1659693473646696

CONTENTS
1. Adjustment of SICOS-AC 1 2. Troubleshooting 58
1-1. Explanation of the monitor display ........... 1 2-1. Self diagnosis function ........................... 58
1-1-1. Indicator panel 1 2-1-1. Display 56
1-1-2. Indication of display 2 2-1-2. Error messages and Display conditions 60
1-1-3. Function of display 3
2-2. Error history memory .............................. 62
1-1-4. Various kinds of mode selection 9
2-2-1. Error history memory 1 62
1-2. Explanation of the MPU board ............... 14 2-2-2. Error history memory 2 63
1-2-1. Basic control board construction 14 2-2-3. Clearing the error history memory
1-2-2. Travel/ Hydraulic board (MPU board) 14 (memory initialization) 65
1-2-3. EPS controller 15
2-3. I/O Check ............................................... 66
1-2-4. Rotary switch on the Travel/ Hydraulic board 16
2-3-1. I/O check mode display method 66
1-2-5. Rotary switch on the EPS controller 17
2-3-2. I/O port table 68
1-2-6. Adjustment Standards List for FBRF-70 series 18
1-2-7. Confirmation of other services 19
1-3. SICOS-AC check and adjustment .......... 21

1-3-1. Chassis insulation check 21
1-3-2. Battery voltage adjustment 22
1-3-3. Current detector check 23
1-3-4. Forklift model setting check and adjustment 27
1-3-5. Safety circuit for control
(contactor tripping) check 28
1-3-6. Hydraulic setting check and adjustment 29
1-3-7. Switch back (plugging/ regenerative)
braking force adjustment 31
1-3-8. Regenerative braking force check and adjustment 32
1-3-9. Safety monitor symbol check and adjustment 33
1-3-10. Steering setting check and adjustment 35
1-3-11. Optional setting check and adjustment 37
1-3-12. Display brightness check and adjustment 39
1-3-13. Hour meter working check 40
1-3-14. Checking the function of auto power off 40
1-3-15. Cooling fan working check [Fan(1)] 41
1-3-16. Lift interrupt working check 41
1-3-17. Turning speed reduction setting 42
1-3-18. Foot switch working check 43
1-3-19. Checking the function of neutral safety 43
1-3-20. Checking the function of
battery tray interlock 43
1-3-21. Accelerator potentiometer adjustment 44
1-3-22. Brake potentiometer adjustment 46
1-3-23. Hydraulic lever (joystick)
adjustment and check 48
1-3-24. Valve electric current adjustment 50
1-3-25. AOS setting (optional) 52
3. Wiring 71
3-1. FBRF-70 System wiring ......................... 71

3-2. FBRF-70 Body wiring ............................. 72
3-3. FBRF-70 Body harness(1) ..................... 73
3-4. FBRF-70 Body harness(2) ..................... 74
3-4-1. FBRF14/16/20-70 (Std/RP) 74
3-4-2. FBRF14/16/20-70 (CS) 75
3-5. FBRF-70 Floor harness .......................... 76

3-6. FBRF-70 Body harness(AOS) ................ 77
3-7. FBRF-70 Controller wiring ...................... 78
3-8. FBRF-70 Controller harness .................. 79
3-9. FBRF-70 Main contorller ........................ 80
3-10. FBRF-70 Harness IGBT board ............. 81
3-11. FBRF-70 Wiring PS .............................. 82
3-12. FBRF-70 Harness PS .......................... 83
3-13. FBRF-70 Lever panel wiring ................ 84
3-14. FBRF-70 Lever panel harness ............. 85
3-15. FBRF-70 Wiring, chime ........................ 86
3-16. FBRF-70 Wiring, light ........................... 87
3-17. FBRF-70 Harness, head guard ............ 88
1. Adjustment of SICOS-AC
1- 1. Explanation of the monitor display
1-1-1. Indicator panel
Monitor display
2 14 15 16 17 18
1 3 4 5
9 11 12 13
7 10 8
Mode select switch
19
152T001
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 (battery tray interlock)
17. Safety monitor for hydraulic lever
18. Safety monitor for travel
19. Mode select button
NOTE Icons of 10 to 18 and 2 shown in the illustration are displayed for the explanation. It is
not actual indication. They are displayed when abnormalities are occurred.
1
Adjustment of SICOS-AC 1
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 blinked
three times for warning to the operator. After 1.5 seconds
The normal screen is displayed.

If any abnormalities are detected, the error message
After 1 seconds
is displayed. If the long message is displayed or some
messages are displayed, they are scrolled from right to
left alternatively.
NOTE Normal screen Flashed 3 times

If traveling or hydraulic operation is done while
this (with-in 3 or 4 seconds), the normal screen is
immediately displayed.
152T002
CAUTION Contact to your local Nichiyu dealer if the error

message is displayed.
Mode setting buttons

NOTE If travel/hydraulic operation is done while one-
touch operation screen is being displayed, it
returns to the normal screen.
152T003
Setting screen by one touch operation
Clock setting screen

Push button. Refer the page 4. for details.
For setting of date and time.
Mode select screen

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

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

This forklift truck has the self-diagnosis function.
2 14 15 16 17 18
1 3 4 5
9 11 12 13
7 10 8
19
152T001
NOTE Icons of 10 to 18, 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 shorten by over-dis-
charging.
Charge the battery as soon as possible when [E]
segment is lit.
Full Charge the battery immediately

charged In case of
40% discharge Less than 20% Less than 10% Empty
Discharge Discharge Discharge Discharge
When the battery capacity is When the capacity is less than 10%,
less than 20%, all blue one red segment is flashed with the
segments are disappeared frame of the indicator.
and two red segments are lit. When the capacity is empty, only the
frame of the indicator is flashed. 121T190E
3
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 blinks Lift speed is reduced to half.
on the screen. One red segment
is started to flash.
When the truck is continued to use, only one red
segment is started to blink 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 9 for details.
152T011
4. Speed meter
The traveling speed is displayed on the screen.
152T005
5. Fork leveling indicator (Special option)

This mark is indicated when the fork is leveled.
152T006
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. 152T008
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.
4
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 152T012
section.
CAUTION The hour meter screen is returned to the normal

screen even less than 5 seconds by operating
traveling or hydraulic function.
5
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
blinked and the presumed defective part name and error

number is displayed. If some problems are occurred at
the same time, each part name and error numner blinks.
NOTE 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.
B11 - B13 : (IGBT U,V,W-TRAVEL)

C21 - C23 : (IGBT U,V,W-HYD)
D31 : (ENCODER-EPS)
D32 : (TR-EPS MAIN)
G61 : ( FAIL CURRENT-TRAVEL )
G62 : ( FAIL CURRENT-HYD )
The , and buttons are disabled while EPS controller

the self-diagnosis screen is displayed.
F01
If rotary switch DISP on the EPS controller
CDE
23
is set to F, the self-diagnosis screen will not
456
AB
789
be displayed. (The normal screen will be
displayed.) DISP="F"
When the abnormalities and/or errors are
resolved, the display will return to the normal
screen.
6
11. Safety monitor (for travel circuit)

When fault is detected in the travel circuit, the travel icon
blinks 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 blinks and the presumed error number is
152T015
displayed.
13. Safety monitor (for power steering circuit)

When fault is detected in the power steering circuit, the
steering icon blinks and the presumed error number is
152T016
displayed.
14. Safety monitor (for overload)

(Special option)
When overloaded, the load icon blinks.
152T017
15. Safety monitor (for hydraulic oil level)

(Special option)
If the hydraulic oil level is low, the icon blinks.
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.
7
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. 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 152T102
off)
The slow speed mode indicator ( ) is not displayed.
Slow speed mode (when the slow speed button is on) When the slow speed button is off
( Turtle mark is not displayed)
The turtle icon and preset speed are displayed on the Preset speed indication
screen.
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)
normal mode and slow speed mode by pushing the 152T023
turtle button.
8
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 These settings are invalid while traveling or

depressing the brake pedal.
If traveling or hydraulic operation is done
while setting, the display is returned to the
normal screen immediately.
When pushing button (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.
and buttons : Move the cursor to select
the value.
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
blinked. 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 152T024
and smooth inching can be realized.
P (POWER)
9 This is the most powerful mode for acceleration.
[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 blinked. 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, 8, 10 and 12km/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.
10
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.
152T020
[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)
1 7
Dark Bright
11
[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 If traveling or hydraulic operation is done

while setting, the display is returned to the
AM / PM is flashed.
normal screen immediately. 152T029
Each time pushing and buttons, the

second is reset at 0.
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.
and buttons : Move the cursor to select
the value.
button : Move the cursor to the previous item.
12
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 blinked three
times.
"TIME COMPLETE" is flashed three times.
CAUTION When pushing the or button, the

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

button, the second is set to "00".
13
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 controller 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 controller
Hydraulic
CPU for hydraulic Gate board
motor
EPS motor
152T123
1-2-2. Travel/ Hydraulic board (MPU board)

<Type : PBC103-XX>
This board controls the traction motor and the
hydraulic motor.
[RS1] : Rotary switch for model selection
(LIFT) (VR1)
Proportional
CN1
(TILT) (VR2)
(ATT1) (VR3)
valve adjustment
(ATT2) (VR4)
CN2
(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
CN5 CN6 CN7 CN8 CN11 CN12
Connector for personal computer

Body harness(1)
152T103
14
1-2-3. EPS controller

<Type : CU104-XXX>
This board controls sharing the data with other boards,
the screen display and EPS motor.
(CPU) CPU drive
Buzzer
[DISP] : Rotary switch for
monitor selection
Battery
PB103-21
CN4
Connector for personal computer
CN1 CN2 CN3
Body harness(1)
152T104
Normal condition while turning on the key switch

LED Travel/Hydraulic board EPS controller
P15 lighting
P6 lighting
HYD lighting
TRV lighting
CPU blinking
CAUTION When the MPU board or EPS controller

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.
In case of changing the settings for the rotary
switches, be sure to turn off the key switch
once before changing them.
15
1-2-4. Rotary switch on the Travel/ Hydraulic board

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

RS1 Applicable forklift models
0 FBRF14
1 FBRF16
2 FBRF20
3
4
5
6
7
8
9
A
B
C
D
E
F
DS1(DIP Switch)
DS1 is not used.
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
16
1-2-5. Rotary switch on the EPS controller

The rotary switch (DISP) on the EPS controller is used for selecting the displays and
adjustments shown in the table below.
DISP setting functions
DISP Functions Remarks
MONITORING OK After turning on the key switch, this message is displayed.

Meters (Battery discharge, Speed, Hour, Error,
Normal screen
Clock)
Hour meter check Total, travel and hydraulic hour meters appear.
Date and time setting Set the time.
Set the maximum speed under the slow speed
Slow speed setting
0 mode. (2, 3, 4, 5, 6, 7, 8km/h)
Travel mode setting Select ECONOMY, NORMAL or POWER.
Meter mode setting Select the hour meter or odometer.
VIEW (contrast)
Display brightness setting
BRIGHTNESS (0-7 intensity of back light)
Adjustment of regenerative brake
Select NON, LOW, MID or HIGH
when accelerator is released
1 Monitor symbol setting STEER, BATT, OIL, LOAD, BRAKE
Drive unit mode, Turn number of steering, Steering
2 EPS mode setting
mode
Plugging strength setting 0 - 32
3
Brake strength setting 0 - 32
Hydraulic response S(Slow) / N(Normal) / Q(Quick)
Maximum lift speed 1 0 - 32 (Fast) : For travel speeds of 0 - 4 Km/h
Maximum lift speed 2 0 - 32 (Fast) : For travel speeds of 4 - 8 Km/h
Maximum lift speed 3 0 - 32 (Fast) : For travel speeds of over 8 Km/h
4 Lift speed 0 - 32 (Fast)
Tilt speed 0 - 32 (Fast)
Reach speed 0 - 32 (Fast)
Side shift speed 0 - 32 (Fast)
Auxiliary 0 - 32 (Fast)
5
6 Option setting Set the options.
7 Voltage, current and temperature check
8 RAM and I/O memory data check
Error history memory 1 Displays the details of the 10 latest cases
9
Error history memory 2 Records all past errors
A Battery voltage setting Voltage settings for capacity standards
B Turning speed reduction 0 - 16
C AOS setting Sets the lift/tilt end and others
D
E Memory initial Clears the error history
F Normal screen 2 No errors are displayed on the screen
17
DISP on EPS controller
RS1 on 4 3 1
Voltage Model MPU
[V] board HYD Travel speed Lift speed
SPD-L SPD-M SPD-H HYD HYD HYD HYD HYD PLUGG BRAKE TRAVEL HYD STEER BATT OIL LOAD BRAKE
RESPONSE LIFT LIFT LIFT LIFT TILT REACH SIDE ATTAT ING TRQ (km/h) (mm/sec)
FBRF14 0 1 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
4
5
6
7
8
9
A
B
C
D
E
F
Memory initial (DISP=E) Option setting (DISP=6)

Slow speed (turtle speed) : 5km/h LIFT LOCK : ON [Lift interrupt]
Travel mode : NORMAL SPEED LIMIT : OFF [Speed limit at high lifting height]
BRIGHTNESS :5
AOS : OFF [With AOS]
Neutral regenerative brake : MID
Meter mode : HR (hour meter) H-DSP : OFF [Lifting height indicator]
Error history : Clear HOUR METER :1 [Hour meter count]
1-2-6. Adjustment Standards List for FBRF-70 series
HOUR METER (hour meter count) setting

1: Key switch ON
2: Actual operation time (motor operation time)
18
1-2-7. Confirmation of other services
Display
<Confirmation>
After pushing button, button and button
together for more than 3 seconds, it is displayed as
follows.
Model confirmation
The model set by rotary switch

on the MPU board (Travel /
Hydraulic) is displayed.
152T034
Software number confirmation

The software program numbers
: T (travel)
H (hydraulic)
P (EPS)
152T035
are displayed.
Buzzer mode setting

Buzzer mode setting is highlighted.
Set buzzer mode by pressing
" " or " " button (OFF/ ON).
ON : Normal
152T036
OFF: Turns off all the buzzer
sound except blinker sound
Rotary SW mode setting
Rotary switch mode setting is

blinking.
Set rotary switch mode by pressing
152T037
" " or " " button (OFF/ ON).
ON : Normal
OFF: The rotary switch is disabled
(continues on next page)
and the setting number of
rotary switch is able to change
by mode select button.
19
(continued from previous page)
Maximum travel speed setting
Maximum travel speed setting

is blinking.
Set maximum speed by pushing
152T038 " " or " " button (from "0"
to "16" km/h)
Maximum travel speed is limited
Return to normal screen
to the setting speed.
CAUTION When the connection is failure between EPS

controller and MPU board, software numbers
are not displayed.
If rotary SW mode is set to OFF, the rotary
SW is disabled on the EPS controller. You can
change the rotary SW setting by "keeping
pressing down button for more than
3 seconds while pressing button" or
"keeping pressing down button for more
than 3 seconds while pressing button".
The default of maximum travel speed setting
is 0km/h. At this time, truck maximum travel
speed is based on specification.
If the setting speed is over specification, the
setting is not available.
20
1- 3. SICOS-AC check and adjustment

CAUTION In case of changing the settings for the rotary
EPS controller
switch DISP, be sure to turn off the key switch
once before changing them. F01
CDE
23
After finishing the setting, be sure to return
456
AB
rotary switch DISP to "0". 789
Before measuring current, change the mode

Return DISP to "0".
depending on the objects.
Traction motor current
AC mode
Hydraulic motor current
Battery current
DC mode
EPS motor current
When the connection is failure between EPS
controller and MPU board, there are possibility
that the setting screens are not displayed.
1-3-1. Chassis insulation check

<Checking procedure>
1. Disconnect the battery plug.
2. Discharge the capacitors in the control unit.
(For the discharge procedure, refer to "WORKSHOP
MANUAL".)
3. Use a tester to measure the insulation resistance
between positive (+) terminal of the chassis battery
plug and chassis, between negative (-) terminal of the
chassis battery plug and chassis.
Specification 1M or greater
21
1-3-2. Battery voltage adjustment

<Measuring points>
Pull out the battery and measure the battery voltage
between positive terminal and negative terminal.
<Measuring conditions>
Specific gravity of the battery electrolyte : over 1.25 at
20
<Measuring instrument>
Use a digital tester that can measure 1/100V.
Use Direct current (DC) mode.
<Adjusting procedure>
1. Set rotary switch DISP on the EPS controller to "A". F01
CDE
23
456
AB
789
2. Turn on the key switch and the following screen

Set DISP to "A".
appears.
Battery voltage setting screen
152T039
Battery Voltage Parameter (blinking)
3. Set the parameter for battery voltage to the same as

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

Press button to decrease the parameter.
22
1-3-3. Current detector check

Traction motor current check
<Measuring point>
IU: traction motor U phase electric current (V phase or
W phase is also possible.)
Specific gravity of the battery electrolyte : over 1.25 at 20
Alternating current (AC) mode
Control unit
Fan (1)
CN4 CN3 CN2 CN1
F+
2P
WH Board Comp., MPU
NA
<7>
EPS controller W2 W1 V2 V1 U2 U1 Traction motor U phase

<6> <5> <4> <3> <2> <1>
CN1 CN2 CN3
2P-X
12P
Analog clamp ammeter
Harness, body (1)
152T040
CAUTION When measuring AC motor current, use the

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

using Hioki 3209 AC/DC (Digital), you need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response
23
1. Set rotary switch DISP on the EPS controller to "7".
F01
CDE
23
456
AB
789
appears. Set DISP to "7".
NOTE If "TR" is not blinking, press or button

to make it blink.
Voltage, current, and temperature checking screen.

Setting of TR (Traction) blinks.
Display
Battery voltage (travel CPU detection)
Traction motor current.
152T042
Setting of TR (Traction) blinks.
Display temperature of MPU board.

152T043
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
24
Hydraulic motor current check
<Measuring point>
IU: hydraulic motor U phase electric current (V phase or
W phase is also possible.)
Specific gravity of the battery electrolyte : over 1.25 at 20
Alternating current (AC) mode
Control unit
Fan (1)
CN4 CN3 CN2 CN1
F+
2P
WH Board Comp., MPU
NA
<7>
EPS controller W2 W1 V2 V1 U2 U1
<6> <5> <4> <3> <2> <1>
CN1 CN2 CN3
Analog clamp ammeter
2P-X
12P
Hydraulic motor U phase
Harness, body (1)
152T041
CAUTION When measuring AC motor current, use the

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

using Hioki 3209 AC/DC (Digital), you need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response
25
F01
CDE
23
456
AB
789
3. Press either or button to make HY blink.
Voltage, current, and temperature checking screen.

Setting of HY (Hydraulic) blinks.
Display
Battery voltage (Hydraulic CPU detection)
Hydraulic motor current.
152T044
Setting of HY (Hydraulic) blinks.
Display temperature of IGBT module.
152T045
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.
26
1-3-4. Forklift model setting check and adjustment

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.
Forklift model type checking screen

MPU board
(In case of rotary switch for model selection on the MPU
board is set to "1") F01
CDE
23
456
AB
789
RS1="1"
152T034
Refer "1-2-4. Rotary switch on the Travel / Hydraulic

board" for details.
27
1-3-5. Safety circuit for control (contactor tripping) check

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 travel/hydraulic board.
(LIFT)
CN1 CN2
(TILT)
(ATT1)
(ATT2)
Connector for hydraulic (REACH)
(PV)
(P15)
(P6)
(HYD)
(TRV)
CN3
CN10 CN9
HYD TRV
Connector for traction
CN4

152T105
CAUTION Do not operate travel or hydraulic with

disconnecting either CN2 or CN4. It may damage
lGBT module.
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 messages comes
on as shown below.
Error messages
D31 : (ENCODER-EPS)
D32 : (TR-EPS MAIN)
28
1-3-6. Hydraulic setting check and adjustment

1. Set rotary switch DISP on the EPS controller to "4". F01
CDE
23
456
AB
789
appears.
3. Confirm that the parameter items are set to the same Set DISP to "4".
as the values on the "Adjustment Standards List" on

page 18.
Hydraulic response setting screen

Setting of hydraulic response blinks.
Set by pushing or button.
S: Slow
N: Normal
Q: Quickly
152T046
Hydraulic speed setting screen
Setting of hydraulic speed limit (when

traveling speed 0-4km/h) blinks.
Set by pushing or button (0-32).
152T047

traveling speed 4-8km/h) blinks.
152T048

traveling speed over 8km/h) blinks.
152T049
Setting of LIFT hydraulic speed blinks.

152T050

29
Setting of TILT hydraulic speed blinks.

152T051
Setting of REACH hydraulic speed blinks.

152T052
Setting of SF (side shift) hydraulic speed

blinks.
152T053
Setting of ATT.1 hydraulic speed blinks.

152T054
Return to Hydraulic response setting screen
1. Press button to move the blinking icon to the each
parameter.
2. Press button to increase the parameter.
3. Press button to decrease the parameter.
30
1-3-7. Switch back (plugging/ regenerative)

braking force adjustment
Flat ground, unladen, and full speed
Specific gravity of the battery electrolyte : 1.25 or over
(at 20°C䎌䎃
F01
CDE
23
456
AB
789
Plugging strength setting screen
Setting of plugging strength blinks.

152T055
To braking strength setting screen
3. Confirm that the "PLG" parameter is blinking.
NOTE If the PLG parameter is not blinking, press

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

5. Press button to decrease the braking force.
<Standard parameter>
Refer to the Adjustment Standards List on page 18.
31
1-3-8. Regenerative braking force check

and adjustment
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.
F01
CDE
23
456
AB
789
Braking strength setting screen
Setting of braking strength blinks.

152T056
To plugging strength setting screen
3. Press button to move the blinking icon to the "BRK"

parameter.
4. Press button to increase the braking force
(regenerative brake).
5. Press button to decrease the braking force
(regenerative brake).
32
1-3-9. Safety monitor symbol check and

adjustment
F01
CDE
23
456
AB
789
appears.
3. Confirm that the parameter items are set to the same Set DISP to "1".
as the values on the "Adjustment Standards List" on
page 18.
Monitoring symbol setting screen
TRAVEL
HYD
STEERING
OVER LOAD
FORK OIL
152T058
item.
2. Press button to turn the item "ON".
3. Press button to turn the item "OFF".
4. Turn off the key switch and return rotary switch DISP
F01
to "0".
CDE
23
456
AB
789
Return DISP to "0".
33
5. Turn on the key switch again.

It indicates the symbols set to "ON" at the monitoring
symbol setting screen.
152T059-
34
1-3-10. Steering setting check and adjustment

<Setting procedure>
F01
CDE
23
456
AB
789
appears.
Set DISP to "2".
Drive unit mode
Setting of drive unit mode blinks.

Set by pushing or button (180
degree / 360 degree).
152T060
NOTE Normaly, turn angle of drive unit is 360 degree. Only

for trucks with drive stopper is selected 180 degree.
Turn number of steering <Std>
Setting of turn number of steering <Std> blinks.

Default: 10
152T061
Turn number of steering <Max>
Setting of turn number of steering <Max> blinks.

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>.

35
Steering mode
Setting of steering mode blinks.

Set by pushing or button (NML
<Normal steering> / RVS <Reverse
152T063
steering>).
Normal steering Reverse steering
Return to drive unit mode setting screen
item.
2. Press either or button to turn the value you
want to set.
36
1-3-11. Optional setting check and adjustment

F01
CDE
23
456
AB
789
appears.
3. Confirm that the options are set correctly. Set DISP to "6".
Optional setting screen
Setting of LIFT LOCK blinks.

Set by pushing or button
(ON/OFF).
Setting of SPEED LIMIT blinks.

(ON/OFF).
Setting of AOS blinks.

(ON/OFF).
Setting of LIFTING HEIGHT DISPLAY blinks.

(ON/OFF).
Setting of HOUR METER blinks.

(ON/OFF).
152T064
37
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 AOS or Lifting height
OFF
INDICATOR indicator function
1 : Key switch ON
HOUR METER 1 2 : Actual operation time
(motor operation time)
item.
2. Press or button to turn the item "ON", "OFF"
or "1", "2".
38
1-3-12. Display brightness check and

adjustment
Confirm that the information on the display can be read
clearly even indoors.
1. Press button repeatedly till the display adjustment
screen appears.
Display adjustment screen
152T065
Display brightness parameter (blinking)
2. Confirm that the "BRIGHT" parameter is blinking.

3. Press or button to adjust the brightness (0-7).
Press button to increase the parameter.
Press button to decrease the parameter.
39
1-3-13. Hour meter working check

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 blinks

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 (blinking)
Normal : key SW ON (white)
Option : actual operation (colored) 152T106
152T067
1-3-14. Checking the function of auto power off

1. Turn on the key switch.
2. Confirm that the main contactor is turned off by keeping
no operation for 15 minutes.
40
1-3-15. Cooling fan working check [Fan(1)]

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.
1-3-16. Lift interrupt working check

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 blinks.
Display : Battery symbol is displayed.
Lift : Lift function is interrupted.
152T069
Frame blinks Battery symbol blinks
41
1-3-17. Turning speed reduction setting

<Setting procedure>
1. Set rotary switch DISP on the EPS controller to "B".
F01
CDE
23
456
AB
2. Turn on the key switch and the following screen 789
appears.
Set DISP to "B".
Turn speed setting screen
Setting of turn speed blinks.

152T070
Default : 5km/h
CAUTION In case that the turn speed is set over the truck
maximum speed, this function does not work.
Turn angle setting screen
Setting of turn angle blinks.

(15/30/45/60/75/90 degree).
152T071
Default : 45 degree
Return to turn speed setting screen
Press the button to increase the parameter.

Press the button to decrease the parameter.
NOTE As the turn angle means the drive wheel direction Forward
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
42
1-3-18. Foot switch working check

1. Operate the directional switch and accelerator without
depressing the foot switch.
2. Confirm that the truck doesn't travel.
1-3-19. Checking the function of neutral safety

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.
1-3-20. Checking the function of battery

tray interlock
1. Operate the any hydraulic lever with depressing the
pedal lightly.
2. Confirm that the hydraulic function doesn't work.
43
1-3-21. Accelerator potentiometer adjustment

F01
CDE
23
456
AB
789
appears.
Set DISP to "8".
RAM . I/O selection

Current device blinks.
Select "I/O" by pushing or button.
CPU selection
Current CPU blinks.

Select "TR" by pushing or button.
Data length setting
Current data length blinks.

Set "W"(double-byte) by pushing or
button.
Data address setting
"0" blinks. (not variable)
152T075
44
The data address (single-byte high) blinks.

Set "1" by pushing or button.
The data address (single-byte low) blinks.

Set "2" or "4" by pushing or
button.
I/O data W0012 : output voltage 1

W0014 : output voltage 2
I/O data is displayed.
152T125
Return to RAM . I/O selection
3. Press , or button to select "I/O", "TR", and

"W0012" or "W0014".
(Refer to "2-3. I/O check" on page 66 for setting.)
released position
4. Adjust the potentiometer by loosing the screw. (Refer to I/O data
"WORKSHOP MANUAL".) 008F
The applicable "I/O data" is as follows at the released
position of accelerator pedal. 00CF
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".
45
1-3-22. Brake potentiometer adjustment

F01
CDE
23
456
AB
789
appears.
Set DISP to "8".
RAM . I/O selection

CPU selection
Current CPU blinks.

Select "TR" by pushing or button.
Data length setting

button.
152T075
46


I/O data
152T076
3. Press , or button to select "I/O", "TR", and

"W0016".
released position
4. Adjust the potentiometer by loosing the screw. (Refer to I/O data
"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".
47
1-3-23. Hydraulic lever (joystick)

adjustment and check
<Adjusting procedure 1 (I/O check)>
F01
CDE
23
456
AB
789
RAM . I/O selection

CPU selection
Current CPU blinks.

Select "HY" by pushing or button.
Data length setting

button.
152T075
48

Set "1" or "2" by pushing or
button.

Set "2", "4" or "6" by pushing or
button.
I/O data
152T124

3. Press , or button to select "I/O", "HY" and to
set the data address.
The data address of each joystick is as follows.
joystick data address
Lift W0012
Tilt W0022
neutral position
Reach W0024
I/O data
Side shift W0026
01E0
4. Confirm that the applicable "I/O data" is as follows at
0220
the neutral position of each joystick.
<Adjusting procedure 2 (Voltage check)> Tester

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

WH
RD
BK
potentiometer. Tester
pole (+)
3. Measure the output voltage between white[WH] line
and black[BK] line by the tester.
4. Confirm that the output voltage is 2.5±0.1V at the
RDBK
neutral position of each joystick.

BK
Tester pole (-)
note ) Lift : YEWH

Tilt : BNYE
Reach : BKRD
Side shift : GNBK 152T107
49
1-3-24. 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
Clamp ammeter (available for measuring small current)
Recommended ammeter : YOKOGAWA CL-612
NOTE Measurement should be performed near the

connector, not near the solenoid valve.
Noise will prevents an accurate measurement.
50
If the currnt value is out of range, adjust the volume on

the MPU board.
Travel / Hydraulic board (MPU board)
(LIFT) (VR1)
CN1 CN2
(TILT) (VR2)
(ATT1) (VR3)
(ATT2) (VR4)
(REACH) (VR5)
(PV)
(P15)
(P6)
(HYD)
(TRV)
CN3
CN10 CN9
HYD TRV
CN4
152T110
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
VR2 TILT Tilt/Side shift
current. Tilt-up 0.70 0.02A
VR3 ATT 1 current.
*Only for 5 levers
VR4 ATT 2 - -
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.
51
1-3-25. AOS setting (optional)

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 "1-3-11. Optional setting check and
adjustment", 37 page.)
152T122
1. Set rotary switch DISP on the EPS controller to "C". F01
CDE
23
456
AB
789

Set DISP to "C".
appears.
3. Press either or or button to move the
blinking icon to the each item.
4. Press either or button to turn the value.
P/M mast selection
Select "M" by pushing button.
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
(continues on next page) 152T073
52
This initial setting is necessary only for AOS with tilt

horizontal. (special option)
Tilt setting screen (tilt down)
Setting of tilt potentiometer blinks.

Current tilt position is displayed.
152T111
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
53
Tilt setting screen (tilt up)

152T112
Pull the tilt lever fully.

(Tilt up the fork fully)
Tilt highest position is displayed.
Value of the tilt highest position is set.
Release button.
152T113
Tilt setting screen (fork horizontal)

152T114
Operate the tilt lever to set the

fork horizontal.
Tilt horizontal position is displayed.

152T115
54
Value of the tilt horizontal position is set.
Release button.
152T116
This initial setting is necessary only for trucks with AOS.

Lift setting screen (lift down)
Setting of lift encoder blinks.

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

is grounded.
Lift lowest position is displayed.
Value of the lift lowest position is set.
Release button.
152T078
55
Lift setting screen (lift up)
Setting of lift encoder blinks.

Current lilt height is displayed.
152T118
Pull the lift lever until the fork is

come at maximum height.
Lift highest position is displayed.
Value of the lift highest position is set.
Release button.
152T119
The distance between stacking end picking
Setting of the distance blinks.

Set the value by pushing or
button (50-200).
The speed reduction at lift stroke end
Setting of the speed reduction blinks.

Select "OFF" or "ON" by pushing or
button.
152T120
56
The speed reduction at tilt stroke end
Setting of the speed reduction blinks.

Select "OFF" or "ON" by pushing or
button.
AOS switch box function setting screen
Setting of switch box function blinks.

Set by pushing or button.
TILT : Tilt horizontal (special option)
152T079 AB RACK : A/B rack switching
Return to P/M mast selection
NOTE When the connection is failure between EPS

controller 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.
57
2. Troubleshooting
2- 1. Self diagnosis function
2-1-1. Display
If abnormalities or errors are detected with the self-
diagnosis function, the following symbols and error
number will be displayed on the screen.
The applicable abnormality and/or error symbol will
blink on the display.
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 blinks.
The abnormality or error number blinks.
The travel symbol blinks.

152T081
Hydraulic (including AOS) system errors

The hydraulic symbol blinks.

152T082
Steering (EPS) system errors

The steering symbol blinks.

152T083
58
2 Troubleshooting
Other errors
The other abnormality or error number

blinks.
152T084
Multiple abnormalities and/or errors

The detected abnormality and/or error

numbers are displayed in the order they are
detected.
All of the symbols for the detected abnormalities

152T085
and/or errors blink.
NOTE 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.

D31 : (ENCODER-EPS)
D32 : (TR-EPS MAIN)
The , and buttons are disabled while EPS controller

the self-diagnosis screen is displayed.
F01
If rotary switch DISP on the EPS controller
CDE
23
is set to F, the self-diagnosis screen will not

456
AB
789
be displayed. (The normal screen will be
displayed.) DISP="F"
When the abnormalities and/or errors are
resolved, the display will return to the normal
screen.
59
Troubleshooting 2
2-1-2. Error messages and Display conditions

Error Error Message (nondisplay) Probable Cause
Number
A01 CONTACTOR-MAIN Main contact is open circuit.
B10 FUSE-MAIN Blown main fuse
B11 Transistor U-TRAVEL Travel U-phase Transistor is failure.
B12 Transistor V-TRAVEL Travel V-phase Transistor is failure.
B13 Transistor W-TRAVEL Travel W-phase Transistor is failure.
B14 SENSOR-CURRENT - TRAVEL Current sensor U phase or V phase for travel is failure.
When the key switch is turned on, the U phase
(CN3-3) or V phase (CN3-13) voltage in the MPU board
is out of 5 ± 0.976V.
B15 ACCELERATOR Accelerator is failure.

The difference between input voltage 1 (CN6-5) and input
voltage 2 (CN6-13) in the MPU board is over ± 0.625V.
Or, input voltage 1 or 2 is under 0.5 V.
Or, input voltage 1 or 2 is over 4.5 V.
B16 DIRECTIONAL SWITCH Directional switch is failure.
B17 FOOT BRAKE Brake potentiometer or brake microswitch is failure.

When the key switch is turned on, the input voltage
(CN6-8) in the MPU board is under 0.15V. or over
3.13V.
Or, it is under 0.78V with the actuator of brake micro-
switch turned off.
Or, it is over 2.42V with the actuator of brake micro-
switch turned on.
C21 Transistor U-HYD. Hydraulic U-phase Transistor is failure.
C22 Transistor V-HYD. Hydraulic V-phase Transistor is failure.
C23 Transistor W-HYD. Hydraulic W-phase Transistor is failure.
C24 SENSOR-CURRENT - HYD. Current sensor U phase or V phase for hydraulic is

failure.
When the key switch is turned on, the U phase (CN1-3)
or V phase (CN1-13) voltage in the MPU board is out of
5 ± 0.976V.
D30 SWITCH-EPS Microswitch for detecting drive unit position is failure.
D31 ENCODER-EPS Encoder for detecting the movement of steering wheel

and drive unit is failure.
D32 TR -EPS MAIN FET for Power Steering control is failure.
60
2 Troubleshooting
Error Error Message (nondisplay) Probable Cause

Number
E40 TR -AOS Valve current is out of range.
E41 POTENTIO-HYD. Potentiometer for AOS control lever is failure.

LEVER In the MPU board,
When the lift lever is on operating, the input voltage (CN8-2)
is under 0.31V or over 4.68V.
When the tilt lever is on operating, the input voltage (CN12-10)
When the reach lever is on operating, the input voltage (CN12-5)
When the side shift lever is on operating, the input voltage (CN12-13)
When the ATT lever is on operating, the input voltage (CN12-8)
E42 ENCODER-HYD. - MAST Encoder for detecting lift height is failure.
G61 FAIL CURRENT-TRAVEL Traction motor current is out of range.
G62 FAIL CURRENT-HYD. Hydraulic motor current is out of range.
G63 FAIL VOLTAGE-TRAVEL Battery voltage is out of range.

When the key switch is turned on, the battery voltage
(CN5-20) in the MPU board is under 24V.
G64 FAIL VOLTAGE-HYD. Battery voltage is out of range.

When the key switch is turned on, the battery voltage
(CN5-20) in the MPU board is under 24V.
G65 REDUCE DUTY- OPERATION The temperature sensor in the MPU board is detecting
over 90 .
G68 FAIL BUS SYSTEM The connection is failure between EPS controller and
MPU board.
G69 FAIL MAIN BOARD The power supply in the MPU board is out of range.
W05 REDUCE THE LOAD Overload
W06 REFILL HYDRAULIC OIL Fork oil
W07 CHARGE THE BATTERY The battery must be recharged.
W08 RELEASE ACCEL TO NEUTRAL The accelerator was depressed when the key switch is
turned on.
The hydraulic lever was operated when the key switch

W09 OFF HYD. LEVER TO NEUTRAL
is turned on.
W13 RETRACT THE BATTERY The battery is not retracted completely.

The pedal is not depressed completely.
note) marked error numbers are not displayed.
Only the symbols are displayed.
61
Troubleshooting 2
2- 2. Error history memory

2-2-1. Error history memory 1
<The 9 most recently detected errors/ abnormalities>
F01
CDE
23
appears.
456
AB
789
NOTE To view less than the nine most recent errors/

Set DISP to "9".
abnormalities, place the blinking cursor on the
last error/abnormality and press button to go
to "Previously detected errors/abnormalities".
If there are no errors/abnormalities, press
button to go to "Previously detected errors/
abnormalities".
The 9 most recently detected errors/abnormalities 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)"

62
2 Troubleshooting
2-2-2. Error history memory 2

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

abnormalities".
Number of times the error/abnormality
152T093 152T094
Previously detected errors/abnormalities (2)
152T095 152T096
The next page is "Previously detected errors/abnormalities (3)".
The next page is "Previously detected errors/abnormalities (4)".
63
Troubleshooting 2
<Previously detected errors/abnormalities (4)>

Rotary switch DISP on EPS controller : 9
F01
NOTE If the same error/abnormality was detected
CDE
23
456
multiple times previously, the data of the most
AB
789
recent detection will be displayed under "Error/
abnormality details". DISP="9"
Previously detected errors/abnormalities (4) Error/abnormality details
The previous page is "Previously detected errors/

abnormalities (1)". Number of times the error/abnormality
Error/abnormality number display
152T098
152T097
Previously detected errors/abnormalities (5)
152T099
152T100
64
2 Troubleshooting
2-2-3. Clearing the error history memory

(memory initialization)
1. Set rotary switch DISP on the EPS controller 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 DISP on the EPS controller to "0".
Set DISP to "E".
Memory Initialization Completion Screen
152T101
NOTE The following items are returned to their initial

values:
Slow speed (turtle) : 5km/h
Travel mode : N (NORMAL)
Meter mode : HR (hour meter)
Neutral regenerative brake : MID
Error history : All clear
BRIGHTNESS (back light brightness) : 5
65
Troubleshooting 2
2- 3. I/O Check
2-3-1. I/O check mode display method
F01
CDE
23
456
AB
2. Turn on the key switch the following screen appears. 789
3. Press button to enter the I/O check mode. The "I/O"

Set DISP to "8".
icon will blink.
RAM . I/O selection

CPU selection
The I/O icon highlights.
The current CPU blinks.

Press either or button to select a
CPU.
TR : Travel
HY : Hydraulic
PS : Power steering
Data length setting
The selected CPU highlights.
The W(double-byte) blinks. (not variable)

66
2 Troubleshooting

Press either or button to set the
data address (0-F).

Press either or button to set the
data address (0-F).
I/O data
The current data address is displayed.
The I/O data is displayed.

152T086
67
Troubleshooting 2
2-3-2. I/O port table

Travel CPU
I/O port table
Port No. IN/OUT Contents Remarks
W000A A/D Traction motor U phase electric current 2.5V ±1.75V = ±700A
W000C A/D Traction motor V phase electric current 2.5V ±1.75V = ±700A
W000E A/D Auxiliary
W0010 A/D Battery voltage 0 - 5V = 0 - 55V
W0012 A/D Accelerator voltage 1 0 - 5V
W0014 A/D Accelerator voltage 2 0 - 5V
W0016 A/D Foot brake 0 - 5V
Power supply voltage for brake
W0018 A/D 0 - 5V
solenoid of front wheel
W001A A/D Board temperature sensor 0 - 5V
W001C A/D Auxiliary 0 - 5V
W001E A/D Power supply observation (V15) 0 - 5V
W0020 A/D Power supply observation (PV) 0 - 5V
W0022 A/D Power supply observation (V5) 0 - 5V
W0024 A/D Front wheel brake output 1 (left) 0 - 5V
W0026 A/D Front wheel brake output 2 (left) 0 - 5V
W0028 MTU Traction motor rotary encoder Counter value

W002A MTU Front wheel rotary encoder 1 (left) Counter value
W002C Memory Front wheel rotary encoder 2 (right) Counter value
68
2 Troubleshooting
Hydraulic CPU
I/O port table
Port No. IN/OUT Contents Remarks
Hydraulic motor U phase electric
W000A A/D 2.5V ±1.75V = ±700A
current
Hydraulic motor V phase electric
W000C A/D 2.5V ±1.75V = ±700A
current
W000E A/D Battery voltage 0 - 5V = 0 - 55V
W0010 A/D IGBT temperature sensor 0 - 5V
W0012 A/D Lift lever potentiometer 0 - 5V
W0014 A/D Auxiliary A/D input 0 - 5V AOS
W0016 A/D Lift valve electric current 0 - 5V
W0018 A/D Tilt valve electric current 0 - 5V AOS
W001A A/D Reach valve electric current 0 - 5V AOS
W001C A/D Attachment 1 valve electric current 0 - 5V AOS
W001E A/D Auxiliary 0 - 5V AOS
W0020 A/D Auxiliary 0 - 5V AOS
W0022 A/D Tilt lever potentiometer 0 - 5V AOS
W0024 A/D Reach lever potentiometer 0 - 5V AOS
W0026 A/D SF lever potentiometer 0 - 5V AOS
W0028 A/D Attachment lever potentiometer 0 - 5V AOS
W002A MTU Hydraulic motor rotary encoder Counter value

W002C MTU Lift rotary encoder Counter value
69
Troubleshooting 2
Display CPU
I/O port table (1)
Port No. last_digits IN/OUT Contents Remarks
1 IN P5 power supply check L:0V H:5V
W0002
2 IN EPS abnormal electric current
EPS encoder 2(steering under position)

IN Pulse
A phase
W0004 1
EPS encoder 2(steering under position)
IN Pulse
B phase
I/O port table (2)

Port No. last_digits IN/OUT Contents Remarks
W000C 2 IN P5 power supply check L:0V H:5V
L : key switch OFF

IN Key switch start
H : key switch start
W0010 1
The switch for detecting drive unit L : mast side
IN
position H : opposite mast side
W0012 IN Battery voltage

W0014 IN EPS power supply voltage
W0016 IN EPS electric current 1
W0018 IN EPS electric current 2
W001A IN EPS output 1
W001C IN EPS output 2
W001E IN Auxiliary input
70
3. Wiring (Diagrams)
*RDWH
*RDWH
*RDBK
*BKWH
2
1 2 3
Battery(48V) PB103-30 PB103-30 PB103-30 PB103-30
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. Reference:
*Only for trucks with laser poiter
VA NA GNRD RD
RPA 7 5 Power supply
Harness mark/color
F1 3 9 Main fuse Traction motor BKRD Tilt level sensor
BU WH RNA 7 15 GND Fan(1)
YERD
Red RD
C1 3 18 Main contactor contact speed sensor BUWH RA1 7 6 A phase signal BUBK HD 5 18
RB1 7 16 B phase signal M LCK 5 16 Fan output Tilt level detector switch Black BK
F1 WHBK
HS7 8 7 Battery tray interlook
Green GN
RNA 7 17 GND Laser poiter switch Yellow YE
Tilt level switch
BK
325A MC 100V,4700 F(x9) RA2 7 8 A phase signal

(option) HS5 8 6 Attachment switch 1 RDYE
RB2 7 18 B phase signal RD
P3 5 9 Power supply White WH
(IN) Laser
RDYE# HS6 8 14 Attachment switch 2 BKYE
P3N 5 19 GND Brown BN
YERD# TPU 3 2 Power supply
(OUT)
TIU BK# TIU 3 3 Signal Reach stroke end HS9 5 17 Spare input 4 Blue BU
Traction TNU 3 12 GND
detector (option) BK Level Gray GY
RDBK#
WHBK#
current sensor BU# TPV 3 4 Power supply HSN 7 1 Switch GND lamp
TIU TUM 4 1 Traction motor U phase TIV BKRD# TIV 3 13 Signal YEBU Pink PK
TNV 3 14 GND SS 5 4 Foot switch
IGBT module BUYE#
TU1 4 2 U phase gate output 1 BK Orange OG
U1 OG#
HSN 7 11 Switch GND *Only for trucks with forward buzzer
TU2 4 10 U phase gate output 1 RDYE#
V1 YERD# HPU 1 2 Power supply
F2 3 19 Hydraulic fuse BNBK Ex) BKWH (=Black/White)
HIU BK# HIU 1 3 Signal X2 OF2 5 6 Forward output
WHBK# Hydraulic HNU 1 12 GND HD3 3 5 Signal (Traction IGBT temperature) Forward buzzer Black colored harness with White line.
TVM 4 4 Traction motor V phase current sensor RDBK# HN3 3 15
TIV
BUYE# BU# HPV 1 4 Power supply GND GNWH
BZ
IGBT module TV1 4 5 V phase gate output 1 HIV BKRD# HIV 1 13 Signal
W1 Traction HNV 1 14 GND PV 1 6 Power supply (Fan Power supply)
OG# PVN 1 16 GND
motor TV2 4 13 V phase gate output 2
IGBT BNYE TPM 3 7 *Only for trucks with backward buzzer
BKWH HD4 1 5 Signal Power supply Battery
T-IGBT HN4 1 15 TIM 3 8 Signal
WHBK# tmperature sensor GND
TNM 3 17 current sensor YEBK
TWM 4 7 Traction motor W phase GND X3 OB2 5 15 Backward output
Backward buzzer
BUYE#
IGBT module TW1 4 8 W phase gate output 1 RD HP2 8 3 Power supply BN
OG# Directional GNWH RPA 7 7 Power supply
HD2 8 10 Signal BZ
TW2 4 16 W phase gate output 2
switch BUYE ADF 5 1 Forward
HN2 8 11 GND
ADB 5 11 Backward
HS1 8 4 Lift 1 switch *Only for trucks with head lamp
White line
WHBK#
HUM 2 1 Hydraulic motor U phase
BUYE# Accelerator HS2 8 12 Lift 2 switch Lamp 40W RH
HU1 2 2 U phase gate output 1 switch HL
OG# RDYE HS3 8 5 Tilt switch
HIU Board HU2 2 10 U phase gate output 2 WH AP1 6 4 Power supply Head lamp
IGBT AD1 6 5 Signal HS4 8 13 Reach switch WHGN
IGBT module AN1 6 12 GND 40W LH
ADN 6 16 Neutral HL
U2 WHBK#
HVM 2 4 Hydraulic motor V phase
BU
AP2 6 6 Power supply HP1 12 1 Power supply Black color
V2 BUYE# AD2 6 13 Signal
*RDWH
HV1 2 5 V phase gate output 1 BKYE
AN2 6 14 GND HD1 12 2 Signal (Tilt level potentiometer)
OG# HN1 12 9 GND
HIV HV2 2 13 V phase gate output 2
2 Foot brake RDGN
IGBT module BK HP 7 4 Power supply RPA 5 13 Power supply
W2 Hydraulic HN 7 14 GND RNA 5 14 GND front wheel (Right)
WHBK# RDBU WHGN
motor HWM 2 7 Hydraulic motor W phase WHBU AP3 6 7 Power supply BUYE TXA 7 2 Traction→EPS Data line RA5 6 3 A phase signal speed sensor
BUYE# BKBU AD3 6 8 Signal WHRD RXA 7 12 Traction←EPS (EPS) RB5 6 11 B phase signal
HW1 2 8 W phase gate output 1 AN3 6 15 GND YERD TXB 7 3 Hydraulic→EPS
OG# WHRD RXB 7 13 Hydraulic←EPS RPA 6 1 Power supply
HW2 2 16 W phase gate output 2 BS1 5 12 Brake switch RNA 6 9 GND front wheel (Left)
Open when turning on the actuator RA4 6 2 A phase signal speed sensor
IGBT module *Only for trucks with front wheel brake RB4 6 10 B phase signal
BNWH# PB103-20
TU0 4 9 Gate power supply output WHBK GNWH
MB1 1 10
RDWH# TI1 5 7 Drive unit position detector Line Connector Electro magnetic brake
TUP 4 3 SOL
*GNRD
Power supply(+) No. CN □ Pin No. WHGN (Left front wheel)

F4 BKWH# MB2 1 9
10A TUN 4 11 Power supply(-) WHBK
4 GNWH
BKWH# YERD MB3 1 20 Electro magnetic brake
HVN 2 11 Signal GND WHRD RXB 2 6 EPS→Hydraulic SOL
RDBK TXB 2 14 EPS←Hydraulic WHGN (Right front wheel)
Lift lever YEWH LP1 8 1 Power supply BUYE Data line MB4 1 19
LD1 8 2 Signal WHGN RXA 2 5 EPS→Traction
potentiometer BK TXA 2 13 EPS←Traction (Travel/Hydraulic) RDWH*
LN1 8 9 GND BK MB 1 8 Electro magnetic brake
BKWH RDGN HNA 2 12 GND
NB 1 7 HPA 2 4 Power supply power supply
Control 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 BKYE V5 1 5 Power supply
F3 VB 5 10 Control power supply(+) EPS encoder 1 VN 1 15 GND SG 5 3 Turning speed reduction
WHYE
10A LP3 12 4 Power supply (Steering) BUYE RA1 1 6 A phase signal
WHBU Reach lever BKRD
LD3 12 5 Signal RB1 1 16 B phase signal LL 5 8 Lift lock
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 WHBU VN 1 17 GND
potentiometer RD
LN4 12 14 GND (Steering) BU RA2 1 8 A phase signal BKRD RPA 7 9 Power supply
F3 3 10 Emergency switch RB2 1 18 B phase signal Lift height encoder RNA 7 19 GND
Electro magnetic WH
RA1 7 10 A phase signal
LP5 12 7 BUWH
brake YEBU Power supply RB1 7 20 B phase signal
GNRD* WH
Attachment LD5 12 8 Signal
RD
BRK LN5 12 15 GND
BKRD V5 1 9 Power supply BU The switch for detecting
EPS encoder 3 VN 1 19 GND HS8 8 15 lift lower limit
(*Only for 5 levers) WHRD BK
(Drive) BURD RA3 1 10 A phase signal HSN 8 8 Switch GND
GNRD* Solenoid valve RB3 1 20 B phase signal
BN 5 BP 12 16 power supply
X4 OS1 5 5 Electro magnetic
brake GNBK *Only for trucks with AOS
B11 11 1 WHBK PB101-11
Horn switch SOL Lift up 4 SR 1 1 Drive unit position detector
Horn WH
BC1 11 11 Line Connector
Low speed switch No. CN □ Pin No.
WHBK BN (turtle switch)
H PB103-20 B12 11 2
SOL Lift down GNWH Control power
Line Connector WHBK SW1 1 11 Low speed(turtle)switch VH 1 1
100V BC1 11 12 supply
No. CN □ Pin No.
22 F K 1 7 Control GND
RD BUBK
MP B21 11 3 Tilt up WHBK
EPS Power supply(+) SOL Mode selection switch RXD 1 12 EPS→AOS Data
BU WHRD /SF right BU
EPS motor K1 BC2 11 13 BKWH TXD 1 6 EPS←AOS line
EPS Power supply(-) BU HND 1 11 GND
GNRD BS1 1 12 UP RDBK (EPS)
B22 11 4 Tilt down HPD 1 5 Power supply
PA A EPS output(A) SOL
WHBU /SF left RD
EPS output(AA) BC2 11 14 BS2 1 3 Down
AA
PB103-20
YE
RDGN* BNRD
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 BKWH HPD 3 1 Power supply Data
YERD B32 11 6 HND 3 9 GND
X1 R+ 2 10 Power supply relay BU line
BNYE SOL
GNWH Reach out RD WHBK TXD 3 10 EPS←AOS
R1- 2 3 BC3 11 16 BK HPC 2 7 Power supply RXD 3 2 EPS→AOS (AOS)
Emergency Key switch HNC 2 15 GND Data line
RDGN* BUWH
switch KS 2 1 Control power supply BUWH WHBU TXC 2 16 EPS←Dispiay (Dispiay)
RD B41 11 7 Dispiay RXC 2 8 EPS→Dispiay
SOL
WHBU Attachment module
X1 BC4 11 17
BN (*Only for 5 levers) BS4 1 4 ‘R’ switch WL1 3 8 Turn signal lamp(Right)
*GNRD
ST 2 2 Key switch start BNWH

*RDWH
*RDBK
B42 11 8 SW6 3 5 Turn signal lamp

*BKWH
SOL Attachment Spare input

RDYE RH 25W
BC4 11 18 IO 3 7 Spare input TSL WL2 3 16 Turn signal lamp(Left)
2 RDWH* RDBU
BNBK R2- 2 11 Spare output BUYE LH 25W
Fan (2)
B51 11 9 TSL
SOL Tilt operation 3 BKWH* V5 3 6 5V output Flash
M BC5 11 19 unit
BUWH
VN 3 14 Spare GND Turn signal lamp SW3 3 11 Turn signal lamp switch(Left)
1 2 B52 11 10 VN 3 15
SOL SF operation Spare GND switch SW2 3 3 Turn signal lamp switch(Right)
BC5 11 20 BUBK *Only for trucks with signal lamp
1 1 AH 1 2 Hour meter counting 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.
3. Dot-dot-dash lines and dashed lines indicate the use of optional equipment. FBRF-70 System wiring 3- 1.
54000-24282-0e
71
3 Wiring (Diagrams)
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Head guard Head guard Lever panel Contactor
(LH) (RH) assembly
Yellow YE
Emergency Control unit Battery plug
White WH *Only for trucks with *Only for trucks with SF
White line head lamp/turn sigunal lamp head lamp/turn sigunal lamp switch -
Brown BN
+
Blue BU *Only for trucks with AOS
CN2 CN1
Gray GY Head Head Fan (1)
<7>
<8>
Pink PK lamp lamp F+
Copper bar
Orange OG
Black color
Tilt 2P Board Comp., 8 8
WH
AOS
CN4 CN3
Copper
Ex) BKWH (=Black/White) Turn Turn MPU RD
bar
Black colored harness with White line. signal 2 2 2 2 signal NA
switch <7>
lamp lamp 8
2 2 2 2 box BU
325A
Reach
WH
Mast wiring Mast wiring
WH
BK
BK
(Only for trucks with AOS) (standard)
2 2 2 2
EPS 8
Selector valve Selector valve 2 2 2 2 W2 W1 V2 V1 U2 U1

Horn switch Lift controller
BK
BK
BU
BU
Tilt operation SF operation Tilt operation SF operation
<6>
<3>
<5>
<2>
<4>
<1>
2P
GNRD
CN1 CN2 CN3 WH
RD
BU
BK
RD
10A
10A
10A
Directional
switch 12P
1 1
GNRD
Harness,
RDGN
RDBK
2P-X
BU
head guard
7 7 7 7 7 7 7 7 1 1 1
20P
WH
RD
BK
RD
WH
BK
BK
BK
BKWH
RDWH
RDBU
Accessory(1)
4P
WH
Lift height
encoder
The switch Hanging on mast(2) Hanging on mast(2)
Bearing for detecting
WHGN
GNWH
sensor lift lower limit
Harness, Harness,
Body harness (1)
mast(2) mast(2)
Water
Water
proof 4P
Water
proof 2P 3P Water
proof proof 3P Head lamp Lever panel harness 1 1
switch
20P
1 1
Power supply 4P
Low speed
WH
relay
BK
Hanging on mast(1) Hanging on mast(1) (turtle) switch RD
Harness, AOS
Fan (2)
Harness,
mast(1)
Harness,
mast(1)
Steering
Display Mode switch Assembly
Water Water Water Water
proof 4P proof 2P 3P proof proof 3P
Key switch Battery
tray
Magnetic brake 4P
RD
4P
interlock relay WH
Body-mast Body-mast Body-mast EPS encoder 1 2P
Water
proof
1
WH
Harness PS Bearing
4P
sensor
Harness, Harness, Harness,
body(AOS) body(2) body(2) 2P Water
2 EPS encoder 2 proof
Bearing
4P
Body Harness(1) sensor
Water
proof
Water Water Water
proof 6P 3P proof
Water 6P 3P proof
proof
Straddle Connect to upper

leg(Left) Accelerator side(A port) Straddle leg(Right)
*Only for trucks
2 *Only for trucks
12 P
6P
with front brake 2P-X with front brake

2P
Proportional control valve
8P
<Note> Electro WH Electro
Water
Water
proof
proof
1. <n> shows lead wire No. magnetic Water 4P Water 2P magnetic

Foot brake proof proof W2 V2 U2
Water
brake brake
proof
2. Terminal symbol Electro magnetic 4P
<6>
<5>
<4>
Water
proof
1 : Plug AMP 170020-2 Potentiometer brake Water

proof
2 : Plug AMP 170020-3
3P
AMP 170002-5 EPS Lift Reach Tilt

motor
RDWH
1 1 Bearing 1 1
BKWH
Drive unit
BUBK
1 : Receptacle AMP 170021-1 sensor position Bearing Hydraulic motor
2 : Receptacle AMP 170021-3 COM detector sensor
AMP 170003-5
1 1 4 EPS encoder 3 1 1 1
WH
WH
BK
BK
7 : Receptacle AMP 41729 NO W1 V1 U1
8P
1 1 1
<3>
<2>
<1>
3. All electrical wires should be fixed to prevent contacting Brake 4
NC
Water
switch
proof
to the part of moving, with edge and of heat source. 1
Floor harness Connect to lower side(B port) Connect and start
BKWH
4. About the expression about travelling direction of relevant to options, hourmeter counting.
for standardizing the name with Reach, mast side is called the advance WHBK Traction motor Harness,
side unlike the original direction. Harness,
Horn
7 Accessory(2) & brake(Right)
brake(Left) BKWH
7 Hourmeter count
5. In case of “CS” (Cold Storage) truck, apply silicone adhesive
between the terminals of microswitch as shown the figure below. BK 1 1
GNWH
WH WHGN
NO
Apply silicone adhesive between the terminals. 1 1
COM NC
1
RDWH
1
BKWH
Accessory BNBK
1
1
YEBK
2P
Foot switch
Water
proof
FBRF-70 Body wiring 3- 2.

54000-24292-0e
72
Wiring (Diagrams) 3
2. : Braided wires under 25mm pitch.

3. All pin layout shows the view from terminal insert side.
4. Write or impress the letters with undamped ink.
5. Pay attention to the pin layout.
6. Connect Ca1a-DC48V-N relay and tie it to the harness.
7. Fuses should be placed in a circle as shown in the figure below.
8. Attach the cover (sleeve) for shur receptacle on this place.
10. The film capacitor and the electrolytic capacitor should be attached
as shown the figure below.
BUYE
RDYE
RDBU
BNYE
BUYE
RD
GNBK
YEWH
RDGN
RDBK
BKRD
RDBK
WHBK
RD
GNWH
BK
RDGN
BKRD
BKRD
BNRD
GNWH
BN
BK
BNBK
BUBK
RDWH
BUWH
BUWH
RDBK
BUBK
BNWH
BNBK
BUWH
BUWH
BNWH
BUYE
YEBU
GNRD
YEWH
WHRD
WHBU
WHBU
YEBK
BN
RD
RD
RD
GNWH
GNWH
GNBK
WHBK
RDGN
YERD
WHRD
BK
WH
BK
WH
WH
BU
BK
BUYE
YERD
WHBK
WHRD
WHGN
WHBK
RDBU
BKBU
WHBU
GNRD
BU
GNBK
RDYE
BKYE
BKRD
WH
BNYE
11. Covered by corrugated tube (Shinagawa-shoko CDP-B907-1 or equivalent).
25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 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
Fuse Fuse
10A 10A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 11 2 12 3 4 13 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 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 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
10A A A A X A A C V Z F1 L N Point "b" Point "b" H H H H D D D P P F1 M M F1 F1 J M Q Q Q Q Q Q M Q Q F1
19B 21B 2B 75B 22B 24B 74A 85A 92A 22A 49A 37A 55A 91C 41A 43A 45A 47A 27A 29A 31A 33A 35A 24A 106A 108A 19A 21A 118A 105A 5A 7A 9A 11A 13A 15A 17A 114A 116A 2A
8 8 A A A C A H V F1 H K N E1 C H H H K D D D P P M M F1 M Q Q Q Q Q Q M Q Q F1 F1 C
20B 1B 3B 57B 23B 52A 86A 23A 48A 25A 38A 54A 57A 42A 44A 46A 26A 28A 30A 32A 34A 36A 107A 109A 20A 104A 6A 8A 10A 12A 14A 16A 18A 115A 117A 1A 3A 4A
Clamp AMP 040 series AMP 040 series AMP 040 series AMP 040 series AMP 040 series AMP 040 series AMP 040 series
Clamp Multi lock connector (mark I) Multi lock connector Multi lock connector Multi lock connector Multi lock connector Multi lock connector Multi lock connector
Fuse 174047-2 175967-2 175966-2 175967-2 175966-2 175967-2 175966-2
Capacitor (20P) CN5 CN6 CN7 CN8 CN11 CN12

Vinyl tube Vinyl tube
Full the inside of 5 6 7 8 11 12
the vinyl tube with 10 9 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 8 7 6 5 4 3 2 1
silicon adhesive. It is possible to use splicing and vinyl tube
instead of soldering, and also to use heat 20 19 18 17 16 15 14 13 12 11 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 16 15 14 13 12 11 10 9
contraction tube(resin filling up type)
instead of silicon adhesive. F1 Panel, lever A MPU board
Tie wrap With solder Tie wrap (See note 4,5)
Point "a" 50
Film capacitor
100
Reference:
Harness mark/color Point "b"
Red RD
Black BK Tie the CA relay
Green GN on this side.
RDBK
GNRD
GNRD
RDGN
Yellow YE
BKWH
RDWH
RDWH
BKWH
RDBU
BU
BUBK
RDWH
RD
RDGN
BN
White WH
WHBU
BNWH
BKWH
RDYE
BUYE
WHGN
WHBU
BKRD
WHRD
BURD
BU
RD
BK
BKWH
RDWH
GNWH
BU
RDGN
RDYE
BKYE
WHYE
BUYE
BK
RD
BK
WHBU
BNWH
YERD
BNYE
BK
BN
WHBK
BUBK
GNRD
BUYE
YERD
BU
RD
RDGN
RDGN
WHRD
WHBU
BUWH
WHGN
YE
WH
BU
RD
BK
RD
BK
RDWH
BKWH
BUWH
RDBK
BU
RDYE
BKYE
WHYE
BUYE
GNWH
YE
WHBU
WHGN
WHBU
A,D
Brown BN F1,F2 ,F1 A,L
Blue BU 74B 57D 4B
Gray GY 1 1 1 1 1 3 3 3 3 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 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 5 5 3 3 25 25 25 25 25 25
Pink PK
GNRD
WH
RDWH
BN
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 1 2 1 2
10A
10A
10A
1 2 3 4 5 6 7 8 9 10 11 12
Orange OG Z, point “a” F2, Z F1 A C L A A A F2 F2 F2 F2 F2 F2 F2 F2 F2 U U
F1 F2 D D D D Z C D D D F1 D S C C
111B
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 51A 111A 112A
Ex) BKWH (=Black/White) B
RDGN
RDWH
YERD
BNYE
Z, E1 V, Z F1 F2,Z D D D D D V V D D D X,L Z, Point "b" X X L A A A F2 F2 Point "b" W F F2 F2 F2 U U S C Point "a" C Point "b"
Black colored harness with White line. 110B
91L 90C 85B 90B 58B 61B 63B 81B 83B 90A 84A 65B 67B 69B 76B 91K 76A 77A 79A 31B 28B 30B 80A 82A 55B 59A 61A 64A 66A 68A 70A 72A 50A 110A 90D 113A 91D
B
GNRD
RDGN
RDBK
3 3 3 3
AMP 040 series AMP 172130-1 AMP 040 series AMP 040 series AMP 1-179958-2 AMP 040 series
AMP 172134-1 AMP 172134-9 Multi lock connector Multi lock connector 1 3 2 4
Multi lock connector (mark I) 1 Multi lock connector (mark I)
Plug Plug Plug 175966-2 175967-2 R A
Z Accessory(1) 4P
WH
174047-2
4P
RD
2P
WH
2P-X
Receptacle
2 174045-2
56A 49B 3 3 3 3
(20P) CN2 CN1 (12P) C,E2 Point "b", L 1 3 2 4
AMP 172130-1 8 (See note 7) 8 8 L,W D
4C 91E
Plug B B 91F 79B
White line 1 2 1 2P
AMP 172134-1
1 2 10 9 8 7 6 5 4 3 2 1 1 2 WH 112B 113B
6 5 4 3 2 1 X D
2 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 1 2
3 4 3 4 12 11 10 9 8 7 Plug 76C 78B
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 4P
WH
Head Key E1 Fan(1) O EPS controller C Contactor unit AMP 172134-9
Black color V guard F2 Control panel X switch B Control unit

1 2
Plug
4P
D EPS controller 3 4
RD
(See note 4,5) Electro magnetic brake

AMP 174661-2 1 2
Note : Water proof type 41B A 1 4
RDYE
BKYE
L Relay 3 4
1. Terminal symbol Plug 12P 42B A 2 4 (See note 5,6) Power supply
WH
1 : Plug (with plating) AMP 170020-2
44B A
43B A 3
4
4
4
BU See note 10 Point "c" 200
Sleeve (for single wire) AMP 170887-1 45B A 5 4
RDBU
1 : Receptacle (with plating) AMP 170021-2 46B A 6 4
BKBU
6 5 4 3 2 1 WHBU
Sleeve (for single wire) AMP 170899-1 12 11 10 9 8 7 47B A 7 4
91J N 8 4
RDWH
3 : Receptacle AMP 170032-5 48B A 9 4
WHRD
AMP 179461-5 52B F1 10 4
WHBK
41
4 : Receptacle AMP 171662-1
AMP 173707-1
H Accelerator/brake 90L N 11 4
BKWH
12 Stopper (See note 9) 40
AMP 172888-2 (stopper) (See note 5) 100V
ERZV20D820
22
(Matsushita)
BKWH
BUBK
BKWH
RDWH
AMP 172748-2 (stopper)
125V 0.022
(See note 9)
GNRD
BKWH
Capacitor
4 : Tab AMP 171661-1
BKRD
BNBK
BUWH
BKWH
BUWH
RD
BU
WHBK
BKWH
WH
BK
BNRD
GNRD
RDWH
WHBK
BUBK
BNWH
BUWH
WHRD
WHBU
WHBU
BNWH
GNWH
GNWH
GNBK
BN
YERD
WH
WHBK
Varistor
AMP 173706-1 91I Point "c" 1 RDWH
125V0.022
H
BKWH
90K R
BKWH
AMP 172888-2 (stopper) 1
Capacitor
H
N Accessory BNBK
WH
37B A 1
: Tab AMP 917805-2
BKRD
BUWH
RD
BKRD
WHRD
BURD
WH
RD
5 YEBK
38B A 1 4 4 4 4 4 4 4 4 4 4 4 4 4 3 3 1 1 1 1 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
AMP 917803-2
WH
BK
1 2 3 3 1 2 1 2 3 1 2 3 4 5 6 1 2 See 1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8
▲▲ note 8 W, Point "c" E2,W
AMP 179956-2 4 4 4 4 W 4 4 4 4 1 2 A A Point "c" A A A L A A A A A A A A
5 5 (See note 9)
6 : Receptacle AMP 173716-2 1 3 2 4 91H 1 3 4 2 L 118B 17B 90H 106B 108B 104B 4D 90G 90F 9B 116B 15B 7B 11B 114B 13B 5B
AMP 175061-2 1 2
D D Point "b" A A 56B Point "c" A A A A D L,T A A A A A A A A
Point "a", W
25 : Receptacle AMP 173681-1 AMP 174352-2 55C
O
Point "c", N 90I 18B 107B 109B 105B 59B 91G 10B 117B 16B 8B 12B 115B 14B 6B
70B 72B 33B 36B
AMP 175062-1 YEBU 50B 90E
Water proof type 25B A 1 4 D D A A 90J
: Pressed sleeve JST FNC-1.25 2 1 BK AMP 174354-2 AMP 174982-2 AMP 174982-2
(GND)
18 AMP 174352-2 AMP 174262-2
(TILT)
Plug 2P 26B A 2 4 O
Accessory(2)
(SF)
71B 73B 34B 35B
AMP 172130-1 AMP 172130-1
Water proof type 51B Water proof type Water proof type Water proof type Water proof type
AMP 174257-2 Cap 2P AMP 174257-2 Plug Plug 2P AMP 174357-2 Plug 6P Plug &Hourmeter Plug 8P Plug 8P
K Foot switch AMP 1-353046-2 2P 2P
WH
W counting
Water proof type
Plug 4P 2P-X
Water proof type
Plug 4P
WH Water proof type 1 2
Plug 3P
1 2 Tab 2 1 3 2 1 4 3 2 1 4 3 2 1
WHBK
To A WHBK 1 6 5 4 8 7 6 5 8 7 6 5
18 To T 1
To D WHBK 2 1 2 1 2 3 2 1 2
BKWH
BKWH To B BKWH
To M BKWH BKWH
4 3
Drive unit 1 2 4 3 Battery tray Proportional
To Z 18 BKWH
To E2 RDWH RDWH
To J BKWH
To R
18 To W
T position detector J interlock E2 Fan(2) Q control valve
To E1 RDWH To L Electro magnetic
To A RDWH 18 RDWH To N EPS encoder 3
EPS Speed R brake M Mast (See note 4,5)
Point "a"
To B
Point "c" U (Drive) S motor P sensor
Point “b” (See note 5) (See note 5)
FBRF-70 Body harness (1) 3- 3.

54000-68854-0E
73
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.
FBRF14/16/20-70 (Std/RP)
WIRING (DIAGRAMS) 3
3-4-1.
54000-71970-0E
74
75
3 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) Brown (5)
Spare Spare
See note 3
FBRF14/16/20-70 (CS)
2. When using lead wires of the same color, mark the number mentioned in ( ).
3. Spare wires should be tied with other lead wires.

3-4-2.
54000-71980-0E
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
B Horn 11B A 7 White WH
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG
Ex) BKWH (=Black/White)

Black colored harness with White line.
White line
Black color
FBRF-70 Floor harness

3- 5.
WIRING (DIAGRAMS) 3
54000-68870-0E
76
77
Water proof
<1> 4 1 2 1
<3> 4 4P 4 3
2
3 WIRING (DIAGRAMS)
<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
Spare
Spare Spare
Spare
See note 3
2. Wire numbers shown in <n> should be indicated by mark bands.
FBRF-70 Body harness

3. Spare wires should be tied with other wires, not be covered with terminator.
(AOS) 3- 6.
54000-71992-0E
Wiring (Diagrams) 3
Note:
1. Terminal symbol 2. The connection of the IGBT gate connectors should
CN1
be made according to the following drawings.
6 : Terminal 1.25-6 The connectors should be connected so that
CN2
the ribs to prevent incorrect connection are
Board comp., MPU G2
E2
facing the outside of the IGBT.
(Both white and black)
CN3
E1
Insert the housing until
it touches the main body
G1
of the IGBT.
CN4
-
CN5 CN6 CN7 CN8 CN11 CN12 Top view Side view
Reference:
Harness mark/color
Red RD
See note 2 Black BK
Green GN
From IGBT board Yellow YE
White WH
Brown BN
Blue BU
G2 G2 G2 Gray GY
E2 2P E2 2P E2 2P Pink PK
WH WH WH
Orange OG
E1 E1 E1 The housing and the harness
G1 2P G1 2P G1 2P should not protrude from the Ex) BKWH (=Black/White)
BK BK BK Black colored harness with White line.
side of the controller.
White line
NA
Battery (-)
HV HU Sensor comp., Black color
heat
4P 4P
6
2P G1 2P G1 2P G1 2P
BK E1 BK E1 BK E1 RD
4P 4P
2P E2 2P E2 TV 2P E2 TU
WH G2 WH G2 WH G2
12P
Cap
BKWH
W2 W1 V2 V1 U2 U1
External terminal
Harness, controller
W2 W1 V2 V1 U2 U1
Hydraulic Travel Hydraulic Travel Hydraulic Travel
W phase W phase V phase V phase U phase U phase
FBRF-70 Controller Wiring 3- 7.

54000-22582-0E
78
Pay attention to
the pin layout
Reference:
Harness mark/color
1
RDYE# Red RD
6 2 F 1A
YERD#
6 3 F 2A Black BK
BK#
6 12 F 3A Green GN
RDBK# 1
6 4 H 4A
BU#
6 13 H 5A
Yellow YE
BKRD# White WH
6 14 H 6A
BNYE
6 5 C 19A Brown BN
BKWH
6 15 C 20A Blue BU
6
BKWH Gray GY
CN1
6 7 D 7A
RDWH Pink PK
6 8 B 8A
WHGN
6 9 B 9A Orange OG
GNWH
6 10 B 10A
WHGN
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
6 19 B 11A
GNWH Ex) BKWH (=Black/White)
6 20 B 12A
11 Black colored harness with White line.
17
18
16
A MPU board
White line
1 Current sensor Current sensor Current sensor Current sensor
RDYE#
6 2 E 13A H (Hyd. V phase) G (Trv. V phase) F (Hyd. U phase) E (Trv. U phase) IGBT temperature
YERD#
6 3 E 14A C sensor
BK#
6 12 E 15A
RDBK# 3 HV TV HU TU
6 4 G 16A Black color
BU# 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1
6 13 G 17A
BKRD# 2
6 14 G 18A
5
WHBU Plug
6 6 B 21A 4P 4P 4P 4P 2P
10 RD
BNWH
6 16 B 23A
CN3
7 6B 18B 3B 15B 20B
8 A
A A A A
17 4B 5B 16B 17B 1B 2B 13B 14B 19B
GNRD
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
6 9 B 24A
A A A A A A A A A
11
BU 1 2
6 18 B 25A 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
15 10 10 10 10 10 10 10 10 10 10 10 10 3 3
19
FBRF-70
20
BK#
BK#
BU#
BU#
BNYE
BKWH
RDBK#
RDBK#
BKRD#
BKRD#
RDYE#
YERD#
RDYE#
YERD#
Pay attention to
the pin layout
Note) 1. Lead wire

marked with “#” : AVS0.3mm 2
not marked : AVS0.5mm 2
3. : Braided wires under 25mm pitch.
4. Impress or write marks on connectors with undamped ink
as indicated in the pin cunfiguration.
BKWH
BKWH
6
7B
A,B
WHBU
BNWH
BKWH
BU
GNRD
RDWH
GNWH
GNWH
WHGN
WHGN
D Battery (-) 6 6 6 6 6 6 6 6 6 6
1 2 3 4 5 6 7 8 9 10 11 12
A A A A
23B 25B 12B 11B
A D A A A A
21B 7C 24B 8B 10B 9B
AMP 040 series

Multi lock connector (Mark I)
174058-2
(12P)
1 2 3 4 5 6
7 8 9 10 11 12
B External terminal
Controller harness 3- 8.
WIRING (DIAGRAMS) 3
54000-22572-0E
79
Wiring (Diagrams) 3
3 21 5 21
See note 1,3,5 4- 9
G2 G2 G2 13 16
E2 E2 E2
E1 E1 E1
G1 G1 G1 14 22
23 24
See note 2
19 2
6 18
G1 G1 G1
CU103-91
12 E1 E1 E1
E2 E2 E2
G2 G2 G2
27 21
Unit type
See note 1,3,5
See note 4
W2 W1 V2 V1 U2 U1
21 4
11 9 7 10 17 7 8 17
1
27 35030-00780 IGBT Module CM400DU-5F 3 400A
15 20
26 54000-22582 Wiring, controller -
22 23 24 25 54000-22572 Harness, controller 1
24 0000-00008 Nut 8 M8
23 0000-70008 Washer, lock 10 M8
22 0000-72008 Washer, plain 8 M8
Standard 21 0016-06012 Bold, w/washers 28 M6x1.0-12
Note: 20 0016-05014 Bold, w/washers (cross recess) 2 M5x0.8-14
1. When installing the " 5 27 Module, IGBT" to the " 1 Sink, heat", Unit type CU103-91B 19 0016-04010 Bold, w/washers 4 M4x0.7-10
18 0077-04016 Screw, w/washers 6 M4x0.7-16
be sure to apply condition compound[G-747] (Shin-Etsu silicones) Applicable 17 0075-04016 Screw, w/washers 4 M4x0.7-16
FBRF14/16/20
to the entire cantact surface. models 16 0075-04008 Screw, w/washers 1 M4x0.7-8
Washer, Voltage 48V 15 24200-66340 Terminal comp., 1
2. Insert washers in the " 14 terminal", as shown in Figure A, and then lock Washer,
14 24200-63030 Terminal 2
plain
installing the " 14 terminal", apply LOCTITE[242] or equivalent to the Trv. Max. current 400A 13 24200-56850 Sensor comp., heat 1
(element rating) (250V) 12 54000-22521 Capacitor comp. 1
screws to prevent looseness. 1
Washer, 600A 11 54000-22511 Bar, lead (4)
Hyd. Max. current
3. Recommended tightening torque for the IGBT. lock (element rating) (250V) 10 54000-22501 Bar, lead (3) 2
54000-22491 1
Main terminal(M6) and mounting(M6) : 3.5-4.5N·m 9 Bar, lead (2)
Remarks 8 54000-22481 Bar, lead (1) 2
(0.36-0.49kg·m) 7 39530-02180 Sensor, current HC-TN700V35UP12 4 Koshin
Figure A
4. Impress a Unit type to the specified position with undamped ink. 6 54000-14090 IGBT Board comp. 1
5 35030-00790 IGBT Module CM600DU-5F 3 600A
5. Use the bolts of attachment for IGBT module. 4 54000-22471 Bracket, board (2) SGCC 1
3 54000-22461 Bracket, board (1) SGCC 1
2 54000-22260 MPU Board comp. 1 (PBC103-31)
1 54000-22441 Sink, heat A6063SS-T5 1
SYM PART NO. PART NAME SIZE MATERIAL QTY MASS REMARKS
FBRF-70 Main controller 3- 9.

54000-22432-0e
80
3 Wiring (Diagrams)
MPU board
AMP 040 multi lock connector

175966-2
8 7 6 5 4 3 2 1 AMP #110 connector

16 15 14 13 12 11 10 9 17162-1(WH), 1717162-2(BK)
(View from terminal insert side)
2 1
CN2 CN4 Terminal name (View from terminal insert side)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BU BU BU
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 2P 2 G21 18 2P 2 G22 18 2P 2 G23 18
WH WH WH WH WH WH
1 E21 18 1 E22 18 1 E23 18
BK BK BK
2P 2 E11 18 2P 2 E12 18 2P 2 E13 18
RD RD RD
RDWH
WHBK
BKWH
BNWH
WHBK
WHBK
BKWH
WHBK
WHBK
WHBK
BK 1 G11 BK 1 G12 BK 1 G13
BUYE
BUYE
BUYE
BUYE
18 18 18
BUYE
BUYE
OG
OG
OG
OG
OG
OG
(W phase for HYD.) (V phase for HYD.) (U phase for HYD.)

Pay attention to
the direction
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
White WH
Brown BN
Blue BU RD RD RD
Gray GY 18 G14 1 2P 18 G15 1 2P 18 G16 1 2P
BK BK BK BK BK BK
Pink PK 18 E14 2 18 E15 2 18 E16 2
Orange OG
Ex) BKWH (=Black/White) WH WH WH

18 E24 1 2P 18 E25 1 2P 18 E26 1 2P
BU WH BU WH BU WH
18 G24 2 18 G25 2 18 G26 2
(W phase for TRV.) (V phase for TRV.) (U phase for TRV.)
Note:
1. Terminal symbol
White line
6 : Receptacle 040 multi lock connector (mark II)
(AMP 173716-2 or 175061-2)
18 : Receptacle (Faston 110 series)
Black color (AMP 2-170043-4)
FBRF-70 Harness IGBT board 3-10.

54000-14090-1E
81
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
White WH
Brown BN White line
Blue BU
Gray GY
Pink PK
Orange OG
<Note> Black color
1.Terminal symbol Ex) BKWH (=Black/White)
16 : Receptacle AMP 170038-2 Black colored harness with White line.
2. All electrical wires should be fixed to prevent contacting 20P 4P

to the part of moving, with edge and of heat source. RD
Harness, body
20P 4P
RD
View from the back of steering panel
6P
WH
Display
4P
WH Harness, PS
Board comp.,
printed
*Only for trucks *Only for trucks

with other options with head lamp
Low speed 2 1
Optional switch Head lamp switch (turtle) switch Water Water
proof 4P 4P proof
Switch, rocker
EPS encoder 2 EPS encoder 1
(under position) (upper position)
Part No. and rating
marking
RD
(3) (1) (2) (4)
(4) (2) (1) (3)

BN
RDGN
B 4
(4) (3) (2) (1)
16 16 16 16
ST 4
FBRF-70 Wiring PS
Part No. and rating
IG
marking 4
BK
WHGN
RDBK
GNWH
Key switch
Steering
WIRING (DIAGRAMS) 3
3-11.
54000-60572-0e
82
Wiring (Diagrams) 3
21A 23A 1A 3A 5A 7A 9A 11A 13A 16A 18A 20A

Reference:
AMP 172133-9
Cap G G D C D B B B E Point "a" F F
A Harness, body
Harness mark/color
Red RD
4P See note 1
Black BK RD 22A 2A 4A 6A 8A 10A 12A 15A 17A 19A
Green GN
Yellow YE G C C B B B E Point "a" F F
White WH 1 2 3 4 5 6 7 8 9 10
Brown BN 2 1 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Blue BU 11 12 13 14 15 16 17 18 19 20
Gray GY 4 3 3 3 3 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
Pink PK AMP 040 series
GNWH
BU
RD
YE
BK
RD
BK
WHBU
BUWH
RDWH
BKWH
RDBK
WHGN
RDYE
BKYE
WHYE
BUYE
WHBU
BU
Orange OG
BN
RD
RDGN
Multi lock connector (markI)
Ex) BKWH (=Black/White) 175652-2
CN1
White line
Black color
See note 2
WHBU
Point "a" 10 1 A 8B
BUWH 10 2 A 9B
RD 10 3 A 6B 6P
BK 10 4 A 7B WH
Point "a"
50 BKWH
RDWH
10
10
5
6 A 10B
A 11B
1 2 3 4 5 6
B Display
See note 1
Capacitor
125V 0.022 See note 4
To F RDYE
To F RDYE 4P
To A RDYE
28 28
BU 11 1 A 2B WH Mode select
To A BKYE
RD
YE
11
11
2
3
A 3B
A 4B
C switch
WHBU
To F BKYE BK 11 4 D 5C 1 2 3 4 See note 1

To F BKYE
RDYE
BKYE
WHYE
BUYE
RDYE
BKYE
BU
4 4 4 4 4 4 4 4
1 3 2 4 1 3 2 4
BN
RDGN
RD
Point "a" A Point "a" A Note :
16B 18B
Point "a" A
16C 20B
Point "a" A
2. Electric wires are should be tied at only ends of the tube,
GNWH
BK
16
16 A,C 5B
A 1B D Low speed (turtle) switch
not inside the tube.
15B 17B 15C 19B
3. Write or impress the letters with undamped ink.
4 4 4
AMP 174257-2 AMP 174257-2

4. When installing the film capacitor to harness, conform
as shown the figure below. 21B 23B
RDBK
WHGN
16
16 A 13B
A 12B E Head lamp switch
Water proof type Water proof type Heat contraction tube or Capacitor A A
Plug 4P Plug 4P vinyl tube (Both ends are tied)
(Colorless)
Vinyl tube (Heatproof type)
(Cover to splicing)
22B G Key switch
A
1 2 Splicing
2 1 2 1 P1.25
4 3 4 3
(upper position) (under position)
F EPS encoder
See note 1,3
FBRF-70 Harness PS 3-12.

54000-68731-0e
83
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
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
FBRF-70
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
White line
20P Bottom view of lever panel
Body harness (1)
Black color
WIRING (DIAGRAMS) 3
Lever panel wiring 3-13.

54000-68032-0E
84
85
RD
4 A 8B
RDGN
4 A 9B
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
3 WIRING (DIAGRAMS)
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
FBRF-70
Multi lock connector (mark II)
Point "a" 175652-2
See note 3 RDBK
13B A
BUYE
GNWH
RDBU
RD
RD
BUYE
RDYE
Point "b" CN1

See note 3 WHBK 2 2 2 4 4 4 4
14B A
To A
To A
To D
To D
To D
To D
To D
To D
To D
To D
1 2 3 4
A Harness, body
BK
BK
BK
BK
BK
To A
To B
To B
Horn switch A A Point "b"
See note 1
RDBK
RDBK
RDBK
RDBK
RDBK
C
RD
RD
RD
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
2 1 Water proof type

4 3 Plug 4P
<Note>
2. Write or impress the figures with undamped ink.
B Directional switch
CE-2
3. Terminal(CE-2) should be tied with wire tie as shown in See note 1
the right figure.
4. When installing electric wires to the terminal, solder them
with strands of lead wires are hooked to the hole.
Lever panel harness 3-14.

54000-68041-0E
10A Key switch
RDWH
Under the floor plate
X1 X1 Fwd/Bwd
buzzer/
chime
(BN)
(BN)
Battery 48V
Relay comp.
BU
BU
BK
54000-70930
Fwd Bwd
buzzer/ buzzer/
RDWH
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

FBRF-70 Wiring, chime

White line
Black color
WIRING (DIAGRAMS) 3
3-15.
54000-70941-1E
86
87
Key switch
RDWH
See note 3
WH
Revolving To strobe light 2P
lamp
3 WIRING (DIAGRAMS)
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
Reference:
RDWH
RDWH
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
FBRF-70 Wiring, light

Ex) BKWH (=Black/White) Body harness (1)
(Z Accessory (1))
White line
Black color
3-16.
54000-70630-0E
Note) 1. Lead wire : AV or AVS or AVSS0.5mm 2
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
FBRF-70
Orange OG

Turn signal Turn signal Black colored harness with White line.
C head lamp(Right) B head lamp(Left)
White line
Black color
WIRING (DIAGRAMS) 3
Harness, head guard 3-17.

54000-70661-0E
88
Reproduction prohibited
First printing : December 2005
Issued by : Nippon Yusoki Co., Ltd

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

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CONTENTS

1. Adjustment of SICOS-AC 1 2. Troubleshooting 58

1-3. SICOS-AC check and adjustment .......... 21

3-1. FBRF-70 System wiring ......................... 71

3-5. FBRF-70 Floor harness .......................... 76

1. Battery discharge indicator

1-1-2. Indication of display

After 0.5 seconds

The normal screen is displayed.

NOTE Normal screen Flashed 3 times

CAUTION Contact to your local Nichiyu dealer if the error

Mode setting buttons

Setting screen by one touch operation

Clock setting screen

Mode select screen

Hour meter screen

1-1-3. Function of display

NOTE Icons of 10 to 18, and 2 shown in the illustration

1. Battery discharge indicator

CAUTION Do not over-discharge.

Full Charge the battery immediately

Discharge Discharge Discharge Discharge

2. Lift interrupt Two red segments are lit.

When all green segments are disappeared and two red

5. Fork leveling indicator (Special option)

7. Slow speed mode monitor (Turtle mark)

to the meter mode setting screen. Refer to the page 12

key switch. (The actual operating hours can be displayed

When pushing or button, each individual

The odometer or lifting height meter (option) can be

CAUTION The hour meter screen is returned to the normal

10. Service icon

blinked and the presumed defective part name and error

NOTE If the following abnormalities and/or errors

B11 - B13 : (IGBT U,V,W-TRAVEL)

The , and buttons are disabled while EPS controller

11. Safety monitor (for travel circuit)

12. Safety monitor (for hydraulic circuit)

13. Safety monitor (for power steering circuit)

14. Safety monitor (for overload)

15. Safety monitor (for hydraulic oil level)

16. Safety monitor (battery tray interlock)

hydraulic function does not work.

17. Safety monitor (for hydraulic lever)

hydraulic funciton does not work.

18. Safety monitor (for travel)

the truck does not run.

19. Mode select button

Slow speed mode button

Slow speed mode Mode select button

The slow speed mode indicator ( ) is not displayed.

normal mode and slow speed mode by pushing the 152T023

1-1-4. Various kinds of mode selection

CAUTION These settings are invalid while traveling or

When pushing button (less than 3 seconds), the

Mode select button

[1] Travel mode setting

Make sure that the current traveling mode indication is

and smooth inching can be realized.