Nichiyu Forklift FB10 30P 75 FB 75 Troubleshooting Manual 1 1

CONTENTS
2-3-11. Display language check and adjustment 39

1. Introduction 1
2-3-12. Optional setting check and adjustment 40
2-3-13. Display brightness check and adjustment 42
1-1. What's new in FB-75.................................1 2-3-14. Hour meter working check 43
1-2. FB-75 new features ..................................2 2-3-15. Auto power off function working check 43
1-2-1. Battery discharge indicator 2 2-3-16. Battery electrolyte level (optional)
working check (for GS battery only) 44
2-3-17. Turn signal lamp working check 44
2-3-18. Hydraulic oil level (optional) working check 45
2-3-19. Brake oil level working check 45
2. Adjustment of SICOS-AC 4 2-3-20. Overload (optional) working check 46
2-3-21. Travel inhibitor (optional) working check 46
2-3-22. Cooling fan working check 46
2-1. Explanation of the monitor display............4
2-3-23. Lift interrupt (optional) working check 47
2-1-1. Indicator panel 4
2-3-24. Turning speed reduction (optional)
2-1-2. Indication of display 5
adjustment and working check 48
2-1-3. Function of display 6
2-3-25. Laser pointer (optional) working check 48
2-1-4. Various kinds of mode selection 12
2-3-26. Accelerator potentiometer adjustment 49
2-2. Explanation of the MPU board................18 2-3-27. Seat switch (optional) working check 50
2-2-1. Basic control board construction 18 2-3-28. Automated fork horizontal stop (optional) 51
2-2-2. Travel/ Hydraulic board 19 2-3-29. Built-in charger (optional) working check 53
2-2-3. Display board 19
2-2-4. Rotary switch on the Travel/ Hydraulic board 20
2-2-5. Rotary switch on the Display board 21
2-2-6. Adjustment Standards List for FB-75 series 22
2-2-7. Confirmation of other services 23
3. Troubleshooting 54
2-3. SICOS-AC check and adjustment ..........25 3-1. Self diagnosis function............................54
2-3-1. Chassis insulation check 25 3-1-1. Display 54
2-3-2. Battery voltage adjustment 26 3-1-2. Error messages and Display conditions 56
2-3-3. Current detector check 27
2-3-4. Forklift model setting check and adjustment 31 3-2. Error history memory ..............................58
2-3-5. Safety circuit for control 3-2-1. Error history memory 1 58
(contactor tripping) check 33 3-2-2. Error history memory 2 59
2-3-6. Hydraulic setting check and adjustment 34 3-2-3. Clearing the error history memory
2-3-7. Descending regeneration check 36 (memory initialization) 61
2-3-8. Switch back (plugging/ regenerative) 3-3. I/O Check................................................62
braking force adjustment 36 3-3-1. I/O check mode display method 62
2-3-9. Regenerative braking force check 3-3-2. I/O port table 64
and adjustment 37
2-3-10. Safety monitor symbol check and adjustment 38
4. Wiring and main controller layout 70 4-11. FB-75 Wiring, chime ............................93
4-11-1. Forward/backward chime 93
4-11-2. Forward chime 94
4-1. FB-75 System wiring..............................70
4-11-3. Backward chime 95
4-1-1. FB10P-28P-75 70
4-1-2. FB30P-75 71 4-12. FB-75 Wiring, license...........................96
4-12-1. Large truck inspections,
4-2. FB-75 Body wiring ................................72
4-12-1. new small truck inspections 96
4-2-1. FB10P-28P-75 72
4-2-2. FB30P-75 73 4-13. FB-75 Wiring, load sensor ...................97
4-2-3. Fingertip specification 74 4-13-1. Analog type 97
4-13-2. Digital type 98
4-3. FB-75 Body harness ..............................75
4-3-1. FB10P-18P-75 (Std/CS/FCS/RP/DRP) 75 4-14. FB-75 Wiring, lift limit...........................99
4-3-2. FB10P-18P-75 4-14-1. Lift limit for 1st stage 99
(Automated fork horizontal stop) 76 4-14-2. Lift limit for 2nd stages 100
4-3-3. FB20P-28P-75 (Std/CS/FCS/RP/DRP) 77
4-15. FB-75 Wiring, seat heater..................101
4-3-4. FB20P-28P-75
(Automated fork horizontal stop) 78 4-16. FB-75 Wiring, rear lamp.....................102
4-3-5. FB30P-75 (Std/CS/FCS/RP/DRP) 79
4-17. FB-75 Wiring, FS ...............................103
4-3-6. FB30P-75 (Automated fork horizontal stop) 80
4-18. FB-75 Wiring, wiper ...........................104
4-4. FB-75 Controller wiring ..........................81
4-18-1. Wiper 104
4-5. FB-75 Controller harness.......................82 4-18-2. Lower wiper 105
4-6. FB-75 Main controller ............................83 4-19. FB-75 Automated fork horizontal
4-6-1. FB10P-28P-75 83 stop System wiring..............................106
4-6-2. FB10P-25P-U75/FB30P-75 84
4-7. FB-75 BC wiring.....................................85

4-7-1. 400V 85
4-7-2. 200V 86
4-8. FB-75 Charger harness .........................87

4-8-1. Charger harness(1) 87
4-8-2. Charger harness(2) 88
4-9. FB-75 Wiring, revolving light..................89

4-9-1. Key switch interlock 89
4-9-2. Forward/backward directional interlock 90
4-9-3. Backward directional interlock 91
4-10. FB-75 Wiring, working lamp.................92

Introduction 1
1. Introduction B
Altered display and board
A Equipped with Sicos-AC (color display / flourscent display)
1- 1. What's new in FB-75 ¡ Improved inching (Interchangeable installation with panel Ass'y)
¡ Enhanced regeneration ¡ 10-step battery discharge indication
¡ Settings for various modes, power mode, and low speed ¡ Time length of hour meter indication key when it is ON
¡ Auto power OFF (actual operation time is OPT)
¡ Neutral safety ¡ Canceled battery electrolyte level display
22 Inclined lift chain / parallel (P mast) ¡ Self-diagnosis function ¡ Altered speed indication (actual speed / converted speed)
¡ Contactless traveling, loading and regeneration 7 Shortened turn signal's come back ¡ Mono-blocked slow speed (turtle) S/W and mode S/W (sheet
type switch)
23 Altered chain anchor figure (P mast)
11 Altered display cover figure
Altered side roller attaching structure

24
(P mast) 28 Altered control bulb spool figure
25 Altered chain attaching location (M mast) 14 Altered hydraulic lever link ratio
26 M mast using 2t type outer mast 4 Altered accelerator structure
¡ FB15P ¡ Made identical with potentiometer FBR-75
27 Enlarged mast's outer width 17 Enlarged opening angle on battery cover
¡ FB20P
5 Controlled travel/hydraulic vector
15 Strengthened front wheel covers 6 Type-VE controller
¡ Mono-blocked heat sink and base, mono-blocked gate board,

16 Strengthened steps mono-blocked condenser (soldering) etc.
¡ FB30P
10 Altered counter weight figure
19 Reduced gear sound because of lowered backlash

Controlled hydraulic motor sensorless
3 (altered board and software)
¡ FB20P
¡ Improved software, hydraulic response
20 Improved brake because of altered wheel cylinders
¡ FB20P 12 Altered oil tank structure 8 Altered hydraulic motor's diameter
¡ FB15P
18 Altered to anti-loose knob on the cover
1
Introduction 1
1- 2. FB-75 new features

1-2-1. Battery discharge indicator
1. 48V capacity indication
<5-step indication (FB-70)>
FB-70 is not completely in proportion to discharging
capacity because it divides voltage by 0.75V.
discharging terminal voltage
percentage (%) (V)
20 50
41 49.25
60 48.5
77 47.75
93 47
<10-step indication (FB-75)>

It sets dividing voltage to be in proportion completely to
the capacity.
discharging terminal voltage
percentage (%) (V)
10 50.25
20 50
30 49.67
40 49.3
50 48.91
60 48.5
70 48.07
80 47.62
90 47.15
100 46.65
discharging voltage and open voltage (10 minutes after)
51
50.5
50
49.5
Open voltage (V)
49
48.5
48
47.5
47
46.5
46
0 20 40 60 80 100 120
Discharging percentage (%)
5-step indication (existing machine) 10-step indication

2
1 Introduction
The graph below shows the relation between discharging

percentage and capacity indication.
From this graph, 5-step indication goes off when the
discharging percentage gets below 93%, and it seems
one segment is on when the discharging percentage gets
93% through 100% in case of 10-step indication. In
deed, however, a red segment is lit when the discharging
percentage gets 93% in case of 5-step indication. In
other words, a red segment is lit when the discharging
percentage gets 93% in case of FB-70. On the other
hand, a red segment is lit when the discharging
percentage gets 80% in case of FB-75.
It is as good as over-discharging lift interrupt option; the

lift speed reduced by half when the red segment is lit. It
limits earlier than FB-70 setting.
F
8
Also, the lift interruption functions when the last red 6
segment is lit. In this case, the segment flashes as well 4
as the frame of the segment. After the last segment goes 2
E
off, only the frame flashes.
FB-70 FB-75
Discharging voltage and capacity indication
11
10
8
Capacity indication
0
0 20 40 60 80 100
Discharging percentage (%)
Existing 5-step indication 10-step indication
3
2. Adjustment of SICOS-AC
2- 1. Explanation of the monitor display
2-1-1. Indicator panel
Monitor display Mode select switch
1 2 3 4 17
5 6 7
8 9 10 11 12 13 14 15 16 221T024E
1. Battery discharge indicator

2. Slow speed mode monitor (Turtle mark)
3. Fork horizontal indicator (Option)
4. Travel speed meter
5. Battery charge reservation indicator (Option with built-in charger)
6. Calendar and clock
7. Hour meter
8. Safety monitor for traction circuit
9. Safety monitor for hydraulic circuit
10.Safety monitor for power steering circuit
11. Safety monitor for brake fluid
12.Safety monitor for battery electrolyte level (Option with GS battery)
13.Safety monitor for overload (Option)
14.Safety monitor for hydraulic oil level (Option)
15.Safety monitor for parking brake
16.Service (spanner) mark
17.Mode select button
NOTE Icons of 8 to 14, and 16 shown in the illustration are displayed for the explanation. It
is not actual indication. They are displayed when abnormalities are occurred.
4
2 Adjustment of SICOS-AC
2-1-2. Indication of display

Turn on the key switch. When the key switch is turned on.
The self-diagnosis function checks the control system

and display "MONITORING OK" when no problems are
found. Icons of "Read operator's manual" and "Fasten
After 0.5 seconds
seat belt" are flashed three times for warning to the
operator.
The normal screen is displayed.

If any abnormalities are detected, the error message is
displayed. If the long message is displayed or some After 2 or 3 seconds
Normal screen
messages are displayed, they are scrolled from right to
left alternatively.
NOTE If traveling or hydraulic operation is done while

this (with-in 3 or 4 seconds), the normal screen is
221T025E
displayed after finishing the initial monitoring

function.
CAUTION Contact to your local Nichiyu dealer if the error

message is displayed.
Mode setting buttons

NOTE If travel/hydraulic operation is done while one-
touch operation screen is being displayed, it
returns to the normal screen.
121T188
Setting screen by one touch operation

Reserve charge screen Refer to the section of the
Push button. a ¡Set the starting time of battery
charge.
¡¡¡ reserve charging on FB-75
OPERATOR'S MANUAL or
WORKSHOP MANUAL.
(This screen is displayed if the
optional built-in charger is equipped.)
Mode select screen

¡Slow speed mode setting
¡Travel mode setting
Push button.
(Release within 3 seconds.)
a ¡Hour meter / odometer selection
¡¡¡ Refer to each setting section.
¡Display mode setting
¡Coast mode setting
Push button
for more than 3 seconds.
a Date / time setting screen
For setting of date and time.
¡¡¡ Refer the page 15 for details.
Hour meter screen

¡ Three hour meters of traction,
Push one of or . a hydraulic and the total hour are
¡¡¡ Refer the page 8 for details.
5 displayed.
Adjustment of SICOS-AC 2
2-1-3. Function of display

This forklift truck has the self-diagnosis function.
1 2 3 4 17
5 6 7
8 9 10 11 12 13 14 15 16 221T026E
NOTE Icons of 8 to 14, and 16 shown in the illustration

are displayed for the explanation. It is not actual
indication. They are displayed when abnormalities
are occurred.
1. Battery discharge indicator

The battery discharge indicator shows the discharged
condition of the battery.
CAUTION Do not over-discharge.

The battery life can be shorten by over-dis-
charging.
Charge the battery as soon as possible when [E]
segment is lit.
Full Charge the battery immediately

charged In case of
40% discharge Less than 20% Less than 10% Empty
Discharge Discharge Discharge Discharge
When the battery capacity is When the capacity is less than 10%,
less than 20%, all blue one red segment is flashed with the
segments are disappeared frame of the indicator.
and two red segments are lit. When the capacity is empty, only the
frame of the indicator is flashed. 121T190E
6
¡Lift interrupt (Option)

When all green segments are disappeared and two red
segments are lit, the lift speed is reduced by half.
At the same time, " CHARGE THE BATTERY "
message appears on the screen. Two red segments are lit.
After 10 minutes
When the truck is continued to use, only one red
segment is started to flash and the lift function is
interrupted.
One red segment is started to flash.

121T191E
2. Slow speed mode monitor (Turtle mark)

When the turtle button is pushed, the turtle mark is
indicated on the screen with the preset speed.
121T192E
3. Fork horizontal indicator (Option)

This mark is indicated when the fork is horizontal and
possible to use the laser pointer.
121T193E
4. Speed meter
The traveling speed is displayed on the screen.
121T194E
5. Reserve charge indication (Option)

The reserved date and time to start charging the battery
is displayed. Refer the section of "Battery and charger"
on FB-75 OPERATOR'S MANUAL or WORKSHOP
MANUAL for details. 121T195E
6. Date and time (Calendar and clock)

The current date and time are displayed. If the
button is pushed for more than 3 seconds, the display is
changed to the setting screen. Refer the page 16 for
details. 121T196E
7
7. Hour meter Total key-on hours

Normal screen
The hour meter shows the total hours of turning on the
key switch.
(The actual operating hours can be displayed as option.)
It is useful to know the total operating hours for the daily
job management and scheduling of the periodical
After 5 seconds,
inspection. Push the normal screen
or is displayed.
Hour meter screen
When pushing or button, each individual hours
for travel, hydraulic and total are displayed for 5
seconds.
The normal screen and hour meter screen are changed
by turn by pushing or button.
Total key-on hours
After 5 seconds, the normal screen is displayed. Total hydraulic hours
Total traveling hours
Total traveling distance
The odometer can be displayed in the normal screen Option
instead of hour meter. Refer the meter mode setting in
the setting mode section.
CAUTION The hour meter screen is returned to the normal

screen even less than 5 seconds by operating 121T197E
traveling or hydraulic function.
When the screen displays the odometer, the word of

“TRAVEL” is flashed while travelling.
121T198E
8. Safety monitor (for travel circuit)

When fault is detected in the travel circuit, the travel icon
flashes and the presumed defective part name is
displayed.
121T199E
9. Safety monitor (for hydraulic circuit)

When fault is detected in the hydraulic circuit, the
hydraulic icon flashes and the presumed defective part
name is displayed.
121T200E
10. Safety monitor (for steering circuit)

When fault is detected in the power steering circuit, the
steering icon flashes and the presumed defective part
name is displayed.
121T201E
8
11. Safety monitor (for brake fluid level)

When the brake fluid level is low, the brake icon flashes
and " REFILL BRAKE OIL " message is displayed.
NOTE When [name of a damaged part] or " REFILL 221T027E
FORK OIL " is lit, please contact the your local

Nichiyu dealer.
12. Safety monitor (for battery electrolyte

level) (for GS battery only)
When the electrolyte level is lower than the specific level,
the battery icon flashes and " REPLENISH REFINED
WATER FOR BATTERY " message is displayed. 121T202E
13. Safety monitor (for overloading)

(Option)
When overloaded, the load icon flashes and "
REDUCE THE LOAD " message is displayed on the
screen. 121T203E
14. Safety monitor (for hydraulic oil)

(Option)
If the hydraulic oil level is low, the icon is flashed and the
message of " REFILL HYDRAULIC OIL " is
displayed. 121T204E
NOTE The hydraulic oil level sensor detects the oil level
for 2 seconds after turning on the key switch. So,
the mast must be retracted completely and fork
must be lowered on the ground before turning on
the key switch. Otherwise, the warning message of
" REFILL HYDRAULIC OIL " may be displayed
even the quantity of oil is normal.
9
15. Safety monitor (for parking brake)

When the parking brake lever is pulled, the parking brake
icon is lit. if the operator move the truck without releasing
the parking lever, the icon flashes and the warning
buzzer is beeped. 221T028E
16. Service icon

The service icon warns the fault of the forklift truck to an
operator. If any faults are detected, the spanner mark is
flashed and the presumed defective part name is
displayed. If some problems are occurred at the same 121T205E
time, each part name is scrolled alternatively for every 5

seconds.
CAUTION ¡If the next fault is detected, all travelling,

hydraulics and power steering functions are
shut down.
B11 : IGBT-TRAVEL
C21 : IGBT-HYD.
FAIL CURRENT-TRAVEL
FAIL CURRENT-HYD
FAIL OPERATION
¡All , , , buttons are invalid while
dis-playing these messages.
17. Mode select button Slow speed mode button
Change the screen to each mode by pushing these

buttons.
Mode select button 121T206E
10
Slow speed mode button

The slow speed mode is activates by pushing this button.
Normal traveling mode (When the slow speed button is

off)
The slow speed mode indicator ( ) is not displayed.
Slow speed mode (when the slow speed button is on)

When the slow speed button is off
(Turtle mark is not displayed)
The turtle icon and preset speed are displayed on the
screen. Preset speed indication
¡If the value of the slow speed mode is preset, the

maximum traveling speed can be changed in the
normal mode and slow speed mode by pushing the
turtle button. When the slow speed button is on
(Turtle mark is displayed) 121T207E
11
2-1-4. Various kinds of mode selection

[1] Slow speed setting
[2] Travel mode setting
[3] Meter mode setting
[4] Display mode setting
[5] Regeneration (Neutral) mode setting
[6] How to set the date and time
CAUTION ¡These settings are invalid while traveling or

depressing the brake pedal.
¡If traveling or hydraulic operation is done
while setting, the display is returned to the
normal screen immediately.
When pushing button, the mode selection screen is

displayed. If pushing button again, the normal
screen is displayed again.
121T188
NOTE When setting the mode of next [1] to [5] , each Mode select button
button works as below.
¡ and buttons : Move the cursor to select
the value.
¡ button : Move the cursor to the next item.
¡ button : Back the cursor to the previous
item.
Slow speed
[1] Slow speed setting Normal screen preset indication
This mode sets the limited maximum travelling speed

under the slow speed mode.
Make sure the turtle button is pushed and the turtle icon
is flashed. Then, push or button to set the
speed. Push
button
The maximum speed can be set to 8 steps of 2, 3, 4, 5,
Slow speed setting
6, 8, 10 and 12km/h.
After setting, push button to move the cursor to the
travel mode setting.
If push the button, the normal screen is displayed.
Set the value
Push Push
button button
To the setting of travel mode 121T208E
12
[2] Travel mode setting Travel mode setting
This screen is used to set the travel mode.
Make sure that the current traveling mode indication is

flashed. Push or to select the mode.
After selection, push button to move the cursor to Set the travel mode.
the meter mode setting. Push Push
If pushing the button, the cursor is moved to the button button
To the setting of meter mode
slow speed mode setting. 121T209E
The traveling mode can be set to the next three modes.
E (ECONOMY)
This mode is convenient for the slow speed inching.
This mode saves the battery energy consumption also.
N (NORMAL)
This is the normal traveling mode. The quick acceleration
and smooth inching can be realized.
P (POWER)
This is the most powerful mode for acceleration.
[3] Meter mode setting Meter mode setting
The hour meter or odometer can be selected by this

mode on the normal screen.
When the cursor is located on the meter mode, "HR"
(hour meter) or "km" (odometer) can be selected by
pushing or button. Select the meter mode.
After selection, push button to move the cursor to
Push Push
the display mode. button button
To the display mode setting screen
If pushing the button, the cursor is returned to the 121T210E
traveling mode area.

The display is switched from the normal screen to the
meter mode screen by pushing or button. The
meter mode screen has 2 kinds. Refer below for details.
13
Normal screen and meter mode screen

In the case of the hour meter (HR) mode In the case of the odometer (km) mode
Total key-on hours Total traveling distance
Normal screen Normal screen
After 5 seconds, After 5 seconds,

Push Push
or the normal screen or the normal screen
is displayed. is displayed.
Confirmation screen Confirmation screen
Total key-on hours Total traveling distance

Total hydraulic hours Total hydraulic hours
Total traveling hours Total traveling hours
Total traveling distance Total key-on hours
* The normal screen is displayed even within 5 seconds
when the traveling or hydraulic operation is done.
121T211E
[4] Display mode setting Display mode setting screen
This mode sets the brightness of the screen.
Make sure that the cursor is located on the brightness

setting area. Push or button to select the
brightness for the best. It can be selected 7 steps (from 0 Set the brightness
to 7).
Push Push
After setting, push button to get the coast mode button button
setting screen. To the setting mode of regeneration

(coast mode) 121T212E
If pushing button, the cursor is returned to the view

(contrast) setting.
NOTE Refer the table below for the brightness settings.

BRIGHTNESS (Intensity of back light)
1 7
Dark Bright
14
[5] Regeneration (Neutral) mode setting Setting mode of regeneration (neutral)
This mode can be set the regenerative braking force

when releasing the accelerator pedal while travelling.
Make sure that the REGEN(NEUTRAL) mode screen is
displayed. Then push or button to select the
strength. Set the regenerative braking force
when releasing the accelerator pedal
The braking strength can be set to 4 steps of "NON" (No
braking), "LOW", "MID" (Middle) and "HIGH". Push Push
button button
Return to the normal screen.
NOTE It is set to "MID" (Middle) as default. 121T214E
After setting, push button to return to the normal

screen.
If pushing the button, the display mode setting
screen is displayed.
[6] How to set the date and time Normal screen
When the button is pushed for more than 3 seconds,

the date and time setting screen is displayed.
Push button to return to the normal screen.
CAUTION If traveling or hydraulic operation is done while Push button

for more than
setting, the display is returned to the normal 3 seconds.
screen immediately.
NOTE When setting the mode of next [1] to [6] ,

each button works as below.
¡ and buttons : Move the cursor to select
Year is flashed.
the value.
121T215E
¡ button : Move the cursor to the next item.

¡ button : Back the cursor to the previous
item.
1. Set the year

Make sure the cursor is located on the year area.
Push or button to set the year. The year can be
set from 2000 to 2999.
After setting, push button to move the cursor to the Set the current year.
month area.
Push Push
If push button, the normal screen is displayed. button button
121T216E
15
2. Set the month

Make sure the cursor is located on the month area.
Push or button to set the month. the month can
be selected from 1 to 12.
After setting, push button for the date setting.
Set the month
If pushing button, the cursor is returned to the year
area. Push Push
button button
121T217E
3. Set the date

Make sure the cursor is located on the date area.
push or button to set the date. The date can be
set from 1 to 31. When setting the date, the day of the
week is set automatically.
Set the date
After setting, push button to move the cursor to the (Day of the week is set automatically)
AM/PM area.
If pushing button, the cursor is returned to the month Push Push
button button
area.
121T218E
4. Set the AM or PM
Push or button to select the AM or PM.
After setting, push button to move the cursor to the
hour area.
If pushing button, the cursor is returned to the data Set "AM" or "PM".
area.
Push Push
button button
121T219E
5. Set the hour

Push or " " button to set the hour. The hour
can be set from 1 to 12.
After setting, push the " " button to move the cursor to
the minute area.
Set the hour
If pushing " " button, the cursor is returned to the AM
or PM area. Push Push
button button
121T220E
16
6. Set the minute

Push the " " or " " button to set the minute. The
minute can be set from 00 to 59.
Set the minute
Push
button
121T221E
After setting, push the " " button.

Then “COMPLETE” message is flashed three times.
In any cases, push " " button to get the previous step.
CAUTION ¡When pushing the " " or " " button, the "COMPLETE" is flashed three times.
second is set to "00".
¡After setting the minute and push the " "
Return to the normal screen.
button, the second is set to "00".
121T222E
¡If set the date and time, the reserve charge

setting is also renewed.
17
2- 2. Explanation of the MPU board

2-2-1. Basic control board construction
As shown in the figure below, the SICOS-AC uses the
display board as the central point for connecting all other
boards for the exchange of data. In addition, all control
boards use a one-chip CPU (with flash ROM) as their
main CPUs, so their ROM can not be removed.
Travel/ Hydraulic board
Switch
Display unit
board Travel circuit
Gate board Motor
control CPU
Display board Hydraulic circuit

Gate board Motor
control CPU
121T051E
Microcomputer EPS control

charger board
18
2-2-2. Travel/ Hydraulic board

<Type : PB104-XX>
Flashes while the hydraulic CPU is on
¡This board controls the traction motor and the Flashes while the travel CPU is on
hydraulic motor. Lights when the 6V power source is normal
Lights when the 15V power source is normal
[RS1] : Rotary switch for truck model selection
CU harness (1)
Connector for personal computer
CN10 CN9
H CN7
HYD TRV
CN4
CN3
Body harness
CN2
CN1
CN5 T
CU harness (2) 221W069E
2-2-3. Display board

<Type : PB103-XXX>
¡This board controls both the data exchanged between
the other boards and the display.
Lights when the 7V power source is normal
Buzzer Flashes while the CPU is on
[RS1] : Rotary switch for monitor selection

Connector for
Connector for
mode select switch
flourscent monitor
F 0 12
B CDE
34 56
7 8 9A
Connector for
personal computer
Backup battery
PB103-XXX CN2 CN1
Body harness 121T240E
CAUTION Even when the key is turned off, voltage from the
battery is still sent to the display board.
Disconnect the battery plug before performing
this work.
19
2-2-4. Rotary switch on the Travel/ Hydraulic board

The rotary switch (RS1) on the travel/hydraulic board is used to select forklift models.
When replacing the travel/hydraulic board, be sure to refer to the table below to match it with
the forklift.
¡RS1 Setting forklift models.
RS1 Applicable forklift models

0 FB10P
1 FB14P FB15P
2 FB18P
3 FB20P
4 FB25P
5 FB28P
6 FB30P
7 FB10P-U
8 FB14P-U FB15P-U
9 FB18P-U
A FB20P-U
B FB25P-U
C FBB15P
D FBB20P FBB25P
E FBB30P
F
Note: The standard board is not equipped with volumes.

Volume No. Function Remarks
Turning the volume clockwise increases the
Attachment 3 proportional control
VR1 current.
valve current adjustment
(Only with optional proportional control valve)

VR2 current.

VR3 current.

Tilt proportional control valve
VR4 current.
current adjustment

Lift proportional control valve
VR5 current.
current adjustment
20
2-2-5. Rotary switch on the Display board

The rotary switch (RS1) on the display board is used for selecting the displays and
adjustments shown in the table below.
¡RS1 setting functions
RS1 Functions Remarks
MONITORING OK Turn the key switch ON.
Normal monitor Meters etc. (See p.4.)
Hour meter check Total, travel, and hydraulic hour meters appear.
Reserve charge screen Specify when charging begins.
Date and time setting Set the date and time.
Set the maximum speed under the slow speed
0 Slow speed setting
mode. (2, 3, 4, 5, 6, 8, 10, 12km/h)
Travel mode setting Select ECONOMY, NORMAL, or POWER.
Meter mode setting Select the hour meter or odometer.
VIEW (contrast)
Display mode setting
BRIGHTNESS (0-F intensity of back light)
Adjustment of regenerative power
Select NON, LOW, MID, or HIGH
when accelerator is released
1 Monitor symbol setting STEER, BATT, OIL, LOAD, BRAKE
2 Forklift model check Displays the settings for the travel/hydraulic board
Plugging strength setting 0 - 32
3 Brake strength setting 0 - 32
Anti-slip setting NON LOW MID HIGH
Maximum lift speed 1 0 - 32 (Fast) : For travel speeds of 0 - 5 Km/h
Maximum lift speed 2 0 - 32 (Fast) : For travel speeds of 5 - 10 Km/h
Maximum lift speed 3 0 - 32 (Fast) : For travel speeds of 10 Km/h
Lift speed 1 0 - 32 (Fast) : 1st microswitch
4 Lift speed 2 0 - 32 (Fast) : 2nd microswitch
Tilt speed 0 - 32 (Fast)
Reach speed 0 - 32 (Fast)
Attachment 1 speed 0 - 32 (Fast)
Attachment 2 speed 0 - 32 (Fast)
5 Display language selection Six languages
6 Option setting Set the options.
7 Voltage, current, and temperature check
8 RAM and I/O memory data check
Error history memory 1 Displays the details of the 10 latest cases
9
Error history memory 2 Records all past errors
A Battery voltage setting Voltage settings for capacity standards
B Turning speed reduction 0 - 16
C AOS setting 1 Sets the lift/tilt end and others
D AOS setting 2 Checks the lever switch
E Memory initial Clears the error history
F Normal screen 2 No errors are displayed on the RS0 screen
* Refer to the Adjustment Standards List on page 22 for parameters.
21
RS1 on display board
RS1 on 4 3 1 5
Voltage Model TRV/ HYD
[V] HYD HYD HYD Travel speed Lift speed Plugging brake
board SPD-L SPD-M SPD-H HYD HYD HYD ATTAT. ATTAT. ATTAT. PLUGG BRAKE TRAVEL HYD STEER BATT OIL LOAD BRAKE Language
LIFT LIFT LIFT LIFT-1 LIFT-2 TILT 1 2 3 ING TRQ (km/h) (mm/sec) distance (m)
FB10P 0 32 26 20 20 32 20 0 0 0 32 28 JAPAN 16.0/14.0 540/350 6.5-8.0
FB14P c c c c c c c c c c c c c c c c 16.0/14.0 540/330 6.5-8.0
1
FB15P c c c c c c c c c c c c c c c c 16.0/14.0 540/320 6.5-8.0
48V FB18P 2 c c c c c c c c c c c c c c c c 15.5/13.5 540/310 6.5-8.0
FB20P 3 c c c c c c c c c c c c c c c c 16.0/14.0 470/280 6.8-8.3
72V FB30P 6 c c c c c c c c c c c c c c c c 15.5/13.5 550/320 6.7-8.2
FB10P-U 7 c c c c c c c c c c c c c c c c 18.0/16.0 650/470 8.1-9.6
FB14P-U c c c c c c c c c c c c c c c c 18.0/16.0 650/450 8.1-9.6
8
FB15P-U c c c c c c c c c c c c c c c c 18.0/16.0 650/420 8.1-9.6
48V
FB18P-U 9 c c c c c c c c c c c c c c c c 17.5/15.5 650/400 8.1-9.6
FB20P-U A c c c c c c c c c c c c c c c c 17.5/15.5 600/360 8.1-9.6
FB25P-U B c c c c c c c c c c c c c c c c 17.0/15.0 600/340 9.0-10.5
48V FBB15P C c c c c c c c c c c c c c c c c 16.0/14.0 650/420 6.5-8.0
FBB20P c c c c c c c c c c c c c c c c 16.0/14.0 600/360 7.0-8.5
D
72V FBB25P c c c c c c c c c c c c c c c c 15.5/13.5 600/340 7.5-9.0
FBB30P E c c c c c c c c c c c c c c c c 15.5/13.5 550/320 6.7-8.2
Series-F F
¡Memory initial (display RS1=E) ¡Option setting (Display board RS1=6) Plugging brake distance
¡Flat, unladen, and full speed
Slow speed (turtle speed) : 5km/h LIFT LOCK : OFF [Lift interrupt] ¡Specific gravity of electrolyte : more than 1.25 at 20
2-2-6. Adjustment Standards List for FB-75 series
Travel mode : NORMAL SPEED LIMIT : OFF [Speed limit at high lifting height] ¡Full acceleration
BRIGHTNESS :5 SEAT SWITCH : OFF fixed [With seat switch]
Neutral regenerative power : MID FINGER TIP : OFF fixed [With finger tip] ¡Language selection (Display board RS1=5)
Meter mode : Hour meter AOS : OFF [With AOS]
JAPANESE > OK
Error history : Clear POWER MODE : ON fixed [Power mode]
ENGLISH > MONITORING OK
CHARGER : ON [Charger]
* When Japanese is not selected for display, "CHARGER" FRENCH > CONTROLEUR OK
TILT STOP : OFF [Automatic tilt leveling]
is automatically set to "OFF". GERMAN > UEBERWACHUNG OK
* Before the car inspection, set "POWER MODE" to "OFF". * When Japanese is not selected for display, SPANISH > MONITOR OK
* HOUR METER (hour meter count) setting "CHARGER" is automatically set to "OFF". DUTCH > MONITORING OK
1: Key SW linked indication
22
2: Actual operation time indication
2-2-7. Confirmation of other services
Display
<Confirmation>
After pressing " " button for more than 3 seconds, it
shows display as shown below.
¡Model confirmation
Shows the models set by RWS

of travel, hydraulic board
121T178
¡Software number confirmation
Shows the software numbers :

T (travel), H (hydraulic), E
121T179
(EPS), D (display)
¡Buzzer mode, rotary SW mode setting
Shows buzzer mode setting by

flashing
¡Set buzzer mode by pressing
121T180
" " or " " button (OFF/

ON)
(continues on next page) ON: (Normal)
OFF: (turns off all the buzzer
except blinkers)
¡ Shows rotary SW mode
setting turned over
23
(continued from previous page)
¡Shows buzzer mode setting

by flashing
121T181
¡ Set rotary SW mode by

Shows number of rotary SW
pressing " " or " "
button (OFF/ ON)
ON: normal
OFF: ignores the RSW setting
on display board and
changes display mode
change SW
CAUTION ¡When unable to communicate between travel,

hydraulic, EPS (broken wires etc.), software
numbers are not displayed.
¡If buzzer mode is set to OFF, all buzzer sounds
are turned off except blinker sound.
¡If rotary SW mode is set to OFF, the rotary SW
is disabled on the board. You can rotate the
rotary SW by "keeping pressing down
button for more than 3 seconds while pressing
button" or "keeping pressing down
button for more than 3 seconds while pressing
button.
24
2- 3. SICOS-AC check and adjustment
CAUTION ¡Even if the key is turned off, battery voltage is

¡Display board
still supplied to the display board. Disconnect
the battery plug before performing this work. F01
CDE
23
¡After finishing the setting, be sure to return
456
AB
rotary switch RS1 to "0". 789
¡When measuring the electric current, measure

Return RS1 to "0".
the motor current in AC mode and the battery
current in DC mode.
2-3-1. Chassis insulation check

<Checking procedure>
1. Disconnect the battery plug.
2. Remove the connector on the battery electrolyte level
detection line (green/black) in the control unit.
[Only models of electrolyte level detector is equipped]
3. Use a tester to measure the insulation resistance

between positive (+) terminal of the chassis battery
plug and chassis, and between negative (-) terminal of
the chassis battery plug and chassis.
Standard value 1M or greater
25
2-3-2. Battery voltage adjustment

<Measuring points>
¡Pull the battery out and disconnect the plug. At the
terminal section where the battery line appears,
measure the battery voltage. Depending on the model
setting, display for 24V or 48V is automatically
selected.
<Measuring conditions>
Specific gravity of the battery electrolyte : more than 1.25
at 20:
<Measuring instrument>
Use a digital tester that can measure 1/100V.
Use Direct current (DC) mode.
<Adjusting procedure> ¡Display board
1. Set rotary switch RS1 on the display board to "A". F01
CDE
23
456
AB
789
2. Turn the key switch ON and the following screen
Set RS1 to "A".
appears.
¡Battery voltage setting screen
121T127
Battery Voltage Parameter (flashing)
3. Set the parameter for battery voltage the same as the

measured value for the tester.
NOTE The allowable error is within 0.1 V.
¡Press button to increase the parameter.

¡Press button to decrease the parameter.
26
2-3-3. Current detector check

Traction motor current check
<Measuring point>
IU: traction motor U phase electric current (V phase and
W phase are also possible.)
at 20:
Alternating current (AC) mode
Control unit
Traction motor
Blower U phase
2P
White Analog clamp
ammeter
2P
White <5>
U1
<8>
U2
CN5
Board comp.,
CN8 <6>
V1
CN6 MPU CN7
<9>
V2
EPS
controller <7>
W1
<10>
CN1 CN2 CN3 CN4
W2
Harness, M
2P
Black
10P
+
2P-X 2P-Y
(waterproof)
-
<3> <2>
<12>
221T018E
CAUTION When measuring AC motor current, use the

recommended ammeter below:
Recommended ammeter :
Hioki 3109-01 (Analog)
Hioki 3209 AC/DC high tester (Digital)
CAUTION When measuring locked travel/hydraulic motor

current using Hioki 3209 AC/DC (Digital), you
need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response
27
1. Set rotary switch RS1 on the display board to "7". ¡Display board
F01
CDE
23
456
AB
2. Turn the key switch ON and the following screen 789
appears.
Set RS1 to "7".
NOTE If TRV is not flashing, press button to make it
flash.
¡Voltage, current, and temperature checking screen.
Flashing Traction motor Current Display
121T128
Flashing
3. With the electric current off, check if the traction motor

current display (MOTOR) shows 000A.
4. Jack up the drive wheel and perform the following.
Idling
Idle away by applying the accelerator fully.
Locked
Release the brake pedal, turn the brake micro switch
ON, strengthen the brake spring (up to the level which
stops the revolution) and then apply the accelerator
fully.
WARNING Before measurement, be sure to jack up the

drive wheel.
5. Check if the traction motor current display (MOTOR)

shows a traction motor current (IU) meter value within
20A.
28
Hydraulic motor current check

<Measuring point>
IU: hydraulic motor U phase electric current (V phase and
W phase are also possible.)
at 20:
Alternating current (AC) mode
Control unit
Blower
2P
White Hydraulic
2P
motor
White <5> U phase Analog clamp
U1
ammeter
<8>
U2
CN5
Board comp.,
CN8 <6>
V1
CN6 MPU CN7
<9>
V2
EPS
controller <7>
W1
<10>
CN1 CN2 CN3 CN4
W2
Harness, M
2P
Black
+
10P 2P-X 2P-Y

(waterproof)
-
<3> <2>
<12>
221T019E
CAUTION When measuring AC motor current, use the

recommended ammeter below:
Recommended ammeter :
Hioki 3109-01 (Analog)
Hioki 3209 AC/DC high tester (Digital)
CAUTION When measuring locked travel/hydraulic motor

current using Hioki 3209 AC/DC (Digital), you
need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response
29
F01
CDE
23
456
AB
appears.
3. Press either or button to make HYD flash. Set RS1 to "7".
¡Voltage, current, and temperature checking screen.
Flashing Hydraulic motor Current Display
121T129
Flashing
4. With the electric current off, check if the hydraulic

motor current display (MOTOR) shows 000A.
5. Set the lift in the relief state.
6. Check if the hydraulic motor current display (MOTOR)
shows a hydraulic motor current (IU) meter value
within 20A.
30
2-3-4. Forklift model setting check and adjustment

<Checking procedure 1>
¡Display board
1. Set rotary switch RS1 on the display board to "2".
2. Turn the key switch ON and the following screen F01
CDE
23
appears.
456
AB
789
3. Make sure the model is set correctly.
Set RS1 to "2".
<Checking procedure 2>

1. Keep pressing button for 5 seconds.
2. The display changes as shown below.
3. Confirm the correct model is set.
4. After confirmation, press button again to exit the
checking.
¡Forklift model checking screen

¡Travel/hydraulic board
(If rotary switch RS1 on the travel/hydraulic board is set
to "2") F01
CDE
23
456
AB
789
RS1="2"
121T178
31
<Adjusting procedure>
1. Forklift model setting: set the model with rotary switch RS1 on the travel/ hydraulic board.
¡RS1 setting forklift models (Travel/ Hydraulic board)

RS1 Applicable forklift models
0 FB10P
1 FB14P FB15P
2 FB18P
3 FB20P
4 FB25P
5 FB28P
6 FB30P
7 FB10P-U
8 FB14P-U FB15P-U
9 FB18P-U
A FB20P-U
B FB25P-U
C FBB15P
D FBB20P FBB25P
E FBB30P
F
32
2-3-5. Safety circuit for control (contactor tripping) check

1. Turn the key switch to OFF, and disconnect the battery
plug.
2. Disconnect connectors of travel/hydraulic board (CN2
and CN4).
H CN7
CN10 CN9
CN4
CN4
CN3
Travel/hydraulic board
CN1 CN2
CN2
CN5 T
Disconnect CN2 and CN4 simultaneously.
221T022E
CAUTION Do not travel or manipulate the hydraulic when

only one end of CN2 or CN4 is disconnected. It
may damage lGBT module.
3. Connect the battery plug and turn the key switch on.
4. Operate the accelerator, and make sure an alarm
sounds, main contactor trips, and the error messages
comes on as shown below.
¡Error messages
B 11 : IGBT-TRAVEL
B 13: FAIL OPERATION
B 13: TURN OFF KEY SWITCH
33
2-3-6. Hydraulic setting check and adjustment

F01
CDE
23
456
appears.
AB
789
3. Make sure that the parameter items are set the same
as the values on the Adjustment Standards List on Set RS1 to "4".
page 22.
¡Hydraulic speed setting screen
The parameters flash.

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

221T003
speed 5-10km/h by pressing or
button (0 - 32).

speed 10-km/h by pressing or
221T004 button (0 - 32).

¡Set LIFT1 hydraulic speed by pressing
or button (0 - 32).
221T005
(continues on next page)
34
(continued from previous page)

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

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

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

or button (0 - 32).
221T009

221T010
or button (0 - 32).
1. Press either or button to move the flashing
icon to the parameter you want to change.
2. Press button to increase the parameter.
3. Press button to decrease the parameter.
<Attachment parameter>
Parameter of attachment is listed below.
Attachment HYD ATTAT parameter
35 SF 09
2-3-7. Descending regeneration check

1. Release the brake pedal to stop the truck on a slope.
2. Make sure that the truck descends the slope at a
speed of 1 km/h 0.5 when the brake pedal is
stepped on.
2-3-8. Switch back (plugging/ regenerative)

braking force adjustment
<Standard parameter>
¡Refer to the Adjustment Standards List on page 22.
¡Flat ground, unladen, and full speed
¡Specific gravity of the battery electrolyte : more than
1.25 at 20:
F01
CDE
23
456
AB
789
appears. Set RS1 to "3".
¡Plugging and braking strength setting screen
221T011
Plugging Strength Parameter (flashing)
3. Check if the PLUGGING parameter is flashing.
NOTE If the PLUGGING parameter is not flashing, press

button.
4. Press button to increase the braking force.

5. Press button to decrease the braking force.
36
2-3-9. Regenerative braking force check

and adjustment
1. Cancel the neutral (released accelerator) regeneration.
Refer to "[5] Regeneration (Neutral) mode setting" on
page 15.
121T141
2. Travel forward at a moderate speed and return the

accelerator lever to the neutral position.
3. Lightly depress the brake pedal.
4. Check if a light braking force (regenerative braking) is
applied.
F01
CDE
23
456
AB
789
appears. Set RS1 to "3".
¡Plugging and braking strength setting screen
221T012
Braking Strength Parameter (flashing)
3. Press button to move the flashing icon to the

BRAKE parameter.
4. Press button to increase the braking force.
5. Press button to decrease the braking force.
37
2-3-10. Safety monitor symbol check and

adjustment
F01
CDE
23
456
AB
appears. 789
3. Make sure that the parameter items are set the same
as the values on the Adjustment Standards List on Set RS1 to "1".
page 22.
¡Monitoring symbol setting screen

The operator can select ON or OFF (flashing).
TRAVEL
HYD
STEER
BATT
BRAKE
LOAD
OIL
221T013
38
icon to the item you want to change.
2. Press button to turn the item ON.
3. Press button to turn the item OFF.
4. Turn the key switch OFF and return rotary switch RS1 ¡Display board
to "0". F01
CDE
23
5. Turn the key on again.
456
AB
The symbol indicating that the monitoring symbol 789
setting screen is set to ON is displayed.
Return RS1 to "0".
121T145E
NOTE When the display board is reset, TRAVEL, HYD,

STEER and BRAKE are automatically turned ON.
2-3-11. Display language check and adjustment

F01
CDE
23

456
AB
appears. 789
3. Check if the display language is set to your preference.
Set RS1 to "5".
¡Display language setting screen.
121T146
Language (flashing)
1. Press either or button to select your preferred
language.
39
2-3-12. Optional setting check and adjustment

F01
CDE
23
456
AB
appears. 789
3. Check if the options are set to your preferences.
Set RS1 to "6".
¡Optional setting screen

The operator can select ON or OFF (flashing).
121T147
40
Standard
Optional setting mode Remarks
setting
Lift locks when only one red segment is left
LIFT LOCK Lift interrupt OFF
on battery discharge indicator
SPEED LIMIT High lift height OFF Need to install action switch separately
SEAT SWITCH With seat switch OFF Need to install seat switch separately
Equipped with finger tip system hydraulic
FINGER TIP With finger tip OFF
lever models
AOS With AOS OFF Equipped with AOS function models
POWER MODE Can change to travel mode ON ON fixed, for FB (disabled to set power mode)
CHARGER Can set a timer for charging ON Does not show timer charging display
Equipped with Tilt Automatic Stop function
TILT STOP Automatic tilt leveling OFF
models
1: Key switch ON
2: Actual operation time (motor operation time)
HOUR METER 1 1
Changing view
(both counting)
1: Using standard turtle switch

SPEED SWITCH 1 1
2: Using old turtle switch
NOTE All modes on standard forklifts other than POWER

MODE are set to OFF. An optional mode can only
be turned ON if that option has been installed on
the forklift.
icon to the item you want to change.
2. Press button to turn the item ON.
3. Press button to turn the item OFF.
41
2-3-13. Display brightness check and

adjustment
¡Make sure that the information on the display can be
read clearly even indoors.
1. Press or button repeatedly till the display
adjustment screen appears.
¡Display adjustment screen
221T016
Display brightness parameter (flashing)
2. Check if the BRIGHTNESS parameter is flashing.

3. Press or button to adjust the brightness (0-7).
¡Press button to increase the parameter.
¡Press button to decrease the parameter.
42
2-3-14. Hour meter working check

1. Connect the following connector terminal.
NOTE Connector terminal

Location : Inside the front cover, underneath Cup holder
the cup holder Black/ White

Wire colors : Blue/black and black/white Blue/ Black
2. Make sure that the hourglass symbol on the display

flashes when the hydraulic or travel controls are
operated.
2211050E
CAUTION ¡ After completing the check, be sure that the

connector terminal is left unplugged until the
forklift is delivered to the customer.
¡ When hour meter actual operation time is
used, set HOUR METER to "2".
("1" is for Key SW linked indication)
121T148E
Hourglass (flashing)
Normal : key SW ON (white)
Option : actual operation (colored)
2-3-15. Auto power off function working check

1. Turn the key switch ON.
2. Make sure that the key turns off automatically after
about 15 minutes.
43
2-3-16. Battery electrolyte level (optional)

working check (for GS battery only)
1. Remove the battery electrolyte level sensor and make
an electrolyte level drop status.
2. Make sure that " REPLENISH REFINED WATER
FOR BATTERY " scrolls from right to left across the
display.
¡Battery electrolyte level
121T149E
Scrolls from right to left Flashing
2-3-17. Turn signal lamp working check

1. When the turn signal lever is operated, make sure that
the turn signal lamp flashes and at the same time a
buzzer sounds.
2. When the turn signal lever is operated in one direction
and the steering wheel is turned in the other direction
within 12 seconds, make sure that the turn signal lamp
goes off. However, if the steering wheel is not turned
within 12 seconds, the turn signal will go off
automatically.
44
2-3-18. Hydraulic oil level (optional)

working check
1. Fully lift-up the lift and turn the key switch to ON.
2. Make sure that " REFILL HYDRAULIC OIL "
scrolls from right to left across the display.
¡Hydraulic oil (optional)
121T150E
2-3-19. Brake oil level working check

1. Remove the sensor and make an oil level drop status.
2. Make sure that " REFILL BRAKE OIL " scrolls
from right to left across the display.
(The display will appear different from below if a
language other than English has been selected.)
¡Brake oil
221T015E
45
2-3-20. Overload (optional) working check

1. Fully lift-up the fork and make a relief valve work.
2. Make sure that " REDUCE THE LOAD " scrolls
from right to left across the display.
¡Over loading (optional)
121T151E
2-3-21. Travel inhibitor (optional) working check

1. Connect the [-] line of "Black/ White" to the connector
of "CN5-2 pin" on the Travel/ Hydraulic board.
(Refer to "4-1. FB-75 System wiring".)
2. Make sure that the truck does not start even if the
accelerator pedal is operated.
2-3-22. Cooling fan working check

1. Make sure that the cooling fan operates during travel
or hydraulic operation.
2. While travel and hydraulic operation are stopped,
make sure that the cooling fan stops when the
temperature inside the control unit is 35: or less, and
that it operates at low speed when the temperature
inside the control unit is 40: or higher.
46
2-3-23. Lift interrupt (optional) working check

2. Turn the key switch ON. F01
CDE
23
3. Set "LIFT LOCK" mode to "ON".
456
AB
Refer to "2-3-12. Optional setting check and adjustment" 789
on page 40.
Set RS1 to "6".
¡Option setting screen Set to ON (flashing)
121T152
4. Turn the key switch OFF and return the rotary switch ¡Display board
RS1 to "0".
F01
5. Connect a 40 - 46V power supply to the battery plug.
CDE
23
456
6. Turn the key on again.
AB
789
7. Make sure that " CHARGE THE BATTERY "
scrolls from right to left across the display. (The display Return RS1 to "0".
will appear different from below if a language other
than English has been selected.)
121T153E
"E" lights up Scrolls from right to left
NOTE Under the above conditions, the lift speed will be

50%. If the battery discharge indicator flashes one
segment, CHARGE THE BATTERY will scroll
continuously across the display and the lift will
stop (There is no need to check this).
47
2-3-24. Turning speed reduction (optional)

adjustment and working check
¡Display board
1. Set rotary switch RS1 on the display board to "B".
F01
CDE
23
456
AB
789
appears. Set RS1 to "B".
¡Turning limit speed setting screen
121T154
Parameter (flashing)
3. Press either the or button to adjust the

parameter (0-16km/h).
¡Press the button to increase the parameter.
¡Press the button to decrease the parameter.
1. Turn the steering wheel all the way to either the right
or the left.
2. Operate the accelerator lever.
3. Make sure that the speed limitation is applied and that
the forklift does not accelerate excessively.
CAUTION A turning detection limit switch must be

installed in order to use this option.
2-3-25. Laser pointer (optional) working check

1. Turn on the laser pointer switch on the front panel.
2. Operate the tilt lever to tilt the mast horizontal.
3. Set the laser pointer horizon sensor to detect
evenness.
4. In a horizontal position, the display shows the status
and LD is output.
48
2-3-26. Accelerator potentiometer adjustment

<Adjusting procedure 1>
F01
CDE
23
456
AB
appears.
Set RS1 to "8".
121T155
3. Press , , , or to select "I/O", "TRV",

and "W0012".
(See "3-3. I/O check" on page 62 to learn setting.)
4. Loosen and adjust the screw on the accelerator

potentiometer to set "DATA" to AFH 20H with the
accelerator in the neutral position.
¡I/O check mode
DATA
8F/0000000010001111
c
d
CF/0000000011001111
121T156
<Adjusting procedure 2>

1. Provide 5 V power supply to the accelerator
Tester
potentiometer. Accelerator
potentiometer
2. Unplug the connector and insert the voltage measuring
adaptor.
Red/Yellow
Blue
White
Black/Yellow
3. Measure the voltage of the white cord by the tester. Tester pole
4. Loosen and adjust the screw on the accelerator (+)
potentiometer to set output voltage to 0.85 0.1 V

with the accelerator in the neutral position. 4P
Tester pole (-)
221T021E
49
2-3-27. Seat switch (optional) working check

F01
CDE
23
456
AB
appears.
Set RS1 to "6".
221T017
Set to ON (flashing)
3. Press or button to set "SEAT SWITCH" to

"ON".
1. Travel without taking a seat.
2. Make sure it is not traveling.
50
2-3-28. Automated fork horizontal stop (optional)
What is automated fork horizontal stop?

¡It detects the mast's tilt angle by potentiometer. It also Automated fork
Forward
horizontal stop button
turns [ON/OFF] the oil flowing in the hydraulic circuit, inclining
and turns [ON/OFF] the hydraulic motor.

¡If the fork is located upper than the horizontal position,
pressing "automated fork horizontal stop" button and
then inclining the tilt lever forward makes the fork to
stop at the horizontal position.
Tilt lever Backward

inclining
2211259
Adjusting the potentio for tilt angle detection

1. Set the rotary switch RS1 to "6" on the display board. ¡Display board
F01
3. Set the "TILT STOP" to "ON".
CDE
23
456
AB
789
¡Option setting screen
Set RS1 to "6".
221T023
Set to "ON" (flashing)
4. Turn the key switch OFF, and set the rotary switch ¡Display board
RS1 to "C".
F01
5. After turning the key switch ON, the following screen
CDE
23
456
will appear.
AB
789
¡AOS setting screen Set RS1 to "C".
121S031
flashing
51
6. The tilt potentiometric value flashes after a while.
121S032
"Tilt potentiometric value" flashes
If the tilt potentiometric value does not appear

¡"Display board" and "travel/hydraulic board" cannot
correspond.
aCheck the wire breaks.
7. Operate the tilt lever and adjust the rod of the Potentiometer
potentiometer for tilt angle detection so that the value

is set as follows. Rod
When the tilt is inclined

most forward Tilt potentiometric value 40
When the tilt is inclined

most backward Tilt potentiometric value 980
2211244
52
2-3-29. Built-in charger (optional) working check
<Total timer>
Magnetic Auto Reserve Equal Indicating LED of charging state
Checking procedure
contactor LED LED LED 1-2 3-4
1 Connect the battery plug. OFF
2 Connect the AC plug to wall outlet. OFF
Press and hold the Auto When pressed ON

3 Button for at least 5
seconds. 5 seconds later ON
The check will end approximately 1 minute and

4 OFF
36 seconds after Auto Button begins flashing.
:On
:Off
:May be on
:Flashing
Auto LED (green)

This LED is turned on when the
battery is fully charged.
Auto button
Reserve LED (green) 4
Completion
cycle LED
3
Equal LED (orange)
Indicating LED (green) of
charging state.
¡The LED lights indicate
2 the charge left in the
battery.
¡If the total timer is
operated, all 4 LEDs will
flash.
1
2211089
CAUTION ¡For a fully charged battery, check after performing approximately 2-3 minutes of
hydraulic operation.
¡If the charging state LEDs flash, they will not stop until the battery plug is
unplugged.
<Earth check>
Make sure the conductivity (0 at "1x" range of the tester) between the chassis and the
earth terminal in the receptacle on the charger panel.
NOTE If the optional setting (display board RS1=6) CHARGER is set to OFF, the charging
timer function will not work.
53
3. Troubleshooting
3- 1. Self diagnosis function
3-1-1. Display
If abnormalities or errors are detected with the self-
diagnosis function, the following symbols and error
messages will be displayed on the screen.
¡The applicable abnormality and/or error symbol will
flash on the display.
¡The applicable error message will be displayed. (If
multiple abnormalities and/or errors are detected, the
applicable error messages will be displayed in order.)
Travel system errors
The service (spanner) mark flashes.
The travel system error message scrolls from

right to left.
The travel symbol flashes.
121T105E
Hydraulic (including AOS) system errors
The hydraulic system error message scrolls

from right to left.
The hydraulic symbol flashes.
121T106E
Steering (EPS) system errors
The steering (EPS) system error message

scrolls from right to left.
The steering symbol flashes.
121T107E
54
3 Troubleshooting
Other errors
121T108E
Multiple abnormalities and/or errors
The detected error messages are scrolled in

order from right to left.
All of the symbols for the abnormalities

and/or errors detected flash from the right in
121T109E the order they are detected.
NOTE ¡ If the following abnormalities and/or errors

occur, travel, hydraulics, and EPS are
interlocked.
B11 : IGBT-TRAVEL
C21 : IGBT-HYD.
FAIL OPERATION
¡ The , , , and buttons are

inoperable while the self-diagnosis screen is
displayed. (You can not switch to the reserve
charge screen.)
¡If rotary switch RS1 on the display board is set to ¡Display board
F, the self-diagnosis screen will not be
F01
CDE
23
displayed. (The normal screen will be displayed.)

456
¡ When the abnormalities and/or errors are

AB
789
resolved, the display will return to the basic
screen. RS="F"
55
Troubleshooting 3
3-1-2. Error messages and Display conditions

Error
Error Message Probable Cause Notes
No.
1 A1 : CONTACTOR-MAIN Poor contactor connection
10 B10 : FUSE-MAIN Blown main fuse
*FAIL OPERATION*
11 B11 : IGBT-TRAVEL Travel phase IGBT error
*TURN OFF KEY SWITCH*
B12 : SENSOR-CURRENT Electric current sensor (traction

12
TRAVEL motor U phase, V phase) error
15 B15 : ACCELERATOR Accelerator error *TURN OFF KEY SWITCH*
*FAIL OPERATION*
21 C21 : IGBT-HYD. Hydraulic phase IGBT error
C24 : SENSOR-CURRENT Electric current sensor (hydraulic

22
HYD. motor U phase, V phase) error
23 C25 : SWITCH-LIFT Lift lever microswitch error
24 C26 : POTENTIO-MAST Tilt level or lift potentiometer error
Blown EPS fuse (Decelerates by

30 D30 : FUSE-EPS
half)
D31 : SENSOR-EPS EPS torque sensor error

31 *TURN OFF KEY SWITCH*
TORQUE (Decelerates by half)
32 D32 : TR-EPS MAIN EPS FET error (Decelerates by half) *TURN OFF KEY SWITCH*
40 E40 : TR-AOS Valve electric current error *TURN OFF KEY SWITCH*
E41 : POTENTIO-HYD. Error in the potentiometer for AOS

41
LEVER control
E42 : ENCODER-HYD
42 Error in the encoder for lift height
MAST
Traction motor electric current error

51 *FAIL CURRENT-TRAVEL* *TURN OFF KEY SWITCH*
(F51)
Hydraulic motor electric current error

52 *FAIL CURRENT-HYD* *TURN OFF KEY SWITCH*
(F52)
53 *FAIL VOLTAGE-TRAVEL* Travel electric current error (F53)
54 *FAIL VOLTAGE-HYD* Hydraulic voltage error (F54)
*REDUCE DUTY-
55 Board or IGBT temperature error
OPERATION*

58 *FAIL BUS SYSTEM* Display transmission error Transmission error between CPUs
from the display
56
3 Troubleshooting
Error
Error Message Probable Cause Notes
No.
Travel/hydraulic operation tripping

*FAIL OPERATION* Displayed when the error occurs
(W00)
Significant error in travel/hydraulic

*TURN OFF KEY SWITCH* Displayed when the error occurs
operations (W01)
The operator attempted to drive the

*RELEASE PARKING When attempted to travel as the
forklift with the parking brake on.
BRAKE* side brake key is on
(W02)
*REPLENISH REFINED Replenish refined water to the When the battery electrolyte gets
WATER FOR BATTERY* battery (W03) below minimum level
When the brake oil gets below

*REFILL BRAKE OIL* Brake oil (W04)
minimum level
*REDUCE THE LOAD* Overload (W05) When overloaded
When the fork oil gets below

*REFILL HYDRAULIC OIL* Fork oil (W06)
minimum level
The battery must be recharged.

*CHARGE THE BATTERY* When the battery is discharging
(W07)
*RELEASE ACCEL TO The accelerator was depressed When the travel CPU is in the
NEUTRAL* when the key was turned on. (W08) neutral safety mode
*OFF HYD. LEVER TO The hydraulic lever was engaged When the hydraulic CPU is in the
NEUTRAL* when the key was turned on. (W09) neutral safety mode
When the emergency stop switch

*AOS FAIL OPERATION* No current on solenoid (W 10)
is pressed
Lift location is set in the wrong way When the lift location is set in the
*RACK MISSET*
(W 11) wrong way
Dismounted from the truck without Seat switch is turned OFF without
*APPLY PARKING BRAKE*
applying the parking brake (W12) applying the parking brake
57
Troubleshooting 3
3- 2. Error history memory

3-2-1. Error history memory 1
<The 10 most recently detected errors/ abnormalities>
appears. F01
CDE
23
456
AB
NOTE ¡To view less than the ten most recent errors/ 789
abnormalities, place the flashing cursor on the
Set RS1 to "9".
last error/abnormality and press button to
go to "Previously detected errors/abnormalities".
¡If there are no errors/abnormalities, press
button to go to "Previously detected errors/
abnormalities".
¡The 10 most recently detected errors/abnormalities ¡Error/abnormality details

The most recent error/abnormality flashes as "A01". Number of times the error/abnormality
occurred when it was detected
121T165E
121T159
Year, month, day, and the time
of the error occurrence
Error/abnormality detection date, time, travel
The second error/abnormality flashes as "B10". distance, and travel and hydraulic hour meter
121T160 121T166E
121T161 121T167E
The ninth error/abnormality flashes as "B10".
(To the next page)

58
3 Troubleshooting
(From the previous page)
121T162 121T168E
The tenth error/abnormality flashes as F55.
The next page is "Previously detected errors/abnormalities (1)".
3-2-2. Error history memory 2

<Previously detected errors/abnormalities (1)>
¡Rotary switch RS1 on display board : 9 ¡Display board
NOTE ¡If there are no previous errors/abnormalities F01
CDE
23
displayed in the list, press button to go to
456
AB
"Previously detected errors/abnormalities (2)". 789
¡ If the same error/abnormality was detected
RS1="9".
multiple times previously, the data of the most
recent detection will be displayed under
"Error/abnormality details".
¡Flashing : Indicates the position of cursor.
Highlighted : Only highlighted numbers are
memorized as error items.
¡Previously detected errors/abnormalities (1) ¡Error/abnormality details

The previous page is "The 10 most recently detected
errors/abnormalities".
121T163 121T165E
121T163 121T166E
The next page is "Previously detected errors/abnormalities (4)".

59
Troubleshooting 3
<Previously detected errors/abnormalities (2)>

¡Rotary switch RS1 on display board : 9
¡Display board
F01
NOTE
CDE
If the same error/abnormality was detected
23
456
multiple times previously, the data of the most
AB
789
recent detection will be displayed under
"Error/abnormality details". RS1="9"
¡Previously detected errors/abnormalities (2) ¡Error/abnormality details
The previous page is "Previously detected

errors/abnormalities (1)". Number of times the error/abnormality
occurred when it was detected
Error/abnormality message display
121T164 121T169E
Error/abnormality detection date, time, travel

distance, and travel and hydraulic hour meter
121T164 121T168E
60
3 Troubleshooting
3-2-3. Clearing the error history memory

(memory initialization)
1. Set rotary switch RS1 on the display board to "E". ¡Display board
F01
3. When the screen shown below is displayed, memory
CDE
23
456
initialization is complete.
AB
789
4. Return rotary switch RS1 on the display board to "0".
Set RS1 to "E".
¡Memory Initialization Completion Screen
121T170
NOTE The following items are returned to their initial

values:
¡Slow speed (turtle) : 5km/h
¡Travel mode : N (NORMAL)
¡Meter mode : HR (hour meter)
¡Accelerator released (neutral) regenerative
force: MID
¡Error history : All clear
¡BRIGHTNESS (back light brightness): 5
61
Troubleshooting 3
3- 3. I/O Check
3-3-1. I/O check mode display method

F01
appears.
CDE
23
456
3. Press button to enter the I/O check mode. The
AB
789
"I/O" icon will flash.
The RAM icon flashes. Set RS1 to "8".
d
¡CPU selection
TRV : Travel
HYD : Hydraulic
EPS : Power steering
DSP : Display
121T155
¡I/O check mode
The I/O icon flashes.
121T156
The I/O icon is highlighted.
¡The selected CPU is highlighted.

¡Press either or button to select a
CPU.
The currently selected data length is
121T171
displayed.
The current data address setting is displayed.

The selected CPU is highlighted.
¡The W icon (2 bytes) flashes.

121T172 ¡(This can not be changed.)
(To the next page)
62
3 Troubleshooting
(From the previous page)

¡The W icon (2 bytes) is displayed.
¡The 0 icon flashes. (This can not be
121T173 changed.)

¡The 0 icon flashes. (This can not be
121T174 changed.)


¡The data address (first byte) setting
121T175 flashes.
¡Press either or button to set the
data address (first byte).
(This is limited to the selected CPU.)

¡The data address (first byte) setting
121T176 flashes.
¡Press either or button to set the
data address (first byte).
(1-F)

¡The current data address setting is
displayed.
121T177
The data is displayed.
NOTE ¡The data length is set to W (2 bytes), regardless

of the CPU selected.
¡The second byte of the data address is set to 00,
regardless of the CPU selected.
63
Troubleshooting 3
3-3-2. I/O port table

Travel CPU
¡I/O port table (1)
PortNO. Bit IN/OUT Contents Remarks
2 OUT CPU run LED for the traction motor Flashes when the travel CPU is normal
5 IN Auxiliary input 1 0-5V input
6 IN Auxiliary input 2 0-5V input
PA 7 IN Auxiliary input 3 0-5V input
(W0000) TCLKC IN Traction motor rotary encoder A 0-5V input
TCLKD IN Traction motor rotary encoder B 0-5V input
10 IN Traction motor U phase voltage 0-5V input
11 IN Traction motor V phase voltage 0-5V input
12 IN Traction motor W phase voltage 0-5V input
POE0 IN Traction motor gate signal open order 1 Gate OPEN when L
PB During hydraulic operation
(W0002) 6 IN When operating at H
(transmission between CPUs)
During travel operation
7 OUT When operating at H
Hydraulic trip
8 IN (transmission between CPUs) Hydraulic trip at H
Travel trip
9 OUT (transmission between CPUs) Travel trip at H
0 IN Accelerator voltage 0 FBR

4 IN Neutral H when in neutral
5 IN Forward H when traveling forward
PC 6 IN Backward H when traveling backward
(W0004) 8 IN Seat switch L when on
9 IN Travel inhibitor L when on
10 IN Turning detector L when on
11 IN Brake switch L when the brake is on
12 IN Main contactor contact H when on
13 IN Main fuse L when open
15 IN EPS fuse L when open
0 OUT Forward output Forward travel when L

PD 1 OUT Backward output Backward travel when L
(W0006) 2 OUT Fan output 1 Fan on when L
3 OUT Fan output 2 Fan on when L
64
3 Troubleshooting

TIOC0A OUT Contacter chopper signal ON when H
1 OUT Main contacter output ON when H
2 OUT Auxiliary contacter output ON when H
4 IN Rotary switch 1 Truck model selection
PE
(W0008) 7 IN Rotary switch 4 Truck model selection
TIOC3B OUT Traction motor U phase lower gate signal ON when L
TIOC3D OUT Traction motor U phase upper gate signal ON when L
TIOC4A OUT Traction motor V phase lower gate signal ON when L
TIOC4B OUT Traction motor W phase lower gate signal ON when L
TIOC4C OUT Traction motor V phase upper gate signal ON when L
TIOC4D OUT Traction motor W phase upper gate signal ON when L
(W000A) AN0 A/D Traction motor U phase electric current 2.5V 1.75V= 700A
(W000C) AN1 A/D Traction motor V phase electric current 2.5V 1.75V= 700A
(W000E) AN2 A/D Battery current 2.5V 1.75V= 700A
(W0010) AN3 A/D Battery voltage 0-5V=0-55V
(W0012) AN4 A/D Accelerator voltage 1 0-5V
(W0014) AN5 A/D Accelerator voltage 2 0-5V
(W0016) AN6 A/D Board temperature sensor 0-5V
(W0018) AN7 A/D Travel IGBT temperature sensor 0-5V
(W001A) TCNT1 MTU Auxiliary rotary encoder Counter value

(W001C) TCNT2 MTU Traction rotary encoder Counter value
65
Troubleshooting 3
Hydraulic CPU
Flashes when the hydraulic CPU is
2 OUT CPU run LED for the hydraulic motor
normal
TCLKA IN Lift rotary encoder A 0-5V input
TCLKB IN Lift rotary encoder A 0-5V input
PA TCLKC IN Hydraulic motor rotary encoder A 0-5V input
(W0000) TCLKD IN Hydraulic motor rotary encoder B 0-5V input
10 IN Hydraulic motor U phase voltage 0-5V input
11 IN Hydraulic motor V phase voltage 0-5V input
12 IN Hydraulic motor W phase voltage 0-5V input
Contents Hydraulic motor gate signal

POE0 IN Gate OPEN when L
open order 1
open order 2
open order 3
PB Contents Hydraulic motor gate signal
(W0002) open order 4
During hydraulic operation
6 OUT When operating at H
During travel operation
7 IN When operating at H
Hydraulic trip
8 OUT Travel trip at H
9 IN Travel trip (transmission between CPUs) Travel trip at H
0 IN Lift 1 switch FBR

2 IN Tilt switch FBR
3 IN Attachment 1 switch FBR
PC 4 IN Attachment 2 switch H when in neutral
(W0004) 5 IN Attachment 3 switch H when traveling forward
6 IN Auxiliary input 7 H when traveling backward
7 IN Auxiliary input 8 L when on
12 IN Main contactor contact L when on
14 IN Hydraulic fuse (Auxiliary) L when on

2 IN Tilt switch FBR
3 IN Attachment 1 switch FBR
PC 4 IN Attachment 2 switch H when in neutral
(W0004) 5 IN Attachment 3 switch H when traveling forward
6 IN Auxiliary input 7 H when traveling backward
7 IN Auxiliary input 8 L when on
12 IN Main contactor contact L when on
14 IN Hydraulic fuse (Auxiliary) L when on
66
3 Troubleshooting

TIOC0A OUT Gate board power chopper signal
1 OUT AOS switching A/D input 1 0: Lift 1: Tilt
2 OUT AOS switching A/D input 2 2: Attachment 1 3: Attachment 2
3 OUT AOS switching A/D input 3 4: Attachment 3
PE 6 IN Rotary switch 3 Truck model selection
(W0008) 7 IN Rotary switch 4 Truck model selection
TIOC3B OUT Traction motor U phase lower gate signal ON when L
TIOC3D OUT Traction motor U phase upper gate signal ON when L
TIOC4A OUT Traction motor V phase lower gate signal ON when L
TIOC4B OUT Traction motor W phase lower gate signal ON when L
TIOC4C OUT Traction motor V phase upper gate signal ON when L
TIOC4D OUT Traction motor W phase upper gate signal ON when L
(W000A) AN0 A/D Hydraulic motor U phase electric current 2.5V 1.75V= 700A
(W000C) AN1 A/D Hydraulic motor V phase electric current 2.5V 1.75V= 700A
(W000E) AN2 A/D Battery voltage 0-5V=0-55V
(W0010) AN3 A/D Hydraulic IGBT temperature sensor 0-5V
(W0012) AN4 A/D Tilt level potentiometer 0-5V
(W0014) AN5 A/D Auxiliary A/D input 0-5V AOS
(W0016) ADS0 A/D Lift lever potentiometer 0-5V AOS
(W0018) ADS1 A/D Tilt lever potentiometer 0-5V AOS
(W001A) ADS2 A/D Attachment 1 lever potentiometer 0-5V AOS
(W001C) ADS3 A/D Attachment 2 lever potentiometer 0-5V AOS
(W001E) ADS4 A/D Attachment 3 lever potentiometer 0-5V AOS
(W0020) ADP0 A/D Lift valve current 0-5V AOS
(W0022) ADP1 A/D Tilt valve current 0-5V AOS
(W0024) ADP2 A/D Attachment valve current 1 0-5V AOS
(W002A) TCNT1 MTU Lift rotary encoder Counter value

(W002C) TCNT2 MTU Hydraulic rotary encoder Counter value
67
Troubleshooting 3
Display CPU
0 IN Switch 1 (up) L when the switch is on
1 IN Switch 2 (down) L when the switch is on
2 IN Switch 3 (mode) L when the switch is on
P1 3 IN Switch 4 (Reserved setting) L when the switch is on
(W0000) 4 IN Hour meter count start Count begins at L
5 IN Key switch start H when the key is turned to start
6 IN Charging interlock relay B contact H when the charging plug is on
7 IN Switch 5 (Turtle) L when switch is ON
P3 IRQ4 IN P5 power check CPU sleep when L

(W0002) 5 IN Battery electrolyte level When lowering 0/1=100/200ms
0 IN Rotary switch 1
P7 1 IN Rotary switch 2
(W0004) 2 IN Rotary switch 3
3 IN Rotary switch 4
0 IN Slow speed mode switch (turtle) H and B contact when the switch is on
1 IN Turn signal switch (right) L when the switch is on
2 IN Turn signal switch (left) L when the switch is on
P9 3 IN Reserve charge start L when starting
(W0006) 4 IN Brake oil level Usually H
5 IN Hydraulic oil level Usually H
6 IN Overload L during overload
7 IN Parking brake L when on
0 OUT LCD reset Reset when H

1 OUT Power source relay drive On when L
2 OUT Turn signal lamp (right) On when L
PE
(W0008) 3 OUT Turn signal lamp (left) On when L
4 OUT Reserve charge Charging begins when L
5 OUT VFD power ON when L
6 IN 5V power source input H when there are 5V
0 OUT CPU stop CPU run when the LED flashes

PF
(W000A) 1 OUT Buzzer drive 4kHz when the buzzer is on
7 IN VFD icon flashing input Lit up when H, Lit off when L
(W000C) AN0 A/D Battery voltage 0-5V=0-55V

(W000E) AN1 A/D VFD power 0-5V=0-70V
(W0010) AN2 A/D Auxiliary 0-5V
68
3 Troubleshooting
EPS CPU
0: Electric current available

0 IN Motor current check
1: Electric current not available
1 IN K. S. check 0: K.S.ON 1: K.S.OFF
0: Power source on
2 OUT Power source retention signal
1: Power source off
0: Correct direction
PA (FET1:ON,FET3:OFF)
(W0000) 4 OUT FET1, 3 gate signal
1: Reverse direction
(FET1:OFF,FET3:ON)
0: Correct direction
(FET2:ON,FET4:OFF)
5 OUT FET2, 4 gate signal
1: Reverse direction
(FET2:OFF,FET4:ON)
0: Lower level FET off

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

7 OUT Upper level FET 3, 4 gate signal
1: Upper level FET chopper ok
PB TIOCA3 OUT Lower level FET 1, 2 gate signal 0: OFF 1: ON

(W0002)
Upper level FET power source chopper
TIOCA4 OUT
signal
(W0004) Abnormal electric current (overload

IRQ0 IN Interrupted at the startup edge
current x 2) check
(W0006) AN0 A/D EPS motor current 0-2.25 0.35V=0-40A

(W0008) AN1 A/D EPS torque sensor 2.5V neutral
69
Wiring and main controller layout 4
4. Wiring and main controller layout

PB100-90 PB100-90 1 2 3 PB100-90
Battery(48V) Line Connector Line Connector Line Connector
V N No. CN Pin No. No. CN Pin No. No. CN Pin No.
RDWH
BKWH
RDBK
VA NA 125V 0.022 F
BUBK RD
C1 5 18 Main contactor contact BKRD
RPA 3 4 Power supply M STP 1 3
F1 GNRD
F1 5 9 Traction motor RNA 3 14 Fan output 1
Travel fuse GND
+ F2 5 19
BUWH
RA1 3 5 A phase signal
Blower
Hydraulic fuse speed sensor WH M DWN 1 4 Fan output 2
BK
MC 325A 80V,5600 F(x9) MIB RB1 3 15 B phase signal

WHBK# X7 + 100V
TUM 6 1 Traction motor U phase RDGN#
TPU 5 2 22 F
Board
BNWH#
TU0 6 9 U phase gate output 0 YERD# Power supply WHBK
TIU
IGBT
BUYE#
TU1 6 2 U phase gate output1 TIU BKYE#
TIU 5 3 Signal H
RDYE
IGBT module OG# Travel TNU 5 12 GND Horn

Traction U RDWH#
TU2 6 10 U phase gate output2 RDBK#
U1 TUP 6 3 U phase power supply(+) current sensor TPV 5 4 Power supply
motor Phase BKWH# BU# YERD
TUN 6 11 U phase power supply(-) TIV BKWH#
TIV 5 13 Signal
X7
TNV 5 14 GND
WH#
TVM 6 4 Traction motor V phase
Board RDGN#
V1TIV BUYE#
TV0 6 12 V phase gate output 0 YERD#
HPU 7 2 Power supply Brake switch WHRD
IGBT TV1 6 5 V phase gate output1 HIU HIU 7 3 Signal BS 1 7 Brake switch
IGBT module OG# BKYE#
W1 V TV2 6 13 V phase gate output2 Hydraulic HNU 7 8 GND GNWH
Phase TVP 6 6 V phase power supply(+) RDBK#
TVN 6 14 V phase power supply(-) current sensor BU#
HPV 7 4 Power supply
HIV BKWH#
HIV 7 9 Signal
HNV 7 10 GND BURD
WHBK#
TWM 6 7 Traction motor W phase X3 OF2 1 9 Forward output
Board TW0 6 15 W phase gate output 0 RDYE
BUYE# AP1 2 1 Power supply
IGBT TW1 6 8 W phase gate output1 WH
IGBT module OG# AD1 2 2 Signal
W TW2 6 16 W phase gate output2 YEBK
Phase TWP 5 1 W phase power supply(+) Accelerator AN1 2 11 GND X4 OB2 1 10 Backward output
TWN 5 11 W phase power supply(-) AP2 2 3 Power supply
potentiometer BU
AD2 2 10 Signal
BKYE BN
AN2 2 9 GND BZ
WHBK#
HUM 8 1 Hydraulic motor U phase X4 Back buzzer RPA 3 6 Power supply
Board HU0 8 9 U phase gate output 0 IGBT BNYE
HD3 5 5 Signal BN RNA 3 16 GND
IGBT
BUYE#
HU1 8 2 U phase gate output1 T-IGBT BKYE
HN3 5 15 GND RA2 3 7
IGBT module OG# temperature sensor Rear combination lamp(Right) A phase signal
Hydraulic U HU2 8 10 U phase gate output2 RB2 3 17 B phase signal
U2 Phase HUP 8 3 U phase power supply(+) HD4 7 5 TPM 5 7 Power supply
motor BKWH#
HUN 8 11 U phase power supply(-) Signal Turn signal TIM 5 8
HN4 7 11 GND Signal
Directional switch 25W TSL lamp TNM 5 17
WHBK#
GND
HVM 8 4 Hydraulic motor V phase RD RPA 3 8 Power supply
Board AP 2 5 Power supply 25W
V2 IGBT BUYE#
HV0 8 12 V phase gate output 0 Open when in neutral
Tail & stop RNA 3 18 GND
HV1 8 5 V phase gate output1 DS3 WHBK RA3 3 9 A phase signal
IGBT module OG# ADN 2 13 Neutral lamp
W2 V HV2 8 13 V phase gate output2 TL RB3 3 19 B phase signal
Phase HVP 8 6 V phase power supply(+) DS1 GNWH
ADF 2 6 Forward 10W HP1 4 1 Power supply
HVN 8 14 V phase power supply(-) HD1 4 2
DS2 BUYE Signal
ADB 2 14 Backward 10W Back lamp HN1 4 9 GND
WHBK#
HWM 8 7 Hydraulic motor W phase BL HP2 4 3 Power supply
Board HW0 8 15 W phase gate output 0
BUYE# BUWH HD2 4 10 Signal
IGBT HW1 8 8 W phase gate output1 HS1 4 4 Lift 1 switch HN2 4 11
IGBT module OG# GND
W HW2 8 16 W phase gate output2 WHBU
Phase HWP 7 1 W phase power supply(+) HS2 4 12 Lift 2 switch Rear combination lamp(Left) TI1 3 10 Auxiliary input 1
HWN 7 7 W phase power supply(-) TI2 3 20 Auxiliary input 2
BNWH TI3 1 6
HS3 4 5 Tilt switch Turn signal Auxiliary input 3
BNRD
F3 YEBU 25W TSL lamp
5 10 EPS fuse HS4 4 13 Attachment switch 1
EPS motor AP 2 4 Power supply
GNWH 25W AN 2 12
HS5 4 6 Attachment switch 2 Tail & stop GND
GN YE AC0 2 7 Accelerator 0
F3
PA BN
HS6 4 14 Attachment switch 3 TL
lamp
AC1 2 15 Accelerator 1
40A 10W AC2 2 8 Accelerator 2
RD BU AC3 2 16
BKWH
NB 5 20 Control GND HS7 4 7 Auxiliary input Accelerator 3
Back lamp
WH EPS MC
WHBU
MC1 5 6 Main contactor HS8 4 15 Auxiliary input
10W
BL
GNWH
TS BU controller BNWH
MC2 5 16 BK
WHBU
HSN 4 16 Switch GND
* Standard for ECC
EPS sensor SC1 1 5 Auxiliary contactor
RD
RDWH
BUWH
WHBU
BKYE
RDYE
YEBU 40W Right

SC2 1 11 SS 1 8 Seat switch HL
GNBK WHGN
RDWH
VB 1 12 Control power supply
TI 1 1 Travel inhibitor Head lamp PB101-23
BURD Left
RDGN
HP 3 3 Power supply
SG 1 2 Turning speed reduction
40W
HL Line Connector
BK BK No. CN
HN 3 13 GND HSN 4 8
Pin No.
WHGN
TXA 3 1 Traction DSP Switch GND
BUYE Data line
WHRD
RXA 3 11 Traction DSP
YERD
TXB 3 2 Hydraulic DSP Lamp switch
RXB 3 12 Hydraulic DSP 25W TSL Right RDYE
WL1 1 4 Turn signal lamp(right)
PB101-23 Forward turn signal lamp
Line Connector 25W TSL Left BUYE
WL2 1 12 Turn signal lamp(left)
No. CN Pin No.
*Only for trucks with laser pointers.
PB101-23
YERD
Line Connector IO1 2 18 Tilt level
RXB 2 3 DSP Hydraulic
WHRD
WHRD
BUYE
TXB 2 13 DSP Hydraulic No. CN Pin No.
RXA 2 2 DSP Traction Data line Mode select switch RD Level lamp
WHGN
BK
TXA 2 12 DSP Traction (Traction/Hydraulic) Laser pointer (OPT.)
RDGN
HNA 2 11 GND GNWH switch
HPA 2 1 Power supply BS5 4 2 Low speed mode switch
RDYE
HPC 2 5 Laser
Power supply (turtle switch)
Charger panel BKYE
HNC 2 15 GND Data line BK
BS1 4 6
WHBU Up Tilt level sensor
*Only for trucks TXC 2 14 DSP EPS (EPS) +
BUWH
with built-in chargers. RXC 2 4 DSP EPS RD
BKWH - Flat cable BS2 4 5 Down
YERD
Charger, YEBK
6P YE
SW4 1 14 Reserve charge start BS3 4 4 Mode select DC/DC
controller BNBK
CHG 2 20
M
Reserve charge GY converter
BS4 4 3 Reserved setting
RD R
VB 1 10 Battery voltage
GN
VN 4 1 Switch GND
Turn signal lamp switch
(*Momentary)
YERD Right WHRD
X2 X1 RLP 1 3 Power supply relay SW2 1 13 Turn signal lamp switch(right)
BNYE WH WHBU
RLN 1 11 HV 5 1 Back light power supply
Key switch BK Left
SW3 1 6 Turn signal lamp switch(left)
F5 RDGN GND 5 2 Back light GND
10A KSW 1 1 Control power supply
RD BKWH 22P
VN 1 9 Control GND BNBK
X2 X1 SW5 1 7 Brake oil level
BN WHBK
F4 KST 2 19
10A YEBU
Key switch start Display SW6 1 15 Hydraulic oil level
RY 1 2 Charging interlock Flat cable 3 BNBK
SW7 1 8 Overload
BUBK
12P BUBK
CHS 2 10 Hour meter counting SW8 1 16 Parking brake switch
BKWH*
*Refer to note 3
RDWH
RDBK
HPD 2 6 Power supply

HND 2 16 GND Data line(Auxiliary)
TXD 2 17 GNBK
Display BWL 2 9 Battery electrolyte level
RXD 2 7 Display Body earth
1 2 3
<Note>
P5O 2 8 5V output
1.Lead wires marked with # or * have different diameters. Reference:
2.Broken lines indicate the use of optional equipment. Harness mark/color
IO1 2 18 Auxiliary input Red RD
3.Connect, and begin the hour meter countdown. Black BK
Green GN
Yellow YE
White
Brown
Blue
WH
BN
BU White line
FB-75 System wiring 4- 1.
Gray GY
Pink PK
Orange OG
Ex) BKWH (=Black/White) Black color

FB10P-28P-75 4-1-1.
Black colored harness with White line. 54000-21401-0e
70
4 Wiring and main controller layout
Battery(72V) PB100-90 PB100-90 1 2 3 PB100-90

V N Line Connector Line Connector Line Connector
No. CN PinNo. No. CN PinNo. No. CN PinNo.
BKWH*
RDWH
48V
RDBK
NA 125V 0.022 F
VA BUBK RD
GNRD C1 5 18 Main contactor contact BKRD RPA 3 4 Power supply M STP 1 3
F1 F1 5 9 Traction motor Fan output 1
+ Travel fuse BUWH RNA 3 14 GND Blower
F2 5 19 Hydraulic fuse speed sensor WH RA1 3 5 A phase signal M DWN 1 4 Fan output 2
MC 325A 80V,5600 F(x9) MIB RB1 3 15 B phase signal
WHBK# X7 + 100V
TUM 6 1 Traction motor U phase RDGN# 22 F
Board BNWH# YERD# TPU 5 2 Power supply WHBK
TU0 6 9 U phase gate output 0
TIU
IGBT
BUYE#
TU1 6 2 U phase gate output1 TIU BKYE# TIU 5 3 Signal H
Traction IGBT module YEBU# Travel TNU 5 12 GND Horn
U RDWH# TU2 6 10 U phase gate output2 RDBK#
U1 motor Phase BKWH# TUP 6 3 U phase power supply(+) current sensor BU# TPV 5 4 Power supply
TUN 6 11 U phase power supply(-) TIV BKWH# TIV 5 13 Signal YERD
X7
TNV 5 14 GND
WH#
BN# TVM 6 4 Traction motor V phase
Board RDGN#
V1TIV IGBT BU# TV0 6 12 V phase gate output 0
YERD# HPU 7 2 Power supply Brake switch WHRD
TV1 6 5 V phase gate output1 HIU BS 1 7 Brake switch
IGBT module V YEBK#
TV2 6 13 V phase gate output2 Hydraulic BKYE# HIU 7 3 Signal
W1 RD# HNU 7 8 GND
Phase TVP 6 6 V phase power supply(+) RDBK# GNWH
BK#
TVN 6 14 V phase power supply(-) current sensor BU# HPV 7 4 Power supply
HIV BKWH# HIV 7 9 Signal
WHRD# HNV 7 10 GND BURD
TWM 6 7 Traction motor W phase X3 OF2 1 9 Forward output
Board BNRD# W phase gate output 0
BURD# TW0 6 15 RDYE
IGBT TW1 6 8 W phase gate output1 AP1 2 1 Power supply
YERD# WH Signal
IGBT module W TW2 6 16 W phase gate output2 AD1 2 2 YEBK
Phase
RDYE#
TWP 5 1 W phase power supply(+) Accelerator AN1 2 11 GND X4 OB2 1 10 Backward output
BKRD# W phase power supply(-) AP2 2 3 Power supply
TWN 5 11 potentiometer BU
AD2 2 10 Signal
BKYE BN
AN2 2 9 GND BZ
WHBK# X4
HUM 8 1 Hydraulic motor U phase RPA 3 6 Power supply
Board BNWH#
HU0 8 9 IGBT BNYE
HD3 5 5 Signal BN
Back buzzer RNA 3 16 GND
BUYE# U phase gate output 0 T-IGBT BKYE
IGBT HU1 8 2 U phase gate output1 temperature sensor HN3 5 15 GND RA2 3 7 A phase signal
Hydraulic IGBT module U YEBU#
HU2 8 10 U phase gate output2
Rear combination lamp(Right) RB2 3 17 B phase signal
RDWH#
U2 motor Phase BKWH# HUP 8 3 U phase power supply(+) HD4 7 5 Signal TPM 5 7 Power supply
HUN 8 11 U phase power supply(-) GND Turn signal
HN4 7 11 lamp TIM 5 8 Signal
Directional switch 25W
TSL TNM 5 17 GND
WH# RD
BN# HVM 8 4 Hydraulic motor V phase AP 2 5 25W RPA 3 8 Power supply
Board Power supply
V2 BU# HV0 8 12 V phase gate output 0 Open when in neutral Tail & stop RNA 3 18 GND
IGBT HV1 8 5 V phase gate output1 DS3 WHBK lamp RA3 3 9 A phase signal
IGBT module YEBK# ADN 2 13 Neutral
W2 V RD# HV2 8 13 V phase gate output2 TL RB3 3 19 B phase signal
Phase HVP 8 6 V phase power supply(+) DS1 GNWH HP1 4 1 Power supply
BK# ADF 2 6 Forward 10W
HVN 8 14 V phase power supply(-) HD1 4 2 Signal
DS2 BUYE Back lamp HN1 4 9 GND
ADB 2 14 Backward 10W
WHRD# BL
Board BNRD# HWM 8 7 Hydraulic motor W phase HP2 4 3 Power supply
BURD# HW0 8 15 W phase gate output 0 BUWH
HS1 4 4 Lift 1 switch
HD2 4 10 Signal
IGBT module
IGBT YERD# HW1 8 8 W phase gate output1 HN2 4 11 GND
W RDYE# HW2 8 16 W phase gate output2 WHBU
HS2 4 12 Lift 2 switch Rear combination lamp(Left) TI1 3 10 Auxiliary input 1
Phase BKRD# HWP 7 1 W phase power supply(+) TI2 3 20 Auxiliary input 2
HWN 7 7 W phase power supply(-) BNWH
HS3 4 5 Tilt switch Turn signal TI3 1 6 Auxiliary input 3
BNRD 25W lamp
F3 5 10 EPS fuse YEBU TSL
HS4 4 13 Attachment switch 1
EPS motor AP 2 4 Power supply
GNWH 25W GND
HS5 4 6 Attachment switch 2 Tail & stop AN 2 12
GN YE lamp AC0 2 7 Accelerator 0
F3
PA BN
HS6 4 14 Attachment switch 3 TL AC1 2 15 Accelerator 1
40A AC2 2 8 Accelerator 2
RD BU BKWH 10W Accelerator 3
HS7 4 7 Auxiliary input AC3 2 16
NB 5 20 Control GND
Back lamp
WH EPS MC
WHBU
MC1 5 6 Main contactor HS8 4 15 Auxiliary input
10W
BL
GNWH controller
TS BU
BNWH
MC2 5 16 BK
WHBU
HSN 4 16 Switch GND
* Standard for ECC
EPS sensor SC1 1 5 Auxiliary contactor
RD
RDWH
BUWH
WHBU
BKYE
RDYE
YEBU 40W Right

SC2 1 11 SS 1 8 Seat switch HL
GNBK Travel inhibitor WHGN
RDWH
VB 1 12 Control power supply
TI 1 1 Head lamp PB101-23
BURD 40W Left
RDGN
HP 3 3 Power supply
SG 1 2 Turning speed reduction HL Line Connector
BK No. CN
HN 3 13 GND BK Switch GND Pin No.
WHGN HSN 4 8
BUYE TXA 3 1 Traction DSP Data line
WHRD RXA 3 11 Traction DSP
TXB 3 2 Hydraulic DSP Lamp
YERD
RXB 3 12 Hydraulic DSP switch 25W Right RDYE
TSL WL1 1 4 Turn signal lamp(right)
PB101-23 Forward turn signal lamp
25W Left BUYE
Line Connector TSL WL2 1 12 Turn signal lamp(left)
No. CN Pin No.
*Only for trucks with laser pointers.
PB101-23
WHRD
YERD Line Connector IO1 2 18 Tilt level
WHRD RXB 2 3 DSP Hydraulic
BUYE TXB 2 13 DSP Hydraulic No. CN Pin No.
RXA 2 2 DSP Traction Data line Mode select switch RD Level lamp
WHGN Laser pointer (OPT.)
BK TXA 2 12 DSP Traction (Traction/Hydraulic)
RDGN HNA 2 11 GND GNWH switch
HPA 2 1 Power supply SW1 1 5 Low speed mode switch
RDYE Laser
HPC 2 5 Power supply (turtle switch)
Charger panel BKYE
HNC 2 15 GND Data line BK
WHBU BS1 4 1 Up Tilt level sensor
*Only for trucks TXC 2 14 DSP EPS (EPS) +
with built-in chargers. BUWH
RXC 2 4 DSP EPS RD
BKWH BS2 4 2 Down
- YERD
RDYE Charger, YEBK YE
SW4 1 14 Reserve charge start BS3 4 3 Mode select DC/DC
controller BNBK M
BK
CHG 2 20 Reserve charge GY converter

RD BS4 4 4 Reserved setting
VB 1 10 Battery voltage R
GN
VN 4 5 Switch GND
Turn signal lamp switch
(*Momentary)
YERD Right WHRD
X2 X1 RLP 1 3 Power supply relay SW2 1 13 Turn signal lamp switch(right)
BNYE WH
RLN 1 11 HV 5 1 Back light power supply WHBU
Key switch BK Left SW3 1 6 Turn signal lamp switch(left)
F5 RDGN GND 5 2 Back light GND
10A KSW 1 1 Control power supply
RD BKWH 22P
VN 1 9 Control GND BNBK
X2 SW5 1 7 Brake oil level
X1 BN
F4
10A YEBU
KST 2 19 Key switch start Display WHBK
SW6 1 15 Hydraulic oil level
RY 1 2 Charging interlock Flat cable BNBK
3 SW7 1 8 Overload
BUBK
22P BUBK
CHS 2 10 Hour meter counting SW8 1 16 Parking brake switch
BKWH*
*Refer to note 3
RDBK
RDWH
HPD 2 6 Power supply

HND 2 16 GND Data line(Auxiliary)
TXD 2 17 Display GNBK Battery electrolyte level
BWL 2 9
RXD 2 7 Display Body earth
1 2 3
Reference:
<Note> Harness mark/color
P5O 2 8 5V output 1.Lead wires marked with # or * have different diameters. Red RD
IO1 2 18 Auxiliary input 2.Broken lines indicate the use of optional equipment. Black BK
3.Connect, and begin the hour meter countdown. Green GN
Yellow YE
White WH
Brown BN
Blue BU White line
Gray GY
Pink PK
Orange OG

FB-75 System wiring 4- 1.
Black colored harness with White line.
FB30P-75 4-1-2.
54000-26880-0e
71
Laser pointer Head guard(right) Control unit

*Only for trucks with laser pointers
RD Blower
P mast Hanging on mast BK HL
(*Refer to note 6)
Harness, mast(1)
4P 2P
resistant
resistant
WH WH
Water
Water
WH
Harness, head guard
2P
2P
GN TSL
Laser
2P
resistant
(*Refer to note 6) WH <5>
Water
Level U1
2P
M mast
Harness, mast(1) Hanging on mast sensor <8>
RDBK
U2
Water RDWH
2P Accessory CN5 CN8 <6>
resistant
resistant BKWH
Hydraulic motor V1
Water
Harness, mast(2) BUYE (front) Board Comp.,
resistant
CN6 CN7
BNYE MPU
Water
Control valve <9>

2P
2P
Laser V2
Only for when using optional equipment. EPS
controller <7>
Att.2 RDBK 1
Horn switch U2 V2 W2 W1
YERD Harness, M(4)
1
(valve lever) <8> <9> <10>
Reference: <10>
Harness mark/color
Att.1
CN1 CN2 CN3 CN4
W2
Red RD
resistant
Harness, M(3)
Water
Black BK Tilt
Green GN
Yellow YE Acceleration 6P
4P
White WH
Lift 1 Harness, M(4) BK
+
2P-X 2P-Y
Brown BN sensor 10P
-
6P
Blue BU Lift 2 BK Harness, M(1) Water
Gray GY resistant <3> <2>
Pink PK <12>
resistant
Traction motor
Water
Orange OG
BU
Ex) BKWH (=Black/White) <1>
+
4P
BUBK
Black colored harness with White line. Connect, and begin the BKWH
hour meter countdown. Bearing sensor Rear combination lamp Rear combination lamp
<2> 4P
(left) (right) RD Control power supply relay
-
Laser pointer switch U1 <5>
*Only for trucks with laser pointers Battery TSL TSL
V1 <6> plug Battery 4P
WH Backward output relay
White line 2P
BK W1 <7> (48V) TL TL
4P
BK Horn relay
BL BL
resistant
Black color Harness, M(3)
Water
Lamp switch 4P
resistant
Water
WH
resistant
6P
6P
Water
Indicator panel Brake oil level BNBK
EPS *Only for EEC or when using
3P
1
BKWH optional equipment.

sensor 1
sensor YEBU YEBU
BKWH BK Seat
Mode select RDWH switch
CN4 CN2
switch BUYE
Board, Harness, body BNYE
CN1
display
Accessory
CN5 BN GN Contactor Ass’y (rear)
Foot brake switch 1
Display Back buzzer 1

BKWH YE EPS motor
CN3 Main
contactor Harness, body
<1> RDGN
6P WHBK 10A
RD RDYE
Horn BKWH 10A
RDBK
"K" BUBK
Transformer <Note>
resistant
Water
*Only for trucks with built-in chargers. 1.<n> indicates the lead wire numbers.
3P
Key switch Parking brake switch 2P 2.Terminal symbols

Harness, charger(2) WH :Plug
1
AMP 170020-3 or
AMP 170002-5
Charger panel <13>
:Plug AMP 170020-2
325A
160A
40A
*Only for trucks with built-in chargers. 4P DC/DC <11>
1
:Receptacle AMP 170021-3 or
converter AMP 170003-5
resistant
BK Transformer
Water
Directional switch :Receptacle AMP 170021-1

primary <3>
4P
*Only for trucks with :Receptacle AMP 41729

6P side <11> RD 3.When installing the charger panel on the truck body, use only bolts
Charger,
BK laser pointers(note5)
Transformer + BNRD
GNRD
and spring washers.
resistant
controller secondary The reasons why only spring washers should be used is that they
Rectifier
Water
break the coating on the charger panel, enduring conductance

side
3P
Turn signal lamp switch 2P <12>

WH
- between the frame and the charger panel.
4."K" and "W" indicate the printed marks on the connector.
"W"
Harness, charger(1) 5.The DC/DC converter for laser pointer should be attached
Magnetic <13> to an appropriate position on the front hood.
contactor 6.Connector for blower should be placed in a circle, as shown the
Horn switch RDBK
Head guard(left)
1
YERD figure below.

(handle post) 1
Blower
RD
BK HL
4P
Harness, short circuit WH WH Clamp
*Only when a charger is not mounted.

Harness, head guard GN TSL
6P
BK
FB-75 Body wiring 4- 2.
FB10P-28P-75 4-2-1.
54000-26891-0e
72
Laser pointer Head guard(right) Control unit

*Only for trucks with laser pointers
RD Blower
P mast BK HL
(*Refer to note 6)
Harness, mast(1) Hanging on mast
4P 2P
resistant
resistant
WH WH
Water
Water
WH
Harness, head guard
2P
2P
GN TSL
Laser
2P
resistant
(*Refer to note 6)
<5>
Water
WH
Level U1
2P
M mast
Harness, mast(1) Hanging on mast sensor <8>
RDBK
U2
Water RDWH
2P Accessory CN5 CN8 <6>
resistant
resistant BKWH
Hydraulic motor V1
Water
Harness, mast(2) BUYE (front) Board Comp.,
CN6 CN7
resistant
BNYE MPU
Water
Control valve <9>

2P
2P
Laser V2
Only for when using optional equipment. EPS
controller <7>
Att.2 RDBK 1
Horn switch U2 V2 W2 W1
YERD Harness, M(4)
1
(valve lever) <8> <9> <10>
<10>
Reference: Att.1
CN1 CN2 CN3 CN4
W2
Harness mark/color
resistant
Harness, M(3)
Water
Red RD Tilt
Black BK
Green GN
Acceleration 6P
4P
Yellow YE Lift 1 Harness, M(4) BK
sensor
+
White WH 2P-X 2P-Y
10P
-
6P Harness, M(1)
Brown BN Lift 2 BK Water
Blue BU resistant <3> <2>
Gray GY <12>
resistant
Traction motor
Water
Pink PK
Orange OG
BU
<1>
4P
BUBK
Ex) BKWH (=Black/White)
Connect, and begin the BKWH
+ (72V)
Black colored harness with White line. hour meter countdown. Bearing sensor
<0> Rear combination lamp Rear combination lamp 4P
+ (48V) (left) (right) RD Control power supply relay
Laser pointer switch U1 <5>
<2>
-
*Only for trucks with laser pointers TSL TSL
V1 <6> Battery Battery 4P
WH Backward output relay
White line
2P
BK W1 <7> plug (72V) TL TL
4P
BK Horn relay
BL BL
resistant
Harness, M(3)
Water
4P
resistant
Black color Lamp switch
Water
WH
resistant
6P
6P
Water
Indicator panel Brake oil level BNBK
EPS *Only for EEC or when using
3P
1
BKWH optional equipment.

sensor
1
sensor YEBU YEBU
BKWH BK Seat
Mode select RDWH switch
CN4 CN2
switch BUYE
Booard, Harness, body <0> BNYE
CN1
display
Accessory
CN5 BN GN Contactor Ass’y (rear)
10A
10A
Foot brake switch 1
Display Back buzzer 1

BKWH YE EPS motor
RDBK
RDYE
RDGN
CN3 Main
contactor Harness, body
<1>
6P WHBK
RD
Horn BKWH
"K" BUBK
Transformer
resistant
Water
*Only for trucks with built-in chargers.

3P
Key switch Parking brake switch 2P

<Note>
Harness, charger(2) WH 1.<n> indicates the lead wire numbers.
<13> 2.Terminal symbols
Charger panel :Plug
1
AMP 170020-3 or
325A
160A
40A
*Only for trucks with built-in chargers. 4P DC/DC <11> AMP 170002-5
converter Transformer :Plug AMP 170020-2
resistant
BK
Water
1
Directional switch primary <3> AMP 170003-5
4P
*Only for trucks with

6P side <11> RD :Receptacle AMP 170021-1
Charger,
BK laser pointers(note5)
Transformer + BNRD
GNRD
:Receptacle AMP 41729
3.When installing the charger panel on the truck body, use only bolts
resistant
controller secondary Rectifier

Water
and spring washers.

side
3P
2P <12> The reasons why only spring washers should be used is that they
Turn signal lamp switch WH
- break the coating on the charger panel, enduring conductance
between the frame and the charger panel.
"W"
Magnetic <13> Harness, charger(1) 4."K" and "W" indicate the printed marks on the connector.
contactor 5. The DC/DC converter for laser pointer should be attached
RDBK
Horn switch to an appropriate position on the front hood.
Head guard(left)
1
YERD
(handle post) 1
6.Connector for blower should be placed in a circle, as shown the
figure below.
RD
BK HL Blower
4P
WH WH
Harness, short circuit
*Only when a charger is not mounted.
Harness, head guard GN TSL
Clamp
6P
BK
FB-75 Body wiring 4- 2.

FB30P-75 4-2-2.
54000-26901-0e
73
Control unit
Hydraulic lever potentiometer
CN12
CN11
CN5 CN8
CN6 Board Comp., MPU CN7
EPS
controller
54000-26910-0e
8P Water 10P Water
CN1 CN2 CN3 CN4
resistant resistant
2
Proportional control valve
8P
Water Harness, body

SOL SOL SOL SOL resistant
Tilt
Lift
Attachment 2
Attachment 1
FB-75 Body wiring

SOL SOL SOL SOL 1 <Note>
Fingertip specification
1. The valve microswitch section of the "harness, body" on the
8P standard truck should not be connected, because this part
has been eliminated.
*Attachments 1 and 2
Water 2. This diagram only describes the site related to the fingertip.
are optional.
resistant
4- 2.
4-2-3.
74
Reference:
*Refer to note 6 RDWH RDWH Harness mark/color
To C To E2
RDWH RDWH Red RD
To D6 To E2 Black BK
RDBK
WHGN
WHBU
WHRD
RD
Green GN
Point"a"
Yellow YE
White WH
BKWH
WHBU
WHRD
1 1 1 1 1
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
GNWH
BUYE
RD
WHBK
RD
RDGN
BN
1 2 3 4 1 2 Brown BN
S1,W1 E1,E2 X,K1
BKWH*
BKWH*
Blue BU
RD
RD
To E1
To E2
To X
To W4
65F 69B 49B
2 2 2 2 2 2 2 2 2 2 Gray GY
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
RDGN
1 1
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
V S1 S2 X A A Point"c" X
Pink PK
76B 77B
65G 67C 32G 41B 13B 11B 34B 50B
Orange OG
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20 X A A D2 Plug 4P Plug 2P
D2 O D2 N2 S2 W2 A A A C C R W4 Horn switch 39B 14B 12B 31C WH BK Ex) BKWH (=Black/White)
W1(post)
RD
RD
To O
To C
To D4
To D1
BKWH*
BKWH*
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A
D4 Point"c"D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1 2 1
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 2
Point"c" Point"d"
CN1 CN2 3 2 1
W 2 1 3 2 1
K Lamp switch Laser pointer
4 3
Point "c"
V Operation switch Pressed sleeve detailed drawing
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 Turn signal switch W4 Key switch White line
(*Refer to note 5) (*Refer to note 5)
Valve
W3 Directional switch T microswitch
X Display board Horn switch 65E U,V 1
RDBK Black color
Plug 4P
S1(Lever) 67B D1,W1 1
YERD
BUWH
WHBU
BNWH
1
1
1
2
A 25B
A 28B
Plug 6P
BK
RDWH 1 3 A 26B
WH 6J N1,N2 1 1 YEBU
2 1 BKWH* 1 4 A 29B
52B N1,Q GNWH
Q Converter 1 2 52C Q,M
75B K1 3 1
4 1
YERD
BKWH*
R Accessory
48B X
BUBK
BKWH 40B X 1
BNBK
BK
1
1
5
6
A 27B
A 30B
1 2 3
3 4
Put the sleeve
32E O,S2
S2 Brake oil 32F R,W2 1
BKWH
4 5 6
for sure receptacle.
<Note>
RD 2 1 V 77C
Water resistant
K3 Level lamp 1.Terminal symbols
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
BKWH* 2 Plug 2P
2
N1 52N : Receptacle
WHBK Water resistant (with plating) AMP 170021-2
M 68B D1 +
*Refer to note 7
Horn
RDYE
RDGN
RD
YEBU
Plug 2P
BKWH
RDWH
WHRD
BUBK
GNWH
BKWH
2 1 : Receptacle
K2Laser
1 1 1 1 1 1 1 1
BNBK
YEBK
BKWH* 1
1 2 3 4
L EPS sensor
52D O,I
Capacitor RD 2 1 V 77A
1 2 3 4
(without plating) AMP 170003-5 or
RDBK
RDWH
BKWH*
BUYE
BNYE
V Q,K3 100V 22 BKWH* 2 V U,K2
2
N2 52J AMP 170021-3
76A 52A 2 1 76C 52I
1 1 1 1 1 1 1 1 1 1 1 1 Sleeve(for single wire) AMP 170889-1
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant Level 6K 37B
Sleeve(for double wire) AMP 170890-1
Plug 4P
74B 34C 33B
F P,R
51B
X
6H 43B
A E1,E2 D4,O
56B C
54B C
1
55B C 2
3
2
2
2
BU
GNWH
WH
YERD
WHRD
2
2
1
2
Q 75A
N2 49C
Plug 2P
K1 sensor F,S1
65D 52H
D2,N2
72B
E2
Plug 4P
: Plug
(with plating) AMP 170020-2
WH 73B 32D 42B 3B 70B 32C 3 2 1 N2,E2 E2 WH 1 : Plug
2 1 (without plating) AMP 170002-5 or
6L 71B
AMP 170020-3
1 2
3 4
Plug 6P
BK
Plug 2P
WH
Plug 6P
RD
Water resistant
U Accessory 1 2
3 4 Sleeve(for double wire) AMP 170888-1
: Receptacle(with sleeve)AMP 41729
Head guard 1P 57B C 4
YE BU Plug 4P Head guard Sleeve(for single wire) AMP 170823-2
N1(left)
1 2 3
4 5 6
1
2
1 2 3
4 5 6 J EPS motor
Yazaki
7123-4113-30
GN
RDYE
BKYE
WH
2
2
2
1
2
3
A 7B
A 10B
A 9B
2 1
H Accelerator sensor N2 (right)
1
Sleeve(for double wire) AMP 1-170823-5
: Receptacle AMP 173716-2 or
2 4 A 8B
1P 58B C 5 4 3
AMP 175061-2
Yazaki
O Charger panel P Brake switch 7122-4113-30 1 : Receptacle AMP 170032-5 or
AMP 179461-5
Capacitor 1 : Tab AMP 170340-3 or
BN 125V 0.022 Water resistant AMP 179462-3
I 66C D3,E2 1
RD Plug 4P
Back buzzer
G Speed sensor
BKWH* 2 1 A 21B 2 : Receptacle AMP 171662-1 or
52E M,D4 1 BKRD 3
2 A 22B AMP 173707-1
10A
BK RDGN BUWH
WH
2 2 A 23B
AMP 174257-2 (Travel)
73A O 2 4 A 24B AMP 172888-2(rubber plug)
2 1
(*Refer to note 9) AMP 172748-2(seal plug)
BK RDBK
8 10A 4 3 3 : Receptacle AMP 316041-2 or
65C D1,U
74A O AMP 179956-2
RDYE
YEBU
4 : Receptacle Yazaki 7116-3251
A 4B
61B D4 8
BUBK RDWH U,Point"a" 6M
5 : Tab Yazaki 7114-3251
BKWH* Point"d" 52L : Pressed sleeve JST FNC-2
WHBU
Plug 60B D4 1 1 BUYE ,E2
Stop & tail lamp
1
2
2P
WH
62B D4 2 1 BNWH BNYE
U 71A
U 72A E2 (right)
2. : :Braided wires under 25mm pitch.
3.The location of connector pin is as viewed from the inserting side.
4.The relay should not be clamped to the harness.
RD Water resistant WHBU WHBU Water resistant 5.Write or impress the letters with undamped ink.
59B C 8 Plug 6P 69A V 1 2 2 1 V 69C Plug 6P
F Contactor fuse 64B D4 8
BNRD
Stop & tail lamp
6G P
52K
Point
"d"
2
3
2
2
BKWH*
RDWH
GNWH
BKWH*
RDWH
GNWH
2
2
2
3 Point
4 "a"
6N
E2 52M 6.Fuses should be placed in a circle, as shown in the figure 1.
7.The end of the spiral tube should be tied together with wire ties,
E1 70A P 4 2 2 P 70C
BN BN and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
(left) 3 2 1
6 5 4
66AD3 5 2
BUYE RDYE
2 5 I 66D 3 2 1
6 5 4
38C N1 6 2 2 6 N2 37C WHBU 1 F 60A 8.The end of the vinyl tube should be tied together with wire ties.
Point"a" BUBK
1
1 2 F 61A Plug 9.The capacitor should be soldered to the speed sensor section, as shown in
Point"d"
BKWH
BNWH
BKWH
1
1
1
3
4
5
F 62A
X,P 32B
Point 52F
6P
WH
1 2 3
4 5 6
D4 Controller Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
with siliconadhesive.
D6 Fan 1
Plug
2P 2B A
6E D5,Point"a" 11
2 1
RDWH
GNWH 53A C 8
BU BNRD 1 6 F 64A
"d"
Backward output Fuse
2 WH
B
Power supply
termianl
RDBK
RDWH
BN
1
1
1
1
2
3
D2,D5 6C
D1 65A
E1,I 66B
Plug
4P
WH
1 2 D3 relay
Ca1a-DC48V-N
10A
10A
YEBK 1 4 A 5B 3 4 *Connect the relay.
RDGN 1 1 X,W4 31B Control power supply
YERD 1 2 X 35B
Plug
D2 relay Tie wrap
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
WHBU
YEBU
BK
RDWH 3 4P 1 2
1 A,D3 6B Clamp
BNYE 4 RD
1 X 36B 3 4 Ca1a-DC48V-N Figure 1 Figure 2
RDBK *Connect the relay.
WH
GNWH
BU
RDYE
WH
BKYE
BU
1 1 D3,F 65B
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
RDYE
BKYE
WHBU
BUWH
YERD Capacitor
1 2
Seal plug
S1 67A
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
BKWH*
WHBK
1 4
1 3
Point"d",U 52G
Plug
4P
BK
1 2
3 4
D1 Horn relay
Ca1a-DC48V-N
Vinyl tube
(Non polarized)
Fill the inside of the vinyl

Vinyl tube
M 68A
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 *Connect the relay. tube with silicon adhesive.
X X Point"a" L J F D5 P H H W3 W3 X X X G G T T T Be careful of the arrangement
of terminals.
46B 45B 6F 55A 57A 59A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 25A 27A 29A
RDWH Plug
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G T T T 1 1 D3,D6 6D 2P 1 Tie wrap With solder Tie wrap
BUWH
47B 44B 34D 54A 56A
Water resistant
58A
2P-X 2P-Y
53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 26A 28A 30A 1 2 A 1B WH 2
D5 Fan Figure 3
Plug 10P Receptacle Receptacle CN1 CN2 CN3 CN4

1 2 3 4
5 4 3 2 1
10 9 8 7 6
6 5 4 3 2 1
12 11 10 9 8 7
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 FB-75 Body harness 4- 3.
Write or impress the numbers
C EPS unit A MPU borad with undamped ink.
FB10P-18P-75
(Std/CS/FCS/RP/DRP) 4-3-1.
54000-19154-1e
75
*Refer to note 6
<Note>
BKWH*
BKWH*
To E1
To E2
To X
To W4
1.Terminal symbols
RD
RD
RDWH RDWH
:Receptacle
RDBK
WHGN
WHBU
WHRD
RD
To C To E2
RDWH RDWH (with plating) AMP 170021-2
To D6 To E2 1 :Receptacle
1 1 1 1 1 (without plating) AMP 170003-5 or
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
BKWH
WHBU
WHRD
GNWH
BUYE
RD
WHBK
RD
RDGN
BN
1 2 3 4 1 2 Point"a"
AMP 170021-3
S1,W1 E1,E2 X,K1
To O
To C
To D4
To D1
Sleeve(for single wire) AMP 170889-1
RD
RD
BKWH*
BKWH*
65F 69B 49B
BK
BUYE
2 2 2 2 2 2 2 2 2 2 Sleeve(for double wire) AMP 170890-1
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
RDGN
1 1
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
:Plug
V S1 S2 X A A Point"c" X 76B 77B
Point"c" (with plating) AMP 170020-2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
65G 67C 32G 41B 13B 11B 34B 50B
Plug 4P Plug 2P
Point"d" 1 :Plug
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20 X A A D2
Horn switch WH BK (without plating) AMP 170002-5 or
D2 O D2 N2 S2 W2 A A A C C R W4 39B 14B 12B 31C
31A 33A 35A 37A 40A 41A
D4 Point"c" D2 N1 W2 O P
19B 16B 18B 44A 46A
A A A C C
48A 50A
V O
W1 (post) Water resistant Water resistant Water resistant 1 2 1
Pressed sleeve detailed drawing AMP 170020-3
3 4 :Receptacle(with sleeve) AMP 41729
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 2
Lamp switch Laser pointer Sleeve(for double wire) AMP 1-170823-5
CN1 CN2 W K :Receptacle AMP 173716-2 or
V Operation switch
1
3 2 1 2 1 3 2 1
4 3 AMP 175061-2
Point"c"
Fork leveling switch 1 :Receptacle AMP 170032-5 or
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 (*Refer
Turn signal switch
to note 5)
W4 Key switch
(*Refer to note 5)
BURD
BK 1
1 A 80B
T 30C S3 (lever) 1 :Tab
AMP 179461-5
AMP 170340-3 or
X Display board
W3 Directional switch Horn switch 65E U,V 1
RDBK 2 :Receptacle
AMP 179462-3
AMP 171662-1 or
Plug 4P
S1(lever) 67B D1,W1 1
YERD
BUWH
WHBU
1
1
1
2
A 25B
A 28B
Plug 6P
BK
Valve
AMP 173707-1
AMP 172888-2(rubber plug)
WH
52B N1,Q
6J N1,N2 1 1
2 1
RDWH
BKWH*
YERD BUBK
BNWH
YEBU
GNWH
1
1
3
4
A 26B
A 29B T microswitch 3 :Receptacle
AMP 172748-2(seal plug)
AMP 316041-2 or
Q Converter 75B K1 3 1
BKWH*
R Accessory
48B X
BNBK
BK
1
1
5
6
A 27B
A,S3 30B
1 2 3 AMP 179956-2
S2 Brake
52C Q,M 4 1
1 2 32E O,S2
BKWH 40B X 1
4 5 6 4 :Receptacle Yazaki 7116-3251
3 4 Put the sleeve oil 32F R,W2 1
BKWH
5 :Tab Yazaki 7114-3251
for sure receptacle. :Pressed sleeve JST FNC-2
Water resistant
K3 Level lamp 5.Write or impress the letters with undamped ink.
WHGN
BKWH*
RDWH
RDYE
WHGN
RDWH
BKWH*
BUYE
RD 1
2 V 77C Plug 2P 6.Fuses should be placed in a circle, as shown in the figure 1.
BKWH* 2
WHBK
2
N1 52N
7.The end of the spiral tube should be tied together with wire ties,
M 68B D1
+ Water resistant
*Refer to note 7
Horn Plug 2P and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
RDWH
WHRD
BUBK
GNWH
BKWH
K2
RDYE
RDGN
RD
BKWH
YEBU
1 1 1 1 1 1 1 1
BNBK
YEBK
BKWH* 2 1
1 2 3 4
L EPS sensor 52D O,I
Capacitor RD
BKWH*
2 1 V 77A Laser 1 2 3 4 8.The end of the vinyl tube should be tied together with wire ties.
RDBK
RDWH
BKWH*
BUYE
BNYE
V Q,K3 100V 22 2 V U,K2 9.The capacitor should be soldered to the speed sensor section, as shown in
2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2 with siliconadhesive.
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B
Plug 4P
74B 34C 33B
F P,R
51B
X
6H 43B
A E1,E2 D4,O
56B C
54B C
1
55B C 2
3
2
2
2
BU
GNWH
WH
YERD
WHRD
2
2
1
2
Q 75A
V 49C
Plug 2P
K1Level sensor F,S1
65D
D2,N2
52H
E2
72B Plug 4P
Fuse
10A
10A
WH 73B 32D 42B 3B 70B 32C 3 2 1 N2,A E2 WH
2 1
6L 71B
U Accessory
Water resistant
1 2 Plug 6P Plug 2P Plug 6P Plug 3P 1 2
GNRD RDBK
3 4 BK WH RD Electromagnetic 84B A
WHBU
2 1 A 81B 3 4 Tie wrap
Head guard Y valve

85B A GNRD
BKYE
2
2
2
3
A 82B
A 83B K3 Tilt detector Head guard Clamp
N1 (left) 1 2 3
4 5 6
1
2
1 2 3
4 5 6 Water resistant
3 2 1
N2 (right)
Figure 1
Capacitor
Figure 2
YE (Non polarized)
Plug 4P Vinyl tube
Charger Brake Yazaki 1P
57B C 4 BU 1 A 10B Vinyl tube
P switch
2
O panel
J EPS motor
7123-4113-30
1P 58B C 5
GN
RDYE
BKYE
WH
2
2
2
2
3
4
A 7B
A 8B
A 9B
2 1
4 3
H Accelerator sensor Fill the inside of the vinyl
tube with silicon adhesive.
Yazaki
7122-4113-30
Tie wrap With solder Tie wrap
Capacitor
125V 0.022 Water resistant Figure 3
BN RD Plug 4P
BK RDGN 2 1 A 21B Speed sensor
I Back buzzer 66C D3,E2 1
10A
73A O
52E M,D4
BKWH*
BKRD
BUWH
2
2
3
2 A 23B
A 22B
AMP 174257-2
G (Travel)
WHBU
BUBK
1
1
1
2 F 61A
F 60A
Plug
D4
1
WH 4 BKWH
BK RDBK 2 A 24B 3 X,P 32B 6P
8 10A
2 1
(*Refer to note 9) BNWH
1
4 WH
1 2 3 Controller
65C D1,U 1 F 62A
4 3 BKWH 1 5 Point 52F 4 5 6
74A O BNRD
RDYE 1 6 F 64A "d"
YEBU Backward output
Plug 60B D4
61B D4 8
BUBK
WHBU
RDWH
BKWH*
BUYE
A, A 4B
Point"a" 6M Point"d"
,E2 52L
RDBK
RDWH
BN
1
1
1
2
3
D2,D5 6C
D1 65A
E1,I 66B
Plug
4P
WH
1 2
D3 relay
Ca1a-DC48V-N
Reference:
1 1 1
U 71A Stop & tail lamp YEBK
1
3 4 Harness mark/color
2
2P
WH
U 72A
E2 (right) RDGN
1
1
4
1
A 5B
X,W4 31B
*Connect the relay.
Control power supply
Red
Black
RD
BK
59B C 8
RD Water resistant
Plug 6P 69A V 1 2
WHBU WHBU 2 1 V 69C
Water resistant
Plug 6P
YERD
RDWH
BNYE
1
1
2
3
4
X 35B
A,D3 6B
Plug
4P
RD
1 2 D2 relay Green
Yellow
GN
YE
F Contactor fuse BKWH* BKWH* 3 4 Ca1a-DC48V-N
1
52K Point 2 2 2 2 E2 52M X 36B
BNRD "d" RDWH RDWH 3 Point 6N *Connect the relay.
64B D4 8 6G P 3 2 2 RDBK White WH
Stop & tail lamp GNWH GNWH "a" 1 1 D3,F 65B
E1 70A P 4 2 2 4 P 70C YERD

BN BN 1 2 S1 67A Brown BN
(left) 3 2 1
6 5 4
66AD3
38C N1
5
6
2
2
BUYE
Point"a"
RDYE
2
2
5 I 66D
6 N2 37C
3 2 1
6 5 4
BKWH*
WHBK
1 4
Point"d"52G
,U
Plug
4P
BK
1 2
3 4
D1 Horn relay
Ca1a-DC48V-N
Blue
Gray
BU
GY
1 3 M 68A
*Connect the relay. Pink PK
Point"d" Be careful of the arrangement
of terminals.
Orange OG
RDWH Plug
D6 Fan Plug D5,

6E Point"a"
RDWH Power supply BU
BUWH
1 1
1 2
D3,D6 6D
A 1B 2P 1
2 D5 Fan
B WH
1 1
1 2P GNWH 53A C 8
2 WH
2B A 2 1
termianl
RDWH
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
BURD
WHBU
YEBU
BK
RDWH
White line
WH
GNWH
BU
GNRD
WHBU
RDYE
WH
BKYE
BU
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
RDBK
GNRD
BKYE
RDYE
BKYE
WHBU
BUWH
Seal plug
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16
X X Point"a" L J F D5 P H H W3 W3 X X X G G K3 K3 T T T Y Black color
46B 45B 6F 55A 57A 59A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 81A 83A 25A 27A 29A 84A
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G K3 T S3 T T Y E2,U
47B 44B 34D 54A 56A 58A 53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 82A 26A 80A 28A 30A 85A 6O
Water resistant 2P-X 2P-Y

Plug 10P Receptacle Receptacle CN1 CN2 CN3 CN4 CN11 CN12
1 2 3 4 11 12
5 4 3 2 1
10 9 8 7 6
6 5 4 3 2 1
12 11 10 9 8 7
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
FB-75 Body harness 4- 3.
C EPS unit A MPU board with undamped ink.
FB10P-18P-75
(Automated fork horizontal stop) 4-3-2.
54000-19182-0e
76
*Refer to note 6
RDWH RDWH Reference:
To C To E2
RDBK
WHGN
WHBU
RDWH RDWH Harness mark/color
WHRD
RD
To D6 To E2 Red RD
Black BK
Point"a"
RD
RDGN
BN
GNWH
Green GN
BKWH
WHBU
WHRD
BUYE
RD
WHBK
1 1 1 1 1
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
1 2 3 4 1 2
Yellow YE
S1,W1 E1,E2 X,K1
White WH
BKWH*
BKWH*
65F 69B 49B
2 2 2 2 2 2 2 2 2 2 Brown BN
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
RDGN
1 1
RD
RD
To E1
To E2
To X
To W4
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
V S1 S2 X A A Point"c" X
Blue BU
76B 77B
65G 67C 32G 41B 13B 11B 34B 50B
Gray GY
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
X A A D2 Pink PK
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20 Plug 4P Plug 2P
D2 O D2 N2 S2 W2 A A A C C R W4 Horn switch 39B 14B 12B 31C WH BK Orange OG
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A W1(post)
RD
RD
BKWH*
BKWH*
To O
To C
To D4
To D1
D4 Point"c" D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1 2 Ex) BKWH (=Black/White)
1
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 Black colored harness with White line.
2
CN1 CN2 3 2 1
W 2 1 3 2 1
K Laser switch Laser pointer Point"c" Point"d"
4 3
Point"c"
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 Turn signal switch W4(*Refer
Key switch
(*Refer to note 5) to note 5)
Valve White line
W3 Directional switch T microswitch
X Display board Horn switch 65E U,V
RDBK
S1(lever)
1
Plug 6P
BUWH 1
YERD 1 A 25B BK
Plug 4P 77A 67B D1,W1 1 WHBU 1 2 A 28B Black color
RDWH BNWH 3
6J N1,N2 1 1 1 A 26B
WH BKWH* YEBU 4
52B N1,Q 2 1 1 A 29B
YERD BUBK GNWH
75B K1 3 1
4 1 BKWH*
R Accessory
48B X
BKWH 40B X 1
BNBK
BK
1
1
5
6
A 27B
A 30B
1 2 3
3 4
Put the sleeve
32E O,S2
BKWH
4 5 6
Water resistant
<Note>
RD
K3 Level lamp
WHGN
BKWH*
RDWH
RDYE
1.Terminal symbols
WHGN
RDWH
BKWH*
BUYE
2 1 V 77C
BKWH* 2
Plug 2P
2
N1 52N :Receptacle
WHBK Water resistant (with plating) AMP 170021-2
M 68B D1
+
*Refer to note 7
Horn 2 1 :Receptacle
RDWH
WHRD
BUBK
GNWH
Plug 2P
K2
BKWH
RDYE
RDGN
RD
BKWH
YEBU
1 1 1 1 1 1 1 1 1
BNBK
YEBK
BKWH*
1 2 3 4
Capacitor RD 1 V 77A Laser 1 2 3 4 (without plating) AMP 170003-5 or
BKWH*
2
RDBK
RDWH
BUYE
BNYE
V Q,K3 100V 22 BKWH* 2 V U,K2 AMP 170021-3
2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Sleeve(for single wire) AMP 170889-1
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2 Sleeve(for double wire) AMP 170890-1
Plug 4P
74B 34C 33B
F P,R
51B
X
6H 43B
A E1,E2 D4,O
56B C 1
55B C 2
2
2
BU
GNWH
WH
YERD
WHRD
2
2
1
2
Q 75A
N2 49C
Plug 2P K1Level sensor F,S1
65D 52H
D2,N2
72B
E2
Plug 4P
:Plug
WH 3 2 1 54B C 3 2
N2,E2 E2 WH 1 :Plug
73B 32D 42B 3B 70B 32C
2 1
6L 71B
AMP 170020-3
1 2 1 2
3 4
Plug 6P
BK
Plug 2P
WH
Plug 6P
RD
Water resistant U Accessory 3 4
:Receptacle(with sleeve) AMP 41729
Head guard YE Plug 4P Head guard Sleeve(for single wire) AMP 170823-2
N1 (left) 1 2 3
4 5 6
1
2
1 2 3
4 5 6 J EPS motor
Yazaki
1P
7123-4113-30
57B C 4 BU
RDYE
BKYE
2
2
2
1
2
3
A 7B
A 10B
A 9B H Accelerator sensor N2 (right) 1

GN WH 4 A 8B
2 1
1P 58B C 5
2
4 3 AMP 175061-2
Yazaki
O Charger panel P Brake switch 7122-4113-30
1
1
:Receptacle
:Tab
AMP 170032-5 or
AMP 179461-5
AMP 170340-3 or
Capacitor
125V 0.022 Water resistant AMP 179462-3
BN

RD Plug 4P 2 :Receptacle AMP 171662-1 or
BKWH* 2 1 A 21B Speed sensor AMP 173707-1
10A
BK RDGN
73A O
52E M,D4 1 BKRD
BUWH
WH
2
2
2
3
2
4
A 23B
A 22B
A 24B
AMP 174257-2
G (Travel) AMP 172888-2(rubber plug)
2 1
(*Refer to note 9)
8 10A
BK RDBK
4 3
3 :Receptacle AMP 316041-2 or
65C D1,U AMP 179956-2
74A O 4 :Receptacle Yazaki 7116-3251
RDYE
YEBU
A 4B
5 :Tab Yazaki 7114-3251
BUBK RDWH U,
61B D4 8 Point"a"
6M :Pressed sleeve JST FNC-2
BKWH* Point"d" 52L
Plug 60B D4 WHBU BUYE ,E2 2. : :Braided wires under 25mm pitch.
1 1 1
U 71A Stop & tail lamp
2
2P
WH
U 72A
E2 (right) 3.The location of connector pin is as viewed from the inserting side.
5.Write or impress the letters with undamped ink.
RD Water resistant WHBU WHBU Water resistant
Contactor 59B C 8 Plug 6P 69A V 1 2 2 1 V 69C Plug 6P 6.Fuses should be placed in a circle, as shown in the figure 1.
F fuse 64B D4 8
BNRD
Stop & tail lamp 6G P
52K Point
"d"
2
3
2
2
BKWH*
RDWH
GNWH
BKWH*
RDWH
GNWH
2
2
2
3Point
4 "a"
6N
E2 52M 7.The end of the spiral tube should be tied together with wire ties,
and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
E1 70A P 4 2 2 P 70C
3 2 1 BN BN 3 2 1
(left) 6 5 4
66AD3 5
6
2
BUYE RDYE
2 5 I
6
66D
6 5 4
8.The end of the vinyl tube should be tied together with wire ties.
38C N1 2 2 N2 37C WHBU 1 9.The capacitor should be soldered to the speed sensor section, as shown in
Point"a" BUBK
1
1 2 F 61A
F 60A
Plug Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
Point"d"
BKWH
BNWH
BKWH
1
1
1
3
4
5
F 62A
X,P 32B
Point 52F
6P
WH
1 2 3
4 5 6
D4 Controller with siliconadhesive.
D5, RDWH BNRD
D6 Fan 1
Plug
2P 2B A
6E Point"a" 1 1
2 1
GNWH 53A C 8
BU 1 6 F 64A "d"
Backward output
Fuse
10A
2 WH
B
Power supply
terminal
RDBK
RDWH
BN
1
1
1
1
2
3
D2,D5 6C
D1 65A
E1,I 66B
Plug
4P
WH
1 2 D3 relayCa1a-DC48V-N
10A

RDGN Tie wrap
1 1 X,W4 31B Control power supply
YERD 1 2 X 35B
Plug
D2 relay Clamp
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
WHBU
YEBU
BK
RDWH 4P 1 2
BNYE
1 3 A,D3 6B
RD Figure 1 Figure 2
1 4 3 4 Ca1a-DC48V-N
X 36B
RDBK *Connect the relay. Capacitor
WH
GNWH
BU
WHGN
RDYE
WH
BKYE
BU
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
1 1 D3,F 65B (Non polarized)

RDYE
BKYE
WHBU
BUWH
YERD
Seal plug
1 2 S1 67A Vinyl tube Vinyl tube
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
BKWH*
WHBK
1 4
1 3
Point"d" 52G
,U
Plug
4P
BK
1 2
3 4
D1 Horn relay
Ca1a-DC48V-N
M 68A
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 *Connect the relay.
X X Point"a" L J F D5 P H H W3 W3 X X X G G T T T Be careful of the arrangement
46B 45B 6F 55A 57A 59A of terminals.
1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 25A 27A 29A Tie wrap With solder Tie wrap
RDWH Plug
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G T T T 1 1 D3,D6 6D 2P 1 Figure 3
BUWH
47B 44B 34D 54A 56A
Water resistant
58A
2P-X 2P-Y
D5 Fan
5 4 3 2 1
10 9 8 7 6
6 5 4 3 2 1
12 11 10 9 8 7
1
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
2
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
3
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
4
C EPS unit A MPU board
with undamped ink.
FB20P 28P-75
(Std/CS/FCS/RP/DRP) 4-3-3.
54000-19164-1e
77
*Refer to note 6
<Note>
BKWH*
BKWH*
To E1
To E2
To X
To W4
RD
RD
1.Terminal symbols
RDWH RDWH
:Receptacle
RDBK
WHGN
WHBU
WHRD
RD
To C To E2
To D6 To E2 1 :Receptacle
RD
RDGN
BN
BKWH
WHBU
WHRD
GNWH
BUYE
RD
WHBK
1 1 1 1 1
RD
BUBK
WHRD
BN
BNBK
RDBK
YERD
Point"a"
RDGN
BKWH
YEBU
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
1 2 3 4 1 2
AMP 170021-3
S1,W1 E1,E2 X,K1
To O
To C
RD
RD
To D4
To D1
BKWH*
BKWH*
65F 69B 49B
2 2 2 2 2 2 2 2 2 2 Sleeve(for double wire) AMP 170890-1
RDGN
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
1 1
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
:Plug
Point"c" (with plating) AMP 170020-2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
65G 67C 32G 41B 13B 11B 34B 50B
Plug 4P Plug 2P
Point"d" 1 :Plug
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20 X A A D2
Horn switch WH BK (without plating) AMP 170002-5 or
D2 O D2 N2 S2 W2 A A A C C R W4 39B 14B 12B 31C
31A 33A 35A 37A 40A 41A
D4 Point"c"D2 N1 W2 O P
19B 16B 18B 44A 46A
A A A C C
48A 50A
V O
W1 (post) Water resistant Water resistant Water resistant 1 2 1
Pressed sleeve detailed drawing Sleeve(for double wire)
AMP 170020-3
AMP 170888-1
Plug 3P Plug 4P Plug 3P 3 4 :Receptacle(with sleeve) AMP 41729
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A 2
Lamp switch Laser pointer Sleeve(for double wire) AMP 1-170823-5
CN1 CN2 W K 1 :Receptacle AMP 173716-2 or
3 2 1 2 1
4 3
3 2 1
Point"c" VOperation switch Fork leveling switch 1 :Receptacle
AMP 175061-2
AMP 170032-5 or
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 Turn signal switch
(*Refer to note 5)
W4 Key switch
(*Refer to note 5)
BURD
BK 1
1 A 80B
T 30C S3 (lever) 1 :Tab
AMP 179461-5
AMP 170340-3 or
X Display board W3 switch

Directional Horn switch 65E U,V 1
RDBK 2 :Receptacle
AMP 179462-3
AMP 171662-1 or
Plug 4P
S1(lever) 67B D1,W1 1
YERD
BUWH
WHBU
1
1
1
2
A 25B
A 28B
Plug 6P
BK Valve AMP 173707-1
WH
52B N1,Q
6J N1,N2 1 1
2 1
RDWH
BKWH*
YERD BUBK
BNWH
YEBU
GNWH
1
1
3
4
A 26B
A 29B T microswitch 3 :Receptacle
AMP 316041-2 or
75B K1 3 1
4 1 BKWH*
R Accessory
48B X
BKWH 40B X 1
BNBK
BK
1
1
5
6
A 27B
A,S3 30B
1 2 3 AMP 179956-2
3 4
Put the sleeve
32E O,S2
BKWH
4 5 6 4
5
:Receptacle
:Tab
Yazaki 7116-3251
Yazaki 7114-3251
for sure receptacle. :Pressed sleeve JST FNC-2
Water resistant
K3 Level Lamp 5.Write or impress the letters with undamped ink.
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
RD 1
2 V 77C Plug 2P 6.Fuses should be placed in a circle, as shown in the figure 1.
BKWH* 2
WHBK
2
N1 52N
Water resistant 7.The end of the spiral tube should be tied together with wire ties,
M 68B D1
+
*Refer to note 7
Horn and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
RDWH
WHRD
BUBK
GNWH
BKWH
Plug 2P
K2 Laser
RDYE
RDGN
RD
BKWH
YEBU
1 1 1 1 1 1 1 1
BNBK
YEBK
BKWH* 2 1
1 2 3 4
LEPS sensor 52D O,I
Capacitor RD
BKWH*
2 1 V 77A
1 2 3 4 8.The end of the vinyl tube should be tied together with wire ties.
RDBK
RDWH
BKWH*
BUYE
BNYE
V Q,K3 100V 22 2 V U,K2 9.The capacitor should be soldered to the speed sensor section, as shown in
2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2 with siliconadhesive.
Plug 4P
74B 34C 33B
F P,R
51B
X
6H 43B
A E1,E2 D4,O
56B C
54B C
1
55B C 2
3
2
2
2
BU
GNWH
WH
YERD
WHRD
2
2
1
2
Q 75A
V 49C
Plug 2P
K1Level sensor F,S1
65D
D2,N2
52H
E2
72B Plug 4P
Fuse
10A
10A
WH 73B 32D 42B 3B 70B 32C 3 2 1 N2,A E2 WH
2 1
6L 71B
Water resistant
1 2
3 4
Plug 6P
BK
Plug 2P
WH
Plug 6P
RD Electromagnetic 84B A
GNRD
WHBU
RDBK 2 1 A 81B
Plug 3P U
Accessory 1 2
3 4 Tie wrap
Head guard Y valve

85B A GNRD
BKYE
2
2
2
3
A 82B
A 83B 3 2 1 K3 Tilt detector Head guard Figure 1
Clamp
Figure 2
N1 (left) 1 2 3
4 5 6
1
2
1 2 3
N2 (right) Capacitor
(Non polarized)
YE Plug 4P Vinyl tube
Charger Brake Yazaki
1P 57B C 4 BU 2 1 A 10B Vinyl tube
O panel P switch
J EPS motor
7123-4113-30
1P 58B C 5
GN
RDYE
BKYE
WH
2
2
2
2
3
4
A 7B
A 8B
A 9B
2 1
4 3
H Accelerator sensor Fill the inside of the vinyl
Yazaki
7122-4113-30
Tie wrap With solder Tie wrap
Capacitor
125V 0.022 Water resistant Figure 3
RD Plug 4P
BK RDGN BN 2 1 A 21B Speed sensor
10A
73A O
52E M,D4 1
BKWH*
BKRD
BUWH
WH
2
2
3
2 A 23B
A 22B
AMP 174257-2
G (Travel) WHBU
BUBK
1
1
1
2 F 61A
F 60A
Plug
8 10A
BK
74A O
RDBK
65C D1,U
2 4 A 24B
2 1
4 3
(*Refer to note 9)
BKWH
BNWH
BKWH
1
1
1
3
4
5
F 62A
X,P 32B
Point 52F
6P
WH
1 2 3
4 5 6
D4 Controller
BNRD
RDYE 1 6 F 64A "d"
Plug 60B D4
61B D4 8
BUBK
WHBU
RDWH
BKWH*
BUYE
A, A 4B
,E2 52L
RDBK
RDWH
BN
1
1
1
2
3
D2,D5 6C
D1 65A
E1,I 66B
Plug
4P
WH
1 2 D3 relay
Ca1a-DC48V-N
1 1 1
1
3 4
2
2P
WH
U 72A
E2 (right) RDGN
1
1
4
1
A 5B
X,W4 31B
*Connect the relay.
Contactor 59B C 8
RD Water resistant
Plug 6P 69A V 1 2
WHBU WHBU 2 1 V 69C
Water resistant
Plug 6P
YERD
RDWH
BNYE
1
1
2
3
4
X 35B
A,D3 6B
Plug
4P
RD
1 2 D2 relay Reference:
Harness mark/color
F BKWH* BKWH* 3 4 Ca1a-DC48V-N
1
52K Point2 2 2 2 E2 52M X 36B
fuse 64B D4 8
BNRD
6G P
"d" 3 2
RDWH RDWH 2 3Point 6N RDBK *Connect the relay. Red RD
E1 70A P 4 2 2 4 P 70C YERD

3 2 1 BN BN 3 2 1 1 2 S1 67A Black BK
(left) 6 5 4
66AD3
38C N1 6
5 2
2
BUYE
Point"a"
RDYE
2
2
5 I
6
66D
N2 37C 6 5 4
BKWH*
WHBK
1 4
1 3
Point"d"
,U 52G
Plug
4P
BK
1 2
3 4
D1 Horn relay
Ca1a-DC48V-N
Green
Yellow
GN
YE
M 68A
*Connect the relay. White WH
of terminals.
Brown BN
Blue BU
RDWH Plug
D3,D6 6D Gray GY
D5 Fan
1 1
BUWH 1
D5, RDWH Power supply 1 2 A 1B 2P
D6 Fan 1
2
Plug
2P
WH
2B A
6E Point"a" 1 1
2 1
GNWH
B termianl 53A C 8
BU WH 2 Pink
Orange OG
PK

RDWH Black colored harness with White line.
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
BURD
WHBU
YEBU
BK
RDWH
WH
GNWH
BU
RDYE
WH
BKYE
BU
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
GNRD
WHBU
RDYE
BKYE
WHBU
BUWH
RDBK
GNRD
BKYE
Seal plug
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 White line
X X Point"a" L J F D5 P H H W3 W3 X X X G G K3 K3 T T T Y
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G K3 T S3 T T Y E2,U
Water resistant 2P-X 2P-Y Black color

1 2 3 4 11 12
5 4 3 2 1
10 9 8 7 6 B 6 5 4 3 2 1
12 11 10 9 8 7
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 FB-75 Body harness 4- 3.
FB20P-28P-75
54000-19192-0e
78
*Refer to note 6
RDWH RDWH
Reference:
To C To E2 Harness mark/color
RDWH RDWH
RDBK
WHGN
WHBU
Red RD
WHRD
RD
To D5 To E2
Black BK
Point"a" Green GN
GNWH
RD
RDGN
BN
BKWH
WHBU
WHRD
BUYE
RD
WHBK
1 1 1 1 1 Yellow YE
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
1 2 3 4 1 2
White WH
S1,W1 E1,E2 X,K1
Brown BN
BKWH*
BKWH*
RDGN
65F 69B 49B
RD
RD
To E1
To E2
To X
To W4
2 2 2 2 2 2 2 2 2 2
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
1 1
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
Blue BU
Gray GY
65G 67C 32G 41B 13B 11B 34B 50B Pink PK
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20 X A A D2 Plug 4P Plug 2P Orange OG
D2 O D2 N2 S2 W2 A A A C C R W4 Horn switch 39B 14B 12B 31C WH BK
W1(post) Ex) BKWH (=Black/White)
RD
RD
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A
BKWH*
BKWH*
To O
To C
To D4
To D1
D4 Point"c" D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1 2 1
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 2
CN1 CN2 3 2 1
W 2 1 3 2 1
K Lamp switch Laser pointer
Point"c" Point"d"
4 3
Point"c"
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 Turn signal switch W4 Key switch
(*Refer to note 5) (*Refer to note 5) White line
Valve
X Display board W3 Directional switch T microswitch
Horn switch 65E U,V 1
RDBK
Plug 4P
S1 (lever) 67B D1,W1 1
YERD
BUWH
WHBU
BNWH
1
1
1
2
A 25B
A 28B
Plug 6P
BK
Black color
RDWH 1 3 A 26B
WH 6J N1,N2 1 1 YEBU
2 1 BKWH* 1 4 A 29B
52B N1,Q BUBK GNWH
YERD
75B K1 3 1
4 1 BKWH*
R Accessory
48B X
BKWH 40B X 1
BNBK
BK
1
1
5
6
A 27B
A 30B
1 2 3
3 4
Put the sleeve
32E O,S2
BKWH
4 5 6
Water resistant
<Note>
RD 1 1.Terminal symbols
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
V 77C
K3 Level lamp
2
BKWH* 2
Plug 2P
2
N1 52N : Receptacle
WHBK (with plating) AMP 170021-2
M Horn 68B D1
+
*Refer to note 7
2 1
: Receptacle
RDWH
WHRD
BUBK
GNWH
BKWH
RDYE
RDGN
RD
BKWH
YEBU
1 1 1 1 1 1 1 1 1
BNBK
YEBK
BKWH* Water resistant

1 2 3 4
Capacitor RD 2 1 V 77A Plug 2P
K2 Laser
1 2 3 4 (without plating) AMP 170003-5 or
RDBK
RDWH
BKWH*
BUYE
BNYE
V Q,K3 100V 22 BKWH* 2 V U,K2 AMP 170021-3
2
N2 52J
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Sleeve(for single wire) AMP 170889-1
P,Q X,E1 2 1 Q,U X,E2
1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Sleeve(for double wire) AMP 170890-1
: Plug
Plug 4P
74B 34C 33B
F P,R
51B
X
6H 43B
A E1,E2 D4,O
56B C
54B C
1
55B C 2
3
2
2
2
BU
GNWH
WH
YERD
WHRD
2
2
1
2
Q 75A
N2 49C
Plug 2P K1 Level sensor F,S1
65D 52H
D2,N2
72B
E2
Plug 4P
1 : Plug
WH 73B 32D 42B 3B 70B 32C 3 2 1 N2,E2 E2 WH
2 1
6L 71B
(without plating)AMP 170002-5 or
AMP 170020-3
1 2 1 2
3 4
Plug 6P
BK
Plug 2P
WH
Plug 6P
RD
Water resistant
U Accessory 3 4
: Receptacle(with sleeve) AMP 41729
Head guard 1P YE
BU Plug 4P Head guard Sleeve(for single wire) AMP 170823-2
57B C
N2
4
N1 (left) 1 2 3
4 5 6
1
2
1 2 3
4 5 6 J EPS motor
Yazaki
7123-4113-30
GN
RDYE
BKYE
WH
2
2
2
1
2
3
A 7B
A 10B
A 9B
2 1
H Accelerator sensor (right)
1
: Receptacle AMP 173716-2 or
2 4 A 8B
1P 58B C 5 4 3 AMP 175061-2
Yazaki
O Charger panel P Brake switch 7122-4113-30
1
1
: Receptacle
: Tab
AMP 170032-5 or
AMP 179461-5
AMP 170340-3 or
Capacitor
125V 0.022 Water resistant AMP 179462-3
BN

RD Plug 4P 2 : Receptacle AMP 171662-1 or
BKWH* 2 1 A 21B Speed sensor AMP 173707-1
BK* Length 100 10A
BK RDGN
73A O
52E M,D4 1 BKRD
BUWH
WH
2
2
2
3
2
4
A 23B
A 22B
A 24B
AMP 174257-2
G (Travel) AMP 172888-2(rubber plug)
2 1
(*Refer to note 9)
10A
BK RDBK
4 3
3 : Receptacle AMP 316041-2 or
65C D1,U AMP 179956-2
74A O 4 : Receptacle Yazaki 7116-3251
RDYE(Length 300)
YEBU
A 4B
5 : Tab Yazaki 7114-3251
BUBK(Length 200) RDWH U,
61B D4 8 Point"a" 6M Point"d" : Pressed sleeve JST FNC-2
BKWH*
WHBU ,E2 52L 2. : :Braided wires under 25mm pitch.
1
Plug 60B D4 1 1 BUYE
U 71A Stop & tail lamp
2
2P
WH
U 72A
E2 (right) 3.The location of connector pin is as viewed from the inserting side.
RD Water resistant WHBU WHBU Water resistant
Contactor 59B C 8 Plug 6P 69A V 1 2 2 1 V 69C Plug 6P 6.Fuses should be placed in a circle, as shown in the figure 1.
F fuse 64B D4 8
BNRD
Stop & tail lamp 6G P
52K Point
"d"
2
3
2
2
BKWH*
RDWH
GNWH
BKWH*
RDWH
GNWH
2
2
2
3Point
"a" 6N
E2 52M 7.The end of the spiral tube should be tied together with wire ties,
and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
E1 70A P 4 2 2 4 P 70C
3 2 1 BN BN 3 2 1
(left) 6 5 4
66AD3 5
6
2
BUYE RDYE
2 5 I
6
66D
6 5 4
38C N1 2 2 N2 37C WHBU
Point"a" BUBK
1 1 F 60A 9.The capacitor should be soldered to the speed sensor section, as shown in
1 2 F 61A Plug Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
Point"d"
BKWH
BNWH
BKWH
1
1
1
3
4
5
F 62A
X,P 32B
Point 52F
6P
WH
1 2 3
4 5 6
D4 Controller with siliconadhesive.
D5, 1 RDWH BNRD
D6 Fan 1
Plug
2P 2B A
6E Point"a"
2
1
1
GNWH 53A C 8
BU 1 6 F 64A "d"
Backward output
Fuse
10A
2 WH
Power supply
B terminal
RDBK
RDWH
BN
1
1
1
1
2
3
D2,D5 6C
Plug
D1 65A
4P
E1,I 66B WH
1 2 D3 relay
Ca1a-DC48V-N
10A

RDGN Tie wrap
1 1 X,W4 31B Control power supply
YERD 1 2 X 35B
Plug
D2 relay Clamp
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
WHBU
YEBU
BK
RDWH 4P 1 2
BNYE
1 3 A,D3 6B
RD Figure 1 Figure 2
1 4 3 4 Ca1a-DC48V-N
X 36B
RDBK *Connect the relay. Capacitor
WH
GNWH
BU
WHGN
RDYE
WH
BKYE
BU
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
1 1 D3,F 65B (Non polarized)

RDYE
BKYE
WHBU
BUWH
YERD
Seal plug
1 2 S1 67A Vinyl tube Vinyl tube
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
BKWH*
WHBK
1 4
1 3
Point"d"
,U
Plug
4P
52G BK
1 2
3 4
D1Horn relay
Ca1a-DC48V-N
M 68A
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 *Connect the relay.
X X Point"a" L J F D5 P H H W3 W3 Be careful of the arrangement
X X X G G T T T
of terminals.
46B 45B 6F 55A 57A 59A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 25A 27A 29A Tie wrap With solder Tie wrap
RDWH Plug
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G T T T 1 1 D3,D6 6D 2P 1 Figure 3
BUWH
47B 44B 34D 54A 56A
Water resistant
58A
2P-X 2P-Y
D5 Fan
1 2 3 4
5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
10 9 8 7 6
12 11 10 9 8 7 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
C EPS unit A MPU board

with undamped ink.
FB30P-75 (Std/CS/FCS/RP/DRP) 4-3-5.
54000-19174-1e
79
<Note>
*Refer to note 6 1.Terminal symbols
BKWH*
BKWH*
:Receptacle
To E1
To E2
To X
To W4
RD
RD
RDBK
WHGN
WHBU
WHRD
RD
To C To E2
RDWH RDWH 1 :Receptacle
To D6 To E2 (without plating) AMP 170003-5 or
AMP 170021-3
GNWH
BUYE
RD
WHBK
RD
RDGN
BN
BKWH
WHBU
WHRD
1 1 1 1 1
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
1 2 3 4 1 2 Point"a" Sleeve(for single wire) AMP 170889-1
S1,W1 E1,E2 X,K1 Sleeve(for double wire) AMP 170890-1
To O
To C
BKWH*
BKWH*
To D4
To D1
RD
RD
65F 69B 49B :Plug
RDGN
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
1 1 2 2 2 2 2 2 2 2 2 2
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3 (with plating) AMP 170020-2
V S1 S2 X A A Point"c" X 76B 77B 1 :Plug
65G 67C 32G 41B 13B 11B 34B 50B Point"c" Point"d" (without plating) AMP 170002-5 or
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
X A A D2 Plug 4P Plug 2P
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20 AMP 170020-3
D2 O D2 N2 S2 W2 A A A C C R W4 Horn switch 39B 14B 12B 31C WH BK
31A 33A 35A 37A 40A 41A
D4 Point"c" D2 N1 W2 O P
19B 16B 18B 44A 46A
A A A C C
48A 50A
V O
W1 (post)
Water resistant Water resistant Water resistant 1 2 1
Pressed sleeve detailed drawing :Receptacle(with sleeve) AMP 41729
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 2 Sleeve(for double wire) AMP 1-170823-5
Lamp switch Laser pointer 1 :Receptacle AMP 173716-2 or
CN1 CN2 W K AMP 175061-2
3 2 1 2 1
4 3
3 2 1
Point"c" V Operation switch Fork leveling switch
1 :Receptacle AMP 170032-5 or
AMP 179461-5
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 (*Refer
Turn signal switch
to note 5)
W4 Key switch
(*Refer to note 5)
BURD
BK 1
1 A 80B
T 30C S3 (lever) 1 :Tab AMP 170340-3 or
AMP 179462-3
Display 2
X board
W3 switch
Directional
S1 (lever)
Horn switch 65E U,V 1
RDBK
YERD
BUWH 1 1 A 25B
Plug 6P
BK
AMP 173707-1
Plug 4P
67B D1,W1 1 WHBU 1 2 A 28B Valve AMP 172748-2(seal plug)
WH
52B N1,Q
6J N1,N2 1 1
2 1
RDWH
BKWH*
YERD BUBK
BNWH
YEBU
GNWH
1
1
3
4
A 26B
A 29B T microswitch 3 :Receptacle AMP 316041-2 or
AMP 179956-2
75B K1 3 1
4 1 BKWH*
R Accessory
48B X
BKWH Brake 40B X 1
BNBK
BK
1
1
5
6
A 27B
A,S3 30B
1 2 3 4 :Receptacle Yazaki 7116-3251
3 4
Put the sleeve
32E O,S2
S2 oil 32F R,W2 1
BKWH
4 5 6 5 :Tab
:Pressed sleeve
Yazaki 7114-3251
JST FNC-2
for sure receptacle. 2. : :Braided wires under 25mm pitch.
Water resistant
K3 Level lamp 6.Fuses should be placed in a circle, as shown in the figure 1.
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
RD 1
2 V 77C Plug 2P 7.The end of the spiral tube should be tied together with wire ties,
BKWH* 2
2
N1 52N
WHBK Water resistant and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
M Horn 68B D1
+
*Refer to note 7
RDYE
RDGN
RD
YEBU
Plug 2P
BKWH
K2
1 1 1 1 1 1 1 1
BNBK
YEBK
2 1
RDWH
WHRD
BUBK
GNWH
BKWH
BKWH*
1 2 3 4
Capacitor RD 2 1 V 77A Laser 1 2 3 4 9.The capacitor should be soldered to the speed sensor section, as shown in
RDBK
RDWH
BKWH*
BUYE
BNYE
V Q,K3 100V 22 BKWH* 2 V U,K2 Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I with siliconadhesive.
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B Fuse
Plug 4P
74B 34C 33B
F P,R
51B
X
6H 43B
A E1,E2 D4,O
56B C
54B C
1
55B C 2
3
2
2
2
BU
GNWH
WH
YERD
WHRD
2
2
1
2
Q 75A
V 49C
Plug 2P
K1Level sensor F,S1
65D
D2,N2
52H
E2
72B Plug 4P
10A
10A
WH 73B 32D 42B 3B 70B 32C 3 2 1 N2,A E2 WH

2 1
6L 71B
Water resistant
1 2
3 4
Plug 6P
BK
Plug 2P
WH
Plug 6P
RD Electromagnetic 84B A
GNRD
WHBU
RDBK 2 1 A 81B
Plug 3P U Accessory 1 2
3 4 Clamp
Tie wrap
Head guard Y valve

85B A GNRD
BKYE
2
2
2
3
A 82B
A 83B K3 Tilt detector Head guard
Figure 1 Figure 2
N1 (left) 1 2 3
4 5 6
1
2
1 2 3
3 2 1
N2 (right) Vinyl tube
Capacitor
(Non polarized)
Vinyl tube
YE Plug 4P
Charger Brake Yazaki
1P 57B C 4 BU 2 1 A 10B
O panel P switch
J EPS motor
7123-4113-30
1P 58B C 5
GN
RDYE
BKYE
WH
2
2
2
2
3
4
A 7B
A 8B
A 9B
2 1
4 3
H Accelerator sensor
Yazaki Tie wrap With solder Tie wrap
7122-4113-30
Figure 3
Capacitor
125V 0.022 Water resistant
BN RD Plug 4P
BK RDGN 2 1 A 21B Speed sensor
BK* Length 100 10A
73A O
52E M,D4 1
BKWH*
BKRD
BUWH
WH
2
2
3
2 A 23B
A 22B
AMP 174257-2
G (Travel) WHBU
BUBK
1
1
1
2 F 61A
F 60A
Plug
10A
BK
74A O
RDBK
65C D1,U
2 4 A 24B
2 1
4 3
(*Refer to note 9)
BKWH
BNWH
BKWH
1
1
1
3
4
5
F 62A
X,P 63B
Point 52F
6P
WH
1 2 3
4 5 6
D4 Controller
RDYE(Length 300) BNRD 6
"d"
1 F 64A
Plug 60B D4
61B D4 8
BUBK(Length 200)
WHBU
RDWH
BKWH*
BUYE
A, A 4B
,E2 52L
RDBK
RDWH
BN
1
1
1
2
3
D2,D5 6C
D1 65A
E1,I 66B
Plug
4P
WH
1 2 D3 relay
Ca1a-DC48V-N
1 1 1
1
3 4
2
2P
WH
U 72A
E2 (right) RDGN
1
1
4
1
A 5B
X,W4 31B
*Connect the relay.
Contactor 59B C 8
RD Water resistant
Plug 6P 69A V 1 2
WHBU WHBU 2 1 V 69C
Water resistant
Plug 6P
YERD
RDWH
BNYE
1
1
2
3
4
X 35B
A,D3 6B
Plug
4P
RD
1 2 D2 relay
F BKWH* BKWH* 3 4 Ca1a-DC48V-N
1 X 36B
52K 2
Point"d" 2 2 2 E2 52M
fuse 64B D4 8
BNRD
6G P 3 2
RDWH RDWH 2 3Point 6N RDBK *Connect the relay.
E1 (left) 70A P 4 4 P 70C YERD

3 2 1
2
BN BN
2
3 2 1 1 2 S1 67A Reference:
6 5 4
66AD3
38C N1 6
5 2
2
BUYE
Point"a"
RDYE
2
2
5 I
6
66D
N2 37C 6 5 4
BKWH*
WHBK
1 4
1 3
Point"d"
,U 52G
Plug
4P
BK
1 2
3 4
D1 Horn relay
Ca1a-DC48V-N
Harness mark/color
Red RD
M 68A
*Connect the relay. Black BK
of terminals.
Green GN
Yellow YE
RDWH Plug
D3,D6 6D
D5 Fan
1 1 White WH
D5, RDWH Power supply BUWH 1 2 A 1B 2P 1
D6 Fan 1
2
Plug
2P
WH
2B A
6E Point"a" 1 1
2 1
GNWH
B termianl 53A C 8
BU WH 2 Brown
Blue
BN
BU
Gray GY
Pink PK
RDWH Orange OG
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
BURD
WHBU
YEBU
BK
RDWH
WH
GNWH
BU
WHGN
GNRD
RDYE
WH
BKYE
BU
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
WHBU
RDYE
BKYE
WHBU
BUWH
RDBK
GNRD
BKYE
Seal plug
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16
X X Point"a" L J F D5 P H H W3 W3 X X X G G K3 K3 T T T Y
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G K3 T S3 T T Y E2,U White line
Water resistant 2P-X 2P-Y

1 2 3 4 11 12
5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
Black color
10 9 8 7 6
12 11 10 9 8 7 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9

FB30P-75
54000-19202-0e
80
<Note>
1. This diagram shows that IGBT is a 400A item. 3. The connection of the IGBT gate connectors should be made according to the
When it is a 600A item, even though the size of following drawings.
the IGBT is different, the wiring is all the same.
The connectors should be connected so
2.Terminal symbols that the ribs to prevent incorrect connection
6 :Terminal 1.25-6
G2
are facing the outside of the IGBT.
E2
(Both white and black)
E1 Insert the housing all the way
G1 in, until it touches the main
body of the IGBT.
-
The top view The side view
*Refer to note 3
T CN5 PB100- XX
CN1 CN2
From Board, IGBT
GNRD G2
E2 2P
G2
E2 2P
G2
E2 2P
WH WH WH
CN3
F+
E1 E1 E1
G1 2P G1 2P G1 2P
6 BK BK BK
Battery(+)
CN4
CN9 CN10
CN7 H
The housing and the harness
should not protrude from the
side of the controller.
HV HU
4P 4P
From Board,IGBT Sensor Comp.
,heat
NA
Battery(-) G1 2P 6 2P G1 2P G1
E1 BK BK E1 BK E1
2P
RD
BKWH
E2 2P 2P E2 TV 2P E2 TU
G2 WH WH G2 WH G2
Reference: 4P 4P
Harness mark/color
Red RD
Black BK
Green GN 6PWH
Yellow
White
YE
WH
Cap
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG Harness, controller
Ex) BKWH (=Black/White) 54000-17480 W2 W1 V2 V1 U2 U1
W2 W1 V2 V1 U2 U1
Hydraulic Travel Hydraulic Travel Hydraulic Travel
White line
W phase W phase V phase V phase U phase U phase
Black color
FB-75 Controller wiring 4- 4.

54000-17491-0e
81
Line No. From To Color Length(mm)

1A 1B A 6 10 D RDGN# 550
2A 2B A 6 10 D YERD# 550
3A 3B A 6 10 D BKYE# 550
1
A MPU board L
4A 4B A 6 10 F RDBK# 450
5A 5B A 6 10 F BU# 450
6A 6B A 6 10 F BKWH# 450
10 9 8 7 6 5 4 3 2 1
7A 7B A 6 3 E BNYE 560
20 19 18 17 16 15 14 13 12 11
7C B 6 360
Current sensor CN5 8A 8B A 6 3 E BKYE 560
G (Hydraulic V phase) F Current sensor

(Travel V phase) D
1A
D
3A
F
5A 7A
E I
9A
J
12A
9A
10A
9B
10B
A
A
6
6
3
3
I
I
WHBU
BNWH
760
760
D F F E I I I H 11A 11B A 6 3 I BUBK 760
Be careful of the arrangement
HV TV of terminals. 2A 4A 6A 8A 10A 11A 13A 14A 12A 12B A 6 6 J GNRD 300
1 2 3 4 1 2 3 4 3
1 11 2 3 12 4 13 14 5 15 6 16 7 8 17 18 9 10 19 20 13A 13B A 6 3 I BNRD 760
6 6 6 6 6 6 6 6 6 6 6 6 6 6 14A 14B A 6 6 H BKWH 510
8
RDGN#
YERD#
BKYE#
RDBK#
BU#
BKWH#
BNYE
BKYE
WHBU
BNWH
BUBK
GNRD
BNRD
BKWH
14C I 3 BKWH* 450
4P 4P
Current sensor 14D I 3 BKWH* 450
20B 6B
C (Hydraulic U phase) D Current sensor
(Travel U phase) E
IGBT
temperature sensor 15A 15B B 6 10 C RDGN# 380
B A 16A 16B B 6 10 C YERD# 380
18B 19B 4B 5B HU TU
1 2 3 4 1 2 3 4 1 17A 17B B 6 10 C BKYE# 380
B B A A 9 2
1 2 3 4 1 2 3 4 4 18A 18B B 6 10 G RDBK# 280
10 10 10 10 10 10 Plug 19A 19B B 6 10 G BU# 280
4P 4P 2P
RDBK#
BU#
BKWH#
RDBK#
BU#
BKWH#
RD 20A 20B B 6 10 G BKWH# 280
10
17B 3B 8B
B A A
J Battery(+) 15B 16B 1B 2B 7B
A,B
Reference:
Harness mark/color
B B A A
5 Red RD
1 2 3 4 1 2 3 4 1 2 Black BK
6 A 12B
GNRD 10 10 10 10 10 10 3 3 Green GN
RDGN#
YERD#
BKYE#
RDGN#
YERD#
BKYE#
BNYE
BKYE
Yellow YE
White WH
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG

White line
Black color
<Note>
BKWH/BKWH*
1.Lead wires
# :AVS0.3mm2
WHBU
BUBK
BKWH*
BNWH
BKWH*
BNRD
2
11 *Others :AVS0.85mm
:AVS0.5mm2
BKWH#
RDGN#
YERD#
RDBK#
BKYE#
BNYE

BU#
3 3 3 3 3 3
6
1 2 3 4 5 6
Be careful of the arrangement 3. :Braided wires under 25mm pitch.
7 of terminals.
A A A
A, I, I 6 6 6 6 6 6 6 4.Impress marks on connectors with undamped ink as indicated in
1 7 2 3 8 4 9 10 5 11 6 12
14B the pin configuration.
11B 10B 13B C C G E
A H H
9B 14C 14D H Battery(-) 15A 17A 19A 7C

C G G
16A 18A 20A
14 Wire, lead AVS0.85mm2 See lead wire table.
Cap
6P WH CN7 13 Wire, lead AVS0.5mm2 See lead wire table.
12 Wire, lead AVS0.3mm2 See lead wire table.
6
3 2 1 11 0340-00506 Terminal 5.5-6 1 6
6 5 4 3 2 1
6 5 4 10 0340-00106 Terminal 1.25-6 1 6
12 11 10 9 8 7 BXH-0016-P0.6
9 37010-22990 Contact SXH-0016-P0.6 12 JST 10
I External terminal 8
7
37010-21960
37010-21460
Housing
Tab
XHP-4
179462-3/170340-3
4P 4
5
JST
AMP 3
B MPU board R 2
6
5
37010-21360
37010-21470
Housing, cap
Receptacle
171897-1
179461-5/170032-5
6PWH 1
2
AMP
AMP 3
4 37010-21720 Housing, plug 172130-9 2PRD 1 AMP
3 37010-21490 Receptacle 175061-2/173716-2 21 AMP 6
2 37010-21870 Housing, plug 175965-2 12P 1 AMP
1 37010-21020 Housing, plug 175967-2 20P 1 AMP
SYM PART NO. PART NAME SIZE MATERIAL QTY MASS REMARKS
FB-75 Controller harness 4- 5.

54000-17483-0e
82
21 6
1
Unit type
21 3
*Refer to note 4 *Refer to note 1
CU104-XXX
19 2
16 22
13
27 26 25 17 14
*Refer to note 2 Upper
24 7
15
23 8
27 26 25 17
21 5
*Refer to note 2
21 4
W2 W1 V2 V1 U2 U1
27 26 25 20 18
29 54000-17491 Wiring, controller
28 54000-17483 Harness, controller
27 0000-00008 Nut
12 10 11 9 11 9 26 0000-70008 Washer, lock
25 0000-72008 Washer, plain
24 0077-04016 Screw, w/washer
23 0075-04016 Screw, w/washers
21 0016-06012 Bolt, w/washers
18 24200-66340 Terminal Comp.
17 24200-63030 Terminal
16 24200-56850 Sensor Comp., heat
Note 15 54000-19620 Capacitor Comp.
1. When installing a " 5 6 Module ,IGBT" to the " 1 Sink, heat", be sure to 14 54000-15680 Bar, lead(8)
apply condition compund[G-747] (Shin-Etsu silicones) to the entire 13 54000-15670 Bar, lead(7)
contact surface. 12 54000-14130 Bar, lead(4)
2. Insert washers in the " 17 terminal", as shown in Figure A, and then 11 54000-14120 Bar, lead(3)
10 54000-14110 Bar, lead(2)
installing the " 17 terminal", apply LOCTITE[242] or a similar material
9 54000-14100 Bar, lead(1)
to the screws to prevent looseness. 8 39530-02180 Sensor, current
3. Recommended tightening torque for the IGBT. Maximum current 7 54000-19610 Board Comp., IGBT
Applicable 2 Board comp., MPU
Main terminal(M6) and mounting(M6) : 3.5-4.5N.m(0.36-0.49kg.m) models Part No. Type (IGBT rating) Remarks 6 35030-00780 Module, IGBT
Travel Hydraulic Part No. Type 35030-00790 Module, IGBT
4. Impress a Unit type to the specified position with undamped ink. 5
5. Use the terminal bolt included for the "IGBT module" . 600A 400A 4 54000-19601 Bracket, board(2)
STD 54000-15491-1 CU104-50 (250V) (250V) 54000-20411 PBC104-00 When installing,
make sure the 3 54000-20691 Bracket, board(1)
6. In order to improve vibration resistance, apply to the "capacitor comp."
a silicone adhesive agent on the bottom to fix it into place. Figure A OPT 54000-19351-1 CU104-53 54000-20431 PBC104-02 arrow points up. 2 Board Comp., MPU
1 54000-19490 Sink, heat
FB-75 Main controller 4- 6.

FB10P-28P-75 4-6-1.
E0000-04271-1e
83
21 5
1
Unit type
21 3
*Refer to note 4. *Refer to note 1.
CU104-XXX
19 2
16 22
13
27 26 25 17 14
*Refer to note 2. Upper
24 7
15
23 8
27 26 25 17
21 5
*Refer to note 2.
21 4
W2 W1 V2 V1 U2 U1
27 26 25 20 18
12 10 11 9 11 9 54000-17491
29 Wiring, controller
28 54000-17483 Harness, controller
27 0000-00008 Nut
26 0000-70008 Washer, lock
25 0000-72008 Washer, plain
24 0077-04016 Screw, w/washer
18 24200-66340 Terminal Comp.
17 24200-63030 Terminal
16 24200-56850 Sensor comp., heat
Note
15 54000-19630 Capacitor Comp.
1. When installing a " 5 6 Module ,IGBT" to the " 1 Sink, heat", be sure to 14 54000-15680 Bar, lead(8)
apply condition compund[G-747] (Shin-Etsu silicones) to the entire 13 54000-15670 Bar, lead(7)
contact surface. 12 54000-14130 Bar, lead(4)
2. Insert washers in the " 17 terminal", as shown in Figure A, and then Maximum corrent 11 54000-14120 Bar, lead(3)
Applicable (IGBT rating) 2 Board comp., MPU 15 Capacitor comp.
installing the " 17 terminal", apply LOCTITE[242] or a similar material Part No. Type Remarks 10 54000-14110 Bar, lead(2)
models Travel Hydraulic Part No. Type Part No. Rating 9 54000-14100 Bar, lead(1)
to the screws to prevent looseness.
FB30-75 54000-19361-1 CU104-51 600A 600A 54000-20421 PBC104-01 54000-19630 100V 8 39530-02180 Sensor, current
3. Recommended tightening torque for the IGBT. STD (250V) (250V) 4700 F 7 54000-19610 Board Comp., IGBT
Main terminal(M6) and mounting(M6) : 3.5-4.5N.m(0.36-0.49kg.m) FB-U75 80V When installing, 6
54000-20731-1 CU104-52 54000-19620
4. Impress a Unit type to the specified position with undamped ink. Figure A STD 5600 F make sure the 5 35030-00790 Module, IGBT
5. Use the terminal bolt included for the "IGBT module" . FB30-75 100V arrow points up. 4 54000-19601 Bracket, board(2)
54000-19371-1 CU104-54 54000-20441 PBC104-03 54000-19630
6. In order to improve vibration resistance, apply to the "capacitor comp." OPT 4700 F 3 54000-20690 Bracket, board(1)
a silicone adhesive agent on the bottom to fix it into place. FB-U75 80V 2 Board Comp., MPU
54000-20991-1 CU104-55 54000-19620
OPT 5600 F 1 54000-15480 Sink, heat
FB-75 Main controller 4- 6.

FB10P-25P-U75/FB30P-75 4-6-2.
E0000-04281-1e
84
Reference: Panel, charger

Harness mark/color
Red RD <Note>
Black BK *Refer to note 6 1.Lead wire
Green GN Charger, microcomputer
Yellow YE Others :AV/AVS0.5mm2
Socket White WH
Be sure to put. BK
1 :F-KIV/KIV/LV 1.25mm2 /0.75mm2
GN Brown BN
Blue BU 2 RDYE <> :F-KIV/KIV/LV 2.0mm2
<4>
Gray GY Earth terminal BNBK 2.Terminal symbols
<GN>
RD Pink PK 3
Orange OG
4 :Tab 179462-3 or 170340-3
WH
Ex) BKWH (=Black/White) 5 WH :Contact, socket SLF-41T-1.3E
BK Black colored harness with White line. <RD> <1> RD
6
BKWH 3.Thermal relay setting value
7
AC 5 3 1 <WH> <2> Relay
3 8 Capacity Setting value
400V 9 YEBK 1 2 3
Thermal relay 5.2kVA 7.5A
<BK> <3> BNWH
10 6.4kVA 10.0A
White line
*Refer to 7.0kVA 11.0A
6 4 2 11 4 5 6
note 5
Socket 12 10.0kVA 15.0A
<WH>
<RD>
<BK>
Contactor 12.0kVA 18.0A

Black color
R U 4.Use pressed terminal without sleeve.
Transformer Thermal relay
S V *Refer to note 3. CA1-DC48V-N
Clamp with 5.Connecting wires around socket is as below figure.
Primary side (15A/20A/30A) Wire lead,
X Matsushita
T W socket wire ties. Screw
6PBK Eyelet
Wire
<WH>
WH
<RD>
<BK>
96 5 3 1
Plug
RD WH
Mctt 1 2 3
Terminal
4 5 6
BK
RD
RD
RD
WH
RDGN a.The bare part of the line should be 10–1mm
Fuse 95 6 4 2
(Viewed from the b.The tightening torque for the screws is 0.98-1.18N.m(10-12kgf.cm)
inserting side of the terminal)
<7>
<6>
<5>
<WH>
WH
<RD>
<BK>
10E6 X 6.Detail of connecting the earth terminal is as below figure.
Relay
<WH>
<RD>
<BK>
95 CA1-DC48V-N
Panel, charger
GN
RDBK
Key switch 1 3 5 13 A1 Receptacle
96 Harness, BC
YEBU
Charging interlock
RDYE Contactor
Battery +48
BKWH 2 4 6 14 A2
Battery GND
*Refer to note 7
BK
WH
RD
BNBK Ring terminal
Reserve charge start
WH
Install with a toothed washer and nut
YEBK
Reserve charge switch (You can not use a "washer, plain" or a "washer, lock")
RDYE
YEBK
BNWH
BKWH
BNBK
The ground terminal (GN) for the receptacle should be installed in

BK
WH
RD
the panel (as shown in the figure above).

After assembly, check for conduction between the ground terminal
and "bracket, panel".
7.The contactor terminal should be wired with the topside up,

1 2 3 4 5 6 7 8 9 10 11 12
as shown in the figure below.
Harness, charger(2)
Upper A1
1 2 3 4
BKWH
Plug housing
RDGN
RDYE
RDBK
YEBU
BNBK
YEBK
GND VB1 CST 1 3 5 13
JST 5 6 7 8
MC AC4 NB Mctt
9 10 11 12
Receptacle housing
JST
RSW DCR Transformer
2 4 6 14
Primary side
(Viewed from the inserting side of the terminal) 1 2 3 4 5 6 1 2 A2
Cap Cap (Matsushita)

6PBK 2PWH
Cap Cap
3 2 1 1
6 5 4 2
(Viewed from the inserting side of the terminal)
FB-75 BC wiring 4- 7.
400V 4-7-1.
24900-30280-0e
85
Reference:
Harness mark/color <Note>
Red RD 1.Lead wire
Black
Green
Yellow
BK
GN
YE
Panel, charger Others :AV/AVS0.5mm2
White WH
:F-KIV/KIV/LV 1.25mm2 /0.75mm2
Brown BN <> :Refer to below table.
Blue BU *Refer to note 6
Socket Gray GY Charger, microcomputer Lead wire F-KIV/KIV/LV F-KIV/KIV/LV
Pink PK Be sure to put. BK Capacity 3.5mm2 5.5mm2
GN Orange OG 1
2 RDYE 5.2 kVA
<RD> Ex) BKWH (=Black/White) <4>
Earth terminal
<GN>
BNBK 6.4/7.0 kVA
Black colored harness with White line. 3
<WH> RD 10.0/12.0 kVA
4
WH
<BK> 5
2.Terminal symbols
<RD> <1> 6
:Tab 179462-3 or 170340-3
AC 7 BKWH
3
White line <WH> <2> Relay :Contact, socket SLF-41T-1.3E
200V 8
Fuse YEBK 1 2 3
9 3.Using fuse
(15A/20A/30A) <BK> <3> BNWH
10 Fuse FA-6-15 FA-6-20 FA-6-30
*Refer to
<WH>
15A
<RD>
11 20A 30A
<BK>
Black color 4 5 6 Capacity

note 5
Contactor Socket 12 5.2 kVA
R U 6.4/7.0 kVA
<WH>
<RD>
<BK>
S V Transformer Wire, socket 10.0/12.0 kVA
T W
Primary side X CA1-DC48V-N
Matsushita 4.Use pressed terminal without sleeve.
Fuse Clamp with wire ties.
*Refer to note 3 6PBK 5.Connecting wires around socket is as below figure.
<WH>
<RD>
<BK>
(15A/20A/30A) Screw
Plug Eyelet
Wire
RD WH
Mctt
1 2 3
RDGN
Fuse 4 5 6
BK
RD
RD
RD
(Viewed from the Terminal
<7>
<6>
<5>
10E6 X inserting side of the terminal) a.The bare part of the line should be 10±1mm
Relay b.The tightening torque for the screws is 0.98-1.18N.m(10-12kgf.cm)
CA1-DC48V-N
<WH>
<RD>
<BK>
6.Detail of connecting the earth terminal is as below figure.
RDBK
Key switch Panel, charger
YEBU 1 3 5 13 A1 GN
Charging interlock Harness, BC Receptacle
RDYE
Battery +48 Contactor
BKWH
Battery GND 2 4 6 14 A2
BNBK
Reserve charge start *Refer to note 7
BK
WH
RD
WH
YEBK
Reserve charge switch Ring terminal
Install with a toothed washer and nut
BNWH
BKWH
RDYE
BNBK
YEBK
(You can not use a "washer, plain" or a "washer, lock")

BK
RD
WH
The ground terminal (GN) for the receptacle should be installed in

the panel (as shown in the figure above).
After assembly, check for conduction between the ground terminal
and "bracket, panel".
1 2 3 4 5 6 7 8 9 10 11 12
Harness, charger(2)
BKWH
RDGN
1 2 3 4
RDYE
RDBK
YEBU
BNBK
7.The contactor terminal should be wired with the topside up,
YEBK
Plug housing GND VB1 CST AC2
JST as shown in the figure below.
5 6 7 8
MC NB
Upper Upper A1
9 10 11 12 Transformer A2 A1
Receptacle housing
RSW DCR 1 3 5 13
JST Primary side 1 3 5 13
1 2 3 4 5 6 1 2
Mctt
(Viewed from the inserting side of the terminal) Mctt
Cap Cap
6PBK 2PWH 2 4 6 14
2 4 6 14
A2
Cap Cap For 5.2/6.4/7.0kVA For 10.0/12.0kVA
(Mitsubishi) (Matsushita)
3 2 1 1
6 5 4 2
(Viewed from the inserting side of the terminal)
FB-75 BC wiring 4- 7.
200V 4-7-2.
24900-29962-1e
86
<11>
<11>
<12>
Side A
<12>
Side B
Wire tie
Rectifier side Contactor unit side
(Note)
1.Wire length means the length to the tip of the wire.
The length of the bare section of the lead wire is
a=22mm2, and a=15mm for 30 or 38mm2.
L:Wire length
E0000-04520-0e
a a
FB10 10 330 10 400-

FB14 14 330 14 400-
Applicable models FB15 15 ALL
FB18 18 ALL 2.Refer to the figure below for the crimping direction.
and battery capacity
FB-75 FB20 20 -600 20 650- Crimping direction
FB25 25 -600 25 650-
FB28 28 -600 28 650-
FB30 30 ALL
Part No. 54000- 21170-0 21180-0 21190-0 21200-0 21210-0 3.Wrap red electrician’s tape around the B side of the
positive (+) terminal on the lead wire to indicate
22-S8 1912-04029 4 pieces polarity.(See the figure below)
Terminal 38-S8 37950-00840 4 pieces
Red electrician’s tape
Wire Side A Side B
Wire type Wire size Length Length Length Length Length Remarks
No. Terminal Mark Terminal Mark
Charger harness(1)
22-S8 *Note 4 + 22-S8 + LV 22 550
Connecting Rectifier
38-S8 *Note 4 38-S8 LV 30 550 550
<11> positive (+) side with
38-S8 *Note 4 38-S8 WCT 38 550 550 Contactor 4.Install a TCV cap on the A side terminal.
22-S8 *Note 4 - 22-S8 - LV 22 1750 The positive (+) side is red, and the negative (-) side
Connecting Rectifier
38-S8 *Note 4 38-S8 LV 30 1750 1800 is red, and the negative (-) side is blue.
<12> negative (-) side with
38-S8 *Note 4 38-S8 WCT 38 1800 1900 Unit
5.Wire No. <n> does not need to be indicated.
FB-75 Charger harness 4- 8.

4-8-1.
87
88
Wire color Wire color
:White :Black
Wire color
:Red
<13> <13>
Side A Side B
Transformer primary side Magnetic contactor side
E0000-04530-0e
FB10 10 ALL (Note)
FB14 14 ALL
FB15 15 ALL 1.Wire length means the length to the tip of the wire.
Applicable models FB18 18 ALL (See the figure below.)
FB-75 and battery capacity FB20 20 -600 20 650- L:Wire length
FB25 25 -600 25 650-
FB28 28 -600 28 650-
FB30 30 ALL
Part No. 54000- 21220-0 21230-0 21380-0 21390-0 2.The indicated wire length refers to the length of the red wire.
3.Refer to the figure below for the crimping direction.
Charger harness(2)
5.5-5 37910-01550 3 pieces
Terminal 5.5-S4X 37910-02170 3 pieces Crimping direction
R8-6 or an
equivalent product 37910-02270 6 pieces
Wire Side A Side B

No. Terminal Mark Terminal Mark
Wire type Wire size Length Length Length Length Remarks
4.Wire No.<N> does not need to be indicated.
5.5-5 5.5-S4X VCT(3pieces) 3.5 2700 2900
Connecting Transformer 5.Use R8-6 type terminal or an equivalent product.
5.5 2900 3150
<13> primary side with
R8-6 R8-6 VCT(3pieces ) 8
Magnetic contactor
FB-75 Charger harness 4- 8.

4-8-2.
FB30-75 Battery(72V)
Install on the
V N Revolving head guard
light
48V
VA NA
WH
BK
FB10-28-75 Battery(48V)
V N
Harness, accessory(1)
VA NA
VKF or VCTT
F5 Key switch 1.25mm2 2 pieces
10A Revolving
35W light
REV
X2 X1
F4
10A
WH
BK
24801-10760-1(75)e
RDWH
RDBK
BKWH
BNYE
BUYE
FB-75
RDWH
BKWH
1 2 3
System wiring
Reference: <Note>
Harness mark/color
Red RD
1.Terminal symbols
Black BK
Green GN
:Receptacle
Yellow YE
White WH
Brown
Blue
BN
BU
A’1Accessory
Gray GY
To harness, body
Pink PK
:Plug
Key switch interlock

Orange OG (with plating) AMP 170020-2
Ex) BKWH (=Black/White) Sleeve(for single wire) AMP 170897-1
White line
Black color
Wiring, revolving light 4- 9.

4-9-1.
89
90
Revolving Installed on the
V N A’2Accessory head guard
RDBK
RDWH
BNYE
light
48V
VA NA
WH
BK
RDBK
RDWH
BNYE
BKWH
BUYE
V N H Back buzzer
VA NA
1
Harness, revolving
VKF or VCTF
F5 Key switch PB100-90 1.25mm2 2 pieces
BNYE
10A Line Connector
No. CN Pin No. 1 1
X2 X1 A’1Accessory
F4 BURD
WH
BK
10A X3 OF2 1 9
BKWH
BN
YEBK
BNYE
BKWH
RDWH
BUYE
X4 OB2 1 10
Revolving
BNYE 35W light
REV Harness, body
X3
1G6
24801-10770-1(75)e
BN BNYE
BZ <Note>
X4 Back buzzer
BURD
1.Terminal symbols
BN
:Receptacle
Back lamp 1 :Receptacle 1
CN1-9
(without plating) AMP 170003-5 or AMP 170021-3
FB-75
RDBK
RDWH
BKWH
Sleeve(for double wire) AMP 170890-1 CN1
1 2 3 :Plug
4PWH 4PRD 4PWH 4PBK
(with plating) AMP 170020-2 1
System wiring 1 :Plug 6 5 4 3 2 1
X3 X1 X4 X7
Reference: (without plating) AMP 170002-5 or AMP 170020-3 12 11 10 9 8 7
Harness mark/color Sleeve(for single wire) AMP 170887-1 AMP.040 series multi-lock connector
Red RD Sleeve(for double wire) AMP 170888-1 175965-2
Black BK 1 :Receptacle AMP 173716-2 or AMP 175061-2
Green GN F Relay
Yellow YE 2.The location of the connector pin is as viewed from the inserting side. A MPU board
White WH 3.Clamp and fix the area where the "harness, body " and the "harness, revolving"
Brown BN
Blue BU is level to an appropriate area on the "harness, body".
Gray GY
Pink PK
Orange OG

White line
Black color

Forward/backward directional interlock 4-9-2.
Install on the
V N Revolving head guard
light
48V
VA NA
Battery(48V)
WH
BK
FB10-28-75
V N
VA NA
VKF or VCTT
F4 1.25mm2 2 pieces
10A
BN BN Back buzzer To rear combination lamp
Back lamp(25W)
(right)
X4
Revolving
WH
BK
BN 35W REV light
24801-10781-0(75)e
Water
resistant 6P
BKWH
RDBK
BN
BKWH
RDWH
BUYE
BNYE
FB-75
1 3
Reference:
System wiring
Harness mark/color
<Note>
Red RD 1.Terminal symbols
Black BK
Green GN :Receptacle
Yellow YE
White WH (with plating) AMP 170021-2
RDYE
GNWH
RDWH
BKWH
WHBU
BN
Brown BN
Blue BU Sleeve(for single wire) AMP 170889-1 16
Gray GY
Pink PK :Plug
Orange OG
To harness, body
(rear combination lamp)
White line
Black color

Backward directional interlock 4-9-3.

91
92
Working Installed on the Working
FB30-75 Battery(72V) lamp head guard lamp
V N
1 1 Harness, accessory 1 1
48V
BK
BK
VA NA WH WH
A'2 Accessory
RDBK
BUYE
BK BK
Harness, accessory
BK
BK
V N
Harness, accessory
WH
BK
RDBK
BUYE
RDWH
BKWH
BNYE
VA NA
F4 Harness, accessory
10A Working
BUYE 40W
WL
lamp W Operation switch Harness, switch
Working lamp switch VKF or VCTT
2P 1.25mm2 2 pieces
Working BK Laser pointer switch
40W lamp
WL
4P
Lamp switch
A'1 Accessory
WH
WH
BK
2P 2P
BK Connect BK
RDBK
BKWH
24801-10910-1(75)e
BUYE
BKWH
RDWH
BNYE
1 3 Switch Comp., toggle

System wiring
FB-75
Reference:
Harness mark/color Harness, body
Red RD
Black BK
Green GN
Yellow YE
White WH
Brown BN
Blue BU
Gray GY <Note>
Pink PK
1.Termial symbols
Orange OG
:Receptacle
Ex) BKWH (=Black/White) (with plating) AMP 170021-2
Black colored harness with White line. 1 :Receptacle
:Plug
1 :Plug
White line (without plating) AMP 170002-5 or AMP 170020-3
2.Clamp and fix the area where the "harness, body " and the "harness, revolving"
Black color is level to an appropriate area on the "harness, body".
Wiring, working lamp 4-10.

Reference:
Harness mark/color
Red RD
Black BK
Battery(72V) Green GN
FB30-75 Yellow YE
V N A'2 Accessory White WH
RDBK
RDWH
Brown BN
Blue BU
48V
VA NA Gray GY
Pink PK
Orange OG
RDBK
RDWH
BKWH
BUYE
BNYE
Chime Ex) BKWH (=Black/White)
V N H (back buzzer) Black colored harness with White line.
CHM
VA NA
1
Harness, buzzer
F5 Key switch PB100-90
BNYE
10A Line Connector
No. CN Pin No. 1 1 BNYE White line
X2 X1
F4 BURD
10A X3 OF2 1 9
BKWH
BN
Black color
YEBK
X4 OB2 1 10
24801-11000-1(75)e
BNYE BNYE
CHM
Harness, body
X3 Chime
1G6
BN
X4 <Note>
BN
1.Terminal symbols
BURD
:Receptacle
Back lamp (with plating) AMP 170021-2 1
CN1-9
1 :Receptacle
RDBK
BKWH
RDWH
Sleeve(for single wire) AMP 170889-1 CN1
1 2 3 Sleeve(for double wire) AMP 170890-1
4PWH 4PRD 4PWH 4PBK
:Plug 1
System wiring (with plating) AMP 170020-2 6 5 4 3 2 1
1
X3 X1 X4 X7
:Plug 12 11 10 9 8 7
AMP.040 series multi-lock connector
FB-75 Wiring, chime

175965-2
1 :Receptacle AMP 173716-2 or AMP 175061-2
Relay
Forward/backward chime
2.The location of the connector pin is as viewed from the inserting side. F AMPU board
is level to an appropriate area on the "harness, body".
4-11.
4-11-1.
93
94
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
FB30-75 Battery(72V) White WH
Brown BN
V N A’2Accessory Blue BU
RDBK
RDWH
Gray GY
48V Pink PK
VA NA Orange OG
Battery(48V) Ex) BKWH (=Black/White)

FB10-28-75 Black colored harness with White line.
RDBK
RDWH
BKWH
BUYE
BNYE
Chime
V N H (back buzzer)
BZ CHM
VA NA
1 1
Harness, chime Harness, accessory
BK
BK
F5 Key switch PB100-90
10A Connector White line
Line
No. CN Pin No. 1 1 1
X2 X1
F4 BURD
10A X3 OF2 1 9
BN
BKWH
BNYE
Black color
YEBK
OB2 1 10
24801-11010-1(75)e
X4
BNYE BNYE
CHM BK
Harness, body
X3 Chime
BN BN
BZ BK
X4 Back buzzer <Note>
BN
1.Terminal symbols
BURD
:Receptacle
Forward chime
Back lamp (with plating) AMP 170021-2 1
CN1-9
1 :Receptacle
RDBK
RDWH
BKWH
Sleeve(for single wire) AMP 170889-1 CN1
1 2 3 Sleeve(for double wire) AMP 170890-1
4PWH 4PRD 4PWH 4PBK
:Plug 1
System wiring (with plating) AMP 170020-2 6 5 4 3 2 1
1
X3 X1 X4 X7
:Plug 12 11 10 9 8 7
FB-75 Wiring, chime

Sleeve(for single wire) AMP 170887-1 175965-2
2.The location of the connector pin is as viewed from the inserting side. F Relay A MPU board
is level to an appropriate area on the "harness, body".
4-11.
4-11-2.
V N
48V Chime
VA NA H (back buzzer)
Battery(48V) CHM
FB10-28-75
V N
1 1
VA NA
BN
BKWH
F4
10A
BN BN CHM
X4 Chime
BN
24801-11020-0(75)e
Back lamp Harness, body
RDBK
BKWH
1 System wiring <Note> 3
Reference:
Harness mark/color 1.Terminal symbols
Red RD
1 :Receptacle
Black BK
Green GN
Yellow YE (without plating) AMP 170003-5 or AMP 170021-3
White WH
Brown BN Sleeve(for double wire) AMP 170890-1
Backward chime
Blue BU
Gray GY 1 :Plug
Pink PK
Orange OG (without plating) AMP 170002-5 or AMP 170020-3
Ex) BKWH (=Black/White) Sleeve(for single wire) AMP 170887-1
FB-75 Wiring, chime

White line
Black color
4-11.
4-11-3.
95
96
Left side of Right side of
FB30-75 Battery(72v) the head guard the head guard Only for the large
V N truck inspection License
48V
lamp
VA NA Clearance Head Head Clearance
lamp lamp lamp lamp 1
1
FB10-28-75 Battery(48V) WH
BK
V N 1 1 1 1 1 1 1 1
WH
BK
WH
BK
WH
BK
WH
BK
VA NA Turn signal Turn signal Harness, license(2)
lamp lamp
Key switch
WH
BK
F5 VKF or VCTF
WH
BK
Harness, clearance Harness, clearance
10A 1.25mm2 2 pieces
1 1 1 1 1 1 1 1
X2 X1
WH
BK
RD
GN
RD
GN
WH
BK
F4
10A
WH
BK
GNRD 25W To rear combination

Brake microswitch Tail & stop lamp lamp(right)
TL
Harness, head guard Harness, head guard
WHBU
BKWH*
10W
10W License lamp

LL VCT 0.5mm2 4 pieces VCT 0.5mm2 4 pieces Water
resistant 6P
25W
24801-11060-0(75)e
Tail & stop lamp
TL 4P 4P
10W WH WH
Harness, license(1)
10W Clearance lamp Water

CL resistant
6P
Right side
To harness, body To harness, body
40W HL (Left side of the head guard) (Right side of the head guard)
WHGN
To harness, body
Head lamp
WHBU
(Rear combination lamp)
40W HL
Left lamp
10W <Note>
Lamp switch CL
Clearance lamp 1.Terminal symbols
Reference:
BKWH*
:Receptacle
RDBK
RDWH
Harness mark/color
1 2 3 Red RD
1 :Receptacle Black BK
(without plating) AMP 170003-5 or AMP 170021-3 Green GN
System wiring Yellow YE
Sleeve(for double wire) AMP 170890-1 White WH
Brown BN White line
FB-75 Wiring, license

:Tab Blue BU
(with plating) AMP 170020-2 Gray GY
1 :Tab Pink PK
(without plating) AMP 170002-5 or AMP 170020-3 Orange OG
Sleeve(for single wire) AMP 170887-1 Black color
Sleeve(for double wire) AMP 170888-1 Black colored harness with White line.
4-12.
Large truck inspections, new small truck inspections 4-12-1.
Push switch Load sensor
FB30-75 Battery(72V) (same specifications as the horn switch) electric Ass'y Load sensor
V N (Indicator)
GN BN BN BN
48V
VA NA BK BN BN BN
Switch wiring
V N
Remove the Y terminal,
and connect with
RD
GN
PK
BK
VA NA plug and receptacle.
BN RD
Key switch Tape the ends
F5
RD BK GN
10A
GN Load sensor Load sensor PK
PK (Indicator)
X2 X1 BK BNBK OG electric Ass'y BK
F4 BK RD YE
10A
1A
BK
GN
PK
RD
P Display board
BN
BN
1A 1
YE RD
Load sensor BN 8 7 6 5 4 3 2 1
OG electric Ass'y BK 16 15 14 13 12 11 10 9

175966-2 When using optional specifications
BN
BN
for turning the overload buzzer on and off, A'2 Accessory
RDWH
BK
the switch should be inserted in this area.

CN1 (Refer to the specifications above.)
24801-11180-1(75)e
BN
BN
CN1-8
1
With switch
RDWH
BKWH
RDBK
BUYE
BNYE
FB-75
BNBK
Harness, load sensor
Harness, body
PB101-20
Line Connector
No. CN Pin No.
Analog type
BNBK SW7 1 8 <Note>
Overload
1.Terminal symbols
BKWH*
RDBK
RDWH
:Receptacle
1 2 3 (with plating) AMP 170021-2
System wiring Sleeve(for single wire) AMP 170889-1
:Plug
Reference: (with plating) AMP 170020-2
Harness mark/color
Red RD
Black BK Sleeve(for double wire) AMP 170888-1
Green GN
Yellow YE 2.The location of the connector pin is as viewed from the inserting side.
White WH
Brown BN White line 3.Clamp and fix the area where the "harness, body " and the "harness, revolving"
Blue BU is level to an appropriate area on the "harness, body".
Gray GY 4.Lead wire : AV or AVS 0.5mm2
Pink PK
Orange OG
Black color
Wiring, load sensor 4-13.

4-13-1.
97
98
V N
Digital load sensor
48V (Body)
VA NA
GN BK
V N
BK BK
RD RD
VA NA
3A
WH BNBK
F5 Key switch
10A
P Display board
X2 X1
F4
1
10A 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

175966-2
3A A’2Accessory
RD GN
Load sensor
RD
BK
WH electric Ass’y BK
CN1
CN1-8
1
RDWH
BKWH
RDBK
BUYE
BNYE
24801-11190-1(75)e
BNBK
PB101-20
Harness, load sensor
Line Connector Harness, body
No.
FB-75
CN Pin No.
BNBK
SW7 1 8 Overload
BKWH*
RDBK
RDWH
Digital type
1 2 3
System wiring
<Note>
Reference: 1.Terminal symbols
Harness mark/color :Receptacle
Red RD (with plating) AMP 170021-2
Black BK Sleeve(for single wire) AMP 170889-1
Green GN :Plug
Yellow YE
White WH
Brown BN Sleeve(for single wire) AMP 170887-1
White line
Blue BU Sleeve(for double wire) AMP 170888-1
Gray GY 1 :Receptacle AMP 173716-2 or AMP 175061-2
Pink PK
Orange OG
2.The location of the connector pin is as viewed from the inserting side.
3.The section that is connected from the digital load sensor to the display board, and
Black color
Ex) BKWH (=Black/White) the section that is parallel to the "harness, body" should be clamped properly to the
Black colored harness with White line. "harness, body" to secure them.
4.Lead wire : AV or AVS 0.5mm2
Wiring, load sensor 4-13.

4-13-2.
V N 1 1
BN RD RDWH RDWH
VA 48V NA Sensor, BU 2 2 BK BKWH BKWH

magnetic Controller
BK 3 3 WH Ass’y YE YE
FB10-28-75 Battery(48V) RDGN BN BN

V N <Wiring between the chassis and the mast>
BT-VCT 0.75mm2 3 pieces
Tape the ends. Harness, lift limit
VA (Make the length of the wiring as required.)
NA
RDBK
F5 Key switch
BUYE
10A
A’2Accessory BNYE
X2 X1 RDWH RDWH
F4
10A
BKWH BKWH*
W Operation switch
2P Laser pointer switch
BK
To valve microswitch
Sensor 4P Switch comp.,toggle(*Refer to note 3)
WH Lamp switch 6P
BK
RDGN
NO Valve
YE BN 2P 2P
X BK
Connect
BK X microswitch
Lifting height limit SW C NC
(for 1st stage) Relay Lifting height limit
HC4-HTM PB100-90
24801-11421-0(75)e
Connector SW for 1st stage 6P
Line BK
No. CN Pin No.
Harness, body
BK
HSN 4 16
BK BU BUWH
HS1 4 4
Lift 1 switch X-1 Relay
BK WH WHBU
HS2 4 12 HC4-HTM X
Lift 2 switch X-2 DC48V
(Matsushita)
RDBK
RDWH
Reference:
BKWH*
<Note> Harness mark/color
1 2 3 Red RD
System wiring 1.Terminal symbols
Black BK
:Receptacle Green GN
(with plating) AMP 170021-2 Yellow YE
Sleeve(for single wire) AMP 170889-1 White WH
Lift limit for 1st stage

:Plug Brown BN White line
(with plating) AMP 170020-2 Blue BU
Gray GY
Sleeve(for single wire) AMP 170887-1 Pink PK
2.Clamp and fix the area where the "harness, body" and the Orange OG
FB-75 Wiring, lift limit

"harness, lift limit" is level to an appropriate area on the Black color
"harness, body".
3.The "Switch comp., toggle" should be installed so that the lifting
height limit is signaled when the lever is swung to the side of the
plate marked "Lift height limit SW for the 1st stage" (the switch is
ON when the lever is pointing down).
4-14.
4-14-1.
99
2nd stage sensor 2nd stage unit
100
BN 4 4 RD RDWH RDWH
Sensor, BU 5 5 BK BKWH BKWH
V N magnetic Controller
BK 6 6 WH Ass’y YE YERD
VA 48V NA
RDGN BN BN
FB10-28-75 Battery(48V) Tape the ends.

<Wiring between the
V N 1st stage sensor chassis and the mast> 1st stage unit
BN BT-VCT 0.75mm2 RD RDWH RDWH
1 6 pieces 1
VA NA Sensor, BU 2 (Make the length of the 2 BK BKWH BKWH
wiring as required.) Controller
magnetic
BK 3 3 WH Ass’y YE YEWH
F5 Key switch
10A RDGN BN BN
X2 X1 Tape the ends. Harness, lift limit

F4
10A
W Operation switch RDBK
1st stage 2P BUYE

sensor BK Laser pointer switch
A’2Accessory BNYE
RDGN
NO RDWH RDWH
4P Lamp switch Switch comp., toggle(*Refer to note 4)
YEWH BN WH
X *Refer to note 3
Lifting height limit C NC BKWH BKWH*
SW for 1st stage Relay
1st stage unit HC4-HTM 2P 2P Lifting height limit
WH BK
Connect SW for 2nd stage
2nd stage
sensor
2P 2P Lifting height limit To valve microswitch
PB100-90 BK BK
RDGN Connect SW for 1st stage
24801-11431-0(75)e
NO
Line Connector
YERD BN 6P
No. CN Pin No.
Switch Comp., toggle(*Refer to note 4)
BK
Lifting height limit C NC
SW for 2nd stage Valve
2nd stage unit Relay
BK HC4-HTM X
X microswitch
HSN 4 16 DC48V
(Matsushita)
6P
BK BU BUWH BK
HS1 4 4
Lift 1 switch X-1
BK WH WHBU Harness, body
HS2 4 12
Lift 2 switch X-2
<Note>
RDBK
RDWH
BKWH*
1.Terminal symbols Reference:
1 2 3 :Receptacle Harness mark/color
System wiring (with plating) AMP 170021-2 Red RD
Black BK
Green GN
Sleeve(for double wire)AMP 170890-1 Yellow YE
:Plug White WH
Lift limit for 2nd stages

(with plating) AMP 170020-2 Brown BN
White line
Sleeve(for double wire)AMP 170888-1 Blue BU
FB-75 Wiring, lift limit

Gray GY
2.Clamp and fix the area where the "harness, body" and the Pink PK
"harness, lift limit" is level to an appropriate area on the Orange OG
"harness, body". Black color
3.Connect the black 2P connector for the head limit 2nd stage
switch to the white 2P connector on the "harness, body".
4.The "Switch comp., toggle" should be installed so that the
lifting height limit is signaled when the lever is swung to the
side of the plate marked "Lift height limit" (the switch is
ON when the lever is pointing up).
4-14.
4-14-2.
Seat heater
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE Accessory(front)
White WH
BUYE
RDWH
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG 1 1
WH
BK
BUYE
BKWH
BNYE5
RDWH
RDBK
Harness, accessory
White line
Operation switch
Harness, switch
Black color 2P VKF or VCTF1.25mm2 2 pieces

BK Laser pointer switch
24801-11740-1(75)e
4P
Accessory(rear)
System wiring
WH Lamp switch
FB-75
WH
BK
RDWH
2P
BK
BUYE
BKWH
RDWH
BNYE5
Switch comp., toggle
RDYE3
Seat heater
Harness, body
BKWH
<Note>
1.Lead wire: AV or AVS0.5mm2
2.Terminal symbols
1 :Sure plug AMP 170020-3 or 170002-5
:Sure plug AMP 170020-2
1 :Sure receptacle AMP 170021-3 or 170003-5
:Sure receptacle AMP 170021-2
Wiring, seat heater 4-15.

101
102
Rear lamp
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
White WH Accessory(front)
RDBK
RDYE
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG
1 1
WH
BK
BUYE3
BKWH
BNYE5
RDBK
RDWH
White line Harness, accessory

Operation switch
Harness, switch
Black color
2P VKF or VCTF 1.25mm2 2 pieces
BK Laser pointer switch
24801-11750-0e
System wiring 4P
Accessory(rear)
WH Lamp switch
WH
BK
RDBK
2P
BK
BUYE3
BKWH
RDWH
BNYE5
RDYE3
Rear lamp
Harness, body
BKWH
<Note>
1.Lead wire: AV or AVS0.5mm2
2.Terminal symbols
1 :Sure plug AMP 170020-3 or 170002-5
1 :Sure receptacle AMP 170021-3 or 170003-5
FB-75 Wiring, rear lamp 4-16.

Wire cutting and terminal connection is not
required between the junction box and the indicator. Junction box
Indicator DC/DC converter

Inside the indicator
Pulley
YE
RD 15
1 4
GN
14 BU Load
RDBK WH 2 4 13
WH 4
RD WH cell
4 3 1 12
Accessory(front) IN 4
WH WH RD
4 2 11
terminal BK 4 5 4
GN BU
BKWH BK 3
6 4
BU GN 4 RD
6
{ 7 4
YE YE
5 7
8
WH
BU Load
GN cell
9 YE
10
VKF 1.25mm2 2 pieces Wiring between the chassis and the mast ETFE 0.5mm2
24801-11760-1(75)e
Nylon hose
Reference: Make a spiral here.

Harness mark/color
Red RD Connect the lead wire to
Black BK the load cell.
Green GN
Yellow YE
White WH
Brown BN White line
Blue BU
Gray GY
Pink PK <Note>
Orange OG
1.Termial symbols
Ex) BKWH (=Black/White) Black color 4 :Terminal 1.25-4
FB-75 Wiring, FS
:Sleeve(for single wire) AMP 170887-1
(with plating)
4-17.
103
104
4P
WH RDWH
Controller, wiper
WHBU
Motor, Controller, 6P BU
wiper wiper RD To harness, head guard 2W
1 S
680
Motor,
wiper
BK
WHGN
Harness, wiper
GNBK
100W 63V
X1
30 1000 F
BKWH
GNRD
BU
RDWH
WHBU
RDWH
BKWH
X1
BKWH
24801-16840-0e
BU
System wiring
WHBU
BKWH
RDWH
RDWH
Wiper
Harness, wiper
To harness, body
accessory(front)
BU 1
Reference: WHBU 2
Harness mark/color RDWH 3
Red RD <Note>
Black BK
Green GN 1.Terminal symbols
Yellow YE
Key groove :Sure plug AMP 170020-2
White WH :Sure receptacle AMP 170021-2
Brown BN White line
Blue BU
Gray GY
Pink PK
FB-75 Wiring, wiper

Orange OG

4-18.
4-18-1.
RDWH
BK BKWH Controller, wiper
To harness, head guard
BKWH BKWH
To harness, body
RDWH RDWH accessory(front) WHBU
BU
Harness, wiper 2W
1 S
680
Motor,
wiper
WHGN
4P Switch comp., toggle
WH GNBK
BU 1
Motor, wiper 100W 63V
WHBU 2 X1
30 1000 F
RDWH 3 GNRD
Controller, wiper X1
24801-17450-0e
6P
Key groove BKWH
RD
System wiring
Reference:
Harness mark/color
Red RD
Black BK
Lower wiper
Green GN
Yellow YE
White WH
Brown BN
Blue BU
White line <Note>
Gray GY 1.Terminal symbols
Pink PK
Orange OG
FB-75 Wiring, wiper

4-18.
4-18-2.
105
106
PB100-90/93
2 Line Connector
No. CN Pin No.
RDWH
RDWH
BP 12 16 Valve solenoid power
GNRD
SOL4 B22 11 4 Tilt down
WHBU (Automatic fork leveling)
BC2 11 14
24900-31290-0e
RDBK HP1 4 1 Power supply
Tilt level GNRD Reference:
HD1 4 2 Signal Harness mark/color
potentiometer BKYE HN1 4 9 GND Red RD
Black BK
Green GN
Yellow YE
White WH
Brown BN
stop System wiring

Blue BU
Gray GY
BURD Pink PK
Fork leveling HS7 4 7 Auxiliary input 7
Orange OG
switch BK Ex) BKWH (=Black/White)

HSN 4 16 Switch GND Black colored harness with White line.
White line
Note) This diagram shows parts only relevant
FB-75 Automated fork horizontal

to the automatic fork leveling system. Black color
4- 19.
Reproduction prohibited
First printing : December 2003
Issued by : Nippon Yusoki Co., Ltd

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

Nichiyu Forklift FB10 30P 75 FB 75 Troubleshooting Manual 1 1

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Nichiyu Forklift FB10 30P 75 FB 75 Troubleshooting Manual 1 1

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CONTENTS

2-3-11. Display language check and adjustment 39

4-7. FB-75 BC wiring.....................................85

4-8. FB-75 Charger harness .........................87

4-9. FB-75 Wiring, revolving light..................89

4-10. FB-75 Wiring, working lamp.................92

11 Altered display cover figure

Altered side roller attaching structure

26 M mast using 2t type outer mast 4 Altered accelerator structure

¡ FB15P ¡ Made identical with potentiometer FBR-75

27 Enlarged mast's outer width 17 Enlarged opening angle on battery cover

5 Controlled travel/hydraulic vector

15 Strengthened front wheel covers 6 Type-VE controller

¡ Mono-blocked heat sink and base, mono-blocked gate board,

19 Reduced gear sound because of lowered backlash

¡ Improved software, hydraulic response

20 Improved brake because of altered wheel cylinders

¡ FB20P 12 Altered oil tank structure 8 Altered hydraulic motor's diameter

18 Altered to anti-loose knob on the cover

1- 2. FB-75 new features

<10-step indication (FB-75)>

discharging voltage and open voltage (10 minutes after)

5-step indication (existing machine) 10-step indication

The graph below shows the relation between discharging

It is as good as over-discharging lift interrupt option; the

Existing 5-step indication 10-step indication

1. Battery discharge indicator

2-1-2. Indication of display

The self-diagnosis function checks the control system

The normal screen is displayed.

NOTE If traveling or hydraulic operation is done while

displayed after finishing the initial monitoring

CAUTION Contact to your local Nichiyu dealer if the error

Mode setting buttons

Setting screen by one touch operation

Mode select screen

Hour meter screen

2-1-3. Function of display

NOTE Icons of 8 to 14, and 16 shown in the illustration

1. Battery discharge indicator

CAUTION Do not over-discharge.

Full Charge the battery immediately

Discharge Discharge Discharge Discharge

¡Lift interrupt (Option)

One red segment is started to flash.

2. Slow speed mode monitor (Turtle mark)

3. Fork horizontal indicator (Option)

5. Reserve charge indication (Option)

6. Date and time (Calendar and clock)

7. Hour meter Total key-on hours

CAUTION The hour meter screen is returned to the normal

traveling or hydraulic function.

When the screen displays the odometer, the word of

8. Safety monitor (for travel circuit)

9. Safety monitor (for hydraulic circuit)

10. Safety monitor (for steering circuit)

11. Safety monitor (for brake fluid level)

NOTE When [name of a damaged part] or " REFILL 221T027E

FORK OIL " is lit, please contact the your local

12. Safety monitor (for battery electrolyte

13. Safety monitor (for overloading)

14. Safety monitor (for hydraulic oil)