DOWNLOAD PDF TOYOTA Forklift 7FBCU15-55 Vol 1&2 Repair Manual

FOREWORD This manual covers the service procedures of the TOYOTA ELECTRIC POWERED FORKLIFT 7FBCU15 to 55 series. Please use this manual for providing quick, correct servicing of the corresponding forklift models.

For the portion not covered herein, please refer to the repair manuals shown below.

This manual deals with the above models as of August 2005. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News.

(Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL EQUIPMENT 7FBCU15~55 REPAIR MANUAL VOL1, VOL2 (No. CU321, CU322)

SECTION INDEX NAME

GENERAL CONTROLLER MULTI-DISPLAY FUNCTIONS TROUBLESHOOTING STEERING OIL CONTROL VALVE APPENDIX

SECTION

0 1 2 3 4 5 6

0-1

GENERAL Page

PERIODIC MAINTENANCE .................................0-2 DEVELOPMENT OBJECTIVE .............................0-3 CONTROLLER .....................................................0-4 STEERING............................................................0-5 DRIVING POSITION.............................................0-6 SEAT ....................................................................0-6 MULTI-DISPLAY ..................................................0-7 AUXILIARY EQUIPMENT ....................................0-8 OPS ......................................................................0-9 MATERIAL HANDLING OPS SYSTEM (35 ~ 55 MODEL).............................................0-10 DEADMAN BRAKE MODEL..............................0-11

0

0-2

PERIODIC MAINTENANCE INSPECTION METHOD I : Inspection·Repair or Replacement if required.

M : Measurement·Repair or Adjustment if required.

T : Retightening C: Cleaning L: Lubrication * : For new vehicle *1 : Flaw detector Inspection Period

Every 6 weeks

Every 3 months

Every 6 months

Every 12 months

Every 250 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Loosening and damage of mounting

I

←

←

←

Seatbelt damage and function

I

←

←

←

Seat switch function

I

←

←

←

Functions

I

←

←

←

Item SAFETY DEVICES, ETC. Seat OPS

0-3

DEVELOPMENT OBJECTIVE ADDITION OF OPS SYSTEM The OPS (Operator Presence Sensing) system is added as standard.

The switch installed on the seat detects the operator, and when there is no operator the OPS system interrupts the traveling power and restricts material handling operation. (Refer to page 0-9.)

When the controller detects the seat switch turned off, it informs OPS operation to the operator by sounding the buzzer (pi-)* for about 0.5 seconds and the display indication. Moreover, the display indication keeps while turning off the seat switch. *: The buzzer sounds only export model.

When the controller detects malfunction, the display indicate the diagnosis error code.

0

0-4

CONTROLLER MAJOR CONTROLLER FUNCTIONS Comparison with Former Edition: New Model Features, Pub. No. PU312, Page 2-18- to 2-20 New: 8.

OPS When the operator is not sitting on the seat, the OPS system interrupts the traveling power and restricts material handling operation. (Refer to page 0-9 OPS for details.)

16. Return-to-neutral function If the key switch or the deadman switch turns ON with the direction lever at the forward or reverse position or with the accelerator pedal depressed, the vehicle will not start. The operator has to return the direction lever and accelerator pedal to their neutral positions.

Add: 22. Accelerator and brake simultaneous operation

23.

(1)

UL specification The traveling is stopped while depressing the brake at the same time as operating the accelerator.

(2)

General export specification It is possible to travel even if depressing the brake at the same time as operating the accelerator. The performance is restricted to protect the controller and the motor against the overcurrent at the simultaneous operation.

YFS specification (OPT) It is possible to travel even if depressing the brake at the same time as operating the accelerator, and the fine operation is facilitated. The performance is not restricted. The time that can be operated is restricted when the motor output is more than a set value. The time can be changed by the tuning setting value.

0-5

STEERING DIRECTION SWITCH 1.

Difference with a previous model We have adopted the same type of direction switch as in 7FGU25 series.

2.

Direction switch lever

0

(1)

The direction switch is level type as in 7FGU25 series.

(2)

The direction switch lever is always on the left side.

(3)

There is no direction switch lever for EZ pedal (OPT), because there are switches at acceleration pedal.

Old

Direction switch

New

Direction switch

0-6

DRIVING POSITION FORK FRONT END VISIBILITY Relocation of the display. Improved the visibility for tip of forks.

Before Improvement

After Improvement

SEAT • All seats equip seat switch for operator presence sensing system.

• When replacing seat, install a genuine TOYOTA seat designed specifically for this lift truck. (The OPS may fail to operate unless the correct seat is used.)

0-7

MULTI-DISPLAY FUNCTION EXPLANATION Comparison with Former Edition: New Model Features, Pub. No. PU312, Page 5-21 Add:

• OPS indicator OPS indicator flashes and sounds for half seconds when the operator leaves the seat.

Note: The buzzer sounds only export model.

0-8

AUXILIARY EQUIPMENT LIGHT SWITCH The position of the light switch has been changed to the right side of steering wheel, and it improves operability.

The switch is 2-step switching, and it is possible to be switched the lights with one switch.

1st step: Clearance lights and Tail lights.

2nd step: Head lights, Clearance lights and Tail lights. t

Light switch

Turn signal switch

Switch for rear working light (OPT)

2nd step

Turn signal switch 1st step

L Neutral

OFF

T

OFF

N R

Light switch

H

0-9

OPS GENERAL When the operator is not being in the normal operating position detected by the seat switch, the OPS system interrupts the traveling power and restricts load handling operation.

Note: When OPS operates, the power assistance of the steering wheel is lost because the pump motor is stopped. (Only 7FBCU 35 ~ 55 models)

Control specification 1.

Travel OPS (Not change from the present specification) When the controller detects the seat switch turned off for two seconds, the drive motor control is stopped.

Travel OPS is released by returning the direction lever and accelerator pedal to the neutral position and turning on the seat switch.

2.

Material handling OPS 7FBCU 15 ~ 32, 7FBCU 35 ~ 55 (With deadman brake spec. (OPT)): When the OPS controller detects seat switch OFF for 2 seconds, the lift lock valve, tilt control valve and backward tilting lock valve are controlled to disable fork lowering and forward tilting operations. Backward tilting, fork lifting and attachment operations are disabled by stopping the pump motor. The disabled material handling operations are released upon lapse of 1 second after seat switch ON. Caution: • Backward tilting: If the material handling lever is operated while the OPS is functioning, the mast may move because of its own weight when it is in a backward tilted position.

• Attachment: If the material handling lever is operated while the OPS is functioning, the attachment may move because of its own weight.

7FBCU 35 ~ 55 (Without deadman brake): When the OPS controller detects seat switch OFF for 2 seconds, the lift lock valve, tilt control valve and backward tilting lock valve are controlled to disable fork lowering and forward/backward tilting operations. Fork lifting and attachment operations are disabled by interrupting the hydraulic oil supply by means of the unload valve. Fork lowering operation is stopped by stopping the pump motor. The material handling operations disabled by the OPS are released upon lapse of 1 second after seat switch ON. Caution: • Attachment: If the material handling lever is operated while the OPS is functioning, the attachment may move because of its own weight.

• Fork lifting and attachment: If the material handling lever is operated with the brake pedal depressed while the OPS is functioning, pump motor runs at a low speed to ensure brake power assist, causing fork lifting and attachment operation at creeping speeds.

3.

OPS operation information When the controller detects the seat switch turned off, it informs OPS operation to the operator by sounding the buzzer (pi-) for about 0.5 seconds and the display indication. Moreover, the display indication keeps while turning off the seat switch.

Note: The buzzer is installed only in the export specification.

4.

Return to neutral warning (Not change from the present specification) When the accelerator pedal is operated with turning on the seat switch without returning the direction lever to the neutral position, it informs the operator that the travel OPS is not released by sounding the buzzer (pipipipi).

5.

Malfunction warning When the controller detects malfunction, the display indicate the diagnosis error code.

0-10

MATERIAL HANDLING OPS SYSTEM (35 ~ 55 MODEL) STD MODEL (DEADMAN BRAKE LESS) OPS solenoid lock valve (new adoption)

Tilt cylinder Lift cylinder

Oil control valve

C4 C5

C2 C3

Seat SW

C/V-T

C3 TILT Tilt control

C1

C/V-L

C1 LIFT Lift lock

Controller

SAS valve

T1

Control circuit

P

Brake booster

M

Pump motor No. 2

Power steering valve

(Return to tank)

M

Pump motor No. 1

SAS Control The SAS valve controls the key-lift interlock, automatic tilt neutral position stop, and forward tilting angle restriction function. (Same as on old models)

OPS Control • When the operator leaves the seat, the OPS solenoid lock valve (new adoption) and the SAS valve (same as on old models) are controlled by the seat switch signal to stop fork lowering, forward tilting and backward tilting.

• Even under the OPS control, the machine rotates the pump motor only when the brake pedal is stepped on. The PS operates only in that case.

0-11

DEADMAN BRAKE MODEL Tilt cylinder

Lift cylinder

Oil control valve

C4 C5 SAS valve

C2 C3

Seat SW

C/V-T

C3 TILT Tilt control

C1

C/V-L

C1 LIFT Lift lock

T1

P Brake booster

Power steering valve

Controller

(Return to tank)

OPT: Deadman brake Deadman brake control

M

M T P

A Parking brake operation sol: OFF

Pump motor No. 2

Parking brake release sol: ON

Pump motor No. 1 Deadman solenoid valve

Note: The system configuration is the same as in the conventional deadman brake model.

SAS Control The SAS valve controls the key-lift interlock, automatic tilt neutral position stop, and forward tilting angle restriction function. (Same as on old models)

Deadman Brake Control The deadman solenoid valve is controlled by the seat SW signal to apply the deadman brake. (Same as on old models)

OPS Control • When the operator leaves the seat, the seat SW signal controls the SAS valve (same as on old models) to disable fork lowering and forward tilting.

• When the operator leaves the seat, the seat SW signal stops pump motors No. 1 and No. 2 to disable backward tilting. (Fork lifting and ATT forward/backward tilting are also disabled.)

• When the OPS is operated, hydraulic oil supply to the foot brake and PS valve is stopped to disable the foot brake and PS to function.

0-12

DEADMAN BRAKE Comparison with Former Edition: New Model Features, Pub. No. PU312, Page 8-10 Only item 2 in the Outline has been changed as follows (addition of underlined portion).

New: 2.

When the operator sits on the seat, turn the key switch ON, set the direction lever to either the forward or reverse position, and depresses the accelerator pedal, the solenoid valve is closed to operate the cylinder by the hydraulic oil from the PS pump to release the brake.

PS pump

To oil tank Solenoid valve

Link Drive motor

Deadman brake assembly

Spring Deadman cylinder

1-1

CONTROLLER Page

COMBINATION SWITCH ASSY ..........................1-2 REMOVAL · INSTALLATION ..................................1-2 DISASSEMBLY · INSPECTION · REASSEMBLY ......1-3

1

1-2

COMBINATION SWITCH ASSY REMOVAL · INSTALLATION T=N·m (kgf·cm) [ft·lbf] 2

T=25~45(255~459)[18.4~33.2]

3 5

3

3

Removal Procedure 1.

Disconnect the battery plug.

2.

Remove the steering wheel. (See page 4-5.)

3.

Remove the steering column cover.

4.

Disconnect the switch wiring.

5.

Remove the combination switch ASSY.

Installation Procedure The installation procedure is the reverse of the removal procedure.

1-3

DISASSEMBLY · INSPECTION · REASSEMBLY 2

5

1

4

3

1

Disassembly Procedure 1.

Remove the steering angle sensor.

2.

Remove the cam.

3.

Remove the horn contact.

4.

Remove the direction switch ASSY. [Point 1]

5.

Remove the light control switch ASSY. [Point 2]

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

1-4

Point Operations [Point 1] Inspection: Check electrical continuity between switch connector terminals.

8 7 6 5 4 3 2

VBKY

DSR

DSFO

{

F 2: DSBU 3: DSFO 4: DSR 5: DSF 6: LS7: VBKY 8: VBKY

DSF

DSBU

LS-

{ {

{

N

{

R

{ {

{

[Point 2] T L

OFF

H

Inspection: Check electrical continuity between switch connector terminals.

1.

Light switch

N R

H

LH

{ {

{ {

{

10 9 8 2.

8: LH 9: LT 10: EL 12: TR 13: TL 14: TB

LT

OFF T

14 1312

EL

Turn signal switch R

TB

TR

{

{

TL

N L

{

{

2-1

MULTI-DISPLAY FUNCTIONS Page

MULTIPLE DISPLAY ...........................................2-2 GENERAL FUNCTION ...........................................2-2 DISPLAY INDICATION LIST ...................................2-2

MASK FUNCTIONS .............................................2-3 ANALYZER ..........................................................2-3 OPTION SET ........................................................2-3

DIAGNOSIS..........................................................2-6 DIAGNOSIS CODE LIST ........................................2-6

2

2-2

MULTIPLE DISPLAY GENERAL FUNCTION Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 3-7 Add:

{: User available

∆: Manager available (protected by the password 2) Model

Functions Status display

OPS indicator

DISPLAY INDICATION LIST Details of service Function Screen Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 3-10 Add: OPTION SET

SEAT BUZZER

Setting the OPS buzzer sounds

USA Spec. model

Export model

{

{

2-3

MASK FUNCTIONS ANALYZER Vehicle Abnormalities Not Stored in Diag Memory Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 3-36 Change: Alarm item

Alarm content

Symbol displayed

4. Return to neutral alarm Alarm occurs when the key switch or the seat switch is turned to ON while the direction switch is set at the forward or reverse position.

• Alarm sound (short high pitched electronic sound)

No display

OPTION SET Option Set Menu List Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 3-50 Add: No. OPT-17

Indication SEAT BUZZER

Selection

Description Enables/disables the OPS buzzer sounds.

Y

N

Enable

Disable

2

2-4 Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 3-52 to 3-53 New:

Operation Procedure Screen New:

1.

2.

3.

4.

Input the password on the normal function screen (see page 3-30 (Pub.No.CU322)) to display the SERVICE FUNCTION screen.

Press switch (2) twice to display 3. OPTION SET. Press switch (3) (enter) to display the OPTION SET screen.

Select a desired option menu item using switches (3).

Functions of switches on the OPTION SET screens are as follows: • Switch (1): Changes the setting from N to Y. • Switch (2): Changes the setting from Y to N. • Switch (3): Enters (changes to the next item setting screen)

Note: Press switch (3) on the OPT-17 OPTION SET screen to return to the SERVICE FUNCTION screen.

Switch (1) Switch (2)

Switch (3) Switch (4) Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3) *1

Press switch (3)

Press switch (3)

Press switch (3)

2-5

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

Press switch (3)

*1: Hour meter starting method 1. Press switch (1) for 2 seconds or more.

2. Press switch (1) while pressing switch (2) (held in the state of 1 above).

2

2-6

DIAGNOSIS DIAGNOSIS CODE LIST Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 3-59 and 3-63 Add: 15 ~ 32 Model and 35 ~ 55 Model Display indication

Diag memory

A5

A5

Faulty portion Seat switch

Defect mode Switch abnormality

Phenomenon on vehicle The OPS function is disabled.

Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 3-66 Add: 35 ~ 55 Model Display indication

Diag memory

G4-1

G4-1

Backward tilting lock solenoid

Solenoid open

Backward tilting operation is disabled.

(STD model: dead-man brake less)

G4-2

G4-2

Backward tilting lock solenoid

Solenoid shorted

Backward tilting is disabled.

(STD model: dead-man brake less)

Faulty portion

Defect mode

Phenomenon on vehicle

3-1

TROUBLESHOOTING Page

TROUBLESHOOTING (15 ~ 32 MODEL) ............3-2 COMPOSITION LIST .............................................3-2 TRAVELING / MATERIAL HANDLING SYSTEM .......3-3 WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED .......................3-3 WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED .......................3-5

TROUBLESHOOTING (35 ~ 55 MODEL) ............3-8 COMPOSITION LIST .............................................3-8 TRAVELING / MATERIAL HANDLING SYSTEM .......3-9 WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED .......................3-9 WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED .....................3-15

3

3-2

TROUBLESHOOTING (15 ~ 32 MODEL) 3

COMPOSITION LIST Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 4-24 to 4-26.

Add: WHEN A DIAGNOSIS ERROR CODE IS DEISPLAYED

Page

Displayed code

Diag memory code

Defect mode

A5

A5

Seat switch abnormality

3-3

C7

C7

Direction switch abnormality

3-4

WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED

Page

Only traveling disabled or wobbing

3-5

Failure in PS operations only (EHPH)

3-6

Both traveling and material handling disabled with OPS operation display even when sitting on the seat

3-7

3-3

TRAVELING / MATERIAL HANDLING SYSTEM WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED A5

Seat switch abnormality

Related portion ST board

CPU board CN101-5 (67, LSD)

CN141-17 CN141-11 (320, STPOT-)

CN-101-12 (51, LS-) CN37-13

CN94-1 CN142-8 (304, STLSD)

CN22-1

CN94-2

CN22-2

Seat switch

CN37-10

Condition for error detection Output while the seat switch is kept ON Kept sitting on the seat before the key switch is turned ON?

YES

Normal

NO Disconnect seat SW harness CN22 and check LSD and STLSD. ANL: I/O MONITOR 2 I/O2-4 LSD ON/OFF check STLSD ON/OFF check

LSD : 0 STLSD : 0

LSD : 1 STLSD : 0

LSD : 1 STLSD : 1

Seat SW abnormality

• Harness abnormality (67 voltage line shorted to GND) between CPU and ST • ST board abnormality • CPU board abnormality • Harness abnormality (304 voltage line shorted to GND) between Seat and ST • ST board abnormality

3

3-4 C7

Direction switch abnormality

Related portion

CPU board

CN101-1 (45, DSF)

5

CN101-2 (46, DSR)

4

CN101-12 (51, LS-)

*6

CN9

Direction Switch

*: EZ pedal spec.: 1

Condition for error detection Output when both forward and reverse direction switches (DSF and DSR) are ON

Disconnect battery plug and disconnect CN9.

ANL : I/O MONITOR 2 I/O2-2 Check with the direction lever in neutral position.

Becomes OFF

DSF or DSR ON CN101-1 (45)…When DSF is ON CN101-2 (46)…When DSR is ON b Voltage measurement N1 OK (approx. 5 V) • CPU board defect

NG (Other than OK)

• Harness short circuit

• Direction switch inspection

3-5 WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED Only traveling disabled or wobbling Related portion

CPU board

DC/MD board

TMD

3

On a vehicle with the deadman brake, check if No. 16 SEAT BRAKE is set to Y by option setting on the display.

ANL : I/O MONITOR 2 I/O2-1 Direction switch inspection and accelerator potentiometer reading check

Direction switch : No ON/OFF Accelerator potentiometer reading: No change

• Inspect direction switch and accelerator

Direction switch : ON/OFF Accelerator potentiometer reading : Change ANL : I/O MONITOR 2 I/O2-3 Inspect brake switch (LSB) with pedal depression

1

• Brake inspection *1 All ON (blinking) : LEDs light up and go out sequentially *2 Some OFF : Any of six LEDs lights up

0 Disconnect battery plug, connect SST3 to CN113, connect battery plug, and turn key switch ON

Disconnect battery plug, connect SST11 to CN107, and connect battery plug

Some OFF *2

All ON (blinking) *2

All ON (blinking) *1

Some OFF *2

• CPU board defect Check voltage at motor cable terminals upon direction switch ON 0 V or approx. 36 V (36 V spec.) approx. 48 V (48 V spec.)

• Inspect TMD

Other than 0 V or approx. 36 V (36 V spec.) approx. 48 V (48 V spec.)

• Motor defect • Motor cable defect

Inspect connector and harness between CN105 and CN108 OK • DC/MD board defect

NG • Harness defect between CN105 and CN108

3-6 Failure in PS operations only (EHPS) Related portion P1

DC/MD board TMPS

P21

CN111-9

M

CN111-3

CN145-1

EHPS board

CN146-3

1 3 4 2

Steering angle sensor CN19

N1

Does the PS motor run when the steering wheel is operated after key switch ON?

Runs.

• Motor defect • Motor cable defect

Does not run CN145-1 (+) b Voltage measurement N1 (-)

Less than 20 V

• Main harness inspection

20 V or more CN111-3 (+) b Voltage measurement CN111-9 (-)

Less than 12 V

• DC/MD board defect

12 V or more Connect SST13 between CN19-1 and CN19-3

Does the PS motor run upon key switch ON? Does not run • EHPS board defect

Runs.

• Steering angle sensor defect

3-7 Both traveling and material handling disabled with OPS operation display even when sitting on the seat Related portion

ST board

CPU board CN101-5 (67, LSD)

CN141-17 CN141-11 (320, STPOT-)

CN-101-12 (51, LS-) CN37-13

Check LSD and STLSD after disconnecting CN22 and connecting SST2 to CN22 ANL: I/O MONITOR 2 I/O2-4 LSD ON/OFF check STLSD ON/OFF check

CN94-1 CN142-8 (304, STLSD)

CN22-1

CN94-2

CN22-2

Seat switch

CN37-10

LSD : 0 STLSD : 0

LSD : 0 STLSD : 1

LSD : 1 STLSD : 1

• Harness abnormality (304 voltage line discontinuity) between ST board and CN22 • ST board abnormality

• Harness abnormality (67 voltage line discontinuity) between CPU and ST board • ST board abnormality • CPU board abnormality Seat SW abnormality

3-8

TROUBLESHOOTING (35 ~ 55 MODEL) COMPOSITION LIST Comparison with Former Edition: Repair Manual, Pub. No. CU322, Page 4-124 to 4-126.

Add: WHEN A DIAGNOSIS ERROR CODE IS DEISPLAYED

Page

Displayed code

Diag memory code

Defect mode

A5

A5

Seat switch abnormality

3-9

C7

C7

Direction switch abnormality

3-10

G4-1,2

G4-1,2

Deadman solenoid abnormality (deadman brake spec.)

3-11

G4-1,2

G4-1,2

Backward tilting lock solenoid abnormality (STD model: deadman brake less)

3-13

WHEN NO DIAGNOSIS ERROR CODE IS DEISPLAYED

Page

Only traveling disabled or wobbing

3-15

Power assist disabled

3-17

Both traveling and material handling disabled with OPS operation display even when sitting on the seat

3-21

3-9

TRAVELING / MATERIAL HANDLING SYSTEM WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED A5

Seat switch abnormality

Related portion ST board

CPU board CN161-5 (67, LSD)

CN141-17 CN141-11 (320, STPOT-)

CN-161-16 (51, LS-) CN37-13

CN94-1 CN142-8 (304, STLSD)

CN22-1

CN94-2

CN22-2

Seat switch

CN37-10

Condition for error detection Output while the seat SW is kept ON Kept sitting on the seat before the key switch is turned ON?

YES

Normal

NO Disconnect seat SW harness CN22 and check LSD and STLSD. ANL: I/O MONITOR 2 I/O2-4 LSD ON/OFF check STLSD ON/OFF check

LSD : 0 STLSD : 0

LSD : 1 STLSD : 0

LSD : 1 STLSD : 1

Seat SW abnormality

• Harness abnormality (67 voltage line shorted to GND) between CPU and ST • ST board abnormality • CPU board abnormality • Harness abnormality (304 voltage line shorted to GND) between Seat and ST • ST board abnormality

3-10 C7

Direction switch abnormality

Related portion

CPU board

CN101-1 (45, DSF)

1

CN101-2 (46, DSR)

2

CN101-26 (51, LS-)

16

CN161

5

CN9

Direction switch

4 13

CN37

6

Condition for error detection Output when both forward and reverse direction switches (DSF and DSR) are ON

Disconnect battery plug and disconnect CN9.

ANL : I/O MONITOR 2 I/O2-2 DSF, DSR: Check with the direction lever in neutral position.

Becomes OFF

DSF or DSR ON CN101-1 (45)…When DSF is ON CN101-2 (46)…When DSR is ON b Voltage measurement N1 OK (approx. 5 V) • CPU board defect

NG (Other than OK)

• Harness short circuit

• Direction switch

3-11 G4-1, 2

Deadman solenoid abnormality (deadman brake spec.)

Related portion ST board CN143-8 (331, SOLLD+) CN143-3 (334, SOLD-)

CN166-1 CN166-2

CN167-1 CN167-2

CN94-5 CN94-6

CN82-1 CN82-2

Dead man solenoid

Condition for error detection Output when the line from the ST board to the deadman solenoid is discontinuous or shorted G4-1 deadman solenoid open abnormality G4-2 deadman solenoid short-circuit abnormality

• G4-1 Check if the option data is in compliance with the machine specification.

Machine specification: SEAT BRAKE: N if without deadman seat Machine specification: SEAT BRAKE: Y if provided with deadman seat

Wrong option data Option setting correction

Correct option data Inspection 1. Solenoid resistance check Extract the battery plug, and disconnect CN143.

CN143-8 (331) - CN143-3 (334) Other than 11.8 ± 1 Ω (at. 20°C) Inspection 2. Solenoid resistance check Extract the battery plug and disconnect CN94 CN94-5 (331) - CN94-6 (334) Other than 11.8 ± 1 Ω (at. 20°C) CN94-deadman solenoid sub-harness defect or deadman solenoid defect

11.8 ± 1 Ω (at. 20°C) ST board defect

11.8 ± 1 Ω (at. 20°C) CN143-CN94 harness defect

3-12 • G4-2 Check if the option data is in compliance with the machine specification.

Machine specification: SEAT BRAKE: N if without deadman brake Machine specification: SEAT BRAKE: Y if provided with deadman brake

Wrong option data Option setting correction

Correct option data Extract the battery plug and disconnect CN94.

Battery plug ON, key switch ON, seat switch ON, direction switch ON, and acceleration switch ON G4-2 appears.

Inspection 3. Solenoid circuit resistance check Extract the battery plug and disconnect CN143.

CN143-8 (331) - CN143-3 (334) 3 Ω or more ST board defect

G4-1 appears.

CN94-deadman solenoid sub-harness defect or deadman solenoid defect

Less than 3 Ω CN143 - CN94 harness defect

3-13 G4-1, 2

Backward tilt lock solenoid abnormality (STD model: deadman brake less)

Related portion ST board CN143-8 (331, SOLLD+) CN143-3 (334, SOLD-)

CN166-1 CN166-2

Backward tilt lock solenoid

Condition for error detection Output for discontinuity or short circuit of the line from the ST board to the backward tilt lock solenoid G4-1 Backward tilt lock solenoid open abnormality G4-2 Backward tilt lock solenoid short circuit abnormality

• G4-1 Check if the option data is in compliance with the machine specification.

Machine specification: SEAT BRAKE: N if without deadman brake Machine specification: SEAT BRAKE: Y if provided with deadman seat

Wrong option data Option setting correction

Correct option data Inspection 1. Solenoid resistance check Extract the battery plug and disconnect CN143 CN143-8 (331) - CN143-3 (334) Other than 9.9 ± 5%Ω (at. 20°C) Inspection 2. Solenoid resistance check Extract the battery plug and disconnect CN166 CN166-1 (331) - CN166-2 (334) Other than 9.9 ± 5%Ω (at. 20°C) Backward tilt solenoid defect

9.9 ± 5%Ω (at. 20°C) ST board defect

9.9 ± 5%Ω (at. 20°C) Harness defect

3-14 • G4-2 Check if the option data is in compliance with the machine specification.

Machine specification: SEAT BRAKE: N if without deadman brake Machine specification: SEAT BRAKE: Y if provided with deadman seat

Wrong option data Option setting correction

Correct option data Extract the battery plug and disconnect CN166

Battery plug ON, key switch ON, seat switch ON, and backward tilt switch ON

G4-1 appears Backward tilt solenoid defect

G4-2 appears IInspection 3. Solenoid circuit resistance check Extract battery plug and disconnect CN143 CN143-8(331)-CN143-3(334) 3 Ω or more ST board defect

Less than 3 Ω CN143 - CN166 harness defect

3-15 WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED Only traveling disabled or wobbling Related portion CPU board

CN102-1 (64, SWAC)

1

CN162

4

CN25

CN26-2

CN102-2 (52, POTA)

2

1

CN102-14 (53, POTA+)

11

2

CN26-3 CN26-4

CN102-22 (51, POT-)

5

3

CN26-1

CN101-1 (25, DSF)

1

CN101-2 (46, DSR)

2

CN101-26 (51, LS-)

16

CN161

5

CN9

4 CN137 13

Accelerator potentiometer

Direction switch

6

If the vehicle is equipped with the deadman brake, make sure that No. 16 SEAT BRAKE is set to Y by option setting on the display.

ANL : I/O MONITOR 2 I/O2-1 Direction switch inspection and accelerator potentiometer reading check

Direction switch : No ON/OFF Accelerator potentiometer reading : No change

Direction switch : ON/OFF Accelerator potentiometer reading : Change ANL : I/O MONITOR 2 I/O2-3 Inspect brake switch (LSB) with pedal depression

1

• Brake inspection

0 Inspect connection condition of drive motor cable.

OK

A

NG

• Correct

• Inspect direction switch and accelerator

3-16

A

Jack up the vehicle to cause the front wheels to float, and turn the direction and acceleration switches ON

Tires rotate very slowly s

• Inspect rpm sensor

Tires do not move Disconnect drive motor cable, connect SST3 to CN111

Check if the LED on SST3 lights up on turning the direction and acceleration switches ON

*1 All ON (blinking) *2 Some OFF

: LEDs light up and go out sequentially : Any of six LEDs lights up

Disconnect the battery plug, and connect SST4 to CN106 − CN110, and SST9 to CN107

Some OFF *2

All ON (blinking) *1

Check if the LED on SST3 lights up on turning the direction and acceleration switches ON All ON (blinking) *1 Disconnect battery plug, connect SST3 to CN112

Some OFF *2

• DC/MD board defect • Harness discontinuity • CPU board defect

Check if the LED on SST3 lights up on turning the direction and acceleration switches ON

Some OFF *2

Disconnect the battery plug, and connect SST4 to CN107 − CN109, and SST9 to CN106

All ON (blinking) *1 Disconnect battery plug and reconnect CN112 to the original position

Check if the LED on SST3 lights up on turning the direction and acceleration switches ON All ON (blinking) *1

Connect battery plug

P7, P8, P9 (P71, P81, P91) b Voltage measurement N1

• DC/MD board defect • Harness discontinuity Other than 0 V or approx. 48 V (48 V spec.)

• CPU board defect

Other than 0 V or approx. 36 V (36 V spec.)

0 V or approx. 48 V (48 V spec.)

0 V or approx. 36 V (36 V spec.)

• Inspect TMD

Some OFF *2

• Motor defect • Motor cable defect

3-17 Power assist disable Related portion

SCPU board

CN19 CN147-17 (311, STS+)

1

CN147-6 (312, STS1)

3

CN147-7 (313, STS2)

4

CN147-16 (315, STS-)

2

ANL : I/O MONITOR 4 I/O4-1 Check if STS1 or STS2 indication varies when the steering wheel is rotated.

STS1 stays at 0

STS1 stays at 1

STS2 stays at 0

STS2 stays at 1 Both STS1 and STS2 stay at 0

A

B

C

D

E

Steering angle sensor

3-18

B

A

Battery plug OFF. Use SST2 to short-circuit between CN19-2 and 19-3 (main harness side).

Battery plug ON and key switch ON.

ANL: I/O MONITOR4 I/O4-1 Check STS1 input value.

Turns to 1 Stays at 0

Inspection 1. Continuity check (harness discontinuity) Disconnect CN147 with the battery plug OFF and SST2 kept connected to CN19.

CN147-6 (312) - CN147-16 (315) Continuity

Steering angle sensor defect

No continuity

Main harness defect

SCPU board defect

Battery plug OFF, CN19 disconnection.

Battery plug ON, key switch ON

ANL: I/O MONITOR4 I/O4-1 Check STS1 input value.

Turns to 0 Stays at 1

Inspection 2. Continuity check (harness short-circuit) Battery plug OFF, CN19 and CN147 disconnection CN147-6 (312) - CN147-16(315)

Steering angle sensor defect

Continuity

No continuity Main harness defect SCPU board defect

3-19

D

C

Battery plug OFF. Use SST2 and short-circuit between CN19-2 and 19-4 (main harness side).

Battery plug ON, and key switch ON.

ANL: I/O MONITOR4 I/O4-1 Check STS2 input value.

Turns to 1.

Stays at 0.

Inspection 3. Continuity check (harness discontinuity) Disconnect CN147 with battery plug OFF and SST2 kept connected to CN19.

CN147-7 (313) - CN147-16 (315) Continuity

Steering angle sensor defect.

No continuity

Main harness defect

SCPU board defect

Battery plug OFF, CN19 disconnection.

Battery plug ON, and key switch ON.

ANL: I/O MONITOR4 I/O4-1 STS2 input value check Turns to 0 Stays at 1

Inspection 4. Continuity check (harness short-circuit) Battery plug OFF, CN19 and CN147 disconnection.

CN147-7 (313) - CN147-16 (315)

Steering angle sensor defect

Continuity

No continuity Main harness defect SCPU board defect

3-20

E

Battery plug OFF and CN19 disconnection.

Battery plug ON and key switch ON.

Sensor supply power voltage check CN19-1 (311) - CN19-2 (315)

Approx. 15 V

A. To troubleshooting C

Other than approx. 15 V

Battery plug OFF, CN147 disconnection.

Sensor power supply voltage check CN147-17 (311) - CN147-16 (315)

Other than approx. 15 V

SCPU board defect

Approx. 15 V

Main harness defect

3-21 Both traveling and material handling disabled with OPS operation display even when sitting on the seat Related portion

ST board

CPU board CN161-5 (67, LSD)

CN141-17 CN141-11 (320, STPOT-)

CN161-16 (51, LS-) CN37-13

After disconnecting CN22 and connecting SST2 to CN22, check LSD and STLSD. ANL: I/O MONITOR 2 I/O2-4 LSD ON/OFF check STLSD ON/OFF check

CN94-1 CN142-8 (304, STLSD)

CN22-1

CN94-2

CN22-2

Seat switch

CN37-10

LSD : 0 STLSD : 0

LSD : 0 STLSD : 1

LSD : 1 STLSD : 1

• ST board-CN22 harness abnormality (304 voltage line discontinuity) • ST board abnormality

• CPU-ST board harness abnormality (67 voltage line discontinuity) • ST board abnormality • CPU board abnormality Seat switch abnormality

4-1

STEERING Page

GENERAL ............................................................4-2 COMPONENTS ....................................................4-3 STEERING WHEEL · MAST JACKET .................4-5 REMOVAL · INSTALLATION ..................................4-5 DISASSEMBLY · INSPECTION · REASSEMBLY ......4-7

4

4-2

GENERAL

4-3

COMPONENTS 4502

4

4502-248

4-4 4502

4502-238

4502

4502-240

4-5

STEERING WHEEL · MAST JACKET REMOVAL · INSTALLATION

T=N·m (kgf·cm) [ft·lbf]

T = 25~45 (255~459) [18.4~33.2]

2 8 5

3

T = 8.4~14 (86~143) [6.2~10.3] 11 T = 10~14 (102~143) [7.4~10.3] 3

12 6 T = 29.4~39.2 (300~400) [21.7~28.9]

13

14

3

12

T = 34.3~53.9 (350~550) [25.3~39.8]

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

Disconnect the battery plug.

Remove the steering wheel. [Point 1] Remove the steering column cover.

Disconnect the connectors of the combination switch.

Remove the combination switch ASSY. Remove the meter box ASSY set bolts.

Disconnect the connectors of the display and key switch.

Remove the meter box ASSY. Remove the lower panel.

Remove the instrument panel.

Remove the tilt lock mechanism. [Point 2] Remove the steering valve set bolts and keep the valve free.

Remove the return spring.

Remove the mast jacket ASSY.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: • Apply MP grease to the sliding surface of the tilt lock device and the collar of the mast jacket set bolt.

• Fill MP grease to the coupling between the tilt steering shaft and steering valve.

4

4-6

SST

Point Operations [Point 1] Removal: SST 09950-76003-71 (STT 09950-50012)

Cam

Pin

Approx. 5°

Installation: Steering wheel installation procedure 1. Apply rubber grease to the sliding portion of the cam.

2. Position the pins on the cam as shown in the illustration.

3. After installation, rotate the steering wheel. As the steering wheel is rotated, the 3 pins on the cam are automatically set in the holes on the steering wheel side.

[Point 2] Installation: Install the tilt lock mechanism so that the angle between the lines of the tilt lever and the meter box is approximately 5 degrees at the maximum tilt backward position.

Check if the tilt lock works properly.

4-7

DISASSEMBLY · INSPECTION · REASSEMBLY 1 3

4

2

Disassembly Procedure 1

Remove the snap ring.

2

Remove the steering shaft.

3

Remove the bearing.

4

Remove the bracket.

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

5-1

OIL CONTROL VALVE Page

GENERAL ............................................................5-2 COMPONENTS ....................................................5-4 TILT LOCK VALVE ASSY (for OPS) (35 ~ 55 MODEL)...............................................5-5 REMOVAL · INSTALLATION ..................................5-5 DISASSEMBLY · INSPECTION · REASSEMBLY ......5-6

5

5-2

GENERAL Tilt Lock Valve ASSY (for OPS) (35 ~ 55 model)

Y

Y

X

*

C2

C/V-C2 *: Not used in this model.

X

5-3

5

Section Y-Y Section X-X

C2 TILT

C/V-C2

*: Not used in this model.

*

5-4

COMPONENTS 6821

43

BE

43A 02 BG BK BI BJ BN BH BD

BP

BQ BO

10

BR

BF 02K=(INCL.

BM

)

BL

45A 45

6821-014A

5-5

TILT LOCK VALVE ASSY (for OPS) (35 ~ 55 MODEL) REMOVAL · INSTALLATION Note: Operate the control lever and bring the mast and fork to the vertical and lowermost positions, respectively, to release the residual pressure in the load handling system before starting removal.

4

5

5

3

Removal Procedure 1 2 3 4 5 6

Disconnect the battery plug.

Remove the toe board (front and rear) and lower panel.

Disconnect the piping and wiring.

Remove the tilt lock valve ASSY W/bracket.

Remove the tilt lock valve ASSY. Remove the fitting.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Check the hydraulic oil level, and add if insufficient.

5-6

DISASSEMBLY · INSPECTION · REASSEMBLY Note: • Since parts are finished with high precision, carefully disassemble and reassemble them to prevent any damage • Use a clean location for the job T=N·m (kgf·cm) [ft·lbf] T = 21 (210) [15.2]

T = 3.9 (40) [2.9]

T = 49 (500) [36.2] 1

2

T = 98 (1000) [72.4]

Disassembly Procedure 1 2

Remove the solenoid ASSY. [Point 1] Remove the tilt lock valve. [Point 2]

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. (+) (-)

Point Operations [Point 1] Inspection: Check continuity of the solenoid.

Inspection: Inspect and wash the orifice to eliminate clogging.

5-7 [Point 2] Inspection: Inspect the plunger and clean if clogged.

6-1

APPENDIX Page

CONNECTOR DRAWING (15 ~ 32 MODEL).......6-2 CONNECTOR DRAWING (35 ~ 55 MODEL).....6-11 CONNECTING DIAGRAM (15 ~ 32 MODEL) ....6-20 CONNECTING DIAGRAM (35 ~ 55 MODEL) ....6-21 WIRING DIAGRAM (15 ~ 32 MODEL) ...............6-22 WIRING DIAGRAM (35 ~ 55 MODEL) ...............6-23

6

6-2

CONNECTOR DRAWING (15 ~ 32 MODEL) 6

CN1 4

3

2 1

8

7

6

CN6 2

5

1

2

3

4

5

6

7

8

TAB NO 1 2 3 4 5 6 7 8

P 14 16 141 143 138 137 144 142

C BR GR LG O Y G SL P

NO 1 2 3 4 5 6 7 8

P 14 16 141 143 138 137 144 142

C BR GR LG O Y G SL P

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

TAB

REC

C

J

115 116 N2

-

LH LT EL

108 109 110

-

TR TL TB

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

P

C

115 116 N2

P LG O

CN47-3 CN46-3 J29

108 109 110

BR G-Y GR

CN13-4 CN17-4 CN12-2

1 4

TAB

REC J AM IG

NO 1 4

P 41 43

C Y L

J CN29-1 CN29-2

CN4 (OPT) 2 4

2 4 TAB NO 2 4

P 41 43

C -

REC J AM IG

NO 2 4

P 41 43

C Y L

J CN29-1 CN29-2

CN5 2

1

1

TAB NO 1 2

P 101 111

C R SL

2

REC J LSST LSST

NO 1 2

P 51 65

1

P 101 111

C R SL

J J10 CN38-2

C R BR

J CN37-1 CN101-3

1

P 48 41

C B B

2

REC J SA SA

NO 1 2

P 48 41

C P Y

J J30 J3

CN8 1 2

1 2 TAB

4 C -

NO 1 2

TAB

NO 1 2

1

P 41 43

REC J LSB LSB

2

J

CN4

NO 1 4

C R BR

2

CN7

NO 1 2

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

P

P 51 65

J CN111-13 CN111-5 CN103-8 CN103-6 CN141-10 CN141-1 CN103-5 CN103-7

CN2

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

1

TAB NO 1 2

REC J CN70-30 CN70-14 CN70-22 CN70-24 CN70-5 CN70-4 CN70-23 CN70-21

1

P 48 41

C -

REC J HO+ HO-

NO 1 2

P 48 41

C P Y

J H (J30) J3

CN9 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10

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

TAB NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

REC

P

C

J

103 120 46 45 51 43 43

-

DSBU DSFO DSR DSF LSVBKY VBKY

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P

C

J

103 120 46 45 51 43 43

O G-Y SL G R L L

CN165-4 CN24-1 CN101-2 CN101-1 CN37-12 J2 J2

6-3

CN9 (OPT) 3 6

2 5

1 4

CN15 1 4

TAB NO 1 2 3 4 5 6

P C 51 O 120 B 103 G 46 W-O 45 W-BR 43 R

2 5

2

3 6

NO 1 2 3 4 5 6

P 51 120 103 46 45 43

C R G-Y O SL G L

J CN37-12 CN24-1 CN165-4 CN101-2 CN101-1 J2

NO 1 2

P 51 66

NO 1 2 3

P 60 51 63

1

1

TAB

REC J LSL NO LSATT

NO 1 2 3

P 60 51 63

C G-Y R L

1

2

J FRY FRY

NO 1 2

P 43 110

NO 1 2

P 102 N1

C Y W

2 5

1 4

1 4

TAB NO 1 2 3 4 5 6

P N1 104 102 108 N1 101

C W G Y G-Y W R

C L GR

C W G Y G-Y W

2

3

4

5

6

REC J CN18-3 CN18-4 CN20-1 CN18-1 CN18-2

NO 1 2 3 4 5 6

P N1 104 102 109 N1

1

2

3

4

5

6

NO 1 2 3 4 5 6

P N1 104 102 108 N1 101

C W G Y BR W R

2 4 NO 1 2 3 4

P 109 N1 N1 104

J CN37-16 J11 J12 CN2-12 CN37-15 J10

1 3

1 3

TAB NO 1 2 3 4

P 108 N1 N1 104

C G Y W R

2 4

REC J LF-R LF-R LC-R LC-R

NO 1 2 3 4

C G Y W R

P 108 N1 N1 104

C G-Y W W G

J CN13-4 CN13-5 CN13-1 CN13-2

1 3

2 4

REC J LF-L LF-L LC-L LC-L

NO 1 2 3 4

P 109 N1 N1 104

2

C G-Y W W G

1

1

J CN17-4 CN17-5 CN17-1 CN17-2

6 5 4 3

NO 1 2 3 4 5 6

P 338 315 312 313

C -

2

3 4 5 6

TAB

1 3

J CN37-7 CN46-4 (J11) CN47-4 (J12) CN2-13 CN37-6

CN19

CN14 2 4

C W G Y G-Y W

CN18

J J2 CN2-14

REC J CN14-3 CN14-4 CN16-1 CN14-1 CN14-2 CN96-7

J CN13-3 J24

1

TAB

2 5

2

REC J H/L H/L

TAB P N1 104 102 109 N1

CN13 3 6

J CN37-2 CN101-4

1

REC

C -

C R V

1

C B B

3

NO 1 2 3 4 5 6

2

TAB

P 102 N1

J CN101-8 CN37-3 CN101-6

1

2

P 43 110

P 51 66

CN17

CN12

NO 1 2

NO 1 2

CN16

NO 1 2

2 3

C G-Y R L

J LSPB LSPB

TAB

3

2

REC

C -

CN11 2

1

TAB

REC J DSF, DSR DSFO DSBU DSR DSF DSFO, DSBU

1

REC J IG ESS SS1 SS2

NO 1 2 3 4 5 6

P 338 315 312 313

C GR BR G P

J CN111-3 CN111-9 CN28-2 CN28-3

6

6-4

CN20

CN26

1

2

TAB NO 1 2

P 102 N1

C B B

2

1

4

NO 1 2

P 102 N1

C Y W

J CN17-3 J24

CN22 2

1

1

TAB NO 1 2

P 304 320

C P R

NO 1 2 3 4

P 50 64 52 53

NO 1 2

P 304 320

C -

C P R

4

3

2

1

8

7

6

5

P 303 312 313 315 342 343 345 346

C L G P BR LG SL Y V

J CN94-1 CN94-2

1

1

2

2

C R-W B

REC J CHI CHI

NO 1 2

P 198 N1

C R W

J J27 N1

NO 1 2 3 4 5 6 7 8

P 103 N1

1

2

2

TAB

REC J BZ BZ

NO 1 2

P 103 N1

2

NO 1 2 3 4

P 50 64 52 53

C R GR SL Y

J CN25-3 CN25-4 CN25-1 CN25-2

1

2

3

4

5

6

7

8

NO 1 2 3 4 5 6 7 8

P 303 312 313 315 342 343 345 346

C LG G P BR LG SL Y V

C O W

1

1

TAB J CN33-3 J25

NO 1 2

P 41 43

C Y L

J J31 CN19-3 CN19-4 J1 CN101-15 CN101-14 CN103-12 CN103-13

2

REC J CN4-1 CN4-4

NO 1 2

P 41 43

C Y L

J CN136-2 (J3) CN38-1 (J2)

CN31

CN24 1

2 1

1 2

2

4 3

3 4

REC NO 1 2

4

CN29

1

C R B

3

REC J CN145-1 CN145-3 CN145-4 CN145-5 CN145-8 CN145-9 CN145-10 CN145-11

CN23-2

NO 1 2

2

REC J E2 IDL VTA VC

TAB

TAB P 103 N1

1

CN28

CN23

NO 1 2

1

2

REC J LSDS LSDS

2

TAB

REC J H/L H/L

3

P 120 N1

C G-Y W

TAB J CN9-3 CN37-5

CN25

NO 1 2 3 4

P 104 111 109 N1

C L L L L

REC J TL STP TRN E

NO 1 2 3 4

P 104 111 109 N1

C G SL G-Y W

J CN38-4 CN38-2 CN38-6 CN38-8

CN33 2

1

1

2

4

3

3

4

TAB NO 1 2 3 4

P 52 53 50 64

C SL Y R GR

2 4

TAB

REC J CN26-3 CN26-4 CN26-1 CN26-2

NO 1 2 3 4

P 52 53 50 64

C SL Y R GR

1 3

1 3

J CN102-2 CN102-11 CN102-8 CN102-1

NO 1 2 3 4

P 107 N1 103 43

C V W O L

2 4

REC J CN35-1 CN35-2 CN23-2-1 LR

NO 1 2 3 4

P 107 N1 103 43

C V W O L

J CN38-7 J23 J21 CN38-1

6-5

CN34

CN38

2 1

1 2

3

4 3

3 4

8 7 6 5 4

6 5

5 6

TAB

REC

1 2

2 1

4 5 6 7 8

TAB NO 1 2 3 4 5 6

P 104 111 103

C R R R

J TL STP B/U

108 N1

R R

TRN E

NO 1 2 3 4 5 6

P 104 111 103

C G SL O

J J22 J20 CN38-3

108 N1

BR W

CN38-5 J23

NO 1 2 3 4 5 6 7 8

P 43 111 198 104 108 109 107 N1

REC

C L SL R G BR G-Y V W

J CN29-2 (J2) CN5-2 CN165-5 J11 J8 J9 SWR CN37-17

CN35 2

P 107 N1

1

1

2

2

NO 1 2

J W/L W/L

P 107 N1

C V W

1

4 5 6 7 14 15 16 17 18 19 REC NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

C L SL O G BR G-Y V W

1

J CN33-1 CN33-2

NO 1 2

P 68 51

J CN33-4 CN31-2 CN34-3 CN31-1 CN34-5 CN31-3 CN33-1 CN31-4

P 51 51 51 N1 N1 N1 N1 320 320 320 51 51 51

C R R R W W W W R R R R R R

J CN6-1 CN15-1 CN11-2 J13 CN24-2 CN17-5 CN17-1 CN87-4 CN87-2 CN94-2 CN39-2 CN9-6 CN101-12

N1 N1 N1 N1 N1 320 320 320

W W W W W R R R

CN13-5 CN13-1 CN38-4 H CN165-2 CN90-8 CN90-2 CN141-11

2

REC

C V R

NO 1 2

J LSL2 LSL2

P 68 51

C O R

J CN101-10 CN37-11

6

CN40

CN37

1 2 3 11 12 13

P 43 111 103 104 108 109 107 N1

TAB

REC

C B B

NO 1 2 3 4 5 6 7 8

CN39

TAB NO 1 2

3

8 9 10 20 21 22

2

1

1

2

4

3

3

4

TAB NO P 1 P22 2 P1 3 9 4 10

C W R G Y

REC J MPS terminal F3 fuse MPS (-) MPS (+)

NO P 1 P22 2 P1 3 9 4 10

C G R O G

J CN50-1 P1 terminal CN55-2 CN55-1

CN41 2

1

1

3

3

TAB NO 1 2 3

P 89 88 193

2

C V L G

REC J CN44-1 CN44-2 CN44-3

NO 1 2 3

P 89 88 193

C V L G

J CN102-7 CN102-6 CN101-17

CN44 2

1

1

3

3

TAB NO 1 2 3

P 89 88 193

C -

2

REC J DMP DMP DMP

NO 1 2 3

P 89 88 193

C V L G

J CN41-1 CN41-2 CN41-3

6-6

CN45

CN54

1 TAB NO 1

P 196

2

1

C GR

NO 1

P 196

1

TAB

REC J CN55-3

1

C -

J DMPS

NO 1 2

P 82 80

REC

C -

J SSD2 SSD2

CN46 2 4 P 101 101 116 104

1 3

C -

1 3

2 4

2

NO 1 2 3 4

P 101 101 116 104

C R R LG G

J CN136-1 (J10) J10 CN2-9 CN17-2 (J11)

1 3

2 4

CN47 2 4

1 3

TAB NO 1 2 3 4

P 101 101 115 102

C -

NO 1 2 3 4

P 101 101 115 102

J J10 J10 CN2-8 CN17-3 (J12)

1

1

2

4

3

3

4

TAB NO P 1 P21 2 P1 3 P23 4 N1

C G R W B

1

1

P 87 86

C -

NO 1 2

REC J CN40-4 CN40-3 CN45-1

2 5

P 87 86

J CN50-1 P1 terminal CN50-2 N1 terminal

2

C P O

P 81 80

C -

1

1

1 4

TAB NO 1 2 3 4 5 6

NO 1 2

J CN111-2 CN111-8 CN101-16

2 5

3 6

REC

P 80 81 82 86

C B G BR O

J CN53-2 CN53-1 CN54-1 CN52-2

87

P

CN52-1

NO 1 2 3 4 5 6

P 80 81 82 86

C B G BR O

J CN102-3 CN102-5 CN102-4 CN102-9

87

P

CN102-10

CN70 14 30

21 22 23 24 TAB

14 30

J CN57-6 CN57-4

NO 4 5 14 21 22 23 24 30

P 137 138 16 142 141 144 143 14

5 4 24 23 22 21

C -

2

2

REC J SSD1 SSD1

C G O GR

REC J SL/L+ SL/LD15V SDTMA SMTDA SMTDK SDTMK GNDD

NO 4 5 14 21 22 23 24 30

P 137 138 16 142 141 144 143 14

C G Y GR P LG SL O BR

J CN1-6 CN1-5 CN1-2 CN1-8 CN1-3 CN1-7 CN1-4 CN1-1

CN82

TAB NO 1 2

P 10 9 196

1 4

CN53 2

NO 1 2 3

4 5

REC J STMD STMD

2 3

TAB

TAB NO 1 2

1

C G O GR

REC J FET/C1 F3 fuse FET/C2E1 shunt

1

REC

CN52 2

P 10 9 196

3 6

C R R P Y

2

C W R G B

J CN57-3 J26

CN57

CN51

NO P 1 P21 2 P1 3 P23 4 N1

C BR B

TAB NO 1 2 3

REC J COIL+ SW+ COILSW-

P 82 80

3

REC J COIL+ SW+ COILSW-

NO 1 2

CN55

TAB NO 1 2 3 4

2

P 81 80

C G B

J CN57-2 CN57-1

1

1

TAB NO 1 2

P 331 334

C -

2

REC J SOLLD+ SOLD-

NO 1 2

P 331 334

C GR O

J CN94-5 CN94-6

6-7

CN90

CN85 2

1

1

TAB NO 1 2

P 70 320

P 57 56 320

3

2

1

8

7

6

5

P 91 320 59 58

C GR R Y L

J CN92-3 CN92-1 CN91-2 CN91-3

90

SL

CN92-2

320

R

CN91-1

1

2

3

4

5

6

7

8

REC

C -

J SWTK SWTK

NO 1 2

P 70 320

C BR R

J CN142-4 J4

CN86

NO 1 2 3

4

2

3 2 1

1 2 3

TAB

REC

C -

J POTT+ POTT SPOT-

NO 1 2 3

P 57 56 320

C V G R

TAB NO 1 2 3 4 5 6 7 8

REC

J CN141-2 CN141-3 J4

NO 1 2 3 4 5 6 7 8

P 91 320 59 58

C GR R Y L

J CN142-3 CN37-21 CN141-12 CN141-4

90

SL

CN142-2

320

R

CN37-20

CN91 3

CN87

2

1

1

TAB

2 1 4 3

1 2 3 4

TAB NO 1 2 3 4

P 305 320 306 320

NO 1 2 3

REC

C G-R R-L L R-L

J STLSTF SPOTSTLSTR SPOT-

NO 1 2 3 4

P 305 320 306 320

C G R L R

P 320 59 58

J CN142-9 CN37-9 CN142-10 CN37-8

1

TAB NO 1 2

P 331 332

J SOLLD+ SOLL-

NO 1 2

P 331 332

C R B

NO 1 2 3

2

P 320 90 91

J CN143-8 CN143-5

2 REC

NO 1 2

P 327 330

C L P

J CN90-8 CN90-3 CN90-4

C R SL GR

REC J CN90-2 CN90-6 CN90-1

NO 1 2 3

P 320 90 91

C -

J SWMH1 SWMH1 SWMH1

CN94

C GR BR

1

J SOL TS+ SOLT-

C R Y L

1 2 3

3

2

1

1

2

3

6

5

4

4

5

6

TAB

1

TAB P 327 330

P 320 59 58

3 2 1

CN89

NO 1 2

NO 1 2 3

CN92

REC

C R B

2

J STPOTSPL SPL+

TAB

1

3

REC

C -

CN88 2

2

J CN143-7 CN143-1

NO 1 2 3 4 5 6

P 304 320 327 328 331 334

C P R L Y GR O

REC J CN22-1 CN22-2 CN95-1 CN95-2 CN82-1 CN82-2

NO 1 2 3 4 5 6

P 304 320 327 328 331 334

C P R L Y GR O

J CN142-8 CN37-10 J5 CN143-2 J6 CN143-3

CN95 2

1

1

TAB NO 1 2

P 327 328

C -

2

REC J SOLS SOLS

NO 1 2

P 327 328

C L Y

J CN94-3 CN94-4

6-8

CN96 1

CN103 7

7 TAB NO 1 7

P 320 59

C -

TAB

REC NO 1 7

J STPOTSPL

P 112 59

C SL Y

J CLMP CN13-6

CN101 4 3 2 1 8 7 6 5 18 17 16 15 14 13 12 11 10 9 5 6 7 8 1 2 3 4 9 10 11 12 13 14 15 16 17 18 TAB NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P 45 46 65 66 67 63 61 60 68 69 51 199 343 342 196 193

C -

REC NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

J DSF DSR LSB LSPB LSD LSAT1 LST LSL1 DSL2 DSAT2 LSOPT0 ISPSISPS+ BMPS BMP

P 45 46 65 66 67 63 61 60

C G SL BR V G-Y L LG G-Y

J CN9-5 CN9-4 CN6-2 CN15-2 CN141-17 CN11-3 CN141-15 CN11-1

68

O

CN39-1

51 199 343 342 196 193

R B SL LG GR G

CN37-13 CN165-6 CN28-6 CN28-5 CN55-3 CN41-3

CN102 5 4 12 11

10 9

3 2 1 8 7 6

1 2 3 6 7 8

J SWAC POTA SSD+ SSD2 SSD1 TP+ TPPOTTD+ TDPOTA+

NO 1 2 3 4 5 6 7 8 9 10 11 12

TAB NO 1 2 3 4 5 6 7 8 9 10 11 12

P 64 52 80 82 81 88 89 50 86 87 53

C -

9 10

4 5 11 12

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

REC

P 307 308 309 310 144 143 142 141 326 324

C -

J SMTSA SMTSK SSTMA SSTMK SMTDK SDTMK SDTMA SMTDA SS0SS0+

345 346

-

ERR+ ERR-

C GR SL B BR G L V R O P Y

J CN25-4 CN25-1 CN57-1 CN57-3 CN57-2 CN41-2 CN41-1 CN25-3 CN57-4 CN57-6 CN25-2

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

P 307 308 309 310 144 143 142 141 326 324

C SL V P LG SL O P LG GR BR

J CN141-6 CN141-8 CN141-5 CN141-7 CN1-7 CN1-4 CN1-8 CN1-3 CN141-14 CN141-13

345 346

Y V

CN28-7 CN28-8

CN111 6 5 4 3 2 1 14 13 12 11 10 9 8 7

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

TAB NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

REC

P 41 10 338 11 16 43

C -

J B48V MPS+ (H15V+) S20V+ D15V VBKY

9 315 338 44 12 14

-

MPSV20V-(H15V-) B20V+ VBMB S20VGNDO

REC P 64 52 80 82 81 88 89 50 86 87 53

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

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

1

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

P 41 10 338 11 16 43

C Y G GR G-Y GR L

J J3 CN55-1 CN19-1 CN142-5 CN1-2 J2

9 315

O BR

CN55-2 CN19-2

12 14

V BR

CN142-11 CN1-1

CN136 2 4

1 3

1 3

TAB NO 1 2 3 4

P 101 41 N2 303

C R Y O LG

2 4

REC

J CN46-1 (J10) CN29-1 (J3) CN142-7 (J29) CN142-1 (J31)

NO 1 2 3 4

P 101 41 N2 303

C R Y O LG

J F4 F5 CN137-2 F7

CN137 1 2 3 4 5 6

2 1 6 5 4 3 TAB NO 1 2 3 4 5 6

P 2 N2 1 6 5 44

C

REC J MBN2 MB+ MPMP+ F6

NO 1 2 3 4 5 6

P 2 N2 1 6 5 44

C

J MBN2 MB+ MPMP+ F6

6-9

CN139 1

CN143

2

1

TAB NO 1 2

P 18 N2

C

REC J FAN3+ FAN3-

NO 1 2

P 18 N2

C

TAB J FAN3+ FAN3-

CN141 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TAB NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P 137 57 56 58 309 307 310 308 51 138 320 59 324 326 61 51 67

C -

REC J SL/L+ POTT+ POTT SPL+ SSTMA SSTSA SSTMK SMTSK OLSDSL/LSTPOTSPL SS+ SSOLST+ OLSTOLSD+

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P 137 57 56 58 309 307 310 308 51 138 320 59 324 326 61 51 67

C G V G L P SL LG V R Y R Y BR GR LG R G-Y

J CN1-6 CN86-1 CN86-2 CN90-4 CN103-3 CN103-1 CN103-4 CN103-2 J14 CN1-5 CN37-22 CN90-3 CN103-10 CN103-9 CN101-7 J14 CN101-5

CN142

TAB NO P 1 303 2 90 91 3 70 4 11 5 6 (N2) N2 7 304 8 9 305 10 306 11 12 12 (12)

C -

NO P 1 330 2 328 334 3 4 332 5 6 (327) 327 7 331 8 9 10 11 12

J SOLTSOLSSOLD-

-

SOLL(SOLTS+) SOLTS+ SOLLD+ SXTSA SSTXA SXTSK SSTXK

NO 1 2 3 4 5 6 7 8 9 10 11 12

P 303 90 91 70 11

C LG SL GR BR G-Y

J CN136-4(J31) CN90-6 CN90-1 CN85-1 CN111-4

N2 304 305 306 12

O P G L V

CN136-3(J29) CN94-1 CN87-1 CN87-3 CN111-12

NO 1 2 3 4 5 6 7 8 9 10 11 12

P 330 328 334

C P Y O

J CN89-2 CN94-4 CN94-6

332

BR

CN88-2

327 331

L GR

CN89-1 CN88-1

CN145 (OPT) 1 2 3 4 5 6 7 8 9 10 11 12

5 4 3 2 1 12 11 10 9 8 7 6 TAB NO 1 2 3 4 5 6 7 8 9 10 11 12

REC

P 303

C -

J VBKY

312 313 315

-

STS1 STS2 STS-

342 343 345 346

-

ASTPA ASTPK ERR+ ER-

NO 1 2 3 4 5 6 7 8 9 10 11 12

P 303

C L

J CN28-1

312 313 315

G P BR

CN28-2 CN28-3 CN28-4

342 343 345 346

LG SL Y V

CN28-5 CN28-6 CN28-7 CN28-8

CN165 (EXCEPT EZ PEDAL)

REC J VBMB2 MH1 MH2-1 SWTK S20V+ (N2) N2 STLSD STLSTF STLSTR S20V(S20V-)

REC

C -

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

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

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

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

2

3 6

2 5

1 4

1 4

TAB NO 1 2 3 4 5 6

2 5

3 6

REC

P

C

J

103 103

G G

CN165-5 CN165-4

NO 1 2 3 4 5 6

P 16 N1 43 103 198 199

C GR W L O R B

J J28 CN37-19 J2 CN9-2 CN38-3 CN101-13

CN165 (EZ PEDAL) 3 6

2 5

1 4

1 4

TAB NO 1 2 3 4 5 6

2 5

3 6

REC

P 16 N1 43

C W B R

J IN+ GND OUT+

198 199

W W

OUTIN-

NO 1 2 3 4 5 6

P 16 N1 43 103 198 199

C GR W L O R B

J J28 CN37-19 J2 CN9-2 CN38-3 CN101-13

6-10

Main harness joint

Rear-upper harness joint

CN37-13

CN141-16

CN165-5

J14

CN38-2

J27

CN141-9

CN101-12

CN38-3

(51, R) CN8-4

CN111-9

J21

CN38-4

J23

CN33-2

CN33-3

CN34-6

CN31-4

(103, O)

(108, BR)

CN29-2

(104, G)

CN34-3

CN13-4

(315, BR)

(111, SL)

CN38-7

CN34-1

CN31-1

CN38-1

J8

CN28-4

J22

CN34-2

CN31-2

(198, R)

CN19-3

J1

J20

CN23-1

CN38-8

(N1, W)

CN8-5

CN12-1

CN111-6

J2

J9

CN165-3

CN38-6

Front pillar harness joint CN14-3

CN9-7

CN9-8

CN17-4

CN38-1

(43, L)

(109, G-Y)

CN136-1

CN20-2

J24

CN16-2

CN136-1 CN47-2

CN13-1

CN46-2

(N1, W) CN8-2

J3

CN111-1

CN7-2

CN13-6

J10

CN5-1

SWR

CN47-1

CN46-1

CN29-1

(41, Y)

(101, R)

CN141-11

Rear option harness joint CN33-2

CN46-4 CN23-2-2

CN86-3

J4

CN85-2

CN37-22

CN38-4

J11 CN17-2

(320, R) CN143-7

J5

J25

CN13-2

LR

CN35-2

(104, G)

(N1, W)

CN47-4

CN94-3

J12

CN13-3

Drive motor harness joint CN57-1

CN89-1

CN17-3

(327, L) CN143-8

(102, Y)

J26

CN54-2

N1 terminal CN53-2

J6

CN94-5

CN88-1

J13

CN37-4

(80, B)

CN23-2

(331, GR) CN2-10

(N1, W) CN1-2

J29

CN142-7

CN136-3

(N2, O)

CN136-4

H

J28

CN165-1

CN111-5

(16, GR)

J30

CN7-1

J31

CN28-1

CN142-1

CN8-1

(48, P)

(303, LG)

6-11

CONNECTOR DRAWING (35 ~ 55 MODEL) CN1 4

3

2 1

8

7

6

CN6 2

5

1

2

3

4

5

6

7

8

TAB NO 1 2 3 4 5 6 7 8

P 14 16 141 143 138 137 144 142

C BR GR LG O Y G SL P

NO 1 2 3 4 5 6 7 8

P 14 16 141 143 138 137 144 142

C BR GR LG O Y G SL P

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

TAB

REC

C

J

115 116 N2

-

LH LT EL

108 109 110

-

TR TL TB

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

P

C

115 116 N2

P LG O

CN47-3 CN46-3 J29

108 109 110

BR G-Y GR

CN13-4 CN17-4 CN12-2

1 4

TAB

REC J AM IG

NO 1 4

P 41 43

C Y L

J CN29-1 CN29-2

CN4 (OPT) 2 4

2 4 TAB NO 2 4

P 41 43

C -

REC J AM IG

NO 2 4

P 41 43

C Y L

J CN29-1 CN29-2

CN5 2

1

1

TAB NO 1 2

P 101 111

C R SL

2

REC J LSST LSST

NO 1 2

1

P 101 111

C R SL

J J10 CN38-2

C R BR

J CN37-1 CN161-3

1

P 48 41

C B B

2

REC NO 1 2

J SA SA

P 48 41

C P Y

J J30 J3

CN8 1 2

1 2 TAB

4 C -

P 51 65

TAB

NO 1 2

1

P 41 43

REC NO 1 2

J LSB LSB

2

J

CN4

NO 1 4

C R BR

2

CN7

NO 1 2

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

P

P 51 65

J CN162-6 CN162-16 CN162-4 CN162-13 CN141-10 CN141-1 CN162-3 CN162-12

CN2

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

1

TAB NO 1 2

REC J CN70-30 CN70-14 CN70-22 CN70-24 CN70-5 CN70-4 CN70-23 CN70-21

1

P 48 41

C -

REC NO 1 2

J HO+ HO-

P 48 41

C P Y

J H (J30) J3

CN9 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10

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

TAB NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

REC

P

C

J

103 120 46 45 51 43 43

-

DSBU DSFO DSR DSF LSVBKY VBKY

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P

C

J

103 120 46 45 51 43 43

O G-Y SL G R L L

CN165-4 CN24-1 CN161-2 CN161-1 CN37-12 J2 J2

6-12

CN9 (OPT) 3 6

2 5

1 4

CN15 1 4

TAB NO 1 2 3 4 5 6

P C 51 O 120 B 103 G 46 W-O 45 W-BR 43 R

2 5

2

3 6

NO 1 2 3 4 5 6

P 51 120 103 46 45 43

C R G-Y O SL G L

J CN37-12 CN24-1 CN165-4 CN161-2 CN161-1 J2

NO 1 2

P 51 66

NO 1 2 3

P 351 350 355

1

1

TAB

REC J LSL NO LSATT

NO 1 2 3

P 351 350 355

C G-Y P L

1

2

J FRY FRY

NO 1 2

P 43 110

NO 1 2

P 102 N1

C Y W

2 5

1 4

1 4

TAB NO 1 2 3 4 5 6

P N1 104 102 108 N1 101

C W G Y G-Y W R

C L GR

C W G Y G-Y W

2

3

4

5

6

REC J CN18-3 CN18-4 CN20-1 CN18-1 CN18-2

NO 1 2 3 4 5 6

P N1 104 102 109 N1

1

2

3

4

5

6

NO 1 2 3 4 5 6

P N1 104 102 108 N1 101

C W G Y BR W R

2 4 NO 1 2 3 4

P 109 N1 N1 104

J CN37-16 J11 J12 CN2-12 CN37-15 J10

1 3

1 3

TAB NO 1 2 3 4

P 108 N1 N1 104

C G Y W R

2 4

REC J LF-R LF-R LC-R LC-R

NO 1 2 3 4

C G Y W R

P 108 N1 N1 104

C G-Y W W G

J CN13-4 CN13-5 CN13-1 CN13-2

1 3

2 4

REC J LF-L LF-L LC-L LC-L

NO 1 2 3 4

P 109 N1 N1 104

2

C G-Y W W G

1

1

J CN17-4 CN17-5 CN17-1 CN17-2

6 5 4 3

NO 1 2 3 4 5 6

P 311 315 312 313

C -

2

3 4 5 6

TAB

1 3

J CN37-7 CN46-4 (11) CN47-4 (J12) CN2-13 CN37-6

CN19

CN14 2 4

C W G Y G-Y W

CN18

J J2 CN2-14

REC J CN14-3 CN14-4 CN16-1 CN14-1 CN14-2 CN96-7

J CN13-3 J24

1

TAB

2 5

2

REC J H/L H/L

TAB P N1 104 102 109 N1

CN13 3 6

J CN37-2 CN161-4

1

REC

C -

C R V

1

C B B

3

NO 1 2 3 4 5 6

2

TAB

P 102 N1

J CN155-3 J16 CN155-9

1

2

P 43 110

P 51 66

CN17

CN12

NO 1 2

NO 1 2

CN16

NO 1 2

2 3

C G-Y R L

J LSPB LSPB

TAB

3

2

REC

C -

CN11 2

1

TAB

REC J DSF, DSR DSFO DSBU DSR DSF DSFO, DSBU

1

REC J IG ESS SS1 SS2

NO 1 2 3 4 5 6

P 311 315 312 313

C GR BR G P

J CN147-17 CN147-16 CN147-6 CN147-7

6-13

CN20

CN26

1

2

TAB NO 1 2

P 102 N1

C B B

2

1

4

NO 1 2

P 102 N1

C Y W

J CN17-3 J24

CN22 2

1

1

TAB NO 1 2

P 304 320

C P R

NO 1 2

P 304 320

P 103 N1

C P R

2

TAB

REC NO 1 2

P 198 N1

P 103 N1

C R W

1 2

TAB

REC NO 1 2

P 103 N1

NO 1 2 3 4

P 50 64 52 53

1

C R GR SL Y

1

P 41 43

C Y L

4 J CN25-3 CN25-4 CN25-1 CN25-2

2

REC J CN4-1 CN4-4

NO 1 2

P 41 43

C Y L

J CN136-2 (J3) CN38-2 (J2)

C O W

2 1

1 2

4 3

3 4

TAB NO 1 2 3 4

2

J BZ BZ

3

REC J E2 IDL VTA VC

TAB NO 1 2

J J27 N1

1

C R B

C -

2

CN23-2

NO 1 2

P 50 64 52 53

2

CN31

1

2

J CHI CHI

1

CN29

J CN94-1 CN94-2

1

C R-W B

1

2

CN23

NO 1 2

NO 1 2 3 4

REC J LSDS LSDS

2

TAB

REC J H/L H/L

3

P 104 111 109 N1

C L L L L

REC J TL STP TRN E

NO 1 2 3 4

P 104 111 109 N1

C G SL G-Y W

J CN38-4 CN38-2 CN38-6 CN38-8

CN33 J CN33-3 J25

2 4

CN24

1 3

1 3

TAB NO 1 2 3 4

1 2

P 107 N1 103 43

C V W O L

2 4

REC J CN35-1 CN35-2 CN23-2-1 LR

NO 1 2 3 4

P 107 N1 103 43

C V W O L

J CN38-7 J23 J21 CN38-1

REC NO 1 2

P 120 N1

C G-Y W

CN34

J CN9-3 CN37-5

2

1

1

2

4

3

3

4

TAB NO 1 2 3 4

P 52 53 51 64

C SL Y R GR

NO 1 2 3 4

P 52 53 51 64

C SL Y R GR

4 3

3 4

6 5

5 6

TAB

REC J CN26-3 CN26-4 CN26-1 CN26-2

1 2

2 1

CN25

J CN162-2 CN162-11 CN162-5 CN162-1

NO 1 2 3 4 5 6

REC

P 104 111 103

C R R R

J TL STP B/U

108 N1

R R

TRN E

NO 1 2 3 4 5 6

P 104 111 103

C G SL O

J J22 J20 CN38-3

108 N1

BR W

CN38-5 J23

6-14

CN35 2

CN41

1

1

2

2

1

1

3 TAB NO 1 2

P 107 N1

REC

C B B

NO 1 2

J W/L W/L

P 107 N1

C V W

J CN33-1 CN33-2

CN37

TAB NO 1 2 3

P 341 340 193

2 3

C

REC J STP1STP1+ BMP

NO 1 2 3

P 341 340 193

C V L G

J CN148-2 CN148-10 CN155-1

CN42 1 2 3 11 12 13

4 5 6 7 14 15 16 17 18 19

2

8 9 10 20 21 22

REC NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

1

1

3 TAB

P 51 51 51 N1 N1 N1 N1 320 320 320 51 51 51

C R R R W W W W R R R R R R

J CN6-1 CN15-1 CN141-9 J13 CN24-2 CN17-5 CN17-1 CN87-2 CN87-4 CN94-2 CN39-2 CN9-6 CN161-16

N1 N1 N1 N1 N1 320 320 320

W W W W W R R R

CN13-5 CN13-1 CN38-4 H CN165-2 CN90-8 CN90-2 CN141-11

NO 1 2 3

P 343 342 194

C

REC J STP2STP2+ BMP2

NO 1 2 3

P 343 342 194

2 4

1 3

1 3

TAB NO 1 2 3 4

P 101 101 116 104

C -

2 4

P 43 111 198 104 108 109 107 N1

C L SL R G BR G-Y V W

3

4 5 6 7 8

TAB NO 1 2 3 4 5 6 7 8

REC J CN29-2 (J2) CN5-2 CN165-5 J11 J8 J9 SWR CN37-17

NO 1 2 3 4 5 6 7 8

P 43 111 198 104 108 109 107 N1

2 4

REC J COIL+ SW+ COILSW-

NO 1 2 3 4

P 101 101 116 104

1 3

TAB

8 7 6 5 4

J CN148-3 CN148-11 CN155-6

C R R LG G

J CN136-1 (J10) J10 CN2-9 CN17-2 (J11)

1 3

2 4

CN47

1 2

2 1

C BR O SL

CN46

CN38 3

2 3

C L SL O G BR G-Y V W

J CN33-4 CN31-2 CN34-3 CN31-1 CN34-5 CN31-3 CN33-1 CN31-4

CN39

NO 1 2 3 4

P 101 101 115 102

C -

REC J COIL+ SW+ COILSW-

NO 1 2 3 4

P 101 101 115 102

C R R P Y

J J10 J10 CN2-8 CN17-3 (J12)

1

2

CN52 2

1

TAB NO 1 2

P 87 86

C -

REC J STMD STMD

NO 1 2

P 87 86

C P O

J CN57-6 CN57-4

CN53 2

1

1

TAB NO 1 2

P 68 51

C V R

2

2

REC J LSL2 LSL2

NO 1 2

P 68 51

C O R

J CN161-11 CN37-11

1

1

TAB NO 1 2

P 81 80

C -

2

REC J SSD1 SSD1

NO 1 2

P 81 80

C G B

J CN57-2 CN57-1

6-15

CN54 2

CN85

1

1

TAB NO 1 2

P 82 80

2

2

1

1

2

REC

C -

J SSD2 SSD2

NO 1 2

P 82 80

C BR B

J CN57-3 J26

TAB NO 1 2

P 70 320

REC

C -

J SWTK SWTK

NO 1 2

P 70 320

C BR R

J CN142-4 J4

CN57 CN86 3 6

2 5

1 4

1 4

TAB NO 1 2 3 4 5 6

2 5

3 6

3 2 1 TAB

REC

P 80 81 82 86

C B G BR O

J CN53-2 CN53-1 CN54-1 CN52-2

87

P

CN52-1

NO 1 2 3 4 5 6

P 80 81 82 86

C B G BR O

J CN162-18 CN162-7 CN162-8 CN161-17

87

P

CN161-18

NO 1 2 3

P 57 56 320

P 89 88

1

C G L

1

NO 1 2

P 57 56 320

P 89 88

C G L

TAB

J CN162-10 CN162-9

NO 1 2 3 4

P 305 320 306 320

14 30

21 22 23 24

REC

C G-R R-L L R-L

J STLSTF SPOTSTLSTR SPOT-

NO 1 2 3 4

P 306 320 305 320

2

1

TAB

P 137 138 16 142 141 144 143 14

C -

2

REC J SL/L+ SL/LD15V SDTMA SMTDA SMTDK SDTMK GNDD

NO 4 5 14 21 22 23 24 30

P 137 138 16 142 141 144 143 14

C G Y GR P LG SL O BR

J CN1-6 CN1-5 CN1-2 CN1-8 CN1-3 CN1-7 CN1-4 CN1-1

C -

1

2

REC NO 1 2

P 331 332

1

2 REC

C R B

J SOLLD+ SOLL-

NO 1 2

P 331 332

P 331 334

C GR O

J CN94-5 CN94-6

C GR BR

J CN143-8 (J6) CN143-5

1

2

CN89 2

1

TAB

1

J SOLLD+ SOLD-

NO 1 2

NO 1 2

TAB P 331 334

J CN142-10 CN37-8 CN142-9 CN37-9

TAB

CN82

NO 1 2

C L R G R

5 4 24 23 22 21 TAB

NO 4 5 14 21 22 23 24 30

J CN141-2 CN141-3 J4

CN88

4 5

14 30

C V G R

1 2 3 4

CN70

REC

NO 1 2 3

CN87

2

REC J CN52-1 CN52-2

J POTT+ POTT SPOT-

2 1 4 3

TAB NO 1 2

REC

C -

CN58 2

1 2 3

P 327 330

C R B

REC J SOL TS+ SOLT-

NO 1 2

P 327 330

C L P

J CN143-7 CN143-1

6-16

CN90 4

3

8

2

7

CN96

1

6

5

1

2

3

4

5

6

7

8

1

1 7

7 TAB

TAB NO 1 2 3 4 5 6 7 8

REC

P 91 320 59 58

C GR R Y L

J CN92-3 CN92-1 CN91-2 CN91-3

90

SL

CN92-2

320

R

CN91-1

NO 1 2 3 4 5 6 7 8

P 91 320 59 58

C GR R Y L

J CN142-3 CN37-21 CN141-12 CN141-4

90

SL

CN142-2

320

R

CN37-20

2

1

1

TAB NO 1 2 3

P 320 59 58

2

J STPOTSPL SPL+

NO 1 2 3

P 320 59 58

C R Y L

1 2 3

TAB

REC

C R SL GR

J CN90-2 CN90-6 CN90-1

NO 1 2 3

NO 1 7

P 112 101

P 320 90 91

C -

1 2

TAB NO 1 7

P 18 N2

REC

C R O

J FAN FAN

NO 1 7

P 18 N2

2 4

1 3

TAB NO 1 2 3 4

P 101 41 N2 303

C R Y O LG

2

1

1

2

3

6

5

4

4

5

6

TAB

REC J CN22-1 CN22-2 CN95-1 CN95-2 CN82-1 CN82-2

NO 1 2 3 4 5 6

P 304 320 327 328 331 334

C P R L Y GR O

J CN142-8 CN37-10 J5 CN143-2 CN167-1 CN167-2

CN95 2

1

1

TAB NO 1 2

P 327 328

C -

2

REC J SOLS SOLS

NO 1 2

P 327 328

C L Y

J CN159-1 CN159-2

2 4

REC

J CN46-1 (J10) CN29-2 (J3) CN142-7 (J29) CN142-1

3

J SWMH1 SWMH1 SWMH1

3

C P R L Y GR O

C R O

1 3 NO 1 2 3 4

P 101 41 N2 303

C R Y O LG

1 2

2 1

J F4 F5 CN137-6 F7

J CN94-3 CN94-4

NO 1 2 3 4 5 6 7 8

P 2 1 6 5 44 N2 4 3

C

3

4 5 6 7 8

8 7 6 5 4 TAB

P 304 320 327 328 331 334

J CLMP CN13-6

CN137

CN94

NO 1 2 3 4 5 6

C SL R

CN136

J CN90-8 CN90-3 CN90-4

3 2 1

P 320 90 91

J SW SW

CN97

REC

C -

REC

C -

3

CN92

NO 1 2 3

P 112 101

2 1

CN91 3

NO 1 7

REC J MBMB+ MPMP+ VBMB N2 MBPMBP+

NO 1 2 3 4 5 6 7 8

P 2 1 6 5 44 N2 4 3

C

J MBMB+ MPMP+ VBMB N2 MBPMBP+

6-17

CN141

CN147

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

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TAB NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P 137 57 56 58 309 307 310 308 51 138 320 59 324 325 354 350 67

C -

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

REC J SL/L+ POTT+ POTT SPL+ SSTMA SSTSA SSTMK SMTSK OLSDSL/LSTPOTSPL SS+ SSOLST+ OLSTOLSD+

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P 137 57 56 58 309 307 310 308 51 138 320 59 324 325 354 350 67

C G V G L P SL LG V R Y R Y BR GR LG P G-Y

TAB J CN1-6 CN86-1 CN86-2 CN90-4 CN161-19 CN161-8 CN161-20 CN161-9 CN37-3 CN1-5 CN37-22 CN90-3 CN161-15 CN162-14 CN155-2 CN155-10 CN161-5

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P

316 318 312 313

317 319

315 311

C -

REC J SSTYA SYTSA SXTSA SSTXA STS1 STS2 SSTYK SYTSK SXTSK SSTXK

STSSTS+

CN142

TAB NO P 303 1 90 2 91 3 70 4 11 5 6 (N2) N2 7 304 8 306 9 10 305 11 12 12 (12)

C -

NO 1 2 3 4 5 6 7 8 9 10 11 12

P 303 90 91 70 11

C LG SL GR BR G-Y

J CN136-4(J31) CN90-6 CN90-1 CN85-1 CN155-7

N2 304 305 306 12

O P G L V

CN136-3(J29) CN94-1 CN87-3 CN87-1 CN155-8

CN143

10 9

TAB

REC

C -

J SOLTSOLSSOLD-

-

SOLL(SOLTS+) SOLTS+ SOLLD+ SXTSA SSTXA SXTSK SSTXK

NO 1 2 3 4 5 6 7 8 9 10 11 12

C

J

316 318

LG O

CN143-9 CN143-10

312 313

G P

CN19-3 CN19-4

317 319

SL V

CN143-11 CN143-12

315 311

BR GR

CN19-2 CN19-1

3 2 1 8 7 6 1 2 3 6 7 8

TAB NO 1 2 3 4 5 6 7 8 9 10 11 12

P 330 328 334

C P Y O

J CN89-2 CN94-4 CN166-2

332

BR

CN88-2

327 331 316 318 317 319

L GR LG O SL V

CN89-1 CN88-1 (J6) CN147-3 CN147-4 CN147-11 CN147-12

9 10

4 5 11 12

REC

P

C

J

341 343

-

STP1STP2-

51

-

OLSL-

340 342 60

-

STP1+ STP2+ OLSL+

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

5 4 3 2 1 12 11 10 9 8 7 6 NO P 1 330 2 328 334 3 4 5 332 6 (327) 7 327 331 8 316 9 10 318 11 317 12 319

5 4 12 11

REC J VBMB2 MH1 MH2-1 SWTK S20V+ (N2) N2 STLSD STLSTR STLSTF S20V(S20V-)

P

CN148 1 2 3 4 5 6 7 8 9 10 11 12

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

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

NO 1 2 3 4 5 6 7 8 9 10 11 12

P

C

J

341 343

V BR

CN41-1 CN42-1

51

R

J1

340 342 60

L O G-Y

CN41-2 CN42-2 CN161-7

CN155 4 3 10 9

8 7

NO 1 2 3 4 5 6 7 8 9 10

C -

2 1 6 5

1 2 5 6

TAB P 193 354 351

194 11 12 355 350

7 8

3 4 9 10

REC J BMP PLST PLSL1 PLSAT2 CKT-G BMP2 S20V+ S20VPLSAT1 PLS-

NO 1 2 3 4 5 6 7 8 9 10

P 193 354 351

C G LG G-Y

J CN141-3 CN141-15 CN11-1

194 11 12 355 350

SL G-Y V L P

CN42-3 CN142-5 CN142-11 CN11-3 CN141-16

6-18

CN156

CN162 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9

TAB NO 1

P 41

REC

C Y

J CN154

NO 1

P 41

C Y

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

J J3

TAB

CN159 1

1

2

2

TAB NO 1 2

P 18 N2

REC

C R O

J CN97-1 CN97-2

NO 1 2

P 18 N2

C R O

J RFAN N2

CN161 5 4 3 2 1 9 8 7 6 20 19 18 17 16 15 14 13 12 11 10 6 7 8 9 1 2 3 4 5 10 11 12 13 14 15 16 17 18 19 20 TAB NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

C -

J DSF DSR LSB LSPB LSD

60 307 308 199 68

-

LSL SMTSA SMTSK OPT0 LSL2

-

SSO+ LSTD+ TDSSTMA SSTMK

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

P 45 46 65 66 67

C G SL BR V G-Y

J CN9-5 CN9-4 CN6-2 CN15-2 CN141-17

60 307 308 199 68

G-Y SL V B O

CN148-12 CN141-6 CN141-8 CN165-6 CN39-1

324 51 86 87 309 310

BR R O P P LG

CN141-13 CN37-13 CN57-4 CN57-6 CN141-5 CN141-7

REC

P 64 52

C -

J SWAC POTA

51

-

POT-

81 82 88 89 53

-

SSD1 SSD2 TD2+ TD2POTA+

325 41

-

SSDVBBT

80

-

SSD+

REC

P 45 46 65 66 67

324 51 86 87 309 310

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P 64 52 144 141 51 14 81 82 88 89 53 142 143 325 41 16 43 80

CN165 (EXCEPT EZ PEDAL) 3 6

2 5

1 4

1 4

TAB NO 1 2 3 4 5 6

C

J

103 103

G G

CN165-5 CN165-4

NO 1 2 3 4 5 6

P 16 N1 43 103 198 199

C GR W L O R B

2 5

1 4

1 4

TAB

1

TAB

C W B R

J IN+ GND OUT+

198 199

W W

OUTIN-

2

2 REC

J CN94-5 CN94-6

NO 1 2

2 5

3 6

NO 1 2 3 4 5 6

P 16 N1 43 103 198 199

C GR W L O R B

J J28 CN37-19 J2 CN9-2 CN38-3 CN101-13

1

2

CN166

1

C GR O

J J28 CN37-19 J2 CN9-2 CN38-3 CN101-13

REC

P 16 N1 43

CN167

P 331 334

3 6

CN165 (EZ PEDAL)

NO 1 2 3 4 5 6

NO 1 2

2 5 REC

P

3 6

2

J CN25-4 CN25-1 CN1-7 CN1-3 CN25-3 CN1-1 CN57-2 CN57-3 CN58-2 CN58-1 CN25-2 CN1-8 CN1-4 CN141-14 J3 CN1-2 J2 CN57-1

C GR SL SL LG R BR G BR L G Y P O GR Y GR L B

P

C

1

TAB J

NO 1 2

P 331 334

C -

REC J SOLLD+ SOLL-

NO 1 2

P 331 334

C GR O

J J-6 CN143-3

6-19

Main harness joint

Rear-upper harness joint

CN161-16

J1

CN165-5

J27

CN148-5

CN37-13

CN38-2

J20

CN23-1

CN38-3

(51, R)

J22

CN34-2

CN8-4

(111, SL)

(104, G)

CN38-1

CN165-3

CN34-1

CN31-1

CN31-2

(198, R)

CN29-2

CN38-8

CN38-4

CN12-1

J2

J8

CN162-17

CN9-8

CN9-7

(43, L)

(108, BR)

CN29-1

(N1, W)

CN162-15

J3

J9

CN38-6

Front pillar harness joint CN14-3

CN-156-1 CN136-2

CN17-4

(41, Y)

(109, G-Y)

CN141-2

CN20-2

J24

CN16-2

CN136-1 CN47-1

CN13-1

CN13-6

(N1, W) CN85-2

J4

CN86-3

CN47-2 CN46-2

CN37-22

J10

SWR CN-5-1

CN46-1

(320, R)

(101, R)

CN143-7

Rear option harness joint CN33-2

CN46-4 CN23-2-2

J5

CN94-3

CN89-1

CN38-4

J11

J25

CN13-2

CN17-2

(327, L) CN143-8

J6

LR

CN35-2

(104, G)

(N1, W)

CN47-4

CN166-1

J12

CN13-3

Drive motor harness joint CN57-1

CN88-1

CN17-3

(331, GR) CN141-16

(102, Y)

J26

CN54-2

N1 terminal CN53-2

J16

CN11-2

CN155-10

CN37-4

J13

CN2-10

(N1,W) CN1-2

J29

(80, B)

CN23-2

(350, P)

CN142-7

CN136-3

(N2, O)

H

J28

CN165-1

CN111-5

(16, GR)

J30

CN34-6

CN31-4

(103, O)

CN8-5

CN7-2 CN8-2

J23

CN33-2

CN33-3

CN34-3

CN13-4

CN38-1

J21

CN38-7

CN7-1

CN8-1

(48, P)

6-20

CONNECTING DIAGRAM (15 ~ 32 MODEL) <LEVER CONT. UNIT> CN9 TAB REC

SW D

SW H SW D SW L

CN8 COM

TAB REC

B-W R-L

NO

CN19 SA

LS PB

TAB REC

CN15 TAB REC

CN7

SW CMP

SST

TAB REC

CN96

CN2 TAB REC

LC-L TAB REC

SWR (101,R)J10

LF-L

(107,V)CN38-1

LH-L

SW H

TAB REC

NC

SW L

SW K

SW K

TAB REC

TAB REC

CN4

L CMP SW TK LF-R

CN4

CN20

CN18

TAB REC COM

COM

CN17

NO

R BR

NC

CN5

LS ST REC TAB

LS B

SL

NC

CN16

CN14

CN70

OPT CN29

NO

REC TAB

TAB REC

TAB REC

R

LH-R

LC-R

DISPLAY

TAB REC

TAB REC

TAB REC

KEY-LESS-KEY

TAB REC

CN13

CN6

TAB REC

(48,P)CN8-1(J30)

CN38

H COM

TAB REC

NO

FR Y

CN92

(N1,W)CN37-18

TAB REC

NC

CN12

STCONT

TAB REC

SW MH1

CN46

CN47

TR Y

HRY

TAB REC

TAB REC

CN1 TAB REC

CN91

TAB REC

CN141

TAB REC

CN142

CN143

REC TAB

CN86

CN90 TAB REC

CN57 REC

REC TAB

V REC TAB

SSD2 W

CHI

CN23 (R)

CN54

CN11

TILT

NO NC

R G-Y

R L

COM NO

CN26

CN165

VRAT

COM

TAB REC

NC

COM NO NC

LS ATT

LS L

BACK RELAY

AM D

CN53

REC TAB

U

REC TAB

SSD1

VRAD

REC TAB

REC TAB

STM D

ACCEL

CN24 (F)

R V TAB REC

CN52

LS L NO2

CN39

TAB REC

REC TAB

SP L

TAB REC

CN25

ONLY EZ PEDAL

LS TF

TAB REC

CN37

LS TR

JOINT CONNECTOR

CN55 REC TAB

TAB REC

CN28 REC TAB

TAB REC

CN40

CN45 TAB REC

CN136

CN88

CN89

<DEAD MAN SOLENOID OPT>

CN28

CN55 REC TAB

CN41

REC TAB

CN94

SOLD

DM PS

REC TAB

TAB REC

P1

CONTACTER

A1

P3

REC TAB

LW REC TAB

N1

LR or FB

CN95

TAB REC

B SOLS

CONTROLLER

TAB REC

F

A

CN35

BZ

TAB REC

Y-R

TAB REC

DM P

W-B

TAB REC

CN111

CN145

<EHPS OPT>

CN82

TAB REC

CN101 CN102

PS CONT (EHPS)

R

REC TAB

P14

CN103

CN51

CN45

A2

CN137

REC TAB TAB REC

TAB REC

REC TAB

SOL T

SOL L

PS CONT (FHPS) TAB TAB REC REC

BATT

CN87

TAB REC

CN44 CONTROLLER

P3

P7

P8

P9

P15 P14

TAB REC

<2,3TON ONLY>

TAB REC

FAN

LS D

LF-LL

CN22

L T -L L ST -L

TAB REC

L BU -R

L T -R L F -RR L ST -R

TAB REC

CN31

CN34 TAB REC

CN33 <RR-COMBI OPT>

CN23-2

6-21

CONNECTING DIAGRAM (35 ~ 55 MODEL) <LEVER CONT. UNIT> CN9 TAB REC

SW D SW H

CN8 TAB REC

B-W R-L

CN19

LF-L

LS PB TAB REC

LC-L

CN7

TAB REC

SWR

SST

SW CMP

CN2 TAB REC

(107,V)CN38-7

SA

(101,R)J10

NO

SW D SW L

TAB REC

COM

NC

LH-L

SW H

SW L

SW K

SW K

TAB REC

TAB REC

CN20

SL

L CMP

TAB REC

LF-R

CN70

CN4

TAB REC

CN96

DISPLAY

CN4

CN15 TAB REC

TAB REC

R

LH-R

LC-R

TAB REC

CN18 COM

COM

CN17

NO

NO

R BR

SL

CN5

LS ST

NC

NC

REC TAB

LS B

TAB REC

TAB REC

REC TAB

TAB REC

CN16

CN14

CN29

R

TAB REC

CN13

CN6

TAB REC

(48,P)CN8-1(J30)

CN38

H TAB REC

NO

FR Y

CN92

COM

(N1,W)CN37-18

TAB REC

NC

CN12

CN1 TAB REC

CN91

HR Y

TAB REC

TAB REC

CN142

CN143

TILT RR SOL

TILT

REC TAB

REC

CN54

VRAD

CHI

REC TAB

CN23 (R)

AMD1

A REC TAB

NC

R G-Y

R L

COM NO NC

COM NO NC

LS L CN25

LS ATT

CN37

TAB REC

V

NO

TAB REC

ONLY EZ PEDAL

W

CN11

COM

CN26

CN165 W1 V1 U1

R V

TAB REC

BACK RELAY

SSD2

CN53

REC TAB

REC TAB

AMD2

REC TAB

REC TAB

STM D

CN52

REC TAB

SSD1

CN54

CN53 REC TAB

STM D

CN52 DM P 1

REC TAB

ACCEL

CN24 (F)

LS L NO2

CN39

TAB REC

CN97 TAB REC

TAB REC

TAB REC

VRAT

CN57

REC TAB

FAN

TAB REC

REC TAB

CN58

CN166

F

TAB REC

CN86

REC TAB

SP L EE ONLY

CN47

TR Y

CN90

CN167

U

JOINT CONNECTOR

P15

P16

P14

P1

TAB REC

A1

P3

N1

CN87

P16

P12 F1

CN147

CN148

CONTACTER PANEL

CN155

CN89

<DEAD MAN SOLENOID OPT>

CN136 REC TAB

EE ONLY

CN88

SOL T

TAB REC

REC TAB

CN156

TAB REC

TAB TAB REC REC

TAB REC

SOL L

P12

CHOPPER PANEL TAB REC

REC TAB

CN137

CN159

P81

P91

CN82

REC TAB

LW

B

DRIVE CONTROLLER

DM P 2

CN161

TAB REC

TAB REC

BATT

A1

CN35

BZ

TAB REC

TAB REC

CN162 TAB REC

CN42

REC TAB

CN94

N1 P3 LF-LL

L T -L L ST -L

L BU -R

L T -R L F -RR L ST -R

TAB REC

+

LS D

F1

LR or FB

CN95

Y-R

P71

R

P9

W-B

P8

REC TAB

SOL D

P7

SOL S

CN41

TAB REC

CN141

REC TAB

CN46 ST CONT

TAB REC

SW MH1

CN22

TAB REC

TAB REC

CN31

CN34 TAB REC

CN33

<RR-COMBI OPT>

CN23-2

6-22

WIRING DIAGRAM (15 ~ 32 MODEL) F6 PB CPU P2 F 1

MB

44

F7

303

P3

PB ST PB EHPS

2,3T ONLY

P4

ACCEL VRAD

CSBATT

-

SW AC

P1

+

PB ST

SW K

(P1,B)

F5

(41,Y)

(43,L)

DS F DS R

LS B

LS PB

LS L

LS ATT

LS L2

(18,R)

FAN3 F4

(101,R) (17,R)

L BU DC/MD

D15V

PB CPU

OPT0

BACK RELAY

(48,P)

(16,GR) (199,B)

LF

LF

-LR

-RR

CASE OF EZ PEDAL

P12

MPS(9,O) (B)

(P24, Y)

LST

LSAT2 LSOPT1 LSOPT2 OPTO

(61,LG)

(67,G-Y) LSD

(68,O) LSL2

LSAT1

LSL1

(63,L)

(60,G-Y)

(66,V) LSPB

SMTDK SDTMK SDTMA SMTDA (144,SL) (143,O) (142,P) (141,LG)

TD+ TD(86,O) (87,P)

(80,B) (81,G)

(82,BR)

SSD2

SSD+ SSD1

CSDB (72,R)

CSDA CSDCSD+ (71,W) (76,G) (75,Y)

(77,P) (78,SL)

(79,GR)

PB D

MMP

MMP

G PB MD

PB MD S

S

S

P6

TMD AD PB D

PB D

G

G

G

MMP

SH

PB MD

P15

PB D

MMP

G

PB MD

S

PB MD S

S

AM D STMD

P9

TMD CD

MMP

PB MD

P8

CSD B

TMD BD

PB D

MMP

P7

CSD A

DMP STMP TMP D

ST

PB EHPS

SSD

P5

CSP

CO

PB EHPS

L FB

LSB

THC+ THCD

THCP

BMP TP+ TP-

(N2,O)

(193,G) (88,L) (89,V)

N2

CSBATT

BMPS

G

P14

(P23, R-W) (A)

(65,BR)

(46,SL) DSR

(45,G)

LS-

POTA+

DSF

(51,R)

(53,Y)

(52,SL) POTA

POT-

SWAC

(50,R)

(64,GR)

(44,BR) (P4,L) VBMB VBP4

(43,L) (41,Y)

(29,W) (31,BR)

(15,SL) C15V

(14,O) GNDC

CHOPS OCL CSP CSPCSP+

TMPAD-

VBKY VBBT (54,L)

(196,GR)

G

TMD CU

DMPS

(N1,W)

BZ

LF-R

PB D

MMP

S

LR

TMD BU

PB D

G

BZ

PB CPU LF-L

TMD AU

PB MD

H

-R

PB ST PB EHPS

DMP

TMPS

CHIR L BU

THCP

PB D

P21

F3

-R

(108,BR)

PB

(109,G-Y)

(43,L)

THCD

TMP U

SW F

SW K

(198,R)

MPS -

(110,GR)

SA

+ (10,G)

MPS+

N2 N2

(103,O)

FR Y SW H

DM PS CSBATT

(N2,O) (N2,O)

(33,V) (20,L) (21,W) (22,BR) (23,G) (24,Y) (25,O) (26,R) (26,V) (34,B) (35,B) (37,V)

-R

(32,G)

L ST

TMDAU1+ TMDAU2+ TMDAU-G TMDAU-SD TMDAD1+ TMDAD2+ TMDAD-G TMDAD-SD TMDBU1+ TMDBU2+ TMDBU-G TMDBU-SD TMDBD1+ TMDBD2+ TMDBD-G TMDBD-SD TMDCU1+ TMDCU2+ TMDCU-G TMDCU-SD TMDCD1+ TMDCD2+ TMDCD-G TMDCD-SD

LH-R

(150,R) (150,R) (151,BR) (P5,B) (152,G) (152,G) (153,L) (N2,W) (154,Y) (154,Y) (155,P) (P6,B) (156,V) (156,V) (157,O) (N2,W) (158,L) (158,L) (159,SL) (P9,B) (160,GR) (160,GR) (161,R) (N2,W)

LT-R

MB-(MD-)

LC-R

(11,G-Y) (12,V) (338,GR) EHPS (315,BR) (162,B) (162,B) (163,BR) (N2,L)

ST

DS BU

-L

MB+(MD+)

L ST

(2,V)

LW

PB CPU

(MD)

LH-L

MP-

LT-L

D15V GNDD VBMB S20V+ S20VH15V+ H15VTMPD1+ TMPD2+ TMPD-G TMPD-SD

- MB + (1,R)

LC-L

(16,GR) DISP (14,BR)

MP+

BATT 36V (48V)

(111,SL)

CMP

(107,V)

L

(102,Y)

(104,G)

(73,V) (76,B) (75,Y)

PB DC/MD

TMPD+ TMDAUTMDBUTMDCUTMDADTMDBDTMDCDTMDU+ TMDD+ CKDV CKPV CK20V

HS

(6,Y)

(112.SL)

-

SW L

T

+ (5,G)

SW L

FAN-

(8,W)

MP

DC/DC

-

HM

(115,P)

(116,LG) SW CMP

-

+

B48V

VBKY

FANCD

HRY

TRY +

VBMB FAN+

(7,P)

FAN1

(36,L)

FD

OUT PUT

(38,R) FAN+ (38,R) FAN+ (39,BR) DDC (40,G) PDC (94,GR) CKFAND+ (97,Y) CKFAND(13,O) 20VNO.1 (19,W) 20VNO.2 (27,R) CHOPB (28,L) CHOPP

FAN2

LS ST

S

DC/MD

CHI R N1

N2

(N1,W)

TMD CU

TRANSISTOR, MAIN, DRIVE, PHASE C UPR

LS PB

LIMIT SWITCH, PARKING BRAKE

F4

FUSE, LAMP

TMD AD

TRANSISTOR, MAIN, DRIVE, PHASE A LWR

LS TF

LIMIT SWITCH, TILT FR

F5

FUSE, CONTROL CIRCUIT

TMD BD

TRANSISTOR, MAIN, DRIVE, PHASE B LWR

LS TR

LIMIT SWITCH, TILT RR

F6

FUSE, CONTROLLER

TMD CD

TRANSISTOR, MAIN, DRIVE, PHASE C LWR

LS D

LIMIT SWITCH, DEAD MAN

F7

FUSE, ST CONTROLLER

TMP U

TRANSISTOR, MAIN, PUMP, PHASE UPR

LS L2

LIMIT SWITCH, LIFT NO2

FD

FUSE, DC/DC CONVERTER

TMP D

TRANSISTOR, MAIN, PUMP, PHASE LWR

SW AC

SWITCH, ACCEL

P15 N1

SWITCH, LIGHT

THCD

THERMO, DRIVE

SW F

SWITCH, FLASHER

THCP

THERMO, PUMP

TMPS

TRANSISTOR, MAIN, POWER STEERING

SW H

SWITCH, HORN

AM D

MOTOR, DRIVE

SH

SHANT, POWER STEERING

SW TK

SWITCH, TILT KNOB

DM P

MOTOR, PUMP

CO

CAPACITOR, OVERALL

SW MH1

SWITCH, HIGHT NO.1

DM PS

MOTOR, POWER STEERING

CSB ATT CURRENT SENSOR, BATTERY

SW CMP

SWITCH, COMPARTMENT

CSD A

CURRENT SENSOR, DRIVE, PHASE A

L H-L

LAMP, HEAD LH

B C U 15 - 32

CSD B

CURRENT SENSOR, DRIVE, PHASE B

L H-R

LAMP, HEAD RH

L CMP

LAMP, COMPARTMENT

SOL D

SOLENOID, DEAD MAN

CSP

CURRENT SENSOR, PUMP, PHASE

L C-L

LAMP, CLEARANCE LH

L ST-L

LAMP, STOP LH

SOL L

SOLENOID, LIFT

SSD

SENSOR, SPEED, DRIVE

L C-R

LAMP, CLEARANCE RH

L ST-R

LAMP, STOP RH

SOL T

SOLENOID, TILT

SYR

SENSOR, YAWRATE

L T-L

LAMP, TAIL LH

LR

LAMP, ROTALY

FAN1

FAN

SPL

SENSOR, PRESSURE LIFT

L T-R

LAMP, TAIL RH

L BU-R

LAMP, BACK-UP RH

FAN2

FAN

SST

SENSOR, STEERING

LW

LAMP, WORKING

L FB

LAMP, FLASH BEACON

FAN3

FAN

VARI-OHM, TILT

N2

PB ST

(APPLICATION)

SOLENOID, SWING

VRT

N1

NOTE) .THIS DRAWING SHOWS CASE OF FULL OPTION.

SOL S

VARI-OHM, ACCEL, DRIVE

PB CPU

MPS

CONTACTOR, POWER STEERING

L F-LR

LAMP, FLASHER LH (REAR)

BZ

BUZZER

MP

CONTACTOR, PUMP

L F-RR

LAMP, FLASHER RH (REAR)

CHI R

CHIME, REVERSE

MB(MD)

CONTACTOR, BATTERY (DRIVE)

L F-L

LAMP, FLASHER LH

H

HORN

L F-R

LAMP, FLASHER RH

FR Y

RELAY, FLASHER

(338,GR) DC/MD H15V+

STS-

SW L

PB EHPS

(315,BR)

SWITCH, KEY

DC/DC CONVERTER

DMPS (F)

STS1 STS2

SW K

DC/DC

P22

DM P STMP

(315,BR) DC/MD H15V-

SPL

SST SOL D SOL L

SOL S

SW MH1

SW TK

DC/MD

DF3

(312,G) (313,P)

LCD DISP LCD DISPLAY

(A)

F7

SOL T

-

+ VRT

SYR

STLSD

FUSE, POWER STEERING

N2

(304,P)

F3

MPS

P14

(90,SL) MH1 (91,GR) MH2-1

LIMIT SWITCH, BRAKE

STLSTR

LS B

(306,L)

TRANSISTOR, MAIN, DRIVE, PHASE B UPR

STLSTF

TMD BU

(305,G)

FUSE, PUMP

(70,BR)

F2

P21

MP

SWTK

LIMIT SWITCH, STOP LAMP

SYR+ SYR SYR-

LS ST

(321,R) (322,W) (323,B)

TRANSISTOR, MAIN, DRIVE, PHASE A UPR

POTT+

TMD AU

(57,V)

FUSE, DRIVE

F3 PB CPU

POTT

F1

P1

(320,R) (56,G)

LIMIT SWITCH, ATTACHMENT

STPOT-

LIMIT SWITCH, LIFT

LS ATT

SPL+

LS L

PRINT BOARD, EHPS

(58,L)

PRINT BOARD, ST COMPUTER

PB EHPS

SPL

PB ST BATTERY

(59,Y)

P11

P3

(324,BR) (326,GR) (67,G-Y) (61,LG) (51,R) (51,R) (307,SL) (308,V) (309,P) (310,LG)

F2

F1

(340,G)

P2

TMPSG

MD

BATT

VRAD

TMPS

DIRECTION SWITCH, BACK-UP (303,LG) VBKY (342,LG) ISTPA (343,SL) ISTPK (345,Y) ERR+ (346,V) ERR-

DS BU

LCD DISP

(137,G) (138,Y)

PRINT BOARD, DMP

GNDD D15V SMTDK SDTMK SDTMA SMTDA N1 48V

SL/L+ SL/L-

PB DMP

F7 P1

SOLT-

PRINT BOARD, MMP

(330,P)

PB MMP

S20V+ S20VVBMB2

SURGE ABSOBER

(11,G-Y) (12,V) (303,LG)

SA

SOLS-

DIRECTION SWITCH, REVERSE

(328,Y)

DS R

SOLLSOLTS+

PRINT BOARD, DC/MD

(327,L)

PB DC/MD

(332,BR)

RELAY,TAIL LAMP

SOLD-

TR Y

PB CPU

CASE OF EHPS LESS

CASE OF LOAD HANDLING CHOPPER LESS

(334,O)

DIRECTION SWITCH, FORWARD

SOLLD+

DS F

(331,GR )

PRINT BOARD, COMPUTER

SS+ SSOLSD+ OLST+ OLSDOLSTSMTSA SMTSK SSTMA SSTMK

PB CPU

(P24,Y) (N1,B)

RELAY, HEAD LAMP

SH+ SH-

HR Y

LSTF LS TR LS D

6-23

WIRING DIAGRAM (35 ~ 55 MODEL) PB CPU

(P2,R)

303

PB ST

P4 CSBATT

F 2A

P1

44

F7

P3

P2 F 1

MD2

F6

P11 P16

F 2B

EE ONLY

P12

MP1

ACCEL VRAD -

SW AC

MD1

COP

+

PB SCPU

PB ST

MP2 DS F DS R

LS B LS PB LSL2

SWK

SWCMP

(199,B)

SA

TMDAU2

SW F

TMD BU2

PB D

L BU -R

MMP

L BU

PB DC/PD

CASE OF EZ PEDAL (48,P)

P17

PB MD

PB SCPU

LF

LF

-LR

-RR

LF-L

S

G

PB MD

PB MD

S

LF-R

LSL

LSOPT2 OPTO AOPT

(60,G-Y)

(67,G-Y) LSD

(68,O) LSL2

LSPB

LSB

(66,V)

(65,BR)

(46,SL) DSR

DF3

(49,O )

VBMB

LFB

MMP

G

G PB MD

(N1,W)

PB MD

COP

PB D

MMP

G PB MD

S

S

SSD

P81

P5 P6

AM D2 STMD2

TMD BD2

TMD CD2

PB D

PB D

PB D

PB D

PB D

G

G

G

G

G

S

PB MD

S

MMP

STMD

P9

MMP

G

PB

PB MD

MD

S

S

TMD CD

AM D

PB D

MMP

PB MD

P8

CSD B

TMD BD

TMD AD

P91

MMP

PB MD

P7

CSD A

TMD AD2

S

S

N2

TMD CD2 TMPU

TRANSISTOR, MAIN, DRIVE, PHASE C LWR 2 TRANSISTOR, MAIN, PUMP, PHASE UPR

LS D L H-L

LIMIT SWITCH, DEAD MAN LAMP, HEAD LH

DM P2

MOTOR, PUMP 2

TMPD

TRANSISTOR, MAIN, PUMP, PHASE LWR

L H-R

LAMP, HEAD RH

SOL S

SOLENOID, SWING

CO

CAPACITOR, OVERALL

L C-L

LAMP, CLEARANCE LH

SOL D SOL L

SOLENOID, DEAD MAN

COP

CAPACITOR, OVERALL PUMP

L C-R

LAMP, CLEARANCE RH

SOLENOID, LIFT

CSBATT

CURRENT SENSOR, BATTERY

L T-L

LAMP, TAIL LH

SOL T

SOLENOID, TILT

CSD A

CURRENT SENSOR, DRIVE, PHASE A

L T-R

LAMP, TAIL RH

FAN D1

FAN, DRIVE 1

CSD B

CURRENT SENSOR, DRIVE, PHASE B

LW

LAMP, WORKING

FAN D2

FAN, DRIVE 2

CSD A2

CURRENT SENSOR, DRIVE, PHASE A2

L F-LR

LAMP, FLASHER LH (REAR)

FAN D3

FAN, DRIVE 3

CSD B2

CURRENT SENSOR, DRIVE, PHASE B2

L F-RR

LAMP, FLASHER RH (REAR)

FAN PM

FAN, PUMP MOTOR

CSP

CURRENT SENSOR, PUMP, PHASE

L F-L

LAMP, FLASHER LH

VRAD

VARI-OHM, ACCEL, DRIVE

MD1

CONTACTOR, DRIVE 1

L F-R

LAMP, FLASHER RH

VRT

VARI-OHM, TILT

MD2

CONTACTOR, DRIVE 2

L ST-L

LAMP, STOP LH

PB CPU

PRINT BOARD, COMPUTER

MP1

CONTACTOR, PUMP 1

L ST-R

LAMP, STOP RH

PB DC/MD

PRINT BOARD, DC/MD

MP2

CONTACTOR, PUMP 2

LR

LAMP, ROTALY

PB CD

PRINT BOARD, CD

SW AC

SWITCH, ACCEL

L BU-R

LAMP, BACK-UP RH

PB MMP

PRINT BOARD, MMP

SW K

SWITCH, KEY

L FB

LAMP, FLASH BEACON

PB DMP

PRINT BOARD, DMP

SW L

SWITCH, LIGHT

PB SCPU

PRINT BOARD, SK/PS COMPUTER

SW F

SWITCH, FLASHER

L CMP BZ

PB ST (11,G-Y) (12,V) (41,Y)

41 P12

PB DC/PD

PRINT BOARD, DC/PD

SW H

SWITCH, HORN

CHI R

CHIME, REVERSE

PRINT BOARD, ST

SW TK

SWITCH, TILT KNOB

H

HORN

SYR

SENSOR, YAWRATE

SW MH1

SWITCH, HIGHT NO.1

FR Y

RELAY, FLASHER

PB DC/PD

S20V+ S20VB48V

THCP

DMP

S

P14 P13

TMP D

CSP DMP STMP

PB D

MMP

G PB MD S

N1

SSTXA SSTXK SXTSA SXTSK

PB ST

(APPLICATION)

G

COP

(316,LG) (317,SL) (318,O) (319,V)

+ VRT

SYR

DMP2

TMP U PB D

LAMP, COMPARTMENT BUZZER

PB ST

DMP2

STLSD

MOTOR, PUMP

(304,P)

MOTOR, DRIVE 2

(90,SL) MH1 (91,GR) MH2-1

MOTOR, DRIVE

AM D2 DM P

STLSTR

AM D

LIMIT SWITCH, TILT FR LIMIT SWITCH, TILT RR

(306,L)

LIMIT SWITCH, PARKIG BRAKE

LS TF LS TR

STLSTF

LS PB

TRANSISTOR, MAIN, DRIVE, PHASE A LWR 2 TRANSISTOR, MAIN, DRIVE, PHASE B LWR 2

SWTK

TRANSISTOR, MAIN, DRIVE, PHASE C UPR 2

TMD AD2 TMD BD2

(305,G)

TMD CU2

(70,BR)

THERMO, DRIVE 2 THERMO, PUMP

SW MH1

SW TK

SYR+ SYR SYR-

THCD2 THCP

F7

PB SCPU

PB ST

(321,R) (322,W) (323,B)

LIMIT SWITCH, BRAKE

POTT+

LIMIT SWITCH, STOP LAMP

LS B

(57,V)

LS ST

TRANSISTOR, MAIN, DRIVE, PHASE B UPR 2

POTT

TRANSISTOR, MAIN, DRIVE, PHASE A UPR 2

TMD BU2

(320,R) (56,G)

TMD AU2

PB DC/PD

STPOT-

LCD DISPLAY THERMO, DRIVE

PB DC/PD

N2

SPL+

LCD DISP

THCD

LS ATT

LS L

(58,L)

LIMIT SWITCH, ATTACHMENT

SPL

LIMIT SWITCH, LIFT NO2

LS ATT

(59,Y)

LS L2

TRANSISTOR, MAIN, DRIVE, PHASE C LWR

(137,G) (138,Y)

TRANSISTOR, MAIN, DRIVE, PHASE B LWR

TMD CD

SL/L+ SL/L-

TMD BD

SOLT-

FUSE, ST CONTROLLER FUSE, DC/DC CONVERTER

(330,P)

F7

PB CPU

(11,G-Y) (12,V) (303,LG)

LIMIT SWITCH, LIFT

S20V+ S20VVBMB2

LS L

SOLS-

TRANSISTOR, MAIN, DRIVE, PHASE A LWR

(328,Y)

TMD AD

(327,L)

FUSE, CONTROLLER

SOLLSOLTS+

DIRECTION SWITCH, BACK-UP

F6

(332,BR)

DIRECTION SWITCH, REVERSE

DS BU

SOLD-

DS R

TRANSISTOR, MAIN, DRIVE, PHASE C UPR

(334,O)

TRANSISTOR, MAIN, DRIVE, PHASE B UPR

TMD CU

SOLLD+

TMD BU

FUSE, CONTROL CIRCUIT

(331,GR )

FUSE, LAMP

F5

(324,BR) (325,GR) (67,G-Y) (354,LG) (51,R) (350,P) (307,SL) (308,V) (309,P) (310,LG)

F4

GNDD D15V SMTDK SDTMK SDTMA SMTDA N1 48V

LCD DISP

SS+ SSOLSD+ OLST+ OLSDOLSTSMTSA SMTSK SSTMA SSTMK

DIRECTION SWITCH, FORWARD

N2

DS F

BMP

FUSE, PUMP NO.2

SENSOR, STEERING TRANSISTOR, MAIN, DRIVE, PHASE A UPR

(193,G)

F2B

SST TMD AU

BMP2

FUSE, PUMP NO.1

(194,SL)

F2A

PB CPU

SST

(335,Y) (344,Y) (345,Y) (346,Y) (347,Y) (348,Y) (349,Y) (P12,Y) (352,Y) (353,Y) (342,O) (343,BR) (340,L) (341,V)

DC/DC CONVERTER

PCSP+ PCSP PCSP-

SWITCH, COMPARTMENT

DC/DC

(352,R) (337,G) (353,Y)

SW CMP

SENSOR, PRESSURE LIFT

THP THP+

SENSOR, SPEED, DRIVE

SPL

(339,R) (338,V)

SSD

FUSE, DRIVE

PLS(351,G-Y) VBMBP PLSL1 N1 (354,LG) PLSAT2 TMPD1+ PLST (355,L) TMPD2+ TMPD-G PLSAT1 TMPD-SD

BATTERY

F1

(P12,B) (N1,W)

BATT

(350,P)

N1

P71

CSD B2

MMP

TD+ TDGNDD D15V SMTDK SDTMK SDTMA SMTDA

SSD2 (82,BR)

CSBATT

CD-

CD+ + (47,W ) MD2 -

MMP

S

P61

CO

DMP2 STMP2

(86,O) (87,P) (14,BR) (16,GR) (144,SL) (143,O) (142,P) (141,LG)

CSBATT

SSD+ SSD1 (80,B) (81,G)

(54,L)

CSDB (72,R)

(19,Y)

(71,P) (76,G) (75,Y)

CSDA CSDCSD+

CHOPCD-

THC+ THCD N2

PB D

S

TMD CU

TMD BU

PB D

PB MD

CSD A2

MMP

FD

MMP

G

LR

H

.THIS DRAWING SHOWS CASE OF FULL OPTION.

MMP

TMD AU

BZ

CHI R (N1,W)

PB D

G

P51

CHI R

PB ST

(311,GR) STS+ (312,G) STS1 (313,P) STS2 STSC (315,BR) STSDRPMOS PDUTY SELT1 SELT2 DATA1 (60,G-Y) DATA2 OLSL+ (51,R) OUTAD OLSLVBMBP SC15V GNDSC (316,LG) SXTSA STP2+ (317,SL) STP2SXTSK (318,O) STP1+ SSTXA (319,V) STP1SSTXK

BZ

(108,BR)

(109,G-Y)

-R

PB CD

THCD2

TMD CU2 PB D

(356,L) (357,O) (358,GR) (359,BR)

BACK RELAY

(110,GR)

(198,R)

(103,O)

FR Y SW H

(16,GR)

(77,P) (78,P)

-

THCD

(169,W) (N2,BR) (170,L) (170,L) (171,O) (P16,B) (172,GR) (172,GR) (173,R) (N2,W) (150,R) (150,R) (151,BR) (P5,B) (152,G) (152,G) (153,V) (N2,W) (154,Y) (154,Y) (155,P) (P6,B) (156,V) (156,V) (157,O) (N2,W) (158,L) (158,L) (159,SL) (P9,B) (160,GR) (160,GR) (161,R) (N2,W)

OPT0

(167,SL) (P13,P) (168,V) (168,V)

PB CPU D15V

(45,G)

(51,R) LSTHCD2

MP2

(6,Y)

(79,Y)

MP2-

MP2+

MP1-

+ (5,G)

MP1+

(4,B)

+ (3,GR) MP1

MD1+

TD2+ TD2-

N2 N2C

CSDB2

MD1(2,V)

-

-R

MD1

L ST

+ (1,R)

LH-R

-

LT-R

(88,L) (89,G)

LC-R

(P12,B) (164,G) (164,G) (165,P) (N2,GR) (166,Y) (166,Y)

-L

TMDAU21+ TMDAU22+ TMDAU2-G TMDAU2-SD TMDAD21+ TMDAD22+ TMDAD2-G TMDAD2-SD TMDBU21+ TMDBU22+

(N2,O) (N2,O)

LH-L

N2 N2

CSDA2 CSD2CSD2+

(111,SL)

(107,V)

LT-L

(162,O) (162,R) (163,BR)

DS BU

L ST

LW

LC-L

(N2,O)

SWK

(43,L)

DSF

POTA

(53,Y)

(52,SL)

(64,GR) SWAC

(P4,V) (44,R) (44,R) (51,R) VBP4 VBMB VBMB POT-

(43,L) (41,Y) (41,Y)

PB CPU

(74,R)

LCMP

PB DC/MD

FAND2+ FAND2-

TMDBU2-G TMDBU2-SD TMDBD21+ TMDBD22+ TMDBD2-G TMDBD2-SD TMDCU21+ TMDCU22+ TMDCU2-G TMDCU2-SD TMDCD21+ TMDCD22+ TMDCD2-G TMDCD2-SD TMDAU1+ TMDAU2+ TMDAU-G TMDAU-SD TMDAD1+ TMDAD2+ TMDAD-G TMDAD-SD TMDBU1+ TMDBU2+ TMDBU-G TMDBU-SD TMDBD1+ TMDBD2+ TMDBD-G TMDBD-SD TMDCU1+ TMDCU2+ TMDCU-G TMDCU-SD TMDCD1+ TMDCD2+ TMDCD-G TMDCD-SD

BATT 36V (48V)

FAND-

(N2,O)

(102,Y)

(112.SL)

(104,G)

-

(9,P) (10,W)

FAN D2

LSAT2

HM

POTA+

HS

(73,P) (76,B) (75,Y)

DC/DC

-

T

FAND+

VBKY VBBT B48V

(7,P) (8,W)

FAN D1

(100,B) (14,O) (14,O) (16,L) (15,G) (13,G) (41,Y)

SWL

+

CHGFAN GNDD GNDC D15V C15V C20V

VBMB (17,R)

FAN D3

LS ST +

(18,R)

FAN PM

(38,R) FAN+ (39,BR) DDC (40,G) D2DC (94,GR) CKFAND+ (97,Y) CKFAND(98,O) CKFAND2+ (99,V) CKFAND2-

(101,R)

(36,L) (37,W)

F4

(43,L)

FANCD FANCD2

OUT PUT

(41,Y)

TMDAU2TMDBU2TMDCU2TMDAD2TMDBD2TMDCD2TMDU2+ TMDD2+ TMDAUTMDBUTMDCUTMDADTMDBDTMDCDTMDU+ TMDD+ CKDV CKDV2

FD

PB DC/PD

F5

(27,L) (28,W) (29,BR) (30,G) (31,Y) (32,O) (33,R) (33,V) (20,L) (21,W) (22,BR) (23,G) (24,Y) (25,O) (26,R) (26,V) (34,B) (35,B)

(P1,B)

P15

BCU 35 - 55

SPL

SOL D

SOL L

SOL S

SOL T

-

LSTF LS TR LS D

Published by

1st Printing: Oct. 2005 Pub. No. CU335 Printed in Japan

C