INTRODUCTION

4Most accident happens due to the disregard of basic safety rules or

precautions. In order to prevent accidents from happening, the factors
responsible for accidents must be avoided beforehand.
For this reason, please read this manual and fully understand the
precautions for safety and the proper procedures and directions for
inspection and maintenance before starting operation.

Performing maintenance and repair without adequate knowledge may

cause inadvertent accidents.

4It is not possible to cover all the possible cases of accidents in this
"TROUBLESHOOTING MANUAL". Therefore, attention should
be given to precautions other than the ones mentioned in this
"TROUBLESHOOTING MANUAL". Especially, when repair and
maintenance work which are not covered in this "TROUBLESHOOTING
MANUAL" are carried out, always work under the direction of an
instructor who understands the matter.
 Using this "TROUBLESHOOTING MANUAL"
This manual has information about the layout and names of main components, procedures for
disassembly, assembly, inspection, adjustment, maintenance, and hints for troubleshooting which are in
effect mainly for the model FBRF-75 .
Since the parts used in this machine are subject to change for the sake of better quality, performance
enhancement and safety, some portions of the contents and illustrations of this "TROUBLESHOOTING
MANUAL" may not be identical.
Directions with and marks are very important, and must be followed.

Indicates a potentially hazardous situation which, if not avoided,

DANGER could result in death or serious injury.
You must follow this instruction.
Indicates a potentially hazardous situation which, if not avoided,
WARNING could result in death or serious injury.
You must follow this instruction.
Indicates a potentially hazardous situation which, if not avoided,
CAUTION may result in minor or moderate injury.
You must follow this instruction.
Indicates suggestions, tips and hints related to the safety of a
NOTE
operator and maintain of truck.

1. Personnel this "TROUBLESHOOTING MANUAL" is aimed at:

This "TROUBLESHOOTING MANUAL" is directed at personnel who possess sufficient knowledge
and technical expertise. If you do not understand any of the contents of this "TROUBLESHOOTING
MANUAL", perform operation under the guidance of personnel who does.

2. Conditions of a facility
The work conditions described in the "TROUBLESHOOTING MANUAL" are written on the assumption
that the work is performed at a standard work facilities and tools for the maintenance of NICHIYU
ELECTRIC LIFT TRUCKS are available.
For safe and reliable maintenance, the work should be performed at a shop which is equivalent to these
described in this "TROUBLESHOOTING MANUAL" with following all instructions strictly.

Copyright© 2010
NIPPON YUSOKI CO., LTD.
All Rights Reserved
 CONTENTS

1. Basic setting 1 3. Troubleshooting 58

1-1. Explanation of the monitor display............... 1 3-1. Self diagnosis function............................... 58
1-1-1. Indicator panel 1 3-1-1. Display 58
1-1-2. Indication of display 2 3-1-2. Error messages and Display conditions 60
1-1-3. Function of display 3 3-1-3. Servicing data 62
1-1-4. Various kinds of mode selection 10 3-1-4. Electrical failures when no error code is
1-2. Explanation of the MPU board................... 15 displayed 63
1-2-1. Basic control board construction 15
1-2-2. MPU board (Travel/ Hydraulic board) 15
1-2-3. EPS controler (EPS/DSP board) 16
4. Other electric check and adjustment 64
1-2-4. MPU board setting 17
1-2-5. EPS controler setting 18 4-1-1. Hour meter working check 64
4-1-2. Chassis insulation check 64
1-2-6. Adjustment Standards List 4-1-3. Display brightness check and adjustment 65
for FBRF-75 series 20 4-1-4. OIS (Operation Interlock System)
working check 66
4-1-5. Valve electric current adjustment 68
4-1-6. Safety circuit for control
2. Various setting and adjustment 21
(contactor tripping) check 70
2-1. Setting with MPU board and 4-1-7. Foot switch working check 71
the monitor display..................................... 21 4-1-8. Checking the function of neutral safety 71
2-1-1. Model setting 21 4-1-9. Lift interrupt working check 71
2-2. Setting with EPS controler and 4-1-10. Cooling fan working check [Fan(1)] 72

the monitor display..................................... 22

4-1-11. Checking the function of battery tray interlock 72
4-1-12. Checking the function of auto power off 72
2-2-1. Display monitor symbol (icon)
check and setting 22
2-2-2. Steering setting check and adjustment 23
2-2-3. Switch back (plugging/ regenerative) braking 5. O
 peration procedures for truck
force adjustment 25 with AOS 73
2-2-4. Regenerative braking force check and
adjustment 26 5-1. Operation procedures................................ 73
2-2-5. Hydraulic speed setting and adjustment 27 5-1-1. Joystick operation 73
2-2-6. Optional function check and setting 29 5-1-2. Automatic lifting stop operation 74
2-2-7. Display of voltage, current and temperature 31 5-1-3. A/B rack switching 77
2-2-8. Current detector check 32 5-1-4. Lifting height limit mode switching 77
2-2-9. Accelerator potentiometer adjustment 36 5-1-5. Storing the stop position 78
2-2-10. Brake potentiometer adjustment 38 5-1-6. Stop (emergency stop) operation 82
2-2-11. I/O check 40
2-2-12. Hydraulic lever (joystick)
adjustment and check 44
2-2-13. Error history memory 1 46
2-2-14. Error history memory 2 47
2-2-15. Battery voltage calibration 49
2-2-16. Turning speed reduction setting 50
2-2-17. AOS setting (OPTION) 51
2-2-18. Clearing the error history memory
(memory initialization) 57
6. Wiring (Diagrams) 83
6-1. FBRF-75 System wiring............................ 83
6-2. FBRF-75 Body wiring................................ 84
6-3. FBRF-75 Body harness (1)....................... 85
6-4. FBRF-75 Body harness (2)....................... 86
6-4-1. FBRF14/16/20-75 (Std) 86
6-4-2. FBRF14/16/20-75 (CS/FCS) 87
6-5. FBRF-75 Floor harness............................ 88
6-6. FBRF-75 Switch harness.......................... 89
6-7. FBRF-75 Body harness (AOS)................. 90
6-8. FBRF-75 Body harness comp.. ................ 91
6-8-1. FBRF14/16/20-75 (4 spools) 91
6-9. FBRF-75 Main controler. .......................... 93
6-10. FBRF-75 Controller Wiring...................... 94
6-11. FBRF-75 Controler Harness. .................. 95
6-12. FBRF-75 Lead wire (for main controler). 96
6-13. FBRF-75 Wiring PS. ............................... 97
6-14. FBRF-75 Harness PS............................. 98
6-15. FBRF-75 Lever panel wiring................... 99
6-16. FBRF-75 Lever panel harness.............. 100
6-17. FBRF-75 Lever harness
(for 4spools (5way-piping)...................... 101
6-18. FBRF-75 Wiring, chime/buzzer............. 102
6-19. FBRF-75 Wiring, light............................ 103
6-20. FBRF-75 Wiring, head lamp. ................ 104
6-21. FBRF-75 Harness, head guard............. 105
 1. Basic setting
1- 1. Explanation of the monitor display
1-1-1. Indicator panel
Monitor display

2 14 15 16 17 18 19

1 3 4 5

9 11 12 13

7 10 8
Mode select switch

20
152T0100

1. Battery discharge indicator

2. Safety monitor for battery
3. Travel mode monitor
4. Travel speed meter
5. Fork leveling indicator (Special option)
6. Wheel indicator
7. Slow speed mode monitor (Turtle mark)
8. Clock
9. Hour meter
10. Service (spanner) mark
11. Safety monitor for travel circuit
12. Safety monitor for hydraulic circuit
13. Safety monitor for power steering circuit
14. Safety monitor for overload (Special option)
15. Safety monitor for hydraulic oil level (Special option)
16. Safety monitor for battery tray interlock
17. Safety monitor for hydraulic lever
18. Safety monitor for travel
19. Safety monitor for OIS (Operation Interlock System)
20. Mode select switch

NOTE Icons of 10 to 19 and 2 shown in the illustration are displayed for the explanation.
It is not actual indication. They are displayed when abnormalities are occurred.

 1 Basic setting

1-1-2. Indication of display

Turn on the key switch. When the key switch is turned on.

After 0.5 seconds

The self-diagnosis function checks the control system
and display "MONITORING OK" when no problems are
found. Icons of "Read operator's manual" are flashed
three times for warning to the operator. After 1.5 seconds

The normal screen is displayed.

If any abnormalities are detected, the error message and
After 1 seconds
/ or icon is displayed.

NOTE If traveling or hydraulic operation is done while

system checking for the first 3 or 4 seconds after
Flashed 3 times
turning on the key switch, the normal screen is Normal screen

displayed immediately.

CAUTION Contact to your local Nichiyu dealer if the error

152T002
code is displayed.

Mode select switch

NOTE If travel/hydraulic operation is done while the

mode setting, the display is returned to the normal
screen. 152T003

Setting screen by one touch operation

Clock setting screen

Push button. lll Refer the page 4. for details.
For setting of date and time.

Mode select screen

l Travel mode setting
l Slow speed mode setting
Push button for more l Hour meter / odometer / lll Refer to each setting section.
than 3 seconds. lifting height selection
l Display brightness setting
l Regenerative brake setting
l Time setting

Hour meter screen

l Three hour meters of traction,
Push one of or . lll Refer the page 5. for details.
hydraulic and the total hour are
displayed.


 Basic setting 1

1-1-3. Function of display

This forklift truck has the self-diagnosis function.

2 14 15 16 17 18 19

1 3 4 5

9 11 12 13

7 10 8

20
152T0100

NOTE Icons of 10 to 19 and 2 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 shortened by over-dis-
charging.
Charge the battery as soon as possible when all
green segments are disappeared.

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 green one red segment is flashed with the
segments are disappeared outline of the gauge.
and two red segments stay on. When the capacity is empty, only the
outline of the gauge is flashed. 121T190E


 1 Basic setting

2. Lift interrupt Two red segments are lit.

When all green segments are disappeared and two red

segments are lit, the lift speed is reduced by half.
At the same time, safety monitor symble of battery Lift speed is reduced to half.
flashes on the screen. One red segment
is started to flash.
When the truck is continued to use, only one red
segment is started to flash and the lift function is
interrupted.
Lift function is interrupted.
321S004

3. Travel mode
The current traveling mode is displayed on the screen.
Refer to the page 10 for details.
152T0113

4. Speed meter
The traveling speed is displayed on the screen.

152T0114

5. F o r k l e v e l i n g i n d i c a t o r ( S p e c i a l
option)
This mark is indicated when the fork is leveled.
152T0115

6. Wheel indicator
The current direction of the drive wheel is indicated.

152T007

7. Slow speed mode monitor (Turtle mark)

When the turtle button is pushed, the turtle mark is
indicated on the screen with the preset speed.
152T0116

8. Clock
The current time are displayed. If the button is
pushed for less than 3 seconds, the display is changed
152T009
to the meter mode setting screen. Refer to the page 12
for details.


 Basic setting 1

9. Hour meter Total key-on hours

The hour meter shows the total hours of turning on the Normal screen

key switch. (The actual operating hours can be displayed

as option.)
It is useful to know the total operating hours for the
After 5 seconds,
daily job management and scheduling of the periodical Push the normal screen
or is displayed.
inspection.
Hour meter screen

When pushing or button, each individual

hours for travel, hydraulic and total are displayed for 5
seconds. Total traveling distance
Total hydraulic hours
The normal screen and hour meter screen are changed Total traveling hours
Total key-on hours
by turn by pushing or button.
Actual operating hours
After 5 seconds, the normal screen is displayed. Option

The odometer or lifting height meter (option) can be

displayed in the normal screen instead of hour meter.
Refer the meter mode setting in the setting mode 152T0117

section.

CAUTION The hour meter screen is returned to the normal

screen even less than 5 seconds by operating
traveling or hydraulic function.


 1 Basic setting

10. Service icon

The service icon warns the fault of the forklift truck to an
operator. If any faults are detected, the spanner mark is
152T013
flashed and error number is displayed. If some problems
are occurred at the same time, each error numner is
displayed.

NOTE l If the following abnormalities and/or errors

o c c u r, t r a v e l , h y d r a u l i c s a n d E P S a r e
interlocked.
*Only the error number is displayed, and the
message is not displayed.
B11 - B13 : Traction U,V,W-phase FET
C21 - C23 : Hydraulic U,V,W-phase FET
D30 - D34 : EPS error
G61 : Traction current error
G62 : Hydraulic current error
l The , and buttons are disabled
while the self-diagnosis screen is displayed. lEPS controler

l If rotary switch RS1 on the EPS controler is F01

set to F, the self-diagnosis screen will not

CDE

23
456
be displayed. (The normal screen will be
AB
789
displayed.)
l When the abnormalities and/or errors are RS1="F"

resolved, the display will return to the normal

screen.


 Basic setting 1

11. Safety monitor (for travel circuit)

When fault is detected in the travel circuit, the travel icon
flashes and the presumed error number is displayed.
152T014

12. Safety monitor (for hydraulic circuit)

When fault is detected in the hydraulic circuit, the
hydraulic icon flashes and the presumed error number is
152T0118
displayed.

13. Safety monitor (for power steering circuit)

When fault is detected in the power steering circuit, the
steering icon flashes and the presumed error number is
152T016
displayed.

14. Safety monitor (for overload)

(Special option)
When overloaded, the load icon flashes.
152T017

15. Safety monitor (for hydraulic oil level)

(Special option)
If the hydraulic oil level is low, the icon flashes.
152T018

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.

16. Safety monitor (battery tray interlock)

If the pedal is not depressed fully in the battery pull-in
or pull-out operation, the battery icon is flashed and the
152T019
hydraulic function does not work.


 1 Basic setting

17. Safety monitor (for hydraulic lever)

If the key switch is turned on with operating any hydraulic
levers, the hydraulic lever icon is flashed and the
152T021
hydraulic funciton does not work.

18. Safety monitor (for travel)

If the key switch is turned on with depressing the
accelerator pedal, the parking brake icon is flashed and
152T022
the truck does not run.

19. S afety monitor for OIS (Operator Interlock

System)
This system interlocks traction and hydraulic functions if 152T0101

the operator does not stand on the floor plate correctly.

If the operator leaves the driver's compartment while
operating the truck, the OIS icon flashes to warn to the
operator. If that situation is continued for more than 2
seconds, the buzzer beeps and all functions of traveling
and hydraulics are interlocked. If the operator stands on
the floor plate correctly within 2 seconds, the interlock
does not activate and traveling and hydraulic functions
are not interrupted.

NOTE l Even if the interlock is activated, the power

for the motor is shut off but the brake is not
applied. So, the truck keeps coasting. If the
interlock is activated on a slope, the truck may
be rolled back.
l When the interlock is activated, the hydraulic
function will be started after 1 second if the
operator sits on the seat with operating a
hydraulic lever.


 Basic setting 1

20. Mode select button

Change the screen to each mode by pushing these
buttons.

Slow speed mode button

The slow speed mode is activates by pushing this button.

Slow speed mode Mode select button

button
Normal traveling mode (When the slow speed button is 152T0119

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)

Preset speed indication

The turtle icon and preset speed are displayed on the
screen.

l If the value of the slow speed mode is preset, the When the slow speed button is on
maximum traveling speed can be changed in the ( Turtle mark is displayed)
152T0120

normal mode and slow speed mode by pushing the

turtle button.


 1 Basic setting

1-1-4. Various kinds of mode selection

[1] Travel mode setting
[2] Slow speed mode setting
[3] Meter mode setting
[4] Display brightness setting
[5] Regenerative (Neutral) brake setting
[6] Time setting

CAUTION l These settings are invalid while traveling or

depressing the brake pedal.
l If traveling or hydraulic operation is done
while setting, the display is returned to the
normal screen immediately.

When pushing button (less than 3 seconds), the

mode selection screen is displayed. If pushing button
again, the next setting screen is displayed. 152T003

Mode select button

NOTE When setting the mode of next [1] to [5] , each
button works as below.
l and buttons : Move the cursor to select
the value.
l button : Move the cursor to the previous item.

[1] Travel mode setting Normal screen

This screen is used to set the travel mode.

Make sure that the current traveling mode indication is

Travel mode preset indication
flashed. Push or to select the mode.
Push
After selection, push button to move the cursor to the button
slow speed setting. Travel mode setting
The traveling mode can be set to the next three modes.

E (ECONOMY)
This mode is convenient for the slow speed inching. Set the travel mode.
This mode saves the battery energy consumption also.
Push
button
N (NORMAL) To the setting of slow speed mode
This is the normal traveling mode. The quick acceleration 152T0121

and smooth inching can be realized.

P (POWER)
10 This is the most powerful mode for acceleration.
 Basic setting 1

[2] Slow speed mode setting Slow speed mode setting

This mode sets the limited maximum travelling speed

under the slow speed mode.

Set the value

Make sure the turtle button is pushed and the turtle
Push
icon is flashed. Then, push or button to set the button
speed. To the setting of meter mode
The maximum speed can be set to 8 steps of 2, 3, 4, 5, 152T025

6, 7 and 8km/h.
After setting, push button to move the cursor to the
meter mode setting.

[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"
Select the meter mode.
(hour meter) or "TIME" (clock) or "km" (odometer) or
Meter mode setting (option)
"LIFT" (lifting height meter)(Option for AOS or Lifting
height indicator) can be selected by pushing or
button.
After selection, push button to move the cursor to the Select the meter mode.
display brightness setting.
Push
The display is switched from the normal screen to the button
meter mode screen by pushing or button. The To the display brightness setting screen
meter mode screen has 3 (4 - Option) kinds. Refer next 152T026

page for details.

11
 1 Basic setting

Normal screen and meter mode screen

Normal screen
In the case of the clock (TIME) mode In the case of the odometer (km) mode
Current time Total traveling distance

In the case of the hour meter (HR) mode In the case of the lifting height meter (LIFT) mode
(Option)
Total key-on hours Current lifting height

Push Push
or or or
or after 5 seconds.

Confirmation screen

Total traveling distance

Total hydraulic hours
Total traveling hours
Total key-on hours

* The normal screen is displayed even within 5 seconds

when the traveling or hydraulic operation is done.
152T0122

[4] Display brightness setting Display brightness setting screen

This mode sets the brightness of the screen.

Make sure that the cursor is located on the brightness

Set the brightness
setting area. Push or button to select the
brightness for the best. It can be selected 7 steps Push
button
(from 0 to 7).
To the setting mode of regenerative
After setting, push button to move the cursor to the brake
152T027
regeneration (Neutral) mode setting,

NOTE Refer the table below for the brightness settings.

BRIGHTNESS (Intensity of back light)

0 7
Dark Bright

12
 Basic setting 1

[5] Regenerative (Neutral) brake setting Setting mode of regenerative brake

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 Set the regenerative braking force
when releasing the accelerator pedal
strength.
Push
The braking strength can be set to 4 steps of "NON" (No button
braking), "LOW", "MID" (Middle) and "HIGH". Return to the normal screen.
152T028

NOTE It is set to "MID" (Middle) as default.

After setting, push button to return to the normal

screen.

[6] Time setting Normal screen

When the button is pushed for more than 3 seconds,

the time setting screen is displayed.
Push button to move to the next screen (AM / PM,
Push button
hour, minute). Push button three times to return to for more than
3 seconds.
the normal screen.

CAUTION l If traveling or hydraulic operation is done

while setting, the display is returned to the
AM / PM is flashed.
normal screen immediately. 152T029

l Each time pushing and buttons, the

second is reset at 0.
l When the minute is set and button is
pushed, the second is reset at 0.

When pushing button (more than 3 seconds), the

mode selection screen is displayed. If pushing button
again, the next setting screen is displayed.

NOTE When setting the mode of next [1] to [3] , each

button works as below.
l and buttons : Move the cursor to select
the value.
l button : Move the cursor to the previous
item.

13
 1 Basic setting

1. Set the AM or PM
Push or button to select the AM or PM.
After setting, push button to move the cursor to the
Set "AM" or "PM".
hour area.
Push
button
152T030

2. Set the hour

Push or " button to set the hour. The hour
can be set from 1 to 12.
Set the hour
After setting, push the button to move the cursor to
Push
the minute area. button
152T031

3. 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
152T032

After setting, push the button.

Then “TIME COMPLETE” message is flashed three
times.
"TIME COMPLETE" is flashed three times.

CAUTION l When pushing the or button, the

second is set to "00". Return to the normal screen.
152T033
l After setting the minute and push the
button, the second is set to "00".

14
 Basic setting 1

1- 2. Explanation of the MPU board

1-2-1. Basic control board construction
As shown in the figure below, the SICOS-AC uses the
EPS controler 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 (MPU board)

Display unit Switch board

Traction
CPU for travel Gate board
motor

EPS controler

Hydraulic
CPU for hydraulic Gate board
motor
EPS motor

152T123

1-2-2. MPU board (Travel/ Hydraulic board)

<Type : PBC109-XX>
l This board controls the traction motor and the
hydraulic motor.

[RS1] : Rotary switch for model selection

Controler harness

(LIFT) (VR1)
(TILT) (VR2)
Proportional
valve adjustment
CN1 CN2/H

(ATT1) (VR3)
(ATT2) (VR4)
(REACH) (VR5)
(PV)
(P15)
(P6)
(P15) 15V power supply
(HYD)
(TRV) (P6) 6V power supply
CN3

CN10 CN9
HYD TRV

Hydraulic CPU drive

Travel CPU drive
CN4/T

CN5 CN6 CN7 CN8 CN11 CN12

Board comp., FET

Connector for personal computer
Body harness(1)
152T0103

15
 1 Basic setting

1-2-3. EPS controler (EPS/DSP board)

<Type : PB103-XXX>
l This board controls sharing the data with other boards,
the screen display and EPS motor.

(P7) 7V power supply

Connector for
[RS1] : R
 otary switch for personal computer
monitor selection

PB103-xxx 21
0F
P7

ED
43

CB
CPU

65
A9

CN4
87

(CPU) CPU drive

CN2
Body harness(1)

CN1
FET

CN3
AOS switch box
(option)

152T0104

<Normal condition while turning on the key switch>

Board LED Condition

P15 lighting
P6 lighting
MPU board
HYD flashing
TRV flashing

<Normal condition while connecting the battery plug>

Board LED Condition

CPU flashing
EPS controler
P7 lighting

CAUTION l When the MPU board or EPS controler

are replaced, specification such as model
setting and option setting has changed. After
replacement of the board, adjust the settings
in accordance with this manual.
l In case of changing the settings for the rotary
switches, be sure to turn off the key switch
once before changing them.

16
 Basic setting 1

1-2-4. MPU board setting

<Rotary switch (RS1) setting: Truck model selection>
The rotary switch (RS1) on the MPU board is used for truck model selection.
When replacing the MPU board, be sure to refer to the table below to match it with the truck
model.

RS1 Applicable forklift models

0 FBRF14
1 FBRF16
2 FBRF20
3-F Not used

<Dip switch (DS1) setting: Truck specification setting>

DS1 is not used.

<Volume setting: Proportional control valve current adjustment>

Volume No. Function Remarks

LIFT Lift proportional control valve Turning the volume clockwise decrease the
(VR1) current adjustment current. Lift-up 0.7A ±0.02A
TILT Tilt/Side shift proportional Turning the volume clockwise decrease the
(VR2) control valve current adjustment current. Tilt-up 0.7A ±0.02A
ATT 1 Auxiliary proportional control Turning the volume clockwise decrease the
(VR3) valve current adjustment current.
ATT 2
Not used
(VR4)
REACH Reach proportional control Turning the volume clockwise decrease the
(VR5) valve current adjustment current. Reach-in 0.7A ±0.02A

17
 1 Basic setting

1-2-5. EPS controler setting

The rotary switch (RS1) on the EPS controler is used for changing display and setting of
various functions in the table below.

<Rotary Switch (RS1) setting>

RS1 Functions Contents Page
MONITORING OK Displayed when key switch is ON. P.2
Battery discharge indicator, Travel speed, Hour
Normal monitor screen P.3
meter, Error, Clock
Reading of hour meter counter
Hour meter check P.5
(Total, Travel and Hydraulic)
Date / time setting screen Setting of date and time P.13
Setting of maximum speed in slow speed mode (2,
Slow speed mode setting P.11
0 3, 4, 5, 6, 7, 8, km/h)
Travel mode setting Selecting travel mode (Economy, Normal, Power) P.10
Selecting of meter indication
Hour meter / odometer setting P.11
(Hour meter or Odometer)
Setting of brightness of the display screen
Display mode setting P.12
(0-7: back light adjustment)
Neutral (accelerator OFF) Selecting neutral regeneration mode
P.13
regeneration mode setting (Non, Low, Mid, High)
Setting of monitor symbol
1 Monitor symbol setting P.22
(STEER, BATT, OIL, LOAD, BRAKE)
Setting of drive wheel turn angle, steering wheel
2 EPS mode setting turning number and steering mode (standard/ P.23
reverse)
Setting of plugging (switch back) brake strength
Plugging strength setting P.25
3 (0-32)
Brake strength setting Setting of regenerative brake strength (0-32) P.26
Setting of hydraulic speed
Hydraulic response P.27
(S(Slow) / N(Normal) / Q(Quick))
Lift speed limitation 1 setting: Setting of lift speed limitation (0-32):
P.27
Low travel speed Travel speed 0-4 km/h
Lift speed limitation 1 setting: Setting of lift speed limitation (0-32):
P.27
Middle travel speed Travel speed 4-8 km/h
Lift speed limitation 1 setting: Setting of lift speed limitation (0-32):
4 P.27
High travel speed Travel speed 8km/h over
Lift speed setting Setting of lift speed (0-32) P.28
Tilt speed setting Setting of tilt speed (0-32) P.28
Reach speed setting Setting of reach speed (0-32) P.28
Side shift speed setting Setting of side shift speed (0-32) P.28
Auxiliary 0 - 32 (Fast) P.28
5
6 Option setting Setting of optional functions P.29
7 Status check Checking of voltage, motor current, transistor temperature P.31

18
 Basic setting 1

RS1 Functions Contents Page

Accelerator potentiometer setting Adjustment of accelerator potentiometer P.36
Brake potentiometer setting Adjustment of brake potentiometer P.38
8 RAM and I/O memory data check P.40
Adjustment and checking of hydraulic lever
Hydraulic lever (joystick) check P.44
(joystick)
Error history memory 1 check Checking of error history (latest 10 cases) P.46
9
Error history memory 2 check Checking of error history (all past cases) P.47
A Battery voltage setting Voltage settings for capacity standards P.49
Turning speed reduction 0 - 16 P.50
B
Turning angle setting 15, 30, 45, 60, 75, 90 P.50
C AOS setting Setting of lift end / tilt end and other settings <Option> P.51
D
E Memory initializing Initializing error history memories. P.57
F Normal screen 2 No errors are displayed on the screen P.59

19
20
RS1 on EPS controller
Confirmation
1 Basic setting

RS1 on 4 3 1
Voltage Model MPU
[V] board HYD SPD-L SPD-M SPD-H HYD HYD HYD HYD HYD PLUGG BRAKE Travel speed Lift speed
RESPONSE LIFT LIFT LIFT LIFT TILT REACH SIDE ATTAT ING TRQ TRAVEL HYD STEER BATT OIL LOAD BRAKE (km/h) (mm/sec)
FBRF14 0 N 32 26 20 32 10 14 5 0 32 32 12.0/12.0 370/560
48V FBRF16 1 12.0/12.0 370/560
FBRF20 2 12.0/12.0 300/460
3-F Not used

�Memory initial (RS1=E) �Option setting (RS1=2)

Slow speed (turtle speed) : 5km/h
DRIVE : 360 [360 degree turning]
Travel mode : NORMAL
STEERING : 10-20 [Steering wheel turning number
BRIGHTNESS :5
Neutral regenerative brake : MID standard - maximum]
Meter mode : HR (hour meter) STEERING : RVS [Reverse steering]
Error history : Clear

�Option setting (RS1=6)

LIFT LOCK : ON [Lift interrupt]

SPEED LIMIT : OFF [Speed limit at high lifting height]
AOS : OFF [With AOS]
H-DSP : OFF [Lifting height indicator]
HOUR METER :1 [Hour meter count]

* HOUR METER (hour meter count) setting

1: Key SW linked indication
2: Actual operation time indication
1-2-6. Adjustment Standards List for FBRF-75 series
 2. Various setting and adjustment
CAUTION l Even if the key is turned off, battery voltage
is still supplied to the board (EPS controler
and MPU board). Disconnect the battery plug
before performing this work.
l After finishing the setting, be sure to return
F01
rotary switch RS1 to "0".

CDE

23
456
l Before measuring current, change the mode

AB
789
depending on the objects.
Traction motor current Return RS1 to "0".
AC mode
Hydraulic motor current
Battery current
DC mode
EPS motor current
l When measuring the electric current by the
current tester, measure the motor current in
AC mode and the battery current in DC mode.

2- 1. Setting with MPU board and the monitor display

2-1-1. Model setting
<Checking procedure>
1. Keep pressing button, button and button
together for more than 3 seconds.
2. The following screen appears.
3. Confirm that the model type is set correctly.
4. Push button to return to normal screen.

l Forklift model type checking screen

l MPU board
(In case of rotary switch for model selection on the
MPU board is set to "1") F01
CDE

23
456
AB

789

Set RS1 to "1"

152T034

Refer "1-2-4. MPU board setting" for details.

21
 2 Various setting and adjustment

2- 2. Setting with EPS controler and the monitor display

2-2-1. Display monitor symbol (icon) check and setting
<Checking procedure> lEPS controler
1. Set rotary switch RS1 on the EPS controler to "1".
F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
3. Confirm that the parameter items are set to the same Set RS1 to "1".
as the values on the "Adjustment Standards List" on
page **.

l Monitoring symbol setting screen

TRAVEL

HYD

STEERING

OVER LOAD (Option)

FORK OIL (Option)

152T0112

<Adjusting procedure>
1. Push button to move the flashing icon to the each
item.
2. Push button to turn the item "ON". lEPS controler
3. Push button to turn the item "OFF".
4. Turn off the key switch and return rotary switch RS1 to "0". F01
CDE

23
456
AB

5. Turn on the key switch again. 789

It indicates the symbols set to "ON" at the monitoring
Return RS1 to "0".
symbol setting screen.

152T059

22
 Various setting and adjustment 2

2-2-2. Steering setting check and adjustment

<Setting procedure> lEPS controler
1. Set rotary switch RS1 on the EPS controler to "2".
F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
Set RS1 to "2".
l Drive unit mode

Parameter of drive unit mode

flashes.
lSet by pushing or button
152T060 (180 degree / 360 degree).

NOTE Normaly, turn angle of drive unit is 360 degree.

Only for trucks with drive stopper is selected 180
degree.

l Turn number of steering <Std>

Parameter of turn number of
steering <Std> flashes.
lSet by pushing or button
(8-16).
Default: 10
152T061

l Turn number of steering <Max>

Parameter of turn number of
steering <Max> flashes.
lSet by pushing or button
(12-30).
Default: 20
152T062

NOTE The turn number of steering wheel for 360

degree turn of the drive unit changes according
to the truck travel speed.
When the truck travel speed is under 4km/h, the
turn number of the steering <Std> is applied.
When the truck travel speed is over 12km/h, the
turn number of steering <Max> is applied.
When the truck travel speed is from 4 to 12km/h,
the turn number of steering changes from <Std>
to <Max>.

(To the next page)

23
 2 Various setting and adjustment

(From the previous page)

l Steering mode

Setting of steering mode flashes.

Set by pushing
l or button
(NML <Normal steering> / RVS
152T063
<Reverse steering>).
Normal steering Reverse steering

Return to drive unit mode setting screen

<Steering and travel direction>

Control Steering direction Forward Backward

Clockwise

RVS

Reverse
(Standard) Counterclockwise

Clockwise

NML

Normal
(Option) Counterclockwise

<Adjusting procedure>
1. Push button to move the flashing icon to the each
item.
2. Push either or button to turn the value you
want to set.

24
 Various setting and adjustment 2

2-2-3. Switch back (plugging/ regenerative) braking force adjustment

<Measuring conditions>
l Flat ground, unladen, and full speed
l Specific gravity of the battery electrolyte : 1.25 or over
(at 20°C)­

<Adjusting procedure> lEPS controler

1. Set rotary switch RS1 on the EPS controler to "3".
F01

CDE

23
456
AB
789
2. Turn on the key switch and the following screen
appears. Set RS1 to "3".

l Plugging strength setting screen

Setting of plugging strength flashes.

Set by pushing
l or button
(0-32).

152T055

To braking strength setting screen

3. Confirm that the "PLG" parameter is flashing.

NOTE If the PLUGGING parameter is not flashing, push

button to move the cursor on the PLUGGING
parameter.

4. Push button to increase the braking force.

5. Push button to decrease the braking force.

<Standard parameter>
l Refer to the Adjustment Standards List on page 18.

25
 2 Various setting and adjustment

2-2-4. Regenerative braking force check and adjustment

<Checking procedure>
1. Select the "NON" at the regenerative brake setting.
Refer to "[5] Regenerative (neutral) brake setting" on
page 12.

152T057

2. Travel forward in a moderate speed.

3. Release the accel pedal and depress the brake pedal
lightly.
4. Confirm that braking force (regenerative brake) is
applied lightly.
5. After checking, re-select the "MID" at the regenerative
brake setting.

<Adjusting procedure> lEPS controler

1. Set rotary switch RS1 on the EPS controler to "3".
F01
CDE

23
456
AB 789
2. Turn on the key switch and the following screen
appears. Set RS1 to "3".

l Braking strength setting screen

Parameter of braking strength

flashes.
lSet by pushing or button
152T0201
(0-32).

To plugging strength setting screen

3. Push button to move the flashing icon to the "BRK"

parameter.
4. Push button to increase the braking force
(regenerative brake).
5. Push button to decrease the braking force
(regenerative brake).

26
 Various setting and adjustment 2

2-2-5. Hydraulic speed setting and adjustment

<Checking procedure> lEPS controler

1. Set rotary switch RS1 on the EPS controler to "4". F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
3. Confirm that the parameter items are set to the same Set RS1 to "4".

as the values on the "Adjustment Standards List" on

page **.

l Hydraulic response speed setting screen

Setting of hydraulic response
flashes.
lSet by pushing or button.
S: Slow
N: Normal
152T046
Q: Quickly

l Lifting speed setting screen by the travelling speed

When the cursor is flashing at this

l
position, the lifting speed for the
travelling speed range "0~4 km/h"
can be adjusted.
Push or button to change
152T0202 the speed. (0-32)

When the cursor is flashing at this

l
position, the lifting speed for the
travelling speed range "4~8 km/h"
can be adjusted.
Push or button to change
152T0203 the speed. (0-32)

When the cursor is flashing at this

l
position, the lifting speed for the
travelling speed range "8~ km/h"
can be adjusted.
Push or button to change
152T0204 the speed. (0-32)

(To the next page)

27
 2 Various setting and adjustment

(From the previous page)

When the cursor is flashing at this
l
position, the second (top) lifting
speed can be adjusted when the
lift lever is pulled fully.
Push or button to change
the speed. (0-32)
152T0205

NOTE If the speed setting value is different

from values in the first 3 screens in
the previous page, the smaller value
is prior to larger ones.

The parameters flash.

Set TILT hydraulic speed by
l
pushing or button (0 - 32).
152T0206

The parameters flash.

Set REACH hydraulic speed by
l
pushing or button (0 - 32).

152T207

The parameters flash.

Set SF (side shift) hydraulic speed
l
by pushing or button
(0-32).
152T0208

The parameters flash.

Set attachment speed by pushing
l
or button (0-32).

152T0209

Return to Hydraulic response setting screen

<Adjusting procedure>
1. Push button to move the flashing icon to the each
parameter.
2. Push button to increase the parameter.
3. Push button to decrease the parameter.

28
 Various setting and adjustment 2

2-2-6. Optional function check and setting

<Checking procedure> lEPS controler
1. Set rotary switch RS1 on the EPS controler to "6".
F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
3. Confirm that the options are set correctly. Set RS1 to "6".

l Optional setting screen

Parameter of LIFT LOCK flashes.

Set by pushing
l or button
(ON/OFF).

Parameter of SPEED LIMIT flashes.

Set by pushing
l or button
(ON/OFF).

Parameter of AOS flashes.

Set by pushing
l or button
(ON/OFF).

Parameter of LIFTING HEIGHT

DISPLAY flashes.
Set by pushing
l or button
(ON/OFF).

Parameter of HOUR METER

flashes.
lSet by pushing or button
152T064
(ON/OFF).

29
 2 Various setting and adjustment

Standard
Optional setting mode Remarks
setting
Lift locks when only one red segment is left
LIFT LOCK Lift interrupt ON
on battery discharge indicator.
SPEED LIMIT High lift height OFF Need to install the switch for detecting.
AOS OFF ON : Equipped with AOS function.
LIFTING HEIGHT ON : Equipped with Lifting height indicator
OFF
INDICATOR function
1 : Key switch ON
HOUR METER 1 2 : Actual operation time
(motor operation time)

<Adjusting procedure>
1. Push button to move the flashing icon to the each
item.
2. Push or button to turn the item "ON", "OFF"
or "1", "2".

30
 Various setting and adjustment 2

2-2-7. Display of voltage, current and temperature

It is possible to check the voltage, current and temperature of
traction, hydraulic and EPS circuit.

<Checking procedure> l EPS controler

1. Set rotary switch RS1 on the EPS controler to "7".
F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
3. Push either or button, and select TR (traction) Set RS1 to "7".
/HY (hydraulic) /PS (power steering).

l Voltage, current, and temperature checking screen.

152T0215

BV : Battery voltage (common)

MC : Each the motor current
BT : MPU board temperature (common)
TT : Each the module (FET) temperature

4. After the checking, set rotary switch RS1 to "0".

31
 2 Various setting and adjustment

2-2-8. Current detector check

Traction motor current check
<Measuring point>
IU: traction motor U phase electric current (V phase or
W phase is also possible.)

<Measuring conditions>
Specific gravity of the battery electrolyte : over 1.25 at 20

<Measuring instrument>
Alternating current (AC) mode
Traction motor U phase
Digtal clamp
Battery plug Control unit ammeter
-
+

<1>
TU
<7>

<8>

8 325A 8 CN12 CN11 CN8CN7 CN6CN5

<2>
TV

CN1 CN2/H CN3 CN4/T

<3>
8 TW
Contactor Board comp., MPU
F+
<4>
HU
<5>
HV
<6>
HW
8
NA

2P
White Harness, controler
12P
10A
10A

10A

Harness, body (1)

Wire, load (to motor) 152T0105

CAUTION When measuring AC motor current, use the lDigital high tester
recommended ammeter below:
Recommended ammeter : RANGE
Hioki 3209 AC/DC high tester (Digital)
<PROCEDURE>
1. Push [MODE] button 2 times, and change the
mode to AC + DC. SAMPL
2. Push [RANGE] button 2 times, and change the MODE
range to H.
3. Push [SAMPL] button 1 time, and change the 281W0101

response mode to SLOW.

4. Measure motor current.

32
 Various setting and adjustment 2

<Checking procedure> l EPS controler

1. Set rotary switch RS1 on the EPS controler to "7".
F01

CDE

23
456
AB
789
2. Turn on the key switch and the following screen
appears. Set RS1 to "7".

NOTE If "TR" is not flashing, push or button

to make it flash.

l Voltage, current, and temperature checking screen.

Setting of TR (Traction) flashes.

Display
Battery voltage (travel CPU detection)
Traction motor current.

152T0210

Setting of TR (Traction) flashes.

Display temperature of MPU board.

152T0211

3. Not depressing the accelerator pedal, check if the

traction motor current (MC) shows 000A.

4. Jack up the drive wheel and depress the accelerator

pedal fully.

5. At this condition, check if the traction motor current

(MC) shows a traction motor current (IU) meter value
within ±20A

33
 2 Various setting and adjustment

Hydraulic motor current check

<Measuring point>
IU: hydraulic motor U phase electric current (V phase or
W phase is also possible.)

<Measuring conditions>
Specific gravity of the battery electrolyte : over 1.25 at 20

<Measuring instrument>
Alternating current (AC) mode

Battery plug Control unit

-
+

<1>
TU Hydraulic motor
<7>

<8>

8 325A 8 CN12 CN11 CN8CN7 CN6CN5

<2> U phase
TV

CN1 CN2/H CN3 CN4/T

<3> Digtal clamp
8 TW
Contactor Board comp., MPU ammeter
F+
<4>
HU
<5>
HV
<6>
HW
8
NA

2P Harness, controler
White
12P
10A
10A

10A

Harness, body (1)

Wire, load (to motor)

152T0106

CAUTION When measuring AC motor current, use the lDigital high tester
recommended ammeter below:
Recommended ammeter : RANGE
Hioki 3209 AC/DC high tester (Digital)
<PROCEDURE>
1. Push [MODE] button 2 times, and change the
mode to AC + DC. SAMPL
2. Push [RANGE] button 2 times, and change the MODE
range to H.
3. Push [SAMPL] button 1 time, and change the 281W0101

response mode to SLOW.

4. Measure motor current.

34
 Various setting and adjustment 2

<Checking procedure> l EPS controler

1. Set rotary switch RS1 on the EPS controler to "7".
F01

CDE

23
456
AB
789
2. Turn on the key switch and the following screen
appears. Set RS1 to "7".

3. Push either or button to make HY flash.

l Voltage, current, and temperature checking screen.

Setting of HY (Hydraulic) flashes.

Display
Battery voltage (Hydraulic CPU detection)
Hydraulic motor current.

152T0212

Setting of HY (Hydraulic) flashes.

Display temperature of FET module.

152T0213

4. Not operating the lift lever, check if the hydraulic motor

current (MC) shows 000A.

5. Pull the lift lever (lift up) fully until lift relief position (lift
stroke end).

6. At this lift relief current, check if the hydraulic motor

current (MC) shows a hydraulic motor current (IU)
meter value within 20A.

35
 2 Various setting and adjustment

2-2-9. Accelerator potentiometer adjustment

<Adjusting procedure> lEPS controler
1. Set rotary switch RS1 on the EPS controler to "8".
F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
Set RS1 to "8".

l RAM . I/O selection

Current device flashes.

Select "I/O" by pushing
l or
button.

l CPU selection

Current CPU flashes.

Select "TR" by pushing
l or
button.

l Data length setting

Current data length flashes.

Set "W"(double-byte) by pushing
l
or button.

l Data address setting

"0" flashes. (not variable)

"0" flashes. (not variable)

152T075

(To the next page)

36
 Various setting and adjustment 2

(From the previous page)

The data address (single-byte high) flashes.

l Set "1" by pushing or button.

The data address (single-byte low) flashes.

l Set "2" or "4" by pushing or
button.

l I/O data W0012 : output voltage 1

W0014 : output voltage 2

I/O data is displayed.

152T125

Return to RAM . I/O selection

3. Push , or button to select "I/O", "TR", and

"W0012" or "W0014".
(Refer to "2-2-11. I/O check" on page 40 for setting.)

4. Adjust the potentiometer by loosing the screw. (Refer

I/O data
to "WORKSHOP MANUAL".)
released position : 008F
The applicable "I/O data" is the following range.
(Accelerator pedal position : release - full) full position : 0398

NOTE When the error message "B15" (ACCELERATOR)

is occurred or replacing the accelerator
potentio-meter, perform the voltage adjustment,
surely.
Use this I/O check as a confirmation.

<Voltage adjustment>
Refer to "WORKSHOP MANUAL".

37
 2 Various setting and adjustment

2-2-10. Brake potentiometer adjustment

<Adjusting procedure> lEPS controler
1. Set rotary switch RS1 on the EPS controler to "8".
F01

CDE

23
456
2. Turn on the key switch and the following screen

AB
789
appears.
Set RS1 to "8".

l RAM . I/O selection

Current device flashes.
l Select "I/O" by pushing or button.

l CPU selection

Current CPU flashes.

l Select "TR" by pushing or button.

l Data length setting

Current data length flashes.

l Set "W"(double-byte) by pushing or
button.

l Data address setting

"0" flashes. (not variable)

"0" flashes. (not variable)

152T075

(To the next page)

38
 Various setting and adjustment 2

(From the previous page)

The data address (single-byte high)

flashes.
lSet "1" by pushing or
button.

The data address (single-byte low)

flashes.
lSet "6" by pushing or
button.
l I/O data

I/O data is displayed.

152T076

Return to RAM . I/O selection

3. Push , or button to select "I/O", "TR", and

"W0016".
(Refer to "2-2-11. I/O check" on page 40 for setting.)

released position
4. Adjust the potentiometer by loosing the screw. (Refer I/O data
to "WORKSHOP MANUAL".) 01E0
The applicable "I/O data" is as follows at the released
position of brake pedal. 0220

NOTE When the error message "B17" (FOOT

BRAKE) is occurred or replacing the brake
potentiometer, perform the voltage adjustment,
surely.
Use this I/O check as a confirmation.

<Voltage adjustment>
Refer to "WORKSHOP MANUAL".

39
 2 Various setting and adjustment

2-2-11. I/O check

lEPS controler
1. Set rotary switch RS1 on the EPS controler to "8".
F01

CDE

23
456
AB
2. Turn on the key switch the following screen appears. 789

3. Push button to enter the I/O check mode. The "I/O"

Set RS1 to "8".
icon will flashes.

l RAM . I/O selection

lCurrent device flashes.
Select "I/O" by pushing
l or
button.

l CPU selection
The I/O icon is highlighted.
lThe current CPU flashes.
Push either
l or button to
select a CPU.
TR : Travel
HY : Hydraulic
l Data length setting PS : EPS

The I/O icon is highlighted.

The selected CPU is highlighted.

The W(double-byte) flashes. (not

l
variable)

l Data address setting

The I/O icon is highlighted.
The selected CPU is highlighted.

l"0" flashes. (not variable)

The I/O icon is highlighted.

The selected CPU is highlighted.

l"0" flashes. (not variable)

(To the next page)

40
 Various setting and adjustment 2

(From the previous page)

The I/O icon is highlighted.

The selected CPU is highlighted.

The data address (single-byte

l
high) flashes.
Push either
l or button to
set the data address (0-F).

The I/O icon is highlighted.

The selected CPU is highlighted.

The data address (single-byte low)

l
flashes.
Push either
l or button to
set the data address (0-F).

l I/O data
I/O data is displayed.

lThe current data address is displayed.

The I/O data is displayed.

152T086

Return to RAM • I/O selection

41
 2 Various setting and adjustment

I/O check table

Reference value
Port Address Default Check location Operation
Changed
value
7E8F Foot switch Foot switch ON
778F Brake switch Brake pedal ON
IO TR W0004 7F8F
7FAF Forward directional switch Forward directional switch ON
7FCF Reverse directional switch Reverse directional switch ON
2BFD Forward directional switch Forward directional switch ON
2BFE Reverse directional switch Reverse directional switch ON

IO TR W0006 2BFF Forward directional switch ON /

2AFD Accelerator (forward)
Accelerator ON
Reverse directional switch ON /
2AFE Accelerator (reverse)
Accelerator ON
W0012 0000 0300 Accelerator potentiometer Full accelerator Range of change
IO TR
W0014 0000 0300 Accelerator potentiometer Full accelerator "0000-0398" H
Range of change
IO TR W0016 0200 0000 Brake potentiometer Full brake
"0000-0280" H
IO HY W0004 F3DF F39F Battery interlock switch Battery interlock switch ON
67FF Battery interlock switch Battery interlock switch ON
37FE Lift lever ON / lift-up
Lift lever potentiometer
37FD Lift lever ON / lift-down
3FF7 Tilt lever ON / tilt-up
Tilt lever potentiometer
IO HY W0006 27FF 36FF Tilt lever ON / tilt-down
37EF Reach lever ON / reach-in
Reach lever potentiometer
37DF Reach lever ON / reach-out
35FB SF lever ON / shift of right
SF lever potentiometer
35F7 SF lever ON / shift of left
No operation
0200 (standard value
"0200±20=01E0-0220"H)
Lift lever operation : Range of change
IO HY W0012 0200 0080 Lift lever potentiometer Full lever operation / "0040-03C0" H
lift-down
Lift lever operation :
0370 Full lever operation /
lift-up

Conteinued on the next page.

42
 Various setting and adjustment 2

Reference value
Port Address Default Check location Operation
Changed
value
No operation
0200 (standard value
"0200±20=01E0-0220"H)
Tilt lever operation :
IO HY W0022 0200 0080 Tilt lever potentiometer Full lever operation /
tilt-down
Tilt lever operation :
0370 Full lever operation /
tilt-up
No operation
0200 (standard value
"0200±20=01E0-0220"H)
Reach lever operation Range of change
IO HY W0024 0200 0080 Reach lever potentiometer : Full lever operation / "0040-03C0" H
reach-out
Reach lever operation
0370 : Full lever operation /
reach-in
No operation
0200 (standard value
"0200±20=01E0-0220"H)
SF lever operation :
IO HY W0026 0200 0080 SF lever potentiometer Full lever operation /
right end
SF lever operation :
0370 Full lever operation /
left end
IO PS W0006 0075 007D Turtle (slow) switch Turtle (slow) switch ON
00EF "+" switch "+" switch ON
IO PS W000C 00FF
00DF "-" switch "-" switch ON
00[0/1] 00[0/1]4 Steering left operation
IO PS W0010 EPS encoder
[4/C] 00[0/1]C Steering right operation
Note : I/O data display uses hexadecimal notation.
Operating the accelerator lever or any hydraulic lever (switch) from the I/O check screen causes
the truck to operate.

43
 2 Various setting and adjustment

2-2-12. Hydraulic lever (joystick) adjustment and check

<Adjusting procedure 1 (I/O check)>
lEPS controler
1. Set rotary switch RS1 on the EPS controler to "8".
F01

CDE

23
2. Turn on the key switch and the following screen

456
AB
appears.
789

Set RS1 to "8".

l RAM . I/O selection

Current device flashes.
lSelect "I/O" by pushing or
button.

l CPU selection

Current CPU flashes.

lSelect "HY" by pushing or
button.

l Data length setting

Current data length flashes.

lSet "W"(double-byte) by pushing
or button.

l Data address setting

"0" flashes. (not variable)

"0" flashes. (not variable)

152T075

(To the next page)

44
 Various setting and adjustment 2

(From the previous page)

The data address (single-byte high)

flashes.
lSet "1" or "2" by pushing or
button.

The data address (single-byte low)

flashes.
lSet "2", "4" or "6" by pushing
or button.
l I/O data

I/O data is displayed.

152T124

Return to RAM . I/O selection

3. Push , or button to select "I/O", "HY" and to
set the data address.
The data address of each joystick is as follows.
(Refer to "2-2-11. I/O check" on page 40 for setting.)
Joystick Data address neutral position

Lift W0012 I/O data

Tilt W0022 01E0
Reach W0024
0220
Side shift W0026

4. Confirm that the applicable "I/O data" is as follows at

the neutral position of each joystick.
Joystick
(potentiometer)

<Adjusting procedure 2 (Voltage check)>

1. Disconnect the 3P plug and insert the adaptor for
3P
measuring the voltage by tester. Adaptor for measuring
2. Turn on the key switch to apply 5V power supply to the
potentiometer.
281T0103

3. Measure the output voltage between white[WH] line

and black[BK] line by the tester.
Tester
4. Confirm that the output voltage is 2.5±0.1V at the
WH
RD

BK

neutral position of each joystick.

lever panel
Harness,

Tester pole (-)

Tester pole (+)
45
 2 Various setting and adjustment

2-2-13. Error history memory 1

<The 9 most recently detected errors/ abnormalities>
1. Set rotary switch RS1 on the EPS controler to "9". lEPS controler
2. Turn on the key switch and the following screen
F01
appears.

CDE

23
456
AB
789

NOTE l To view less than the 9 most recent errors/

abnormalities, place the blinking cursor on the Set RS1 to "9".

last error/abnormality and press button to go

to "Previously detected errors/abnormalities".
l If there are no errors/abnormalities, press
button to go to "Previously detected errors/
abnormalities".

l The 9 most recently detected errors/abnormalities l Error/abnormality details

Number of times the error/abnormality
The most recent error/abnormality blinks as "A01".
occurred when it was detected

152T087 152T088

­Error/abnormality detection total key-on hours.

The second error/abnormality blinks as "G65".

152T089 152T090

152T091
152T092

The ninth error/abnormality blinks as "E40".

The next page is "Previously detected errors/abbnormalities (1)"

46
 Various setting and adjustment 2

2-2-14. Error history memory 2

<Previously detected errors/abnormalities (1)>
l Rotary switch RS1 on EPS controler : 9 lEPS controler

F01
NOTE l If there are no previous errors/abnormalities

CDE

23
displayed in the list, press button to go to

456
AB
789
"Previously detected errors/abnormalities (2)".
l If the same error/abnormality was detected Set RS1 to "9".
multiple times previously, the data of the
most recent detection will be displayed under
"Error/abnormality details".
l Blinking : Indicates the position of cursor.
Highlighted : Only highlighted numbers are
memorized as error items.

l Previously detected errors/abnormalities (1) l Error/abnormality details

The previous page is "The 9 most recently detected errors/

abnormalities".
Number of times the error/abnormality
occurred when it was detected

152T0216 152T094

­Error/abnormality detection total key-on hours.

l Previously detected errors/abnormalities (2)

152T0218 152T096

The next page is "Previously detected errors/abnormalities (3)".

47
 2 Various setting and adjustment

<Previously detected errors/abnormalities (4)>

l Rotary switch RS1 on EPS controler : 9 lEPS controler

F01
NOTE

CDE

23
If the same error/abnormality was detected

456
multiple times previously, the data of the most

AB
789
recent detection will be displayed under "Error/
abnormality details". Set RS1 to "9".

l Previously detected errors/abnormalities (3) l 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 number display

152T098
152T0219

­Error/abnormality detection total key-on hours.

l Previously detected errors/abnormalities (4)

152T0220
152T100

Refer "2-2-17. Clearing the error history memory

(memory initialization)" for clearing all error history.

48
 Various setting and adjustment 2

2-2-15. Battery voltage calibration

The battery voltage calibration is required when
replacing the EPS controler to activate the battery
discharge indicator correctly.

<Preparation>
l Pull out the battery and set the digital tester to
measure the battery voltage.
Depending on the model setting, display for 24V or
48V is automatically selected.
(Apply the positive (+) prove to the positive terminal of
the battery.)
(Apply the negative (-) prove to the negative terminal
of the battery.)
l The specific gravity of the battery electrolyte should
be more than 1.25 at 20 . (It means that you need to
use the fully charged battery for this calibration.)

<Calibration procedure>
1. Set rotary switch RS1 on the EPS controler to "A". l EPS controler

F01

CDE

23
2. Turn the key switch ON and the following screen

456
AB
appears.
789

l Battery voltage setting screen Set RS1 to "A".

152T039

Battery Voltage Parameter (flashing)

3. Set the parameter for battery voltage to the same

value as the actual battery voltage measured by the
tester.

NOTE The allowance is within 0.1 V.

lPush button to increase the parameter.

lPush button to decrease the parameter.

49
 2 Various setting and adjustment

2-2-16. Turning speed reduction setting

<Setting procedure> lEPS controler
1. Set rotary switch RS1 on the EPS controler to "B".
F01

CDE

23
456
AB
2. Turn on the key switch and the following screen 789
appears.
Set RS1 to "B".
l Turn speed setting screen

Parameter of turn speed flashes.

Set by pushing
l or button
(0-16).
152T0217
Default : 5km/h

CAUTION In case that the turn speed is set over the truck
maximum speed, this function does not work.

l Turn angle setting screen

Parameter of turn angle flashes.

Set by pushing
l or button
(15/30/45/60/75/90 degree).
152T071
Default : 45 degree

Return to turn speed setting screen

l Push the button to increase the parameter.

l Push the button to decrease the parameter.

NOTE As t he tur n angl e m eans t h e dr ive w h e el Forward

direction from the forward (backward) direction
where this function starts working, this function
does not work in case of setting 90 degree
( =90). deceleration deceleration

Backward 152T072

50
 Various setting and adjustment 2

2-2-17. AOS setting (OPTION)

In case that the truck is equipped AOS (Advanced
AOS switch box
Operation System) or Lifting height indicator as an
optional extra, this initial setting is necessary.

NOTE The optional setting of "AOS" or "H-DSP" is

necessary to display the following screen.
(Refer to "1-3-**. Optional function check and
setting", ** page.)

152T0111

lEPS controler
<Adjusting procedure>
1. Set rotary switch RS1 on the EPS controler to "C". F01

CDE

23
456
AB
789

2. Turn on the key switch and the following screen

Set RS1 to "C".
appears.
3. Push either or or button to move the
flashing icon to the each item.
4. Push either or button to turn the value.

l P/M mast selection

Select "M" by pushing

l button.

l Maximum lift height

Set the maximum lift height of the

truck by pushing or button.
Ex.) in case of maximum lift height
6500mm
only for trucks with AOS

(To the next page) 152T073

51
 2 Various setting and adjustment

This initial setting is necessary only for AOS with tilt

horizontal. (special option)

(From the previous page)

l Tilt setting screen (tilt down)

Setting of tilt potentiometer flashes.

152T111
lCurrent tilt position is displayed.
Push the tilt lever fully.
(Tilt down the fork fully)

Tilt lowest position is displayed.

Keep on pushing button.

Value of the tilt lowest position is set.

Release button.

152T074

(To the next page)

52
 Various setting and adjustment 2

(From the previous page)

l Tilt setting screen (tilt up)

Setting of tilt potentiometer flashes.

152T112
lCurrent tilt position is displayed.
Pull the tilt lever fully.
(Tilt up the fork fully)

Tilt highest position is displayed.

Keep on pushing button.

Value of the tilt highest position is set.

Release button.

152T113

l Tilt setting screen (fork horizontal)

Setting of tilt potentiometer flashes.

152T114
lCurrent tilt position is displayed.
Operate the tilt lever to set the
fork horizontal.

Tilt horizontal position is displayed.

152T115

Keep on pushing button.

(To the next page)

53
 2 Various setting and adjustment

(From the previous page)

Value of the tilt horizontal position is

set.

Release button.

152T116

This initial setting is necessary only for trucks with AOS.

l Lift setting screen (lift down)

Setting of lift encoder flashes.

152T117
lCurrent lilt height is displayed.
Push the lift lever until the fork
is grounded.

Lift lowest position is displayed.

Keep on pushing button.

Value of the lift lowest position is set.

Release button.

152T078

(To the next page)

54
 Various setting and adjustment 2

(From the previous page)

l Lift setting screen (lift up)

Setting of lift encoder flashes.

152T118
lCurrent lilt height is displayed.
Pull the lift lever until the fork is
come at maximum height.

Lift highest position is displayed.

Keep on pushing button.

Value of the lift highest position is set.

Release button.

152T119

l The distance between stacking end picking

Setting of the distance flashes.

Set the value by pushing
l or
button (50-200).

l The speed reduction at lift stroke end

Setting of the speed reduction

flashes.
lSelect "OFF" or "ON" by pushing
152T120
or button.

(To the next page)

55
 2 Various setting and adjustment

(From the previous page)

l The speed reduction at tilt stroke end

Setting of the speed reduction

flashes.
lSelect "OFF" or "ON" by pushing
or button.

l AOS switch box function setting screen

Setting of switch box function

flashes.
lSet by pushing or button.
152T079 TILT : Tilt horizontal (special option)
AB RACK : A/B rack switching

Return to P/M mast selection

NOTE When the connection is failure between EPS

controler and MPU board, the current lift (or tilt)
position is unknown and not showing the value
in the screen.
It is not possible to set each item.
The current tilt position is unknown.

The current lift position is unknown.

56
 Various setting and adjustment 2

2-2-18. Clearing the error history memory

(memory initialization)
lEPS controler
1. Set rotary switch RS1 on the EPS controler to "E".
2. Turn on the key switch. F01

CDE

23
3. The following screen appears and memory initialization

456
AB
is complete. 789
4. Return rotary switch RS1 on the EPS controler to "0".
Set RS1 to "E".

l Memory Initialization Completion Screen

152T101

NOTE The following items are returned to their initial

values:
l Slow speed (turtle) : 5km/h
l Travel mode : N (NORMAL)
l Meter mode : HR (hour meter)
l Neutral regenerative brake : MID
l Error history : All clear
l BRIGHTNESS (back light brightness) : 5

57
 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
number will be displayed on the screen.
l The applicable abnormality and/or error symbol will
flash on the display.
l The applicable error number will be displayed. (If
multiple abnormalities and/or errors are detected, the
applicable error numbers will be displayed in order.)

Travel system errors

The service (spanner) mark flashes.

The abnormality or error number

flashes.

The travel symbol flashes.

152T081

Hydraulic (including AOS) system errors

The service (spanner) mark flashes.

The abnormality or error number

flashes.

The hydraulic symbol flashes.

152T082

Steering (EPS) system errors

The service (spanner) mark flashes.

The abnormality or error number

flashes.

The steering symbol flashes.

152T083

58
 Troubleshooting 3

Other errors

The other abnormality or error

number blinks.

152T084

Multiple abnormalities and/or errors

The service (spanner) mark flashes.

The detected abnormality and/or

error numbers are displayed in the
order they are detected.

All of the symbols for the detected

152T085 abnormalities and/or errors flash.

NOTE l If the following abnormalities and/or errors

o c c u r, t r a v e l , h y d r a u l i c s a n d E P S a r e
interlocked.
*Only the error number is displayed, and the
message is not displayed.
B11 - B13 : Traction U,V,W-phase FET
C21 - C23 : Hydraulic U,V,W-phase FET
D30 - D34 : EPS error
G61 : Traction current error
G62 : Hydraulic current error
l The , buttons are disabled lEPS controler
and
while the self-diagnosis screen is displayed. F01
l If rotary switch RS1 on the EPS controler is
CDE

23
456

set to F, the self-diagnosis screen will not

AB

789
be displayed. (The normal screen will be
displayed.) DISP="F"

l When the abnormalities and/or errors are

resolved, the display will return to the normal
screen.

59
 3 Troubleshooting

3-1-2. Error messages and Display conditions

Code Contents Remarks Error detection condition CPU Likely cause

When an error is detected: Traction/hydraulic/
EPS operation not possible (*Operation is Simultaneously detected main contactor ON signal and main contactor •Main contactor contact malfunction
A01 Main contactor Traction
still possible in case of an open circuit in the OFF signal. •Main contactor coil malfunction
detection line.)
When an error is detected: Traction/hydraulic
operation not possible (*Operation is still Simultaneously detected main contactor contact ON and fuse check
B10 Main fuse Traction •Main fuse blown
possible in case of an open circuit in the terminal OFF.
detection line.)
B11 Traction U-phase FET
(1) FET ON detected when traction control is stopped.
•Traction FET malfunction
B12 Traction V-phase FET When an error is detected: Contactor trip (2) FET ON/OFF switching error detected during traction control. Traction
•FET board malfunction
(3) Current balance error detected.
B13 Traction W-phase FET
Detect out-of-range sensor output voltage at either U-phase or V-phase.
B14 Traction motor current sensor When an error is detected: Contactor trip Traction •Traction current sensor malfunction
(Sensor output voltage standard when traction is stopped: 5V±0.976V)
(1) Detected a difference of 0.625V or more in the accelerator input value 1
When an error is detected: Traction control and 2. •Accelerator lever potentiometer malfunction
B15 Accelerator Traction
stopped (2) Detected accelerator input value over 0.5V or accelerator input value •Accelerator lever potentiometer neutral adjustment malfunction
under 4.5V.
When an error is detected: Traction control
B16 Directional switch Simultaneously detected forward switch ON and reverse switch ON. Traction •Directional switch malfunction
stopped
(1) Detected brake switch input value =< 0.15V or brake switch input value
>= 3.13V.
When an error is detected: Traction control (2) When brake switch OFF (brake pedal ON), detected brake switch input •Brake potentiometer malfunction
B17 Foot brake Traction
stopped value >= 2.42V. •Brake potentiometer malfunction
(3) When brake switch OFF (brake pedal ON), detected brake switch input
value =<0.78V.
C21 Hydraulic U-phase FET
(1) FET ON detected when hydraulic control is stopped.
•Hydraulic FET malfunction
C22 Hydraulic V-phase FET When an error is detected: Contactor trip (2) FET ON/OFF switching error detected during hydraulic control. Hydraulic
•FET board malfunction
(3) Current balance error detected.
C23 Hydraulic W-phase FET
Detected out-of-range sensor output voltage at U-phase or V-phase.
C24 Hydraulic motor current sensor When an error is detected: Contactor trip Hydraulic •Hydraulic current sensor malfunction
(Sensor output voltage standard when hydraulic is stopped: 5V±0.976V)
When no input signal of EPS limit switch, detected drive wheel angle >=
D30 EPS limit switch When an error is detected: Contactor trip EPS/DSP •EPS limit switch malfunction
240 degrees.
EPS encoder (steering angle Detected a difference of over 4 times in the angles detected at encoder 1
D31 When an error is detected: Contactor trip EPS/DSP •EPS encoder (steering angle detection) malfunction
detection) and encoder 2.
D32 EPS transistor When an error is detected: Contactor trip Detected an abnormal voltage of EPS drive FET. EPS/DSP •EPS controler malfunction
(1) When EPS motor ON (FET chopper rate >= 80%), detected EPS
EPS encoder (drive wheel angle encoder angle = 0 degree for 1s.
D33 When an error is detected: Contactor trip EPS/DSP •EPS encoder (drive wheel angle detection) malfunction
detection) (2) When EPS motor OFF (FET chopper rate = 0%), detected EPS
encoder angle >= 10 degrees for 200ms.
D34 EPS current When an error is detected: Contactor trip Detected EPS motor current >= 35A for 3s (Max.45A) EPS/DSP •EPS motor malfunction
(1) Detected valve input value >= 4.15V.
When an error is detected: Hydraulic control
E40 Solenoid valve (2) Detected valve input value >= 0.49V when hyd. lever OFF. Hydraulic •Solenoid valve malfunction
stopped
(3) Detected valve input value =< 0.49V when hyd. lever ON.

60
 Troubleshooting 3

Code Contents Remarks Error detection condition CPU Likely cause

When an error is detected: Hydraulic control Detected lever potentio. input value =< 0.31V or lever potentio. Input
E41 Lever potentiometer Hydraulic •Lever potentiometer malfunction
stopped value>= 4.8V.
When AOS option is ON
(1) Detected fork-height detection encoder position input that is lower than
Fork-height detection encoder When an error is detected: Error code is
E42 300mm than the bottom stage position setting. Hydraulic •Fork-height detection encoder malfunction
(*option) displayed
(2) Detected fork-height detection encoder position input that is higher than
300mm than the top stage position setting.
G61 Traction current error Traction •Traction motor malfunction
When an error is detected: Contactor trip Detected overcurrent.
G62 Hydraulic current error Hydraulic •Hydraulic motor malfunction
Traction voltage error (battery
G63 Traction
voltage error) When an error is detected: Error code is
Detected battery voltage < 18V. •Battery power voltage malfunction
Hydraulic voltage error (battery displayed
G64 Hydraulic
voltage error)
When an error is detected: Error code is (1) Detected temp.on main board >= 90°C (The error is automatically
displayed canseled when the temperature on board drops to =< 85°C).
When an error is detected: Traction reduced- (2) Detected traction FET temp. >= 105°C (The error is automatically
Main board / FET temperature
G65 speed control according to temperature. canseled when the traction FET temperature drops to =< 100°C). Traction •Overheating
error
When an error is detected: Hydraulic
(3) Detected hyd. FET temp. >= 105°C (The error is automatically
reduced-speed control according to
canseled when the hydraulic FET temperature drops to =< 100°C).
temperature.
When an error is detected: Error code is Communications error between traction / hydraulic / EPS and display •Traction/hydraulic board malfunction or EPS controler malfunction
G68 Display communication error EPS/DSP
displayed detected. •Wiring malfunction
When an error is detected: Error code is (1) Detected FET gate power =< 10V.
G69 Control power error Traction •Traction/hydraulic board malfunction
displayed (2) Detected 5V power =< 1.7V or >= 6.3V.
When an error is detected: Hydraulic control
W05 Overload warning (*option) Detected overload. EPS/DSP •Overloading
stopped
When an error is detected: Hydraulic control
W06 Fork oil warning (*option) Detected lowering of hydraulic oil level. EPS/DSP •Lowering of hydraulic oil level
stopped
When an error is detected: Hydraulic
operation half speed control (When over
discharge lift lock ON) (1) Battery discharge indicator : 80% discharge
W07 Battery charge warning EPS/DSP •Battery over discharge
(2) Battery discharge indicator : 90% discharge
When an error is detected: Hydraulic control
stopped
When an error is detected: Traction/hydraulic After turning key switch ON, detected directional switch and accelerator
W08 Traction unit neutral safety Traction •Traction operation when power is ON
control stopped On within 200ms.
When an error is detected: Traction/hydraulic After turning key switch ON, detected hydraulic lever potentiometer ON
W09 Hydraulic unit neutral safety Hydraulic •Hydraulic operation when power is ON
control stopped within 200ms.
When an error is detected: Traction/hydraulic Leaving the operator's seat>= 2s (Hyd. control ON in 1 sec. after seated / Traction/
W11 OIS warning •Leaving operator's seat under traction/hydraulic operation
control stopped Traction control ON when accelerator OFF after seated). Hydraulic
When an error is detected: Traction/hydraulic When battery interlock is ON, detected hydraulic lever ON or accelerator Traction/
W13 Battery interlock warning •Traction/hydraulic operation during battery drawn out
control stopped ON. Hydraulic
* The above causes contain only the primary systems. It is also necessary to check for wiring malfunctions (open or short circuits), connector connection malfunctions and control board malfunctions.

61
 3 Troubleshooting

3-1-3. Servicing data

System name Servicing data

Coil supply voltage: 36V (400 ms) 12V hold
Main contactor
Coil resistance: 15.3Ω
Check continuity using the digital (+) (-)
tester continuity check mode.If there
is continuity at any of the right items, a (1) P G1/U
malfunction (short circuit) has occurred. (2) P G1/V
Traction / Hydraulic FET (3) P G1/W
In the case of a FET malfunction, check
that there is no damage to the FET (4) U G2/U
board and traction/hydraulic board. If any (5) V G2/V
abnormality is found, replace the board. (6) W G2/W

FET board Supplied voltage: 12V

Traction / Hydraulic current Supplied voltage: 12V
sensor Sensor output voltage when the motor current is 0A: 5V ± 0.976V (4.024 - 5.976V)
Supplied voltage: 5V
Accelerator potentiometer Output voltage when the accelerator OFF: 0.5 - 0.98V
Output voltage when FULL accelerator: 5V ± 0.2V
Supplied voltage: 5V
Brake potentiometer Output voltage when the accelerator OFF: 0.5 - 0.98V
Output voltage when FULL accelerator: 5V ± 0.2V
Coil supply voltage: 36V (400 ms) 12V hold
Body-side hydraulic solenoid
Permissible current (at full operation): 0.7A ± 0.02A
valve
Coil resistance (main): 17.5Ω
Mast-side hydraulic solenoid Coil supply voltage (tilt/SF): 36V (400 ms) 12V hold
valve Coil resistance (tilt/SF)): 24.2Ω
Supplied voltage: 5V
Hydraulic lever potentiometer Output voltage when the lever is in the neutral position: 2.5V±0.2V
Output voltage when the lever is operated: 0.6V±0.2V - 4.4V±0.2V
EPS motor Limit current: 30A
Supplied voltage: 5V
EPS sensor (steering) Output voltage when the steering wheel is straight ahead (drive straight): 2.75V±
0.1V (2.65 - 2.85V)
Supplied voltage: 5V
EPS sensor (drive) Output voltage when the steering wheel is straight ahead (drive straight): 2.75V±
0.1V (2.65 - 2.85V)
Supplied voltage: 48V
Electromagnetic brake
Coil resistance: 32.1Ω±10%
Fan Supplied voltage: 48V
Horn Supplied voltage: 48V

62
 Troubleshooting 3

3-1-4. Electrical failures when no error code is displayed

Symptom Likely cause

•EPS/DSP board LED Error (OFF) Power line error (battery,
The display does not start when
the key switch is turned ON, and all fuse, key switch, power relay, other) Emergency switch is
(1) currently engaged.
traction/hydraulic/EPS operations are
not possible. •EPS/DSP board LED Normal Board failure or display failure
The display does not start when the
key switch is turned ON, however
(2) Display failure
traction/hydraulic/EPS operations are
possible.
•Drive/hydraulic board LED Error (OFF) Board failure
Truck body jumps during travel or only
(3) •Drive/hydraulic board LED Normal Traction motor speed
low-speed travel is possible.
sensor failure

The causes listed above contain only the primary systems. It is also necessary to check for wiring
failures(open or short circuits), connector connection failures and other failures.

63
 4. Other electric check and adjustment
4-1-1. Hour meter working check
<Checking procedure>
1. Open the bonnet and connect "Blue/Black" wire and Black/White Hydralulic
Black/White" wire of the accessory terminal. motor
The hour meter starts counting.

2. Confirm that the hourglass symbol on the display

flashes when you turn on the key switch. Blue/Black

CAUTION After completing the check, be sure that the

connector terminal is left unplugged until the
forklift is delivered to the customer.

152T066

Hourglass (flashing)

Normal : key SW ON (white)

Option : actual operation (colored) 152T106

152T067

4-1-2. Chassis insulation check

<Checking procedure>
1. Disconnect the battery plug.
2. Use a tester to measure the insulation resistance
between positive (+) terminal of the chassis battery
plug and chassis, and between negative (-) terminal of
the chassis battery plug and chassis.
Standard value 1M or greater

64
 Other electric check and adjustment 4

4-1-3. Display brightness check and adjustment

<Checking procedure>
l Confirm that the information on the display can be read
clearly even indoors.

<Adjusting procedure>
1. Push button repeatedly till the display adjustment
screen appears.

l Display adjustment screen

152T065
Display brightness parameter (flashing)

2. Confirm that the "BRIGHT" parameter is flashing.

3. Push or button to adjust the brightness (0-7).
l Push button to increase the parameter.
l Push button to decrease the parameter.

65
 4 Other electric check and adjustment

4-1-4. OIS (Operation Interlock System) working check

<Checking OIS function>
1. Leave the operator’s seat.
2. Make sure that the following monitor symbol (OIS
symbol) is displayed.

152T0102

3. Make sure that the travel and hydraulic functions are

interlocked after 2 seconds. (Make sure that the truck
does not work after interlocking.)

<Checking cancellation of OIS>

1. Sit on the operator’s seat.
2. Make sure that the hydraulic function will be possible to
operate after 1 second.
3. Release the accelerator pedal.
4. Make sure that the travelling function works normally
with depressing the brake pedal.

<Checking travel neutral safety function>

1. Leave the operator’s seat to activate the OIS.
2. Sit on the operator’s seat with depressing both the
brake pedal and the accelerator pedal.
3. Make sure that the OIS monitor symbol is displayed.
4. Make sure that the hydraulic function will be possible to
operate after 1 second.
5. Then make sure that the following monitor symbol
(Parking symbol) flashes on the display.

152T0109

6. Release the accelerator pedal.

7. Make sure that the flashing disappears and the travel
function works normally.

66
 Other electric check and adjustment 4

<Checking hydraulic neutral safety function>

1. Leave the operator’s seat to activate the OIS.
2. Sit on the operator’s seat with depressing the brake
pedal and engaging the hydraulic lever.
3. Make sure that the OIS monitor symbol is displayed.
4. Make sure that the travel function will be possible to
operate after 1 second.
5. Then make sure that the following monitor symbol
(Hydraulic lever symbol) flashes on the display.

152T0110

6. Set the hydraulic lever in the neutral position.

7. Make sure that the flashing disappears and the
hydraulic function works normally.

67
 4 Other electric check and adjustment

4-1-5. Valve electric current adjustment

<Solenoid valve current check> Solenoid valve

Check that the solenoid valve current value is 0.70

0.02A with pulling the hydraulic lever fully.

CAUTION Solenoid valve Check point

No.
current Wire color of clamp ammeter
Lift-up side (pulling the lift lever fully)
1 Lift current
Green/Black or White
Proportional control valve
Reach-in side (pulling the reach lever
Reach fully)
2
current
Brown/Red or Brown/White
Tilt/Side shift Tilt-up side (pulling the tilt lever fully) 121S062E
3
current Blue/Black or White/Red Clamp ammeter

<Measuring instrument>
Clamp ammeter (available for measuring small current)
Recommended ammeter : YOKOGAWA CL-612

NOTE l Measurement should be performed near the

connector, not near the solenoid valve.
Noise will prevents an accurate measurement.

68
 Other electric check and adjustment 4

If the currnt value is out of range, adjust the volume on

the MPU board.

l Travel / Hydraulic board (MPU board)

(LIFT) (VR1)
(TILT) (VR2)
CN1 CN2/H

(ATT1) (VR3)
(ATT2) (VR4)
(REACH) (VR5)
(PV)
(P15)
(P6)
(HYD)
(TRV)
CN3

CN10 CN9
HYD TRV
CN4/T

CN5 CN6 CN7 CN8 CN11 CN12

152T0108

Print on the
Volume No. Solenoid valve Remarks
MPU board
Turning the volume clockwise decrease the
VR1 LIFT Lift
current. Lift-up 0.70 0.02A
Turning the volume clockwise decrease the
VR2 TILT Tilt/Side shift
current. Tilt-up 0.70 0.02A
Turning the volume clockwise decrease the
VR3 ATT 1 current.
*Only for 5 levers
VR4 ATT 2 - -
Turning the volume clockwise decrease the
VR5 REACH ATT. 1
current. Reach-in 0.70 0.02A

NOTE When the error message "E40" (TR-AOS) is

occurred or replacing the MPU board, check the
current value.

69
 4 Other electric check and adjustment

4-1-6. Safety circuit for control (contactor tripping) check

<Checking procedure>
1. Turn off the key switch, disconnect the battery plug and
discharge the capacitors in the contol unit.
2. Disconnect connector "CN4" (for traction) and "CN2"
(for hydraulic) of MPU board.

(LIFT)
(TILT)
CN1 CN2/H
(ATT1)
(ATT2)
Connector for hydraulic (REACH)
(PV)
(P15)
(P6)
(HYD)
(TRV)
CN3 CN4/T

CN10 CN9
HYD TRV
Connector for traction

CN5 CN6 CN7 CN8 CN11 CN12

152T0107

CAUTION l Do not travel or manipulate the hydraulic

when only one end of CN2 or CN4 is
disconnected. It may damage FET module.
l Be short-circuited between the gate sources
pulled out.

3. Connect the battery plug and turn on the key switch.

4. Operate the accelerator, and confirm an alarm sounds,
main contactor trips, and the error number is displayed
as shown below.
Error number Error message (nondisplay)
B11 - B13 Traction U,V,W-phase FET
C21 - C23 Hydraulic U,V,W-phase FET
D31 EPS encoder (steering angle detection)
D32 EPS transistor
D33 EPS encoder (drive wheel angle detection)
D34 EPS current
G61 Traction current error
G62 Hydraulic current error

70
 Other electric check and adjustment 4

4-1-7. Foot switch working check

<Checking procedure>
1. Operate the directional switch and accelerator without
depressing the foot switch.
2. Confirm that the truck doesn't travel.

4-1-8. Checking the function of neutral safety

<Checking procedure>
1. Turn on the key switch with depressing the accelerator
pedal.
2. Confirm that the truck doesn't travel.
3. Turn on the key switch with operating any hydraulic
lever.
4. Confirm that the hydraulic function doesn't work.

4-1-9. Lift interrupt working check

<Checking procedure>
1. Connect a 40 - 46V power supply to the battery plug.
2. Turn on the key switch.
3. Confirm the followings.
Battery indicator : The frame flashes.
Display : Battery symbol is displayed.
Lift : Lift function is interrupted.

152T069

Frame flashes Battery symbol flashes

71
 4 Other electric check and adjustment

4-1-10. Cooling fan working check [Fan(1)]

<Checking procedure>
1. Confirm that the cooling fan is working during travel or
hydraulic operation.
2. While travel and hydraulic operation are stopped,
confirm that the cooling fan is stopping when the
temperature inside the control unit is 35°C or lower,
and that it is working when the temperature inside the
control unit is 40°C or higher.

NOTE Cooling fan [Fan(2)] is working with turning on

the key switch.

4-1-11. Checking the function of battery tray interlock

<Checking procedure>
1. Operate the any hydraulic lever with depressing the
pedal lightly.
2. Confirm that the hydraulic function doesn't work.

4-1-12. Checking the function of auto power off

<Checking procedure>
1. Turn on the key switch.
2. Confirm that the main contactor is turned off by
keeping no operation for 15 minutes.

72
 5. Operation procedures for truck with
AOS
5- 1. Operation procedures
5-1-1. Joystick operation
Joysticks for "Lift", "Tilt", "Tilt" and "Side shift" can be operated as same as the standard
model (without AOS).

Lift Reach Tilt Side shift

152T0401

l When lifting the forks up or down with the joysticks, the level number LED lights up or
goes off according to the height.
l When lifting the forks up with the joysticks in the lifting height limit mode, the forks
automatically stop at the preset height.

73
 5 Operation procedures for truck with AOS

5-1-2. Automatic lifting stop operation

1. After turning ON the key switch, set the lift to the lowest level.
All the LEDs should not flash.

l When all the LEDs are flashing, the lift is not set to the lowest level after the key switch is
turned ON.
Lower the forks up to the level where the LEDs do not flash.

l The lift is not set to the lowest level. l The lift is set to the lowest level.

LIFT LIFT
LIMIT 3 6 LIMIT 3 6
Lifting down
㪘㩷㪆㩷㪙 2 5 㪘㩷㪆㩷㪙 2 5

M 1 4 M 1 4

STOP STOP : Off

: On
: Flashing

* It depends on the memorized stop positions and

previous operations. 152T0403

NOTE When the lift is not set to the lowest level,

l operations with the valve lever and the joystick can be performed.
l automatic lifting stop operation cannot be performed.
l the operation switching for the automatic fork leveling, lifting height limit and
A/B rack cannot be performed.
l the stop position cannot be memorized.
l the automatic fork leveling mode and the lifting height limit mode that were set
at the end of the previous operation are effective.

74
 Operation procedures for truck with AOS 5

2. Check that the LEDs for the level number, where you want to stop the lift
automatically, light up.

Level number LED (on)

㪘㩷㪆㩷㪙

: Off
: On
: Flashing 152T0404

* The figure shows that stop positions are set at 1 - 6 levels.

When the LEDs are not lit,

l stop positions have not been stored.
Store them (refer to "4-1-6. Storing the stop position" on page **).
l the lift is positioned above the level where you want to stop it automatically.
Lower the lift up to below the level where you want to stop it automatically.
l the lifting height limit mode is selected and the desired level exceeds the limit.
Cancel the lifting height limit mode (refer to "4-1-5. Lifting height limit mode switching"
on page **).

3. Press the button for the level number where you want to stop the lift automatically.
The LED flashes and the picking and the stacking LEDs are turned on.
The stacking LED may not light up depending on the lift's height.

Level number button Level number LED (flashing)

LIFT LIFT
LIMIT 3 6 LIMIT 3 6
The 5 button is pressed.
㪘㩷㪆㩷㪙 2 5 㪘㩷㪆㩷㪙 2 5

M 1 4 M 1 4

STOP STOP : Off

: On
: Flashing
152T0405
* The figure shows that the stop positions Picking LED (on) Stacking LED (on)
* are stored at 1 - 6 levels.

75
 5 Operation procedures for truck with AOS

4. Press the picking or the stacking button.

The level number LED lights up and the LED for unselected button (either the
picking or stacking LED) is turned off.

Level number button (on)

㪘㩷㪆㩷㪙

Picking LED (on) Stacking LED (off)

Picking button Stacking button

: Off
: On
: Flashing
152T0406

* The figure shows that the picking button is pressed.

NOTE If neither the picking nor stacking buttons are pressed for a certain period of
time, the operation status automatically returns to 2 .

5. The forks are automatically lifted and stopped at the height of the level number that
was selected in operation 3. The level number LED and the LED that was selected
in operation 4 (either the picking or stacking LED) flash.

Level number LED (flashing)

㪘㩷㪆㩷㪙

Picking LED (flashing)

: Off
: On
: Flashing
152T0407

* The figure shows that the picking button is pressed.

NOTE l If you operate the valve lever or joystick while in the automatic lifting stop
mode, the mode is cancelled.
l If you press the STOP button while in the automatic lifting stop mode, the mode
is cancelled and the operation stops.

6. Pick or stack the load.

7. Repeat operations 2 - 6.

76
 Operation procedures for truck with AOS 5

5-1-3. A/B rack switching

1. Press the A/B button to select the A (the LED is off) or B rack (the LED is on).

NOTE l Each time the button is pressed, the rack is switched. The level number LED
and the LIFT LIMIT LED are turned on or off according to the selected rack.
l The previously stored lifting height limit is applied according to the selected
rack.

A/B rack LED

A/B rack select button

For the A rack: The A/B LED goes off.

For the B rack: The A/B LED lights up.

: Off
: On
: Flashing

152T0410

5-1-4. Lifting height limit mode switching

1. Press the LIFT LIMIT button to select the lifting height limit mode.
The LED lights up.

Lifting height limit LED (on)

Lifting height limit button

㪘㩷㪆㩷㪙

: Off
: On
: Flashing
152T0411

NOTE Each time the button is pressed, the lifting height limit mode switches between
on and off.
(When the lifting height limit mode is canceled, the LIFT LIMIT LED is turned off.)

77
 5 Operation procedures for truck with AOS

5-1-5. Storing the stop position

A/B rack: For each rack, the automatic lifting stop position and lifting height limit can be
stored. In total, 12 automatic lifting stop positions and 2 lifting height limits can be
stored.

1. Press the M button until the LED is turned on to enter the memory mode.
The LED is turned on by holding down the M button for a few seconds.

Memory LED (on) 㪘㩷㪆㩷㪙

Memory button

: Off
: On
: Flashing

152T0412

2. For a truck with A/B rack, press the A/B button to select the rack.

A/B rack LED

A/B rack select button

For the A rack: The A/B LED goes off.

For the B rack: The A/B LED lights up.

: Off
: On
: Flashing

152T0410

78
 Operation procedures for truck with AOS 5

3. Check that the LED of the level number where you want to store the stop position is
turned off.
If it is turned off, the stop position has not stored.

Level number LED Level number LED

(When it lights up, the stop position has been stored.) (When it goes off, the stop position has not been stored.)

㪘㩷㪆㩷㪙

: Off
: On
: Flashing
152T0413

l When it is turned on, the stop position has been stored.

Press down the level number button until the LED goes off.
The previously stored data will be erased.

4. Set the lift with the valve lever or the joystick to the position that you want to store.
* The position should be the picking height.
* The stacking height is automatically set where the picking and stacking height
distance (50 - 200mm) is added to the picking height. The default distance is 100mm
(refer to "3-1-6. Setting the distance of the picking and stacking heights").

5. Press the level number button where you want to memorize the stop position.
The level number LED lights up and the stop position is stored.

Level number LED Level number LED

(When it lights up, the stop (When it goes off, the stop
position has been stored.) position has not been stored.) Level number LED (on)

The 2 button is pressed.

㪘㩷㪆㩷㪙 㪘㩷㪆㩷㪙

: Off
: On
: Flashing
152T0414

79
 5 Operation procedures for truck with AOS

When the level number LED is not turned off, following safety monitor symbol
appears on the display.

152T0402

l The lift is positioned above the lift end (maximum) height (as for the lift end, refer to
"2-2-17. AOS setting (OPTION)" on page **).
Lower the lift up to below the lift end (maximum) position.

l The lift is positioned above the registered level.

[Ex.]: The registered level number is 3 and the lift is positioned at one of the 4 - 6 levels.
Lower the lift up to the stored level or below.

l The lift is positioned below the registered level.

[Ex.]: The registered level number is 3 and the lift is positioned at either 1 or 2 level.
Raise the lift up to the stored level or above.

6. Check that the LIFT LIMIT LED is turned off.

If it is turned off, the lifting height limit has not been stored.

Lifting height limit LED (off)

㪘㩷㪆㩷㪙

: Off
: On
: Flashing
152T0415

l When it is not turned off, the lifting height limit has already been stored.
Press down the LIFT LIMIT button until the LED is turned off. The data is erased.

80
 Operation procedures for truck with AOS 5

7. Set the lift with the valve lever or the joystick to the position where you want to
register the lifting height limit.

8. Press the LIFT LIMIT button.

The LED lights up and the limit is stored.

Lifting height limit LED (on)

Lifting height limit button

㪘㩷㪆㩷㪙

: Off
: On
: Flashing
152T0416

9. Repeat operations 3 - 8.

10. Press the M button.

The LED lights up and the memory mode is cancelled.

Memory LED (off) 㪘㩷㪆㩷㪙

Memory button

: Off
: On
: Flashing
152T0417

81
 5 Operation procedures for truck with AOS

5-1-6. Stop (emergency stop) operation

1. Press the STOP button during the valve lever, joystick, or the automatic lifting stop
operation.
The LED lights up.

㪘㩷㪆㩷㪙

Stop LED (on)

Stop button
: Off
: On
: Flashing

152T0418

2. The operation is stopped.

3. Return the valve lever or the joystick to the neutral position and wait for a certain
period of time (approx. 5 seconds).

4. The emergency stop is cancelled.

The LED goes off.

㪘㩷㪆㩷㪙

Stop LED (off)

: Off
: On
: Flashing

152T0419

82
 3. Wiring (Diagrams)
2
1 2 3
Battery(48V) MPU MPU MPU MPU

RDWH*

RDBK*
RDWH*

BKWH*
Line Connector Line Connector Line Connector Line Connector
V N No. CN Pin No. No. CN Pin No. No. CN Pin No. No. CN Pin No.
*Only for trucks with laser poiter
VA NA RD
BU RPA 7 5 Power supply Reference:
C1 3 18
Main contactor contact Traction motor BKRD RNA 7 15 GND Fan(1) Tilt level sensor
WH YERD Harness mark/color
GNRD Main fuse speed sensor BUWH
RA1 7 6 A phase signal
M
BUBK
LCK 5 16 Fan output HD 5 18 Tilt level detector switch Red RD
F1 3 9 RB1 7 16 B phase signal
F1 Black BK
WHBK
+ HS7 8 7 Battery tray interlook Green GN
Hydraulic motor RNA 7 17
BK

GND Laser poiter switch

MC RA2 7 8 A phase signal Tilt level switch Yellow YE
325A 100V,4700 F(x9) speed sensor (option) HS5 8 6 Attachment switch 1 RDYE RD White WH
RB2 7 18 B phase signal P3 5 9 Power supply
Laser Brown BN
RDYE2# HS6 8 14 Attachment switch 2 (OIS switch input) BKYE
YERD2# TPU 3 2 Power supply P3N 5 19 GND Blue BU
TIU TIU 3 3 Signal Reach stroke end (OUT) Gray GY
Traction
BK2#
TNU 3 12 GND HS9 5 17 Spare input 4
RDBK2# detector (option) BK Level Pink PK
current sensor BU2# TPV 3 4 Power supply HSN 7 1 Switch GND lamp Orange OG
BK# TUM 4 1 TIV TIV 3 13 Signal
TIU Traction motor U phase BKRD2#
TNV 3 14 GND YEBU SS 5 4 Foot switch
FETmodule BU# TU1 4 2
Ex) BKWH (=Black/White)
U phase gate output 1 BK HSN 7 11 Switch GND Black colored harness with White line.
U1 RD# *Only for trucks with forward buzzer
TU2 4 10 U phase gate output 1 RDYE1#
HPU 1 2 Power supply
YERD1# F2 3 19
V1 HIU HIU 1 3 Signal Hydraulic fuse BNBK
Hydraulic BK1#
HNU 1 12 GND FET BNYE1# X2
Forward buzzer
OF2 5 6 Forward output
BKRD# tmperature sensor T-FET HD3 3 5 Signal
TIV TVM 4 4 Traction motor V phase current sensor RDBK1#
HPV 1 4 Power supply BKWH1#
HN3 3 15 GND GNWH BZ
FETmodule BUWH# TV1 4 5 V phase gate output 1 HIV
BU1#
BKRD1# HIV 1 13 Signal (travel)
W1 HNV 1 14 GND PV 1 6 Power supply (Fan Power supply)
Traction RDBK# TV2 4 13 V phase gate output 2 PVN 1 16 GND
FET BNYE2# *Only for trucks with backward buzzer
motor tmperature sensor HD4 1 5 Signal TPM 3 7 Power supply Battery White line
H-FET BKWH2#
HN4 1 15 GND TIM 3 8 Signal
BKYE# TWM (hydraulic) TNM 3 17 current sensor YEBK
4 7 Traction motor W phase GND X3 OB2 5 15 Backward output
Backward buzzer
BURD# TW1 4 8
FETmodule W phase gate output 1 RD RPA 7 7 HP2 8 3 Power supply BN BZ
RDYE# TW2 Directional GNWH ADF 5 1
Power supply
HD2 8 10 Signal
4 16 W phase gate output 2 Forward
switch BUYE ADB 5 11 Backward HN2 8 11 GND Black color
BK# HUM HS1 8 4 Lift 1 switch *Only for trucks with head lamp
2 1 Hydraulic motor U phase
BU# HU1 Accelerator HS2 8 12 Lift 2 switch Lamp 40W RH
2 2 U phase gate output 1 switch HL
RD# HU2 RDYE AP1 HS3 8 5 Tilt switch
HIU
䉭䊷䊃
2 10 U phase gate output 2 6 4 Power supply Head lamp
㚟േ WH AD1 6 5 Signal HS4 8 13 Reach switch WHGN
FETmodule ࿁〝 AN1 6 12 GND 40W LH
ADN 6 16 Neutral HL
U2 BKRD# HVM 2 4 Hydraulic motor V phase AP2 6 6 Power supply Power supply
V2 BUWH# HV1 BU AD2 6 13 Signal HP1 12 1
2 5 V phase gate output 1 BKYE AN2 6 14 GND HD1 12 2 Signal (Tilt level potentiometer)
RDBK# HV2 HN1 12 9 GND
HIV 2 13 V phase gate output 2
2 Foot brake RDGN HP 7 4 Power supply
W2
FETmodule
BK RPA 5 13
Hydraulic BKYE# HWM HN 7 14 GND RNA 5 14
2 7 Hydraulic motor W phase RDBU AP3 6 7 WHGN TXA 7 2 Traction→EPS Data line

RDWH*
Power supply BUYE RA5 6 3
motor WHBU AD3 6 8 Signal (Turning angle) RXA 7 12 Traction←EPS (EPS) RB5 6 11
BURD# HW1 2 8 BKBU AN3 WHRD TXB 7 3
W phase gate output 1 6 15 GND YERD
Hydraulic→EPS
RDYE# HW2 WHRD RXB 7 13 Hydraulic←EPS RPA 6 1
2 16 W phase gate output 2 BS1 5 12 Brake switch RNA 6 9
Open when turning on
FETmodule the actuator RA4 6 2
RB4 6 10
RDWH# EPS/DSP
HP 2 3 Power supply(+) WHBK MB1 1 10
RDWH# TI1 5 7 Drive unit position detector Line Connector
TP 4 3 Power supply(+) Close when drive direction
F4 is reversed No. CN Pin No. MB2 1 9
BKWH#
10A TN 4 11 Power supply(-) 4 WHBK MB3 1 20
BKWH# HN 2 11 Power supply(-)
YERD RXB 2 6 EPS→Hydraulic
RDBK LP1 8 1 Power supply
WHRD TXB 2 14 EPS←Hydraulic
Lift lever BUYE Data line MB4 1 19
GNRD*

YEWH LD1 8 2 Signal RXA 2 5 EPS→Traction

potentiometer BK LN1 8 9 GND
WHGN TXA 2 13 EPS←Traction (Travel/Hydraulic) RDWH*
BK HNA 2 12 GND MB 1 8 Electro magnetic brake
BKWH RDGN power supply
NB 1 7 Control power supply(-) HPA 2 4 Power supply
F2 LP2 12 3 Power supply
RDGN* RDGN Tilt lever BNYE LD2 12 10 Signal
VBM 5 20 Battery voltage
RDWH potentiometer LN2 12 11 GND RDYE TI 5 2 Travel inhibitor
10A V5 1 5 Power supply
F3 VB 5 10 Control power supply(+) EPS encoder 1 BKYE VN 1 15 GND SG 5 3 Turning speed reduction
WHYE
10A Reach lever LP3
BKRD LD3
12 4 Power supply (Steering) BUYE
RA1 1 6 A phase signal
LL 5 8 Lift lock
OPTION
WHBU 12 5 Signal RB1 1 16 B phase signal
MC1 3 6 Main contactor(+) potentiometer LN3 12 12 GND HSN 8 16 Switch GND
BNWH *Only for trucks with AOS
MC MC2 3 16 Main contactor(-) or Lift height indicator
SF lever LP4 12 6 Power supply V5 1 7 Power supply
GNBK LD4 12 13 Signal EPS encoder 2 VN 1 17 GND
potentiometer LN4 12 14 GND (Steering) WHBU RA2 1 8 A phase signal RD RPA 7 9 Power supply
BU RB2 1 18 B phase signal BKRD RNA 7 19 GND
Electro magnetic F3 3 10 Emergency switch Lift height encoder WH RA1 7 10 A phase signal
brake LP5 12 7 Power supply BUWH RB1 7 20 B phase signal
Attachment YEBU LD5 12 8 Signal
GNRD* WH LN5 12 15 GND RD V5 1 9 Power supply
BRK BKRD BU HS8 8 15 The switch for detecting
(*Only for 5 levers) EPS encoder 3 WHRD
VN 1 19 GND lift lower limit
(Drive) RA3 1 10 A phase signal BK HSN 8 8 Switch GND
Solenoid valve BURD RB3 1 20 B phase signal
GNRD*
BN 5 BP 12 16 power supply
X4 OS1 5 5 Electro magnetic
brake GNBK *Only for trucks with AOS
B11 11 1 WHBK AOS
Horn switch SOL
WH Lift up 4 SR 1 1 Drive unit position detector
Horn BC1 11 11 Line Connector
Low speed switch No. CN Pin No.
WHBK BN (turtle switch)
H EPS/DSP B12 11 2
SOL Lift down GNWH
Line Connector WHBK SW1 1 11 Low speed(turtle)switch BK1/RD
VH 1 1 Control power supply
100V BC1 11 12
No. CN Pin No. BK4/BK
K 1 2 Control GND
22 F BUBK
RD B21 11 3 Tilt up
MP EPS Power supply(+) SOL Mode selection switch BK6/BU
RXD 1 8 EPS→AOS Data
BU WHRD /SF right BK3/WH
TXD 1 7 EPS←AOS
EPS motor K1 EPS Power supply(-) BC2 11 13 BK5/GY line
+ BU GND 1 6 GND
GNRD BS1 1 12 UP BK2/PK
VCC 1 5 (EPS)
PA A B22 11 4 Tilt down Power supply
EPS output(A) SOL -
WHBU /SF left RD
BC2 11 14 BS2 1 3 Down
AA EPS output(AA)
䌍 EPS/DSP
BNRD YE
RDGN B31 11 5 BS3 1 13 ‘M’ switch Line Connector
VB 2 9 Battery voltage SOL Reach in No. CN Pin No.
BNWH BK
BC3 11 15 VN 1 14 Switch GND RDBK
YERD HPD 3 1 Power supply Data
YERD B32 11 6 BKWH
HND 3 9 GND
X1 R+ 2 10 Power supply relay BU line
BNYE SOL
GNWH Reach out RD TXD 3 10 EPS←AOS
R1- 2 3 BC3 11 16 HPC 2 7 Power supply WHBK
RXD 3 2 EPS→AOS (AOS)
Emergency Key switch BK HNC 2 15 GND Data line
switch RDGN* BUWH TXC 2 16 EPS←Dispiay (Dispiay)
KS 2 1 Control power supply BUWH Dispiay WHBU RXC 2 8
RD B41 11 7 EPS→Dispiay
SOL
WHBU Attachment unit
X1 BC4 11 17
BN
ST 2 2 Key switch start
(*Only for 5 levers) BNWH
BS4 1 4 ‘R’ switch WL1 3 8 Turn signal lamp(Right)
B42 11 8 Turn signal lamp
Attachment SW6 3 5 Spare input
SOL
RDYE RH 25W
BC4 11 18 IO 3 7 Spare input TSL WL2 3 16 Turn signal lamp(Left)
2 RDWH* RDBU
GNRD*

BNBK R2- 2 11 Spare output LH 25W

RDWH*

BUYE
RDBK*

Fan (2) B51 11 9 TSL

3 BKWH* Flash
BKWH*

SOL Tilt operation V5 3 6 5V output

M BC5 11 19 unit
VN 3 14 Spare GND SW3 3 11 Turn signal lamp switch(Left) OPTION
BUWH
1 2
SOL
B52 11 10
SF operation VN 3 15 Spare GND Turn signal lamp switch SW2 3 3 Turn signal lamp switch(Right)
BC5 11 20 BUBK
1 1 AH 1 2 Hour meter counting *Only for trucks with turn signal lamp SW6 3 4 Hydraulic oil level
5 3 BKWH*
3 (Connect and start SW7 3 12 Overload
hourmeter counting) VN 3 13 Spare GND
<Note>
1. Terminal symbol
1 : Plug(with plating) AMP 170020-2
1 : Receptacle(with plating) AMP 170021-2
2. Lead wires marked with # or * have different diameters.

FBRF-75 System wiring

3. Dot-dot-dash lines and dashed lines indicate the use of optional equipment.
4. This diagram is changed from “54000-24282-0” for FET drive.
6- 1.
54001-75560-0E
83
 3 Wiring (Diagrams)

Head guard Head guard Lever panel Battery plug Control unit
Reference: (LH) (RH)
Harness mark/color
Only for trucks with Only for trucks with Emergency SF - RD

+
Red RD switch
head lamp/turn sigunal lamp head lamp/turn sigunal lamp
Only for trucks <1>
Black BK
1
with AOS

<8>
<7>
Green GN CN5 CN6 CN7 CN8 CN11 CN12
Fan (1) 8 325A 8
Yellow YE
Head Head <2>
White WH 2

bar
lamp lamp

CN4/T
per
Brown BN
<3>

Cop
Blue BU Tilt
Gray GY 2P 8 3

CN3
Pink PK AOS WH
Turn Turn
Orange OG
signal 2 2 2 2 signal
switch
F+
Contactor Board Comp.,MPU
box <4>

CN2/H
Ex) BKWH (=Black/White) lamp
Black colored harness with White line.
lamp 4
2 2 2 2
Reach <5>

CN1
Mast wiring 5

WH
WH

BK
BK
(standard) Install and tightening together
<6>
Selector valve
2 2 2 2
EPS the duct cover with bolt.
6
White line 2 2 2 2
Lift
controller 8
NA

BU
BK
Tilt operation SF operation

BU
BK
6P

BU
CN1 CN2 CN3 2P
Black color WH

RD
BU
Mast wiring Directional 12P
(For trucks with AOS additional.) switch

RD
BK

10A
10A

10A
GNRD
Harness,

BU
head guard 2P-X
7 7 7 7
1 1
Bearing 20P

RDGN
RDBK

GNRD
WH
RD
BK

BK
sensor Accessory(1)
1 1 1
4P

RDWH
BKWH
RDBU
WH
4P
Water proof

The switch Hanging on mast(2) Magnetic brake

Power supply
for detecting
lift lower limit relay relay
Harness, body(1)
Harness,
mast(2) 4P 4P
2P 3P Connect body earth RD WH
Water proof Water proof Head lamp
switch
GN

20P
GN 1 1
Sheet
When connect, remove
Low speed
Harness, AOS Hanging on mast(1) (turtle) switch the connect for shorting
(harness, short circuit).
Fan (2)
Harness,
mast(1) Steering
Display Mode switch Assembly 6P
2P 4P 3P
Water proof Water proof Water proof BK
Battery
Key switch tray

4P
6P

RD
interlock
BK
Body-mast Body-mast
1 EPS encoder 1 2P
Harness, swich WH

Water proof
Bearing Harness, short circuit Tank, ASS’Y oil

4P
sensor
Harness, Harness, 2P
body(AOS) body(2) Water proof
2 EPS encoder 2
2P

Water proof
Bearing

4P
6P 3P sensor BK
Water proof Water proof

Connect to upper
Accelerator side(B port)
Water proof

Water proof

2
12 P

2P-X
6P

2P Proportional control valve

Water proof
Note: WH

8P
4P 2P
1. <n> shows lead wire No. Foot brake Water proof Water proof
W2 V2 U2
2. Terminal symbol 4P

<6>
Electro magnetic

<4>
<5>
Water proof
1 : Plug AMP 170020-2 Potentiometer brake

BUBK

BKWH
RDWH
2 : Plug AMP 170020-3
Water proof

AMP 170002-5 EPS

3P

Lift Reach Tilt

1 : Receptacle AMP 170021-1 Bearing Drive unit Motor
: Receptacle AMP 170021-3 sensor position Bearing
2
COM detector sensor Hydraulic motor
AMP 170003-5 4 EPS encoder 3
7 : Receptacle AMP 41729 1
NO W1 V1 U1

Water proof
3. All electrical wires should be fixed to prevent contacting

8P
1 1 1

<1>
<3>
<2>
to the part of moving, with edge and of heat source. Brake 4
NC
switch Connect and start
4. About the expression about travelling direction of relevant to options, Connect to lower
hourmeter counting.
1
for standardizing the name with Reach, mast side is called the advance Floor harness side(A port)

BKWH
side unlike the original direction.
WHBK Traction motor
5. In case of “CS” (Cold Storage) truck, apply silicone adhesive 7
Accessory(2) &
Horn BKWH
between the terminals of microswitch as shown the figure below. 7 Hourmeter count
NO
Apply silicone adhesive between the terminals.
COM NC

1
RDWH
BKWH
1
Accessory BNBK
1
1
YEBK
Water proof

Foot switch
2P

FBRF-75 Body wiring 6- 2.

54001-75570-1E
84
 Wiring (Diagrams) 3

: Braided wires under 25mm pitch.

F1 Panel, lever
2.
10 9 8 7 6 5 4 3 2 1
3. All pin layout shows the view from terminal insert side.
4. Write or impress the letters with undamped ink. 20 19 18 17 16 15 14 13 12 11
5. Pay attention to the pin layout.
6. Connect Ca1a-DC48V-N relay and tie it to the harness.

GNRD1

GNWH

GNWH
WHRD

RDWH
WHGN
WHBU

BNWH

BUWH
BUWH
WHBU
BNWH

WHRD

GNWH
WHBK

BUWH
WHBK

BUWH

BUWH

WHRD
GNRD

YEWH

RDGN
WHBU
GNBK

RDGN

WHBK
GNBK

BNRD
BKRD

YERD
BUBK

BNBK

RDBK
BNTE

YERD

BKRD

BKRD

RDBU
BUYE

RDYE

BKBU

BUYE

YEBU

BNBK
BUBK
BKYE

YEBK
7. Fuses should be placed in a circle as shown in the figure below. (20P)

WH

WH
WH

WH
BN

RD

RD

RD

BU
BK
RD
BK

BK
BK

BN
BK
8. The table of electric wires and the table of parts are shown at “Parts, harness”(54001-75690).
9. Attach the cover (sleeve) for shur receptacle on this place. AMP 040 series 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
10. The film capacitor and the electrolytic capacitor should be attached Multi lock connector (mark I) 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 11 2 12 3 13 4 14 5 15 6 16 9 10 7 17 8 18 19 20 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 9 2 10 3 11 4 14 5 13 6 12 7 15 8 16 1 11 2 12 3 4 13 14 5 15 6 16 7 17 8 18 9 19 10 20
as shown the figure below. 174047-2
F1 Q Q Q Q Q Q M Q Q F1 F1 J M x1 D D D P P F1 M M H H H H F1 L N Point "b" Point "b"
A A A C A H V
11. Covered by corrugated tube (Shinagawa-shoko CDP-B907-1 or equivalent). 2A 5A 7A 9A 11A 13A 15A 17A 114A 116A 19A 21A 118A 105A 121A 27A 29A 31A 33A 35A 24A 106A 108A 41A 43A 45A 47A 22A 49A 37A 55A 91C
20B 1B 3B 57B 23B 52A 86A

Fuse Fuse A A A X A A C V Z A MPU board F1 F1 C Q Q Q Q Q Q M Q Q F1 x1 M K D D D P P M M H H H F1 H K N E1 C

(See note 4,5) 1A 3A 4A 6A 8A 10A 12A 14A 16A 18A 115A 117A 20A 120A 104A 26A 28A 30A 32A 34A 36A 107A 109A 42A 44A 46A 23A 48A 25A 38A 54A 57A
10A 10A 19B 21B 2B 75B 22B 24B 74A 85A 92A
10A AMP 040 series AMP 040 series AMP 040 series AMP 040 series AMP 040 series AMP 040 series
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Multi lock connector Multi lock connector Multi lock connector
Multi lock connector Multi lock connector Multi lock connector
25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 175966-2 175967-2 175966-2 175967-2 175966-2 175967-2
8 8
CN12 CN11 CN8 CN7 CN6 CN5

BKRD
YEWH

RD

GNWH

WHBK
RD
BNYE

RDGN

BUYE

BUYE

RDBU
RDBK
BK

RDBK
GNBK

RDYE
Clamp Clamp 12 11 8 7 6 5
Fuse 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 10 9 8 7 6 5 4 3 2 1
Capacitor 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 20 19 18 17 16 15 14 13 12 11
Vinyl tube Vinyl tube
Full the inside of
the vinyl tube with
silicon adhesive. It is possible to use splicing and vinyl tube
instead of soldering, and also to use heat
contraction tube(resin filling up type)
instead of silicon adhesive. Point "a"
Tie wrap With solder Tie wrap 50
Film capacitor

100
Point "b"
Tie the CA relay
on this side.

WH
BK
BKWH
RDWH
RDWH
BKWH
RDBU

BURD
Reference:

GNRD1

GNRD2
Harness mark/color

BU
WHBU

GNWH
WHRD

BUWH
WHGN

GNRD2
Red RD

WHBK

WHRD
WHBU
WHYE
RDGN
RDGN

RDGN
RDWH

BNRD

BUBK
YERD

BUYE

BKRD

RDWH
BUYE
WHGN

BNWH
BKYE
RDYE

BURD
GNWH

WHGN

BNYE

BKWH
BUBK
RDWH

WHBU
WHBU
BUWH

WHBU

RDGN
WHBK

BKWH

WHYE
RDYE

RDBK

RDYE
BUYE

BUYE
BKYE

RDGN
RDGN
Black BK

RDBK
RD
BU
RD

RD
BN

BU
BK

BK

YE

BK
BN
RD

BU
RD

RD
BU

BU
YE
BK

BK A,L
Green GN
Yellow YE 1 1 1 1 1 3 3 3 3 3 3 3 3 3 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 4B

GN
25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 5 5

BN
RDWH
WH

YERD
BNYE
GNRD

RDWH
25 25 25 25 25 25

RDGN
White WH

BNWH
WHBU
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 1 2 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 A,D 1 2 1 2 3 4 5 6 7 8 9 10 11 12
Brown BN F1,F2 ,F1
Z.Point "a" F2.Z F1 F1 F2 D D D D Z C D D D F1 D A C L A A A F2 F2 F2 F2 F2 F2 F2 F2 F2 U U S
Blue BU C C

10A
74B 57D
Gray GY 90M 91B 92B 86B 84B 60B 62B 80B 82B 91A 74C 64B 66B 68B 75A 77B 54B 57C 78A 32B 27B 29B 81A 83A 58A 60A 62A 63A 65A 67A 69A 71A 73A
3 3 51A 111A 112A
Pink PK X X L A A A F2 F2
Z,E1 V,Z F1 F2,Z D D D D D V V D D D D,L Z, Point "b" Point "b" W F F2 F2 F2 U U
1 2 S C Point "a" C Point "b"
Orange OG
76A 77A 79A 31B 28B 30B 80A 82A 55B 59A 61A 64A 66A 68A 70A 72A

10A

10A
91L 90C 85B 90B 58B 61B 63B 81B 83B 90A 84A 65B 67B 69B 76B 91K 50A 110A 90D 113A 91D
111B 1 3 3 3 3 3 3 3 3
Ex) BKWH (=Black/White) AMP 040 series
AMP 040 series AMP 172134-9 AMP 172130-1 AMP 040 series AMP 1-179958-2 AMP 040 series
Black colored harness with White line. AMP 172134-1 Multi lock connector (mark I) Multi lock connector Multi lock connector B G1 1 3 2 4 1 3 2 4
Multi lock connector (mark I)

GNRD1
Z Plug Plug Plug 175967-2 R A L,W D
174047-2 175966-2
Accessory(1)
110B
2P-X 174045-2 39B
4P 4P 2P 56A 49B 91F 79B
RD WH B Receptacle
WH
(20P) CN2 CN1 (12P)
G2 Oiltank
C,E2 Point "b" ,L X D

RDGN
RDBK
1

GN
4C 91E 76C 78B
2 8 8

1 2 1 2
1 2 1 B B AMP 172134-1 AMP 172134-9
White line 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 1 2 6 5 4 3 2 1
2 AMP 172130-1 Plug Plug
3 4 20 19 18 17 16 15 14 13 12 11 3 4 112B 113B
12 11 10 9 8 7
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 8 4P 4P
Plug 8
WH RD

Head Key E1 Fan(1)

2P
WH
(See note 7) G2 O EPS controller
Black color V guard F2 Control panel X switch
39A
B Control unit 1 2 1 2
D EPS controller C Contactor unit G1Body earth 3 4 3 4
(See note 4,5) Electro magnetic brake Power supply
AMP 174661-2
Water proof type 41B A 1 24
RDYE
BKYE
L Relay
Plug 12P 42B A 2 24
WH (See note 5,6)
43B A 3 24
See note 11
Point "c"
44B A 4 24
BU
RDBU
200
45B A 5 24
Note : 46B A 6 24
BKBU
6 5 4 3 2 1 WHBU
1. Terminal symbol 47B A 7 24
12 11 10 9 8 7 RDWH
91J N 8 24
1 : Plug (with plating) AMP 170020-2 48B A 9 24
WHRD
WHBK
Sleeve (for double wire) AMP 170888-1 52B F1 10 24
1 : Receptacle (with plating)
Sleeve (for single wire)
AMP 170021-2
AMP 170889-1
H Accelerator/brake 90L N 11 24
BKWH
(See note 10)
(See note 5) 12 Stopper 100V
Sleeve (for double wire) AMP 170890-1 22
3 : Receptacle AMP 170384-2 (See note 9)
Condenser
125V 0.022

RDWH
BUWH
BKWH
BKWH
ERZV20D151
(Matsushita)

GNRD1
: Receptacle AMP 171630-1 Point "c" RDWH

BUWH

BKWH
BKWH

GNWH

GNWH
WHRD
24

BNWH

WHBU
BUWH
WHBU

BNWH
RDWH

BUWH

BUWH
WHBK

WHBK
WHBK
BKWH

GNRD
BNBK
91I 1

BNRD

GNBK
YERD
BKRD

BUBK
Condenser
H

125V 0.022
90K R
BKWH
AMP 171699-1

WH
1

WH
N

BN
RD

BU
BK

BK
H

Varistor
AMP 70000-79650 (stopper) Accessory 37B A 1
BNBK
YEBK

BKWH
38B A 1

BUWH
24 24 24 24 24 24 24 24 24 24 24 24 24 3 3 3 3 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24
WHRD

1 1 1 1

BKRD
AMP 172748-2 (stopper)
BURD
BKRD

(See note 9)

WH
WH
WH

RD
BK
RD

AMP 171631-1 1 2 1 2 1 2 3 1 2 3 4 5 6 1 2 1 2 1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8
24 : Tab
W,Point "c" E2.W
AMP 173600-1 24 24 24 24 W 5 5 24 24 24 24 3 3 A A Point "c" A A A A L A A A A A A A A
(See note 10)
AMP 70000-79650 (stopper) 1 3 2 4 91H 1 2 1 3 4 2 1 2 118B 17B 90H 106B 108B 104B 120B 4D 90G 90F 9B 116B 15B 7B 11B 114B 13B 5B
5 : Tab AMP 917805-2 D D Point "b" O A A L Point "c" A A A A D L,T A A A A A A A A
AMP 917803-2 A Point "a" ,W
AMP 174352-2 70B 72B 55C 50B 33B 36B 56B 90I 18B 107B 109B 105B 59B 91G 10B 117B 16B 8B 12B 115B 14B 6B
5 : Receptacle AMP 316041-2 YEBU 121B 90E
Water proof type 25B A 1 24 D D O A A Point "c" ,N
AMP 179956-2 2 1 BK AMP 174354-2 AMP 174352-2 AMP 174262-2 AMP 174982-2 AMP 174982-2

(GND)
Plug 2P Accessory(2)

(SF)
26B A 2 24

(TILT)
6 : Receptacle AMP 173716-2 71B 73B 51B 34B 35B 90J AMP 172130-2 AMP 172130-1
Water proof type Water proof type Water proof type Water proof type Water proof type
AMP 175061-2 Cap 2P Plug 2P Plug 6P Plug Plug &Hourmeter Plug 8P Plug 8P
25 : Receptacle AMP 175180-1
K Foot switch
AMP 174257-2 AMP 1-353046-2 AMP 174257-2 AMP 172130-1
Plug
AMP 174357-2 2P
BK
2P
WH
W counting
Water proof type 2P-X
Tab
Water proof type
2P
Water proof type 1 2
18 : Pressed sleeve JST FNC-1.25 Plug 4P Plug 4P WH Plug 3P
1 2 2 1 3 2 1 4 3 2 1 4 3 2 1
6 5 4 8 7 6 5 8 7 6 5
1 1
2 1 1 2 2 1 1 3 2 1 2 2
4 3
Drive unit 4 3 2 Battery tray Proportional
To A WHBK
18 WHBK To T T position detector J interlock E2 Fan(2) Q control valve
BKWH To B To D WHBK
EPS encoder 3 Electro magnetic (See note 4,5)
To Z BKWH
18
To M BKWH
To W EPS Speed R brake M Mast X1 For OIS swich
U (Drive)
BKWH
P sensor
To J BKWH
BKWH To E2 To R BKWH
18
S motor
To E1 RDWH RDWH To L (See note 5) (See note 5)
To A RDWH
18
Point "a" To B RDWH RDWH
To N Point "c"
Point "b"

FBRF-75 Body harness (1) 6- 3.

54001-75681-0E
85
 Water proof Water proof

Red Red
1 4 4 1
3P White White 3P
1 2 3 2 4 4 2 3 2 1
Cap Black Black Plug
3 4 4 3

Yellow Yellow
Spare Spare
Green Green
Spare Spare
Brown Brown
Spare Spare

See note 2

Note) 1. All pin layout shows the view from terminal insert side.
2. Spare wires should be tied with other electric wires.

FBRF14/16/20-75 (Std)
54000-71970-0E
FBRF-75 Body harness (2) 6- 4.
Wiring (Diagrams) 6

6-4-1.

86
87
6 Wiring (Diagrams)

Insert ETFE0.5mm 2
into “Hose, H.P.” (See note 2)

Water proof Water proof

4
Red (1) Red (1) 4
3P 1 1 3P
4
White (2) White (2) 4
1 2 3 2 2 3 2 1
Cap 4
Black (3) Black (3) 4
Plug
3 3

Blue (4) Blue (4)

Spare Spare
Brown (5) Take treatment for cold condition. Brown (5)
Spare Spare

See note 3

Note) 1. All pin layout shows the view from terminal insert side.
2. When using lead wires of the same color, mark the number mentioned in ( ).
3. Spare wires should be tied with other lead wires.

FBRF14/16/20-75 (CS/FCS)
54000-71981-1E
FBRF-75 Body harness (2) 6- 4.
6-4-2.
 RDYE AMP 174663-2
4 1 E 1A
BKYE
4 2 E 2A Water proof type
WH
4 3 E 3A Cap 12P
RDYE BU
AMP 174262-2 1B A 3 4 4 4 E 4A
BKYE RDBU
2B A 5 4 4 5 D 5A
WH BKBU
E Accelerator 3 2 1 Water proof type 3B A 6 4 4 6 D 6A
BU WHBU
6 5 4 Plug 6P 4B A 2 4 4 7 D 7A 1 2 3 4 5 6
RDWH
1 Stopper 4 8 C 8A 7 8 9 10 11 12
WHRD
4 Stopper 4 9 C 9A
WHBK
4 10 B 10A
BKWH
Pay attention to 4 11 B 11A
the pin layout. Stopper A Body harness

AMP 174257-2
5B A 1 4 RDBU
3 2 1
Water proof type BKBU
D Brake potentiometer 6B A 3 4
Plug 3P 7B A 2 4 WHBU

8B A
RDWH
4
C Brake switch WHRD
9B A 4
Reference:
Harness mark/color
Red RD
Black BK
10B A 7
WHBK Green GN
BKWH Yellow YE
11B A 7
B Horn White WH
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG

Ex) BKWH (=Black/White)

Black colored harness with White line.

Note) 1. All pin layout shows the view from terminal insert side.

White line

Black color

FBRF-75 Floor harness

54000-68870-0E
6- 5.
Wiring (Diagrams) 6

88
89
6 Wiring (Diagrams)

17
BlueWhite
1
2 BlueWhite
1 2 3 17
Black 3 1 Cap
3 2P
1

Plug
4 5 6 4 17 Black 3 Black 2
2

6P White
5
6 17

Insert only terminal.

Note)1. All pin layout shows the view from terminal insert side.

FBRF-75 Switch harness

54001-75720-0E
6- 6.
 Water proof
<1> 4 1 2 1
<3> 4 4P 4 3
2
<2> 4 3 Plug
Insert ETFE0.5mm 2 <4> 4
Water proof 4
<1> into “Hose, H.P.”.(See note 2)
1 4

4
<2>
2
1 2 3 6P <3> Water proof
3 4
4 5 6 <4>
Cap 4 4

4
<5> <5>
5 4 1 2P
4
<6> <6> 2 1
6 4 2 Plug
In case of CS/FCS model,
take treatment for cold condition.
Spare
Spare Spare
Spare
See note 3

Note) 1. All pin layout shows the view from terminal insert side.
2. Wire numbers shown in <n> should be indicated by mark bands.
3. Spare wires should be tied with other wires, not be covered with terminator.

54000-71992-0E / 54001-41340-0E
FBRF-75 Body harness (AOS) 6- 7.
Wiring (Diagrams) 6

90
91
2
Control unit side
6 Wiring (Diagrams)

RDBK
YEBU
BK

6 6 6
7 8 15

CN12

5 6 7 8 11 12
8 7 6 5 4 3 2 1
(20P) (20P) (16P) (20P) (16P) (20P) 16 15 14 13 12 11 10 9

3P (16P)

(Water proof)
Panel, lever MPU board

<Working procedure>
1. Clamp the branch point of “Harness, body” and “Harness,
lever” shown in this diagram by tie strap.
2. On MPU board, insert the terminal to the pin number of
connector shown in this diagram.
Note) 1. All pin layout shows the view from terminal insert side.

FBRF14/16/20-75 (4 spools)
54001-75700-0E
2 54001-75710 Harness, lever 1
1 54001-75681 Harness, body 1
SYM PART NO. PART NAME SIZE QTY

FBRF-75 Body harness comp. 6- 8.

6-8-1.
 Wiring (Diagrams) 3

Note:
1. When installing the " 6 7 Module, FET" to the " 1 Sink, heat",
be sure to apply condition compound[G-747] (Shin-Etsu silicones)
25 to the entire cantact surface.
See note 3
13 6 8 11 12 2. Insert washers in the " 14 terminal", as shown in Figure A, and then
installing the " 14 terminal", apply LOCTITE[242] or equivalent to the
screws to prevent looseness.
22 CU109-** 3. Impress a Unit type to the specified position with undamped ink (or seal).
4. Recommended tightening torque for the FET.
18 Main terminal(M6) and mounting(M6) : 3.5-4.5N·m
23 (0.36-0.49kg·m)
Use the bolts of attachment for terminal.

BN-325A
5. Insert the washer,plain , one of bar, lead side , two of condenser COMP. side
(refer to figure B).
See note 5 24
Nut, spring
Washer, plain
21
Condenser comp.

Heat sink
Washer, plain

20
Washer, lock

Figure A

Fuse
Condenser comp.
19
Bar, lead Fuse

Fuse
Insert two washer,plain
Insert the washer,plain

Bar, lead side Condenser COMP. side

Figure B

18 wire,lead
7 8 Parts number Unit type Spare
Parts number

CU109-60 54001-24940 STD specifications

2 3 54001-75410-0

4 5 9 10 54001-75470-0 CU109-61 54001-34420 CS specifications

28 32390-12100 Grease, silicon Not indicate 1

27 54001-34500 Wiring, controller Not indicate 1
26 54001-24290 Harness, controller Not indicate 1
25 1995-32015 Fuse BN-325A 1
24 0000-72008 Washer, plain For fitting
holder,fuse 3
23 0077-05014 Screw, w/washers M5-14 For fitting
holder,fuse 2
22 1995-32001 Holder, fuse BFH-1P-N For fitting
holder,fuse 1
21 54001-24330 Bar, lead C1100BB-1/2H 1
20 0016-06012 Bolt, w/washers For fitting capacotor 2
See note 5 1
4 5 19
18
70000-13680 Capacitor
Wire, lead
HR-15P4A
1
17 70000-59250 Nut, spring M8 For fitting
condenser COMP. 1
16 0000-72008 Washer, plain M8 For fitting
condenser COMP. 2
15 0000-70008 Washer, lock For fitting
condenser COMP. 1
14 54001-03090 Terminal 1
13 54001-24220 Condenser comp. 1
12 0075-04010 Screw, w/washers For fitting sensor
4
11 70001-10861 Sensor, current NV-70F 4
10 0075-04016 Screw, w/washers M4×0.7-16 For fitting FET board 4
9 54001-03031 FET Board comp. 1
8 0016-06012 Bolt, w/washers M6-12 For fitting FET 8
7 70000-56760 FET Module FM600TU-07A For hydraulic 1
1 6 70000-56750 FET Module FM400TU-07A For traction 1
5 0016-06012 Bolt, w/washers For fitting bracket 4
4 54001-24270 Bracket, board SGCC 2
3 0016-04010 Bolt, w/washers M4×0.7-10 For fitting board 4
2 54001-75420 MPU Board comp. 1
1 54001-33451 Sink, heat 1
14 15 16 17 SYM PART NO. PART NAME SIZE MATERIAL QTY MASS

FBRF-75 Main controler 6- 9.

E0000-29120-0E
93
 3 Wiring (Diagrams)

Board comp., MPU

(Controller ASS'Y, main fitting top side)

CN4/T
Board comp., FET
(Board comp., MPU fitting back side)

CN3
See note 3

CN2/H
CN1
Controller ASS'Y, main

Battery (+)

4P TV
2P
1 6
For traction

2 6
4P TU
3 See note 2
12P 6
CN-T
4P HV
2P
4 6
For hydraulic
6

5 6 Note:
4P HU Wire,lead 1) Terminal symbol
6 See note 2
6 : Terminal 7009-1323-02
12P 6
6 : Terminal 38-6
CN-H
External terminal 2) After wiring of FET module, bind “wire, lead” with binding band.
3) Connect the connector as follows.
12P
Battery (-) The connector written H : To “CN2/H”
The connector written T : To “CN4/T”
Harness, controller

FBRF-75 Controller Wiring 6-10.

54001-34500-1E
94
 Wiring (Diagrams) 3

1
RDYE2#
6 2 E 17A
YERD2# 6 3 E 18A
BK2# 6 12 E 19A
RDBK2# 6 4 G 20A 3
BU2#
13 G 21A

20 19 18 17 16 15 14 13 12 11
6

10 9 8 7 6 5 4 3 2 1
BKRD2# 6 14 G 22A
BNYE1# 6 5 F 23A
BKWH1#
6 15 F 24A
WHBU 6 6 I 25A
10 20P
BNWH
6 16 I 27A
7
8
17
GNRD 6 9 I 28A
11
BU
6 18 I 29A Reference:
19 Harness mark/color
20 Red RD
Black BK
Temperature Temperature Green GN

C (Hyd. F sensor
Pay attention to
the pin layout sensor Yellow YE
FET) (Trv. FET) White WH

Pay attention to
A MPU board Brown
Blue
Gray
BN
BU
GY
the pin layout 1 2 1 2 Pink PK

B
Orange OG
Current sensor
(Hyd. U phase) 2P 2P
Ex) BKWH (=Black/White)
1
D E G
RDYE1# Current sensor Current sensor Current sensor Black colored harness with White line.
2 6 B 1A 7B 10B (Hyd. V phase) (Trv. U phase) 23B 24B (Trv. V phase)
YERD1#
3 6 B 2A
BK1# A A A A
12 6 B 3A
RDBK1#
4 6 D 4A 1 HU 1 2 HV TU 1 2 TV
BU1#

20 19 18 17 16 15 14 13 12 11
13 D 5A

10 9 8 7 6 5 4 3 2 1
6 4 3 2 1 15 15 4 3 2 1 4 3 2 1 15 15 4 3 2 1
BKRD1#
14 6 D 6A White line
BNYE2#

BNYE1#

BKWH1#
BNYE2#

BKWH2#
5 6 C 7A
BKWH
7 6 J 8A 4P 4P 4P 4P
RD
8 6 I 9A
20P
9 Black color
10 3B 6B 19B 22B
19 A A A A
20 1B 2B 4B 5B 17B 18B 20B 21B
11
BKWH2#
6 15 C 10A A A A A A A A A
17 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
18 11 11 11 11 11 11 11 11 11 11 11 11
6

RDBK2#

BU2#
BKRD2#
RDYE1#

YERD1#
BK1#

RDYE2#

YERD2#
BK2#
RDBK1#

BU1#
BKRD1#
16

Note:
1. Lead wire
marked with “#” : AVSS 0.3mm 2
not marked : AVSS 0.5mm 2
2. All pin layout shows the view from terminal insert side.
3. : Braided wires under 25mm pitch.
4. Impress or write marks on connectors with undamped ink
as indicated in the pin cunfiguration.
5. All of the mark bands indicated in this diagram are not necessary.
BKWH
WHBU
BNWH
BKWH

GNRD

RD
BU

6 6 6 6 6 6

1 2 3 4 5 6 7 8 9 10 11 12 6
A A
A,I
27B 29B
A J A A
8B
25B 8C 28B 9B

AMP 040 series

Multi lock connector (Mark I)
J Battery (-)
174058-2

(12P)
I External terminal
1 2 3 4 5 6
7 8 9 10 11 12

FBRF-75 Controler Harness 6-11.

54001-24290-2E
95
 Wiring No. <3> <6> Wiring No. <3> <6>
TCV Cap
<2> <5> <2> <5> 2
1
1 2 3 4 5 6 <1> <4> <1> <4>
P[420] P[410] P[410] P[300] P[290] P[280] <2>
<3> <2>
<1> <1> 3
Section A-A Section B-B
<3>

Section C-C
<1> <2> <3> <4> <5> <6> A B
C

D
A

P B D
<5>

<4>
<6>
<5>
NOTE: 5
<6>
<4>
1. Length “L” is length to the tip of the electric wire. 4. P□[ ] under the mark show distance from P□ point.
4
Refer to figure 1 about bare wire length of lead wire. Distance is distance to the tip of the electric wire.
Without bushing : a=22mm, Effective a=27mm (Refer to figure 3) Section D-D 6
L=30mm : b=15mm, L=50mm : 19mm Distance from P□
L:length of the electric wire TCV Cap
a b

<Figure 3>
<Plug> <Terminal>
<Figure 1> 5. Attach the TVC cap to terminal indication.
: RD , : WH , : BU
2.Refer to figure 2 for solderless direction.
6. Refer to figure 4 for stamp
Solderless direction

FBRF-75 Lead wire

the symbol mark of part direction.

<Figure 2>

E0000-22870-4E
Stamp the symbol mark direction.
3.Wire No.<n> is not necessary.
<Figure 4>
Wiring (Diagrams) 6

(for main controler) 6-12.

96
 Wiring (Diagrams) 3

Note:
1.Terminal symbol
16 : Receptacle AMP 170038-2
2. All electrical wires should be fixed to prevent contacting 20P 4P Reference:
to the part of moving, with edge and of heat source. Harness, body RD Harness mark/color
Red RD

3. About the expression about travelling direction of relevant 54001-33751 Black

Green
BK
GN
to options, for standardizing the name with FBR,
fork side is regarded as the advance side. 20P 4P 6P Yellow
White
YE
WH

RD
Brown BN

4. Each of 2 waterproof connectors of the steering unit

BK Blue
Gray
BU
GY
Pink PK
can be connected to either of right and left side. Only for
View from the back of steering panel
Orange OG

trucks OPT. Ex) BKWH (=Black/White)

Black colored harness with White line.

6P White line
WH Display Harness, PS
54000-24470 No OPT.:54001-61240
Black color
(Trucks OPT.:54001-61250~61270)
4P Board comp.,
WH printed
54000-08220

Only for trucks

Low speed
with other options (turtle) switch

SW3 SW2 Optional switch Switch, rocker 4P 4P

70000-05200 (Water proof) (Water proof)

Part No. and Steering UNIT Steering UNIT

rating marking 70001-30090 70001-30090
(See note 4) (See note 4)
(3) (3)
(1) (1) (3) (1) (2) (4)

RD
(4) (4)
(2) (2) (4) (2) (1) (3)
(4) (3) (4) (3) (4) (3) (2) (1)

RDGN
OPT.3 OPT.2 OPT.1 Head lamp Part No. and 16 16

BN
16 rating marking B4
GNWH

16 16 16 16 16 16 16
BK

ST 4
RDBK
BNBK
BNYE

BNRD
BNWH

YEBK
YERD

WHGN

IG
4

Key switch Steering

OPT.1P OPT.2P OPT.3P
Trucks with
head lamp No head lamp
OPT.1 OPT.1
SW1 Head lamp OPT.1 or or
Head lamp Head lamp
SW2 OPT.2 OPT.2
SW3 OPT.3

FBRF-75 Wiring PS 6-13.

54001-37391-0E
97
 3 Wiring (Diagrams)

*Only for trucks with option(s)

1 option / 2 options / 3 options

3 2 1 AMP 172133-9
6 5 4
A Harness, body
Reference:
Cap 21A 23A 1A 3A 5A 7A 9A 11A 13A 16A 18A 20A Harness mark/color

Cap 4P Red RD
G G D C D B B B E Point "a" F F Black BK
6PBK RD See note 1 Green
Yellow
GN
YE
White WH
22A 2A 4A 6A 8A 10A 12A 15A 17A 19A Brown BN
25A 27A 29A Blue BU

2 1 G C C B B B E Point "a" F F Gray GY

H H H 1 2 3 4 5 6 7 8 9 10
Pink
Orange
PK
OG
24A 26A 28A 4 3 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11121314151617181920
H H H 11 12 13 14 15 16 17 18 19 20 Ex) BKWH (=Black/White)
Black colored harness with White line.
26 26 26 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
1 2 3 4 5 6 AMP 040 series

GNWH

RD

RD

WHBU
BUWH
RDWH
BKWH
RDBK
WHGN
RDYE
BKYE
WHYE
BUYE
WHBU
BU

BU
RD
RDGN

YE
BK

BK
BN
26 26 26 26 26 26 Multi lock connector (markI)
175652-2
YERD
YEBK
BNWH
BNRD
BNYE
BNBK

White line
CN1
Black color

Point "b"
See note 2

550
Point "a"
120
WHBU
Point "b" Point "a" BUWH
10 1 A 8B 1 2 3 4 5 6
10 2 A 9B
To A RD
To A Capacitor
See note 3 10 3 A 6B
125V 0.022μ BK

B Display
4 A 7B
RDYE

BKYE

10
RDYE BKWH
10 5 A 11B 6P
To point “b” BKYE RDWH
28 28 10 6 A 10B WH
To F See note 1
Capacitor BU
4P
RDYE
RDYE
BKYE
BKYE

125V 0.022μ See note 3 11 1 A 2B

RD 1 2 3 4
RDYE
11 2 A 3B WH
To point “b” BKYE 11 3 A 4B
BK

C ModeSeeselect
To point “a” 11 4 D 5C
WHBU
WHYE

switch
To point “a” To F
RDYE

RDYE
BUYE
BKYE

BKYE

BU

note 1
24 24 24 24 24 24 24 24

D Low speed (turtle) switch

RD

RDGN
BN
1 3 2 4 1 3 2 4 GNWH
16 A 1B
BK
16 A,C 5B
A A
E Head lamp switch
Point "a" Point "a"
RDBK
16B 17B 16C 20B
Note : 16 A 12B
WHGN
16 A 13B
Point "a" A Point "a" A
1. All pin layout shows the view from terminal insert side.
2. Electric wires are should be tied at only ends of the tube,
15B 18B 15C 19B
not inside the tube. 4 4 4
YERD
16 A 24B
3. When installing the film capacitor to harness, conform YEBK 16 A 25B
as shown the figure below.
H OPT.switch
AMP 174257-2 AMP 174257-2 21B 23B BNWH
16 A 26B
BNRD
16 A 27B
Water proof type Water proof type A A
G Key switch BNYE
Heat contraction tube or Capacitor
Plug 4P Plug 4P vinyl tube (Both ends are tied) Vinyl tube (Heatproof type)
22B
16 A 28B
BNBK
(Colorless)
(Cover to splicing) 16 A 29B
A

Splicing *Only for trucks with option(s)

2 1 2 1 P1.25 1 option / 2 options / 3 options
4 3 4 3

F EPS encoder
See note 1

FBRF-75 Harness PS 6-14.

54001-61240/61250/61260/61270-1E
98
 Note)
1. All wires should be fixed to prevent contacting to the part Only for trucks with turn signal lamp
of moving, of heat source and with edge. Horn switch
2. The wiring should be placed inside the range surrounded
with dot-dash lines in this diagram.
Turn signal switch
3. Symbols Joystick Switch comp., toggle
2 : Plug AMP 170020-3
Only for trucks with 5 levers 54000-69830
AMP 170002-5
2 : Receptacle AMP 170021-3
AMP 170003-5 Attachment Side shift Tilt Reach Lift Directional switch
4 : Terminal JST 1.25-4

RDBU
BUYE
RDYE
2
2
2

2
2
2

Switch assembly,
BUYE
RDYE
RDBU

Water Water Water Water directional

3P proof type 3P proof type 3P proof type 3P proof type
4P Water
proof type
4 3 2 1

Reference:
Harness mark/color Harness, lever panel
Red RD
Black BK (Harness should not be fixed to the panel.)
Green GN
Yellow YE
White WH
Brown BN

RDGN

RD
Blue BU
Gray GY
Pink PK
Orange OG 4 4
Ex) BKWH (=Black/White) Water
Black colored harness with White line. proof
type

20P 3P
Emergency switch
3P
White line
20P Lever harness Bottom view of lever panel

54000-68032-0E
Black color Body harness (1)
Wiring (Diagrams) 6

FBRF-75 Lever panel wiring 6-15.

99
100
RD
4 A 8B
RDGN
4 A 9B
6 Wiring (Diagrams)

AMP 174357-2 RDBK

4 1E Point "a" 1 4
Water proof type GNBK E Emergency switch
6B A 2 4
3 2 1 BK
Plug 3P 2E Point "a" 3 4
RDBK 25 Point "a"
1 1A
BK 25
Side shift 2 Point "a" 2A
YEWH 25 3 D 3A
AMP 174357-2 BNYE 25
RDBK 4 D 4A
3 1D Point "a" 1 4 BKRD 25
Water proof type BNYE 5 D 5A
4B A 2 4 GNBK 25
3 2 1 BK 6 D 6A
Plug 3P 2D Point "a" 3 4 RD 25
70 7 E 8A
RDGN 25 8 E 9A
GNWH 25
Tilt 9 B 10A
BUYE 25
AMP 174357-2 10 B 11A
RDBK RD 25
2 1C Point "a" 1 4 50 11 Point "b" 12A
Water proof type BKRD Point "a" 12
5B A 2 4 RDBK
3 2 1 BK 25 13 C 13A
Plug 3P 2C Point "a" 3 4 WHBK
25 14 C 14A
BUYE
25 15 F 15A
Reach RDYE
Point "b" 25 16 F 16A
AMP 174357-2 RDBU
RDBK 25 17 F 17A
1 1B Point "a" 1 4 18
Water proof type YEWH
3B A 2 4 19
3 2 1 BK
Plug 3P 2B Point "a" 3 4 20

Lift
D Hyd. lever potentiometer 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
See note 1, 2
AMP 040 series
Multi lock connector (mark II)
Point "a" 175652-2
See note 3 RDBK
BUYE
GNWH

Point "b"
RDBU
RD
RD

BUYE
RDYE

13B A CN1
See note 3 WHBK

To A
To A

To D
To D
To D
To D
To D
To D
To D
To D
14B A 2 2 2 4 4 4 4
1 2 3 4

BK
BK
BK
BK
BK
To A
To B
To B
A Harness, body

RDBK
RDBK
RDBK
RDBK
RDBK
A A Point "b"
See note 1

RD
RD
RD
C Horn switch
16B 11B 12C
See note 4
A A A Point "b"
15B 17B 10B 12B
17 17

17 F Turn signal lamp

AMP 174257-2

54000-68041-0E
<Note> 2 1 Water proof type
1. All pin layout shows the view from terminal insert side. 4 3 Plug 4P
2. Write or impress the figures with undamped ink.
CE-2
3. Terminal(CE-2) should be tied with wire tie as shown in
the right figure.
4. When installing electric wires to the terminal, solder them B Directional switch

FBRF-75 Lever panel harness 6-16.

with strands of lead wires are hooked to the hole. See note 1
 AMP 174257-2
RDBK
24 RDBK 6
Water proof type YEBU YEBU
3 2 1 Plug 3P 24 6
BK BK
24 6

A Panel, lever B MPU board

Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
White WH
Brown BN
Blue BU
Gray GY
Note: Pink PK
Orange OG
1. All pin layout shows the view from terminal insert side. Ex) BKWH (=Black/White)
Black colored harness with White line.

White line

Black color

FBRF-75 Lever harness

54001-75710-0E
Wiring (Diagrams) 6

(for 4spools (5way-piping) 6-17.

101
102
10A Key switch
RDWH
Under the floor plate
6 Wiring (Diagrams)

X1 X1 Fwd/Bwd
buzzer/
chime

(BN)

(BN)

Battery 48V
BU
BU
Relay comp.

BK
54000-70930
Fwd Bwd

RDWH
buzzer/ buzzer/
chime chime

1
1

YEBK

BNBK
BKWH
BU
BN

BU
RDWH

BKWH
1

Line No. OF2 OB2

PB103 CN 5 5
-30 Connector
Pin No. 6 15
Fwd output Bwd output
1

1
1
1

System wiring
connect to this side.

When “fwd”chime/buzzer,
When “bwd”chime/buzzer,

connect to this side.

YEBK

RDWH
BNBK

Reference:
Harness mark/color
Note : Red RD
Black BK
1. Terminal symbol Green GN
Yellow YE Body harness (1)
1 : Shur plug (with plating) 170020-2 White WH
Brown BN
1 : Shur receptacle (with plating) 170021-2 Blue BU
(N Accessory)
Gray GY
Pink PK
Orange OG

Ex) BKWH (=Black/White)

Black colored harness with White line.

FBRF-75 Wiring, chime/buzzer

54000-70941-1E
White line

Black color

6-18.
 Key switch
RDWH

See note 3
WH
Revolving To strobe light 2P
lamp

WH
WH
Revolving Wiring for

2
2
lamp strobe light See note 2

Battery 48V
BK
WH

BK
BK
Harness comp., lamp
See note 2 54000-29680
Harness, accessory
BKWH 24800-98671

Revolving lamp Strobe light wiring

Inside the panel (1)

System wiring
BK
BK

WH
WH

1
1
1
1

BKWH
BKWH

RDWH
RDWH

Reference: Note) 1. Terminal symbol

Harness mark/color
Red RD
1 : Shur plug (with plating) 170020-2
Black BK
Green GN 1 : Shur receptacle (with plating) 170021-2
Yellow YE
White WH 2
Brown BN
: Shur plug (without plating) 170020-3
Blue BU 2 : Shur receptacle (without plating) 170021-3
Gray GY
Revolving lamp Strobe light wiring
Pink PK 2. Pass the harness through inside the pipe of head guard.
Orange OG

Ex) BKWH (=Black/White) Body harness (1)

Black colored harness with White line.
(Z Accessory (1))

FBRF-75 Wiring, light

54000-70630-0E
White line

Black color
Wiring (Diagrams) 6

6-19.

103
104
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
Key SW White WH
10A Brown BN
6 Wiring (Diagrams)

RDWH Blue BU
Gray GY
10A Pink PK
RDBK Turn Turn Orange OG
Head lamp signal lamp Head lamp signal lamp
(LH) (RH) Ex) BKWH (=Black/White)
Flasher unit (LH) (RH) Black colored harness with White line.

2
2
2
2
2
2
2
2

RDBU
White line
RDYE

BUYE

BKWH
BKWH
BKWH
BKWH

WHGN
WHGN

WHGN
Black color

Battery 48V
BUYE
RDYE
Turn Turn
Head lamp Head lamp signal lamp signal lamp
(LH) (RH) (LH) (RH)
See note 2

BKWH Inside Lever panel

Inside the resin cover
of steering wheel side Inside Steering Ass’y
System wiring Turn signal lamp SW
(only w/turn signal
Relay comp., flasher Head lamp SW lamp)
(only w/turn
signal lamp)
Harness, headguard
54000-70670
54000-70660
RDWH
RDBU

“Accessory (1)”
1
1

4P section of
“Headguard” section of WH Harness, body
Note) 1. Terminal symbol Harness, body
1
RDBU
RDWH

: Shur plug (with plating) 170020-2

1 : Shur receptacle (with plating) 170021-2
2 : Shur plug (without plating) 170020-3 Harness, body
2 : Shur receptacle (without plating) 170021-3

54000-70680-0E
2. Pass the harness through inside the pipe of head guard.
3. In this diagram, the truck direction is defined as follows.
Forward : mast side
LH : left side in the state that look to forward

FBRF-75 Wiring, head lamp 6-20.

RH : right side in the state that look to forward
 Note) 1. Lead wire : AV or AVS or AVSS0.5mm 2
2. All pin layout shows the view from terminal insert side.

RDYE
3 1 C 1A
Cap
BUYE
3 2 B 2A 2 1
WHGN 4P
3 3 B,C 3B 4 3
BKWH WH
3 4 B,C 4C

A Body harness

RDYE
WHGN
BKWH
BKWH
BUYE
WHGN
BKWH
BKWH
Reference:

2
2
2
2
Harness mark/color

2
2
2
2
Red RD
A A,C Black BK
Green GN
1B 4D A B Yellow YE
A C White WH
2B 4A Brown BN
3C 4E A B,A Blue BU
Gray GY
3A 4B Pink PK
Orange OG

Ex) BKWH (=Black/White)

Turn signal Turn signal Black colored harness with White line.

C head lamp(Right) B head lamp(Left)

White line

FBRF-75 Harness, head guard

54000-70661-0E
Black color
Wiring (Diagrams) 6

6-21.

105
 Reproduction prohibited
First printing : May 2010

Issued by : Nippon Yusoki Co., Ltd

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