P53 NB3
4 4
1 9
Accelerator power supply Accelerator (1) GND
72 73
5 5
6 16
Speed sensitive EPS (SP1) Speed sensitive EPS (SP2)
AC0 AC1 AC2 AC3 NB7 47
6 6 6 6 6 6
2 10 3 11 9 15
Accelerator GND Reach switch
60 NB5
5 5
3 13
Speed sensor 1 signal Speed sensor 1 GND
61 NB6
5 5
4 14
Speed sensor 2 signal Speed sensor 2 GND
86
4
12
Lift interrupt
47
6
15
Lift limit (OPT.)
left
BNRD2
X3
RDGN3 GNBK1 BK1
RD4
RD4 BNYE1 BKYE
P52
4
Power supply for accelerator
4
2
Signal for accelerator(1)
3
5
Signal for accelerator(2)
14
GND for accelerator(2)
3
GNBK1
13
BNYE1
12 NB2
3
BKYE
Brained wire
Brained wire
BKWH
BZ right
4
Directional switch
BN1 WHRD2
BKWH
BL
Back lamp 25Wx2 BL
P57
6
1
Power supply for directional switch
40
6
4
Neutral
41
6
12
Forward
42
6
5
Reverse
BU4
37
1
14
28
1
10
38
1
11
25W 10W
GNBK2 or GNRD3
10W
Lamp switch
BKWH
Reverse contactor (right)
YEWH3
58
5
12
Low speed
56
5
11
Mode select
Mode select switch
YERD
Low speed
55
5
1
Up
YEBK1
Travel bypass contactor
57
5
2
Down
5
X5 10E6
4
BKWH 40Wx2 BKWH
BKWH
WHGN2
Forward buzzer(OPT.) 100V 22
F
BK WHBK2
IA Hyd. contactor
EPS contactor
Relay for power supply
Travel current sensor IF
H
RDBK3 BU1 BKRD1
P50 10 NB0
3 3 3
1 2 11
Power supply for current sensor (IA) Signal for current sensor (IA) GND for current sensor (IA)
RDYE2 YERD1 BK2
P51 11 NB1
3 3 3
3 12 13
Power supply for current sensor (IF) Signal for current sensor (IF) GND for current sensor (IF)
YEBU1
X2
Horn switch
BKWH
Display unit
Flat cable 16P
BKWH
Available ports (name for A-SICOS)
Brained wire
9 7
HL
BKWH
Regenerative contactor
Warning buzzer 97
left
BZ
16P P12
TL
left
GNBK3
M
Forward contactor (right)
Tail & stop lamp
HL
WH1 GNWH2
BKWH
TL
right
Low speed
Reverse contactor (left)
right
25W
Head lamp
7
BK/BKWH
BUWH1
RDWH
1
26
1
RDWH3
Black color
33
1
GNRD1
2
2
22
GNRD
White line
10
1
RDBK1
WHRD3
Ex) BKWH (=Black/White) Black colored harness with White line.
2
23
13
RD2
M7
Harness mark/color Red RD Black BK Green GN Yellow YE White WH Brown BN Blue BU Gray GY Pink PK Orange OG
31
1
WHBU3
5
Back buzzer
Abnomal of EPS chopper Abnomal of EPS sensor
ST
36
RDGN1
M6
81
TSL
left
BUYE
WHGN
Hour meter counting
17
right
RDGN5
X4 M2
7
5
76
Turn signal lamp GNRD2
BNBK
M1
5
75
BK
Turn signal switch
RDGN4
RD
X1 Mctt
3 3 3
EPS TS Sensor RDYE
BUYE1
Battery electrolyte level (*GS battery only(OPT.))
3
1
BU
RDGN2
10A
RDBK
RDYE
WHBK1
15
80
10E6 E2 B2 C6
Accelerator
EPS Controller RDWH
RD
RDYE4
F4
PA
GNWH1
OPT.
BNBK4 BURD5
YE
EPS motor
OPT. OPT.
Parking brake switch Power supply for contactor Power supply for control
DC/DC Converter
YERD4
Laser
PA
40A
13 7 6
Tilt level sensor FC2
F3
4 2 2
w/ Laser pointer
D4
275A
BURD1
To connect : To start counting
RDBK
*
YEWH
7
46
90 VB VH
Connetor Pin NO.
Line NO. CN
Body earth
44
Turn off when releasing brake pedal *BU2
BK/BKWH
Connetor Pin NO.
Line NO. CN
RDYE5
D1 D2
BK/BKWH
Connetor Pin NO.
Line NO. CN
4 BU4
2)
NA
F(
RDWH
275A
F5 10A
VA
3 100V2200
F1
Combination lamp(OPT.)
V
Accelerator
1. * Marking shows only for the truck with Regenerative braking.
3
FBT-67 System wiring
14- 2.
54000-27690-0E
38
14 SERVICE DATA AND WIRING (DIAGRAMS) Parking brake swith Key switch Lamp switch
1
1
1
1
1
1
RD GN
2P RD
1
RDGN2 RD
Horn swith (on valve lever)
BK WH
1 1
B
micro switch Horn switch (on handle post)
RDBK
1 1
Turn signal lamp
WH1
1 1
Foot brake
BK WH
1 1
RD GN
6P
Head lamp
Indicator panel
Flat cable
Water resistant
Tilt micro switch
ST IG
Acceleration sensor
RDYE
Turn signal lamp
Lift micro switch
Lift 2 micro switch
1
Head lamp
2P Harness, mast(2)
Water resistant
1
1 1
Level sensor
Hanging on mast
w/ Laser pointer
Harness, mast(1) 2P
1
1
2P
Water resistant
Water resistant
Water resistant
Water resistant
8P Water resistant
6P WH
*Refer to note 4
2P
FL 8
Water resistant
Traction motor (left) FFL 8
Water resistant
AAL 8
1
FR 8
FFR
AAR 8
FR
WHBK2 BKWH
Battery plug
-+
1
: Sure plug (with sleeve)
7
: Receptacle (with sleeve)
n
1 1 1 1
Ex) BKWH (=Black/White) Black colored harness with White line.
White line
3. Secure all wires so they do not contact movable parts, edged surfaces, or heat sources. Black color
4. When wiring the main terminals of the Traction motor, cover them with caps.
7
w/ seat switch
Horn 7
2P
Hydraulic motor Water resistant
PF 8
Seat switch
8 L
8
1
Harness mark/color Red RD Black BK Green GN Yellow YE White WH Brown BN Blue BU Gray GY Pink PK Orange OG
: Terminal
8 M12
FL
1
BK WH 1 RD 1 GN 1 1
2. Symbol of terminal 1 : Sure receptacle (with sleeve)
Wire, lead
Wire, lead
1
1. indicates the lead wire numbers.
Traction motor FFR (right) 8
M1,M2 (left) For./Rev. contactor
8
8
BKWH WH1 RDGN5 GNRD2 RDWH RDBK GNBK2
Contactor Ass’y, front
M3,M4 8 M34 (right) 8 R For./Rev. contactor
Reference:
6P BK
*Refer to note 4
AR 8
AL 8
Harness, head guard
1
1 1
1
1
1
2P BK
Harness, body
w/ Laser pointer (Simplex mast)
Laser
WH1 BKWH RD5 1 GNRD2 1
1
3P
RDBK
WH BK RD GN
2P
4P
YEBU1
Water resistant
4P
Laser
Harness, head gurad
RDBK
Harness, mast(1)
YEBU1
Hanging on mast
1
Harness, adapter w/ Laser pointer (Triplex mast)
8
FFL
PA 8
5
5
5
D2 8
8 5
5
5
5
6 M8
Plugging diode
6
8
Control unit
8 M6 8
HF 8
Wire, lead
40A EPS 275A Hyd.
8
275A Travel
BKWH 1 1
1
BK
Accessory 8 DF
8
Contactor unit, rear
M5M5+ 8 M5 8 Bypass contactor
Connect: hour meter counting
FBT-67 Body wiring
14- 3.
With Regen.
14-3-1.
54000-27670-0E
39
Turn switch Turn switch (Turn on when (Turn on when turning to left) turning to right)
1
D 8
M7+M78 8
1
8
1
L
D3
Travel FET Comp.
RDGN RDBK RDYE4
1
10A 10A
AL 8 M6 8 Regen contactor
1
Current sensor
Capacitor
EPS contactor
BNWH2
8
5
8 D+
3P
Harness, turn switch
BUWH2
Capacitor
D1
Back buzzer
Harness, EPS Harness, contactor
Current sensor
Water resistant
EPS motor
BURD1
MPU board
4P XY
BK
D4
2PY
3P
EPS sensor
1
PF 8
8 AAR
BU
Hydraulic FET Comp.
8
Fly wheel diode
2PX
Water resistant
RD
CN6 CN5 CN4 CN3 CN2 CN1
EPS controller
PK
4P WH
1
10P
4P RD
RDYE5
Water resistant
Harness, CU
BK
6P RD
6P WH
6P BK
RDWH BKWH BU4 GNBK2
Harness, contactor
Wire, lead
4P WH
SERVICE DATA AND WIRING (DIAGRAMS) 14 Parking brake swith
Head lamp
1
1
1 1
1
RD GN
1 1
BK WH
RDBK
2P RD
Horn swith (on valve lever)
1
Turn signal lamp
WH1
RDGN2 RD
BK WH
6P Water resistant
Tilt micro switch
B
Horn switch (on handle post)
Flat cable
Lift micro switch
ST IG
Foot brake switch
1
1
w/ Rear combination lamp
Indicator panel
1
1
1
1
Acceleration sensor
RD GN
1
1
Turn signal lamp
Lift 2 micro switch
Key switch Lamp switch
RDYE
Head lamp
w/ Laser pointer 2P
Water resistant
2P
FL 8
Water resistant
M3,M4 8 M34 (right) 8 R For./Rev. contactor
AAL 8
8
AR 8
1
FR 8
Traction motor FFR (right) 8
AAR 8
WHBK2 BKWH
-+
1
: Sure plug (with sleeve)
7
: Receptacle (with sleeve)
n
1
1
1
1
1
1
Harness mark/color Red RD Black BK Green GN Yellow YE White WH Brown BN Blue BU Gray GY Pink PK Orange OG
BK WH RD GN
1 1 1
Ex) BKWH (=Black/White) Black colored harness with White line.
White line
3. Secure all wires so they do not contact movable parts, edged surfaces, or heat sources. Black color
4. When wiring the main terminals of the Traction motor, cover them with caps.
7
w/ seat switch
Horn 7
Hydraulic motor
2P Water resistant
PF 8
Seat switch
8 L
8
1
: Terminal
8 M12
FL
1
2. Symbol of terminal 1 : Sure receptacle (with sleeve)
Wire, lead
Wire, lead
BKWH WH1 RDGN5 GNRD2 RDWH RDBK GNBK2
1. indicates the lead wire numbers.
FR
Reference:
6P BK
*Refer to note 4
Battery plug
M1,M2 (left) For./Rev. contactor
AL 8
Traction motor (left) FFL 8
Water resistant
8
1
1 1
1 1
*Refer to note 4
Contactor Ass’y, front
FFR
6P WH
Harness, head guard
RDBK
Water resistant
YEBU1
Water resistant
1
Level sensor
Hanging on mast
Harness, mast(1) 2P
1
Water resistant
Harness, body
w/ Laser pointer (Simplex mast)
Laser
1
Harness, mast(2)
Water resistant
1
1
2P BK
2P
WH1 BKWH RD5 1 GNRD2 1
1
8P
WH BK RD GN
2P
3P
Water resistant
4P
RDBK
4P
Laser
Harness, head gurad
YEBU1
Harness, mast(1)
1
Hanging on mast
1
Harness, adapter w/ Laser pointer (Triplex mast)
8
FFL
PA 8
5
8
8 5
M8
5
5
6
Plugging diode
5
6
Current sensor
BKWH 1
Harness, turn switch
BK BUWH2
BNWH2
1
BK 1
HF 8
Wire, lead
3P
Turn switch Turn switch (Turn on when (Turn on when turning to left) turning to right)
Accessory 8
M7+M78 8
Control unit
1
D 8
1
L 8
Travel FET Comp.
10A RDGN RDBK 10A RDYE4
1
Capacitor
EPS contactor
1
5
D2
5
BURD1
5
8
Water resistant
EPS motor
Back buzzer
Harness, EPS Harness, contactor
Current sensor
8 D+
4P XY
BK
Capacitor
D1
2PY
1
D4
2PX
8 AAR
3P
EPS sensor
RDWH BKWH BU4 GNBK2
MPU board
PF 8
8
40A EPS 275A Hyd.
8
275A Travel
8 DF
8
Contactor unit, rear
BU
Hydraulic FET Comp.
Fly wheel diode
EPS controller
PK
CN6 CN5 CN4 CN3 CN2 CN1
4P WH
1
10P
4P RD
Water resistant
1
Water resistant
Harness, CU
RDYE5
6P RD
6P WH
6P BK
RD
Harness, contactor
Wire, lead
4P WH
M5M5+ 8 M5 8 Bypass contactor
Connect: hour meter counting
FBT-67 Body wiring
14- 3.
Without Regen.
14-3-2.
54000-27660-0E
40
14 SERVICE DATA AND WIRING (DIAGRAMS) AMP 174257-2
K Horn relay Reference:
M
brake L Parking switch
Relay CA1a-DC48V-N
Harness mark/color Red RD Black BK Green GN Yellow YE White WH Brown BN Blue BU Gray GY Pink PK Orange OG
Plug 2P RD 1 2 3 4
Plug 4P WH
I,T 1
16B
K,P 2 3 4
F 5
1
1
1
1
2 1
4 3
8
7
6 5
panel O Indicator
1B
F 1
F 3
2
2
1
12B
11B
18B
61B
F
F
F
F
F
F 7B
2
49A E 4
2
1
2
2
P
O
49C
60B
32I
54A
F 3
E 5
F 7
T 1
T 3
2
4
2
2
6
2
2
8
2
2
2
2
2
S Valve micro switch
1
brake Q Foot switch
52B
17B 2
2
Plug 3P
Plug 8P 2B
R DC/DC Converter
AMP 174357-2
Water resistant
Water resistant
Plug 4P
2
1
Horn switch
Plug 2P BK
32F 46B
S,L
W
M,U K,U
1
2
1
1
1
1
2
1 2 3 4
1 2 3 4 5 6
Plug 4P WH
1 2
Plug 6P BK
62B 44B 63A 64A
50C 8B
N T,K Z2
Z1
1
2
3
4
9B
6B
50B
1
1
1
1
F
F
T,Q
BURD5
BNWH6
BKWH*
YERD4
BU4
RDWH
YEBU1
RDBK*
RDGN5
RD5
RDBK*
BUWH1
RDWH3
GNWH2
BK
YERD
YEWH3
YEBK1
BK
BNBK
RDGN4
WHRD2
BN1
RDWH
YERD4
WHBK2
BKWH*
YEBU1
RDBK*
RDGN2
1
1
3
3
R Q,L
1
4
3B
62A 50D
6
2 1
Water resistant
1 2
E
32E
RDBK*
1
D 53B
Plug 2P BK
20C
RDYE
3
1
RD*
2 10E6 4 or 1 equivalent 1
1
51C
WH1
G
F 2
BNWH5
T,I
Q,E 1
RDWH
44B 45B
D,M P
1
50D 29B
1 2
32D 46A
Switch pointer) N (Laser
Plug 6P WH
1 2 3 4 5 6
CA Relay
Ex) BKWH (=Black/White) Black colored harness with White line.
Key & lamp switch
AMP 174982-2
5B
F 1
2
F 3
4
F 5
6
1
1
1
1
1
1
T Head guard(right)
RDWH
GNWH3
YEBU2
BNWH1
WHBU
BUWH3
White line
10B
4B
WH1
Front M 53C
GNRD2
Black color
RDGN5
J Charger
Clamp the horn relay here.
1 1 1
RDYE4 RDGN*
AMP 174655-2
BKWH*
Vinyl tube (BK) 53A
3
2 1
8
7 6
13B
19B
51A
41B
39B
F
F
D
B
B
32B 42B 32A
2
31B F 4
E,Y
F,Q C Brake GND
T F E,A Spare
X,D 1
C 3
X 2
1
1
1 10E6 1
or equivalent
KS
46C 32G
Water resistant Plug 2P 1
E 1
F 2
7
7
Yazaki 6180-2181
+
S
O
4A
2A
S
O
6A
7A
O
E
I
X
O
Y
W
O
O
Y
O
O
S
Q
24A
61A
26A
27A
31A
11A
13A
14A
60A
17A
19A
1A
3A
5A
8A
S 10A
1
1
1
1
2
3 4 5 6 C O,O
F,M
Write a 4 with undamped ink.
Write a 5 with undamped ink.
CN4
7
6
5
4
Write a 6 with undamped ink.
CN5
2
1
2
1
10
16 15 14 13 12 11 10
9
20 19 18 17 16 15 14 13 12 11
3
9
8
7
6
5
4
3
F MPU board
20B
CN6
7
6
5
4
2
1
16 15 14 13 12 11 10
9
8
3
1
47C
1
1
1
1
1
1
1
1
1
2
3
4
5
6
F
F 30B
49B
56A
25B
G
V,W
F
H
H
50E
44E
48B
26B
55A
57A
1 2 3 4 5 6
E Control unit
8
6. Fuses should be put together like a concentric circle as below figure.
H
L,W
Plug 6PWH
10A
10A
S 9A
Plug 6PBK 1 2 3 4 5 6
D Fuse
Fuse 10A 10A
About 40
E 20A
A
2
2
2
2
2
2
3
1
2
3
Y
F
39A
24B
41A
C
Receptacle (with sleeve) AMP41729 Sleeve (for double wire) 1-170823-5 Sleeve (for single wire) 170823-2 Receptacle
AMP175061-2 or 173716-2
1
Receptacle
2
Receptacle
2
Tab
7
Terminal (F) Yazaki Terminal (M) Yazaki
AMP179461-5 or 170032-5 AMP173707-1 or 171662-1 or 172888-2 AMP173706-1 or 171661-1 1500-0110 1600-0105
40
Clamp
W 48D
Y
F
40A
15B
Plug 3P
Cap 3P
Water resistant
Water resistant
3 2 1
1 2 3
AMP 174357-2
AMP 174359-2
B EPS sensor ATurn switch
8
70
Spare W 59B
Sure plug AMP170020-2 Sleeve (for single wire) 170887-1 Sleeve (for double wire) 170888-1 1 Sure plug AMP170020-3 or (With plating) 170002-5 Sleeve (for single wire) 170887-1 Sure receptacle AMP170021-2 (With plating) Sleeve (for double wire) 170890-1 Sleeve (for single wire) 170889-1 1 Sure receptacle AMP170003-5 or (With plating) 170021-3 Sleeve (for double wire) 170890-1
BK
2
2
1 Y
Back buzzer
BNWH2
2
42A
GND K 44A
(With plating)
BUWH2
2
47B
BU3
WH
2
X
BK
2
BK
O 18A
2
RD4
M 16A
2
BU2
A 15A
2
BK
O 12A
2
BK
E 30A
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BK
2
BK
2
BKYE
2
BNYE1
2
BURD
2
WHRD1
2
BKWH*
2
BKWH*
L 29A
2
RDYE
V 28A
2
RDWH
E 25A
2
GNWH3
H 22A
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BU4 BN1
2
YEBU2 BNWH1 BUWH3 WHRD2 BNBK
2
RDGN
2
RDYE
2
YEWH1
2
BUBK
2
GNWH2 YEWH3 REGN2 RDWH3 BNWH2 BURD1
2
YEBK1 YERD
2
BU2 BNRD2 BNWH5
2
BUYE1 GNRD2
WHRD1 BURD BUWH1
BUWH2
GNBK1 2
1 2 9 4 5 6 7 8 16 3 10 11 12 13 14 15
W,E
S 50A
48A 28B
GNBU1
X,K
RDYE5
BKWH*
RDBK*
RD*
Condenser 100V, 4.7 F
KS
1. Symbol of terminal
2
Y,M
7
Terminal (pressed sleeve)FNC-2 2. Lead wire * : AVS0.85mm2 For others : AVS0.5mm2 Brained wire : Braddie wire under 25mm pitch. 3. Location of connector pin is looked from inserting side. 4. The mark bands in the figure are not necessary for complete harnesses. 5. When installing diodes and capacitors, solder them and cover them with insulating vinyl tubes.
FBT-67 Body harness 54000-27532-0E
41
2
BKWH* Condenser 100V/22 F
32C
U O 32H
switch (on valve lever) U Horn
Vinyl tube (BK)
51B
P48
1
P,T
Yazaki 6187-2171
62A 62B
WHBK2
44D IE
Right O 54B
1
P
Put the sleeve for shur plug rec.
Clamp the relay here.
8
GNBK2
+
G Horn
7
V
AMP 174352-2
Z2 Level sensor 45A K
7
V
BUYE1
1
3
BK
2
1
4
BK
Water resistant
2
BURD1
1 Z1 65B Plug R 63B 2 2P
2
GNBK2
2 2
2
59A 14B 48C
BKWH*
BNBK4 BNWH6
1
Water resistant
BKWH*
44E J G
2
2
VSeat switch
8B 47A
BU4
RD5
Plug 1 Z2 65A 2P R 64B 2
2
4P
50F
RDWH
O
2 2
2
Plug
W Accessory BNRD2
52A
BNBK4 BURD5
B
1 2 3 4 5 6 7 8 9 10 2
AMP 174257-2
1 2
Plug 4P WH
RDBK*
GNRD2
W
1 2 3 4
RDYE5
F T
40B
RDBK*
27B
50G
BU3 GNBU1 WH RDWH RD* (Seal plug) YE1 (Seal plug) BUBK (Seal plug)
I
Head guard (left)
2
(Back buzzer)
AMP 174352-2
1 E 56B E 55B 2 3 E 57B F 22B 4
CA Relay
Plug 10P
Z1Laser
Write a M with undamped ink.
WH1
M
5 4 10 9
Relay CA1a-DC48V-N
Water resistant
RD*
BNYE1 2 RD4 2 BKYE 2 GNBK1
RDBK*
1
X Relay
BKWH*
YEBU1
34B D 1 33B D 2 51B Y M 3 44D K 4 I
Y EPS controller
Water resistant
RDWH
BK
1 2 3 4
H Acceleration sensor BK
Plug 4P BK
RDBK*
Trun I 27C signal
14- 4.
SERVICE DATA AND WIRING (DIAGRAMS) 14
A Outer terminal 2 1 4 3
3 2 1 6 5 4
B Contactor unit
3 2 1 6 5 4
1 2 3 4
3 2 1 6 5 4
1 2 3 4
Cap
Cap
Cap
Cap
Plug
Plug
4PWH
6PRD
6PWH
6PBK
4PRD
4PWH
17B
22B
2B
40B
13B
43A
44A
45A
46A
48A
31B
1B
7B
6B
14B
E
E
E
E
E
D
H
H
G
F
E
E
E
E
E
18B
23B
5B
8B
37B
20B
44C
45C
47A
30B
32B
3B
9B
16B
42B
E
E
E
E
E
D,E
H
H
L
E
E
E
E
E
E
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4
1 2 3 4
1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1
1 1 1 1
RDYE3 BNYE GNRD YEBU
RDYE RDWH BKWH* BKWH* BK BK
BU2 WHRD1 BURD RD4 BNYE1 BKYE
RDBK1 RDGN1 WHGN WHBU3
1 2 3 4 5 6
RDYE1 RDWH2 YEWH2 BUWH1 BUYE GNBU2
1 2 3 4
RD1 RDWH1 WHBK BNWH1
1. Lead wire : KIV2mm2 * : AV or AVS0.85mm2 # : AV or AVS0.3mm2 For others:AV or AVS0.5mm2 2. Symbol of terminal 1 : Recptacle AMP 175027-6 or 173631-6 2 : Recptacle AMP 175061-2 or 173716-2 1 : Tab AMP 179462-3 or 170340-3 1 : Recptacle AMP 179461-5 or 170032-5 : Contact JST BXH-001G-P0.6 or SXH-001G-P0.6 : Recptacle AMP 41729 8 : Terminal 1.25-8 or 2-8 3. Location of connector pin is looked from inserting side. 4. The mark bands are not necessary for these harnesses. 5. The mark bands in the figure are not necessary for complete harnesses. 6. The wires shown below should be twisted in a pitch of 25mm or shorter.
Wires to be twisted RDBK3-BU1-BKRD1 RDYE2-YERD1-BK2 RD4-BNYE1-BKYE BUWH-BKRD BU-BK
FET Comp. C Hydraulic
1
1 1 1
BU BURD WH
Plug 48B A 2 4P 3 51C L GN
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 11 3 12 13 4 5 14 6 16 7 17 8 9 10 15 18 19 20 L
4
L
24A
30A
28A
H
C
21A
32A
H
A
35A
37A
J
B
A
B
1A
22A
A
3A
B
5A
B
7A
D
9A
RDBK3#
13A
H
C
K
C
A
B
B
A
A
H
A
A
K
B
A
D
K
B
25A
27A
29A
31A
33A
34A
36A
38A
40A
42A
16A
18A
20A
21C
23A
2A
4A
6A
8A
10A
12A
14A
CN3(20P)
CN2(10P)
10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11
4 3 2 1 10 9 8 7 6 5
1 1 1 1
1 A 43B 2 E 10B 3 A E 20C 4 E 11B
EMPU board Plug 4P BK
1 2 3 4
BU1# BKRD1#
CN1(14P) 6 5 4 3 2 1 14 13 12 11 10 9 8 7
Write a 2 with undamped ink.
DRelay Clamp this properly.
1 E 24B 2 3 E 25B 4 E 26B
4P
1 2 3 4
White line
Write a A with undamped ink. RDYE2#
JTravel diode 49B
YERD1# BK2#
15B
F
E
8
8
1 E 27B 2 3 E 28B 4 E 29B
4P
1 2 3 4
Black color
Write a F with undamped ink. WH WHRD1
8 F 51B 8 A 47B
sensor L Current
8 BU2
1 1 1
8
8
E
A,A
A,A
33B
45B
44B
1 2 3 4 E,E 21B E 41B
2 1 4 3
Ex) BKWH (=Black/White) Black colored harness with White line.
A
11A
A
RD2
46B A
D 20D
19A
L
RDYE RDBK2 RDWH GNRD1
Regen. diode
17A
L
Write a 3 with undamped ink.
G
K
A
15A
41A
Write a 1 with undamped ink.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14
L
BK BK BKWH* BKWH*
F
Pre-energizing board resistor
A
A
L
26A
1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10
Cap 4PGN
H
Travel FET Comp.
BNRD
BU
GNBK
1
WHRD3
RD
Harness mark/color Red RD Black BK Green GN Yellow YE White WH Brown BN Blue BU Gray GY Pink PK Orange OG
BNWH
1
RD
Plug 49A J 1 2P WH 50A F 2
50B F
1 2 3 4
Reference:
BKRD GNWH BUWH
RDBK1 RDYE1 RDGN1 RD2 RDWH2 RDYE3 WHGN BUWH1 WHBU3 RDBK2 GNRD1 WHRD3 BUYE GNRD
1 2
1 1 1
BNWH BNYE RD1 RDWH1 GNBK RDWH RDWH BK WHBK BNWH1
1 38B E 2 3 34B E 4
YEWH2 GNBU YEBU
35B E
RDBK3# BU1# BKRD1# RDYE2# YERD1# BK2# RD4 BNYE1 BKYE BU BK BUWH BKRD BNRD GNBU GNWH
Cap 4P RD
BK GNBU BU
2 1 4 3
8
8
E
E
E
E
4B
12B
19B
36B
contactor K Hyd.
FBT-67 Control unit harness With Regen.
14- 5. 14-5-1.
24200-58061-3E
s
CU101-51E/57E 42
14 SERVICE DATA AND WIRING (DIAGRAMS)
A Outer terminal
B Contactor unit
2 1 4 3
3 2 1 6 5 4
3 2 1 6 5 4
3 2 1 6 5 4
1 2 3 4
1 2 3 4
Cap 4PWH
Cap 6PRD
Cap 6PWH
Cap 6PBK
Plug 4PRD
Plug 4PWH
17B
22B
2B
40B
13B
43A
44A
45A
31B
1B
7B
6B
14B
E
E
E
E
E
D
H
H
E
E
E
E
E
23B
5B
8B
37B
20B
44C
45C
30B
32B
16B
42B
E
E
E
E
E
D,E
H
H
E
E
E
E
1 1 1 1 1 1
1 1 1
1
1
1 1 1 1
RDYE3 BNYE GNRD YEBU
1 1 1 1 1 1
1 2 3 4
WHGN
1 1 1 1
1 2 3 4
RDBK1
1 2 3 4 5 6
RD4 BNYE1 BKYE
1 2 3 4 5 6
RDYE1 RDWH2 YEWH2 BUWH1 BUYE GNBU2
1 2 3 4 5 6
RD1 RDWH1 WHBK BNWH1
1 2 3 4
RDYE RDWH BKWH* BKWH* BK BK
18B
1. Lead wire : KIV2mm2 * : AV or AVS0.85mm2 # : AV or AVS0.3mm2 For others:AV or AVS0.5mm2 2. Symbol of terminal 1 : Recptacle AMP 175027-6 or 173631-6 2 : Recptacle AMP 175061-2 or 173716-2 1 : Tab AMP 179462-3 or 170340-3 1 : Recptacle AMP 179461-5 or 170032-5 : Contact JST BXH-001G-P0.6 or SXH-001G-P0.6 : Recptacle AMP 41729 8 : Terminal 1.25-8 or 2-8 3. Location of connector pin is looked from inserting side. 4. The mark bands are not necessary for these harnesses. 5. The mark bands in the figure are not necessary for complete harnesses. 6. The wires shown below should be twisted in a pitch of 25mm or shorter.
Wires to be twisted RDBK3-BU1-BKRD1 RDYE2-YERD1-BK2 RD4-BNYE1-BKYE BUWH-BKRD BU-BK
FET Comp. C Hydraulic
Harness mark/color Red RD Black BK Green GN Yellow YE White WH Brown BN Blue BU Gray GY Pink PK Orange OG
L
L
24A
A
A
L
26A
30A
28A
H
A
C
21A
32A
35A
1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10
H
37A
A
J 15A
41A
K
17A
A
D 20D
19A
RDBK2 GNRD1 WHRD3 BUYE GNRD
RD2 RDWH2 RDYE3 WHGN BUWH1
B
22A
A
1A
B
5A
A
D
7A
11A
RDBK3#
13A
L
L
L
A
H
C
K
C
A
B
B
A
A
H
A
A
K
B
A
D
K
B
25A
27A
29A
31A
33A
34A
36A
38A
40A
42A
16A
18A
20A
21C
23A
2A
4A
6A
8A
10A
12A
14A
CN3(20P)
CN2(10P)
10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11
Write a 3 with undamped ink.
4 3 2 1 10 9 8 7 6 5
EMPU board RDYE RDBK2 RDWH GNRD1
1 1 1 1
1 A 43B E 10B 2 3 A E 20C 4 E 11B
Plug 4P BK
1 2 3 4
Ex) BKWH (=Black/White) Black colored harness with White line.
1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14
BU1# BKRD1#
CN1(14P) 6 5 4 3 2 1 14 13 12 11 10 9 8 7
Write a 2 with undamped ink.
DRelay Clamp this properly.
4P
1 2 3 4
White line
Write a A with undamped ink. RDYE2#
JTravel diode
Write a 1 with undamped ink.
1 E 24B 2 3 E 25B 4 E 26B
YERD1# BK2#
15B
1 E 27B 2 3 E 28B 4 E 29B
4P
1 2 3 4
Black color
Write a F with undamped ink.
E
8 BNWH
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 11 3 12 13 4 5 14 6 16 7 17 8 9 10 15 18 19 20
RDBK1 RDYE1
BKRD GNWH BUWH
BNWH BNYE RD1 RDWH1 GNBK RDWH RDWH BK WHBK BNWH1
1 1 1
YEWH2 GNBU YEBU
Cap 4P RD
1 38B E 2 3 34B E 4
RDBK3# BU1# BKRD1# RDYE2# YERD1# BK2# RD4 BNYE1 BKYE BU BK BUWH BKRD BNRD GNBU2 GNWH
2 1 4 3
35B E
Reference:
1 1 1
8
8
E
A,A
A,A
33B
45B
44B
1 2 3 4 E,E 21B E 41B
2 1 4 3
43
Cap 4PGN
H
Travel FET Comp.
GNBK
BNRD
BK BK BKWH* BKWH*
BK GNBU BU
RD2
WHRD3
sensor L Current
8
8
E
E
E
E
4B
12B
19B
36B
contactor K Hyd.
FBT-67 Control unit harness Without Regen.
14- 5. 14-5-2.
24200-58071-3E
s
CU101-52
SERVICE DATA AND WIRING (DIAGRAMS) 14
Plug 4PWH
1 2 3 4
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4
1 2 3 4
1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1
1 1 1 1
Only with Regen.
RDBK1 RDYE1 RDGN1 RD2 RDWH2 RDYE3 WHGN BUWH1 WHBU3 RDBK2 GNRD1 WHRD3 BUYE GNRD
Plug 4PRD
BNWH BNYE RD1 RDWH1 GNBK RDWH RDWH BK WHBK BNWH1
Cap 6PBK
YEWH2 GNBU YEBU
Cap 6PWH
RDYE3 BNYE GNRD YEBU
Cap 6PRD
RDBK1 RDGN1 WHGN WHBU3
1 2 3 4
BU2 WHRD1 BURD RD4 BNYE1 BKYE
1 2 3 4
RDYE RDWH BKWH* BKWH* BK BK
3 2 1 6 5 4
RDYE1 RDWH2 YEWH2 BUWH1 BUYE GNBU2
3 2 1 6 5 4
RD1 RDWH1 WHBK BNWH1
Cap 4PWH
3 2 1 6 5 4
RDBK3# BU1# BKRD1# RDYE2# YERD1# BK2# RD4 BNYE1 BKYE BU BK BUWH BKRD BNRD GNBU2 GNWH
Only with Regen.
2 1 4 3
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 11 3 12 13 4 5 14 6 16 7 17 8 9 10 15 18 19 20
1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN3(20P)
CN2(10P)
CN1(14P)
10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11
4 3 2 1 10 9 8 7 6 5
6 5 4 3 2 1 14 13 12 11 10 9 8 7
MPU board
2
1
BU
PA (8)
(1)
Only with Regen. 1 2 3 4
BU 1 BURD 1 WH 1
4P
8
D+ 8
4P RDYE RDBK2 RDWH GNRD1
1 1 1 1
1 2 3 4
1 2 3 4 4P BK
(6) Relay
Only with Regen.
2 1 BK 1 1
4 3 GNBU 1 2 4P 1. Lead wire BU 1 3 RD : Main lead wire 4 : Lead bar : KIV2mm2 BK * : AV or AVS0.85mm2 BK # : AV or AVS0.3mm2 BKWH* For others:AV or AVS0.5mm2 BKWH* 2. Symbol of terminal A 1 : Recptacle AMP 175027-6 or 173631-6 BU2 2 : Recptacle AMP 175061-2 or 173716-2 8 Only with Regen. 1 : Tab AMP 179462-3 or 170340-3 1 : Recptacle AMP 179461-5 or 170032-5 Only with Regen. 4. Recinnebded tightening torque for the Diode. : Contact JST BXH-001G-P0.6 or SXH-001G-P0.6 Nihon inter Electronics make : 9.5-12.5 N m (97-127 kg cm) : Recptacle AMP 41729 Semikron make : 9.0-11.0 N m(92-112kg cm) 8 : Terminal 1.25-8 or 2-8 5. Recinnebded tightening torque of M8 terminal ALBRIGHT make contactor . 3. Location of connector pin is looked from inserting side. 8.75N m 10% (89kg cm 10%)
M7+
RDBK3# BU1# BKRD1# Only with Regen.
1 2 3 4
RDYE2# YERD1# BK2# Write a F with undamped ink.
Reference: Harness mark/color Red RD Black BK Green GN Yellow YE White WH Brown BN Blue BU Gray GY Pink PK Orange OG
M7
Travel FET Comp.
6. indicates the lead wire numbers.
1 2 3 4
8
1 2 3 4
WHRD1 WH
BNRD
RD
WHRD3
1
-
RD2
1
Write a A with undamped ink.
1 2 3 4
GNBK
4P GN
)
Hydraulic FET Comp.
)
Preenergizing PB
(9
) (3
1 2 3 4
4P RD
(7
Resistor
1 2 3 4
2 1 4 3
1 2 2P WH
1 1 1
RD BNWH
BKRD GNWH BUWH
8
Ex) BKWH (=Black/White) Black colored harness with White line.
M7M6
(2)
White line
Black color
FBT-67 Control unit wiring
14- 6.
24200-58100-2E
44
14 SERVICE DATA AND WIRING (DIAGRAMS)
33 34
34 35 1
4
32 33
31
14 30
11
9
15
14 30
31
6
37
22 13
7
31
8
15
14 30
20 35
17
54000-29310-0 CU101-52D Without regen
Part No.
10 21 3
Bracket(1), MPU board
24200-57681
24200-57561
54000-29320-0 CU101-56D Without regen CS
54000-29330-0 CU101-57E With regen CS
24200-57681
24200-57561
35810-05590 SW80-643
35810-05590 SW80-643
35810-05630 SW80-704
35810-05630 SW80-704
Lead wire SHLV
Lead wire SHLV
Lead wire WL1
Lead wire WL1
Contactor
Remarks
29
54000-29300-0 CU101-51E With regen
27
-
-
Upper
1. Apply conductive compound TSK550(Toshiba Silicones Co., Ltd) on all surfaces between the "FET comp." , "Diode", "Sink, heat", "Sheet, insulator", and the base. 2. Recinnebded tightening torque for the diode. Nihon inter Electronics make : 9.5-12.5 N m (97-127 kg cm) Semikron make : 9.0-11.0 N m(92-112kg cm) 3. Recinnebded tightening torque for the contactor M8 terminal. 8.75N m 10% (89kg cm 10%)
+
-
+
18
+
+ 36 24
25
30 14 27
15
9
31
6
11
32 33
19
26
16
14 30
5
34 35
12
31
33
2
3
29
28
20 35
Only with Regen.
33 34 27
CU10151E/52D/56D/57E
Type 23
Applicable models
21
FBT-65/67 48 V
Travel
Power voltage Current limitation Maximum current
390 A 1000 A
(Main element)
Hydraulic
Power voltage
48 V
Relief current
280 A
Maximum current
700 A
(Main element)
Remarks
When installing, make sure the arrow points up.
37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
0077-05010 24200-59260 0000-00008 0000-70008 0000-72008 0110-08020 0016-08016 31010-02200 31010-03600 31010-03590 0075-04010 0075-03006 35890-00030 24200-64980 54000-29200 24200-58830 24200-63030 24200-14910 24200-54830 24200-54810 39110-01180 or 39110-01120 24200-05570 25200-00450 8432-10020 24200-19610 25200-00470 25200-00280 35010-01700 1911-59015 25200-01650 24200-48090 24200-36180 24200-36170 24200-54801 24200-57921
Screw, w/washer Resistor comp. Nut Washer, lock Washer, plain Bolt Bolt, w/washers Bolt, w/washers Bolt, w/washers Bolt, w/washers Screw, w/washers Screw, w/washers Spacer Board comp., printed Board comp., MPU Bracket(1), MPU board Bracket(1), MPU board Terminal Bar, capacitor Bar (2), lead Sensor Comp., current Capacitor Tube Cup, insulator Sheet, insulator Sheet, insulator Sheet, insulator Sheet, insulator Diode Diode Sink, heat Sink, heat FET comp. FET comp. Contactor Bracket, contactor Base, control unit
FBT-67 Main controller ass'y
14- 7.
1E-06168-12E
s CU101-51E/52D/56D/57E 45
Reproduction prohibited First printing Issued by Edited by
: March
2004
: Nippon Yusoki Co., Ltd : Overseas division Nippon Yusoki Co., Ltd.
