FBR 80 - Troubleshooting Manual 1

TROUBLESHOOTING MANUAL
ELECTRIC FORKLIFT TRUCK

TROUBLESHOOTING
MANUAL
80 SERIES
FBR9N/10N/12N
FBR9N~40 - 80 Series
FBR10/12
FBR14/15/16/18
FBR20/25/30
FBR35/40
FBR9NL/10NL/12NL
FBR14L/15L/18L
Printed in Japan
Pub No. SM15-002-R2
000/1603
Copy rights
Using this "TROUBLESHOOTING MANUAL"
This manual has information about the layout and names of main components, explains disassembly,
assembly, inspection, adjustment, and maintenance procedures, and contains troubleshooting hints that
apply mainly to the model FBR-80.
It is important to note that in order to improve quality, performance, and safety parts used in this
forklift truck are subject to change and that some portions of the contents and illustrations in the
Troubleshooting Manual at the time of printing may not be identical due to these changes.
Instructions with and marks are very important and must always be followed.
Indicates a potentially hazardous situation that can result in death

DANGER or serious injury if not avoided.
You must always observe this precaution.
Indicates a potentially hazardous situation that can result in death
WARNING or serious injury if not avoided.
Indicates a potentially hazardous situation that can result in minor
CAUTION or moderate injury if not avoided.
Indicates suggestions, tips, and hints related to safe operation
NOTE
and maintenance.
1. Who should use this Troubleshooting Manual

The Troubleshooting Manual assumes that the person using it has a certain degree of technical
knowledge and expertise. If you do not understand the content in this Troubleshooting Manual, perform
your task under the guidance of someone who does.
Copyright© 2015
MITSUBISHI NICHIYU FORKLIFT CO., LTD.
All Rights Reserved
CONTENTS
5 NEUTRAL RES. 31
1. Introduction 1
6 ANTISLIP FUNC. 31
1-1. FBR-80 Control Overview............................ 1 7 LIFT (HIGH) 32
8 LIFT (LOW) 32
1-2. Main Board Basic configuration................... 2
9 TILT 32
1-2-1. Main Board Basic configuration 2
10 REACH 33
1-2-2. Capacitor - discharge 3
11 Att 1(OPT) 33
1-3. Required Settings........................................ 4 12 Att 2(OPT) 33
1-3-1. Settings for main board replacing / Memory
13 FUNCTION RESET 33
initialization 4
2-3-2. Custom feeling 34
1-4. Reference.................................................... 6
2-3-3. Fixed feeling 35
1-4-1. Fuse 6
2-3-4. Password change 36
1-4-2. Indication of display 7
2. User and Manager screen setting 9 3. Model check screen settings 37
2-1. Monitor display functions............................. 9 How to access

Press the switch in order of while
2-1-1. Indicator panel 9 pressing switch on the normal screen.
2-1-2. Indication of display 10
2-1-3. Function 10
3-1. Function list and description of all items.... 37
2-1-4. Sheet switch 12 3-2. Model check/Setting screen....................... 38
2-2. Setting screen............................................ 14 3-2-1. TYPE (Type setting) 38
3-2-2. SOFTWARE (Program No. check) 39
2-2-1. Operation setting 15
3-2-3. BUZZER (Buzzer setting) 40
1 OPERATION FEELING 15
3-2-4. HOUR METER(Hour meter count start) 40
2 NEUTRAL REG POWER 17
3-2-5. TIRE DATA ADJUST (Tire diameter adjustment) 41
2-2-2. Function setting 18
3-2-6. LOAD SENSOR ADJUST (Load sensor setting) 42
1 SPEED LIMIT (Turtle button) 18
2 TARE SETTING (Option) 19
3 RESERVED CHARGE 20
4 LASER POINTER (Option)
4. SERVICE DSP. setting 45
20
5 COUNT FOR CHARGE (Option) 21
2-2-3. Display setting 22 How to access
Press the switch in order of
1 DISPLAY CONTENT 22 while pressing switch on the
2 LOAD METER SIZE 23 manager screen.
3 CLOCK SETTING 24
4-1. Settings list and description of items.......... 45
4 BRIGHTNESS 25
4-2. TYPE SETTING (Model setting)................ 47
5 CONTRAST 25
6 DISPLAY TYPE 26
4-3. TRAVEL SETTING..................................... 48
2-3. Manager screen......................................... 27 4-3-1. LMT. SPEED (TURN)
(Turn speed reduction setting) 48
ow to access
H
Press button on the normal screen. 4-4. PUMP (HYD) SETTING............................. 49
Setting screen Press button for a while. 4-4-1. LIMITED LIFT-SPD.
2-3-1. Function setting 29 (Lift speed reduction setting) 49
1 SPEED LIMIT 29 4-4-2. OPR-PRIORITY SET.
(Hydraulic simultaneous operation priority setting) 50
2 SPEED ALARM 29
4-4-3. OPR-L/R SETTING
3 SWITCHBACK PWR. 30
(Reach valve opening amount setting) 51
4 BRAKE POWER 30
4-5. LANGUAGE SETTING.............................. 52 5. Inspection and adjustment of equipment/functions 87
4-6. OPTION SETTING..................................... 53
4-6-1. HOUR METER 5-1. Cautions when inspecting and adjusting.... 87
(Hour meter display contents) 53
5-2. How to check and adjust............................ 88
4-6-2. VALVE (Hydraulic valve number setting) 54
5-2-1. Chassis insulation check 88
4-6-3. ACCEL. ANGLE (Accelerator option setting) 55
5-2-2. Body ground check 88
4-6-4. LASER POINTER (Laser pointer option setting) 56
5-2-3. Traction and Hydraulic motor insulation-
4-6-5. LIFT LOCK (Lift interrupt function setting) 57 inspection 88
4-6-6. LOAD METER (Load sensor option setting) 58 5-2-4. Traction motor current measurement 89
4-6-7. CHARGER (Built-in charger option setting) 59 5-2-5. Hydraulic motor current measurement 91
4-6-8. Wh METER 5-2-6. EPS motor - inspection 93
(Electricity consumption meter option setting) 59
5-2-7. Transformer - inspection (for built-in charger) 93
4-6-9. BATT. LVL-MTR
5-2-8. Diode - inspection 94
(Battery electrolyte level sensor option setting) 61
5-2-9. Descending regeneration check 94
4-6-10. FL-PUMP OIL
(Fork oil level sensor option setting) 62 5-2-10. Auto-power-off function check 94
4-6-11. FORK SCALE (Fork scale option setting) 5-2-11. OIS (Operation Interlock System) check 95
(Special spec.) 63 5-2-12. Turn signal lamp check 95
4-6-12. EASY PW-ENTRY 5-2-13. Travel inhibitor check (Option) 96
(Easy password entry setting) 64 5-2-14. Lift lock (Lift limit) operation check (Option) 96
4-6-13. BUZZER FUNC. (Random output setting) 65 5-2-15. Cooling fan check 96
4-6-14. AUTO PWR.-OFF 5-2-16. Accelerator sensor adjustment 97
(Auto-power-off function setting) 66 5-2-17. Drive angle sensor adjustment 98
4-6-15. SUSPENS. LOCK 5-2-18. Torque sensor neutral - check and adjustment 99
(Suspension lock function setting) 67
5-2-19. IPM module - inspection and replacement 102
4-6-16. L-REMOTE CTRL
5-2-20. Battery front loading travel/hydraulic interlock 103
(Lift remote control function setting) 68
5-2-21. Built-in charger function check (Total timer) 103
4-6-17. AOS (AOS setting) 69
4-6-18. SPD-LMT BY H
(AOS travel speed reduction at high lift height setting) 70
4-6-19. MULTI. LEVER (Multi lever setting) 71 6. Troubleshooting 105
4-6-20. TILT-HRZN
(Automatic tilt horizontal stop function setting) 72 6-1. Caution for electricity-related repairs....... 105
4-6-21. CHARGE COUNT 6-2. Self diagnosis function............................. 106
(Total charging number display option setting) 73 6-2-1. Display 106
4-6-22. WAITING(CHG) 6-2-2. Error message list 107
(Power failure error detection time setting) 74
6-3. Trouble when an error message does not appear.113
4-6-23. FAN (Fan setting) 75
6-3-1. Trouble of error non-occurrence 113
4-6-24. HORN(CHG) (Horn setting) 76
6-4. Error history memory................................114
4-7. Other settings............................................. 77
6-4-1. Error history memory (LATEST 10) 114
4-7-1. FOR LEVEL METER
6-4-2. Error history memory (ALL) 115
(Battery indicator display correction) 77
6-4-3. Memory initialize (Setting/error history reset) 116
4-7-2. FOR CTL. / CHG (Control voltage adjustment) 78
4-7-3. MAINTE-TIMER SET. (Maintenance timer setting) 79 6-5. I / O monitor check....................................117
4-7-4. ERROR DSP. SET. (Error display setting) 80 6-5-1. Display method 117
4-7-5. STEERING TORQUE (Steering torque setting) 81 6-5-2. Travel CPU monitor (TRV CPU) 118
4-7-6. STEERING OFFSET 6-5-3. Travel I/O port table 120
(Torque sensor neutral voltage adjustment) 82 6-5-4. Hydraulic CPU monitor (HYD CPU) 121
4-7-7. STEERING END STOP 6-5-5. Hydraulic micro switch I / O monitor check 123
(Steering end stop setting) 85 6-5-6. Hydraulic I/O port table 124
6-5-7. EPS/DSP display CPU monitor (EPS/DSP CPU) 125
6-5-8. DSP I/O port table 127
7. Wiring (Diagrams) 129 7-13.Wiring, buzzer......................................... 161
7-13-1. Wiring, buzzer 161
7-1. Wiring, system......................................... 129 7-14.Wiring, lift limit......................................... 162
7-1-1. FBR-80 129 7-14-1. P-mast (2 stage mast) (High lift height detection:
only when the lift height is 4500 mm or more) 162
7-2. Wiring, body............................................. 130
7-14-2. M(NM)/PFL-mast (2 stage / 3 stage full free mast)
7-2-1. FBR-80 130
(High lift height detection: only when the lift height is
7-3. Harness, body 4500 mm or more) 163
7-3-1. FBR-80 Body harness 131 7-14-3. Lift limit (w/release switch) 164
7-3-2. FBR-H80 Body harness (2) 132 7-14-4. Lift limit (w.o./release switch) 165
7-3-3. FBR-80 Body harness (3) 133 7-15.Wiring, fan............................................... 166
7-3-4. FBR-H80 Body harness (3) 134 7-15-1. FBR - 80 6.4kVA 166
7-4. Wiring, controller...................................... 135
7-4-1. FBR-80 135
7-5. Harness, controller................................... 136
7-5-1. FBR-80 136
7-6. Wiring, panel........................................... 137
7-6-1. FBR-80 137
7-7. Harness, panel......................................... 138
7-7-1. FBR9 - 40 - 80 138
7-7-2. FBR9N - 12N - 80 139
7-8. Wiring, charger panel............................... 140
7-8-1. FBR - 80 (3Ø, 200V) 140
7-8-2. FBR - 80 (3Ø, 200V) 6.4kVA 141
7-9. Harness, BC............................................. 142
7-9-1. FBR - 80 STD 142
7-9-2. FBR - 80 w/charging monitoring system (CMS) 143
7-9-3. FBR - 80 w/electric power usage meter 144
7-9-4. FBR - 80 6.4kVA STD 145
7-9-5. FBR - 80 6.4kVA w/charging monitoring system (CMS) 146
7-9-6. FBR - 80 6.4kVA w/electric power usage meter 147
7-10.Wiring, accessory.................................... 148
7-10-1. Wiring for strobe light 148
7-11.Wiring, lamp............................................. 149
7-11-1. Revolving lamp 149
7-11-2. Revolving lamp interlocking reverse travelling 150
7-11-3. Working lamp 151
7-11-4. Back-up lamp (reversing lamp) 152
7-11-5. Rear lamp 153
7-11-6. Rear lamp interlocking reverse travelling 154
7-11-7 Rear lamp 24V +
separately interlocking reverse travelling 155
7-11-8. Spot lamp 156
7-11-9. Spot lamp 157
7-11-10.Signal, display replenish water message 158
7-12.Wiring, chime.......................................... 159
7-12-1. Wiring, chime 159
7-12-2. Wiring, chime (w/back buzzer) 160
1. Introduction
1- 1. FBR-80 Control Overview
Charging
Display EPS motor
contactor
Main board
M(Main) CPU
(EPS/DSP CPU)
X1 relay
Travel CPU Hydraulic CPU
IPM module IPM module
Gate circuit Gate circuit
Traction motor Hydraulic motor

131T0100E
The CPUs of Travel, Hydraulic, and EPS/DSP controls are integrated on the main board.
T (Travel) CPU Travel control

H (Hydraulic) CPU Hydraulic control
M (Main) CPU (EPS/DSP CPU) DSP/EPS charging control
1
1 Introduction
1- 2. Main Board Basic configuration

1-2-1. Main Board Basic configuration
P15
P11
P7A
P7B
TCPU
MCPU
HCPU
Main CPU Travel Hydraulic
(EPS/DSP CPU) CPU CPU
P15
P11
P7A
P7B
TCPU
MCPU
HCPU
(MCPU) (TCPU) (HCPU)
㻲㻱㼀㻌㼒㼛㼞㻌㻱㻼㻿㻌㻹㻻㼀㻻㻾
㻯㼛㼚㼠㼞㼛㼘 CPU CPU CPU
(M) (TRV) (HYD)
CN8
CN6 CN5 CN4 CN3 CN2 CN1
CN7
Body harness
131W0924
<Main board type>

Main board type
STD PBC111-XXX
STD
HIGH PBC111-XXX
STD PBC111-XXX
CS
HIGH PBC111-XXX
*HIGH : High performance model
<Details on Main board LED>

LED Details Status Remarks
Flashes in every 0.5
TCPU Travel CPU seconds after key switch
starts.
Flashes in every 1.5
HCPU Hydraulic CPU seconds after key switch
starts.
MCPU Normally flashes when the Main CPU: CPU for the display,
Main CPU
(EPS/DSP CPU) battery plug is connected. EPS, and charging
Lights up when battery power
Normally lights when the
P7A 5V power supply is supplied to CN5-133 (control
battery plug is connected.
power supply)
Lights up when battery power
is supplied to CN5-132 (control
Fully lights up after key
P7B 5V power supply power supply X1 relay gearing)
switch starts.
* Battery voltage is provided
after X1 relay operates
2
Introduction 1
LED Details Status Remarks

1. Lights up after key
switch starts.
P11 11V power supply 2. During connecting Power supply for display
charging plug (only built-
in charger)
High performance front wheel
Lights up after key switch brake circuit for EPS control
P15 15V power supply
starts. and IPM module gate drive
circuit
CAUTION The battery sends current to main board even if the key is turned off.
Before performing maintenance, always disconnect the battery plug and discharge the capacitor.
1-2-2. Capacitor - discharge

Capacitor retains an electric charge even after
disconnecting the battery plug. Before starting work,
discharge the capacitor.
<Procedure>
1. Turn the key switch off and disconnect the battery plug.
2. Prepare the enameled resistor ("20W, 50 ", "50W,
10 " or "10W, 15 ").
3. Apply the terminals of the enameled resistor between
the red and the blue line of the control unit connector
(CN8) of main board (as shown in the figure on the
below).
4. Keep the connection for about 10 to 30 seconds.
Red
Blue
Discharge the capacitor

by connecting the enameled
resistor to the connector (CN8).
Control unit
144W0910
3
1 Introduction
1- 3. Required Settings
1-3-1. Settings for main board replacing / Memory initialization
When replacing main boards for the reasons such as
failure, or when initializing the EEPROM memory, The
following settings are required.
Initial settings
Setting Setting screen
TYPE SETTING SERVICE DSP. TYPE SETTING See page 47.
BATTERY
VOLTAGE SERVICE DSP. BATT-VOLTAGE ADJ. FOR CTL. / CHG. See page 78.
ADJUSTMENT
CLOCK SETTING SETTING DSP. DISPLAY SETTING CLOCK SETTING See page 24.
STEERING
SERVICE DSP. EPS SETTING STEERING OFFSET See page 82.
OFFSET
OPTION SETTING
When the options are equipped, set them on SERVICE DSP. OPTION SETTING.
See "4-6. OPTION SETTING" on page 52.
NOTE Multiple settings must be done in the following

options. All settings should be done.
Setting Setting screen

SERVICE DSP. OPTION SETTING LASER POINTER See page 56.
LASER POINTER
(OPTION)
SETTING DSP. FUNCTION SETTING LASER POINTER See page 20.
LOAD METER SERVICE DSP. OPTION SETTING LOAD METER See page 58.
(Lift pressure sensor)
SETTING
MODEL CHECK DSP. LOAD SENSOR ADJUST See page 42.
(OPTION)
Wh METER
SERVICE DSP. OPTION SETTING Wh METER See page 59.
(OPTION)
When the options are equipped other than the above

three, you should set them on the SERVICE screen.
(To the next page)
4
Introduction 1
Other parameters
If the parameters such as SPEED LIMIT, HYDRAULIC SPEED, OPERATION FEELING are
changed from default, check the set values before changing and set them again.
CAUTION After replacing the main board or initializing the

memory, you must check for any abnormalities of
travelling, hydraulics, EPS or display screen.
AOS SETTING
For AOS, change the specified initial value of the hydraulic speed as
follows on MANAGEMENT DSP. FUNCTION SET.
Setting Specified value AOS

LIFT (HIGH) 32 32
LIFT (LOW) 14 not used
TILT 12 12
REACH 15 12
ATT. 1 0 0
ATT. 2 0 0
If the travel, hydraulics, EPS, AOS, and other settings are done with
special specifications, set those settings again.
For details of setting AOS and Lift remote control specifications,

see "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
NOTE Because the initial value is FBR15, when installed to 24V specification forklift truck, a
l
voltage error occurs when turning the key switch on. This error is resolved when turning
the key switch off and then turn the key switch on after setting the model.
The data can be read, saved from the failed board by using the maintenance tool and
l
that data can be copied to a new board.
The above mentioned operations can be done only if the circuits (EPS/DSP CPU) around
the M (Main) CPU are working properly.
Other required settings

The required settings must be done for the following cases:
Item Required setting

When adding an accessory
FOR LEVEL METER See page 77.
(mainly heater)
When exchanging tires TIRE DATA ADJUST See page 41.
When supplying to the client HOUR METER See page 40.
OPTION SETTING
When equipping an option * Note that laser pointer, load meter (lift pressure See page 53.
sensor), coulometer require multiple settings.
5
1 Introduction
1- 4. Reference
1-4-1. Fuse
The fuse is inserted in the truck harness to protect the
main board from short circuits and overcurrent.
When the fuse melts, always replace it with the fuse of
specified capacity.
<Fuse type>
Rating
Fuse (Current/ Part No. Purpose
Voltage)
325A
F1 325A / 96V 1995-32015 Travel / Hydraulic TRV/HYD
fuse
F2 40A / 96V 1995-32023 EPS (F1)
Transformer fuse 100A / 70V 70000-15440 Transformer / Diode

Control power 100A 40A
F4 10A / 125V 1910-98019 Transformer EPS fuse
supply fuse (F2)
Power supply to
F5 10A / 125V 1910-98019
accessories
10A
Glass
tube fuse
(F4, F5)
131W0911
6
Introduction 1
1-4-2. Indication of display

User and Manager access Manager access Service man access
Key switch ON
Easy password-entry screen

(When option ON)
If you have forgotten the password,

press the switch in order of
Checking screen while pressing switch .
CHECKING...
2015. 10. 30 Fri
Normal screen Press the switch in order of Model check screen

while pressing switch .
Setting screen PASSWORD (MANAGER)

OPERATION SETTING
FUNCTION SETTING Press for
DISPLAY SETTING a while.
2015. 10. 30 Fri
Press the switch in order of
while
If you have forgotten pressing switch .
Management screen Service screen
the password, enter the
master password [7105]. MANAGEMENT DSP.
FUNCTION SET.
CUSTOM FEELING
FIXED FEELING
To Normal screen by turning To Normal screen by turning

the key switch OFF/ON. the key switch OFF/ON.
<To return to the previous screen>

l Press button.
7
MEMO
8
2. User and Manager screen setting
2- 1. Monitor display functions
2-1-1. Indicator panel
Normal screen Sheet switch

1 2 3 4 8 10 12 13
Powerful
MODE Normal
Customize
MENU
0 km/h OK ECO
22.0 h 1 2 3
C
5 PM 12:46 Back
4 5
5 6 7 9 11 14 131T0101E
Normal screen Sheet switch

1. Battery discharge indicator 8. OK (Menu) button
2. Hour meter icon (operating hours) 9. Cancel (Back) button
3. Hour meter 10. Cursor up button
4. Travel speed meter 11. Cursor down button
5. Slow speed mode monitor (Turtle mark) 12. MODE LED
6. Laser pointer icon (Option) 13. Economy mode select button
7. Clock 14. Slow speed mode button
9
2 User and Manager screen setting
2-1-2. Indication of display

When the key switch is turned on. Key switch ON
Password screen
Input password by the sheet switch. (Option)
PASSWORD
NOTE 4 different passwords can be memorized. Ⅎℳℴ
⃸‒⃸‒⃸‒⃸
Factory default setting is [1111], [2222], [3333] and ≦ℵℶ
[4444]. Password can be changed.
See "2-3-4. Password change" on page 36. Checking screen
After 2 seconds, the normal screen is displayed. CHECKING. . .

If any abnormalities are detected, the error message is
․•‣‧‒†‒‣•‒†‒‥•‒‒‸⁤⁛
displayed.
See "6-2.Self diagnosis function" on page 106. Normal screen
After 2 seconds
2-1-3. Function 22.0 h 0 km/h

5 PM 12:46
1. Battery indicator
Error screen
The battery indicator shows the discharge condition of
B11 : FET-TRAVEL
the battery. FAIL OPERATION
TURN OFF KEY SWITCH
CAUTION Do not over-discharge. PM 12:46

The battery life can be shortened by over-discharging. 131T0102E
Charge the battery immediately

Full
charged In case of
40% discharge Less than 20% Less than 10% Empty
Discharge Discharge Discharge Discharge
When the battery capacity is less than When the capacity is less than 10%, one red
20%, white segments are disappeared segment is turned on. When the capacity is
and two red segments are lit. empty, only the frame of the indicator is lit.
131T0103E
Lift Lock (Lift interrupt function) CHARGE BATTERY

When the battery indicator segments on the normal
screen become 2, lifting speed reduce to half. This PM 12:46
limitation is not applied to the other hydraulic operations.
When the battery indicator segment on the normal screen

CHARGE BATTERY
become 1 or less, lifting operation stops. This limitation is
not applied to the other hydraulic operations.
PM 12:46
131T0162E
10
User and Manager screen setting 2
2. Hour meter icon (operating hours) Hour meter screen

3. Hour meter
The hour meter is displayed when the hour meter mode 22.0 h 0 km/h
is selected. (The key switch operating mode is option.) 5 PM 12:46
This mode is useful to manage the effectiveness of
131T0158E
operation and/or the timing of periodical inspection.
The display can be used as the load meter.

See "2-2-3. Display setting" " 1 DISPLAY CONTENT"
on page 22.
NOTE The Load meter is an optional equipment. Load meter screen

See "4-6-6. LOAD METER (Load sensor option
setting)" on page 58. 0 kg 0 km/h
5 PM 12:46
Raise the load a little (less than 40cm high), Then the
load icon is flashed while measuring and stayed on after 131T0159E
measured.
When pressing or button on the sheet switch, the

hour meter mode screens of odometer, travelling hour,
hydraulic hour and total operating hour are displayed.
See " Hour Meter Screen" on page 13.
4. Travel speed meter

The actual travelling speed is indicated.
131T0105
5. Slow speed mode monitor (Turtle mark)

When the turtle button ( ) is pressed, the turtle icon and
preset speed are displayed.
The preset speed can be changed by function setting
screen. 131T0106
S ee "2-2-2.Function setting" " 1 SPEED LIMIT

(Turtle button)" on page 18.
6. Laser pointer icon (Option)
The icon is displayed when the laser pointer is turned on.
See "2-2-2. Function setting" " 4 LASER POINTER
(OPTION)" on page 20.
131T0107
7. Clock
The current time is displayed.
ee "2-2-3. Display setting" " 3 CLOCK SETTING"
S
on page 24.
131T0108
11
2-1-4. Sheet switch
8. OK (Menu) button
By pressing this button, the normal screen is changed to
the setting screen.
This button is also used as the “OK” button to confirm the
setting.
9. Cancel (Back) button

By pressing this button, the screen is returned to
131T0109
previous one.
10. Cursor up button

By pressing this button, the display is changed to the
hour meter screen.
This button is also used to change the settings.
11. Cursor down button

By pressing this button, the screen is returned to the
hour meter mode.
This button is also used to change the settings.
12. MODE LED

The MODE LED change the color as red (“P” mode),
yellow (“C” mode) or disappeared (“N” mode).
13. Economy mode select button

By pressing this button, the ECO mode is activated.
The ECO mode restricts the maximum performance of
the travelling speed and the lifting speed to save the
energy. (approximate 15% per day)
If the maximum performance is not required, keep this
mode to save the battery energy consumption.
14. Slow speed mode button

By pressing this button, the turtle icon and the preset
speed are displayed. Then, the maximum travelling
speed is restricted to the preset value. If the maximum
travelling speed is required to change at site (inside
and outside of the warehouse, for example), this mode
is useful. After presetting the restricted speed, the
maximum speed can be changed by pressing this button
after stopping.
12
Hour Meter Screen Normal screen
By pressing or button at the normal screen, the

display is changed to the hour meter screen. 22.0 h 0 km/h
The odometer, travelling hour, hydraulic hour and total 5 PM 12:46
operating hour are displayed.
Push
The total operating hour can be changed to the total key- or
Hour meter screen

on time. (option)
ᵦᵭᵳᵰᴾᵫᵣᵲᵣᵰ
ᴾ ᵲᵰᵟᵴᵣᵪᴾ ᵏᵐᵌᵕᴾ ᶉᶋ
NOTE left end of the screen shows the number of page of 1ᴾ ᵲᵰᵟᵴᵣᵪᴾ ᵐᵎᵌᵓᴾ ᾷ
ᴾ ᵦᵷᵢᵌᴾ ᵐᵌᵎᴾ ᶆ
that screen. ᴾ ᵲᵭᵲᵟᵪᴾ ᵐᵐᵌᵎᴾ ᶆ
By pressing or button, the screen is changed to Total operating hours [h]
the next page or previous page. Total hydraulic hours [h]
Total traveling hours [h]
Total traveling distance [km]
Number of pages
Indication of Electric power usage, CO2 amount [day] (Option)
Power rate and Discharged CO2 ᴾ

ᵡᵭᵐᴾᵟᵫᵭᵳᵬᵲ
ᶉᵵᶆᴾ ᾺᾶὉᾒᾞᾁ
(Option) 7 ᵏᵐᵍᴾᴾᵐᴾ
ᵏᵐᵍᴾᴾᵏᴾ
ᵐᵎᵌᵎᴾ
ᵏᵗᵌᵓᴾ
ᵏᵏᵌᵎ
ᵏᵎᵌᵕᵐ
ᵏᵏᵍᵑᵎᴾ ᵐᵏᵌᵎᴾ ᵏᵏᵌᵒᵗ
Date of charge, usage of electric power (kWh) and
power rate (Yen), or discharged quantity of CO2 can be CO2 amount total [month] (Option)
displayed on the screen. ᵡᵭᵐᴾᵟᵫᵭᵳᵬᵲᴾᵲᵭᵲᵟᵪ

ᴾ ᶉᵵᶆᴾ ᾺᾶὉᾒᾞᾁ
10 ᵏᵐᵍᵋᴾ ᵗᵗᵗᵗᴾ ᵗᵗᵗᵗᵌᵗ
NOTE l The standard screen setting is "Electricity rate". As ᵏᵏᵍᵋᴾ
ᵏᵎᵍᵋᴾ
ᵗᵗᵗᵗᴾ
ᵗᵗᵗᵗᴾ
ᵗᵗᵗᵗᵌᵗ
ᵗᵗᵗᵗᵌᵗ
for the change of screen setting.
l As the backup function, there are data both for last 7 131T0110E
days and for last 6 months.

l You can check the electric power usage by pressing
or button on the normal screen when the key
switch is turned ON.
13
2- 2. Setting screen
Normal screen
CAOTION These set tings are invalid while traveling or
l
depressing the brake pedal.
If traveling or hydraulic operation is done while
l 22.0 h 0 km/h
setting, the display is returned to the normal screen 5 PM 12:46
immediately.
Setting screen
▶ O PE RAT I O N S E T T I NG
NOTE Operation setting, Function setting and Display setting
FU NC T I O N S E T T I NG
can be memorized only one setting each even different DI S PLAY S E T T I NG
operator's password. If these setting value is changed, ․•‣‧‒†‒‣•‒†‒‥•‒‒‸⁤⁛
it is reflected for all password entries.

Operation setting
At the normal screen, press the to move to the O PE RAT I O N S E T T I NG

setting screen.
▶ O PE RAT I O N FE E LI NG
NE U T RAL RE G PO W ER
Operation feeling
O PE RAT I O N FE E LI NG
▶ Ｐ PO WE R
Ｎ NO RM AL
Ｃ CUSTOM
to custom setting to operation setting

screen screen after setting
the operation feeling.
131T0111
[Setting screen list]

Reference
Item Details Setting values Default
page
Operation OPERATION FEELING P / N / C1 / C2 / C3 P P.15
setting NEUTRAL REG POWER HIGH / MID / LOW / NON MID P.17
SPEED LIMIT (Turtle button) 2 - 10 5 (km/h) P.18
TARE SETTING (Option)
(only if equipped with LOAD RESET / SET RESET P.19
Function METER option)
setting RESERVED CHARGE Day, Time -
P.20
LASER POINTER (Option) ON/OFF OFF
COUNT FOR CHARGE
- - P.21
(Option)
DISPLAY CONTENT HOUR METER / LOAD METER HOUR METER P.22
LOAD METER SIZE (Option) BIG / SMALL BIG P.23
CLOCK SETTING Date, Time - P.24
Display
setting BRIGHTNESS 0-7 5
P.25
CONTRAST 0-7 5
NEGATIVE TYPE/
DISPLAY TYPE NEGATIVE P.26
POSITIVE TYPE
14
Normal screen
2-2-1. Operation setting
22.0 h 0 km/h
CAUTION If the feeling set function is interlocked by manager, the 5 PM 12:46
setting screen is not displayed and cannot set by an operator.
Then, the setting must be done in the manager screen. Setting screen
See "2-3. Manager screen" on page 27. ▶ O PE RAT I O N S E T T I NG
DI S PLAY S E T T I NG
1 OPERATION FEELING ․•‣‧‒†‒‣•‒†‒‥•‒‒‸⁤⁛
The travelling and hydraulic feel can be set to preferable

value. Operation setting
By pressing or button, it can change to “P”(power), O PE RAT I O N S E T T I NG

“N”(normal), “C1”, “C2”, or “C3” (custom).
▶ O PE RAT I O N FE E LI NG
NE U T RAL RE G PO W ER
Operation feeling
O PE RAT I O N FE E LI NG
▶ Ｐ PO WE R
Ｎ NO RM AL
Ｃ CUSTOM
to custom setting to operation setting

screen screen after setting
the operation feeling.
131T0111
Maximum speed [km/h] Travel Hydraulic

Lever character.
Lever character.
Lever reaction
Lever reaction
Accelerating
Accelerating
Mode FBR FBR FBR FBR FBR

pwr.
pwr.
(*)
9(N) - 18 20/25 30 35 40
P 10.5 11.5 11.0 9.0 8.5 12 12 5 5 5 5

N 9.5 10.5 10.0 8.0 7.5 10 12 5 5 5 5
C1 10.5 11.5 11.0 9.0 8.5 7 9 5 3 4 5
C2 ↑ ↑ ↑ ↑ ↑ 5 9 5 1 4 5
C3 ↑ ↑ ↑ ↑ ↑ 5 5 5 0 3 5
*Hydraulic lever character is enabled only if equipped
with proportional control valve (option).
The “MODE” lamp is lit red (“P” mode) or yellow (“C”

mode).
When the “N” mode, the lamp is not lit.
fter setting, press
A to return to the operation setting
screen.
131T0112
15
<Custom mode selection (C1, C2, C3)> Custom setting
When selecting the custom mode, choose “C CUSTOM” O PE RAT I O N FE E LI NG

Ｐ PO WE R
on the custom setting screen and press the button. Ｎ NO RM AL
▶ Ｃ CUSTOM
Choose one of C1, C2 or C3, and press button. CUSTOM

▶Ｃ１
Ｃ２
Ｃ３
C U S T O M FE E LI NG C 1
▶ SET
C O NFI RM AT I O N
et each item to preferable value and press

S to C U S T O M FE E LI NG C 1
return to the custom setting screen.
SET
▶ C O NFI RM AT I O N
You can check the current settings by selecting C U S T O M C 1 (T RAV E L)

“CONFIRMATION” on each custom feeling screen. AC C E LE RAT I NG PWR. 7
1/2 LE V E R RE AC T I O NS 9
LE V E R C HARAC T E R. 5
CAUTION To change the value of the settings, the login as
the manager is required.
See "2-3. Manager screen" on page 27.
C U S T O M C 1 (HYD.)
AC C E LE RAT I NG PWR. 3
1/2 LE V E R RE AC T I O NS 4
NOTE The “LEVER CHARACTER” is shown if the optional AOS
LE V E R C HARAC T E R. 5
is set.
131T0113E
16
2 NEUTRAL REG POWER Operation setting
This is the setting of the regenerative braking force when O PE RAT I O N S E T T I NG
releasing the accelerator lever while traveling. O PE RAT I O N FE E LI N G

▶ NE U T RAL RE G PO WER
NOTE Neutral REG power:

While charging, the automatic (electric) brake is Neutral reg power
applied when releasing the accelerator lever. This is NE U T RAL RE G PO WE R
the Lever-off regeneration. The regenerative circuit HIGH
1/2 ▶ MIDDLE
creates the electric power by braking and returns it to LOW
the battery for longer operation.
Return to the operation setting screen after
setting of “HIGH”, “MID”, “LOW” or “NON”.
The braking force of the Neutral REG power can be set
by pressing or button with 4 steps. (HIGH, MID, 131T0114E
LOW, and NON)

After choosing, press to return to the setting
screen.
CAUTION If you choose “NON”, the regenerative brake does not

work and the truck keeps going by inertia.
17
2-2-2. Function setting

Normal screen
22.0 h 0 km/h
5 PM 12:46
Setting screen
O PE RAT I O N S E T T I NG
▶ FU NC T I O N S E T T I NG
․•‣‧‒†‒‣•‒†‒‥•‒‒‸⁤⁛
Function setting
1 SPEED LIMIT (Turtle button) FU NC T I O N S E T T I NG
▶ S PE E D LI M I T
This can set the maximum travel speed when pressing 1/2 T ARE S E T T I NG
RE S E RV E D C HARG E
the turtle button ( ).
Speed limit
Set the maximum travel speed by pressing or S PE E D LI M I T

button.
５ km/ｈ［2-10］
The maximum speed can be set from 2 km/h to 10 km/h.
After setting, press to fix and return to the function
setting screen. After fixing the turtle mode speed,
return to the function setting screen.
131T0115E
NOTE If any other speed restrictions are set, the minimum

setting is prior than others.
18
2 TARE SETTING (Option) Function setting
Select "SET" or "RESET". Then press button. S PE E D LI M I T
1/2 ▶ T ARE S E T T I NG
RE S E RV E D C HARG E
NOTE The tare setting function activate with following
conditions.
l The optional load meter is equipped. Tare setting
l The load weight is within the loading capacity of the T ARE S E T T I NG
forklift truck. (no overloading) ▶ RE S E T .

l The load is determined 5 seconds after lifting up. SET
To tare setting Return to the

function function setting
screen after reset.
131T0116
Raise the tare (such as a pallet) less than 400mm from Tare setting
the floor and wait for 5 seconds. T ARE S E T T I NG
Then, choose “SET” on the screen and press button.
RE S E T .
▶ SET
The weight of the tare is indicated with “TARE SETTING” T ARE S E T T I NG . . .

message.
×× kg
Then, the load indication is return to “0 kg” with “TARE T ARE S E T . C O M PLE T E
SET COMPLETE” message. ０ kg

2 seconds later, the screen is returned to the normal Return to the normal screen 2 seconds
later of the tare set completion.
indication.
131T0117E
When setting the tare setting function, the load icon is RESET SET
changed. (see illustration)
NOTE When pressing the

l button for a few seconds,
the tare setting can be done. (In this case, the
131T0118E
button is the short cut key for this function.)
The overloading function works for the total weight
l
of the load (includes tare) even if the tare setting
function is activated.
19
3 RESERVED CHARGE Function setting
S PE E D LI M I T
CAUTION This func tion work s if the built-in charger is
l 1/2 T ARE S E T T I NG
equipped on the forklift truck. ▶ RE S E RV E D C HARG E
After setting, do not forget to connect the AC cable

l
between the forklift truck and wall outlet. Reserved charge
RE S E RV E D T I M E S E T .
To s e t t h e r e s e r v e d t i m e , c h o o s e “ R E S E RV E D
EVER Y D A Y
CHARGE” on the function setting screen and press A M 0： 00
button. Then, the reserved charge screen appears.
Press or to select the day of activation. (such as RE S E RV E D T I M E S E T .

every day, every week Monday, etc.)
EVER Y W EEK M O N D AY
A M 0： 00
Press or to set time. (hour and minute)

RE S E RV E D T I M E S E T .
After completion, press to return to the function setting
screen. EVER Y W EEK M O N D AY
P M 11： 00
NOTE The indicated reserved time is the starting time of

charging the battery. It is not the finishing time of Return to the function setting screen.
charging. 131T0119E
4 LASER POINTER (Option) Function setting
This is the activation setting of the optional laser pointer. FU NC T I O N S E T T I NG

▶ LAS E R PO I NT E R
2/2 C O U NT FO R C HARGE
Select “LASER POINTER” option on the function setting

screen, and press button. Laser pointer
LAS E R PO I NT E R
Select “ON” and press to engage the laser pointer.
▶ ON
OF F
Return to the function setting screen.

131T0120E
20
5 COUNT FOR CHARGE (Option) Function setting
This function shows the total number of charging. FU NC T I O N S E T T I NG

LAS E R PO I NT E R
2/2 ▶ C O U NT FO R C HARGE
NOTE This function counts the number for completion of

charging. Interrupted charging is not counted. Count for charge
C O U NT FO R C HARG E
0 C YC LE

To reset the number, choose “RESET COUNT?” and ▶ RE S E T C O U NT ?
press button.
Then, the display returns to the normal screen. Return to the function setting screen
after reset the number.
131T0121E
21
2-2-3. Display setting
Normal screen
22.0 h 0 km/h
5 PM 12:46
Setting screen
O PE RAT I O N S E T T I NG
▶ DI S PLAY S E T T I NG
․•‣‧‒†‒‣•‒†‒‥•‒‒‸⁤⁛
1 DISPLAY CONTENT Display setting
This is the selection of the item (hour meter or load DI S PLAY S E T T I NG

▶ DI S PLAY C O NT E NT
weight gauge (option)) which is displayed in the center of 1/2 LO AD M E T E R S I Z E
the screen. C LO C K S E T T I NG
Display Content
Press or to select “HOUR METER” or “LOAD DI S PLAY C O NT E NT
METER”.
▶ HO U R M E T E R
Press to set and return to the setting screen LOAD METER
Set the display content and

return to the setting screen.
131T0122E
Set item is displayed in the center of the screen. Hour meter screen
NOTE The hour meter shows the actual operating hours. The 22.0 h 0 km/h
key switch hours are option. 5 PM 12:46
Load meter screen
0 kg 0 km/h
5 PM 12:46
131T0123E
22
2 LOAD METER SIZE Display setting
The letter size of the load weight indication can be DI S PLAY S E T T I NG

DI S PLAY C O NT E NT
changed. (Displays only when the Load Meter (Lift 1/2 ▶ LO AD M E T E R S I Z E
pressure sensor) is ‘ON’) C LO C K S E T T I NG
NOTE Even if the “BIG” is selected, it shows with small

l
Load meter size
letters when the warning message is displayed. The
LO AD M E T E R S I Z E
Load meter is an optional equipment.
Load meter is optional.
l ▶ BI G
S M ALL
See "4-6-6. LOAD METER (Load sensor option
setting)" on page 58.
Set the font size and return to
the setting screen.
131T0124E
Press or to select “BIG” (large font) or “SMALL”

(small font). Then press to set and return to the setting
screen.
The display shows the load weight with the selected size BIG
of font.
20 kg 0 km/h
5 PM 12:46
SMALL
20 kg 0 km/h
5 PM 12:46
131T0125E
23
3 CLOCK SETTING Display setting
Set the date and time. DI S PLAY S E T T I NG

DI S PLAY C O NT E NT
1/2 LO AD M E T E R S I Z E
▶ C LO C K S E T T I NG
Clock setting
Press or to select “year”. C LO C K S E T T I NG
Press to go to the next step.
２０１５．１０．１０
ＰＭ０：００
Press or to select “month”.

C LO C K S E T T I NG
２０１５．１０．１０
If you want to go back to the previous screen, press ＰＭ０：００
button.
Press or to select “day”. C LO C K S E T T I NG

２０１５．１０．１０
button.
Press or to select “hour”. C LO C K S E T T I NG
Press to go to the next step. ２０１５．１０．１０

button.
Press or to select “minute”. C LO C K S E T T I NG

２０１５．１０．１０
button.
After setting, press to return to the setting screen.
After setting date and time,
131T0126E
24
4 BRIGHTNESS Display setting
Set the brightness of the screen. DI S PLAY S E T T I NG

▶ BRI G HT NE S S
2/2 C O NT RAS T
DI S PLAY T YPE
Brightness
Press or to choose the brightness from 8 (eight)
steps. (from 0 to7) BRI G HT NE S S (DS P.)
Press to set and return to the setting screen. ５［0‒7］
NOTE Press button af ter choosing. Other wise the After setting of brightness,
selected step is not set.
131T0127E
5 CONTRAST Display setting
Set the contrast of the screen. DI S PLAY S E T T I NG

BRI G HT NE S S
2/2 ▶ C O NT RAS T
DI S PLAY T YPE
Contrast
Press or to choose the contrast from 8 (eight)
steps. (from 0 to7) C O NT RAS T
Press to set and return to the setting screen. ５［0‒7］
NOTE Press button af ter choosing. Other wise the After setting of contrast,
131T0128E
25
6 DISPLAY TYPE Display setting
Set the back screen of the display. DI S PLAY S E T T I NG

BRI G HT NE S S
2/2 C O NT RAS T
▶ DI S PLAY T YPE
Contrast
Press or to select “NEGATIVE” or “POSITIVE”.
DI S PLAY T YPE
Press to set and return to the setting screen.
▶ NE G AT I V E T YPE
P O S I T I V E T YPE
NOTE Press button af ter selection. Other wise the After setting of display type,
131T0129E
NEGATIVE TYPE
22.0 h 0 km/h
5 PM 12:46
POSITIVE TYPE
22.0 h 0 km/h
5 PM 12:46
131T0130E
26
2- 3. Manager screen
On the normal screen, press to get the setting Normal screen
screen.
22.0 h 0 km/h
5 PM 12:46
Setting screen
Press button for a while. Then, the manager screen ▶ O PE RAT I O N S E T T I NG
comes up. FU NC T I O N S E T T I NG
․•‣‧‒†‒‣•‒†‒‥•‒‒‸⁤⁛
keep pressing
PASSWORD（MANAGER）
PASSWORD（MANAGER）
Input the password by the sheet switch.
Press or to choose the number. ⃸‒⃸‒⃸‒⃸
Then press to move the cursor to the next digit.
After input the password, press to enter the manager
screen. to the manager screen
131T0131E
NOTE The factory default setting of the password is “0000”.

The password can be changed.
See "2-3-4.Password change" on page 36.
27
<Setting list>
Reference
page
SPEED LIMIT -/2 - 10 -
P.29
SPEED ALARM -/2 - 10 -
SWITCHBACK PWR. 0 - 15 14
P.30
BRAKE POWER 0 - 15 6
NEUTRAL RES. 0 - 15 6
NON / HIGH / P.31
ANTISLIP FUNC. MID
MIDDLE /LOW
Function setting LIFT (HIGH) 0 - 32 32
LIFT (LOW) 0 - 32 14 P.32
TILT 0 - 32 12
REACH 0 - 32 15
ATT.1 0 - 32 0
P.33
ATT.2 0 - 32 0
FUNCTION RESET NO/YES -
C1 TRAVEL ACCELERATING PWR. 0 - 15 7
C1 TRAVEL LEVER REACTIONS 0 - 15 9
C1 TRAVEL LEVER CHARACTER 0 - 15 5
C1 HYD. ACCELERATING PWR. 0-8 3
C1 HYD. LEVER REACTIONS 0-8 4
C1 HYD. LEVER CHARACTER
0-8 5
(Only if equipped with proportional control valve)
Custom feeling P.34
0-8 5
0-8 5
OFF / P / N /
Fixed feeling FIXED FEELING OFF P.35
C1 / C2/ C3
Manager：0000
Operator 1 :1111
Password change PASSWORD CHANGE Operator 2 :2222 - P.36
Operator 3 :3333
Operator 4 :4444
28
2-3-1. Function setting

1 SPEED LIMIT MANAGEMENT DSP.
The maximum traveling speed can be restricted. M A N A GE M E N T D SP.

▶ FU N CTI O N SE T.
1/2 CU STO M FE E LI N G
FI XE D FE E LI N G
FUNCTION SET.
FU N CTI O N SE T.
▶ S PEED LIMIT −
1/4 S PEED ALARM −
SWITCHBACK PWR. 14
Press or to choose the maximum speed.

The speed can be set to “no restriction” or 9 steps from 2 SPEED LIMIT
km/h to 10 km/h. S PEED LIMIT
fter choosing the speed restriction, press

A to set −− km/h ［2‒10］
and return to the function set screen.
Set the speed limit and

return to the function set screen.
131T0132E
2 SPEED ALARM FUNCTION SET.
The over speed warning can be set. FU N CTI O N SE T.

S PEED LIMIT −
If the traveling speed exceeds the preset value, the 1/4 ▶ S PEED ALARM −
warning buzzer beeps. SWITCHBACK PWR. 14
SPEED ALARM
Press or to choose the warning speed. S PEED ALARM
The speed can be set to “no warning” or 9 steps from 2 −− km/h ［2‒10］
km/h to 10 km/h.
After choosing the speed warning, press to set and
return to the function set screen. Set the over speed warning and
131T0133E
29
3 SWITCHBACK PWR. FUNCTION SET.
This is the plugging brake force setting. FU NC T I O N S E T .

S P EED L I M I T −
1/4 S P EED A L A R M −
▶ S W I TC H B A C K P W R . 14
SWITCHBACK PWR.
S W I TC H B A C K P W R .
Press or to choose the plugging brake force.
The plugging brake force can be set from "0" to "15". １４［0‒15］
A fter choosing, press to set and return to the
function set screen.
Set the plugging brake force and
131T0134E
4 BRAKE POWER FUNCTION SET.
This is the regenerative brake force setting. FU NC T I O N S E T .

▶ B R A K E P O W ER 6
2/4 N EU TR A L R ES . 6
A N TI S L I P F U N C . M
BRAKE POWER
B R A K E P O W ER
Press or to choose the regenerative brake force.
６［0‒15］
The regenerative brake force can be set from "0" to "15".
Set the regenerative brake force and
131T0135
30
5 NEUTRAL RES. FUNCTION SET.
Set the time lug from releasing the accelerator lever until FU NC T I O N S E T .
B R A K E P O W ER 6
neutral regeneration is started. 2/4 ▶ N EU TR A L R ES . 6
A N TI S L I P F U N C . M
NEUTRAL RES.
Press or to choose the NEUTRAL RES. N EU TR A L R ES .
NEUTRAL RES. can be set from "0" (Slow) to "15"
６［0‒15］
(Fast).
Set the neutral regeneration and
131T0136E
6 ANTISLIP FUNC. FUNCTION SET.
This is the ant-slip setting. FU NC T I O N S E T .

B R A K E P O W ER 6
2/4 N EU TR A L R ES . 6
▶ A N TI S L I P F U N C . M
ANTISLIP FUNC.
A N TI S L I P F U N C .
Press or to choose the anti-slip function. HIGH
1/2 ▶ M I D D L E
The anti-slip function can be set to "HIGH" "MIDDLE" or LOW
"LOW".
Set the anti-slip function and
function set screen. return to the function set screen.
131T0137E
31
7 LIFT (HIGH) FUNCTION SET.
This is the high lift speed setting. FU NC T I O N S E T .

▶ L I F T（ H I G H ） 32
3/4 L I F T（ L O W ） 14
TI L T 12
LIFT（HIGH）
L I F T（ H I G H ）
Press or to choose the lifting speed.
The high lift speed can be set from "0" to "32". ３２［0‒32］
After choosing, press to set and return to the

Set the high lift speed and
131T0138E
8 LIFT (LOW) FUNCTION SET.
This is the low lift speed setting. FU NC T I O N S E T .

L I F T（ H I G H ） 32
3/4 ▶ L I F T（ L O W ） 14
TI L T 12
LIFT（LOW）
L I F T（ L O W ）
Press or to choose the lifting speed.
１４［0‒32］
The low lift speed can be set from "0" to "32".
Set the low lift speed and
131T0139E
9 TILT FUNCTION SET.
This is the tilt speed setting. FU NC T I O N S E T .

L I F T（ H I G H ） 32
3/4 L I F T（ L O W ） 14
▶ TI L T 12
TILT
TI L T
Press or to choose the tilt speed.
The tilt speed can be set from "0" to "32". １２［0‒32］

Set the tilt speed and
131T0140E
32
10 REACH FUNCTION SET.
This is the reach speed setting. FU NC T I O N S E T .

▶ R EA C H 15
4/4 A TT. 1 0
A TT. 2 0
REACH
R EA C H
Press or to choose the reach speed.
The reach speed can be set from "0" to "32". １５［0‒32］

Set the reach speed and
131T0141E
11 Att 1 (OPT) FUNCTION SET.
FU NC T I O N S E T .
12 Att 2 (OPT) R EA C H 15
4/4 ▶ A TT. 1 0
These are the optional hydraulic speed setting.
A TT. 2 0
If any attachments are installed, these settings are
possible. 131T0142E
As well as the lift, tilt and reach, the speed can be set
from "0" to "32".
13 FUNCTION RESET FUNCTION SET.
All function settings will be changed to factory default FU NC T I O N S E T .

▶ R ES ET
settings by this mode. 4/4
RESET
R ES ET S ETTI N G ?
Press or to select "NO" or "YES". （ TR A VEL / P U M P ）
▶ NO
After selecting, press to set and return to the YES
Reset all function settings and

131T0143E
33
2-3-2. Custom feeling MANAGEMENT DSPLAY
M ANAG E M E NT DS P.
FU NC T I O N S E T .
The custom feeling "C1", "C2" and "C3" can be set. 1/2 ▶ C U S T O M FE E LI NG
FI X E D FE E LI NG
Custom setting is possible for the acceleration, response
and lever characteristics of traveling and hydraulics (lift
only). CUSTOM FEELING
C U S T O M FE E LI NG
▶Ｃ１
Ｃ２
Ｃ３
C1 TRAVEL
C 1 T RAV E L
▶ AC C E LE RAT I O N 7
1/3 LE V E R RE S PO NC E 9
LE V E R C HARAC T E R 5
C1 PUMP（HYD）
C 1 PU M P（HYD）
▶ AC C E LE RAT I O N 3
2/3 LE V E R RE S PO NC E 4
131T0144E
The custom feeling "C1", "C2" and/or "C3" can be reset. C１ RESET
C1
▶ R ES ET
3/3
RESET
R ES ET S ETTI N G ?
Press or to select "NO" or "YES". ( C U S TO M F EEL I N G C 1)
After selecting, press to reset and return to the ▶ NO
YES
reset screen.
Reset the custom feeling “C1”,

return to the “C1” reset screen.
131T0145E
34
2-3-3. Fixed feeling MANAGEMENT DSPLAY
M ANAG E M E NT DS P.
Operating feel can be fixed to "OFF", "P", "N", "C1", FU NC T I O N S E T .
1/2 C U S T O M FE E LI NG
"C2", or "C3". ▶ FI X E D FE E LI NG
After fixing, press to return to the management
screen.
FIXED FEELING
FI X E D FE E LI NG
▶ＯＦＦ
1/2 Ｐ PO WE R
Ｎ NO RM AL
FI X E D FE E LI NG
▶Ｃ１
2/2 Ｃ２
Ｃ３
Reset all function settings and

131T0146E
35
2-3-4. Password change

MANAGEMENT DSP.
Password for manager and optional operator 1 to 4 can M ANAG E M E NT DS P.
be changed by this procedure. ▶ PAS S WO RD C HANG E
2/2
PASSWORD CHANGE
PAS S WO RD C HANG E
▶ M ANAG E R
Press or to choose the number by digit. 1/2 O PE RAT O R 1
O PE RAT O R 2
Then, press to move the cursor to the next digit.
▶ M ANAG E R
The operator password is also can be changed by the
００００
same procedure.
▶ M ANAG E R
After input all digits, press to return to the １２３４

management display.
After changing the password,

return to the password change screen.
131T0147E
NOTE To return to the normal screen from the management

display, turn off the key switch once and turn to the
start position again.
36
3. Model check screen settings
3- 1. Function list and description of all items
On the model check screen, you can mainly check and
set such as model check, program No. check, buzzer
ring setting, hour meter start, load meter (lift pressure
sensor) setting, electricity consumption setting.
Press the switch in order of while pressing The special command ; Press
switch on the normal screen, and then display the model the switch in order of
while pressing switch
check screen.
on the normal screen.
NOTE l To return the screen from the model check screen to

the normal screen, once turn off the key switch and
turn to the start position again.
l Model check screen displays only English content.
131T0211
<Function list>
Reference
page
TYPE Type setting - - P.38
SOFTWARE Program No. check - - P.39
BUZZER Buzzer setting ON/OFF ON
ON(START)/ P.40
HOUR METER Hour meter count start OFF
OFF(STOP)
TIRE DATA ADJUST Tire diameter adjustment - - P.41
LOAD SENSOR ADJUST (Load sensor setting)
BUZZER Buzzer setting (overload warning) ON/OFF OFF P.40
WEIGHT Sets the default value of load
(capacity code) meter (lift pressure sensor)
OVER Sets the warning display load ----, 50 - 5000 ---- P.43
Sets no-load state (0 kg)
0 kg ----, 1 - 4095 ----
lift pressure
LOAD Sets lift pressure in load state ----, 50 - 5000 ---- P.44
37
3 Model check screen settings
3- 2. Model check/Setting screen

3-2-1. TYPE (Type setting)
Display the set models.
131T0211
131T0348
<Model type>
Setting
Specification
value
FBR Model
A Long wheel base
W Wide leg
Capacity 24V model : 9N/10N/12N
code 48V model : 9/10/12/14/15/16/18/20/25/30/35/40
-H High performance with front wheel brake
-CAB Cabin model
Cold storage use for -35°C
-CS
*Display only the multiple specifications
NOTE Set the model on the service screen.

l
SERVICE DSP. TYPE SETTING See P.47
Model names are used as identification information

l
required for forklift truck control, note that the
notation slightly differs from the actual model.
38
Model check screen settings 3
3-2-2. SOFTWARE (Program No. check)

Display the program No. written on the main board.
131T0249
131T0377
CPUs indicated by the alphabet on the left side of the program Nos. are as follows.
<CPU list>
Setting
Specification
value
T (TRV) Travel CPU program
H (HYD) Hydraulic CPU program
D (DSP) EPS/DSP CPU program
L (LCD) Liquid crystal display program
A (AOS) Proportional valve specification OPT CPU program
NOTE OPT CPU program No. is displayed only when AOS option setting is
l
ON.
SERVICE DSP. OPTION SETTING AOS ON See P.69
Multiple CPU program Nos. is displayed only if the trucks have
l
multiple specifications.
39
3-2-3. BUZZER (Buzzer setting)

Set ON/OFF of the buzzer that sounds when occurring
error / warning, when checking the settings, and when
transiting the screen.
131T0251
131T0352
NOTE Even if a buzzer sound is set to OFF, the buzzer of a

direction indicator rings.
3-2-4. HOUR METER(Hour meter count start)

Set hour meter count start / stop.
131T0253
131T0354
NOTE When you start the hour meter, hourglass icon on the
normal screen blinks, and when you stop the hour
meter, the hourglass icon lights up.
40
3-2-5. TIRE DATA ADJUST (Tire diameter adjustment)

Adjust the tire diameter ratio between a front wheel and a drive wheel to
make the anti-slip control operate normally.
Perform this adjustment when the tire diameter significantly changes in
the cases such as replacing the worn tire.
CAUTION If this adjustment is not performed, the main controller

recognizes that the tire is skidding, and reduces
travelling speed.
131T0255
131T0356
131T0257
When starting the adjustment, countdown of 60 seconds

is started at the same time. During the countdown, you
operate the forklift truck on the floor which is not slippery
and repeat traveling it forward and backward.
(Speed limit : 5km/h)
131T0358
After 60 seconds elapse, tire data adjustment is complete.
NOTE Tire diameter adjustment is carried out during normal

travel little by little.
41
3-2-6. LOAD SENSOR ADJUST (Load sensor setting)

This setting can be used when the load meter (lift
pressure sensor (option)) is installed.
Also, set "4- 6 - 6.LOAD METER (load meter option
setting)" to ON.
SERVICE DSP. OPTION SETTING LOAD METER See P.58
1) Set ON/OFF of the buzzer that sounds when overload

warning "REDUCE THE LOAD" occurs.
2) Set the default value of the load meter (lift pressure
sensor).
(Set as shown in 1 to 3 )
1 Buzzer setting (overload warning)
131T0259
131T0360
131T0361
2 Load meter (lift pressure sensor) default setting
131T0259
(To the next page)

42
(From the previous page)
131T0362
131T0363
1 "OVER" display warning load

setting
Set the load for which the load
over warning is displayed. Can be
set in units of 50 kg.
131T0364 (Set the value by pressing )
2 "0kg" Lift pressure settings in

131T0365 a no-load state (0kg)
(1) Put a cursor on "0kg".
(2) In the no-load state, perform
a lift up operation for a few
seconds.
(*Do not perform this
operation in a relief state)
(3) To stabilize the lift pressure,
131T0366 press the button after
three seconds.
CAUTION
When lowering the forks on the
ground or relieving the lift, the
settings are not properly done.
131T0367
Press button to display the

(To the next page) value automatically.
43
Before setting the "Load", load a known weight.

(A weight closer to the maximum load of a truck is
desirable) 3 "LOAD" Lift pressure settings
* Do not perform lift up operation at this time. in a load state
(From the previous page) (1) Put a cursor on "LOAD".
(2) In the load state, perform
a lift up operation for a few
seconds.
(*Do not perform this
operation in a relief state)
(3) To stabilize the lift pressure,
131T0368
press the button after
three seconds.
NOTE
Lifting up the load suitable to
a truck enables you to set the
load display more accurately.
131T0369
Press button and set the

loaded weight by pressing
or button.
131T0370
NOTE l When the LOAD pressure is less than 0 kg, it causes a

setting error.
l When a load meter (lift pressure sensor) setting is
not complete, the load is displayed as "----kg" on the
normal screen.
And the tare setting is disabled.
44
4. SERVICE DSP. setting
4- 1. Settings list and description of items
SERVICE DSP. screen is provided specially for the
Service Department, and you can perform advanced
settings (model setting, option setting), monitor internal
data, check the error history and resets the forklift truck
The special command ; Press
data.
the switch in order of
Press the switch in order of while
while pressing switch on the manager pressing switch on the
screen, and then display SERVICE DSP. screen. manager screen.
NOTE l To return the screen from the SERVICE DSP. screen to

the normal screen, once turn off the key switch and
turn to the start position again.
l SERVICE DSP. screen displays only English content. 131T0250
<Setting list>
Reference
page
TYPE SETTING Model setting FBR - A - W - xx - H - CS -CAB - P.47
TRAVEL SETTING (Travel setting)
*Special spec. supported
(Separate harness
connection is required.)
LIMITED SPEED (IO) Travel speed reduction setting *The maximum speed - -
limit can be set on
FUNCTION SETTING
→SPEED LIMIT.
LMT SPEED (TURN) Turn speed reduction setting 3-7 7 (km/h) P.48
PUMP (HYD) SETTING (Hydraulic speed setting)
LIMITED LIFT-SPD (Lift speed reduction setting)
Lift speed reduction
TRV 0-4 km/h 0 - 32 32
(0 to 4 km/h)
TRV 4-8 km/h 0 - 32 26 P.49
(4 to 8 km/h)
TRV 8- km/h 0 - 32 20
(8 km/h ~)
Hydraulic simultaneous SLOW / FAST
OPR-PRIORITY SET SLOW P.50
operation priority setting (Tilt / Reach / Att.1 / Att.2)
Reach valve opening amount
OPR-L/R SETTING 0 - 32 32 P.51
setting
LANGUAGE SETTING JAPANESE / ENGLISH /
Language setting JAPANESE P.52
(Language setting) CHINESE / RUSSIAN
OPTION SETTING (Option setting)
HOUR METER Hour meter display contents KEY / WORK WORK P.53
VALVE Hydraulic valve number setting 3-5 3 P.54
ACCEL. ANGLE Accelerator option setting 37° / 50° 37° P.55
LASER POINTER Laser pointer option setting OFF / ON OFF P.56
45
4 SERVICE DSP. setting
Reference
page
LIFT LOCK Lift interrupt function setting OFF / ON ON P.57
LOAD METER Load sensor option setting OFF/ON OFF P.58
CHARGER Built-in charger option setting OFF/ON ON
Electricity consumption meter P.59
Wh METER OFF/ON/ON+CHG.MON OFF
option setting
FL INSPECTION Truck inspection setting Not used - -
Battery electrolyte level sensor
BATT LVL-MTR OFF / ON OFF P.61
option setting
Fork oil level sensor option
FL-PUMP OIL OFF / ON OFF P.62
setting (Special spec.)
FL-BRAKE OIL Brake oil level sensor option setting Not used - -
Fork scale option setting
FORK SCALE OFF / ON OFF P.63
(Special spec.)
EASY PW-ENTRY Easy password entry setting OFF / ON OFF P.64
BUZZER FUNC Random output setting R / F / FR R P.65
AUTO PWR-OFF Auto-power-off setting OFF / ON ON P.66
Suspension lock function
SUSPENS LOCK UNLOCK / ACTIVE / LOCK ACTIVE P.67
setting
L-REMOTE CTRL Lift remote control function setting OFF / ON OFF P.68
AOS AOS settings OFF / ON OFF P.69
AOS travel speed reduction at
SPD-LMT BY H OFF / ON OFF P.70
high lift height setting
MULTI. LEVER Multi lever setting OFF / ON OFF P.71
Automatic tilt horizontal stop
TILT-HRZN OFF / ON OFF P.72
function setting
Total charging number display
CHARGE COUNT OFF / ON OFF P.73
option settings
Power failure error detection
WAITING (CHG) 1-5 1 P.74
time setting
FAN Fan setting OFF / ON / AUTO AUTO P.75
HORN (CHG) Horn setting OFF / ON ON P.76
DATA CHECKING Internal data monitoring - - P.117
ERROR HISTORY Error history check - - P.114
BATT-VOLTAGE ADJ (Battery voltage correction)
FOR LEVEL METER Battery indicator display correction -1.00 to 1.00 0.00 V P.77
FOR CTL/CHG Control voltage adjustment -2.00 to 2.00 0.00 V P.78
OFF / ON /
MAINTE-TIMER SET Maintenance timer setting OFF
ON+PWR-DOWN P.79
DISPLAYED TIMER SET Maintenance timer display time setting Date -
AOS specifications only
(For details, see "FBR-80
AOS SETTING AOS setting - -
AOS/Lift remote control Service
Manual" (SM15-010).)
MEMORY INITIAL Memory clear SETTING / ERROR - P.116
ERROR DSP. SET. Error display setting OFF / ON ON P.80
EPS SETTING (EPS setting)
STEERING TORQUE Steering torque setting 0-9 7 P.81
STEERING OFFSET Steering offset setting -0.30 to 0.30V 0.00V P.82
STEERING END STOP Steering stop position setting OFF / ON OFF P.85
46
SERVICE DSP. setting 4
4- 2. TYPE SETTING (Model setting)

Set the forklift model type.
131T0435
131T0436
Selected setting are highlighted.

button : value increase
button : value decrease
<Model type>
Setting
Specification
value
FBR Model
A Long wheel base
W Wide leg
Capacity 24V model : 9N/10N/12N
code 48V model : 9/10/12/14/15/16/18/20/25/30/35/40
-H High performance with front wheel brake
-CAB Cabin model
Cold storage use for -35°C
-CS
*Display only the multiple specifications
NOTE l You can confirm the set model from the model check
screen.
Model check screen TYPE See P.38
For explosion-proof specif ication and multi-

l
specification model, you cannot set the capacity and
option that is not provided in the lineup.
Model names are used as identification information
l
required for forklift truck control, note that the
notation slightly differs from the actual model.
47
4- 3. TRAVEL SETTING
4-3-1. LMT. SPEED (TURN) (Turn speed reduction setting)
Set the speed limit for turning.
131T0437
131T0441
131T0442
NOTE When other speed limit values are applied, priority is

given to the slowest speed.
<Relation between drive angle and speed reduction>

Reduction speed when turning
Limit speed 6.5 km/h
Forklift truck maximum speed [km/h]
Drive angle [deg]

48 131T0443
4- 4. PUMP (HYD) SETTING

4-4-1. LIMITED LIFT-SPD. (Lift speed reduction setting)
Set the lift up speed limit suitable to the travel speed.
131T0444
131T0445
131T0446
131T0447
NOTE l Priority is given to the slowest speed by comparing with

the lift speed set on the manager screen.
M A N A G E M E N T D S P. F U N C T I O N S E T. L I F T
See P.32
l Basically, set the slower lift speed inversely proportional

with faster travel speed.
49
4-4-2. OPR-PRIORITY SET. (Hydraulic simultaneous operation priority setting)

When lift up and other hydraulic operations are simultaneously
performed, set the hydraulic speed to which the priority is to be given.
131T0444
131T0448
If you move the cursor to

"REACH" or "TILT" by pressing
button and then press
button, "SLOW" flashes.
During flashing you can
switch "SLOW" and "FAST" by
131T0449 pressing button.
<When TILT is set to SLOW >

When lift and tilt simultaneously operate, priority is given
to slower speed setting.
For example) lift 32, Tilt 10 10
<When TILT is set to FAST>

When lift and tilt simultaneously operate, priority is given
to faster speed setting.
For example) lift 32, tilt 10 32
NOTE l Set the hydraulic speed on the manager screen.

MANAGEMENT DSP. FUNCTION SET.
l For any simultaneous operation of the lever other than lift, priority is given to the faster
speed setting only when both the options are set to FAST.
l "ATT.1" is visible only when number of hydraulic valves is set as 4 or 5 at option setting.
SERVICE DSP. OPTION SETTING VALVE See P.54
"ATT.2" is visible only when number of hydraulic valves is set as 5 at option setting.
l
SERVICE DSP. OPTION SETTING VALVE 5 See P.54
50
4-4-3. OPR-L/R SETTING (Reach valve opening amount setting)

Set the reach valve opening amount for the simultaneous operation lift
and reach as per the AOS (Proportional valve) specification.
131T0450
131T0451
NOTE It is displayed only when AOS option setting is ON.

SERVICE DSP. OPTION SETTING AOS ON See P.69
51
4- 5. LANGUAGE SETTING
Set the display language.
131T0452
131T0453
Only the following screens for user are displayed in the set language.
Contents on the other screens are displayed in English.
l CHECKING screen
l Normal screen
l Setting screen
l Hour meter screen
l Manager screen
52
4- 6. OPTION SETTING
This setting is applied when each option is equipped.
131T0454
4-6-1. HOUR METER (Hour meter display contents)

Set the hour meter display contents displayed on the
normal screen and the hour meter screen.
On the SERVICE DSP. screen

select OPTION SETTING
131T0455
131T0456
The hourglass icon displayed on the normal screen

changes according to the settings.
KEY Total key-on hours :
WORK Actual operating hours : (default)
NOTE Unlike 75 series, the actual operating time is set as

default.
53
4-6-2. VALVE (Hydraulic valve number setting)

131T0457
131T0458
When you set "4", the following settings are additionally displayed.
MANAGEMENT DSP. FUNCTION SET. Att.1
SERVICE DSP. PUMP (HYD) SETTING OPR-PRIORITY SET. Att.1
When you set "5", the following settings are additionally displayed.
MANAGEMENT DSP. FUNCTION SET. Att.1 See P.33
MANAGEMENT DSP. FUNCTION SET. Att.2 See P.33
SERVICE DSP. PUMP (HYD) SETTING OPR-PRIORITY SET. Att.1 See P.50
SERVICE DSP. PUMP (HYD) SETTING OPR-PRIORITY SET. Att.2 See P.50
54
4-6-3. ACCEL. ANGLE (Accelerator option setting)

Set the equipped accelerator type.

131T0459
131T0460
NOTE In the standard specifications, the accelerator lever tilt

angle is specified as 37°. For accelerator lever tilt angle
50°, use the option specifications of 75 series.
55
4-6-4. LASER POINTER (Laser pointer option setting)

Set ON/OFF of the laser pointer function.
* Separately, laser pointer must be connected.

131T0461
131T0462
<When set to ON>

The following settings are additionally displayed.
N ormal screen Setting screen FUNCTION SETTING LASER POINTER
See P.20
NOTE To make the laser pointer operate, the laser pointer setting
on the above screen must also be turned ON.
56
4-6-5. LIFT LOCK (Lift interrupt function setting)

Set On/OFF of the over discharge lift lock function.

131T0463
131T0464
<Operation when lift lock is turned ON >

• When the battery indicator segments on the normal
screen becomes 2, lifting speed reduces to half.
This limitation is not applied to the other hydraulic
operations.
•When the battery indicator segment on the normal
screen becomes 1 or less, lifting operation stops .
This limitation is not applied to the other hydraulic
operations.
57
4-6-6. LOAD METER (Load sensor option setting)

Set ON/OFF of the load meter (lift pressure sensor)
function.
*Separately, load meter (lift pressure sensor) must be
connected.

131T0465
131T0466
<When set to ON>

Complete the load meter (lift pressure sensor) setting on the model check screen.
Model check screen LOAD SENSOR ADJUST WEIGHT See P.42
NOTE If the load meter (lift pressure sensor) setting is not

completed on the model check screen, load on the
normal screen is displayed as "----kg", even if this
setting is ON.
<When set to OFF>

Load on the normal screen is displayed as "----kg".
58
4-6-7. CHARGER (Built-in charger option setting)

Set ON/OFF of the built-in charger.
* When the truck is equipped with a built-in charger.

131T0467
131T0468
<When set to OFF >

Even if the charger plug is connected to the forklift truck,
the charging screen is not displayed.
4-6-8. Wh METER (Electricity consumption meter option setting)

Set the Electric power usage meter and charging
monitoring system function.

131T0469
(To the next page)
59
Press to select OFF, ON or

ON+CHG.MON.
131T0470
To accurately calculate the
electric power after selecting
ON or ON+CHG.MON on the
previous screen, measure
the actual AC power supply
voltage of customer premises
by using a tester, and then
131T0471
perform this setting.
<When Wh meter is set to ON >
• Measure the electric power during charging.(Two current sensors are
installed.)
• The error "G63 CURRENT-CHG" for the current failure can be
detected during charging.
<When ON + CHG. MON (Charging monitoring system) is set>

• Detect the abnormal temperature at the battery plug (receptacle). (A
thermistor is installed on the battery plug (receptacle) in addition to
current sensor.)
• The error " G64 PLUG-CHG " for the overheating of the charging plug
(receptacle) can be detected.
When this setting is ON, the horn sound that warns of the error must
be set.
SERVICE DSP. OPTION SETTING HORN(CHG) See P.76
<Voltage (CHG)>
• Mesure the actual voltage of power source for charging.
• Set the voltage on this screen by pressing or button till it reaches
the mesured voltage.
60
4-6-9. BATT. LVL-MTR (Battery electrolyte level sensor option setting)

Set the ON/OFF of the S type battery electrolyte level sensor.
* When the truck is equipped with a battery electrolyte level meter.

131T0474
131T0475
<When set to ON>

Display the warning "REPLENISH REFINED WATER FOR BATTERY"
when the battery electrolyte level low signal is received from the sensor.
61
4-6-10. FL-PUMP OIL (Fork oil level sensor option setting)

Set the ON/OFF of the fork oil (hydraulic oil) level sensor.
In FBR-80 series, a separate fork oil level sensor must
be connected to support the special specifications.

131T0476
131T0477
<When set to ON>

Display the warning "REFILL HYDRAULIC OIL" when the fork oil level
low signal is received from the sensor within two seconds from turning
the key switch on.
62
4-6-11. FORK SCALE (Fork scale option setting) (Special spec.)

<When set to ON>
 "REDUCE THE LOAD" warning is displayed when
overload signal is received from the fork scale.
* Wiring is required.
* When the truck is equipped with a fork scale (load
sensor).
NOTE Even when a digital load meter (lift pressure sensor)

is additionally mounted on the truck, the overload
warning is displayed when the signal from fork scale
(load sensor) is received. Mounting of only one fork
scale is recommended.

131T0480
131T0481
NOTE Additionally, precise fork lift scales (equipped/not

equipped with certificate, and printer) are available.
The FORK SCALE displayed in the above display is
analog/digital load sensor.
63
4-6-12. EASY PW-ENTRY (Easy password entry setting)

Set ON/OFF of the easy password entry function.

131T0482
131T0483
<When set to ON>

PW change is additionally displayed on the manager screen.
MANAGEMENT DSP. PASSWORD CHANGE OPERATOR 1 - 4 See P.36
64
4-6-13. BUZZER FUNC. (Random output setting)

Set the buz zer wor king simult aneously with the
accelerator.
* Separate buzzer connection is required.

131T0484
131T0485
<Output condition>
Setting Output condition
F Accelerator forward travel
R Accelerator reverse travel
F/R Accelerator forward/reverse travel
A dedicated output port is available for the forward movement; however,

it is not available for the reverse movement; therefore, use a random
output port by using R（reverse）settings.
Forward accessory
๓㐍䜰䜽䝉䝃䝸
BrownBlack
䝏䝱䜽䝻 Forward
๓㐍ฟຊ output
㻼㻻㻡㻙㻝㻞㻣㼀
Forward accessory / Back buzzer
๓㐍䜰䜽䝉䝃䝸䠋䝞䝑䜽䝤䝄䞊
Brown
䝏䝱
Random
௵ពฟຊ output
㻼㻻㻢㻙㻝㻞㻤㼀 (Forward/Reverse
㻔๓㐍䠋ᚋ㐍䠋๓ᚋ㐍ฟຊ㻕
forward & reverse)
131T0486
NOTE When a forklift truck cannot travel due to the reason

such as brakes and OIS functions, the signal is not
output even when the accelerator is operated.
65
4-6-14. AUTO PWR.-OFF (Auto-power-off function setting)

Set ON/OFF of the auto power off function.

131T0487
131T0488
<When set to ON>

• When the forklift truck is left for 15 minutes or more in the key switch
ON state, the power supply gets disconnected automatically.
• The 15 minutes timer is reset to 0 when the sheet switch is pressed or
a travel/hydraulic operation is performed. The steering operation is not
reset.
• Auto power off does not work when the model check screen and
SERVICE DSP. screen are displayed.
66
4-6-15. SUSPENS. LOCK (Suspension lock function setting)

Set the auto suspension lock valve function.

131T0489
131T0490
Control method of the auto suspension lock valve varies

according to the settings.
<Setting list>
Setting Controls
UNLOCK The suspension is not locked normally.
Automatic control is performed after detecting
ACTIVE
the forklift truck status.
LOCK The suspension is normally locked.
<Lock conditions when ACTIVE is set>

• Accelerator indication is 75% or more during turning.
• Travel speed is 5.0 km/h or more during turning.
• Brake ON during turning
• Reverse travel 0.5km/h or more , and , brake ON
• Accelerator OFF and hydraulic operation
• Travel speed is less than 0.5km/h and the state is
continued for two seconds.
• High lift height detected
• Travel speed is 4km/h or more during steering
operation.
67
4-6-16. L-REMOTE CTRL (Lift remote control function setting)

Set ON/OFF of the lift remote control.
* When the truck is equipped with a lift remote control.

131T0491
131T0492
To make the "L-REMOTE CTRL." operate, the AOS setting must be done.
SERVICE DSP. AOS SETTING See P.69
F or details of setting AOS and Lift remote control

specifications, see "FBR-80 AOS/Lift remote control
Service Manual" (SM15-010).
68
4-6-17. AOS (AOS setting)

Set ON/OFF of the AOS (proportional valve).
* When the truck is equipped with AOS.

131T0493
131T0494
<When set to ON >

The following settings are additionally displayed
S
etting screen OPERATION SETTING OPERATION FEELING CUSTOM Cx
CONFIRMATION LEVER CHARACTER. See P.15
M
ANAGEMENT DSP. CUSTOM FEELING Cx LEVER CHARCTER See P.34
SERVICE DSP. PUMP (HYD) SETTING OPR-L/R SETTING See P.51
SERVICE DSP. DATA CHECKING OPT CPU
SERVICE DSP. AOS SETTING
SERVICE DSP. AOS LEVER
F or details of setting AOS and Lift remote control

69
4-6-18. SPD-LMT BY H (AOS travel speed reduction at high lift height setting)
Set the travel speed control function of the AOS model in
the high lift height state.

131T0495
131T0496
< When set to ON>

Send speed limit to TRV CPU as per the lift height
detected by OPT CPU. The slowest speed is limited to
3km/h.
NOTE Without relation to this setting, high lift height

detection switch is installed in the mast of 4.5 m or
more. When high lift height is detected, limit the
acceleration and reaction of the travel hydraulic to
90%, limit the reach speed -2, and turn deceleration-1
km/h.
㼂㻡㻢㻝㻥㻞㟁※㻔㻗㻡㼂㻕
Power supply (+ 5V)
Only for high lift height mast
㧗ᥭ㧗䝬䝇䝖䛾䜏㻭㻢㻢㻝㻥㻥㼀 Signal
ಙྕ
䝅䝻
White
㻳㻺㻰㻢㻝㻤㻞㻳㻺㻰
䜽䝻
Black
㻿㻞㻟㻢㻝㻣㻜㼀 Lift height detector SW
ᥭ㧗᳨ฟ䝇䜲䝑䝏
131T0497
or details of setting AOS and Lift remote control

F
70
4-6-19. MULTI. LEVER (Multi lever setting)

Set the joystick equipment of the lift remote control
specification model.

131T0498
131T0499
or details of setting AOS and Lift remote control

F
71
4-6-20. TILT-HRZN (Automatic tilt horizontal stop function setting)

Set ON/OFF of the tilt horizontal stop function.

131T0500
131T0501
<When set to ON >

• Tilt stops horizontally when the tilt horizontal stop
signal is received.
• After stopping, when the tilt lever is changed to neutral
position, operation is enabled again.
72
4-6-21. CHARGE COUNT (Total charging number display option setting)

Set ON/OFF of the charge count display function.

131T0502
131T0503
<When set to ON>

• Charge count is displayed within five seconds from start of charging.
• The charge count display is added on the setting screen.
Setting screen FUNCTION SETTING COUNT FOR CHARGE See P.21
• The charge count can be reset to 0 by the operator.
<When set to OFF>

• Charge count can be checked on the SERVICE DSP. screen.
SERVICE DSP. DATA CHECKING EPS/DSP CPU CHARGE COUNT See P.125
NOTE This setting is not enabled till the option setting

"CHARGER" is set to ON. See P.59
73
4-6-22. WAITING(CHG) (Power failure error detection time setting)

Set the time till the power failure error gets detected
during charging.

131T0504
131T0505
At power failure, after exceeding the set time, "G62

* E L EC T R I C O U TAG E * C H A R G E S TO P P E D " i s
displayed on the display.
NOTE Set this option not to stop charging for the power
failure error when rolling blackouts occurs due to such
as the earthquake.
NOTE This setting is not enabled till the option setting

"CHARGER" is set to ON. See P.59
74
4-6-23. FAN (Fan setting)

Set the fan.
Models of 2.0t and more are equipped the fan.

131T0506
131T0507
<Fan settings list>

Setting Control
Set when the fan is removed from the models
OFF
of 2.0t or more.
Set when the fan is installed in the models of
ON
1.8t or less.
Installation of the fan is automatically decided
AUTO
from the models.
<When fan is equipped>

• Fan is driven when the travel/hydraulic IPM module
temperature is detected as 50°C or more. Fan stops
when the temperature is 45°C or less.
• Fan is controlled and error is detected.
<When fan is not equipped>

• Fan is not controlled and error is not detected.
75
4-6-24. HORN(CHG) (Horn setting)

Set the horn sound when charging overheating error
"G64 PLUG-CHG" is detected.
This setting is enabled in only model that are equipped
with charging monitoring system option.
SERVICE DSP. OPTION SETTING Wh METER ON+CHG.MON See P.59

131T0508
131T0509
<When set to ON >

• When the overheating error "G64 PLUG-CHG" of the
charging plug is detected, horn sounds for 15 minutes
in the cycle of 10 seconds (1 second sounding, 9
seconds mute).
• Consider for surroundings.
76
4- 7. Other settings
4-7-1. FOR LEVEL METER (Battery indicator display correction)
Correct the voltage that is displayed on battery indicator
in the range of ± 1.0V.
When an accessor y (such as heater) is equipped,
the battery voltage reduces and the battery indicator
might not reach 10 even if the battery is fully charged;
therefore, correct that voltage drop.
6(59,&('63
(5525+,6725<

%$7792/7$*($'-
0$,17(7,0(56(7 131T0518
%$7792/7$*($'-
)25/(9(/0(7(5
)25&7/&+* 131T0529
%$7792/7$*($'-
)25/(9(/0(7(5
9
131T0530
<How to correct>
• Check the voltage on this screen when accessory is
OFF. Voltage drops when accessories are turned ON.
• Adjust the voltage by pressing or button till it
reaches the accessory OFF voltage. Press button to
end the correction.
NOTE This adjustment is used for battery indicator display

adjustment and not related to the control voltage
adjustment.
77
4-7-2. FOR CTL. / CHG (Control voltage adjustment)

Adjust the control voltage. The battery voltage that
is detected by EPS/DSP CPU causes an error of
approximately 1% due to manufacturing error of the
board. Correct this voltage to implement the accurate
charging control always.
6(59,&('63
(5525+,6725<

%$7792/7$*($'-
0$,17(7,0(56(7 131T0518
%$7792/7$*($'-
)25/(9(/0(7(5
)25&7/&+* 131T0519
%$7792/7$*($'-
)25)25./,)7$1'
&+$5*(&21752/
9
131T0520
<How to correct>
• Measure the battery voltage (power source used for
accessory may also be included) by using a tester.
• Adjust the voltage on the screen to match with the
measured voltage by pressing or button. Press
button to end the correction.
NOTE l The voltage before and after correction can be

checked as follows:
SERVICE DSP. DATA CHECKING
EPS / DSP CPU CONTROL VOLTAGE See P.126
l The corrected data is reset when replacing the main
board and initializing the memory; therefore, you
must readjust the setting again.
78
4-7-3. MAINTE-TIMER SET. (Maintenance timer setting)

Set the maintenance timer function.
When you set this function ON, set a date that start to
display maintenance timing.
6(59,&('63
(5525+,6725<

%$7792/7$*($'-
0$,17(7,0(56(7 131T0521
0$,17(1$1&(7,0(5
6(7
2))
21
213:5'2:1 131T0522
0$,17(1$1&(7,0(5
',63/$<('7,0(56(7 Press to set the data and
then press button to go to
131T0523
the next step.
<When set to ON>

The maintenance time is displayed to the operator on the
CHECKING screen after the set date.
<When set to ON+PWR-DOWN>

The maintenance time is displayed to the operator on
the CHECKING screen after the set date, and limits are
applied on travel speed 4km/h and hydraulic speed 16.
NOTE Please note that if you change the date of the clock on
the settings screen to a past date, the maintenance
time may not appear on the screen.
NOTE The slowest value in proportion to other settings is

prioritized.
79
4-7-4. ERROR DSP. SET. (Error display setting)

Set the display/hide for error and warning on the normal
screen.
6(59,&('63
0(025<,1,7,$/

(5525'636(7
(366(77,1* 131T0531
(5525'636(77,1*
21
2))
131T0532
NOTE Even if the error becomes invisible, forklift truck

operation is controlled according to the error. The
error history is also maintained.
80
4-7-5. STEERING TORQUE (Steering torque setting)

Set the steering torque.
6(59,&('63
0(025<,1,7,$/

(5525'636(7
(366(77,1* 131T0524
(366(77,1*
67((5,1*72548(
67((5,1*2))6(7
67((5,1*(1'6723 131T0525
67((5,1*72548(
>@
131T0526
As setting value becomes larger, the steering torque

becomes smaller. When the steering torque is set to “0”,
assist by EPS motor is invalid.
NOTE l The factory setting is "7". When the value becomes

greater than 7, hunting generates and the steering
wheel easily trembles; therefore, setting a number
greater than 7 is not recommended. By any chance,
if hunting occurs in “7” setting, reduce the setting
value.
Without decision by
l button, the steering torque
changes by pressing or button. Confirm the
appropriate steering torque and then press
button to complete the setting.
81
4-7-6. STEERING OFFSET (Torque sensor neutral voltage adjustment)

The steering torque sensor neutral value should be 2.5V
when the steering is not operated.
Shifting of the torque sensor neutral value from 2.5V
results in self-steering. Therefore, always implement
neutral offset of the torque sensor when the following
operations are performed:
l After replacing the main circuit board
l After resetting the main board settings
Service display → MEMORY INITIAL → SETTING
After removing the link between the torque sensor and
l
shaft Comp. (after removing top cover)
After adjusting the neutral voltage of the torque sensor
l
(See "5 -2-18.Torque sensor neutral - check and
adjustment" on page 99.)
NOTE The following adjustments are applicable to MCPU

AA4300 and newer models.
For AA4200 or older models, adjust the offset by
manually entering the offset value, or rewrite the value
in the MCPU program.
<Procedure>
Handle knob in 9 o'clock direction
1. Set the drive tire straight. The handle knob will
be in the 9 o'clock direction.
2. "STEERING OFFSET." is displayed. Press or
button on the sheet switch to bring the cursor on
"ADJUST".
6(59,&('63
0(025<,1,7,$/

(5525'636(7
(366(77,1* 131T0524
Tire in straight direction

142T0408
(366(77,1*
67((5,1*72548(
67((5,1*2))6(7
67((5,1*(1'6723 142T0402
67((5,1*2))6(7
$'-867 9
5(6(7
2))6(7 9
82 142T0404
3. Wiggle the handle to right and left, or tap lightly to

return it to neutral.
NOTE Always follow the given procedure, because even after

hand is removed from the handle, the handle may not
completely return to the neutral due to friction inside
the gear box. Wiggle the
handle to
right and left
142T0409
After step 3 was performed, if the voltage before

offset is not in the range of 2.35V to 2.65V, the torque Tap
sensor is faulty. Replace the sensor. lightly
142T0410
Voltage before offset
67((5,1*2))6(7
$'-867 9 To select [ADJUST], use or
button.
5(6(7
2))6(7 9 142T0404
4. Press button to complete the offset.
Voltage after offset
67((5,1*2))6(7
$'-867 9
5(6(7
2))6(7 9 142T0405
Offset voltage
5. Turn the key switch OFF/ON, and confirm that the

straight travel is stable and there is no self-steering.
If the straight travel is unstable, follow the procedure
on the next page to re-offset the steering.
83
<Re-offset method>
1. "STEERING OFFSET DSP." is displayed. Select
[RESET].
6(59,&('63
0(025<,1,7,$/

(5525'636(7
(366(77,1* 131T0524
(366(77,1*
67((5,1*72548(
67((5,1*2))6(7
67((5,1*(1'6723 142T0402
67((5,1*2))6(7
$'-867 9
5(6(7 To select [RESET], use or
button.
2))6(7 9 142T0406
2. Press button to reset the offset.
67((5,1*2))6(7
$'-867 9
5(6(7
2))6(7 9 142T0407
Offset voltage reset
3. Once the offset is reset, re-offset the steering by

following the procedure from step 2 given on page 82.
84
4-7-7. STEERING END STOP (Steering end stop setting)

Set minimum turning radius stop / no-stop on the steering
end.
6(59,&('63
0(025<,1,7,$/

(5525'636(7
(366(77,1* 131T0527
(366(77,1*
67((5,1*72548(
67((5,1*2))6(7
67((5,1*(1'6723 131T0525
67((5,1*(1'6723
21
2))
131T0528
NOTE For 75 series, the steering stops when the Drive unit
comes into contact with the mechanical end of the
forklift truck.
For 80 series, Drive unit does not come into contact
with the mechanical end because the power steering
force stops when Drive unit is at the angle of minimum
turning radius.
85
<When STEERING END STOP is set to OFF>

While the assist force is stopped, it is impossible to rotate
the steering wheel; however, the drive rotates to the
mechanical end due to self-aligning torque generated
between tire and road surface when travelling in forward
direction.
Assist force
Minimum turning radius
Drive angle
6°
131T0533
<When STEERING END STOP is set to ON>

Even if the drive attempts to rotate due to the self-
aligning torque, the reaction force gets generated and the
minimum turning radius is maintained.
Assist force
Minimum turning radius
Drive angle
6°
Reaction force suitable

to the excessive angle
131T0534
86
5. Inspection and adjustment of
equipment/functions
5- 1. Cautions when inspecting and adjusting
CAUTION The battery sends current to Main board even if the key
is turned off. And the capacitor retains an electric charge
even after disconnecting the battery plug.
Before starting work, discharge the capacitor.
See "1-2-2. Capacitor - discharge" on page 3.
CAUTION l Check the existence of the electrical charge, and

handle the equipment with caution.
l When measuring current and voltage, set the mode according
to the measurement target and then take the measurements.
*The mode setting differs according to tester; therefore, refer
to its manual.
Measurement target Tester mode
Traction motor
AC mode
Hydraulic motor
Battery
DC mode
EPS motor
CAUTION Do not pull the power supply cable when removing the
battery plug.
Hold the battery plug and then pull it out.
CAUTION When removing the connector, do not pull the harness

part. Hold the connector housing part firmly, and then
unlock and remove the connector.
87
5 Inspection and adjustment of equipment/functions
5- 2. How to check and adjust

5-2-1. Chassis insulation check
<How to check>
1. Disconnect the battery plug.
2. Use a tester to measure insulation resistance.
(1) Between the positive (+) terminal of the plug on the chassis side
and the chassis (Metal part (Unpainted surface)).
(2) Between the negative (-) terminal of the plug on the chassis side
and the chassis (Metal part (Unpainted surface)).
<Specified value>
1 MΩ or greater
5-2-2. Body ground check

* This checking is only for built in charger.
<How to check>
Use the circuit tester to measure the continuity between each
terminal in the receptacle on the charger panel and the chassis
(Metal part (Unpainted surface)).
<Specified value>
100Ω or less
5-2-3. Traction and Hydraulic motor insulation- inspection

Measure the insulation between terminals and stator
comp. with the Megger.
<Resistance>
Measuring device Specified resistance
Megger 0.5 M or greater (DC500V)
Stator
<Measuring procedure> Comp.
1. Apply the earth probe (negative [-]) of the Megger to Terminal

131W0809
the stator comp.
2. Apply the line probe (positive [+]) of the Megger to
each terminal. (U, V and W)
88
Inspection and adjustment of equipment/functions 5
5-2-4. Traction motor current measurement

<Measurement point>
IU: traction motor U phase current (V phase and W phase are also acceptable.)
<Measurement conditions>
Specific gravity of the battery electrolyte : over 1.25 (at 20°C)
<How to set>
Select DATA CHEKING on SERVICE DSP. screen
lDATA CHEKING screen
Press
to select TRV CPU.
131T0205
lTRV-CPU screen
Press to select
TRV-MOTOR CURRENT.
131T0206
lMOTOR CURRENT (TRAVEL) screen
131T0207
89
<How to check traction motor current>

1. Without depressing the accelerator pedal, check that
traction motor current (TRAVEL) and value measured
by the ammeter is 0A.
2. Jack up the dr ive wheels, and do the following
operations.
WARNING l Make sure to install a wheel stopper on the load

wheel, and then jack up the drive wheels.
l Lift or jack up the forklift truck, and then support it
with safety blocks or rigid stands.
Check idling current Traction motor

Fully depress the accelerator pedal for 10 seconds.
Make sure that the display value is within ±20A of the
value measured by an ammeter.
Check locking current

Release the brake pedal to make the brake switch be in a
conduction state, and then depress fully the accelerator.
* When the brake disk rotates in this state, strengthen the
brake spring, and measure the current in a state where
brake is locked even if the accelerator is fully pressed.
a) Under these conditions, check that the display indicates Digital high tester
a hydraulic motor current (TRAVEL) within ± 20A. 131T0537
b) Check that the value displayed by the ammeter is within

the specified value range described in the following table.
<Specified value>
Model Traction motor locking current
FBR9N-12N 370 ± 50
FBR10-18 230 ± 50
FBR20-30 250 ± 50
FBR35/40 310 ± 50
l Digital high tester

CAUTION When measuring AC motor current, use the following
recommended ammeter:
RANGE
Hioki 3290 AC/DC high tester (Digital)
<How to measure motor current>
1. Press [MODE] button and select "AC + DC" for the mode.
2. Press [RANGE] button and select "H" for the range. SAMPL
3. Press [SAMPL] button and select "SLOW" for the response. MODE
4. Measure the motor current.
281W0101
90
5-2-5. Hydraulic motor current measurement

<Measurement point>
IU: hydraulic motor U phase current (V phase and W phase are also acceptable.)
<Measurement conditions>
Specific gravity of the battery electrolyte : over 1.25 (at 20°C)
<How to set>
Press to select
PUMP(HYD) CPU.
131T0208
lHYD-CPU screen
Press to select
HYD-MOTOR CURRENT.
131T0209
lMOTOR CURRENT (HYD) screen
131T0210
91
<How to check hydraulic motor current>

1. Without operating the lift lever, check that hydraulic motor current
(HYD) is 0A.
2. Fully pull up the lift lever until it reaches lift relief position (lift end-of-
stroke) and hold for 10 seconds.
a) Under these conditions, check that the display indicates a hydraulic
motor current (HYD) within ± 20A.
b) Check that the value displayed by the ammeter is within the specified
value range described in the following table.
<Specified value>
Model Hydraulic motor relief current
FBR9N-12N 300 ± 50
FBR10-20 250 ± 50
FBR25-40 280 ± 50
To motor Lead wire
Main controller
8 <3>
HYD-U 8
<4> Digital high tester
HYD-V 8
<5>
HYD-W 8
<6>
<7>
TRV-U 8
<8>
TRV-V 8
8 TRV-W 8
8
131T0511
Body harness
CAUTION l Digital high tester

When measuring AC motor current, use the following
recommended ammeter:
RANGE
Hioki 3290 AC/DC high tester (Digital)
<How to measure motor current>
1. Press [MODE] button and select "AC + DC" for the mode.
2. Press [RANGE] button and select "H" for the range. SAMPL
3. Press [SAMPL] button and select "SLOW" for the response. MODE
4. Measure the motor current.
281W0101
92
5-2-6. EPS motor - inspection

Inspect with the following procedure after assembling.
[1] Abnormal noise and spark

Operate the motor. Then make sure that abnormal noise is
not heard and sparks of brushes are not seen.
[2] Inspection of insulation

Terminal
Measure the insulation between terminals in the connector
and the end cover with the Megger. （+）
<Resistance>
Measuring device Specified resistance
Megger 0.1 M or greater (DC500V)

（-）
<Measuring procedure> Yoke
1. Apply the earth probe (negative [-]) of the Megger to the Megger
152W225
yoke.
2. Apply the line probe (positive [+]) of the Megger to each
terminal of connector plug.
5-2-7. Transformer - inspection (for built-in charger)

1. Check for damage and dirt.
If the transformer is dirty, clean it with compressed air.
2. Measure insulation resistance.
<Specified value>
Insulation resistance
5M or more
specified value
<Measurement procedure>
Megger
CAUTION
lAlways disconnect Battery plug before measuring.
Transformer
l If you are using a Megger, do not touch measurement terminals.
1. Remove all diodes from Transformer.

2. Check insulation by measuring the following locations with
Megger.
lBetween primary and secondary coils
Between primary coil and chassis (Metal part (unpainted surface))
l 131W0926
Between secondary coil and chassis (Metal part (unpainted surface))

l
93
5-2-8. Diode - inspection

Inspect Diode by measuring resistance.
<Specified resistance values>

Terminal Tester
Resistance[k ] Diode
[+] Positive [-] Negative
Anode(A) Cathode(K) 10 - 100k
Cathode(K) Anode(A)
NOTE The above values are reference values. Measured

values may slightly vary depending on the tester. K A
<How to measure diode resistance>

Measure the diode resistance as per the diode measurement A K
range of the tester.

121W231
5-2-9. Descending regeneration check

<How to check>
1. Apply the parking brake at an appropriate slope and stop
the truck.
2. Make sure that the truck descends the slope at a speed of
1 km/h ± 0.5 km/h when the parking brake and brake pedal
are released.
5-2-10. Auto-power-off function check

<How to check>
1. Turn the key switch on and do not operate the forklift truck.
2. Confirm that the power supply turns off automatically after
about 15 minutes.
* However, the power supply does not turn off if traveling/
hydraulic operation is done or the sheet switch is pressed
in 15 minutes or less.
NOTE On the service screen and model check screen, the key
switch is not turn off automatically.
94
5-2-11. OIS (Operation Interlock System) check

<How to check OIS>
1. Move away from the presence pedal for two seconds or more.
2. Make sure that "ASSUME CORRECT STANDING POSITION"
appears on the display.
3. Make sure that the travel and hydraulic functions interlock, and also
confirm that the forklift truck cannot operate after interlocking.
<How to check OIS cancellation function>

1. While "ASSUME CORRECT STANDING POSITION" is displayed on
the display, ride the forklift truck (step on the presence pedal).
2. Make sure that the message "ASSUME CORRECT STANDING
POSITION" on the display disappears and travel/hydraulic operations
can be performed.
<Checking the traction neutral safety function>

the display, operate the accelerator lever and ride the forklift truck
(step on the presence pedal).
2. Make sure that the message " RELE ASE ACCEL LE VER TO
NEUTRAL" is displayed on the display.
3. Operate the accelerator off, and make sure that the message
disappears and travel is enabled.
<Checking the hydraulic neutral safety function>

the display, operate the hydraulic lever and ride the forklift truck (step
on the presence pedal).
2. Make sure that "RELEASE HYD. LEVER TO NEUTRAL" appears on the display.
3. Operate the hydraulic lever off, and make sure that the display
disappears and hydraulic operations are enabled.
5-2-12. Turn signal lamp check

<How to check>
1. When the turn signal lamp breaks down, blinker blinks.
At this moment, make sure that the buz zer sound r ings in
synchronization with this blinking.
2. If the turn signal lever breaks down and then a steering operation is
performed within 12 seconds in the direction opposite to the direction
of breaking down of the switch, at that time make sure that the turn
signal lamp turns OFF.
However, if you do not perform the steering operation for equal to or
more than 12 seconds, the blinker automatically turns OFF.
95
5-2-13. Travel inhibitor check (Option)

<How to connect>
Connect the connector OPT line [CN3-74] (yellow-black)
to the GND line [CN3-79] (black).
<How the check the travel inhibitor>

Confirm that the travel inhibitor prevents the forklift truck
from traveling.
CAUTION Always check the travel inhibitor while the drive wheel
is jacked up.
5-2-14. Lift lock (Lift limit) operation check (Option)

<How to connect>
Connect the connector OPT line [CN3-89] (blue-red) to
the GND line [CN3-79] (black).
<How the check the lift lock>

Make sure that lifting up is not possible. (Lowering lift, tilt
and reach operation is normal.)
5-2-15. Cooling fan check

<Models which are equipped with the cooling fan>
2t and more
<Working condition of the cooling fan>

Check the following condition.
• Temperature of any one of traveling FET or hydraulic
FET is 50 or more.
: Operate the unit cooling fan
• Temperature of any one of traveling FET or hydraulic
FET is below 45
: Stop the unit cooling fan
• Turn the key switch off and make sure that the cooling
fan stops.
96
5-2-16. Accelerator sensor adjustment
CAUTION Release the brake pedal and turn the OIS sensor off.
And then adjust the accelerator sensor with the forklift
truck stopped.
<How to confirm>
Check the voltage on the display. And then loosen the
screw for sensor adjustment and adjust the output voltage.

37° type 50° type
Maximum 3.95 V or more, 3.91 V or more,
4.34 V or less 4.42 V or less
Neutral 2.5 ± 0.03 V
Minimum 0.66 V or more, 0.58 V or more,
1.05 V or less 1.09 V or less
Select DATA CHEKING on SERVICE DSP. screen Adjustment screw

131T0535
lDATA CHECKING screen
Press
to select TRV CPU.
131T0238
lDATA (TRV CPU) screen
Press
to select ACCEL SENSOR.
131T0239
lACCELERATOR SENSOR screen
Adjust only the value of sensor 1

to be within 2.5 ± 0.03 V.
131T0240
97
5-2-17. Drive angle sensor adjustment
CAUTION Disconnect the EPS motor lead wire, and then adjust
the drive angle sensor.
<How to check>
Check the voltage on the display.
1. Set the driving angle to the straight travel condition.

2. Loosen the sensor fitting bolt, shift the position of the
sensor and adjust the drive sensor angle in such a way that
the display value for the upper signal only is 2.5±0.05 V
while the drive angle is in the straight travel condition. Sensor fitting bolt
NOTE After adjusting the voltage, fix the rubber wheels such
that gear does not rotate, and then tighten the sensor
fitting bolts.
* After adjusting the angle, tighten the fitting bolt.
Adjustment gear
131T0536
Press
to select EPS/DSP CPU.
131T0241
lEPS/DSP CPU screen
Press
to select ANGLE SENSOR.
131T0242
lANGLE SENSOR screen
Adjust only the upper value to be

within 2.5±0.05V.
98 131T0243
5-2-18. Torque sensor neutral - check and adjustment
CAUTION When Lift or jack up the forklift truck, support it with

safety blocks or rigid stands.
[1] Checking torque sensor neutral

Check voltage/current value on the display.
1. Make sure that the voltage of the torque sensor is

2.5±0.1V.
2. Make sure that the value of current of the EPS motor is
0.0A.
When values in both 2. and 3. are normal, the torque
sensor midpoint is considered to be normal.

Maximum value 4.45 V or more, 3.80 V or less
Neutral 2.5 ± 0.1V
Minimum value 0.58 V or more, 1.20 V or less
Press
to select EPS/DSP CPU.
131T0241
lEPS/DSP CPU screen
'$7$
㸦(36'63&38㸧 Press
67((5,1*6(1625 to select STEERING SENSOR.

$1*/(6(1625
%$77/9/6(1625
131T0514
(To the next page)
99
lSTEERING SENSOR screen

67((5,1*6(1625
㸦+$1'/(6,'(㸧
Check if the voltage of the
9 STEERING SENSOR is 2.5±0.1V.
131T0515
Press to return
to DATA CHECKING screen.
131T0241
'$7$㸦(36'63&38㸧 Press
(3602725&855(17 to select EPS-MOTOR.

%2$5'7(03(5$785(
'5,9($1*/(
131T0516
lMOTOR CURRENT(EPS) screen

02725&855(17(36
/,0,7$
$'-GLJLW Check if the value of MOTOR
&85$$ CURRENT is 0.0A.
131T0517
100
[2] Neutral adjustment of torque sensor

1. Turn off the key switch.
2. Loosen the torque sensor fitting bolts. Torque sensor
3. Adjust the torque sensor as following by using a

shim and install the torque sensor again.
l When the neutral voltage of the torque sensor is
Shim
low : Remove one shim.
l When the neutral voltage of the torque sensor is
high : Insert one shim
4. Turn the key switch on.
5. Check the torque sensor neutral voltage on
the display in a state where the steering is not
operated and check whether the voltage is within
2.5±0.1V.
Repeat the procedure from 3 to 5 if the voltage is
out of range.
131W0405
lSTEERING SENSOR screen

67((5,1*6(1625
㸦+$1'/(6,'(㸧
9
131T0515
NOTE If the torque sensor is replaced, then ensure that you

perform 'Torque sensor neutral offset' too in addition
to the neutral adjustment.
See "4-7-6. STEERING OFFSET (Torque sensor neutral
voltage adjustment)" on page 82.
101
5-2-19. IPM module - inspection and replacement

CAUTION Do not directly touch the terminals of the IPM module.
The static electricity destroys the elements.
<How to check>
1. Turn the key switch off, disconnect the battery plug, and then
discharge the capacitor.
2. Remove the IPM module from the main controller.
3. With a digital tester, perform a continuity test at test points 1 to 6, as
shown in the table below.
Use the semiconductor continuity test mode. Do not use the resistance range.
If you detect continuity at any test point, replace the module (Travel or
Hydraulic) with a new one.
NOTE When replacing the IPM module, check the condition and years of capacitor Ass’y usage,
and replace in the following cases:
• IPM module usage period is over.
* C apacitor Ass'y replacement period: 3 years (Hour meter value:3600H)
• When abnormality is observed in the external appearance(such as bulging, cracks, and leakage)
<Measuring point> l IPM module

"Positive test" "Negative W
lead at test" lead at
1 P U V
2 P V
N
3 P W
U
4 N U
5 N V
6 N W P
* Both positive(+) and negative(-) are

acceptable for the test. Perform the
continuity check of the tester in advance. Main controller
㻤
㻤
HYD. 㻤
IPM
㻤
TRV. 㻤
IPM
㻤
Capacitor Ass'y
131T0512
102
5-2-20. Battery front loading travel/hydraulic interlock

<How to check>
1. Match the fork height and tilt to the reference position and perform
reach-in.
2. Step on the battery front loading lever up to the middle of the stroke
(A state where battery front loading micro switch is ON) Do not push
all the way).
3. Make sure that travel or hydraulic operations cannot be performed at
this time.
4. Make sure that "REFRACT THE BATTERY" is displayed on the
display.
5-2-21. Built-in charger function check (Total timer)

<How to check>
Check the function in a test charging that total time is shortened by 10
seconds.
When the battery charging does not complete within 16 hours from
starting due to the reasons such as battery deterioration, the charging
stops with error. This is confirmation to check whether the charging
function smoothly operates.
<How to operate>
Magnetic
Checking procedure Display
contactor
Connect the battery charging plug to
1 OFF
the socket on chassis.
Connect the power plug to the
2 OFF Charging mode selection
building-side power receptacle.
3 While pressing button, press the OFF Test charging

button in order of .
4 Press button. ON Test charging is being performed.
The battery charging completes after
5 OFF Test charging complete.
10 seconds.
CAUTION I f you interrupt to charge the bat ter y, push the b e fore
disconnecting the battery plug to prevent from sparking.
103
MEMO
104
6. Troubleshooting
6- 1. Caution for electricity-related repairs
CAUTION When doing electricity-related repairs, always turn off
the key switch, unplug the battery, and discharge the
capacitor.
CAUTION Do not pull the power supply cable when removing the
battery plug.
Hold the battery plug and then pull it out.
CAUTION When removing the connector, do not pull the harness

part. Hold the connector housing part firmly, and then
unlock and remove the connector.
WARNING When troubleshooting, apply stopper to the load

l
wheel and jack up the drive wheel side. And then
check the problems.
Lift or jack up the forklift truck, and then support it
l
with safety blocks or rigid stands.
CAUTION Always you must set the required items when replacing
the main board.
See "1-3. Required settings" on page 4.
105
6 Troubleshooting
6- 2. Self diagnosis function

6-2-1. Display
When the self-diagnosis function detects an abnormality
or error, the screen displays the error messages.
When detecting error
Key switch ON
2 seconds later
lNormal screen
000T0324
lMonitoring error display

B11 FET-TRAVEL The service (wrench) mark flashes.
FAIL OPERATION
TURN OFF KEY SWITCH
131T0325E
106
Troubleshooting 6
6-2-2. Error message list * The possible causes column in the following table describes only main devices.
* When replacing Main board and when initializing the memory, always set the required items. See P.4
Code Error Message Truck response when error is detected Conditions for detecting error CPU Possible Cause
• Faulty contact point
• Faulty contactor coil
•Disconnection of red / black wire between contact point and CN2-32 (main
Control voltage 1 (CN2-32) is equal to or below threshold for continuous 200 ms
contactor)
A01 CONTACTOR-M Main contactor trip during main contactor ON command. HYD
• Disconnection of contactor coil harness
(Threshold: 24V model: 9V / 48V model: 18V)
<How to check>
[SERVICE DSP.>DATA CHECKING>TRV CPU/BATT. VOLTAGE]
See P.119
Voltage difference between control voltage 1 (CN2-32) and control voltage 2 • Blown Fuse [F1]
(CN2-33) is equal to or more than threshold for continuous 100 ms during main • Disconnection of yellow / red wire between F1 fuse and CN2-33
A02 FUSE-MAIN contactor ON command. HYD <How to check>
(Threshold: 24V model: ± 12V / 48V model: ± 24V) [SERVICE DSP. >DATA CHECKING>TRV CPU/BATT. VOLTAGE]
* Error is not detected when main contactor trips. See P.119
FET-TRAVEL • Failure of travel IPM module
a) IPM error output (CN2-38) detects the high level.
B11 FAIL OPERATION Main contactor trip TRV <How to check>
b) Error detection signal is detected 5 times or more (in total).
TURN OFF KEY SWITCH See P.102
• Disconnection or failure of travel current sensor (U phase)
Offset of travel current sensor (U phase) neutral voltage (CN2-58) is out of range <How to check>
B12 C. SENSOR_U-T Main contactor trip TRV
of 2.5V ± 0.488V for continuous 100 ms. [SERVICE DSP. >DATA CHECKING>TRV CPU/T-CUR. SENSOR]
See P.119
• Disconnection or failure of travel current sensor (W phase)
Offset of travel current sensor (W phase) neutral voltage (CN2-66) is out of range <How to check>
B13 C. SENSOR_W-T Main contactor trip TRV
of 2.5V ± 0.488V for continuous 100ms [SERVICE DSP. >DATA CHECKING>TRV CPU/T-CUR. SENSOR]
See P.119
a) S
ensor input voltage (CN4-125, CN4-126) is 0.5V or 4.5V for continuously • Disconnection or failure of accelerator sensor
ACCELERATOR 100ms. <How to check>
B14 Shutoff for Travel operation TRV
TURN OFF KEY SWITCH b) S
um of sensor input voltage (CN4-125, CN4-126) is out of range of 5V ± 1.25V [SERVICE DSP. >DATA CHECKING>TRV CPU/ACCEL. SENSOR]
for continuous 100ms. See P.119
• Disconnection or failure of OIS sensor
PRESEN. SENSOR Shutoff for Travel operation Sensor input voltage (CN4-105) is 0.5V or 4.5V continuously. <How to check>
B16 TRV
TURN OFF KEY SWITCH Shutoff for Hydraulic operation * Error is not detected for FCS cabin model. [SERVICE DSP. >DATA CHECKING>TRV CPU/OIS SWITCH]
See P.119
Traction motor • Disconnection or failure of traction motor speed sensor
Following states is detected for continuous 10sec at the same time. <How to check>
Traction motor : torque limit
• Accelerator sensor input 50% [SERVICE DSP. >DATA CHECKING>TRV CPU/TRV-MOTOR SPEED]
• Traveling speed ＜ 0.1km/h See P.119
B17 SENSOR-TRV Front wheel (R) *Front wheel (L) (opiton) • Disconnection or failure of front wheel (R) speed sensor and Front wheel (L)
Front wheel (R) : Anti slip function is Following states is detected for continuous 10sec at the same time. speed sensor
disabled. • Accelerator sensor input 50% <How to check>
*Front wheel (L) (opiton) • Drive angle 40% Front wheel (R) See P.119 (F-WHEEL SPEED R)
• Front wheel traveling speed ＜ 0.5km/h Front wheel (L) See P.122 (F-WHEEL SPEED L)
FET-HYD • Failure of hydraulic IPM module
IPM error output (CN2-39) detects high level.
C21 FAIL OPERATION Main contactor trip HYD <How to check>
Error detection signal is detected 5 times of more (in total).
TURN OFF KEY SWITCH See P.102
• Disconnection or failure of hydraulic current sensor (U phase)
Offset of hydraulic current sensor (U phase) neutral voltage (CN2-54) is out of <How to check>
C22 C. SENSOR_U-H Main contactor trip HYD
range of 2.5V ± 0.488V for continuous 100ms. [SERVICE DSP. >DATA CHECKING>HYD CPU/H-CUR. SENSOR]
See P.122
• Disconnection or failure of hydraulic current sensor (W phase)
Offset of hydraulic current sensor (W phase) neutral voltage (CN2-62) is out of <How to check>
C23 C. SENSOR_W-H Main contactor trip HYD
range of 2.5V ± 0.488V for continuous 100ms. [SERVICE DSP. >DATA CHECKING>HYD CPU/H-CUR. SENSOR]
See P.122
107
6 Troubleshooting
Lift 1 switch remains in ON state for continuous 1000 ms after lift 2 switch turns
• Failure of lift SW (high speed/ low speed)
C24 SWITCH-LIFT ON (In normal conditions, operation sequence is lift 1 switch ON lift 2 switch HYD
• Installation position adjustment defect
ON).
• Blown EPS (F2) fuse
EPS power supply voltage is 10V for continuous 100ms.
D30 FUSE-EPS Travel speed reduced by half. DSP • Disconnection of red wire between F2 fuse and CN8-B1
* Error is not detected when the main contactor trips.
• Faulty contact point (main contactor)
• Disconnection or failure of torque sensor.
T. SENSOR-EPS Travel speed reduced by half. Sensor input voltage (CN5-162) is 0.5V or 4.5V for continuous 10ms.
D31 DSP • Installation adjustment defect
TURN OFF KEY SWITCH Shutoff for Power steering operation * Error is not detected when main contactor trips.
See P.82, P.99
a) E rror is detected when port input L is detected continuously for 100 times when
upper step is ON.
FET-EPS Travel speed reduced by half.
D32 b) E rror is detected when port input H is detected continuously for 100 times DSP • Failure of main board
TURN OFF KEY SWITCH Shutoff for Power steering operation
when lower step is ON.
* Error is not detected when main contactor trips , and when EPS voltage is 15V.
• Disconnection of EPS motor (if error occurs when operating steering.)
a) C urrent is ± 3A for continuous 1000ms for Duty output is 75% or 25%. • Failure of main board (if error occurs as soon as turning on key SW.)
Travel speed reduced by half.
D33 C. SENSOR-EPS b) Current sensor neutral offset is ± 5A. DSP <How to check>
Shutoff for Power steering operation
*E
rror is not detected when main contactor trips, and when EPS voltage is 15V. [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>EPS-MOTOR CURRENT]
See P.126
Proportional valve current of either of lift, tilt, reach Att.1 and Att.2 is in either of
following states for 100ms:
a) P roportional valve current input value 900mA.
• Failure of OPT board
b) When any hydraulic operation is not commanded, proportional valve current
• Disconnection of solenoid valve harness
FET-AOS input value 145mA. AOS
E40 Main contactor trip *C onditions for detecting error vary if truck is Lift remote control specifications.
TURN OFF KEY SWITCH c) When any hydraulic operation is commanded, proportional valve current input (option)
value 145mA.
See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Error is detected only in following condition.
Att.1→number of hydraulic valve : 4, 5
Att.2→number of hydraulic valve : 5
• Disconnection or failure of lift lever potentiometer
Either of following states is detected for continuous 100ms.
<How to check>
a) When (S1 + S2) - 5.0V exceeds ± 0.625V
L. SENSOR-LIFT AOS [SERVICE DSP. >DATA CHECKING>OPT CPU>LIFT SENSOR ]
E41 Shutoff for Hydraulic control b) S1 or S2 is 0.5V or 4.5V.
TURN OFF KEY SWITCH (option) * C
onditions for detecting error vary if truck is Lift remote control specifications.
*S1：OPT board lift lever potentiometer signal 1 (CN2-3）
S2：OPT board lift lever potentiometer signal 2 (CN2-23）
See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Either of following states is detected for continuous 100ms. • Disconnection or failure of tilt lever potentiometer
a) When (S1 + S2) - 5.0V exceeds ± 0.625V <How to check>
L. SENSOR-TILT AOS
E42 Shutoff for Hydraulic control b) S1 or S2 is 0.5V or 4.5V. [SERVICE DSP. >DATA CHECKING>OPT CPU>TILT SENSOR ]
TURN OFF KEY SWITCH (option)
*S1：OPT board tilt lever potentiometer signal 1 (CN2-5） For details of setting AOS and Lift remote control specifications,
S2：OPT board tilt lever potentiometer signal 2 (CN2-25） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Either of following states is detected for continuous 100ms. • Disconnection or failure of reach lever potentiometer
a) When (S1 + S2) - 5.0V exceeds ± 0.625V <How to check>
L. SENSOR-RCH AOS
E43 Shutoff for Hydraulic control b) S1 or S2 is 0.5V or 4.5V. [SERVICE DSP. >DATA CHECKING>OPT CPU>REACH SENSOR ]
TURN OFF KEY SWITCH (option)
*S1：OPT board reach lever potentiometer signal 1 (CN2-7） For details of setting AOS and Lift remote control specifications,
S2：OPT board reach lever potentiometer signal 2 (CN2-27） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Either of following states is detected for continuous 100ms. • Disconnection or failure of Att.1 lever potentiometer
Error is detected when the value set in hydraulic valve number setting is 4 or 5. <How to check>
L. SENSOR-ATT1 a) When (S1 + S2) - 5.0V exceeds ± 0.625V AOS [SERVICE DSP. >DATA CHECKING>OPT CPU>ATT.1 SENSOR ]
E44 Shutoff for Hydraulic control
TURN OFF KEY SWITCH b) S1 or S2 is 0.5V or 4.5V. (option) * C
*S1：OPT board Att.1 lever potentiometer signal 1 (CN2-9） For details of setting AOS and Lift remote control specifications,
S2：OPT board Att.1 lever potentiometer signal 2 (CN2-29） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
108
Troubleshooting 6
Either of following states is detected for continuous 100ms. • Disconnection or failure of Att.2 lever potentiometer
Error is detected when the value set in hydraulic valve number setting is 5. <How to check>
L. SENSOR-ATT2 a) When (S1 + S2) - 5.0V exceeds ± 0.625V AOS [SERVICE DSP. >DATA CHECKING>OPT CPU>ATT.2 SENSOR ]
E45 Shutoff for Hydraulic control
TURN OFF KEY SWITCH b) S1 or S2 is 0.5V or 4.5V. (option) * C
*S1：OPT board Att.2 lever potentiometer signal 1 (CN2-11） For details of setting AOS and Lift remote control specifications,
S2：OPT board Att.2 lever potentiometer signal 2 (CN2-31） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
a) 5
seconds have passed after turning key SW ON.
Lowest fork height switch is detected after key SW is turned ON.
[Encoder reel type]
Lift current position Lowest setting value -300 (100mm), or
Lift current position Highest setting value +300 (100mm) • Mistake of lift end setting
When all the above conditions of a) are detected for continuous 500 ms. <How to check>
[SERVICE DSP. >AOS SETTING>LIFT]
b) During AOS automatic fork height stop control
Lift standard position is not detected. • Failure or installation mistake of lowest limit lift sensor
Lift fork height does not change for continuous 2000 ms. AOS
E46 M. SENSOR-LIFT AOS emergency stop
When all the above conditions of b) are detected. (option)
• Failure, disconnection, or installation mistake of lift height detection encoder
c) During height limit function operation <How to check>
During manual operation [SERVICE DSP. >DATA CHECKING>EPS/OPT CPU>LIFT HEIGHT]
Lift standard position is not detected. For details of setting AOS and Lift remote control specifications,
During lift-up See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Lift analog input value is 1/2 or more than maximum.
Lift height does not change for continuous 2000 ms.
When all above conditions of c) are detected.
Error is detected when either of above conditions a) to c).
Input value of potentiometer for horizontal detection are analogue value 1 and 2. • Failure, disconnection, or installation mistake of tilt horizontal detection
a) 'FORK LEVEL' button of the AOS switch box is ON (LED is lit). potentiometer
b) Signal voltage of the tilt lever potentiometer (OPT board CN2-20) is 0.5V or 4.5V. AOS <How to check>
E47 M. SENSOR-TILT
(option)) [SERVICE DSP. >DATA CHECKING>EPS/OPT CPU>TILT-HRZN. SENSOR ]
Error occurs when both the conditions are detected simultaneously for For details of setting AOS and Lift remote control specifications,
continuous 100 ms. See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
a)Sensor input voltage (CN5-161 or CN5-160) is 0.5V or 4.5V for continuous • Disconnection or failure of drive angle sensor
Travel speed restricted to 5km/h 100 ms. • Installation adjustment defects
F50 STEER. SENSOR (reduction in turning speed) b)Sum of voltage of cross type 2 wires (CN5-161 + CN5-160) is 4.5V or 5.5V DSP <How to check>
steering end stop function OFF for continuous 100ms. [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>ANGLE SENSOR ]
* Error is not detected when main contactor trips. See P.126
• Disconnection or failure of lift pressure sensor
<How to check>
F52 VALVE SENSOR Sensor input voltage (CN4-124) is 4.7V or 0.3V for continuous 100ms. HYD
[SERVICE DSP. >DATA CHECKING>HYD CPU/LIFT-PRES. SENSOR]
See P.122
a) F
an power supply voltage is 5V for continuous 1 second while fan is stopped
(detection of disconnection).
• Disconnection, failure or, non-mounting of fan
F53 FAN b) F
an power supply voltage is 15V for continuous 1 second during fan drive DSP
• Failure of main board
(FET fault detection).
* The truck 2 ton or above equipped with fan only.
TOTAL TIMER • Defect of battery
G60 Shutoff for Charging In normal charging, equalize charging does not complete within 16 hours. DSP
CHARGE STOPPED • Failure of transformer
a) High voltage:Control voltage is 70V for three times in 10ms while charging (48V model)
Control voltage is 35V for three times in 10ms while charging (24V model) • Defect of battery
VOLTAGE-CHG
G61 Shutoff for Charging b) Low voltage:Control voltage is 46V for continuous 5 seconds while charging (48V model) DSP • Failure of transformer
CHARGE STOPPED
Control voltage is 23V for continuous 5 seconds while charging (24V model) • Detachment of battery plug while charging
*Control voltage：CN5-133
109
6 Troubleshooting
*ELECTRIC OUTAGE* • Disconnection for AC connection detection line (CN7-2)
Charging timer stop AC connection detected as OFF while charging.
CHARGE STOPPING... • Failure of power supply while charging
G62 DSP
*ELECTRIC OUTAGE* • Detachment of battery plug while charging
Charging timer stop AC connection detected as OFF longer than set time while charging. • Open phase of input power source
CHARGE STOPPED
a) D
eviation of 3-phase peak current is 10A (8A for 24V model) for continuous 5 seconds.
CURRENT-CHG • Failure of transformer
G63 Shutoff for Charging b) D
eviation of 3-phase peak current is 40A (20A for 24V model) for continuous 5 seconds. DSP
CHARGE STOPPED • Disconnection or failure of charging current sensor
c) Neutral offset electric current is 5A.
a) Charging plug temperature is 110°C during charging mode. • a) Defect of contact point of charging plug
Shutoff for Charging b) Charging plug temperature is -999°C or during charging mode (detection of • b), c) Defect or disconnection of thermistor
PLUG-CHG
G64 Horn sound (sounds for 15 minutes at disconnection). DSP <How to check>
CHARGE STOPPED
10s intervals when settings is ON.) c) Charging plug temperature is -44°C and difference of two wires is 10°C [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>PLUG TEMPERATURE]
during charging mode. See P.126
a) E ffective motor current value is equal to or more than maximum current set
value for continuous 100ms. • Overcurrent of traction motor current
Maximum current set (When motor starts) • Disconnection or failure of travel current sensor
IPM: 400A 318A • Short-circuit of traction motor
CURRENT-TRV IPM: 600A 474A (FBR35/40)
H70 Main contactor trip TRV • Mistake of model setting (current limitation value is different.)
TURN OFF KEY SWITCH b) When overcurrent detection (POE) hardware detects overcurrent threshold for
more than 20 times. <How to check>
Overcurrent threshold [SERVICE DSP. >DATA CHECKING>TRV CPU/T-CUR. SENSOR]
IPM: 400A 450 Apeak See P.119
IPM: 600A 670 Apeak (FBR35/40)
a) T he effective motor current value is more than maximum current set value for
continuous 100ms. • Overcurrent of hydraulic motor current
Maximum current set (At the time of motor start) • Disconnection or failure of hydraulic current sensor
IPM: 400A 318A • Short-circuit of hydraulic motor
CURRENT-HYD IPM: 600A 474A
H71 Main contactor trip HYD • Mistake of model setting (current limiting value is different.)
TURN OFF KEY SWITCH b) When overcurrent detection (POE) hardware detects overcurrent threshold for
more than 20 times. <How to check>
Overcurrent threshold [SERVICE DSP. >DATA CHECKING>HYD CPU/H-CUR. SENSOR]
IPM: 400A 450 Apeak See P.122
IPM: 600A 670 Apeak (FBR35/40)
• Overcurrent of EPS motor
EPS POE signal is detected for total 20 times.
H72 CURRENT-EPS Travel speed reduced by half. DSP • Short-circuit of EPS motor
* Error is not detected when main contactor trips.
[High voltage detection]
(Main contactor trip: 66V (48V model) or 33V (24 model))
• Mistake of model setting
• Battery plug came off during regeneration operation.
a) L ow voltage check
(Error is not displayed; however, it is stored in the error history.)
During contactor ON command,
a) L
ow voltage check 24V:Power supply voltage (Main Power supply voltage 1 (CN2-32)) is 12V [Low voltage detection]
Shutoff for Travel operation for continuous 100ms ( 24V (48V model) or 12V (24V model))
• Interruption of control voltage (loosening of bolt, connector)
H73 VOLTAGE-TRV 48V:Power supply voltage (Main Power supply voltage 1 (CN2-32)) is 24V TRV
b) H
igh voltage check for continuous 100ms • Failure of battery
Main contactor trip b) High voltage check • Faulty contact point (main contactor)
24V:Power supply voltage (Main Power supply voltage 2 (CN2-33)) is 33V • Mistake of model setting
48V:Power supply voltage (Main Power supply voltage 2 (CN2-33)) is 66V • Battery plug came off when the key SW is turned ON.
<How to check>
[SERVICE DSP. >DATA CHECKING>TRV CPU>BATT. VOLTAGE]
See P.119
110
Troubleshooting 6
• Battery plug came off during regeneration operation
a) Low voltage check
During contactor ON command,
a) L
ow voltage check 24V:Power supply voltage (Main Power supply voltage 1 (CN2-32) ) is 12V [Low voltage detection]
Shutoff for Hydraulic operation for continuous 100ms ( 24V (48V model) or 12V (24V model))
H74 VOLTAGE-HYD 48V:Power supply voltage (Main Power supply voltage 1 (CN2-32) ) is 24V HYD
b) H
igh voltage check for continuous 100ms • Failure of battery
Main contactor trip b) High voltage check • Faulty contact point (main contactor)
24V:Power supply voltage (Main Power supply voltage 2 (CN2-33) ) is 33V • Mistake of model setting
48V:Power supply voltage (Main Power supply voltage 2 (CN2-33) ) is 66V • Battery plug came off when the key SW is turned ON
<How to check>
[SERVICE DSP. >DATA CHECKING>HYD CPU>CONTROL VOLTAGE]
See P.122
• Excessive stationary steering
Current limiting value 10A a) Board temperature is 100°C
REDUCE DUTY-OPERATION- <How to check>
H75 * stationary steering is not possible, b) Root mean-square current (sampling 100ms) of latest 60 seconds is 15A DSP
EPS [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>BORAD TEMPERATURE]
travel steering is possible threshold.
See P.122
• Temperature of travel IPM module is 105°C.
Error is not detected when thermistor harness disconnection.
REDUCE DUTY-OPERATION-
H76 Travel limit (Stop at 120°C) Travel IPM thermistor is at 105°C for continuous 1000ms. TRV <How to check>
TRV
[SERVICE DSP. >DATA CHECKING>TRV CPU/TRV-FET TEMP.]
See P.119
• Temperature of the Hydraulic IPM module is 105°C.
Error is not detected when thermistor harness disconnection.
REDUCE DUTY-OPERATION-
H77 Hydraulic limit (Stop at 120°C) Hydraulic IPM thermistor is at 105°C for continuous 1000ms. HYD <How to check>
HYD
[SERVICE DSP. >DATA CHECKING>HYD CPU/HYD-FET TEMP.]
See P.122
a) D uring initial communication in set data, 1000ms have passed without
receiving initial value request after power supply relay is turned ON.
FAIL BUS SYSTEM-AOS b) During initial communication in set data, 1000ms have passed after receiving • Disconnection or mistake in connection of harness and OPT board
H78 Shutoff for Hydraulic operation DSP
TURN OFF KEY SWITCH first initial value request without receiving the completion flag. • Failure of main board, OPT board
c) When reception of control data is interrupted continuously for 1000ms after
receiving completion flag.
• Failure of main board V15 power source
<How to check>
H79 VOLTAGE-GATE Main contactor trip Gate voltage (CN2-36/CN2-37) is 10V for continuous 100ms. TRV
[SERVICE DSP. >DATA CHECKING>TRV CPU/FET-GATE VOL.]
See P.119
• Battery plug came off during regeneration operation
a) L
ow voltage check
24V: Control voltage (CN5-133) is 12V for continuous 100ms. [Low voltage detection]
48V: Control voltage (CN5-133) is 24V for continuous 100ms. ( 24V (48V model) or 12V (24V model))
H80 VOLTAGE-CTL DSP
b) High voltage check • Failure of battery
24V: Control voltage (CN5-133) is 33V. • Faulty contact point (main contactor)
48V: Control voltage (CN5-133) is 66V. • Mistake of model setting
• Battery plug came off when the key SW is turned ON
<How to check>
[SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>CONTROL VOLTAGE]
See P.126
111
6 Troubleshooting
<How to check>
H81 VOLTAGE-OUT1 Main contactor trip External output voltage 1 (5V) is 3.7V for continuous 100ms. HYD
[SERVICE DSP. >DATA CHECKING>HYD CPU/EXTERNAL PS VOL.>PS5V]
See P.122
• Short-circuit of harness in 5V power supply sensor
• Voltage drop of V5A power supply
H82 VOLTAGE-OUT2 Main contactor trip External output voltage 2 (5V) is 3.9V for continuous 100ms. HYD
<How to check>
[SERVICE DSP. >DATA CHECKING>HYD CPU/EXTERNAL PS VOL.>FUSE]
See P.122
• Defect of X1 relay coil
• Disconnection of X1 relay coil harness
FAIL BUS SYSTEM-TRV
H83 Shutoff for Travel operation Fail in communication between each CPU of main board. DSP • Defect of X1 relay contact point
TURN OFF KEY SWITCH
• Disconnection of CAN-BUS communication harness
• Defect of X1 relay coil
• Disconnection of X1 relay coil harness
FAIL BUS SYSTEM-HYD
H84 Shutoff for Hydraulic operation Fail in communication between each CPU of main board. DSP • Defect of X1 relay contact point
TURN OFF KEY SWITCH
• Disconnection of CAN-BUS communication harness
• EEPROM read failure when data is recovered by key SW OFF/ON.
• Data corruption when data is recovered by resetting the configuration.
a) Fail in reading data from memory • Failure of board
H85 FAIL BUS SYSTEM-MEMORY DSP
b) Fail in writting data to memory <How to reset the memory settings>
[SERVICE DSP. >SERVISE DISP.>MOMORY INITIAL>SETTING]
See P.116
RELEASE ACCEL LEVER TO
Shutoff for Travel operation Accelerator is turned ON at the time of turning key SW ON. TRV
NEUTRAL
ASSUME CURRECT STANDING Error display after one second of leaving seat (continuous), shutoff for travel
Shutoff for Travel operation TRV
POSITION operation after two seconds of leaving seat (continuous).
RELEASE HYD.LEVER TO
Shutoff for Hydraulic operation Hydraulic lever is turned ON at the time of turning key SW ON. HYD
NEUTRAL
a) Shutoff for Travel operation Battery front loading switch is turned ON when travel or hydraulic operation.
RETRACT THE BATTERY TRV
b) Shutoff for Hydraulic operation * Only for battery front loading model
REDUCE THE LOAD Load is heavier than configured load for continuous one second or more. DSP
REFILL HYDRAULIC OIL When fork oil shortage is detected within 2 seconds after key SW ON. DSP
REPLENISH REFINED WATER

Voltage is 2.0V for 20 times or more in 1000ms. DSP
FOR BATTERY
CHARGE BATTERY Battery indicator is detected level two or less. DSP
When "STOP" button of AOS switch is pressed.

FAIL OPERATION-AOS Shutoff for Hydraulic operation DSP
* Only AOS specification model
When inconsistency is found in configured fork height in memory mode.

RACK MISSET DSP
* Only AOS specification model
112
Troubleshooting 6
6- 3. Trouble when an error message does not appear

6-3-1. Trouble of error non-occurrence
The defects that occur if error cannot be detected or if there is a mistake in setting are mentioned below.
Trouble Possible Cause Reference
[Backlight OFF]
Failure of display
Failure of main board V12 power supply
Connector connection failed, 12V power supply harness
disconnected. (CN5-136, CN5-137)
Display does not work. [Backlight ON]
Failure of display
CAN-BUS communication harness disconnected. (CN5-156, CN5-164)
Display termination resistor harness is not connected.
* Truck can be operated even without display.
*S ettings cannot be changed Possible by using maintenance tool
* Built-in charger not available Charge by stationary charger
Failure of display
Flat cable disconnected, contact failed.
Sheet switch does not Defective sheet switch
work. * Truck can be operated even sheetswitch does not work.
*S ettings cannot be changed Possible by using maintenance tool
* Built-in charger not available Charge by stationary charger
Load meter (lift pressure sensor) Load meter (lift pressure sensor) option is not set. See page 58
is not displayed correctly. Load meter (lift pressure sensor) is not set. See page 42.
Laser pointer does not Laser pointer option is not set. See page 56.
work. Laser pointer operation is not set. See page 20.
Voltage error occurs when
Mistake of model setting See page 47.
key SW turned ON.
Hour meter does not work. Hour meter START is not set. See page 40.
After tire replacement, tire diameter is not corrected. Hence, anti-
See page 41.
slip control is not working correctly.
Slowest speed limit is enabled.
(Speed limit, speed control, LIMITED SPEED (IO))
Traveling speed is slow.
Brake wire is stretched, brake disk is not fully released.
Traction motor speed sensor failed and disconnected.
See page 119.
[SERVICE DSP. >DATA CHECKING>TRV CPU>TRV-MOTOR SPEED]
N mode or ECO mode are selected.
Start speed is slow for
Front wheel (R) speed sensor failed and disconnected.
about 5 seconds, and then
[SERVICE DSP. >DATA CHECKING>TRV CPU> See page 119.
achieve to full speed.
F-WHEEL SPEED R]
(The plugging force is weak or none.)
Front wheel (R) speed sensor and Front wheel (L) speed sensor
The start speed is fast only failed and disconnected.
for few seconds, and then
[SERVICE DSP. >DATA CHECKING>TRV CPU>
slow down. See page 119.
F-WHEEL SPEED R]
*F or high-performance
model only [SERVICE DSP. >DATA CHECKING>HYD CPU>
See page 122.
F-WHEEL SPEED L]
Steering force of left and Neutral of torque sensor is shifted.
See page 126.
right are different. [SERVICE DSP. >DATA CHECKING>EPS/DSPCPU>STEERING SENSOR]
LMT. SPEED (TURN) is set to slow speed.
If terminal of lift height detection switch is disconnected, speed
decelerates by 1km/h during rotation.
Turning speed is slow. 㼂㻡㻢㻝㻥㻞 Power supply (+5V)
㟁※㻔㻗㻡㼂㻕 See page 48.
㧗ᥭ㧗䝬䝇䝖䛾䜏
Only for high lift height mast 㻭㻢㻢㻝㻥㻥㼀 ಙྕ
Signal
White
䝅䝻
㻳㻺㻰㻢㻝㻤㻞㻳㻺㻰
Black
䜽䝻
㻿㻞㻟㻢㻝㻣㻜㼀 ᥭ㧗᳨ฟ䝇䜲䝑䝏
Lift height detection switch
Charging screen does not display

Built-in charger option is OFF. See page 59.
when charging plug is connected.
113
6 Troubleshooting
6- 4. Error history memory

6-4-1. Error history memory (LATEST 10)
<Recently detected latest 10 errors>
The special command ; Press the switch

in order of
while pressing switch on the
manager screen.
lSERVICE DSP. screen
Press
to select ERROR HISTORY.
131T0322
lERROR HISTORY screen
Press
to select LATEST 10 .
131T0323
lLATEST10 screen
Display and select 10 errors with

Error ID
131T0326
Display the detection date, time

and error count (total number of
times) of the selected error ID.
131T0327
NOTE When key switch is turn OFF, the current error is

recorded. Next time when key is turned ON, if the same
error occurs within 2 seconds, the error history will not
be saved considering that the error will continue.
114
Troubleshooting 6
6-4-2. Error history memory (ALL)

<All errors detected in past>
in order of
manager screen.
Press
to select ERROR HISTORY.
131T0322
lERROR HISTORY screen
Press to select ALL.

131T0330
lALL screen
$ $ % % % Display a list of Error IDs and
select
% & & ) )
* Highlighted: Error is displayed
) + + + +
131T0376
131T0332
Display the detection date, time and error count (total

number of times) of the selected error ID.
NOTE Error occurrence date and time is updated to the most recent date
l
and time when error occurs.
lWhen key switch is turn OFF, the current error is recorded. Next time when
key is turned ON, if the same error occurs within 2 seconds, the error
history will not be saved considering that the error will continue.
115
6 Troubleshooting
6-4-3. Memory initialize (Setting/error history reset)

Reset each setting or error history.
in order of
manager screen.
Press to select
MEMORY INITIAL.
131T0335
lEMEMORY INITIALIZE selection screen
Press to select SETTING

or ERROR.
Item Details
131T0336
Resets all settings to default
values.
SETTING
* Model is reset to FBR15.
lEMEMORY INITIALIZE screen * Error history is not reset.
ERROR Resets only the error history.
Select "YES" to initialize.

131T0337
CAUTION l It takes about 1 second to complete the memory

initialization. In the meantime, do not perform
operations such as turning key OFF and turning
power off. Data might get damaged.
l If initialization is done with SETTING, you need to set
again.
See "1-3-1. Settings for main board replacing /
Memory initialization" on page 4.
116
Troubleshooting 6
6- 5. I / O monitor check
6-5-1. Display method
in order of
manager screen.
Press
to select DATA CHECKING.
131T0344
Press to select CPU

according to the measurement
item.
131T0345
NOTE OPT CPU is displayed only when AOS option setting is

ON.
117
6 Troubleshooting
6-5-2. Travel CPU monitor (TRV CPU)

l TRV CPU (Travel CPU monitor) screen
'$7$
㸦759&38㸧 02725&855(17 )(77(03(5$785(
75902725&855(17 㸦75$9(/㸧㸦75$9(/㸧

759)(77(03
759027257(03 $506 GHJ
'$7$
㸦759&38㸧 &855(176(1625 $&&(/(5$7256(1625
7&856(1625 㸦75$9(/㸧

$&&(/6(1625 6(1625ࠉࠉ9 6(1625ࠉࠉ9
6(162563$5( 6(1625ࠉࠉ9 6(1625ࠉࠉ9
'$7$
㸦759&38㸧 %$77(5<92/7$*( *$7(92/7$*(
%$7792/7$*( %()25($'-9 㸦)(702'8/(㸧

)(7*$7(92/ &217$&7259
28738792/635 )86(ࠉࠉ9 9
'$7$
㸦759&38㸧 %5$.(6:,7&+ 2,66:,7&+
%5$.(6:,7&+

2,66:,7&+
,138792/63$5( 9 9
'$7$
㸦759&38㸧 0272563((' )5217:+((/63(('
7590272563((' 㸦75$9(/㸧㸦5,*+7㸧

):+((/63(('5
&2817 &2817
'$7$
㸦759&38㸧 ,2759 ,2759>3257$@
,2 3257$ +(; %&$

5$0 3257% %,1$5<
3257'
15 Bit 0 Bit
131T0603
118
Troubleshooting 6
l TRV CPU (Travel CPU monitor)
Item Details/Connector – Pin No. Check method

TRV-MOTOR Traction motor effective current Traction motor current measurement See P.89
CURRENT
TRV-FET TEMP. Travel IPM module temperature Error "H76 REDUCE DUTY-OPERATION-TRV" is occurred
when temperature is 105°C.
Travel stopped when temperature is 120°C.
After this error is occurred, it was resolved by detecting
temperature 100°C.
Stop operation and decrease temperature for a while.
T-CUR. SENSOR Travel current sensor voltage Normal: 2.5V±0.488V with SENSOR1 and 2 (neutral)
(neutral 5.0V) Error condition: In other than normal range, "B12 / B13
SENSOR1:CN2-58 C.SENSOR_U/W-T" error occur.
SENSOR2:CN2-66
ACCEL. Accelerator sensor voltage Normal: 2.5V±0.03V with SENSOR 1 and 2 in accelerator neutral
SENSOR (neutral 2.5V) Error condition:
SENSOR1:CN4-125 (1) Voltage of SENSOR 1 or 2 is equal to or 4.5V or 0.5V
SENSOR2:CN4-126 (2) Sum of SENSOR 1 and 2 is out of range 5.0V±1.25V
"B14 ACCELERATOR" error occurs due to (1) or (2).
Adjustment : See P.97
BATT. VOLTAGE Battery voltage • [CONTACTOR]: Normal: Battery voltage (24/48V)

[CONTACTOR]: Error condition: 24V model: 9V
CN2-32 (Contactor contact) 48V model: 18V. Error occurred in A01
[FUSE]: connector (main)
CN2-33 (battery voltage) • [FUSE]: Normal: Battery voltage (24/48V)
Error condition: When F1 fuse (325A) is melted, error
occurred in A02 fuse (main).
㻞㻠㻛㻠㻤㼂㻹㻭㻵㻺
Line Connector
䝷䜲䞁
䝁䝛䜽䝍
㻯㻼㼁
No.
㻺㼛㻚㻯㻺㻌䕕䝢䞁㻺㼛㻚
Pin No.
RedBlack#
䜰䜹䜽䝻䠀
㻮㻞㻞㻟㻞㼀㻘㻴 Contactor
䝁䞁䝍䜽䝍᥋Ⅼ contact
䜰䜹
㻹㻯
Red
YellowRed#
䜻䜰䜹䠀
㻮㻟㻞㻟㻟㼀㻘㻴 Battery
䝞䝑䝔䝸㟁ᅽ voltage
㻲㻝
㻗
㻟㻞㻡㻭
FET-GATE VOL. Gate drive circuit power supply Normal: Approximately 15V
voltage CN2-36 & CN2-37 Error condition: gate voltage error occurs in H79 when voltage is 10V
BRAKE SWITCH Brake switch Normal: Depress the brake pedal 0V / Release the brake pedal 5V
CN5-140 Error: 5V does not change even if pedal is depressed
Travel not possible
* Brake switch failed, harness disconnected
OIS SWITCH OIS switch sensor voltage Normal:Ride forklift truck (Brake pedal depress) CN4-105 signal
OIS SWITCH: voltage 2.5V±0.6V
CN4-105 (Sensor signal Get off forklift truck (brake pedal release) CN4-105
voltage) signal voltage 1.0V±0.4V
Error condition: Error occurs in B16 OIS sensor when sensor signal
voltage CN4-105 is 4.5V or 0.5V.
TRV-MOTOR Traction motor encoder count Normal: When traction motor (brake disc) is rotated 1 turn travel
SPEED (Number of output pulses of forward direction, the count increases from 0 to 256.
traction motor speed sensor) Error: Count does not increase (disconnection, sensor failure)
* Travel speed becomes slow if traction motor speed sensor
fails and sensor harness disconnects.
F-WHEEL Right front wheel encoder Normal:When right load wheel rotates 1 turn in forward direction,
SPEED R count the count increases from 0 to 180.
(Number of output pulses of Error: Count does not amount to 180 (disconnection, sensor failure)
* If front wheel speed sensor is defective or sensor harness is
speed sensor of front wheel (R))
disconnected, the start speed gets slower for a few seconds
and then the speed increases to maximum.
119
6 Troubleshooting
6-5-3. Travel I/O port table

Address Pin No Bit IN/OUT Initial Contents Remarks
68 1 IN L Over-current detection
66 3 IN L Serial communication receive
65 4 OUT L Serial communication transmission
Traction motor speed sensor phase
62 6 IN L 0 or 5V
A
Traction motor speed sensor phase
61 7 IN L 0 or 5V
PA B
Front wheel (R) speed sensor phase
60 8 IN L 0 or 5V
A
Front wheel (R) speed sensor phase
58 9 IN L 0 or 5V
B
56 10 OUT L Over-current selection
46 2 IN L POE0
45 3 IN L High lift height detection
CANbus
CANbus date transmission CH0
42 6 OUT L communication
PB (control)
(between CPUs)
CANbus
41 7 IN L CANbus date receive CH0 (control) communication
(between CPUs)
34 4 IN L Neutral
33 5 IN L Forward
32 6 IN L Backward
PD ON when "L"
29 9 IN L Travel inhibitor (CN3-74)
from 1 to 0
ON when "L"
28 10 IN L Travel speed reduction (CN3-73)
from1 to 0
25 2 OUT H Suspension lock

24 3 OUT H Forward transmission
23 4 OUT H Backward transmission
20 7 OUT L LED receive
19 8 OUT H Brake transmission
Travel gate signal output When chopper
17 9 OUT H
(phase U lower) stopped PE9
15 11 OUT H
E-L (phase U upper) stopped PE11
13 12 OUT H
(phase V lower) stopped PE12
12 13 OUT H
(phase W lower) stopped PE13
10 14 OUT H
(phase V upper) stopped PE14
9 15 OUT H
(phase W upper) stopped PE15
8 16(1Bit) OUT L Right front wheel brake H-bridge circuit output
7 17(2Bit) OUT L Right front wheel brake H-bridge circuit output
E-H
6 18(3Bit) OUT L Left front wheel brake H-bridge circuit output
4 20(5Bit) OUT L Left front wheel brake H-bridge circuit output
H : High 1 L : Low 0
120
Troubleshooting 6
6-5-4. Hydraulic CPU monitor (HYD CPU)

l HTD CPU (Travel CPU monitor) screen
'$7$㸦+<'&38㸧 02725&855(17 )(77(03(5$785(

+<'02725&855(17 㸦+<'㸧㸦+<'㸧

+<')(77(03
+<'027257(03 $506 GHJ
'$7$㸦+<'&38㸧 &855(176(1625 35(6685(6(1625 +25,=216(1625

+&856(1625 㸦+<'㸧㸦/,)7㸧㸦7,/7㸧

/,)735(66(1625 6(1625ࠉࠉ9
7,/7+5=16(1625 6(1625ࠉࠉ9 9 9
'$7$㸦+<'&38㸧 &21752/92/7$*( (;7(51$/3692/

&21752/92/7$*( %2$5')86(&+(&.

(;7(51$/3692/ 3699
)$192/7$*( 9 )86(ࠉࠉ9
'$7$㸦759&38㸧 )5217:+((/63(('
):+((/63(('/ 㸦/()7㸧

&2817
'$7$㸦+<'&38㸧 ,2+<' ,2+<'>3257$@

,2 3257$ +(; &$

5$0 3257% %,1$5<
3257'
15 Bit 0 Bit 131T0605
121
6 Troubleshooting
l HYD CPU (Hydraulic CPU monitor)

HYD-MOTOR Hydraulic motor effective See hydraulic motor current measurement See P.91
CURRENT current
HYD-FET TEMP. Hydraulic IPM Error "H77 REDUCE DUTY-OPERATION-HYD" occurs when
Module temperature temperature is 105°C.
Hydraulic stopped when temperature is 120°C.
After this error is occurred, it was resolved by detecting
temperature 100°C.
Stop operation and decrease temperature for a while.
H-CUR. Hydraulic current sensor Normal: 2.5V±0.488V with SENSOR1 and 2 (neutral)
SENSOR voltage (neutral 5.0V) Error condition: In other than normal range, "C22/C23
SENSOR1:CN2-54 C.SENSOR_U/W-H" error occur.
SENSOR2:CN2-62
LIFT-PRES. Lift Sensor signal voltage (CN4-124)
SENSOR pressure sensor voltage When 4.7V and 0.3V , "F52 VALVE SENSOR" error
CN4-124 occurs.
TILT-HRZN. Tilt
SENSOR Horizontal sensor voltage
CONTROL Control voltage Normal: Battery voltage (24/48V)

VOLTAGE Travel/ hydraulic CPU control Error condition:Under following conditions, "H73 VOLTAGE-
voltage TRV/ H74 VOLTAGE-HYD" error occur.
a) Low voltage check
a) Low voltage check: CN2-32 During contactor ON command
b) High voltage check: CN2-33 24V : voltage 12V for continuous 100ms
48V : voltage 24V for continuous 100ms
b) High voltage check
24V : 33V detected
48V : 66V detected
EXTERNAL PS External output 5VPower-supply PS5V :
VOL. voltage (V5, V5A) Normal: 5V
PS5V: 5V series sensor power FUSE :
supply voltage Normal: 5V
FUSE: 5V system sensor power
supply fuse in main board
F-WHEEL Left front wheel encoder count Normal: When left load wheel rotates 1 turn in reverse direction,
SPEED L Number of output pulses of the count increases from 0 to 180.
speed sensor of front wheel (L) Error: Count does not amount to 180 (disconnection, sensor
*Equipped in high-performance failure)
model only * If both of front wheel speed sensor (L) and (R) are
disconnected, the start speed gets slower for a few seconds
and then the speed increases to maximum.
122
Troubleshooting 6
6-5-5. Hydraulic micro switch I / O monitor check
Press
to select PUMP(HYD) CPU.
131T0609
lDATA CHECKING screen (Lower layer)

'$7$㸦+<'&38㸧
,2 Press to select I/O.

5$0
131T0605
lDATA CHECKING screen (Lower layer)

,2㸦+<'㸧
3257$

3257%
3257' Press to select PORT "D".
131T0606
lMonitor screen 131T0607
,2+<'>3257'@

+(; &$ Check according to the following
%,1$5< table

8 Bit 0 Bit
Connector-
Bit IN/OUT Item Remarks
Pin No.
0 IN CN4-104 Lift 1 switch When SW is ON, 0 bit changes from 1 to 0 (terminal voltage 5V 0V)
1 IN CN4-103 Lift 2 switch When SW is ON, 1 bit changes from 1 to 0 (terminal voltage 5V 0V)
2 IN CN4-102 Tilt switch When SW is ON, 2 bit changes from 1 to 0 (terminal voltage 5V 0V)
3 IN CN4-101 Reach switch When SW is ON, 3 bit changes from 1 to 0 (terminal voltage 5V 0V)
4 IN CN4-100 Att.1 switch When SW is ON, 4 bit changes from 1 to 0 (terminal voltage 5V 0V)
5 IN CN6-169 Att.2 switch When SW is ON, 5 bit changes from 1 to 0 (terminal voltage 5V 0V)
Tilt horizontal
6 IN CN6-168 When SW is ON, 6 bit changes from 1 to 0 (terminal voltage 5V 0V)
stop switch
Battery front
8 IN CN4-123 When SW is ON, 8 bit changes from 1 to 0 (terminal voltage 5V 0V)
loading switch
123
6 Troubleshooting
6-5-6. Hydraulic I/O port table

68 1 IN L Over-current detection
66 3 IN L Serial communication receive
65 4 OUT L Serial communication transmission
62 6 IN L Spare speed sensor phase A 0 or 5V
PA 61 7 IN L Spare speed sensor phase B 0 or 5V
60 8 IN L Front wheel (L) speed sensor phase A 0 or 5V
58 9 IN L Front wheel (L) speed sensor phase B 0 or 5V
46 2 IN L POE0
CANbus date transmission CH0
PB 42 6 OUT L
(control)
41 7 IN L CANbus date receive CH0 (control)
40 0 IN L Lift 1 switch ON when "L" from 1 to 0

38 1 IN L Lift 2 switch ON when "L" from 1 to 0
37 2 IN L Tilt switch ON when "L" from 1 to 0
35 3 IN L Reach switch ON when "L" from 1 to 0
PD 34 4 IN L Attachment 1 switch ON when "L" from 1 to 0
33 5 IN L Attachment 2 switch ON when "L" from 1 to 0
32 6 IN L Tilt horizontal stop switch ON when "L" from 1 to 0
31 7 IN L Lift lock ON when "L" from 1 to 0
30 8 IN L Battery front loading switch ON when "L" from 1 to 0
27 0 OUT H Main contactor

27 1 OUT H Lift lock valve
25 2 OUT H Fan
20 7 OUT L LED input ON when "H" from 1 to 0
Hydraulic gate signal output When chopper
17 9 OUT H
(phase U lower) stopped PE9
15 11 OUT H
(phase U upper) stopped PE11
E-L
13 12 OUT H
(phase V lower) stopped PE12
12 13 OUT H
(phase W lower) stopped PE13
10 14 OUT H
(phase V upper) stopped PE14
9 15 OUT H
(phase W upper) stopped PE15
124
Troubleshooting 6
6-5-7. EPS/DSP CPU monitor (EPS/DSP CPU)

l EPS/DSP CPU (EPS/display CPU monitor) screen
'$7$㸦(36'63&38㸧 02725&855(17(36 %2$5'7(03(5$785( '5,9($1*/(
(3602725&855(17 /,0,7$

%2$5'7(03(5$785( $'-GLJLW GHJV
'5,9($1*/( &85$$ GHJ GHJ
'$7$㸦(36'63&38㸧 67((5,1*6(1625 $1*/(6(1625 %$77(5</(9(/

67((5,1*6(1625 㸦+$1'/(6,'(㸧㸦'5$,9(6,'(㸧 6(1625

$1*/(6(1625 9
%$77/9/6(1625 9 9 9
'$7$㸦(36'63&38㸧 &21752/92/7$*( 3/8*7(03(5$785(

&21752/92/7$*(

:,1.(5/$0392/ %()25($'- 9 3/8* GHJ
3/8*7(03(5$785( $)7(5$'- 9 3/8* GHJ
'$7$㸦(36'63&38㸧 &+$5*(&2817
&+$5*(&2817 727$/

1250$/&+*
/2:7(03
'$7$㸦(36'63&38㸧 ,2㸦'63㸧 ,2'63>3257$@

,2 3257$ +(; )(

5$0 3257% %,1$5<
3257'
131T0608
15 Bit 0 Bit
125
6 Troubleshooting
lEPS/DSP CPU (display CPU monitor)

EPS-MOTOR LIMIT: Limit value ADJ
CURRENT ADJ: Neutral correction
value Normal: Within ±106 digit =Current sensor neutral correction value is
within ± 5A.
CUR : EPS motor current
Error condition:"D33 C.SENSOR-EPS" error occurs out of above range.
/ root-mean-square
current Sensor inside main board is defective.
BOARD EPS board temperature "H75 REDUSE DUTY-OPERATION-EPS" error occurs at 100 °C
TEMPERATURE (near EPS FET) When error occurs, current limiting value is controlled at 10A.
DRIVE Drive angle (Straight 0°), Display of drive turning angle.
ANGLE speed at drive angle
STEERING Torque sensor Normal: 2.5V±0.1V when the steering wheel does not operated.
SENSOR (neutral 2.5V) Error condition: "D31 T.SENSOR-EPS" error occurs is out of range of
CN5-162 (Sensor signal 0.5V to 4.5V.
voltage) Adjustment : See P.82, P.99
ANGLE Turning angle (drive angle) Normal: B
oth SENSOR 1 and 2 are in 2.5V±0.1V when drive wheel is
SENSOR sensor (straight 2.5V) in straight position.
SENSOR1 : CN5-161 Error condition: "F50 STEER. SENSOR" error occurs when SENSOR 1
SENSOR2 : CN5-160 or 2 is out of range of 0.5V to 4.5V.
Adjustment : See P.98
BATT. LVL. Liquid level gauge sensor Normal: 5V output
SENSOR voltage Error condition: When outputting pulse waveform (battery liquid level is
CN3-97 low), "REPLENISH REFINED WATER FOR BATTERY
(option)" is displayed.
CONTROL Control voltage Normal: Battery voltage (24/48V)
VOLTAGE (Before and after correction) Error condition: "H80 VOLTAGE-CTL" error occurs when detection
CN5-133 continues for 100ms.
24V model: 12V or 33V
48V model: 24V or 66V
PLUG Charger plug temperature Error condition:
TEMPERATURE During charging mode, 110°C temperature of charger plug is detected.
During charging mode, -999°C temperature of charger plug is
detected.(disconnection)
During charging mode, that charger plug temperature is -44°C and
difference of two lines is 10°C is detected.
In above conditions, "G64 PLUG-CHG CHARGE STOPPED" error
occurs.
CHARGE Charge count Display charge count
COUNT
126
Troubleshooting 6
6-5-8. DSP I/O port table

Serial communication receive CH0
69 0 IN L
(EEPROM)
Serial communication transmission
68 1 OUT L
CH0 (EEPROM)
Serial clock transmission CH0
67 2 OUT L
(EEPROM)
Serial communication receive CH1
66 3 IN L Monitor receive
(Debugging monitor)
PA Serial communication transmission
65 4 OUT L Monitor transmission
CH1 (Debugging monitor)
63 5 IN H Key start (CN5-148) ON when "L" from 1 to 0
56 10 IN H Headlight switch (CN5-147) ON when "L" from 1 to 0
55 11 IN H Horn switch (CN5-146) ON when "L" from 1 to 0
54 12 IN H Tilt level sensor ON when "L" from 1 to 0
53 13 IN H Charging interlock switch (only for RB) ON when "L" from 1 to 0
52 14 IN H Chopper error detection 1 Phase A H when "L"
51 15 IN H Chopper error detection 2 Phase AA H when "L"
CANbus date transmission CH1 CANbus communication

49 0 OUT L
(LCD) (LCD)
CANbus communication
47 1 IN L CANbus date receive CH1 (LCD)
(LCD)
46 2 IN L EPS current hard trip POE
PB AC (Charger plug ) connection Three-phase AC
43 5 IN L
detection detection
CANbus date transmission CH0 CANbus communication
42 6 OUT L
(control) (between CPUs)
CANbus communication
41 7 IN L CANbus date receive CH0 (control)
(between CPUs)
40 0 IN H Key switch (CN5-149) ON when "L" from 1 to 0

38 1 IN H Parking brake switch (only for FB) ON when "L" from 1 to 0
37 2 IN H Brake oil level sensor (only for FB) ON when "L" from 1 to 0
35 3 IN H Hydraulic oil level sensor (CN6-173) ON when "L" from 1 to 0
PD
34 4 IN H Over-load sensor (CN6-172) ON when "L" from 1 to 0
32 6 IN L Serial communication receive CH2 (RTC)
31 7 OUT L Serial communication transmission CH2 (RTC)
30 8 OUT L Serial clock transmission CH2 (RTC)
27 0 OUT H Electromagnetic switch output ON when "L" from 1 to 0

27 1 OUT H Power supply relay output ON when "L" from 1 to 0
24 3 OUT H AUTO charging LED ON when "L" from 1 to 0
23 4 OUT H EQUAL charging LED ON when "L" from 1 to 0
22 5 OUT H RESERVE charging LED ON when "L" from 1 to 0
21 6 OUT H Headlight output ON when "L" from 1 to 0
E-L
20 7 OUT H MCPU (LED) ON when "L" from 1 to 0
18 10 OUT H Horn output ON when "L" from 1 to 0
13 12 OUT L EPS gate signal output
12 13 OUT H Directional switch (L) output ON when "L" from 1 to 0
10 14 OUT L EPS gate signal output
9 15 OUT H Directional switch (R) output ON when "L" from 1 to 0
8 16(0Bit) OUT L 11V power supply (LCD power supply) ON when "H" from 0 to 1
3V power supply (laser pointer
7 17(1Bit) OUT L ON when "H" from 0 to 1
power supply)
E-H
6 18(2Bit) OUT H Fan output ON when "L" from 1 to 0
4 20(4Bit) OUT H EEPROM chip selection Writing when "L"
2 21(5Bit) OUT L RTC chip enable ON when "H" from 1 to 0
127
MEMO
128
7. Wiring (Diagrams) 24/48V MAIN MAIN MAIN
FBR-80 Service data
No.
Device
name
Connector
pin No.
Service data
1 1.Rated voltage
LINE CONNECTOR LINE CONNECTOR
(OPT.) LINE CONNECTOR
No. CN □ PIN No.
CPU
No. CN □ PIN No.
CPU
ONLY FOR TRUCKS WITH No. CN □ PIN No.
CPU Battery voltage 24/48V type (battery
CHARGE MONITORING SYSTEM voltage)
RDBK#
T,H INPUT FOR CONTACT OF MAIN CONTACTOR RDBK# +12V RDYE P5A 5 155 +5V
RDBK
B2 2 32 (+) 24/48V V12 2 47 CN5-134(+) 2.Terminal voltage
WHRD# RD
TIU TIU 2 58 T SIGNAL PHASE U M3 6 200 M SIGNAL
MC
RD
YERD#
B3 2 33 T,H INPUT FOR VOLTAGE OF BATTERY
(+) 24/48V
BK#
GND 2 43 GND
CURRENT
SENSOR
BK
GND 5 163 GND Red Green CN Key OFF :0V
F1
+ CURRENT
SENSOR
TIW
RDBK#
BURD#
V12
TIW
2
2
46
66 T
+12V
SIGNAL
FOR CHARGE
PHASE V
WH
V5
A5
6
5
193
159
+5V
M SIGNAL 1 X1 relay
5-134(+) Key IG, Start :24/48V type
FOR TRV BK#
325A GND 2 42 GND GND 6 183 GND (battery voltage)
CURRENT
RD
CN5-135(-) CN Key OFF :0V
RD# V15 2 36 +15V SENSOR RDBK# M2 6 174 M MULTI INPUT2
BK# FOR HYD WHBU#
V12 2 45 +12V PHASE U BK
Brown Yellow 5-135(-)
GND 2 34 GND HIU HIU 2 54 H SIGNAL THERMISTOR GND 6 180 GND Key IG :24/48V type
TU WHRD# TUP 2 63 T OUTPUT FOR SIGNAL OF UPPER OF PHASE U BK#
GND 2 41 FOR CHARGE
TIU GND WH
BURD# TUN 2 55 T OUTPUT FOR SIGNAL OF LOWER OF PHASE U RDBK# (OPT.) M1 6 175 M MULTI INPUT1 (battery voltage)
M TV WH# V12 2 44 +12V PHASE V
MOS-IPM TVP 2 57 T OUTPUT FOR SIGNAL OF UPPER OF PHASE V BU# After key Start :0V
3 BUWH#
TVN 2 56 T OUTPUT FOR SIGNAL OF LOWER OF PHASE V HIW HIW 2 62 H SIGNAL V5 6 190
BK# +5V
WHBU# GND 2 40 GND
TW BU#
TWP 2 65 T OUTPUT FOR SIGNAL OF UPPER OF PHASE W A13 6 188 H SIGNAL CN1-11(+) 1.Coil rated voltage :48V/24V type :24V
TRV MOTOR BNYE# TWN 2 64 T OUTPUT FOR SIGNAL OF LOWER OF PHASE W
2.Terminal voltage
YERD# TH1 2 49 T INPUT FOR THERMISTOR RDYE#
A14 6 189 H SIGNAL Suspension Red Green
TIW FO1 2 38 T INPUT FOR OUTPUT OF ERROR SPEED SENSOR V5A 3 90 H +5V 2
BU#
RA2 3 83 H PHASE A SIGNAL TH2 6 198 T SIGNAL lock valve CN1-21(-) CN1-11(+) :Battery voltage (24/28V)
FOR WH#
RB2 3 93 H PHASE B SIGNAL CN1-22(-) :24/48V type battery voltage 24V
FRONT WHEEL(LEFT) BK#
GND 3 80 H GND
TH4 6 197 H SIGNAL Brown
RD# V15 2 37 +15V 1.Coil rated voltage
BK# GND
(ONLY FOR FBR(M)-H80)
V5A 3 91 H +5V B4 3 87 H INPUT FOR WIPER SWITCH
HU WHRD# GND 2 35 RA3 3 84 H PHASE A SIGNAL 48V type : 12.0V 24V type : 6.0V
HIU HUP 2 60 H OUTPUT FOR SIGNAL OF UPPER OF PHASE U CN1-2(+)
BURD# SPEED SENSOR RB3 3 94 H PHASE B SIGNAL
M HV HUN 2 59 H OUTPUT FOR SIGNAL OF LOWER OF PHASE U S3 3 96 M INPUT FOR PARKING BRAKE SWITCH 2.Terminal voltage
MOS-IPM
WH#
HVP 2 52 H OUTPUT FOR SIGNAL OF UPPER OF PHASE V
FOR FRONT WHEEL GND 3 81 H GND Red Green
3 BUWH#
H
(RIGHT) S4 3 95 M INPUT FOR BRAKE OILLEVEL CN1-2(+) :After key Start : 24/48V
WHBU# HVN 2 61 OUTPUT FOR SIGNAL OF LOWER OF PHASE V RDYE#
V5A 3 92 T +5V Main
HW HWP 2 53 H OUTPUT FOR SIGNAL OF UPPER OF PHASE W BURD#
RA4 3 85 T PHASE A SIGNAL S16 3 77 T INPUT FOR NEUTRAL SWITCH 3 type (battery voltage)
HYD MOTOR
BU#
HWN 2 51 H OUTPUT FOR SIGNAL OF LOWER OF PHASE W WHRD# contactor CN1-2(-)
BKYE#
TH3 2 50 H BK#
RB4 3 86 T PHASE B SIGNAL S17 3 76 T INPUT FOR FWD SWICH CN1-2(-) :48V type :36V (battery voltage 12V)
WHBK# INPUT FOR THERMISTOR GND 3 82 T GND Brown
HIW FO2 2 39 H INPUT FOR OUTPUT OF ERROR S18 3 75 T INPUT FOR RVS SWITCH 24V type :18V (battery voltage 6V)
White
WHBK
3.Coil resistance value
F2 125V S5 6 173 M INPUT FOR HYDRAULIC OILLEVEL
RD▲ MP 8 B1 M INPUT FOR EPS POWER SUPPLY(+) 0.022μ BNBK 48V type :36Ω±1Ω 24V type :9Ω±0.5Ω
BU▲
S6 6 172 M INPUT FOR OVERLOAD
1.Coil rated voltage 48V/24V type : 12V
40A K1 8 B2 M INPUT FOR EPS POWER SUPPLY(-) YEBK
RDYE# V5A 4 117 T +5V S21 3 74 T INPUT FOR TRV-LOCK CN1-12(+)
WH▲ 2.Terminal voltage
EPS MOTOR M BK▲
A 8 A1 M OUTPUT FOR EPS MOTOR(A)
SPEED SENSOR
WH#
BU#
RA1 4 127 T PHASE A SIGNAL BUBK
S22 3 73 T INPUT FOR LIFT-LOCK Lift lock Red Green CN1-12(+) :24/48V type (battery voltage)
AA 8 A2 M OUTPUT FOR EPS MOTOR(AA) FOR TRV MOTER BK#
RB1 4 128 T PHASE B SIGNAL
S30 6 168 H INPUT FOR STOP OF TILT LEVEL 4
F5 F4 GND 4 107 T GND BURD
valve CN1-22(-) CN1-22(-) :48V type :36V (battery voltage 12V)
10A 10A S31 3 89 H INPUT FOR LIFT LOCK
ONLY FOR TRUCKS WITH CHARGER RDYE# V5 4 121 +5V Yellow Blue :24V type :12V (battery voltage 12V)
POTENTIOMETER WHRD#
A3 5 161 M SIGNAL 1 S33 3 88 H INPUT FOR SPARE
FOR STEERING BU# BK
ANGLE DETECION BURD#
GND 4 111 GND GND 3 79 GND
A4 5 160 M SIGNAL 2
TO TRANSFORMER
WH䕧 MC 7 4 M OUTPUT FOR MAGNETIC CONTACTOR RDYE# +5V
MC WH#
V5 4 120 V5 6 192 +5V
COIL VOLTAGE:AC200V/AC400V RD䕧
R 7 1 M INPUT FOR DETECTION OF BK#
A7 4 125 T SIGNAL 1 ONLY FOR HIGH-MAST (over 4.5m) A6 6 199 T SIGNAL
RDGN
BK䕧 AC POWER SUPPLY POTENTIOMETER GND 4 110 GND WH

S 7 2 M FOR ACCELERATOR BU#
GND 6 182 GND
A8 4 126 T SIGNAL 2 BK
S23 6 170 T INPUT FOR SWITCH OF HIGH-MAST
DO1 5 154 M OUTPUT FOR AUTO LED OF CHARGER <NOTE>
1.EACH LEAD WIRE MARKED WITH # OR ▲ OR 䕧 HAVE DIFFERENT DIAMETERS.
EMERGECY SWITCH
DO2 5 153 M OUTPUT FOR EQUAL LED OF CHARGER When switch is turn on : S15 6 171 M INPUT FOR SPARE
BUYE INPUT FOR HEAD Turning speed is reduced 1 km
DO3 5 152 M OUTPUT FOR RESERVE LED OF CHARGER S7 5 147 M LAMP SWITCH SW OFF:5V Reach speed is reduced 2 S34 6 167 H INPUT FOR SPARE
YERD ON :0V Travel / hydraulic acceleration response is limited 90%.
M S8 5 146 M INPUT FOR HORN SWITCH
S10 5 144 INPUT FOR AUTO SWITCH OF CHARGER
BK
D1 6 179 M INPUT FOR SPARE HARNESS COLOR GROUND
S11 5 143 M INPUT FOR EQUAL SWITCH OF CHARGER GND 4 106 GND
D2 6 178 M INPUT FOR SPARE STRIPE
BUWH#
S12 5 142 M INPUT FOR RESERVE SWITCH OF CHARGER S24 4 104 H INPUT FOR LIFT 1 SWITCH D3 6 177 T INPUT FOR SPARE BK BLACK YE YELLOW BN BROWN
WHBU#
S13 5 141 M INPUT FOR STOP SWITCH OF CHARGER S25 4 103 H INPUT FOR LIFT 2 SWITCH D4 6 176 H INPUT FOR SPARE
S14 4 129 M INPUT FOR CHARGER INTERLOCK SWITCH
BNYE#
S26 4 102 H INPUT FOR TILT SWITCH MICRO SW GND 3 78 GND WH WHITE GN GREEN BU BLUE
RDBU
YERD# OFF:5V Ex. 'BKWH' = GROUND:BLACK,

GND 4 115 GND S27 4 101 H INPUT FOR REACH SWITCH
ON :0V STRIPE:WHITE
GNWH# Att.1SW VO2+ 1 3 RD RED
RDYE#
S28 4 100 H INPUT FOR Att.1 SWITCH
V5 4 122 +5V BUYE# ONLY FOR FBR(M)-H80 VO2- 1 4 T OUTPUT FOR SPARE
GNWH# S29 6 169 Att.2SW
H INPUT
EPS SENSOR
BK#
A1 5 162 M SIGNAL
BK# FOR Att.2 SWITCH MC
RDGN
VO3+ 1 8
GND 4 112 GND GND 4 113 GND RATED VOLTAGE:24V WH
(OPT.) VO3- 1 18 T OUTPUT FOR ELECTRICAL MAGNET BRAKE(LEFT)
IG SENSOR FOR PRESSURE RDGN DISPLAY
KEY SW WH# INPUT FOR KEY SWITCH RDYE#
MC VO4+ 1 19
S1 5 149 M (Key OFF: 5V, Key IG/ST: 0V) V5 4 118 +5V RATED VOLTAGE:24V WH
B WHBU# VO4- 1 9 T OUTPUT FOR ELECTRICAL MAGNET BRAKE(RIGHT) LINE CONNECTOR
BNYE#
S2 5 148 M INPUT FOR KEY SWITCH START BK#
A11 4 124 H SIGNAL CPU
ST
GND 4 108 GND VO5+ 1 10 No. CN □ PIN No.
BK# (Key OFF: IG 5V, INPUT FOR SWITCH OF
GND 1 30 GND only when keeping Key ST: 0V) VO5- 1 20 T WHRD
V5 4 119 +5V SW_7 1 A1 TURN SIGNAL LAMP(RIGHT) SW OFF:5V
ONLY FOR TRUCKS WITHOUT CHARGER RDGN ON :0V
RDBU
VB1 5 133 M INPUT FOR CONTORL POWER (24/48V) A9 4 131 T SIGNAL 1 MC VO6+ 1 11 WHBU
SW_8 1 A2 INPUT FOR SWITCH OF
GND 4 109 GND RATED VOLTAGE:24V BN TURN SIGNAL LAMP(LEFT)
BKWH
NB 5 138 CONTORL GROUND VO6- 1 21 T OUTPUT FOR SUSPENSION LOCK COIL SW_9 1 A3
RDGN (REFER TO SERVICE DATA No.2)
A10 4 130 T SIGNAL 2 MC VO7+ 1 2 SW_10 1 A4 INPUT FOR SPARE
RATED VOLTAGE:24V/48V BNWH
RDGN OUTPUT FOR 24/48V X1 RELAY (-) VO7- 1 1 H OUTPUT FOR MAIN CONTACTOR
X1 X1 VO1+ 5 134 (Refer to service data No.1) (REFER TO SERVICE DATA No.3)
CAN_ID 1 A5 CAN0 COMMUNICATION_EXCHANGE OF ID
SWITCH RDGN
RATED VOLTAGE:24V/48V BNYE
VO1- 5 135 M MC VO8+ 1 12 BK GND 1 A6 GND
OUTPUT FOR X1 RELAY (-) FOR BRAKE WHRD# RATED VOLTAGE:12V YEBU
S19 5 140 T INPUT FOR BRAKE SWITCH VO8- 1 22 H OUTPUT FOR LIFT LOCK COIL WHGN#
CANH1 1 B1 CAN1-H (CAN1 COMMUNICATION_H)
Released: 5V RDGN (REFER TO SERVICE DATA No.4)
RDWH
VB2 5
INPUT FOR CONTORL POWER
132 T,H SYNCHRONIZATION IN KEY SWITCH GND 1 16 GND Depressed: 0V FAN VO9+ 1 13 GNWH#
CANL1 1 B4 CAN1-L (CAN1 COMMUNICATION_L)
BUBK
X1 RELAY (+) 24/48V VO9- 1 23 M OUTPUT FOR BLOWER 4
CANH2 1 B2 CAN0 COMMUNICATION_TERMINATION
WHBU V5 1 24 +5V ONLY FOR TRUCKS WITH FAN 5
CN0H 5 157 M/T/H CAN0-H (CAN0 COMMUNICATION_H) CO1+ 1 14 CANL2 1 B3 CAN0 COMMUNICATION_TERMINATION
BUWH RD
OBD CN0L 5 165 M/T/H CAN0-L (CAN0 COMMUNICATION_L) CO1- 1 15 H OUTPUT FOR SPARE Vcc12V 1 B5 POWER SUPPLY FOR DISPLAY
CONNECTOR BN BK
MD1 5 150 M/T/H WRITE FOR PROGRAM GND 1 B6 GND
BK
GND 4 114 GND OIS SENSOR RIGHT WHGN
6
RDYE#
V5 1 25 +5V PO1- 1 5 M OUTPUT FOR HEAD LAMP 7
BUWH#
WHBU# BK#
S20 4 105 T SIGNAL LEFT HEAD LAMP(40W X 2)
CN0H 6 184 M/T/H CAN0-H (CAN0 COMMUNICATION_H) GND 1 17 GND
BUWH#
RDBK
CN0L 6 194 M/T/H CAN0-L (CAN0 COMMUNICATION_L) WHBK# INPUT FOR BATTERY
S32 4 123 H FRONT LOADING SWITCH
8 BK#
SW OFF:5V
+ 100V 22μ
9 BK#
GND 4 116 GND WHBK
1 CN0R+ 5 158 M/T/H CAN0 COMMUNICATION_TERMINATION ON :0V PO2- 1 26 M OUTPUT FOR HORN
SENSOR
CN0R- 5 166 M/T/H FOR TILT LEVEL HORN
RDYE +5V
YEBK
V5 6 191
WHGN# CAN1-H BK
A12 6 187 H SIGNAL
CN1H 5 156 M (CAN1 COMMUNICATION_H) GND 6 181 GND TURN SIGNAL LAMP (25W) BUYE
GNWH#
PO3- 1 6 M OUTPUT FOR TURN SIGNAL LAMP(LEFT)
RDWH
CN1L 5 164 M CAN1-L ONLY FOR TRUCKS WITH LASER POINTER

4 (CAN1 COMMUNICATION_L)
RDGN# TURN SIGNAL LAMP (25W) RDYE
5 RD POWER SUPPLY FOR DISPLAY V3 5 151 M (+3V) PO4- 1 7 M OUTPUT FOR TURN SIGNAL LAMP(RIGHT)
2 V11 5 136 AFTER KEY SW START (+ 11V) BK#
GND 5 139
BK
LASER GND
GND 5 137 GND WHRD#
S9 5 145 M INPUT FOR TILT LEVEL SENSOR ACCESSORY FOR FWD BNBK
6 LEVEL SENSOR PO5- 1 27 T OUTPUT FOR FWD
7 CAN2-H
CN2H 6 185 T (CAN2 COMMUNICATION_H) ACCESSORY FOR FWD
BKWH
/ BUZZER FOR RVS BN

CN2L 6 195 T CAN2-L PO6- 1 28 T OUTPUT FOR FWD/RVS/FWD & RVS
(CAN2 COMMUNICATION_L) TILT LEVEL LAMP (OPT.)
GNBK
3 GND 1 31 GND
BW 3 97 M INPUT FOR BATTERY ELECTROLYTE LEVEL PO7- 1 29 T OUTPUT FOR LOOP LAMP OF CABIN MODEL
line for Opt board (AOS/Multi)
Wiring, system 7- 1.
SENSOR FOR
BATTERY ELECTROLYTE LEVEL
54001-91640-0
FBR-80 7-1-1. 129
7 Wiring (Diagrams)
NOTE
1) REFER TO MNS P0030 FOR DRAWING INSTRUCTION.
2) REFER TO MNS D0035 FOR WIRE TREATMENT. POINT A
3) <n> SHOWS LEAD WIRE No.
4) WHEN INSTALLING THE CHARGER PANAL ON THE TRUCK BODY,
Rear
USE TOOTHED WASHER FOR ELECTRICAL CONTINUITY.
5) THE CHARACTER OF THE CONNECTOR SHOW THE PRINTING OF THE CONNECTOR.
6)ࠉࠉࠉSHOWS PUSHMOUNT WITH HARNESSBODY.ࠉࠉࠉࠉࠉࠉ
7) OPTIONAL SPECIFICATION DRIVE ROOM ͤA POINT ”㹑”
ࠉMARKED "ͤ" SHOW THE WIRING FOR EACH OPTIONAL SPECIFICATION. EPS MOTOR
2P
4P
DRIVE TIRE
ࠉͤ1. TURN SIGNAL LAMP X ANGLE SENSOR
ࠉͤ2. WITH CHARGER
ࠉͤ3. WITHOUT CHARGER 24V/48V 1
RDBK
ࠉͤ4. DRAWING BATTERY IN FRONT 24V/48V 1
RDBK 1
BN POINT B
<6>
<7>
<8>
OUTPUT AT WILL
ࠉͤ5. HIGH PERFORMANCE SPEC. BRAKE SW. CHARGER PANEL CHARGER PANEL OUTPUT FOR FWD.
1
1
BNBK
ࠉͤ6. WITH FAN (WITHOUT CHARGER) (WITH CHARGER)
ࠉͤ7. LASER POSITIONER 2
BEARING 4
ࠉͤ8. LEVEL LAMP ENCORDER 䈜㻟䈜㻞
4 3P EPS SENSOR
8 8 8
ࠉͤ9. LOAD METER CHARGER 䠇㻨㻥㻪䈜㻟
㻨㻝㻜㻪䈜㻟 RECEPTACLE U1 V1 W1
ࠉͤ10. ATTACHMENT DEVICE PLUG 䠉
”㹀”
ͤ11. 5TH VALVE CLAMP 3 BEARING
RDGN 4P
8)ࠉ5/6 VALVES(OPT) , 䈜㻟 SUSPENSION 1 1
BN
ENCORDER
EPS MOTOR HARNESS,BC LOCK VALVE 1 1
INSERT A TERMINAL OPT.(ATT.2/ATTACHMENT2). GHG. INTERLOCK 䈜㻞
15P
DRIVE TIRE SW. TRACTION MOTOR
ANGLE SENSOR MAGNETIC
9) ONLY R9N㹼12N (↑LOWER SIDE)
2P CONTACTOR
WH
HEAD LAMP 䈜㻟 HEAD LAMP
3
SWITCH COMP., 2P BRAKE SW.
ͤ1
POINT B CHARGER 3P
䈜㻝
WH
TURN SIGNAL 4P TURN SIGNAL
LAMP KEY SW. KEY SW. RD
HYDRAULIC MOTOR LAMP
䈜㻠
(↑FRONT SIDE) 2
䈜㻠䈜㻞
BATTERY 2P BATTERY 䈜㻞
PRESENCE INTERLOCK SW. 2P <10>
3P INTERLOCK SW. 8
OPT.
OPT.
OPT.
U2 V2 W2
SW.
TRANSFORMER 8 8 8 1
2
2
2
2
2
2
2
2
(↑FRONT SIDE)
2
2
2
2
2
2
2
2
2
2
2
WHGN
DISPLAY 䈜㻞
CONTROL PANEL
RDBK
RDYE
RDBK
WHGN
<9>
YERD
RDBK
RDBK
BUYE
BNYE
BUBK
<3>
<4>
<5>
8 䠇
12P
TURN SIGNAL 䈜㻞
HORN SW. NOTE.9
SW. HARNESS,PANEL WIRE,LEAD(2)
HARNESS,HEAD GUARD(R) UNDER THE FLOOR 8P
HARNESS,HEAD GUARD(L) THE BACK OF CHARGER PANEL
ACCELERATOR
HEAD LAMP EMERGENCY
SW. SW.
TOP COVER MPU BOARD MAST ͤ8

WH 1 1
WH
WIRE,LEAD ͤ8 BK BK LEVEL LAMP
HEAD GUARD(R) HEAD GUARD(L) HARNESS,ACCESSORY
1 1
6P
6P 4P RDGN RD
10A
BK BK
WH
YERD
BNYE
BUBK
BK
RDBK 10A RD 4P
4P WHBK RD 4P
7
HORN
1
1
WH RDBK WH
7 CN7
2
2
2
P MAST
1
1
HARNESS,MAST(2)
CN8 CN6 CN5 CN4 CN3 CN2 CN1
OPT.
OPT.
OPT.
ͤ7
WH
BK
ͤ7
”1”
4P
OBD7 CONNECTOR
BK
6P 6P 6P 6P 2P LEVEL SENSOR
HYDRAULIC VALVE ͤ7
ͤ8 ”2”
䈜㻝㻝䈜㻝㻜 2P HARNESS,LAMP
WH ͤ7 2P LASER DEVICE
NOTE.8 OPT.(ATTACHMENT2) BUYE
ATTACHMENT2 ATTACHMENT1 LIFT1 SW. MAIN CONTROLLER HARNESS,MAST(1)
1 1
BNBK SWITCH COMP.,VALVE SW. SW. FAN 䈜㻢
OPT.(OVER LOAD) 1
OPT.(TRAVEL INTERLOCK) YEBK BN OUTPUT AT WILL

1
RDBK
1
24V/48V HARNESS,MAST(3) HARNESS,MAST(2) M/PFL MAST
OPT.(TRAVEL SPEED LIMIT)
LIFT LOCK REACH SW. TILT SW. LIFT2 SW. 䈜㻞 RDWH
1
BUBK
COIL 24V/48V(KEY) ͤ7 ͤ7
1
BURD <9> <3> BKWH
1
GND
OPT.(LIFT LOCK) 1 8 1
䈜㻟 HYD-U 8 ͤ7
OPT. GNBK <9> BK SW. FOR HIGH MAST ”1”
(BATTERY ELECTROLYTE LEVEL)
1
<4> WH
1 1
HARNESS,SENSOR 6P 2P LEVEL SENSOR
OPT.(GND) BK
1 HYD-V 8
<5>
BUYE
ͤ7
ͤ5 ”2”
2P HYD-W BEARING 2P LASER DEVICE
1
BEARING BEARING 6P 8
ENCORDER
ENCORDER ENCORDER <6>
1
BUYE 4P 4P
RED BK ͤ5
ͤ5 3P
TRV-U 8 <7> ELECTROMAGNRTIC
ELECTROMAGNRTIC
BRAKE
BRAKE
<8>
TRV-V 8
ͤ9
PRESSURE
䠇
8 TRV-W 8
3P 䠉 8
SENSOR
1
1
1
1
4P 4P 4P
1
1
1
1
RDGN
RDGN
<2>,<10>
WH
ͤ2
WH
BKWH
HARNESS,M
<10>
ͤ3
<1>
RD
䈜㻡
2P HARNESS,BODY(3)
HARNESS,BODY(3) HARNESS,BODY(3)
WH
HARNESS,BODY
䈜㻡
4P HARNESS,BODY(2) 4P
2P 2P
STRADDLE LEG(R) STRADDLE LEG(R)
(STD) (HIGH FUNCTION) FRONT HOOD STRADDLE LEG(L)
<1> 䠇䠇
<2> 䠉䠉 BATTERY
HARNESS COLOR GROUND
STRIPE
Front (Fork side) Wiring, body 7- 2.
BK BLACK YE YELLOW BN BROWN
WH WHITE GN GREEN BU BLUE

Ex. 'BKWH' = GROUND:BLACK,
FBR-80 7-2-1.
STRIPE:WHITE
RD RED
130 54002-61712-1E
Wiring (Diagrams) 7
㼃㻝 SWITCH FOR VALVE MICRO L4 Y CONTROL PANEL X SWITCH FOR OIS
VINYL TUBE CAPACITOR
A-A B-B C-C D-D RDGN C
CAPAVITOR 23B A BUWH# RDBU
3 1 POINT 81B PLUG
(NO POLARITY)
1 24 3 2 L 52C 6P 1 2 3 BUWH#
(NO POLARITY)
3 2 1 22B A 2 WHBU# WHGN# 24 㻝㻭 24B WATERPROOF TYPE 3 2 1
VINYL TUBE Heat contraction tube WATERPROOF TYPE 24
BNYE# GNWH#
26 3 A 67B 4 5 6 BK# 㻭 10B
(Colorless) VINYL TUBE
6 5 4 21B A 3 24 26 4 A 68B BLACK RDYE#
24 㻞 PLUG 3P
UPWARD DIRECTION UPWARD DIRECTION UPWARD DIRECTION UPWARD DIRECTION PLUG 6P YERD# RD AMP 171898-2 㻟㻭 15B
FILL THE SILICON ADHESIVE ES1000-2(Raychem)
or equivalent
OF PAPER SURFACE OF PAPER SURFACE OF PAPER SURFACE OF PAPER SURFACE 20B A 4 24
GNWH# BK
3 5 A 55B 24
IN VINYL TUBE.
19B A 5 24 3 6 A 56B AMP 174357-2
BK#
26B A 6
FILL THE SILICON ADHESIVE
24
IN VINYL TUBE.
AMP 174262-2 ENCORDER FOR
a FRONT WHEEL(RIGHT)
Sleep P1.25
TY-RAP SOLDERING TY-RAP 70000-79960 BUYE 3 1 A 62B PLUG
YERD 2 A 61B 1 2
3 4P
A 9B BLACK
BK 3 3 3 4
FIG.2 BK#
4 AMP 172134-2 24 㻝㻭 107B
A BURD#
DETAILED CHART FOR USE
A POINT C RDYE#
24 㻞㻭 109B
WATERPROOF TYPE 2 1
24 㻟㻭 108B
PART OF PRESS SLEEVE WHRD# 24 㻠㻭 110B PLUG 4P 4 3
(NOTE.6) ※UNLESS OTHERWISE SPECIFIED, DIRECTION IS NOT DECIDED.
(NOTE.1) AMP 174257-2
N1
F5 to U to I1
to K 㻸
※85
AC125V 10A RELAY FOR CONTROL SOURCE
U ACCELERATOR
80A
Y
F4 PART NUMBER 54002-58520-7 54002-58530-7 54002-58540-7 54002-76190-5
81A AC125V 10A PARTS,HARNESS PART NUMBER 54002-58550 54002-58560 54002-58570 ←
to C to M (NOTE.1)
RDYE#
RDYE#
RD
RDYE#
RDYE#
RDBU A
FBR(M)9N∼12N FBR(M)9∼18 FBR(M)20∼30 FBR(M)35∼40 RDYE#
WH#
MODEL
A POINT 37B
WH#
BU#
BK#
BK#
3 1 PLUG 24 1
BU#
A
BK#
BK#
RDGN Y
52B WH#
L1 300 300 400 ← 3 2 A 53B 24 2 POINT 44B A
RDWH 3 3 A
51B
4P 1 2 BK# 24 3 A POINT 36B 3 2 1
L2 350 400 450 ← BNYE P RED RDYE# 24 4 POINT 37C A 6 5 4
3 4 A 54B 3 4 BU# POINT 45B
POINT C L3 300 400 400 ←
18 18 18 18 BK# 24
24
5 A
6 POINT 36C
AMP 172134-9
WIRE LENGTH
L4 200 250 250 ←
AMP 174262-2
200
FIG.1 L5 130 130 160 ←
NOTE
RDYE#
䠘䚷䚷䚷㻌䚷䠚 +10 +10 +10
L6 165 165 115 ← WATERPROOF TYPE
GNWH#
WHRD#
0 0 0
BURD#
RDYE#
RDYE#
RDYE#
1. TERMINA MARKING
PLUG 6P
BK#
L7
1 㻦䚷PLUG(WITH PLATING.） AMP 170020-2 35 35 85 ←
WHBK
BK#
BK#
BK#
SLEEVE(FOR ONE） AMP 170887-1 7 㻭㻝㻢㻮
1 㻦䚷RECEPTACLE(WITH PLATING.） AMP 170021-2
HARNESS COLOR RDBK
SLEEVE(FOR ONE） AMP 170899-1 GROUND + 7 㻺㻞㻤㻜㻱
SLEEVE(FOR TWO） AMP 170890-1
STRIPE
W LIFT LOCK VALVE
3 㻦䚷RECEPTACLE AMP 170032-5
AMP 179461-5
/STRIP FORM
/LOOSE PIECE BK BLACK YE YELLOW BN BROWN
to A to A
2 1
(NOTE.6) POINT A
100V
22μ V HORN
24 㻦䚷RECEPTACLE AMP 171630-1 /STRIP FORM
AMP 171699-1 /LOOSE PIECE to A to A WATERPROOF TYPE
AMP 172746-1 /RUBBER PLUG WH WHITE GN GREEN BU BLUE PLUG 2P
50
AMP 172748-2 /CAVITY PLUG Ex. 'BKWH' = GROUND:BLACK, AMP 174352-2
STRIPE:WHITE DETAILED CHART FOR POINT A DETAILED CHART FOR POINT B DETAILED CHART FOR POINT D
5 㻦䚷TAB AMP 917805-2
AMP 917803-2
/STRIP FORM
/LOOSE PIECE
RD RED 8B A 1 24 BKWH
YEBU
13B A 2 24
AMP 179956-2
/STRIP FORM
/LOOSE PIECE Z Connector for OBD7
6 㻦䚷RECEPTACLE AMP 173716-2 /STRIP FORM A
AMP 175061-2 /LOOSE PIECE WHBU Plug
㻦䚷RECEPTACLE(WITH SLEEVE） AMP 41729 SENSOR FOR PRESSURE BUWH
3
3
1
2 A 70B
A 69B
1 2
4P
㻾 BN
7
AMP 350536-1 /STRIP FORM (opt) ※30 BK

3 3 A 65B
Black 3 4
9 㻦䚷SOCKET 3 4 A 27B
AMP 350550-1 /LOOSE PIECE L1 A L2
AMP 106529-2 /STRIP FORM L3 AMP 172134-2
Sumitomo 6189-0131
17 㻦䚷RECEPTACLE AMP 1-106529-2 /LOOSE PIECE RDBK E
Waterproof type 3 1 80F
RDYE# 㻝㻡 1
RDYE V PLUG
18 㻦䚷PRESS SLEEVE JST FNC-1.25 WHBU# 㻭㻟㻟㻮 Plug 3P 3 2 A 5B
4P 1 2
I2
㻝㻡 2 㻭㻠㻟㻮 3
BK# GNWH
AMP 1376701-1
/STRIP FORM 㻝㻡 3 㻭㻟㻞㻮 KEY SWITCH 3 4 N1 3C WHITE 3 4
/LOOSE PIECE 3 1
1 26 BK#
PLUG 25B A WH# AMP 172134-1
21 㻦䚷RECEPTACLE AMP 316836-1 /STRIP FORM 2 12 64B A 2 26
4P
22 㻦䚷RECEPTACLE
AMP 1376700-1
AMP 1123343-2
/LOOSE PIECE
/STRIP FORM
3 4 RED 63B A 3 26
4
BNYE# BUYE
BNBK
BUBK
1
1
A 84B
A 85B
N2 OVERHEAD GUARD (RIGHT)
AMP 1318143-2 /LOOSE PIECE AMP 172134-9 YEBK 1 A 116B
AMP 1123343-1 /STRIP FORM BURD 1 A 115B
㻦䚷RECEPTACLE AMP 1318143-1 /LOOSE PIECE 42B A 1 24
WHBK# GNBK 1 A 117B
23
BK# 1 A 118B
33
26
㻦䚷RECEPTACLE
㻦䚷RECEPTACLE
AMP 183035-1-1
AMP 170384-2 /STRIP FORM J SWITCH FOR
BATTERY INTERLOCK
29B A 2 24 BK 1 A 119B
S OPTION
1.FUSE AND RELAY ARE TIED AROUND POINT C.(FIG.1)
2 1 WATERPROOF TYPE L5 B
PLUG 2P BK#
2.STRAND PART AT THE PITCH OF 25 MM AND BELOW. 1 POINT 40B B
L1+50
24 WATERPROOF TYPE
GNWH# POINT 74B
3.REFER TO MNS D0035 FOR WIRE TREATMENT. 24 2 B
RDYE# POINT PLUG 3P
4.REFER to MNS P0030 FOR DRAWING INSTRUCTION.
D ENCORDER FOR TRV MOTER AMP 174352-2 24 3 41B
5.All PIN LAYOUT SHOWS OF CONNECTOR THE VIEW
FROM TERMINAL INSERT SIDE.
6.DISPLAY THE ALPHABET WITH DESCRIPTION OR STAMPING
(NOTE.6) CSENSOR FOR EPS
3 2 1
OR THE SEAL (ONLY THE FUSE) IN IMMORTAL INK.
7.THE ELECTRIC WIRE TABLE AND THE PART COLUMN ARE SHOWN Capacitor
125V,0.22μF
O VALVE FOR SUSPENSION LOCK B B
IN THE PARTS,HARNESS(E0000-46480). NOTE THE PIN ARRAY. AMP 174357-2
8.SOLDER THE INSTALLATION OF THE CAPACITOR OF THE SPEED SENSOR
2 1
(Note.8)
RDGN I1 CHARGER PANEL
AS SHOWN IN FIG.2. WATERPROOF TYPE RDYE# 1 A 7B
4 3 31B A 1 24 BU
AND FILL THE SILICON ADHESIVE IN THE VINYL TUBE
PLUG 4P 30B A 3 24
BK#
WH#
1 A 12B
9.IN CASE OF FBR(M)9N∼12N(54002-58520),THIS PART IS UNNECESSARY. 46B A 2 24 B B
47B A 4 24
BU#
AMP 174257-2
※50
0
RDYE
RDYE
WH△
15 H SWITCH FOR BRAKE
RD△
POINT D
BK△
WH
WH
RD
RD
BK
BK
BK
BK
WATERPROOF TYPE WHRD#
2 1 59B A 1 24
PLUG 2P 104BA
2 24 BK#
(NOTE.9)
T2 ENCORDER FOR FRONT WHEEL
L6
9 9 9 9 9 9 9 9 9 9 9 9 9
AMP 174352-2 1 2 3 4 5 6 7 8 9 101112131415

AMP 172134-9
B A A D D D
POINT POINT POINT A,I1 A BK#
POINT B WHRD# 26 1 PLUG
B BU# 111B A
POTENTIOMETER FOR 2 1 WATERPROOF TYPE 73B POINT 1 24 RDYE# L7 75B 77B 90B 88B 89B 92B 94B 26 2 1 2 4P 113B A
M DRIVE TIRE ANGLE 4 3 PLUG 4P 121B
B
POINT
122B
B
2 24
POINT 3 24
BK#
BURD# A D D D
A I1
RDYE#
WH#
26
26
3
4
3 4 RED
112B A
114B A
E BUZZER FOR FWD & RVS

POINT POINT POINT
POINT B C K FUSE (NOTE.6) 72B 4 24

FBR9(N)-30 B B 76B 88C 89C 91B 93B 92C
RD
POINT AMP 174257-2
WH▲ AMP 172134-2
8 81C 78B A 1 5 RDBK P 15P
1 80D
BKWH TERMINAL FOR G EPS MOTOR 2P-X
Tab
79B A 2 5
BK▲
B
L7 RDBK
BN 1 E 80G E
N2 350784-1(AMP)
RDGN
RDGN
3 1
1 2
PLUG 100B A
8 A 1 P WH
3 2 4P 101B A
P 57B
30 Q GROUND AMP 1-353046-2 FBR35/40
BK▲
BNBK
1 A 17B
18C
WH
3
3
3
4
3 4 BLACK 102B A
103B A
79B A 1 5
13 10 7 4 1
RDGN
3 1 A 2B
PLUG
2P 1 t CONTACTOR 78B A 2 5
WH▲
14 11 8 5 2 T BRAKE FOR FRONT WHEEL
BNWH
3 2 A 1B WHITE 2 15 12 9 6 3
AMP 172130-1 FBR35/40: WH and BK is inversion from FBR9(N) - 30.
P ACCESSORY
BN 1
A 18B
RDBK 1
N1 80C E
RDWH 1
E L 51C
BKWH 1
Q
57C
B
WH△
WH▲
B
RD△
BK△
BK▲
CONNECT AND DELIVER IT.

BK
5 5 17 17 17 1 A 87B
GNWH#
WHRD#
WHBU#
BUWH#
BUWH#
WHBU#
GNWH#
GNWH#
WHGN#
2 1
WHBK#
WHRD#
WHRD#
WHRD#
4321
BURD#
RDGN#
RDYE#
RDYE#
RDYE#
RDYE#
RDYE#
RDYE#
RDYE#
YERD#
WH
BURD#
GNYE#
BNYE#
RDWH
BUWH
WHBU
BKWH
GNBK
BURD
RDGN
BNBK
BUYE
BUBK
RDBU
YEBK
RDYE
YERD
BUYE
BNYE
㻳㻵㻝 1 A 86B
WH#
WH#
WH#
WH#
BU#
BU#
BU#
BK#
BK#
BK#
BK#
BK#
BK#
BK#
BK#
BK#
BK#
BK#
BK#
79A
WH
WH
WH
RD
RD
RD
BK
BK
76A
BK
BN
BK
BK
BK
BK
㻳 78A B HARNESS, MAST(1)
BK#
BN
BNBK
WHBK
RDYE#
BUBK
YEBU
BN
RDGN
WH
BK#
BK#
RDGN
RDGN
RDGN
WH
RDGN
RDYE
BUYE
WHGN
RDGN
BNWH
㻵㻝㻵㻝
77A 75A
WHRD# 24 1 A 60B
2P-X 22 22 22 22 23 22 2222 23 23 2323
RECE. 22 23 23 23 23 21 21 21 22 22 22 22 22 22 22 22 22 22 22 22 22 23 23 23 23 23 23 23 23 21 21 21 21 21 20 20 22 22 23 22 22 22 2223 22 2223 22 22 22 23 23 23 23 23 21 21 21 21 21 21 21
22
RDGN#
(CAVITY PLUG) 2 3 2 1
4 3 24 3 A 66B
CN8(2P) 199 197 192 190 188 186 195 184 193 182 180 178 176 174 172 170 168 166 161 154 165 164 163 159 152 150149148147 146 144 142 140 138 136 134 132 131 129 122 121 125 110 124 108 127 107 115 113 109 105 103 101 999897969594918988878492868582 93 83 81 78 76 74 72 70 68 BK# 24 4 58B
6 5 4
2 1 198 196 191 189 187 185 194 200 183 181 179 177 175 173 171 169 167 162 160 158 157 156 155 153 151 145 143 141 139 137 135 133 130 123 112 126 120 119 118 128 117 116 114 111 106 104 102 100
90 80 79 77 75 73 71 69 67 RDWH 24 5
A
MOLEX/Mini-Fit Jr. S a a T2 T2 S BKWH 24 6 P 51D

D POINT I1 I1 S P B
B POINT
POINT
A Z Y D POINT B I2 Y B B Y L L J B POINT
A POINT
A POINT R R D D W1 X W1 W1 117A 108A109A
22 22222222 222222 22 22 23 23 23 23 23 23 23 21 21 21 21 21 P 57D AMP 174262-2
39-01-2040 114A 113A 116A
(5557-04R) 90A 92A 93A 85A 87A 74A 72A 71A 69A 67A 88A 66A 64A 62A 60A 58A 56A 54A 52A 42A 40A 44A 37A 43A 32A 46A 30A 26A 24A 22A 20A S 31 29 27 25 23 21 19 17 15 13 11 9 7 5 3 1 WATERPROOF TYPE
a a T2 T2 S S 30 28 26 24 22 20 18 16 14 12 10 8
NOTE THE PIN ARRAY.
P I1 6 4 2 Plug 6P
CN7(4P) S H B POINT A POINT 118A 110A 107A
f
Q Y L L Z B POINT Y W1 W1 W1 112A 111A 119A
A B POINT Z Y D POINT D POINT Z I2 Y B POINT A POINT R D D J 115A I2 P V W T H W T N1 t C
86A 94A 84A 59A 57A 55A 53A 51A Fan POINT
71B 73A 70A 68A 89A 91A 65A 63A 61A 41A 122A 45A 36A 33A 47A 31A 29A 27A 121A 9A 23A 21A 19A RDBK
25A 18A 16A 13A 102A 104A 8A 100A 4A 2A
BUYE
3 1 P 80B PLUG
(NOTE.9) 3 2 A 4B
E X f O T X f O T N2 N1 t
PLUG
3 1 2 4P
17A 15A 106A 12A 101A 10A 105A 7A 103A 5A 3A 1A 2P 1 GNWH A WHITE
3 4 3 4
WHITE 2 N2 3B
173 172 171 170 169 168 167 138 137 136 135 134 133 132 72 71 70 69 68 67 (NOTE.9) (NOTE.9)
106 105 104 103 102 101 100 AMP 172130-1 AMP 172134-1
183 182 181 180 179178 177 176175 174 150 149 148 147 146 145 144 143 142 141 140 139 116 115 114 113 112 111 110 109108107 82 81 80 79 78 77 76 75 74 73 OVERHEAD
RDGN
193 192 191 190 189188 187 186185 184 158 157 156 155 154 153 152 151 92 91 90 89 88 87 86 85 84 83 105B A 1 3 BUBK 㻺㻝 GUARD (LEFT)
126125124123122 121120 119 118 117 7 6 5 4 3 2 1 106B A 2 3
200199 198 197 196195 194 166 165 164 163 162 161 160 159 131130 129 128127 99 98 97 96 95 94 93 17 161514 13 12 11 10 9 8
AMP .025(.064)SERIES CONNECTOR 25 24 23 22 21 20 19 18
Harness, body 7- 3.
AMP .025(.064)SERIES CONNECTOR AMP .025(.064)SERIES CONNECTOR AMP .025(.064)SERIES CONNECTOR
1123337-1(34 POSITIONS) 1123338-1(35 POSITIONS A) 1123339-1(32 POSITIONS) 1473651-1(33 POSITIONS) 3130 29 28 27 26
A MPU BOARD
AMP .025(.064)SERIES CONNECTOR
CN6(34P) CN5(35P A) CN4(32P) CN3(33P) 1123341-1(31 POSITIONS)
(NOTE.6) CN1(31P)
FBR-80 Body harness 7-3-1.

E0000-46470-7E
131
7 Wiring (Diagrams)
WIRE NUMBER FROM TO WIRE COLOR LENGTH REMARKS
1A 1B A 3 24 C RED YELLOW# 450

2A 2B A 3 24 C BLACK# 450
3A 3B A 3 24 C BLUE# 450
A SPEED SENSOR FOR FRONT WHEEL 4A 4B A 3 24 C WHITE# 450
7A 7B B 3 24 C GREEN RED 450
2 1 B BRAKE FOR FRONT WHEEL 8A 8B B 3 24 C WHITE 450

4 3 9A 9B B 3 24 D GREEN RED L1+200
10A 10B B 3 24 D WHITE L1+200
CAP 2 1
4P RED
4 3
C C
4A 1A CAP
NOTE THE PIN ARRAY. C C 4P BLACK PART NUMBER 54002-59790-1 54002-59800-1
3A 2A
D D MODEL FBR(M)9-18 FBR(M)20-40
4 2 3 1
9A 10A
3 3 3 3 C C
7A 8A
1 2 3 4
RDYE#
NOTE
WH#
1.TERMINA MARKING
BU#
BK#
3 3 3 3
3 RECEPTACLE AMP 170032-5/STRIP FORM
AMP 179461-5/LOOSE PIECE
24 RECEPTACLE AMP 171630-1/STRIP FORM
NOTE.7
RDGN
RDGN
AMP 171699-1/LOOSE PIECE
WH
WH
AMP 172746-1/RUBBER PLUG
2.STRAND PART AT THE PITCH OF 25 MM AND BELOW.
5.All PIN LAYOUT SHOWS OF CONNECTOR THE VIEW FROM TERMINAL INSERT SIDE.
6.LEAD WIRE
#:AVSS 0.3mm 2
2
OTHERS AVSS 0.5mm.
7.TWIST BY FOUR LINES OF A BLACK LINE / RED YELLOW LINE / BLUE LINE / WHITE LINE.

STRIPE

STRIPE:WHITE
RD RED
RDYE#
RDGN
RDGN
WH#
BU#
BK#
WH
WH
NOTE THE PIN ARRAY. 24 24 24 24 24 24 24 24
3 1 4 2 1 2 1 2
A A B B
1B 4B 7B 9B
A A B B
2B 3B 8B 10B
WATERPROOF TYPE WATERPROOF TYPE WATERPROOF TYPE

PLUG 4P PLUG 2P PLUG 2P
Harness, body 7- 3.
ENCORDER FOR 2 1 BRAKE FOR
C FRONT WHEEL(LEFT) 4 3
2 1 2 1
D FRONT WHEEL(RIGHT)
FBR-H80 Body harness (2) 7-3-2.
E0000-46500-1E-R1
132
Wiring (Diagrams) 7
1A 1B A 24 24 B RED 200+A
2A 2B A 24 24 B BLACK 200+A
3A 3B A 24 24 B WHITE 200+A
4A 4B A 24 24 B BLUE 200+A
B ENCORDER FOR FRONT WHEEL A HARNESS, BODY
WATERPROOF TYPE
WATERPROOF TYPE CAP 4P
PLUG 4P
WH BK
3B A 1 24 24 1 B 2A AMP 174259-2
AMP 174257-2 RD BU
1B A 2 24 24 2 B 4A
BU RD
4B A 3 24 24 3 B 1A
BK WH
2B A 4 24 24 4 B 3A
2 1 1 2
4 3
A 3 4
NOTE.4
PART NUMBER SPECIFIC
54002-47891-0 FBR9N/10N/9/10
54002-47901-0 FBR12N/(A)12/14
54002-47911-0 FBRA14/15/16
54002-47921-0 FBRA15/A16/(A)18/20
54002-47931-0 FBRA20/(A)25/30
54002-47941-0 FBRA30/35
54002-66640-0 FBR40
<NOTE>
3.THE PIN LAYOUT OF THE CONNECTORS IS HARNESS COLOR GROUND
THE VIEW FROM TERMINAL INSERT SIDE. BK BLACK YE YELLOW BN BROWN

STRIPE
4.SECURE THE BOTH ENDS AND POINT A

OF THE VINYL TUBE WITH CABLE TIES. Ex. 'BKWH' = GROUND:BLACK,
STRIPE:WHITE
RD RED
5.STRAND PART AT THE PITCH OF 25 mm AND LESS.
Harness, body 7- 3.
FBR-80 Body harness (3) 7-3-3.
E0000-42911-0E
133
7 Wiring (Diagrams)
1A 1B A 24 24 B RED# 200+A
2A 2B A 24 24 B BLACK# 200+A
3A 3B A 24 24 B WHITE# 200+A
4A 4B A 24 24 B BLUE# 200+A
5A
6A
5B
6B
A
A
24
24
1
1
C
C
RED GREEN
WHITE
200+A
200+A
B ENCORDER FOR FRONT WHEEL
A HARNESS, BODY
WATERPROOF TYPE
WATERPROOF TYPE
CAP 4P
PLUG 4P
WH#
3B A 1 24 AMP 174259-2
AMP 174257-2 RD#
1B A 2 24
BU#
4B A 3 24
BK#
2B A 4 24
2 1 BK#
24 1 B 2A 1 2
4 3 BU#
2
RD#
24
24 3 B 1A
B 4A 3 4
WH#
24 4 B 3A
RDGN
24 1 B 5A
WH
24 2 B 6A 1 2
A
RDGN NOTE.4 WATERPROOF TYPE
5B A 1
CAP 2P
WH
6B A 1 AMP 174352-2
CELECTROMAGNETIC BRAKE
PART NUMBER SPECIFIC
54002-48001-0 FBR9/10
54002-48011-0 FBR(A)12/14
54002-48021-0 FBRA14/15/16
54002-48031-0 FBRA15/A16/(A)18/20
54002-48041-0 FBRA20/(A)25/30
54002-48051-0 FBRA30/35
54002-66650-0 FBR40
<NOTE>
3.THE PIN LAYOUT OF THE CONNECTORS IS
THE VIEW FROM TERMINAL INSERT SIDE.
4.SECURE THE BOTH ENDS AND POINT A
OF THE VINYL TUBE WITH CABLE TIES. HARNESS COLOR GROUND
5.STRAND PART AT THE PITCH OF 25 mm AND LESS. BK BLACK YE YELLOW BN BROWN

STRIPE
6.LEAD WIRE WH WHITE GN GREEN BU BLUE

# : AVSS 0.3mm2 Ex. 'BKWH' = GROUND:BLACK,
STRIPE:WHITE
RD RED
THE OTHERS AVSS 0.5mm 2
Harness, body 7- 3.
FBR-H80 Body harness (3) 7-3-4.
E0000-42921-0E
134
Wiring (Diagrams) 7
MAIN BOARD

STRIPE

STRIPE:WHITE
RD RED
CN7
CN8
CN6 CN5 CN4 CN3 CN2 CN1
RD YERD
MAIN CONTROLLER
8 8
4P
U 6 <3>
H
16P
<4> <HYD.>
V 6
4P
<5>
W 6
4P
RDBK
8 <6>
N
U 6
T <7>
16P V 6 <TRV.>
4P
<8>
W 6
P
8
CU111-**
BATTERY(+) BATTERY(-)
(BU)
WIRE, LEAD
HARNESS, CONTROLLER(1)
Wiring, controller 7- 4.
FBR-80 7-4-1.
54001-91390-0E
135
7 Wiring (Diagrams)
NOTE. WIRE END NAME FROM TO WIRE COLOR LENGTH
All PIN LAYOUT SHOWS THE VIEW FROM TERMINAL INSERT SIDE. 1A 1B A 21 8 I RED BLACK1 650
2A 2B A 21 8 G YELLOW RED1 530
3A 3B A 21 22 J BLACK1 210
4A 4B A 21 22 H BLACK2 330
5A 5B A J
I
21 22 RED1 210
RDBK1 6A 6B A H
8 A 1B CONTACTOR
21 22 RED2 330
HARNESS COLOR GROUND 7A 7B A 23 22 J YELLOW RED2 210
F SENSOR FOR CURRENT

STRIPE 8A 8B A 23 22 H YELLOW WHITE 330
(HYD.U-PHASE)
WH WHITE GN GREEN BU BLUE 9A 9B A 23 10 E BLACK6 360
Ex. 'BKWH' = GROUND:BLACK, 13A 13B A 23 10 E RED BLACK5 360
HU RD RED
STRIPE:WHITE
30A 30B A 22 10 E BLUE3 360
1 2 3 4 RDBK4
14B A 1 10
G
RD▲
8 B 35B 10A 10B A F BLACK5
2 YERD1 FUSE
23 10 400
22B A 3 10
WHBU3 8 A 2B 14A 14B A 23 10 F RED BLACK4 400
4P 10B A 4 10
BK5 22A 22B A 22 10 F WHITE BLUE3 400
11A 11B A 23 10 C BLACK4 240

15A 15B A 23 10 C RED BLACK3 240
E
BKYE
1 A 18B
H FET-IPM(HYD.)
SENSOR FOR CURRENT 22 34A 34B A 22 10 C BLUE RED3 240
BURD2
(HYD.W-PHASE) 22 2 A 27B
BUWH2
22 3 A 29B 12A 12B A 23 10 D BLACK3 280
H
BU2
22 4 A 19B 16A 16B A D
HW
23 10 RED BLACK2 280
BK2
22 5 A 4B 26A 26B A 22 10 D WHITE RED3 280
1 2 3 4
13B A 1 10
RDBK5 6
8 7 6 5 4 3 2 1
2 7 17A 17B A 22 22 J BROWN YELLOW 210
16 15 14 13 12 11 10 9
30B A 3 10
BU3 8 18A 18B A 22 22 H BLACK YELLOW 330
YEWH
4P 9B A 4 10
BK6 22 9 A 8B AMP .025(.064)SERIES CONNECTOR 19A 19B A 22 22 H BLUE2 330
WHRD2 22 10 A 28B 1318386-1 20A 20B A 22 22 H WHITE2 330
WH2
22 11 A 20B
WHBU2 16P
22 12 A 21B 21A 21B A 22 22 H WHITE BLUE2 330
RD2
22 13 A 6B
14 23A 23B A 22 22 J BLUE RED1 210
15 24A 24B A 22 22 J BLUE WHITE1 210
16 25A 25B A 22 22 J WHITE1 210
27A 27B A 22 22 H BLUE RED2 330

NOTE THE PIN ARRAY 28A 28B A 22 22 H WHITE RED2 330
D
29A 29B A 22 22 H BLUE WHITE2 330
SENSOR FOR CURRENT BNYE
1 A 17B
J FET-IPM(TRV.)
22
(TRV.U-PHASE) BURD1
22 2 A 23B 31A 31B A 22 22 J WHITE RED1 210
BUWH1 RDBK1
22 3 A 24B 21 32 I 1A 32A 32B A 22 22 J BLUE1 210
1 2 3 4
TU BU1
BK1
22 4
A 3B
A 32B T YERD1
BK1
21 33 G 2A 33A 33B A 22 22 J WHITE BLUE1 210
RDBK2
22 5 21 34 J 3A
16B A 1 10
6
BK2
21 35 H 4A
8 7 6 5 4 3 2 1 35A 35B B 5 8 G RED▲ 630
2 7
RD1
21 36 J 5A
WHRD3 16 15 14 13 12 11 10 9 36A 36B B 5 8 K BLUE▲ 420
26B A 3 10
8
RD2
21 37 H 6A
4P 12B A 4 10
BK3 YERD YERD
22 9 A 7B AMP .025(.064)SERIES CONNECTOR 23 38 J 7A
WHRD1 1318386-1 YEWH
22 10 A 31B 23 39 H 8A
A
WH1 BK6
22 11 A 25B 23 40 E 9A
WHBU1 16P RDBK5
22 12 A 33B 23 44 E 13A MAIN BOARD(1)
C SENSOR FOR CURRET RD1 BU3

22 13 A 5B 22 62 E 30A
(TRV.W-PHASE)
14
BK5
23 41 F 10A CN2
RDBK4
15 23 45 F 14A
TW 16 WHBU3
BK4
22 54 F 22A 37 36 35 34 33 32
1 2 3 4 23 42 C 11A
15B A 1 10
RDBK3 RDBK3 47 46 45 44 43 42 41 40 39 38
23 46 C 15A 58 57 56 55 54 53 52 51 50 49 48
2 BURD3
22 66 C 34A
BURD3 66 65 64 63 62 61 60 59
34B A 3 10 BK3
23 43 D 12A
4P 11B A 4 10
BK4 RDBK2
23 47 D 16A AMP .025(.064)SERIES CONNECTOR
WHRD3
22 58 D 26A 1123340-1(35 POSITIONS B)
B MAIN BOARD(2) BNYE
BKYE
22
48
49 J 17A
35P
22 50 H 18A
RD▲ BU2
5 1 G 35A 2P-Y 22 51 H 19A
WH2
BU▲
5 2 K 36A RECE. 22 52 H 20A
BU▲ WHBU2
36B B
8
22 53 H 21A
BURD1
22 55 J 23A
BUWH1
22 56 J 24A
WH1
57 J
K
22 25A
BURD2
TERMINAL FOR GROUND
22 59 H 27A
WHRD2
22 60 H 28A
BUWH2
22 61 H 29A
WHRD1
22 63 J 31A
BU1
22 64 J 32A
WHBU1
22 65 J 33A
Harness, controller 7- 5.
FBR-80 7-5-1.
54001-91380-2E
136
Wiring (Diagrams) 7
DETAIL OF AFFIXTURE OF BASE, MOUNT (SCALE 1:2)

PANEL, CONTROL
(VIEW FROM THE BACK OF PANEL) PANEL,CONTROL
VIEW FROM THE BACK OF PANEL
<SWITCH FOR EMERGENCY>

LOCK LEVER
NOTE.7 A GLOVE COMPARTMENT

ABOUT 10 BASE,MOUNT
<SWITCH FOR HEADLAMP> RDGN
NOTE.4 BK3 4 NOTE.8
1 18
BUYE
1b 18
RDBU
4
HARNESS,PANEL
ABOUT 25
HARNESS,PANEL
NOTE.3
WHRD
<SWITCH FOR TURN SIGNAL>
NOTE.5 / BK1
ONLY SGL SPECIFICATON WHBU
KEY WAY
YERD
BODY,HARNESS DISPLAY OR HARNESS,DISPLAY
<SWITCH FOR HORN>
NOTE.6
BK3
4P
BLACK
<HARNESS,BODY> 䈜FBR9~40-80/FBRO-80
6P 12P <DISPLAY (TOP COVER)>

BLACK
䈜FBR9N~12N-80
8P
WATERPROOF
TYPE <HARNESS,DISPLAY (TOP COVER)>
NOTE.
3.DON'T TOUCH THE HARNESS TO THE MOVING PART, THE EDGE, AND THE HEAT SOURCE.
4.INSTALL THE HEADLAMP SW THAT HAVE THE MODEL NAME TO RIGHT SIDE FROM VIEW OF THE BACK OF PANEL. HARNESS COLOR GROUND
5.INSTALL THE TURN SIGNAL SW THAT HAVE THE KEY WAY TO LEFT SIDE FROM VIEW OF THE BACK OF PANEL. STRIPE
6.INSTALL THE HORN SW THAT HAVE THE TERMINAL TO UPPER SIDE FROM VIEW OF THE BACK OF PANEL.
7.WIRE“REDGREEN”TO THE LOCK LEVER SIDE OF EMERGENCY SW. WH WHITE GN GREEN BU BLUE
8.AFFIX BASE,MOUNT TO PANEL,CONTROL AND FIX HARNESS,PANEL WITH BANDING BAND. Ex. 'BKWH' = GROUND:BLACK,
STRIPE:WHITE
RD RED
Wiring, panel 7- 6.
FBR-80 7-6-1.
54001-92011-0E
137
7 Wiring (Diagrams)
A
WIRE END NAME FROM TO WIRE COLOR LENGTH
LCD DISPLAY 1A 1B A 23 D WHITE RED

500
䈜FOR 'WITHOUT SGL' 2A 2B A 23 D WHITE BLUE
500
NOTE THE PIN ARRAY. 3A 3B A 23 D BLACK1
500
4A 4B A 23 3 F WHITE GREEN
470
5A 5B A 23 3 F GREEN WHITE
470
A1 6A 6B A 23 3 F RED
470
A2
7A 7B A 23 3 F BLACK2
470
A3
A4 8A 8B B 4 3 F RED GREEN 415
A6 A5 A4 A3 A2 A1
B6 B5 B4 B3 B2 B1
A5 9A 9B B 4 3 F RED BLUE 355

A6 10A 10B C 18 3 F BLUE YELLOW 520
12P WHGN
4A F B1 23
GNWH 11A 11B C 18 E BLACK3 230
5A F B4 23
C 450
WHGN
13A A B2 23
13B A B3 23
WHGN SWITCH FOR HEADLAMP 11C F 3
B
RD
AMP 1-1827864-6 6A F B5 23 12A 12B E 3 F YELLOW RED 450
BK2
7A F B6 23 SWITCH FOR EMERGENCY 13A 13B A 23 23 A WHITE GREEN 100
䈜WIRE END NAME 1,2,3 ARE FOR 'WITH SGL'.

9A 8A COVER WITH THE SLEEVE.
F F
䈜FOR 'WITH SGL' BUYE
4 4 18 F 10A
NOTE THE PIN ARRAY.
BK3
18 E 11A
WHRD
1A D A1 䈜ONLY FOR 'WITH SGINAL LAMP'
(RDGN)
23
(RDBU)
D
WHBU
2A D A2 23
A3 50 SWITCH FOR TURN SIGNAL

A4
A6 A5 A4 A3 A2 A1
B6 B5 B4 B3 B2 B1
A5 WHRD A 1B 1
BK1
3A D A6 23 BK1 2
12P WHGN
4A F B1 23
WHBU A 3B 3
GNWH
5A F B4 23
A 2B
WHGN
13A A B2 23
WHGN
13B A B3 23
6A F B5 23
RD KEY WAY SIDE
AMP 1-1827864-6
BK2
7A F B6 23
CONNECT BY SOLDERING
F 12A
YERD
BK3 E SWITCH FOR HORN
CF 11B
BUYE
4P 10B C 1 3
2 1 BLACK 12B E 2 3
YERD
4 3 11C E 3 3
BK3
CAP
AMP 172133-2
F BODY HARNESS 8B B 1 3
RDGN
RDBU
NOTE.
3.ALL PIN LAYOUT SHOWS THE VIEW FROM TERMINAL
9B B 2 3
6P
3 2 1
BLACK
4B A 3 3
WHGN
INSERT SIDE. HARNESS COLOR
GNWH GROUND
6 5 4 CAP
5B A 4 3
RD
4.STRAND PART AT THE PITCH OF 25mm AND STRIPE
AMP 171897-2
6B A 5 3
BELOW. BK BLACK YE YELLOW BN BROWN
BK2
7B A 6 3
5.THE MARK BAND IN FIGURE IS UNNECESSARY FOR WH WHITE GN GREEN BU BLUE
THE PRODUCT. RD RED
STRIPE:WHITE
Harness, panel 7- 7.
FBR9 - 40 - 80 7-7-1.
E0000-45591-0E
138
Wiring (Diagrams) 7
A
1A 1B A 24 D WHITE RED 370
CONNECT WITH LCD DISPLAY 2A 2B A 24 D WHITE BLUE 370
3A 3B A 24 D BLACK 370
䈜FOR 'WITHOUT SGL' 4A 4B A 24 F
3 WHITE GREEN 280
5A 5B A 24 3 F GREEN WHITE 280
6A 6B A 24 3 F RED 280
NOTE THE PIN ARRAY.
7A 7B A 24 3 F BLACK2 280
8A 8B B 4 3 F RED GREEN 355
9A 9B B 4 3 F RED BLUE 295
1 CAVITY PLUG
10A 10B C 18 3 F BLUE YELLOW 460
2 CAVITY PLUG
11A 11B C 18 E BLACK3 230
3 CAVITY PLUG
C 390
WATERPROOF
4 3 2 1 4 CAVITY PLUG
TYPE WHGN SWITCH FOR HEADLAMP 11C F 3
8 7 6 5
8P 4A F 5 24
GNWH
B
5A F 6 24 12A 12B E 3 F YELLOW RED 390
RD
AMP 174982-2 6A F 7 24 SWITCH FOR EMERGENCY
BK2
7A F 8 24 䈜WIRE END NAME 1,2,3 ARE FOR 'WITH SGL'.
9A 8A COVER WITH THE SLEEVE.
䈜FOR 'WITH SGL' F F
BUYE
4 4 18 F 10A
BK3
NOTE THE PIN ARRAY. 18 E 11A
RDGN
RDBU
䈜ONLY FOR 'WITH SGL'
1A D1 24
WHRD
WHBU
D SWITCH FOR TURN SIGNAL
2A D 2 24
3A D3 24
BK1
WHRD A 1B 1
WATERPROOF
4 3 2 1
TYPE
4 CAVITY PLUG BK1 2
WHGN
8 7 6 5
8P 4A F 5 24
WHBU A 3B 3
GNWH
5A F 6 24
A 2B
RD
AMP 174982-2 6A F 7 24
BK2
7A F 8 24
KEY WAY SIDE
CONNECT BY SOLDERING
F 12A
YERD
E
BUYE
4P 1
10B C 3
2 1 BLACK 12B E 2 3
YERD
SWITCH FOR HORN
BK3
4 3 11C E 3 3
BK3
CAP
AMP 172133-2 CF 11B
F BODY HARNESS
8B B 1 3
RDGN
RDBU
9B B 2 3
6P WHGN
3 2 1 4B A 3 3
BLACK GNWH
6 5 4 CAP
5B A 4 3
RD
AMP 171897-2
6B A 5 3
BK2
7B A 6 3
NOTE.
STRIPE
3.All PIN LAYOUT SHOWS THE VIEW FROM TERMINAL INSERT SIDE.
4.STRAND PART AT THE PITCH OF 25 mm AND BELOW. Ex. 'BKWH' = GROUND:BLACK,
STRIPE:WHITE
5.THE MARK BAND IN FIGURE IS UNNECESSARY FOR THE PRODUCT. RD RED
Harness, panel 7- 7.
FBR9N - 12N - 80 7-7-2.
E0000-32335-1E
139
7 Wiring (Diagrams)
ONLY FOR
䞉CHARGE MONITORING SYSTEM (CMS)(OPT.)
䞉WH METER (OPT)
SWITCH ASS'Y,KEY
SCREW,PAN HEAD
MAGNETIC CONTACTOR (WITH THERMAL)
BRACKET,CHARGER
GREEN
RECEPTACLE
ST
IG
4
CLAMPING POINT (NOTE.3) RD NUT
WASHER,LOCK
B 4 WASHER,PLAIN
4
WH FASTEN IT BY TOOTHED LOCK WASHER AND NUT.
TERMINAL DO NOT USE WASHER,LOCK OR WASHER,PRAIN.
WH
RD
BK
RD1 <FIG.1>
BNYE
WH
BK
BK
RD2
RD RD
4 4 4 A1 3 SCREW,W/WASHERS
1/R 3/S 5/T THERMISTOR
WH WH
BU HARNESS,BC BK
A2 3 TERMINAL STOPPER
BU
95 3 WIRE,LEAD
䡡TIGHTENING TORQUE OF
TERMINAL:0.98~1.18Nm
GROUND TERMINAL
(GN) TERMINAL OF WIRE,LEAD

RECEPTACLE 䡡PART OF NAKED WIRE:10±1mm
WH
2 4 4 4 6 4 96 3
NOTE.1
RECEPTACLE(OUTLET) 4
(REFER TO FIG.2)
DETAIL TO ATTACH THERMISTOR
FASTEN WIRE,LEAD BY TERMINAL,AND CONNECT THERMISTER TO TERMINAL
BY SCREW,W/WASHERS(M3 L=8).
4P
RED BASE,MOUNT (NOTE.4)
WH
RD
BK
ONLY FOR CHARGE MONITORING SYSTEM (CMS)(OPT.)

CAP PANEL,CHARGER
(VIEW FROM THE BACK OF PANEL)
<WITH CHARGE MONITORNIG SYSTEM (CMS)>

TO HARNESS,BODY
80
80 PAN HEAD SCREW
BRACKET,CHARGER
STOPPER
(VIEW FROM THE BACK OF BRACKET)
FIT TO THE BOTTOM EDGES 3P-X 15P 䡡TIGHTENING TORQUE OF

PAN HEAD SCREW:0.98~1.18Nm
OF THE BRACKET,CHARGER
WITH THE BASE,MOUNT.
TO TRANSFORMER TO HARNESS,BODY TERMINAL OF WIRE,LEAD

<OTHERS>
<FIG.2>

NOTE.
STRIPE
1.INSTALL GROUND TERMINAL OF RECEPTACLE IN BRACKET,CHARGER.
(REFER TO FIG.1)
AND,CONFIRM GROUND TERMINAL AND BRACKET ARE CONDUCTING.
WH WHITE GN GREEN BU BLUE 2.REFER TO WIRING,SYSTEM FOR DRAWING OF SYSTEM.
Ex. 'BKWH' = GROUND:BLACK, 3.THIS DRAWING SHOWS CLAMPING IN BANDING BAND.
RD RED
STRIPE:WHITE 4.AFFIX BASE,MOUNT TO BRACKET,CHARGER, AND FIX HARNESS,BC
AND HARNESS,CHARGERPANEL WITH BANDING BAND.
Wiring, charger panel 7- 8.

FBR - 80 (3Ø, 200V) 7-8-1.
54002-66840-2E
140
Wiring (Diagrams) 7
ONLY FOR
䞉CHARGE MONITORING SYSTEM (CMS)(OPT.)
䞉WH METER (OPT)
SWITCH ASS'Y,KEY
SCREW,PAN HEAD
BRACKET,CHARGER
GREEN
RECEPTACLE
MAGNETIC CONTACTOR (WITH THERMAL)
NUT
WASHER,LOCK
WASHER,PLAIN
ST
IG CLAMPING POINT (NOTE.3)
4 FASTEN IT BY TOOTHED LOCK WASHER AND NUT.
B 4 RD
TERMINAL DO NOT USE WASHER,LOCK OR WASHER,PRAIN.
4
RD <FIG.1>
RD
WH
BNYE
WH
BK
BK
WH
BK
SCREW,W/WASHERS
RDBK
THERMISTOR
RD
BU
RD RD
13 3 1 4 3 4 5 4 3 3
A1 A2
WH WH TERMINAL STOPPER
䡡TIGHTENING TORQUE OF
TERMINAL:0.98~1.18Nm
HARNESS,BC BK
14 3
YERD
TERMINAL OF WIRE,LEAD
BU
95 3 WIRE,LEAD
GROUND TERMINAL
DETAIL TO ATTACH THERMISTOR

GN FASTEN WIRE,LEAD BY TERMINAL,AND CONNECT THERMISTER TO TERMINAL
BY SCREW,W/WASHERS(M3 L=8).
REFER TO FIG.2
WH
2 4 4 4 6 4 96 3
NOTE.1
4 <WITH CHARGE MONITORNIG SYSTEM (CMS)>
RECEPTACLE(OUTLET)
WH
RD
BK
4P
RED BASE,MOUNT (NOTE.4)
ONLY FOR CHARGE MONITORING SYSTEM (CMS)(OPT.)
CAP PANEL,CHARGER
(VIEW FROM THE BACK OF PANEL)
PAN HEAD SCREW

TO HARNESS,BODY
80 80 䡡TIGHTENING TORQUE OF
STOPPER
PAN HEAD SCREW:0.98~1.18Nm
BRACKET,CHARGER
(VIEW FROM THE BACK OF BRACKET) TERMINAL OF WIRE,LEAD
3P-X
FIT TO THE BOTTOM EDGES
OF THE BRACKET,CHARGER
15P
WITH THE BASE,MOUNT. <OTHERS>
TO TRANSFORMER TO HARNESS,BODY
<FIG.2>

NOTE.
STRIPE
1.INSTALL GROUND TERMINAL OF RECEPTACLE IN BRACKET,CHARGER.
(REFER TO FIG.1)
AND,CONFIRM GROUND TERMINAL AND BRACKET ARE CONDUCTING.
WH WHITE GN GREEN BU BLUE 2.REFER TO WIRING,SYSTEM FOR DRAWING OF SYSTEM.
Ex. 'BKWH' = GROUND:BLACK, 3.THIS DRAWING SHOWS CLAMPING IN BANDING BAND.
RD RED
STRIPE:WHITE 4.AFFIX BASE,MOUNT TO BRACKET,CHARGER, AND FIX HARNESS,BC
AND HARNESS,CHARGERPANEL WITH BANDING BAND.
Wiring, charger panel 7- 8.

FBR - 80 (3Ø, 200V) 6.4kVA 7-8-2.
54002-75510-0E
141
7 Wiring (Diagrams)
NOTE.
INSERT SIDE.
5.WHEN USE TERMINAL THAT NOT COARTING PRESS DOWN,
THERMAL CONTRACTION
COVER TERMINAL IN THE THERMAL CONTRACTION TUBE
10 OR LESS AS SHOW IN FIG.1.
TUBE
RD1䕧 6.HOWEVER,WHEN USE THE THERMAL CONTRACTION TUBE IN PART,

1B A 4 COVER TWO WIRING IN THE THERMAL CONTRACTION TUBE
NOTE.6
RD2䕧
AS SHOW IN FIG.2.
5A C 4 FIG.1
THERMAL CONTRACTION
TUBE WIRE END NAME FROM TO WIRE COLOR LENGTH
RD2䕧
5B C 3
10 OR LESS HARNESS COLOR GROUND
1A 1B A 39 4 C RED1䕧 260
STRIPE
RD1䕧
WH WHITE GN GREEN BU BLUE 2A 2B A 39 4 C BLACK䕧 240
RD2䕧
2B A 4
BK䕧 RD RED
STRIPE:WHITE
3A 3B A 39 3 ▲ B WHITE䕧 190
FIG.2 4A 4B B 3 3 ▲ B BLUE䕧 210
5A 5B C 4 3 C RED2䕧 70
C THE UPPER PART OF

MAGNETIC CONTACTOR
AMP 350736-1
RD1䕧
BK䕧
39 1 C 1A
39 2 C 2A
WH䕧 PLUG 1 4 7 10 13
BU䕧 39 3 B 3A
4A B 3
4 15P
5 2 5 8 11 14
6
7 3 6 9 12 15
BU䕧
4B B ▲ 3 8
9
A BODY HARNESS
10
11
WH䕧 12
3B A ▲3 13
14
15
B THE LOWER PART OF

MAGNETIC CONTACTOR
Harness, BC 7- 9.
FBR - 80 STD 7-9-1.
54002-59112-0E
142
Wiring (Diagrams) 7
NOTE.
1.STRAND PART AT THE PITCH OF 25mm AND BELOW.
10 OR LESS THERMAL CONTRACTION 10 OR LESS STRIPE WIRE END NAME FROM TO WIRE COLOR LENGTH
TUBE 4.ALL PIN LAYOUT SHOWS THE VIEW FROM TERMINAL
RD1䕧 INSERT SIDE. 1A 1B A 39 4 C RED1䕧 260
WH WHITE GN GREEN BU BLUE 5.DISPLAY THE ALPHABET WITH DESCRIPTION OR STAMPING
THERMAL CONTRACTION TUBE RD2䕧 Ex. 'BKWH' = GROUND:BLACK,
IN IMMARTAL INK.
RD RED
STRIPE:WHITE 2A 2B A 39 4 C BLACK䕧 240
7.DISPLAY THE ALPHABET OR COLOR TO TAPE OR BAND MARKING.
FIG.1 FIG.2 8.WHEN USE TERMINAL THAT NOT COARTING PRESS DOWN, 3A 3B A 39 3 ▲ B WHITE䕧 190
COVER TERMINAL IN THE THERMAL CONTRACTION TUBE 4A 4B A 39 10 D RED YELLOW 250
AS SHOW IN FIG.1.
9.HOWEVER,WHEN USE THE THERMAL CONTRACTION TUBE IN PART, 5A 5B A 39 10 D RED 250
COVER TWO WIRING IN THE THERMAL CONTRACTION TUBE 6A 6B A 39 10 D BLACK 250
AS SHOW IN FIG.2.
7A 7B A 39 10 D RED YELLOW 240
8A 8B A 39 10 D WHITE 240
9A 9B A 39 10 D BLACK 240
RD1䕧
1B A 4 10A 10B B 3 3 ▲ B BLUE䕧 210
NOTE.9
11A C 4
RD2䕧 11A 11B C 4 3 C RED2䕧 70
11B C 3
RD2䕧
DCURRENT SENSOR FOR CHARGE
(NOTE.5)
BK䕧
2B A 4
RDYE
10 1 4B 1 2 3 4
A
C THE UPPER PART OF RD

2
10 3 5B
MAGNETIC CONTACTOR BK A
10 4
A 6B 4P
RD
RDYE
10 1 7B 1 2 3 4
A
WH
2
10 3 8B
BK A
10 4
A 9B 4P WH
RD1䕧
AMP 350736-1
A BODY HARNESS
BK䕧
39 1 C 1A
WH䕧
39 2 C 2A
BU䕧
RDYE
39 3 B 3A
10A B 3
39 4 D 4A
RD
BK
39 5 D 5A
39 6 D 6A 1 4 7 10 13
RDYE
39 7 D 7A PLUG
BU䕧 WH 2 5 8 11 14
10B B ▲3 BK
39 8 D 8A 15P
39 9 D 9A 3 6 9 12 15
BK1
56 10
BK1
WH䕧 56 11
3B A ▲3 CLAMP 12
BK2
56 13
BK2
56 14
15
ATTACH A PIN TO THE THERMISTOR WIRING.
INSERT THE PIN INTO THE PLUG.
B THE LOWER PART OF

MAGNETIC CONTACTOR BK1
BK1
RD
NO POLARITY
BK2 WH
BK2
ETHERMISTER (NOTE.7)
Harness, BC 7- 9.
FBR - 80 w/charging monitoring system (CMS) 7-9-2.
54002-52252-0E
143
7 Wiring (Diagrams)
NOTE.
THERMAL CONTRACTION 1.STRAND PART AT THE PITCH OF 25mm AND BELOW. HARNESS COLOR GROUND WIRE END NAME FROM TO WIRE COLOR LENGTH
10 OR LESS TUBE 10 OR LESS 4.ALL PIN LAYOUT SHOWS THE VIEW FROM TERMINAL
INSERT SIDE. BK BLACK YE YELLOW BN BROWN
STRIPE
1A 1B A 39 4 C RED1䕧 260
(RD1䕧) 5.DISPLAY THE ALPHABET WITH DESCRIPTION OR STAMPING
THERMAL CONTRACTION IN IMMARTAL INK. WH WHITE GN GREEN BU BLUE
TUBE (RD2䕧) Ex. 'BKWH' = GROUND:BLACK, 2A 2B A 39 4 C BLACK䕧 240
STRIPE:WHITE
7.WHEN USE TERMINAL THAT NOT COARTING PRESS DOWN, RD RED 3A 3B ▲
A 39 3 B WHITE䕧 190
FIG.1 FIG.2 COVER TERMINAL IN THE THERMAL CONTRACTION TUBE
AS SHOW IN FIG.1. 4A 4B A 39 10 D RED YELLOW 250
8.HOWEVER,WHEN USE THE THERMAL CONTRACTION TUBE IN PART, 5A 5B A 39 10 D RED 250
COVER TWO WIRING IN THE THERMAL CONTRACTION TUBE
AS SHOW IN FIG.2. 6A 6B A 39 10 D BLACK 250
7A 7B A 39 10 D RED YELLOW 240
8A 8B A 39 10 D WHITE 240
9A 9B A 39 10 D BLACK 240
RD1䕧
1B A 4 10A 10B B 3 3 ▲ B BLUE䕧 210
NOTE.8
RD2䕧 11A 11B C 4 3 C RED2䕧 70
11A C 4
11B C 3
RD2䕧
D CURRENT SENSOR FOR CHARGE
(NOTE.5)
BK䕧
2B A 4
RDYE
10 1 4B 1 2 3 4
A
C THE UPPER PART OF 2

RD
10 3 5B
10 4
A 6B 4P
RD
RDYE 1 2 3 4
10 1 7B
A
2
WH
10 3 8B
A
BK 10 4
A 9B 4P WH
RD1䕧
AMP 350736-1
A BODY HARNESS
BK䕧
39 1 C 1A
WH䕧
39 2 C 2A
BU䕧
RDYE
39 3 B 3A
10A B 3
39 4 D 4A
RD
BK
39 5 D 5A
39 6 D 6A 1 4 7 10 13
RDYE
39 7 D 7A PLUG
BU䕧 WH 2 5 8 11 14
10B B ▲3 BK
39 8 D 8A 15P
39 9 D 9A 3 6 9 12 15
10
11
WH䕧 12
3B A ▲3 13
14
15
B MAGNETIC
THE LOWER PART OF
CONTACTOR
Harness, BC 7- 9.
FBR - 80 w/electric power usage meter 7-9-3.
54002-61682-0E
144
Wiring (Diagrams) 7
1A 1B A 39 4 C RED䕧 280
1C C 3 70
2A 2B A 39 4 C BLACK䕧 260
3A 3B A 3 ▲ B WHITE䕧 210
10A 10B C ▲ 3 3 ▲ B BLUE䕧 330
11A 11B A 3 ▲ C RDBK 320
12A 12B A 3 ▲ B YERD 270
RDBK
11B A ▲ 3
RD䕧
1B A,C 4
RD䕧
1C C 3
BU䕧
10A B ▲ 3
BK䕧
2B A 4
C THE UPPER PART OF

MAGNETIC CONTACTOR
NOTE.
A
INSERT SIDE.
BODY HARNESS
AMP 350736-1
RD䕧 39 1 C 1A
BK䕧 39 2 C 2A
WH䕧
YERD 39 3 B 3A
12B A ▲ 3
4
5 HARNESS COLOR GROUND
6 1 4 7 10 13 STRIPE
7 PLUG BK BLACK YE YELLOW BN BROWN
BU䕧 2 5 8 11 14
10B C ▲3 8 15P
9 WH WHITE GN GREEN BU BLUE
RDBK 3 6 9 12 15
39 12 C 11A Ex. 'BKWH' = GROUND:BLACK,
YERD STRIPE:WHITE
39 15 B 12A RD RED
WH䕧 10
3B A ▲3 11
13
14
NOTE THE PIN ARRAY.
B THE LOWER PART OF

MAGNETIC CONTACTOR
Harness, BC 7- 9.
FBR - 80 6.4kVA STD 7-9-4.
54002-75480-0E
145
7 Wiring (Diagrams)
1A 1B A 39 4 C RED䕧 280
1C C 3 70
4A 4B 39 10 D RED YELLOW 250
5A 5B A 39 10 D RED 250
6A 6B A 39 10 D BLACK 250
RDBK 7A 7B A 39 10 D RED YELLOW 240
11B A ▲ 3
8A 8B A 39 10 D WHITE 240
9A 9B A 39 10 D BLACK 240
RD䕧
1B A,C 4 10A 10B C ▲ 3 3 ▲ B BLUE䕧 330
RD䕧 11A 11B A 3 ▲ C RDBK 320
1C C 3

12A 12B A 3 ▲ B YERD 270
BU䕧
10A B ▲ 3
(NOTE.5)
BK䕧 NOTE.
2B A 4
1.STRAND PART AT THE PITCH OF 25mm AND BELOW.
RDYE 4.ALL PIN LAYOUT SHOWS THE VIEW FROM TERMINAL
10 1 4B 1 2 3 4
A INSERT SIDE.
C
2
THE UPPER PART OF RD
10 3 5B 5.DISPLAY THE ALPHABET WITH DESCRIPTION OR STAMPING
10 4
A 6B 4P
RD IN IMMARTAL INK.
RDYE 7.DISPLAY THE ALPHABET OR COLOR TO TAPE OR BAND MARKING.

10 1 7B 1 2 3 4
A
WH
2
10 3 8B
BK A
10 4
A 9B 4P WH
A
STRIPE
BODY HARNESS
AMP 350736-1
RD䕧 WH WHITE GN GREEN BU BLUE
BK䕧
39 1 C 1A Ex. 'BKWH' = GROUND:BLACK,
WH䕧
39 2 C 2A STRIPE:WHITE
YERD 39 3 B 3A RD RED
12B A ▲ 3 RDYE
39 4 D 4A
RD
BK
39 5 D 5A
39 6 D 6A 1 4 7 10 13
RDYE
WH
39 7 D 7A PLUG
BU䕧 2 5 8 11 14
10B C ▲3 BK
39 8 D 8A 15P
39 9 D 9A
RDBK 3 6 9 12 15
YERD
39 12 C 11A
39 15 B 12A
WH䕧
3B A ▲3 CLAMP
BK1
56 10
BK1
56 11
BK2
56 13
BK2
56 14
BTHE LOWER PART OF ATTACH A PIN TO THE THERMISTOR WIRING. NOTE THE PIN ARRAY.
MAGNETIC CONTACTOR (BK1) RD INSERT THE PIN INTO THE PLUG.
(BK1)
NO POLARITY
(BK2) WH
(BK2)
E THERMISTER (NOTE.7)
Harness, BC 7- 9.
FBR - 80 6.4kVA w/charging monitoring system (CMS) 7-9-5.
54002-75490-0E
146
Wiring (Diagrams) 7
1A 1B A 39 4 C RED䕧 280
1C C 3 70
4A 4B 39 10 D RED YELLOW 250
5A 5B A 39 10 D RED 250
6A 6B A 39 10 D BLACK 250
RDBK 7A 7B A 39 10 D RED YELLOW 240
11B A ▲ 3
8A 8B A 39 10 D WHITE 240
9A 9B A 39 10 D BLACK 240
RD䕧
1B A,C 4 10A 10B C ▲ 3 3 ▲ B BLUE䕧 330
RD䕧 11A 11B A 3 ▲ C RDBK 320
1C C 3

12A 12B A 3 ▲ B YERD 270
BU䕧
10A B ▲ 3
(NOTE.5)
BK䕧 NOTE.
2B A 4 1.STRAND PART AT THE PITCH OF 25mm AND BELOW.
RDYE 4.ALL PIN LAYOUT SHOWS THE VIEW FROM TERMINAL
10 1 4B 1 2 3 4 INSERT SIDE.
A
C THE UPPER PART OF RD

2
10 3 5.DISPLAY THE ALPHABET WITH DESCRIPTION OR STAMPING
5B
MAGNETIC CONTACTOR BK A IN IMMARTAL INK.
10 4
A 6B 4P
RD
RDYE
10 1 7B 1 2 3 4
A
WH
2
10 3 8B
BK A
10 4
A 9B 4P WH HARNESS COLOR GROUND
STRIPE
A BODY HARNESS

AMP 350736-1 Ex. 'BKWH' = GROUND:BLACK,
RD䕧
BK䕧
39 1 C 1A RD RED
STRIPE:WHITE
WH䕧
39 2 C 2A
YERD 39 3 B 3A
12B A ▲ 3 RDYE
39 4 D 4A
RD
39 5 D 5A
BK
39 6 D 6A 1 4 7 10 13
RDYE
39 7 D 7A PLUG
BU䕧 WH 2 5 8 11 14
10B C ▲3 BK
39 8 D 8A 15P
RDBK
39 9 D 9A 3 6 9 12 15
YERD
39 12 C 11A
39 15 B 12A
WH䕧 10
3B A ▲3 11
13
14
NOTE THE PIN ARRAY.
B THE LOWER PART OF

MAGNETIC CONTACTOR
Harness, BC 7- 9.
FBR - 80 6.4kVA w/electric power usage meter 7-9-6.
54002-75500-0E
147
7 Wiring (Diagrams)
Harness Color Ground

Stripe
BK Black YE Yellow BN Brown
WH White GN Green BU Blue

Ex. 'BKWH' = Ground:Black,
Stripe:White
RD Red
WIRING,SYSTEM
Battery voltage output after
RDWH
BKWH
turning on a key switch
WH BK
Wire for Strobelight
Note:
3.Terminal
1 :Shur Plug(plating) 170020-2 2P WH To Strobelight
1 :Shur Receptacle(plating) 170021-2
4.HARNESS COMP.,LAMP is drawn out from the edge of PROTECTOR,HEAD GUARD. Note.4
HARNESS COMP.,LAMP is collectively fixed to the HEAD GUARD like circle.
PROTECTOR,HEAD GUARD
HEAD GUARD for Driver's seat side
HARNESS COMP.,LAMP
The inside of top cover
WH
BK
1 1
Accessory
1 1
RDWH
BKWH
HARNESS,BODY
Wiring, accessory 7- 10.

Wiring for strobe light 7-10-1.
54000-30330-1E
148
Wiring (Diagrams) 7

Stripe REVOLVING LAMP

Stripe:White
RD Red
WH
BK
WIRING,SYSTEM 2 2
RDWH
BKWH
2 2
Battery voltage output after
turning on a key switch
WH
BK
WH
BK
HARNESS,ACCESORY
1 1
1 1 TUBE
REVOLVING LAMP
YERD
BNYE
Insert
Note: PROTECTOR,HEAD GUARD

1.Terminal
1 :Shur Plug 170020-2
2 :Shur Plug 170020-3(Loose Piece)
170002-5(Strip Form) HARNESS,HEAD GUARD
1 :Shur Receptacle 170021-2
2 :Shur Receptacle 170021-3(Loose Piece)
170003-5(Strip Form)
4.It covers the HARNESS,ACCESORY from the PROTECTOR,HEAD GUARD
to the REAR LAMP with the TUBE. The inside of front hood
RDWH 1 1
YERD
BKWH 1 1
BNYE
Accessory
HARNESS,BODY
Wiring, lamp 7- 11.

Revolving lamp 7-11-1.
24801-35171-1E
149
7 Wiring (Diagrams)
WIRING,SYSTEM
REVOLVING LAMP
BATTERY VOLTAGE OUTPUT

RDBK
MAIN BOARD
WH
YERD WH BK BNYE BN
BK
CN1-28
(OUTPUT FOR REVERSE)
REVOLVING LAMP 2 2
2 2
WH
BK
WH
BK
1 1
HARNESS, ACCESSORY
1 1
TUBE
YERD
BNYE
NOTE: INSERT
1.TERMINAL
1 :SHUR PLUG 170020-2
2 :SHUR PLUG 170020-3(LOOSE PIECE)
170002-5(STRIP FORM)
1 :SHUR RECEPTACLE 170021-2
2 :SHUR RECEPTACLE 170021-3(LOOSE PIECE)
4.IT COVERS THE HARNESS,HEAD GUARD FROM PROTECTOR,HEADGUARD
THE PROTECTOR,HEAD GUARD TO THE REVOLVING LAMP
WITH THE TUBE.
HARNESS,HEAD GUARD

STRIPE
WH WHITE GN GREEN BU BLUE THE INSIDE OF FRONT HOOD

Ex. 'BKWH' = GROUND:BLACK, HARNESS, BODY
STRIPE:WHITE
RD RED
RDBK 1 1
YERD
BN 1 1
BNYE
ACCESSORY
Wiring, lamp 7- 11.

Revolving lamp interlocking reverse travelling 7-11-2.
150 54002-68100-1E
Wiring (Diagrams) 7

STRIPE
WORKING LAMP
STRIPE:WHITE
RD RED
2 2
WIRING,SYSTEM 2 2
WORKING LAMP SW
NOTE.4
WH
BKWH
BK
RDBK
1 1b
18 18
WH
WORKING LAMP
RDBK
TUBE
WH
INSERT
THE INSIDE OF FRONT HOOD
NOTE:
1.TERMINAL
1 :SHUR PLUG 170020-2
2 :SHUR PLUG 170020-3(LOOSE PIECE) THE INSIDE OF CONTROL PANEL
170002-5(STRIP FORM) HARNESS,ACCESORY
18 :RECEPTACLE(#110) 170043-2 WH WH
4.INSTALL THE WORKINGLAMP SW THAT HAVE THE MODEL NAME 1 1
TO RIGHT SIDE FROM VIEW OF THE BACK OF PANEL.
ACCESSORY
HARNESS,SWITCH
HARNESS,BODY
RDBK 1
RDBK 1 1
RDBK
BK 1 1
BKWH
Wiring, lamp 7- 11.

Working lamp 7-11-3.
54002-67810-0E
151
7 Wiring (Diagrams)
WIRING,SYSTEM
RDBK
BACK UP LAMP
BN MAIN BOARD
TO CN1-28
(OUTPUT FOR RVS)
BACK UP LAMP
2 2
2 2
WH
BK
NOTE:
1.TERMINAL
1 :SHUR PLUG 170020-2
170002-5(STRIP FORM) TUBE
170003-5(STRIP FORM) INSERT
THE INSIDE OF
HARNESS COLOR GROUND FRONT HOOD
STRIPE

STRIPE:WHITE
RD RED
HARNESS,ACCESORY
HARNESS,BODY
RDBK 1 1
WH
BN 1 1
BK
Accessory
Wiring, lamp 7- 11.
Back-up lamp (reversing lamp) 7-11-4.
54002-67840-0E
152
Wiring (Diagrams) 7

STRIPE
BK BLACK YE YELLOW BN BROWN REAR LAMP

STRIPE:WHITE
RD RED
2 2
2 2
WIRING,SYSTEM REAR LAMP SW
NOTE.4
BKWH
RDBK
WH
BK
WH
BK
1 1
1 1
YERD
BNYE
1 1b
18 18
INSERT
WH REAR LAMP
RDBK
TUBE
WH
NOTE:
1.TERMINAL
1 :SHUR PLUG 170020-2
2 :SHUR PLUG 170020-3(LOOSE PIECE) THE INSIDE OF CONTROL
170002-5(STRIP FORM) PANEL THE INSIDE OF FRONT HOOD
18 :RECEPTACLE(#110) 170043-2 WH YERD
4.INSTALL THE REARLAMP SW THAT HAVE THE MODEL NAME 1 1 HARNESS,HEAD GUARD
ACCESSORY
HARNESS,SWITCH
HARNESS,BODY
RDBK 1
RDBK 1 1
RDBK
BNYE 1 1
BKWH
Wiring, lamp 7- 11.

Rear lamp 7-11-5.
54002-68280-0E
153
7 Wiring (Diagrams)
WIRING,SYSTEM REAR LAMP

RDBK
MAIN BOARD 2 2
BN TO CN1-28
(OUTPUT FOR RVS) 2 2
䠳䠤
䠞䠧
REAR LAMP
HARNESS,ACCESSORY
䠳䠤
䠞䠧
NOTE:
1.TERMINAL
1 1
䚷䚷䚷䚷䠖SHUR
1 PLUG 170020-2
䚷䚷䚷䚷䠖SHUR
2 PLUG 170020-3(LOOSE PIECE)
1 1
TUBE
䠞䠪䠵䠡
䠵䠡䠮䠠
䚷䚷䚷䚷䠖SHUR RECEPTACLE 170021-2
1
䚷䚷䚷䚷䠖SHUR
2 RECEPTACLE 170021-3(LOOSE PIECE)

STRIPE
WH WHITE GN GREEN BU BLUE HARNESS,HEAD GUARD
䠡䡔. 'BKWH' = GROUND:BLACK,
䚷䚷䚷 STRIPE:WHITE
RD RED

HARNESS,BODY
RDBK 1 1
YERD
BN 1 1
BNYE
ACCESSORY
Wiring, lamp 7- 11.
Rear lamp interlocking reverse travelling 7-11-6.
54002-68290-0E
154
Wiring (Diagrams) 7
WIRING,SYSTEM HARNESS COLOR GROUND

REAR LAMP
STRIPE
BKWH
RDBK
STRIPE:WHITE
RD RED
2 2
BN MAIN BOARD
TO CN1-28
X
2 2
(OUTPUT FOR RVS)
WH
BK
YERD
REAR LAMP
HARNESS, ACCESSORY
NOTE:
WH
BK
1.TERMINAL
1 1
1 :SHUR PLUG 170020-2
1 1
TUBE
:SHUR RECEPTACLE 170021-2
YERD
BNYE
1
PROTECTOR, HEAD GUARD

HARNESS,HEAD GUARD
CA
RERAY
4P THE INSIDE OF
HARNESS,BODY BK FRONT HOOD
RDBK HARNESS,RELAY
1
RDBK 1 1
RDBK
BN 1 1
BN YERD 1 1
YERD
BKWH 1 1
BKWH BNYE
ACCESSORY
Wiring, lamp 7- 11.

Rear lamp 24V + separately interlocking reverse travelling 7-11-7.
54002-68300-0E
155
7 Wiring (Diagrams)

10A
RDBK
STRIPE
BK BLACK YE YELLOW BN BROWN SPOT LAMP
䠡䡔. 'BKWH' = GROUND:BLACK,
SPOT LAMP SW
䚷䚷䚷 STRIPE:WHITE
RD RED
2 2
2 2
WH
BK
(WH)
WH
BK
NOTE: 2 1 1
3.LEAD WIRE:AVSS 0.5mm
4.TERMINAL SPOT LAMP 1 1
䚷䚷䚷䚷䠖SHUR
2 PLUG 170020-3(LOOSE PIECE) TUBE
YERD
BNYE
1
䚷䚷䚷䚷䠖SHUR PLUG 170020-2
2
䚷䚷䚷䚷䠖SHUR RECEPTACLE 170021-3(LOOSE PIECE) INSERT
1
䚷䚷䚷䚷䠖SHUR RECEPTACLE 170021-2
18
䚷䚷䚷䚷䠖RECEPTACLE(#110) 170043-2 BKWH
5.CLAMP IT AT A SUITABLE POSITION, AND FIX
THE HARNESS,SWITCH TO HARNESS,BODY.
6.IT COVERS THE HARNESS,ACCESORY FROM
THE PROTECTOR,HEAD GUARD TO THE SPOT LAMP WIRING,SYSTEM PROTECTOR,HEAD GUARD
WITH THE TUBE.
7.INSTALL THE SPOTLAMP SW THAT HAVE THE MODEL NAME HARNESS,ACCESORY
ACCESSORY
CONTROL PANEL
YERD
BNYE
NOTE.7
1 1
RDBK
1 1
1 1
18 1
1
WH 18 1b
BKWH
RDBK
RDBK
RDBK
WH
HARNESS,SWITCH
HARNESS,BODY
Wiring, lamp 7- 11.

Spot lamp 7-11-8.
54002-68110-0E
156
Wiring (Diagrams) 7
NOTE:
3. Teminal
:SHUR PLUG 170020-2
1
BKWH
RDBK 4. Don’t touch the harness to the moving part, the edge, and the register part (heat source plate).
5. To switch the lamp ON and OFF, turn the rotary switch located near the head of the lamp.
6. Since the black wire for the Flexible Lamp is the body ground, when attaching the lamp, clamp it between an Oiles washer or
flange bushing (Truck G parts arrangement ), and then attach it.
SPOT LAMP After attaching the Flexible Lamp, be sure to thoroughly check truck insulation.
24V
100Ω,40W
BK RD/BU BU
(Attach to 48V truck only)

(Unnecessary for 24V truck)
ON/OFF SW
WIRING, SYSTEM
(Attach to 48V truck only)
(Unnecessary for 24V truck) REGISTER SPOT LAMP
COMP. (FLEXIBLE LAMP)
(100Ω,40W)
NOTE6
(48V SPEC.) (24V SPEC.)
RD
RD
BK
BK
BU
BU
1 1 1 1 1 1
Pay attention to wire color
1 1 Attach to terminal 1 1 1 1
BKWH
BU
BKWH
BU
RDBK
RDBK
ACCESSORY
RDBK 1 1
RDBK
BKWH 1 1
BKWH HARNESS, ACCESSORY
1
RDBK
HARNESS, BODY BKWH
1

STRIPE

STRIPE:WHITE
RD RED
Wiring, lamp 7- 11.

Spot lamp 7-11-9.
54002-81340-1E
157
7 Wiring (Diagrams)
MAIN
<NOTE>
LINE CONNECTOR 1.TERMINAL
2PIN CPU
No. CN □ 1 :SHUR PLUG AMP 170020-2
No.
1 :SHUR RECEPTACLE AMP 170887-1
GNBK INPUT FOR BATTERY
BW 3 97 M ELECTROLYTE LEVEL 52 :PLUG SATO-PARTS TJ-2-P
52 :SUHR RECEPTACLE SATO-PARTS TJ-2-J
4.HARNESS,SIGNAL IS CLAMP WITH WIRE COMP.,BATTERY.

STRIPE
SENSOR FOR
BATTERY ELECTROLYTE LEVEL WH WHITE GN GREEN BU BLUE
WIRING,SYSTEM Ex. 'BKWH' = GROUND:BLACK,
STRIPE:WHITE
RD RED
HARNESS,SIGNAL(NOTE.4)
PLUG,BATTERY
WIRE COMP.,BATTERY
52 52
CLAMPING(CLAMP IN THE SAME PLACE
<1> WITH WIRE COMP.,BATTERY)
-
<2> +
-
CLAMPING(WITH "+"LINE) BANDING BAND(WITH "+"LINE)

50 50 50 50
CLAMP IS UNNECESARRY
BATTERY
GNBK GNBK
1 1
HARNESS,MAIN
HARNESS,BODY
Wiring, lamp 7- 11.

Signal, display replenish water message 7-11-10.
54002-70320-0E
158
Wiring (Diagrams) 7
㻯㻴㻵㻹㻱
㻮㻭㻯㻷㼃㻭㻾㻰㻌㻯㻴㻵㻹㻱㻺㻻㼀㻱㻦
ͤWITHOUT ON/OFF SW
ͤWITH ON/OFF SW
㻝㻚㼀㻱㻾㻹㻵㻺㻭㻸
䚷䚷䚷䚷䠖㻿㻴㼁㻾㻌㻼㻸㼁㻳㻌㻝㻣㻜㻜㻞㻜㻙㻞
RD
㻝
BK
䚷䚷䚷䚷䠖㻿㻴㼁㻾㻌㻾㻱㻯㻱㻼㼀㻭㻯㻸㻱㻌㻝㻣㻜㻜㻞㻝㻙㻞
㻝
㻯㻴㻵㻹㻱
䚷䚷䚷䚷䠖㻾㻱㻯㻱㻼㼀㻭㻯㻸㻱㻔㻏㻝㻝㻜㻕㻌㻝㻣㻜㻜㻠㻟㻙㻞
㻝㻤㻻㻺㻛㻻㻲㻲㻌㻿㼃 NOTE.4
㻞㻚㻾㻱㻲㻱㻾㻌㼀㻻㻌㻹㻺㻿㻌㻰㻜㻜㻟㻡㻌㻲㻻㻾㻌㼃㻵㻾㻱㻌㼀㻾㻱㻭㼀㻹㻱㻺㼀㻚
RD
BK
㻟㻚㻾㻱㻲㻱㻾㻌㼀㻻㻌㻹㻺㻿㻌㻼㻜㻜㻟㻜㻌㻲㻻㻾㻌㻰㻾㻭㼃㻵㻺㻳㻌㻵㻺㻿㼀㻾㼁㻯㼀㻵㻻㻺㻚㻴㻭㻾㻺㻱㻿㻿㻘㻯㻴㻵㻹㻱㻝㻝
㻠㻚㻵㻺㻿㼀㻭㻸㻸㻌㼀㻴㻱㻌㻻㻺㻛㻻㻲㻲㻌㻿㼃㻌㼀㻴㻭㼀㻌㻴㻭㼂㻱㻌㼀㻴㻱㻌㻹㻻㻰㻱㻸㻌㻺㻭㻹㻱㻡㻠㻜㻜㻞㻙㻣㻥㻞㻟㻜㻙㻜
㻝㻝
㼀㻴㻱㻌㻵㻺㻿㻵㻰㻱㻌㻻㻲㻌㻰㻾㻵㼂㻱㻌㻾㻻㻻㻹
㻌㻌㼀㻻㻌㻾㻵㻳㻴㼀㻌㻿㻵㻰㻱㻌㻲㻾㻻㻹㻌㼂㻵㻱㼃㻌㻻㻲㻌㼀㻴㻱㻌㻮㻭㻯㻷㻌㻻㻲㻌㻼㻭㻺㻱㻸㻚
WIRING,SYSTEM 㻴㻭㻾㻺㻱㻿㻿㻘㻯㻴㻵㻹㻱㻝㻝
㻝㻝㼎
RD
BK
㻝㻝
㻡㻠㻜㻜㻞㻙㻣㻥㻞㻟㻜㻙㻜㻝㻤㻝㻤㻴㻭㻾㻺㻱㻿㻿㻘㻭㻯㻯㻱㻿㻿㻻㻾㼅㻔㻞㻕㻮㻭㼀㼀㻱㻾㼅㻌㻼㻻㼃㻱㻾
㻝
㻡㻠㻜㻜㻞㻙㻢㻣㻥㻤㻜㻙㻞㻔㼃㻵㼀㻴㻌㻿㼃㻵㼀㻯㻴㻕
RD
BK
㻝㻝
㻔㻮㻭㼀㼀㻱㻾㼅㻌㼂㻻㻸㼀㻭㻳㻱㻌㻻㼁㼀㻼㼁㼀㻕
RDBK
㻝㻝
RD
RD
RDBK
㻮㻭㼀㼀㻱㻾㼅㻌㻼㻻㼃㻱㻾㻌㻝
㻝㻝 RDBK 㻝㻝
㻝㻝
㻻㻺㻸㼅㻌㻻㻺㻛㻻㻲㻲㻌㻿㼃㻌㼀㼅㻼㻱
5.1kΩ BK
RDBK
RD 㼀㻴㻱㻌㻵㻺㻿㻵㻰㻱㻌㻻㻲㻌㻯㻻㻺㼀㻾㻻㻸㻌㻼㻭㻺㻱㻸㻌㻌
RDBK
ษ᭰SW 㻌㻌
BN
BN
RDBK RD RD BK BN 㻹㻼㼁㻌㻮㻻㻭㻾㻰
㼀㻻㻌㻯㻺㻝㻙㻞㻤㻴㻭㻾㻺㻱㻿㻿㻘㻮㻻㻰㼅㻌㻌
㻯㻴㻵㻹㻱㻔㻾㼂㻿㻌㻻㼁㼀㻼㼁㼀㻕㻴㻭㻾㻺㻱㻿㻿㻘㻮㻻㻰㼅
㻻㼁㼀㻌㻼㼁㼀㻌㻲㻻㻾㻌㻾㼂㻿
㻻㼁㼀㻌㻼㼁㼀㻌㻲㻻㻾㻌㻾㼂㻿
㻲㻻㻾㼃㻭㻾㻰㻌㻯㻴㻵㻹㻱 ͤWITHOUT ON/OFF SW ͤWITH ON/OFF SW

㻺㻻㼀㻱㻦
㻝㻚㼀㻱㻾㻹㻵㻺㻭㻸㻯㻴㻵㻹㻱
㻝㻯㻴㻵㻹㻱
㻝
㻻㻺㻛㻻㻲㻲㻌㻿㼃
RD
BK
㻝㻤 NOTE.4
RD
BK
㻟㻚㻾㻱㻲㻱㻾㻌㼀㻻㻌㻹㻺㻿㻌㻼㻜㻜㻟㻜㻌㻲㻻㻾㻌㻰㻾㻭㼃㻵㻺㻳㻌㻵㻺㻿㼀㻾㼁㻯㼀㻵㻻㻺㻚
㻠㻚㻵㻺㻿㼀㻭㻸㻸㻌㼀㻴㻱㻌㻻㻺㻛㻻㻲㻲㻌㻿㼃㻌㼀㻴㻭㼀㻌㻴㻭㼂㻱㻌㼀㻴㻱㻌㻹㻻㻰㻱㻸㻌㻺㻭㻹㻱㻝㻝
㻌㻌㼀㻻㻌㻾㻵㻳㻴㼀㻌㻿㻵㻰㻱㻌㻲㻾㻻㻹㻌㼂㻵㻱㼃㻌㻻㻲㻌㼀㻴㻱㻌㻮㻭㻯㻷㻌㻻㻲㻌㻼㻭㻺㻱㻸㻚㻴㻭㻾㻺㻱㻿㻿㻘㻯㻴㻵㻹㻱
WIRING,SYSTEM
㻝㻝㻝㻝
㻴㻭㻾㻺㻱㻿㻿㻘㻯㻴㻵㻹㻱㻡㻠㻜㻜㻞㻙㻣㻥㻞㻟㻜㻙㻜
㻝㻝㻝㻝㼎
㻡㻠㻜㻜㻞㻙㻣㻥㻞㻟㻜㻙㻜
㻝㻤㻝㻤
RD
BK
㻴㻭㻾㻺㻱㻿㻿㻘㻭㻯㻯㻱㻿㻿㻻㻾㼅㻔㻞㻕
RD
BK
㻮㻭㼀㼀㻱㻾㼅㻌㻼㻻㼃㻱㻾
㻡㻠㻜㻜㻞㻙㻢㻣㻥㻤㻜㻙㻞㻔㼃㻵㼀㻴㻌㻿㼃㻵㼀㻯㻴㻕㻝
㻝㻝
RDBK
㻮㻭㼀㼀㻱㻾㼅㻌㻼㻻㼃㻱㻾㻌
RDBK
㻝㻝㻝
RD
㻝㻝
㻝㻝 RD
㻻㻺㻸㼅㻌㻻㻺㻛㻻㻲㻲㻌㻿㼃㻌㼀㼅㻼㻱
RD 5.1kΩ BK RDBK 㻝㻝
RDBK
ษ᭰SW
BNBK
㼀㻴㻱㻌㻵㻺㻿㻵㻰㻱㻌㻻㻲㻌㻯㻻㻺㼀㻾㻻㻸㻌㻼㻭㻺㻱㻸
㻌㻌㻮㻭㼀㼀㻱㻾㼅㻌㻼㻻㼃㻱㻾㻌㻝
RDBK RD RD BK BNBK 㻹㻼㼁㻌㻮㻻㻭㻾㻰
BNBK
RDBK
㼀㻻㻌㻯㻺㻝㻙㻞㻣㻌㻌
㻴㻭㻾㻺㻱㻿㻿㻘㻮㻻㻰㼅㻌㻌
㻯㻴㻵㻹㻱㻔㻲㼃㻰㻌㻻㼁㼀㻼㼁㼀㻕
㻻㼁㼀㻌㻼㼁㼀㻌㻲㻻㻾㻌㻲㼃㻰㻴㻭㻾㻺㻱㻿㻿㻘㻮㻻㻰㼅
㻻㼁㼀㻌㻼㼁㼀㻌㻲㻻㻾㻌㻲㼃㻰
㻲㻻㻾㼃㻭㻾㻰㻛㻮㻭㻯㻷㼃㻭㻾㻰㻌㻯㻴㻵㻹㻱 ͤWITHOUT ON/OFF SW ͤWITH ON/OFF SW

㻺㻻㼀㻱㻦
㻝㻚㼀㻱㻾㻹㻵㻺㻭㻸㻯㻴㻵㻹㻱㻯㻴㻵㻹㻱
㻝
㻝
㻝㻤㻻㻺㻛㻻㻲㻲㻌㻿㼃
RD
BK
RD
BK
㻟㻚㻾㻱㻲㻱㻾㻌㼀㻻㻌㻹㻺㻿㻌㻼㻜㻜㻟㻜㻌㻲㻻㻾㻌㻰㻾㻭㼃㻵㻺㻳㻌㻵㻺㻿㼀㻾㼁㻯㼀㻵㻻㻺㻚 NOTE.4
㻠㻚㻵㻺㻿㼀㻭㻸㻸㻌㼀㻴㻱㻌㻻㻺㻛㻻㻲㻲㻌㻿㼃㻌㼀㻴㻭㼀㻌㻴㻭㼂㻱㻌㼀㻴㻱㻌㻹㻻㻰㻱㻸㻌㻺㻭㻹㻱
㻌㻌㼀㻻㻌㻾㻵㻳㻴㼀㻌㻿㻵㻰㻱㻌㻲㻾㻻㻹㻌㼂㻵㻱㼃㻌㻻㻲㻌㼀㻴㻱㻌㻮㻭㻯㻷㻌㻻㻲㻌㻼㻭㻺㻱㻸㻚㻴㻭㻾㻺㻱㻿㻿㻘㻯㻴㻵㻹㻱㻝㻝㻴㻭㻾㻺㻱㻿㻿㻘㻯㻴㻵㻹㻱㻝㻝
㻝㻝㻝㻝
㻡㻠㻜㻜㻞㻙㻣㻥㻞㻠㻜㻙㻜㻡㻠㻜㻜㻞㻙㻣㻥㻞㻠㻜㻙㻜
WIRING,SYSTEM
RD
RD
BK
BK
㻝㻝㼎
㻝㻤㻝㻤
㻴㻭㻾㻺㻱㻿㻿㻘㻭㻯㻯㻱㻿㻿㻻㻾㼅㻔㻞㻕
㻮㻭㼀㼀㻱㻾㼅㻌㻼㻻㼃㻱㻾
㻮㻭㼀㼀㻱㻾㼅㻌㻼㻻㼃㻱㻾㻌㻝㻡㻠㻜㻜㻞㻙㻢㻣㻥㻤㻜㻙㻞㻔㼃㻵㼀㻴㻌㻿㼃㻵㼀㻯㻴㻕

㻝
㻝㻝㻝
BN 㻹㻼㼁㻌㻮㻻㻭㻾㻰㻝㻝㻝
RDBK
BK 㻝㻝㻝㻝㻝㻝
㼀㻻㻌㻯㻺㻝㻙㻞㻤
RD
RDBK
㻔㻾㼂㻿㻌㻻㼁㼀㻼㼁㼀㻕 RD
㻻㻺㻸㼅㻌㻻㻺㻛㻻㻲㻲㻌㻿㼃㻌㼀㼅㻼㻱 RDBK
RDBK
BNBK
RD 5.1kΩ BK 㻝㻝
ษ᭰SW 㻌㻌
BN
㻌㻌㼀㻴㻱㻌㻵㻺㻿㻵㻰㻱㻌㻻㻲㻌㻯㻻㻺㼀㻾㻻㻸㻌㻼㻭㻺㻱㻸㻌㻌
RDBK
BNBK
RDBK RD RD BK BNBK 㻹㻼㼁㻌㻮㻻㻭㻾㻰
BN
㼀㻻㻌㻯㻺㻝㻙㻞㻣
㻯㻴㻵㻹㻱㻔㻲㼃㻰㻌㻻㼁㼀㻼㼁㼀㻕
㻴㻭㻾㻺㻱㻿㻿㻘㻮㻻㻰㼅
㻴㻭㻾㻺㻱㻿㻿㻘㻮㻻㻰㼅
㻻㼁㼀㻌㻼㼁㼀㻌㻲㻻㻾㻌㻾㼂㻿㻛㻲㼃㻰㻻㼁㼀㻌㻼㼁㼀㻌㻲㻻㻾㻌㻾㼂㻿㻛㻲㼃㻰
Wiring, chime 7- 12.

Stripe
Wiring, chime 7-12-1.

Stripe:White
RD Red
54002-67881-0E
159
7 Wiring (Diagrams)
BACKWARD CHIME CHIME
RD
BK
THE INSIDE OF DRIVE ROOM

NOTE: 1 1
1.TERMINAL 1 1
1 :SHUR PLUG 170020-2
RDBK
18 :RECEPTACLE(#110) 170043-2
BK
WIRING,SYSTEM
HARNESS,CHIME

RDBK
1 1 1
1 1
RDBK
BN
RD BK BN MAIN BOARD
TO CN1-28(RVS OUTPUT) HARNESS,BODY
CHIME OUT PUT FOR RVS
FORWARD CHIME CHIME
RD
BK

1 1
1 1
RDBK
BK
WIRING,SYSTEM
HARNESS,CHIME
RDBK
1 1 1
1 1
RDBK
BNBK
RD BK BNBK MAIN BOARD HARNESS,BODY
TO CN1-27(FWD OUTPUT)
CHIME OUT PUT FOR FWD
CHIME
FORWARD/BACKWARD CHIME
RD
BK
1 1
1 1
HARNESS,CHIME

BK
WIRING,SYSTEM 1
1
RDBK
HARNESS,ACCESSORY
BU
RDBK
BU BN MAIN BOARD
TO CN1-28(RVS OUTPUT) 1 1 1 1
1 1 1
RDBK
BNBK
MAIN BOARD
BN
RD BK BNBK
CHIME HARNESS,BODY
OUT PUT FOR RVS/FWD

Stripe
BK
WH
Black
White
YE
GN
Yellow
Green
BN
BU
Brown
Blue
Wiring, Chime/buzzer 7- 12.
Wiring, chime (w/back buzzer) 7-12-2.

Stripe:White
RD Red
54002-67930-0E
160
Wiring (Diagrams) 7
NOTE:
BACKWARD BUZZER 1.TERMINAL BUZZER
YE
YE
1 :SHUR PLUG 170020-2 YE
1 :SHUR RECEPTACLE 170021-2 Wiring for ON/OFF SW BUZZER YE
18 :RECEPTACLE(#110) 170043-2 volume control NOTE.4
4.INSTALL THE ON/OFF SW THAT HAVE THE MODEL NAME (Volume becomes Wiring for
TO RIGHT SIDE FROM VIEW OF THE BACK OF PANEL. large at the volume control

time of connection.) HARNESS,ACCESSORY(2) (Volume becomes
RD
BK
large at the
RD
BK
time of connection.)
1 1b
1 1 18 18

1 1 RD
WIRING,SYSTEM 1 1 1
RDBK
RDBK
1
1 1
RDBK
WH
THE INSIDE OF CONTROL PANEL
RDBK
BN
ONLY ON/OFF SW TYPE
RDBK
BN
RDBK RD RD BK BN MAIN BOARD
TO CN1-28(RVS OUTPUT) HARNESS,BODY
OUTPUT FOR RVS HARNESS,BODY
BUZZER
OUTPUT FOR RVS
YE
FORWARD BUZZER BUZZER YE
Wiring for YE
volume control ON/OFF SW BUZZER YE
(Volume becomes NOTE.4
large at the Wiring for

time of connection.) volume control
RD
BK
HARNESS,ACCESSORY(2) (Volume becomes
large at the
RD
BK
1 1b
1 1
1 1 18 18
WIRING,SYSTEM RD

1 1
1
RDBK
RDBK 1 1
1
RDBK
WH
RDBK
BNBK
ONLY ON/OFF SW TYPE
RDBK
BNBK
RDBK RD RD BK BNBK MAIN BOARD HARNESS,BODY
BUZZER OUTPUT FOR FWD
HARNESS,BODY
OUTPUT FOR FWD
YE
FORWARD/BACKWARD BUZZER BUZZER YE
YE
Wiring for BUZZER YE
volume control
(Volume becomes Wiring for
RD
BK
large at the volume control
time of connection.) ON/OFF SW (Volume becomes
RD
large at the
B)
1 NOTE.4

1
1
WIRING,SYSTEM HARNESS,ACCESSORY(2) 1
HARNESS,ACCESSORY HARNESS,ACCESSORY

BU
1 1b
RDBK
1 1 1
BU
18 18
1 1 1
BU BN MAIN BOARD RD 1 1
TO CN1-28(RVS OUTPUT) RDBK 1 1
1 1 1 1
RDBK
WH
RDBK
BNBK
ONLY ON/OFF SW TYPE

BN
RDBK RD RD BK BNBK MAIN BOARD
RDBK
BNBK
BN
BUZZER HARNESS,BODY
OUTPUT FOR RVS/FWD HARNESS,BODY
OUTPUT FOR RVS/FWD
Stripe
RD Red
Stripe:White Wiring, buzzer 7- 13.
Wiring, buzzer 7-13-1.
54002-68230-1E
161
7 Wiring (Diagrams)
MAIN
Note) 1.OPEN THE WHITE WIRE-BLACK WIRE OF ACCESSORY,
LINE CONNECTOR AND CONNECT THE HARNESS,MAST(1).
CPU
No. CN □ PIN No.
Stripe
WH
GND 6 182 GND BK Black YE Yellow BN Brown
BK
S23 6 170 T INPUT FOR SWITCH OF HIGH-MAST WH White GN Green BU Blue
Stripe:White
RD Red
WIRING,SYSTEM
Harness,Accessory Switch Comp., micro
HARNESS,BODY
BK BK
1 1
Waterproof
type
2P
WH WH
1 1
OPEN
HARNESS,MAST(1)
BK WH
1 1
ACCESSORY
Wiring, lift limit 7- 14.

P-mast (2 stage mast) (High lift height detection: only when the lift height is 4500 mm or more) 7-14-1.
54002-59701-0E
162
Wiring (Diagrams) 7
HEIGHT SENSOR
MAIN
INSTALL THE SENSOR SO THAT IF MAY Note）
1.OPEN THE WHITE WIRE-BLACK WIRE OF ACCESSORY, AND CONNECT THE HARNESS,MAST(1).
RDWH
DETECT LESS THAN THE SET HEIGHT. LINE CONNECTOR

CPU
No. CN □ Pin No.
BN
HARNESS COLOR
BK BU WH WH GND 6 182 GND
GROUND
STRIPE
BK BK WH WHITE GN GREEN BU BLUE

S23 6 170 T INPUT FOR SWITCH OF HIGH-MAST Ex. 'BKWH' = GROUND:BLACK,
STRIPE:WHITE
RD RED
WIRING,SYSTEM
HARNESS,ACCESSORY Sensor Comp., magnetic
HARNESS, BODY
BK 1 1
BK
WH WH
1 1
Waterproof
Waterproof
type
type
3P
3P
OPEN IN THE CASE OF MAST
HEIGHT AT 4501∼6000.
BK WH
1 1 HARNESS,MAST(1) WH 1 1
WH
BK BK
Waterproof
type
3P
1 1
RD 1 1
RD
IN THE CASE OF MAST

RDWH 1 1
RD HEIGHT AT 6000∼.
1
RDWH
ACCESSORY

M(NM)/PFL-mast (2 stage / 3 stage full free mast) (High lift height detection: only when the lift height is 4500 mm or more) 7-14-2.
54002-59451-2E
163
7 Wiring (Diagrams)
NOTE.
HARNESS COLOR GROUND 1.TERMINAL
STRIPE 1 :SHUR PLAG AMP 170020-2
BK BLACK YE YELLOW BN BROWN 1 :SHUR RECEPTACLE AMP 170021-2
18 :RECEPTACLE(#110) 170043-2
WH WHITE GN GREEN BU BLUE 4.INSTALL THE SW THAT HAVE THE MODEL NAME
Ex. 'BKWH' = GROUND:BLACK, TO RIGHT SIDE FROM VIEW OF THE BACK OF PANEL.
STRIPE:WHITE
RD RED
HEIGHT SENSOR
BATTERY VOLTAGE OUTPUT AFTER

REAR LAMP SW
RDWH
INSTALL THE SENSOR SO THAT IF MAY
DETECT MORE THAN THE SET HEIGHT.
NOTE.4
TURNING ON A KEY SWITCH

RD BN
1 1b BK BU WH WHBK MAIN BOARD TO CN3-79(GND)
18 18
BK BURD BURD
MAIN BOARD TO CN3-89(LIFT LOCK)
BUBK
BU
WIRING,SYSTEM
HARNESS,SWITCH
HARNESS,LIFT LIMIT
HARNESS,MAST
2P
BK
BURD1 BK
1 1
WHBK WH BN BN HEIGHT SENSOR
1 1 1 1
RDWH BK BK
1 1
1
BU BU INSTALL THE SENSOR SO THAT IF MAY
RDWH WH 1 1 DETECT MORE THAN THE SET HEIGHT.
HARNESS,BODY 1 1
CONNECT WITH ATTENTION
CONNECT WITH ATTENTION TO WIRE COLOR.
TO WIRE COLOR.
RDWH RDWH BETWEEN THE BODY AND MAST

1 1
ACCESSORY(L)
WHBK
1
BK WHBK
1 1
BURD BURD2
1 1

ACCESSORY(R) TO WIRE COLOR.

Lift limit (w/release switch) 7-14-3.
54002-71760-0E
164
Wiring (Diagrams) 7
NOTE.
1.TERMINAL
STRIPE 1 :SHUR PLAG AMP 170020-2
BK BLACK YE YELLOW BN BROWN 1 :SHUR RECEPTACLE AMP 170021-2

STRIPE:WHITE
RD RED
HEIGHT SENSOR
INSTALL THE SENSOR SO THAT IF MAY
BATTERY VOLTAGE OUTPUT AFTER

DETECT MORE THAN THE SET HEIGHT.
RDWH
TURNING ON A KEY SWITCH
RD BN
BK BU WH WHBK
MAIN BOARD TO CN3-79(GND)
BK BURD BURD
MAIN BOARD TO CN3-89(LIFT LOCK)
WIRING,SYSTEM
HARNESS,ACCESSORY
HARNESS,LIFT LIMIT
HARNESS,MAST
2P
BK
BURD1 BK
1 1
WHBK WH BN BN HEIGHT SENSOR
1 1 1 1
RDWH BK BK
1 1 INSTALL THE SENSOR SO THAT IF MAY
1
BU BU DETECT MORE THAN THE SET HEIGHT.
RDWH WH 1 1
1 1
HARNESS,BODY
CONNECT WITH ATTENTION TO WIRE COLOR.
TO WIRE COLOR.
RDWH RDWH BETWEEN THE BODY AND MAST

1 1
ACCESSORY(L)
WHBK
1
BK WHBK
1 1
BURD BURD2
1 1
ACCESSORY(R) CONNECT WITH ATTENTION

TO WIRE COLOR.

Lift limit (w.o./release switch) 7-14-4.
54002-71770-0E
165
7 Wiring (Diagrams)
NOTE
1) TERMINA MARKING AMP 170020-2
1 PLUG(WITH PLATING.) AMP 170887-1
SLEEVE(FOR ONE)
48V AMP 170021-2
STRIPE
1 RECEPTACLE(WITH PLATING.) AMP 170899-1
SLEEVE(FOR ONE) BK BLACK YE YELLOW BN BROWN
AMP 170890-1
SLEEVE(FOR TWO) AMP 350536-1 STRIP FORM
9 SOCKET AMP 350550-1 LOOSE PIECE Ex. 'BKWH' = GROUND:BLACK,
STRIPE:WHITE
4) ALL PIN LAYOUT SHOWS OF THE VIEW FROM TERMINAL INSERT SIDE. RD RED
5) BAND HARNESS,FAN TO HARNESS,BODY AT THE PLACE WHERE HARNESS,
FAN IS PARALLEL TO HARNESS,BODY.
RD
1 1
F5 F4 MAIN
10A 10A
LINE CONNECTOR
CPU
No. CN □ FAN
BKWH
RDBK
PIN No.
ACCESSORY TERMINAL
TO TRANSFORMER
WH
MC MC 7 4 M (OUTPUT FOR MAGNETIC CONTACTOR)
COIL VOLTAGE:AC200V/AC400V RD
R 7 1 M (INPUT FOR DETECTION OF
RDGN
BK
S 7 2 M
AC POWER SUPPLY)
CHARGER PANEL
BKWH
RDBK
YELLOW RED 350784-1(AMP)
5W 180Ω FAN FOR COOLING TRANCE
EMERGECY SWITCH
13 10 7 4 1
14 11 8 5 2 2P 1 1 1
INSERT THE TERMINAL OF YELLOW RED TO 15 PIN.
INSERT THE TERMINAL OF RED BLACK TO 12 PIN. WHITE 1 1 1 1 1
15 12 9 6 3
15 12
9 9 䞉䞉䞉 9 9 9 9
RDBU
RDWH
BKWH
RDBK
WH
BN
BK
YERD
RDBK
X1
RDBK
5W 180Ω
RDWH
BKWH
HARNESS,FAN
2 3 NOTE.5
HARNESS,BODY
SYSTEM DRAWING
4P
RED
THIS DRAWING ONLY SHOWS PARTS OF THE COOLING FAN FOR TRANS(6.4kVA).
KEY SWITCH
Wiring, fan 7- 15.

FBR - 80 6.4kVA 7-15-1.
54002-76470-0E
166
Reproduction prohibited
First printing : November 2015
2nd printing : March 2016
3rd printing : December 2016
Issued by: Mitsubishi Nichiyu Forklift Co., Ltd.

Edited by: Overseas Customer Service Division
Mitsubishi Nichiyu Forklift Co., Ltd.

FBR 80 - Troubleshooting Manual 1

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FBR 80 - Troubleshooting Manual 1

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TROUBLESHOOTING MANUAL

ELECTRIC FORKLIFT TRUCK

Indicates a potentially hazardous situation that can result in death

1. Who should use this Troubleshooting Manual

2. User and Manager screen setting 9 3. Model check screen settings 37

2-1. Monitor display functions............................. 9 How to access

Travel CPU Hydraulic CPU

IPM module IPM module

Gate circuit Gate circuit

Traction motor Hydraulic motor

T (Travel) CPU Travel control

1- 2. Main Board Basic configuration

<Main board type>

<Details on Main board LED>

LED Details Status Remarks

1-2-2. Capacitor - discharge

Discharge the capacitor

NOTE Multiple settings must be done in the following

Setting Setting screen

When the options are equipped other than the above

(To the next page)

CAUTION After replacing the main board or initializing the

Setting Specified value AOS

For details of setting AOS and Lift remote control specifications,

Other required settings

Item Required setting

Transformer fuse 100A / 70V 70000-15440 Transformer / Diode

1-4-2. Indication of display

Easy password-entry screen

If you have forgotten the password,

2015. 10. 30 Fri

Normal screen Press the switch in order of Model check screen

Setting screen PASSWORD (MANAGER)

To Normal screen by turning To Normal screen by turning

<To return to the previous screen>

Normal screen Sheet switch

Normal screen Sheet switch

2-1-2. Indication of display

After 2 seconds, the normal screen is displayed. CHECKING. . .

2-1-3. Function 22.0 h 0 km/h

CAUTION Do not over-discharge. PM 12:46

Charge the battery immediately

Discharge Discharge Discharge Discharge

Lift Lock (Lift interrupt function) CHARGE BATTERY

When the battery indicator segment on the normal screen

2. Hour meter icon (operating hours) Hour meter screen

The display can be used as the load meter.

NOTE The Load meter is an optional equipment. Load meter screen

When pressing or button on the sheet switch, the

4. Travel speed meter

5. Slow speed mode monitor (Turtle mark)

S ee "2-2-2.Function setting" " 1 SPEED LIMIT

2-1-4. Sheet switch

9. Cancel (Back) button

10. Cursor up button

11. Cursor down button

12. MODE LED

13. Economy mode select button

14. Slow speed mode button

Hour Meter Screen Normal screen

By pressing or button at the normal screen, the

Hour meter screen

Indication of Electric power usage, CO2 amount [day] (Option)

2-1. Monitor display functions............................. 9 How to access

For details of setting AOS and Lift remote control specifications,

S ee "2-2-2.Function setting" " 1 SPEED LIMIT

Indication of Electric power usage, CO2 amount [day] (Option)

et each item to preferable value and press

Press to set and return to the setting screen. ５［0‒7］

Press to set and return to the setting screen. ５［0‒7］