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www.truck-freeworkshop.com www.truck-freeworkshop.com FOREWORD This Manual (Volume 1) contains maintenance, specifications and repair procedure for the chassis, body and material handling system of the TOYOTA ELECTRICAL POWERED FORKLIFT 8FBN15 to 30, 50-8FBN15·18·20 series For diagnosis and service procedures of electrical controller and display, refer to Volume (Pub No CE350) Please use these manuals for providing quick, correct servicing of the corresponding forklift models This manual deals with the above models as of January, 2012 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 www.truck-freeworkshop.com SECTION INDEX NAME SECTION GENERAL BATTERY CHARGER (OPT) CONTROLLER DISPLAY FUNCTIONS TROUBLESHOOTING FRONT MODULE REAR AXLE STEERING BODY MATERIAL HANDLING SYSTEM 10 MAST 11 CYLINDER 12 SAS-ε FUNCTIONS (OPT) 13 MATCHING 14 APPENDIX 15 Section indicated by solid characters are included in this manual Section indicated by half-tone characters: Refer to vol (Pub No CE350) www.truck-freeworkshop.com 0-1 GENERAL Page EXTERIOR VIEWS 0-2 VEHICLE MODEL 0-3 FRAME NUMBER 0-4 TERMINOLOGY 0-5 ABBREVIATIONS 0-5 SI UNITS 0-6 OPERATIONAL TIPS 0-7 JACK-UP POINT 0-9 HOISTING THE VEHICLE 0-10 CIRCUIT TESTER 0-11 STANDARD BOLT & NUT TIGHTENING TORQUE 0-13 BOLT STRENGTH CLASS IDENTIFICATION METHOD 0-13 PRECOAT BOLTS 0-16 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 0-16 WIRE ROPE SUSPENSION ANGLE LIST .0-17 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE .0-17 COMPONENTS WEIGHT 0-18 RECOMMENDED LUBRICANT QUANTITY & TYPES 0-19 LUBRICATION CHART 0-20 PERIODIC MAINTENANCE 0-21 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS 0-25 10 11 12 13 14 0-2 www.truck-freeworkshop.com EXTERIOR VIEWS (Models with OPT) G85709101_ www.truck-freeworkshop.com 0-3 VEHICLE MODEL Classification ton series ton series ton series *: China only Vehicle model Voltage (V) 8FBN15 48 *50-8FBN15 ↑ *8FBN16 ↑ 8FBN18 ↑ *50-8FBN18 ↑ 8FBN20 ↑ *50-8FBN20 ↑ 8FBN25 ↑ 8FBN30 80 2 10 11 12 13 14 www.truck-freeworkshop.com 0-4 FRAME NUMBER Frame No Punching Position Punching Position (Models with OPT) Series G85700101_ Vehicle models Punching format Except EEC spec EEC spec 8FBN15 8FBN16 ton 50-8FBN18 8FBN20 ton 8FBN18 10011 8FBN25 10011 8FBN30 10011 8FBN18 50-8FBN15 ton 8FBN18-10011 8FBN25 508FBN18-10011 8FBN25-10011 50-8FBN20 508FBN20-10011 8FBN30 8FBN30-10011 www.truck-freeworkshop.com 0-5 TERMINOLOGY Caution: Important matters of which negligence may cause accidents Be sure to observe them Note: Important items of which negligence may cause accidents, or matters in operation procedure requiring special attention Standard: Values showing allowable range in inspection and adjustment Limit: Maximum or minimum allowable value in inspection or adjustment ABBREVIATIONS Abbreviation (code) Meaning Abbreviation (code) Meaning ASC Auto Speed Control RH Right hand ATT Attachment RR Rear EHPS Electronically controlled fully hydraulic power steering SAE Society of Automotive Engineers (USA) FR Front SAS System of active stability J/B Junction block SOL Solenoid ASSY Assembly SST Special service tool LH Left hand STD Standard LLC Long life coolant T= Tightening torque M/T Manual transmission T/C Torque converter & transmission NMR No-load maximum speed TBC Traction and brake control OPS Operator Presence Sensing {{T Number of teeth ({ {) 10 OPT Option U/S Undersize O/S Oversize W/ With PS Power steering L/ Less R/B Relay block 11 12 13 14 www.truck-freeworkshop.com 0-6 SI UNITS Meaning of SI SI represents the International System of Units, which has been established for unifying various systems of units used in the past, for smoother international technical communication New Units Adopted in SI Characteristic New unit Conventional unit Conversion rate*1 (1[conventional unit] = X[SI unit]) Force*2 N (newton) kgf kgf = 9.80665 N Torque (moment) N·m kgf·cm kgf·cm = 9.80665 N·m Pressure*2 P (pascal) kgf/cm2 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa ↑ ↑ mmHg mmHg = 0.133322kPa Revolving speed r/min rpm rpm = r/min Spring constant*2 N/mm kgf/mm kgf/mm = 9.80665 N/mm Volume L cc cc = mL Power W PS PS = 0.735499 kW Heat quantity W·h cal kcal = 1.16279 W·h Specific fuel consumption g/W·h g/PS·h g/PS·h = 1.3596 g/kW·h *2 *1: X represents the value in SI units as converted from [in conventional units], which can be used as the rate for conversion between conventional and SI units *2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which should be used as the unit of force Conversion between Conventional and SI Units Equation for conversion Value in SI unit = Conversion rate × Value in conventional unit Value in conventional unit = Value in SI unit ÷ Conversion rate Conversion rate: Figure corresponding to X in the conversion rate column in the table above Caution: When converting, change the unit of the value in conventional or SI units to the one in the conversion rate column in the table above before calculation For example, when converting 100 W to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499 www.truck-freeworkshop.com 0-7 OPERATIONAL TIPS Safe operation (1) After jacking up, always support with wooden blocks or rigid stands (2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity (3) Always turn the key switch OFF and disconnect the battery plug before the inspection, maintenance or disassembly of electrical parts Tactful operation (1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation (2) Before disconnecting wiring, always check the cable color and wiring state (3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to prevent confusion (4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location (5) Follow the described procedures for disassembly, inspection and reassembly (6) Replace, gaskets, packing and O-rings with new ones each time they are disassembled (7) Use genuine Toyota parts for replacement (8) Use specified bolts and nuts Observe the specified tightening torque at the time of reassembly (Tighten to the center of the specified tightening torque range.) If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table Protection of functional parts Thoroughly check each connector for any failure in or imperfect connection before reconnecting the battery plug after the end of vehicle inspection or maintenance Failure in or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers Grasping the trouble state When a trouble occurs, not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for remedying Disposal of waste fluid, etc When draining waste fluid from the vehicle, receive it in a container If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped without permission, it will either adversely affect human health or destroy the environment Always sort waste fluids, etc and treat them properly by requesting disposal by specialized companies Greasing up each part In addition to periodic grease-up according to the lubrication chart, apply MP grease (or molybdenum disulfide grease) to each sliding contact face when repairing a portion (like pedal link) involving sliding contact www.truck-freeworkshop.com CN55:PM TEMP SSR CN70:DISPLAY 1 18 17 16 15 14 13 12 11 10 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 REC TAB NO P 89 88 C - NO P C 89 R-W 88 GR-R J STPM STPM+ 15-21 J CN111-22 CN111-23 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 REC TAB CN56:PM SPD SSR 1 REC TAB NO P 82 81 C - NO P C 82 R-B 81 GR-G J SSP1 SSP+ J CN111-4 CN111-6 CN68:THERMO SW(TRANS) 1 REC TAB NO P C 139 14 - NO P C 139 P 14 W-G J SWTT DGND J CN70-28 J12 CN69:CHG SW BOX 1 12 11 10 7 10 11 12 J CHGMS CHGAC CHGGND CHG7V SW3 SW2 SW1 LED4 LED3 LED2 LED1 - NO P 132 129 130 128 121 122 123 124 125 10 126 11 127 12 - C G-W G-R BR R G Y O Y-P Y-G Y-B Y-R - J CN70-33 CN70-25 CN70-2 CN70-1 CN70-24 CN70-23 CN70-22 CN70-32 CN70-29 CN70-30 CN70-31 - P U V W C W R B J CN69-4 CN69-3 CN33-7 J12 CN103-14 CN33-3 CN33-1 CN33-9 CN33-4 CN33-8 CN33-5 CN201-7 CN201-10 J18 CN33-10 CN33-2 CN33-6 CN69-7 CN69-6 CN69-5 CN69-2 CN35-1 CN68-1 CN69-9 CN69-10 CN69-11 CN69-8 CN69-1 J25 1 REC TAB NO P C 107 101 - NO P C 107 R-B 101 GR J SWSW+ J J33 J28 CN75:RR WORK PILOT 2 4 REC TAB NO P C 107 N2 - J RR WORK PILOT+ RR WORK PILOT- NO P C 107 R-B N2 W-B J J33 J25 REC TAB NO NO P C 128 R 130 BR 169 GR-R 14 W-G 16 Y-B 162 G 160 B-Y 166 GR-L 10 165 R-Y 11 164 L-O 12 167 G-Y 13 14 15 146 W-L 16 145 L-R 17 18 43 B-Y 19 168 L-B 20 161 R-B 21 163 W-L 22 123 O 23 122 Y 24 121 G 25 129 G-R 26 140 V-Y 27 28 139 P 29 125 Y-G 30 126 Y-B 31 127 Y-R 32 124 Y-P 33 132 G-W 34 35 36 N2 W-B CN73:WORK SW CN61:TRANS J CHG7V CHGND TGND DGND D7V ITKY3 ITKY1 OTKY3 OTKY2 OTKY1 LEDTKY1 CAN1L CAN1H 48V LEDTKY2 ITKY2 IPSTKY1 SW1 SW2 SW3 CHGAC SLLT SWTT LED3 LED2 LED1 LED4 CHGMS GND REC TAB NO P C 132 129 130 128 121 122 123 124 125 10 126 11 127 12 - NO P C 128 130 169 14 16 162 160 166 10 165 11 164 12 167 13 14 15 146 16 145 17 18 43 19 168 20 161 21 163 22 123 23 122 24 121 25 129 26 140 27 28 139 29 125 30 126 31 127 32 124 33 132 34 35 36 N2 - J THR THR THR NO P U V W C - J TRANS TRANS TRANS CN76:HOOD1 1 10 6 10 REC TAB NO 10 P 29 22 51 23 24 25 26 31 27 30 C R-Y R-W GR R-L R-B P-L P-B P-G L-Y R-G J CN101-28 CN102-23 J4 CN102-22 CN102-21 CN102-20 CN102-29 CN101-30 CN102-28 CN101-29 NO 10 P 29 22 51 23 24 25 26 31 27 30 C R-Y R-W GR R-L R-B P-L P-B P-G L-Y R-G J CN163-4 CN163-3 J8 CN163-2 CN164-3 CN164-2 CN165-3 CN165-4 CN165-2 CN164-4 G85714004_ www.truck-freeworkshop.com 15-22 CN88:LIFT SOL CN77:HOOD2 15 14 13 12 11 10 7 10 11 12 13 14 15 REC TAB NO P C 43 B-Y 43 B-Y 119 Y-R 21 V-G 20 V-R 28 V-W 60 P-L 68 B-R 67 L-O 10 221 R-B 11 45 GR-R 12 46 B-O 13 51 BR 14 103 R-W 15 70 B-L J J18 J18 CN24-1 CN103-18 CN103-26 CN101-25 CN104-15 CN104-28 CN104-18 CN103-25 CN104-26 CN104-19 J10 CN23-1 CN103-32 NO P C 43 B-Y 43 B-Y 119 Y-R 21 V-G 20 V-R 28 V-W 60 P-L 68 B-R 67 L-O 10 221 R-B 11 45 GR-R 12 46 B-O 13 51 BR 14 103 R-W 15 70 B-L 1 REC TAB J CN166-8 CN166-7 CN166-3 CN162-2 CN162-3 CN162-4 J17 CN160-3 CN168-2 CN167-2 CN166-5 CN166-4 J11 CN166-2 J16 NO P C B-Y V J CN102-16 CN101-1 1 5 P 10 33 36 39 32 32 C B-Y W-G W-R Y-B G-W L L G-W 1 C W Y-R P 10 33 36 39 32 32 J CN102-19 CN101-2 C - J SLPLSTPLSA1PLSA2PLSLLA2+ SLTA1+ SLTA1+ SLLA2+ TAB REC NO P 51 70 1 4 REC TAB NO P C 51 G 220 R-W 90 L 51 BR 91 L-B 219 BR-Y J CN93-1 CN93-3 CN92-2 CN92-1 CN92-3 CN93-2 P 57 56 51 C - J LSSTK P C 57 L-Y 56 Y-R 51 G NO REC C - J SPLF+ SPLF POT- 1 5 J CN101-16 CN101-13 CN101-11 CN101-15 J6 J7 J7 J6 P 11 34 37 40 32 32 C - P C 58 Y-R 59 Y-G 51 G J CN104-12 CN103-29 J1 J SLPSSTPSSA1PSSA2PSSLLA2+ SLTA1+ SLTA1+ SLLA2+ REC TAB P C 51 BR 90 L 91 L-B J CN90-4 CN90-3 CN90-5 NO P 51 90 91 C - J LSSH1 SH2-1 CN93:HS SSR REC NO NO 3 NO 3 C B-W W-L G-B B-R G-W L L G-W P 58 59 51 CN92:HEIGHT SW P 11 34 37 40 32 32 TAB NO J CN101-20 CN103-17 J1 CN87:C/V PUSH SOL TAB REC NO J J1 CN103-28 CN104-22 J9 CN103-24 CN101-24 1 J VRTA+ VRTA POT- NO P C 51 G 220 R-W 90 R 51 B 91 W 219 BR-Y C - TAB NO J SLTFLSLTFB+ CN86:TILT ANGLE SSR C - CN91:PRESS SSR J J10 CN103-32 NO P CN85:NTRL TILT SW NO P C 51 BR 70 B-L REC TAB NO P REC TAB NO J SLLLSOLLU+ CN90:MAST J CN101-17 CN101-12 CN101-10 CN101-14 J6 J7 J7 J6 C - CN89:TILT SOL CN78:C/V PULL SOL NO NO P 1 3 REC TAB NO P C 51 219 220 - J POTVRH+ VRH - NO P C 51 G 219 BR-Y 220 R-W - J CN90-1 CN90-6 CN90-2 - G85714005_ www.truck-freeworkshop.com CN117:COWL CN94:RR LWR NO P 51 317 316 1 TAB REC C GR L-R L-W J CN97-1 CN97-2 CN97-3 NO P 51 317 316 C GR L-R L-W J J3,J4 CN102-31 CN101-23 CN97:TIRE ANGLE SSR 1 1 5 P 24 30 25 51 26 31 27 C R-B R-G P-L GR P-B P-G L-Y P 24 30 25 51 26 31 27 C R-B R-G P-L GR P-B P-G L-Y REC TAB NO J CN102-21 CN101-29 CN102-20 J3 CN102-29 CN101-30 CN102-28 NO J POTVRTRA VRTRA+ NO P 51 317 316 C GR L-R L-W J CN94-1 CN94-2 CN94-3 CN118:HL SW 2 1 REC TAB CN98:STEERING SOL NO P C 51 221 - J SHLSHL+ NO P C 51 BR 221 R-B J J10 CN103-25 REC TAB NO P C 330 329 - J CN119-2 CN119-4 CN119-3 J15 CN120-2 CN120-4 CN120-3 REC TAB NO P C 51 317 316 - 15-23 J SLSSLS+ NO P C 330 W-L 329 R J CN102-14 CN102-7 CN113:INV FAN NO P 1 98 1 TAB REC C - J FAN+ FNDC NO P C 1 B-W 98 V-Y J J23,CN128-3 J21,CN128-10 CN114:CHG FAN NO P 1 98 1 TAB REC C - J CBAT+ FNDC NO P C 1 B-W 98 V-Y J J23,CN128-4 J21,CN128-8 CN115:LIFT LVR 1 REC TAB NO P 51 20 21 28 C - J POTVRL1 VRL2 VRL+ NO P 51 20 21 28 C GR V-R V-G V-W J J3 CN103-26 CN103-18 CN101-25 CN116:TILT LVR 1 REC TAB NO P 51 22 23 29 C - J POTVRT1 VRT2 VRT+ NO P 51 22 23 29 C GR R-W R-L R-Y J J3 CN102-23 CN102-22 CN101-28 G85714006_ www.truck-freeworkshop.com 15-24 CN101:CPU1(48V) 1 17 16 15 14 13 12 11 10 27 26 25 24 23 22 21 20 19 18 32 31 30 29 28 34 33 7 REC NO P C V Y-R 97 R-W 41 G G-W 32 L 10 36 W-R 11 37 G-B 12 33 W-G 13 34 W-L 14 39 Y-B 15 40 B-R 16 11 B-W 17 10 B-Y 18 19 43 B-Y 20 57 L-Y 21 22 50 B-O 23 316 L-W 24 219 BR-Y 25 28 V-W 26 55 GR-R 27 53 BR-W 28 29 R-Y 29 30 R-G 30 31 P-G 31 32 51 G 33 74 BR-R 34 72 L-O J SOLLU+ SLTFB+ FAN+ VBBT SLLA2+ SLTA1+ SA1PLSA1PSSTPLSTPSSA2PLSA2PSSLPSSLPLVBKY VRTA+ VRAVRTRA+ VRH+ VRL+ VRA2+ VRA1+ VRT+ VRAT1+ VRAT2+ POTVRB2+ VRB1+ 19 18 17 16 15 14 13 12 11 10 27 26 25 24 23 22 21 20 33 32 31 30 29 28 35 34 TAB NO P C 19 19 17 17 329 10 51 11 12 13 335 14 330 15 16 17 18 19 20 25 21 24 22 23 23 22 24 304 25 73 26 51 27 28 27 29 26 30 52 31 317 32 54 33 71 34 35 305 - J VBMBSL VBMBSL SOLCOM SOLCOM SLS+ LSRY1 SLSSLLLSLTFLVRA12 VRA11 VRT2 VRT1 CSBAT VRB2 POTVRA22 VRA21 VRA1 VRTRA VRA2 VRB1 CSBAT- 2 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 REC TAB NO P C 97 41 32 10 36 11 37 12 33 13 34 14 39 15 40 16 11 17 10 18 99 19 43 20 57 21 22 50 23 316 24 219 25 28 26 55 27 53 28 29 29 30 30 31 31 32 51 33 74 34 72 - J CN88-2 CN89-2 CN127-2 J19 J6 J7 CN78-3 CN87-3 CN78-2 CN87-2 CN78-4 CN87-4 CN87-1 CN78-1 J18 CN86-1 J2 CN94-3 CN90-6 CN77-6,CN115-4 CN26-1 CN26-5 CN76-1,CN116-4 CN76-10,CN117-3 CN76-8,CN117-7 CN26-2,J1 CN6-5 CN6-1 NO P C V Y-R 97 R-W 41 G G-W 32 L 10 36 W-R 11 37 G-B 12 33 W-G 13 34 W-L 14 39 Y-B 15 40 B-R 16 11 B-W 17 10 B-Y 18 99 V-Y 19 43 B-Y 20 57 L-Y 21 22 50 B-O 23 316 L-W 24 219 BR-Y 25 28 V-W 26 55 GR-R 27 53 BR-W 28 29 R-Y 29 30 R-G 30 31 P-G 31 32 51 G 33 74 BR-R 34 72 L-O J SOLLU+ SLTFB+ FAN+ VBBT SLLA2+ SLTA1+ SA1PLSA1PSSTPLSTPSSA2PLSA2PSSLPSSLPLVBBA VBMB VRTA+ VRAVRTRA+ VRH+ VRL+ VRA2+ VRA1+ VRT+ VRAT1+ VRAT2+ POTVRB2+ VRB1+ CN102:CPU2 17 16 15 14 13 12 11 10 27 26 25 24 23 22 21 20 19 18 32 31 30 29 28 34 33 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 TAB NO P C 97 41 32 10 36 11 37 12 33 13 34 14 39 15 40 16 11 17 10 18 19 43 20 57 21 22 50 23 316 24 219 25 28 26 55 27 53 28 29 29 30 30 31 31 32 51 33 74 34 72 - CN101:CPU1(80V) J CN88-2 CN89-2 CN127-2 J19 J6 J7 CN78-3 CN87-3 CN78-2 CN87-2 CN78-4 CN87-4 CN87-1 CN78-1 CN128-9 J18 CN86-1 J2 CN94-3 CN90-6 CN77-6,CN115-4 CN26-1 CN26-5 CN76-1,CN116-4 CN76-10,CN117-3 CN76-8,CN117-7 CN26-2,J1 CN6-5 CN6-1 CN103:CPU3 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 J J20 J20 J22 J22 CN98-2 J10 CN127-4 CN98-1 CN88-1 CN89-1 CN76-6,CN117-4 CN76-5,CN117-2 CN76-4,CN116-3 CN76-2,CN116-2 CN137-3 CN6-3 J3,J4 CN76-9,CN117-8 CN76-7,CN117-6 CN26-4 CN94-2 CN26-3 CN137-2 16 15 14 13 12 11 10 27 26 25 24 23 22 21 20 19 18 17 35 34 33 32 31 30 29 28 REC NO P C 19 Y-B 19 Y-B 17 G-W 17 G-W 329 R 10 51 BR 11 12 13 335 LG 14 330 W-L 15 16 B-Y 17 18 19 W 20 25 P-L 21 24 R-B 22 23 R-L 23 22 R-W 24 304 L-O 25 73 Y-R 26 51 GR 27 28 27 L-Y 29 26 P-B 30 52 BR-R 31 317 L-R 32 54 BR-Y 33 71 Y-B 34 35 305 B-O 4 REC TAB NO P C 14 42 N2 51 300 10 11 145 12 146 13 311 14 16 15 16 17 56 18 21 19 302 20 21 22 23 24 91 25 221 26 20 27 28 220 29 59 30 301 31 32 70 33 34 35 - 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 J DGND KYSAT N2 LSIPL+ CAN1H CAN1L SSTR+ D7V VRTA VRL2 IPL2 SH2-1 SHL VRL1 VRH SPLF IPL1 STK - NO P C 14 W-G 42 R-Y N2 W-B 51 B 300 L-B 10 11 145 GR-R 12 146 P-B 13 311 P-L 14 16 Y-B 15 16 17 56 Y-R 18 21 V-G 19 302 V-Y 20 21 22 23 24 91 W 25 221 R-B 26 20 V-R 27 28 220 R-W 29 59 Y-G 30 301 W-L 31 32 70 B-L 33 34 35 - J J12 CN136-7 J14 J9 CN201-7 CN201-1 CN200-10 CN19-1 CN70-5 CN86-2 CN77-4,CN115-3 CN129-2 CN90-5 CN77-10,CN118-2 CN77-5,CN115-2 CN90-2 CN91-2 CN130-2 CN77-15,CN85-2 - G85714007_ www.truck-freeworkshop.com CN104:CPU4(48V) 17 16 15 14 13 12 11 10 25 24 23 22 21 20 19 18 31 30 27 26 29 28 CN104:CPU4(80V) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 28 29 J B48V VBMB CBAT+ N2 N2 N2 FNDC CBATCSBAT+ SPLF+ PSACC+ PSSW+ SDM DSR SPB SH1 SWBK SSTRC DSF SHS SSTR1 SSTR2 NO P C 41 G 44 R-B B-W N2 W-B N2 W-B N2 W-B 98 V-Y LG-B 10 303 GR-L 11 12 58 Y-R 13 14 334 L-O 15 60 P-L 16 17 18 67 L-O 19 46 B-O 20 66 G-W 21 22 90 R 23 65 Y 24 314 G-Y 25 26 45 GR-R 27 28 68 B-R/P-L 29 30 312 B-Y 31 313 L-W J J19 CN136-5 J23 J14 J13 J13 J21,CN128-2 CN136-3 CN137-1 CN91-1 CN47-12 CN77-7 CN77-9,CN43-2 CN77-12,CN10-4,CN9-6 CN15-1 CN90-3 CN2-3 CN19-5 CN77-11,CN10-5,CN9-5 CN77-8,CN11-1 CN19-3 CN19-4 TAB NO P C 14 80 79 78 42 10 146 11 12 13 14 15 16 17 145 18 19 20 21 22 87 23 86 - J CANGND SSD2 SSD1 SSD+ KYSAT CAN1L CAN1H STDM STDM+ 1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 28 29 REC TAB NO P C 18 19 N2 N2 N2 98 10 303 11 12 58 13 14 334 15 60 16 17 18 67 19 46 20 66 21 22 90 23 24 314 25 26 45 27 28 68 29 30 312 31 313 - J B80V VBMB CBAT+ N2 N2 N2 FNDC CBATCSBAT+ SPLF+ PSACC+ PSSW+ SDM DSR SPB SH1 SSTRC DSF SHS SSTR1 SSTR2 CN110:DRIVE INV LH 15 14 13 12 11 10 23 22 21 20 19 18 17 16 17 16 15 14 13 12 11 10 25 24 23 22 21 20 19 18 31 30 27 26 29 28 REC TAB NO P C 41 44 N2 N2 N2 98 10 303 11 12 58 13 14 334 15 60 16 17 18 67 19 46 20 66 21 22 90 23 65 24 314 25 26 45 27 28 68 29 30 312 31 313 - 15-25 NO P C 18 R-B 19 Y-B B-W N2 W-B N2 W-B N2 W-B 98 V-Y/B-L LG-B 10 303 GR-L 11 12 58 Y-R 13 14 334 L-O 15 60 P-L 16 17 18 67 L-O 19 46 B-O 20 66 G-W 21 22 90 R 23 24 314 G-Y 25 26 45 GR-R 27 28 68 B-R/P-L 29 30 312 B-Y 31 313 L-W J CN136-5 J20 J23 J14 J13 J13 J21,CN128-2 CN136-6 CN137-1 CN91-1 CN47-12 CN77-7 CN77-9,CN43-2 CN77-12,CN10-4,CN9-6 CN15-1 CN90-3 CN19-5 CN77-11,CN10-5,CN7-5 CN11-1,CN77-8 CN19-3 CN19-4 CN111:PUMP INV 10 11 12 13 14 15 16 17 18 19 20 21 22 23 15 14 13 12 11 10 23 22 21 20 19 18 17 16 REC NO P C 14 W-G 80 LG-R 79 LG-B 78 LG 42 R-Y 10 146 P-G 11 12 13 14 15 16 17 145 GR-G 18 19 20 21 22 87 R-W 23 86 GR-R J J12 CN54-1 CN53-1 CN201-5 J24 CN201-8 CN201-11 CN52-1 CN52-2 TAB NO P C 14 82 81 42 10 146 11 152 12 152 13 14 15 16 17 145 18 19 20 21 22 88 23 89 - J CANGND SSP1 SSP+ KYSAT CAN1L STEPSTEP1 CAN1H STPM STPM+ 10 11 12 13 14 15 16 17 18 19 20 21 22 23 REC NO P C 14 W-G 82 R-B 81 GR-G 42 R-Y 10 146 V 11 152 BR-R 12 152 BR-R 13 14 15 16 17 145 P 18 19 20 21 22 89 R-W 23 88 GR-R J J12 CN56-1 CN56-2 J24 CN200-12 CN111-12 CN111-11 CN200-9 CN55-1 CN55-2 G85714008_ www.truck-freeworkshop.com 15-26 CN119:ATT1 LVR NO P 51 24 25 30 CN136:CONTACTOR PANEL 1 TAB REC C - J POTVRA11 VRA12 VRAT1+ NO P 51 24 25 30 C GR R-B P-L R-G J J15 CN117-2 CN117-4 CN117-3 CN120:ATT2 LVR 1 P 51 26 27 31 C - 5 J POTVRA21 VRA22 VRAT2+ NO P 51 26 27 31 C GR P-B L-Y P-G J J15 CN117-6 CN117-8 CN117-7 CN127:RY1 8 NO P C 101 41 44 18 19 42 42 - J FLP B48V CBATCBAT+ VBMB(48V) VBMB(80V) VBMBSL KYSAT KYSAT CN137:CURRENT SSR 3 NO P C 303 305 304 - REC J CSBAT+ CSBATCSBAT J FAN+ RY1 VBMBSL SOLCOM NO P 97 335 19 17 C R-W LG Y-B G-W J CN101-3 CN102-13 J20 J22 2 REC TAB NO P PO PO C - J +48V +48V 10 11 12 TAB REC J FNDC MB+ MB+ MB+ VBBA VBBA VBBA - NO 10 11 12 P 98 1 98 99 98 - C B B NO P PO PO J PO PO CN144:DC/DC 12 11 10 C - C J B-L CN104-8 B-W CN113-1 B-W CN114-1 B-W J23 V-Y CN114-2 V-Y CN101-18(80V) V-Y CN113-2 - 3 REC TAB NO P C 233 232 235 234 - J ININ+ OUTOUT+ NO P 233 232 235 234 C W-R L-R B R-W CN129:IMPACT SSR2 1 REC TAB J POTIPL2 IPL+ NO P 51 302 300 REC TAB C G V-Y L-B J J1 CN103-19 CN200-5 J N2 CN145-2 OV CN145-3 CN145:F8&F9 FUSE NO P C 51 302 300 - J CN104-10 CN102-35 CN102-24 CN141:CONTACTOR PANEL(3ton) CN128:FAN RESISTER(3ton) P 98 1 98 99 98 - NO P C 303 GR-L 305 B-O 304 L-O REC TAB NO 10 11 12 REC TAB NO P C J 101 GR J28 J19 41 G LG-B CN104-9 B-W J23 44 R-B CN104-2(48V) 18 R-B CN104-1(80V) 19 Y-B J20 42 R-Y CN103-4 42 R-Y J24 TAB NO P C 97 335 19 17 - REC TAB NO NO P C 231 232 234 236 - J F8 F8 F9 F9 NO P 231 232 234 236 C Y-R L-R R-W R J P2 CN144-2 CN144-4 12V CN150:WIPER SW CN130:IMPACT SSR1 NO P C 51 301 300 - 1 TAB REC J POTIPL1 IPL+ NO P 51 301 300 C G W-L L-B J J1 CN103-30 CN200-6 5 REC TAB NO P C 185 R-L 188 R - J SW+ SW- NO P C 185 R-L 188 R - J J35 CN154-2 - G85714014_ www.truck-freeworkshop.com CN154:WIPER MTR CN165:ATT2 LVR 4 NO P 188 N2 185 J + N2 + C R W-B R-L J CN150-7 J34 J35 NO P 51 27 26 31 3 C R-L R-L R-L R-L NO P 187 185 186 187 J + + C R-L R-L R-L R-L J J35 CN49-1 SW+ CN49-1 REC TAB P 60 51 68 C - J PSSW+ SLMSLM NO NO P 51 27 26 31 C GR L-Y P-B P-G J J8 CN76-9 CN76-7 CN76-8 10 11 12 13 14 15 16 17 18 REC TAB CN160:LOAD SW NO REC J POTVRA22 VRA21 VRAT2+ 18 17 16 15 14 13 12 11 10 REC TAB NO P 187 185 186 187 C - CN166:DIRECTION SW(ARMREST) CN155:WIPER 2 TAB REC TAB NO P C 188 N2 185 - 15-27 P C 60 P-L 51 BR 68 B-R J J17 J11 CN77-8 NO P C 103 119 46 45 51 43 43 10 11 12 13 14 15 16 17 18 - J DSBU DSFO DSR DSF LSVBKY VBKY - NO P C 103 R-W 119 Y-R 46 B-O 45 GR-R 51 BR 43 B-Y 43 B-Y 10 11 12 13 14 15 16 17 18 - J CN77-14 CN77-3 CN77-12 CN77-11 J11 CN77-2 CN77-1 - CN167:HS SW CN161:NTRL TILT SW 3 P 60 51 70 C - NO J IG E P1 P C 60 P-L 51 BR 70 B-L P 51 21 20 28 C - J SHLSHL+ NO P C 51 BR 221 R-B J POTVRL2 VRL1 VRL+ NO P 51 21 20 28 C GR V-G V-R V-W CN168:SEAT SW NO P 51 67 J J8 CN77-4 CN77-5 CN77-6 1 TAB REC C - J SDMSDM+ NO P C 51 BR 67 L-O 1 3 C - NO P C 70 B-L REC J J16 NO P C 70 B-L J POTVRT2 VRT1 VRT+ NO P 51 23 22 29 C GR R-L R-W R-Y J J8 CN76-4 CN76-2 CN76-1 CN170:RR UPR RH 3 REC TAB CN164:ATT1 LVR 1 REC TAB NO P 51 25 24 30 C - J CN160-3 REC TAB P 51 23 22 29 J J11 CN77-9 CN169:JOYSTICK SHORT CONNECTOR TAB CN163:TILT LVR NO J J11 CN77-10 REC TAB NO REC J J17 J11 J16 CN162:LIFT LVR 1 TAB NO P C 51 221 - REC TAB NO J POTVRA12 VRA11 VRAT1+ NO P 51 25 24 30 C GR P-L R-B R-G J J8 CN76-6 CN76-5 CN76-10 NO P 111 104 N2 108 103 - C R-L G-R W-B R-Y R-W - J J5 J29 J26 J31 J30 - NO P 111 104 N2 108 103 - C R-L G-R W-B R-Y R-W - J CN34-3 CN34-1 CN34-6 CN34-5 CN34-4 - G85714015_ www.truck-freeworkshop.com 15-28 CN171:RR UPR LH 3 REC TAB NO P 111 104 N2 109 - C R-L G-R W-B G-Y - J J5 J29 J26 J32 - NO P 111 104 N2 109 - C R-L G-R W-B R-Y - J CN34-3 CN34-1 CN34-6 CN34-5 - CN180:WASHER MTR 2 REC TAB NO P C N2 189 - J WSRWSR+ NO P C N2 W-B 189 B-Y J J34 SW- CN200:CAN J/C1-1 10 11 12 REC TAB NO P C J NO P C 78 LG 78 LG 300 L-B 300 L-B 145 GR-R 145 R-L 145 P 10 146 P-B 11 146 L-Y 12 146 V J CN53-2 CN54-2 CN129-3 CN130-3 CN103-11 CN47-8 CN111-17 CN103-12 CN47-9 CN111-10 CN201:CAN J/C1-2 10 11 12 REC TAB NO P C J NO P C 300 L-B 78 LG 146 W-L 146 P-G 10 145 L-R 11 145 GR-G 12 - J CN103-8 CN110-6 CN70-15 CN110-10 CN70-16 CN110-17 - G85714016_ www.truck-freeworkshop.com 15-29 JOINT BODY MAIN CN6-2 CN130-1 CN129-1 CN26-2 CN101-6 CN78-7 CN86-3 J1 CN101-32 CN78-6 CN91-3 CN90-1 J7 CN87-7 CN87-6 51,G 32,L CN6-6 CN2-1 CN101-22 CN26-6 J2 CN103-6 CN115-1 CN102-26 CN117-5 J3 CN136-2 CN85-1 51,GR 51,BR CN76-3 CN70-4 CN94 J4 CN111-2 CN136-6 CN104-1 (48V) CN40-1 J19 N2 CN7-9 CN8-11 CN7-11 CN104-2 J20 CN171-3 J26 CN3-2 CN30-4 J27 98,V-Y 48,L-O CN102-5 CN5-1 CN102-6 J22 CN170-1 CN127-8 CN104-5 17,G-W N2,W-B CN104-3 CN78-5 CN101-5 CN78-8 J6 CN87-8 N2 N2 CN87-5 9,G-W CN36-1 CN73-2 N104-4 CN114-1 J23 J33 CN21 14,W-G 111,R-L CN7-12 CN104-8 CN40-4 N2 CN8-6 109,G-Y CN113-2 J28 CN46-2 CN171-4 J32 CN22 N2,W-B 51,GR J13 CN17-4 19,Y-B CN114-2 CN104-6 CN13-4 108,R-Y CN170-3 CN23-2 CN37-1 CN24-2 CN30-3 J21 CN8-4 J31 CN170-4 CN12-1 CN110-2 J5 CN70-36 N2 CN102-26 CN171-1 CN7-14 CN17-1 CN17-3 J25 CN47-3 CN30-2 103,R-W CN8-9 CN75-2 CN13-1 CN49-2 CN13-3 CN102-4 CN68-2 CN5-2 J30 CN170-5 N2,W-B CN127-6 CN103-3 J12 CN3-1 CN102-3 CN43-1 J10 CN111-8 J24 42,R-Y CN101-4 41,G CN9-4 CN118-1 CN102-10 CN116-1 CN136-8 CN10-8 CN70-18 CN12-4 CN49-1 CN47-4 51,B CN11-2 CN10-7 J18 CN4-1 CN15-3 CN23-1 CN77-1 CN40-2 CN10-6 CN77-13 CN110-8 CN9-3 CN19-2 50,B-O CN94-1 CN77-2 CN9-2 CN4-4 43,B-Y J9 CN90-4 CN101-19 CN75-1 CN73-1 107,R-B CN45-1 CN45-2 CN46-1 101,GR CN13-5 CN113-4 CN136-4 CN171-2 J29 CN103-5 CN128-5 CN170-2 N2,W-B 1,B-W 104,G-R CN17-5 CN46-4 WIPER CN150-1 CN49-2 J34 CN180-1 J35 CN154-3 CN155-1 CN154-4 185,R-L N2,W-B HOOD CN76-3 CN165-1 CN77-13 CN162-1 CN168-1 J8 CN164-1 CN163-1 51,GR CN167-1 J11 CN117-5 CN161-2 CN160-2 CN120-1 J15 CN77-15 CN119-1 CN77-7 J16 CN169-3 J17 CN161-3 CN160-1 CN161-1 CN166-6 51,BR 51,GR 70,B-L 60,P-L G85714009_ 15-30 www.truck-freeworkshop.com www.truck-freeworkshop.com 15-31 CN115 CN85 (N2,W-B)CN22 CN23 P0 IMPACT SSR2 CHIME BACK BUZZER HORN RELEY U V MS CHG CN61 REC TAB W - + + U U V V W W - N2 - REC TAB REC TAB REC TAB REC TAB CHIME DIODE RR COMBI RH CN103 CN104 MAIN CONTROLLER CN101 REC REC REC REC TAB TAB TAB TAB CN136 CN137 CN127 RY CONTACTOR PANEL CN34 CN24 CN67 RR UPR SUB WIRE P1 DC/DC P2 CN144 N2 N1 CN145 (+,R) (-,B) DC/DC REC TAB + CHG AC PLUG P2 CN23 CN170 CN102 TAB TRANSFORMER REC TAB IMPACT SSR1 REC TAB TAB P4 REC TAB REC REC TAB TAB CONTACTOR (MB) DRIVE INV REC CN110 REC TAB REC TAB CURRENT SSR CN68 REC TAB PUMP INV REC CN111 CN128 DCAN J/C1-1 F4&F5 FUSE REC TAB FAN R CN97 INV FAN DCAN J/C1-2 REC TAB TIRE ANGLE SSR REC TAB F6&F7 FUSE REC TAB ATT2 LVR G REC TAB REC TAB REC TAB CN44 CN141 TAB REC CN113 ATT1 LVR SEAT SW TAB REC CN40 CN201 DIRECTION SW W CN24 LQD LVL SSR REC TAB V REC TAB CN69 CN166 REC TAB - + CN94 CN114 THERMO SW TAB REC CHG SW BOX NTRL TILT SW REC TAB CN129 BATTERY SPD U CN200 REC TAB CN169 CN167 CN161 REC TAB CN43 CN56 W CHG FAN TILT LVR CN65 CN63 G CN62 W CN35 REC TAB PUMP MOTOR CN163 CN164 CN130 TEMP LOAD SW REC TAB CN30 CN55 U HL SW LIFT LVR REC TAB Y-R REC TAB LAMP DIODE REC TAB REC TAB HS SW JOYSTICK SHORT CONNECTOR SEAT SW CN168 REC TAB CN165 REC CN37 TAB CN53 CN54 TAB REC REC TAB CN2 REC TAB CN77 CN6 TAB REC CN65 CN76 TAB REC CN5 HORN CN160 RR UPR WIRE (-,W-B) CN32 GRIP HORN ROTARY LAMP (+,R-B) (120,Y-R) REVERSE (-,W-B) REC TAB CN162 CN63 Y-R TAB REC CN26 REC TAB LIFT LVR NTRL LIFT LVR TILT LVR CN116 HS SW ATT2 LVR CN120 FLASHER RELAY CN12 ATT1 LVR TAIL LP RELAY CN46 CN119 HEAD LP RELAY CN45 (-,R-L) REC TAB (48,L-O)CN21 REC TAB V TAB REC TAB REC TAB REC SPD1 TEMP SPD2 W CN62 CN91 TAB REC HEIGHT SW HS SSR RR COMBI LH RR UPR SUB WIRE REC TAB CN171 STOP LP SW BRAKE SSR BRAKE SW CN52 REC TAB MINI LEVER PEDAL UNIT ACCEL SSR HEAD LP RH CN13 REC TAB CN86 WORKING LAMP CN78 (N1,W-B) FORWARD (103,R-W) C/V PULL SOL FR COMBI RH (102,R-G) TAB REC CN118 (+,R-B) CN87 DRIVE MOTOR TAB REC C/V PUSH SOL TAB REC TAB REC WIPER SW CN92 REC TAB TAB REC CN18 CN11 REC TAB REC TAB CN89 TAB REC CN93 TAB REC FR STAY RH WIRE CN17 REC TAB TILT SOL PRESS SSR CN34 REC TAB REC TAB CN88 REC TAB CN15 MAST WIRE LIFT SOL REC TAB CN73 WORK SW TAB REC TILTANGLE SSR TAB REC REC TAB CN90 TAB REC TAB REC OIL CONTROL VALVE PKB SW CN75 REC TAB RR WORK PILOT REC TAB TAB REC REC TAB CN49 REC TAB TAB REC WASHER SW CN150 STEERING SOL TAB REC CN47 WASHER MTR (-,B-Y) DISPLAY TAB CN98 WIPER MTR TAB REC (+,R-L) TEN KEY CN70 REC TAB CN180 CN33 OIL CONTROL LEVER REC TAB CN154 CN18 DIAGNOSIS TAB REC CN4 CN17 REC WIPER WIRE CN155 CN7 CN9 TAB REC (-,R-L) TURN< SW(LH DIR) TAB REC (+,R-L) TURN< SW(RH DIR) STEERING SSR TAB REC CN8 HORN SW TAB REC CN19 DIRECTION SW(RH DIR) TAB REC CN3 DIRECTION SW(LH DIR) TAB REC KEY SW REC TAB WIPER RESISTOR WIPER RESISTOR TAB REC CN10 (N2,W-B) (102,R-G) HEAD LP LH FR COMBI LH FR STAY LH WIRE LEVER CONT UNIT (+,R-L) CONNECTING DIAGRAM F8&F9 FUSE DC+12V 0V G85714010_ N1 PBCPU CHG BOX TEN KEY TGND LEDTKY2 (N2,W-B) P7 SSD GND N2 (139,P) 48V DSR (45,GR-R) DSR DSF SHL SDM SLM LS- SSTR+ (51,B) (311,P-L) (312,B-Y) (313,L-W) (314,G-Y) (66,G-W) (91,W) (90,R) (65,Y) (317,L-R) (316,L-W) FAN SSTR1 SSTR2 SSTRC SPB SH2-1 SH1 SWA VRTRA+ VRTRA SWP SWMH SWBK VRATA (46,B-O) (221,R-B) DSF (67,L-O) (68,B-R) - LSHL LSS + (146,L-Y) (51,GR) (27,L-Y) + PSACC+ VBKY (140,V-Y) (145,R-L) POT- VRA22 (26,P-B) (31,P-G) + PSSW+ STK LS- VRAT2+ VRA21 + (60,P-L) (70,B-L) (51,BR) DGND D7V VRAAT22 CAN1L CAN1H SWNT SLL (169,GR-R) (14,W-G) (16,Y-B) VRAAT21 - (168,L-B) LEDTKY1 DISPLAY (167,G-Y) OTKY3 (145,L-R) (25,P-L) ATT1 LEVER (166,GR-L) OTKY2 D7V DGND CAN1H VRA12 VRAT1+ (30,R-G) VRA11 (24,R-B) (23,R-L) (22,R-W) (29,R-Y) (21,V-G) (20,V-R) (28,V-W) VRAAT12 - (165,R-Y) OTKY1 IPSTKY1 CHG BOX (164,L-O) (146,W-L) C (163,W-L) CAN1L SLLT ITKY3 ITKY2 SLTFL- VRT2 VRT+ VRT1 VRL2 VRL+ VRL1 (51,G) (302,V-Y) (301,W-L) (300,L-B) (59,Y-G) (58,Y-R) (220,B-W) (219,BR-Y) (56,Y-R) (57,L-Y) (71,Y-B) (72,L-O) (73,Y-R) (74,BR-R) (50,B-O) (52,BR-R) (53,BR-W) (54,BR-Y) IPL2 VRAAT11 - (162,G) (7,W) IPL2 POT- (305,B-O) (55,GR-R) - ITKY1 (95) SLTFB+ SLLL- SOLLU+ SLS- SLS+ SA2PS- SA2PL- SA1PS- IPL1 IPL+ SPLF SPLF+ VRH VRH+ VRTA VRTA+ VRB1+ VRB1 VRB2 VRB2+ VRA1 VRA- VRA1+ VRA2 VRA2+ CSBAT- (17,G-W) VRAT2 (161,R-B) CHGMS AC200 (6,Y-R) (4,B-Y) (3,V) (330,W-L) (329,R) (40,B-R) (39,Y-B) (37,G-B) SA1PL- STPS- SLTA1+ STPL- SLPS- SLLA2+ SLPL- CAN1L CAN1H KYSAT N2 CBAT+ (303,GR-L) CSBAT+ (304,L-O) CSBAT (1,B-W) (2,LG-B) (19,Y-B) TILT LEVER (160,B-Y) (132,G-W) (135) (136) CUD AC CHGGND STMD SOLL (129,G-R) CHG7V LED4 LED3 SSD2 CANGND (146,P-G) CAN1L (145,GR-G) CAN1H (86,GR-R) STDM+ (87,R-W) STDM (79,LG-B) SSD1 (78,LG-) SSD+ (36,W-R) (34,W-L) (32,L) (33,W-G) (11,B-W) (9,G-W) (10,B-Y) (146,P-B) (145,GR-R) (42,R-Y) (N2,W-B) N2 N2 N2 VBMBSL CBAT- VBMBSL (19,Y-B) (17,G-W) (335,LG) + CHGMS FAN - (130,BR) PBCPU VRAT1 GND (43,B-Y) KYSAT + DCH (128,R) VBMBSL + 7V F6 AMD SOLST (124,Y-P) P2 P9 LED2 PBCPU P8 LED1 3TON(80V) V SW3 N1 W SW2 (152,BR-R) - - (125,Y-G) (19,Y-B) SW1 N2 (126,Y-B) F7 STMP (N2,W-B) (N2,W-B) PSACC+ SOLCOM SOLCOM LIFT LEVER LED4 LSST CUP AMP VRAL2 LED3 F4 (101,GR) P16 (127,Y-R) F5 (41,G) SOLTPS SOLA1PL SOLA1PS SOLA2PL SOLA2PS LED2 P0 P15 + LED1 48V CUF V U (121,G) P4 W (80,LG-R) SW3 F1 RCP SSP - SW2 P3 P14 (122,Y) N1 U VRAL1 MSCH W1 (97,R-W) + SW1 THR P3 IPL1 CHGACR W MB VRTA (123,O) MSCH CS BRAKE2 CHGACS CUP SOLTPL (1,B-W) TF P1 BRAKE1 CBAT+ SWTT SOLLPS (98,B-L) SOLLPL (99,V-Y) + FCH KYSAT CANGND (146,V-) CAN1L (145,P-) CAN1H (88,GR-R) STPM+ (89,R-W) SETP1 STPM (81,GR-G) SSP+ (82,R-B) SETPSSP1 B VBBA T (334,L-O) A (19,Y-B) CH (41,G) B DETAIL RY1- ACCEL1 (18,R-B) A DETAIL UICL (N2,W-B) CH (98,V-Y) RCP FAN+ (101,GR) FAC VRB FNDC V1 F4 (43,B-Y) ACCEL2 VBMB U1 V (41,G) FNDC (44,R-B) SPL F5 RY1 B80V U S F6 VBBT R P3 P3 P4 VBMB VBKY VBBT B48V F1 F7 BATT 80V VRA P3 (V) 60Hz 200 210 220 50Hz 200 210 220 (V) MB BATT 48V 15-32 www.truck-freeworkshop.com WIRING DIAGRAM WIRING DIAGRAM No P1 CS P2 ATT2 LEVER SWK VRH SST PBCPU SWHS TF SOLT DIAGNOSIS TEN KEY C DETAIL DISPLAY SWTT SWK PSFN FAN G85714011_ www.truck-freeworkshop.com WIRING DIAGRAM No.2 WIRING DIAGRAM No.3 P2 F8 (231,Y-R) CH TF MSCH DCH FCH SWTT BATT F1 F4 F5 F6 F7 AMD AMP SOLLPL SOLLPS SOLTPL SOLTPS SOLA1PL SOLA1PS SOLA2PL SOLA2PS SOLST SOLL SOLT VRAL1 VRAL2 VRAT1 VRAT2 VRAAT11 VRAAT12 VRAAT21 VRAAT22 CUD CUP SLL PBCPU MB SST SPL IPL1 IPL2 VRATA VRH VRTA VRB VRA SSP SSD STMP STDM CS SWK P2(48V) P0(80V) TO CONTACTOR PANEL F5 (41,G) F4 (101,GR) (43,B-Y) F10 (187,R-L) LSST SWW HRY TRY (116,LG) (115,P) SWL SWL (108,R-Y) (109,G-Y) BZ (188,B) MWSH (188,R) OUT- OUT+ MWIP F9 (48,L-O) (189,B-Y) (235,B) SWWSH LBU-R SWRG DC/DC(for 48V) SA (189,B) SA SWF LF-RR CHIR H LF-L CHIF (236,R) LF-LR LF-R LR TO N2 (186,B) (119,Y-R) FRY (110,L-O) SA (103,R-W) SWH GSRY (234,R-W) LST-R (232,L-R) PLW IN+ LH-R IN- LT-R DSFO (233,W-R) LC-R DSBU (185,B) LST-L RESISTOR LW (185,R-L) LH-L SWWIP LT-L (186,R-L) LC-L RESISTOR (102,G-R) (111,R-L) (104,G-R) (107,R-B) HS (118,L-Y) TO CONTACTOR PANEL 15-33 12V POWER TAKE OFF (N2,W-B) G85714012_ CHARGER TRANSFORMER MAGNET SWITCH,CHARGER DIODE,CHARGER FUSE,CHARGER SWITCH,TRANS,THERMO BATTERY FUSE,DRIVE FUSE,LAMP FUSE,CONTROL CIRCUIT FUSE,CONTROL CIRCUIT FUSE MOTOR,DRIVE MOTOR,PUMP SOLENOID,LIFT PULL SOLENOID,LIFT PUSH SOLENOID,TILT PULL SOLENOID,TILT PUSH SOLENOID,ATT1 PULL SOLENOID,ATT1 PUSH SOLENOID,ATT2 PULL SOLENOID,ATT2 PUSH SOLENOID,STEERING SOLENOID,LIFT SOLENOID,TILT VARI-OHM,LIFT,NO.1 VARI-OHM,LIFT,NO.2 VARI-OHM,TILT,NO.1 VARI-OHM,TILT,NO.2 VARI-OHM,ATTACHMENT1,NO.1 VARI-OHM,ATTACHMENT1,NO.2 VARI-OHM,ATTACHMENT2,NO.1 VARI-OHM,ATTACHMENT2,NO.2 CONTROL UNIT,DRIVE CONTROL UNIT,PUMP SENSOR,LIQUID LEVEL PRINT BOARD,COMPUTER CONTACTOR,BATTERY SENSOR,STEERING SENSOR,PRESSURE LIFT SENSOR,IMPACT,NO.1 SENSOR,IMPACT,NO.2 VARI-OHM,TTIRE ANGLE VARI-OHM,HEIGHT VARI-OHM,TILT ANGLE VARI-OHM,BRAKE VARI-OHM,ACCEL SENSOR,SPEED,PUMP SENSOR,SPEED,DRIVE SENSOR,TEMPERATURE PUMP SENSOR,TEMPERATURE DRIVE SENSOR,CURRENT DSR DSF LSHL LSS SWBK SWP SWMH SWHS SWNT SWK RCP UICL PSFN DSBU DSFO LSST SWRG SWH SWL SWF SWW SWWIP SWWSH MWIP MWSH PLW LW LR CHIF CHIR BZ DC/DC LR-R LST-R LST-L LF-R LF-RR LF-L LF-LR LT-R LT-L LH-R LH-L LC-R LC-L H SA HRY TRY FRY GSRY DIRECTION SWITCH,REVERSE DIRECTION SWITCH,FOWARD LIMIT SWITCH,HEIGHT LIMIT LIMIT SWITCH,SEAT SWITCH,BRAKE SWITCH,PARKING BRAKE SWITCH,MAST HEIGHT SWITCH,HEIGHT SELECTOR SWITCH,NEUTRAL TILT SWITCH,KEY RESISTOR,CURRENT PROTECT UNIT,INRUSH PROTECT POWER SOURCE,FAN(80V) DIRECTION SWITCH,BACK-UP DIRECTION SWITCH,FOWARD(OPT) LIMIT SWITCH,STOP LAMP SWITCH,HORN,REAR ASSIST GRIP SWITCH,HORN SWITCH,LIGHT SWITCH,FLASHER SWITCH,WORKING LAMP SWITCH,WIPER SWITCH,WASHER MOTOR,WIPER MOTOR,WASHER PILOT LAMP,WORKING LAMP,WORKING LAMO,ROTARY CHIME,FORWARD CHIME,REVERSE BUZZER DC/DC CONVERTER LAMP,BACK-UP RH LAMP,STOP RH LAMP,STOP LH LAMP,FLASHER RHG LAMP,FLASHER RH REAR LAMP,FLASHER LH LAMP,FLASHER LH REAR LAMP,TAIL RH LAMP,TAIL LH LAMP,HEAD RH LAMP,HEAD LH LAMP,CLEARANCE RH LAMP,CLEARANCE LH HORN SURGE ABSORBER RELAY,HEAD LAMP RELAY,TAIL LAMP RELAY,FLASHER RELAY,GRIP SWITCH G85714013_ www.truck-freeworkshop.com Published by 1st Printing: Jan 2012 Pub No CE349 Printed in Japan DA www.truck-freeworkshop.com