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
RB10/15-70 RBC7/9/10-70 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 an

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 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© 2007
NIPPON YUSOKI CO., LTD.
All Rights Reserved
 CONTENTS

SAFETY WORK 1 1b .ACCELERATOR ASS'Y 28

1. Precautions for safe inspection 1b-1.Name .......................................................... 28
and maintenance work .................................. 1 1b-2.Disassembling and reassembling. ............. 30
Maintenance shops 1 1b-2-1.Accelerator ass'y - removal and installation 30
Work clothing 2 1b-2-2.Accelerator ass'y - disassembling and
Tools and gauges 2 reassembling 33
Safety work 2
Parts 3 1b-3.Inspection and adjustment ......................... 35
Repair of electrical components 3 1b-3-1.Shaft - inspecton 35
Hydraulics 4 1b-3-2.Adjustment of the potentiometer 35
Tightening torque 4 1b-3-3.Button, emergency - working check 36
2.Safety labels ................................................... 5
3.Model name and serial numbers ........................ 9
4.Caution for maintenance .................................... 13 1c . BATTERY 37
5.Tightening torque for bolts ................................ 16
6.Load center and load chart ............................... 17 1c-1.Disassembling and reassembling ............... 37
7.Maintenance tools and inspection devices ....... 18 1c-2.Inspection and adjustment ......................... 39
1c-2-1.Battery - Inspection and adjustment 39
1c-2-2.Battery - cleaning 40

1 .ELECTRIC DEVICES 20
1-1.Name ............................................................ 20 1d. STEERING ANGLE POTENTIOMETER 41
1d-1.Disassembling and reassembling ............. 41
1d-1-1.Steering angle potntiometer -
disassembling and reassembling 41
1a .CONTROL UNIT 21 1d-2.Checking and adjustment ........................... 42
1a-1.Name .......................................................... 21 1d-2-1.Adjustment of the steering angle potentiometer 42
1a-2.Disassembling and reassembling. ............. 22
1a-2-1.Control unit - removal and installation 22
1a-2-2.Control unit - disassembling and reassembling
23 1e . CHARGER 43
1a-3.Inspection,replacement and attention ........ 25
1a-3-1.Contactor - check and replacement 25
1e-1.Disassembling and reassembling ............. 43
1a-3-2.Traction controller - specification 26
1e-1-1.Charger - disassembling and reassembling 43
1a-3-3.EPS controller - specification 27
1e-1-2.Transformer - disassembling and reassembling
45
1e-2.Inspection and replacement ....................... 46
1e-2-1.Switch, magnet - inspection 46
1e-2-2.Plug comp. and receptacle -
inspection and replacement 46
1e-2-3.Fuse and fuse base - inspection 46
1e-2-4.Transformer - inspection 47
1e-2-5.Transformer - specification 47
 2 . WORKING CHECK 48
2-1.Brake switch - working check ....................... 48
2-2.Neutral safety mechanism - working check .. 48
2-3.Hydraulic mechanism - working check ......... 48
2-3-1.Lift mechanism - working check 48
2-3-2.Tilt mechanism - working check 49
2-4.Turning speed reduction - working check ..... 49
2-5.EPS - working check .................................... 49
2-6.Charger - working check .............................. 50
2-6-1.End timer working check 50
2-6-2.Total timer working check 50
2-7.Setting parameter of travel controller ........... 51
2-7-1.Handheld programmer 51
2-7-2.Change to set the parameter 52
2-7-3.Parameter table 53
2-8.Battery indicator ........................................... 55

3 . TROUBLESHOOTING 56
3-1.Self diagnostic function ................................ 56
3-1-1 Diagnostic LED 56
3-1-2 Error message 57

4 . WIRING DIAGRAM 59
4-1.System wiring ............................................... 59
4-2.Body wiring ................................................... 60
4-3.Harness, body .............................................. 61
4-3-1.PLD/KLD-70 61
4-3-2.FBD/SBW-70 62
4-4.Controller wiring ........................................... 63
4-5.CU Harness .................................................. 64
4-6.Controller harness ........................................ 65
4-6-1.PLD/KLD/FBD/SBW-70 65
4-6-2.PLD/KLD-70(Center-rider) 66
 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

rs
accidents, such as a roll-over of the forklift

te ale
truck, may result.

bu e
tri d D
CAUTION Well-ventilated area
Work such as welding painted components or
D ize

sanding down coated parts should be carried

out in well-ventilated areas.
ot or

If this is not observed, harmful toxic gas or dust

is
N uth

may be inhaled.
D rA

CAUTION Location equipped with fire extinguishing

fo

equipment
o
y

 Equipment such as first-aid boxes and fire

nl

extinguishers should be nearby when work is

O

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
be caught by a machine, and results serious
injuries.

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 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 and

discharge the capacitors in the control unit
when replacing electrical component.

CAUTION Be sure to jack up the drive wheel when trouble

shooting of 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.
Failure 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.
If 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 14

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.

PLD KLD
(3) (5) (4) (2)
(1)

321S001e

*This illustration shows PLD10.

No. Parts No. Parts Name Q'ty Notes

(1) 24700-13740 Plate, Caution 1 Caution in operation
(2) 0902-69774 Plate, Warning 1 Warning:cut off hands
(3) 24700-13830 Plate, Caution 1 Caution in the charge
(4) 24700-04630 Plate, Caution 1 Electric shock attention
(5) 38540-00520 Plate, Caution 1 Manual of the battery

(2)

69774

5
 SAFETY WORK

(1) (4)

�������
A driver shall observe the following notes for safety.

1. Only a trained and authorized operator shall be allowed to

operate the truck.
2. The operator should read the operator’s manual carefully
and understand the safe operation.
3. Carry out the daily inspection before operation. If any
abnormalities are found, do not operate until they are
repaired completely. Repair and/or adjustment should be
done by an authorized service person.
4. Make sure that the accelerator knob is in the neutral
position, the tiller arm is stood upright and the broke is
applied before turning on the key switch. 24700-04630

5. The key switch must be turned from the normal operating

position.
6. Do not overload. Do not handle an off-center load.
7. Always check the road condition, and stay away from soft
or uneven ground.
8. Keep enough clearance between the truck and operator’s
body for safe operation.
9. When travelling up or down a grade with a load, keep the
load upgrade to maintain control. Do not turn on a grade.
10. Do not make a sudden start, stop or turn.
11. Do not ride on the truck except the riding step or riding
compartment.
12. When leaving the truck, next procedure must be followed.
[ 1 ] Stand the tiller arm upright to apply the brake.
[ 2 ] Release the accelerator knob to return to the neutral.
[ 3 ] Lower the fork or platform to the lowest position.
[ 4 ] Turn off the key switch and remove the key.
13. Slow down the speed when descending a grade.
14. Use prescribed fuse for replacement.
15. Never allow anyone to ride on a fork or pallet.

24700-13740

(3)
������������������������������
1. Always charge the battery in a well ventilated area.
Do not smoke. Keep flames away.
2. Do not use equipment that is liable to
produce sparkes, in this area.
3. Do not disconnect plugs before turning off
������� the charger when interrupting to charge.
4. Keep the battery cover open during to charge.
5. Do not touch only internal parts of the charger when
connecting the power cable. 24700-13830

(5)

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 wellÐventilayed 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 overÐfilling 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.

6
 SAFETY WORK

FBD SBW

(7) Double mast

(2)
(2)

(7)

(6)
(3)
(5)

(4)
(1)

361S001

*This illustration shows FBD7.

No. Parts No. Parts Name Q'ty Notes

(1) 24700-13740 Plate, Caution 1 Caution in operation
(2) 24700-04610 Plate, Fooking 2
(3) 24700-13830 Plate, Caution 1 Caution in the charge
(4) 38540-00520 Plate, Caution 1 Manual of the battery
(5) 24700-04630 Plate, Warning 1 Electric shock attention
(6) 24700-04620 Plate, Warning 2 No person on/under forks
(7) 24700-06320 Plate, Warning 1 Caution for fingers

(2) (3)
������������������������������
1. Always charge the battery in a well ventilated area.
Do not smoke. Keep flames away.
2. Do not use equipment that is liable to
produce sparkes, in this area.
3. Do not disconnect plugs before turning off
������� the charger when interrupting to charge.
24700-04610
4. Keep the battery cover open during to charge.
5. Do not touch only internal parts of the charger when
connecting the power cable. 24700-13830

7
 SAFETY WORK

(1) (5)
�������
A driver shall observe the following notes for safety.

1. Only a trained and authorized operator shall be allowed to

operate the truck.
2. The operator should read the operator’s manual carefully
and understand the safe operation.
3. Carry out the daily inspection before operation. If any
abnormalities are found, do not operate until they are
repaired completely. Repair and/or adjustment should be
done by an authorized service person.
4. Make sure that the accelerator knob is in the neutral
24700-04630
position, the tiller arm is stood upright and the broke is
applied before turning on the key switch.
5. The key switch must be turned from the normal operating
position.
6. Do not overload. Do not handle an off-center load.
7. Always check the road condition, and stay away from soft
or uneven ground.
(6)
8. Keep enough clearance between the truck and operator’s
body for safe operation.
9. When travelling up or down a grade with a load, keep the
load upgrade to maintain control. Do not turn on a grade. WARNING
10. Do not make a sudden start, stop or turn.
11. Do not ride on the truck except the riding step or riding
compartment.
12. When leaving the truck, next procedure must be followed.
[ 1 ] Stand the tiller arm upright to apply the brake.
[ 2 ] Release the accelerator knob to return to the neutral.
[ 3 ] Lower the fork or platform to the lowest position.
[ 4 ] Turn off the key switch and remove the key.
13. Slow down the speed when descending a grade.
14. Use prescribed fuse for replacement.
15. Never allow anyone to ride on a fork or pallet.

24700-13740

(7)

警 告
WARNING

24700-04620

(4)

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 wellÐventilayed 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 overÐfilling 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.

8
 SAFETY WORK

3. Model name and serial numbers

PLD KLD
Model name
Name plate

Capacity code 10 : 1000kg
15 : 1500kg
20 : 2000kg
30 : 3000kg

No code : Walkie type
　　 S : Sub‑step type
　　 R : Center‑rider type

Model serial No.

No code : Built-in charger

　 　 C : Stationary charger

Fork（Platform）outer width(mm)
10/15 20/30
PLD KLD PLD KLD
Fork (platform) width A 660 610 680 660
B 610 510 555 570
C 560
D 510

Fork (platform) length 07 : 765mm
09 : 915mm
10 : 1068mm
12 : 1220mm
13 : 1372mm
15 : 1525mm

CS : Cold storage use for ｰ35℃

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 base frame. (upside)

Location of serial numbers

(1)

(2)

*This illustration shows PLD10. 321S002E

10
 SAFETY WORK

FBD SBW
Model name
Name plate

LOAD CHART
MODEL LIFT HEIGHT
mm
MAXIMUM kg mm

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

BATTERY WEIGHT MIN. kg

FBD
SBW
Capacity code 7 : 700kg
9 : 900kg
10 : 1000kg (FBD)

No code : Walkie type
　　 S : Sub‑step type

Model serial No.

No code : Built-in charger

　 　 C : Stationary charger

Maximum lifting height(mm)
Double mast
Single mast
FBD SBW
Maximum lifting height 200 2000 2000
230 2300 2300
250 2500 2500
150 1500 270 2700
300 3000
330 3300
350 3500

No code : Without tilt

      T : With tilt
      
     
CS : Cold storage use for ｰ35℃

11
 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 base frame.(upside)

Location of serial numbers

LOAD CHART
MODEL LIFT HEIGHT
mm
MAXIMUM kg mm

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

BATTERY WEIGHT MIN. kg

(1)

(2)

*This illustration shows FBD7. 361S002E

12
 SAFETY WORK

4. Cautions for maintenance

General precautions
 When replacing any parts, be sure to use genuine
NICHIYU parts.
 When assembling parts, always replace old packing
and O-rings with new ones. In addition, be sure to
apply a light coat of grease on 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 inserting 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, observe

Oil grooves
the direction of installation.

152E104

 When connecting and disconnecting couplers of

electrical harnesses, always disconnect the battery
plug.
13
 SAFETY WORK

Using liquid packing

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

152E105

 Applying liquid packing

1. Wipe off the mating surface 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 around bolt holes, 3 -3.5 mm

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

4. Fit the cover on the mating surfaces within 15 minutes

Apply liquid packing
after the liquid gasket is applied.
Within 15 minutes
5. When tightening the bolts, always tighten temporarily
Assemble
first, and then tighten them gradually, with a diagonal
order. Wait for 30 minutes or more

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

14
 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 is separated from the liquid gasket and the gasket

appears shiny when it is squeezed out, 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

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

15
 SAFETY WORK

5. Tightening torque for bolts

Classification of bolt 4T 8T Brass Stainless

SCM435
Material of bolt SS400
(S55C)
BsBM2S-0 SUS304

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}

rs
te ale
4.7 10 3.1 3.6
M6 1.0 {0.48} {1.1} {0.32} {0.37}
bu e
11 26 7.8 9.0
tri d D
M8 1.25
{1.1} {2.7} {0.80} {0.92}
22 55 15 18
D ize

M 10 1.25 {2.3} {5.7} {1.6} {1.9}

39 98 29 33
ot or

M 12 1.25 {4.0} {10} {3.0} {3.4}

is
N uth

62 150 47 53
(M 14) 1.5 {6.3} {16} {4.8} {5.4}
D rA

97 240 73 81
M 16 1.5
fo

{9.9} {25} {7.5} {8.3}

o

180 500 140 150

y

M 20 1.5
nl

{19} {51} {15} {16}

O

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 above table, the thread pitch of the bolt which is sized from M3 to M8 has
the coarse thread and bolts which are sized M10 or larger have the fine thread
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.)

16
 SAFETY WORK

6. LOAD CENTER AND LOAD CHART

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

FBD7 FBD9 FBD10

800 1000 1100

2490mm 2490mm 2490mm

700 900 1000
2690mm
2690mm 2690mm
2990mm
C a p a c ity (k g )

C a p a c ity (k g )

C a p a c ity (k g )
2990mm 800 2990mm 900
600 3290mm
3290mm 3290mm 3490mm
700 800
3490mm
500 3490mm
600 700
400
500 600

300 400 500

200 300 400

400 500 600 700 800 400 500 600 700 800 500 600 700 800 900
L o a d c e n te r (k g ) L o a d c e n te r (k g ) L o a d c e n te r (k g )

SBW7 SBW9
800 1000

2540mm 2540mm
700 900
C a p a c ity (k g )

C a p a c ity (k g )

800
600
700
500
600
400
500

300 400

200 300
400 500 600 700 800 400 500 600 700 800
L o a d c e n te r (k g ) L o a d c e n te r (k g )

CAUTION 1) Completely insert forks beneath the loading object.

2) Do not apply unequal weight on the front half of the fork. It may cause
damages on the mast or forks even if the total weight of the load is
within the maximum loading capacity.
3) If the load is off-centered, the load may slide to sides. Do not handle
the off-centered load.
4) When loading an object, operate the hydraulic valve lever carefully.
5) Sudden operation during high stacking may cause big impacts on the
truck, and may result in tip over.

17
 SAFETY WORK

7. Maintenance tools and inspection devices

The table shows tools/devices required for inspection and maintenance.
Type No. Tool/Device name Detail
1 Double-ended 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 Needle nose plier 150mm
Maintenance
12 Cutting pliers 150mm
tools
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 Adjustable wrench
22 Chisel
23 File
24 Thickness gauge 0.03-3mm
25 Measure 300mm, 1000mm
26 Tape measure 10m
Resistor
27 20Wx50 or 50Wx10 or 10Wx15
(For discharging capacitors)
28 Digital tester
29 Clamp tester
30 Analog clamp ammeter Hioki 3109-01
31 Digital clamp ammeter Hioki 3209AC/DC high tester/Yokogawa CL-612(for measuring solenoid valve current)

Inspection Megger
32
devices
(For inspection of insulation)
33 Oil pressure gauge 25MPa
34 Thermometer Alcohol thermometer
35 Hydrometer Suction type
36 Flaw detector Color check
37 Stop watch
38 Torque wrench 05-1.5, 3-15, 40-200, 150-800Nm(preset type)
39 Dial gauge
40 Spring scale
41 Angle gauge
18
MEMO

19
1. ELECTRIC DEVICES
1- 1. Name
� Battery � Potentiometer � Accelerator Ass’y

Refer to Page35
**ページ参照 Refer to Page28
**ページ参照

Refer to Page37
**ページ参照

� Transformer

Refer to Page45
**ページ参照

� Control Unit

� Traction controller � EPS controller � Steering angle 

　 potentiometer
CU104-90(24V/30A)

Refer**ページ参照
to Page21

**ページ参照
Refer to Page41

Refer to Page26
**ページ参照 Refer to Page27
**ページ参照

321S200e

20
 1a. CONTROL UNIT
1a- 1. Name
 Main parts of Control unit

(2) Contactor

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

(1) Controller
(5) Controller Ass'y,EPS

321S201

No. Part name number Remarks

(1) Controller 1 Curtis 1230-2302
(2) Contactor 1
(3) Fuse 1 Travel/Hydraulic 96V/275A
(4) Diode 1
(5) Controller Ass'y, EPS. 1
(6) Fuse 1 for charger : 250V/15A

21
 CONTROL UNIT 1a

1a- 2. Disassembling and reassembling

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.

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

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

2. Remove the control unit as following procedure.

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

 Removing the control unit

Cover, top

Cover, steering

Control unit

Fitting bolt

321S202

* Install the control unit in reverse order when reassembling.

22
1a CONTROL UNIT

1a-2-2. Control unit - disassembling and reassembling

 Disassembling and reassembling the control unit (1)
 Main terminal (M8)
Tightening torque
8.75 N m 10%

Controller sub ass'y, panel

Controller sub ass'y, main Contactor

Diode

Holder,
fuse
 Main terminal (M5)
Fuse
1 Tightening torque
Board comp., MPU
1.5 - 2.5 N m
Base  Fitting bolt (M6)
2 Tightening torque
2.5 - 3.9 N m

Controller Ass'y, EPS

Controller  Main terminal (M5)

Tightening torque
9 N m 10%

: Tightening torque 321S203

23
 CONTROL UNIT 1a

 Disassembling and reassembling the control unit (2)

Controller sub Ass'y, panel

BC

Panel

Indicator, battery

Fuse BC
Plate, name
Holder,
fuse Switch, push

Receptacle

Switch,
magnet

Socket

20A

Receptacle

Horn

321S204

 Disassembling and reassembling the control unit (3)

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

Panel
Switch

Unit (case side)

Switch,
push

Fit side on the unit in case guide

ditch on the switch.
: Tightening torque 321S226

24
1a CONTROL UNIT

1a- 3. Inspection, replacement and attention

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

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

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

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

If it is damaged, replace it.

CAUTION To be safe, the assembly should be replaced

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

<Type of contactor> 321S205

Applicable  Main terminal (M5)

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

CAUTION Be sure to check chassis insulation when parts

of the control unit are replaced.

25
 CONTROL UNIT 1a

2 Chassis insulation - check

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

Specification 1M or greater

Chassis
battery plug Tester

Fork side

Chassis
side
321S206

1a-3-2. Traction controller - specification

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

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

V
W 321S207

Main terminal (M5))

Tightening torque
9 N m 10%

: Tightening torque

26
1a CONTROL UNIT

1a-3-3. EPS controller - specification

Applicable Current  EPS controller

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

[Blue] : to traction
controller (B-)

[Red] : to traction To EPS motor

controller (B+) (2P-X)

321S314

27
1b. ACCELERATOR ASS'Y
1b- 1. Name
 Main parts of Accelerator Ass'y (1)

Cover, controller

Switch
Comp., (EM)

Spring, return

Knob, speed

Shaft

Link
Bracket, controller

Potentiometer
Knob, speed

Arm
Case,
CS controller

Register Comp.

Bracket,
controller

321S209

28
1b ACCELERATOR ASS'Y

 Main parts of Accelerator Ass'y (2)

Switch Comp., (up/down)

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

Switch, Switch, Bracket,

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

Switch,
micro

Key

Bracket, controller
Switch, key

Cap

Button,
emergency

Actuater

Handle

Case, controller

361S201

29
 ACCELERATOR ASS'Y 1b

1b- 2. Disassembling and reassembling

 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.

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

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

CAUTION Record places of lead wire connections before disassembling.

2. Remove "Cover, controller"

3. Remove the switches.

 Removing "Cover, controller".

Switch,
push button(tilt)

Key
Switch,
Switch, key
push button(horn)

Cap

Fitting screw

321S210

30
1b ACCELERATOR ASS'Y

2. Remove "Handle".
 Removing the handle

Handle

rs
te ale
321S211

bu e
(Refer the illustration on the next page.)
tri d D
3. Remove "Knob, speed".
D ize

1. Disconnect the fitting screw (*1), (*2).

2. Remove "Link", the washer and "Spring, return".
ot or

3. Remove "Knob, speed", "shaft" and the bushing.

is
N uth

4. Remove "Bracket, controller".

D rA

1. Disconnect the wiring connecter.

fo

2. Disconnect the fitting screw (*3) to remove "Bracket, controller".

o
y

3. Remove the each switch of EM, UP and DOWN.

nl

4. Remove "Arm" and "potentiometer".

O

CAUTION Record places of lead wire connections before disassembling.

31
 ACCELERATOR ASS'Y 1b

5. Remove "Button, emergency".

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

 Removing the accelerator Ass'y

Button, down

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

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

Bushing
Spring, return Knob, speed

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

Bush
Potentiometer

Fitting screw (*1)

Arm

Spring

Fitting screw (*3)

321S212

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

32
1b ACCELERATOR ASS'Y

1b-2-2. Accelerator Ass'y - disassembling and reassembling

 Disassembling and reassembling of Accelerator Ass'y (1)
Screw
Washer

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

Spring, return G
Apply grease

Switch Knob, speed

Comp., (EM)

Shaft

Bracket, 2 Knob, speed B

controller
Degrease and apply CEMEDINE
Link [#575] or an equivalent product when
fitting.

Knob, speed

Potentiometer
Arm
Case, controller
CS

Register,
Comp.

Bracket,
controller

B : Apply bond
G : Apply grease
321S213

33
 ACCELERATOR ASS'Y 1b

 Disassembling and reassembling of Accelerator Ass'y (2)

Switch Comp., (Lift/Down)

Button, down

FBD7-10 Button, lift

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

Switch,
micro

Bracket,
controller

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

Button,
Switch, key emergency

Handle

Case, controller

B : Apply bond
361S202

34
1b ACCELERATOR ASS'Y

1b- 3. Inspection and adjustment

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.

1b-3-1. Shaft - inspection

1. Check for wear.
Inspection of shaft
[mm]
Item Specific dimension Wear limit
D
Shaft [ D] 10 9.9

321S214

1b-3-2. Adjustment of the potentiometer

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

between white (IN) and black (GND).

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

2 Check of potentiometer output voltage

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

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

<Specification>
Knob, speed is in neutral 50% 2% of the power supply voltage

Forward and backward ends 12 - 88% of the power supply voltage

NOTE The voltage (5V) is applied to the potentiometer

circuit even if the key switch is turned off.

CAUTION Be sure not to measure resistance of the

potentiometer directly.

35
 ACCELERATOR ASS'Y 1b

1b-3-3. Button, emergency - working check

Walk behind and Sub-step type
1. Tilt the handle to the drive position. Button, emergency - working check
2.Check that the travel direction is reversed by pressing
the emergency button while the truck moves forward Button, emergency
(sub-step : backward). Press

NOTE The reversal movement is ended within one

second.

CAUTION After releasing "Button, emergency", return the

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

321S216

Center-rider type (PLD KLD)

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

NOTE The hydraulic operation is possible even in this

state.

36
 1c. BATTERY
1c-1 Disassembling and reassembling
CAUTION  Turn off the key switch and disconnect the battery plug before working.
 Be careful not to touch with electrolyte to the body.
 If the electrolyte is splashed into eye, wash out with water, and consult
physician immediately.
The inspection of the battery should be done in a place where is well
ventilated and kept away from fire.

PLD KLD
 Removing and installation the battery
PLD . KLD

Battery Ass'y

Plug, battery

Case, battery

Lift Ass'y

321S217

37
 BATTERY 1c

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

Battery Ass'y
Plug, battery

Case, battery

Frame

361S203

38
1c BATTERY

1c-2 Inspection and adjustment

1c-2-1. Battery - inspection and adjustment
1 Inspection of quantity of electrolyte and  Inspection of electrolyte level
replenishment Appropriate level

<Checking procedure>
1. Disconnect the battery plug.
2. Open the battery cover and apply the stopper.
3. Check electrolyte level.

<Specification> Proper level of electrolyte

 If the red float can see, electrolyte level is correct.
If not, replenish with refined or distilled water.

Lowest level of electrolyte

Replenish water

<Replenishing with refined water>

1. Remove the lid of the plastic tank, dip the hose with a  Replenishing procedure
lid into the tank deeply and tighten it up. Bottle Lidden hose
2. Open the cap and put another end of the hose into the
Hose
battery sell.
Pinch-cock
3. Open the pinch-cock and press the tank at the both
sides several times. Cap
4. Refined water will flow into the cell by siphon action.
5. Close the pinch-cock to stop replenishing just before Vent plug
the red-float touches the indicating plate of the cap.

Cap

White line Float

Battery

Level of
electrolyte

461E254

39
 BATTERY 1c

2 Measurement of specific gravity of electrolyte in each cell

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

Difference between max. and min. Less than 0.05

specific gravity

<Recharging procedure>
1. Carry out equalizing charging.
2. Check specific gravity at each cell after equalizing
charge and make sure the difference is within a
standard value.  Conversion
The standard specific gravity is based on the
1.330
temperature with 20 . Convert the actual specific 1.310
gravity to the value at 20 . 1.300 1.290

Specific gravity at 20

Specific gravity at 20
1.290
<How to convert to specific gravity at 20 > 1.280
1.270
1.270
1.260 1.250
1. Measure temperature of electrolyte. 1.250
1.240 1.230
1.230
1.210
CAUTION Use thermometer to measire. 1.220
1.210
1.190
1.200
1.190 1.170
2. Measure specific gravity of electrolyte. 1.180
1.170 1.150
3. Measured specific gravity shall be converted to the 1.160
1.150
value at 20 . 50 40 30 20 10 0 -10 -20

[Conversion formula] Temperature

S20=St+0.0007(t-20)
S20:specific gravity converted at 20 .
St: Measured specific gravity
t : Temperature of electrolyte.

1c-2-2. Battery - cleaning

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

2 Cleaning vent plug

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

NOTE If the cap damaged, replace with new one.

40
 1d. STEERING ANGLE POTENTIOMETER
1d- 1. Disassembling and reassembling
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.

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

disassembling and reassembling

 Removing and installation of steering angle potentiometer

Bracket,
potentiometer

Potentiometer

Steering angle
potentiometer

321S218

41
 STEERING ANGLE POTENTIOMETER 1d

1d- 2. Checking and adjustment

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

<Specification>
Steering position is in Tester
ハンドル直進状態での出力50% 2%電源電圧の supply voltage
of the power 50% 2% stick(+） 3P
neutral
出力電圧範囲 電源電圧の 12 ～ 88%
Right and left ends of

Black(GND)
White(IN)
Red(OUT)
12 - 88% of the power supply voltage
steering
Tester stick(-)

321S227

NOTE The voltage (5V) is applied to the potentiometer

circuit (between "White" and "Black") even if the
key switch is turned off.

CAUTION Be sure not to measure resistance of the

potentiometer.

2 Adjustment procedure
1. P r o v i d e 5 V p o w e r s u p p l y t o t h e a c c e l e r a t o r
potentiometer.
2. Unplug the connector and insert the voltage measuring
adaptor.
3. Measure the output voltage between red and black wires.

42
1e CHARGER

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

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

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

charger)
Controller sub Ass'y, panel

Panel

Indicator, battery
Fuse

Plate, name
Switch, push
Holder, fuse

Receptacle

Switch, magnet

Socket
20A

Receptacle

Horn

321S219

43
 CHARGER 1e

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

charger)

Fuse

LY relay

To potentiometer To bearing To steering To power supply

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

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

Harness, CU

Diode Condenser

321S220

44
1e CHARGER

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

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

Frame

Primary coil
Transformer
0V

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

[+]

Secondary coil

321S221

45
 CHARGER 1e

1e- 2. Inspection and replacement

1e-2-1. Switch, magnet- inspection
1. Check any burnings or damages. Inspection of Switch magnet

Terminal
Switch, magnet

321S222

1e-2-2. Plug comp. and receptacle - inspection and replacement

rs
te ale
1. Check any burnings or discoloration on the receptacle.  Inspection of plug comp. and
receptacle
bu e
If finding any abnormalities, replace both the plug comp.
tri d D
Fitting nut
and the receptacle.
2. Check if the earth wire is tightened securely.
D ize

Receptacle
ot or
is
N uth

Earth wire
D rA
fo

Plug comp.
o
y
nl
O

321S223

1e-2-3. Fuse and Holder, fuse - inspection

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

Fuse

Holder, fuse

321S224

46
1e CHARGER

1e-2-4. Transformer - inspection

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

Specific parameter for insulation

5M or greater
resistance

2 Transformer insulation measurement Transformer insulation measurement

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

1. Use a megger to measure the following locations and

check the insulation.
Between the primary and secondary coils
Between the primary coil and the chassis
Between the secondary coil and the chassis

321S225

1e-2-5. Transformer - specification

Power supply
Applicable model Battery capacity Capacity Transformer
voltage
PLD KLD10-20
FBD7-10 165-201Ah 1.6KVA T0111-0600
90V/100V/110V SBW7/9
PLD KLD30 250Ah 2.1KVA T0111-0610

47
 2. WORKING CHECK
2- 1. Brake switch - working check
1. Set the handle at horizontal or vertical position.
2. Check if the truck is inactivated and does not move.  Working check of brake switch

Locked

NOTE The hydraulic operation still works even in this Handle

state.

Locked

321S307

2- 2. Neutral safety function

- working check
1.Turn off the key switch.
2.Tilt the handle to drive position and turn on the key
switch with operating the accelerator knob.
3.Check if the truck is inactivated and does not move.
4.Check that you can operate the truck after returning the
accelerator to neutral.

2- 3. Hydraulic system
- working check
2-3-1. Lift mechanism- working check
 Working check of lift mechanism
1. Check that the hydraulic motor starts and the fork is
raised by pressing the lift button.
Lower button Lift button

NOTE As for PLD/KLD, lift function stops automatically at

the upper limit.

2.Check that the down solenoid valve opens and the fork
is lowered by pressing the lower button.

321S301

48
2 WORKING CHECK

2-3-2. Tilt mechanism - working check

(Only for FBD with tilt function)
1. Check that the fork is tilted up by pressing "Tilt up  Working check of tilt mechanism
button".
2. Check that the fork is tilted down by pressing "Tilt down
button".

Tilt down
button
Tilt up
button

321S302

2- 4. Turning speed reduction

- working check
1. Check that the travelling speed is reduced when the
steering handle is turned.

2- 5. EPS - working check

1. Check that the direction of the steering handle matches
with the direction of the drive tire.
2. Check that the truck goes straight when the steering
handle is parallel to the chassis.
If it does not go straight, refer to "1b-3-2 Adjustment of
potentiometer" and "1d-2-1 Adjustment of steering angle
potentiometer" for adjustment.
3. Check that the steering mechanism doesn't hit the
mechanical stopper when the steering handle is turned to
the right or left end.

49
 WORKING CHECK 2

2- 6. Charger - working check

(Only for truck with built-in charger)
2-6-1. End timer working check
1. Connect the AC plug to the receptacle on the chassis.  Working check of charger (1)
2. When press the charge button, charging starts.
Receptacle
Make sure that the charging current flows to the battery.
3. After charging starts, disconnect the battery plug.
Charge button
4. Make sure that the timer stops about 10 seconds later (Charge LED)
and the charge LED turns off.
Press

To AC plug
321S304

2-6-2. Total timer working check

 Working check of charger (2)
1. Connect the AC plug to the receptacle on the chassis.
2. When press the charge button, charging starts.
Make sure that the charging current flows to the battery.
3. Press and hold the charge button for at least 3
seconds, and the test mode starts.

NOTE After the test mode starts, the charge LED blinks 3
CHARGE
times.

Charge LED(Charge button) blinks

4. Make sure that charging stops about 100 seconds later 321S305e

and charge LED flashes at 0.4 second interval.

50
2 WORKING CHECK

2- 7. Setting parameter of travel controller

2-7-1. Handheld programmer
Use the handheld programmer to set up the parameter of
the travel controller

 Handheld programmer

LCD display

Data INC/DEC key

Menu navigation key

Bookmark key

321S309

1 Connecting procedure of handheld programmer

1.Turn off the key switch.
Travel controller
2.Remove "Cover, top".
Refer to "1-2-1. Drive unit - removal and installation".

3.Connect the handheld programmer to the travel

controller.
4.Turn on the key switch.

NOTE Turn off the key switch before connecting or

disconnecting the programmer because the power
for the handheld programmer is supplied from the
chassis.

5.LCD display is appeared several seconds later, and you Connect the
handheld programer
can change setting values.
321S313

51
 WORKING CHECK 2

2-7-2. Change to set the parameter

1.Check that the parameter grouping screen appears on
LCD display.
2.Press button or button on the Menu navigation
key to change the parameter grouping.
3.Press button and display the parameter item screen.

 Parameter grouping screen

Program
Parameter grouping is displayed.
Monitor
Faults indicates the current grouping.
Functions
Move the grouping
to choose. *This screen is for reference, it may be different from actual
Information
Programmer Setup one.

321S310

4.Repeat the operation (2 3) until showing the second

parameter which will be changed.
5.When the required parameter is displayed, select the
item by pressing button or button.
6.Press button to get the parameter change screen.

 Parameter item screen

Program
Max Speed 92% Current setting value is displayed.
Acceleration 1.2s
Monitor indicates the current item.
Faults
Move the grouping
to choose. *This screen is for reference, it may be different from actual
Functions
one.

321S311

7.Change the value by pressing button or button.

CAUTION Pay attention not to put the wrong data because

the setting is changed at the same time when
the value is changed.
 Parameter value changing screen

Program Current setting value is displayed.

Max Speed
Yo u c a n c h a n g e t h e v a l u e b y
92%
pressing button or button
Min Max
10 100
321S312
*This screen is for reference, it may be different from actual
one.
8.In case of changing another parameter, return to the
upper level by pressing button or button and
repeat the procedure 2 - 7.

52
2 WORKING CHECK

2-7-3. Parameter table

<Type>
Number Type
(1) PLD KLD10/15/20/30 Std, Sub-step type
(2) PLD KLD10/15 Center-rider type
(3) FBD7/9/10 SBW7/9 Std, Sub-step type
(4) PLD KLD20/30 Center-rider type

CAUTION Traction controller has two travelling modes "Mode1(M1)" and

"Mode2(M2)" and you can set up "acceleration", "deceleration" and
"Maximum speed" on each mode.
The mode is exclusive for each model and the traction feel does not
change even changing values if they are not used for that model. Make
sure if the selected mode is correct for the truck.
Mode Type
Mode 1 (M1) (1), (2), (4)
Mode 2 (M2) (3)

<Specifications>
Setting value
Grouping Item function Specification
Range Unit
Type(1) Type(2) Type(3) Type(4)
0.1-5.0
M1 Accel Rate acceleration1 1.7 1.7 (1.7) 2.2 Sec.
(*Note 1)
0.1-5.0
M2 Accel Rate acceleration2 (2.2) (2.2) 2.2 (2.2) Sec.
(*Note1)
Rates
0.5-10.0
M1 Decel Rate deceleration1 1.7 1.7 (1.7) 1.7 Sec.
(*Note 2)
VEHICLE
0.5-10.0
M2 Decel Rate deceleration2 (1.7) (1.7) 1.7 (1.7) Sec.
(*Note 2)
Maximum 5-100
M1 Max Speed 90 90 (90) 100 %
speed1 (*Note 3)
Speed
Maximum 5-100
M2 Max Speed (90) (90) 90 (70) %
speed2 (*Note 3)
Maximum 2200 or 3100
Motor Max Motor Speed 2200 3100 2200 3100 PRM
speed (*Note 4)

*Note1) Time to be necessary to reach maximum speed when the accelerator knob turns
from OFF to FULL. Acceleration becomes slow when the value is big.

*Note2) Time to be necessary that the truck stops when the accelerator knob returns
from FULL to OFF. Dcceleration becomes weak when a number is big.

CAUTION Note that the stopping distance becomes considerably long

when the value is too much.

53
 WORKING CHECK 2

*Note3) The item to restrict the maximum speed

Set the percentage against the maximum speed which is set by
"Note4" .
Refer to the following for the setting procedure.

*Note4) The specification of the maximum speed.

Do not set more than the specification.

Max Motor Speed Speed

2200 5 km/h
3100 7 km/h

1 Setting procedure of Max speed

① [Max Motor Speed] × A(%) ＝ Max. speed to set up A is
setted up to [M1/2 Max Speed].

(Example) In the case of you change the Max. speed of Model 1 to 3km/h.
[60] is setted up to [M1 Max Speed].
[Max Motor Speed]：2200 ＝ 5（km/h）
5（km/h）× 60（%）＝ 3（km/h）

(Example) In the case of you change the Max. speed of Model 1 to 6km/h.
1) [3100] is setted up to [Max Motor Speed].
2) [85] is setted up to [M1 Max Speed].
[Max Motor Speed]：3100 ＝ 7（km/h）
7（km/h）× 85（%）＝ 6（km/h）

54
2 WORKING CHECK

2- 8. Battery indicator
Battery indicator displays discharging state by illuminating 10 LEDs.

CAUTION Charge it when the remaining capacity becomes less than

20%. The life time of the battery will be shortened if it is used
until the truck couldn't be moved.

 Battery indicattor

1 2

4 3
TERMINALS:
1 : Battery [+]
2 : Battery [-]
3 : Not used
4 : from Key switch
321S306

55
 3. TROUBLESHOOTING
3- 1. Self diagnostic function
3-1-1. Diagnostic LED
Diagnostic LED is mounted between the connectors in  Error display lamp

front of the controller. Traction controller

It shows diagnostic as explained below.

NOTE Only one error is displayed at one time, and

doesn't show some different errors at the same
time.

Error display
lamp
321S303

56
3 TROUBLESHOOTING

3-1-2. Error message

LED turn-off  LED brinking
Diagnostic LED Probable Cause
Turn-off Power is not supplied or controller is out of order
Lighting stably The inside of controller is faulted
Diagnostic is impossible
Travel speed encoder is faulted or safety device is faulted.
Motor current is out of range
SRO sequence is faulted
Accelerator potentiometer error is high
HPD sequence is faulted
Accelerator potentiometer error is low
Main contactor is faulted
Brake is faulted
Battery voltage is out of range
Tempature of controller is failure
Controller is faulted
Controller is faulted
Controller is faulted

57
TROUBLESHOOTING 3

58
 WIRING DIAGRAM 4

4. WIRING DIAGRAM
Reference:
Harness mark/color
Red RD
Black BK
Green GN
TRAC. CONTROLLER TRAC. CONTROLLER
Yellow YE
BATTERY(24V) (1230‑2X02) (1230‑2X02) White WH
Brown BN
CONNECTOR CONNECTOR Blue BU
2 LINE LINE Gray GY
3 4 NAME Pink PK
HYD. MOTOR
HYD. CONTACTOR NAME CN
□ PIN No. CN □ PIN No. Orange OG
(※２) M

 RED/WHITE
M2 (※２) Ex) BKWH (=Black/White)

RED/BLACK
P5 1  5 POWER
ACCELERATOR WHITE ACC 1  6 SIGNAL
Black wire with White line.
F1 B‑ POTENTIOMETER
 275A TRACTION CONTACTOR BATTERY(‑) NA 1  7 GND
VA

B+ BATTERY(+)
M1 YELLOW LMT 1  10
U SPEED LIMIT INPUT
WHITE
RDYE

U PHASE U
1 TRACTION M V
V
MC 1  22 TRACTION 
   CONTACTOR
White line
MOTOR PHASE V
3 W
F2 W PHASE W
10A EPS(CU104‑90)

CONNECTOR Black color

LINE
RDBK

X2 X1 NAME
(DETECT AC) KEY SW (※６) CN □PIN No.
RED (※２) (YELLOW)
SW2 1  11 LIFT UP SW  TRACTION 
  (※２) (BLUE) ERR 1   6    CONTACTO
R
SW3 1  12 LIFT DOWN SW
WHITE

(※１) (GREEN) W 1  18 SPEED LIMIT(W)

SW4 1  15 EMERGENCY SW RED
(BLACK) H 1   8 SPEED LIMIT(H)
SW5 1  2 BRAKE SW L 1  19 SPEED LIMIT(L)
(※７) (Hi : Brake release
)
 BLACK/YELLOW
RED/BLACK 1  16
HEATER (※４) P24 POWER
RED/WHITE KS 1   1 KEY SW
BDI
BROWN/WHITE
BLACK/WHITE

M1 M1 1  7 TRACTION 
(※７) R
   CONTACTO

HORN ＳＷ
WHITE/BLACK HORN RED/BLACK
+ GREEN/WHITE
P51 1   2 POWER
EPS SENSOR PT1 1   3 SIGNAL
X1 (STEERING)  BLACK/RED NA1 1  13 GND
100V 22μ
BDI 1   4
RED/YELLOW
P52 1  14 POWER
WHITE/RED PT2
VH 1  1 CONTOROLLER POWER EPS SENSOR 1  15 SIGNAL
X2 (DRIVE)  BLACK/YELLOW NA2
(※２) GND
RED M2 1  23 (DETECT AC)
M2 HYD. CONTACTOR
 RED/WHITE

(※２,３) IN 1  10 SPARE INPUT

SOL UP SOLENOID
OUT 1  20 SPARE OUTPUT
RED/BLACK

(※２) BLUE/YELLOW PS
SOL 1  24 DOWN SOLENOID RY 1  11 BATTERY VOLTAGE
WHITE/RED 1  9 GND
NS WHITE/YELLOW SW 1   5 START/STOP
RED/GREEN BLACK VN 1  12

RED/GREEN
MB PB 2  6 BRAKE SOLENOID(+) GND

3 BLACK/RED NB 2  3 BROWN
BRAKE SOLENOID(‑) LED 1   9 LED

1 1 YELLOW/RED 1
SW6 3 LOW SPEED SW BLUE/YELLOW
FBD/SBW:CONNECT PLD/KLD/NTT90:OPEN MC M2 1  17 CHARGING
  CONTACTOR
RED RP 2  1 POWER
   SPEED WHITE (ONLY THE TRUCK WITH RED
  SENSOR RA 2  2 PHASE A  ON‑BOARD CHARGER) 1 MP
BLUE 2  4 PHASE B
(TRACTION) BLACK RB BLUE
4 RN 2  5 GND 2 K1
EPS MOTOR
A
M WHITE

NOTE. BLACK AA
 ・Symbols with  "※" mark mean・・・
   ※１： Center rider and NTT90 doesn't have this device.
   ※２： NTT90 doesn't have this device
.
   ※３： Only FBD and SBW have this device.
   ※４： Only "CS" (Cold Storage) trucks have this device.
   ※6： Only PLD/KLD.
   ※７： Only Center rider/NTT90.

PLD.KLD.FBD.SBW-70
System wiring 4- 1.
54000-37320-2e

59
4 WIRING DIAGRAM

Reference:
Harness mark/color
Red RD
Black BK
Green GN
W/ Built‑in charger Yellow YE
BATTERY Ass'y White WH
SEE NOTE. 7 Brown BN
Blue BU
Gray GY
<A> Pink PK
<B> Orange OG
0V BLACK <12>
5
<15> Ex) BKWH (=Black/White)
90V 6 ※Remove the two wires(PA,PF) to the hydraulic motor in case of 
NTT90.  Black wire with White line.
6
－ <14>
100V RED <10>
5 Reverse these two wires if the 
6 <16>
truck is center‑rider or NTT90 type
.
110V PLD/KLD FBD/SBW

White line

  

rs
SENSOR‑BEARING DOWN
TRANSFORMER 4P

WHITE/RED
WHITE
SOLENOID Black color
ELECTRO MAGNETIC

te ale
BRAKE HYD. UNIT

RED
PA BLUE/YELLOW RED
7 7

  W V U 7 7
8 WHITE/RED WHITE/RED
HARNESS,BODY HYD. 7 7

8 8 8 CONTACTOR UP SOLENOID

bu e
4P M2
PF

tri d D
8

(WHITE)
(BLUE)

(RED)
HYD.
  2P CONTACTOR
WHITE

7 7
TRACTION MOTOR M2 8

D ize
BLUE/YELLOW 7
PA 8 PF

WHITE/RED
3P EPS Sensor WHITE/RED
(Drive) 7

RED
DOWN SOLENOID HYD. UNIT

ot or
275A
2P
ACCELERATOR,W/SW

is
N th
X

B‑

u
  Note:
U V W

D rA
EPS MOTOR 1. < n > shows lead wire No.
2.Terminal symbol
7 : Receptacle (with sleeve) 
n : Terminal
fo
3P
24P BDI 1 : Terminal
CENTER RIDER,NTT90 ONLY

o 7 7 1 : Terminal
y

6P
BLACK TOP‑MOUNTED 3.All electrical wires should be fixed to prevent from contacti
ng
nl

CONTROLLER,MAIN 3P SUBSTEP,
CENTER RIDER, to the part of moving, with edge and of heat source.
RED/WHITE

BLACK/WHITE

NTT90 ONLY 4.Do not use �plane washer�, use only �Bolt and spring washer�.
6P
O

WHITE
It is to keep electrical connection between �Panel�and �Frame o
f the truck�,
6P to break painted coating of panel by spring washer when assembl
ing.
WHITE
EPS Sensor
(Steering) 5.Refer NIS B7038 for wire treatment.
6.Refer NIS A4010 for drawing instruction.
7.When the battery is �EB Battery�,see WIRING,BATTRY(54000‑5037 0) for wiring instruction.

LIFT UPPER LIMIT SW
YELLOW/RED
YELLOW
YELLOW

HARNESS,CONTROLLER
RED/WHITE

(PLD/KLD ONLY)
FBD/SBW:CONNECT TERMINALS 1 1
1 1
1 1 1 1
FBD/SBW    :CONNECT
BLACK

PLD/KLD/NTT:OPEN
WHITE

PLD.KLD.FBD.SBW-70
Body wiring 4- 2.
54000-37291-2e

60
 Reference:
Harness mark/color
Note:1.Electric wire 2 Red RD
            　: AVS 0.5 mm 2 Black BK
         ☆   : LV or KIV or F‑KIV or WL1 or WRNCT 14 mm Green GN
                   (Refer to the table) Yellow YE
     2.Stamp the symbol mentioned in (  ) or fit mark band on w
ires marked ☆ in this drawing. 
       However the place marked following symbol, can be covere
d by colored TCV cap mentioned below
,  White WH
       no need for marking in this case. Brown BN
        □:Red　　　▽:White　　　△:Blue Blue BU
     3.All pin layout shows the view from terminal insert side. Gray GY
     4.Refer to �Wiring treatment instruction� NIS B7038 for wi
ring treatment. Pink PK
     5.Refer to NIS A4010 for drawing instruction. Orange OG
     6.Refer JIS C2805 for acceptable value of tension to the t
erminals.
Ex) BKWH (=Black/White)
C Traction motor Black wire with White line.

8B
B
7B
B Traction controller 6B 8
B
B
8   D Hyd. motor
8A 8
White line
C

☆(△W)
4A 7A 5B

E0000-08231-2e
5A 5 B

☆(▽V)
E C
F
8 6A 5 8
5 4B

☆(□U)
C Black color

☆(W)
B
5
☆(PF)

☆(V)

☆(FU)
☆(B－)
☆(U)
☆(PA)

RD 7 A 1B Hyd. Contactor
A Steering

PLD KLD-70
WHRD 7 F 2B
E Coil
2A E 1 3 WHRD
AMP 171897‑1 1A E 2 3 RD
CAP 3A F 3 3 BUYE
3 2 1
6P 4
6 5 4 WHITE

Body Harness
5
6 BUYE 7 A 3B Down
WHRD 7 E 2C F Solenoid Valve

WIRE,LEAD (with ☆ mark)
PART NO SPECIFIC
CROSS‑SECTION
Kind of wire A
        ARE
2
54000‑41651‑2 LV, KIV, F‑KIV 14mm STD/RP
54000‑41661‑2 WL1,  WRNCT 14mm 2 CS

4- 3.
WIRING DIAGRAM 4

4-3-1.
61
62
Reference:
Harness mark/color
Red RD
Black BK
Note:1.Electric wire Green GN
2
            　: AVS 0.5 mm Yellow YE
2
         ☆         : LV or KIV or F‑KIV or WL1 or WRNCT 14 mm White WH
4 WIRING DIAGRAM

                    (Refer to the table) Brown BN
     2.Stamp the symbol mentioned in (  ) or fit mark band on w
ires marked ☆ in this drawing.  Blue BU
       However the place marked following symbol, can be covere
d by colored TCV cap mentioned below,  Gray GY
       no need for marking in this case. Pink PK
        □:Red　　　▽:White　　　△:Blue Orange OG
     3.All pin layout shows the view from terminal insert side.
     4.Refer to �Wiring treatment instruction� NIS B7038 for wi
ring treatment. Ex) BKWH (=Black/White)
Black wire with White line.
     5.Refer to NIS A4010 for drawing instruction.
     6.Refer JIS C2805 for acceptable value of tension to the t
erminals.

F Tilt(opt) White line

1 2
3 4

B Traction controller C Traction motor DHyd. motor AMP 172134‑1 Black color

E0000-10291-1e
7B Plug 4P White
10A 10B
C B B E Hyd. Contactor
6A 9A 9B 6B G Lift up H Lift down
5 8 6 1 2 3 4

 
7A C 8B B B
D

 
D B 2B 4B 5B 2C 1C
 
8 8A 5 8 8
5 8 A,F A A E,G E,G
C 1B 2D 1D 3B 1E

☆(W)
1 3 3 3 3

☆(PF)

☆(△W)
5 A,F F F,H A G

☆(V)

☆(FU)
1 1 1 1 1

☆(▽V)

☆(B－)
RD

☆(□PA)

☆(□U)
WH
GNWH
RD
WHRD

☆(U)
RD
WHRD
BUYE
WHRD

WHRD

FBD SBW-70
A Steering
1A E 1 3
WHRD
AMP 171897‑1 2A E 2 3
RD

Body Harness
3A H 3 3 BUYE
3 2 1 Cap 4
6 5 4 6P White WH
4A F 5 3
5A F 6 3
GNWH

 
WIRE,LEAD (with ☆ mark)
PARTS No. SPECIFIC
Kind of wire cross‑section area

54000‑51931‑1 LV, KIV, F‑KIV 14mm 2 STD

54000‑51941‑1 WL1,  WRNCT 14mm2 CS
   

4- 3.
4-3-2.
 WIRING DIAGRAM 4

Reference:
Harness mark/color
Red RD
Black BK
To Harness, Body To Transformer Green GN
CONTROLLER SUBASS'Y,PANEL

(Not unnecessary for NTT90)
Yellow YE
External teminal (Only for truck

(Not unnecessary for NTT90)
(1Φ100V only) White WH

RDWH
(Note 7)

BKWH
 with chrger)  1 28 PLUG Brown BN

RDWH

CENTER RIDER
BKWH
 1 28 Note6 Blue BU
Harness, body

CENTER RIDER

   
To CONTROLLER SUBASS'Y, PANEL Note5 RD☆ <3> Gray GY
4
5 5 5 GN☆ 7 7 Pink PK
(NOTE 9) 4
15 7 7 GN☆ WH☆ <4> Orange OG
Plug FUSE 4
COMP. RDYE 31
10A WH☆

<16>
Ex) BKWH (=Black/White)

<14>

<15>
NOTE 3

 
4 BK☆ <5>
GN☆ BDI 4
Black wire with White line.
4
M‑ M+ BDI RD☆ GN☆

WH☆
RD☆
4 CHRGE SWITCH 4
<6>
CHRGE SWITCH 9 29 Note5
<2> 5 L‑
<13> 8 8 PLUG WHYE 18
NC 18 BN 30 4
GN☆ <6>
9

WH☆
L‑ GN☆
18 RDGN

RD☆
  5 BK NO 18
WHYE 18
NC 18 BN 29 30 COM 10
31
11
3 S＋ 2 1 BK NO 18 18 RDGN MAGNET SWITCH White line
DIODE MAIN CONTACTOR COM 10
11
(NOTE 8) 5 5 5  1
RDWH 10 16
7 RDGN A B BUYE
BNWH
 7
M1 7 Mctt 7
<A> ＋ 8 275A 8
FU 7
10 16
AC FUSE
RD☆
<7>
7
19 20
7 RD☆
<10>
Black color

RDGN A B BUYE RD☆ 3 3 RD☆

7 BK☆ 7 Mctt 7 <7> <3>
WH☆ 7 15 16 WH☆
FUSE <1> <9>
WH☆ WH☆ <8>
7 <11>
RD☆ 13 14 RD☆ 3 3
RD 7 7 <8> <4>
 28 <10> BK☆ 7 13 14 BK☆
BK☆ 3 3 BK☆ 7
BKWH
5 5 BK☆ 11 12 BK☆ <9> <5> <9> <12>
BU <9> 7 7 12
<12> 11
B+ F+ B‑ EPS CONTROLLER
WH☆
7 MAGNET SW
  
<B> NOTE 4
AC FUSE
 

<10>
<12>

<10>
<11>
<12>
5 5 5

WH☆
BK☆
RD☆
RD☆
BK☆
U V W CA 
RELAY

WHBK

BKWH

WHBK

BKWH
27 28
5 5 LY RELAY 27 5 5 5 LY RELAY
28
(NOTE 10) to TRANSFORMER (NOTE 10)
to TRANSFORMER
HARNESS,CU 7 7 (Only the truck 7 7 (Only the truck
 with chrger)  with chrger)
TRACTION CONTROLLER (NOTE 7)
(NOTE 7)

20P HORN to CONTROLLER  HORN to CONTROLLER 

6P    SUBASS'Y,MAIN    SUBASS'Y,MAIN

BU
RD
1Φ100V 3Φ200V
to HARNESS,
CONTROLLER
(Note7)

(Not unnecessary for NTT90)
CONTROLLER SUBASS'Y,MAIN CONTROLLER SUBASS'Y,PANEL

RDWH

BKWH
(BACK SIDE  VIEW) 28
 1

CENTER RIDER
Note.
1. Wire  (not specified) CONTROLLER ASS'Y,MAIN
2
 　　　　：AVS0.5mm 8. TIGHTENING TORQUE OF THE CHARGING DIODE) 7 7
☆ 2
 　　　　：KIV0.75 or 1.25 or 2mm     Fitting(M6)：2.5～3.9N・m
 2. Terminal     　Terminal(M5)：1.5～2.5N・m
 　　　　：Receptacle　AMP 41729
7 BDI
9. 10A FUSE should be tied to the main harness <1>.
n
 　　　　：Rounded terminal　JST
 3. Contactor(ALL BRIGHT inc.) M8 terminal tightening torque 7. The extraction direction of the harneses should be like the 
6. Wiring for the charging plug of 3
Φ200V should be like  drawing below.
 　　8.75N・ｍ±10%     the drawing below. 
 4. Traction controller(CURTIS inc.) M5 terminal tightening tor
que
 　　9N・ｍ±10% 

WH
GN
SCREW
5. The earthing terminal of the charging plug (GN) should be li
ke
WIRE Strip length : 10±1mm 2P 8
GROMMET
WH
the drawing below.Check the earthng resistance after assembling
. to the transformer
Tightening torque : 0.98～1.18Nm

BKWH
WHBK
TERMINAL
4P Water 27 28 to CONTROLLER 
resistant
   SUBASS'Y,MAIN
PANEL to PLUG COMP. to HARNESS,BODY
GREEN 7 7
10. Wiring of the LY‑RELA
Y 3P Water
PLUG resistant

NC 10 6P
HORN
25 RD RDGN
NO
TERMINAL WH
Tighten up with washer‑w/teeth and nut. 15 RDBK C RDBK 15 Without CHARGER
Don't use plane‑washer or lock‑washer.
6P
30 RD WH 29 BK
   11. Numbers with "  " mark show the wire
 
    numbers in the drawing of HARNESS,CU
. 3P Water
resistant

PLD.KLD.FBD.SBW-70
Controller wiring 4- 4.
54000-52020-3e

63
4 WIRING DIAGRAM

Reference:
Potentiometer Harness mark/color
Sensor
C Electro
magnetic brake B (drive) D bearing Red RD
E Steering Black
Green
BK
GN
Yellow YE
White WH

 
2 1
1 1 2 3 1 2 3 1 2 3 Brown BN
4 3
2 4 5 6 4 5 6 Blue BU
AMP 172130‑1 AMP 174359‑2 AMP 174257‑2
AMP 171898‑2 AMP 171898‑1 F Power supply Gray
Pink
GY
PK
Plug Water Water Plug Plug
resistant resistant Orange OG
Charge
2P White Plug 4P 6P BK 6P WH
G LY relay I

 
Cap 3P

24B 13B 20B 22B 17B 18B 31A 26A 28A

8
(Note.7)
H AC
contactor
switch Ex) BKWH (=Black/White)
Black wire with White line.

RDYE
O A O O A A L N N
21B 4B 14B 19B 23B 6B 8B 1B 25A 27A
O A A O A A A A,N G J 5 30A 15E 10B 10C 16B 11B 9B
L G A,H G,I A A A

10A
(Note.5)
1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6

BKWH
5B 10D

Fuse
29A 15D 25B
3 3 4 4 4 4 4 4 4 3 3 3 3 3 3 3 3 3 3 7 7
L F,G E A H

RDBK
RDGN

WHRD
BKRD

RDWH
GN※
BKYE
White line

RD

WHBK
BKWH
RD
RDYE

YE

WH
BKYE

WH
WH

BU
RD
18 18 18 18

BK
16 16 16 16 16 16

RDGN
BUYE
15C 28C
N,G F,K

RD
RDGN

WHYE
BK
RDBK

RDGN
RDBK

BN
WH※
RD※
Black color

CA relay
tied position

Note.8 Note.8
Note.8

＋
100V

BKWH
ＢＮWH
22μ

RDWH
RDWH
BKWH
RDBK

RDWH
WH
RDGN
BKRD
GNWH

WHBK
BNWH
RDWH

WHRD

BKWH
GNWH

RDGN
WHYE
RDBK

BKRD

RDBK
RDBK

BKRD

BUYE
RDYE

BKYE

BKYE

ＷＨ☆

ＷＨ※

ＧＮ☆

GN※
RD☆

RD※
WH

BU
RD

BK
WH

BN
RD

BK

YE

3 3 3 3 7 7 7 7
1 2 3 4 A F,J
6 6 6 6 6 6 6 6 6 7 7
4 4 4 6 6 6 6 6 6 6 6 6 17 17 17 17 17 17
E E,F 7
4 7 4 4 4
1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7B 28D
E,K L G,L L G,L L E,L M K
A A D C 26B 28B
E P I M I G P B H E D E 28E
A,F E,M 1D 29C 29B 30C 30B 31C 31B 1E
2B 12B 19A 21A 23A
1A 3A 5A 7A 9A 10A 12A 14A 16A 18A 27B
A D D C 15B 1C
P B E E I B N E

J
3B 20A 22A 24A
2A 4A 6A 8A 11A 13A 15A 17A
Horn
AMP 174357‑2
Water
AMP 175967‑2
AMP 794954‑6
Plug
4P White M Contactor L Plug
K BDI
resistant Plug 6P
Plug 3P (20P) AMP 172134‑1
 
1 2
1 2 3 3 4
3 2 1 10 9 8 7 6 5 4 3 2 1
4 5 6 Pay attention to 
20 19 18 17 16 15 14 13 12 11
the pin layout.
N CA relay
(Note.6)
Potentiometer Traction
P (steering) A EPS Controller O controller

Note:1.Electric wire
            　: AVS 0.5 mm
2      7.Refer to the figure below for relays.      8.Refer to the figure below to treat
            ※: KIV 0.75 mm2        (No need to tie up.)        the wire of this part.
2
            ☆: KIV 2 mm
     2.All pin layout shows the view from terminal
 
       insert side. RD 25B 10B
NC RDGN
     3.Refer to �Wiring treatment instruction� 
15D NO 15E
       E40850 for wiring treatment. RDBK C RDBK
Don�t tie up.
     4.Refer to NIS A4010 for drawing instruction. Receptacle
30A 29A
     6.Fit relay (CA1a‑DC24V) to tie up on the place of RD※ WH※ or rounded terminal 
.
       this drawing The arangement of relay

PLD.KLD.FBD.SBW-70
Control Unit Harness 4- 5.
54000-42281-2e

64
 WIRING DIAGRAM 4

Reference:
Harness mark/color
Red RD
Main
3 2 1
6 5 4
C controller 3 2 1
Black
Green
BK
GN
6 5 4 Yellow YE
AMP 171897‑1 AMP 171897‑2 White WH
CAP CAP Brown BN
6P 6P Blue BU
WHITE BLACK
Gray GY

(Accelerator power
Pink PK

(Accelerator GND)
Orange OG

(Relay back)
D Key SW

(Contactor)
(Reduction)
(KS front)
(KS back)
Ex) BKWH (=Black/White)

(Brake)

(Earth)
C

supply)
(Horn)
RD☆

(OPT1)
4 G 22C Black wire with White line.

(GND)
BU☆ 4
C
E 16B
16A 17A 19A 12B 4A 1B

B Low speed
D E I A F A,B LENGTH220
mode terminal 22B 18A 2B 8B 6A 15A (Don�t tie with another wire.)
J,D I A,J A F I
RDWH BU☆ D 16C White line
2A C
1A C 1
2
17
17
BK☆
YERD
1C
1

3
2 3 4 5 6

3
1

3
2

3
3 4 5

3
6 WH☆ C 17B E Horn SW
3A B 3 17 C
4 3B W/O TERMINAL
Pay attention to the 5 Black color
pin layout. A

RDWH
WH☆ Water

WH☆

WH☆

GN☆
BU☆
RD☆

RD☆
BK☆

BK☆

BK☆
5A F 6 17 resistant

WH
PLUG 3P

YE
7
1 RD☆ 4 1
1 C 4B
8 WH☆ 4 Accelerator
F potentiometer
1 2 3 4 5 6 7 8 9 10 11 12 2 A 5B
WHRD
13 14 15 16 17 18 19 20 21 22 23 24 7A 17K 9 Attach the cover (sleeve) BK☆ 4 3 2 1
3 C 6B

RDWH
YE

YERD
8A C 10 17 for shur receptacle.
AMP 2‑794954‑4 YE☆
9A L 11 17 AMP 174357‑2
10A H 12 17 BU☆
Plug 13
24P PLUG
11A
14
G 15 17
GN☆ (WITHIN 10mm) RD☆
3 1
D
H 22D
2P
WHITE
G Emergency SW
A Traction
controller
16
17
GN☆ 2 A 11B
1
2
18
AMP 172130‑1
19
20 (TUBE LENGTH 330 (SEE NOTE.4))
(TUBE LENGTH 530 (SEE NOTE.5))
21 PLUG
WH RD☆ 4P
12A C 22 17 1 G 22E WHITE
13A K 23
24
17
RD YE☆
BU☆
2
3 A 10B
L 9D
1 2
H Lift SW
4 3 4
RD☆ AMP 172134‑1
C 22A
BK☆
YE☆
YE☆

C 2C
BK☆
I OPT.terminal
1 1 1 C 18B (GND)
WH☆
1 2 3 1 C 19B (OPT1)
WHRD GY☆
4 5 6 (COM) 7B 1 3 H   1 K 20A (OPT2)

J Brake SW
A
RD Be sure to connect. W/O TERMINAL GN☆
AMP 171898‑1 (L/U) 13A A 2 3 9C 1 K 21A (OPT3)
3 A Fold down the conductor and crimp the wire 
Plug 4 9B  if only one wire is in the shur plug.
6P GY☆
White (OPT2) 20B I 5

K Hyd. wire
(OPT3) 21B I 6
GN☆
L Lift limit GN☆
8 C 15B

Note:
1.Code of wire
    　 : (No mark) AV/AVS/AVSS 0.5mm2
     ☆: KQE 0.3mm2
2.Refer to NIS B7038 for wire treatment
.
3.Refer to NIS A4010 for drawing instruction.
4.Covered by plastic tube (Tyton P‑075 or equivalent) with both end tied up.
.
  However never tie up inner wire of the tube, should be free
5.Covered by colgate tube (Shinagawa‑shoko CDP‑11S or equivalen t).
   To prevent the wire to be squeezed to cut out by the slit o
f tube, 
   Several places of wire inside the tube should be tied lightl
y by vinyl tape 
   Several places of outside of the tube should be tied lightly .
 by vinyl tape as well
.
6.All pin layout shows the view from terminal insert side

Controller Harness 4- 6.
PLD KLD FBD SBW-70 4-6-1.
54000-54261-1e

65
4 WIRING DIAGRAM

Reference:

Main
K Hyd. wire Harness mark/color
Red RD

3 2 1
C controller
3 2 1 1 2 3
Black
Green
BK
GN
6 5 4 6 5 4
Yellow YE
4 5 6
White WH
A Traction
AMP 171897‑1 AMP 171897‑2 AMP 171898‑1
Brown BN
CAP
6P
CAP
6P controller Pay attention to the Blue BU
WHITE BLACK pin layout. Gray GY
PLUG
Pink PK

(Accelerator power
6P

(Accelerator GND)
WHITE Orange OG
PLUG 1 2 3 4 5 6 7 8 9 10 11 12

(Relay back)
D Key SW

(Contactor)
(Reduction)
24P 13 14 15 16 17 18 19 20 21 22 23 24
Ex) BKWH (=Black/White)
(KS front)
(KS back)

(Brake)

(Earth)
supply)
(Horn)
AMP 2‑794954‑ 4 RD☆ Black wire with White line.
(OPT1)

(COM)
C
(GND)

(L/D)
(L/U)

(OPT2)
(OPT3)
4 G 22B
BU☆ C
5A 8A 10A 12A 14A 4 E 16B
16A 17A 19A 12B 4A 1B 7B 14A 20B 2A
C F C H C K
D E I A F A,B A A I LENGTH220
22A 18A 2B 8B 6A 15A 13A 21B 1A 3A 7A 9A 13A
(DON'T TIE WITH ANOTHER WIRE)
D,K I,K A,J A F I A I C B K L K
BU☆ White line
E Horn SW
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 D 16C
1 2 3 4 5 6 1 2 3 4 5 6 WH☆
3 3 3 17 17 17 17 17 17 17 17 17 17 17 C 17B
3 3 3 3 3

WHRD

GN☆
GY☆
RD
BUYE

RD
WH
BK☆

BU☆

BUYE
YERD

WH☆

YE☆
RDWH

WHRD
YE
(W/O TERMINAL) Black color
RDWH
WH☆

WH☆

GN☆
RD☆
BU☆
RD☆

BK☆

BK☆

BK☆

Water
resistant
WH
YE

PLUG 3P
RD☆ 4 1 C 4B
Accelerator
WH☆
BK☆
4
4
2 A
3
5B
C 6B
3 2 1 F potentiometer
AMP 174357‑2

PLUG
(WITHIN 10mm)
RD☆
3 1
D
H 22C
2P
WHITE
G Emergency SW
(TUBE LENGTH 990 (SEE NOTE.5)) GN☆ 2 J 11B 1
2
AMP 172130‑1

(TUBE LENGTH 90 (SEE NOTE.4)
) PLUG
RD☆ 4P
1 G 22D WHITE

GN☆
YE☆
BU☆
2
3 A 10B
L 9D
1 2
H Lift SW
Attach the cover(sleeve) G 11A 3 4
BK☆ 4
for shure receptacle C 2C AMP 172134‑1
RDWH
YE☆
YE☆

YERD

J Brake SW
1 1

H
1 1

A (W/O TERMINAL)
BK☆
WH☆
1
1 C 19B
C 18B (GND)
(OPT1)
I OPT.terminal
GY☆ (OPT2)
1 K 20A
(CONNECT) GN☆
K K 21A
9C 3B 1 (OPT3)
RD☆
A C
BK☆
7 C 22F BDI Fold down the conductor and crimp the wire
 
7 C 18C  if only one wire is in the shur plug
.
9B 1C

L Lift limit B Low speed
mode terminal GN☆ 8 C 15B

Water
Water resistant
resistant PLUG 3P
CAP 3P RD☆ RD☆
23A 1 4 M 23B
L 4 1
Steering
M
Main
controller 1 2 3 25A L
24A L 2
3
4
4
WH☆
BK☆
WH☆
BK☆
4
4
2
3
M 24B
M 25B
3 2 1 L potentiometer
AMP 174359‑2
AMP 174357‑2

Note:
1.Code of wire
    　 : (No mark) AV/AVS/AVSS 0.5mm2
     ☆  : KQE 0.3mm2
  Instead of using multicolored wire, single color wire also ca
n be used.
  In this case, wire numbers should be indicated by mark bands.
  Wire numbers should be based on the table on the top right of
 this drawing.
2.Refer to NIS B7038 for wire treatment.
3.Refer to NIS A4010 for drawing instruction.
4.Covered by plastic tube (Tyton P‑075 or equivalent) with both end tied up.
  However never tie up inner wire of the tube, should be free.
5.Covered by colgate tube (Shinagawa‑shoko CDP‑11S or equivalen t).

 
   To prevent the wire to be squeezed to cut out by the slit of
 tube, 
   Several places of wire inside the tube should be tied lightl
y by vinyl tape 
   Several places of outside of the tube should be tied lightly
 by vinyl tape as well.
6.All pin layout shows the view from terminal insert side.

Controller Harness 4- 6.
PLD KLD-70 (Center-rider) 4-6-2.
54000-72771-1e

66
 Reproduction prohibited
First printing : January 2007

Issued by : Nippon Yusoki Co., Ltd

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