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Dia 2052 001
Dia 2052 001
Electrical Diagrams
Electrical Diagrams
This index contains the electrical diagrams that are ap-
plicable to your lift truck. See the end of this section for
wire color codes, power cable codes, and electrical di-
.
agram symbols.
A B C
HN1
HNS1 +
FU16
LIGHT OPTIONS
FAN OPTIONS
1 FREEZER OPTIONS 1
FU4
NOTE: LIFT TRUCK IS SHOWN WITH NO POWER, LOWERED, AND NO OPERATOR PRESENT
+ ACCESS 2 3
8 (CA404)
FAN2
TLT 9 POT4
14
4
TBS
12
AXS1
13
AXS2
17
+ SV1
2
2 + SVOP 18 16 2
+ SV3 P_THERM TS3
21 W W NEG
V
M3
V LH 12V
UA B NEG
U
20 ECR3
TLMS 5
6
1
+BV BNEG
FU2
ACS ACCESS 3™ 17
8 (CA403) 16 + - POT1
FS
15
6 18
RS
+ - POT2
7
BRKS1 19
9 21
33 + - POT3
SES
3 5 20
3
ACCESS 1
(CA360) 8 34
14 35
16 + WS
P_THERM
TS2
+ 10 - BRK2 W NEG
A5 1 LH 30 M2 12V
ECR4 B 11 + FAN1 VS V
LH
- US U A B NEG
12 ECR2
9 + BRK1 24
- 31
2 RH 23
+ 13 ALM1 27 12
PT1
21 + 11
17 L 24
TR2 15 4 25
-T°
KYS TR1
P_THERM
TS1
HGTS1 26 WM W NEG
TP1 START
K1 -T°
10 M1
ACC
IGN
VM V
RH 12V
FU15 3 UA B NEG
OFF TP2 FU6 UM ECR1
CR2 13
4 CR1
+ K1
14
2
4
1
+BV BNEG
L FU1
36/48V TP3
+
A B C
155497 A
474
SCHEMATIC DIAGRAMS
Manual Lever Distribution Board
K2/K3
2902 SPLICE3 +BV (K1) 9 K1
991 PC629-2 +BV (K2) F/CSWITCHED K2 10 CR5
516 SPLICE4 BNEG 11 K2 3 J1 CR3
2992 PC629-1 F/C K2 COIL NEG 12 CR4
TP3
CA202
1
9292 SPLICE91 F/C K2 CONTACT 2
CA405
1
2
238 SPLICE1 +BV (FU16) 3 246 PC606-1 +BV (FU16)
2951 4 531 PC606-2 BNEG
5 247 PC606-3 +BV (FU15)
507 SPLICE2 BNEG 6 532 PC606-4 BNEG
CA406
001 PC401-1 CAN H ACCESS 3 1 CAN
002 PC630-19 CAN H ACCESS 1 2 SHORTING
003 PC604-1 CAN H ACCESS 3 PLUG
004 PC401-6 CAN L ACCESS 3 4
005 PC630-18 CAN L ACCESS 1 5 NOTES:
006 PC604-2 CAN L ACCESS 6 1 OPTIONAL FEATURES SHOWN AS
007 PC404-15 CAN L ACCESS 2 7 DASHED LINES
8
9 2 REPLACE FU7 WITH 2A FUSE FOR
010 PC404-23 CAN H ACCESS 2 10 EE OPTION (ANSI ONLY)
11 3 J1 JUMPED BETWEEN PINS 2 AND 3
12
3 1 3
515 SPLICE4 BNEG BRES
5910 PC630-3 BNEG ACCESS 1 INPUT
CA409
303 PC403-16 +BV (12V) ACCESS 3 COMM A + POT1
101 PC403-17 ACCESS 3 INPUT C S
- HALL EFFECT
525 PC403-15 BNEG ACCESS 3 COMM B STR
CA410
214
2958 JC605-6 +BV (K1) TOW 1 216
2 BLK SES FlexSeat™
2931 SPLICE21 +BV (K1) 3 2977
2952 SPLICE5 +BV (K1) SES 4 RED
5 WHT 1
2967 PC630-7 +BV (K1) ACCESS 1 INPUT 6
SBS SUSPENSION
CA410 CA411 SEAT
2958 JC605-6 +BV (K1) TOW 1 29267
29268
29269 BLK
1 GRY
2 BLK 2 BLU
2931 SPLICE21 +BV (K1) 3 29270 3
2952 SPLICE5 +BV (K1) SES 4 RED 4 SES 1
5 WHT 5
4 2967 PC630-7 +BV (K1) ACCESS 1 INPUT 6
SBS
6 4
CA419
2934 SPLICE21 +BV (K1) 1 RED + FAN2
5904 PC404-8 BNEG ACCESS 2 NEG 2 BLUE ACCESS 2 COOLING
CA420
RED + FAN1
2944 PC403-30 +BV ACCESS 3 POS 1 BLUE ACCESS 3 COOLING
5902 PC403-31 BNEG ACCESS 3 NEG 2
A B C
155499 A SH 1
475
SCHEMATIC DIAGRAMS
Manual Lever - Access 3™
A B C
CA401 ACCESS 3.
001 PC406-1 CAN H 1 CAN H
2 CAN H
035 3 120 OHMS
1 4 CAN L
1
5
004 PC406-4 CAN L 6 CAN L
7
8
CA401
M1 1 3
4 5
CA624 6 8
TS1 BROWN
1 105
T+ BRN/WHT
2 104
CA626 CA402
12V BROWN 1 301
BLACK
2 523
NEG
ECR1 021
CHA BLUE 3
CHB WHITE 4 022
2 CA403 2
1 RH MTR ECR1 POS (12V)
2 RH MTR ECR1 NEG
2963 PC201-6 +BV (K1) FU6 3 KEYSWITCH (KYS) (+BV = CLOSED, 0V = OPEN)
4
2937 SLICE5 +BV (K1) SES 5 SEAT SWITCH (SES) (+BV = CLOSED, 0V = OPEN)
29127 PC601-6 +BV (K1) FS 6 FORWARD SWITCH (FS) (+BV = CLOSED, 0V = OPEN)
2938 SPLICE10 +BV (K1) RS 7 REVERSE SWITCH (RS) (+BV = CLOSED, 0V = OPEN)
2939 (CA612) +BV (K1) ACS 8 ACCELERATOR SWITCH (ACS) (+BV = CLOSED, 0V = OPEN)
2940 SPLICE6 +BV (K1) BRKS1 9 BRAKE SWITCH (BRKS1) (+BV = CLOSED, 0V = OPEN)
2941 SPLICE7 +BV (K1) HGTS1 10 HEIGHT SWITCH (HGTS1) (+BV = CLOSED, 0V = OPEN)
11 LH MTR ECR2 POS (12V)
12 LH MTR ECR2 NEG
13 RH MTR ECR1 CHA
14 RH MTR ECR1 CHB
525 PC409-2 BNEG POT1 15 POT1 (STEER) NEG
303 PC409-1 +BV (12V) POT1 16 POT1 (STEER) POS (12V)
101 PC409-3 WIPER POT1 17 POT1 (STEER) WIPER
102 PC622-2 WIPER POT2 18 POT2 (BRAKE) WIPER
525 PC622-3 BNEG POT2 19 POT2 (BRAKE) NEG
527 PC612-3 BNEG POT3 20 POT3 (ACCELERATOR) NEG
103 PC612-2 WIPER POT3 21 POT3 (ACCELERATOR) WIPER
22 LH MTR ECR2 CHA
23 LH MTR ECR2 CHB
3 24 RH MTR TS1 NEG 3
25 RH MTR TS1 SIGNAL
5901 (CA201) LINE NEG 26 LINE CONTACTOR NEG
2942 (CA201) LINE POS 27 LINE CONTACTOR POS (+BV)
528 PC603-2 BNEG ALM2 28 ALM2 (TRAVEL) NEG
2943 PC603-1 +BV (K1) ALM2 29 ALM2 (TRAVEL) POS (+BV)
2944 PC420-1 BNEG FAN1 30 FAN1 POS (+BV) ON < 40 °C (104 °F
5902 PC420-2 BNEG FAN1 31 FAN1 NEG (+BV) ON > 45 °C (113 °F
305 PC622-1 +BV (12V) POT2 SPLICE 9 32
306 PC612-1 +BV (12V) POT3 304 33 POT2 & POT3 (Brake/ACCELERATOR) POS (12V)
34 LH MTR TS2 NEG
35 LH MTR TS2 SIGNAL
M2
CA623 CA403
TS2
BROWN
1 107 12
T+
106 1
BRN/WHT
2 13 23
24 35
CA625
12V
BROWN
1 302
BLACK 524
ECR2 NEG 2
024
4 CHB
BLUE
WHITE
3
023 4
CHA 4
A B C
155499 A SH 3
476
SCHEMATIC DIAGRAMS
Manual Lever - Access 2
1 1
M3
CA418
TS3 BROWN 109
1
T+ BRN/WHT
2 534
CA408
RED
1 310
BLACK
2 533
ECR3 WHITE 027
3
BLUE
4 028 ACCESS 2
CA404
2932 SPLICE21 +BV (K1) 1 KEYSWITCH (KYS) (+BV = CLOSE, 0V = OPEN)
59120 (CA631) SV1 NEG 2 SV1 NEG
3120 PC631-1 +BV (12V) COMM 308 3 ECR3, POT4 POS (12V)
SPLICE 11 529
5122 PC631-3 BNEG COMM 4 ECR3, POT4, TS3 NEG
SPLICE 12 5 ECR3 CHA
6 ECR3 CHB
29129 (CA622) +BV (K1) VTS 7 VERTICAL MAST SWITCH (VTS) (+BV = CLOSED, 0V = OPEN
2 5904 PC419-2 FAN2 BNEG 8 FAN2 NEG (ACCESS 2 COOLING FAN) 2
1120 PC631-2 WIPER POT4 9 POT4 WIPER
29130 PC631-10 +BV (K1) TPAS 10 TILT POS ASSIST SWITCH (TPAS) (+BV = CLOSED, 0V = OPEN
2946 PC414-2 +BV (K1) MDLK 11 MODEL KEY (MDLK)
29131 PC631-5 +BV (K1) TBS 12 TILT BACK SWITCH (TBS) (+BV = CLOSED, 0V = OPEN
29132 PC631-7 +BV (K1) AXS1 13 HYD ACCESSORY SWITCH (AXS1) (+BV = CLOSED, 0V = OPEN
29133 PC631-6 +BV (K1) TLT 14 TILT SWITCH (TLT) (+BV = CLOSED, 0V = OPEN
007 PC406-7 CAN L ACCESS 2 15 CAN LOW
16 TS3 SIGNAL
29134 PC631-8 +BV (K1) AXS2 17 HYD ACCESSORY SWITCH (AXS2) (+BV = CLOSED, 0V = OPEN
59121 (CA631) SVOP NEG 18 SVOP NEG
2947 PC616-2 +BV (K1) HGTS3 19 HEIGHT SWITCH (HGTS3) (+BV = CLOSED, 0V = OPEN
29135 (CA622) +BV (K1) TLMS 20 TILT LIMIT SWITCH (TLMS) (+BV = CLOSED, 0V = OPEN
59122 (CA622) SV3 NEG 21 SV3 NEG
22
010 PC406-10 CAN H ACCESS 2 23 CAN HIGH
CA404
1 8
9 15
16 23
3 3
4 4
A B C
155499 A SH 4
477
SCHEMATIC DIAGRAMS
Manual Lever - Front Page
A B C
BACK VIEW OF KYS
KYS
START
ACC BATT ACC
CA601
274 204 IGN START
249 PC604-6 +BV (FU15) 1 1
2964 PC201-7 +BV (KYS) ACC 2 29122 2 2922 OFF IGN GND
1 2901 PC201-8 +BV (KYS) IGN 3 29123 3 2923 RS 1
2915 SPLICE19 +BV (K1) 29124 2924 START
4 4
2954 SPLICE10 +BV (K1) REVERSE 5 29126 274 5 2926 1 2
29127 2927
2925
29127 PC403-6+BV (K1) ACCESS 3 INPUT 29137
6 29128
6 FS
7 7 2928
8 29130 8 2930 1 2
239 SPLICE1 +BV (FU16) 29196 9 210 HNS
9 STEER
10 29197 10 205
29115 COLUMN
11 11
HN1 12 12 HNS2
BLK
511 SPLICE2 BNEG + WHT
RIGHT
B-POST
3 HNS3
29125
BLK
RS FLOORBOARD
WHT
29116 29170 FS HNS5
1 BLK
LEFT
WHT B-POST
CA603 1
BLK +
2943 PC403-29 +BV (K1) ACCESS 3 POS 1 ALM2
528 PC403-28 BNEG ACCESS 3 NEG 2 WHT TRAVEL
1
2 CA604 2
003 PC406-3 CAN H INTERFACE 1
006 PC406-6 CAN L INTERFACE 2 SERVICE CAN INTERFACE
518 SPLICE4 BNEG 3
235 (CA202) FU15 +BV 4
2905 SPLICE3 +BV (K1) 5 250
249 PC601-1 +BV (FU15) KYS 6 CA608
HGTS2 C10 3 4 R/W 1
CA607
242 SPLICE1 +BV (FU5) 1 BLK 2
2919 SPLICE19 BNEG 2970
2 3
510 SPLICE2 BNEG 3 WHT R/W 4
2966 PC630-6 ACCESS 1 INPUT 29102
4 5
6
1 2
CA612
306 SPLICE9 +BV (12V) ACCESS 3 COMM A
103 PC403-21 ACCESS 3 INPUT B POT3 (5K)
527 PC403-20 BNEG ACCESS 3 COMM C ACC
ACS
2914 SPLICE19 +BV (K1)
2939 PC403-8 +BV (K1) ACCESS 3 INPUT
HGTS1
CA613 CA614
3 2917 SPLICE19 +BV (K1) BLK BLK 3
2961 SPLICE7 +BV (K1) HGTS1 SIGNAL WHT BLK
CA622 NOTES:
305 SPLICE9 +BV (12V) ACCESS 3 COMM A POT2 (5K) 1 OPTIONAL FEATURES SHOWN AS DASHED LINES
102 PC403-18 ACCESS 3 INPUT B BRK 2 OPTIONAL LIFT CUTOUT WITH OVERRIDE
526 PC403-19 BNEG ACCESS 3 COMM C 3
BRKS1 OPTIONAL FOOT OPERATED DIRECTIONAL CONTROL
(FODC)
2908 SPLICE3 +BV (K1)
2949 SPLICE6 +BV (K1) BRKS1 SIGNAL
BRKS2
2948
1
4 2986 PC651-5 +BV (K1) LGT5, LGT6 4
TMS
29121 SPLICE3 +BV (K1)
29135 PC404-20 +BV (K1) ACCESS 2 INPUT
29141
VTS
A B C
155499 A SH 6
478
SCHEMATIC DIAGRAMS
Manual Lever - Access 1
CA602
NEG 1 535
ECR4 CHA 2 031
120 PULSE
+5V 3 701
/REV
CHB 4 032
ACCESS 1
CA630
1 BRK2 LOW (LH)
2 BRK1 LOW (RH)
5910 PC407-2 BNEG BRES 3 BATTERY RES SWITCH (BRES) (BNEG = CLOSED, 0V = OPEN)
517 SPLICE4 BNEG 4 DISPLAY BNEG
5 ECR4 (STEER) CHA
2 2966 PC607-4 +BV (K1) ORS2/HGTS2 6 HEIGHT SWITCH (HGTS2) (+BV = CLOSED, 0V = OPEN) 2
2967 PC410-6 +BV (K1) SBS 7 SEAT BELT SWITCH (SBS) (+BV = CLOSED, 0V = OPEN)
2968 SPLICE5 +BV (K1) SES 8 SEAT SWITCH (SES) (+BV = CLOSED, 0V = OPEN)
9 +BV BRK1 HIGH (RH)
10 ECR4 (STEER) POS 5V
11 ECR4 (STEER) CHB
12 ECR4 NEG
13 PT1 INPUT (LOAD SENSE) +15V
2970 SPLICE6 +BV (K1) BRKS1 14 BRAKE SWITCH (BRKS1) (+BV = CLOSED, 0V = OPEN)
2971 SPLICE7 +BV (K1) HGTS1 15 HEIGHT SWITCH (HGTS1) (+BV = CLOSED, 0V = OPEN)
16 +BV BRK2 HIGH (LH)
2913 SPLICE19 +BV (K1) 17 DISPLAY +BV (K1)
005 PC406-5 CAN L ACCESS 1 18 CAN LOW
002 PC406-2 CAN H ACCESS 1 19 CAN HIGH
20 ZONE SELECT
21 PT1 INPUT (LOAD SENSE)
22
2973 PC662-1 +BV (K1) FANS5 & FANS6 POS 23 +BV POSITIVE FANS5 & FANS6
CA618 CA630
1 112
PT1 312 1 8
9 15
LOAD 2 ALM1
3 SENSE 3 16 23
3
4
SHIPPING NOTES:
TOWING THE LIFT TRUCK WITHOUT A BATTERY TOWING THE LIFT TRUCK WITH A BATTERY
- HARNESS USED TO RELEASE THE BRAKES - REMOVE PC605 FROM JC605 CONNECTORS
- REMOVE PC605 FROM JC605 ARE BELOW THE FLOOR BOARD COVERS
- PLUG PC606 INTO JC605 - PLUG PC606 INTO JC605
- REMOVE PC405 FROM JC405
- HANG JC405 OUT BACK OF LIFT TRUCK - VERIFY PC405 IS PLUGGED INTO JC405
- PLUG A VOLTAGE SOURCE INTO JC405
ACCORDING TO THE 24V OR 36/48V
WIRING DIAGRAM SHOWN BELOW
A B C
155499 A SH 5
479
SCHEMATIC DIAGRAMS
Manual Lever
Manual Lever
A B C
CA633 SPLICE 15
CA631
1 GRN
3120 SPLICE11 +BV (12V) ACCESS 2 COMM 1 311
111 2 RED POT4 TBS 29180
1120 PC404-9 ACCESS 2 INPUT 2 557 3 YEL LIFT
5122 SPLICE12 BNEG ACCESS 2 COMM 3 29172 4 TLT 29181
29123 SPLICE19 +BV (K1) 4 29174
1 29131 PC404-12 +BV (K1) ACCESS 2 INPUT 5 29175 AXS1 29183 1
29133 PC404-14 +BV (K1) ACCESS 2 INPUT 6 29176
29132 PC404-13 +BV (K1) ACCESS 2 INPUT 7 29177 AXS2
29134 PC404-17 +BV (K1) ACCESS 2 INPUT 8 29187 29184
29124 SPLICE19 +BV (K1) 9 1 29117
29130 PC404-10 +BV (K1) ACCESS 2 INPUT 10 29214 1 29118
5123 SPLICE4 BNEG 11 555 1
12 29186 29119 2
556 DS20 29185
1 1
RES50 536
TPAS ORS1
1
SB80
1 WHT
C4 1 AXS3
2
CA615
1 29111
506 3 4
29110
3 + SVX 2
+ 4
5 BLK
CA633 SPLICE 15
CA631 1 GRN
3 3120 SPLICE11 +BV (12V) ACCESS 2 COMM 311
1 111 2 RED POT4 TBS 29180 3
1120 PC404-9 ACCESS 2 INPUT 2 557 3 YEL LIFT
5122 SPLICE12 BNEG ACCESS 2 COMM 3 29172 4 TLT 29181
29123 SPLICE19 +BV (K1) 29184
4 29174 AXS1
29131 PC404-12 +BV (K1) ACCESS 2 INPUT 5 29175 29183
29133 PC404-14 +BV (K1) ACCESS 2 INPUT 6 29176
29132 PC404-13 +BV (K1) ACCESS 2 INPUT 7 29177 29190
29134 PC404-17 +BV (K1) ACCESS 2 INPUT 8 29187 29117 AXS2
29185
1
2
CA638
A B C
155499 A SH 8
480
SCHEMATIC DIAGRAMS
Manual Lever - Operator, M1 , M2 Fans
FAN4
OPERATOR
1
+
CA641 LGS1 NOT
240 SPLICE1 +BV (FU16) 221
1 29171 USED
2985 PC651-3 +BV (FU16) LGT1/LGT2 222
2 29167 BLK 1
274 (CA651) +BV (FU16) 3 29168 LGS2 224 554 1
4 226 WHT
2975 SPLICE10 +BV (K1) REVERSE 1
5 537
508 SPLICE2 BNEG 6 227 1
252 (CA201) PC412-1 +BV (FU7) 7 553
504 SPLICE16 BNEG 8 CA642 FNS CR8 CR9
29142
1 1 29144
2 2
± BV CABLE 1 29143 1 29145
NOT
USED
2 1 2
CA651 1 PC651 JC651
2916 SPLICE19 +BV (K1) 1 1 29341 29344
1
2984 SPLICE10 +BV (K1) REVERSE 2 2 29342 2343
2
2985 PC641-2 +BV (FU16) LGT1/LGT2 3 3 3
237 SPLICE1 +BV (FU16) LGT3 POS 4 4 2344 2345 4
2986 (CA622) +BV (K1) BRKS2 5 5 29345 5
509 SPLICE2 BNEG 6 OPTIONAL OHG 6 5346 59346 6
519 SPLICE4 BNEG 7 LIGHTS 7 5347 59348 8
7
5912 (CA652) BNEG DR1 LG3 8 8 29349
9 9 29340 9
10 10 10
11 11 29346 11
12 12 9342 12
5346 GRN
1 DR3
29343 RED/WHT
1
OPTIONAL KEYED 59347 GRN/WHT
WORKLIGHTS 1
FU8 1
3 FLASHER
3
FLS MODULE
1
GRN
513 SPLICE2 BNEG 1
RED/WHT DR1
2974 PC641-3 +BV (FU16/K1) LGTS2 1
GRN/WHT
5912 PC651-8 BNEG LGT3 NEG 1
1 29101 +
FAN5
CA662 5101
RIGHT TRACTION
SPLICE34 MOTOR (M1)
2973 PC630-23 +BV (K1) ACCESS 1 POS 1 29100
SPLICE35
4 520 SPLICE4 BNEG 2 5100
29102 +
4
FAN6
5102 LEFT TRACTION
MOTOR (M2)
NOTES:
1 OPTIONAL FEATURES SHOWN AS DASHED LINES
A B C
155499 A SH 7
481
SCHEMATIC DIAGRAMS
Manual Lever - Freezer Condition
A B C
1 1
1 2 THS1
CA639
5292
RES39
SPLICE94 9298
1
SPLICE93 2 4
3 THS2
2 2
5293 GRN
1
9299 RED/WHT DR2
1
59291 GRN/WHT
1
FREEZER CONDITION
SCHEMATIC
FU4 RES1
KYS RES2
FU15 K1 K2
5
K2
THS1
+
GRN/WHT
3 THS2 3
RED/WHT DR2
RES39
4 GRN
NOTES:
1 OPTIONAL FEATURES SHOWN AS DASHED LINES
2 THS1 SHOWN AT 21 °C (70 °F) SWITCH CLOSES AT LESS THAN 4 °C (39 °F) AND OPENS AT GREATER THAN 16 °C (60 °F)
3 THS2 SHOWN AT 21 °C (70 °F) SWITCH CLOSES AT LESS THAN 60 °C (140 °F) AND OPENS AT GREATER THAN 71 °C (160 °F)
4 RES39 IS 585 OHM FOR 36V LIFT TRUCKS, 1244 OHM FOR 48V LIFT TRUCKS
5 K2 IS A 12V COIL FOR 36V LIFT TRUCKS, 24V COIL FOR 48V LIFT TRUCKS
4 4
A B C
155499 A SH 9
482
SCHEMATIC DIAGRAMS
Manual Lever - Wire Splice
SPLICE 9
(REF CA403)
3 2954 PC601-5 +BV (K1) RS
3
2938 PC403-7 +BV (K1) ACCESS 3 INPUT SPLICE 10
2975 PC641-4 +BV (K1) LGS2 +BV REVERSE
2984 PC651-2 +BV (K1) BACKUP LIGHT
SPLICE 11 - 12
(REF CA404)
SPLICE 16
(REF CA202)
2903 SPLICE3 +BV (K1)
2913 PC630-17 +BV (K1) ACCESS 1
2914 (CA612) +BV (K1) ACS COMM
2915 PC601-4 +BV (K1) FS/RS COMM
2916 PC651-1 +BV (K1) TAIL/STROBE LIGHT
2917 PC613-1 +BV (K1) HGTS1 SPLICE 19
2918 PC616-1 +BV (K1) HGTS3 +BV (K1)
2919 PC607-2 +BV (K1) OPTIONS
29123 PC631-4 +BV (K1) HYD SWITCH POS
4 29124 PC631-9 +BV (K1) TPAS/CLS POS 4
29125 (CA631) +BV (K1) SV1/SV3 POS
A B C
155499 A SH 2
483
SCHEMATIC DIAGRAMS
Manual Lever - Power Cables
A B C
685 mm (27 in)
BATTERY COMPARTMENT
M3 ITEM PART NO. TYPE
1 086749-037 SB
W U 086749-044 SBE
1 V 086749-050 DIN 1
086749-040 SB
ITEM 14 2 086749-047 SBE
086749-053 DIN
ITEM 13 3 086749-043
ITEM 12 4 084573-306
LINE 5 084573-307
+ 6 084572-396
ACCESS 2 7 084572-397
8 084572-398
9 084572-399
U B- 10 084572-400
11 084572-401
12 084573-297
+ 13 084573-298
V
14 084573-299
840 mm (33 in)
FU2 BATTERY COMPARTMENT
W
ITEM PART NO. TYPE
ITEM 5 086749-038 SB
2 B+ 1 2
086749-045 SBE
ITEM 4 086749-051 DIN
086749-041 SB
2 086749-048 SBE
ACCESS 3™ 086749-054 DIN
3 086749-043
4 084573-306
5 084573-307
6 084572-396
7 084572-397
WS VS US WM VM UM 8 084572-398
9 084572-399
ITEM 3 10 084572-400
11 084572-401
12 084573-297
BNEG 13 084573-298
14 084573-299
FU1 +BV 915 mm (36 in)
BATTERY COMPARTMENT
ITEM 1
3 +BTF +BT ITEM PART NO. TYPE 3
1 086749-039 SB
ITEM 2 086749-046 SBE
1 086749-052 DIN
086749-042 SB
2 086749-049 SBE
ITEM 11 ITEM 8 086749-055 DIN
3 086749-043
ITEM 10 ITEM 7 4 084573-306
5 084573-307
POS NEG 6 084572-408
ITEM 9 ITEM 6
36/48V 7 084572-409
LIFT TRUCK VS VM 8 084572-410
BATTERY WS US WM UM 9 084572-411
10 084572-412
11 084572-413
M2 M1 12 084573-303
13 084573-304
4 14 084573-305 4
NOTES:
1 ITEMS 1 AND 2 ARE DEPENDENT ON THE BATTERY
CONNECTOR TYPE. SEE TABLES FOR DETAILS. FUSE PART NO. CABLE PART NO.
FU1 132083-003 PC 1/0 084572
FU2 132083-003 PC 2/0 084573
PC 3/0 086479
A B C
155496 B
01 Rev. 10/16
484
SCHEMATIC DIAGRAMS
Manual Lever - Power Cables
Harnesses
127272-001 Mast height switch harness: 2260 mm (89 in) collapsed height TF, TL, TT, mast 2110 mm (83 in)
Quad mast
127272-002 Mast height switch harness: 2415 mm (95 in) collapsed height TF, TL, TT, mast
127272-003 Mast height switch harness: 2565 mm (101 in) collapsed height TF, TL, TT, mast
127272-004 Mast height switch harness: 2720 mm (107 in) collapsed height TF, TL, TT, mast 2260 mm
(89 in) Quad mast
127272-005 Mast height switch harness: 2870 mm (113 in) collapsed height TF, TL, TT, mast 2415 mm
(95 in) Quad mast
127272-006 Mast height switch harness: 3025 mm (119 in) collapsed height TF, TL, TT, mast 2565 mm
(101 in) Quad mast
127272-007 Mast height switch harness: 3025 mm (125 in) collapsed height TL, mast, 2720 mm (107 in)
Quad mast
127272-011 Mast height switch harness: 2110 mm (83 in) collapsed height TF, TL, TT, mast
127272-012 Mast height switch harness: 1955 mm (77 in) collapsed height TF, TL, mast
127511 5th function accessory harness: PC615, handle, hydraulic harness
127515-002 5th function three conductor harness: TF mast, 2415 mm (95 in), or less collapsed height,
JC615
127515-004 5th function three conductor harness: TT mast, 2260 mm (89 in), or less collapsed height,
JC615
127515-006 5th function three conductor harness: TL, TF mast 2415 mm (95 in), or greater collapsed height,
JC615
127515-007 5th function three conductor harness: TT mast 2260–2720 mm (89–107 in) collapsed height,
JC615
127515-008 5th function three conductor harness: TL mast 2415 mm (95 in) or less collapsed height, JC615
127515-010 5th function three conductor harness: TT mast 2720–3175 mm (107–125 in) or collapsed
height, JC615
128720 Front freezer condition harness: JC813, THS1, THS2, RES2, RES3
130117-001 36 V freezer condition harness includes resistor (062033-007)
130117-002 48 V freezer condition harness includes resistor (062033-036)
130583 36 V FODC freezer condition harness: JC813, PC813, PC814 includes resistor (062032-004)
130584 48 V FODC freezer condition harness: JC813, PC813, PC814 includes resistor (062032-004)
140290-001 InfoLink® wire harness: Alarm, CAN, Current, Load, Module, PROG, PROX, RC232, Shock
141045 Steering harness: JC601, HNS, KYS, FS, RS
141601 FODC freezer condition harness: JC601, PC601, includes switch (089362)
141624 FODC freezer condition harness: JC601, PC601, JC814 includes switch (089362)
01 Rev. 10/16
486
SCHEMATIC DIAGRAMS
Manual Lever - Power Cables
155484 Main manual lever harness: PC201, PC401, PC403, PC404, JC405, PC405, PC406, PC408,
PC409, PC410, PC414, PC418, PC419, PC420, PC601, PC602, PC603, JC604, PC604,
JC605, PC605, PC606, PC607, PC612, PC613, PC616, PC618, PC622, PC623, PC624,
PC625, PC627, PC628, PC629, PC630, PC631, PC641, PC651, PC652, PC662, Access 1,
Access 2, Access 3™, ACCY POS, ACS, ALM1, BPOS, BRES, +BV, -BV, BRK1, BRK2,
BRKS1, BRKS2, DR1, ECR1, ECR2, ECR3, FU15, FU16, L, FAN1, FAN2, FAN5, FAN6, FNS,
HGTS1, HGTS2, HGTS3, HN1, InfoLink®, KYS, LGS1, LGS2, M1, M2, M3, POT1, POT2,
POT3, SBS, SES, SV1, SV2, SVOP, TLMS, TS1, TS2, TS3, TSS, VTS
155488 Floorboard fan harness: JC662, FAN5, FAN6
155489 Floorboard freezer condition harness: PC202, JC629, PC639, PC813, distribution board, DR2
155490 Overhead guard lights and turn signal harness: JC651, PC806, PC832, PC813, LGT1, LGT2,
LGT3, LGT5, LGT6, LGT11
155490-002 Overhead guard lights and no turn signal harness: JC651, PC806, PC832, PC813, LGT1,
LGT2, LGT3, LGT5, LGT6, LGT11
155492 Turn signal harness: JC652, PC653, PC654, TS, TSS
155493 Fuse jumper harness: includes fuse (094362-001, 094362-003)
155494 Carton clamp harness: PC638, AXS2, BPOS, BNEG, CLS, SVC1
158083 Worklight key jumper harness: JC651, PC651, DR1
158662 InfoLink® harness: LC Filter, LPBK
159906 Fuel cell wire harness: EWS
159907-001 Fuel cell wire harness: Display
Wire Color-Codes and Sche- wire has a three or four digit number. The first one or
two digits identify the color of the lead. The last two
matic Symbols digits identify the lead from one through 99. It is possi-
ble that some vendor component leads do not have
This section includes information on wire color-codes these same numbers or colors. A wire pictorial identi-
and schematic symbols that are standard on Crown fies each wire by number. See WIRING DIAGRAMS for
electrical diagrams. wire pictorials and electrical diagrams.
Wire Color-Codes
The applicable wire colors are in the chart below. The
function of the circuit determines the wire color. Each
488
SCHEMATIC DIAGRAMS
Wire Color-Codes and Schematic Symbols
Power Cables
The designators and dash numbers below identify the
power cables. An example of such a power cable is
Fig. 3 (8117-01)
PC#1/0 – 10. The part number for this cable is 084572-
010. or
PC#4/0 137636
Switches
Fig. 6 (8120-01)
The switch symbols show: • Maintained contact is an open circle (an open circle
also shows the common terminal).
• The switch type
• The number of terminals
• If the switch is a momentary contact switch or main-
tained contact switch
Fig. 7 (8115-01)
• How the switch is connected or
• How the switch operates
• Function.
Fig. 1 (8115-01)
or
Fig. 2 (8116-01)
• Without common
489
SCHEMATIC DIAGRAMS
Wire Color-Codes and Schematic Symbols
How the Switch is Connected these switches include the symbols on the actual
switch.
To know how the switch is connected, look carefully at
the contact symbols. An open circle shows a main- Example:
tained contact, thus it is the normally closed terminal. A
shaded triangle shows a momentary contact, thus it is
the normally open terminal.
Switches that have more than one maintained contact
do not have a normally open or normally closed termi- Fig. 9 (8121-01)
nal, although they can have a common. Symbols for
Function
A component designator shows the switch function (for
example: FS = forward switch). See COMPONENTRY
for more information on the applicable component des-
ignators for your lift truck.
Note:
• On an electrical diagram, the condition of a circuit
includes a note (for example: the lift truck is fully
lowered with no operator on the lift truck).
• Positive action switches have this symbol:
Fig. 18 (8126-02)
490
SCHEMATIC DIAGRAMS
Wire Color-Codes and Schematic Symbols
Fig. 19 (8100-01)
491
SCHEMATIC DIAGRAMS
Wire Color-Codes and Schematic Symbols
Fig. 20 (8101-02)
492
SCHEMATIC DIAGRAMS
Wire Color-Codes and Schematic Symbols
Specialty Switches
Pressure Switch
Fig. 21 (8127)
Reed Switch
Fig. 22 (8128)
Temperature Switch
Fig. 23 (8129)
Brake Fluid Switch
Fig. 24 (8130)
Three Position Key Switch
Start
Off
Fig. 25 (8131-01)
493
SCHEMATIC DIAGRAMS
Wire Color-Codes and Schematic Symbols
Signal Flow
Simultaneous T-Connection Thermistor
Signal Flow
Double Mov/
Alternate
Junction Transzorb
Chassis
Ground Mast Cable
Capacitor
Common Power Nonpolarized
Return Termination
Capacitor
Female/ Polarized
Test Point Socket
Current
Male Shunt
Cable Pin
Shielded Inductor
Cable Socket & Pin
Twisted Pair
LVDT
Connector
Fixed/Jack
Cable Multi- Ferrite Bead
Twisted Pairs Connector
Moveable/
Plug
Diode
Cable Multi-
Conductor Connector
Assembly
LED
Cable Multi-
Conductor Resistor
Zener Diode
Cable
Unconnected Pot
Transistor
Insulated
NPN
Junction
Point Rheostat
Fig. 26 (8132-02)
494
SCHEMATIC DIAGRAMS
Wire Color-Codes and Schematic Symbols
1 2 34 5
Transistor DC/DC
Dual
PNP Converter
Suppressor
Power Supply 115487
Darlington Battery + – +
NPN Dual
Contactor 082495, 086322, 093757
Suppressor
Normally
Darlington Open
PNP
Contactor 1 3 Filter Block
Normally 112533 5
N-FET With
Closed
Diode Clamp
Coil
P-FET With
Diode Clamp Coil
Suppression
Motor Field, Fuse - Band
Series Shows Positive
Feed
Motor Field,
Shunt Tach Sensor
TT
Series Motor, Hour Meter
M
DC
Lamp
M Shunt Motor,
DC
Horn
Permanent
M Magnet
Encoder
Motor
Suppressor
M Separately 077732
Excited Motor, DC
+ –
Suppressor
M Motor, AC
077728, 085670, 091181
3
Suppressor
Transformer
085484, 086755
Fig. 27 (29910)
495