Nichiyu Fb10 30p Dc70 Series Trs

02W-2201
FB-DC70 SERIES
10P/15P/18P
FB 20P/25P/30P
Contents
1. How to adjust SICOS 60 (Major point only) .........................1

1-1 The name and function of mode select switch .......................1
q Slow speed mode button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
w Mode select button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
e Up button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
r Down button (2 functions) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 How to set the each mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
q Speed setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
w Power setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
e Acceleration feeling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
r Option setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
t Language selection on LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
y Safety monitor symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Adjustment of starting current and current limitation . . . . . . . . . . . . . . . . . . 6
q Zero(0) adjusting for installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
w Adjustment of starting current and current limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Adjustment for other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

q Auto-torque up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
w Safety circuit for out of control (contactor tripping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
e Power setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
r Hydraulic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
t Switch back braking distance (Plugging/Regenerative braking) . . . . . . . . . . . . . . . . . . . . 12
y Regenerative braking force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
u Adjustment of brightness of the back light on monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 14
i Checking of speed sensor output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
o Hour meter working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
!0 Confirming the working of auto-power cut off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
!1 Adjusting of battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
q Confirming Over loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
w Confirming the travel inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
e Confirming the lift locking working at over discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
r Confirming the seat switch working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Outline of New EPS system for FB–DC70 . . . . . . . . . . . . . . . . . . . . . 18
4-1 Outline of New EPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-3 Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
q Protection of overheat for motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
w Self diagnosis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-4 Checking and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
q Neutral adjustment of torque sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
w Checking by voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5. Self diagnosis history memory and I/O check . . . . . . . . . . . . . . . . 22

5-1 Self diagnosis history memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-2 I/O check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6. Practical trouble shooting (How to find the cause of problem) . . . . . . . . 31

6-1 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
q Location of negative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
w Layout of the connectors on MPU board and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-2 Attention for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
q Visual checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
w Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
e Error message and possible defective parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-3 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6-4 Analysis of malfunction causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
q No indications are made on the LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
w Indication of the LCD display is normal, but the truck abnormally travels . . . . . . . . . . . 38
e On the LCD display, error meassages appear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-5 Flowchart for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7. Wiring and layout of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1. How to adjust SICOS60
(Major point only)
1-1 The name and function of

mode select switch
q Slow speed mode button.
Change to traveling mode.
When the slow speed mode button is turned
on, the speed is regulated to the preset
speed. (5km/h–12km/h). Slow speed mode button
œWhen the slow speed mode button is turned on,

the turtle mark is displayed on the monitor.
Off On
w Mode select button.

Change the select mode. Mode select button
Speed setting mode (SPEED)
Power setting mode (POWER)
M
Acceleration feeling mode (ACCEL)
e Up button (2 functions)
Increase the parameter of each selected mode.
M UP button
Showing the travel hour meter.

TRAVEL HYD STEER BATT OIL LOAD BRAKE
DISCHARGE
CAUTION
Be sure to check that the decimal point F km/m 0 5 10 15 20
8 SPEED
flashes when the hour meter counts by 6
4
2
traveling or hydraulic operation. E POWER 50 75 100 ACCEL SOFT STD FULL
TRAVEL km
Travel hour meter

DISCHARGE
F km/m 0 5 10 15 20
8 SPEED
6
4
2
E POWER 50 75 100 ACCEL SOFT STD FULL
TRAVEL km
When hour meter counts,

the decimal point flashes.
–1–
r Down button (2 functions).
Decrease the parameter of each selected
mode. M
Showing the hydraulic hour meter. Down button
CAUTION
Be sure to check that the decimal point DISCHARGE
flashes when the hour meter counts by F km/m 0 5 10 15 20
operating traveling or the hydraulic lever. 8

6
SPEED
4
2
TRAVEL km
Hydraulic hour meter

DISCHARGE
F km/m 0 5 10 15 20
8 SPEED
6
4
2
TRAVEL km
When hour meter counts,

the decimal point flashes.
1-2 How to set the each mode
Press the mode select button M to adjust the Mode select button
each mode.
œThe each mode can be changed by pressing the M
mode select button M as follows.
M : Normal
M M : Speed setting mode
M : Power setting mode
: Acceleration feeling mode
–2–
q Speed setting mode
The travel speed can be set at 5km/h through
12km/h by every 1km/h.
Up button for increasing, Down but-

ton for decreasing. M M
NOTE When the slow speed mode button is off,

Down button Up button
the travel speed can not be regulated
even if it is set. Also no display of preset
speed and the “turtle” mark.
km/m 5 10 15 20
SPEED
POWER 50 75 100 ACCEL SOFT STD FULL
w Power setting mode

The power can be set at 3 steps, 100%, 75%,
and 50% by pressing the Up button or
Down button .
M M

(50%–75%–100%)
The preset power is displayed at the km/m 5 10 15 20

“POWER” column on the display. SPEED

}
Preset power
e Acceleration feeling mode

The acceleration feeling mode can be set at 3
modes, Soft, Std (standard) and Full.
M M
: Easy inching

: Normal
(SOFT–STD–FULL)
: Quick accelerator
response
km/m 5 10 15 20
SPEED
NOTE Better inching operation can be achieved

by selecting the "soft" mode. POWER 50 75 100 ACCEL SOFT STD FULL
}
The preset accelerator feeling is displayed at Preset accelerator feeling
the “ACCEL” column on the display.
–3–
r Option setting
1) Set the rotary switch RS1 to “7”, and turn the F01
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23
key switch on.
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AB
789
2) Press the mode select button M to shift the
setting position. Set RS1 to “7”
œThe setting position which flashes can be moved
to the right by pressing the mode select button M.
3) Press,
the Up button to set : display “1”.
[ the Down button to reset : display “0”. M
for each optional specification.
Mode select button

NOTE After finishing to set or reset, be sure to
turn off the key switch and to return the
rotary switch RS1 to “0”.
M M
NOTE When replacing the MPU board, be sure to
set the each function same as original Up button Down button
setting.
Option Set 0 1
Not used – – DISCHARGE
Over Drive
without with
(Option) km/m 0 5 10 15 20
F
Hydrauric by- 8 SPEED
without with 6
pass (Option)
4
Regenerative 2
with without
contactor E POWER 50 75 100 ACCEL SOFT STD FULL
Monitoring displayed off

Seat switch without with TRAVEL km
Lift lock at
off on
over discharge
Not used – –
Not used Monitoring
If the bit of “Seat switch” is changed “0” to
“1” on a standard truch, hydraulic system Over drive (Opt.) Seat switch
and indicator are normal, but the truck
cannot travel. Hydraulic by-pass (Opt.) Lift lock at over discharge
If all bits is changed “0” to “1” on the
standard truck, 4 error messages appear Regenerative contactor Not used
on the indicator.
A10 : FET7-OVER DRIVE
B20 : FET4-HYD. BY pass
D24 : PC. BOARD-AOS
* TURN OFF KEY SWITCH *
NOTE When replacing the MPU board, it is set “1” to each option setting for safety. Confirm the
specification of the truck and set it properly.
NOTE The option setting which is standard specification is set to “0”.

For example, Regenerative braking system is equipped as standard. Therefore, setting
“0” means “with regenerative brake” “1” means “without regenerative brake”.
–4–
t Language selection on LCD display
œEach language can be selected by this opera- F01
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tion.
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AB
789
1) Set the rotary switch RS1 to “6” and turn the
key switch on. Set RS1 to “6”
2) Choose the each language shown below by

pressing Up button or Down button .
M M
<Display on LCD> Displayed language when turning key switch on.
NOTE After finishing to set or reset, be sure to

turn the key switch off and to return the
rotary switch RS1 to “0”. F01
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789
Set RS 1 to “5”
y Safety monitor symbol.
œEach monitor symbol can be set by this opera-
tion
1) Set the rotary switch RS1 to “5”.

M
2) Use the mode select button M to shift the set-
ting position.
Mode select button
œThe setting position which flashes can be

moved to the right by pressing the mode
button M.
M M
DOWN button UP button

–5–
3) Press,
the Up button to set : displayed “1”.
[ the Down button to reset : displayed “0”.
for each safety monitor symbol.

DISCHARGE
F km/m 0 5 10 15 20
8 SPEED
6
4
2
TRAVEL km
TRAVEL
: Travel
HYD BRAKE
: Hydraulic Parking brake :

STEER LOAD
: Steering Over load :

OIL
BATT
: Battery Oil level :
* For having GS battery and GS electrolyte level sensor only.
NOTE The symbol for Travel, Hyd, Steer and Brake are preset as a standard at the factory.(dis-
played “1”)
NOTE After finishing to set or reset, be sure to turn the key switch off and to return the rotary
switch RS1 to “0”.
1-3 Adjustment of starting current

and current limitation
q Zero(0) adjusting for installed

Zero(0) adjusting is required for the installed
current detector to adjust the starting current
F01
and current limitation correctly.
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23
456
AB
<Condition on checking>
789
Battery electrolyte over 1.25 (at 20°C)
Set RS1 to “1”
<Adjusting procedure>
1) Set the rotary switch RS1 to “1”, and turn the
key switch on.
2) The each mode can be changed by pressing
the mode select button M as follows. M
M Mode select button
M M
–6–
3) Adjust If LEVEL, and Ia LEVEL to be “000A”
at no motor current condition by pressing Up
button or Down button
M M
CAUTION
As MPU board has an auto-zero level
adjustment function, no need to re-adjust
these mode normally. However, be sure to
Up button Down button
confirm it.
Press Up button when Press Down button
indication on monitor when indication on
4) Press, shows minus(–) value. monitor shows Plus
the Up button when the indication shows (+) value.
minus(–) value.
the Down button when the indication
shows plus (+) value.
5) After adjusting If GAIN and Ia GAIN, be sure

to turn the key switch off and to set back the
<Initializing (initial setting)>

Initializing should be done by pressing the Up
button and Down button simultane-
ously for approx. three (3) seconds. M
Then, each setting (SPEED, POWER,
ACCEL) will be initial setting mode with show-
ing “INITIALIZED” and a beep sound. Press Up and Down button simultaneously
for approx. 3 seconds.
NOTE This "initialize" operation is also accepted km/m 5 10 15 20
by each manual setting of, SPEED
SPEED : to 7km/h
POWER : to 100%
ACCEL : to STD
] = “INITIALIZED”
Initial setting mode
w Adjustment of starting current and cur-

rent limitation
1) Be sure to check that the specific gravity of
the battery electrolyte. It should be more than F01
1.25 at 20°C and the operation of “initialize”
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23
456
should be done, and initializing also finished.

AB
789
2) Set the rotary switch RS1 to “2”, and turn the

Set RS1 to “2”
key switch on.
œThe each mode can be changed by pressing the
mode select button M as follows.
M
M M
Mode select button
–7–
3) Adjusting staring current
The “CURR START” will be shown after key
switch on.
4) Operate the directional switch to forward, depress

the foot brake. Then depress the accelerator
pedal until the regenerative contactor just goes
Wall
on, and hold at that position.
CAUTION
When adjusting the starting current and
current limitation, lock the traveling motor
by operating as follows.
Park the truck against a wall, and touch
the tip of forks to the wall.
Then apply the parking brake lever.
Depress the foot brake pedal.
5) Adjust the starting current on the monitor with-

in specified range by pressing Up button
or Down button .
Model Starting Current (A)

M M
FB10P 35 ± 5
FB15P, 18P 45 ± 5
FB20P, 25P 50 ± 5
Press Down button when Press Up button when
FB30P 45 ± 5 monitor indication shows monitor indication shows
higher than the specified lower than the specified
value. value.
–8–
6) Adjusting current limitation
Set the “CURR LIMIT” mode by pressing
mode select button M.
7) Operate the directional switch to forward, depress

the foot brake. Then depress the accelerator
Wall
pedal all the way down and hold it.
NOTE The current limitation should be read and

adjusted within two (2) seconds, otherwise
it will be increased by 130% for the auto-
matic torque increase function. Then the
forcible bypass contactor will be turned on.
CAUTION
When adjusting the starting current and
current limitation, lock the traveling motor
by operating as follows.
Park the truck against a wall, and touch
the tip of forks to the wall.
Then apply the parking brake lever.
Depress the foot brake pedal.
8) Adjust the current limitation on the monitor

within specified range by pressing Up button
or Down button .
Model Current limitation (A)

FB10P 280 ± 5
FB15P, 18P 330 ± 5
FB20P, 25P 380 ± 5
FB30P 330 ± 5
M M

Press Down button when Press Up button when
monitor indication shows monitor indication shows
higher than the specified lower than the specified
value. value.
NOTE Use the clamp on meter as a reference
when checking and adjusting. There may
be some difference between the current
value on monitor and the reading by the
clamp on meter.
NOTE After finishing the adjustment, be sure to

return the rotary switch RS1 to “0”.
–9–
Setting of rotary switch
(Confirmation) RS0 RS1 Traveling

speed
Voltage 3 4 5 6
Model Unladen
SPD-L SPD-M SPD-H HYD HYD HYD HYD HYD HYD PLUGG- REGENE BRAKE OVER TRAVEL HYD STEER BATT OIL LOAD BRAKE
(V) Plugging /Laden
Starting Current LIFT LIFT LIFT LIFT-1 LIFT-2 TILT ATT.1 ATT.2 ATT.3 ING RATE TRQ DRIVE
brake Langu-
current limitation
distance Speed Speed Speed Attach- Attach- Attach- Switch back brake force Braking Over age (km/h)
(A) (A)
(m) L lift M lift H lift Lift 1 Lift 2 Tilt ment 1 ment 2 ment 3 Plugging Regeneration force drive
FB10P 35 ± 5 280 ± 10 5.0 - 6.0 0 64 48 32 50 64 56 32 32 32 060 046 020 060 \ \ \ \ \ 0 15.0/13.0
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
FB15P, 18P 45 ± 5 330 ± 10 5.0 - 6.0 4 15.0/13.0
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
FB20P, 25P 50 ± 5 380 ± 10 5.0 - 6.0 6 064 15.0/12.5
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
FB30P 45 ± 5 330 ± 10 5.0 - 6.0 9 14.5/12.5
48V Not used A
Not used B
Not used C
Not used D
Not used E
– 10 –
Starting current
/Current limitation Switch back brake distance * For having GS battery and GS * In case of no indication display language
• Motor current • Flat, Unladen, Full speed electrolyte level sensor only. JAPANESE Domestic : 0 : JAPANESE
• Power 100% • Specific gravity of electrolyte ENGLISH : 1 : ENGLISH
• Specific gravity of electrolyte more than 1.25 at 20°C Except for Japan
more than 1.25 at 20°C • Full acceleration
RS1-7 (Option setting) RS1-5 (monitoring setting) RS1-6 Language Indication of key switch on
0 0 0 0 0 0 0 0 1 1 1 1 0 0 1 0 0 : JAPANESE JAPANESE
1 : ENGLISH ENGLISH MONITORING OK
Not used Monitoring TRAVEL
2 : FRENCH FRENCH CONTROLEUR OK
Over drive (Opt.) Seat switch HYD BRAKE 3 : GERMAN GERMAN UEBERWACHUNG OK
The specification of each adjustment for FB-DC70
Hydraulic by-pass (Opt.) Over discharge lift lock STEER LOAD 4 : SPANISH SPANISH MONITOR OK
regenerative contactor Not used BATT OIL 5 : DUTCH DUTCH MONITORING OK
Option setting should be set “0” for standard specification. * For having GS battery and GS
Set to “1” in case of some option being installed. electrolyte level sensor only.
2. Adjustment for other functions
qAuto-torque up
A: Specific gravity of the battery electrolyte:
more than 1.25 at 20°C
B: Make an initializing (Initialize mode setting)
<Confirming procedure>
1) Check the current limitation.
2) Confirm that the current limitation should be
increased by 130% of the value of current lim-
Current 130%
itation after 3 seconds. limitation Forcible by-pass
100% contactor on
3sec 2sec
wSafety circuit for out of control

(contactor tripping)
1) Be sure to check that the forward and back-
ward contactor has not gone in.
2) Make a jumper wire between a main terminal
of bypass contactor. (Wire size about 0.5mm2)
3) Be sure to check the warning beap sound and
the error massage on the display.
4) Confirm that even though operate the acceler-
ator, after that the forward (backward) contac-
tor will not go in.
ePower setting
Specific gravity of the battery electrolyte:
Set the power setting to 50%
1) Check the current limitation.
2) Be sure to check that the motor current becomes
to about 70% of the current limitation.
– 11 –
rHydraulic setting
Be sure to check that the each setting is set F01
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as listed on “The specification of each adjust-
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789
ment for FB-DC70” (p.10).
Set the rotary switch

<Adjustment procedure> RS1 to “3”
1) Set the rotary switch RS1 to “3”.
2) The each mode can be changed by pressing

M
the mode select button M and adjust the set-
ting by up button or down button .
Mode select button
NOTE After finishing the adjustment, be sure to M

M
M M
tSwitch back braking distance

(Plugging/Regenerative braking)
<Condition on checking> F01

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23

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AB

789
B: Flat ground, Unladen, Full speed

RS1 to “4”
<Adjustment procedure>
1) Set the rotary switch RS1 to “4”, and adjust
the braking force by pressing up button or
M
down button . The each mode can be
changed by pressing the mode select button
M. (either plugging or Regenerative brake) Mode select button
2) Be sure to check the regenerative contactor
goes off when switch back braking operation
is done, and goes on just before starting on
reverse. M
M
M
– 12 –
3) Adjust the plugging braking distance by press-
ing up button or down button .
The braking distance will be,
shorten by pressing up button .
.
M M
longer by pressing down button
NOTE After finishing the adjustment, be sure to Up button Down button

For shorter distance. For longer distance.
yRegenerative braking force
B: Flat ground, Unladen, Full speed
1) Traveling forward with middle speed and release
the foot from the accelerator pedal.
2) Depress the foot brake pedal lightly.
F01
3) Be sure to check the forward contactor is off and
CDE
23
456
reverse contactor is on, Then regenerative brak-
AB
789
ing is worked.

RS1 to “4”
1) Set the rotary switch RS1 to “4”, and change
the mode of “BRAKE TRQ” by pressing mode M
select button M.
Mode select button
M
M
M
2) Adjust the regenerative braking force by
pressing up button or down button .
The braking force will be,
Strong by pressing up button .
Poor by pressing down button .
M M
NOTE After finishing the adjustment, be sure to
For poor braking For strong braking
effect. effect.
– 13 –
uAdjustment of brightness of the back Turning it clockwise
light on monitor for bright contrast.
Adjust the brightness of the back light on
monitor by the volume VR0. Turning it clock-
CFL
wise for bright contrast. VR0
iChecking of speed sensor output

F01
CDE
23
456
AB
789
1) Set the rotary switch RS1 to “C” and turn the
key switch on. The each mode can be Set the rotary switch
changed by pressing the mode select button RS1 to “C”
M as follows.
M
M M
Mode select button
Traveling direction
Sensor output 1 : left side F : Forward, R : Reverse
Sensor output total

Sensor output 2 : right side (value of output 1+2)
2) Set the “SPD” (Speed sensor checking) mode.

3) Check the indication of sensor output by traveling.
œNormally, the value of sensor output 1 and 2 should be the same when traveling.
In case that the value of sensor output 1 or 2 is not varied when traveling. (=always shown “0”)
Check the sensor or its wire harness connected to MPU board.
In case that the value of sensor output 1 and 2 are the same with no changing.
Check and adjust the potentiometor for sensor 1 or 2 by the shims.
In case that the value of sensor output 1 plus 2 does not make a sensor output total.
(=output 1+2≠total)
It may be influenced by the noise. Please check some wire near the wire of sensor 1 and 2.
In case that the indication of traveling direction is opposite from the actual moving direction.
Check the connection of sensor 1 and 2, They may be opposite.
NOTE After confirming the working, be sure to turn the key switch off and return the rotary
switch RS1 to “0”.
– 14 –
oHour meter working
1) Connect the wireharness of [Blue/Red 1] and
[Black] located inside the front cover.
2) Be sure to check that the decimal point flash-

es when the hour meter counts by traveling or
hydraulic operation.
!0Confirming the working of auto-power cut off function
1) Turn the key switch on.
2) Be sure to check that the main power will be cut off after approx.15minutes automatically if there
is no operation either traveling or hydraulic operation.
!1Adjusting of battery voltage

Item (function) Condition for checking Check and adjustment procedure
1) Check the battery voltage at, + : Hyd. fuse, - : Minus (–) terminal
in the control unit.
2) Set the rotary switch RS1 to “A”, and turn the key switch on.
3) Set to “VB LEVEL” mode by pressing mode select button M.
MSpecific gravity : M M
Battery voltage
more than 1.25 at
(for battery capacity
20°C
indicator)
4) Adjust the “VB LEVEL” to be the same value checked at 1) by
pressing Up or Down button.
CAUTION
The VOLTAGE figure will not be changed
even if adjusting the VB LEVEL.
– 15 –
3. Option
qConfirming Over loading
1) Lift up to the end and make a relief condition.
2) Confirm the display *REDUCE THE LOAD*.
wConfirming the travel inhibit
1) Connect the - line (black) to the connector
[CN4-4pin] on the MPU board.
2) Confirm that the tuck does not travel when
operating the traveling.
eConfirming the lift locking working at

over discharge
key switch on.
2) Set 2nd bit of the lift lock at over discharge to F01
CDE
23
“1”.
456
AB
3) Supply the voltage of 30–36V to the battery 789

plug.
4) Confirm Set the rotary switch
Battery capacity indicator : [Red] lamp turn- RS1 to “7”
ing on.
Indication on display :*CHAGE THE BAT- DISCHARGE
TERY* km/m 0 5 10 15 20
F
8 SPEED
6
4
2
CAUTION
Lifting speed will be half. Then after ten E POWER 50 75 100 ACCEL SOFT STD FULL
minutes operation, TRAVEL km
Battery capacity indicator : [Red] lamp

flashes.
The lift locking at
Indication on display : ✳CHARGE THE over discharge
BATTERY✳ (2nd bit)
and lifting will be suspended.
NOTE After confirming the working, be sure to

turn the key switch off and return the
– 16 –
rConfirming the seat switch working
F01
<Setting procedure>
CDE
23
456
AB
789
key switch on.
2) Set 1st bit of the seat switch to “1”.
RS1 to “7”
1) Operate the traveling without sitting on the seat. TRAVEL HYD STEER BATT OIL LOAD BRAKE
DISCHARGE
2) Confirm the truck does not travel.
F km/m 0 5 10 15 20
8 SPEED
6
NOTE After confirming the working, be sure to 4
2
turn the key switch off and return the E POWER 50 75 100 ACCEL SOFT STD FULL
rotary switch RS1 to “0”. TRAVEL km
Seat switch
(1st bit)
– 17 –
4. Outline of New EPS
system for FB–DC70
4-1 Outline of New EPS system
steering gear box
controller motor actuator rear axle
The EPS system is constructed with steering gear box, new design potentiometer actuator, and
controller (new design) above. The torque sensor in the steering gear box detects the opposite
force from the steering tire when the steering wheel is operated, and send the signal which is pro-
portioned with the force and direction to the controller. The controller controlls the magnitude and
direction of the steering motor current.
The steering motor creates the force by this current to assist the steering operation.
When the shock is applied to the tire, the torque sensor detects it and the actuator creates the
equivalent force against it. So, no kick back force is applied to the steering wheel.
– 18 –
4-2 Operation
Actuator Ass’y
Torque sensor Controller Actuator
w e r t
Steering + Torque sensor Motor

Output of Wheel
output current Assist force
Operation – control motor torque steering
1) When the key switch is turned on, the contac-

tor is activated and the power is supplied.
2) When the steering wheel is operated, the
steering force is detected by the torque sen-
sor and output the voltage corresponded for it.
3) The output voltage from the torque sensor is
applied to the controller and converted to the
current for the motor on the actuator.
4) The motor creates the output torque which is
proportioned with the input current.
5) The output force of the actuator assists to
steer the wheels.
6) The steering force is reduced by this assist
force.
4-3 Feature
qProtection of overheat for motor
When the motor current continues over 25A
for about 5 seconds, the motor output will be
turned off automatically. When put back the
input of torque sensor to neutral, it returns at
normal control condition.
wSelf diagnosis function DISCHARGE

1) If the problem is occurred at the torque sen-

F km/m 0 5 10 15 20
sor, scrolls the message of [C29:SENSOR- 8
6
SPEED
EPS TORQUE] on the display (Torque sensor 4

2
error). E POWER 50 75 100 ACCEL SOFT STD FULL
TRAVEL km
2) If the problem is occurred at a main FET cir-

cuit in the EPS controller, scrolls the message DISCHARGE
of [C30: TR-EPS MAIN] on the display (chop-

km/m 0 5 10 15 20
per error). F
8 SPEED
6
4
2
TRAVEL km
– 19 –
4-4 Checking and Adjustment
EPS
controller
qNeutral adjustment of torque sensor
<Checking procedure>
1) Turn the key switch off.
yellow
green
2) Jack up the rear wheels from the ground.
3) Open the side cover at right side.
A
4) Put the clamp meter to the wire [yellow] or
[green] between EPS controller and EPS clamp meter
motor [DC range]
black
red
5) Turn the key switch on and measure the indi-
cation at the clamp meter without steering
operation. (= at neutral steer) If the indication EPS motor
shows 0A, it is normal.
6) If any current is flown, adjust the potentiometer
by the following procedure.
1) Turn the key switch off and disconnect the battery plug.
2) Disconnect the 3P water proof type connector of EPS sensor.
3P water proof type
connector (tab side)
1.5
k
EPS potentiometer
+
sensor ass’y –
3) Check the resistance at sensor side (tab side) between,

<standard value>
• q pin (Orange) and e pin (Black/Red) = Approx. 5k ............... A
• q pin (Orange) and w pin (Green/Red) = Approx. 2.5k ........... B These should be
• w pin (Green/Red) and e pin (Black/Red) = Approx. 2.5k ...... C even value.
q Orange q Blue 3
From EPS
sensor w Green/Red w Green /Blue 1 To EPS
Tab Rece controller
(potentiometer) e Black/Red e White
3P water proof type connector
4) Adjust it by removing or inserting a shim to be the even value between B and C above.
NOTE The resistance value may depend on the type of tester and each unit.
– 20 –
5) Connect the battery plug and turn the key switch on. Check and confirm that there is no EPS
motor current at the neutral steer by the above procedure, <Checking procedure>.
wChecking by voltage
When it is difficult to adjust the torque sensor very precisely. Use this method.
Neutral adjustment of the potentiometer can be checked by its output voltage.
<Checking procedure>
1) Turn the key switch off.
2) Disconnect the connector of the torque sensor and put the adaptor for measuring voltage.
NOTE As the connector of the torque sensor is waterproof type, it is impossible to put the
tester probe. Make an adapter by using the same type adapter.
3) Check the voltage at w pin [Green/Red or Green/Blue 1] of the adaptor.

4) Turn the key switch on and operate the steering wheel from right side end to left side end, then
check the voltage. The following values are the standard.
right side end 0.8 V ± 0.3

neutral 2.5 V ± 0.3
left side end 4.2 V ± 0.3
q Orange q Blue 3
From EPS
sensor w Green / Red w Green/Blue 1 To EPS
Tab Rece controller
(potentiometer) e Black / Red e White
3P water proof type connector
q pin
w pin
Rece Tab Adaptor
e pin
Tab
+ probe – probe
to w pin to e pin
(output) (negative)
V
+
–
– 21 –
5. Self diagnosis history memory
and I/O check.
5-1 Self diagnosis history memory
The total 34 error histories which have occurred

at least once can be memorized. There are two
(2) kind of information for this function.
The one is to memorized the operated condition

when the trouble has occurred (called “Format
1”), the other one is to memorize the each mal-
function (called “Format 2”).
œThe basic system of “Format 2” is same as the

one adopted on SICOS 50/60 and A-SICOS for
FBR-60 series.
S
CO
W -SI
NE
TRAVEL HYD STEER BATT OIL LOAD BRAKE TRAVEL HYD STEER BATT OIL LOAD BRAKE
DISCHARGE DISCHARGE
F km/m 0 5 10 15 20 F km/m 0 5 10 15 20
8 SPEED 8 SPEED
6 6
4 4
2 2
E POWER 50 75 100 ACCEL SOFT STD FULL E POWER 50 75 100 ACCEL SOFT STD FULL
TRAVEL km TRAVEL km
<Format 1> <Format 2>

Memory and display for the operated condition Memory and display for the each malfunction.
when the trouble has occurred. *same as SICOS 50/60 and A-SICOS or FBR-60 series.
– 22 –
<How to check the error history memories>
1) Set the rotary switch RS1 to “B”, and turn the F01
CDE
23
key switch on.
456
2) Press the mode select button M to call the
AB
789
each mode.
Set RS 1 to “B”
NOTE Do not turn the key switch on/off when
the rotary switch RS0 is set to “F” as the
history memory is cleared.
M
CAUTION
The truck can be moved even though the
history memory is called.
Mode select button
A: Format 1 of history memory

3) Press Up or Down button to change
the each history No..
M M
History memory No. can be changed (called)

by pressing Up/Down button.

DISCHARGE
F km/m 0 5 10 15 20
8 SPEED
6
4
2
TRAVEL km
[1] : History No. (0-9) [5] : Traveling mileage

Each error is displayed in order. Traveling mileage will be displayed when some trouble
0 : Latest error happen.
9 : Oldest error
* It is naturally cleared for the errors [4] : Hydraulic motion mode No.
over 11th. The history No. can be Hydraulic motion (condition) is displayed when the trouble has occured.
changed by pressing UP/Down button. (see the page24 “[2] Hydraulic motion (condition) mode No.” in details)
[3] : Traveling motion mode No.

Traveling motion (condition) is displayed when the trouble has occured.
(see the page24 “[1] Traveling motion (condition) mode No.” in details)
[2] : Error No. (If “00” is displayed, there is no error memory)

Error No. of error message is displayed
(see the page35 table)
– 23 –
[1] Traveling motion mode No.
Mode No. Content

00 Neutral
01 Forward mode: Regenerative contactor OFF
02 Forward mode: Traveling contactor ON
03 Forward mode: Regenerative contactor ON
04 Forward mode: Traveling speed control
05 Forward mode: Bypass contactor ON
06 Forward mode: Bypass contactor OFF
07 Forward mode: Bypass control
08 Forward mode: Over driving contactor ON
09 Forward mode: Over driving contactor OFF
0A Forward mode: Over driving control
0B Forward mode: Pre-energizing
0C Forward mode: Regenerative control
11 Reverse mode: Regenerative contactor OFF
12 Reverse mode: Traveling contactor ON
13 Reverse mode: Regenerative contactor ON
14 Reverse mode: Traveling speed control
15 Reverse mode: Bypass contactor ON
16 Reverse mode: Bypass contactor OFF
17 Reverse mode: Bypass control
18 Reverse mode: Over driving contactor ON
19 Reverse mode: Over driving contactor OFF
1A Reverse mode: Over driving control
1B Reverse mode: Pre-energizing
1C Reverse mode: Regenerative control
[2] Hydraulic motion mode No.
Mode No. Content

0 Hydraulic neutral
1 Hydraulic control
2 Hydraulic bypass contactor ON
3 Hydraulic bypass contactor OFF
4 Hydraulic bypass control
– 24 –
B: Format 2 of history memory
3) Press Up or Down button to change
(call) the each Error memory No..
If there has been a problem at least once, the M M

bit shows “1”. If not, it shows “0” on the moni-
tor.
“0” . . .No trouble
[ “1” . . .Troubled (at least once)
History memory No. can be changed (called)
by pressing Up/Down button.

DISCHARGE
F
8 SPEED LIMIT 0 30 40 60 80 %
6
4
2
Error
memory No. 7th bit 6th bit 5th bit 4th bit 3rd bit 2nd bit 1st bit 0 bit
A5 : A3 :
ERR0 A6 : FET9- A4 : FET10- A2 : FET6- A1 : FUSE-
CONTACTOR- CONTACTOR- *FAIL HYD* *FAIL TRAVEL*
REVERSE FORWARD REGEN TRAVEL
FORWARD REGEN
A14 : SENSOR- A13 : ACCEL- A7 :

A12 : A11 : A10 : FET7- A9 : A8 : FET8-
ERR1 CURRENT CONTACTOR-
ACCELERATOR TR-REGEN TR-TRAVEL OVER DRIVE CONTACTOR BYPASS
(ARMATURE) MAIN MAIN BYPASS REVERSE
B21 : B20 : FET4- B19 : A16 : A15 : SENSOR-

B22 : B18 : FET5- B17 :
ERR2 TR-HYD HYD. CONTACTOR- HYD SENSOR- CURRENT
SWITCH-LIFT FUSE HYD
MAIN BYPASS HYD SPEED (FIELD)
*REFILL C31 : C30 : C29 : SENSOR-

*REDUCE
ERR3 HYDRAULIC Not used Not used TR-EPS EPS Not used
THE LOAD* FUSE EPS
OIL* MAIN TORQUE
*REPLENISH
REFINED *REFILL
ERR4 Not used Not used Not used Not used Not used Not used WATER FOR BRAKE OIL*
BATTERY*
– 25 –
<How to clear the error history memories>
1) Turn the key switch OFF. OFF ON

START
2) Set the rotary switch RS0 to “F”.

F01
CDE
23
456
AB
789

RS0 to “F”
3) Turn the key switch ON. (To START)

OFF ON
START
4) Turn the key switch OFF.

OFF ON
5) Set the rotary switch RS0 at the original posi-

tion.
6) Make sure to be clear it.
– 26 –
5-2 I/O check
I/O (Input/Output) check is the function that the

input and output signal for the microcomputer
can be displayed on the LCD by the binary code
of [1] or [0] to check if each part is normal.
Approx. 90 points of input/output signals can be
checked. Set RS 1 to “E”
F01
<Procedure of display>
CDE
23
1) Set the rotary switch RS1 to “E”, and turn the
456
AB
key switch on.
789
2) Select the port by pressing Up or Down Select the port No.

button.
Refer to the I/O table for the detail of each
port.
M M
NOTE After confirming the I/O check, be sure to
turn the key switch off and return the
rotary switch RS1 to “0”. DOWN button UP button
<Example of I/O check>

For example, in case of the port No.10
(=IOM10), the following screen is displayed.

DISCHARGE
F km/m 0 5 10 15 20
8 SPEED
6
4
2
TRAVEL km
Directional switch for reverse

1 : ON Not used
0 : OFF
Not used
Directional switch for forward
1 : ON Not used
0 : OFF
Directional switch for neutral Not used

1 : Neutral
0 : Not Neutral Not used
– 27 –
I/O TABLE (1)
PORT NO. BIT IN/OUT CONTENTS REMARKS
0 IN Button [UP] 0: Up [brake closed]
1 IN Button [Mode select] 0 : select
2 IN Button [Down] 0 : Down
RS1-E 3 IN Button [Slow speed] 1 : Slow speed
NO.OD 4 IN Hydraulic oil level 0 : Detection
5 IN Brake oil level 0 : Detection
6 IN Overload 0 : Detection
7 IN Not used
0 IN Switch [Brake] 0 : ON [brake closed]

1 IN Switch [Lift 1] 1 : ON
2 IN Switch [Lift 2] 1 : ON
RS1-E 3 IN Switch [Tilt] 1 : ON
NO.OE 4 IN Switch [Attachment 1] 1 : ON
5 IN Switch [Attachment 2] 1 : ON
6 IN Switch [Attachment 3] 1 : ON
7 IN Switch [Parking brake] 1 : ON
0 IN Contact [Regenerative] 1 : ON
1 IN Contact [Hydraulic] 1 : ON
2 IN Contact [Forward] 0 : ON
RS1-E 3 IN Contact [Reverse] 0 : ON
NO.OF 4 Not used
5 IN Fuse [Travel] 0 : Fault
6 IN Fuse [Hydraulic] 0 : Fault
7 IN Fuse [EPS] 0 : Fault
0 IN Rotary switch RS-0 EX) 0000 : "0"

1 IN Rotary switch RS-0 0000 : "1"
RS1-E 3 IN Rotary switch RS-0 0000 : "8"
NO.OC 4 IN Rotary switch RS-1 EX) 0000 : "0"
– 28 –
I/O TABLE (2)
1 IN Not used
2 IN Not used
3 IN Not used
RS1-E
4 IN Not used
NO.10
5 IN Directional [Neutral] 1 : Neutral
6 IN Directional [Forward] 1 : Forward
7 IN Directional [Reverse] 1 : Reverse
0 Not used
1 Not used
2 Not used
RS1-E 3 Not used
NO.11 4 IN Hour mete clear 1 : Clear
5 IN Hour meter count stop 1 : Stop
6 IN Hour meter option [Hydraulic] 1 : Counting
7 OUT Not used
Current [Armature]
Use 10 bits by binary system. "1 and 0 bits of NO.01 and 7 to 0 bits of NO.00"
RS1-E \\ \\\\\\\\
NO.00 bit 1 0 7 6 5 4 3 2 1 0
NO.01 NO.01 NO.00
Analog / Digital conversion 0 - 500A / 1.2 - 4.0V
Current [Field]
RS1-E \\ \\\\\\\\
NO.02 bit 1 0 7 6 5 4 3 2 1 0
NO.03 NO.03 NO.02
Analog / Digital conversion 0 - 500A / 1.2 - 4.0V
Voltage [Battery]
RS1-E \\ \\\\\\\\
NO.04 bit 1 0 7 6 5 4 3 2 1 0
NO.05 NO.05 NO.04
Analog / Digital conversion 0 - 55V / 0 - 5V
Voltage [Battery capacity]

RS1-E \\ \\\\\\\\
NO.06 bit 1 0 7 6 5 4 3 2 1 0
NO.07 NO.07 NO.06
Analog / Digital conversion 44.6 - 55V / 1.2 - 4.0V
– 29 –
I/O TABLE (3)
Accelerator voltage 1
RS1-E \\ \\\\\\\\
NO.08 bit 1 0 7 6 5 4 3 2 1 0
NO.09 NO.09 NO.08
Analog / Digital conversion 0 - 0.5V
Accelerator voltage 2
Use 10 bits by binary system. "1 and 0 bits of NO.0B and 7 to 0 bits of NO.0A"
RS1-E \\ \\\\\\\\
NO.0A bit 1 0 7 6 5 4 3 2 1 0
NO.0B NO.0B NO.0A
Analog / Digital conversion 0 - 0.5V

0 OUT Contactor select [Forward] 1 : ON
1 OUT Contactor select [Reverse] 1 : ON
2 OUT Contactor select [By-pass] 1 : ON
RS1-E 3 OUT Contactor select [Overdrive] 1 : ON
NO.18 4 OUT Contactor select [Regenerative] 1 : ON
5 OUT Contactor select [Hydraulic] 1 : ON
6 OUT Contactor select [Hydraulic by-pass] 1 : ON
7 Not used
– 30 –
6. Practical trouble shooting
(How to find the cause of problem)
6-1 Before starting

Basically the same procedure can be used as the previous SICOS-50 for the troubleshooting.
However, the display unit, MPU board, accelerator etc. are changed in design and some new func-
tions are added. I/O checking also has the different procedure to recall on the display unit.
The details of the procedure are explained in the following sections. In this section, the following
matters should be understood.
qLocation of negative circuit

Fit the negative(–) probe of circuit tester to; Minus (–) terminal in the control unit or the ribbon
wire of M4 contactor when checking the voltage.
Battery : 48V(FB10-25P)
72V (FB30P)
(The auxiliary 48 volts output is equipped
in the case of the 72 volts battery.
V N
Capacitor : 100V 2200µF X 1 (FB10/15/18P)
X 2 (FB20/25P)
F1
NA
VA
X 3 (FB30P)
275A D1
D2
VC
M4
M1
A
M3 FC1
IA IF
Pre-energizing resistor :
M2
30W 2.2Ω X 4 (10-25)
40W 2.2Ω X 2 (30)
WH
D3
RD
PB83-62
Pre-energizing
<(–) line>
BU
(–) terminal or ribbon wire

X 2 (FB20/25P)
of M4 contactor
X 3 (FB30P)
D4
F2 M7
PA
FC2
<SYSTEM WIRING>
(–) probe
(–) probe
Battery (–) terminal
M4 contactor ribbon
Wire
<CONTROL UNIT> (Bypass contactor)
– 31 –
wLayout of the connectors on MPU board
and others
1) MIC connector
MPU board
PB84-XX
CN1 CN2 CN3 CN4 CN5 CN6
A
6 5 4 3 2 1 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8 7 10 9 8 7 6 5 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
CN1 CN2 CN5 CN6
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
CN3 CN4
View from A (receptacle/harness side)
Each No. in the connector indicates pin No.

For example, CN3-6
Pin No. (see picture in above)
Connector No. (CN1-CN6)
NOTE Pin location for connectors are shown

from insertion side of pins.
– 32 –
2) Waterproof type connector
Each No. in the connector indicates pin No. .
12 pin type 10 pin type 8 pin type 6 pin type 3 pin type 2 pin type
6 5 4 3 2 1 5 4 3 2 1 4 3 2 1 3 2 1
Rece side 3 2 1 2 1
12 11 10 9 8 7 10 9 8 7 6 8 7 6 5 6 5 4
1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 1 2 3
Tab side 1 2 3 1 2
7 8 9 10 11 12 6 7 8 9 10 5 6 7 8 4 5 6
3) Other connector
Each No. in the connector indicates pin No. .
6 pin type 4 pin type (1) 4 pin type (2) 2 pin type
Rece side 1 2 3 1 2 1
4 5 6 3 4 2
Tab side 3 2 1 1 2 3 4 2 1
6 5 4 4 3
6-2 Attention for the troubleshooting
NOTE Initially correctly understand content and

phenomena of problems.
After understanding customer’s operator
sayings and actual forklift truck status
as correctly as possible ( including prob-
lems that often occur).
qVisual checking
The visual checking may help to find the main
cause, check the each parts carefully.
Example)
Is there any parts or wire which is burned out ?
How about the looseness of connector ?
– 33 –
wFault finding
When the cause is unknown even after visual
check,
safety guard
1) Place the rigid blocks under the outer mast to
stable the truck.
2) Tilt the mast forward by pushing the tilt lever to
rise the front wheels.
Rigid block
NOTE Place the safety guards for safety !
Do not rotate the drive wheels off the floor
at high speed, because the drive motor
and internal parts of the gear box could
be damaged.
Measurement of voltage should be
done in a short time.
Be sure to disconnect the battery plug
when connecting the volt-ohm meter,
repairing and replacing parts.
– 34 –
eError message and Possible defective part
Error No. and error message is displayed.
Symbol Error
Message Possible defective part Remarks
(Flash for defect) No.
3 * FAIL TRAVEL. * FET, D2, MPU board ... etc.
4 * FAIL HYD. * FET, MPU board ... etc.
* TURN OFF KEY SWITCH * linked with other message
5 A1 : FUSE-TRAVEL. Travel fuse
6 A2 : FET6-REGEN. Regen. contactor coil, MPU board Half speed
7 A3 : CONTACTOR-REGEN. Regen. contactor, MPU board
Forward contactor coil(Left), MPU
8 A4 : FET10-FORWARD Half speed
board
9 A5 : CONTACTOR-FORWARD Forward contactor
TRAVEL Reverse contactor coil (Left), MPU
10 A6 : FET9-REVERSE Half speed
board
11 A7 : CONTACTOR-REVERSE Reverse contactor
12 A8 : FET8-BYPASS Bypass contactor coil, MPU board Half speed
13 A9 : CONTACTOR-BYPASS Bypass contactor, MPU board
14 A10 : FET7-OVER DRIVE
15 A11 : TR-TRAVEL. MAIN FET, Bypass contactor, MPU board
16 A12 : TR-REGEN. MAIN Pre-energizing board, Resistor

17 A13 : ACCEL-ACCELERATOR Accel., Directional sw.
18 A14 : SENSOR-CURRENT (ARMATURE) Current sensor (Ia)
19 A15 : SENSOR-CURRENT (FIELD) Current sensor (If)
20 A16 : SENSOR-SPEED Speed sensor
21 B17 : FUSE-HYD. Hydraulic fuse
22 B18 : FET5-HYD. Hydraulic contactor coil, MPU board Half speed
23 B19 : CONTACTOR-HYD. Hydraulic contactor, MPU board
24 B20 : FET4-HYD. BYPASS
25 B21 : TR-HYD. MAIN Hydraulic FET, MPU board
HYD
26 B22 : SWITCH-LIFT Lift micro switch (1), (2)
27 B23 : SENSOR-CURRENT (HYD.)
D24 : PC. BOARD-AOS
* FAIL AOS *
D25 : TR-AOS
D26 : RELAY-AOS
D27 : POTENTIO-HYD. LEVER
D28 : POTENTIO-MAST
34 C29 : SENSOR-EPS TORQUE
STEER 35 C30 : TR-EPS MAIN
36 C31 : FUSE-EPS
37 C32 : FET3-EPS
38 C33 : CONTACTOR-EPS
* The following parts cannot be diagnosed and displayed.

1) Diodes : D1, D2, D3 and D4 5) Motors 9) Connectors
2) Capacitors for surge absorbing 6) A part of MPU board 10) Back contacts of forward / reverse contactror
3) A part of current sensor 7) A part of microswitches 11) LCD display
4) A part of pre-energizing board 8) Wire harness
* The error messages for the current sensor and the pre-energizing board are depend on the defect conditions to display.
– 35 –
Symbol Error
Message Possible defective part Remarks
(Flash for defect) No.
39 * REFILL HYDRAULIC OIL * Shortage of hydraulic oil
40 * REDUCE THE LOAD * Overloaded Opt.
41 * REFILL BRAKE OIL * Shortage of brake oil Opt.
* REPLENISH REFINED WATER

42 Shortage of battery electrolyte GS batt.
FOR BATTERY *
* CHARGE THE BATTERY * Need to charge battery
* RELEASE ACCEL. TO NEUTRAL * Accelerator is operated before power on
* OFF HYD. LEVER TO NEUTRAL * Hyd. lever is operated before power on
6-3 Troubleshooting Procedure
Correct understanding of the content and phe-

nomena of the problems is a great prerequisite.
However, after understanding them, the indica-
tions on the display (safety monitor, error mes-
sage, I/O checking ) become effective means.
An indication is not made on the LCD dis-

play.
No indications or abnormal.
Indication of the LCD display is normal.
No error message appears.
Indication of the LCD display is normal.
Error messages appears.
These cases are assumed. Considering them

and referring to the error messages and circuit
diagram (system wiring), trace the malfunctions.
Approximate guess is required.
Thoughtless tracing greatly wastes time. The
basic considerations are the same as the
SICOS50/60.
However, glance over this manual and roughly
take note of the key matters.
6-4 Analysis of malfunction causes
It was previously stated that initial understanding

of the content and phenomena of the problems is
an important point in finding the malfunctions.
With prerequisite that a malfunction results in
any error, the following checkings lead to a start
for the procedure.
– 36 –
Check for truck status
LCD display status
1) Check to ensure that the display is normal.
(Ordinary display or non-display)
2) Check to ensure that the display indicates
error messages.
Next, the malfunctions can be classified mainly

into following three:
No indications are made on the LCD display.
Indication of the LCD display is normal, but
the truck abnormally travels.
On the LCD display, error messages appear.
The following are the counter measures.

qNo indications are made on the LCD
display.
In this case, only the display does not make
an indication. Whether the forklift truck nor-
mally travels or not is a judgement diverge.
1) If only indication problems exist;
LCD display
MPU board that is controlling LCD.
Cables including connector between MPU
and LCD shall be checked.
2) Without LCD indications, the forklift truck
abnormally travels. (In many cases, the truck
does not travel quite). The power circuits
seem to have problems.
At the LCD lighting on the MPU board, the
MPU board, wirings or fuses are judged to
have problems.
PROCEDURE:Example,
No LCD
Are all lit?

Can truck travel and operate No No
LED0:12V
hydraulics normally? Replace MPU board.
LED1: 5V
LED2:CPU run
Yes
Yes
Replace LCD dispraly. Checking for power line.

F4 fuse, Mctt replay,
Yes CN2-6 pin, CN5-20 pin,
CN5-10 pin.
Is LCD indication made?
Yes
Check for MPU board or

wirings.
– 37 –
wIndication of the LCD display is normal,
but the truck abnormally travels.
In this case, especially checking for malfunc-
tions of the truck must be done.
They are largely classified into two(2):
Traveling and Hydraulic malfunctions.
1) Truck traveling status
The truck does not travel.
The truck rushes out.
The electric braking (plugging) force is weak.
If the LCD display indication is normal and the

traveling system has an error, the following
checkings must be initially done.
Check to ensure that all adjustments have
been done.
(See 1-3 Adjustment of starting current and
current limitation)
Check to ensure that the option setting is
correct.
Check to ensure that the hour meter display
is normal. Check for the parts which are not
self-diagnosed regarding travel,
(See 6-2 eError message and Possible
defective part)
2) Hydraulic malfunctions
A hydraulic motion is not made.
The hydraulic speed control is impossible.
If the hydraulic systems have errors, perform

checking in the same way as the traveling
systems.
Check to ensure that all adjustments have
been done.
(See 1-3 Adjustment of starting current and
current limitation)
Check for malfunctions of the option and
hour meter display.
eOn the LCD display, error messages

appear.
In this case, with reference to Section 6
Practical trouble shooting.
Please try checking.
The detailed procedure will be notified to you

soon later. Main signal lines for error message
will be attached to the system wiring base.
Please refer to it.
– 38 –
6-5 Flowchart for troubleshooting
q Check point
1) Is model select correct?
2) Check the specification.
With option.
Special truck?
After checking the above, start to troubleshoot.
When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the
CAUTION following.
1. MPU board
(1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.)
(2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-
check the setting.
(3) Check the plugging brake distance. (See Adjustment Specification Table.)
2. Current sensor
(1) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
3. FET Comp.
1. Be sure to turn off the key switch when setting Rotary switches.
CAUTION 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit.
w Contents of flowchart
ERROR NO.1 *RELEASE ACCEL TO NEUTRAL*

ERROR NO.2 *OFF HYD. LEVER TO NEUTRAL*
ERROR NO.3 *FAIL TRAVEL* *TURN OFF KEY SWITCH*
ERROR NO.4 *FAIL HYD.* *TURN OFF KEY SWITCH*
ERROR NO.5 A1:FUSE-TRAVEL ERROR NO.6 A2:FET6-REGEN.
ERROR NO.7 A3:CONTACTOR-REGEN. ERROR NO.8 A4:FET10-FORWARD
ERROR NO.9 A5:CONTACTOR-FORWARD ERROR NO.10 A6:FET9-REVERSE
ERROR NO.11 A7:CONTACTOR-REVERSE ERROR NO.12 A8:FET8-BYPASS
ERROR NO.13 A9:CONTACTOR-BYPASS ERROR NO.15 A11:TR-TRAVEL MAIN
ERROR NO.16 A12:TR-REGEN. MAIN ERROR NO.17 A13:ACCEL-ACCELERATOR
ERROR NO.18 A14:SENSOR-CURRENT(ARMATURE) ERROR NO.19 A15:SENSOR-CURRENT(FIELD)
ERROR NO.20 A16:SENSOR-SPEED ERROR NO.21 A17:FUSE-HYD.
ERROR NO.22 A18:FET5-HYD. ERROR NO.23 B19:CONTACTOR-HYD.
ERROR NO.24 B20:FET4-HYD. BYPASS ERROR NO.25 B21:TR-HYD. MAIN
ERROR NO.26 B22:SWITCH-LIFT ERROR NO.34 C29:SENSOR-EPS TORQUE
ERROR NO.35 C30:TR-EPS MAIN ERROR NO.36 C31:FUSE-EPS
– 39 –
Error No.1 * RELEASE ACCEL TO NEUTRAL *
LCD Display
*RELEASE ACCEL TO NEUTRAL*
Operate Accelerator before No No

Slit plate normal? Adjust.
turning on Key switch?
Yes
Yes
Replace the accelerator printed

Return the accelerator to the board.
neutral position.
Then operate it again.
No
Operation become normal?
Yes
This situation is occurred by the
neutral safety function.
This is not problem. END
This function warns to the
operator to take the correct
procedure to operate. The following each wiring between
Accelerator and MPU board is normal?
Accelerator PB-CN3-4 (Red4)
No Accelerator PB-CN3-5 (Brown/Yellow1)
Accelerator PB-CN3-14 (Black/Yellow)
Accelerator PB-CN4-1 (Red/Green3)
Accelerator PB-CN4-2 (Green/Black1)
Accelerator PB-CN4-9 (Black1)
Repair.
Yes
Replace MPU board.
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 40 –
Error No.2 * OFF HYD. LEVER TO NEUTRAL *
LCD Display
*OFF HYD. LEVER TO NEUTRAL*
Operate the hydraulic lever No

Turn off key switch.
before turning the key switch?
Yes
Set RS1 at [E].

Return the hydraulic lever to the
neutral position.
Then operate it again.
Turn on key switch.
This situation is occurred by the

neutral safety function. Select [IOM 0E].
This is not problem.
This function warns to the
operator to take the correct
procedure to operate. Release the hydraulic lever. No
Replace MPU board.
Any bit shows [1]?
Yes
No
Hyd. micro switch normal? Repair.
Yes
The following wiring between Hyd. Micro SW

and MPU board are normal?
Lift1 micro SW-CN6-6 (Brown/Red1)
Lift2 micro SW-CN6-14(Blue/Yellow2) No
Repair.
Tilt micro SW-CN6-7 (Red3)
Reach micro SW-CN6-15 (Yellow/Black)
Attachment micro SW-CN6-8 (Green/White3)
Attachment micro SW-CN6-16 (Blue/Yelloew3)
Yes
7 6 5 4 3 2 1 0
Replace Micro SW of the bit that
IOM 0E/ shows [1].
No
ATTACHMEMT SW
ATTACHMEMT SW

REACH SW
LIFT2 SW
LIFT1 SW
TILT SW
Yes
END Replace MPU board.
– 41 –
Error No.3 * FAIL TRAVEL* *TURN OFF KEY SWITCH*
LCD Display
FAIL TRAVEL
* *
TURN OFF KEY SWITCH
* *
No No
The other error messages The contact of M4 Bypass
appear at the same time? contactor is welded?
Yes Yes
The “Green/Blue” wire
between drain of Travel No
See the flowchart in which
FET and CN3-19 pin is
the error message appears
Replace the contact of normal?
and check it.
Bypass contactor. Yes
Repair.
No q Turn off key switch.

w Disconnect
Operation become the connector of Travel FET
normal? “4P Green”.
Yes
Turn on key switch.

END
No The error messages “*FAIL

TRAVEL*” appears?
Yes
Replace MPU board.
Replace Travel FET.
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 42 –
Error No.4 * FAIL HYD.* *TURN OFF KEY SWITCH*
LCD Display
FAIL HYD.
* *
*TURN OFF KEY SWITCH*
No No
The other error messages
Hyd. Bypass installed?
appear at the same time?
Yes
Yes
No The “Green/White” wire

See the flowchart in which No
The contact of M7 between drain of Hyd.
the error message appears
contractor welded? FET and CN3-10 pin is
and check it.
normal?
Yes
Yes
Repair.
Replace M7 contractor.
q Turn off the key switch.
w Disconnect
the connector. (2P Black)
Turn on key switch.
The error message

No “*FAIL HYD.*
* TURN OFF KEY SWITCH*”
appears?
Yes
Replace MU board.
Replace Hyd. FET.
– 43 –
Error No.5 A1:FUSE TRAVEL
LCD Display
A1:FUSE TRAVEL
No
Fuse F1 for travel is normal?
Yes
q Turn off the key switch. Replace Fuse for travel.

w Set RS1 at [E].
e Turn on key switch and
select I/O port [IOM 0F].
This bit 5 shows [1] on LCD display?
LCD display
No
7 6 5 4 3 2 1 0
IOM 0F
1:normal 0:abnormal The “Brown/White” wire No

between F1 (fuse) and CN2-1
Yes
pin is normal?
Yes
Replace MPU board.
Repair.
Replace MPU board.
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 44 –
Error No.6 A2:FET6-REGEN.
LCD Display
A2:FET6-REGEN.
OPTION SET Adjust.
RS1 [7]
No
Regenerative function Check 7 6 5 4 3 2 1 0
installed? OPTION SET.
OPTION
Yes
Bit 4 shows [0]?
The error message appears No Yes

after turning on key switch Replace MPU board.
Yes
without traveling?
q Set the bit 4 at [0].

Then reset RS1 at [0].
w Turn off and on key switch.
q Turn off key switch.
w Disconnect CN1 from MPU
board.
Replace MPU board.
The “Red/Green1” wire Yes The coil resistance of M3 No

between coil of M3 contactor contactor is normal?
and CN1-3 pin is normal? 32.5-35.5Ω
No Yes
Replace M3 contactor and MPU

Repair. Replace MPU board.
board at the same time.
– 45 –
Error No.7 A3:CONTACTOR-REGEN.
LCD Display
A3:CONTACTOR-REGEN.
OPTION SET Adjust.
No RS1 [7]
No
Regenerative function is Check 7 6 5 4 3 2 1 0
OPTION
Yes
Bit 4 shows [0]?
Turn off key switch. Yes
q Set the bit 4 at [0].

w Turn off and on key switch.
The contact of Regen. No
contactor (M3) is welded?
Yes Replace MPU board.
Replace M3 Contactor.
The error message
No
appears at the moment
when key switch, Foot Replace M3 Contactor.
switch and Accelerator
are turned on?
Yes No
Operation become
normal?
The “Blue2” wire between
No Yes
contact of M3 contactor
and CN4-15 pin is
damaged? END
Yes
Replace MPU board.
Repair.
The connection of M3 No
contactor is bad ?
Yes
Replace MPU board.
Replace M3 Contactor.
– 46 –
Error No.8 A4:FET10-FORWARD
LCD Display
A4:FET10-FORWARD
No
The error message appears
without traveling.
Yes

board.
The “Red1” wire between coil No

of M1 contactor and CN2-3 pin Repair.
is normal?
Yes
The coil resistance of M1 No

contactor is normal? Replace M1 contactor and MPU
32.5-35.5Ω board at the same time.
Yes
Replace MPU board.
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 47 –
Error No.9 A5:CONTACTOR-FORWARD
LCD Display
A5:CONTACTOR-FORWARD
Turn on key switch.
Yes
The truck can travel when No

operating the accelerator after Replace M1 contactor.
pushing the lever forward?
Yes
The “Yellow/White2” wire

between contact of M1
contactor and CN3-18 pin is
normal? No
And also the “Green/Blue2” Repair.
wire between contact of M2
normal?
Yes
Replace MPU board.
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 48 –
Error No.10 A6:FET9-REVERSE
LCD Display
A6:FET9-REVERSE
The error message appears No

without traveling.
Yes

board.
The “Red/White1” wire between

No
coil of M2 contactor and CN2-4
pin is short-circuited with the Repair.
other wire?
Yes

contactor is normal?
32.5-35.5Ω
Yes
Replace MPU board.
– 49 –
Error No.11 A7:CONTACTOR-REVERSE
LCD Display
A7:CONTACTOR-REVERSE
Turn on key switch.
Yes
The truck can travel when No

operating the accelerator after Replace M1 contactor.
pushing the lever forward?
Yes
The “Yellow/White2” wire

between contact of M1
normal? No
And also the “Green/Blue2” Repair.
wire between contact of M2
normal?
Yes
Replace MPU board.
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 50 –
Error No.12 A8:FET8-BYPASS
LCD Display
A8:FET8-BYPASS
The error message appears No

without traveling.
Yes

board.
The “Red/Black1” wire between

No
coil of M4 contactor and CN1-1
pin is short-circuited with the Repair.
other wire?
Yes

contactor is normal?
32.5-35.5Ω
Yes
Replace MPU board.
– 51 –
Error No.13 A9:CONTACTOR-BYPASS
LCD Display
A9:CONTACTOR-BYPASS
The error message of “*FAIL No

TRAVEL*” appear at the same Replace M4 contactor.
time?
Yes
The contact of M4 contactor No

welded?
Yes
The “Green/Blue” wire between No
drain of Travel FET and CN3-19 Repair.
Replace the contact of M4
pin is normal?
contactor.
Yes
No q Turn off key switch

Operation become normal? w Disconnect the connector of
Yes Travel FET (4P Green).
END
Turn on key switch.
No
The error message of “*FAIL
TRAVEL*” appear?
Yes
Replace MPU board.
Replace Travel FET.
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 52 –
Error No.15 A11:TR-TRAVEL MAIN
LCD Display
A11:TR-TRAVEL MAIN
The error message of “*FAIL No The “Green/Blue” wire between No

TRAVEL*” appears at the contactor of Travel FET and Repair.
same time? CN3-19 pin is normal?
Yes
Yes
Replace Travel FET.
The contact of M4 contactor No

welded?
Yes
Replace the contact of M4

contactor.
No The “Green/Blue” wire between No

Operation become normal? contactor of Travel FET and Repair.
CN3-19 pin is normal?
Yes
Yes
END
q Turn off key switch
w Disconnect the connector of
Travel FET (4P Green).
Turn on key switch.
No
TRAVEL*” appears?
Yes
Replace MPU board.
Replace Travel FET.
– 53 –
Error No.16 A12:TR-REGEN. MAIN
LCD Display
A12:TR-REGEN. MAIN
No
Regen. contactor (M4) is installed? Replace MPU board.
Yes
Resistors for pre-energizing are normal? No

48V : 2.2Ω, 30W (4 pcs.) Replace.
24V : 1.0Ω, 30W (2 pcs.)
Yes
The following 2mm2 wires are normal? (short-circuited or broken?)

No
q “Red” wire between contact of M3 contactor and the resistors for pre-energizing.
w “Blue” wire between the resistors and pre-energizing PB.
Repair.
e “White” wire between pre-energizing PB and D2 [A].
Yes
The following wires are normal? (short-circuited or broken?)

No
q “Blue/Red” wire between pre-energizing PB and MPU board (CN4-8 pin).
w “White/Red1” wire between pre-energizing PB and MPU board (CN4-16 pin).
Repair.
e “Brown/White” wire between D2 [K] and MPU board (CN2-1 pin).
Yes
Replace pre-energizing PB.
No
Operation become normal? Replace MPU board.
Yes
END
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 54 –
Error No.17 A13:ACCEL-ACCELERATOR
7 6 5 4 3 2 1 0
LCD Display
IOM 10
A13:ACCEL-ACCELERATOR
NTRAL
BWD
NO USED
FAD
Accel, bit
(Gray code)
q Turn off key switch. DECIMAL
w Set RS1 at [E]. 0 0 0 0 0 0
e Turn on key switch, and 1 0 0 0 1 0
select I/O port [IOM 10]. 2 0 0 1 1 0
3 0 0 1 0 0
4 0 1 1 0 0
5 0 1 1 1 0
6 0 1 0 1 0
Bit1-Bit4 change like the right table when 7 0 1 0 0 0
pulling and/or pushing Accelerator? 8 1 1 0 0 0
No 9 1 1 0 1 0
Bit 7 6 5 10 1 1 1 1 0
Push 0 1 0 Forward 11 1 1 1 0 0
Release 0 0 1 Neutral 12 1 0 1 0 0
13 1 0 1 1 0
Pull 1 0 0 Backward
14 1 0 0 1 0
15 1 0 0 0 0
Yes

Connector 6P
MPU board
of Accelerator
1 pin – CN3-14 (Black/Yellow)
Micro switch of Directional No
2 pin – CN3-5 (Brown/Yellow1)
3 pin – CN3-4 (Red4) No switch is normal?
4 pin – CN4-9 (Black1) Yes
5 pin – CN4-2 (Green/Black1)
6 pin – CN4-1 (Red/Green3)
Repair. Adjust or Replace.
Each wire of the above is broken or bad
connector?
Yes
Directional MPU board
switch
Replace Accelerator PB. Forward – CN6-12 (Brown2)
No
Backward – CN6-5 (White/Red2)
Neutral – CN6-4 (Brown/Black1)
Each wire of the above is broken or bad
No connector?
Yes
Yes
Repair.
Replace MPU board. Replace MPU board.
END
I/O check of Accelerator signal is displayed by Gray code.

CAUTION It is not Binary code. Pay attention.
– 55 –
Error No.18 A14:SENSOR-CURRENT (ARMATURE)
LCD Display
A14:SENSOR CURRENT
(ARMATURE)

No
[la] level can be adjust as
0[A]?
q Set RS1 at [1]. Yes

w Turn on key switch.
Adjust at 0[A].
[la] level of current sensor No

is 0[A]?
The following wires are normal?
Yes q “Red/Black3” wire between Current sensor
and CN3-1 pin. No
w “Blue” wire between Current sensor and
Replace MPU board.
CN3-2 pin.
e “Black/Red1” wire between Current sensor
and CN3-11 pin.
Operation become No Yes
normal?
Repair.
Yes Replace Current sensor [la].
END Replace Current sensor [la].

Operation become No
normal?
Yes
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 56 –
Error No.19 A15:SENSOR-CURRENT (FIELD)
LCD Display
A15:SENSOR CURRENT
(FIELD)

No
[lf] level can be adjust as
0[A]?
q Set RS1 at [1]. Yes

w Turn on key switch.
Adjust at 0[A].
[lf] level of current sensor No

is 0[A]?
Yes q “Red/Yellow3” wire between Current
sensor and CN3-3 pin. No
w “Yellow/Red2” wire between Current
Replace MPU board.
sensor and CN3-12 pin.
e “Black2” wire between Current sensor and
CN3-13 pin.
Operation become No Yes
normal?
Repair.
Yes Replace Current sensor [lf].
END Replace Current sensor [lf].
Operation become No
normal?
Yes
– 57 –
Error No.20 A16:SENSOR-SPEED
LCD Display
A16:SENSOR-SPEED
No
Speed sensor1 and Speed
sensor2 are installed normally? Adjust.
Yes

q “White1” wire between Speed sensor1 and MPU board (CN5-3 pin). No
w “Black/White1” wire between Speed sensor1 and MPU board (CN5-13 pin). Repair.
e “White2” wire between Speed sensor2 and MPU board (CN5-4 pin).
r “Black/Yellow1” wire between Speed sensor2 and MPU board (CN5-14 pin).
Yes
Replace Speed sensor1 and

Speed sensor2.
No
Yes
END
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 58 –
Error No.21 B17:FUSE-HYD.
LCD Display
B17:FUSE-HYD.
No
Hyd. fuse F2 is normal?
Yes
q Turn off the key switch. Replace.

w Set RS1 at [E].
This bit6 shows [1] on LCD display?
LCD display
No
7 6 5 4 3 2 1 0
IOM 0F/
1:normal 0:abnormal The “Green/Black” wire No

Yes
pin is normal?
Yes
Replace MPU board.
Replace.
Replace MPU board. (Damage or bad connection)
– 59 –
Error No.22 B18:FET5-HYD.
LCD Display
A18:FET-HYD.
No
The error message appears
when turning on key switch Replace MPU board.
without traveling.
Yes

board.
The “Red2” wire between coil No

of M6 contactor and CN1-4 pin Repair.
is normal?
Yes

contactor is normal? Replace MPU board.
32.5-35.5Ω
Yes

CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 60 –
Error No.23 B19:CONTACTOR-HYD.
LCD Display
A19:CONTACTOR-HYD.
No No
Replace M6
Hyd. operation is normal? Hyd. contactor (M6) can work?
contactor.
Yes Yes
No
The contact of M6 contactor is Replace M6
conductive? contactor.
Yes
The “Brown/Red” wire between No

contact of M6 contactor and Repair.
Yes
Replace MPU board.
No The “Brown/Red” wire between No

The contact of M6 contactor is
contact of M6 contactor and Repair.
welded?
Yes
Yes
Replace M6 contactor.
Replace MPU board.
– 61 –
Error No.24 B20:FET4-HYD. BYPASS
LCD Display
B20:FET4-HYD. BYPASS OPTION SET Adjust.
No RS1 [7]
No
Hyd. bypass system is Check 7 6 5 4 3 2 1 0
OPTION
Yes
Bit 5 shows [0]?
Yes
The error message Replace MPU board.

appears after turning on No
Replace MPU board.
key switch without
traveling?
Yes q Set the bit 5 at [0].
q Turn off key switch. w Turn off and on key switch.
w Disconnect CN1 from
MPU board.
The “Red/White2” wire

between coil of M7 No
Repair.
contactor and CN1-5 pin
is normal?
Yes

contactor is normal? Replace MPU board.
32.5-35.5Ω
Yes

CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 62 –
Error No.25 B21:TR-HYD. MAIN
LCD Display
B21:TR-HYD. MAIN
The error message of “*FAIL No The “Green/White” wire No

HYD.*” appears at the same between drain of Hyd. FET and Repair.
time? CN3-10 pin is normal?
Yes Yes
Replace Hyd. FET.

Hyd. bypass system is No
installed.
Yes
No The “Green/White” wire No

Hyd. bypass contactor is
between drain of Hyd. FET and Repair.
welded?
Yes
Yes

Replace M7 contactor. w Disconnect Gate “4P Red” of
Hyd. FET.
No Turn on key switch.

Yes
No
HYD.*” appears on LCD?
END Yes
Replace MPU board.
Replace Hyd. FET.
– 63 –
Error No.26 B22:SWITCH-LIFT
LCD Display
B22:SWITCH-LIFT
No
q Turn off key switch. Lift(2) Micro switch is installed
Adjust.
w Set RS1 at [E]. normally?
Yes
The “Green/Yellow” wire No

Turn on key switch.
between Lift(2) and CN6-14 pin Repair.
Yes is normal?
No
Yes
Bit2 shows [0] when not operating Hyd.
levers? Replace Lift (2) Micro
LCD display switch.
7 6 5 4 3 2 1 0
IOM 0E/ No
Yes Yes
Replace MPU board.
Bit2 changes to [1] after Bit1 changes to
END
[1] when operating Hyd. levers?
LCD display
7 6 5 4 3 2 1 0
No Micro switch which does not No
IOM 0E/ change to [1] is installed Adjust.
normally?
7 6 5 4 3 2 1 0 Yes
IOM 0E/
The wire of which Micro switch is abnormal? No
q Between Lift(1) and CN6-6 “Brown/Red1”.
Yes w Between Lift(2) and CN6-14 “Blue/Yellow2”.
Yes
Replace MPU board.
Replace the Micro switch Repair.
which is abnormal.
No
Yes
Replace MPU board.
END
– 64 –
Error No.34 C29:SENSOR-EPS TORQUE
LCD Display
C29:SENSOR-EPS TORQUE
The “Yellow/White1” wire between 4 pin of No

10 P water-resistant connector of EPS Repair.
controller and CN5-15 pin is normal?
Yes
The “Blue3”, “Green/Blue1”, “White” wires No

between EPS controller and EPS sensor Repair.
is damaged or broken?
Yes
Check the resistance at sensor side (tab side) between,

<standard value>
• q pin (Orange) and e pin (Black/Red) Adjust EPS sensor by
= Approx. 5kΩ ................... A No removing or insterting
• q pin (Orange) and w pin (Green/Red) a shim to be even value
= Approx. 2.5kΩ .............. B between B and C.
• w pin (Green/Red) and e pin (Black/Red)
= Approx. 2.5kΩ .............. C
Yes
NOTE
Refer to page 20.
Replace EPS controller.
No
Yes
END
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 65 –
Error No.35 C30:TR-EPS MAIN
LCD Display
C30:TR-EPS MAIN
The “Blue/Black” wire

between 2 pin of 10 P No
water-resistant connector Replace EPS controller.
and CN5-5 pin is short-
circuited with other wires?
Yes
No
Repair. Yes
END
CAUTION following.
1. MPU board
check the setting.
2. Current sensor
3. FET Comp.
– 66 –
Error No.36 C31:FUSE-EPS
LCD Display
C31:FUSE-EPS
No
EPS fuse F3 is normal?
Yes
q Turn off the key switch Replace EPS fuse.

w Set RS1 at [E].
Bit 7 shows [1] on LCD display?
LCD display
No
7 6 5 4 3 2 1 0
IOM 0F/
1:normal 0:abnormal The “Brown/Yellow” wire No

Yes
pin is normal?
Yes
Replace MPU board.
Repair.
Replace MPU board.
– 67 –
7. Wiring and layout of control unit
– 68 –
Battery:48V(FB10-25P)
72V (FB30P)
(The auxiliary 48 volts output is equipped
in the case of the 72 volts battery.
2 3 4 1 3 4
V N
BKWH
BK
RDWH
BKWH✻
RDBK
BK
X 2 (FB20/25P)
F1 Connector Connector
NA
Connector
VA
X 3 (FB30P) Line Line Line
CN Pin CN Pin NO. CN Pin
NO. No. No. NO. No. No. No. No.
275A D1
BNRD1 BURD1
VC D2 44 6 6 Lifut 1 switch 1 1 75 5 7 Hour meter counting
To connect :To start counting
BUYE2 (YEBK2) Hour meter(OPT.)
M4 45 6 14 Lifut 2 switch 76 5 17
M1 RD3
46 6 7 Tilt switch OPT. BUWH3
NB 5 19 Control GND OPT. 81 5 8 Hydraulic oil level(OPT.)
A YEBK YEWH3
M3 FC1 BK 47 6 15 Attachment switch 1 (OPT.) 82 5 18 Brake oill level
IA IF BU
E1 3 16 Travel FET Comp. source GNWH3 OPT. GNWH1
Pre-energizing resistor :
M2 B1 3 6 Travel FET Comp. gate 48 6 8 Attachment switch 2 (OPT.) 83 4 3 Over load(OPT.)

30W 2.2Ω X 4 (10-25)
GNBU
C5 3 19 Travel FET Comp. drain voltage BUYE3
40W 2.2Ω X 2 (30)
YEWH2 49 6 16 Attachment switch 3 (OPT.)

C3 3 18 Contact of For. contactor OPT.
WH
GNBU2 BU4 WHBK1
C4 3 9 Contact of Rev. contactor 5 85 4 4 Travel inhibit(OPT.)
D3 Turn on depressing
BU4 Input for spare
43 6 13 Brake switch 86 4 12
BU2 BNWH5 OPT. BNWH2
C1 4 15 Contact of regenerative contactor 90 4 13 Parking brake switch 87 4 5 Reducing speed when tuming(OPT.)
RD
RDWH Only for EEC

VB 2 7 Power supply for contactor coil BUYE1
PB83-62 84 4 11 Seat switch(OPT.)
Pre-energizing RDWH VH 2 6
BU WHRD1 Power supply for contorol
3 4 16 Pre-energizing FET source Only for trucks with laser pointer
RDYE1
BURD
B3 4 8 Pre-energizing FET gate
Laser pointer switch
BNWH GNRD2
VC 2 1 Trave lfuse X5 39 4 10 Tum signal lamp
YERD4 DC/DC
Capacitor : 100V 2200µF X 1 (FB10/15/18P) BK
NA 2 8 GND of contactor coil Converter
X 2 (FB20/25P)
X 3 (FB30P) BNWH6
Laser RDGN5 25W right
BNBK4 TSL
BURD5
D4
Tilt level sensor
F2 M7 Leveiing lamp Turn signal 25W left X5
PA
BNBK4
switch TSL
BURD5 RD5
M6 bypass contactor (M7) : FC2 BUWH2
275A BKRD
Opt.(FB15-25P) E2 3 17 Hyd. FET Comp .source RDWH3
BUWH
Std.(FB30P) B2 3 7 Hyd. FET Comp gate P12 5 9 P12V
GNWH
C6 3 10 Hyd. FET Comp drain voltage BUWH1 97 4 7 Waring buzzer
For trucks with 72V Battery
For trucks with 48V Battery
BNRD RDGN4
BUBK4 C2 3 8 Contact of Hyd. contactor P57 6 1
VD 2 5 Hyd fuse (GNWH2) 95 4 6 Forward signal
DS3 Tum on when BNBK1
40 6 4 Neutral
BNYE neutral position Load 200mA max.
VE 2 2 EPS fuse Drectional
C7 3 20 Contact of Rev. contactor switch DS1 BN2
41 6 12 Forward X2
BNRD2
96 4 14 Reverse signl
(FB10-25P)
PA EPSMotor
DS2 WHRD2
42 6 5 Reverse
Load 200mA max.
Back buzzer
YE
GN
(FB30P)
NB7 6 9
F3
RDYE4
BZ
WH
RD BU
BUBK Low speed X2
70 5 5 Abnomal of EPS chopper
40A EPS GNWH2
RDYE5
YEWH1
BN1
71 5 15 Abnomal of EPS sensor 58 5 12 Low speed
Controller 72 5 6 Speed sensitive for EPS(SP1)
10A
10A
BNBK
RD
73 5 16 Speed sensitive for EPS(SP2) M

F5
F4
EPS YEWH4 56 5 11 Mode select Rear combination lamp(right)

The truck with Sensor Mode select
RDWH
built in charger BU3 switch

RDGN
key GNBU1 YERD Tail & stop lamp

RDBK
X4 switch
X1 TS 55 5 1 Up BU4
WH 5 25W
TL
VF VG YEBK1 10W
57 5 2 Down
1 Back lamp
X4 25W
GNRD3
RDYE BL
15 5 20 Battery voltage
Accessory
RDGN2 Turn signal lamp
ST 5 10 Start for key switch WH1
60 5 3 Signal for speed sensor 1 25W
BKWH1 TSL
Charger, NB5 5 13 GND for speed sensor 1
Speed
Controller Sensor WH1
RD1 61 5 4 Signal for speed sensor 2
BKYE1
M1 20 2 3 Forward contactor NB6 5 14 GND for speed sensor 2
Rear combination lamp(left)
Charger panel WHBK
30 2 9 Harness mark/color
Brained wire Tail & stop lamp
RDWH1
M2 21 2 4 Reverse contactor RDBK1 25W Red RD
BNWH1 BU1
P50 3 1 Power supply for current sensor (Ia) TL
31 2 10 IA 10 3 2 Signal for current sensor (Ia) 10W Black BK
BKRD1
RDBK1 NB0 3 11 GND for current sensor (Ia) Back lamp Green GN
M4 22 1 1 Travel bypass contactor Travel
current sensor 25W
Yellow
WHGN RDYE3 BL YE
32 1 7 P51 3 3 Power supply for current sensor (If)
YERD1 Turn signal lamp White WH
IF BK2
11 3 12 Signal for current sensor (Ia)
23 1 2 Over drive contactor NB1 3 13 GND for current sensor (Ia) 25W Brown BN
TSL
33 1 8 Blue BU
Brained wire
RDGN1 Gray GY
M3 24 1 3 Regenerative contactor RD4 Ramp switch
WHBU P52 3 4 Power supply for accelerator Pink PK
BNYE1 right
34 1 9 BKYE
12 3 5 Signal for accelerator
RD2 NB2 3 14 GND for accelerator HL
M6 25 1 4 Hyd. contactor Accelerator Head
Ex) BKWH (=Black/White)
RDGN3 40Wx2
WHRD GNBK1 P53 4 1 Power supply for accelerator WH3 lamp Black colored harness with White line.
35 1 12 13 4 2 Signal for accelerator HL
BK1 NB3 4 9 GND for accelerator
RDWH2 left
M7 26 1 5 Hyd.bypass contactor
BUYE Opt. (FB10-25P) AC0 6 2 White line
36 1 13 Std. (FB30P) AC1 6 10 100V 22µF
Brained wire AC2 6 3 X3 Black color
27 1 6 EPS contactor AC3 6 11 WHBK2
20P H
}
37 1 14
RDBK2 Flat Horn
X1 28 1 10 Relay for power supply Display unit cable 20p 7
GNRD1
38 1 11 YEBU1
RDWH
X3
YEWH (Post)
BKWH✻
BKWH✻
80 3 15 Battery electrolyte level

Body
2 earth
BK
BK
(lever)
3 4 3 4 Horn switch
FB10-30P-DC70
SYSTEM WIRING
– 69 –
Laser pointer (Laser &Level sensor) Head guard (right) Main controller
✻Only for trucks with laser pointers
RD
P mast Harness,mast(1) Hanging on mast "M" BK
1 1
HL
1 1
1E-06145 "M"
4P
WH
Controller
WH 1
Harness,head guard GN
1
TSL Ass’y,EPS
2P
2P
Laser Water Water 24801-10111
1 1
M3 M1 M2 M4 M6
resistant resistant
<5>
Level
2P
M mast Harness,mast(1) Hanging on mast sensor Water <7> <8> <9>
resistant
1E-06145 RDBK 1
RDWH
Water
resistant BKWH
1 Accessory
Harness,mast(2) 2P "M" GNBK2
1
1
(front)
2E-15273
Control valve
Laser <6> AA <10>
2P
PA
2P
RDBK
Water
resistant
Water
resistant
✻Only for when using opthional eduipment.
YEBU1
2 2 Horn switch
Att.3
2P
BK
2 2
(valve lever) Hydraulic motor
"L"
275A
40A
Att.2 Traction Hydraulic
FET FET
Comp. Comp. M7
Indicator lamp
Acceleration <3>
2P
for forkleveling LED Att.1 PA PF
6P
Water
resistant sensor <9> <10>
275A
Water
Tilt resistant
Water
resistant
Lift 1 Speed
Harness mark/color
sensor <4>
2P
Red 6P <4>
RD Lift 2 (right) Harness,"M"(4)
BK
Black BK "L" Harness,"M"(1) 2E-15680
Green GN 10-25 : 2E-15405 Board comp.,MPU
Yellow YE
Speed 30 : 2E-15406
2P
sensor CN4 CN5 CN6
White WH 1
BURD1 (left)
Brown BK Water Harness,"M"(2)
BN Connect , and bigin the hour meter countdown.
1
resistant
Blue BU (Connect wires after removal of the cup holder) 2E-15407
Gray GY Traction motor <1>
+ <1>
+ (72V)
Pink PK Laser pointer (switch & Converter)
<0>
<2> <0>
Ex) BKWH (=Black/White) ✻Only for trucks with laser pointers
– + (48V)
Black colored harness with White line.
✻10-25 ✻30 Rear combination
<2> lamp (right)
DC/DC Converter 4P <8> <7> Battery – 4P 6P
WH FF F Accessory
1
White line
plug 4P 2P WH WH 2P-X
10P
Battery WH WH (rear)
1
Black color
plug Water TSL
<6> <5> resistant
1
1
1
2P AA A
Laser pointer switch WH
48V 72V
RDWH
BKWH
GNBK
10A
10A
10A
10A
TL
Battery Battery
BKWH✻
BKWH✻
(10-25) (30)
RDYE4
RDYE4
RDGN
RDGN
RDBK
RDBK
BL
Indicator panel
BK
BK
Harness,"M"(3)
4P
Lamp switch WH 2E-15680
Harness Comp.,panel
24300-32030
6P
YEWH3
Brake oil level sensor
2 2
EPS
3P
2
BK <3>,<4>,<5>,<6>,<7>,<8>,<9>,<10> Water resistant
2
sensor
Water
resistant
Display
Rear combination
lamp (left)
Harness,body ✻Only for EEC or when using
optional equipment
4P
Control power supply relay 10-25 TSL
Warning buzzer Foot brake switch
RD STD : 24801-32180
Water 30 STD : 24801-32200 Seat
resistant
RDYE5 GN 10-25 EEC : 24801-32220 switch
Back 2 2
4P 30 EEC : 24801-32240 TL
Mode serect switch EPS motor
8P
6P buzzer 2 2
BKWH YE WH Backward output relay
Water
2P
RD resistant
BL
WHBK2 4P
1 1
GNWH 7
Harness,charger(2) BK Horn relay
Low speed mode switch 1 1
BK Parking brake switch Horn 7
BKWH
2E-15425
6P
"K"
Transformer 4P
YE Turn signal relay
Charger panel ✻Only for trucks with built-in chargers. Water
resistant
3P
Key switch <13>

Water
✻Only for trucks with built-in chargers. Transformer
primary NOTE:
resistant
side Terminal
1. <n> indicates the lead wire numbers.
4P
BK Transformer + <11> <1>,<3>,
+ 2. Terminal symbols
Directional switch Charger, secondary Rectifier 2 :Plug AMP 170020-3
4P
<12> <2>,<4>,<12>
Water
resistant
controller side
– Harness,charger(1)
– 1 :Plug
AMP 170002-5
AMP 170020-2
2 :Receptacle AMP 170021-3
2E-15424 AMP 170003-5
Tun signal lamp switch
3P
Water 1 :Receptacle AMP 170021-1

resistant
Magnetic <13> 7 :Receptacle AMP 41729
"W" controller Harness, head guard(left) 3. When installing the charger panel on the truck body,use only bolts
and spring washers.
RDBK
Hurn switch 2 2
YEBU1
RD 1 1
The reason why only spring washers should be used is that they
(handle post) 2 2 BK 1 1
HL break the coating on the charger panel ,enduring conductance
4P between the frame and the charger panel.
Conector comp. WH WH
Harness, head guard 1 1 4. "M" , "S" , "L" , "K" , and "W" indicate the printed marks on the connector.
24300-21472 GN 1 1
TSL
✻Only when a chargers is not mounted. 6P 24801-10111
BK
FB10-30P-DC70
BODY WIRING
– 70 –
(✻Refer to note 6 ) RDBK AMP 172134-1
WH3
GNRD3
3
3
3
1 V,Q
2
59G
3 E1,E2 55B
M1,M2 43B Plug 4P
WH 1 2 W Lamp switch
4 3 4
AMP 172130-2
RDWH
YERD4
3
3
1 X
2
60I
a1 100A
Plug 2P
WH
1
2
a5 Laser pointer switch
RDWH3
WHRD2
BUWH1
GNWH2
YEWH4
RDGN5
RDGN2
RDGN4
YEBU1
BNBK1
YEBK1
AMP 172134-1
YERD
RDBK
RDBK
RDYE
RD5
BN2
YERD4
RD
BK
BK
3 1 a5 100B
Horn switch 59F P2,W 2
RDBK BKWH✻
BNWH6
3 2 M1,P2 61K Plug 4P
WH
1 2
a1 DC/DC Converter
2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3 3 a4 101B 3 4
W,R V
1 2 3
Q M2 A
1 2 3 4
A
1 2 3
b A
1 2 3 4 5 6 7 8
Point c A N A
V (Hydraulic) 41B F1,Q 2
YEBU1 BURD5 3 4 a2,a3 102B
59H 41C 59I 46A 28B 26B 54C 24B 58C 12B 58F 23B
M1 A A F2 A A A A
BNRD1 3 1 A 31B AMP 171898-2
Horn switch 44A 29B 27B 25C 13B 11B 14B 7B
YEWH3 BUYE2
Q
3 2 A 32B
(steering)
water resistant water resistant water resistant water resistant
N Brake oil 22B
58E
A
O,U
2
2
BK
RD3
YEBK
GNWH3
3
3
3
4
A 33B
A 34B
Plug 6P
BK
1 2 3
4 5 6
X Valve microswitch
Plug 3P Plug 4P Plug 3P Plug 8P 3 5 A 35B
RDWH 3 6 P2,a5 60H AMP 172134-1
AMP 174357-2 AMP 174257-2 AMP 174357-2 AMP 174982-2 BURD1 WH3 3 1 W 43C
21B A 1 RDGN5
W K BKWH✻
3 2 R,Point a 46B Plug 4P 1 2
3 2 1 2 1 3 2 1 4 3 2 1 BK 3 3 P2 61M WH 3 4
58D C,N 1 BUWH2 3 4 M1,E2 47D
4 3 8 7 6 5
Put the sleeve
for sure receptacle.
R
Turn signal
switch S
Directional
switch T Key switch U Indicator panel O Hour meter AMP 174352-2
M2 Head guard (right)
BNBK4
BURD5
4
4
1 Point b 103A
2 a1 102A
water resistant
Plug 2P 2 1
M a2 Laser
RDBK
RDWH
BKWH✻
GNBK2
AMP 174352-2
L a3 Level lamp
4)
AMP 174357-2 BNBK4
1
1
1
1
BU3 4 1 Point b 103B water resistant
te
WH3
RD5
BKWH✻
BUWH2
J EPS sensor 53B C 1 4 BURD5 2 1
no
water resistant GNBU1 4 2 a1 102C Plug 2P
52B C 2 4 F3,V a1,M2
WH
r to
3 2 1 Plug 3P 51B C 3 4
fe
59E 61L
Re
RDYE4
RDGN
RD
BKWH✻
RDWH
BNWH5
BU4
RDWH
3
3
3
3
(✻
K,X P1
1 2 3 4 AMP 174352-2
W b,a1
1P 49B C 8
YE▲
Point "b" BNWH6
BNBK4
4 1 a1 101A water resistant
2 1
S a4 Level sensor 60G 57B
P2 Accessory(front)
3
3
3
3
3
3
3
43A 61J 4 2 Point b 103C Plug 2P
R, Point a F4,M2
1 2 3 4
D C,T
1 2 3 4 5 6
F2,K A
I EPS motor 1P 50B C 9
GN▲
44B 47C 110B 54B 60E 5B
D G,M1 A, Point c K,P2 AMP 174352-2

AMP 172134-1
111B 61I 39B 60F BKWH1 4 1 A 16B water resistant
L
Plug 4P 1 2 WH1 Plug 2P 2 1
4 2 A 15B
RDYE5
WH 3 4 AMP 172134-2 AMP 171898-9
H Back buzzer 48C F3,E2 2
BKWH✻ AMP 174352-2 B Speed sensor
M1 Head guard(left) Plug 4P
BK
1 2
3 4
Plug 6P
RD
1 2 3
4 5 6
61G F4,G 2
BKYE1
WH2
4
4
1 A 18B
2 A 17B
water resistant
Plug 2P 2 1
NOTE:
1,Terminal symbols
b Charger panel K Brake switch G Horn 42B F1 7

WHBK2
+
1
2
:Receptacle(with plating)
:Receptacle(without plating)
AMP
AMP
170021-2
170003-5 or 170021-3
BKWH✻ BKYE AMP 174262-2 Sleeve(for single wire) AMP 170089-1
61H H,b 7 4 1 D 38B
Condenser BNYE1 4 2 D 37B Sleeve(for double wire) AMP 170890-1
BUWH2 100v 22µ
F4 Turn signal reiay

AMP 172134-7
Plug
4P
47B E1,M1 1
45A Point a 2
3
3
RDYE1
Point "a"
RD4
BK1
GNBK1
4
4
4
3 D 36B
4
5 A 3B
A 2B
water resistant
Plug6P
3 2 1
6 5 4
L Accelerator sensor 1 :Plug(with plating) AMP 170020-2
1 2 YE RDGN3 4 6 A 1B
2 :Receptacle(without plating) AMP 170002-5 or 170020-3
✻ Connect the relay "Cala-48V-N". 4B A 4 3 GNRD2 Sleeve(for double wire) AMP 170888-1
3 4 BKWH✻
Do not bind with the body harness. 61F F1,G 3 3
3 :Receptacle AMP 170032-5 or 179461-5
RDBK RDWH 3 :Tab AMP 170340-3 or 179462-3

AMP 172134-1
Plug
59C F1,F3 1
59D F3,P2 2
3
3
RDBK
Point "c"
BKWH✻
GNBK2
1
1
D,F2 60C
E2,Pointc 61D P1 Accessory 4 :Receptacle AMP 171662-1 or 173707-1
F3 Backward output relay 1 2
3 4
4P
WH
6B A 4 3 BNRD2
1 P2 57A
AMP 172888-2(rubber plug)
AMP 172748-2(seal plug)
✻ Connect the relay "Cala-48V-N". 48B E1,H 3 3
RDYE5
Do not bind with the body harness. AMP 174262-2 GNRD3 GNRD3 AMP 174262-2 5 :Receptacle AMP 316041-2 or 179956-2
55A W 1 4 4 1 Point c 55C
61A D 2 4
BKWH✻ BKWH✻ 4 2 Point c 61C
AMP 172134-9
25B A,T 1 3
RDYE
3 2 1
6 5 4
water resistant
Plug 6P
44D Point a 3
30C Point c 4
4
4
RD5
BU4
RDYE5
RDGN5
BU4
RDYE5
4
4
3 M2 46D
4 Point c 39D
water resistant
Plug6P
3 2 1
6 5 4 E2 Stop & tail lamp (right) 6 :Receptacle AMP 173716-2 or 175061-2
Plug RDBK2 48A F3 5 4

BUWH2 BUWH2
4 5 H 48D 7 :Receptacle(with sleeve) AMP 41729
F2 Control power supply relay 1 2
3 4
4P
RD 60D P1,K
39B D 2
3
40B D 4
3
3
3
RDWH
GNRD1
E1 Stop & tail lamp (left)
47A F4 6 4 4 6 M2 47E Sleeve(for single wire)
Sleeve(for double wire)
AMP 178023-2
AMP 1-170823-5
✻ Connect the relay "Cala-48V-N". 8 :Receptacle Yszaki 7116-3251
Do not bind with the body harness. 9 :Tab Yszaki 7114-3251
12 :Pressed sleeve JST FNE-2
59B D,F3 1 3
RDBK 15 :Terminal(F) Yszaki 1500-0110
AMP 172134-2
YEBU1
RDWH
BUBK
YEWH1
YE▲
GN▲
RDBK
RDYE4
BKWH✻
BK
BU2
WHRD1
BURD
RDWH
RDBK2
GNRD1
GNRD2
BNWH5
BNRD2
BUWH1
BU2
BURD
WHRD1
YERD
YEWH4
YEBK1
GNWH2
BUBK
YEWH1
BURD1
YEWH3
RDWH3
RDGN2
RDYE
RDGN4
BNBK1
BN2
WHRD2
BU4
BNRD1
BUYE2
RD3
YEBK
GNWH3
F1 Horn relay
RD
RDGN
Plug
41A V 2 3 15 :Terminal(M) Yszaki 1600-0105
4P b F1
1 2 BK 111A 59A
BKWH✻ 2,
(✻Refer to note 5)
✻ Connect the relay "Cala-48V-N". 3 4 61E Point c,F4 4 3 :Braid wire under 25mm pitch.
BU3
RDGN3
BK1
GNBK1
WH1
BKWH1
WH2
BKYE1
RD4
BNYE1
BKYE
WH
GNBU1
WHBK2
BK
BK
12
12
Do not bind with the body harness. 42A G 3 3 3, The location of the connector pin is as viewed from the inserting side.
4, The ends of the insulating tube should be tied together with wire ties.
Seal plug
Seal plug
Seal plug
5, Fuses should be placed in a circle, as shown in Figure 1.

10A
10A
6, The ends of the spiral tube should be tied together with wire ties,
4
4
4
4
4
4
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
and then theube should be coiled with a gap of 2 ± 1mm.(Refer to Figure 2.)
1 2 3 4 5 6 7 8 9 10 1 2 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
D J I I L L U D U U B B C O U T S S S X X X
3
3
3
3
3
3
3
3
3
3
3
3
60A 52A 49A 50A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 24A 26A 27A 29A 31A 33A 35A
1 2 3 4 1 2 3 4 1 2 3 4 5 6
Harness mark/color A A b J J AMP L F4 K F3 D D U U B B C N F2 S K X X
1-179958-2 E1,Point c A A L L F2
19B 20B 54A 51A 53A 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 25A 28A 30A 32A 34A
Red RD 61B 8B 9B 36A 38A 40A
2P-X
Black BK water resistant Receptacle b Point c A C,P1 L F2 Fuse
Plug10P 110A 58A 10B 60B 37A 39A CN4 CN5 CN6 10A
10A
Green GN
Yellow YE AMP 174655-2 Cap 2P Plug 4P Plug 6P
4 5 6 12
WH WH BK 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
White WH Wire tie
5 4 3 2 1 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 Clamp
Brown BN 10 9 8 7 6 AMP 172133-1 AMP 172134-1 AMP 171898-2
AMP.040 series multi-lock connector AMP.040 series multi-lock connector AMP.040 series multi-lock connector
Blue BU 2 1 1 2 1 2 3 175966-2 175967-2 175966-2 Figure 1 Figure 2
Gray GY C EPS unit 4 3 3 4 4 5 6
A MPU board
Pink PK D Controller
BKWH✻
To O

To U
To F1
To K
BK
BK
BU4
FB10-25P-DC70
44C M1,E1 RD5
RDYE1 To M1
To F4 RD5 12 12 12
To E1 BNBK4
To a2 BNBK4
White line
BKWH✻
BKWH✻
12
To P1
46C M2,E2
To E1
To E2
BNBK4 To a4
To D
BU4
RDGN5
BU4
To D
BK
RDYE1 To M2 To a3
Black color To F4
Point "a"
RDGN5
To E2
Point "b" Point "c" BODY HARNESS
– 71 –
RDBK AMP 172134-1
WH3
GNRD3
3
3
3
1 V,Q
2
3 E1,E2
59G
55B
M1,M2 43B Plug 4P
4 3 4
AMP 172130-2
RDWH
YERD4
3
3
1 X 60I
2 a1 100A
Plug 2P
WH
1
2
YEBU1
RDBK
GNWH2
WHRD2
RDWH3
BUWH1
YEWH4
RDGN5
RDGN2
RDGN4
BNBK1
AMP 172134-1
YEBK1
RDBK
RDYE
YERD
RD5
BN2
YERD4
RD
BK
BK
3 1 a5 100B

RDBK BKWH✻
BNWH6
3
3
2
3 a4 101B
M1,P2 61K Plug 4P
WH
1 2
3 4 a1 DC/DC Converter
2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
W,R V Q
1 2 3
M2 A
1 2 3 4
A b
1 2 3
A
1 2 3 4 5 6 7 8
Piont c A N A
59H 41C 59I 46A 28B 26B 54C 24B 58C 12B 58F 23B
M1 A A F2 A A A A
BNRD1 3 1 A 31B AMP 171898-2
Horn switch 44A 29B 27B 25C 13B 11B 14B 7B BUYE2
Q (steering)
N Brake oil 22B A 2
YEWH3
BK
RD3
YEBK
3
3
3
2
3
4
A 33B
A 32B
A 34B
Plug 6P
BK
1 2 3
4 5 6
X Valve microswitch
58E O,U 2 GNWH3 3 5 A 35B
Plug 3P Plug 4P Plug 3P Plug 8P RDWH 3 6 P2,a5 60H AMP 172134-1
AMP 174357-2 AMP 174257-2 AMP 174357-2 AMP 174982-2
BURD1 WH3 3 1 W 43C
21B A 1 RDGN5
W K BKWH✻
3 2 1 2 1 3 2 1 4 3 2 1 58D C,N 1
BK 3 3 P2 61M WH 3 4
BUWH2 3 4 M1,E2 47D
4 3 8 7 6 5
Put the sleeve
R
Turn signal
switch S
Directional
M
BNBK4
BURD5
4
4
1 Point b 103A
2 a1 102A
water resistant
Plug 2P 2 1 a2 Laser
RDBK
RDWH
BKWH✻
GNBK2
AMP 174352-2
AMP 174357-2 BNBK4 L a3 Level lamp
1
1
1
1
BU3 4 1 Point b 103B
BKWH✻
water resistant
BUWH2
4)
53B C 1 4 BURD5 2 1
J EPS sensor GNBU1 4 2 a1 102C Plug 2P
te
water resistant
WH3
52B C 2 4
RD5
F3,V a1,M2
no
3 2 1 Plug 3P 51B C 3 4 WH
r to
59E 61L
efe
BKWH✻
BNWH5
RDYE4
RDWH
RDWH
R
RDGN
3
3
3
3
(✻
K,X P1
BU4
Point "b" AMP 174352-2
RD
W
1 2 3 4
b,a1
YE▲
BNWH6 4 1 a1 101A water resistant
1P 49B C 8 BNBK4 2 1
P2 Accessory(front)
3
3
3
3
3
3
3
R, Point a F4,M2
1 2 3 4
D C,T
1 2 3 4 5 6
F2,K A
GN▲
44B 47C 110B 54B 60E 5B
D G,M1 K,P2 AMP 174352-2

AMP 172134-1 A, Point c
L
Plug 4P 1 2 WH1 4 2 A 15B Plug 2P
2 1
WH RDYE5
3 4 AMP 172134-2 AMP 171898-9 48C F3,E2 2
1 2 1 2 3
H Back buzzer BKWH✻ AMP 174352-2
NOTE:
BK 3 4
Plug 6P
RD 4 5 6
61G F4,G 2
BKYE1
WH2
4
4
1
2
A 18B
A 17B
water resistant
Plug 2P
2 1
1,Terminal symbols

WHBK2
+
1
2
AMP
AMP
170021-2
170003-5 or 170021-3
BKWH✻ BKYE AMP 174262-2 Sleeve(for single wire) AMP 170089-1
61H H,b 7 4 1 D 38B
Condenser BNYE1 4 2 D 37B Sleeve(for double wire) AMP 170890-1
BUWH2 100v 22µ RD4
47B E1,M1 1 3 Point "a"
F4 Turn signal reiay
AMP 172134-7
1 2
Plug
4P
45A Point a 2 3
RDYE1 BK1
GNBK1
4
4
4
3 D 36B
4
5 A 3B
A 2B
water resistant
Plug6P
3 2 1
6 5 4 L Accelerator sensor 1 :Plug(with plating) AMP 170020-2
RDGN3 4 6 A 1B 2 :Receptacle(without plating) AMP 170002-5 or 170020-3
✻ Connect the relay "Cala-48V-N". YE GNRD2
3 4 4B A 4 3
BKWH✻ BK 15 Sleeve(for double wire) AMP 170888-1
c 121A 58B Point c1 15 BK
Do not bind with the body harness. 61F F1,G 3 3 Cap Plug BUYE1
BK 15 c 121B 2P 2P 120B A 2 15
water resistant water resistant
Lengs 50
(✻
RDBK RDWH 3 :Tab AMP 170340-3 or 179462-3
Re
AMP 172134-1 59C F1,F3 1 3
RDBK 1 2 BKWH✻
1 D,F2 60C
P1 Accessory
fer
2 1
F3 Backward output relay Plug

59D F3,P2 2 3
GNBK2
1 E2,Pointc 61D
to
4P 1 P2 57A
Point "c"
no
1 2
c Seat switch AMP 172888-2(rubber plug)
te
WH BNRD2
✻ Connect the relay "Cala-48V-N". 6B A 4 3 AMP 172748-2(seal plug)
4)
3 4 RDYE5
Do not bind with the body harness. 48B E1,H 3 3
AMP 174262-2 GNRD3 GNRD3 AMP 174262-2 5 :Receptacle AMP 316041-2 or 179956-2
55A W 1 4 4 1 Point c 55C
61A D 2 4
RD5 RDGN5 6 :Receptacle AMP 173716-2 or 175061-2
AMP 172134-9 RDYE
3 2 1
6 5 4
water resistant
Plug 6P
44D Point a 3
30C Point c 4
4
4
BU4
RDYE5
BU4
RDYE5
4
4
3 M2 46D
4 Point c 39D
water resistant
Plug6P
3 2 1
6 5 4 E2 Stop & tail lamp (right)
Plug
4P
25B A,T
60D P1,K
39B D
1
2
3
3
3
3
RDBK2
RDWH
GNRD1
48A F3
47A F4 6
5 4
4
BUWH2 BUWH2
4
4
5 H 48D
6 M2 47E
7 :Receptacle(with sleeve)
Sleeve(for single wire)
AMP 41729
AMP 178023-2
✻ Connect the relay "Cala-48V-N".
Do not bind with the body harness.
3 4
RD 40B D 4 3
E1 Stop & tail lamp (left) 8
:Receptacle
AMP 1-170823-5
Yszaki 7116-3251
9 :Tab Yszaki 7114-3251
59B D,F3 1 3
RDBK 15 :Terminal(F) Yszaki 1500-0110
GNRD2
BNWH5
BNRD2
BUWH1
BU2
BURD
WHRD1
BUYE1
AMP 172134-2
BUBK
YEWH1
RD
RDWH
YE▲
GN▲
RDGN
RDBK
RDYE4
BKWH✻
BK
BU2
WHRD1
BURD
RDWH
RDBK2
GNRD1
YERD
YEWH4
YEBK1
GNWH2
BUBK
YEWH1
BURD1
YEWH3
RDWH3
RDGN2
RDYE
RDGN4
BNBK1
BN2
WHRD2
BU4
BNRD1
BUYE2
RD3
YEBK
GNWH3
YEBU1
F1 Horn relay 1 2
Plug
4P
BK
41A V 2 3
BKWH✻
b
111A
F1
59A
15 :Terminal(M) Yszaki 1600-0105
2,
WH
GNBU1
BU3
BKYE
RDGN3
BK1
GNBK1
RD4
BNYE1
:Braid wire under 25mm pitch.
WH1
BKWH1
WH2
BKYE1
3 4 61E Point c,F4 4 3
WHBK2
12
12
Do not bind with the body harness. 42A G 3 3 3, The location of the connector pin is as viewed from the inserting side.
BK
BK
4, The ends of the insulating tube should be tied together with wire ties.
Seal plug
Seal plug
Seal plug

10A
10A
4
4
4
4
4
4
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
1 2 3 4 5 6 7 8 9 10 1 2 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
3
3
3
3
3
3
3
3
3
3
3
3
Harness mark/color 1 2 3 4 1 2 3 4 1 2 3 4 5 6
A A b J J AMP L F4 c K F3 D D U U B B C N F2 S K X X
E1,Point c A A L L F2
Red RD 19B 20B 54A 51A 53A 1-179958-2 2A 4A 120A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 25A 28A 30A 32A 34A
61B 8B 9B 36A 38A 40A
Black BK 2P-X
water resistant
Receptacle b Point c A C,P1 L F2 Fuse
Green GN Ex) BKWH (=Black/White) Plug10P 110A 58A 10B 60B 37A 39A CN4 CN5 CN6 10A
10A
Yellow YE Black colored harness with White line. AMP 174655-2
White WH
Cap 2P
WH
Plug 4P
WH
Plug 6P
BK
4 5 6 12
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
Brown BN 5 4 3 2 1 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 Clamp Wire tie
10 9 8 7 6 AMP 172133-1 AMP 172134-1 AMP 171898-2
Blue BU White line
2 1 1 2 1 2 3 175966-2 175967-2 175966-2 Figure 1 Figure 2
Gray GY Black color 4 3 3 4 4 5 6
Pink PK C EPS unit A MPU board
D Controller
BKWH✻
To F1
To K
To O
BU4
To U
FB10-25P-DC70
BK
BK
44C M1,E1 RD5

RDYE1 To M1
To F4 RD5 12 12 12
To E1 BNBK4
To a2 BNBK4
BKWH✻
12
BKWH✻
To P1
46C M2,E2
To E2
To E1
BNBK4 To a4
BU4
BU4
To D
RDGN5
To D
To C
BK
BK
BODY HARNESS (EEC) RDYE1 To M2 To a3

To F4 RDGN5
To E2
Point "a" Point "b" Point "c"
– 72 –
RDBK AMP 172134-1
(✻Refer to note 6) WH3
GNRD3
3
3
3
1 V,Q
2
3 E1,E2
59G
55B
M1,M2 43B Plug 4P
4 3 4
AMP 172130-2
RDWH
YERD4
3
3
1 X
2
60I
a1 100A
Plug 2P
WH
1
2
GNWH2
WHRD2
RDWH3
BUWH1
YEWH4
RDGN5
RDGN4
RDGN2
AMP 172134-1
YEBU1
BNBK1
YEBK1
RDBK
RDBK
RDYE
YERD
YERD4
RD5
BN2
RD
3 1 a5 100B
BK
a1 DC/DC Converter
BK
BKWH✻ 1 2
RDBK
BNWH6
3 2 M1,P2 61K Plug 4P
V 3 3 a4 101B WH 3 4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1 2 3 1 2 3 4 1 2 3 1 2 3 4 5 6 7 8 (Hydraulic) 41B F1,Q 2
W,R V Q M2 A A b A Point c A N A
59H 41C 59I 46A 28B 26B 54C 24B 58C 12B 58F 23B
M1 A A F2 A A A A
BNRD1 3 1 A 31B AMP 171898-2
44A 29B 27B 25C 13B 11B 14B 7B
Horn switch YEWH3 BUYE2
Q (steering)
N Brake oil 22B
58E
A
O,U
2
2
BK
RD3
YEBK
GNWH3
3
3
3
2
3
4
A 33B
A 32B
A 34B
Plug 6P
BK
1 2 3
4 5 6
X Valve microswitch
RDWH 3 6 P2,a5 60H AMP 172134-1
AMP 174357-2 AMP 174257-2 AMP 174357-2 AMP 174982-2
BURD1 WH3 3 1 W 43C
21B A 1 RDGN5
W K BK BKWH✻
3 2 R,Point a 46B Plug 4P
WH
1 2
3 2 1 2 1 3 2 1 4 3 2 1 58D C,N 1 BUWH2
3 3 P2 61M 3 4
4 3 8 7 6 5 3 4 M1,E2 47D
Put the sleeve
R Turn signal
switch S Directional
BNBK4
BURD5
4
4
1 Point b 103A
2 a1 102A
water resistant
Plug 2P
2 1
M a2 Laser
RDBK
RDWH
BKWH✻
GNBK2
AMP 174352-2
L a3 Level lamp
)
BNBK4
4
AMP 174357-2 BU3
1
1
1
1
4 1 Point b 103B water resistant
WH3
RD5
BKWH✻
BUWH2
te
53B C 1 4 BURD5 2 1
J EPS sensor GNBU1 4 2 a1 102C Plug 2P
no
water resistant 52B C 2 4
WH F3,V a1,M2
Plug 3P
r to
3 2 1 51B C 3 4
59E 61L
fe
RDYE4
RDGN
RD
BKWH✻
RDWH
BNWH5
BU4
RDWH
Re
3
3
3
3
(✻
K,X P1
1 2 3 4 Point "b" AMP 174352-2
W b,a1
1P 49B C
YE▲ BNWH6
BNBK4
2 1
P2 Accessory(front)
8
3
3
3
3
3
3
3
R, Point a F4,M2
1 2 3 4
D C,T
1 2 3 4 5 6
F2,K A
GN▲
44B 47C 110B 54B 60E 5B
D G,M1 A, Point c K,P2 AMP 174352-2

AMP 172134-1
L
2 1
RDYE5
WH 3 4 AMP 172134-2
1 2
AMP 171898-9
1 2 3
H Back buzzer
48C F3,E2
61G F4,G
2
2
BKWH✻ AMP 174352-2 B Speed sensor NOTE:

BK 3 4
Plug 6P
RD 4 5 6 BKYE1
WH2
4
4
1
2
A 18B
A 17B
water resistant
Plug 2P 2 1
1,Terminal symbols
1 :Receptacle(with plating) AMP 170021-2
WHBK2
+
2 :Receptacle(without plating)
AMP
AMP
170003-5 or 170021-3
170089-1
BKWH✻ BKYE AMP 174262-2 Sleeve(for double wire) AMP 170890-1
61H H,b 7 4 1 D 38B
Condenser BNYE1 4 2 D 37B
BUWH2
L Accelerator sensor
100v 22µ RD4
AMP 172134-7 47B E1,M1 1 3
RDYE1 BK1
4 3 D 36B water resistant 3 2 1 1 :Plug(with plating) AMP 170020-2
45A Point a 2 3
F4 Turn signal reiay 1 2
Plug
4P
YE GNRD2
GNBK1
RDGN3
4
4
4
4
5 A 3B
6
A 2B
A 1B
Plug6P 6 5 4 2 :Receptacle(without plating)
AMP 170002-5 or 170020-3
AMP 170888-1
✻ Connect the relay "Cala-48V-N". 3 4 4B A 4 3 Point "a"
61F F1,G 3 3
BKWH✻
Do not bind with the body harness. 3 :Receptacle AMP 170032-5 or 179461-5
3 :Tab AMP 170340-3 or 179462-3
RDBK RDWH
F3 Backward output relay

AMP 172134-1
Plug
4P
59C F1,F3
59D F3,P2
1
2
3
3 RDBK
Point "c"
BKWH✻
GNBK2
1
1
1
D,F2 60C
P2 57A
E2,Pointc 61D P1 Accessory 4 :Receptacle AMP 171662-1 or 173707-1
AMP 172888-2(rubber plug)
1 2 AMP 172748-2(seal plug)
WH 3 BNRD2
3 4 6B A 4
✻ Connect the relay "Cala-48V-N". 48B E1,H 3 3 RDYE5 5 :Receptacle AMP 316041-2 or 179956-2
Do not bind with the body harness. AMP 174262-2 GNRD3 GNRD3 AMP 174262-2
55A W 1 4 4 1 Point c 55C 6 :Receptacle AMP 173716-2 or 175061-2
61A D 2 4
AMP 172134-9
25B A,T 1 3 RDYE
3 2 1
6 5 4
water resistant
Plug 6P
44D Point a 3
30C Point c 4
4
4
RD5
BU4
RDYE5
RDGN5
BU4
RDYE5
4
4
3 M2 46D
4 Point c 39D
water resistant
Plug6P
3 2 1
6 5 4 E2 Stop & tail lamp (right) 7 :Receptacle(with sleeve) AMP 41729

Plug
4P
60D P1,K
39B D 2
3
3
3
RDBK2
RDWH
48A F3
47A F4 6
5 4
4
BUWH2 BUWH2
4
4
5 H 48D
6 M2 47E
AMP 178023-2
AMP 1-170823-5
3 4
RD 40B D 4 3 GNRD1
E1 Stop & tail lamp (left) 8
9
:Receptacle
:Tab
Yszaki 7116-3251
Yszaki 7114-3251
15 :Terminal(F) Yszaki 1500-0110
59B D,F3 1 3 RDBK 15 :Terminal(M) Yszaki 1600-0105
AMP 172134-2
YE▲
GN▲
BUBK
YEWH1
RD
RDWH
RDGN
RDBK
RDYE4
BKWH✻
BK
BU2
WHRD1
BURD
RDWH
RDBK2
GNRD1
GNRD2
BNWH5
BNRD2
BUWH1
BU2
BURD
WHRD1
YERD
YEWH4
YEBK1
GNWH2
BUBK
YEWH1
BURD1
YEWH3
RDWH3
RDGN2
RDYE
RDGN4
BNBK1
BN2
WHRD2
BU4
YEBK
BNRD1
BUYE2
RD3
GNWH3
41A V 2 3 YEBU1
F1 Horn relay 1 2
Plug
4P
BK BKWH✻
b
111A
F1
59A
2,
3,
:Braid wire under 25mm pitch.
The location of the connector pin is as viewed from the inserting side.
3 4 61E Point c,F4 4 3
RD4
BNYE1
BKYE

WH
GNBU1
BU3
RDGN3
BK1
GNBK1
WH1
BKWH1
WH2
BKYE1
WHBK2
12
12
42A G 3 3 4, The ends of the insulating tube should be tied together with wire ties.
BK
BK
Seal plug
Seal plug
Seal plug
10A
10A
4
4
4
4
4
4
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
1 2 3 4 5 6 7 8 9 10 1 2 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
D
Harness mark/color 62A
12
3
3
3
3
3
3
3
3
3
3
3
1 2 1 2 3 4 1 2 3 4 5 6
Red
BK✻
RD A A b J J AMP L F4 K F3 D D U U B B C N F2 S K X X
1-179958-2 E1,Point c A A L L F2
Black BK 19B 20B 54A 51A 53A
D 61B 8B 9B 36A 38A 40A
2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 25A 28A 30A 32A 34A
Fuse
1
2P-X 10A
Green GN water resistant Receptacle 62B b Point c A C,P1 L F2 10A
Yellow YE Plug10P 110A 58A 10B 60B 37A 39A CN4 CN5 CN6
White 12
WH AMP 174655-2 Cap 2P Plug 4P Plug 6P
4 5 6
Brown BN WH WH BK 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Clamp Wire tie
5 4 3 2 1 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
Blue BU 10 9 8 7 6 AMP 172129-1 AMP 172134-1 AMP 171898-2
AMP.040 series multi-lock connector AMP.040 series multi-lock connector AMP.040 series multi-lock connector Figure 1 Figure 2
Gray GY 1 1 2 1 2 3 175966-2 175967-2 175966-2
Pink PK
C EPS unit
2 3 4 4 5 6
A MPU board
Ex) BKWH (=Black/White) D Controller
BKWH✻
To F1
To K
To O
BU4
To U
BK
BK
44C M1,E1
FB30P-DC70
RD5
RDYE1 To M1
White line To F4 RD5
To E1 BNBK4
12 12 12
To a2 BNBK4
BKWH✻
12
BKWH✻
46C M2,E2
To P1
To E2
To E1
Black color BNBK4 To a4

BU4
BU4
To D
RDGN5
To D
BK
RDYE1 To M2 To a3
BODY HARNESS
To F4 RDGN5
To E2
– 73 –
RDBK AMP 172134-1
WH3
GNRD3
3
3
3
1 V,Q
2
3 E1,E2
59G
55B
M1,M2 43B Plug 4P
4 3 4
AMP 172130-2
RDWH
YERD4
3
3
1 X
2
60I
a1 100A
Plug 2P
WH
1
2
GNWH2
WHRD2
RDWH3
BUWH1
YEWH4
RDGN5
RDGN2
RDGN4
YEBU1
BNBK1
YEBK1
AMP 172134-1
RDBK
RDBK
RDYE
YERD
RD5
BN2
YERD4
RD
BK
BK
3 1 a5 100B

RDBK BKWH✻
BNWH6
3
3
2
3 a4 101B
M1,P2 61K Plug 4P
WH
1 2
3 4
a1 DC/DC Converter
2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
W,R V
1 2 3
Q M2 A
1 2 3 4
A b
1 2 3
A
1 2 3 4 5 6 7 8
Point c A N A
59H 41C 59I 46A 28B 26B 54C 24B 58C 12B 58F 23B
M1 A A F2 A A A A
BNRD1 3 1 A 31B AMP 171898-2
44A 29B 27B 25C 13B 11B 14B 7B
Horn switch YEWH3 BUYE2
Q
3 2 A 32B
(steering)
N Brake oil 22B
58E
A
O,U
2
2
BK
RD3
YEBK
GNWH3
3
3
3
4
A 33B
A 34B
Plug 6P
BK
1 2 3
4 5 6
X Valve microswitch
RDWH 3 6 P2,a5 60H AMP 172134-1
AMP 174357-2 AMP 174257-2 AMP 174357-2 AMP 174982-2 BURD1 WH3 3 1 W 43C
21B A 1 RDGN5
W K BK BKWH✻
3 2 1 2 1 3 2 1 4 3 2 1 58D C,N 1
3 3 P2 61M WH 3 4
BUWH2 3 4 M1,E2 47D
4 3 8 7 6 5
Put the sleeve
Turn signal Directional
T Key switch U Indicator panel O Hour meter M2 Head guard (right)
R switch S switch AMP 174352-2
BNBK4
BURD5
4
4
1 Point b 103A
2 a1 102A
water resistant
Plug 2P 2 1
M a2 Laser
RDBK
RDWH
BKWH✻
GNBK2
AMP 174352-2
L a3 Level lamp
4)
AMP 174357-2 BNBK4
BKWH✻
1
1
1
1
BUWH2
BU3 4 1 Point b 103B water resistant
te
J EPS sensor 53B C 1 4
GNBU1 BURD5 Plug 2P 2 1
no
4 2 a1 102C
WH3
water resistant
RD5
52B C 2 4 F3,V a1,M2

WH
r to
3 2 1 Plug 3P 51B C 3 4
59E 61L
fe
BKWH✻
BNWH5
Re
RDYE4
RDWH
RDWH
RDGN
3
3
3
3
(✻
K,X P1
BU4
Point "b" AMP 174352-2
RD
1 2 3 4
W b,a1
1P
YE▲
BNWH6
BNBK4
2 1
49B C 8
P2 Accessory(front)
3
3
3
3
3
3
3
R, Point a F4,M2
1 2 3 4
D C,T
1 2 3 4 5 6
F2,K A
GN▲
44B 47C 110B 54B 60E 5B
D G,M1 AMP 174352-2

AMP 172134-1 A, Point c K,P2
L
2 1
RDYE5
WH 3 4 AMP 172134-2 AMP 171898-9
H Back buzzer
48C F3,E2 2
BKWH✻ AMP 174352-2 B Speed sensor
BK
1 2
3 4
Plug 6P
RD
1 2 3
4 5 6
61G F4,G 2
BKYE1
WH2
4
4
1
2
A 18B
A 17B
water resistant
Plug 2P
2 1

WHBK2
+ NOTE:
61H H,b 7
BKWH✻ BKYE AMP 174262-2
4 1 D 38B
Condenser BNYE1 4 2 D 37B 1,Terminal symbols
BUWH2 100v 22µ RD4
AMP 172134-7 47B E1,M1 1 3
RDYE1 Point "a" 4 3 D 36B water resistant 3 2 1
BK1
F4 Turn signal reiay 1 2
Plug
4P
YE
45A Point a 2 3
GNRD2
GNBK1
RDGN3
4
4
4
4
5 A 3B
6
A 2B
A 1B
Plug6P 6 5 4
L Accelerator sensor 1
2
AMP
AMP
170021-2
170003-5 or 170021-3
✻ Connect the relay "Cala-48V-N". 3 4 4B A 4 3 BK Sleeve(for single wire) AMP 170089-1
BKWH✻ 15 c 121A 58B Point c 1 15 BK
61F F1,G 3 3 Cap Plug Sleeve(for double wire) AMP 170890-1
Do not bind with the body harness. BK 2 15 BUYE1
15 c 121B 2P 2P 120B A
water resistant water resistant 1 :Plug(with plating) AMP 170020-2
(✻
Lengs 50
RDBK RDWH 2 :Receptacle(without plating) AMP 170002-5 or 170020-3
Re
AMP 172134-1 59C F1,F3 1 3
RDBK 2 1 1 2 BKWH✻
1 D,F2 60C
P1 Accessory Sleeve(for double wire) AMP 170888-1
fer
59D F3,P2 2 3 1 E2,Pointc 61D
F3 Backward output relay Plug
Point "c" GNBK2 1 P2 57A
to
4P
1 2
c Seat switch
no
WH BNRD2 3 :Receptacle AMP 170032-5 or 179461-5
3 4 6B A 4 3
te
✻ Connect the relay "Cala-48V-N". RDYE5
48B E1,H 3 3
5)
Do not bind with the body harness. AMP 174262-2 AMP 174262-2 3 :Tab AMP 170340-3 or 179462-3
55A W 1 4 GNRD3 GNRD3 4 1 Point c 55C
BKWH✻ BKWH✻
61A D 2 4
RD5 RDGN5
4 2 Point c 61C 4 :Receptacle AMP 171662-1 or 173707-1
AMP 172134-9
25B A,T 1 3 RDYE
3 2 1
6 5 4
water resistant
Plug 6P
44D Point a
48A F3
3
30C Point c 4
5
4
4
4
BU4
RDYE5
BU4
RDYE5
4
4
4
3 M2 46D
4
5 H 48D
Point c 39D
water resistant
Plug6P
3 2 1
6 5 4 E2 Stop & tail lamp (right) AMP 172888-2(rubber plug)
AMP 172748-2(seal plug)
Plug
4P
RD
60D P1,K
39B D 2
3
3
3
RDBK2
RDWH
GNRD1
47A F4 6 4 BUWH2 BUWH2 4 6 M2 47E
3 4 40B D 4 3
E1 Stop & tail lamp (left) 6 :Receptacle AMP 173716-2 or 175061-2
7 :Receptacle(with sleeve) AMP 41729

59B D,F3 1 3
RDBK Sleeve(for single wire) AMP 178023-2
AMP 172134-2
GNRD2
BNWH5
BNRD2
BUWH1
BU2
BURD
WHRD1
YERD
YEWH4
YEBK1
GNWH2
BUBK
YEWH1
BURD1
YEWH3
RDWH3
RDGN2
RDYE
RDGN4
BNBK1
BN2
WHRD2
BU4
YEBK
BUYE1
BNRD1
BUYE2
RD3
GNWH3
BUBK
YEWH1
RD
RDWH
YE▲
GN▲
RDGN
RDBK
RDYE4
BKWH✻
BK
BU2
WHRD1
BURD
RDWH
RDBK2
GNRD1
41A V 2 3
YEBU1 Sleeve(for double wire) AMP 1-170823-5
F1 Horn relay 1 2
Plug
4P
BK BKWH✻
b
111A
F1
59A
8
9
:Receptacle
:Tab
Yszaki 7116-3251
Yszaki 7114-3251
WH
GNBU1
BU3
BKYE
RDGN3
BK1
GNBK1
WH1
BKWH1
WH2
BKYE1
61E Point c,F4 4 3
RD4
BNYE1
✻ Connect the relay "Cala-48V-N". 3 4

WHBK2 12 :Pressed sleeve JST FNE-2

12
12
42A G 3 3
Do not bind with the body harness. 15 :Terminal(F) Yszaki 1500-0110
BK
BK
Seal plug
Seal plug
Seal plug
15 :Terminal(M) Yszaki 1600-0105

10A
10A
4
4
4
4
4
4
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
1 2 3 4 5 6 7 8 9 10 1 2 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 2, :Braid wire under 25mm pitch.
Harness mark/color D J I I
D
L L U D U U B B C O U T S S S X X X 3, The location of the connector pin is as viewed from the inserting side.
62A 4, The ends of the insulating tube should be tied together with wire ties.
12
3
3
3
3
3
3
3
3
3
3
3
Red RD 1 2 1 2 3 4 1 2 3 4 5 6 5, Fuses should be placed in a circle, as shown in Figure 1.
BK✻
A A b J J L F4 c K F3 D D U U B B C N F2 S K X X 6, The ends of the spiral tube should be tied together with wire ties,
Black BK AMP E1,Point c A A L L F2
19B 20B 54A 51A 53A 1-179958-2 2A 4A 120A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 25A 28A 30A 32A 34A and then theube should be coiled with a gap of 2 ± 1mm.(Refer to Figure 2.)
Green D 61B 8B 9B 36A 38A 40A
1
GN 2P-X
Receptacle 62B b Point c A C,P1 L F2
Yellow YE Ex) BKWH (=Black/White) water resistant
Plug10P CN4 CN5 CN6
110A 58A 10B 60B 37A 39A
White WH Black colored harness with White line. Fuse
AMP 174655-2
Brown BN Cap 2P
WH
Plug 4P
WH
Plug 6P
BK
4 5 6 10A
10A
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
Blue BU 5 4 3 2 1 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
Gray GY White line 10 9 8 7 6 AMP 172129-1 AMP 172134-1 AMP 171898-2 12
1 1 2 1 2 3 175966-2 175967-2 175966-2 Wire tie
Pink PK Black color Clamp
2 3 4 4 5 6
C EPS unit D Controller A MPU board Figure 1 Figure 2
BKWH✻
To F1
To K
To O
BU4
To U
BK
BK
44C M1,E1 RD5

RDYE1 To M1
FB30P-DC70 To F4 RD5
To E1 BNBK4
To a2 BNBK4
12 12 12
BKWH✻
BKWH✻
12
To P1
46C M2,E2
To E2
To E1
BNBK4 To a4
BU4
BU4
To D
RDGN5
To D
To C
BK
BK
RDYE1 To M2 To a3
To F4 RDGN5
BODY HARNESS (EEC)

To E2
– 74 –
FB10-25P Note: 1.Terminal symbols
:Terminal
FB30P <5> <2>
:Lead bar
:Plug 170020-2
:Receptacle 170021-2
<6>
<4>
2.The terminal is fixed in place
M3 M1 M2 M4 M6 by the fitting for the connector.
3. Connect only if a GS battery
2P 2P
<8>
2P 2P 2P 2P 2P
is installed.
GNBU2
YEWH2
<7>
WH WH WH WH WH WH WH
<3>
<13>
BNRD
<6>
CF
4PWH
FB10P F FB20/25/30P
F
WH*
<3>
A PA
<4>
WHRD1
<13>
<2>
4PWH D1 PF
Only FB30P
S+ H+ Controller Ass’y.,EPS
<12>
<9>
BUBK4
40A 275A
<11>
D+ FET FET M7
<5>
Comp. Comp.
RDYE
BNYE
FB15/18 Only FB10-25P
RD* (FB30P has no this line)
RD
<10>
2P 275A
<1>
<8> WH
<7>
2 A
BU
Refer to note 2 T+
<1>
Pre-energizing
BNWH
YEWH
BKWH✻
BU Board Comp.,MPU
4P
GN GN RD 1
4P 4P Refer to note 3
1
1 2 3
Harness mark/color Harness,Controller

Red RD FB10-25P : 24200-68871
Black BK FB30P : 24200-68941
Green GN
Yellow YE
White WH Wire, Lead ( <1>-<13> )
Brown BN
Blue BU 4P 2P 4P 6P 10P For Std. For EEC
Water resistant
Gray GY WH WH WH WH 2P FB10P 24200-68792 24200-68832
Pink PK TipeX FB15/18P 24200-68802 24200-68842
FB10-25P FB30P
FB20/25P 24200-68812 24200-68852
FB30P 24200-68822 24200-68862
White line
Black color To Harness,Body
FB10-30P-DC70
CONTROL UNIT WIRING
– 75 –
Harness mark/color B Contactor NOTE:
Red RD
Black BK 1 1 1 1 1 1. Lead wire
2 2 2 2 2
Green GN 16B
A
17B
A
15B
A
# :AVS 0.3mm 2
Yellow YE Plug Plug

2P
Plug Plug
2P
Plug ✻ :AVS 0.85mm 2
2P 2P 2P
White WH :KIV 2.0mm 2
*
WH WH WH WH WH
8 8 8
Brown BN
Blue
Others :AV S0.5mm 2
YEWH2
BU
GNBU2
30B 29B 23B 25B 24B 27B 28B 37B 32B 35B
BNRD
Gray GY A A A A A A A A A A
2. The location of the pin is as viewed from the inserting side.
Pink PK 1 2 1 2 1 2 1 2 1 2
3. : Braid wire under 25mm pitch.
3
RDGN1
RD1
WHBK
RDWH1
BNWH1
RDBK1
WHGN
RD2
WHRD
WHBU
Black colored harness with White line. 4. Do not use sure-plugs and receptacles.
White line
Black color
A MPU board C Fuse

1 2 3
RDBK3#
BKRD1#
RDYE3#
YERD1#
WHRD1
7 6 5 4 3 2 1 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 26B
BU1#
BK2#
WH*
RD*
BU*
14 13 12 11 10 9 8 10 9 8 7 6 20 19 18 17 16 15 14 13 12 11 A
22B 44B
10
10
10
10
10
10
3
A H,H
1 2 3 4 1 2 3 4 1 2 14P 10P 20P 8
8 20B
A
BUBK4
A A A A J I 8 8
1B 3B 5B 4B I,H 39B 38B 35A 33A 31A 29A 27A 25A 12D 21C 21A 18A 16A 14A 12A 10A 8A 6A 4A 2A
A A
RDYE4
40B B H H B B B H H H K B M K N H E E E 8
BNYE
2B 6B 37A 32A 30A 28A 26A 24A 23A 22A 20A 19A 17A 15A 13A 11A 9A 7A 5A 3A 1A
Plug
2P B B B B C B B C C M B B M K H H E E E
BNWH
4P 4P F Terminal WH
14 7 13 6 12 5 11 4 10 3 9 2 8 1 10 5 9 4 8 3 7 2 6 1 20 10 19 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
1
BNWH
RD1
RDBK3#
WHGN
WHRD
GNRD1
RD2
RDGN1
WHBU
RDBK1
BNWH1
BUBK4
WHBK
RDWH1
BK
RDWH
BNYE
RDWH
GNWH
GNBU
GNBU2
YEWH2
BNRD
BKRD
BUWH
BK
BU
YEWH
BNYE1
BKYE
RD4
BK2#
RDYE3#
YERD1#
BU1#
BKRD1#
RDBK2
A F 2
1 2 3 4 1 2 3 4
G Resistor
E Current sensor
BURD
WH*
BU*
BKWH✻
3
3
3
WHRD1
BKWH✻
GNRD1
RDBK2
RDYE4
RDYE4
BNYE1
GNWH
RDWH
BUWH
YEWH
GNBU
BURD
BU2
BKRD
BKYE
1 2 3 4
RD4
BU2
BU
BK
BK
G F A
8 8
38A 40A 10B
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
H
RD*
1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 1 2 3 4
1
43B H 10C H
42B C L J I A A A A,H A A A N 41A

8
44A 41B 42A 43A 7B 8B 33B 12B 11B 14B 13B
Plug 4P
L Battery(–)
YEWH
C K,A F A,A A A A A
GN G 44C 12C 40C 21B 9B 31B 18B 19B
39A
6
1 2
Plug 4P Cap 4P Cap 6P Cap 4p Cap 4P
3 4
WH WH BK GN RD
N
I Pre-energizing PB J Diode 1 2 2 1 3 2 1 2 1 2 1
10D
3 4 4 3 6 5 4 4 3 4 3
N Body earth
FET comp. Refer to note 4
H External terminal K (travel)

M
FET comp.
(hidraulic)
FB10-25P-DC70
CONTROL UNIT HARNESS
– 76 –
Harness mark/color
Red RD
B Contactor NOTE:
Black BK
Green 1 1 1 1 1 1. Lead wire
GN
Yellow YE
2 2 16B 2 17B 2 2 15B # :AVS 0.3mm 2
White WH Plug Plug

A
Plug
A A ✻ :AVS 0.85mm 2
Plug Plug
:KIV 2.0mm
*
2P 2P 2P 2P 2P 2
Brown BN WH WH WH WH WH
8 8 8
Blue BU Others :AV S0.5mm 2
BNRD
Gray GY 30B 29B 23B 25B 24B 27B 28B 37B 32B 35B
2. The location of the pin is as viewed from the inserting side.
YEWH2
GNBU2
Pink PK A A A A A A A A A A

1 2 1 2 1 2 1 2 1 2
3. : Braid wire under 25mm pitch.
3
4. Do not use sure-plugs and receptacles.
RDGN1
RD1
WHBK
RDWH1
BNWH1
RDBK1
WHGN
RD2
WHRD
WHBU
White line
Black color
A MPU board
1 2 3
C Fuse
D Contactor
RDBK3#
RDYE3#
YERD1#
BKRD1#
WHRD1
7 6 5 4 3 2 1 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 26B
BU1#
BK2#
WH*
RD*
BU*
14 13 12 11 10 9 8 10 9 8 7 6 20 19 18 17 16 15 14 13 12 11 A
22B
1
10
10
10
10
10
10
3
A
1 2 3 4 1 2 3 4 1 2 14P 10P 20P 8
2
8 20B
A
BUBK4
A A A A J I 8 Plug
1B 3B 5B 4B I,H 39B 38B 36A 35A 33A 31A 29A 27A 25A 12D 21C 21A 18A 16A 14A 12A 10A 8A 6A 4A 2A 2P
WH
BNYE
A A 40B D B H H B B B H H H K B M K N H E E E 8
2B 6B 37A 34A 32A 30A 28A 26A 24A 23A 22A 20A 19A 17A 15A 13A 11A 9A 7A 5A 3A 1A
BNWH
Plug
4P 4P
F Terminal 2P
WH
B D
14 7 13 6 12 5 11 4 10 3 9 2 8 1
B B B C
10 5 9 4 8 3 7 2 6 1
B B C C M B B M
20 10 19 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1
K H H E E E 34B 36B
A A
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
1 2
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
1
A F
RDGN1
BNWH1
3
RDWH1
WHGN
BUYE
WHRD
WHBU
RDBK1
BUBK4
WHBK
BK
RD1
RDWH
BNYE
RDWH
BNWH
GNWH
GNBU
GNBU2
YEWH2
BNRD
BKRD
BUWH
BK
BU
YEWH
BNYE1
BKYE
RD4
BK2#
RDYE3#
YERD1#
BU1#
BKRD1#
RDBK3#
RDWH2
RD2
GNRD1
RDBK2
2
RDWH2
1 2 3 4 1 2 3 4
BUYE
Resistor
E Current sensor
BURD
WH*
BU*
BKWH✻
3
3
3
BKWH✻
WHRD1
GNRD1
RDBK2
RDWH
GNWH
BNYE1
BU2
BUWH
YEWH
BURD
GNBU
BKRD
BKYE
1 2 3 4
BU2
RD4
BU
BK
BK
G F A
8 8
38A 40A 10B
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
3
3
3
H
RD*
1 2 1 2 3 4 1 2 3 4 5 6 1 2 3 4 1 2 3 4
1
43B H 10C H
42B L J I A A A A,H A A A N 41A
YEWH
8
41B 42A 43A 7B 8B 33B 12B 11B 14B 13B
Plug 4P
GN
G
39A
K,A
12C
F
40C
A,A
21B
A
9B 31B
A
18B
A
19B
A
L Battery(–)
6
1 2
Plug Cap4P Cap 6P Cap 4P Cap 4P
3 4 2P
WH WH BK GN RD N
I Pre-energizing PB J Diode 2 1 3 2 1 2 1 2 1
10D
1
2 4 3 6 5 4 4 3 4 3
N Body earth
H External terminal K
FET comp.
(travel) FET comp.
Refer to note 4
M (hidraulic)
FB30P-DC70
CONTROL UNIT HARNESS
– 77 –
Reference
Connector for MPU board

Double lock plate pushing part
1. Pin layout of housing Locking lever
Rib for preventing
inverse insertion
Double lock plate
6 5 4 3 2 1
14 13 12 11 10 9 8 7
CN1 (gray)
[P/No.37010-21040]
Ratchet part Plug housing

4 3 2 1
10 9 8 7 6 5 CN3, 4, 5 6
CN2 (gray)
[P/No.37010-21030]
(2) Crimping terminals

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
CN3 (black) Housing lance Contacting part

CN5 (black) fixing part (inside box)
[P/No.37010-21020]
Wire barrel
8 7 6 5 4 3 2 1 Insulation barrel
16 15 14 13 12 11 10 9
CN1&CN2
CN4 (black) [P/No. 37010-21480]
CN6 (black)
[P/No.37010-21010]
2. Names of parts Housing lance Contacting part

fixing part (inside box)
(1) housing
Wire barrel
Double lock plate pushing part Insulation barrel
Locking lever
Double lock plate
CN3, 4, 5, 6
[P/No. 37010-21490]
Ratchet part
Plug housing
CN1&CN2
– 79 –
3. Insertion terminal into housing (3) Press the crimping part of the double lock
(1) With the locking lever of housing upward plate. The plate will go down and release
and the crimping part of terminal upward, from the ratchet part and will sound snap-
insert the housing into corresponding port. ping. And after finishing the inserting the
(Fig.1) terminal, pull the wire lightly to make sure
the locking. When the double lock plate
When it is impossible to insert the would work correctly, the condition would
CAUTION
terminal easily, do not force to insert be like as Fig.4.
it.
At first, check the corresponding CAUTION
When there are some unlocked termi-
port. When inserting forcedly, the nals, the double lock plate would not
housing will be damaged at the hous- work correctly, the plate would be
ing. Pay attention to insertion of ter- one side locking and the ratchet
minal. would be raised at one side Remove
the terminal by using the ejection tool
and do over again correctly.
Locking lever Double lock plate
Plug housing pressed part
Double lock part
Double lock part

Pull the wire
Crimping part lightly
Insulation barrel
Housing lance Terminal

Fig.1 [Completed double locking]
Fig.4
(2) Verify the terminal is locked correctly into There a gap on The inserting groove
normal condition for ejection tool
the housing. When inserting the terminal
like as Fig.2, the terminal which the crimp-
ing part is placed in the middle of the
retainer would come to lose, insert the
terminal into the housing like as Fig.3. [Completed double locking] [Incompleted detente locking]
When the terminal is locked, it would [One side locking of ratchet]
sound snapping. And after inserting the Fig.5

terminal, pull the wire lightly to make
sure the locking it.
4. Pulling terminal
When remove the terminal for doing (1) Release the double locking (Fig.6)
CAUTION
over again, use the specified pulling q Insert the jig into the groove .
tool. w Lay it to the direction of arrow and bend
the wall of housing, and then rise the plate
crimping part and remove the ratchet.
Repeat the same way at the opposite side
Pull the wire also.
lightly
CAUTION
Do not vent the wall of housing
[Unlocked condition [Correct locked condition
strongly, it will come to be damaged.
of terminal] of terminal]
Fig.2 Fig.3
– 80 –
[In case of CN1, 2] CAUTION
Be careful not to insert the ejection
Rib of plate tool into the housing side of crimping
crimping part
terminal.
Operation
from q to w
Inserting groove
for ejection jig e
w
q
q r
Fig.7
Cut face
should be inside
• Insert the jig into the groove 5. Crimping tool (AMP made)
and bend the housing.
w (1) Crimping terminal for CN1&2
• After the housing would (P/No.37010-21480) applicable hand tool
be bended, rise the rib of
plate crimping part to the Model: 911788-2
arrow direction.
Rib of plate Mark of crimping part

crimping part
Fig.6 Crimping die
[In case of CN3, 4, 5, 6] Rib of plate m

5m
crimping part Pin and
Bared length -4.
of insulation 3.5
retaining ring
Handle
Operation
from q to w Crimping part
Crimping pressure of wire
control device press down part
Inserting groove of insulation
for ejection jig
Radio pliers q
(article on the market)
(2) Crimping terminal for CN3, 4, 5, 6

Ejection jig (AMP)
(P/No.37010-21490) applicable hand tool
Model: 755430-1
Model: 911738-1
w
Crimping die
(Inside)
Crimping part
of wire
press down part
of insulation
Clamp the housing and Rib of plate
retainer by the radio pliers, crimping part Bared length
then release the ratchet of insulation
When insert the jig into 4mm (Reference)
part (sounds clipping) and the housing, move the jig
repeat the same outline at to the arrow direction and Crimping pressure
the opposite side. vent the housing. control device
Handle
(2) Pulling out the crimping terminal

qPush the crimping terminal to the arrow
direction.
wInsert the ejection jig tool to the groove.
eRise the lance.
rPull the crimping terminal.
– 81 –

Nichiyu Fb10 30p Dc70 Series Trs

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02W-2201

1. How to adjust SICOS 60 (Major point only) .........................1

2. Adjustment for other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5. Self diagnosis history memory and I/O check . . . . . . . . . . . . . . . . 22

6. Practical trouble shooting (How to find the cause of problem) . . . . . . . . 31

7. Wiring and layout of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1-1 The name and function of

œWhen the slow speed mode button is turned on,

w Mode select button.

Showing the travel hour meter.

Travel hour meter

TRAVEL HYD STEER BATT OIL LOAD BRAKE

When hour meter counts,

Showing the hydraulic hour meter. Down button

TRAVEL HYD STEER BATT OIL LOAD BRAKE

flashes when the hour meter counts by F km/m 0 5 10 15 20

operating traveling or the hydraulic lever. 8

Hydraulic hour meter

TRAVEL HYD STEER BATT OIL LOAD BRAKE

When hour meter counts,

1-2 How to set the each mode

M M : Speed setting mode

M : Power setting mode

: Acceleration feeling mode

Up button for increasing, Down but-

NOTE When the slow speed mode button is off,

POWER 50 75 100 ACCEL SOFT STD FULL

w Power setting mode

Down button Up button

The preset power is displayed at the km/m 5 10 15 20

POWER 50 75 100 ACCEL SOFT STD FULL

e Acceleration feeling mode

Down button Up button

NOTE Better inching operation can be achieved

The preset accelerator feeling is displayed at Preset accelerator feeling

the “ACCEL” column on the display.

Mode select button

Monitoring displayed off

NOTE The option setting which is standard specification is set to “0”.

2) Choose the each language shown below by

Down button Up button

<Display on LCD> Displayed language when turning key switch on.

NOTE After finishing to set or reset, be sure to

1) Set the rotary switch RS1 to “5”.

œThe setting position which flashes can be

DOWN button UP button

TRAVEL HYD STEER BATT OIL LOAD BRAKE

: Hydraulic Parking brake :

: Steering Over load :

: Battery Oil level :

* For having GS battery and GS electrolyte level sensor only.

1-3 Adjustment of starting current

q Zero(0) adjusting for installed

M Mode select button

5) After adjusting If GAIN and Ia GAIN, be sure

<Initializing (initial setting)>

w Adjustment of starting current and cur-

should be done, and initializing also finished.

2) Set the rotary switch RS1 to “2”, and turn the

4) Operate the directional switch to forward, depress

5) Adjust the starting current on the monitor with-

Model Starting Current (A)

7) Operate the directional switch to forward, depress

NOTE The current limitation should be read and