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FB-DC70 SERIES
FB
10P/15P/18P
20P/25P/30P
Contents
1. How to adjust SICOS 60 (Major point only)
.........................1
.......................1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
. . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
On
e Up button (2 functions)
Increase the parameter of each selected mode.
UP button
HYD
STEER
BATT
LOAD
OIL
BRAKE
DISCHARGE
CAUTION
F
8
6
4
2
E
km/m
10
15
20
SPEED
POWER
50
75
ACCEL
100
SOFT
STD
FULL
TRAVEL
km
HYD
STEER
BATT
OIL
LOAD
BRAKE
DISCHARGE
F
8
6
4
2
E
km/m
10
15
POWER
50
75
100
ACCEL
SOFT
TRAVEL
20
SPEED
STD
FULL
km
M
Down button
CAUTION
TRAVEL
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
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
: Normal
but-
Down button
Up button
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
STD
FULL
Down button
Up button
(50%75%100%)
at
the
km/m
10
15
20
SPEED
POWER
50
75
100
ACCEL
SOFT
STD
FULL
}
Preset power
: Easy inching
Down button
: Normal
Up button
(SOFTSTDFULL)
: Quick accelerator
response
5
km/m
10
15
20
SPEED
NOTE
POWER
50
75
100
ACCEL
SOFT
STD
FULL
}
The preset accelerator feeling is displayed at
the ACCEL column on the display.
3
r Option setting
AB
789
456
CDE
F01
23
Set RS1 to 7
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
M
NOTE
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
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
AB
789
456
CDE
F01
23
Set RS1 to 6
Down button
<Display on LCD>
F01
456
AB
23
CDE
789
NOTE
Up button
Set RS 1 to 5
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 :
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.
F01
<Condition on checking>
Battery electrolyte over 1.25 (at 20C)
456
AB
23
CDE
789
Set RS1 to 1
<Adjusting procedure>
1) Set the rotary switch RS1 to 1, and turn the
key switch on.
2) The each mode can be changed by pressing
the mode select button M as follows.
M
M
M
M
Up button
Down button
= INITIALIZED
km/m
10
POWER
50
75
ACCEL
100
F01
456
AB
23
CDE
Set RS1 to 2
M
M
M
Mode select button
15
20
SPEED
789
NOTE
SOFT
STD
FULL
CAUTION
Wall
5) Adjust the starting current on the monitor within specified range by pressing Up button
or Down button
.
Model
FB10P
35 5
FB15P, 18P
45 5
FB20P, 25P
50 5
FB30P
45 5
Down button
Up button
NOTE
CAUTION
Wall
FB10P
280 5
FB15P, 18P
330 5
FB20P, 25P
380 5
FB30P
330 5
NOTE
NOTE
Down button
Up button
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
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
1 : ENGLISH
Language
JAPANESE
0 : JAPANESE
RS1-6
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
0 0 1 0
BATT
STEER
HYD
Seat switch
1 1 1 1
TRAVEL
060
064
Monitoring
0 0 0 0
48
32
56
64
50
64
32
Tilt
Lift 2
Lift 1
32
Over
drive
PLUGG- REGENE
ING
RATE
OVER
DRIVE
HYD
ATT.3
BRAKE
TRQ
HYD
ATT.2
HYD
ATT.1
HYD
TILT
Not used
0 0 0 0
Starting current
/Current limitation
Motor current
Power 100%
Specific gravity of electrolyte
more than 1.25 at 20C
48V
35 5
FB10P
Starting
current
(A)
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
(V)
Model
/
/
/
Voltage
/
/
Traveling
speed
/
/
RS1
/
/
/
/
RS0
/
/
(Confirmation)
Forcible by-pass
contactor on
100%
3sec 2sec
ePower setting
<Condition on checking>
Specific gravity of the battery electrolyte:
more than 1.25 at 20C
Set the power setting to 50%
<Confirming procedure>
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
789
<Adjustment procedure>
1) Set the rotary switch RS1 to 3.
M
M
M
M
M
M
M
M
M
AB
456
CDE
F01
23
<Condition on checking>
A: Specific gravity of the battery electrolyte:
more than 1.25 at 20C
B: Flat ground, Unladen, Full speed
789
NOTE
<Adjustment procedure>
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.
M
M
M
12
Up button
Down button
AB
456
CDE
F01
23
<Adjustment procedure>
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
<Adjustment procedure>
1) Set the rotary switch RS1 to 4, and change
the mode of BRAKE TRQ by pressing mode
select button M.
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
Turning it clockwise
for bright contrast.
CFL
VR0
F01
456
AB
23
789
<Adjustment procedure>
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
M
M
M
Mode select button
Traveling direction
F : Forward, R : Reverse
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
Battery voltage
(for battery capacity
indicator)
MSpecific gravity :
more than 1.25 at
20C
CAUTION
15
3. Option
qConfirming Over loading
<Confirming procedure>
1) Lift up to the end and make a relief condition.
2) Confirm the display *REDUCE THE LOAD*.
16
AB
789
NOTE
456
CAUTION
F01
23
<Adjusting procedure>
1) Set the rotary switch RS1 to 7 and turn the
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
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
CDE
AB
789
NOTE
456
<Confirming procedure>
1) Operate the traveling without sitting on the seat.
2) Confirm the truck does not travel.
F01
23
<Setting procedure>
1) Set the rotary switch RS1 to 7 and turn the
key switch on.
2) Set 1st bit of the seat switch to 1.
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
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.
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
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
<Adjusting procedure>
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
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
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.
0.8 V 0.3
neutral
2.5 V 0.3
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
Rece
e pin
Tab
Adaptor
Tab
+ probe
to w pin
(output)
probe
to e pin
(negative)
21
To EPS
controller
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>
22
AB
456
CDE
F01
23
789
Set RS 1 to B
NOTE
M
CAUTION
button to change
DOWN button
UP 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
20
SPEED
23
Content
00
Neutral
01
02
03
04
05
06
07
08
09
0A
0B
0C
11
12
13
14
15
16
17
18
19
1A
1B
1C
Content
Hydraulic neutral
Hydraulic control
24
DOWN button
0 . . .No trouble
[ 1
. . .Troubled (at least once)
UP 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
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*
OFF
ON
START
F01
456
AB
23
CDE
789
ON
START
OFF
26
ON
Set RS 1 to E
AB
789
M
NOTE
DOWN button
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
Not used
Not used
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
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
0 : Detection
IN
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
IN
0000 : "1"
IN
0000 : "3"
IN
0000 : "8"
IN
IN
0001 : "1"
IN
0011 : "3"
IN
1000 : "8"
28
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
1 : Clear
IN
1 : Stop
IN
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
Current [Field]
Use 10 bits by binary system. "1 and 0 bits of NO.03 and 7 to 0 bits of NO.020"
RS1-E
NO.02
NO.03
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.03
NO.02
Voltage [Battery]
Use 10 bits by binary system. "1 and 0 bits of NO.05 and 7 to 0 bits of NO.04"
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
\\ \\\\\\\\
bit
1 0 7 6 5 4 3 2 1 0
NO.07
NO.06
\\ \\\\\\\\
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
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
D4
F2
PA
M7
FC2
<SYSTEM WIRING>
() probe
() probe
Battery () terminal
M4 contactor ribbon
Wire
(Bypass contactor)
<CONTROL UNIT>
31
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
NOTE
32
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
1
3
2
4
2
4
1
3
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
34
Rigid block
Message
* FAIL TRAVEL. *
* FAIL HYD. *
A1 : FUSE-TRAVEL.
Travel fuse
A2 : FET6-REGEN.
A3 : CONTACTOR-REGEN.
A4 : FET10-FORWARD
A5 : CONTACTOR-FORWARD
Forward contactor
10
A6 : FET9-REVERSE
11
A7 : CONTACTOR-REVERSE
Reverse contactor
12
A8 : FET8-BYPASS
13
A9 : CONTACTOR-BYPASS
14
15
16
17
A13 : ACCEL-ACCELERATOR
18
19
20
A16 : SENSOR-SPEED
Speed sensor
21
B17 : FUSE-HYD.
Hydraulic fuse
22
B18 : FET5-HYD.
23
B19 : CONTACTOR-HYD.
24
25
26
B22 : SWITCH-LIFT
27
TRAVEL
HYD
Remarks
Half speed
Half speed
Half speed
Half speed
Half speed
34
35
36
C31 : FUSE-EPS
37
C32 : FET3-EPS
38
C33 : CONTACTOR-EPS
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
Remarks
39
40
Overloaded
Opt.
41
Opt.
42
GS batt.
No
Yes
Yes
37
No
Replace MPU board.
38
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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
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
LCD Display
No
No
Slit plate normal?
Yes
Yes
Adjust.
No
Yes
END
No
Repair.
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
40
Error No.2
LCD Display
Yes
Set RS1 at [E].
Return the hydraulic lever to the
neutral position.
Then operate it again.
Turn on key switch.
No
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/
41
Repair.
Error No.3
LCD Display
FAIL TRAVEL
*
*
TURN OFF KEY SWITCH
*
No
Yes
See the flowchart in which
the error message appears
and check it.
No
Yes
No
Yes
Repair.
No
Operation become
normal?
Yes
Turn on key switch.
END
No
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
42
Error No.4
LCD Display
FAIL HYD.
*
*
*TURN OFF KEY SWITCH*
No
No
Hyd. Bypass installed?
Yes
Yes
No
The contact of M7
contractor welded?
Yes
No
Yes
Repair.
Replace M7 contractor.
No
Replace MU board.
Replace Hyd. FET.
43
Error No.5
A1:FUSE TRAVEL
LCD Display
A1:FUSE TRAVEL
No
Yes
q Turn off the key switch.
w Set RS1 at [E].
e Turn on key switch and
7 6 5 4
3 2 1 0
No
IOM 0F
1:normal
0:abnormal
Yes
No
Yes
Repair.
Replace MPU board.
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
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.
board.
Replace MPU board.
Yes
No
Repair.
No
45
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
No
Yes
Replace M3 Contactor.
No
Replace M3 Contactor.
Yes
Operation become
normal?
No
Yes
No
END
Yes
Replace MPU board.
Repair.
The connection of M3
contactor is bad ?
No
Yes
Replace MPU board.
Replace M3 Contactor.
46
No
Error No.8
A4:FET10-FORWARD
LCD Display
A4:FET10-FORWARD
No
Replace MPU board.
Yes
board.
No
Repair.
Yes
No
Yes
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
47
Error No.9
A5:CONTACTOR-FORWARD
LCD Display
A5:CONTACTOR-FORWARD
No
Replace M1 contactor.
Yes
No
Repair.
Yes
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
48
Error No.10
A6:FET9-REVERSE
LCD Display
A6:FET9-REVERSE
No
Replace MPU board.
Yes
board.
No
Repair.
Yes
No
Yes
49
Error No.11
A7:CONTACTOR-REVERSE
LCD Display
A7:CONTACTOR-REVERSE
No
Replace M1 contactor.
Yes
No
Repair.
Yes
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
50
Error No.12
A8:FET8-BYPASS
LCD Display
A8:FET8-BYPASS
No
Replace MPU board.
Yes
board.
No
Repair.
Yes
No
Yes
51
Error No.13
A9:CONTACTOR-BYPASS
LCD Display
A9:CONTACTOR-BYPASS
No
Replace M4 contactor.
Yes
The contact of M4 contactor
welded?
No
Yes
No
Repair.
Yes
No
Yes
END
Turn on key switch.
No
Yes
Replace MPU board.
Replace Travel FET.
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
52
Error No.15
A11:TR-TRAVEL MAIN
LCD Display
A11:TR-TRAVEL MAIN
No
Yes
No
Repair.
Yes
Replace Travel FET.
No
Yes
No
Operation become normal?
Yes
No
Repair.
Yes
END
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?
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
Operation become normal?
Yes
END
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
54
Error No.17
A13:ACCEL-ACCELERATOR
7 6 5 4 3 2 1 0
LCD Display
(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
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?
No
No
Yes
Yes
Replace MPU board.
END
CAUTION
Repair.
NO USED
FAD
BWD
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
7
0
0
1
Accel, bit
DECIMAL
Bit
Push
Release
Pull
NTRAL
IOM 10
A13:ACCEL-ACCELERATOR
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)
No
Yes
Adjust at 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.
No
Yes
END
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
56
Error No.19
A15:SENSOR-CURRENT (FIELD)
LCD Display
A15:SENSOR CURRENT
(FIELD)
No
Yes
Adjust at 0[A].
No
The following wires are normal?
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.
No
Yes
END
57
LCD Display
A16:SENSOR-SPEED
No
Adjust.
Yes
No
Repair.
Yes
No
Operation become normal?
Yes
END
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
58
Error No.21
B17:FUSE-HYD.
LCD Display
B17:FUSE-HYD.
No
Yes
q Turn off the key switch.
w Set RS1 at [E].
e Turn on key switch and
Replace.
7 6 5 4
3 2 1 0
No
IOM 0F/
1:normal
0:abnormal
Yes
No
Yes
59
Replace.
(Damage or bad connection)
Error No.22
B18:FET5-HYD.
LCD Display
A18:FET-HYD.
No
Replace MPU board.
Yes
board.
No
Repair.
Yes
No
Replace MPU board.
Yes
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
60
Error No.23
B19:CONTACTOR-HYD.
LCD Display
A19:CONTACTOR-HYD.
No
No
Hyd. operation is normal?
Replace M6
contactor.
Yes
Yes
No
Replace M6
contactor.
Yes
No
Repair.
Yes
No
Yes
Replace M6 contactor.
Yes
61
No
Repair.
LCD Display
B20:FET4-HYD. BYPASS
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]?
Turn off key switch.
Yes
The error message
appears after turning on
key switch without
traveling?
Yes
MPU board.
No
Repair.
Yes
The coil resistance of M7
contactor is normal?
32.5-35.5
No
Replace MPU board.
Yes
Replace M7 contactor and MPU
board at the same time.
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
62
Error No.25
B21:TR-HYD. MAIN
LCD Display
B21:TR-HYD. MAIN
No
No
Repair.
Yes
Yes
No
Yes
No
Yes
No
Repair.
Yes
q Turn off key switch.
w Disconnect Gate 4P Red of
Replace M7 contactor.
Hyd. FET.
No
No
Yes
END
63
Error No.26
B22:SWITCH-LIFT
LCD Display
B22:SWITCH-LIFT
No
Adjust.
Yes
The Green/Yellow wire
between Lift(2) and CN6-14 pin
is normal?
No
Repair.
Yes
7 6 5 4
No
3 2 1 0
IOM 0E/
No
Operation become normal?
Yes
Yes
Replace MPU board.
7 6 5 4
END
3 2 1 0
No
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
Operation become normal?
Yes
Replace MPU board.
END
64
Error No.34
C29:SENSOR-EPS TORQUE
LCD Display
C29:SENSOR-EPS TORQUE
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
Yes
NOTE
No
Operation become normal?
Yes
END
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
65
Error No.35
C30:TR-EPS MAIN
LCD Display
C30:TR-EPS MAIN
No
Replace EPS controller.
Yes
No
Operation become normal?
Yes
Repair.
END
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) Adjust Start current and Current limitation.
Repeat the plugging operation a few times and re-check the setting.
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.
66
Error No.36
C31:FUSE-EPS
LCD Display
C31:FUSE-EPS
No
Yes
q Turn off the key switch
w Set RS1 at [E].
e Turn on key switch and
7 6 5 4
3 2 1 0
No
IOM 0F/
1:normal
0:abnormal
Yes
No
Yes
Repair.
Replace MPU board.
67
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
GNWH3
BUYE3
BU
BURD
BNWH
BK
BNWH5
16
B3
VC
Trave lfuse
NA
F2
M6
X4
BUBK
YEWH1
BN1
BNBK
YE
GN
Controller
key
switch
X1
15
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
VB
VH
RDYE
15
ST
5
5
20
10
BUYE1
RDGN4
DS3
DS1
DS2
Drectional
switch
BNBK1
Tum on when
neutral position
BN2
WHRD2
P57
40
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
WH1
BKYE1
61
NB6
5
5
4
14
P50
10
NB0
3
3
3
1
2
11
IA
IF
RDYE3
YERD1
BK2
Travel
current sensor
RD4
BNYE1
BKYE
Accelerator
RDGN3
GNBK1
BK1
Brained wire
Display unit
18
83
Over load(OPT.)
85
Travel inhibit(OPT.)
86
12
87
84
11
Seat switch(OPT.)
39
10
P12
97
5
4
9
7
P12V
Waring buzzer
95
Forward signal
Load 200mA max.
96
14
Reverse signl
Load 200mA max.
TL
10W
Back lamp
25W
BL
TSL
TL
10W
Back lamp
25W
20P
Relay for power supply
82
WH1
BKWH1
RDBK1
BU1
BKRD1
Regenerative contactor
27
81
BZ
P51
11
NB1
3
3
3
3
12
13
P52
12
NB2
3
3
3
4
5
14
BL
TSL
Brained wire
36
Hour meter(OPT.)
Back buzzer
Reverse contactor
Hyd.bypass contactor
Opt. (FB10-25P)
Std. (FB30P)
17
X5
BNRD2
Brained wire
Hyd. contactor
X2
76
right
(GNWH2)
Battery voltage
75
Neutral
Low speed
Flat
cable 20p
YEWH
BK
RD1
25W
Turn signal
switch
RD5
Speed
Sensor
WHBK
GNRD2
RDWH3
BUWH1
Charger,
Controller
M1
BNWH2
YEBK1
RDGN2
WHBK1
OPT.
RDGN5
Mode select
switch
X4
GNWH1
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
BNYE
F4
10A
F5
10A
RDBK
BKRD
BUWH
GNWH
BNRD
BUBK4
PA
Line
NO.
BURD1
BNBK4
BURD5
FC2
Opt.(FB15-25P)
Std.(FB30P)
46
DC/DC
Converter
YERD4
Leveiing lamp
Lifut 2 switch
Laser
M7
PA
Lifut 1 switch
14
D4
BU4
OPT.
Turn on depressing
RDWH
WHRD1
45
BU4
RDWH
PB83-62
Pre-energizing
44
OPT.
Control GND
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
BK
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
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
HL
left
100V 22F
X3
WHBK2
White line
Black color
Horn
7
YEBU1
3
15
X3
(Post)
(lever)
Horn switch
FB10-30P-DC70
SYSTEM WIRING
69
Main controller
RD
BK
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
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>
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
8P
4P
RD
GNWH
BK
6P
RD
Back
buzzer
Horn
3P
Charger panel
4P
2
Magnetic
controller
70
BKWH
<13>
4P
WH
6P
BK
4P
BK
Horn relay
4P
YE
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
RDBK
YEBU1
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
Directional switch
Transformer
"K"
Key switch
6P
Warning buzzer
Hurn switch
(handle post)
TL
BL
Harness,body
TSL
2E-15680
Display
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
+ (48V)
<2>
RDWH
BKWH
GNBK
<0>
<2>
+ (72V)
<1>
10A
<1>
10A
Traction motor
4P
WH
CN5 CN6
CN4
Harness,"M"(2)
Board comp.,MPU
Water
resistant
<4>
2E-15680
RDGN
RDBK
RDYE4
BKWH
BK
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
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
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
O Hour meter
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
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)
:Receptacle(without plating)
Sleeve(for double wire)
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
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
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
:Tab
:Receptacle
:Receptacle
:Receptacle
:Receptacle(with sleeve)
Sleeve(for single wire)
Sleeve(for double wire)
:Receptacle
:Tab
:Pressed sleeve
:Terminal(F)
:Terminal(M)
AMP 174262-2
3 2 1
6 5 4
water resistant
Plug6P
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
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,
Fuse
CN6
5
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10A
10A
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
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
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
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
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
Connect the relay "Cala-48V-N".
Do not bind with the body harness.
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
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
F4 Turn signal reiay
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
:Receptacle(with plating)
:Receptacle(without plating)
Sleeve(for single wire)
Sleeve(for double wire)
AMP
AMP
AMP
AMP
:Plug(with plating)
:Receptacle(without plating)
Sleeve(for double wire)
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
L Accelerator sensor
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
:Tab
:Receptacle
:Receptacle
:Receptacle
:Receptacle(with sleeve)
Sleeve(for single wire)
Sleeve(for double wire)
: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
AMP.040 series multi-lock connector
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
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
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
Connect the relay "Cala-48V-N".
Do not bind with the body harness.
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
O Hour meter
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
:Receptacle(with plating)
:Receptacle(without plating)
Sleeve(for single wire)
Sleeve(for double wire)
AMP
AMP
AMP
AMP
:Plug(with plating)
:Receptacle(without plating)
Sleeve(for double wire)
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
L Accelerator sensor
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
:Tab
:Receptacle
P1 Accessory
:Receptacle
:Receptacle
:Receptacle(with sleeve)
Sleeve(for single wire)
Sleeve(for double wire)
: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
AMP.040 series multi-lock connector
175967-2
Fuse
10A
10A
CN6
5
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
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
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)
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
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
L Accelerator sensor
A 1B
P1 Accessory
E2,Pointc 61D
P2 57A
AMP 174262-2
36A
38A
AMP
AMP
AMP
AMP
:Plug(with plating)
:Receptacle(without plating)
Sleeve(for double wire)
AMP 170020-2
AMP 170002-5 or 170020-3
AMP 170888-1
:Receptacle
:Tab
:Receptacle
:Receptacle
:Receptacle
:Receptacle(with sleeve)
Sleeve(for single wire)
Sleeve(for double wire)
: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
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
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
:Receptacle(with plating)
:Receptacle(without plating)
Sleeve(for single wire)
Sleeve(for double wire)
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
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
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
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
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
M6
<7>
WH
YEWH2
2P
GNBU2
<8>
2P
M4
M2
<3>
M1
M3
WH
<4>
<2>
<6>
<5>
<13>
FB30P
<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
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
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
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
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
Locking lever
Rib for preventing
inverse insertion
6 5 4
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]
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
Insulation barrel
Locking lever
CN3, 4, 5, 6
[P/No. 37010-21490]
Ratchet part
Plug housing
CN1&CN2
79
Locking lever
Plug housing
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.
Crimping part
Insulation barrel
Housing lance
Terminal
Fig.1
Fig.4
There a gap on
normal condition
4. Pulling terminal
CAUTION
[Unlocked condition
of terminal]
Fig.2
Fig.3
80
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
Rib of plate
crimping part
Fig.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
Crimping part
of wire
Crimping die
(Inside)
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