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FOREWORD

This Manual contains specifications, maintenance, repair, diagnostic and


service pr~cadklrssfor $ h e chassis, body, electrical controliter and material
handling system of t h e TOYOTA ELECTRIC POWERED FOWKLiiFT 7FBEU15
to 20 series and SFBEHU?8.

Please use this manuaA for providing quick, coesec"6servicing of the corre-
sponding forklift models.

This manual deals with the above models as of April 2003. Please under-
stand that disagreement can take place between the descriptions in the man-
ual 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.

TOYOTA Material Handling Company


A Division of TOYOTA INDUSTRIES CORPORATION
SECTION INDEX
NAME SECTION

GENERAL
BATTERY
CONTROLLER
MULTI-DISPLAY FUNCTIONS
TROUBLESHOOTING

DRIVE UNIT & FRONT AXLE

STEERING
BRAKE
BODY & FRAME

MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
@ a

APPENDIX
GENERAL
Page Page
VEHICLE EXTERIOR VIEW ........... 0-2 RECOMMENDED LUBRICANT
VEHICLE MODELS..........................0-3
QUANTITY AND TYPES ...........0-16 rn
FRAME NUMBER.............................0-3 LUBRICATION CHART
................. 0-17
PERIODIC MAINTENANCE ......... 0-18
HOW TO USE THIS MANUAL ......0-4
EXPLANATION METHOD ................. 0-4 PERIODIC REPLACEMENT OF
PARTS AND LUBRICANTS .....0-23
TERMINOLOGY ................................0-5
ABBREVIATIONS ..............................0-5
OPERATING TIPS ............................0-6
GENERAL INSTRUCTIONS ..............0-6
JACK-UP POINT ...............................0-7
HOISTING THE VEHICLE .................0-8
WlRE ROPE
SUSPENSION ANGLE LIST ..........0-9
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ...................0-9
MEMBER WEIGHTS ........................0-10
TOWING THE VEHICLE ..................0-10
ELECTRICAL PARTS
INSPECTION ................................ 0-11
NOTES ON SAS ..............................0-12
STANDARD BOLT & NUT
TIGHTENING TORQUE ............. 0-13
BOLT STRENGTH CLASS
IDENTIFICATION METHOD .........0-13
TIGHTENING TORQUE TABLE ...... 0-14
PRECOATED BOLTS ......................0-15
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ............. 0-15
0-2

VEHICLE EXTERIOR VIEW


VEHICLE MODELS
Vehicle model code Load Capacity Vehicle Model Control method Voltage (V)
15 30001bs 7FBEU15 AC microcomputer controller 36 (48)
18 35001bs 7FBEU18 'T 'T
18 35001bs 7FBEHU18 'T ?
20 40001bs 7FBEU20 ? T' -

FRAME NUMBER
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
Pattern A: Each step of the operation is explained with its own illustration.
Pattern B: The entire operation is indicated by step numbers in one illustration, followed by
cautions, notes, and point operations.

Example of pattern B
DISASSEMBLY. INSPECTION. REASSEMBLY
Tightening torque unit T=N-m(kg.m)[ft.lbfl

omitted in some illustrations.


When a part requiring
tightening torque instruction is
not indicated in the illustration,
the part name is described in
the illustration frame.

T=46.1 to48.1

Disassembly Procedure
1 Remove the cover. [Point I ]
2 Remove the bushing. [Point 21
3 Remove the gear.
- Operation to be explained

Point Operations
Explanation of operation point with illustration
[POINT I ]
Disassembly: /
Make match marks before removing the pump cover

[POINT 21
Inspection:
Measure the bushing inside diameter.
Limit 19.12 mm (0.7528in)
2. How to read component figures (Example)
( 1 The component figures use the illustration in the parts
catalog for the vehicle model. Please refer to the catalog
to check the part name.
3. Matters omitted from this manual d Parts catalog
FIG number

(1) This manual omits descriptions of the following jobs, but perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)

TERMINOLOGY
Caution:
Important matters, negligence of which may cause accidents. Be sure to observe them.
Note:
Important items, negligence of which may cause accidents, or matters in operating procedure
which require special attention.
Standard: Value showing the allowable range in inspection or adjustment
Limit: The maximum or minimum value allowed in inspection or adjustment.

ABBREVIATIONS

Abbreviation Meaning Abbreviation Meaning


ASSY Assembly RH Right hand
Society of Automotive Engineers
ATT Attachment SAE
(USA)
Electronically controlled fully
EHPS SAS System of active stability
hydraulic power steering
FHPS Fully hydraulic power steering SST Special service tool
LH Left hand STD Standard
U Less T= Tightening torque
OPT Option OOT Number of teeth (OOT)
01s Oversize UIS Undersize
PS Power steering W/ With
OPERATING TIPS
GENERAL INSTRUCTIONS
1. 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 disconnect the battery plug before the inspection or servicing of electrical parts.
2. Skillful operation
(1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure
gauge, etc.) and SSTs before starting operation.
( 2 ) Check the cable color and wiring state before disconnecting any wiring.
(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts
neatly to prevent confusion.
(4) When disassembling and inspecting a precision part such as the control valve, use clean tools and
operate in a clean location.
(5) Follow the specified procedures for disassembly, inspection and reassembly.
(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each
time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling.
(Tighten to the medium value of the specified tightening torque range.) If no tightening torque is
specified, use the value given in the "standard tightening torque table".
3. Protection of functional parts (battery operated vehicles)
(1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each
connector for any connection failure or imperfect connection.
Failure or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.
4. Defect status check
Do not start disassembly and/or replacement immediately, but first check that disassembly and/or
replacement is necessary for the defect.
5. Waste fluid disposal
Always use a proper container when draining waste fluid from the vehicle.
Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely
affect human health and the environment. Always collect and sort well, and ask specialized companies
for appropriate disposal.
JACK-UP POINT
Always observe the following instructions when jacking up the vehicle:
When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an
inclined or rough surface.
Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up
at any other point is dangerous.
Always support the load of jacked-up vehicle with wooden blocks at specified points.
Supporting the vehicle with the jack only is very dangerous.
Never, under any circumstances, put any part of the body (including hands and feet) under the
jacked-up vehicle.

Wooden block or stand


setting points
HOISTING THE VEHICLE
When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist
by any other attachment section as it is very dangerous.
0-9

WlRE ROPE SUSPENSION ANGLE LIST


Suspension Tension Compression Suspension Suspension Tension Compression Suspension

Ago'
Angle method Angle method

0" 1.oo 0time 90" I '41 1 .00time


time time
2?
ht* 2t

30" '04
time
0.27time
$fiO
h
120°
time
2'00
1.73time
+ 2t

60" ''I6 0.58time


60"
time
&
2
h'

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE


- -
Unit: N (tf) [Ibfl
Rope Cutting Single-rope Two-rope suspension four-rope suspension
diameter load suspension
0" 0" 30" 60" 90" 0" 30" 60" 90"
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0'24in) 148071 [683.6] [I3671 [I3231 [I1691 19701 [2734] [2646] 2337 [I9401
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
1
(3.21)
(0'32in) [7078] 1 [992.3] 1 I I
(0.9) (0.87) (0.78) (0.64)
(0.45)1[I9851 [I9181 [I7201 [I4111 1 I 1
(1.8) (1.74) (1.56) (1.28)
[3969] [3937] [3440] [2322]I

14 mm
(0.56in)
0-10

MEMBER WEIGHTS
Unit: kg (Ibs)
I
I BATTERY ASSY
Member
I
Vehicle model
See page 1-2.
Weight
I
I Drive motor ASSY I All Models I Approx. 37 (82) 1
I Pump motor ASSY I All Models 1 Approx. 31 (68) 1
I Front axle ASSY Wl drive motor ASSY I All Models I Approx. 122 (269) 1
I Rear axle ASSY W/ rear axle cylinder ASSY
- --
1 All Models I Approx. 44 (97) 1
/ Approx. 637 (1405) 1
Counterweight
1 7FBEU18 1 Approx. 808 (1782) 1
1 7FBEHU18 I Approx. 637 (1405) 1
1 Approx. 882 (1945) 1
Mast ASSY W l lift bracket (WI lift cylinder, L l fork,
All Models
Lifting height 3000mm (118 in), V mast)

Vehicle weight (without battery)

TOWING THE VEHICLE


Note the cautions below when towing the vehicle.
1. Lift the rear wheels for towing
2. The traveling speed when towing must not exceed the
maximum traveling speed of the forklift.
3. Before starting towing, always set the key switch to OFF
and the direction switch to the neutral position.
4. Before towing, either remove the fork or take action to
prevent the fork from coming into contact with the
ground due to bouncing.
ELECTRICAL PARTS INSPECTION
1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers
and relays, to impact.
( 2 ) Never expose electronic parts to high temperature or
moisture.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.

u
3. Use a circuit tester that matches the object and purpose of measurement.
Analog type: This type is convenient for observing movement during operation and the operating
condition. Measured value is only a reference

Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or
movement.

(1) Difference between results of measurement with analog and digital types
* The results of measurements using the analog type and the digital type may be different.
Differences between the polarities of the analog type and the digital type are described below.
1) Analog circuit tester
Example of measurement result
Forward Reverse
Tester range: kR range
Analog type
Continuity
Forward
11 kR
No continuity
Reverse
W

2) Digital circuit tester


Example of measurement result
Forward Reverse Tester range: 2 MR range
Digital type
No continuity
Forward
1
Continuity
Reverse
2 MR
NOTES ON SAS
1. For the explanations of SAS functions and operation, also see "New Model Feature 7FBEU15 to 20
and 7FBEHU18 Pub. No.PU315".
2. See page 16-6 FOR REPAIR WORK of this repair manual before servicing.
3. If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform
necessary matching to ensure proper SAS function (see page 3-68).
4. always be sure to operate the vehicle carefully. Be aware of the difference in control features between
with and without SAS.
5. Many precision valves are used in the SAS oil control valves. When disassembling or replacing
hydraulic parts (valves, piping, etc.), be sure to clean the parts before installation. Periodic change of
the hydraulic oil is also very important.
6. As the vehicle is equipped with high-precision electronic devices, modification of electrical parts may
cause vehicle failure. Be sure to use genuine Toyota parts for replacement and installation of the
electrical parts (auxiliary equipment, optional parts, etc.).
STANDARD BOLT & NUT TIGHTENING TORQUE
Tightening torque of standard bolts and nuts are not indicated throughout the manual.
Use the charts and table below to judge the standard tightening torque.
1. Find the class of the bolt strength on the table below and then find the bolt tightening torque on the
tightening torque table.
2. The nut tightening torque can be judged from its corresponding bolt type.
BOLT STRENGTH CLASS IDENTIFICATION METHOD
Identification by bolt shape Identification by part No.
Shape and class Class Hexagon head bolt
Hexagon 4 = 4T
Bolt with raised 5 = 5T Part No.
head bolt

Hexagon
bolt

(standard)
or etched
numeral on head

No mark
6 = 6T
7 = 7T
8 = 8T

4T
IL
91611-40625
Length (mm)
Nominal diameter (mm)
Class

No mark 4T
flange bolt

Hexagon Bolt with two


head bolt
(standard) 8 raised lines on
head
5T
minal diameter

Hexagon
flange bolt

Hexagon
0 Bolt with two
raised lines on
head
Bolt with three
6T

head bolt raised lines on 7T


(standard) head Stud bolt
Hexagon Bolt with four
head bolt
(standard) 0 raised lines on
head
8T Part No.
92132-40614
Length (mm)
Nominal diameter (mm)
Welded bolt 4T Class

No mark 4T minal diameter

1 1 &- 2 mm groove(s)
on onelboth
edge(.
IT 1
0-14

TIGHTENING TORQUE TABLE


Standard tightening torque

Nominal Hexagon Hexagon


Pitch head bolt
Class diameter flange bolt
mm
mm

N.m kgf.cm ft.lbf N.m kgf.cm fi.lbf


6 1 .O 5.4 55 48 in.lbf 5.9 60 52 in.lbf
8 1.25 13 130 9 14 145 10
10 1.25 25 260 19 28 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 75 760 55 83 850 61
16 1.5 113 1150 83 - - -

6 1 .O 6.4 65 56 in.lbf 7.5 75 65 indbf


8 1.25 16 160 12 18 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1050 76
16 1.5 137 1400 101 157 1600 116
6 1 .O 7.8 80 69 in.lbf 8.8 90 78 indbf
8 1.25 19 195 14 21 215 16
10 1.25 38 400 29 43 440 32
6T
12 1.25 72 730 53 79 810 59
14 1.5 110 1100 80 123 1250 90
16 1.5 170 1750 127 191 1950 141
6 1 .O 11 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 103 1050 76
14 1.5 147 1500 108 167 1700 123
16 1.5 226 2300 166 - - -
6 1 .O 12 125 9 14 145 9
8 1.25 29 300 22 32 330 24
10 1.25 61 620 45 68 690 50
8T
12 1.25 108 1100 80 123 1250 90
14 1.5 172 1750 127 I96 2000 145
16 1.5 265 2700 195 299 3050 221
PRECOATED BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not replace or restore a precoated bolt as it is in the
following cases:
(1) After it has been removed.
(2) When it has been moved by tightness check, etc.
(loosened or tightened)
NOTE:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves,
Seal lock agent
retighten it according to the steps below.
2. How to reuse precoated bolts
(1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when
replacing the bolt with a new one)
(2) Completely dry the washed parts by blowing with air.
(3) Apply a specified seal lock agent to the threaded
portion of the bolt.

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE


1. When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact
surfaces with a clean cloth to remove foreign matter and dirt. Also check that there are no dents or
other damage on the contact surfaces before installation.
2. When connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.

Nominal diameter Tightening torque standard N.m (kgfem) [ftdbfl Inside diameter
of screw of hose
Standard Tightening range mm (in)
7116-20UNF 25 (50) [18.1] 24 to 26 (240 to 270) [ I 7.4 to 19.51 6 (0.24)
9116-18UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.31 9 (0.35)
314-16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.61 12 (0.47)
718-14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.61 12 (0.47)
718-14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.81 15 (0.59)
1.1116-12UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.41 19 (0.75)
1,5116-12UNF 137 (1400) [ I01.31 130 to 144 (1330 to 1470) C96.2 to 106.41 25 (0.98)
PF114 25 (250) [ I8. I ] 24 to 26 (240 to 270) [ I 7.4 to 19.51 6 (0.24)
PF318 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.31 9 (0.35)
PFI I2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.61 12 (0.47)
PF3/4 118(1200)[86.8] 112to123(1140to1250)[82.5to90.4] 19 (0.75)
PFI 137 (1400) [ I01.31 130 to 144 (1330 to 1470) [96.2 to 106.41 25 (0.98)
RECOMMENDED LUBRICANT QUANTITY AND TYPES
Application TYpe Capacity
Hypoid gear oil Approx. 0.4 1 (0.11 US gal)
Drive unit
(API GL-4, SAE 75W-80) (Until purring out from the filler port)
STD: Hydraulic oil (IS0 VG32) See "Hydraulic oil level by lifting
Hydraulic oil
Cold storage vehicle: Mobil Aero HFE height" below
MP grease
Chassis parts Molybdenum disulfide grease Appropriate amount
Essobeacon325
Battery Distilled water Appropriate amount

Hydraulic oil level by lifting height


Unit:c (US gal)
Lifting height V mast FV Mast FSV Mast
Capacity 14 (3.70) 17 (4.49) -
To 3000mm
('I8 in) Hydraulic oil level in the tank 12.4 (3.27)

To 4000mm Capacity 15 (3.96) 19 (5.01) 16 (4.22)


(157.5 in) Hydraulic oil level in the tank 14.2 (3.75)
Capacity - 19 (5.01)
To 6000mm 18 (4.75)
(236 in) Hydraulic oil level in the tank 17.2 (4.54)
LUBRICATION CHART

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

_rr:j
-
IV-
I11

-
- v -

0 :Inspection and addition I. Inspection every 8 hours (daily)


0 :Replacement II. Inspection every 40 hours (weekly)
A: MP grease Ill. Inspection every 250 hours (6 weekly)
B: Motor oil IV. Inspection every 1000 hours (6 monthly)
C: Gear oil (SAE 75W-80) V. Inspection 2000 hours (annual)
D: Hydraulic oil (IS0 VG32)
E: Molybdenum disulfide grease

1. Mast strip 8. Steering rack and pinion gear


2. Tilt cylinder front pin 9. Accelerator link
3. Mast support bushing 10. Oil tank
4. Lift chain 11. Tilt steering lock device
5. Drive unit 12. Rear wheel bearing
6. Brake link 13. Rear axle bearing
7. Oil control valve lever pin
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection,Repair or Replacement if required
M: MeasurementRepair or Adjustment if required
T Retightening C: Cleaning L: Lubrication
*: For new vehicle *I: Flaw detector

Inspection timing Every 6 Every 3 Every 6 Every 12


weeks months months months
Item Every Every Every Every
- 250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound abnormality I t t t

Motor Looseness in the connecting parts T t t t

lnsulation resistance M t t

Charging level (Display) I t t t

Electrolyte level I t t t

Electrolyte specific gravity M t t t

Looseness in the connecting parts I c t t


Battery
Abnormality in the upper portion of the I t t t
battery andlor the case
Insulation resistance M t t

Voltage measurement of each battery cell M


after charging
Contact looseness, damage, abrasion I t t t

Operating condition, contamination and I t t t


abrasion of the auxiliary contact
Mounting condition of the arc shooter I
Magnet switch -
Operating condition and timing I
Looseness of the coil installation locations I
Mounting condition and looseness of the I
main circuit lead wire
Operating condition and timing I t t t
Micro switch Damage and looseness of installation I t t t
locations
Direction switch Operating condition, damage I t t t

Operating condition I c c c
Controller Interior contamination, damage C t t t

Motor input voltage M


Fuses Looseness of the installation locations I t t t
Inspection timing Every 6 Every 3 Every 6 Every 12
weeks months months months
Item Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
Harness deterioration, damage and I t t t
looseness of the clamp
Wiring
(incl. charging Looseness of the connections, taping I t t t
cable) condition
Connecting condition and damage of the I t C t
battery connector ,
POWER TRANSMISSION SYSTEM
Oil leak I t c t

Drive unit Oil level I t c t


Bolt or nut looseness T
DRIVE SYSTEM
Front axle Damage and deformation I
Damage and deformation I
Rear axle Looseness of rear axle bearing I
Abnormal noise of rear axle bearing I
Tire pressure (OPT) M t c t

Tire crack, damage and abnormal wear I t t t

Tire tread depth M t t t

Metal piece, stone and other foreign matter I t t t


on tire
Wheels Loosening of wheel nut and bolt T t t t

Rim, side ring and disc wheel damage I t t t

Looseness and abnormal noise of front I t t t


wheel bearing
Looseness and abnormal noise of rear I t t t
wheel bearing
STEERING SYSTEM
Play, loosening, looseness I t t t
Steering wheel
Function I t t t

Oil leak I c t t
Steering valve
Looseness of the installation locations T t c t

Wheelsfor Turning angle to left and right I


steering
Oil leak I t t t

Power steering Looseness of the installation locations I t t t

Damage of power steering hose I


Inspection timing Every 6 Every 3 Every 6 Every 12
weeks months months months
Every Every Every Every
Item
250 hours 500 hours 1000 hours 2000 hours
BRAKING SYSTEM
Reserve M t t t
Brake pedal
Braking performance I t t t

Operating force and pull margin I t t t


Parking brake
Braking performance I t t t

Looseness and damage I t t t


Rod and cable
Operating condition I t t t

Clearance between disc and pad M t t t

Wear of sliding portion and pad I


Disc wear and damage I
Disc brake
Looseness of the disc installation locations I
Operating condition I
Return spring fatigue I
MATERIAL HANDLING SYSTEM
Damage or wear of fork or stopper pin I t t t

Fork Fork deformation and wear I t t t

Cracks at fork root and welded part of tooth I*'


Deformation and damage of each part and I t t t
crack at welded part
Wear and damage of roller I t t t

Mast and Mast and lift bracket looseness I c t t


lift bracket
Wear and damage of mast support bushing I
Wear and damage of roller pin I
Wear and damage of mast strip I t t t

Chain lubrication I t t t

Deformation, damage and slackness of I t t t


Chain and chain
chain wheel Abnormality of chain anchor bolt I t t c
Wear, damage and revolution of chain I t 7
'- t
wheel
Various Abnormality and installation condition of I t t t
attachments each part
Inspection timing Every 6 Every 3 Every 6 Every 12
weeks months months months
Item Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
HYDRAULIC SYSTEM
Looseness, deformation and damage of rod I t C t
and rod end
Cylinder operation I t t t

Natural drop and natural forward tilt M t c t

Oil leak and damage I t t t


Cylinder Wear and damage of pin and cylinder I t t t
bearing
Loosening and damage of cylinder T t c t
mounting
Lifting speed M t t t

Uneven movement I t t t

Oil pump Oil leak and abnormal sound I t t t

Oil level and contamination I t t t


Hydraulic oil
Oil leak I t t t
tank
Tank and oil strainer cleaning C t

oil Filter clogging c


filter
Loose linkage I t t t
Control lever
Operation I t t t

Oil leak I t t t
Oil control
Safety valve function I t t t
valve
Relief pressure measurement M

Hydraulic hose Oil leakage, deformation and damage I t t t


and piping Looseness T t t t

SAFETY DEVICES, ETC.


Looseness of the installation locations T t t t
Head guard Deformation, crack and damage I t t t
and backrest
Crack at welded portion I t t t

Lighting system Function and installation condition I t t t

Direction Function and installation condition I t t t


indicator
Horn Function and installation condition I t t t

Backup buzzer Function and installation condition I t t t

Rear view Rear reflection status I t t t


mirror Dirt, damage I t t t
Inspection timing Every 6 Every 3 Every 6 Every 12
weeks months months months
Item Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
Instruments Operation I t t t

Loosening and damage of mounting I t t t

Seat Seat belt damage and function I t t t

Deadman seat operation I t t t

Damage and cracks in frame, cross mem- I


Body bers, etc.
Bolts and nuts looseness T
Functions I t t t

Loosening and damage at sensor mounting I t t t


portion
SAS Damage, deformation, oil leakage and loos- I t t t
ened installation of functional parts
Loosening and damage of wire harnesses I t t t

Rusting and corrosion of load sensor I


Others Grease up L t t t
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
: Replacement
Every Every Every Every
Replacement cycle
weeks 3 months 6 months 12 months
Every Every Every Every
Item
250 hours 500 hours 1000 hours 2000 hours
Drive unit gear oil • t

Hydraulic oil • t

New
Hydraulic oil filter vehicle initial t
replacement
Rear wheel bearing grease • t

Every
Power steering hose
2 years
Every
Power steering rubber parts
2 years
Every
Hydraulic hose
2 years
Every
Lift chain
3 years
BATTERY
Page
BATTERY COMPARTMENT AND
REQUIRED WEIGHT ......................... 1-2
SERVICE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . .1-3
DISPLAY ..................................... 1-3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
BATTERY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
REMOVAL . INSTALLATION ..................... 1-5
INSPECTION ................................. 1-6
REPLACING BATTERY PLUG TERMINAL .......... 1-8
BATTERY COMPARTMENT AND REQUIRED WEIGHT
When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.

Compartment dimensions r ~ ~
(in)m Minimum required battery
Vehicle model Remarks
weight (with case) Kg (Ib)
Depth X Width Y Height Z
7FBEU15
551 (21.7) 997 (39.2) 613 (24.1) 700 (1543)
7FBEU18
7FBEU20
7FBEHU18
638 (25.1) 'r 'r 955 (2105)

E
j ,, .EJ
a,
I

v
Y
4 b
Width
SERVICE STANDARDS
Specific gravity 1.280 [20°C (68"F)I
Specific gravity 1.150 120°C (68"F)I
36 V 32 V
Discharge end voltage
48 V 42.5 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water
Insulation resistance 1MR or more

DISPLAY
Battery Charge Indicator
The battery charge indicator indicates 10 levels of battery
charge on the LCD.

Low Remaining Battery Charge Warning


When the battery charge becomes below the set level, the
battery charge indicator blinks and the alarm will sound for
five seconds after the key switch is set to the ON position.
Battery Overdischarge Warning
When the battery charge decreases further below the set
level after the remaining battery charge warning, any attempt
at traveling or material handling operation will cause all
charge indicator segments to blink and the alarm to sound to
warn the operator.
TROUBLESHOOTING

', Improper charging ---H


'\
\\
End of life
\
7 \
Short circuit
\
if-
\
Long storage
without operation
\
\ Repeated overdischarge1
overcharge

_f
Defective
electrolyte
\
\'

'\

,r
\
\
between cells
Insufficient
electrolyte

Overdischarge 4 4
Defect of electrolyte

Excessive ambient
temperature
\
k-
Excessive charging
current

1 0

Damaged
separator
-1
I
I Improper
water supply
-/- I Crack or
chipping of cell

/t-- Overcharge
connection

Deposition of freed Fouled terminal or


active substance connecting plug 7
at bottom of cell
1 Electrolyte leakage and reduction 1 Loosened or corroded connection 1
BATTERY ASSY
REMOVAL . INSTALLATION

Removal Procedure
1 Disconnect the battery plug.
2 Open the seat stand.
3 Release the steering release lever.
4 Remove the battery ASSY.[Point I]
Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operations
[POINT I]
Removal . Installation:
SST 25009-13201-71
INSPECTION
1. Electrolyte inspection
THe battery electrolyte is normal when it is transparent.
Check turbidity when inspecting the specific gravity.lf it
cannot be checked clearly, put the electrolyte in a
beaker for inspection.

2. Battery electrolyte specific gravity inspection


Use a hydrometer to measure the specific gravity of the
electrolyte.
Specific gravity upon complete charging ....
1 .28O[2O0C(68"F)]
Specific gravity upon end of discharge ....
1 .I5O[2O0C(68"F)]

The specific gravity of the electrolyte at 20°C (68°F) is


used.68
Equation for converting specific gravity
S2,=St+0.0007 (t-20)
S:, Specific gravity at 20°C
St: Specific gravity at t°C
t: Electrolyte temperature upon measurement ("C)

* How to use the hydrometer


(1) Insert the nozzle of the hydrometer into the
electrolyte port and allow the electrolyte to be
sucked into its outer tube.
(2) Let the hydrometer float correctly without
contact with the outer tube, top or bottom, and
read the scale at the highest point of the
electrolyte surface as illustrated at left when
the bubbles in the electrolyte disappear.
(3) After the measurement, wash the inside and
outside of the hydrometer well with clear
water and store it after wiping water off with
clean cloth.
3. Insulation resistance inspection
Measure the resistance between the battery and battery
case with an insulation resistance meter
(megohmmeter).
Insulation resistance .... 1 MQ or more
Note:
When the insulation resistance is less than 1 MQ, wash
the battery with water after removing it from the vehicle.
Fully dry the washed battery and measure the insulation
resistance again. Install the battery on the vehicle after
confirming that the insulation resistance is 1 MQ or more.
* Battery control table
Prepare a control table for each battery to record and maintain the inspection results.

inspection date Specific Electrolyte Added water


Inspected cell No. Remarks Inspector
and time gravity temperature quantity
REPLACING BATTERY PLUG TERMINAL
1. Disconnect battery plug cable one by one.
Caution:
Never disconnect more than one cable at the same
time.Fatal accident may result by short circuit.

Terminal

Spring
*
Screw driver

Spring
2. Insert a screwdriver from the terminal side, push down
the spring at the bottom of the terminal and pull the
cable to draw out the terminal.

3. Peel off the tip of the cable for Approx. 30mm, solder
sufficiently and insert it to the contact portion of the new
terminal.
Note:
Be sure to prevent solder from pouring out and adhere
to the contact surface of the terminal.

Crimping method 4. When crimping cables, never bend the terminal with a
crimping tool.
Crimping tool

Pad
(To prevent the contact
piece from bending)

5. Insert the terminal to the battery plug.


Check that the tip of the terminal goes over the tip of the
Case Terminal spring and securely set in the position.
CONTROLLER
Page
GENERAL .................................... 2-2
SPECIFICATIONS ............................. 2-3
COMPONENTS ............................... 2-4
BEFORE REPAIR ............................. 2-6
CONNECTOR INSPECTION ................... 2-7
CONTROLLER ................................ 2-26
MAIN CONTROLLER ASSY ..................... 2-26
TRAVELING AC DRIVER ........................ 2-27
MATERIAL HANDLING AC DRIVER. CONTACTOR PANEL
ASSY ...................................... 2-28
CHECK MOTOR INPUT VOLTAGE ................ 2-30
REASSEMBLY ................................ 2-32
DISPLAY ..................................... 2-33
DIRECTION SWITCH .......................... 2-34
REMOVAL INSTALLATION ..................... 2-34
DISASSEMBLY INSPECTION REASSEMBLY ..... 2-36
ACCELERATOR POTENTIOMETER
ADJUSTMENT .............................. 2-37
BRAKE SWITCH ADJUSTMENT ............... 2-38
MATERIAL HANDLING LEVER SWITCH
ADJUSTMENT .............................. 2-39
GENERAL
7FBEU series models are equipped with travelinglmaterial handling controllers that control traveling and
material handling system. They are multi-functional controller that utilize micro computer.
The travelinglmaterial handling controller provides high performance in a wide range by means of inverter
control of the AC motor drive system.
The main controller has a self-diagnosis function that automatically detects any abnormality of the main
drivelpump circuits, accelerator, SAS function or any other sensor and displays the corresponding error
code together with a warning beep.
At the same time, an action such as disabling traveling, disabling material handling or restriction of
traveling speed is automatically taken to ensure safety.
Identification of faulty portion and functional inspection of the main drivelpump circuits, each operating
system and sensors are also possible by setting the display to the analyzer (fault analysis) mode.
See page 3-24 in the "MULTI-DISPLAY FUNCTIONS" section for the diagnosis.
See page 3-34 in the "MULTI-DISPLAY FUNCTIONS" section for the analyzer.
SPECIFICATIONS
All Models
F1 (for drive and pump circuits) 500A
F4 (for lights) 10A
FUSES
F5 (for control circuit) 1OA
F6 (SAS, for solenoid) 1 OA
Contactor MB (for power supply) ME251
COMPONENTS
BEFORE REPAIR
INSPECTION

1. Insulation resistance measurement


Note:
Always measure before inspecting the travelinglmaterial
handling controller.
(1) Disconnect the battery plug and measure the
resistance between battery plug and body.

Measurement terminals Controller side of battery plug-body


Resistance value depends greatly on the vehicle operating state, place and
Standard: weather.
(Approx. 1 MQ or more)
Some components can be inspected after they are removed from the vehicle, while others can only be
inspected as installed on the vehicle.
The CPU board must be inspected as installed on the vehicle since the battery voltage must be applied.
The explanation here is mainly for inspection of the controller ASSY as removed from the vehicle.
Disassembly Procedure
Overhauling the control panel is rarely necessary. In most cases, failed parts is replaced after finding out
the cause of the failure from inspection. Therefore, make sure to repair correctly by referring to the
. figures of configuration and ASSY
Do not disassemble travelinglmaterial handling controller, as it should be replaced in a form of ASSY.
Caution for part replacement
Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of
tightening may cause other failure.
When disconnecting the bars and harness, record the connecting location and place tags. When
connecting them again, be sure to confirm with the record and tags to prevent incorrect connection.
Incorrect connection may cause other failure.
Always apply new silicon grease when reassembling parts originally coated with silicon grease.
Otherwise, overheating may occur.
After installation, check that there is no interference of the bar and harness connection with other
portion.
CONNECTOR INSPECTION
When inspecting each board and the cause of the trouble is found, do not immediately replace the board
but check the following items.
Abnormality in related harnesses
Looseness of the related connectors
Bending or damage of connector pin and defective contact of any related connector pin.
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will
be damaged.
Always replace the board after careful inspection.
When the cause of trouble is determined to be in the CPU board or other board, connect SST 09240-
23400-71 or to the corresponding connector pin and measure the applied voltage and resistance. Always
disconnect the battery plug before measuring the resistance.
Caution:
Disconnect the battery plug before connecting or disconnecting CPU board.
Note:
When the CPU or DClMD board is determined to be the cause of trouble as the result of
troubleshooting, always measure the applied voltage and resistance of each related portion when
replacing.
(1) SST Setting Method
(a) Key switch OFF and battery plug disconnected.
(b) Connect the SST to the corresponding connector pin.
Caution:
As connection of the wrong connector pin may damage normal portions, make sure to confirm the
connector pin number before connecting i t to the SST.

Connectors to which SST 09240-24300-71 is applicable


CPU board: CNlOl to CN104

SST09230-13700-71Applicable connector
CPU board: CN 100,CN105
(2) Measurement method and standard list
How to read the list
Tester p o r b e a

I rTester porbe G
I r
+I
Connector pin No.

Connector No. - +
Connector
I
Conditions Standard Remarks
I

CN101-1 CN101-26
Key switch OFF, DSF ON. Approx.OV
(45, DSF) (51, LS-) I

4 4 t
Part name
Level No. Conditions for measurement
Main controller
CPU board
CNlOl connector basic conditions (battery plug connected, key switch ON) [Standard vehicle]
Connector No.aConnector No. Conditions Standard: Remarks
CN101-1 CN101-16 Key switch OFF, DSF ON Approx. OV
(45, DSF) (51, LS-) key switch OFF, DSF OFF Approx. 5V
CN101-2 CN101-16 Key switch OFF, DSR ON Approx. OV
(46, DSR) (51, LS-) Key switch OFF, DSR OFF Approx. 5V
CN101-3 CN101-16 Key switch OFF, LSB ON Approx. 5V
(65, LSB) (51, LS-) Key switch OFF, LSB OFF Approx. OV
CN101-4 CN101-16 Key switch OFF, LSPB ON Approx. 5V
(66, LSPB) (51, LS-) Key switch OFF, LSPB OFF Approx. OV
CN101-5 CN101-16 Key switch OFF, LSD ON Approx. OV
(67, LSD) (51, LS-) Key switch OFF, LSD OFF Approx. 5V
CN101-6 - Unused -

CN101-7 CN101-16 -
Unused
, OPTO)
(- (51, LS-)
CN101-8 CN101-16 -
Unused
(-, LEDTK) (51, LS-)
FAN OFF Approx. 48V
CN101-9 CN101-16
Approx. 36V
(39, FAN-) (519 LS-)
FAN ON Approx. OV
FAN OFF Approx. 48V
CN101-10 CN101-16
Approx. 36V
(39, FAN-) (51 LS-)
9
FAN ON Approx. OV
CN101-11 CN101-16 LSATI OFF Approx. 5V
(63, LSATI+) (51, LS-) LSATI ON Approx. OV
CN101-12 - -
Unused
(309, SSTMA)
Connector No.wConnector No. Conditions Standard: Remarks
CN101-13 - -
Unused
(310, SSTMK)
CN101-14 - -
Unused
(307, SMTSA)
CN101-15 - -
Unused
(308, SMTSK)
CN101-16 - - -
(51, LS-)
CN101-17 CN101-16 LSTR OFF Approx. 5V
(62, LSTR+) (51, LS-) LSTR ON Approx. OV
CN101-18 CN101-16 Key switch OFF, SWTK ON Approx. OV
(70, SWTK) (51, LS-) Key switch OFF, SWTK OFF Approx. 5V
CN101-19 CN101-16 Lift cylinder at the bottom posi-
Approx. OV
(90, MHI) (51, LS-) tion
CN101-20 CN101-16 Lift cylinder at the bottom posi-
Approx. 5V
(91, MH2-1) (51, LS-) tion
CN101-21 CN101-16 Only vehicle with steering syn- Approx. OV or
(314, STSC) (5 1, LS-) chronizer Approx. 5V
CN101-22 CN101-16 -
Unused
(68, LSAT2+) (51, LS-)
CN101-23 CN101-16 LSTF OFF Approx. 5V
(61, LSTF+) (51, LS-) LSTF ON Approx. OV
CN101-24 CN101-16 Steering operation (only vehi- Approx. OV to
(312, STSI) (51, LS-) cle with steering synchronizer) Approx. 5V
CN101-25 - - -

CN101-26 - - -
(51, LS-)
CN10-1-27 CN101-16 -
Unused
(71, SWLE) (51, LS-)
CN101-28 - - -

CN101-29 - - -

CN101-30 CN101-16 Steering operation (only vehi- Approx. OV to


(313, STS2) (51, LS-) cle with steering synchronizer) Approx. 5V
CN101-31 - - -

CN101-32 CN101-16 LSL OFF Approx. 5V


(60, LSL+) (51, LS-) LSL ON Approx. OV
CN101-33 - - -

CN101-34 CN101-16
Approx. OV
(51, POT-) (51, LS-)
CNlOl connector basic conditions (battery plug connected, key switch ON)
[Mini-lever specification vehicle]
Connector No.wConnector No. Conditions Standard: Remarks
CN101-1 CN101-16 Key switch OFF, DSF ON Approx. OV
(45, DSF) (51, LS-) key switch OFF, DSF OFF Approx. 5V
CN101-2 CN101-16 Key switch OFF, DSR ON Approx. OV
(46, DSR) (51, LS-) Key switch OFF, DSR OFF Approx. 5V
CN101-3 CN101-16 Key switch OFF, LSB ON Approx. 5V
(65, LSB) (51, LS-) Key switch OFF, LSB OFF Approx. OV
CN101-4 CN101-16 Key switch OFF, LSPB ON Approx. 5V
(66, LSPB) (51, LS-) Key switch OFF, LSPB OFF Approx. OV
CN101-5 CN101-16 Key switch OFF, LSD ON Approx. OV
(67, LSD) (51, LS-) Key switch OFF, LSD OFF Approx. 5V
CN101-6 - Unused -

CN101-7 CN101-16 -
Unused
(-, OPTO) (51, LS-)
CN101-8 CN101-16 -
Unused
(-, LEDTK) (51, LS-)
FAN OFF Approx. 48V
CN101-9 CN101-16
Approx. 36V
(39, FAN-) (51, LS-)
FAN ON Approx. OV
FAN OFF Approx. 48V
CN101-10 CN101-16
Approx. 36V
(39, FAN-) (51, LS-)
FAN ON Approx. OV
CN101-11 CN101-16 - -
(63, LSATI+) (51, LS-)
CN101-12 - -
Unused
(309, SSTMA)
CN101-13 - -
Unused
(310, SSTMK)
CN101-14 - -
Unused
(307, SMTSA)
CN101-15 - -
Unused
(308, SMTSK)
CN101-16 - - -
(51, LS-)
CN101-17 CN101-16 - -
(62, LSTR+) (51, LS-)
CN101-18 CN101-16 Key switch OFF, SWTK ON Approx. OV
(70, SWTK) (51, LS-) Key switch OFF, SWTK OFF Approx. 5V
CN101-19 CN101-16 Lift cylinder at the bottom posi-
Approx. OV
(90, MHI) (51, LS-) tion
Connector No.-Connector No. Conditions Standard: Remarks
CN101-20 CN101-16 Lift cylinder at the bottom posi-
Approx. 5V
(91, MH2-1) (51, LS-) tion
CN101-21 CN101-16 Only vehicle with steering syn- Approx. OV or
(314, STSC) (51, LS-) chronizer Approx. 5V
CN101-22 CN101-16 -
Unused
(68, LSAT2+) (51, LS-)
CN101-23 CN101-16 - -
(61, LSTF+) (51, LS-)
CN101-24 CN101-16 Steering operation (only vehi- Approx. OV to
(312, STSI) (51, LS-) cle with steering synchronizer) Approx. 5V
CN101-25 - - -

CN101-26 - - -
(51, LS-)
CN101-27 CN101-16 -
Unused
(71, SWLE) (51, LS-)
CN101-28 - - -

CN101-29 - - -

CN101-30 CN101-16 Steering operation (only vehi- Approx. OV to


(313, STS2) (51, LS-) cle with steering synchronizer) Approx. 5V
CN101-31 - - -

CN101-32 CN101-16 - -
(60, LSL+) (51, LS-)
CN101-33 - - -

CN101-34 CN101-16
Approx. OV
(51, POT-) (51, LS-)
CN102 connector basic conditions (battery plug connected, key switch ON)[Standard vehicle]
Connector No.-Connector No. Conditions Standard: Remarks
CN102-1 CN102-22 Key switch OFF, SWAC ON Approx. OV
(64, SWAC) (51, POT-) Key switch OFF, SWAC OFF Approx. 5V
CN102-2 CN102-22 Key switch OFF, accelerator
0.4V to 3V
(52, POTA) (51, POT-) pedal fully depressed
CN102-3 CN102-22 - -
(317, POTH) (51, POT-)
CN102-4 CN102-22 Variation upon changeover
0.5V to 3V
(56, POTTA) (51, POT-) from forward to backward tilting
CN102-5 CN102-22 - 0.5V to 4.5V
(59, SPL) (51, POT-)
Connector No.~Connector
No. Conditions Standard: Remarks
CN102-6 CN 102-22 LSL OFF Approx. 5V
(60, LSL) (51,POT-) LSLON Approx. OV
CN102-7 CN102-22 - -
(21, POTL2) (51, POT-)
When the tilt lever is in the neu-
Approx. 5V
CN102-8 CN102-22 tral position
(61, LSTF) (51, POT-) When the tilt lever is in the for-
Approx. OV
ward tilt position
When the tilt lever is in the neu-
Approx. 5V
CN102-9 CN102-22 tral position
(62, LSTR) (51, POT-) When the tilt lever is in the
Approx. OV
backward tilt position
CN102-10
CN102-22 LSATI OFF Approx. 5V
(63, (51, POT-) LSATI ON Approx. OV
LSAT1, LSAT2)
CN102-11 CN102-22 - -
(25, POTATI2) (51, POT-)
CN102-12 CN102-22 - -
(26, POTAT21) (51, POT-)
CN102-13 CN102-22 -
(27, POTAT22) (51, POT-)
CN102-14 CN102-22 - Approx. 4.6V
(53, POTA+) (51, POT-)
CN102-15 CN102-22 - Approx. 4.7V
(316, POTH+) (51, POT-)
CN102-16 CN 102-22 -
(57, POTTA+) (51, POT-) Approx. 4.7V
- -

~~102-17 CNI02-22 - Approx. 5V


(58, SPL+) (51, POT-)
CN102-18 CN102-22 - -
(28, POTL+) (51, POT-)
CN102-19 CN102-22 - -
(29, POTT+) (51, POT-)
CN102-20 CN102-22 - -
(30, POTATI+) (51, POT-)
CN102-21 CN102-22 - -
(31, POTAT2+) (51, POT-)
CN102-22 - - -
(51, POT-)
CN102 connector basic conditions (battery plug connected, key switch ON)
[Mini-lever specification vehicle]
Connector No.~ConnectorNo. Conditions Standard: Remarks
CN102-1 CN102-22 Key switch OFF, SWAC ON Approx. OV
(64, SWAC) (51, POT-) Key switch OFF, SWAC OFF Approx. 5V
CN102-2 CN102-22 Key switch OFF, accelerator
0.4V to 3V
(52, POTA) (51, POT-) pedal fully depressed
CN102-3 CN102-22 - -
(317, POTH) (51, POT-)
CN102-4 CN102-22 Variation upon changeover
0.5V to 3V
(56, POTTA) (51, POT-) from forward to backward tilting
CN102-5 CN 102-22 - 0.5V to 4.5V
(59, SPL) (51, POT-)
Lever is in the neutral position
CN102-6 CN102-22 Approx. 1.3V
Change when the lift lever is
(20, POLTI) (51 0.5V to 2.2V
tilted forward and backward
Lever is in the neutral position
CN102-7 CN102-22 Approx. 3.3V
Change when the lift lever is
(21, POTL2) (51, POT-) 2.3V to 4V
tilted forward and backward
Lever is in the neutral position
CN102-8 CN102-22 Approx. 1.3V
Change when the tilt lever is
(22, POTTI) (51 0.5V to 2.2V
tilted forward and backward
Lever is in the neutral position
. CN102-9 CN102-22 Approx. 3,3V
Change when the tilt lever is
(23, POTT2) 2.3V to 4V
tilted forward and backward
Lever is in the neutral position
CN102-10 CN102-22 Change when the attachment 1 APP~OX. 1.W
(24, POTATI1) (51, POT-) lever is tilted forward and back- 0.5V to 2.2V
ward
Lever in neutral position
CN102-11 CN102-22 Change when attachment 1 Approx. 3.3V
(25, POTAT12) (51, POT-) lever is tilted forward and back- 2.3V to 4V
ward
Lever in neutral position
CN102-12 CN102-22 Change when attachment2 Approx. 1.3V
(26, POTAT21) (51, POT-) lever is tilted forward and back- 0.5V to 2.2V
ward
Lever in neutral position
CN102-13 CN 102-22 Change when attachment2 Approx. 3.3V
(27, POTAT22) (51, POT-) lever is tilted forward and back- 2.3V to 4V
ward
CN102-14 CN102-22 - Approx. 4.6V
(53, POTA+) (51, POT-)
Connector No.-Connector No. Conditions Standard: Remarks
CN102-15 CN102-22 -
(316, POTH+) Approx. 4.7V
(51, POT-)
CN102-16 CN102-22 -
(57, POTTA+) Approx. 4.7V
(51, POT-)
CN102-17 CN102-22 -
(58, SPL+) Approx. 5V
(51, POT-)
CN102-18 CN102-22 -
(28, POTL+) Approx. 4.5V
(51, POT-)
CN102-19 CN102-22 -
(29, POTT+) Approx. 4.5V
(51, POT-)
CN102-20 CN102-22 -
(30, POTATI+) (51, POT-) Approx. 4.5V

CN102-21 CN102-22 -
(31, POTAT2+) (51, POT-) Approx. 4.5V

CN102-22 - - -
(51, POT-)
CN103 connector basic conditions (battery plug connected, key switch ON)[Standard vehicle]
Connector No.- Connector No. Conditions Standard: Remarks
CN103-1 - -
(145, CANH) Immeasurable

CN103-2 - -
(146, CANL) Immeasurable

CN103-3 CN103-12 -
(147, CANGND) (14, GNDD) Approx. OV

CN103-4 CN103-12 Key switch OFF Approx. OV


(43, VBKY) Approx. 48V
(14, GNDD) Key switch ON
Approx. 36V
CN103-5 CN103-12 -
(324, SSO+) unused
(14, GNDD)
CN103-6 CN103-12 -
(325, SSO-) Unused
(14, GNDD)
CN103-7 CN103-12 - Approx. 48V
(41, VBBT) (14, GNDD) Approx. 36V
CN103-8 CN103-12 -
(-, CHK15V) unused
(14, GNDD)
CN103-9 CN103-12 -
Unused
, CHK5V)
(- (14, GNDD)
CN103-10 CN103-12
(16, D15V) Approx. 15V
(14, GNDD)
Connector No.- Connector No. Conditions Standard: Remarks
CN103-11 CN103-12 -
Unused
, CHK3.3V)
(- (14, GNDD)
CN103-12 - - -
(14, GNDD)
CN103-13 - -
lmmeasurable
(144, SMTDK)
CN103-14 - -
Immeasurable
(143, SDTMK)
CN103-15 - -
Immeasurable
(142, SDTMA)
CN103-16 - -
Immeasurable
(141, SMTDA)
CN103 connector basic conditions (battery plug connected, key switch ON)
[Mini-lever specification vehicle]
Connector No.- Connector No. Conditions Standard: Remarks
CN103-1 - -
Immeasurable
(145, CANH)
CN103-2 - -
Immeasurable
(146, CANL)
CN103-3 CN103-12 - Approx. OV
(147, CANGND) (14, GNDD)
Approx. OV
CN103-4 CN103-12 Key switch OFF
Approx. 48V
(43, VBKY) (14, GNDD) Key switch ON
Approx. 36V
CN103-5 CN103-12 -
unused
(324, SSO+) (14, GNDD)
CN103-6 CN103-12 -
Unused
(325, SSO-) (14, GNDD)
CN103-7 CN103-12 - Approx. 48V
(41, VBBT) (14, GNDD) Approx. 36V
CN103-8 CN103-12 -
Unused
(-, CHK15V) (14, GNDD)
CN 103-9 CN 103-12 -
Unused
, CHK5V)
(- (14, GNDD)
CN103-10 CN103-12 - Approx. 15V
(16, D15V) (14, GNDD)
CN103-11 CN103-12 -
Unused
(-, CHK3.3V) (14, GNDD)
CN103-12 - - -
(14, GNDD)
Connector No.@ Connector No. Conditions Standard: Remarks
CN103-13 - -
Immeasurable
(144, SMTDK)
CN103-14 - Immeasurable
(143, SDTMK)
CN103-15 -
Immeasurable
(142, SDTMA)
CN103-16 - -
Immeasurable
(141, SMTDA)
CN104 Connector basic conditions (battery plug connected, key switch ON)[Standard vehicle]
Connector No.@Connector No. Conditions Standard: Remarks
CN104-1 CN 04-" Approx. 48V
Key switch OFF
(18, B48V) (N2, N2) Approx. 36V
CN104-2 CN104-22 Approx. 48V
Key switch OFF
(18, B48V) (N2, N2) Approx. 36V
CN104-3 CN1044
Approx. 11V
(3, SOLL+) (4, SOLL-)
CN1044 CN104-3 Resistance measurement with
Approx. 10Q
(4, SOLL-) (3, SOLL+) battery plug disconnected
CN104-5 CN104-3 - -
(5, SOL a l ) (3, SOLL+)
CN104-6 CN104-7 - -
(6, SOL2+) (7, SOL a2)
CN104-6 CN104-8 - -
(6, SOL2+) (8, SOL b2)
Tilt lever in the neutral position
CN104-6 CN 04-"
Tilt lever in the forward or back- Approx. 11V
(6, SOLT+) (7, SOLT-)
ward position
CN104-7 CN104-22 Resistance measurement with
Approx. 10Q
(7, SOLT-) (6, SOLT+) battery plug disconnected
CN104-8 CN104-6 - -
(8, SOL b2) (6, SOL2+)
CN104-9 CN104-22 Approx. 48V
(55, CPR) (N2, N2) Approx. 36V
CN104-10 CN104-22 Approx. 48V
(55, CPR) (N2, N2) Approx. 36V
CN104-11 CN104-12 - -
(9, SOL3+) (10, SOL a3)
, CN104-11 CN104-13 - -
(9, SOL3+) (11, SOL b3)
Connector No.eConnector No. Conditions Standard: Remarks
CN104-12 CN104-11 - -
(10, SOL a3) (9, SOL3+)
CN104-13 CN104-11 - -
(11, SOL b3) (9, SOL3+)
CN104-14 CN104-22 Approx. 48V
(44, VBMB) (N2, N2) Approx. 36V
CNl04-15 CN 104-22 Approx. 48V
(44, VBMB) (N2, N2) Approx. 36V
CN104-16 CN104-17 - -
(34, SOL4+) (35, SOL a4)
CN104-16 CN104-18 - -
(34, SOL4+) (36, SOL b4)
CN104-17 CN104-16 - -
(35, SOL a4) (34, SOL4+)
CN104-18 CN104-16 - -
(36, SOL b4) (34, SOL b4)
CN104-19 CN104-20 Measurement with (-) probe in
Approx. 11V
(1, MB+) (2, MB-) contact with CN104-20
CN104-20 CN104-19 Resistance measurement with
(2, MB-) (1, MB+) battery plug disconnected Approx. 20R

Measurement with (-) probe in


CN104-21 CN104-28 contact with CN104-28
(329, SOLST+) (330, SOLST-) (only vehicle with steering syn- Approx. 11V
chronizer)
CN104-22 - - -
(N2, N2)
CN104-23 - - -
(N2, N2)
CN104-24 CN104-22 -
Unused
(39, FAN-) (N2, N2)
Key switch OFF Approx. OV
CN104-25 CN104-22
Key switch ON Approx. 48V
(42, KEYSTART) (N2, N2) Approx. 36V
CN104-26 CN104-27 - -
(12, SOLP+) (13, SOLP-)
CN104-27 CN104-26 - -
(13, SOLP-) (12, SOLP+)
Resistance measurement with
CN 104-28 CN104-21 battery plug disconnected
Approx. 10~2
(330, SOLST-) (329, SOLST+) (only vehicle with steering syn-
chronizer)
CN104 Connector basic conditions (battery plug connected, key switch ON)
[Mini-lever specification vehicle]
Connector No.-Connector No. Conditions Standard: Remarks
CN104-1 CN104-22 Approx. 48V
Key switch OFF
(18, B48V) (N2, N2) Approx. 36V
CN104-2 CN104-22 Approx. 48V
Key switch OFF
(18, B48V) (N2, N2) Approx. 36V
CN104-3 CN104-4 Lever in neutral position Approx. OV
(3, SOLl+) (4, SOL b l ) Change when fork is raised 2V to 8V
CN104-3 CN104-5 Lever in neutral position Approx. OV
(3, SOLl+) (5, SOL a l ) Change when fork is lowered 2V to 8V
CN104-4 CN104-3 Resistance measurement with
Approx. 752
(4, SOL b l ) (3, SOL1+) battery plug disconnected
CN104-5 CN104-3 Resistance measurement with
Approx. 7R
(5, SOL a l ) (3, SOL1+) battery plug disconnected
Amount of change when tilting
CN104-6 CN104-7 Approx. OV
forward with the lever in the
(6, SOL2+) (71 a2) 2V to 8V
neutral position
Amount of change when tilting
CN104-6 CN104-8 Approx. OV
backward with the lever in the
(6, SOL2+) (81 b2) 2V to 8V
neutral position
CN104-7 CN104-6 Resistance measurement with
Approx. 7R
(7, SOL a2) (6, SOL2+) battery plug disconnected
CN104-8 CN104-6 Resistance measurement with
Approx. 7R
(8, SOL b2) (6, SOL2+) battery plug disconnected
CN104-9 CN104-22 Approx. 48V
(55, CPR) (N2, N2) Approx. 36V
CN104-10 CN104-22 Approx. 48V
(55, CPR) (N2, N2) Approx. 36V
Lever in neutral position Approx. OV
CN104-11 CN104-12
Change when attachment 1 2V to 8V
(9, SOL3+) (I0' a3) lever is tilted backward
Lever in neutral position Approx. OV
CN104-11 CN
Change when attachment 1 2V to 8V
(9, SOL3+) (I ' b3) lever is tilted forward
CN104-12 CN104-11 Resistance measurement with
Approx. 7R
(10, SOL a3) (9, SOL3+) battery plug disconnected
CN104-13 CN104-11 Resistance measurement with
Approx. 7Q
(11, SOL b3) (9, SOL3+) battery plug disconnected
CN104-14 CN104-22 Approx. 48V
(44, VBMB) (N2, N2) Approx. 36V
Connector No.aConnector No. Conditions Standard: Remarks
CN104-15 CN104-22 Approx. 48V
(44, VBMB) (N2, N2) Approx. 36V
Lever in neutral position
CN104-16 CN104-1 Approx. OV
Change when attachment 2
(34, SOL4+) (35' a4) 2V to 8V
lever is tilted forward
Lever in neutral position
CN104-16 CN O4-I Approx. OV
Change when attachment2
(34, SOL4+) (36' b4) 2V to 8V
lever is tilted backward
CN104-17 CN104-16 Resistance measurement with
Approx. 7R
(35, SOL a4) (34, SOL4+) battery plug disconnected
CN104-18 CN104-16 Resistance measurement with
Approx. 7R
(36, SOL b4) (34, SOL b4) battery plug disconnected
CN104-19 CN104-20 Measurement with (-) probe in
Approx. 1V
(1, MB+) (2, MB-) contact with CN104-20
CN104-20 CN104-19 Resistance measurement with
Approx. 20R
(2, MB-) (1, MB+) battery plug disconnected
Measurement with (-) probe in
CN104-21 CN 104-28 contact with CN104-28
Approx. 11V
(329, SOLST+) (330, SOLST-) (only vehicle with steering syn-
chronizer)
CN104-22 - - -
(N2, N2)
CN104-23 - - -
(N2, N2)
CN104-24 CN104-22 -
Unused
(39, FAN-) (N2, N2)
Key switch OFF Approx. OV
CN104-25 CN104-22
Key switch ON Approx. 48V
(42, KEYSTART) (N2, N2) Approx. 36V
CN104-26 CN104-27 Measurement with (-) probe in
Approx. 11V
(12, SOLP+) (13, SOLP-) contact with CN104-27
CN104-27 CN104-26 Resistance measurement with
Approx. 10R
(13, SOLP-) (12, SOLP+) battery plug disconnected
Resistance measurement with
CN104-28 CN104-21 battery plug disconnected
Approx. 10R
(330, SOLST-) (329, SOLST+) (only vehicle with steering syn-
chronizer)
2-20

CN105 connector basic conditions (battery plug connected, key switch ON)
Connector No.uConnector No. Conditions Standard: Remarks
Approx. 48V
CN105-1 CN104-22 FAN stopped
Approx. 36V
(39, FAN-) (N2, N2) FAN ON
Approx. OV
Approx. 48V
CN105-2 CN104-22 FAN stopped
Approx. 36V
(39, FAN-) (N2, N2) FAN ON
Approx. OV
Approx. 48V
CN105-3 CN104-22 FAN stopped
Approx. 36V
(39, FAN-) (N2, N2) FAN ON
Approx. OV
Approx. 48V
FAN stopped Approx. 36V
CN1054 CN104-22
FAN ON (depending on the Approx. 1V
(130, FANI) (N2' N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
FAN stopped Approx. 36V
CN 105-5 CN104-22
FAN ON (depending on the Approx. 1V
(131, FAN2) (N2' N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
FAN stopped Approx. 36V
CN105-6 CN104-22
FAN ON (depending on the Approx. 1V
(132, FAN3) (N2' N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
FAN stopped Approx. 36V
CN105-7 CN104-22
FAN ON (depending on the Approx. 1V
(133, FAN4) (N27N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
FAN stopped Approx. 36V
CN105-8 CN104-22
FAN ON (depending on the Approx. 1V
(134, FANS) (N2' N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
FAN stopped Approx. 36V
CN105-9 CN104-22
FAN ON (depending on the Approx. 1V
(135, FANG) (N21N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
CN105-10 - -
Unused
(-, FAN7)

CN105-11 - -
Unused
(-, CHKG)
2-21
CN107 connector basic conditions (battery plug connected, key switch ON, connector disconnected)
Connector No.aConnector No. Conditions Standard: Remarks
CN107-1 CN107-2 -
Unused
(127, FANR+) (128, FANR-)
CN107-2 - -
Unused
(128, FANR-)

CNlOO connector basic conditions (battery plug connected, key switch ON)
Connector No.wConnector No. Conditions Standard: Remarks
CN100-1 - -
Unused
(-, C5V)
CN100-2 - -
Unused
, GNDC)
(-
CN100-3 - -
Unused
(-,FTXD)
CN100-4 - -
Unused
(-, FwE)
CN100-5 - -
Unused
(-, MD1)
CN100-6 - -
Unused
(-, FRES)
CN100-7 - -
Unused
(-, FRXD)

CN100-8 - -
Unused
(-, SELR)

CN26 connector basic conditions (battery plug connected, key switch ON)
Connector No.aConnector No. Conditions Standard: Remarks
CN26-1 CN26-2 Resistance measurement with
Approx. 20R
(55, CPR) (p2, p2) battery plug disconnected
CN26-2 - - -
(P2, P2)
Traveling AC driver 2
CN109 connector basic conditions (battery plug connected, key switch ON)
Connector No.cConnector No. Conditions Standard: Remarks
CN109-10
CN109-1
(82, SSD2-, Approx. OV
(-, CUDIDO)
TD2-)
CN109-2 - -
Unused
, CUDIDI)
(-

CN109-3 - -
Immeasurable
(145, CANH)
CN109-4 - -
Immeasurable
(146, CANL)
CN109-5 - -
Unused
(-, CANTRD)

CN109-6 CN109-6
Approx. OV
(147, CANGND) (147, GNDD)
CN109-7 N2 Approx. 48V
(55, KEYSTART) (N2, N2) Approx. 36V
CN109-8 -
Unused
(-, CUDON)
CN109-10
CN109-9 -
(78, SSD2-, Approx. 12V
(75, SSD2+)
TD2-)
CN109-10 CN109-10
(78, SSD2-, (78, SSD2-, - Approx. OV
TD2-) TD2-)
CN109-10
CN109-11 -
(78, SSD2-, 0 to 12V
(76, SSD21)
TD2-)
CN109-10
CN109-12 -
(78, SSD2-, 0 to 12V
(77, SSD22)
TD2-)
CN109-13 - lmmeasurable
(78, TD2+)
Traveling AC driver 1
CN I10 connector basic conditions (battery plug connected, key switch ON)
Connector No.eConnector No. Conditions Standard: Remarks
CN110-I - -
Unused
(-, CUDIDO)
CN110-2 - -
Unused
(-, CUDIDI)
CN110-3 - -
Immeasurable
(145, CANH)
CN110-4 - -
Immeasurable
(146, CANL)
CN110-5 - -
Unused
(-, CANTRD)
CN110-6 CN110-6
Approx. OV
(147, CANGND) (147, GNDD)
CN110-7 N2 Approx. 48V
(55, KEYSTART) (N2, N2) Approx. 36V
CN110-8 - -
Unused
(-, CUDON)
CN110-10
CN110-9 -
(78, SSD2-, Approx. 12V
(80, SSD+)
TD2-)
CN110-10 CN110-10
(83, SSDI -, (83, SSDI-, - Approx. OV
TDI-) TDI-)
CN110-10
CN110-11 -
(83, SSDI-, 0 to 12V
(81, SSD11)
TDI-)
CN110-10
CN110-12 -
(83, SSDI-, 0 to 12V
(82, SSD12)
TDI-)
CN110-13 - -
Immeasurable
(88, TDI+)
Material handling AC driver
C N l l l connector basic conditions (battery plug connected, key switch ON)
Connector No.wConnector No. Conditions Standard: Remarks
CN111-1 - -
Unused
(-, CUPIDO)
CN111-10
CN II1-2
(87, SSP-, Approx. OV
(87, CUPIDI)
TP-)
CN111-3 - -
Immeasurable
(145, CANH)
CN II1-4 - -
Immeasurable
(146, CANL)
CNlll-5 - -
Unused
(-, CANTRD)
CN111-6 CN111-6
Approx. OV
(147, CANGND) (147, CANGND)
CNlll-7 N2 Approx. 48V
(55, KEYSTART) (N2, N2) Approx. 36V
CN II1-8 - -
Unused
(-, CUPON)
pp

CN111-10
CNII1-9 -
(87, SSP-, Approx. 12V
(84, SSP+)
TP-)
CN111-10 CN111-10
(87, SSP-, (87, SSP-, - Approx. OV
TP-) TP-)
CN111-10
CN111-11 -
(87, SSP-, 0 to 12V
(85, SSPI)
TP-)
CN111-10
CNlll-12 -
(87, SSP-, 0 to 12V
(86, SSP2)
TP-)
CNlll-13 - -
Immeasurable
(89, TP+)

Contactor panel ASSY


CN27 connector basic conditions (battery plug connected, key switch ON)
Connector No.mConnector No. Conditions Standard: Remarks
CN27-1 P I terminal Battery plug OFF and CN
Approx. O n
(PI, P I ) (PI, P I ) 27 disconnection
CN27-2 P I terminal Battery plug OFF and CN
Approx. O n
(PI, P I ) (PI, P I ) 27 disconnection
Connector No.-Connector No. Conditions Standard: Remarks
CN27-3 P2 terminal Battery plug OFF and CN
Approx. OR
(p2, p2) (p2, p2) 27 disconnection
CN27-4 P I terminal Battery plug OFF and CN
Approx. OR
(101, F4) (PI, P I ) 27 disconnection
CN27-5 P I terminal Battery plug OFF and CN
Approx. O n
(41, F5) (PI, PI) 27 disconnection
CN27-6 P2 terminal Battery plug OFF and CN
Approx. OR
(44, F6) (p2, p2) 27 disconnection
CN136connector basic conditions (battery plug connected, key switch ON)
Connector No.uConnector No. Conditions Standard: Remarks
CN136-1 CN136-2 Battery plug OFF and CN
Approx. 2052
(PI, P I ) (1, MB+) 136 disconnection
CN136-2 CN136-1 Measurement with (-) probe in
Approx. 11V
(PI, P I ) (2, MB-) contact with CN136-1
CN136-3 P I terminal Battery plug OFF and CN
Approx. OR
(p2, p2) (PI, P I ) 136 disconnection
CN136-3, P I terminal Battery plug OFF and CN
Approx. OR
(101, F4) (PI, P I ) 136 disconnection
CN136-4 P2 terminal Battery plug OFF and CN
Approx. OR
(41, F5) (p2, p2) 136 disconnection
CN136-4, P2 terminal Battery plug OFF and CN
Approx. OR
(44, F6) (P2, P2) 136 disconnection
2-26

CONTROLLER
MAIN CONTROLLER ASSY
REMOVAL INSTALLATION

Removal Procedure
1 Disconnect the battery plug.
2 Open the battery hood.
3 Remove the main controller cover.
4 Disconnect the wiring of the main controller ASSY.
5 Remove the main controller ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
TRAVELING AC DRIVER
REMOVAL INSTALLATION
Caution:
Before starting the job, measure the voltage between P3 and N l ; if there is any voltage, insert a
resistor at approx. 100Q between P3 and N to discharge the capacitor.

Removal Procedure
1. Disconnect the battery plug.
2. Open the battery hood.
3. Remove the main controller cover.
4. Remove the rear side cover.
5. Remove the controller fan.
6. Disconnect the outer wiring of the traveling AC driver (LH, RH) at the connectors and terminals.
7. Remove the traveling AC driver (LH).
8. Remove the traveling AC driver (RH).
Installation Procedure
The installation procedure is the reverse of the removal procedure.
MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL ASSY
REMOVALoINSTALLATION
Caution:
Before starting the job, measure the voltage between P3 and N2; if there is any voltage, insert a
resistor at approx. 100R between P3 and N to discharge the capacitor.

Removal Procedure
1. Disconnect the battery plug.
2. Open the battery hood.
3. Remove the main controller cover.
4. Remove the rear side cover.
5. Remove the cooling fan.
6. Disconnect the outer wiring of the material handling AC driver at the connectors and terminals.
7. Remove the material handling AC driver.
8. Remove the contactor panel ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
INSPECTION
1. Cooling fan (for travelinglmaterial handling AC driver)
lnspection method
Disconnect the fan connector
Portion
Measurement
to be Standard Tester range
terminals
inspected
CN113-1 (7)-
Traveling

Material
CN113-2 (8)
CN114-1 (9) -
- R R x l

handling CN114-2 (10)

2. MB (power supply contactor)


lnspection method
Disconnect CN134 connector, and measure the
resistance of the MB coil.
Portion
Measurement
to be Standard Tester range
terminals
inspected
Approx.
Both terminals of
MB coil 20 fi (at R x l
CN134
20°C)

3. FUSES
lnspection method
Disconnect the fuse and measure the insulation
resistance
Portion
Measurement
to be Standard Tester range
terminals
inspected
Both terminals of
FUSES 0 fi R x l
fuse
CHECK MOTOR INPUT VOLTAGE
When traveling or material handling operation seems abnormal, it is possible to accurately judge if the
controller is functioning correctly or not by measuring the motor input voltage.
Drive Motor Input Voltage Measurement
Measuring method Procedure
(1) Disconnect the battery plug.
(2) Jack up the front wheels.
(3) Open the battery hood
(4) Remove the side cover and rear side cover.
(5) Connect the (-) of the analog voltmeter to N1 terminal of traveling AC driver 1 (or 2).
(6) Connect the (+) probe of the voltmeter to P7 (or P71).
(7) Connect the battery plug.
(8) Turn the key switch to ON. Release the parking brake.
(9) Shift the direction switch to the forward (or backward) position.
(10) Depress the accelerator pedal fully and record the voltmeter reading at the time. (Without applying
the brake)
(11) Repeat steps (6) through (10) also for P8 (P81) and P9 (P91).
(12) Repeat steps (5) through (11) also for traveling AC driver2.
(13) Compare voltages measured between N1 and each of P7, P8, P9, P71, P81 and P91 and check
that the difference between the measured voltages meets the standard shown below.
Difference of input voltage at P7, P8, P9, P71, P81, and P91
Standard: 2V or less

1
Traveling AC driver 1

CNllO

Traveling AC
Pump Motor Input Voltage Measurement
Measuring method Procedure
(1) Disconnect the battery plug.
(2) Open the battery hood
(3) Remove the side cover and rear side cover.
(4) Connect the (-) probe of an analog voltmeter to the N2 terminal.
(5) Connect the (+) probe of the voltmeter to P14.
(6) Connect the battery plug.
(7) Turn the key switch to ON.
(8) Operate the tilt lever to the backward position and record the voltmeter reading in the relief state.
(9) Repeat steps (5) through (8) also for P I 5 and P16.
(10) Compare voltages measured between N2 and each of P14, P I 5 and P I 6 and check that the
difference between the measured voltages meets the standard shown below.
Difference of input voltage at P I 4, P I 5 and P I6
Standard: 2V or less
-- -

REASSEMBLY
Contactor Panel ASSY Reassembly Drawing

Caution:
Insulation sheet Be sure to install insulating sheets without fail.
Failure to install the insulating sheet under the MB
contactor will cause a critical failure.
Check the insulation resistance between the bracket and
each P terminal after controller reassembly.
Standard: 3 MQ or more
DISPLAY
If the cause of trouble is judged to exist in the display, measure the voltage at the connector to which
voltage is applied.

CN70 connector basic condition (Battery plug connected)


Connector No. a Connector No. Conditions Standard: Remarks
CN70-14 CN70-30
Approx. 10 to 18V
(16, D15V) (14, GNDD)
DIRECTION SWITCH
REMOVAL INSTALLATION

Removal Procedure
1. Disconnect the battery plug.
2. Remove the steering wheel. [Point I]
3. Remove the instrument panel.
4. Remove the direction cover (rear and front)
5. Remove the column cover (rear).
6. Disconnect the wiring of the direction switch, lamp switch and key switch.
7. Remove the direction switch.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[POINT I]
Disassembly:
Use the SST to remove the steering wheel.
SST 09950-76003-71
(09950-50012)
2-36

DISASSEMBLYeINSPECTION lREASSEMBLY

Disassembly Procedure
1. Remove the cam.
2. Remove the horn contact.
3. Remove the steering angle sensor.
4. Remove the light control valve ASSY.
5. Remove the direction switch ASSY.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
ACCELERATOR POTENTIOMETER
ADJUSTMENT
1. Check the ONIOFF condition of the switch (SWAC) by
operating accelerator pedal.
Measurement terminals 51 - 64
Pedal not oper-
42
Standard: ated
Pedal operated Continuity

Adjustment of Accelerator Potentiometer Installation


(1) Apply Three Bond 1401B to the threaded portion of a
set screw and assembly accelerator ASSY.
(2) Temporarily install the potentiometer.
(3) Check the ONIOFF switching point of the accelerator
switch (SW AC).
When thickness gauge I.Omm (0.039in) is inserted:
OFF
When thickness gauge 2.0mm (0.079in) is inserted:
ON

(4) After adjusting the switch ONIOFF operation, apply


yellow paint to the head of a set screw.
BRAKE SWITCH ADJUSTMENT
FOOT BRAKE
1. Adjust brake pedal play.
Standard 5 to 9mm(0.20 to 0.35in)
2. Adjust brake rod length.
(See P9-15)
3. Check continuity of the limit switch for the stop light
when the brake pedal is operated.

Standard: Not operated: OFF (6.Q)


Operated: ON(OR)
4. Check that the limit switch for the regenerative brake
turns ON (OFF) when the brake pedal is depressed
further (5 to 6mm [0.2 to 0.24inl) from the position
without any play.
Standard: Not operated: ON(OR)
Operated: OFF (6.R)

5. If the standard is not met, adjust by bending each limit


switch bracket.

PARKING BRAKE
1. Check the ONIOFF operation of the parking brake limit
switch.
Standard: Lever returned to original position:
ON (OQ)
Lever pulled: OFF (m Q)
2. If the standard is not met, adjust the limit switch
installation location.
MATERIAL HANDLING LEVER SWITCH
ADJUSTMENT
1. Operate the material handling lever and check continuity
of the limit switch.
Standard: Lift: CN11-I- CN11-2
Not operated: OFF (- R)
Operated: ON (0 Q)
2. Operate the material handling lever and check that the
limit switch is turned on at dimension A beyond the no-
play position.
A = 5 to 15mm (0.39 to 0.79in)
3. If the limit switch ON timing does not occur within
dimension A, adjust the limit switch installation location.
As for the tilt lever operation, adjustment is not necessary, as
the micro switch is built in the control valve ASSY.
MULTI-DISPLAY FUNCTIONS
Page
MULTIPLE DISPLAY .......................... 3-2
GENERAL .................................... 3-2
SPECIFICATIONS.............................. 3-6
GENERAL FUNCTION AND MANAGER'S FUNCTION 3-7
DISPLAY INDICATION LIST ...................... 3-8
ABBREVIATIONS DISPLAYED ON THE SCREEN .... 3-10
GENERAL FUNCTIONS ....................... 3-11
OPERATING PROCEDURE OF FUNCTION SETTING 3-13 .
MANAGER'S FUNCTIONS ..................... 3-18
PASSWORD FOR MANAGER'S FUNCTION ........ 3-18
.
OPERATING PROCEDURE OF FUNCTION SETTING 3-19
DIAGNOSIS .................................. 3-24
DIAGNOSIS CODE LIST ........................ 3-24
MASK FUNCTIONS ........................... 3-30
GENERAL .................................... 3-30
PASSWORD FOR MASK FUNCTION .............. 3-32
OPERATION ON MASK MENU SCREEN ........... 3-33
ANALYZER ................................... 3-34
TUNING ...................................... 3-54
OPTION SET .................................. 3-64
MATCHING ................................... 3-68
TIRE CONSTANT SET .......................... 3-71
MULTIPLE DISPLAY
GENERAL
The multiple display indicates various types of vehicle information by switching the screen according to
need.
Display and Buttons

Initial screen upon key switch on


f , I I

During traveling Upon error occurrence

(1) Parking brake ON indicator (7) Multiple display area

(2) Travel speed limit indicator ( 8 ) DOWN button


(3) Diagnosis ON indicator (9) UP button

(4) Overheat warning indicator (10) Power select button


(5) Battery charge indicator (11) Hour meter selector button
(6) Power select indicator
(1) Parking brake ON indicator
This indicator comes on when the parking brake is activated. If the accelerator pedal is depressed with
the direction lever in the forward or reverse position, beeps sound to warn the operator.
(2) Travel speed limit indicator
This indicator comes on when the level is set to 7 or less on the TRAVEL SPEED LlMlTTER LEVEL
SETTING screen. (The setting in USA models can be changed only by the Manager's functions.)
(3) Diagnosis ON indicator
Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same
time, the corresponding error code is displayed and buzzer sounds to warn the operator.
Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to
six error codes are displayed with alternation at intervals of 2 seconds.
On a vehicle without matching performed for the SAS function, this indicator comes on to warn the
service person. This indicator also comes on to warn the service person on a mini lever model vehicle
without matching performed for the mini lever function. Perform matching by referring to the
MATCHING section.
(4) Overheat warning indicator
If the temperature of the main controller, traveling AC driver, material handling AC driver, drive motor or
pump motor rises beyond the specified level, the overheat warning indicatorblinks. At the same time,
a buzzer sounds to warn the operator.
When the indicator is blinking, vehicle operation is restricted and the overheat section indication blinks.
Description
Overheat warning indicator
Indication Overheat section
f \

CIR Main controller


DCR Traveling AC driver
PCR Material handling AC driver

'. 1 DM Drive motor

Overheat section PM Pump motor

Vehicle Operation Restriction when Overheated


Overheat Specifica- Description of control
Mode
section tion Primary control Secondary control Tertiary control

STD . 1. Character indication and indicator blink


Main
UL-EEspec P 2. Buzzer for 5 seconds
controller
(OPT) 3. Change to half throttle
s
STD . 1. Character indication and indicator blink
Traveling
UL-EE spec P 2. Buzzer for 5 seconds
AC driver
(OPT) 3. Change to half throttle
s
Material STD . 1. Character indication and indicator blink
handling UL-EE spec P 2. Buzzer for 5 seconds
AC driver (OPT) 3. Restrict material handling output
Overheat Specifica- Description of control
Mode
section tion Primary control Secondary control Tertiary control
1. Character indication 1. Character indication
and indicator blink and indicator blink
H 2. Buzzer for 5 2. Buzzer continues
seconds 3. Change to half
3. Change to S mode throttle
STD 1. Character indication
P and indicator blink
blink
2. Buzzer continues
S 3. Change to half
throttle
Drive motor
1. Character indication 1. Character indication
Character indication
and indicator blink and indicator blink
and indicator blink
H 2. Buzzer for 5 2.Buzzer continues
2. No buzzer
seconds 3. Change to half
3. Restrict drive output
3. Change to S mode throttle
UL-EE spec
(OPT) 1. Character indication Character indication
P and indicator blink and indicator blink
2. Buzzer for 5 2. Buzzer continues
seconds 3. Change to half
S 3. Restrict drive
throttle
output

1. Character indication and indicator blink


STD P 2. Buzzer continues
3. Restrict material handling output
S
1. Character indication 1. Character indication
Character indication
and indicator blink and indicator blink
and indicator blink
H 2. Buzzer for 5 2. Buzzer continues
2. No buzzer
seconds 3. Restrict material
3. Change to P mode 3. Change to mode handling output
Pump motor 1. Character indication 1. Character indication
and indicator blink and indicator blink
UL-EEspec 2. Buzzer continues
P 2. Buzzer for 5
(OPT) seconds 3. Restrict material
3. Change to S mode handling output
1. Character indication
and indicator blink
S 2. Buzzer continues
3. Restrict material
handling output
(5) Battery charge indicator
This indicator indicates the remaining battery charge in 10 stages.
A: Low remaining battery charge warning
Low remaining battery charge warning The battery charge indicator blinks when the remaining
battery charge drops to the set level or below. When the
key switch is turned from OFF to ON in this state, a
buzzer sounds for 5 seconds to warn the operator.
B: Battery overdischarge warning (lift interrupt function)
When the battery charge decreases further below the
set level after the remaining battery charge warning, any
Number of segments corresponding to attempt at traveling or material handling operation will
the remaining battery charge. cause all charge indicator segments to blink and the
alarm to sound to warn the operator. At this time, the
material handling operation is disabled in USA and
Battery overdischarge warning Canada models. However, when the key switch is turned
f- 7
from .OFF to ON, the operation can be performed only
once for 30 seconds. In export models, the material
handling operation during traveling is disabled.
Note:
The level can be set using TUNING function of the mask
\ J
1 function. (See page 3-54.)
All segments blink.

(6) Power select indicator (traveling and material handling)


A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by
pressing the power select button on the GENERAL screen.
If all symbols are enclosed, control is performed in the original mode (level set on the POWER
CONTROL LEVEL SETTING screen).
(7) Multiple display area
The date and time are normally displayed in this area. This area is also used for various function
settings and error code displays of the diagnosis function.
(8) DOWN button
The DOWN button is used for setting the clock on the GENERAL screen.The DOWN button is also
used for setting the level of each function on the MANAGER'S FUNCTION screen*.
*: Operation can be performed by inputting the manager's password.
(9) UP button
The UP button is used for setting the clock on the GENERAL screen.The UP button is also used for
setting the level of each function on the MANAGER'S FUNCTION screen*.
*: Operation can be performed by inputting the manager's password.
(11) Power select button
USA models:
Press the button for 2 seconds or more on the GENERAL screen to set the clock.
Only when "YES" is selected on the MANAGER'S FUNCTION screen*, the S, P or H modes can be
changed by this button. ..A square indicating the selection moves to the right each time the power
select button is pressed.
Press the button for 2 seconds or more to set the level of each function.
Export models:
The button selects S, P or H mode. The selected mode can be changed each time the power select
button is pressed on the GENERAL screen.
Press the button for 2 seconds or more to set the level of each function.
*: Operation can be performed by inputting the manager's password.
(11) Hour meter selector button
This button changes displayed items of multi-hour meter function.
(12) Low temperature warning indicator
Warn the low temperature of the traveling and material handling AC drivers. When the material
handling AC driver temperature becomes low, a buzzer sounds to warn the operator for 5 seconds. At
the same time, it restricts the material handling output.
The low temperature section indication blinks.
Description
r I Indication Low temperature section
COLD DCR Traveling AC driver
\i . - - - - - - - - - - - - COLD PCR Material handling AC driver
L. S P H

\ J

Low temperature section

(13) Maintenance timer indicator


This indicator blinks to notify the need of maintenance when
the time set on the PLANNED MAINTENANCE HOUR
SETTING screen passes. When the key switch is turned
from OFF to ON in this state, the buzzer sounds for 5
seconds to warn the operator.

Maintenance timer indicator

SPECIFICATIONS
LCD Dot matrix + fixed display
Buttons Four buttons
Back light LED type that comes on when the key switch is turned to ON
Heater Temperature detection type (provided only on the cold-storage model)
GENERAL FUNCTION AND MANAGER'S FUNCTION
1. General functions can generally been used or seen by the user.
2. The Manager's function is a function that the manager can use by inputting the password.
3. The functions included in the General function and the Manager's function differ in accordance with the
specifications of the model as follows.
0:General function .:Manager's function
USA model
Export model
Functions (standard model)
Battery charge indicator 0 0
Speedometer 0 0
Status display Travel speed limiter indicator 0 0
function
Parking brake ON indicator 0 0
Power select indicator 0 0
Power select 0
Traveling power control level setting 0
Level setting
Material handling power control level setting 0
function
Travel speed limiter level setting 0
Maintenance hour meter setting
Key ON hour meter 0 0
Traveling hour meter 0 0
Material handling hour meter 0 0
Traveling or Material handling hour meter 0 0
Multi-hour meter
Odometer 0 0
function
Lap time meter 0 0
Trip meter 0 0
Maintenance hour meter 0 0
Calendar . clock 0 0
Battery overdischarge warning 0 0
Low remaining battery charge warning 0 0
Overheat warning 0 0
Low temperature warning 0 0
Parking brake ON warning 0 0
Warning function Parking brake OFF warning 0 0
-
Return to neutral warning 0 0
Material handling operation lock 0*1 0*1
Overspeed alarm 0 0
Maintenance indicator 0 0
Diagnosis display 0 0
Only for models with mini lever (OPT).
*I:
DISPLAY INDICATION LIST
USA models (standard models)

elected by the user


ng to hour meter display IChecking traveling or material handling system operation time I
a W Q
&
+-w To be set by the user
Clock set I Adjustment of indicated time I
*l:Press button (3) for 2 sec. or more.
+
C
W 7
[MANAGER'S FUNCTION screen1
r
s To be selected by the manager
Switching to hour meter display I Checking traveling or material handling system operation time
Power select I Power mode selection
To be set by the manager
Travel speed limiter level setting Setting the travel speed limiter level
Speed alarm Traveling speed setting for overspeed alarm
----+ Power control select Fine adjustment of each of traveling and material handling
power control levels
F F
Clock set Adjustment of indicated time
*l:Press button (3) for 2 sec. or more.

OPTION SET
Export models
3-10

ABBREVIATIONS DISPLAYED ON THE SCREEN


Abbreviation Meaning Abbreviation Meaning
A1 Attachment switch 1 SSD2 Drive motor 2 rpm sensor
A2 Attachment switch 2 SSP Pump motor rpm sensor
CIR Controller STS Steering angle sensor
DCR Traveling AC driver STS I Steering angle sensor 1
DM Drive motor STS2 Steering angle sensor 2
Steering angle sensor for straight
DSF Forward direction switch STSC
traveling
DSR Backward direction switch SWAC Accelerator switch
FAN Cooling fan SWTK Tilt knob switch
HIM Hour meter T Forward and backward tilt switch
Deviation of steering angle knob posi- Traveling AC driver control board
K-DIFF TBD
tion surface temperature
Material handling AC driver control
K-POS Steering angle knob position TBP
board surface temperature
KSOL Steering synchronizer solenoid TD Drive motor temperature
LOAD Material handling hydraulic pressure TEMP CPU board surface temperature
L Lift switch THCD Main drive circuit temperature
LSB Brake switch THCP Main pump circuit temperature
LSD Seat switch TILTF Forward tilt restriction position
MH Lifting height switch TILTL Tilt level position
PIC Power control TIRE Tire angle sensor voltage
PCR Material handling AC driver TP Pump motor temperature
PM Pump motor VB48 Battery voltage
Traveling AC driver power source
POTA Accelerator potentiometer VBBD
voltage
Material handling AC driver power
POTT Tilt angle potentiometer VBBP
source voltage
SPD Main traveling speed VBKS Voltage after key switch
SPL Load sensor VBMB Main controller input voltage
SSDl Drive motor 1 rpm sensor VBSOL Solenoid power source voltage
3-11

GENERAL FUNCTIONS
Changing Display
USA models (standard models)

Button (I)Button (2)

GENERAL screen Hour meter display


selection

.'
1
Button (3)

0 Press button (3)


for 2 seconds or more.

CLOCK SET FUNCTION


SELECTION screen

0 Press button (3)

GENERAL screen
3-12

Export models
Button (1) Button (2)

Hour meter display


selection
GENERAL screen

Button (3)
Press button (3) *
I

for 2 seconds or more. I*


*
I
**
*
I

TRAVEL SPEED LlMlTTER *


I

LEVEL SETTING screen **


*
**
I

**
.' J *

0 Press button (3)


***
**
**
*

OVERSPEED ALARM
SETTING screen
I*
L /
**
*I

0 Press button (3)


**

*
I
**a

I
**
I
*a
POWER CONTROL **
FUNCTION SELECTION **
*
screen *
***
*I
I
**

0 Press button (3) **


I

**
**

CLOCK SET FUNCTION


SELECTION screen
(To GENERAL screen)
OPERATING PROCEDURE OF FUNCTION SETTING
GENERAL SCREEN
1. Hour meter display selection
Press button (4) to select the hour-meter display.

Button (2)
GENERAL screen
f
f

a -----*--------------I-.----
a
a
a
a
a
a
.' 1 *I
1 \ I
a
Button (3) Button (4) a

0 Press button (4) Press button (4)

A: Key ON hour meter H : Maintenance hour meter


f

\ J

0 Press button (4) 0 Press button (4)

B:Traveling hour meter


C:Material handling hour meter G :Trip meter
f \

\ 1

0 Press button (4) 0 Press button (4)


D:Traveling or material handling hour meter
E:Odometer F : Lap time meter

Press
button (4)
The lap t ~ m emeter and trip meter can be reset by pressing button (1) for 2 seconds or more.
Press button (3) on each screen to return to the GENERAL screen.
Function Description
A Key ON hour meter Indicates the total key ON time
B Traveling hour meter Traveling operation time
C Material handling hour meter Material handling operation time
Total time of traveling and material handling operation (when both
Travelinglmaterial handling
operations occur at the same time, only operation time of either
hour meter
operation)
E Odometer Total distance traveled
F Lap time meter Lap time upon key ON
G Trip meter Trip distance
H Maintenance hour meter Accumulated time total in key on-state since last maintenance

2. Power select mode switching (S, P or H) (Export models


f \
only)
Press button (3) on the GENERAL screen to change the
travellmaterial handling power select mode. When all of
S, P and H are highlighted by squares, the control is
performed in the mode set on the Power Control Level
\ J Set Menu screen.
S: Standard mode
Button (3)
P: Power mode
Power select indicator
H: High power mode

TRAVEL SPEED LIMITER LEVEL SETTING


SCREEN (Export models only)
The travel speed limiter level is set on this screen.
Press button (3) on the GENERAL screen for 2 seconds or
more to display the TRAVEL SPEED LIMITER LEVEL
SETTING screen.
1. Press button ( I ) to decrease the travel speed limiter
level.
2. Press button (2) to increase the travel speed limiter
Button (3) level.
3. Press button (3) to display the next screen.

OVERSPEED ALARM SETTING SCREEN


Button (I)Button (2)
(Export models only)
The traveling speed level for the overspeed alarm is set on
this screen.
Press button (3) on the TRAVEL SPEED LIMITER LEVEL
SETTING screen to display the OVERSPEED ALARM
SETTING screen.
1. Press button (1) to decrease the traveling speed setting.
2. Press button (2) to increase the traveling speed setting.
Traveling speed setting 3. Press button (3) to display the next screen.
for overspeed alarm
POWER CONTROL FUNCTION SELECTION
Button (1)
\
Button (2)
/
SCREEN (Export models only)
F
The travel and material handling power control levels can be
set independently using this screen.
Press button (3) on the OVERSPEED ALARM SETTING
screen to display the POWER CONTROL FUNCTION
SELECTION screen.
L /
Button (3) 1. Press button ( I ) on the POWER CONTROL FUNCTION
Select ''YES'' and SELECTION screen, select "YES" and press button (3)
press button (3) to display the TRAVELING POWER CONTROL LEVEL
TRAVELING POWER CONTROL SETTING screen.
LEVEL SETTING screen
(1) TRAVELING POWER CONTROL LEVEL SETTING
screen
1) Press button ( I ) to select the lower level.
2 ) ' ~ r e s sbutton (2) to select the higher level.
3) Press button (3) to display MATERIAL HANDLING
POWER CONTROL LEVEL SETTING screen.
0 Press button (3) (2) MATERIAL HANDLING POWER CONTROL LEVEL
MATERIAL HANDLING POWER SETTING screen
CONTROL LEVEL SETTING screen 1) Press button ( I ) to select the lower level.
2) Press button (1) to select the higher level.
3) Press button (3) to display the next screen.
2. To display the next screen, press button (2) on the
POWER CONTROL FUNCTION SELECTION screen,
select "NO" and press button (3); alternatively, press
button (3) on the MATERIAL HANDLING POWER
0 Press button (3) CONTROL LEVEL SETTING screen.
PLANNED MAINTENANCE
HOUR SETTING screen
CLOCK SET FUNCTION SELECTION SCREEN
The year, month, day, day of week, time and 12124-hour display can be set independently.
USA models
Press button (3) on the GENERAL screen for 2 seconds or more to display the CLOCK SET FUNCTION
SELECTION screen.
Button (I)Button (2)
f \

.' J
~utton(3) Button (4)
Press button (3)
for 2 seconds or more.

'. J \ /

0Press button (3) 0Press button (3)


a
a
a
a
a
a
a
a
8
0
a
a
a
a
a
a
a

0 Each press of button will shift


(3)
: the selection item in this order:
a
a
a
a

month, day, ... and minute.


End of clock
< r \

Press button (3)


L /

1. Press button ( I ) on the CLOCK SET FUNCTION SELECTION screen, select "YES" and press button
(3) to display the CLOCK SET screen.
(1) CLOCK SET screen
1) Press button (1) to decrease the selected (blinking) value.
2) Press button (2) to increase the selected (blinking) value.
3) Press button (3) to enter the selected (blinking) value and proceed to the next item.
4) Press button (3) when "MINUTES" is selected on the CLOCK SET FUNCTION SELECTION
screen to display the'next screen (GENERAL screen).
2. Press button (2) on the CLOCK SET FUNCTION SELECTION screen, select "NO" and press button
(3) to display the GENERAL screen.
Export models
Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select "NO", and press
button (3), or press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING
screen to display the CLOCK SET FUNCTION SELECTION screen.
Button ( I ) Button (2)
r \

'
.
I

Button (3) Button (4)


\

0 Press button (3)


Select "NO" and I
I
press button (3) I
I
roorrrrrr-rrrr-r-r---------.---------------------------
0
I-r-r~r--~r--r-r---r--*--- --C---.)----------------.------
I

0
, ------------Y?, F,.,%-L!-O
a ~ l ~ ~ l l Hl ~ @ S P

0 Press button (3) 0 Press button (3)


I
I
I
I
I
I
I
I
I
I
I
I
I
I
L J I
#
I
#
Each press of button (3) will shift I

: the selection item in this order: month,


day, . . and minute
End of clock setting

Press button (3)


L J L J

3. Press button ( I ) on the CLOCK SET FUNCTION SELECTION screen, select "YES" and press button
(3) to display the CLOCK SET screen.
(1) CLOCK SET screen
1) Press button ( I ) to decrease the selected (blinking) value.
2) Press button (2) to increase the selected (blinking) value.
3) Press button (3) to enter the selected (blinking) value and proceed to the next item.
4) Press button (3) when "MINUTES" is selected on the CLOCK SET FUNCTION SELECTION
screen to display the next screen (GENERAL screen).
4. Press button (2) on the CLOCK SET FUNCTION SELECTION screen, select "NO" and press button
(3) to display the GENERAL screen.
MANAGER'S FUNCTIONS
PASSWORD FOR MANAGER'S FUNCTION
Note on password input
1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button
may be damaged.
2. If a mistake is made part of the way through, turn the key switch to OFF and begin again. If the
MANAGER'S FUNCTION screen does not appear after several attempts, the system may be faulty.
Password Input Procedure

/ \
Button (3) Button (4)
1. Press buttons (3) and (4) at the same time.

0
Button (1)
/
\ \

I-
a I,
[ S E P I B O AM
I----_________________

\
L 1
2. Within 10 seconds, press button (1)
MANAGER'S FUNCTION screen

-0 0

3. Within 10 seconds, press button (2) 4. Within 10 seconds, press buttons (1) and (2)
at the same time for more than 2 seconds.
Procedure Operation Vehicle operation
1 Press buttons (3) and (4) at the same time. A short beep sounds.
2 Press button (1). (in 10 seconds after pressing button (3) and (4)) A short beep sounds.
3 Press button (2). (in 10 seconds after pressing button (1)) A short beep sounds.
Press buttons (1) and (2) at the same time and hold for 2 seconds
4 or more. (in 10 seconds after pressing button (2), End of password Short beeps sound.
input)
5 The MANAGER'S FUNCTION screen appears automatically.
OPERATING PROCEDURE OF FUNCTION SETTING
Changing Display
Input the password o n the GENERAL screen t o display the MANAGER'S FUNCTION screen.

MANAGER'S Button (1) Button (2)


FUNCTION screen
f Press button (4)
) Hourmeter display selection
b Power control selection
Select "NO" and press button (3)
) GENERAL screen

..................................

I
L I
I
I
Button (3) Button (4) a

0 Press button (3) for 2 seconds or more.


I
I
I
e
I
TRAVEL SPEED LIMITER I
e
I
LEVEL SETTING screen I
I
I
I
e
I
I
I
I
e
I
I
I
I
I
I
.'
0
1

Press button (3) 6 Press button (3)

OVER SPEED ALARM CLOCK SET FUNCTION


SETTING screen SELECTION screen

0 Press button (3) 0 Press button (3)

POWER CONTROL PLANNED MAINTENANCE


FUNCTION SELECTION screen HOUR SETTING screen
\

Press button (3).


\ 1 \ J
Select "YES" and
press button (3).
0 Press button (3)

TRAVELING POWER CONTROL MATERIAL HANDLING POWER


LEVEL SETTING screen CONTROL LEVEL SETTING screen

\ J \ 1
MANAGER'S FUNCTION SCREEN
1 . Hour meter display selection
Press button (4) to select the hour-meter display.
*: The displayed contents on each function screen is the same as that for the GENERAL function.

a .....-----.-.-.....-.------ 0
0
o
m
0
o
m
0
0
0
0

0 Press button (4) 6 Press button (4)

A:Key ON hour meter H:Ma~ntenancehour meter

,' J

9 Press button (4) 0 Press button (4)

B:Traveling hour meter


C:Material handling hour meter G:Trip meter

---------------
RESET- lSW

0 Press button (4) 0 Press button (4)


D:Traveling or material handling hour meter
E:Odometer F:Lap time meter

Press
L J button (4)
The lap time meter and trip meter can be reset by pressing button ( I ) for 2 seconds or more.
2. Power select mode switching (S, P or H)
f Press button (3) on the MANAGER'S FUNCTION
screen to change the travellmaterial handling power
select mode. When all of S, P and H are highlighted by
squares, the control is performed in the mode set on the
Power Control Level Set Menu screen.
\ S: Standard mode
\ P: Power mode
Button (3)
Power select indicator H: High power mode
*: For Export models, the mode can be set by the GENERAL
FUNCTION.

TRAVEL SPEED LIMITER LEVEL SETTING


SCREEN
The travel speed limiter level is set on this screen.
Press button (3) on the MANAGER'S FUNCTION screen for
2 seconds or more to display the TRAVEL SPEED LIMITER
LEVEL SETTING screen.
1. Press button ( I ) to decrease the travel speed limiter
level.
2. Press button (2) to increase the travel speed limiter
Button (3) level.
3. Press button (3) to display the next screen.
*: For Export models, the mode can be set by the GENERAL
FUNCTION.

OVERSPEED ALARM SETTING SCREEN


Button (I)Button (2) The traveling speed level for the overspeed alarm is set on
this screen.
Press button (3) on the TRAVEL SPEED LIMITER LEVEL
SETTING screen to display the OVERSPEED ALARM
SETTING screen.
1. Press button (1) to decrease the traveling speed setting.
2. Press button (2) to increase the traveling speed setting.
3. Press button (3) to display the next screen.
*: For Export models, the mode can be set by the GENERAL
for overspeed alarm FUNCTION.
POWER CONTROL FUNCTION SELECTION
Button (1) Button (2) SCREEN
\ /
The travel and material handling power control levels can be
r
set independently using this screen.
Press button (3) on the OVERSPEED ALARM SETTING
screen to display the POWER CONTROL FUNCTION
SELECTION screen.
\
I
Button (3) 1. Press button ( I ) on the POWER CONTROL FUNCTION
Select "YES" and SELECTION screen, select "YES" and press button (3)
press button (3) to display the TRAVELING POWER CONTROL LEVEL
TRAVELING POWER CONTROL SETTING screen.
LEVEL SETTING screen
(1) TRAVELING POWER CONTROL LEVEL SETTING
screen
1) Press button (1) to select the lower level.
2) Press button (2) to select the higher level.
3) Press button (3) to display MATERIAL HANDLING
POWER CONTROL LEVEL SETTING screen.

0 Press button (3) (2) MATERIAL HANDLING POWER CONTROL LEVEL


SETTING screen
MATERIAL HANDLING POWER
1) Press button ( I ) to select the lower level.
CONTROL LEVEL SETTING screen
2) Press button (1) to select the higher level.
3) Press button (3) to display the next screen.
2. To display the next screen, press button (2) on the
POWER CONTROL FUNCTION SELECTION screen,
select " N O and press button (3); alternatively, press
button (3) on the MATERIAL HANDLING POWER
0 Press button (3)
CONTROL LEVEL SETTING screen.
*: For Export models, the mode can be set by the GENERAL
PLANNED MAINTENANCE FUNCTION.
HOUR SETTING screen

PLANNED MAINTENANCE HOUR SETTING


SCREEN
Planned maintenance hour is set on this screen.The time
setting can be set 10 to 2000 hours.
Press button (2) on the POWER CONTROL FUNCTION
SELECTION screen, select "NO" and press button (3);
alternatively, press button (3) on the MATERIAL HANDLING
POWER CONTROL LEVEL SETTING screen to display the
Current time Button (3) PLANNED MAINTENANCE HOUR SETTING screen.
1. Press button ( I ) to decrease the setting time.
2. Press button (2) to increase the setting time.
3. Press button (4) for 2 seconds or more to reset the
current time.
4. Press button (3) to display the next screen.
CLOCK SET FUNCTION SELECTION SCREEN
The year, month, day, day of week, time and 12124-hour display can be set independently. (They can also
be set on the GENERAL screen)
Press button (3) on the PLANNED MAINTENANCE HOUR SETTING screen to display the CLOCK SET
FUNCTION SELECTION screen.

Button (1) Button (2)


\ I
f

L
.' /
\ 1
Button (3) Button (4)
0 Press button (3)
:-..-.....--...~-..--------------------------
0

L J '
. 1

0 Press button (3) 0 Press button (3)


I
*0
I
I
I
I
0
**
I
0
0
0
I
I
I

9
I
I
I
Each press of button (3) will shift
; the selection item in this order:
month, day, ... and minute. MANAGER'S FUNCTION screen
(end of clock setting)

Press button (3)


\ 1

1. Press button ( I ) on the CLOCK SET FUNCTION SELECTION screen, select "YES" and press button
(3) to display the CLOCK SET screen.
2. Press button (2) on the CLOCK SET FUNCTION SELECTION screen, select "NO" and press button
(3), or press button (3) when "MINUTES" is selected on the CLOCK SET FUNCTION SELECTION
screen to display the MANAGER"S FUNCTION screen.
*: As for the setting method for CLOCK SET FUNCTION SELECTION screen, refer to CLOCK SET
FUNCTION SELECTION screen in GENERAL functions. (See page 3-16.)
DIAGNOSIS
1. When diagnosis is activated, the diagnosis ON indicator
Wrench symbol comes on and blinks on the screen and a beep sounds
to warn the operator that some abnormality has
occurred on the vehicle.
2. Also, up to three diagnosis error codes are displayed on
the screen. When the number of error codes exceeds
three, up to six are displayed on screens.
3. In order to enable battery level checking, battery charge
indicator is displayed during diagnosis error codes
Abnormality detection time display.
(Key ON hour meter)

DIAGNOSIS CODE LIST


Displayed code: Code indicated on the display when an abnormality occurs in the vehicle
Diag memory code: Code indicated on the display when mask function DlAG MEMORY is in use P3-39
CIR: Main controller, DCR-LH: Traveling AC driver 1, DCR-RH: Traveling AC driver 2,
PCR: Material handling AC driver
Diag
Displayed Detection
memory Faulty Phenomenon on vehicle
code controller
code
COLD - DCR: Low temperature Display only DCR-LH,
DCR DCR-RH
COLD - Restricted material
PCR: Low temperature PCR
. PCR handling output
30-1 30-1 DCR-LH: Low voltage DCR-LH
Traveling disabled
30-2 30-2 DCR-RH: Low voltage DCR-RH
Material handling and
30-3 30-3 PCR: Low voltage PCR
power steering stop
31-1 31-1 DCR-LH: Low starting voltage DCR-LH
Traveling disabled
31-2 31-2 DCR-RH: Low starting voltage DCR-RH
Material handling and
31-3 31-3 PCR: Low starting voltage PCR
power steering stop
32-1 32-1 DCR-LH: EEPROM abnormality DCR-LH
32-2 32-2 DCR-RH: EEPROM abnormality Operate under the default DCR-RH
32-3 32-3 PCR: EEPROM abnormality PCR
Communication abnormality from CIR to
33-1 33-1 DCR-LH
DCR-LH
Traveling disabled
Communication abnormality from CIR to
33-2 33-2 DCR-RH
DCR-RH
Communication abnormality from C/R to Material handling and
33-3 33-3 PCR
PCR power steering stop
61-1 61-1 Load sensor: Open .No NL control and forward
tilt restriction CIR
61-2 61-2 Load sensor: Short circuit .No automatic leveling
Diag
Displayed Detection
memory Faulty Phenomenon on vehicle
'Ode controller
code
62-1 62-1 Tilt angle sensor: Open .No forward tilt restriction
C/R
62-2 62-2 Tilt angle sensor: Short circuit .No automatic leveling
Forward and backward tilt SWs:
63-1 63-1
simultaneously on
.No forward tilt restriction
Forward tilt SW: Short circuit for more than
63-2 63-2 N o automatic leveling C/R
2 minutes
(Forward tilt disabled)
Backward tilt SW: Short circuit for more
63-3 63-3
than 2 minutes
64-1 64-1 Lift solenoid: Open
lnterruption of lift solenoid
64-2 64-2 Lift solenoid: Short circuit CIR
output
64-3 64-3 Lift solenoid: Drive circuit abnormality
65-1 65-1 Tilt solenoid: Open
Interruption of tilt solenoid
65-2 65-2 Tilt solenoid: Short circuit C/R
output
65-3 65-3 Tilt solenoid: Drive circuit abnormality
.NOforward tilt restriction
66-1 66-1 Tilt matching abnormality CIR
.No automatic leveling
.No low lift restriction and
67-1 67-1 Lifting height switch abnormality forward tilt restriction C/R
.No automatic leveling
71-1 71-1 Tire angle sensor: Open Traveling stop, no steering
C/R
71-2 71-2 Tire angle sensor: Short circuit knob synchronizer
72-1 * I 72-1 Steering angle sensor: STSl abnormality
72-2 * I 72-2 Steering angle sensor: STS2 abnormality NO steering knob
C/R
72-3 * I 72-3 Steering angle sensor: STSC abnormality synchronizer
72-4 * I 72-4 Steering angle sensor: Open
73-1 * I 73-1 Steering knob synchronizer solenoid: Open
Steering knob synchronizer solenoid: Short Steering knob
73-2 * I 73-2
circuit synchronizer solenoid C/R
Steering knob synchronizer solenoid: output stop
73-3 *' 73-3
Drive circuit abnormality
Traveling restriction,
74-1 74-1 Tire angle sensor matching abnormality C/R
no steering synchronizer

llml1 AO-1 DCR main drive circuit overheat Restricted traveling output
DCR-LH,
DCR-RH
DCR

41m1i AO-2 PCR main drive circuit overheat


Restricted material
handling output
PCR
PCR
.Traveling disabled
Material handling and
kl-1 Al-I C/R: High voltage C/R
power steering disabled
(solenoid off)
Diag
Displayed Detection
memory Faulty Phenomenon on vehicle
'Ode controller
code
A1-2 A1-2 DCR-LH: High voltage DCR-LH
Traveling disabled
A1-3 A1-3 DCR-RH: High voltage DCR-RH
Material handling and
A1-4 A1-4 PCR: High voltage PCR
power steering disabled

llml1 A2-1 CPU board overheat Restricted traveling output CIR


C/R

4[m11 A2-2 DCR-LH or DCR-RH board overheat Restricted traveling output


DCR LH
DCR~R,,'
DCR

l(ml1 A2-3 PCR board overheat


Restricted material han-
dling output
PCR
PCR
.Traveling disabled
.Material handling and
A3 A3 Incorrect battery connection CIR
power steering disabled
.MB not turned on
A4 A4 Accelerator switch abnormality Traveling disabled CIR
A6-1 A6-1 Lift switch abnormality
A6-3 A6-3 Tilt switch abnormality Material handling disabled CIR
A6-5 A6-5 Attachment switch Iabnormality
AA-1 AA-1 CPU board thermo-sensor abnormality CIR
AA-2 AA-2 DCR-L board thermo-sensor abnormality Restricted traveling output DCR-LH
AA-3 AA-3 DCR-R board thermo-sensor abnormality DCR-RH
Restricted material han-
AA-4 AA-4 PCR board thermo-sensor abnormality PCR
output
dling
.Traveling disabled
.Material handling and
AC AC Semiconductor switch abnormality CIR
power steering disabled
.MB not turned on
Communication abnormality from DCR-L
AD-1 Traveling CIR
to CIR (1)
Traveling disabled
Communication abnormality from DCR-L (when AD-4 and AD-6
AD-2 AD-2 CR
I
to CIR (2) occur at the same time,
MB not turned on)
Communication abnormality from DCR-R
AD-3 AD-3 Traveling disabled CIR
to CIR (1)
Traveling disabled
Communication abnormality from DCR-R (when AD-2 and AD-6
AD-4 AD-4 CR
,
to CIR (2) occur at the same time,
MB not turned on)
Communication abnormality from PCR to Material handling and
AD-5 AD-5 CIR
CIR (1) power steering disabled
Diag
Displayed Detection
memory Faulty Phenomenon on vehicle
'Ode controller
code
Material handling and
power steering disabled
Communication abnormality from PCR to
AD-6 AD-6 (when AD-2 and AD-4 CIR
CIR (2)
occur at the same time,
MB not turned on)
AF-1 AF-1 CPU abnormality ( I )
AF-2 AF-2 CPU abnormality (2) ,Traveling disabled
.Material handling disabled CIR
AF-3 AF-3 CPU abnormality (3) .Power steering disabled
AF-4 AF-4 CPU abnormality (4)
C1-I C1-I DCR-LH current sensor offset abnormality
DCR-LH
C1-2 C1-2 DCR-LH: Overcurrent
Traveling disabled
C1-3 C1-3 DCR-RH current sensor offset abnormality
DCR-RH
C1-4 C1-4 DCR-RH: Overcurrent

l ~ m ~C2-I Drive motor overheat


DCR-LH
DCR-RH
DM
Drive motor 1 thermo-sensor Restricted traveling output
C2-2 C2-2 DCR-LH
abnormality
Drive motor 2 thermo-sensor
C2-3 C2-3 DCR-RH
abnormality
DCR-LH main drive circuit thermo-sensor
C3-1 C3-1 DCR-LH
abnormality
. Restricted traveling output
DCR-RH main drive circuit thermo-sensor
C3-2 C3-2 DCR-RH
abnormality
C4-1 C4-1 Accelerator potentiometer abnormality (1)
C4-2 C4-2 Accelerator potentiometer abnormality (2) Traveling disabled
CIR
C4-3 C4-3 Accelerator potentiometer abnormality (3)
C4-4 C4-4 Accelerator potentiometer abnormality (4) Display only
C7 C7 Direction switch abnormality Traveling disabled CIR
C8-1 C8-1 Drive motor 1 rpm sensor abnormality DCR-LH
Restricted traveling output
C8-2 C8-2 Drive motor 2 rpm sensor abnormality DCR-RH
.Traveling disabled
.Material handling and
CB-1 CB-1 MB contactor abnormality CIR
power steering disabled
(solenoid off)
CB-2 CB-2 MB contactor fused Display only CIR
El-1 El-1 PCR current Sensor offset abnormality Material handling and
PCR
El-2 E l -2 PCR: Overcurrent power steering disabled

*[mil
PM
E2-1 Pump motor overheat Restricted material
handling output
PCR
E2-2 E2-2 Pump motor thermo-sensor abnormality
Diag
Displayed Detection
memory Faulty Phenomenon on vehicle
'Ode controller
code
PCR main drive circuit thermo-sensor Restricted material
E3 E3 PCR
abnormality handling output
E8 E8 Pump motor rpm sensor abnormality Material handling disabled PCR
Communication abnormality from Display
EE-1 EE-l
to CIR ( I )
Display only CIR
Communication abnormality from Display
EE-2 EE-2
to CIR (2)
Communication abnormality from Display
EE-3 EE-3 Operate under the default CIR
to CIR (3)
EF-1 EF-1 EEPROM abnormality ( I ) Operate under the default
EF-2 EF-2 EEPROM abnormality (2) Operate under the default
CIR
EF-3 EF-3 CPU abnormality Display only
EF-4 EF-1 EEPROM abnormality (3) Operate under the default
Communication abnormality from CIR to
F1-I F1-l
Display ( I )
Display only Display
Communication abnormality from CIR to
F1-2 F1-2
Display (2)
FF FF D l 5V overcurrent Display off CIR
H I-1 *2 H I-1 *2 Lift potentiometer abnormality (1)
H1-2 *2 H I-2 *2 Lift potentiometer abnormality (2)
H I-3 "2 H I-3 *2 Lift potentiometer abnormality (3) Lift operation stop C/R
HI-4 *2 HI-4 "2 Lift potentiometer neutral abnormality
HI-5 *2 HI-5 *2 Lift potentiometer matching abnormality
H2-1 *2 H2-1 *2 Tilt potentiometer abnormality (1)
H2-2 *2 H2-2 *2 Tilt potentiometer abnormality (2)
H2-3 *2 H2-3 *2 Tilt potentiometer abnormality (3) Tilt operation stop CIR
H2-4 *2 H2-4 *2 Tilt potentiometer neutral abnormality
H2-5 *2 H2-5 *2 Tilt potentiometer matching abnormality
Attachment 1 potentiometer abnormality
H3-1 *2 H3-1 *2
(1)
Attachment 1 potentiometer abnormality
H3-2 *2 H3-2 *2
(2)
Attachment 1 potentiometer abnormality Attachment 1 operation
H3-3 *2 H3-3 *2 C/R
(3) stop
Attachment 1 potentiometer neutral abnor-
H3-4 '2 H3-4 *2
mality
Attachment 1 potentiometer matching
H3-5 '2 H3-5 '2
abnormality
Attachment 2 potentiometer abnormality Attachment 2 operation
H4-1 *2 H4-1 *2 CIR
(1) stop
Diag
Displayed Detection
memory Faulty Phenomenon on vehicle
'Ode controller
code
Attachment 2 potentiometer abnormality
H4-2 *2 H4-2 "2
(2)
Attachment 2 potentiometer abnormality
H4-3 *2 H4-3 *2
(3) Attachment 2 operation
CIR
Attachment 2 potentiometer neutral stop
H4-4 '2 H4-4 *2
abnormality
Attachment 2 potentiometer matching
H4-5 '2 H4-5 *2
abnormality
H5-1 *2 H5-1 *2 Lift b l (UP) solenoid abnormality ( I ) Lift operation stop
H5-2 *2 H5-2 *2 Lift b l (UP) solenoid abnormality (2) Material handling disabled
H5-3 *2 H5-3 "2 Lift a1 (DOWN) solenoid abnormality (1) Lift operation stop CIR
H5-4 *2 H5-4 *2 Lift a1 (DOWN) solenoid abnormality (2) Material handling disabled
H5-5 *2 H5-5 *2 Lift solenoid drive circuit abnormality Material handling disabled
H6-1 *2 H6-1 *2 Tilt a2 (FRONT) solenoid abnormality (1) Tilt operation stop
H6-2 *2 H6-2 *2 Tilt a2 (FRONT) solenoid abnormality (2) Material handling disabled
H6-3 *2 H6-3 *2 Tilt b2 (REAR) solenoid abnormality (1) Tilt operation stop CIR
H6-4 *2 H6-4 *2 Tilt b2 (REAR) solenoid abnormality (2) Material handling disabled
H6-5 *2 H6-5 *2 Tilt solenoid drive circuit abnormality Material handling disabled
Attachment 1 operation
H7-1 *2 H7-1 '2 Attachment 1 a3 solenoid abnormality ( I )
Stop
H7-2 *2 H7-2 *2 Attachment 1 a3 solenoid abnormality (2) Material handling disabled
Attachment 1 operation
H7-3 '2 H7-3 '2 Attachment 1 b3 solenoid abnormality ( I ) CIR
Stop
H7-4 *2 H7-4 *2 Attachment 1 b3 solenoid abnormality (2) Material handling disabled
Attachment 1 solenoid drive circuit
H7-5 '2 H7-5 '2 Material handling disabled
abnormality
Attachment 2 operation
H8-1 *2 H8-1 *2 Attachment 2 a4 solenoid abnormality (1)
stop
H8-2 *2 H8-2 *2 Attachment 2 a4 solenoid abnormality (2) Material handling disabled
Attachment 2 operation
H8-3 *2 H8-3 '2 Attachment 2 b4 solenoid abnormality (1) CIR
Stop
H8-4 *2 H8-4 *2 Attachment 2 b4 solenoid abnormality (2) Material handling disabled
Attachment 2 solenoid drive circuit
H8-5 *2 H8-5 '2 Material handling disabled
abnormality
H9-1 *2 H9-1 *2 Unload valve solenoid open
H9-2 *2 H9-2 *2 Unload valve solenoid short
Material handling disabled CIR
Unload valve solenoid drive circuit
H9-3 '2 H9-3 *2
abnormality
* I : Only on the vehicle with the steering knob synchronizer (OPT).
*2: Only on the vehicle with the mini lever (OPT).
MASK FUNCTIONS
GENERAL
In addition to the functions described in the instruction manual for use by general users, the multiple
display provides the following mask functions for use by the service staff for vehicle maintenance and
specification setting.
The mask functions are protected by password to prevent damage of the data by unintentional operation
by users.
Mask Function List
When used

Function Description Board


vehicle
replace- Others
delivery
ment
Displays the vehicle's electrical
Upon vehicle
system operating status and reads - -
Analyzer abnormality
the error information detected by
detection
controllers.
Makes fine adjustment of traveling - 0 As requested
Tuning
and material handling functions. *2 by customer
Specification Sets each vehicle option and other - 0 A

setting specifications. * I *2 . *3
Each control
Enables or disables each control - 0
function enable1
*2 . *3
A

function.
disable
Option set
0 -
Hour meter start Starts the hour meter count. 0
*3
Enables or disables the demo Upon new
Demo mode mode. (Material handling prohibition - A
vehicle
during traveling for vehicle delivery) demonstration
Updates voltage values of sensor
- 0 -
Matching signals under the standard vehicle
*2
condition.
Makes the speedometer reading - 0 -
Tire constant set
appropriate. *2
* I: This matches the controller and screen control according to the installed options and control functions
equipped on the vehicle; note that this function does not enable or disable the option or control function
itself.
*2: Board ... main controller
*3: Board ... Multiple display control board
Preparation for the MASK MENU screen
Caution:
When going to the MASK MENU screen from the general
screen, always jack up the vehicle until the drive wheels
(front tires) leave the ground, and support the vehicle
with wooden blocks under the front frames.
Be sure to fully lower the fork.
1. Check that the battery plug is connected securely and
turn the key switch to ON.
2. Operate mask functions according to Password Input
Procedure. (See page 3-32.)
PASSWORD FOR MASK FUNCTION
Note on password input
1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button
may be damaged.
2. If a mistake is made part of the way through, turn the key switch to OFF and begin again. If the MASK
MENU screen does not appear after several attempts, the system may be faulty.
Password Input Procedure

Button (1) Button (2)


f \

I-
a l,
[ S E P I ~ OAM
I----_____-_---________

L 1
1. Press buttons (1) and (2) at the same time. MASK MENU screen

-0 Button (1) 0
f
/ \

2
L J
2. Within 10 seconds, press button (1) 5. The VERSION screen is displayed for
about 3 seconds.
0 Button (2)

3. Within 10 seconds, press button (2) 4. Within 10 seconds, press buttons (2) and (3)
at the same time for more than 2 seconds.
Procedure Operation Vehicle operation
1 Press buttons (1) and (2) at the same time. A short beep sounds.
2 Press button (1). (in 10 seconds after pressing button (1) and (2)) A short beep sounds.
3 Press button (2). (in 10 seconds after pressing button (1)) A short beep sounds.
Press buttons (2) and (3) at the same time and hold for 2
4 seconds or more. (in 10 seconds after pressing button (2), End of Short beeps sound.
password input)
5 The version screen is displayed automatically.
After displaying the version screen for 3 seconds, the MASK MENU screen appears
6
automatically.
VERSION screen OPERATION ON MASK MENU SCREEN
Caution:
Unlike the analyzer function selection on of previous
models, display of test screen does not prohibit the
vehicle's ordinary operation.
1. Input the password on the general screen (see page
3-32) to display the MASK MENU screen.
2. Press button (1) or (2) to select the desired menu item,
Button (3) and press button (3) (enter) to display the menu or
Press button ( I ) or setting screen for each function.
(2) to switch screen.
(1) ANALYZER screen
\
This screen displays the vehicle's electrical system
operating status and the error code detected by the
controller.
(2) TUNING screen
Performs fine adjustment of traveling and material
handling control.
Press button ( I ) or (3) OPTION SET screen
(2) to switch screen. Matches the controller or display control according to
the set option or control.
(4) MATCHING screen
This screen is for updating the sensor output voltage
stored in the controller (output voltage values from the
SAS function sensors in the standard vehicle
< / condition).
Press button (I) or (5) WHEEL DlA screen
(2) to switch screen. Updates the tire information in the controller to correct
' the speed and trip meter display.
(6) END screen
GENERAL screen can displayed from this screen.
Press button (3) on this screen to display the
GENERAL screen.
As an alternative method, turn the key switch to OFF
when any screen is displayed to display the general
Press button ( I ) or
(2) to switch screen.
screen.

Press button ( I ) or
(2) to switch screen.

0 Press button (3)


GENERAL screen
ANALYZER
GENERAL
1. The analyzer supports inspection and troubleshooting of the control system using the communication
function between the travelinglmaterial handling controller and the display.
2. Setting the display into the ANALYZER screen makes it possible to inspect and detect abnormality in
functions of the operating system and sensors, such as main traveling, material handling, EHPS, SAS
circuits and the accelerator.
3. Utilization of the analyzer functions enables quick, easy servicing.
4. The analyzer has the following functions:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes detected in the electrical system in the past. The
diagnosis memory function displays these error codes.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) Inlout monitor function (I10 MONITOR)
This function displays the analog input values from individual sensors in the traveling, material
handling, EHPS and SAS systems. The circuit or sensor quality can be judged by monitoring the
displayed value.
(a) I10 MONITOR1
Displays the temperature of each electrical functional part and the analog input voltage
detected by each controller.
(b) I10 MONITOR2
Displays the ONIOFF states of traveling-related switches and the analog input voltage from
related sensors.
(c) I10 MONITOR3
Displays ONIOFF of switches related to traveling and mast control and the analog input
voltage values from related sensors.
(d) I10 MONITOR4
Displays the ONIOFF states of steering knob synchronizer-related and other switches and
the analog input voltage values from related sensors.
(3) Active test function (ACTIVE TEST)
The controller outputs an operation signal (ON or OFF signal) to the selected item in order to permit
operation check of that function.
(4) One error code at the time is displayed in the upper righthand portion on both the I10 MONITOR
and ACTIVE TEST screens.
3-35

ANALYZER MENU SCREEN


* Values shown i n the 2nd column are display examples and not the standard values.
ANALYZER MENU Display
Meaning
screen Ist column 2nd column
DIAG-1 to Error codes and
1. DlAG MEMORY Error display
DIAG-l detection time
Main drive circuit 1 temperature (heat sink): "C
I10 1-1 THCD:+251+25
Main drive circuit 2 temperature (heat sink): "C
110 1-2 THCP:+25 Main pump circuit temperature (heat sink): "C
Drive motor 1 temperature: "C
110 1-3 TD: +25/+25
Drive motor 2 temperature: "C
110 1-4 TP:+25 Pump motor temperature: "C
Traveling AC driver 1 board temperature: "C
110 1-5 TBD:c251+25
Traveling AC driver 2 board temperature: "C
2. 110 MONITOR1 Material handling AC driver board temperature:
TBP:+25
(voltage, "C
temperature)
110 1-7 TEMP:+25.0 CPU board temperature: "C
110 1-8 VB48:38.0 Battery voltage: V
I10 1-9 VBKS:38.0 Key start voltage: V
110 1-10 VBSOL:38 Solenoid voltage: V
110 1-11 VBMB:38 Main battery input voltage: V
Traveling AC driver 1 DC-BUS voltage: V
110 1-12 VBBD:38138
Traveling AC driver 2 DC-BUS voltage: V
110 1-13 VBBP:38 Material handling AC driver DC-BUS voltage: V
POTA:0.71 Accelerator potentiometer voltage: V
110 2-1
SWAC:0 Acceleration switch: 0 (OFF), 1 (ON)
DSF:O Forward switch: 0 (OFF), 1 (ON)
110 2-2
DSR:O Reverse switch: 0 (OFF), 1 (ON)
LSB:1 Brake switch: 0 (OFF), 1 (ON)
3. 110 MONITOR2 2-3
LSD:1 Seat switch: 0 (OFF), 1 (ON)
(traveling system)
SSDI :3000 Drove motor 1 rpm: rpm
110 2-4
[3000] [Main controller instruction rpm: rpm]
SSD2:3000 Drove motor 2 rpm: rpm
110 2-5
[3000] [Main controller instruction rpm: rpm]
110 2-6 SPD:10.0 Main traveling speed: kmlh
L.-.- - - 1- Lift switch: 0 (OFF), 1 (ON)
4. 110 MONITOR3
(material handling Lift lever angle 1 sensor voltage: V
110 3-1 *1 Lift lever angle 2 sensor voltage: V
system and mast
control) L:0.90 3.50 10 Lift raise switch: 0 (OFF), 1 (ON)
Lift lower switch: 0 (OFF), 1 (ON)
ANALYZER MENU Display
Meaning
screen Ist column 2nd column
L (SOL):-.- Unused
110 3-2 *I
Lift proportional valve current: A
L (SOL):0.35
Forward tilt switch: 0 (OFF), 1 (ON)
T-.- -.- 10
Backward tilt switch: 0 (OFF), 1 (ON)
110 3-3 Tilt lever angle 1 sensor voltage: V
*I Tilt lever angle 2 sensor voltage: V
T0.90 3.50 10 Forward tilt switch: 0 (OFF), 1 (ON)
Backward tilt switch: 0 (OFF), 1 (ON)
T (SOL):-.- Unused
110 3-4 *I
Tilt proportional valve current: A
T (SOL):0.35
A l : -.- -.-- 1- Attachment 1 switch: 0 (OFF), 1 (ON)
Attachment 1 lever angle 1 sensor voltage: V
110 3-5 *2 Attachment 1 lever angle 2 sensor voltage: V
A1 :0.90 3.50 01 Attachment 1 raise switch: 0 (OFF), 1 (ON)
4. 110 MONITOR3 Attachment 1 lower switch: 0 (OFF), 1 (ON)
(material handling
system and mast A1 (SOL):-.- Unused
control) 110 3-6 *2
Attachment 1 proportional valve current: A
A1 (SOL):0.35
A2:-.-- -.- - Unused
Attachment 2 lever angle 1 sensor voltage: V
110 3-7 *3 Attachment 2 lever angle 2 sensor voltage: V
A2:0.90 3.50 01 Attachment 2 raise switch: 0 (OFF), 1 (ON)
Attachment 2 lower switch: 0 (OFF), 1 (ON)
A2 (SOL):-.- Unused
110 3-8 *3
Attachment 2 proportional valve current: A
A2 (SOL):0.35
110 3-9 SWTK:0 Tilt knob switch: 0 (OFF), 1 (ON)
SSP:2000 Pump motor rpm: rpm
110 3-10
[2000] [Main controller instruction rpm: rpm]
110 3-11 MH:10- Lifting height switch: 0 (OFF), 1 (ON)
110 3-12 POTT2.50 Tilt angle sensor voltage: V
110 3-13 SPL:0.84 (1.7) Load sensor voltage: V (MPa display)
ANALYZER MENU Display
Meaning
screen 1st column 2nd column
STS:- Unused
110 4-1 *4
Steering angle sensor pulse: 0 (OFF), 1 (ON)
STS:001
K-P0S:-- (-) Unused
110 4-2 *4
Steering angle knob position: Actual (target)
5. 110 MONITOR4 K-POS:159 (150)
(steering control)
K-DIFF:--
Unused
SOL:-
110 4-3 *4 Deviation of steering angle knob position
K-DIFF:100 Steering knob synchronizer solenoid:
S0L:O 0 (OFF), 1 (ON)
110 4-4 TIRE:2.40 Tire angle sensor voltage: V
FAN: ONIOFF Fan output
ACT-1
(36) Fan voltage: V
KS0L:-I-(-) Unused
Steering knob synchronizer solenoid output
ACT-2 *4
Steering knob synchronizer solenoid check
6. ACTIVE TEST KSOL:
signal:
(operation test) ONloFF (O) o (normal), I (error)

PS0L:-I- (-) Unused

ACT-3 *I
Unload valve output
PSOL:
Unload valve check signal: 0 (normal), 1 (error)
ONIOFF (0)
* I : Mini lever models (OPT)
*2: 3-way and 4-way mini lever models (OPT)
*3: 4-way mini lever models (OPT)
*4: Steering knob synchronizer models (OPT)
Operating Procedure
1. Input the password on the general screen (see page 3-32) to display the MASK MENU screen.
2. Check that "1. ANALYZER is selected on the MASK MENU screen and press button (3) (enter) to
display the ANALYZER MENU screen.
3. Select the menu item using buttons (I) and (2) and then press button (3) (enter) to display the set
screen.
Button (1): To the previous menu item screen
Button (2): To the next menu item screen
Button (3): Enter (to the selected menu item screen)
If you select "7. END" on the MENU screen of the analyzer and press button (3), the MASK MENU screen
is displayed.

..-.-
Pre; button (3)

@ 7. END screen

I . DIAG MEMORYscreen
'. J

Press button (1) or


(2) to switch screen.
6. ACTIVE TEST screen
Press button (I) or
\ , (2) to switch screen.
Press button ( I ) or
(2) to switch screen.
2. 110 MONITOR1 screen

Press button ( I ) or
(2) to switch screen.
5. 110 MONITOR4 screen

Press button ( I ) or
(2) to switch screen.
3. 110 MONITOR2 screen

Press button ( I ) or
(2) to switch screen.
4. 110 MONITOR3 screen
>
L

Press button ( I ) or
(2) to switch screen.
\ J
Diagnosis Memory Function (DIAG MEMORY)
The controller stores up to 10 of the most recent errors. The DlAG MEMORY screen displays these
diagnosis error codes together with their detection time (as key ON hour meter reading).
The most recent diagnosis error code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to
DIAG-10.

Button (1) Operating Procedure


1. Display the ANALYZER MENU screen.
2. Check that "1. DlAG MEMORY" is displayed and press
button (3) (enter). Past diagnosis codes are displayed
sequentially starting with the newest one.
3. Functions of buttons on the 1. DlAG MEMORY screen
are as follows:
Button (1): Unused
Button (2): Unused
0 Press button (3)
*.
Button (3): Displays past diagnosis codes
f \
Press button (3) on the DIAG-10 screen to display the
ANALYZER MENU screen.
When no error codes are displayed on the screen and the
hour meter time is "O.OhW, it indicates that no error codes
J
i 1 are stored in the memory.
/
Key ON hour meter Other screen cannot be displayed from DlAG MEMORY
Press button (3)
screen. Display ANALYZER MENU screen to display other
screen.
*: For the details of diagnosis error codes, see DIAGNOSIS
CODE LIST on P3-24.

Press button (3)

No error occurrence : Press button (3)


is indicated
0

Press button (3)


ANALYZER MENU screen
Vehicle Abnormalities Not Stored in Diag Memory
Some abnormalities are not stored in diag memory even when the controller detects it and warn the
operator.
Warning indicators Warning method Displayed code
Indication
Parking brake ON warning: Parking brake ON
Warns if the direction switch is turned to the warning indicator
forward or reverse position and the vehicle blinks
travels when the parking brake is on. Beep
Short beeps
Parking brake OFF warning:
Warns if the operator vacates the seat without Beep
No display
pulling the parking brake lever. (Warns even Short beeps
when the key switch is OFF)
Overdischarge warning (lift interrupt):
Warns if the battery discharge exceeds the level
set by the tuning function. (see page 3-54.)
lndication
When the warning is activated, material handling , I ,
Battery charge i -
operation is disabled on USA models (Including
blinks
ndica nBBBBBBBBBBm
Canadian models). However, when the key tor / I I I I I I I I \
Beep
switch is turned from OFF to ON, the operation
Short beeps
can be performed only once for 30 seconds. As
for export models, the material handling
operation during traveling is disabled.
Return to neutral warning:
Warns if the key switch is turned to ON when the Beep
No display
direction switch is in the forward or reverse Short beeps
position.
Material handling lock (OPT):
When the operator leaves the seat while
Beep
5 operating the mini lever and then sits down No display
Short beeps
again, a buzzer sounds to warn the operator and
the material handling operation will be disabled.
Incomplete matching warning:
(1) Tilt angle sensor at fork in the level position
(2) Tilt angle sensor at the forward tilt restriction
angle
(3) Pressure sensor at no-load state
(4) Tire angle sensor at straight travel position
(5) Lift lever angle sensor in lift lever neutral Indication
5 position (OPT) Wrench symbol
(6) Tilt lever angle sensor at tilt lever neutral
position (OPT)
(7) Attachment 1 lever angle sensor at
attachment 1 lever neutral position (OPT)
(8) Attachment 2 lever angle sensor at
attachment 2 lever neutral position (OPT)
I10 MONITOR
This function displays the analog input voltage from each of
Activated Detected error code
traveling, material handling and SAS sensors.
function No at present
Monitoring the displayed values enables the quality of each
circuitlsensor to be judged.
When any abnormality is detected, it is displayed as an error
code on the screen.

Description of activated function

110 MONlTORl
This function displays the temperature of each electrical functional part and the voltage at the respective
terminal.
Operating Procedure
Button (1)
Button (2) 1. Display the ANALYZER MENU screen.
ANALYZER MENU screen /
r 2. Press button (2).
3. Check that "2. 110 MONITORI" is displayed and press
button (3) (enter). I10 monitor function (1) is activated
I=ANL MENU-
:~--!!o-MoN!IToR! and I10 1-1 to 110 1-13 are displayed sequential every
~Bllllllm~
-8

s P H
time button (3) is pressed.
\ \ 4. Functions of buttons on the I10 MONlTORl screen are
.' 1
\ as follows:
Button (3)
0 Press button (3)
Button (1): Unused
Button (2): Unused
Button (3): Displays I10 1-1 to 110 1-13 screens
(1) I10 1-1 screen sequentially
*: Press button (3) on the 110 1-13 screen to display the
ANALYZER MENU screen.
Other screen cannot be displayed from I10 MONlTORl
screen.
Display ANALYZER MENU screen to display other screen.

0 Press button (3)


(1) I10 1-1 screen
THCD: Main drive circuit (1) (2) temperature ("C)
Temperatures of the main drive circuit element (1) (2)
(2) 110 1-2 screen are displayed
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(2) 110 1-2 screen
THCP: Main pump circuit temperature ("C)
0 Press button (3)
Temperature of the main pump circuit element is
displayed.
110 1-3 screen
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
I 110 1-2 screen I (3) 110 1-3 screen
TD: Drive motor ( I ) (2) temperature ("C)

(3) 110 1-3 screen


0 Butto? (1)
Button (2)
/
Temperatures of the drive motor (1) (2) is displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(4) I10 1-4 screen
TP: Pump motor temperature ("C)
~utton (3) Temperature of the pump motor is displayed.

(4) 110 1-4 screen


0 Press button (3) Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(5) 110 1-5 screen
TBD:.
Traveling AC driver 112 board surface temperature ("C)
Surface temperatures of the traveling AC driver 112
Press button (3) board are displayed.
( 5 ) 110 1-5 screen
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(6) 110 1-6 screen
TBP:
Material handling AC driver board surface temperature
1 (6) 110 1-6 screen
Press button (3)
I ("C)
Surface temperature of the material handling AC driver
board is displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
'
. /
displayed.

(7) 110 1-7 screen


0 Press button (3) (7) I10 1-7 screen
TEMP: CPU board temperature ("C)
The surface temperature of the main controller CPU
board is displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.

(8) 110 1-8 screen


9 Press button (3) (8) I10 1-8 screen
VB48: Battery voltage (V)
The battery voltage is displayed.
Standard: 36 V (36V models)
48 V (48V models)

\ J

0 Press button (3)


110 1-9 screen
(9) 110 1-9 screen
110 1-8 screen VBKS: Key start voltage (V)
Button (2) Power source voltage of traveling and material handling
AC drivers are displayed.
(9) 110 1-9 screen \
f -l
Standard: 36 V (36V models)
48 V (48V models)
(10) 110 1-10 screen
VBSOL: Solenoid power source voltage (V)
Solenoid power source voltage is displayed.
L J Standard: 36 V (36V models)
Button (3) 48 V (48V models)
9 Press button (3)
(11) 110 1-11 screen
(10) 110 1-10 screen VBMB: Main battery voltage input (V)
Main controller input voltage after the MB contactor is
displayed.
Ivssoc------------- Standard: 36 V (36V models)
48 V (48V models)
(12) 110 1-12 screen
-0 Press button (3) VBBD:
Traveling AC driver 112 main drive circuit voltage (V)
(11) 110 1-11 screen Voltages of the traveling AC driver 112 main drive circuit
are displayed.
Standard: 36 V (36V models)
48 V (48V models)
(13) 110 1-13 screen
VBBP:
Material handling AC driver main drive circuit voltage (V)
0 Press button (3) Voltage of the material handling AC driver main drive
circuit is displayed.
(12) 110 1-12 screen Standard: 36 V (36V models)
( \
48 V (48V models)

L J

0 Press button (3)


(13) 110 1-13 screen

I<1101-13>

L ,'
0 Press button (3)
ANALYZER MENU screen
Displays each switch ONIOFF state and analog input voltages from sensors for traveling and swing
control.
Operating Procedure
Button (1)
Button (2) 1. Display the ANALYZER MENU screen.
ANALYZER MENU screen 2. Press button (2) twice.
r
3. Check that "3. 110 MONITOR2" is displayed and press
button (3) (enter). I10 monitor function (2) is activated
and 110 2-1 to 110 2-6 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I10 MONITOR2 screen are
L J
I as follows:
Button (1): Unused
Button (2): Unused
(1) 110 2-1 screen Button (3): Displays 110 2-1 to 110 2-6 screens
sequentially
*: Press button (3) on the 110 2-6 screen to display the
.....................
~ P O T A0 7 l S W A C
ANALYZER MENU screen.
aDllllllDB~ Other screen cannot be displayed from I10 MONITOR2
screen.
Display ANALYZER MENU screen to display other screen
0 Press button (3)
(1) 110 2-1 screen
110 2-2 screen
POTA: Accelerator potentiometer voltage (V)
A: When the accelerator pedal is released
(SWAC: OFF)
Standard: 0.3 to 2.4 V
B: Standard voltage when the accelerator pedal is
depressed to its stroke end
Standard: 1.7 to 4.7 V
B - A = 1.4Vorabove
SWAC: Accelerator switch
When the accelerator pedal is released
SWAC: 0 = OFF
Standard voltage when the accelerator pedal is
depressed to its stroke end
SWAC: 1 = ON
Operate the accelerator pedal to judge switch ONIOFF
quality.
(2) 110 2-2 screen
I10 2-1screen Direction switch inspection
DSF: Forward traveling switch
Button (2) DSR: Reverse traveling switch
Button (1)
(2) 110 2-2 screen \
f I
DSF DSR

Forward traveling 1 (=ON) 0 (=OFF)


Neutral 0 (=OFF) 0 (=OFF)
,'
- 1 Reverse traveling 0 (=OFF) 1 (=ON)
Operate the direction lever to judge switch ONIOFF
quality.
(3) 110 2-3 screen
(3) 110 2-3 screen
LSB: Brake switch inspection
When the brake pedal is released
LSB: I = ON
When the brake pedal is depressed
LSB: 0 = OFF
Operate the brake pedal to judge switch ONIOFF
0 Press button (3) quality.
LSD: Deadman seat check
(4) 110 2-4 screen
When the seat is occupied
LSD: 1 = ON
When the seat is not occupied
LSD: 0 = OFF
Take or leave a seat to judge switch ONIOFF quality.
(4) 110 2-4 screen
SSDI : Drive motor 1 rprn [target rpm]
0 Press button (3) lnspect the rprn sensor while the vehicle is traveling.
The rprn of the drive motor increases according to the
(5) 110 2-5 screen
\ speed increase.
(5) 110 2-5 screen
SSD2: Drive motor 2 rprn [target rpm]
lnspect the rprn sensor while the vehicle is traveling.
The rprn of the drive motor increases according to the
speed increase.

9 Press button (3)


(6) 110 2-6 screen
SPD: Traveling speed (mph or kmlh)
(6) 110 2-6 screen Check the traveling speed while the vehicle is jacked up.
Gradually depress the accelerator pedal. Check that the
traveling speed increase is almost at the same rate of
the depression of the accelerator pedal to judge the
L5r-Q-----------LO--! -:
aDllllllDm P
quality.

0 Press button (3)


ANALYZER MENU screen
This function displays the ONIOFF status of material handling and mast control switches and analog input
doltages from sensors.
Operating Procedure
Button (1)
ANALYZER MENU screen Button (2) / /
1. Display the ANALYZER MENU screen.
2. Press button (2) three times.
3. Check that "4. 110 MONITOR3" is displayed and press
a-n,@ button (3) (enter). I t 0 monitor function (3) is activated
~ ] [ q ~ ]
I'ANL MENU'
~--!!.I-Mo-N_!-T_oP.~ -: and 110 3-1 to I10 3-13 are displayed sequential every
time button (3) is pressed.
1 Button (3)
4. Functions of buttons on the I10 MONITOR3 screen are
as follows:
0 Press button (3) Button (1): Unused
Button (2): Unused
110 3-1 screen
(I)
Standard models
Button (3): Displays 110 3-1 to 110 3-13 screens
f I 1
sequentially
*: Press button (3) on the 110 3-13 screen to display the
ANALYZER MENU screen.
Other screen cannot be displayed from I10 MONITOR3
screen.
Display ANALYZER MENU screen to display other screen
Mini lever models (OPT)
(1) 110 3-1 screen
Standard models
L: Lift switch inspection
When the lift lever is in the UP position
L: -.- -.- 1- = ON
When the lift lever is in the neutral or DOWN position
L.- - -. - - . 0- =OFF
0 Press button (3) Operate the lift lever to judge ONlOFF quality.
. . 110 3-2 screen
(2) Mini lever models (OPT)
,
Standard models \
L: Lift lever angle 1 sensor voltage (V)
Lift lever angle 2 sensor voltage (V)
Lift raise switch (O=OFF, 1=ON)
Lift lower switch (O=OFF, l=ON)
Judge the raise and lower input quality by lift lever
operation.
Lift lever angle 1 Lift lever angle 2
,
Mini lever models (OPT) . sensor voltage sensor voltage
Raising 1.1 to 2.3 V 2.2 to 3.5 V
Lowering 0.4 to 1.6 V 2.9 to 4.2 V

(2) 110 3-2 screen


Standard models
9 Press button (3) L (SOL): Unused
110 3-3 screen Mini lever models (OPT)
L (SOL): Lift proportional valve solenoid current (A)
Judge the output quality to lift proportional valve
solenoid by lift lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
(3) 110 3-3 screen
110 3-2 screen
Standard models
T Forward and backward tilt switch inspection
Forward Backward
Operation Display tilt switch tilt switch
Forward tilt T -.- 10 1 (=ON) 0 (=OFF)
Neutral T -.-- 00 0 (=OFF) 0 (=OFF)
Backward tilt T: -.- 01 0 (=OFF) 1 (=ON)
Operate the tilt lever to judge ONIOFF quality.
M i n ~lever models (OPT) Button (3)
Mini lever models (OPT)
T Tilt lever angle 1 sensor voltage (V)
Tilt lever angle 2 sensor voltage (V)
Forward tilt switch (O=OFF, 1=ON)
Backward tilt switch (O=OFF, 1=ON)
Judge the forward and backward tilt input quality by lift
lever operation.

(4) 110 3-4 screen


0 Press button (3)

Standard models

(4) 110 3-4 screen


Standard models
.' /
T (SOL): Unused
M i n ~lever models (OPT) Mini lever models (OPT)
T (SOL): Tilt proportional valve solenoid current (A)
Judge the output quality to the tilt proportional valve
solenoid by tilt lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
(5) 110 3-5 screen
Standard models

(5) 110 3-5 screen


0 Press button (3) A1: Attachment 1 lever inspection
When the attachment 1 lever is ON
Standard models A1: -.- -.- 1- = ON
When the attachment 1 lever is in the neutral position
A1 : -.- -.- 0- = OFF
Operate the attachment 1 lever to judge ONIOFF quality.
3-way and 4-way mini lever models (OPT)
A l : Attachment 1 lever angle 1 sensor voltage (V)
Attachment 1 lever angle 2 sensor voltage (V)
3-way and 4-way mlnl lever models (OPT) Attachment 1 raise switch (O=OFF, 1=ON)
Attachment 1 lower switch (O=OFF, 1=ON)
Judge the input quality by attachment 1 lever operation.
Attachment 1 lever Attachment Ilever
angle 1 sensor angle 2 sensor
L J
voltage voltage

0 Press button (3)


Raising
Lowering
1.1 to 2.3V
0.4 to 1.6 V
2.2 to 3.5 V
2.9 to 4.2 V
110 3-6 screen
110 3-5 screen (6) 110 3-6 screen
Standard models
(6) 110 3-6 screen Button (1)
0
Button (2) A1 (SOL): Unused

r
-
Standard models \
\
3-way and 4-way mini lever models (OPT)
A1 (SOL): Attachment 1 proportional valve solenoid
current (A)
Judge the output quality to attachment ( I ) proportional
valve solenoid by attachment 1 lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
\ J
(7) 110 3-7 screen
Button (3)
Standard models, 2-way and 3-way mini lever
. 3-way and 4-way mini lever models (OPT) models (OPT)
f
A2: Unused
4-way mini lever models (OPT)
A2: Attachment 2 lever angle 1 sensor voltage
Attachment 2 lever angle 2 sensor voltage
Attachment 2 raise switch (O=OFF,I=ON)
Attachment 2 lower switch (O=OFF, 1=ON)

(7) 110 3-7 screen


0
Press button (3) Judge the forward and backward tilt input quality by tilt
lever operation.
Standard models
2-way and 3-way mini lever models (OPT)
Attachment 2 lever Attachment 2 lever
r I angle 2 sensor angle 2 sensor
voltage voltage
Raising 1.1 to 2.3V 2.2 to 3.5 V
:AL-:--:-:_-:--::--: I:

flBlljlllma s P H Lowering 0.4 to 1.6 V 2.9 to 4.2 V


\ 1
4-way mlni lever models (OPT) (8) 110 3-8 screen
Standard models, 2-way and 3-way mini lever
models (OPT)
A2 (SOL): Unused
4-way mini lever models (OPT)
A2 (SOL): Attachment 2 proportional valve solenoid
current (A)

(8) 110 3-8 screen


0
Press button (3)
Judge the output quality to attachment 2 proportional
valve solenoid by attachment 2 lever operation.
Standard models Standard: 0.3 to 0.85 A (Lever operated)
2-way and 3-way mini lever models (OPT)

\ /
4-way mini lever models (OPT)

0 Press button (3)


110 3-9 screen
(9) 110 3-9 screen
110 3-8 screen
S W K : Automatic fork leveling cancel switch inspection
0 = OFF
1 =ON
Operate the tilt knob switch to judge ONIOFF quality.
(10) 110 3-10 screen
SSP: Pump motor rpm [target rpm]
Inspect the rpm sensor during the actual material
handling operation. Check that the pump motor rpm
increases according to the material handling speed
Button (3)
0 Press button (3)
increase.
(11) 110 3-11 screen
(10) 110 3-10 screen
MH: Lifting height switch inspection
Combination of lifting height switch ONIOFF
MH2-1
switch switch

0 Press button (3)


Change the lifting height to judge ONIOFF quality.
(11) 110 3-11 screen
\ (12) 110 3-12 screen
POTT Tilt angle sensor voltage (V)
Check the input voltage of tilt angle sensor controller
Standard when the mast is in the vertical position:
Approx. 1.3 V
L J
When operating the mast forward from the vertical
position: lnput voltage decrease
0 Press button (3) When operating the mast backward from the vertical
position: lnput voltage increase
(12) 110 3-12 screen
f (13) 110 3-13 screen
SPL: Load sensor voltage (V), (MPa display)
Check the input voltage of load sensor controller.
Standard without load: Approx. 0.8 V
lnput voltage increases according to the load increase

0 Press button (3)

(13) 110 3-13 screen


F \

\ J

0 Press button (3)

ANALYZER MENU screen


ONIOFF state of knob steering synchronizer and other switches and the analog input value from each
sensor are indicated.
Operating Procedure
Button (1)
1. Display the ANALYZER MENU screen.
2. Press button (2) four times.
3. Check that "5. 110 MONITOR4" is displayed and press
button (3) (enter). I10 monitor function (4) is activated
and 110 4-1 to 110 4-4 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I10 MONITOR4 screen are
as follows:
Button (3)
0 Press button (3)
Button (1): Unused
Button (2): Unused
(1) 110 4-1 screen Button (3): Displays 110 4-1 to 110 4-4 screens
r \
sequentially.

1< 1 1 0 4 - 1
*: Press button (3) on the 110 4-4 screen to display the
L?T-?---!-L! --------- -@ ANALYZER MENU screen.
Other screen cannot be displayed from I10 MONITOR4
\ J
screen.
Display ANALYZER MENU screen to display other screen.
0 Press button (3)
110 4-2 screen

(1) 110 4-1 screen


Standard models
. ,__________________--------------------------------- STS: Unused
;< 1 1 0 4 - 1 ' Steering knob synchronizer model (OPT)
STS: Steering angle sensor inspection
0 = OFF
1 =ON

1
STSl STS2 STSC

Turning the steering wheel one round will turn STSl and
STS2 ON, OFF and then ON. STSC turns on only when
the steering wheel is in the standard position.
STSC sensor turns on when the actual value is 80 on
the 110 4-2 screen.
(2) 110 4-2 screen
110 4-1 screen
Standard models
K-POS: Unused
Steering knob synchronizer models (OPT)
K-POS: Actual value of knob position (target)
Actual value:
Knob position computed by the controller from the
steering angle sensor signal.
Target value:
Knob position computed by the controller from the tire
angle sensor signal,
Button (3)
0 Press button (3)
110 4-3 screen

Assuming the steering wheel is divided into 160 (0 to


159), the knob position of 80 is as indicated in the
illustration to the left. This value increases when turning
the steering wheel clockwise and decreases when
turning it counterclockwise.

(3) 110 4-3 screen


110 4-2 screen
Standard models
K-DIFF: Unused
Button (2)
SOL: Unused
Steering knob synchronizer models (OPT)
K-DIFF: Deviation of steering angle knob position
Difference between target and actual values at 110 4-2.
- D l F F 1 0 0
SOL: Steering synchronizer solenoid
0 = OFF
1 =ON
Operate the steering wheel to check that the steering
Button (3) synchronizer solenoid turns on when there is deviation
0 Press button (3) of steering angle knob position.
(4) 110 4-4 screen
(4) 110 4-4 screen
TIRE: Tire angle sensor voltage (V)
Operate the steering wheel to check the variation in
voltage.
Standard at tire straight travel position:
Approx. 2.40 V

0 Press button (3)


ANALYZER MENU screen
ACTIVE TEST
This function outputs ONIOFF signals to each switch related to the electrical system and compares
controller input signals with those signals.
Operating Procedure
Button (1)
1. Display the ANALYZER MENU screen.
ANALYZER MENU screen Button (2)
f
/
2. Press button (2) five times.
3. Check that "6. ACTIVE TEST is displayed and press
button (3) (enter). ACTIVE TEST function is activated
and ACT-1 to ACT-3 are displayed sequential every time
button (3) is pressed.
4. Functions of buttons on the ACTIVE TEST screen are
\ / as follows:
0PressButton
button
(3)
(3)
Button (1): Forced ON
Button (2): Forced OFF
(1) ACT-1 screen
Button (3): Displays ACT-1 and ACT-3 sequentially
*: Press button (3) on ACT-3 screen to display the
ANALYZER MENU screen.
Other screen cannot be displayed from ACTIVE TEST
screen.
Display ANALYZER MENU screen to display other screen.

0Press button (3) (1) ACT-1 screen


FAN: Fan (fan voltage (V))
(2) ACT-2 screen
Forcibly output the ONIOFF signal to check the fan
operation and display visually.
Press button ( I ) to select ON.
+Fan rotates and fan voltage is displayed.
Press button (2) to select OFF.
+Fan stops rotating and fan voltage is displayed.
Note:
0Press button (3) Be sure to open the battery hood and remove the side
cover to check the fan operation.
ACT-3 screen
(2) ACT-2 screen
Standard models
KSOL: Unused
Steering knob synchronizer models (OPT)
KSOL: Steering knob synchronizer solenoid
I: Signal check line ON (error)
0:Signal check line OFF (normal)
Turn the steering wheel slowly to check the deviation in
the rear tire movement.
ON (bypass open) selected: Tires rarely move
OFF (bypass close) selected: Tires normally move
(3) ACT-3 screen
ACT-2 screen
Standard models
PSOL: Unused
Mini lever models (OPT)
PSOL: Unload valve solenoid
1: Signal check line ON (error)
0:Signal check line OFF (normal)
Turn the key switch to ON and operate the material
handling lever.
+If the unload valve turns on normally, material
handling operation is possible.lf the unload valve
Button (3) stays off, material handling operation is disabled.
Mini lever models (OPT) Turn the key switch to OFF and operate the material
handling lever.
+If the unload valve turns off normally, material
:P-SRL--ON!-OE.F--!P )I handling operation is disabled.lf the unload valve
stays on, material handling operation is possible.

0 Press button (3)

ANALYZER MENU screen


TUNING
General
This function performs fine adjustment of traveling and material handling controls.
When the use requests to limit the maximum speed or weaken the regenerative braking force, each setting
can be performed on the TUNING screen in the procedures same as power control level setting.
59 tuning items are prepared including spares.
Tuning Item List

decreasing rate of battery charge

Tilt power control:


Changes the pump motor output for when

*I
: 4-way mini lever models (OPT)
Tuning Level (a : Initial setting position)
No. Item I I
1 1 2 3 4 5 6 7 8 1
I I
Lift lowering adjustment (I): I I

20 Adjusts solenoid output current at the beginning Small I4


I
b I
I
Large
of lift lowering operation. I I

I I
I I
Lift lowering adjustment (2):
21
Adjusts inching speed during lift lowering operation.
o w 1- - Fast
I I
I I
I I
Lift lowering adjustment (3): I I
a
22 Adjusts the maximum solenoid output current during Small 14 w
lift lowering operation. I I
I I
I I
Lift lowering adjustment (4):
23
Adjusts acceleration during lift lowering operation.
Weak I4
I
a
w t j Strong
I I

I I
I I
Lift lowering adjustment (5):
24
Adjusts deceleration during lift lowering operation.
Weak I4 A
w b I Strong
I I
I I

Lift raising adjustment (1): I I


a
25 Adjusts solenoid output current at the beginning of Small I4 w b Large
lift raising operation. I I
I I
I I
Lift raising adjustment (2): I
a I
26 slow r w w I Fast
Adjusts inching speed during lift raising operation. I I
I I
I I
Lift raising adjustment (3): I I

27 Adjusts the maximum solenoid output current during Small a


w t I Large
I I
lift raising operation. I 1

I I
I I
Lift raising adjustment (4):
28
Adjusts acceleration during lift raising operation.
Weak I4
a
w b I Strong
I I
I I
I I

*'
I I
Lift raising adjustment (5): I I

Adjusts deceleration during lift raising operation.


Weak 14 a
b I Strong
I I
I I
I I
Forward tilt adjustment (I): I I
I
30 Adjusts solenoid output current at the beginning of Small 4
forward tilt operation. ,I II
I I
I I
Forward tilt adjustment (2):
31 Slow I4 a
w tI Fast
Adjusts inching speed during forward tilt operation. I I
I I

Forward tilt adjustment (3): I I


a
32 Adjusts the maximum solenoid output current during Small 14 bf Large
I I
forward tilt operation. I I
I I
I I

33
Forward tilt adjustment (4):
Adjusts acceleration during forward tilt operation.
Weak
I
14 w
A
* I
Strong
I I
I I
I I
I I
Forward tilt adjustment (5):
34
Adjusts deceleration during forward tilt operation.
Weak I4 a
b I Strong
I I

35
Backward tilt adjustment (1):
Adjusts solenoid output current at the beginning of
backward tilt operation.
Small
I
I

I4
I
I
-
a
+I
I
I

I
I
Large
Attachment 1 lowering adjustment (3): I I

42 Adjusts the maximum solenoid output current during Small / 4 a I

lowering operation of attachment 1.

-
II II
I I
Attachment 1 lowering adjustment (4): I I

43 Adjusts acceleration during lowering operation of Weak I4


I
a
* I Strong
attachment 1. I I

I I
Attachment 1 lowering adjustment (5): I I
44 Adjusts deceleration during lowering operation of Weak I4
I
a
w *I I
Strong
attachment 1.

-
I I
I 1
Attachment 1 raising adjustment (1):
45 Adjusts solenoid output current at the beginning of Small
I
I4 a
* I
Large
raising operation of attachment 1.

-
I I
I I
Attachment 1 raising adjustment (2): I I

46 Adjusts inching speed during raising operation of Slow / 4


a
* I
I Fast
attachment 1. I I

-
I I
I I
Attachment 1 raising adjustment (3): I I

47 Adjusts the maximum solenoid output current during Small I4


I
a
*I I
Large
raising operation of attachment 1. I I

48
Attachment 1 raising adjustment (4):
Adjusts acceleration during raising operation of
attachment 1.
Weak
I

I
I
I
4 -
a
W
I
I
I
I
I
Strong

Attachment 1 raising adjustment (5): I I


49 Adjusts deceleration during raising operation of Weak 1 4 a
W I Strong
attachment 1. I
I
I
I
I I
Attachment 2 lowering adjustment (I): I I

50 Adjusts solenoid output current at the beginning of Small 4


a
w *I I
Large
raising operation of attachment 2. I I

51
Attachment 2 lowering adjustment (2):
Adjusts inching speed during lowering operation of
attachment 2.
Slow
I
I
1
I
I
4 -
a *I
I
I

I
I
Fast
Tuning Level (0 : Initial setting position)
Item I I
No. ; 1 2 3 4 5 6 7 8 ;
I I
Attachment 2 lowering adjustment (3): I I

52 Adjusts the maximum solenoid output current during Small I4 a


b I
I
Large
I
lowering operation of attachment 2. I I

I I
Attachment 2 lowering adjustment (4): I I

53 Adjusts acceleration during lowering operation of Weak I+ a


v t Strong
I I
attachment 2. I I
I I
Attachment 2 lowering adjustment (5): I I
54 Adjusts deceleration during lowering operation of Weak I4 a
b Strong
attachment 2.

-
I I
I I
Attachment 2 raising adjustment ( I ) : I I

55 Adjusts solenoid output current at the beginning of Small + a


b I
I
Large
raising operation of attachment 2. I I

I I
Attachment 2 raising adjustment (2): I I

56 Adjusts inching speed during raising operation of Slow I4 a


v b I Fast
I I
attachment 2. I I

Attachment 2 raising adjustment (3): I I


57 Adjusts the maximum solenoid output current during Small 4
a
v b 1 Large
raising operation of attachment 2. I II
I I
Attachment 2 raising adjustment (4): I II
a
58 Adjusts acceleration during raising operation of Weak 14 v
attachment 2. I
I
I
I
I I
Attachment 2 raising adjustment (5): I I

59 Adjusts deceleration during raising operation of Weak I4


I
a
*I I
Strong
attachment 2. I I
TUNING Screen Operating Procedure
1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen.
2. Press button (2) to display "2. TUNING" and press button (3) (enter) to display the TUNING MENU
screen.
3. Press button (1) or (2) to display the tuning item desired to be set. Press button (3) (enter) to display
the TUNING screen of the selected item.
Button (1): Display the previous tuning item
Button (2): Display the next tuning item
Button (3): Enter (display the selected tuning item)
*: Press button (3) on the TUNING MENU screen, select "6. END" and press (3) to display MASK MENU
screen.
"2.TUNING2 LIFTV" to "5.TUNING5 ATT2V (tuning No.20 to 59) are not used on the standard models.
They are only used on the mini lever models (OPT).

( I ) Button (2)
MASK MENU screen

.' \ 1
a o o o ~ o o o o ~ ~ ~ o o o ~ ~ ~ ~ o ~ . o - ~ ~ o o ~
a
I
a
a
I
a
a
a
Button (3)
0 Press button (3) Press button (3)

Press button (I) or


(2) to switch screen
Press button ( I ) or Press button ( I ) or
(2) to switch screen (2) to switch screen
*: Mini lever models only *: Mini lever models only

L 1 L J

Press button ( I ) or Press button ( I ) or


(2) to switch screen (2) to switch screen
*: Mini lever models only *: Mini lever models only
3

"!
:?--LuN!!c3_--I!_I_LJ
nDllllllm@
s P H
Press button ( I )
L , or (2) to switch 1
screen
Button (I)Button (2) TUNING 1
This function sets the tuning level of the standard functions.
OPERATING PROCEDURE
1. Display the TUNING MENU screen.
2. Check that "1. TUNINGI" is displayed and press button
(3) (enter) to display TUNING level setting screen.
Button (3)
0 Press button (3)
3. Press button (3) to display the tuning item desired to be
set.
4. Functions of buttons on the TUNING level setting screen
are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
Press button (3) *: Press button (3) on the TUNING No.12 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level setting
screen of TUNING1. Display TUNING MENU screen to
display other screen.

9 Press button (3)


TUNING MENU screen

Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels (TUNING No.3)
*: The default is level 7.
TUNING 2 LIFTV
Button (I)Button (2)
TUNING MENU screen
f
/ This function changes the tuning level of the lift lever.
OPERATING PROCEDURE
1. Display the TUNING MENU screen.
2. Press button ( I ) or (2) to display "2.TUNING2 LIFTV"
and press button (3) (enter) to display TUNING level
.' setting screen.
~ u t h (3)
n
0 Press button (3)
3. Press button (3) to display the tuning item desired to be
set.
4. Functions of buttons on the TUNING level setting screen
are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)

0 Press button (3)


\
*: Press button (3) on the TUNING No.29 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level setting
screen of TUNING2 LIFTV. Display TUNING MENU screen
to display other screen.
-:
- - K C --<l--mlmlu--
C J ~ ~ S PBH B ~ ~ ~ ~ ~

9
+Press button (3)

9Press button (3)


TUNING MENU screen
TUNING 3 TILTV
Button (I)Button (2)
TUNING MENU screen This function changes the tuning level of the tilt lever.
c r l I
OPERATING PROCEDURE
:=TUN MENU= 1. Display the TUNING MENU screen.
v:
I~-_T__U~N_!-N_G~--'-!~I
tlml~l~~~rna 2. Press button (1) or (2) to display "3.TUNING3 TILTV
L \ J
and press button (3) (enter) to display TUNING level
\ setting screen.
~ u t t b (3)
n
0 Press button (3)
3. Press button (3) to display the tuning item desired to be
set.
4. Functions of buttons on the TUNING level setting screen
are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)

0 Press button (3)


*: Press button (3) on the TUNING No.39 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level setting
screen of TUNING3 TILTV. Display TUNING MENU screen
to display other screen.

Q
6Press button (3)
~DllllllCBP)~
\ J

0Press button (3)


TUNING MENU screen
TUNING 4 ATTIV
Button (I)Button (2)
This function changes the tuning level of the attachment 1
lever.
OPERATING PROCEDURE
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display "4.TUNING4 A T T I V
and press button (3) (enter) to display TUNING level
setting screen.
3. Press button (3) to display the tuning item desired to be
set.
4. Functions of buttons on the TUNING level setting screen
#<TUN> are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
L / Button (3): Enter (to the next item screen)
0 Press button (3) *: Press button (3) on the TUNING No.49 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level setting
screen of TUNING4 ATTIV. Display TUNING MENU
screen to display other screen.

6
9 Press button (3)

0 Press button (3)


TUNING MENU screen
--
TUNING 5 ATT2V
Button (I)Button (2)
TUNING MENU screen This function changes the tuning level of the attachment 2
f
lever.
OPERATING PROCEDURE
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display "5.TUNING5 ATT2V"
i / and press button (3) (enter) to display TUNING level
~uttbn (3)
0 Press button (3) 3.
setting screen.
Press button (3) to display the tuning item desired to be
set.
4. Functions of buttons on the TUNING level setting screen
are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
0 Press button (3) *: Press button (3) on the TUNING No.59 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level setting
screen of TUNING5 ATT2V. Display TUNING MENU
screen to display other screen.

6
9 Press button (3)

0 Press button (3)


TUNING MENU screen
3-64

OPTION SET
OPTION SET Menu List
Selection
No. Indication Description Indi- Indi-
Meaning Meaning
cation cation
Enables simultaneous operation of
OPT-1 DEMO MODE traveling and material handling before Y Enable N disable
starting the hour meter.
No
OPT-2 HIM START Starts hour meter count. Y Counting N
counting
Disables level setting of travelinglmaterial
OPT-3 PIC LOCK handling power control, 2-speed travel Y Lock N Unlock
speed and overspeed alarm (OPT).
Other
Sets the data according to the
OPT-4 DESTI * J Japan I than
destination. Changes the display.
Japan
OPT-5 - Not used. - - - -

Setting to Set to
OPT-6 MPH * Changes the traveling speed unit to mph. Y
mph kmlh
OPT-7 - Not used - - - -

Adjust the charge indicator calculation Feature Feature


OPT-8 BATTERY * A
constant. A B
OPT-9 - Not used - - - -

Enablesldisables operation of the auto


OPT-10 SEAT P-OFF power-off function in relation to the seat Y Enable N disable
switch.
Enablesldisables parking brake OFF
OPT-11 PARKING ERR
warning.
Y Enable N disable
Enablesldisables the active mast front tilt
OPT-12 TILT CONT Enable disable
angle limit
Enablesldisables the steering knob
OPT-13 KNOB CONT Y Enable N disable
synchronizer.
Enablesldisables the mast forward tilt
OPT-l4 F-LIM Y Enable N disable
speed limit control.
OPT-15 B-TYPE * Battery type 1 TYPE1 2 TYPE2
Switches the battery voltage between
OPT-16 36V * Y 36V N 48V
36V and 48V.
Other
Sets specification of 2-way mini lever
OPT-17 2-WAY VALVE * Y 2-way N than
models
2-way
Other
Sets specification of 4-way mini lever
OPT-18 4-WAY VALVE * Y 4-way N than
models
4-way
OPT-19 USA* Sets specification of USA models Y USA N Others
OPT-20 - Not used - - - -
OPT-21 - Not used - -
OPT-22 - Not used - - - -

*: The specification of the vehicle is selected at the time of vehicle shipment.


Caution:
These functions are used to adjust the controller and
display control according to the options installed o n
the vehicle; they do not enable or disable the actual
function of the options.
When the controller board i s replaced, it is necessary
to reset it according to the vehicle specifications.
I When OPT-12 TlLT CONT is disabled by option setting,
Indication when disable the disabled status is indicated for 5 seconds on the
display upon key switch ON.
Meaning of indication
T-OFF: TlLT CONT (active mast front tilt angle control)
is disabled

Operating Procedure for OPTION SET Screen


1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen.
2. Press button (2) twice to display "3. OPTION S E T and press button (3) (enter) to display the OPTION
SET MENU screen.
3. Press button (3) to display the desired option item to be set on the screen.
4. Functions of buttons on the OPTION SET screen are as follows:
Button (1): N+Y
Button (2): Y+N
Button (3): Enter (to the next item screen)
*: Press button (3) on OPT-22 OPTION SET screen to display the MASK MENU screen.
OPT-4 screen
Button (1)
Press button (3)
Button (2)
MASK MENU screen
f I
\ I 7

n-I,
a
[=MENU=

L 1
\
Button (3)
0 Press button (3) Press button (3)

Press
button (3)
OPT-2 (HIM START) hour meter starting method:
pressed
Press button (2) while keeping button (I)
for 2 seconds or more.
-
OPT-3 screen
OPT-16 screen
w Button (1) Button (2)
. f
Press button (3)
-f -7

Not used V Press button (3) 6. Press button (3)


/ \ f \

:<OPT-I 4'
lI _
T_l L_ T F_
___ - _ L_ I_M- - _ Y
__~ _
N_; ____

nBlllll)m@s P H

\ J

0 Press button (3) Press button (3)

Not used
/
Press button (3) 0 Press button (3)

0 Press button (3) Press button (3)

Not used
0 Press button (3) 0 Press button (3)

Press button (3)


OPT-15 screen

0 Button (2)
Button (1) /

1Button (3)
0 Press button (3)

0 Press button (3)

0 Press button (3)

Not used
<>v
Press button (3)

f , r 1 7

MASK MENU screen

Not used
0 Press button (3)
Not used
0 Press button (3)

Press
button (3)
MATCHING
General
Of the sensors used for SAS, steering knob synchronizer (OPT) and mlni lever (OPT), the signal voltage
values of the tilt angle, load and tire angle sensors in the mast vertical position, no load state, and tire
straight travel position respectively are stored in the controller at the time of vehicle shipment to be used
as the bases for control. Therefore, if maintenance or parts replacement related to these sensors is
performed, matching (updating sensor signal voltage values of the vehicle in the vehicle standard state)
becomes necessary.
Matching of the tilt angle sensor is also necessary when the vehicle posture is remarkably changed.
Matching of the load sensor is also necessary when the load in the no load state is changed including
removal and addition of attachments.
Each lever angle sensor for mini lever function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment.Therefore, when maintenance or
parts replacement related to these sensors is required, matching needs to be performed.
SAS Matching ltems and Conditions
No. Indication Description Condition
* I . * 2 . * 3 . *6
1 TlLTL Tilt angle sensor output in the fork level position is stored in the controller.
.7 . .8
Tilt angle sensor output of forward tilt control in the mast vertical position * I . *2 . *3 . *6
is stored in the controller. *7. *8
3 LOAD Load sensor output in the no load state is stored in the controller. *I . * 4 . * 6 . *7

Steering knob synchronizer Matching Item and Condition (OPT)


No. Indication Description Condition
Tire angle sensor output in the straight travel position is stored in the
*I .*5
controller.

-Mini lever Matching ltems and Conditions (OPT)


No. Indication Description Condition
Lift lever angle sensor output in the lift lever neutral position is stored in
. .g
the controller.
Tilt lever angle sensor output in the tilt lever neutral position is stored in
. *ol
the controller.
Attachment 1 lever angle sensor output in the attachment 1 lever neutral
ATTI , *11
position is stored in the controller.
Attachment 2 lever angle sensor output in the attachment 2 lever neutral
ATT2 . *12
position is stored in the controller.
Meaning of Conditions
* I: When the main controller is replaced
*2: When the tilt angle sensor is replaced
*3: When the tilt angle sensor rod is replaced or its length is changed
*4: When the load sensor is replaced
*5: When the tire angle sensor and sensor cover is removed/installed/replaced
*6: When an attachment is changed
*7: When the mast is replaced
*8: When the tilt cylinder is replaced
*9: When the lift lever angle sensor is replaced
*lo: When the tilt lever angle sensor is replaced
*11: When the attachment 1 lever angle sensor is replaced
*12: When the attachment 2 lever angle sensor is replaced
Before Matching
Vehicle should be in the "Standard state" for matching.
"Standard state" means the vehicle satisfies the following conditions:
1. Surface levelness check
Matching on the unleveled or inclined surface may
cause deviation of the standard. Perform matching on a
level surface (inclination below 0.5").
2. No-load vertical condition check
Signal voltage of the load sensor in no-load state is
stored. Make sure that the following conditions are met.
Raise the fork of the V mast to approx. 500 mm
(19.7 in). Make sure that the mast is in the vertical
position by checking with an angle gauge.
FV*FSV mast The rear cylinder rod extension of the FV and FSV
mast should be approx.
100 mm (3.9 in).
Make sure that the mast is in the vertical position by
checking with an angle gauge.
Tilt the mast from backward tilt position to forward until
it becomes vertical.
3. Tire pressure check (for optional Pneumatic tire models
only)
Make sure that the tire pressure is at the specified level.
Low pressure and deviation of tire pressure among the
tires may hinder accurate matching.

4. Tire straight traveling position check


Signal voltage of the tire angle sensor in tire straight
travel position is stored. Tire straight travel position is
the condition in which driving the vehicle 5 meters (16 ft)
with the steering wheel fixed causes the center of the
vehicle to stay within 50 mm (2.0 in) to the left and right
of the line.

Operating Procedure for MATCHING screen


1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen.
2. Press button (2) three times to display "4. MATCHING" and press button (3) (enter) to display the
MATCHING setting screen.
3. Press button (3) to display the desired matching item.
4. Functions of buttons on the MATCHING setting screen are as follows:
Button (1): Unused
Button (2): Starts matching for the selected item
Button (3): Display the next item
': Press button (3) on the ATT2 matching set screen to display the MASK MENU screen.
OK on the display is indicated only after matching (by pressing button (2)).
The value in parentheses is the one stored at present.
The value outside parentheses is the one under the present vehicle condition.
Note:
Matching is necessary when the two values, inside and outside the parentheses are different in
vehicle standard condition.

Button (1) Button (2)


M A S K MENU screen

.............................. a
a
a
a
a
a
\ !
~utton(3)
Press button (3)
0 Press button (3)

0 Press button (3) 0 Press button (3)

0 Press button (3) 0 Press button (3)

0 Press button (3) 0 Press button (3)

/ \

Press button (3)


\ ,
TIRE CONSTANT SET
General
In order to optimize the speed meter, tire constant that matches the tire outside diameter needs to be input
in the controller.
Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire
size is changed or the tires are worn excessively to a degree affecting the speedometer function.
Operating Procedure for Tire Constant Setting
Button ( I ) Button (2)
1. Input the password on the general screen (see page
MASK MENU screen
f
\ 3-32) to display the MASK MENU screen.
2. Press button (2) four times to display "5. WHEEL D I A
:=MENU=
and press button (3) (enter) to display the tire constant
~?-w!-E__E-c--o_!-! -1 setting screen.
omllllllm@ S P H
3. Press button (1) or (2) to set the desired tire constant
and press button (3) (enter) to display the MASK MENU
L J
\ screen.
Button (3)
0 Press button (3)
4. Functions of buttons on the tire constant setting screen
are as follows:
/ -, Button (1): Decrease the tire constant
Button (2): Increase the tire constant
Button (3): Enter and display MASK MENU screen

'
L I 1
1
Tire constant

Tire Constant List


Tire type Tire size Applicable model Tire constant
Smooth
Cushion
Lug
18 x 7 x 12.118 All models 25
Smooth
Cushion Non-Mark .
Lug
Pneumatic J lug 18 x 7-8-16 7FBEU 15,18 20

Flatless J lug 18 x 7-8 7FBEU 15,18 24


TROUBLESHOOTING
Page
BEFORE TROUBLESHOOTING ................ 4-2
TROUBLESHOOTING METHOD ............... 4-4
SST SETTING METHOD ....................... 4-5
DIAGNOSIS CODE LIST ....................... 4-11
WHEN AN ERROR CODE IS DISPLAYED ....... 4-15
CPU BOARD .................................. 4-15
TRAVELINGIMATERIAL HANDLING AC DRIVER .... 4-105
0
SAS SYSTEM ................................. 4-137
MULTI-DISPLAY ............................... 4-143
WHEN NO ERROR CODE IS DISPLAYED ....... 4-144
BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull it at the
harness but hold the connector itself and pull it after
unlocking it.
To connect, push the connector fully until it is locked in
position.

3. Bring a tester probe into contact with a connector


terminal from the rear side of the coupler (harness side).
4. If insertion from the rear side is impossible, as in the
case of a waterproof connector, bring the tester probe
carefully into contact with the terminal so as not to cause
deformation of the connector terminal.
5. Do not touch connector terminals directly with your
hand.
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other.

WIRE HARNESS AND CONNECTOR


INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and
wire harness of the related circuit according to the following
procedure:
Continuity check
1. Disconnect the connectors at both ends of the
corresponding harness.
2. Measure the resistance between corresponding
terminals of the connectors at both ends.
Standard:lO W or less
Note:
Measure while lightly shaking the wire harness up and
down and sideways.
Reference:
Open circuit at the wire harness occurs rarely partway
through a vehicle wiring but mostly at connectors.
Inspect especially the sensor connectors with sufficient care.
Short circuit check
1. Disconnect the connectors at both ends of the
corresponding harness.
2. Disconnect the connectors at both ends of the
corresponding harness.
Standard: 1MR or more
Note:
Measure while lightly shaking the wire harness up and
down and sideways.

3. Measure the resistance between a terminal


corresponding to the connector terminal and N1.Always
inspect the connectors at both ends.
Standard: IMR or more
Note:
The wiring may short-circuit due to pinching by the body
or defective clamping.

Visual and contact pressure checks


Disconnect the connectors at both ends of the
corresponding harness.
Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals.
Inspect that there is no loosening or damage at the locked
portion. Also, lightly pull the wire harness from the
connector to check that it does not come off.

Insert a male terminal same as that of the terminal to a


female connector and check the extracting force.
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals.
Note:
Even if there is rust or foreign matter trapped at the
terminal, or the contact pressure between male and
female terminals is low, abnormal contact condition may
be changed to normal by disconnecting and
reconnecting the connector.ln that case, repeat
connector connection and disconnection several times.
If defect is perceived even once, terminal contact may be
defective.
TROUBLESHOOTING METHOD

,.-------------------
Disconnect the battery plug. I

: Connect SSTl to C N l l l and


I

I
connect A and 1. I

t Defective portion
Repair or replacement
___- - - -
CPU board . I
Turn cooling fan on.
- - - _____- - -
To the next step depending on the result.

CN100-9 (43) OK
T Voltage measurement -w Cooling fan replacement
C N l l l - 4 (NI)

Connector and harness


inspection between CNlOO Repair or replace the defective portion.
and CN111.

Explanation of Frames
Voltage No. Upper row: Tester positive (+) probe

-
A single frame indicates measurement with a
tester or an ordinary step.
Voltage measurement
C N l l l - 4 (N1)

I'
connector and pin No.
Lower row: Tester negative (-) probe

T
,est item
A double frame indicates inspection by an
ANL.:I/O ACTIVE TEST ACT-1 analyzer function.
Turn cooling fan on.

Test method

A dash-line frame indicates SST connection.

An oval frame indicates connector or wire


harness inspection.
SST SETTING METHOD
Use SSTs for quick, accurate electrical troubleshooting on the 7FBE series.
Correct check will fail if the connection method is wrong.Since boards may be damaged by incorrect
connection, careful operation is necessary.

( SST No. I Part No. I SST name I Remarks I


Shorting harness
09232-13130-71 SST 09230-13130-71
(forCN19,32,52,55,58,86and90)
(Controller check har-
Accelerator potentiometer check harness ness for 7FB)
SST8 09238-1 3130-71
(for CN26. 41 and 42)
SSTl3 1 09234-13900-71 1 Shorting harness (for CNl 01 and 102) 1 I
Drive and pump motor rpm sensor check
SSTI 9 09231-21320-71 harness
(for CN109, 110 and 111)
Lift, Tilt, ATTI, ATT2 solenoid check harness
SST2O 09232-21320-71
(for CN74 and 75)

Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug
is kept connected, various boards may be damaged.
SSTI 9 Setting Method
Set SSTI 9 when the error codes C8-1 and E8 are displayed.
(1) Disconnect the battery plug.
(2) Connect SST19 and CNllO (CN109, CN111) and connect CN1 and CN3 of SST19.
(3) Connect the battery plug.
(4) Turn key switch ON and check LED while traveling.
- -- - -

CPU BOARD CONNECTOR

IIT;d CN104 CN103 CN102 CNlOl gn I

CNlOl CN102 CN103 CN104


1

CNlOl CN104
No. P J
1 45 DSF I l l 145 1 CANH
2 46 DSR
3 65 LSB POTH
4 66 LSPB POTTA
5 67 LSD 5 59 SPI

SOLa4
SOLb4

20 MB-

N2
N2 N2
24 FAN-

SOLP+
271 13 1 SOLP-
28 1 330 1 SOLST-
-
34 1 51 I POT-
- -

MAIN CONTROLLER CONNECTOR COMPONENTS

4-; ;
I!, I
I I
I I
(4-1 I
.I I I
-1 I
---
I I

CPR
I I
:
< (

@ I
I
I
I
I
I

I
I
I
I
I
I

ww w
CNlOl CN102 CN103 CN104
TRAVELING AC DRIVER 1 CONNECTOR COMPONENTS

CNllO

P3 P7 P8 P9 N1

TRAVELING AC DRIVER 2 CONNECTOR COMPONENTS


MATERIAL HANDLING AC DRIVER CONNECTOR COMPONENTS
DIAGNOSIS CODE LIST
When an Error Code Is Displayed
Diag memory
Displayed code Error mode Page
code
30-1 30-1 Traveling AC driver 1 low voltage 4-105
30-2 30-2 Traveling AC driver 2 low voltage 4-106
30-3 30-3 Material handling AC driver low voltage 4-107
31-1 31-1 Traveling AC driver 1 low starting voltage 4-108
31-2 31-2 Traveling AC driver 2 low starting voltage 4-109
31-3 31-3 Material handling AC driver low starting voltage 4-110
32-1 32-1 Traveling AC driver 1 EEPROM abnormality 4-111
32-2 32-2 Traveling AC driver 2 EEPROM abnormality 4-111
32-3 32-3 Material handling AC driver EEPROM abnormality 4-112
Main controller + Traveling AC driver 1 communication
33-1 33-1 4-113
abnormality
Main controller + Traveling AC driver 2 communication
33-2 33-2 4-114
abnormality
Main controller + Material handling AC driver
33-3 33-3 4-115
communication abnormality
61-1,2 61-1,Z Load sensor abnormality 4-137
62-1,2 62-1,2 Tilt angle sensor abnormality 4-139
63-1,2,3 63-1,2,3 Tilt switch abnormality 4-15
64-1,2,3 64-1,2,3 Lift solenoid abnormality 4-16
65-1,2,3 65-1,2,3 Tilt solenoid abnormality 4-18
66-1 66-1 Tilt matching abnormality 4-140
67-1 67-1 Lifting height switch abnormality 4-141
71-1,2 71-1,2 Tire angle sensor abnormality 4-20
72-1,2,3,4 72-1,2,3,4 Steering angle sensor abnormality 4-22
73-1,2,3 73-1,2,3 Steering knob synchronizer solenoid abnormality 4-27
74-1 74-1 Tire angle matching abnormality 4-29

IIWI

DCR
1 AO-1 Main drive circuit overheat 4-116

4~~~

PCR
9 AO-2 Main pump circuit overheat 4-117

A1-1 A1-1 Main controller high voltage 4-30


A1-2 A1-2 Traveling AC driver 1 high voltage 4-118
A1-3 A1-3 Traveling AC driver 2 high voltage 4-119
A1-4 A1-4 Material handling AC driver high voltage 4-120
I When an Error Code Is Displayed
Diag memory
Displayed code Error mode Page
code

CPU board overheat

alml1 Traveling AC driver board overheat


DCR

A2-3 Material handling AC driver board overheat 4-122


PCR
A3 A3 Battery connection incorrect (CHG) 4-32
A4 A4 Acceleration switch abnormality 4-33
A6-1,3,5 A6-1,3,5 Material handling switch abnormality 4-34
AA-1 AA-1 CPU board thermo-sensor abnormality 4-36
AA-2 AA-2 Traveling AC driver 1 board thermo-sensor abnormality 4-122
AA-3 AA-3 Traveling AC driver 2 board thermo-sensor abnormality 4-123
Material handling AC driver board thermo-sensor
AA-4 AA-4 4-123
abnormality
I I I

AC AC ( Semiconductor switch abnormality 1 4-37


Traveling AC driver 1 + main controller communication
AD-1 AD-1 4-39
abnormality

1 AD-2 I AD-2 I Traveling AC driver 1 + main controller communication


abnormality
1 4-40 1
Traveling AC driver 2 + main controller communication
AD-3 AD-3 4-41
abnormality
Traveling AC driver 2 + main controller communication
AD-4 AD-4 4.42
abnormality
Material handling AC driver + main controller
AD-5 AD-5 4-43
communication abnormality
Material handling AC driver + main controller
AD-6 AD-6 4-44
communication abnormality
AF-1,2,3,4 AF-1,2,3,4 CPU abnormality 4-45
C1-I C1-I Traveling AC driver 1 current sensor offset abnormality 4-124
C1-2 C1-2 Traveling AC driver 1 overcurrent 4-124
C1-3 C1-3 Traveling AC driver 2 current sensor offset abnormality 4-125
C1-4 C1-4 Traveling AC driver 2 overcurrent 4-125

C2-1 Drive motor overheat 4-126


DM
C2-2 C2-2 Drive motor 1 thermo-sensor abnormality 4-127
C2-3 C2-3 Drive motor 2 thermo-sensor abnormality 4-128
When an Error Code Is Displayed
Diag memory
Displayed code Error mode Page
code
Traveling AC driver 1 main drive circuit thermo-sensor
C3-1 C3-1 4-129
abnormality
Traveling AC driver 2 main drive circuit thermo-sensor
C3-2 C3-2 4-129
abnormality
C4-1,2,3,4 C4-1,2,3,4 Accelerator potentiometer abnormality 4-46
C7 C7 Direction switch abnormality 4-48
C8-1 C8-1 Drive motor 1 rpm sensor abnormality 4-130
C8-2 C8-2 Drive motor 2 rpm sensor abnormality 4-131
CB-I CB-1 MB contactor abnormality 4-49
CB-2 CB-2 MB contactor fusion 4-51
Material handling AC driver current sensor offset
El-I El-I 4-132
abnormality
El-2 El-2 Material handling AC driver overcurrent 4-132

IIWI

PM
1 E2-1 Pump motor overheat 4-133

E2-2 E2-2 Pump motor thermo-sensor abnormality 4-134


Material handling AC driver main drive circuit
E3 E3 4-135
thermo-sensor abnormality
E8 E8 Pump motor rpm sensor abnormality 4-136
EE-1,2,3 EE-1,2,3 Abnormal communication from multi-display 4-52
EF-1,2,4 EF-1,2,4 Main controller EEP-ROM abnormality 4-53
EF-3 EF-3 Main controller CPU abnormality 4-53
Main controller + multi-display communication
F1-1,2 F1-1,2 4-143
abnormality
FF FF D l5 overcurrent 4-54
HI-1,2 HI-1,2 Lift lever potentiometer abnormality 4-55
HI-3 HI-3 Lift lever potentiometer abnormality 4-60
H1-4 HI-4 Lift lever potentiometer abnormality 4-62
HI-5 HI-5 Lift lever potentiometer abnormality 4-63
HZ-1,2 HZ-1,2 Tilt lever potentiometer abnormality 4-64
HZ-3 HZ-3 Tilt lever potentiometer abnormality 4-69
HZ-4 HZ-4 Tilt lever potentiometer abnormality 4-71
HZ-5 HZ-5 Tilt lever potentiometer abnormality 4-72
H3-1,2 H3-1,2 Attachment 1 lever potentiometer abnormality 4-73
H3-3 H3-3 Attachment 1 lever potentiometer abnormality 4-78
H3-4 H3-4 Attachment 1 lever potentiometer abnormality 4-80
H3-5 H3-5 Attachment 1 lever potentiometer abnormality 4-81
H4-1,2 H4-1,2 Attachment 2 lever potentiometer abnormality 4-82
When an Error Code Is Displayed
Diag memory
Displayed code Error mode Page
code
H4-3 H4-3 Attachment 2 lever potentiometer abnormality 4-87
H4-4 H4-4 Attachment 2 lever potentiometer abnormality 4-89
H4-5 H4-5 Attachment 2 lever potentiometer abnormality 4-90
H5-1,2,3,4,5 H5-1,2,3,4,5 Lift solenoid abnormality 4-91
H6-1,2,3,4,5 H6-1,2,3,4,5 Tilt solenoid abnormality 4-94
H7-1,2,3,4,5 H7-1,2,3,4,5 Attachment 1 solenoid abnormality 4-97
H8-1,2,3,4,5 H8-1,2,3,4,5 Attachment 2 solenoid abnormality 4-100
H9-I ,2,3 H9-1,2,3 Unload valve solenoid abnormality 4-103
.
When no Error Code Is Displayed
Displayed code Vehicle condition Page
- No display on multi-display 4-144
- The vehicle does not move at all (display off) 4-145
- Only traveling disabled (no motor revolution) 4-146
- Wobbling 4-148
- Only material handling is disabled (standard models) 4-149
- Only material handling is disabled (Mini lever models) 4-150
- Steering knob not in the right position 4-151
- Constant automatic fork leveling 4-152

COLD Traveling AC driver 1, 2 low temperature warning 4-153


DCR
COLD Material handling AC driver low temperature warning 4-153
PCR
4-15

WHEN AN ERROR CODE IS DISPLAYED


CPU BOARD

63-1,2,3 Tilt switch abnormality

Related portion

- Tilt switch
CN101-23(61, LSTF+)
CN87
CN 102-8(61, LSTF) 15 -1
-
CPU CN101-17(62, LSTR+) -------
3
board -
CN1 02-9(62, LSTR)
4
-
CN101-16(51, LS-)

4 ' 2

.
Output when open or short circuit of the tilt switch line from the CPU board to the tilt switch is detected.
63-1 Forward and backward tilt switch abnormality
63-2 Forward tilt switch abnormality
63-3 Backward tilt switch abnormality

A6-3 error is
Disconnect battery plug.
Connect battery plug again and turn indicated Perform troubleshooting for A6-3.
key switch ON.
I No error
f 63-1 error is
Check if an error is detected when indicated Tilt switch installation defect
the tilt lever is operated in either Tilt switch abnormality
direction.

ANL : I10 MONITOR 3 1103-3 1 is displayed on either switch.


Operate the tilt lever in either
II direction and check the switch II
11 input valve when the tilt lever is 11
I neutral position. I1
I
II
I 0 is displayed on either switch after
Ioperating the tilt lever several times.

Memory 63-2, 63-3 The tilt lever has been turned ON for two
Check the diagnosis memory
minutes or more in the past.

The forward and backward tilt switches were


turned ON at the same time in the past.
(Check adjustment of each switch installation)
64-1,2,3 Lift solenoid abnormality

Related portion

CN88
CN 104-3(3, SOLL+)
1

[
Lift
board CN 104-4(4, SOLL-) solenoid
- 2
cpu -

Condition for error detection


Output when open or short circuit of the lift solenoid line from the CPU board to the lift solenoid is
detected.
64-1 Lift solenoid open
64-2 Lift solenoid load short
63-3 Lift solenoid drive circuit MOS short circuit

Disconnect battery plug


and disconnect CN88.

Connect battery plug, and turn the


key switch to ON.
Check the voltage of solenoid drive 5 V or more
Lift solenoid defect
CN88-l(3)
. .
$ Voltage measurement
CN88-2(4)
I I
Less than 5 V

f
I Disconnect battery plug
and disconnect CN104.
CN 104-3(3)
$ Continuity check Continuity
) CPU board defect
CN88-l(3)
CN 104-4(4)
$ Continuity check
CN88-2(4)
I I
No continuity

~arnessdefect
Disconnect battery plug and
disconnect CN88.

'I 64-2 error is


Connect battery plug, and turn key not indicated
b Lift solenoid defect
switch ON.
64-2 error is
indicated

t
Disconnect battery plug and
disconnect CN104.
Continuity
CN 104-3(3) b Harness defect
$ Continuity check
CN 104-4(4)
No continuity

7
CPU board defect

Disconnect battery plug and


disconnect CN104, and turn key
switch ON.
Continuity
Check continuity of harness b Harness defect
CN 104-3(3)-P1
CN 104-3(3)-P2
CN104-4(4)-P 1
CN104-4(4)-P2
No continuity

t
CPU board defect
65-1,2,3 Tilt solenoid abnormality

CN89
-
CN 104-6(6, SOLT+)
1
CPU Tilt
board CN104-7(7, SOLT-) solenoid
2
-

Condition for error detection


Output when open or short circuit of the tilt solenoid line from the CPU board to the tilt solenoid is
detected.
65-1 Tilt solenoid open
65-2 Tilt solenoid load short
65-3 Tilt solenoid drive circuit MOS short circuit

Connect battery plug, and turn key


No error
switch ON. Operate the tilt lever to Connector connection check
I
I
the forward
I
5-1 error is indicated

Disconnect battery plug and


disconnect CN89.

Connect battery plug, and turn key


switch ON. Operate the tilt lever to
the forward position.
5 V or more
Check the voltage of solenoid drive rn Tilt solenoid defect
CN89-l(6)
$ Voltage measurement
CN89-2(7)
Less than 5 V

Disconnect battery plug and


disconnect CN104.
CN 104-6(6)
$ Continuity check Continuity
CN89-l(6) rn CPU board defect
CN 104-7(7)
$ Continuity check
CN89-2(7)
No continuity.

~ a r n e s sdefect
65-2 error is
Connect battery plug and turn key
not indicated
switch ON. Operate the tilt lever to -bConnector connection check

I
I the forward position.
I
I
65-2 error
is indicated
T
Disconnect battery plug.
Disconnect CN89.

Connect battery plug and turn key 65-2 error is


indicated
switch ON. Operate the tilt lever to w Tilt solenoid defect
the forward position.
65-2 error is indicated

1
Disconnect CN104.
CN 104-6(6) Harness defect
Continuity measurement
CN 104-7(7)
I I
No continuity

t
CPU board defect

65-3 error is
Connect battery plug and turn key
not indicated
switch ON. Operate the tilt lever to + Connector connection defect
the forward position.
65-3 error is indicated

1
Disconnect battery plug.
Disconnect CN104, and turn key
switch ON.
Continuity check Continuity
b Harness defect
CN 104-6(6)-PI
CN 104-6(6)-P2
CN 104-7(7)-PI
CN 104-7(7)-P2
No continuity

1
CPU board defect
71 -1,2 Tire angle sensor abnormality

Related portion

CN32
-
CN102-15(316, POTH+)
1
CPU CN 102-3(317,POTH) Tire angle
2 sensor
board
-
CN102-22(51, POT-)
3
-

Output when the voltage of the tire angle sensor is outside the specified range (open or short).
71-1 Tire angle sensor open
71-2 Tire angle sensor short

71-1
r - - - - - - - - - - - - - - - - - - - -

I Disconnect battery plug and I

disconnect CN32. Connect SST2


I 1 71-2 error is
between CN32-1 and CN32-2
I I indicated.
Tire angle sensor defect
I (Main harness side). Connect I
1 battery plug and turn key switch
I .ON. I
_ --------
error
L

-177-2 .sn;t- ''

( indicated.

1
Disconnect battery plug.
Disconnect CN102.
(SST2 is the connection state.)
CN102-15(316)
Continuity check
CNjO2-3(3I 7)
* No continuity
Main harness defect

c (SST2 is the connection state.)


CN 102-3(317)
Continuity

CPU board defect


$ Continuity check
I I
Continuity

i
Main harness defect
Disconnect battery plug, disconnect
Change to 71-1 error.
CN32, connect battery plug, and
turn key switch ON.
71-2 error is indicated.

Disconnect battery plug.


Disconnect CN102. No continuity
CN102-15(316) CPU board defect
$ Continuity check
CN 102-3(317)
1 Continuity r - - - - - _ - - - 3-- - - - - - - -
I Disconnect battery plug.
I Disconnect CN142.
t I
I
Connect SST2 between CN32-2
Main harness defect I and CN32-3. (Main harness side)
I CN1 02-3(317)
I $ Continuity check
I CN 102-22(51)
I
L - - - - - - - - _ _ - _ _ - - - - - - - A

Continuity No continuity

v
Tire angle sensor defect
v
Harness defect
72-1,2,3,4 Steering angle sensor abnormality

CN131 CN19
-
CN103-lO(16, D15V) 1
3

CN101-24(312,
- STS1)
15 3

CN101-30(313, STS2) Steering


CPU 16 4
angle
board sensor
CN101-21(314, STSC)
17 5

CN130
-2
1

Condition for error detection


Output when open or short circuit of the sensor line from the CPU board to the steering angle sensor is
detected.
72-1 Steering angle sensor S T S l abnormality
72-2 Steering angle sensor STS2 abnormality
72-3 Steering angle sensor STSC abnormality
72-4 Steering angle sensor open

72-1
72-1 error is
Connect battery plug and turn the
not indicated
key switch ON. ) Connector connection check
Turn the steering wheel.

indicated

Remain 1
Check the STSl input value
turning the steering wheel.

0 Remain 0
r - - - - - - - - - - t- - - - - - - - - -
I Disconnect battery plug. I
I I
I Disconnect CN32. I
I Short between CN19-3 and CN19-2 I

I of main harness side with SST2.


I

I Connect battery plug and turn the I


I
I
I
key switch ON. I

ANL : 110 MONITOR 4 1104-1 Change to 1


b Steering angle sensor defect
Check the STSl input value

0 0
Disconnect battery plug.
Remain 0

Disconnect CN101.
(SST2 is connection state.) No continuity
CN101-24(312) -
+ Main harness defect
$ Continuity check 7
CN101-16(51) Disconnect battery plug.
I Disconnect CN19.
Continuity Connect battery plug and turn the
key switch ON.

CPU board defect


I
ANL : I10 MONITOR 4 1104-1
Steering angle sensor defect Check the STSl input value

I Remain 1

Disconnect battery plug.


Disconnect CN19, CN101.
Main harness defect CN101-24(312)
Continuity check
CN101-16(51)

c t
No continuity

CPU board defect


72-2
I

Connect battery plug and turn the


key switch ON.
,-I ,72-2 error is
not indicated Connector connection check
Turn the steering wheel.

indicated

ANL : I10 MONITOR 4 1104-1


Remain 1
Check the STS2 input value
turning the steering wheel.

Remain 0

t
r - - - - - - - - - - - - - - - - - - - -

I Disconnect battery plug. I


I I
I Disconnect CN32. I
I Short between CN19-2 and CN19-4 I
I I
I of main harness side with SST2.
I Connect battery plug and turn the I

I key switch ON. I


I

I
II
ANL : I10 MONITOR 4 1104-1
Check the STS2 input value

Remain 0
I,
Change to 1
)Steering angle sensor defect

Disconnect battery plug.


Disconnect CN101.
(SST2 is connection state.)
CN101-30(313)
No continuity
, Main harness defect
$ Continuity check 7
I
CN101-16(51)
I
I Disconnect battery plug.
Continuity Disconnect CN19.
Connect battery plug and turn the
t
CPU board defect
key switch ON.

Steering angle sensor defect


ANL : 110 MONITOR 4 1104-1
Check the STS2 input value I
,
II I I
Remain 1

Disconnect battery plug.


Disconnect CN19, CN101.
Main harness defect CN101-30(313)
$ Continuity check
CN101-16(51)
I No continuity
t
CPU board defect
r ~ o n i e cbattery

I
I
t
key switch ON.
plug- and turn the
. .

Turn the steering wheel to left or


right for one round or more.

ANL : I t 0 MONITOR 4 1104-1


Check the STSC input value
turning the steering wheel.

1 Remain 0
.
172-3 error is

I
not indicated

72-3 error is indicated

Remain 1
Connector connection check

r - - - - - - - - - - t- ---------
I Disconnect battery plug. I
I
I Disconnect CN32. I
I Short between CN19-2 and CN19-5
I of main harness side with SST2. ,
I Connect battery plug and turn the
key switch ON.
-
I
--------- ----------
I

Change to 1
b
Check the STSC input value

Remain 0

Disconnect battery plug.


Disconnect CN101.
(SST2 is connection state.) No continuity
bMain harness defect
CN101-21(314)
Continuity measurement battery plug.
CN101-16(51) Disconnect CN19.
Continuity Connect battery plug and turn the
key switch ON.

CPU board defect I


ANL : I10 MONITOR 4 1104-1
Steering angle sensor defect Check the STSC input value
I '
Remain 1

Disconnect battery plug.


Disconnect CN19, CN101.
Main harness defect CN101-21(314)
$ Continuity measurement
CN101-16(51)
No continuity

CPU board defect


72-4

kev switch ON.


+- I
Connect battery plug and turn the
,72-4 error is
not indicated Connector connection check
Turn the steering wheel.

r
Disconnect battery plug.
Disconnect CN19.
Connect battery plug.

-
Disconnect battery plug.

I7
Disconnect CN101, CN103.
Check voltage of power supply for Connect battery plug.
steering angle sensor. Approx. 0 V Check voltage of power supply for Approx. 0 V
CN19-l(16) steering angle sensor (at controller
Voltage measurement side connector).
CN19-2(51) CN103-1O(16)
Continuity check
CN101-16(51)
t
CPU board defect

Connect CN19. t
Main harness defect
Connect battery plug and turn the
key switch ON.

t
Perform troubleshooting for 72-1 (STSI), 72-2(STS2)
73-1,2,3 Steering knob synchronizer solenoid abnormality

Related portion

CN131 CN98
-
CN104-21(329, SOLST+)
19 . I Steering knob
CPU
board synchronizer
CN 104-28(330, SOLST-)
-20 2 solenoid
-

Output when open or short circuit of the solenoid line from the CPU board to the steering knob synchro-
nizer solenoid is detected.
73-1 Steering knob synchronizer solenoid open
73-2 Steering knob synchronizer solenoid short
73-3 Drive circuit MOS of steering knob synchronizer solenoid short

73-1
73-1 error is not
indicated.
Turn the steering knob b Connector connection check

73-1 error is
indicated.
7
Disconnect battery plug.
Disconnect CN98.

t
Disconnect battery plug.
Disconnect CN104.
CN104-21(329)
9.9 * 1 Q (at 25°C) b CPU board defect
$ Resistance measurement
CN 104-28(330)
*
Other than 9.9 1 Q (at
25°C)
7
Disconnect CN98.
CN98-l(329) 9.9 * 1 Q (at 25°C) b Main harness defect
$ Resistance measurement
CN98-2(330)
Other than 9.9 *1Q
(at 25°C)
7
Steering knob synchronizer solenoid defect
- 73-2 error is not
ACTIVE TEST : ACT-2 KSOL indicated.
Turn the steering knob Connector connection check
11 synchronizer solenoid ON.
II
indicated.

Disconnect battery plug.


Disconnect CN98.

1 -
73-1 error is
indicated.
Turn the steering knob Steering knob synchronizer solenoid defect
synchronizer solenoid ON.

73-2 error is
indicated.
v
Disconnect battery plug.
Disconnect CN104.
CN104-2 l(329) Harness defect
Continuity check
CN 104-28(330)
1 No continuity

f
CPU board defect

73-3 error is not


indicated.
Turn the steering knob ,Connector connection check
synchronizer solenoid ON.

73-3 error is
indicated.
7
Disconnect battery plug.
Disconnect CN152 and turn the key
switch ON.
Check continuity
CN104-21(329)-PI
CN104-21(329)-P2
CN 104-28(330)-P1
CN 104-28(330)-P2
I No continuity

CPU board defect


74-1 Tire angle matching abnormality

CPU board

Output when the tire angle matching value is outside the specified range.

CPU board defect


A1-1 Main controller high voltage

Related portion

F6 P2
CN104-14,15(44, VBMB)
0

CPU
board

Output when overcurrent is detected on VBMB line.

Turn key switch to OFF and then


ON again.

Is A1-1 error displayed?


NO
YES
)
Si
ANL : I10 MONITOR 1 1/01-11
VBMB: Voltage value check.
Less than 110 V

110 V or more CPU board defect

110 V or more
Battery voltage c
Approx. 36 V (STD)
Approx. 48 V (48 V)
7
I C Replace battery
CPU board defect

NG (- R)
F6 fuse inspectio w Replace F6 fuse

Was the battery plug disconnected Do not disconnect battery plug during
during traveling? traveling except in an emergency.

f
Check battery plug.
A2-1 CPU board overheat

CPU board

Thermo-sensor

0 THlOl

_
Condition for error detection / 1
I Outpdt when the thermo-sensor on the ~ P board
U detects a voltage over the set level.

III ANL : I10 MONITOR 1 1101-7


TEMP: CPU board temperature
l180°Cormore
Allow vehicle to stand for a while

c
check. (approx. 30 min.)
Less than 80 "C

Has the vehicle been subjected to Stop vehicle and perform check test with
continuous overloaded operation? standard load after 30 minutes.

v
CPU board defect
I A3 Battery connection incorrect (CHG)

Related portion

F5
CN104-2(18, B48V) P
0

CPU
board

Output when the voltage of B48V line after F5 fuse exceeds the set level.

Do not connect charger plug to the controller


side plug.

The settings are wrong.


Check the settings of battery W Correct the settings

The settings are correct.

7 Less than 48 V (STD)


Less than 65 V (48 V)
Voltage check e CPU board defect

48 V or more (STD)
65 V or more (48 V)

7 Less than 48 V (STD)


P I+ Less than 65 V (48 V)
Voltage measurement CPU board defect
N1-
48 V or more (STD)
65 V or more (48 V)

7
Check the battery and replace it
with the a correct battery.
A4 I Acceleration switch abnormality
Related portion

CN132
CN102-l(64, SWAC)
c 12
CPU -
CN1 02-22(51, POT-)
9

CN130

Condition for error detection


Output when the acceleration ON signal is detected upon battery plug ON.

Was the accelerator pedal operated


Normal
upon battery plug connection?

I Disconnect CN26. I

v
Reconnect battery plug.

NO
b Adjust acceleration switch
YES

Disconnect battery plug and Continuity


disconnect CN102.
CN102-1(64) Harness defect
Continuity check
CN 102-22(51)

f
CPU board defect
A6-1,3,5 Material handling switch abnormality

CNll

CN102-6(60, LSL) V I-
CN130 ( , MLi'
111
switch I
L 14J I
CN21 I

-- -
CN101-ll(63, LSAT1+)
CN102-lO(63, LSATI)
1 Attachment
2 No.1 switch
I I
I
I
I
I
?
1 I
I I CN87
CN101-23(61, LSTF+) I I

CN 102-8(61, LSTF)
r

1Forward
tilt switch
-

-
CN101-17(62, LSTR+)
16 Backward
CN 102-9(62, LSTR)
-
4 tilt switch

Condition for error detection


Output when the material handling switch ON signal is detected upon battery plug ON.
A6-1 Lift switch abnormality
A6-3 Forward and backward tilt switch abnormality
A6-5 Attachment No. 1 switch abnormality

Was the material handling lever


YES
operated upon battery plug + Normal
connection?

Disconnect C N l l (A6-I), CN87


(A6-3) or CN21 (A6-5), and connect
battery plug.

Is A6 error displ ) Adjust limit switch or switch abnormality.

YES
Disconnect battery plug.
Disconnect CN101, CN102.
Continuity check
A6-1
CN101-32(60)-CN 102-6(60) NG (open circuit)
Harness defect
A6-3
CN?01-23(61)-CN102-8(61)
CN101-1 7(62)-CN 102-9(62)
A6-5
CN101-ll(63)-CN102-lO(63)

0
v
Continuity check
OK (short circuit)

A6-1
CN102-6(60)-CN101-16(51)
A6-3 NG (short circuit)
CN102-8(61)-CN101-16(51) b Harness defect
CN102-9(62)-CN101-16(51)
A6-5
CNl02-lO(63)-CN101-16(51)

CPU board defect


AA-1 CPU board thermo-sensor abnormality

Related portion

CPU board

Thermo-sensor

€I- THlOl

Output upon CPU board thermo-sensor abnormality detection

To correct, replace the CPU board


AC Semiconductor switch abnormality

Related portion I
CN126
CN104-9 (55, CPR)
CPR
P3

r \\
CN 104-2 (18, B48V)

F5 Traveling AC CNI 09-7 CPU


- board
driver 2
CN104-25
- 42, KEY START)
7
- Traveling AC CN110-7
I driver 1
I
I
I Material
- handling AC . CN -7
driver
I

u
Condition for
Output when overcurrent in the semiconductor switch of the CPU board is detected.

If CB-1 occurs at the same time, perform troubleshooting for CB-I first.
Disconnect CN126, connect battery AC error is not indicated.
plug and turn key switch ON.
I

I AC error is indicated. r I

t AC error is not
Disconnect CN110, and measure
resistance between 7 pins by the Approx. 20 R
Disconnect CN110, connect battery indicated.
+ side of harness, and N1. or more
plug and turn key switch ON. 7 pin [Tester probe -1
AC error is indicated. Resistance measurement
N1 [Tester probe +]
~ .a or less
A P P ~ o20 Traveli; AC driver
1 defect
Harness check
I

t
I17
Disconnect CN109, and measure
AC error is not
indicated. resistance between 7 pins by the Approx. 20 R
Disconnect CN109, connect battery
plug and turn key switch ON. + side of harness, and N1. or more

c AC error is indicated.
I
7 pin [Tester probe -1
Resistance measurement
N1 [Tester probe +]

ApprOx.20
Harness check
Or less
I
1
Traveling AC driver
2 defect

t
7
I
Disconnect CN111, and resistance
AC error is not
indicated. measurement between 7 pins by Approx. 20 R
Disconnect CN111, connect battery
plug and turn key switch ON.
+ the side of harness, and N1. or more
7 pin [Tester probe -1
Resistance measurement
N1 [Tester probe +]

CPU board defect A P P ~ o20


~ .R or less Material handling
Harness defect AC driver defect
Harness check
v NG (Other than OK)
CPR resistance check b CPR defect
OK (Approx. 20 R)

+
7
It short-circuits for a
moment and resistance
P2 [Tester probe -1 rises gradually
Resistance measurement - b CPU board defect
I
I
N1 [Tester probe +I
I
I
Short circuit

Disconnect P3 and N1 cable or


copper bar from the traveling
controller 1. Resistance
Short circuit
measurement between P3 of b Traveling AC driver 1 defect
controller side and N1.
P3 [Tester probe -1
Resistance measurement
N1 [Tester probe +]

0 Open circuit

Disconnect P3 and N1 cable or


copper bar from the traveling
controller 1. Resistance
Short circuit
measurement between P3 of b Traveling AC driver 2 defect
controller side and N1.
P3 [Tester probe -1
Resistance measurement
N1 [Tester probe +]
I I
Open circuit

t
Disconnect P3 and N1 cable or
copper bar from the material
handling controller defect.
Short circuit
Resistance measurement between b Material handling defect
P3 of controller side and N1.
P3 [Tester probe -1
$ Resistance measurement
N1 [Tester probe +]
1 I
Open circuit

t
Check P3 or N1 cable
AD-1 Traveling AC driver 1 + main controller communication abnormality

Related portion /
-
CN103-l(145, CANH) CN110-3(145, CANH)
-
a

CN103-2(146, CANL) CN11 0-4(146, CANL)


-
a

CPU CN103-3(147, CANGND) CN110-6(147, CANGND) Traveling


board
-
a

AC driver 1
CN104-25(42, KEY START) CN110-7(42, KEY START)
- CN112
1 -
R
2 -
3

Condition for error detection 1


1 Outpdt when the CPU board cannot reckive data from the traveling AC driver 1 within specified time.
I
YES
Is AD-2 error displayed? b See AD-2 error.

Check CN103, CN104, CNllO and CN112


Was traveling AC driver 1 just YES connection condition.
replaced? Turn the key switch OFF and ON, and it checks
I NO that an error is not displayed.
v Travelina AC driver 1 resets on the wav.
(There is possibility that traveling AC driver 1 is
defect.)
Harness check (Especially No. 42 line)
AC driver 1.
Check CN103. CN104. CNllO and
I
Blank display CN112 connection condition
1
Disconnect CN110. 15 V or
CN11 0-7(42) Less than 15 V CN 110-7(42)
$ Voltage measurement
$ Voltage measurement
N1
N1
Less than
Traveling AC driver 1
Disconnect battery plug, disconnect defect
CN112 Other than
CN 104-25(42)
CN112-1 I s than 15 V
$ Voltage measurement
Resistance measurement
CN112-2
120 * 10 Q ~ e s i s t defect
e~
I

1 5 V o r more
I

f
I
CPU board defect
Harness defect
Check the continuity of
communication line harness
-
CN103-l(145) CN110-3(145)
L No continuity (- Q)
Harness defect

-
CN103-l(145) CN112-l(145)
-
CN103-2(146) CN110-4(146) Continuity (0 Q) Traveling AC driver 1 defect
-
CN 103-2(146) CN112-2(146) (There is possibility that CPU board is defect.)
-
CN103-3(147) CN110-6(147)
AD-2 Traveling AC driver 1 + main controller communication abnormality

-
CN103-l(145, CANH) CN 110-3(145, CANH)
7

CN103-2(146, CANL) - CN110-4(146, CANL)


CPU CN103-3(147, CANGND) CN110-6(147, CANGND) Traveling
board - AC driver 1
CN 104-25(42,KEY START) CN1 10-7(42, KEY START)
- CN112
1 -
R
2 -
- 3

Output when the CPU board cannot receive ID code from the traveling AC driver 1 upon key switch on.

YES Check CN103, CN104, CNllO and


Was traveling AC driver 1 just
replaced?
+ CN112 connection condition
Harness check (Especially No. 42 line.)

Is AD-2 error displayed even if it


repeats the key switch with OFF NO
and ON?

Disconnect CN110. 15Vor


CN11 0-7(42)
Less than 15 V CN110-7(42) more
$ Voltage measurement )
$ Voltage measurement
N1
N1
15Vor more
I Less than Traveling- AC driver 1
Disconnect battery plug, disconnect defect
Other than
CN112.
CN112-1
*
120 10 SZ CN 104-25(42)
Less than 15 V
$ Voltage measurement
$ Resistance measurement N1
CN112-2
120 * 10 R Resister defect
15 V or more
CPU board defect

Check the continuity of Harness defect


communication line harness.
--
CN103-1(145) CN110-3(145)
CN103-l(145) CN112-l(145)
No continuity (W R)
+ Harness defect
--
CN 103-2(146) CN110-4(146)
CN 103-2(146) CN112-2(146)
-
CN103-3(147) CN110-6(147)
I
Continuity (0 R)

Traveling AC driver 1 defect


(There is possibility that CPU board is defect.)
AD-3 Traveling AC driver 2 + main controller communication abnormality
Related portion

-
CN103-l(145, CANH) - CN 109-3(145, CANH)
CNl03-2(146, CANL) CN 109-4(146, CANL)
-
CPU
board
CN103-3(147, CANGND)
-- CN109-6(147, CANGND) Traveling
AC driver 2
CN 104-25(42, KEY START)

1 -
R
2
- 3
-

Condition for error detection


Output when the CPU board cannot receive data from the traveling AC driver 2 within specified time.

YES
)See AD-4 error.

YES Check CN103, CN104, CN109 and CN112


Was traveling AC driver 2 just
) connection condition.
replaced?
Turn the key switch OFF and ON, and it checks
lNO that an error is not displayed.
Traveling AC driver 2 resets on the way.
(There is possibility that traveling AC driver 2 is
defect.)
driver 2. Harness check (Especially No. 42 line)
Check CN103, CN104, CN109 and CN112
Blank display connection condition.
1

CN 109-7(42) Disconnect CN109. 15 V or


$ Voltage measurement Less than 15 V CN 109-7(42) more
)
N1 $ Voltage measurement
I I
1 5 V o r more
Less than Traveling AC driver
/ Disconnect battery plug, disconnect I Other than 2 defect
CN112 120 k 10 R Less than
CN112-1 CN 104-25(42)
$ Voltage measurement 15 V
$ Resistance measurement
CN112-2 N1
7
120 i10 Q Resister defect 1 5 V o r more
CPU board defect
I
Harness defect
Check the continuity of No continuity (- 51)
communication line harness Harness defect
-
CN103-l(145) CN109-3(145)
-
CN103-l(145) CN112-l(145)
--
CN 103-2(146) CN109-4(146)
CN 103-2(146) CN112-2(146)
Traveling AC driver 2 defect
(There is possibility that CPU board is defect.)
AD-4 Traveling AC driver 2 + main controller communication abnormality

I 7CN103-l(145. CANH) -
7

CN103-2(146, CANL) CN 1094(146, CANL)


-
CN103-3(147, CANGND) CN 109-6(147, CANGND) Traveling AC
CPU - CN109-7(42, KEY START) driver
board CN 104-25(42, KEY START)
CN109-l(82, CUDIDO)
-
f

Condition for error detection


1 o u t p i t when the CPU board cannot recLive ID code from the traveling AC driver 2 upon key switch on. /
YES Check CN103, CN104, CN109 and CN112
Was traveling AC driver 2 just
replaced? * connection condition
Harness check (Especially No. 42 line.)
h NO There is possibility that A D 4 error will be

.
1
displayed upon key switch turning to ON at first
Is AD-4 error displayed even if it repeats NO
time after replacing the traveling AC driver 2.
the key switch with OFF and ON?
I J
YES
CN109-7 (42)
Less than 15 V Disconnect CN109. 15 V or
2 Voltage check CN109-7 (42) more
N1
$ Voltage check
15 V or more N1
Disconnect battery plug, disconnect Less than Traveling AC driver 2
Other than
CN112.
CN112-1
120 10 R * 15 V defect

Resistance measurement
7 Less than
CN104-25 (42)
CN112-2 15 v
$ Voltage check
120 l o n N1
Check the continuity of
7
Resister defect
communication line harness.
-
CN103-1 (145) CN109-3 (145)

--
~ a r n e s defect
s
CN103-1 (145) CN112-1 (145) (W n, Harness defect
CN103-2 (146) CN109-4 (146)

Continuity 10 Q)
CN109-1 (82) No continuity (m R)
$ Continuity check Harness defect
CN109-10 (82)
Continuity (0 R)
Traveling AC driver 2 defect
(There is possibility that CPU board is defect.)
AD-5 Material handling AC driver + main controller communication abnormality

-
CN103-l(145, CANH) CN111-3(145, CANH)
T
CN103-2(146, CANL) - CNlll-4(146, CANL)
Material
CPU CN103-3(147, CANGND) CN111-6(147, CANGND) handling
board
AC driver
CN 104-25(42, KEY START)

1 -
R
2 -

Condition for error detection 1


Output when the CPU board cannot receive data from the material handling AC driver within specified time.

YES
Is AD-6 error displ +See AD-6 error

Check CN103, CN104, C N l l l and CN112


Was material handling controller YES connection condition.
just replaced? ** Turn the key switch OFF and ON, and it checks
that an error is not displayed.
Material handling AC driver resets on the way.

II I----
ANL. : 110 MONITOR 1 1101-2,4,6,13 (There is possibility that material handling AC
data
The data check from the material -, driver is defect.)
II
handling controller.
II
I I
Harness check (Especially No. 42 line)
Check CN103, CN104, CN111 and
Blank display CN112 connection condition

I Disconnect CN111.
1 N
: volt'agk measurement
115~or

I
1 5 V o r more

Disconnect battery plug, disconnect Other than


CN112 120 10 R * Less than
CN112-1 CN 104-25(42) 15 V
$ Resistance measurement $ Voltage measurement

Resister defect
CPU board defect
~ a r n e s defect
s
Check the continuity of
communication line harness No continuity (M R)
Harness defect
-
CN103-l(145) CN111-3(145)
-
CN103-l(145) CN112-l(145)
-
CN 103-2(146) CN111-4(146)
--
CN 103-2(146) CN112-2(146)
CN 103-3(147) CN111-6(147)
Continuity (0 R) Material handling AC driver defect
(There is possibility that CPU board is defect.)
AD-6 Material handling AC driver + main controller communication abnormality
Related portion

- CN103-l(145, CANH) -- C N l l l-3(145, CANH)


CN 103-2(146, CANL)
- CNlll-4(146, CANL)
CN 111-6(147, CANGND) Material
CPU CN103-3(147, CANGND)
- handling
board CN 104-25(42, KEY START) CNl 11-7(42, KEY START)
AC driver
CNlll-2(87, CUPIDI)
- I
~ ~ 1 1 2 CN111-10(87,
- SSP-, TP-)
- 1 -
R
2 -
- 3

Output when the CPU board cannot receive ID code from the material handling AC driver upon key
switch on.

Was material handling AC driver YES CheckCN103, CN104, C N l l l and CN112


just replaced? k connection condition
Harness check (Especially No. 42 line.)
C No
T
I There is possibility that AD-6 error will be
displayed upon key switch turning to ON at first
Is AD-6 error displayed even if it repeats NO
time after replacing the material handling AC
the key switch with OFF and ON?
I J
driver.
YES
CN111-7(42)
Less than 15 V Disconnect CN111. 15 V or
$ Voltage check
CN 111-7(42) more
N1
$ Voltage check
15Vormore N1
Disconnect battery plug, disconnect Less than Material handling

1 I:"";T-:""
Other than
CN112.
CN112-1
120 l o n
I
* w
15 V AC driver defect

$ Resistance measurement
(3112-2 + Voltage check
*
120 10 r;2
Check the continuity of Resister defect
communication line harness. l5Or CPU board defect
--
L
CN103-l(145) CN111-3(145) ~arn=ssdefect
CN103-l(145) CN112-l(145) No continuity (- Q)
-
CN103-2(146) CN111-4(146) Harness defect

CN111-2(87)
$ Continuity check
CN111-1O(87)
' 1 No continuity (W 52)
Harness defect

$. Continuity (0 a )
Material handling AC driver defect
(There is possibility that CPU board is defect.)
AF-1,2,3,4 CPU abnormality

Related portion

CPU board

Output when abnormality of CPU element is detected.

CPU board defect


C4-1,2,3,4 Accelerator potentiometer abnormality
I
- CN132 CN26[

.
CN102-1(64, SWAC) CN26-2
12 .

CN 102-2(52, POTA)
- CN26-3
13 -
Accelerator
CN102-14(53, POTA+) CN26-4
14 . potentiometer
CPU
board CN130
CN 102-22(51, POT-) CN26-1
9
I

C4-1 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is on.
C4-2 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is on.
C4-3 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is off.
C4-4 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is being
operated.

ANL : I10 MONITOR 2 110 2-1


Check the POTA value when the 0.3 V or more
accelerator switch SWAC is turned CPU board defect
from 0 to 1.
,
I

I Less than 0.3V


1
The POTA value
ANL : I10 MONITOR 2 110 2-1
changes.
Check the POTA value as the b Potentiometer adiustment defect
11'
I
accelerator is depressed further.
I1
I

( The POTA value does


+-not change.
----------- ----------
I Disconnect CN26, and short I
Error is not indicated
I between
I
t I

I POTA and POTA+ with SST8. I


I
L - - - - - - - - - - - - - - - - - - - - J

Potentiometer defect
C Error is indicated CN 102-2(52)

N1
$ Voltage measurement
I

14.8 V or more I Less than 4.8 V


I

v
CPU board defect
v
Main harness defect
I
Does C4-2 go out after
disconnecting CN26?

CN 102-2(52)
$ Voltage measurement
N1

C4-3
t
Less than 4.5 V

CPU board defect

from 0 to 1 as the accelerator


pedal is depressed.

Changes to 1.
.
w
I
4.5 V or more
Accelerator potentiometer check

Main harness defect

) Accelerator switch defect

I//I ANL : I10 MONITOR 2 1102-1


Check maximum POTA value II ~ e s s ~ Is C4-3 error displayed?
YES
I

I
when SWAC is 0.
I I NO 1
I
I

12.5 V or more

Does C4-3 go out after


1T
CPU board defect

Accelerator potentiometer check


disconnecting CN26?

CN 102-2(52)
2.5 V or more
3: Voltage measurement Main harness defect
N1
I

Less than 2.5 V

t
CPU board defect

If C4-2, 3 occurs at the same time, perform troubleshooting for C4-2, 3 first.

b Potentiometer adjustment defect


SWAC display is turned from 0 to
1 or from 1 to 0.

Less than 1.4 V

CPU board defect


I C-7 Direction switch abnormality

Related portion

- CN101-l(45, DSF) CN130 CN9


2 -5 -
-
CPU CN101-2(46, DSR) Direction
3 4 -
switch
board
CN101-16(51, LS-)
-
1 6 -
-

Output when both forward and reverse direction switches are ON.

Disconnect battery plug and


disconnect CN9.

7
Becomes 0.
Check the value of DSF, DSR. + Direction switch inspection
DSF or DSR display will be 1.

7
CN101-l(45)
CN101-2(46) NG (Other than OK)
Voltage measurement b Harness shorl circuit
N1
OK (approx. 5 V)

7
CPU board defect
I CB-1 MB contactor abnormality

-1 Related portion 1
CN104-14,15(44, VBMB)

contactor coil CN134 CN136

Condition for error detection


Output when the voltage difference between B48V and VBMB lines exceeds the set level.

If 31-1, 2, 3, A l - I , 2, 3, 4, AD-2, 4, 6, C1-2, 4 and El-2 occurs at the same time, perform troubleshooting
for 31-1, 2, 3, A l - I , 2, 3, 4, AD-2, 4, 6, C1-2, 4 and El-2 first.
Is the contactor ON sound heard NO
upon key switch ON?

Check the deference of voltage


value between VB48 and VBMB.
Less than
30V
-___)
I,

-1 ANL : 110 MONITOR1 1101-8


VB48 : Battery voltage check
I
,I Less than 32 V (STD)
Less than 4"; (48 V)

I' I I 1
I
32 V or more (STD) Battery charge
30 V or more 43 V or more (48 V)

value between P1 and P2


P I , P2 30 V or more
MB contactor defect
5 Voltage measurement
N1
I I

Less than 30V

The voltage difference check of 1 and 2.


1 .CN104-14(44)

1 2
N1
Voltage measurement

YN104-l(18)
Voltage measurement
30 V or more Harness check

Check the deference of voltage value


between CN104-1 and CN104-147.
I J
Less than 30V
CPU board defect
1
Measure contactor signal voltage. NG Signal voltage check of CPU board
Disconnect connector of contactor, (Less than 9 V) connector. Less than 9 V
and measure voltage between CN104-19(1)
connector terminals on CPU board Voltage measurement
side. CN 104-20(2)
CPU board defect
1 OK (9 V or more) 9 V or more

f
MB contactor defect
Check the harness between CN104
and MB contactor.

1
15 V or more (STD)
ANL : I10 MONITOR1 1/01-11
Check the VBMB voltage at the 20 or more (48 V)
CPU board defect
time of travelinglmaterial handling
operation.
Less than 15 V (STD)

Less than 20 V (48 V)

Check the P2 voltage at the time of


travelinglmaterial handling 20 V or more (48 V)
operation. F6 fuse check
P2 Harness check
Voltage measurement

Less than 20 V (48 V)

t
MB contactor defect
CB-2 MB contactor fusion

Related portion

I
-
PI CN104-14,15(44, VBMB)

CPU
board
MB contactor coil CN134 CN136

Condition for err


I o u t p i t when the battery (VBMB line) vo;tage does not drop after key switch OFF

If 30-3, 31-3, 33-3, AO-2, A1-4, A2-3, AC, AD-5, 6, E l - I , 2 and E2-1 occurs at the same time, perform
troubleshooting for 30-3, 31-3, 33-3, AO-2, A1-4, A2-3, AC, AD-5, 6, E l - I , 2 and E2-1 first.
Is contactor OFF sound heard upon Check voltage change upon key

0@
key switch ON to OFF?

1
switch OFF.

N1
voltage measurement

Disconnect battery plug, and Fusion Drop to 15 V or less in No voltage change


inspect contactor contact. 5 seconds after key upon key switch

I
I I
Normal
Replace
v MB contactor. I CPU board defect ater rial handling AC driver
abnormality
Although there was "Itage Under Material handling
Error change for a moment after prohibition error generation
key switch OFF, it went up
again by more than 15 V.

- t - 1
Perform troubleshooting of the corresponding error.
CPU board defect

t Except CB-2
Is MB contactor turned OFF with YES Turn key switch ON, and check the
the key switch OFF? ) error display.
I I I 1

NO No error CB-2 display

Turn key switch OFF.


CN104-19(1) NG(8 - 10V) Check CN104,CN134,CN136
connection condition.
$ Voltage measurement

t
CPU board defect
MB contactor defect Harness leak
I EE-1,2,3 Abnormal communication from multi-display

- CN131 CN1
CN103-13(144, SMTDK) - CN70-23
4 7
CN103-14(143, SDTMK) - CN70-24
4
CN103-15(142, SDTMA) CN70-21
8
CPU CN103-16(141, SMTDA) CN70-22 Display
P
3
board

CN103-10(16, D15V) CN70-14


2
CN103-12(14, GNDD) CN70-30
2 1
-

Output upon detection of communication data abnormality from display

1 Is F1 error displayed? I L"

b See F1 error

Was the battery plug connected


when the display is removed? + I=I
Connect Me display

NO
Disconnect CN1
Does the display turn on upon key NO CN103-10 (16)
switch ON? Voltage measurement
l YES CN103-12 (14)
I
1 14 V or more I Less than 14 V
I

t t
Sub harness defect CPU board defect
Display defect Harness defect

Disconnect battery plug and


disconnect CN103 and CN70.
Check the continuity. Connector connection defect
-
CN103-15 (142) CN70-21 (142) Harness defect

I I

OK (Approx. 0 Q)

Display defect
CPU board defect
EE-3
Reset the tuning value.
If EE-3 is displayed frequently, either the CPU board or the display may be defective.
EF-1,2,4 Main controller EEP-ROM abnormality

CPU board

Condition for error detection


Output when abnormality of EEP-ROM element is detected.

CPU board defect

EF-3 Main controller CPU abnormality

Related portion

CPU board

Condition for error detection


Output when abnormality of CPU element is detected.

CPU board defect


FF D l5 overcurrent

Related portion

- CN1
CN103-10(16, D15V) CN70-14(16, D15V)
CPU 2 Multi-display
board CN103-12(14, GNDD) CN70-30(14, GNDD) board
1

Condition for error detection


Output when overcurrent of D l5V power source is detected.

Disconnect CN70, connect battery No error


b Display defect
plug, and turn key switch ON.
FF error is indicated.

7
Disconnect battery plug, disconnect
CN103, and measure the Approx.
resistance between 10 pin and 12 1k R or less
pin of harness side. b Harness defect
CN103-10 pin (Tester probe -)
$ Resistance measurement
CN103-12 pin (Tester probe +)
Approx. 1k R or more

7
CPU board defect
H I -1,Z Lift lever potentiometer abnormality

Related portion I
CN77
CN41
- CN102-18(28,POTL+)
3 1
-
CNl02-6(20,POTL1)
1 ---------- 2
CPU - -
CN102-7(21, POTL2) Lift lever
board
2 3
-
CN101-34(51,POT-)
-10 4
- -

Condition for
Output when the voltage of the lift lever potentiometer is outside the specified range (open or short).
Error indication (reference)
H 1-1 Lift lever potentiometer open abnormality
H I-2 Lift lever potentiometer short abnormality
HI-I
Do not operate the material handling lever during all checking.
H I - I error is
Connect battery plug.
not indicated.
Turn key switch ON. b Check connector connection
Lift lever at neutral position.
H I - I error is
indicated.

T
Chek the lift lever potentiometer
voltage.

Only voltage Only voltage Both voltage 1


1 is less than 2 is less than and 2 are less
0.3 V. 0.3 V. than 0.3 V.
I Disconnect battery plug. I
Disconnect battery plug.
I I
I Disconnect CN41. I H1-2 error is Connect CN41.
I

I
Short between CN41-3 (28) and
CN41-1 (20) (at main harness side)
; indicated. Replace the connectors of lift lever HI-1 ~ ~ ~ a i n s .
(CN77) with tilt lever (CN78).
I with SST8. I
Connect battery plug.
I Connect battery plug. I
I
Turn key switch ON.
I Turn key switch ON. I
L _ _ _ _ _ _ _ _ _ - _ _ - - - - - - - - ~
H1-1 changes
H1-2 error is
to H2-1. Sub-harnzs defect
not indicated.

Lift defect

-
Disconnect battery plug.
Disconnect CNlOl and CN102.
(SST8 is the connection state.) 1. No continuity
1. CN102-18 (28) 2. Continuity
5 Continuity check Main harness defect
CN102-6 (20)
2. CN102-6 (20)
$ Continuity check
CN101-34 (51)

2. No continuity

CPU board defect


t
--------- -1- - --------
I Disconnect battery plug. I
Disconnect battery plug.
I I
I Disconnect CN41. I HI-2 error is Connect CN41.
I Short between CN41-3 (28) and Replace the connectors of lift lever
I CN41-2 (21) (at main harness side) (CN77) with tilt lever (CN78).
I with SST8.
I Connect battery plug.
I Turn kev switch ON.
L - - - - - _ - -

H1-2 error is
- - - - - - - - - - - - d
H I - I changes
to H2-1.
t
Sub-harness defect
not indicated.

t v
Lift potentiometer defect
Disconnect battery plug.
Disconnect CNlOl and CN102.
(SST8 is the connection state.) 1. No continuity
1. CN 102-18 (28) 2. Continuity
x
Continuity check
CN102-7 (21)
-- . Main harness defect

2. CN102-7 (21)
2 Continuity check
CN101-34 (51)

2. No continuity

CPU board defect


f
r - - - - - - - - - -

I Disconnect battery plug.


t- I
--------- Disconnect battery plug.
Disconnect CNl 01 and CN102.
I I
I Disconnect CN41. (SST8 is the connection state.) 1. No continuity
I H1-2 error is
I Short between CN41-3 (28) and 1. CN102-18 (28) 2. Continuity
;not indicated.
I
I
CN41-1 (20) (at main harness side) b T Continuity check 1
I
)
I
with SST8.
Connect battery plug.
Turn key switch ON.
H I-2 error is
indicated.
I
I
I
I
L - - - - - - - - - - - - - - - - - - - - d
CN102-6 (20)
2. CN102-6 (20)
5 Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
I
Main harness
defect
v
CPU board defect

r - - - - - - - - - -

I
---------
Disconnect battery plug.
t I
Disconnect battery plug.
Disconnect CNl 01 and CN102.
I I
I Disconnect CN41. (SST8 is the connection state.) 1. NO continuity
I H1-2 error is
1. CN102-18 (28)
I

II
Short between CN41-3 (28) and
CN41-2 (21) (at main harness side)
not indicated. ; b $ Continuity check
2. Continuity

I with SST8. I CN102-7 (21)


) Connect battery plug. I
I
2. CN102-7 (21)
I Turn kev switch ON. I 5 Continuity check
L - - - - - - - - - - - - - - - - - - - - J

H1-2 error is t
indicated. Main harness
2. No continuity defect

Disconnect battery plug. CPU board defect


Connect CN41.
Replace the connectors of lift lever HI-1 remains
(CN77) with tilt lever (CN78).
Connect battery plug.
Turn key switch ON.
H I - I changes
to H2-1 Sub-harnLs defect

t
Lift potentiometer defect
HI-2
Do not operate the material handling lever during all checking.
HI-2 error is
Connect battery plug. not indicated.
Turn key switch ON. +Check connector connection
Lift lever at neutral position.

indicated.

Disconnect battery plug


Disconnect battery plug. H1-2 changes
Disconnect CN 101 No continuity
Disconnect CN41. to H1-1.
Connect battery plug and turn the
+ CN101-34 (51)
$ Continuity check
key switch to ON. CN41-10 (51)
H I-2 remains. Continuity
'I
Main harness
defect
Disconnect battery plug.
Disconnect CN102. Disconnect battery plug.
1. CN102-18 (28) 1. Continuity Connect CN41 and CN101.
$ Continuity check 2. Continuity Replace the connectors of lift lever HA-2remains
CN 102-6 (20) (CN77) with tilt lever (CN78).
2. CN102-18 (28) Connect battery plug.
Turn key switch ON.
5 Continuity check
CN102-7 (21) 'I H1-2 changes
1. No continuity
Main harness to H2-2 'I
defect Sub-harness defect
2. No continuity
'I
v Lift potentiometer defect
CPU boaid defect
H I -3 Lift lever potentiometer abnormality
I
CN41 CN77
- CN102-18(28,POTL+)
3 . - 1
-
CN102-6(20,POTLI)
1 - 2
CPU
board CN102-7(21,POTL2) Lift lever
2 3
CN101-34(51,POT-)
10 4
-

Output when the voltage of the lift lever potentiometers 1, 2 with the lift lever at neutral position is outside
the specified range.
Error indication (reference)
H I-3 Lift lever potentiometer abnormality

H1-3 error is
Connect battery plug.
not indicated.
Turn key switch ON. +Check connector connection
I Lift lever operation.
I

.
H1-3 error is
indicated.

Chek the lift lever potentiometer

v
Disconnect battery plug.
Replace the connectors of the lift
lever (CN77) with the tilt lever
(CN78).
Connect battery plug and turn the
key switch to ON.

ANL : I10 MONITOR3 1103-3


Chek the tilt lever potentiometer
*
Within (*I) 0.2 V Lift lever potentiometer
voltage defect
II I I
Below or above (*I) 0.2 V *
v
I

I
I

I
I

I
I
Disconnect battery plug.
Disconnect CN102.
Return the lift lever connector
(CN77) and the tilt lever connector
(CN78) to the original connection.
Connect battery plug and turn key
switch ON.

ANL : I10 MONITOR3 1103-1


Chek the lift lever potentiometer
voltage

r - - - - - - - - -

; Disconnect battery plug.


0.3 V or less

3- - - - - - - _ _ _ .
Short at the connectors below (CPU
board side) with the alligator clip of
SST13 in connection.
Connect battery plug and turn key
switch ON.
CN101-11 (63) CN102-6 (20)
CN101-11 (63) CN102-7 (21)
L - - - - - - - - -
--
-1
- - - - - - - - - - A
.
I
I

1
I
0.3 V or more
CPU board defect

.
ANL : I10 MONITOR3 1103-1
Chek the lift lever potentiometer
voltage
1 4.5 V or more
Harness defect

CPU board defect


H I-4 Lift lever potentiometer abnormality

CN41 CN77
- CN102-18(28,POTL+)
3 1
CN102-6(20,POTL1)
1 2
CPU
board CN 102-7(21,POTL2) Lift lever
2 3
CN101-34(51,POT-)
10 4
-

Condition for error detection


Output when the lift lever voltage value is outside the specified neutral range (lever operated) upon key
switch ON.
Error indication (reference)
H1-4 Lift lever neutral abnormality

Check that the lift lever returned to


neutral position.
Turn key switch ON again.
H1-4 goes out.
* Normal
Do not operate the lever upon key switch ON.
H I-4 remains.

7
Check the installation state of the lift NG
lever potentiometer. + Readjustment
OK

potentiometer neutral voltage + Vehicle operation can be started.


again.

NG

7
Lift potentiometer defect
I H I-5 Lift lever potentiometer abnormality
1
Related portion

CPU board

Condition for
Output when lift lever neutral matching value is outside the specified range.
Error indication (reference)
HI-5 Lift lever neutral matching value abnormality

CPU board defect


H2-1,2 Tilt lever potentiometer abnormality

Related portion

CN41 CN78
- CN 102-19(29,POTT+)
6 1
CN 102-8(22,POTTl)
4 2
CPU
board CN 102-9(23,POTT2) Tilt lever
-
- 5 3
CN101-34(51,POT-)
-
10 4
-

Condition for error detection


Output when the voltage of the tilt lever potentiometer is outside the specified range (open or short).
Error indication (reference)
H2-1 Tilt lever potentiometer open
H2-2 Tilt lever potentiometer short

Do not operate the material handling lever during all checking.


H2-1 error is
Connect battery plug.
not indicated.
Turn key switch ON. +Check connector connection
Tilt lever at neutral position.
I I

H2-1 error is
indicated.

Chek the tilt lever potentiometer

Only voltage Only voltage Both voltage 1


1 is less than 2 is less than and 2 are less
0.3 V. 0.3 V. than 0.3 V.
r - - - - - - - - - -

I Disconnect battery plug.


i ---------
Disconnect battery plug.
I I
I Disconnect CN41. I H2-2 error is Connect CN41.
I Short between CN41-6 (29) and l indicated. Replace the connectors of lift lever HZ-1 remains.
I CN41-4 (22) (at main harness side) -)
(CN77) with tilt lever (CN78).
I with SST8. Connect battery plug.
I
I
Connect battery plug. Turn key switch ON.
I Turn key switch ON.
L - - - - - - - - - - - - - - - - - - - -
H2-1 changes
H2-2 error is
to H I - I . Sub-harnzs defect
not indicated.

It Tilt potentiometer defect


Disconnect battery plug.
Disconnect CNl 01 and CN102.
(SST8 is the connection state.) 1. No continuity
1. CN102-19 (29)
5 Continuity check --
2. Continuity
Main harness defect
CN102-8 (22)
2. CN102-8 (22)
5 Continuity check
CN101-34 (51)

2. No continuity

CPU board defect


I Disconnect battery plug. I
I I Disconnect battery plug.
I Disconnect CN41. H2-2 error is
I Connect CN41.
I Short between CN41-6 (29) and l indicated. Replace the connectors of lift lever H2-1 remains.
I CN41-5 (23) (at main harness side) -b
(CN77) with tilt lever (CN78).
I with SST8.
Connect battery plug.
I Connect battery plug.
Turn key switch ON.
I Turn key switch ON.
L - - - _ - - _ _ - - - _ - - - - - - - -

H2-2 error is H2-1 changes


not indicated. to H I - I . Sub-harn!ss defect

t
Tilt potentiometer defect
Disconnect battery plug.
Disconnect CNl 01 and CN102.
(SST8 is the connection state.) 1. No continuity
1. CN102-19 (29) 2. Continuity
$ Continuity check -w Main harness defect
CN102-9 (23)
2. CN102-9 (23)
1 Continuity check
CN101-34 (51)
I I
1. Continuity
2. No continuity

CPU board defect


I
A
r - - - - - - - - - - - - - - - - - - - - Disconnect battery plug.
I Disconnect battery- plug.
. - Disconnect CNl 01 and CN102.
I
I Disconnect CN41. H2-2 error is (SST8 is the connection state.) 1. No continuity
1 Short between CN41-6 (29) and 1. CN102-19 (29) 2. Continuity
not indicated,
I CN41-4 (22) (at main harness side) $ Continuity check
I with SST8. I CN 102-8 (22)
/ Connect battery plug. I
I
2. CN 102-8 (22)
I Turn key switch ON. I $ Continuity check
t
L _ _ _ _ _ _ _ - - - - - - - - - - - - - A

H2-2 error is CN101-34 (51)


indicated. 1. Continuity Main harness
2. No continuity defect

t
CPU board defect

r - - - - - - - - - - t- --------- Disconnect battery plug.


Disconnect CNl 01 and CN102.
I Disconnect battery plug. I
I I
I Disconnect CN41. (SST8 is the connection state.) 1, NO continuity
I H2-2 error is
,;
1 Short between CN41-6 (29) and 1. CN102-19 (29) 2. Continuity
not indicated.
I CN41-5 (23) (at main harness side) W 3 Continuity check
I with SST8. I CN102-9 (23)
I
I
I
Connect battery plug. I
2. CN102-9 (23)
I Turn key switch ON. I 3 Continuity check
L - - - - - - - - - - - - - - - - - - - - A
CN101-34 (51)
H2-2 error is 7
indicated. 1. Continuity Main harness
2. No continuity defect

t
CPU board defect
Disconnect battery plug.
Connect CN41.
Replace the connectors of lifi lever H2-1 ~ - ~ - ~ a i n s .
(CN77) with tilt lever (CN78).
Connect battery plug.
Turn key switch ON.
H2-1 changes
to H I - I . Sub-harne!s defect

Tilt potentiometer defect


t
H2-2
Do not operate the material handling lever during all checking.
H2-2 error is
Connect battery plug. not indicated.
Turn key switch ON. )Check connector connection
Tilt lever at neutral position.

indicated.

Disconnect CN41.
1
I Disconnect battery plug.-
- . I H2-2 changes
to H2-1.
I Disconnect battery plug
Disconnect CN 101 I No continuity
CN101-34 (51)
Connect battery plug and turn the 3 Continuity check
/ key switch to ON. I 11 CN41-10 (51)
H2-2 remains. I
Continuity

Main harness
defect
Disconnect battery plug.
Disconnect battery plug.
Disconnect CN102.
1. Continuity Connect CN41 and CN101.
1. CN102-19 (29)
2. Continuity Replace the connectors of lift lever ~ 2 - remains.
2
3 Continuity check (CN77) with tilt lever (CN78).
CN102-8 (22)
Connect battery plug.
2. CN102-19 (29)
Turn key switch ON.
$ Continuity check
CN 102-9 (23) H2-2 changes
1 Main harness to HI-2. 7
1. No continuity defect Sub-harness defect
2. No continuity
t
t Tilt potentiometer defect
CPU board defect
H2-3 Tilt lever potentiometer abnormality

CN41 CN78
- CN102-19(29,POTT+)
6 1
-
CN102-8(22,POTT1)
4 2
CPU
CN 102-9(23,POTT2) Tilt lever
board
-5 3
CN101-34(51,POT-)
10 . 4
-

Output when the voltage of the tilt lever potentiometers 1, 2 with the tilt lever at neutral position is outside
the specified range.
Error indication (reference)
H2-3 Tilt lever potentiometer abnormality

H2-3 error is
Connect battery plug.
not indicated.
Turn key switch ON. bCheck connector connection
I Tilt lever operation.

.
i H2-3 error is
indicated

ANL : I10 MONITOR3 1103-3


Chek the tilt lever potentiometer

f
Disconnect battery plug.
Replace the connectors of the lift
lever (CN77) with the tilt lever
(CN78).
Connect battery plug and turn the
key switch to ON.

ANL : I10 MONITOR3 1103-1


Chek the lift lever potentiometer
Within (*I) * 0.2 V Tilt lever potentiometer
voltage. defect
I II

Below or above (*I) 0.2 V*


- -

Disconnect battery plug.


Disconnect CN102.
Return the lift lever connector
(CN77) and the tilt lever connector
(CN78) to the original connection.
Connect battery plug and turn key
switch ON.

ANL : I10 MONITOR3 1103-3


0.3 V or more
Chek the tilt lever potentiometer )CPU board defect
voltage

0.3 V or less

r - - - - - - - - - - t- - - - - - - - - -
I Disconnect battery plug. I
I
I Short at the connectors below (CPU
I board side) with the alligator clip of )
I SSTI 3 in connection. I

I Connect battery plug and turn key


I switch ON.
I
I
I
--
CN101-11 (63) CN102-8 (22)
CN101-11 (63) CN102-9 (23)
I

1
I
L - - - - - - - - - - - - - - - - - - - a

-1

4.5 V or more
Chek the tilt lever potentiometer b Harness defect
voltage

4.5 V or less

7
CPU board defect
H2-4 Tilt lever potentiometer abnormality

Related portion

CN41 CN78
- CN1 02-19(29,POTT+)
6 - 1
CN102-8(22,POlT1)
4 2
CPU -
board CN102-9(23,POTT2) Tilt lever
5 - 3
CN101-34(51,POT-)
10 4
-

Output when the tilt lever voltage value is outside the specified neutral range (lever operated) upon key
switch ON.
Error indication (reference)
HZ-4 Tilt lever neutral abnormality

1 Check that the tilt lever returned to 1


neutral position. Normal
Turn key switch ON again. Do not operate the lever upon key switch ON.
I I
1 H2-4 remains.

f
Check the installation state of the tilt NG
b Readjustment
lever potentiometer.

MATCHING: LIFT
Perform matching of the tilt lever
Vehicle operation can be started.
potentiometer neutral voltage
again.
I NG
1
Tilt potentiometer defect
H2-5 Tilt lever potentiometer abnormality

CPU board

Output when tilt lever neutral matching value is outside the specified range.
Error indication (reference)
H2-5 Tilt lever neutral matching abnormality
CPU board defect
H3-I ,2 Attachment 1 lever potentiometer abnormality
I I

Related portion
1
CN102-lO(24,POTATll)
7
CPU Attachment 1
board CN102-11(25,POTAT12) lever
8 3

Condition for error detection


Output when the voltage of the attachment 1 lever potentiometer is outside the specified range (open or
short).
Error indication (reference)
H3-1 Attachment 1 lever potentiometer open
H3-2 Attachment 1 lever potentiometer short

H3-1
Do not operate the material handling lever during all checking.
Connect battery plug. H3-1 error is
Turn key switch ON.
Attachment 1 lever at neutral Check connector connection
position.
H3-1 error is
indicated.

i
1
ANL : I10 MONITOR3 1103-5
Chek the attachment 1 lever
potentiometer voltage.
II
0.3 V. than 0.3 V.
- -------- -I- - --------
I Disconnect battery plug. I Disconnect battery plug.
I I
I Disconnect CN41. I H3-2 error is Connect CN41.
I Short between CN41-9 (30) and indicated Replace the connectors of the lift H3-1 remains.
I CN41-7 (24) (at main harness side) -I 1
lever (CN77) with the attachment 1
I with SST8. I lever (CN79).
I Connect battery plug. I
I
Connect battery plug.
I Turn key switch ON. I Turn key switch ON.
t
L - - - - - - - - - - - - - - - - - - - - d I
H3-2 error is H3-1 changes
not indicated. to H I - I . Sub-harness defect

d t
Attachment 1 potentiometer

-
Disconnect battery plug.
Disconnect CNl 01 and CN102. defect
(SST8 is the connection state.) I. No continuity
1. CN102-20 (30) 2. Continuity
5 Continuity check Main harness defect
CN102-10 (24)
2. CN102-10 (24)
5 Continuity check
CN101-34 (51)

2. No continuity

CPU board defect


t
I
I
I

I
Disconnect battery plug.
Disconnect CN41.
Short between CN41-9 (30) and
+
r - - - - - - - - - - - - - - - - - - - -

I
I
I H3-2 error is
Disconnect battery plug.
Connect CN41.
Replace the connectors of the lift ~ 3 - remains.
1
indicated.
I CN41-8 (25) (at main harness side)
1
+ lever (CN77) with the attachment 1
I with SST8. I lever (CN79).
I
I
I
Connect battery plug. I Connect battery plug.
I Turn key switch ON. I Turn key switch ON.
L _ _ - - - - - - - - - - - - - - - - - - A

H3-2 error is H3-1 changes


not indicated. to H I - I . Sub-harn!ss defect

c Disconnect battery plug.


v
Attachment 1 potentiometer
Disconnect CNl 01 and CN102. defect
(SST8 is the connection state.) I I . No continuity
1. CN102-20 (30)
$ Continuity check Main harness defect
CN 102-11 (25)
2. CN102-11 (25)
$ Continuity check
CN101-34 (51)

2. No continuity

CPU board defect


v
r - - - - - - - - - - t- --------- Disconnect battery plug.
Disconnect CNl 01 and CN102.
I Disconnect battery plug. I
I I
I Disconnect CN41. (SST8 is the connection state.) 1. No continuity
I H3-2 error is
I Short between CN41-9 (30) and 1. CN102-20 (30) 2. Continuity
not indicated.
I CN41-7 (24) (at main harness side) b 2 Continuity check
I
I
with SST8.
Connect battery plug.
I
I
CN102-10 (24)
2. CN102-10 (24)
1
I
I Turn key switch ON. I 2 Continuity check
L - - - - - - - - _ - - - - - - - - - - - d

H3-2 error is CN101-34 (51)


indicated. 1. Continuity Main harness
2. No continuity defect

7
CPU board defect

------ --- -I- ------- - -, Disconnect battery plug.


I Disconnect battery plug. I Disconnect CNlOl and CN102.
I I
(SST8 is the connection state.)
I

1
Disconnect CN41.
Short between CN41-9 (30) and
I H3-2 error is 1. CN102-20 (30)
1. No continuity
2. Continuity
I CN41-8 (25) (at main harness side) , not indicated, 2 Continuity check
I with SST8. I CN102-11 (25)
I Connect battery plug. I
I
2. CN102-11 (25)
I Turn key switch ON.
L - - - - - - - - - - - - - - - - - - - - J
I 2 Continuity check
H3-2 error is I I

indicated. 1. Continuity Main harness


2. No continuity defect

t
CPU board defect
Disconnect battery plug.
Connect CN41.
Replace the connectors of the lift H3-1 remains.
lever (CN77) with the attachment 1
lever (CN79).
Connect battery plug.
Turn key switch ON.
t
Sub-harness defect
to HI- I.

t
Tilt potentiometer defect
-
H3-2
Do not operate the material handling lever during all checking.
H3-2 error is
Connect battery plug. not indicated.
Turn key switch ON. Check connector connection
Attachment 1 lever at neutral
position.

indicated.

Disconnect battery plug


Disconnect battery plug. H3-2 changes
Disconnect CNl 01 No continuity
Disconnect CN41. CN101-34 (51)
Connect battery plug and turn the $ Continuity check
key switch to ON. CN41-10 (51)
I
H3-2 remains Continuity
I

Main harness
defect

1
Disconnect battery plug.
Disconnect CN102. Disconnect battery plug.
1. CN102-20 (30) 1. Continuity Connect CN41.
2. Continuity Replace the connectors of the lift ~ 3 - remains.
2
$ Continuity check
lever (CN77) with the attachment 1
CN102-10 (24)
2. CN102-20 (30) lever (CN79).
Connect battery plug.
$ Continuity check
Turn key switch ON.
CN 102-11 (25)
1. No continuity
Main harness
defect
f
Sub-harness defect

+
2. No continuity to HI-2.

i
CPU board defect
Attachment 1 potentiometer defect
Disconnect battery plug.
Disconnect CN102.
Return the lift lever connector
(CN77) and the attachment 1 lever
connector (CN79) to the original
connection.
Connect battery plug and turn key
switch ON.

.
.
ANL : I10 MONITOR3 1103-5
0.3 V or more
Chek the attachment 1 lever CPU board defect
potentiometer voltage.

v
r - - - - - - - - -

; Disconnect battery plug.


1
0.3 V or less

--------__.
I

I Short at the connectors below (CPU I


I board side) with the alligator clip of
I SST13 in connection. I

I Connect battery plug and turn key


I switch ON. I

;CN101-ll(63)-CN102-lO(24) 1
I CN101-11 (63)
L _ _ _ _
CN102-11 (25)
_ _ _ _ _ _ _
-
_ _ _ _ _ _ _ - - 2
I

II
I/
ANL : I10 MONITOR3 1103-5
Chek the attachment 1 lever
potentiometer voltage.
4.5 V or more
Harness defect

LL I I
4.5 V or less

CPU board defect


H3-4 Attachment 1 lever potentiometer abnormality

CN41 CN79
- CN102-20(30,POTATI+)
- 9 1
CN102-lO(24,POTATll)
7
CPU Attachment 1
board CN102-11(25,POTAT12) lever
8 3
CN101-34(51,POT-)
-
10 4
-

Condition for error detection


Output when the attachment 1 lever voltage value is outside the specified neutral range (lever operated)
upon key switch ON.
Error indication (reference)
H3-4 Attachment 1 lever neutral abnormality

Check that the attachment 1 lever


returned to neutral position. H3-4 goes out.
w Normal
Turn key switch ON again. Do not operate the lever upon key switch ON.
H3-4 remains.

1
Check the installation state of the NG
b Readjustment
attachment 1 lever potentiometer.
OK

1
Perform matching of the
Vehicle operation can be started.
attachment 1 lever potentiometer
neutral voltage again.
NG

1
Attachment 1 potentiometer
defect
H3-5 Attachment 1 lever potentiometer abnormality

CPU board

Condition for error detection


Output when attachment 1 lever neutral matching value is outside the specified range.
Error indication (reference)
H3-5 Attachment 1 lever neutral matching value abnormality
CPU board defect
H4-1,2 Attachment 2 lever potentiometer abnormality

Related portion

CN42 CN80
- CN102-21(31,POTAT2+)
O 3
-
CN102-12(26,POTAT21)
1
CPU Attachment 2
board CN102-13(27,POTAT22) lever
2 3
CN41
CN101-34(51,POT-)
10 4
-
I

Output when the voltage of the attachment 2 lever potentiometer is outside the specified range (open or
short).
Error indication (reference)
H4-1 Attachment 2 lever potentiometer open
H4-2 Attachment 2 lever potentiometer short
H4-1
Do not operate the material handling lever during all checking.
Connect battery plug. H4-1 error is
Turn key switch ON. not indicated.
Attachment 2 lever at neutral b Check connector connection
position.
H4-1 error is
indicated.

t
Chek the attachment 2 lever
potentiometer voltage.

0.3 V. 0.3 V. than 0.3 V.


r - - - - - - - - - - t- - - - - - - - - -
I Disconnect battery plug. I Disconnect battery plug.
I I
I Disconnect CN41, CN42. 1 H4-2 error is Connect CN41, CN42.
I Short between CN42-3 (31) and indicated, Replace the connectors of the lift ~ 4 - remains,
1
I CN42-1 (26) (at main harness side) W lever (CN77) with the attachment 2
I with SST8. I lever (CN80).
I
I
I
Connect battery plug. I
Connect battery plug.
I Turn key switch ON. I Turn key switch ON.
L _ _ _ _ _ _ _ - - - - - - - - - - - - - J

H4-2 error is H4-1 changes


not indicated. to H I - I . Sub-harn!ss defect

c Disconnect battery plug.


t
Attachment 2 potentiometer
Disconnect CNlOl and CN102. defect
(SST8 is the connection state.) 1. No continuity
1. CN102-21 (31) 2. Continuity
1 Continuity check -b Main harness defect
CN102-12 (26)
2. CN102-12 (26)
1 Continuity check
CN101-34 (51)
1. Continuity
2. No continuity

CPU board defect


f
r - - - - - - - - - - t- - - - - - - - - -
I Disconnect battery plug. I Disconnect battery plug.
I I
I Disconnect CN41, CN42. I H4-2 error is Connect CN41, CN42.

,; indicated.
1 Short between CN42-3 (31) and Replace the connectors of the lift ~ 4 - remains,
1
I CN42-2 (27) (at main harness side) b lever (CN77) with the attachment 2
I with SST8. I lever (CN80).
j Connect battery plug. I
I
Connect battery plug.
I Turn key switch ON. I Turn key switch ON.
L - - - - - - - - _ _ _ - - - - - - - - - d

H4-2 error is H4-1 changes


not indicated. to H I - I . Sub-hamis defect

t t
Attachment 2 potentiometer
Disconnect battery plug.
Disconnect CN 101 and CN102. defect
(SST8 is the connection state.) 1. No continuity
1. CN102-21 (31) 2. Continuity
$ Continuity check -b Main harness defect
CN102-13 (27)
2. CN102-13 (27)
$ Continuity check
CN101-34 (51)

2. No continuity

t
CPU board defect
I
I
I
Disconnect battery plug.
Disconnect CN41, CN42.
i
r - - - - - - - - - - - - - - - - - - - -

I Short between CN42-3 (31) and

I CN42-2 (26) (at main harness side)


I
I

; H4-2indicated,
I error is
+
Disconnect battery plug.
Disconnect CNl 01 and CN102.
(SST8 is the connection state.)
I . CN102-21 (31)
5 Continuity check
1. No continuity
2. Continuity

I with SST8. I CN102-12 (26)


I Connect battery plug.
I
I
2. CN102-12 (26)
I Turn key switch ON. I $ Continuity check
L - - - - - _ _ _ _ - - - - - - - - - - - A

H4-2 error is
indicated.
CN101-34 (51)
I I . Continuity
v
Main harness

12. No continuity

CPU board defect


defect

r - - - - - - - - - - t- --------- Disconnect battery plug.


Disconnect CNl 01 and CN102.
I Disconnect battery plug. I
I I
(SST8 is the connection state.)
I

I
Disconnect SST8 from CN41.
Short between CN42-3 (31) and
I H4-2 error is 1. CN102-21 (31)
1. No continuity
2. Continuity
not indicated.
I CN42-2 (27) (at main harness side) + 5 Continuity check
I with SST8. I CN102-13 (27)
I Connect battery plug.
I
I
2. CN102-13 (27)
I Turn key switch ON. I 1 Continuity check
L - - - - - - - - - - - - - - - - - - - - J
CN101-34 (51)
H4-2 error is
indicated. 1. Continuity Main harness

v
2. No continuity defect

t
CPU board defect
Disconnect battery plug.

h
Connect CN41, CN42.
Replace the connectors of the lift ~ 4 - remains.
1
lever (CN77) with the attachment 2
lever (CN80).
Connect battery plug.
Turn key switch ON.
t
Sub-harness defect
to H I - I .

t
Attachment 2 potentiometer
defect
H4-2
Do not operate the material handling lever during all checking.
- H4-2 error is
Connect battery plug. not indicated.
Turn key switch ON. )Check connector connection
Attachment 2 lever at neutral
position.

indicated.

Disconnect battery plug


Disconnect battery plug. H4-2 changes Disconnect CN 101
Disconnect CN41, CN42. No continuity
CN101-34 (51)
Connect battery plug and turn the Continuity check
key switch to ON. CN41-10 (51)
I
H4-2 remains.
Continuity

Main harness
defect
Disconnect battery plug.
Disconnect CN102. Disconnect battery plug.
1. CN102-21 (31) 1. Continuity Connect CN41, CN42.
2. Continuity Replace the connectors of the lift H4-2 remains.
1 Continuity check
lever (CN77) with the attachment 2
CN102-12 (26)
lever (CN80).
1
2. CN102-21 (31)
Connect battery plug.
$ Continuity check
Turn key switch ON.

to HI-2.
v
Sub-harness defect

+
CPU board defect
Attachment 2 potentiometer
defect
H4-3 Attachment 2 lever potentiometer abnormality

Related portion

CN42 CN80
- CN102-21(31,POTAT2+)
3 1
CN102-12(26,POTAT21)
1 2
CPU Attachment 2
board CN102-13(27,POTAT22) lever
2 3
CN41
CN101-34(51,POT-)
10 4
-

Condition for error detection


Output when the voltage of the attachment 2 lever potentiometer 1, 2 with the attachment 2 lever at
neutral position is outside the specified range.
Error indication (reference)
H4-3 Attachment 2 lever potentiometer abnormality

H4-3 error is
Connect battery plug.
not indicated.
Turn key switch ON. +Check connector connection
I Attachment 2 lever operation. I

.
H4-3 error is
indicated

Chek the attachment 2 lever


potentiometer voltage. (*I)

Disconnect battery plug.


Replace the connectors of the lift
lever (CN77) with the attachment 2
lever (CN80).
Connect battery plug and turn the
key switch to ON.

ANL : 110 MONITOR3 1103-1


*
Within (*I) 0.2 V

v
Chek the lift lever potentiometer Attachment 2 potentiometer
voltage. defect

Below or above (*I) + 0.2 V


- -

Disconnect battery plug.


Disconnect CN102.
Return the lift lever connector
(CN77) and the attachment 2 lever
connector (CN80) to the original
connection
Connect battery plug and turn key
switch ON.

III ANL : I10 MONITOR3 1103-7


Chek the attachment 2 lever
potentiometer voltage.
0.3 V or more
CPU board defect
L
0.3 V or less

r - - - - - - - - - - t- - - - - - - - - -
I Disconnect battery plug. I

I Short at the connectors below (CPU I


I board side) with the alligator clip of I
I SST13 in connection. I

I Connect battery plug and turn key I


switch ON.
I

I
--
CN101-11 (63) CN102-12 (26)
CN101-11 (63) CN102-13 (27)
I

1
I
L - - - - - - - _ _ - - _ _ _ - - - - - - J

4.5 V or more
Chek the attachment 2 lever )Harness defect

4.5 V or less

t
CPU board defect
H4-4 Attachment 2 lever potentiometer abnormality

I elated portion /
CN42 CN80
-
CN102-21(31,POTAT2+)
3 . 1
CN102-12(26,POTAT21)
1 2
CPU Attachment 2
board CN102-13(27,POTAT22) lever
2
CN41
CN101-34(51,POT-)
10 4
-

Condition for error detection


Output when the attachment 2 lever voltage value is outside the specified neutral range (lever operated)
upon key switch ON.
Error indication (reference)
H4-4 Attachment 2 lever neutral matching value abnormality

Check that the attachment 2 lever


returned to neutral position.
Turn key switch ON again.
H4-4 goes out.
* Normal
Do not operate the lever upon key switch ON.
H4-4 remains.

7
Check the installation state of the NG
b Readjustment
attachment 2 lever potentiometer.
OK

b°K
MATCHING: ATT2
Perform matching of the
b Vehicle operation can be started.
attachment 2 lever potentiometer
neutral voltage again.
NG

7
Attachment 2 potentiometer
defect
H4-5 Attachment 2 lever potentiometer abnormality

Related portion

CPU board

Output when attachment 2 lever neutral matching value is outside the specified range.
Error indication (reference)
H4-5 Attachment 2 lever neutral abnormality
CPU board defect
H5-1,2,3,4,5 Lift solenoid abnormality

Related portion

CN130 CN75
-T
I
- J45
CN104-3(3,SOL1+)
14 4
Lift a1 (DOWN)
II CNI 0 4 - 5 ( 5 , ~ 0 ~ a l )
15 I 8
solenoid
I
CPU
board
4
CN132 Lift b l (UP)
CN104-4(4,SOLbl) solenoid
- 15 8
-

Condition for error detection


Output when open or short circuit is detected in the lift solenoid line from CPU board to the lift solenoid
(raise andlor lower).
Error indication (reference)
H5-1 Lift b l (UP) solenoid open-circuit abnormality
H5-2 Lift b l (UP) solenoid load short-circuit abnormality
H5-1 Lift a1 (DOWN) solenoid open-circuit abnormality
H5-2 Lift a1 (DOWN) solenoid load short-circuit abnormality
H5-5 Lift solenoid drive circuit MOS short-circuit

H5-1 error is

.
Connect battery plug.
Turn key switch ON. not indicated.
Check connector connection
I

_
Lift raising operation.
I
A
II 1
H5-1 error is indicated.

ANL : I10 MONITOR3 1103-2


Check lift solenoid current (during
0.1 A or more
CPU board defect
// lift raising operation). - II
II
I
1 0.1 A or less
r - - - - - - - - - 3- - - - - - - - - - 7

1 Disconnect battery plug. I


I
I Replace CN74 with CN75. I

1 (Use SST 20)

Connect battery plug and turn key H5-1 error is


switch ON. not indicated.
Lift raising operation. (note that lift Lift b l (UP) solenoid defect
I
I
on the vehicle is lowered.)
I
I
H5-1 error is indicated.

Harness defect
H5-2
H5-2 error is
Connect battery plug. not indicated.
Turn key switch ON. b Check connector connection
Lift raising operation.
H5-2 error is indicated.

Disconnect battery plug.


Disconnect CN74.

H5-1 error is
Connect battery plug.
indicated.
Turn key switch ON. b Lift b l (UP) solenoid defect
Lift raising operation.
H5-2 error is indicated.

Disconnect battery plug.


Disconnect CN104. Continuity
CN104-3 (3) b Harness defect
$ Continuity check
CN104-4 (4)
No continuity

CPU board defect

H5-3
H5-3 error is
Connect battery plug.
Turn key switch ON.
Lift lowering operation.
not indicated.
* Check connector connection
H5-3 error is indicated.

0.1 A or more
Check lift solenoid current (during b CPU board defect

-
r
---------
; Disconnect battery plug.
-

I
I Replace CN74 with CN75. I

I (Use SST 20) I


I

Connect battery plug and turn key


switch ON.
Lift a1 (DOWN) solenoid defect
Lift lowering operation. (note that lift
I on the vehicle is raised.)
IH5-3 error is indicated.
t
Harness defect
H5-4 error is
not indicated.
Turn key switch ON. w Check connector connection
Lift lowering operation.
L I

H5-4 error is indicated.

Disconnect battery plug.


Disconnect CN75.

7
H5-3 error is
Connect battery plug.
indicated.
Turn key switch ON. b Lift a1 (DOWN) solenoid defect
II Lift lowering operation. I
I
H5-4 error is indicated.

Disconnect battery plug.


Disconnect CN104. Continuity
CN104-3 (3) w Harness defect
$ Continuity check
CN104-5 (5)
No continuity

CPU board defect

Connect battery plug. H5-5 error is


Turn key switch ON. not indicated.
w Check connector connection
Lift raisingllowering operation.
H5-5 error is
indicated.

Disconnect battery plug.


Disconnect CN104.
Connect battery plug and turn key
switch ON. 10 V or more
Lift lever at neutral position. w Harness defect
Check the voltage between
CN104-3 (3) and CN104-23 (N2),
CN104-5 (5) and CN104-23 (N2),
CN104-4 (4) and CN104-23 (N2).
1 0 V o r less

CPU board defect


H6-1,2,3,4,5 Tilt solenoid abnormality

CN130 CN75
- J46
CN104-6(6,SOL2+)
-16
- Tilt a2 (FRONT)
solenoid
-
CN104-7(7,SOLa2)
17 -
CPU -
board CN74

CN132 7
Tilt b2 (REAR)
CN 104-8(8,SOLb2) solenoid

'
I u
16
,
u
7

Output when open or short circuit is detected in the tilt solenoid line from CPU board to the tilt solenoid
(forward andlor backward).
Error indication (reference)
H6-1 Tilt a2 (FRONT) solenoid open-circuit abnormality
H6-2 Tilt a2 (FRONT) solenoid load short-circuit abnormality
H6-3 Tilt b2 (REAR) solenoid open-circuit abnormality
H6-4 Tilt b2 (REAR) solenoid load short-circuit abnormality
H6-5 Tilt solenoid drive circuit MOS short-circuit

H6-1 error is
Check connector connection
Forward tilt operation.

ANL : I10 MONITOR3 1103-4


0.1 A or more
Check tilt solenoid current (during CPU board defect
forward tilt operation).
II
10.1 Aor less
r - - - - - - - - - 9- - - - - - - - - - ,
I Disconnect battery plug. I
I
I Replace CN74 with CN75. I

I (Use SST 20) I


I

Connect battery plug and turn key


switch ON. not indicated.
Forward tilt operation. (note that Tilt a2 (FRONT) solenoid defect
mast is tilted backward on the
vehicle.)
H6-1 error is indicated.

Harness defect
I

(
I

----

I
L
Connect battery plug.
Turn key switch ON.
Forward tilt operation.

Disconnect CN75.

CN104-7 (7)
7

Connect battery plug.


Turn key switch ON.
Forward tilt operation.

Disconnect battery plug.


Disconnect CN104.
CN104-6 (6)
Continuity check

Connect battery plug.


Turn key switch ON.
No continuity

CPU board defect

Backward tilt operation.

Check tilt solenoid current (during

------
I Disconnect battery plug.
Replace CN74 with CN75.
(Use SST 20)
---------
.
I

I
I

I
I
I
I
I
H6-2 error is
not indicated.

H6-2 error is indicated.

Disconnect battery plug.

H6-1 error is
indicated.

H6-2 error is indicated.

Continuity

H6-3 error is
not indicated.

H6-3 error is indicated.

0.1 A or more
+ Check connector connection

b Tilt a2 (FRONT) solenoid defect

Harness defect

b Check connector connection

w CPU board defect

Connect battery plug and turn key


switch ON.
Backward tilt operation. (note that
mast is tilted forward on the
vehicle.)
L H6-3 error is
not indicated.
Tilt b2 (REAR) solenoid defect

Harness defect
H6-4
-
Connect battery plug.
- H6-4 error is
not indicated.
Turn key switch ON. b Check connector connection
Backward tilt operation.
H6-4 error is indicated.
-
Disconnect battery plug.
Disconnect CN74.

H6-3 error is
Connect battery plug.
indicated.
Turn key switch ON. + Tilt b2 (REAR) solenoid defect
Forward tilt operation.
H6-4 error is indicated.

Disconnect battery plug.


Disconnect CN104. Continuity
CN104-6 (6) + Harness defect
Continuity check
CN104-8 (8)
No continuity

CPU board defect

H6-5
H6-5 error is
Connect battery plug.
not indicated.
Turn key switch ON. w Check connector connection
Forwardlbackward tilt operation.
H6-5 error is
indicated.

Disconnect battery plug.


Disconnect CN104.
Connect battery plug and turn key
switch ON. 10 V or more
Tilt lever at neutral position. b Harness defect
Check the voltage between
CN104-6 (6) and CN104-23 (N2),
CN104-7 (7) and CN104-23 (N2),
CN104-8 (8) and CN 104-23 (N2).
10 V or less

CPU board defect


H7-1,2,3,4,5 Attachment 1 solenoid abnormality

CN131 CN75
-CN104-11(9,SOL3+) J47
8 2
Attachment 1
CN104-13(11,SOLb3) b3 solenoid
6
CPU
board CN132 CN74

CN131 2
Attachment 1
CN104-12(10,SOLa3) a3 solenoid
9 6

.
Condition for error detection
Output when open or short circuit is detected in the attachment 1 solenoid line from the CPU board to the
attachment 1 solenoid (raise andlor lower).
Error indication (reference)
H7-1 Attachment 1 a3 solenoid open-circuit abnormality
H7-2 Attachment 1 a3 solenoid load short-circuit abnormality
H7-3 Attachment 1 b3 solenoid open-circuit abnormality
H7-4 Attachment 1 b3 solenoid load short-circuit abnormality
H7-5 Attachment 1 solenoid drive circuit MOS short-circuit

H7-1 error is
Connect battery plug.
not indicated.
Turn key switch ON. + Check connector connection
I Attachment 1 raising operation. I

Check attachment 1 solenoid


current (during attachment 1 CPU board defect
raising operation).
0.1 A or less
r - - - - - - - - - - - - - - - - - - - -

I Disconnect battery plug.


I Replace CN74 with CN75. I

j (Use SST 20) I


I

Connect battery plug and turn key


switch ON. not indicated.
Attachment 1 raising operation. Attachment 1 a3 solenoid defect
(note that the attachment 1 is
lowered on the vehicle.)

Harness defect
H7-2
H7-2 error is
Connect battery plug.
not indicated.
Turn key switch ON. b Check connector connection
Attachment 1 raising operation.
H7-2 error is indicated.

Disconnect battery plug.


Disconnect CN74.

H7-1 error is
Connect battery plug.
Turn key switch ON.
Attachment 1 raising operation.
indicated.
* Attachment 1 a3 solenoid defect
H7-2 error is indicated.

Disconnect battery plug.


Disconnect CN104.
CN104-11 (9)
Continuity
* Harness defect
Continuity check
CN104-12 (10)
No continuity

CPU board defect

H7-3
H7-3 error is
Connect battery plug.
not indicated.
Turn key switch ON. b Check connector connection
Attachment 1 lowering operation.
H7-3 error is indicated.

Check attachment 1 solenoid


current (during attachment 1
0.1 A or more
* CPU board defect
lowering operation).

- -- -------
I Disconnect battery plug. I
I
I Replace CN74 with CN75. I

I (Use SST 20) I


I

Connect battery plug and turn key


switch ON.
Attachment 1 lowering operation. Attachment 1 b3 solenoid defect
(note that the attachment 1 is raised
on the vehicle.)

Harness defect
H7-4
H7-4 error is
Connect battery plug.
not indicated.
Turn key switch ON. b Check connector connection
Attachment 1 lowering operation.
H7-4 error is indicated.

Disconnect battery plug.


Disconnect CN75.

H7-3 error is
Connect battery plug. indicated.
Turn key switch ON. b Attachment 1 b3 solenoid defect
Attachment 1 lowering operation.
H7-4 error is indicated.

Disconnect battery plug.


Disconnect CN104. Continuity
CN104-11 (9) + Harness defect
Continuity check
CN104-13 (11)
No continuity

CPU board defect

H7-5
Connect battery plug. H7-5 error is
Turn key switch ON. not indicated.
b Check connector connection
Attachment 1 raisingllowering
operation.
H7-5 error is
indicated.

Disconnect battery plug.


Disconnect CN104.
Connect battery plug and turn key
switch ON.
Attachment 1 lever at neutral 10 V or more
b Harness defect
position.
Check the voltage between
CN104-11 (9) and CN104-23 (N2),
CN104-12 (10) and CN104-23 (N2),
CN 104-13 (11) and CN104-23 (N2).

f
CPU board defect
H8-1,2,3,4,5 Attachment 2 solenoid abnormality

CN131 CN75
- J48
CN104-16(34,SOL4+)
11 . 1
Attachment 2 a4
CN104-17(35,SOLa4)
- solenoid
12 5
CPU
board CN74

CN132 1
Attachment 2 b4
CN104-18(36,SOLb4) solenoid
18 5
-

Condition for
Output when open or short circuit is detected in the attachment 2 solenoid line from the CPU board to the
attachment 2 solenoid (forward andlor backward).
Error indication (reference)
H8-1 Attachment 2 a4 solenoid open-circuit abnormality
H8-2 Attachment 2 a4 solenoid load short-circuit abnormality
H8-3 Attachment 2 b4 solenoid open-circuit abnormality
H8-4 Attachment 2 b4 solenoid load short-circuit abnormality
H8-5 Attachment 2 solenoid drive circuit MOS short-circuit

.
I H8-1 error is indicated.

ANL : I10 MONITOR3 1103-8


Check attachment 2 solenoid 0.1 A or more
current (during attachment 2 b CPU board defect

-------- -
I Disconnect battery plug. I

I Replace CN74 with CN75.


I
I

I (Use SST 20) I


I

Connect battery plug and turn key error is


switch ON. not indicated.
Attachment 2 forward tilt operation. Attachment 2 a4 solenoid defect
(note that the attachment 2 is tilted
backward on the vehicle.)

Harness defect
H8-2 error is
Connect battery plug.
not indicated.
Turn key switch ON. b Check connector connection
I
I
Attachment 2 forward tilt operation. I
J
H8-2 error is indicated.

Disconnect battery plug.


Disconnect CN75.

i H8-1 error is
Connect battery plug. indicated.
Turn key switch ON. b Attachment 2 a4 solenoid defect
Attachment 2 forward tilt operation.
H8-2 error is indicated.

Disconnect battery plug.


Disconnect CN104. Continuity
CN104-16 (34) b Harness defect
Continuity check
CN104-17 (35)
I I
No continuity

CPU board defect

I Connect battery plug. I H8-3 error is


Turn key switch ON: not indicated.
b Check connector connection
Attachment 2 backward tilt
1
I
operation.
I
I

H8-3 error is indicated.

Check attachment 2 solenoid 0.1 A or more


b CPU board defect
current (during attachment 2
backward tilt operation).

--- ------
1 Disconnect battery plug. I
I
I Replace CN74 with CN75. I

I (Use SST 20) I


I

Connect battery plug and turn key H8-3 error is


switch ON. not indicated.
Attachment 2 backward tilt ) Attachment 2 b4 solenoid defect
operation. (note that the attachment
2 is tilted forward on the vehicle.)

Harness defect
Connect battery plug. H8-4 error is
Turn key switch ON.
Check connector connection
Attachment 2 backward tilt
I
L
operation. I
I
H8-4 error is indicated.

Disconnect battery plug.


Disconnect CN74.

t
Connect battery plug. H8-3 error is
Turn key switch ON. indicated.
) Attachment 2 b4 solenoid defect
Attachment 2 backward tilt
operation.
H8-4 error is indicated.

Disconnect battery plug.


Disconnect CN104.
CN104-16 (34)
Continuity check
Continuity
* Harness defect
CN 104-18 (36)
No continuity

CPU board defect

Connect battery plug. H8-5 error is


Turn key switch ON.
Attachment 2 forwardlbackward
not indicated.
* Check connector connection
operation.

Disconnect battery plug.


Disconnect CN104.
Connect battery plug and turn key
switch ON.
Attachment 2 lever at neutral 1 0 V o r more
b Harness defect
position.
Check the voltage between
CN104-16 (34) and CN104-23 (N2),
CN104-17 (35) and CN104-23 (N2),
CN104-18 (36) and CN104-23 (N2).
10 V or less

CPU board defect


H9-1,2,3 Unload valve solenoid abnormality

Related portion

CN132 CN76
-
CN104-26(12,SOLP+)
1 1
CPU Unload valve
board CN 104-27(13,SOLP-) solenoid
2 2
-
CN130

I I

Condition for error detection


Output when open or short circuit is detected in the unload valve solenoid line from the CPU board to the
unload valve solenoid.
Error indication (reference)
H9-1 Unload valve solenoid open-circuit abnormality
H9-2 Unload valve solenoid load short-circuit abnormality
H9-3 Unload valve solenoid drive circuit MOS short-circuit

H9-1

H9-1 error is
ON in the ACTIVE TEST. + Check connector connection
(Connect battery plug and turn key
switch ON.)
H9-1 error is
indicated.
1
Disconnect battery plug
Disconnect CN104
CN104-26 (12) 9.9klQ (at 25°C)
b CPU board defect
Harness continuity check
CN 104-27 (13)
Other than 9.9k1Q
(at 25°C)
1
Disconnect CN76
CN76-1 (12)
Solenoid resistance check 9.9*1 Q (at 25°C)
CN76-2 (13) b Harness defect

Other than 9.9klQ


(at 25°C)
1
Unload valve solenoid defect
ON in the ACTIVE TEST.
(Connect battery plug and turn key
switch ON.)
H9-2 error is
- Check connector connection

H9-2 error is indicated.

Disconnect battery plug.


Disconnect CN76.

-
H9-2 error is
ON in the ACTIVE TEST. + Unload valve solenoid defect
(Connect battery plug and turn key
switch ON.)
H9-2 error is indicated.

-
Disconnect battery plug.
Disconnect CN104. Continuity exists
CN104-26 (I 2) b Harness defect
Harness continuity check
CN104-27 (13)
No continuity

CPU board defect

H9-3

I11 ACTIVE TEST : ACT-3 PSOL


Set the unload valve solenoid to
ON in the ACTIVE TEST. I
H9-3 error is
not indicated.
W Check connector connection
(Connect battery plug and turn key
switch ON.)

Disconnect battery plug.


Disconnect CN104.
Connect battery plug and turn key
switch ON. 10 V or more
Voltage check (short circuit in the
w Harness defect
harness) between
CN104-26 (12) and CN104-23 (N2),
CN104-27 (13) and CN104-23 (N2).
10 V or less

t
CPU board defect
TRAVELlNGlMATERlAL HANDLING AC DRIVER

30-1 Traveling AC driver 1 low voltage

Related portion

Traveling
AC driver 1

/
--
o u t p i t when low voltage of the battery (b3) line of the traveling AC driver 1 is detected

If 31-1 and C B - I occurs at the same time, perform troubleshooting for 31-1 and C B - I first.
31-1 error is
indicated.
)Perform troubleshooting for 31-1
I No error II I

I
During traveling operation, does an
error come on?
CB-1 error is
indicated.
No error
I
30-1 error is
indicated.
ANL : I10 MONITOR 1 1/01-12
Turn key switch OFF and then ON
b again. W~thtraveling operation,
check the VBBD voltage when an
error occurs.
115 or more

Traveling AC
driver 1 defect
'I
P3 cable and terminal check
F1 fuse check
1
Perform troubleshooting
for CB-1 check the VB48 voltage when an
I I error occurs. ll i
I
'I ~ a t t & plug check
1 5 V o r more
Battery charge

I-
Turn key switch OFF and then ON Turn key switch OFF and then ON
again. With traveling operation, Less than again. With traveling operation,
check the battery voltage between check the traveling AC driver 1
P2 and N1 when an error occurs. input voltage between P3 and N1
P2 when an error occurs.
$ Voltage measurement P3
N1 $ Voltage measurement
N1

I Less than 15 V

MB contactor defect
I 15 V or more

P3 cable and terminal check


F1 fuse check
1 5 ~ 0more

t
r

Traveling AC driver 1 defect


30-2 Traveling AC driver 2 low voltage

rr PI P2 F1 P3
n
Traveling
AC driver 2

I
I -
I
I

Condition for error detection


Output when low voltage of the battery (P3) line of the traveling AC driver 2 is detected.

If 31-2 and CB-1 occurs at the same time, perform troubleshooting for 31-2 and CB-1 first.
31-2 error is
1 -
Turn key switch ON.
indicated.
w Perform troubleshooting for 31-2
1 No error I, I I
30-1 error is ANL : I10 MONITOR 1 1/01-12
indicated. Turn key switch OFF and then ON 15 V or more
During traveling operation, does an again. With traveling operation,
check the VBBD voltage when an
error come on?
II error occurs.
I1 i
is indicated.
I '
1 Less than 15 V 'I Trav;ling AC
driver 2 defect
1 P3 cable and terminal check
C
4
Perform troubleshooting
F1 fuse check
ANL : I10 MONITOR 1 1/01-8
Turn key switch OFF and then ON Less than 15 V
for CB-1 again. With traveling operation,

I'
check the VB48 voltage when an
error occurs.

1
1 5 V o r more
I
7Battery plug check

Battery charge

Turn key switch OFF and then ON Turn key switch OFF and then ON
again. With traveling operation, Less than again. With traveling operation,
check the battery voltage between 15 V check the traveling AC driver 2 input
P2 and N1 when an error occurs. 4 voltage between P3 and N1 when an
P2 error occurs.
$ Voltage measurement P3
N1 $ Voltage measurement
Less than 15 V N1
15 V or more

MB contactor defect P3 cable and terminal check 'I


F1 fuse check Traveling AC driver 2 defect
30-3 Material handling AC driver low voltage 1
Related portion

Output when low voltage of the battery (P3) line of the material handling AC driver is detected.

If 31-3 and CB-1 occurs at the same time, perform troubleshooting for 31-3 and CB-1 first.
31-3 error is
indicated.
Perform troubleshooting for 31-3
INO error
I, I

During lifting operation is carried


out, does an error come on?
CB-I error is
indicated.
No error
I
30-3 error is
indicated.
ANL : I10 MONITOR 1 1/01-13
Turn key switch OFF and then ON
again. With traveling operation,
check the VBBP voltage when an
error occurs.
1 or more

Material handling
AC driver defect
P3 cable and terminal check
F1 fuse check
I
Perform troubleshooting again. With traveling operation,
for CB-1 check the VB48 voltage at the time

15 V or more
Battery charge
1

Turn key switch OFF and then ON Turn key switch OFF and then ON
again. With traveling operation, Less than again. With traveling operation,
check the battery voltage between check the material handling AC
P2 and N1 when an error occurs. 4 driver input voltage between P3 and
P2 N1 when an error occurs.
Voltage measurement P3
N1 $ Voltage measurement
Less than 15 V N1
15Vor more

MB contactor defect P3 cable and terminal check 7


F1 fuse check Material handling AC driver defect
31-1 Traveling AC driver 1 low starting voltage

Related portion

PI P2 F1
n
P3
Traveling
AC driver 1

CPR
CN 104-9(55, CPR)
CPU
-L
F5
7
1 CN1 04-2(18, B48V) board
I
I
I
II

Condition for er
Output when voltage of P3 of the traveling AC driver 1 is detected not to exceed the set level.

31-1 error is
indicated 23 V or more
* VBBD
ANL : I10 MONITOR 1 1/01-12
: Voltage check
-
No error
Less than 23 V
Traveling AC driver 1
Check the traveling AC driver 1 -defect
Battery plug check
Traveling AC driver cable and terminal check input voltage between P3 and N1. 23 or more
CPR check P3
Harness check $ Voltage measurement
N1
T

Check the CPR resistance


q Less than 23 V

ANL : I10 MONITOR 1 1101-9


Traveling AC driver 1
defect

VBKS : Key start voltage check


Approx. 20 Q Other than
approx. 20 Q Less than 23 V

F1 fuse check CPR defect


I
I'
ANL : I10 MONITOR 1 1101-8
B48V : Voltage check
Less than 23 V

CPU board defect


Check the battery voltage
PI 23 V or more
$ Voltage measurement
N1
Less than 23 V 7
F5 fuse check
Battery charge Harness check
I 31-2 Traveling AC driver 2 low starting voltage

Related portion

P1 P2 F1
P3 Traveling
AC driver 2

CPR
CN104-9(55, CPR)
- F5 CPU
CN104-2(18, B48V) board

Condition for error detection


Output when voltage of P3 of the traveling AC driver 2 is detected not to exceed the set level.

31-2 error is -
indicated ANL : I10 MONITOR 1 1/01-12 23 V or more
Turn key switch ON. ) VBBD : Voltage check 1
L I I II

+
No error
I Less than 23 V
Traveling AC driver 2
defect
Battery plug check Check the traveling AC driver 2
Traveling AC driver cable and terminal check input voltage between P3 and N1. 23 or more
CPR check P3
Harness check $ Voltage measurement
N1

VBKS : Voltage check

approx. 20 R

t t T

ANL : I10 MONITOR 1 1101-8 23 V or more


F1 fuse check CPR defect
B48V : Voltage check
I
pss than 23
II
t
CPU board defect

Check the battery voltage


PI 23 V or more
$ Voltage measurement
N1
Less than 23 V F5 fuse check
Harness check
Battery charge
31-3 Material handling AC driver low starting voltage

F1
P2
n P3 Material
handling
AC driver

CPR
CN 104-9(55, CPR)
- CPU
F5
7
I CNI 04-2(18, ~ 4 8 ~ )board
I
I
I
I
I

Condition for error detection


Output when voltage of P3 of the material handling AC driver is detected not to exceed the set level.

31-3 error is
indicated ANL : I10 MONITOR 1 1/01-13 23 V or more
Turn key switch ON.
VBBP voltage
- check
No error I
I Less than 23 II
t
Material handling
AC driver defect
Battery plug check Check the material handling AC
Material handling AC driver cable and terminal driver input voltage. 23 V or more
check P3
CPR check Voltage measurement
Harness check N1
I I
Less than 23 V ate rial handling
AC driver defect

ANL : I10 MONITOR 1 1101-9


Check the CPR resistance
VBKS : Voltage check
Approx. 20 Q Other than
approx. 20 R I Less than 23 V
t t
F1 fuse check CPR defect
I ANL : I10 MONITOR 1 1/01-8
B48V : Voltage check
Less than 23 V
CPU board defect
+ .

Check the battery voltage

Voltage measurement
1 23 v or more

Less than 23 V F5 fuse check


t
Battery charge
Harness check
I 32-1 Traveling AC driver 1 EEPROM abnormality

Traveling AC driver 1

Condition for error detection


Data abnormality when traveling AC driver 1 is activated
EEPROM element of traveling AC driver 1 CPU board damaged

Turn key switch OFF and ON No error Was traveling AC driver 1 just
several times. replaced?
I I I I
32-1 error is indicated. NO YES

t
Traveling AC driver 1 defect
t
Traveling AC driver 1 connector
t
Normal
check (ID signal)

32-2 Traveling AC driver 2 EEPROM abnormality


I
Related portion

Traveling AC driver 2

Condition for err


Data abnormality when traveling AC driver 2 is activated
EEPROM element of traveling AC driver 2 CPU board damaged

Turn key switch OFF and ON No error Was traveling AC driver 2 just
several times )
replaced?
I I I I
32-2 error is indicated NO YES

t
Traveling AC driver 2 defect
t
Traveling AC driver 2 connector
v
Normal
check (ID signal)
1 32-3 Material handling AC driver EEPROM abnormality
I
Related portion

Material handling AC driver

Condition for error detection

*
Data abnormality when pump motor circuit is activated
EEPROM element of pump motor driver CPU board damaged

,32-3 error is
Turn key switch OFF and ON indicated
several times. Material handling AC driver defect

1
No error

Was material handling AC driver


just replaced? brn Normal

t
Material handling AC driver
connector check (ID signal)
33-1 Main controller + Traveling AC driver 1 communication abnormality

Related portion

CN103-l(145, CANH) CN110-3(145, CANH)


CN103-2(146, CANL)
CN103-3(147, CANGND)
-
7
w
CN110-4(146, CANL)
CN110-6(147, CANGND)
w Traveling

-
CPU
AC driver 1
board CN 104-25(42, KEYSTART) CN110-7(42, KEYSTART)

CN112
1
u

Output when the traveling AC driver 1 cannot receive data from the CPU board within specified time.

Does AD-1 error display or


diagnosis memory memorize? I=- Perform troubleshooting for AD-1.

Check CN103, CN104, CN110 and CN112


Was traveling AC driver 1 just YES connection condition. Turn key switch OFF and
replaced? ON, and it checks that an error is not displayed.
NO

No error CN103, CN104, CN110, CN112 connector check


Harness check
1 33-1 error is indicated. I AD-1 or AD-2
(AD-1 and AD-2 are is indicated.
not indicated.)

v
1
Harness check
Perform troubleshooting for AD-1 or AD-2.

Traveling AC driver 1 defect


(There is possibility that CPU board is defect.)
33-2 Main controller + Traveling AC driver 2 communication abnormality

CN103-l(145, CANH) -- CN109-3(145, CANH)


CN 103-2(146, CANL)
CN103-3(147, CANGND)
v
- CN109-4(146, CANL)
CN 109-6(147, CANGND)
CPU Traveling

-
board CN104-25(42, KEYSTART) CN109-7(42, KEYSTART) AC driver2

CN112

u
Condition for error detection
Output when the traveling AC driver 2 cannot receive data from the CPU board within specified time.

Does AD-3 error display or


diagnosis memory memorize? Perform troubleshooting for AD-3.

t Check CN103, CN104, CN109 and CN112


Was traveling AC driver 2 just YES connection condition. Turn key switch OFF and
replaced? ON, and it checks that an error is not displayed.

t No error
1 Turn key switch ON? CN103, CN104, CN109, CN112 connector check
Harness check

not indicated.)

Perform troubleshooting for AD-3 or AD-4.

f
Harness check
Traveling AC driver 2 defect
(There is possibility that CPU board is defect.)
33-3 Main controller + Material handling AC driver communication abnormality

Related portion

CN103-l(145, CANH) a CN111-3(145, CANH)


CN103-2(146, CANL) CNlll-4(146, CANL)
.
I
CN103-3(147, CANGND) CN111-6(147, CANGND)
7 Material
CPU

-
handling

-
board CN104-25(42, KEY START) CN111-7(42, KEYSTART) AC driver

CN112

14fl 1

Condition for error detection


Output when the material handling AC driver cannot receive data from the CPU board within specified
time.

Does AD-5 error display or


diagnosis memory memorize? Perform troubleshooting for AD-5.

Check CN103, CN104, C N l l l and CN112


Is material handling AC driver just YES connection condition. Turn key switch OFF and ON,
replaced? and it checks that an error is not displayed.
NO

No error CN103, CN104, CN111, CN112 connector check


Harness check
1 33-3 error is indicated. I AD-5 or AD-6 is
(AD-5 and AD-6 are
not indicated.)

1
Perform troubleshooting for AD-5
or AD-6.

Harness check
Material handling AC driver defect
(There is possibility that CPU board is defect.)
I AO-1 Main drive circuit overheat
I
CN104-14,15(44, VBMB) -
w
1-
CN113

CN101-9(39, FAN-) 2 FAN


a
w -
Short harness
-
CN 105-2(FAN-)
1 CN114
CPU CN105-3(FAN-) - 7

board CN 105-4(FAN1) 2 FAN


CN 105-5(FAN2) -
CN 105-6(FAN3)

Output when the temperature detected by the main drive circuit thermo-sensor exceeds the set level.

Allow the vehicle to stand for a No abnormality


while (about 15 min.) and operate. +Normal
overheat warning

e:

I1 I L I I
I I IC: L ~I:I I~ C :awl
I
ANL : ACTIVE TEST ACT-1 ANL : I10 MONITOR 1 1101-1
does not change.
Turn all cooling fans ON and THCD : Check the value of
check that they run normally. traveling AC driver thermo-sensor
while traveling.
Not run
The temperature

I t Traveling AC driver 112 defect


Is the exhaust port covered with paper?
Is it overloaded?
Less than Short harness continuity check
Turn the cooling fan ON and check 20 V CN105-2,3 Some OQ
the voltage. $ Resistance measurement
CN105-4,5,6,7,8,9
20 V or more
t
CPU board defect
CN113-1 Short harness defect
T Voltage measurement 20 V or
CN113-2 more Fan check
CN114-1 Connector connection check
$ Voltage measurement
CN114-2

CN104-CN 113. CN104-CN114 Harness defect


AO-2 Main pump circuit overheat

-1 Related portion /
CN104-14,15(44, VBMB)
- 2
1-
CN113
FAN
- - -

.
-

handling
AC driver

Condition for error detection 1


1 Outpdt when the temperature detected dy the main pump circuit thermo-sensor exceeds the set level. I
Allow the vehicle to stand for a
while (about 15 min.) and operate. Normal
Immediate indication of
overheat warning

The temperature
does not change.
Turn all cooling fans ON and THCP : Check the value of material
handling AC driver thermo-sensor
while material handling operation.

MatJial handling
changes. AC driver defect
Is the exhaust port covered with paper?
7 Is it overloaded?

Less than Short harness continuity check


ANL : ACTIVE TEST ACT-1 CN105-2,3 Some OR
Turn the cooling fan ON and check )
$ Resistance measurement
the voltage. CN105-4,5,6,7,8,9
20v
20 V or more
7
I CN113-1 Short harness defect CPU board defect

I--
I Voltage measurement 20 V or
CN113-2 * Fan check
CN114-1 Connector connection check
2 Voltage measurement
CN114-2
I I
Less than 20 V

CN104-CN113. CN104-CN114 Harness defect


A1-2 Traveling AC driver 1 high voltage

Related portion

rf-.
F1
P3
Traveling AC
driver 1

7
---l
I
I
I
I

Condition for error detection


Output when overvoltage of the battery line of the traveling AC driver 1 is detected.

If A1-1 occurs at the same time, perform troubleshooting for A1-1 first.
A1-2 error , , I
is indicated ANL : I10 MONITOR 1 1/01-12 Less than 66 V
VBBD : Voltage check
No error
66 V or more
Traveling AC driver
1 defect.

66 V or more
Battery voltage c
Approx. 36 V (STD)
x ' (48V) Replace battery.
A ~ ~ r o48

t
Traveling AC driver 1 defect.

F1 fuse inspection
NG (- )'
, Replace F1 fuse.

Was the battery plug disconnected Do not disconnect battery plug during traveling except
during traveling? in an emergency.

t
Check battery plug.
A1 -3 Traveling AC driver 2 high voltage

Related portion

.
F1
P3

I---
7

t
I
I
I
- N
Traveling AC
driver 2

Output when overvoltage of the battery line of the traveling AC driver 2 is detected.

If A l - I occurs at the same time, perform troubleshooting for A l - I first.


A1-3 error is
indicated ANL: I10 MONITOR 1 1/01-12 Less than 66 V
Turn key switch ON. )
VBBD : Voltage check
I' I
No error
66 V or more
I
t
Traveling AC driver
2 defect.

66 V or more
Battery voltage check.

Replace battery
t
Traveling AC driver 2 defect.

t NG (- Q)
F1 fuse inspection Replace F1 fuse.

-v
Was the battery plug disconnected - YES ) Do not disconnect battery plug during traveling
during traveling? except in an emergency.

+
Check battery plug.
A1-4 Material handling AC driver high voltage

Related portion

Material
handling
AC driver

I I

Output when overvoltage of the battery line of the material handling AC driver is detected.

If A l - I occurs at the same time, perform troubleshooting for A l - I first.


A1-4 error is I. I

indicated ANL: 110 MONITOR 1 1/01-13


Turn key switch ON.
No error
66 V or more

I driver defect

7
Battery voltage check I
66 V or more
I
I

1
I
I Approx. 36 V (STD)
/ Approx 48 (48V) 7
Replace battery.
v
Material handling AC driver defect

I
NG (w R)
F1 fuse inspection +Replace F1 fuse.

I
YES
Was the battery plug disconnected bDo not disconnect battery plug during traveling
during traveling? except in an emergency.

t
Check battery plug.
A2-2 Traveling AC driver board overheat

Traveling AC driver 1 Traveling AC driver 2

PCB Thermo-sensor PCB Thermo-sensor

Output when the temperature detected by the traveling AC driver 112 thermo-sensor exceeds the
specified level.

Display only for safe monitor.


113 "Cormore
TBD: Traveling AC driver 112 )Allow the vehicle to stand for a while.
(about. 30 min.)
Less than 113 "C

7 YES
Has the vehicle been subjected to )Stop vehicle and perform check test with
continuous overloaded operation? standard load after 30 minutes.
NO

f
Traveling AC driver 112 defect
A2-3 Material handling AC driver board overheat

Material handling AC driver

PCB Thermo-sensor

-€I--

Output when the temperature detected by the material handling AC driver thermo-sensor exceeds the
specified level.

Display only for safe monitor.

I1 ANL : I10 MONITOR 1 1101-6


TBP: Material handling AC driver
board temperature check.
I/
104 "C or more
Allow the vehicle to stand for a while.
(about. 30 min.)
r s s than 104 OC

Y E S
Has the vehicle been subjected to )Stop vehicle and perform check test with
continuous overloaded operation? standard load after 30 minutes.
I J
NO

Material handling AC driver defect

AA-2 Traveling AC driver 1 board thermo-sensor abnormality:

Traveling AC driver 1

PCB Thermo-sensor

u
Condition for error detection
Output when abnormality of the traveling AC driver 1 thermo-sensor is detected.

If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
To correct, replace the traveling AC driver 1.
AA-3 Traveling AC driver 2 board thermo-sensor abnormality

Related portion

Traveling AC driver 2

PCB Thermo-sensor

-El--

Condition for error detection


Output when abnormality of the traveling AC driver 2 thermo-sensor is detected.

If AD-3 occurs at the same time, perform troubleshooting for AD-3 first.
To correct, replace the traveling AC driver 2.

AA-4 Material handling AC driver board thermo-sensor abnormality

Material handling AC driver

PCB Thermo-sensor

--El---

Output when abnormality of the material handling AC driver thermo-sensor is detected.

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.
To correct, replace the material handling AC driver.
C1-1 Traveling AC driver 1 current sensor offset abnormality

Related portion

Traveling AC driver 1

pGGq

Output when abnormality is detected for current sensor offset adjustment when starting the traveling AC
driver 1.

To correct, replace the traveling AC driver 1.

I C1-2 Traveling AC driver 1 overcurrent

Related portion

P7
0
Traveling AC P8
driver 1 0
P9
0

Condition for error detection


Output when overcurrent of the traveling AC driver 1 is detected.
-
Turn key switch ON and OFF
NO error
b
Drive motor 1 cable check
several times. Drive motor 1 continuity check

CI-2 error is
indicated
7
Traveling AC driver 1 defect
C1-3 Traveling AC driver 2 current sensor offset abnormality

Traveling AC driver 2

p i G q

Condition for error detection


Output when abnormality is detected for current sensor offset adjustment when starting the traveling AC
driver 2.

To correct, replace the traveling AC driver 2.

C1-4 Traveling AC driver 2 overcurrent

Related portion

P71
0
Traveling AC P81
driver 2 0
P91
0

Condition for error detection


Output when overcurrent of the traveling AC driver 2 is detected.

- No error
Turn key switch ON and OFF + Drive motor 2 cable check
Drive motor 2 continuity check
several times.
C1-4 error is
indicated
T
Traveling AC driver 2 defect
C2-1 Drive motor overheat
I

Traveling AC
driver
Thermo-sensor

Condition for err


Output when the thermo-sensor value of the drive motor is above the specified level.

If AD-1 and AD-3 occurs at the same time, perform troubleshooting for AD-1 and AD-3 first.
Stand the vehicle for a while (about 30 minutes).
C2-2 Drive motor 1 thermo-sensor abnormality

Related portion

CN58
CN110-13(87, TDI+) 2
Traveling AC Drive motor 1
driver 1 CN110-lO(78, TDI-) 1 Thermo-sensor

Condition for error detection


Output when the drive motor 1 thermo-sensor output value is outside the specified range (disconnection
or short circuit)

If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
CN110-13 (87)
Disconnect battery plug. Except $ Continuity check No continuity
Disconnect CN110. 300-2k R CN58-2 (87)
CN110-13 (at harness side)
$ Resistance measurement
CN110-10 (at harness side)
300-2k R
CN110-10 (78)
$ Continuity check
CN58-1 (78)
..!:
Harness defect
Continuity (0 R)

Connect CN I10 and Disconnect Disconnect CN58.


CN58. Connect battery plug and Continuity
CN58-2 (at harness side) (0R)
turn the key switch ON. Less than 1 V
$ Continuity check
CN58-2 CN58-1 (at harness side)
Voltage measurement
CN58-1 No continuity (W R) Harness defect
1 V or more
1
Traveling AC driver
1 defect CN58 connector check
- -------- ---------
I Disconnect battery plug. I OK
I Connect SST2 between CN58-1 j Repair or replace
j and CN58-2. I
I
harness
L --------- --------- J
CN58-2 (at sensor side)
$ Resistance measurement
CN58-1 (at sensor side)
Connect battery plug and turn the
key switch ON. 300-2k R Except 300-2k R
CN110-13
$ Voltage measurement
Thermo-sensor defect
CN110-10
Except 0-0.1 V
v
There is possibility that connector connection defect.
Connect CN110, CN58 and check CN110, CN58
Thermo-sensor defect 7 connection condition.
Traveling AC driver 1 defect Connect battery plug, turn the key switch ON, and it
Harness defect checks that an error is not displayed.
C2-3 Drive motor 2 thermo-sensor abnormality

CN52
CNI09-13(88, TD2+) 2
Traveling AC - Drive motor 2
driver Thermo-sensor
CN109-1O(82, TD2-) -1

Output when the drive motor 2 thermo-sensor output value is outside the specified range (disconnection
or short circuit)

If AD-3 occurs at the same time, perform troubleshooting for AD-3 first.
CN 109-13 (88)
Disconnect battery plug. Except $ Continuity check No continuity
Disconnect CN109. 300-2k S2 CN52-2 (88)
CN109-13 (at harness side) "CN109-10 (82)
$ Resistance measurement
CN109-10 (at harness side)
300-2k Q
$ Continuity check
CN52-1 (82)
Continuity (0 R)
7
Harness defect

Connect CN109 and Disconnect 7


CN52. Connect battery plug and Disconnect CN52. Continuity
turn the key switch ON. ~ e s than
s 1v CN52-2 (at harness side)
CN52-2 (0 Q)
Continuity check
$ Voltage measurement CN52-1 (at harness side)
CN52-1
No continuity (m R) Harness defect
Or TravelinJAC
r - - - - - - - - - - - - - - - - - - - -
driver 2 defect 7 NG
I Disconnect battery plug. I CN52 connector check
I Connect SST2 between CN52-1 I OK
I -and- -CN52-2.
------
I
I Repair or replace
7
L - - - - - - - - - - I

harness
CN52-2 (at sensor side)
$ Resistance measurement
Connect battery plug and turn the CN52-1 (at sensor side)
key switch ON.
CN109-13 300-2k R Except 300-2k R
$ Voltage measurement
CN 109-10
Thermo sensor defect
Except O-O.l There is possi!ility that connector connection defect.
Connect CN109, CN52 and check CN109, CN52
Thermo-sensor defect 7 connection condition.
Traveling AC driver 2 defect Connect battery plug, turn the key switch ON, and it
Harness defect checks that an error is not displayed.
C3-1 Traveling AC driver 1 main drive circuit thermo-sensor abnormality

Traveling AC driver1

Thermo-sensor

Condition for error detection


Output when abnormality of the traveling AC driver 1 heat sink thermo-sensor exceeds the specified
level.

If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
To correct, replace the traveling AC driver 1.

C3-2 Traveling AC driver 2 main drive circuit thermo-sensor abnormality


I
Related portion

Traveling AC driver 2

Thermo-sensor

Condition for error detection


Output when abnormality of the traveling AC driver 2 heat sink thermo-sensor exceeds the specified
level.

If AD-3 occurs at the same time, perform troubleshooting for AD-3 first.
To correct, replace the traveling AC driver 2.
C8-1 Drive motor I rpm sensor abnormality
1
CN59
CN110-9(75, SSDI +) CN59-l(75, SSDI +)

CN110-ll(76, SSD11) CN59-2(76, SSDI1)


Traveling AC
driver 1 CN110-12(77, SSD12) CN59-4(77, SSD12)

CN110-lO(86, SSDI-) CN59-3(78, SSDI-)

Drive mot01
rI
rpm sensor

Condition for error detection


Output when the traveling AC driver 1 detects the abnormality of the drive motor 1 rpm sensor.
r - - - - - - - - - - - - - - - - - - - -

I Disconnect battery plug, connect


I SST19 to CN110, and connect I

I CN1 and CN3 of SSTI9. I

L _ _ _ --_ --- I

-I----------J
t
Connect battery plug, turn the key r - - - - - - - - - - - - - - - - - - - -

switch ON, and check the state of 2 LEDs ON I Disconnect battery plug, connect I

LEDs of SST during traveling & SSTI9 to CN110, and connect I

operation. I CN2 and CN3 of SST19. I


L - - - - - - - - - - - - - - - - - - - - J

One of LEDs turns OFF. 2 LEDs OFF

v
Check the CN1 and
v
Traveling AC driver
CN3 connection of 1 defect
SST. Connect battery plug, turn the key
NG (Both LEDs blink). switch ON, and check the state of
LEDs of SST during traveling
operation.
Other than NG
Traveling AC driver 1 defect

Disconnect CN59.
NG (all 8 V - 13 V) CN59-1[+],2[+],4[+]
$ Voltage measurement
CN59-3[-]

Drive motor 1 rpm Other than NG


sensor defect
~ a r n e s sdefect
I C8-2 Drive motor 2 rpm sensor abnormality

Related portion

CN53
CN109-9(79, SSD2+) CN53-l(79, SSD2+)

CN109-11(80, SSD21) CN53-2(80, SSD21)


Traveling AC
driver 2 CN109-12(81, SSD22) CN53-4(81, SSD22)

CN109-1O(82, SSD2-) CN53-3(82,


- SSD2-)

Drive mot01
rpm sensor

Condition for error detection


Output when the traveling AC driver 2 detects the abnormality of the drive motor 2 rpm sensor.
r - - - - - - - - - - - - - - - - - - - -

I Disconnect battery plug, connect


I SST19 to CN109, and connect CN1 I

I and CN3 of SSTl9. I


I
L ---_ ----- -------- - 2

r ....................
Connect battery plug, turn the key
switch ON, and check the state of 2 LEDs ON
I
I
Disconnect battery plug, connect I
)1SST19 to CN109, and connect CN2 I
LEDs of SST during traveling I I
and CN3 of SST19.
operation. I
- - - - - - - - - - - - - - - - - - - - d
I

One of LEDs turns OFF.

Check the CN1 and Traveling AC


CN3 connection of driver 2 defect
SST. Connect battery plug, turn the key
NG (Both LEDs blink). switch ON, and check the state of
LEDs of SST during traveling

I
Traveling AC driver 2 defect
operation.
Other than NG

Disconnect CN53.
CN53-1[+],2[+],4[+]
Voltage measurement
CN53-3[-]
Drive motor 2 rpm
sensor defect

Harness defect
E l -1 Material handling AC driver current sensor offset abnormality

Material handling AC driver

pizi-q

Output when abnormality is detected for current sensor offset adjustment when starting the material han-
dling AC driver.

To correct, replace the material handling AC driver.

E l-2 Material handling AC driver overcurrent

0
Material handling
AC driver

Condition for error detection


Output when overcurrent of the material handling AC driver is detected.

-NO error
Turn key switch ON and OFF b Pump motor cable check
several time. Pump motor continuity check

E1-2 error is
indicated
7
Material handling AC driver defect
I Pump motor overheat
- -

Related portion

Output when the pump motor thermo-sensor value is above the specified level.

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.
Stand the vehicle for a while (about 30 minutes).
E2-2 Pump motor thermo-sensor abnormality
I
Related portion

CN55
CN111-1 3(89, TP+) 2
Material Pump motor
handling AC CN 111-1O(86, TP-) 1 thermo-sensor
driver

Output when the pump motor thermo-sensor output value is outside the specified range. (disconnection
or short circuit)

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.

CNlll-13 (89)

k-
Disconnect battery plug, disconnect except $ Continuity check
CNlll 300-2k C2 CN55-2 (89) No continuity (WR)
CN 111-13 (at harness side) CN111-10 (86)
Resistance measurement
CN111-10 (at harness side)
$ Continuity check
CN55-1 (86) 7
Harness defect
Continuity (0 R)

Connect CN111, disconnect CN55.


Connect battery plug and turn the
I Disconnect CN55 I
CN55-2 (at harness side) Continuity (0 R)
key switch ON. Continuity check
CN55-2

1 CN55-1
Voltage measurement
I

r - - - - - - - - - 3
I 1 V or more
- - - - - - - - - - 7
I
7
Material handling
AC driver defect ( C ~ 5 5
connector check
-, NG
I

I Disconnect battery plug, short I

I between CN55-1 and CN55-2 with I Repair or replace


I SST2 I
I harness
CN55-2 (at sensor side)
$ Resistance measurement
CN55-1 (at sensor side)
I
Connect battery plug and turn the 1 300-2k C2 I Except 300-2k R
key switch ON.
CNlll-13
$ Voltage measurement I Thermo-sensor defect
CN111-10
I I
There is possibility that connector connection defect.
Except 0-0.1 V Connect the CN111, CN55 and check CN111, CN55
connection condition.
Material handling AC driver defect Connect battery plug, turn the key switch ON, and it
Thermo-sensor
checks that an error is not displayed.
defect Harness defect
E3 Material handling AC driver main drive circuit thermo-sensor abnormality

---j Related portion I

Material handling AC driver

Thermo-sensor

Condition for error detection


Output when abnormality of the material handling AC driver heat sink thermo-sensor exceeds the
specified level.

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.
To correct, replace the material handling AC driver.
E8 Pump motor rpm sensor abnormality

Related portion

CN56
CN 111-9(83, SSP+) CN56-l(83, SSP+)

CN111-11(84, SSPI) CN56-2(84, SSP1)


Material
handling AC CN 111-12(85, SSP2) CN56-4(85, SSP2)
driver
CN111-lO(86, SSP- CN56-3(86, SSP-)

Pump motor
rpm sensor

Output when the material handling AC driver detects the abnormality of the pump motor rpm sensor.
r - - - - - - - - - - - - - - - - - - - -

I Disconnect battery plug, connect


I SST19 to CN111, and connect CN1 I

I and CN3 of SST19. I


I
L - _ - - - - - - _ - - - - - - - - - - A

-1
r - - - - - - - - - - - - - - - - - - - -

Disconnect battery plug, connect


SST19 to CN111, and connect CN2 I
LEDs of SST during material I
and CN3 of SSTIQ.
handling operation. L - - - - - - - - - - - - - - - - - - - - J
I

Check the CN1 and CN3 Material handling AC


connection of SST driver defect
Connect battery j u g , turn the key
blink.) switch ON, and check the state of
LEDs of SST during material
handling operation.
I I
Material handling AC driver defect Other than NG

-
-

Disconnect CN56
CN56-1[+],2[+],4[+]
$ Voltage measurement

Pump motor rpm


sensor defect
+
~ a r n e s defect
s
SAS SYSTEM

I 61 -1,Z I Load sensor abnormality I


/ elated portion I
I
- CN102-17(58, SPL+) CN130 CN90 CN91
-11 . 4 - 1
CPU CN102-5(59, SPL) Load
board 10 3 - sensor
CN102-22(51, POT-)
9 8 - 3
-

Condition for error detection


Output when the voltage of the load sensor is outside the specified range (open or short).
61-1 Load sensor open
61-2 Load sensor short

61-1
r - - - - - - - - - - - - - - - - - - - -

I Disconnect battery plug. I


I
I Disconnect CN90. II 61-2 error is
I Short between CN90-3 and CN90-4 I indicated. Load sensor defect
I
I of main harness side with SST2. ) Sub harness defect
I Connect battery plug and turn the I
I
I
I
key switch ON. I
-- - - - - - - - - - - - - - - - - - - - -
61-2 error is not indicated.

t
Disconnect battery plug.
Disconnect CN102.
(SST2 is connection state.) No continuity
PMain harness defect
CN102-17 (58)
$ Continuity check
CN102-5 (59)
Continuity

t
CN102-5 (59)
No continuity
$ Continuity check b CPU board defect
CN 102-22(51)
Continuity

t
Main harness defect
Disconnect battery plug, disconnect
CN90, connect battery plug, and Change to 61-1 error.
turn the key switch ON.

T-
-
61-2 error remains.

Disconnect battery plug.


Disconnect CN102 No continuity
CN102-17 (58) )CPU board defect
1 Continuity check
CN102-5(59)

i .,- --- ----


I Disconnect battery plug.
t - ---------
I
I
Main harness defect I Disconnect CN102 I

I Short between CN90-3 and CN90-8


I of main harness side with SST2. I
I CN 102-5(59) I
I
I 1 Continuity check I

I CN 102-22(51) I
I
L _ _ _ - - - - - - - - - - - - - - - - - A

Continuity No continuity

t
Load sensor defect
t
Main harness defect
Sub harness defect
Disconnect battery plug, disconnect
CN86, connect battery plug, and Change to 62-1 error.
turn the key switch ON.
62-2 error remains.

Disconnect CN102.
CN102-16 (57)

,
Disconnect battery plug.

Continuity check
CN fO2-4 (i6)'

v
Continuity
I
1
1
No continuity
CPU board defect

I
Disconnect battery plug.
I Disconnect CN102.
Short between CN86-2 and CN86-3
I of main harness side with SST2.
I
I
I

I
Main harness defect I CN102-4 (56) I
I
I I Continuity check I
I CN 102-22 (51) I
I
----------
1Continuity NO continuity
- - - - J

'- - - -

+
Tilt angle sensor defect

Main harness defect

66-1 Tilt matching abnormality

CPU board

Condition for error detection


Output when any of tilt neutral position matching, forward tilt angle matching and load sensor matching is
outside the specified range.

CPU board defect


67-1 Lifting height switch abnormality I
Related portion

Lifting height
CN130 CN90 CN92 switch
-
CN101-20(91, MH2-1)
6 1 3 -
CPU CN101-19(90, MHI)
board 7 6 - 2
CN101-16(51, LS-)
1 2 - 1
1

Condition for error detection


Output when open or short circuit of the lifting height switch line from the CPU board to the lifting height
switch is detected.

I
I/
ANL : I10 MONITOR 3-11
Check the lifting height switch
input value
I MH : O0-

I' I I
I Other than MH : 00-

Disconnect battery plug and


disconnect CN90.

ANL : I10 MONITOR 3-11


MH : 00- Sub harness defect
Check the lifting height switch
input value. (with battery plug Lifting height switch defect
connected)

Disconnect battery plug and


disconnect CN101, and check the
continuity. No continuity
CN101-20(91)-CN101-16(51) b CPU board defect
CN101-19(90)-CN101-16(51)
CN101-20(91)-CN101-19(90)

i
Main harness defect
Disconnect battery plug and CN90,
and check continuity.
Check the lifting height upon error
indicating.
H2000 or more -
CN90-6 (90) ~ ~ 9 b(51) - 2
[OK] No continuity, [NG] Continuity
I
Less than H2000
I -
CN90-1 (91) ~ ~ 9 0(51) - 2
[OK] Continuity, [NG] No continuity

Disconnect battery plug and CN90,


and check continuity.
-
CN90-6 (90) CN90-2 (51)
NG
v
Sub harness defect
[OK] Continuity, [NG] No continuity
-
CN90-1 (91) CN90-2 (51) * - Lifting height switch defect
1 [OK] No continuity, [NG] continuity I

I
--- ------ -.- -
Disconnect battery plug, disconnect
--------
I
I CNl 01 and CN103, and check the
I continuity. I
I I
I Short between CN90-6 and 1
1 CN9O-2 of main harness side with I
I SST2. I

I the harness continuity. I

I CN101-19 (90) I
No continuity
I Continuity check I Main harness defect
I
) CN101-16 (51) I
I Short between CN90-1 I

I and CN90-2 of main harness side I


I with SST2. I

I CN101-20(91)
I
I
I $ Continuity check I

I CN101-16 (51)
L - - - - - - - - - - - - - - - - - - - - J
I
I

Continuity

CPU board defect


MULTI-DISPLAY

F1-1,2 Main controller + multi-display communication abnormality

CN131 CN1
CN103-16(141, SMTDA) 7- 3- CN70-22(141, SMTDA)

CPU CNIO3-I3(I44, SMTDK) 4 7 CN70-23(1447 SMTDK) ~ulti-display


board
- -

7
1 Condition for error detection I 1
1 O u t p i t upon detection of communicatio; data abnormality from CPU board

CN103, CN131, CN70 and CN1 NG


) Correct the defect
connection condition check

Disconnect battery plug, disconnect


CN103 and CN70.
CN103-16(141) Continuity CPU board defect
Continuity check
CN70-22(141)
* Multi-display defect

CN103-13(144)
Continuity check
CN70-23(144)
I No continuity

Harness defect
(Between CN103 and CN70)

NOTE:
Other error codes, if any, are not indicated because of no communication from the CPU board
when F1-I occurs. F1-I is kept indicated on the multi-display screen regardless of key switch On
or OFF.
WHEN NO ERROR CODE IS DISPLAYED

No display on multi-display

Related portion

CN131 CN1
CN103-lO(16, D15V) 3- 2- CN70-14(16, D15V)

CPU CN103-12(14, GNDD)


2 1 CN70-30(14. GNDD)
board - Multi-display
- -

Condition for error detection


No power supply to multi-display
Multi-display defect

It is possible to perform traveling


See page 5-94. (Vehicle does not move.)
and material handing operation.

Disconnect battery plug, disconnect Disconnect battery plug, connect


CN1, and connect battery plug. CN1, disconnect CN70, and
CN1-2(16) (Approx. 15 V) connect battery plug.
Voltage measurement CN70-14(16)
$ Voltage measurement
CN1-l(14)

v
I Disconnect battery plug,
'1
CN70-30(14)

(Approx. 15 V)

Harness defect
disconnect CN1 and CN103. t
Multi-display defect
(Between CN1 and
1. CN70)
CN1-2(16)
$ Continuity check
CN103-10(16)
CN1-1(14)
$ Continuity check
CN103-12(14)
2.
CN1-2(16)
$ Short-circuit check
CN1-l(14)
OK (1. Approx. 0 0
2. 51)
M

CPU board defect


The vehicle does not move at all (display off)

-1 Related portion I
P1 P2 F6
CN104-14,15(44,VBMB)

CN104-1,2(18, B48V)

rI
ah
board
CN 103-7(41, VBBT) I

PA [+I
$ Voltage measurement than 20 + Battery charge
N1[-I
20 V or more

NG (m R)
Check the F5 fuse w Replace F5 fuse

CN104-l(18)
$ Voltage measurement -Less than 20 V
+ Harness check
CN104-22(N2)
I I
20 V or more

I Check the voltage with the key I


switch ON.
1. NG
CN 103-4(43) - 1 - hc NG
Voltage measurement
CN104-22(N2) OK
2.
CN103-7(41)
7
Replace the key
$ Voltage measurement switch
CN 104-22(N2)
v

--
OK (Voltage of 2 is 15 V or more, Battery plug check or battery
and voltage difference of 1 and 2 is check or harness check
13 V or less.
CPU board defect
Only traveling disabled (no motor revolution)
I
Related portion
CN130 CN9
CN101-l(45, DSF) 5-
CN101-2(46, DSR) 4 Direction
switch
CN101-16(51, LS-) 1
-
CN132 CN26
CN102-l(64, SWAC) CN26-2 -
CPU
board CN 102-2(52, POTA) CN26-3
Accelerator
CN102-14(53,-
POTA+) CN26-4 potentiometer
CN102-22(51, POT-) CN26-1
-
CN130
CN101-5(67, LSD) 7
8 Seat switch
-
L

+-
I.
ANL : 110 MONITOR 2 1102-1
SWAC and POTA value check with
accelerator pedal depressing.

Both change.
II
Both have no
change. + Accelerator check

b ANL : 110 MONITOR 2 1102-2


DSF and DSR value check with
change
)Direction switch check

0-
direction switch operation.
11 I I
Changes

ANL : 110 MONITOR 2 1102-3 Display 0


LSD value check by sitting on the Seat switch check

Display 1

Voltage measures with direction


switch ON and accelerator ON. * I
P7 [+I, P8 [+I, P9 [+I
$ Voltage measurement Other than OK
N1 [-I )Traveling AC driver defect
P71 [+I, P81 [+I, P91 [+I
Voltage measurement
N1 [-I
OK (All approx. 2 V) *1: When it cannot be measured, even the seat is not
occupied, it can be measured by disconnecting
CN22 and connecting SST8.
t NO
)Motor cable and motor check

I
I
Disconnect battery plug.
Does front wheels rotate when jack
up the vehicle to cause the front
wheels to float.
k
I
I
Rotates
Brake check

Does not rotates

t
Perform troubleshooting for C8
Wobbling

Jack up the vehicle to cause the Of front wheels at


front wheels to float, and keep the the same Veed Type of tires, a diameter of tires and air
steering wheel in straight position. pressure valve check.

not rotate at the same speed

Does change upon turning the Normal


steering wheel?
I
Wobbling
Does not change
I use it aB it is.

Abnormal
Installation check of the tire angle
sensor.
Normal
Install to correct
position.
Disconnect drive motor cables
Turn direction switch ON 7
Accelerator ON CPU board defect
P7[+1 Other than OK
$ Voltage measurement )Traveling AC driver defect
N1[-I
P71 [+I
$ Voltage measurement
N1[-I

(48V: All approx. 24 V)

L
Is there sound from the motor? Motor cables and motor check

Disconnect battery plug. Rotates


Does front wheels rotate when jack b Brake check
up the vehicle to cause the front
wheels to float.
I I
Does not rotates

*When it cannot measure, even if it does not


t
Troubleshooting of C8 error.
sit on the seat, it can measure by
disconnecting CN22 and connecting SST8.
A-I AR

.
Only material handling is disabled.
Standard models (STD lever)
I
I ANL : 110MONITOR 3 1/03-1,3
Lift, tilt switch check
Lift, tilt switch check

I
The switch is operated

Does pump motor rotate upon Rotates


turning steering wheel? w Control valve check

----I--
Does not rotate

Disconnect the material handling


AC driver cable. Operate the lift
lever to up position.
P14[+]
$ Voltage measurement
NI[-I Other than OK
Material handling AC driver defect
P1 5[+]
$ Voltage measurement
NIL-]
P1 6[+]
$ Voltage measurement
N 1[-I
OK (STD: All approx. 18 V)
(48V: All approx. 24 V)

NG
Pump motor cable check ) Cable repair

--I- Perform troubleshooting for E8.


Mini lever models

Material handling is disabled only Yes


when a certain operation is
performed. levers and control valves of the
No vehicle?
Yes Reset the values
7 of OPTION SET
Does pump motor rotate upon
turning steering wheel? Value does not
change
Does not rotate Check the value when operating
the lever that does not work for

T Value Lever angle sensor


Disconnect motor cable and changes inspection
measure the voltage at the pump
motor driver terminal with the lift 7
Approx. 0.5A
switch ON.
or more
P14[+]
$ Voltage measurement Other than OK
N1[-I
P15[+] Less than Control valve
$ Voltage measurement approx. 0.5A inspection
Material handling
N1[-I AC driver defect 7
P I6[+]
Voltage measurement Measure the solenoid resistance of Approx. 7R
NI[-l the proportional valve that does not
work for material handling
OK (STD: All approx. 18 V)
(48V: All approx. 24 V) Other than Harness
approx. 752 inspection
7
Solenoid inspection

Cable repair
Perform troubleshooting for E8.

Approx.

CI- Measure the solenoid resistance of


the proportional valve that does not
work for material handling
Other than
A

approx. 10Q

7
Solenoid inspection Control valve inspection
Steering knob not in the right position

II OPTION SET : OPT-13


Check the steering knob
1 Setting is N.
Change the setting to Y.

I'
synchronizer setting.
II
lj
Setting is Y.

Set the steering knob synchronizer


6 rotates or more Steering knob synchronizer solenoid
solenoid to OFF. Check the
number of rotation when rotate the )valve check.
steering wheel from end to end.
(The speed of rotation is 1 rotation
12-3 minutes.)
Less than 6 rotates

(1 ANL : ACTIVE TEST ACT-2


Set the steering knob synchronizer
Does not idle

.
solenoid to OFF. Check if that the Steering knob synchronizer solenoid
steering wheel idles at tire end valve check.
position.(The speed of rotation is 1
rotation 12-3 minutes.)

1
Normal
Perform matching )Use it as it is.
I I

Abnormal

Installation check of the tire angle ~bnormal


Install to correct position.
sensor and the steering angle
I I
1 Normal

CPU board defect


Constant automatic fork leveling

- CN101-18(70, S W K ) CN132 CN84


-
CPU -
board - Knob switch
CN101-16,26(51,LS-)
- -
CN130

ANL : 110 MONITOR 3 1103-9 Operate


ON (display 1) normally
Check the valve of automatic fork Tilt knob switch OFF
Automatic fork
leveling is remained
OFF (display 0)
ON 7
Use it as it is.

11
ANL : I10 MONITOR 3 1103-9
-o
frk /
leveling switch
II
A ON (display 1)

I
CN101-18[+]
Voltage measurement
CN101-16,26[-]
Approx. 5 V
h
I
Approx. 0 V

CPU board defect

Harness defect
Leaned forward Switch defect
from levelinn
Lift down the fork and operate the
tilt lever to the forward position. Perform matching No. I , No.2

Not leaned forward


from leveling position

Does pump motor stop without a


turning steering wheel when
direction switch is neutral position CPU board defect
and the fork is at leveling position.
I

Does not stop

t
Tilt cylinder check
Safety monitor Traveling AC driver 112 low temperature warning

Output when the temperature detected by the traveling AC driver 112 main drive circuit thermo-sensor is
below the specified level.
Output when the temperature detected by the traveling AC driver 112 board thermo-sensor is below the
specified level.
Output when the temperature detected by the drive motor 112 thermo-sensor is below the specified level.

If the temperature rises after some traveling, the warning will go out.

Safety monitor Material handling AC driver low temperature warning

Output when the temperature detected by the material handling AC driver main drive circuit
thermo-sensor is below the specified level.
Output when the temperature detected by the material handling AC driver board thermo-sensor is below
the specified level.
Output when the pump motor thermo-sensor value is below the specified level.

If the temperature rises after some material handling, the warning will go out.
MOTOR
Page
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 5-5
DISASSEMBLY INSPECTION REASSEMBLY ..... 5-7
PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
GENERAL .................................... 5-10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
REMOVAL INSTALLATION ..................... 5-12
DISASSEMBLY INSPECTION REASSEMBLY ..... 5-14
5-2

DRIVE MOTOR
GENERAL

SPECIFICATIONS
Vehicle model
All Models

Three-phase alternating
TYpe current
t

Nominal voltage V 36 48
Rated output (rated in 60min) kW 3.6 4.9
Size (Outer shape x length) mm (in) +I80 x 227 ($7.1 x 8.9) t

Weight (Including drive unit case) kg (N) 37 (362.8) t

Insulation class F t
COMPONENTS
REMOVAL INSTALLATION
T=N.m (kgf.cm) [ft.lbf]

Removal Procedure
1 Disconnect the battery plug.
2 Remove the mast ASSY. (PI2-4)
3 Jack up the vehicle and remove front wheels. [Point I ]
4 Drain gear oil. [Point 21
5 Disconnect the piping and wiring.
6 Disconnect the brake ASSY link.
7 Remove the tie rod.
8 Remove the reamer bolt of the drive unit bracket (RH). [Point 31
9 Remove the drive unit W1drive motor (RH). [Point 41
10 Remove the drive unit ASSY (RH). [Point 51
11 Remove the brake ASSY and disc brake of the drive motor (RH).
12 Remove the reamer bolt of the drive unit bracket (LH). [Point 31
13 Remove the drive unit Wl drive motor (LH). [Point 41
14 Remove the drive unit ASSY (LH). [Point 51
15 Remove the brake ASSY and disc brake of the drive motor (LH).
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[POINT I]
Removal:
Always jack up the vehicle at the jack-up point. Jacking
up the vehicle at the other location is very dangerous.
Always support the load of jacked-up vehicle with
wooden blocks at specified points.

[POINT 21
Installation:
After installation, fill hypoid gear oil to the specified level.
A=lOmm (0.39in) or less

[POINT 31
Removal:
SST 09310-23320-71

[POINT 41
Removal:
For removal of the drive motor, place a garage jack at
the drive motor bracket and hoist the drive motor.

[POINT 51
Installation:
Apply gasket sealant to the mating face with the drive
unit.
Gasket sealant: Three Bond #I281
DISASSEMBLY INSPECTION REASSEMBLY
T=N.m (kgf.cm) [ftdbfl

Disassembly Procedure
1 Remove the terminal.
2 Remove the end frame. [Point I ]
3 Remove the rpm sensor bearing.
4 Remove the rotor ASSY. [Point 21
5 Remove the stator ASSY. [Point31
6 Remove the bracket. [Point 41
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Caution:
Be sure not to apply impact to the rpm sensor bearing.
Point Operations
[POINT I]
Disassembly:
SST 09950-76013-71
(09950-40010)

Reassembly:
After installing the end bracket, use the SST and hand
press and install the rpm sensor bearing.
SST 09608-76003-71
(09608-04031)
Reference:
After installing the brake disk wheel, it may as well be
used the brake disk wheel set nut to install the rpm
sensor bearing.

[POINT 21
Disassembly:
Use a copper bar to remove the rotor ASSY.

Reassembly:
Use the SST and hand press to install the rotor ASSY.
SST 09150-10920-71
Caution:
After inserting the bearing in the front axle bracket
and fitting the oil seal, set the stator and press fit the
rotor in the bearing.
Before inserting the bearing, make sure that the shield
of the bearing is positioned lower.

[POINT 31
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
Standard: IMR or more
Inspection:
Check continuity between motor cables.
Measurement terminals: U-V,V-W,W-U
Standard: OR

Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of
temperature sensor connector
Standard: 540 to 620R (at 20 "C)

[POINT 41
Disassembly:
Use the SST to remove the bearing.
SST 09950-76018-7 1......(1)
(09950-60010)
SST 09950-76020-71......(2)
(09950-70010)

Reassembly:
Use the SST and hand press to install the bearing and
oil seal.
SST 09950-76018-7 1......(1)
(09950-60010)
SST 09950-76020-71......(2)
(09950-70010)
5-10

PUMP MOTOR
GENERAL

SPECIFICATIONS
Vehicle model
All Model

Three-phase alternating
TYpe C
current
Nominal voltage V 36 48
Rated output (rated in 60min) kW 6.9 9.2
Size (Outer shape x length) mm(in) $180x290($7.1x11.4) c
Weight kg (N) 31(304.0) t

Insulation class F t
5-11

COMPONENTS
1402
.-2
6
4
0
2

1402

W
=rcir
.-
0
e

L...
5-12

REMOVAL INSTALLATION
T=N.m (kgfcm) [ft-lbfl

Removal Procedure
1 Remove the battery ASSY.
2 Remove the toe board (FR, RR) and tilt cover.
3 Disconnect the piping of the priority valve.
4 Remove the front battery cover.
5 Disconnect the pump motor wiring.
6 Remove the return filter set bolt and keep the filter free.
7 Drain hydraulic oil. [Point I]
8 Disconnect the oil pump piping (outlet hose).
9 Temporarily hoist the pump motor. [Point 21
10 Hoist the pump motor WI oil pump and disconnect the inlet hose. [Point 31
11 Remove the oil pump and insulator.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease to the spline section of the pump before installation.
Point Operations
[POINT I]
Removal:
Remove the gauge and filter and drain the hydraulic oil.

[POINT 21
Removal:
Loosen the set bolt of the terminal bracket and hoist the
pump motor.

[POINT 31
Removal:
When hoisting the pump motor, make sure not to apply
excess force on the hose.
Note:
Be sure to loosen the hose clamp sufficiently.
If the hose and tank pipe stick hard, do not forcefully
hoist the pump motor as it may damage the hydraulic
oil tank.
Remove the adhesion of the hose and tank pipe.
5-14

DISASSEMBLYeINSPECTION l REASSEMBLY
T=N.m (kgfzm) [ftdbfl

Disassembly Procedure
1 Remove the terminal.
2 Remove the end frame. [Point I]
3 Remove the rpm sensor bearing.
4 Remove the rotor ASSY. [Point 21
5 Remove the stator ASSY. [Point 31
6 Remove the bracket.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Caution:
Be sure not to apply impact to the rpm sensor bearing.
Point Operations
[POINT I ]
Disassembly:
SST 09950-76013-71......(1)
(09950-40010)
SST 09140-10920-7 1..... .(2)

Reassembly:
After installing the end bracket, use the SST and hand
press and install the rpm sensor bearing.
SST 09608-76003-71
(09608-04031)

Reassembly:
Install the end frame and rpm sensor to the position with
the dimension A.
Dimension A 11.0 to 13.3mm(0.43 to 0.52in)

[POINT 21
Inspection:
Inspect the bearing of the rotor ASSY and replace it if
abnormal noise or damage is observed.
Disassembly:
SST 09950-76014-71.. ....(1)
(09950-40011)
SST 09950-76018-71...... (2)
(09950-60010)

Reassembly:
SST 09410-40120-71
[POINT 31
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
Standard: 1MR or more

Inspection:
Check continuity between motor cables.
Measurement terminals: U-V,V-W,W-U
Standard: OR

Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of
temperature sensor connector
Standard: 540 to 620R (at 20 O C )
DRIVE UNlT & FRONT AXLE
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
FRONT AXLE HUB & DRIVE UNIT . . . . . . . . . . . . . 6-5
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 6-5
l

DISASSEMBLY INSPECTION REASSEMBLY ..... 6-7


l
e
GENERAL
SPECIFICATIONS
Vehicle model
7FBEU15 7FBEU18 7FBEHU18 7FBEU20

Total reduction ratio 27.040 t t t

Front tire size 18 x 7 X 12'18 t t t

COMPONENTS
6-5

FRONT AXLE HUB & DRIVE UNIT


REMOVAL INSTALLATION
T=N .m (kgf.cm) [ft-lbfl

Removal Procedure
1 Jack up the vehicle and remove front wheels. [Point I ]
2 Drain gear oil. [Point 21
3 Remove the front axle hub. [Point 31
4 Remove the drive unit ASSY. [Point 41
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Type and quantity of gear oil
STD
TYpe Hypoid gear oil W
Cold storage type
Quantity 0.4! (0.1 US gal)
Type of grease
31U
MP grease
Cold storage type
Point Operations
[POINT I ]
Removal:
Always jack up the vehicle at the jack-up point.Jacking
up the vehicle at the other location is very dangerous.
Always support the load of jacked-up vehicle with
wooden blocks at specified points.

[POINT 21
Installation:
After installation, fill hypoid gear oil to the specified level.
A=lOmm (0.39in) or less

[POINT 31
Removal:
SST 09950-76014-71
(09950-40011)

Inspection:
Measure the front axle hub starting force.

Standard
7FBEU15 23.9 - 47.3 (2.4 - 4.8) [5.3 - 10.61
27.2 - 53.9 (2.8 - 5.5) 16.2 - 12.11
7FBEU18'20
7FBEHU18

[POINT 41
Installation:
For installation, apply gasket sealant to the mating face
with the drive unit.Be sure to remove the grease on the
face.
Liquid gasket: 08826-76002-71
(08826-00090)
DISASSEMBLY INSPECTION REASSEMBLY

Disassembly Procedure
1 Remove the idle gear bearing. [Point I ]
2 Remove the planetary gear. [Point 21
3 Remove the axle shaft bearing and inner bearing.
4 Remove the oil seal and outer bearing. [Point31
5 Remove the bearing outer race. [Point 41
6 Remove the inner bearing outer race. [Point 51
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply gear oil to the planetary gear and bearing and install them.
Point Operations
[POINT I ]
Disassembly:
Use the SST to remove the idle gear bearing.
SST 09950-76014-71
(09950-40011)

Disassembly:
Use the SST to install the idle gear bearing.
SST 09950-76018-71.. .... (1)
(09950-60010)
SST 09950-76020-71 ......(2)
(09950-70010)

[POINT 21
Reassembly:
Measure the backlash of the planetary gear, idle gear
and ring gear.
Standard: 0.2mm (0.008in)or less

[POINT 31
Reassembly:
Use the SST to install the oil seal.
SST 09700-30200-71

[POINT 41
Disassembly:
Use the SST to remove the outer bearing outer race.
SST 09700-30200-71
Reassembly:
Use the SST to install the outer bearing outer race.
SST 09700-30200-71

[POINT 51
Disassembly:
Use the SST to remove the inner bearing outer race.
SST 09700-30200-71

Reassembly:
Use the SST to install the inner bearing outer race.
SST 09700-30200-71
REAR AXLE
Page
REAR AXLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7-6
DISASSEMBLY INSPECTION REASSEMBLY . . . . . 7-10
REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7-13
REAR AXLE CYLINDER ASSY . . . . . . . . . . . . . . . . . 7-16
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7-16
DISASSEMBLY INSPECTION REASSEMBLY . . . . . 7-18
0
TIRE ANGLE SENSOR (OPT) . . . . . . . . . . . . . . . . . . 7-20
REMOVAL INSTALLATION ..................... 7-20
7-2

REAR AXLE ASSY


GENERAL
7-3
SPECIFICATIONS

7FBEU15 7FBEU18 7FBEHU18 7FBEU20

TYpe Full-floating
Tire size 15 x 5 x ll1I4 t t t

COMPONENTS
Rear axle ASSY

fer to 4302-01
0
7-6

REMOVAL INSTALLATION
T=N.m (kgf-cm) [ftelbfl

Removal Procedure
1 Remove the rear cover.
2 Remove the counterweight.
3 Jack up the vehicle. [Point I]
4 Remove the hubcap, rear wheel and outer bearing. [Point 21
5 Remove the outer bearing outer race. [Point 31
6 Remove the inner bearing outer race. [Point 41
7 Disconnect the piping of the power steering cylinder.
8 Remove the tire angle sensor.
9 Measure the rear axle ASSY starting force. [Point 51
10 Loosen the rear axle set bolts.
I 1 Hoist the rear axle temporarily and remove the set bolts. [Point 61
12 Remove the rear axle.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the tire angle sensor is removed and installed or replaced, perform matching.
(See page 16-11.)
Apply grease before installation.
Outer bearing Inner bearing Inside rear wheel
STD MP grease
TYpe Cold storage
Esso beacon 325
spec.
14 - 19 11 -- 150.03) 22 -- 270.06)
Amount (Ib) (0.03 - 0.04) (0.02 (0.05
After tightening the castle nut, fill MP grease (Esso beacon 325) i n the hub cap.

Point Operations
[POINT I ]
Removal:
Jack up the vehicle at the specified jack-up point.
Jacking up at any other point is very dangerous.
Always support the vehicle with wooden blocks at
specified points.

[POINT 21
Inspection:
Measure the rear wheel starting force.
- -
Standard: 15 39N (1.5 4kgf) [3.3 8.81bfl -

Reassembly:
When installing a claw washer, position it with its edge
facing the rear axle.
[POINT 31
Disassembly:
Use a copper bar to remove the outer bearing outer
race.

Reassembly:
Use the SST to install the outer bearing outer race.
SST 09950-76019-71 ......(1)
(09950-60020)
SST 09950-76020-71 ......(2)
(09950-70010)

[POINT 41
Disassembly:
Use a copper bar to remove the inner bearing outer
race.

Reassembly:
Use the SST to install the inner bearing outer race.
SST 09950-76019-71.. ....(1)
(09950-60020)
SST 09950-76020-7 1...... (2)
(09950-70010)

[POINT 51
Inspection:
Measure the rear axle ASSY starting force.
- -
Standards: 100 20