Toyota 8FGDU15-32, 8FGCU15, 8FGCU20-32, 18, SU20 Wiring Diagram

WIRING DIAGRAM

8FG(D)U15-32, 8FGCU20-32

CHAPER 1 INTRODUCTION	E1
CHAPTER 2 ELECTRICAL WIRING ROUTING AND RELAY LOCATION	E2
CHAPTER 3 SYSTEM CIRCUITS	E3
CHAPTER 4 GROUND POINTS	E4
CHAPTER 5 FUSES FOR POWER SUPPLY	E5
CHAPTER 6 CONNECTOR LIST	E6
8FGCU15, 18, SU20
CHAPTER 7 ELECTRICAL WIRING ROUTING AND RELAY LOCATION	E7
CHAPTER 8 SYSTEM CIRCUITS	E8
CHAPTER 9 GROUND POINTS	E9
CHAPTER 10 FUSES FOR POWER SUPPLY	E10
CHAPTER 11 CONNECTOR LIST	E11

E1-1

INTRODUCTION

CHAPTER 1 INTRODUCTION	E1
CHAPTERS OF THIS SECTION..........................................................................	E1-2
HOW TO READ CHAPTERS
Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS	E1-3
ELECTRICAL WIRING ROUTINGS ..........................................................
RELAY LOCATIONS
JUNCTION BLOCK (J/B) / RELAY BLOCK (R/B)...................................	E1-4
Chapter 3 SYSTEM CIRCUITS	E1-6
POWER SUPPLY CIRCUIT......................................................................
REFERENCE PAGE.................................................................................	E1-10
Chapter 4 GROUND POINTS	E1-11
GROUND POINTS ...................................................................................
Chapter 5 FUSES FOR POWER SUPPLY	E1-11
FUSES FOR POWER SUPPLY ................................................................
Chapter 6 CONNECTOR LIST	E1-12
CONNECTOR LIST ..................................................................................
WIRE TO WIRE.......................................................................................	E1-13
ABBREVIATIONS .............................................................................	E1-14
GLOSSARY OF TERMS AND SYMBOLS........................................	E1-15

E

E1-2

INTRODUCTION

CHAPTERS OF THIS SECTION

This section consists of the following 6 chapters:

Chapter 1 INTRODUCTION		Gives brief explanation of each chapter, provides instructions on how
		to use this manual, and defines the abbreviations used in the electrical
		circuit diagrams.
Chapter 2 ELECTRICAL WIRING		Electrical wiring routings show installation positions, ground points,
	ROUTINGS and	connector numbers, and part names related to wire harnesses,
	RELAY LOCATIONS	connectors, relay blocks and junction blocks used in the forklift, such as
		in the engine room, instrument panel and mast area.
		Relay locations show design drawings and internal circuit diagrams
		related to relays, relay blocks (R/B), junction blocks (J/B), fusible links
		(F/L) and junction connectors (J/C).
Chapter 3	SYSTEM CIRCUITS	Show power supply circuit diagrams and wiring diagrams for each
		system, such as the engine.
		(Only wiring information for complete circuits is shown.)
Chapter 4	GROUND POINTS	Show related systems for each ground point.
Chapter 5	FUSES FOR POWER	Show power distribution from each power supply (fuse or fusible link) to
	SUPPLY	various systems.
Chapter 6	CONNECTOR LIST	Shows shapes and part numbers of connectors used in electrical wiring
		routings and electrical wiring diagrams.

E1-3

INTRODUCTION

HOW TO READ CHAPTERS

Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS ELECTRICAL WIRING ROUTINGS

Electrical wiring routings show installation positions, ground points, connector numbers, and part names related to wire harnesses, connectors, relay blocks and junction blocks used in the forklift.

(Connector codes are the same as those used in the electrical wiring diagrams.)

E2-10		ELECTRICAL WIRING ROUTINGS
FRONT BODY
	C SIDE RH
	WIRE			G ENGINE WIRE
						1 ENGINE ROOM RELAY BLOCK
				to E2-2	A24
	AC1	to E2-16
AA1	to E2-4		A57
AC3		A48	A37				to E2-14
		A40
AG3			A38
			A46
AC2		A47				A25
A42			A45
A54		D1
AD
	A55	to E2-8
	DA1
				AC			O LH SIDE WIRE
			AB
		AA
	D TC HEAT GAUGE WIRE							J/B
			A BODY MAIN WIRE
								1A
							G29
						A65	AG1	1B
								A55
								1C
					A27	DA1		1D
					G27			1E
					G28
					AO2
	A29		A34		AO1
		A30						G73
		A31
		A33	A32				AO3	A66

E2-11

ELECTRICAL WIRING ROUTINGS

A24	FUSIBLE LINK BLOCK ASSY						AA		FRONT PLATE LEFT OUTSIDE EARTH
A25	DIAGNOSIS
A27	JUNCTION CONNECTOR						AB		FRONT PLATE LEFT OUTSIDE EARTH
A29	CAN JOINT CONNECTOR
A30	CAN JOINT CONNECTOR						AC		FRONT PLATE LEFT OUTSIDE EARTH
A31	CAN JOINT CONNECTOR
A32	CAN JOINT CONNECTOR						AD		TRANSMISSION UPPER
A33	CAN JOINT CONNECTOR
A34	CAN JOINT CONNECTOR
A37	LPG WARNING RELAY
A38	LPG WARNING BUZZER
A40	BACK UP LAMP SWITCH
A42	TILT ANGLE SENSOR
A45	MATCHING CONNECTOR
A46	MATCHING CONNECTOR
A47	SHIFT SOLENOID(2)
A48	SHIFT SOLENOID(2)
A54	SHIFT SOLENOID(1)
A55	SHIFT SOLENOID(1)
A57	TO PUSH PULL RELAY
A65	JUNCTION CONNECTOR (A)
A66	JUNCTION CONNECTOR (B)
D1	T/C OIL TEMPERATURE SENSOR
G27	ENGINE ECU
G28	ENGINE ECU
G29	JUNCTION CONNECTOR (B)
G73	JUNCTION CONNECTOR (A)
1A
1B	BODY MAIN WIRE to J/B
1C
1D	ENGINE WIRE to J/B
1E	LH SIDE WIRE to J/B
	BODY MAIN WIRE to BODY MAIN WIRE
AA1
AC1
	BODY MAIN WIRE to SIDE RH WIRE
AC2
AC3
AG1	BODY MAIN WIRE to ENGINE WIRE
AG3
AO1
	BODY MAIN WIRE to LH SIDE WIRE
AO2
AO3
	T/C HEAT GAUGE WIRE to BODY MAIN WIRE
DA1

[A] Title

Indicates a location on the forklift. [B] Wire harness

Indicates a wire harness name.

[C]Reference page for electrical wiring routing Indicates a reference page showing a wire harness location when the wire harness continues to the different electrical wiring routing.

[D]Junction block

Indicates a junction block name and a connector code to be connected.

[E] Junction block connector

Indicates a connector code connected to a junction block.

[F]Wire harness and junction block connection Indicates a junction block name and a wire harness name to be connected.

[G] Ground point code

Indicates a ground point code. [H] Ground point name

Indicates a ground point name. [I] Harness to harness connector

Indicates a connector code that joins two wire harnesses.

[J] Wire harness names

Indicate two wire harness names for a wire harness and wire harness connection.

[K] Part connector

Indicates a connector code connected to a part. [L] Part name

Indicates a part name connected to a connector.

E

E1-4

INTRODUCTION

RELAY LOCATIONS

Relay locations show connectors connected to junction blocks, relays, fuses and internal circuit diagrams.

E2-20				RELAY LOCATIONS
JUNCTION BLOCK:LEFT STEP(INNER CIRCUIT SEE PAGE E2-24)
	1A											BLACK 1B
90980-12506
	18	1										90980-12383
												19		1
	19	2
	20	3										20		2
	21	4										21		3
	22	5										22		4
	23	6										23		5
	24	7										24		6
	25	8										25		7
	26	9										26		8
27 10												27		9
28 11												28 10
29 12												29 11
30 13												30 12
31 14												31 13
32 15												32 14
33 16			T/C FR RELAY									33 15
34 17								1	19			34 16
				3		1	18			1	18	35 17
								2	20			36		18
				5		2	19			2	19
								3	21
						3	20			3	20
			1	4	2			4	22
						4	21			4 21		1C
								5	23
						5	22	6	24	5	22	90980-12320
						6 23				6	23
						7	24	7	25	7	24
				3				8	26			18		1
						8	25			8	25
				5				9	27			19		2
						9	26			9	26
			1	4	2	10	27	10	28	10	27	20		3
								11	29			21		4
						11	28			11	28
								12	30			22		5
						12	29			12	29
			T/C RR RELAY					13	31			23		6
						13 30				13	30
						14	31	14	32	14	31	24		7
								15	33			25		8
						15	32			15	32
								16	34			26		9
						16	33			16	33
								17	35			27		10
						17 34				17	34
								18 36				28 11
												29 12
					WORK LP RELAY BCON LP RELAY							30 13
			32 16									31 14
												32 15
			31 15			3		3
												33 16
			30 14			5		5
												34 17
			29 13
						1	2	1	2	24 12
			28 12									1D
			27 11							23	11
												90980-12308
			26 10							22 10
			25	9		1				21	9	12	24
			24	8			5	3		20	8
												11	23
			23	7						19	7
						2						10	22
			22	6						18	6
			21	5		HORN RELAY				17	5	9	21
1E			20	4						16	4	8	20
							2					7	19
			19	3						15	3
90980-12311
			18	2				3		14	2	6	18
			17	1						13	1	5	17
16	32						1					4	16
15 31												3	15
14 30						FLASHER RELAY						2	14
13 29												1	13
12 28
11 27
10 26
9	25
8	24
7	23
6	22
5	21
4	20
3	19
2	18
1	17
E2-24

										E2-21
1 ENGINE ROOM R/B:ENGINE ROOM LEFT
* 1:15A E-THRO (4Y-E)
7.5A ECU-B2 (1DZ, 2Z)
* 2:7.5A (1DZ, 2Z)
15A (4Y-E)
* 3:DPF RELAY (1DZ, 2Z)			SPARE		30A		BLR	1	25A	2
15A (4Y-E)
* 3:DPF RELAY (1DZ, 2Z)			SPARE		7.5A		STA	1	30A	2
EFI MAIN RELAY (4Y-E)
* 4:C/OPN RELAY (4Y-E)
ASC RELAY (1DZ, 2Z)		HOUR MET		2	7.5A	1	RR WIP	1	20A	2
* 5:EFI (4Y-E)
DPF (1DZ, 2Z)			ST	2	7.5A	1	FR WIP	1	20A	2
		GAUGE		2	10A
						1		1	2
*3		BACK LP		2	10A			40AAM1
1
			SFT	2	7.5A	1
5	3
2			TURN	2	7.5A	1
	2		IGN	2	*2	1
3	5						HORN	1	15A	2
	1		SPARE		15A
	*4						CDS	1	15A	2
DOUBLE HORN RELAY							*5	1	15A	2
			SPARE		10A
1		ECU-IG		2	10A	1	ALT-S	1	7.5A	2
5	3						STOP	1	7.5A	2
2
	2						ACC-B	1	7.5A	2
							TAIL
3	5							1	7.5A	2
	1
LPG MAIN RELAY							ECU-B	1	7.5A	2
		AM2 RELAY					*1	1		2
		1					HTR	1	15A	2
		5	3
		2					WORK LP	1	15A	2
			2				HEAD	1	15A	2
		3	5
			1					1	2
		ST RELAY
								40AAM2

JUNCTION BLOCK (INNER CIRCUIT) (1/3)

	13	1C			1	1D
	31	1A			14	1D
	33	1B	BCON LP RELAY		15 1D
	15	1E	5	3	32	1A
	15	1B	1	2	16	1E
					16	1B
	23	1E
					28	1B
	25	1E
					24	1E
	13	1A	WORK LP RELAY
	15	1C	5	3	13	1E
	9	1E	1	2	31	1B
	19	1B			29	1B
	36	1B			10	1E
	19	1E			4	1A
				4
				3	5	1A
	8	1B	1	2	7	1A
	3	1B	T/C FR RELAY		13 1D
	17	1B			2	1E
	22	1E			3	1A
	18	1E		4
				3	2	1A
	34	1B
					1	1B
	18	1D	1	2
					19	1A
	11	1C	T/C RR RELAY
					11	1E
				3
	28	1C	1		35	1B
	26	1B		2	7 1D
	22	1B
			FLASHER RELAY		8 1D
	24	1A
					21	1E
	25	1B
					33 1C
	23	1B
					29 1C
	3	1C
					12	1A
	4	1C
					30 1C
	21	1A
	2	1C

E1-5

INTRODUCTION

[A] Junction block /relay block

Indicates a junction block or relay block name, its location and a reference page for an internal circuit diagram.

[B] Connector code and color

Indicates the code and color of a connector connected to a junction block. [C] Connector part number

Indicates the part number of a connector. [D] Connector shape and terminal number

Indicates a connector shape on the junction block side. Numbers indicate terminal numbers.

[E] Connector shape and terminal number

Indicates a connector shape on the wire harness side. Numbers indicate terminal numbers.

[F] Fuse

Indicates a fuse name and capacity.

Terminal 1 is on the primary side and terminal 2 is on the secondary side. [G] Internal circuit diagram

Indicates an internal circuit diagram of a junction block. [H] Connector code and terminal number

Indicates a connector code and a terminal number connected to a junction block.

E1-6

INTRODUCTION

Chapter 3 SYSTEM CIRCUITS (1) SYSTEM CIRCUITS

A system circuit consists of a power source circuit diagram and respective system circuit diagrams. A power source circuit diagram shows the connections from the power source to fuses. A system diagram shows the connections from fuses to ground points of each system.

E3-12

ENGINE CONTROL (4Y-E)

a b c

d e f g

h i j

k l m n

B-Y LG LG-R

O R-W R-L R-L

JUNCTIONCONNECTOR

R-L R-L R-L

R-B L-B R-L W-B

*1

*2

*1

*1

*3

*1

LAMP

A66

*1

7

6

R-L

R-L

GASOLINE LPG INDICATORGASOLINEWITH CNG

89

543

AC29

*1

R-L

R-L

R-L

R-L

(LPG)

R-W

R-L

1:

3:

(GASOLINE)

2

2:    4:

R-B

* * * *

10B

1

121D

41D

R-L

R-L

*1

B

R-W

12

LPGCHANGESWITCH

T6

*1

L

A

AC3

4 R-

R-W

R-W

R-W

R-W

7

A1B5 A8

3

TC21 TC22

6 3

GAS LPG

73(B)65(A),GA  CONNECTORJUNCTION(A)

R-B

AC3

IG

R-B

R-B

R-B

4

*3

(GASOLINE)

R-B

R-B

*2

A

B

R-B

2

6

R-B

*2 *4

*4

*2 *4

*2 *4

*2

*4

Y-B

73(B)65(A),GA  CONNECTORJUNCTION (A)

B2 1 B

*1

GK1

GK2

*2

1 A

1 B

2 A

2 B

*1

GK1

GK2

*1

(BAT)

15A EFI

2

1

B-Y

W-R

*1

Y

Y

L-B

L-B

GG

GK18

1

2

GK12

7 7

OIL PRESSURE SWITCH (*2)

6 6

K 5(B    )

OIL PRESSURE SWITCH (*1)

K1(A  )

*2

*2

*2

*2

Y

Y

(MAIN)

W-B

W-B

*1

LPGSOLENOID

E1-7

INTRODUCTION

[A] Section page

Indicates the page number for the section. [B] System title

Indicates a system name. [C] Part name and connector code

Indicates a part name and connector code to be connected.For connector shapes, refer to chapter 6 CONNECTOR LIST.

C7 Part connector

The wire harness in which the connector is located.

Example: "C" indicates a connector used in the C wire harness.

For wire harness names, refer to Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS.

Serial number allocated to the connector

D11 (A), D42 (D)

Connector number

Used to indicate different connectors when multiple connectors are connected to a part, or multiple types of connectors are used according to specifications.

[D] Fuse

Indicates a fuse name and capacity.

Terminal 1 is on the primary side and terminal 2 is on the secondary side.

For fuse installation positions, refer to chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS.

[E] Power supply information

Indicates the ignition key position when power is supplied to a fuse.

[F] Specification information

Indicates that connectors or wire colors vary depending on forklift models, engine types or specifications.

[G] Page-to-page connection code

Indicates a wire harness continues onto the following page from the matching code.

[H] Harness to harness connector

Indicates a connector code that connects two wire harnesses.

For the connector shape, refer to chapter 6 CONNECTOR LIST.

Harness to harness connector

8 Terminal number

AK1

Wire harness to be connected Example: "AK" means a connection of the female connector*1 of the "A" wire and the male connector*2 of the "K" wire.

*1: A female connector has a female

 terminal.

*2: A male connector has a male

 terminal.

Serial number of a connector

Male terminal side

E1-8

INTRODUCTION

Chapter 3 SYSTEM CIRCUITS (2)

E3-12

ENGINE CONTROL (4Y-E)

a b c

d e f g

h i j

k l m n

B-Y LG LG-R

O R-W R-L R-L

JUNCTIONCONNECTOR

R-L R-L R-L

R-B L-B R-L W-B

*1

*2

*1

*1

*3

*1

LAMP

A66

*1

7

6

R-L

R-L

GASOLINE LPG INDICATORGASOLINEWITH CNG

89

543

AC29

*1

R-L

R-L

R-L

R-L

(LPG)

R-W

R-L

1:

3:

(GASOLINE)

2

2:    4:

R-B

* * * *

10B

1

121D

41D

R-L

R-L

*1

B

R-W

12

LPGCHANGESWITCH

T6

*1

L

A

AC3

4 R-

R-W

R-W

R-W

R-W

7

A1B5 A8

3

TC21 TC22

6 3

GAS LPG

73(B)65(A),GA  CONNECTORJUNCTION(A)

R-B

AC3

IG

R-B

R-B

R-B

4

*3

(GASOLINE)

R-B

R-B

*2

A

B

R-B

2

6

R-B

*2 *4

*4

*2 *4

*2 *4

*2

*4

Y-B

73(B)65(A),GA  CONNECTORJUNCTION (A)

B2 1 B

*1

GK1

GK2

*2

1 A

1 B

2 A

2 B

*1

GK1

GK2

*1

(BAT)

15A EFI

2

1

B-Y

W-R

*1

Y

Y

L-B

L-B

GG

GK18

1

2

GK12

7 7

OIL PRESSURE SWITCH (*2)

6 6

K 5(B    )

OIL PRESSURE SWITCH (*1)

K1(A  )

*2

*2

*2

*2

Y

Y

(MAIN)

W-B

W-B

*1

LPGSOLENOID

E1-9

INTRODUCTION

[I] Terminal number

Indicates a terminal number of a connector to be connected.

[J] Junction block connector

Indicates a connector code connected to a junction block.

For a connector shape, refer to chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS.

Junction block connector

Inside of a junction block

Junction block type

Serial number allocated to the connector. Example: "1B" indicates connector B in the center junction block.

Terminal number

A number inside indicates a relay block or fuse block.

For shapes, refer to chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS.

[K] Ground point code

Indicates a ground point code.

For ground point positions, refer to chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS.

[L] Wire color

Indicates a wire harness color.

When two alphabetical codes are indicated, for example "W-B", the first letter indicates the basic wire color and the second letter indicates the color of the stripe.

Code	Wire Color		Code	Wire Color		Code	Wire Color
B	Black		L	Blue		SB	Sky Blue
BR	Brown		LG	Light Green		V	Violet
DG	Dark Gray		O	Orange		W	White
G	Green		P	Pink		Y	Yellow
GR	Gray		R	Red		AM	Amber

Example : W-B	W	B
	(White)	(Black)

[M] Switch

Circuit diagrams are shown with the switches in the OFF position.

For switch operation conditions, refer to the repair manual.

Ground point code

Wire harness connected to the ground point

A ground point is indicated by an alphabetical code.

Example: "MJ" indicates that the M wire harness is grounded at point J.

E1-10

INTRODUCTION

REFERENCE PAGE

PARTS

Code		See Page	Code	See Page	Code		See Page	Code	See Page
A 20		E2-8	G 7	E2-2	G 21		E2-2	K 6	E2-2
A 25		E2-10	G 8	E2-2	G 25		E2-2	O 2	E2-14
A 27		E2-10	G 9	E2-2	G 26		E2-2	Q 1	E2-8
A 35		E2-10	G 10	E2-2	G 27		E2-10	S 12	E2-14
A 36		E2-10	G 11	E2-2	G 28		E2-10	T 6	E2-16
A 65		E2-10	G 12	E2-2	G 29		E2-10	a 1	E2-8
A 66		E2-10	G 13	E2-2	G 73		E2-10
C 1		E2-16	G 16	E2-2	K 1		E2-2
C 3		E2-16	G 18	E2-2	K 2		E2-2
G 6		E2-2	G 19	E2-2	K 3		E2-2
RELAY BLOCK , JUNCTION BLOCK
Code		See Page		Relay Blocks Name or Joining Wire Harness and J/B
1		E2-10	Engine Room R/B
1C		E2-19	BODY MAIN WIRE to J/B
1D		E2-18	ENGINE WIRE to J/B
1E		E2-18	LH SIDE WIRE to J/B
WIRE TO WIRE
Code		See Page			Joining Wire Harness and Wire Harness
AC2		E2-10	BODY MAIN WIRE to SIDE RH WIRE
AC3		E2-10	BODY MAIN WIRE to SIDE RH WIRE
AG1		E2-10	BODY MAIN WIRE to ENGINE WIRE
AO1		E2-10	BODY MAIN WIRE to LH SIDE WIRE
Aa1		E2-8	BODY MAIN WIRE to SUB ACCEL WIRE
GK1		E2-2	ENGINE WIRE to ENGINE SUB WIRE
GK2		E2-2	ENGINE WIRE to ENGINE SUB WIRE
QA1		E2-8	INSTRUMENT PANEL WIRE to BODY MAIN WIRE
SO1		E2-14	REAR UPPER MAIN WIRE to LH SIDE WIRE
TC2		E2-16	REAR UPPER SUB RH WIRE to SIDE RH WIRE
TS1		E2-16	REAR UPPER SUB RH WIRE to REAR UPPER MAIN WIRE
EARTH
Code		See Page			Name
AB		E2-10	FRONT PLATE LEFT OUTSIDE EARTH
GF		E2-2	ENGINE UPPER EARTH
GG		E2-2	ENGINE UPPER EARTH
OK		E2-14	REAR PILLER LEFT UNDER EARTH

[A] Parts

Indicates pages showing electrical wiring routings for the parts. [B] Relay blocks and junction blocks

Indicates titles and pages showing electrical wiring routings for the relay blocks or junction blocks. [C] Connections of wire harness and wire harness

Indicates titles and pages showing electrical wiring routings for the connections of two wire harnesses. [D] Ground points

Indicates titles and pages showing electrical wiring routings for the ground points.

E1-11

INTRODUCTION

Chapter 4 GROUND POINTS

GROUND POINTS

These tables describe related systems for each ground point.

E4-2

GROUND POINTS

	CODE	GROUND POINT LOCATION	SYSTEM NAME	PAGE
			SAS/OPS SYSTEM	E3-36
			CLEARANCE LAMP	E3-72
			STOP LAMP	E3-76
	AA	FRONT PLATE LEFT OUTSIDE	STROBE LIGHT	E3-52
			TURN SIGNAL LAMP	E3-70
			BACK UP LAMP BUZZER	E3-74
			HEAD LAMP	E3-68
			POWER SHIFT TRANSMISSIN	E3-32
			SAS/OPS SYSTEM	E3-36
			ENGINE CONTROL (4Y-E)	E3-10
	AB	FRONT PLATE LEFT OUTSIDE	COOLER	E3-80
			CLEARANCE LAMP	E3-72
			COMBINATION METER	E3-54
			BACK UP LAMP BUZZER	E3-74
			WET BRAKE	E3-34
			DIAG	E3-42
			COOLER	E3-80
			STARTING	E3-6
			STROBE LIGHT	E3-52
			TURN SIGNAL LAMP	E3-70
	AC	FRONT PLATE LEFT OUTSIDE	HEATER	E3-78
			FRONT WIPER AND WASHER	E3-60
			HEAD LAMP	E3-68

Chapter 5 FUSES FOR POWER FUSES FOR POWER

These tables describe power distribution from each power supply (fuse or fusible link) to various systems.

E5-3

FUSE FOR POWER SUPPLY

FUSIBLE LINK BLOCK ASSY

		FUSE	SYSTEM	Page
	100A	GLOW	GLOW	E3-76
			INTAKE HEATER	E3-84
	120A	ALT	CHARGING	E3-96
	ENGINE ROOM R/B
		FUSE	SYSTEM	Page
	7.5A	ACC-B	OPS SYSTEM	E3-250
			SAS/OPS SYSTEM	E3-258
	7.5A	ALT-S	CHARGING	E3-194
	7.5A	ECU-B	SAS/OPS SYSTEM	E3-234
			BACK UP LAMP BUZZER	E3-220
	10A	BACK LP	REAR WORKING LAMP	E3-204
			STROBE LIGHT	E3-182
			GLOW	E3-162
			INTAKE HEATER	E3-166

E1-12

INTRODUCTION

Chapter 6 CONNECTOR LIST

CONNECTOR LIST

E6-3

													CONNECTOR LIST
				A 43								A 44							A 45						A 46			A 47
																			DARK GRAY						DARK GRAY			DARK GRAY
1	2	3	4	5	6	7	8	9	1	2	3			4	5		6		1	2					2	1		1	2
									7	8	9	10	11	12	13	14
																												3	4
10	11	12	13	14	15	16	17	18											90980-11162
																								90980-11168
											90980-10807
																											90980-10942
			90980-11594
A 48						A 49			A 50								A 51						A 52				A 53
DARK GRAY						BLACK			BLACK								GRAY										BLACK
2	1					1	2		1	2						4	3	2	1			4	3	2	1		1	2
4	3					90980-11235			90980-11051							8	7	6	5			8	7	6	5		90980-11051
90980-10941																90980-10896						90980-10890
A 54						A 55			A 56							A 57				A 58						A 59			A 60
GRAY						GRAY			BLACK							GRAY				GRAY									BLACK
1	2					1	2		2	1						1	2		1	2	3					1			1	2
															90980-11051				90980-11296							2		90980-11162
90980-10899						90980-10899			90980-11168
																									90980-10213
				A 64								A 65							A 66								A 67
												BLACK							BLUE

[A] Connector shape and terminal number

Indicates the connector shape on the wire harness side, which is connected to a part. Numbers indicate terminal numbers that are used in the circuit diagrams.

[B] Connector color

Indicates a connector color. [C] Part connector

Indicates a connector number connected to a part.

The code is the same as that used in the electrical wiring routing. [D] Connector part number

Indicates the part number of a connector.

E1-13

INTRODUCTION

HARNESS TO HARNESS CONNECTOR

E6-13

WIRE to WIRE

SO3

ST1

SV1

SW1

BLACK

GRAY

1	2		2	1				1	2				1			2		2			1			1	1
										2	1		3	4	5	6
3	4		4	3				3	4									6	5	4	3		2	3
										4	3														3	2
													90980-10797
90980-11036								90980-10795															90980-10980
																		90980-10796							90980-10979
			90980-11035
										90980-10794
			SW2									Sx1
	GRAY
1	2		3	3			2	1		1	2		1
													99144-12239
4	5	6 7	8
				8	7	6	5	4
	90980-10799									90980-10906
					90980-10798
							TC1													TC2					TS1
																		DARK GRAY
1	2	3	4	5	6			6	5	4	3	2	1			1	2	3			3	2	1		1	1

[A] Connector shape and terminal number

Indicates the connector shape that connects two wire harnesses.

On left: Female connector*1 shape (This example indicates a connector for the G wire) On right: Male connector*2 shape (This example indicates a connector for the K wire)

*1: A female connector has a female terminal. *2: A male connector has a male terminal.

B] Connector color

Indicates a connector color. [C] Harness to harness connector

Indicates a connector code that connects two wire harnesses

The code is the same as that used in the electrical wiring routing and wiring diagram. [D] Connector part number

Indicates the part number of a connector

E1-14

INTRODUCTION

ABBREVIATIONS

The following abbreviations are used in this section.

Abbreviations	Explanation
ASC	Auto Speed Control
ASSY	Assembly
CNG	Compressed Nutural Gas
DPF	Diesel Particulate Filter
ECU	Electronic Control Unit
FR	Front
J/B	Junction Block
LH	Left-Hand
LPG	Liquefied Petroleum Gas
M/T	Manual Transmission
OPS	Operator Presence Sensing
PS	Power Steering
R/B	Relay Block
RH	Right-Hand
RR	Rear
SAS	System of Active Stability
SOL	Solenoid
SPEC.	Specification
T/C	Torque Converter & Transmission
W/	With
W/O	Without

E1-15

INTRODUCTION

GLOSSARY OF TERMS AND SYMBOLS

BATTERY	GROUND	RELAY	SWITCH, MANUAL
		1. NORMALLY	1. NORMALLY
		CLOSED	OPEN
CAPACITOR	HEADLIGHTS
(Condenser)		2. NORMALLY	2. NORMALLY
	1. SINGLE
		OPEN	CLOSED
	FILAMENT
CIGARETTE LIGHTER		RELAY, DOUBLE THROW	SWITCH, DOUBLE THROW
	2. DOUBLE
	FILAMENT
DIODE	HORN	RESISTOR, TAPPED	SWITCH, IGNITION

DIODE, ZENER

LIGHT

SENSOR (Termistor)

LED	METER, ANALOG	SENSOR	SWITCH, WIPER PARK
(Light Emitting Diode)

PHOTODIODE

METER, DIGITAL

SHORT PIN

WIRES

1. NOT

CONNECTED

MOTOR

RESISTOR

FUSE

2. SPLICED

SPEAKER		RESISTOR,			SOLENOID			HIGH-TENSION WIRE
		VALIABLE or RHEOSTAT

TRANSISTOR

MEMO

E2-1

CHAPTER 2 ELECTRICAL WIRING ROUTINGS AND

RELAY LOCATIONS

E2

ELECTRICAL WIRING ROUTINGS

ENGINE ROOM (4Y-E)	..................................................................... E2-2
ENGINE ROOM (1DZ) .......................................................................	E2-4
INSTRUMENT PANEL ......................................................................	E2-6
FRONT BODY ...................................................................................	E2-8
MAST AREA ....................................................................................	E2-10
REAR BODY (NO.1) ........................................................................	E2-12
REAR BODY (NO.2) ........................................................................	E2-14

RELAY LOCATIONS

JUNCTION BLOCK (J/B) / RELAY BLOCK (R/B) ...........................

E2-16

SYMBOLS	WIRE NAME	SYMBOLS	WIRE NAME
A	BODY MAIN WIRE	T	RR UPR SUB RH WIRE
B	BODY SUB NO.1 WIRE	U	HEAD GUARD SW WIRE
C	SIDE RH WIRE	X	HOOD MAIN WIRE
D	T/C HEAT GAUGE WIRE	Y	HOOD SUB NO.1 WIRE
G	ENGINE WIRE	Z	RR LWR WIRE
H	BATTERY STARTER WIRE	a	SUB ACCEL WIRE
I	BATTERY EARTH WIRE	b	MAST SENSOR WIRE
J	ENGINE EARTH WIRE	d	FR STAY WIRE LH
K	ENGINE SUB WIRE	g	CNG PRESSURE SENSOR WIRE
M	LPG PRESSURE SWITCH WIRE	h	WIPER SUB WIRE
O	SIDE LH WIRE	i	DIGITAL METER WIRE
Q	INSTRUMENT PANEL WIRE	j	INSTRUMENT PANEL SW WIRE
R	FR STAY WIRE RH	k	EZ PEDAL LIMIT SW WIRE
S	RR UPR MAIN WIRE	m	INSTRUMENT PANEL WIRE

E2-2

ELECTRICAL WIRING ROUTINGS

ENGINE ROOM(4Y-E)

G80

H BATTERY STARTER WIRE

G24	H3
to E2-8
G86
J ENGINE EARTH WIRE
J3
I1
GK1
GK2
I BATTERY EARTH WIRE
K ENGINE SUB WIRE	K1
IH

KM1

Kg1

K6 K3

K2

G76

G79

G78

G ENGINE WIRE

G77 G12

H1

G23

G22

G26

G13

J1

G25

G88

G14

K5

G21

G19	G16	GG
M1	G18
M2

g1

M LPG PRESSURE SWITCH WIRE

g CNG PRESSURE SENSOR WIRE

G11

G10

G6

G74

G9

G8

G4

G75

G2

GF

E2-3

ELECTRICAL WIRING ROUTINGS

	G2	ALTERNATOR	GK1	ENGINE WIRE to ENGINE SUB WIRE
	G4	ALTERNATOR	GK2
	G6	THROTTLE POSITION SENSOR(WITH MOTOR)	KM1	ENGINE SUB WIRE to LPG PRESSURE SWITCH WIRE
	G8	INJECTOR NO.1	Kg1	ENGINE SUB WIRE to CNG PRESSURE SENSOR WIRE
	G9	INJECTOR NO.2
	G10	INJECTOR NO.3
	G11	INJECTOR NO.4	GF	ENGINE UPPER EARTH
	G12	VACUUM SENSOR
	G13	FCM STEP MOTOR	GG	ENGINE UPPER EARTH
	G14	WATER TEMPERATURE SENDER
	G16	WATER TEMPERATURE SENSOR	IH	REAR PILLAR LEFT UNDER EARTH
	G18	G2 SENSOR
	G19	DISTRIBUTOR
	G21	IGNITION COIL
	G22	OIL PRESSURE SWITCH
	G23	STARTER
	G24	FUSIBLE LINK BLOCK ASSY
	G25	IGNITER
	G26	TACHO CHECK
	G74	LPG INJCTOR
	G75	ALTERNATOR
	G76	FUSIBLE LINK BLOCK-1
	G77	DISCONNECT SWITCH(BATT)
	G78	DISCONNECT SWITCH(ALT)
	G79	DISCONNECT SWITCH(ALT)
	G80	DISCONNECT SWITCH(BATT)
	G86	BATTERY
	G88	GASOLINE/LPG SWITCH
	H1	STARTER
	H3	BATTERY
	I1	BATTERY
	J1	STARTER
	J3	BATTERY
	K1	LPG SOLENOID(SLOW)
	K2	LPG RESISTOR
	K3	LPG SOLENOID(MAIN)
	K5	CNG SOLENOID
	K6	CNG RESISTOR
	M1	LPG PRESSURE SWITCH
	M2	LPG PRESSURE SWITCH
	g1	CNG PRESSURE SENSOR

E2-4

ELECTRICAL WIRING ROUTINGS

ENGINE ROOM(1DZ)

			G87
			G76
			G79
	G80
	JL		G78
J ENGINE EARTH WIRE	G33		G77
	H3	G36	G37
G24			G82
to E2-8			G83
			H2
GL
	J2		G84
H BATTERY STARTER WIRE			G85
I2			G30	G4
I BATTERY EARTH WIRE	G32		G17	G75
	G34			G1
			G14
	G31
IH			G22
	GJ

G ENGINE WIRE

E2-5

ELECTRICAL WIRING ROUTINGS

G1	ALTERNATOR
G4	ALTERNATOR
G14	WATER TEMPERATURE SENDER
G17	WATER TEMPERATURE SENSOR
G22	OIL PRESSURE SWITCH
G24	FUSIBLE LINK BLOCK ASSY
G30	GLOW PLUG
G31	INJECTOR PUMP
G32	STARTER
G33	GLOW PLUG RELAY
G34	FUEL CUT SOLENOID
G36	OPEN CLOSE SWITCH
G37	STEP MOTOR
G75	ALTERNATOR
G76	FUSIBLE LINK BLOCK-1
G77	DISCONNECT SWITCH(BATT)
G78	DISCONNECT SWITCH(ALT)
G79	DISCONNECT SWITCH(ALT)
G80	DISCONNECT SWITCH(BATT)
G82	GLOW PLUG NO.1
G83	GLOW PLUG NO.2
G84	GLOW PLUG NO.3
G85	GLOW PLUG NO.4
G87	FUSIBLE LINK BLOCK-2
H2	STARTER
H3	BATTERY
I2	BATTERY
J2	STARTER
GJ	JUNCTION BLOCK IN FRONT INSIDE EARTH
GL	JUNCTION BLOCK IN FRONT INSIDE EARTH
IH	REAR PILLAR LEFT UNDER EARTH
JL	FRONT PLATE LEFT INSIDE EARTH

E2-6

ELECTRICAL WIRING ROUTINGS

INSTRUMENT PANEL

A BODY MAIN WIRE	R FR STAY WIRE RH	b	MAST SENSOR WIRE
B BODY SUB NO.1 WIRE	U HEAD GUARD SW WIRE	d	FR STAY WIRE LH
Q INSTRUMENT PANEL WIRE	a SUB ACCEL WIRE	h	WIPER SUB WIRE
		i	DIGITAL METER WIRE
		j	INSTRUMENT PANEL SW WIRE
		m INSTRUMENT PANEL WIRE
		k EZ PEDAL LIMIT SW WIRE

		Ah1	h2	h1			to E2-10
	to E2-10				A20	Q2	QA1
		A80		A2
				A21		Q1
		A9		A23
	A7		h			Q	R
							U

A8								A49
d								A12
A69	hA1							A10
					to E2-10			A11
						b
A68		A41		A6				B
	A		A4		k1
		A1					AQ1
			A3
			A19	k	A87		A52
			A18			A86	A51	to E2-14
	to E2-8		A78			a1	A70
							A42
			Aa1
					Ak1

a

[W/ CNG DIGITAL METER]

	i2		i4				Q2
	i1	i3	Ai1			Q1
				j2	A15		A14

A10

Q1

j1

A12

j

A56

jA1	Q	A13
mA1
	AQ1	A11
AQ1
m		QA1
m1

E2-7

ELECTRICAL WIRING ROUTINGS

A1	HORN SWITCH	AQ1	BODY MAIN WIRE to INSTRUMENT PANEL WIRE
A2	IGNITION SWITCH		BODY MAIN WIRE to SUB ACCEL WIRE
		Aa1
A3	STEERING SENSOR		BODY MAIN WIRE to WIPER SUB WIRE
		Ah1
A4	LIGHT CONTROL SWITCH		BODY MAIN WIRE to DIGITAL METER WIRE
		Ai1
A6	STOP LAMP SWITCH		BODY MAIN WIRE to EZ PEDAL LIMIT SW WIRE
		Ak1
A7	BRAKE WARNING SWITCH		INSTRUMENT PANEL WIRE to BODY MAIN WIRE
		mA1
A8	OPS WARNING BUZZER		INSTRUMENT PANEL WIRE to BODY MAIN WIRE
		QA1
A9	PARKING BRAKE SWITCH		WIPER SUB WIRE to BODY MAIN WIRE
		hA1
A10	TILT SOLENOID		INSTRUMENT PANEL SW WIRE to BODY MAIN WIRE
		jA1
A11	LIFT SOLENOID
A12	UNLOAD SOLENOID
A13	TILT SWITCH
A14	LIFT SWITCH
A15	NEUTRAL TILT SWITCH
A18	PRESSURE SENSOR
A19	SPEED SENSOR
A20	SAS/OPS ECU
A21	SAS/OPS ECU
A23	MINI LEVER ECU
A41	LEFT T/C SHIFT SWITCH
A42	TILT ANGLE SENSOR
A49	HORN
A51	CONTROL VALVE PUSH SOLENOID
A52	CONTROL VALVE PULL SOLENOID
A56	BACK TILT SOLENOID
A68	WET BRAKE BUZZER
A69	WET BRAKE LAMP
A70	PRESSURE SWITCH
A78	EZ PEDAL DIRECTION SWITCH
A80	PARKING WARNING LAMP
A86	SHORT CONNECTOR
A87	SHORT CONNECTOR
Q1	COMBINATION METER
Q2	DISPLAY
a1	ACCEL SENSOR
h1	FRONT WIPER RELAY
h2	FRONT WIPER MOTOR
i1	CNG DIGITAL METER
i2	CNG DIGITAL METER
i3	CNG DIGITAL METER
i4	CNG DIGITAL METER
j1	INPANE SWITCH(+)
j2	INPANE SWITCH(-)
k1	ACCEL SWITCH
m1	12V POWER SUPPLY

E2-8

ELECTRICAL WIRING ROUTINGS

FRONT BODY

			G ENGINE WIRE
	C SIDE RH WIRE
			to E2-2
		to E2-14	to E2-4	A24
A76	A48

	A74	A75
		A47	DA1	A37	1	ENGINE ROOM R/B
	A73
			A38
	AC2		A46			to E2-12
			A45
					A25
	AC4		A82
	A54		A83			O SIDE LH WIRE

AD

A55

A84

D1

to E2-6

A85

D T/C HEAT GAUGE WIRE

AA

AB AC

A BODY MAIN WIRE

	AG4	A26	AG1	J/B
				1A
A79			G29
				1B
A71				1C
				1D
AO2				1E
A64				G73
AO1			A65
	A27	A81	A66
		AO3
			A36
			A35	G27
A32		[4Y-E]
A31				G28
A34
A29	A33

[1DZ W/O ASC]

AG2

G35

AG1

G43

[1DZ W/ ASC]

G39

AG2

G35

AG1

G38 G43

E2-9

ELECTRICAL WIRING ROUTINGS

A24

A25

A26

A27

A29

A31

A32

A33

A34

A35

A36

A37

A38

A45

A46

A47

A48

A54

A55

A64

A65

A66

A71

A73

A74

A75

A76

A79

A81

A82

A83

A84

A85

D1

G27

G28

G29 G35 G38 G39 G43 G73

FUSIBLE LINK BLOCK ASSY DIAGNOSIS

DIODE

JUNCTION CONNECTOR

CAN JOINT CONNECTOR CAN JOINT CONNECTOR CAN JOINT CONNECTOR CAN JOINT CONNECTOR CAN JOINT CONNECTOR ENGINE ECU

ENGINE ECU

LPG WARNING RELAY

LPG WARNING BUZZER

MATCHING CONNECTOR MATCHING CONNECTOR SHIFT SOLENOID2 SHIFT SOLENOID2 SHIFT SOLENOID1 SHIFT SOLENOID1

JUNCTION CONNECTOR(J) JUNCTION CONNECTOR(A) JUNCTION CONNECTOR(B) DIODE(WET BRAKE)

T/C INTERLOCK(FR) SHORT CONNECTOR(FR) T/C INTERLOCK(RR) SHORT CONNECTOR(RR) BUZZER DIODE PARKING LAMP DIODE FRONT SOLENOID RELAY REAR SOLENOID RELAY EZ PEDAL MAIN RELAY NEUTRAL START RELAY

T/C OIL TEMPERATURE SENSOR ENGINE ECU

ENGINE ECU

JUNCTION CONNECTOR(B) GLOW PLUG TIMER ASC ECU ASC ECU JUNCTION CONNECTOR(E) JUNCTION CONNECTOR(A)

1A
1B	BODY MAIN WIRE to J/B
1C
1D	ENGINE WIRE to J/B
1E	SIDE LH WIRE to J/B
AC2	BODY MAIN WIRE to SIDE RH WIRE
AC4
AG1
	BODY MAIN WIRE to ENGINE WIRE
AG2
AG4
AO1
	BODY MAIN WIRE to SIDE LH WIRE
AO2
AO3
	T/C HEAT GAUGE WIRE to BODY MAIN WIRE
DA1
AA	FRONT PLATE LEFT OUTSIDE EARTH
AB	FRONT PLATE LEFT OUTSIDE EARTH
AC	FRONT PLATE LEFT OUTSIDE EARTH
AD	TRANSMISSION UPPER EARTH

E2-10

ELECTRICAL WIRING ROUTINGS

MAST AREA

*1:V MAST *2:FSV MAST

U2 U3

U1

U5

U6

U8

*2

U7 b1

U HEAD GUARD SW WIRE

	dA2	d6
UA1	R1		d1
	R6
UA2
UB1			A BODY MAIN WIRE
B BODY SUB NO.1 WIRE
to E2-14		b1	*1

d FR STAY WIRE LH

BA1

RA2

R FR STAY WIRE RH

Ab1

b MAST SENSOR WIRE

E2-11

ELECTRICAL WIRING ROUTINGS

R1	FRONT COMBINATION LAMP RIGHT
R6	HEAD LAMP RIGHT
U1	HEATER SWITCH
U2	FRONT WIPER SWITCH
U3	REAR WIPER SWITCH
U5	LPG WARNING SWITCH
U6	FAN SWITCH
U7	FAN MOTOR(B)
U8	FAN MOTOR(E)
b1	MAST SWITCH
d1	FRONT COMBINATION LAMP LEFT
d6	HEAD LAMP LEFT
	BODY MAIN WIRE to MAST SENSOR WIRE
Ab1
	BODY SUB NO.1 WIRE to BODY MAIN WIRE
BA1
	FR STAY WIRE RH to BODY MAIN WIRE
RA2
UA1	HEAD GUARD SW WIRE to BODY MAIN WIRE
UA2
	HEAD GUARD SW WIRE to BODY SUB NO.1 WIRE
UB1
	FR STAY WIRE LH to BODY MAIN WIRE
dA2

E2-12

ELECTRICAL WIRING ROUTINGS

REAR BODY(NO.1)

*1:CABIN
*2:EXCEPT CABIN
											Y8
										Y4	Y2
											Y3
										Y1
										Y7	Y9
					S15		to E2-14			Y6	Y5
				S16
				S22			S11
			S21					S19	*2
	*2	S17							S19	*1
									S20	*1
*2	S18						S20	*2			a
	S23						S4
						S13
							S14
	*1	S17			S3
				S2
		*1	S18								Y HOOD SUB NO.1 WIRE
				S8
S RR UPR MAIN WIRE			YX2
					a
		X1
					YX1

X HOOD MAIN WIRE	OK

	SO3	XO4
	O4
to E2-8		XO2
	O1
		XO1
			Z RR LWR WIRE
		XO3
O SIDE LH WIRE			Z3

ZO1 Z1

O2 SO2

O3 SO1