Professional Documents
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Controller
FB10/14/15/18(H)CA 221AE0001-up
FB20/25(H)CA,28CA 241AC0001-up
FB30CA 251AC0001-up
99N19-53100
Mitsubishi Forklift Trucks Service Manual FB10-18(H)CA, FB20/25(H)CA, FB25/30CA Forklift Trucks 99N19-53100
Mitsubishi Caterpillar Forklift Europe B.V.
Hefbrugweg 77 1332 AM
Almere, The Netherlands
99N19-53100 Copyright © 2008 by MCFA. All Rights Reserved. Printed in The Netherlands
CONTENTS
1. Introduction B
Altered display and board
A Equipped with Sicos-AC (color display / flourscent display)
1- 1. What's new in FB-CA Improved inching (Interchangeable installation with panel Ass'y)
Enhanced regeneration 10-step battery discharge indication
Settings for various modes, power mode, and low speed Time length of hour meter indication key when it is ON (actual
Auto power OFF operation time is OPT)
Neutral safety Canceled battery electrolyte level display
22 Inclined lift chain / parallel (2SP mast) Self-diagnosis function Altered speed indication (actual speed / converted speed)
Contactless traveling, loading and regeneration 7 Shortened turn signal's come back Mono-blocked slow speed (turtle) S/W and mode S/W (sheet
type switch)
23 Altered chain anchor figure (2SP mast)
25 Altered chain attaching location (3FP mast) 14 Altered hydraulic lever link ratio
FB20CA
FB30CA
10 Altered counter weight figure
FB15CA
1
Introduction 1
51
50.5
50
49.5
Open voltage (V)
49
48.5
48
47.5
47
46.5
46
0 20 40 60 80 100 120
Discharging percentage (%)
11
10
7
Capacity indication
0
0 20 40 60 80 100
Discharging percentage (%)
3
2. Adjustment of SICOS-AC
2- 1. Explanation of the monitor display
2-1-1. Indicator panel
Monitor display Mode select switch
1 2 3 4 17
5 6 7
8 9 10 11 12 13 14 15 16
NOTE Icons of 8 to 14, and 16 shown in the illustration are displayed for the explanation. It
is not actual indication. They are displayed when abnormalities are occurred.
4
2 Adjustment of SICOS-AC
5 6 7
8 9 10 11 12 13 14 15 16
When the battery capacity is When the capacity is less than 10%,
less than 20%, all blue one red segment is flashed with the
segments are disappeared frame of the indicator.
and two red segments are lit. When the capacity is empty, only the
frame of the indicator is flashed.
6
2 Adjustment of SICOS-AC
4. Speed meter
The traveling speed is displayed on the screen.
7
Adjustment of SICOS-AC 2
8
2 Adjustment of SICOS-AC
NOTE The hydraulic oil level sensor detects the oil level
for 2 seconds after turning on the key switch. So,
the mast must be retracted completely and fork
must be lowered on the ground before turning on
the key switch. Otherwise, the warning message of
" REFILL HYDRAULIC OIL " may be displayed
even the quantity of oil is normal.
9
Adjustment of SICOS-AC 2
16.Service icon
The service icon warns the fault of the forklift truck to an
operator. If any faults are detected, the spanner mark
is flashed and the presumed defective part name is
displayed. If some problems are occurred at the same
time, each part name is scrolled alternatively for every 5
seconds.
10
2 Adjustment of SICOS-AC
11
Adjustment of SICOS-AC 2
NOTE When setting the mode of next [1] to [6] , each Mode select button
button works as below.
and buttons : Move the cursor to select
the value.
button : Move the cursor to the next item.
button : Back the cursor to the previous item.
Slow speed
[1] Slow speed setting Normal screen preset indication
Make sure the turtle button is pushed and the turtle icon
is flashed. Then, push or button to set the speed.
The maximum speed can be set to 8 steps of 2, 3, 4, 5, Push
button
6, 8, 10 and 12km/h.
Slow speed setting
After setting, push button to move the cursor to the
travel mode setting.
If push the button, the normal screen is displayed.
Push Push
button button
To the setting of travel mode
12
2 Adjustment of SICOS-AC
E (ECONOMY)
This mode is convenient for the slow speed inching.
This mode saves the battery energy consumption also.
N (NORMAL)
This is the normal traveling mode. The quick acceleration
and smooth inching can be realized.
P (POWER)
This is the most powerful mode for acceleration.
If pushing the button, the cursor is returned to the To the display mode setting screen
traveling mode area.
The display is switched from the normal screen to the
meter mode screen by pushing or button. The
meter mode screen has 2 kinds. Refer below for details.
13
Adjustment of SICOS-AC 2
14
2 Adjustment of SICOS-AC
15
Adjustment of SICOS-AC 2
4. Set the AM or PM
Push or button to select the AM or PM.
After setting, push button to move the cursor to the
hour area.
If pushing button, the cursor is returned to the data Set "AM" or "PM".
area.
Push Push
button button
16
2 Adjustment of SICOS-AC
Push
button
CAUTION When pushing the " " or " " button, the "COMPLETE" is flashed three times.
second is set to "00".
After setting the minute and push the " "
button, the second is set to "00". Return to the normal screen.
17
Adjustment of SICOS-AC 2
Switch
Display unit
board Travel circuit
Gate board Motor
control CPU
18
2 Adjustment of SICOS-AC
CN10 CN9
H CN7
HYD TRV
CN4
CN3
Body harness
CN2
CN1
CN5 T
CU harness (2)
34 56
7 8 9A
Connector for
personal computer
Backup battery
PB103-XXX CN2 CN1
Body harness
19
Adjustment of SICOS-AC 2
20
2 Adjustment of SICOS-AC
�Memory initial (display RS1=E) �Option setting (Display board RS1=6) Plugging brake distance
�Flat, unladen, and full speed
Slow speed (turtle speed) : 5km/h LIFT LOCK : OFF [Lift interrupt] �Specific gravity of electrolyte : more than 1.25 at 20
Travel mode : NORMAL SPEED LIMIT : OFF [Speed limit at high lifting height] �Full acceleration
BRIGHTNESS :5 SEAT SWITCH : OFF fixed [With seat switch]
Neutral regenerative power : MID FINGER TIP : OFF fixed [With finger tip] �Language selection (Display board RS1=5)
Meter mode : Hour meter AOS : OFF [With AOS] JAPANESE > OK
Error history : Clear POWER MODE : ON fixed [Power mode] ENGLISH > MONITORING OK
CHARGER : ON [Charger] FRENCH > CONTROLEUR OK
2-2-6. Adjustment Standards List for FB-CA
* When Japanese is not selected for display, "CHARGER" TILT STOP : OFF [Automatic tilt leveling]
is automatically set to "OFF". GERMAN > UEBERWACHUNG OK
* Before the car inspection, set "POWER MODE" to "OFF". * When Japanese is not selected for display, SPANISH > MONITOR OK
* HOUR METER (hour meter count) setting "CHARGER" is automatically set to "OFF". DUTCH > MONITORING OK
1: Key SW linked indication
2: Actual operation time indication
Adjustment of SICOS-AC 2
22
2 Adjustment of SICOS-AC
Display
<Confirmation>
After pressing " " button for more than 3 seconds, it
shows display as shown below.
Model confirmation
23
Adjustment of SICOS-AC 2
24
2 Adjustment of SICOS-AC
CDE
23
After finishing the setting, be sure to return
456
AB
rotary switch RS1 to "0".
789
25
Adjustment of SICOS-AC 2
<Measuring conditions>
Specific gravity of the battery electrolyte : more than 1.25
at 20:
<Measuring instrument>
Use a digital tester that can measure 1/100V.
Use Direct current (DC) mode.
Display board
<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "A". F01
CDE
23
456
AB
789
2. Turn the key switch ON and the following screen
Set RS1 to "A".
appears.
26
2 Adjustment of SICOS-AC
<Measuring conditions>
Specific gravity of the battery electrolyte : more than 1.25
at 20:
<Measuring instrument>
Alternating current (AC) mode
Control unit
Traction motor
Blower U phase
2P
White Analog clamp
ammeter
2P
White <5>
U1
<8>
U2
CN5
Board comp.,
CN8 <6>
V1
CN6 MPU CN7
<9>
V2
EPS
controller <7>
W1
<10>
CN1 CN2 CN3 CN4
W2
Harness, M
2P
Black
10P 2P-X 2P-Y
+
(waterproof)
-
<3> <2>
<12>
27
Adjustment of SICOS-AC 2
<Checking procedure>
1. Set rotary switch RS1 on the display board to "7". Display board
F01
CDE
23
456
2. Turn the key switch ON and the following screen
AB
789
appears.
Set RS1 to "7".
NOTE If TRV is not flashing, press button to make it
flash.
Flashing
28
2 Adjustment of SICOS-AC
<Measuring conditions>
Specific gravity of the battery electrolyte : more than 1.25
at 20:
<Measuring instrument>
Alternating current (AC) mode
Control unit
Blower
2P
White Hydraulic
2P
motor
White <5> U phase Analog clamp
U1
ammeter
<8>
U2
CN5
Board comp.,
CN8 <6>
V1
CN6 MPU CN7
<9>
V2
EPS
controller <7>
W1
<10>
CN1 CN2 CN3 CN4
W2
Harness, M
2P
Black
10P 2P-X 2P-Y
+
(waterproof)
-
<3> <2>
<12>
29
Adjustment of SICOS-AC 2
<Checking procedure>
1. Set rotary switch RS1 on the display board to "7". Display board
F01
CDE
23
456
2. Turn the key switch ON and the following screen
AB
789
appears.
3. Press either or button to make HYD flash. Set RS1 to "7".
Flashing
30
2 Adjustment of SICOS-AC
CDE
23
appears.
456
AB
3. Make sure the model is set correctly. 789
CDE
23
456
AB
789
31
Adjustment of SICOS-AC 2
<Adjusting procedure>
1. Forklift truck model setting: set the model with rotary switch RS1 on the travel/ hydraulic
board.
32
2 Adjustment of SICOS-AC
H CN7
CN10 CN9
CN4
CN4
CN3
Travel/hydraulic board
CN1 CN2
CN2
CN5 T
Disconnect CN2 and CN4 simultaneously.
3. Connect the battery plug and turn the key switch on.
4. Operate the accelerator, and make sure an alarm
sounds, main contactor trips, and the error messages
appears as shown.
Error messages
B 11 : IGBT-TRAVEL
B 13: FAIL OPERATION
B 13: TURN OFF KEY SWITCH
33
Adjustment of SICOS-AC 2
F01
2. Turn the key switch ON and the following screen
CDE
23
456
appears.
AB
789
3. Make sure that the parameter items are set the same
as the values on the Adjustment Standards List on Set RS1 to "4".
page 22.
34
2 Adjustment of SICOS-AC
<Measuring conditions>
Flat ground, unladen, and full speed.
Specific gravity of the battery electrolyte : more than 1.25
at 20:
<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "3". Display board
F01
CDE
23
456
AB
789
2. Turn the key switch ON and the following screen
appears. Set RS1 to "3".
36
2 Adjustment of SICOS-AC
<Adjusting procedure>
1. Set rotary switch RS1 on the display board to "3". Display board
CDE F01
23
456
AB
789
2. Turn the key switch ON and the following screen
appears. Set RS1 to "3".
37
Adjustment of SICOS-AC 2
F01
2. Turn the key switch ON and the following screen
CDE
23
456
appears.
AB
789
3. Make sure that the parameter items are set the same
as the values on the Adjustment Standards List on Set RS1 to "1".
page 22.
TRAVEL
HYD
STEER
BATT
BRAKE
LOAD
OIL
38
2 Adjustment of SICOS-AC
<Adjusting procedure>
1. Press either or button to move the flashing
icon to the item you want to change.
2. Press button to turn the item ON.
3. Press button to turn the item OFF.
4. Turn the key switch OFF and return rotary switch RS1 Display board
to "0".
F01
5. Turn the key on again.
CDE
23
456
The symbol indicating that the monitoring symbol
AB
789
setting screen is set to ON is displayed.
Return RS1 to "0".
F01
2. Turn the key switch ON and the following screen
CDE
23
456
appears.
AB
789
3. Check if the display language is set to your preference.
Set RS1 to "5".
Language (flashing)
<Adjusting procedure>
1. Press either or button to select your preferred
language.
39
Adjustment of SICOS-AC 2
F01
2. Turn the key switch ON and the following screen
CDE
23
456
appears.
AB
789
3. Check if the options are set to your preferences.
Set RS1 to "6".
40
2 Adjustment of SICOS-AC
Standard
Optional setting mode Remarks
setting
Lift locks when only one red segment is left
LIFT LOCK Lift interrupt OFF
on battery discharge indicator
SPEED LIMIT High lift height OFF Need to install action switch separately
SEAT SWITCH With seat switch OFF Need to install seat switch separately
Equipped with finger tip system hydraulic
FINGER TIP With finger tip OFF
lever models
AOS With AOS OFF Equipped with AOS function models
POWER MODE Can change to travel mode ON ON fixed, for FB (disabled to set power mode)
CHARGER Can set a timer for charging ON Does not show timer charging display
Equipped with Tilt Automatic Stop function
TILT STOP Automatic tilt leveling OFF
models
1: Key switch ON
2: Actual operation time (motor operation time)
HOUR METER 1 1
Changing view
(both counting)
<Adjusting procedure>
1. Press either or button to move the flashing
icon to the item you want to change.
2. Press button to turn the item ON.
3. Press button to turn the item OFF.
41
Adjustment of SICOS-AC 2
<Adjusting procedure>
1. Press or button repeatedly till the display
adjustment screen appears.
42
2 Adjustment of SICOS-AC
121T148E
Hourglass (flashing)
43
Adjustment of SICOS-AC 2
44
2 Adjustment of SICOS-AC
Brake oil
45
Adjustment of SICOS-AC 2
46
2 Adjustment of SICOS-AC
CDE
23
456
Optional setting check and adjustment" on page 40.
AB
789
Set to ON (flashing)
Option setting screen
4. Turn the key switch OFF and return the rotary switch Display board
RS1 to "0".
F01
5. Connect a 40 - 46V power supply to the battery plug.
CDE
23
6. Turn the key on again.
456
AB
789
7. Make sure that " CHARGE THE BATTERY " scrolls
from right to left across the display. (The display will Return RS1 to "0".
appear different from below if a language other than
English has been selected.)
47
Adjustment of SICOS-AC 2
CDE
23
456
AB
2. Turn the key switch ON and the following screen 789
appears.
Set RS1 to "B".
Parameter (flashing)
<Checking procedure>
1. Turn the steering wheel all the way to either the right
or the left.
2. Operate the accelerator lever.
3. Make sure that the speed limitation is applied and that
the forklift does not accelerate excessively.
CAUTION A t ur nin g d et e c t i on li m i t sw i t c h mu st b e
installed in order to use this option.
48
2 Adjustment of SICOS-AC
F01
CDE
23
456
2. Turn the key switch ON and the following screen
AB
789
appears.
Set RS1 to "8".
3. P r e s s , , , or to select "I/O",
" T R V " , a n d " W 0 0 1 2 " .
(See "3-3. I/O check" on page 62 to learn setting.)
DATA
8F/0000000010001111
CF/0000000011001111
White
Black/Yellow
49
Adjustment of SICOS-AC 2
F01
CDE
23
456
2. Turn the key switch ON and the following screen
AB
789
appears.
Set RS1 to "6".
Set to ON (flashing)
<Checking procedure>
1. Travel without taking a seat.
2. Make sure it is not traveling.
50
2 Adjustment of SICOS-AC
CDE
23
456
AB
789
Option setting screen
Set RS1 to "6".
4. Turn the key switch OFF, and set the rotary switch Display board
RS1 to "C".
F01
5. After turning the key switch ON, the following screen
CDE
23
456
will appear.
AB
789
flashing
51
Adjustment of SICOS-AC 2
52
2 Adjustment of SICOS-AC
<Total timer>
Magnetic Auto Reserve Equal Indicating LED of charging state
Checking procedure
contactor LED LED LED 1-2 3-4
1 Connect the battery plug. OFF
Auto button
Completion
cycle LED
3
Equal LED (orange)
Indicating LED (green) of
charging state.
l The LED lights indicate
2 the charge left in the
battery.
l If the total timer is
operated, all 4 LEDs will
flash.
1
CAUTION For a fully charged battery, check after performing approximately 2-3 minutes of
hydraulic operation.
If the charging state LEDs flash, they will not stop until the battery plug is
unplugged.
<Earth check>
Make sure the conductivity (0 at "1x" range of the tester) between the chassis and the
earth terminal in the receptacle on the charger panel.
NOTE If the optional setting (display board RS1=6) CHARGER is set to OFF, the
charging timer function will not work.
53
3. Troubleshooting
3- 1. Self diagnosis function
3-1-1. Display
If abnormalities or errors are detected with the self-
diagnosis function, the following symbols and error
messages will be displayed on the screen.
The applicable abnormality and/or error symbol will
flash on the display.
The applicable error message will be displayed. (If
multiple abnormalities and/or errors are detected, the
applicable error messages will be displayed in order.)
54
3 Troubleshooting
Other errors
B11 : IGBT-TRAVEL
C21 : IGBT-HYD.
FAIL OPERATION
23
displayed.)
456
AB
789
When the abnor malities and/or errors are
resolved, the display will return to the basic RS="F"
screen.
55
Troubleshooting 3
*FAIL OPERATION*
11 B11 : IGBT-TRAVEL Travel phase IGBT error
*TURN OFF KEY SWITCH*
*FAIL OPERATION*
21 C21 : IGBT-HYD. Hydraulic phase IGBT error
*TURN OFF KEY SWITCH*
32 D32 : TR-EPS MAIN EPS FET error (Decelerates by half) *TURN OFF KEY SWITCH*
40 E40 : TR-AOS Valve electric current error *TURN OFF KEY SWITCH*
E42 : ENCODER-HYD
42 Error in the encoder for lift height
MAST
*REDUCE DUTY-
55 Board or IGBT temperature error
OPERATION*
56
3 Troubleshooting
Error
Error Message Probable Cause Notes
No.
*REPLENISH REFINED Replenish refined water to the When the battery electrolyte gets
WATER FOR BATTERY* battery (W03) below minimum level
*RELEASE ACCEL TO The accelerator was depressed When the travel CPU is in the
NEUTRAL* when the key was turned on. (W08) neutral safety mode
*OFF HYD. LEVER TO The hydraulic lever was engaged When the hydraulic CPU is in the
NEUTRAL* when the key was turned on. (W09) neutral safety mode
Lift location is set in the wrong way When the lift location is set in the
*RACK MISSET*
(W 11) wrong way
Dismounted from the forklift truck Seat switch is turned OFF without
*APPLY PARKING BRAKE*
without applying the parking brake (W12) applying the parking brake
57
Troubleshooting 3
CDE
23
456
NOTE
AB
To view less than the ten most recent errors/ 789
abnormalities, place the flashing cursor on the last
Set RS1 to "9".
error/abnormality and press button to go to
"Previously detected errors/abnormalities".
If there are no errors/abnormalities, press
button to go to "Previously detected errors/
abnormalities".
58
3 Troubleshooting
CDE
23
displayed in the list, press button to go to
456
AB
"Previously detected errors/abnormalities (2)". 789
If the same error/abnormality was detected
RS1="9".
multiple times previously, the data of the most
recent detection will be displayed under "Error/
abnormality details".
Flashing : Indicates the position of cursor.
Highlighted : Only highlighted numbers are
memorized as error items.
F01
NOTE If the same error/abnormality was detected
CDE
23
456
multiple times previously, the data of the most
AB
789
recent detection will be displayed under "Error/
abnormality details". RS1="9"
60
3 Troubleshooting
CDE
23
initialization is complete.
456
AB
789
4. Return rotary switch RS1 on the display board to "0".
Set RS1 to "E".
61
Troubleshooting 3
3- 3. I/O Check
3-3-1. I/O check mode display method
1. Set rotary switch RS1 on the display board to "8". Display board
2. Turn the key switch ON and the following screen
F01
appears.
CDE
23
456
3. Press button to enter the I/O check mode. The
AB
789
"I/O" icon will flash.
The RAM icon flashes. Set RS1 to "8".
lCPU selection
TRV : Travel
HYD : Hydraulic
EPS : Power steering
DSP : Display
62
3 Troubleshooting
POE0 IN Traction motor gate signal open order 1 Gate OPEN when L
POE1 IN Traction motor gate signal open order 2 Gate OPEN when L
POE2 IN Traction motor gate signal open order 3 Gate OPEN when L
POE3 IN Traction motor gate signal open order 4 Gate OPEN when L
PB During hydraulic operation
(W0002) 6 IN When operating at H
(transmission between CPUs)
During travel operation
7 OUT When operating at H
(transmission between CPUs)
Hydraulic trip
8 IN (transmission between CPUs) Hydraulic trip at H
Travel trip
9 OUT (transmission between CPUs) Travel trip at H
64
3 Troubleshooting
(W000A) AN0 A/D Traction motor U phase electric current 2.5V 1.75V= 700A
(W000C) AN1 A/D Traction motor V phase electric current 2.5V 1.75V= 700A
(W000E) AN2 A/D Battery current 2.5V 1.75V= 700A
(W0010) AN3 A/D Battery voltage 0-5V=0-55V
(W0012) AN4 A/D Accelerator voltage 1 0-5V
(W0014) AN5 A/D Accelerator voltage 2 0-5V
(W0016) AN6 A/D Board temperature sensor 0-5V
(W0018) AN7 A/D Travel IGBT temperature sensor 0-5V
65
Troubleshooting 3
Hydraulic CPU
I/O port table (1)
PortNO. Bit IN/OUT Contents Remarks
Flashes when the hydraulic CPU is
2 OUT CPU run LED for the hydraulic motor
normal
TCLKA IN Lift rotary encoder A 0-5V input
TCLKB IN Lift rotary encoder A 0-5V input
PA TCLKC IN Hydraulic motor rotary encoder A 0-5V input
(W0000) TCLKD IN Hydraulic motor rotary encoder B 0-5V input
10 IN Hydraulic motor U phase voltage 0-5V input
11 IN Hydraulic motor V phase voltage 0-5V input
12 IN Hydraulic motor W phase voltage 0-5V input
66
3 Troubleshooting
(W000A) AN0 A/D Hydraulic motor U phase electric current 2.5V 1.75V= 700A
(W000C) AN1 A/D Hydraulic motor V phase electric current 2.5V 1.75V= 700A
(W000E) AN2 A/D Battery voltage 0-5V=0-55V
(W0010) AN3 A/D Hydraulic IGBT temperature sensor 0-5V
(W0012) AN4 A/D Tilt level potentiometer 0-5V
(W0014) AN5 A/D Auxiliary A/D input 0-5V AOS
(W0016) ADS0 A/D Lift lever potentiometer 0-5V AOS
(W0018) ADS1 A/D Tilt lever potentiometer 0-5V AOS
(W001A) ADS2 A/D Attachment 1 lever potentiometer 0-5V AOS
(W001C) ADS3 A/D Attachment 2 lever potentiometer 0-5V AOS
(W001E) ADS4 A/D Attachment 3 lever potentiometer 0-5V AOS
(W0020) ADP0 A/D Lift valve current 0-5V AOS
(W0022) ADP1 A/D Tilt valve current 0-5V AOS
(W0024) ADP2 A/D Attachment valve current 1 0-5V AOS
(W0026) ADP3 A/D Attachment valve current 2 0-5V AOS
(W0028) ADP4 A/D Attachment valve current 3 0-5V AOS
67
Troubleshooting 3
Display CPU
I/O port table (1)
PortNO. Bit IN/OUT Contents Remarks
0 IN Switch 1 (up) L when the switch is on
1 IN Switch 2 (down) L when the switch is on
2 IN Switch 3 (mode) L when the switch is on
P1 3 IN Switch 4 (Reserved setting) L when the switch is on
(W0000) 4 IN Hour meter count start Count begins at L
5 IN Key switch start H when the key is turned to start
6 IN Charging interlock relay B contact H when the charging plug is on
7 IN Switch 5 (Turtle) L when switch is ON
0 IN Rotary switch 1
P7 1 IN Rotary switch 2
(W0004) 2 IN Rotary switch 3
3 IN Rotary switch 4
0 IN Slow speed mode switch (turtle) H and B contact when the switch is on
1 IN Turn signal switch (right) L when the switch is on
2 IN Turn signal switch (left) L when the switch is on
P9 3 IN Reserve charge start L when starting
(W0006) 4 IN Brake oil level Usually H
5 IN Hydraulic oil level Usually H
6 IN Overload L during overload
7 IN Parking brake L when on
68
3 Troubleshooting
EPS CPU
I/O port table (1)
PortNO. Bit IN/OUT Contents Remarks
0: Power source on
2 OUT Power source retention signal
1: Power source off
0: Correct direction
PA (FET1:ON,FET3:OFF)
(W0000) 4 OUT FET1, 3 gate signal
1: Reverse direction
(FET1:OFF,FET3:ON)
0: Correct direction
(FET2:ON,FET4:OFF)
5 OUT FET2, 4 gate signal
1: Reverse direction
(FET2:OFF,FET4:ON)
69
4. Wiring and main controller layout
PB100-90 PB100-90 1 2 3 PB100-90
Battery(48V) Line Connector Line Connector Line Connector
V N No. CN Pin No. No. CN Pin No. No. CN Pin No.
RDWH
BKWH
RDBK
VA NA 125V 0.022 F
BUBK RD
C1 5 18 Main contactor contact RPA 3 4 Power supply
F1 GNRD
F1 5 9 Traction motor BKRD
RNA 3 14 M STP 1 3 Fan output 1
Travel fuse GND
+ BUWH
RA1 3 5 A phase signal
Blower
MC 80V,5600 F(x9)
F2 5 19 Hydraulic fuse speed sensor WH
RB1 3 15 M DWN 1 4 Fan output 2
BK
WHBU
Switch GND
* Standard for ECC
EPS sensor SC1 1 5 Auxiliary contactor
RD
RDWH
BUWH
WHBU
BKYE
RDYE
WHRD
BUYE
TXB 2 13 DSP Hydraulic No. CN Pin No.
RXA 2 2 DSP Traction Data line Mode select switch RD Level lamp
WHGN
BK
TXA 2 12 DSP Traction (Traction/Hydraulic) Laser pointer (OPT.)
RDGN
HNA 2 11 GND GNWH switch
HPA 2 1 Power supply BS5 4 2 Low speed mode switch
RDYE
HPC 2 5 Laser
Power supply (turtle switch)
Charger panel BKYE
HNC 2 15 GND Data line BK
BS1 4 6
WHBU Up Tilt level sensor
*Only for trucks TXC 2 14 DSP EPS (EPS) +
BUWH
with built-in chargers. RXC 2 4 DSP EPS RD
BKWH - Flat cable BS2 4 5 Down
YERD
Charger, YEBK
6P YE
SW4 1 14 Reserve charge start BS3 4 4 Mode select DC/DC
controller BNBK M
CHG 2 20 Reserve charge GY converter
BS4 4 3 Reserved setting
RD R
VB 1 10 Battery voltage
GN
VN 4 1 Switch GND
Turn signal lamp switch
(*Momentary)
YERD Right WHRD
X2 X1 RLP 1 3 Power supply relay SW2 1 13 Turn signal lamp switch(right)
BNYE WH WHBU
RLN 1 11 HV 5 1
Key switch BK
Back light power supply
Left
SW3 1 6 Turn signal lamp switch(left)
F5 RDGN GND 5 2 Back light GND
10A KSW 1 1 Control power supply
RD BKWH 22P
VN 1 9 Control GND BNBK
X2 X1 SW5 1 7 Brake oil level
BN WHBK
F4
10A
KST 2 19 Key switch start Display SW6 1 15 Hydraulic oil level
YEBU
RY 1 2 Charging interlock Flat cable 3 BNBK
SW7 1 8 Overload
BUBK
12P BUBK
CHS 2 10 Hour meter counting SW8 1 16 Parking brake switch
*Refer to note 3
BKWH*
RDWH
RDBK
FB10CA-28CA 4-1-1.
Pink PK
Orange OG
70
4 Wiring and main controller layout
BKWH*
48V
RDWH
RDBK
NA 125V 0.022 F
VA BUBK
C1 5 18
RD
GNRD Main contactor contact BKRD RPA 3 4 Power supply M STP 1 3 Fan output 1
F1 F1 5 9 Travel fuse Traction motor BUWH RNA 3 14 GND
+ WH RA1 3 5 A phase signal
Blower
MC 325A 80V,5600 F(x9)
F2 5 19 Hydraulic fuse speed sensor RB1 3 15 B phase signal
M DWN 1 4 Fan output 2
MIB
WHBK# X7 + 100V
BNWH# TUM 6 1 Traction motor U phase RDGN# 22 F
Board TU0 6 9 U phase gate output 0 YERD# TPU 5 2 Power supply WHBK
TIU
IGBT
BUYE#
TU1 6 2 U phase gate output1 TIU BKYE# TIU 5 3 Signal H
Traction IGBT module U
YEBU#
TU2 6 10 U phase gate output2 Travel TNU 5 12 GND Horn
RDWH# RDBK#
U1 motor Phase BKWH# TUP 6 3 U phase power supply(+) current sensor BU# TPV 5 4 Power supply
TUN 6 11 U phase power supply(-) TIV BKWH# TIV 5 13 Signal YERD
X7
TNV 5 14 GND
WH#
BN# TVM 6 4 Traction motor V phase
Board RDGN#
V1TIV IGBT BU# TV0 6 12 V phase gate output 0
YERD# HPU 7 2 Power supply Brake switch WHRD
YEBK# TV1 6 5 V phase gate output1 HIU BKYE# HIU 7 3 Signal BS 1 7 Brake switch
W1 IGBT module V
RD# TV2 6 13 V phase gate output2 Hydraulic HNU 7 8 GND
Phase TVP 6 6 V phase power supply(+) RDBK# GNWH
BK#
TVN 6 14 V phase power supply(-) current sensor BU# HPV 7 4 Power supply
HIV BKWH# HIV 7 9 Signal
WHRD# HNV 7 10 GND BURD
TWM 6 7 Traction motor W phase X3 OF2 1 9 Forward output
Board BNRD# W phase gate output 0
BURD# TW0 6 15 RDYE
IGBT TW1 6 8 W phase gate output1 AP1 2 1 Power supply
YERD# WH Signal
IGBT module W TW2 6 16 W phase gate output2 AD1 2 2 YEBK
Phase
RDYE#
TWP 5 1 W phase power supply(+) Accelerator AN1 2 11 GND X4 OB2 1 10 Backward output
BKRD# AP2 2 3 Power supply
TWN 5 11 W phase power supply(-) potentiometer BU
AD2 2 10 Signal
BKYE BN
AN2 2 9 GND BZ
WHBK# X4
HUM 8 1 Hydraulic motor U phase RPA 3 6 Power supply
Board BNWH#
HU0 8 9 IGBT BNYE
HD3 5 5 Signal BN
Back buzzer RNA 3 16 GND
BUYE# U phase gate output 0 T-IGBT BKYE
IGBT HU1 8 2 U phase gate output1 temperature sensor HN3 5 15 GND RA2 3 7 A phase signal
Hydraulic IGBT module U YEBU#
HU2 8 10 U phase gate output2
Rear combination lamp(Right) RB2 3 17 B phase signal
RDWH#
U2 motor Phase BKWH# HUP 8 3 U phase power supply(+) HD4 7 5 Signal
Turn signal TPM 5 7 Power supply
HUN 8 11 U phase power supply(-) HN4 7 11 GND TIM 5 8 Signal
Directional switch 25W lamp
TSL TNM 5 17 GND
WH# RD
BN# HVM 8 4 Hydraulic motor V phase AP 2 5 25W RPA 3 8 Power supply
Power supply
V2 Board
BU# HV0 8 12 V phase gate output 0 Open when in neutral Tail & stop RNA 3 18 GND
IGBT HV1 8 5 V phase gate output1 DS3 WHBK lamp RA3 3 9 A phase signal
IGBT module YEBK# ADN 2 13 Neutral
W2 V RD# HV2 8 13 V phase gate output2 TL RB3 3 19 B phase signal
Phase HVP 8 6 V phase power supply(+) DS1 GNWH HP1 4 1 Power supply
BK# ADF 2 6 Forward 10W
HVN 8 14 V phase power supply(-) HD1 4 2 Signal
DS2 BUYE Back lamp HN1 4 9 GND
ADB 2 14 Backward 10W
WHRD# BL
Board BNRD# HWM 8 7 Hydraulic motor W phase HP2 4 3 Power supply
BURD# HW0 8 15 W phase gate output 0 BUWH
HS1 4 4 Lift 1 switch
HD2 4 10 Signal
IGBT module
IGBT YERD# HW1 8 8 W phase gate output1 HN2 4 11 GND
W RDYE# HW2 8 16 W phase gate output2 WHBU
HS2 4 12 Lift 2 switch Rear combination lamp(Left) TI1 3 10 Auxiliary input 1
Phase BKRD# HWP 7 1 W phase power supply(+) TI2 3 20 Auxiliary input 2
HWN 7 7 W phase power supply(-) BNWH
HS3 4 5 Tilt switch Turn signal TI3 1 6 Auxiliary input 3
BNRD 25W lamp
F3 5 10 EPS fuse YEBU TSL
HS4 4 13 Attachment switch 1
EPS motor AP 2 4 Power supply
GNWH 25W AN 2 12 GND
HS5 4 6 Attachment switch 2 Tail & stop
GN YE AC0 2 7 Accelerator 0
F3
PA BN
HS6 4 14 Attachment switch 3 TL
lamp
AC1 2 15 Accelerator 1
40A AC2 2 8 Accelerator 2
RD BU BKWH 10W Accelerator 3
HS7 4 7 Auxiliary input AC3 2 16
NB 5 20 Control GND
Back lamp
WH EPS MC
WHBU
MC1 5 6 Main contactor HS8 4 15 Auxiliary input
10W
BL
TS GNWH
BU
controller BNWH
MC2 5 16 BK
HSN 4 16 Switch GND
WHBU
* Standard for ECC
EPS sensor SC1 1 5 Auxiliary contactor
RD
RDWH
BUWH
WHBU
BKYE
RDYE
WHRD
YERD Line Connector IO1 2 18 Tilt level
WHRD RXB 2 3 DSP Hydraulic
BUYE TXB 2 13 DSP Hydraulic No. CN Pin No.
WHGN RXA 2 2 DSP Traction Data line Mode select switch RD Level lamp
TXA 2 12 DSP Traction (Traction/Hydraulic) Laser pointer (OPT.)
BK
RDGN HNA 2 11 GND GNWH switch
HPA 2 1 Power supply SW1 1 5 Low speed mode switch
RDYE Laser
HPC 2 5 Power supply (turtle switch)
Charger panel BKYE
HNC 2 15 GND Data line BK
WHBU BS1 4 1 Up Tilt level sensor
*Only for trucks TXC 2 14 DSP EPS (EPS) +
with built-in chargers. BUWH
RXC 2 4 DSP EPS RD
BKWH BS2 4 2 Down
- YERD
RDYE Charger, YEBK YE
SW4 1 14 Reserve charge start BS3 4 3 Mode select DC/DC
controller BNBK M
BK
RDWH
FB30CA 4-1-2.
71
Wiring and main controller layout 4
resistant
resistant
WH WH WH
Water
Water
Harness, head guard GN TSL
2P
2P
Laser 2P
(*Refer to note 6)
<5>
resistant
WH
U1
Water
Level
3FP mast
2P
Harness, mast(1) Hanging on mast sensor <8>
RDBK
U2
Water RDWH
2P Accessory <6>
Hydraulic motor
resistant BKWH CN5 CN8
V1
resistant
(front) Board Comp.,
Water
Harness, mast(2) BUYE
BNYE CN6
MPU CN7
Control valve
resistant
<9>
Water
V2
2P
2P
Laser
Only for when using optional equipment. EPS
controller <7>
Att.2 RDBK 1
Horn switch U2 V2 W2 W1
YERD Harness, M(4)
Reference:
1
(valve lever) <8> <9> <10>
<10>
Harness mark/color
Att.1
CN1 CN2 CN3 CN4
W2
Red RD
Harness, M(3)
resistant
Black BK Tilt
Water
Green GN
Yellow YE
Lift 1 Acceleration 6P
4P
White WH Harness, M(4) BK
sensor 10P 2P-X 2P-Y
+
Brown BN
6P
Harness, M(1)
-
Blue BU Lift 2 BK Water
Gray GY resistant <3> <2>
Pink PK <12>
Traction motor
resistant
Orange OG
Water
Ex) BKWH (=Black/White) <1>
BU
+
BUBK
4P
Black colored harness with White line. Connect, and begin the BKWH
hour meter countdown. Bearing sensor Rear combination lamp Rear combination lamp
<2> (left) (right)
4P
RD Control power supply relay
Laser pointer switch
-
U1 <5> Battery
Battery
*Only for trucks with laser pointers TSL TSL
4P
V1 <6> plug WH Backward output relay
White line 2P
BK W1 <7> (48V) TL TL
4P
BK Horn relay
BL BL
Harness, M(3)
resistant
Black color
Lamp switch
Water
4P
resistant
WH
Water
resistant
6P
6P
Water
Indicator panel Brake oil level BNBK
EPS *Only for EEC or when using
3P
1
2P
Harness, charger(2) WH 1
:Plug AMP 170020-3 or
Charger panel <13>
:Plug
AMP 170002-5
AMP 170020-2
325A
160A
40A
*Only for trucks with built-in chargers. 4P DC/DC <11>
1
:Receptacle AMP 170021-3 or
BK converter Transformer AMP 170003-5
resistant
controller Rectifier
Water
(handle post) 1
YERD
Blower
RD
BK HL
4P
Harness, short circuit WH WH Clamp
FB10CA-28CA 4-2-1.
72
4 Wiring and main controller layout
resistant
resistant
WH WH WH
Water
Water
Laser Harness, head guard GN TSL
2P
2P
2P
(*Refer to note 6)
resistant
WH <5>
U1
Water
3FP mast Level
2P
Harness, mast(1) Hanging on mast sensor <8>
RDBK
U2
Water RDWH
2P Accessory <6>
Hydraulic motor
resistant BKWH CN5 CN8
V1
resistant
(front) Board Comp.,
Water
Harness, mast(2) BUYE
BNYE CN6
MPU CN7
Control valve
resistant
<9>
Water
Laser V2
2P
2P
Only for when using optional equipment. EPS
controller <7>
Att.2 RDBK 1
Horn switch U2 V2 W2 W1
YERD Harness, M(4)
1
(valve lever) <8> <9> <10>
<10>
Reference: Att.1
CN1 CN2 CN3 CN4
W2
Harness mark/color
Harness, M(3)
resistant
Red RD Tilt
Water
Black BK
Green GN
Lift 1 Acceleration Harness, M(4)
6P
4P
Yellow YE BK
White WH sensor 10P 2P-X 2P-Y
+
6P Harness, M(1)
-
Brown BN Lift 2 BK Water
Blue BU resistant <3> <2>
Gray GY <12>
Traction motor
resistant
Pink PK
Water
Orange OG
<1>
BU
BUBK
+ (72V)
4P
Ex) BKWH (=Black/White)
Connect, and begin the BKWH
Black colored harness with White line. Bearing sensor
hour meter countdown.
<0> Rear combination lamp Rear combination lamp 4P
+ (48V) (left) (right) RD Control power supply relay
Laser pointer switch U1 <5>
<2>
- TSL TSL
Battery
*Only for trucks with laser pointers
4P
V1 <6> Battery WH Backward output relay
White line
2P
BK W1 <7> plug (72V) TL TL
4P
BK Horn relay
BL BL
Harness, M(3)
resistant
Water
4P
Black color Lamp switch
resistant
WH
Water
resistant
6P
6P
Water
Indicator panel Brake oil level BNBK
EPS *Only for EEC or when using
3P
1
10A
10A
1
RDBK
RDYE
RDGN
contactor Harness, body
<1>
6P WHBK
RD
Horn BKWH
"K"
Transformer BUBK
resistant
Water
2P
Harness, charger(2) WH 1.<n> indicates the lead wire numbers.
2.Terminal symbols
Charger panel <13> 1
:Plug AMP 170020-3 or
325A
160A
AMP 170002-5
40A
*Only for trucks with built-in chargers. 4P DC/DC <11>
BK converter Transformer :Plug AMP 170020-2
resistant
controller
and spring washers.
Water
side
Turn signal lamp switch
-
2P <12> The reasons why only spring washers should be used is that they
3P
WH
break the coating on the charger panel, enduring conductance
"W"
between the frame and the charger panel.
Magnetic <13> Harness, charger(1) 4."K" and "W" indicate the printed marks on the connector.
contactor 5. The DC/DC converter for laser pointer should be attached
Horn switch RDBK
Head guard(left) to an appropriate position on the front hood.
1
YERD
(handle post) 1
6.Connector for blower should be placed in a circle, as shown the
figure below.
RD
BK HL Blower
4P
WH
Harness, short circuit WH
*Only when a charger is not mounted.
Harness, head guard GN TSL
Clamp
6P
FB30CA 4-2-2.
73
Control unit
Hydraulic lever potentiometer
CN12
CN11
CN5 CN8
EPS
controller
2
Proportional control valve
8P
Tilt
Lift
Attachment 2
Attachment 1
SOL SOL SOL SOL 1 <Note>
Fingertip specification
FB-CA Body wiring
1. The valve microswitch section of the "harness, body" on the
8P standard forklift truck should not be connected, because this part
has been eliminated.
*Attachments 1 and 2
Water 2. This diagram only describes the site related to the fingertip.
are optional.
resistant
4-2-3.
4- 2.
Wiring and main controller layout 4
74
Wiring and main controller layout 4
Reference:
*Refer to note 6 RDWH RDWH Harness mark/color
To C To E2
RDWH RDWH Red RD
To D6 To E2 Black BK
RDBK
WHGN
WHBU
WHRD
RD
Green GN
Point"a"
Yellow YE
1 1 1 1 1 White WH
BKWH
WHBU
WHRD
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
GNWH
BUYE
RD
WHBK
RD
RDGN
BN
1 2 3 4 1 2 Brown BN
S1,W1 E1,E2 X,K1
Blue BU
BKWH*
BKWH*
RD
RD
To E1
To E2
To X
To W4
65F 69B 49B
1 1 2 2 2 2 2 2 2 2 2 2 Gray GY
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
RDGN
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
V S1 S2 X A A Point"c" X
Pink PK
76B 77B
65G 67C 32G 41B 13B 11B 34B 50B
Orange OG
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
X A A D2 Plug 4P Plug 2P
Horn switch 39B
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20
W1(post)
D2 O D2 N2 S2 W2 A A A C C R W4 14B 12B 31C WH BK Ex) BKWH (=Black/White)
RD
RD
Black colored harness with White line.
To O
To C
To D4
To D1
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A
BKWH*
BKWH*
D4 Point"c"D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1 2 1
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 2
Point"c" Point"d"
CN1 CN2 3 2 1
W 2 1 3 2 1
K Lamp switch Laser pointer
4 3
Point "c"
V Operation switch Pressed sleeve detailed drawing
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 Turn signal switch W4 Key switch White line
(*Refer to note 5) (*Refer to note 5)
Valve
W3 Directional switch T microswitch
X Display board Horn switch
S1(Lever)
65E U,V 1
RDBK
Plug 6P Black color
BUWH
YERD 1 1 A 25B BK
67B D1,W1 1 WHBU
Plug 4P 1 2 A 28B
RDWH BNWH
6J N1,N2 1 1 1 3 A 26B
WH YEBU
Q
BKWH* 1 4 A 29B
52B N1,Q 2 1
R Accessory
YERD BUBK GNWH
Converter
48B X 1 5 A 27B
75B K1 3 1 BK 1 2 3
S2 Brake oil
BKWH* BNBK 1 6 A 30B
1 2 52C Q,M 4 1
BKWH 40B X
32E O,S2
1
4 5 6
3 4 32F R,W2
BKWH
Put the sleeve 1
<Note>
RD
BKWH*
2 1 V 77C
Water resistant
K3 Level lamp 1.Terminal symbols
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
2 2
N1 52N Plug 2P
: Receptacle
M
WHBK
68B D1 + Water resistant (with plating) AMP 170021-2
Horn
K2Laser
*Refer to note 7
L
1 1 1 1 2 1 Plug 2P 1 1 1 1 : Receptacle
RDYE
RDGN
RD
YEBU
BKWH*
BKWH
RDWH
WHRD
BUBK
GNWH
BKWH
1
BNBK
YEBK
52D O,I
1 2 3 4
V Q,K3 EPS sensor Capacitor RD
BKWH*
2 1 V 77A
1 2 3 4
V U,K2
(without plating) AMP 170003-5 or
RDBK
RDWH
BKWH*
BUYE
BNYE
100V 22 2
N2 52J
2
2 1 AMP 170021-3
76A 52A 76C 52I
1 1 1 1 1 1 1 1 1 1 1 1 Sleeve(for single wire) AMP 170889-1
P,Q X,E1 Water resistant Q,U X,E2
Level
1 2 3 4 5 6 1 2 1 2 3 4 5 6
Sleeve(for double wire) AMP 170890-1
K1 sensor
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B
BU F,S1 D2,N2 E2 : Plug
74B 34C 33B 51B 6H 43B 56B C 1 2
YERD Plug 2P
GNWH 1 Q 75A
Plug 4P
F P,R X A E1,E2 D4,O
55B C 2 2
WH WHRD
2
2 N2 49C 65D 52H 72B Plug 4P (with plating) AMP 170020-2
54B C 3 2 2
WH 73B 32D 42B 3B 70B 32C 3 2 1 N2,E2 E2 WH 1 : Plug
2 1
6L 71B (without plating) AMP 170002-5 or
U Accessory
1 2 Plug 6P Plug 2P Plug 6P 1 2 AMP 170020-3
3 4 BK WH RD 3 4 Sleeve(for double wire) AMP 170888-1
Water resistant
Head guard Plug 4P Head guard : Receptacle(with sleeve)AMP 41729
N2
1P YE BU Sleeve(for single wire) AMP 170823-2
N1
57B C
J H
4
Yazaki
(right)
1 2 3 1 1 2 3
2 1 A 10B
(left)
RDYE
4 5 6 2 4 5 6 EPS motor 7123-4113-30 BKYE
WH
2
2
2
3
A 7B
A 9B
2 1
Accelerator sensor Sleeve(for double wire) AMP 1-170823-5
: Receptacle AMP 173716-2 or
GN 4 A 8B
1
1P
2
58B C 5 4 3
AMP 175061-2
O Charger panel P
Yazaki
Brake switch 7122-4113-30 1 : Receptacle AMP 170032-5 or
AMP 179461-5
Capacitor 1 : Tab AMP 170340-3 or
I Back buzzer
BN 125V 0.022 Water resistant AMP 179462-3
66C D3,E2 1
G Speed
Plug 4P
52E M,D4
BKWH*
RD
BKRD
2 1 A 21B sensor 2 : Receptacle AMP 171662-1 or
1 3 A 22B AMP 173707-1
(Travel)
2
BK RDGN BUWH AMP 174257-2
10A 2 2 A 23B
73A O
WH 4 A 24B AMP 172888-2(rubber plug)
2
2 1
(*Refer to note 9) AMP 172748-2(seal plug)
BK RDBK
8 10A 4 3 3 : Receptacle AMP 316041-2 or
65C D1,U
74A O AMP 179956-2
RDYE
YEBU
4 : Receptacle Yazaki 7116-3251
A 4B
61B D4 8
BUBK RDWH U,Point"a" 6M
5 : Tab Yazaki 7114-3251
BKWH* Point"d" 52L : Pressed sleeve JST FNC-2
E2
1
Plug 60B D4
2P
1 1 WHBU
BNWH
BUYE
U 71A
,E2
Stop & tail lamp 2. : :Braided wires under 25mm pitch.
BNYE
2 WH
62B D4 2 1
U 72A (right) 3.The location of connector pin is as viewed from the inserting side.
4.The relay should not be clamped to the harness.
RD Water resistant Water resistant 5.Write or impress the letters with undamped ink.
F Contactor fuse
WHBU WHBU
59B C 8 Plug 6P 69A V 1 2
BKWH* BKWH*
2 1 V 69C Plug 6P
52K
Point
2 2 2 2 E2 52M 6.Fuses should be placed in a circle, as shown in the figure 1.
BNRD "d" RDWH RDWH
64B D4 8 6G P 3 3 Point 6N 7.The end of the spiral tube should be tied together with wire ties,
E1
Stop & tail lamp
2 2
GNWH GNWH 4 "a"
70A P 4 2 2 P 70C
BN BN and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
(left) 3 2 1 66AD3 5 2
BUYE RDYE
2 5 I 66D 3 2 1
6 5 4 38C N1 6 2 2 6 N2 37C 6 5 4 WHBU 8.The end of the vinyl tube should be tied together with wire ties.
Point"a" BUBK
1 1 F 60A
D4 Controller
1 2 F 61A Plug 9.The capacitor should be soldered to the speed sensor section, as shown in
BKWH 6P
BNWH
1 3 X,P 32B 1 2 3 Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
4 F 62A WH
Point"d"
1
BKWH 4 5 6 with siliconadhesive.
D6
1 5 Point 52F
Plug RDWH BU BNRD "d"
6E D5,Point"a" 11 1 6 F 64A
Fan GNWH 53A C 8
Backward output
D3 relay
1 2P 2B A 2 1
Power supply
2 RDBK Fuse
B
WH 1 1 D1 65APlug 10A
RDWH 4P
terminal 1 2
1 2 D2,D5 6C 10A
BN 1 3 E1,I 66B WH Ca1a-DC48V-N
YEBK 1 4 A 5B 3 4 *Connect the relay.
RDGN
Control power supply
D2 relay
1 1 X,W4 31B
YERD Plug Tie wrap
1 2 X 35B
RDWH 4P
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
WHBU
YEBU
BK
1 3 A,D3 6B 1 2 Clamp
BNYE RD
1 4
X 36B 3 4 Ca1a-DC48V-N Figure 1 Figure 2
RDBK *Connect the relay.
WH
GNWH
BU
1 1 D3,F 65B
RDYE
WH
BKYE
BU
Capacitor
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
YERD
D1 Horn relay
RDYE
BKYE
WHBU
BUWH
1 2 S1 67A Plug
Seal plug
(Non polarized)
4P 1 2 Vinyl tube Vinyl tube
BKWH* 1 4 Point"d",U 52G BK
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 WHBK 1 3 M 68A 3 4 Ca1a-DC48V-N Fill the inside of the vinyl
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 *Connect the relay. tube with silicon adhesive.
X X Point"a" L J F D5 P H H W3 W3 X X X G G T T T Be careful of the arrangement
of terminals.
46B 45B 6F 55A 57A 59A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 25A 27A 29A
RDWH Plug
D6 E2 D3 D2
D5 Fan
X X Point"c" L L J B H H W3 W3 X X X G G T T T 1 1 D3,D6 6D 2P 1 Tie wrap With solder Tie wrap
BUWH 2
47B 44B 34D 54A 56A 58A 53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 26A 28A 30A 1 2 A 1B WH
Figure 3
FB10CA-18CA
(Std/CS/FCS/RP/DRP) 4-3-1.
75
4 Wiring and main controller layout
*Refer to note 6
<Note>
BKWH*
BKWH*
1.Terminal symbols
To E1
To E2
To X
To W4
RDWH RDWH
RD
RD
To C To E2 :Receptacle
RDBK
WHGN
WHBU
WHRD
RD
RDWH RDWH (with plating) AMP 170021-2
To D6 To E2 1 :Receptacle
(without plating) AMP 170003-5 or
1 1 1 1 1
Point"a"
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
BKWH
WHBU
WHRD
GNWH
BUYE
RD
WHBK
RD
RDGN
BN
1 2 3 4 1 2
AMP 170021-3
S1,W1 E1,E2 X,K1
Sleeve(for single wire) AMP 170889-1
To O
To C
To D4
To D1
RD
RD
BKWH*
BKWH*
65F 69B 49B
1 1 2 2 2 2 2 2 2 2 2 2 Sleeve(for double wire) AMP 170890-1
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
RDGN 1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
:Plug
V S1 S2 X A A Point"c" X 76B 77B
65G 67C 32G 41B 13B 11B 34B 50B Point"c" Point"d"
(with plating) AMP 170020-2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Plug 4P Plug 2P 1 :Plug
X A A D2
Horn switch
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20
(without plating) AMP 170002-5 or
W1 (post)
WH BK
Pressed sleeve detailed drawing
D2 O D2 N2 S2 W2 A A A C C R W4 39B 14B 12B 31C
AMP 170020-3
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A
1 2 Sleeve(for double wire)AMP 170888-1
D4 Point"c" D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1
3 4 :Receptacle(with sleeve)AMP 41729
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 2
Sleeve(for single wire)AMP 170823-2
CN1 CN2 W K Lamp switch Laser pointer Sleeve(for double wire)AMP 1-170823-5
V Operation switch
3 2 1 2 1 3 2 1
1 :Receptacle AMP 173716-2 or
AMP 175061-2
4 3
Point"c"
Fork leveling switch
W2 (*Refer W4 Key
:Receptacle AMP 170032-5 or
S3 (lever)
1
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 Turn signal switch switch BURD
BK
1 A 80B AMP 179461-5
1 T 30C :Tab AMP 170340-3 or
to note 5) (*Refer to note 5)
1
X Display board
W3 Directional switch Horn switch
AMP 179462-3
S1(lever)
65E U,V
RDBK 2 :Receptacle AMP 171662-1 or
1
Plug 6P
BUWH AMP 173707-1
YERD A 25B BK
Valve
1 1
WHBU
T
67B D1,W1 1
AMP 172888-2(rubber plug)
Plug 4P 1 2 A 28B
BNWH
microswitch
RDWH 3 A 26B
WH 6J N1,N2 1 1
BKWH* YEBU
1 AMP 172748-2(seal plug)
Q
52B N1,Q 2 1 1 4 A 29B
R Accessory
YERD BUBK GNWH 3 :Receptacle AMP 316041-2 or
Converter
48B X 1 5 A 27B
75B K1 3 1 BK 1 2 3
S2 Brake
BKWH* BNBK 1 6 A,S3 30B AMP 179956-2
1 2 52C Q,M 4 1
BKWH 40B X
32E O,S2
1
4 5 6 :Receptacle Yazaki 7116-3251
oil
4
3 4 Put the sleeve 32F R,W2
BKWH
1 5 :Tab Yazaki 7114-3251
for sure receptacle. :Pressed sleeve JST FNC-2
2. : :Braided wires under 25mm pitch.
3.The location of connector pin is as viewed from the inserting side.
4.The relay should not be clamped to the harness.
Water resistant
K3 Level lamp 5.Write or impress the letters with undamped ink.
WHGN
BKWH*
RDWH
RDYE
RD
WHGN
RDWH
BKWH*
BUYE
M
2
WHBK 7.The end of the spiral tube should be tied together with wire ties,
Horn
68B D1
+ Water resistant
K2
and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
L EPS sensor
*Refer to note 7
1 1 1 1 BKWH* 2 1 Plug 2P 1 1 1 1
RDWH
WHRD
BUBK
GNWH
BKWH
Laser
RDYE
RDGN
RD
BKWH
YEBU
BNBK
YEBK
1 2 3 4 52D O,I RD 1 2 3 4 8.The end of the vinyl tube should be tied together with wire ties.
Capacitor 2 1 V 77A
V Q,K3 100V 22 BKWH* V U,K2 9.The capacitor should be soldered to the speed sensor section, as shown in
RDBK
RDWH
BKWH*
BUYE
BNYE
2 2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2 with siliconadhesive.
K1Level sensor
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B
BU F,S1 D2,N2 E2
74B 34C 33B 51B 6H 43B 56B C 1 2
YERD Plug 2P
GNWH 1 Q 75A Fuse
Plug 4P 55B C 2 2
WHRD
2
65D 52H 72B Plug 4P 10A
F P,R X A E1,E2 D4,O WH 2 V 49C
WH 3 2 1 54B C 3 2 2
WH 10A
73B 32D 42B 3B 70B 32C N2,A E2
2 1
U Accessory
6L 71B
Water resistant
1 2 Plug 6P Plug 2P Plug 6P Plug 3P 1 2
Electromagnetic GNRD RDBK
K3
3 4 BK WH RD 84B A 1 A 81B 3 4 Tie wrap
Y valve
2
WHBU GNRD
Head guard
85B A 2 2 A 82B
Tilt detector Head guard Clamp
N1 N2
BKYE 2 3 A 83B 3 2 1 Figure 1 Figure 2
(left) 1 2 3 1
2
1 2 3 (right)
4 5 6 4 5 6 Water resistant Capacitor
YE (Non polarized)
Plug 4P
Brake
P switch
Vinyl tube
Charger Yazaki 1P
57B C BU
H
4 Vinyl tube
O
2 1 A 10B
RDYE
Accelerator sensor
J EPS motor
2 A 7B Fill the inside of the vinyl
panel 7123-4113-30 2
BKYE tube with silicon adhesive.
2 3 A 9B
GN WH 2 1
4 A 8B
1P
2
58B C 5 4 3
Yazaki
7122-4113-30
Tie wrap With solder Tie wrap
Capacitor
125V 0.022 Water resistant Figure 3
Plug 4P
I Back buzzer
RD
G
10A
BK RDGN 66C D3,E2 1
BN
BKRD
2 1
3
A 21B
A 22B
Speed sensor WHBU
(Travel) 1 F 60A
2 1
BUWH AMP 174257-2
D4
73A O BKWH* 2 A 23B BUBK
52E M,D4 1
WH
2 1 2 F 61A Plug
BK RDBK 4 A 24B BKWH
(*Refer to note 9) 3 X,P 32B 6P 1 2 3 Controller
2
1
8 10A BNWH
65C D1,U
2 1 1 4 F 62A WH
4 3 BKWH 1 5 Point 52F 4 5 6
74A O BNRD
RDYE 1 6 F 64A "d"
Backward output
D3
YEBU
A 4B RDBK
61B D4 8
BUBK RDWH
BKWH*
A,
Point"a" 6M Point"d" RDWH
1
1
1
2 D2,D5 6C
D1 65A Plug
4P 1 2
relay Reference:
WHBU ,E2 52L BN
E2
Plug 60B D4 1 1 BUYE Stop & tail lamp 1 3 E1,I 66B WH Ca1a-DC48V-N Harness mark/color
1 2P BNWH BNYE
U 71A YEBK 1 4 A 5B 3 4 *Connect the relay.
62B D4
(right)
2 1
2 WH U 72A Red RD
D2
RDGN
YERD
1 1 X,W4 31B
Plug Control power supply Black BK
X 35B
relay
1 2
RD Water resistant WHBU WHBU Water resistant RDWH 1 3 A,D3 6B
4P 1 2 Green GN
F Contactor fuse
59B C 8 Plug 6P 69A V 1 1 V 69C
Plug 6P BNYE RD
Yellow YE
2 2
52K Point 2 2
BKWH* BKWH* 2 2 E2 52M
1 4
X 36B 3 4 Ca1a-DC48V-N
BNRD "d" RDWH RDWH 3 Point 6N *Connect the relay.
64B D4 8 6G P 3 RDBK White WH
E1
Stop & tail lamp
2 2
GNWH GNWH "a" 1 1 D3,F 65B
D1 Horn relay
70A P 4 2 2 4 P 70C YERD Brown BN
BN BN 1 2 S1 67A
(left) 3 2 1
6 5 4
66AD3 5 2
BUYE RDYE
2 5 I 66D 3 2 1
6 5 4
Plug
4P Blue BU
38C N1 6 2 2 6 N2 37C 1 2
Point"a" BKWH*
WHBK
1 4
Point"d"52G
,U BK
3 4 Ca1a-DC48V-N Gray GY
1 3 M 68A
*Connect the relay. Pink PK
Point"d" Be careful of the arrangement
of terminals.
Orange OG
D5
RDWH Plug
1 1 D3,D6 6D Ex) BKWH (=Black/White)
Power supply
D6 Fan
BUWH 2P 1
Fan
B
D5, RDWH BU 1 2 A 1B
Plug 6E Point"a" 1 1
8 WH 2 Black colored harness with White line.
terminal
1 2P GNWH 53A C
2B A 2 1
2 WH
RDWH
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
BURD
WHBU
YEBU
BK
RDWH
White line
WH
GNWH
BU
GNRD
WHBU
RDYE
WH
BKYE
BU
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
RDBK
GNRD
BKYE
RDYE
BKYE
WHBU
BUWH
Seal plug
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16
X X Point"a" L J F D5 P H H W3 W3 X X X G G K3 K3 T T T Y Black color
46B 45B 6F 55A 57A 59A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 81A 83A 25A 27A 29A 84A
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G K3 T S3 T T Y E2,U
47B 44B 34D 54A 56A 58A 53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 82A 26A 80A 28A 30A 85A 6O
*Refer to note 6
RDWH RDWH Reference:
To C To E2 Harness mark/color
RDBK
WHGN
WHBU
RDWH RDWH
WHRD
RD
To D6 To E2 Red RD
Black BK
Point"a" Green GN
RD
RDGN
BN
GNWH
1 1 1 1 1
BKWH
WHBU
WHRD
BUYE
RD
WHBK
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
1 2 3 4 1 2
Yellow YE
S1,W1 E1,E2 X,K1
White WH
65F 69B 49B
BKWH*
BKWH*
1 1 2 2 2 2 2 2 2 2 2 2 Brown BN
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
RDGN
RD
RD
To E1
To E2
To X
To W4
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
V S1 S2 X A A Point"c" X
Blue BU
76B 77B
65G 67C 32G 41B 13B 11B 34B 50B
Gray GY
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
X A A D2 Pink PK
Plug 4P Plug 2P
Horn switch
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20
W1(post)
D2 O D2 N2 S2 W2 A A A C C R W4 39B 14B 12B 31C WH BK Orange OG
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A
RD
RD
Ex) BKWH (=Black/White)
BKWH*
BKWH*
To O
To C
To D4
To D1
D4 Point"c" D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1 2 1
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 Black colored harness with White line.
2
CN1 CN2 3 2 1
W 2 1 3 2 1
K Laser switch Laser pointer Point"c" Point"d"
Point"c"
V Operation switch
4 3
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 Turn signal switch W4(*Refer
Key switch Pressed sleeve detailed drawing
(*Refer to note 5) to note 5)
Valve White line
W3 Directional switch T
X Display board Horn switch
microswitch
S1(lever)
RDBK
65E U,V 1
Plug 6P
BUWH
YERD 1 1 A 25B BK
Plug 4P 77A 67B D1,W1 1 WHBU 1 2 A 28B Black color
RDWH BNWH
6J N1,N2 1 1 1 3 A 26B
WH BKWH* YEBU
Q Converter
52B N1,Q 2 1 1 4 A 29B
R Accessory
YERD BUBK GNWH
48B X 1 5 A 27B
75B K1 3 1 BK 1 2 3
S2 Brake oil
BKWH* BNBK 1 6 A 30B
1 2 52C Q,M 4 1
BKWH 40B X
32E O,S2
1
4 5 6
3 4 BKWH
Put the sleeve 32F R,W2 1
<Note>
K3 Level lamp
RD Water resistant
1.Terminal symbols
WHGN
BKWH*
1 V 77C
RDWH
RDYE
WHGN
RDWH
BKWH*
BUYE
2
BKWH* Plug 2P
2 2
N1 52N :Receptacle
M
WHBK (with plating) AMP 170021-2
68B D1
+ Water resistant
Horn
K2
*Refer to note 7
:Receptacle
L EPS sensor
2 1
Plug 2P
RDWH
WHRD
BUBK
GNWH
1 1 1 1 BKWH* 1 1 1 1 1
BKWH
Laser
RDYE
RDGN
RD
BKWH
YEBU
BNBK
YEBK
52D O,I
1 2 3 4
Capacitor RD 2 1 V 77A
1 2 3 4 (without plating) AMP 170003-5 or
BKWH*
BKWH*
RDBK
RDWH
BUYE
BNYE
V Q,K3 100V 22 V U,K2 AMP 170021-3
2 2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Sleeve(for single wire) AMP 170889-1
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2 Sleeve(for double wire) AMP 170890-1
K1Level sensor
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B
:Plug
BU F,S1 D2,N2 E2
74B 34C 33B 51B 6H 43B 56B C 1 2
YERD Plug 2P
Plug 4P 55B C 2 2
GNWH
WHRD
2 1 Q 75A Plug 4P (with plating) AMP 170020-2
F P,R X A E1,E2 D4,O WH 2 N2 49C 65D 52H 72B
WH 3 2 1 54B C 3 2 2
N2,E2 E2 WH 1 :Plug
73B 32D 42B 3B 70B 32C
2 1
6L 71B
(without plating) AMP 170002-5 or
AMP 170020-3
U Accessory
1 2 Plug 6P Plug 2P Plug 6P 1 2
Sleeve(for double wire) AMP 170888-1
3 4 BK WH RD 3 4 :Receptacle(with sleeve) AMP 41729
Water resistant
Head guard Head guard
N1
Plug 4P
N2 (right)
1P 57B C
YE
BU Sleeve(for single wire) AMP 170823-2
I Back buzzer
BN 125V 0.022 Water resistant
66C D3,E2 1
Plug 4P :Receptacle AMP 171662-1 or
RD 2
G
52E M,D4 1
BKWH* BKRD
2 1
3
A 21B
A 22B
Speed sensor AMP 173707-1
(Travel)
2
BK RDGN BUWH AMP 174257-2 AMP 172888-2(rubber plug)
10A 2 2 A 23B
WH
73A O 2 4 A 24B
(*Refer to note 9) AMP 172748-2(seal plug)
2 1
8 10A
BK RDBK
4 3
3 :Receptacle AMP 316041-2 or
65C D1,U AMP 179956-2
74A O :Receptacle Yazaki 7116-3251
RDYE 4
YEBU
A 4B
5 :Tab Yazaki 7114-3251
BUBK RDWH U,
61B D4 8 Point"a"
6M :Pressed sleeve JST FNC-2
BKWH* Point"d" 52L
WHBU 2. : :Braided wires under 25mm pitch.
E2
1
Plug 60B D4
2P
1 1
BNWH
BUYE
BNYE
U 71A
,E2
Stop & tail lamp
3.The location of connector pin is as viewed from the inserting side.
62B D4
(right)
2 1
2 WH U 72A
4.The relay should not be clamped to the harness.
5.Write or impress the letters with undamped ink.
RD Water resistant WHBU WHBU Water resistant
Contactor
F fuse
59B C 8 Plug 6P 69A V 1 2 2 1 V 69C Plug 6P 6.Fuses should be placed in a circle, as shown in the figure 1.
BKWH* BKWH*
52K Point 2 2 2 2 E2 52M 7.The end of the spiral tube should be tied together with wire ties,
BNRD "d" RDWH RDWH 3Point
64B D4 8 6G P 3 6N
E1
Stop & tail lamp
2 2
70A P 4 2
GNWH GNWH 2 4 "a" P 70C and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
BN BN
(left) 3 2 1
6 5 4
66AD3 5 2
BUYE RDYE
2 5 I 66D 3 2 1
6 5 4
8.The end of the vinyl tube should be tied together with wire ties.
38C N1 6 6 N2 37C WHBU 9.The capacitor should be soldered to the speed sensor section, as shown in
Point"a"
2 2
1 1 F 60A
BUBK
D4
1 2 F 61A Plug Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
BKWH X,P 32B 6P
1 3 1 2 3
BNWH 4 F 62A WH Controller with siliconadhesive.
Point"d"
1
BKWH 4 5 6
D6 Fan
D5,
1 5 Point 52F
Plug RDWH BU BNRD
6E Point"a" 1 1 1 6 F 64A "d" Fuse
GNWH 53A C 8
Backward output
D3
1 2P 2B A 2 1 10A
Power supply
2 WH RDBK
B
RDWH
1
1
1
2 D2,D5 6C
D1 65A Plug
4P 1 2
relay 10A
terminal BN
YEBK
1 3 E1,I 66B WH
3 4
Ca1a-DC48V-N
1 4 A 5B *Connect the relay.
RDGN Tie wrap
Control power supply
D2
1 1 X,W4 31B
YERD Plug Clamp
X 35B
relay
1 2
RDWH 4P
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
WHBU
YEBU
BK
1 3 A,D3 6B 1 2 Figure 1 Figure 2
BNYE RD
1 4
X 36B 3 4 Ca1a-DC48V-N
RDBK *Connect the relay. Capacitor
WH
GNWH
BU
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
YERD
D1 Horn relay
RDYE
BKYE
WHBU
BUWH
D5
X X Point"c" L L J B H H W3 W3 X X X G G T T T 1 1 D3,D6 6D 2P 1 Figure 3
BUWH 2
47B 44B 34D 54A 56A 58A 53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 26A 28A 30A 1 2 A 1B WH
Fan
CN1 CN2 CN3 CN4
Water resistant 2P-X 2P-Y
Plug 10P Receptacle Receptacle
5 4 3 2 1
10 9 8 7 6
6 5 4 3 2 1
12 11 10 9 8 7
1
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
2
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
3
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
4
FB-CA Body harness 4- 3.
C EPS unit A MPU board
Write or impress the numbers
with undamped ink.
FB20CA-28CA
(Std/CS/FCS/RP/DRP) 4-3-3.
77
4 Wiring and main controller layout
*Refer to note 6
<Note>
1.Terminal symbols
BKWH*
BKWH*
To E1
To E2
To X
To W4
RD
RD
RDWH RDWH
To C To E2 :Receptacle
RDBK
WHGN
WHBU
WHRD
RD
RDWH RDWH (with plating) AMP 170021-2
To D6 To E2 1 :Receptacle
(without plating) AMP 170003-5 or
RD
RDGN
BN
1 1 1 1 1
Point"a"
BKWH
WHBU
WHRD
GNWH
BUYE
RD
WHBK
RD
BUBK
WHRD
BN
BNBK
RDBK
YERD
RDGN
BKWH
YEBU
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK 1 2 3 4 1 2
AMP 170021-3
S1,W1 E1,E2 X,K1
Sleeve(for single wire) AMP 170889-1
To O
To C
RD
RD
To D4
To D1
BKWH*
BKWH*
65F 69B 49B
RDGN 1 1 2 2 2 2 2 2 2 2 2 2 Sleeve(for double wire) AMP 170890-1
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
:Plug
V S1 S2 X A A Point"c" X 76B 77B
65G 67C 32G 41B 13B 11B 34B 50B Point"c" Point"d"
(with plating) AMP 170020-2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Plug 4P Plug 2P 1 :Plug
X A A D2
Horn switch
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20
(without plating) AMP 170002-5 or
W1 (post)
WH BK
Pressed sleeve detailed drawing
D2 O D2 N2 S2 W2 A A A C C R W4 39B 14B 12B 31C
AMP 170020-3
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A
1 2 Sleeve(for double wire) AMP 170888-1
D4 Point"c"D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1
Plug 3P Plug 4P Plug 3P 3 4 :Receptacle(with sleeve) AMP 41729
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A 2
Sleeve(for single wire) AMP 170823-2
CN1 CN2 W K Lamp switch Laser pointer Sleeve(for double wire) AMP 1-170823-5
VOperation switch
3 2 1 2 1 3 2 1
1 :Receptacle AMP 173716-2 or
AMP 175061-2
4 3
Point"c"
Fork leveling switch
W2 Turn W4 Key
:Receptacle AMP 170032-5 or
S3 (lever)
1
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 signal switch switch BURD
BK
1 A 80B AMP 179461-5
1 T 30C :Tab AMP 170340-3 or
(*Refer to note 5) (*Refer to note 5)
1
S1(lever)
U,V
RDBK 2 :Receptacle AMP 171662-1 or
1
Plug 6P
YERD
BUWH
WHBU
1 1 A 25B BK Valve AMP 173707-1
T microswitch
67B D1,W1 1
AMP 172888-2(rubber plug)
Plug 4P 1 2 A 28B
RDWH BNWH
6J N1,N2 1 1 3 A 26B AMP 172748-2(seal plug)
WH 1
BKWH* YEBU
Q Converter
52B N1,Q 2 1 4 A 29B
R Accessory
1
YERD 48B X
BUBK GNWH 1 5 A 27B
3 :Receptacle AMP 316041-2 or
75B K1 3 1 BK 1 2 3
S2 Brake oil
BKWH* BNBK 1 6 A,S3 30B AMP 179956-2
1 2 52C Q,M 4 1 BKWH 40B X
32E O,S2
1
4 5 6 4 :Receptacle Yazaki 7116-3251
3 4 BKWH
Put the sleeve 32F R,W2 1 5 :Tab Yazaki 7114-3251
for sure receptacle. :Pressed sleeve JST FNC-2
2. : :Braided wires under 25mm pitch.
3.The location of connector pin is as viewed from the inserting side.
4.The relay should not be clamped to the harness.
RD
Water resistant
K3 Level Lamp 5.Write or impress the letters with undamped ink.
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
2 1 V 77C Plug 2P 6.Fuses should be placed in a circle, as shown in the figure 1.
BKWH* 2 2
N1 52N
M
WHBK 7.The end of the spiral tube should be tied together with wire ties,
Horn
68B D1
+ Water resistant
K2 Laser
and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
*Refer to note 7
LEPS sensor
Plug 2P
RDWH
WHRD
BUBK
GNWH
BKWH
1 1 1 1 BKWH* 2 1 1 1 1 1
RDYE
RDGN
RD
BKWH
YEBU
BNBK
YEBK
1 2 3 4 52D O,I RD 1 2 3 4 8.The end of the vinyl tube should be tied together with wire ties.
Capacitor 2 1 V 77A
V Q,K3 100V 22 BKWH* V U,K2 9.The capacitor should be soldered to the speed sensor section, as shown in
RDBK
RDWH
BKWH*
BUYE
BNYE
2 2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2 with siliconadhesive.
K1Level sensor
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B
BU F,S1 D2,N2 E2
74B 34C 33B 51B 6H 43B 56B C 1 2
YERD Plug 2P
GNWH 1 Q 75A Fuse
Plug 4P 55B C 2 2
WHRD
2
65D 52H 72B Plug 4P 10A
F P,R X A E1,E2 D4,O WH 2 V 49C
WH 3 2 1 54B C 3 2 2
WH 10A
73B 32D 42B 3B 70B 32C N2,A E2
2 1
6L 71B
U
Water resistant
1 2 1 2
Plug 6P Plug 2P Plug 6P
Electromagnetic GNRD RDBK
Plug 3P Accessory
K3
3 4 BK WH RD 84B A 2 1 A 81B 3 4 Tie wrap
Y valve
WHBU GNRD
Head guard
85B A
BKYE
2 2 A 82B
Tilt detector Head guard
Clamp
N1 (left) N2 (right)
2 3 A 83B 3 2 1 Figure 1 Figure 2
1 2 3 1 1 2 3
4 5 6 2 4 5 6 Water resistant Capacitor
(Non polarized)
Charger Brake 1P 57B C
YE BU Plug 4P Vinyl tube
H
4 Vinyl tube
Yazaki 1 A 10B
O panel P
2
RDYE
Accelerator sensor
J EPS motor
7123-4113-30 2 A 7B Fill the inside of the vinyl
switch
2
BKYE tube with silicon adhesive.
2 3 A 9B
GN WH 2 1
2 4 A 8B
1P 58B C 5 4 3
Yazaki
7122-4113-30
Tie wrap With solder Tie wrap
Capacitor
125V 0.022 Water resistant Figure 3
Plug 4P
I Back buzzer
RD
Speed sensor
G (Travel)
BK RDGN BN 1 A 21B
66C D3,E2 1
BKRD
2
10A 3 A 22B WHBU
73A O BUWH
2
AMP 174257-2 1 1 F 60A
BUBK
D4
BKWH* 2 A 23B F 61A Plug
52E M,D4 1
WH
2
1 2
BK RDBK 4 A 24B BKWH
(*Refer to note 9) 3 X,P 32B 6P 1 2 3 Controller
2
8 1
10A BNWH WH
65C D1,U
2 1 1 4 F 62A
4 3 BKWH 1 5 Point 52F 4 5 6
74A O BNRD
RDYE 1 6 F 64A "d"
Backward output
D3 relay
YEBU
BUBK A, A 4B RDBK Plug
61B D4 8 RDWH 1 1 D1 65A
BKWH* Point"a" 6M Point"d" RDWH 1 2 D2,D5 6C 4P 1 2
WHBU ,E2 52L BN
E2 (right)
Plug 60B D4 1 1 BUYE Stop & tail lamp 1 3 E1,I 66B WH Ca1a-DC48V-N
1 2P BNWH BNYE
U 71A YEBK 1 4 A 5B 3 4 *Connect the relay.
2 62B D4 2 1
U 72A
WH
RDGN
Control power supply
D2 relay
1 1 X,W4 31B
YERD Plug
RD Water resistant WHBU WHBU Water resistant RDWH
1
1
2
3
X 35B
A,D3 6B
4P 1 2 Reference:
F
Contactor 59B C 8 Plug 6P 69A V
52K Point2
1 2
BKWH* BKWH*
2 1 V
2
69C
E2 52M
Plug 6P BNYE 1 4
X 36B
RD
3 4 Ca1a-DC48V-N Harness mark/color
fuse
2 2
BNRD "d" 3 RDWH RDWH 3Point *Connect the relay.
64B D4 8 6G P 6N RDBK Red RD
E1
Stop & tail lamp
2 2
GNWH GNWH "a" 1 1 D3,F 65B
YERD
D1 Horn relay
70A P 4 2 2 4 P 70C Black BK
BN BN 1 2 S1 67A
(left) 3 2 1
6 5 4
66AD3 5 2
BUYE RDYE
2 5 I 66D 3 2 1
6 5 4
Plug
4P Green GN
38C N1 6 6 N2 37C 1 2
Point"a"
2 2
BKWH* Point"d"
WHBK
1 4 ,U 52G BK
3 4 Ca1a-DC48V-N Yellow YE
1 3 M 68A
*Connect the relay. White WH
Point"d" Be careful of the arrangement
of terminals.
Brown BN
Blue BU
D5 Fan
RDWH Plug
1 1 D3,D6 6D Gray GY
Power supply
D6 Fan
BUWH 2P 1
B terminal
D5, RDWH BU 1 2 A 1B
1
Plug 6E Point"a" 1 1
GNWH 53A C 8 WH 2 Pink PK
2P 2B A 2 1
2 WH Orange OG
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
BURD
WHBU
YEBU
BK
RDWH
WH
GNWH
BU
RDYE
WH
BKYE
BU
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
GNRD
WHBU
RDYE
BKYE
WHBU
BUWH
RDBK
GNRD
BKYE
Seal plug
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 White line
X X Point"a" L J F D5 P H H W3 W3 X X X G G K3 K3 T T T Y
46B 45B 6F 55A 57A 59A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 81A 83A 25A 27A 29A 84A
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G K3 T S3 T T Y E2,U
47B 44B 34D 54A 56A 58A 53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 82A 26A 80A 28A 30A 85A 6O
Black color
CN1 CN2 CN3 CN4 CN11 CN12
Water resistant 2P-X 2P-Y
Plug 10P Receptacle Receptacle
FB20CA-28CA
(Automated fork horizontal stop) 4-3-4.
78
Wiring and main controller layout 4
*Refer to note 6
RDWH RDWH
Reference:
To C To E2 Harness mark/color
RDWH RDWH Red RD
RDBK
WHGN
WHBU
WHRD
RD
To D5 To E2
Black BK
Point"a" Green GN
GNWH
RD
RDGN
BN
1 1 1 1 1 Yellow YE
BKWH
WHBU
WHRD
BUYE
RD
WHBK
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
1 2 3 4 1 2
White WH
S1,W1 E1,E2 X,K1
Brown BN
BKWH*
BKWH*
65F 69B 49B
RDGN
2 2 2 2 2 2 2 2 2 2
Blue BU
RD
RD
To E1
To E2
To X
To W4
1 1
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3
V S1 S2 X A A Point"c" X 76B 77B
Gray GY
65G 67C 32G 41B 13B 11B 34B 50B Pink PK
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
X A A D2 Plug 4P Plug 2P Orange OG
Horn switch
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20
W1(post) WH BK
D2 O D2 N2 S2 W2 A A A C C R W4 39B 14B 12B 31C
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A Ex) BKWH (=Black/White)
RD
RD
BKWH*
BKWH*
To O
To C
To D4
To D1
D4 Point"c" D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1 2 1
Black colored harness with White line.
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 2
CN1 CN2 3 2 1
W 2 1 3 2 1
K Lamp switch Laser pointer
Point"c" Point"d"
Point"c"
V Operation switch
4 3
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 W2 Turn signal switch W4 Key switch Pressed sleeve detailed drawing
(*Refer to note 5) (*Refer to note 5) White line
Valve
X Display board W3 Directional switch T microswitch
Horn switch
S1
RDBK
65E U,V 1
Plug 6P
(lever) 67B D1,W1 1
YERD
BUWH
WHBU
1 1 A 25B BK
Black color
Plug 4P 1 2 A 28B
RDWH BNWH
6J N1,N2 1 1 3 A 26B
WH 1
BKWH* YEBU
Q Converter
52B N1,Q 2 1 4 A 29B
R Accessory
1 BUBK GNWH
YERD 48B X 1 5 A 27B
75B K1 3 1 BK 1 2 3
S2 Brake oil
BKWH* BNBK 1 6 A 30B
1 2 52C Q,M 4 1 BKWH 40B X
32E O,S2
1
4 5 6
3 4 BKWH
Put the sleeve 32F R,W2 1
Water resistant
<Note>
K3
RD 1.Terminal symbols
2 1 V 77C Plug 2P
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
BKWH* 2 2
N1 52N Level lamp : Receptacle
M Horn
WHBK (with plating) AMP 170021-2
68B D1
+
L EPS sensor
2 1
*Refer to note 7
1 1 1 1 BKWH* Water resistant 1 1 1 1 1 : Receptacle
RDWH
WHRD
BUBK
GNWH
BKWH
RDYE
RDGN
RD
BKWH
YEBU
BNBK
YEBK
K2 Laser
52D O,I
1 2 3 4
Capacitor RD 2 1 V 77A Plug 2P 1 2 3 4 (without plating) AMP 170003-5 or
V Q,K3 BKWH* V U,K2
RDBK
RDWH
BKWH*
BUYE
BNYE
100V 22 AMP 170021-3
2 2
N2 52J
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I Sleeve(for single wire) AMP 170889-1
P,Q X,E1 2 1 Q,U X,E2
1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Sleeve(for double wire) AMP 170890-1
K1 Level sensor
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B
: Plug
BU F,S1
74B 34C 33B 51B 6H 43B 56B C 1 2
YERD Plug 2P D2,N2 E2
Plug 4P 55B C 2 2
GNWH
WHRD
2 1 Q 75A Plug 4P (with plating) AMP 170020-2
F P,R X A E1,E2 D4,O WH 2 N2 49C 65D 52H 72B
WH 3 2 1 54B C 3 2 2
N2,E2 E2 WH 1 : Plug
73B 32D 42B 3B 70B 32C
2 1
6L 71B
(without plating)AMP 170002-5 or
AMP 170020-3
U Accessory
1 2 Plug 6P Plug 2P Plug 6P 1 2
Sleeve(for double wire)
AMP 170888-1
3 4 BK WH RD 3 4 : Receptacle(with sleeve)
AMP 41729
Water resistant
Head guard Head guard
N1 N2 (right)
1P 57B C
YE
BU Plug 4P Sleeve(for single wire)
AMP 170823-2
O Charger panel
5 4 3
P
Yazaki : Receptacle AMP 170032-5 or
Brake switch
1
7122-4113-30
AMP 179461-5
1 : Tab AMP 170340-3 or
Capacitor
AMP 179462-3
I Back buzzer
BN 125V 0.022 Water resistant
66C D3,E2 1
: Receptacle AMP 171662-1 or
RD Plug 4P 2
G (Travel)
52E M,D4 1
BKWH* BKRD
2
2
1
3
A 21B
A 22B
Speed sensor AMP 173707-1
BK RDGN BUWH AMP 174257-2 AMP 172888-2(rubber plug)
BK* Length 100 10A 2 2 A 23B
WH
73A O 2 4 A 24B
(*Refer to note 9) AMP 172748-2(seal plug)
2 1
10A
BK RDBK
4 3
3 : Receptacle AMP 316041-2 or
65C D1,U AMP 179956-2
74A O : Receptacle Yazaki 7116-3251
RDYE(Length 300) 4
YEBU
A 4B
5 : Tab Yazaki 7114-3251
BUBK(Length 200) RDWH U,
61B D4 8 Point"a" 6M Point"d" : Pressed sleeve JST FNC-2
BKWH*
,E2 52L 2. : :Braided wires under 25mm pitch.
WHBU
Stop & tail lamp
E2 (right)
Plug 60B D4 1 1 BUYE
1 2P BNWH U 71A
62B D4 2 1 BNYE 3.The location of connector pin is as viewed from the inserting side.
2 WH U 72A
4.The relay should not be clamped to the harness.
5.Write or impress the letters with undamped ink.
RD Water resistant WHBU WHBU Water resistant
Contactor
F fuse
59B C 8 Plug 6P 69A V 1 2 2 1 V 69C Plug 6P 6.Fuses should be placed in a circle, as shown in the figure 1.
BKWH* BKWH*
52K Point 2 2 2 2 E2 52M 7.The end of the spiral tube should be tied together with wire ties,
BNRD "d" RDWH RDWH 3Point
64B D4 8
Stop & tail lamp 6G P 3 6N
E1
2 2
70A P 4 2
GNWH GNWH 2 4
"a"
P 70C and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
BN BN
(left) 3 2 1
6 5 4
66AD3 5 2
BUYE RDYE
2 5 I 66D 3 2 1
6 5 4
8.The end of the vinyl tube should be tied together with wire ties.
38C N1 6 2 2 6 N2 37C WHBU
Point"a" BUBK
1 1 F 60A 9.The capacitor should be soldered to the speed sensor section, as shown in
D4 Controller
1 2 F 61A Plug Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
BKWH X,P 32B 6P
BNWH
1 3 1 2 3 with siliconadhesive.
4 F 62A WH
Point"d"
1
BKWH 4 5 6
D6 Fan
1 5 Point 52F
D5, 1 1 RDWH BNRD
Plug 6E Point"a" BU 1 6 F 64A "d" Fuse
GNWH 53A C 8
Backward output
D3 relay
1 2P 2B A 2 1 10A
2 WH
Power supply RDBK Plug 10A
B terminal
1 1 D1 65A
RDWH 4P
BN
1 2 D2,D5 6C 1 2
1 3 E1,I 66B WH Ca1a-DC48V-N
YEBK 1 4 A 5B 3 4 *Connect the relay.
RDGN Tie wrap
Control power supply
D2 relay
1 1 X,W4 31B
YERD Plug Clamp
1 2 X 35B
RDWH 4P
RD
RDWH
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
WHBU
YEBU
BK
1 3 A,D3 6B 1 2 Figure 1 Figure 2
BNYE RD
1 4
X 36B 3 4 Ca1a-DC48V-N
RDBK *Connect the relay. Capacitor
WH
GNWH
BU
WHGN
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
YERD
D1Horn relay
RDYE
BKYE
WHBU
BUWH
D5 Fan
X X Point"c" L L J B H H W3 W3 X X X G G T T T 1 1 D3,D6 6D 2P 1 Figure 3
BUWH 2
47B 44B 34D 54A 56A 58A 53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 26A 28A 30A 1 2 A 1B WH
1 2 3 4
5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
10 9 8 7 6
12 11 10 9 8 7 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
<Note>
*Refer to note 6 1.Terminal symbols
:Receptacle
BKWH*
BKWH*
To E1
To E2
To X
To W4
RDWH RDWH
RD
RD
(with plating) AMP 170021-2
To C To E2
RDBK
WHGN
WHBU
WHRD
RD
RDWH RDWH 1 :Receptacle
To D6 To E2 (without plating) AMP 170003-5 or
AMP 170021-3
1 1 1 1 1
Point"a"
GNWH
BUYE
RD
WHBK
RD
RDGN
BN
BKWH
WHBU
WHRD
RDGN
BKWH
YEBU
RD
YERD
BNYE
RDYE
BUYE
WHBU
BNBK
WHRD
YEBK
BUBK
BUBK
WHRD
BN
BNBK
RDBK
YERD
1 2 3 4 1 2 Sleeve(for single wire) AMP 170889-1
S1,W1 E1,E2 X,K1 Sleeve(for double wire) AMP 170890-1
To O
To C
BKWH*
BKWH*
To D4
To D1
RD
RD
2 2 2 2 2 2 2 2 2 2 65F 69B 49B :Plug
RDGN
BK
BUYE
WHGN
YERD
WHRD
BUWH
WHBU
RDYE
BKYE
1 1
1 2 3 1 2 3 4 1 2 3 N1,N2 K2,K3 (with plating) AMP 170020-2
V S1 S2 X A A Point"c" X 76B 77B :Plug
65G 67C 32G 41B 13B 11B 34B 50B Point"c" Point"d"
1
(without plating)
AMP 170002-5 or
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
X A A D2 Plug 4P Plug 2P
AMP 170020-3
Horn switch
1 9 2 10 3 11 4 12 5 6 7 8 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 9 10 18 19 20
WH BK
W1(post) Pressed sleeve detailed drawing
D2 O D2 N2 S2 W2 A A A C C R W4 39B 14B 12B 31C
Sleeve(for double wire) AMP 170888-1
31A 33A 35A 37A 40A 41A 19B 16B 18B 44A 46A 48A 50A
:Receptacle(with sleeve) AMP 41729
D4 Point"c" D2 N1 W2 O P A A A C C V O Water resistant Water resistant Water resistant 1 2 1 Sleeve(for single wire) AMP 170823-2
32A 34A 36A 38A 39A 42A 43A 20B 15B 17B 45A 47A 49A 51A Plug 3P Plug 4P Plug 3P 3 4 2 Sleeve(for double wire) AMP 1-170823-5
CN1
:Receptacle AMP 173716-2 or
CN2 W K Lamp switch Laser pointer 1
V Operation switch
AMP 175061-2
3 2 1 2 1 3 2 1
:Receptacle AMP 170032-5 or
Point"c"
1
4 3
Fork leveling switch
W2 (*Refer W4 Key
AMP 179461-5
S3 (lever)
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 Turn signal switch switch BURD
BK 1
1 A 80B
T 30C
1 :Tab AMP 170340-3 or
AMP 179462-3
to note 5) (*Refer to note 5) :Receptacle AMP 171662-1 or
X
Display 2
W3 switch
Directional Horn switch AMP 173707-1
S1 (lever)
RDBK
board 65E U,V 1
Plug 6P AMP 172888-2(rubber plug)
BUWH
YERD
WHBU
1 1 A 25B BK Valve AMP 172748-2(seal plug)
T
67B D1,W1 1
Plug 4P 1 2 A 28B
BNWH
microswitch
RDWH 1 3 A 26B 3 :Receptacle AMP 316041-2 or
WH 6J N1,N2 1 1 YEBU
BKWH*
Q Converter
52B N1,Q 2 1 1 4 A 29B AMP 179956-2
R Accessory
YERD BUBK GNWH
48B X 1 5 A 27B
75B K1 3 1 BK 1 2 3 :Receptacle Yazaki 7116-3251
Brake
S2
BKWH* BNBK 1 6 A,S3 30B 4
1 2 52C Q,M 4 1
BKWH 40B X
32E O,S2
1
4 5 6 5 :Tab Yazaki 7114-3251
3 4
Put the sleeve
oil 32F R,W2 1
BKWH :Pressed sleeve JST FNC-2
for sure receptacle. 2. : :Braided wires under 25mm pitch.
3.The location of connector pin is as viewed from the inserting side.
4.The relay should not be clamped to the harness.
5.Write or impress the letters with undamped ink.
RD
Water resistant
K3 Level lamp 6.Fuses should be placed in a circle, as shown in the figure 1.
WHGN
RDWH
BKWH*
BUYE
WHGN
RDWH
BKWH*
RDYE
2 1 V 77C Plug 2P 7.The end of the spiral tube should be tied together with wire ties,
BKWH* 2 2
N1 52N
M Horn
WHBK and then the tube should be coiled with a gap of 2 1mm.(Refer to Figure 2).
68B D1
+ Water resistant
K2
8.The end of the vinyl tube should be tied together with wire ties.
*Refer to note 7
L EPS sensor
1 1 1 1 2 1 Plug 2P 1 1 1 1
RDYE
RDGN
RD
YEBU
BKWH*
BKWH
Laser
BNBK
YEBK
RDWH
WHRD
BUBK
GNWH
BKWH
1 2 3 4 52D O,I RD 1 2 3 4 9.The capacitor should be soldered to the speed sensor section, as shown in
Capacitor 2 1 V 77A
V Q,K3 BKWH* V U,K2 Fig. 3. The inside of the vinyl tube covering the capacitor should be filled
RDBK
RDWH
BKWH*
BUYE
BNYE
100V 22 2 2
N2 52J 2 1
76A 52A 1 1 1 1 1 1 1 1 1 1 1 1 76C 52I with siliconadhesive.
P,Q X,E1 1 2 3 4 5 6 1 2 1 2 3 4 5 6 Water resistant Q,U X,E2
K1Level sensor
6I 38B F Point"c" X X E1,N1 X Plug 3P Water resistant 6K 37B Fuse
BU F,S1 D2,N2 E2 10A
74B 34C 33B 51B 6H 43B 56B C 1 2
YERD Plug 2P
55B C 2
GNWH 2 1 Q 75A 10A
Plug 4P F P,R X A E1,E2 D4,O
2
WH WHRD 65D 52H 72B Plug 4P
54B C 3 2 2 2 V 49C
WH 73B 32D 42B 3B 70B 32C 3 2 1 N2,A E2 WH
2 1
6L 71B
U Accessory
Water resistant Tie wrap
1 2 Plug 6P Plug 2P Plug 6P Plug 3P 1 2
Electromagnetic GNRD RDBK Clamp
K3
3 4 BK WH RD 84B A 1 A 81B 3 4
Y valve
2
WHBU GNRD Figure 1 Figure 2
Head guard
85B A 2 2 A 82B
Tilt detector Head guard
N2 (right)
BKYE
N1 (left)
2 3 A 83B 3 2 1
1 2 3 1 1 2 3 Capacitor
(Non polarized)
4 5 6 2 4 5 6 Water resistant Vinyl tube Vinyl tube
Charger Plug 4P
YE
Brake 1P 57B C BU Fill the inside of the vinyl
O P H Accelerator sensor
4
Yazaki RDYE
2 1 A 10B tube with silicon adhesive.
panel switch
J EPS motor
7123-4113-30 2 2 A 7B
BKYE 2 3 A 9B
GN WH 2 1
4 A 8B
1P
2
58B C 5 4 3
Yazaki Tie wrap With solder Tie wrap
7122-4113-30
Figure 3
Capacitor
125V 0.022 Water resistant
Plug 4P
I Back buzzer
RD
G (Travel)
BK* Length 100 10A
BK RDGN 66C D3,E2 1
BN
BKRD
2 1
3
A 21B
A 22B
Speed sensor WHBU
73A O BUWH
2
AMP 174257-2 1 1 F 60A
BUBK
D4 Controller
BKWH* 2 A 23B F 61A Plug
52E M,D4 1
WH
2
1 2
BK RDBK 4 A 24B BKWH
(*Refer to note 9) 3 6P 1 2 3
2
1 X,P 63B
10A BNWH WH
65C D1,U
2 1 1 4 F 62A
4 3 BKWH 1 5 Point 52F 4 5 6
74A O BNRD "d"
RDYE(Length 300) 1 6 F 64A
Backward output
D3 relay
YEBU
BUBK(Length 200) A, A 4B RDBK Plug
61B D4 8 RDWH 1 1 D1 65A
BKWH* Point"a" 6M Point"d" RDWH 1 2 D2,D5 6C 4P 1 2
WHBU ,E2 52L BN
E2 (right)
Plug 60B D4 1 1 BUYE Stop & tail lamp 1 3 E1,I 66B WH Ca1a-DC48V-N
1 2P BNWH BNYE
U 71A YEBK 1 4 A 5B 3 4 *Connect the relay.
2 62B D4 2 1
U 72A
WH
RDGN
Control power supply
D2 relay
1 1 X,W4 31B
YERD Plug
1 2 X 35B
RD Water resistant Water resistant RDWH 4P 1 2
WHBU WHBU 3 A,D3 6B
Contactor
1
F
59B C 8 Plug 6P 69A V 1 2 2 1 V 69C Plug 6P BNYE RD
52K
Point"d"
2 BKWH* BKWH* 2 E2 52M
1 4
X 36B 3 4 Ca1a-DC48V-N
fuse
2 2
BNRD RDWH RDWH 3Point *Connect the relay.
64B D4 8 6G P 3 6N RDBK
E1 (left)
Stop & tail lamp
2 2
GNWH GNWH "a" 1 1 D3,F 65B
YERD Reference:
D1 Horn relay
70A P 4 2 2 4 P 70C
3 2 1 BN BN 3 2 1 1 2 S1 67A Plug
66AD3 5 2 2 5 I 66D
6 5 4 BUYE RDYE 6 5 4 4P Harness mark/color
38C N1 6 6 N2 37C 1 2
Point"a"
2 2
BKWH* Point"d"
WHBK
1 4 ,U 52G BK
3 4 Ca1a-DC48V-N Red RD
1 3 M 68A
*Connect the relay. Black BK
Point"d" Be careful of the arrangement
of terminals.
Green GN
Yellow YE
D5 Fan
RDWH Plug
Power supply D3,D6 6D White WH
1 1
D6 Fan
1
B terminal
BUWH 2P
Plug D5, RDWH BU 1 2 A 1B
1
6E Point"a" 1 1
GNWH 53A C 8 WH 2 Brown BN
2P 2B A 2 1
2 WH Blue BU
Gray GY
Pink PK
RDWH Orange OG
YE
GN
RD
BU
BUWH
GNWH
WHRD
YEBU
YEBK
RDWH
RD
WHBK
GNWH
BUYE
BUWH
BNWH
GNWH
BURD
WHBU
YEBU
BK
RDWH
Black colored harness with White line.
WH
GNWH
BU
WHGN
GNRD
RDYE
WH
BKYE
BU
BUYE
WHRD
YERD
RDGN
BK
RD
BKRD
BUWH
WH
WHBU
RDYE
BKYE
WHBU
BUWH
RDBK
GNRD
BKYE
Seal plug
2 2 2 2 2 2 2 2 2 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 9 10 3 11 4 12 5 13 6 14 7 8 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 9 3 10 11 4 5 6 7 8 12 13 14 15 16
X X Point"a" L J F D5 P H H W3 W3 X X X G G K3 K3 T T T Y
46B 45B 6F 55A 57A 59A 1A 3A 7A 9A 11A 13A 15A 17A 19A 21A 23A 81A 83A 25A 27A 29A 84A
X X Point"c" L L J B D6 E2 D3 D2 H H W3 W3 X X X G G K3 T S3 T T Y E2,U White line
47B 44B 34D 54A 56A 58A 53B 2A 4A 5A 6A 8A 10A 12A 14A 16A 18A 20A 22A 24A 82A 26A 80A 28A 30A 85A 6O
1 2 3 4 11 12
5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
Black color
10 9 8 7 6
12 11 10 9 8 7 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
FB30CA
(Automated fork horizontal stop) 4-3-6.
80
Wiring and main controller layout 4
<Note>
1. This diagram shows that IGBT is a 400A item. 3. The connection of the IGBT gate connectors should be made according to the
When it is a 600A item, even though the size of following drawings.
the IGBT is different, the wiring is all the same.
The connectors should be connected so
2.Terminal symbols that the ribs to prevent incorrect connection
6 :Terminal 1.25-6
G2
are facing the outside of the IGBT.
(Both white and black)
E2
*Refer to note 3
T CN5 PB100- XX
CN1 CN2
GNRD G2
2P
G2
2P
G2
2P
WH WH WH
E2 E2 E2
CN3
F+ 2P
E1 E1 E1
2P 2P
Battery(+) 6 BK BK BK
G1 G1 G1
CN4
CN9 CN10
CN7 H
The housing and the harness
should not protrude from the
side of the controller.
HV HU
4P 4P
From Board,IGBT Sensor Comp.
,heat
NA
Battery(-) G1 2P 6 2P G1 2P G1
E1 BK BK E1 BK E1
2P
RD
E2 2P 2P E2
BKWH
TV 2P E2 TU
G2 WH WH G2 WH G2
Reference: 4P 4P
Harness mark/color
Red RD
Black BK
Green GN 6PWH
Yellow
White
YE
WH
Cap
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG Harness, controller
Ex) BKWH (=Black/White)
Black colored harness with White line.
W2 W1 V2 V1 U2 U1
W2 W1 V2 V1 U2 U1
Hydraulic Travel Hydraulic Travel Hydraulic Travel
White line
W phase W phase V phase V phase U phase U phase
Black color
A
3A 3B A 6 10 D BKYE# 550
1
MPU board L
4A 4B A 6 10 F RDBK# 450
5A 5B A 6 10 F BU# 450
6A 6B A 6 10 F BKWH# 450
10 9 8 7 6 5 4 3 2 1
7A 7B A 6 3 E BNYE 560
20 19 18 17 16 15 14 13 12 11
7C B 6 360
RDGN#
YERD#
BKYE#
RDBK#
BU#
BKWH#
BNYE
BKYE
WHBU
BNWH
BUBK
GNRD
BNRD
BKWH
3
4P 4P
Current sensor 14D I BKWH* 450
C D
3
Current sensor
20B 6B
(Hydraulic U phase) (Travel U phase) E IGBT
temperature sensor 15A 15B B 6 10 C RDGN# 380
B A 16A 16B B 6 10 C YERD# 380
18B 19B 4B 5B HU TU
1 2 3 4 1 2 3 4 1 17A 17B B 6 10 C BKYE# 380
B B A A 9 2
1 2 3 4 1 2 3 4 4 18A 18B B 6 10 G RDBK# 280
10 10 10 10 10 10 Plug 19A 19B B 6 10 G BU# 280
4P 4P 2P
RDBK#
BU#
BKWH#
RDBK#
BU#
BKWH#
RD 20A 20B B 6 10 G BKWH# 280
10
17B 3B 8B
J Battery(+)
B A A
15B 16B 1B 2B 7B Reference:
B B A A A,B Harness mark/color
5 Red RD
1 2 3 4 1 2 3 4 1 2 Black BK
6 A 12B
GNRD 10 10 10 10 10 10 3 3 Green GN
Yellow YE
RDGN#
YERD#
BKYE#
RDGN#
YERD#
BKYE#
BNYE
BKYE
White WH
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG
White line
Black color
<Note>
BKWH/BKWH*
1.Lead wires
# :AVS0.3mm2
WHBU
BUBK
BKWH*
BNWH
BKWH*
BNRD
RDBK#
BKYE#
BNYE
3 3 3 3 3 3 2.The location of connector pin is as viewed from the inserting side.
BU#
6
1 2 3 4 5 6
Be careful of the arrangement 3. :Braided wires under 25mm pitch.
7 of terminals.
A A A
A, I, I 6 6 6 6 6 6 6 4.Impress marks on connectors with undamped ink as indicated in
14B
1 7 2 3 8 4 9 10 5 11 6 12
the pin configuration.
11B 10B 13B C C G E
H Battery(-)
A H H
15A 17A 19A 7C
9B 14C 14D C G G
16A 18A 20A
14 Wire, lead AVS0.85mm2 See lead wire table.
Cap
6P WH CN7 13 Wire, lead AVS0.5mm2 See lead wire table.
12 Wire, lead AVS0.3mm2 See lead wire table.
6
3 2 1 11 Terminal 5.5-6 1 6
6 5 4 3 2 1
6 5 4 10 Terminal 1.25-6 1 6
12 11 10 9 8 7 BXH-0016-P0.6
9 Contact 12 JST 10
I External terminal
SXH-0016-P0.6
8 Housing XHP-4 4P 4 JST
7 Tab 179462-3/170340-3 5 AMP 3
B MPU board R 2
6
5
Housing, cap
Receptacle
171897-1
179461-5/170032-5
6PWH 1
2
AMP
AMP 3
4 Housing, plug 172130-9 2PRD 1 AMP
3 Receptacle 175061-2/173716-2 21 AMP 6
2 Housing, plug 175965-2 12P 1 AMP
1 Housing, plug 175967-2 20P 1 AMP
SYM PART NAME SIZE MATERIAL QTY MASS REMARKS
21 6
1
Unit type
21 3
*Refer to note 4 *Refer to note 1
CU104-XXX
19 2
16 22
13
27 26 25 17 14
*Refer to note 2 Upper
24 7
15
23 8
27 26 25 17
21 5
*Refer to note 2
21 4
W2 W1 V2 V1 U2 U1
27 26 25 20 18
29 Wiring, controller
28 Harness, controller
27 Nut
12 10 11 9 11 9 26 Washer, lock
25 Washer, plain
24 Screw, w/washer
23 Screw, w/washers
22 Screw, w/washers
21 Bolt, w/washers
20 Bolt, w/washers
19 Bolt, w/washers
18 Terminal Comp.
17 Terminal
16 Sensor Comp., heat
Note 15 Capacitor Comp.
1. When installing a " 5 6 Module ,IGBT" to the " 1 Sink, heat", be sure to 14 Bar, lead(8)
apply condition compund[G-747] (Shin-Etsu silicones) to the entire 13 Bar, lead(7)
contact surface. 12 Bar, lead(4)
2. Insert washers in the " 17 terminal", as shown in Figure A, and then 11 Bar, lead(3)
10 Bar, lead(2)
installing the " 17 terminal", apply LOCTITE[242] or a similar material
9 Bar, lead(1)
to the screws to prevent looseness. 8 Sensor, current
3. Recommended tightening torque for the IGBT. Maximum current 7 Board Comp., IGBT
Applicable 2 Board comp., MPU
Main terminal(M6) and mounting(M6) : 3.5-4.5N.m(0.36-0.49kg.m) models
Type (IGBT rating) Remarks 6 Module, IGBT
Travel Hydraulic Type
4. Impress a Unit type to the specified position with undamped ink. 5 Module, IGBT
5. Use the terminal bolt included for the "IGBT module" . 600A 400A 4 Bracket, board(2)
STD CU104-50 (250V) (250V) PBC104-00 When installing,
make sure the 3 Bracket, board(1)
6. In order to improve vibration resistance, apply to the "capacitor comp."
a silicone adhesive agent on the bottom to fix it into place. Figure A OPT CU104-53 PBC104-02 arrow points up. 2 Board Comp., MPU
1 Sink, heat
21 5
1
Unit type
21 3
*Refer to note 4. *Refer to note 1.
CU104-XXX 19 2
16 22
13
27 26 25 17 14
*Refer to note 2. Upper
24 7
15
23 8
27 26 25 17
21 5
*Refer to note 2.
21 4
W2 W1 V2 V1 U2 U1
27 26 25 20 18
12 10 11 9 11 9
29 Wiring, controller
28 Harness, controller
27 Nut
26 Washer, lock
25 Washer, plain
24 Screw, w/washer
23 Screw, w/washers
22 Screw, w/washers
21 Bolt, w/washers
20 Bolt, w/washers
19 Bolt, w/washers
18 Terminal Comp.
17 Terminal
16 Sensor comp., heat
Note
15 Capacitor Comp.
1. When installing a " 5 6 Module ,IGBT" to the " 1 Sink, heat", be sure to 14 Bar, lead(8)
apply condition compund[G-747] (Shin-Etsu silicones) to the entire 13 Bar, lead(7)
contact surface. 12 Bar, lead(4)
2. Insert washers in the " 17 terminal", as shown in Figure A, and then Maximum corrent 2 Board comp., 15 Capacitor 11 Bar, lead(3)
Applicable Type (IGBT rating) MPU comp. Remarks
installing the " 17 terminal", apply LOCTITE[242] or a similar material 10 Bar, lead(2)
models Travel Hydraulic Type Rating 9 Bar, lead(1)
to the screws to prevent looseness.
FB30CA CU104-51 600A 600A PBC104-01 100V 8 Sensor, current
3. Recommended tightening torque for the IGBT. STD (250V) (250V) 4700 F 7 Board Comp., IGBT
Main terminal(M6) and mounting(M6) : 3.5-4.5N.m(0.36-0.49kg.m) FB-HCA 80V When installing, 6
CU104-52
4. Impress a Unit type to the specified position with undamped ink. Figure A STD 5600 F make sure the 5 Module, IGBT
5. Use the terminal bolt included for the "IGBT module" . FB30CA CU104-54 PBC104-03 100V arrow points up. 4 Bracket, board(2)
6. In order to improve vibration resistance, apply to the "capacitor comp." OPT 4700 F 3 Bracket, board(1)
a silicone adhesive agent on the bottom to fix it into place. FB-HCA 80V 2 Board Comp., MPU
CU104-55
OPT 5600 F 1 Sink, heat
<GN>
Pink PK
Orange OG
4 :Tab 179462-3 or 170340-3
WH
Ex) BKWH (=Black/White) 5 WH :Contact, socket SLF-41T-1.3E
BK Black colored harness with White line. <RD> <1> RD
6
BKWH 3.Thermal relay setting value
AC 5 3 1 <WH> <2>
7
Relay
3 8 Capacity Setting value
400V 9 YEBK 1 2 3
Thermal relay 5.2kVA 7.5A
<BK> <3> BNWH
10 6.4kVA 10.0A
White line
*Refer to 7.0kVA 11.0A
6 4 2 11 4 5 6
note 5
Socket 12 10.0kVA 15.0A
Contactor
<WH>
12.0kVA 18.0A
<RD>
<BK>
Black color
R U 4.Use pressed terminal without sleeve.
Transformer Thermal relay
S V *Refer to note 3. CA1-DC48V-N
Clamp with 5.Connecting wires around socket is as below figure.
Primary side (15A/20A/30A) Matsushita
Wire lead,
X
T W socket wire ties. Screw
6PBK Eyelet
Wire
<WH>
WH
<RD>
<BK>
96 5 3 1
Plug
RD WH
Mctt 1 2 3
Terminal
RDGN 4 5 6 a.The bare part of the line should be 10±1mm
Fuse
BK
RD
RD
RD
WH
b.The tightening torque for the screws is 0.98-1.18N.m(10-12kgf.cm)
95 6 4 2
(Viewed from the
inserting side of the terminal)
<7>
<6>
<5>
<WH>
WH
<RD>
<BK>
10E6 X 6.Detail of connecting the earth terminal is as below figure.
Relay
CA1-DC48V-N
<WH>
95
<RD>
<BK>
Panel, charger
GN
RDBK
Key switch 1 3 5 13 A1 Receptacle
96 Harness, BC
YEBU
Charging interlock
RDYE Contactor
Battery +48
BKWH 2 4 6 14 A2
Battery GND
BNBK *Refer to note 7 Ring terminal
Reserve charge start
BK
WH
RD
Install with a toothed washer and nut
WH
YEBK
Reserve charge switch (You can not use a "washer, plain" or a "washer, lock")
RDYE
YEBK
BNWH
WH
RD
BKWH
RDGN
1 3 5 13
RDYE
RDBK
YEBU
GND VB1 CST
BNBK
YEBK
JST 5 6 7 8
MC AC4 NB Mctt
9 10 11 12
Receptacle housing
JST
RSW DCR Transformer
2 4 6 14
Primary side
(Viewed from the inserting side of the terminal) 1 2 3 4 5 6 1 2 A2
Cap Cap
3 2 1 1
6 5 4 2
(Viewed from the inserting side of the terminal)
FB-CA BC wiring 4- 7.
400V 4-7-1.
85
4 Wiring and main controller layout
Reference:
Harness mark/color <Note>
Red RD 1.Lead wire
Black
Green
Yellow
BK
GN
YE
Panel, charger Others :AV/AVS0.5mm2
White WH
:F-KIV/KIV/LV 1.25mm2 /0.75mm2
Brown BN <> :Refer to below table.
*Refer to note 6
Socket
Blue
Gray
BU
GY Charger, microcomputer Lead wire F-KIV/KIV/LV F-KIV/KIV/LV
Pink PK Be sure to put. BK Capacity 3.5mm2 5.5mm2
GN Orange OG 1
2 RDYE 5.2 kVA
<RD> Ex) BKWH (=Black/White) <4>
Earth terminal BNBK
<GN>
Black colored harness with White line. 3 6.4/7.0 kVA
<WH> RD 10.0/12.0 kVA
4
WH
<BK> 5
2.Terminal symbols
<RD> <1> 6
:Tab 179462-3 or 170340-3
AC 7 BKWH
3
White line <WH> <2> Relay :Contact, socket SLF-41T-1.3E
200V 8
Fuse YEBK 1 2 3
9 3.Using fuse
(15A/20A/30A) <BK> <3> BNWH
10 Fuse FA-6-15 FA-6-20 FA-6-30
*Refer to 15A
<WH>
11 4 5 6 20A 30A
<RD>
note 5
Contactor Socket 12 5.2 kVA
R U 6.4/7.0 kVA
<WH>
<RD>
<BK>
S V Transformer Wire, socket 10.0/12.0 kVA
T W
Primary side CA1-DC48V-N
X
Matsushita 4.Use pressed terminal without sleeve.
Fuse Clamp with wire ties.
*Refer to note 3 6PBK 5.Connecting wires around socket is as below figure.
<WH>
<RD>
<BK>
(15A/20A/30A) Screw
Plug Eyelet
Wire
RD WH
Mctt
1 2 3
RDGN
Fuse 4 5 6
BK
RD
RD
RD
(Viewed from the Terminal
inserting side of the terminal) a.The bare part of the line should be 10±1mm
<7>
<6>
<5>
10E6
b.The tightening torque for the screws is 0.98-1.18N.m(10-12kgf.cm)
X Relay
CA1-DC48V-N
<WH>
<RD>
<BK>
6.Detail of connecting the earth terminal is as below figure.
RDBK
Key switch Panel, charger
YEBU 1 3 5 13 A1 GN
Charging interlock Harness, BC Receptacle
RDYE
Battery +48 Contactor
BKWH
Battery GND 2 4 6 14 A2
BNBK
Reserve charge start *Refer to note 7
BK
WH
RD
YEBK
WH
Reserve charge switch Ring terminal
Install with a toothed washer and nut
BNWH
BKWH
YEBK
BK
RD
WH
BKWH
RDGN
7.The contactor terminal should be wired with the topside up,
RDYE
RDBK
YEBU
BNBK
YEBK
Plug housing GND VB1 CST AC2
JST as shown in the figure below.
5 6 7 8
MC NB
Upper Upper A1
Receptacle housing 9 10 11 12 Transformer A2 A1
RSW DCR 1 3 5 13
JST Primary side 1 2 3 4 5 6 1 2 1 3 5 13
Mctt
(Viewed from the inserting side of the terminal) Mctt
Cap Cap
6PBK 2PWH 2 4 6 14
2 4 6 14
A2
Cap Cap For 5.2/6.4/7.0kVA For 10.0/12.0kVA
(Mitsubishi) (Matsushita)
3 2 1 1
6 5 4 2
(Viewed from the inserting side of the terminal)
Side A
<12>
Side B
Wire tie
Rectifier side Contactor unit side
(Note)
1.Wire length means the length to the tip of the wire.
The length of the bare section of the lead wire is
a=22mm2, and a=15mm for 30 or 38mm2.
L:Wire length
a a
Part No. 54000- 21170-0 21180-0 21190-0 21200-0 21210-0 3.Wrap red electrician's tape around the B side of the
positive (+) terminal on the lead wire to indicate
22-S8 1912-04029 4 pieces polarity.(See the figure below)
Terminal 38-S8 37950-00840 4 pieces
Red electrician's tape
Wire Side A Side B
Wire type Wire size Length Length Length Length Length Remarks
Charger harness(1)
No. Terminal Mark Terminal Mark
22-S8 *Note 4 + 22-S8 + LV 22 550
Connecting Rectifier
38-S8 *Note 4 38-S8 LV 30 550 550
positive (+) side with
<11> 38-S8 *Note 4 38-S8 WCT 38 550 550 Contactor 4.Install a TCV cap on the A side terminal.
22-S8 *Note 4 - 22-S8 - LV 22 1750 The positive (+) side is red, and the negative (-) side
Connecting Rectifier
4- 8.
Wiring and main controller layout 4
4-8-1.
87
88
Wire color Wire color
:White :Black
Wire color
:Red
<13> <13>
4 Wiring and main controller layout
Side A Side B
Part No. 54000- 21220-0 21230-0 21380-0 21390-0 2.The indicated wire length refers to the length of the red wire.
Charger harness(2)
5.5-5 37910-01550 3 pieces 3.Refer to the figure below for the crimping direction.
Terminal 5.5-S4X 37910-02170 3 pieces Crimping direction
R8-6 or an
equivalent product 37910-02270 6 pieces
4- 8.
4-8-2.
FB30CA Battery(72V)
Install on the
V N Revolving head guard
light
48V
VA NA
WH
BK
FB10CA-28CA Battery(48V)
V N
Harness, accessory(1)
VA NA
VKF or VCTT
F5 Key switch 1.25mm2 2 pieces
10A Revolving
35W light
REV
X2 X1
F4
WH
BK
10A
RDWH
RDBK
BKWH
BNYE
BUYE
RDWH
BKWH
FB-CA
1 2 3
System wiring
Reference: <Note>
Harness mark/color
Red RD
1.Terminal symbols
Black BK
Green GN
:Receptacle
Yellow YE
White WH
(with plating) AMP 170021-2
Brown BN
Blue BU
Sleeve(for single wire) AMP 170889-1
A'1 Accessory
Gray GY
To harness, body
Pink PK
:Plug
Black color
4- 9.
Wiring and main controller layout 4
4-9-1.
89
90
FB30CA Battery(72V)
Revolving Installed on the
V N head guard
RDBK
RDWH
BNYE
A'2 Accessory light
48V
VA NA
WH
BK
RDBK
RDWH
BNYE
BKWH
BUYE
FB10CA-28CA Battery(48V)
V N H Back buzzer
Harness, accessory(1)
VA NA
1
Harness, revolving
VKF or VCTF
Key switch PB100-90 1.25mm2 2 pieces
BNYE
F5
10A Line Connector
No. CN Pin No. 1 1
X2 X1 A'1 Accessory
F4 BURD
WH
BK
10A X3 OF2 1 9
BKWH
BN
4 Wiring and main controller layout
YEBK
BNYE
BKWH
RDWH
BUYE
X4 OB2 1 10
Revolving
BNYE 35W light
REV Harness, body
X3
1G6
BN BNYE
BZ <Note>
X4
BURD
RDBK
RDWH
BKWH
Sleeve(for single wire) AMP 170889-1
FB-CA
Sleeve(for double wire) AMP 170890-1 CN1
1 2 3 :Plug
4PWH 4PRD 4PWH 4PBK
(with plating) AMP 170020-2 1
System wiring 1 :Plug 6 5 4 3 2 1
X3 X1 X4 X7
Reference: (without plating) AMP 170002-5 or AMP 170020-3 12 11 10 9 8 7
Harness mark/color Sleeve(for single wire) AMP 170887-1 AMP.040 series multi-lock connector
Red RD Sleeve(for double wire) AMP 170888-1 175965-2
Black BK 1 :Receptacle AMP 173716-2 or AMP 175061-2
Green GN F Relay
Yellow YE 2.The location of the connector pin is as viewed from the inserting side. A MPU board
White WH 3.Clamp and fix the area where the "harness, body " and the "harness, revolving"
Brown BN
Blue BU is level to an appropriate area on the "harness, body".
Gray GY
Pink PK
Orange OG
White line
WH
BK
FB10CA-28CA Battery(48V)
V N
Harness, accessory(1)
VA NA
VKF or VCTT
F4 1.25mm2 2 pieces
10A
BN BN Back buzzer To rear combination lamp
Back lamp(25W)
(right)
X4
Revolving
WH
BK
Water
resistant 6P
BKWH
RDBK
BN
BKWH
RDWH
BUYE
BNYE
1 3
FB-CA
Reference:
System wiring
Harness mark/color
<Note>
Red RD 1.Terminal symbols
Black BK
Green GN :Receptacle
Yellow YE
White WH (with plating) AMP 170021-2
RDYE
GNWH
RDWH
BKWH
WHBU
BN
Brown BN
Blue BU Sleeve(for single wire) AMP 170889-1 16
Gray GY
Pink PK :Plug
Orange OG
(with plating) AMP 170020-2
Ex) BKWH (=Black/White)
Black colored harness with White line.
Sleeve(for single wire) AMP 170887-1
To harness, body
(rear combination lamp)
White line
Black color
48V
BK
BK
VA NA WH WH
RDBK
BUYE
A'2 Accessory
BK BK
Battery(48V)
BK
BK
FB10CA-28CA Harness, accessory
V N
Harness, accessory
WH
BK
RDBK
BUYE
RDWH
BKWH
BNYE
VA NA
4 Wiring and main controller layout
F4 Harness, accessory
10A Working
BUYE 40W lamp W Operation switch Harness, switch
Working lamp switch
WL VKF or VCTT
2P 1.25mm2 2 pieces
Working BK Laser pointer switch
40W lamp
WL
4P A'1 Accessory
WH Lamp switch
WH
BK
2P 2P
RDBK
BK Connect BK
BKWH
BUYE
BKWH
RDWH
BNYE
FB-CA
Harness mark/color Harness, body
Red RD
Black BK
Green GN
Yellow YE
White WH
Brown BN
Blue BU
Gray GY <Note>
Pink PK
Orange OG
1.Termial symbols
:Receptacle
Ex) BKWH (=Black/White) (with plating) AMP 170021-2
Black colored harness with White line. 1 :Receptacle
(without plating) AMP 170003-5 or AMP 170021-3
Sleeve(for single wire) AMP 170889-1
:Plug
(with plating) AMP 170020-2
1 :Plug
White line (without plating) AMP 170002-5 or AMP 170020-3
Sleeve(for single wire) AMP 170887-1
Sleeve(for double wire) AMP 170888-1
2.Clamp and fix the area where the "harness, body " and the "harness, revolving"
Black color is level to an appropriate area on the "harness, body".
RDBK
RDWH
A'2 Accessory Brown BN
Blue BU
48V
VA NA Gray GY
Pink PK
Orange OG
FB10CA-28CA Battery(48V)
RDBK
RDWH
BKWH
BUYE
BNYE
Chime Ex) BKWH (=Black/White)
V N H (back buzzer) Black colored harness with White line.
CHM
VA NA
1
Harness, buzzer
BNYE
10A Line Connector
BNYE
No. CN Pin No. 1 1 White line
X2 X1
F4 BURD
10A X3 OF2 1 9
BKWH
BN
Black color
YEBK
X4 OB2 1 10
BNYE BNYE
CHM
Harness, body
X3 Chime
1G6
BN
X4 <Note>
BN
BURD
1.Terminal symbols
:Receptacle
Back lamp (with plating) AMP 170021-2 1
CN1-9
1 :Receptacle
RDBK
(without plating) AMP 170003-5 or AMP 170021-3
BKWH
RDWH
Sleeve(for single wire) AMP 170889-1 CN1
1 2 3 Sleeve(for double wire) AMP 170890-1
4PWH 4PRD 4PWH 4PBK
:Plug 1
System wiring (with plating) AMP 170020-2 6 5 4 3 2 1
1
X3 X1 X4 X7
:Plug 12 11 10 9 8 7
(without plating) AMP 170002-5 or AMP 170020-3
AMP.040 series multi-lock connector
Sleeve(for single wire) AMP 170887-1 175965-2
Forward/backward chime
2.The location of the connector pin is as viewed from the inserting side. F AMPU board
3.Clamp and fix the area where the "harness, body " and the "harness, revolving"
is level to an appropriate area on the "harness, body".
Wiring and main controller layout 4
4-11.
4-11-1.
93
94
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
FB30CA Battery(72V) White WH
Brown BN
V N Blue BU
RDBK
RDWH
A'2 Accessory
Gray GY
48V Pink PK
VA NA Orange OG
RDBK
RDWH
BKWH
BUYE
BNYE
Chime Black colored harness with White line.
V N H (back buzzer)
4 Wiring and main controller layout
BZ CHM
VA NA
1 1
Harness, chime Harness, accessory
BK
BK
F5 Key switch PB100-90
10A Connector White line
Line
No. CN Pin No. 1 1 1
X2 X1
F4 BURD
10A X3 OF2 1 9
BN
BKWH
BNYE
Black color
YEBK
X4 OB2 1 10
BNYE BNYE
CHM BK
Harness, body
X3 Chime
BN BN
BZ BK
X4 Back buzzer <Note>
BN
BURD
1.Terminal symbols
:Receptacle
Forward chime
Back lamp (with plating) AMP 170021-2 1
CN1-9
1 :Receptacle
(without plating) AMP 170003-5 or AMP 170021-3
RDBK
RDWH
BKWH
Sleeve(for single wire) AMP 170889-1 CN1
1 2 3 Sleeve(for double wire) AMP 170890-1
4PWH 4PRD 4PWH 4PBK
:Plug 1
System wiring (with plating) AMP 170020-2 6 5 4 3 2 1
1
X3 X1 X4 X7
:Plug 12 11 10 9 8 7
(without plating) AMP 170002-5 or AMP 170020-3
AMP.040 series multi-lock connector
4-11.
4-11-2.
FB30CA Battery(72V)
V N
48V Chime
VA NA H (back buzzer)
Battery(48V) CHM
FB10CA-28CA
V N
1 1
VA NA BN
BKWH
F4
10A
BN BN CHM
X4 Chime
BN
RDBK
1 BKWH3
System wiring <Note>
Reference:
Harness mark/color 1.Terminal symbols
Red RD
1
Black BK :Receptacle
Green GN
Yellow YE (without plating) AMP 170003-5 or AMP 170021-3
White WH
Backward chime
Brown BN Sleeve(for double wire) AMP 170890-1
Blue BU
Gray GY 1 :Plug
Pink PK
Orange OG (without plating) AMP 170002-5 or AMP 170020-3
Ex) BKWH (=Black/White) Sleeve(for single wire) AMP 170887-1
Black colored harness with White line.
Black color
Wiring and main controller layout 4
4-11.
4-11-3.
95
96
Left side of Right side of
FB30CA Battery(72v) the head guard the head guard Only for the large
V N forklift truck License
48V inspection lamp
VA NA Clearance Head Head Clearance
lamp lamp lamp lamp 1
1
FB10CA-28CA Battery(48V)
WH
BK
V N 1 1 1 1 1 1 1 1
WH
BK
WH
BK
WH
BK
WH
BK
VA NA Turn signal Turn signal Harness, license(2)
lamp lamp
WH
BK
WH
BK
F5 Key switch Harness, clearance Harness, clearance VKF or VCTF
10A 1.25mm2 2 pieces
1 1 1 1 1 1 1 1
4 Wiring and main controller layout
X2 X1
WH
BK
RD
GN
RD
GN
WH
BK
F4
10A
WH
BK
WHBU
Head lamp (Rear combination lamp)
40W HL
Left lamp
10W <Note>
Lamp switch CL
Clearance lamp 1.Terminal symbols
Reference:
BKWH*
RDBK
RDWH
:Receptacle
Harness mark/color
(with plating) AMP 170021-2
1 2 3 Red RD
1 :Receptacle Black BK
(without plating) AMP 170003-5 or AMP 170021-3 Green GN
System wiring Yellow YE
Sleeve(for single wire) AMP 170889-1
White WH
4-12.
Large forklift truck inspections, new small forklift truck inspections 4-12-1.
Push switch Load sensor
FB30CA Battery(72V) (same specifications as the horn switch) electric Ass'y Load sensor
V N (Indicator)
GN BN BN BN
48V
VA NA BK BN BN BN
FB10CA-28CA Battery(48V)
Switch wiring
V N
Remove the Y terminal,
and connect with
RD
GN
PK
BK
BN RD
Key switch Tape the ends
F5
RD BK GN
10A
GN Load sensor Load sensor PK
PK (Indicator)
X2 X1 BK BNBK OG electric Ass'y BK
F4 BK RD YE
10A
1A
BK
GN
PK
RD
BN
BN
PDisplay board
1A 1
YE RD
Load sensor BN 8 7 6 5 4 3 2 1
OG electric Ass'y BK 16 15 14 13 12 11 10 9
BN
BN
for turning the overload buzzer on and off,
RDWH
A'2 Accessory
BK
BN
BN
CN1-8
1
With switch
RDWH
BKWH
RDBK
BUYE
BNYE
BNBK
Harness, load sensor
FB-CA
Harness, body
PB101-20
Line Connector
No. CN Pin No.
Analog type
BNBK SW7 1 8 <Note>
Overload
1.Terminal symbols
BKWH*
RDBK
RDWH
:Receptacle
1 2 3 (with plating) AMP 170021-2
System wiring Sleeve(for single wire) AMP 170889-1
:Plug
Reference: (with plating) AMP 170020-2
Harness mark/color
Red RD
Sleeve(for single wire) AMP 170887-1
Black BK Sleeve(for double wire) AMP 170888-1
1 :Receptacle AMP 173716-2 or AMP 175061-2
Green GN
Yellow YE 2.The location of the connector pin is as viewed from the inserting side.
White WH
Brown BN White line 3.Clamp and fix the area where the "harness, body " and the "harness, revolving"
Blue BU is level to an appropriate area on the "harness, body".
Gray GY 4.Lead wire : AV or AVS 0.5mm2
Pink PK
Orange OG
Black color
Ex) BKWH (=Black/White)
Black colored harness with White line.
Wiring and main controller layout 4
FB10CA-28CA Battery(48V)
GN BK
V N
BK BK
RD RD
VA NA
3A
WH BNBK
F5 Key switch
10A
4 Wiring and main controller layout
P Display board
X2 X1
F4
1
10A 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
WH electric Ass'y BK
CN1
CN1-8
1
RDWH
BKWH
RDBK
BUYE
BNYE
BNBK
PB101-20
Harness, load sensor
Line Connector Harness, body
No. CN Pin No.
FB-CA
BNBK
SW7 1 8 Overload
BKWH*
RDBK
RDWH
Digital type
1 2 3
System wiring
<Note>
Reference: 1.Terminal symbols
Harness mark/color :Receptacle
Red RD (with plating) AMP 170021-2
Black BK Sleeve(for single wire) AMP 170889-1
Green GN :Plug
Yellow YE
(with plating) AMP 170020-2
White WH
Brown BN Sleeve(for single wire) AMP 170887-1
White line
Blue BU Sleeve(for double wire) AMP 170888-1
Gray GY 1 :Receptacle AMP 173716-2 or AMP 175061-2
Pink PK
Orange OG
2.The location of the connector pin is as viewed from the inserting side.
3.The section that is connected from the digital load sensor to the display board, and
Black color
Ex) BKWH (=Black/White) the section that is parallel to the "harness, body" should be clamped properly to the
Black colored harness with White line. "harness, body" to secure them.
4.Lead wire : AV or AVS 0.5mm2
F5 Key switch
BUYE
10A
BNYE
A'2Accessory
X2 X1 RDWH RDWH
F4
10A
BKWH BKWH*
W Operation switch
2P Laser pointer switch
BK
To valve microswitch
Sensor 4P Switch comp.,toggle(*Refer to note 3)
WH Lamp switch 6P
BK
RDGN
NO Valve
YE BN 2P 2P
X BK BK X microswitch
Lifting height limit SW C NC Connect
(for 1st stage) Relay Lifting height limit
HC4-HTM PB100-90
Connector SW for 1st stage 6P
Line BK
No. CN Pin No.
Harness, body
BK
HSN 4 16
BK BU BUWH
HS1 4 4
Lift 1 switch X-1 Relay
BK WH WHBU
HS2 4 12 HC4-HTM X
Lift 2 switch X-2 DC48V
(Matsushita)
RDBK
RDWH
BKWH*
Reference:
<Note> Harness mark/color
1 2 3 Red RD
System wiring 1.Terminal symbols
Black BK
:Receptacle Green GN
(with plating) AMP 170021-2 Yellow YE
Sleeve(for single wire) AMP 170889-1 White WH
4-14.
4-14-1.
99
2nd stage sensor 2nd stage unit
100
BN 4 4 RD RDWH RDWH
FB30CA Battery(72V)
Sensor, BU 5 5 BK BKWH BKWH
V N magnetic Controller
BK 6 6 WH Ass'y YE YERD
VA 48V NA
RDGN BN BN
W Operation switch
1st stage 2P BUYE
sensor BK Laser pointer switch
BNYE
A'2Accessory
RDGN
NO RDWH RDWH
4P Lamp switch Switch comp., toggle(*Refer to note 4)
YEWH BN WH
X *Refer to note 3
Lifting height limit C NC BKWH BKWH*
SW for 1st stage Relay
1st stage unit HC4-HTM 2P 2P Lifting height limit
WH BK
Connect SW for 2nd stage
2nd stage
sensor
2P 2P Lifting height limit To valve microswitch
PB100-90 BK BK
RDGN Connect SW for 1st stage
NO
Line Connector
YERD BN 6P
No. CN Pin No.
Switch Comp., toggle(*Refer to note 4)
BK
Lifting height limit C NC
SW for 2nd stage Valve
2nd stage unit Relay
BK HC4-HTM X
X microswitch
HSN 4 16 DC48V
(Matsushita)
6P
BK BU BUWH BK
HS1 4 4
Lift 1 switch X-1
BK WH WHBU Harness, body
HS2 4 12
Lift 2 switch X-2
<Note>
RDBK
RDWH
BKWH*
1.Terminal symbols Reference:
1 2 3 :Receptacle Harness mark/color
System wiring (with plating) AMP 170021-2 Red RD
Black BK
Sleeve(for single wire) AMP 170889-1
Green GN
Sleeve(for double wire)AMP 170890-1 Yellow YE
:Plug White WH
4-14.
ON when the lever is pointing up).
4-14-2.
Seat heater
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE Accessory(front)
White WH
BUYE
RDWH
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG 1 1
WH
BK
Black colored harness with White line.
BUYE
BKWH
BNYE5
RDWH
RDBK
Harness, accessory
White line
Operation switch
Harness, switch
4P
Accessory(rear)
System wiring
WH Lamp switch
WH
BK
FB-CA
RDWH
2P
BK
BUYE
BKWH
RDWH
BNYE5
RDYE3
Seat heater
Harness, body
BKWH
<Note>
1.Lead wire: AV or AVS0.5mm2
2.Terminal symbols
1 :Sure plug AMP 170020-3 or 170002-5
:Sure plug AMP 170020-2
1 :Sure receptacle AMP 170021-3 or 170003-5
:Sure receptacle AMP 170021-2
Wiring and main controller layout 4
RDBK
RDYE
Accessory(front)
Brown BN
Blue BU
Gray GY
Pink PK
Orange OG
1 1
Ex) BKWH (=Black/White)
Black colored harness with White line.
WH
BK
BUYE3
BKWH
BNYE5
RDBK
RDWH
4 Wiring and main controller layout
System wiring 4P
Accessory(rear)
WH Lamp switch
WH
BK
RDBK
2P
BK
BUYE3
BKWH
RDWH
BNYE5
RDYE3
Rear lamp
Harness, body
BKWH
<Note>
4-16.
Wire cutting and terminal connection is not
required between the junction box and the indicator. Junction box
FB-CA Wiring, FS
:Sure plug AMP 170020-2
(with plating)
Wiring and main controller layout 4
4-17.
103
104
4P
WH RDWH
Controller, wiper
WHBU
Motor, Controller, 6P BU
wiper wiper RD To harness, head guard 2W
1 S
680
Motor,
BK
wiper
4 Wiring and main controller layout
WHGN
Harness, wiper
GNBK
100W 63V
X1
BKWH
30 1000 F
GNRD
BU
RDWH
WHBU
RDWH
BKWH
X1
BKWH
BU
WHBU
BKWH
RDWH
RDWH
System wiring
Wiper
Harness, wiper
To harness, body
accessory(front)
Switch comp., toggle
BU 1
Reference: WHBU 2
Harness mark/color RDWH 3
Red RD <Note>
Black BK
Green GN 1.Terminal symbols
Yellow YE
Key groove :Sure plug AMP 170020-2
White WH :Sure receptacle AMP 170021-2
Brown BN White line
Blue BU
Gray GY
Pink PK
4-18.
4-18-1.
RDWH
BK BKWH Controller, wiper
To harness, head guard
BKWH BKWH
To harness, body
RDWH RDWH accessory(front) WHBU
BU
Harness, wiper 2W
1 S
680
Motor,
wiper
WHGN
4P Switch comp., toggle
WH GNBK
BU 1
Motor, wiper 100W 63V
WHBU 2 X1
30 1000 F
RDWH 3 GNRD
Controller, wiper X1
6P
Key groove BKWH
RD
System wiring
Reference:
Harness mark/color
Red RD
Lower wiper
Black BK
Green GN
Yellow YE
White WH
Brown BN
Blue BU
White line <Note>
Gray GY 1.Terminal symbols
Pink PK
Orange OG
:Sure receptacle AMP 170020-2
:Sure receptacle AMP 170021-2
Ex) BKWH (=Black/White) Black color
Black colored harness with White line.
4-18.
4-18-2.
105
106
PB100-90/93
2 Line Connector
No. CN Pin No.
RDWH
RDWH
BP 12 16 Valve solenoid power
4 Wiring and main controller layout
GNRD
SOL4 B22 11 4 Tilt down
WHBU (Automatic fork leveling)
BC2 11 14
RDBK 1
HP1 4 Power supply
Tilt level GNRD Reference:
HD1 4 2 Signal Harness mark/color
potentiometer BKYE 4 9 Red RD
HN1 GND Black BK
Green GN
Yellow YE
White WH
Brown BN
Blue BU
Gray GY
BURD Pink PK
Fork leveling HS7 4 7 Auxiliary input 7
Orange OG
White line