Fb10 30p Dc70 Series Trs [PDF]

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02W-2201



FB-DC70 SERIES



FB



10P/15P/18P 20P/25P/30P



Contents 1. How to adjust SICOS 60 (Major point only)



.........................1



1-1 The name and function of mode select switch



.......................1



q Slow speed mode button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 w Mode select button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 e Up button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 r Down button (2 functions) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2



1-2 How to set the each mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 q Speed setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 w Power setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 e Acceleration feeling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 r Option setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 t Language selection on LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 y Safety monitor symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5



1-3 Adjustment of starting current and current limitation . . . . . . . . . . . . . . . . . . 6 q Zero(0) adjusting for installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 w Adjustment of starting current and current limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7



2. Adjustment for other functions



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11



q Auto-torque up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 w Safety circuit for out of control (contactor tripping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 e Power setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 r Hydraulic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 t Switch back braking distance (Plugging/Regenerative braking) . . . . . . . . . . . . . . . . . . . . 12 y Regenerative braking force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 u Adjustment of brightness of the back light on monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 14 i Checking of speed sensor output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 o Hour meter working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 !0 Confirming the working of auto-power cut off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 !1 Adjusting of battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15



3. Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 q Confirming Over loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 w Confirming the travel inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 e Confirming the lift locking working at over discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 r Confirming the seat switch working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17



4. Outline of New EPS system for FB–DC70



. . . . . . . . . . . . . . . . . . . . . 18



4-1 Outline of New EPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-3 Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 q Protection of overheat for motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 w Self diagnosis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19



4-4 Checking and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 q Neutral adjustment of torque sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 w Checking by voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21



5. Self diagnosis history memory and I/O check



. . . . . . . . . . . . . . . . 22



5-1 Self diagnosis history memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5-2 I/O check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27



6. Practical trouble shooting (How to find the cause of problem) . . . . . . . . 31 6-1 Before starting



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31



q Location of negative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 w Layout of the connectors on MPU board and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32



6-2 Attention for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 q Visual checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 w Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 e Error message and possible defective parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35



6-3 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6-4 Analysis of malfunction causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 q No indications are made on the LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 w Indication of the LCD display is normal, but the truck abnormally travels . . . . . . . . . . . 38 e On the LCD display, error meassages appear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38



6-5 Flowchart for troubleshooting



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39



7. Wiring and layout of control unit Reference



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79



1. How to adjust SICOS60 (Major point only) 1-1 The name and function of mode select switch q Slow speed mode button. Change to traveling mode. When the slow speed mode button is turned on, the speed is regulated to the preset speed. (5km/h–12km/h).



Slow speed mode button



œWhen the slow speed mode button is turned on, the turtle mark is displayed on the monitor. Off



On



w Mode select button. Change the select mode. Speed setting mode (SPEED) Power setting mode (POWER) Acceleration feeling mode (ACCEL)



Mode select button



M



e Up button (2 functions) Increase the parameter of each selected mode.



M



UP button



Showing the travel hour meter. TRAVEL



HYD



STEER



BATT



LOAD



OIL



BRAKE



DISCHARGE



CAUTION



Be sure to check that the decimal point flashes when the hour meter counts by traveling or hydraulic operation.



F 8 6 4 2 E



5



0



km/m



10



15



20



SPEED



POWER



50



75



ACCEL



100



SOFT



STD



FULL



TRAVEL



km



Travel hour meter TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



5



0



km/m



10



15



POWER



50



75



100



ACCEL



SOFT



TRAVEL



When hour meter counts, the decimal point flashes. –1–



20



SPEED



STD



FULL



km



r Down button (2 functions). Decrease the parameter of each selected mode.



M Down button



Showing the hydraulic hour meter.



CAUTION



TRAVEL



Be sure to check that the decimal point flashes when the hour meter counts by operating traveling or the hydraulic lever.



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



0



km/m



5



10



15



20



SPEED



POWER



50



75



ACCEL



100



SOFT



STD



FULL



TRAVEL



km



Hydraulic hour meter



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



5



0



km/m



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



TRAVEL



STD



FULL



km



When hour meter counts, the decimal point flashes.



1-2 How to set the each mode Mode select button



Press the mode select button M to adjust the each mode.



M



œThe each mode can be changed by pressing the mode select button M as follows.



M



M



: Normal



M



: Speed setting mode



M



: Power setting mode



: Acceleration feeling mode



–2–



q Speed setting mode The travel speed can be set at 5km/h through 12km/h by every 1km/h. Up button for increasing, Down ton for decreasing. NOTE



but-



M



When the slow speed mode button is off, the travel speed can not be regulated even if it is set. Also no display of preset speed and the “turtle” mark.



M



Down button



Up button



5



km/m



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



STD



FULL



w Power setting mode The power can be set at 3 steps, 100%, 75%, and 50% by pressing the Up button or Down button .



M



M



Down button



Up button



(50%–75%–100%)



The preset power is displayed “POWER” column on the display.



at



the



5



km/m



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



STD



FULL



} Preset power



e Acceleration feeling mode The acceleration feeling mode can be set at 3 modes, Soft, Std (standard) and Full.



M



M



: Easy inching Down button : Normal



Up button



(SOFT–STD–FULL)



: Quick accelerator response 5



km/m



10



15



20



SPEED



NOTE



Better inching operation can be achieved by selecting the "soft" mode.



POWER



50



75



100



ACCEL



SOFT



STD



FULL



} The preset accelerator feeling is displayed at the “ACCEL” column on the display. –3–



Preset accelerator feeling



r Option setting



AB



789



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



456



CDE



F01



23



1) Set the rotary switch RS1 to “7”, and turn the key switch on.



Set RS1 to “7”



œThe setting position which flashes can be moved to the right by pressing the mode select button M.



3) Press, the Up button to set : display “1”. the Down button to reset : display “0”. for each optional specification.



[



M Mode select button



NOTE



After finishing to set or reset, be sure to turn off the key switch and to return the rotary switch RS1 to “0”.



M NOTE



When replacing the MPU board, be sure to set the each function same as original setting.



Option Set



0



Not used – Over Drive without (Option) Hydrauric bywithout pass (Option) Regenerative with contactor Monitoring displayed Seat switch without Lift lock at off over discharge Not used –



M



Up button



Down button



1 –



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



with F 8 6 4 2 E



with without



5



0



km/m



10



15



20



SPEED



POWER



off with



50



75



100



ACCEL



SOFT



TRAVEL



STD



FULL



km



on –



If the bit of “Seat switch” is changed “0” to “1” on a standard truch, hydraulic system and indicator are normal, but the truck cannot travel. If all bits is changed “0” to “1” on the standard truck, 4 error messages appear on the indicator. A10 : FET7-OVER DRIVE B20 : FET4-HYD. BY pass D24 : PC. BOARD-AOS * TURN OFF KEY SWITCH *



Not used Over drive (Opt.) Hydraulic by-pass (Opt.) Regenerative contactor



Monitoring Seat switch Lift lock at over discharge Not used



NOTE



When replacing the MPU board, it is set “1” to each option setting for safety. Confirm the specification of the truck and set it properly.



NOTE



The option setting which is standard specification is set to “0”. For example, Regenerative braking system is equipped as standard. Therefore, setting “0” means “with regenerative brake” “1” means “without regenerative brake”. –4–



t Language selection on LCD display



AB



789



1) Set the rotary switch RS1 to “6” and turn the key switch on.



456



CDE



F01



23



œEach language can be selected by this operation.



Set RS1 to “6”



2) Choose the each language shown below by pressing Up button or Down button .



M



M



Down button



F01



456



AB



23



After finishing to set or reset, be sure to turn the key switch off and to return the rotary switch RS1 to “0”.



CDE



Displayed language when turning key switch on.



789



NOTE



Up button



Set RS 1 to “5”



y Safety monitor symbol. œEach monitor symbol can be set by this operation



1) Set the rotary switch RS1 to “5”.



M



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



Mode select button



œThe setting position which flashes can be



moved to the right by pressing the mode button M.



M DOWN button –5–



M UP button



3) Press, the Up button to set : displayed “1”. the Down button to reset : displayed “0”. for each safety monitor symbol.



[



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



5



0



km/m



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



STD



TRAVEL



FULL



km



TRAVEL



: Travel BRAKE



HYD



: Hydraulic



Parking brake : LOAD



STEER



: Steering



Over load : OIL



BATT



: Battery



Oil level :



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



The symbol for Travel, Hyd, Steer and Brake are preset as a standard at the factory.(displayed “1”)



NOTE



After finishing to set or reset, be sure to turn the key switch off and to return the rotary switch RS1 to “0”.



1-3 Adjustment of starting current and current limitation



F01



Battery electrolyte over 1.25 (at 20°C)



456



AB



23



Zero(0) adjusting is required for the installed current detector to adjust the starting current and current limitation correctly.



CDE



q Zero(0) adjusting for installed



789



Set RS1 to “1”



1) Set the rotary switch RS1 to “1”, and turn the key switch on. 2) The each mode can be changed by pressing the mode select button M as follows.



M M



M



Mode select button



M M



–6–



3) Adjust If LEVEL, and Ia LEVEL to be “000A” at no motor current condition by pressing Up button or Down button CAUTION



As MPU board has an auto-zero level adjustment function, no need to re-adjust these mode normally. However, be sure to confirm it. 4) Press, the Up button when the indication shows minus(–) value. the Down button when the indication shows plus (+) value.



M



M



Up button



Down button



Press Up button when indication on monitor shows minus(–) value.



Press Down button when indication on monitor shows Plus (+) value.



5) After adjusting If GAIN and Ia GAIN, be sure to turn the key switch off and to set back the rotary switch RS1 to “0”.



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



]



= “INITIALIZED”



Press Up and Down button simultaneously for approx. 3 seconds. 5



km/m



10



POWER



50



75



ACCEL



100



Initial setting mode



F01



2) Set the rotary switch RS1 to “2”, and turn the key switch on.



456



AB



23



CDE



w Adjustment of starting current and current limitation 1) Be sure to check that the specific gravity of the battery electrolyte. It should be more than 1.25 at 20°C and the operation of “initialize” should be done, and initializing also finished.



Set RS1 to “2”



œThe each mode can be changed by pressing the mode select button M as follows.



M M



M Mode select button



–7–



15



20



SPEED



789



NOTE



M



SOFT



STD



FULL



3) Adjusting staring current The “CURR START” will be shown after key switch on.



CAUTION



Wall



4) Operate the directional switch to forward, depress the foot brake. Then depress the accelerator pedal until the regenerative contactor just goes on, and hold at that position. When adjusting the starting current and current limitation, lock the traveling motor by operating as follows. Park the truck against a wall, and touch the tip of forks to the wall. Then apply the parking brake lever. Depress the foot brake pedal.



5) Adjust the starting current on the monitor within specified range by pressing Up button or Down button . Model



Starting Current (A)



FB10P



35 ± 5



FB15P, 18P



45 ± 5



FB20P, 25P



50 ± 5



FB30P



45 ± 5



M



–8–



M



Down button



Up button



Press Down button when monitor indication shows higher than the specified value.



Press Up button when monitor indication shows lower than the specified value.



6) Adjusting current limitation Set the “CURR LIMIT” mode by pressing mode select button M.



NOTE



CAUTION



Wall



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



When adjusting the starting current and current limitation, lock the traveling motor by operating as follows. Park the truck against a wall, and touch the tip of forks to the wall. Then apply the parking brake lever. Depress the foot brake pedal. 8) Adjust the current limitation on the monitor within specified range by pressing Up button or Down button . Model



Current limitation (A)



FB10P



280 ± 5



FB15P, 18P



330 ± 5



FB20P, 25P



380 ± 5



FB30P



330 ± 5



M



NOTE



Use the clamp on meter as a reference when checking and adjusting. There may be some difference between the current value on monitor and the reading by the clamp on meter.



NOTE



After finishing the adjustment, be sure to return the rotary switch RS1 to “0”. –9–



M



Down button



Up button



Press Down button when monitor indication shows higher than the specified value.



Press Up button when monitor indication shows lower than the specified value.



– 10 –



D



E



Not used



Not used



C



9



Not used



5.0 - 6.0



6



4



B



330 ± 10



5.0 - 6.0



5.0 - 6.0



Not used



45 ± 5



FB30P



380 ± 10



330 ± 10



0



A



50 ± 5



FB20P, 25P



5.0 - 6.0



Plugging brake distance (m)



Not used



45 ± 5



FB15P, 18P



280 ± 10



Current limitation (A) 32



Not used



Option setting should be set “0” for standard specification. Set to “1” in case of some option being installed.



regenerative contactor



046



020



OIL



LOAD



BRAKE



\



\



\



OIL



\



LOAD BRAKE



0



Language



6



5 : DUTCH



4 : SPANISH



DUTCH



SPANISH



GERMAN



MONITORING OK



MONITOR OK



UEBERWACHUNG OK



FRENCH 3 : GERMAN



MONITORING OK CONTROLEUR OK



ENGLISH 2 : FRENCH



Indication of key switch on



1 : ENGLISH



Language JAPANESE



0 : JAPANESE



RS1-6



* In case of no indication display language JAPANESE Domestic : 0 : JAPANESE ENGLISH : 1 : ENGLISH Except for Japan



15.0/13.0



15.0/13.0



(km/h)



Unladen /Laden



14.5/12.5



\



5 STEER BATT



15.0/12.5



060



TRAVEL HYD



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



0 0 1 0



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



BATT



STEER



HYD



Seat switch



Over discharge lift lock



Over drive (Opt.)



1 1 1 1



RS1-5 (monitoring setting)



Switch back brake distance • Flat, Unladen, Full speed • Specific gravity of electrolyte more than 1.25 at 20°C • Full acceleration



TRAVEL



Hydraulic by-pass (Opt.)



060



064



Monitoring



0 0 0 0



48



32



56



64



50



64



32



Tilt



Lift 2



Lift 1 32



Over drive



Speed Speed Speed L lift M lift H lift



Attach- Attach- Attach- Switch back brake force Braking ment 1 ment 2 ment 3 Plugging Regeneration force



PLUGG- REGENE ING RATE



OVER DRIVE



HYD ATT.3



BRAKE TRQ



HYD ATT.2



HYD ATT.1



HYD TILT



4



SPD-L SPD-M SPD-H HYD HYD LIFT LIFT LIFT LIFT-1 LIFT-2



Not used



0 0 0 0



RS1-7 (Option setting)



Starting current /Current limitation • Motor current • Power 100% • Specific gravity of electrolyte more than 1.25 at 20°C



48V



35 ± 5



FB10P



Starting current (A)



/



/



/



/ / /



/ / /



/ / /



/ / /



/ / /



/ / /



/ / /



/ / /



/ /



/



/



/



(V)



3



/



Model



/ / /



/



/



Voltage



/ /



/



/



Traveling speed



/ /



/



/



RS1



/ /



/



/



Setting of rotary switch



/ /



/



/



RS0



/ /



(Confirmation)



The specification of each adjustment for FB-DC70



2. Adjustment for other functions qAuto-torque up



A: Specific gravity of the battery electrolyte: more than 1.25 at 20°C B: Make an initializing (Initialize mode setting)



1) Check the current limitation. 2) Confirm that the current limitation should be increased by 130% of the value of current limCurrent 130% itation after 3 seconds. limitation



Forcible by-pass contactor on



100%



3sec 2sec



wSafety circuit for out of control (contactor tripping)



1) Be sure to check that the forward and backward contactor has not gone in. 2) Make a jumper wire between a main terminal of bypass contactor. (Wire size about 0.5mm2) 3) Be sure to check the warning beap sound and the error massage on the display. 4) Confirm that even though operate the accelerator, after that the forward (backward) contactor will not go in.



ePower setting



Specific gravity of the battery electrolyte: more than 1.25 at 20°C Set the power setting to 50%



1) Check the current limitation. 2) Be sure to check that the motor current becomes to about 70% of the current limitation.



– 11 –



rHydraulic setting



AB



456



CDE



F01



23



Be sure to check that the each setting is set as listed on “The specification of each adjustment for FB-DC70” (p.10).



789



Set the rotary switch RS1 to “3”



1) Set the rotary switch RS1 to “3”.



2) The each mode can be changed by pressing the mode select button M and adjust the setting by up button or down button .



M



Mode select button



After finishing the adjustment, be sure to return the rotary switch RS1 to “0”.



M M M M M



M M M M



tSwitch back braking distance (Plugging/Regenerative braking)



AB



456



CDE



F01



23



A: Specific gravity of the battery electrolyte: more than 1.25 at 20°C B: Flat ground, Unladen, Full speed



789



NOTE



Set the rotary switch RS1 to “4”



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



M



Mode select button



M M M



– 12 –



3) Adjust the plugging braking distance by press. ing up button or down button The braking distance will be, . shorten by pressing up button . longer by pressing down button NOTE



After finishing the adjustment, be sure to return the rotary switch RS1 to “0”.



M



M



Up button



Down button



For shorter distance.



For longer distance.



yRegenerative braking force



A: Specific gravity of the battery electrolyte: more than 1.25 at 20°C B: Flat ground, Unladen, Full speed



AB



456



CDE



F01



23



1) Traveling forward with middle speed and release the foot from the accelerator pedal. 2) Depress the foot brake pedal lightly. 3) Be sure to check the forward contactor is off and reverse contactor is on, Then regenerative braking is worked.



789



Set the rotary switch RS1 to “4”



1) Set the rotary switch RS1 to “4”, and change the mode of “BRAKE TRQ” by pressing mode select button M.



M



Mode select button



M M M 2) Adjust the regenerative braking force by . pressing up button or down button The braking force will be, . Strong by pressing up button . Poor by pressing down button NOTE



After finishing the adjustment, be sure to return the rotary switch RS1 to “0”.



– 13 –



M



M



Down button



Up button



For poor braking effect.



For strong braking effect.



uAdjustment of brightness of the back light on monitor Adjust the brightness of the back light on monitor by the volume VR0. Turning it clockwise for bright contrast.



Turning it clockwise for bright contrast.



CFL VR0



F01



456



AB



23



789



1) Set the rotary switch RS1 to “C” and turn the key switch on. The each mode can be changed by pressing the mode select button M as follows.



CDE



iChecking of speed sensor output



Set the rotary switch RS1 to “C”



M M



M Mode select button



Sensor output 1 : left side



Traveling direction F : Forward, R : Reverse



Sensor output 2 : right side



Sensor output total (value of output 1+2)



2) Set the “SPD” (Speed sensor checking) mode. 3) Check the indication of sensor output by traveling. œNormally, the value of sensor output 1 and 2 should be the same when traveling.



In case that the value of sensor output 1 or 2 is not varied when traveling. (=always shown “0”) Check the sensor or its wire harness connected to MPU board. In case that the value of sensor output 1 and 2 are the same with no changing. Check and adjust the potentiometor for sensor 1 or 2 by the shims. In case that the value of sensor output 1 plus 2 does not make a sensor output total. (=output 1+2≠total) It may be influenced by the noise. Please check some wire near the wire of sensor 1 and 2. In case that the indication of traveling direction is opposite from the actual moving direction. Check the connection of sensor 1 and 2, They may be opposite. NOTE



After confirming the working, be sure to turn the key switch off and return the rotary switch RS1 to “0”.



– 14 –



oHour meter working



1) Connect the wireharness of [Blue/Red 1] and [Black] located inside the front cover. 2) Be sure to check that the decimal point flashes when the hour meter counts by traveling or hydraulic operation.



!0Confirming the working of auto-power cut off function



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



!1Adjusting of battery voltage Item (function)



Condition for checking



Check and adjustment procedure 1) Check the battery voltage at, + : Hyd. fuse, - : Minus (–) terminal in the control unit. 2) Set the rotary switch RS1 to “A”, and turn the key switch on. 3) Set to “VB LEVEL” mode by pressing mode select button M.



Battery voltage (for battery capacity indicator)



MSpecific gravity : more than 1.25 at 20°C



M



M



4) Adjust the “VB LEVEL” to be the same value checked at 1) by pressing Up or Down button.



CAUTION



– 15 –



The VOLTAGE figure will not be changed even if adjusting the VB LEVEL.



3. Option qConfirming Over loading



1) Lift up to the end and make a relief condition. 2) Confirm the display *REDUCE THE LOAD*.



wConfirming the travel inhibit



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



After confirming the working, be sure to turn the key switch off and return the rotary switch RS1 to “0”.



– 16 –



AB



789



NOTE



Lifting speed will be half. Then after ten minutes operation, Battery capacity indicator : [Red] lamp flashes. Indication on display : ✳CHARGE THE BATTERY✳ and lifting will be suspended.



456



CAUTION



F01



23



1) Set the rotary switch RS1 to “7” and turn the key switch on. 2) Set 2nd bit of the lift lock at over discharge to “1”. 3) Supply the voltage of 30–36V to the battery plug. 4) Confirm Battery capacity indicator : [Red] lamp turning on. Indication on display :*CHAGE THE BATTERY*



CDE



eConfirming the lift locking working at over discharge



Set the rotary switch RS1 to “7” TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



5



0



km/m



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



STD



TRAVEL



FULL



km



The lift locking at over discharge (2nd bit)



rConfirming the seat switch working



After confirming the working, be sure to turn the key switch off and return the rotary switch RS1 to “0”.



CDE



AB



789



NOTE



456



1) Operate the traveling without sitting on the seat. 2) Confirm the truck does not travel.



F01



23



1) Set the rotary switch RS1 to “7” and turn the key switch on. 2) Set 1st bit of the seat switch to “1”.



Set the rotary switch RS1 to “7” TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



5



0



km/m



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



TRAVEL



STD



FULL



km



Seat switch (1st bit)



– 17 –



4. Outline of New EPS system for FB–DC70 4-1 Outline of New EPS system



steering gear box



controller



motor



actuator



rear axle



The EPS system is constructed with steering gear box, new design potentiometer actuator, and controller (new design) above. The torque sensor in the steering gear box detects the opposite force from the steering tire when the steering wheel is operated, and send the signal which is proportioned with the force and direction to the controller. The controller controlls the magnitude and direction of the steering motor current. The steering motor creates the force by this current to assist the steering operation. When the shock is applied to the tire, the torque sensor detects it and the actuator creates the equivalent force against it. So, no kick back force is applied to the steering wheel.



– 18 –



4-2 Operation Actuator Ass’y Torque sensor



Steering Operation



+ –



Controller



Actuator



w



e



r



t



Torque sensor output



Motor current control



Output of motor torque



Assist force



Wheel steering



y



1) When the key switch is turned on, the contactor is activated and the power is supplied. 2) When the steering wheel is operated, the steering force is detected by the torque sensor and output the voltage corresponded for it. 3) The output voltage from the torque sensor is applied to the controller and converted to the current for the motor on the actuator. 4) The motor creates the output torque which is proportioned with the input current. 5) The output force of the actuator assists to steer the wheels. 6) The steering force is reduced by this assist force.



4-3 Feature qProtection of overheat for motor When the motor current for about 5 seconds, the turned off automatically. input of torque sensor to normal control condition.



continues over 25A motor output will be When put back the neutral, it returns at



wSelf diagnosis function



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



1) If the problem is occurred at the torque sensor, scrolls the message of [C29:SENSOREPS TORQUE] on the display (Torque sensor error).



F 8 6 4 2 E



5



0



km/m



10



15



20



SPEED



POWER



50



75



ACCEL



100



SOFT



STD



FULL



TRAVEL



2) If the problem is occurred at a main FET circuit in the EPS controller, scrolls the message of [C30: TR-EPS MAIN] on the display (chopper error).



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



5



0



km/m



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



TRAVEL



– 19 –



km



STD



FULL



km



4-4 Checking and Adjustment qNeutral adjustment of torque sensor



yellow



1) Turn the key switch off. 2) Jack up the rear wheels from the ground. 3) Open the side cover at right side. 4) Put the clamp meter to the wire [yellow] or [green] between EPS controller and EPS motor [DC range] 5) Turn the key switch on and measure the indication at the clamp meter without steering operation. (= at neutral steer) If the indication shows 0A, it is normal. 6) If any current is flown, adjust the potentiometer by the following procedure.



green



EPS controller



A



black



red



clamp meter



EPS motor



1) Turn the key switch off and disconnect the battery plug. 2) Disconnect the 3P water proof type connector of EPS sensor. 3P water proof type connector (tab side)



1.5



k



potentiometer



EPS sensor ass’y



+ –



3) Check the resistance at sensor side (tab side) between,



• q pin (Orange) and e pin (Black/Red) = Approx. 5k ............... A • q pin (Orange) and w pin (Green/Red) = Approx. 2.5k ........... B • w pin (Green/Red) and e pin (Black/Red) = Approx. 2.5k ...... C



From EPS sensor (potentiometer)



q Orange w Green/Red e Black/Red



These should be even value.



q Blue 3



Tab



Rece



w Green /Blue 1 e White



To EPS controller



3P water proof type connector



4) Adjust it by removing or inserting a shim to be the even value between B and C above. NOTE



The resistance value may depend on the type of tester and each unit. – 20 –



5) Connect the battery plug and turn the key switch on. Check and confirm that there is no EPS motor current at the neutral steer by the above procedure, .



wChecking by voltage When it is difficult to adjust the torque sensor very precisely. Use this method. Neutral adjustment of the potentiometer can be checked by its output voltage.



1) Turn the key switch off. 2) Disconnect the connector of the torque sensor and put the adaptor for measuring voltage. NOTE



As the connector of the torque sensor is waterproof type, it is impossible to put the tester probe. Make an adapter by using the same type adapter.



3) Check the voltage at w pin [Green/Red or Green/Blue 1] of the adaptor. 4) Turn the key switch on and operate the steering wheel from right side end to left side end, then check the voltage. The following values are the standard.



right side end



0.8 V ± 0.3



neutral



2.5 V ± 0.3



left side end



4.2 V ± 0.3



From EPS sensor (potentiometer)



q Orange



q Blue 3



w Green / Red e Black / Red



Tab



w Green/Blue 1



Rece



e White



3P water proof type connector q pin w pin



Rece



e pin



Tab



Adaptor



Tab + probe to w pin (output)



– probe to e pin (negative)



V



+ –



– 21 –



To EPS controller



5. Self diagnosis history memory and I/O check. 5-1 Self diagnosis history memory The total 34 error histories which have occurred at least once can be memorized. There are two (2) kind of information for this function. The one is to memorized the operated condition when the trouble has occurred (called “Format 1”), the other one is to memorize the each malfunction (called “Format 2”). œThe basic system of “Format 2” is same as the one adopted on SICOS 50/60 and A-SICOS for FBR-60 series.



S



CO -SI



W



NE



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



TRAVEL



DISCHARGE



F 8 6 4 2 E



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



0



km/m



5



10



15



20



F 8 6 4 2 E



SPEED



POWER



50



75



100



ACCEL



SOFT



TRAVEL



STD



FULL



0



km/m



5



10



15



20



SPEED



POWER



50



75



100



ACCEL



km



SOFT



TRAVEL



STD



FULL



km







Memory and display for the operated condition when the trouble has occurred.



Memory and display for the each malfunction. *same as SICOS 50/60 and A-SICOS or FBR-60 series.



– 22 –



AB



456



CDE



F01



23



1) Set the rotary switch RS1 to “B”, and turn the key switch on. 2) Press the mode select button M to call the each mode.



789



Set RS 1 to “B” NOTE



Do not turn the key switch on/off when the rotary switch RS0 is set to “F” as the history memory is cleared.



M CAUTION



The truck can be moved even though the history memory is called. Mode select button



A: Format 1 of history memory 3) Press Up or Down the each history No..



button to change



M



M



DOWN button



UP button



History memory No. can be changed (called) by pressing Up/Down button.



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



0



km/m



5



10



15



POWER



50



75



100



ACCEL



SOFT



TRAVEL



STD



FULL



km



[5] : Traveling mileage Traveling mileage will be displayed when some trouble happen.



[1] : History No. (0-9) Each error is displayed in order. 0 : Latest error 9 : Oldest error * It is naturally cleared for the errors over 11th. The history No. can be changed by pressing UP/Down button.



20



SPEED



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



– 23 –



[1] Traveling motion mode No. Mode No.



Content



00



Neutral



01



Forward mode: Regenerative contactor OFF



02



Forward mode: Traveling contactor ON



03



Forward mode: Regenerative contactor ON



04



Forward mode: Traveling speed control



05



Forward mode: Bypass contactor ON



06



Forward mode: Bypass contactor OFF



07



Forward mode: Bypass control



08



Forward mode: Over driving contactor ON



09



Forward mode: Over driving contactor OFF



0A



Forward mode: Over driving control



0B



Forward mode: Pre-energizing



0C



Forward mode: Regenerative control



11



Reverse mode: Regenerative contactor OFF



12



Reverse mode: Traveling contactor ON



13



Reverse mode: Regenerative contactor ON



14



Reverse mode: Traveling speed control



15



Reverse mode: Bypass contactor ON



16



Reverse mode: Bypass contactor OFF



17



Reverse mode: Bypass control



18



Reverse mode: Over driving contactor ON



19



Reverse mode: Over driving contactor OFF



1A



Reverse mode: Over driving control



1B



Reverse mode: Pre-energizing



1C



Reverse mode: Regenerative control



[2] Hydraulic motion mode No. Mode No.



Content



0



Hydraulic neutral



1



Hydraulic control



2



Hydraulic bypass contactor ON



3



Hydraulic bypass contactor OFF



4



Hydraulic bypass control



– 24 –



B: Format 2 of history memory 3) Press Up or Down button to change (call) the each Error memory No..



M



If there has been a problem at least once, the bit shows “1”. If not, it shows “0” on the monitor.



M



DOWN button



“0” . . .No trouble [ “1” . . .Troubled (at least once)



UP button



History memory No. can be changed (called) by pressing Up/Down button.



TRAVEL



HYD



BATT



OIL



LOAD



30 40



60



80



STEER



BRAKE



DISCHARGE



F 8 6 4 2 E



Error memory No.



7th bit



6th bit



0



SPEED LIMIT



POWER



5th bit



50



75



100



4th bit



ACCEL



SOFT



%



STD



3rd bit



2nd bit A1 : FUSETRAVEL



ERR0



A5 : A6 : FET9CONTACTORREVERSE FORWARD



A4 : FET10FORWARD



A3 : A2 : FET6CONTACTORREGEN REGEN



ERR1



A14 : SENSOR- A13 : ACCELCURRENT ACCELERATOR (ARMATURE)



A12 : TR-REGEN MAIN



A11 : TR-TRAVEL MAIN



ERR2



B21 : B22 : TR-HYD SWITCH-LIFT MAIN



B20 : FET4HYD. BYPASS



B19 : B18 : FET5CONTACTOR- HYD HYD



ERR3



*REDUCE THE LOAD*



*REFILL HYDRAULIC OIL*



Not used



Not used



C31 : FUSE EPS



ERR4



Not used



Not used



Not used



Not used



Not used



– 25 –



FULL



1st bit



*FAIL HYD*



0 bit



*FAIL TRAVEL*



A10 : FET7- A9 : A8 : FET8OVER DRIVE CONTACTOR BYPASS BYPASS



A7 : CONTACTORREVERSE



B17 : FUSE HYD



A16 : SENSORSPEED



A15 : SENSORCURRENT (FIELD)



C30 : TR-EPS MAIN



C29 : SENSOREPS TORQUE



Not used



Not used



*REPLENISH *REFILL REFINED WATER FOR BRAKE OIL* BATTERY*



1) Turn the key switch OFF.



OFF



ON START



F01



456



AB



23



CDE



2) Set the rotary switch RS0 to “F”.



789



Set the rotary switch RS0 to “F”



3) Turn the key switch ON. (To START) OFF



ON START



4) Turn the key switch OFF.



OFF



5) Set the rotary switch RS0 at the original position.



6) Make sure to be clear it.



– 26 –



ON



5-2 I/O check I/O (Input/Output) check is the function that the input and output signal for the microcomputer can be displayed on the LCD by the binary code of [1] or [0] to check if each part is normal. Approx. 90 points of input/output signals can be checked.



Set RS 1 to “E”



AB



789



2) Select the port by pressing Up or Down button. Refer to the I/O table for the detail of each port.



Select the port No.



M NOTE



After confirming the I/O check, be sure to turn the key switch off and return the rotary switch RS1 to “0”.



M



DOWN button



For example, in case of the port No.10 (=IOM10), the following screen is displayed.



TRAVEL



HYD



STEER



BATT



OIL



LOAD



BRAKE



DISCHARGE



F 8 6 4 2 E



0



km/m



5



10



15



20



SPEED



POWER



50



75



100



ACCEL



SOFT



TRAVEL



Directional switch for reverse 1 : ON 0 : OFF



STD



FULL



km



Not used Not used



Directional switch for forward 1 : ON 0 : OFF Directional switch for neutral 1 : Neutral 0 : Not Neutral



– 27 –



456



CDE



F01



23



1) Set the rotary switch RS1 to “E”, and turn the key switch on.



Not used Not used Not used



UP button



I/O TABLE (1) PORT NO.



RS1-E NO.OD



RS1-E NO.OE



RS1-E NO.OF



RS1-E NO.OC



BIT



IN/OUT



0



IN



Button



[UP]



0: Up [brake closed]



1



IN



Button



[Mode select]



0 : select



2



IN



Button



[Down]



0 : Down



3



IN



Button



[Slow speed]



1 : Slow speed



4



IN



Hydraulic oil level



0 : Detection



5



IN



Brake oil level



0 : Detection



6



IN



Overload



0 : Detection



7



IN



Not used



0



IN



Switch



[Brake]



0 : ON [brake closed]



1



IN



Switch



[Lift 1]



1 : ON



2



IN



Switch



[Lift 2]



1 : ON



3



IN



Switch



[Tilt]



1 : ON



4



IN



Switch



[Attachment 1]



1 : ON



5



IN



Switch



[Attachment 2]



1 : ON



6



IN



Switch



[Attachment 3]



1 : ON



7



IN



Switch



[Parking brake]



1 : ON



0



IN



Contact



[Regenerative]



1 : ON



1



IN



Contact



[Hydraulic]



1 : ON



2



IN



Contact



[Forward]



0 : ON



3



IN



Contact



[Reverse]



0 : ON



4



CONTENTS



REMARKS



Not used



5



IN



Fuse



[Travel]



0 : Fault



6



IN



Fuse



[Hydraulic]



0 : Fault



7



IN



Fuse



[EPS]



0 : Fault



0



IN



Rotary switch RS-0



EX) 0000 : "0"



1



IN



Rotary switch RS-0



0000 : "1"



2



IN



Rotary switch RS-0



0000 : "3"



3



IN



Rotary switch RS-0



0000 : "8"



4



IN



Rotary switch RS-1



EX) 0000 : "0"



5



IN



Rotary switch RS-1



0001 : "1"



6



IN



Rotary switch RS-1



0011 : "3"



7



IN



Rotary switch RS-1



1000 : "8"



– 28 –



I/O TABLE (2) PORT NO.



RS1-E NO.10



RS1-E NO.11



BIT



IN/OUT



CONTENTS



1



IN



Not used



2



IN



Not used



3



IN



Not used



4



IN



Not used



5



IN



Directional



[Neutral]



1 : Neutral



6



IN



Directional



[Forward]



1 : Forward



7



IN



Directional



[Reverse]



1 : Reverse



0



Not used



1



Not used



2



Not used



3



Not used



REMARKS



4



IN



Hour mete clear



1 : Clear



5



IN



Hour meter count stop



1 : Stop



6



IN



Hour meter option



1 : Counting



7



OUT



[Hydraulic]



Not used



Current [Armature] Use 10 bits by binary system. "1 and 0 bits of NO.01 and 7 to 0 bits of NO.00" RS1-E NO.00 NO.01



\\ \\\\\\\\



bit



1 0 7 6 5 4 3 2 1 0 NO.01



NO.00



Analog / Digital conversion



0 - 500A / 1.2 - 4.0V



Current [Field] Use 10 bits by binary system. "1 and 0 bits of NO.03 and 7 to 0 bits of NO.020" RS1-E NO.02 NO.03



\\ \\\\\\\\



bit



1 0 7 6 5 4 3 2 1 0 NO.03



NO.02



Analog / Digital conversion



0 - 500A / 1.2 - 4.0V



Voltage [Battery] Use 10 bits by binary system. "1 and 0 bits of NO.05 and 7 to 0 bits of NO.04" RS1-E NO.04 NO.05



\\ \\\\\\\\



bit



1 0 7 6 5 4 3 2 1 0 NO.05



NO.04



Analog / Digital conversion



0 - 55V / 0 - 5V



Voltage [Battery capacity] Use 10 bits by binary system. "1 and 0 bits of NO.07 and 7 to 0 bits of NO.06" RS1-E NO.06 NO.07



\\ \\\\\\\\



bit



1 0 7 6 5 4 3 2 1 0 NO.07



NO.06



Analog / Digital conversion – 29 –



44.6 - 55V / 1.2 - 4.0V



I/O TABLE (3) Accelerator voltage 1 Use 10 bits by binary system. "1 and 0 bits of NO.09 and 7 to 0 bits of NO.08" RS1-E NO.08 NO.09



\\ \\\\\\\\



bit



1 0 7 6 5 4 3 2 1 0 NO.09



NO.08



Analog / Digital conversion



0 - 0.5V



Accelerator voltage 2 Use 10 bits by binary system. "1 and 0 bits of NO.0B and 7 to 0 bits of NO.0A" RS1-E NO.0A NO.0B



\\ \\\\\\\\



bit



1 0 7 6 5 4 3 2 1 0 NO.0B



NO.0A



Analog / Digital conversion



PORT NO.



RS1-E NO.18



0 - 0.5V



BIT



IN/OUT



0



OUT



Contactor select



[Forward]



1 : ON



1



OUT



Contactor select



[Reverse]



1 : ON



2



OUT



Contactor select



[By-pass]



1 : ON



3



OUT



Contactor select



[Overdrive]



1 : ON



4



OUT



Contactor select



[Regenerative]



1 : ON



5



OUT



Contactor select



[Hydraulic]



1 : ON



6



OUT



Contactor select



[Hydraulic by-pass]



1 : ON



7



CONTENTS



Not used



– 30 –



REMARKS



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



qLocation of negative circuit Fit the negative(–) probe of circuit tester to; Minus (–) terminal in the control unit or the ribbon wire of M4 contactor when checking the voltage. Battery : 48V(FB10-25P) 72V (FB30P) (The auxiliary 48 volts output is equipped in the case of the 72 volts battery.



VA



F1



N



2200µF X 1 (FB10/15/18P) X 2 (FB20/25P) X 3 (FB30P)



NA



V



Capacitor : 100V



D1



275A VC



D2 M4



M1 A



IF



IA



FC1 M2



WH



Pre-energizing resistor : 30W 2.2Ω X 4 (10-25) 40W 2.2Ω X 2 (30)



RD



M3



D3



PB83-62 Pre-energizing



BU



(–) terminal or ribbon wire of M4 contactor



Capacitor : 100V 2200µF X 1 (FB10/15/18P) X 2 (FB20/25P) X 3 (FB30P)



D4 F2 PA



M7 FC2



(–) probe (–) probe



Battery (–) terminal



M4 contactor ribbon Wire (Bypass contactor)



– 31 –



wLayout of the connectors on MPU board and others 1) MIC connector MPU board



PB84-XX



CN1



CN3



CN2



CN4



CN5



CN6



A 6 5 4 3 14 13 12 11 10 9



CN1



2 8



1 7



4 3 10 9



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



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



CN2



CN5



CN6



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



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



CN3



CN4



8



7



2 6



1 5



View from A (receptacle/harness side) Each No. in the connector indicates pin No. For example, CN3-6 Pin No. (see picture in above) Connector No. (CN1-CN6)



NOTE



Pin location for connectors are shown from insertion side of pins.



– 32 –



2) Waterproof type connector Each No. in the connector indicates pin No. . 12 pin type



10 pin type



8 pin type



6 pin type



3 pin type



2 pin type



Rece side



6 5 4 3 2 1 12 11 10 9 8 7



5 4 3 2 1 10 9 8 7 6



4 3 2 1 8 7 6 5



3 2 1 6 5 4



3 2 1



2 1



Tab side



1 2 3 4 5 6 7 8 9 10 11 12



1 2 3 4 5 6 7 8 9 10



1 2 3 4 5 6 7 8



1 2 3 4 5 6



1 2 3



1 2



3) Other connector Each No. in the connector indicates pin No. . 6 pin type



Rece side



1 4



2 5



3 6



Tab side



3 6



2 5



1 4



4 pin type (1)



1



2



3



4



4 pin type (2)



1 3



2 4



2 4



1 3



6-2 Attention for the troubleshooting NOTE



Initially correctly understand content and phenomena of problems. After understanding customer’s operator sayings and actual forklift truck status as correctly as possible ( including problems that often occur).



qVisual checking The visual checking may help to find the main cause, check the each parts carefully. Example) Is there any parts or wire which is burned out ? How about the looseness of connector ?



– 33 –



2 pin type



1 2



wFault finding When the cause is unknown even after visual check, safety guard



1) Place the rigid blocks under the outer mast to stable the truck. 2) Tilt the mast forward by pushing the tilt lever to rise the front wheels. NOTE



Place the safety guards for safety ! Do not rotate the drive wheels off the floor at high speed, because the drive motor and internal parts of the gear box could be damaged. Measurement of voltage should be done in a short time. Be sure to disconnect the battery plug when connecting the volt-ohm meter, repairing and replacing parts.



– 34 –



Rigid block



eError message and Possible defective part Error No. and error message is displayed. Symbol Error (Flash for defect) No.



Message



Possible defective part



3



* FAIL TRAVEL. *



FET, D2, MPU board ... etc.



4



* FAIL HYD. *



FET, MPU board ... etc.



* TURN OFF KEY SWITCH *



linked with other message



5



A1 : FUSE-TRAVEL.



Travel fuse



6



A2 : FET6-REGEN.



Regen. contactor coil, MPU board



7



A3 : CONTACTOR-REGEN.



Regen. contactor, MPU board



8



A4 : FET10-FORWARD



Forward contactor coil(Left), MPU board



9



A5 : CONTACTOR-FORWARD



Forward contactor



10



A6 : FET9-REVERSE



Reverse contactor coil (Left), MPU board



11



A7 : CONTACTOR-REVERSE



Reverse contactor



12



A8 : FET8-BYPASS



Bypass contactor coil, MPU board



13



A9 : CONTACTOR-BYPASS



Bypass contactor, MPU board



14



A10 : FET7-OVER DRIVE



15



A11 : TR-TRAVEL. MAIN



FET, Bypass contactor, MPU board



16



A12 : TR-REGEN. MAIN



Pre-energizing board, Resistor



17



A13 : ACCEL-ACCELERATOR



Accel., Directional sw.



18



A14 : SENSOR-CURRENT (ARMATURE)



Current sensor (Ia)



19



A15 : SENSOR-CURRENT (FIELD)



Current sensor (If)



20



A16 : SENSOR-SPEED



Speed sensor



21



B17 : FUSE-HYD.



Hydraulic fuse



22



B18 : FET5-HYD.



Hydraulic contactor coil, MPU board



23



B19 : CONTACTOR-HYD.



Hydraulic contactor, MPU board



24



B20 : FET4-HYD. BYPASS



25



B21 : TR-HYD. MAIN



Hydraulic FET, MPU board



26



B22 : SWITCH-LIFT



Lift micro switch (1), (2)



27



B23 : SENSOR-CURRENT (HYD.)



TRAVEL



HYD



Remarks



Half speed



Half speed



Half speed



Half speed



Half speed



D24 : PC. BOARD-AOS * FAIL AOS * D25 : TR-AOS D26 : RELAY-AOS D27 : POTENTIO-HYD. LEVER D28 : POTENTIO-MAST STEER



34



C29 : SENSOR-EPS TORQUE



35



C30 : TR-EPS MAIN



36



C31 : FUSE-EPS



37



C32 : FET3-EPS



38



C33 : CONTACTOR-EPS



* The following parts cannot be diagnosed and displayed. 1) Diodes : D1, D2, D3 and D4 5) Motors 2) Capacitors for surge absorbing 6) A part of MPU board 3) A part of current sensor 7) A part of microswitches 4) A part of pre-energizing board 8) Wire harness



9) Connectors 10) Back contacts of forward / reverse contactror 11) LCD display



* The error messages for the current sensor and the pre-energizing board are depend on the defect conditions to display. – 35 –



Symbol Error (Flash for defect) No.



Message



Possible defective part



Remarks



39



* REFILL HYDRAULIC OIL *



Shortage of hydraulic oil



40



* REDUCE THE LOAD *



Overloaded



Opt.



41



* REFILL BRAKE OIL *



Shortage of brake oil



Opt.



42



* REPLENISH REFINED WATER FOR BATTERY *



Shortage of battery electrolyte



* CHARGE THE BATTERY *



Need to charge battery



* RELEASE ACCEL. TO NEUTRAL *



Accelerator is operated before power on



* OFF HYD. LEVER TO NEUTRAL *



Hyd. lever is operated before power on



6-3 Troubleshooting Procedure Correct understanding of the content and phenomena of the problems is a great prerequisite. However, after understanding them, the indications on the display (safety monitor, error message, I/O checking ) become effective means. An indication is not made on the LCD display. No indications or abnormal. Indication of the LCD display is normal. No error message appears. Indication of the LCD display is normal. Error messages appears. These cases are assumed. Considering them and referring to the error messages and circuit diagram (system wiring), trace the malfunctions. Approximate guess is required. Thoughtless tracing greatly wastes time. The basic considerations are the same as the SICOS50/60. However, glance over this manual and roughly take note of the key matters.



6-4 Analysis of malfunction causes It was previously stated that initial understanding of the content and phenomena of the problems is an important point in finding the malfunctions. With prerequisite that a malfunction results in any error, the following checkings lead to a start for the procedure. – 36 –



GS batt.



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



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



Can truck travel and operate hydraulics normally?



Are all lit? LED0:12V LED1: 5V LED2:CPU run



No



Yes



Yes



Replace LCD dispraly. Yes



Checking for power line. F4 fuse, Mctt replay, CN2-6 pin, CN5-20 pin, CN5-10 pin.



Is LCD indication made? Yes



Check for MPU board or wirings.



– 37 –



No Replace MPU board.



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



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



– 38 –



6-5 Flowchart for troubleshooting q Check point 1) Is model select correct? 2) Check the specification. With option. Special truck? After checking the above, start to troubleshoot.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit.



w Contents of flowchart ERROR NO.1 ERROR NO.2 ERROR NO.3 ERROR NO.4 ERROR NO.5 ERROR NO.7 ERROR NO.9 ERROR NO.11 ERROR NO.13 ERROR NO.16 ERROR NO.18 ERROR NO.20 ERROR NO.22 ERROR NO.24 ERROR NO.26 ERROR NO.35



*RELEASE ACCEL TO NEUTRAL* *OFF HYD. LEVER TO NEUTRAL* *FAIL TRAVEL* *TURN OFF KEY SWITCH* *FAIL HYD.* *TURN OFF KEY SWITCH* A1:FUSE-TRAVEL ERROR NO.6 A3:CONTACTOR-REGEN. ERROR NO.8 A5:CONTACTOR-FORWARD ERROR NO.10 A7:CONTACTOR-REVERSE ERROR NO.12 A9:CONTACTOR-BYPASS ERROR NO.15 A12:TR-REGEN. MAIN ERROR NO.17 A14:SENSOR-CURRENT(ARMATURE) ERROR NO.19 A16:SENSOR-SPEED ERROR NO.21 A18:FET5-HYD. ERROR NO.23 B20:FET4-HYD. BYPASS ERROR NO.25 B22:SWITCH-LIFT ERROR NO.34 C30:TR-EPS MAIN ERROR NO.36



– 39 –



A2:FET6-REGEN. A4:FET10-FORWARD A6:FET9-REVERSE A8:FET8-BYPASS A11:TR-TRAVEL MAIN A13:ACCEL-ACCELERATOR A15:SENSOR-CURRENT(FIELD) A17:FUSE-HYD. B19:CONTACTOR-HYD. B21:TR-HYD. MAIN C29:SENSOR-EPS TORQUE C31:FUSE-EPS



Error No.1



* RELEASE ACCEL TO NEUTRAL *



LCD Display



*RELEASE ACCEL TO NEUTRAL* Operate Accelerator before turning on Key switch?



No



No Slit plate normal? Yes



Yes



Return the accelerator to the neutral position. Then operate it again.



Adjust.



Replace the accelerator printed board.



Operation become normal?



No



Yes



This situation is occurred by the neutral safety function. This is not problem. This function warns to the operator to take the correct procedure to operate.



END



No



Repair.



The following each wiring between Accelerator and MPU board is normal? Accelerator PB-CN3-4 (Red4) Accelerator PB-CN3-5 (Brown/Yellow1) Accelerator PB-CN3-14 (Black/Yellow) Accelerator PB-CN4-1 (Red/Green3) Accelerator PB-CN4-2 (Green/Black1) Accelerator PB-CN4-9 (Black1) Yes Replace MPU board.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 40 –



Error No.2



* OFF HYD. LEVER TO NEUTRAL *



LCD Display



*OFF HYD. LEVER TO NEUTRAL* No



Operate the hydraulic lever before turning the key switch?



Turn off key switch.



Yes Set RS1 at [E]. Return the hydraulic lever to the neutral position. Then operate it again. Turn on key switch.



This situation is occurred by the neutral safety function. This is not problem. This function warns to the operator to take the correct procedure to operate.



Select [IOM 0E].



No



Release the hydraulic lever. Any bit shows [1]?



Replace MPU board.



Yes No Hyd. micro switch normal?



Repair.



Yes The following wiring between Hyd. Micro SW and MPU board are normal? Lift1 micro SW-CN6-6 (Brown/Red1) Lift2 micro SW-CN6-14(Blue/Yellow2) Tilt micro SW-CN6-7 (Red3) Reach micro SW-CN6-15 (Yellow/Black) Attachment micro SW-CN6-8 (Green/White3) Attachment micro SW-CN6-16 (Blue/Yelloew3)



No



Yes



7 6 5 4 3 2 1 0 Replace Micro SW of the bit that shows [1].



LIFT1 SW



LIFT2 SW



TILT SW



No REACH SW



ATTACHMEMT SW



ATTACHMEMT SW



IOM 0E/



Operation become normal? Yes END



– 41 –



Replace MPU board.



Repair.



Error No.3



* FAIL TRAVEL* *TURN OFF KEY SWITCH*



LCD Display



*



FAIL TRAVEL * * TURN OFF KEY SWITCH



The other error messages appear at the same time?



* No



The contact of M4 Bypass contactor is welded?



Yes See the flowchart in which the error message appears and check it.



No



Yes



The “Green/Blue” wire between drain of Travel FET and CN3-19 pin is normal?



Replace the contact of Bypass contactor.



No



Yes Repair. No



q Turn off key switch. w Disconnect



Operation become normal?



the connector of Travel FET “4P Green”.



Yes Turn on key switch. END No



The error messages “*FAIL TRAVEL*” appears? Yes



Replace MPU board. Replace Travel FET.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 42 –



Error No.4



* FAIL HYD.* *TURN OFF KEY SWITCH*



LCD Display FAIL HYD. * * *TURN OFF KEY SWITCH*



The other error messages appear at the same time?



No



No Hyd. Bypass installed? Yes



Yes



See the flowchart in which the error message appears and check it.



No The contact of M7 contractor welded? Yes



The “Green/White” wire between drain of Hyd. FET and CN3-10 pin is normal?



No



Yes Repair. Replace M7 contractor.



q Turn off the key switch. w Disconnect the connector. (2P Black)



Turn on key switch.



No



The error message “*FAIL HYD.* TURN OFF KEY SWITCH*” * appears? Yes



Replace MU board. Replace Hyd. FET.



– 43 –



Error No.5



A1:FUSE TRAVEL



LCD Display A1:FUSE TRAVEL



Turn off key switch.



Fuse F1 for travel is normal?



No



Yes q Turn off the key switch. w Set RS1 at [E]. e Turn on key switch and



Replace Fuse for travel.



select I/O port [IOM 0F].



This bit 5 shows [1] on LCD display? LCD display



7 6 5 4



3 2 1 0



No



IOM 0F 1:normal



0:abnormal



The “Brown/White” wire between F1 (fuse) and CN2-1 pin is normal?



Yes



No



Yes



Replace MPU board.



Repair. Replace MPU board.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 44 –



Error No.6



A2:FET6-REGEN.



LCD Display A2:FET6-REGEN. OPTION SET Adjust. RS1 Regenerative function installed?



[7]



7 6 5 4



Check OPTION SET.



3 2 1 0



No



OPTION



Yes Bit 4 shows [0]? The error message appears after turning on key switch Yes without traveling?



Yes



No Replace MPU board.



q Set the bit 4 at [0].



Then reset RS1 at [0]. w Turn off and on key switch. q Turn off key switch. w Disconnect CN1 from MPU



board. Replace MPU board.



The “Red/Green1” wire between coil of M3 contactor and CN1-3 pin is normal?



Yes



The coil resistance of M3 contactor is normal? 32.5-35.5Ω Yes



No



Repair.



No



Replace MPU board.



– 45 –



Replace M3 contactor and MPU board at the same time.



Error No.7



A3:CONTACTOR-REGEN.



LCD Display A3:CONTACTOR-REGEN. OPTION SET Adjust. RS1



No Regenerative function is installed?



[7]



7 6 5 4



Check OPTION SET.



3 2 1 0



OPTION Yes Bit 4 shows [0]? Yes



Turn off key switch.



q Set the bit 4 at [0].



Then reset RS1 at [0]. The contact of Regen. contactor (M3) is welded?



w Turn off and on key switch.



No



Yes



Replace M3 Contactor.



Replace MPU board.



The error message appears at the moment when key switch, Foot switch and Accelerator are turned on?



No Replace M3 Contactor.



Yes



Operation become normal?



The “Blue2” wire between contact of M3 contactor and CN4-15 pin is damaged?



No



Yes



No



END



Yes Replace MPU board. Repair. The connection of M3 contactor is bad ?



No



Yes Replace MPU board.



Replace M3 Contactor.



– 46 –



No



Error No.8



A4:FET10-FORWARD



LCD Display A4:FET10-FORWARD



The error message appears after turning on key switch without traveling.



No Replace MPU board.



Yes



q Turn off key switch. w Disconnect CN2 from MPU



board.



The “Red1” wire between coil of M1 contactor and CN2-3 pin is normal?



No Repair.



Yes



The coil resistance of M1 contactor is normal? 32.5-35.5Ω



No



Replace M1 contactor and MPU board at the same time.



Yes



Replace MPU board.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 47 –



Error No.9



A5:CONTACTOR-FORWARD



LCD Display A5:CONTACTOR-FORWARD



Turn on key switch. Yes



The truck can travel when operating the accelerator after pushing the lever forward?



No Replace M1 contactor.



Yes



The “Yellow/White2” wire between contact of M1 contactor and CN3-18 pin is normal? And also the “Green/Blue2” wire between contact of M2 contactor and CN3-9 pin is normal?



No Repair.



Yes



Replace MPU board.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 48 –



Error No.10



A6:FET9-REVERSE



LCD Display A6:FET9-REVERSE



The error message appears after turning on key switch without traveling.



No Replace MPU board.



Yes



q Turn off key switch. w Disconnect CN2 from MPU



board.



The “Red/White1” wire between coil of M2 contactor and CN2-4 pin is short-circuited with the other wire?



No Repair.



Yes



The coil resistance of M2 contactor is normal? 32.5-35.5Ω



No



Replace M2 contactor and MPU board at the same time.



Yes



Replace MPU board.



– 49 –



Error No.11



A7:CONTACTOR-REVERSE



LCD Display A7:CONTACTOR-REVERSE



Turn on key switch. Yes



The truck can travel when operating the accelerator after pushing the lever forward?



No Replace M1 contactor.



Yes



The “Yellow/White2” wire between contact of M1 contactor and CN3-18 pin is normal? And also the “Green/Blue2” wire between contact of M2 contactor and CN3-9 pin is normal?



No Repair.



Yes



Replace MPU board.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 50 –



Error No.12



A8:FET8-BYPASS



LCD Display A8:FET8-BYPASS



The error message appears after turning on key switch without traveling.



No Replace MPU board.



Yes



q Turn off key switch. w Disconnect CN1 from MPU



board.



The “Red/Black1” wire between coil of M4 contactor and CN1-1 pin is short-circuited with the other wire?



No Repair.



Yes



The coil resistance of M4 contactor is normal? 32.5-35.5Ω



No



Replace M4 contactor and MPU board at the same time.



Yes



Replace MPU board.



– 51 –



Error No.13



A9:CONTACTOR-BYPASS



LCD Display A9:CONTACTOR-BYPASS



The error message of “*FAIL TRAVEL*” appear at the same time?



No Replace M4 contactor.



Yes The contact of M4 contactor welded?



No



Yes



The “Green/Blue” wire between drain of Travel FET and CN3-19 pin is normal?



Replace the contact of M4 contactor.



No Repair.



Yes No



q Turn off key switch w Disconnect the connector of



Operation become normal?



Travel FET (4P Green).



Yes



END Turn on key switch.



The error message of “*FAIL TRAVEL*” appear?



No



Yes Replace MPU board. Replace Travel FET.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 52 –



Error No.15



A11:TR-TRAVEL MAIN



LCD Display A11:TR-TRAVEL MAIN



The error message of “*FAIL TRAVEL*” appears at the same time?



No



The “Green/Blue” wire between contactor of Travel FET and CN3-19 pin is normal?



Yes



No Repair.



Yes Replace Travel FET.



The contact of M4 contactor welded?



No



Yes



Replace the contact of M4 contactor.



The “Green/Blue” wire between contactor of Travel FET and CN3-19 pin is normal?



No Operation become normal? Yes



No Repair.



Yes



END



q Turn off key switch w Disconnect the connector of



Travel FET (4P Green).



Turn on key switch.



The error message of “*FAIL TRAVEL*” appears?



No



Yes Replace MPU board. Replace Travel FET.



– 53 –



Error No.16



A12:TR-REGEN. MAIN



LCD Display A12:TR-REGEN. MAIN No Regen. contactor (M4) is installed?



Replace MPU board.



Yes Resistors for pre-energizing are normal? 48V : 2.2Ω, 30W (4 pcs.) 24V : 1.0Ω, 30W (2 pcs.)



No Replace.



Yes The following 2mm2 wires are normal? (short-circuited or broken?) q “Red” wire between contact of M3 contactor and the resistors for pre-energizing. w “Blue” wire between the resistors and pre-energizing PB. e “White” wire between pre-energizing PB and D2 [A].



No Repair.



Yes The following wires are normal? (short-circuited or broken?) q “Blue/Red” wire between pre-energizing PB and MPU board (CN4-8 pin). w “White/Red1” wire between pre-energizing PB and MPU board (CN4-16 pin). e “Brown/White” wire between D2 [K] and MPU board (CN2-1 pin).



No Repair.



Yes Replace pre-energizing PB.



No Operation become normal?



Replace MPU board.



Yes END



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 54 –



Error No.17



A13:ACCEL-ACCELERATOR 7 6 5 4 3 2 1 0



LCD Display



Bit1-Bit4 change like the right table when pulling and/or pushing Accelerator? No 6 1 0 0



(Gray code)



5 0 Forward 1 Neutral 0 Backward Yes



0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1



0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0



0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0



0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0



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



Micro switch of Directional switch is normal?



No



No



Yes Adjust or Replace.



Repair.



Yes Directional MPU board switch Forward – CN6-12 (Brown2) Backward – CN6-5 (White/Red2) Neutral – CN6-4 (Brown/Black1) Each wire of the above is broken or bad connector?



Replace Accelerator PB.



Operation become normal?



No



No



Yes Yes Replace MPU board. END



CAUTION



I/O check of Accelerator signal is displayed by Gray code. It is not Binary code. Pay attention. – 55 –



Replace MPU board.



Repair.



NO USED



FAD



BWD



0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15



select I/O port [IOM 10].



7 0 0 1



Accel, bit



DECIMAL



q Turn off key switch. w Set RS1 at [E]. e Turn on key switch, and



Bit Push Release Pull



NTRAL



IOM 10



A13:ACCEL-ACCELERATOR



0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0



Error No.18



A14:SENSOR-CURRENT (ARMATURE)



LCD Display A14:SENSOR CURRENT (ARMATURE)



Turn off key switch. [la] level can be adjust as 0[A]?



No



Yes



q Set RS1 at [1]. w Turn on key switch.



Adjust at 0[A].



[la] level of current sensor is 0[A]?



No The following wires are normal? q “Red/Black3” wire between Current sensor and CN3-1 pin. w “Blue” wire between Current sensor and CN3-2 pin. e “Black/Red1” wire between Current sensor and CN3-11 pin.



Yes Replace MPU board.



Operation become normal?



No



Yes



Yes END



No



Repair.



Replace Current sensor [la]. Replace Current sensor [la]. Operation become normal?



No



Yes END



CAUTION



CAUTION



Replace MPU board.



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 56 –



Error No.19



A15:SENSOR-CURRENT (FIELD)



LCD Display A15:SENSOR CURRENT (FIELD)



Turn off key switch. [lf] level can be adjust as 0[A]?



No



Yes



q Set RS1 at [1]. w Turn on key switch.



Adjust at 0[A].



[lf] level of current sensor is 0[A]?



No The following wires are normal? q “Red/Yellow3” wire between Current sensor and CN3-3 pin. w “Yellow/Red2” wire between Current sensor and CN3-12 pin. e “Black2” wire between Current sensor and CN3-13 pin.



Yes Replace MPU board.



Operation become normal?



No



Yes



Yes END



No



Repair.



Replace Current sensor [lf]. Replace Current sensor [lf]. Operation become normal?



No



Yes END



– 57 –



Replace MPU board.



Error No.20 A16:SENSOR-SPEED



LCD Display A16:SENSOR-SPEED



Speed sensor1 and Speed sensor2 are installed normally?



No Adjust.



Yes



The following wires are normal? q “White1” wire between Speed sensor1 and MPU board (CN5-3 pin). w “Black/White1” wire between Speed sensor1 and MPU board (CN5-13 pin). e “White2” wire between Speed sensor2 and MPU board (CN5-4 pin). r “Black/Yellow1” wire between Speed sensor2 and MPU board (CN5-14 pin).



No Repair.



Yes



Replace Speed sensor1 and Speed sensor2.



No Operation become normal?



Replace MPU board.



Yes



END



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit.



– 58 –



Error No.21



B17:FUSE-HYD.



LCD Display B17:FUSE-HYD.



Turn off key switch.



Hyd. fuse F2 is normal?



No



Yes q Turn off the key switch. w Set RS1 at [E]. e Turn on key switch and



Replace.



select I/O port [IOM 0F].



This bit6 shows [1] on LCD display? LCD display



7 6 5 4



3 2 1 0



No



IOM 0F/ 1:normal



0:abnormal Yes



The “Green/Black” wire between F2 (fuse) and CN2-5 pin is normal?



No



Yes



Replace MPU board.



Replace MPU board.



– 59 –



Replace. (Damage or bad connection)



Error No.22



B18:FET5-HYD.



LCD Display A18:FET-HYD.



The error message appears when turning on key switch without traveling.



No Replace MPU board.



Yes



q Turn off key switch. w Disconnect CN1 from MPU



board.



The “Red2” wire between coil of M6 contactor and CN1-4 pin is normal?



No Repair.



Yes



The coil resistance of M6 contactor is normal? 32.5-35.5Ω



No Replace MPU board.



Yes



Replace M4 contactor and MPU board at the same time.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 60 –



Error No.23



B19:CONTACTOR-HYD.



LCD Display A19:CONTACTOR-HYD.



No



No Hyd. operation is normal?



Hyd. contactor (M6) can work?



Replace M6 contactor.



Yes



Yes



The contact of M6 contactor is conductive?



No



Replace M6 contactor.



Yes



The “Brown/Red” wire between contact of M6 contactor and CN3-8 pin is normal?



No Repair.



Yes



Replace MPU board.



The contact of M6 contactor is welded?



No



The “Brown/Red” wire between contact of M6 contactor and CN3-8 pin is normal?



Yes



Replace M6 contactor.



Yes



Replace MPU board.



– 61 –



No Repair.



Error No.24 B20:FET4-HYD. BYPASS



LCD Display B20:FET4-HYD. BYPASS



OPTION SET Adjust. RS1



No Hyd. bypass system is installed?



[7]



7 6 5 4



Check OPTION SET.



3 2 1 0



No



OPTION Yes Bit 5 shows [0]? Turn off key switch. Yes The error message appears after turning on key switch without traveling?



Replace MPU board. No Replace MPU board. q Set the bit 5 at [0].



Yes



Then reset RS1 at [0]. w Turn off and on key switch.



q Turn off key switch. w Disconnect CN1 from



MPU board.



The “Red/White2” wire between coil of M7 contactor and CN1-5 pin is normal?



No Repair.



Yes The coil resistance of M7 contactor is normal? 32.5-35.5Ω



No Replace MPU board.



Yes Replace M7 contactor and MPU board at the same time.



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 62 –



Error No.25



B21:TR-HYD. MAIN



LCD Display B21:TR-HYD. MAIN



The error message of “*FAIL HYD.*” appears at the same time?



No



The “Green/White” wire between drain of Hyd. FET and CN3-10 pin is normal?



No Repair.



Yes



Yes



Replace Hyd. FET. Hyd. bypass system is installed.



No



Yes



Hyd. bypass contactor is welded?



The “Green/White” wire between drain of Hyd. FET and CN3-10 pin is normal?



No



Yes



No Repair.



Yes q Turn off key switch. w Disconnect Gate “4P Red” of



Replace M7 contactor.



Hyd. FET.



No



Turn on key switch.



Operation become normal? Yes The error message of “*FAIL HYD.*” appears on LCD?



No



Yes



END



Replace MPU board. Replace Hyd. FET.



– 63 –



Error No.26



B22:SWITCH-LIFT



LCD Display B22:SWITCH-LIFT



Lift(2) Micro switch is installed normally?



q Turn off key switch. w Set RS1 at [E].



No Adjust.



Yes The “Green/Yellow” wire between Lift(2) and CN6-14 pin is normal?



Turn on key switch. Yes



No



Repair.



Yes



Bit2 shows [0] when not operating Hyd. levers? LCD display



7 6 5 4



No



Replace Lift (2) Micro switch.



3 2 1 0



IOM 0E/



No Operation become normal? Yes



Yes Replace MPU board.



Bit2 changes to [1] after Bit1 changes to [1] when operating Hyd. levers? LCD display



7 6 5 4



END



3 2 1 0 No



Micro switch which does not change to [1] is installed normally?



IOM 0E/



7 6 5 4



3 2 1 0



IOM 0E/ Yes



No Adjust.



Yes The wire of which Micro switch is abnormal? q Between Lift(1) and CN6-6 “Brown/Red1”. w Between Lift(2) and CN6-14 “Blue/Yellow2”.



No



Yes Replace MPU board. Replace the Micro switch which is abnormal.



Repair.



No Operation become normal? Yes Replace MPU board. END



– 64 –



Error No.34



C29:SENSOR-EPS TORQUE



LCD Display C29:SENSOR-EPS TORQUE



Turn off key switch.



The “Yellow/White1” wire between 4 pin of 10 P water-resistant connector of EPS controller and CN5-15 pin is normal?



No Repair.



Yes The “Blue3”, “Green/Blue1”, “White” wires between EPS controller and EPS sensor is damaged or broken?



No Repair.



Yes Check the resistance at sensor side (tab side) between,



• q pin (Orange) and e pin (Black/Red) = Approx. 5kΩ ................... A • q pin (Orange) and w pin (Green/Red) = Approx. 2.5kΩ .............. B • w pin (Green/Red) and e pin (Black/Red) = Approx. 2.5kΩ .............. C



No



Adjust EPS sensor by removing or insterting a shim to be even value between B and C.



Yes NOTE



Replace EPS controller.



Refer to page 20.



No Operation become normal?



Replace MPU board.



Yes END



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 65 –



Error No.35



C30:TR-EPS MAIN



LCD Display C30:TR-EPS MAIN



The “Blue/Black” wire between 2 pin of 10 P water-resistant connector and CN5-5 pin is shortcircuited with other wires?



No Replace EPS controller.



Yes



No Operation become normal?



Replace MPU board.



Yes



Repair.



END



CAUTION



CAUTION



When replacing MPU board and/or Current sensor, and/or FET comp. be sure to check the following. 1. MPU board (1) Check the setting of Rotary switch (RS0, RS1-7). (See Adjustment Specification Table.) (2) Adjust Start current and Current limitation. Repeat the plugging operation a few times and recheck the setting. (3) Check the plugging brake distance. (See Adjustment Specification Table.) 2. Current sensor (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting. 3. FET Comp. (1) Adjust Start current and Current limitation. Repeat the plugging operation a few times and re-check the setting.



1. Be sure to turn off the key switch when setting Rotary switches. 2. Be sure to disconnect the battery plug when replacing the inner parts of Control unit. – 66 –



Error No.36



C31:FUSE-EPS



LCD Display C31:FUSE-EPS



Turn off key switch.



EPS fuse F3 is normal?



No



Yes q Turn off the key switch w Set RS1 at [E]. e Turn on key switch and



Replace EPS fuse.



select I/O port [IOM 0F].



Bit 7 shows [1] on LCD display? LCD display



7 6 5 4



3 2 1 0



No



IOM 0F/ 1:normal



0:abnormal



The “Brown/Yellow” wire between F3 (fuse) and CN2-2 pin is normal?



Yes



No



Yes



Replace MPU board.



Repair. Replace MPU board.



– 67 –



7. Wiring and layout of control unit



– 68 –



Battery:48V(FB10-25P) 72V (FB30P)



BNRD1



RD3 NB



Pre-energizing resistor : 30W 2.2Ω X 4 (10-25) 40W 2.2Ω X 2 (30)



BK BU GNBU



19



M2



WH



YEWH2 GNBU2



E1 B1 C5 C3 C4



3 3 3 3 3



16 6 19 18 9



D3 BU2



C1



4



15



Travel FET Comp. source Travel FET Comp. gate Travel FET Comp. drain voltage Contact of For. contactor



GNWH3 BUYE3



5



BU



BURD BNWH BK



Capacitor : 100V 2200µF X 1 (FB10/15/18P) X 2 (FB20/25P) X 3 (FB30P)



BNWH5



4



16



Pre-energizing FET source



B3



4



8



Pre-energizing FET gate



VC



2



1



Trave lfuse



NA



2



8



GND of contactor coil



F2 M6



For trucks with 48V Battery (FB10-25P)



X4



BUBK YEWH1 BN1 BNBK



YE



GN



Controller



key switch



X1



6



15



Attachment switch 1 (OPT.)



48



6



8



Attachment switch 2 (OPT.)



49



6



16



Attachment switch 3 (OPT.)



E2 B2 C6 C2 VD VE C7



3 3 3 3 2 2 3



17 7 10 8 5 2 20



EPS Sensor



BU3 GNBU1 WH



70 71 72 73



5 5 5 5



5 15 6 16



OPT.



43



6



13



Brake switch



90



4



13



Parking brake switch



VB



2



7



Power supply for contactor coil



VH



2



6



Power supply for contorol



RDYE



15 ST



5 5



20 10



BUYE1



RDGN4



DS3 DS1 DS2



Drectional switch



BNBK1



Tum on when neutral position



BN2 WHRD2



P57



6



1



40



6



4



Abnomal of EPS chopper Abnomal of EPS sensor Speed sensitive for EPS(SP1) Speed sensitive for EPS(SP2)



Charger panel



RDWH1



M2



BNWH1 RDBK1



M4



WHGN



RDGN1



M3



WHBU RD2



M6



WHRD RDWH2



M7



BUYE



RDBK2



X1



BKWH✻



2



3



BK



RDWH



GNRD1



4



20



2



3



30



2



9



21



2



4



31



2



10



22



1



1



32



1



7



23



1



2



33



1



8



24



1



3



34



1



9



25



1



4



35



1



12



26



1



5



TSL



GNWH2 M



YEWH4 YERD



Forward contactor



25W TSL BUWH2



left



41



6



12



Forward



42



6



5



Reverse



NB7



6



9



X2



58



5



12



Low speed



56



5



11



Mode select



55



5



1



Up



1



13



1



6



EPS contactor



37



1



14



28



1



10



38



1



11



57



5



2



Down



5



60 NB5



5 5



3 13



Signal for speed sensor 1 GND for speed sensor 1



WH1 BKYE1



61 NB6



5 5



4 14



Signal for speed sensor 2 GND for speed sensor 2



P50 10 NB0



3 3 3



1 2 11



Power supply for current sensor (Ia) Signal for current sensor (Ia) GND for current sensor (Ia)



IA



IF



RDYE3 YERD1 BK2



Travel current sensor



RD4 BNYE1 BKYE



Accelerator



RDGN3 GNBK1 BK1



Brained wire



Display unit



8



Hydraulic oil level(OPT.)



5



18



Brake oill level



83



4



3



Over load(OPT.)



85



4



4



Travel inhibit(OPT.)



86



4



12



Input for spare



87



4



5



Reducing speed when tuming(OPT.)



84



4



11



Seat switch(OPT.)



39



4



10



Tum signal lamp



P12 97



5 4



9 7



P12V Waring buzzer



95



4



6



Forward signal Load 200mA max.



96



4



14



Reverse signl Load 200mA max.



Tail & stop lamp 25W



TL



10W



Back lamp 25W



BL



Turn signal lamp 25W



TSL



Rear combination lamp(left) 25W



TL



10W



Back lamp 25W



20P Relay for power supply



5



82



Rear combination lamp(right) BU4



WH1 BKWH1



RDBK1 BU1 BKRD1



Regenerative contactor



27



81



BZ



P51 11 NB1



3 3 3



3 12 13



Power supply for current sensor (If) Signal for current sensor (Ia) GND for current sensor (Ia)



P52 12 NB2



3 3 3



4 5 14



Power supply for accelerator Signal for accelerator GND for accelerator



BL



Turn signal lamp 25W



TSL



Brained wire



36



Hour meter(OPT.)



Back buzzer



Tail & stop lamp



Reverse contactor



Hyd.bypass contactor Opt. (FB10-25P) Std. (FB30P)



Hour meter counting



17



X5



BNRD2



Brained wire



Hyd. contactor



7



5



X2



Start for key switch



Over drive contactor



5



76



right



(GNWH2)



Battery voltage



Travel bypass contactor



75



Neutral



Low speed



Flat cable 20p



3



YEWH BK



RD1



25W



Turn signal switch RD5



Speed Sensor WHBK



GNRD2



RDWH3 BUWH1



Contact of Hyd. contactor Hyd fuse



Charger, Controller M1



BNWH2



Only for EEC



Tilt level sensor



YEBK1



RDGN2



WHBK1



OPT.



RDGN5



Mode select switch



X4



GNWH1



Hyd. FET Comp .source Hyd. FET Comp gate Hyd. FET Comp drain voltage



EPS fuse Contact of Rev. contactor



BK



YEWH3



BNWH6



TS



Accessory



BUWH3



X5



VG



VF



47



OPT.



BNBK4 BURD5



EPSMotor



EPS



RD The truck with built in charger



Tilt switch



BU



RD



40A



7



(YEBK2)



Connector CN Pin No. No.



RDYE1



BKWH✻



RDGN



F3



RDWH



WH



RDYE4



For trucks with 72V Battery (FB30P)



BNYE



F4 10A



F5 10A RDBK



BKRD BUWH GNWH BNRD BUBK4



PA



6



Line NO. BURD1



1



To connect :To start counting



BNBK4 BURD5



FC2



Opt.(FB15-25P) Std.(FB30P)



46



1



DC/DC Converter



YERD4



Leveiing lamp



bypass contactor (M7) :



Lifut 2 switch



Laser pointer switch



Laser



M7



PA



Lifut 1 switch



14



Only for trucks with laser pointer



D4



1



BU4



Contact of regenerative contactor



3



6



6



OPT.



Turn on depressing



RDWH WHRD1



6



45



BU4



RDWH



PB83-62 Pre-energizing



44



OPT.



Control GND



Contact of Rev. contactor



Connector CN Pin No. No.



4



RDYE5



IF



IA



5



YEBK



FC1



3



GNRD3



VC



BUYE2



M4



A



M3



275A



Line NO.



D2 M1



RD



Connector CN Pin No. No.



1



4



BKWH✻



D1



275A



BKWH



Line NO.



RDWH



F1



3



RDBK



2



N



NA



VA



V



Capacitor : 100V 2200µF X 1 (FB10/15/18P) X 2 (FB20/25P) X 3 (FB30P)



BK



(The auxiliary 48 volts output is equipped in the case of the 72 volts battery.



4



Body earth



P53 13 NB3



4 4 4



1 2 9



AC0 AC1 AC2 AC3



6 6 6 6



2 10 3 11



} 80



Ramp switch right HL



Power supply for accelerator Signal for accelerator GND for accelerator



Head lamp



WH3



40Wx2



Harness mark/color Red Black Green Yellow White Brown Blue Gray Pink



RD BK GN YE WH BN BU GY PK



Ex) BKWH (=Black/White) Black colored harness with White line.



HL



left 100V 22µF X3



WHBK2



White line Black color



H



Horn 7



YEBU1 3



15



Battery electrolyte level



X3



(Post)



(lever) Horn switch



FB10-30P-DC70 SYSTEM WIRING



– 69 –



Head guard (right)



Laser pointer (Laser &Level sensor)



Main controller



✻Only for trucks with laser pointers



RD BK



Hanging on mast "M"



Water resistant



Water resistant



Harness,mast(1)



Harness,head guard



24801-10111



Level sensor



Hanging on mast



1E-06145



Water resistant



2P



"M"



Water resistant



2P



2P



Laser



Water resistant



1



1



1



1



HL TSL



M3



RDBK YEBU1



✻Only for when using opthional eduipment. 2P BK



Att.3



2



2



2



2



M2



M1



M4



Controller Ass’y,EPS



M6







1 1 1 1



Control valve



2E-15273



1



RDBK RDWH BKWH GNBK2



Water resistant



Harness,mast(2)



WH GN



1



1



Accessory (front) AA



Horn switch (valve lever)



PA



Hydraulic motor Traction FET Comp.



Water resistant



Tilt



Lift 2



Harness,"M"(1)



10-25 : 2E-15405 30 : 2E-15406



2E-15407



DC/DC Converter



White line



FF



F



Battery plug



2P WH



AA



A



Brake oil level sensor



2



2



2



YEWH3 BK



Accessory (rear)



2P-X



10P



EPS sensor



,,,,,,,



Water resistant



Water resistant



Rear combination lamp (left)



Water resistant



Foot brake switch



8P



Mode serect switch



4P RD



1



1



1



1



GNWH BK



6P RD



Back buzzer Horn



Parking brake switch



3P



Charger panel



4P 2



2



2



Magnetic controller



– 70 –



BKWH



4P WH 6P BK



Harness, head guard 24801-10111



Backward output relay



4P BK



Horn relay



4P YE



Turn signal relay



1



1



1



1



WH GN



1



1



1



1



HL TSL



STD : 24801-32180 STD : 24801-32200 EEC : 24801-32220 EEC : 24801-32240



TSL Seat switch



,,



,, Harness,charger(1) 2E-15424



TL Water resistant



BL



Water resistant



Terminal



RD BK



10-25 30 10-25 30



2P



Harness,charger(2) 2E-15425



Harness, head guard(left)



RDBK YEBU1



✻Only when a chargers is not mounted.



BODY WIRING



7



Transformer secondary Rectifier side



Charger, controller



Conector comp. 24300-21472



FB10-30P-DC70



7



WHBK2



4P WH



EPS motor



3P



"W"



2



YE



+ –



4P BK



Water resistant



GN



BKWH



Transformer primary side



Water resistant



Water resistant



RDYE5



2



✻Only for trucks with built-in chargers.



✻Only for trucks with built-in chargers.



Directional switch



2



2



Transformer



"K"



Key switch



2



✻Only for EEC or when using optional equipment



Control power supply relay



6P



Warning buzzer



Hurn switch (handle post)



TL BL



Harness,body



Tun signal lamp switch



TSL



2E-15680



Display



Low speed mode switch



Rear combination lamp (right)



6P



2



6P WH



Battery



3P



Lamp switch



Harness Comp.,panel 24300-32030



2P WH



4P WH



Water resistant



Harness,"M"(3) 4P WH



✻30 4P WH



72V (30)



48V



Battery



(10-25)



Indicator panel



✻10-25



–



Battery plug



Black color



Laser pointer switch



+ (48V)



RDWH BKWH GNBK



–







+ (72V)



1



✻Only for trucks with laser pointers



1



+



10A



10A



Traction motor



4P WH



CN5 CN6



CN4 Harness,"M"(2)



Laser pointer (switch & Converter)



Ex) BKWH (=Black/White) Black colored harness with White line.



Board comp.,MPU



Water resistant



(Connect wires after removal of the cup holder)



2E-15680



RDGN RDBK RDYE4 BKWH✻ BK



Connect , and bigin the hour meter countdown.



Speed sensor (left)



BURD1 BK



Harness,"M"(4) "L"



10A



1



Speed sensor (right)



10A



1



1



6P BK



2P



RD BK GN YE WH BN BU GY PK



2P



Red Black Green Yellow White Brown Blue Gray Pink



M7



Water resistant



Lift 1



Harness mark/color



PA PF



Hydraulic FET Comp.



275A



Acceleration sensor



Att.1



RDGN RDBK RDYE4 BKWH✻ BK



Water resistant



6P



2P



Att.2 Indicator lamp for forkleveling LED



40A



"L"



275A



M mast



"M"



1



2P



Laser



4P WH



2P



2P



1E-06145



1



Harness,mast(1)



1



P mast



+ –



NOTE: 1. indicates the lead wire numbers. 2. Terminal symbols 2



:Plug



1 2



:Plug :Receptacle



1 7



:Receptacle :Receptacle



AMP 170020-3 AMP 170002-5 AMP 170020-2 AMP 170021-3 AMP 170003-5 AMP 170021-1 AMP 41729



3. When installing the charger panel on the truck body,use only bolts and spring washers. The reason why only spring washers should be used is that they break the coating on the charger panel ,enduring conductance between the frame and the charger panel. 4. "M" , "S" , "L" , "K" , and "W" indicate the printed marks on the connector.



(✻Refer to note 6 )



RDBK WH3 GNRD3



3 3 3



1 V,Q 59G 2 3 E1,E2 55B 4



3 3



1 X 2



AMP 172134-1 M1,M2 43B



Plug 4P



W Lamp switch



1 2 3 4



WH



AMP 172130-2



Q



BK YEBK1 YEWH4 YERD BK GNWH2 RDWH3 BUWH1



4 4 4



4 4 4 4 4 4 4 4



RD RDYE RDGN2



4 4 4 4



RDBK RD5 RDGN5 1 2 3



1 2 3 4



1 2 3



1 2 3 4 5 6 7 8



Q M2 59I 46A



V



59H 41C



A A 28B 26B



M1 44A



Horn switch (steering)



b



water resistant Plug 3P



water resistant Plug 3P



A



N Brake oil



water resistant Plug 8P



AMP 174982-2



AMP 174357-2



W



K 2 1 4 3



3 2 1



Horn switch (Hydraulic)



V



A A A A 13B 11B 14B 7B



25C



AMP 174257-2



AMP 174357-2



a5 Laser pointer switch



1 2



WH



a1 100A



59F P2,W



2



41B F1,Q



2



22B



A



2



58E



O,U



2



RDBK YEBU1



YERD4 BKWH✻ BNWH6 BURD5



3 3 3 3



1 a5 100B 2 M1,P2 61K 3 a4 101B a2,a3 102B 4



BNRD1 BUYE2 RD3 YEBK GNWH3 RDWH



3 3 3 3 3 3



1 2 3 4 5 6



Plug 4P



WH



a1 DC/DC Converter



1 2 3 4



58C 12B 58F 23B



F2



water resistant Plug 4P



N



Point c A



A



54C 24B



A A 29B 27B



Plug 2P



60I



AMP 172134-1



4 4 4



YEBU1 2



RDBK 2 W,R



BN2 WHRD2 RDGN4 BNBK1



RDWH YERD4



3 2 1



4 3 2 1 8 7 6 5



21B A



1



58D C,N



1



YEWH3 BK



AMP 171898-2



A 31B A 32B Plug 6P



A 33B A 34B



BK



A 35B



X Valve microswitch



1 2 3 4 5 6



P2,a5 60H



AMP 172134-1



WH3 RDGN5 BKWH✻ BUWH2



BURD1 BK



3 3 3 3



1 W 43C 2 R,Point a 46B 3 P2 61M 4 M1,E2 47D



1 2 3 4



Plug 4P



WH



Put the sleeve for sure receptacle.



T Key switch U Indicator panel



O Hour meter



M2 Head guard (right)



AMP 174352-2



BNBK4 BURD5



a2 Laser



M



4 4



1 Point b 103A a1 102A 2



water resistant Plug 2P



4 4



1 Point b 103B 2 a1 102C



water resistant Plug 2P



2 1



44B



D



47C



WH



1 2 3 4 BK



F4 Turn signal reiay ✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



47B E1,M1 Plug 4P



1 2 3 4



YE



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



Plug 4P



1 2 3 4



WH



6B



1 45A Point a 2



Plug 6P



RD



A



3 3



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2 3 4



RD



te no Re fe (✻



RDWH 3



1P



9



4 4



S



water resistant Plug 2P



1 a1 101A 2 Point b 103C



2 1



a4 Level sensor



GN▲



3 3



RDBK RDBK



4 48B E1,H 3



3 3



BNRD2 RDYE5



1 39B D 2 3 60D P1,K 40B D 4



3 3 3 3



48C F3,E2



2



61G F4,G



2



42B F1



7



61H H,b



7



BKWH1 WH1



4 4



1 A 16B 2 A 15B



water resistant Plug 2P



BKYE1 WH2



4 4



1 A 18B 2 A 17B



water resistant Plug 2P



RDYE5



P1



60G



57B



P2 Accessory(front)



RDYE RDBK2 RDWH GNRD1



55A W



1 61A D 2 3 44D Point a 30C Point c 4 48A F3 5 47A F4 6



:Receptacle(with plating) :Receptacle(without plating) Sleeve(for single wire) Sleeve(for double wire)



AMP AMP AMP AMP



BKWH✻



2



:Plug(with plating) :Receptacle(without plating) Sleeve(for double wire)



AMP 170020-2 AMP 170002-5 or 170020-3 AMP 170888-1



2



Condenser 100v 22µ



GNRD3 BKWH✻ RD5 BU4 RDYE5 BUWH2



4 4 4 4 4 4



NOTE: 1,Terminal symbols



2 1



1



+



Point "c"



water resistant Plug 6P



B Speed sensor



WHBK2



Point "a"



3 2 1 6 5 4



L 2 1



AMP 174352-2



BKWH✻



GNRD2 BKWH✻



1 59D F3,P2 2



AMP 172134-9



F2 Control power supply relay



8



50B C



G Horn



BUWH2 RDYE1



3 3



25B A,T



49B C



H Back buzzer



1 2 3 4 5 6



AMP 174262-2



Plug 4P



1P



BNWH6 BNBK4



YE▲



61L



K,X



AMP 174352-2



K Brake switch



4 61F F1,G 3



A



59C F1,F3



AMP 172134-1



F3 Backward output relay



4B



I EPS motor



A



AMP 171898-9



b Charger panel AMP 172134-7



F3,V a1,M2 59E



39B 60F



1 2 3 4



Plug 4P



a3 Level lamp



L 2 1



AMP 174352-2



A, Point c K,P2



61I



AMP 172134-2



M1 Head guard(left)



BNBK4 BURD5



60E 5B



D G,M1 111B



Plug 4P



F2,K



1 4 52B C 2 4 51B C 3 4



Point "b"



1 2 3 4 5 6



C,T



110B 54B



AMP 172134-1



BNWH5 BU4



RDWH



1 2 3 4 R, Point a F4,M2



3 3



61J



3 3 3 3



43A



3



RDYE4 RDGN RD BKWH✻



3 3 3 3 b,a1



water resistant Plug 3P



3 2 1



BU3 GNBU1 WH



53B C



r to



WH3 RD5 BKWH✻ BUWH2



J EPS sensor



1 2 3 4 W



4)



AMP 174352-2 AMP 174357-2



RDBK RDWH BKWH✻ GNBK2



S



Directional switch



1 1 1 1



R



Turn signal switch



BKYE BNYE1 RD4 BK1 GNBK1 RDGN3



4 4 4 4 4 4



1 D 38B 2 D 37B 3 D 36B A 2B 4 5 A 3B A 1B 6



RDWH BKWH✻ GNBK2



1 1 1



D,F2 60C



GNRD3 BKWH✻ RDGN5 BU4 RDYE5 BUWH2



4 4 4 4 4 4



1 Point c 55C Point c 61C 2 3 M2 46D Point c 39D 4 5 H 48D M2 47E 6



AMP 174262-2 water resistant Plug6P



E2,Pointc 61D



P2 57A



L Accelerator sensor



3 2 1 6 5 4



P1 Accessory



1



3



:Receptacle



AMP 170032-5 or 179461-5



3



:Tab



AMP 170340-3 or 179462-3



4



:Receptacle



AMP 171662-1 or 173707-1 AMP 172888-2(rubber plug) AMP 172748-2(seal plug)



5



:Receptacle



AMP 316041-2 or 179956-2



6



:Receptacle



AMP 173716-2 or 175061-2



7



:Receptacle(with sleeve) Sleeve(for single wire) Sleeve(for double wire) :Receptacle :Tab :Pressed sleeve :Terminal(F) :Terminal(M)



AMP 174262-2



E2 Stop & tail lamp (right)



3 2 1 6 5 4



water resistant Plug6P



E1 Stop & tail lamp (left)



8 9 12



A



61B



8B



A 9B A C,P1



Point c



L



L



F2



AMP 174655-2



Cap 2P



Plug 4P



WH



WH



BK



5 4 3 2 1 10 9 8 7 6



AMP 172133-1



AMP 172134-1



AMP 171898-2



2 1 4 3



1 2 3 4



U



D



7A



9A



L



F4



2A



4A



K



F3



5A



6A



37A 39A



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



Point "a"



Point "b"



BNBK1 BN2 WHRD2 BU4 BNRD1 BUYE2 RD3 YEBK GNWH3



RDGN4



RDGN2 RDYE



YEWH3 RDWH3



BURD1



BUBK YEWH1 B



O



U



U



B



B



U



N



F2



22A



25A



C



12A 14A 16A 18A 20A



4



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 AMP.040 series multi-lock connector 175967-2



6 6 6 6 6 6 6 6 6



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



T



23A 24A



21A



6



6 6



6 6



6



C



26A



S



S



X



X



2, 3, 4, 5, 6,



:Braid wire under 25mm pitch. The location of the connector pin is as viewed from the inserting side. The ends of the insulating tube should be tied together with wire ties. Fuses should be placed in a circle, as shown in Figure 1. The ends of the spiral tube should be tied together with wire ties, and then theube should be coiled with a gap of 2 ± 1mm.(Refer to Figure 2.)



X



27A 29A 31A 33A 35A S



K



X



X



28A 30A 32A 34A



Fuse



CN6 5



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



10A 10A



6



AMP.040 series multi-lock connector 175966-2



12



Clamp Figure 1



Wire tie Figure 2



Point "c"



To K



BU4



FB10-25P-DC70



BU4



12 BU4



BK



To O



12



To E1



BNBK4 To a4



To E2



12 12



To D



RDYE1 To F4



BNBK4 To a2 BNBK4 To a3



BK



RDGN5 To M2 RDGN5 To E2



To U



46C M2,E2



B



15



AMP 41729 AMP 178023-2 AMP 1-170823-5 Yszaki 7116-3251 Yszaki 7114-3251 JST FNE-2 Yszaki 1500-0110 Yszaki 1600-0105



A MPU board



BK



White line



U



CN5



AMP.040 series multi-lock connector 175966-2



1 2 3 4 5 6



U



8A 10A



Plug 6P



1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 11A 13A 15A 17A 19A



D



CN4



BKWH✻



RD5 To M1 RD5 To E1



D



6 6 6 6 6 6 6 6 6 6



WH1 BKWH1 WH2 BKYE1



L 3A



D Controller 44C M1,E1



YERD YEWH4 YEBK1 GNWH2



BNWH5



L 1A



F2



10B 60B



RDYE1 To F4



6 6 6 6 6



6



RDGN3 BK1 GNBK1



L



36A 38A 40A



110A 58A



Ex) BKWH (=Black/White) Black colored harness with White line.



BNRD2 BUWH1 BU2 BURD WHRD1



GNRD2



RDBK2 GNRD1



6 6 6 6 E1,Point c



b



Receptacle



C EPS unit



Black color



RD4 BNYE1 BKYE 1 2 3 4 5 6



2P-X water resistant Plug10P



BU2 WHRD1 BURD RDWH



RDBK RDYE4 BKWH✻ BK 12



GN▲



RDGN 12



BK



BK



10A



10A



1 2 3 4



To F1



19B 20B 54A 51A 53A



RD BK GN YE WH BN BU GY PK



1 2 3 4 AMP 1-179958-2



To D



J



To P1



J



BKWH✻



b



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



A



I



BKWH✻



Red Black Green Yellow White Brown Blue Gray Pink



A



2



I



49A 50A



60A 52A



Harness mark/color



1



3 3 3 3



J



F1



59A



111A



3 3 3



D



b



(✻Refer to note 5)



1 2 3 4 5 6 7 8 9 10



5



BKWH✻ WHBK2



YE▲



4 3 42A G 3 3



5



61E Point c,F4



RD RDWH



BK



15



YEWH1



Plug 4P



RDBK YEBU1



BUBK



1 2 3 4



1 3 41A V 2 3



Seal plug 4 Seal plug 4 Seal plug 4 4 WH 4 GNBU1 4 BU3 4



F1 Horn relay ✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



59B D,F3



AMP 172134-2



170021-2 170003-5 or 170021-3 170089-1 170890-1



BODY HARNESS



– 71 –



(✻Refer to note 6)



RDBK WH3 GNRD3



3 3 3



1 V,Q 2 3 E1,E2 4



RDWH YERD4



3 3



1 X 60I 2



AMP 172134-1



59G M1,M2



Plug 4P



43B



W Lamp switch



1 2 3 4



WH



55B



W,R



Q



BK YEBK1 YEWH4 YERD BK GNWH2 RDWH3 BUWH1



4 4 4



4 4 4 4 4 4 4 4



RD RDYE RDGN2



BN2 WHRD2 RDGN4 BNBK1 4 4 4 4



RDBK RD5 RDGN5



V



1 2 3



1 2 3 4



1 2 3



1 2 3 4 5 6 7 8



Q 59I



59H 41C



M2 46A



A 28B



M1 44A



Horn switch (steering)



A 26B



A 29B



water resistant Plug 3P



water resistant Plug 4P



AMP 174357-2



b A 54C 24B



Piont c A 58C 12B



F2 25C



A 13B



A 27B



water resistant Plug 3P



AMP 174257-2



N 58F



A 11B



Horn switch



V (Hydraulic)



2 1 4 3



N Brake oil



AMP 174982-2 21B



Turn signal switch



Directional switch



4 3 2 1 8 7 6 5



3 2 1



2



41B F1,Q



2



22B



A



2



58E



O,U



2



YEBU1



A 7B



K



3 2 1



59F P2,W



RDBK



YERD4 BKWH✻ BNWH6 BURD5



3 3 3 3



1 a5 100B M1,P2 2 3 a4 101B a2,a3 4



BNRD1 BUYE2 RD3 YEBK GNWH3 RDWH



3 3 3 3 3 3



1 2 3 4 5 6



61K



Plug 4P



WH



a1 DC/DC Converter



1 2 3 4



102B



A 23B



A 14B



water resistant Plug 8P



AMP 174357-2



W



a5 Laser pointer switch



1 2



WH



AMP 172134-1



4 4 4



2



2



RDBK



YEBU1



AMP 172130-2 Plug 2P



a1 100A



A



BK



AMP 171898-2



A 31B A 32B A 33B



Plug 6P



A 34B



BK



A 35B P2,a5



X Valve microswitch



1 2 3 4 5 6



60H



AMP 172134-1



WH3 RDGN5 BKWH✻ BUWH2



BURD1



1



58D C,N



YEWH3



BK



1



3 3 3 3



1 W 43C R,Point a 46B 2 3 P2 61M 4 M1,E2 47D



1 2 3 4



Plug 4P



WH



Put the sleeve for sure receptacle.



T Key switch



U Indicator panel



M2 Head guard (right)



AMP 174352-2



BNBK4 BURD5



4 4



1 Point b 103A a1 102A 2



water resistant Plug 2P



4 4



1 Point b 103B 2 a1 102C



water resistant Plug 2P



M 2 1



AMP 174352-2



1 2 3 4 R, Point a F4,M2



44B



D



47C



110B



Plug 4P



WH



F2,K



A



54B



60E



5B



G,M1



111B



61I



1 2 3 4



A, Point c 39B



AMP 172134-2



M1 Head guard(left)



BK



Plug 6P



RD



b Charger panel F4 Turn signal reiay



1 2 3 4



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



Plug 4P



YE



8



1P



50B C



9



H Back buzzer



1 2 3 4 5 6



48C F3,E2



2



61G F4,G



2



G Horn



42B



7



F1



3 3



Lengs 50



RDBK RDBK



Cap 2P



F2 Control power supply relay ✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2 3 4



Plug 4P



RD



25B A,T 39B D 60D P1,K 40B D



1 2 3 4



3 3 3 3



BKYE1 WH2



4 4



1 2



A 18B



A 15B



water resistant Plug 2P



A 17B



water resistant Plug 2P



a4 Level sensor



P1



60G



57B



P2 Accessory(front)



RDYE RDBK2 RDWH GNRD1



:Receptacle(with plating) :Receptacle(without plating) Sleeve(for single wire) Sleeve(for double wire)



AMP AMP AMP AMP



7



2



:Plug(with plating) :Receptacle(without plating) Sleeve(for double wire)



AMP 170020-2 AMP 170002-5 or 170020-3 AMP 170888-1



2



+



BKYE BNYE1 RD4 BK1 GNBK1 RDGN3



4 4 4 4 4 4



1 D 38B 2 3 D 36B 4 5 A 3B 6



RDWH BKWH✻ GNBK2



1 1 1



D,F2 60C



GNRD3 BKWH✻ RDGN5 BU4 RDYE5 BUWH2



4 4 4 4 4 4



1 Point c 55C Point c 61C 2 3 M2 46D Point c 39D 4 5 H 48D M2 47E 6



AMP 174262-2 D 37B A 2B



L Accelerator sensor



3 2 1 6 5 4



water resistant Plug6P



A 1B



1



BK BUYE1



58B Point c1 15 2 15



120B A



1 2



55A W 1 61A D 2 44D Point a 3 30C Point c 4 48A F3 5 47A F4 6



water resistant Plug 6P



1,Terminal symbols 1



BKWH✻



c Seat switch 3 2 1 6 5 4



NOTE:



2 1



Point "c"



P1 Accessory



E2,Pointc 61D



P2 57A



4 4 4 4 4 4



GNRD3 BKWH✻ RD5 BU4 RDYE5 BUWH2



3



:Receptacle



AMP 170032-5 or 179461-5



:Tab



AMP 170340-3 or 179462-3



4



:Receptacle



AMP 171662-1 or 173707-1 AMP 172888-2(rubber plug) AMP 172748-2(seal plug)



5



:Receptacle



AMP 316041-2 or 179956-2



6



:Receptacle



AMP 173716-2 or 175061-2



7



:Receptacle(with sleeve) Sleeve(for single wire) Sleeve(for double wire) :Receptacle :Tab :Pressed sleeve :Terminal(F) :Terminal(M)



AMP 174262-2



E2 Stop & tail lamp (right)



3 2 1 6 5 4



water resistant Plug6P



E1 Stop & tail lamp (left)



8 9



L



F2



36A



38A



40A



Receptacle



b 110A



AMP 174655-2



Cap 2P



AMP 172133-1



2 1 4 3



C EPS unit



C,P1



L



F2



60B



37A



39A



Plug 4P



Point "a"



BNBK1 BN2 WHRD2 BU4 BNRD1 BUYE2 RD3 YEBK GNWH3



RDGN4



6 6 6 6 6 6 6 6 6 S



X



X



X



29A



31A



33A



35A



L



F4



c



K



F3



D



D



U



U



B



B



C



N



F2



S



K



X



X



2A



4A



120A



5A



6A



8A



10A



12A



14A



16A



18A



20A



22A



25A



28A



30A



32A



34A



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



CN5 4



AMP.040 series multi-lock connector



175966-2



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 AMP.040 series multi-lock connector



175967-2



A MPU board To K



BU4



Point "c"



BU4



12 To E2



12 BU4



12



Point "b"



6



S 27A



1 2 3 4 5 6



BNBK4 To a4



RDGN2 RDYE



S 26A



BK



12



6 6 T 24A



To E1



BNBK4 To a2 BNBK4 To a3



YEWH3 RDWH3 U 23A



BK



RDGN5 To M2 RDGN5 To E2



6 6



O 21A



To O



46C M2,E2



BURD1



C 19A



BK



RD5 To M1 RD5 To E1



6



B 17A



BK



44C M1,E1 RDYE1 To F4



BUBK YEWH1 WH1 BKWH1 WH2 BKYE1 B 15A



CN4



AMP 171898-2



1 2 3 4



YERD YEWH4 YEBK1 GNWH2



BNWH5



U 13A



Plug 6P



WH AMP 172134-1



6 6 6 6 6 6 6 6 6 6



6 6 6 6 6



6



U 11A



D Controller



RDYE1 To F4



BNRD2 BUWH1 BU2 BURD WHRD1



GNRD2



BUYE1 6



D 9A



To D



BODY HARNESS (EEC)



5 4 3 2 1 10 9 8 7 6



A 10B



Point c 58A



U 7A



To U



Black color



RDGN3 BK1 GNBK1 6 6 6 6



L



9B



WH



White line



RDBK2 GNRD1



A



8B



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



L 3A



BK



water resistant Plug10P



RD4 BNYE1 BKYE A



61B



1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20



L 1A



To C



Ex) BKWH (=Black/White) Black colored harness with White line.



BU2 WHRD1 BURD RDWH



RDBK RDYE4 BKWH✻ BK 12



BK 10A



BK 10A



AMP 1-179958-2



To F1



J 53A



1 2 3 4 5 6



BKWH✻



J 51A



1 2 3 4



To D



b 54A



1 2 3 4 E1,Point c



To P1



A 20B



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



BKWH✻



A 19B



RDGN 12



I 50A



2P-X



FB10-25P-DC70



– 72 –



I 49A



BKWH✻



RD BK GN YE WH BN BU GY PK



2



J 52A



3 3 3 3 3



Red Black Green Yellow White Brown Blue Gray Pink



1



D 60A



3 3 3 3



Harness mark/color



F1 59A



3 3 3



1 2 3 4 5 6 7 8 9 10



b 111A



(✻Refer to note 5)



BKWH✻ WHBK2



GN▲



3 3



YE▲



4 42A G 3



5



61E Point c,F4



5



BK



RD RDWH



Plug 4P



YEWH1



1 2 3 4



RDBK YEBU1



Seal plug 4 Seal plug 4 Seal plug 4 4 WH 4 GNBU1 4 BU3 4



F1 Horn relay ✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



3 3



41A V



BUBK



12



1 2



59B D,F3



AMP 172134-2



15 15



2, 3, 4, 5, 6,



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



AMP 41729 AMP 178023-2 AMP 1-170823-5 Yszaki 7116-3251 Yszaki 7114-3251 JST FNE-2 Yszaki 1500-0110 Yszaki 1600-0105



:Braid wire under 25mm pitch. The location of the connector pin is as viewed from the inserting side. The ends of the insulating tube should be tied together with wire ties. Fuses should be placed in a circle, as shown in Figure 1. The ends of the spiral tube should be tied together with wire ties, and then theube should be coiled with a gap of 2 ± 1mm.(Refer to Figure 2.)



Fuse



CN6 5



170021-2 170003-5 or 170021-3 170089-1 170890-1



3



water resistant



2 1



BNRD2 RDYE5



L 2 1



WHBK2



Condenser 100v 22µ



Plug 2P



water resistant



AMP 174262-2



AMP 172134-9



2 1



4)



48B E1,H



4 3



S



water resistant Plug 2P



AMP 174352-2



te



A



c 121B



A 16B



BKWH✻



no



6B



c 121A



BK 15



1 2



RDYE5



Point "a"



BK 15



4 4



to



WH



3 3



1 a1 101A 2 Point b 103C



AMP 174352-2



BKWH1 WH1



fer



1 2 3 4



59D F3,P2



Plug 4P



1 2



3 3



GNRD2 BKWH✻



4 4



61L



K,X



GN▲



Re



59C F1,F3



4 3



BUWH2 RDYE1



4) efe



49B C



BNWH6 BNBK4



60F



K Brake switch



3 3



F3,V a1,M2



Point "b"



YE▲



(✻



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



A 61F F1,G



AMP 172134-1



F3 Backward output relay



4B



1 45A Point a 2



a3 Level lamp



59E



(✻ R



3



1P



61H H,b 47B E1,M1



AMP 172134-7



L 2 1



AMP 174352-2



K,P2



AMP 171898-9



1 2 3 4



Plug 4P



I EPS motor



1 2 3 4 5 6



C,T



D



AMP 172134-1



3 3



61J



3



3 3 3 3



b,a1



43A



BNBK4 BURD5



te



water resistant Plug 3P



3 2 1



BU3 GNBU1 WH



4 4 4



no



1 52B C 2 51B C 3



RDWH



BNWH5 BU4



1 2 3 4 W



RDWH



3 3 3 3



RDYE4 RDGN RD BKWH✻



J EPS sensor



53B C



r to



WH3 RD5 BKWH✻ BUWH2



AMP 174357-2



a2 Laser RDBK RDWH BKWH✻ GNBK2



S



1 1 1 1



R



O Hour meter



10A 10A



6



12



Clamp



Wire tie



AMP.040 series multi-lock connector



175966-2



Figure 1



Figure 2



RDBK WH3 GNRD3



(✻Refer to note 6)



3 3 3



1 V,Q 2 3 E1,E2 4



3 3



1 X 2



AMP 172134-1



59G M1,M2



Plug 4P



43B



W Lamp switch



1 2 3 4



WH



55B



AMP 172130-2



Q



BK YEBK1 YEWH4 YERD BK GNWH2 RDWH3 BUWH1



4 4 4



4 4 4 4 4 4 4 4



RD RDYE RDGN2



4 4 4 4



RDBK RD5 RDGN5 1 2 3



1 2 3 4



1 2 3



1 2 3 4 5 6 7 8



Q



V



59I



59H 41C



M2 46A



A 28B



M1 44A



Horn switch (steering)



A 26B



A 29B



AMP 174357-2



Point c A 58C 12B



F2 25C



A 13B



water resistant Plug 3P



water resistant Plug 4P



water resistant Plug 3P



b A 54C 24B



A 27B



AMP 174257-2



N 58F



A 11B



A 7B



N Brake oil



AMP 174982-2 21B



3 2 1



2 1 4 3



a5 Laser pointer switch



1 2



WH



a1 100A



59F P2,W



2



41B F1,Q



2



22B



A



2



58E



O,U



2



RDBK YEBU1



YERD4 BKWH✻ BNWH6 BURD5



3 3 3 3



1 a5 100B M1,P2 2 3 a4 101B a2,a3 4



BNRD1 BUYE2 RD3 YEBK GNWH3 RDWH



3 3 3 3 3 3



1 2 3 4 5 6



61K



Plug 4P



WH



a1 DC/DC Converter



1 2 3 4



102B



A 23B



A 14B



K



3 2 1



Horn switch (Hydraulic)



V



water resistant Plug 8P



AMP 174357-2



W



Plug 2P



60I



AMP 172134-1



4 4 4



YEBU1



RDBK



2



2 W,R



BN2 WHRD2 RDGN4 BNBK1



RDWH YERD4



4 3 2 1 8 7 6 5



58D C,N



BK



AMP 171898-2



A 31B A 32B Plug 6P



A 33B A 34B



BK



A 35B P2,a5



X Valve microswitch



1 2 3 4 5 6



60H



AMP 172134-1



WH3 RDGN5 BKWH✻ BUWH2



BURD1



1



A



YEWH3



BK



1



3 3 3 3



1 W 43C R,Point a 46B 2 3 P2 61M 4 M1,E2 47D



Plug 4P



WH



1 2 3 4



Put the sleeve for sure receptacle.



O Hour meter



T Key switch U Indicator panel



M2 Head guard (right)



AMP 174352-2



BNBK4 BURD5



4 4



1 Point b 103A 2 a1 102A



water resistant Plug 2P



BNBK4 BURD5



4 4



1 Point b 103B 2 a1 102C



water resistant Plug 2P



M



a2 Laser



L



a3 Level lamp



2 1



1 2 3 4 F4,M2



44B



47C



D 110B



WH



54B



60E



111B



61I



1 2 3 4



Plug 4P



F2,K



G,M1



M1 Head guard(left)



47B E1,M1



F4 Turn signal reiay ✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2 3 4



Plug 4P



YE



Plug 6P



RD



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2 3 4



1 45A Point a 2



A 61F F1,G



59C F1,F3



AMP 172134-1



F3 Backward output relay



4B



59D F3,P2



Plug 4P



WH



6B



A 48B E1,H



4 3



1 2



4 3



3 3



3 3



3 3



3 3



AMP 172134-9



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2 3 4



RD



25B A,T 39B D 60D P1,K 40B D



(✻ Re fe



3



50B C



9



H Back buzzer



1 2 3 4 5 6



K Brake switch



1 2 3 4



3 3 3 3



4 4



1 a1 101A 2 Point b 103C



a4 Level sensor



S



water resistant Plug 2P



2 1



GN▲



48C F3,E2



2



61G F4,G



2



G Horn



F1



7



61H H,b



7



42B



GNRD2 BKWH✻



BKWH1 WH1



4 4



1 2



A 16B



BKYE1 WH2



4 4



1 2



A 18B



RDYE5



A 15B



water resistant Plug 2P



A 17B



water resistant Plug 2P



P1



60G



57B



P2 Accessory(front)



L 2 1



B Speed sensor



AMP 174352-2



BKWH✻



NOTE: 1,Terminal symbols



2 1



:Receptacle(with plating) :Receptacle(without plating) Sleeve(for single wire) Sleeve(for double wire)



AMP AMP AMP AMP



2



:Plug(with plating) :Receptacle(without plating) Sleeve(for double wire)



AMP 170020-2 AMP 170002-5 or 170020-3 AMP 170888-1



1 2



WHBK2 BKWH✻



+



BKYE BNYE1 RD4 BK1 GNBK1 RDGN3



Condenser 100v 22µ



BUWH2 RDYE1



Point "a"



RDBK RDBK



Point "c"



4 4 4 4 4 4



1 D 38B 2 3 D 36B 4 5 A 3B 6



AMP 174262-2 D 37B A 2B



L Accelerator sensor



3 2 1 6 5 4



water resistant Plug6P



1



A 1B



RDWH BKWH✻ GNBK2



1 1 1



D,F2 60C



GNRD3 BKWH✻ RDGN5 BU4 RDYE5 BUWH2



4 4 4 4 4 4



1 Point c 55C Point c 61C 2 3 M2 46D Point c 39D 4 5 H 48D M2 47E 6



E2,Pointc 61D



P2 57A



55A W



1 2 3 44D Point a 30C Point c 4 48A F3 5 47A F4 6



3 2 1 6 5 4



RDYE RDBK2 RDWH GNRD1



water resistant Plug 6P



GNRD3 BKWH✻ RD5 BU4 RDYE5 BUWH2



4 4 4 4 4 4



3



:Receptacle



AMP 170032-5 or 179461-5



:Tab



AMP 170340-3 or 179462-3



4



:Receptacle



AMP 171662-1 or 173707-1 AMP 172888-2(rubber plug) AMP 172748-2(seal plug)



P1 Accessory



5



:Receptacle



AMP 316041-2 or 179956-2



6



:Receptacle



AMP 173716-2 or 175061-2



7



:Receptacle(with sleeve) Sleeve(for single wire) Sleeve(for double wire) :Receptacle :Tab :Pressed sleeve :Terminal(F) :Terminal(M)



AMP 174262-2 water resistant Plug6P



E2 Stop & tail lamp (right)



3 2 1 6 5 4



E1 Stop & tail lamp (left)



8 9 12



62B



Receptacle



5 4 3 2 1 10 9 8 7 6



A



L



L



F2



8B



9B



36A



38A



40A



A



C,P1



L



F2



10B



60B



37A



39A



Point c 58A Cap 2P



Plug 4P



Plug 6P



WH



WH



BK



AMP 172129-1



AMP 172134-1



1 2



C EPS unit



Point "a"



Point "b"



BNBK1 BN2 WHRD2 BU4 BNRD1 BUYE2 RD3 YEBK GNWH3



RDGN4



6 6 6 6 6 6 6 6 6



T



S



S



S



X



X



X



24A



26A



27A



29A



31A



33A



35A



L



F4



K



F3



D



D



U



U



B



B



C



N



F2



S



K



X



X



2A



4A



5A



6A



8A



10A



12A



14A



16A



18A



20A



22A



25A



28A



30A



32A



34A



4



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 AMP.040 series multi-lock connector 175967-2



:Braid wire under 25mm pitch. The location of the connector pin is as viewed from the inserting side. The ends of the insulating tube should be tied together with wire ties. Fuses should be placed in a circle, as shown in Figure 1. The ends of the spiral tube should be tied together with wire ties, and then theube should be coiled with a gap of 2 ± 1mm.(Refer to Figure 2.)



Fuse 10A 10A



CN6 5



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



6



AMP.040 series multi-lock connector 175966-2



12



Clamp Figure 1



Wire tie Figure 2



Point "c"



BU4



To K



FB30P-DC70



BU4



12 BU4



BK



To O



12



To E2



BNBK4 To a4



6



U 23A



To E1



RDYE1 To F4



12



RDGN2 RDYE



O 21A



CN5



2, 3, 4, 5, 6,



A MPU board



12 BNBK4 To a2 BNBK4 To a3



6 6



C 19A



BK



RDGN5 To M2 RDGN5 To E2



6 6



B 17A



To U



46C M2,E2



BURD1



B 15A



AMP.040 series multi-lock connector 175966-2



To F1



RD5 To M1 RD5 To E1



YEWH3 RDWH3



U 13A



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



BKWH✻



44C M1,E1



6



U 11A



D Controller RDYE1 To F4



BUBK YEWH1 WH1 BKWH1 WH2 BKYE1



D 9A



CN4



1 2 3 4 5 6



6 6 6 6 6 6 6 6 6 6



U 7A



AMP 171898-2



1 2 3 4



YERD YEWH4 YEBK1 GNWH2



BNRD2 BUWH1 BU2 BURD WHRD1 6 6 6 6 6



6 6 6 6



6



RDGN3 BK1 GNBK1



BNWH5



GNRD2



RDBK2 GNRD1



A



61B



15



AMP 41729 AMP 178023-2 AMP 1-170823-5 Yszaki 7116-3251 Yszaki 7114-3251 JST FNE-2 Yszaki 1500-0110 Yszaki 1600-0105



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



L 3A



To D



Black color



E1,Point c



1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20



L 1A



BK



White line



RD4 BNYE1 BKYE



10A b 110A



AMP 174655-2



Ex) BKWH (=Black/White) Black colored harness with White line.



BU2 WHRD1 BURD RDWH



12



12



BK



BK D



2P-X water resistant Plug10P



10A



AMP 1-179958-2



To D



J 53A



1 2 3 4 5 6



To P1



J 51A



1 2 3 4



BKWH✻



b 54A



1 2



BKWH✻



A 20B



3 3 3 3 3



A 19B



1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 D 62A



3 3 3 3



I 50A



3 3



I 49A



12



2



J 52A



BK✻



1



D 60A



RDBK RDYE4 BKWH✻ BK



RDGN



F1 59A



1



1 2 3 4 5 6 7 8 9 10



RD BK GN YE WH BN BU GY PK



b 111A



Harness mark/color Red Black Green Yellow White Brown Blue Gray Pink



GN▲



BKWH✻ WHBK2



YE▲



3 3



RD RDWH



4 42A G 3



(✻Refer to note 5)



61E Point c,F4



5



BK



5



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



41A V



Plug 4P



YEWH1



1 2 3 4



RDBK YEBU1



Seal plug 4 Seal plug 4 Seal plug 4 4 WH 4 GNBU1 4 BU3 4



F1 Horn relay



3 3



BUBK



15



1 2



59B D,F3



AMP 172134-2



170021-2 170003-5 or 170021-3 170089-1 170890-1



3



BNRD2 RDYE5 61A D



Plug 4P



1P



BNWH6 BNBK4



61L



K,X



AMP 174352-2



AMP 174262-2



F2 Control power supply relay



59E AMP 174352-2



YE▲



60F



AMP 171898-9



b Charger panel AMP 172134-7



1P



8



F3,V a1,M2



5B



39B



1 2 3 4



BK



A



49B C



2 1



Point "b"



A, Point c K,P2



AMP 172134-2 Plug 4P



I EPS motor



1 2 3 4 5 6



C,T



D



AMP 172134-1



3 3



61J



3



43A



3 3 3 3



b,a1



R, Point a



no



water resistant Plug 3P



3 2 1



BU3 GNBU1 WH



4 4 4



RDWH



RDWH



BNWH5 BU4



RDYE4 RDGN RD BKWH✻



3 3 3 3 1 2 3 4 W



1 52B C 2 51B C 3



r to



WH3 RD5 BKWH✻ BUWH2



J EPS sensor



53B C



te 4



)



AMP 174352-2 AMP 174357-2



RDBK RDWH BKWH✻ GNBK2



S



Directional switch



1 1 1 1



R



Turn signal switch



BODY HARNESS



– 73 –



RDBK WH3 GNRD3



(✻Refer to note 6)



3 3 3



1 V,Q 2 3 E1,E2 4



3 3



1 X 2



AMP 172134-1



59G M1,M2



Plug 4P



43B



W Lamp switch



1 2 3 4



WH



55B



AMP 172130-2



BK YEBK1 YEWH4 YERD BK GNWH2 RDWH3 BUWH1



4 4 4



4 4 4 4 4 4 4 4



RD RDYE RDGN2



4 4 4 4



RDBK RD5 RDGN5



1 2 3 4



1 2 3



1 2 3 4 5 6 7 8



Q 59I



59H 41C



Q



1 2 3 V



M2 46A



A 28B



M1 44A



Horn switch (steering)



A 26B



A 29B



water resistant Plug 3P



Point c A 58C 12B



F2 25C



A 13B



A 27B



water resistant Plug 4P



AMP 174357-2



b A 54C 24B



water resistant Plug 3P



AMP 174257-2



N 58F



A 11B



V



A 23B



N Brake oil



water resistant Plug 8P



AMP 174357-2



AMP 174982-2



W



21B



K



3 2 1



3 2 1



2 1 4 3



Horn switch (Hydraulic)



59F P2,W



2



a5 Laser pointer switch



1 2



WH



a1 100A



41B F1,Q



2



22B



A



2



58E



O,U



2



4 3 2 1 8 7 6 5



A



YEBU1



BNRD1 BUYE2 RD3 YEBK GNWH3 RDWH



YEWH3 BK



3 3 3 3



1 a5 100B M1,P2 2 3 a4 101B a2,a3 4



3 3 3 3 3 3



1 2 3 4 5 6



61K



Plug 4P



WH



a1 DC/DC Converter



1 2 3 4



102B



AMP 171898-2



A 31B A 32B Plug 6P



A 33B A 34B



BK



A 35B P2,a5



X Valve microswitch



1 2 3 4 5 6



60H



AMP 172134-1



WH3 RDGN5 BKWH✻ BUWH2



BURD1



1



58D C,N



YERD4 BKWH✻ BNWH6 BURD5



RDBK



A 7B



A 14B



Plug 2P



60I



AMP 172134-1



4 4 4



RDBK



YEBU1 2



2 W,R



BN2 WHRD2 RDGN4 BNBK1



RDWH YERD4



BK



1



3 3 3 3



1 W 43C R,Point a 46B 2 3 P2 61M 4 M1,E2 47D



Put the sleeve for sure receptacle.



T Key switch



O Hour meter



U Indicator panel



M2 Head guard (right)



AMP 174352-2



BNBK4 BURD5



4 4



1 Point b 103A 2 a1 102A



water resistant Plug 2P



4 4



1 Point b 103B 2 a1 102C



water resistant Plug 2P



M



a2 Laser



L



a3 Level lamp



2 1



BK



15



c 121A



15



c 121B



J 53A



50A



AMP 1-179958-2



water resistant Plug10P



D



Receptacle



62B



– 74 –



1 2 E1,Point c 61B



b 110A



5 4 3 2 1 10 9 8 7 6



1 2 3 4



1 2 3 4 5 6



A



L



A



8B



9B



L



D,F2 60C



GNRD3 BKWH✻ RDGN5 BU4 RDYE5 BUWH2



4 4 4 4 4 4



1 Point c 55C Point c 61C 2 3 M2 46D Point c 39D 4 5 H 48D M2 47E 6



L Accelerator sensor



A 1B



P1 Accessory



E2,Pointc 61D



P2 57A



AMP 174262-2



36A



38A



AMP AMP AMP AMP



2



:Plug(with plating) :Receptacle(without plating) Sleeve(for double wire)



AMP 170020-2 AMP 170002-5 or 170020-3 AMP 170888-1



2



3



:Receptacle



AMP 170032-5 or 179461-5



:Tab



AMP 170340-3 or 179462-3



4



:Receptacle



AMP 171662-1 or 173707-1 AMP 172888-2(rubber plug) AMP 172748-2(seal plug)



5



:Receptacle



AMP 316041-2 or 179956-2



6



:Receptacle



AMP 173716-2 or 175061-2



7



:Receptacle(with sleeve) Sleeve(for single wire) Sleeve(for double wire) :Receptacle :Tab :Pressed sleeve :Terminal(F) :Terminal(M)



8 9 12 15



C,P1



L



F2



60B



37A



39A



Cap 2P



Plug 4P



Plug 6P



WH



WH



BK



AMP 172134-1



44C M1,E1



RD5 To M1 RD5 To E1



46C M2,E2



RDGN5 To M2 RDGN5 To E2



Point "a"



BNBK4 To a2 BNBK4 To a3



BNBK4 To a4



Point "b"



11A



13A



B



15A



C



17A



O



19A



21A



U



T



23A



24A



X



29A



X



31A



X



33A



35A



c



K



F3



D



D



U



U



B



B



C



N



F2



S



K



X



X



4A



120A



5A



6A



8A



10A



12A



14A



16A



18A



20A



22A



25A



28A



30A



32A



34A



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



CN5 4



AMP.040 series multi-lock connector 175966-2



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 AMP.040 series multi-lock connector 175967-2



A MPU board 12



12



Point "c"



AMP 41729 AMP 178023-2 AMP 1-170823-5 Yszaki 7116-3251 Yszaki 7114-3251 JST FNE-2 Yszaki 1500-0110 Yszaki 1600-0105



6 6 6 6 6 6 6 6 6 S



F4



12 12



6



27A



9A



7A



B



L



CN4



1 2 3 4 5 6



6 6 6 6 6 6 6 6 6 6



26A



3A



U



2A



D Controller RDYE1 To F4



6 6 6 6 6



S



AMP 171898-2



1 2 3 4



6



S



D



170021-2 170003-5 or 170021-3 170089-1 170890-1



3



BNBK1 BN2 WHRD2 BU4 BNRD1 BUYE2 RD3 YEBK GNWH3



RDGN4



BURD1



BUBK YEWH1 WH1 BKWH1 WH2 BKYE1



YERD YEWH4 YEBK1 GNWH2



BNRD2 BUWH1 BU2 BURD WHRD1



BNWH5



BUYE1



GNRD2



40A



A



1 2



RDYE1 To F4



:Receptacle(with plating) :Receptacle(without plating) Sleeve(for single wire) Sleeve(for double wire)



1



E2 Stop & tail lamp (right)



3 2 1 6 5 4



water resistant Plug6P



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



1A



F2



10B



Point c 58A



AMP 172129-1



C EPS unit



BODY HARNESS (EEC)



1 1 1



1,Terminal symbols 3 2 1 6 5 4



water resistant Plug6P



A 2B



U



U



To K



J 51A



Black color



FB30P-DC70



RDWH BKWH✻ GNBK2



NOTE:



AMP 174262-2 D 37B



1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20



L



BU4



b 54A



AMP 174655-2



White line



1 D 38B 2 3 D 36B 4 5 A 3B 6



L



To E2



A 20B



2P-X



Ex) BKWH (=Black/White) Black colored harness with White line.



4 4 4 4 4 4



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



BU4



49A



A 19B



D 62A



6



I



BU4



52A



2



I



To E1



60A



1



BK



J



To O



RD BK GN YE WH BN BU GY PK



BKYE BNYE1 RD4 BK1 GNBK1 RDGN3



15



BK



Red Black Green Yellow White Brown Blue Gray Pink



D



F1 59A



To D



1 2 3 4 5 6 7 8 9 10



Harness mark/color



b 111A



RDGN3 BK1 GNBK1



BKWH✻ WHBK2



6 6 6 6



3 3



GNRD3 BKWH✻ RD5 BU4 RDYE5 BUWH2



BK



61E Point c,F4



4 4 4 4 4 4



To U



BK



Point "c"



BK



4 42A G 3



41A V



Plug 4P



GN▲



RDBK YEBU1



B Speed sensor



2 1



E1 Stop & tail lamp (left) YE▲



3 3



water resistant Plug 6P



5



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2



1 61A D 2 3 44D Point a 30C Point c 4 48A F3 5 47A F4 6



5



1 2 3 4



40B D



59B D,F3



AMP 172134-2



F1 Horn relay



39B D 60D P1,K



3 2 1 6 5 4



RDYE RDBK2 RDWH GNRD1



RD RDWH



RD



3 3 3 3



YEWH1



1 2 3 4



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2 3 4



BUBK



F2 Control power supply relay



25B A,T



55A W



Seal plug 4 Seal plug 4 Seal plug 4 4 WH 4 GNBU1 4 BU3 4



AMP 172134-9 Plug 4P



te



c Seat switch AMP 174262-2



L



1



To C



BNRD2 RDYE5



1 2



2 1



To F1



3 3



water resistant



Lengs 50



BKWH✻



4 3



P2 Accessory(front)



2 1



5)



48B E1,H



A



57B



te



6B



2 1



P1



60G



no



WH



120B A



to



RDBK RDBK



A 17B



water resistant Plug 2P



fer



3 3



A 18B



Re



1 2 3 4



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



1 2



1 2



(✻



F3 Backward output relay



Plug 4P



water resistant Plug 2P



a4 Level sensor



BK BUYE1



58B Point c 1 15 2 15



Plug 2P



Cap 2P water resistant



59D F3,P2



59C F1,F3



AMP 172134-1



no Re fe (✻



RDWH



BK



4 4



+



To D



61F F1,G



BKYE1 WH2



A 15B



water resistant Plug 2P



Condenser 100v 22µ



Point "a"



GNRD2 BKWH✻



A 16B



BKWH✻



To P1



3 3



7



BKWH✻



4 3



A



61H H,b



BKWH✻



4B



S



WHBK2



RDBK2 GNRD1



✻ Connect the relay "Cala-48V-N". Do not bind with the body harness.



YE



3 3



7



1 2



AMP 174352-2



RD4 BNYE1 BKYE



1 2 3 4



1 45A Point a 2



G Horn



BUWH2 RDYE1



F1



42B



4 4



BKWH✻



3 3 3 3 3



F4 Turn signal reiay



Plug 4P



2



BU2 WHRD1 BURD RDWH



47B E1,M1



AMP 172134-7



K Brake switch



2



61G F4,G



3 3 3 3



b Charger panel



48C F3,E2



RDBK RDYE4 BKWH✻ BK



RD



H Back buzzer



1 2 3 4 5 6



BKWH1 WH1 RDYE5



12



Plug 6P



1 a1 101A 2 Point b 103C



61L



K,X



AMP 174352-2



BK



BK



9



60F



AMP 171898-9



1 2 3 4



Plug 4P



4 4



GN▲



10A



AMP 172134-2



M1 Head guard(left)



YE▲



8



3 3



39B



RDGN



1 2 3 4



BNWH6 BNBK4



A, Point c K,P2



12



WH



50B C



1P



BK



61I



49B C



10A



G,M1



1P



I EPS motor



12



D 111B



59E



6



5B



F3,V a1,M2



AMP 174352-2



RDGN2 RDYE



A



60E



2 1



Point "b"



6 6



F2,K



54B



BNBK4 BURD5



YEWH3 RDWH3



C,T



BU3 GNBU1 WH



4 4 4



6 6



D 110B



AMP 172134-1



Plug 4P



BNWH5 BU4



1 2 3 4 5 6



BK✻



47C



1 2 3 4



1



44B



RDWH



RDYE4 RDGN RD BKWH✻



F4,M2



3 2 1



(✻Refer to note 7)



61J



water resistant Plug 3P



3



43A R, Point a



3 3



b,a1 3



W



3 3 3 3



3 3 3 3 1 2 3 4



1 52B C 2 51B C 3



r to



WH3 RD5 BKWH✻ BUWH2



J EPS sensor



53B C



4)



AMP 174352-2 AMP 174357-2



RDBK RDWH BKWH✻ GNBK2



S



Directional switch



WH



1 1 1 1



R



Turn signal switch



1 2 3 4



Plug 4P



2, 3, 4, 5, 6,



:Braid wire under 25mm pitch. The location of the connector pin is as viewed from the inserting side. The ends of the insulating tube should be tied together with wire ties. Fuses should be placed in a circle, as shown in Figure 1. The ends of the spiral tube should be tied together with wire ties, and then theube should be coiled with a gap of 2 ± 1mm.(Refer to Figure 2.)



CN6 5



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



Fuse



6



AMP.040 series multi-lock connector 175966-2



10A 10A



12



Clamp Figure 1



Wire tie Figure 2



FB10-25P



2P



2P



WH



WH



2P



2P



WH



WH BNRD



2P WH



170020-2 170021-2



2.The terminal is fixed in place by the fitting for the connector. 3. Connect only if a GS battery is installed.



M6



WH



YEWH2



2P



GNBU2



2P



M4



M2



M1



M3



WH















FB30P



Note: 1.Terminal symbols :Terminal :Lead bar :Plug :Receptacle



CF



4PWH



F



FB20/25/30P



F



WH*



A



Only FB30P



S+



PF



40A



275A



275A



Controller Ass’y.,EPS



H+



BUBK4



D1



4PWH



A







PA WHRD1



RD



FB10P



FET Comp.



M7



RD*







Only FB10-25P (FB30P has no this line)



WH



A



RD 4P



GN 4P



YEWH



BKWH✻ 4P GN



T+ BNWH



Refer to note 2



Pre-energizing



2 BU



2P







BNYE



FB15/18



FET Comp.



D+



RDYE



Board Comp.,MPU



BU



1



Refer to note 3



1



1



3



Harness,Controller



Harness mark/color Red Black Green Yellow White Brown Blue Gray Pink



2



RD BK GN YE WH BN BU GY PK



FB10-25P : 24200-68871 FB30P : 24200-68941



Wire, Lead ( - ) 4P



2P



4P



6P



WH



WH



WH



WH



FB10-25P



FB30P



Ex) BKWH (=Black/White) Black colored harness with White line.



FB10P



For Std. 24200-68792



24200-68832



FB15/18P



24200-68802



24200-68842



FB20/25P



24200-68812



24200-68852



FB30P



24200-68822



24200-68862



10P Water resistant



2P TipeX



For EEC



White line Black color



To Harness,Body



FB10-30P-DC70 CONTROL UNIT WIRING



– 75 –



B Contactor



Harness mark/color



32B 35B



GNBU2



A



A



A



A



2



1



2



RDBK1



RDWH1



WHBK



2



2



*



8



1 3



A



2 3



A



1 3



3



28B 37B



8



24B 27B



2



15B A



BNWH1



3



RDGN1



Ex) BKWH (=Black/White) Black colored harness with White line.



YEWH2



A



2



8



3



A



1 RD1



A



2



3



A



1



Plug 2P WH



A



Plug 2P WH



BNRD



23B 25B



Plug 2P WH



17B



A



NOTE: 1. Lead wire # :AVS 0.3mm ✻ :AVS 0.85mm :KIV 2.0mm Others :AV S0.5mm



2



2. The location of the pin is as viewed from the inserting side. : Braid wire under 25mm pitch. 3. 4. Do not use sure-plugs and receptacles.



3



30B 29B



16B



1 2



3



Plug 2P WH



1 2



RD2



Plug 2P WH



1 2



WHRD



1 2



3



1 2



WHGN



RD BK GN YE WH BN BU GY PK



WHBU



Red Black Green Yellow White Brown Blue Gray Pink



White line Black color



10P



20P



8



Resistor



B



C



C



N



6A



H



4A



E



BUBK4



8A



2A



E



E



19A



17A



15A



13A



11A



9A



7A



5A



3A



1A



M



B



B



M



K



H



H



E



E



E



6



6



6



6



6



6



6



6



6



6



6



6



6



8



BKWH✻



YEWH 1



3



3



3



BKRD GNWH BUWH



3



BU



GNBU



3



BK



3



3



3



3



RD4 BNYE1 BKYE RDBK2 GNRD1 3



3



3



3



3



BU2 WHRD1 BURD RDWH 3



3



3



8



3



BU2



RDYE4 RDYE4 BKWH✻ BK



3 F



40A



A



Current sensor



3



G



38A



8



20 10 19 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1



BU* BURD WH* 3



3



1 2 3 4



8



20B



10A



K



H,H



BNWH



B



M



44B



A



RDYE4



C



10 5 9 4 8 3 7 2 6 1



B



12A



22B



BNYE



20A



6



14



14



14



14



14



RDBK1



G



14



1 2



F 1 2 3 4



K



22A



14A



6



B



H



23A



6



B



H



24A



6



B



H



26A



6



B



14 7 13 6 12 5 11 4 10 3 9 2 8 1



B



16A



A



GNWH GNBU GNBU2 YEWH2 BNRD BKRD BUWH BK BU YEWH BNYE1 BKYE RD4 BK2# RDYE3# YERD1# BU1# BKRD1# RDBK3#



28A



18A



14



30A



21A



6



B



32A



21C



14



B



37A



12D



14



H



25A



14



H



27A



29A



14



B



31A



14



33A



14



35A



14



F Terminal



4P



A



E



Plug 2P WH



14P



14



4P



40B



26B



WHRD



A



6B



14



A



2B



39B 38B



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



GNRD1 RD2 RDBK2 RDGN1 WHBU



4B



5 4 3 2 1 10 9 8 7 6



14



I,H



C Fuse



3



7 6 5 4 3 2 1 14 13 12 11 10 9 8



14



A



2



BNWH1 BUBK4 WHBK RDWH1 BK RD1 RDWH BNYE RDWH BNWH



I



5B



1 2 3 4



BU* 3



J



8



WHGN



3B



RD* 3



2



A



1B



WH* WHRD1



1



A



A



YERD1# BK2# 10



1 2 3 4



1 2 3 4



10



RDYE3# 10



BU1# BKRD1# 10



10



10



RDBK3#



A MPU board 1



A



8



10B



H



42B



8



Plug 4P GN



G



1 2 3 4



1 2 3 4 5 6



1 2 3 4



1 2 3 4



C



L



J



I



A



A



A



A,H



A



A



A



44A



41B



42A



43A



7B



8B



33B



12B



11B



14B



13B



C



K,A



F



A,A



A



A



A



A



44C



12C



40C



21B



9B



31B



18B



19B



1



1 2 3 4



39A



1 2 3 4



I Pre-energizing PB J Diode



CONTROL UNIT HARNESS



– 76 –



H



N



41A



L Battery(–)



6



Plug 4P WH



Cap 4P WH



Cap 4P RD



Cap 4p GN



Cap 6P BK



N



10D



1 2 3 4



2 1 4 3



3 2 1 6 5 4



H External terminal FB10-25P-DC70



10C



YEWH



43B



RD*



H



2 1 4 3



K



FET comp. (travel)



2 1 4 3



N Body earth Refer to note 4



M



FET comp. (hidraulic)



B Contactor



Harness mark/color



1 2



16B



Plug 2P WH



28B 37B



32B 35B



2



A



1



2



BNRD



A



RD2



2



2



2. The location of the pin is as viewed from the inserting side. : Braid wire under 25mm pitch. 3. 4. Do not use sure-plugs and receptacles.



3



A



2



3



A



RDBK1



*



8



1 3



GNBU2



A



2 3



A



1 RDWH1



Plug 2P WH



8



24B 27B



WHBK



RDGN1



White line



8



3



A



2



2



15B A



BNWH1



A



1



Plug 2P WH



3



A



2



RD1



A



1



1 2



A



YEWH2



23B 25B



3



30B 29B



3



Plug 2P WH



3



Ex) BKWH (=Black/White) Black colored harness with White line.



Plug 2P WH



1 2



17B



A



NOTE: 1. Lead wire # :AVS 0.3mm ✻ :AVS 0.85mm :KIV 2.0mm Others :AV S0.5mm



WHRD



1 2



3



1 2



WHGN



RD BK GN YE WH BN BU GY PK



WHBU



Red Black Green Yellow White Brown Blue Gray Pink



Black color



18A



16A



14A



12A



10A



8A



6A



4A



2A



D



B



H



H



B



B



B



H



H



H



K



B



M



K



N



H



E



E



E



37A



34A



32A



30A



28A



26A



24A



23A



22A



20A



19A



17A



15A



13A



11A



9A



7A



5A



3A



1A



B



D



B



B



B



C



B



B



C



C



M



B



B



M



K



H



H



E



E



E



34B 36B A



A



1



2



3



6



6



6



6



6



6



6



6



6



6



6



6



6



6



6



6



6



6



Plug 2P WH



8



RDWH2



GNWH GNBU GNBU2 YEWH2 BNRD BKRD BUWH BK BU YEWH BNYE1 BKYE RD4 BK2# RDYE3# YERD1# BU1# BKRD1# RDBK3#



6



14



14



14



14



14



14



14



14



14



14



14



14



14



20 10 19 9 18 8 17 7 16 6 15 5 14 4 13 3 12 2 11 1



A



43B



8



Plug 4P



GN



G



1 2 3 4



L



J



I



A



A



A



A,H



A



A



A



41B



42A



43A



7B



8B



33B



12B



11B



14B



13B



K,A



F



A,A



A



A



A



A



12C



40C



21B



9B



31B



18B



19B



39A



1 2 3 4



I Pre-energizing PB



J Diode



BKWH✻



YEWH 1



3



3



1 2 3 4



3



BKRD GNWH BUWH



3



3



1 2 3 4 5 6



3



BK GNBU BU



3



3



3



RD4 BNYE1 BKYE RDBK2 GNRD1 3



3



3



3



3



3



BU2 WHRD1 BURD RDWH 1 2 3 4



A



8



10B



1



H



42B



1 2



YEWH



H



3



8



3



F



40A



RD*



G



38A



BU2



1 2 3 4



BKWH✻ BK



3



3



3



BU* BURD WH*



Resistor



RDBK1



G



E Current sensor



8



3



21A



BUYE



21C



BNWH



12D



BNYE



25A



BUBK4



27A



10 5 9 4 8 3 7 2 6 1



1 2



A



20B



29A



14



1 2



8



31A



14 7 13 6 12 5 11 4 10 3 9 2 8 1



F



20P



BNWH1 BUBK4 WHBK RDWH1 BK RD1 RDWH BNYE RDWH BNWH



1 2 3 4



Plug 2P WH



10P



33A



14



4P



A



BU*



40B



F Terminal



A



35A



14



6B



D Contactor



26B



36A



14



2B



I



14



A



J



39B 38B



14



A



4P



RD*



I,H



14P



WHRD RDWH2 GNRD1 RD2 RDBK2 RDGN1 WHBU



A



4B



2



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



5 4 3 2 1 10 9 8 7 6



C Fuse



3



22B



14



A



5B



1



8



2



7 6 5 4 3 2 1 14 13 12 11 10 9 8



WHGN BUYE



A



3B



3



A



1 2 3 4



WH* WHRD1



YERD1# BK2# 10



1 2 3 4



1B



1 3



1 2 3 4



10



RDYE3# 10



10



10



10



BU1# BKRD1#



RDBK3#



A MPU board



10C



H



N



41A



L Battery(–)



6



Plug 2P WH



Cap4P



Cap 6P



WH



BK



Cap 4P GN



Cap 4P RD



1 2



2 1 4 3



3 2 1 6 5 4



2 1 4 3



2 1 4 3



N



10D



H External terminal



K



FET comp. (travel)



N Body earth Refer to note 4



M



FET comp. (hidraulic)



FB30P-DC70 CONTROL UNIT HARNESS



– 77 –



Reference Connector for MPU board Double lock plate pushing part



1. Pin layout of housing



Locking lever Rib for preventing inverse insertion



6 5 4



Double lock plate



3 2 1



14 13 12 11 10 9 8 7



CN1 (gray) [P/No.37010-21040] Ratchet part 4 3



Plug housing



2 1



CN3, 4, 5 6



10 9 8 7 6 5



CN2 (gray) [P/No.37010-21030]



(2) Crimping terminals 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



CN3 (black) CN5 (black) [P/No.37010-21020]



Housing lance fixing part



Contacting part (inside box)



Wire barrel 8 7 6 5 4 3 2 1



Insulation barrel



16 15 14 13 12 11 10 9



CN1&CN2 [P/No. 37010-21480]



CN4 (black) CN6 (black) [P/No.37010-21010]



2. Names of parts (1) housing



Housing lance fixing part



Contacting part (inside box) Wire barrel



Double lock plate pushing part



Insulation barrel



Locking lever



CN3, 4, 5, 6 [P/No. 37010-21490]



Double lock plate



Ratchet part



Plug housing



CN1&CN2



– 79 –



3. Insertion terminal into housing (1) With the locking lever of housing upward and the crimping part of terminal upward, insert the housing into corresponding port. (Fig.1) CAUTION



When it is impossible to insert the terminal easily, do not force to insert it. At first, check the corresponding port. When inserting forcedly, the housing will be damaged at the housing. Pay attention to insertion of terminal.



Locking lever Plug housing



(3) Press the crimping part of the double lock plate. The plate will go down and release from the ratchet part and will sound snapping. And after finishing the inserting the terminal, pull the wire lightly to make sure the locking. When the double lock plate would work correctly, the condition would be like as Fig.4. CAUTION



When there are some unlocked terminals, the double lock plate would not work correctly, the plate would be one side locking and the ratchet would be raised at one side Remove the terminal by using the ejection tool and do over again correctly.



Double lock plate pressed part Double lock part Double lock part



Pull the wire lightly



Crimping part



Insulation barrel Housing lance



Terminal



[Completed double locking]



Fig.1



(2) Verify the terminal is locked correctly into the housing. When inserting the terminal like as Fig.2, the terminal which the crimping part is placed in the middle of the retainer would come to lose, insert the terminal into the housing like as Fig.3. When the terminal is locked, it would sound snapping. And after inserting the terminal, pull the wire lightly to make sure the locking it.



Fig.4



There a gap on normal condition



The inserting groove for ejection tool



[Completed double locking]



[Incompleted detente locking] [One side locking of ratchet] Fig.5



4. Pulling terminal CAUTION



When remove the terminal for doing over again, use the specified pulling tool.



Pull the wire lightly



(1) Release the double locking (Fig.6) q Insert the jig into the groove . w Lay it to the direction of arrow and bend the wall of housing, and then rise the plate crimping part and remove the ratchet. Repeat the same way at the opposite side also. CAUTION



[Unlocked condition of terminal]



[Correct locked condition of terminal]



Fig.2



Fig.3



– 80 –



Do not vent the wall of housing strongly, it will come to be damaged.



[In case of CN1, 2]



Be careful not to insert the ejection tool into the housing side of crimping terminal.



CAUTION



Rib of plate crimping part Operation from q to w Inserting groove for ejection jig



e w



q



q



r



Fig.7



Cut face should be inside



w



• Insert the jig into the groove and bend the housing. • After the housing would be bended, rise the rib of plate crimping part to the arrow direction.



Rib of plate crimping part



5. Crimping tool (AMP made) (1) Crimping terminal for CN1&2 (P/No.37010-21480) applicable hand tool Model: 911788-2 Mark of crimping part Crimping die



Fig.6



[In case of CN3, 4, 5, 6]



m



Rib of plate crimping part



Pin and retaining ring Handle



Operation from q to w



Radio pliers (article on the market)



5m Bared length -4. of insulation 3.5



Inserting groove for ejection jig



Crimping pressure control device



press down part of insulation



Crimping part of wire



q



(2) Crimping terminal for CN3, 4, 5, 6 (P/No.37010-21490) applicable hand tool Model: 911738-1



Ejection jig (AMP) Model: 755430-1



w



Crimping die (Inside)



Clamp the housing and retainer by the radio pliers, then release the ratchet part (sounds clipping) and repeat the same outline at the opposite side.



Crimping part of wire press down part of insulation



Rib of plate crimping part When insert the jig into the housing, move the jig to the arrow direction and vent the housing.



Bared length of insulation 4mm (Reference)



Crimping pressure control device Handle



(2) Pulling out the crimping terminal qPush the crimping terminal to the arrow direction. wInsert the ejection jig tool to the groove. eRise the lance. rPull the crimping terminal. – 81 –