Fb10 30p Dc70 Series Trs

02W-2201
FB-DC70 SERIES
FB
10P/15P/18P
20P/25P/30P
Contents
1. How to adjust SICOS 60 (Major point only)
.........................1
1-1 The name and function of mode select switch
.......................1
q Slow speed mode button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

w Mode select button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
e Up button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
r Down button (2 functions) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 How to set the each mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

q Speed setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
w Power setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
e Acceleration feeling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
r Option setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
t Language selection on LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
y Safety monitor symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Adjustment of starting current and current limitation . . . . . . . . . . . . . . . . . . 6

q Zero(0) adjusting for installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
w Adjustment of starting current and current limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Adjustment for other functions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
q Auto-torque up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
w Safety circuit for out of control (contactor tripping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
e Power setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
r Hydraulic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
t Switch back braking distance (Plugging/Regenerative braking) . . . . . . . . . . . . . . . . . . . . 12
y Regenerative braking force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
u Adjustment of brightness of the back light on monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 14
i Checking of speed sensor output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
o Hour meter working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
!0 Confirming the working of auto-power cut off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
!1 Adjusting of battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
q Confirming Over loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
w Confirming the travel inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
e Confirming the lift locking working at over discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
r Confirming the seat switch working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Outline of New EPS system for FBDC70
. . . . . . . . . . . . . . . . . . . . . 18
4-1 Outline of New EPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-3 Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
q Protection of overheat for motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
w Self diagnosis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-4 Checking and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

q Neutral adjustment of torque sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
w Checking by voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5. Self diagnosis history memory and I/O check
. . . . . . . . . . . . . . . . 22
5-1 Self diagnosis history memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-2 I/O check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6. Practical trouble shooting (How to find the cause of problem) . . . . . . . . 31

6-1 Before starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
q Location of negative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

w Layout of the connectors on MPU board and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-2 Attention for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

q Visual checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
w Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
e Error message and possible defective parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-3 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6-4 Analysis of malfunction causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
q No indications are made on the LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
w Indication of the LCD display is normal, but the truck abnormally travels . . . . . . . . . . . 38
e On the LCD display, error meassages appear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-5 Flowchart for troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7. Wiring and layout of control unit

Reference
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1. How to adjust SICOS60

(Major point only)
1-1 The name and function of
mode select switch
q Slow speed mode button.
Change to traveling mode.
When the slow speed mode button is turned
on, the speed is regulated to the preset
speed. (5km/h12km/h).
Slow speed mode button
When the slow speed mode button is turned on,

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

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

TRAVEL
HYD
STEER
BATT
LOAD
OIL
BRAKE
DISCHARGE
CAUTION
Be sure to check that the decimal point

flashes when the hour meter counts by
traveling or hydraulic operation.
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
ACCEL
100
SOFT
STD
FULL
TRAVEL
km
Travel hour meter

TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
POWER
50
75
100
ACCEL
SOFT
TRAVEL
When hour meter counts,

the decimal point flashes.
1
20
SPEED
STD
FULL
km
r Down button (2 functions).

Decrease the parameter of each selected
mode.
M
Down button
Showing the hydraulic hour meter.
CAUTION
TRAVEL
Be sure to check that the decimal point

flashes when the hour meter counts by
operating traveling or the hydraulic lever.
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
ACCEL
100
SOFT
STD
FULL
TRAVEL
km
Hydraulic hour meter
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
TRAVEL
STD
FULL
km
When hour meter counts,

the decimal point flashes.
1-2 How to set the each mode

Mode select button
Press the mode select button M to adjust the

each mode.
The each mode can be changed by pressing the

mode select button M as follows.
: Normal
: Speed setting mode
: Power setting mode
: Acceleration feeling mode
q Speed setting mode

The travel speed can be set at 5km/h through
12km/h by every 1km/h.
Up
button for increasing, Down
ton for decreasing.
NOTE
but-
When the slow speed mode button is off,

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

The power can be set at 3 steps, 100%, 75%,
and 50% by pressing the Up button
or
Down button
.
Down button
Up button
(50%75%100%)
The preset power is displayed

POWER column on the display.
at
the
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
STD
FULL
}
Preset power
e Acceleration feeling mode

The acceleration feeling mode can be set at 3
modes, Soft, Std (standard) and Full.
: Easy inching
Down button
: Normal
Up button
(SOFTSTDFULL)
: Quick accelerator
response
5
km/m
10
15
20
SPEED
NOTE
Better inching operation can be achieved

by selecting the "soft" mode.
POWER
50
75
100
ACCEL
SOFT
STD
FULL
}
The preset accelerator feeling is displayed at
the ACCEL column on the display.
3
Preset accelerator feeling
r Option setting
AB
789
2) Press the mode select button M to shift the

setting position.
456
CDE
F01
23
1) Set the rotary switch RS1 to 7, and turn the

key switch on.
Set RS1 to 7
The setting position which flashes can be moved

to the right by pressing the mode select button M.
3) Press,
the Up button
to set : display 1.
the Down button
to reset : display 0.
for each optional specification.
M
Mode select button
NOTE
After finishing to set or reset, be sure to

turn off the key switch and to return the
rotary switch RS1 to 0.
M
NOTE
When replacing the MPU board, be sure to

set the each function same as original
setting.
Option Set
Not used
Over Drive
without
(Option)
Hydrauric bywithout
pass (Option)
Regenerative
with
contactor
Monitoring
displayed
Seat switch
without
Lift lock at
off
over discharge
Not used
Up button
Down button
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
with
F
8
6
4
2
E
with
without
km/m
10
15
20
SPEED
POWER
off
with
50
75
100
ACCEL
SOFT
TRAVEL
STD
FULL
km
on
If the bit of Seat switch is changed 0 to

1 on a standard truch, hydraulic system
and indicator are normal, but the truck
cannot travel.
If all bits is changed 0 to 1 on the
standard truck, 4 error messages appear
on the indicator.
A10 : FET7-OVER DRIVE
B20 : FET4-HYD. BY pass
D24 : PC. BOARD-AOS
* TURN OFF KEY SWITCH *
Not used
Over drive (Opt.)
Hydraulic by-pass (Opt.)
Regenerative contactor
Monitoring
Seat switch
Lift lock at over discharge
Not used
NOTE
When replacing the MPU board, it is set 1 to each option setting for safety. Confirm the
specification of the truck and set it properly.
NOTE
The option setting which is standard specification is set to 0.

For example, Regenerative braking system is equipped as standard. Therefore, setting
0 means with regenerative brake 1 means without regenerative brake.
4
t Language selection on LCD display
AB
789
1) Set the rotary switch RS1 to 6 and turn the

key switch on.
456
CDE
F01
23
Each language can be selected by this operation.
Set RS1 to 6
2) Choose the each language shown below by

pressing Up button
or Down button
.
Down button
<Display on LCD>
F01
456
AB
23
After finishing to set or reset, be sure to

turn the key switch off and to return the
CDE
Displayed language when turning key switch on.
789
NOTE
Up button
Set RS 1 to 5
y Safety monitor symbol.

Each monitor symbol can be set by this operation
1) Set the rotary switch RS1 to 5.
2) Use the mode select button M to shift the setting position.
Mode select button
The setting position which flashes can be
moved to the right by pressing the mode

button M.
M
DOWN button
5
M
UP button
3) Press,
the Up button
to set : displayed 1.
the Down button
to reset : displayed 0.
for each safety monitor symbol.
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
STD
TRAVEL
FULL
km
TRAVEL
: Travel
BRAKE
HYD
: Hydraulic
Parking brake :
LOAD
STEER
: Steering
Over load :
OIL
BATT
: Battery
Oil level :
* For having GS battery and GS electrolyte level sensor only.

NOTE
The symbol for Travel, Hyd, Steer and Brake are preset as a standard at the factory.(displayed 1)
NOTE
After finishing to set or reset, be sure to turn the key switch off and to return the rotary
switch RS1 to 0.
1-3 Adjustment of starting current

and current limitation
F01
<Condition on checking>
Battery electrolyte over 1.25 (at 20C)
456
AB
23
Zero(0) adjusting is required for the installed

current detector to adjust the starting current
and current limitation correctly.
CDE
q Zero(0) adjusting for installed
789
Set RS1 to 1
<Adjusting procedure>
key switch on.
2) The each mode can be changed by pressing
the mode select button M as follows.
M
M
Mode select button
M
M
3) Adjust If LEVEL, and Ia LEVEL to be 000A

at no motor current condition by pressing Up
button
or Down button
CAUTION
As MPU board has an auto-zero level

adjustment function, no need to re-adjust
these mode normally. However, be sure to
confirm it.
4) Press,
the Up button
when the indication shows
minus() value.
the Down button
when the indication
shows plus (+) value.
Up button
Down button
Press Up button when

indication on monitor
shows minus() value.
Press Down button

when indication on
monitor shows Plus
(+) value.
5) After adjusting If GAIN and Ia GAIN, be sure

to turn the key switch off and to set back the
<Initializing (initial setting)>
Initializing should be done by pressing the Up
button
and Down button
simultaneously for approx. three (3) seconds.
Then, each setting (SPEED, POWER,
ACCEL) will be initial setting mode with showing INITIALIZED and a beep sound.
This "initialize" operation is also accepted
by each manual setting of,
SPEED : to 7km/h
POWER : to 100%
ACCEL : to STD
= INITIALIZED
Press Up and Down button simultaneously

for approx. 3 seconds.
5
km/m
10
POWER
50
75
ACCEL
100
Initial setting mode
F01

key switch on.
456
AB
23
CDE
w Adjustment of starting current and current limitation

1) Be sure to check that the specific gravity of
the battery electrolyte. It should be more than
1.25 at 20C and the operation of initialize
should be done, and initializing also finished.
Set RS1 to 2
The each mode can be changed by pressing the

mode select button M as follows.
M
M
M
Mode select button
15
20
SPEED
789
NOTE
SOFT
STD
FULL
3) Adjusting staring current

The CURR START will be shown after key
switch on.
CAUTION
Wall
4) Operate the directional switch to forward, depress

the foot brake. Then depress the accelerator
pedal until the regenerative contactor just goes
on, and hold at that position.
When adjusting the starting current and
current limitation, lock the traveling motor
by operating as follows.
Park the truck against a wall, and touch
the tip of forks to the wall.
Then apply the parking brake lever.
Depress the foot brake pedal.
5) Adjust the starting current on the monitor within specified range by pressing Up button
or Down button
.
Model
Starting Current (A)
FB10P
35 5
FB15P, 18P
45 5
FB20P, 25P
50 5
FB30P
45 5
Down button
Up button
Press Down button when

monitor indication shows
higher than the specified
value.

lower than the specified
value.
6) Adjusting current limitation

Set the CURR LIMIT mode by pressing
mode select button M.
NOTE
CAUTION
Wall
7) Operate the directional switch to forward, depress

the foot brake. Then depress the accelerator
pedal all the way down and hold it.
The current limitation should be read and
adjusted within two (2) seconds, otherwise
it will be increased by 130% for the automatic torque increase function. Then the
forcible bypass contactor will be turned on.
When adjusting the starting current and

current limitation, lock the traveling motor
by operating as follows.
Park the truck against a wall, and touch
the tip of forks to the wall.
Then apply the parking brake lever.
Depress the foot brake pedal.
8) Adjust the current limitation on the monitor
within specified range by pressing Up button
or Down button
.
Model
Current limitation (A)
FB10P
280 5
FB15P, 18P
330 5
FB20P, 25P
380 5
FB30P
330 5
NOTE
Use the clamp on meter as a reference

when checking and adjusting. There may
be some difference between the current
value on monitor and the reading by the
clamp on meter.
NOTE
After finishing the adjustment, be sure to

return the rotary switch RS1 to 0.
9
Down button
Up button
Press Down button when

higher than the specified
value.

lower than the specified
value.
10
Not used
Not used
Not used
5.0 - 6.0
330 10
5.0 - 6.0
5.0 - 6.0
Not used
45 5
FB30P
380 10
330 10
50 5
FB20P, 25P
5.0 - 6.0
Plugging
brake
distance
(m)
Not used
45 5
FB15P, 18P
280 10
Current
limitation
(A)
32
Not used
Option setting should be set 0 for standard specification.

Set to 1 in case of some option being installed.
regenerative contactor
046
020
OIL
LOAD
BRAKE
OIL
LOAD BRAKE
Language
5 : DUTCH
4 : SPANISH
DUTCH
SPANISH
GERMAN
MONITORING OK
MONITOR OK
UEBERWACHUNG OK
FRENCH
3 : GERMAN
MONITORING OK
CONTROLEUR OK
ENGLISH
2 : FRENCH
Indication of key switch on
1 : ENGLISH
Language
JAPANESE
0 : JAPANESE
RS1-6
* In case of no indication display language

JAPANESE Domestic : 0 : JAPANESE
ENGLISH : 1 : ENGLISH
Except for Japan
15.0/13.0
15.0/13.0
(km/h)
Unladen
/Laden
14.5/12.5
5
STEER BATT
15.0/12.5
060
TRAVEL HYD
* For having GS battery and GS

electrolyte level sensor only.
0 0 1 0
* For having GS battery and GS

electrolyte level sensor only.
BATT
STEER
HYD
Seat switch
Over discharge lift lock
Over drive (Opt.)
1 1 1 1
RS1-5 (monitoring setting)
Switch back brake distance

Flat, Unladen, Full speed
Specific gravity of electrolyte
more than 1.25 at 20C
Full acceleration
TRAVEL
Hydraulic by-pass (Opt.)
060
064
Monitoring
0 0 0 0
48
32
56
64
50
64
32
Tilt
Lift 2
Lift 1
32
Over
drive
Speed Speed Speed

L lift M lift H lift
Attach- Attach- Attach- Switch back brake force Braking

ment 1 ment 2 ment 3 Plugging Regeneration force
PLUGG- REGENE
ING
RATE
OVER
DRIVE
HYD
ATT.3
BRAKE
TRQ
HYD
ATT.2
HYD
ATT.1
HYD
TILT
SPD-L SPD-M SPD-H HYD

HYD
LIFT
LIFT
LIFT LIFT-1 LIFT-2
Not used
0 0 0 0
RS1-7 (Option setting)
Starting current
/Current limitation
Motor current
Power 100%
Specific gravity of electrolyte
48V
35 5
FB10P
Starting
current
(A)
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
(V)
Model
/
/
/
Voltage
/
/
Traveling
speed
/
/
RS1
/
/
Setting of rotary switch
/
/
RS0
/
/
(Confirmation)
The specification of each adjustment for FB-DC70
2. Adjustment for other functions

qAuto-torque up
A: Specific gravity of the battery electrolyte:
B: Make an initializing (Initialize mode setting)
<Confirming procedure>
1) Check the current limitation.
2) Confirm that the current limitation should be
increased by 130% of the value of current limCurrent 130%
itation after 3 seconds.
limitation
Forcible by-pass
contactor on
100%
3sec 2sec
wSafety circuit for out of control

(contactor tripping)
1) Be sure to check that the forward and backward contactor has not gone in.
2) Make a jumper wire between a main terminal
of bypass contactor. (Wire size about 0.5mm2)
3) Be sure to check the warning beap sound and
the error massage on the display.
4) Confirm that even though operate the accelerator, after that the forward (backward) contactor will not go in.
ePower setting
Specific gravity of the battery electrolyte:
Set the power setting to 50%
1) Check the current limitation.
2) Be sure to check that the motor current becomes
to about 70% of the current limitation.
11
rHydraulic setting
AB
456
CDE
F01
23
Be sure to check that the each setting is set

as listed on The specification of each adjustment for FB-DC70 (p.10).
789
Set the rotary switch

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

the mode select button M and adjust the setting by up button
or down button
.
Mode select button

M
M
M
M
M
M
M
M
M
tSwitch back braking distance

(Plugging/Regenerative braking)
AB
456
CDE
F01
23
B: Flat ground, Unladen, Full speed
789
NOTE

RS1 to 4
1) Set the rotary switch RS1 to 4, and adjust
the braking force by pressing up button
or
.
down button
The each mode can be
changed by pressing the mode select button
M. (either plugging or Regenerative brake)
2) Be sure to check the regenerative contactor
goes off when switch back braking operation
is done, and goes on just before starting on
reverse.
Mode select button
M
M
M
12
3) Adjust the plugging braking distance by press.

ing up button
or down button
The braking distance will be,
.
shorten by pressing up button
.
longer by pressing down button
NOTE

Up button
Down button
For shorter distance.
For longer distance.
yRegenerative braking force

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

RS1 to 4
1) Set the rotary switch RS1 to 4, and change
the mode of BRAKE TRQ by pressing mode
select button M.
Mode select button
M
M
M
2) Adjust the regenerative braking force by
.
pressing up button
or down button
The braking force will be,
.
Strong by pressing up button
.
Poor by pressing down button
NOTE

13
Down button
Up button
For poor braking

effect.
For strong braking

effect.
uAdjustment of brightness of the back

light on monitor
Adjust the brightness of the back light on
monitor by the volume VR0. Turning it clockwise for bright contrast.
Turning it clockwise
for bright contrast.
CFL
VR0
F01
456
AB
23
789
1) Set the rotary switch RS1 to C and turn the
key switch on. The each mode can be
changed by pressing the mode select button
M as follows.
CDE
iChecking of speed sensor output

RS1 to C
M
M
M
Mode select button
Sensor output 1 : left side
Traveling direction
F : Forward, R : Reverse
Sensor output 2 : right side
Sensor output total

(value of output 1+2)
2) Set the SPD (Speed sensor checking) mode.

3) Check the indication of sensor output by traveling.
Normally, the value of sensor output 1 and 2 should be the same when traveling.
In case that the value of sensor output 1 or 2 is not varied when traveling. (=always shown 0)
Check the sensor or its wire harness connected to MPU board.
In case that the value of sensor output 1 and 2 are the same with no changing.
Check and adjust the potentiometor for sensor 1 or 2 by the shims.
In case that the value of sensor output 1 plus 2 does not make a sensor output total.
(=output 1+2total)
It may be influenced by the noise. Please check some wire near the wire of sensor 1 and 2.
In case that the indication of traveling direction is opposite from the actual moving direction.
Check the connection of sensor 1 and 2, They may be opposite.
NOTE
After confirming the working, be sure to turn the key switch off and return the rotary
switch RS1 to 0.
14
oHour meter working

1) Connect the wireharness of [Blue/Red 1] and
[Black] located inside the front cover.
2) Be sure to check that the decimal point flashes when the hour meter counts by traveling or
hydraulic operation.
!0Confirming the working of auto-power cut off function

1) Turn the key switch on.
2) Be sure to check that the main power will be cut off after approx.15minutes automatically if there
is no operation either traveling or hydraulic operation.
!1Adjusting of battery voltage

Item (function)
Condition for checking
Check and adjustment procedure

1) Check the battery voltage at, + : Hyd. fuse, - : Minus () terminal
in the control unit.
2) Set the rotary switch RS1 to A, and turn the key switch on.
3) Set to VB LEVEL mode by pressing mode select button M.
Battery voltage
(for battery capacity
indicator)
MSpecific gravity :
more than 1.25 at
20C
4) Adjust the VB LEVEL to be the same value checked at 1) by

pressing Up or Down button.
CAUTION
15
The VOLTAGE figure will not be changed

even if adjusting the VB LEVEL.
3. Option
qConfirming Over loading
1) Lift up to the end and make a relief condition.
2) Confirm the display *REDUCE THE LOAD*.
wConfirming the travel inhibit

1) Connect the - line (black) to the connector
[CN4-4pin] on the MPU board.
2) Confirm that the tuck does not travel when
operating the traveling.
After confirming the working, be sure to

turn the key switch off and return the
16
AB
789
NOTE
Lifting speed will be half. Then after ten

minutes operation,
Battery capacity indicator : [Red] lamp
flashes.
Indication on display : CHARGE THE
BATTERY
and lifting will be suspended.
456
CAUTION
F01
23
key switch on.
2) Set 2nd bit of the lift lock at over discharge to
1.
3) Supply the voltage of 3036V to the battery
plug.
4) Confirm
Battery capacity indicator : [Red] lamp turning on.
Indication on display :*CHAGE THE BATTERY*
CDE
eConfirming the lift locking working at

over discharge

RS1 to 7
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
STD
TRAVEL
FULL
km
The lift locking at

over discharge
(2nd bit)
rConfirming the seat switch working
After confirming the working, be sure to

CDE
AB
789
NOTE
456
1) Operate the traveling without sitting on the seat.
2) Confirm the truck does not travel.
F01
23
<Setting procedure>
key switch on.
2) Set 1st bit of the seat switch to 1.

RS1 to 7
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
TRAVEL
STD
FULL
km
Seat switch
(1st bit)
17
4. Outline of New EPS

system for FBDC70
4-1 Outline of New EPS system
steering gear box
controller
motor
actuator
rear axle
The EPS system is constructed with steering gear box, new design potentiometer actuator, and
controller (new design) above. The torque sensor in the steering gear box detects the opposite
force from the steering tire when the steering wheel is operated, and send the signal which is proportioned with the force and direction to the controller. The controller controlls the magnitude and
direction of the steering motor current.
The steering motor creates the force by this current to assist the steering operation.
When the shock is applied to the tire, the torque sensor detects it and the actuator creates the
equivalent force against it. So, no kick back force is applied to the steering wheel.
18
4-2 Operation
Actuator Assy
Torque sensor
Steering
Operation
Controller
Actuator
Torque sensor
output
Motor
current
control
Output of
motor torque
Assist force
Wheel
steering
1) When the key switch is turned on, the contactor is activated and the power is supplied.
2) When the steering wheel is operated, the
steering force is detected by the torque sensor and output the voltage corresponded for it.
3) The output voltage from the torque sensor is
applied to the controller and converted to the
current for the motor on the actuator.
4) The motor creates the output torque which is
proportioned with the input current.
5) The output force of the actuator assists to
steer the wheels.
6) The steering force is reduced by this assist
force.
4-3 Feature
qProtection of overheat for motor
When the motor current
for about 5 seconds, the
turned off automatically.
input of torque sensor to
normal control condition.
continues over 25A

motor output will be
When put back the
neutral, it returns at
wSelf diagnosis function
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
1) If the problem is occurred at the torque sensor, scrolls the message of [C29:SENSOREPS TORQUE] on the display (Torque sensor
error).
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
ACCEL
100
SOFT
STD
FULL
TRAVEL
2) If the problem is occurred at a main FET circuit in the EPS controller, scrolls the message
of [C30: TR-EPS MAIN] on the display (chopper error).
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
TRAVEL
19
km
STD
FULL
km
4-4 Checking and Adjustment

qNeutral adjustment of torque sensor
yellow
<Checking procedure>
1) Turn the key switch off.
2) Jack up the rear wheels from the ground.
3) Open the side cover at right side.
4) Put the clamp meter to the wire [yellow] or
[green] between EPS controller and EPS
motor [DC range]
5) Turn the key switch on and measure the indication at the clamp meter without steering
operation. (= at neutral steer) If the indication
shows 0A, it is normal.
6) If any current is flown, adjust the potentiometer
by the following procedure.
green
EPS
controller
black
red
clamp meter
EPS motor
1) Turn the key switch off and disconnect the battery plug.
2) Disconnect the 3P water proof type connector of EPS sensor.
3P water proof type
connector (tab side)
1.5
potentiometer
EPS
sensor assy
3) Check the resistance at sensor side (tab side) between,

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

4) Turn the key switch on and operate the steering wheel from right side end to left side end, then
check the voltage. The following values are the standard.
right side end
0.8 V 0.3
neutral
2.5 V 0.3
left side end
4.2 V 0.3
From EPS
sensor
(potentiometer)
q Orange
q Blue 3
w Green / Red
e Black / Red
Tab
w Green/Blue 1
Rece
e White
3P water proof type connector

q pin
w pin
Rece
e pin
Tab
Adaptor
Tab
+ probe
to w pin
(output)
probe
to e pin
(negative)
21
To EPS
controller
5. Self diagnosis history memory

and I/O check.
5-1 Self diagnosis history memory
The total 34 error histories which have occurred
at least once can be memorized. There are two
(2) kind of information for this function.
The one is to memorized the operated condition
when the trouble has occurred (called Format
1), the other one is to memorize the each malfunction (called Format 2).
The basic system of Format 2 is same as the
one adopted on SICOS 50/60 and A-SICOS for
FBR-60 series.
CO
-SI
NE
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
TRAVEL
DISCHARGE
F
8
6
4
2
E
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
km/m
10
15
20
F
8
6
4
2
E
SPEED
POWER
50
75
100
ACCEL
SOFT
TRAVEL
STD
FULL
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
km
SOFT
TRAVEL
STD
FULL
km
<Format 1>
<Format 2>
Memory and display for the operated condition

when the trouble has occurred.
Memory and display for the each malfunction.

*same as SICOS 50/60 and A-SICOS or FBR-60 series.
22
AB
456
CDE
F01
23
<How to check the error history memories>

1) Set the rotary switch RS1 to B, and turn the
key switch on.
2) Press the mode select button M to call the
each mode.
789
Set RS 1 to B
NOTE
Do not turn the key switch on/off when

the rotary switch RS0 is set to F as the
history memory is cleared.
M
CAUTION
The truck can be moved even though the

history memory is called.
Mode select button
A: Format 1 of history memory

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

by pressing Up/Down button.
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
POWER
50
75
100
ACCEL
SOFT
TRAVEL
STD
FULL
km
[5] : Traveling mileage

Traveling mileage will be displayed when some trouble
happen.
[1] : History No. (0-9)

Each error is displayed in order.
0 : Latest error
9 : Oldest error
* It is naturally cleared for the errors
over 11th. The history No. can be
changed by pressing UP/Down button.
20
SPEED
[4] : Hydraulic motion mode No.

Hydraulic motion (condition) is displayed when the trouble has occured.
(see the page24 [2] Hydraulic motion (condition) mode No. in details)
[3] : Traveling motion mode No.
Traveling motion (condition) is displayed when the trouble has occured.
(see the page24 [1] Traveling motion (condition) mode No. in details)
[2] : Error No. (If 00 is displayed, there is no error memory)
Error No. of error message is displayed
(see the page35 table)
23
[1] Traveling motion mode No.

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

Mode No.
Content
Hydraulic neutral
Hydraulic control
Hydraulic bypass contactor ON
Hydraulic bypass contactor OFF
Hydraulic bypass control
24
B: Format 2 of history memory

3) Press Up
or Down
button to change
(call) the each Error memory No..
If there has been a problem at least once, the

bit shows 1. If not, it shows 0 on the monitor.
DOWN button
0 . . .No trouble
[ 1
. . .Troubled (at least once)
UP button
History memory No. can be changed (called)

by pressing Up/Down button.
TRAVEL
HYD
BATT
OIL
LOAD
30 40
60
80
STEER
BRAKE
DISCHARGE
F
8
6
4
2
E
Error
memory No.
7th bit
6th bit
SPEED LIMIT
POWER
5th bit
50
75
100
4th bit
ACCEL
SOFT
STD
3rd bit
2nd bit
A1 : FUSETRAVEL
ERR0
A5 :
A6 : FET9CONTACTORREVERSE
FORWARD
A4 : FET10FORWARD
A3 :
A2 : FET6CONTACTORREGEN
REGEN
ERR1
A14 : SENSOR- A13 : ACCELCURRENT

ACCELERATOR
(ARMATURE)
A12 :
TR-REGEN
MAIN
A11 :
TR-TRAVEL
MAIN
ERR2
B21 :
B22 :
TR-HYD
SWITCH-LIFT
MAIN
B20 : FET4HYD.
BYPASS
B19 :
B18 : FET5CONTACTOR- HYD
HYD
ERR3
*REDUCE
THE LOAD*
*REFILL
HYDRAULIC
OIL*
Not used
Not used
C31 :
FUSE EPS
ERR4
Not used
Not used
Not used
Not used
Not used
25
FULL
1st bit
*FAIL HYD*
0 bit
*FAIL TRAVEL*
A10 : FET7- A9 :
A8 : FET8OVER DRIVE CONTACTOR BYPASS
BYPASS
A7 :
CONTACTORREVERSE
B17 :
FUSE HYD
A16 :
SENSORSPEED
A15 : SENSORCURRENT
(FIELD)
C30 :
TR-EPS
MAIN
C29 : SENSOREPS
TORQUE
Not used
Not used
*REPLENISH
*REFILL
REFINED
WATER FOR BRAKE OIL*
BATTERY*
<How to clear the error history memories>

1) Turn the key switch OFF.
OFF
ON
START
F01
456
AB
23
CDE
2) Set the rotary switch RS0 to F.
789

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

OFF
ON
START
4) Turn the key switch OFF.
OFF
5) Set the rotary switch RS0 at the original position.
6) Make sure to be clear it.
26
ON
5-2 I/O check

I/O (Input/Output) check is the function that the
input and output signal for the microcomputer
can be displayed on the LCD by the binary code
of [1] or [0] to check if each part is normal.
Approx. 90 points of input/output signals can be
checked.
Set RS 1 to E
AB
789
2) Select the port by pressing Up

or Down
button.
Refer to the I/O table for the detail of each
port.
Select the port No.
M
NOTE
After confirming the I/O check, be sure to

DOWN button
<Example of I/O check>

For example, in case of the port No.10
(=IOM10), the following screen is displayed.
TRAVEL
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
TRAVEL
Directional switch for reverse

1 : ON
0 : OFF
STD
FULL
km
Not used
Not used
Directional switch for forward

1 : ON
0 : OFF
Directional switch for neutral
1 : Neutral
0 : Not Neutral
27
456
CDE
F01
23
<Procedure of display>
1) Set the rotary switch RS1 to E, and turn the
key switch on.
Not used
Not used
Not used
UP button
I/O TABLE (1)

PORT NO.
RS1-E
NO.OD
RS1-E
NO.OE
RS1-E
NO.OF
RS1-E
NO.OC
BIT
IN/OUT
IN
Button
[UP]
0: Up [brake closed]
IN
Button
[Mode select]
0 : select
IN
Button
[Down]
0 : Down
IN
Button
[Slow speed]
1 : Slow speed
IN
Hydraulic oil level
0 : Detection
IN
Brake oil level
0 : Detection
IN
Overload
0 : Detection
IN
Not used
IN
Switch
[Brake]
0 : ON [brake closed]
IN
Switch
[Lift 1]
1 : ON
IN
Switch
[Lift 2]
1 : ON
IN
Switch
[Tilt]
1 : ON
IN
Switch
[Attachment 1]
1 : ON
IN
Switch
[Attachment 2]
1 : ON
IN
Switch
[Attachment 3]
1 : ON
IN
Switch
[Parking brake]
1 : ON
IN
Contact
[Regenerative]
1 : ON
IN
Contact
[Hydraulic]
1 : ON
IN
Contact
[Forward]
0 : ON
IN
Contact
[Reverse]
0 : ON
CONTENTS
REMARKS
Not used
IN
Fuse
[Travel]
0 : Fault
IN
Fuse
[Hydraulic]
0 : Fault
IN
Fuse
[EPS]
0 : Fault
IN
Rotary switch RS-0
EX) 0000 : "0"
IN
Rotary switch RS-0
0000 : "1"
IN
Rotary switch RS-0
0000 : "3"
IN
Rotary switch RS-0
0000 : "8"
IN
Rotary switch RS-1
EX) 0000 : "0"
IN
Rotary switch RS-1
0001 : "1"
IN
Rotary switch RS-1
0011 : "3"
IN
Rotary switch RS-1
1000 : "8"
28
I/O TABLE (2)

PORT NO.
RS1-E
NO.10
RS1-E
NO.11
BIT
IN/OUT
CONTENTS
IN
Not used
IN
Not used
IN
Not used
IN
Not used
IN
Directional
[Neutral]
1 : Neutral
IN
Directional
[Forward]
1 : Forward
IN
Directional
[Reverse]
1 : Reverse
Not used
Not used
Not used
Not used
REMARKS
IN
Hour mete clear
1 : Clear
IN
Hour meter count stop
1 : Stop
IN
Hour meter option
1 : Counting
OUT
[Hydraulic]
Not used
Current [Armature]
Use 10 bits by binary system. "1 and 0 bits of NO.01 and 7 to 0 bits of NO.00"
RS1-E
NO.00
NO.01
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.01
NO.00
Analog / Digital conversion
0 - 500A / 1.2 - 4.0V
Current [Field]
RS1-E
NO.02
NO.03
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.03
NO.02
0 - 500A / 1.2 - 4.0V
Voltage [Battery]
RS1-E
NO.04
NO.05
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.05
NO.04
0 - 55V / 0 - 5V
Voltage [Battery capacity]

RS1-E
NO.06
NO.07
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.07
NO.06

29
44.6 - 55V / 1.2 - 4.0V
I/O TABLE (3)

Accelerator voltage 1
RS1-E
NO.08
NO.09
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.09
NO.08
0 - 0.5V
Accelerator voltage 2
Use 10 bits by binary system. "1 and 0 bits of NO.0B and 7 to 0 bits of NO.0A"
RS1-E
NO.0A
NO.0B
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.0B
NO.0A
PORT NO.
RS1-E
NO.18
0 - 0.5V
BIT
IN/OUT
OUT
Contactor select
[Forward]
1 : ON
OUT
Contactor select
[Reverse]
1 : ON
OUT
Contactor select
[By-pass]
1 : ON
OUT
Contactor select
[Overdrive]
1 : ON
OUT
Contactor select
[Regenerative]
1 : ON
OUT
Contactor select
[Hydraulic]
1 : ON
OUT
Contactor select
[Hydraulic by-pass]
1 : ON
CONTENTS
Not used
30
REMARKS
6. Practical trouble shooting

(How to find the cause of problem)
6-1 Before starting
Basically the same procedure can be used as the previous SICOS-50 for the troubleshooting.
However, the display unit, MPU board, accelerator etc. are changed in design and some new functions are added. I/O checking also has the different procedure to recall on the display unit.
The details of the procedure are explained in the following sections. In this section, the following
matters should be understood.
qLocation of negative circuit

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

of M4 contactor
Capacitor : 100V 2200F X 1 (FB10/15/18P)

X 2 (FB20/25P)
X 3 (FB30P)
D4
F2
PA
M7
FC2
<SYSTEM WIRING>
() probe
() probe
Battery () terminal
M4 contactor ribbon
Wire
(Bypass contactor)
<CONTROL UNIT>
31
wLayout of the connectors on MPU board

and others
1) MIC connector
MPU board
PB84-XX
CN1
CN3
CN2
CN4
CN5
CN6
A
6 5 4
3
14 13 12 11 10 9
CN1
2
8
1
7
4 3
10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
CN2
CN5
CN6
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
CN3
CN4
2
6
1
5
View from A (receptacle/harness side)

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

from insertion side of pins.
32
2) Waterproof type connector

Each No. in the connector indicates pin No. .
12 pin type
10 pin type
8 pin type
6 pin type
3 pin type
2 pin type
Rece side
6 5 4 3 2 1
12 11 10 9 8 7
5 4 3 2 1
10 9 8 7 6
4 3 2 1
8 7 6 5
3 2 1
6 5 4
3 2 1
2 1
Tab side
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5
6 7 8 9 10
1 2 3 4
5 6 7 8
1 2 3
4 5 6
1 2 3
1 2
3) Other connector
Each No. in the connector indicates pin No. .
6 pin type
Rece side
1
4
2
5
3
6
Tab side
3
6
2
5
1
4
4 pin type (1)
4 pin type (2)
1
3
2
4
2
4
1
3
6-2 Attention for the troubleshooting

NOTE
Initially correctly understand content and

phenomena of problems.
After understanding customers operator
sayings and actual forklift truck status
as correctly as possible ( including problems that often occur).
qVisual checking
The visual checking may help to find the main
cause, check the each parts carefully.
Example)
Is there any parts or wire which is burned out ?
How about the looseness of connector ?
33
2 pin type
1
2
wFault finding
When the cause is unknown even after visual
check,
safety guard
1) Place the rigid blocks under the outer mast to

stable the truck.
2) Tilt the mast forward by pushing the tilt lever to
rise the front wheels.
NOTE
Place the safety guards for safety !

Do not rotate the drive wheels off the floor
at high speed, because the drive motor
and internal parts of the gear box could
be damaged.
Measurement of voltage should be
done in a short time.
Be sure to disconnect the battery plug
when connecting the volt-ohm meter,
repairing and replacing parts.
34
Rigid block
eError message and Possible defective part

Error No. and error message is displayed.
Symbol
Error
(Flash for defect) No.
Message
Possible defective part
* FAIL TRAVEL. *
FET, D2, MPU board ... etc.
* FAIL HYD. *
FET, MPU board ... etc.
* TURN OFF KEY SWITCH *
linked with other message
A1 : FUSE-TRAVEL.
Travel fuse
A2 : FET6-REGEN.
Regen. contactor coil, MPU board
A3 : CONTACTOR-REGEN.
Regen. contactor, MPU board
A4 : FET10-FORWARD
Forward contactor coil(Left), MPU

board
A5 : CONTACTOR-FORWARD
Forward contactor
10
A6 : FET9-REVERSE
Reverse contactor coil (Left), MPU

board
11
A7 : CONTACTOR-REVERSE
Reverse contactor
12
A8 : FET8-BYPASS
Bypass contactor coil, MPU board
13
A9 : CONTACTOR-BYPASS
Bypass contactor, MPU board
14
A10 : FET7-OVER DRIVE
15
A11 : TR-TRAVEL. MAIN
FET, Bypass contactor, MPU board
16
A12 : TR-REGEN. MAIN
Pre-energizing board, Resistor
17
A13 : ACCEL-ACCELERATOR
Accel., Directional sw.
18
A14 : SENSOR-CURRENT (ARMATURE)
Current sensor (Ia)
19
A15 : SENSOR-CURRENT (FIELD)
Current sensor (If)
20
A16 : SENSOR-SPEED
Speed sensor
21
B17 : FUSE-HYD.
Hydraulic fuse
22
B18 : FET5-HYD.
Hydraulic contactor coil, MPU board
23
B19 : CONTACTOR-HYD.
Hydraulic contactor, MPU board
24
B20 : FET4-HYD. BYPASS
25
B21 : TR-HYD. MAIN
Hydraulic FET, MPU board
26
B22 : SWITCH-LIFT
Lift micro switch (1), (2)
27
B23 : SENSOR-CURRENT (HYD.)
TRAVEL
HYD
Remarks
Half speed
Half speed
Half speed
Half speed
Half speed
D24 : PC. BOARD-AOS

* FAIL AOS *
D25 : TR-AOS
D26 : RELAY-AOS
D27 : POTENTIO-HYD. LEVER
D28 : POTENTIO-MAST
STEER
34
C29 : SENSOR-EPS TORQUE
35
C30 : TR-EPS MAIN
36
C31 : FUSE-EPS
37
C32 : FET3-EPS
38
C33 : CONTACTOR-EPS
* The following parts cannot be diagnosed and displayed.

1) Diodes : D1, D2, D3 and D4
5) Motors
2) Capacitors for surge absorbing
6) A part of MPU board
3) A part of current sensor
7) A part of microswitches
4) A part of pre-energizing board
8) Wire harness
9) Connectors
10) Back contacts of forward / reverse contactror
11) LCD display
* The error messages for the current sensor and the pre-energizing board are depend on the defect conditions to display.
35
Symbol
Error
(Flash for defect) No.
Message
Possible defective part
Remarks
39
* REFILL HYDRAULIC OIL *
Shortage of hydraulic oil
40
* REDUCE THE LOAD *
Overloaded
Opt.
41
* REFILL BRAKE OIL *
Shortage of brake oil
Opt.
42
* REPLENISH REFINED WATER

FOR BATTERY *
Shortage of battery electrolyte
* CHARGE THE BATTERY *
Need to charge battery
* RELEASE ACCEL. TO NEUTRAL *
Accelerator is operated before power on
* OFF HYD. LEVER TO NEUTRAL *
Hyd. lever is operated before power on
6-3 Troubleshooting Procedure

Correct understanding of the content and phenomena of the problems is a great prerequisite.
However, after understanding them, the indications on the display (safety monitor, error message, I/O checking ) become effective means.
An indication is not made on the LCD display.
No indications or abnormal.
Indication of the LCD display is normal.
No error message appears.
Indication of the LCD display is normal.
Error messages appears.
These cases are assumed. Considering them
and referring to the error messages and circuit
diagram (system wiring), trace the malfunctions.
Approximate guess is required.
Thoughtless tracing greatly wastes time. The
basic considerations are the same as the
SICOS50/60.
However, glance over this manual and roughly
take note of the key matters.
6-4 Analysis of malfunction causes

It was previously stated that initial understanding
of the content and phenomena of the problems is
an important point in finding the malfunctions.
With prerequisite that a malfunction results in
any error, the following checkings lead to a start
for the procedure.
36
GS batt.
Check for truck status

LCD display status
1) Check to ensure that the display is normal.
(Ordinary display or non-display)
2) Check to ensure that the display indicates
error messages.
Next, the malfunctions can be classified mainly
into following three:
No indications are made on the LCD display.
Indication of the LCD display is normal, but
the truck abnormally travels.
On the LCD display, error messages appear.
The following are the counter measures.
qNo indications are made on the LCD

display.
In this case, only the display does not make
an indication. Whether the forklift truck normally travels or not is a judgement diverge.
1) If only indication problems exist;
LCD display
MPU board that is controlling LCD.
Cables including connector between MPU
and LCD shall be checked.
2) Without LCD indications, the forklift truck
abnormally travels. (In many cases, the truck
does not travel quite). The power circuits
seem to have problems.
At the LCD lighting on the MPU board, the
MPU board, wirings or fuses are judged to
have problems.
PROCEDURE:Example,
No LCD
Can truck travel and operate

hydraulics normally?
Are all lit?

LED0:12V
LED1: 5V
LED2:CPU run
No
Yes
Yes
Replace LCD dispraly.

Yes
Checking for power line.

F4 fuse, Mctt replay,
CN2-6 pin, CN5-20 pin,
CN5-10 pin.
Is LCD indication made?

Yes
Check for MPU board or

wirings.
37
No
Replace MPU board.
wIndication of the LCD display is normal,

but the truck abnormally travels.
In this case, especially checking for malfunctions of the truck must be done.
They are largely classified into two(2):
Traveling and Hydraulic malfunctions.
1) Truck traveling status
The truck does not travel.
The truck rushes out.
The electric braking (plugging) force is weak.
If the LCD display indication is normal and the
traveling system has an error, the following
checkings must be initially done.
Check to ensure that all adjustments have
been done.
(See 1-3 Adjustment of starting current and
current limitation)
Check to ensure that the option setting is
correct.
Check to ensure that the hour meter display
is normal. Check for the parts which are not
self-diagnosed regarding travel,
(See 6-2 eError message and Possible
defective part)
2) Hydraulic malfunctions
A hydraulic motion is not made.
The hydraulic speed control is impossible.
If the hydraulic systems have errors, perform
checking in the same way as the traveling
systems.
Check to ensure that all adjustments have
been done.
(See 1-3 Adjustment of starting current and
current limitation)
Check for malfunctions of the option and
hour meter display.
eOn the LCD display, error messages

appear.
In this case, with reference to Section 6
Practical trouble shooting.
Please try checking.
The detailed procedure will be notified to you
soon later. Main signal lines for error message
will be attached to the system wiring base.
Please refer to it.
38
6-5 Flowchart for troubleshooting

q Check point
1) Is model select correct?
2) Check the specification.
With option.
Special truck?
After checking the above, start to troubleshoot.
CAUTION
CAUTION
When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the
following.
1. MPU board
(1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.)
(2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting.
(3) Check the plugging brake distance. (See Adjustment Specification Table.)
2. Current sensor
(1) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
3. FET Comp.
1. Be sure to turn off the key switch when setting Rotary switches.
2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit.
w Contents of flowchart
ERROR NO.1
ERROR NO.2
ERROR NO.3
ERROR NO.4
ERROR NO.5
ERROR NO.7
ERROR NO.9
ERROR NO.11
ERROR NO.13
ERROR NO.16
ERROR NO.18
ERROR NO.20
ERROR NO.22
ERROR NO.24
ERROR NO.26
ERROR NO.35
*RELEASE ACCEL TO NEUTRAL*

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

Operate Accelerator before
turning on Key switch?
No
No
Slit plate normal?
Yes
Yes
Return the accelerator to the

neutral position.
Then operate it again.
Adjust.
Replace the accelerator printed

board.
Operation become normal?
No
Yes
This situation is occurred by the

neutral safety function.
This is not problem.
This function warns to the
operator to take the correct
procedure to operate.
END
No
Repair.
The following each wiring between

Accelerator and MPU board is normal?
Accelerator PB-CN3-4 (Red4)
Accelerator PB-CN3-5 (Brown/Yellow1)
Accelerator PB-CN3-14 (Black/Yellow)
Accelerator PB-CN4-1 (Red/Green3)
Accelerator PB-CN4-2 (Green/Black1)
Accelerator PB-CN4-9 (Black1)
Yes
Replace MPU board.
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
40
Error No.2
* OFF HYD. LEVER TO NEUTRAL *
LCD Display
*OFF HYD. LEVER TO NEUTRAL*

No
Operate the hydraulic lever

before turning the key switch?
Turn off key switch.
Yes
Set RS1 at [E].
Return the hydraulic lever to the
neutral position.
Then operate it again.
Turn on key switch.
This situation is occurred by the

neutral safety function.
This is not problem.
This function warns to the
operator to take the correct
procedure to operate.
Select [IOM 0E].
No
Release the hydraulic lever.

Any bit shows [1]?
Replace MPU board.
Yes
No
Hyd. micro switch normal?
Repair.
Yes
The following wiring between Hyd. Micro SW
and MPU board are normal?
Lift1 micro SW-CN6-6 (Brown/Red1)
Lift2 micro SW-CN6-14(Blue/Yellow2)
Tilt micro SW-CN6-7 (Red3)
Reach micro SW-CN6-15 (Yellow/Black)
Attachment micro SW-CN6-8 (Green/White3)
Attachment micro SW-CN6-16 (Blue/Yelloew3)
No
Yes
7 6 5 4 3 2 1 0
Replace Micro SW of the bit that
shows [1].
LIFT1 SW
LIFT2 SW
TILT SW
No
REACH SW
ATTACHMEMT SW
ATTACHMEMT SW
IOM 0E/

Yes
END
41
Replace MPU board.
Repair.
Error No.3
* FAIL TRAVEL* *TURN OFF KEY SWITCH*
LCD Display
FAIL TRAVEL
*
*
TURN OFF KEY SWITCH
The other error messages

appear at the same time?
*
No
The contact of M4 Bypass

contactor is welded?
Yes
See the flowchart in which
the error message appears
and check it.
No
Yes
The Green/Blue wire

between drain of Travel
FET and CN3-19 pin is
normal?
Replace the contact of

Bypass contactor.
No
Yes
Repair.
No
q Turn off key switch.

w Disconnect
Operation become
normal?
the connector of Travel FET

4P Green.
Yes
Turn on key switch.
END
No
The error messages *FAIL

TRAVEL* appears?
Yes
Replace MPU board.

Replace Travel FET.
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
42
Error No.4
* FAIL HYD.* *TURN OFF KEY SWITCH*
LCD Display
FAIL HYD.
*
*
*TURN OFF KEY SWITCH*
The other error messages

appear at the same time?
No
No
Hyd. Bypass installed?
Yes
Yes
See the flowchart in which

the error message appears
and check it.
No
The contact of M7
contractor welded?
Yes
The Green/White wire

between drain of Hyd.
FET and CN3-10 pin is
normal?
No
Yes
Repair.
Replace M7 contractor.
q Turn off the key switch.

w Disconnect
the connector. (2P Black)
Turn on key switch.
No
The error message

*FAIL HYD.*
TURN
OFF KEY SWITCH*
*
appears?
Yes
Replace MU board.
Replace Hyd. FET.
43
Error No.5
A1:FUSE TRAVEL
LCD Display
A1:FUSE TRAVEL
Fuse F1 for travel is normal?
No
Yes
w Set RS1 at [E].
e Turn on key switch and
Replace Fuse for travel.
select I/O port [IOM 0F].
This bit 5 shows [1] on LCD display?

LCD display
7 6 5 4
3 2 1 0
No
IOM 0F
1:normal
0:abnormal
The Brown/White wire

between F1 (fuse) and CN2-1
pin is normal?
Yes
No
Yes
Replace MPU board.
Repair.
Replace MPU board.
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
44
Error No.6
A2:FET6-REGEN.
LCD Display
A2:FET6-REGEN.
OPTION SET Adjust.
RS1
Regenerative function
installed?
[7]
7 6 5 4
Check
OPTION SET.
3 2 1 0
No
OPTION
Yes
Bit 4 shows [0]?
The error message appears
after turning on key switch
Yes
without traveling?
Yes
No
Replace MPU board.
q Set the bit 4 at [0].
Then reset RS1 at [0].

w Turn off and on key switch.
w Disconnect CN1 from MPU
board.
Replace MPU board.
The Red/Green1 wire

between coil of M3 contactor
and CN1-3 pin is normal?
Yes
The coil resistance of M3

contactor is normal?
32.5-35.5
Yes
No
Repair.
No
Replace MPU board.
45
Replace M3 contactor and MPU

board at the same time.
Error No.7
A3:CONTACTOR-REGEN.
LCD Display
A3:CONTACTOR-REGEN.
OPTION SET Adjust.
RS1
No
Regenerative function is
installed?
[7]
7 6 5 4
Check
OPTION SET.
3 2 1 0
OPTION
Yes
Bit 4 shows [0]?
Yes

The contact of Regen.
contactor (M3) is welded?
No
Yes
Replace M3 Contactor.
Replace MPU board.
The error message

appears at the moment
when key switch, Foot
switch and Accelerator
are turned on?
No
Yes
Operation become
normal?
The Blue2 wire between

contact of M3 contactor
and CN4-15 pin is
damaged?
No
Yes
No
END
Yes
Replace MPU board.
Repair.
The connection of M3
contactor is bad ?
No
Yes
Replace MPU board.
46
No
Error No.8
A4:FET10-FORWARD
LCD Display
A4:FET10-FORWARD

without traveling.
No
Replace MPU board.
Yes

board.
The Red1 wire between coil

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

32.5-35.5
No

Yes
Replace MPU board.
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
47
Error No.9
LCD Display
Turn on key switch.

Yes
The truck can travel when

operating the accelerator after
pushing the lever forward?
No
Replace M1 contactor.
Yes
The Yellow/White2 wire

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

without traveling.
No
Replace MPU board.
Yes

board.
The Red/White1 wire between

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

32.5-35.5
No

Yes
Replace MPU board.
49
Error No.11
LCD Display
Turn on key switch.

Yes
The truck can travel when

operating the accelerator after
pushing the lever forward?
No
Yes
The Yellow/White2 wire

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

without traveling.
No
Replace MPU board.
Yes

board.
The Red/Black1 wire between

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

32.5-35.5
No

Yes
Replace MPU board.
51
Error No.13
A9:CONTACTOR-BYPASS
LCD Display
A9:CONTACTOR-BYPASS
The error message of *FAIL

TRAVEL* appear at the same
time?
No
Yes
The contact of M4 contactor
welded?
No
Yes
The Green/Blue wire between

drain of Travel FET and CN3-19
pin is normal?
Replace the contact of M4

contactor.
No
Repair.
Yes
No
q Turn off key switch

w Disconnect the connector of
Travel FET (4P Green).
Yes
END
Turn on key switch.

TRAVEL* appear?
No
Yes
Replace MPU board.
Replace Travel FET.
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
52
Error No.15
A11:TR-TRAVEL MAIN
LCD Display
A11:TR-TRAVEL MAIN

TRAVEL* appears at the
same time?
No

contactor of Travel FET and
CN3-19 pin is normal?
Yes
No
Repair.
Yes
Replace Travel FET.
The contact of M4 contactor

welded?
No
Yes
Replace the contact of M4

contactor.

contactor of Travel FET and
No
Yes
No
Repair.
Yes
END
q Turn off key switch

w Disconnect the connector of
Travel FET (4P Green).
Turn on key switch.

TRAVEL* appears?
No
Yes
Replace MPU board.
Replace Travel FET.
53
Error No.16
A12:TR-REGEN. MAIN
LCD Display
A12:TR-REGEN. MAIN
No
Regen. contactor (M4) is installed?
Replace MPU board.
Yes
Resistors for pre-energizing are normal?
48V : 2.2, 30W (4 pcs.)
24V : 1.0, 30W (2 pcs.)
No
Replace.
Yes
The following 2mm2 wires are normal? (short-circuited or broken?)
q Red wire between contact of M3 contactor and the resistors for pre-energizing.
w Blue wire between the resistors and pre-energizing PB.
e White wire between pre-energizing PB and D2 [A].
No
Repair.
Yes
The following wires are normal? (short-circuited or broken?)
q Blue/Red wire between pre-energizing PB and MPU board (CN4-8 pin).
w White/Red1 wire between pre-energizing PB and MPU board (CN4-16 pin).
e Brown/White wire between D2 [K] and MPU board (CN2-1 pin).
No
Repair.
Yes
Replace pre-energizing PB.
No
Replace MPU board.
Yes
END
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
54
Error No.17
7 6 5 4 3 2 1 0
LCD Display
Bit1-Bit4 change like the right table when

pulling and/or pushing Accelerator?
No
6
1
0
0
(Gray code)
5
0 Forward
1 Neutral
0 Backward
Yes
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0

Connector 6P
MPU board
of Accelerator
1 pin
CN3-14 (Black/Yellow)
2 pin
CN3-5
(Brown/Yellow1)
3 pin
CN3-4
(Red4)
4 pin
CN4-9
(Black1)
5 pin
CN4-2
(Green/Black1)
6 pin
CN4-1
(Red/Green3)
Each wire of the above is broken or bad
connector?
Micro switch of Directional

switch is normal?
No
No
Yes
Adjust or Replace.
Repair.
Yes
Directional
MPU board
switch
Forward
CN6-12 (Brown2)
Backward
CN6-5 (White/Red2)
Neutral
CN6-4 (Brown/Black1)
Each wire of the above is broken or bad
connector?
Replace Accelerator PB.
No
No
Yes
Yes
Replace MPU board.
END
CAUTION
I/O check of Accelerator signal is displayed by Gray code.

It is not Binary code. Pay attention.
55
Replace MPU board.
Repair.
NO USED
FAD
BWD
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
select I/O port [IOM 10].
7
0
0
1
Accel, bit
DECIMAL

w Set RS1 at [E].
e Turn on key switch, and
Bit
Push
Release
Pull
NTRAL
IOM 10
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Error No.18
A14:SENSOR-CURRENT (ARMATURE)
LCD Display
A14:SENSOR CURRENT
(ARMATURE)

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

w Turn on key switch.
Adjust at 0[A].
[la] level of current sensor

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

Replace Current sensor [la].
Operation become
normal?
No
Yes
END
CAUTION
CAUTION
Replace MPU board.
following.
1. MPU board
2. Current sensor
3. FET Comp.
56
Error No.19
A15:SENSOR-CURRENT (FIELD)
LCD Display
A15:SENSOR CURRENT
(FIELD)

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

w Turn on key switch.
Adjust at 0[A].
[lf] level of current sensor

is 0[A]?
No
q Red/Yellow3 wire between Current
sensor and CN3-3 pin.
w Yellow/Red2 wire between Current
sensor and CN3-12 pin.
e Black2 wire between Current sensor and
CN3-13 pin.
Yes
Replace MPU board.
Operation become
normal?
No
Yes
Yes
END
No
Repair.
Replace Current sensor [lf].

Replace Current sensor [lf].
Operation become
normal?
No
Yes
END
57
Replace MPU board.
Error No.20 A16:SENSOR-SPEED
LCD Display
A16:SENSOR-SPEED
Speed sensor1 and Speed

sensor2 are installed normally?
No
Adjust.
Yes

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

Speed sensor2.
No
Replace MPU board.
Yes
END
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
58
Error No.21
B17:FUSE-HYD.
LCD Display
B17:FUSE-HYD.
Hyd. fuse F2 is normal?
No
Yes
w Set RS1 at [E].
Replace.
This bit6 shows [1] on LCD display?

LCD display
7 6 5 4
3 2 1 0
No
IOM 0F/
1:normal
0:abnormal
Yes
The Green/Black wire

pin is normal?
No
Yes
Replace MPU board.
Replace MPU board.
59
Replace.
(Damage or bad connection)
Error No.22
B18:FET5-HYD.
LCD Display
A18:FET-HYD.

when turning on key switch
without traveling.
No
Replace MPU board.
Yes

board.
The Red2 wire between coil

of M6 contactor and CN1-4 pin
is normal?
No
Repair.
Yes

32.5-35.5
No
Replace MPU board.
Yes

CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
60
Error No.23
B19:CONTACTOR-HYD.
LCD Display
A19:CONTACTOR-HYD.
No
No
Hyd. operation is normal?
Hyd. contactor (M6) can work?
Replace M6
contactor.
Yes
Yes
The contact of M6 contactor is

conductive?
No
Replace M6
contactor.
Yes
The Brown/Red wire between

contact of M6 contactor and
No
Repair.
Yes
Replace MPU board.
The contact of M6 contactor is

welded?
No
The Brown/Red wire between

contact of M6 contactor and
Yes
Yes
Replace MPU board.
61
No
Repair.
Error No.24 B20:FET4-HYD. BYPASS
LCD Display
B20:FET4-HYD. BYPASS
OPTION SET Adjust.

RS1
No
Hyd. bypass system is
installed?
[7]
7 6 5 4
Check
OPTION SET.
3 2 1 0
No
OPTION
Yes
Bit 5 shows [0]?
Yes
The error message
appears after turning on
key switch without
traveling?
Replace MPU board.

No
Replace MPU board.
Yes


w Disconnect CN1 from
MPU board.
The Red/White2 wire

between coil of M7
contactor and CN1-5 pin
is normal?
No
Repair.
Yes
32.5-35.5
No
Replace MPU board.
Yes
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
62
Error No.25
B21:TR-HYD. MAIN
LCD Display
B21:TR-HYD. MAIN

HYD.* appears at the same
time?
No

between drain of Hyd. FET and
No
Repair.
Yes
Yes
Replace Hyd. FET.

Hyd. bypass system is
installed.
No
Yes
Hyd. bypass contactor is

welded?

between drain of Hyd. FET and
No
Yes
No
Repair.
Yes
w Disconnect Gate 4P Red of
Hyd. FET.
No
Turn on key switch.

Yes
HYD.* appears on LCD?
No
Yes
END
Replace MPU board.

Replace Hyd. FET.
63
Error No.26
B22:SWITCH-LIFT
LCD Display
B22:SWITCH-LIFT
Lift(2) Micro switch is installed

normally?

w Set RS1 at [E].
No
Adjust.
Yes
The Green/Yellow wire
between Lift(2) and CN6-14 pin
is normal?
Turn on key switch.

Yes
No
Repair.
Yes
Bit2 shows [0] when not operating Hyd.

levers?
LCD display
7 6 5 4
No
Replace Lift (2) Micro

switch.
3 2 1 0
IOM 0E/
No
Yes
Yes
Replace MPU board.
Bit2 changes to [1] after Bit1 changes to

[1] when operating Hyd. levers?
LCD display
7 6 5 4
END
3 2 1 0
No
Micro switch which does not

change to [1] is installed
normally?
IOM 0E/
7 6 5 4
3 2 1 0
IOM 0E/
Yes
No
Adjust.
Yes
The wire of which Micro switch is abnormal?
q Between Lift(1) and CN6-6 Brown/Red1.
w Between Lift(2) and CN6-14 Blue/Yellow2.
No
Yes
Replace MPU board.
Replace the Micro switch
which is abnormal.
Repair.
No
Yes
Replace MPU board.
END
64
Error No.34
LCD Display
The Yellow/White1 wire between 4 pin of

10 P water-resistant connector of EPS
controller and CN5-15 pin is normal?
No
Repair.
Yes
The Blue3, Green/Blue1, White wires
between EPS controller and EPS sensor
is damaged or broken?
No
Repair.
Yes
Check the resistance at sensor side (tab side) between,
<standard value>
q pin (Orange) and e pin (Black/Red)
= Approx. 5k ................... A
q pin (Orange) and w pin (Green/Red)
= Approx. 2.5k .............. B
w pin (Green/Red) and e pin (Black/Red)
= Approx. 2.5k .............. C
No
Adjust EPS sensor by

removing or insterting
a shim to be even value
between B and C.
Yes
NOTE
Replace EPS controller.
Refer to page 20.
No
Replace MPU board.
Yes
END
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
65
Error No.35
C30:TR-EPS MAIN
LCD Display
C30:TR-EPS MAIN
The Blue/Black wire

between 2 pin of 10 P
water-resistant connector
and CN5-5 pin is shortcircuited with other wires?
No
Replace EPS controller.
Yes
No
Replace MPU board.
Yes
Repair.
END
CAUTION
CAUTION
following.
1. MPU board
2. Current sensor
3. FET Comp.
66
Error No.36
C31:FUSE-EPS
LCD Display
C31:FUSE-EPS
EPS fuse F3 is normal?
No
Yes
q Turn off the key switch
w Set RS1 at [E].
Replace EPS fuse.
Bit 7 shows [1] on LCD display?

LCD display
7 6 5 4
3 2 1 0
No
IOM 0F/
1:normal
0:abnormal
The Brown/Yellow wire

pin is normal?
Yes
No
Yes
Replace MPU board.
Repair.
Replace MPU board.
67
7. Wiring and layout of control unit
68
Battery:48V(FB10-25P)
72V (FB30P)
BNRD1
RD3
NB
Pre-energizing resistor :
30W 2.2 X 4 (10-25)
40W 2.2 X 2 (30)
BK
BU
GNBU
19
M2
WH
YEWH2
GNBU2
E1
B1
C5
C3
C4
3
3
3
3
3
16
6
19
18
9
D3
BU2
C1
15
Travel FET Comp. source

Travel FET Comp. gate
Travel FET Comp. drain voltage
Contact of For. contactor
GNWH3
BUYE3
BU
BURD
BNWH
BK

X 2 (FB20/25P)
X 3 (FB30P)
BNWH5
16
Pre-energizing FET source
B3
Pre-energizing FET gate
VC
Trave lfuse
NA
GND of contactor coil
F2
M6
For trucks with 48V Battery

(FB10-25P)
X4
BUBK
YEWH1
BN1
BNBK
YE
GN
Controller
key
switch
X1
15
Attachment switch 1 (OPT.)
48
49
16
E2
B2
C6
C2
VD
VE
C7
3
3
3
3
2
2
3
17
7
10
8
5
2
20
EPS
Sensor
BU3
GNBU1
WH
70
71
72
73
5
5
5
5
5
15
6
16
OPT.
43
13
Brake switch
90
13
Parking brake switch
VB
Power supply for contactor coil
VH
Power supply for contorol
RDYE
15
ST
5
5
20
10
BUYE1
RDGN4
DS3
DS1
DS2
Drectional
switch
BNBK1
Tum on when
neutral position
BN2
WHRD2
P57
40
Abnomal of EPS chopper

Abnomal of EPS sensor
Speed sensitive for EPS(SP1)
Speed sensitive for EPS(SP2)
Charger panel
RDWH1
M2
BNWH1
RDBK1
M4
WHGN
RDGN1
M3
WHBU
RD2
M6
WHRD
RDWH2
M7
BUYE
RDBK2
X1
BKWH
BK
RDWH
GNRD1
20
30
21
31
10
22
32
23
33
24
34
25
35
12
26
TSL
GNWH2
M
YEWH4
YERD
Forward contactor
25W
TSL
BUWH2
left
41
12
Forward
42
Reverse
NB7
X2
58
12
Low speed
56
11
Mode select
55
Up
13
EPS contactor
37
14
28
10
38
11
57
Down
60
NB5
5
5
3
13
Signal for speed sensor 1

GND for speed sensor 1
WH1
BKYE1
61
NB6
5
5
4
14
Signal for speed sensor 2

GND for speed sensor 2
P50
10
NB0
3
3
3
1
2
11
Power supply for current sensor (Ia)

Signal for current sensor (Ia)
GND for current sensor (Ia)
IA
IF
RDYE3
YERD1
BK2
Travel
current sensor
RD4
BNYE1
BKYE
Accelerator
RDGN3
GNBK1
BK1
Brained wire
Display unit
Hydraulic oil level(OPT.)
18
Brake oill level
83
Over load(OPT.)
85
Travel inhibit(OPT.)
86
12
Input for spare
87
Reducing speed when tuming(OPT.)
84
11
Seat switch(OPT.)
39
10
Tum signal lamp
P12
97
5
4
9
7
P12V
Waring buzzer
95
Forward signal
Load 200mA max.
96
14
Reverse signl
Load 200mA max.
Tail & stop lamp

25W
TL
10W
Back lamp
25W
BL
Turn signal lamp

25W
TSL
Rear combination lamp(left)

25W
TL
10W
Back lamp
25W
20P
Relay for power supply
82
Rear combination lamp(right)

BU4
WH1
BKWH1
RDBK1
BU1
BKRD1
Regenerative contactor
27
81
BZ
P51
11
NB1
3
3
3
3
12
13
Power supply for current sensor (If)

Signal for current sensor (Ia)
GND for current sensor (Ia)
P52
12
NB2
3
3
3
4
5
14
Power supply for accelerator

Signal for accelerator
GND for accelerator
BL
Turn signal lamp

25W
TSL
Brained wire
36
Hour meter(OPT.)
Back buzzer
Tail & stop lamp
Reverse contactor
Hyd.bypass contactor
Opt. (FB10-25P)
Std. (FB30P)
Hour meter counting
17
X5
BNRD2
Brained wire
Hyd. contactor
X2
Start for key switch
Over drive contactor
76
right
(GNWH2)
Battery voltage
Travel bypass contactor
75
Neutral
Low speed
Flat
cable 20p
YEWH
BK
RD1
25W
Turn signal
switch
RD5
Speed
Sensor
WHBK
GNRD2
RDWH3
BUWH1
Contact of Hyd. contactor

Hyd fuse
Charger,
Controller
M1
BNWH2
Only for EEC
Tilt level sensor
YEBK1
RDGN2
WHBK1
OPT.
RDGN5
Mode select
switch
X4
GNWH1
Hyd. FET Comp .source

Hyd. FET Comp gate
Hyd. FET Comp drain voltage
EPS fuse
Contact of Rev. contactor
BK
YEWH3
BNWH6
TS
Accessory
BUWH3
X5
VG
VF
47
OPT.
BNBK4
BURD5
EPSMotor
EPS
RD
The truck with
built in charger
Tilt switch
BU
RD
40A
(YEBK2)
Connector
CN Pin
No. No.
RDYE1
BKWH
RDGN
F3
RDWH
WH
RDYE4
For trucks with 72V Battery

(FB30P)
BNYE
F4
10A
F5
10A
RDBK
BKRD
BUWH
GNWH
BNRD
BUBK4
PA
Line
NO.
BURD1
To connect :To start counting
BNBK4
BURD5
FC2
Opt.(FB15-25P)
Std.(FB30P)
46
DC/DC
Converter
YERD4
Leveiing lamp
bypass contactor (M7) :
Lifut 2 switch
Laser pointer switch
Laser
M7
PA
Lifut 1 switch
14
Only for trucks with laser pointer
D4
BU4
Contact of regenerative contactor
OPT.
Turn on depressing
RDWH
WHRD1
45
BU4
RDWH
PB83-62
Pre-energizing
44
OPT.
Control GND
Contact of Rev. contactor
Connector
CN Pin
No. No.
RDYE5
IF
IA
YEBK
FC1
GNRD3
VC
BUYE2
M4
M3
275A
Line
NO.
D2
M1
RD
Connector
CN Pin
No. No.
BKWH
D1
275A
BKWH
Line
NO.
RDWH
F1
RDBK
NA
VA

X 2 (FB20/25P)
X 3 (FB30P)
BK
(The auxiliary 48 volts output is equipped

in the case of the 72 volts battery.
Body
earth
P53
13
NB3
4
4
4
1
2
9
AC0
AC1
AC2
AC3
6
6
6
6
2
10
3
11
}
80
Ramp switch
right
HL
Power supply for accelerator

Signal for accelerator
GND for accelerator
Head
lamp
WH3
40Wx2
Harness mark/color
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
RD
BK
GN
YE
WH
BN
BU
GY
PK
Ex) BKWH (=Black/White)

Black colored harness with White line.
HL
left
100V 22F
X3
WHBK2
White line
Black color
Horn
7
YEBU1
3
15
Battery electrolyte level
X3
(Post)
(lever)
Horn switch
FB10-30P-DC70
SYSTEM WIRING
69
Head guard (right)
Laser pointer (Laser &Level sensor)
Main controller
Only for trucks with laser pointers
RD
BK
Hanging on mast "M"
Water
resistant
Water
resistant
Harness,mast(1)
Harness,head guard
24801-10111
Level
sensor
Hanging on mast
1E-06145
Water
resistant
2P
"M"
Water
resistant
2P
2P
Laser
Water
resistant
HL
TSL
M3
RDBK
YEBU1
Only for when using opthional eduipment.

2P
BK
Att.3
M2
M1
M4
Controller
Assy,EPS
M6
<5>
<8>
<9>
1
1
1
1
Control valve
2E-15273
<7>
RDBK
RDWH
BKWH
GNBK2
Water
resistant
Harness,mast(2)
WH
GN
Accessory
(front)
<6> AA
Horn switch
(valve lever)
<10>
PA
Hydraulic motor
Traction
FET
Comp.
Water
resistant
Tilt
Lift 2
Harness,"M"(1)
10-25 : 2E-15405
30 : 2E-15406
2E-15407
DC/DC Converter
White line
<8>
FF
<7>
<0>
Battery
plug
2P
WH
<6>
AA
<5>
Brake oil level sensor
YEWH3
BK
Accessory
(rear)
2P-X
10P
EPS
sensor
<3>,<4>,<5>,<6>,<7>,<8>,<9>,<10>
Water resistant
Water
resistant
Rear combination
lamp (left)
Water
resistant
Foot brake switch
8P
Mode serect switch
4P
RD
GNWH
BK
6P
RD
Back
buzzer
Horn
Parking brake switch
3P
Charger panel
4P
2
Magnetic
controller
70
BKWH
<13>
4P
WH
6P
BK
Harness, head guard

24801-10111
Backward output relay
4P
BK
Horn relay
4P
YE
Turn signal relay
WH
GN
HL
TSL
STD : 24801-32180
STD : 24801-32200
EEC : 24801-32220
EEC : 24801-32240
TSL
Seat
switch
<11>
<1>,<3>,
<12>
<2>,<4>,<12>
Harness,charger(1)
2E-15424
TL
Water
resistant
BL
Water
resistant
Terminal
RD
BK
10-25
30
10-25
30
2P
Harness,charger(2)
2E-15425
Harness, head guard(left)
RDBK
YEBU1
Only when a chargers is not mounted.
BODY WIRING
Transformer
secondary
Rectifier
side
Charger,
controller
Conector comp.
24300-21472
FB10-30P-DC70
WHBK2
4P
WH
EPS motor
3P
"W"
YE
4P
BK
Water
resistant
GN
BKWH
<13>
Transformer
primary
side
Water
resistant
Water
resistant
RDYE5
Only for trucks with built-in chargers.
Only for trucks with built-in chargers.
Directional switch
Transformer
"K"
Key switch
Only for EEC or when using

optional equipment
Control power supply relay
6P
Warning buzzer
Hurn switch
(handle post)
TL
BL
Harness,body
Tun signal lamp switch
TSL
2E-15680
Display
Low speed mode switch
Rear combination
lamp (right)
6P
6P
WH
Battery
3P
Lamp switch
Harness Comp.,panel
24300-32030
2P
WH
4P
WH
Water
resistant
Harness,"M"(3)
4P
WH
30
4P
WH
72V
(30)
48V
Battery
(10-25)
Indicator panel
10-25
Battery
plug
Black color
Laser pointer switch
+ (48V)
<2>
RDWH
BKWH
GNBK
<0>
<2>
+ (72V)
Only for trucks with laser pointers
<1>
10A
<1>
10A
Traction motor
4P
WH
CN5 CN6
CN4
Harness,"M"(2)
Laser pointer (switch & Converter)

Board comp.,MPU
Water
resistant
(Connect wires after removal of the cup holder)
<4>
2E-15680
RDGN
RDBK
RDYE4
BKWH
BK
Connect , and bigin the hour meter countdown.
Speed
sensor
(left)
BURD1
BK
<4>
Harness,"M"(4)
"L"
10A
Speed
sensor
(right)
10A
<3>
6P
BK
2P
RD
BK
GN
YE
WH
BN
BU
GY
PK
2P
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
M7
Water
resistant
Lift 1
Harness mark/color
PA
PF
<9> <10>
Hydraulic
FET
Comp.
275A
Acceleration
sensor
Att.1
RDGN
RDBK
RDYE4
BKWH
BK
Water
resistant
6P
2P
Att.2
Indicator lamp
for forkleveling LED
40A
"L"
275A
M mast
"M"
2P
Laser
4P
WH
2P
2P
1E-06145
Harness,mast(1)
P mast
NOTE:
1. <n> indicates the lead wire numbers.
2. Terminal symbols
2
:Plug
1
2
:Plug
:Receptacle
1
7
:Receptacle
:Receptacle
AMP 170020-3
AMP 170002-5
AMP 170020-2
AMP 170021-3
AMP 170003-5
AMP 170021-1
AMP 41729
3. When installing the charger panel on the truck body,use only bolts
and spring washers.
The reason why only spring washers should be used is that they
break the coating on the charger panel ,enduring conductance
between the frame and the charger panel.
4. "M" , "S" , "L" , "K" , and "W" indicate the printed marks on the connector.
(Refer to note 6 )
RDBK
WH3
GNRD3
3
3
3
1 V,Q
59G
2
3 E1,E2 55B
4
3
3
1 X
2
AMP 172134-1
M1,M2 43B
Plug 4P
W Lamp switch
1 2
3 4
WH
AMP 172130-2
BK
YEBK1
YEWH4
YERD
BK
GNWH2
RDWH3
BUWH1
4
4
4
4
4
4
4
4
4
4
4
RD
RDYE
RDGN2
4
4
4
4
RDBK
RD5
RDGN5
1 2 3
1 2 3 4
1 2 3
1 2 3 4 5 6 7 8
Q M2
59I 46A
59H 41C
A
A
28B 26B
M1
44A
Horn switch
(steering)
water resistant
Plug 3P
water resistant
Plug 3P
N Brake oil
water resistant
Plug 8P
AMP 174982-2
AMP 174357-2
K
2 1
4 3
3 2 1
Horn switch
(Hydraulic)
A
A
A
A
13B 11B 14B 7B
25C
AMP 174257-2
AMP 174357-2
a5 Laser pointer switch
1
2
WH
a1 100A
59F P2,W
41B F1,Q
22B
58E
O,U
RDBK
YEBU1
YERD4
BKWH
BNWH6
BURD5
3
3
3
3
1 a5 100B
2
M1,P2 61K
3 a4 101B
a2,a3 102B
4
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDWH
3
3
3
3
3
3
1
2
3
4
5
6
Plug 4P
WH
a1 DC/DC Converter
1 2
3 4
58C 12B 58F 23B
F2
water resistant
Plug 4P
Point c A
54C 24B
A
A
29B 27B
Plug 2P
60I
AMP 172134-1
4
4
4
YEBU1
2
RDBK
2
W,R
BN2
WHRD2
RDGN4
BNBK1
RDWH
YERD4
3 2 1
4 3 2 1
8 7 6 5
21B A
58D C,N
YEWH3
BK
AMP 171898-2
A 31B
A 32B
Plug 6P
A 33B
A 34B
BK
A 35B
X Valve microswitch
1 2 3
4 5 6
P2,a5 60H
AMP 172134-1
WH3
RDGN5
BKWH
BUWH2
BURD1
BK
3
3
3
3
1 W 43C
2
R,Point a 46B
3 P2 61M
4
M1,E2 47D
1 2
3 4
Plug 4P
WH
Put the sleeve

for sure receptacle.
T Key switch U Indicator panel
O Hour meter
M2 Head guard (right)
AMP 174352-2
BNBK4
BURD5
a2 Laser
4
4
1 Point b 103A
a1 102A
2
water resistant
Plug 2P
4
4
1 Point b 103B
2
a1 102C
water resistant
Plug 2P
2 1
44B
47C
WH
1 2
3 4
BK
F4 Turn signal reiay

Connect the relay "Cala-48V-N".
Do not bind with the body harness.
47B E1,M1
Plug
4P
1 2
3 4
YE

Plug
4P
1 2
3 4
WH
6B
1
45A Point a 2
Plug 6P
RD
3
3

1 2
3 4
RD
te
no
Re
fe
(
RDWH
3
1P
4
4
water resistant
Plug 2P
1 a1 101A
2
Point b 103C
2 1
a4 Level sensor
GN
3
3
RDBK
RDBK
4
48B E1,H 3
3
3
BNRD2
RDYE5
1
39B D 2
3
60D P1,K
40B D 4
3
3
3
3
48C F3,E2
61G F4,G
42B F1
61H H,b
BKWH1
WH1
4
4
1 A 16B
2
A 15B
water resistant
Plug 2P
BKYE1
WH2
4
4
1 A 18B
2
A 17B
water resistant
Plug 2P
RDYE5
P1
60G
57B
P2 Accessory(front)
RDYE
RDBK2
RDWH
GNRD1
55A W
1
61A D 2
3
44D Point a
30C Point c 4
48A F3
5
47A F4 6
:Receptacle(with plating)
:Receptacle(without plating)
Sleeve(for single wire)
Sleeve(for double wire)
AMP
AMP
AMP
AMP
BKWH
:Plug(with plating)
AMP 170020-2
AMP 170002-5 or 170020-3
AMP 170888-1
Condenser
100v 22
GNRD3
BKWH
RD5
BU4
RDYE5
BUWH2
4
4
4
4
4
4
NOTE:
1,Terminal symbols
2 1
Point "c"
water resistant
Plug 6P
B Speed sensor
WHBK2
Point "a"
3 2 1
6 5 4
L
2 1
AMP 174352-2
BKWH
GNRD2
BKWH
1
59D F3,P2 2
AMP 172134-9
F2 Control power supply relay
50B C
G Horn
BUWH2
RDYE1
3
3
25B A,T
49B C
H Back buzzer
1 2 3
4 5 6
AMP 174262-2
Plug
4P
1P
BNWH6
BNBK4
YE
61L
K,X
AMP 174352-2
K Brake switch
4
61F F1,G 3
59C F1,F3
AMP 172134-1
F3 Backward output relay
4B
I EPS motor
AMP 171898-9
b Charger panel
AMP 172134-7
F3,V a1,M2
59E
39B 60F
1 2
3 4
Plug 4P
a3 Level lamp
L
2 1
AMP 174352-2
A, Point c K,P2
61I
AMP 172134-2
M1 Head guard(left)
BNBK4
BURD5
60E 5B
D G,M1
111B
Plug 4P
F2,K
1 4
52B C 2 4
51B C
3 4
Point "b"
1 2 3 4 5 6
C,T
110B 54B
AMP 172134-1
BNWH5
BU4
RDWH
1 2 3 4
R, Point a F4,M2
3
3
61J
3
3
3
3
43A
RDYE4
RDGN
RD
BKWH
3
3
3
3
b,a1
water resistant
Plug 3P
3 2 1
BU3
GNBU1
WH
53B C
r to
WH3
RD5
BKWH
BUWH2
J EPS sensor
1 2 3 4
W
4)
AMP 174352-2
AMP 174357-2
RDBK
RDWH
BKWH
GNBK2
Directional
switch
1
1
1
1
Turn signal
switch
BKYE
BNYE1
RD4
BK1
GNBK1
RDGN3
4
4
4
4
4
4
1 D 38B
2
D 37B
3 D 36B
A 2B
4
5 A 3B
A 1B
6
RDWH
BKWH
GNBK2
1
1
1
D,F2 60C
GNRD3
BKWH
RDGN5
BU4
RDYE5
BUWH2
4
4
4
4
4
4
1 Point c 55C
Point c 61C
2
3 M2 46D
Point c 39D
4
5 H 48D
M2 47E
6
AMP 174262-2
water resistant
Plug6P
E2,Pointc 61D
P2 57A
L Accelerator sensor
3 2 1
6 5 4
P1 Accessory
:Receptacle
AMP 170032-5 or 179461-5
:Tab
AMP 170340-3 or 179462-3
:Receptacle
AMP 171662-1 or 173707-1

AMP 172888-2(rubber plug)
AMP 172748-2(seal plug)
:Receptacle
AMP 316041-2 or 179956-2
:Receptacle
AMP 173716-2 or 175061-2
:Receptacle(with sleeve)
:Receptacle
:Tab
:Pressed sleeve
:Terminal(F)
:Terminal(M)
AMP 174262-2
E2 Stop & tail lamp (right)
3 2 1
6 5 4
water resistant
Plug6P
E1 Stop & tail lamp (left)
8
9
12
61B
8B
A
9B
A C,P1
Point c
F2
AMP 174655-2
Cap 2P
Plug 4P
WH
WH
BK
5 4 3 2 1
10 9 8 7 6
AMP 172133-1
AMP 172134-1
AMP 171898-2
2 1
4 3
1 2
3 4
7A
9A
F4
2A
4A
F3
5A
6A
37A 39A
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Point "a"
Point "b"
BNBK1
BN2
WHRD2
BU4
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDGN4
RDGN2
RDYE
YEWH3
RDWH3
BURD1
BUBK
YEWH1
B
F2
22A
25A
12A 14A 16A 18A 20A
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
AMP.040 series multi-lock connector
175967-2
6
6
6
6
6
6
6
6
6
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
S
23A 24A
21A
6
6
6
6
26A
2,
3,
4,
5,
6,
:Braid wire under 25mm pitch.

The location of the connector pin is as viewed from the inserting side.
The ends of the insulating tube should be tied together with wire ties.
Fuses should be placed in a circle, as shown in Figure 1.
The ends of the spiral tube should be tied together with wire ties,
and then theube should be coiled with a gap of 2 1mm.(Refer to Figure 2.)
27A 29A 31A 33A 35A

S
28A 30A 32A 34A
Fuse
CN6
5
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10A
10A

175966-2
12
Clamp
Figure 1
Wire tie
Figure 2
Point "c"
To K
BU4
FB10-25P-DC70
BU4
12
BU4
BK
To O
12
To E1
BNBK4
To a4
To E2
12
12
To D
RDYE1
To F4
BNBK4
To a2
BNBK4
To a3
BK
RDGN5
To M2
RDGN5
To E2
To U
46C M2,E2
15
AMP 41729
AMP 178023-2
AMP 1-170823-5
Yszaki 7116-3251
Yszaki 7114-3251
JST FNE-2
Yszaki 1500-0110
Yszaki 1600-0105
A MPU board
BK
White line
CN5

175966-2
1 2 3
4 5 6
8A 10A
Plug 6P
1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20
11A 13A 15A 17A 19A
CN4
BKWH
RD5
To M1
RD5
To E1
6
6
6
6
6
6
6
6
6
6
WH1
BKWH1
WH2
BKYE1
L
3A
D Controller
44C M1,E1
YERD
YEWH4
YEBK1
GNWH2
BNWH5
L
1A
F2
10B 60B
RDYE1
To F4
6
6
6
6
6
RDGN3
BK1
GNBK1
36A 38A 40A
110A 58A

BNRD2
BUWH1
BU2
BURD
WHRD1
GNRD2
RDBK2
GNRD1
6
6
6
6
E1,Point c
Receptacle
C EPS unit
Black color
RD4
BNYE1
BKYE
1 2 3 4 5 6
2P-X
water resistant
Plug10P
BU2
WHRD1
BURD
RDWH
RDBK
RDYE4
BKWH
BK
12
GN
RDGN
12
BK
BK
10A
10A
1 2 3 4
To F1
19B 20B 54A 51A 53A
RD
BK
GN
YE
WH
BN
BU
GY
PK
1 2 3 4
AMP
1-179958-2
To D
To P1
BKWH
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
3
3
3
3
3
BKWH
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
49A 50A
60A 52A
Harness mark/color
3
3
3
3
F1
59A
111A
3
3
3
(Refer to note 5)
1 2 3 4 5 6 7 8 9 10
BKWH
WHBK2
YE
4 3
42A G 3 3
61E Point c,F4
RD
RDWH
BK
15
YEWH1
Plug
4P
RDBK
YEBU1
BUBK
1 2
3 4
1 3
41A V 2 3
Seal plug
4
Seal plug
4
Seal plug
4
4
WH
4
GNBU1
4
BU3
4
F1 Horn relay
59B D,F3
AMP 172134-2
170021-2
170003-5 or 170021-3
170089-1
170890-1
BODY HARNESS
71
(Refer to note 6)
RDBK
WH3
GNRD3
3
3
3
1 V,Q
2
3 E1,E2
4
RDWH
YERD4
3
3
1 X 60I
2
AMP 172134-1
59G
M1,M2
Plug 4P
43B
W Lamp switch
1 2
3 4
WH
55B
W,R
BK
YEBK1
YEWH4
YERD
BK
GNWH2
RDWH3
BUWH1
4
4
4
4
4
4
4
4
4
4
4
RD
RDYE
RDGN2
BN2
WHRD2
RDGN4
BNBK1
4
4
4
4
RDBK
RD5
RDGN5
1 2 3
1 2 3 4
1 2 3
1 2 3 4 5 6 7 8
Q
59I
59H 41C
M2
46A
A
28B
M1
44A
Horn switch
(steering)
A
26B
A
29B
water resistant
Plug 3P
water resistant
Plug 4P
AMP 174357-2
b
A
54C 24B
Piont c A
58C 12B
F2
25C
A
13B
A
27B
water resistant
Plug 3P
AMP 174257-2
N
58F
A
11B
Horn switch
V (Hydraulic)
2 1
4 3
N Brake oil
AMP 174982-2
21B
Turn signal
switch
Directional
switch
4 3 2 1
8 7 6 5
3 2 1
41B F1,Q
22B
58E
O,U
YEBU1
A
7B
3 2 1
59F P2,W
RDBK
YERD4
BKWH
BNWH6
BURD5
3
3
3
3
1 a5 100B
M1,P2
2
3 a4 101B
a2,a3
4
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDWH
3
3
3
3
3
3
1
2
3
4
5
6
61K
Plug 4P
WH
a1 DC/DC Converter
1 2
3 4
102B
A
23B
A
14B
water resistant
Plug 8P
AMP 174357-2
1
2
WH
AMP 172134-1
4
4
4
RDBK
YEBU1
AMP 172130-2
Plug 2P
a1 100A
BK
AMP 171898-2
A 31B
A 32B
A 33B
Plug 6P
A 34B
BK
A 35B
P2,a5
X Valve microswitch
1 2 3
4 5 6
60H
AMP 172134-1
WH3
RDGN5
BKWH
BUWH2
BURD1
58D C,N
YEWH3
BK
3
3
3
3
1 W 43C
R,Point a 46B
2
3 P2 61M
4
M1,E2 47D
1 2
3 4
Plug 4P
WH
Put the sleeve

T Key switch
U Indicator panel
AMP 174352-2
BNBK4
BURD5
4
4
1 Point b 103A
a1 102A
2
water resistant
Plug 2P
4
4
1 Point b 103B
2
a1 102C
water resistant
Plug 2P
M
2 1
AMP 174352-2
1 2 3 4
R, Point a F4,M2
44B
47C
110B
Plug 4P
WH
F2,K
54B
60E
5B
G,M1
111B
61I
1 2
3 4
A, Point c
39B
AMP 172134-2
M1 Head guard(left)
BK
Plug 6P
RD
b Charger panel
1 2
3 4

Plug
4P
YE
1P
50B C
H Back buzzer
1 2 3
4 5 6
48C F3,E2
61G F4,G
G Horn
42B
F1
3
3
Lengs 50
RDBK
RDBK
Cap
2P

1 2
3 4
Plug
4P
RD
25B A,T
39B D
60D P1,K
40B D
1
2
3
4
3
3
3
3
BKYE1
WH2
4
4
1
2
A 18B
A 15B
water resistant
Plug 2P
A 17B
water resistant
Plug 2P
a4 Level sensor
P1
60G
57B
P2 Accessory(front)
RDYE
RDBK2
RDWH
GNRD1
AMP
AMP
AMP
AMP
:Plug(with plating)
AMP 170020-2
AMP 170002-5 or 170020-3
AMP 170888-1
BKYE
BNYE1
RD4
BK1
GNBK1
RDGN3
4
4
4
4
4
4
1 D 38B
2
3 D 36B
4
5 A 3B
6
RDWH
BKWH
GNBK2
1
1
1
D,F2 60C
GNRD3
BKWH
RDGN5
BU4
RDYE5
BUWH2
4
4
4
4
4
4
1 Point c 55C
Point c 61C
2
3 M2 46D
Point c 39D
4
5 H 48D
M2 47E
6
AMP 174262-2
D 37B
A 2B
3 2 1
6 5 4
water resistant
Plug6P
A 1B
BK
BUYE1
58B Point c1 15
2 15
120B A
1 2
55A W
1
61A D 2
44D Point a
3
30C Point c 4
48A F3
5
47A F4 6
water resistant
Plug 6P
1,Terminal symbols
1
BKWH
c Seat switch
3 2 1
6 5 4
NOTE:
2 1
Point "c"
P1 Accessory
E2,Pointc 61D
P2 57A
4
4
4
4
4
4
GNRD3
BKWH
RD5
BU4
RDYE5
BUWH2
:Receptacle
AMP 170032-5 or 179461-5
:Tab
AMP 170340-3 or 179462-3
:Receptacle
AMP 171662-1 or 173707-1

:Receptacle
AMP 316041-2 or 179956-2
:Receptacle
AMP 173716-2 or 175061-2
:Receptacle
:Tab
:Pressed sleeve
:Terminal(F)
:Terminal(M)
AMP 174262-2
3 2 1
6 5 4
water resistant
Plug6P
8
9
F2
36A
38A
40A
Receptacle
b
110A
AMP 174655-2
Cap 2P
AMP 172133-1
2 1
4 3
C EPS unit
C,P1
F2
60B
37A
39A
Plug 4P
Point "a"
BNBK1
BN2
WHRD2
BU4
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDGN4
6
6
6
6
6
6
6
6
6
S
29A
31A
33A
35A
F4
F3
F2
2A
4A
120A
5A
6A
8A
10A
12A
14A
16A
18A
20A
22A
25A
28A
30A
32A
34A
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
CN5
4
175966-2
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
175967-2
A MPU board
To K
BU4
Point "c"
BU4
12
To E2
12
BU4
12
Point "b"
S
27A
1 2 3
4 5 6
BNBK4
To a4
RDGN2
RDYE
S
26A
BK
12
6
6
T
24A
To E1
BNBK4
To a2
BNBK4
To a3
YEWH3
RDWH3
U
23A
BK
RDGN5
To M2
RDGN5
To E2
6
6
O
21A
To O
46C M2,E2
BURD1
C
19A
BK
RD5
To M1
RD5
To E1
B
17A
BK
44C M1,E1
RDYE1
To F4
BUBK
YEWH1
WH1
BKWH1
WH2
BKYE1
B
15A
CN4
AMP 171898-2
1 2
3 4
YERD
YEWH4
YEBK1
GNWH2
BNWH5
U
13A
Plug 6P
WH
AMP 172134-1
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
U
11A
D Controller
RDYE1
To F4
BNRD2
BUWH1
BU2
BURD
WHRD1
GNRD2
BUYE1
6
D
9A
To D
BODY HARNESS (EEC)
5 4 3 2 1
10 9 8 7 6
A
10B
Point c
58A
U
7A
To U
Black color
RDGN3
BK1
GNBK1
6
6
6
6
9B
WH
White line
RDBK2
GNRD1
8B
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
L
3A
BK
water resistant
Plug10P
RD4
BNYE1
BKYE
A
61B
1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20
L
1A
To C

BU2
WHRD1
BURD
RDWH
RDBK
RDYE4
BKWH
BK
12
BK
10A
BK
10A
AMP
1-179958-2
To F1
J
53A
1 2 3 4 5 6
BKWH
J
51A
1 2 3 4
To D
b
54A
1 2 3 4
E1,Point c
To P1
A
20B
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
BKWH
A
19B
RDGN
12
I
50A
2P-X
FB10-25P-DC70
72
I
49A
BKWH
RD
BK
GN
YE
WH
BN
BU
GY
PK
J
52A
3
3
3
3
3
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
D
60A
3
3
3
3
Harness mark/color
F1
59A
3
3
3
1 2 3 4 5 6 7 8 9 10
b
111A
(Refer to note 5)
BKWH
WHBK2
GN
3
3
YE
4
42A G 3
61E Point c,F4
BK
RD
RDWH
Plug
4P
YEWH1
1 2
3 4
RDBK
YEBU1
Seal plug
4
Seal plug
4
Seal plug
4
4
WH
4
GNBU1
4
BU3
4
F1 Horn relay
3
3
41A V
BUBK
12
1
2
59B D,F3
AMP 172134-2
15
15
2,
3,
4,
5,
6,
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
AMP 41729
AMP 178023-2
AMP 1-170823-5
Yszaki 7116-3251
Yszaki 7114-3251
JST FNE-2
Yszaki 1500-0110
Yszaki 1600-0105

Fuse
CN6
5
170021-2
170003-5 or 170021-3
170089-1
170890-1
water resistant
2 1
BNRD2
RDYE5
L
2 1
WHBK2
Condenser
100v 22
Plug
2P
water resistant
AMP 174262-2
AMP 172134-9
2 1
4)
48B E1,H
4
3
water resistant
Plug 2P
AMP 174352-2
te
c 121B
A 16B
BKWH
no
6B
c 121A
BK 15
1
2
RDYE5
Point "a"
BK 15
4
4
to
WH
3
3
1 a1 101A
2
Point b 103C
AMP 174352-2
BKWH1
WH1
fer
1 2
3 4
59D F3,P2
Plug
4P
1
2
3
3
GNRD2
BKWH
4
4
61L
K,X
GN
Re
59C F1,F3
4
3
BUWH2
RDYE1
4)
efe
49B C
BNWH6
BNBK4
60F
K Brake switch
3
3
F3,V a1,M2
Point "b"
YE

A
61F F1,G
AMP 172134-1
4B
1
45A Point a 2
a3 Level lamp
59E
(
R
1P
61H H,b
47B E1,M1
AMP 172134-7
L
2 1
AMP 174352-2
K,P2
AMP 171898-9
1 2
3 4
Plug 4P
I EPS motor
1 2 3 4 5 6
C,T
AMP 172134-1
3
3
61J
3
3
3
3
b,a1
43A
BNBK4
BURD5
te
water resistant
Plug 3P
3 2 1
BU3
GNBU1
WH
4
4
4
no
1
52B C 2
51B C
3
RDWH
BNWH5
BU4
1 2 3 4
W
RDWH
3
3
3
3
RDYE4
RDGN
RD
BKWH
J EPS sensor
53B C
r to
WH3
RD5
BKWH
BUWH2
AMP 174357-2
a2 Laser
RDBK
RDWH
BKWH
GNBK2
1
1
1
1
O Hour meter
10A
10A
12
Clamp
Wire tie
175966-2
Figure 1
Figure 2
RDBK
WH3
GNRD3
(Refer to note 6)
3
3
3
1 V,Q
2
3 E1,E2
4
3
3
1 X
2
AMP 172134-1
59G
M1,M2
Plug 4P
43B
W Lamp switch
1 2
3 4
WH
55B
AMP 172130-2
BK
YEBK1
YEWH4
YERD
BK
GNWH2
RDWH3
BUWH1
4
4
4
4
4
4
4
4
4
4
4
RD
RDYE
RDGN2
4
4
4
4
RDBK
RD5
RDGN5
1 2 3
1 2 3 4
1 2 3
1 2 3 4 5 6 7 8
59I
59H 41C
M2
46A
A
28B
M1
44A
Horn switch
(steering)
A
26B
A
29B
AMP 174357-2
Point c A
58C 12B
F2
25C
A
13B
water resistant
Plug 3P
water resistant
Plug 4P
water resistant
Plug 3P
b
A
54C 24B
A
27B
AMP 174257-2
N
58F
A
11B
A
7B
N Brake oil
AMP 174982-2
21B
3 2 1
2 1
4 3
1
2
WH
a1 100A
59F P2,W
41B F1,Q
22B
58E
O,U
RDBK
YEBU1
YERD4
BKWH
BNWH6
BURD5
3
3
3
3
1 a5 100B
M1,P2
2
3 a4 101B
a2,a3
4
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDWH
3
3
3
3
3
3
1
2
3
4
5
6
61K
Plug 4P
WH
a1 DC/DC Converter
1 2
3 4
102B
A
23B
A
14B
3 2 1
Horn switch
(Hydraulic)
water resistant
Plug 8P
AMP 174357-2
Plug 2P
60I
AMP 172134-1
4
4
4
YEBU1
RDBK
2
W,R
BN2
WHRD2
RDGN4
BNBK1
RDWH
YERD4
4 3 2 1
8 7 6 5
58D C,N
BK
AMP 171898-2
A 31B
A 32B
Plug 6P
A 33B
A 34B
BK
A 35B
P2,a5
X Valve microswitch
1 2 3
4 5 6
60H
AMP 172134-1
WH3
RDGN5
BKWH
BUWH2
BURD1
YEWH3
BK
3
3
3
3
1 W 43C
R,Point a 46B
2
3 P2 61M
4
M1,E2 47D
Plug 4P
WH
1 2
3 4
Put the sleeve

O Hour meter
T Key switch U Indicator panel
AMP 174352-2
BNBK4
BURD5
4
4
1 Point b 103A
2
a1 102A
water resistant
Plug 2P
BNBK4
BURD5
4
4
1 Point b 103B
2
a1 102C
water resistant
Plug 2P
a2 Laser
a3 Level lamp
2 1
1 2 3 4
F4,M2
44B
47C
D
110B
WH
54B
60E
111B
61I
1 2
3 4
Plug 4P
F2,K
G,M1
M1 Head guard(left)
47B E1,M1

1 2
3 4
Plug
4P
YE
Plug 6P
RD

1 2
3 4
1
45A Point a 2
A
61F F1,G
59C F1,F3
AMP 172134-1
4B
59D F3,P2
Plug
4P
WH
6B
A
48B E1,H
4
3
1
2
4
3
3
3
3
3
3
3
3
3
AMP 172134-9

1 2
3 4
RD
25B A,T
39B D
60D P1,K
40B D
(
Re
fe
50B C
H Back buzzer
1 2 3
4 5 6
K Brake switch
1
2
3
4
3
3
3
3
4
4
1 a1 101A
2
Point b 103C
a4 Level sensor
water resistant
Plug 2P
2 1
GN
48C F3,E2
61G F4,G
G Horn
F1
61H H,b
42B
GNRD2
BKWH
BKWH1
WH1
4
4
1
2
A 16B
BKYE1
WH2
4
4
1
2
A 18B
RDYE5
A 15B
water resistant
Plug 2P
A 17B
water resistant
Plug 2P
P1
60G
57B
P2 Accessory(front)
L
2 1
B Speed sensor
AMP 174352-2
BKWH
NOTE:
1,Terminal symbols
2 1
AMP
AMP
AMP
AMP
:Plug(with plating)
AMP 170020-2
AMP 170002-5 or 170020-3
AMP 170888-1
1
2
WHBK2
BKWH
BKYE
BNYE1
RD4
BK1
GNBK1
RDGN3
Condenser
100v 22
BUWH2
RDYE1
Point "a"
RDBK
RDBK
Point "c"
4
4
4
4
4
4
1 D 38B
2
3 D 36B
4
5 A 3B
6
AMP 174262-2
D 37B
A 2B
3 2 1
6 5 4
water resistant
Plug6P
A 1B
RDWH
BKWH
GNBK2
1
1
1
D,F2 60C
GNRD3
BKWH
RDGN5
BU4
RDYE5
BUWH2
4
4
4
4
4
4
1 Point c 55C
Point c 61C
2
3 M2 46D
Point c 39D
4
5 H 48D
M2 47E
6
E2,Pointc 61D
P2 57A
55A W
1
2
3
44D Point a
30C Point c 4
48A F3
5
47A F4 6
3 2 1
6 5 4
RDYE
RDBK2
RDWH
GNRD1
water resistant
Plug 6P
GNRD3
BKWH
RD5
BU4
RDYE5
BUWH2
4
4
4
4
4
4
:Receptacle
AMP 170032-5 or 179461-5
:Tab
AMP 170340-3 or 179462-3
:Receptacle
AMP 171662-1 or 173707-1

P1 Accessory
:Receptacle
AMP 316041-2 or 179956-2
:Receptacle
AMP 173716-2 or 175061-2
:Receptacle
:Tab
:Pressed sleeve
:Terminal(F)
:Terminal(M)
AMP 174262-2
water resistant
Plug6P
3 2 1
6 5 4
8
9
12
62B
Receptacle
5 4 3 2 1
10 9 8 7 6
F2
8B
9B
36A
38A
40A
C,P1
F2
10B
60B
37A
39A
Point c
58A
Cap 2P
Plug 4P
Plug 6P
WH
WH
BK
AMP 172129-1
AMP 172134-1
1
2
C EPS unit
Point "a"
Point "b"
BNBK1
BN2
WHRD2
BU4
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDGN4
6
6
6
6
6
6
6
6
6
24A
26A
27A
29A
31A
33A
35A
F4
F3
F2
2A
4A
5A
6A
8A
10A
12A
14A
16A
18A
20A
22A
25A
28A
30A
32A
34A
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
175967-2

Fuse
10A
10A
CN6
5
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

175966-2
12
Clamp
Figure 1
Wire tie
Figure 2
Point "c"
BU4
To K
FB30P-DC70
BU4
12
BU4
BK
To O
12
To E2
BNBK4
To a4
U
23A
To E1
RDYE1
To F4
12
RDGN2
RDYE
O
21A
CN5
2,
3,
4,
5,
6,
A MPU board
12
BNBK4
To a2
BNBK4
To a3
6
6
C
19A
BK
RDGN5
To M2
RDGN5
To E2
6
6
B
17A
To U
46C M2,E2
BURD1
B
15A

175966-2
To F1
RD5
To M1
RD5
To E1
YEWH3
RDWH3
U
13A
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
BKWH
44C M1,E1
U
11A
D Controller
RDYE1
To F4
BUBK
YEWH1
WH1
BKWH1
WH2
BKYE1
D
9A
CN4
1 2 3
4 5 6
6
6
6
6
6
6
6
6
6
6
U
7A
AMP 171898-2
1 2
3 4
YERD
YEWH4
YEBK1
GNWH2
BNRD2
BUWH1
BU2
BURD
WHRD1
6
6
6
6
6
6
6
6
6
RDGN3
BK1
GNBK1
BNWH5
GNRD2
RDBK2
GNRD1
61B
15
AMP 41729
AMP 178023-2
AMP 1-170823-5
Yszaki 7116-3251
Yszaki 7114-3251
JST FNE-2
Yszaki 1500-0110
Yszaki 1600-0105
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
L
3A
To D
Black color
E1,Point c
1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20
L
1A
BK
White line
RD4
BNYE1
BKYE
10A
b
110A
AMP 174655-2

BU2
WHRD1
BURD
RDWH
12
12
BK
BK
D
2P-X
water resistant
Plug10P
10A
AMP
1-179958-2
To D
J
53A
1 2 3 4 5 6
To P1
J
51A
1 2 3 4
BKWH
b
54A
1 2
BKWH
A
20B
3
3
3
3
3
A
19B
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
D
62A
3
3
3
3
I
50A
3
3
I
49A
12
J
52A
BK
D
60A
RDBK
RDYE4
BKWH
BK
RDGN
F1
59A
1 2 3 4 5 6 7 8 9 10
RD
BK
GN
YE
WH
BN
BU
GY
PK
b
111A
Harness mark/color
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
GN
BKWH
WHBK2
YE
3
3
RD
RDWH
4
42A G 3
(Refer to note 5)
61E Point c,F4
BK

41A V
Plug
4P
YEWH1
1 2
3 4
RDBK
YEBU1
Seal plug
4
Seal plug
4
Seal plug
4
4
WH
4
GNBU1
4
BU3
4
F1 Horn relay
3
3
BUBK
15
1
2
59B D,F3
AMP 172134-2
170021-2
170003-5 or 170021-3
170089-1
170890-1
BNRD2
RDYE5
61A D
Plug
4P
1P
BNWH6
BNBK4
61L
K,X
AMP 174352-2
AMP 174262-2
59E
AMP 174352-2
YE
60F
AMP 171898-9
b Charger panel
AMP 172134-7
1P
F3,V a1,M2
5B
39B
1 2
3 4
BK
49B C
2 1
Point "b"
A, Point c K,P2
AMP 172134-2
Plug 4P
I EPS motor
1 2 3 4 5 6
C,T
AMP 172134-1
3
3
61J
43A
3
3
3
3
b,a1
R, Point a
no
water resistant
Plug 3P
3 2 1
BU3
GNBU1
WH
4
4
4
RDWH
RDWH
BNWH5
BU4
RDYE4
RDGN
RD
BKWH
3
3
3
3
1 2 3 4
W
1
52B C 2
51B C
3
r to
WH3
RD5
BKWH
BUWH2
J EPS sensor
53B C
te
4
AMP 174352-2
AMP 174357-2
RDBK
RDWH
BKWH
GNBK2
Directional
switch
1
1
1
1
Turn signal
switch
BODY HARNESS
73
RDBK
WH3
GNRD3
(Refer to note 6)
3
3
3
1 V,Q
2
3 E1,E2
4
3
3
1 X
2
AMP 172134-1
59G
M1,M2
Plug 4P
43B
W Lamp switch
1 2
3 4
WH
55B
AMP 172130-2
BK
YEBK1
YEWH4
YERD
BK
GNWH2
RDWH3
BUWH1
4
4
4
4
4
4
4
4
4
4
4
RD
RDYE
RDGN2
4
4
4
4
RDBK
RD5
RDGN5
1 2 3 4
1 2 3
1 2 3 4 5 6 7 8
Q
59I
59H 41C
1 2 3
V
M2
46A
A
28B
M1
44A
Horn switch
(steering)
A
26B
A
29B
water resistant
Plug 3P
Point c A
58C 12B
F2
25C
A
13B
A
27B
water resistant
Plug 4P
AMP 174357-2
b
A
54C 24B
water resistant
Plug 3P
AMP 174257-2
N
58F
A
11B
A
23B
N Brake oil
water resistant
Plug 8P
AMP 174357-2
AMP 174982-2
21B
3 2 1
3 2 1
2 1
4 3
Horn switch
(Hydraulic)
59F P2,W
1
2
WH
a1 100A
41B F1,Q
22B
58E
O,U
4 3 2 1
8 7 6 5
YEBU1
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDWH
YEWH3
BK
3
3
3
3
1 a5 100B
M1,P2
2
3 a4 101B
a2,a3
4
3
3
3
3
3
3
1
2
3
4
5
6
61K
Plug 4P
WH
a1 DC/DC Converter
1 2
3 4
102B
AMP 171898-2
A 31B
A 32B
Plug 6P
A 33B
A 34B
BK
A 35B
P2,a5
X Valve microswitch
1 2 3
4 5 6
60H
AMP 172134-1
WH3
RDGN5
BKWH
BUWH2
BURD1
58D C,N
YERD4
BKWH
BNWH6
BURD5
RDBK
A
7B
A
14B
Plug 2P
60I
AMP 172134-1
4
4
4
RDBK
YEBU1
2
2
W,R
BN2
WHRD2
RDGN4
BNBK1
RDWH
YERD4
BK
3
3
3
3
1 W 43C
R,Point a 46B
2
3 P2 61M
4
M1,E2 47D
Put the sleeve

T Key switch
O Hour meter
U Indicator panel
AMP 174352-2
BNBK4
BURD5
4
4
1 Point b 103A
2
a1 102A
water resistant
Plug 2P
4
4
1 Point b 103B
2
a1 102C
water resistant
Plug 2P
a2 Laser
a3 Level lamp
2 1
BK
15
c 121A
15
c 121B
J
53A
50A
AMP
1-179958-2
water resistant
Plug10P
Receptacle
62B
74
1 2
E1,Point c
61B
b
110A
5 4 3 2 1
10 9 8 7 6
1 2 3 4
1 2 3 4 5 6
8B
9B
D,F2 60C
GNRD3
BKWH
RDGN5
BU4
RDYE5
BUWH2
4
4
4
4
4
4
1 Point c 55C
Point c 61C
2
3 M2 46D
Point c 39D
4
5 H 48D
M2 47E
6
A 1B
P1 Accessory
E2,Pointc 61D
P2 57A
AMP 174262-2
36A
38A
AMP
AMP
AMP
AMP
:Plug(with plating)
AMP 170020-2
AMP 170002-5 or 170020-3
AMP 170888-1
:Receptacle
AMP 170032-5 or 179461-5
:Tab
AMP 170340-3 or 179462-3
:Receptacle
AMP 171662-1 or 173707-1

:Receptacle
AMP 316041-2 or 179956-2
:Receptacle
AMP 173716-2 or 175061-2
:Receptacle
:Tab
:Pressed sleeve
:Terminal(F)
:Terminal(M)
8
9
12
15
C,P1
F2
60B
37A
39A
Cap 2P
Plug 4P
Plug 6P
WH
WH
BK
AMP 172134-1
44C M1,E1
RD5
To M1
RD5
To E1
46C M2,E2
RDGN5
To M2
RDGN5
To E2
Point "a"
BNBK4
To a2
BNBK4
To a3
BNBK4
To a4
Point "b"
11A
13A
15A
17A
19A
21A
23A
24A
29A
31A
33A
35A
F3
F2
4A
120A
5A
6A
8A
10A
12A
14A
16A
18A
20A
22A
25A
28A
30A
32A
34A
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
CN5
4

175966-2
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
175967-2
A MPU board
12
12
Point "c"
AMP 41729
AMP 178023-2
AMP 1-170823-5
Yszaki 7116-3251
Yszaki 7114-3251
JST FNE-2
Yszaki 1500-0110
Yszaki 1600-0105
6
6
6
6
6
6
6
6
6
S
F4
12
12
27A
9A
7A
CN4
1 2 3
4 5 6
6
6
6
6
6
6
6
6
6
6
26A
3A
2A
D Controller
RDYE1
To F4
6
6
6
6
6
AMP 171898-2
1 2
3 4
170021-2
170003-5 or 170021-3
170089-1
170890-1
BNBK1
BN2
WHRD2
BU4
BNRD1
BUYE2
RD3
YEBK
GNWH3
RDGN4
BURD1
BUBK
YEWH1
WH1
BKWH1
WH2
BKYE1
YERD
YEWH4
YEBK1
GNWH2
BNRD2
BUWH1
BU2
BURD
WHRD1
BNWH5
BUYE1
GNRD2
40A
1
2
RDYE1
To F4
3 2 1
6 5 4
water resistant
Plug6P
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
1A
F2
10B
Point c
58A
AMP 172129-1
C EPS unit
BODY HARNESS (EEC)
1
1
1
1,Terminal symbols
3 2 1
6 5 4
water resistant
Plug6P
A 2B
To K
J
51A
Black color
FB30P-DC70
RDWH
BKWH
GNBK2
NOTE:
AMP 174262-2
D 37B
1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20
BU4
b
54A
AMP 174655-2
White line
1 D 38B
2
3 D 36B
4
5 A 3B
6
To E2
A
20B
2P-X

4
4
4
4
4
4
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
BU4
49A
A
19B
D
62A
BU4
52A
To E1
60A
BK
To O
RD
BK
GN
YE
WH
BN
BU
GY
PK
BKYE
BNYE1
RD4
BK1
GNBK1
RDGN3
15
BK
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
F1
59A
To D
1 2 3 4 5 6 7 8 9 10
Harness mark/color
b
111A
RDGN3
BK1
GNBK1
BKWH
WHBK2
6
6
6
6
3
3
GNRD3
BKWH
RD5
BU4
RDYE5
BUWH2
BK
61E Point c,F4
4
4
4
4
4
4
To U
BK
Point "c"
BK
4
42A G 3
41A V
Plug
4P
GN
RDBK
YEBU1
B Speed sensor
2 1

YE
3
3
water resistant
Plug 6P

1
2
1
61A D 2
3
44D Point a
30C Point c 4
48A F3
5
47A F4 6
1 2
3 4
40B D
59B D,F3
AMP 172134-2
F1 Horn relay
39B D
60D P1,K
3 2 1
6 5 4
RDYE
RDBK2
RDWH
GNRD1
RD
RDWH
RD
3
3
3
3
YEWH1
1 2
3 4

1
2
3
4
BUBK
25B A,T
55A W
Seal plug
4
Seal plug
4
Seal plug
4
4
WH
4
GNBU1
4
BU3
4
AMP 172134-9
Plug
4P
te
c Seat switch
AMP 174262-2
To C
BNRD2
RDYE5
1 2
2 1
To F1
3
3
water resistant
Lengs 50
BKWH
4
3
P2 Accessory(front)
2 1
5)
48B E1,H
57B
te
6B
2 1
P1
60G
no
WH
120B A
to
RDBK
RDBK
A 17B
water resistant
Plug 2P
fer
3
3
A 18B
Re
1 2
3 4

1
2
1
2
Plug
4P
water resistant
Plug 2P
a4 Level sensor
BK
BUYE1
58B Point c 1 15
2 15
Plug
2P
Cap
2P
water resistant
59D F3,P2
59C F1,F3
AMP 172134-1
no
Re
fe
(
RDWH
BK
4
4
To D
61F F1,G
BKYE1
WH2
A 15B
water resistant
Plug 2P
Condenser
100v 22
Point "a"
GNRD2
BKWH
A 16B
BKWH
To P1
3
3
BKWH
4
3
61H H,b
BKWH
4B
WHBK2
RDBK2
GNRD1

YE
3
3
1
2
AMP 174352-2
RD4
BNYE1
BKYE
1 2
3 4
1
45A Point a 2
G Horn
BUWH2
RDYE1
F1
42B
4
4
BKWH
3
3
3
3
3
Plug
4P
BU2
WHRD1
BURD
RDWH
47B E1,M1
AMP 172134-7
K Brake switch
61G F4,G
3
3
3
3
b Charger panel
48C F3,E2
RDBK
RDYE4
BKWH
BK
RD
H Back buzzer
1 2 3
4 5 6
BKWH1
WH1
RDYE5
12
Plug 6P
1 a1 101A
2
Point b 103C
61L
K,X
AMP 174352-2
BK
BK
60F
AMP 171898-9
1 2
3 4
Plug 4P
4
4
GN
10A
AMP 172134-2
M1 Head guard(left)
YE
3
3
39B
RDGN
1 2
3 4
BNWH6
BNBK4
A, Point c K,P2
12
WH
50B C
1P
BK
61I
49B C
10A
G,M1
1P
I EPS motor
12
D
111B
59E
5B
F3,V a1,M2
AMP 174352-2
RDGN2
RDYE
60E
2 1
Point "b"
6
6
F2,K
54B
BNBK4
BURD5
YEWH3
RDWH3
C,T
BU3
GNBU1
WH
4
4
4
6
6
D
110B
AMP 172134-1
Plug 4P
BNWH5
BU4
1 2 3 4 5 6
BK
47C
1 2 3 4
44B
RDWH
RDYE4
RDGN
RD
BKWH
F4,M2
3 2 1
(Refer to note 7)
61J
water resistant
Plug 3P
43A
R, Point a
3
3
b,a1
3
3
3
3
3
3
3
3
3
1 2 3 4
1
52B C 2
51B C
3
r to
WH3
RD5
BKWH
BUWH2
J EPS sensor
53B C
4)
AMP 174352-2
AMP 174357-2
RDBK
RDWH
BKWH
GNBK2
Directional
switch
WH
1
1
1
1
Turn signal
switch
1 2
3 4
Plug 4P
2,
3,
4,
5,
6,

CN6
5
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Fuse

175966-2
10A
10A
12
Clamp
Figure 1
Wire tie
Figure 2
FB10-25P
2P
2P
WH
WH
2P
2P
WH
WH
BNRD
2P
WH
170020-2
170021-2
2.The terminal is fixed in place

by the fitting for the connector.
3. Connect only if a GS battery
is installed.
M6
<7>
WH
YEWH2
2P
GNBU2
<8>
2P
M4
M2
<3>
M1
M3
WH
<4>
<2>
<6>
<5>
<13>
FB30P
Note: 1.Terminal symbols

:Terminal
:Lead bar
:Plug
:Receptacle
<6>
CF
4PWH
FB20/25/30P
WH*
<3>
Only FB30P
S+
PF
<12>
40A
275A
275A
Controller Assy.,EPS
H+
<9>
BUBK4
D1
4PWH
<2>
<13>
<4>
PA
WHRD1
RD
FB10P
FET
Comp.
M7
RD*
<1>
<10>
Only FB10-25P
(FB30P has no this line)
WH
RD
4P
GN
4P
YEWH
BKWH
4P
GN
T+
BNWH
Refer to note 2
Pre-energizing
<1>
2
BU
2P
<7>
<8>
BNYE
FB15/18
FET
Comp.
D+
<5>
RDYE
<11>
Board Comp.,MPU
BU
Refer to note 3
Harness,Controller
Harness mark/color
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
RD
BK
GN
YE
WH
BN
BU
GY
PK
FB10-25P : 24200-68871
FB30P
: 24200-68941
Wire, Lead ( <1>-<13> )

4P
2P
4P
6P
WH
WH
WH
WH
FB10-25P
FB30P

FB10P
For Std.
24200-68792
24200-68832
FB15/18P
24200-68802
24200-68842
FB20/25P
24200-68812
24200-68852
FB30P
24200-68822
24200-68862
10P
Water resistant
2P
TipeX
For EEC
White line
Black color
To Harness,Body
FB10-30P-DC70
CONTROL UNIT WIRING
75
B Contactor
Harness mark/color
32B 35B
GNBU2
RDBK1
RDWH1
WHBK
1
3
2
3
1
3
28B 37B
24B 27B
15B
A
BNWH1
RDGN1

YEWH2
1
RD1
Plug
2P
WH
Plug
2P
WH
BNRD
23B 25B
Plug
2P
WH
17B
NOTE:
1. Lead wire
# :AVS 0.3mm
:AVS 0.85mm
:KIV 2.0mm
Others :AV S0.5mm
2. The location of the pin is as viewed from the inserting side.

: Braid wire under 25mm pitch.
3.
4. Do not use sure-plugs and receptacles.
30B 29B
16B
1
2
Plug
2P
WH
1
2
RD2
Plug
2P
WH
1
2
WHRD
1
2
1
2
WHGN
RD
BK
GN
YE
WH
BN
BU
GY
PK
WHBU
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
White line
Black color
10P
20P
Resistor
6A
4A
BUBK4
8A
2A
19A
17A
15A
13A
11A
9A
7A
5A
3A
1A
BKWH
YEWH
1
BKRD
GNWH
BUWH
BU
GNBU
BK
RD4
BNYE1
BKYE
RDBK2
GNRD1
3
BU2
WHRD1
BURD
RDWH
3
BU2
RDYE4
RDYE4
BKWH
BK
3
F
40A
Current sensor
38A
20 10 19 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1
BU*
BURD
WH*
3
1 2 3 4
20B
10A
H,H
BNWH
44B
RDYE4
10 5 9 4 8 3 7 2 6 1
12A
22B
BNYE
20A
14
14
14
14
14
RDBK1
14
1
2
F
1 2 3 4
22A
14A
23A
24A
26A
14 7 13 6 12 5 11 4 10 3 9 2 8 1
16A
GNWH
GNBU
GNBU2
YEWH2
BNRD
BKRD
BUWH
BK
BU
YEWH
BNYE1
BKYE
RD4
BK2#
RDYE3#
YERD1#
BU1#
BKRD1#
RDBK3#
28A
18A
14
30A
21A
32A
21C
14
37A
12D
14
25A
14
27A
29A
14
31A
14
33A
14
35A
14
F Terminal
4P
Plug
2P
WH
14P
14
4P
40B
26B
WHRD
6B
14
2B
39B 38B
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
GNRD1
RD2
RDBK2
RDGN1
WHBU
4B
5 4 3 2 1
10 9 8 7 6
14
I,H
C Fuse
7 6 5 4 3 2 1
14 13 12 11 10 9 8
14
BNWH1
BUBK4
WHBK
RDWH1
BK
RD1
RDWH
BNYE
RDWH
BNWH
5B
1 2 3 4
BU*
3
WHGN
3B
RD*
3
1B
WH*
WHRD1
YERD1#
BK2#
10
1 2 3 4
1 2 3 4
10
RDYE3#
10
BU1#
BKRD1#
10
10
10
RDBK3#
A MPU board
1
10B
42B
Plug 4P
GN
1 2 3 4
1 2 3 4 5 6
1 2 3 4
1 2 3 4
A,H
44A
41B
42A
43A
7B
8B
33B
12B
11B
14B
13B
K,A
A,A
44C
12C
40C
21B
9B
31B
18B
19B
1 2 3 4
39A
1 2
3 4
I Pre-energizing PB J Diode
CONTROL UNIT HARNESS
76
41A
L Battery()
Plug 4P
WH
Cap 4P
WH
Cap 4P
RD
Cap 4p
GN
Cap 6P
BK
10D
1 2
3 4
2 1
4 3
3 2 1
6 5 4
H External terminal
FB10-25P-DC70
10C
YEWH
43B
RD*
2 1
4 3
FET comp.
(travel)
2 1
4 3
N Body earth
Refer to note 4
FET comp.
(hidraulic)
B Contactor
Harness mark/color
1
2
16B
Plug
2P
WH
28B 37B
32B 35B
BNRD
RD2
2. The location of the pin is as viewed from the inserting side.

: Braid wire under 25mm pitch.
3.
4. Do not use sure-plugs and receptacles.
RDBK1
1
3
GNBU2
2
3
1
RDWH1
Plug
2P
WH
24B 27B
WHBK
RDGN1
White line
15B
A
BNWH1
Plug
2P
WH
RD1
1
2
YEWH2
23B 25B
30B 29B
Plug
2P
WH

Plug
2P
WH
1
2
17B
NOTE:
1. Lead wire
# :AVS 0.3mm
:AVS 0.85mm
:KIV 2.0mm
Others :AV S0.5mm
WHRD
1
2
1
2
WHGN
RD
BK
GN
YE
WH
BN
BU
GY
PK
WHBU
Red
Black
Green
Yellow
White
Brown
Blue
Gray
Pink
Black color
18A
16A
14A
12A
10A
8A
6A
4A
2A
37A
34A
32A
30A
28A
26A
24A
23A
22A
20A
19A
17A
15A
13A
11A
9A
7A
5A
3A
1A
34B 36B
A
Plug
2P
WH
RDWH2
GNWH
GNBU
GNBU2
YEWH2
BNRD
BKRD
BUWH
BK
BU
YEWH
BNYE1
BKYE
RD4
BK2#
RDYE3#
YERD1#
BU1#
BKRD1#
RDBK3#
14
14
14
14
14
14
14
14
14
14
14
14
14
20 10 19 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1
43B
Plug 4P
GN
1 2 3 4
A,H
41B
42A
43A
7B
8B
33B
12B
11B
14B
13B
K,A
A,A
12C
40C
21B
9B
31B
18B
19B
39A
1 2
3 4
I Pre-energizing PB
J Diode
BKWH
YEWH
1
1 2 3 4
BKRD
GNWH
BUWH
1 2 3 4 5 6
BK
GNBU
BU
RD4
BNYE1
BKYE
RDBK2
GNRD1
3
BU2
WHRD1
BURD
RDWH
1 2 3 4
10B
42B
1 2
YEWH
40A
RD*
38A
BU2
1 2 3 4
BKWH
BK
BU*
BURD
WH*
Resistor
RDBK1
E Current sensor
21A
BUYE
21C
BNWH
12D
BNYE
25A
BUBK4
27A
10 5 9 4 8 3 7 2 6 1
1
2
20B
29A
14
1
2
31A
14 7 13 6 12 5 11 4 10 3 9 2 8 1
20P
BNWH1
BUBK4
WHBK
RDWH1
BK
RD1
RDWH
BNYE
RDWH
BNWH
1 2 3 4
Plug
2P
WH
10P
33A
14
4P
BU*
40B
F Terminal
35A
14
6B
D Contactor
26B
36A
14
2B
14
39B 38B
14
4P
RD*
I,H
14P
WHRD
RDWH2
GNRD1
RD2
RDBK2
RDGN1
WHBU
4B
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
5 4 3 2 1
10 9 8 7 6
C Fuse
22B
14
5B
7 6 5 4 3 2 1
14 13 12 11 10 9 8
WHGN
BUYE
3B
1 2 3 4
WH*
WHRD1
YERD1#
BK2#
10
1 2 3 4
1B
1
3
1 2 3 4
10
RDYE3#
10
10
10
10
BU1#
BKRD1#
RDBK3#
A MPU board
10C
41A
L Battery()
Plug
2P
WH
Cap4P
Cap 6P
WH
BK
Cap 4P
GN
Cap 4P
RD
1
2
2 1
4 3
3 2 1
6 5 4
2 1
4 3
2 1
4 3
10D
H External terminal
FET comp.
(travel)
N Body earth
Refer to note 4
FET comp.
(hidraulic)
FB30P-DC70
CONTROL UNIT HARNESS
77
Reference
Connector for MPU board
Double lock plate pushing part
1. Pin layout of housing
Locking lever
Rib for preventing
inverse insertion
6 5 4
Double lock plate
3 2 1
14 13 12 11 10 9 8 7
CN1 (gray)
[P/No.37010-21040]
Ratchet part
4 3
Plug housing
2 1
CN3, 4, 5 6
10 9 8 7 6 5
CN2 (gray)
[P/No.37010-21030]
(2) Crimping terminals

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
CN3 (black)
CN5 (black)
[P/No.37010-21020]
Housing lance
fixing part
Contacting part
(inside box)
Wire barrel
8 7 6 5 4 3 2 1
Insulation barrel
16 15 14 13 12 11 10 9
CN1&CN2
[P/No. 37010-21480]
CN4 (black)
CN6 (black)
[P/No.37010-21010]
2. Names of parts
(1) housing
Housing lance
fixing part
Contacting part
(inside box)
Wire barrel
Double lock plate pushing part
Insulation barrel
Locking lever
CN3, 4, 5, 6
[P/No. 37010-21490]
Double lock plate
Ratchet part
Plug housing
CN1&CN2
79
3. Insertion terminal into housing

(1) With the locking lever of housing upward
and the crimping part of terminal upward,
insert the housing into corresponding port.
(Fig.1)
CAUTION
When it is impossible to insert the

terminal easily, do not force to insert
it.
At first, check the corresponding
port. When inserting forcedly, the
housing will be damaged at the housing. Pay attention to insertion of terminal.
Locking lever
Plug housing
(3) Press the crimping part of the double lock

plate. The plate will go down and release
from the ratchet part and will sound snapping. And after finishing the inserting the
terminal, pull the wire lightly to make sure
the locking. When the double lock plate
would work correctly, the condition would
be like as Fig.4.
CAUTION
When there are some unlocked terminals, the double lock plate would not
work correctly, the plate would be
one side locking and the ratchet
would be raised at one side Remove
the terminal by using the ejection tool
and do over again correctly.
Double lock plate

pressed part
Double lock part
Double lock part
Pull the wire

lightly
Crimping part
Insulation barrel
Housing lance
Terminal
[Completed double locking]
Fig.1
(2) Verify the terminal is locked correctly into

the housing. When inserting the terminal
like as Fig.2, the terminal which the crimping part is placed in the middle of the
retainer would come to lose, insert the
terminal into the housing like as Fig.3.
When the terminal is locked, it would
sound snapping. And after inserting the
terminal, pull the wire lightly to make
sure the locking it.
Fig.4
There a gap on
normal condition
The inserting groove

for ejection tool
[Completed double locking]
[Incompleted detente locking]

[One side locking of ratchet]
Fig.5
4. Pulling terminal
CAUTION
When remove the terminal for doing

over again, use the specified pulling
tool.
Pull the wire

lightly
(1) Release the double locking (Fig.6)

q Insert the jig into the groove .
w Lay it to the direction of arrow and bend
the wall of housing, and then rise the plate
crimping part and remove the ratchet.
Repeat the same way at the opposite side
also.
CAUTION
[Unlocked condition
of terminal]
[Correct locked condition

of terminal]
Fig.2
Fig.3
80
Do not vent the wall of housing

strongly, it will come to be damaged.
[In case of CN1, 2]
Be careful not to insert the ejection

tool into the housing side of crimping
terminal.
CAUTION
Rib of plate
crimping part
Operation
from q to w
Inserting groove
for ejection jig
e
w
Fig.7
Cut face
should be inside
Insert the jig into the groove

and bend the housing.
After the housing would
be bended, rise the rib of
plate crimping part to the
arrow direction.
Rib of plate
crimping part
5. Crimping tool (AMP made)

(1) Crimping terminal for CN1&2
(P/No.37010-21480) applicable hand tool
Model: 911788-2
Mark of crimping part
Crimping die
Fig.6
[In case of CN3, 4, 5, 6]
Rib of plate
crimping part
Pin and
retaining ring
Handle
Operation
from q to w
Radio pliers
(article on the market)
5m
Bared length
-4.
of insulation 3.5
Inserting groove
for ejection jig
Crimping pressure
control device
press down part

of insulation
Crimping part
of wire
(2) Crimping terminal for CN3, 4, 5, 6

(P/No.37010-21490) applicable hand tool
Model: 911738-1
Ejection jig (AMP)

Model: 755430-1
Crimping die
(Inside)
Clamp the housing and

retainer by the radio pliers,
then release the ratchet
part (sounds clipping) and
repeat the same outline at
the opposite side.
Crimping part
of wire
press down part
of insulation
Rib of plate
crimping part
When insert the jig into
the housing, move the jig
to the arrow direction and
vent the housing.
Bared length
of insulation
4mm (Reference)
Crimping pressure
control device
Handle
(2) Pulling out the crimping terminal

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

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02W-2201

1-1 The name and function of mode select switch

q Slow speed mode button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 How to set the each mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-3 Adjustment of starting current and current limitation . . . . . . . . . . . . . . . . . . 6

2. Adjustment for other functions

4. Outline of New EPS system for FBDC70

4-1 Outline of New EPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-4 Checking and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5. Self diagnosis history memory and I/O check

5-1 Self diagnosis history memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

q Location of negative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6-2 Attention for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6-3 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6-5 Flowchart for troubleshooting

7. Wiring and layout of control unit

1. How to adjust SICOS60

Slow speed mode button

When the slow speed mode button is turned on,

w Mode select button.

Mode select button

Showing the travel hour meter.

Be sure to check that the decimal point

Travel hour meter

When hour meter counts,

r Down button (2 functions).

Showing the hydraulic hour meter.

Be sure to check that the decimal point

Hydraulic hour meter

When hour meter counts,

1-2 How to set the each mode

Press the mode select button M to adjust the

The each mode can be changed by pressing the

: Speed setting mode

: Power setting mode

: Acceleration feeling mode

q Speed setting mode

When the slow speed mode button is off,

w Power setting mode

The preset power is displayed

e Acceleration feeling mode

Better inching operation can be achieved

Preset accelerator feeling

2) Press the mode select button M to shift the

1) Set the rotary switch RS1 to 7, and turn the

The setting position which flashes can be moved

After finishing to set or reset, be sure to

When replacing the MPU board, be sure to

If the bit of Seat switch is changed 0 to

The option setting which is standard specification is set to 0.

t Language selection on LCD display

1) Set the rotary switch RS1 to 6 and turn the

Each language can be selected by this operation.

2) Choose the each language shown below by

After finishing to set or reset, be sure to

Displayed language when turning key switch on.

y Safety monitor symbol.

1) Set the rotary switch RS1 to 5.

2) Use the mode select button M to shift the setting position.

Mode select button

The setting position which flashes can be

moved to the right by pressing the mode

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